Baxi Potterton Gold FSB 30 HE User Manual

You can rely on

Installation & Service Instructions

Gold

FSB 30 HE

Floor Standing

Condensing Boiler

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Competent Person's

Building Control

Self Certification Scheme

Install and Commission this

appliance to manufacturer's

instructions

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact

a government approved

inspector

Complete the

Benchmark Checklist

If you notify via the ‘Gas Safe

the Building Regulations

Install and Commission this

appliance to manufacturer's

instructions

certificate on members’ behalf

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

Complete the

Benchmark Checklist

or log onto:

www.gassaferegister.co.uk

within 10 days

You must ensure that the

certificate number issued by

the ‘Gas Safe Register’ is written

onto the Benchmark Checklist

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant LABC

LABC will record the data

and will issue a

certificate of compliance

Legislation

This company declare that no substances harmful to

health are contained in the appliance or used during

appliance manufacture.

IMPORTANT - Installation, Commissioning, Service & Repair

This appliance must be installed in accordance with the manufacturer’s instructions and

the regulations in force. Read the instructions fully before installing or using the

appliance.

The appliance is suitable only for installation in GB and IE

and should be installed in accordance with the rules in

force, and only used in a suitably ventilated location.

In GB, this must be carried out by a competent person as stated in the Gas Safety

(Installation & Use) Regulations.

In GB, the installation must be carried out by a Gas Safe

Registered Installer. It must be carried out in accordance

with the relevant requirements of the:

Gas Safety (Installation & Use) Regulations.

The appropriate Building Regulations either The Building

Regulations, The Building Regulations (Scotland), Building

Regulations (Northern Ireland).

The Water Fittings Regulations or Water Byelaws in

Scotland.

The Current I.E.E. Wiring Regulations.

Definition of competence: A person who works for a Gas Safe registered company

•

and holding current certificates in the relevant ACS modules, is deemed competent.

In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic

Gas Installations”.

•

The addition of anything that may interfere with the normal operation of the appliance

without express written permission from the manufacturer or his agent could invalidate

the appliance warranty. In GB this could also infringe the Gas Safety (Installation and

Use) Regulations.

Where no specific instructions are given, reference should

be made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent

Person and installed in accordance with the current edition

of I.S. 813 ‘Domestic Gas Installations’, the current Building

Regulations and reference should be made to the current

ETCI rules for electrical installation.

Warning - Check the information on the data plate is compatible with local supply

conditions.

All systems must be thoroughly flushed and treated

with inhibitor (see section 6.2).

All Gas Safe registered engineers carry an ID card with their licence number and a

photograph. You can check your engineer is registered by telephoning

0800 408 5500 or online at www.gassaferegister.co.uk

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)

Regulations 1993 N^o3083” and is deemed to meet the requirements of Directive

92/42/EEC on the energy efficiency requirements for new hot water boilers fired with

liquid or gaseous fuels:-

Codes of Practice, most recent version should be used

In GB the following Codes of Practice apply:

Standard

Scope

BS 6891

Gas Installation.

BS 5482 Part 1

BS 5546

Butane & Propane Gas Installation

Installation of hot water supplies for domestic

purposes.

Type test for purpose of Regulation 5 certified by:

Notified Body 0087.

BS EN 12828

BS EN 12831

BS EN 14336

Heating systems in buildings.

Heating systems in buildings - Calculation of load.

Installation & commissioning of water based

heating systems.

Product/Production certified by:

Notified Body 0086.

BS 6798

Installation of gas fired hot water boilers.

Flues.

Ventilation.

Expansion vessels and ancillary equipment for

sealed water systems.

BS 5440 Part 1

BS 5440 Part 2

BS 7074

For GB/IE only.

BS 7593

Treatment of water in domestic hot water

central heating systems.

In IE the following Codes of Practice apply:

Standard

Scope

I.S. 813

Domestic Gas Installations.

The following standards give valuable additional information;

BS 5546

Installation of hot water supplies for domestic

purposes.

BS EN 12828

BS EN 12831

BS EN 14336

Heating systems in buildings.

Heating systems in buildings - Calculation of load.

Installation & commissioning of water based

heating systems.

BS 7074

BS 7593

Expansion vessels and ancillary equipment for

sealed water systems.

Treatment of water in domestic hot water

central heating systems.

Contents

Section

1.0

Page

Introduction

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

General Layout

Boiler Operation

Technical Data

Dimensions and Fixings

System Details

Site Requirements

Flue Options

Plume Displacement

10.0 Installation

11.0 Electrical

12.0 Commissioning the Boiler

13.0 Completion

14.0 Servicing the Boiler

15.0 Changing Components

16.0 Short Parts List

17.0 Fault Finding

Benchmark Checklist

Facia Securing Screws

1.0 Introduction

1.1

Description

Optional Integral Timer

Position of Label

1. The Potterton Gold FSB 30 HE is a gas fired room

sealed fan assisted condensing central heating boiler.

2. The maximum output of the boiler is 30.18 kW (Non -

Condensing) 32.61 kW (Condensing).

3. The boiler is designed for use on Natural Gas (G20)

only.

4. The boiler is suitable for fully pumped open vented and

sealed systems, providing heating and hot water.

5. A label giving details of the model, serial number and

Gas Council number is situated on the rear of the drop

down facia panel (Fig. 1).

6. The boiler data badge is positioned on the air box door

(Fig. 2).

Fig. 1

7. The boiler is intended to be installed in residential /

commercial / light industrial E.M.C. environments on a

governed meter supply only.

8. The boiler must be installed with one of the purpose

designed flues such as the standard horizontal flue kit, part

no 236921.

Case Securing Screws

1.2

Important Information

Man-made mineral fibre

• Some component parts of this boiler (insulation pads,

gaskets and rope seals) are manufactured from man-made

mineral fibre.

• Prolonged or excessive exposure to this material may

result in some irritation to the eyes, skin or respiratory

tract.

• It is advisable to wear gloves when handling these items.

• Irritant dust will only be released from the items if they

are broken up or subjected to severe abrasion. In these

instances a suitable dust mask and goggles should be

worn.

• Always thoroughly wash hands after installation,

servicing or changing components.

Air Box Door

• When disposing of any items manufactured from man-

made mineral fibre care must be exercised.

• If any irritation of the eyes or severe irritation of the skin

is experienced seek medical attention.

Fig. 2

Data Badge

2.0 General Layout

2.1

Layout (Figs. 3, 4, 5 & 6)

Condensate Pump

Flue Elbow (supplied in std. flue kit)

Heat Exchanger

Burner

Air Box

Fan Protection Thermostat - Black

Fan Assembly

Fig. 5

Condensate Trap

PCB Housing Assembly

Gas Tap

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Gas / Air Ratio Valve

Flow Pipe Connection

Return Pipe Connection

Flow Temperature Safety Thermostat - Black

Flow Temperature Thermistor - Red

Flow Switch (dry fire protection)

Position of Optional Integral Timer Wiring

Pipe Access Panel

Manual Air Vent

2.2

KIT

110Ø Concentric Flues & Optional Extras

PART N^o

Standard Flue Kit 850mm (inc. elbow)

Extended Flue Kit - 1.75M ( inc. elbow)

Flue Plume Deflector Kit

236921

5111457

248167

248484

Terminal Guard (suitable for use with above)

FLUE EXTENSION KITS (110/70)

Flue Extension 250mm

241692

241694

241695

Flue Extension 500mm

Flue Extension 1000mm (Use two kits for 2M etc.)

Flue Bend x 2 - 45° (Reduce overall length of flue

by 0.5m when fitting this bend)

241689

241687

Fig. 3

Flue Bend - 93° (Reduce overall length of flue

by 1m when fitting each bend)

VERTICAL FLUE

Vertical Flue Terminal

242802

Vertical Flue Adaptor

5106888

See Section 7.12 for more flue option details

Integral Twin Channel Timer

5117696

Fig. 6

Fig. 4

3.0 Boiler Operation

3.1

Boiler Operation

Mains On.

Condensate Pump will

operate as necessary (3.1.9)

1. Switched Live On: When switched live is supplied to

the boiler and the flow temperature is less than the set

point the sequence below commences.

Flow

temperature less

than set point ?

2. Flow Switch: After 10 seconds if the flow switch has

made then fan pre-purge occurs. After 10 seconds if

the flow switch has not made then anti-cycle occurs.

3. Fan Pre-Purge: The flow switch is made and the fan

is on while the spark generator and gas valve are off.

After 5 seconds ignition occurs.

YES

System Pump

Running and Flow

switch made ?

4. Ignition: The flow switch is made, fan, spark

generator and gas valve are on. If a flame is detected

then burner on occurs. If a flame is not detected within

5 seconds and less than 5 ignition attempts have been

made then fan purge occurs. If a flame is not detected

within 5 seconds and 5 ignition attempts have been

made then ignition lockout occurs.

YES

Ignition done

and less than 5

attempts made ?

YES

5 second

Fan Pre-Purge.

5. Burner On: The flow switch is made, fan and gas

valve are on while the spark generator is off. Flow

temperature is controlled by varying the fan speed (and

thereby the gas rate) to achieve optimum operation. If

the flow temperature is greater than the set point or

the TRVs all shut down then fan post purge occurs.

5 second

Ignition Period.

6. Fan Post Purge: The fan is on while the spark

generator and gas valve are off. After 5 seconds if the

TRVs are shut down then anti-cycle occurs.

Flame Detected ?

Ignition done and

5 attempts made ?

7. Anti-cycle: The fan, spark generator and gas valve

YES

are off.

Burner On.

YES

8. Ignition Lockout: The fan, spark generator and gas

valve are off. The boiler can only be reset by manually

using the reset button.

All TRVs

shut or Flow temperature

greater than set point ?

Ignition

Lockout.

9. Condensate Pump: Condensate accumulates in a

reservoir within the pump assembly. The pump may

run at any time, independent of boiler operation, to

discharge the condensate to drain.

YES

5 second

Fan Post Purge.

YES

All TRVs

shut down ?

3 minute

Anti-cycle.

4.0 Technical Data

Appliance Type

C₁₃

C₃₃

Horizontal

Electrical Supply

230V~ 50Hz

Flue Terminal

Dimensions

Diameter - 110mm

Projection - 150mm

The boiler must be connected to an earthed

supply. A permanent and switched live are

required. The boiler has a 4 wire connection.

Appliance Category

CAT I

Heat Input (Q)(Gross)

Max

33.76

Min

Connections

Gas Supply

Central Heating Flow

Central Heating Return

Condensate Drain (Pump)

Power Consumption

80W

15mm

28mm

10mm o.d.

10.3

External Fuse Rating

Heat Output (P)

(Non Condensing 70° C Mean Water Temp)

Internal Fuse Rating (BS 4265)

Max

Min

Outercase Dimensions

Casing Height

Casing Width

Fuse

3.15 AT (PCB)

IPXX

30.18

9.2

850mm

390mm

520mm

Electrical Protection

Heat Output (P)

Casing Depth

(Condensing 40° C Mean Water Temp)

Max

Water Content

Min

Minimum Clearances

litres

2.6

(For unventilated compartments see Section 7.2)

32.61

10.0

Both Sides

Above Casing

Under fixed worktop -

(It is recommended that any

worktop is removable)

Front (For Servicing)

Front (In Operation)

5mm

15mm

Static Head

max

Max Gas Rate (2H - G20 - 20mbar)

(After 10 Mins)

30 metres

1 metre

min

kW Input

m³/hr

33.76

3.4

Low Head

0.2m min

25mm

500mm

5mm

Inlet Pressure at Gas Valve (Natural Gas)

System Detail

Fully pumped open vented & sealed systems.

No bypass required.

Min

18.1 mbar

Max

22.5 mbar

Weights

(see Section 10.1)

Packaged Boiler Carton

Packaged Flue Kit

Installation Lift Weight

Installed Weight (dry)

49.5

3.6

37.5

44.5

Controls

Injector (Natural Gas)

boiler thermostat, safety thermostat,

flow switch, electronic flame sensing,

temperature protection thermostat &

condensate blockage and level sensors

Diameter

6.5mm

0.004

CO/CO²Ratio

Recommended System

Temperature Drop

Condensing

NO Class

Boiler Flow Temperature (adjustable)

20°C

55° C to 78° C (± 5° C)

Condensate Pump

Head

3 metres

Flow Rate

Connection

1.8 l/min

10mm o.d. (pipe supplied)

Boiler Hydraulic Resistance Chart

SEDBUK Declaration

220

200

180

160

140

120

100

SAP 2005 Seasonal Efficiency

model is 90.9%

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of

dwellings. The test data from which it has been

calculated has been certified by 0087.

Water Flow Rate (litres/min)

5.0 Dimensions and Fixings

DIMENSIONS

A 850mm

At least

1.5°

B 520mm

C 390mm

D 125mm Ø Min.

E 175mm

F 150mm

The 1.5° fall provided by the elbow

is to allow condensate to run back to

the boiler, for discharge through the

condensate disposal system.

Flue Ø 110mm

Fig. 7

SIDE FLUE (left and right)

For every 1m of horizontal flue

length, the clearance above the top

of the flue elbow should be 27.5mm

to incorporate the 1.5° fall in the flue

from the terminal to the elbow. It is

especially important to consider

this when fitting the boiler under a

work top !

At least

1.5°

Flue length (Y)

up to 1m

1m - 2m

Clearance (X)

27.5mm

55mm

2m - 3m

82.5mm

3m - 4m

110mm

Fig. 8

6.0 System Details

6.1

Water Circulating Systems

1. The boiler is suitable for use with open vent fully

pumped systems and sealed systems .

The following conditions should be observed on all

systems:

• The static head must not exceed 30m of water.

• The boiler must not be used with a direct cylinder.

• Drain cocks should be fitted to all system low points.

• All gas and water pipes and electrical wiring must be

installed in a way which would not restrict the servicing

of the boiler.

• Position isolating valves as close to circulating pump as

possible.

6.2

Treatment of Water Circulating

Systems

1. All recirculatory water systems will be subject to

corrosion unless they are flushed and an appropriate

water treatment is applied. To prevent this, follow the

guidelines given in BS 7593 “Treatment of Water in

Domestic Hot Water Central Heating Systems” and the

treatment manufacturers instructions.

2. Treatment must involve the use of a proprietary

cleanser, such as Sentinel X300 or X400, or Fernox F3

and an inhibitor such as Sentinel X100 or Fernox MB-1.

3. Full instructions are supplied with the products, for

further information contact Sentinel (0800 389 4670) or

Fernox (0870 870 0362).

Failure to flush and add inhibitor to the system will

invalidate the appliance warranty.

4. It is important to check the inhibitor concentration after

installation, system modification and at every service in

accordance with the inhibitor manufacturer’s instructions.

(Test kits are available from inhibitor stockists.)

5. For information or advice regarding any of the above

contact Technical Enquiries 0844 871 1555.

Boiler Air

Vent

Copper

0.5m

6.0 System Details

Copper

0.5m

Flow

6.3

Pipework

Boiler

Return

Copper

1. The sizes of flow and return pipes from the boiler

should be determined by normal methods, according to

the requirements of the system.

Fig. 9

2. The connection tails for the boiler are 28mm diameter.

The 28mm section of the tails can be cut back to 22mm if

required.

22mm

Open Vent

45°

3. The flow & return tails are push - fit ‘O’ ring

and clip connections within the boiler case.

1000mm

Min

15mm

Cold

Feed

400mm

Min Head

Boiler Air

Vent

4. A 20 °C drop in temperature across the system is

recommended for condensing boilers. Existing radiators

may be oversized and so allow this, but where radiator

sizing is marginal it may be advisable to retain a system

temperature drop of 11°C.

150mm

Max

Boiler

Pump

5. In systems using non-metallic pipework it is necessary

to use copper pipe for the boiler Flow and Return. The

copper must extend at least 1 metre from the boiler and

include any branches (Fig. 9).

Flow

Return

Typical Low Head Installation

Fig. 10

6. This boiler does not require a bypass.

6.4

Low Head Installation

22mm

Open Vent

45°

1. Using a close couple arrangement the minimum head is

as shown in the diagrams (Figs. 10 & 11) subject to the

following conditions:

Boiler Air

Vent

15mm

Cold

Feed

400mm

Min Head

1000mm

Min

a) The pump being adjusted to give a 20°C drop across

the boiler.

b) The pump must be fitted on the flow.

c) The pump must be fitted in accordance with the

pump manufacturer's instructions.

Boiler

150mm

Max

d) The open vent pipe must be taken up from a tee in a

horizontal section of the flow pipe.

Pump

Flow

Return

2. For heads below 400mm then an alternative utilising a

combined vent and feed pipe may be connected (Fig. 12).

This must be a minimum of 22mm diameter. It is

recommended that an air separator is fitted when using a

combined feed and vent pipe.

If Conditions Require,

This System Possible

Fig. 11

6.5

Air Vents

22mm

Feed & Vent

Pipe

For correct operation of the flow switch the boiler

and system MUST be completely vented.

200mm

Min

Boiler Air

Vent

1. A manual air vent is fitted on the flow pipe, to enable

complete venting of the boiler. The pipe access panel

must be removed to do this.

Air

Separator

2. Additional vents should be fitted at suitable points on

the system as required.

Boiler

Pump

Flow

Return

Fig. 12

Alternative Low Head Installation

Key to colours

Blue

6.0 System Details

Brown

White

Orange

Grey

6.6

System Controls & Wiring

g/y

Green/Yellow

This boiler requires a permanent live for

operation of the condensate pump and frost

protection.

230V

50Hz

1. To comply with Part L1 of the Building Regulations the

heating system into which the boiler is installed should

include the following:

Y Plan

Diverter

Valve

g/y

Cylinder

Stat

a) zone controls

Room

Stat

b) timing controls

c) boiler control interlocks

2. Such a system needs to be fully pumped and must

provide independent temperature and time control to

both the heating and hot water circuits and have a boiler

and system pump interlock.

S/L

P/L

System Control

Wiring Centre

Boiler Connection

(4 Core Wire)

Timer

3. The boiler should be controlled so that it operates on

demand only. Where it is proposed to effect control by

thermostatic radiator valves a room thermostat should

also be provided to switch off the boiler when there is

no demand for heating.

CH on

HW on

HW off

N E

Pump

Y Plan, Room Thermostat System, CH Interlocked By Room Thermostat,

DHW Interlocked By Cylinder Thermostat

At least the Radiator(s) near the Room Thermostat not TRV’d

Pump run from Switched Live

230V

50Hz

Motor

S Plan

Valve

S Plan

Valve

g/y

Cylinder

Stat

Room

Stat

S/L

P/L

System Control

Wiring Centre

Boiler Connection

(4 Core Wire)

Timer

CH on

HW on

N E

Pump

S Plan, Room Thermostat System, CH Interlocked By Room Thermostat,

DHW Interlocked By Cylinder Thermostat

At least the Radiator(s) near the Room Thermostat not TRV’d

Pump run from Switched Live

6.0 System Details

3 Litre

Top Up Bottle

(if required)

Air

Vent

6.7

Sealed Systems (Fig. 13)

1. SAFETY VALVE - A safety valve complying with the

requirements of BS 6750 Part 1 must be fitted close to

the boiler on the flow pipe by means of a horizontal or

vertically upward connection with no intervening valve

or restrictions and should be positioned to facilitate

testing. The valve should be pre-set and non-adjustable

to operate at a pressure of 3 bar (45 Ibf/in²). It must be

arranged to discharge any water or steam through a pipe

to a safe outlet position.

Filling

Point

Pressure

Gauge

Safety

Valve

Pump

Radiator

Circuit

Expansion

Vessel

2. PRESSURE GAUGE - A pressure gauge of minimum

range 0-4 bar (0-60 Ibf/in²) with a fill pressure indicator

must be fitted to the system, preferably at the same

point as the expansion vessel in an easily visible position.

Boiler

System Drains at

Low Point

Max Boiler Flow

Temp = 82° C

3. EXPANSION VESSEL - An expansion vessel

complying with the requirements of BS 4814 must be

fitted to the system by means of a connection close to

the inlet side of the circulating pump in accordance with

the manufacturers instructions, the connecting pipe being

unrestricted and not less than 15mm (¹/²in) nominal size.

The volume of the vessel should be suitable for the

system water content and the nitrogen or air charge

pressure should not be less than the system static head

(See Table. 1).

Fig. 13

Method of determining minimum expansion

vessel volume for sealed systems.

Multiply Total

Vessel Charge

Pressure (Bar)

Initial System

Pressure (Bar)

Water Content Of

System By (Litres)

Further details of sealed system design can be obtained

from BS 5449 and the British Gas publication entitled

'Specifications for Domestic Wet Central Heating

Systems'.

0.5

1.0

1.5

2.0

0.067

0.112

0.207

0.441

0.5

1.0

1.5

4. FILLING POINT - A filling point connection on the

central heating return pipework must be provided to

facilitate initial filling and pressurising and also any

subsequent water loss replacement / refilling. The sealed

primary circuits may be filled or replenished by means of

a temporary connection between the primary circuit and

a supply pipe provided a ‘Listed’ double check valve or

some other no less effective backflow prevention device

is permanently connected at the inlet to the circuit and

the temporary connection is removed after use. The

filling method adopted must be in accordance with all

relevant water supply regulations and use approved

equipment.

1.0

1.5

2.0

0.087

0.152

0.330

1.5

2.0

0.125

0.265

Example :- System Volume = 75 litres

Vessel Charge Pressure = 1.0 bar

Initial System Pressure = 1.5 bar

Then :- 75 x 0.152 = 11.4 litres

Expansion Vessel Volume

Table. 1

Your attention is drawn to, for GB: Guidance G24.2 and

recommendation R24.2 of the Water Regulations Guide.

for IE: the current edition of I.S. 813 “Domestic Gas

Installations”.

NOTE

Where a vessel of the calculated size is not obtainable then

the next available larger size should be used.

5. MAKE UP SYSTEM - A method of replacing water

lost from the system should be provided either by

means of a make up vessel of not more than 3 litres (5

pints) capacity, mounted above the highest point of the

system, or by re-pressurisation of the system.

6. VENTING - A method of venting the system during

filling and commissioning must be provided by fitting

automatic air vents or by venting manually.

Double

Check

Valve

7. HOT WATER STORAGE - The hot water storage

vessel must be of the indirect coil type.

Stop

Valve

Stop

Valve

8. COMPONENTS - All components used in the system

must be suitable for operation at 110°C (230°F) and at

the pressure allowed by the safety valve.

Mains

Inlet

Temporary

Hose

Return

Fig. 14

7.0 Site Requirements

7.1

Location

NOTE: Due to the high efficiency of the boiler a

plume of water vapour will be discharged from the

flue. This should be taken into account when siting

the flue terminal.

1. The boiler must be fitted on a suitable flat and level

surface capable of supporting the weight. Any wall behind

the boiler must be at 90° to the floor to allow case top

cover to fit correctly.

Zone 2

Window

2. The flue must pass through an outside wall or roof and

discharge to atmosphere in a position permitting

satisfactory removal of combustion products and

providing an adequate air supply.

Recess

Zone 1

Zone 0

Zone 2

3. The boiler should be fitted within the building unless

otherwise protected by a suitable enclosure i.e. garage or

outhouse.

0.6 m

Window

Recess

4. The boiler incorporates a frost protection device. This

will only protect the boiler. To ensure protection of the

system pipework and components it is recommended to

incorporate an appropriate device within the system

controls.

Zone 2

5. If the boiler is fitted in a room containing a bath or

shower, it can only be fitted in Zone 3, (Figs. A & B

shows zone dimensions for a bathtub. For other

examples refer to the Current I.E.E. Wiring Regulations).

Reference must be made to the relevant requirements:-

In GB this is the current I.E.E. Wiring Regulations and

Building Regulations.

Fig. A

In GB Only

Ceiling

Window Recess

Zone 2

Outside Zones

In IE reference should be made to the current edition of

I.S. 813 “Domestic Gas Installations” and the current

ETCI rules.

6. If the boiler is to be fitted into a building of timber

frame construction then reference must be made to the

current edition of Institute of Gas Engineers Publication

IGE/UP/7 (Gas Installations in Timber Framed Housing).

2.25 m

Zone 1

Zone 0

Zone 2

0.6 m

7.2

Compartment

1. Where the boiler is installed in a cupboard or

compartment, no air vents are required for cooling

purposes providing that the minimum dimensions below

are maintained.

Fig. B

In GB Only

Width

Height

Depth

400mm

875mm

525mm

2. Any compartment should be large enough to house

the boiler only.

7.0 Site Requirements

5mm Min

390mm

7.3

Clearances (Figs. 15 &16)

15mm Min

1. These dimensions include the necessary clearances

around the boiler for case removal, spanner access and air

movement. Additional clearances may be required for the

passage of pipes around local obstructions such as joists

running parallel to the front face of the boiler. For side flue

installations also See Section 8.1, Figs. 20 & 21.

(25mm if under

non removable

worktop)

2. It is recommended that any worktop is removable for

servicing access.

7.4

Gas Supply

850mm

1. Check that the information concerning the state of

adjustment given on the data plate is compatible with local

supply conditions.

2. The gas installation should be in accordance with the

relevant standards. In GB this is BS 6891. In IE this is the

current edition of I.S. 813 “Domestic Gas Installations”.

3. The connection to the boiler is a 15mm tail on the gas

service cock. The tail protrudes through the boiler rear

panel and is protected by a transit bracket which may be

removed to aid connection.

Fig. 15

4. Ensure that the pipework from the meter to the boiler

is of adequate size. (If the boiler is further than 3 metres

from the Gas Meter 22mm pipe should be used). Do not

use pipes of a smaller diameter than the boiler gas

connection.

7.5

Electrical Supply

1. External wiring must be correctly earthed, polarised and

in accordance with relevant regulations/rules. In GB this is

the current I.E.E. Wiring Regulations. In IE reference

should be made to the current edition of ETCI rules.

2. The mains supply is 230V ~ 50Hz fused at 3A.

500mm Min

NOTE: “The method of connection to the electricity

supply must facilitate complete electrical isolation of the

appliance and system”.

For Servicing

Purposes

Connection may be via a fused double-pole isolator with a

contact separation of at least 3mm in all poles, which must

be in an accessible position to the user and serve the

boiler and system controls only.

There is no method of isolating the boiler at the user

interface.

3. Four core cable is required to supply the boiler as a

permanent live is necessary for the operation of the

condensate pump and frost protection.

520mm

5mm Min

Fig. 16

In Operation

7.0 Site Requirements

Condensate Pump Flow Graph

7.6

Condensate Drain - General

Failure to install the condensate discharge pipework

correctly will affect the reliable operation of the boiler.

1. Ensure the discharge of condensate complies with any

national or local regulations in force.

BS 6798 & Part H1 of the Building Regulations give further

guidance.

2. If any further drain pipe is required (additional to that supplied

with the boiler), it should be run in a proprietary material

e.g. PVC, PVC-U, ABS, PVC-C or PP.

3.5

2.5

Flow (l/min)

1.5

3. Metal pipework is NOT suitable for use in condensate

discharge systems.

4. Any pipe fitted externally must be kept as short as possible to

minimise the potential of freezing and must be insulated using

waterproof material.

Min. radius 100mm

Point ‘A’

5. When discharging condensate into a soil stack or waste pipe

the effects of existing plumbing must be considered.

Gravity Drain min. fall 3°

7.7

Condensate Disposal

Note: The point of discharge from

1. This boiler incorporates an automatic pumped condensate

system. See the graph opposite for available pump flow rates.

the pumped length of condensate

pipe (point ‘A’) must not be below

the level of the pump, whether

discharging direct into a drain or

into an additional gravity drain.

Max. Head

3 metres

2. 3.5 metres of flexible 10mm PVC pipe are supplied with the

boiler. 0.5 metres of this length remains coiled within the boiler

to allow removal of the pump assembly. This must not be

uncoiled to provide extra length.

Boiler

3. A fitting and securing clip (Fig. B) to accept the 10mm PVC

pipe and connect to 21.5mm overflow pipe is also supplied.

Alternative Horizontal

Discharge

4. The 10mm pipe can be routed to a maximum of 3 metres

vertically and then discharge via gravity or be routed horizontally

(Fig. A). A combination of vertical and horizontal runs is

permissible.

Fig. A

5. The pipe must be supported, either using suitably spaced clips

or run within larger diameter pipe. When using clips take care

not to deform the pipe.

10mm PVC Pipe

(8.5mm I.D.)

6. When routing the pipe through a wall it must be suitably

sleeved. Also the pipe must not be exposed to sources of heat,

and should be protected in locations where it may be damaged.

Securing Clip

8.5mm Ø O.D.

7. The pipe should be routed so that any sharp bends, dips and

loops are avoided. A minimum radius of 100mm is

recommended for any bends. No slope is necessary and air

breaks are not required on the pumped part of the condensate

run.

8. If the boiler is fitted in an unheated location the entire length

of condensate pipe should be treated as external, and run within

insulated larger diameter pipe.

21.5mm Ø O.D. to fit

Overflow Pipe

Condensate Pipe

Direct Connect

Fitting

Fig. B

7.0 Site Requirement

Termination via internal discharge branch e.g

sink waste - downstream

7.7

Condensate Disposal (cont.)

Pipe must terminate

Direct Connect Fitting

above water level but

below surrounding surface

9. Ensure that the condensate can discharge freely (without

blockage or restriction of the pipe) into the drain.

Sink

10. Examples are shown of condensate pipe methods of

termination:-

Branch of Tee to be

± 10° from vertical

i) via an internal discharge branch

(e.g. sink waste) - Fig. C.

10°

ii) to an internal or external soil and vent pipe -

Fig. D.

From Boiler

Fig. C

iii) to a drain or gully - Fig. E. Ensure that the

condensate can discharge freely (without

blockage or restriction of the pipe) into the

drain.

iv) to a soakaway - Fig. F.

Termination to an internal soil and vent pipe

Direct Connect Fitting

From Boiler

Min. 450mm

Fig. D

Termination to a drain or gully

Pipe must terminate above

water level but below

surrounding surface

From Boiler

Fig. E

Termination to a purpose made

soak-away

500mm Min

Holes in the soak-away must

face away from the building

From Boiler

Fig. F

7.0 Site Requirements

Terminal Position with Minimum Distance (Fig. 17)

(mm)

Directly below an opening, air brick, opening

windows, etc.

Above an opening, air brick, opening window etc.

Horizontally to an opening, air brick, opening window etc.

Below gutters, soil pipes or drain pipes.

Below eaves.

300

7.8

Flue

NOTE: Due to the high efficiency of the boiler a plume of

water vapour will be discharged from the flue. This should

be taken into account when siting the flue terminal.

Below balconies or car port roof.

From a vertical drain pipe or soil pipe.

1. The following guidelines indicate the general requirements

for siting balanced flue terminals.

For GB recommendations are given in BS 5440 Pt.1.

For IE recommendations are given in the current edition of I.S.

813 “Domestic Gas Installations”.

115

300

600

1200

600

(i)

(ii)

(i)

(ii)

From an internal or external

corner.

Above ground, roof or balcony level.

From a surface or boundary line facing a terminal.

From a terminal facing a terminal (Horizontal flue).

From a terminal facing a terminal (Vertical flue).

From an opening in carport (e.g. door, window)

into the dwelling.

2. If the terminal discharges onto a pathway or passageway,

check that combustion products will not cause a nuisance and

that the terminal will not obstruct the passageway.

1200

1500

300

Vertically from a terminal on the same wall.

Horizontally from a terminal on the same wall.

3. When siting the flue take into consideration the effect the

plume of water vapour may have on neighbours .

From adjacent wall to flue (vertical only).

From an adjacent opening window (vertical only).

Adjacent to windows or openings on pitched and flat roofs

Below windows or openings on pitched roofs

300

1000

600

4. Adjacent surfaces close to the flue terminal may need

protection from the effects of condensation. Alternatively a flue

deflector kit (part no. 248167) is available.

2000

Table. 2

5. For installation of the flue into an internal corner at the

25mm dimension the flue plume deflector kit (part no. 248167)

must be fitted.

In addition, the terminal should be no nearer than 150 mm to an

opening in the building fabric formed for the purpose of accommodating

a built-in element such as a window frame. See BS 5440 Pt. 1.

6. * Reduction to the boundary is possible down to 25mm but

the flue plume deflector kit (part no. 248167) must be fitted.

NOTE: The distance from a fanned draught boiler terminal

installed parallel to a boundary may not be less than 300mm

in accordance with the diagram below, unless the flue deflector

kit is used (see 7.8.6 opposite)

7. If a terminal is less than 2 metres above a balcony, above

ground or above a flat roof to which people have access, then

a suitable terminal guard must be provided.

300 min

Terminal

Assembly

8. If required a suitable terminal guard (part no. 248484) is

available from Potterton for use with the flue deflector. See

also Section 8.8.

9. For fitting under low soffits and eaves the Plume

Displacement Kit or Flue Deflector Kit is recommended.

TopView Rear Flue

IMPORTANT:

• Only ONE 25mm clearance is allowed per installation.

• Under car ports we recommend the use of the plume

displacement kit.

Fig. 16a

Property Boundary Line

• The terminal position must ensure the safe and

nuisance - free dispersal of combustion products.

IMPORTANT: If fitting a Plume

Displacement Flue Kit, the air inlet

must be a minimum of 150mm from

any opening windows or doors.

J,K

Plume

Displacement Kit

J,K

Air Inlet

Likely flue positions requiring

a flue terminal guard

Fig. 17

Opening Window

or Door

150mm

MIN.

Fig. 17a

8.0 Flue Options

8.1

Horizontal Flue Systems

Only a flue approved with the Potterton Gold FSB HE 30

can be used.

(ii)

(i)

Concentric

The maximum equivalent lengths are 4m (horizontal) or

(vertical). Their lengths exclude the standard elbow and

flue/terminal assembly (horizontal) and terminal assembly

(vertical).

Horizontal

Flue System Examples

Any additional “in line” bends in the flue system must be

taken into consideration. Their equivalent lengths are:

Concentric Pipes:

45° bend

93° bend

0.5 m

1.0 m

(ii)

(i)

NOTE: Flue length is measured from point (i) to (ii) as

shown.

Plume Displacement 70/110 dia Kit

1M Extensions, 45° & 93° bends

are also available - see Section 9.0

IMPORTANT: All flue systems must be securely

supported at least once every metre. Suitable pipe

supports are available as accessories.

NOTE: Horizontal flue pipes should always be installed with a 1.5° fall from the

terminal to allow condensate to run back to the boiler.

This bend is equivalent to

0.5 metre

(ii)

This bend is equivalent to

0.5 metre

(i)

Total equivalent length =

A+B+2x45°Bends

Vertical Flue System

Examples (Twin Pipe)

8.0 Flue Options

8.2

Twin & Vertical Flue Systems

Concentric

The maximum equivalent lengths are 4m (vertical). Their

lengths exclude the standard elbow and terminal assembly

(vertical).

(ii)

(i)

Twin Flue

The total maximum equivalent flue length is 150m.

NOTE: Each 1m of flue duct should be calculated as 2m.

Any additional “in line” bends in the flue system must be

taken into consideration. Their equivalent lengths are:

Concentric Pipes:

135° bend

93° bend

0.5 m

1.0 m

Twin Flue Pipe:

135° bend (air duct)

135° bend (flue duct)

90° bend (air duct)

90° bend (flue duct)

1.3 m

2.6 m

4.8 m

9.6 m

(ii)

(i)

IMPORTANT: All flue systems must be securely

supported at least once every metre. Suitable pipe

supports are available as accessories.

Vertical Flue

System Examples

Total Equivalent Length =

A+B+C+1x90°Bend

Roof

Terminal

All vertical and angled runs must be included,

measured from the boiler adaptor (point X) to the

joint with the flue terminal (point Y). One 91.5°

bend or two 135° bends can be included without

reduction of the flue length.

The total equivalent length

for this example is

17.2 + 34.4 = 51.6 metres.

If further elbows are required the flue length must

be reduced by the following amounts:-

(ii)

1 metre for each 91.5° bend

0.5 metre for each 135° bend

AIR DUCT

N^oof

Equivalent

Sub total

Length Value

fittings/pipes

1m extension

135°bend

5.0m

2.6m

9.6m

1.3m

4.8m

91.5°bend

This bend is equivalent to

1 metre

Equivalent Length Air Duct = 17.2m

FLUE DUCT

N^oof

Sub total

Equivalent

Length Value

fittings/pipes

(i)

1m extension

135°bend

10.0m

5.2m

2.6m

91.5°bend

19.2m

9.6m

Equivalent Length Flue Duct = 34.4m

8.0 Flue Options

8.3

Flue Accessories

Key Accessory

FLUE GROUP B

Concentric Flue System 110mm diameter

Size

Code No

Horizontal Flue Terminal

Horizontal Flue Terminal (incl elbow)

850mm

243013BAX

236921

Flue Extension

1000mm 241695

500mm

250mm

93°

135°

110mm

241694

241692

241687

241689

243014BAX

5106888

248167

Flue Bend

Flue Bend (pair)

Pipe Support

Vertical Flue Boiler Adaptor

Flue Terminal Deflector

FLUE GROUP P

Twin Flue System 80mm diameter

Flue Extension (pair)

1000mm 246137

500mm

250mm

90°

246136

246135

5121560

5121561

242757

5111081

Flue Bend (pair)

Flue Bend (2 pair)

Vertical Flue Boiler Adaptor Kit

Pipe Support (pair)

135°

80mm

FLUE GROUP B,P

Vertical Flue Kits

Vertical Flue Terminal

242802

243015

243131

243016BAX

Pitched Roof Flashing

Roof Cover Plate

Flat Roof Flashing

25°/50°

U,W

8.0 Flue Options

For Vertical Flues

8.4

For Vertical Flue Systems

Vertical Flue

Adaptor

1. Undo the screws securing the blanking plate to the

boiler top panel. Discard the plate.

Gasket

2. Fix the vertical adaptor and gasket to the top panel with

the previously removed screws.

Blank Plate

8.5

For Twin Flue Systems

1. Undo the screws securing the blanking plate to the

boiler top panel. Discard the plate.

2. Fix both the air and flue adaptors with their gaskets

onto the boiler top panel. Secure with screws.

For Twin Flues

Air Duct

Adaptor

Flue Duct

Adaptor

Gasket

8.0 Flue Options

8.6

For Roof Terminals

1. In the case of a pitched roof 25 - 50 degrees, position

the lead tile to replace/flash over existing roof tiling. Make

an aperture in the roof suitable for the lower tube of the

roof terminal and ensure the integrity of the roof cover is

maintained. The adjustable plastic collar can either be

positioned on the lead tile or the lower tube of the roof

terminal prior to the final positioning of the vertical flue

through the tile. Check the collar is correctly located to suit

required roof pitch (either 25° to 38° or 37° to 50°). From

inside the roof adjust the flue to a vertical position and

secure to the roof structure with the clamp supplied.

Approx

1425mm

2. For flat roof installations the aluminium flashing must be

incorporated into the roof covering and the appropriate

aperture made in the roof decking. The vertical flue is

lowered onto the flashing making sure the collar of the flue

locates securely with the flashing. (A mastic seal may be

necessary). From inside the roof, adjust the flue to a vertical

position and secure to the roof structure with the clamp

supplied.

Cut the same

amount off the

Air Duct &

Flue Duct

Air Duct

Flue Duct

Push Fit Adaptor

IMPORTANT: If the boiler is not fitted immediately

after the flue system, temporary precautions must be

taken to prevent rain entry into the room of installation.

Any precautionary measures must be removed prior to

commissioning the boiler.

8.7

Flue Dimensions

The standard horizontal flue kit allows for flue lengths

between 270mm (10⁵/⁸”) and 800mm (32”) from elbow to

terminal (Fig. 18).

The maximum permissible equivalent flue length is: 4

Flue Deflector

metres.

NOTE: Each additional 45° of flue bend will account

for an equivalent flue length of 0.5m.

Fig. 18

eg. 45° = 0.5m,

90° = 2 x 45° = 1m etc.

8.8

Terminal Guard (Fig. 19)

Fig. 18a

1. When codes of practice dictate the use of terminal

guards, they can be obtained from most Plumbers’ and

Builders’ Merchants.

2. When ordering a terminal guard, quote the appliance

model number.

3. The flue terminal guard should be positioned centrally

over the terminal and fixed as illustrated.

8.9

Flue Deflector (Fig. 18a)

1. If required, push the flue deflector over the terminal end

and rotate to the optimum angle for deflecting plume.

Secure the deflector to the terminal with screws provided.

Fig. 19

9.0 Plume Displacement

Plume Outlet (‘Peak’

MUST be Uppermost)

9.1

Plume Displacement Kit (P.D.K.)

Kit No 5121371

Content of kit

70/110 Concentric Flue

1m 70 Dia Exhaust Flue Pipe

Support Brackets

0.94 metre

93° Elbow/Plume Outlet Assembly

Flue Trim

“O” Rings

Elbow with Gasket

1. This kit is recommended for installations where the

condensate plume emitted from the flue may cause a nuisance

or affect the surroundings.

2. The terminal must be positioned outside the building with

the outlet connection upwards.

3. The 70Ø pipe connects to the outlet of the concentric

terminal assembly. The elbow/plume outlet must be fitted to

the end of the 70Ø pipe.

NOTE: The plume outlet must always be at least 45° to

the wall, with the ‘peak’ uppermost to prevent rain entry

(Figs. A & B), and be at least 2 metres above ground level.

It must be secured as shown in Fig. C.

The outlet must be positioned so that any condensate

plume is directed away from adjacent surfaces.

Fig. C

4. It is possible to reduce or increase (with the addition of

extensions) the length of either or both the 70/110 concentric

and 70Ø exhaust.

5. Standard concentric flue extension kits may be added

between the boiler elbow and the terminal assembly.

Outlet must be

at least 45° from

wall face

‘Peak’ MUST be

Uppermost

45°

6. The minimum length of the concentric flue is 100mm when

measured from the edge of the boiler flue elbow. There is a

further 45mm engagement into the elbow.

IMPORTANT: The maximum equivalent length of

concentric flue is:- 4 metres

Additional elbows may be fitted in the concentric flue, but

the equivalent length must be reduced by 1 metre (93°

elbow) or 0.5 metres (45° elbow).

7. 70Ø 1 metre extensions (including support bracket), and

additional 93° & 45° elbows are available. Any additional 93°

& 45° elbows must be accounted for when calculating flue

lengths. 70Ø 93° elbows are equivalent to 3.5 metres of

straight length and 45° elbows to 1 metre.

500mm Min.

NOTE: Permitted positions of the plume outlet relative to

doors, windows etc. are the same as for conventional

concentric flues as detailed in the main Installation &

Servicing Instructions and BS5440 Pt. 1. It is NOT

necessary to fit a terminal guard over the air inlet or the

plume outlet.

Fig. A

Outlet Connection

upwards

Fig. B

9.0 Plume Displacement

9.2

Determining Permissible Lengths - P.D.K.

In the graph the solid line diagonal represents the

relationship between the concentric flue assembly (and any

extensions) and the 70Ø exhaust (and any extensions or

additional bends).

Example 1 - Not Permissible

If, for instance, a concentric length of 3.25 metres was

required and the 70Ø exhaust needed to be 10 metres the

graph shows that this combination would NOT be

permissible as the intersection point would be above the

solid diagonal line.

Concentric 70/110 Flue (metres)

Example 1

Example 2

Flue Lengths - Not Permissible

Flue Lengths - OK

Example 2 - Flue Lengths OK

Where both lengths have been determined they can be

applied to the graph to check that the installation is

permissible. For example, if it was known that 2 metres of

concentric flue and 4 metres of 70Ø exhaust were required,

the values could be applied to the graph as shown in

Example 2.. As the point of intersection of the dotted lines is

below the solid diagonal line, the combination of lengths is

shown to be acceptable.

Example 3 - Flue Lengths OK

In the example shown, assume that the concentric part of

the flue needs to be 2 metres long. Find the position of ‘2’ on

the horizontal axis of the graph and then project upwards to

the solid diagonal line. This is represented by the vertical

thick dotted line. Where this dotted line intersects with the

solid diagonal line on the graph, project across to the vertical

axis. As can be seen this corresponds with 14 metres.

Therefore, the total equivalent length of the 70Ø exhaust

can be up to 14 metres. Any elbow equivalencies must be

accounted for i.e. 93° elbows are equal to 1 metre, each 45°

elbow to 0.5 metres.

Concentric 70/110 Flue (metres)

Example 3

Flue Lengths - OK

Support

Bracket

70Ø Exhaust

45° Elbow

Flue Length - Worked Example

In Fig. D opposite an additional 93° elbow and pair of 45°

elbows have been included in the 70Ø exhaust.

Also 3 straight extension pieces have been used.

93° Elbow

1 metre Extension

To calculate total length:-

1 metre supplied in kit

Length of 70Ø supplied in kit =

3 x 1 metre Extensions =

1 x 93° Elbow =

1 metre

3 metres

1 metre

Concentric 70/110 Flue

(MUST be installed

horizontally)

2 x 45° Elbow =

1 metre (0.5 metres each)

Concentric Flue

Total 70Ø =

6 metres

After consulting the table in Example 3 it can be determined

that the concentric flue could be up to approximately 3.25

metres long.

Additional Accessories

A - 93° Elbow

B - 45° Elbow (Pair)

5117381

5117382

C - 1 metre 60Ø Extension 5117380

Fig. D

9.0 Plume Displacement

9.3

General Fitting Notes - P.D.K.

1. Cut a hole in the external wall which the horizontal

concentric flue assembly will pass through.

This section of the

flue MUST be

horizontal

2. When completed the terminal must be at least 2 metres

above ground level (Fig. E).

Min. 2 metres

3. Measure and cut to size the concentric assembly and any

extensions that are being used.

4. Insert the concentric assembly through the hole from

outside the building and mark the position of the flue trim

securing holes.

Min. 0.3 metres

5. Drill and plug the wall to accept the flue trim securing

screws, and re-insert the concentric assembly through the

wall.

6. Connect any extensions that are being used to the

concentric assembly. Engage the extension or concentric

assembly in the boiler flue elbow.

7. Fit the boiler flue elbow to the boiler top panel, ensuring

the gasket is in place (Fig. F).

Fig. E

Ensure that the concentric assembly is horizontal and that

the external air inlet is to the bottom. Any extensions

should fall back to the boiler.

8. Use suitable brackets to support the concentric assembly

and any extensions, and make good inside and outside.

Secure the flue trim to the wall.

9. The 70Ø exhaust can now be fitted to the spigot at the

terminal end.

10. If it is necessary to shorten the 70Ø exhaust or any of

the extensions, the excess material must be cut from the

plain end of the pipe.

Fig. F

11. Determine the position of the 70Ø exhaust and mark

on the wall a suitable position for the support bracket. Drill

and plug the wall. If extensions are being used, a support

bracket is supplied in each kit.

12. Engage the M6 threaded part of the mounting bolt in

the boss on the support bracket. Using the bracket for

leverage, screw the mounting bolt into the plugged hole

until the bracket is secure and level (Fig. G).

13. Slacken the two screws securing the retaining strap to

the bracket, and pivot the strap aside to allow fitting the

70Ø exhaust.

14. Complete the installation of the 70Ø exhaust, securing

in the brackets. Fit the 93° elbow and plume outlet. Ensure

the plume outlet is at least 45° to the wall and that the

‘peak’ is uppermost.

Fig. G

15. Continue with installation and commissioning of the

boiler.

9.0 Plume Displacement

Plume Outlet

9.3

General Fitting Notes - P.D.K. (cont.)

Elbow

16. For aesthetic purposes it is permissible to route the

70Ø exhaust in an enclosed box, but the air inlet and

plume outlet MUST remain in free air.

17. It is also possible to separate the plume outlet from

the 93° elbow to allow the flue to be installed as shown

in Fig. H.

18. When the plume outlet is positioned under a balcony

or other projection (Figs. I & J) it must protrude at least

200mm (it is not necessary to extend it further than this).

Fig. H

200mm Min.

Fig. I

200mm Min.

Fig. J

10.0 Installation

Example

Edge of Boiler

125mm

Check Site Requirements before commencing.

EXAMPLE: If the boiler is 2 metres

away from corner of wall the flue

duct hole will be 55mm higher than

the horizontal side flue centre line.

This will maintain an approx. 1.5°

backfall to the boiler. It is especially

important to consider this when

fitting the boiler under a work top !

10.1

Initial Preparation & Installation

Example

V = 55mm

1. Remove the outer carton.

2. For the boiler to operate correctly it must be level

in both planes. Place the fixing template in the

proposed boiler position ensuring that it is level.

Horizontal

Side Flue

Centre Line

3. Mark the centre of the flue hole (rear exit).

For side exit: project the horizontal side flue centre

line into the corner of the room and along the wall to

where the flue hole will be drilled. (Fig. 20).

Centre

Hole

Wall Thickness

up to 227mm

Flue Hole ø

125mm core drill

150mm core drill

175mm core drill

The diagram (Fig. 21) shows the dimensions required

to ensure any horizontal flue is installed with the

correct fall to the boiler. Mark the offset (V) dimension

and if required, mark the position of the gas, water and

condensate pipes. Remove the template.

up to 750mm

up to 1200mm

Template

Fig. 20

4. Cut the hole for the flue (minimum diameter

125mm, see table (Fig. 20) for wall thicknesses and flue

hole diameters).

Backfall to the boiler, ie. 2m flue offset (V) position 55mm

Flue Duct Hole

OffsetV (mm)

13.5

27.5

82.5

110 (mm)

5. Complete any pipework and wiring that will be

inaccessible once the boiler is in position.

1.5°

6. Undo the securing screws and remove the facia,

front door panel and top panel (see Figs. 1 & 2 on

page 6). Remove the securing screw and disengage the

pipe access panel.

0.5

1.0

2.0

3.0

10.2

Making the Water Connections

4.0

(metres)

1. If desired the flow and return tails supplied with the

boiler can be fitted at this stage and secured with the

spring clips. The flow and return connections are

identified on the boiler rear panel. The flow pipe

incorporates a manual air vent.

Fig. 21

2. Note that the seal is made by use of an ‘O’ ring,

therefore some pipe movement will be evident even

though a water tight seal has been achieved. Excessive

force could result in damage to the connection.

3. Make all soldered joints before connecting the tails

to the boiler to avoid damaging the ‘O’ rings.

4. Refit the pipe access panel.

10.3

Making the Gas Connection

1. The connection to the boiler is a 15mm tail on the

gas service cock. The tail protrudes through the boiler

rear panel and is protected by a transit bracket which

may be removed to aid connection (see Fig. 22).

Flow

Tail

Hole for

Electrical

Cable

Return

Tail

2. If solder joints are being used for the gas connection,

remove the gas tap from the valve as excessive heat

may damage the ‘O’ ring seal.

Hole for

Transit

Bracket

Condensate

Drain Outlet

10.4

Priming the Condensate Trap

1. Using a funnel and tube, carefully pour

Gas

approximately 1 cupful (250ml) of tap water into the

flue products exhaust at the terminal or flue elbow

sampling point to ensure a seal is made in the trap.

Connection

Fig. 22

10.0 Installation

Wall Thickness

10.5

Fitting the Standard Flue

IMPORTANT: The flue should always be installed

with at least 1.5° fall from terminal to elbow, to

allow condensate to run back to the boiler.

At least

1.5°

1. The standard flue is suitable for lengths 270mm

minimum to 800mm maximum (measured from the

edge of the flue elbow outlet).

Rear Flue: maximum wall thickness - 575mm

Side Flue: maximum wall thickness - 535mm

2. For rear exit - measure the wall thickness

(Fig. 26) and to this dimension add 270mm. This

dimension to be known as (X).

i.e. (X) = wall thickness + 270

3. Take the flue and mark off (X) from the terminal end

as indicated in the diagram (Fig. 27).

4. For side exit - measure the distance from the edge

of the boiler case to the inner face of the wall (Fig. 26)

and to this dimension add the wall thickness + 280mm.

This dimension to be known as (Z).

i.e. (Z) = case to wall + wall thickness + 280

5. Take the flue and mark off (Z) from the terminal end

as indicated (Fig. 27).

Edge of Boiler Case to Wall

Wall Thickness

Before cutting check your dimensions !

6. The flue tubes are fixed together. Cut through both

tubes whilst resting the flue on the semi-circular packing

pieces. Deburr both tube ends.

Fig. 26

NOTE: When cutting ensure the cut does not

interfere with the inner flue support bracket

(Fig. 27a).

(Z) = Side Exit

(X) = Rear Exit

Waste

Flue

Fig. 27

Inner Flue Support Bracket

Fig. 27a

10.0 Installation

10.5

Fitting the Standard Flue (Cont)

Inner Flue Support Bracket

7. Ensure the inner flue support bracket is positioned

in the flue (Fig. 28).

8. Engage the flue into the flue elbow using soap

solution to ease the engagement, ensuring the flue

terminal is positioned as shown (Fig. 29).

Fig. 28

9. Place the gasket over the flue exit on the boiler.

10. Slide the flue assembly through the hole in the wall.

Flue

11. Engage the elbow on to the flue connection on top

of the boiler. Secure with the four screws supplied in

the kit.

12. Make good between the wall and air duct outside

the building ensuring the 3° drop between the terminal

and elbow.

Flue Elbow

13. The flue trim should be fitted once the installation

is complete and the flue secure (Fig. 30). Apply a

suitable mastic to the inside of the trim and press

against the wall finish, making sure the brickwork is

dust free and dry.

Fig. 29

14. If necessary fit a flue plume deflector kit and/or

terminal guard (see Sections 7.6 & 8.8).

Gasket

Fig. 30

Flue Trim

Shaded Areas indicate

Recommended Handling

Points

Min. radius 100mm

Point ‘A’

10.0 Installation

Gravity Drain min. fall 3°

Note: The point of discharge from

10.6

Making the Condensate Drain

Connection

the pumped length of condensate

pipe (point ‘A’) must not be below

the level of the pump, whether

discharging direct into a drain or

into an additional gravity drain.

Max. Head

3 metres

Boiler

1. 3.5 metres of flexible 10mm PVC pipe are supplied

with the boiler, ready connected to the pump. 0.5

metres of this length remains coiled within the boiler

to allow removal of the pump assembly. This must not

be uncoiled to provide extra length.

Alternative Horizontal

Discharge

2. A fitting and securing clip (Fig. B) to accept the

10mm PVC pipe and connect to 21.5mm overflow

pipe is also supplied. When using this fitting to connect

to a 21.5mm overflow tee piece the branch must be

vertical ± 10° (Fig. C).

Fig. A

10mm PVC Pipe

(8.5mm I.D.)

Condensate Pipe

Direct Connect

Fitting

3. Feed the pipe through the grommet in the rear

panel and connect to the drain system.

Securing Clip

4. The 10mm pipe can be routed to a maximum of 3

metres vertically and then discharge via gravity or be

routed horizontally (Fig. A). A combination of vertical

and horizontal runs is permissible.

8.5mm Ø O.D.

21.5mm Ø O.D. to fit

Overflow Pipe

Fig. B

5. The pipe must be supported, either using suitably

spaced clips or run within larger diameter pipe. When

using clips take care not to deform the pipe.

Termination via internal discharge branch e.g

sink waste - downstream

Pipe must terminate

Direct Connect Fitting

Branch of Tee to be

± 10° from vertical

above water level but

below surrounding surface

10°

6. When routing the pipe through a wall it must be

suitably sleeved. Also the pipe must not be exposed to

sources of heat, and should be protected in locations

where it may be damaged.

Sink

7. The pipe should be routed so that any sharp bends,

dips and loops are avoided. A minimum radius of

100mm is recommended for any bends. No slope is

necessary and air breaks are not required on the

pumped part of the condensate run.

From Boiler

Fig. C

Termination to an internal soil and vent pipe

8. If the boiler is fitted in an unheated location the

entire length of condensate pipe should be treated as

external, and run within insulated larger diameter pipe.

Direct Connect Fitting

9. Ensure that the condensate can discharge freely

(without blockage or restriction of the pipe) into the

drain.

From Boiler

Min. 450mm

Fig. D

10. Examples are shown of condensate pipe methods

of termination:-

Termination to a drain or gully

i) via an internal discharge branch

(e.g. sink waste) - Fig. B.

Pipe must terminate above

water level but below

surrounding surface

ii) to an internal or external soil and vent

pipe - Fig. C.

Termination to a purpose made

soak-away

iii) to a drain or gully - Fig. D. Ensure that

the condensate can discharge freely

(without blockage or restriction of the

pipe) into the drain.

From Boiler

500mm Min

Fig. E

iv) to a soakaway - Fig. E.

From Boiler

Holes in the soak-

away must face away

from the building

Fig. F

10.0 Installation

10.7

Making The Electrical Connections

W ARN IN G: T his boile r m ust be e ar t he d

IMPORTANT: Four core cable is required to supply the

boiler as a permanent live is necessary for the operation

of the condensate pump and frost protection.

1. The electrical connections are on the right hand side of the

boiler. Depending upon the nature of the installation it may

be preferable to wire up to the boiler first before

manoeuvering into position.

2. Undo the two screws securing the cable clamp and place

to one side (Fig. 31).

3. Route the incoming electrical cable(s) from the system

control wiring centre through the grommet in rear of the

boiler and the grommet in the support bracket. This will

prevent damage to the cable(s).

4. Lay the cable through the cable clamp to gauge the length

of wire required when it is connected to the 4-way terminal

block.

5. Connect the (S/L), ( ), (N) and (P/L) wires to the

4-way terminal block (Fig. 33) and refit the cable clamp

(Fig. 31).

Fig. 31

Cable Clamp

INTEGRAL PROGRAMMER

If the optional integral programmer is being fitted it can be

done at this stage. Consult the instructions supplied in the

programmer kit.

Check the electrical installation for;

earth continuity, short circuits, resistance to earth, correct

polarity and fuse rating.

Fig. 32

4-way Terminal Block

Fig. 33

S/L

P/L

Wiring from System

Controls

S/L Switched Live

Earth

Neutral

Permanent Live

P/L

11.0 Electrical

11.1

Schematic Wiring Diagram

Condensate Removal System

Condensate Pump

Condensate

Level Switch

Condensate

Over-Level Switch

Fan

Overheat

Thermostat

Condensate

Trap

g/y

Flow

Switch

325Vdc

DC Fan

Spark

Electrode Detection

Electrode

Flame

Flow

Gas

Valve

Thermistor

Flow

Overheat

Thermostat

g/y

PCB

Optional InternalTimer

g/y

Electrical

Filter

Earths not shown to aid

clarity of diagram

Boiler Connection

(4 Core Cable)

P/L

S/L

Key To Wiring Colours

b - Blue

- Red

bk - Black

w - White

br - Brown

gy - Grey

o - Orange

g - Green

g/y- Green/Yellow

op - Opaque

y - Yellow

v - Violet

11.0 Electrical

11.2

Illustrated Wiring Diagram

P/L

S/L

Flow

Thermistor

g/y

Flow Switch

Electrical

Filter

g/y

Spark

Electrode

Flame

Detection

Electrode

Main

PCB

g/y

Layout of PCB Pins

CondensateTrap

GasValve

g/y

Fan Overheat

Thermostat

Fan

Flow Overheat

Thermostat

g/y

Wiring Key

- Blue

bk - Black

br - Brown

- Red

- White

g/y - Green/Yellow

- Green

gy - Grey

op - Opaque

- Yellow

12.0 Commissioning the Boiler

12.1

Commissioning the Boiler

W ARN IN G: T he PCB Cont r ol and Fan Asse m bly

ar e 325 Vdc. Isolat e at supply be for e acce ss.

1. Reference should be made to BS:EN 12828 & 14336 when

commissioning the boiler.

Flue Sampling Point

2. At the time of commissioning, complete all relevant sections

of the Benchmark Checklist at the rear of this publications.

Manual Air Vent

3. Flush the whole system using a suitable flushing agent (see

Section 6.2) and vent the radiators. Check for water leaks.

Gas Service

Cock

4. Refill the system with inhibitor following the inhibitor

manufacturer’s instructions and BS 7593 Code of Practice for

Treatment of Water in Domestic Hot Water Central Heating

Systems (see Section 6.2).

5. Complete the label supplied with the inhibitor and attach to

the inside of the boiler case. Detail of system treatment should

be added for future reference.

Fig. 35

Open

Fig. 34

6. Turn the gas supply on and purge according to in GB BS 6891

and in IE I.S. 813 “Domestic Gas Installations”.

7. Turn the gas service cock anticlockwise to the ON position

and check for gas tightness up to the gas valve (Fig. 34). Turn the

power to the boiler ON.

DO NOT check gas pressure here

IMPORTANT: The combustion for this appliance has been

checked, adjusted and preset at the factory for operation on

the gas type specified on the appliance data plate. No

measurement of the combustion is necessary. Do not adjust

the air/gas ratio valve.

Fig. 36

8. Having checked:

• That the boiler has been installed in accordance with

these instructions.

Inlet Gas Pressure Test Point

•The integrity of the flue system and the flue seals.

•The integrity of the boiler combustion circuit and the

relevant seals.

Turn the Central Heating Control Knob clockwise

to increase or anticlockwise to decrease the

boiler flow temperature.

Central Heating

Control Knob

(No OFF Position)

Low

Proceed to put the boiler into operation as follows:

High

The Reset Button should extinguish the

Flame Failure Light and restore normal

operation.

Reset Button

12.2

Priming the Condensate Pump

Reset

1. Using a funnel and tube, carefully pour approximately 1litre of

tap water into the flue products exhaust at the terminal or flue

elbow sampling point to fill the trap and allow the condensate

pump reservoir to fill.

This indicates that there is electricity to the Boiler.

Mains On

(Green Light)

This indicates that the Burner has fired up

and is heating your system.

Burner On

(Green Light)

If Flame Failure Light is ON. Press the Reset

Button. If Flame Failure occurs persistently

consult your Installer or Service Engineer.

Flame Failure

(Red Light)

2. Continue filling with water until the condensate pump

operates.

This indicates that the Condensate Pump is running.

The pump ONLY runs when the condensate reservoir is full.

Condensate Pump

(Green Light)

3. Check that the condensate drain pipework is not leaking and

that it is discharging correctly to drain.

4. See Fig. 36a for operation of LEDs on boiler facia.

Fig. 36a

12.0 Commissioning the Boiler

12.3

Check the Operational (Working) Gas

Inlet Pressure

1. Ensure that all controls are calling for heat and

maximum load is applied to the system.

2. With the boiler operating in the maximum rate

condition check that the operational (working) gas

pressure at the inlet gas pressure test point is in

accordance with B.S. 6798 & B.S. 6891.

3. Ensure that this inlet pressure can be obtained with

all other gas appliances in the property working.

Measure the Gas Rate

4. With any other appliances & pilot lights turned OFF

the gas rate can be measured. It should be as shown in

Section 4.0 Technical Data.

DO NOT check gas pressure here

5. Carefully read and complete all sections of the

Benchmark Commissioning Checklist at the rear of this

publication that are relevant to the boiler and

installation. These details will be required in the event of

any warranty work. The publication must be handed to

the user for safe keeping and each subsequent regular

service visit recorded.

Fig. 36b

6. For IE, it is necessary to complete a “Declaration of

Conformity” to indicate compliance with I.S. 813. An

example of this is given in I.S. 813 “Domestic Gas

Installations”. This is in addition to the Benchmark

Commissioning Checklist.

Inlet Gas Pressure Test Point

13.0 Completion

13.1

Fitting The Case Panels & Facia

1. Refit the case top panel and front door, securing with

the screws previously removed (Fig.37).

2. Locate the facia panel and secure with the screws

previously removed (Fig. 38).

3. The “Important Ventilation Information” label can be

removed unless the boiler is installed in an unventilated

compartment.

13.2

‘Benchmark’ Checklist

1. Carefully read and complete all sections of the

Benchmark Commissioning Checklist at the rear of this

publication that are relevant to the boiler and

installation. These details will be required in the event

of any warranty work. The publication must be handed

to the user for safe keeping and each subsequent

regular service visit recorded.

Outercase Securing

Screws

2. For IE, it is necessary to complete a “Declaration of

Conformity” to indicate compliance to I.S. 813. An

example of this is given in I.S. 813 “Domestic Gas

Installations”. This is in addition to the Benchmark

Commissioning Checklist.

Fig. 37

13.3

Handover

1. Instruct the user in the operation of the boiler and

system controls. Hand over the User’s Operating,

Installation and Servicing Instructions, giving advice on

the necessity of regular servicing.

2. Demonstrate to the user the action required if a gas

leak occurs or is suspected. Show them how to turn off

the gas supply at the meter control, and advise them

not to operate electric light or power switches, and to

ventilate the property.

3. Show the user the location of the system control

isolation switch, and demonstrate its operation.

4. Advise the user that they may observe a plume of

vapour from the flue terminal, and that it is part of the

normal efficient operation of the boiler.

Facia Securing Screws

Fig. 38

14.0 Servicing the Boiler

14.1

Annual Servicing

W ARN IN G: T he PCB Cont r ol and Fan

Asse m bly ar e 325 Vdc. Isolat e syst e m cont r ols

be for e acce ss.

IMPORTANT: When servicing ensure that both the gas and

electrical supplies, including Switched and Permanent Live to the

boiler are isolated before any work is started.

The four LEDs on the facia will all be OFF.

It is important to isolate the electrical supply at the system

isolation switch as it is not possible to do this on the boiler itself.

Hazardous materials are not used in the construction of this

product, however reasonable care during service is

recommended - see Section 1.2.

When replacing the combustion box door after servicing it is

essential that the retaining screws are tightened fully.

1. For reasons of safety and economy, it is recommended that

the boiler is serviced annually. Servicing must be performed by a

competent person in accordance with B.S. 7967-4.

2. After servicing, complete the relevant Service Interval Record

section of the Benchmark Commissioning Checklist at the rear of

this publication.

IMPORTANT: During routine servicing, and after any

maintenance or change of part of the combustion circuit, the

following must be checked:-

• The integrity of the complete flue system and the flue seals.

• The integrity of the boiler combustion circuit and relevant

seals as described in Section 14.2.

• The operational gas inlet pressure as described in Section

12.2.1 to 12.2.3 and the gas rate as described in 12.2.4.

• The combustion performance as described in ‘Check the

Combustion Performance’ (14.1.4 to 14.1.6 below).

3. Competence to carry out Checking Combustion

Performance

B.S. 6798 ‘Specification for Installation & Maintenance of Gas

Fired Boilers not exceeding 70kW’ advises that:-

• The person carrying out a combustion measurement should

have been assessed as competent in the use of a flue gas

analyser and the interpretation of the results.

• The flue gas analyser used should be one meeting the

requirements of BS7927 or BS-EN50379-3 and be calibrated

in accordance with the analyser manufacturers’ requirements.

• Competence can be demonstrated by satisfactory

completion of the CPA1 ACS assessment, which covers the

use of electronic portable combustion gas analysers in

accordance with BS 7967, Parts 1 to 4.

Check the Combustion Performance (CO/CO ratio)

4. Set the boiler to operate at maximum rate as described in

Section 12.2.

5. Remove the cap from the flue sampling point, insert the

analyser probe and obtain the CO/CO ratio. This must be

less than 0.004.

6. If the combustion reading (CO/CO ratio) is greater than

this, and the integrity of the complete flue system and

combustion circuit seals has been verified, and the inlet gas

pressure and gas rate are satisfactory either:

• Perform the ‘Annual Servicing - Inspection’ (Section 14.2) &

re-check.

• Replace the gas valve (Section 15.8) & re-check.

14.0 Servicing the Boiler

14.2

Annual Servicing - Inspection

W ARN IN G: T he PCB Cont r ol and Fan

Asse m bly ar e 325 Vdc. Isolat e syst e m

cont r ols be for e acce ss

1. Ensure that the boiler is cool.

2. Remove the facia and front door panel.

3. Release the four ¹/⁴turn screws securing the air box door

panel and remove the panel (Fig. 39).

4. Disconnect the three leads from the terminals (Fig. 40).

5. Undo the four screws securing the combustion box door

and remove the door (Fig. 41).

6. Visually check for debris/damage and clean or replace if

necessary the following:

a) Burner.

Air Box Door Panel

b) Heat exchanger fins.

Fig. 39

c) Fan compartment (Check also for condensate leaks).

d) Insulation.

e) Door seals-Important: Pay particular attention to

the condition of the combustion box door seals.

f) Electrodes.

g) The condensate trap.

h) The condensate pump

i) Top of heat exchanger.

Spark

Sleeve

Sensing

Lead Terminals

Fig. 40

Earth

Combustion Box

Door Panel

Fig. 41

14.0 Servicing the Boiler

14.2

Annual Servicing - Inspection (Cont)

Flue Sampling Point

7. To clean the heat exchanger and burner proceed as

follows:

a) Disconnect the electrical leads to the fan component

protection sensor (Fig. 42).

Fig. 41a

b) Loosen the screw retaining the gas injector pipe at

the venturi (Fig. 42).

c) Undo the two wing nuts to disconnect the fan

(Fig. 42).

d) Remove the fan and disconnect the electrical supply

to it (Fig. 42).

e) Remove the gas injector pipe from the gas valve

(push-fit) (Fig. 42).

Injector Pipe

f) Remove the condensate trap drain plug and place a

vessel underneath to catch the condensate (care should

be taken as this could be hot). The condensate drain

pipe may be removed to increase access.

Injector Pipe Retaining

Screw

g) Undo the condensate trap securing nut, lock nut and

the condensate drain pipe. Remove the condensate trap

and disconnect the sensor leads (Fig. 43). Clean the trap

and refit the drain plug.

Securing Nut

Fan

h) Remove the two screws securing the burner and

remove the burner. Visually inspect the internal burner

baffle for obstruction, check seal around baffle for

cracks/damage. Clean with a soft brush.

Sensor

Leads

Protection

Sensor Leads

Electrical Supply

i) Loosen the two screws retaining the heat exchanger

support bracket and slide to the left to remove

(Fig. 44).

Condensate

Trap

Fig. 42

Wing Nuts

Lock Nut

Service Drain

Plug

j) Remove the four screws securing the heat

exchanger/combustion box base and withdraw the

base.

Trap to Condensate

Pump Inlet Pipe

Central Insulation Panel

k) Lower the central insulation panel and check

condition (Fig. 44). Replace the lower insulation pad if

necessary.

Fig. 43

l) Ensure the heat exchanger fins are clear of any

obstruction.

Burner

m) Check condition of all seals. Important: Pay

particular attention to the condition of the

combustion box door seals.

Combustion

Box Base

Heat Exchanger

Support Bracket

n) Reassemble in reverse order and check for leaks.

8. Check the operation of the condensate pump and

drain pipework (see Section 10.1)

9. Check CO/CO

See section 4.0.

ratio at flue sampling point (Fig.41a).

Combustion Box Base

Securing Screws

Burner Securing

Screws

10. Complete the relevant Service Interval Record

section of the Benchmark Commissioning Checklist at

the rear of this publication and then hand it back to the

user.

Fig. 44

15.0 Changing Components

15.1

Changing Components & Preparation

W ARN IN G: T he PCB Cont r ol and Fan

Asse m bly ar e 325 Vdc. Isolat e syst e m

cont r ols be for e acce ss.

IMPORTANT: Ensure that both the gas and electrical

supplies, including Switched and Permanent Live to the

boiler are isolated before any work is started.

The four facia LEDs will be all OFF.

It is important to isolate the electrical supply at the

system isolation switch as it is not possible to do this

on the boiler itself.

Hazardous materials are not used in the construction of

this product, however reasonable care is recommended

- see Section 1.2.

When replacing the combustion box door it is essential

that the retaining screws are tightened fully.

Remove the facia and front door panel.

For the replacement of some components it will be

necessary to drain the boiler. Proceed as follows:-

Fig. 45

Heat Exchanger

Manifold

1. Isolate the water circuit and drain the system as

necessary. A drain point is located on the heat

exchanger manifold at the right hand side of the boiler

(Fig. 45) to enable the heat exchanger to be drained.

2. Place a tube on the drain point to drain water away

from the electrics. Turn anticlockwise to open (Fig. 45).

Drain Point

Tube

3. After changing a component recommission the boiler

where appropriate and check the inhibitor

concentration (see Section 6.2 and 10.1).

Electrical Connections

Pipe Access

Panel

The thermistor, safety thermostat, interface PCB and

the flow switch can be accessed after removal of the

pipe access panel (Fig. 46).

Flow Temperature Thermistor (Red)

15.2

Flow Temperature Thermistor and

Safety Thermostat (Fig. 46)

1. The procedure is the same for both the thermistor

and the safety thermostat.

Safety

Thermostat

(Black)

2. Remove the pipe access panel and disconnect the

electrical connections from the sensor.

Fig. 46

3. Remove the sensor from the pipe.

4. Fit the new thermistor or safety thermostat and

reassemble in reverse order.

15.0 Changing Components

Pipe Access

Panel

15.3

Flowswitch (Fig. 47)

1. Drain the boiler (see Section 13.1 paragraph 2 & 3).

2. Remove the pipe access panel and remove the securing

clip from the ‘O’ ring joint between the flow pipe and the

system. Undo screws on support bracket.

Support Bracket

3. Remove the securing clip from the ‘O’ ring joint

between the flow pipe and the flowswitch.

4. Remove the two screws securing the flow switch to the

boiler.

5. Disconnect the inline electrical connection and remove

the flowswitch.

Flow Switch

6. Fit the new flowswitch and reassemble in reverse order.

7. Recommission the boiler and check the inhibitor

concentration (see Section 6.2 and 10.1).

Flow Pipe

15.4

Condensate Pump - Complete (Fig. 47a)

Fig. 47

1. Remove the pipe from the trap to the pump inlet and

disconnect the electrical plug.

2. Lift the pump off the support studs and ease it

forwards. Release the snap fit clip and disconnect the

condensate outlet pipe.

Clip

Over Level Switch

3. Connect the condensate outlet pipe to the new pump

using the new clip provided.

4. With the new pump in place on the studs, refit the trap

discharge pipe, ensuring the ‘O’ ring is in place. Reconnect

the electrical plug.

5. Neatly coil the excess condensate outlet pipe adjacent

to the pump, ensuring that it is not kinked or restricted.

6. Check operation of the pump - See Section 10.2.

15.5

Condensate Pump - Level Switches

(Fig. 47a)

1. Remove the complete Condensate Pump as described

in Section 13.4, and remove the cover.

Condensate Pump

(Cover Removed)

Fig. 47a

2. Disconnect the wires from the switch(es) and remove

the retaining screws. On the Level Switch remove the

circlip and washers connecting the plunger to the

actuating arm.

3. Fit the new switch(es). Align the actuating arm of the

Level Switch with the plunger, ensuring that there is a

washer at each side of the arm.

Level Switch

4. Reconnect the wires. On the Over Level Switch there

is no connection to the lower spade terminal.

5. Check operation of the pump - See Section 10.2.

15.0 Changing Components

15.6

PCB (Figs. 48 & 49)

Control

Knob

W ARN IN G: T he PCB Cont r ol and Fan

Asse m bly ar e 325 Vdc. Isolat e syst e m

cont r ols be for e acce ss.

1. Pull the control knob off the spindle and remove the

plastic button cover. Refit them onto the new PCB

(Fig. 48).

2. Remove the top right hand securing screw and swing

out the PCB housing. Remove the PCB cover and

disconnect the electrical plugs noting their positions

3. Remove the screw securing the PCB to the housing.

The PCB can be removed from the housing.

4. Ensure that the two jumpers are fitted to the new

PCB as shown (Fig. 49).

Fig. 48

PCB Housing Securing

Screw

5. Reconnect the plugs, fit the new PCB to the housing

and reassemble in reverse order.

Plastic Button

Cover

Hinge open

PCB Housing

Blue (CN11) Jumper

Red (CN12) Jumper

Fig. 49

15.0 Changing Components

The fan and venturi, gas valve, injector pipe,

condensate trap, fan protection sensor, spark and

sensing electrodes can be accessed and changed on

the removal of the airbox door panel.

1. Remove the airbox door panel by loosening the four

turn screws (Fig. 50).

15.7

Spark and Sensing Electrodes

(Fig. 51)

1. Disconnect all three leads from tabs.

Spark

Earth

Opaque cable

Green/Yellow cable

White cable

Sensing

2. Remove the two screws securing each of the

electrodes to the combustion box door and remove the

electrodes.

3. Fit the new electrodes (and new gasket, as required)

and reassemble in reverse order.

Air Box Door Panel

Fig. 50

15.8

Fan (Fig. 52)

W ARN IN G: T he PCB Cont r ol and Fan

Asse m bly ar e 325 Vdc. Isolat e syst e m

cont r ols be for e acce ss.

1. Loosen the screw holding the injector pipe into the

venturi.

2. Remove the electrical connections to the fan and

protection sensor on the fan.

Sensing

Combustion

Box Door

Earth

Spark

3. Remove the wing nuts securing the fan to the base of

the combustion box.

Fig. 51

4. Lower the fan and remove.

5. If changing the fan, remove the screws securing the

venturi and fan protection sensor bracket, noting the

positions of the injector opening and sensor bracket, fix

them to the new fan.

Injector Pipe

Injector

Opening

Screw

6. Fit the new fan and reassemble in reverse order.

Gasket

Fan

The injector pipe, condensate trap and gas valve can

be changed after the removal of

the fan.

Protection

Sensor

Venturi

Electrical Connections

Fig. 52

Electrical Connection

Wing Nuts

15.0 Changing Components

The removal of the fan is necessary to enable the changing of

the injector pipe, condensate trap and gas valve (see section

13.6).

15.9

Injector Pipe (Fig. 53)

1. Remove the injector pipe by pulling out from the ‘O’ ring

joint in the gas valve.

2. Fit the new injector pipe and reassemble in reverse order.

Injector Pipe

15.10 Gas Valve (Fig. 53)

IMPORTANT: After replacing the valve the CO must be

checked as detailed in Section 14.1.4 to 14.1.6. Only

change the valve if a suitable calibrated combustion

analyser is available, operated by a competent person -

see Section 14.1.3.

Gas Valve

Securing Screws

Case Pressure Pipe

Gasket

1. Isolate gas supply and disconnect the gas tap by removing

the four screws.

2. If required remove the condensate pump to increase access

(see Section 13.4) and undo the case pressure pipe from the

valve.

Boiler Side

3. Disconnect the electrical plug from the gas valve.

4. Remove the fan (see Section 13.6) and injector pipe.

Aluminium

Spacer

‘O ring’

Gas Valve

Gas Tap

5. Remove the two gas valve securing screws from inside the

air box holding the gas valve, and remove the valve.

6. Remove the aluminium spacer and its gasket from the gas

valve.

Fig. 53

Electrical Plug

7. Fit the aluminium spacer and its gasket to the new valve.

8. Fit the new gas valve and reassemble in reverse order.

NOTE: Check for gas tightness after replacing gas valve.

9. Check the CO²level. If the level is greater than that quoted,

telephone the Technical Enquiries for further advice.

Securing

Nut

15.11 Condensate Trap (Fig. 54)

Sensor

Leads

1. Disconnect the condensate trap from the base of the heat

exchanger.

2. Disconnect the condensate drain ‘O’ ring connection from

the condensate trap and condensate pump. For ease of access

also remove the pump.

Condensate

Trap

3. Undo the condensate trap lock nut.

4. Remove the condensate trap from the boiler.

5. Disconnect the sensor leads.

Lock Nut

Service Drain

Plug

6. Fit the new condensate trap and reassemble in reverse

order. When refitting the pipe from the trap to the pump

ensure that all seals and connections are made.

Trap to Condensate

Pump Inlet Pipe

Fig. 54

7. Prime the condensate trap (fill first chamber), check for leaks

(see Section 8.5).

15.0 Changing Components

Combustion Box

Door Panel

The burner and heat exchanger can be changed after

removal of the combustion box door. To change the

heat exchanger, the fan and burner must be removed

first (see section 13.6 and 13.10).

1. Remove the combustion box door by removing the

four securing screws (Fig. 55).

IMPORTANT: On refitting the combustion box

door check the condition of the combustion box

door seals.

15.12 Burner (Fig. 56)

Fig. 55

1. Remove the two screws securing the burner to the

base of the combustion box.

Burner

Support

Bracket

2. Remove the burner carefully from the combustion

box base.

Return

Connection

3. Check the burner seal on the heat exchanger base,

replace if necessary. Fit the new burner and reassemble

in reverse order.

Fig. 57

15.13 Heat Exchanger

Fig. 56

1. Drain the boiler (see section 13.1 paragraph 2 & 3).

2. Remove all components in the base of the airbox.

Flow

Switch

Securing Screws

3. Undo the screws on the support bracket. Remove

the screws securing the flow switch and return

connections and remove the connections (Fig. 57).

4. Remove the screws securing the heat exchanger

manifold and remove the manifold (Fig. 58).

5. Ease the combustion box left hand side panel to clear

the stud, lift the heat exchanger assembly (Fig. 59) and

rotate the bottom upwards whilst pulling it forwards

out of the airbox.

6. Ensure that the heat exchanger is disengaged from

the flue elbow and clear of the stud in the left hand side

of the combustion box.

Fig. 58

7. Fit the new heat exchanger and reassemble in reverse

order.

Heat Exchanger

Manifold

8. Recommission the boiler and check the inhibitor

concentration (see Section 6.2 and 10.1).

Heat Exchanger

Assembly

Fig. 59

15.0 Changing Components

15.14 Heat Exchanger Lower Insulation Pad

(Fig. 60)

1. Remove all components in the base of the airbox.

2. Remove the burner (see section 13.10).

3. Remove the four bolts securing the combustion box

base.

4. Remove the combustion box base.

5. Pull the central insulation panel down from the

centre of the heat exchanger and remove the lower

insulation pad.

Central Insulation Panel

Upper Insulation

6. Fit the new insulation pad and reassemble in reverse

order.

Pad

Lower Insulation

Pad

15.15 Heat Exchanger Upper Insulation Pad

(Fig. 60)

Fig. 60

Burner

1. Remove all components in the base of the airbox.

2. Remove the burner (see section 13.10).

Combustion

Box Base

3. Remove the heat exchanger (see section 13.11).

4. Remove the four bolts securing the combustion box

base.

Support Bracket

5. Remove the combustion box base.

Combustion Box Base

Securing Screws

6. Pull the central insulation panel down from the

centre of the heat exchanger.

Burner Securing

Screws

7. Fit the new insulation pad and reassemble in reverse

order.

16.0 Short Parts List

Short Parts List

Key

No.

G.C.

No.

Description

Manufacturers

Part No.

E06 058

Flow Temperature

Thermistor (Red)

240670

242459

E06 059

E06 060

Flow Switch

Safety Thermostat

(Black)

242235

PCB

5129147

5109925

241900

Fan

Gas Valve

E06 085

Viewing Window

Condensate Trap

Electrodes Kit

Burner Assy

242484

5111714

5132366

5107430

242497

E06 097

Heat Exchanger Assy

Control Knob

Condensate Pump

Level Switch

Over Level Switch

5109996

5117661

5117591

5117592

17.0 Fault Finding

NOTE: The fan is supplied with 325 Vdc.

Fan Fault Finding should only be carried out after the

boiler has been electrically isolated.

Mains On

LED Light LED Light LED Light

(Green)

(Green) (Red)

Boiler On

Lockout

General Fault Finding should only be carried out by

someone who is appropriately qualified.

denotes LED flashing

Lights

Off Off Off

Lights

Go to Electrical Supply

section of the fault finding

instructions.

Go to Thermistor section

YES

of the fault finding

instructions.

Low Electrical Supply

Incoming Voltage less than

180V. Check System

Lights

Off On

Off onn

Live & Neutral Reversed

Incoming Live and Neutral

reversed.

Controls & System Wiring.

Otherwise contact Electricity

Provider.

LV Wiring Harness

Ensure the small 8 way

connector is securely plugged

into the PCB. If the fault

Lights

On On On

YES

Lights

Go to Dry-Fire

section of the fault finding

instructions.

* *

persists replace wiring harness.

Lights

On onn

PCB Fault

Replace PCB.

Lights

On Off On

Go to Ignition Lockout section

of the fault finding instructions.

Lights

On On

PCB Fault

Replace PCB.

Lights

On Off on

Go to Overheat Lockout

section of the fault finding

instructions.

Lights

On On onn

YES

PCB Fault

Replace PCB.

Lights

Go to Fan Lockout

section of the fault finding

instructions.

On on onn

Lights

Go to Condensate Pump

section of the fault finding

instructions.

* *

Lights

Off Off Off

17.0 Fault Finding

ELECTRICAL SUPPLY

No Permanent Live to

boiler. Check Mains Fuse

and

240V at A ?

System Wiring.

YES

No Switched Live to

boiler. Check System

Controls and System

Wiring.

240V at B ?

P/L

S/L

YES

Check P/L wiring from

terminal block to PCB.

240V at C ?

YES

Check S/L wiring from

terminal block to PCB.

240V at D ?

YES

Check for short circuit on

condensate pump, fan &

gas valve. Replace if

PCB fuse OK ?

shorted & replace fuse.

YES

Replace PCB.

Fuse

Lights

* * ^On

17.0 Fault Finding

DRY-FIRE

Is the

Fill system with water and

system full of water ?

bleed out all air.

YES

Is the

Pump or Pump Wiring

fault.

pump running ?

YES

Unplug

5-way PCB

connector. Is

there continuity

between H

YES

Replace PCB.

Viewed from

Wire Entry end

Disconnect

Flow Switch Inline

connector. With pump running is

there continuity across flow

switch ?

YES

Wires from inline

connector to PCB faulty.

Remove

Is there a

flow switch from boiler.

Is there a physical blockage to

the paddle within the

flow switch ?

Replace Flow Switch.

blockage in the system ?

YES

Remove Blockage.

Lights

On Off On

17.0 Fault Finding

IGNITION LOCKOUT

Gas Valve 5-way

Connector Plug

Is there

Check isolation valve and

gas supply.

gas at gas valve inlet ?

YES

Remove

5-way connector

YES

Reset Lockout.

Is there gas flow

(check at meter) ?

from gas valve. Is there 240

Vdc between I & J

Replace Gas Valve.

during ignition ?

YES

Remove

the larger of the

two 6-way PCB connectors.

Is there continuity from I to L

& from J to K ?

Remove Gas Valve & check

inlet filter for blockage.

Otherwise incorrect gas supply

to boiler.

there at least

Lead from PCB to Gas

Valve faulty.

18mbar dynamic at gas valve

inlet ?

YES

Replace PCB.

YES

Condensate Trap

blocked or water on

terminals ?

Clear blockage and dry

sensors.

YES

Check and if necessary

change over level switch

(see Section 13.5)

Condensate Pump

reservoir full ?

6-way Connector

Replace spark or flame

detection probe and

gaskets.

spark or flame detection

probe damaged ?

Set spark gap to 3.5mm.

spark gap between 3 and

4mm ?

YES

Is the

YES

wiring from PCB

to spark probe & flame

detection probe OK ?

burner blocked or

damaged ?

Replace PCB.

YES

Clean burner or replace as

necessary.

Rectify wiring.

Lights

On Off onn

17.0 Fault Finding

OVERHEAT LOCKOUT

Disconnect

black stat on flow pipe.

When flow < 60° C is there

continuity across stat ?

Replace Stat.

YES

Reconnect stat.

Disconnect fan stat.

When fan temp < 60° C

is there continuity

across stat ?

Replace Stat.

YES

Reconnect stat.

Disconnect the larger of

the 6-way PCB connectors.

Is there continuity

Wiring from PCB to

thermostats faulty.

across M ?

YES

6-way Connector

Disconnect

thermistor

(red sensor on flow pipe).

Is resistance between

0.5kë & 20kë ?

Replace thermistor.

YES

Replace combustion

chamber door seal & trim

seal.

combustion chamber

door seal damaged or not in

place ?

Replace PCB.

Lights

17.0 Fault Finding

On on on

FAN LOCKOUT

NOTE: The fan is supplied with 325 Vdc.

Fan Fault Finding should only be carried out after the

boiler has been electrically isolated.

Fan

PCB

Connection

Unplug

3-way PCB connector

& unplug fan. Is there

continuity from N to O &

from P to Q ?

Rectify wiring.

YES

Fan

PCB

Connection

Unplug

the smaller of the

6-way PCB connector. Is there

continuity from R to S & from T

to U & from

Rectify wiring.

V to W ?

YES

Viewed from

Wire Entry end

Replace fan.

17.0 Fault Finding

Lights

THERMISTOR

Unplug

thermistor,

Is thermistor resistance between

Replace thermistor.

0.5kë & 20kë ?

YES

Plug in

thermistor, leave

Wiring from PCB to

thermistor faulty.

8-way connector unplugged.

Is resistance at D between

0.5kë & 20kë ?

Viewed from

Wire Entry end

YES

Replace PCB.

17.0 Fault Finding

CONDENSATE PUMP

Lights

On Off On

* * ^On

Reset boiler

and add approx. 1 litre

tap water to the condensate

system via the flue or

sample point

Condensate pump level switch

activated for longer than 3

minutes - boiler locks out.

Boiler will try to relight 4 times

in 5 minutes.

Condensate pump over level

switch activated - pump

reservoir level too high

resulting in ignition lockout.

5Vdc at A ?

No - replace PCB

Does the

pump motor run as

the condensate level

rises ?

Mechanical fault

on float, linkage or switch.

Mechanical fault on pump

or impellor.

5Vdc at B ? No - check wiring.

240V across C & D ?

No - replace level

switch

YES

Go to diagram for

connections to check

Is motor

resistance across C & D

approx. 40 ohms ?

No - replace pump

assembly

If fault cannot be rectified

replace level switch or

pump assembly.

Condensate pipe

blocked or kinked, or outlet

blocked or frozen

at drain.

Condensate pump

outlet back check valve

blocked or seized shut.

As the pump motor runs

does the condensate flow to

drain ?

YES

Rectify fault, replacing pipe

if necessary.

If fault cannot be rectified

replace pump assembly.

YES

Condensate pipe

has high resistance - too long

or restricted, head greater than

3 metres.

condensate flow

rate at least 1.8 l/min and run

time less than 3

Pump motor or

impellor worn - replace

pump assembly

minutes ?

YES

Rectify fault, replacing or

re - routing pipe

if necessary.

Condensate Pump Assembly

Condensate

Level Switch

Condensate Pump

Condensate

Motor

Over-Level Switch

Does

Mechanical fault on

float, linkage or level switch.

After 3 mins boiler

pump motor stop

as level in reservoir

falls ?

‘C’ ‘D’

‘B’

will lock out.

YES

If fault cannot be rectified

replace level switch or

pump assembly.

PCB

Operation correct

‘A’

Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This

does not affect the customer’s statutory rights.

If yes, and if required by the manufacturer, has a water scale reducer been ﬁtted?

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798

If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation ﬁtted?

Yes

Service Record

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the

manufacturer’s instructions.

Always use the manufacturer’s speciﬁed spare part when replacing controls.

Service 1

Service 2

Date:

Engineer Name:

Company Name:

Telephone No.

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Gas Safe Register No.

Comments:

Signature:

Service 3

Service 4

Date:

Engineer Name:

Company Name:

Telephone No.

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Gas Safe Register No.

Comments:

Signature:

Service 5

Service 6

Date:

Engineer Name:

Company Name:

Telephone No.

Company Name:

Telephone No.

Operative ID No.

Comments:

Gas Safe Register No.

Comments:

Signature:

Service 7

Service 8

Date:

Engineer Name:

Company Name:

Telephone No.

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Gas Safe Register No.

Comments:

Signature:

Service 9

Service 10

Date:

Engineer Name:

Company Name:

Telephone No.

Company Name:

Telephone No.

Gas Safe Register No.

Comments:

Gas Safe Register No.

Comments:

Signature:

All descriptions and illustrations provided in this leaflet have been carefully

prepared but we reserve the right to make changes and improvements in

our products which may affect the accuracy of the information contained in

this leaflet. All goods are sold subject to our standard Conditions of Sale

which are available on request.

PO TTERTO N

A Tr ading Divisio n o f Baxi Heat ing UK Lt d (3879156)

Brooks House, Coventry Road, Warwick. CV34 4LL

After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555

Website www.potterton.co.uk

e&oe

Comp No. 720896601 (6/11)

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