Baxi
Інструкція Baxi Instruction Baxi Assure System installation manual
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Інструкція · Українська · Оновлено: 11 серпня 2026 р.
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Сторінка 1
These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. They must be read in conjunction with the Flue Installation Guide. United Kingdom en Installation and Service Manual High Efficiency Wall Hung Condensing Gas Boiler Baxi Assure System 12 - 15 - 18 - 24 18 - 24 LPG
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Dear Customer, Thank you very much for buying this appliance. Please read through the manual carefully before using the product, and keep it in a safe place for later reference. In order to ensure continued safe and efficient operation we recommend that the product is serviced regularly. Our service and customer service organisation can assist with this. We hope you enjoy years of problem-free operation with the product.
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Contents 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1 Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1.1 Building Regulations and the Benchmark Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 1.1.2 The Benchmark Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1.3 Installer Notification Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.3 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.4 Specific safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.4.1 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 1.5 Liabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.5.1 Manufacturer's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.5.2 Installer's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.5.3 User's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 2 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.2 Additional documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.3 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.3.1 Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.4 Abbreviations/Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1 Homologations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1.1 Safety, Performance & Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1.2 Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1.3 Gas category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1.4 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 3.2.1 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 3.2.2 Technical parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 3.3 Dimensions and connections/clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3.4 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4 Description of the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 4.2 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.2.1 Air-gas adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 4.2.2 Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.2.3 Heating and domestic hot water production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.2.4 Central heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.2.5 Frost protection mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.2.6 Pump protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 4.3 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.3.1 List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 4.4 Control panel description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.4.1 Description of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.5 Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.5.1 Contents of the carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.6 Accessories and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.6.1 Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5 Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5.1 Installation regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5.2 Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 5.2.1 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 5.2.2 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 5.2.3 Hard water area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 5.2.4 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 5.2.5 System control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 5.2.6 Treatment of water circulating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.2.7 Showers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 5.2.8 Expansion vessel (CH only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 5.2.9 Safety pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5.3 Choice of the location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Contents 3
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5.3.1 Location of the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.3.2 Bath and shower rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 5.3.3 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3.4 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3.5 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 5.3.6 Flue/chimney location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.3.7 Horizontal flue/chimney systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.3.8 Flue/chimney trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.3.9 Terminal guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 5.3.10 Flue/chimney deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 5.3.11 Flue/chimney accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 5.5 Unpacking & initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.5.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.5.2 Initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.6 Connecting diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 5.6.1 Filling information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 6.2.1 Fitting the pressure relief discharge pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 6.2.2 Connecting the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.3 Air supply/flue gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.3.1 Connecting the flue/chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.4.1 Making the electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.5 Filling the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 6.5.1 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 6.5.2 Fill the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6.5.3 Filling the condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 7.2 Checklist before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 7.2.1 Preliminary electrical checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 7.2.2 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 7.3 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 7.3.1 De-Aeration function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 7.4 Gas settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 7.4.1 Check the operational (working gas inlet pressure and gas rate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 7.4.2 Checking combustion - chimney sweep mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 7.5 Configuring the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.5.1 System draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 7.6 Final instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.6.1 Handover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 8.1 Use of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 8.1.1 Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 8.2 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 8.3 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 9.2 Standard inspection and maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 9.2.1 Annual Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 9.2.2 Checking the water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 9.2.3 Checking the expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 9.2.4 Checking the automatic air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 9.2.5 Checking the burner and cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 9.3 Specific maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 9.3.1 Detection/spark ignition electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 9.3.2 NTC flue sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 9.3.3 Flow and return sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 9.3.4 Safety overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Contents 4
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9.3.5 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 9.3.6 Safety pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 9.3.7 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 9.3.8 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 9.3.9 Pump - head only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 9.3.10 Pump - complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 10.1 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 10.1.1 Initial error fault finding checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 10.1.2 Display of error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 10.2 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 10.2.1 Central heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 10.2.2 Fault finding solutions sections A to E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 10.2.3 Fault finding solutions sections F to H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 10.2.4 Fault finding solutions sections I to M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 11 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 11.1 Decommissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 12.1 Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 13 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 13.1 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 14 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 14.1 Benchmark commissioning checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 14.2 Service records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Contents 5 14.3 LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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1 Safety 1.1 Benchmark 1.1.1 Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. This can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly. The Health & Safety Executive operates the ’Gas Safe Register’, a selfcertification scheme for gas heating appliances. This company is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency. Building Regulations require that installations should comply with manufacturer’s instructions. It is therefore important that the commissioning checklist is completed by the installer. The relevant section of Building Regulations only relates to dwellings. Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure. The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations. 1.1.2 The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.centralheating.co.uk for more information. Fig.1 Benchmark AD-3000725-01 1 Safety 6
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1.1.3 Installer Notification Guidelines Fig.2 Installer Notification Guidelines AD-3000696-01 Choose Building Regulations Notification Route Contact your relevant Local Authority Building Control (LABC) who will arrange an inspection or contact a government approved inspector LABC will record the data and will issue a certificate of compliance ‘Gas Safe Register’ will issue a Building Regulations Compliance Certificate to the property owner and inform the relevant LABC You must ensure that the certificate number issued by the ‘Gas Safe Register’ is written onto the Benchmark Checklist Scheme Members only Call ‘Gas Safe Register’ on: 0800 408 5577 or log onto: www.gassaferegister.co.uk within 10 days If you notify via the ‘Gas Safe Register’, the register will issue the Building Regulations certificate on members’ behalf Complete the Benchmark Checklist Install and Commission this appliance to manufacturer's instructions Competent Person's Self Certification Scheme Building Control Complete the Benchmark Checklist Install and Commission this appliance to manufacturer's instructions 1 Safety 7
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1.2 General safety instructions Danger This boiler can be used by children aged 8 years and above and by persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge when they have been given supervision or instruction concerning the safe use of the device and understand the resulting risks. Children must not be allowed to play with the appliance. Cleaning and user maintenance must not be carried out by children without supervision. Danger If you smell gas: 1. Do not use a naked flame, do not smoke, do not operate electrical contacts or switches (doorbell, light, motor, lift, etc.). 2. Shut off gas supply. 3. Open the windows. 4. Trace possible leaks and seal them immediately. 5. If the gas leak is before the gas meter, contact the supplier 6. Telephone the National Gas Emergency Service on:- 0800 111 999. Danger If you smell flue gases: 1. Switch off the boiler. 2. Open the windows. 3. Trace possible leaks and seal them immediately. Warning Do not touch the flue gas pipes. Depending on the boiler settings, the temperature of the flue gas pipes may exceed 60oC. Warning Do not touch the radiators for long periods. Depending on the boiler settings, the temperature of the radiators may exceed 60oC. Warning Take precautions with the domestic hot water. Depending on the boiler settings, the domestic hot water temperature may exceed 65oC. Danger Before any work, switch off the mains supply to the boiler. Caution After maintenance or repair work, check the entire heating installation to ensure that there are no leaks. 1.3 Recommendations Warning Installation and maintenance of the boiler must be carried out by a qualified installer in accordance with local and national regulations. Warning If the mains lead is damaged, it must be replaced by the original manufacturer, the manufacturer's dealer or another suitably skilled person to prevent hazardous situations from arising. Warning Always disconnect the mains supply and close the main gas tap when working on the boiler. 1 Safety 8
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Caution Make sure the boiler can be reached at all times. The boiler must be installed in a frost-free area. In the case of a fixed connection to the power cord, you must always install a main bipolar switch with an opening gap of at least 3 mm (EN 60335-1). Drain the boiler and central heating system if you are not going to use your home for a long time and there is a chance of frost. The frost protection does not work if the boiler is out of operation. The boiler protection only protects the boiler, not the system. Check the water pressure in the system regularly. If the water pressure is lower than 0.8 bar, the system must be topped up (recommended water pressure between 1 and 2 bar). Important Keep this document near to the boiler. Important Casing panels may only be removed for maintenance and servicing purposes. Refit all panels when maintenance work and servicing are complete. Important Instruction and warning labels must never be removed or covered and must be clearly legible throughout the entire service life of the boiler. Replace damaged or illegible instruction and warning labels immediately. Important The boiler must not be modified in any way. 1.4 Specific safety instructions 1.4.1 Handling General The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance. Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health & Safety is the responsibility of EVERYONE. There is no "safe" limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE. Do not handle or lift unless you feel physically able. Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc. Preparation Co-ordinate movements - know where, and when, you are both going. Minimise the number of times needed to move the boiler - plan ahead. Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care on ladders/into lofts. Technique When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible. Where possible transport the boiler using a sack truck or other suitable trolley. 1 Safety 9
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Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the "Installation" section of these instructions for recommended lift points. Remember The circumstances of each installation are different. Always assess the risks associated with handling and lifting according to the individual conditions. If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT "work through" the pain - you may cause further injury. IF IN ANY DOUBT DO NO HANDLE OR LIFT THE BOILER — OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING ! 1.5 Liabilities 1.5.1 Manufacturer's liability Our products are manufactured in compliance with the requirements of all applicable Directives and Regulations. They are therefore delivered with the marking and any documents necessary. In the interests of the quality of our products, we strive constantly to improve them. We therefore reserve the right to modify the specifications given in this document. Our liability as manufacturer may not be invoked in the following cases: Failure to abide by the instructions on installing the appliance. Failure to abide by the instructions on using the appliance. Faulty or insufficient maintenance of the appliance. 1.5.2 Installer's liability The installer is responsible for the installation and initial commissioning of the appliance. The installer must observe the following instructions: Read and follow the instructions given in the manuals provided with the appliance. Install the appliance in compliance with prevailing legislation and standards. Carry out initial commissioning and any checks necessary. Explain the installation to the user. If maintenance is necessary, warn the user of the obligation to check the appliance and keep it in good working order. Give all the instruction manuals to the user. 1.5.3 User's liability To guarantee optimum operation of the system, you must abide by the following instructions: Read and follow the instructions given in the manuals provided with the appliance. Call on a qualified professional to carry out installation and initial commissioning. Get your installer to explain your installation to you. Have the required inspections and maintenance carried out by a qualified installer. Keep the instruction manuals in good condition close to the appliance. 1 Safety 10
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2 About this manual 2.1 General This manual is intended for the installer of a Baxi Assure System boiler. 2.2 Additional documentation These Installation & Service Instructions must be read in conjunction with the Flue Accessories Fitting Guide supplied in the Literature Pack. Various timers, external controls, etc. are available as optional extras. Full details are contained in the relevant sales literature 2.3 Symbols used 2.3.1 Symbols used in the manual This manual uses various danger levels to draw attention to special instructions. We do this to improve user safety, to prevent problems and to guarantee correct operation of the appliance. Danger Risk of dangerous situations that may result in serious personal injury. Danger of electric shock Risk of electric shock. Warning Risk of dangerous situations that may result in minor personal injury. Caution Risk of material damage. Important Please note: important information. See Reference to other manuals or pages in this manual. 2.4 Abbreviations/Glossary BS British Standard CH Central heating DHW Domestic hot water GB Great Britain HHIC Heating and Hotwater Industry Council Hi Lower heating value (LHV) Hs Higher heating value (HHV) IE Ireland PCU PCB for managing burner operation Pn Nominal output Pnc Condensing output SU Safety PCB 2 About this manual 11
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3 Technical specifications 3.1 Homologations 3.1.1 Safety, Performance & Quality This boiler has been assessed by an appropriate Notified Body and shown to meet the requirements of all Directives and Regulations as applicable. These Directives and Regulations lay down requirements for the safety and efficiency of the appliance, together with its design, construction and use of materials. They also require the production process to be covered by an approved and monitored system of quality assurance. 3.1.2 Certifications Tab.1 Certifications CE certificate number 0085CS0215 NOx class 6 Boiler type C13, C33 3.1.3 Gas category Tab.2 Gas category, type and supply pressure Gas category Gas type Supply pressure (mbar) I2H G20 20 3.1.4 Standards Codes of Practice — refer to the most recent version Tab.3 In GB the following Codes of Practice apply: Standard Scope BS 6891 Gas Installation. BS 5546 Installation of hot water supplies for domestic purposes. BS EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings — Calculation of load. BS EN 14336 Installation & commissioning of water based heating sys tems. BS 6798 Installation of gas fired hot water boilers. BS 5440 Part 1 Flues. BS 5440 Part 2 Ventilation. BS 7074 Expansion vessels and ancillary equipment for sealed wa ter systems. BS 7593 Treatment of water in domestic hot water central heating systems. BS 4814 Specification for Expansion Vessels using an internal dia phragm, for sealed hot water systems. IGE/UP/ 7/1998 Guide for gas installations in timber framed housing. 3 Technical specifications 12
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Tab.4 In IE the following Code of Practice apply: Standard Scope IS 813 Domestic Gas Installations. The following standards give valuable additional information: BS 5546 Installation of hot water supplies for domestic purposes. BS EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings — Calculation of load. BS EN 14336 Installation & commissioning of water based heating sys tems. BS 7074 Expansion vessels and ancillary equipment for sealed wa ter systems. BS 7593 Treatment of water in domestic hot water central heating systems. 3.2 Technical data 3.2.1 Technical information Important All data in these sections are nominal and subject to normal production tolerances. 3 Technical specifications 13 Tab.5 General 15 18 Gas council numbers Nominal heat input — central heating — Maximum rate Net (Qn Hi) kW 15.5 18.6 Gross (Qn Hs) kW 17.2 20.6 Nominal heat input 80/60C° — Minimum rate Net (Qn Hi) kW 4.64 4.64 Gross (Qn Hs) kW 5.2 5.2 Nominal heat output 80/60°C — central heat ing — Maximum rate Pn kW 15 18 Nominal heat output 80/60°C — central heat ing — Factory setting Pn kW 15 18 Nominal heat output 80/60°C — Minimum rate Pn kW 4.5 4.5 Nominal heat output 50/30°C — central heat ing — Maximum rate Pnc kW 16.2 19.4 Nominal heat output 50/30°C — central heat ing — Minimum rate Pn kW 4.9 4.9 Tab.6 Central heating circuit specifications All models Maximum pressure bar 3 Minimum pressure bar 0.5 Central heating temperature adjustment (±5°C) °C 25 / 80 Expansion vessel water capacity litres 7.0 Expansion vessel pre charge pressure bar 1.0 Maximum capacity of central heating system litres 100 Primary water content of boiler (unpressurised) litres 2.5 Baxi Assure System Baxi Assure System 41 470 86 41 470 87 12 24 12.4 13.7 4.64 5.2 12 12 4.5 12.9 4.9 24.7 27.7 4.64 5.2 24 24 4.5 25.9 4.9 41 470 85 41 470 88
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3 Technical specifications 14 Tab.7 Characteristics of combustion 15 18 Natural gas rate (G20) Qmax m3/h 1.64 1.96 Natural gas rate (G20) Qmin m3/h 0.49 0.49 Important Dynamic (nominal) inlet pressure (Natural gas — G20) 20mbar with a CV of 37.78 MJ/m3 Tab.8 Electrical specifications All models Nominal electrical power supply voltage V 230 Nominal electrical power supply frequency Hz 50 Nominal power consumption when firing W 60 (12 & 15) - 70 (18) - 100 (24) External fuse rating Amp 3 Internal fuse rating Amp F2A H250V Important Boiler must be connected to an earth supply. Tab.9 Other specifications Degree of protection against humidity (EN 60529) IP IPX5D Dimensions (height / width / depth) mm H 700/W 390/D 285 Tab.10 Connections (copper tails) Gas inlet mm 22 Heating flow mm 22 Heating return mm 22 Pressure relief discharge mm 15 Condensate discharge drain plastic waste pipe mm 21.5 Tab.11 Clearances Above casing mm 178 Below casing (min) mm 200 Front — for servicing mm 450 Front — for operation mm 5 Sides LH mm 5 Sides RH mm 5 Tab.12 Weights Packaged boiler kg 30.6 Boiler lift weight (dry) kg 28.1 Installed weight (dry) kg 29.0 Installed weight when filled with water kg 31.6 Baxi Assure System Baxi Assure System Baxi Assure System Baxi Assure System Baxi Assure System Baxi Assure System 12 24 0.49 1.31 0.49 2.61 All models All models All models All models
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3.2.2 Technical parameters See The back cover for contact details. 3 Technical specifications 15 Tab.13 Technical parameters for boiler space heaters 15 18 Condensing boiler Yes Yes Low-temperature boiler(1) No No B1 boiler No No Cogeneration space heater No No Combination heater No No Rated heat output Prated kW 15 18 Useful heat output at rated heat output and high tem perature regime(2) P4 kW 15 18 Useful heat output at 30% of rated heat output and low temperature regime P1 kW 5.0 6.0 Seasonal space heating energy efficiency ƞs % 93 93 Useful efficiency at rated heat output and high temper ature regime ƞ4 % 88.2 88.2 Useful efficiency at 30% of rated heat output and low temperature regime ƞ1 % 97.8 97.8 Auxiliary electricity consumption Full load elmax kW 0.025 0.030 Part load elmin kW 0.011 0.011 Standby mode PSB kW 0.003 0.003 Other items Standby heat loss Pstby kW 0.040 0.040 Ignition burner power consumption Pign kW 0 0 Annual energy consumption QHE GJ 46 56 Sound power level, indoors LWA dB 46 48 Emissions of nitrogen oxides NOX mg/kWh 29 30 (1) Low temperature means for condensing boilers 30°C, for low temperature boilers 37°C and for other heaters 50°C return temperature (at heater inlet). (2) High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet. Baxi Assure System 12 Yes No No No No 12 12 24 Yes No No No No 24 24 4.0 93 88.2 97.8 0.020 0.011 0.003 0.040 0 38 44 24 8.0 93 88.0 97.8 0.060 0.011 0.003 0.040 0 74 51 28
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3.3 Dimensions and connections/clearances Fig.3 Dimensions and connections / clearances 1 2 3 4 5 6 7 PN-0000624 9 700 285 390 5 5 178 200 450 5 10 The clearances shown in the diagram are minimum requirements to allow for case removal, spanner access and air movement. These should be observed at all times and kept clear of obstructions. 1 Condensate trap sump 2 Condensate drain 3 Heating circuit water flow 4 Gas inlet 5 Pressure relief pipe 6 Heating circuit water return 7 Pump drain point 9 Cable entry points 10 Boiler drain point on flow isolation tap Fig.4 Flue position = = 160 106 >1.5° Ø116 min 154 Ø100 PN-0000649 3 Technical specifications 16
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3.4 Electrical diagram Fig.5 Electrical wiring diagram X23 X37 X36 X22 X20 X24 X10 X11 X12 X13 X1 X2 X3 g g g r r g b g b g br bk b b r r br b g/y g/y g/y g/y g/y br X31 br br PN-0000342 A C D E F H I K L N M b br b b O P L N E M1 1 2 5 6 7 8 9 10 3 4 M2 b bk bk bk br g g g/y bk — black br — brown b — blue g — green r — red w — while g/y — green/ yellow Key Description Key Description A Gas valve K Pump C Flue sensor L Terminal strip D Hydraulic pressure switch M Fan E Heating return sensor N Safety thermostat F Heating flow sensor O Earth point on boiler chassis H M2 low voltage external control connection P Printed circuit board (PCB) I Spark ignition electrode 3 Technical specifications 17
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4 Description of the product 4.1 General description The Baxi Assure System range are fully automatic gas fired wall mounted condensing boilers. They are room sealed and fan assisted and will serve central heating and mains fed domestic hot water. Tab.14 The boiler is set to give a maximum output of :- The boiler is factory set for use on Natural Gas (G20). The boiler is suitable for use on fully pumped sealed heating systems. An information label giving details of the model, serial number and Gas Council number is situated on the front middle underside of the outercase and is accessed by swinging forward gently. A Information label The boiler data badge is positioned on the control box and can be seen when the outercase panel is removed. The boiler is intended to be installed in residential / domestic environments on a governed meter supply only. The boiler must be installed with one of the purpose designed flues such as one of the standard horizontal telescopic flue kits detailed in the Flue Accessories and Fitting Guide. Important All systems must be thoroughly cleansed, flushed and treated with inhibitor. Important These installation and servicing instructions must be read in conjunction with the Flue Accessories and Fitting Guide supplied in the literature pack. 4.2 Operating principle 4.2.1 Air-gas adjustment The air is drawn in by the fan and gas injected directly at the top of the mixer valve. The fan rotation speed is regulated automatically by the electronic board based on temperature adjustment and other parameters. The gas and air are mixed in the manifold. The gas/air ratio ensures that the quantity of gas and air are adjusted correctly to always obtain optimal combustion. The gas/air mixture is fed into the burner at the front of the heat exchanger. The mixture is ignited by the spark electrode. 4.2.2 Combustion The burner heats the heating water circulating in the heat exchanger. When the temperature of the combustion gas is lower than the dew point (around 55 °C), the water vapour contained in the combustion gas condenses in the flue gas side of the heat exchanger. The heat recovered during this condensation process (the latent heat or condensing heat) is also transferred to the heating water. Once cooled, the combustion gases are discharged through the flue exhaust. The condensed water is discharged through a trap. Fig.6 Information label PN-0000368 A 4 Description of the product 18 15 models 15 kW - 16.2 kW Pnc (Condensing) 18 models 18 kW - 19.4 kW Pnc (Condensing) 24 models 24kW - 25.8 kW Pnc (Condensing) 12 models 12kW - 12.9kW Pnc (Condensing)
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4.2.3 Heating and domestic hot water production System boilers can provide both heating and domestic hot water. Domestic hot water will be heated in a separate cylinder or tank by the system primary water via a submerged coil or similar. The system controls will prioritise the production of either heating or domestic hot water by the operation of a diverter valve in the primary circuit. 4.2.4 Central heating mode With a demand for heating the pump circulates water through the primary circuit. Once the main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor. When the flow temperature exceeds the set temperature, a 3 minute delay occurs before the burner relights automatically (anti-cycling). The pump continues to run during this period. When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes (Pump Overrun). Key to components 1. Pump with automatic air vent 2. Boiler drain tap 3. Pressure gauge 4. Safety pressure relief valve 5. Hydraulic pressure switch 6. Gas valve 7. Safety thermostat 8. Heating flow sensor 9. Flue sensor 10. Flue adaptor 11. Primary heat exchanger 12. Electrode 13. Air / gas collector 14. Heating return sensor 15. Burner / door assembly 16. Air / gas venturi 17. Expansion vessel 18. Fan Key to connections A Condensate drain B Heating flow C Gas inlet D Heating return 4.2.5 Frost protection mode Where the boiler is sited in an unheated enclosure and during periods when the heating system is to be unused it is recommended that the permanent live is left on to give boiler frost protection. When the boiler temperature falls below 5° C, the boiler will fire until a temperature of 30° C is reached. Important This will not protect the system ! Further protection can be incorporated by using a system frost thermostat. 4.2.6 Pump protection If the boiler has been inactive for a period of 24 hours the pump will automatically operate for 1 minute to prevent sticking. Fig.7 Operating schematic (system) PN-0000310 1 2 3 4 6 7 8 9 10 11 15 12 13 14 18 16 17 A B C D 5 4 Description of the product 19
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4.3 Main components 4.3.1 List of components Fig.9 Hydraulic layout 21 13 20 18 19 12 14 PN-0000387 Tab.15 Component descriptions Key Description Key Description Key Description 1 Expansion vessel 9 Flue sensor 17 Flue adaptor 2 Expansion vessel valve 10 Spark ignition electrode 18 Heating flow sensor 3 Primary heat exchanger 11 Control box 19 Safety thermostat 4 DHW plate heat exchanger (not on System Models) 12 Condensate trap 20 Water Pressure Switch 5 Pump with automatic air vent 13 Safety pressure relief valve 21 Condensate outlet 6 CH system pressure gauge 14 Gas valve 22 Silencer 7 Fan assembly 15 Diverter valve motor (not on System Models) 23 Hall effect sensor (not on Sys tem Models) 8 Burner / door assembly 16 Boiler controls Fig.8 Component descriptions PN-0000262 1 2 17 5 3 6 16 7 8 9 11 10 22 4 Description of the product 20
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4.4 Control panel description 4.4.1 Description of the control panel 1 Display 2 Reset button 3 Central heating temperature control 4 Service diagnostic port 5 System water pressure gauge Display description The following symbols may be seen on the display OFF (frost protection still enabled) Indicates errors that prevent the burner from starting Error — not resettable by user Water pressure too low R Indicates a resettable error Not applicable Not applicable Generic error Burner lit Heating mode Units for temperature Units for pressure 4.5 Standard delivery 4.5.1 Contents of the carton The boiler is delivered in a carton comprising: Wall hung gas boiler Wall bracket for fastening the boiler to the wall Clipping bracket for running pipes upwards Fitting kit, including taps Literature pack containing: Installation and service manual User guide manual Template Flue accessories fitting guide Warranty documentations ErP product and package leaflets System additives leaflets Important These installation and service instructions MUST be read in conjunction with the flue accessories fitting guide supplied in the literature pack. Fig.10 Control panel R Reset bar 0 1 2 3 4 1 2 3 4 5 PN-0000335 M i n M a x Fig.11 Display screen R PN-0000337 4 Description of the product 21
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4.6 Accessories and options 4.6.1 Optional accessories The table shows the accessories available for this boiler range. Tab.16 Optional accessories Part number Accessory 7211473 EP2 programmer 7212443 Twin channel timer wired 720971601 Wired room thermostat 720648301 Multifit condensate & PRV combined pump 720644401 Multifit 1m condensate drain pipe 'trace heating' element 720664101 Multifit 2m Condensate drain pipe 'trace heating' element 720664201 Multifit 3m condensate drain pipe 'trace Heating' element 720664401 Multifit 5m condensate drain pipe 'trace heating' element 5121379 Multifit remote secondary PRV kit 7683087 Multifit wired outdoor sensor (System version) For flue accessories (elbows, extensions, clamps etc.) refer to the Flue Accessories Fitting Guide supplied in the literature pack. Any of the above MUST be fitted ONLY by a qualified competent person. Further details can be found in the relevant sales literature and at www.baxi.co.uk 4 Description of the product 22
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5 Before installation 5.1 Installation regulations Warning Installation, repair and maintenance must only be carried out by a competent person. This document is intended for use by competent persons. Installation must be carried out in accordance with the prevailing regulations, the code of practice and the recommendations in these instructions. Installation must also respect the following points: This instruction manual and any other applicable documentation. Building Regulations. British Standards. Gas Safety Regulations. Water Supply Regulations, 5.2 Installation requirements 5.2.1 Gas supply The gas installation should be in accordance with the relevant standards. In GB this is BS 6891 (NG). In IE this is the current edition of IS 813 Domestic Gas Installations. The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock. Ensure that the pipework from the meter to the appliance is of adequate size, and the demands of any other gas appliances in the property are taken into consideration. Do not use pipes of a smaller diameter than the boiler gas connection (22mm) UNLESS the stated gas rate can be achieved with pipe of lesser diameter and with all other gas appliances operating at maximum rate. 5.2.2 Electrical supply External wiring must be correctly earthed, polarised and in accordance with relevant regulations/rules. In GB this is the current IEE Wiring Regulations. In IE reference should be made to the current edition of ETCI rules. The mains supply is 230V ~ 50Hz fused at 3A. Important The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance. Connection may be via a fused double-pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only. The boiler must be connected to the mains fused 3A 230V 50HZ supply & control system using cable of 3 core 0.75mm 3183Y multi strand flexible type. 5 Before installation 23
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Important Any wiring to the boiler, from either the mains or an external control, MUST be cable of the following specification:- 0.75mm 3183/4/5Y (depending on installation) multi strand flexible cable conforming to BS 50525-2-11. Cable of the above specification is sufficiently flexible to withstand normal regular opening and closing of the facia/ control box as expected during routine servicing and other maintenance work. Use ONLY cable glands supplied with the boiler, or provided as spares by the manufacturer. Under no circumstances must solid core cable be used as it is not intended for applications where movement may occur. The use of solid core cable could result in situations potentially hazardous to health. These points must be considered when initially wiring the boiler to the installation, and if replacing any wiring during the service life of the boiler. 5.2.3 Hard water area Important Only water that has NOT been artificially softened must be used when filling or re-pressurising the primary system. If the mains cold water to the property is fitted with an artificial softening/ treatment device the source utilised to fill or re-pressurise the system must be upstream of such a device. 5.2.4 Bypass The boiler is fitted with an automatic integral bypass. 5.2.5 System control Further external controls (e.g. room thermostat sensors) MUST be fitted to optimise the economical operation of the boiler in accordance with Part L of the Building Regulations. A range of optional controls is available. Full details are contained in the relevant Sales Literature. 5.2.6 Treatment of water circulating systems All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems. When fitting new systems flux will be evident within the system, which can lead to damage of system components. BS 7593 gives extensive recommendations on system cleansing and water treatment. All systems must be thoroughly drained and flushed out using appropriate proprietary flushing agent. A suitable inhibitor must then be added to the system. All system additives (flushing agents, cleansers, inhibitors etc.) must comply with the requirements of BS 7593. Full instructions are supplied with the products and for further information contact the additive manufacturer directly or consult their website. Important Failure to flush and add inhibitor to the system will invalidate the appliance warranty. 5 Before installation 24
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It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the inhibitor manufacturer. (Test kits are available from inhibitor stockists.) For information or advice regarding any of the above contact Baxi Customer Support 0344 871 1545. 5.2.7 Showers If a shower control is supplied from the appliance it should be of the thermostatic or pressure balanced type. Thermostatic type shower valves provide the best comfort and guard against water at too high a temperature. Existing controls may not be suitable - refer to the shower valve manufacturer. 5.2.8 Expansion vessel (CH only) The appliance expansion vessel is pre-charged to 1.0 bar. Therefore, the minimum cold fill pressure is 1.0 bar. The vessel is suitable for correct operation for system capacities up to 120 litres. For greater system capacities an additional expansion vessel must be fitted. For GB refer to BS 7074 Pt 1. For IE, the current edition of IS 813 Domestic Gas Installations. Checking the charge pressure of the vessel - to check the charge accurately ensure the system is cold. It is also necessary to relieve the pressure by draining the boiler. Using a suitable gauge check the pressure at the valve on the underside of the vessel. Adjust the pressure as required and repressurise the system. 5.2.9 Safety pressure relief valve 1 Discharge pipe 2 Pressure relief valve A The end of the pipe should terminate facing down and towards the wall See BS 6798 for full details. The pressure relief valve is set at 3 bar, therefore all pipework, fittings, etc. should be suitable for pressures in excess of 3 bar and temperature in excess of 100°C. The pressure relief discharge pipe should be not less than 15mm diameter, run continuously downward, and discharge outside the building, preferably over a drain. It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components. If it is anticipated that any part of the pipe may be subject to freezing it should be suitably insulated. The end of the pipe should terminate facing down and towards the wall. The discharge must not be above a window, entrance or other public access. Consideration must be given to the possibility that boiling water/ steam could discharge from the pipe. Important The relief valve must never be used to drain the system. A remote relief valve kit is available to enable the boiler to be installed in cellars or similar locations below outside ground level. A boiler discharge pump is available which will dispose of both condensate & high temperature water from the relief valve. It has a maximum head of 5 metres. Fig.12 Discharge pipe PN-0000604 1 1 2 A 5 Before installation 25
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5.3 Choice of the location 5.3.1 Location of the boiler The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard.) Where the boiler is sited in an unheated enclosure and during periods when the heating system is to be unused it is recommended that the permanent live is left on to give BOILER frost protection. NOTE: THIS WILL NOT PROTECT THE SYSTEM ! If the boiler is fitted in a room containing a bath or shower reference must be made to the relevant requirements. In GB this is the current IEE Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of IS 813 Domestic Gas Installations and the current ETCI rules. 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). 5.3.2 Bath and shower rooms A Zone 0 B Zone 1 C Zone 2 D Window recess Zone 2 E Ceiling F Outside zones Important Where an optional plug-in integral timer, RF receiver or thermostat is NOT FITTED the boiler has a protection rating of IPX5D and if installed in a room containing a bath or shower can be within Zone 2 (but not 0 or 1). Important A boiler fitted with an optional plug-in integral timer, RF receiver or thermostat CANNOT be fitted in any zone. Bathroom 1 and 2 ( in GB only) shows zone dimensions for a bathtub. For other examples refer to the Current IEE Wiring Regulations). Reference must be made to the relevant requirements. In GB this is the current IEE. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of IS 813 “Domestic Gas Installations” and the current ETCI rules. Fig.13 Bathroom 1 and 2 PN-0000400 A B C D D 0.6m A B C D E F 0.6m 2.25m 5 Before installation 26
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5.3.3 Ventilation Where the appliance is installed in a cupboard or compartment, no air vents are required. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. 5.3.4 Condensate drain It is strongly recommended to discharge internally into the household drainage system. If connecting to a rain water drain, that drain MUST discharge into a foul drain. 1 Pipework. 2 Insulation. 3 50mm per metre of pipe run — 2.5° minimum run. 4 450mm minimum is applicable to properties up to 3 storeys. For multi-storey building installations consult BS 6798. 5 Boiler. 6 Sink. 7 Pipe must terminate above water level but below surrounding surface. Cut end at 45°. 8 Holes in the soak-away must face away from the building. 9 500mm mimimum. 10 Basement or similar (heated) 11 Condensate pump 12 Unheated Location (e.g. Garage) Tab.17 Examples are shown of the following methods of termination Key Description A Termination to an internal soil and vent pipe. B External termination via internal discharge branch e.g. sink waste — downstream (It is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle!) C Termination to a drain or gully. D Termination to a purpose made soakaway Further specific re quirements for soakaway design are referred to in BS 6798 E Pumped into an internal discharge branch (e.g. sink waste) down stream of the trap. F Pumped into an external soil and vent pipe. G Termination to a drain or gully with extended external run and trace heating. The "Trace Heating" element must be installed in accordance with the instructions supplied. External runs and those in unheated locations still require insulation. Fig.14 Pipework and method of termination PN-0000389 A B C D 3 3 3 3 4 6 5 5 5 5 7 7 8 9 21.5mm 32mm 2 5 Before installation 27
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Important Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler. Careful consideration must be given to the possibility of the pipework being subject to freezing conditions and appropriate measures taken to prevent blockage. Correct installation in accordance with this section will considerably minimise the likelihood of blockage and subsequent boiler lock-out. A condensate discharge pump and pipe "Trace Heating" are available as accessories. The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run EXCEPT when employing a suitable condensate pump in basement and cellar or similar applications. The boiler condensate trap incorporates a seal of 75mm, therefore it is unnecessary to install an air break and trap in the discharge pipework. The condensate outlet will accept 21.5mm (3/4in) plastic overflow pipe. It is strongly recommended that this discharges internally into the household drainage system. Where this is not possible, discharge into an outside drain is permissible providing every possible precaution is taken to prevent freezing. Ensure the discharge of condensate complies with any national or local regulations in force. BS 6798 & Part H1 of the Building Regulations give further detailed guidance. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP. Metal pipework is NOT suitable for use in condensate discharge systems. The pipe should be a minimum of 21.5mm diameter and must be supported using suitably spaced clips of the correct design to prevent sagging. It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres. Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe. External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external use. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly. In all cases discharge pipe must be installed to aid disposal of the condensate. To reduce the risk of condensate being trapped, as few bends and fittings as possible should be used and any burrs on cut pipe removed. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC's are flushed or sinks emptied then backpressure may force water out of the boiler trap and cause appliance lockout. A boiler discharge pump is available which will dispose of both condensate & high temperature water from the relief valve. It has a maximum head of 5 metres. Follow the instructions supplied with the pump. Condensate Drain Pipe "Trace Heating" Elements are available in various lengths, 1, 2, 3 & 5 metres. Where the drain is between 3 & 5 metres a 5 metre kit can be used and "doubled back" upon itself. It is possible to fit the element externally on the condensate drain or internally as detailed in the instructions provided. Fig.15 Methods of termination continued PN-0000455 E 3 5 F G 3 3 5 5 7 7 10 11 11 10 12 6 5 Before installation 28
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The fitting of a "Trace Heating" Element is NOT a substitute for correct installation of the condensate drain. ALL requirements in this section must still be adhered to. 5.3.5 Clearances A flat vertical area is required for the installation of the boiler and it should be capable of bearing the weight of the boiler when full of water. 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. In the diagram these are MINIMUM recommended dimensions. Greater clearance will aid installation and maintenance. 5.3.6 Flue/chimney location 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. Important Due to the nature 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. Fig.16 Flue outlets R T U J,K J,K A D E C I I I A A S F H H B G F I I L N M PN-0000456 1 1 Flue positions marked require a flue terminal guard. Tab.18 Terminal position with minimum distance Key Description mm Key Description mm A (1) Directly below an opening, air brick open ing window etc. 300 J From a surface or boundary line facing a terminal 600 B (1) Above an opening, air brick, opening win dow etc. 300 K From a terminal facing a terminal (Horizontal flue) 1200 From a terminal facing a terminal (Ver tical flue) 600 C (1) Horizontally to an opening, air brick, opening window etc. 300 L From an opening in carport (e.g. door, window) into the dwelling 1200 5 Before installation 29
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Key Description mm Key Description mm D (2) Below gutters, soil pipes or drain pipes 25 (75) M Vertically from a terminal on the same wall 1500 E (2) Below eaves 25 (200) N Horizontally from a terminal on the same wall 300 F (2) Below balconies or car port roof 25 (200) R From adjacent wall to flue (vertical on ly) 300 G (2) From a vertical drain pipe or soil pipe 25 (150) S From an adjacent opening window (vertical only) 1000 H (2) From an internal or external corner 25 (300) T Adjacent to windows or openings on pitched and flat roofs 600 I Above ground, roof, or balcony level 300 U Below windows or openings on pitch ed roofs 2000 (1) In addition, the terminal should be no nearer than 150mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame. (2) Only ONE 25mm clearance is allowed per installation. If one of the dimension D,E,F,G or H is 25mm then the remainder MUST be as shown in brackets, in accordance with BS 5440–1. Important Under car ports we recommend the use of the plume displacement kit. The terminal position must ensure the safe and nuisance - free dispersal of combustion products. 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. 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. 1 Property boundary line 2 Terminal assembly 3 Top view rear flue A 300mm minimum* *Reduction to the boundary is possible down to 25mm but the flue deflector must be used. Important The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram opposite. 1 Opening window or door 2 Air inlet 3 Plume displacement kit A 150mm minimum Important If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 150mm from any opening windows or doors. Important The Plume Displacement flue gas discharge terminal and air inlet must always terminate in the same pressure zone i.e. on the same facing wall. Fig.17 Property boundary PN-0000457 3 1 2 A* Fig.18 Plume displacement kit PN-0000458 3 1 2 A 5 Before installation 30
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5.3.7 Horizontal flue/chimney systems 1 315mm to 500mm 2 Flue trims 3 This bend is equivalent to 1 metre Total equivalent length = A+B+C+2x90° bends Important Horizontal flue extensions should always be installed with a fall of at least 1.5° from the terminal to allow condensate to run back to the boiler. The standard telescopic flue is suitable only for horizontal termination applications. It allows for lengths between 315mm and 500mm from elbow to terminal without the need for cutting. Extensions of 250mm, 500mm and 1m are available. All fittings should be fully engaged. The approximate engagement is 40mm. Apply the lubricant supplied to the seal on each fitting to aid assembly. Tab.19 Maximum permissible equivalent flue lengths are:- Horizontal concentric 60/100 Diameter 80/125 Diameter 10 metres 20 metres Any additional "in line" bends in the flue system must be taken into consideration. Tab.20 Their equivalent lengths are:- Concentric pipes 135° bend 0.5 metres 93° bend 1.0 metres The elbow supplied with the standard horizontal telescopic flue kit is not included in any equivalent length calculations. Important Flue length is measured from point (i) to (ii) as shown. See Read this section in conjunction with the Flue Installation Guide supplied with the boiler. This document includes details of vertical flue/chimney systems and plume displacement kits. Warning SUPPORT - All flue systems MUST be securely supported at a MINIMUM of once every metre & every change of direction. It is recommended that every straight piece is supported irrespective of length. Additional supports are available as accessories. VOIDS - Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual inspection. 5.3.8 Flue/chimney trim The flexible flue trims supplied can be fitted on the outer and inner faces of the wall of installation. Fig.19 Horizontal flues PN-0000459 3 1 2 A 3 C B (i) (ii) Fig.20 Flexible flue trims PN-0000390 5 Before installation 31
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5.3.9 Terminal guard 1 ENSURE THAT NO PART OF THE WHITE OUTER CHIMNEY DUCT IS VISIBLE. When codes of practice dictate the use of terminal guards Multifit accessory part no. 720627901 can be used Important This guard is not compatible with Flue Deflector referred to below. There must be a clearance of at least 50mm between any part of the terminal and the guard. When ordering a terminal guard, quote the appliance name and model number. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated. 5.3.10 Flue/chimney deflector 1 Flue deflector Push the flue deflector over the terminal end. It may point upwards as shown, or up to 45° either way from vertical. Secure the deflector to the terminal with screws provided. 5.3.11 Flue/chimney accessories See For full details of Flue Accessories (elbows, extensions, clamps etc.) refer to the Flue Installation Guide supplied in the literature pack. 5.4 Transport This product should be lifted and handled by two people. When lifting always keep your back straight and wear protective equipment where necessary. Carrying and lifting equipment should be used as required. e.g. when install in a loft. Fig.21 Terminal guard PN-0000460 1 Fig.22 Flue deflector PN-0000461 1 5 Before installation 32
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5.5 Unpacking & initial preparation 5.5.1 Unpacking Caution RISK ASSESSMENT - Before commencing the installation it is recommended that the "Five Steps to Risk Assessment" document published by the HSE is consulted, and an assessment performed as described. GAS SUPPLY - The gas supply, gas type and pressure must be checked for suitability before connection. See Handling, page 9 before unpacking or lifting the boiler. To unpack the boiler: 1. Remove the banding and the cardboard sleeve. 2. Remove the polystyrene top piece and installation kit. 3. Snap off the rear part of the polystyrene bottom piece. Important Polystyrene base should be removed completely if fitting the boiler into a space with minimum side clearances of 5 mm each side. Important If removing the polystyrene base, the sealing caps can also be removed at this stage. Care must be taken to avoid damage from any residual water in the boiler. 5.5.2 Initial preparation 1. After considering the site requirements position the fixing template on the wall ensuring it is level both horizontally and vertically. 2. Mark the position of the two most suitable fixing slots for the wall plate. 3. Mark the position of the centre of the flue hole (rear exit). For side flue exit, mark as shown. 4. If required, mark the position of the gas and water pipes. Remove the template. 5. Cut the hole for the flue (minimum diameter 116mm). 6. Drill the wall as previously marked to accept the wall plugs supplied. Secure the wall plate using the fixing screws. 7. Using a spirit level ensure that the plate is level before finally tightening the screws. 5.6 Connecting diagrams 5.6.1 Filling information 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 filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment. Your attention is drawn to: for GB: Guidance G24.2 and recommendation R24.2 of the Water Regulations Guide. Fig.23 Unpacking the boiler PN-0000345 Fig.24 Template PN-0000346 150 mm Ø 8mm 50mm MIN Heating Return (22mm) Gas (22mm) Heating Flow (22mm) Hot Water Outlet (15mm) Combi Only Not System Cold Water Inlet (15mm) Combi Only Not System Clearance above 178mm Clearance below 200mm 7664094-02 Ø 22mm Condensate Drain Pressure Relief Side Clearance 5mm Side Clearance 5mm 195.5mm 195.5mm 65mm 65mm 65mm 65mm 22mm CH F & R 22mm Gas This leg into tap 15mm DHW In/Out This leg into tap Pipe Profiles. (Where copper tails are not supplied with the boiler) To ensure that the vertical pipework is at the optimum distance (whether piping up or down) make up in accordance with these exactly sized profiles. View from under boiler Safety Pressure Relief Condensate Primary Drain Wall 116mm Dia Minimum Aperture For Flue Tube Pipework run to rear of boiler. If it is desired to route pipework vertically behind the boiler the 5 position clip bracket must be used. This guides the gas pipe and one of the DHW pipes to one side of the flue. They may be set to the right or left. To engage in the bracket the gas pipe must be offset by 70mm and the DHW by 35mm. Compression fittings cannot be used behind the boiler. The use of 90o elbows is not recommended. The clip bracket is retained using the same screws that fasten the wall plate in position. DO NOT ROUTE THE PRV OR CONDENSATE DISCHRGE UPWARDS ! Clip Bracket 5 Before installation 33
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for IE: the current edition of I.S. 813 Domestic Gas Installations. The sealed primary circuits may be filled or replenished by means of a temporary connection between the 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. When the optional permanent filling link is fitted it is not necessary to remove any part of it after filling or re-pressurising. 5 Before installation 34
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6 Installation 6.1 General Installation must be carried out in accordance with the prevailing regulations, codes of practice and the recommendations in this manual. Danger If the boiler is installed in a compartment do not use it for storage purposes. Do not obstruct any purpose provided ventilation openings. Caution Where the boiler is sited in an unheated enclosure provision must be made to protect against frost, e.g. frost thermostat, pipe thermostat. 1. Lift the boiler by gripping "a" and "b" and hook the boiler onto the wall plate. 2. Remove the polstyrene bottom piece by slipping it off downwards. 3. Remove the sealing caps from the boiler connections under the boiler (including the condensate trap). c Sealing caps Warning Some residual water may escape when removing the sealing caps. Take precautions to avoid damage to components ! 4. Remove the taps and sealing washers from the fitting kit. The taps accept 22mm copper pipe — see template. 5. Using the sealing washers provided connect the appropriate tap to the heating flow and return & gas supply. 6. Always fit the tap with the drain point to the heating flow. 7. Ensure all joints are tight. Important Connect the pressure relief discharge pipe first before any other pipework. 6.2 Assembly 6.2.1 Fitting the pressure relief discharge pipe 1. The valve and discharge pipe are assembled to the boiler, terminating in a threaded male coupling. 2. Determine the routing of the discharge pipe in the vicinity of the boiler. Make up as much of the pipework as is practical, including the 15mm elbow and nut supplied. Important Make all soldered joints before connecting to the pressure relief valve. Do not adjust the position of the valve. The discharge pipe must be installed before pressurising the system. 3. The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building. 4. Complete the discharge pipework and route it to the outside discharge point. 5. The pipework must be clipped at suitable intervals to support it, commencing as close to the boiler as possible. Fig.25 Mounting the boiler a PN-0000320 b c Fig.26 Connecting the taps PN-0000322 Fig.27 Pressure relief pipe connection PN-0000632 6 Installation 35
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6.2.2 Connecting the condensate drain 1. Remove the blanking cap, and using the elbow supplied, connect the condensate drain pipework to the boiler condensate trap outlet pipe. See Ensure the discharge of condensate complies with any national or local regulations in force (see HHIC recommendations). See Condensate drain, page 27. 2. The elbow will accept 21.5mm (3/4 in) plastic overflow pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable. Important The boiler condensate trap should be primed by pouring approximately 300ml of water into the flue spigot. Do not allow any water to fall into the air inlet. 6.3 Air supply/flue gas connections 6.3.1 Connecting the flue/chimney HORIZONTAL TELESCOPIC FLUE (concentric 60/100) 1 315mm to 500mm 2 Connection assembly 3 Terminal assembly There are two telescopic sections, the terminal assembly and the connection assembly, a roll of sealing tape and two self tapping screws. A 93° elbow is also supplied. The two sections can be adjusted to provide a length between 315mm and 500mm when measured from the flue elbow (there is 40mm engagement into the elbow). 1. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation. Important The flue elbow is angled at 93° to ensure a fall back to the boiler. 2. Measure the distance from the outside wall face to the elbow. This dimension will be known as " X" . 3. If the distance from the flue elbow to the outside face of the wall is less than 250mm the connection assembly can be discarded and the terminal assembly fitted directly into the elbow. 4. In instances where the dimension " X" is between 250mm and 315mm it will be necessary to shorten the terminal assembly by careful cutting to accommodate walls of these thicknesses. Fig.28 Pour 300ml of water into flue spigot PN-0000602 Fig.29 Telescopic flue PN-0000462 3 1 2 Fig.30 Flue dimension X PN-0000463 X X 6 Installation 36
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5. To dimension " X" add 40mm. This dimension to be known as "Y" . 1 TOP label 2 Sealing tape 3 Securing screw 4 Peak to be uppermost 6. Adjust the two telescopic sections to dimension "Y" and seal the joint with the tape provided. Ensure that the labels marked "TOP" on the terminal and connection assemblies are uppermost. 7. Using the clearance holes in the connection assembly secure it to the terminal assembly using the screws supplied with the telescopic flue. 8. Remove the flue elbow and insert the flue through the hole in the wall. Fit the flue trims if required, and refit the elbow to the boiler adaptor, ensuring that it is pushed fully in. Secure the elbow with the screws supplied in the boiler fitting kit. 1 Flue elbow 2 Boiler adaptor 3 Telescopic flue 4 Flue trim 5 Securing screw A Apply the lubricant supplied for ease of assembly (do not use any other type). Ensure flue is fully engaged into elbow. B Apply the lubricant supplied for ease of assembly (do not use any other type). Ensure elbow is fully engaged into boiler adaptor. C Peak to be uppermost 9. Draw the flue back through the wall and engage it in the elbow. It may be necessary to lubricate to ease assembly of the elbow and flue. 10. Ensure that the terminal is positioned with the slots to the bottom. Secure to the elbow with the screws supplied with the telescopic flue. Important It is essential that the flue terminal is fitted as shown to ensure correct boiler operation and prevent water entering the flue. 11. Make good between the wall and air duct outside the building, appropriate to the wall construction and fire rating. 12. If necessary fit a terminal guard. Important There must be no part of the air duct (white tube) visible outside the property. Fig.31 Flue dimension Y PN-0000464 Y 1 2 1 3 4 Fig.32 Attaching the flue PN-0000465 1 2 3 4 4 5 A B C 6 Installation 37
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6.4 Electrical connections See Electrical supply, page 23 for details of the electrical supply. Warning Check that the total nominal consumption of the accessories connected to the appliance is less than 1 amp. If it is higher, a relay must be installed between the accessories and the electronic board. 6.4.1 Making the electrical connection Fig.33 Remove terminal cover PN-0000395 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 G H M2 M1 Outdoor Weather Sensor Low Voltage Controls (OpenTherm) Important When fitting external controls remove the yellow link wire from the Mains Terminal Block M1. Important Consideration must be given to Health and Safety Document 635 (The Electricity at Work Regulations, 1989). 1. Remove the front panel. See Specific maintenance instructions, page 51 to remove the front panel. 2. Hinge down the control box and unclip the terminal block cover. 3. Slacken both gland nuts in the bottom of the boiler lower panel and insert the mains cable and the external control system cable through them. 4. Leave sufficient slack in the cables to allow the control box to be hinged fully open. Tighten both gland nuts. 6 Installation 38
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5. Connect the earth, permanent live and neutral wires to the terminal block. Important Both the permanent live and neutral connections are fused. Key Description Key Description A Fused Spur b Blue B Room Thermostat bk Black C External Clock br Brown D Frost Thermostat g/y Green/Yellow F Pipe Thermostat E Earth G Mains Terminal Block M1 N Neutral H Low Voltage Terminal Block M2 L Live 6. Refer to the instructions supplied with the external control(s). 7. Remove the link between terminals 1 and 2. 8. The 230V supply at terminal 2 must be connected to the thermostat. 9. The switched output from the thermostat must be connect to terminal 1. Important The 230V switched signal for external controls (frost thermostat — room thermostat — timer) must always be taken from terminal 2 at the boiler. Live, Neutral and Earth to power these controls must be taken from the Fused Spur. 10. Reclip the terminal block cover back into position and hinge back the control box. Important When an OpenTherm controller is connected adjustment of the boiler, e.g. heating temperature, is made using the OpenTherm controller rather than the boiler controls. The boiler controls are overridden by the OpenTherm control. Please check the functionality with the manufacturer of the OpenTherm controller. Preliminary electrical checks Prior to commissioning the boiler preliminary electrical system checks should be carried out. These should be performed using a suitable meter, and include checks for Earth Continuity, Resistance to Eart, Short Circuit and Polarity. Fig.34 Typical electrical connections PN-0000396 b br b bk g/y 1 N L 2 N N L 230V 230V b br b bk g/y 1 N L 2 N N L E 230V E E E A B A B C D F G G 6 Installation 39
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6.5 Filling the installation 6.5.1 Flushing the system Flush thoroughly and treat the system according to guidance given in BS 7593. 6.5.2 Fill the installation 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. 1. Fill the installation using approved equipment and in accordance with all relevant water supply regulations. Important 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" . 2. The sealed primary circuits may be filled or replenished by means of a temporary connection between the 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. 3. Fill or replenish the sealed primary circuits by means of a temporary connection between the circuit and a supply pipe: Permanently connect a ‘Listed’ double check valve or some other no less effective backflow prevention device at the inlet to the circuit. Remove the temporary connection after use except if where a permanent connection is used. 6.5.3 Filling the condensate trap 1. Check that the boiler condensate trap has been primed before commissioning the boiler. 6 Installation 40
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7 Commissioning 7.1 General Reference should be made to BS:EN 12828, 12831 & 14336 when commissioning the boiler. Ensure that the condensate drain trap has been primed. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publication. Open the mains water supply to the boiler and all hot water taps to purge the DHW system. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. Ensure that the cap on the automatic air vent on the pump body is opened. The system must be flushed in accordance with BS 7593 and the flushing agent manufacturer’s instructions. Pressurise the system to 1.5 bar then close and disconnect the temporary filling loop except where a permanent loop is fitted. Test for gas tightness, turn the gas supply on and purge according to GB BS 6891 and in IE I.S. 813 "Domestic Gas Installations" . 7.2 Checklist before commissioning 7.2.1 Preliminary electrical checks Important Consideration must be given to Health & Safety Document 635 (The Electricity at Work Regulations, 1989). Prior to commissioning the boiler preliminary electrical system checks should be carried out. These should be performed using a suitable meter, and include checks for Earth Continuity, Resistance to Earth, Short Circuit and Polarity. 7.2.2 Checks Checked: That the boiler has been installed in accordance with these instructions. The integrity of the flue system and the flue seals. The integrity of the boiler combustion circuit and the relevant seals. That the condensate trap has been primed. 7 Commissioning 41
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7.3 Commissioning procedure 7.3.1 De-Aeration function Before turning on the power to the boiler, rotate the CH control knob ( ) fully anticlockwise. The purpose of the function is to remove as much air as possible from the heating system. To assist this it is essential that all precautions are taken to remove air manually before enabling the function. Ensure that all radiators are fully bled, starting on the lowest floor in properties of more than one storey. Any high points in the system should be fitted with a suitable venting device. On the boiler’s first power up de-aeration lasts approximately 7 minutes. The boiler will not operate during this process. 1. Turn on the power to the boiler. The display shows "000" . 2. Turn the CH control knob ( ) 1/4 turn clockwise twice in quick succession (within 2 seconds). 3. Display shows "312" while de-aeration is taking place (approximately 7 minutes). 4. When de-aeration has completed, the display will show the primary flow temperature and the CH ( ) symbols. Important If during the first commissioning process the power to the boiler is interrupted the de-aeration function will re-start automatically at the point which it stopped once power is restored. Caution If the system is drained in the future (even partly, when replacing a radiator for example) the de-aeration function must be repeated. Also the inhibitor concentration must be checked and replenished if necessary. 7.4 Gas settings 7.4.1 Check the operational (working gas inlet pressure and gas rate) Important If the pressure drops are greater than shown in the diagram opposite, a problem with the pipework or connections is indicated. Permissible pressure drop across system pipework ≤ 1mbar. Carry out chimney sweep. See Checking combustion - chimney sweep mode, page 43. Fig.35 Setting de-aeration R Reset bar 0 1 2 3 4 M i n M a x M a x M i n R M a x M i n R x 2 PN-0000398 Fig.36 Gas meter to valve EV1 EV2 P. OUT 1 2 3 4 VENT RQ ADJ. 17-21 mbar PN-0000361 19-23 mbar 18-22 mbar A 7 Commissioning 42
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1. 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 BS 6798 & BS 6891. This must be AT LEAST 18mb ! 2. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working. The pressure should be measured at the gas test point on the gas inlet (A). 3. Measure the gas rate— With any other appliances & pilot lights turned OFF the gas rate can be measured. It should be:- Tab.21 Natural gas 7.4.2 Checking combustion - chimney sweep mode The case front panel must be fitted when checking combustion. Ensure the system is cold and the gas and electric supplies are turned on. Important 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. 1 Combustion test point 2 Incoming air for combustion test point Important Allow the combustion to stabilise before inserting the Combustion Analyser Probe into the Test Point (1). This will prevent saturation of the analyser. The combustion must be measured and recorded at the Maximum and Minimum heat inputs. Fig.37 Gas inlet test point A PN-0000362 Fig.38 Flue adaptor test points PN-0000363 1 2 7 Commissioning 43 15 18 Natural gas rate (G20) Qmax m3/h 1.64 1.96 Natural gas rate (G20) Qmin m3/h 0.49 0.49 Assure System 12 24 0.49 1.31 0.49 2.61
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Warning Ensure that both flue test point plugs are in place after checking combustion. Setting maximum and minimum output 1. Turn both control knobs fully anticlockwise and leave for 10 seconds. 2. Turn the right hand knob 1/ 4 turn twice in quick succession (within 2 seconds). 3. "304" will appear in the display. 4. Turn the CH knob ( ) fully clockwise. "100" will appear in the display, indicating maximum output. 5. After checking at maximum turn the CH knob ( ) fully anticlockwise. "0" will appear in the display, indicating minimum output. Measuring the combustion Turn on the domestic hot water tap. Carry out inlet working gas pressure gas rate and combustion checks. Once all relevant tests are completed, take out of chimney sweep mode by turning the DHW control knob clockwise. Boiler is now ready to use. Fig.39 Setting chimney sweep mode Reset bar 0 1 2 3 4 R M i n M a x [ M a x M i n M a x M i n PN-0000399 R 7 Commissioning 44
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Fig.40 Combustion procedure Set Boiler to Maximum Rate Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser. Perform Flue Integrity Combustion Check Insert the analyser probe into the air inlet test point, allowing the reading to stabilise. Is O2 ≥ 20.6% and CO2 < 0.2% ? Verify Flue Integrity Indication that products of combustion & inlet air are mixing - further investigation is required. Check all flue components are correctly assembled, fixed & supported. Check the flue & terminal are unobstructed. Is O2 ≥ 20.6% and CO2 < 0.2% ? TURN APPLIANCE OFF ! Call 0344 871 1545 for advice. The appliance MUST NOT be commissioned until all problems are identified and resolved. Check CO & Combustion Ratio at Maximum Rate Whilst the boiler is still operating at maximum insert the analyser probe into the flue gas test point, allowing the reading to stabilise. Is CO < 350ppm and CO/CO2 ratio < 0.004 ? Verify Integrity of Seals Check all burner seals, internal flue seals, door & case seals. Replace any seals that appear unsound. Is CO < 350ppm and CO/CO2 ratio < 0.004 ? TURN APPLIANCE OFF ! Call 0344 871 1545 for advice. The appliance MUST NOT be commissioned until all problems are identified and resolved. If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with the GSIUR. Note: Check & record the CO & combustion ratio at both maximum & minimum rates before calling 0344 871 1545. Set Boiler to Minimum Rate Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser. Yes No No Yes No Yes Check CO & Combustion Ratio at Minimum Rate Whilst the boiler is operating at minimum insert the analyser probe into the flue gas test point, allowing the reading to stabilise. Yes No Is CO < 350ppm and CO/CO2 ratio < 0.004 ? No Yes BOILER OPERATING SATISFACTORILY. NO FURTHER ACTION REQUIRED Ensure test points are capped, the boiler case front panel is correctly fitted & secured and all other commissioning procedures completed. Complete the ‘Benchmark’ Checklist, recording the CO & combustion ratio readings as required. PN-0000466 7 Commissioning 45
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7.5 Configuring the system 7.5.1 System draining If at any time after installation it is necessary to drain and refill the central heating system (e.g. when replacing a radiator) the De-Aeration function must be activated to avoid air being trapped in the system. See De-Aeration function, page 42. Once De-Aeration is complete recommission the boiler and check that the inhibitor concentration is sufficient. 7.6 Final instructions 7.6.1 Handover 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. Important The warranty will be invalidated if the Benchmark section is incomplete. 2. The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded. 3. Complete the Package Fiche in the User Guide. 4. Hand over the User Guide and Installation and Servicing Instructions, giving advice on the necessity of regular servicing. 5. 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. 6. Set the central heating and hot water temperatures to the requirements of the user. Instruct the user in the operation of the boiler and system. 7. Instruct the user in the operation of the boiler controls. 8. 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 switched, and to ventilate the property. 9. Show the user the location of the system control isolation switch, and demonstrate its operation. 10. Advise the user that they may observe a plume of vapour from the flue terminal, and that it is part of the normal operation of the boiler. Fig.41 People PN-0000333 7 Commissioning 46
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8 Operation 8.1 Use of the control panel 8.1.1 Control panel The controls are operated by the control knobs and a reset button. 1 Display screen 2 Reset button 3 CH temperature control knob 4 Service diagnostic port 6 System water pressure gauge Important When an OpenTherm controller is connected adjustment of the boiler, e.g. heating temperature, is made using the OpenTherm controller rather than the boiler controls. The boiler controls are overridden by the OpenTherm control. Please check the functionality with the manufacturer of the OpenTherm controller. 8.2 Start up If there is no power to the boiler, switch on at the fused spur unit and ensure that the time control is in the on position and any other controls (e.g. room thermostat) are calling for heat. The boiler will begin its start sequence. This procedure performs a series of tests, after which the installation is purged (this takes approximately five minutes). 8.3 Frost protection Where possible, draining the system should be avoided. If the system is to be unused during winter months several precautions must be taken: Any parts of the system that are in unheated areas of the dwelling should be fitted with a device such as a pipe thermostat or frost thermostat. Power must remain supplied to the boiler and controls. Gas must remain supplied to the boiler. The boiler pump will operate if the system temperature drops below 7°C. If the temperature falls to 4°C the burner will ignite and remain lit until the temperature reaches 10°C. At this temperature the burner will extinguish but the pump will continue to operate for 15 minutes. This feature will protect the boiler and to some extent adjacent parts of the system but additional devices must be incorporated to guarantee frost protection. Fig.42 Control panel R Reset bar 0 1 2 3 4 1 2 3 4 5 PN-0000335 M i n M a x 8 Operation 47
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9 Maintenance 9.1 General Warning When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed recommission the boiler. Always examine any seals or gaskets, replacing where necessary. The case front panel MUST seal effectively against the boiler side panels. Warning After servicing or performing any maintenance on the boiler ensure that Both flue test point plugs are in place The front cover is correctly fitted The front cover securing screws are fully tightened 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 BS 7967-4. 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 by checking air inlet sample to eliminate the possibility of recirculation. O2 ≥ 20.6% & CO2< 0.2% The integrity of the boiler combustion circuit and relevant seals. The operational gas inlet pressure and the gas rate. The combustion performance as described in "Check the Combustion Performance" below. Competence to carry out checking combustion performance BS 6798 "Specification for Installation & Maintenance of Gas Fired Boilers not exceeding 70kWh" 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 BS 7927 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/CO2 ratio) Set the boiler to operate at maximum rate. See Checking combustion - chimney sweep mode, page 43 for details. 9 Maintenance 48
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Remove the plug from the combustion test point, insert the analyser probe and obtain the CO/CO2 ratio. This must be less than 0.004. If the combustion reading (CO/CO2 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 "Standard Inspection and Maintenance" . Perform "Setting the Gas Valve" . Replace and set the gas valve. 1 Combustion test point 2 Incoming air for combustion test point Warning Ensure that both flue test point plugs are in place after checking combustion. 9.2 Standard inspection and maintenance operations 9.2.1 Annual Servicing Warning Ensure that the boiler is cool. Ensure that both the gas and electrical supplies to the boiler are isolated. Caution Always examine any seals or gaskets, replacing where necessary. Where a seal or gasket is supplied with a spare part it should be used, irrespective of the condition of the original. Use only original spare parts that are intended for use with this type of boiler. Important When performing any inspection or maintenance, personal protective equipment must be used where appropriate. 1. Ensure that both the gas and electrical supplies to the boiler are isolated and that the boiler is cool. 2. Remove the case front panel and hinge down the control panel. See Specific maintenance instructions, page 51 3. Disconnect the pipe from the top of the condensate trap and the drain pipe from the condensate drain pipe connection. Undo the screw securing the bracket and trap to the boiler lower panel. 4. Remove the trap. Take care not to spill any residual condensate on the controls and P.C.B. Thoroughly rinse the trap and examine the gasket on the trap base, replacing if necessary. 5. Remove the clip securing the gas feed pipe to the air/gas venturi on the fan. Disconnect the pipe. Do not break the joint between the pipe ang gas valve unless necessary. 6. Disconnect the electrode lead and the fan electrical plug. 7. Undo the four nuts retaining the burner / door assembly to the heat exchanger. 8. Carefully draw the burner / door assembly forward and remove. See Checking the burner and cleaning the heat exchanger, page 50 9. Clean any debris from the heat exchanger and check that the gaps between the tubes are clear. 10. Inspect the burner, insulation and position and condition of the electrode, cleaning or replacing if necessary. Clean any dirt or dust from the airbox. Fig.43 Flue adaptor test points PN-0000363 1 2 Fig.44 Remove the condensate trap PN-0000381 9 Maintenance 49
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11. Carefully examine all seals and gaskets, replacing if necessary. Look for any evidence of leaks or corrosion and if found determine and rectify the cause. 12. Reassemble in reverse order. 13. 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. 9.2.2 Checking the water pressure In order for the boiler to operate correctly, the pressure of the water in the heating circuit must be between 1.0 and 1.5 bar. Restore the water pressure if necessary. 9.2.3 Checking the expansion vessel Check the expansion vessel and recharge or replace it if necessary. Check its pre-charge every year and restore the pressure to 1 bar if necessary. 9.2.4 Checking the automatic air vent Check that the boiler pump venting valve is working. In the event of a leak, replace the valve. 9.2.5 Checking the burner and cleaning the heat exchanger 1. Isolate the boiler from the gas & electrical supplies. 2. Remove the front panel. 3. Remove the silencer. 4. Disconnect the spark electrode lead and earth wire from the detection / spark electrode. 5. Remove the clip securing the gas feed pipe to the fan. Disconnect the pipe. 6. Completely remove the combustion chamber / burner door assembly by unscrewing the four M6 nuts and drawing it forwards to disengage it from the heat exchanger.. 7. Check that the detection/spark electrode is not worn. Replace the electrode if necessary. 8. Check the condition of the burner, the gasket and the insulation board. 9. Any loose deposits in the heat exchanger should be removed using a vacuum cleaner. 10. A brush with plastic bristles can be used to dislodge any stubborn deposits, which should then also be removed by vacuum. 11. Do not use any chemicals to clean the heat exchanger. 12. The burner does not require any maintenance as it is self-cleaning. Check that there are no cracks and/or other damage on the surface of the burner. If the burner is damaged, replace it. 13. Reassemble in reverse order. Fig.45 PN-0000382 Fig.46 Remove burner / door assembly PN-0000394 9 Maintenance 50
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9.3 Specific maintenance instructions Warning When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed recommission the boiler. Always examine any seals or gaskets, replacing where necessary. The case font panel MUST seal effectively against the boiler side panels. To remove the case front panel proceed as follows: Unscrew the two screws located on the bottom of the front panel. Slide the bottom of the front panel forward and lift upwards to disengage the panel. Hinge down the control panel. 9.3.1 Detection/spark ignition electrode 1. Disconnect the electrode lead and earthing cable. 2. Using a T15 Torx key, remove the retaining screws securing the electrode to the combustion chamber door and remove the electrode, noting its orientation. 3. Fit the new electrode with the sealing gasket. 4. Reassemble in reverse order. 9.3.2 NTC flue sensor 1. Turn the sensor 90° anticlockwise to remove — it is a bayonet connection. 2. Ease the retaining tab on the sensor away and disconnect the electrical plug. 3. Fit new sensor and reassemble in reverse order. 9.3.3 Flow and return sensors There is one sensor on the flow (red wires) and one sensor on the return (blue wires). 1. After noting the position of each sensors, prise the sensor clip off the pipe and disconnect the plug. 2. Connect the plug to the new sensor and ease the clip onto the pipe in its original position. Fig.47 Remove detection/spark ignition electrode PN-0000331 Fig.48 Remove NTC flue sensor PN-0000332 Fig.49 Remove flow and return sensors PN-0000384 9 Maintenance 51
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9.3.4 Safety overheat thermostat 1. Pull the two spade connections off the safety overheat thermostat. 2. Remove the screws securing the thermostat to the mounting plate on the flow pipe and remove it. 3. Fit the new safety overheat thermostat to the mounting plate with the two screw previously removed. 4. Connect the two spade connections to the safety overheat thermostat ensuring that they are pushed fully on. 9.3.5 Pressure Gauge 1. Drain the primary circuit and undo the nut on the pressure gauge capillary. 2. Ease the two retaining tabs holding the pressure gauge bracket away and remove the bracket. 3. Remove the gauge assembly. 4. Examine the sealing washer on the pressure gauge capillary, replace if necessary. 5. Reassemble in reverse order with the new pressure gauge. 9.3.6 Safety pressure relief valve 1 Safety pressure relief valve 2 "O" ring seal 3 Sealing grommet 4 Discharge pipe 5 Grub screw 1. Drain the primary circuit. 2. Disconnect the discharge pipe from the valve and remove the sealing grommet. 3. Using a suitable hexagon key undo the grub screw sufficiently to release the valve. 4. Note the orientation of the valve, rotate it and withdraw it from the manifold. 5. Fit the new valve and ‘O’ ring seal and set to the previously noted orientation. Tighten the grub screw. 6. Reconnect the discharge pipe ensuring the sealing grommet is in place to maintain the integrity of the case seal. Fig.50 Removing safety overheat thermostat PN-0000383 Fig.51 Remove safety pressure relief valve PN-0000622 5 1 3 2 4 9 Maintenance 52
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9.3.7 Expansion vessel Warning Take precautions to protect other components from water damage when removing the expansion vessel. 1. Close the flow and return isolation taps and drain the boiler primary circuit. 2. Relieve the pressure from the expansion vessel. 3. Remove the silencer. 4. Prise off the securing clips and disconnect the braided hose from the vessel and hydraulic inlet assembly, taking care as water may still be in the vessel. 5. Ensure that the braided hose is free of restriction, as a boiler with a blocked hose will exhibit symptoms similar to one with a failed vessel. Important Where the hose is found to be blocked, it must be cleared or replaced and the vessel recharged to 1 bar. 6. If the hose is clear support the vessel, undo the locknut and manoeuvre the vessel out of the boiler. 7. Replace the expansion vessel with the new one and reassemble in reverse order and recharge to 1 bar. 9.3.8 Gas valve Tab.22 Characteristics of combustion Baxi Assure System Case front panel on CO2 % (maximum) 9.0 + 0.3 – 0.2 % (minimum) 8.5 + 0.1 – 0.4 Important After replacing the gas valve the CO2 must be checked and adjusted. Only change the valve if a suitable calibrated combustion analyer is available, operated by a competent person. 1. Undo the screw and disconnect the electrical plug. 2. Turn the gas cock off and undo the nut on the gas valve inlet underneath the boiler. 3. Undo the nut on the gas valve outlet. Ease the pipe aside. Important The gas nozzle injector is inserted in the gas valve outlet. 4. Remove the screws securing the gas valve to the boiler bottom panel. Remove the valve. 5. Transfer the gas nozzle injector to the new valve, ensuring it sits in the valve outlet. Examine the sealing washers, replacing if necessary. 6. Reassemble in reverse order. Important Check gas tightness and combustion. Fig.52 Remove expansion vessel PN-0000378 Fig.53 Removing the gas valve PN-0000308 9 Maintenance 53 Baxi Assure System Case front panel off CO2 % (maximum) 8.8 + 0.3 – 0.2 % (minimum) 8.3 + 0.1 – 0.4
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Setting the gas valve (CO2) Important The CO2 must be only checked and adjusted to set the valve if a suitable calibrated combustion analyser is available, operated by a competent person. See Annual Servicing, page 49 1. The combustion (CO2) may be checked after running the boiler for several minutes. To do this it is necessary to set the boiler to "Calibration Mode" . 2. Ensure that all external controls are calling for heat. The actual current boiler temperature is shown on the display. 3. Turn both control knobs fully anticlockwise, then quickly turn the right hand knob 1/4 clockwise twice and back in quick succession (within 2 seconds). "304" will appear in the display screen. 4. Turn the left hand knob fully clockwise. "100" will appear in the display screen, indicating maximum output. 1 Combustion test point 2 Incoming air for combustion test point A Throttle Adjustment Screw B Offset Adjustment Screw 5. Remove the plug from the flue sampling test point. Insert the analyser probe and allow sufficient time for the reading to settle. Baxi Assure System CO2 % (maximum) 8.8 + 0.3 – 0.2 6. It is possible to alter the CO2 by adjustment of the gas valve. Remove the plastic cover from the Throttle Adjustment Screw. At maximum rate the throttle adjustment screw should be turned, using a suitable hexagon key, until the correct reading is obtained. Turning clockwise will reduce the CO2. Turning anticlockwise will increase the CO2. 7. The CO2 must then be checked at minimum rate. Turn the left hand knob fully anticlockwise. As the knob is turned the display will change, indicating the fan speed. When the display reads "0" the boiler runs at minimum rate. Baxi Assure System CO2 % (minimum) 8.3 + 0.1 — 0.4 8. With the boiler on minimum, the Offset Adjustment Screw must be altered, using a suitable hexagon key, after removing the cap. Turning clockwise will increase the CO2. Turning anticlockwise will reduce the CO2. 9. The calibration function is maintained for 20 minutes unless the maximum central heating temperature is exceeded. The function can be disabled at any time by turning the right hand knob. 10. Check the combustion performance (CO/CO2 ratio). This must be less than 0.004. Fig.54 Setting the gas valve Reset bar 0 1 2 3 4 R M i n M a x [ M a x M i n M a x M i n PN-0000397 R 1 2 EV1 EV2 P. OUT 1 2 3 4 VENT RQ ADJ. P . R . A D J . A B 9 Maintenance 54
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Warning Ensure that both flue test point plugs are in place after checking combustion. 9.3.9 Pump - head only To remove the pump head only. 1. Drain the boiler primary circuit and disconnect the electrical plug from the pump 2. Remove the socket head screws securing the pump head to the body and draw the head away. 3. Fit the new pump head and reassemble in reverse order. 9.3.10 Pump - complete Warning Take precautions to protect other components from water damage when removing the pump and auto air vent. 1. Hinge the control box down. 2. Close the flow and return isolation taps and drain the boiler primary circuit. 3. Disconnect the electrical plugs from the pump motor. 4. Prise off the securing clip that is holding the pump return pipe in position. Pull away the pipe. 5. Pull out the securing clip that is holding the pump body to the hydraulic inlet assembly. 6. Prise off the securing clip and disconnect the braided hose from the pump body, taking care as water may still be in the hose. 7. Remove the screws securing the pump to the boiler bottom panel. 8. The pump should now be able to be remove. 9. Pull out the securing clip and remove the automatic air vent, transfering it to the new pump body. 10. Examine all ‘O’ ring seals, replace if necessary and reassemble in reverse order. Fig.55 Remove pump head only PN-0000380 Fig.56 Remove pump PN-0000379 9 Maintenance 55
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10 Troubleshooting 10.1 Error codes 10.1.1 Initial error fault finding checks Check that gas, water and electrical supplies are available at the boiler. Electrical supply = 230V ~ 50 Hz. The minimum gas pressure at the meter is 19mb. Carry out electrical system checks, i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter. Ensure all external controls are calling for heat and check all external and internal fuses. Important These checks must be repeated after any servicing or fault finding. 10.1.2 Display of error codes If a fault occurs on the boiler an error code may be shown by the display screen. The codes are a flashing number, either two or three digit, preceded by the symbol :- followed by 20, 28, 40, 160 or 321 indicates possible faulty components. 110 indicates overheat of the primary system water. 118 is displayed when the primary water pressure is less than 0.5 bar. 133, 134 and 135 indicates that the gas supply has been interrupted, ignition has failed or the flame has not been detected. 128 is displayed if there has been a flame failure during normal operation. 125 is displayed in either of two situations:- If between 15 and 30 seconds of the burner lighting, the primary water temperature has not changed by 1° C. If within 10 minutes of the burner lighting, the primary water temperature actual temperature twice exceeds the selected temperature by 30°. In these instances poor primary circulation is indicated. By pressing the Reset button for 1 to 3 seconds when 09, 15, 110, 125, 128, 133, 134, 135, 384 are displayed it is possible to relight the boiler. If this does not have any effect, or the codes are displayed regularly further investigation is required. Fig.57 Display of error codes (UURUFRGH 'HVFULSWLRQRIIDXOW *DVYDOYHFRQQHFWLRQFDEOH *DVYDOYHIDXOW &HQWUDOKHDWLQJ17&IDXOW )OXH17&IDXOW &HQWUDOKHDWLQJUHWXUQ17&IDXOW &RPPXQLFDWLRQHUURU 3UHFLUFXODWLRQIDXOW 6DIHW\WKHUPRVWDWRSHUDWHG 3ULPDU\V\VWHPZDWHUSUHVVXUHWRRORZ &LUFXODWLRQIDXOW SULPDU\ )ODPHIDLOXUH )OXH17&RSHUDWHG ,QWHUUXSWLRQRIJDVVXSSO\RUIODPHIDLOXUH ,QWHUUXSWLRQRIJDVVXSSO\ LQWHUQDOHUURU )ORZUHWXUQVHQVRUWHPSHUDWXUHWHVW )DQRUIDQZLULQJIDXOW &LUFXODWLRQIDXOW 'U\ILUH +RWZDWHU17&IDXOW )DOVHIODPH PN-0000377 10 Troubleshooting 56
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10.2 Fault finding 10.2.1 Central heating Fig.58 Central heating — Follow operational sequence Turn on mains power The display illuminates 20, 28, 40 or 321 flashing 118 flashing 09, 15, 110, 125, 133, 134, 135 or 384 flashing Set Central Heating temperature to Maximum. symbol flashing, pump runs Go to section ‘A’ Go to section ‘D’ Ensure all controls and programmers are calling for heat Go to section ‘B’ If 110 is still flashing go to section ‘H’ YES NO NO NO NO NO NO NO Go to section ‘I’ Ensure controls are set to demand and verify the contacts are closed NO Press the reset button for 1 to 3 seconds YES Fan runs after up to 3 minutes 160 flashing Go to section ‘C’ NO If 09, 15, 110 or 384 is flashing or re-occurs regularly, check all PCB connections. If this has no effect replace the PCB. Fan runs at correct speed 160 flashing Go to section ‘C’ Spark at ignition electrodes up to 5 seconds & for 3 attempts Go to section ‘F’. Press the reset button for 1 to 3 seconds Burner lights Go to section ‘E’ Burner goes out after 5 seconds 128 flashing Go to section ‘G’ NO 109 flashing 125 flashing after 1 min Go to section ‘J’ 110 flashing NO Go to section ‘H’ NO Diverter valve open to Central Heating circuit NO Go to section ‘K’ Burner modulates to maintain set temperature Check Heating flow sensor. Go to section ‘D’ NO 130 flashing NO Go to section ‘M’ Burner goes out NO Fan stops after 10 seconds Boiler operation correct 133 flashing YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES PN-0000315 See Electrical diagram, page 17 for position of terminals and components. 10 Troubleshooting 57
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10.2.2 Fault finding solutions sections A to E Fig.59 Solutions sections A to E Is there 230V at: Main terminals L and N Check electrical supply 1. NO Main terminal fuse Replace fuse Display illuminated 2. NO PCB - X10 connector Main terminals L and N Check wiring 3. NO NO A B C NO Fan connections correct at fan & PCB X11 and X23 connectors - see Wiring Diagram Make connections Fan jammed or faulty wiring Connection OK at X41 Display or Main PCB fault Switch to DHW mode maximum flow and press reset. During next 3 minutes check:- 230V at PCB - X13 connector (between blue & brown - see Wiring Diagram) NO Replace PCB YES 230V between PCB - X13 connector (blue) and PCB - X11 connector (black) - see Wiring Diagram NO Replace PCB YES 230V at pump YES Replace pump NO Check wiring YES NO Replace PCB Replace fan or wire YES YES Temperature sensor faulty. Check correct location and wiring. NO D Replace sensor Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) (resistance reduces with increase in temp.) YES Gas at burner Ensure gas is on and purged Replace PCB Replace gas valve Check wiring and PCB - X36 connector see Wiring Diagram YES NO NO E 230V at PCB - X11 connector (between blue & brown - see Wiring Diagram) PN-0000317 10 Troubleshooting 58
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10.2.3 Fault finding solutions sections F to H Fig.60 Solutions sections F to H Replace PCB Check and correct if necessary 1. Ignition electrode and lead 2. Electrode connection 3. Spark gap and position Check wiring - see Electrical Wiring Diagram page 18 YES NO F 4 ±0.5 10±1 Check and correct if necessary 1. The set of the gas valve (CO2 values - see instruction) 2. Flame sensing electrode and lead connections 3. Flame sensing electrode position 1. 2. G Replace flame sensing electrode or PCB Replace PCB YES Replace safety thermostat YES YES Safety thermostat operated or faulty Check for and correct any system faults H Allow to cool. Continuity across thermostat terminals more than 1.5 ohm NO Check Flow & Return Sensors - see section ‘D’ NO Is 110 still flashing ? YES Check supply pressure at the gas valve:- Natural Gas - Minimum 17 mbar PN-0000318 10 Troubleshooting 59
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10.2.4 Fault finding solutions sections I to M Fig.61 Solutions sections I to M I M Temperature sensors faulty. Cold resistance approximately 10k Ω @ 25° C (CH sensor) 20k Ω @ 25° C (Flue sensor) (resistance reduces with increase in temp.) NO Replace sensor YES If pump is running the heat exchanger could be obstructed Replace heat exchanger 1. 2. Replace hydraulic pressure switch YES Restore system pressure YES NO CH system pressure less than 0.5 bar Check wiring and PCB - X22 connector for approx. 5V DC between green & black - see Wiring Diagram Replace PCB NO J Replace sensor NO System fault - correct NO YES Ensure that the boiler and system are fully vented Check flow temperature sensor connections and position. Cold resistance approximately 10k Ω @ 25° C (CH sensors) (resistance reduces with increase in temp.) YES Go to section ‘B’ K Is there 230V at: Diverter valve motor Replace motor 1. YES PCB - X13 connector terminals between:- Blue & Black (central heating mode) Blue & Brown (domestic hot water mode) see Wiring Diagram Replace PCB 2. NO Check diverter valve cable YES L YES NO Replace PCB Replace Hall Effect Sensor Is mains water filter & assembly clean, and rotor moving freely ? Clean or replace NO Check wiring and PCB - X22 connector for approx. 5V DC between red & blue from Hall Effect sensor - see Wiring Diagram YES PN-0000319 10 Troubleshooting 60
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11 Decommissioning 11.1 Decommissioning procedure Disconnect the gas & electric supplies and isolate them. Drain the primary circuit and disconnect the filling device. Dismantle the chimney system and remove the boiler from the wall mounting frame. 11 Decommissioning 61 12 Disposal 12 Disposal 12.1 Disposal and recycling Caution Removal and disposal of the boiler must be carried out by a qualified person in accordance with local and national regulations.
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62 13 Spare parts 13.1 Short parts list The following spares are available: Tab.23 Part number and description of spare parts Key No. Description Manufacturer’s Spare Part No. A Safety thermostat 720653 B Detection / spark ignition electrode 7686344 C Flow sensor and return sensor 7207471 D NTC flue sensor 7207892 F Auto air vent 7207776 G Burner/door assembly 7686323 H Insulation rear 7661741 J Insulation front 7661745 K Pump assembly 7684006 L Expansion vessel 7683801 O Hydraulic pressure switch 5114748 P Gas valve 7683968 R Pump head 7686336 Q Fan 7683926 Fig.62 Spare parts PN-0000366 D A H J C B G O L P K R Q F 13 Spare parts
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www.centralheating.co.uk www.hhic.co.uk Benchmark Commissioning & Warranty Validation Service Record It is a requirement that the boiler is installed and commissioned to the manufacturers’ instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler warranty the boiler needs to be registered with the manufacturer within one month of the installation. The warranty rests with the end-user (consumer), and they should be made aware it is ultimately their responsibility to register with the manufacturer, within the allotted time period. It is essential that the boiler is serviced in line with the manufacturers’ recommendations, at least annually. This must be carried out by a competent Gas Safe registered engineer. The service details should be recorded on the Benchmark Service and Interim Boiler Work Record and left with the householder. Failure to comply with the manufacturers’ servicing instructions and requirements will invalidate the warranty. This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturers’ instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. © Heating and Hotwater Industry Council (HHIC)
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© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT NAME): Gas Safe registration number: Company name: Telephone number: Company email: Company address: Commissioning date: Heating and hot water system complies with the appropriate Building Regulations? Yes Boiler Plus requirements (tick the appropriate box(s)) Boiler Plus option chosen for combination boiler in ENGLAND Weather compensation Smart thermostat with automisation and optimisation Load compensation Flue Gas Heat Recovery Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination boiler Zone valves pre-existing Fitted Not required Thermostatic radiator valves pre-existing Fitted Not required Automatic bypass to system pre-existing Fitted Not required pre-existing Fitted Not required Water quality instructions Yes What system cleaner was used? Brand: Product: What inhibitor was used? Brand: Product: pre-existing Fitted Not required CENTRAL HEATING MODE measure and record (as appropriate) Gas rate (for combination boilers complete DHW mode gas rate) m3/hr or ft3/hr Central heating output left at factory settings? Yes No If no, what is the maximum central heating output selected? kW Dynamic gas inlet pressure mbar °C Central heating return temperature °C System correctly balanced/rebalanced? Yes COMBINATION BOILERS ONLY Is the installation in a hard water area (above 200ppm)? Yes No Water scale reducer/softener pre-existing Fitted Not required Brand: Product: Yes No If yes- DHW expansion vessel pre-existing Fitted Not required Pressure reducing valve pre-existing Fitted Not required DOMESTIC HOT WATER MODE Measure and record Gas rate m3/hr or ft3/hr Dynamic gas inlet pressure at maximum rate mbar Cold water inlet temperature °C Hot water has been checked at all outlets Yes Temperature °C CONDENSATE DISPOSAL The condensate drain has been installed in accordance with the manufacturers’ instructions and/or BS5546/BS6798 Yes Point of termination Internal External (only where internal termination impractical) Method of disposal Gravity Pumped ALL INSTALLATIONS Record the following At max rate: CO ppm CO2 % CO/CO2 Ratio At min rate (where possible) CO ppm CO2 % CO/CO2 Ratio instructions, and readings are correct? Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturers’ literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes Commissioning Engineer’s signature Customer’s signature Time, temperature control and boiler interlock provided for central heating and hot water Yes
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© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature:
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© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component. SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature: SERVICE/INTERIM WORK ON BOILER delete as appropriate Date: Engineer name: Company name: Telephone No: Gas Safe registration No: Max rate CO ppm CO² % CO/CO² Min rate CO ppm CO² % CO/CO² undertaken in accordance with manufacturers’ instructions, and readings are correct?” yes Gas rate: m3/h OR ft3/h delete as appropriate Yes No System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. * yes n/a Comments: Signature:
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© Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions supplied, remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations. 3. Min. both models 0.34 kg/h Max. 18 model Max. 24 model 1.37 kg/h 1.83 kg/h Measure the gas rate (LPG) Tab.23 Characteristics of combustion Baxi Assure System % (maximum) % (minimum) 10.0 + 0.1 – 0.5 9.3.12 Gas valve 7.4.1 Check the operational (working gas inlet pressure and gas rate) 18 LPG 19.4 kW CH Pnc (Condensing) 24 LPG 25.9 kW CH Pnc (Condensing) 4.1 General description Tab.15 The boiler is set to give a maximum output of :- The boiler is factory set for use on Propane (G31). Baxi Assure System Gas council numbers 3.1.3 Gas category Tab.2 Gas category, type and supply pressure Gas category Gas type Supply pressure (mbar) II2H 3P G31 37 3.2.1 Technical information 14 Appendix 14.3 Differences for LPG models Important The information in this section details the differences between LPG models and equivalent Natural Gas versions 18 LPG 10.5 + 0.5 – 0.1 LPG 41 470 92 24LPG 41 470 93 CO2 % (maximum) % (minimum) 9.8 + 0.1 – 0.5 10.3 + 0.5 – 0.1 CO2 Case On Case Off 67
Сторінка 67 PDF
Сторінка 68
Baxi Customer Support 0344 871 1545 Opening hours Monday - Friday, 8.00am-6.00pm Weekends and Bank Holidays, 8.30am-2.00pm Please note calls may be recorded for training and monitoring purposes baxi.co.uk Register now to activate your warranty: www.baxi.co.uk/registration For the warranty to be maintained, please make sure... Benchmark checklist is completed Warranty is registered within 30 days The boiler has an annual service 1 2 3 For full terms and conditions, visit www.baxi.co.uk/terms. Failure to adhere to terms and conditions will void your manufacturer’s warranty. Baxi Brooks House, Coventry Road, Warwick, CV34 4LL Please ensure the boiler is installed in accordance with these installation instructions and that you adhere to the Building Regulations. e&oe All descriptions and illustrations provided in this document 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. 7750878-01
Сторінка 68 PDF