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This is a Wall Mounted Combination Boiler Gas Fired Central Heating Unit.
The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)
Regulations 1993 No 3083” and is deemed to meet the requirements of Directive
92/42/EEC on the energy efficiency requirements for new hot water boilers fired
with liquid or gaseous fuels:-
2
INSTALLER NOTIFICATION GUIDELINES
Complete the
Benchmark Checklist
Choose Building
Regulations Notification
Route
Competent Person's
Building Control
Self Certification Scheme
CORGI will record the data and LABC will record the data
will send a certificate of and will issue a
compliance to the property certificate of compliance
3
LEGISLATION
IMPORTANT - Installation, Commissioning, Service & Repair
Baxi Potterton declare that no substances harmful
to health are contained in the appliance or used
This appliance must be installed in accordance with the manufacturer’s
during appliance manufacture.
instructions and the regulations in force. Read the instructions fully before
installing or using the appliance. The appliance is suitable only for installation in GB
and IE and should be installed in accordance with
In GB, this must be carried out by a competent person as stated in the Gas the rules in force, and only used in a suitably
Safety (Installation & Use) Regulations. ventilated location.
The addition of anything that may interfere with the normal operation of the In IE, the installation must be carried out by a competent
appliance without express written permission from the manufacturer or his Person and installed in accordance with the current
edition of I.S. 813 ‘Domestic Gas Installations’, the
agent could invalidate the appliance warranty. In GB this could also infringe
current Building Regulations and reference should be
the Gas Safety (Installation and Use) Regulations. made to the current ETCI rules for electrical installation.
Warning - Check the information on the data plate is compatible with local All systems must be thoroughly flushed and
supply conditions. treated with inhibitor (see section 6.1).
4
CONTENTS
Section Page
1.0 Introduction 6
8.0 Installation 19
9.0 Commissioning 24
10.0 Completion 26
11.0 Servicing 27
13.0 Electrical 38
Benchmark Checklist 46
5
1.0 INTRODUCTION
1.1 Description
Data Badge
1.2 Optional Extras
6
2.0 GENERAL LAYOUT
2.1 Layout
8
12 11 Fig. 2
10
9
Reset Burner On
3
1
Flame Failure
Power On 0 4
bar
Fig. 3
19 20 21 22 23 24 10 9
7
3.0 APPLIANCE OPERATION
20
18 3.2 Domestic Hot Water Mode (Fig. 5)
Fig. 4 16 19 15 14 13 12
25
8
24
23
9
22
11
21 17 10
20
Fig. 5 18
16 19 15 14 13 12
8
4.0 TECHNICAL DATA
Electrical Protection
IPX4D
4.5
3.5
3
LPG Gases - Propane G31 Butane G31
2.5
Burner Injector 12 x 0.77mm diameter
Metre wg
2
Burner Pressure Max Rate Min Rate
Propane mbar 36.2 6.4 1.5
in wg 14.5 2.6
Butane mbar 28.3 5.3 1
in wg 11.3 2.1
0.5
9
5.0 DIMENSIONS AND FIXINGS
G E
Dimensions
A
A 780mm
B 345mm
C 450mm
B
D 107mm Ø Min.
F 190mm
D C G 143mm
Tube Ø 100mm
Fig. 6
F
Gas Inlet
165.7mm
View from under the appliance
Left Hand Side 130mm
of Boiler
Wall
Fig. 7
10
6.0 SYSTEM DETAILS
6.1 Information
1. The Main Combi 24 Combination Boiler is a ‘Water
Byelaws Scheme - Approved Product’.
To comply with the Water Byelaws your attention is
drawn to the following installation requirements and notes
(IRN).
a) IRN 001 - See text of entry for installation
requirements and notes.
b) IRN 302 - Byelaw 14.
2. Reference to the WRc publications, ‘Water fittings and
materials directory’ and ‘Water supply byelaws guide’ give
full details of byelaws and the IRNs.
6.3 Bypass
1. The boiler is fitted with an automatic integral bypass.
11
6.0 SYSTEM DETAILS
12
6.0 SYSTEM DETAILS
Stop Tap
4. When the domestic water system includes any
Fig. 11
device which prevents water expanding back towards
the supply (check valve, loose jumpered stopcock,
water meter, water treatment device) then an
expansion vessel must be fitted (eg. Zilmet 160ml,
R1/2 15bar).
6.9 Showers
13
7.0 SITE REQUIREMENTS
7.1 Location
5mm Min 450mm 5mm Min
1. 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
200mm Min 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-see Section 7.3).
Flame Failure
Power On 0 4
bar
450mm Min
For Servicing
Purposes
5mm Min
In Operation
Fig. 13
14
7.0 SITE REQUIREMENTS
15
7.0 SYSTEM REQUIREMENTS
7.6 Flue
L
B,C
K
N
G G
D M
D H,I
J A
A
E F F
G
* In addition, the terminal should be no nearer than 150mm to an Property Boundary Line
opening in the building fabric formed for the purpose of
accommodating a built-in element such as a window frame. See
BS 5440 Pt. 1.
16
7.0 SITE REQUIREMENTS
Flue Trim
Fig. 20
17
7.0 SITE REQUIREMENTS
Vertical
Flues
(Twin Pipe)
Vertical
Flues
Maximum Length = 2m
inc. 2 x 90° bends
18
8.0 INSTALLATION
1. After considering the site requirements aperture for flue tube 200 mm
Minimum
Clearance
(see Section 7.0) position the fixing template on the Vertical Flue
Centre Line
wall ensuring it is level both horizontally and vertically.
Appliance Wall Plate
2. Mark the position of the two most suitable fixing
slots for the wall plate and boiler lower fixing holes. It Boiler Mounting Bracket Fixing Slots
Drill 8 mm diameter x 50 mm deep
Minimum
Fig. 21
8.3 Preparing The Boiler
2. Stand the boiler on its base by using the rear lower Flushing Tube
edge as a pivot.
Fig. 22
Central Heating Return
19
8.0 INSTALLATION
Securing Screw 6. Connect the elbows to the gas service cock and hot
water outlet pipe, and then connect the elbows to the
boiler. Connect the elbows with flared ends to the
valves.
20
8.0 INSTALLATION
HORIZONTAL FLUE
Wall Thickness
1. The standard flue is suitable for lengths 100mm
minimum to 1m maximum (measured from the edge
of the flue elbow outlet).
(X)
Rear Flue: maximum wall thickness - 900mm
Side Flue: maximum wall thickness - 870mm
Fig. 27
(X) Waste
Air Duct
Waste
Fig. 28
Flue Duct
21
8.0 INSTALLATION
11. Locate the flue duct clamp on the flue outlet elbow.
Seal
Draw the flue duct out of the air duct, engage it in the
clamp and tighten the screws (Fig. 31).
Clip
Screws 12. Draw the air duct out of the wall and align it with
the elbow. Position the seal so that it equally covers
the joint (Fig. 32).
15. Make good between the wall and air duct outside
the building.
Flue Duct
Clamp
8.7 Extensions & Additional Elbows
22
8.0 INSTALLATION
1 bk
230V
NOTE: If the room thermostat being used 2 bk IMPORTANT: If an integral timer is fitted to the
incorporates an anticipator it MUST be wired as boiler an external frost thermostat wired as
Terminal Block shown will not operate correctly. Only external
shown in Fig. 37.
timers may be used in such installations, as in
Fig. 36 the diagram.
IMPORTANT: The external control MUST be
Fig. 37
suitable for 230V switching.
Functional Flow Diagram
8. Ensure that both mains input and, where fitted,
external control input cables have sufficient slack to
L Pump
External
allow the control box to drop down. Tighten the cable Controls 230 V br b N
bk b Spark Electrode
br
PCB bk Gas Valve
8.9 Preliminary Electrical Checks bk
Key to Wiring bk Gas Valve Modulator
br - brown r
electrical system checks should be carried out.
bk - black r
Hydraulic Differential Pressure Switch
r - red
2. These should be performed using a suitable meter, Fig. 38
g - green br
3-way Valve Microswitch
and include checks for Ground Continuity, w - white bk b N
Resistance to Ground, Short Circuit and Polarity.
23
9.0 COMMISSIONING
Reset Burner On
3
1
Flame Failure
Power On 0 4
bar
Fig. 41
Central Heating Hot Water
Temperature Control Temperature Control
24
9.0 COMMISSIONING
3
1
Flame Failure
Power On 0 4
bar
Gas Valve
least 10l/min.
25
10.0 COMPLETION
10.1 Completion
26
11.0 SERVICING
Fig. 48
Fan Wires
Outlet Sealing
Fig. 49
Collar
Fig. 50
27
11.0 SERVICING
Baffle
Tab
10. Remove the spring clips retaining the air box side
Spring Clip baffle plates. Disengage the tabs on the baffles from
the slots in the fan hood (Fig. 52).
Fig. 52 12. Draw the burner out of the combustion box, pulling
the electrode grommets from the slots in the
Fig. 51
combustion box lower panel (Fig. 53).
Fan and Hood 13. Disconnect the electrode leads and grommets from
Assembly
the electrodes. Completely remove the burner (Fig. 53).
15. Brush the burner blades and venturis and clean the
combustion box.
D.H.W. Filters
17. If the flow of domestic hot water is diminished, it
Fig. 53 may be necessary to clean the filters.
Electrode 18. Initially check the cold water inlet tap filter.
Grommets
19. Turn the tap off. Undo the blanking cap and remove
the threaded bush (Fig. 53a).
Threaded
Bush
Fig. 53a 20. Extract the filter and rinse thoroughly in clean
water. Reassemble and check the flow. If required
clean the manifold filter as described below.
Cartridge
Body
24. Turn the selector switch fully anticlockwise against
the spring pressure to the reset position and hold for 3
Filter Gauze seconds to reset the boiler before recommissioning.
Fig. 56
25. Complete the relevant Service Interval Record
section of the Benchmark Commissioning Checklist at
Fig. 55 Inlet / Return Manifold the rear of this publication and then hand it back to the
Flow user.
Regulator
Venturi
28
12.0 CHANGING COMPONENTS
Pressure
12.1 Pressure Switch Switch Wires
g/y
12.2 Fan b
Fig. 59
1. Note the positions of the two sensing tubes on the br
outlet elbow and three wires on the fan motor and
remove them (Fig. 58).
-
2. Slacken the screws on the outlet sealing collar.
+
Ease the collar upwards as far as possible (Fig. 59).
Sensing Tubes
Fan and Hood
3. Remove the four screws securing the combustion Assembly
box door and remove the door. Outlet Sealing
Fig. 58 Collar
4. Remove the spring clips retaining the air box side
baffle plates. Disengage the tabs on the baffles from
the slots in the fan hood (Fig. 61).
Flue Outlet Elbow
5. Undo the screws securing the fan hood to the
Fan
appliance back panel, and draw the fan and hood
assembly forwards (Fig. 60). Spring Clip
Baffle
Tab
6. Remove the screws and spring washers securing
the fan to the hood. Transfer the flue outlet elbow to
the new fan (Fig. 60).
7. Fit the new fan to the hood using the screws and
spring washers previously removed.
Securing Screw
Fan Hood
Fig. 60
29
12.0 CHANGING COMPONENTS
Heat Exchanger 7. Lift the heat exchanger to disconnect the flow and
return pipe joints. Withdraw it from the appliance,
taking care not to damage the rear insulation piece.
Electrode
Leads
30
12.0 CHANGING COMPONENTS
Injector
12.5 Injectors (Fig. 64) Inlet Elbow
Manifold
Fig. 64
2. Undo the screws securing the injector manifold to
the inlet elbow and remove the manifold.
Gasket
Electrode
2. Draw the burner out of the combustion box, pulling Grommets
the electrode grommets from the slots in the
combustion box lower panel.
Electrode
Leads
3. Disconnect the lead and grommet from the
electrode being replaced. Undo the securing screw
and withdraw the electrode to the burner.
13.8
Side Insulation
Combustion
Box Door
Front Insulation
Fig. 65
31
12.0 CHANGING COMPONENTS
1. Undo the nut on the gas feed pipe under the boiler.
32
12.0 CHANGING COMPONENTS
Pump Wiring
Cover
Fig. 70
33
12.0 CHANGING COMPONENTS
Fig. 71
2. Remove the timer cover and ease the timer wiring
aside. Undo the screws securing the gauge retaining
bracket (Fig. 72).
Gauge Retaining
Bracket Fig. 72 12.15 Expansion Vessel
Plug/Spark Generator 4. Remove the plug lead from the cable clip and
disconnect the multi-pin plug from the PCB.
Fig. 77
5. Reassemble in reverse order.
34
12.0 CHANGING COMPONENTS
4. Fit the new valve and ‘O’ ring seal and set to the
previously noted orientation. Reassemble in reverse
order.
3. Note the position of all plugs and wires on the Discharge Pipe
P.C.B. and disconnect them. Pull the drive pins off
the P.C.B.
Temperature Control
Knobs
35
12.0 CHANGING COMPONENTS
Fig. 81
2. While supporting the heat exchanger undo the
screws securing it to the brass manifolds.
Seals
Rubber Seal
4. There are four rubber seals between the manifolds
and heat exchanger which may need replacement.
36
12.0 CHANGING COMPONENTS
Central Heating
12.21 Diverter Valve Assembly (Cont) Microswitch & Pressure Differential
Bracket Valve
CH Pressure Differential Valve (Fig. 84)
Sensing Pipe
1. Remove the DHW pressure differential valve as
described above.
Spring Clip
3. Disconnect the pressure gauge capillary from the
diverter manifold and remove the two wires from the
microswitch. Heating
Flow Pipe
4. Prise off the spring clip securing the by-pass pipe
to the diverter manifold and disconnect the sensing
Fig. 84
pipe.
Diverter Manifold
5. Ease the diverter manifold out of the plate heat
exchanger manifold. Remove the assembly from the
appliance. Pressure Gauge
Capillary
6. Undo the screw securing the microswitch bracket
to the valve body. The sensor may now be dismantled
to examine the diaphragm.
CH Pressure Microswitch
(Fig. 84)
1. Remove the two wires from the pressure
microswitch.
2. Unscrew the venturi and remove the flow regulator. Filter Gauze
Fig. 86
3. Check the cleanliness of the filter gauze, rinsing
thoroughly in clean water as necessary. Fit the new
Fig. 85 Inlet / Return Manifold
flow regulator and reassemble in reverse order.
Flow
Regulator
Venturi
37
13.0 ELECTRICAL
Pump
Mains Input
Link
g/y On/Off/Reset
b
br Selector Switch
bk g/y br
b
8 b
b
9 b Hydraulic Differential
10 br Pressure Switch
12 bk
34 bk 11 1 r
17 12 br br
br 18 13 b 2 r
bk 19 14 3 r
20 15 4 r
M3
16 r 5 b
Optional Timers
M1 6
35
7 b
Gas Valve bk
bk 36 Control PCB M2 Overheat Thermostat
br 37
b 38
39
M7
44
M4
bk 43
bk 42
32
31 b
30
29 b
3-Way Valve 28 br Air Pressure
Microswitch Switch
27 br
M5
FA2
Fan
38
14.0 FAULT FINDING
YES
Air pressure NO
Go to section ‘E’
switch proved
YES
Spark at ignition
NO YES Turn selector to the reset
electrodes for up to 10 illuminated
position. If the light does
seconds
not extinguish go to
YES NO sections H & K
Replace PCB
Burner on neon NO
Go to section ‘F’
illuminated
YES
NO
Burner output NO
modulates until set Go to section ‘G’
temperature is reached
YES
YES YES YES Operation sequence
Burner goes out Fan stops Pump stops
correct
39
Domestic Hot Water - Follow operational sequence 14.0 FAULT FINDING
Turn selector to NO
Go to section ‘A’ Replace diaphragm
neon illuminated
YES
YES
Is mains water YES DHW flow valve
filter and differential
diaphragm damaged
assembly clean?
YES NO
Turn thermostat to
NO DHW flow rate more than DHW flow valve rod
max. Open DHW tap fully.
2.5l/min. obstructed
DHW flow switch operated
YES NO Replace DHW flow
Continuity across DHW
Primary water is diverted microswitch
flow microswitch terminals
from CH system to DHW NO
and PCB - M1 connector
heat exchanger and flow
terminals 13 & 14 YES
microswitch operated
(terminals 12-14 open) Replace PCB
YES
NO
Pump runs Go to section ‘B’
YES
Replace PCB
Burner on neon NO
Go to section ‘F’
illuminated
YES
YES
DHW flow valve
senses no flow. NO Diverter valve spindle
Primary water diverted to assembly faulty
CH system. DHW flow
switch released off
YES
NO YES YES Operation sequence
Burner goes out Fan stops Pump stops
correct
40
14.0 FAULT FINDING
NO
1. Main terminals L and N Check electrical supply
YES
2. Main terminal fuse Replace fuse NO
neon
Replace PCB
NO illuminated
3. Selector terminals a & b Check wiring
and a & 3. PCB - M1 Replace selector
connector terminals 9 & 10
NO
1. Pump If pump jammed, release Replace pump
NO
2. PCB - M1 connector terminals 8 & 15 Replace PCB
YES
Change pump supply cable
NO
Replace PCB
41
14.0 FAULT FINDING
F Gas at burner
NO
Ensure gas is on and purged
2.
Voltage at modulating coil of gas valve is:
YES
Max. burner press.approx 9V DC (13V DC LPG) Replace gas valve
Min. burner press.approx 1V DC
2. Electrode connection 37 & 38 and at igniter. YES Replace gas valve electrical
3. Spark gap and position Check wiring plug/spark generator
42
14.0 FAULT FINDING
YES
Replace
PCB
43
15.0 SHORT PARTS LIST
140
Key G.C. Description Manufacturers
No. No. Part No.
101
169 E66 453 Pressure Gauge 248090
102
103
169
32
44
16.0 NOTES
45
BENCHMARK No. 5 1 1 5 8 0 7
COLLECTIVE MARK
GAS BOILER COMMISSIONING CHECKLIST
BOILER SERIAL No. NOTIFICATION No.
CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes
TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT
TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER COMBI BOILER
HEATING ZONE VALVES FITTED NOT REQUIRED
HOT WATER ZONE VALVES FITTED NOT REQUIRED
THERMOSTATIC RADIATOR VALVES FITTED
AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED
SIGNATURE SIGNATURE
SIGNATURE SIGNATURE
SIGNATURE SIGNATURE
SIGNATURE SIGNATURE
SIGNATURE SIGNATURE
47
Publication No. 5115807 - Iss. 2 (05/2005)
BAXI POTTERTON
A Trading Division of Baxi Heating UK Ltd
Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP
After Sales Service 08701 655 644 Technical Enquiries 08706 049 049
Website www.baxipotterton.co.uk
company