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Potterton assure combi 25, Installation And Service Manual

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Potterton assure combi 25 Installation And Service Manual Download Page 36

essary. Carrying and lifting equipment should be used as required. e.g. 

when installing in a loft.

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" docu­

ment published by the HSE is consulted, and an assessment per­

formed 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 re­

moved 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 tight­

ening the screws.

Fig.23

Unpacking the boiler

PN-0000345

Fig.24

Template

Ø 

8mm

5

0

m

m

 M

IN

116mm Dia Minimum
Aperture For 
Flue Tube

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

7664094-01

Ø 22mm

Condensate

Drain

Pressure

Relief

Side Clearance 5mm

Side Clearance 5mm

192.5mm

192.5mm

65mm

65mm

65mm

65mm

View from 
under boiler

Safety Pressure Relief

Condensate

Primary Drain

Wall

PN-0000346

150 mm

5  Before installation

36

7678846 - A - 22052017

Summary of Contents for assure combi 25

Page 1: ...g 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 Potterton Assure Combi 25 30 ...

Page 2: ...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 ...

Page 3: ...ons and connections clearances 17 3 4 Electrical diagram 18 4 Description of the product 19 4 1 General description 19 4 2 Operating principle 19 4 2 1 Air gas adjustment 19 4 2 2 Combustion 19 4 2 3 Central heating and domestic hot water production 20 4 2 4 Central heating mode 20 4 2 5 Domestic hot water mode 20 4 2 6 Frost protection mode 21 4 2 7 Pump protection 21 4 3 Main components 22 4 3 1...

Page 4: ...44 6 5 1 Flushing the system 44 6 5 2 Fill the installation 44 6 5 3 Filling the condensate trap 44 7 Commissioning 45 7 1 General 45 7 2 Checklist before commissioning 45 7 2 1 Preliminary electrical checks 45 7 2 2 Checks 45 7 3 Commissioning procedure 46 7 3 1 De Aeration function 46 7 4 Gas settings 46 7 4 1 Check the operational working gas inlet pressure and gas rate 46 7 4 2 Checking combus...

Page 5: ...2 10 1 Error codes 62 10 1 1 Initial error fault finding checks 62 10 1 2 Display of error codes 62 10 2 Fault finding 63 10 2 1 Central heating 63 10 2 2 Domestic hot water 64 10 2 3 Fault finding solutions sections A to E 65 10 2 4 Fault finding solutions sections F to H 66 10 2 5 Fault finding solutions sections I to M 67 11 Decommissioning 68 11 1 Decommissioning procedure 68 12 Disposal 69 12...

Page 6: ...e 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 neces sary to ensure compliance with Building Regulations 1 1 2 The Benchmark Scheme Benchmark places responsibilities on both manufacturers and insta...

Page 7: ...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 Insta...

Page 8: ...ace 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 boil er settings the temperature of the radiators may exceed 60oC Warning Take precautions with the domestic hot water Depending on the boiler settings the dom...

Page 9: ... 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 should ers arms and hands Health Safety is the respon...

Page 10: ...ing 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...

Page 11: ...er 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 in jury Caution Risk of material damage Important Please note important information See Reference to other manuals or pa...

Page 12: ...92 42 EC Ecodesign Directive 2009 125 EC Directive on energy consumption 2010 30 EC Regulation EU No 813 2013 and 814 2013 Energy Labelling Directive 2010 30 EU Regulation 811 2013 and 812 2013 In addition to the provisions and legal directives also the complementary directives described in these instructions must be observed All the sup plements and additional requirements are applicable at the m...

Page 13: ...ic 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 7...

Page 14: ... capacity litres 7 0 7 0 Expansion vessel pre charge pressure bar 1 0 1 0 Maximum capacity of central heating system litres 100 100 Primary water content of boiler unpressurised litres 2 5 2 5 Tab 7 Domestic hot water circuit specifications Potterton Assure Combi 25 30 Maximum pressure bar 8 8 Dynamic minimum pressure bar 0 5 0 5 Minimum working water flow rate 1 l min 2 0 2 0 Specific flow rate D...

Page 15: ...529 IP IPX5D IPX5D Dimensions height width depth mm H 700 W 390 D 285 H 700 W 390 D 285 Tab 11 Connections Potterton Assure Combi 25 30 Gas inlet mm 22 22 Heating flow mm 22 22 Heating return mm 22 22 Cold water inlet mm 15 15 Hot water outlet mm 15 15 Pressure relief discharge mm 15 15 Condensate discharge drain plastic waste pipe mm 21 5 21 5 Tab 12 Clearances Potterton Assure Combi 25 30 Above ...

Page 16: ...7 7 107 6 Auxiliary electricity consumption Full load elmax kW 68 78 Part load elmin kW 50 53 Standby mode PSB kW 0 003 0 003 Other items Standby heat loss Pstby kW 0 069 0 069 Ignition burner power consumption Pign kW 0 0 Annual energy consumption QHE GJ 62 77 Sound power level indoors LWA dB 50 53 Emissions of nitrogen oxides NOX mg kWh 29 7 28 3 Domestic hot water parameters Declared load profi...

Page 17: ...water flow 4 Hot water outlet 5 Gas inlet 6 Pressure relief pipe 7 Cold water inlet 8 Heating circuit water return 9 Pump drain point 10 Boiler drain point on flow isolation pipe Not shown 11 Cable entry points The clearances shown in the diagram are minimum requirements to allow for case removal spanner access and air movement These should be ob served at all times and kept clear of obstructions ...

Page 18: ...bk bk black br brown b blue g green r red w while g y green yellow Key Description Key Description A Gas valve I Spark ignition electrode B Hall effect sensor J Diverter valve motor C Flue sensor K Pump D Hydraulic pressure switch L Terminal strip E Heating return sensor M Fan F Heating flow sensor N Safety thermostat G DHW NTC sensor O Earth point on boiler chassis H M2 low voltage external contr...

Page 19: ...ystems must be thoroughly cleansed flushed and treated with inhibitor Note These installation and servicing instructions must be read in con junction 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 au...

Page 20: ...mand 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 DHW flow sensor filter restrictor 6 DHW priority sensor 7 DHW NTC sensor 8 Hydraulic pressure switch 9 Diverter valve and motor 10 Plate heat exchanger 11 Gas valve 12 ...

Page 21: ...losure and during periods when the heating system is to be unused it is recommended that the per manent 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 7 Pump protection If th...

Page 22: ...er 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 Boi...

Page 23: ...essure 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 a...

Page 24: ... 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 248221 Multifit filling loop Multifit permanent filling link Multifit upward pipe fitting kit Multifit pre plumbing jig For flue accessories elbows extensions clamps etc refer to the Flue Ac cessori...

Page 25: ... meter to the appliance is of adequate size and the demands of any other gas appliances in the property are tak en into consideration Do not use pipes of a smaller diameter than the boil er 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 ...

Page 26: ...ry side of the DHW plate heat exchanger as 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 Any proprietary OpenTherm contr...

Page 27: ...the pres sure 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 ba...

Page 28: ...board 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 per manent 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 Regulatio...

Page 29: ... 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 5 3 3 Ventilation Where the appliance is installed in a cupboard or...

Page 30: ...n 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...

Page 31: ...he 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 ma terial suitable for external use If the boiler is fitted in an unheated location the entire condens...

Page 32: ... given in BS 5440 Pt 1 For IE recommendations are given in the current edition of I S 813 Do mestic Gas Installations Important Due to the nature of the boiler a plume of water vapour will be dis charged from the flue This should be taken into account when sit ing 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 requ...

Page 33: ...indow 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 displace ment kit The terminal position must ensure the safe and nuisance free dispersal of combustion products If the terminal discharges onto a pathwa...

Page 34: ...ed 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 as sembly Tab 20 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 i...

Page 35: ...erred to below There must be a clearance of at least 50mm between any part of the ter minal 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 ...

Page 36: ...ration 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 ...

Page 37: ... it is not necessary to re move any part of it after filling or re pressurising 5 6 2 Domestic hot water circuit A Boiler B Expansion vessel C Check valve D Pressure reducer E Stop tap F To hot tap G Other tap outlets All DHW circuits connections fittings etc should be fully in accordance with relevant standards and water supply regulations Your attention is drawn to for GB Guidance G17 to G24 and...

Page 38: ... Even in circumstances where a non return device is not fitted any future modifications to the mains inlet e g fitting of a water meter should be considered and an expansion vessel fitted Potterton cannot accept any responsibility for damage to the boiler if these recommendations are not followed The boiler s maximum working mains pressure is 8 bar therefore all pipe work connections fittings etc ...

Page 39: ...ating flow and return pipework gas supply and mains cold inlet 6 Connect the elbow to the DHW flow outlet 7 Using the sealing washers provided connect the taps and elbow to the boiler 8 Ensure all joints are tight Important Connect the pressure relief discharge pipework first 6 2 Assembly 6 2 1 Fitting the pressure relief discharge pipe 1 Remove the discharge pipe from the kit 2 Determine the rout...

Page 40: ... 500mm 2 Connection assembly 3 Terminal assembly There are two telescopic sections the terminal assembly and the connec tion assembly a roll of sealing tape and two self tapping screws A 93 el bow 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 adap...

Page 41: ...ssembly 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 positio...

Page 42: ... Voltage Controls remove the yellow link wire from the Mains Terminal Block M1 Note 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 55 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 boil...

Page 43: ...rmostat must be connect to termi nal 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 Preliminary electrical checks Prior to commissio...

Page 44: ... 2 The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe provi ded 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 tempo...

Page 45: ... 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 Note Consideration must be given to Health Safety Document 635 The Electricity at Work Regulations 1989 Prior to commissi...

Page 46: ...completed the display will show the primary flow temperature and both the CH and DHW 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 aerati...

Page 47: ...ing 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 po...

Page 48: ...imum turn the CH knob fully anticlock wise 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 41 Setting chimney sweep mode Re...

Page 49: ...lue 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 ra...

Page 50: ... User s Operating Installation and Servicing Instruc tions giving advice on the necessity of regular servicing 4 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 Bench mark Commissioning Checklist 5 Set the central heating and hot water temperatures to the ...

Page 51: ...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 thermo stat 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 drop...

Page 52: ...ntegrity 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 performan...

Page 53: ... hinge down the control panel See Specific maintenance instructions page 55 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 g...

Page 54: ...trode lead and earth wire from the detec tion 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 disen gage it from the heat exchanger 7 Check that the detection spark electrode is not worn Replace the electrode if necessary 8 Check the ...

Page 55: ...e 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 elec trode 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 se...

Page 56: ...emperature sensor NTC 1 Turn off the mains cold water supply tap and draw off the residual domestic hot water 2 Ease the retaining tab on the sensor away and disconnect the elec trical plug 3 Unscrew the sensor from the plate heat exchanger manifold Exam ine the sealing washer replacing if necessary 4 Reassemble in reverse order with the new sensor The plug will only fit one way 9 3 6 Pressure Gau...

Page 57: ... Sealing grommet 4 Discharge pipe 5 Grub screw 1 Drain the primary circuit 2 Disconnect the discharge pipe from the valve and remove the seal ing grommet 3 Using a suitable hexagon key undo the grub screw sufficiently to re lease 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 ...

Page 58: ...ct 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 ves sel Important Where the hose is found to be blocked it must be cleared or re placed and the vessel recharged to 1 bar 6 If the hose is clear suppo...

Page 59: ...he 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 pan el 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 necessa ry 6 Reassemble in reverse order Im...

Page 60: ...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 8 The CO2 must then be checked at minimum rate Turn the left hand knob ...

Page 61: ...trical plugs from the pump motor 4 Prise off the securing clip that is holding the pump return pipe in po sition Pull away the pipe 5 Pull out the securing clip that is holding the pump body to the hy draulic 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 boil...

Page 62: ...cted 128 is displayed if there has been a flame failure during normal op eration 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 tem perature actual temperature twice exceeds the selected temper ature by 30 In these instances poor prima...

Page 63: ...rs 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 11...

Page 64: ...ing 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 YES Burner lights Go to section E Burner goes out after 5 seconds 128 flashing Go to section G YES YES NO 109 flashing 125 flashing after 1 min Go to section J YES YES 110 flashing NO Go to section H YES NO Diverter Valve open to Domestic Hot Water circuit NO Go...

Page 65: ...eck 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 ...

Page 66: ...lues 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...

Page 67: ...tem 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 wate...

Page 68: ...ocedure 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 mount ing frame 11 Decommissioning 68 7678846 A 22052017 ...

Page 69: ...isposal 12 1 Disposal and recycling Caution Removal and disposal of the boiler must be carried out by a quali fied person in accordance with local and national regulations 12 Disposal 7678846 A 22052017 69 ...

Page 70: ...ensor 7662085 D NTC flue sensor 7662034 E Diverter valve motor 7207886 F Auto air vent 7207776 G Burner door assembly 7662070 H Insulation rear 7661741 J Insulation front 7661745 K Pump assembly 7220533 L Expansion vessel 7661749 M Plate heat exchanger 25 30 7116128 N Hall effect sensor 7207880 O Hydraulic pressure switch 5693381 P Gas valve 7207523 R Pump head Q Fan Fig 70 Spare parts PN 0000365 ...

Page 71: ...c start control Time and temperature control to hot water Cylinder thermostat and n o i t a n i b m o C r e m i t r e m m a r g o r p Boiler Heating zone valves t o N d e t t i F required Hot water zone valves t o N d e t t i F required Thermostatic radiator val t o N d e t t i F s e v required Automatic bypass to t o N d e t t i F m e t s y s required Boiler interlock Provided Customer e T e m a ...

Page 72: ...No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 02 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 03 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possib...

Page 73: ... Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 09 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 10 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm...

Page 74: ...14 Appendix 74 7678846 A 22052017 ...

Page 75: ...hnological information contained in these technical instructions as well as any drawings and technical de scriptions supplied remain our property and shall not be multiplied without our prior consent in writing Subject to alterations ...

Page 76: ...onditions 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 b...

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