Potterton Promax System HE Plus LPG Installation and maintenance instructions

© Baxi Heating UK Ltd 2008
Installation & Service Instructions
These instructions include the Benchmark Commissioning
Checklist and should be left with the user for safe keeping.
Promax System
HE Plus LPG
Condensing
System Boiler
You can rely on

2© Baxi Heating UK Ltd 2008
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. From 1 April 2005 this
can be achieved via a Competent Persons Self Certification
Scheme as an option to notifying the Local Authority directly.
Similar arrangements will follow for Scotland and will apply in
Northern Ireland from 1 January 2006.
CORGI operate a Self Certification Scheme for gas heating
appliances.
These arrangements represent a change from the situation
whereby compliance with Building Regulations was accepted as
being demonstrated by completion of the Benchmark Logbook
(which was then left on site with the customer).
With the introduction of Self Certification Schemes, the
Benchmark Logbook is being withdrawn. However, a similar
document in the form of a commissioning checklist and service
interval record is incorporated at the back of these instructions.
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.
Baxi Heating UK Ltd is a
BS-EN ISO 9001 Accredited Company
The code of practice for the installation,
commissioning & servicing of central
heating systems.
“Potterton” supports
© Baxi Heating UK Ltd 2008 All rights reserved. No part of this publication may
be reproduced or transmitted in any form or by any means, or stored in any
retrieval system of any nature (including in any database), in each case whether
electronic, mechanical, recording or otherwise, without the prior written
permission of the copyright owner, except for permitted fair dealing under
Copyrights, Designs and Patents Act 1988.
Applications for the copyright owner’s permission to reproduce or make other
use of any part of this publication should be made, giving details of the proposed
use, to the following address:
The Company Secretary, Baxi Heating UK Ltd, The Wyvern Business Park,
Stanier Way, Derby, DE21 6BF.
Full acknowledgement of author and source must be given.
WARNING: Any person who does any unauthorised act in relation to a
copyright work may be liable to criminal prosecution and civil claims for damages.
This product has an energy rating (A) on a scale of A to G.
For more information see www.boilers.org.uk. This is a certification mark.
Propane
Potterton Promax System 24 HE Plus LPG
G.C.No41 592 11

3
Installer Notification Guidelines
© Baxi Heating UK Ltd 2008
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
CORGI will record the data and
will send a certificate of
compliance to the property
You must ensure that the
notification number issued by
CORGI is written onto the
Benchmark Checklist
Scheme Members only
Call CORGI on: 0800 408 1007
or log onto:
www.corgi-notify.com
within 10 days
If you notify via CORGI Scheme,
CORGI will then notify the
relevant Local Authority
Building Control Scheme
on member's 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

4
Legislation
© Baxi Heating UK Ltd 2008
Codes of Practice - refer to the most recent version
IMPORTANT - Installation, Commissioning, Service & Repair
This appliance must be installed in accordance with the manufacturer’s instructions and
the regulations in force. Read the instructions fully before installing or using the
appliance.
In GB, this must be carried out by a competent person as stated in the Gas Safety
(Installation & Use) Regulations.
Definition of competence: A person who works for a CORGI registered company and
holding current certificates in the relevant ACS modules, is deemed competent.
In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic
Gas Installations”.
The addition of anything that may interfere with the normal operation of the appliance
without express written permission from the manufacturer or his agent could invalidate
the appliance warranty. In GB this could also infringe the Gas Safety (Installation and
Use) Regulations.
Warning - Check the information on the data plate is compatible with local supply
conditions.
This company declare that no substances harmful to health
are contained in the appliance or used during appliance
manufacture.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force, and
only used in a suitably ventilated location.
In GB, the installation must be carried out by a CORGI
Registered Installer. It must be carried out in accordance with
the relevant requirements of the:
• Gas Safety (Installation & Use) Regulations.
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
• The Water Fittings Regulations or Water Byelaws in
Scotland.
• The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent
Person and installed in accordance with the current edition of
I.S. 813 ‘Domestic Gas Installations’, the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
All systems must be thoroughly flushed and treated with
inhibitor (see section 6.2).
In GB the following Codes of Practice apply:
Standard Scope
BS 5482 Part 1 Gas Installation.
BS 5546 Installation of hot water supplies for domestic
purposes.
BS 5449 Forced circulation hot water systems.
BS 6798 Installation of gas fired hot water boilers.
BS 5440 Part 1 Flues.
BS 5440 Part 2 Ventilation.
BS 5482 Part 1 Domestic butane and propane gas burning
installations.
BS 7074 Expansion vessels and ancillary equipment for
sealed water systems.
BS 7593 Treatment of water in domestic hot water
central heating systems.
In IE the following Codes of Practice apply:
Standard Scope
I.S. 813 Domestic Gas Installations.
The following standards give valuable additional information;
BS 5482 Part 1 Domestic butane and propane gas burning
installations.
BS 5546 Installation of hot water supplies for domestic
purposes.
BS 5449 Forced circulation hot water systems.
BS 7074 Expansion vessels and ancillary equipment for
sealed water systems.
BS 7593 Treatment of water in domestic hot water
central heating systems.
The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)
Regulations 1993 No3083” 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:-
Type test for purpose of Regulation 5 certified by:
Notified Body 0085.
Product/Production certified by:
Notified Body 0086.
For GB/IE only.
All CORGI registered installers carry a CORGI identification card and have a
registration number. You can check your installer is registered by telephoning
0800 915 0485 or writing to:-
1 Elmwood,
Chineham Park,
Crockford Lane,
Basingstoke. RG24 8WG
or check online at www.trustcorgi.com

5
Safe Manual Handling
© Baxi Heating UK Ltd 2008
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.
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 asses 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 NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

6© Baxi Heating UK Ltd 2008
CONTENTS
1.0 Introduction 7
2.0 General Layout 8
3.0 Appliance Operation 9
4.0 Technical Data 10
5.0 Dimensions and Fixings 11
6.0 System Details 12
7.0 Site Requirements 14
8.0 Flue Options 18
9.0 Plume Displacement 23
10.0 Installation 27
11.0 Commissioning 32
12.0 Completion 34
13.0 Servicing 35
14.0 Changing Components 37
15.0 Combustion Check 45
16.0 Electrical 46
17.0 Short Parts List 47
18.0 Fault Finding 48
Benchmark Checklist 54
Section Page

7
1.0 Introduction
© Baxi Heating UK Ltd 2008
1.1 Description
1. The Potterton Promax System HE Plus LPG is a fully
automatic gas fired wall mounted condensing system boiler. It
is room sealed and fan assisted.
2. The boiler is set to give a maximum output of :-
24 kW
25.9 kW (Condensing)
3. It is designed for use on Propane (G31).
4. The boiler incorporates a circulating pump and expansion
vessel. It is suitable for use only on fully pumped sealed
systems.
5. The boiler data badge gives details of the model, serial
number and Gas Council number and is situated on the inner
door panel. It is visible when the case front panel is removed
(Fig. 1).
6. The boiler model name and serial number are also shown
on the information label on the rear of the lower door panel.
This is for user reference.
7. The boiler is intended to be installed in residential /
commercial / light industrial E.M.C. environments on a
governed meter supply only.
8. The boiler must be installed with one of the purpose
designed flues such as the standard horizontal flue kit, part no.
5118489.
9. All systems must be thoroughly flushed and treated with
inhibitor (see section 6.2).
1.2 Contents of Pack
The pack contains:-
• Boiler
• Wall Plate (including taps)
• Set of Pipe Connections
• Template
• Literature Pack
Fig. 1
Control Box
Case Front Panel
Data Badge
Information Label

8
2.0 General Layout
© Baxi Heating UK Ltd 2008
2.1 Layout
1. Expansion Vessel
2. Automatic Air Vent
3. Circulation Pump
4. Drain Off Point
5. Pressure Relief Valve
6. Selector Switch
7. Central Heating System Pressure Gauge
8. PCB
9. Control Box
10. Gas Valve
11. Condensate Trap
12. Flame Sensing Electrode
13. Spark Electrode
14. Primary Heat Exchanger
15. Fan Assembly
16. On/Off/Reset Selector Switch
17. Central Heating Temperature Control
18. Calibration Control
19. Venturi
20. Air/Gas Collector
21. Combustion Box Cover & Burner
22. Igniter
23. Burner On Light
24. Central Heating Mode Light
25. Display
1
16 17 18 7
Reset
2
1
0
4
3
bar
21
2
3
4
5
6
7
8
9
10
11
12
13
14
15
19
20
22
23
24
25

9
3.0 Appliance Operation
© Baxi Heating UK Ltd 2008
3.1 Operating Mode (Fig. 2)
1. With a demand for heating or hot water, the pump
circulates water through the primary circuit. If the pressure is
at least 0.5 bar and the ignition sequence will start.
2. When the flow temperature exceeds the setting
temperature, a 3 minute delay occurs before the burner
relights automatically (anti-cycling). The pump continues to
run during this period.
3. When the demand is satisfied the burner is extinguished
and the pump continues to run for a period of 3 minutes
(Pump Overrun).
IMPORTANT: When the selector switch is in the ‘0’
(Off) position the electrical supply to the boiler is
isolated. The boiler will not operate.
3.2 Frost Protection Mode
1. The frost protection mode is integral to the appliance and
functions when the selector switch (see Section 2.1) is in the
ON position ( ). If the system temperature falls below
5° C then the boiler will fire on its minimum setting until a
flow temperature of 30° C is reached. Further protection
can be incorporated by using a system frost thermostat.
3.3 Pump Protection
1. With the selector switch (see Section 2.1) in the ON
position ( ) the pump will automatically operate for 1
minute in every 24 hours to prevent sticking.
1
2
4
5
6
7
8
19
18
9
10 1211
14
13
15
16
17
3
Key
1 Heat Exchanger
2 Burner
3 Ignition Electrode
4 Flame Sensing Electrode
5 Gas Valve
6 Pump
7 Automatic Air Vent
8 Pressure Relief Valve
9 Boiler Drain Point
10 Gas Inlet
11 Boiler Flow
12 Boiler Return
13 Pressure Gauge
14 Automatic By-Pass
15 Water Pressure Sensor
16 Safety Thermostat
17 Temperature Sensor
18 Expansion Vessel
19 Return Temperature Sensor
20 Fan
Boiler Primary Circuit
Fig. 2
20

10 © Baxi Heating UK Ltd 2008
This value is used in the UK Government’s Standard Assessment Procedure
(SAP) for energy rating of dwellings. The test data from which it has been
calculated have been certified by 0085.
SEDBUK Declaration For Promax System HE Plus
The seasonal efficiency (SEDBUK) for all models is:-
93.2% Band A
4.0 Technical Data
4.1 Promax System 24 HE Plus LPG
Flue Terminal Diameter 100mm
Dimensions Projection 125mm
Outercase Dimensions
Casing Height - 780mm
Overall Height Inc Flue Elbow - 965mm
Casing Width - 450mm
Casing Depth - 345mm
Central Heating Primary Circuit
Pressures
bar
Safety Discharge 3
Max Operating 2.5
Min Operating 0.5
Recommended Operating Range 1-2
Pump
Available Head See graph below
Expansion Vessel - (Integral with appliance)
bar
Min Pre-charge Pressure 0.5
litre
Max Capacity of
CH System 125
Primary Water Content
of Boiler (unpressurised) 2.5
Connections copper tails
Gas Supply - 22mm
Central Heating Flow - 22mm
Central Heating Return - 22mm
Pressure Relief Discharge - 15mm
Temperatures
Flow Temp (adjustable)
25°C to 80°C max (± 5°C)
NOxClass 5
0
200 400 600 800 1000 1200
0.5
1
1.5
2
2.5
3
3.5
4
Metre (wg)
Flow Rate (l/h)
Pump - Available Head
0
5
5.5
4.5
Clearances
Above Casing 200 mm Min
Below Casing 200 mm Min
Front 450 mm Min (For Servicing)
Front 5 mm Min (In Operation)
L.H. Side 5 mm Min
R.H. Side 5 mm Min (In Operation)
Heat Input (Net) Max Min
24 model kW 24.7 7
Heat Output (Non-Condensing)
Max Min
24 model kW 24 6.8
Electrical Supply 230V~ 50Hz
(Appliance must be connected to an
earthed supply)
Power Consumption
24 model 150W
Electrical Protection
IPX5D
Internal Fuse Rating F2L
Appliance Category CAT I I 2H3P
Appliance Type C13 C33 C53
Heat Output (Condensing)
Max Min
24 model kW 25.9 7.4
Max Gas Rate (Propane - G31)
(After 10 mins)
24 model kg/h 1.92
Condensate Drain
To accept 21.5mm (3/4in) plastic waste pipe
Heat Input (Gross) Max Min
24 model kW 27.4 7.8
External Fuse Rating 3A
Weights
24 model
Packaged Boiler Carton 44.2kg
Installation Lift Weight 39.2kg
Inlet Pressure (Propane - G31)
mbar 37
Injector (Propane - G31)
24 model 7.5mm

11
5.0 Dimensions and Fixings
© Baxi Heating UK Ltd 2008
360° Orientation
Tube Ø 100mm
DC
B
A
E
G
F
At least 1.5°
H
Heating
Return
(22mm)
Heating
Flow
(22mm)
Pressure Relief
Valve
(15mm)
Gas
Inlet
(22mm)
130 mm 130 mm 65 mm
Condensate
Drain
32.5 mm
Tap Rail
Dimensions
A780mm
B345mm
C450mm
D116mm Ø Min.
E185mm
(207mm for 80/125mm
flue systems)
F145mm
G131mm
H180mm

12
6.0 System Details
© Baxi Heating UK Ltd 2008
6.1 Central Heating Circuit
1. The appliance is suitable for fully pumped SEALED SYSTEMS
ONLY.
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.
• All systems must be thoroughly drained and flushed out. Using,
for example Betz-Dearborn Sentinel X300 or X400 or Fernox
Superfloc Universal Cleanser. They should be used following the
flushing agent manufacturer’s instructions.
• System additives - corrosion inhibitors and flushing
agents/descalers should comply to BS7593 requirements, e.g.
Betz-Dearborn Sentinel X100 and Fernox-Copal which should be
used following the inhibitor manufacturer’s instructions.
Failure to flush and add inhibitor to the system will
invalidate the appliance warranty.
• It is important to check the inhibitor concentration after
installation, system modification and at every service in
accordance with the manufacturer’s instructions. (Test kits are
available from inhibitor stockists.)
• For information or advice regarding any of the above contact
Technical Enquiries.
6.2 Bypass
1. The boiler is fitted with an automatic integral bypass.
6.3 System Control
1. For optimum operating conditions, the heating system into
which the boiler is installed should include a control system.
2. Such a system will comprise of a timer control and separate
room or cylinder thermostats as appropriate.
3. The boiler should be controlled so that it operates on
demand only.
4. Operation of the system under control of the boiler
thermostat & TRV’s only does not produce the best results.

13
6.0 System Details
© Baxi Heating UK Ltd 2008
Stop
Valve
Double
Check
Valve
Mains
Cold
Inlet
CH
Return
Temporary
Hose
Stop
Valve
Fig. 3
Filling Loop for
Sealed Systems
6.4 System Filling and Pressurising
Sealed Systems
1. 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.
2. The filling method adopted must be in accordance with all
relevant water supply regulations and use approved equipment.
3. Your attention is drawn to the current edition of I.S. 813
“Domestic Gas Installations”.
4. 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.
‘Semi - Sealed’ Systems
1. ‘Semi - Sealed’ systems require the use of a suitable header
tank and ball cock arrangement to charge and provide subsequent
replenishment of the system.
2. The tank must be placed to provide sufficient head in order to
ensure a minimum system pressure of 0.2 bar.
3. A suitable non - return valve must be fitted in the pipework
between the header tank and heating system.
6.5 Expansion Vessel
1. The appliance expansion vessel is pre-charged to 0.5 bar. The
vessel is suitable for correct operation for system capacities up to
125 litres. For greater system capacities an additional expansion
vessel must be fitted. Refer to BS 7074 Pt 1. For IE, the current
edition of I.S. 813 “Domestic Gas Installations”.
6.6 Pressure Relief Valve (Fig. 4)
1. 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.
2. The pressure relief discharge pipe should be not less than 1/2”
dia, 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. The end of the pipe should
terminate facing down and towards the wall.
3. 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.
Fig. 3a
‘Semi-Sealed’
System
CH
Return
Header Tank
Non-Return
Valve
Fig. 4
Pressure Relief Valve
Discharge Pipe

14
7.0 Site Requirements
© Baxi Heating UK Ltd 2008
7.1 Location
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 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).
2. If the boiler is sited in an unheated enclosure then it is
recommended to leave the ON/OFF Selector Switch in the
On position.
3. 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 I.E.E. Wiring Regulations and Building
Regulations.
In IE reference should be made to the current edition of I.S.
813 “Domestic Gas Installations” and the current ETCI rules.
4. 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. In accordance with BS6798 LPG fuelled appliances shall not
be installed in rooms or internal spaces below ground level.
7.2 Clearances (Figs. 5 & 6)
1. A flat vertical area is required for the installation of the
boiler.
2. 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.
200mm Min
780mm
450mm
200mm Min
(300mm Min if
using 80/125mm
flueing system)
5mm Min
5mm Min
450mm Min
For Servicing
Purposes
Fig. 5
Fig. 6
In Operation
5mm Min
At least 1.5°

15
7.0 Site Requirements
© Baxi Heating UK Ltd 2008
7.3 Ventilation of Compartments
1. Where the appliance is installed in a cupboard or
compartment, no air vents are required.
2. BS 5440: Part 2 refers to room sealed appliances
installed in compartments. The appliance will run sufficiently
cool without ventilation.
7.4 Gas Supply
1. The gas installation should be in accordance with the
relevant standards. In GB this is BS 5482-1. In IE this is the
current edition of I.S. 813 “Domestic Gas Installations”.
2. The connection to the appliance is a 22mm copper tail
located at the rear of the gas service cock (Fig. 7).
3. 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).
7.5 Electrical Supply
1. External wiring must be correctly earthed, polarised and
in accordance with relevant regulations/rules. In GB this is
the current I.E.E. Wiring Regulations. In IE reference should
be made to the current edition of ETCI rules.
2. The mains supply is 230V ~ 50Hzfused at 3A.
NOTE: 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.
3. When the system includes an indirect domestic hot
water cylinder it is recommended that a cylinder
thermostat is used in conjunction with a 3 port 2 position
valve or 2 port zone valve.
7.6 Bath & Shower Rooms
1. If the boiler is fitted in a room containing a bath or
shower and NOT FITTED with any optional integral timer
or thermostat, it can be fitted in zone 2, (Figs. A & B shows
zone dimensions for a bathtub. For other examples refer to
Section 601 of the Current I.E.E. Wiring Regulations)
reference must be made to the relevant requirements.
In GB this is the current I.E.E. Wiring Regulations and
Building Regulations.
In IE reference should be made to the current edition of I.S.
813 “Domestic Gas Installations” and the current ETCI
rules.
Fig. 7
Gas Service Cock
Zone 2
Zone 1
Zone 0
Zone 2
Zone 3
Zone 3
Zone 2
Window
Recess
Window
Recess
0.6 m 2.4 m
Ceiling
Outside
Zones
Outside Zones
Zone 3
Zone 3
Zone 2
Zone 2
Zone 1
Zone 0
2.25 m
Zone 2
Window
Recess
3.0 m
2.4 m
0.6 m
Fig. A
Fig. B
In GB Only
In GB Only

16
7.0 Site Requirements
© Baxi Heating UK Ltd 2008
7.7 Condensate Drain
FAILURE TO INSTALL THE CONDENSATE DISCHARGE
PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE
OPERATION OF THE BOILER
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.
1. The condensate outlet will accept 21.5mm (3/4in) 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.
2. Ensure the discharge of condensate complies with any
national or local regulations in force.
BS 6798:2000 & Part H1 of the Building Regulations give
further guidance.
3. The discharge pipe should be run in a proprietary drain pipe
material e.g. PVC, PVC-U, ABS, PVC-C or PP.
4. Metal pipework is NOT suitable for use in condensate
discharge systems.
5. The pipe should be a minimum of 21.5mm diameter and
must be supported using suitably spaced clips to prevent
sagging.
6. It is advisable to keep the condensate pipe internal.
7. External runs greater than 3 metres or runs in cold areas
should use 32mm waste pipe.
8. If the boiler is fitted in an unheated location the entire
condensate discharge pipe should be treated as an external
run.
9. 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.
10. 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
back-pressure may force water out of the boiler trap and
cause appliance lockout.
Examples are shown of the following methods of termination:-
i) to an internal soil & vent pipe
ii) via an internal discharge branch (e.g. sink waste)
iii) to a drain or gully
iv) to a purpose made soakaway
Boiler
2.5° Minimum fall
Termination to an internal soil and
vent pipe
450mm min
Boiler
2.5° Minimum fall
External termination via internal discharge
branch
e.g sink waste - downstream
Sink
Pipe must terminate
above water level but
below surrounding
surface
Boiler Pipe must terminate above
water level but below
surrounding surface
2.5° Minimum fall
Termination to a drain or gully
Boiler
500mm min
2.5° Minimum fall
Termination to a purpose made soak-
away
Holes in the soak-away must
face away from the building
50mm per metre of pipe run
50mm per metre of pipe run
50mm per metre of pipe run
50mm per metre of pipe run

17
7.0 Site Requirements
© Baxi Heating UK Ltd 2008
7.8 Flue
NOTE: 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.
1. The following guidelines indicate the general requirements
for siting balanced flue terminals. For GB recommendations
are given in BS 5440 Pt 1. For IE recommendations are given
in the current edition of I.S. 813 “Domestic Gas
Installations”.
2. If the terminal discharges onto a pathway or passageway,
check that combustion products will not cause a nuisance
and that the terminal will not obstruct the passageway.
3. 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.
IMPORTANT:
• Only ONE 25mm clearance is allowed per installation.
• 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.
N
I
I
G
F
M
I
AAF
H
J,K
D
E
H
Likely flue positions requiring
a flue terminal guard
C
RA
I
J,K
I
L
S
B
T
U
Fig. 9
Fig. 8
300 min
Terminal
Assembly
Top View Rear Flue
Property Boundary Line
NOTE: The distance from a fanned draught appliance terminal
installed parallel to a boundary may not be less than 300mm in
accordance with the diagram below
Terminal Position with Minimum Distance (Fig. 9) (mm)
AaDirectly below an opening, air brick, opening
windows, etc. 300
BaAbove an opening, air brick, opening window etc. 300
CaHorizontally to an opening, air brick, opening window etc. 300
D Below gutters, soil pipes or drain pipes. 25
E Below eaves. 25
F Below balconies or car port roof. 25
G From a vertical drain pipe or soil pipe. 25
H From an internal or external corner. 25
I Above ground, roof or balcony level. 300
J From a surface or boundary line facing a terminal. 600
K From a terminal facing a terminal (Horizontal flue). 1200
From a terminal facing a terminal (Vertical flue). 600
L From an opening in carport (e.g. door, window)
into the dwelling. 1200
M Vertically from a terminal on the same wall. 1500
N Horizontally from a terminal on the same wall. 300
R From adjacent wall to flue (vertical only). 300
S From an adjacent opening window (vertical only). 1000
T Adjacent to windows or openings on pitched and flat roof 600
U Below windows or openings on pitched roofs 2000
aIn addition, the terminal should be no nearer than 150 mm to an
opening in the building fabric formed for the purpose of accommodating
a built-in element such as a window frame. See BS 5440 Pt. 1.
*
Opening Window
or Door
100mm
MIN.
IMPORTANT: If fitting a Plume
Displacement Flue Kit, the air inlet
must be a minimum of 100mm from
any opening windows or doors (see
Section 9.0).
Plume
Displacement Kit
Air Inlet
Fig. 10

18
8.0 Flue Options
© Baxi Heating UK Ltd 2008
Horizontal
Flues
Y
X
Plume Displacement 60 /100 dia Kit
1M Extensions 45° & 93° bends are
also available - see Section 9.0
Plume Displacement.
8.1 Horizontal Flue Systems
1. The standard flue is suitable only for horizontal
termination applications.
2. Maximum permissible equivalent flue lengths are:-
60/100 80/125
Horizontal Concentric 10 metres 20 metres
3. Any additional “in line” bends in the flue system must be
taken into consideration.
Their equivalent lengths are:-
Concentric Pipes:
135° bend 0.5 metres
93° bend 1.0 metres
Twin Flue Pipe
135° bend 0.25 metres
91.5° bend 0.50 metres
The elbow connected to the boiler adaptor is not included
in any equivalent length calculations
5. The illustrations opposite show examples of permissible
flue systems.
NOTE: Flue length is measured from point X to Y as
shown.
Y
X
This bend is equivalent to
1 metre
Total equivalent length =
A+B+C+2x90°Bends
B
AC
This bend is equivalent to
1 metre
NOTE: Horizontal flue pipes should always be installed with a fall of at least 1.5°
from the terminal to allow condensate to run back to the boiler.

19
8.0 Flue Options
© Baxi Heating UK Ltd 2008
Vertical
Flues
Vertical
Flues
(Twin Pipe)
Y
X
Y
X
8.2 Twin & Vertical Flue Systems
1. Maximum permissible equivalent flue lengths are:-
(60/100) (80/125)
Vertical Concentric 10 metres 20 metres
Vertical Twin Pipe 15 metres
2. Any additional “in line” bends in the flue system must be
taken into consideration.
Their equivalent lengths are:-
Concentric Pipes:
135° bend 0.5 metres
93° bend 1.0 metres
Twin Flue Pipe
135° bend 0.25 metres
91.5° bend 0.50 metres
The elbow supplied with the standard horizontal telescopic
flue kit is not included in any equivalent length calculations
NOTE: Flue length is measured from point X to Y as
shown.
The total equivalent length for this example is
= 6.5 metres.
1m extension
45°bend
91.5°bend
1m
0.25m
0.5m
5
2
2
5.0m
0.5m
1.0m
AIR DUCT
Noof
fittings/pipes
Sub total
Equivalent
Length Value
Equivalent Length Air Duct = 6.5m
1m extension
45°bend
91.5°bend
1m
0.25m
0.5m
5
2
2
5.0m
0.5m
1.0m
FLUE DUCT
Noof
fittings/pipes
Sub total
Equivalent
Length Value
Equivalent Length Flue Duct = 6.5m
Y
X
C
Roof
Terminal
A
B
660mm
This bend is equivalent to
1 metre
Total Equivalent Length =
A+B+C+1x90°Bend
All vertical and angled runs must be included,
measured from the boiler adaptor (point X) to the
joint with the flue terminal (point Y). One 91.5°
bend or two 45° bends can be included without
reduction of the flue length.
If further elbows are required the flue length must
be reduced by the following amounts:-
1 metre for each 91.5° elbow
0.5 metre for each 45° elbow

20
8.0 Flue Options
© Baxi Heating UK Ltd 2008
Key Accessory Size Code No
FLUE GROUP A
Concentric Flue System 100mm diameter
A Horizontal Flue Terminal (incl elbow) 5118489
A2 Telescopic Flue (inc. elbow) 315-500mm 5119654
A3 Telescopic Internal Flue Kit 315-500mm 5119654
B Flue Extension 1000mm 5111074
C Flue Bend 93° 5111075
D Flue Bend (pair) 135° 5111085
U Pipe Support (painted) 100Ømm 5111080
R Vertical Flue Adaptor 5111070
P Wall Liner 5111067
S Flue Terminal Deflector 5111068
FLUE GROUP N
Twin Flue System 80mm diameter
E Flue Extension (pair) 1000mm 5111087
F Flue Bend (pair) 90° 5111072
G Flue Bend (2 pair) 135° 5111086
J Vertical Flue Boiler Adaptor Kit 5111079
H Vertical Flue Adaptor 5111084
W Pipe Support (pair) 80mm 5111081
Y Twin Flue Termination Kit
(horizontal termination) 80mm 5120172
FLUE GROUP G
Concentric Flue System 80/125mm diameter
A4 Horizontal Flue Kit 5118580
B Straight Extension Kit 1000mm 5118584
D Bend Kit (pair) 135° 5118597
C Bend 91.5° 5118588
X Pipe support 125mm 5118610
FLUE GROUP A, N, G
Vertical Flue Kits
K1 Vertical Flue Terminal 5118576
L Pitched Roof Flashing 25°/50° 5122151
M Roof cover plate 246143
N Flat roof flashing 246144
A
A2
B
K1
R
D
C
N
U,W,X
S
L
H
J
M
E
GF
P
8.3 Flue Accessories
A3
A4