Baxi Potterton BBU 15 HE Boiler User Manual
Contents
1. Baxi Heating UK Ltd 2009 7 0 Installation INSTALLATION SEQUENCE There are 4 main elements to the installation of the Baxi Bermuda BBU 15 HE Preparation of pipework amp opening Inserting the flue into the chimney Siting amp fixing the boiler Fitting the terminal assembly The sequence in which these are performed may depend upon various factors beyond the scope of these instructions The above list is intended as a guide based on a typical installation It is not necessary to open the firefront pack until the boiler and flue are installed and the boiler is ready to be commissioned The firefront pack includes full instructions Initial Preparation Remove the outer carton from the boiler pack Discard the packing pieces and remove the fitting kit 2 Ensure that the base of the builders opening is clean and level 3 Complete any pipework installation and routing of electrical cables within the builders opening that may be difficult once the boiler is in place Flue System The actual length of flue as opposed to the vertical di MUST be established before commencing stance from the boiler top to the chimney outlet 2 The flue must have a minimum vertical height of 3m and have no bends greater than 45 NO HORIZONTAL RUNS ARE PERMIT TED 3 Depending on the actual flue length it may be beneficial to shorten the flue at this point to enable easier handling 4 Take2. 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with iquid or gaseous fuels Type test for purpose of Regulation 5 certified by otified Body 0087 Product Production certified by otified Bodies 0086 For GB IE only Baxi Heating UK Ltd 2009 Legislation 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 Gas Safe Registered Installer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation amp 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 LEE 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 LS 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current
3. LABC will record the data and will issue a certificate of compliance 4 IMPORTANT Installation Commissioning Service amp 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 amp Use Regulations Definition of competence A person who works for a Gas Safe registered company and holding current certificates in the relevant ACS modules is deemed competent In IE this must be carried out by a competent person as stated in 1 5 813 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 All Gas Safe registered engineers carry an ID card with their licence number and a photograph You can check your engineer is registered by telephoning 0800 408 5500 or online at www GasSafeRegister co uk The boiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 Ne 3083 and is deemed to meet the requirements of Directive
4. the Min Rate adjustment screw must be altered using a suitable hexagon key after removing the cap Fig 62 Turning anti clockwise will reduce the Clockwise will increase the CO The Calibration Function is maintained for 20 minutes unless the maximum CH temperature is exceeded The function can be disabled at any time by turning the right hand knob 12 Check the CO CO ratio This must be less than 0 004 33 12 0 Fault Finding Initial Fault Finding Checks Check that gas water and electrical supplies are available NOTE When instructed to ss boiler operate the reset button press ia for 5 seconds to reset 2 Electrical supply 230V 50 Hz Check the CH amp DHW the boiler system The preferred minimum gas pressure is 20 mbar 3 Carry out electrical system checks i e Earth Continuity Resistance to Earth Short Circuit and Polarity with a suitable meter NOTE These checks must be repeated after any servicing or fault finding 4 Ensure all external controls are calling for heat and check all external and internal fuses Before any servicing or replacement of parts ensure the gas and electrical supplies are isolated Table Of Error Codes 12 2 Central Heating NTC Fault ncorrect PCB Fitted If a fault occurs on the boiler an error code may be shown Hot Water NTC Fault on the boiler display and the Boiler Control Safety Thermostat or Condensate S
5. 490mm max pre cast concrete or be a proprietary builders opening 584mm min 3 The base of the opening should be sound and non combustible and must be flat and level 4 The base of the builders opening should be at the SURROUND OR FINISHED same height as the finished level of the hearth WALLEACE gt IMPORTANT If a false chimney breast is intended to house the boiler simulated builders opening A within the breast must be provided 1 l i 5 The builders opening must not communicate with i voids pipe ducts or spaces other than the room in E E which the appliance is situated E gg E EE 1 g ati B o Solid combustible hearth Location 1to support the boiler HEARTH specified in BS 5871 2 LEVEL The appliance must be installed in the living space of a A dwelling It is recommended that it is a ground floor location 305mm minimum Fig 9 2 Restrictions to the siting of the appliance are covered by BS 5546 The appliance may not be installed in bathrooms or shower rooms bedrooms or bed sitting rooms Fireplace Opening amp Surround If a fireplace surround is to be used it must be centrally placed and have opening sizes as shown in Fig 9 Firefont Frame Extension Kit To accommodate the firefront there must be at least 95mm from the surround or finished face to the front of the boiler 2 If necessary this can be increased by the use o
6. 60mm flue duct down so that 5 ribs are visible and fit the remaining 60mm lip seal into the first groove Fig 30 The flue duct adaptor can now be fitted in the same manner as the boiler adaptor Fig 31 18 Fit the terminal cap over the flue duct adaptor and air cowl Once the cap is clipped into position it cannot be removed easily without damage Fig 33 19 Cement over the closure plate and air duct collar to a depth of approximately Consideration should be given to the potential accumulation of snow in this area and the possibility of it blocking the air inlet Fig 34 23 Fixing Slot Fig 35 Condensate Discharge remove plug before connection Return Fig 36 Fig 37 24 Baxi Heating UK Ltd 2009 7 0 Installation Siting the Boiler IMPORTANT This product should be lifted and handled by two people Stooping should be avoided and protective equipment worn where necessary Carrying amp lifting equipment should be used as required e g when installing on another floor Lift the boiler from the packing base and place into the opening 2 Align the boiler centrally as far back in the opening as possible and ensure the distance between each side and the opening is equal Check that the boiler is level 3 Mark the hearth through two of the slots in the base Fig 35 Remove the boiler and drill the hearth Insert su
7. For information regarding the use of a Bermuda BBU 15 HE boiler with a storage system contact the appropriate storage system manufacturer Pressure Gauge Air Vent Y Indirect Cylinder Expansion Vessel Radiator Circuit Filling Point Fully Pumped Sealed System Fig 6 Baxi Heating UK Ltd 2009 4 0 System Details Sealed Systems Figs 6 7 amp 8 Installation The installation must comply with the requirements of BS 6798 and BS EN 12828 The British Gas publication British Gas Specification for Domestic Wet Central Heating Systems should also be consulted 2 Pressure Relief Valve A non adjustable spring loaded pressure relief valve preset to operate at 3 bar 45 Ibf in shall be used It must comply with BS 6759 and include a manual testing device It shall be positioned in the flow pipe either horizontally or vertically upwards and close to the boiler No shut off valves are to be placed between the boiler and the safety valve The valve should be installed with a discharge pipe which permits the safe discharge of steam and hot water such that no hazard to persons or damage to electrical components is caused 3 Pressure Gauge A pressure gauge incorporating a fill pressure indicator covering the range 0 4 bar 60 lbf in shall be fitted to the system It should be connected to the system preferably at the same point as the expansion vessel Its location should be
8. damage caused by hard water scale deposits and or aggressive water resulting from corrosion Any other defects or failures either in the connected heating system or outside of the boiler itself Faults caused by inadequate supply of electricity gas or water to the property Installations within commercial settings for which this boiler was not designed Reimbursement of any third party repair or replacement costs that we haven t been told about or agreed with you in advance Compensation for consequential losses e g loss of earnings business losses stress and inconvenience arising from a production breakdown including repair delays caused by factors outside our reasonable control After Sales Service 0844 871 1525 Comp 710161501 7 09
9. recommended that the boiler is installed at this point See Sections 8 3 to 8 7 12 Remove the plastic plug from the boiler flue outlet Grasp the adaptor and locate it into the boiler ensuring the two large barbs lock into position under the boiler top panel Fig 24 Fit the C clip to the adaptor to secure the flue It must fit into the barbs and clip securely into place Fig 24a 13 There will now be an excess of flue and air duct protruding from the chimney 14 Cut the excess concentric ducts to leave approximately 300 to 500mm protrudung from the chimney and pass the square closure plate over the air duct Figs 25 amp 26 15 Cut the 100mm air duct ONLY that 5 ribs are above the level of the chimney taking care not to damage the 60mm flue duct 16 In a similar way to fitting the boiler adaptor fit the air duct clamp to the air duct This will prevent the duct falling back into the chimney Fig 27 Air Cowl Fig 28 Fig 31 Fig 33 Baxi Heating UK Ltd 2009 Air Duct Collar 5 ribs Terminal Cap Cement around Air Duct Collar amp Cowl 7 0 Installation Flue System cont 16 Pass the air duct collar and air cowl over the 60mm flue duct Fig 28 and secure the collar to the closure plate with the screws supplied Fig 29 The air cowl will fit snugly over the collar 17 Cut the protruding
10. 1 8 0 Completion amp Commissioning 25 9 0 Annual Servicing 27 10 0 Changing Components 29 11 0 Setting the Gas Valve 33 12 0 Fault Finding 34 13 0 Short Parts List 38 14 0 Notes 39 Benchmark Checklist 42 Fig Baxi Heating UK Ltd 2009 Fig 2 1 0 Introduction Ls Description The Baxi Bermuda BBU 15 HE is a central heating boiler designed for installation within a builders opening in the living space of a dwelling 2 The boiler is a fully automatic gas fired condensing boiler It is room sealed and fan assisted 3 The boiler output will automatically modulate between Max Min 4 6kW 15 7kW condensing 4 83kW condensing According to system load 4 It must be fitted in conjunction with one of the available electric firefront units as listed on page 2 The separate electric firefront is intended for hearth mounting All instructions fixings etc needed to fit the firefront are included in the firefront pack 5 These instructions relate to the central heating boiler section of the appliance Fig 6 The appliance is designed for use on NATURAL GAS G20 only 7 It can be used on sealed or open vented systems It must NOT be fitted on any type of gravity system The boiler is suitable for fully pumped systems ONLY 8 The boiler is fitted with an integral pump unit for the removal of condensat
11. 2 Uo he operational gas inlet pressure as described in Section 2 14 to 82 16 and the gas rate as described in 8 2 17 he combustion performance as described in 9 1 5 to 9 1 6 Competence to carry out checking Combustion Performance B S 6798 Specification for Installation amp Maintenance of Gas Fired Boilers not exceeding 70kW advises that The person carrying out a combustion measurement should have been assessed as competent in the use of a ue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPAI ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts to 4 Check the Combustion Performance 5 Set the boiler to operate at maximum rate as described in Section 11 1 2 to 11 1 6 6 Remove the threaded plug from the sampling point insert the analyser probe and obtain the CO CO ratio This must be less than 0 004 7 If the combustion reading is greater than this and the integrity of the flue system and combustion circuit seals has been verified and the inlet gas pressure and gas rate are satisfactory either adjust the gas valve Section 1 1 0 replace the gas valve Section 10 8 or contact the heate
12. BAXI Installation amp Servicing Instructions Baxi Bermuda BBU 15 HE Condensing Back Boiler Unit These Instructions must be read in conjunction with those for the separate Valor Dimension electric firefront They include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Baxi Heating UK Ltd 2009 Natural Gas Baxi Bermuda BBU 15 HE G C No 44 075 09 For use with the following electric firefronts Valor Dimension Classica Brass Pewter or Black BBU Firefront Valor Dimension Dream Gold Chrome or Black BBU Firefront Valor Dimension Innova BBU Firefront Valor Dimension Regalia BBU Firefront Valor Dimension Nano Chrome BBU Firefront Valor Dimension Lyrica BBU Firefront 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 Hotwa
13. Heat Input Net Max Min kW 15 4 5 0 Heat Input Gross Max Min kW 17 1 57 Heat Output Non Condensing Max Min kW 15 0 4 88 Heat Output Condensing Max Min kW 15 7 5 25 Boiler Set Temperature Max Min P 75 25 Gas Rate Natural Gas G20 After 10 mins Max Min m h 1 63 0 54 Electrical Supply 230V 50H Appliance must be connected to an earthed supply Boiler Power Consumption 112W Boiler Electrical Protection IPXO Boiler External Fuse Rating Connections Gas Supply 5mm compression Flow 22mm male copper Return 22mm male copper Weights Packaged Boiler Carton 28 kg Installation Lift Weight 27 kg Flue Length Max Min Metres 12 5 3 0 Dimensions Casing Height 538mm Casing Width 383mm Casing Depth 306mm Firefront See the instructions supplied with the firefront for all Technical Data Baxi Heating UK Ltd 2009 4 0 System Details Water Circulating Systems The appliance is surtable for use on fully pumped systems ONLY which may be sealed or open vented 2 The following conditions should be observed at all times The static head must not exceed 30m of water The static head must not be less than m of water The boiler must not be used with a direct cylinder Drain cocks should be fitted to all system low points Al gas and water pipes and electrical wiring must be installe
14. afety Float Switch Operated Error Codes Circulation Fault Primary Circuit 2 The codes are either two or three digit preceded by the nterruption Of Power Supply while in fault mode etter E For example code E133 will be displayed by EI nterruption Of Gas Supply or Flame Failure alternating with 33 E20 is shown as E then 20 Lock Out of Boiler Control Condensate Discharge System Fault E20 amp E28 indicate faulty or incorrect components Fan or Fan Wiring Fault rn rn rn rnm rm EI 10 shows overheat of the primary water or excess condensate in the sump E125 is displayed if within 2 hours of the burner lighting the boiler temperature twice exceeds the selected temperature To perform a Service Reset it is necessary to have access to the boiler by 25 Service Reset By pressing the Reset rocker switch on the right of the boiler case for a n these instances poor primary circulation or no water in the minimum of 5 seconds when error codes are displayed it is possible to system is indicated reset the boiler once the fault has been rectified E133 indicates that the gas supply has been interrupted ignition has failed or the flame has not been detected E155 indicates a Boiler Control reset when Service amp Boiler Restoring Boiler Control Default Control reset counters are out of step Boiler Control default Following a Service Reset it is necessary to restore the Boiler Control to not
15. afety 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 General 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 in
16. ains voltage is applied to the boiler e g when the power has been interrupted and then reinstated 2 If the boiler reset rocker switch has been operated the pump will run also for 2 seconds 3 When the level of condensate in the sump is sufficient to activate the discharge float switch the pump will run for 7 seconds during which time about 0 6 litres of condensate will be discharged 4 In the event of condensate not being discharged the safety float switch will operate when the volume of condensate in the sump reaches 1 05 litres Once the safety float switch has been activated the boiler will lockout 5 The total volume of the sump is 1 5 litres 75 Holes in the soak away must face away from the building Baxi Heating UK Ltd 2009 19 6 0 Boiler Internal Wiring Em Boiler Internal Illustrated Wiring Diagram Central Heating NTC Flow Sensor sr gr Overheat Thermostat 7 Discharge HS Fe Switch Safety Float L Switch bk an bk Ly bk 10987654321 Control PCB zm 2 3 wo 46 7 o5 9 Condensate Pump pe bi I IT IT T bk br bk bk b bk Gas Valve bk Ignition Electrode Mains Input Permanent Live to 3 Switched Live to br brown g green bk black gly green yellow b blue r red w white gr grey y yelow 20 Baxi Heating UK Ltd 2009 Fig 17 Fig 18 Fig 20
17. am Technical Helpline 0844 871 1555 27 PCB Control Box Securing Screw v Boiler Front Panel Spark Generator Electrode Assembly Gas Feed Pipe Fig 44 28 Baxi Heating UK Ltd 2009 _ Discharge Pipe Locking Clip Reset Switch Off Position Gas Valve 9 0 Annual Servicing Annual Servicing Inspection Ensure that the boiler is cool 2 Ensure that the gas supply to the boiler is isolated 3 Operate the Reset switch Fig 41 to activate the condensate pump and then repeat This will empty most of the condensate from the sump 9 Isolate the boiler from the electrical supply 4 Undo amp remove the flue sampling plug and washer Remove the screws retaining the boiler front panel and lift the panel away Fig 43 5 Remove the screw securing the PCB control box and swing the box to the right Fig 43 6 Disconnect the two plugs from the fan motor and remove the sensing pipe from between the gas valve and fan outlet 7 Remove the gas feed pipe and washers and extract the injector from the gas air inlet manifold 8 For ease of access disconnect the following a 2 pin plug on NTC lead b all wires from electrode assembly C all wires from spark generator d both wires from the overheat thermostat e the red and black wires connected together 9 Undo the two securing nuts and remove the spark ge
18. are recommended 3 Metal pipework is NOT suitable for use in condensate discharge systems 4 Any pipe fitted externally must be kept as short as possible to minimise the potential of freezing and must be insulated using waterproof material 5 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered Condensate Disposal Fig 2 This boiler incorporates an automatic pumped condensate system The pump is submerged in a sump assembly and is activated by the discharge float switch A second safety float switch is fitted 2 The pump has an effective head of 3 5 metres The condensate outlet is positioned at the top right front of the boiler It is Omm diameter plastic 3 3 5 metres of flexible Omm condensate discharge pipe and a Omm push fit elbow are supplied with the boiler 4 The Omm pipe can be routed to a maximum of 3 5 metres vertically and then discharge via gravity or be routed horizontally A combination of vertical and horizontal runs is permissible 5 The pipe must be adequately supported either using suitably spaced clips or run within larger diameter pipe When using clips take care not to deform the pipe 6 When routing the pipe through a wall it must be suitably sleeved Also the pipe must not be exposed to sources of heat and should be protected in locations where it may be damaged 7 The pipe should be routed so that any sharp bends di
19. asure and Record Gas Rate m hr OR ft hr Burner Operating Pressure at maximum rate mbar OR Gas Inlet Pressure at maximum rate mbar Cold Water Inlet Temperature C Hot water has been checked at all outlets Yes Temperature Water Flow Rate I min CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 Yes ALL INSTALLATIONS If required by the manufacturer record the following CO OR CO ppm OR CO CO Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will t
20. connected to the same supply as the firefront as their fuse ratings are different and subsequent damage may occur 2 The boiler supply cable within the builders opening should be 0 to IEC 53 code 227 heat resistant 3 It is preferable to route the electrical supply cable to the right hand side of the builders opening If however it must come from the left hand side it must be routed so as not to restrict the servicing of the appliance 4 The cable must be routed to avoid contact with any part of the boiler qum Min radius 100mm Gravity Drain min fall 3 Point A Max Head 3 5 metres Note The point of discharge from the pumped length of condensate pipe point A must be 150mm above the base level of the boiler whether discharging direct into a drain or into an additional gravity drain Boiler Fig 12 18 Baxi Heating UK Ltd 2009 5 0 Site Requirements Condensate Drain General Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler Ensure the discharge of condensate complies with any national or local regulations in force BS 6798 amp Part of the Building Regulations give further guidance 2 If any further drain pipe is required additional to that supplied with the boiler tt should be run in a proprietary material e g PVC PVC U ABS PVC C or PP John Guest Speedfit components
21. d in such a way that they do not restrict the servicing of the boiler Position isolating valves as close as possible to the circulating pump There is a drain cock supplied in the plumbing kit Treatment of Water Circulating Systems All recirculatory water systems will be subject to corrosion unless they are flushed and an appropriate water treatment is applied To prevent this follow the guidelines given in BS 7593 Treatment of Water in Domestic Hot Water Central Heating Systems and the treatment manufacturers instructions Treatment must involve the use of a proprietary cleanser such as Sentinel X300 or X400 or Fernox F3 and an inhibitor such as Sentinel X100 or Fernox Full instructions are supplied with the products for further information contact Sentinel 0800 389 4670 or Fernox 0870 870 0362 Failure to flush and add inhibitor to the system will invalidate the appliance warranty It is important to check the inhibitor concentration after installation system modification and at every service in accordance with the inhibitor manufacturer s instructions Test kits are available from inhibitor stockists For information or advice regarding any of the above contact Technical Enquiries 0844 871 1555 Fig 4 22mm Open Vent Air Vent Y Indirect Cylinder Radiator Circuit Return Fully Pumped System Fig 5 12 Baxi Heating UK Ltd 2009 4 0 System Detai
22. e 9 The boiler data badge gives details of the model serial number and Gas Council number and is situated on the front case panel 0 The boiler is intended to be installed in a residential environment on a governed meter supply only The boiler must be installed with one of the MULTIIFIT vertical concentric Flexi Flue kits available Om kit 720101701 or 12 5m kit 720102001 2 All systems must be thoroughly flushed and treated with inhibitor see section 4 2 Contents The boiler pack contains Boiler Unit Plumbing Kit Condensate Pipe amp Elbow Fixings Kit Literature Pack 2 The flue pack contains Terminal Cap Flue Duct Adaptor inc seal Air Cow Air Duct Collar inc 4 screws Air Duct Clamp Closure Plate Boiler Concentric Adaptor inc 2 seals Om or 12 5m of Concentric Flexible Duct 2 x 60mm grey Seals x 100mm red Seal 8 PCB Control Box Calibration Controls Baxi Heating UK Ltd 2009 2 0 General Layout Layout Fig 3 Automatic Air Vent 2 Flue Connection 3 Spark Generator 4 Spark amp Sensing Electrodes 5 Heat Exchanger 6 Boiler Control Connector 7 Control Wiring Connector 8 Condensate Sump 9 Gas Cock 0 Condensate Pump l Fan 2 Drain w Return Connection Air Sampling Point Flue Sampling Point Flow Connection Condensate Outlet PCB Control Box shown removed for clarity oo N S
23. e bottom on the discharge switch Discharge Float Switch 6 Take the new switch assembly and insert it into the sump Hand tighten the nut and slide the alignment bracket in place to ensure the switch is in position Tighten the nut a further 2 turns 7 Reconnect the lead to the switch ensuring it is fully engaged Safety Float Alignment Switch Bracket Fig 55 32 Baxi Heating UK Ltd 2009 Flue Sampling Point Display d Control Fig 56 Max Rate Min Rate 5 DP EN Adjustment Screw QS gus a cap fitted VO Reduce CO Increase CO at max rate at max rate Reduce CO Increase CO at min rate at min rate If the CO is reset at minimum rate it must be rechecked at maximum rate again and adjusted if required If the CO is reset at maximum rate it must be rechecked at minimum rate and adjusted if required Baxi Heating UK Ltd 2009 11 0 Setting the Gas Valve Ta Setting the Gas Valve CO check IMPORTANT The must be only be checked and adjusted to set the valve if a suitable calibrated combustion analyser is available operated by a competent person see Section 9 1 The combustion CO may be checked after running the boiler for several minutes To do this it is necessary to se the boiler to Calibration Mode 2 Ensure that all external controls are calling for heat The actual cur
24. e 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 BAXI A Trading Division of Baxi Heating UK Ltd 3879156 A Division of Baxi Group Brooks House Coventry Road Warwick CV34 4LL After Sales Service 0844 871 1525 Technical Enquiries 0844 871 1555 Website www baxi co uk e amp oe BAXI GROUP company Baxi Heating UK Ltd 2009 Standard Warranty Terms amp Conditions To activate your second year free warranty you must register your boiler with heateam the service division of Baxi Heating UK Ltd either by completing and returning the registration card or calling our telephone registration line on 0800 013 7989 t is also a requirement of the warranty that the boiler has an annual service every 2 months in accordance with the installation and servicing instructions performed by a Gas Safe registered engineer f you would like heateam to carry this out please call on 0844 871 1525 Our promise to you f you experience a fault with your new boiler we aim to provide a safe and high quality repair service supported by our dedicated national network of highly skilled engineers If your installer can t resolve the problem for you we will do everything we can to get an engineer out to you as quickly as possible othing in this warranty will affect your statutory consumer
25. e position Flame current should be more than 0 5 uA Replace PCB NO Replace flame sensing electrode Overheat Thermostat or Allow to cool Continuity Condensate Safety Float Switch across thermostat terminals Replace Safety Thermostat operated or faulty more than 1 5 ohm Continuity across plug terminals at 3 amp 4 of connector Replace PCB X401 more than 5 ohm Check condensate system and Pump Condensate drain system fault Replace Safety Float Switch or wiring Press the Service Reset switch Restore Boiler Control defaults for 5 seconds K Fan connections correct at fan YES Replace f PCB X401 connector terminals 5 6 7 amp 8 Temperature sensors faulty Cold resistance approximately 10kQ 25 C CH sensor resistance reduces with increase in temp Replace sensor TES 2 if pump is running the heat exchanger could be Replace neat exchanger obstructed IMPORTANT There is no limit to the number of repeated Service Reset operations but the Boiler Control must be refreshed by Restoring Boiler Control Default as described on p 34 following the final Service Reset and before the Boiler Control reset is re used Baxi Heating UK Ltd 2009 37 38 Baxi Heating UK Ltd 2009 13 0 Short Parts List Short Parts List Key Description Manufacturers No Part No A Burner Assy 72012570 B In
26. e spacer frame that is visible to the end user e g lower right hand side 26 Baxi Heating UK Ltd 2009 Flue Sampling Plug Off Position On Position Baxi Heating UK Ltd 2009 Fig 42 Fig 41 9 0 Annual Servicing Etes Annual Servicing For reasons of safety and economy it is recommended that the boiler is serviced annually Servicing must be performed by a competent person in accordance with B S 7967 4 2 After servicing complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication 3 Disconnect the firefront electric supply Remove the fascia from the firefront Unhook its hanging brackets from the slots in the top of the firefront On Classica and Innova models also disengage the retaining magnets at the lower part of the fascia 4 Slacken the firefront retaining wire and unthread it from the bracket on top of the boiler The firefront can now be manoeuvred away from the boiler Do not drag the firefront as it may damage the hearth To completely remove the firefront disconnect the boiler contro cable 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 flue system and the flue seals as described in Section 7 2 The integrity of the boiler combustion circuit and relevant eals as described in Section 9
27. ectly Similar arrangements will follow for Scotland and will apply in Northern Ireland from January 2006 The Health amp Safety Executive operates the Gas Safe Register 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 o
28. ecure the cable and connect the plug to the one on the boiler Auto Air 7 Vent 8 0 Completion amp Commissioning ON OFF Service Boiler Control d Reset b Current Temp amp Demand e Remaining Resets Baxi Heating UK Ltd 2009 e Completion Seal off any secondary openings within the builders opening after wrapping the gas and water pipes through the brickwork and within the opening itself B S 5871 Part 1 2 Take the Boiler Control from the firefront packaging and connect it to the boiler Fig 38 Commissioning the Boiler Reference should be made to BS 5449 Section 5 when commissioning the boiler 2 At the time of commissioning complete all relevant sections of the Benchmark Checklist at the rear of this publication IMPORTANT The heat exchanger air vent on top of the boiler Fig 38 MUST be opened before filling the primary system 3 Ensure all valves in the water system are turned on 4 The system must be flushed in accordance with BS 7593 see Section 5 2 and the flushing agent manufacturers instructions 5 Turn the gas supply on and purge according to in GB BS 6891 and in IE 1 5 813 Domestic Gas Installations 6 Test for gas soundness 7 Ensure all external controls e g room stat timer etc are calling for heat and turn on the mains electrical supply Turn the rocker switch at the top right of the boile
29. ed to take suitable and sufficient steps to prevent the risk of a fall including selecting the most suitable work equipment in accordance with the regulations Mitigate the consequences of a fall where the risk of a person or object falling still remains take suitable and sufficient measures to minimise the distance and consequences of any fall Collective protection measures such as guard rails on scaffold should be given priority over personal protection measures such as safety harnesses Within the regulations framework you are required to Assess the risk to help you decide how to work safely 2 Follow the hierarchy for safe work at height i e avoid prevent and mitigate 3 Plan and organise your work properly taking account of weather conditions and the possibility of emergencies 5 Make use of appropriate work equipment 4 Make sure those working at height are competent 6 Manage the risks from working on or around fragile surfaces and from falling objects 7 Inspect and maintain the work equipment to be used and inspect the place where the work will be carried out for both access and egress Baxi Heating UK Ltd 2009 5 6 Baxi Heating UK Ltd 2009 Section Page 1 0 Introduction 7 2 0 General Layout 8 3 0 Technical Data 10 4 0 System Details 5 0 Site Requirements 15 6 0 Boiler Internal Wiring 20 7 0 Installation 2
30. er supply or to the water storage tank which supplies domestic hot water even through a non return valve without the approval of the Local Water Authority 8 Filling Point A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement refilling The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment 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 IS 813 Domestic Gas Installations 5 0 Site Requirements r ee eS oe CE ye i Builders Opening Fig 9 Builders Opening mmn 5 The boiler unit is designed to fit within a standard 2 builders opening the minimum dimensions of which x as shown Fireplace E 8 5 a Opening 6 5 72 Height 570mm 0 ns Width 584mm E Depth 305mm 5 PNE LU 2 The opening should be soundly constructed of brick
31. f Frame Extension Kits Each extension increases the effective depth of the opening by 50mm 3 See the instructions supplied with the firefront for full details Baxi Heating UK Ltd 2009 5 0 Site Requirements Flue The following guidelines indicate the general requirements for installation of flues For GB recommendations are given in BS 5440 Part For IE recommendations are given in the current edition of L S 813 Domestic Gas Installations 2 Only one of the two available MULTIIFIT vertical concentric Flexi Flue kits approved for use with the boiler can be used kit 720101701 or 12 5m kit 720102001 Any proprietary flue systems terminals adaptors etc MUST NOT BE USED 3 The available flue kits are intended for installation within an existing chimney This should be clean and sound and any other previously installed flue components liners dampers etc removed 4 The flue must have a minimum vertical height of 3m and have no bends greater than 45 NO HORIZONTAL RUNS ARE PERMITTED 5 The terminal must be sited so that free passage of air across it can occur at all times 6 It must also be a MINIMUM of 150mm from any other terminals or obstructions A When adjacent to windows or openings on pitched or flat roofs it must be at least 600mm away A minimum dimension of 2000mm must be mainta
32. g Components To change any components on the back boiler it is necessary to remove the firefront 2 Refer to the Installer Guide that accompanies the firefront for details of removal 3 Ensure that the boiler is cool and that the electrical and gas supplies are isolated 4 After changing any components carry out gas soundness checks 5 Undo amp remove the flue sampling plug and washer Remove the screws retaining the boiler front panel and lift the panel away 6 Remove the screw securing the PCB control box and swing the box to the right Spark Generator Fig 46 Note the position of the two leads on the spark generator and disconnect them Also disconnect the earth wire and plug and remove the screws securing the spark generator to the bracket 2 Remove the spark generator Replace in reverse order of dismantling using the screws previously removed 3 Ensure that the leads and plug are pushed fully on to their terminals Electrode Assembly Fig 47 Note the position of the two leads on the electrode assembly and disconnect them Disconnect the in line connection on the black wire and the earth wire 2 Undo the securing screws and remove the electrode assembly and earth tag from the combustion box panel 3 Replace in reverse order of dismantling using the screws previously removed Examine the sealing gasket and replace if necessary 4 Ensure that the leads are pushed fully
33. gulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather Optimum Start Programmer Timer Room Thermostat Compensation Control Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer Timer Combination Boiler Heating Zone Valves Fitted L Not Required Hot Water Zone Valves Fitted Not Required Thermostatic Radiator Valves Fitted z Not Required Automatic Bypass to System Fitted Not Required Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record Gas Rate m hr OR f hr Burner Operating Pressure if applicable mbar OR Gas Inlet Pressure mbar Central Heating Flow Temperature C Central Heating Return Temperature ue COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes has a water scale reducer been fitted Yes No What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Me
34. hen be issued to the customer enchmari COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING 42 AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls SERVICE 1 Date SERVICE 2 Date Energy Efficiency Checklist completed Yes No Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Gas Safe Register licence No Gas Safe Register licence No Comments Comments Signature Signature SERVICE 3 Date SERVICE 4 Date Energy Efficiency Checklist completed Yes No Energy Efficiency Checklist completed Yes No Engineer Name Enginee
35. ined when below windows or openings in pitched roofs C Fig 10 16 Baxi Heating UK Ltd 2009 Baxi Heating UK Ltd 2009 Gas Connection Electrical Connection 5 0 Site Requirements Ventilation No ventilation is required for the boiler in the room of installation Gas Supply Fig 11 The gas installation should be in accordance with relevant standards GB this is BS 6891 In IE this is I S 813 Domestic Gas Installations The connection at the appliance is 5mm copper tail located at the rear of the gas tap 2 Ensure the pipework from the meter to the appliance is of adequate size It is necessary to route the gas supply pipe to the right hand side of the builders opening It must be routed so as not to restrict the installation and servicing of the appliance Electrical Supply Fig External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current E E Wiring Regulations In IE reference should be made to the current edition of the ETCI rules The mains supply is 230V 50Hz fused at 3A NOTE The method of connection to the electrical supply must facilitate complete electrical isolation of the appliance Connection may be made via a fused double pole isolator with a contact separation of at least 3mm on all poles and serve the boiler and system controls only The boiler MUST NOT be
36. ir inlet NOTE THE POSITION OF THE RESTRICTOR PLATE 7 Remove the securing screws and transfer the fan inlet to the new fan Use a new sealing gasket if necessary 8 Replace in reverse order ENSURE THAT THE RESTRICTOR PLATE IS CORRECTLY FITTED THE SLOT MUST BE TO THE REAR Check the condition of the sealing gaskets between the fan and gas air inlet and the combustion panel and heat exchanger and replace if necessary Burner Fig 50 Proceed as described in points to 5 above 2 Undo the screws securing the burner to the combustion panel Remove the burner 3 Replace in reverse order of dismantling using the PCB Control Box screws previously removed Examine the sealing gasket removed for clarity and replace if necessary Injector Fig 50 Remove the gas feed pipe and washers and extract the injector from the gas air inlet manifold 2 Replace in reverse order of dismantling Examine the sealing washers and replace if necessary Plug oe Gas Feed 9 ui Fig 50 Pipe 77 30 Baxi Heating UK Ltd 2009 PCB Control Box removed for clarity Injector Gas Valve Earth Wire Fig 51 Baxi Heating UK Ltd 2009 10 0 Changing Components Gas Valve Fig 51 IMPORTANT After replacing the valve the CO must be checked and adjusted as detailed in Section 11 0 Setti
37. itable plugs Replace the boiler amp check the alignment within the opening Secure the boiler with suitable screws Water Connections The boiler has one return and one flow connection The flow is the upper connection It is essential the flow and retum pipes are connected correctly Fig 36 Gas Connection Connection to the gas supply is a 5mm compression fitting on the gas cock The gas supply pipe must be routed from the right hand side 2 The positioning of the gas supply pipe must not restrict the servicing of the boiler or installation of the firefront Electrical Connection The boiler requires an electrical supply from the heating controls system WARNING The appliance must be earthed The input cable for the appliance should be 0 75mm to IEC Code 227 heat resistant The system external controls and the boiler must be supplied by the same isolator The boiler MUST NOT be connected to the same supply as the firefront as their fuse ratings are different Making the Electrical Connection Take the 5 pin plug from the boiler fitting kit remove the securing screws and hinge the cover open 2 Route the mains inlet cable under the cable clamp and connect Permanent Live Neutral amp Earth to 3 N amp l respectively Ensure that the Earth lead is longest 3 Connect the switched output from the system external control system to terminal 4 Refit the cover tighten the screws to s
38. jector 72012630 C lgnition Lead 72012750 D Gas Valve 72012700 E P CB 72012580 F Fan 5121447 G NTC Sensor 720126101 H Float Switch Safety or Discharge 720126201 Safety Thermostat 720126401 Spark Generator 5114766 Condensate Pump 720125901 14 0 Notes Baxi Heating UK Ltd 2009 39 14 0 Notes 40 Baxi Heating UK Ltd 2009 14 0 Notes Baxi Heating UK Ltd 2009 41 GAS BOILER SYSTEM COMMISSIONING CHECKLIST 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 this equipment to the manufacturer s instructions may invalidate the warranty but does not affect statutory rights Customer Name Telephone Number Address Boiler Make and Model Boiler Serial Number _ 1 tT tt ttt ti tet tit tt 111 Commissioned by print name Gas Safe Register licence No Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Building Re
39. jured yourself STOP DO NOT work through the pain you may cause further injury IF INANY DOUBT DO NOT HANDLE OR LIFT THE BOILER OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING Working at Height In order to reduce the number of fatalities and major accidents attributable to working at height the Health and Safety Executive has introduced comprehensive regulations and guidance that should be followed by all businesses working at height The following paragraphs consider some of the main features of the regulations and guidance This is however only a limited summary and it is recommended that all businesses planning on undertaking air source heat pump heating installations obtain a copy of the regulations and guidance issued by the Health and Safety Executive and carefully consider the contents The regulations and guidance state that you are required to carry out a risk assessment for all work conducted at height and to put in place arrangements for Eliminating or minimising risks from work at height Safe systems of work for organising and performing work at height Safe systems for selecting suitable work equipment Safe systems for protecting people from the consequences of work at height The regulations and guidance highlight a hierarchy for safe work at height e Avoid the risk by not working at height if practicable Prevent falls Where it is not reasonably practicable to avoid work at height you are requir
40. ls Pipework The sizes of the flow and return pipes from the boiler should be determined by normal methods according to the requirements of the system 2 It is recommended that the system is designed for a drop in temperature across the system of between 1 amp 20 C 3 In systems using non metallic pipework it is necessary to use copper pipe for the boiler Flow and Return The copper must extend at least metre from the boiler and include any branches The copper pipe must not be insulated Fig 4 System Controls The system in which the appliance is installed should include a control system 2 Such a system would comprise a timer control and a separate room and or cylinder thermostat as appropriate 3 The boiler should be controlled so that it operates on demand only Fully Pumped Open Vent System Fig 5 The sizes of the system pipes should be determined by normal methods 2 The open vent pipe should be a minimum of 22mm and must rise continuously to a point above the feed and expansion tank 3 The flow pipe from the boiler form part of the vent pipe No part of the open vent may contain a valve 4 Inverted pipe runs must be avoided 5 On low capacity systems with a maximum available flow rate of less than 8 3l min temperature differential 25 an external bypass must be fitted 6 The bypass must be of the automatic pressure operated type Storage Systems
41. n the process necessary to ensure compliance with Building Regulations BSI amp benchmari COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING OMESTIC HEATING AND HOT WATER SYSTEMS recommended 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 ISO 9001 FM 00866 Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person s Self Certification Scheme Install and Commission this appliance to manufacturer s instructions Complete the Benchmark Checklist If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www GasSafeRegister co uk within 10 days You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Gas Safe Register will issue a Building Regulations Compliance Certificate to the property owner and inform the relevant LABC Baxi Heating UK Ltd 2009 Building Control Contact your relevant Local Authority Building Control LABC who will arrange an inspection or contact a government approved inspector Install and Commission this appliance to manufacturer s instructions Complete the Benchmark Checklist
42. ndensate Pump does not run On Reset is there 230V at PCB X3 connector terminals 5 amp 6 for at least 2 seconds Replace PER 2i Condensate Pump terminals for at Repl iri least 2 seconds eplace wiring Replace Cond Pump Condensate drain system blocked YES NO Replace Float Switch Condensate Pump runs XES Clean condensate drain system D Fan connections correct at fan PCB YES X2 connector is 230V AC across Fan jammed or faulty winding Replace fan terminals 5 amp 7 Replace PCB E E20 Temperature sensor faulty Cold resistance approximately 10kQ 25 C Replace sensor or PCB E28 resistance reduces with increase in temp E28 Incorrect PCB fitted Check and correct the connection of the tube between the venturi and gas valve Replace PCB Replace gas valve G voltage at PCB 2 connector is NO ce eee LOV AC across terminals 2 amp 5 gt Replace PCB Ignition electrode and lead Note from multimeter connect YES 2 Electrode connection i 3 Spark gap and position common to 2 amp volts to 5 gt Replace igniter Check wiring 36 Baxi Heating UK Ltd 2009 H Check the gas supply pressure Zi For Natural Gas greater than 12 0 Fault Finding 10 mbar 2 Check and correct if necessary The mechanical set of the gas valve CO2 values see instruction 2 Flame sensing electrode and lead connections 3 Flame sensing electrod
43. nerator and bracket 10 Undo the combustion panel securing nuts and remove the special spring washers Remove the complete fan amp panel assembly from the boiler Lay the assembly to one side The outer insulation panel is fitted to the rear of the combustion box panel 2 Clean inside the heat exchanger and examine the condition of the fins 3 Examine the burner electrodes insulation and seal replacing if necessary Also check the condition of the three insulation pieces in the rear of the heat exchanger 14 Disconnect the wires on the condensate pump motor and pull off the plastic discharge pipe Cut and remove the transit cable tie It is not necessary to replace this item 5 Squeeze the two retaining clips and turn the pump anticlockwise to remove it Draw it upwards from the sump 6 Clean any debris from the sump and examine the condition of the pump seal replacing if necessary 7 Reassemble in reverse order of dismantling checking and replacing any components as necessary Recommission the boiler and complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication Fig 45 Spark Generator PCB Control Box removed for clarity Electrode Fig 47 Condensate Pump Locking Clip Fig 48 Baxi Heating UK Ltd 2009 10 0 Changing Components DM Changin
44. ng the Gas Valve Only change the valve if a suitable calibrated combustion analyser is available operated by a competent person see Section 9 1 Disconnect the plug and earth wire from the gas valve and remove the sensing pipe from between the valve and fan outlet 2 Remove the gas feed pipe and washers and extract the injector from the gas air inlet manifold 3 Undo the nut on the pipe from the gas cock to the valve inlet adaptor and remove the screws securing the adaptor to the boiler side panel 4 Remove the valve complete with the inlet and outlet adaptors and the seal on the inner face of the side panel Transfer the adaptors to the new valve using new O rings if necessary 5 Replace in reverse order of dismantling using the screws previously removed Examine all sealing gaskets and washers and replace if necessary NOTE To assist the boiler to light prior to final setting use a suitable hexagon key to wind out the Gas Air adjustment screw until it is flush with the valve body then turn the screw 4 full turns clockwise Fig 51 If the boiler will not light or the correct CO cannot be achieved contact the heateam technical helpline 3l 10 0 Changing Components Lad Thermostat 109 PCB Fig 54 Pull off the two control knobs and disengage the securing tabs of the cover Undo the screws securing the PCB Flow Pipe 2 Draw the PCB forwards and disco
45. nnect the wiring Transfer the two potentiometer drive pins to the new PCB and replace in reverse order of dismantling Fig 52 3 Ensure that the wiring connectors are pushed fully on to the PCB terminals EXTR Fig 53 Disconnect the 2 pin plug Remove the clip retaining the NTC in the heat exchanger pocket Pull the NTC out of the pocket 2 Apply suitable heat transfer paste to the new NTC Replace in reverse order of dismantling using the clip previously removed Ensure that the plug is fully engaged ITIN Safety Thermostat Fig 52 Disconnect the two leads from the thermostat 2 Remove the screws securing the thermostat to the mounting plate on the flow pipe 3 Replace in reverse order The thermostat is not polarised either wire can fit either terminal on the thermostat PE Float Switches Fig 55 Remove the fan as described in Section 10 5 paragraphs to 5 2 The two float switches are the same but oriented differently The discharge switch is at the left the safety at the right 3 To remove either switch disconnect the lead and pull off the alignment bracket 4 Undo the retaining nut The sealing grommet will be Cont released from the sump body and allow the switch to be removed 5 Note the orientation of the alignment rib on the switch It is positioned uppermost on the safety float switch and to th
46. o put the boiler into operation as follows Check the Operational Gas Inlet Pressure 14 Set the boiler to operate at maximum rate as described in Section 11 1 2 to 11 1 6 15 With the boiler operating in the maximum rate condition check that the operational gas pressure at the inlet gas pressure test point is 20mb Fig 40a 16 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Measure the Gas Rate 7 With any other appliances amp pilot lights turned OFF Inlet Gas Pressure he gas rate can be measured It should be between 1 55 Fig 40a Test Point and 171 m h 8 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the boiler and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded For IE it is necessary to complete a Declaration of Conformity to indicate compliance with 1 5 813 An example of this is given in 1 5 813 Domestic Gas Installations This is in addition to the Benchmari Commissioning Checklist 19 Disconnect the Boiler Control and fit the firefront in accordance with the instructions supplied with it IMPORTANT The loose boiler serial number label supplied in the boiler kit must be applied to an area of th
47. on to their terminals Condensate Pump Fig 48 Note the position of the two leads and earth wire on the pump motor and disconnect them 2 Cut and remove the transit cable tie It is not necessary to replace this item 3 Squeeze in the two locking clips and turn the pump anti clockwise Pull the condensate discharge pipe off its connection and remove the pump 4 Replace in reverse order of dismantling Examine the sealing ring and replace if necessary 5 Ensure that the leads are pushed fully on to their terminals 29 10 0 Changing Components Fan Fig 49 Disconnect the two plugs from the fan motor and remove the sensing pipe from between the gas valve and fan outlet Spark Generator 2 Remove the gas feed pipe and washers and extract the injector from the gas air inlet manifold 3 For ease of access disconnect the following a 2 pin plug on NTC lead b all wires from electrode assembly c all wires from spark generator d both wires from the overheat thermostat e the red and black wires connected together Note position of Slot 4 Undo the two securing nuts and remove the spark generator and bracket 5 Undo the combustion panel securing nuts and remove the special spring washers Remove the complete fan amp panel assembly from the boiler Check the condition of the insulation piece Fig 49 6 Undo and remove the nuts and washers securing the fan to the gas a
48. one of the 60mm lip seals supplied and fit to the first groove in the flue duct Also fit the 100mm lip seal to the air duct Figs 17 amp 18 NOTE Talcum powder may be used to ease fitting of the adaptors over the seals DO NOT use oil grease or soap 5 Unfasten the clips on the boiler adaptor and insert the end of the flue duct with the seal into the 60mm socket Ensure the seal is positioned past the clips then engage the clips over the larger diameter rib on the duct Fig 19 6 Repeat the process for the 100mm air duct Fig 20 21 Fig 21 Remove plug from here NOTE These seals Fig 23 en factory lubricated Fig 24 Cut to leave 5 ribs visible Fig 25 Fig 26 22 Baxi Heating UK Ltd 2009 7 0 Installation Flue System cont 8 It is recommended that the Pull Cone Flue Adaptor part no 720111801 is used as shown to ease the fitting of the flue into the chimney and prevent damage to the adaptor 9 The cone has two internal lugs that engage on the boiler adaptor in a bayonet action Figs 2 amp 22 10 A suitable weight should then be tied to the guide rope fixed to the cone The weight can then be passed into the chimney and will draw the guide rope down Fig 23 Once the Pull Cone is visible in the builders opening it can be removed It can be re used indefinitely on other installations e It is
49. ps and loops are avoided A minimum radius of 00mm is recommended for any bends No slope is necessary and air breaks are not required on the pumped part of the condensate run 8 Any part of the condensate drain system that is outside the dwelling or in an unheated part of it must be at least 21 5mm diameter Termination via internal discharge branch e g sink waste downstream Direct Connect Fitting must terminate x above water level but below surrounding surface From Boiler Fig 13 Termination to an internal soil and vent pipe Direct Connect Fitting From Boiler Ta Termination to a drain or gully Pipe must terminate above Water level but below surrounding surface From Boiler 500mm Min Termination to a purpose made soak away From Boiler Fig 16 5 0 Site Requirements Condensate Disposal cont 9 Ensure that the condensate can discharge freely without blockage or restriction of the pipe into the drain 10 Examples are shown of condensate pipe methods of termination i via an internal discharge branch e g sink waste Fig 13 i to an internal or external soil and vent pipe Fig 14 il to a drain or gully Fig 15 Ensure that the condensate can discharge freely without blockage or restriction of the pipe into the drain to a soakaway Fig 16 Condensate Pump Operation The pump operates for 2 seconds when m
50. r Name Company Name Company Name Telephone Number Telephone Number Gas Safe Register licence No Gas Safe Register licence No Comments Comments Signature Signature SERVICE 5 Date SERVICE 6 Date Energy Efficiency Checklist completed Yes No Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Gas Safe Register licence No Gas Safe Register licence No Comments Comments Signature Signature SERVICE 7 Date SERVICE 8 Date Energy Efficiency Checklist completed Yes EI No EI Energy Efficiency Checklist completed Yes No EI Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Gas Safe Register licence No Gas Safe Register licence No Comments Comments Signature Signature SERVICE 9 Date SERVICE 10 Date Energy Efficiency Checklist completed Yes No Energy Efficiency Checklist completed Yes No Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number Gas Safe Register licence No Gas Safe Register licence No Comments Comments Signature Signature 43 Please complete the boxes below Serial Number Date of Installation HOOD DD MM Yy Y Installer Details name address and contact number s 9 0 Warranty Service All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to mak
51. r to ON The fan and condensate pump will run briefly 8 The display will count down from 7 to 0 then the current water temperature will be displayed 9 When there is a demand for heating the bar on the top left of the display will be shown and the boiler will commence the ignition sequence 10 When ignition is established the flame symbol on the display is illuminated The display will indicate the flow temperature The appliance is fully preset therefore no adjustment is required If the boiler fails to ignite within the three ignition attempts the error code E133 will appear in the display EI alternating with 33 12 To reset the boiler press the reset button for at least 3 seconds The ignition sequence will then recommence A maximum of four resets in a five hour period are allowed 13 When the reset button is activated the number of available reset attempts will be displayed 25 8 0 Completion amp Commissioning Commissioning the Boiler cont IMPORTANT The combustion for this appliance has been checked adjusted and preset at the factory for operation on the gas type specified on the appliance data plate No measurement of the combustion is necessary Do not adjust the air gas ratio valve Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals as described in Section 7 2 Proceed t
52. rent boiler temperature is shown on the display 3 Tum both control knobs fully anticlockwise then quickly turn the right hand knob 4 clockwise twice and back fully anticlockwise Fig 56 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 57 amp 58 5 Turn the left hand knob fully clockwise As the knob is turned the display will change indicating the fan speed 6 The display will show 00 indicating maximum rate then revert to alternating with the current boiler temperature Figs 59 60 amp 61 7 Remove the plug from the flue sampling test point Insert the analyser probe and allow sufficient time for the reading to settle Fig 56 The should be 9 3 0 2 8 It is possible to alter the by adjustment of the gas valve Remove the plastic cover from the Max Rate adjustment screw At maximum rate the Max Rate adjustment screw should be turned using a suitable hexagon key until the correct reading is obtained Fig 62 Turning clockwise will reduce the Anticlockwise will increase the 9 The CO2 must then be checked at minimum rate Turn the left hand knob fully anti clockwise As the knob is turned the display will change indicating the fan speed When the display reads O the boiler runs at minimum rate The should be 8 2 0 2 10 With the boiler on minimum
53. restored correctly default condition Disconnect the main power supply E158 indicates a condensate discharge system fault On reinstating the power supply the Boiler Control display will count 3 By pressing the Reset button on the Boiler Control for a down from 7 minimum of 5 seconds when EI 10 amp E133 are displayed it is Before the count reaches 3 press both the On Off and Reset buttons possible to relight the boiler simultaneously and hold until the count reaches O The Boiler Control display will show SEt to confirm default restoration 4 If this does not have any effect or the codes are displayed regularly further investigation is required It is possible to reset the boiler up to 4 times in any 5 hour period Further resets via the Boiler Control are then blocked for 5 hours unless a Service Reset is performed 34 Baxi Heating UK Ltd 2009 12 0 Fault Finding NOTE Sections A to L Refer to Section 16 0 Illustrated Wiring Diagram for position of terminals and components Central Heating Follow operational sequence Tum on Power Supply Bos semen referred to in the chart Display llluminates opposite are on the following pages YES 8 Error 10 flashing Press the Service Reset If the error 110 is still flashing Error 131 flashing switch for 5 seconds Go to section NO YES NO Error 158 flashing Go to section C Ensure controls are set to demand and verify the contac
54. rights What you need to do if you experience a problem with your heating system or the operation of the boiler You should always contact your installer first because the cause of the fault may not be related to the boiler If your installer confirms that the fault is with the boiler and he she can t repair it our friendly customer service team is on hand to help Simply call our service division heateam on 0844 871 1525 to book an engineer visit or for any general advice that you may need Our contact centre is open Monday to Friday 8am 6pm weekends and Bank Holidays 8 30am 2pm excluding Christmas Day and New Years Day When calling heateam it would be helpful if you could have the following information to hand Boiler serial number see opposite 2 Boiler make and model number 3 Your installer name and address details 4 Proof of purchase if you do not have the boiler serial number What this warranty covers Free of charge repair or replacement of components found to be of faulty manufacture Free of charge replacement of the complete unit provided always that the failure is related to a manufacturing fault that cannot be repaired or is uneconomic to repair What this warranty does not cover Repairs to boilers which haven t been installed and commissioned properly and as set out in the installation instructions this includes the need to flush the system effectively and add a suitable corrosion inhibitor Any
55. rules for electrical installation All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Codes of Practice most recent version should be used 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 5449 Forced circulation hot water systems BS 6798 Installation of gas fired hot water boilers BS 5440 Part Chimneys BS 5440 Part 2 Ventilation BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems Also the following standard includes relevant information about builders openings BS 5871 Part Installation of gas fires convector heaters fire back boilers and heating stoves In IE the following Codes of Practice apply Standard Scope LS 813 Domestic Gas Installations The following BS standards give valuable additional information BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Forced circulation hot water systems Safe Manual Handling 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 amp S
56. ry to calculate the volume of water in the system in litres The following volumes may be used as a conservative guide to calculating he system volume Boiler Heat Exchanger 1 55 litres Small Bore Pipework litre per KW of system output Micro Bore Pipework 7 litre Steel Panel Radiators 8 litre per kW of system output Low Water Capacity Radiators litre per KW of system output Hot Water Cylinder litre per KW of system output f the system is extended the expansion vessel volume may have to be increased unless provision has been made for extension Where a vessel of the calculated size is not available the next available larger size should be used The boiler flow temperature is controlled at approx 75 C The vessel size can now be determined from the information in table where V System volume in litres 5 Cylinder The hot water cylinder must be an indirect coiler type 6 Method of Make Up Provision shall be made for replacing water loss from the system either a From a make up vessel or tank mounted in a position higher than the top point of the system and connected through a non return valve to the system on the return side of the hot water cylinder or the return side of all heat emitters or b Where access to a make up vessel would be difficult by using the mains top up method or a remote automatic pressurisation and make up unit 7 Mains Connection There shall be no connection to the mains wat
57. s Boiler Control cover open The Boiler Control operates the boiler remotely This is supplied with the firefront and is fitted in operation to the firefront spacer frame IMPORTANT To commission the boiler it is is necessary to remove the Boiler Control from the firefront packaging and connect it to the boiler at the upper right hand side item 6 PCB Control Box removed for clarity Fig 3 Boiler Control 2 0 General Layout Flue Kit 10m amp 12 5m Fig a l Terminal Cap 2 Flue Duct Adaptor 2 3 Air Cowl 4 Air Duct Collar 5 Air Duct Clamp 6 Closure Plate 3 7 Boiler Adaptor 8 60mm Seal 2 Collar Securing Screws x 4 9 10 100mm Seal Ll 60mm Flue Duct 4 12 100mm Air Duct 13 C Clip 8 o 2 13 Fig 3a Baxi Heating UK Ltd 2009 9 Sedbuk Declaration For Bermuda BBU 15 HE The seasonal efficiency SEDBUK is 90 1 This value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated has been certified by 0087 10 Baxi Heating UK Ltd 2009 3 0 Technical Data Bermuda HE CBBU 15 HE Appliance Type C33 Appliance Category CAT DH Inlet Pressure Natural Gas G20 mbar 20 Injector Natural Gas G20 420 4 2 mm NO Class 5 31mg kWh
58. ter Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information Baxi Heating UK Ltd 2009 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 C 0086 R 2 Baxi Heating UK Ltd 2009 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England amp Wales require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department From April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority dir
59. ts are closed Turn Central Heating thermostat to Maximum Pump runs Ensure all external controls are calling for heat Go to section B YES Error 155 flashing Go to section Ensure that the system is full YES primary circulation is OK amp Go to section J Error 125 flashing NO Error 160 flashing een Go to section D YES Error 160 flashing Fan runs at correct speed ps Go to section K YES Spark at ignition electrodes for YES Go to section G up to 5 seconds and for 3 Error 133 flashing gt urn the selector switch to attempts reset Burner does not stay alights YES Error 133 flashing after 5 seconds Go to section H Check the Central Heating NTC sensor Go to section E that there is no blockage NO Burner lights YES Burner output modulates to maintain the temperature set YES Baxi Heating UK Ltd 2009 Burner relights after at least 3 YES YES i i Fan stops after lO seconds minutes when the display is Operation sequence less than the set temperature successful room thermostat open 35 Fault Finding Solutions Sections 12 0 Fault Finding A Is there 230V at Main terminals L and N No 2 NO NO Check electrical supply Replace fuse Display Replace PCB illuminated Check wiring PCB connector terminals 1 2 B Check all system wiring and pump C Co
60. visible from the filling point Temporary Hose Mains Water Hose Y B Supply Union Ph Service Pipe ave Double Check Valve Heating System Filling a Sealed Water System Method Mains Topping Up Method NOTE This method of filling a sealed system Fig 7 may only be used if acceptable to Local Water Undertaking Mains Water Supply Cistern Pressure Pump Reducing Valve if required Na Stop Valve es Filling a Sealed Water System Method 2 Cistern Filling Method NOTE Cistern to be supplied through a temporary connection from a service pipe or Fig 8 cold water distributing pipe Vessel Charge Pressure bar Initial System Pressure bar 10 10 Expansion Vessel Volume litres V V x 0 087 Table l Baxi Heating UK Ltd 2009 4 0 System Details Sealed Systems cont 4 Expansion Vessel A diaphragm type expansion vessel to BS 48141 shall be fitted close to the inlet side of the pump The connecting pipework should not be less than 5mm Pipework connecting the expansion vessel should not incorporate valves of any sort Methods of supporting the vessel are supplied by the vessel manufacturer The nitrogen or air charge pressure of the expansion vessel shall not be less than the hydrostatic head height of the top point of the system above the expansion vessel To size the expansion vessel it is first necessa
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