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Megaflo System installation instructions

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1. Data Badge Information Label Baxi Heating UK Ltd 2015 1 0 Introduction IL Description The Baxi Megaflo System 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 15 models 15 kW 16 2 KW Pnc Condensing 18 models 18 kW 19 4 KW Pnc Condensing 24 models 24 kW 25 9 KW Pnc Condensing 28 models 28 kW 30 3 KW Pnc Condensing 32 models 32 kW 34 4 KW Pnc Condensing 3 It is designed for use on Natural Gas G20 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 domestic 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 telescopic flue kit part no 7205987 01 9 All systems must be thoroughly flushed and treated with inhibitor see section 6 1 IMPORTANT If
2. it with the slots for the electrodes 5 If the rear insulation requires replacement remove it and all debris from the heat exchanger Also it may be necessary to separately remove the spring clip from the pin in the centre of the heat exchanger and the L shaped clips embedded in the insulation 6 DO NOT remove the shrink wrapped coating from the replacement rear insulation Keep the insulation vertical and Heat press firmly into position Exchanger 7 Examine the cover seal and replace if necessary Rear Insulation Spark Electrode Venturi Insulation 28 Fig 52 Collector Electrode Sensing Leads Electrode O Baxi Heating UK Ltd 2015 35 13 0 Changing Components Flue Heat Exchanger Thermostat Sensor Fig 53 Electrical Plug Flue Heat Exchanger Thermostat Sensor Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Turn the sensor 90 anticlockwise to remove it is a bayonet connection 3 Reassemble in reverse order Water Pressure Sensor Fig 55 Fig 53 Drain the primary circuit 2 Disconnect the two wires from the sensor 3 Undo the nut on the flow pipe securing and sealing the sensor 4 Remove the sensor examine the sealing washer replacing if necessary 5 Reassemble in reverse order The component is not polarised either wire
3. 3 Unscrew the automatic air vent from the pump body 4 Examine the O ring seals on the return pipe and manifold replacing if necessary 5 Fit the air vent to the pump body and reassemble in reverse order Socket Headed Screw EME Automatic Air Vent Fig 58 Drain the primary circuit and unscrew the automatic air vent from the pump body 2 Examine the O ring seal replacing if necessary and fit it to the new automatic air vent Pump Head 3 Reassemble in reverse order Fig 57 Automatic Air Fig 58 Baxi Heating UK Ltd 2015 37 E Bracket g S Gauge Retaining E 13 0 Changing Components EMT Pressure Gauge Figs 59 60 Drain the primary circuit and undo the nut on the pressure gauge capillary ie Pressure Gauge Fig 59 2 Undo the screws securing the gauge retaining bracket 3 Remove the bracket and gauge assembly Depress the barbs on the side of the gauge and remove the retaining bracket 4 Examine the sealing washer replace if necessary 5 Reassemble in reverse order mwas Pressure Relief Valve Fig 61 Pressure Gauge i Capillary i Drain the primary circuit 2 Disconnect the discharge pipe from the valve Using a suitable hexagon key undo the grub screw sufficiently to release the valve 3 Note the orientation of the valve rotate it and withdraw it from the manifold 4 Fit t
4. SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate At max rate Record Record At min rate Where Possible At min rate Where Possible Comments Comments SERVICE 03 SERVICE 04 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate At max rate Record Record At min rate Where Possible At min rate Where Possible Comments Comments Signature SERVICE 05 SERVICE 06 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate At max rate Record Record At min rate Where Possible At min rate Where Possible Comments Comments SERVICE 07 SERVICE 08 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate At max rate Record Record At min rate Where Possible At min rate Where Possible Comments Comments Signature SERVICE 09 SERVICE 10 Engineer name Engin
5. 7 0 Site Requirements 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 The following guidelines indicate the general requirements for siting balanced flue terminals For GB recommendations are given in BS 5440 Pt For IE recommendations are given in the current edition of l 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 e Under car ports we recommend the use of the plume displacement kit e The terminal position must ensure the safe and nuisance free dispersal of combustion products Terminal 300 mm i i ve nl 4 Reduction to the boundary is possible down to 25mm SE E KS but flue deflector part no 5111068 must be used i Plume gt 1 Displacement Kit IMPORTANT If fitting a Plume i Displacement Flue Kit the air inlet ft Da must be a da of 150mm from ie OCS any opening windows or doors Top View Rear Fl
6. Check the Combustion Performance 12 1 4 to 12 1 6 below 3 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 flue gas analyser and the interpretation of the results e 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 CPA ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts to 4 Check the Combustion Performance CO CO ratio 4 Set the boiler to operate at maximum rate as described in Section 15 1 1 to 15 1 6 5 Remove the plug from the flue sampling point insert the analyser probe and obtain the CO CO ratio This must be less than 0 004 6 If the combustion reading CO CO ratio is greater than this and the integrity of the complete flue system and combustion circuit seals has been verified and the inlet gas pressure and gas rate are satisfactory either e Perform the Annual Servicing Inspection Section 12 2 amp re check e Adjust the gas valve Section 14 0 amp re check e Replace the gas valve Sect
7. Remove the collector and fan assembly as described in section 3 3 2 Extract the injector from the venturi 3 Undo the screws securing the fan to the venturi and the venturi to the collector IMPORTANT When fitting the new venturi ensure the arrows on it s base point into the collector Fig 50 4 Examine the seals and burner gasket replace if necessary 5 Reassemble in reverse order ensuring that the injector is in place Injector Fig 48 Remove the collector and fan assembly as described in section 3 3 2 Extract and replace the injector and reassemble in reverse order 13 0 Changing Components Burner Fig 51 Undo the screws securing the collector to the venturi and Cover Burner ten extension piece Remove this extension piece from the A cover not 28 model Extension Piece Not on 28 model l Noton mone 2 Withdraw the burner from the cover and replace with the new one 3 Examine the gasket replacing if necessary 7 4 Reassemble in reverse order Venturi Insulation Fig 52 Remove the electrode leads noting their positions Also remove the electrodes as described in section 13 2 2 Undo the screws securing the collector to the venturi and the nuts holding the cover to the heat exchanger Draw the collector and cover assembly away 3 Remove the cover insulation piece 4 Fit the new insulation carefully over the burner and align
8. 50H fused 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 Bath amp Shower Rooms l shower and NOT FITTED with any integral receiver it can f the boiler is fitted in a room containing a bath or be fitted in zone 2 Figs A amp B shows zone dimensions for a bathtub For other examples refer to the Current LEE Wiring Regulations reference must be made to the relevant requirements In GB this is the current LEE Wiring Regulations and Building Regulations In IE reference should be made to the current edition of l S 813 Domestic Gas Installations and the current ETCI rules Examples are shown of the following methods of termination i to an internal soil amp vent pipe ii via an internal discharge branch e g sink waste d iii to a drain or gully iv to a purpose made soakaway v pumped into an internal discharge branch e g sin vi pumped into an external soil amp vent pipe ownstream of the trap k waste downstream of the trap vil to a drain or gully wit
9. BS EN 12828 Heating systems in buildings BS EN 14336 Installation amp commissioning of water based heating systems BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating 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 General 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 8 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 H 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 side
10. at max rate the CO Clockwise will increase the CO Don Reduce CO Increase CO at min rate at min rate Fig 74 Gas Valve 1 The Calibration Function is maintained for 20 minutes 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 unless the maximum CH temperature is exceeded The Do not turn the adjustment function can be disabled at any time by turning the right screws more than 1 8 of a turn at hand knob a time Allow the analyser reading maximum rate it must be rechecked at minimum rate and adjusted if required to settle before any further 12 Check the Combustion Performance CO CO ratio adjustment This must be less than 0 004 40 O Baxi Heating UK Ltd 2015 15 0 Electrical Illustrated Wiring Diagram Central Heating NTC Sensor Overheat Stat EN Le y Return Heating Water Pressure Temperature Sensor Switch Flame Sensing Electrode 987654321 10987654321 Control PCB x501 I2 l xI x2 Pump lo PCB RTE bi 3 6 Way i d Connector lgnition Electrode Mains Input Cable O Baxi Heating UK Ltd 2015 4 16 0 Short Parts List Short Parts List Key Description Manufacturers No
11. Declaration of Conformity Baxi Heating UK Limited being the manufacturer distributor within the European Economic Area of the following Baxi Megaflo 15 18 24 28 32 System ErP declare that the above is in conformity with the provisions of the Council Directive 2009 142 EC 92 42 EEC 2004 108 EC 2006 95 EC 2009 125 EC 2010 30 EU and has been subject to the following conformity procedures laid down in Annex 2 Article 3 of 2009 142 EC under the supervision of the British Standards Institution a Notified Body authorized by the United Kingdom Competent Authority and carrying the Notified Body umber 0086 Type test for purpose of Regulation 5 certified by otified Body 0085 Product Production certified by otified Body 0085 amp 0086 For GB IE only Baxi Heating UK Ltd 2015 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 Buildi
12. Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted 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 What system cleaner was used What inhibitor was used Quantity Has a primary water system filter been installed CENTRAL HEATING MODE measure and record Gas rate OR Burner operating pressure if applicable OR Gas inlet pressure Central heating flow temperature Central heating return temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate OR Burner operating pressure at maximum rate OR Gas inlet pressure at maximum rate Cold water inlet temperature Hot water has been checked at all outlets Yes Temperature Water flow rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 ALL INSTALLATIONS At max rate CO ppm CO CO Record the following At min rate where po
13. IN ACCORDANCE WITH THIS SECTION WILL CONSIDERABLY MINIMISE THE LIKELIHOOD OF BLOCKAGE AND SUBSEQUENT BOILER LOCK OUT A CONDENSATE DISCHARGE PUMP AND PIPE TRACE HEATING ARE AVAILABLE AS ACCESSORIES see paragraphs 7 7 12 to 7 7 15 for further details The condensate discharge pipe MUST NOT RISE at any point along its length There MUST be a fall of AT LEAST 2 5 50mm per metre along the entire run EXCEPT when employing a suitable condensate pump in basement and cellar or similar applications The boiler condensate trap incorporates a seal of 75mm therefore it is unnecessary to install an air break and trap in the discharge pipework The condensate outlet will accept 21 5mm fin plastic overflow pipe It is strongly recommended that this discharges internally into the household drainage system Where this is not possible discharge into an outside drain is permissible providing every possible precaution is taken to prevent freezing 2 Ensure the discharge of condensate complies with any national or local regulations in force BS 6798 amp Part HI of the Building Regulations give further detailed 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 2 1 5mm diameter and be supported using suitably spaced clips of the correct mus design t
14. 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 on the process necessary to ensure compliance with Building Regulations BSI pen CHING COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND
15. The boiler should be fitted within the building unless j otherwise protected by a suitable enclosure i e garage or outhouse The boiler may be fitted inside a cupboard see Section 7 3 2 lf the boiler is sited in an unheated enclosure then it is recommended to leave the ON OFF Selector Switch in the On position 780mm 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 LEE Wiring Regulations and Building Regulations In IE reference should be made to the current edition of l 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 Y edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing 150mm Min Fig 5 Y This is the MINIMUM recommended dimension Greater clearance will aid installation and maintenance y Clearances Figs 5 amp 6 At least 1 5 A 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 450mm Min For Se
16. 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 l 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 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 N 3083 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with iquid or gaseous fuels Type test for purpose of Regulation 5 certified by otified Body 0085 Product Production certified by otified Bodies 0085 amp 0086 For GB IE only Homologations CE Marking EC
17. boiler is installed at a high point in the system it is strongly recommended that Automatic Air Vent Kit 720004701 is fitted Ensure that this vent is open 5 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 6 Pressurise the system to 1 5 bar Fig 31 then close and disconnect the filling loop 7 Turn the gas supply on and purge the system according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 8 Test for gas tightness 9 Hinge the facia panel upwards and refit the case front panel Tighten the securing screws 10 Having checked e That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals Proceed to put the boiler into operation as follows The Combustion Check procedure as shown by the chart in 10 2 is mandatory The method of setting the boiler to operate at maximum and minimum rates to comply with the procedure is described below 2 Ensure that all external controls are calling for heat The actual current boiler temperature is shown on the display 13 Turn both control knobs fully anticlockwise then quickly turn the right hand knob 1 4 clockwise twice and back fully anticlockwise Fig 32 4 The display will now alternate between SF and the curr
18. codes are displayed regularly further investigation is required 43 17 0 Fault Finding Refer to Section 16 0 Illustrated Wiring Diagram for position of terminals and components Central Heating Follow operational sequence Go to section A Turn selector switch to The display illuminates Error 110 flashing Error 130 flashing Error 133 flashing NO NO Turn the selector switch to H the error 10 is still flashing reset position for 5 seconds Go to section J Go to section E Go to section C Turn Central Heating Ensure all controls and thermostat to Maximum integral clock are calling for Go to section B Pump runs heat Ensure that primary Error El25 or El 93 flashing circulation is OK amp that there is no blockage 3 way valve is open to Central YES EA SE gt Go to section K Heating circuit NO F Error 160 flashing eon Go to section D YES Error 60 flashing Fan runs at correct speed re Go to section L YES Spark at ignition electrodes for YES Go to section H up to 5 seconds and for 3 Error 133 flashing Tum the selector switch to attempts reset i YES i Burner lights Burner does not stay alights Error 133 flashing after 5 seconds Go to section Check the Central Heating NTC sensor Ensure controls are set to demand and verify the contacts are closed Go to section E Burner output modulates to Error 130 flashin
19. rating of dwellings The test data from which it has been calculated has been certified by 0085 Metre wg 0 200 400 600 800 1000 1200 10 Baxi Heating UK Ltd 2015 Flow Rate Vh 4 0 Technical Data Technical Parameters Technical parameters for boiler space heaters Baxi Megaflo System ErP 15 18 24 28 32 Condensing boiler Yes Yes Yes Yes Yes Low temperature boiler No No No No No B1 boiler No No No No No Cogeneration space heater No No No No No Combination heater No No No No No Rated heat output Prated kW 15 18 24 28 32 Useful heat output at rated heat output P4 kW 15 0 18 0 24 0 28 0 32 0 and high temperature regime Useful heat output at 30 of rated heat P kW 4 9 5 9 7 9 9 3 10 6 output and low temperature regime Seasonal space heating energy efficiency 7 91 91 92 92 92 Useful efficiency at rated heat output and 74 87 9 87 9 87 9 87 9 87 9 high temperature regime Useful efficiency at 30 of rated heat n 96 7 96 8 96 8 96 8 96 7 output and low temperature regime Auxiliary electricity consumption Full load elmax KW 0 037 0 065 0 042 0 041 0 043 Part load elmin KW 0 014 0 014 0 014 0 015 0 015 Standby mode Psg kW 0 003 0 003 0 003 0 003 0 003 Other items Standby heat loss Pstby KW 0 040 0 040 0 040 0 040 0 040 Ignition burner power consumption Pig kw Annual energy consumption Que kWh 13187 15824 20870 24348 27
20. service visit recorded 4 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with LS 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 5 Hand over the Users Operating Installation and Servicing Instructions giving advice on the necessity of regular servicing Case Front Panel Fig 41 Facia Panel Securing zc Screws Inner Door Panel Trap Fig 43 O Baxi Heating UK Ltd 2015 12 0 Servicing 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 IMPORTANT During routine servicing and after any maintenance or change of part of the combustion circuit the following must be checked e The integrity of the complete flue system and the flue seals The integrity of the boiler combustion circuit and relevant seals as described in Section 2 2 The operational gas inlet pressure as described in Section 0 3 1 to 10 3 7 and the gas rate as described in 10 3 8 The combustion performance as described in
21. 8 Baxi Heating UK Ltd 2015 18 0 Notes Baxi Heating UK Ltd 2015 49 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 according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer name Telephone number Address Boiler make and model Boiler serial number Commissioned by PRINT NAME Gas Safe register number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS tick the appropriate boxes Room thermostat and programmer timer Programmable room thermostat Time and temperature control to heating Load weather compensation Optimum start control Time and temperature control to hot water Cylinder thermostat and programmer timer Combination Boiler
22. 826 GJ 47 57 75 88 100 Sound power level indoors Lwa dB 52 53 58 53 54 Emissions of nitrogen oxides NOx mg kWh 25 29 20 20 24 1 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet 2 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet co See OU The back cover for contact details O Baxi Heating UK Ltd 2015 II 5 0 Dimensions and Fixings Dimensions At least 1 5 l6m 60m 207mm for 80 125mm ue systems 45mm 06mm 80mm Flue 100mm 132 5 mm p lt 1 Condensate l Drain l l l l l 130 mm 130 mm 65 mm I Heating Gas Heating Pressure Relief Flow Inlet Return Valve 22mm 22mm 22mm 15mm Em bi tm Ka 2 Baxi Heating UK Ltd 2015 6 0 System Details 6 1 Central Heating Circuit The appliance is suitable for fully pumped SEALED SYSTEMS ONLY Treatment of Water Circulating Systems e 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 e When fitting new systems flux will be evident
23. Clean any debris from the heat exchanger and check hat the gaps between the tubes are clear Inspect the burner electrodes position and insulation cleaning or replacing if necessary Clean any dirt or dust from the air box 12 Reassemble in reverse order NOTE The sensing pipe must be reconnected to the fan not the venturi 13 Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user SCH E Igniter Igniter Feed Plug Electrode Leads Fig 46 Spark Electrode Electrode Leads Sensing Electrode Fig 47 Baxi Heating UK Ltd 2015 13 0 Changing Components IMPORTANT When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started When the component has been changed turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler before recommissioning See Section 12 2 Annual Servicing for removal of case panel door etc Igniter Fig 46 Disconnect the igniter feed plug and the electrode leads noting their positions 2 Undo the screw securing the bracket to the boiler 3 Remove the igniter and transfer the bracket to the new component 4 Reassemble in revers
24. Part No 302 Flue Thermostat 5114747 306 Burner 15 18 24 5122149 Burner 28 5114697 Burner 32 5114698 311 Fan 5121447 315 gniter Electrode 720222801 316 Sensing Electrode 720222901 415 Pump 7220533 419 Water Pressure Switch 3114748 420 Overheat Thermostat 5114729 421 NTC Sensor 5114725 419 422 Gas Valve 720514301 434 NTC Sensor Return 5114725 503 PCB 5122457 PCB 18 5122458 PCB 24 720045201 PCB 28 720795401 PCB 32 5122459 504 Pressure Gauge 5118385 522 Pump PCB 7222704 42 O Baxi Heating UK Ltd 2015 NOTE When instructed to turn the selector to the reset position turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler Table Of Error Codes Central Heating NTC Fault Flue NTC Fault Safety Thermostat Operated Water Pressure Switch Not Operated Circulation Fault Primary Circuit Flue NTC Operated Interruption Of Gas Supply or Flame Failure Fan or Fan Wiring Fault Pre Circulation Fault Baxi Heating UK Ltd 2015 17 0 Fault Finding Initial Fault Finding Checks Check that gas water and electrical supplies are available at the boiler 2 Electrical supply 230V 50 Hz 3 CH water system pressurised to 0 5 bar minimum when the boiler is cold 4 The preferred minimum gas pressure is 20 mbar 5 Carry out electrical system checks i e Earth Continuity Resistance to Earth S
25. Pressure Ensure that all controls are calling for heat and the selector switch is in the central heating and hot water position iJ The current boiler temperature is shown on the display 2 To check the gas rate it is necessary to set the boiler to Calibration Mode 3 Turn both temperature control knobs fully anticlockwise then quickly turn the Calibration Control knob clockwise twice and back fully anticlockwise Fig 33 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 35 amp 36 5 Turn CH temperature control knob fully clockwise As the knob is turned the display will change from 0 to 00 Fig 39 indicating maximum rate then revert to P alternating with the current boiler temperature Figs 38 amp 39 6 With the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point Fig 34 is in accordance with B S 6798 amp BS 6891 7 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Measure the Gas Rate 8 With any other appliances amp pilot lights turned OFF the gas rate can be measured It should be between 15 model 1 69 m h 18 model 1 95 m3 h 24 model 2 61 m3 h 28 model 3 1 m h 32 model 3 48 m h 9 The Calibration Function is active for 20 minutes unless t
26. SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 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 2015 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 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
27. STALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Please ensure the boiler is installed in accordance with these installation instructions and that you adhere to the Building Regulations egoe All descriptions and illustrations provided in this document have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request 7219674 01 04 15 CE 0086 ele Ce zz BAXI
28. There are two telescopic sections the Terminal Assembly and the Connection Assembly a roll of sealing tape and two self tapping screws A 93 elbow is also supplied 2 The two sections can be adjusted to provide a length between 315mm and 500mm Fig 19 when measured from the flue elbow there is 50mm engagement into the elbow 3 Locate the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 20 NOTE The flue elbow is angled at 93 degrees to ensure a fall back to the boiler 4 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 20 5 If the distance from the flue elbow to the outside face of the wall X in Fig 20 is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into the elbow 6 In instances where the dimension X Fig 20 is between 250mm and 315mm it will be necessary to shorten the Terminal Assembly by careful cutting to accommodate walls of these thicknesses 7 To dimension X add 40mm This dimension to be known as Y 8 Adjust the two telescopic sections to dimension Y and seal the joint with the tape provided Fig 22 Ensure that the labels marked TOP on the Terminal and Connection Assemblies are uppermost 9 Using the clearance holes in the Connection Assembly secure it to the Terminal Assembly using the screws supplied F
29. United Kingdom en Installation and Service Manual Gas Fired Wall Mounted Condensing System Boiler Megaflo System 15 18 24 28 32 These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping They must be read in conjunction with the Flue Installation Guide Natural Gas Baxi Megaflo 15 System ErP G C N 41 470 18 Baxi Megaflo 18 System ErP G C N 41 470 19 Baxi Megaflo 24 System ErP G C N 41 470 20 Baxi Megaflo 28 System ErP G C N 41 470 21 Baxi Megaflo 32 System ErP G C N 41 470 22 The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information O Baxi Heating UK Ltd 2015 All
30. Voltage at PCB X2 connector is at least 100V DC across terminals 2 amp 5 Note from multimeter connect common to 2 amp volt to 5 Check wiring Check and correct if necessary Ignition electrode and lead 2 Electrode connection 3 Spark gap and position Burner Sensing Electrode Spark Ignition Electrode Electrode Position 46 Baxi Heating UK Ltd 2015 17 0 Fault Finding H k Check supply pressure at the gas valve Minimum 7mbar 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 electrode position Replace PCB Replace flame sensing electrode Flame current should be more than 0 5 u A Overheat thermostat operated or Allow to cool Continuity faulty i e continuity across across thermostat terminals thermostat terminals more than 1 5 ohm Replace safety thermostat Replace PCB Fan connections correct at fan YES Replace fi PCB X401 connector terminals 5 6 7 8 K Temperature sensors faulty Cold resistance approximately 10KQ 25 C CH sensor 20kQ 25 C Flue sensor resistance reduces with increase in temp YES 2 Ir pump is running the heat exchanger could be SEET obstructed O Baxi Heating UK Ltd 2015 47 18 0 Notes 4
31. c Condensing f 7 of Boiler unpressurised 25 Max Min Connections copper tails 15 model kW 162 42 Gas Supply 22mm Temperatures mien Central Heating Flow 22mm Flow Temp adjustable 18 model kW 19 4 45 Central Heating Return 22mm 25 C to 80 C max 5 C 24 model kW 259 74 Pressure Relief Discharge 5mm 28 model kW 30 3 10 2 Outercase Dimensions D iair see 32 model kW 344 10 2 Casing Height 780mm N AEE 415 k 430 k Overall Height Inc Flue Elbow 965mm EE SES S Max Gas Rate Natural Gas G20 Casing Width 450mm Installation Lift Weight 36 4 kg 379 kg After 10 mins Casing Depth 345mm 32 3 meee cn re Clearances Packaged Boiler Carton 43 5 kg 18 mode m h 1 95 Above Casing 200 mm Min Installation Lift Weight 38 4 kg 24 mode mh 2 61 Below Casing 150 mm Min Se 5 31 Front 450 mm Min For Servicing HS H i Front 5 mm Min In Operation 32 mode m h 3 48 LH Side 5 mm Min nr R H Side 5 mm Min In Operation NOTE All data in this section are nominal values Injector Natural Gas G20 This is the MINIMUM recommended dimension and subject to normal production tolerances A greater clearance will aid installation and maintenance 15 mode 4 5mm 18 mode 5 7mm 24 mode 7 5mm 28 mode 12mm 32 mode 12mm Product Characteristics Database SEDBUK Pump Available Head SAP 2009 Annual Efficiency 15 18 24 88 6 28 32 88 6 This value is used in the UK Government s Standard Assessment Procedure SAP for energy
32. e order Spark and Sensing Electrodes Fig 47 Disconnect the electrode leads noting their positions 2 Remove the retaining screws securing each of the electrodes to the combustion box cover and remove the electrodes 3 Check the condition of the sealing gaskets and replace if necessary Reassemble in reverse order 33 Venturi Injector Cover Fig 49 Gas Inlet Pipe Fan Inlet Flange ae ieaS 18 model ONLY Gas Inlet Venturi Injector Collector Fig 48 Fig 50 When fitting the venturi ensure that the arrow is pointing forward 34 O Baxi Heating UK Ltd 2015 13 0 Changing Components Fan Fig 48 Undo the nut on the gas inlet pipe to the venturi Fig 68 and pull the sensing pipe off the fan 2 Disconnect the electrode leads noting their position and di sconnect the fan electrical plugs 3 Undo the screws securing the collector to the extension piece 4 Remove the collector and fan assembly being careful to retain the injector in the venturi 5 Undo the screws securing the fan to the venturi and fit the new fan On 18 models ONLY transfer the fan inlet flange to the new fan Replace the seal if necessary 6 Examine the burner gasket and replace if necessary 7 Reassemble in reverse order ensuring that the injector is in place and the sensing pipe is connected to the fan EE Venturi Fig 49
33. eer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate At max rate Record Record At min rate Where Possible At min rate Where Possible Comments Comments Signature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a H encinar Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 51 O Heating and Hotwater Industry Council HHIC www centralheating co uk Baxi Customer Support 0344 871 1525 Opening hours Monday Friday 8 00am 6 00pm Weekends and Bank Holidays 8 30am 2 00pm Please note calls may be recorded for training and monitoring purposes baxi co uk Register now to activate your warranty www baxi co uk registration For the warranty to be maintained please make sure MI Benchmark checklist is completed B Warranty is registered with Baxi El The boiler has an annual service For full terms and conditions visit www baxi co uk terms Failure to adhere to terms and conditions will void your manufacturer s warranty SE Baxi Ss Brooks House Coventry Road Warwick CV34 4LL benchmar THE MARK OF QUALITY FOR THE IN
34. emove the discharge pipe from the kit 2 Determine the routing of the discharge pipe in the vicinity of the boiler Make up as much of the pipework as is practical including the discharge pipe supplied 3 The pipework must be at least 5mm diameter and run continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPORTANT Make all soldered joints before connecting to the pressure relief valve Condensate Drain see section 7 7 Connect the condensate drain to the trap outlet pipe Ensure the discharge of condensate complies with any national or local regulations in force see British Gas Guidance Notes for the Installation of Domestic Gas Condensing Boilers 2 The connection will accept 21 5mm in plastic overflow pipe which should generally discharge internally into the household drainage system If this is not possible discharge into an outside drain is acceptable 23 Wall Thickness Z Fig 20 TOP Label 24 Baxi Heating UK Ltd 2015 Ke Sealing Tape Fig 22 Terminal Assembly Connection Assembly Fig 19 Wall Thickness Peak to be uppermost 9 0 Installation 19 6 Fitting The Flue HORIZONTAL TELESCOPIC FLUE
35. ent boiler temperature and both green LEDs will flash 5 To set to maximum rate 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 P alternating with the current boiler temperature 7 To set to 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 0 the boiler runs at minimum rate 18 This 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 27 10 0 Commissioning Checking Combustion Follow the flow chart opposite Is O2 2 20 6 and CO2 lt 0 2 Is CO lt 350ppm and CO CO ratio lt 0 004 Is O2 2 20 6 and CO2 lt 0 2 Is CO lt 350ppm and CO CO ratio lt 0 004 Is CO lt 350ppm and CO CO ratio lt 0 004 28 Baxi Heating UK Ltd 2015 Central Heating Temperature Control Fig Selector Switch Display 080 A NY Central Heating 33 y Temperature Control Gas Pressure Test Point Fig 35 Fig 38 Baxi Heating UK Ltd 2015 Gas Valve Calibration Control Calibration Control Fig 34 10 0 Commissioning Check the Operational Working Gas Inlet
36. g 66 Drain the primary circuit and undo the nut on the vessel connection pipe 2 Undo and remove the locknut securing the vessel spigot to EN N the boiler air box Expansion Vessel 3 Remove the bracket and vessel from the boiler 4 Locate the retaining bracket on the upper flange of the vessel and fit to the boiler 5 Reassemble in reverse order Boiler Chassis Baxi Heating UK Ltd 2015 39 14 0 Setting the Gas Valve Setting the Gas Valve CO check IMPORTANT The CO 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 14 1 Central Heating Calibration Temperature Control Fig 67 Control The combustion CO may be checked after running the Selector Switch Display boiler for several minutes To do this it is necessary to se Z the boiler to Calibration Mode d y DO x sg 3 Turn both control knobs fully anticlockwise then quickly 2 Ensure that all external controls are calling for heat The actual current boiler temperature is shown on the display 7 ms turn the right hand knob 4 clockwise twice and back fully Central Heating Calibration Control anticlockwise Fig 67 Temperature Control 4 The display will now alternate between SF and the current boiler temperature and bo
37. g maintain the temperature set Go to section M YES Pump continues to run for 3 YES YES P s Bamergoeso His Fan stops after 10 seconds minutes Operation SS room thermostat open PERS 44 Baxi Heating UK Ltd 2015 17 0 Fault Finding Fault Finding Solutions Sections A Is there 230V at Main terminals L and N ES 2 NO NO Eed Check electrical supply Replace fuse Check wiring Display illuminated Replace PCB PCB XI connector terminals 2 B Is there 230V at Check incoming wiring Re pressurise system Check connection water pressure switch terminal YES Replace water COM NO and PCB connector pressure switch X400 terminals 3 4 2 ic air NO ee Check the tap of the automatic air Open the automatic air vent vent is opened D i Fan connections correct at fan PCB X2 connector is 230V AC across Fan jammed or faulty winding terminals 5 amp 7 YES Replace fan Replace PCB Baxi Heating UK Ltd 2015 45 17 0 Fault Finding E Temperature sensors faulty Cold resistance approximately 10kQ 25 C DHW and CH sensors 20kQ 25 C Flue sensor resistance reduces with increase in temp Check and correct the connection of the tube between the venturi and gas valve 2 Ensure gas is on and purged PCB X3 connector is 230V AC across terminals amp 2 NO Replace PCB Replace gas valve
38. h extended external run amp race heating It is strongly recommended to discharge internally into the household drainage system If connecting to a rain water drain that drain MUST discharge into a foul drain 21 5mm vent pipe 450mm min up e g sink design are referred to Baxi Heating UK Ltd 2015 A 450mm is applicable to properties 32mm Insulation i Termination to an internal soil and AAA to 3 storeys For multi storey building installations consult BS 6798 ii External termination via internal discharge branch waste downstream Pipe must terminate above water level but below surrounding surface Cut end at 45 zb is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle iii Termination to a drain or gully Pipe must terminate above water level but below surrounding surface Cut end at 45 iv Termination to a purpose made soakaway Further specific requirements for soakaway in BS 6798 Lg 500mm min Holes in the soak away must face away from the building 7 0 Site Requirements Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER CAREFUL CONSIDERATION MUST BE GIVEN TO THE POSSIBILITY OF THE PIPEWORK BEING SUBJECT TO FREEZING CONDITIONS AND APPROPRIATE MEASURES TAKEN TO PREVENT BLOCKAGE CORRECT INSTALLATION
39. he maximum CH temperature is exceeded 10 The function can be disabled at any time by turning the Calibration Control knob 1 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance 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 12 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with LS 813 An example of this is given in LS 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 29 Facia Panel 30 Baxi Heating UK Ltd 2015 Case Front Panel Fig 40 11 0 Completion Ea Completion Instruct the user in the operation of the boiler and system including external controls explaining the operational sequence 2 Set the central heating and hot water temperature control knobs to the requirements of the user 3 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance 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
40. he new valve and O ring seal and set to the previously noted orientation Reassemble in reverse order EX P C B Fig 62 Note the settings of the temperature control knobs rotate them fully anticlockwise and carefully pull them off the drive pins 2 Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pin Fig 82 3 Note the position of all plugs and wires on the P C B and disconnect them 4 Undo the securing screws and remove the P C B Transfer the control knob drive pins to the new P C B and turn them fully anticlockwise Fig 62 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions d e N i Drive Pins EAE Selector Switch Fig 63 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pin Fig 82 3 Note the position of the electrical connections and the Facia orientation of the switch Remove the electrical connections 4 Remove the screws securing the switch to the facia panel Selector Switch Knob gt i 5 Fit the new switch ensuring that it is correctly positi
41. hort Circuit and Polarity with a suitable meter NOTE These checks must be repeated after any servicing or fault finding 6 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 17 2 Error Codes If a fault occurs on the boiler an error code may be shown by the facia display 2 The codes are either two or three digit preceded by the etter E For example code EI 33 will be displayed by EI alternating with 33 E20 is shown as E then 20 E20 and E28 indicate faulty components El 10 shows overheat of the primary water and El 30 overheat of the flue system El 19 is displayed when the primary water pressure is less han 0 5 bar 33 indicates that the gas supply has been interrupted ignition has failed or the flame has not been detected E125 is displayed in either of two situations i If within 15 seconds of the burner lighting the boiler emperature has not changed by 1 ii If within 10 minutes of the burner lighting the boiler emperature twice exceeds the selected temperature by 30 n these instances poor primary circulation is indicated 3 By turning the selector switch to the Reset position for a minimum of 5 seconds when El 10 E130 amp E133 are displayed it is possible to relight the boiler 4 If this does not have any effect or the
42. ig 23 Flue Elbow Apply Lubricant for ease of assembly Ensure Elbow is fully engaged into Boiler Adaptor Fig 24 Apply the lubricant supplied for ease of assembly do not use any other type Ensure Flue is fully engaged into Elbow Fig 25 Flue to elbow securing screws Elbow to adaptor securing screws Slots at bottom O Baxi Heating UK Ltd 2015 9 0 Installation 96 Fitting the Flue Cont 0 Remove the flue elbow and insert the flue through the hole in the wall Refit the elbow to the boiler adaptor ensuring that it is pushed fully in Fig 24 2 Two flue trims are supplied one for internal use the other for outside The internal trim is packaged and identified as such it should not be used externally 13 It is recommended that if the internal trim is being used it is first fitted over the elbow to allow access to the securing screws and then manouvered into place against the wall 14 Draw the flue back through the wall and engage it in the elbow It may be necessary to lubricate to ease assembly of the elbow and flue Fig 25 15 Ensure that the terminal is positioned with the slots to the bottom Fig 26 Secure the flue to the elbow with the screws supplied Fig 25 16 Secure the elbow flue to the boiler adaptor with the screws supplied in the boiler fittings pack Fig 25 IMPORTANT It is essential that the flue
43. ion 13 24 amp re check Annual Servicing Inspection Ensure that the boiler is cool 2 Ensure that both the gas and electrical supplies to the boiler are isolated 3 Slacken the screws securing the facia panel Lift the outercase panel so that its securing tabs are clear of the facia Remove the panel allowing the facia to hinge down Fig 41 4 Remove the screws securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 42 5 Unscrew the sump from the bottom of the condensate trap assembly Fig 43 and remove any deposits from the sump and trap Clean as necessary and replace the sump 31 sl SZ S Z Burner Z ZS EE A Z Z e Sensing Electrode Spark Ignition Y Electrode 9 N Fan Collector and Cover Assembly Electrode Leads Injector Gas Inlet Pipe Fig 45 32 O Baxi Heating UK Ltd 2015 12 0 Servicing d Annual Servicing Inspection Cont 6 Undo the nut on the gas inlet pipe to the venturi Fig 45 and pull the sensing pipe off the fan 7 Disconnect the electrode leads noting their position and he fan electrical plugs Fig 44 8 Undo to the heat exchanger he four nuts retaining the combustion box cover 9 Carefully draw the fan collector and cover assembly forward being careful to retain the injector in the venturi Figs 44 amp 45 0
44. mount of water may drain from the boiler in the upright position See section Safe Manual Handling before unpacking or lifting the boiler RISK ASSESSMENT Before commencing the installation it is recommended that the Five Steps to Risk Assessment document published by the HSE is consulted and an assessment performed as described 2 Follow the procedure on the carton to unpack the boiler or see Fig 13 3 If pre plumbing Fig 14 the wall jig and fitting kit can be removed without removing the carton sleeve Simply slide banding to the edge and open the perforated flap lift out he jig fitting kit and instructions If the boiler is to be installed at a later date close the flap and reposition the banding straps the boiler can now be stored safely away 4 After considering the site requirements see Section 7 0 position the fixing template on the wall ensuring it is level both horizontally and vertically 5 Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes It is preferable to use the vertical fixing slots 6 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 15 7 If required mark the position of the gas and water pipes Remove the template 8 Cut the hole for the flue minimum diameter 6mm 9 Drill the wall as previously marked to accept the wall plugs supplied Sec
45. ndard horizontal telescopic flue kit is not included in any equivalent length calculations NOTE Flue length is measured from point X to Y as shown IMPORTANT SUPPORT All flue systems MUST be securely supported a MINIMUM of once every metre It is recommended that every straight piece is supported irrespective of length Additional supports are available as accessories VOIDS Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual inspection 6 Read this section in conjunction with the Flue Installation Guide supplied with the boiler Fig 11 Ensure that no part of the white outer chimney duct is visible Baxi Heating UK Ltd 2015 Flue Deflector FIT Flue Accessories amp Fitting Guide 60 100 Flue Systems ster ms Kit 60 100 Fue Stems Fig 12a 8 0 Flue Options Flue Lengths The standard horizontal telescopic flue kit allows for lengths between 315mm and 500mm from elbow to terminal without the need for cutting Fig 1 Extensions of 250mm 500mm amp Im are available The maximum permissible equivalent flue length is 10 metres 60 100 system vertical amp horizontal 20 metres 80 125 system vertical amp horizontal 15 metres 80 80 twin pipe Flue Trim The flexible flue trims supplied can be fitted on the outer and inner faces of the wall of ins
46. ng 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 ETC rules for electrical installation All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Codes of Practice refer to the most recent version In GB the following Codes of Practice apply Standard Scope BS 689 Gas Installation BS 5546 Installation of hot water supplies for domestic purposes BS EN 12828 Heating systems in buildings BS EN 14336 Installation amp commissioning of water based heating systems BS 6798 Installation of gas fired hot water boilers BS 5440 Part Flues 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 In IE the following Codes of Practice apply Standard Scope LS 813 Domestic Gas Installations The following standards give valuable additional information BS 5546 Installation of hot water supplies for domestic purposes
47. ng surface Cut end at 45 7 0 Site Requirements Condensate Drain cont 2 A boiler discharge pump is available MULTIFIT part no 720648301 This pump will dispose of both condensate amp high temperature water from the relief valve It has a maximum head of 5 metres Follow the instructions supplied with the pump 3 Condensate Drain Pipe Trace Heating Elements are available in various lengths MULTIFIT part nos metre 72064440 1 2 metre 720664101 3 metre 720664201 5 metre 72066440 1 Where the drain is between 3 amp 5 metres a 5 metre kit can be used and doubled back upon itself 14 It is possible to fit the element externally on the condensate drain or internally as detailed in the instructions provided 15 The fitting of a Trace Heating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to vii to a drain or gully with extended external run amp trace heating The Trace Heating element must be installed in accordance with the instructions supplied External runs amp those in unheated locations still require insulation Pipe must terminate above water level but below surrounding surface Cut end at 45 Terminal Position with Minimum Distance Fig 9 Al Directly below an opening air brick opening windows etc 300 B Above an opening air b
48. nsion Vessel DO AN AYN E amp NN O Return Temperature Sensor N o Fan O Baxi Heating UK Ltd 2015 9 4 0 Technical Data Megaflo 15 18 24 28 amp 32 System ErP Appliance Type Cis C33 Lo Inlet Pressure Natural Gas G20 NO Class 3 mbar 20 Appliance Category CAT 2H RRE a Central Heating Primary Circuit Or Electrical Supply 230V 50H Pressures Heat Input Qn Hs Gross Max Min Appliance must be connected to an bar 15 model kW 17 1 44 earthed supply Safety Discharge 3 Max Operating 2 5 18 model kW 20 5 4 8 Power Consumption Min Operating 05 24 model kW 274 78 a Ge rue Recommended Operating Range 1 2 mode 28 model kW 32 0 8 Keier 24 model 115 W Pump 32 model kW 36 4 0 8 28 amp 32 models 125 W Available Head See graph below Heat Output Pa Non Condensing Electrical Protection Expansion Vessel DE appliance Max in IPX5D S es Min Pre charge Pressure 0 5 15 model W 15 0 39 External Fuse Rating 3A 18 model W 18 0 4 2 Internal Fuse Rating F2L litre 24 model W 24 0 6 8 Condensate Drain Max Capacity of 28 model AN 28 0 94 To accept 21 5mm s in plastic waste pipe CH System 125 SH For greater system capacities an additional 32 model W 32 0 94 Flue Terminal Diameter 100mm expansion vessel MUST be fitted Dimensions Projection 125mm Primary Water Content Heat Output Pn
49. o 25 litres For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt For IE the current edition of I S 813 Domestic Gas Installations 16 6 Safety Pressure Relief Valve Fig 4 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 15mm 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 4 A remote relief valve kit is available to enable the boiler to be installed in cellars or similar locations below outside ground level kit no 5121379 7 0 Site Requirements Location 175mm Min The boiler may be fitted to any suitable wall with the flue 300mm Min if passing through an outside wall or roof and discharging to using 80 125mm atmosphere in a position permitting satisfactory removal of flueing system combustion products and providing an adequate air supply i
50. o prevent sagging 6 It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres 7 Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe 8 External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external use 9 If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly 10 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used and any burrs on cut pipe removed When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC s are flushed or sinks emptied then back pressure may force water out of the boiler trap and cause appliance lockout v pumped into an internal discharge branch e g sink waste downstream of the trap Basement or similar heated f Boiler Condensate Pump vi pumped into an external soil amp vent pipe Unheated Location e g Garage Basement or similar heated 1 Condensate Pump 18 O Baxi Heating UK Ltd 2015 MM per Metre of Pipe must terminate above water level but below surroundi
51. oned and Fig 63 Temperature Control Knobs reassemble in reverse order 38 Baxi Heating UK Ltd 2015 Venturi Inlet 13 0 Changing Components a CPL Pipe EP Gas Valve Fig 64 Gas Valve E IMPORTANT After replacing the valve the CO must be checked and adjusted as detailed in Section 14 0 Setting the Gas Valve Only change the valve if a suitable calibrated combustion analyser is available operated by a competent person see section 12 1 Turn the gas cock off and undo the nut on the gas feed elbow under the boiler 2 Remove the screws securing the inlet pipe flange to the boiler bottom panel ae D Earth Lead 3 Pull off the earth lead and sensing pipe Gas Feed 4 Undo the nut on the venturi inlet pipe and slacken the nut Elbow on the venturi Ease the pipe aside and remove the gas valve 5 Remove the outlet adaptor and inlet pipe and transfer them to the new valve Examine the O ring seals replace if Fig 64 necessary 6 Reassemble in reverse order Throttle Adjustment Screw NOTE To assist the boiler to light prior to final setting a use a suitable hexagon key to wind out the Throttle Adjustment Screw until it is flush with the valve body then turn the screw 4 full turns clockwise Fig 65 If the boiler will not light or the correct CO2 cannot be achieved contact the heateam technical helpline EA Expansion Vessel Fi
52. ontrol of the boiler thermostat amp TRW s only does not produce the best results Baxi Heating UK Ltd 2015 13 Double StOP Check Stop Valve Valve Valve I Ns ERE Mains Temporary Cold Hose Inlet Fig 3 Pressure Relief Valve Discharge Pipe 14 O Baxi Heating UK Ltd 2015 6 0 System Details System Filling and Pressurising 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 for GB Guidance G24 2 and recommendation R24 2 of the Water Regulations Guide for IE the current edition of l 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 Expansion Vessel The appliance expansion vessel is pre charged to 0 5 bar Therefore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up t
53. rick opening window etc 300 C Horizontally to an opening air brick opening window etc 300 D2 Below gutters soil pipes or drain pipes 25 75 E2 Below eaves 25 200 F2 Below balconies or car port roof 25 200 G2 From a vertical drain pipe or soil pipe 25 150 H2 From an internal or external corner 25 300 Above ground roof or balcony level 300 From a surface or boundary line facing a terminal 600 K From a terminal facing a terminal Horizontal flue 200 From a terminal facing a terminal Vertical flue 600 L From an opening in carport e g door window into the dwelling 200 Vertically from a terminal on the same wall 500 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 000 T Adjacent to windows or openings on pitched and flat roofs 600 U Below windows or openings on pitched roofs 2000 In 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 2 Only ONE 25mm clearance is allowed per installation If one of the dimensions D E F G or H is 25mm NOTE The distance then the remainder MUST be as B S 5440 1 from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below
54. 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 ofthe proposed use to the following address The Company Secretary Baxi Heating UK Limited Brooks House Coventry Road Warwick CV34 4LL 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 CE zs 2 Baxi Heating UK Ltd 2015 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 directly Similar arrangements will follow for Scotland and will apply in Northern Ireland from January 2006 The Health 8 Safety Executive operates the Gas
55. rnal control MUST be suitable for 230V switching and fused 3A maximum 6 Remove the link between terminals amp 2 The switched output from the external control must be connected to terminal 2 Fig 29 7 Ensure that the external control input cable s have sufficient slack to allow the control box to drop down Tighten the cable clamp on the boiler chassis 8 Replace the terminal block cover routing the external control input cable s through the second cut out 98 Preliminary Electrical Checks Prior to commissioning the boiler preliminary electrical system checks should be carried out 2 These should be performed using a suitable meter and include checks for Earth Continuity Resistance to Earth Short Circuit and Polarity Automatic Air Fig 30 Pump Selector Switch Fig 31 Display Central Heating Calibration Control Fig 32 Temperature Control Pressure Gauge Baxi Heating UK Ltd 2015 10 0 Commissioning EU Commissioning the Boiler Reference should be made to BS EN 12828 amp 14336 when commissioning the boiler 2 At the time of commissioning complete all relevant sections of the Benchmark Checklist at the rear of this publications 3 Ensure that the filling loop is connected and open then open the heating flow and return valves on the boller 4 Open the screw on the automatic air vent on the pump body Fig 30 IMPORTANT Ifthe
56. rvicing Purposes In Operation Fig 6 Baxi Heating UK Ltd 2015 IS Gas Service Cock Fig 7 Zone 2 LL Window Recess Window Recess Zone 2 a In GB Only Ceiling Window Recess Outside Zones ee 0 6m Fig B In GB Only 16 Baxi Heating UK Ltd 2015 7 0 Site Requirements Ventilation of Compartments 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 Gas Supply The gas installation should be in accordance with the relevant standards In GB this is BS 6891 In IE this is the current edition of LS 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 Electrical Supply External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current LEE Wiring Regulations In IE reference should be made to the current edition of ETCI rules 2 The mains supply is 230V
57. ssible CO ppm CO CO The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer 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 pen Amar Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 50 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 Interval 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
58. tallation Terminal Guard Fig 12 When codes of practice dictate the use of terminal guards Multifit accessory part no 720627901 can be used Note This is not compatible with Flue Deflector referred to below 2 There must be a clearance of at least 50mm between any part of the terminal and the guard 3 When ordering a terminal guard quote the appliance name and model number 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated Flue Deflector Push the flue deflector over the terminal end It may point upwards as shown or up to 45 either way from vertical Secure the deflector to the terminal with screws provided 86 Flue Accessories Fig 12a For full details of Flue Accessories elbows extensions clamps etc refer to the Flue Installation Guide supplied in the literature pack 21 Pre plumbing r To remove only the wal banding to the edge and Fig 14 For Side Flue Exit Fig 15 Flushing Tube Central Heating Return 22 Baxi Heating UK Ltd 2015 jig slide open flaps Fig 16 Ze LIFT HERE BOTH SIDES Slide the wall jig out of carton then close the flaps Slide banding back on 9 0 Installation EN Unpacking amp Initial Preparation The gas supply gas type and pressure must be checked for suitability before connection see Section 7 4 NOTE a small a
59. tart 0000060900000 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 19 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 Frost Protection Mode The frost protection mode is integral to the appliance and functions when the selector switch see Section 2 1 is in the ON position MIE Ifthe 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 EL D 8 can be incorporated by using a system frost thermostat Pump Protection With the selector switch see Section 2 1 in the ON Y 0 12 position MIE the pump will automatically operate for minute in every 24 hours to prevent sticking Key Fig 2 Heat Exchanger Burner gnition Electrode Flame Sensing Electrode Gas Valve Pump Automatic Air Vent Pressure Relief Valve D MAN AUNT w NN Boiler Drain Point Gas Inlet Boiler Flow Boiler Return Pressure Gauge Automatic By Pass Water Pressure Sensor Safety Thermostat Temperature Sensor Expa
60. terminal is fitted as shown to ensure correct boiler operation and prevent water entering the flue 17 Make good between the wall and air duct outside the building appropriate to the wall construction and fire rating 18 If necessary fit a terminal guard see Section 8 4 25 Cable Clamp Fig 28 Terminal Block Cover Facia Panel Always fit fast blow 2A fuse pese Rs R e 230V Ge Fused supply 3A N bk 230V 50Hz EEE Earth green yellow gy Fuses Neutral blue Live brown Fig 29 Terminal Block 26 Baxi Heating UK Ltd 2015 9 0 Installation Making The Electrical Connections The boiler is fitted with a 1 3m length of 3 core of cable This can be connected to the fused 3A 230V 50Hz supply NOTE Both the Live and Neutral connections are fused To connect an external control proceed as follows Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia Remove the panel 2 Completely undo the screws securing the facia panel and hinge it down Fig 27 3 Undo the terminal block cover securing screw and remove the cover Fig 27 4 Slacken the unused cable c boiler chassis Fig 28 Insert through the clamp and route amp on the LH side of the he external control wiring it to the terminal block 5 Refer to the instructions supplied with the control IMPORTANT The exte
61. th green LEDs will flash Figs 68 amp 69 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 P alternating with the current boiler temperature Figs 70 71 amp 72 7 Remove the plug from the flue sampling test point Insert the analyser probe and allow sufficient time for the reading Fig 70 Fig 71 Fig 72 to settle Fig 73 The CO should be 8 7 0 2 Flue Adaptor Test 8 It is possible to alter the CO by adjustment of the gas Plug valve Remove the plastic cover from the Throttle Adjustment Screw At maximum rate the Throttle Adjustment Screw should be turned using a suitable Analyser Probe hexagon key until the correct reading is obtained Fig 74 Turning clockwise will reduce the CO Anticlockwise will increase the CO Offset Throttle 9 The CO must then be checked at minimum rate Turn ee add Adjustment Screw the left hand knob fully anti clockwise As the knob is turned cover removed the display will change indicating the fan speed When the display reads OI the boiler runs at minimum rate The CO should be 8 4 0 2 10 With the boiler on minimum the Offset Adjustment Cy Screw must be altered using a suitable hexagon key after Reduce CO Increase CO2 removing the cap Fig 74 Turning anti clockwise will reduce at max rate
62. the boiler is installed at a high point in the system it is strongly recommended that Automatic Air Vent Kit 7200047 Ol is fitted Contents of Pack The pack contains Boiler e Wall Plate including taps e Set of Pipe Connections e Template amp Quick Fit Guide e Literature Pack CB Central Heating System Pressure Gauge Expansion Vessel Automatic Air Vent Circulation Pump Drain Off Point Pressure Relief Valve Selector Switch Control Box 2 0 General Layout P Layout l 2 3 4 5 6 7 8 9 0 2 9 ca S 2 5 Es p Ce 00 v T nN o D 3 amp s g 2 es al p E o U u FD O o U LE O a 0 g o E S o x D ce Do X mn D e 0 E op E wo H ei amp A sa Dn o H E 3 9 R U 2 e 1 4 D 9 Gg 0 e o 0 c 0 S B 1 0 T ge 1 9 Uz o I Kai a ua D E z zz n 3 EN 9 oN E 26 EES 8 B54 bE B 5 E O 4 456 FR Ec ER RS SS SZ Ess D TE o 5 a 5 SCH O On Fa JO OU gt lt a cl M Own D N BAH o un A N A A A A KS CAS y 2 o ff Silo 18 17 O Baxi Heating UK Ltd 2015 8 3 0 Appliance Operation Operating Mode Fig 2 Boiler Primary Circuit With a demand for heating or hot water the pump circulates water through the primary circuit H the pressure is at least 0 5 bar and the ignition sequence will s
63. ue i Ma Fig 8 SE I Property Boundary Line JK A s mA Air Inlet _ Opening Window R Likely flue positions requiring a flue terminal guard Fig 9 Baxi Heating UK Ltd 2015 Plume Displacement Kit 60 100 dia IM Extensions 45 amp 93 elbows are also available Horizontal Flues NOTE Horizontal flue pipes should always be installed with a fall of at least 5 from the terminal to allow condensate to run back to the boiler This bend is equivalent to metre This bend is equivalent to metre Total equivalent length A B C 2 x 90 Bends 20 O Baxi Heating UK Ltd 2015 8 0 Flue Options EU Horizontal Flue Systems The standard flue is suitable only for horizontal termination applications 2 All fittings should be fully engaged The approximate engagement is 40mm Apply the lubricant supplied to the seal on each fitting to aid assembly 3 Maximum permissible equivalent flue lengths are 60 100 80 125 Horizontal Concentric 10 metres 20 metres 4 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 5 The elbow supplied with the sta
64. ure the wall plate using the fixing screws 10 Using a spirit level ensure that the plate is level before finally tightening the screws Connect the gas and water pipes to the valves on the wall plate using the copper tails supplied Ensure that the sealing washers are fitted between the connections Flushing Connect a tube to the central heating flow or return pipe Fig 16 2 Flush thoroughly see System Details Section 6 2 Remove Sealing Caps from under the Boiler after lifting into position Fig 17 Pressure Relief Valve Fig 18 Discharge Pipe Baxi Heating UK Ltd 2015 Bo Lit Here h Sides Sealing t Washers 9 0 Installation Fitting The Boiler Fig 17 Remove the sealing caps from the boiler connections NOTE A small amount of water may drain from the boiler once the caps are removed 2 Lift the boiler as indicated by the shaded areas and the bottom polystyrene The boiler should be lifted by TWO PEOPLE Engage the slots at the top rear of the boiler on the wall plate see Safe Manual Handling page 5 3 Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections 4 Tighten all the connections Fitting the Safety Pressure Relief Discharge Pipe Fig 18 R
65. ways 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 welght is concentrated to establish the centre of gravity repositioning yourself as necessary See the installation section of these instructions for recommended lift points Remember The circumstances of each installation are different Always assess the risks associated with handling and lifting according to the individual conditions If at any time when installing the boiler you feel that you may have injured yourself STOP DO NOT work through the pain you may cause further injury IF INANY DOUBT DO NOT HANDLE OR LIFT THE BOILER OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING Baxi Heating UK Ltd 2015 5 CONTENTS Section Page 1 0 Introduction 7 2 0 General Layout 8 3 0 Appliance Operation 9 4 0 Technical Data 0 5 0 Dimensions and Fixings 2 6 0 System Details 3 7 0 Site Requirements 5 8 0 Flue Options 20 9 0 Installation 22 10 0 Commissioning 27 11 0 Completion 30 12 0 Servicing 31 13 0 Changing Component 33 14 0 Setting the Gas Valve 40 15 0 Electrical 41 16 0 Short Parts List 42 17 0 Fault Finding 43 18 0 Notes 48 Benchmark Checklist 50 Baxi Heating UK Ltd 2015 Control Box Fig
66. will fit each terminal Flow Pipe ee EALE Central Heating Temperature Sensor NTC Fig 54 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way EMMY Safety Thermostat Fig 54 Pull the plug off the thermostat 2 Remove the screws securing the thermostat to the mounting plate on the flow pipe 3 Reassemble in reverse order ensuring that the plug is pushed fully on EMP Return Heating Temperature Sensor Fig 56 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Prise the sensor retaining clip off the pipe and remove the sensor from the clip 3 Reassemble in reverse order Return Heating Temperature Sensor Fig 56 36 Baxi Heating UK Ltd 2015 13 0 Changing Components EME Pump Head Only Fig 57 Drain the boiler primary circuit and disconnect the electrical plug from the pump motor 2 Remove the socket head screws securing the pump head to the body and draw the head away 3 Reassemble in reverse order EME Pump Complete Fig 58 Drain the boiler primary circuit and disconnect the electrical plug from the pump motor 2 Undo the two screws securing the body to the pipe and manifold and draw the pump forwards
67. within the system which can lead to damage of system components All systems must be thoroughly drained and flushed out using for example Sentinel X300 or X400 or Fernox F3 They should be used following the flushing agent manufacturer s instructions e System additives corrosion inhibitors and flushing agents descalers should comply to BS7593 requirements e g Sentinel X100 and Fernox MB which should be used following the inhibitor manufacturer s instructions e 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 e 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 e For information or advice regarding any of the above contact Baxi Customer Support 0344 871 1525 Bypass The boiler is fitted with an automatic integral bypass System Control 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 c

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