Supplied by HeatingSpares247.com Installation & Servicing Instructions Baxi Megaflo System HE IE Range Gas Fired Wall Mounted Condensing Boiler These instructions include the Commissioning Checklist and should be left with the user for safe keeping.
Supplied by HeatingSpares247.com Natural Gas Baxi Megaflo System 15 HE IE Baxi Megaflo System 18 HE IE Baxi Megaflo System 24 HE IE Baxi Megaflo System 28 HE IE Baxi Megaflo System 32 HE IE Propane Gas Baxi Megaflo System 24 HE IE LPG Baxi Megaflo System 28 HE IE LPG © Baxi Heating UK Ltd 2011 All rights reserved.
Supplied by HeatingSpares247.com Legislation IMPORTANT - Installation, Commissioning, Service & Repair This appliance must be installed in accordance with the manufacturer’s instructions and the regulations in force. Read the instructions fully before installing or using the appliance. The installation must be carried out by a competent person as stated in I.S. 813 “Domestic Gas Installations”.
Supplied by HeatingSpares247.com Safe Manual Handling General The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance. Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health & Safety is the responsibility of EVERYONE. There is no ‘safe’ limit for one man - each person has different capabilities.
Supplied by HeatingSpares247.com CONTENTS Section © Baxi Heating UK Ltd 2011 Page 1.0 Introduction 6 2.0 General Layout 7 3.0 Appliance Operation 8 4.0 Technical Data 9 5.0 Dimensions and Fixings 11 6.0 System Details 12 7.0 Site Requirements 14 8.0 Flue Options 18 9.0 Plume Displacement 23 10.0 Installation 27 11.0 Commissioning 32 12.0 Completion 34 13.0 Servicing 35 14.0 Changing Components 37 15.0 Setting the Gas Valve 45 16.0 Electrical 46 17.
Supplied by HeatingSpares247.com 1.0 Introduction 1.1 Description 1. The Baxi Megaflo System HE IE is a fully automatic gas fired wall mounted condensing system boiler. It is room sealed and fan assisted. Case Front Panel 2. The boiler is set to give a maximum output of :15 models - 15 kW 16.2 kW (Condensing) 18 models - 18 kW 19.4 kW (Condensing) 24 models - 24 kW 25.9 kW (Condensing) 28 models - 28 kW 30.3 kW (Condensing) 32 models - 32 kW 34.4 kW (Condensing) 3.
Supplied by HeatingSpares247.com 2.0 General Layout 2.1 Layout 22 1 14 21 13 12 20 15 19 6 9 8 7 11 1. Expansion Vessel 2. Automatic Air Vent 3. Circulation Pump 4. Drain Off Point 5. Pressure Relief Valve 6. Selector Switch 7. Central Heating System Pressure Gauge 8. PCB 9. Control Box 10. Gas Valve 11. Condensate Trap 12. Flame Sensing Electrode 13. Spark Electrode 14. Primary Heat Exchanger 15. Fan Assembly 16. On/Off/Reset Selector Switch 17.
Supplied by HeatingSpares247.com 3.0 Appliance Operation 3.1 Operating Mode (Fig. 2) Boiler Primary Circuit 1. With a demand for heating or hot water, the pump circulates water through the primary circuit. If the pressure is at least 0.2 bar the ignition sequence will start. 1 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. 2 20 18 3 3.
Supplied by HeatingSpares247.com 4.0 Technical Data 4.1 Appliance Type C13 Appliance Category C33 C53 CAT I 2H Heat Input (Net) Max Min 15 model kW 15.4 4 18 model kW 18.5 4.3 24 model kW 24.7 7 28 model kW 28.9 9.7 32 model kW 32.8 9.7 Inlet Pressure (Natural Gas - G20) mbar 20 NOx Class Power Consumption 15 model 18 model 24 model 28 & 32 models Max Min 17.1 4.4 18 model kW 20.5 4.8 24 model kW 27.4 7.8 28 model kW 32.1 10.8 32 model kW 36.4 10.
Supplied by HeatingSpares247.com 4.0 Technical Data 4.2 Appliance Type C13 C33 C53 Appliance Category CAT I I 2H3P Power Consumption 24 LPG model 28 LPG model Heat Input (Net) Electrical Protection Max Min 24 LPG model kW 24.7 7 28 LPG model kW 28.9 9.7 Heat Input (Gross) Max Min 24 LPG model kW 27.4 7.8 28 LPG model kW 32.1 10.8 Heat Output (Non-Condensing) Max Min 24 LPG model kW 24 6.8 28 LPG model kW 28 9.4 Max Min kW 25.9 7.4 28 LPG model kW 30.3 10.
Supplied by HeatingSpares247.com 5.0 Dimensions and Fixings Dimensions At least 1.5° G A 780mm E B 345mm C 450mm D 116mm Ø Min. A E 185mm (207mm for 80/125mm flue systems) F 145mm G 131mm B H 180mm 360° Orientation H D C Flue Ø 100mm F Tap Rail 32.
Supplied by HeatingSpares247.com 6.0 System Details 6.1 Central Heating Circuit 1. The appliance is intended for fully pumped sealed systems. However it can be installed in ‘semi-sealed’ systems also. Treatment of Water Circulating Systems • All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied.
Supplied by HeatingSpares247.com 6.0 System Details 6.4 Stop Valve Double Check Valve Mains Cold Water Sealed Systems 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. Stop Valve Temporary Hose System Filling and Pressurising CH Return 2. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment. 3.
Supplied by HeatingSpares247.com 7.0 Site Requirements 450mm 5mm Min 5mm Min 7.1 200mm Min (300mm Min if using 80/125mm flueing system) Location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e.
Supplied by HeatingSpares247.com 7.0 Site Requirement 7.3 Gas Service Cock Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. The appliance will run sufficiently cool without ventilation. 7.4 Gas Supply 1. The gas installation should be in accordance with the relevant standards. In IE this is the current edition of I.S. 813 “Domestic Gas Installations”. 2.
Supplied by HeatingSpares247.com 7.0 Site Requirements Termination to an internal soil and vent pipe Boiler 50mm per me tre of 2.5° M inimum 7.7 Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run. pipe ru n fall 1. The condensate outlet will accept 21.
Supplied by HeatingSpares247.com Terminal Position with Minimum Distance (Fig. 9) (mm) A1 Directly below an opening, air brick, opening windows, etc. B1 Above an opening, air brick, opening window etc. C1 Horizontally to an opening, air brick, opening window etc. D2 Below gutters, soil pipes or drain pipes. E2 Below eaves. F2 Below balconies or car port roof. G2 From a vertical drain pipe or soil pipe. H2 From an internal or external corner. I Above ground, roof or balcony level.
Supplied by HeatingSpares247.com 8.0 Flue Options 8.1 (ii) Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination applications. 2. All fittings should be fully engaged. The approximate engagement is 40mm. Apply soap solution to the seal on each fitting to aid assembly. (i) 3.
Supplied by HeatingSpares247.com Vertical Flues 8.0 Flue Options 8.2 (ii) Twin & Vertical Flue Systems 1. Maximum permissible equivalent flue lengths are:(i) (60/100) 10 metres 15 metres Vertical Concentric Vertical Twin Pipe IMPORTANT: All flue systems must be securely supported at least once every metre. Suitable pipe supports are available as accessories. (80/125) 20 metres 2. Any additional “in line” bends in the flue system must be taken into consideration.
Supplied by HeatingSpares247.com 8.0 Flue Options 8.
Supplied by HeatingSpares247.com 8.0 Flue Options 8.4 Air Duct Connection Twin Flue Duct Adaptor 1. The kit allows connection of a twin flue system to the boiler adaptor. Flue Duct Connection 8.5 Twin Flue Connection 1. Engage the twin flue duct adaptor in the boiler adaptor, making sure that it is pushed down as far as possible. 2. Ensure that the air & flue ducts are connected correctly and that they are adequately supported (at least once every metre using the available pipe supports).
Supplied by HeatingSpares247.com 8.0 Flue Options 8.6 1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make an aperture in the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained. The adjustable plastic collar can either be positioned on the lead tile or the lower tube of the roof terminal prior to the final positioning of the vertical flue through the tile.
Supplied by HeatingSpares247.com 93° Elbow/Plume Outlet Assembly 9.0 Plume Displacement 9.1 60Ø Support Bracket O Ring Kit No 5118638 Content of kit 1 0.9m 60/100 Concentric Flue 1 1m 60 Dia Exhaust Flue Pipe 1 Adaptor 2 60 Dia Support Brackets 1 93° Elbow/Plume Outlet Assembly 1 Flexible Flue Trim 3 “O” Rings 1 ‘Jubilee Clip 1 Elbow 0.9 metres 60Ø Exhaust Flue Pipe 60Ø Support Bracket O Ring Fig. 13 Plume Displacement Kit (Fig. 14) Flexible Flue Trim 1.
Supplied by HeatingSpares247.com 9.0 Plume Displacement 9.2 16 14 12 60 Ø Exhaust (metres) X 60 Ø Exhaust (metres) X 14 15/1 8 10 24 8 6 4 12 8 24 8 6 28/ 32 2 0 In the graph the solid line diagonal represents the relationship between the concentric flue assembly (and any extensions) and the 60Ø exhaust (and any extensions or additional bends).
Supplied by HeatingSpares247.com 9.0 Plume Displacement 9.3 General Fitting Notes 1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall back to the boiler at an angle of at least 1.5°. 2. When completed the terminal must be at least 2 metres above ground level (Fig. 19). Min. 2 metres 3. Measure and cut to size the concentric assembly and any extensions that are being used. 4.
Supplied by HeatingSpares247.com 9.0 Plume Displacement Plume Outlet Elbow 9.3 General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air. 16. It is also possible to separate the plume outlet from the 93° elbow to allow the flue to be installed as shown in Fig. 25. 50 0m m Mi n. 17.
Supplied by HeatingSpares247.com 10.0 Installation 10.1 Unpacking & Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). Remove staples, open flaps and remove the cardboard sheet. Remove the polystyrene side pieces and literature. Two people can then lift out the boiler. NOTE: a small amount of water may drain from the boiler in the upright position. Fig. 30 1. After considering the site requirements (see Section 7.
Supplied by HeatingSpares247.com 10.0 Installation 10.3 Fitting The Boiler 1. Lift the boiler by holding as shown by the shaded areas. The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig. 36) (see Safe Manual Handling page 5). 2. Ease the boiler forwards and remove the sealing caps from the boiler connections. NOTE: A small amount of water may drain from the boiler once the caps are removed. 3.
Supplied by HeatingSpares247.com 10.0 Installation 10.6 m 0m 50 Fitting The Flue HORIZONTAL TELESCOPIC FLUE m m 15 3 1. 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. The outer duct of the Connection Assembly is painted white. On the Terminal Assembly the outer duct is unpainted. Terminal Assembly 2.
Supplied by HeatingSpares247.com 10.0 Installation ’ ‘Y ion ens Dim 10.6 Fitting the Flue (Cont) Securing Screw Fig. 42 ‘Peak’ to be uppermost 8. Adjust the two telescopic sections to dimension ‘Y’ (Fig. 42). Ensure that the rivets and holes in the Connection Assembly are aligned horizontally (Fig. 43). 9. Using a 2mm bit, drill through the holes at the end of the Connection Assembly into the Terminal Assembly and secure them together using the screws supplied (Fig. 42).
Supplied by HeatingSpares247.com 10.0 Installation 10.7 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:1. Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel. Cable Clamp Fig. 49 2.
Supplied by HeatingSpares247.com Heat Exchanger Automatic Air Vent 11.0 Commissioning Fig. 51 11.1 Commissioning the Boiler 1. Reference should be made to BS:EN 12828 & 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. Screw IMPORTANT: The heat exchanger air vent on top of the boiler (Fig. 51) MUST be opened before filling the primary system. Pump Automatic Air Vent 3.
Supplied by HeatingSpares247.comx 2 11.0 Commissioning 11.2 Central Heating Temperature Control Selector Switch 1. Ensure that all controls are calling for heat, and the selector switch is in the central heating and hot water position ( ). The current boiler temperature is shown on the display. Calibration Control Fig. 55 2. To check the gas rate it is necessary to set the boiler to ‘Calibration Mode’. Display 3.
Supplied by HeatingSpares247.com 12.0 Completion 12.1 Case Front Panel Completion 1. Instruct the user in the operation of the boiler and system including the integral timer, 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 Gas Boiler Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation.
Supplied by HeatingSpares247.com 13.0 Servicing 13 .1 Annual Servicing 1. 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. Case Front Panel 2. After servicing, complete the relevant Service Interval Record section of the Commissioning Checklist at the rear of this publication.
Supplied by HeatingSpares247.com Burner 4 ±0.5 13.0 Servicing Viewing Window 13.2 Annual Servicing - Inspection (Cont) 6. Undo the nut on the gas inlet pipe to the venturi (Fig. 65) and pull the sensing pipe off the fan. 7. Disconnect the electrode leads, noting their position, and the fan electrical plugs (Fig. 66). Sensing Electrode 7.5 ±1 Spark Ignition Electrode 8. Undo the four nuts retaining the combustion box cover to the heat exchanger. 10 ±1 9.
Supplied by HeatingSpares247.com 14.0 Changing Components Bracket Igniter Igniter Feed Plug 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 13.2 “Annual Servicing” for removal of case panel, door etc. 14.
Supplied by HeatingSpares247.com 14.0 Changing Components 14.3 Fan (Fig. 69) 1. Undo the nut on the gas inlet pipe to the venturi (Fig. 70) and pull the sensing pipe off the fan. 2. Disconnect the electrode leads, noting their position and disconnect 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.
Supplied by HeatingSpares247.com 14.0 Changing Components Cover 14.6 Burner Burner (Fig. 72) 1. Undo the screws securing the collector to the venturi and extension piece. Remove this extension piece from the cover (not on 28/32 models). Gasket Extension Piece (Not on 28/32 models) 2. Withdraw the burner from the cover and replace with the new one. 3. Examine the gasket, replacing if necessary. 4. Reassemble in reverse order. Venturi 14.7 Insulation (Fig. 73) 1.
Supplied by HeatingSpares247.com 14.0 Changing Components Electrical Plug 14.8 Flue/Heat Exchanger Thermostat Sensor Flue/Heat Exchanger Thermostat Sensor (Fig. 74) 1. Ease the retaining tab on the sensor away and disconnect the electrical plug. 2. Turn the sensor 90o anticlockwise to remove - it is a bayonet connection. 3. Reassemble in reverse order. 14.9 Fig. 74 System Pressure Microswitch (Fig. 76) 1. Remove the two wires from the microswitch. 2.
Supplied by HeatingSpares247.com 14.0 Changing Components 14.13 Pump - Head Only (Fig. 78) 1. Drain the primary circuit and remove the socket head screws securing the pump head to the body and draw the head away. 2. Undo the screw on the pump wiring cover and remove the cover. Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position. 3. A standard replacement Grundfos 15-60 head can now be fitted.
Supplied by HeatingSpares247.com 14.0 Changing Components 14.16 Gauge Retaining Bracket Pressure Gauge (Figs. 81 & 82) 1. Drain the primary circuit and undo the nut on the pressure gauge capillary. 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. Pressure Gauge Fig. 81 4. Examine the sealing washer, replace if necessary. 5. Reassemble in reverse order. 14.
Supplied by HeatingSpares247.com 14.0 Changing Components 14.18 P.C.B. (Fig. 85) 1. 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. 84). 3. Note the position of all plugs and wires on the P.C.B. and disconnect them. 4.
Supplied by HeatingSpares247.com 14.0 Changing Components 14.20 Gas Valve (Fig. 84) IMPORTANT: After replacing the valve the CO2 must be checked and adjusted as detailed in Section 15.0 Setting the Gas Valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see section 13.1. Gas Valve Sensing Pipe 1. Turn the gas cock off and undo the nut on the gas feed elbow under the boiler. Power Lead 2.
Supplied by HeatingSpares247.com x2 15.0 Setting the Gas Valve 15.1 Central Heating Temperature Control Selector Switch IMPORTANT: The CO2 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 13.1 Calibration Control Fig. 88 1. The combustion (CO2) may be checked after running the boiler for several minutes. To do this it is necessary to set the boiler to ‘Calibration Mode’. Display 2.
Supplied by HeatingSpares247.com 16.0 Electrical 16.
Supplied by HeatingSpares247.com 17.0 Short Parts List Short Parts List Key No. G.C. No. Description Manufacturers Part No.
Supplied by HeatingSpares247.com 18.0 Fault Finding 18.1 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. Initial Fault Finding Checks 1. 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.
Supplied by HeatingSpares247.com 18.0 Fault Finding Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence Turn selector switch to The display illuminates NO Go to section ‘A’ YES Error 110 flashing Error 130 flashing Error 133 flashing YES Turn the selector switch to reset position for 5 seconds YES If the error 110 is still flashing.
Supplied by HeatingSpares247.com 18.0 Fault Finding Fault Finding Solutions Sections A Is there 230V at: 1. Main terminals L and N 2. Main terminal fuse 3. B NO Check electrical supply NO Replace fuse NO Check wiring PCB - X1 connector terminals 1,2 NO Display illuminated Is there 230V at: YES 1. Pump 2. PCB - X3 connector terminals 3 & 4 NO If pump jammed, release NO Replace pump Replace PCB YES Change pump supply cable C 1. YES CH system pressure less than 0.5 bar NO 2.
Supplied by HeatingSpares247.com 18.0 Fault Finding E F Temperature sensors faulty. Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) 20kΩ @ 25° C (Flue sensor) (resistance reduces with increase in temp.) 1. 2.
Supplied by HeatingSpares247.com 18.0 Fault Finding H 1. 2. Check the gas supply pressure: Natural Gas minimum 17 mbar Propane minimum 37 mbar Check and correct if necessary 1. The mechanical set of the gas valve (CO2 values - see instruction) 2. Flame sensing electrode and lead connections 3. Flame sensing electrode position YES Flame current should be more than 0.5 μ A I 1. Overheat thermostat operated or faulty, i.e.
Supplied by HeatingSpares247.com 19.
Supplied by HeatingSpares247.com 1.0 Introduction GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No.
Supplied by HeatingSpares247.com SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
Supplied by HeatingSpares247.com Contact us For general enquiries contact branches nationwide For technical advice please contact 056 7720 023 For in warranty service contact 090 6424 062 Branches Nationwide www.heatmerchants.ie For technical enquiries please contact warrantyapp@heatmerchants.
