Installation & Service Instructions System HE Range These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping.
Natural Gas Main System 18 HE G.C.No 41 467 01 Main System 24 HE G.C.No 41 467 02 Main System 28 HE G.C.No 41 467 03 Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly.
Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Self Certification Scheme Building Control Install and Commission this appliance to manufacturer's instructions Contact your relevant Local Authority Building Control (LABC) who will arrange an inspection or contact a government approved inspector Complete the Benchmark Checklist If you notify via CORGI Scheme, CORGI will then notify the relevant Local Authority Building Control Scheme on member's beha
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. In GB, this must be carried out by a competent person as stated in the Gas Safety (Installation & Use) Regulations.
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.
CONTENTS Section 6 © Baxi Heating UK Ltd 2007 Page 1.0 Introduction 7 2.0 General Layout 8 3.0 Appliance Operation 9 4.0 Technical Data 10 5.0 Dimensions and Fixings 13 6.0 System Details 14 7.0 Site Requirements 16 8.0 Flue Options 20 9.0 Plume Displacement 25 10.0 Installation 29 11.0 Commissioning 34 12.0 Completion 36 13.0 Servicing 37 14.0 Changing Components 39 15.0 Electrical 48 16.0 Short Parts List 49 17.
1.0 Introduction 1.1 Description 1. The Main System HE range are fully automatic gas fired wall mounted system boilers. They are room sealed and fan assisted. Case Front Panel 2. The boilers are set to give a maximum output of 18.9kW, 25.2kW or 29.3kW when in condensing mode. 3. They are designed for use on Natural Gas (G20) and can be converted to use Propane. 4. The boiler incorporates a circulating pump and expansion vessel. It is suitable for use only on fully pumped sealed systems. 5.
2.0 General Layout 1 17 2.1 Layout 16 15 14 2 13 12 3 5 4 6 7 11 10 9 8 20 21 22 23 24 25 30° 40° 50° 60° 70° 80° 1. Air Pressure Switch 2. Expansion Vessel 3. Burner Manifold 4. Automatic Air Vent 5. Circulation Pump 6. Drain Off Point 7. Pressure Relief Valve 8. System Pressure Gauge 9. PCB 10. Control Box 11. Condensate Trap 12. Flame Sensing Electrode 13. Spark Electrode 14. Burner 15. Primary Heat Exchanger 16. Fan Assembly 17.
3.0 Appliance Operation Boiler Primary Circuit 3.1 Operating Mode (Fig. 2) 1 20 1. With a demand for heating, the pump circulates water through the primary circuit. At a pre-determined flow rate the hydraulic differential pressure switch operates, initiating the ignition sequence. 19 2. The main burner ignites at low rate, then the gas valve controls the gas rate to maintain the heating temperature measured by the temperature sensor. 2 3 4 7 3.
4.0 Technical Data 4.1 Appliance Type C12 Appliance Category C32 C52 CAT II 2H 3P NOx Class 3 Condensate Drain 1” BSP System 18 HE Central Heating Primary Circuit Pressures kW Max Min 18.7 10.6 Heat Output (Non-Condensing) kW Max Min 18 9.
4.0 Technical Data 4.2 Appliance Type C12 Appliance Category C32 C52 CAT II 2H 3P NOx Class 3 Condensate Drain 1” BSP System 24 HE Central Heating Primary Circuit Pressures kW Max Min 24.8 10.6 Heat Output (Non-Condensing) kW Max Min 24 9.
4.0 Technical Data 4.3 Appliance Type C12 Appliance Category C32 C52 CAT II 2H 3P NOx Class 3 Condensate Drain 1” BSP System 28 HE Central Heating Primary Circuit Pressures kW Max Min 28.9 11.
5.0 Dimensions and Fixings Dimensions A 780mm At Least 1.5° G E B 345mm C 450mm D 107mm Ø Min.
6.0 System Details 6.1 Central Heating Circuit 1. The appliance is suitable for fully pumped SEALED SYSTEMS ONLY. Treatment of Water Circulating Systems • All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems.
6.0 System Detail 6.4 System Filling and Pressurising 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. Double Check Valve Stop Valve Mains Cold Water Fig. 3 Temporary Hose Stop Valve 2. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment. CH Return 3.
7.0 Site Requirement 20mm/5mm Min 450mm 5mm Min see *NOTE: 200mm Min 7.1 Location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard-see Section 7.
7.0 Site Requirement 7.3 Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. Gas Service Cock 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. 7.4 Gas Supply 1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891. In IE this is the current edition of I.S. 813 “Domestic Gas Installations”. 2.
7.0 Site Requirement Termination to an internal soil and vent pipe Boiler 7.7 50mm 2.5° M per me inimum FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER tre of fall pipe ru 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. n 450mm min External termination via internal discharge branch e.
Terminal Position with Minimum Distance (Fig. 9) (mm) Aa Directly below an opening, air brick, opening windows, etc. Ba Above an opening, air brick, opening window etc. Ca Horizontally to an opening, air brick, opening window etc. D Below gutters, soil pipes or drain pipes. E Below eaves. F Below balconies or car port roof. G From a vertical drain pipe or soil pipe. H From an internal or external corner. I Above ground, roof or balcony level. J From a surface or boundary line facing a terminal.
8.0 Flue Options 8.1 Horizontal Flue Systems 1. The Main System HE can be fitted with either horizontal, vertical or twin flue systems as illustrated. Y X 2. The standard flue is suitable only for horizontal applications. 3. Maximum permissible equivalent flue lengths are:Horizontal Concentric (18 model) (24 model) (28 model) 5m 4m 3m 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.
8.0 Flue Options Vertical Flues (Twin Pipe) 8.2 Twin & Vertical Flue Systems 1. Maximum permissible equivalent flue lengths are:Vertical Concentric Vertical Twin Pipe Y (18) 5m 10m (24) 4m 12m (28) 3m 12m 2. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 135° bend 0.5 metres 93° bend 1.0 metres Twin Flue Pipe 135° bend 0.25 metres 91.5° bend 0.
8.0 Flue Options 8.
8.0 Flue Options For Twin Flue Systems fit the adaptors as follows:- 8.4 Flue Duct Adaptor Blanking Plate Boiler Adaptor Flue Duct Adaptor (Fig. 11) 1. Engage the flue duct adaptor on the boiler adaptor, making sure that it is pushed down as far as possible. 8.5 Air duct adaptor (Fig. 12) 1. Undo the screws securing the blanking plate to the boiler top panel. Discard the plate. 2. There are three restrictor plates supplied in the kit.
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.
93° Elbow/Plume Outlet Assembly 9.0 Plume Displacement 60Ø Support Bracket O Ring 9.1 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 Boiler Elbow 0.9 metres 60Ø Exhaust Flue Pipe 60Ø Support Bracket O Ring Fig. 14a Plume Displacement Kit (Fig. 14b) Flexible Flue Trim 1.
4 4 3 3 9.0 Plume Displacement 9.2 E H 28 60 Ø Exhaust (metres) 2 & E H 28 1 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).
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. Insert the concentric assembly through the hole from outside the building. 5.
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. To do this, first slacken the two screws retaining the plume outlet to the elbow, and remove the outlet (Fig. 26).
10.0 Installation 10.1 Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). 1. After considering the site requirements (see Section 7.0) position the fixing template on the wall ensuring it is level both horizontally and vertically. 2. Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes. It is preferable to use the horizontal fixing slots. 3.
10.0 Installation Wall Plate 10.4 Fitting The Boiler 1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig. 32). See ‘Safe Manual Handling’ on page 5. 3. Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections. The rubber washers must be used on the gas connection. 4. Tighten all the connections. 10.
10.0 Installation 10.7 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 33). m m 85 6 m 0m 10 2. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (Fig. 34). NOTE: The flue elbow is angled at 93 degrees to ensure a fall back to the boiler. Fig. 33 3.
10.0 Installation Waste Y 10.7 Fitting the Flue (Cont) 5. Mark dimension ‘Y’ on the flue as shown (Fig. 36). Carefully cut the waste material from the flue, ensuring that the ducts are square and free from burrs. 6. The inner flue duct support bracket may be in the waste portion of the flue. In this case retrieve the bracket before discarding the waste. Flue Fig. 36 7. Take the inner flue support bracket ( if not already fitted) and engage it over the flue duct.
10.0 Installation 10.8 Making The Electrical Connections To connect the mains input cable proceed as follows:1. Slacken the facia securing screws and lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel. Control Box Cover 2. Completely undo the screws securing the facia panel and hinge it down (Fig. 39). Fig. 40 3. Remove the control box cover securing screws. Disengage the barbs on the control box from the cover. Remove the cover (Fig. 40). 4.
11.0 Commissioning 11.1 Commissioning the Boiler 1. Reference should be made to BS 5449 when commissioning the boiler. Screw 2. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. 3. Open the screw on the automatic air vent (Fig. 44). Automatic Air Vent 4. The system must be flushed in accordance with BS 7593 and the flushing agent manufacturers instructions. 5. Pressurise the system to 1.0 bar (Fig.
11.0 Commissioning 11.2 Checking the Burner Pressure 1. Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for heat. Pressure Test Point Sealing Screw OUT 2. Set the temperature control to maximum and the selector switch to the Off position (Fig. 50). 3. Slacken the pressure test point sealing screw on the gas valve and connect a pressure gauge (Fig. 47). MIN Gas Valve 4. Undo the screws securing the inner door panel.
12.0 Completion 12.1 Case Front Panel Completion 1. Hinge the facia panel upwards and refit the case front panel. Tighten the securing screws (Fig. 51). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 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.
13.0 Servicing 13.1 Annual Servicing Case Front Panel 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person. 2. After servicing, complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication. 3. Ensure that the boiler is cool. 4. Ensure that both the gas and electrical supplies to the boiler are isolated. Fig. 52 5.
13.0 Servicing 13.1 Baffle Spring Clip Tab Annual Servicing (Cont) 12. Ease the front edge of the left hand baffle upwards, disengaging the spring clip. Disengage the tabs on the baffle from the slots in the fan hood (Fig. 55). 13. Undo the screws securing the fan and hood to the appliance back panel. Draw the assembly forwards (Fig. 56). 14. On 28 HE models undo the screws securing the burner to the injector manifold. Fig. 55 15.
14.0 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 new component has been fitted turn the selector switch fully anticlockwise against the spring pressure to the ‘Reset’ position and hold for 2 seconds to reset the boiler before recommissioning. Pressure Switch Sensing Tubes See Section 13.1 “Annual Servicing” for removal of case panel, door etc. 14.1 Fig.
14.0 Changing Components 14.3 Heat Exchanger (Fig. 61) 1. Remove the fan as described in section 14.1. 2. Drain the primary circuit. Prise the pipe connecting clips off the joints in the flow and return pipes. Remove the heat exchanger return pipe. Pipe Connecting Clips 3. Lift the heat exchanger to disconnect the flow pipe joint. Withdraw it from the appliance, taking care not to damage the rear insulation piece. 8. Fit the new heat exchanger. 9.
14.0 Changing Components 14.5 Injector Injector Manifold Injectors (Fig. 63) Inlet Elbow 1. Remove the burner as described in Section 14.4. 2. Undo the screws securing the injector manifold to the inlet elbow and remove the manifold. Gasket 3. Unscrew and replace injectors as required and examine the sealing gasket, replacing as necessary. Reassemble in reverse order. 14.6 1. Remove the four screws securing the combustion box door and remove the door. Burner Electrodes Electrodes (Fig. 63) Fig.
14.0 Changing Components 14.8 Modulator Wires Gas Valve (Fig. 65) 1. Undo the nut on the gas feed pipe under the boiler. Ignition Lead 2. Completely undo the securing screws and hinge the facia panel down. Gas Valve 3. Disconnect the wires from the valve modulator and the ignition lead from the spark generator. Disconnect the pressure sensing pipe from the valve. Undo the screw securing the spark generator electrical plug to the valve and disconnect the plug. 4.
14.0 Changing Components 14.12 Pump - Head Only (Fig. 68) 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. Connect the pump wiring to the new head.
14.0 Changing Components Pressure Gauge Capillary 14.15 Pressure Gauge (Figs. 71 & 72) 1. Drain the primary circuit and undo the nut on the pressure gauge capillary. 2. Remove the timer cover and ease the timer wiring aside. Undo the screws securing the gauge retaining bracket. Fig. 71 3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining bracket. Gauge Retaining Bracket 4. Reassemble in reverse order. 14.16 1.
14.0 Changing Components 14.18 Main PCB (Fig. 76) 1. Note the setting of the temperature control knob. Rotate the knob fully anticlockwise and carefully pull it off the drive pin. 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. 75). 3. Note the position of all plugs and wires on the PCB and disconnect them. 4. Undo the securing screws and remove the PCB.
14.0 Changing Components 14.20 Central Heating Differential Valve (Figs. 77 & 78) 1. Drain the primary circuit. 2. Undo the screw securing the microswitch to the differential valve. Allow the microswitch to rest to one side. 3. Undo the pressure gauge capillary nut and heating flow pipe nut from the valve. 4. Prise off the bypass connecting clips and disconnect the heating flow tap. Undo the screws securing the valve to the boiler bottom panel. Remove the valve. 5.
14.0 Changing Components Secondary Heat Exchanger 14.23 Secondary Heat Exchanger) (Fig. 80) 1. Drain the primary circuit Pipe Connecting Clip 2. Undo the four screws securing the right hand case panel. Remove the panel. Fan Spigot Outlet Pipe Clamp Outer Drum 3. Prise the connecting clips from the heat exchanger return pipe and the boiler return pipe. Remove the pipes. 4. Slacken the screws on the left hand fan spigot outlet pipe clamp. Ease the clamp to the right.
15.0 Electrical 15.
16.0 Short Part List Key G.C. No. No. 22 44 140 22 23 32 41 131 528 333 59 E66 408 63 E66 411 72 23 169 Manufacturers Part No. Fan (18 HE) 5113278 Fan (24 HE) 5112627 Fan (28 HE) 5112430 Pressure Switch (18 HE) 5113280 Pressure Switch (24 & 28 HE) 248466 Heat Exchanger (18 HE) 5113284 Heat Exchanger (24 & 28 HE) 5112431 Burner (18 HE) 5113286 Burner (24 & 28 HE) 5112770 135 44 102 Description 41 E66 539 102 Injector 1.18 (18 & 24 HE) 247439 Injector 1.
17.0 Fault Finding Carry out initial fault finding checks 1. Check that gas, water and electrical supplies are available at the boiler. Electrical supply = 230V ~ 50 Hz. CH water system pressurised to 0.5 bar when the boiler is cold. The preferred minimum gas pressure is 19.5mbar (natural gas), or 36mbar (propane). 2. Carry out electrical system checks, i.e. Ground Continuity, Resistance to Ground, Short Circuit and Polarity with a suitable meter.
17.0 Fault Finding Fault Finding Solutions Sections A to E A Is there 230V at: 1. 2. 3. B NO Main terminals L and N Check electrical supply YES Main terminal fuse Selector terminals a & b and a & 3. PCB - A4 connector terminals 4 & 5 Replace fuse NO Check wiring Replace selector neon illuminated NO Replace PCB Is there 230V at: YES 1. Pump 2. PCB - A4 connector terminals 3 & 6 NO If pump jammed, release Replace pump NO Replace PCB YES Change pump supply cable C NO 1.
17.0 Fault Finding G 1. Check the burner setting pressure of the gas valve (see Section 9.2 of Commissioning) 2. Voltage at modulating coil of gas valve is: Max. burner press.approx 9V DC (13V DC LPG) Min. burner press.approx 1V DC Current at modulating coil of gas valve is: (Use an instrument with average function for this measure) 30 ÷ 230 mA DC (45 ÷ 310 mA DC LPG) H I Check and correct if necessary 1. Ignition electrode and lead 2. Electrode connection 3.
18.
BENCHMARK No. 5 1 2 1 1 8 6 GAS BOILER COMMISSIONING CHECKLIST COLLECTIVE MARK BOILER SERIAL No. NOTIFICATION No.
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. Always use the manufacturer’s specified spare part when replacing all controls SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No.
All descriptions and illustrations provided in this leaflet 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. MAIN A Trading Division of Baxi Heating UK Ltd Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 08701 655 644 Technical Enquiries 08706 049 049 Website www.
