Installation & Service Instructions System Eco Elite Range These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping.
Natural Gas Building Regulations and the Benchmark Commissioning Checklist Main System 24 Eco Elite G.C.No 41 467 21 Main System 28 Eco Elite G.C.No 41 467 22 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 the ‘Gas Safe Register’, the register will issue the Building Regulations certificate on members’ behalf
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 2014 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 11 6.0 System Details 12 7.0 Site Requirements 14 8.0 Flue Options 19 9.0 Plume Displacement 24 10.0 Installation 28 11.0 Commissioning 32 12.0 Completion 35 13.0 Servicing 36 14.0 Changing Components 38 15.0 Setting the Gas Valve 46 16.0 Electrical 47 17.0 Short Parts List 48 18.
1.0 Introduction 1.1 Case Front Panel Description 1. The Main System Eco Elite is a fully automatic gas fired wall mounted condensing system boiler. It is room sealed and fan assisted. 2. The boiler is set to give a maximum output of :24 models 28 models - 25.94 kW 26.95 kW (Condensing) 28.63 kW 30.20 kW (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.
13 15 2.0 General Layout 23 2.1 1 22 14 21 16 Layout 1. Expansion Vessel 2. Automatic Air Vent 3. Primary Return Temperature Sensor 4. Circulation Pump 5. Drain Off Point 6. Pressure Relief Valve 7. Selector Switch 8. Central Heating System Pressure Gauge 9. PCB 10. Control Box 11. Gas Valve 12. Condensate Trap 13. Heat Exchanger Air Vent 20 14. Electrode Assembly 7 15. Primary Heat Exchanger 16. Fan Assembly 17. On/Off/Reset Selector Switch 18.
3.0 Appliance Operation Boiler Primary Circuit 1 3.1 Operating Mode (Fig. 2) 1. With a demand for heating or hot water, the pump circulates water through the primary circuit. If the pressure is at least 0.5 bar and the ignition sequence will start. 2. When the flow temperature exceeds the setting temperature, a 3 minute delay occurs before the burner relights automatically (anti-cycling). The pump continues to run during this period.
4.0 Technical Data 4.1 Appliance Type C13 Appliance Category C33 C53 CAT I 2H Heat Input CH (Net) Max Min 24 model kW 26.06 7.82 28 model kW 29.32 8.8 Heat Input CH (Gross) Max Min 24 model kW 28.92 8.68 28 model kW 32.54 9.77 Heat Output CH (Non-Condensing) Max Min 24 model kW 25.94 7.61 28 model kW 28.63 8.56 Min 24 model kW 26.95 8.37 28 model kW 30.20 9.42 Max Gas Rate (Natural Gas - G20) (After 10 mins) 24 model 3 m /h 2.76 28 model m3/h 3.
5.0 Dimensions and Fixings Dimensions A 780mm At Least 1.5° F B 345mm C 450mm D 116mm 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 Details 6.5 Stop Valve DHW Mains Inlet Fig. 6 Double Check Valve Temporary Hose System Filling and Pressurising (Fig. 6) 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 CH Return 2. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment. 3.
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. garage or outhouse.
7.0 Site Requirement Gas Service Cock 7.3 Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. 7.4 Gas Supply 1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891. In IE this is the current edition of I.S. 813 “Domestic Gas Installations”. Fig. 10 2.
Examples are shown of the following methods of termination:i) to an internal soil & vent pipe ii) via an internal discharge branch (e.g. sink waste) downstream of the trap iii) to a drain or gully iv) to a purpose made soakaway v) pumped into an internal discharge branch (e.g. sink waste) downstream of the trap vi) pumped into an external soil & vent pipe vii) to a drain or gully with extended external run & trace heating It is strongly recommended to discharge internally into the household drainage system.
v) pumped into an internal discharge branch (e.g. sink waste) downstream of the trap Sink 50mm 7.0 Site Requirement per me tre of p ipe run 2.5° M inimum fall Pipe must terminate above water level but below surrounding surface. Cut end at 45° 7.7 Condensate Drain (cont.) 12. A boiler discharge pump is available, ‘MULTIFIT’ part no. 720648301. This pump will dispose of both condensate & high temperature water from the relief valve. It has a maximum head of 5 metres.
Terminal Position with Minimum Distance (Fig. 18) (mm) 7.0 Site Requirements 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.
8.0 Flue Options 8.1 Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination (ii) applications. 2. Maximum permissible equivalent flue lengths are:(i) Horizontal Concentric (60/100) 10 metres (80/125) 20 metres 3. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 135° bend 0.5 metres 93° bend 1.0 metres Horizontal Flues Twin Flue Pipe 135° bend 91.5° bend 0.25 metres 0.
Vertical Flues (Twin Pipe) 8.0 Flue Options 300mm Min Apart 8.2 Twin & Vertical Flue Systems 1. Maximum permissible equivalent flue lengths are:- Vertical Concentric 1m Min (ii) to 20m Max Twin Pipe (60/100) 10 metres (80/80) 20 metres (80/125) 20 metres (i) 3. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 135° bend 0.5 metres 93° bend 1.0 metres Twin Flue Pipe Vertical Flues 135° bend 91.5° bend 0.
8.0 Flue Options 8.
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). 3.
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 Elbow 0.9 metres 60Ø Exhaust Flue Pipe 60Ø Support Bracket O Ring Fig. 22 Plume Displacement Kit (Fig. 23) Flexible Flue Trim 1.
16 16 14 14 60 Ø Exhaust (metres) X 60 Ø Exhaust (metres) X 9.0 Plume Displacement 12 10 24 8 6 4 28 9.2 12 10 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. 28). 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. 34. 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. 35).
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). 1. Remove staples, open flaps and remove cardboard sheet. Remove the polystyrene side pieces and literature. Two people can then lift out the boiler (Fig. 39). Fig. 39 Unpacking Procedure 2. After considering the site requirements (see Section 7.0) position the fixing template on the wall ensuring it is level both horizontally and vertically. 3.
10.0 Installation Pressure Relief Valve 10.4 Fitting the Pressure Relief Discharge Pipe (Fig. 44) 1. Remove 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 15mm diameter and run continuously downwards to a discharge point outside the building. See section 6.7 for further details. Fig. 44 Discharge Pipe 4.
10.0 Installation Centralising Collar 10.6 Fitting the Flue (Cont) 6. The centralising collar may be in the waste portion of the flue. In this case retrieve the bracket before discarding the waste. Fig. 50 7. Take the centralising collar (if not already fitted) and engage it over the flue duct. This will centralise the flue and air ducts, and ease assembly (Fig. 51). Apply Lubricant for ease of assembly. Ensure Flue is fully engaged into Flue Elbow 8. Insert the flue through the hole in the wall.
10.0 Installation 10.7 Making The Electrical Connections 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. 2. Completely undo the screws securing the facia panel and hinge it down (Fig. 55). Cable Clamp Fig. 56 3. Undo the terminal block cover securing screw and remove the cover (Fig. 55).
Heat Exchanger Automatic Air Vent 11.0 Commissioning Fig. 58 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. 3. Open the mains water supply to the boiler. Screw IMPORTANT: The heat exchanger air vent on top of the boiler (Fig. 58) MUST be opened before filling the primary system. 4.
Set Boiler to Maximum Rate (see 11.1.17) Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser. 11.0 Commissioning 11.2 Checking Combustion 1. Follow the flow chart opposite. Verify Flue Integrity Indication that products of combustion & inlet air are mixing - further investigation is required. Check all flue components are correctly assembled, fixed & supported. Check the flue & terminal are unobstructed. Is O2 20.6% and CO2 < 0.
x2 11.0 Commissioning 11.3 Central Heating Temperature Control Calibration Control Fig. 62 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. 2. To check the gas rate it is necessary to set the boiler to ‘Calibration Mode’. Display Selector Switch Check the Operational (Working) Gas Inlet Pressure 3.
12.0 Completion 12.1 Case Front Panel Completion 1. Instruct the user in the operation of the boiler and system including external controls, explaining the operational sequence. 2. Set the temperature control knob 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.
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 Benchmark Commissioning Checklist at the rear of this publication.
13.0 Servicing 13.2 Annual Servicing - Inspection (Cont) Injector 6. Undo the nut on the gas pipe at the gas/air inlet (Fig. 72) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. Gas/Air Inlet 7. Disconnect the electrode lead caps, remove the strain relief clip from the sensing lead and disconnect the lead. Remove the fan electrical plugs and pull the sensing pipe off the fan. Gas Pipe Fig. 73 8.
14.0 Changing Components Igniter Igniter Feed Plug Electrode Leads 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 13.1 “Annual Servicing” for removal of case panel, door etc. 14.1 Igniter (Fig. 75) 1.
14.0 Changing Components Injector Gas/Air Inlet 14.3 Fan 1. Undo the nut on the gas pipe at the gas/air inlet (Fig. 77) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. 2. Disconnect the electrode lead caps, remove the strain relief clip from the sensing lead and disconnect the lead. Remove the fan electrical plugs and pull the sensing pipe off the fan. Gas Pipe Fig. 77 3.
14.0 Changing Components 14.5 Burner (Fig. 80) 1. Undo the nut on the gas pipe at the gas/air inlet and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. 2. Disconnect the electrode lead caps, remove the strain relief clip from the sensing lead and disconnect the lead. Remove the fan electrical plugs and pull the sensing pipe off the fan. 3. Undo the screw securing the fan air inlet pipe to the bracket on the boiler top panel. Remove the pipe. 4.
14.0 Changing Components 14.7 Safety Thermostat (Fig. 81) 1. Pull the plug off the thermostat. 2. Remove the screws securing the thermostat to the mounting plate on the flow pipe. Safety Thermostat 3. Reassemble in reverse order, ensuring that the plug is pushed fully on. 14.8 Central Heating Temperature Sensor (NTC) (Fig. 82) 1. Drain the boiler primary circuit. Pull the plug off the safety thermostat and disconnect the in-line plug in the sensor wire. Fig. 81 2.
14.0 Changing Components Heat Exchanger Air Vent 14.11 Heat Exchanger Automatic Air Vent (Fig. 84) 1. Drain the boiler 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. Grommet 3. Reassemble in reverse order, transferring the grommet to the new vent. 4. Ensure that the grommet is sealed correctly to the boiler top panel. Fig. 84 14.12 Pump - Head Only (Fig. 85) 1.
14.0 Changing Components 14.15 Gauge Retaining Bracket Pressure Gauge (Figs. 88 & 89) 1. Drain the boiler primary circuit and undo the nut on the pressure gauge capillary. 2. Undo the screws securing the gauge retaining bracket. Pressure Gauge Fig. 88 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. 14.16 Pressure Relief Valve (Fig. 90) 1.
14.0 Changing Components 14.17 P.C.B. (Figs. 91 & 92) 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. 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.
Venturi Inlet Pipe 14.0 Changing Components 14.19 Gas Valve (Fig. 93) 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.
x2 15.0 Setting the Gas Valve 15.1 Central Heating Temperature Control Selector Switch Setting the Gas Valve (CO2 check) 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. 95 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.
16.0 Electrical 16.
17.0 Short Parts List Short Parts List Key No. D B G.C. No. Description Manufacturers Part No.
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. The preferred minimum gas pressure is 20 mbar. 5.
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 133 flashing YES Turn the selector switch to reset position for 5 seconds YES If the error 110 is still flashing.
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 Replace PCB 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.
18.0 Fault Finding F 1. 2. Check and correct the connection of the tube between the venturi and gas valve Gas at burner NO Ensure gas is on and purged PCB - X3 connector is 230V AC across terminals 1 & 2 YES Replace gas valve NO Replace PCB G H Check and correct if necessary 1. Ignition electrode and lead 2. Electrode connection 3.
18.0 Fault Finding J Is there 230V at: PCB - X3 connector terminals 5 & 6 central heating mode NO Replace PCB YES Change pump supply cable K L Fan connections correct at fan. PCB - X401 connector terminals 5,6,7 & 8 1. Temperature sensors faulty. Cold resistance approximately 10k @ 25° C (CH sensor) (resistance reduces with increase in temp.) YES NO YES 2.
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.
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. SERVICE 01 Date: SERVICE 02 Engineer name: Engineer name: Company name: Company name: Telephone No: Telephone No: Gas safe register No: Record: At max.
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 Tr a d in g D i v i s i on o f B ax i H eat i ng U K Lt d ( 3879156) Brooks House, Coventry Road, Warwick.
