system_35-60__60

Please leave these instructions with the user

Baxi System

35/60 & 60/100

Gas Fired Wall Mounted System Boilers

Installation and

Servicing Instructions

Natural Gas

Baxi System 35/60

G.C.N

o 41 075 18

Baxi System 60/100

G.C.N

o 41 075 19

Baxi UK Limited is one of the leading manufacturers of domestic heating products in the UK.

Our first priority is to give a high quality service to our customers. Quality is designed into every Baxi product

- products which fulfil the demands and needs of customers, offering choice, efficiency and reliability.

To keep ahead of changing trends, we have made a commitment to develop new ideas using the latest technology - with the aim of continuing to make the products that customers want to buy.

Everyone who works at Baxi has a commitment to quality because we know that satisfied customers mean continued success.

We hope you get a satisfactory service from Baxi. If not, please let us know.

The boiler meets the requirements of Statutory Instrument

“ The Boiler (Efficiency) Regulations 1993 N o 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 liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by:

Notified Body 0051.

Product/Production certified by:

Notified Body 0051.

For GB/IE only.

2

Baxi is a BS-EN ISO 9001

Accredited Company

Contents

Section

1.0

Introduction

2.0

General Layout

3.0

Appliance Operation

4.0

Technical Data

5.0

Dimensions and Fixings

6.0

System Details

7.0

Site Requirements

8.0

Installation

9.0

Commissioning the Boiler

10.0 Completion

11.0 Servicing the Boiler

12.0 Changing Components

13.0 Illustrated Wiring Diagram

14.0 Fault Finding

15.0 Short Parts List

40

43

31

39

28

29

17

26

10

12

7

9

Page

4

5

6

3

4

Control Box

Fig. 1

Case Front Panel

Data Badge

NOTE: 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.

“Benchmark” Log Book

As part of the industry-wide “Benchmark” initiative all Baxi boilers now include an Installation, Commissioning and Service Record Log Book.

Please read the Log Book carefully and complete all sections relevant to the appliance and installation. These include sections on the type of controls employed, flushing the system, burner operating pressure etc.

The details of the Log Book will be required in the event of any warranty work. Also, there is a section to be completed at each subsequent regular service visit. The Log Book must be left with the user.

1.0 Introduction

Baxi UK Limited declare that no substances harmful to health are contained in the appliance or used during appliance manufacture.

1.1

Description

1. The Baxi System 35/60 and 60/100 are fully automatic gas fired wall mounted system boilers.

They are room sealed and fan assisted.

2. The boilers are set to give a maximum output of

17.5kW (35/60) or 29.3kW (60/100).

3. They are designed for use on Natural Gas

(G20) and can be converted to use Propane

(35/60 & 60/100) or Butane (35/60).

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 control box. It is visible when the case front panel is removed (Fig. 1).

6. The boiler is intended to be installed in residential / commercial / light industrial E.M.C.

environments on a governed meter supply only.

7. The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit, part no. 247719.

8. All systems must be thoroughly flushed and

treated with inhibitor (see section 6.1).

1.2

Installation

1. The appliance is suitable for installation only in G.B. and

I.E. and should be installed in accordance with the rules in force. For Ireland install in accordance with I.S.813

“I

NSTALLATION OF

G

AS

A

PPLIANCES

”. The installation must be carried out by a CORGI Registered Installer or other competent person and be in accordance with the relevant requirements of G

AS

S

AFETY

(Installation and Use)

R

EGULATIONS

, the B

UILDING

R

EGULATIONS

(Scotland)

(Consolidation), the L

OCAL

B

UILDING

R

EGULATIONS

, the

C

URRENT

I.E.E. W

IRING

R

EGULATIONS

and the bye laws of the

Local Water Undertaking. Where no specific instructions are given, reference should be made to the relevant BRITISH

STANDARD CODES OF PRACTICE.

1.3

Optional Extras

Various flue extensions, bends, vertical flue kits,control accessories etc. are availble as optional extras. These are detailed in a separate publication.

17

16

15

14

13

12

11

10

9

8

20 21 22 23 24

25

30° 40° 50° 60° 70° 80°

7

6

1

2

3

4

5

2.0 General Layout

2.1

Layout

21.

22.

23.

24.

17.

18.

19.

20.

25.

26.

27.

28.

29.

13.

14.

15.

16.

9.

10.

11.

12.

5.

6.

7.

8.

1.

2.

3.

4.

Air Pressure Switch

Expansion Vessel

Burner Manifold

Automatic Air Vent

Circulation Pump

Drain Off Point

Pressure Relief Valve

DHW Relay PCB

System Pressure Gauge

PCB

Control Box

Spark Generator

Flame Sensing Electrode

Spark Electrode

Burner

Primary Heat Exchanger

Fan Assembly

On/Off/Reset Selector Switch

Central Heating Temperature Control

Flame Failure

Safety Thermostat

Fault on Fan or Flue

Fault on Pump or Low System Pressure

Temperature Indication Only

Fault on Central Heating Sensor

Power On

Hot Water Mode

Central Heating Mode

Burner On

When neons 20 to 25 are constantly illuminated, they indicate the temperature of the central heating water.

26 27 28 29

30° 40° 50° 60° 70° 80°

2

1

0

bar

4

3

18

19

9

5

6

Boiler Primary Circuit

15

16

17

14

13

5

11 10

Key

7

8

5

6

3

4

1

2

Heat Exchanger

Burner

Ignition Electrode

Flame Sensing Electrode

Gas Valve

Pump

Automatic Air Vent


9 Boiler Drain Point

10 Gas Inlet

11 Boiler Flow

12 Boiler Return

13 Pressure Gauge

14 Automatic By-Pass

15 Hydraulic Differential Pressure Sensor

16 Safety Thermostat

17 Central Heating Temperature Sensor

18 Expansion Vessel

19 Water Heating Sensor

3.0 Appliance Operation

1

3 4

18

2

6

8

9

19

7

3.1

Operating Mode (Fig. 2)

1. With a demand for heating, the pump circulates water through the primary circuit. At a predetermined flow rate the hydraulic differential pressure switch operates, initiating the ignition sequence.

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.

3. 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. When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes (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.

12

Fig. 2

3.3

Frost Protection Mode

1. The frost protection mode is integral to the appliance and functions only with the selector switch (see Section 2.1) in the domestic hot water and central heating position. If the 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 can be incorporated by using a system frost thermostat.

3.4

Pump Protection

1. With the selector switch (see Section 2.1) in either the central heating or central heating and hot water position the pump will automatically operate for 1 minute in every 24 hours to prevent sticking.

4.0 Technical Data

Appliance Type

C

12

C

32

Appliance Category

CAT II

2H 3+

Heat Input (Gross) kW

Btu/h

Max

19.4

Min

10.6

66,200 36,170

Heat Output

Max kW 17.5

Btu/h

Min

9.3

59,720 31,740

Max Gas Rate (Natural Gas - G20)

(After 10 Mins) m ft 3

3 /h

/h

2.05

72.4

Burner Pressure (Natural Gas - G20)

Max Rate Min Rate mbar 6.9 ± 0.5

2.5 ± 0.5

in wg 2.8 ± 0.2

1.0 ± 0.2

Inlet Pressure (Natural Gas - G20) mbar 20 in wg 8

Burner Injector (Natural Gas - G20)

12 x 1.28mm Diameter

Electrical Supply

230V~ 50Hz

(Appliance must be connected to an earthed supply)

Power Consumption

170W

External Fuse Rating

3A Maximum

Internal Fuse Rating

Fuse 2A Fast Blow to BS 4265

Electrical Protection

IPX5D

4.1

System 35/60

NOx Class

Flue Terminal

Dimensions

3

Diameter 100mm

Projection 95mm

Pump - Grundfos UP 15-50

Available Head See graph below

Expansion Vessel - (Integral with appliance) bar

Min Pre-charge Pressure 0.5

Connections

Gas Supply

Central Heating Flow

Central Heating Return

copper tails

22mm

22mm

22mm

Pressure Relief Discharge 15mm litre

Max Capacity of

CH System 125

Primary Water Content of Boiler (unpressurised) 1.0

Outercase Dimensions

Casing Height

Overall Height Inc Flue

Elbow

Casing Width

Casing Depth

780mm

980mm

450mm

345mm

Clearances

Both Sides

Above Casing

Below Casing

Front

Front

5 mm Min

200 mm Min

200 mm Min

450 mm Min

(For Servicing)

5 mm Min

(In Operation)

Weights

Packaged Boiler Carton

Packaged Flue Kit

Installation Lift Weight kg

45

3

37

Central Heating Primary Circuit

Pressures

Safety Discharge

Max Operating

Min Operating

Recommend Operating bar

3

2.5

0.2

1-2

Temperatures

C.H. Flow Temp

(adjustable)

35°C to 85°C max

(± 5°C)

LPG Gases Propane - G31 and

Butane - G30

Burner Injector 12 x 0.65mm diameter

Burner Pressure

Propane mbar

Butane in wg mbar in wg

Max Rate

36.2 ± 0.5

14.5 ± 0.2

28.8 ± 0.5

Min Rate

10.8 ± 0.5

4.3 ± 0.2

7.7 ± 0.5

11.5 ± 0.2

3.1 ± 0.2

Inlet Pressures

mbar in wg

Propane

37

14.8

Butane

28/30

11.2

SEDBUK Declaration For System Boiler 35/60

The seasonal efficiency (SEDBUK) is 78.8 %

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been certified by 0051.

Pump - Available Head

5

4.5

4

3.5

3

2.5

2

1.5

1

0.5

0 l/h

0 200 400 600 800 1000 1200

7

8

4.0 Technical Data

Appliance Type

C

12

C

32

Appliance Category

CAT II

2H 3P

Heat Input (Gross) kW

Btu/h

Max

32.6

Min

11.9

111,250 40,610

Heat Output

Max kW 29.4

Btu/h

Min

10.4

100,330 35,490

Max Gas Rate (Natural Gas - G20)

(After 10 Mins) m

3

/h ft

3

/h

3.45

122

Burner Pressure (Natural Gas - G20) mbar in wg

Max Rate Min Rate

12.5 ± 0.5

1.8 ± 0.5

5.0 ± 0.2

0.7 ± 0.2

Inlet Pressure (Natural Gas - G20) mbar 20 in wg 8

Burner Injector (Natural Gas - G20)

15 x 1.28mm Diameter


230V~ 50Hz

(Appliance must be connected to an earthed supply)

Power Consumption

190W

External Fuse Rating

3A Maximum

Internal Fuse Rating

Fuse 2A Fast Blow to BS 4265

Electrical Protection

IPX5D

4.2

System 60/100

NOx Class

Flue Terminal

Dimensions

Connections

Gas Supply

3

Diameter 100mm

Projection 95mm

Central Heating Flow


-

-

copper tails

22mm

22mm

22mm

Pressure Relief Discharge 15mm

Outercase Dimensions

Casing Height

Overall Height Inc Flue

Elbow

Casing Width

Casing Depth

780mm

980mm

450mm

345mm

Clearances

Both Sides

Above Casing

Below Casing

Front

Front

5 mm Min

200 mm Min

200 mm Min

450 mm Min

(For Servicing)

5 mm Min

(In Operation)

Weights

Packaged Boiler Carton

Packaged Flue Kit

Installation Lift Weight kg

47

3

39

Central Heating Primary Circuit

Pressures

Safety Discharge

Max Operating

Min Operating

Recommend Operating bar

3

2.5

0.2

1-2

Pump - Grundfos UP 15-60

Available Head See graph below

Expansion Vessel - (For Central Heating only. Integral with appliance) bar

Min Pre-charge Pressure 0.5

litre

Max Capacity of

CH System 125

Primary Water Content of Boiler (unpressurised) 1.1

Temperatures

C.H. Flow Temp

(adjustable)

35°C to 85°C max

(± 5°C)

LPG Gases Propane - G31

Burner Injector 15 x 0.77mm diameter

Burner Pressure

Propane mbar in wg

Max Rate

34.4 ± 0.5

13.8 ± 0.2

Inlet Pressures

mbar in wg

37

14.8

Min Rate

5.1 ± 0.5

2.0 ± 0.2

SEDBUK Declaration For System Boiler 60/100

The seasonal efficiency (SEDBUK) is 78.2 %

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been certified by 0051.

Pump - Available Head

6

5.5

5

4.5

4

3.5

3

2.5

2

1.5

1

0.5

0 l/h

0 200 400 600 800 1000 1200

D

B

360° Orientation

C

G

E

A

Tube Ø 100mm

5.0 Dimensions and Fixings

Dimensions

A 780mm

B 345mm

C 450mm

D 107mm Ø Min.

E 200mm

F 190mm

G 143mm

F

Tap Rail

Heating

Flow

(22mm)

130 mm

Gas

Inlet

(22mm)

130 mm

Heating

Return

(22mm)

65 mm

Pressure Relief

Valve

(15mm)

9

10

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.

•

For optimum performance after installation this boiler and its associated central heating system must be flushed in accordance with the guidelines given in

BS 7593 “Treatment of water in domestic hot water central heating systems”.

•

This must involve the use of a proprietary cleanser, such as BetzDearborn Sentinel X300 or X400, or

Fernox Superfloc. Full instructions are supplied with the products, but for immediate information please contact BetzDearborn (0151 420 9563) or Fernox

(01799 550 811) directly.

•

For long term protection against corrosion and scale, after flushing it is recommended that an inhibitor such as BetzDearborn Sentinel X100, or

Fernox MB-1 or Copal is dosed in accordance with the guidelines given in BS 7593.

Failure to flush and add inhibitor to the system may invalidate the appliance warranty.

•

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.)

•

For information or advice regarding any of the above contact the Baxi Helpline.

6.2

Bypass

1. The boiler is fitted with an automatic integral bypass.

6.3

System Control

1. The boiler is designed for use in a heating system that incorporates external controls, i.e. a minimum of a timer device.

2. For optimum operating conditions and maximum economy the fitting of a programmable room thermostat, such the Baxi Combi Controller, is recommended.

Fig. 3

Stop

Valve

Double

Check

Valve

Stop

Valve

Mains

Cold

Water

Temporary

Hose

CH

Return


Fig. 4

Discharge Pipe

6.0 System Details

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.

2. The filling method adopted must be in accordance with the Water Supply (Water

Fittings) regulations and the Water Bylaws

(Scotland).

3. Your attention is drawn to: Paragraph 24 of

Schedule 2 Section 8 of the publication Water

Regulations Guide which gives recommendations and guidance on approved methods for filling sealed systems.

4. The sealed primary circuits may be filled or replenished by means of a temporary connection between the primary circuit and a supply pipe provided the arrangement in accordance with

Diagram R24.2a of the Water Regulations Guide.

5. The temporary hose must be completely removed at both ends after use.

6.5

Expansion Vessel

1. The appliance expansion vessel is pre-charged to 0.5 bar. The vessel is suitable for correct operation for system capacities up to 125 litres.

For greater system capacities an additional expansion vessel must be fitted - refer to BS 7074

Pt 1.

6.6

Pressure Relief Valve (Fig. 4)

1. The pressure relief valve is set at 3 bar, therefore all pipework, fittings, etc. should be suitable for pressures in excess of 3 bar.

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.

11

Fig. 5

5mm Min

450mm Min

For Servicing

Purposes

12

Fig. 6

5mm Min

In Operation

450mm 5mm Min

200mm Min

780mm

200mm Min

7.0 Site Requirements

7.1

Information

1. The installation must be carried out by a CORGI

Registered Installer or other registered competent person and be in accordance with the relevant requirements of the current G

AS

S

AFETY

(Installation and Use) R

EGULATIONS

, the B

UILDING

R

EGULATIONS

(Scotland)(Consolidation), the L

OCAL

B

UILDING

R

EGULATIONS

, the current I.E.E. W

IRING

R

EGULATIONS

and the bye laws of the L

OCAL

W

ATER

U

NDERTAKING

.

Where no specific instruction is given reference should be made to the relevant BRITISH

STANDARD CODES OF PRACTICE. For Ireland install in accordance with IS 813 “I

NSTALLATION OF

G

AS

A

PPLIANCES

”.

7.2

Standard

BS 6891

BS 5546

BS 5449 Part 1

BS 6798

BS 5440 Part 1

BS 5440 Part 2

BS 7074

BS 7593

B.S. Codes of Practice

Scope

Gas Installation.

Installation of hot water supplies for domestic purposes.

Forced circulation hot water systems.

Installation of gas fired hot water boilers.

Flues.

Ventilation.

Expansion vessels and ancillary equipment for sealed water systems.

Treatment of water in domestic hot water central heating systems.

WARNING - The addition of anything that may interfere with the normal operation of the appliance without the express written permission of Baxi UK Limited could invalidate the appliance warranty and infringe the G

AS

S

AFETY

(Installation and Use) R

EGULATIONS

.

7.3

Clearances (Figs. 5 & 6)

1. 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.

7.4

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 7.5).

2. If the boiler is sited in an unheated enclosure then it is recommended to leave the On/Off/Reset Selector

Switch in the domestic hot water and central heating position to give frost protection.

3. If the boiler is fitted in a room containing a bath or shower reference must be made to the current I.E.E.

W

IRING

R

EGULATIONS

and B

UILDING

R

EGULATIONS

. If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication

IGE/UP/7 (Gas Installations in Timber Framed

Housing).

Gas Service Cock

Fig. 7


7.5

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.

7.6

Gas Supply

1. The gas installation should be in accordance with BS 6891.

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. Do not use pipes of a smaller diameter than the boiler gas connection

(22mm).

7.7


1. External wiring must be correctly earthed, polarised and in accordance with current I.E.E.

Wiring Regulations.

2. The mains supply must be 230V ~ 50Hz and fused at 3A maximum.

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.

4. A switched live feed should be taken from the cylinder thermostat to the boiler. This will operate the boiler when there is a demand for domestic hot water (see Section 8.8 for details of suggested system wiring schemes).

13

14


7.8

Flue

1. The flue terminal position must be in

accordance with the current editions of B.S.

5440 Part 1, and either Part J of the Building

Regulations England and Wales or Part F of the Building Standards (Scotland)

Regulations as appropriate.

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.

D

J

K

G

L

M

E

A

G

B,C

N

G

F

A

D

F

Likely flue positions requiring a flue terminal guard

H,I

Fig. 9

Terminal Position with Minimum Distance (Fig. 9) (mm)

A Directly below an openable window, air vent or any other ventilation opening.

B Below gutter, drain/soil pipe.

C Below eaves.

D Below a balcony/car port roof.

E From vertical drain pipes and soil pipes.

F From internal or external corners.

G Above adjacent ground or balcony level.

H From a surface facing a terminal.

I Facing a terminals.

J From opening (door/window) in carport into dwelling.

K Vertically from a terminal on the same wall.

1200

1500

L Horizontally from a terminal on the same wall.

M Above an opening, air brick, opening window etc.

300

300

N Horizontally to an opening, air brick, opening window etc.

300

300

25

25

25

25

25

300

600

1200

Terminal

Assembly

300 min

Top View Rear Flue

Property Boundary Line

Fig. 11

Adhesive Seal

100mm

1m

Fig. 10

Flue Trim

1.0 Introduction

7.9

Flue Dimensions

The standard horizontal flue kit allows for flue lengths between 100mm and 1m from elbow to terminal (Fig. 10).

The maximum permissible equivalent flue length is: System 35/60 5 metres

System 60/100 4 metres

7.10

Flue Terminal Trim

1. Once the flue is secure the trim can be fitted if required.

2. Remove the protective backing from the adhesive seal. Apply the seal to the rear of the trim flange (Fig. 11).

3. Locate the trim over the flue terminal and push it back to the wall to compress the seal (Fig. 12).

Fig. 12

7.11

Terminal Guard (Fig. 13)

1. When codes of practice dictate the use of terminal guards, they can be obtained from most

Plumbers’ and Builders’ Merchants.

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.

Fig. 13

15

16

Maximum Length = 3m (60/100) 4m (35/60) inc. 2 x 45° bends

Horizontal

Flues

Vertical

Flues

(Twin Pipe)

Maximum Length =

11m (60/100)

14m (35/60) inc. 4 x 45° bends

Vertical

Flues

Maximum Length = 2m inc. 2 x 90° bends


7.12

Flue Options

1. The Baxi System 35/60 and 60/100 can be fitted with flue systems as illustrated.

2. The standard flue is suitable only for horizontal applications.

3. Maximum permissible equivalent flue lengths are:-

Concentric

35/60 60/100

5m 4m

Vertical

Vertical Two-Pipe

4m

15m

4m

12m

4. Any additional “in line” bends in the flue system must be taken into consideration.

Their equivalent lengths are:-

Concentric Pipes:

45° bend

90° bend

Twin Flue Pipe

45° bend

90° bend

0.5 metres

1.0 metres

0.25 metres

0.50 metres

The elbow supplied with the standard horizontal flue is not included in any equivalent length calculations

5. The illustrations opposite show examples of maximum equivalent lengths.

6. Full details of part numbers and descriptions of all optional flue components and kits can be found in the Baxi Gas Central Heating Boilers

Installers’ Guide.

7. Instructions for guidance and fitting are included in each kit where appropriate.

Appliance Wall Plate

190mm

For Side Flue Exit

Flushing Tube


Fig. 15

200 mm

Minimum

Clearance

107mm Dia Minimum

Aperture For Flue Tube

Fixing Template

Horizontal Side Flue

Centre Line

Boiler Mounting Bracket Fixing Slots

Drill 8 mm diameter x 50 mm deep

Vertical Flue

Centre Line

System

Boiler

FIXING

TEMPLATE

5 mm Minimum

Side Clearance

Profile of

Outercase

General

Area For

Electrical

Supply

5 mm Minimum

Side Clearance

IMPORTANT

Keep rear routed pipework, clips and electrical cables clear of all shaded areas to allow the correct fitting of the boiler chassis

Boiler Lower Fixing Holes

Drill 8 mm diameter x 50 mm deep

Fig. 14

95 mm

Heating

Flow

(22mm)

200 mm

Minimum

Clearance

130 mm

Gas

Inlet

(22mm)

130 mm

Heating

Return

(22mm)

65 mm

Pressure Relief

Valve

(15mm)

8.0 Installation

8.1

Initial Preparation

The gas supply, gas type and pressure must be checked for suitability before connection (see

Section 7.6).

1. After considering the site requirements

(see Section 7.0) position the fixing template

(Fig. 14) 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. Mark the position of the centre of the flue hole

(rear exit). For side flue exit, mark as shown.

4. Note the shaded area on the template.

Pipework may be routed upwards behind the boiler, providing it does not conflict with the shaded area.

5. If required, mark the position of the gas and water pipes. Remove the template.

6. Cut the hole for the flue (minimum diameter

107mm).

7. Drill the wall as previously marked to accept the wall plugs supplied. Secure the wall plate using the fixing screws.

8. Using a spirit level ensure that the plate is level before finally tightening the screws.

9. 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.

Wall Plate

8.2

Flushing

1. Connect a tube to the central heating flow or return pipe (Fig. 15).

2. Flush thoroughly (see System Details, Section

6.2).

8.3

Preparing The Boiler

1. Remove all packaging.

2. Stand the boiler on its base by using the rear lower edge as a pivot.

NOTE: A small amount of water may drain from the boiler in the upright position.

Baxi UK Limited declare that no substances harmful to health are contained in the appliance or used during appliance manufacture.

17

18


Fig. 17

Fig. 16

Wall Plate


8.4

Fitting The Boiler

1. Remove the sealing caps from the boiler connections.

2. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate (Fig. 16).

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.

5. Secure the boiler side panels to the boiler wall plate flanges using the screws provided (Fig. 16).

8.5

Fitting the Pressure Relief

Discharge Pipe (Fig. 17)

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 6.6 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.

Discharge Pipe

Fig. 18

Wall Thickness

(X)

(X)

Wall Thickness


8.6

Fitting The Flue

HORIZONTAL FLUE

1. The standard flue is suitable for lengths

100mm minimum to 1m maximum (measured from the edge of the flue elbow outlet).

Rear Flue: maximum wall thickness - 900mm

Side Flue: maximum wall thickness - 870mm

2. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (rear, right or left).

3. Measure the distance from the outside wall face to the elbow (Fig. 18). This dimension will be known as ‘X’.

4. Taking the air duct, mark dimension ‘X’ as shown (Fig. 19). Measure the length of waste material, and transfer the dimension to the flue duct (Fig. 19).

IMPORTANT: Check all measurements before cutting.

5. Remove the waste from both ducts. Ensure that the cut ends are square and free from burrs.

6. Remove the flue elbow from the adaptor.

7. Insert the flue duct into the air duct and pass them through the hole in the wall.

Fig. 19

(X)

Air Duct

Waste

Waste

Flue Duct

19

Elbow

Fig. 20

Seal

Adaptor

Clip

Screws

Seal

Fig. 21

Fig. 22

20

Fig. 23

Clip

Restrictor

Flue Duct

Clamp

Flue Duct

Screws

Seal

Air Duct


8.6

Fitting the Flue (Cont)

IMPORTANT: If the equivalent flue length is greater than 1.5m the restrictor MUST be removed from the adaptor (Fig. 20).

8. Take one of the rubber seals and position it on the boiler flue adaptor. Engage the flue elbow on the adaptor and pull the sleeve up so that it equally covers the joint (Fig. 20).

9. Remove the screws from one of the clips provided. Prise the clip apart and fit it over the seal (Fig. 21). Set the elbow to the required angle.

10. Refit the screws to the clip and tighten them to secure the elbow. Take the second rubber seal and position it on the flue elbow.

11. Locate the flue duct clamp on the flue outlet elbow. Draw the flue duct out of the air duct, engage it in the clamp and tighten the screws

(Fig. 22).

12. Draw the air duct out of the wall and align it with the elbow. Position the seal so that it equally covers the joint (Fig. 23).

13. Remove the screws from the second clip provided. Prise the clip apart and fit it over the seal. Refit the screws to the clip and tighten them

(Fig. 23).

14. Where possible position the clips so that the screws are not visible.

15. Make good between the wall and air duct outside the building.

16. Fit the circular flue trim outside if required, and if necessary fit a terminal guard (see Section 7.10

& 7.11).

8.7

Extensions & Additional Elbows

1. The method of connecting any flue extensions or additional elbows is the same as that for connecting the standard flue and 90° elbow as described above.

2. If, for example, when a flue extension is connected to a 90° elbow the flue duct will project from the air duct at the unconnected end by the same ammount as the flue duct spigot does from the elbow . Further elbows or extensions can then be added to this.

3. Similarly, a concentric flue can be connected to the boiler adaptor in the same manner as it does to the elbow to provide a vertical flue.

4. The additional 90° elbow available is identical to the elbow supplied with the standard flue. 45° elbows are of the same principle.

5. Extensions can be cut according to the requirements of the installation.


8.8

Making The Electrical Connections

Fig. 25

Control Box Cover

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.

2. Remove the screws securing the facia panel and hinge it down (Fig. 24).

3. Remove the control box cover securing screws. Disengage the barbs on the control box from the cover. Remove the cover (Fig. 25).

4. Slacken the cable clamp on the LH side of the boiler chassis (Fig. 26). Insert the cable through the clamp and route it to the terminal block.

Fig. 24

Fig. 26

Cable Clamp

Internal Fuse

230V ~ 50Hz fused 3A maximum

D.H.W. Connections

(DHW Relay PCB)

Always fit fast blow 2A fuse

Facia Panel

5. Slacken the screws in the terminal block, connect the input cable, and tighten the screws.

6. If an external control is to be connected it can be done at this point. Run the input cable from the external control through the second cable clamp on the boiler chassis. Refer to the instructions supplied with the control.

7. To connect external control(s) remove the link between terminals 1 & 2. The switched output from the external control must be connected to terminal 2 (Fig. 27).

230V S/L from external control

Live (brown)

Neutral (blue)

Earth (green/yellow)

1

2 br b g/y bk bk

8. Any domestic hot water control should be connected to the DHW relay PCB (Fig. 24) in most installations. See Section 8.8 for details of suggested system wiring schemes

Terminal Block

Fig. 27

IMPORTANT: The external control MUST be suitable for 230V switching and fused 3A maximium

External

Controls

L

230 V

Fig. 28

bk b br br

Selector /

Reset Switch

DHW

Controls bk

L

N

DHW Relay

PCB r b g g

Key to Wiring

b - blue br - brown bk - black r - red g - green

Functional Flow Diagram

PCB

r r r r g b b g b br

Pump br br bk b br

Fan bk bk b b

Pressure Switch

Safety Overheat Thermostat

Central Heating

NTC Sensor

N

N

Primary Return Sensor

Gas Valve br

Gas Valve Modulator

Flame Sensing Electrode r Spark Electrode

Spark

Generator b

N

Hydraulic Differential Pressure Switch

9. Ensure that both mains input and, where fitted, external control input cables have sufficient slack to allow the control box to drop down. Tighten the cable clamp(s) on the boiler chassis.

21


1. The system should include a domestic hot water cylinder thermostat, room thermostat, timer and zone valve(s).

2. A system frost protection thermostat is shown in each diagram. This is in addition to the boiler frost protection thermostat that is integral to the appliance.

3. When the boiler selector switch is in the central heating and domestic hot water position there will be a 230V supply at terminal 1 of the boiler terminal strip.

4. The boiler incorporates a domestic hot water thermostat that allows a maximum temperature of

65°C. For this feature to operate the boiler requires a switched live feed to the domestic hot water relay

PCB.

230V 50Hz fused 3A maximum

L N E

2 1 E N L

Terminal Block

Baxi System

Boiler

Scheme 1

5. Methods of wiring several typical heating schemes are shown. In Scheme 1 the boiler does not differentiate between central heating and domestic hot water demands. With Schemes 2, 3 &

4 the boiler utilises the benefit of the integral domestic hot water thermostat referred to above which overrides any temperature requirements of the central heating control(s).

6. It is recommended that the central heating temperature control is always set at maximum.

Scheme 1

b g/y

Room

Thermostat w gr o

2 1 3

3 Port Valve

Mid Position

A

AB

B

1 2 3 4 5 6 7 8 9 10 b - blue w - white o - orange gr - grey g/y - green/yellow

L

N

HTG

HW On

HW Off

Timer

Cylinder

Thermostat

1

C 2

7. Scheme 1 shows the use of a 3 port mid position zone valve and is based on a ‘Y’ plan system. The boiler will provide hot water to the central heating system, domestic hot water store or both.

8. A live feed to terminal 2 of the boiler terminal strip controls the boiler. This feed is taken from either the DHW cylinder thermostat or via the mid position valve depending upon demand.

9. The timer must supply a signal to the zone valve when there is no hot water demand in order that port ‘B’ may be closed off.

3

1

Frost

Thermostat

10. It is not necessary to connect any control(s) to the boiler domestic hot water relay PCB. As a result of this the domestic hot water thermostat will not operate and the cylinder thermostat must be relied upon to limit the temperature of DHW.

11. The selector switch must be in the central heating and domestic hot water position at all times for the boiler to operate.

22

8.9

System Wiring



L N E

Frost

Thermostat

Scheme 2

Baxi System

Boiler

PCB

L

Terminal Block

N E 1 2

L N

Relay

Board


L N E

Timer

Scheme 3

gr

Zone Valve

HTG b g/y

Motor

DHW

HTG br

M gr

Zone Valve

DHW o b g/y

Motor o

Cylinder

Thermostat

1

C 2

Room

Thermostat

2 1 3

1 2 3 4 5 6 7 8 9 10

M

Timer

HW

HTG

N L b - blue w - white o - orange br - brown gr - grey g/y - green/yellow

Room

Thermostat

2 1 3

2 1 E N L

Terminal Block

1 2 3 4 5 6 7 8 9 10

Relay

Board

Baxi System

Boiler

N L

PCB br

3 Port Valve

2 Position b g/y

DHW

A

AB

B

HTG

Frost

Thermostat

Cylinder

Thermostat

1

C 2

8.9

System Wiring (cont)

Scheme 2

12. Scheme 2 incorporates two 2 port zone valves and is based on an ‘S’ plan system. The boiler will provide hot water to the central heating system, domestic hot water store or both.

13. The boiler is controlled by a live feed from either zone valve depending upon demand.

14. The domestic hot water relay PCB is fed from the domestic hot water zone valve. Central heating demand is controlled by a live feed to terminal 2 on the boiler terminal strip from the central heating zone valve.

15. When there is a demand for domestic hot water the boiler will not supply water at a temperature greater than 65°C irrespective of the setting of any central heating control(s) or if the cylinder thermostat is set higher.

16. Additional 2 port zone valves may be incorporated in the system as required and wired in the same manner as the basic system.

Scheme 3

17. Scheme 3 shows the use of a 3 port two position zone valve and is based on a ‘W’ plan system. The boiler will provide hot water to the central heating system or domestic hot water store.

18. When there is a demand for domestic hot water and the cylinder thermostat is not satisfied the zone valve will be energised to open port ‘A’.

19. The zone valve is installed so that port ‘A’ is connected to the domestic hot water circuit and port ‘B’ to central heating. This is the reverse of a conventional ‘W’ plan. It ensures that the valve is energised only when there is a hot water demand, not for long periods i.e. central heating demand.

20. The boiler is controlled by a live feed from either room or cylinder thermostat depending upon demand.

21. The domestic hot water relay PCB is fed from the cylinder thermostat. Central heating demand is controlled by a live feed to terminal 2 on the boiler terminal strip from the room thermostat.

22. Whilst there is a domestic hot water demand the central heating circuit will not be served. Once the cylinder thermostat is satisfied the zone valve allows circulation of water through the heating circuit even if the timer still calls for domestic hot water.

23. When there is a demand for domestic hot water the boiler will not supply water at a temperature greater than 65°C even if the cylinder thermostat is set higher.

23


8.9

System Wiring (cont)


L N E

2 1 E N L

Terminal Block

PCB

L

N

Relay

Board

Baxi System

Boiler

Scheme 4

b g/y

Room

Thermostat w gr o

2 1 3

3 Port Valve

2 Position

A

AB

B

1 2 3 4 5 6 7 8 9 10

L

N

HTG

HW On

HW Off

Timer b - blue w - white o - orange gr - grey

Cylinder

Thermostat

1

C 2

Scheme 4

24. Scheme 4 utilises an existing 3 port mid position zone valve and is based on a ‘Y’ plan system but with significant changes. The zone valve operates as a two position type and the boiler is controlled as in Scheme 3.

25. To convert a standard ‘Y’ plan to Scheme 4 proceed as follows:i) Change the orientation of the zone valve so that port ‘A’ serves domestic hot water and port

‘B’ the central heating.

3 1

Frost

Thermostat ii) Remove the wire between 7 on the terminal strip and terminal 2 of the cylinder thermostat.

iii) Disconnect the orange zone valve wire from 8 on the terminal strip and connect to 9.

g/y - green/yellow iv) Disconnect the grey zone valve wire from 7 on the terminal strip and connect to 8.

v) Disconnect the white zone valve wire from 5 on the terminal strip and connect to 8.

vi) Connect 8 on the terminal strip to switched live on the domestic hot water relay PCB.

vii) Connect 5 on the terminal strip to terminal 2 of the boiler terminal block.

26. For isolation purposes both the orange zone valve wire and the live signal from the timer to close the domestic hot water port of the zone valve are connected to “dead” points on the terminal strip.

24

DHW Relay

PCB Cover

Facia Panel

DHW Control

Input Cable

N

L

DHW Relay PCB

Fig. 29


8.10

Domestic Hot Water Wiring

The boiler can be wired to operate when there is a demand for replenishment of an indirect domestic hot water storage cylinder.

1. If not already done, slacken the facia securing screws sufficiently to release the outercase panel securing tabs. Lift and remove the panel.

2. Remove the screws securing the facia panel and hinge it down.

3. Slacken the cable clamp on the R.H. side of the boiler chassis. Insert the cable from the cylinder thermostat through the cable clamp.

4. Undo the screws securing the DHW relay PCB cover. Remove the cover. Slacken the screws in the terminal block on the PCB and connect the switched live and neutral (Fig. 29).

5. Lay the input cable in the cut out in the relay

PCB housing and refit the cover and screws.

6. Ensure that the input cable has sufficient slack to allow the control box to drop down. Tighten the cable clamp on the boiler chassis.

8.11

Preliminary Electrical Checks

1. 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 Ground Continuity,

Resistance to Ground, Short Circuit and Polarity.

25

Fig. 30

Selector Switch

Pump

30° 40° 50° 60° 70° 80°

Screw

Automatic

Air Vent

Fig. 31

2

1

0

bar

4

3

Pressure

Gauge

2

bar

9.0


9.1


1. Reference should be made to BS 5449 when commissioning the boiler.

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. 30).

4. The system must be flushed in accordance with BS 7593 and the flushing agent manufacturers instructions.

5. Pressurise the system to 0.2 bar then close and disconnect the filling loop.

6. Turn the gas supply on and purge the system according to BS 6891.

7. Test for gas soundness.

8. If at any time during commissioning it is required to terminate a particular cycle, e.g. the pump overrun period, turn the selector to the Off position and then back to the On position ( )

(Fig. 32).

Power On

Neon

Central Heating

Temperature Control

Fig. 32

26

Fig. 33

Plastic

Protection

Cap

Pressure Test Point

Sealing Screw

Modulator

Wire

Minimum Rate

Adjustment Nut

Maximum Rate

Adjustment Nut

Fig. 34

Selector Switch

30° 40° 50° 60° 70° 80°

Gas Valve

Power On Neon

Temperature Control

Fig. 36

Fig. 35

2

1

0

bar

4

3

Pressure

Gauge

2

bar

9.0


9.2

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.

2. Set the temperature control to maximum and the selector switch to the Off position (Fig. 36).

3. Slacken the pressure test point sealing screw on the gas valve and connect a pressure gauge

(Fig. 33).

4. Undo the screws securing the inner door panel.

Lift the panel slightly to disengage it from the studs on top of the case.

5. Turn the selector switch fully anticlockwise against the spring pressure to position R and hold for 2 seconds to reset the boiler.

6. Turn the selector switch to the Cental Heating and Domestic Hot Water position ( ). The power On neon ( ) will illuminate (Fig. 36).

7. The pressure should be as quoted in Section

4.0 Technical Data. If not, check that the gas supply pressure is correct (Natural Gas 20mbar,

Butane 30mbar and Propane 37mbar).

8. The pressure can be adjusted if required.

9. To check and set minimum pressure first remove one of the modulator wires.

Adjusting the Pressure (Fig 34)

10. Remove the plastic protection cap from the pressure adjustment nuts on the valve.

11. The smaller nut (5mm) adjusts minimum pressure and the larger nut (8mm) maximum pressure.

12. Using a suitable spanner adjust the relevant nut until the correct pressure is achieved.

13. Once the pressure has been set turn the boiler off and disconnect the pressure gauge.

14. Tighten the pressure test screw and refit the modulator to the valve. Reassemble in reverse order.

27

28

Case Front Panel

Fig. 37

Facia Panel

10.0 Completion

10.1

Completion

1. Hinge the facia panel upwards and refit the case front panel. Secure them with the screws previously removed (Fig. 37).

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” Installation, Commissioning and

Service Record Log Book that are relevant to the appliance and installation. The details of the Log

Book will be required in the event of any warranty work. The Log Book must be handed to the user for safe keeping and each subsequent regular service visit recorded.

4. Hand over the Users Operating, Installation and Servicing Instructions and the Log Book, giving advice on the necessity of regular servicing.

11.0 Servicing the Boiler

Case Front Panel

Fan Wires

Fan

Inner Door

Panel

Fig. 38

Facia Panel

Securing Screws

Combustion

Box Door

Sensing

Tubes

Fig. 40

11 .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.

2. After servicing, complete the relevant section of the “Benchmark” Installation, Commissioning and

Service Record Log Book. This should be in the possession of the user.

3. Ensure that the boiler is cool.

4. Ensure that both the gas and electrical

supplies to the boiler are isolated.

Ease Outlet Sealing

Collar Upwards

5. Slacken the screws securing the facia panel.

Lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel (Fig. 38).

6 Remove the facia securing screws and hinge the panel down.

Outlet Sealing

Collar

7. Remove the screws (2 on 35/60, 4 on 60/100) securing the inner door panel. Lift the panel slightly to disengage it from the studs on top of the case (Fig. 39).

8. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them (Fig. 40).

9. Slacken the screws on the outlet sealing collar.

Ease the collar upwards as far as possible

(Fig. 40).

10. Remove the four screws securing the combustion box door and remove the door

(Fig. 39).

35/60 models

Fig. 41

60/100 models

Combustion

Box Door

Inner Door

Panel

29

Fan and Hood

Assembly

Fig. 42

Electrode

Grommets

Burner

Fig. 43

Spring Clip

Fig. 41

Baffle

Tab

11.0

Servicing the Boiler

11.1

Annual Servicing (Cont)

11. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood (Fig. 41).

12. Undo the screws securing the fan and hood to the appliance back panel. Draw the assembly forwards (Fig. 42).

13. Undo the screws securing the burner to the injector manifold (60/100 model only). Draw the burner out of the combustion box, pulling the electrode grommets from the slots in the combustion box lower panel (Fig. 43).

14. Disconnect the electrode leads and grommets from the electrodes. Completely remove the burner (Fig. 43).

15. Brush any deposits from the injectors. Do not use a pin or wire to clean them.

16. Brush the burner blades and venturis and clean the combustion box.

17. Ensure that the heat exchanger fins are clear of any obstruction.

18. Check that the pressure vessel charge is

0.5bar and reassemble in reverse order of dismantling.

19. Turn the selector switch fully anticlockwise against the spring pressure to position R and hold for 2 seconds to reset the boiler before recommissioning.

20. Complete the relevant section of the

“Benchmark” Installation, Commissioning and

Service Record Log Book and hand it back to the user.

30


Pressure

Switch

Pressure

Switch Wires

Fig. 44

Fan Wires

Fan and Hood

Assembly

Fan

Sensing

Tubes

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 position R and hold for 2 seconds to reset the boiler before recommissioning.

See Section 11.1 “Annual Servicing” for removal of case panel, door etc.

12.1

Pressure Switch (Fig. 44)

1. Note the positions of the two sensing tubes and three wires and remove them.

2. Remove the two screws holding the pressure switch to the combustion box top panel.

3. Fit the new pressure switch and reassemble all components in reverse order of dismantling.

Sensing Tubes

Fig. 45

Outlet Sealing

Collar

Spring Clip

Baffle

Tab

12.2

Fan (Figs. 45 & 46)

1. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them.


Ease the collar upwards as far as possible.

3. Remove the four screws securing the combustion box door and remove the door.

4. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood.

5. Undo the screws securing the fan hood to the appliance back panel, and draw the fan and hood assembly forwards.

6. Remove the screws and spring washers securing the fan to the hood.

7. Fit the new fan to the hood using the screws and spring washers previously removed.

8. Reassemble in reverse order of dismantling.

Spring

Washer

Securing Screw

Fan Hood

Fig. 46

31

Pipe Connecting

Clips

Heat Exchanger

(35/60 model)

Heat Exchanger

(60/100 model)

Pipe Connecting

Clips

Fig. 47

Electrodes

Electrode

Grommets

Electrode

Leads

32

Burner

Fig. 48


12.3

Heat Exchanger (Fig. 47)

1. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them.


Ease the collar upwards as far as possible.


4. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood.

5. Undo the screws securing the fan hood to the appliance back panel, and draw the fan and hood assembly forwards.

6. Drain the primary circuit. Prise the two pipe connecting clips off the joints in the flow and return pipes.

7. Lift the heat exchanger to disconnect the flow and return pipe joints. Withdraw it from the appliance, taking care not to damage the rear insulation piece.

8. Fit the new heat exchanger.

9. Reassemble in reverse order of dismantling, and repressurise the system.

12.4

Burner (Fig. 48)


2. Undo the screws securing the burner to the injector manifold (60/100 model only). Draw the burner out of the combustion box, pulling the electrode grommets from the slots in the combustion box lower panel.

3. Disconnect the electrode leads and grommets from the electrodes. Completely remove the burner.

4. Undo the screws securing the electrodes to the burner. Examine the condition of the electrodes, replacing if necessary. Fit the electrodes to the new burner.

5. Engage the burner location brackets over the studs on the injector manifold and reassemble in reverse order.

Electrodes

Electrode

Grommets

Electrode

Leads

Side Insulation

Injector

Manifold

Injector

Burner

Fig. 49

Rear Insulation

Inlet Elbow

Gasket


12.5

Injectors (Fig. 49)

1. Remove the burner as described in Section

12.4.

2. Undo the screws securing the injector manifold to the inlet elbow and remove the manifold.

3. Unscrew and replace injectors as required and examine the sealing gasket, replacing as necessary. Reassemble in reverse order.

12.6

Electrodes (Fig. 49)


2. Undo the screws securing the burner to the injector manifold (60/100 model only). Draw the burner out of the combustion box, pulling the electrode grommets from the slots in the combustion box lower panel.

3. Disconnect the lead and grommet from the electrode being replaced. Undo the securing screw and withdraw the electrode to the burner.

4. Reassemble in reverse order.

12.7

Insulation (Fig. 50)


2. Slide the side insulation pieces carefully out of their carriers.

3. To replace the rear insulation piece it is necessary to remove the heat exchanger as described in Section 12.3 and slide out the side pieces.

4. The combustion box door insulation piece can be replaced by carefully bending up the two retaining tabs.

5. Replace all insulation pieces and reassemble in reverse order.

13.8

Combustion

Box Door

Fig. 50

Front Insulation

Side Insulation

33

Modulator

Wires

Electrical

Plug

Earth Wire

Inlet Pipe

Fig. 51

Gas Feed

Pipe

Flow Pipe

Central Heating

Temperature Sensor

Safety

Thermostat

Fig. 52

34

Return Heating

Temperature Sensor

Retaining Clip

Gas Valve

Heating Return Pipe

Fig. 53


12.8

Gas Valve (Fig. 51)

1. Undo the nut on the gas feed pipe under the boiler.

2. Remove the securing screws and hinge the facia panel down.

3. Disconnect the earth wire and pressure sensing pipe from the valve. Undo the screw securing the electrical plug to the valve and disconnect the plug. Disconnect the wires from the valve modulator.

4. Remove the screws securing the inlet pipe flange to the boiler bottom panel and those securing the outlet manifold to the burner manifold.

5. Remove the valve from the boiler.

6. Note the orientation of the inlet pipe and outlet manifold. Undo the securing screws and remove the pipe and manifold.

7. Examine the ‘O’ ring seals for damage, replacing as necessary.

8. Fit the inlet pipe and outlet manifold to the new valve, ensuring that the ‘O’ ring seals are in place.

9. Reassemble in reverse order and check the burner pressure as described in Section 9.2.

12.9

Central Heating Temperature Sensor

(Fig. 52)

1. 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.

12.10

Safety Thermostat

(Fig. 52)

1. Pull the electrical connections off the thermostat.

2. Remove the screws securing the thermostat to the mounting plate on the flow pipe.

3. Reassemble in reverse order. The thermostat is not polarised - either wire can fit either terminal on the thermostat.

12.11

Return Heating

Temperature Sensor

(Fig. 53)

1. 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.


Pump Wiring

Cover

Pump Body

Socket Headed

Screw

Fig. 55

Pump Setting

Pump Wiring

Cover

Pump Head

Fig. 54

Automatic

Air Vent


12.12

Pump - Head Only (Fig. 54)

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 Grundfos replacement head can now be fitted. A Grundfos 15-50 head is suitable for the System 35/60. The System 60/100 requires a 15-60 head. Connect the wiring to the new head. The pump speed must be set to 3

(Fig. 55).


12.13

Pump - Complete (Fig. 56)

1. Drain the primary circuit and unscrew the automatic air vent from the pump body. Undo the two screws securing the body to the pipe and manifold and draw the pump forwards.

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. Connect the wiring to the new pump. Examine the ‘O’ ring seals on the return pipe and manifold, replacing if necessary.

4. Fit the air vent to the pump body and reassemble in reverse order.

12.14

Automatic Air Vent (Fig. 56)

1. 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.


Fig. 56

35

Fig. 57

Gauge Retaining

Bracket

Fig. 58

Boiler

Chassis

Lock Nut

Fig. 59

Mounting Bracket

Pressure Gauge

Capillary

Pressure Gauge

Expansion Vessel

Vessel Outlet

Spigot

Spring

Washer

Timer Cover


12.15

Pressure Gauge (Figs. 57 & 58)

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.

3. Remove the bracket and gauge assembly.

Depress the barbs on the side of the gauge and remove the retaining bracket.


12.16

Expansion Vessel (Fig. 59)

1. To replace the expansion vessel it is necessary to remove the boiler from the wall.

Retaining Clip

NOTE: Alternatively a vessel of equivalent capacity can be fitted on the system return pipe as close as possible to the boiler.

2. Drain the system and undo all gas and water connections. Remove the flue elbow.

3. Lift the boiler off the wall plate and lay it on either side on a clean flat surface.

Upper Cross

Member

4. Undo the nut on the vessel outlet spigot, and remove the locknut and spring washer securing the spigot to the boiler chassis.

5. Undo the screws and remove the appliance upper cross member. Slide the expansion vessel out of the retaining clips.

6. Reassemble in reverse order. Fully recommission the appliance and system.

12.17

Spark Generator (Fig. 60)

1. Pull the electrode lead off the spark generator. Remove the screws and spring washers securing the generator to its mounting bracket.

2. Pull the rubber shroud off the generator input plug and disconnect the plug.


Spark Generator

Fig. 60

Electrode Lead

36

Fig. 61

Control Box Cover

PCB

Selector

Switch

Facia

Selector Switch Knob

Fig. 62


12.18

DHW Relay PCB (Fig. 62)

1. Undo the screws securing the DHW relay PCB cover. Remove the cover.

2. Remove 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. Disconnect the live feed and neutral from the external control at the relay PCB.

4. Disconnect the green wires from the 2-way electrical connection block adjacent to the main

PCB. Undo the securing screws and remove the relay PCB.


DHW

Potentiometer

12.19

Main PCB (Fig. 62)

Control Knob

Drive Pin

DHW Relay

PCB

1. Note the setting of the temperature control knob. Rotate the knob fully anticlockwise and carefully pull it off the drive pin.

2. Remove 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. 61).

3. Note the position of all plugs and wires on the

PCB and disconnect them.

4. Undo the securing screws and remove the

PCB. Transfer the control knob drive pin to the new PCB and turn it fully anticlockwise.

5. Reassemble in reverse order, ensuring that the temperature controller is reset to the previous position.

6. Ensure that the DHW potentiometer is fully anticlockwise once the new PCB is fitted.

Temperature Control Knob

12.20

Selector Switch (Fig. 62)

1. Note the setting of the selector switch knob and carefully pull it off the facia.

2. Remove 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 the electrical connections and the orientation of the switch. Remove the electrical connections.

4. Remove the screws securing the switch to the facia panel.

5. Fit the new switch, ensuring that it is correctly positioned and reassemble in reverse order.

37

Microswitch

Bracket

Fig. 63

Fig. 64

Diaphragm

‘O’ ring seal

Grub Screw

Fig. 65

38

Discharge Pipe



12.21

Central Heating Differential Valve

(Figs. 63 & 64)

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. Remove the screws securing the cover from the valve body. Examine the condition of the diaphragm, spring and pushrod, replacing as necessary.

6. If required the complete valve assembly can be replaced.

7. Examine the sealing washers and ‘O’ ring on the pipes and capillary, replacing as necessary.

12.22

Central Heating Differential Valve

Microswitch (Fig. 64)

1. Remove the two wires from the microswitch.

2. Undo the screw securing the microswitch to the valve body.


12.23

Pressure Relief Valve (Fig. 65)

1. 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 the new valve and ‘O’ ring seal and set to the previously noted orientation. Reassemble in reverse order.

13.0 Illustrated Wiring Diagram

Cylinder Stat

Input

N S/L

Fan

Air Pressure

Switch

Pump

Relay Board

Hydraulic Differential

Pressure Switch

Control PCB

10

9

8

7

6

5

4

3

2

1

A5

bk bk r r g g g r g r

Flame

Sensing

Electrode

F2 br bk b r g g/y w

- brown

- black

- blue

- red

- green

- green / yellow

- white

A1

1 2 3 4 5 b b br br

A2

1 2 3 4 b br br bk b

5 6 7 8 9 b b

1

A3

2 3 4 1 2 b

A4

4 5 br

3 6 r b br bk

Return Heating

Temperature Sensor

Central Heating

NTC Sensor

Mains Input

Link g/y b br

Fuse bk g/y

Overheat Stat

Gas Valve

Spark Generator br b

Reset Selector Switch

39

40


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), 27mbar

(butane) or 36mbar (propane).

2. Carry out electrical system checks, i.e. Ground Continuity, Resistance to Ground, Short Circuit and Polarity with a suitable meter.

NOTE: These checks must be repeated after any servicing or fault finding.

3. 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.

Refer to Section 13.0 “Illustrated Wiring Diagram” for position of numbered terminals

Central Heating - Follow operational sequence

Turn selector to neon illuminated

YES

NO

Go to section ‘A’

NOTE: When instructed to turn the selector to the reset position turn the selector switch fully anticlockwise against the spring pressure to position R and hold for 2 seconds to reset the boiler.

neon flashing

Go to section ‘B’

YES

Turn temperature control to max.

Pump runs

YES

Primary flow switch operated

NO

NO

External controls calling for heat neon flashing

Go to section ‘C’

NO

Ensure controls are set to demand and verify the contacts are closed

YES

Fan runs at max speed

YES

NO neon flashing

NO neons flashing

Go to section ‘D’

YES

Turn selector to reset position. If regular resetting is required or appliance still does not operate investigation is necessary

Go to section ‘J’

Air pressure switch proved

YES

Spark at ignition electrodes for up to 10 seconds

YES

NO

NO neon flashing

Go to section ‘E’ neon flashing

NO

Replace PCB

YES

Turn selector to the reset position. If the neon does not extinguish go to sections ‘H’ & ‘K’

Burner on neon illuminated

YES

Burner extinguishes after 10 seconds

NO

YES

NO

Burner output modulates until set temperature is reached

YES

NO

YES

Burner goes out

Go to section ‘F’ neon flashing

Go to section ‘I’

Go to section ‘G’

Fan stops

YES

Pump stops

YES

Operation sequence correct

Fault Finding Solutions Sections A to E

A

Is there 230V at:

1.

Main terminals L and N

YES

Main terminal fuse

NO

2.

NO

3.

Selector terminals a & b and a & 3. PCB - A4 connector terminals 4 & 5

Check electrical supply

Replace fuse

Check wiring

Replace selector


neon illuminated

NO

B

Is there 230V at:

1.

2.

Pump

NO

If pump jammed, release

NO

PCB - A4 connector terminals 3 & 6

YES

Change pump supply cable

Replace pump

Replace PCB

C

1.

2.

3.

CH system pressure 0.5 to 1.5 bar

NO

Check the tap of the automatic air vent is opened

NO

Primary flow valve diaphragm damaged

NO

YES

Re-pressurise system

Open the automatic air vent

Replace diaphragm

Flow valve rod obstructed

D

1.

Continuity across flow microswitch and PCB - A5 connector terminals 7 & 8

NO

Replace microswitch

2.

Primary temperature sensor faulty.

Cold resistance approx. 11K ohms

(resistance reduces with increase in temp.)

YES

Replace sensor

3.

Fan connections correct at fan.

PCB - A2 connector, is 230V across terminals 5 & 7

NO

YES

Fan jammed or faulty winding

YES

Replace PCB

E

Check and correct if necessary

1. Electrical and pressure tube connections

2. Blockage of pressure tubes

3. Restriction in flue

4. Venturi

NO

Replace air pressure switch

Replace fan

Replace PCB

F

Gas at burner

NO

Ensure gas is on and purged

PCB - A1 connector has 230V AC across terminals 2 & 4

NO

YES neon flashing

YES

NO

Replace PCB

Replace gas valve

Turn selector switch to reset position

R

41

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

YES

Replace gas valve

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)

NO

Replace PCB


H


1. Ignition electrode and lead

2. Electrode connection

3. Spark gap and position

YES

NO

230V at PCB - A1 connector across terminals

3 & 5. Check wiring

YES

Replace PCB

Replace igniter

I

Ensure that mains input terminal L is Live (230V) and

N is Neutral (0V)

YES


1. Flame sensing electrode and lead connections

2. Electrode position

YES

Flame current should be 1 µA approx.

NO

Replace PCB

Replace flame sensing electrode

J

Overheat thermostat operated or faulty, i.e. continuity across thermostat terminals

YES

Replace

PCB

NO

Allow to cool. Continuity across thermostat terminals more than 1.5 ohm

YES Replace safety thermostat

K

NO

Check terminal 1 of On/Off/Reset selector is in connection with PCB - A4 connector terminal 2

Check electrical continuity across terminals 1 & a of On/Off/Reset selector when turned to position

R

YES

Replace On/Off/Reset selector

Replace PCB

42

72

102

63

22

528

140

169

41

131

15.0 Short Parts List

Short Parts List

135

23

44

Key G.C.

No.

No.

22

Description

E66 383 Fan 35/60

E66 527 Fan 60/100

Manufacturers

Part No.

248001

248002

23

32

393 374 Pressure Switch 247380

E66 393 Heat Exchanger 35/60 248016

E66 535 Heat Exchanger 60/100 248017

41

44

59

63

E66 398 Burner 35/60

E66 399 Burner 60/100

E66 408

Injector

Electrode Lead

248029

248030

248210

248037

72

E66 411 Spark or Sensing

Electrode

E66 431 Pump 35/60

E66 539 Pump 60/100

247384

248041

248042

102 Hydraulic Outlet Assy

131 342 571 Temperature Sensor

248490

135 E66 439 Safety Thermostat

247394

248079

140

154

Gas Valve

PCB

5107339

248074

156

169 E66 453 Pressure Gauge

528

DHW Relay PCB

Return Heating

Temperature Sensor

248620

248090

248497

59

154

156

32

35/60 models

32

60/100 models

43

Comp N o 248544 - Iss 5 - 7/02

After Sales Service

08706 096 096

Technical Enquiries

08706 049 049

Baxi UK Limited

Brownedge Road

Bamber Bridge Preston

Lancashire

PR5 6SN www.baxi.com

922.553.1

system_35-60__60

Please leave these instructions with the user

Gas Fired Wall Mounted System Boilers

Installation and

Servicing Instructions

Natural Gas

Contents

“Benchmark” Log Book

Description

Installation

Optional Extras

Layout

Key

Operating Mode (Fig. 2)

Frost Protection Mode

Pump Protection

System 35/60

Pump - Available Head

System 60/100

D

B

C

G

E

A

Dimensions

A 780mm

B 345mm

C 450mm

D 107mm Ø Min.

E 200mm

F 190mm

G 143mm

F

Central Heating Circuit

Bypass

System Control

System Filling and Pressurising

Expansion Vessel

Pressure Relief Valve (Fig. 4)

Information

B.S. Codes of Practice

Clearances (Figs. 5 & 6)

Location

Ventilation of Compartments

Gas Supply

Electrical Supply

Flue

Flue Dimensions

Flue Terminal Trim

Terminal Guard (Fig. 13)

Horizontal

Flues

Vertical

Flues

(Twin Pipe)

Vertical

Flues

Flue Options

Fixing Template

System

Boiler

FIXING

TEMPLATE

Initial Preparation

Flushing

Preparing The Boiler

Fitting The Boiler

Fitting the Pressure Relief

Discharge Pipe (Fig. 17)

Fitting The Flue

Fitting the Flue (Cont)

Extensions & Additional Elbows

Making The Electrical Connections

System Wiring

System Wiring (cont)

System Wiring (cont)

Domestic Hot Water Wiring

Preliminary Electrical Checks

Commissioning the Boiler