Installation & Servicing Instructions Megaflo 2 System Compact GA Range Gas Fired Wall Mounted Condensing System Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2012 Model Range Baxi Megaflo 2 System 12 Compact GA G.C.No 41-075-70 Baxi Megaflo 2 System 15 Compact GA G.C.No 41-075-71 Baxi Megaflo 2 System 18 Compact GA G.C.No 41-075-72 Baxi Megaflo 2 System 24 Compact GA G.C.No 41-075-73 Baxi Megaflo 2 System 28 Compact GA G.C.No 41-075-74 Baxi Megaflo 2 System 32 Compact GA G.C.No 41-075-75 The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Howitzer Industry Council who manage and promote the Scheme. Visit www.centralisation.co.UK for more information. © Baxi Heating UK Ltd 2012 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988. Applications for the copyright owner’s permission to reproduce or make other use of any part of this publication should be made, giving details of the proposed use, to the following address: The Company Secretary, Baxi Heating UK Limited, Brooks House, Coventry Road, Warwick. CV34 4LL Full acknowledgement of author and source must be given. Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly. The Health & Safety Executive operates the ‘Gas Safe Register’, a self-certification scheme for gas heating appliances. These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook (which was then left on site with the customer). With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn. However, a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions. This company is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency. Building Regulations require that installations should comply with manufacturer's instructions. It is therefore important that the commissioning checklist is completed by the installer. The relevant section of Building Regulations only relates to dwellings. Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure. The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations. WARNING: Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages. 0086 ISO 9001 FLEM 00866 2 © Baxi Heating UK Ltd 2012 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 Install and Commission this appliance to manufacturer's instructions Scheme Members only Call ‘Gas Safe Register’ on: 0800 408 5577 or log onto: www.gassaferegister.co.uk within 10 days Complete the Benchmark Checklist You must ensure that the certificate number issued by the ‘Gas Safe Register’ is written onto the Benchmark Checklist ‘Gas Safe Register’ will issue a Building Regulations Compliance Certificate to the property owner and inform the relevant LABC © Baxi Heating UK Ltd 2012 LABC will record the data and will issue a certificate of compliance 3 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. Definition of competence: A person who works for a Gas Safe registered company and holding current certificates in the relevant ACS modules, is deemed competent. In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic Gas Installations”. The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty. In GB this could also infringe the Gas Safety (Installation and Use) Regulations. Warning - Check the information on the data plate is compatible with local supply conditions. This company declares that no substances harmful to health are contained in the appliance or used during appliance manufacture. The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force, and only used in a suitably ventilated location. In GB, the installation must be carried out by a Gas Safe Registered Installer. It must be carried out in accordance with the relevant requirements of the: • Gas Safety (Installation & Use) Regulations. • The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland). • The Water Fittings Regulations or Water Byelaws in Scotland. • The Current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice. In IE, the installation must be carried out by a competent Person and installed in accordance with the current edition of I.S. 813 ‘Domestic Gas Installations’, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation. All Gas Safe registered engineers carry an ID card with their licence number and a photograph. You can check your engineer is registered by telephoning 0800 408 5500 or online at www.gasgaferegister.co.uk All systems must be thoroughly flushed and treated with inhibitor (see section 6.2). The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations 1993 No 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:- Codes of Practice - refer to the most recent version Type test for purpose of Regulation 5 certified by: Notified Body 0085. Product/Production certified by: Notified Bodies 0085 & 0086. For GB/IE only. In GB the following Codes of Practice apply: Standard Scope BS 6891 Gas Installation. BS 5546 Installation of hot water supplies for domestic purposes. BS 6798 Installation of gas fired hot water boilers. BS 5440 Part 1 Flues. BS 5440 Part 2 Ventilation. BS 7074 Expansion vessels and ancillary equipment for sealed water systems. BS 7593 Treatment of water in domestic hot water central heating systems. BS EN 12828 Heating systems in buildings - Design for water-based heating systems BS EN 12831 Heating systems in buildings - Method for calculation of the design heat load BS EN 14336 Heating systems in buildings - Installation and commissioning of water-based heating systems In IE the following Codes of Practice apply: Standard Scope I.S. 813 Domestic Gas Installations. The following standards give valuable additional information; BS 5546 Installation of hot water supplies for domestic purposes. BS 7074 BS 7593 BS EN 12828 BS EN 12831 BS EN 14336 4 © Baxi Heating UK Ltd 2012 Expansion vessels and ancillary equipment for sealed water systems. Treatment of water in domestic hot water central heating systems. Heating systems in buildings - Design for water-based heating systems Heating systems in buildings - Method for calculation of the design heat load Heating systems in buildings - Installation and commissioning of water-based heating systems 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. The boiler should be handled and lifted by TWO PEOPLE. Do not handle or lift unless you feel physically able. Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc. Preparation Co-ordinate movements - know where, and when, you are both going. Minimise the number of times needed to move the boiler - plan ahead. Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care on ladders/into lofts. Technique When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible. Where possible transport the boiler using a sack truck or other suitable trolley. Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the ‘Installation’ section of these instructions for recommended lift points. Remember The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions. If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT ‘work through’ the pain - you may cause further injury. IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !! © Baxi Heating UK Ltd 2012 5 CONTENTS Section 6 © Baxi Heating UK Ltd 2012 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 20 9.0 Installation 22 10.0 Commissioning 27 11.0 Completion & System Draining 29 12.0 Servicing 30 13.0 Changing Components 32 14.0 Combustion & Calibration 39 15.0 Electrical 40 16.0 Short Parts List 41 17.0 Fault Finding 42 18.0 32 kW Model Supplement 47 Benchmark Checklist 50 The 12 to 28 kW models in the Baxi Megaflo 2 System Compact GA Range are of the same dimensions and layout. The 32 kW model differs in several respects - these are detailed in Section 18.0 ‘32 kW Model Supplement’ 1.0 Introduction 1.1 Description 1. The Baxi Megaflo 2 System Compact GA Range are fully automatic gas fired wall mounted condensing system boilers. They are room sealed and fan assisted. 2. The boiler is set to give a maximum output of :12 models - 12 kW 12.7 kW (Condensing) 15 models - 15 kW 15.9 kW (Condensing) 18 models - 18 kW 19 kW (Condensing) 24 models - 24 kW 25.4 kW (Condensing) 28 models - 28 kW 29.6 kW (Condensing) 32 models - 32 kW 33.8 kW (Condensing) Information Label 3. The boiler is factory set for use on Natural Gas (G20). It can be adapted to operate on Propane (G31) - see Section 10.1 ‘Gas Type Check’. 4. The boiler incorporates a circulating pump and expansion vessel. It is suitable for use only on fully pumped sealed systems. Fig. 1 Control Flap 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. 2). 6. The boiler model name and serial number are also shown on the information label behind the boiler control flap (Fig. 1). This is for user reference. 7. The boiler is intended to be installed in residential / commercial / light industrial E.M.C. environments on a governed meter supply only. 8. The boiler must be installed with one of the purpose designed flues such as one of the standard horizontal telescopic flue kits detailed in the Flue Installation Guide. 9. All systems must be thoroughly flushed and treated with inhibitor (see section 6.1). 1.2 Gas Type Label Data Badge Fig. 2 Various timers, external controls, etc. are available as optional extras. Full details are contained in the relevant sales literature. 1.3 NOTE: These Installation & Servicing Instructions MUST be read in conjunction with the Flue Installation Guide supplied in the Literature Pack. © Baxi Heating UK Ltd 2012 Optional Extras Contents of Pack The pack contains:• Boiler • Wall Plate (including taps) • Template • Literature Pack 7 2.0 General Layout 2.1 Layout 12 - 28 Models 3 4 2 1 11 10 1. Expansion Vessel 2. Expansion Vessel Locating Stud 3. Boiler Adaptor 4. Primary Heat Exchanger 5. Pump with Automatic Air Vent 6. Central Heating System Pressure Gauge 7. Fan Assembly 8. Flame Sensing Electrode 9. Air/Gas Collector 10. Spark Ignition Electrode 9 11. Combustion Box Cover & Burner 8 12. Condensate Trap 13. Safety Pressure Relief Valve 14. Boiler Control 15. Gas Valve 16. Boiler Drain Tap 17. Control Box Display 18. Heating Flow Sensor 19. Safety Thermostat 7 12 13 14 17 15 18 5 19 6 16 8 © Baxi Heating UK Ltd 2012 13 3.0 Appliance Operation 3.1 14 12 Operating Mode 1. With a demand for heating, the pump circulates water through the primary circuit. 15 2. Once main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor. 16 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. 17 18 4. When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes (Pump Overrun). 19 20 3.2 21 11 10 Boiler Frost Protection Mode 1. The frost protection mode is integral to the appliance and functions as long as there is power to the boiler, as indicated by the standby signal . 22 2. When the boiler temperature falls below 5°C the boiler will fire until a temperature of 30°C is reached. 9 3. Further protection can be incorporated by using a system frost thermostat. 1 3.3 1. If the boiler has been inactive for a period of 24 hours the pump will automatically operate for 1 minute to prevent sticking. 7 8 2 5 A 6 Pump Protection 3 4 B C D Fig. 3 Key 1. Pump with Automatic Air Vent 2. CH System Pressure Gauge 3. Central Heating Filter 4. Non-return valve 5. Hydraulic Pressure Sensor 6. Boiler Drain Tap 7. Pressure Relief Valve 8. Condensate Trap 9. Gas Valve 10. Safety Thermostat (105°C) 11. Heating Flow Sensor 12. Flue Sensor 13. Boiler Adaptor 14. Primary Heat Exchanger 15. Spark Ignition Electrode 16. Burner 17. Flame Sensing Electrode 18. Air/Gas Collector 19. Heating Return Sensor 20. Fan 21. Air-Gas Venturi 22. Expansion Vessel Connections:A – Condensate Drain B – Heating Flow C – Gas Inlet D – Heating Return © Baxi Heating UK Ltd 2012 9 4.0 Technical Data 4.1 Appliance Category CAT I 2H 3P Electrical Supply 230V~ 50Hz (Appliance must be connected to an earthed supply) Heat Input CH (Net) 12 model kW 15 model kW 18 model kW 24 model kW 28 model kW Max 12 15 18 24 28 Power Consumption 12 model W 15 model W 18 model W 24 model W 28 model W C13 C33 C43 C53 Min 2.1 2.2 2.6 3.5 4.1 Min 2 2.1 2.5 3.4 4 Heat Output CH (Condensing) Max 12 model kW 12.7 15 model kW 15.9 18 model kW 19 24 model kW 25.4 28 model kW 29.6 Min 2.2 2.3 2.8 3.7 4.3 mm mm mm mm mm 3 3.3 3.6 4.6 4.9 NATURAL GAS ONLY ! Max Gas Rate 12 model 15 model 18 model 24 model 28 model (Natural Gas - G20) (After 10 mins) m3/h 1.27 m3/h 1.59 1.90 m3/h m3/h 2.54 m3/h 2.96 Inlet Pressure (Natural Gas - G20) mbar 20 PROPANE ONLY ! Max Gas Rate 12 model 15 model 18 model 24 model 28 model (Propane - G31) (After 10 mins) kg/h 0.93 kg/h 1.17 kg/h 1.4 kg/h 1.86 kg/h 2.18 Inlet Pressure (Propane - G31) mbar 37 NOTE: All data in this section are nominal values and subject to normal production tolerances. Packaged Boiler Carton Installation Lift Weight (12/15/18/24) 36.5kg 32.5kg (28 model) 38.5kg 34.5kg NOx Class 5 Packaged Boiler Carton Installation Lift Weight 110 108 125 104 135 N.G. 9.0% ± 0.7 L.P.G. 10.5% ± 1.0 CO2 Electrical Protection Heat Output CH (Non-Condensing) Max 12 model kW 12 15 model kW 15 18 model kW 18 24 model kW 24 28 model kW 28 Injector 12 model 15 model 18 model 24 model 28 model Weights IPX5D External Fuse Rating 3A Internal Fuse Rating F2L Central Heating Primary Circuit Pressures Condensate Drain To accept 21.5mm (3/4 in) plastic waste pipe Flue Terminal Dimensions Diameter Projection Connections Gas Inlet Heating Flow Heating Return Pressure Relief Discharge Clearances Above Casing Below Casing Front Front L.H. Side R.H. Side - 100mm 125mm Pump Available Head copper tails 22mm 22mm 22mm 15mm (12, 15, 18, 24 & 28) litre *This is MINIMUM recommended dimension. Greater clearance will aid installation and maintenance. - See graph below Expansion Vessel - (For Central Heating only. Integral with appliance) bar Min Pre-charge Pressure 0.5 175 mm Min 150mm Min* 450mm Min (For Servicing) 5mm Min (In Operation) 5mm Min 5mm Min Outercase Dimensions Casing Height Overall Height Inc Flue Elbow Casing Width Casing Depth Max Capacity of CH System 100 Primary Water Content of Boiler (unpressurised) 2.5 Temperatures C.H. Flow Temp (adjustable) 25°C to 80°C max (± 5°C) 700mm 860mm 390mm 300*mm *This can be reduced to 290mm by removing the boiler control access flap Pump - Available Head SEDBUK Declaration 6 SAP 2005 Seasonal Efficiency for N. G. models is 91.1% SAP 2005 Seasonal Efficiency for L.P.G. models is 93.2% SAP 2009 Annual Efficiency for N. G. models is 89% SAP 2009 Annual Efficiency for L.P.G. models is 91% This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of 5.5 5 4.5 4 3.5 3 2.5 2 dwellings. The test data from which it has been calculated 1.5 has been certified by 0087. 1 0.5 0 0 200 400 600 Flow Rate (l/h) 10 © Baxi Heating UK Ltd 2012 bar 3 2.5 0.5 1-2 Safety Discharge Max Operating Min Operating Recommended Operating Range Metre (wg) Appliance Type (See Section 18.0 for 32 kW model) 800 1000 1200 5.0 Dimensions and Fixings Dimensions At least 1.5° G E A 700mm B 300*mm *This can be reduced to 290mm by removing the boiler control access flap A C 390mm D 116mm Ø Min. E 160mm (207mm for 80/125mm flue systems) B F 130mm 360° Orientation G 106mm H D C H 228mm J J 162mm Flue Ø 100mm F Tap Rail Boiler Side Boiler Side Condensate Drain 40 mm Pressure Relief Valve (15mm) 25 mm 130 mm 130 mm 65 mm 162.5 mm Heating Flow (22mm) © Baxi Heating UK Ltd 2012 Gas Inlet (22mm) Heating Return (22mm) 11 6.0 System Details 6.1 Treatment of Water Circulating Systems 1. All recirculatory water systems will be subject to corrosion unless they are flushed and an appropriate water treatment is applied. To prevent this, follow the guidelines given in BS 7593 “Treatment of Water in Domestic Hot Water Central Heating Systems” and the treatment manufacturers instructions. 2. Treatment must involve the use of a proprietary cleanser, such as Sentinel X300 or X400, or Fernox F3 and an inhibitor such as Sentinel X100 or Fernox MB-1. 3. Full instructions are supplied with the products, for further information contact Sentinel (0800 389 4670) or Fernox (0870 870 0362). Failure to flush and add inhibitor to the system will invalidate the appliance warranty. 4. It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the inhibitor manufacturer’s instructions. (Test kits are available from inhibitor stockists.) 5. For information or advice regarding any of the above contact Technical Enquiries 0844 871 1555. 6.2 Bypass 1. The boiler is fitted with an automatic integral bypass. Some systems may require an additional external bypass. 6.3 System Control 1. Further external controls (e.g. room thermostat sensors) MUST be fitted to optimise the economical operation of the boiler in accordance with Part L of the Building Regulations (2010). A range of optional controls are available. Full details are contained in the relevant Sales Literature. 12 © Baxi Heating UK Ltd 2012 6.0 System Details 6.4 Stop Valve Double Check Valve 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 Fig. 4 DHW Mains Inlet Temporary Loop System Filling and Pressurising CH Return 2. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment. 3. Your attention is drawn to: for GB: Guidance G24.2 and recommendation R24.2 of the Water Regulations Guide. for IE: the current edition of I.S. 813 “Domestic Gas Installations”. 4. The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe, provided a ‘Listed’ double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use. 6.5 Fig. 5 Expansion Vessel (Central Heating only) 1. The appliance expansion vessel is pre-charged to 0.5 bar. Therefore, the minimum cold fill pressure is 0.5 bar. The vessel is suitable for correct operation for system capacities up to 100 litres (32 kW model - 155 litres). For greater system capacities an additional expansion vessel must be fitted. For GB refer to BS 7074 Pt 1. For IE, the current edition of I.S. 813 “Domestic Gas Installations”. 6.6 Safety Pressure Relief Valve (Fig. 6) 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 and temperature in excess of 100°C. 2. The pressure relief discharge pipe should be not less than 15mm dia, run continuously downward, and discharge outside the building, preferably over a drain. It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components. The end of the pipe should terminate facing down and towards the wall (Fig. 6a). The end of the pipe should terminate facing down and towards the wall Fig. 6a 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. Control Box removed for clarity Fig. 6 Pressure Relief Valve Discharge Pipe © Baxi Heating UK Ltd 2012 4. A remote relief valve kit is available to enable the boiler to be installed in cellars or similar locations below outside ground level (kit no. 5121379). 5. A boiler discharge pump is available, 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. 13 390mm 5mm Min 7.0 Site Requirements 5mm Min 7.1 175mm 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. (The boiler may be fitted inside a cupboard-see Section 7.3). 2. Where the boiler is sited in an unheated enclosure and during periods when the heating system is to be unused it is recommended that the permanent live is left on to give BOILER frost protection. NOTE: THIS WILL NOT PROTECT THE SYSTEM ! 700mm 3. If the boiler is fitted in a room containing a bath or shower reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules. 4. If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE/UP/7 (Gas Installations in Timber Framed Housing). Fig. 8 150mm* Min 7.2 Clearances (Figs. 8 & 9) 1. A flat vertical area is required for the installation of the boiler. At least 1.5° 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. *This is MINIMUM recommended dimension. Greater clearance will aid installation and maintenance. 7.3 450mm Min Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. For Servicing Purposes 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. 5mm Min 300mm In Operation (290mm with flap removed) Fig. 9 14 © Baxi Heating UK Ltd 2012 7.0 Site Requirement 7.4 Gas Supply 1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891 (NG) or BS 5482 Pt. 1 (LPG). In IE this is the current edition of I.S. 813 “Domestic Gas Installations”. 2. The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock (Fig. 10). 3. Ensure that the pipework from the meter to the appliance is of adequate size, and the demands of any other gas appliances in the property are taken into consideration. Do not use pipes of a smaller diameter than the boiler gas connection (22mm). Gas Service Cock 7.5 Electrical Supply Fig. 10 1. External wiring must be correctly earthed, polarised and in accordance with relevant regulations/rules. In GB this is the current I.E.E. Wiring Regulations. In IE reference should be made to the current edition of ETCI rules. Zone 2 2. The mains supply is 230V ~ 50Hz fused at 3A. Window Recess NOTE: The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance. Zone 1 Zone 2 Zone 0 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. 0.6 m Window Recess Zone 2 7.6 Fig. A In GB Only Ceiling Window Recess Zone 2 Zone 1 Zone 2 Outside Zones Bath & Shower Rooms 1. If the boiler is fitted in a room containing a bath or shower it can be fitted in zone 2, (Figs. A & B shows zone dimensions for a bathtub. For other examples refer to the Current I.E.E. Wiring Regulations) reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules. 2.25 m Zone 0 0.6 m Fig. B © Baxi Heating UK Ltd 2012 In GB Only 15 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. If connecting to a rain water drain, that drain MUST discharge into a foul drain. Insulation 32mm 21.5mm 7.0 Site Requirements 7.7 Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER. CAREFUL CONSIDERATION MUST BE GIVEN TO THE POSSIBILITY OF THE PIPEWORK BEING SUBJECT TO FREEZING CONDITIONS AND APPROPRIATE MEASURES TAKEN TO PREVENT BLOCKAGE. CORRECT INSTALLATION IN ACCORDANCE WITH THIS SECTION WILL CONSIDERABLY MINIMISE THE LIKELIHOOD OF BLOCKAGE AND SUBSEQUENT BOILER LOCK-OUT. A CONDENSATE DISCHARGE PUMP AND PIPE ‘TRACE HEATING’ ARE AVAILABLE AS ACCESSORIES - see paragraphs 7.7.12 to 7.715 for further details. The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run EXCEPT when employing a suitable condensate pump in basement and cellar or similar applications. i) Termination to an internal soil and vent pipe 50mm per me 2.5° M tre of inimum 1. The condensate outlet will accept 21.5mm (3/4in) plastic overflow pipe. It is strongly recommended that this discharges internally into the household drainage system. Where this is not possible, discharge into an outside drain is permissible providing every possible precaution is taken to prevent freezing. pipe ru n fall 2. Ensure the discharge of condensate complies with any national or local regulations in force. BS 6798 & Part H1 of the Building Regulations give further detailed guidance. 450mm min* *450mm is applicable to properties up to 3 storeys. For multi-storey building installations consult BS 6798. ii) External termination via internal discharge branch e.g sink waste - downstream* Boiler The boiler condensate trap incorporates a seal of 75mm, therefore it is unnecessary to install an air break and trap in the discharge pipework. 3. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP. 4. Metal pipework is NOT suitable for use in condensate discharge systems. 5. The pipe should be a minimum of 21.5mm diameter and must be supported using suitably spaced clips of the correct design to prevent sagging. 6. It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres. 7. Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe. Sink 50mm per me 2.5° M tre of inimum fall pipe ru n Pipe must terminate above water level but below surrounding surface. Cut end at 45° 8. External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external use. 9. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly. 10. In all cases discharge pipe must be installed to aid disposal of the condensate. To reduce the risk of condensate being trapped, as few bends and fittings as possible should be used and any burrs on cut pipe removed. *It is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle ! 16 © Baxi Heating UK Ltd 2012 7.0 Site Requirement 7.7 iii) Termination to a drain or gully Boiler 50mm Pipe must terminate above water level but below surrounding surface. Cut end at 45° per me tre of 2.5° M inimum Condensate Drain (cont.) 11. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC's are flushed or sinks emptied then back-pressure may force water out of the boiler trap and cause appliance lockout. pipe ru n fall iv) Termination to a purpose made soakaway Further specific requirements for soakaway design are referred to in BS 6798. Boiler 500mm min 50mm p er metr e of pip 2.5° Min e run imum fa © Baxi Heating UK Ltd 2012 ll Holes in the soak-away must face away from the building 17 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. Follow the instructions supplied with the pump. 13. Condensate Drain Pipe ‘Trace Heating’ Elements are available in various lengths. ‘MULTIFIT’ part nos.:- Basement or similar (heated) 1 metre 720644401 2 metre 720664101 3 metre 720664201 5 metre 720664401* Boiler *Where the drain is between 3 & 5 metres a 5 metre kit can be used and “doubled back” upon itself. 14. It is possible to fit the element externally on the condensate drain or internally as detailed in the instructions provided. Condensate Pump 15. The fitting of a ‘Trace Heating’ Element is NOT a substitute for correct installation of the condensate drain. ALL requirements in this section must still be adhered to. vi) pumped into an external soil & vent pipe 50mm Unheated Location (e.g. Garage) per me tre of p ipe run 2.5° M inimum fall Basement or similar (heated) vii) to a drain or gully with extended external run & trace heating Boiler The ‘Trace Heating’ element must be installed in accordance with the instructions supplied. External runs & those in unheated locations still require insulation. Boiler Condensate Pump 50mm per me tre of 2.5° M inimum 18 © Baxi Heating UK Ltd 2012 pipe ru n fall Pipe must terminate above water level but below surrounding surface. Cut end at 45° Terminal Position with Minimum Distance (Fig. 12) (mm) A1 Directly below an opening, air brick, opening windows, etc. B1 Above an opening, air brick, opening window etc. C1 Horizontally to an opening, air brick, opening window etc. D2 Below gutters, soil pipes or drain pipes. E2 Below eaves. F2 Below balconies or car port roof. G2 From a vertical drain pipe or soil pipe. H2 From an internal or external corner. I Above ground, roof or balcony level. J From a surface or boundary line facing a terminal. K From a terminal facing a terminal (Horizontal flue). From a terminal facing a terminal (Vertical flue). L From an opening in carport (e.g. door, window) into the dwelling. M Vertically from a terminal on the same wall. N Horizontally from a terminal on the same wall. R From adjacent wall to flue (vertical only). S From an adjacent opening window (vertical only). T Adjacent to windows or openings on pitched and flat roofs U Below windows or openings on pitched roofs 7.0 Site Requirements 300 300 300 25 (75) 25 (200) 25 (200) 25 (150) 25 (300) 300 600 1200 600 7.8 NOTE: Due to the nature of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. 1. The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendations are given in BS 5440 Pt 1. For IE recommendations are given in the current edition of I.S. 813 “Domestic Gas Installations”. 1200 1500 300 300 1000 600 2000 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. 1 In addition, the terminal should be no nearer than 150 mm to an opening in the 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. building fabric formed for the purpose of accommodating a built-in element such as a window frame. 2 Only ONE 25mm clearance is allowed per installation. If one of the dimensions IMPORTANT: • Under car ports we recommend the use of the plume displacement kit. • The terminal position must ensure the safe and nuisance - free dispersal of combustion products. D, E, F, G or H is 25mm then the remainder MUST be as shown in brackets, in accordance with B.S.5440-1. NOTE: The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below 300 min Terminal Assembly Flue *4. Reduction to the boundary is possible down to 25mm but flue deflector part no. 5111068 must be used. * Plume Displacement Kit IMPORTANT: If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 150mm from any opening windows or doors (see Section 9.0). Top View Rear Flue Fig. 11 Property Boundary Line J,K Air Inlet T U Opening Window or Door 150mm MIN. N R I M C I I F D E A S I F J,K B L G A A H Fig. 13 H I Likely flue positions requiring a flue terminal guard © Baxi Heating UK Ltd 2012 Fig. 12 19 8.0 Flue 8.1 Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination applications. (ii) (i) 2. All fittings should be fully engaged. The approximate engagement is 40mm. Apply the lubricant supplied to the seal on each fitting to aid assembly. 3. Maximum permissible equivalent flue lengths are:(60/100) (80/125) Horizontal Concentric 10 metres 20 metres 4. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 135° bend 0.5 metres 93° bend 1.0 metres 5. The elbow supplied with the standard horizontal telescopic flue kit is not included in any equivalent length calculations. Plume Displacement Kit 60 /100 dia 1M Extensions 45° & 93° elbows are also available. NOTE: Flue length is measured from point (i) to (ii) as shown. Horizontal Flues IMPORTANT SUPPORT - All flue systems MUST be securely supported a MINIMUM of once every metre. It is recommended that every straight piece is supported irrespective of length. Additional supports are available as accessories. VOIDS - Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual inspection. NOTE: Horizontal flue pipes should always be installed with a fall of at least 1.5° from the terminal to allow condensate to run back to the boiler. This bend is equivalent to 1 metre C A (ii) B (i) This bend is equivalent to 1 metre Total equivalent length = A+B+C+2 x 90° Bends 20 © Baxi Heating UK Ltd 2012 6. Read this section in conjunction with the Flue Installation Guide supplied with the boiler. 8.0 Flue 8.2 Flue Lengths The standard horizontal telescopic flue kit allows for lengths between 315mm and 500mm from elbow to terminal (Fig. 14). Extensions of 250mm, 500mm & 1m are available. m The maximum permissible equivalent flue length is: 10 metres (60/100 system - vertical & horizontal) 20 metres (80/125 system - vertical & horizontal) 15 metres (80/80 twin pipe) 8 metres (60/100 system - vertical connected to ridge terminal) 0m 50 m 5m 31 Flue Deflector Fig. 14 For details of Plume Displacement Kit lengths see the Flue Installation Guide supplied in the literature pack. 8.3 Flue Trim 1. The flexible flue trims supplied can be fitted on the outer and inner faces of the wall of installation. Fig. 16 8.4 Terminal Guard (Fig. 15) 1. When codes of practice dictate the use of terminal guards, ‘Multifit’ accessory part no. 720627901 can be used (Note: This is not compatible with Flue Deflector referred to below). 2. If a proprietary guard is used it must be identified as suitable for use with condensing boilers. Fig. 15 3. There must be a clearance of at least 50mm between any part of the terminal and the guard. 4. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated. 8.5 Flue Deflector (Fig. 16) 1. If required, push the flue deflector over the terminal end and rotate to the optimum angle for deflecting plume. Secure the deflector to the terminal with screws provided. 8.6 Flue Accessories 1. For full details of Flue Accessories (elbows, extensions, clamps etc.) refer to the Flue Installation Guide supplied in the literature pack. © Baxi Heating UK Ltd 2012 21 9.0 Installation 9.1 Unpacking & Initial Preparation IMPORTANT RISK ASSESSMENT - Before commencing the installation it is recommended that the ‘Five Steps to Risk Assessment’ document published by the HSE is consulted, and an assessment performed as described. GAS SUPPLY - The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). NOTE: a small amount of water may drain from the boiler in the upright position. If pre-plumbing it will be necessary to turn the carton over to access the wall plate first. 1. Remove staples, open flaps and remove the cardboard sheet. Remove the polystyrene side pieces and literature. Two people can then lift out the boiler (Fig. 17). Fig. 17 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. 116mm Dia Minimum Aperture For Flue Tube 130mm Side Flue Centre Line 175mm Minimum Clearance 3. Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes. 4. Mark the position of the centre of the flue hole (rear exit). For side flue exit, mark as shown (Fig. 18). Vertical Flue Centre Line 228 mm Boiler Mounting Bracket Fixing Slots 50 mm 5. If required, mark the position of the gas and water pipes. Remove the template. For Side Flue Exit 6. Cut the hole for the flue (minimum diameter 116mm). Fig. 18 8mm Dia 8mm Dia 7. Drill the wall as previously marked to accept the wall plugs supplied. Secure the wall plate using the fixing screws. Profile of Outercase 5 mm Minimum Side Clearance 8. Using a spirit level ensure that the plate is level before finally tightening the screws. 5 mm Minimum Side Clearance 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. 10. Fit the filling loop as described in the instructions supplied with it. Condensate Drain Pressure Relief Valve (15mm) 25 40 mm mm 200mm Recommended 150mm Minimum Clearance 130 mm 130 mm 65 mm 162.5 mm Heating Flow (22mm) Gas Inlet (22mm) 9.2 Flushing Heating Return (22mm) 1. Connect a tube to the heating flow or return pipe (Fig. 20). Fig. 19 Flushing Tube Heating Flow Fig. 20 22 © Baxi Heating UK Ltd 2007 Heating Return 2. Make the flow and return connections to the isolation taps. Flush the system thoroughly to remove all impurities (see System Details, Section 6.1). Boiler Mounting Bracket 9.0 Installation 9.3 Fitting The Boiler 1. Remove the sealing caps from the boiler connections. NOTE: A small amount of water may drain from the boiler once the caps are removed. Sealing Washers 2. Lift the boiler as indicated by the shaded areas. The boiler should be lifted by TWO PEOPLE. Engage the mounting bracket at the top rear of the boiler on the wall plate (Fig.21) (see Safe Manual Handling page 5). 3. Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections. 4. Tighten all the connections. Fig. 21 Suggested Lifting Points shown as shaded area 9.4 Remove Sealing Caps from under the Boiler after lifting into position Fitting the Pressure Relief Discharge Pipe (Fig. 22) 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. Prime Trap by pouring 300ml of water into flue spigot IMPORTANT: Make all soldered joints before connecting to the pressure relief valve. The relief valve is intentionally angled to the right of the boiler. DO NOT adjust the position of the valve. The discharge pipe must be installed before pressurising the system. 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. Pressure Relief Valve 4. Utilising one of the sealing washers, connect the discharge pipe to the adaptor and tighten the nut hand tight, plus 1/4 turn to seal. 5. Complete the discharge pipework and route it to the outside discharge point. 9.5 Fig. 22 Discharge Pipe Condensate Drain (see section 7.7) (Fig. 23) 1. Using the short piece of rubber hose supplied, connect the condensate drain pipework to the boiler condensate trap outlet pipe. When connecting the hose, ensure that the condensate sump is not inadvertantly unscrewed. Control Box removed for clarity Ensure the discharge of condensate complies with any national or local regulations in force (see British Gas “Guidance Notes for the Installation of Domestic Gas Condensing Boilers” & HHIC recommendations). 2. The hose will accept 21.5mm (3/4in) plastic overflow pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable. Condensate Trap Outlet Pipe Fig. 23 © Baxi Heating UK Ltd 2012 3. The boiler condensate trap should be primed by pouring approximately 300ml of water into the flue spigot. Do not allow any water to fall into the air inlet. 23 9.0 Installation m 0m 50 m 5m 31 9.6 Fitting The Flue HORIZONTAL TELESCOPIC FLUE Terminal Assembly Connection Assembly Fig. 24 1. There are two telescopic sections, the Terminal Assembly and the Connection Assembly, a roll of sealing tape and two self tapping screws. A 93° elbow is also supplied. The outer duct of the Connection Assembly is painted white. On the Terminal Assembly the outer duct is unpainted. 2. The two sections can be adjusted to provide a length between 315mm and 500mm (Fig. 24) when measured from the flue elbow (there is 50mm engagement into the elbow). Wall Thickness 3. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (Fig. 25). (X) NOTE: The flue elbow is angled at 93 degrees to ensure a fall back to the boiler. 4. Measure the distance from the outside wall face to the elbow. This dimension will be known as ‘X’ (Fig. 25). 5. If the distance from the flue elbow to the outside face of the wall (‘X’ in Fig. 25) is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into the elbow. (X) Wall Thickness Fig. 25 6. In instances where the dimension ‘X’ (Fig. 25) is between 250mm and 315mm it will be necessary to shorten the Terminal Assembly by careful cutting to accommodate walls of these thicknesses. 7. To dimension ‘X’ add 50mm. This dimension to be known as ‘Y’. ‘Peak’ to be uppermost 8. Adjust the two telescopic sections to dimension ‘Y’ and seal the joint with the tape provided (Fig. 27). Ensure that the labels marked ‘TOP’ on the Terminal and Connection Assemblies are uppermost. Fig. 26 9. Using the clearance holes in the Connection Assembly secure it to the Terminal Assembly using the screws supplied (Fig. 28). ‘TOP’ Label ’ n ‘Y io ens Dim Securing Screw Sealing Tape Fig. 27 ‘TOP’ Label 24 © Baxi Heating UK Ltd 2012 Fig. 28 9.0 Installation Flue Elbow Apply the lubricant supplied for ease of assembly (do not use any other type). 9.6 Ensure Flue Elbow is fully engaged into Boiler Adaptor Fitting the Flue (Cont) 10. Remove the flue elbow and insert the flue through the hole in the wall. Fit the flue trims if required, and refit the elbow to the boiler adaptor, ensuring that it is pushed fully in (Fig. 29). Boiler Adaptor 11. Draw the flue back through the wall and engage it in the elbow. It may be necessary to lubricate to ease assembly of the elbow and flue (Fig. 30). Fig. 29 12. Ensure that the terminal is positioned with the slots to the bottom (Fig. 31). Secure the flue to the elbow with the screws supplied (Fig. 30). Apply the lubricant supplied for ease of assembly (do not use any other type). IMPORTANT: It is essential that the flue terminal is fitted as shown to ensure correct boiler operation and prevent water entering the flue. Ensure Flue is fully engaged into Elbow 13. Make good between the wall and air duct outside the building, appropriate to the wall construction and fire rating. 14. If necessary fit a terminal guard (see Section 8.4). Fig. 30 Slots at bottom © Baxi Heating UK Ltd 2012 Fig. 31 25 9.0 Installation 9.7 Making The Electrical Connections 1. See Section 7.5 for details of the electrical supply. Undo the securing screws and lift the case front panel off. 2. Disengage the securing tab and hinge the control box downwards. Undo the terminal block cover securing screw and remove the cover (Fig. 32). 3. Slacken the gland nut in the left of the boiler lower panel and pass the mains cable through it. Remove the grommet adjacent to the gland nut, pierce the diaphragm and insert the cable from the external control system. Control Box 4. Leave sufficient slack in the cables to allow the Control Box to be hinged fully open. Tighten the gland nut and refit the grommet. 5. Connect the Earth, Permanent Live and Neutral wires to the terminal strip. Fig. 32 NOTE: Both the Permanent Live and Neutral connections are fused. 6. Refer to the instructions supplied with the external control(s). IMPORTANT: The room thermostat MUST be suitable for 230V switching. Always fit fast blow 2A fuse Fused supply 3A 230V ~ 50Hz 230V 1 b 2 bk Earth (green/yellow) g/y Neutral (blue) b Live (brown) br Terminal Block Fig. 33 26 © Baxi Heating UK Ltd 2012 7. Remove the link between terminals 1 & 2. The switched output from the external control must be connected to terminal 1. (Fig. 33). 8. Replace the terminal block cover. 9.8 Preliminary Electrical Checks 1. Prior to commissioning the boiler preliminary electrical system checks should be carried out. Fuses 2. These should be performed using a suitable meter, and include checks for Earth Continuity, Resistance to Earth, Short Circuit and Polarity.