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  5. Installation & Service Instructions Manual

Main System 24 Eco Installation & Service Instructions Manual

Summary of System 24 Eco

  • Page 1

    © baxi heating uk ltd 2011 installation & service instructions system eco range these instructions include the benchmark commissioning checklist and should be left with the user for safe keeping. Supplied by heatingspares247.Com.

  • Page 2

    2 © baxi heating uk ltd 2011 natural gas main system 24 eco g.C.N o 41 467 11 main system 28 eco g.C.N o 41 467 12 © baxi heating uk ltd 2011 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...

  • Page 3

    3 installer notification guidelines © baxi heating uk ltd 2011 choose building regulations notification route contact your relevant local authority building control (labc) who will arrange an inspection or contact a government approved inspector labc will record the data and will issue a certificate...

  • Page 4

    4 legislation © baxi heating uk ltd 2011 codes of practice - refer to the most recent version this company declare 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 inst...

  • Page 5

    5 safe manual handling © baxi heating uk ltd 2011 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 pa...

  • Page 6

    6 © baxi heating uk ltd 2011 contents 1.0 introduction 7 2.0 general layout 8 3.0 appliance operation 9 4.0 technical data 10 5.0 dimensions and fixings 11 6.0 system details 12 7.0 site requirements 14 8.0 flue options 18 9.0 plume displacement 23 10.0 installation 27 11.0 commissioning 33 12.0 com...

  • Page 7

    7 1.0 introduction © baxi heating uk ltd 2011 1.1 description 1. The main system eco is a fully automatic gas fired wall mounted condensing system boiler. It is room sealed and fan assisted. 2. The boiler is set to give a maximum output of :- 24 models - 25.94 kw 26.95 kw (condensing) 28 models - 28...

  • Page 8

    8 2.0 general layout © baxi heating uk ltd 2011 2.1 layout 1. Expansion vessel 2. Automatic air vent 3. Primary return temperature sensor 4. Circulation pump 5. Drain off point 6. Pressure relief valve 7. Selector switch 8. Central heating system pressure gauge 9. Pcb 10. Control box 11. Gas valve 1...

  • Page 9

    9 3.0 appliance operation © baxi heating uk ltd 2011 1 2 4 5 6 7 8 19 18 9 10 12 11 14 13 15 16 17 3 key 1 heat exchanger 2 burner 3 ignition electrode 4 flame sensing electrode 5 gas valve 6 pump 7 automatic air vent 8 pressure relief valve 9 boiler drain point 10 gas inlet 11 boiler flow 12 boiler...

  • Page 10

    10 4.0 technical data © baxi heating uk ltd 2011 4.1 system 24 & 28 eco flue terminal diameter 100mm dimensions projection 125mm outercase dimensions casing height - 780mm overall height inc flue elbow - 965mm casing width - 450mm casing depth - 345mm weights packaged boiler carton 51.1 kg (24 &28) ...

  • Page 11

    11 5.0 dimensions and fixings © baxi heating uk ltd 2011 tap rail 360° orientation tube Ø 100mm d c b a g f h h heating return (22mm) heating flow (22mm) pressure relief valve (15mm) gas inlet (22mm) 130 mm 130 mm 65 mm condensate drain 127 mm dimensions a 780mm b 345mm c 450mm d 116mm Ø min. F 145m...

  • Page 12

    12 6.0 system details © baxi heating uk ltd 2011 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...

  • Page 13

    13 6.0 system details © baxi heating uk ltd 2011 6.5 system filling and pressurising (fig. 6) 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. 2. The filling ...

  • Page 14

    14 7.0 site requirements © baxi heating uk ltd 2011 7.1 location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air sup...

  • Page 15

    15 7.0 site requirement © baxi heating uk ltd 2011 7.3 ventilation of compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. Bs 5440: part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool with...

  • Page 16

    16 7.0 site requirements © baxi heating uk ltd 2011 7.7 condensate drain failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler the condensate discharge pipe must not rise at any point along its length. There must be a fall of at least 2.5° (5...

  • Page 17

    17 7.0 site requirements © baxi heating uk ltd 2011 7.8 flue (figs. 17 & 18) 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 ...

  • Page 18

    18 8.0 flue options © baxi heating uk ltd 2011 8.1 horizontal flue systems 1. The standard flue is suitable only for horizontal termination applications. 2. Maximum permissible equivalent flue lengths are:- (60/100) (80/125) horizontal concentric 10 metres 20 metres 3. Any additional “in line” bends...

  • Page 19

    19 8.0 flue options © baxi heating uk ltd 2011 vertical flues vertical flues (twin pipe) (ii) (i) (ii) (i) 8.2 twin & vertical flue systems 1. Maximum permissible equivalent flue lengths are:- (60/100) (80/125) vertical concentric 10 metres 20 metres (80/80) twin pipe 20 metres 3. Any additional “in...

  • Page 20

    20 8.0 flue options © baxi heating uk ltd 2011 a b k,k1 r d c n u,w s l h j m e g f p 8.3 flue accessories a2 key accessory size code no flue group a concentric flue system 100mm diameter a3 telescopic internal flue kit 315-500mm 5119654 a2 telescopic flue (incl elbow) 5118069 a horizontal flue term...

  • Page 21

    21 8.0 flue options © baxi heating uk ltd 2011 8.4 twin flue duct adaptor 1. The kit allows connection of a twin flue system to the boiler adaptor. 8.5 twin flue connection 1. Engage the twin flue duct adaptor in the boiler adaptor, making sure that it is pushed down as far as possible. 2. Ensure th...

  • Page 22

    22 8.0 flue options © baxi heating uk ltd 2011 fig. 19 100mm 685mm 8.6 for roof terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make an aperture in the roof suitable for the lower tube of the roof terminal and ensure the ...

  • Page 23

    23 9.0 plume displacement © baxi heating uk ltd 2011 9.1 plume displacement kit (fig. 23) kit no 5118638 content of kit 1 0.9m 60/100 concentric flue 1 1m 60 dia exhaust flue pipe 1 adaptor 2 60 dia support brackets 1 93° elbow/plume outlet assembly 1 flexible flue trim 3 “o” rings 1 ‘jubilee clip 1...

  • Page 24

    24 9.0 plume displacement © baxi heating uk ltd 2011 concentric 60/100 flue 60Ø exhaust x y fig. 26 fig. 27 flue length - worked example main system 28 eco in fig. 27 opposite an additional 93° elbow and pair of 45° elbows have been included in the 60Ø exhaust. Also 3 straight extension pieces have ...

  • Page 25

    25 9.0 plume displacement © baxi heating uk ltd 2011 min. 2 metres fig. 28 fig. 33 30mm 30mm fig. 30 fig. 32 fig. 31 adaptor 50mm flue trim position of ‘jubilee’ clip screw fig. 29 spigot 9.3 general fitting notes 1. Cut a hole in the external wall which the concentric flue assembly will pass throug...

  • Page 26

    26 9.0 plume displacement © baxi heating uk ltd 2011 9.3 general fitting notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet must remain in free air. 16. It is also possible to separate the plume outlet from the 9...

  • Page 27

    27 10.0 installation © baxi heating uk ltd 2011 10.1 unpacking & initial preparation the gas supply, gas type and pressure must be checked for suitability before connection (see section 7.4). 1. Remove staples, open flaps and remove cardboard sheet. Remove the polystyrene side pieces and literature....

  • Page 28

    28 10.0 installation © baxi heating uk ltd 2011 10.3 fitting the boiler 1. Lift the boiler using the lifting points as shown by the shaded areas (fig. 43). The boiler should be lifted by two people. Engage the slots at the top rear of the boiler on the wall plate (fig. 42) (see safe manual handling ...

  • Page 29

    29 10.0 installation © baxi heating uk ltd 2011 fig. 45 10.6 fitting the flue horizontal flue 1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (fig. 45). 2. Locate t...

  • Page 30

    30 10.0 installation © baxi heating uk ltd 2011 slots at bottom inner flue support bracket fig. 50 fig. 51 fig. 52 apply lubricant for ease of assembly. Ensure flue is fully engaged into flue elbow 10.6 fitting the flue (cont) 6. The inner flue duct support bracket may be in the waste portion of the...

  • Page 31

    31 © baxi heating uk ltd 2011 10.6 fitting the flue (cont) concentric vertical flue 15. Once the length of the vertical concentric extension has been determined mark and carefully cut off the excess material. The cut end must be square and free of burrs to ensure correct insertion into the boiler ad...

  • Page 32

    32 10.0 installation © baxi heating uk ltd 2011 10.7 making the electrical connections note: both the live and neutral connections are fused. To connect an external control proceed as follows:- 1. Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clea...

  • Page 33

    33 11.0 commissioning © baxi heating uk ltd 2011 pump automatic air vent pressure gauge screw bar 0 1 2 3 4 fig. 59 selector switch central heating temperature control calibration control reset bar 0 1 2 3 4 pump fig. 61 fig. 60 display heat exchanger automatic air vent fig. 58 11.1 commissioning th...

  • Page 34

    34 11.0 commissioning © baxi heating uk ltd 2011 selector switch display reset bar 0 1 2 3 4 central heating temperature control calibration control fig. 63 fig. 64 fig. 65 fig. 66 fig. 67 central heating temperature control calibration control fig. 62 x 2 11.2 check the operational (working) gas in...

  • Page 35

    35 12.0 completion © baxi heating uk ltd 2011 12.1 completion 1. Instruct the user in the operation of the boiler and system including the integral timer, explaining the operational sequence. 2. Set the central heating and hot water temperature control knobs to the requirements of the user. 3. Caref...

  • Page 36

    36 13.0 servicing © baxi heating uk ltd 2011 case front panel fig. 69 facia panel securing screws fig. 70 inner door panel fig. 71 condensate trap sump 13 .1 annual servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by ...

  • Page 37

    37 13.0 servicing © baxi heating uk ltd 2011 13.2 annual servicing - inspection (cont) 6. Undo the nut on the gas pipe at the gas/air inlet (fig. 72) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. 7. Disconnect the electrode lead caps, remo...

  • Page 38

    38 14.0 changing components © baxi heating uk ltd 2011 important: when changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed turn the selector switch fully anticlockwise against the spring press...

  • Page 39

    39 14.0 changing components © baxi heating uk ltd 2011 14.3 fan 1. Undo the nut on the gas pipe at the gas/air inlet (fig. 77) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. 2. Disconnect the electrode lead caps, remove the strain relief cl...

  • Page 40

    40 14.0 changing components © baxi heating uk ltd 2011 14.5 burner (fig. 80) 1. Undo the nut on the gas pipe at the gas/air inlet and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. 2. Disconnect the electrode lead caps, remove the strain relief...

  • Page 41

    41 14.0 changing components © baxi heating uk ltd 2011 14.7 safety thermostat (fig. 81) 1. Pull the plug off the thermostat. 2. Remove the screws securing the thermostat to the mounting plate on the flow pipe. 3. Reassemble in reverse order, ensuring that the plug is pushed fully on. 14.8 central he...

  • Page 42

    42 14.0 changing components © baxi heating uk ltd 2011 14.11 heat exchanger automatic air vent (fig. 84) 1. Drain the boiler primary circuit and unscrew the automatic air vent from the pump body. 2. Examine the ‘o’ ring seal, replacing if necessary, and fit it to the new automatic air vent. 3. Reass...

  • Page 43

    43 14.0 changing components © baxi heating uk ltd 2011 14.15 pressure gauge (figs. 88 & 89) 1. Drain the boiler primary circuit and undo the nut on the pressure gauge capillary. 2. Undo the screws securing the gauge retaining bracket. 3. Remove the bracket and gauge assembly. Depress the barbs on th...

  • Page 44

    44 14.0 changing components © baxi heating uk ltd 2011 14.18 p.C.B. (figs. 91 & 92) 1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins. 2. Completely undo the screws securing the control box cover and release the cover re...

  • Page 45

    45 14.0 changing components © baxi heating uk ltd 2011 14.20 gas valve (fig. 93) important: after replacing the valve the co 2 must be checked and adjusted as detailed in section 15.0 setting the gas valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by ...

  • Page 46

    46 © baxi heating uk ltd 2011 selector switch display reset bar 0 1 2 3 4 central heating temperature control domestic hot water temperature control fig. 96 fig. 97 fig. 98 fig. 99 fig. 100 central heating temperature control calibration control fig. 95 x 2 fig. 101 flue adaptor test point plug anal...

  • Page 47

    47 16.0 electrical © baxi heating uk ltd 2011 - brown - black - blue - white br bk b w - green - green / yellow - red g g/y r control pcb x2 x3 x9 x501 1 2 1 2 3 3 4 4 5 5 6 7 8 9 x1 1 2 return heating temp sensor central heating ntc sensor fan gas valve overheat stat pump x400 x401 g g b b r r b b ...

  • Page 48

    48 17.0 short parts list © baxi heating uk ltd 2011 short parts list key g.C. Description manufacturers no. No. Part no. A fan 5121447 b electrode assembly 5130293 c gas valve 5122149 d burner 5130292 e water pressure switch 5114748 f pump 248042 g ntc sensor 5114725 h overheat thermostat 5114729 j ...

  • Page 49

    49 18.0 fault finding © baxi heating uk ltd 2011 note: when instructed to turn the selector to the reset position turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler. 18.1 initial fault finding checks 1. Check that...

  • Page 50

    50 18.0 fault finding © baxi heating uk ltd 2011 refer to section 16.0 “illustrated wiring diagram” for position of terminals and components central heating - follow operational sequence turn selector switch to the display illuminates error 20, 28 or 50 flashing error 119 flashing burner lights erro...

  • Page 51

    51 18.0 fault finding © baxi heating uk ltd 2011 fault finding solutions sections is there 230v at: is there 230v at: main terminals l and n check electrical supply 1. No main terminal fuse replace fuse replace pcb display illuminated 2. No pcb - x1 connector terminals 1,2 check wiring 3. No no a pu...

  • Page 52

    52 18.0 fault finding © baxi heating uk ltd 2011 gas at burner ensure gas is on and purged replace pcb replace gas valve pcb - x3 connector is 230v ac across terminals 1 & 2 yes no no f replace pcb g check and correct if necessary 1. Ignition electrode and lead 2. Electrode connection 3. Spark gap a...

  • Page 53

    53 © baxi heating uk ltd 2011 18.0 fault finding k j l is there 230v at: pcb - x3 connector terminals 5 & 6 central heating mode replace pcb no change pump supply cable yes fan connections correct at fan. Pcb - x401 connector terminals 5,6,7 & 8 yes replace fan temperature sensors faulty. Cold resis...

  • Page 54

    Failure to install and commission according to the manufacturer’s instructions and complete this benchmark commissioning checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the manufacturer, has a water scale reducer been fitted? C...

  • Page 55: Service Record

    Service record it is recommended that your heating system is serviced regularly and that the appropriate service interval record is completed. Service provider before completing the appropriate service record below, please ensure you have carried out the service as described in the manufacturer’s in...

  • Page 56

    © baxi heating uk ltd 2011 comp n o 5119528 - iss 5 - 6 /11 all descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet. A...