Академический Документы
Профессиональный Документы
Культура Документы
Baxi System
35/60 & 60/100
Gas Fired Wall Mounted System Boilers
Installation and
Servicing Instructions
This file has been downloaded from DanTheGas
http://www.danthegas.com/
Any questions, don’t hesitate to contact me; but I do not give technical support
to other engineers, nor do I teach end user’s how to play with gas systems.
Natural Gas
Everyone who works at Baxi has a commitment to Type test for purpose of Regulation 5 certified by:
quality because we know that satisfied customers Notified Body 0051.
mean continued success.
Product/Production certified by:
Notified Body 0051.
We hope you get a satisfactory service from Baxi. If
not, please let us know. For GB/IE only.
2
Contents
Section Page
1.0 Introduction 4
8.0 Installation 17
10.0 Completion 28
3
1.0 Introduction
Baxi UK Limited declare that no substances
harmful to health are contained in the
Case Front Panel
appliance or used during appliance
manufacture.
1.1 Description
1.2 Installation
1. The appliance is suitable for installation only in G.B. and
NOTE: This appliance must be installed in I.E. and should be installed in accordance with the rules in
force. For Ireland install in accordance with I.S.813
accordance with the manufacturer’s instructions
“INSTALLATION OF GAS APPLIANCES”. The installation must be
and the regulations in force.Read the instructions carried out by a CORGI Registered Installer or other
fully before installing or using the appliance. competent person and be in accordance with the relevant
requirements of GAS SAFETY (Installation and Use)
REGULATIONS, the BUILDING REGULATIONS (Scotland)
(Consolidation), the LOCAL BUILDING REGULATIONS, the
CURRENT I.E.E. WIRING REGULATIONS 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.
4
2.0 General Layout
2.1 Layout
4 15. Burner
16. Primary Heat Exchanger
17. Fan Assembly
18. On/Off/Reset Selector Switch
26 27 28 29
0 4
bar
18 19 9
5
3.0 Appliance Operation
Boiler Primary Circuit
3.1 Operating Mode (Fig. 2)
1
1. With a demand for heating, the pump circulates
water through the primary circuit. At a pre-
determined flow rate the hydraulic differential
pressure switch operates, initiating the ignition
sequence.
19
2 2. The main burner ignites at low rate, then the
3 4 gas valve controls the gas rate to maintain the
7 heating temperature measured by the
temperature sensor.
5 6
3. When the flow temperature exceeds the setting
18 temperature, a 3 minute delay occurs before the
burner relights automatically (anti-cycling). The
pump continues to run during this period.
16
4. When the demand is satisfied the burner is
17
extinguished and the pump continues to run for a
8 period of 3 minutes (Pump Overrun).
13
6
4.0 Technical Data
Electrical Protection
IPX5D
4.5
SEDBUK Declaration For System Boiler 35/60
4
3.5
The seasonal efficiency (SEDBUK) is 78.8 %
3
2.5
This value is used in the UK Government’s Standard
Metre wg
The test data from which it has been calculated have been 1.5
certified by 0051. 1
0.5
0
l/h 0 200 400 600 800 1000 1200
7
4.0 Technical Data
Electrical Protection
IPX5D
5.5
4.5
3.5
The test data from which it has been calculated have been 2
0.5
0
l/h 0 200 400 600 800 1000 1200
8
5.0 Dimensions and Fixings
Dimensions
E A 780mm
G
B 345mm
C 450mm
A D 107mm Ø Min.
E 200mm
F 190mm
B
G 143mm
360° Orientation
D C
Tube Ø 100mm
Tap Rail
130 mm 130 mm 65 mm
9
6.0 System Details
6.2 Bypass
10
6.0 System Details
11
7.0 Site Requirements
5mm Min 450mm 5mm Min
7.1 Information
7.4 Location
13
7.0 Site Requirements
7.8 Flue
L
B,C
K
N
G G
D M
D H,I
J A
A
E F F
G
Fig. 9
14
1.0 Introduction
Fig. 10
7.10 Flue Terminal Trim
Fig. 13
15
7.0 Site Requirements
Vertical
Flues
Maximum Length = 2m
inc. 2 x 90° bends
16
Fixing Template
8.0 Installation
107mm Dia Minimum
200 mm Aperture For Flue Tube
Minimum
Clearance Horizontal Side Flue
Centre Line
Vertical Flue
The gas supply, gas type and pressure must be
Centre Line
checked for suitability before connection (see
Appliance Wall Plate Section 7.6).
Heating Gas Heating Pressure Relief 9. Connect the gas and water pipes to the valves
Flow Inlet Return Valve
200 mm
(22mm) (22mm) (22mm) (15mm) on the wall plate using the copper tails supplied.
Fig. 14 Minimum
Clearance Ensure that the sealing washers are fitted
between the connections.
Fig. 17
Discharge Pipe
18
8.0 Installation
Wall Thickness
8.6 Fitting The Flue
HORIZONTAL FLUE
(X) 1. The standard flue is suitable for lengths
100mm minimum to 1m maximum (measured
from the edge of the flue elbow outlet).
(X) Waste
Air Duct
Waste
Fig. 19
Flue Duct
19
Elbow
8.0 Installation
Flue Duct 16. Fit the circular flue trim outside if required, and
if necessary fit a terminal guard (see Section 7.10
Flue Duct & 7.11).
Clamp
8.7 Extensions & Additional Elbows
bk
8. Any domestic hot water control should be
1
230V S/L from 2 bk
connected to the DHW relay PCB (Fig. 24) in
external control most installations. See Section 8.8 for details of
suggested system wiring schemes
Terminal Block
Functional Flow Diagram 9. Ensure that both mains input and, where fitted,
external control input cables have sufficient slack
External L Pump to allow the control box to drop down. Tighten the
Controls 230 V br b N
bk
cable clamp(s) on the boiler chassis.
br b Pressure Switch
br
Fan
br Selector / br b N
b Reset Switch
bk
b
Safety Overheat Thermostat
b
r Central Heating
b
r NTC Sensor
r
g
Primary Return Sensor
bk g
PCB b
DHW L DHW Relay g br
N PCB g Gas Valve
Controls
bk
bk Gas Valve Modulator
Key to Wiring
Flame Sensing Electrode
b - blue
r Spark Electrode
br - brown br
b N
bk - black Spark
Fig. 28 r - red Generator
r
g - green r
Hydraulic Differential Pressure Switch
21
8.0 Installation
Scheme 1
3 Port Valve
230V 50Hz Mid Position Cylinder
fused 3A maximum b Thermostat 7. Scheme 1 shows the use of a 3 port mid
g/y
L N E position zone valve and is based on a ‘Y’ plan
w system. The boiler will provide hot water to the
Room 1
gr A B central heating system, domestic hot water store or
Thermostat
o C 2 both.
2 1 3 AB
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.
1 2 3 4 5 6 7 8 9 10
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.
L
N 10. It is not necessary to connect any control(s) to
HTG 3 1
the boiler domestic hot water relay PCB. As a
HW On
2 1 E N L HW Off Frost result of this the domestic hot water thermostat will
Thermostat not operate and the cylinder thermostat must be
Terminal Block Timer
relied upon to limit the temperature of DHW.
Baxi System b - blue
Boiler w - white
o - orange 11. The selector switch must be in the central
Scheme 1 gr - grey heating and domestic hot water position at all times
g/y - green/yellow for the boiler to operate.
22
8.0 Installation
Cylinder
gr 8.9 System Wiring (cont)
Thermostat
gr
1 Scheme 2
Zone Valve Zone Valve
HTG DHW
C 2
12. Scheme 2 incorporates two 2 port zone valves
b Motor b Motor and is based on an ‘S’ plan system. The boiler will
Room
g/y g/y Thermostat provide hot water to the central heating system,
o o domestic hot water store or both.
br 2 1 3
13. The boiler is controlled by a live feed from
either zone valve depending upon demand.
Scheme 2 Scheme 3
Baxi System
b - blue
w - white Boiler 17. Scheme 3 shows the use of a 3 port two
o - orange position zone valve and is based on a ‘W’ plan
br - brown system. The boiler will provide hot water to the
gr - grey central heating system or domestic hot water
g/y - green/yellow store.
1 2 3 4 5 6 7 8 9 10
i) Change the orientation of the zone valve so
that port ‘A’ serves domestic hot water and port
‘B’ the central heating.
L
N iv) Disconnect the grey zone valve wire from 7
PCB Relay on the terminal strip and connect to 8.
Board
b - blue
w - white v) Disconnect the white zone valve wire from 5
Baxi System
o - orange on the terminal strip and connect to 8.
Boiler gr - grey
g/y - green/yellow vi) Connect 8 on the terminal strip to switched
Scheme 4
live on the domestic hot water relay PCB.
24
8.0 Installation
DHW Control
Input Cable 8.11 Preliminary Electrical Checks
N L
1. Prior to commissioning the boiler preliminary
electrical system checks should be carried out.
Fig. 29
25
9.0 Commissioning the Boiler
2
7. Test for gas soundness.
3
1
0 4
8. If at any time during commissioning it is
bar
required to terminate a particular cycle, e.g. the
Selector Switch pump overrun period, turn the selector to the Off
Pressure position and then back to the On position ( )
Fig. 31 Gauge (Fig. 32).
0 4
bar
Power On
Neon
Central Heating
Temperature Control
Fig. 32
26
9.0 Commissioning the Boiler
Pressure Test Point
OUT Sealing Screw
9.2 Checking the Burner Pressure
pressure.
0 4
bar
Temperature Control 13. Once the pressure has been set turn the
Fig. 36 boiler off and disconnect the pressure gauge.
27
10.0 Completion
Fig. 37
Facia Panel
28
Case Front Panel
11.0 Servicing the Boiler
11 .1 Annual Servicing
Ease Outlet Sealing 6 Remove the facia securing screws and hinge
Collar Upwards the panel down.
Inner Door
10. Remove the four screws securing the
Panel
combustion box door and remove the door
Combustion
(Fig. 39).
Box Door
35/60 models
Fig. 41
Combustion
Box Door
Electrode 17. Ensure that the heat exchanger fins are clear
Grommets of any obstruction.
30
12.0 Changing Components
Fig. 44
12.1 Pressure Switch (Fig. 44)
Pressure
Switch Wires
1. Note the positions of the two sensing tubes
and three wires and remove them.
Fan Wires
12.2 Fan (Figs. 45 & 46)
Sensing Tubes
Fan and Hood 3. Remove the four screws securing the
Assembly combustion box door and remove the door.
Outlet Sealing
Collar 4. Remove the spring clips retaining the air box
Fig. 45
side baffle plates. Disengage the tabs on the
baffles from the slots in the fan hood.
Spring
Washer
Securing Screw
Fig. 46
Fan Hood
31
12.0 Changing Components
32
12.0 Changing Components
Injector
Inlet Elbow
Manifold 12.5 Injectors (Fig. 49)
Electrodes Burner
12.6 Electrodes (Fig. 49)
Fig. 49
13.8
Side Insulation
Combustion
Box Door
Front Insulation
Fig. 50
33
12.0 Changing Components
34
12.0 Changing Components
Pump Setting
Automatic 12.14 Automatic Air Vent (Fig. 56)
Air Vent
Fig. 55
1. Drain the primary circuit and unscrew the
automatic air vent from the pump body.
Pump Wiring
Cover 2. Examine the ‘O’ ring seal, replacing if
necessary, and fit it to the new automatic air vent.
Fig. 56
35
12.0 Changing Components
Pressure Gauge
Capillary 12.15 Pressure Gauge (Figs. 57 & 58)
Mounting Bracket
2. Pull the rubber shroud off the generator input
plug and disconnect the plug.
Spark Generator
Fig. 60
Electrode Lead
36
12.0 Changing Components
Selector Switch Knob 1. Note the setting of the selector switch knob and
carefully pull it off the facia.
Fig. 62 Temperature Control Knob
37
12.0 Changing Components
‘O’ ring seal 4. Fit the new valve and ‘O’ ring seal and set to
the previously noted orientation. Reassemble in
reverse order.
Grub Screw
Fig. 65
Pressure Relief Valve
Discharge Pipe
38
13.0 Illustrated Wiring Diagram
Cylinder Stat
Input
N S/L
Fan Air Pressure Pump
Switch
Relay Board
Hydraulic Differential
Pressure Switch
10 bk
9 bk
8 r
7 r
Control PCB 6 g
5 g
4 g
3 r
2 g Return Heating
1 r
A5
Temperature Sensor
Flame
Sensing Central Heating
Electrode NTC Sensor
F2
b br br bk b A3 b A4 br Mains Input
br - brown Link
1 2 3 4 5 1 2 3 4 1 2 3 4 1 2 4 5
bk - black g/y
A1 A2 b
b - blue br
5 6 7 8 9 3 6
r - red
b b br br b b bk
g - green
g/y - green / yellow r b br Fuse
w - white
bk
g/y
Overheat Stat
Gas Valve
Spark Generator
Reset Selector Switch
br
39
14.0 Fault Finding
Refer to Section 13.0 “Illustrated Wiring Diagram” for position of numbered terminals NOTE: When instructed to turn the
Central Heating - Follow operational sequence selector to the reset position turn the
selector switch fully anticlockwise
Turn selector to NO against the spring pressure to
Go to section ‘A’
neon illuminated position R and hold for 2 seconds to
reset the boiler.
YES
neon flashing
Go to section ‘B’
YES
YES
Turn selector to the reset
Spark at ignition
NO YES position. If the neon does
electrodes for up to 10 neon flashing
not extinguish go to
seconds
NO sections ‘H’ & ‘K’
Burner on neon NO
Go to section ‘F’
illuminated
YES
NO
Burner output
NO
modulates until set Go to section ‘G’
temperature is reached
YES
40
Fault Finding Solutions Sections A to E 14.0 Fault Finding
NO
1. Main terminals L and N Check electrical supply
YES
2. Main terminal fuse Replace fuse NO
neon
Replace PCB
NO illuminated
3. Selector terminals a & b Check wiring
and a & 3. PCB - A4 Replace selector
connector terminals 4 & 5
NO
1. Pump If pump jammed, release Replace pump
NO
2. PCB - A4 connector terminals 3 & 6 Replace PCB
YES
Change pump supply cable
NO
Replace PCB
F Gas at burner
NO
Ensure gas is on and purged
2.
Voltage at modulating coil of gas valve is:
YES
Max. burner press.approx 9V DC (13V DC LPG) Replace gas valve
Min. burner press.approx 1V DC
YES
Replace
PCB
42
15.0 Short Parts List
131 135
528 41 E66 398 Burner 35/60 248029
E66 399 Burner 60/100 248030
63
44 Injector 248210
41
154 PCB 248074
72
156 DHW Relay PCB 248620
59
154
32
156 35/60 models 32
60/100 models
43
Comp No 248544 - Iss 5 - 7/02
Technical Enquiries
08706 049 049
Baxi UK Limited
Brownedge Road
Bamber Bridge Preston
Lancashire
PR5 6SN
www.baxi.com 922.553.1