Baxi Potterton BBU 15 HE User Manual

Installation & Servicing Instructions

Baxi Bermuda BBU 15 HE

Condensing Back Boiler Unit

These Instructions must be read in conjunction with those for

the separate Valor Dimension electric firefront.

They include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Competent Person's

Building Control

Self Certification Scheme

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

the Building Regulations

Install and Commission this

appliance to manufacturer's

instructions

certificate on members’ behalf

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

Complete the

Benchmark Checklist

or log onto:

www.GasSafeRegister.co.uk

within 10 days

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

LABC will record the data

and will issue a

certificate of compliance

Legislation

IMPORTANT - Installation, Commissioning, Service & Repair

This company declare that no substances harmful to health

are contained in the appliance or used during appliance

manufacture.

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.

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, this must be carried out by a competent person as stated in the Gas Safety

(Installation & Use) Regulations.

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:

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.

• 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.

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.

• 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.

Warning - Check the information on the data plate is compatible with local supply

conditions.

All systems must be thoroughly flushed and treated with

inhibitor (see section 6.2).

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.GasSafeRegister.co.uk

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)

Codes of Practice, most recent version should be used

Regulations 1993 N 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:-

In GB the following Codes of Practice apply:

Standard

BS 6891

BS 5546

Scope

Gas Installation.

Installation of hot water supplies for

domestic purposes.

Type test for purpose of Regulation 5 certified by:

Notified Body 0087.

BS 5449

BS 6798

BS 5440 Part 1

BS 5440 Part 2

BS 7074

Forced circulation hot water systems.

Installation of gas fired hot water boilers.

Chimneys.

Product/Production certified by:

Notified Bodies 0086.

Ventilation.

Expansion vessels and ancillary equipment for

sealed water systems.

BS 7593

Treatment of water in domestic hot water central

heating systems.

For GB/IE only.

Also the following standard includes relevant information about

builders openings:

BS 5871 Part 1

Installation of gas fires, convector heaters,

fire/back boilers and heating stoves.

In IE the following Codes of Practice apply:

Standard

I.S. 813

Scope

Domestic Gas Installations.

The following BS standards give valuable additional information;

BS 5546

BS 5449

Installation of hot water supplies for

domestic purposes.

Forced circulation hot water 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 !!

Working at Height

In order to reduce the number of fatalities and major accidents attributable to working at height, the Health and Safety Executive has introduced comprehensive

regulations and guidance that should be followed by all businesses working at height.

The following paragraphs consider some of the main features of the regulations and guidance. This is, however, only a limited summary and it is recommended

that all businesses planning on undertaking air source heat pump heating installations obtain a copy of the regulations and guidance issued by the Health and

Safety Executive and carefully consider the contents.

The regulations and guidance state that you are required to carry out a risk assessment for all work conducted at height and to put in place arrangements for:

•

Eliminating or minimising risks from work at height.

Safe systems of work for organising and performing work at height.

Safe systems for selecting suitable work equipment.

Safe systems for protecting people from the consequences of work at height.

The regulations and guidance highlight a hierarchy for safe work at height:

•

Avoid the risk by not working at height if practicable.

Prevent falls. Where it is not reasonably practicable to avoid work at height, you are required to take suitable and sufficient steps to prevent the risk of a fall

including selecting the most suitable work equipment (in accordance with the regulations).

Mitigate the consequences of a fall; where the risk of a person or object falling still remains, take suitable and sufficient measures to minimise

the distance and consequences of any fall.

•

Collective protection measures, such as guard rails on scaffold, should be given priority over personal protection measures, such as safety harnesses.

Within the regulations’ framework, you are required to:

1) Assess the risk to help you decide how to work safely.

2) Follow the hierarchy for safe work at height (i.e. avoid, prevent and mitigate).

3) Plan and organise your work properly, taking account of weather conditions and the possibility of emergencies.

4) Make sure those working at height are competent.

5) Make use of appropriate work equipment.

6) Manage the risks from working on or around fragile surfaces and from falling objects.

7) Inspect and maintain the work equipment to be used and inspect the place where the work will be carried out for both access and egress.

Contents

Section

Page

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

Introduction

General Layout

Technical Data

System Details

Site Requirements

Boiler Internal Wiring

Installation

Completion & Commissioning

9.0

Annual Servicing

10.0 Changing Components

11.0 Setting the Gas Valve

12.0 Fault Finding

13.0 Short Parts List

14.0 Notes

Benchmark Checklist

1.0 Introduction

1.1

Description

1. The Baxi Bermuda BBU 15 HE is a central heating

boiler designed for installation within a builders opening

in the living space of a dwelling.

2. The boiler is a fully automatic gas fired condensing

boiler. It is room sealed and fan assisted.

3. The boiler output will automatically modulate

between:

Max

Min

15kW

4.6kW

15.7kW (condensing) 4.83kW (condensing)

According to system load

4. It must be fitted in conjunction with one of the

available electric firefront units as listed on page 2.

The separate electric firefront is intended for hearth

mounting. All instructions, fixings etc. needed to fit the

firefront are included in the firefront pack.

5. These instructions relate to the central heating boiler

section of the appliance (Fig. 1).

6. The appliance is designed for use on NATURAL

GAS (G20) only.

Fig. 1

7. It can be used on sealed or open vented systems.

It must NOT be fitted on any type of gravity system.

The boiler is suitable for fully pumped systems ONLY.

8. The boiler is fitted with an integral pump unit for the

removal of condensate.

9. The boiler data badge gives details of the model,

serial number and Gas Council number and is situated

on the front case panel.

10. The boiler is intended to be installed in a residential

environment on a governed meter supply only.

11. The boiler must be installed with one of the

MULTIIFIT vertical concentric Flexi Flue kits available:-

10m kit 720101701 or 12.5m kit 720102001.

12. All systems must be thoroughly flushed and

treated with inhibitor (see section 4.2).

1.2

Contents

1. The boiler pack contains:

• Boiler Unit

• Plumbing Kit

• Condensate Pipe & Elbow

Fig. 2

• Fixings Kit

• Literature Pack

2. The flue pack contains:

• Terminal Cap

• Flue Duct Adaptor (inc. seal)

• Air Cowl

• Air Duct Collar (inc. 4 screws)

• Air Duct Clamp

• Closure Plate

• Boiler Concentric

Adaptor (inc. 2 seals)

• 10m or 12.5m of Concentric

Flexible Duct

• 2 x 60mm grey Seals

• 1 x 100mm red Seal

2.0 General Layout

2.1

Layout (Fig. 3)

Automatic Air Vent

Flue Connection

Spark Generator

Spark & Sensing Electrodes

Heat Exchanger

Boiler Control Connector

Control Wiring Connector

Condensate Sump

Gas Cock

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

Condensate Pump

Fan

Drain

Return Connection

Air Sampling Point

Flue Sampling Point

Flow Connection

Condensate Outlet

PCB Control Box (shown removed for clarity)

Boiler Control (cover open)

The Boiler Control operates the boiler remotely. This is

supplied with the firefront and is fitted, in operation, to the

firefront spacer frame.

IMPORTANT: To commission the boiler it is is necessary

to remove the Boiler Control from the firefront

packaging and connect it to the boiler at the upper right

hand side (item 6).

PCB Control Box

removed for clarity

Fig. 3

PCB Control Box

Calibration Controls

2.0 General Layout

2.2

Flue Kit (10m & 12.5m) (Fig. 3a)

Terminal Cap

Flue Duct Adaptor

Air Cowl

Air Duct Collar

Air Duct Clamp

Closure Plate

Boiler Adaptor

60mm Ø Seal

Collar Securing Screws x 4

100mm Ø Seal

10.

11.

12.

13.

60mm Ø Flue Duct

100mm Ø Air Duct

‘C’ Clip

Fig. 3a

3.0 Technical Data

3.1

Bermuda HE CBBU 15 HE

Appliance Type

Appliance Category

C₃₃

Sedbuk Declaration For Bermuda

BBU 15 HE

CAT I

The seasonal efficiency (SEDBUK) is 90.1%

Inlet Pressure (Natural Gas - G20)

mbar 20

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 has been certified by 0087.

Injector (Natural Gas - G20)

420 (4.2 mm)

NO Class

5 (31mg/kWh)

Heat Input (Net)

Max

15.4

Min

5.0

Heat Input (Gross)

Max

17.1

Min

5.7

Heat Output (Non-Condensing)

Max

Min

15.0

4.88

Heat Output (Condensing)

Max

15.7

Min

5.25

Boiler Set Temperature

°C

Max

Min

Gas Rate

(Natural Gas - G20)

(After 10 mins)

Max

1.63

Min

0.54

m /h

Electrical Supply

230V~ 50H

(Appliance must be connected to an

earthed supply)

Boiler Power Consumption

112W

Boiler Electrical Protection

IPX0

Boiler External Fuse Rating 3A

Connections

Gas Supply

Flow

Return

15mm compression

22mm male copper

Weights

Packaged Boiler Carton

Installation Lift Weight

28 kg

27 kg

Flue Length

Max

12.5

Min

3.0

Metres

Dimensions

Casing Height

Casing Width

Casing Depth

- 538mm

- 383mm

- 306mm

Firefront

See the instructions supplied with the firefront for

all Technical Data

4.0 System Details

4.1

Water Circulating Systems

1. The appliance is suitable for use on fully pumped

systems ONLY which may be sealed or open vented.

2. The following conditions should be observed at all

times:

The static head must not exceed 30m

of water.

The static head must not be less than

1m of water.

The boiler must not be used with a

direct cylinder.

Drain cocks should be fitted to all

system low points.

All gas and water pipes and electrical

wiring must be installed in such a way

that they do not restrict the servicing of

the boiler.

Position isolating valves as close as

possible to the circulating pump.

There is a drain cock supplied in the

plumbing kit.

4.2

Treatment of Water Circulating

Systems

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.

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.

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.

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.)

For information or advice regarding any of the above

contact Technical Enquiries 0844 871 1555.

4.0 System Details

Copper

0.5m

4.3

Pipework

Copper

0.5m

Flow

1. The sizes of the flow and return pipes from the

boiler should be determined by normal methods

according to the requirements of the system.

Boiler

Return

Copper

2. It is recommended that the system is designed for a

drop in temperature across the system of between

11& 20°C.

Fig. 4

3. In systems using non-metallic pipework it is

necessary to use copper pipe for the boiler Flow and

Return. The copper must extend at least 1 metre from

the boiler and include any branches. The copper pipe

must not be insulated (Fig. 4).

22mm

Open Vent

Air Vent

4.4

System Controls

Indirect

Cylinder

15mm

Cold

Feed

1. The system in which the appliance is installed should

include a control system.

2. Such a system would comprise a timer control and a

separate room and/or cylinder thermostat as

appropriate.

Pump

Radiator

Circuit

3. The boiler should be controlled so that it operates

on demand only.

Flow

Return

Boiler

4.5

Fully Pumped Open Vent System (Fig. 5)

Fully Pumped System

1. The sizes of the system pipes should be determined

by normal methods.

Fig. 5

2. The open vent pipe should be a minimum of 22mm

and must rise continuously to a point above the feed

and expansion tank.

3. The flow pipe from the boiler form part of the vent

pipe. No part of the open vent may contain a valve.

4. Inverted pipe runs must be avoided.

5. On low capacity systems with a maximum available

flow rate of less than 8.3l/min (temperature differential

›25°C) an external bypass must be fitted .

6. The bypass must be of the automatic pressure

operated type.

4.6

Storage Systems

1. For information regarding the use of a Bermuda

BBU 15 HE boiler with a storage system, contact the

appropriate storage system manufacturer.

4.0 System Details

4.7

Sealed Systems (Figs. 6, 7 & 8)

1. Installation. The installation must comply with the

requirements of BS 6798 and BS EN 12828. The British

Gas publication “British Gas Specification for Domestic

Wet Central Heating Systems” should also be

consulted.

Pressure

Gauge

Air Vent

2. Pressure Relief Valve. A non-adjustable spring loaded

Safety

Valve

pressure relief valve, preset to operate at 3 bar

Indirect

Cylinder

(45 lbf/in ) shall be used. It must comply with BS 6759:1

and include a manual testing device. It shall be

positioned in the flow pipe either horizontally or

vertically upwards and close to the boiler. No shut off

valves are to be placed between the boiler and the

safety valve. The valve should be installed with a

discharge pipe which permits the safe discharge of

steam and hot water such that no hazard to persons or

damage to electrical components is caused.

Pump

Expansion

Vessel

Radiator

Circuit

Flow

Return

Boiler

3. Pressure Gauge. A pressure gauge incorporating a fill

Filling

Point

pressure indicator, covering the range 0-4 bar (60

lbf/in ) shall be fitted to the system. It should be

connected to the system, preferably at the same point

as the expansion vessel. Its location should be visible

from the filling point.

Fully Pumped Sealed System

Fig. 6

4.0 System Details

4.7

Sealed Systems (cont)

4. Expansion Vessel. A diaphragm type expansion vessel to

BS 4814:1 shall be fitted close to the inlet side of the pump.

The connecting pipework should not be less than 15mm.

Pipework connecting the expansion vessel should not

incorporate valves of any sort.

Temporary

Hose

Mains Water

Supply

(Service Pipe)

Hose

Union

Stop

Valve

Methods of supporting the vessel are supplied by the vessel

manufacturer.

The nitrogen or air charge pressure of the expansion vessel

shall not be less than the hydrostatic head, (height of the

top point of the system above the expansion vessel). To

size the expansion vessel it is first necessary to calculate the

volume of water in the system in litres. The following

volumes may be used as a conservative guide to calculating

the system volume.

Double

Check

Valve

Heating

System

Boiler Heat Exchanger:

Small Bore Pipework:

Micro Bore Pipework:

Steel Panel Radiators:

Low Water Capacity Radiators:

Hot Water Cylinder:

1.55 litres

1 litre per kW of system output

7 litre

8 litre per kW of system output

1 litre per kW of system output

Filling a Sealed Water System (Method 1)

Mains Topping Up Method

NOTE: This method of filling a sealed system

may only be used if acceptable to Local Water

Undertaking

Fig. 7

If the system is extended, the expansion vessel volume may

have to be increased unless provision has been made for

extension. Where a vessel of the calculated size is not

available, the next available larger size should be used.

The boiler flow temperature is controlled at approx. 75°C.

The vessel size can now be determined from the

information in table 1 where V = System volume in litres.

5. Cylinder. The hot water cylinder must be an indirect

coiler type.

Mains Water

Supply

6. Method of Make Up. Provision shall be made for

replacing water loss from the system either:-

Cistern

Pressure Pump

Reducing Valve

(if required)

a) From a make up vessel or tank mounted in a position

higher than the top point of the system and connected

through a non-return valve to the system on the return side

of the hot water cylinder or the return side of all heat

emitters.

b) Where access to a make up vessel would be difficult by

using the mains top up method or a remote automatic

pressurisation and make up unit.

Stop

Valve

7. Mains Connection. There shall be no connection to the

mains water supply or to the water storage tank which

supplies domestic hot water even through a non-return

valve, without the approval of the Local Water Authority.

Heating

System

Filling a Sealed Water System (Method 2)

8. Filling Point. 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.

Cistern Filling Method

Fig. 8

NOTE: Cistern to be supplied through a

temporary connection from a service pipe or

cold water distributing pipe

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.

The filling method adopted must be in accordance with all

relevant water supply regulations and use approved

equipment.

Vessel Charge Pressure (bar)

Initial System Pressure (bar)

Expansion Vessel Volume (litres)

0.5

1.0

1.5

1.0

V x 0.11

V x 0.087

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 IS 813 “Domestic Gas

Installations”.

Table 1

5.0 Site Requirements

5.1

Builders Opening (Fig. 9)

Builders

Opening

1. The boiler unit is designed to fit within a standard

builders opening, the minimum dimensions of which are

as shown.

Fireplace

Opening

Height

Width

Depth

570mm

584mm

305mm

390mm min

490mm max

2. The opening should be soundly constructed of brick,

pre-cast concrete or be a proprietary builders opening.

584mm min

3. The base of the opening should be sound and non-

combustible and must be flat and level.

4. The base of the builders opening should be at the

same height as the finished level of the hearth.

SURROUND OR FINISHED

WALL FACE

IMPORTANT: If a false chimney breast is intended

to house the boiler, a simulated builders opening,

within the breast, must be provided.

5. The builders opening must not communicate with

voids, pipe ducts or spaces other than the room in

which the appliance is situated.

Solid, non combustible hearth

to support the boiler,

as specified in BS 5871.

5.2

Location

HEARTH

LEVEL

1. The appliance must be installed in the living space of a

dwelling. It is recommended that it is a ground floor

location.

305mm minimum

Fig. 9

2. Restrictions to the siting of the appliance are covered

by BS 5546. The appliance may not be installed in

bathrooms or shower rooms. bedrooms or bed sitting

rooms.

5.3

Fireplace Opening & Surround

1. If a fireplace surround is to be used, it must be

centrally placed and have opening sizes as shown in

Fig. 9.

5.4

Firefont Frame Extension Kit

1. To accommodate the firefront there must be at least

95mm from the surround or finished face to the front of

the boiler.

2. If necessary this can be increased by the use of Frame

Extension Kits. Each extension increases the effective

depth of the opening by 50mm.

3. See the instructions supplied with the firefront for full

details.

5.0 Site Requirements

5.5

Flue

1. The following guidelines indicate the general

requirements for installation of flues.

For GB recommendations are given in BS 5440 Part 1.

For IE recommendations are given in the current edition

of I.S. 813 “Domestic Gas Installations”.

2. Only one of the two available MULTIIFIT vertical

concentric Flexi Flue kits approved for use with the

boiler can be used (10m kit 720101701 or 12.5m kit

720102001). Any proprietary flue systems, terminals,

adaptors etc. MUST NOT BE USED.

3. The available flue kits are intended for installation

within an existing chimney. This should be clean and

sound, and any other previously installed flue

components (liners, dampers etc.) removed.

4. The flue must have a minimum vertical height of 3m

and have no bends greater than 45°.

NO HORIZONTAL RUNS ARE PERMITTED !

5. The terminal must be sited so that free passage of air

across it can occur at all times.

Fig. 10

6. It must also be a MINIMUM of 150mm from any

other terminals or obstructions (A). When adjacent to

windows or openings on pitched or flat roofs it must be

at least 600mm away (B). A minimum dimension of

2000mm must be maintained when below windows or

openings in pitched roofs (C) (Fig. 10).

5.0 Site Requirements

5.6

Ventilation

1. No ventilation is required for the boiler in the room of

installation.

5.7

Gas Supply (Fig. 11)

1. The gas installation should be in accordance with

relevant standards. In GB this is BS 6891. In IE this is I.S.

813 “Domestic Gas Installations”. The connection at the

appliance is 15mm copper tail located at the rear of the

gas tap.

2. Ensure the pipework from the meter to the appliance is

of adequate size. It is necessary to route the gas supply

pipe to the right hand side of the builders opening. It must

be routed so as not to restrict the installation and

servicing of the appliance.

5.8

Electrical Supply (Fig. 11)

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 the ETCI rules.

The mains supply is 230V ~ 50Hz fused at 3A.

NOTE: The method of connection to the electrical supply

must facilitate complete electrical isolation of the

appliance. Connection may be made via a fused double

pole isolator with a contact separation of at least 3mm on

all poles and serve the boiler and system controls only.

The boiler MUST NOT be connected to the same supply

as the firefront as their fuse ratings are different and

subsequent damage may occur.

Fig. 11

Electrical Connection

2. The boiler supply cable within the builders opening

should be 0.75mm to IEC 53 code 227 (heat resistant).

3. It is preferable to route the electrical supply cable to

the right hand side of the builders opening. If however it

must come from the left hand side it must be routed so

as not to restrict the servicing of the appliance.

Gas Connection

4. The cable must be routed to avoid contact with any

part of the boiler.

5.0 Site Requirements

5.9

Condensate Drain - General

Failure to install the condensate discharge pipework

correctly will affect the reliable operation of the boiler.

1. Ensure the discharge of condensate complies with any

national or local regulations in force.

BS 6798 & Part H1 of the Building Regulations give further

guidance.

2. If any further drain pipe is required (additional to that supplied

with the boiler), it should be run in a proprietary material

e.g. PVC, PVC-U, ABS, PVC-C or PP. John Guest ‘Speedfit’

components are recommended.

3. Metal pipework is NOT suitable for use in condensate

discharge systems.

4. Any pipe fitted externally must be kept as short as possible to

minimise the potential of freezing and must be insulated using

waterproof material.

Min. radius 100mm

Point ‘A’

Gravity Drain

min. fall 3°

5. When discharging condensate into a soil stack or waste pipe

the effects of existing plumbing must be considered.

Max. Head

3.5 metres

Note: The point of discharge from the

pumped length of condensate pipe

(point ‘A’) must be 150mm above the

base level of the boiler, whether

discharging direct into a drain or into

an additional gravity drain.

5.10

Condensate Disposal (Fig. 12)

1. This boiler incorporates an automatic pumped condensate

system. The pump is submerged in a sump assembly and is

activated by the discharge float switch. A second (safety) float

switch is fitted.

Boiler

2. The pump has an effective head of 3.5 metres. The

condensate outlet is positioned at the top right front of the

boiler. It is 10mm diameter plastic.

3. 3.5 metres of flexible 10mm condensate discharge pipe and a

10mm push fit elbow are supplied with the boiler.

Fig. 12

4. The 10mm pipe can be routed to a maximum of 3.5 metres

vertically and then discharge via gravity or be routed

horizontally. A combination of vertical and horizontal runs is

permissible.

5. The pipe must be adequately supported, either using suitably

spaced clips or run within larger diameter pipe. When using clips

take care not to deform the pipe.

6. When routing the pipe through a wall it must be suitably

sleeved. Also the pipe must not be exposed to sources of heat,

and should be protected in locations where it may be damaged.

7. The pipe should be routed so that any sharp bends, dips and

loops are avoided. A minimum radius of 100mm is

recommended for any bends. No slope is necessary and air

breaks are not required on the pumped part of the condensate

run.

8. Any part of the condensate drain system that is outside the

dwelling, or in an unheated part of it must be at least 21.5mm

diameter.

5.0 Site Requirements

5.10

Condensate Disposal (cont.)

Termination via internal discharge branch e.g

sink waste - downstream

9. Ensure that the condensate can discharge freely (without

blockage or restriction of the pipe) into the drain.

Pipe must terminate

above water level but

below surrounding surface

Direct Connect Fitting

10. Examples are shown of condensate pipe methods of

termination:-

Sink

i) via an internal discharge branch

(e.g. sink waste) - Fig. 13.

ii) to an internal or external soil and vent pipe -

Fig. 14.

From Boiler

iii) to a drain or gully - Fig. 15. Ensure that the

condensate can discharge freely (without

blockage or restriction of the pipe) into the

drain.

Fig. 13

Termination to an internal soil and vent pipe

iv) to a soakaway - Fig. 16.

Direct Connect Fitting

5.11

Condensate Pump Operation

1. The pump operates for 2 seconds when mains voltage is

applied to the boiler, e.g. when the power has been

interrupted and then reinstated.

From Boiler

Min. 450mm

Fig. 14

2. If the boiler reset rocker switch has been operated the

pump will run also for 2 seconds.

Termination to a drain or gully

Pipe must terminate above

water level but below

surrounding surface

3. When the level of condensate in the sump is sufficient to

activate the discharge float switch the pump will run for 7

seconds, during which time about 0.6 litres of condensate will

be discharged.

From Boiler

Fig. 15

4. In the event of condensate not being discharged the safety

float switch will operate when the volume of condensate in

the sump reaches 1.05 litres. Once the safety float switch has

been activated the boiler will lockout.

500mm Min.

5. The total volume of the sump is 1.5 litres.

Termination to a purpose made

soak-away

From Boiler

Fig. 16

Holes in the soak-away must

face away from the building

6.0 Boiler Internal Wiring

6.1

Boiler Internal Illustrated Wiring Diagram

Central Heating

NTC Flow Sensor

OverheatThermostat

Discharge Float

Switch

Safety Float

Switch

Fan

g/y

X400

X401

X900

8 7

X300

Control PCB

X501

X500

Condensate Pump

ON/OFF

Reset

Spark

Generator

GasValve

Ignition

Electrode

Mains Input

(Permanent Live to 3,

Switched Live to 1)

- green

g/y - green / yellow

- red

gr - grey

br - brown

bk - black

- blue

- white

- yellow

7.0 Installation

INSTALLATION SEQUENCE

There are 4 main elements to the installation of the

Baxi Bermuda BBU 15 HE:-

• Preparation of pipework & opening

• Inserting the flue into the chimney

• Siting & fixing the boiler

• Fitting the terminal assembly

The sequence in which these are performed may

depend upon various factors beyond the scope of

these instructions. The above list is intended as a

guide based on a typical installation.

It is not necessary to open the firefront pack until

the boiler and flue are installed, and the boiler is

ready to be commissioned. The firefront pack

includes full instructions.

7.1

Initial Preparation

1. Remove the outer carton from the boiler pack.

Discard the packing pieces and remove the fitting kit.

Fig. 17

2. Ensure that the base of the builders opening is clean

and level.

3. Complete any pipework installation and routing of

electrical cables within the builders opening that may be

difficult once the boiler is in place.

7.2

Flue System

1. The actual length of flue (as opposed to the vertical

distance from the boiler top to the chimney outlet)

MUST be established before commencing.

Fig. 18

2. The flue must have a minimum vertical height of 3m

and have no bends greater than 45°.

NO HORIZONTAL RUNS ARE PERMITTED !

3. Depending on the actual flue length it may be

beneficial to shorten the flue at this point to enable

easier handling.

4. Take one of the 60mm lip seals supplied and fit to

the first groove in the flue duct. Also fit the 100mm lip

seal to the air duct. (Figs. 17 & 18).

Fig. 19

NOTE: Talcum powder may be used to ease fitting

of the adaptors over the seals. DO NOT use oil,

grease or soap.

5. Unfasten the clips on the boiler adaptor and insert

the end of the flue duct with the seal into the 60mm

socket. Ensure the seal is positioned past the clips, then

engage the clips over the larger diameter ‘rib’ on the

duct (Fig. 19).

6. Repeat the process for the 100mm air duct (Fig. 20)

Fig. 20

7.0 Installation

7.2

Flue System (cont.)

8. It is recommended that the Pull Cone Flue Adaptor

(part no. 720111801) is used as shown to ease the

fitting of the flue into the chimney and prevent damage

to the adaptor.

Fig. 22

Fig. 21

9. The cone has two internal lugs that engage on the

boiler adaptor in a bayonet action (Figs. 21 & 22).

10. A suitable weight should then be tied to the guide

rope fixed to the cone. The weight can then be passed

into the chimney and will draw the guide rope down

(Fig. 23).

Remove plug

from here

11. Once the Pull Cone is visible in the builders opening

it can be removed. It can be re-used indefinitely on

other installations.

Note: It is recommended that the boiler is installed

at this point. See Sections 8.3 to 8.7

NOTE: These seals

factory lubricated

Fig. 23

12. Remove the plastic plug from the boiler flue outlet.

Grasp the adaptor and locate it into the boiler, ensuring

the two large barbs lock into position under the boiler

top panel (Fig. 24) Fit the ‘C’ clip to the adaptor to

secure the flue. It must fit into the barbs and clip

securely into place (Fig. 24a).

Fig. 24

Barb

13. There will now be an excess of flue and air duct

protruding from the chimney.

14. Cut the excess concentric ducts to leave

approximately 300 to 500mm protrudung from the

chimney and pass the square closure plate over the air

duct (Figs. 25 & 26).

‘C’ Clip

15. Cut the 100mm air duct ONLY that 5 ‘ribs’ are

above the level of the chimney, taking care not to

damage the 60mm flue duct.

Fig. 24a

16. In a similar way to fitting the boiler adaptor fit the

air duct clamp to the air duct. This will prevent the duct

falling back into the chimney (Fig. 27).

Cut to leave

5 ribs visible

Fig. 25

Fig. 27

Fig. 26

7.0 Installation

7.2

Flue System (cont.)

Air Cowl

16. Pass the air duct collar and air cowl over the 60mm

flue duct (Fig. 28) and secure the collar to the closure

plate with the screws supplied (Fig. 29). The air cowl

will fit snugly over the collar.

Fig. 29

17. Cut the protruding 60mm flue duct down so that 5

ribs are visible and fit the remaining 60mm lip seal into

the first groove (Fig. 30). The flue duct adaptor can

now be fitted in the same manner as the boiler adaptor

(Fig. 31).

Air Duct

Collar

5 ribs

18. Fit the terminal cap over the flue duct adaptor and

air cowl. Once the cap is clipped into position it cannot

be removed easily without damage (Fig. 33).

Fig. 28

19. Cement over the closure plate and air duct collar to

a depth of approximately 100mm. Consideration should

be given to the potential accumulation of snow in this

area, and the possibility of it blocking the air inlet

(Fig. 34).

Fig. 30

Fig. 31

Fig. 32

Terminal

Cap

Cement around

Air Duct Collar

& Cowl

Fig. 33

Fig. 34

7.0 Installation

7.3

Siting the Boiler

IMPORTANT - This product should be lifted and

handled by two people. Stooping should be avoided and

protective equipment worn where necessary. Carrying

& lifting equipment should be used as required, e.g.

when installing on another floor.

Fixing Slot

1. Lift the boiler from the packing base and place into the

opening.

2. Align the boiler centrally as far back in the opening as

possible, and ensure the distance between each side and

the opening is equal. Check that the boiler is level.

3. Mark the hearth through two of the slots in the base

(Fig. 35). Remove the boiler and drill the hearth. Insert

suitable plugs. Replace the boiler & check the alignment

within the opening. Secure the boiler with suitable screws.

Fig. 35

Condensate

7.4

Water Connections

Discharge (remove

plug before connection)

1. The boiler has one return and one flow connection. The

flow is the upper connection. It is essential the flow and

return pipes are connected correctly (Fig. 36).

7.5

Gas Connection

1. Connection to the gas supply is a 15mm compression

fitting on the gas cock. The gas supply pipe must be routed

from the right hand side.

2. The positioning of the gas supply pipe must not restrict

the servicing of the boiler or installation of the firefront.

7.6

Electrical Connection

1. The boiler requires an electrical supply from the heating

controls system.

Return

Flow

WARNING: The appliance must be earthed.

The input cable for the appliance should be 0.75mm²to

IEC Code 227 (heat resistant). The system external

controls and the boiler must be supplied by the same

isolator. The boiler MUST NOT be connected to the

same supply as the firefront as their fuse ratings are

different.

Fig. 36

7.7

Making the Electrical Connection

1. Take the 5 pin plug from the boiler fitting kit, remove

the securing screws and hinge the cover open.

2. Route the mains inlet cable under the cable clamp and

connect Permanent Live, Neutral & Earth to 3, N &

respectively. Ensure that the Earth lead is longest.

3. Connect the switched output from the system external

control system to terminal 1.

Fig. 37

4. Refit the cover, tighten the screws to secure the cable

and connect the plug to the one on the boiler.

Auto Air

Vent

8.0 Completion & Commissioning

ON/OFF

8.1

Completion

Service

Reset

1. Seal off any secondary openings within the builders

opening after wrapping the gas and water pipes through the

brickwork and within the opening itself. (B.S. 5871 Part 1).

2. Take the Boiler Control from the firefront packaging and

connect it to the boiler (Fig. 38).

8.2

Commissioning the Boiler

1. Reference should be made to BS 5449 Section 5 when

commissioning the boiler.

Fig. 38

2. At the time of commissioning, complete all relevant

sections of the Benchmark Checklist at the rear of this

publication.

IMPORTANT: The heat exchanger air vent on top of the

boiler (Fig. 38) MUST be opened before filling the

primary system.

3. Ensure all valves in the water system are turned on.

4. The system must be flushed in accordance with BS 7593

(see Section 5.2) and the flushing agent manufacturers

instructions.

Fig. 39

5. Turn the gas supply on and purge according to in GB BS

6891 and in IE I.S. 813 "Domestic Gas Installations".

6. Test for gas soundness.

7. Ensure all external controls e.g. room stat, timer etc. are

calling for heat and turn on the mains electrical supply. Turn

the rocker switch at the top right of the boiler to ON. The

fan and condensate pump will run briefly.

Countdown

8. The display will count down from 7 to 0, then the current

water temperature will be displayed.

9. When there is a demand for heating the bar on the top

left of the display will be shown and the boiler will

commence the ignition sequence.

Current Temp.

& Demand

10. When ignition is established the ‘flame’ symbol on the

display is illuminated. The display will indicate the flow

temperature. The appliance is fully preset, therefore no

adjustment is required.

Burner Lit

11. If the boiler fails to ignite within the three ignition

attempts the error code E133 will appear in the display, ‘E1’

alternating with ‘33’.

12. To reset the boiler press the reset button for at least 3

seconds. The ignition sequence will then recommence. A

maximum of four resets in a five hour period are allowed.

Remaining

Resets

13. When the reset button is activated the number of

available reset attempts will be displayed

Fig. 40

8.0 Completion & Commissioning

8.2

Commissioning the Boiler (cont.)

IMPORTANT: The combustion for this appliance has

been checked, adjusted and preset at the factory for

operation on the gas type specified on the appliance data

plate. No measurement of the combustion is necessary.

Do not adjust the air/gas ratio valve.

Having checked:

That the boiler has been installed in accordance with

these instructions.

The integrity of the flue system and the flue seals, as

described in Section 7.2.

Proceed to put the boiler into operation as follows:

Check the Operational Gas Inlet Pressure

14. Set the boiler to operate at maximum rate as

described in Section 11.1.2 to 11.1.6.

15. With the boiler operating in the maximum rate

condition check that the operational gas pressure at the

inlet gas pressure test point is 20mb (Fig. 40a).

16. Ensure that this inlet pressure can be obtained with

all other gas appliances in the property working.

Measure the Gas Rate

17. With any other appliances & pilot lights turned OFF

the gas rate can be measured. It should be between 1.55

Inlet Gas Pressure

Test Point

Fig. 40a

and 1.71m /h.

18. Carefully read and complete all sections of the

Benchmark Commissioning Checklist at the rear of this

publication that are relevant to the boiler and installation.

These details will be required in the event of any

warranty work. The publication must be handed to the

user for safe keeping and each subsequent regular service

visit recorded.

For IE, it is necessary to complete a “Declaration of

Conformity” to indicate compliance with I.S. 813. An

example of this is given in I.S. 813 “Domestic Gas

Installations”. This is in addition to the Benchmark

Commissioning Checklist.

19. Disconnect the Boiler Control and fit the firefront in

accordance with the instructions supplied with it.

IMPORTANT: The loose boiler serial number label

supplied in the boiler kit must be applied to an area of

the spacer frame that is visible to the end user e.g.

lower right hand side.

9.0 Annual Servicing

9.1

Annual Servicing

1. For reasons of safety and economy, it is recommended that

the boiler is serviced annually. Servicing must be performed by

a competent person in accordance with B.S. 7967-4.

2. After servicing, complete the relevant Service Interval

Record section of the Benchmark Commissioning Checklist at

the rear of this publication.

3. Disconnect the firefront electric supply. Remove the fascia

from the firefront. Unhook its hanging brackets from the slots

in the top of the firefront. On Classica and Innova models also

disengage the retaining magnets at the lower part of the fascia.

4. Slacken the firefront retaining wire and unthread it from the

bracket on top of the boiler. The firefront can now be

manoeuvred away from the boiler. Do not drag the firefront

as it may damage the hearth. To completely remove the

firefront disconnect the boiler control cable.

Flue Sampling

Plug

IMPORTANT: During routine servicing, and after any

maintenance or change of part of the combustion circuit, the

following must be checked:-

The integrity of the flue system and the flue seals, as

described in Section 7.2.

The integrity of the boiler combustion circuit and relevant

seals as described in Section 9.2.

The operational gas inlet pressure as described in Section

8.2.14 to 8.2.16 and the gas rate as described in 8.2.17.

The combustion performance as described in 9.1.5 to 9.1.6.

Competence to carry out checking Combustion

Performance

B.S. 6798 ‘Specification for Installation & Maintenance of Gas

Fired Boilers not exceeding 70kW’ advises that:-

The person carrying out a combustion measurement

should have been assessed as competent in the use of a

flue gas analyser and the interpretation of the results.

Fig. 41

The flue gas analyser used should be one meeting the

requirements of BS7927 or BS-EN50379-3 and be

calibrated in accordance with the analyser manufacturers’

requirements.

Off Position

Competence can be demonstrated by satisfactory

completion of the CPA1 ACS assessment, which covers

the use of electronic portable combustion gas analysers in

accordance with BS 7967, Parts 1 to 4.

Check the Combustion Performance

5. Set the boiler to operate at maximum rate as described in

Section 11.1.2 to 11.1.6.

6. Remove the threaded plug from the sampling point, insert

the analyser probe and obtain the CO/CO²ratio. This must

be less than 0.004.

On Position

7. If the combustion reading is greater than this, and the

integrity of the flue system and combustion circuit seals has

been verified, and the inlet gas pressure and gas rate are

satisfactory either adjust the gas valve (Section 11.0), replace

the gas valve (Section 10.8) or contact the ‘heateam’ Technical

Helpline (0844 871 1555).

Fig. 42

9.0 Annual Servicing

PCB Control Box

Securing Screw

9.2

Annual Servicing - Inspection

Reset Switch

1. Ensure that the boiler is cool.

PCB Control

Box

2. Ensure that the gas supply to the boiler is isolated.

3. Operate the Reset switch (Fig. 41) to activate the

condensate pump and then repeat. This will empty most of

the condensate from the sump.9. Isolate the boiler from the

electrical supply.

4. Undo & remove the flue sampling plug and washer. Remove

the screws retaining the boiler front panel, and lift the panel

away (Fig. 43).

Off Position

Fig. 43

5. Remove the screw securing the PCB control box and swing

the box to the right (Fig. 43).

Boiler Front

Panel

6. Disconnect the two plugs from the fan motor and remove

the sensing pipe from between the gas valve and fan outlet.

7. Remove the gas feed pipe and washers, and extract the

injector from the gas/air inlet manifold.

Spark

Generator

8. For ease of access disconnect the following:-

a) 2 pin plug on NTC lead

b) all wires from electrode assembly

c) all wires from spark generator

d) both wires from the overheat thermostat

e) the red and black wires connected together

Electrode

Assembly

9. Undo the two securing nuts and remove the spark

generator and bracket.

10. Undo the combustion panel securing nuts and remove the

special spring washers. Remove the complete fan & panel

assembly from the boiler.

Injector

Sensing Pipe

Gas Valve

11. Lay the assembly to one side. The outer insulation panel is

fitted to the rear of the combustion box panel.

Gas Feed

Pipe

12. Clean inside the heat exchanger and examine the

condition of the fins.

13. Examine the burner, electrodes, insulation and seal,

replacing if necessary. Also check the condition of the three

insulation pieces in the rear of the heat exchanger.

Discharge Pipe

14. Disconnect the wires on the condensate pump motor and

pull off the plastic discharge pipe. Cut and remove the transit

cable tie. It is not necessary to replace this item.

Locking Clip

Fan

15. Squeeze the two retaining clips and turn the pump

anticlockwise to remove it. Draw it upwards from the sump.

Condensate Pump

16. Clean any debris from the sump and examine the

condition of the pump seal, replacing if necessary.

17. Reassemble in reverse order of dismantling, checking and

replacing any components as necessary. Recommission the

boiler and complete the relevant Service Interval Record

section of the Benchmark Commissioning Checklist at the rear

of this publication.

Fig. 44

10.0 Changing Components

10.1

Changing Components

1. To change any components on the back boiler it is

necessary to remove the firefront.

2. Refer to the Installer Guide that accompanies the

firefront for details of removal.

3. Ensure that the boiler is cool and that the electrical

and gas supplies are isolated.

4. After changing any components carry out gas

soundness checks.

Fig. 45

5. Undo & remove the flue sampling plug and washer.

Remove the screws retaining the boiler front panel, and

lift the panel away.

Spark Generator

6. Remove the screw securing the PCB control box and

swing the box to the right.

10.2

Spark Generator (Fig. 46)

Plug

1. Note the position of the two leads on the spark

generator and disconnect them. Also disconnect the

earth wire and plug, and remove the screws securing the

spark generator to the bracket.

Fig. 46

2. Remove the spark generator. Replace in reverse order

of dismantling, using the screws previously removed.

3. Ensure that the leads and plug are pushed fully on to

their terminals.

10.3

Electrode Assembly (Fig. 47)

PCB Control Box

removed for clarity

1. Note the position of the two leads on the electrode

assembly and disconnect them. Disconnect the in-line

connection on the black wire and the earth wire.

2. Undo the securing screws and remove the electrode

assembly and earth tag from the combustion box panel.

Sealing Gasket

3. Replace in reverse order of dismantling, using the

screws previously removed. Examine the sealing gasket

and replace if necessary.

Electrode

Fig. 47

4. Ensure that the leads are pushed fully on to their

terminals.

Condensate Pump

10.4

Condensate Pump (Fig.48)

1. Note the position of the two leads and earth wire on

the pump motor and disconnect them.

Locking Clip

2. Cut and remove the transit cable tie. It is not

necessary to replace this item.

3. Squeeze in the two locking clips and turn the pump

anti-clockwise. Pull the condensate discharge pipe off its

connection and remove the pump.

4. Replace in reverse order of dismantling. Examine the

sealing ring and replace if necessary.

5. Ensure that the leads are pushed fully on to their

terminals.

Fig. 48

Spark Generator

10.0 Changing Components

10.5

Fan (Fig. 49)

1. Disconnect the two plugs from the fan motor and

remove the sensing pipe from between the gas valve

and fan outlet.

Plug

2. Remove the gas feed pipe and washers, and extract

the injector from the gas/air inlet manifold.

Injector

3. For ease of access disconnect the following:-

a) 2 pin plug on NTC lead

Note position

of Slot

b) all wires from electrode assembly

c) all wires from spark generator

Electrode

d) both wires from the overheat thermostat

e) the red and black wires connected together

4. Undo the two securing nuts and remove the spark

generator and bracket.

5. Undo the combustion panel securing nuts and remove

the special spring washers. Remove the complete fan &

panel assembly from the boiler. Check the condition of

the insulation piece.

Fig. 49

6. Undo and remove the nuts and washers securing the

fan to the gas/air inlet. NOTE THE POSITION OF THE

RESTRICTOR PLATE !

Fan

7. Remove the securing screws and transfer the fan inlet

to the new fan. Use a new sealing gasket if necessary.

8. Replace in reverse order. ENSURE THAT THE

RESTRICTOR PLATE IS CORRECTLY FITTED ! THE

SLOT MUST BE TO THE REAR. Check the condition of

the sealing gaskets between the fan and gas/air inlet and

the combustion panel and heat exchanger and replace if

necessary.

10.6

Burner (Fig. 50)

1. Proceed as described in points 1. to 5. above.

2. Undo the screws securing the burner to the

combustion panel. Remove the burner.

3. Replace in reverse order of dismantling, using the

screws previously removed. Examine the sealing gasket

and replace if necessary.

PCB Control Box

removed for clarity

10.7

Injector (Fig. 50)

Burner

1. Remove the gas feed pipe and washers, and extract

the injector from the gas/air inlet manifold.

2. Replace in reverse order of dismantling. Examine the

sealing washers and replace if necessary.

Spark Generator

Plug

Fig. 50

Gas Feed

Pipe

Injector

10.0 Changing Components

10.8

Gas Valve (Fig. 51)

IMPORTANT: After replacing the valve the CO²must be

checked and adjusted as detailed in Section 11.0 Setting

the Gas Valve. Only change the valve if a suitable

calibrated combustion analyser is available, operated by a

competent person - see Section 9.1

1. Disconnect the plug and earth wire from the gas valve and

remove the sensing pipe from between the valve and fan

outlet.

2. Remove the gas feed pipe and washers, and extract the

injector from the gas/air inlet manifold.

3. Undo the nut on the pipe from the gas cock to the valve

inlet adaptor, and remove the screws securing the adaptor to

the boiler side panel.

PCB Control Box

removed for clarity

4. Remove the valve complete with the inlet and outlet

adaptors, and the seal on the inner face of the side panel.

Transfer the adaptors to the new valve, using new ‘O’ rings if

necessary.

5. Replace in reverse order of dismantling, using the screws

previously removed. Examine all sealing gaskets and washers

and replace if necessary.

Injector

NOTE: To assist the boiler to light prior to final setting,

use a suitable hexagon key to wind out the Gas/Air

adjustment screw until it is flush with the valve body, then

turn the screw 4 full turns clockwise (Fig. 51). If the boiler

will not light, or the correct CO²cannot be achieved

contact the ‘heateam’ technical helpline.

Gas Valve

Earth Wire

Fig. 51

10.0 Changing Components

Safety Thermostat

10.9

PCB (Fig. 54)

1. Pull off the two control knobs and disengage the

securing tabs of the cover. Undo the screws securing the

PCB.

Flow Pipe

2. Draw the PCB forwards and disconnect the wiring.

Transfer the two potentiometer drive pins to the new

PCB and replace in reverse order of dismantling.

Fig. 52

3. Ensure that the wiring connectors are pushed fully on

to the PCB terminals.

10.10 NTC (Fig. 53)

1. Disconnect the 2 pin plug. Remove the clip retaining

the NTC in the heat exchanger pocket. Pull the NTC

out of the pocket.

2. Apply suitable heat transfer paste to the new NTC.

Replace in reverse order of dismantling, using the clip

previously removed. Ensure that the plug is fully engaged.

Clip

10.11 Safety Thermostat (Fig. 52)

1. Disconnect the two leads from the thermostat.

Fig. 53

NTC

2. Remove the screws securing the thermostat to the

mounting plate on the flow pipe.

3. Replace in reverse order. The thermostat is not

polarised - either wire can fit either terminal on the

thermostat.

10.12 Float Switches (Fig. 55)

1. Remove the fan as described in Section 10.5,

paragraphs 1 to 5.

2. The two float switches are the same, but oriented

differently. The discharge switch is at the left, the safety

at the right.

PCB

3. To remove either switch disconnect the lead and pull

off the alignment bracket.

Fig. 54

4. Undo the retaining nut. The sealing grommet will be

released from the sump body and allow the switch to be

removed.

Control Knobs

5. Note the orientation of the alignment rib on the

switch. It is positioned uppermost on the safety float

switch and to the bottom on the discharge switch.

Discharge

Float Switch

6. Take the new switch assembly and insert it into the

sump. Hand tighten the nut and slide the alignment

bracket in place to ensure the switch is in position.

Tighten the nut a further 2 turns.

7. Reconnect the lead to the switch, ensuring it is fully

engaged.

Safety Float

Switch

Alignment

Bracket

Fig. 55

11.0 Setting the Gas Valve

11.1

Setting the Gas Valve (CO²check)

IMPORTANT: The CO²must be only be checked and

adjusted to set the valve if a suitable calibrated

combustion analyser is available, operated by a

competent person - see Section 9.1

Flue Sampling

Point

1. The combustion (CO²) may be checked after running the

boiler for several minutes. To do this it is necessary to set

the boiler to ‘Calibration Mode’.

Display

2. Ensure that all external controls are calling for heat. The

actual current boiler temperature is shown on the display.

3. Turn both control knobs fully anticlockwise, then quickly

Fig. 56

turn the right hand knob /⁴clockwise twice and back fully

Control

Knobs

anticlockwise (Fig. 56).

4. The display will now alternate between ‘SF’ and the

current boiler temperature and both green LEDs will flash

(Figs. 57 & 58).

5. Turn the left hand knob fully clockwise. As the knob is

turned the display will change, indicating the fan speed.

Fig. 57

Fig. 58

6. The display will show ‘00’, indicating maximum rate, then

revert to ‘P ‘ alternating with the current boiler temperature

(Figs. 59, 60 & 61 ).

Fig. 59

7. Remove the plug from the flue sampling test point. Insert

the analyser probe and allow sufficient time for the reading

to settle (Fig. 56).

The CO²should be 9.3% 0.2

8. It is possible to alter the CO²by adjustment of the gas

valve. Remove the plastic cover from the ‘Max Rate’

adjustment screw. At maximum rate the ‘Max. Rate’

adjustment screw should be turned, using a suitable hexagon

key, until the correct reading is obtained (Fig. 62).

Fig. 60

Fig. 61

Turning clockwise will reduce the CO². Anticlockwise will

increase the CO²

Max Rate

Adjustment Screw

(cover removed)

Min Rate

Adjustment Screw

(cap fitted)

9. The CO²must then be checked at minimum rate. Turn

the left hand knob fully anti-clockwise. As the knob is turned

the display will change, indicating the fan speed. When the

display reads ‘ 0’ the boiler runs at minimum rate.

The CO²should be 8.2% 0.2

Reduce CO²Increase CO²

at min. rate

at max. rate

10. With the boiler on minimum, the ‘Min. Rate’ adjustment

screw must be altered, using a suitable hexagon key, after

removing the cap (Fig. 62). Turning anti-clockwise will reduce

the CO². Clockwise will increase the CO²

11. The ‘Calibration Function’ is maintained for 20 minutes

unless the maximum CH temperature is exceeded. The

function can be disabled at any time by turning the right

hand knob.

Fig. 62

If the CO²is reset at minimum rate it must

be rechecked at maximum rate again and

adjusted if required. If the CO²is reset at

12. Check the CO/CO²ratio. This must be less than 0.004.

maximum rate it must be rechecked at

minimum rate and adjusted if required.

12.0 Fault Finding

12.1

Initial Fault Finding Checks

1. Check that gas, water and electrical supplies are available

at the boiler.

NOTE: When instructed to

operate the reset button, press

and hold for 5 seconds to reset

the boiler.

2. Electrical supply = 230V ~ 50 Hz. Check the CH & DHW

system. The preferred minimum gas pressure is 20 mbar.

3. Carry out electrical system checks, i.e. Earth Continuity,

Resistance to Earth, Short Circuit and Polarity with a suitable

meter.

NOTE: These checks must be repeated after any

servicing or fault finding.

4. 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.

Table Of Error Codes

12.2

Error Codes

E20

Central Heating NTC Fault

Incorrect PCB Fitted

1. If a fault occurs on the boiler an error code may be shown

on the boiler display and the Boiler Control.

E28

E50

Hot Water NTC Fault

E110

E125

E131

E133

E155

E158

E160

Safety Thermostat or Condensate Safety Float Switch Operated

Circulation Fault (Primary Circuit)

Interruption Of Power Supply while in fault mode

Interruption Of Gas Supply or Flame Failure

Lock Out of Boiler Control

2. The codes are either two or three digit, preceded by the

letter 'E'. For example, code E133 will be displayed by 'E1'

alternating with '33'. E20 is shown as 'E' then '20'

E20 & E28 indicate faulty or incorrect components.

Condensate Discharge System Fault

Fan or Fan Wiring Fault

E110 shows overheat of the primary water or excess

condensate in the sump.

E125 is displayed if within 2 hours of the burner lighting the

boiler temperature twice exceeds the selected temperature

by 25°.

In these instances poor primary circulation or no water in the

system is indicated.

Service Reset

To perform a Service Reset it is necessary to have access to the boiler.

By pressing the Reset rocker switch on the right of the boiler case for a

minimum of 5 seconds when error codes are displayed it is possible to

reset the boiler once the fault has been rectified.

E133 indicates that the gas supply has been interrupted,

ignition has failed or the flame has not been detected.

E155 indicates a Boiler Control reset when Service & Boiler

Control reset counters are out of step. Boiler Control default

not restored correctly.

Restoring Boiler Control Default

Following a Service Reset it is necessary to restore the Boiler Control to

default condition:-

E158 indicates a condensate discharge system fault.

Disconnect the main power supply

On reinstating the power supply the Boiler Control display will count

down from 7.

3. By pressing the 'Reset' button on the Boiler Control for a

minimum of 5 seconds when E110 & E133 are displayed it is

possible to relight the boiler.

Before the count reaches 3 press both the ‘On/Off’ and ‘Reset’ buttons

simultaneously and hold until the count reaches 0.

The Boiler Control display will show ‘SEt’ to confirm default restoration.

4. If this does not have any effect, or the codes are displayed

regularly further investigation is required. It is possible to

reset the boiler up to 4 times in any 5 hour period. Further

resets via the Boiler Control are then blocked for 5 hours

unless a Service Reset is performed.

12.0 Fault Finding

Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components

Central Heating - Follow operational sequence

NOTE: Sections ‘A’ to ‘L’

Turn on Power Supply

Display Illuminates

referred to in the chart

opposite are on the

following pages

Go to section ‘A’

YES

Error 110 flashing

Error 131 flashing

If the error 110 is still flashing.

Press the Service Reset

switch for 5 seconds

YES

Go to section ‘I’

YES

Error 20 or 28 flashing

Go to section ‘E’

Error 158 flashing

Go to section ‘C’

Ensure controls are set to

demand and verify the

contacts are closed

Turn Central Heating

thermostat to Maximum.

Pump runs

Ensure all external controls

are calling for heat

YES

Go to section ‘B’

YES

Go to section ‘J’

Error 155 flashing

Ensure that the system is full,

primary circulation is OK &

that there is no blockage

YES

Error 125 flashing

Go to section ‘J’

Error 160 flashing

Go to section ‘D’

Fan runs

YES

Error 160 flashing

Go to section ‘K’

Fan runs at correct speed

YES

Go to section ‘G’

Turn the selector switch to

reset

Spark at ignition electrodes for

up to 5 seconds and for 3

attempts

YES

Error 133 flashing

Go to section ‘F’

YES

Burner does not stay alights

after 5 seconds

Error 133 flashing

Go to section ‘H’

Burner lights

YES

Check the Central Heating

NTC sensor

Burner output modulates to

maintain the temperature set

Go to section ‘E’

YES

Burner relights after at least 3

minutes, when the display is

less than the set temperature

(room thermostat open)

YES

Operation sequence

successful

Burner goes out

Fan stops after 10 seconds

Fault Finding Solutions Sections

12.0 Fault Finding

Is there 230V at:

Main terminals L and N

Main terminal fuse

Check electrical supply

Replace fuse

Display

illuminated

Replace PCB

Check wiring

PCB - X1 connector

terminals 1,2

Check all system wiring and pump

Service Reset

Condensate Pump does not run

On Reset is there 230V at:

PCB - X3 connector terminals 5 &

6 for at least 2 seconds

Replace PCB

Condensate Pump terminals for at

least 2 seconds

Replace wiring

YES

Replace Cond. Pump

YES

Condensate Pump runs

Condensate drain system blocked

Clean condensate drain system

Replace Float Switch

Fan connections correct at fan. PCB -

X2 connector, is 230V AC across

terminals 5 & 7

YES

Fan jammed or faulty winding

Replace PCB

Replace fan

E20 - Temperature sensor faulty.

Cold resistance approximately

10kΩ @ 25° C

Replace sensor or PCB (E28)

(resistance reduces with increase in temp.)

E28 - Incorrect PCB fitted

Check and correct the connection of the

tube between the venturi and gas valve

Gas at burner

Ensure gas is on and purged

Replace PCB

YES

PCB - X3 connector is 230V AC across

terminals 1 & 2

Replace gas valve

voltage at PCB - X2 connector is

110V AC across terminals 2 & 5

(Note: from multimeter connect

‘common’ to 2 & ‘volts’ to 5)

Check wiring

Check and correct if necessary

1. Ignition electrode and lead

2. Electrode connection

Replace PCB

Replace igniter

YES

3. Spark gap and position

Check the gas supply pressure:

For Natural Gas greater than

10 - 11 mbar

12.0 Fault Finding

Check and correct if necessary

1. The mechanical set of the gas valve

(CO2 values - see instruction)

2. Flame sensing electrode and lead connections

3. Flame sensing electrode position

YES

Replace PCB

Replace flame sensing electrode

Flame current should be more than 0.5 μA

Overheat Thermostat or

Condensate Safety Float Switch

operated or faulty

Allow to cool. Continuity

across thermostat terminals

more than 1.5 ohm

YES

Replace Safety Thermostat

Replace PCB

Continuity across plug

terminals at 3 & 4 of connector

X401 more than1.5 ohm

YES

Check condensate system

and Pump

Condensate drain system fault

Replace Safety Float Switch

or wiring

Press the Service Reset switch

for 5 seconds

Restore Boiler Control defaults

YES

Fan connections correct at fan.

PCB - X401 connector terminals 5,6,7 & 8

Replace fan

Temperature sensors faulty.

Cold resistance approximately

10kΩ @ 25° C (CH sensor)

Replace sensor

(resistance reduces with increase in temp.)

YES

Replace heat exchanger

If pump is running the heat exchanger could be

obstructed

IMPORTANT:There is no limit to the number of repeated ‘Service Reset’

operations but the Boiler Control must be refreshed by ‘Restoring Boiler

Control Default’ as described on p.34 following the final ‘Service Reset’ and

before the Boiler Control reset is re-used.

13.0

Short Parts List

Key

No.

Description

Manufacturers

Part No.

Burner Assy

Injector

720125701

720126301

720127501

720127001

720125801

5121447

Ignition Lead

Gas Valve

P.C.B

Fan

NTC Sensor

Float Switch ^{(Safety or Discharge)}

Safety Thermostat

Spark Generator

Condensate Pump

720126101

720126201

720126401

5114766

720125901

14.0 Notes

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating

compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

Customer Name

Address

Telephone Number

Boiler Make and Model

Boiler Serial Number

Commissioned by (print name)

Company Name

Gas Safe Register licence No.

Telephone Number

Company Address

Commissioning Date

To be completed by the customer on receipt of a Building Regulations Compliance Certiﬁcate :

Building Regulations Notiﬁcation Number (if applicable)

CONTROLS Tick the appropriate boxes

Time and Temperature Control to Heating

Room Thermostat and

Programmer/Timer

Programmable

Room Thermostat

Load/Weather

Compensation

Optimum Start

Control

Time and Temperature Control to Hot Water

Heating Zone Valves

Cylinder Thermostat and Programmer/Timer

Combination Boiler

Not Required

Provided

Fitted

Hot Water Zone Valves

Thermostatic Radiator Valves

Automatic Bypass to System

Boiler Interlock

ALL SYSTEMS

The system has been ﬂushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions

Yes

What system cleaner was used?

What inhibitor was used?

Quantity

litres

ft³/hr

CENTRAL HEATING MODE Measure and Record:

m³/hr

mbar

Gas Rate

Burner Operating Pressure (if applicable)

Central Heating Flow Temperature

Central Heating Return Temperature

Gas Inlet Pressure

mbar

°C

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)?

If yes, has a water scale reducer been ﬁtted?

What type of scale reducer has been ﬁtted?

DOMESTIC HOT WATER MODE Measure and Record:

Gas Rate

Yes

ft³/hr

m³/hr OR

mbar OR

Burner Operating Pressure (at maximum rate)

Cold Water Inlet Temperature

Gas Inlet Pressure (at maximum rate)

mbar

°C

Hot water has been checked at all outlets

Water Flow Rate

Yes

Temperature

°C

l/min

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798

Yes

ALL INSTALLATIONS

If required by the manufacturer, record the following

CO₂

OR CO

ppm OR CO/CO₂Ratio

The heating and hot water system complies with the appropriate Building Regulations

Yes

The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions

The operation of the boiler and system controls have been demonstrated to and understood by the customer

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer

Commissioning Engineer’s Signature

Customer’s Signature

(To conﬁrm satisfactory demonstration and receipt of manufacturer’s literature)

All installations in England and Wales must be notiﬁed to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.

A Building Regulations Compliance Certiﬁcate will then be issued to the customer.

www.centralheating.co.uk

SERVICE RECORD

It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s

instructions.

Always use the manufacturer’s speciﬁed spare part when replacing controls.

SERVICE 1 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 2 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Yes

Company Name

Telephone Number

Gas Safe Register licence No.

Comments

Gas Safe Register licence No.

Comments

Signature

SERVICE 3 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 4 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Company Name

Telephone Number

Gas Safe Register licence No.

Comments

Gas Safe Register licence No.

Comments

Signature

SERVICE 5 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 6 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Company Name

Telephone Number

Gas Safe Register licence No.

Comments

Gas Safe Register licence No.

Comments

Signature

SERVICE 7 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 8 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Company Name

Telephone Number

Gas Safe Register licence No.

Comments

Gas Safe Register licence No.

Comments

Signature

SERVICE 9 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 10 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Company Name

Telephone Number

Gas Safe Register licence No.

Comments

Gas Safe Register licence No.

Comments

Signature

Please complete the boxes below

9.0 Warranty & Service

Serial Number

Standard Warranty Terms & Conditions

To activate your second year free warranty you must register your boiler with

heateam the service division of Baxi Heating UK Ltd either by completing and

returning the registration card or calling our telephone registration line on

0800 013 7989.

It is also a requirement of the warranty that the boiler has an annual service

(every 12 months) in accordance with the installation and servicing

instructions, performed by a Gas Safe registered engineer.

Date of Installation

If you would like heateam to carry this out please call on 0844 871 1525.

Our promise to you

If you experience a fault with your new boiler, we aim to provide a safe and

high quality repair service supported by our dedicated national network of

highly skilled engineers. If your installer can’t resolve the problem for you, we

will do everything we can to get an engineer out to you as quickly as possible.

Nothing in this warranty will affect your statutory consumer rights.

M M

Installer Details (name, address and contact number(s))

What you need to do if you experience a problem with your heating system

or the operation of the boiler

You should always contact your installer first, because the cause of the fault

may not be related to the boiler. If your installer confirms that the fault is with

the boiler and he/she can’t repair it, our friendly customer service team is on

hand to help. Simply call our service division heateam on 0844 871 1525 to

book an engineer visit or for any general advice that you may need. Our

contact centre is open Monday to Friday 8am - 6pm, weekends and Bank

Holidays 8.30am - 2pm, excluding Christmas Day and New Years Day.

When calling heateam it would be helpful if you could have the following

information to hand:-

Boiler serial number (see opposite).

Boiler make and model number.

Your installer name and address details.

Proof of purchase (if you do not have the boiler serial number).

What this warranty covers

Free of charge repair or replacement of components found to be of faulty

manufacture.

Free of charge replacement of the complete unit provided always that the

failure is related to a manufacturing fault that cannot be repaired or is

uneconomic to repair.

What this warranty does not cover

Repairs to boilers which haven’t been installed and commissioned properly,

and as set out in the installation instructions (this includes the need to flush the

system effectively and add a suitable corrosion inhibitor).

Any damage caused by hard water scale deposits and/or aggressive water

resulting from corrosion.

Any other defects or failures, either in the connected heating system or

outside of the boiler itself.

Faults caused by inadequate supply of electricity, gas or water to the property.

Installations within commercial settings for which this boiler was not designed.

All descriptions and illustrations provided in this leaflet have been carefully

prepared but we reserve the right to make changes and improvements in

our products which may affect the accuracy of the information contained in

this leaflet. All goods are sold subject to our standard Conditions of Sale

which are available on request.

Reimbursement of any third party repair or replacement costs that we haven’t

been told about or agreed with you in advance.

Compensation for consequential losses (e.g. loss of earnings, business losses,

stress and inconvenience) arising from a production breakdown, including

repair delays caused by factors outside our reasonable control.

BAXI

A Trading Division of Baxi Heating UK Ltd (3879156)

A Division of Baxi Group

After Sales Service 0844 871 1525

Brooks House, Coventry Road, Warwick. CV34 4LL

After Sales Service 0844 871 1525 Technical Enquiries 0844 871 1555

Website www.baxi.co.uk

e&oe

Comp N 710161501 (7/09)

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