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United Kingdom
en
Installation and Service Manual
Gas Fired Wall Mounted Condensing Boiler
Heat
613 - 616 - 619 - 625 - 630
These instructions include the Benchmark Commissioning Checklist and should be left with the
user for safe keeping. They must be read in conjunction with the Flue Installation Guide.
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Table of Contents
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Summary of Contents for Baxi Heat 616
- Page 1 United Kingdom Installation and Service Manual Gas Fired Wall Mounted Condensing Boiler Heat 613 - 616 - 619 - 625 - 630 These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. They must be read in conjunction with the Flue Installation Guide.
- Page 2 © Baxi Heating UK Ltd 2019 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988.
- Page 3 Installation Notification Guidelines installer notification guidelines Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme Install and Commission this Contact your relevant Local appliance to manufacturer's Authority Building Control instructions (LABC) who will arrange an inspection or contact a government approved inspector Complete the...
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Page 4: Table Of Contents
Contents Contents introduction General Additional Documentation Symbols Used Abbreviations Extent of Liabilities 1.5.1 Manufacturer’s Liability 1.5.2 Installer’s Liability Homologations 1.6.1 Safety, Performance & Quality 1.6.2 Standards Safety General Safety Instructions Recommendations Specific Safety Instructions 2.3.1 Handling Technical Specifications Technical Data Technical Parameters Dimensions and Connections Electrical Diagram... - Page 5 Contents 5.3.9 Flue/Chimney Trim 5.3.10 Terminal Guard 5.3.11 Flue/Chimney Deflector 5.3.12 Flue/Chimney Accessories 5.3.13 In Case Rear Flue Unpacking & Initial Preparation 5.4.1 Unpacking 5.4.2 Initial Preparation 5.4.3 Making the Water Connection 5.4.4 Filling the Condensate Trap 5.4.5 Connecting the Condensate Drain 5.4.6 Connecting the Gas Supply installation...
- Page 6 Contents Maintenance 10.1 General 10.2 Standard Inspection & Maintenance Operation 10.3 Specific Maintenance Operation 10.3.1 Spark Ignition Electrode 10.3.2 Automatic Air Vent 10.3.3 Condensate Trap 10.3.4 Removal of Ducts 10.3.5 Pressure Switch (625 & 630 only) 10.3.6 Flow Temperature Sensor 10.3.7 Overheat Sensor 10.3.8...
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Page 7: Introduction
Introduction introduction general WaRning Installation, repair and maintenance must only be carried out only by a competent person. This document is intended for use by competent persons, 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 This appliance must be installed in accordance with the... -
Page 8: Additional Documentation
Introduction additional Documentation These Installation & Service Instructions must be read in conjunction with the Flue Accessories & Fitting Guide supplied in the Literature Pack. Various timers, external controls, flue accessories, etc. are available as optional extras. Full details are contained in the relevant sales literature. -
Page 9: Extent Of Liabilities
Introduction Extent of Liabilities 1.5.1 Manufacturer's Liability Our products are manufactured in compliance with the requirements of the various european applicable Directives. They are therefore delivered with marking and all relevant documentation. In the interest of customers, we are continuously endeavouring to make improvements in product quality. -
Page 10: Installer's Liability
Introduction 1.5.2 installer's Responsibility The installer is responsible for the installation and initial start up of the appliance. The installer must adhere to the following: Read and follow the instructions given in the manuals provided with the appliance. Carry out installation in compliance with the prevailing legislation and standards. -
Page 11: Standards
Introduction 1.6.2 Standards Codes of Practice - refer to the most recent version In GB the following Codes of Practice apply: Standard Scope BS 6891 Gas Installation. BS 5546 Installation of hot water supplies for domestic purposes. BS EN 12828 Heating systems in buildings. -
Page 12: Safety
Safety Safety general Safety instructions DangER If you smell gas: Turn off the gas supply at the meter Open windows and doors in the hazardous area Do not operate light switches Do not operate any electrical equipment Do not use a telephone in the hazardous area Extinguish any naked flame and do not smoke Warn any other occupants and vacate the premises... -
Page 13: Specific Safety Instructions
Safety Specific Safety instructions 2.3.1 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. -
Page 14: Technical Specifications
Technical Specifications Technical Specifications Technical Data nOx Class appliance Type Horizontal Flue Terminal Diameter 100mm Electrical Supply 230V~ 50Hz appliance Category CAT I Dimensions Projection 125mm (Appliance must be connected to an Heat input Qn Hs (Gross) Connections earthed supply) Gas Supply 22mm Power Consumption... -
Page 15: Technical Parameters
Technical Specification Technical Parameters Technical parameters for boiler space heaters Baxi 600 Heat Condensing boiler Low-temperature boiler B1 boiler Cogeneration space heater Combination heater Prated Rated heat output Useful heat output at rated heat output 13.0 16.0 19.0 25.0 30.0... -
Page 16: Dimensions And Connections
Technical Specification Dimensions and Connections DIMENSIONS a 625mm a2 25mm at Least B 270mm 1.5° at Least C 370mm 1.5° D 116mm Ø Min. E 165mm F 155mm g 110mm H 550mm For clearances see Section 5.3.6 360° Orientation nOTE: There must be no part of the air duct (white tube) visible outside the property after installation. -
Page 17: Electrical Diagram
Technical Specification Electrical Diagram Electrode Gas Valve Mains Safety Thermostat User Interaction Controller Electrical Test Point Not used Return Sensor Flow Sensor Parameter Unit Pressure Switch (where fitted) FROM COLOUR LINK HIGH LIMIT BLACK PRESURE SWITCH Loop Connector FLOW SENSOR BLACK COMBI ONLY (where no pressure... -
Page 18: Description Of The Product
Description of the Product Description of the Product general Description 1. The Baxi 600 Heat Range are gas fired wall mounted powered flue condensing boilers. 2. The maximum output of the boiler is :- 612 model - 13 kW 616 model - 16 kW... -
Page 19: Operating Principle
Modulate output appliance. Any lock-out errors that occur regularly will require further investigation and rectification. Flow temp or Baxi Customer Support: 0344 871 1545. rate of rise too high ? Burner Off Mains Off (Demand satisfied) -
Page 20: Main Components
Description of the Product Main Components Heat Exchanger Combustion Control Unit Condensate Trap Exhaust Tube Inlet Silencer User Interaction Controller Gas Cock Air Pressure Switch (25 & 30 models only) System Drain Cock Air Vent 600 Heat 7726858-01 (1/19) -
Page 21: Control Panel Description
Description of the Product Control Panel Description 4.4.1 User interaction Controller (Control Panel) Key to symbols (Fig. 2) Heating Water Temperature Sweep Key and Status Signals Reset button and On/Off Signal 1. The User Interaction Controller has 2 illuminating push buttons which provide information about the operating condition of the boiler. -
Page 22: Before Installation
Before Installation Before installation installation Regulations WaRning Installation, repair and maintenance must only be carried out by a competent person. This document is intended for use by competent persons. Installation must be carried out in accordance with the prevailing regulations, the codes of practice and the recommendations in these instructions. -
Page 23: Hard Water Areas
(Test kits are available from inhibitor stockists.) 8. For information or advice regarding any of the above contact Baxi Customer Support 0344 871 1545. 7726858-01 (1/19) 600 Heat... -
Page 24: System Details - General
Before Installation 5.2.7 System Details - general Water Circulating Systems 1. The appliance is suitable for use with open vent fully pumped systems and sealed systems . The following conditions should be observed on all systems: • The static head must not exceed 25m of water. •... -
Page 25: Sealed Systems Details
Before Installation 5.2.9 Sealed Systems Details 3 Litre Top Up Bottle (if required) 1. SaFETY VaLVE - A safety valve complying with the Vent requirements of BS EN ISO 4126-1 must be fitted close to the Filling boiler on the flow pipe by means of a horizontal or vertically Pressure Point upward connection with no intervening valve or restrictions and... -
Page 26: Choice Of The Location
Before Installation Choice of the Location 5.3.1 Location of the appliance Due to the high efficiency 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. -
Page 27: Condensate Drain
Before Installation 5.3.5 Condensate Drain Examples are shown of the following methods of termination:- i) to an internal soil & vent pipe FAILURE TO INSTALL THE CONDENSATE ii) via an internal discharge branch (e.g. sink waste) DISCHARGE PIPEWORK CORRECTLY WILL AFFECT downstream of the trap THE RELIABLE OPERATION OF THE BOILER. - Page 28 Before Installation 9. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run iii) Termination to a drain Boiler and sized and insulated accordingly. or gully 10. In all cases discharge pipe must be installed to aid disposal of the condensate.
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Page 29: Clearances - Access In Service
Before Installation 370mm 5mm Min 5mm Min 190mm At least 1.5° 500mm Min 625mm For Servicing Purposes 35mm Min* in Cupboard 270mm 5mm Min Fig. 9 In Operation 120mm Min* 5mm Min 370mm 5mm Min 35mm Min* in cupboard (cut-outs required for pipework) 85mm Min* below... -
Page 30: Flue/Chimney Location
Before Installation 5.3.7 Flue/Chimney Location 1. The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendations are given in BS 5440 Pt 1. For IE recommendations are given in the current edition of I.S. 813 “Domestic Gas Installations”. Under car ports we recommend the use of the plume displacement kit. - Page 31 Before Installation 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. 2. If the terminal discharges onto a pathway or passageway, check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway.
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Page 32: Horizontal Flue/Chimney Systems
Before Installation 5.3.8 Horizontal Flue/Chimney Systems 1. The standard telescopic flue is suitable only for horizontal termination applications. It allows for lengths between 315mm and 500mm from elbow to terminal without the need for cutting (ii) (Fig. 14). Extensions of 250mm, 500mm & 1m are available. 2. -
Page 33: Flue/Chimney Trim
Before Installation Ensure that no part of the 5.3.9 Flue/Chimney Trim white outer chimney duct is visible 1. The flexible flue trims supplied can be fitted on the outer and inner faces of the wall of installation (Fig. 14). Terminal 5.3.10 Terminal guard Guard... -
Page 34: Unpacking & Initial Preparation
Before Installation Unpacking & initial Preparation 5.4.1 Unpacking 1. Follow the procedure on the carton to unpack the boiler (Fig. 18). See Section 2.3.1 Handling before lifting the boiler. 5.4.2 initial Preparation 1. After considering the site requirements, position the fixing template on the wall ensuring it is level both horizontally and vertically (Fig. -
Page 35: Making The Water Connection
5.4.3 Making the Water Connections (Fig. 22) 1. There are two water connections at the top of the boiler. The left connection is the return pipe (indicated with blue label) and the flow the right hand one (indicated with red label). Remove the sealing caps from the boiler connections. -
Page 36: Installation
Installation installation air Supply / Flue gas Connections 6.1.1 Connecting the Top Flue HORIZONTAL TELESCOPIC FLUE 1. There are two telescopic sections, the Terminal Assembly and the Connection Assembly, a roll of sealing tape and two self tapping screws. A 93° elbow is also supplied. Terminal Assembly 2. - Page 37 Installation 10. Remove the boiler blank adaptor and replace with the boiler Boiler Blank Boiler Adaptor adaptor ensuring that the gasket is in position. Replace the Adaptor gasket if necessary (Fig. 28). Gasket Gasket 11. Insert the flue through the hole in the wall. Fit the elbow to the boiler adaptor, ensuring that it is pushed fully in (Fig.
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Page 38: Connecting The 'In Case' Rear Flue
Installation Upper Slots 6.1.2 Connecting the ‘in Case’ Rear Flue Part No. 7212282-01 116mm Dia Minimum Internal Fitting Kit part no. 7215374 is available for the Aperture For Flue Tube Heating Heating Position of Elbow Rear Flue Return Flow (22mm) (22mm) ‘In Case’... - Page 39 Installation Rear Flue Blanking Plate 9. Undo the screws securing the rear flue blanking plate. Firmly grip the central spigot and pull the plate off the boiler. Ensure that the flue connection seals remain in place (Fig. 37). 10. Lift the boiler and locate the slots in the wall bracket over the horizontal tongues on the wall bracket.
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Page 40: Electrical Connections
Installation Electrical Connections 6.2.1 Electrical Connections of the appliance 1. See Section 5.2.2. for details of the electrical supply. 1 metre of 3 core cable is supplied connected to the boiler. 2. Switched live must be connected to the brown (live) wire of the 3 core cable. -
Page 41: Filling The System
Installation Filling the System See Section 5.2.6. for details of treating the system, Section 5.2.7. for open vent system details, Section 5.2.9. for sealed system details and Section 5.4.4. for filling the condensate trap. Completing the installation 6.4.1 Completion 1. Before turning on the electrical and gas supply to commission the boiler, check that all the installation requirements for the chosen heating system and flue options have been satisfied. -
Page 42: Commissioning General
Commissioning Commissioning general 1. Reference should be made to BS:EN 12828 & 14336 when commissioning the boiler. 2. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publications. 3. Turn the gas supply on and purge according to in GB BS 6891 and in IE I.S. -
Page 43: Gas Settings
Commissioning gas Settings 7.4.1 ‘Chimney Sweep’ Mode (CSM) Flue Sampling Point 1. The current operating condition of the boiler is shown by the Plug button on the User Interaction Controller. The button can flash in a range of colours and at different frequencies. -
Page 44: Chimney Sweep' Mode - Combustion Check
Commissioning 7.4.2 ‘Chimney Sweep’ Mode - Combustion Check Set Boiler to Maximum Rate 1. Follow the flow chart opposite. Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser. Perform Flue integrity Combustion Check Insert the analyser probe into the air inlet test point, allowing Verify Flue integrity the reading to stabilise. -
Page 45: Configuring The System
Commissioning Configuring the System 7.5.1 Check the Operational (Working) gas inlet Pressure 1. Ensure that all controls are calling for heat and maximum load is applied to the system. 2. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point is in accordance with B.S. -
Page 46: Final Instructions
Commissioning Final instructions 1. 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. 2. -
Page 47: Operation
Operation/Settings Operation general 1. It is the responsibility of the installer to instruct the user in the day to day operation of the boiler and controls and to hand over the completed Benchmark Checklist at the back of this manual. 2. -
Page 48: Maintenance
Maintenance Maintenance 10.1 general 1. For reasons of safety and economy, it is recommended that WaRning the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4. When changing components ensure that both the 2. -
Page 49: Standard Inspection & Maintenance Operation
Maintenance 10.2 Standard inspection and Maintenance Operation WaRning Ensure that the boiler is cool. Ensure that both the gas and electrical supplies to the boiler are isolated. Electrical isolation can be checked at the electrical test point. CaUTiOn Always examine any seals or gaskets, replacing Fig. - Page 50 Maintenance 10.2 Standard inspection and Maintenance Operation (cont.) Over Centre Catches An ESD wrist strap should be used when working on these components. A T25 screwdriver will be required. 5. Remove the air duct by pulling the bottom of the duct forward to disengage it from the gas valve and then sliding the top of the duct left away from the fan (see 10.3.4).
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Page 51: 10.3 Specific Maintenance Operation
Maintenance 10.3 Specific Maintenance Operation Spark Ignition Earth Gasket WaRning Electrode Wire When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. Electrical isolation can be checked at the electrical test point. -
Page 52: Condensate Trap
Maintenance 10.3.3 Condensate Trap (Fig. 48) 1. Disengage the condensate trap securing clip by pulling forwards and hinging upwards. 2. Disconnect the 90° rubber hose from the trap and dismantle the condensate drain pipework as necessary. Carefully pull out 90° rubber hose the trap and discard. -
Page 53: Overheat Sensor
Maintenance 10.3.6 Flow Temperature Sensor (Fig. 51) Flow Fig. 51 Temperature Sensor The sensor is fitted in a ‘dry’ pocket. 1. Disconnect the wiring from the flow temperature sensor. 2. Unscrew the sensor from the top of the heat exchanger. 3. -
Page 54: Combustion Control Unit
4 full turns clockwise. If the boiler Electrical will not light, or the correct CO 2 cannot be achieved Plug contact the ‘Baxi Customer Support’ technical helpline. Fig. 56 See Section 10.3.11 for CO 2 check. Fig. 57... -
Page 55: Setting The Gas Valve (Co Check)
Fig. 58 the boiler will not light, or the correct CO 2 cannot be achieved contact Baxi Customer Support. 1. The maximum rate CO 2 setting can only be reached via the minimum rate. Press the Chimney Sweep (Fig. 59) button for approximately 3 seconds. -
Page 56: Troubleshooting
Troubleshooting Troubleshooting 11.1 Error Codes Operation status and error codes are displayed on the “chimney sweep” button (3) on the control panel. In normal operation this button is illuminated and goes off for a time once periodically. When normal operation is interrupted for some reason this button will turn off and flash on a number of times periodically. -
Page 57: Lockout Condition
Troubleshooting Lock-out conditions (Red flashes on “chimney sweep”) The following table describes the conditions that may result in a lock-out condition and red flashing signal being displayed. To reset a lock-out condition press and hold the reset button until the fault indication flashes rapidly and goes out. nOTE: a lock-out condition can be re-set up to 5 times within one hour using the reset button. -
Page 58: 12.1 Decommissioning Procedure
Decommissioning Decommissioning 12.1 Decommissioning Procedure 1. Isolate the gas & electric supplies and disconnect them. 2. Drain the primary circuit and disconnect the filling device. 3. Dismantle the chimney system and remove the boiler from the wall mounting frame. 600 Heat 7726858-01 (1/19) -
Page 59: Spare Parts
Spare Parts Spare Parts 13.1 general 1. If, following the annual inspection or maintenance any part of the boiler is found to need replacing, use Baxi Genuine Parts only. 13.2 Spare Parts List Description Manufacturer’s Part No. Sensor Kit 7216301... -
Page 60: Benchmark Commissioning Checklist
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 according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. - Page 61 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 instructions. SERVICE 01 SERVICE 02 Date:...
- Page 62 notes 600 Heat 7726858-01 (1/19)
- Page 63 notes 7726858-01 (1/19) 600 Heat...
- Page 64 For the warranty to be maintained, please make sure... Benchmark checklist is completed Warranty is registered within 30 days The boiler has an annual service For full terms and conditions, visit www.baxi.co.uk/terms. Failure to adhere to terms and conditions will void your manufacturer’s warranty. Baxi Brooks House,...