Related Manuals for Baxi System 35/60
Summary of Contents for Baxi System 35/60
- Page 1 Please leave these instructions with the user Baxi System 35/60 & 60/100 Gas Fired Wall Mounted System Boilers Installation and Servicing Instructions...
- Page 2 Notified Body 0051. mean continued success. Product/Production certified by: Notified Body 0051. We hope you get a satisfactory service from Baxi. If not, please let us know. For GB/IE only. Baxi is a BS-EN ISO 9001 Accredited Company...
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Page 3: Table Of Contents
Contents Section Page Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Installation Commissioning the Boiler 10.0 Completion 11.0 Servicing the Boiler 12.0 Changing Components 13.0 Illustrated Wiring Diagram 14.0 Fault Finding 15.0 Short Parts List... -
Page 4: Introduction
STANDARD CODES OF PRACTICE. “Benchmark” Log Book Optional Extras As part of the industry-wide “Benchmark” initiative all Baxi boilers now include an Installation, Commissioning and Service Record Log Book. Various flue extensions, bends, vertical flue Please read the Log Book carefully and complete all sections relevant to kits,control accessories etc. -
Page 5: General Layout
2.0 General Layout Layout Air Pressure Switch Expansion Vessel Burner Manifold Automatic Air Vent Circulation Pump Drain Off Point Pressure Relief Valve DHW Relay PCB System Pressure Gauge Control Box Spark Generator Flame Sensing Electrode Spark Electrode Burner Primary Heat Exchanger Fan Assembly On/Off/Reset Selector Switch Central Heating Temperature Control... -
Page 6: Appliance Operation
3.0 Appliance Operation Boiler Primary Circuit Operating Mode (Fig. 2) 1. With a demand for heating, the pump circulates water through the primary circuit. At a pre- determined flow rate the hydraulic differential pressure switch operates, initiating the ignition sequence. 2. -
Page 7: Technical Data
4.0 Technical Data System 35/60 Appliance Type Pump - Grundfos UP 15-50 NO x Class Available Head See graph below Appliance Category CAT II Flue Terminal Diameter 100mm 2H 3+ Expansion Vessel - (Integral with appliance) Dimensions Projection 95mm Heat Input (Gross) - Page 8 4.0 Technical Data System 60/100 Appliance Type Pump - Grundfos UP 15-60 NO x Class Available Head See graph below Appliance Category CAT II Flue Terminal Diameter 100mm 2H 3P Expansion Vessel - (For Central Heating Dimensions Projection 95mm Heat Input (Gross) only.
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Page 9: Dimensions And Fixings
5.0 Dimensions and Fixings Dimensions A 780mm B 345mm C 450mm D 107mm Ø Min. E 200mm F 190mm G 143mm 360° Orientation Tube Ø 100mm Tap Rail 130 mm 130 mm 65 mm Heating Heating Pressure Relief Return Valve Flow Inlet (22mm) -
Page 10: System Details
1. The boiler is designed for use in a heating system that incorporates external controls, i.e. a minimum of a timer device. 2. For optimum operating conditions and maximum economy the fitting of a programmable room thermostat, such the Baxi Combi Controller, is recommended. - Page 11 6.0 System Details System Filling and Pressurising 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. Double Stop Check Stop 2. The filling method adopted must be in Valve Valve Valve...
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Page 12: Site Requirements
WARNING - The addition of anything that may 200mm Min interfere with the normal operation of the appliance without the express written permission of Baxi UK Limited could invalidate the appliance warranty and infringe the G (Installation Fig. 5 AFETY... - Page 13 7.0 Site Requirements Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.
- Page 14 7.0 Site Requirements Flue 1. The flue terminal position must be in accordance with the current editions of B.S. 5440 Part 1, and either Part J of the Building Regulations England and Wales or Part F of the Building Standards (Scotland) Regulations as appropriate.
- Page 15 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 1m from elbow to terminal (Fig. 10). The maximum permissible equivalent flue length is: System 35/60 5 metres System 60/100 4 metres Fig. 10 7.10 Flue Terminal Trim 1.
- Page 16 7.0 Site Requirements 7.12 Flue Options 1. The Baxi System 35/60 and 60/100 can be fitted with flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. Maximum Length = 3m (60/100) 4m (35/60) 3. Maximum permissible equivalent flue lengths inc.
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Page 17: Installation
NOTE: A small amount of water may drain from the boiler in the upright position. Central Heating Return Baxi UK Limited declare that no substances harmful to health are contained in the Fig. 15 appliance or used during appliance... - Page 18 Wall Plate 8.0 Installation Fitting The Boiler 1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate (Fig. 16). 3.
- Page 19 8.0 Installation Wall Thickness Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths 100mm minimum to 1m maximum (measured from the edge of the flue elbow outlet). Rear Flue: maximum wall thickness - 900mm Side Flue: maximum wall thickness - 870mm 2.
- Page 20 8.0 Installation Elbow Fitting the Flue (Cont) IMPORTANT: If the equivalent flue length is Seal greater than 1.5m the restrictor MUST be Restrictor removed from the adaptor (Fig. 20). Adaptor 8. Take one of the rubber seals and position it on Fig.
- Page 21 8.0 Installation Making The Electrical Connections To connect the mains input cable proceed as follows:- 1. Slacken the facia securing screws and lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel. Control Box Cover 2.
- Page 22 HW Off Thermostat not operate and the cylinder thermostat must be Terminal Block Timer relied upon to limit the temperature of DHW. Baxi System - blue Boiler w - white 11. The selector switch must be in the central - orange...
- Page 23 Frost Timer in the same manner as the basic system. Thermostat Scheme 3 Scheme 2 Baxi System - blue Boiler w - white 17. Scheme 3 shows the use of a 3 port two - orange position zone valve and is based on a ‘W’ plan br - brown system.
- Page 24 8. Relay Board - blue v) Disconnect the white zone valve wire from 5 w - white Baxi System - orange on the terminal strip and connect to 8. Boiler gr - grey g/y - green/yellow...
- Page 25 8.0 Installation 8.10 Domestic Hot Water Wiring The boiler can be wired to operate when there is a demand for replenishment of an indirect domestic hot water storage cylinder. 1. If not already done, slacken the facia securing screws sufficiently to release the outercase panel securing tabs.
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Page 26: Commissioning The Boiler
Commissioning the Boiler Commissioning the Boiler Screw 1. Reference should be made to BS 5449 when commissioning the boiler. 2. Ensure that the filling loop is connected and Automatic open, then open the heating flow and return Air Vent valves on the boiler. 3. - Page 27 Commissioning the Boiler Pressure Test Point Sealing Screw Checking the Burner Pressure 1. Turn on the gas and electrical supplies to the boiler and ensure that all external controls are Gas Valve calling for heat. 2. Set the temperature control to maximum and the selector switch to the Off position (Fig.
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Page 28: Completion
10.0 Completion 10.1 Completion Case Front Panel 1. Hinge the facia panel upwards and refit the case front panel. Secure them with the screws previously removed (Fig. 37). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3. -
Page 29: Servicing The Boiler
11.0 Servicing the Boiler Case Front Panel 11 .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. 2. After servicing, complete the relevant section of the “Benchmark”... - Page 30 Baffle 11.0 Servicing the Boiler Spring Clip 11.1 Annual Servicing (Cont) 11. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood (Fig. 41). 12. Undo the screws securing the fan and hood to the appliance back panel.
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Page 31: Changing Components
12.0 Changing Components IMPORTANT: When changing components Pressure ensure that both the gas and electrical Switch supplies to the boiler are isolated before any work is started. When the new component has been fitted turn the selector switch fully anticlockwise against the spring pressure to Sensing position R and hold for 2 seconds to reset the Tubes... - Page 32 12.0 Changing Components 12.3 Heat Exchanger (Fig. 47) Heat Exchanger 1. Note the positions of the two sensing tubes on (35/60 model) the outlet elbow and three wires on the fan motor and remove them. 2. Slacken the screws on the outlet sealing collar. Ease the collar upwards as far as possible.
- Page 33 12.0 Changing Components Injector Inlet Elbow Manifold 12.5 Injectors (Fig. 49) 1. Remove the burner as described in Section 12.4. 2. Undo the screws securing the injector Gasket manifold to the inlet elbow and remove the manifold. 3. Unscrew and replace injectors as required Injector and examine the sealing gasket, replacing as necessary.
- Page 34 12.0 Changing Components 12.8 Gas Valve (Fig. 51) 1. Undo the nut on the gas feed pipe under the Gas Valve boiler. Modulator Wires 2. Remove the securing screws and hinge the facia panel down. 3. Disconnect the earth wire and pressure sensing pipe from the valve.
- Page 35 3. A standard Grundfos replacement head can now be fitted. A Grundfos 15-50 head is suitable for the System 35/60. The System 60/100 requires a 15-60 head. Connect the wiring to the new head. The pump speed must be set to 3 (Fig.
- Page 36 12.0 Changing Components Pressure Gauge Capillary 12.15 Pressure Gauge (Figs. 57 & 58) 1. Drain the primary circuit and undo the nut on the pressure gauge capillary. 2. Remove the timer cover and ease the timer wiring aside. Undo the screws securing the gauge retaining bracket.
- Page 37 12.0 Changing Components 12.18 DHW Relay PCB (Fig. 62) 1. Undo the screws securing the DHW relay PCB cover. Remove the cover. 2. Remove the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear of the cover from the control box hinge pin.
- Page 38 12.0 Changing Components 12.21 Central Heating Differential Valve (Figs. 63 & 64) 1. Drain the primary circuit. 2. Undo the screw securing the microswitch to the differential valve. Allow the microswitch to rest to one side. 3. Undo the pressure gauge capillary nut and heating flow pipe nut from the valve.
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Page 39: Illustrated Wiring Diagram
13.0 Illustrated Wiring Diagram Cylinder Stat Input N S/L Pump Air Pressure Switch Relay Board Hydraulic Differential Pressure Switch Control PCB Return Heating Temperature Sensor Flame Sensing Central Heating Electrode NTC Sensor Mains Input - brown Link - black - blue - red - green - green / yellow... -
Page 40: Fault Finding
14.0 Fault Finding Carry out initial fault finding checks 1. Check that gas, water and electrical supplies are available at the boiler. Electrical supply = 230V ~ 50 Hz. CH water system pressurised to 0.5 bar when the boiler is cold. The preferred minimum gas pressure is 19.5mbar (natural gas), 27mbar (butane) or 36mbar (propane). - Page 41 14.0 Fault Finding Fault Finding Solutions Sections A to E Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse neon Replace PCB illuminated Selector terminals a & b Check wiring and a & 3. PCB - A4 Replace selector connector terminals 4 &...
- Page 42 14.0 Fault Finding Check the burner setting pressure of the gas valve (see Section 9.2 of Commissioning) Voltage at modulating coil of gas valve is: Max. burner press.approx 9V DC (13V DC LPG) Replace gas valve Min. burner press.approx 1V DC Current at modulating coil of gas valve is: (Use an instrument with average function for this measure)
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Page 43: Short Parts List
15.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. E66 383 Fan 35/60 248001 E66 527 Fan 60/100 248002 393 374 Pressure Switch 247380 E66 393 Heat Exchanger 35/60 248016 E66 535 Heat Exchanger 60/100 248017 E66 398 Burner 35/60 248029 E66 399... - Page 44 Comp N 248544 - Iss 5 - 7/02 After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www.baxi.com 922.553.1...