Baxi Megaflo System HE A Range Installation & Servicing Instructions Manual
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Baxi Megaflo System HE A Range Installation & Servicing Instructions Manual

Baxi Megaflo System HE A Range Installation & Servicing Instructions Manual

Megaflo system he a series gas fired wall mounted condensing boiler
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Installation & Servicing Instructions
Megaflo System HE
Range
A
Gas Fired Wall Mounted Condensing Boiler
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2013

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Summary of Contents for Baxi Megaflo System HE A Range

  • Page 1 Installation & Servicing Instructions Megaflo System HE Range Gas Fired Wall Mounted Condensing Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2013...

  • Page 2: Natural Gas

    Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure. © Baxi Heating UK Ltd 2013 All rights reserved. No part of this publication may The flowchart opposite gives guidance for installers on the...

  • Page 3: Installer Notification Guidelines

    Benchmark Checklist ‘Gas Safe Register’ will issue a LABC will record the data Building Regulations Compliance and will issue a Certificate to the property owner certificate of compliance and inform the relevant LABC © Baxi Heating UK Ltd 2013...
  • Page 4 BS EN 14336 Installation & commissioning of water based heating systems. BS 7074 Expansion vessels and ancillary equipment for sealed water systems. BS 7593 Treatment of water in domestic hot water central heating systems. © Baxi Heating UK Ltd 2013...
  • Page 5 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 !! © Baxi Heating UK Ltd 2013...

  • Page 6: Table Of Contents

    System Details Site Requirements Flue Options Plume Displacement 10.0 Installation 11.0 Commissioning 12.0 Completion 13.0 Servicing 14.0 Changing Components 15.0 Setting the Gas Valve 16.0 Electrical 17.0 Short Parts List 18.0 Fault Finding Benchmark Checklist © Baxi Heating UK Ltd 2013...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Baxi Megaflo System HE is a fully automatic gas fired wall mounted condensing system boiler. It is room sealed and fan assisted. Case Front Panel 2. The boiler is set to give a maximum output of :- 15 models - 15 kW 16.2 kW (Condensing)

  • Page 8: General Layout

    Flame Sensing Electrode Spark Electrode Primary Heat Exchanger Fan Assembly On/Off/Reset Selector Switch Central Heating Temperature Control Calibration Control Venturi Air/Gas Collector Combustion Box Cover & Burner Igniter Burner On Light Central Heating Mode Light Display © Baxi Heating UK Ltd 2013...

  • Page 9: Appliance Operation

    Gas Valve Pump Automatic Air Vent Pressure Relief Valve Boiler Drain Point Gas Inlet Boiler Flow Boiler Return Pressure Gauge Automatic By-Pass Water Pressure Sensor Safety Thermostat Temperature Sensor Expansion Vessel Return Temperature Sensor © Baxi Heating UK Ltd 2013...

  • Page 10: Technical Data

    This value is used in the UK Government’s Standard Assessment Procedure (SAP 2005) for energy rating of dwellings. The test data from which it has been calculated have been certified by 0087. 1000 1200 © Baxi Heating UK Ltd 2013 Flow Rate (l/h)

  • Page 11: Dimensions And Fixings

    F 145mm G 131mm H 180mm 360° Orientation Tube Ø 100mm Tap Rail 32.5 mm Condensate Drain 130 mm 130 mm 65 mm Heating Heating Pressure Relief Return Flow Inlet Valve (22mm) (22mm) (22mm) (15mm) © Baxi Heating UK Ltd 2013...

  • Page 12: System Details

    3. The boiler should be controlled so that it operates on demand only. 4. Operation of the system under control of the boiler thermostat & TRV’s only does not produce the best results. © Baxi Heating UK Ltd 2013...
  • Page 13 4. A remote relief valve kit is available to enable the boiler to be installed in cellars or similar locations below outside ground level (kit no. 5121379). © Baxi Heating UK Ltd 2013...

  • Page 14: Site Requirements

    *This is the MINIMUM recommended dimension. Greater clearance will aid installation and maintenance. 450mm Min For Servicing Purposes 5mm Min In Operation Fig. 6 © Baxi Heating UK Ltd 2013...
  • Page 15 In GB this is the current I.E.E. Wiring Regulations and Building Regulations. Fig. B In IE reference should be made to the current edition of I.S. In GB Only 813 “Domestic Gas Installations” and the current ETCI rules. © Baxi Heating UK Ltd 2013...
  • Page 16 *It is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle ! © Baxi Heating UK Ltd 2013...
  • Page 17 45° iv) Termination to a purpose made soakaway Further specific requirements for soakaway Boiler design are referred to in BS 6798. 500mm min Holes in the soak-away must face away from the building © Baxi Heating UK Ltd 2013...
  • Page 18 Boiler External runs & those in unheated locations still require insulation. Condensate Pump Pipe must terminate above water level but below surrounding surface. Cut end at 45° © Baxi Heating UK Ltd 2013...
  • Page 19 (see Top View Rear Flue Section 9.0). Fig. 8 Property Boundary Line Air Inlet Opening Window or Door 150mm Fig. 10 MIN. Likely flue positions requiring Fig. 9 a flue terminal guard © Baxi Heating UK Ltd 2013...

  • Page 20: Flue Options

    NOTE: Horizontal flue pipes should always be installed with a fall of at least 1.5° from the terminal to allow condensate to run back to the boiler. This bend is equivalent to 1 metre (ii) This bend is equivalent to 1 metre Total equivalent length = A+B+C+2x90°Bends © Baxi Heating UK Ltd 2013...
  • Page 21 Equivalent Length Air Duct = 6.5m This bend is equivalent to 1 metre FLUE DUCT Equivalent Sub total Length Value fittings/pipes 1m extension 5.0m 135°bend 0.25m 0.5m 91.5°bend 0.5m 1.0m Equivalent Length Flue Duct = 6.5m © Baxi Heating UK Ltd 2013...
  • Page 22 91.5° 5118588 FLUE GROUP A, N, G Vertical Flue Kits Vertical Flue Terminal 5111078 (use with 5111070) Vertical Flue Terminal 5118576 Pitch Roof Flashing 25°/50° 5122151 Roof Cover Plate 246143 Flat Roof Flashing 246144 © Baxi Heating UK Ltd 2013...
  • Page 23 (at least once every metre using the available pipe supports). Boiler Adaptor 3. Ensure that all joints and elbows are fully engaged and cannot become disconnected during operation. © Baxi Heating UK Ltd 2013...
  • Page 24 8.10 Flue Deflector Fig. 12 1. If required, push the flue deflector over the teminal end and rotate to the optimum angle for deflecting plume. Secure the deflector to the terminal with screws provided. © Baxi Heating UK Ltd 2013...

  • Page 25: Plume Displacement

    Installation & Servicing Instructions and BS5440 Pt. 1. It is NOT necessary to fit a terminal guard over the air inlet or the plume outlet. © Baxi Heating UK Ltd 2013...
  • Page 26 After consulting the table in Example 3 it can be determined Additional Accessories that the concentric flue could be up to approximately 2.3 93° Elbow 5121369 metres long. 45° Elbow (Pair) 5121370 Fig. 18 1 metre 60Ø Extension 5121368 © Baxi Heating UK Ltd 2013...
  • Page 27 14. Fit the 93° elbow/plume outlet and secure with the two remaining screws supplied. Ensure the plume outlet is at least 45° to the wall and that the ‘peak’ is uppermost (Fig. 24). Fig. 24 © Baxi Heating UK Ltd 2013...
  • Page 28 25. All other minimum & maximum dimensions must be adhered to, and the air inlet positioned such that it will not be subject to rain entry. Fig. 28 70° Concentric Flue Length (shown end-on) Outlet Spigot Fig. 29 © Baxi Heating UK Ltd 2013...

  • Page 29: Installation

    Flushing Tube Wall Plate 10.2 Flushing 1. Connect a tube to the central heating flow or return pipe (Fig. 33). 2. Flush thoroughly (see System Details, Section 6.2). Fig. 33 Central Heating Return © Baxi Heating UK Ltd 2010...
  • Page 30 Condensing Boilers”. 2. The connection will accept 21.5mm ( in) plastic overflow pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable. © Baxi Heating UK Ltd 2010...
  • Page 31 Terminal Assembly by careful cutting to accommodate engaged into Boiler Adaptor walls of these thicknesses. Adaptor 7. To dimension ‘X’ add 50mm. This dimension to be known as ‘Y’. Fig. 38 Wall Thickness Fig. 37 © Baxi Heating UK Ltd 2013...
  • Page 32 Extension Adaptor Tape Cut End Fig. 43 Apply Lubricant for ease of assembly. Ensure Extension is fully engaged into Boiler Adaptor © Baxi Heating UK Ltd 2013 Fig. 44...
  • Page 33 1. Prior to commissioning the boiler preliminary electrical system checks should be carried out. 2. These should be performed using a suitable meter, and include checks for Earth Continuity, Fig. 47 Resistance to Earth, Short Circuit and Polarity. © Baxi Heating UK Ltd 2013...

  • Page 34: Commissioning

    • The integrity of the flue system and the flue seals. • The integrity of the boiler combustion circuit and the relevant seals. Proceed to put the boiler into operation as follows: © Baxi Heating UK Ltd 2013...
  • Page 35 12. 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. Fig. 57 Fig. 56 © Baxi Heating UK Ltd 2013...

  • Page 36: Completion

    I.S. 813 “Domestic Gas Installations”. This is in addition to the Benchmark Commissioning Checklist. 5. Hand over the Users Operating, Installation and Servicing Instructions giving advice on the necessity of regular servicing. Facia Panel Fig. 58 © Baxi Heating UK Ltd 2013...

  • Page 37: Servicing

    (Fig. 60). 5. Unscrew the sump from the bottom of the condensate trap Sump assembly (Fig. 61) and remove any deposits from the sump and trap. Clean as necessary and replace the sump. Fig. 61 © Baxi Heating UK Ltd 2013...
  • Page 38 13. Complete the relevant Service Interval Record section of Fig. 62 the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user. Venturi Injector Gas Inlet Pipe Fig. 63 © Baxi Heating UK Ltd 2013...

  • Page 39: Changing Components

    3. Check the condition of the sealing gaskets and replace if necessary. Reassemble in reverse order. Spark Electrode ElectrodeL eads Sensing Electrode Fig. 65 © Baxi Heating UK Ltd 2013...
  • Page 40 1. Remove the collector and fan assembly as described in Collector section 14.3. Fig. 66 2. Extract and replace the injector and reassemble in reverse order. Fig. 68 When fitting the venturi ensure that the arrow is pointing forward © Baxi Heating UK Ltd 2013...
  • Page 41 Keep the insulation vertical and Heat press firmly into position. Exchanger 7. Examine the cover seal and replace if necessary. Rear Insulation Spark Electrode Venturi Cover Insulation Seal Fig. 70 Collector Electrode Sensing Leads Electrode © Baxi Heating UK Ltd 2013...
  • Page 42 2. Prise the sensor retaining clip off the pipe and remove the sensor from the clip. 3. Reassemble in reverse order. Return Heating Temperature Sensor Pressure Sensor Fig. 73 Fig. 74 © Baxi Heating UK Ltd 2013...
  • Page 43 Pump Setting Fig. 76 2. Examine the ‘O’ ring seal, replacing if necessary, and fit it Automatic Air to the new automatic air vent. Vent 3. Reassemble in reverse order. Pump Wiring Cover Fig. 77 © Baxi Heating UK Ltd 2013...
  • Page 44 Selector Switch Knob 4. Remove the screws securing the switch to the facia panel. Temperature Control Knobs 5. Fit the new switch, ensuring that it is correctly positioned and Fig. 82 reassemble in reverse order. © Baxi Heating UK Ltd 2013...
  • Page 45 3. Remove the bracket and vessel from the boiler. Retaining Bracket 4. Locate the retaining bracket on the upper flange of the vessel and fit to the boiler. Expansion Vessel 5. Reassemble in reverse order. Boiler Chassis Lock Nut Fig. 85 © Baxi Heating UK Ltd 2013...

  • Page 46: Setting The Gas Valve

    Allow the analyser reading maximum rate it must be to settle before any further 12. Check the Combustion Performance (CO/CO ratio). rechecked at minimum rate and adjustment This must be less than 0.004. adjusted if required. © Baxi Heating UK Ltd 2013...

  • Page 47: Electrical

    8 7 6 5 4 3 2 1 Control PCB X501 Flame Pump Sensing Electrode Spark Generator Gas Valve Link Ignition Electrode Mains Input Cable - green - brown - green / yellow - black - red - blue - white © Baxi Heating UK Ltd 2013...

  • Page 48: Short Parts List

    Water Pressure Switch 5114748 Overheat Thermostat 5114729 NTC Sensor 5114725 Gas Valve 720301001 NTC Sensor (Return) 5114725 PCB 15 5122457 PCB 18 5122458 PCB 24 720045201 PCB 28 720795401 PCB 32 5122459 Pressure Gauge 248090 © Baxi Heating UK Ltd 2013...

  • Page 49: Fault Finding

    5 seconds when E110, E130 & E133 are displayed it is possible to relight the boiler. 4. If this does not have any effect, or the codes are displayed regularly further investigation is required. © Baxi Heating UK Ltd 2013...
  • Page 50 Burner output modulates to Error 130 flashing maintain the temperature set Go to section ‘K’ Pump continues to run for 3 Operation sequence Burner goes out Fan stops after 10 seconds minutes successful (room thermostat open) © Baxi Heating UK Ltd 2013...
  • Page 51 Open the automatic air vent vent is opened Fan connections correct at fan. PCB - X2 connector, is 230V AC across Fan jammed or faulty winding Replace fan terminals 5 & 7 Replace PCB © Baxi Heating UK Ltd 2013...
  • Page 52 1. Ignition electrode and lead (Note: from multimeter connect 2. Electrode connection ‘common’ to 2 & ‘volt’ to 5) Replace igniter 3. Spark gap and position Check wiring Burner Viewing Window Sensing Spark Ignition Electrode Electrode Electrode Position © Baxi Heating UK Ltd 2013...
  • Page 53 Cold resistance approximately @ 25° C (CH sensor) Replace sensor @ 25° C (Flue sensor) (resistance reduces with increase in temp.) Replace heat exchanger If pump is running the heat exchanger could be obstructed © Baxi Heating UK Ltd 2013...

  • Page 54: Benchmark 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 55: Service Record

    Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
  • Page 56 A T r a d i n g D i v i s i o n o f B a x i H e a t i n g U K L t d ( 3 8 7 9 1 5 6 ) 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 UK Comp N 5122328 - Iss 10 - 1/13 © Baxi Heating UK Ltd 2013...

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