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Baxi Ecogen 24/1.0 Installation & Servicing Instructions Manual

Gas fired wall mounted condensing boiler and power generator
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See also: Installation & Servicing Instructions Manual
Installation & Servicing Instructions
Ecogen 24/1.0
Gas Fired Wall Mounted Condensing Boiler
and Power Generator
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2012

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Summary of Contents for Baxi Ecogen 24/1.0

  • Page 1 Installation & Servicing Instructions Ecogen 24/1.0 Gas Fired Wall Mounted Condensing Boiler and Power Generator These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2012...
  • Page 2 UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency. © Baxi Heating UK Ltd 2012 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any...
  • Page 3 Benchmark Checklist grid. ‘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 2012...
  • Page 4 BS 7593 Treatment of water in domestic hot water central heating systems. BS 7671 Requirements for electrical installations BS 50438 Requirement for the connection of micro- generators in parallel with public low-voltage distribution networks. © Baxi Heating UK Ltd 2012...
  • Page 5 NOTE: The appliance must be transported at all times in the upright position. The appliance must not be laid on its back / side / front. IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !! © Baxi Heating UK Ltd 2012...

  • Page 6: Table Of Contents

    10.0 Electrical 11.0 Commissioning 12.0 Completion 13.0 Servicing 14.0 Changing Components 15.0 Combustion Check 16.0 Schematic Wiring 17.0 Fault Finding 18.0 Engine Fault Finding 19.0 Short Parts List 20.0 Pages for Notes Benchmark Checklist © Baxi Heating UK Ltd 2012...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Baxi Ecogen 24/1.0 is a fully automatic gas fired wall mounted condensing heat only boiler which will produce up to 1kW of electricity for use by the householder. Any electricity excess to requirements at the time of production will be fed back into the national grid.

  • Page 8: General Layout

    Engine Head Thermocouples Service Reset Button Overcurrent Switch Start/Stop Resistors THINK Controller Drain Ignition Coils Ambient Sensor Fig. 2 Wall Plate EMC Mains Filter View from Underneath Bottom cover removed for Clarity Fig. 2a © Baxi Heating UK Ltd 2012...

  • Page 9: Appliance Operation

    Customers Overtravel Switches Boiler Return should be informed that the temperature reached may be considerably higher than their normal requirements (See Section 11.3 paragraph j). © Baxi Heating UK Ltd 2012...

  • Page 10: Technical Data

    4.0 Technical Data Ecogen 24/1.0 and Ecogen 24/1.0 LPG Country - GB/IE - Natural Gas Appliance Category CAT I Appliance Type NO x Class Max Gas Rate (m /hr) Central Heating Primary Circuit Both 2.68 Engine 0.82 Supplementary 1.86 Electrical Supply...

  • Page 11: Dimensions And Fixings

    A 950mm At Least 1.5° B 426mm C 450mm D 116mm Ø Min. E 190mm Allow at least 250mm for assembly and servicing F 133mm G 145mm H 268mm 125mm 360° Orientation Tube Ø 100mm © Baxi Heating UK Ltd 2012...

  • Page 12: System Details

    Fernox for analysis to confirm the system cleaning and dosing process has been successful. A copy of the report to be sent to Baxi Heating UK Ltd, heateam, Ecogen team, Brooks House, Coventry Road Warwick CV3 4LL.
  • Page 13 1. A ‘ADEY MagnaClean TwinTech’ Magnetic Filter must be fitted on the return to boiler as close to the Return Flow appliance as possible. FAILURE TO FIT THIS DEVICE WILL INVALIDATE THE APPLIANCE WARRANTY. Pump Boiler Fig. 5 © Baxi Heating UK Ltd 2012...
  • Page 14 6. HOT WATER STORAGE - The hot water storage vessel must be of the indirect coil type. All components used in the system must be suitable for operation at 110°C and at the pressure allowed by the safety valve. © Baxi Heating UK Ltd 2012...
  • Page 15 5 LED NOTE:- Either a 5 LED Receiver or a THINK Controller must be fitted to the appliance for the safety of the user or visiting service personnel. © Baxi Heating UK Ltd 2012...

  • Page 16: Site Requirements

    450mm Min 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool For Servicing without ventilation. Purposes 5mm Min 426mm In Operation Fig. 10 © Baxi Heating UK Ltd 2012...
  • Page 17 Spur servicing the boiler and system controls only. NOTE: this appliance will not work in conjunction with prepaid meters. Prepaid meters must be replaced by the electricity provider to enable export of electricity back into the grid. © Baxi Heating UK Ltd 2012...
  • Page 18 An example of the warning label to be left on site is shown (Fig. 12a). Fig. 12a 10. There are two ways in which the Ecogen 24/1.0 appliance can be electrically installed. Connection by dedicated circuit (Fig. 13) Connection into an existing final circuit (Fig.
  • Page 19 IMPORTANT: In designing a connection for the Ecogen 24/1.0 the electrical installer has to 7.0 Site Requirements consider all the issues that would need to be covered for a conventional final circuit, including:- In Accordance with BS: 7671. • the maximum demand (and the generator output) Electrical Connection (cont) - Installer information •...
  • Page 20 *It is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle ! © Baxi Heating UK Ltd 2012...
  • Page 21 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 2012...
  • Page 22 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 2012...
  • Page 23 (see Top View Rear Flue Section 8.11). Fig. 14 Property Boundary Line Air Inlet Opening Window or Door 150mm Fig. 15a MIN. Likely flue positions requiring Fig. 15 a flue terminal guard © Baxi Heating UK Ltd 2012...

  • Page 24: Flue Options

    NOTE: Horizontal flue pipes should always be installed with at least 1.5° fall from the terminal to allow condensate to run back to the boiler. This bend is equivalent to 1 metre This bend is equivalent to 1 metre Total equivalent length = A+B+C+2x90°Bends © Baxi Heating UK Ltd 2012...
  • Page 25 This bend is equivalent to Equivalent Length Air Duct = 6.5m 1 metre FLUE DUCT Equivalent Sub total Length Value fittings/pipes 1m extension 5.0m 135°bend 0.5m 0.25m 91.5°bend 1.0m 0.5m Equivalent Length Flue Duct = 6.5m © Baxi Heating UK Ltd 2012...
  • Page 26 FLUE GROUP A, N, G Vertical Flue Kits Vertical Flue Terminal 5111078 (80/125 use with Item H) Vertical Flue Terminal 5118576 (60/100) Pitch Roof Flashing 25°/50° 5122151 Roof Cover Plate 246143 Flat Roof Flashing 246144 © Baxi Heating UK Ltd 2012...
  • Page 27 3. Using the screws previously removed secure the inlet adaptor to the top panel. 4. Continue to fit the twin flue system. Fig. 17 Air Duct Adaptor Gasket Fig. 18 © Baxi Heating UK Ltd 2012...
  • Page 28 Flue Deflector (Fig. 21) 1. If required, push the flue deflector over the terminal end and Fig. 20 rotate to the optimum angle for deflecting plume. Secure the deflector to the terminal with screws provided. © Baxi Heating UK Ltd 2012...
  • Page 29 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 2012...
  • Page 30 After consulting the table in Example 3 it can be determined Additional Accessories that the concentric flue could be up to approximately 1.6 93° Elbow 5121369 metres long. 45° Elbow (Pair) 5121370 Fig. 21f 1 metre 60Ø Extension 5121368 © Baxi Heating UK Ltd 2012...
  • Page 31 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. 21m). Fig. 21m © Baxi Heating UK Ltd 2012...
  • Page 32 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. 21r 70° Concentric Flue Length (shown end-on) Outlet Spigot Fig. 21s © Baxi Heating UK Ltd 2012...

  • Page 33: Installation

    9.0 Installation NOTE: - Installers of this appliance must have undergone Baxi Ecogen Training and been approved to install this appliance. Unpacking & Initial Preparation NOTE: Maintain the appliance upright at all times. Do not lay the appliance on its back, sides or front. Drilling of the wall or ceiling for flue and pipe work must be completed before the appliance is fitted to the wall.
  • Page 34 3. The condensate trap should be primed by pouring Fig. 30 approximately 300ml of water into the flue spigot. Do not Fig. 30a allow any water to fall into the air inlet. © Baxi Heating UK Ltd 2010...
  • Page 35 Terminal Assembly by careful cutting to accommodate engaged into Boiler walls of these thicknesses. Adaptor 7. To dimension ‘X’ add 50mm. This dimension to be known as ‘Y’. Fig. 33 Wall Thickness Fig. 32 © Baxi Heating UK Ltd 2012...
  • Page 36 Extension Tape Cut End Fig. 38 Apply Lubricant for ease of assembly. Ensure Extension is fully engaged into Boiler Adaptor © Baxi Heating UK Ltd 2012 Fig. 39...

  • Page 37: Electrical

    DHW thermostat and programmer. An outdoor sensor for weather compensation cannot be used in this case. The THINK Controller must remain on the appliance (See Section 10.11). © Baxi Heating UK Ltd 2012...
  • Page 38 * NOTE: All Fuses 3.15 A ** Permanent Live once the 230V supply is connected *** Ensure all system wiring is correct to wiring regulations (BS7671) and fully tested before connection to avoid any damage to the appliance controls. © Baxi Heating UK Ltd 2012...
  • Page 39 Mid Position Valve (On) (On) (On) (Off) Valve Valve (Out) (In) Out Door Sensor (In) Out Door Sensor (Out) Tank Sensor (In) Tank Sensor (Out) Back Light (+12v) Ground (0V) Data Signal (+V) Wall Cradle © Baxi Heating UK Ltd 2012...
  • Page 40 (On) (On) (On) (Off) Valve Valve (In) (Out) Out Door Sensor (In) Out Door Sensor (Out) Out Tank Sensor (Out) In Tank Sensor (In) Back Light (+12v) Ground (0V) Data Signal (+V) Wall Cradle © Baxi Heating UK Ltd 2012...
  • Page 41 Spring Return Valve (On) (On) (On) (Off) Valve Valve (Out) (In) Out Door Sensor (In) Out Door Sensor (Out) Cylinder Sensor (In) Cylinder Sensor (Out) Back Light (+12v) Ground (0V) Data Signal (+V) Wall Cradle © Baxi Heating UK Ltd 2012...
  • Page 42 (On) (On) (On) (Off) Valve Valve (In) (Out) Out Door Sensor (In) Out Door Sensor (Out) Out Tank Sensor (Out) In Tank Sensor (In) Back Light (+12v) Ground (0V) Data Signal (+V) Wall Cradle © Baxi Heating UK Ltd 2012...
  • Page 43 2 Port Valve (On) (Off) Isolate Valve Valve (Out) (In) Out Door Sensor (In) Out Door Sensor (Out) Cylinder Sensor (In) Cylinder Sensor (Out) Back Light (+12v) Ground (0V) Data Signal (+V) Wall Cradle © Baxi Heating UK Ltd 2012...
  • Page 44 2 Port Valve (On) Isolate (Off) Valve Valve (In) (Out) Out Door Sensor (In) Out Door Sensor (Out) Out Tank Sensor (Out) In Tank Sensor (In) Back Light (+12v) Ground (0V) Data Signal (+V) Wall Cradle © Baxi Heating UK Ltd 2012...
  • Page 45 Isolate Valve Valve Valve (Out) (In) Megaflo Out Door Sensor (In) Out Door Sensor (Out) Cylinder Sensor (In) Cylinder Sensor (Out) Back Light (+12v) Ground (0V) Data Signal (+V) Wall Cradle 2nd Wall Cradle © Baxi Heating UK Ltd 2012...

  • Page 46: Mains Supply

    Boiler On (In) (On) (On) (On) (Off) Valve Valve (Out) (In) Out Door Sensor (Out) Out Door Sensor (In) Out Tank Sensor (Out) In Tank Sensor (In) Back Light (+12v) CL + Signal CL - Signal © Baxi Heating UK Ltd 2012...
  • Page 47 Supplementary burner status Turn the Selector Button to highlight ‘Used as’ and press Red LED Fault status to select, whilst flashing turn the Selector Button to show the desired room unit and press to select. © Baxi Heating UK Ltd 2012...
  • Page 48 THINK Controller is on the wall cradle. Once the parameters appliance have been checked down power the appliance for 10 seconds and then switch the appliance back on. © Baxi Heating UK Ltd 2012...
  • Page 49 6. When correctly connected and once the ‘Save sensor’ procedure has been done (See Section 11.4), the outside temperature and icon will be display on the THINK Controller (See Section 10.12 and Fig 42). © Baxi Heating UK Ltd 2012...
  • Page 50 Move the unit to a location where at least 20 of these signals are echoed back. If few or no signals are received it will be necessary to use a repeater unit to relay the signal. © Baxi Heating UK Ltd 2012...

  • Page 51: Commissioning

    I.S. 813 “Domestic Gas Installations”. IMPORTANT : Lockout may occur and Error Codes E261 & E262 displayed if the gas supply pipe is not adequately Push On purged. Fig. 48b Connector 7. Test for gas tightness. © Baxi Heating UK Ltd 2012...
  • Page 52 - see Section 7.0 of the User’s Operating Instructions. Section 7.1 Selecting the Space Heating Mode. Section 7.4 Selecting the DHW Mode. c) Temperature Settings. Please refer to the User’s Operating Instructions Section 7.0. © Baxi Heating UK Ltd 2012...
  • Page 53 • Press Selector Button to confirm. • Press ‘Menu’ to escape to normal operating screen. Remember: The function is most likely to activate the pump during the night. Pump activation at less than 1.5° C. © Baxi Heating UK Ltd 2012...
  • Page 54 If it is required to replace the THINK Controller back on the appliance then parameter 40 must be reassigned to operator unit 1 - see section 10.13. After all reprogramming of these parameters the appliance must be down powered and then repowered after 10 seconds. © Baxi Heating UK Ltd 2012...
  • Page 55 • The ‘yes’ will change back to ‘no’ to show that the sensors have been saved. 3. The sensors that are connected to the appliance are automatically recognised and used to control the comfort levels. © Baxi Heating UK Ltd 2012...
  • Page 56 (working) gas pressure at the inlet gas pressure test point (Fig. 50) is in accordance with B.S. 6798 & B.S. 6891. 9. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working. © Baxi Heating UK Ltd 2012...

  • Page 57: Completion

    Instructions giving advice on the necessity of regular servicing. Advise the customer of the necessity of informing the electricity provider with regard to billing and payback. See the Users Operating instructions section 13.3. NOTE: See also www.baxi.co.uk/products/get-fit-with-baxi-ecogen © Baxi Heating UK Ltd 2012...

  • Page 58: Servicing

    Benchmark Commissioning Checklist at the rear of this publication. NOTE: Service and maintenance engineers must have PINT undergone Baxi Ecogen Training and been approved to service this appliance. 3. Before electrically isolating the appliance: remove all demands Inlet Test Gas Valve for heat and ensure the engine has disconnected from the grid.
  • Page 59 If it observed that there is excessive amounts of corrosion product - black residue/sludge check the inhibitor level in the system and top up with inhibitor solution as required. © Baxi Heating UK Ltd 2012...
  • Page 60 M4 Screw earth wire. Flame Sense Lead Fig. 55 Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user. © Baxi Heating UK Ltd 2012...

This manual is also suitable for:

Ecogen 24/1.0 lpg

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