Baxi Megaflo System 15 HE Installation And Servicing Instructions
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Baxi Megaflo System 15 HE Installation And Servicing Instructions

Gas fired wall mounted condensing boiler
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Installation & Servicing Instructions
Baxi
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 2007

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  • Page 1 Installation & Servicing Instructions Baxi 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 2007...
  • Page 2 Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure. © Baxi Heating UK Ltd 2007 All rights reserved. No part of this publication may The flowchart opposite gives guidance for installers on the...
  • Page 3 CORGI is written onto the Benchmark Checklist CORGI will record the data and LABC will record the data will send a certificate of and will issue a compliance to the property certificate of compliance © Baxi Heating UK Ltd 2007...

  • Page 4: Systems

    BS 5449 Forced circulation hot water systems. For GB/IE only. 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 2007...
  • 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 2007...

  • Page 6: Table Of Contents

    Dimensions and Fixings 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 Combustion Check 16.0 Electrical 17.0 Short Parts List 18.0 Fault Finding Benchmark Checklist © Baxi Heating UK Ltd 2007...

  • 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 2007...

  • 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 2007...

  • Page 10: Technical Data

    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 have been certified by 0087. 1000 1200 © Baxi Heating UK Ltd 2007 Flow Rate (l/h)

  • Page 11: Dimensions And Fixings

    F 145mm G 131mm 360° Orientation H 180mm Tube Ø 100mm Tap Rail 32.5 mm Condensate Drain 130 mm 130 mm 65 mm Heating Pressure Relief Heating Return Flow Inlet Valve (22mm) (22mm) (22mm) (15mm) © Baxi Heating UK Ltd 2007...

  • 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 2007...
  • Page 13 3. The discharge must not be above a window, entrance or other public access. Consideration must be given to the Fig. 4 possibility that boiling water/steam could discharge from the pipe. Pressure Relief Valve Discharge Pipe © Baxi Heating UK Ltd 2007...

  • Page 14: Site Requirements

    Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler. 450mm Min For Servicing Purposes 5mm Min In Operation Fig. 6 © Baxi Heating UK Ltd 2007...
  • Page 15 In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. Fig. B In GB Only 813 “Domestic Gas Installations” and the current ETCI rules. © Baxi Heating UK Ltd 2007...
  • Page 16 Boiler ii) via an internal discharge branch (e.g. sink waste) iii) to a drain or gully 500mm min iv) to a purpose made soakaway Holes in the soak-away must face away from the building © Baxi Heating UK Ltd 2007...
  • Page 17 (see Top View Rear Flue Section 9.0). Fig. 8 Property Boundary Line Air Inlet Opening Window or Door 100mm Fig. 10 MIN. Likely flue positions requiring Fig. 9 a flue terminal guard © Baxi Heating UK Ltd 2007...

  • Page 18: Flue Options

    NOTE: Horizontal flue pipes should always be installed with a 1.5° to 3° 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 2007...
  • Page 19 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 2007...
  • Page 20 FLUE GROUP A, N, G Vertical Flue Kits Vertical Flue Terminal 5111078 (use with 5111070) Vertical Flue Terminal 5118576 Pitch Roof Flashing 25°/45° 246141 Pitch Roof Flashing 35°/55° 246142 Roof Cover Plate 246143 Flat Roof Flashing 246144 © Baxi Heating UK Ltd 2007...
  • Page 21 5. Using the screws previously removed secure the inlet adaptor to the top panel. 6. Continue to fit the twin flue system. Air Duct Adaptor Position of Restrictor Gasket Restrictor Gasket 15/18 kW models 24 kW models 28/32 kW models © Baxi Heating UK Ltd 2007...
  • Page 22 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 2007...

  • Page 23: 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 2007...
  • Page 24 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 5121639 metres long. 45° Elbow (Pair) 5121370 Fig. 18 1 metre 60Ø Extension 5121638 © Baxi Heating UK Ltd 2007...
  • Page 25 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 2007...
  • Page 26 25. All other minimum & maximum dimensions must be adhered to, and the air inlet positioned such that it will not be subjetc to rain entry. Fig. 28 70° Concentric Flue Length (shown end-on) Outlet Spigot Fig. 29 © Baxi Heating UK Ltd 2007...

  • Page 27: Installation

    For Side Flue Exit 1. Connect a tube to the central heating flow or return pipe Fig. 34 (Fig. 35). Flushing Tube 2. Flush thoroughly (see System Details, Section 6.2). Wall Plate Fig. 35 Central Heating Return © Baxi Heating UK Ltd 2007...
  • Page 28 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. Discharge Pipe © Baxi Heating UK Ltd 2007...
  • Page 29 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. 41 Wall Thickness Fig. 40 © Baxi Heating UK Ltd 2007...
  • Page 30 Extension Adaptor Tape Cut End Fig. 46 Apply Lubricant for ease of assembly. Ensure Extension is fully engaged into Boiler Adaptor © Baxi Heating UK Ltd 2007 Fig. 47...
  • Page 31 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. 50 Resistance to Earth, Short Circuit and Polarity. © Baxi Heating UK Ltd 2007...

  • Page 32: Commissioning

    When the knob is turned the display will alter and show the selected temperature. After a few seconds the display reverts to show the current boiler temperature (Fig. 54). Central Heating Calibration Control Temperature Control Fig. 54 © Baxi Heating UK Ltd 2007...
  • Page 33 9. The ‘Calibration Function’ is active for 20 minutes unless the maximum CH temperature is exceeded. 10. The function can be disabled at any time by turning the Calibration Control knob. Fig. 58 Fig. 60 Fig. 59 © Baxi Heating UK Ltd 2007...

  • Page 34: 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. 61 © Baxi Heating UK Ltd 2007...

  • Page 35: Servicing

    7. Unscrew the sump from the bottom of the condensate trap assembly (Fig. 64). 8. Remove any deposits from the sump and trap. Clean as necessary and replace the sump. Inner Door Fig. 63 Panel Condensate Trap Sump Fig. 64 © Baxi Heating UK Ltd 2007...
  • Page 36 Clean any dirt or dust from the air box. 13. Reassemble in reverse order. NOTE: The sensing pipe must be reconnected to the Electrode fan, not the venturi. Leads Fig. 66 Venturi Injector Gas Inlet Pipe Fig. 65 © Baxi Heating UK Ltd 2007...

  • Page 37: 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. 68 © Baxi Heating UK Ltd 2007...
  • Page 38 1. Remove the collector and fan assembly as described in Collector section 14.3. Fig. 69 2. Extract and replace the injector and reassemble in reverse order. Fig. 71 When fitting the venturi ensure that the arrow is pointing forward © Baxi Heating UK Ltd 2007...
  • Page 39 6. Examine the cover seal and replace if necessary. Heat Exchanger Rear Insulation Spark Electrode Venturi Cover Insulation Seal Fig. 73 Collector Electrode Sensing Leads Electrode © Baxi Heating UK Ltd 2007...
  • Page 40 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. 76 Fig. 77 © Baxi Heating UK Ltd 2007...
  • Page 41 Pump Setting Fig. 79 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. 80 © Baxi Heating UK Ltd 2007...
  • Page 42 3. Note the orientation of the valve, rotate it and withdraw it from the manifold. 4. Fit the new valve and ‘O’ ring seal and set to the previously noted orientation. Reassemble in reverse order. ‘O’ Ring Seal Grub Screw Discharge Pipe Fig. 83 © Baxi Heating UK Ltd 2007...
  • Page 43 4. Remove the screws securing the switch to the facia panel. Facia 5. Fit the new switch, ensuring that it is correctly positioned and reassemble in reverse order. Selector Switch Knob Temperature Control Knobs Fig. 85 © Baxi Heating UK Ltd 2007...
  • Page 44 3. Remove the bracket and vessel from the boiler. 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 Spring Washer Lock Nut Fig. 87 © Baxi Heating UK Ltd 2007...

  • Page 45: Combustion Check

    12. 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 Gas Valve Fig. 95 Calibration Control knob. © Baxi Heating UK Ltd 2007...

  • Page 46: Electrical

    8 7 6 5 4 3 2 1 Control PCB X501 Flame Pump Sensing Electrode Spark Generator Gas Valve Link Ignition Electrode Boiler ‘Flying Lead’ - green - brown - green / yellow - black - red - blue - white © Baxi Heating UK Ltd 2007...

  • Page 47: Short Parts List

    Water Pressure Switch 5114748 Overheat Thermostat 5114729 NTC Sensor 5114725 Gas Valve 5114734 NTC Sensor (Return) 5114725 PCB 15 5122457 PCB 18 5122458 PCB 24 5118297 PCB 28 5118642 PCB 32 5122459 Pressure Gauge 248090 © Baxi Heating UK Ltd 2007...

  • Page 48: 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 2007...
  • Page 49 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 2007...

  • Page 50: Fault Finding Solutions Sections

    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 2007...
  • Page 51 (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 7.5 ± 1 4 ± 0.5 10 ± 1 Electrode Position © Baxi Heating UK Ltd 2007...
  • Page 52 Cold resistance approximately 10kΩ @ 25° C (CH sensor) Replace sensor 20kΩ @ 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 2007...
  • Page 53 19.0 Notes © Baxi Heating UK Ltd 2007...

  • Page 54: Benchmark Checklist

    CO/CO RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER COMMISSIONING ENG’S NAME PRINT CORGI ID No. SIGN DATE © Baxi Heating UK Ltd 2007...

  • Page 55: Service Interval Record

    SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.

  • Page 56: Description

    Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 08700 60 30 60 Technical Enquiries 08706 049 049 Website www.baxi.co.uk e&oe ompany IT Comp N 925.266.2 UK Comp N 5122328 - Iss 3 - 8/07 © Baxi Heating UK Ltd 2007...

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