Main System 28 Eco Installation & Service Instructions Manual
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Main System 28 Eco Installation & Service Instructions Manual

Main System 28 Eco Installation & Service Instructions Manual

System eco series
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Supplied by HeatingSpares247.com
Installation & Service Instructions
System Eco
Range
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2011

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  • Page 1 Supplied by HeatingSpares247.com Installation & Service Instructions System Eco Range These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2011...
  • Page 2 Main System 24 Eco G.C.N 41 467 11 Building Regulations (England & Wales) require notification of Main System 28 Eco the installation of a heating appliance to the relevant Local G.C.N 41 467 12 Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly.
  • Page 3 Supplied by HeatingSpares247.com 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...

  • Page 4: Systems

    Supplied by HeatingSpares247.com Legislation IMPORTANT - Installation, Commissioning, Service & Repair This company declare that no substances harmful to health are contained in the appliance or used during appliance This appliance must be installed in accordance with the manufacturer’s instructions and manufacture.
  • Page 5 Supplied by HeatingSpares247.com Safe Manual 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. Health &...

  • Page 6: Table Of Contents

    Supplied by HeatingSpares247.com CONTENTS Section Page Introduction General Layout Appliance Operation Technical Data 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 Setting the Gas Valve 16.0 Electrical 17.0...

  • Page 7: Introduction

    1.0 Introduction Description Case Front Panel 1. The Main System Eco is a fully automatic gas fired wall mounted condensing system boiler. It is room sealed and fan assisted. 2. The boiler is set to give a maximum output of :- 24 models - 25.94 kW...

  • Page 8: General Layout

    Supplied by HeatingSpares247.com 2.0 General Layout Layout Expansion Vessel Automatic Air Vent Primary Return Temperature Sensor Circulation Pump Drain Off Point Pressure Relief Valve Selector Switch Central Heating System Pressure Gauge Control Box Gas Valve Condensate Trap Heat Exchanger Air Vent Electrode Assembly Primary Heat Exchanger Fan Assembly...

  • Page 9: Appliance Operation

    Supplied by HeatingSpares247.com 3.0 Appliance Operation Boiler Primary Circuit Operating Mode (Fig. 2) 1. With a demand for heating or hot water, the pump circulates water through the primary circuit. If the pressure is at least 0.5 bar and the ignition sequence will start. 2.

  • Page 10: Technical Data

    Supplied by HeatingSpares247.com 4.0 Technical Data System 24 & 28 Eco Appliance Type NO x Class Inlet Pressure (Natural Gas - G20) mbar Appliance Category CAT I Central Heating Primary Circuit Pressures Injector (Natural Gas - G20) Heat Input CH (Net) 24 model 26.06 7.82...

  • Page 11: Dimensions And Fixings

    Supplied by HeatingSpares247.com 5.0 Dimensions and Fixings Dimensions A 780mm At Least 1.5 B 345mm C 450mm D 116mm Ø Min. F 145mm G 132mm 210mm (80/125) H 225mm 360° Orientation Tube Ø 100mm Tap Rail 127 mm Condensate Drain 130 mm 130 mm 65 mm...

  • Page 12: System Details

    Supplied by HeatingSpares247.com 6.0 System Details Central Heating Circuit 1. The appliance is suitable for fully pumped SEALED SYSTEMS ONLY. Treatment of Water Circulating Systems • All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems.
  • Page 13 Supplied by HeatingSpares247.com 6.0 System Details System Filling and Pressurising (Fig. 6) 1. A filling point connection on the central heating return Double Stop Stop Check pipework must be provided to facilitate initial filling and Valve Valve Valve pressurising and also any subsequent water loss replacement/refilling.

  • Page 14: Site Requirements

    Supplied by HeatingSpares247.com 7.0 Site Requirements 5mm Min 450mm 5mm Min Location 1. The boiler may be fitted to any suitable wall with the flue 200mm Min passing through an outside wall or roof and discharging to (300mm Min if using 80/125mm atmosphere in a position permitting satisfactory removal of flueing system)
  • Page 15 Supplied by HeatingSpares247.com 7.0 Site Requirement Gas Service Cock 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 16 Supplied by HeatingSpares247.com 7.0 Site Requirements Condensate Drain Termination to an internal soil and Boiler vent pipe FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length.
  • Page 17 Supplied by HeatingSpares247.com Terminal Position with Minimum Distance (Fig. 18) (mm) 7.0 Site Requirements Directly below an opening, air brick, opening windows, etc. Above an opening, air brick, opening window etc. Horizontally to an opening, air brick, opening window etc. Flue (Figs.

  • Page 18: Flue Options

    Supplied by HeatingSpares247.com 8.0 Flue Options Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination applications. (ii) 2. Maximum permissible equivalent flue lengths are:- (60/100) (80/125) Horizontal Concentric 10 metres 20 metres 3. Any additional “in line” bends in the flue system must be taken into consideration.
  • Page 19 Supplied by HeatingSpares247.com Vertical Flues 8.0 Flue Options (Twin Pipe) 300mm Min Apart Twin & Vertical Flue Systems 1. Maximum permissible equivalent flue lengths are:- (60/100) (80/125) Vertical Concentric 10 metres 20 metres 1m Min (80/80) (ii) Twin Pipe 20 metres 20m Max 3.
  • Page 20 Supplied by HeatingSpares247.com 8.0 Flue Options Flue Accessories Accessory Size Code No FLUE GROUP A Concentric Flue System 100mm diameter Telescopic Internal Flue Kit 315-500mm 5119654 Telescopic Flue (incl elbow) 5118069 Horizontal Flue Terminal (incl elbow) 5118489 Flue Extension 1000mm 5111074 Flue Bend 93°...
  • Page 21 Supplied by HeatingSpares247.com 8.0 Flue Options Twin Flue Duct Adaptor 1. The kit allows connection of a twin flue system to the Air Duct Connection boiler adaptor. Flue Duct Connection Twin Flue Connection 1. Engage the twin flue duct adaptor in the boiler adaptor, making sure that it is pushed down as far as possible.
  • Page 22 Supplied by HeatingSpares247.com 8.0 Flue Options For Roof Terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead Approx tile to replace/flash over existing roof tiling. Make an aperture in 1425mm the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained.

  • Page 23: Plume Displacement

    NOTE: Permitted positions of the plume outlet relative to doors, windows etc. are the same as for conventional concentric flues as detailed in the main Installation & Servicing Instructions and BS5440 Pt. 1. It is NOT necessary to fit a terminal guard over the air inlet or the plume outlet.
  • Page 24 Bracket 45° Elbow Flue Length - Worked Example 93° Elbow Main System 28 Eco 1 metre Extension Concentric 60/100 Flue In Fig. 27 opposite an additional 93° elbow and pair of 45° elbows have been included in the 60Ø exhaust.
  • Page 25 Supplied by HeatingSpares247.com 9.0 Plume Displacement General Fitting Notes 1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall back to the boiler at an angle of at least 1.5°. 2.
  • Page 26 Supplied by HeatingSpares247.com 9.0 Plume Displacement Plume Outlet Elbow General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air. 16.

  • Page 27: Installation

    Supplied by HeatingSpares247.com 10.0 Installation 10.1 Unpacking & Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). 1. Remove staples, open flaps and remove cardboard sheet. Remove the polystyrene side pieces and literature. Two people can then lift out the boiler (Fig.
  • Page 28 Supplied by HeatingSpares247.com 10.0 Installation Wall Plate 10.3 Fitting The Boiler 1. Lift the boiler using the Lifting Points as shown by the shaded areas (Fig. 43). The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig.
  • Page 29 Supplied by HeatingSpares247.com 10.0 Installation 10.6 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig.
  • Page 30 Supplied by HeatingSpares247.com 10.0 Installation 10.6 Fitting the Flue (Cont) Inner Flue Support Bracket 6. The inner flue duct support bracket may be in the waste portion of the flue. In this case retrieve the bracket before discarding the waste. 7.
  • Page 31 Supplied by HeatingSpares247.com 10.0 Installation 10.6 Fitting the Flue (Cont) CONCENTRIC VERTICAL FLUE 15. Once the length of the vertical concentric extension has been determined mark and carefully cut off the excess 25mm material. The cut end MUST be square and free of burrs to ensure correct insertion into the boiler adaptor.
  • Page 32 Supplied by HeatingSpares247.com 10.0 Installation 10.7 Making The Electrical Connections NOTE: Both the Live and Neutral connections are fused. To connect an external control proceed as follows:- 1. Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia.

  • Page 33: Commissioning

    Supplied by HeatingSpares247.com Heat Exchanger 11.0 Commissioning Automatic Air Vent Fig. 58 11.1 Commissioning the Boiler 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.
  • Page 34 Supplied by HeatingSpares247.com 11.0 Commissioning 11.2 Check the Operational (Working) Gas Inlet Pressure 1. Ensure that all controls are calling for heat, and the selector switch is in the central heating and hot water position ( The current boiler temperature is shown on the display. Central Heating Calibration Control Temperature Control...

  • Page 35: Completion

    Supplied by HeatingSpares247.com 12.0 Completion 12.1 Completion Case Front Panel 1. Instruct the user in the operation of the boiler and system including the integral timer, explaining the operational sequence. 2. Set the central heating and hot water temperature control knobs to the requirements of the user. 3.

  • Page 36: Servicing

    Supplied by HeatingSpares247.com 13.0 Servicing 13 .1 Annual Servicing 1. For reasons of safety and economy, it is recommended that Case Front Panel the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4. 2.
  • Page 37 Supplied by HeatingSpares247.com 13.0 Servicing 13.2 Annual Servicing - Inspection (Cont) Injector 6. Undo the nut on the gas pipe at the gas/air inlet (Fig. 72) Gas/Air Inlet and the gas valve. Remove the pipe, taking care not to lose the sealing washers.

  • Page 38: Changing Components

    Supplied by HeatingSpares247.com 14.0 Changing Components IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed turn the selector switch fully anticlockwise against the spring pressure to the Igniter reset position and hold for 5 seconds to reset the boiler before recommissioning.
  • Page 39 Supplied by HeatingSpares247.com 14.0 Changing Components Injector Gas/Air Inlet 14.3 1. Undo the nut on the gas pipe at the gas/air inlet (Fig. 77) and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. Gas Pipe 2.
  • Page 40 Supplied by HeatingSpares247.com 14.0 Changing Components 14.5 Burner (Fig. 80) 1. Undo the nut on the gas pipe at the gas/air inlet and the gas valve. Remove the pipe, taking care not to lose the sealing washers. Also remove the injector. 2.
  • Page 41 Supplied by HeatingSpares247.com 14.0 Changing Components 14.7 Safety Thermostat (Fig. 81) 1. Pull the plug off the thermostat. 2. Remove the screws securing the thermostat to the mounting plate on the flow pipe. Safety Thermostat 3. Reassemble in reverse order, ensuring that the plug is pushed fully on.
  • Page 42 Supplied by HeatingSpares247.com 14.0 Changing Components Heat Exchanger Air Vent 14.11 Heat Exchanger Automatic Air Vent (Fig. 84) 1. Drain the boiler primary circuit and unscrew the automatic air vent from the pump body. 2. Examine the ‘O’ ring seal, replacing if necessary, and fit it to the new automatic air vent.
  • Page 43 Supplied by HeatingSpares247.com 14.0 Changing Components 14.15 Pressure Gauge (Figs. 88 & 89) Gauge Retaining Bracket 1. Drain the boiler primary circuit and undo the nut on the pressure gauge capillary. 2. Undo the screws securing the gauge retaining bracket. 3.
  • Page 44 Supplied by HeatingSpares247.com 14.0 Changing Components 14.18 P.C.B. (Figs. 91 & 92) 1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins. 2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots.
  • Page 45 Supplied by HeatingSpares247.com Venturi Inlet 14.0 Changing Components Pipe 14.20 Gas Valve (Fig. 93) IMPORTANT: After replacing the valve the CO must be Gas Valve checked and adjusted as detailed in Section 15.0 Setting the Gas Valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see section 13.1.

  • Page 46: Setting The Gas Valve

    Supplied by HeatingSpares247.com 15.0 Setting the Gas Valve 15.1 Setting the Gas Valve ( check) IMPORTANT: The CO must be only be checked and adjusted to set the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see Section 13.1 Central Heating Calibration Control...

  • Page 47: Electrical

    Supplied by HeatingSpares247.com 16.0 Electrical 16.1 Illustrated Wiring Diagram Central Heating NTC Sensor gr gr Return Heating Overheat Stat Temp Sensor Water Pressure Switch X400 X401 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Control PCB X501 Pump...

  • Page 48: Short Parts List

    Supplied by HeatingSpares247.com 17.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. 5121447 Electrode Assembly 5130293 Gas Valve 5122149 Burner 5130292 Water Pressure Switch 5114748 Pump 248042 NTC Sensor 5114725 Overheat Thermostat 5114729 NTC Sensor 5130291 Pressure Gauge 248090 PCB 24 5131262...

  • Page 49: Fault Finding

    Supplied by HeatingSpares247.com 18.0 Fault Finding 18.1 Initial Fault Finding Checks NOTE: When instructed to turn the 1. Check that gas, water and electrical supplies are available selector to the reset position turn the at the boiler. selector switch fully anticlockwise against the spring pressure to the reset position 2.
  • Page 50 Supplied by HeatingSpares247.com 18.0 Fault Finding Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence Turn selector switch to Go to section ‘A’ The display illuminates Error 110 flashing If the error 110 is still flashing. Turn the selector switch to Error 133 flashing Go to section ‘I’...

  • Page 51: Fault Finding Solutions Sections

    Supplied by HeatingSpares247.com 18.0 Fault Finding Fault Finding Solutions Sections Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse Display Replace PCB illuminated Check wiring PCB - X1 connector terminals 1,2 Is there 230V at:...
  • Page 52 Supplied by HeatingSpares247.com 18.0 Fault Finding Check and correct the connection of the tube between the venturi and gas valve Gas at burner Ensure gas is on and purged PCB - X3 connector is 230V AC across Replace gas valve terminals 1 &...
  • Page 53 Supplied by HeatingSpares247.com 18.0 Fault Finding Is there 230V at: Replace PCB PCB - X3 connector terminals 5 & 6 central heating mode Change pump supply cable Fan connections correct at fan. Replace fan PCB - X401 connector terminals 5,6,7 & 8 Temperature sensors faulty.

  • Page 54: Benchmark Checklist

    Supplied by HeatingSpares247.com Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. If yes, and if required by the manufacturer, has a water scale reducer been fitted? CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798 If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?

  • Page 55: Service Record

    Supplied by HeatingSpares247.com 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: Description

    Supplied by HeatingSpares247.com All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet. All goods are sold subject to our standard Conditions of Sale which are available on request.

This manual is also suitable for:

System 24 eco

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