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Benchmark MAIN Installation & Service Instructions Manual

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System HE
Installation & Service Instructions
Range
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 System HE Installation & Service Instructions Range These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2007...

  • Page 2: Natural Gas

    This company is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the...
  • Page 3 (LABC) who will arrange instructions an inspection or contact a government approved inspector Complete the Benchmark Checklist If you notify via CORGI Scheme, CORGI will then notify the relevant Local Authority Install and Commission this Building Control Scheme appliance to manufacturer's...

  • Page 4: Systems

    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. the regulations in force. Read the instructions fully before installing or using the appliance.
  • Page 5 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.

  • Page 6: Table Of Contents

    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 Electrical 16.0 Short Parts List 17.0 Fault Finding Benchmark Checklist © Baxi Heating UK Ltd 2007...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Main System HE range are fully automatic gas fired wall mounted system boilers. They are room sealed and fan Case Front Panel assisted. 2. The boilers are set to give a maximum output of 18.9kW, 25.2kW or 29.3kW when in condensing mode.

  • Page 8: 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 System Pressure Gauge Control Box Condensate Trap Flame Sensing Electrode Spark Electrode Burner Primary Heat Exchanger Fan Assembly Secondary Heat Exchanger On/Off/Reset Selector Switch Temperature Control...

  • Page 9: Appliance Operation

    At a pre-determined flow rate the hydraulic differential pressure switch operates, initiating the ignition sequence. 2. The main burner ignites at low rate, then the gas valve controls the gas rate to maintain the heating temperature measured by the temperature sensor.

  • Page 10: Technical Data

    4.0 Technical Data System 18 HE Appliance Type NO x Class Central Heating Primary Circuit Pressures Appliance Category CAT II 2H 3P Condensate Drain 1” BSP Safety Discharge Heat Input Max Operating Flue Terminal Diameter 100mm Min Operating Dimensions Projection 125mm 18.7 10.6...
  • Page 11 4.0 Technical Data System 24 HE Appliance Type NO x Class Central Heating Primary Circuit Pressures Appliance Category CAT II 2H 3P Condensate Drain 1” BSP Safety Discharge Heat Input Max Operating Flue Terminal Diameter 100mm Min Operating Dimensions Projection 125mm 24.8 10.6...
  • Page 12 4.0 Technical Data System 28 HE Appliance Type NO x Class Central Heating Primary Circuit Pressures Appliance Category CAT II 2H 3P Condensate Drain 1” BSP Safety Discharge Heat Input Max Operating Flue Terminal Diameter 100mm Min Operating Dimensions Projection 125mm 28.9 11.9...

  • Page 13: Dimensions And Fixings

    5.0 Dimensions and Fixings Dimensions A 780mm At Least 1.5° B 345mm C 450mm D 107mm Ø Min. E 185mm F 190mm G 131mm 360° Orientation Tube Ø 100mm Tap Rail 28mm Condensate Drain 130 mm 130 mm 65 mm Heating Pressure Relief Heating...

  • Page 14: System Details

    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 15 6.0 System Detail 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 Stop Check 2. The filling method adopted must be in accordance with Valve Valve Valve...

  • Page 16: Site Requirements

    7.0 Site Requirement 20mm/5mm Min see *NOTE: 5mm Min 450mm Location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of 200mm Min combustion products and providing an adequate air supply.
  • Page 17 7.0 Site Requirement Ventilation of Compartments 1. Where the appliance is installed in a cupboard or Gas Service Cock 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 18 7.0 Site Requirement Termination to an internal soil and Boiler vent pipe Condensate Drain 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 19 Terminal Position with Minimum Distance (Fig. 9) (mm) 7.0 Site Requirement A a Directly below an opening, air brick, opening windows, etc. B a Above an opening, air brick, opening window etc. Flue C a Horizontally to an opening, air brick, opening window etc. D Below gutters, soil pipes or drain pipes.

  • Page 20: Flue Options

    8.0 Flue Options Horizontal Flue Systems 1. The Main System HE can be fitted with either horizontal, vertical or twin flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. 3. Maximum permissible equivalent flue lengths are:-...
  • Page 21 8.0 Flue Options Vertical Twin & Vertical Flue Systems Flues (Twin Pipe) 1. Maximum permissible equivalent flue lengths are:- (18) (24) (28) Vertical Concentric Vertical Twin Pipe 2. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:- Concentric Pipes: 135°...
  • Page 22 8.0 Flue Options Flue Accessories Accessory Size Baxi Code No Concentric Flue System 100mm diameter Horizontal flue Terminal 5111073 Horizontal flue Terminal (incl elbow) 5118489 Flue extension 1000mm 5111074 Flue Bend 93° 5111075 Flue Bend (pair) 135° 5111085 Pipe support 100mm 5111080 Vertical flue adaptor...
  • Page 23 8.0 Flue Options For Twin Flue Systems fit the adaptors as follows:- Flue Duct Adaptor (Fig. 11) Flue Duct Adaptor 1. Engage the flue duct adaptor on the boiler adaptor, Blanking Plate making sure that it is pushed down as far as possible. Air duct adaptor (Fig.
  • Page 24 8.0 Flue Options For Roof Terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make an aperture in Approx 1425mm the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained.

  • Page 25: 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 26 Support Flue Length - Worked Example 93° Elbow Bracket Main System 24 HE In Fig. 18 opposite an additional 93° bend has been included Extension in the 60Ø exhaust. with 2 x 1metre extensions which have been cut to 0.25metres and fitted. The waste is discarded.
  • Page 27 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 28 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. It is also possible to separate the plume outlet from the 93°...

  • Page 29: Installation

    10.0 Installation 10.1 Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). 1. After considering the site requirements (see Section 7.0) position the fixing template on the wall ensuring it is level both horizontally and vertically. 2.
  • Page 30 10.0 Installation Wall Plate 10.4 Fitting The Boiler 1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig.
  • Page 31 10.0 Installation 10.7 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. 33). 2.
  • Page 32 Fig. 37 11. Fit the flue trim if required, and if necessary fit a terminal guard (see Section 8.8 & 8.9. VERTICAL FLUE 1. Only a flue approved with the Main System HE range can be used. Flue Elbow Fig. 38...
  • Page 33 10.0 Installation 10.8 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 34: Commissioning

    11.0 Commissioning 11.1 Commissioning the Boiler 1. Reference should be made to BS 5449 when commissioning the boiler. Screw 2. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. 3.
  • Page 35 11.0 Commissioning 11.2 Checking the Burner Pressure 1. Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for heat. Pressure Test Point 2. Set the temperature control to maximum and the selector Sealing Screw switch to the Off position (Fig.

  • Page 36: Completion

    2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3. Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation. These details will be required in the event of any warranty work.

  • Page 37: Servicing

    Servicing must be performed by a competent person. 2. After servicing, complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication. 3. Ensure that the boiler is cool.
  • Page 38 R and hold for 2 seconds to reset the boiler before recommissioning. 22. 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. Fig. 57 Burner ©...

  • Page 39: Changing Components

    14.0 Changing Components IMPORTANT: When changing components ensure that Pressure both the gas and electrical supplies to the boiler are Switch isolated before any work is started. When the new component has been fitted turn the selector switch fully anticlockwise against the spring pressure to the ‘Reset’ position and hold for 2 seconds to reset the boiler Sensing before recommissioning.
  • Page 40 14.0 Changing Components 14.3 Heat Exchanger (Fig. 61) 1. Remove the fan as described in section 14.1. 2. Drain the primary circuit. Prise the pipe connecting clips off the joints in the flow and return pipes. Remove the heat exchanger return pipe. Pipe Connecting 3.
  • Page 41 14.0 Changing Components 14.5 Injectors (Fig. 63) Injector Inlet Elbow Manifold 1. Remove the burner as described in Section 14.4. Injector 2. Undo the screws securing the injector manifold to the inlet elbow and remove the manifold. Gasket 3. Unscrew and replace injectors as required and examine the sealing gasket, replacing as necessary.
  • Page 42 14.0 Changing Components 14.8 Gas Valve (Fig. 65) Modulator 1. Undo the nut on the gas feed pipe under the boiler. Wires 2. Completely undo the securing screws and hinge the facia Ignition panel down. Gas Valve Lead 3. Disconnect the wires from the valve modulator and the ignition lead from the spark generator.
  • Page 43 14.0 Changing Components 14.12 Pump - Head Only (Fig. 68) 1. Drain the primary circuit and remove the socket head screws securing the pump head to the body and draw the head away. 2. Undo the screw on the pump wiring cover and remove the cover.
  • Page 44 14.0 Changing Components Pressure Gauge Capillary 14.15 Pressure Gauge (Figs. 71 & 72) 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. Fig.
  • Page 45 14.0 Changing Components 14.18 Main PCB (Fig. 76) 1. Note the setting of the temperature control knob. Rotate the knob fully anticlockwise and carefully pull it off the drive pin. 2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots.
  • Page 46 14.0 Changing Components 14.20 Central Heating Differential Valve (Figs. 77 & 78) 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.
  • Page 47 14.0 Changing Components Secondary 14.23 Secondary Heat Exchanger) (Fig. 80) Heat Exchanger 1. Drain the primary circuit Pipe Connecting Clip 2. Undo the four screws securing the right hand case panel. Remove the panel. Fan Spigot Outlet Pipe Clamp 3. Prise the connecting clips from the heat exchanger return Outer Drum pipe and the boiler return pipe.

  • Page 48: Electrical

    15.0 Electrical 15.1 Illustrated Wiring Diagram Pump Air Pressure Switch Hydraulic Differential Pressure Switch Control PCB Return Heating Temperature Sensor Flame Sensing Central Heating Electrode NTC Sensor Mains Input Link Fuse Overheat Stat Flue Stat - brown - black - blue Reset Selector Switch - red Gas Valve...

  • Page 49: Short Parts List

    16.0 Short Part List Key G.C. Description Manufacturers No. No. Part No. Fan (18 HE) 5113278 Fan (24 HE) 5112627 Fan (28 HE) 5112430 Pressure Switch (18 HE) 5113280 Pressure Switch (24 & 28 HE) 248466 Heat Exchanger (18 HE) 5113284 Heat Exchanger (24 &...

  • Page 50: Fault Finding

    17.0 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), or 36mbar (propane).
  • Page 51 17.0 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 and a Check wiring &...
  • Page 52 17.0 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)
  • Page 53 18.0 Notes © Baxi Heating UK Ltd 2007...

  • Page 54: Benchmark Checklist

    5 1 2 1 1 8 6 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...

  • 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

    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.

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