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Baxi 44 075 03, Manual

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Baxi 44 075 03 Manual Download Page 28

Supplied By www.heating spares.co  Tel. 0161 620 6677

28

10.0 Fault Finding

Check solenoid

leads for continuity

Replace P.C.B.

Does

“

Boiler On

”

neon light ?

Is

resistance

across sensor correct ?

(1M OHM @ 25

o

C)

Are

potentiometer

resistances correct ? 

(see table on 

page 26)

Check gas pressure

at inlet to valve

(20mb)

Check main injector

for blockage/damage

Is

there mains

voltage at main 

solenoid ?

Is

burner setting

pressure correct ?

Disconnect blue

leads & check resistance

across main gas solenoid

(approx 5K OHM)

Replace wiring

harness

Replace V404A

solenoid

Check gas valve is

operating correctly

Replace

potentiometer

Replace sensor

Replace P.C.B.

Check pump for

circulation

Check sensor is

located correctly

in pocket

Boiler unit

satisfactory

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

Replace P.C.B.

NO

Does

main burner 

ignite ?

With

thermostat on

high, does boiler switch off

at approx. 82

o

C on

flow ?

Does

the boiler

operate and then 

lockout ?

Check flue pull

and ventilation

Check boiler sensor

and potentiometer

Check valve

solenoids

NO

YES

YES

YES

Summary of Contents for 44 075 03

Page 1: ...pplied By www heating spares co Tel 0161 620 6677 Baxi Bermuda Inset 2 Boiler 50 4 E Fireside Gas Central Heating Unit Installation and Servicing Instructions Please leave these instructions with the user ...

Page 2: ...he products that customers want to buy Baxi is also the largest manufacturing partnership in the country Everyone who works at the company has a commitment to quality because as shareholders we know that satisfied customers mean continued success We hope you get a satisfactory service from Baxi If not please let us know Natural Gas Baxi Bermuda Inset 2 Boiler 50 4 E G C No 44 075 03 For use with t...

Page 3: ...ing the Boiler Hood Siting the Boiler Securing the Boiler Water Connections Fully Pumped Systems Pumped Heating Gravity Hot Water Gas Connection Electrical Connection Making the Electrical Connection Flue Connection Completion 7 0 Commissioning the Appliance 18 8 0 Annual Servicing 19 Annual Servicing Removal of Firefront Removal of Controls Cleaning the Lint Arrestor Cleaning the Burner Main Inje...

Page 4: ...staller or other competent person and be in accordance with the relevant requirements of Gas Safety Installation and Use Regulations the Building Regulations Scotland Consolidation the Local Building Regulations the Current I E E Wiring Regulations and the bye laws of the Local Water Undertaking Where no specific instructions are given reference should be made to the relevant B S CODES OF PRACTICE...

Page 5: ...ed electronic flame sensing with atmospheric sensing device Gas Rate 1 8m3 h after 10 mins 63 57ft3 h Lifting Weight 33 2 kg 73 2 lbs Dimensions Height 516mm Width 440mm Depth 368mm Flue Diameter mm 125 in 5 Heat Exchanger Cast Iron Low Head Min mm 1000 in 393 8 Water Systems Fully pumped or pumped heating with gravity hot water Sealed system with optional safety limit thermostat 0 2 6 10 4 8 12 1...

Page 6: ...st be flushed in accordance with the guidelines given in BS7593 1992 Treatment of water in domestic hot water central heating systems This must involve the use of a proprietary cleanser such as BetzDearborn s Sentinel X300 or X400 or Fernox s Superfloc Full instructions are supplied with the products but for immediate information please contact BetzDearborn 0151 420 9563 or Fernox 01799 550811 For...

Page 7: ...d should include a control system 2 Such a system would comprise a timer control and a separate room and or cylinder thermostat as appropriate 3 The boiler should be controlled so that it operates on demand only 4 It is not economical to rely on the boiler thermostat to control operation of the system 3 5 Fully Pumped System Fig 3 1 The sizes of the system pipes should be determined by normal meth...

Page 8: ...using 28mm pipes Smaller pipe sizes and longer horizontal runs are acceptable with suitably increased circulating heads 8 The gravity circuit should be designed with a minimum of restriction avoiding possible air traps and long horizontal runs 9 The system should be designed to prevent gravity circulation in the heating system when the pump is not running 3 8 Safety Limit Kit Sealed Systems 1 A sa...

Page 9: ... 5546 The appliance may not be installed in bathrooms shower rooms bedrooms or bed sitting rooms 4 3 Fireplace Opening Surround 1 If a fireplace surround is to be used it must be centrally placed and have opening sizes and a vertical flat area as detailed in the Installation and Servicing Instructions for the fire 4 4 Frame Extension Kit 1 If the depth of the builders opening is less than the 375m...

Page 10: ...lders opening The flue must be sealed between the liner and the brickwork at both the top and bottom 3 Acid Resistant Liner A flue constructed of acid resistant liners is satisfactory provided the size requirements are met The boiler flue outlet can be connected to the flue by means of a short length of 125mm 5in of flue pipe A seal must be made in the annular space between the outer face of this ...

Page 11: ...oute the gas supply pipe to the right hand side of the builders opening It must be routed so as not to restrict the installation and servicing of the appliance 4 8 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with current IEE wiring regulations The mains supply is 230V 50Hz fused at 5A A permanent live supply is required for all Super Model Firefronts N...

Page 12: ...S L L 230V L b r b or p p or bk r b w y r PCB Schematic Wiring Diagram Electrode Printed Circuit Board Control Potentiometer Switch Thermostat Sensor Gas Valve b r g y b or y r or bk r b w p p w Sensing Probe w 5 1 Illustrated Wiring Diagram 5 2 Functional Flow Diagram Key b blue r red p pink w white or orange g y green yellow or bk orange black r b red blue y r yellow red Fig 7 Fig 8 ...

Page 13: ... appliance and remove the side blanking plate 6 Transfer the 3 sealing rings from the holes in the left hand side of the boiler to those on the right 7 Rotate the heat exchanger to place the water connections at the right hand side return the heat exchanger to the combustion box DO NOT TURN THE HEAT EXCHANGER UPSIDE DOWN NOTE The heat exchanger is correctly oriented when the three water connection...

Page 14: ...Requirements 3 It may be desirable to insert the required fittings into the heat exchanger at this point depending on the size of the fireplace opening and whether or not the gravity injector tee is to be used 4 Locate and mark the centre line of the finished opening and hearth Fig 15 5 Hold the boiler by its combustion box at either side of the heat exchanger lift from the packing base and place ...

Page 15: ...d adaptor compression nut and olive are provided in the kit for the return connection 2 The 1in x 22mm threaded adaptor provided must be fitted to the lower tapping marked RETURN Connect the pumped return into the adaptor using the nut and olive 3 Fit a 1in x 22mm threaded adaptor into one of the higher tapping positions marked FLOW and connect the pumped flow into the adaptor 4 Fit a 1in plug to ...

Page 16: ... compression fitting of the injector tee 5 Take the gravity hot water return pipe to a level beneath that of the injector tee and connect upwards to the 28mm branch of the injector tee oriented as shown 6 Connect the pumped flow to one of the connections marked FLOW Connect the gravity flow to the remaining connection 7 The gravity flow pipes must rise vertically as close as possible to the applia...

Page 17: ... box on the fire front 4 Connect the cables as indicated Fig 23 Mains Inlet cable Permanent live to L Controls system switched live to SL Control system neutral to N Earth to Fire cable Brown live to L Blue neutral to N Green and Yellow earth to Re fit the cable clamps ensuring that the outer insulation is securely held and re fit the plug cover Ensure that all cables are routed away from the boil...

Page 18: ...rned on third orange light illuminates and spark generator operates e Pilot established green light illuminates and power supplied to main burner solenoid f Boiler fault orange light illuminates and boiler goes to lockout The pilot flame should be without a yellow tip and be approximately 20mm long No adjustment is possible Operate the burner and allow the system to reach normal operating temperat...

Page 19: ...rn the boiler thermostat to O position Fig 31 2 Pull the electrical input plug from the socket on the P C B Fig 33 3 Disconnect the union at the gas service cock and remove the fire feed pipe Fig 35 4 Remove the thermostat sensor and retaining strip from the boiler Fig 32 5 Undo the nut on the sensing pipe at the adaptor Fig 34 6 Undo the four screws retaining the door and remove the door Fig 36 7...

Page 20: ...er and refit the lint arrestor 8 6 Cleaning the Pilot A S D Assembly NOTE No attempt should be made to clean the device using any hard tools including pins or wire WARNING The pilot A S D assembly must not be adjusted in any way 1 The A S D must not be altered so that it will not operate or be bypassed in any way 2 Ensure that the pilot burner aeration hole is free from lint debris etc Fig 41 3 If...

Page 21: ...th suitable brushes and remove any deposits from the combustion box base tray 5 Clean away any lint or other deposits from the boiler hood and builders opening 6 Reassemble the insulation in reverse order and refit the baffles 7 Reassemble the appliance in reverse order re greasing the thermostat phial if required 8 Re commission the appliance and check for gas soundness 9 Complete the relevant se...

Page 22: ...stat Sensor Fig 49 50 1 Remove controls heat shield 2 Remove the thermostat sensor retaining strip from the boiler 3 Undo the three screws retaining the control box cover and remove the cover 4 Disconnect the thermostat sensor plug from the PCB 5 Reassemble in reverse order 9 5 Thermostat Potentiometer Fig 51 1 Remove the controls heat shield from its retaining clips 2 Undo the three screws retain...

Page 23: ...eads and Pilot A S D Assembly proceed as follows 9 7 Removal of Controls 1 Turn the boiler thermostat to O 2 Pull the input plug from the socket on the P C B Fig 55 3 Disconnect the union at the gas service cock and remove the fire feed pipe Fig 56 4 Remove the thermostat sensor and retaining strip from the boiler 5 Undo the nut on the sensing pipe at the adaptor Fig 54 6 Loosen the P clip and sli...

Page 24: ...ce Fig 60 7 Remove the valve from the controls mounting bracket Fig 60 8 Remove the tailpiece and union nut from the original valve and fit to the new one Fig 60 9 Reassemble in reverse order 9 9 Burner Main Injector 1 Remove the lint arrestor by pulling forward Fig 61 2 Remove the four hexagon headed screws holding the burner to the mounting plate Fig 62 3 If required the main injector can be uns...

Page 25: ...es 4 Engage the tab on the A S D bracket in the hole in the burner mounting plate Ensure that the pilot aeration tube seal sits in the recess in the sensing pipe adaptor Refit the retaining screw 5 Reassemble in reverse order 9 11 Ignition Lead 1 Remove controls heat shield 2 Remove the three screws securing the controls box cover and remove the electrode lead from its terminal on the PCB and the ...

Page 26: ...hermostat is calling for heat turn fully clockwise Disconnect and check resistance across sensor 1M ohm 25o C remove from boiler if hot Check potentiometer resistances are correct see below Replace P C B Check electrode lead for breaks in the insulation Check connections Check spark gap 2 5 4 0mm Replace P C B Replace sensor Replace potentiometer Is the ignition neon lit indicating start of igniti...

Page 27: ...continuity Replace wiring harness Check gas valve is operating correctly Replace P C B YES YES YES YES YES NO NO NO NO NO NO Disconnect red blue leads check resistance of pilot solenoid approx 1 5 K OHM Replace pilot solenoid Does pilot burner ignite Does pilot remain alight and ignition sparking stop Check gas pressure at inlet to valve 20mb YES YES NO Rectify flue Is flue pull O K Replace P C B ...

Page 28: ...nnect orange blue leads check resistance across main gas solenoid approx 5K OHM Replace wiring harness Replace V404A solenoid Check gas valve is operating correctly Replace potentiometer Replace sensor Replace P C B Check pump for circulation Check sensor is located correctly in pocket Boiler unit satisfactory YES YES YES YES YES YES YES NO NO NO NO NO NO NO Replace P C B NO Does main burner ignit...

Page 29: ...rers No No Part No 39 E02 416 Burner 238652 60 378 882 Injector B19 234014 51 E00 121 Ignition Lead 237811 52 E00 122 Sensing Lead 237812 35 193 182 Valve 236579 33 E37 405 Pilot A S D 246386 Assembly 28 E00 118 P C B 237730 48 378 909 Potentiometer 235900 Leads 20 E37 397 Thermostat 246381 Sensor 51 60 39 52 20 48 28 35 33 ...

Page 30: ...Supplied By www heating spares co Tel 0161 620 6677 30 12 0Notes ...

Page 31: ...comprehensive range of products for the domestic heating market Gas Central Heating Boilers Wall Floor and Fireside models Independent Gas Fires Renewal Firefronts Gas Wall Heaters Solid Fuel Fires If you require information on any of these products please write to the Sales Department ...

Page 32: ...Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www baxi com The Baxi Helplines For General Enquiries 44 0 8706 060 780 For After Sales Service 44 0 8706 096 096 For Technical Enquiries 44 0 8706 049 049 Comp No 245025 Iss 5 6 00 ...

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