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Baxi Bermuda BBU 15 HE, Installation & Servicing Instructions Manual

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Baxi Bermuda BBU 15 HE Installation & Servicing Instructions Manual Download Page 20

20

© Baxi Heating UK Ltd 2009

6.0 Boiler Internal Wiring

6.1

Boiler Internal Illustrated Wiring Diagram

- brown
- black
- blue
- white
- yellow

br
bk
b
w
y

- green
- green / yellow
- red

g
g/y
r 

Control PCB

X2

X3

X9

X501

1

2

1

2

3

3

4

4

5

5

6

7

8

9

X1

1

2

Central Heating 
NTC Flow Sensor

Fan

Gas Valve

Overheat Thermostat

Condensate Pump

X400

X401

bk

bk

gr

gr

b

b

br

bk

g

b

br

g/y

b

br

br

b

bk

b

br

bk

bk

bk

b

br

b

y

b

Spark
Generator

Ignition
Electrode

9 8 7 6 5 4 3 2 1

9

10

8 7 6 5 4 3 2 1

12

3

4

r

r

1

4

2

5

3

1

2

a

b

bk

bk

- grey

gr

gr gr

Safety Float

Switch

Discharge Float

Switch

ON/OFF

Reset

Mains Input
(Permanent Live to 3,
Switched Live to 1)

r

bk

bk

bk

bk

r

br

br

y

b

1

N

2

3

br

1

N

2

3

y

X300

X900

X500

b

b

b

Summary of Contents for Bermuda BBU 15 HE

Page 1: ...ack Boiler Unit These Instructions must be read in conjunction with those for the separate Valor Dimension electric firefront They include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Installation Servicing Instructions ...

Page 2: ...f Building Regulations only relates to dwellings Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations 0086 ISO 9001 FM 00866 This product has an energy rating A on a scale of A to G For more information see www boil...

Page 3: ...elevant LABC You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www GasSafeRegister co uk within 10 days If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Complete the Benchmark Checklist Instal...

Page 4: ...anty In GB this could also infringe the Gas Safety Installation and Use Regulations Warning Check the information on the data plate is compatible with local supply conditions This company declare that no substances harmful to health are contained in the appliance or used during appliance manufacture The appliance is suitable only for installation in GB and IE and should be installed in accordance ...

Page 5: ...g at height the Health and Safety Executive has introduced comprehensive regulations and guidance that should be followed by all businesses working at height The following paragraphs consider some of the main features of the regulations and guidance This is however only a limited summary and it is recommended that all businesses planning on undertaking air source heat pump heating installations ob...

Page 6: ...tails 11 5 0 Site Requirements 15 6 0 Boiler Internal Wiring 20 7 0 Installation 21 8 0 Completion Commissioning 25 9 0 Annual Servicing 27 10 0 Changing Components 29 11 0 Setting the Gas Valve 33 12 0 Fault Finding 34 13 0 Short Parts List 38 14 0 Notes 39 Benchmark Checklist 42 Section Page Contents ...

Page 7: ...ed on sealed or open vented systems It must NOT be fitted on any type of gravity system The boiler is suitable for fully pumped systems ONLY 8 The boiler is fitted with an integral pump unit for the removal of condensate 9 The boiler data badge gives details of the model serial number and Gas Council number and is situated on the front case panel 10 The boiler is intended to be installed in a resi...

Page 8: ...low Connection 17 Condensate Outlet 18 PCB Control Box shown removed for clarity 19 Boiler Control cover open The Boiler Control operates the boiler remotely This is supplied with the firefront and is fitted in operation to the firefront spacer frame IMPORTANT To commission the boiler it is is necessary to remove the Boiler Control from the firefront packaging and connect it to the boiler at the u...

Page 9: ... Fig 3a 1 Terminal Cap 2 Flue Duct Adaptor 3 Air Cowl 4 Air Duct Collar 5 Air Duct Clamp 6 Closure Plate 7 Boiler Adaptor 8 60mm Ø Seal 9 Collar Securing Screws x 4 10 100mm Ø Seal 11 60mm Ø Flue Duct 12 100mm Ø Air Duct 13 C Clip 1 2 3 4 5 6 7 8 9 10 8 11 12 Fig 3a 13 ...

Page 10: ...ss Max Min kW 17 1 5 7 Heat Output Non Condensing Max Min kW 15 0 4 88 Heat Output Condensing Max Min kW 15 7 5 25 Gas Rate Natural Gas G20 After 10 mins Max Min m3 h 1 63 0 54 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Boiler Power Consumption 112W Boiler Electrical Protection IPX0 Boiler External Fuse Rating 3A Connections Gas Supply 15mm compression Flow 22mm m...

Page 11: ...systems will be subject to corrosion unless they are flushed and an appropriate water treatment is applied To prevent this follow the guidelines given in BS 7593 Treatment of Water in Domestic Hot Water Central Heating Systems and the treatment manufacturers instructions Treatment must involve the use of a proprietary cleanser such as Sentinel X300 or X400 or Fernox F3 and an inhibitor such as Sen...

Page 12: ...ly 4 5 Fully Pumped Open Vent System Fig 5 1 The sizes of the system pipes should be determined by normal methods 2 The open vent pipe should be a minimum of 22mm and must rise continuously to a point above the feed and expansion tank 3 The flow pipe from the boiler form part of the vent pipe No part of the open vent may contain a valve 4 Inverted pipe runs must be avoided 5 On low capacity system...

Page 13: ... vertically upwards and close to the boiler No shut off valves are to be placed between the boiler and the safety valve The valve should be installed with a discharge pipe which permits the safe discharge of steam and hot water such that no hazard to persons or damage to electrical components is caused 3 Pressure Gauge A pressure gauge incorporating a fill pressure indicator covering the range 0 4...

Page 14: ... the return side of the hot water cylinder or the return side of all heat emitters or b Where access to a make up vessel would be difficult by using the mains top up method or a remote automatic pressurisation and make up unit 7 Mains Connection There shall be no connection to the mains water supply or to the water storage tank which supplies domestic hot water even through a non return valve with...

Page 15: ... recommended that it is a ground floor location 2 Restrictions to the siting of the appliance are covered by BS 5546 The appliance may not be installed in bathrooms or shower rooms bedrooms or bed sitting rooms 5 3 Fireplace Opening Surround 1 If a fireplace surround is to be used it must be centrally placed and have opening sizes as shown in Fig 9 5 4 Firefont Frame Extension Kit 1 To accommodate...

Page 16: ...ST NOT BE USED 3 The available flue kits are intended for installation within an existing chimney This should be clean and sound and any other previously installed flue components liners dampers etc removed 4 The flue must have a minimum vertical height of 3m and have no bends greater than 45 NO HORIZONTAL RUNS ARE PERMITTED 5 The terminal must be sited so that free passage of air across it can oc...

Page 17: ...rent I E E Wiring Regulations In IE reference should be made to the current edition of the ETCI rules The mains supply is 230V 50Hz fused at 3A NOTE The method of connection to the electrical supply must facilitate complete electrical isolation of the appliance Connection may be made via a fused double pole isolator with a contact separation of at least 3mm on all poles and serve the boiler and sy...

Page 18: ...te outlet is positioned at the top right front of the boiler It is 10mm diameter plastic 3 3 5 metres of flexible 10mm condensate discharge pipe and a 10mm push fit elbow are supplied with the boiler 4 The 10mm pipe can be routed to a maximum of 3 5 metres vertically and then discharge via gravity or be routed horizontally A combination of vertical and horizontal runs is permissible 5 The pipe mus...

Page 19: ...s 3 When the level of condensate in the sump is sufficient to activate the discharge float switch the pump will run for 7 seconds during which time about 0 6 litres of condensate will be discharged 4 In the event of condensate not being discharged the safety float switch will operate when the volume of condensate in the sump reaches 1 05 litres Once the safety float switch has been activated the b...

Page 20: ...ting NTC Flow Sensor Fan GasValve OverheatThermostat Condensate Pump X400 X401 bk bk gr gr b b br bk g b br g y b br br b bk b br bk bk bk b br b y b Spark Generator Ignition Electrode 9 8 7 6 5 4 3 2 1 9 10 8 7 6 5 4 3 2 1 1 2 3 4 r r 1 4 2 5 3 1 2 a b bk bk grey gr gr gr Safety Float Switch Discharge Float Switch ON OFF Reset Mains Input Permanent Live to 3 Switched Live to 1 r bk bk bk bk r br ...

Page 21: ...uting of electrical cables within the builders opening that may be difficult once the boiler is in place 7 2 Flue System 1 The actual length of flue as opposed to the vertical distance from the boiler top to the chimney outlet MUST be established before commencing 2 The flue must have a minimum vertical height of 3m and have no bends greater than 45 NO HORIZONTAL RUNS ARE PERMITTED 3 Depending on ...

Page 22: ...g from the boiler flue outlet Grasp the adaptor and locate it into the boiler ensuring the two large barbs lock into position under the boiler top panel Fig 24 Fit the C clip to the adaptor to secure the flue It must fit into the barbs and clip securely into place Fig 24a 13 There will now be an excess of flue and air duct protruding from the chimney 14 Cut the excess concentric ducts to leave app...

Page 23: ... The flue duct adaptor can now be fitted in the same manner as the boiler adaptor Fig 31 18 Fit the terminal cap over the flue duct adaptor and air cowl Once the cap is clipped into position it cannot be removed easily without damage Fig 33 19 Cement over the closure plate and air duct collar to a depth of approximately 100mm Consideration should be given to the potential accumulation of snow in t...

Page 24: ...sion fitting on the gas cock The gas supply pipe must be routed from the right hand side 2 The positioning of the gas supply pipe must not restrict the servicing of the boiler or installation of the firefront 7 6 Electrical Connection 1 The boiler requires an electrical supply from the heating controls system WARNING The appliance must be earthed The input cable for the appliance should be 0 75mm2...

Page 25: ...oundness 7 Ensure all external controls e g room stat timer etc are calling for heat and turn on the mains electrical supply Turn the rocker switch at the top right of the boiler to ON The fan and condensate pump will run briefly 8 The display will count down from 7 to 0 then the current water temperature will be displayed 9 When there is a demand for heating the bar on the top left of the display...

Page 26: ... with all other gas appliances in the property working Measure the Gas Rate 17 With any other appliances pilot lights turned OFF the gas rate can be measured It should be between 1 55 and 1 71m3 h 18 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the boiler and installation These details will be required in the...

Page 27: ... 9 2 The operational gas inlet pressure as described in Section 8 2 14 to 8 2 16 and the gas rate as described in 8 2 17 The combustion performance as described in 9 1 5 to 9 1 6 Competence to carry out checking Combustion Performance B S 6798 Specification for Installation Maintenance of Gas Fired Boilers not exceeding 70kW advises that The person carrying out a combustion measurement should have...

Page 28: ...ng nuts and remove the special spring washers Remove the complete fan panel assembly from the boiler 11 Lay the assembly to one side The outer insulation panel is fitted to the rear of the combustion box panel 12 Clean inside the heat exchanger and examine the condition of the fins 13 Examine the burner electrodes insulation and seal replacing if necessary Also check the condition of the three ins...

Page 29: ...are pushed fully on to their terminals 10 3 Electrode Assembly Fig 47 1 Note the position of the two leads on the electrode assembly and disconnect them Disconnect the in line connection on the black wire and the earth wire 2 Undo the securing screws and remove the electrode assembly and earth tag from the combustion box panel 3 Replace in reverse order of dismantling using the screws previously r...

Page 30: ...PLATE 7 Remove the securing screws and transfer the fan inlet to the new fan Use a new sealing gasket if necessary 8 Replace in reverse order ENSURE THAT THE RESTRICTOR PLATE IS CORRECTLY FITTED THE SLOT MUST BE TO THE REAR Check the condition of the sealing gaskets between the fan and gas air inlet and the combustion panel and heat exchanger and replace if necessary 10 6 Burner Fig 50 1 Proceed a...

Page 31: ...e inlet adaptor and remove the screws securing the adaptor to the boiler side panel 4 Remove the valve complete with the inlet and outlet adaptors and the seal on the inner face of the side panel Transfer the adaptors to the new valve using new O rings if necessary 5 Replace in reverse order of dismantling using the screws previously removed Examine all sealing gaskets and washers and replace if n...

Page 32: ...The thermostat is not polarised either wire can fit either terminal on the thermostat 10 12 Float Switches Fig 55 1 Remove the fan as described in Section 10 5 paragraphs 1 to 5 2 The two float switches are the same but oriented differently The discharge switch is at the left the safety at the right 3 To remove either switch disconnect the lead and pull off the alignment bracket 4 Undo the retaini...

Page 33: ...tment of the gas valve Remove the plastic cover from the Max Rate adjustment screw At maximum rate the Max Rate adjustment screw should be turned using a suitable hexagon key until the correct reading is obtained Fig 62 Turning clockwise will reduce the CO2 Anticlockwise will increase the CO2 9 The CO2 must then be checked at minimum rate Turn the left hand knob fully anti clockwise As the knob is...

Page 34: ...eset when Service Boiler Control reset counters are out of step Boiler Control default not restored correctly E158 indicates a condensate discharge system fault 3 By pressing the Reset button on the Boiler Control for a minimum of 5 seconds when E110 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...

Page 35: ...eration sequence successful If the error 110 is still flashing Go to section I Fan runs at correct speed YES YES NO NO NO YES YES YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO NO Burner output modulates to maintain the temperature set Burner goes out Go to section C Ensure controls are set to demand and verify the contacts are closed Error 160 flashing Go to section K YES Go to section G ...

Page 36: ...s at burner Ensure gas is on and purged Replace PCB Replace gas valve PCB X3 connector is 230V AC across terminals 1 2 YES NO NO F Check and correct the connection of the tube between the venturi and gas valve 1 2 Service Reset Condensate Pump does not run On Reset is there 230V at PCB X3 connector terminals 5 6 for at least 2 seconds Replace PCB NO Condensate Pump terminals for at least 2 seconds...

Page 37: ... seconds Fan connections correct at fan PCB X401 connector terminals 5 6 7 8 YES Replace fan Temperature sensors faulty Cold resistance approximately 10kΩ 25 C CH sensor resistance reduces with increase in temp NO Replace sensor YES If pump is running the heat exchanger could be obstructed Replace heat exchanger 1 2 Restore Boiler Control defaults NO Continuity across plug terminals at 3 4 of conn...

Page 38: ...rt No A Burner Assy 720125701 B Injector 720126301 C Ignition Lead 720127501 D Gas Valve 720127001 E P C B 720125801 F Fan 5121447 G NTC Sensor 720126101 H Float Switch Safety or Discharge 720126201 I Safety Thermostat 720126401 J Spark Generator 5114766 K Condensate Pump 720125901 H I A G E B F D K J C ...

Page 39: ...39 Baxi Heating UK Ltd 2009 14 0 Notes ...

Page 40: ...40 Baxi Heating UK Ltd 2009 14 0 Notes ...

Page 41: ...14 0 Notes 41 Baxi Heating UK Ltd 2009 ...

Page 42: ... a d r o c c a n i d e l l a t s n i n e e b s a h n i a r d e t a s n e d n o c e h T ALL INSTALLATIONS O C g n i w o l l o f e h t d r o c e r r e r u t c a f u n a m e h t y b d e r i u q e r f I 2 OR CO ppm OR CO CO2 Ratio s e Y s n o i t a l u g e R g n i d l i u B e t a i r p o r p p a e h t h t i w s e i l p m o c m e t s y s r e t a w t o h d n a g n i t a e h e h T s e Y s n o i t c u r t...

Page 43: ...Comments Signature SERVICE 9 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 2 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 4 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 6 Da...

Page 44: ...team is on hand to help Simply call our service division heateam on 0844 871 1525 to book an engineer visit or for any general advice that you may need Our contact centre is open Monday to Friday 8am 6pm weekends and Bank Holidays 8 30am 2pm excluding Christmas Day and New Years Day When calling heateam it would be helpful if you could have the following information to hand 1 Boiler serial number ...

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