Baxi EcoBlue 12 Heat ErP Installation And Service Manual Download Page 1

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Installation and Service Manual

Gas Fired Wall Mounted Condensing Boiler

United Kingdom

These instructions include the Benchmark Commissioning Checklist and should be left with the

user for safe keeping. They must be read in conjunction with the Flue Installation Guide.

EcoBlue Heat

12 - 15 - 18 - 21 - 24

Summary of Contents for EcoBlue 12 Heat ErP

Page 1: ...unted Condensing Boiler en United Kingdom These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping They must be read in conjunction with the Flue Installation Guide EcoBlue Heat 12 15 18 21 24 ...

Page 2: ...hmark initiative and fully supports the aims of the programme Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency Building Regulations require that installations should comply with manufacturer s instructions It is therefore important that the...

Page 3: ...ou 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 Install and Commissi...

Page 4: ... Control Panel Description 4 4 1 User Interaction Controller 4 5 Standard Delivery 4 6 Accessories Options 4 6 1 Optional Extras 5 Before Installation 5 1 Installation Regulations 5 2 Installation Requirements 5 2 1 Gas Supply 5 2 2 Electrical Supply 5 2 3 Hard Water Areas 5 2 4 Bypass 5 2 5 System Control 5 2 6 Treatment of Water Circulating Systems 5 2 7 System Details General 5 2 8 Low Head Ins...

Page 5: ... the Appliance 6 2 2 Connecting External Devices 6 3 Filling the System 6 4 Completing the Installation 6 4 1 Completion 7 Commissioning 7 1 General 7 2 Checklist before Commissioning 7 2 1 Preliminary Electrical Checks 7 2 2 Checks 7 3 Commissioning Procedure 7 4 Gas Settings 7 4 1 Chimney Sweep Mode 7 4 2 Chimney Sweep Mode Combustion Check 7 5 Configuring the System 7 5 1 Check the Operational ...

Page 6: ...r 10 3 8 Overheat Sensor 10 3 9 Return Temperature Sensor 10 3 10 Parameter Unit 10 3 11 Gas Valve 10 3 12 Control Fan Assembly 10 3 13 User Interaction Controller 10 3 14 Fan 10 3 15 PCB 10 3 16 Setting the Gas Valve CO2 Check 11 Troubleshooting 11 1 Error Codes Auto Reset 11 2 Lockout Condition 12 Decommissioning Procedure 12 1 Decommissioning Procedure 13 Spare Parts 13 1 General 13 2 Spare Par...

Page 7: ...tated in the Gas Safety Installation Use Regulations as may be amended from time to time Definition of competence A person who works for a Gas Safe registered company and holding current certificates in the relevant ACS modules is deemed competent In IE this must be carried out by a competent person as stated in I S 813 Domestic Gas Installations The addition of anything that may interfere with th...

Page 8: ...als important information Signals a referral to other instructions or other pages in the instructions 1 4 Abbreviations 1 2 Additional Documentation These Installation Service Instructions must be read in conjunction with the Flue Accessories Fitting Guide supplied in the Literature Pack Various timers external controls flue accessories etc are available as optional extras Full details are contain...

Page 9: ... in accordance with the rules in force and only used in a suitably ventilated location In GB the installation must be carried out by a Gas Safe Registered Installer It must be carried out in accordance with the current and relevant requirements of legislation and guidance including the Gas Safety Installation Use Regulations The appropriate Building Regulations either The Building Regulations The ...

Page 10: ... order Give all the instruction manuals to the user 1 6 Homologations 1 6 1 Certifications EC Declaration of Conformity Baxi Heating Uk Limited being the manufacturer distributor within the European Economic Area of the following Baxi EcoBlue Heat ErP declare that the above is in conformity with the provisions of the Council Directive 2009 142 EC 92 42 EEC 2004 108 EC 2006 95 EC 2009 125 EC 2010 3...

Page 11: ... 5440 Part 2 Ventilation BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems In IE the following Codes of Practice apply Standard Scope I S 813 Domestic Gas Installations The following standards give valuable additional information BS 5546 Installation of hot water supplies for domestic purposes BS EN 1...

Page 12: ...nd vacate the premises 8 Telephone the National Gas Emergency Service on 0800 111 999 WARNING Installation repair and maintenance must be carried out by a Gas Safe Registered Engineer in accordance with prevailing local and national regulations When working on the boiler always disconnect the boiler from the mains and close the main gas inlet valve After maintenance or repair work check the instal...

Page 13: ...ndling or lifting the route is clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straight bend your knees Don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible trans...

Page 14: ...Internal Fuse Rating Terminal Strip Fuse 1 6T Appliance Type C13 C33 C53 Nox Class 5 Water Content litres 1 7 Static Head max 25 metres Low Head 0 4m min System Detail fully pumped open vented sealed systems Electrical Protection IPX4D CO CO2 Ratio Up to a maximum of 0 004 Flow Temperature adjustable 30 C to 80 C 5 C Max Gas Rate Natural Gas G20 After 10 Mins m3 hr 12 model 1 42 15 model 1 75 18 m...

Page 15: ...ns for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet 2 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet See The back cover for contact details Baxi EcoBlue Heat ErP Rated heat output Seasonal space heating energy efficiency Auxiliary electricity consumption Other...

Page 16: ...ed ensure the clearance above the top of the flue elbow X is as shown in the table below 360 Orientation Tube Ø 100mm D C B A E F At Least 3 At Least 1 5 Flue length Y up to 1m 1m 2m 2m 3m 3m 4m 4m 5m 5m 6m Clearance X 30mm 84mm 134mm 186mm 238mm 290mm NOTE There must be no part of the air duct white tube visible outside the property after installation The flue seal should fit neatly and effect a ...

Page 17: ... Mains g y br b Loop Connector where no pressure switch fitted Key To Wiring Colours b Blue r Red br Brown g y Green Yellow All other wires are black FROM TO COLOUR LINK PRESURE SWITCH PRESURE SWITCH COMBI ONLY COMBI ONLY COMBI ONLY FLOW TEMP FLOW TEMP RETURN TEMP RETURN TEMP FLOW SENSOR FLOW SENSOR FLOW SENSOR HIGH LIMIT BLACK BLACK BLACK BLACK BLUE RED PSU PSU PSU PSU BLACK BLACK BLACK BLACK BLA...

Page 18: ... information label giving details of the model serial number and Gas Council number is situated on the front left underside of the outercase and is accessed by pulling forward gently Fig 1 7 The boiler data label is positioned on the inside lower right hand side of the boiler and can be seen when the outercase panel is removed Fig 1 8 The boiler is intended to be installed in residential domestic ...

Page 19: ...gas rate to achieve the optimum boiler operation If the boiler flow temperature exceeds the boiler set point the burner will turn off Fan and Gas Valve off 5 Overtemperature If a boiler overtemperature event occurs triggering the safety thermostat the burner shuts down Fan off and Gas Valve off A locking signal is generated and an error code is displayed 6 Lockout If a lock out error is displayed ...

Page 20: ...p 4 Exhaust Tube 5 Inlet Silencer 6 User Interaction Controller 7 Gas Cock 8 Air Pressure Switch 21 24 model only 9 System Drain Cock 10 Air Vent 11 Socket See Electrical Test Point 1 2 3 4 5 6 7 8 9 10 11 11 Socket See Electrical Test Point The test point enables engineers to perform preliminary electrical checks test for safe isolation etc ...

Page 21: ...information about the operating condition of the boiler 2 The RESET button lights up green when the boiler has a demand for CH or DHW 3 The button can flash in a range of colours and at different frequencies 4 The User Interaction Controller also has one rotary knob The rotary knob can be used to set the maximum flow temperature of the heating water Maximum temperature is 80 C 5 The temperature on...

Page 22: ...t Registration Card Envelope Fernox Leaflet Wall Template Product Leaflet Package Leaflet 4 6 Accessories Options 4 6 1 Optional Extras 1 Various items are available as optional extras Flue Accessories elbows extensions clamps etc refer to the Flue Accessories Fitting Guide supplied in the literature pack Remote relief valve kit 1M Condensate Drain Pipe Trace Heating Element 2M Condensate Drain Pi...

Page 23: ...dition of I S 813 Domestic Gas Installations 2 The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock It is not necessary for the gas supply pipework to be 22mm providing that the requirements in paragraph 5 2 1 3 below are achieved 3 Ensure that the pipework from the meter to the appliance is of adequate size and the demands of any other gas appliances i...

Page 24: ...pplied 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 2 Treatment must involve the use of a proprietary cleanser such as Sentinel X300 or X400 or Fernox F3 and an inhibitor such as Sentinel X100 or Fernox MB 1 3 Full instructions are supplied with the cleansing products for further...

Page 25: ...must extend at least 1 metre from the boiler and include any branches Fig 3 5 2 8 Low Head Installation Open 1 Using a close coupled arrangement the minimum head is as shown in the diagrams Figs 4 5 6 subject to the following conditions a The pump being adjusted to give a 20 C drop across the boiler b Ideally the pump should be fitted on the flow but providing that the cold feed and open vent pipe...

Page 26: ...e check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment Your attention is drawn to for GB Guidance G24 2 and recommendation R24 2 of the Water Regulations Guide ...

Page 27: ...e current edition of I S 813 Domestic Gas Installations and the current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing 5 3 2 Data Plate 1 The boiler data label gives details of the model serial number and Gas Counc...

Page 28: ...ge pipe should be run in a proprietary drain pipe material e g PVC PVC U ABS PVC C or PP 4 Metal pipework is NOT suitable for use in condensate discharge systems 5 The pipe should be a minimum of 21 5mm diameter and must be supported using suitably spaced clips of the correct design to prevent sagging 6 It is advisable that the full length of condensate pipe is run internally and preferably be les...

Page 29: ...o fit the element externally on the condensate drain or internally as detailed in the instructions provided 15 The fitting of a Trace Heating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to Boiler 2 5 Minimum fall iii Termination to a drain or gully Boiler 500mm min 2 5 Minimum fall iv Termination to a purpose m...

Page 30: ... Figs 9 10 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 These are MINIMUM recommended dimensions Greater clearance will aid installation and maintenance 35mm Min in Cupboard 625mm 370mm 190mm 5mm Min 5mm Min 500mm Min For Servicing Purposes In Operation 5mm Min 270mm At least 1 5 Fig 9 120mm...

Page 31: ...nal or external corner 25 300 I Above ground roof or balcony level 300 J From a surface or boundary line facing a terminal 600 K From a terminal facing a terminal Horizontal flue 1200 From a terminal facing a terminal Vertical flue 600 L From an opening in carport e g door window into the dwelling 1200 M Vertically from a terminal on the same wall 1500 N Horizontally from a terminal on the same wa...

Page 32: ...erminal guard must be provided 4 The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram opposite Fig 12 Reduction to the boundary is possible down to 25mm but flue deflector part no 5111068 or the appropriate Plume Displacement Kit must be used The nuisance factor must still be taken into account when these o...

Page 33: ...n the flue system must be taken into consideration Their equivalent lengths are 135 bend 0 5 metres 93 bend 1 0 metres 5 The elbow supplied with the standard horizontal telescopic flue kit is not included in any equivalent length calculations Flue length is measured from point i to ii as shown below Read this section in conjunction with the Flue Accessories Fitting Guide supplied with the boiler T...

Page 34: ...Flue Chimney Deflector 1 Push the flue deflector over the terminal end it may point upwards as shown or up to 45 either way from vertical Secure the deflector to the terminal with screws provided Fig 16 5 3 12 Flue Chimney Accessories For full details of Flue Accessories elbows extensions clamps etc refer to the Flue Accessories Fitting Guide supplied in the literature pack Flue Deflector Fig 15 F...

Page 35: ...locate the slots in the wall bracket over the horizontal tongues on the wall bracket As the boiler is pushed back the wall bracket spring latch will positively engage over the wall bracket Figs AA BB CC 9 Locate the slots in the safety bracket over the two vertical tongues on the wall bracket and secure with the two screws Fig CC Adjust the jack screw to ensure the boiler is fully vertical and the...

Page 36: ...as Condensing Boilers HHIC recommendations and Section 5 3 5 2 The hose will accept 21 5mm 3 4in 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 5 4 6 Connecting the Gas Supply Fig 23a 1 The elbow and nut assembly supplied must be used to connect to the gas supply The flared e...

Page 37: ... as X Fig 25 5 If the distance from the flue elbow to the outside face of the wall X in Fig 25 is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into the elbow 6 In instances where the dimension X Fig 25 is between 250mm and 315mm it will be necessary to shorten the Terminal Assembly by careful cutting to accommodate walls of these thicknesses 7 ...

Page 38: ...th the screws supplied Fig 30 It is essential that the flue terminal is fitted as shown to ensure correct boiler operation and prevent water entering the flue There must be no part of the air duct white tube visible outside the property after installation 15 Make good between the wall and air duct outside the building appropriate to the wall construction and fire rating 16 If necessary fit a termi...

Page 39: ...ey to colours b Blue br Brown w White o Orange gr Grey g y Green Yellow Fig 32 6 2 1 Electrical Connections of the Appliance 1 See Section 5 2 2 for details of the electrical supply 1 3 metres of 3 core cable are supplied connected to the boiler 2 Switched live must be connected to the brown live wire of the 3 core cable 6 2 2 Connecting External Devices 1 System Controls This boiler operates on a...

Page 40: ...5 2 9 for sealed system details and Section 5 4 4 for filling the condensate trap 6 4 Completing the Installation 6 4 1 Completion 1 Before turning on the electrical and gas supply to commission the boiler check that all the installation requirements for the chosen heating system and flue options have been satisfied 2 Ensure that the system is vented to expel any excess air ...

Page 41: ...ary electrical system checks should be carried out 2 These should be performed using a suitable meter and include checks for Earth Continuity Resistance to Earth Short Circuit and Polarity 7 2 2 Checks Check that the boiler has been installed in accordance with these instructions Check the integrity of the flue system and the flue seals Check the integrity of the boiler combustion circuit and the ...

Page 42: ...2 Follow the flow chart on the next page to comply with the requirement to check combustion on commissioning 3 Setting the boiler to maximum and minimum heat outputs is achieved as follows Press the button for 3 seconds CSM is activated and will go to the min rate Pressing again will make it adjust to max rate To exit press the RESET for 3 seconds Plug Analyser Probe Flue Sampling Point After refi...

Page 43: ...e seals door case seals Replace any seals that appear unsound Is CO 350ppm and CO CO2 ratio 0 004 TURN APPLIANCE OFF Call 0344 871 1525 for advice The appliance MUST NOT be commissioned until all problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with the GSIUR Note Check record the CO combustion rati...

Page 44: ...pliances in the property working Measure the Gas Rate 4 With any other appliances pilot lights turned OFF the gas rate can be measured It should be as shown in Section 3 1 Technical Data 5 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissio...

Page 45: ...tions This is in addition to the Benchmark Commissioning Checklist 5 Instruct the user in the operation of the boiler controls Hand over the User s Operating Installation and Servicing Instructions giving advice on the necessity of regular servicing 6 Demonstrate to the user the action required if a gas leak occurs or is suspected Show them how to turn off the gas supply at the meter control and a...

Page 46: ...of the normal operation of the boiler 5 When installed on a sealed system the method of repressurising the primary system should be demonstrated 8 2 Start up 1 Switch on the boiler at the fused spur unit and ensure that the time control is in the on position and any other controls i e room thermostat are calling for heat The boiler will begin its start sequence 8 3 Shutdown 1 If the CH system is s...

Page 47: ...ompetence to carry out Checking Combustion Performance B S 6798 Specification for Installation Maintenance of Gas Fired Boilers not exceeding 70kWh advises that The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or ...

Page 48: ...rsonal protective equipment must be used where appropriate 1 Unscrew the two screws located on the lower front panel Fig 36 2 Slide the lower front panel forward and hinge down or remove Fig 37 3 Unscrew the two securing screws on the front panel Remove the front panel Fig 38 4 Visually check for debris damage and clean or replace if necessary the following a Check the water pressure sealed system...

Page 49: ...mponents disconnect the electrode lead earth lead mains power cable and the main sensor harness from the board Re engage the fan protective cover 9 Disconnect the plug from the gas valve and undo the nut on the gas inlet pipe at the base of the valve 10 Remove the gas assembly Fig 38b from the boiler by releasing the over centre catches Fig 38a that secure it to the heat exchanger 11 Remove the ig...

Page 50: ...ecuring and remove the electrode and gasket 4 Fit the new electrode and if necessary replace the gasket Connect the electrode lead to the PCB and earth wire to the new electrode 10 3 2 Automatic Air Vent Fig 40 1 Remove the clip securing the automatic air vent 2 Manoeuvre the air vent out of the adaptor in the heat exchanger 3 Fit the new air vent and if necessary replace the O ring Refit the secu...

Page 51: ...Depress the retaining latch to release the pressure switch pull to the right and remove it from the top flue duct tube 3 Fit the new pressure switch ensuring the O ring is in place on the lower spigot and reconnect to the wiring harness from the overheat sensor 10 3 6 Socket See Electrical Test Point Fig 43a 1 Disconnect the test point wiring from the mains 3 core cable 2 Disengage the fan protect...

Page 52: ... the wiring 10 3 9 Return Temperature Sensor Fig 45 The sensor is fitted in a dry pocket 1 Disconnect the wiring from the return temperature sensor 2 Unscrew the sensor from the top of the heat exchanger 3 Fit the new sensor and reconnect the wiring 10 3 10 Parameter Unit Fig 46 1 Push the retaining latch to release the parameter unit and slide it upwards to remove 2 Disconnect the wiring from the...

Page 53: ...as valve from its seat and pull it gently downwards to release it from the fan assembly 8 Remove the 2 O Rings from the gas feed pipe and replace with new ones supplied in the kit Take care not to damage the O Rings when refitting Apply a small quantity of the silicone grease provided to aid reassembly of the gas valve Fig 49 9 Push the new gas valve onto the gas feed pipe taking care not to damag...

Page 54: ...manifold and set the manifold aside 8 Fit the burner manifold to the new fan and PCB assembly using the new seals and screws provided in the kit Do not overcompress the manifold gasket or use any grease Check visually that the gasket is correctly in place 9 Replace the gas valve ensuring new O ring seals are greased prior to replacing the pipe 10 Reassemble all components in reverse order When a s...

Page 55: ...e gas inlet pipe Fig 61c at the base of the valve and the four manifold securing screws Fig 53f Remove the cover by rotating through 180 and sliding to the right The fan gas valve assembly can now be removed 7 Remove the screws securing the gas valve to the fan Fig 53g Lift the valve from its seat and pull it gently downwards to release it from the fan assembly 8 The new fan and gas supply pipe ca...

Page 56: ...nt from its location and lower the cover fully 3 Wearing the ESD wrist strap disconnect the electrode lead earth lead and the main sensor harness from the PCB taking care not to touch any of the PCB components 4 Disconnect the electrical plug from the gas valve and remove the screws securing the fan driver PCB to the fan motor Fig 53i Note the 2 locating pins that align the PCB Fig 53j Push the re...

Page 57: ...e probe of the flue gas analyser 4 Check the CO2 is 9 3 0 1 If the CO2 is incorrect alter the Throttle Adjustment Screw Fig 57 Turn the screw anticlockwise to increase the CO2 or clockwise to decrease 2 5mm hexagon key Do not turn either adjustment screw more than 1 8 of a turn at a time Allow the analyser reading to settle before any further adjustment 5 Press the Chimney Sweep button twice to se...

Page 58: ... necessary replace control fan assy 5 flashes green Parameter fault Parameter error or faulty PU Configuration error or PCB fault Replace PU and recommission Replace control fan assy 6 flashes green Miscellaneous Internal fault in combustion control unit Replace combustion control unit Operation status and error codes are displayed on the chimney sweep button 3 on the control panel In normal opera...

Page 59: ...of flame detected Check earthing of the appliance Check ignition electrode condition and clean replace if necessary Check gas valve operation Check flue condition Check correct combustion gas valve settings 4 flashes red Fan fault Fan calibration error Fan failure If fan operates check flue installation and condition Replace control fan assy 5 flashes red Parameter fault Bad connection to PU Param...

Page 60: ...g 12 Decommissioning 12 1 Decommissioning Procedure 1 Isolate the gas electric supplies and disconnect them 2 Drain the primary circuit and disconnect the filling device 3 Dismantle the chimney system and remove the boiler from the wall mounting frame ...

Page 61: ...2 Spare Parts List Key Description Manufacturer s No Part No A Parameter Unit 7216298 B Sensor Kit 7216301 C Automatic Air Vent 7216300 D Ignition Sensing Electrode 7216299 E Pressure Switch 7212522 F Combustion Control Unit 7216292 G User Interaction Controller 7600498 H Gas Valve 7222055 I Control Fan Assembly 7618106 J PCB Only not illustrated 7223161 K Fan Only not illustreated 7223159 A B C D...

Page 62: ...equired Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL SYSTEMS s instructions Yes What system cleaner was used What inhibitor was used Quantity litres Yes No CENTRAL HEATING MODE measure and record Gas rate m hr OR ft hr Burner operating pressure if applicable mbar OR Gas inlet pressure mbar C Central heating return tem...

Page 63: ...e Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 06 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 07 Date Engineer name Company name Telephone No Gas safe register No Record At m...

Page 64: ...ll terms and conditions visit www baxi co uk terms Failure to adhere to terms and conditions will void your manufacturer s warranty Baxi Brooks House Coventry Road Warwick CV34 4LL Please ensure the boiler is installed in accordance with these installation instructions and that you adhere to the Building Regulations e oe All descriptions and illustrations provided in this document have been carefu...

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