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Baxi ECOGEN 24/1.0, Installation & Servicing Instructions Manual

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Baxi ECOGEN 24/1.0 Installation & Servicing Instructions Manual Download Page 10

Appliance Hydraulic Resistance Chart

page 10

5.0 Dimensions and Fixings

Dimensions
A 950mm
B 426mm
C 450mm
D 116mm Ø Min.
E 190mm Allow at least 250mm for assembly and servicing
F 133mm
G 145mm
H 268mm
J 125mm

page 11

6.0 System Details

6.1 Water Circulating Systems

1. The appliance is only suitable for use on sealed systems.
2. Ideally fit a new sealed heating system to Building Regulations part L1 (2010). If an existing sealed system is to be used the following procedure must be completed before

the Ecogen is installed.

Summary of Contents for ECOGEN 24/1.0

Page 1: ...the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information Baxi Heating UK Ltd 2012 All rights reserved No part of this publication...

Page 2: ...d at the back of these instructions This company is a member of the Benchmark initiative and fully supports the aims of the programme Its aim is to improve the standards of installation and commission...

Page 3: ...ions section 15 87 G83 1 Energy Networks Association Engineering Recommendation G83 1 The recommendations for the connection of Small Scale Embedded Generators up to 16A per phase in parallel with Low...

Page 4: ...408 5500 or online at www gassaferegister co uk Type test for purpose of Regulation 5 certified by Notified Body 0087 Product Production certified by Notified Body 0086 For GB IE only page 4 Safe Man...

Page 5: ...set to give a maximum output of 24 kW Heat 1kW Electric 3 The boiler is suitable for use only on fully pumped sealed systems 4 The boiler data badge gives details of the model serial number and Gas C...

Page 6: ...Electrode 9 Engine Gas Valve 10 Gas Inlet 11 Boiler Flow 12 Boiler Return 13 Engine Alternator 14 PCB Control Cover 15 Water Flow Sensor 16 Safety Thermostats 17 Flow Temperature Sensor 18 Condensate...

Page 7: ...flow is 4 0 L min or above the ignition sequence will start 2 When the flow temperature reaches the set point temperature a 5 minute delay occurs before the burner relights automatically anti cycling...

Page 8: ...0 C 3 If an existing room thermostat is to be used then further protection for the system can be incorporated by using a wall mounted frost thermostat In certain circumstances it may be necessary to f...

Page 9: ...IPX4 External Fuse Rating 13A Internal Fuse Rating for pump diverter valve 3 15A Condensate Drain To accept 21 5mm 3 4 in plastic waste pipe Flue Terminal Dimensions Diameter 100mm Projection 125mm C...

Page 10: ...y and servicing F 133mm G 145mm H 268mm J 125mm page 11 6 0 System Details 6 1 Water Circulating Systems 1 The appliance is only suitable for use on sealed systems 2 Ideally fit a new sealed heating s...

Page 11: ...re from the boiler and include any branches Fig 4 Fig 4 6 4 Bypass Requirements 1 An Automatic Bypass must be fitted The appliance requires a minimum bypass of 7 l min for open vented systems 6 5 Magn...

Page 12: ...liance as standard It can be mounted on a wall cradle and configured to use as an room sensor IMPORTANT Before running the appliance ensure parameter 5700 has been set according to the type of system...

Page 13: ...the lifting equipment Genie GL 8 lifting equipment dimensions are 64cm wide x 175cm high x 95cm deep This space must be maintained for future access of the lifting equipment for maintenance 3 Wall str...

Page 14: ...482 1 Propane Gas In IE this is the current edition of I S 813 Domestic Gas Installations 2 A gas service cock is supplied to enable connection using 15mm copper pipe Fig 11 3 Ensure that the pipework...

Page 15: ...ibution networks 7 The Distribution Network Operator DNO must be provided with information regarding the SSEG Guidance Notes installation on the day of commissioning A notification sheet is provided w...

Page 16: ...oad protective device and Ig is the rated output current of the Ecogen This may require the protective device to be replaced with one having a lower nominal current rating Disconnection of the final c...

Page 17: ...guidance 3 The discharge 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 shou...

Page 18: ...ing must be considered If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC s are flushed or sinks emptied then back pressure may force water out of the boiler trap and...

Page 19: ...5 metre 720664401 Where the drain is between 3 5 metres a 5 metre kit can be used and doubled back upon itself 14 It is possible to fit the element externally on the condensate drain or internally as...

Page 20: ...w etc 300 C1 Horizontally to an opening air brick opening window etc 300 D2 Below gutters soil pipes or drain pipes 25 75 E2 Below eaves 25 200 F2 Below balconies or car port roof 25 200 G2 From a ver...

Page 21: ...ible equivalent flue lengths are Horizontal Concentric 60 100 5 metres 5 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes...

Page 22: ...e Vertical Concentric 60 100 5 metres Vertical Twin Pipe 80 80 10 metres 2 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipe...

Page 23: ...Length A B C 1x90 Bend All vertical and angled runs must be included measured from the boiler adaptor point X to the joint with the flue terminal point Y One 91 5 bend or two 135 bends can be included...

Page 24: ...elbow 5118069 A Horizontal Flue Terminal incl elbow 5118489 B Flue Extension 1000mm 5111074 C Flue Bend 93 5111075 D Flue Bend pair 135 5111085 U Pipe Support painted 100mm 5111080 P Wall Liner 51110...

Page 25: ...it is pushed down as far as possible 8 5 Air duct adaptor Fig 18 1 Undo the screws securing the blanking plate to the boiler top panel Discard the plate 2 Take one of the gaskets supplied in the kit a...

Page 26: ...om inside the roof adjust the flue to a vertical position and secure to the roof structure with the clamp supplied 2 For flat roof installations the aluminium flashing must be incorporated into the ro...

Page 27: ...n 315mm and 500mm from elbow to terminal Fig 19 The maximum permissible equivalent horizontal flue length is 5 metres Fig 19 Fig 20 Fig 21 8 8 Flue Trim 1 The rubber flue trim supplied may be fitted t...

Page 28: ...igs 21c 21d and be at least 2 metres above ground level It must be secured as shown in Fig 15a The plume outlet must also be at least 500mm from the air inlet in any direction Fig 21d NOTE The outlet...

Page 29: ...embly and any extensions and the 60 exhaust and any extensions or additional bends Example 1 Not Permissible If for instance a concentric length of 4 metres was required and the 60 exhaust needed to b...

Page 30: ...ertical thick dotted line Where this dotted line intersects with the solid diagonal line on the graph project across to the vertical axis As can be seen this corresponds with 4 0 metres Therefore the...

Page 31: ...ler at an angle of at least 1 5 and that the external air inlet is to the bottom 8 Use suitable brackets to support the concentric assembly and any extensions and make good inside and outside 9 The 60...

Page 32: ...the female end of the extension at 30mm as shown in two positions directly opposite each other Fig 21q 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the s...

Page 33: ...he six most suitable fixing holes for the wall plate positions B C as marked on the template Where possible mark the position of the centre top fixing position A marked on template 3 Mark the position...

Page 34: ...ll plate Figs 27 28 Ensure that there is adequate clearance for the lifting equipment see Section 7 2 2 Push the appliance back onto the wall plate and engage the securing nuts at the top of the appli...

Page 35: ...ing Remove the bottom cover and lower the control tray See Section 10 1 paragraph 3 and Figs 40 and 41 Install with the test nipple to the left see Fig 11 this allows the connection to the appliance t...

Page 36: ...s painted white On the Terminal Assembly the outer duct is unpainted 2 The two sections can be adjusted to provide a length between 315mm and 500mm Fig 31 when measured from the flue elbow there is 50...

Page 37: ...the boiler adaptor ensuring that it is pushed fully in Fig 36 11 Draw the flue back through the wall and engage it in the elbow It may be necessary to use soap solution or similar to ease assembly of...

Page 38: ...d remove the cover Fig 40 3 Remove the two screws holding the control tray Pull the front of the control tray forward and lower it carefully Fig 41 DO NOT allow the tray to fall in an uncontrolled man...

Page 39: ...he appliance ensure parameter 5700 has been set according to the type of system installed See sections 10 4 to 10 11 for system types and section 11 3 k for the change procedure NOTE All Fuses 3 15 A...

Page 40: ...s shown 2 Set parameter 5700 to 2 for one heating circuit see section 11 3 k 3 The DHW set point on the THINK Controller must be the same as the thermostat set point on the cylinder If this is not don...

Page 41: ...ter 5700 to 2 for one heating circuit see section 11 3 k 3 The rest port of the 3 port valve needs to be connected to the central heating circuit so that the valve is driven to the DHW position It is...

Page 42: ...o be connected to the central heating circuit so that the valve is driven to the DHW position It is most likely that the three port valve on an existing primary circuit will have to be turned round 4...

Page 43: ...an with DHW Cylinder sensor 1 The appliance MUST have a permanent Live Neutral Earth connection The pump must be connected to the appliance as shown 2 Set parameter 5700 to 2 for one heating circuit s...

Page 44: ...pump must be connected to the appliance as shown 2 Set parameter 5700 to 2 for one heating circuit see section 11 3 k 3 The DHW set point on the THINK Controller must be the same as the thermostat set...

Page 45: ...liance as shown 2 Set parameter 5700 to 3 for two heating circuits see section 11 3 k 3 To control the second heating circuit a second THINK Controller is required this is available as an optional ext...

Page 46: ...gh an external wiring centre To check the parameter see section 11 3 k As an external programmer will be used to control the central heating and domestic hot water times the installer must make sure t...

Page 47: ...THINK Controller is effectively an interface which allows the householder to programme the appliance to provide the desired comfort levels for the central heating and hot water It also gives informati...

Page 48: ...or Button to highlight operator section and press to select Turn the Selector Button to highlight Used as and press to select whilst flashing turn the Selector Button to show the desired room unit and...

Page 49: ...o the appliance 8 Switch on the appliance 9 If the THINK Controller has not been configured as a Room Sensor correctly you may see error 84 BSB collision If this does happen repeat from Section 10 13...

Page 50: ...11 Press the menu button to enter the user menu and then press and hold the easy menu and menu buttons until the other access levels appear Scroll down to the commissioning option and select by pressi...

Page 51: ...uctions 5 Pressurise the system to 1 5 bar then close and disconnect the filling loop 6 Turn the gas supply on and purge the system according to in GB BS 6891 Natural Gas BS 5482 1 Propane Gas and in...

Page 52: ...W setpoint on the THINK Controller is equal to or greater than the set point on the thermostat at the cylinder If this procedure is not performed the recovery time of the DHW maybe be increased unacce...

Page 53: ...correctly the THINK Controller s should show a small 1 and 2 next to the radiator along with the room unit symbol as in Fig 42 If it is required to replace the THINK Controller back on the appliance t...

Page 54: ...B S 6891 9 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Fig 49a STEP 1 STEP 2 STEP 3 STEP 4 page 56 10 Carry out the rate measurement The burn...

Page 55: ...ribed in Check the Combustion Performance 15 1 4 Competence to carry out Checking Combustion Performance B S 6798 Specification for Installation Maintenance of Gas Fired Boilers not exceeding 70kW adv...

Page 56: ...y signs of water damage and rectify any leaks 6 Generally check the conditions of the wiring of the appliance and the external wiring for and loose poor connections and remake if necessary 7 Inspect t...

Page 57: ...the burner door and manifold 6 Clean any debris form the heat exchanger and check that the gaps between the tubes are clear 7 Inspect the burner insulation and the electrodes clean or replace if neces...

Page 58: ...ir positions 2 Undo the screws securing the igniter and remove it being careful to retain the washers 3 Reassemble in reverse order 14 2 Supplementary Igniter and Sensing Electrodes Fig 57 1 Disconnec...

Page 59: ...5 Spool Valve Motor Figs 59 60 1 Remove the Fan Venturi Spool Valve Assembly as in section 14 4 2 Remove the 3 screws holding the motor in place 3 Reassemble in reverse order ensuring the motor drive...

Page 60: ...e manifold to the burner door and the supplementary venturi 2 Remove the manifold and the burner gasket 3 Withdraw the burner from the burner door and replace with the new one 4 Examine the gasket and...

Page 61: ...d align it with the slots for the electrodes 5 Inspect the rear insulation replace if cracked or broken It is retained by a small screw and a large washer Undo the screw carefully remove the insulatio...

Page 62: ...ti clockwise b Withdraw the sensor element c Reassemble in the reverse order there is a key way to ensure the sensor is lined up with the body correctly d Reconnect the 3 wire connector Fig 65a To rem...

Page 63: ...en swing the pipes away from the supplementary heat exchanger 5 Using a 5mm hex drive undo and remove the clamping collar between the supplementary heat exchanger and the engine burner 6 Disconnect th...

Page 64: ...corners Lift at the left hand side and disengage from the G83 24V power supply housing on the right 4 Carefully remove the connections There are three connections to each burner control unit BCU Four...

Page 65: ...he control tray pull the assembly forward and carefully allow the assembly to drop down 3 Remove the Mains connections from either side of the filter 4 Undo the screws securing the filter to the under...

Page 66: ...body anti clockwise and lower the trap until the electrical connections are visible between the gas valve brackets Detach the push on connections noting their positions 5 Withdraw the condensate trap...

Page 67: ...iler set flow temperature is set to 90 to avoid interruption of the rate measurement 4 After 1 minute remove the plug from the flue adaptor test point Insert the analyser probe and allow time for the...

Page 68: ...used to make the adjustment 6 Now check the combustion Carbon dioxide and Carbon Monoxide at the maximum rate for each air gas valve Using a Combustion Analyser to adjust the valve offset Follow the p...

Page 69: ...Fig 77 Fig 78 Fig 79 page 69 16 0 Schematic Wiring 16 1 Burner Control Units BCU Connections...

Page 70: ...page 70 16 2 Milligrid 24 way Connector...

Page 71: ...page 71 16 3 14 way Connector...

Page 72: ...page 72 16 4 Engine Circuit...

Page 73: ...page 73 16 5 Power Monitoring 24Vdc Power Supply...

Page 74: ...page 74 16 6 External Connections External Wiring...

Page 75: ...in the flow temperature is not sufficient to satisfy demand within a certain time 4 Once these criteria are met the supplementary burner will be lit at the ignition rate 2 will appear next to the drop...

Page 76: ...ion of stored data for instance and implies that the PCB will have to be replaced page 77 17 4 List of Error Codes In the table below PCB Main Control Board BCU Burner Control Unit Error code Display...

Page 77: ...e spool valve did not register a correct calibration SR SR H page 78 Error code Display Description Lockout reset action Fault Section Eng Sup 270 exc temp diff h exch Excessive max temperature differ...

Page 78: ...st min AR C 400 Flow dir heat gen Return temperature flow temperature for longer than 3 minutes UR UR I 421 Eng bu exc temp diff h ex Engine burner excessive temperature difference across the heat exc...

Page 79: ...red LED will go out b on the appliance THINK Controller from the standard screen press the Selector Button twice after a few seconds the error symbol should disappear 3 The error will clear and the ap...

Page 80: ...be followed for your own safety Before servicing ensure that the boiler is cool with the engine head below 120 C otherwise there is a risk of electric shock even with the supplies disconnected The hea...

Page 81: ...t to the aerial and repeat the binding process If the problem persists check the connection of the aerial back to the main PCB if other units appear to be bound and operational replace the RF unit Err...

Page 82: ...the connector mounted on engine support bracket see Fig AA and the milligrid connection to the board If the connections are good and a thermocouple is found to be open circuit replace the thermocouple...

Page 83: ...the appliance operation will be restored The most likely reason for this error is air in the system it is therefore important to purge the system thoroughly A permanent 164 error indicates that the s...

Page 84: ...g cool down 3 WARNING The LFPSE remains dangerously hot after the burner is turned off and may continue to generate electricity until it cools Wait one hour after turning the engine burner off or ensu...

Page 85: ...page 87...

Page 86: ...page 88...

Page 87: ...page 89 Section P...

Page 88: ...page 90...

Page 89: ...page 91 Section Q Engine developing less than 950W after 15 minutes running at maximum rate...

Page 90: ...t 5132953 G Thermostat Overheat Kit 5132954 H Sensor Kit 5132955 J Spark Generator Kit 5132956 K Burner Supplementary Kit 5132957 L Ignition Electrode Recuperator Kit 5132958 M Sensor Recuperator Kit...

Page 91: ...page 93 page 94 page 95 page 96 MICRO CHP SYSTEM COMMISSIONING CHECKLIST...

Page 92: ...page 97...

Page 93: ...ts and feed in tariff Heating and Hotwater Industry Council HHIC page 98 Service Record It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Recor...

Page 94: ...uracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request BAXI A Trading Division of Baxi Heating UK Ltd 3879156 B...

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