Baxi Megaflo System 15 HE A Installation & Servicing Instructions Manual Download | Manualshive

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6.0 System Details

© Baxi Heating UK Ltd 2013

6.1

Central Heating Circuit

1. The appliance is suitable for fully pumped SEALED SYSTEMS
ONLY.

Treatment of Water Circulating Systems
1. All recirculatory water 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.

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 products, for further
information contact Sentinel (0800 389 4670) or Fernox
(0870 870 0362).

Failure to flush and add inhibitor to the system will
invalidate the appliance warranty.

4. It is important to check the inhibitor concentration after
installation, system modification and at every service in
accordance with the inhibitor manufacturer’s instructions.
(Test kits are available from inhibitor stockists.)

5. For information or advice regarding any of the above
contact Technical Enquiries 0844 871 1555.

6.2

Bypass

1. The boiler is fitted with an automatic integral bypass.

6.3

System Control

1. For optimum operating conditions, the heating system into
which the boiler is installed should include a control system.

2. Such a system will comprise of a timer control and separate
room or cylinder thermostats as appropriate.

3. The boiler should be controlled so that it operates on
demand only.

4. Operation of the system under control of the boiler
thermostat & TRV’s only does not produce the best results.

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Summary of Contents for Megaflo System 15 HE A

Page 1: ...2013 Megaflo System HE A Range Gas Fired Wall Mounted Condensing Boiler Installation Servicing Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping ...

Page 2: ...sary to ensure compliance with Building Regulations Baxi Heating UK Ltd 2013 All rights reserved No part of this publication may be reproduced or transmitted in any form or by any means or stored in any retrieval system of any nature including in any database in each case whether electronic mechanical recording or otherwise without the prior written permission of the copyright owner except for per...

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: ...n reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation All systems must be thoroughly flushed and treated ...

Page 5: ...s 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 transport the boiler using a sack ...

Page 6: ... Fixings 11 6 0 System Details 12 7 0 Site Requirements 14 8 0 Flue Options 20 9 0 Plume Displacement 25 10 0 Installation 29 11 0 Commissioning 34 12 0 Completion 36 13 0 Servicing 37 14 0 Changing Components 39 15 0 Setting the Gas Valve 46 16 0 Electrical 47 17 0 Short Parts List 48 18 0 Fault Finding 49 Benchmark Checklist 54 Section Page ...

Page 7: ... panel It is visible when the case front panel is removed Fig 1 6 The boiler model name and serial number are also shown on the information label on the rear of the lower door panel This is for user reference 7 The boiler is intended to be installed in residential commercial light industrial E M C environments on a governed meter supply only 8 The boiler must be installed with one of the purpose d...

Page 8: ...Box 10 Gas Valve 11 Condensate Trap 12 Flame Sensing Electrode 13 Spark Electrode 14 Primary Heat Exchanger 15 Fan Assembly 16 On Off Reset Selector Switch 17 Central Heating Temperature Control 18 Calibration Control 19 Venturi 20 Air Gas Collector 21 Combustion Box Cover Burner 22 Igniter 23 Burner On Light 24 Central Heating Mode Light 25 Display 1 16 17 18 7 bar 0 1 2 3 4 21 2 3 4 5 6 7 8 9 10...

Page 9: ...ode is integral to the appliance and functions when the selector switch see Section 2 1 is in the ON position If the system temperature falls below 5 C then the boiler will fire on its minimum setting until a flow temperature of 30 C is reached Further protection can be incorporated by using a system frost thermostat 3 3 Pump Protection 1 With the selector switch see Section 2 1 in the ON position...

Page 10: ...in In Operation This is the MINIMUM recommended dimension A greater clearance will aid installation and maintenance Heat Input Net Max Min 15 model kW 15 4 4 18 model kW 18 5 4 3 24 model kW 24 7 7 28 model kW 28 9 9 7 32 model kW 32 8 9 7 Heat Output Non Condensing Max Min 15 model kW 15 3 9 18 model kW 18 4 2 24 model kW 24 6 8 28 model kW 28 9 4 32 model kW 32 9 4 Electrical Supply 230V 50Hz Ap...

Page 11: ...00mm D C B A E G F At least 1 5 H Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 130 mm 130 mm 65 mm Condensate Drain 32 5 mm Tap Rail Dimensions A 780mm B 345mm C 450mm D 116mm Ø Min E 185mm 207mm for 80 125mm flue systems F 145mm G 131mm H 180mm ...

Page 12: ...9 4670 or Fernox 0870 870 0362 Failure to flush and add inhibitor to the system will invalidate the appliance warranty 4 It is important to check the inhibitor concentration after installation system modification and at every service in accordance with the inhibitor manufacturer s instructions Test kits are available from inhibitor stockists 5 For information or advice regarding any of the above c...

Page 13: ...efore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Domestic Gas Installations 6 6 Safety Pressure Relief Valve Fig 4 1 The pressure relief valve is set at 3 bar therefore all p...

Page 14: ...ng Regulations In IE reference should be made to the 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 7 2 Clearances Figs 5 6 1 A flat vertical ar...

Page 15: ...t edition of ETCI rules 2 The mains supply is 230V 50Hz fused at 3A NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection may be via a fused double pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only 3 When the system includes an indirect domestic hot water...

Page 16: ...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 less than 3 metres 7 Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe 8 External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external us...

Page 17: ... emptied then back pressure may force water out of the boiler trap and cause appliance lockout Boiler 2 5 Minimum fall iii Termination to a drain or gully Boiler 500mm min 2 5 Minimum fall iv Termination to a purpose made soakaway Holes in the soak away must face away from the building 50mm per metre of pipe run 50mm per metre of pipe run Further specific requirements for soakaway design are refer...

Page 18: ...ce Heating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to Boiler vi pumped into an external soil vent pipe 2 5 Minimum fall 50mm per metre of pipe run Condensate Pump Unheated Location e g Garage Basement or similar heated Boiler 2 5 Minimum fall 50mm per metre of pipe run Pipe must terminate above water level ...

Page 19: ...elow Opening Window or Door 150mm MIN IMPORTANT If fitting a Plume Displacement Flue Kit the air inlet must be a minimum of 150mm from any opening windows or doors see Section 9 0 Plume Displacement Kit Air Inlet Fig 10 Terminal Position with Minimum Distance Fig 9 mm A1 Directly below an opening air brick opening windows etc 300 B1 Above an opening air brick opening window etc 300 C1 Horizontally...

Page 20: ... 20 metres 4 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 135 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 135 bend 0 25 metres 91 5 bend 0 50 metres The elbow supplied with the standard horizontal telescopic flue kit is not included in any equivalent length calculations NOTE Flue length is measured from point i...

Page 21: ...No of fittings pipes Sub total Equivalent Length Value Equivalent Length Air Duct 6 5m 1m extension 135 bend 91 5 bend 1m 0 25m 0 5m 5 2 2 5 0m 0 5m 1 0m FLUE DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Flue Duct 6 5m ii i C Roof Terminal A B 660mm This bend is equivalent to 1 metre Total Equivalent Length A B C 1x90 Bend All vertical and angled runs must be inclu...

Page 22: ... pair 90 5111072 G Flue Bend 2 pair 135 5111086 J Vertical Flue Boiler Adaptor Kit 720089801 H Vertical Flue Adaptor 5111084 W Pipe Support pair 80mm 5111081 Y Flue Termination Kit horizontal termination 80mm 5120172 Z Single Terminal 80mm 5121791 Q Adaptor 60 80 5121792 T Pitched Roof Terminal 25 45 5106164 FLUE GROUP G Flue System 80 125mm diameter A4 Horizontal Flue Kit 5118580 B Straight Exten...

Page 23: ... adaptor in the boiler adaptor making sure that it is pushed down as far as possible 2 Ensure that the air flue ducts are connected correctly and that they are adequately supported at least once every metre using the available pipe supports 3 Ensure that all joints and elbows are fully engaged and cannot become disconnected during operation Flue Duct Connection Boiler Adaptor Air Duct Connection ...

Page 24: ...tely after the flue system temporary precautions must be taken to prevent rain entry into the room of installation Any precautionary measures must be removed prior to commissioning the boiler 8 7 Flue Dimensions The standard horizontal telescopic flue kit allows for lengths between 315mm and 500mm from elbow to terminal Fig 11 The maximum permissible equivalent horizontal flue length is 10 metres ...

Page 25: ...e addition of extensions the length of either or both the 60 100 concentric and 60Ø exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow IMPORTANT The maximum equivalent length of concentric flue is 8 metres 24 28 32 14 metres 15 18 Additio...

Page 26: ... assembly and any extensions and the 60Ø exhaust and any extensions or additional bends Example 1 Not Permissible If for instance a concentric length of 5 metres was required and the 60Ø exhaust needed to be 6 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Where both lengths have been ...

Page 27: ...ure that the concentric assembly and any extensions fall back to the boiler at an angle of 3 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 60Ø exhaust can now be fitted Slide the adaptor over the plain end of the 60Ø exhaust Fig 22 and engage the exhaust in the terminal Slide the...

Page 28: ...the extension at 30mm as shown in two positions directly opposite each other Fig 27 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The remaining screw must be used to secure the adaptor to the concentric terminal 22 When the plume outlet is positioned under a balcony or other projection Fig 28 it must protrude at least 200mm it is ...

Page 29: ...t is preferable to use the vertical fixing slots 4 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 32 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 116mm 7 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 8 ...

Page 30: ...plied 3 The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPORTANT Make all soldered joints before connecting to the ...

Page 31: ...g 38 NOTE The flue elbow is angled at 93 degrees to ensure a fall back to the boiler 4 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 37 5 If the distance from the flue elbow to the outside face of the wall X in Fig 37 is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into the elbow 6 In instanc...

Page 32: ...rrect boiler operation and prevent water entering the flue 13 Make good between the wall and air duct outside the building 14 Fit the flue trim if required and if necessary fit a terminal guard see Section 8 8 8 9 CONCENTRIC VERTICAL FLUE 15 Once the length of the vertical concentric extension has been determined mark and carefully cut off the excess material The cut end MUST be square and free of...

Page 33: ...tions supplied with the control IMPORTANT The external control MUST be suitable for 230V switching and fused 3A maximum 6 Remove the link between terminals 1 2 The switched output from the external control must be connected to terminal 1 Fig 47 7 Ensure that the external control input cable s have sufficient slack to allow the control box to drop down Tighten the cable clamp on the boiler chassis ...

Page 34: ... 1 5 bar then close and disconnect the filling loop 7 Turn the gas supply on and purge the system according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 8 Test for gas tightness 9 Hinge the facia panel upwards and refit the case front panel Tighten the securing screws IMPORTANT The combustion for this appliance has been checked adjusted and preset at the factory for operation on t...

Page 35: ...can be obtained with all other gas appliances in the property working Measure the Gas Rate 8 With any other appliances pilot lights turned OFF the gas rate can be measured It should be between 15 model 1 69 m3 h 18 model 1 95 m3 h 24 model 2 61 m3 h 28 model 3 1 m3 h 32 model 3 48 m3 h 9 The Calibration Function is active for 20 minutes unless the maximum CH temperature is exceeded 10 The function...

Page 36: ...e relevant to the appliance and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 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 a...

Page 37: ...ing the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Check the Combustion Performance CO CO2 ratio 4 Set the boiler to operate at maxim...

Page 38: ...n any debris from the heat exchanger and check that the gaps between the tubes are clear 11 Inspect the burner electrodes position and insulation cleaning or replacing if necessary Clean any dirt or dust from the air box 12 Reassemble in reverse order NOTE The sensing pipe must be reconnected to the fan not the venturi 13 Complete the relevant Service Interval Record section of the Benchmark Commi...

Page 39: ...iter Fig 64 1 Disconnect the igniter feed plug and the electrode leads noting their positions 2 Undo the screw securing the bracket to the boiler 3 Remove the igniter and transfer the bracket to the new component 4 Reassemble in reverse order 14 2 Spark and Sensing Electrodes Fig 66 1 Disconnect the electrode leads noting their positions 2 Remove the retaining screws securing each of the electrode...

Page 40: ...g that the injector is in place and the sensing pipe is connected to the fan 14 4 Venturi Fig 66 1 Remove the collector and fan assembly as described in section 14 3 2 Extract the injector from the venturi 3 Undo the screws securing the fan to the venturi and the venturi to the collector IMPORTANT When fitting the new venturi ensure the arrows on it s base point into the collector Fig 68 4 Examine...

Page 41: ...their positions Also remove the electrodes as described in section 14 2 2 Undo the screws securing the collector to the venturi and the nuts holding the cover to the heat exchanger Draw the collector and cover assembly away 3 Remove the cover insulation piece 4 Fit the new insulation carefully over the burner and align it with the slots for the electrodes 5 If the rear insulation requires replacem...

Page 42: ...e Sensor NTC Fig 72 1 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way 14 11 Safety Thermostat Fig 72 1 Pull the plug off the thermostat 2 Remove the screws securing the thermostat to the mounting plate on the flow pipe 3 Reassemble in reverse order ensuring that the plu...

Page 43: ...the body to the pipe and manifold and draw the pump forwards 3 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 4 Unscrew the automatic air vent from the pump body 5 Connect the wiring to the new pump Examine the O ring seals on the return pipe and manifo...

Page 44: ...ining barbs from their slots Disengage the rear of the cover from the control box hinge pin Fig 81 3 Note the position of all plugs and wires on the P C B and disconnect them 4 Undo the securing screws and remove the P C B Transfer the control knob drive pins to the new P C B and turn them fully anticlockwise 5 Reassemble in reverse order ensuring that the temperature controllers are reset to thei...

Page 45: ...ing that all seals are in place and the injector is fitted NOTE To assist the boiler to light prior to final setting use a suitable hexagon key to wind out the Throttle Adjustment Screw until it is flush with the valve body then turn the screw 4 full turns clockwise Fig 91a If the boiler will not light or the correct CO2 cannot be achieved contact the heateam technical helpline 14 24 Expansion Ves...

Page 46: ...nd back fully anticlockwise Fig 102 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 103 104 5 Turn the left hand knob fully clockwise As the knob is turned the display will change indicating the fan speed 6 The display will show 00 indicating maximum rate then revert to P alternating with the current boiler temperature Figs 105 106...

Page 47: ...an Gas Valve Overheat Stat Flame Sensing Electrode Pump Flue Sensor X401 r r b b b b b br bk g b br g y b br b br br b b b br br br b b br r bk r bk Spark Generator Ignition Electrode 9 10 8 7 6 5 4 3 2 1 N L w g 1 4 2 5 3 1 2 a b Link bk b g y br Mains Input Cable br b X9 Return Heating Temperature Sensor X400 g g b b Water Pressure Switch 9 8 7 6 5 4 3 2 1 b w 16 1 Illustrated Wiring Diagram ...

Page 48: ...4698 311 Fan 5114684 315 Igniter Electrode 720222801 316 Sensing Electrode 720222901 415 Pump 248042 419 Water Pressure Switch 5114748 420 Overheat Thermostat 5114729 421 NTC Sensor 5114725 422 Gas Valve 720301001 434 NTC Sensor Return 5114725 503 PCB 15 5122457 PCB 18 5122458 PCB 24 720045201 PCB 28 720795401 PCB 32 5122459 504 Pressure Gauge 248090 306 315 316 311 422 419 415 302 421 420 503 504...

Page 49: ... For example code E133 will be displayed by E1 alternating with 33 E20 is shown as E then 20 E20 and E28 indicate faulty components E110 shows overheat of the primary water and E130 overheat of the flue system E119 is displayed when the primary water pressure is less than 0 5 bar E133 indicates that the gas supply has been interrupted ignition has failed or the flame has not been detected E125 is ...

Page 50: ...flashing Burner does not stay alights after 5 seconds Error 133 flashing Go to section H Operation 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...

Page 51: ...onnector terminals 3 4 Replace PCB 2 NO Change pump supply cable YES B CH system pressure less than 0 5 bar Re pressurise system 1 YES Check the tap of the automatic air vent is opened Open the automatic air vent 2 NO C 1 NO YES Fan connections correct at fan PCB X2 connector is 230V AC across terminals 5 7 Fan jammed or faulty winding Replace PCB Replace fan YES D If pump jammed release NO NO Rep...

Page 52: ... 230V AC across terminals 1 2 YES NO NO F Replace PCB Check and correct if necessary 1 Ignition electrode and lead 2 Electrode connection 3 Spark gap and position Voltage at PCB X2 connector is at least 100V DC across terminals 2 5 Note from multimeter connect common to 2 volt to 5 Check wiring YES NO Replace igniter YES G Check and correct the connection of the tube between the venturi and gas va...

Page 53: ...he gas valve Minimum 17mbar H Replace safety thermostat YES NO Overheat thermostat operated or faulty i e continuity across thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm I J K Fan connections correct at fan PCB X401 connector terminals 5 6 7 8 1 YES Replace fan Temperature sensors faulty Cold resistance approximately 10kì 25 C CH sensor 20kì 25 C Flue ...

Page 54: ...em cleaner was used Gas Rate Burner Operating Pressure if applicable Central Heating Flow Temperature Central Heating Return Temperature Gas Rate Burner Operating Pressure at maximum rate Cold Water Inlet Temperature Hot Water has been checked at all outlets If required by the manufacturer record the following The heating and hot water system complies with the appropriate Building Regulations The ...

Page 55: ...Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments...

Page 56: ... 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 BAXI A Trading Division of Baxi Heating UK Ltd 3879156 Brooks House Coventry Road Warwick CV34 4LL After Sales Service 0844 871 1525 Technical Enquiries 0844 871 1555 Website www baxi co uk e oe ...

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