Baxi Megaflo System 24 HE IE LPG Page 53 Installation & Servicing Instructions Manual Download

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

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Summary of Contents for Megaflo System 24 HE IE LPG

Page 1: ...20 6677 Baxi Heating UK Ltd 2011 Baxi Megaflo System HE IE Range Gas Fired Wall Mounted Condensing Boiler Installation Servicing Instructions These instructions include the Commissioning Checklist and should be left with the user for safe keeping ...

Page 2: ...database in each case whether electronic mechanical recording or otherwise without the prior written permission of the copyright owner except for permitted fair dealing under Copyrights Designs and Patents Act 1988 Applications for the copyright owner s permission to reproduce or make other use of any part of this publication should be made giving details of the proposed use to the following addre...

Page 3: ...ference should be made to the relevant British Standard Code of Practice 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 with inhib...

Page 4: ...ing 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 transpor...

Page 5: ...ta 9 5 0 Dimensions and Fixings 11 6 0 System Details 12 7 0 Site Requirements 14 8 0 Flue Options 18 9 0 Plume Displacement 23 10 0 Installation 27 11 0 Commissioning 32 12 0 Completion 34 13 0 Servicing 35 14 0 Changing Components 37 15 0 Setting the Gas Valve 45 16 0 Electrical 46 17 0 Short Parts List 47 18 0 Fault Finding 48 Commissioning Checklist 54 Section Page ...

Page 6: ...ssel It is suitable for use only on fully pumped sealed systems 5 The boiler data badge gives details of the model and serial number and is situated on the inner door 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 ...

Page 7: ...ure Gauge 8 PCB 9 Control 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 2 1 0 4 3...

Page 8: ...e 1 The frost protection mode 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 Sect...

Page 9: ...ce 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 Appliance must be connected to an earthed supply Power Consumption 15 model 130W 18 model 140W 24 model 150W 28 32 ...

Page 10: ...y Power Consumption 24 LPG model 150W 28 LPG model 160W Electrical Protection IPX5D Internal Fuse Rating F2L Appliance Category CAT II 2H3P Inlet Pressure Propane G31 mbar 37 Injector Propane Gas G31 24 LPG model 7 5mm 28 LPG model 12mm Appliance Type C13 C33 C53 Heat Output Condensing Max Min 24 LPG model kW 25 9 7 4 28 LPG model kW 30 3 10 2 Max Gas Rate Propane Gas G31 After 10 mins 24 LPG mode...

Page 11: ...011 360 Orientation Flue Ø 100mm D C B A E G F At least 1 5 H Heating Return 3 4 Heating Flow 3 4 Pressure Relief Valve 1 2 Gas Inlet 3 4 130 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: ...uld comply to BS7593 requirements e g Sentinel X100 and Fernox MB 1 which should be used following the inhibitor manufacturer s instructions 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 It is important to check the inhibitor conc...

Page 13: ... sufficient head in order to ensure a minimum system pressure of 0 2 bar 3 A suitable non return valve must be fitted in the pipework between the header tank and heating system 6 5 Expansion Vessel 1 The appliance expansion vessel is pre charged to 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres For greater system capacities an additional expansion vesse...

Page 14: ...ts 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 area is requir...

Page 15: ...r than the boiler gas connection 3 4 7 5 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In IE reference should be made to the current 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 Connec...

Page 16: ...s fitted in an unheated location the entire condensate discharge pipe should be treated as an external run 9 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used 10 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be conside...

Page 17: ... accordance with the diagram below 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 ...

Page 18: ... Horizontal Concentric all 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 lengt...

Page 19: ...d 1m 0 25m 0 5m 5 2 2 5 0m 0 5m 1 0m AIR DUCT 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 B...

Page 20: ...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 Extension Kit ...

Page 21: ... Engage the twin flue duct 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 Ada...

Page 22: ...ler is not fitted immediately 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 ...

Page 23: ...reduce or increase with the 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 ...

Page 24: ...between the concentric flue 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 Wh...

Page 25: ...he boiler adaptor 7 Ensure that the concentric assembly and any extensions fall back to the boiler 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 60Ø exhaust can now be fitted Slide the adaptor over the plain end of the 60Ø exhaust Fig 22 and engage the...

Page 26: ... end of 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 200m...

Page 27: ...lower fixing holes It is preferable to use the vertical fixing slots 3 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 34 4 If required mark the position of the gas and water pipes Remove the template 5 Cut the hole for the flue minimum diameter 116mm 6 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using ...

Page 28: ...he boiler Make up as much of the pipework as is practical including the discharge pipe supplied 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 t...

Page 29: ...required orientation Fig 41 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 40 5 If the distance from the flue elbow to the outside face of the wall X in Fig 40 is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into...

Page 30: ...tted as shown to ensure correct 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 ...

Page 31: ...ock 5 Refer to the instructions 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 50 7 Ensure that the external control input cable s have sufficient slack to allow the control box to drop down Tighten the cable cl...

Page 32: ...automatic air vent on the pump body Fig 52 5 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 6 On sealed systems it is recommended to pressurise the system to 1 5 bar then close and disconnect the filling loop On semi sealed systems ensure that the gauge is showing at least 0 2 bar 7 Turn the gas supply on and purge the system...

Page 33: ...operational working gas pressure at the inlet gas pressure test point Fig 55a is in accordance with B S 6798 B S 6891 7 Ensure that this inlet pressure 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 Natural Gas 15 model 1 69 m3 h 18 model 1 95 m3 h 24 mo...

Page 34: ...of this publication that are 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...

Page 35: ...ed should be one meeting 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 boile...

Page 36: ...cal plugs Fig 66 8 Undo the four nuts retaining the combustion box cover to the heat exchanger 9 Carefully draw the fan collector and cover assembly forward being careful to retain the injector in the venturi Figs 65 66 10 Clean 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 ne...

Page 37: ...se panel door etc 14 1 Igniter Fig 67 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 68 1 Disconnect the electrode leads noting their positions 2 Remove the retaining screws secu...

Page 38: ...e in reverse order ensuring that the injector is in place and the sensing pipe is connected to the fan 14 4 Venturi Fig 69 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 ...

Page 39: ...hanger 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 replacement remove it and all debris from the heat exchanger Also it may be necessary to separately remove the spring clip from the pin in the centre of the heat exchanger and the L ...

Page 40: ...ensor 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 75 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 plug is pushed fully on 14 12 Return Heating Temperature...

Page 41: ...o the two screws securing 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 ...

Page 42: ...t 4 Examine the sealing washer replace if necessary 5 Reassemble in reverse order 14 17 Pressure Relief Valve Fig 83 1 Drain the primary circuit 2 Disconnect the discharge pipe from the valve Using a suitable hexagon key undo the grub screw sufficiently to release the valve 3 Note the orientation of the valve rotate it and withdraw it from the manifold 4 Fit the new valve and O ring seal and set t...

Page 43: ...rn them fully anticlockwise 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 14 19 Selector Switch Fig 85 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover fro...

Page 44: ... pipe at the gas air inlet and the gas valve Remove the pipe taking care not to lose the sealing washers Remove the valve 5 Reassemble in reverse order ensuring 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...

Page 45: ...ttle Fig 94 The CO2 should be N G 8 7 0 2 L P G 10 0 2 8 It is possible to alter the CO2 by adjustment of the gas valve Remove the plastic cover from the Throttle Adjustment Screw At maximum rate the Throttle Adjustment Screw should be turned using a suitable hexagon key until the correct reading is obtained Fig 95 Turning clockwise will reduce the CO2 Anticlockwise will increase the CO2 9 The CO2...

Page 46: ...al Heating NTC Sensor Fan 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 Microswitch 9 8 7 6 5 4 3 2 1 b w Gas Valve 16 1 Il...

Page 47: ...11 Fan 5121447 315 Igniter Electrode 720222801 316 Sensing Electrode 720222901 415 Pump 248042 419 Microswitch 248067 420 Overheat Thermostat 5114729 421 NTC Sensor 5114725 422 Gas Valve 720301001 434 NTC Sensor Return 5114725 503 PCB IE 15 5129831 PCB IE 18 5129832 PCB IE 24 720045501 PCB IE 28 5129834 PCB IE 32 5129835 PCB IE 24 LPG 720045801 PCB IE 28 LPG 5129837 504 Pressure Gauge 248090 306 3...

Page 48: ...ree digit preceded by the letter E 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 fl...

Page 49: ...Go to section D Error 133 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 ...

Page 50: ...eplace pump 1 YES PCB X3 connector 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 pum...

Page 51: ... gas valve PCB X3 connector is 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 110V DC across terminals 2 5 Note from multimeter connect common to 2 volts to 5 Check wiring YES NO Replace igniter YES G Check and correct the connection of the tube between ...

Page 52: ... supply pressure Natural Gas minimum 17 mbar Propane minimum 37 mbar 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 approxim...

Page 53: ...Supplied By www heating spares co Tel 0161 620 6677 53 19 0 Notes Baxi Heating UK Ltd 2011 ...

Page 54: ...ORD GAS RATE ft3 hr BURNER OPERATING PRESSURE IF APPLICABLE mbar CENTRAL HEATING FLOW TEMPERATURE C CENTRAL HEATING RETURN TEMPERATURE C CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSI...

Page 55: ...NTS SIGNATURE SERVICE 7 DATE ENGINEER NAME COMPANY NAME TEL No ENGINEER ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No ENGINEER ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No ENGINEER ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No ENGINEER ID CARD SERIAL No COMMENTS SIGNATURE SERVI...

Page 56: ... prepared but we reserve the right to make changes and 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 Contact us For general enquiries contact branches nationwide For technical advice please contact 056 7720 023 For in warranty service contact 090 64...

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