Benchmark MAIN Installation & Service Instructions Manual Download Page 49

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16.0 Short Part List

Key G.C.

Description

Manufacturers

No. No.

Part No.

Fan (18 HE)

5113278

Fan (24 HE)

5112627

Fan (28 HE)

5112430

Pressure Switch (18 HE)

5113280

Pressure Switch (24 & 28 HE)

248466

Heat Exchanger (18 HE)

5113284

Heat Exchanger (24 & 28 HE)

5112431

Burner (18 HE)

5113286

Burner (24 & 28 HE)

5112770

Injector 1.18 (18 & 24 HE)

247439

Injector 1.25 (28 HE)

5112376

E66 408

Electrode Lead

248037

E66 411

Spark or Sensing

Electrode

247384

E66 539

Pump

248042

102

Hydraulic Outlet Assy

248490

131

342 571

Temperature Sensor

247394

135

E66 439

Safety Thermostat

248079

140

Gas Valve

5107339

154

PCB

5112380

169

E66 453

Pressure Gauge

248090

528

Return Heating

248497

Temperature Sensor

371 Igniter/Gas

Valve

Cable

5112385

333

Flue Overheat

Thermostat

5112395

140

102

135

154

169

131

528

333

371

Summary of Contents for MAIN

Page 1: ...Baxi Heating UK Ltd 2007 Installation Service Instructions System HE Range These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping...

Page 2: ...ing systems to ensure safety and efficiency Building Regulations require that installations should comply with manufacturer s instructions It is therefore important that the commissioning checklist is...

Page 3: ...ty You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist Scheme Members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days...

Page 4: ...Safety Installation Use Regulations The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland The Water Fittings Regu...

Page 5: ...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...

Page 6: ...Dimensions and Fixings 13 6 0 System Details 14 7 0 Site Requirements 16 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 1...

Page 7: ...umber and is situated on the control box It is visible when the case front panel is removed Fig 1 6 The boiler is intended to be installed in residential commercial light industrial E M C environments...

Page 8: ...dary Heat Exchanger 18 On Off Reset Selector Switch 19 Temperature Control 20 Flame Failure or Blocked Condensate Drain 21 Safety Thermostat Activated Boiler or Flue 22 Fault on Fan or Flue 23 Fault o...

Page 9: ...boiler will not operate 3 2 Frost Protection Mode 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 t...

Page 10: ...Boiler unpressurised 1 2 Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Pressure Relief Discharge 15mm Temperatures Flow Temp adjustable 35 C to 85 C m...

Page 11: ...Boiler unpressurised 1 2 Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Pressure Relief Discharge 15mm Temperatures Flow Temp adjustable 35 C to 85 C m...

Page 12: ...Boiler unpressurised 1 2 Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Pressure Relief Discharge 15mm Temperatures Flow Temp adjustable 35 C to 85 C m...

Page 13: ...Dimensions A 780mm B 345mm C 450mm D 107mm Min E 185mm F 190mm G 131mm Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 130 mm 130 mm 65 mm Tap Rail 360 Orientation Tube...

Page 14: ...ing agents descalers should comply to BS7593 requirements e g Betz Dearborn Sentinel X100 and Fernox Copal which should be used following the inhibitor manufacturer s instructions Failure to flush and...

Page 15: ...liance 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 vessel must...

Page 16: ...ations 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 Publicat...

Page 17: ...fused at 3A maximum 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 co...

Page 18: ...itted 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...

Page 19: ...undary may not be less than 300mm in accordance with the diagram below Terminal Position with Minimum Distance Fig 9 mm Aa Directly below an opening air brick opening windows etc 300 Ba Above an openi...

Page 20: ...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 flue is not included in any equivalent length calculations 6 The illustrat...

Page 21: ...rom 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 without reduction of the flue length If further elbows are required the flue l...

Page 22: ...lue adaptor 5111070 P Wall Liner 5111067 S Flue Terminal Deflector 5111068 Twin Flue System 80mm diameter E Flue extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend pair 135 5111086...

Page 23: ...n the kit One marked 23 can be discarded The unmarked restrictor and the one marked 27 MUST be positioned as shown in the diagrams below 3 Take one of the gaskets supplied in the kit and place on the...

Page 24: ...be necessary From inside the roof adjust the flue to a vertical position and secure to the roof structure with the clamp supplied 8 7 Flue Dimensions The standard horizontal flue kit allows for flue l...

Page 25: ...nsions the length of either or both the 60 100 concentric and 60 exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length...

Page 26: ...ble If for instance a concentric length of 3 metres was required and the 60 exhaust needed to be 1 5 metres the graph shows that this combination would NOT be permissible as the intersection point wou...

Page 27: ...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 a...

Page 28: ...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 r...

Page 29: ...ea 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 supp...

Page 30: ...inuously downwards to a discharge point outside the building See section 6 6 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5...

Page 31: ...e the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 34 NOTE The flue elbow is angled at 93 degrees to ensure a fall back to the boiler 3 Measure the...

Page 32: ...will centralise the flue and air ducts and ease assembly Fig 37 8 Insert the flue through the hole in the wall Fit the elbow to the boiler adaptor ensuring that it is pushed fully in 9 Draw the flue b...

Page 33: ...nal control MUST be suitable for 230V switching and fused 3A maximum 8 Ensure that both mains input and any external control input cables have sufficient slack to allow the control box to drop down Ti...

Page 34: ...ions 5 Pressurise the system to 1 0 bar Fig 45 then close and disconnect the filling loop 6 Turn the gas supply on and purge the system according to in GB BS 6891 and in IE I S 813 Domestic Gas Instal...

Page 35: ...n Section 4 0 Technical Data If not check that the gas supply pressure is correct Natural Gas 20mbar and Propane 37mbar 8 The pressure can be adjusted if required 9 To check and set minimum pressure f...

Page 36: ...he 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 rec...

Page 37: ...emove the screws securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 54 7 Note the positions of the sensing tube s 28 HE has two one tube on 18...

Page 38: ...the burner Fig 57 17 Brush any deposits from the injectors Do not use a pin or wire to clean them 18 Brush the burner blades and venturis and clean the combustion box 19 Ensure that the heat exchanger...

Page 39: ...uring the combustion box door and remove the door 5 Ease the front edge of the left hand baffle upwards disengaging the spring clip Disengage the tabs on the baffle from the slots in the fan hood 6 Un...

Page 40: ...e the four screws securing the combustion box door and remove the door 2 On 28 HE models undo the screws securing the burner to the injector manifold 3 Draw the burner out of the combustion box pullin...

Page 41: ...he lead and grommet from the electrode being replaced Undo the securing screw and withdraw the electrode to the burner 4 Reassemble in reverse order 14 7 Insulation Fig 64 1 Remove the four screws sec...

Page 42: ...suring that the O ring seals are in place 10 Reassemble in reverse order and check the burner pressure as described in Section 11 2 14 9 Central Heating Temperature Sensor Fig 66 1 Ease the retaining...

Page 43: ...nt from the pump body Undo the two screws securing the body to the pipe and manifold and draw the pump forwards 2 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bla...

Page 44: ...utlet spigot and remove the locknut and spring washer securing the spigot to the boiler chassis 5 Undo the screws and remove the appliance upper cross member Slide the expansion vessel out of the reta...

Page 45: ...re controller is reset to the previous position 6 Ensure that the DHW potentiometer is fully anticlockwise once the new PCB is fitted 14 19 Selector Switch Fig 76 1 Note the setting of the selector sw...

Page 46: ...uired the complete valve assembly can be replaced 7 Examine the sealing washers and O ring on the pipes and capillary replacing as necessary 14 21 Central Heating Differential Valve Microswitch Fig 78...

Page 47: ...he outer drum by easing it forward 7 Reassemble in reverse order of dismantling 14 24 Flue Overheat Thermostat Fig 81 NOTE The flue overheat thermostat includes a reset button Check that the thermosta...

Page 48: ...2 A3 A4 A5 F2 1 bk bk r r g g 2 1 2 3 3 4 1 1 2 3 4 5 6 7 8 9 10 2 3 4 1 2 3 6 4 5 4 5 5 6 7 8 9 Central Heating NTC Sensor Fan Gas Valve Overheat Stat Hydraulic Differential Pressure Switch Air Press...

Page 49: ...12770 44 Injector 1 18 18 24 HE 247439 Injector 1 25 28 HE 5112376 59 E66 408 Electrode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 E66 539 Pump 248042 102 Hydraulic Outlet Assy 248490...

Page 50: ...temperature control to max Pump runs Air pressure switch proved neon flashing Burner on neon illuminated Burner output modulates until set temperature is reached Spark at ignition electrodes for up t...

Page 51: ...c air vent is opened Open the automatic air vent 2 NO NO C YES Continuity across flow microswitch and PCB A5 connector terminals 7 8 Replace microswitch 1 NO NO Flow or Return temperature sensor fault...

Page 52: ...1 A approx Replace PCB Replace PCB NO YES Replace flame sensing electrode NO YES Ensure that mains input terminal L is Live 230V and N is Neutral 0V I Check terminal 1 of On Off Reset selector is in...

Page 53: ...53 18 0 Notes Baxi Heating UK Ltd 2007...

Page 54: ...OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TE...

Page 55: ...NEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPAN...

Page 56: ...s 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 MAIN A Trading Division of Bax...

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