Main System 24 Eco, Installation & Service Instructions Manual

Page 1: ...ng UK Ltd 2011 Installation Service Instructions System Eco Range These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Supplied by HeatingSpares247 com ...

Page 2: ...the Scheme Visit www centralheating co uk for more information 0086 ISO 9001 FM 00866 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England Wales require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as ...

Page 3: ...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 Commission ...

Page 4: ...ns in force Read the instructions fully before installing or using the appliance In GB this must be carried out by a competent person as stated in the Gas Safety Installation Use Regulations 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 pers...

Page 5: ...tructed 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 truck or other su...

Page 6: ...ystem Details 12 7 0 Site Requirements 14 8 0 Flue Options 18 9 0 Plume Displacement 23 10 0 Installation 27 11 0 Commissioning 33 12 0 Completion 35 13 0 Servicing 36 14 0 Changing Components 38 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 Supplied by HeatingSpares247 com ...

Page 7: ...ic plate It is visible when the case front panel is removed and the control box hinged down Fig 1 1a 6 The boiler model name and serial number are also shown on the information label on the back of the facia door 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 inst...

Page 8: ...Condensate Trap 13 Heat Exchanger Air Vent 14 Electrode Assembly 15 Primary Heat Exchanger 16 Fan Assembly 17 On Off Reset Selector Switch 18 Central Heating Temperature Control 19 Calibration Control 20 Water Pressure Sensor 21 Gas Air Inlet 22 Burner Mounting Panel 23 Igniter 24 Burner On Light 25 Central Heating Mode Light 26 Calibration Mode Light 27 Display 13 17 18 19 8 Reset bar 0 1 2 3 4 2...

Page 9: ...a 3 minute delay occurs before the burner relights automatically anti cycling The pump continues to run during this period 3 When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes Pump Overrun IMPORTANT When the selector switch is in the 0 Off position the electrical supply to the boiler is isolated The boiler will not operate 3 2 Frost Prot...

Page 10: ...m flue Below Casing 200 mm Min Front 450 mm Min For Servicing Front 5 mm Min In Operation L H Side 5 mm Min R H Side 5 mm Min In Operation Heat Input CH Net Max Min 24 model kW 26 06 7 82 28 model kW 29 32 8 8 Heat Output CH Non Condensing Max Min 24 model kW 25 94 7 61 28 model kW 28 63 8 56 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 150W Electr...

Page 11: ...be Ø 100mm D C B A G F H H Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 130 mm 130 mm 65 mm Condensate Drain 127 mm Dimensions A 780mm B 345mm C 450mm D 116mm Ø Min F 145mm G 132mm 210mm 80 125 H 225mm At Least 1 5o Supplied by HeatingSpares247 com ...

Page 12: ...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 concentration after installation system modification and at every servic...

Page 13: ...e the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres 18 24 155 litres 27 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 7 Safety Pressure Relief Valve Fig 7 1 The pressure relief valve is set at 3 bar...

Page 14: ...s In GB this is the current I E E Wiring Regulations and Building 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 Tim...

Page 15: ...t 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 cylinder it is recommended that a cylinder thermostat is used ...

Page 16: ...hould 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 considered If soil pipes or waste pipes are subjected to internal pressure flu...

Page 17: ...ith 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 Fig 18a Plume Displacement Kit Air Inlet Terminal Position with Minimum Distance Fig 18 mm A1 Directly below an opening air brick opening windows etc 300 B1 Above an opening air brick opening window etc ...

Page 18: ...ith the standard horizontal telescopic flue kit is not included in any equivalent length calculations NOTE Flue length is measured from point i to ii as shown IMPORTANT All flue systems must be securely supported at least once every metre Suitable pipe supports are available as accessories Horizontal Flues ii i Plume Displacement Kit 60 100 Ø 1M Extensions 45 93 elbows are also available see Secti...

Page 19: ...pe supports are available as accessories The total equivalent length for this example is 6 5 metres 1m extension 135 bend 91 5 bend 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 Equiv...

Page 20: ...System 80mm diameter E Flue Extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend 2 pair 135 5111086 J Vertical Flue Boiler Adaptor Kit 720089801 H Vertical Flue Adaptor 5111084 Y Flue Horizontal Terminal Kit 5120172 W Pipe Support pair 80mm 5111081 FLUE GROUP G Flue System 80 125mm diameter A4 Horizontal Flue Kit 5118580 B Straight Extension Kit 1000mm 5118584 D Bend Kit pair 135 ...

Page 21: ...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 Air Duct Connection Supplied by HeatingSpares...

Page 22: ...ANT If the boiler 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 flue kit allows for lengths between 100mm and 685mm from elbow to terminal Fig 19 The maximum permissible equivalent flue len...

Page 23: ...dition 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 Additional bends may be fitted in th...

Page 24: ... OK Where both lengths have been determined they can be applied to the graph to check that the installation is permissible For example if it was known that 2 metres of concentric flue and 4 metres of 60Ø exhaust were required the values could be applied to the graph as shown in Example 2 As the point of intersection of the dotted lines is below the solid diagonal line the combination of lengths is...

Page 25: ...ric 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 31 and engage the exhaust in the terminal Slide the adaptor ...

Page 26: ...30mm as shown in two positions directly opposite each other Fig 36 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 37 it must protrude at least 200mm it is not necessary to ...

Page 27: ...n of the centre of the flue hole rear exit For side flue exit mark as shown Fig 40 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 Using a spirit level ensure that the plate is level before finally ...

Page 28: ... 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 to the outside discharge point IMPORTANT Make all soldered joints before connectin...

Page 29: ...at 93 degrees to ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 48 4 To dimension X add 50mm This dimension to be known as Y IMPORTANT Check all dimensions before cutting 5 Mark dimension Y on the flue as shown Fig 49 Carefully cut the waste material from the flue ensuring that the ducts are square and free from...

Page 30: ...sembly Fig 51 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 back through the wall and engage it in the elbow It may be necessary to use soap solution or similar to ease assembly of the elbow adaptor and flue Fig 51 10 Ensure that the terminal is positioned with the slots to the bottom Fig 52 IMPORTANT It is es...

Page 31: ...iler adaptor 16 Measure 25mm from the end of the flue extension and apply a length of tape around the outer duct Fig 53 17 Engage the extension into the adaptor up to this position Fig 54 Once the installation of the flue is complete and all support brackets are securely in place remove the tape Adaptor Apply Lubricant for ease of assembly Ensure Extension is fully engaged into Boiler Adaptor 25mm...

Page 32: ...MUST be suitable for 230V switching 6 Remove the link between terminals 1 2 The switched output from the external control must be connected to terminal 1 Fig 57 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 8 Replace the terminal block cover routing the external control input cable s throug...

Page 33: ...e screw on the automatic air vent on the pump body Fig 59 7 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 8 Pressurise the system to 1 5 bar Fig 60 then close and disconnect the filling loop 9 Turn the gas supply on and purge according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 10 Test for gas tightness 11...

Page 34: ...iler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point Fig 62a 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 bet...

Page 35: ...e 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 addition to the B...

Page 36: ...ents 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 maximum rate as descr...

Page 37: ...bracket on the boiler top panel Remove the pipe Fig 73 9 Undo the five retaining nuts and washers and remove the fan gas air inlet and burner assembly Figs 74 10 Carefully clean any debris from the heat exchanger 11 Inspect the burner electrode position insulation and gasket cleaning or replacing if necessary Clean any dirt or dust from the air box 12 Reassemble in reverse order 13 Complete the re...

Page 38: ...igniter feed plug and the electrode leads noting their positions 2 Undo the nuts and screws securing the igniter to the boiler top panel Remove the igniter 3 Fit the new igniter and reassemble in reverse order 14 2 Electrode Assembly Fig 76 1 Disconnect the electrode lead caps remove the strain relief clip from the sensing lead and disconnect the lead 2 Undo the extended nuts securing the electrod...

Page 39: ...lace the gasket if necessary 6 Remove the four nuts and separate the fan from the gas air inlet Note the position of the orifice plate and examine the gasket replacing if necessary Fig 79 7 Fit the new fan ensuring that the orifice plate is correctly fitted and that the gasket is in position 8 Examine the insulation around the burner and the heat exchanger gasket and replace if necessary 9 Reassem...

Page 40: ...and gasket examine the insulation and heat exchanger gasket replacing if necessary 7 Reassemble in reverse order 14 6 Insulation Fig 80 1 Undo the nut on the gas pipe at the gas air inlet and the gas valve Remove the pipe taking care not to lose the sealing washers Also remove the injector 2 Disconnect the electrode lead caps remove the strain relief clip from the sensing lead and disconnect the l...

Page 41: ... boiler primary circuit 2 Disconnect the two wires from the sensor 3 Unscrew the sensor from the hydraulic outlet assembly examine the sealing washer and replace if necessary 4 Reassemble in reverse order The component is not polarised either wire will fit each terminal 14 10 DHW Temperature Sensor NTC Fig 83 1 Turn off the mains cold water supply tap and draw off the residual domestic hot water 2...

Page 42: ...speed must be set to 3 Fig 86 4 Reassemble in reverse order 14 13 Pump Complete Fig 87 1 Drain the boiler primary circuit 2 Undo 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...

Page 43: ...Reassemble in reverse order 14 17 Pressure Relief Valve Fig 90 1 Drain the boiler 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 to the previously noted orientation Reassemble i...

Page 44: ... reverse order ensuring that the temperature controllers are reset to their previous positions 14 19 Selector Switch Figs 91 92 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 from the control box hinge pin 3 Note the ...

Page 45: ...tor 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 93a If the boiler will not light or the correct CO2 cannot be achieved contact the heateam technical helpline 14 21 Expansion Vessel Fig 94 1 Drain the boiler primary circuit...

Page 46: ...ack fully anticlockwise Fig 95 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 96 97 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 98 99 100 7 Re...

Page 47: ... Central Heating NTC Sensor Fan GasValve Overheat Stat Pump X400 X401 g g b b r r 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 Water Pressure Switch Spark Generator Ignition Electrode 9 8 7 6 5 4 3 2 1 9 10 8 7 6 5 4 3 2 1 N L br br 1 4 2 5 3 1 2 a b Link b g y br Mains Input br b bk bk bk grey gr gr gr E NL 16 1 Illustrated Wiring Diagram Supplied by HeatingSpares247 com ...

Page 48: ... No A Fan 5121447 B Electrode Assembly 5130293 C Gas Valve 5122149 D Burner 5130292 E Water Pressure Switch 5114748 F Pump 248042 G NTC Sensor 5114725 H Overheat Thermostat 5114729 J NTC Sensor 5130291 K Pressure Gauge 248090 L PCB 24 5131262 PCB 28 5131263 D A C E F L K B J G H Supplied by HeatingSpares247 com ...

Page 49: ...133 will be displayed by E1 alternating with 33 E50 is shown as E then 50 E20 E28 E50 indicate faulty or incorrect components E110 shows overheat of the primary water 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 displayed in either of two situations i If ...

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 deman...

Page 51: ...stem 1 YES Check the tap of the automatic air vent is opened Open the automatic air vent 2 NO C 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 Replace water pressure switch Check connection water pressure switch terminal COM NO and PCB connector X400 terminals 3 4 YES E20...

Page 52: ...heck and correct the connection of the tube between the venturi and gas valve 1 2 Check and correct if necessary 1 The mechanical set of the gas valve CO2 values see instruction 2 Flame sensing electrode and lead connections 3 Flame sensing electrode position Flame current should be more than 0 5 μ A Replace PCB Replace PCB YES YES Replace flame sensing electrode NO Check the gas supply pressure F...

Page 53: ...ly cable YES Fan connections correct at fan PCB X401 connector terminals 5 6 7 8 YES Replace fan Temperature sensors faulty Cold resistance approximately 10kΩ 25 C CH sensor resistance reduces with increase in temp NO Replace sensor YES If pump is running the heat exchanger could be obstructed Replace heat exchanger 1 2 Supplied by HeatingSpares247 com ...

Page 54: ...s statutory rights If yes and if required by the manufacturer has a water scale reducer been fitted CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 Yes If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted Yes 54 Supplied by HeatingSpares247 com ...

Page 55: ...ame 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 Operative ID No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Eng...

Page 56: ...roducts 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 Baxi Heating UK Ltd 3879156 Brooks House Coventry Road Warwick CV34 4LL After Sales Service 0844 871 1570 Technical Enquiries 0844 871 1555 Website www mainheating co uk e oe Supplied by HeatingSpa...