Baxi Bermuda 45/4 M, Bermuda 45/4 E, Bermuda 57/4 M, Bermuda 57/4 E Installation And Servicing Instructions
Baxi Bermuda 45/4 & 57/4 Boilers
Gas Fired Central Heating Unit
Gas Type G20 (Natural Gas)
Comp N
Baxi Bermuda 45/4 M - G.C.No 44 077 71
Baxi Bermuda 57/4 M - G.C.No 44 077 72
Baxi Bermuda 45/4 E - G.C.No 44 077 73
Baxi Bermuda 57/4 E - G.C.No 44 077 74
These Instructions must be read in conjunction with those
for the separate Firefront.
o
241794 - Iss 9 - 6/00
Installation
And
Servicing
Instructions
Natural Gas
Baxi Bermuda 45/4 M
G.C.No. 44 077 71
Baxi Bermuda 57/4 M
G.C.No. 44 077 72
Baxi Bermuda 45/4 E
G.C.No. 44 077 73
Baxi Bermuda 57/4 E
G.C.No. 44 077 74
These Instructions must be read in
conjunction with those for the
separate Firefront.
Baxi UK Limited is one of the leading manufacturers
of domestic heating products in the UK.
Our first priority is to give a high quality service to our
customers. Quality is built into every Baxi product -products
which fulfil the demands and needs of customers, offering
choice, efficiency and reliability.
To keep ahead of changing trends, we have made a
commitment to develop new ideas using the latest
technology - with the aim of continuing to make the products
that customers want to buy.
Baxi is also the largest manufacturing partnership in the
country. Everyone who works at the company has a
commitment to quality because, as shareholders, we know
that satisfied customers mean continued success.
We hope you get a satisfactory service from Baxi. If not,
please let us know.
Baxi is a BS-EN ISO 9001
Accredited Company
The boiler meets requirements of Statutory Instrument “The
Boiler (Efficiency) Regulations 1993 No 3083” and is
deemed to meet the requirements of Directive 92/42/EEC on
the efficiency requirements for new hot water boilers fired
with liquid or gaseous fuels.
Type test for purpose of Regulation 5 certified by:
Notified Body 0086.
Product/production certified by: Notified Body 0086.
CONTENTS - Page 3
Introduction
Technical Data
System Details
Site Requirements
PAGE 4
PAGE 5
PAGE 6 - 8
Water Circulating Systems
Treatment of Water Circulating Systems
Pipework
System Controls
Fully Pumped System
Overheat Kit & Sealed Systems
Storage Systems
Pumped Heating & Gravity Hot Water
PAGE 9 - 12
Builders & Fireplace Opening
Location
Fireplace Surround
Flue
Ventilation
Gas Supply
Electrical Supply
Installation
Commissioning the Appliance
Annual Servicing
Changing Components
Short Parts List
Fault Finding
PAGE 13 - 22
Initial Preparation
Siting the Boiler
Securing the Boiler
Water Connections
Fully Pumped Systems
Overheat Thermostat
Pumped Heating & Gravity Hot Water
Gas Connection
Electrical Connection
Making the Electrical Connection
Refilling the Controls
Flue Connection
Completion
PAGE 23 - 24
PAGE 25 - 28
Removal of Firefront
Removal of Controls
Cleaning the Lint Arrestor
Cleaning the Burner & Main Injector
Cleaning the Pilot / A.S.D. Assembly
Cleaning the Heat Exchanger
PAGE 29 - 34
Removal of Firefront
Flame Sensing Lead
Ignition Lead
Gas Valve
Burner & Main Injector
Pilot / A.S.D. Assembly
Thermostat
Piezo Igniter Unit
Suppression Capacitor
Thermostat Sensor
Thermostat Potentiometer
Printed Circuit Board
PAGE 35
PAGE 36 - 40
INTRODUCTION - Page 4
Description
The Baxi Bermuda is a combined central heating boiler and
gas fire designed for installation within a builders opening in
the living space of a dwelling.
These installation and servicing instructions cover all natural
gas models. There are two physical sizes of boiler, the
Bermuda 45 being the smaller. Both Bermuda 45 and 57 are
available with either electronic or manual controls. The
appliance is fitted with an Atmospheric Sensing Device
which will shut the boiler down in the event of adverse flue
conditions. All installation and servicing procedures are the
same for each size of boiler. Any differences in procedure
between electronic and manual control versions are covered
in this booklet.
These instructions relate to the central heating boiler section
of the appliance.
The two models of the boiler have range rated outputs
as shown.
Each appliance is preset at its MIDRANGE heat input rate
and is designed for use on NATURAL GAS only. The boilers
are suitable for fully pumped and pumped central heating
with gravity hot water systems. The propane back boiler is
covered by its own instructions supplied with it. An optional
overheat thermostat kit is available for sealed systems or
where additional system protection is required.
“Benchmark” Log Book
As part of the industry-wide “Benchmark” initiative all Baxi
boilers now include an Installation, Commissioning and
Service Record Log Book. Please read the Log Book
carefully and complete all sections relevant to the appliance
and installation. These include sections on the type of
controls employed, flushing the system, burner operating
pressure etc. The details of the Log Book will be required in
the event of any warranty work. Also, there is a section to be
completed at each subsequent regular service visit.
Baxi Part No 235565 for 45/4E & 57/4E
Baxi Part No 234885 for 45/4M & 57/4M
Installation
The installation must be carried out by a CORGI Registered
Installer or other Competent Person and be in accordance
with the relevant requirements of GAS SAFETY (Installation
and Use) REGULATIONS, the BUILDING REGULATIONS
(Scotland) (Consolidation), the LOCAL BUILDING
REGULATIONS, the current I.E.E. WIRING REGULATIONS
and the bye laws of the LOCAL WATER UNDERTAKING.
Where no specific instructions are given, reference should
be made to the relevant B.S. CODES OF PRACTICE.
All systems must be thoroughly flushed and treated with
inhibitor (see System Details).
B.S. Codes of Practice
STANDARD
BS 6891
BS 5546
BS 5449
BS 6798
BS 5440 Pt 1
BS 5440 Pt 2
BS 5871 Pt 1
BS 6500
SCOPE
Gas Installation.
Installation of hot water supplies
for domestic purposes.
Forced circulation hot water
systems.
Installation of gas fired hot water
boilers.
Flues.
Air Supply.
Installation of fire/back boilers,
gas appliances.
Cables
TECHNICAL DATA - Page 5
Bermuda Boiler 57/4
Bermuda Boiler 45/4
Sedbuk Declaration For Bermuda
45/4 and 57/4 Boilers
The seasonal efficiency (SEDBUK) are
45/4M 72.7%
45/4E 76.8%
57/4M 71.8%
57/4E 75.8%
This value is used in the UK
Government’s Standard Assessment
Procedure (SAP) for energy rating of
dwellings. The test data from which it
has been calculated has been certified
by 0086.
SYSTEM DETAILS - Page 6
Water Circulating Systems
The appliance is suitable for open vented systems which are
either fully pumped or pumped central heating with gravity
domestic hot water.
An overheat thermostat modification kit is available where
additional control protection is required and for sealed
system applications. This must not be used on gravity
systems
The following conditions should be observed at all
times:
The static head must not exceed 30m (100ft) of
water.
The boiler must not be used with a direct cylinder.
Drain cocks should be fitted to all system low points.
All gas and water pipes and electrical wiring must
be installed in such a way that it does not restrict the
servicing of the boiler. Position isolating valves as
close as possible to the circulating pump
Treatment of Water Circulating Systems
For optimum performance after installation, this boiler and its
associated central heating system must be flushed in
accordance with the guidelines given in B57593: 1992
‘Treatment of water in domestic hot water central heating
systems’.
This must involve the use of a proprietary cleanser, such as
BetzDearborn’s Sentinel X300 or X400, or Fernox’s
Superfloc. Full instructions are supplied with the products,
but for immediate information, please contact BetzDearborn
on 0151 420 9563, or Fernox on 01799 550811.
For long term protection against corrosion and scale, after
flushing, it is recommended that an inhibitor such as
BetzDearborn’s Sentinal X100, or Fernox’s MB-1 or Copal is
dosed in accordance with the guidelines given in B5S593:
1992.
Failure to flush and add inhibitor to the system may
invalidate the appliance warranty.
Pipework
The sizes of the flow and return pipes from the boiler should
be determined by normal methods according to the
requirements of the system (BS 5449).
It is recommended that the system is designed for an
11ºC (20ºF) drop in temperature across the system.
In systems using non-metallic pipework it is necessary to
use copper pipe for the boiler Flow and Return. The copper
must extend at least 1 metre from the boiler and include any
branches. The copper pipe must not be insulated (Fig. 1).
SYSTEM DETAILS - Page 7
System Controls
For optimum operating conditions, the heating system into
which the appliance is installed should include a control
system.
Such a system would comprise a timer control and a
separate room and/or cylinder thermostat as appropriate.
The boiler should be controlled so that it operates on
demand only.
It is not economical to rely on the boiler thermostat to
control operation of the system.
Fully Pumped System
The sizes of the system pipes should be determined by
normal methods (BS 5449).
The open vent pipe should be a minimum of 22mm and must
rise continuously to a point above the feed and expansion
tank.
The flow pipe from the boiler may form part of the vent pipe.
No part of the open vent should contain a valve.
The cold feed pipe (15mm mm) should preferably be
connected to the boiler return.
Close coupling of the cold feed pipe to the flow pipe at a
maximum of 150mm (6 in) from the vent pipe is permissible
but there must always be an open cold water path to the
boiler return connection.
SYSTEM DETAILS - Page 8
Overheat Kit And Sealed Systems
An overheat thermostat modification kit is available to
facilitate the installation of a Bermuda boiler to systems
incorporating a combined feed and vent and to flats and
dwellings where the building design prevents the boiler vent
pipe rising continuously to the feed and expansion tank.
(This must not be used on gravity systems.)
Baxi Part No 235565 for Electronic Controls
Baxi Part No 234885 for Manual Controls
The boiler can be applied to a sealed system with the
use of the overheat kit.
Information regarding the application of the overheat
thermostat is included with the kit.
Storage Systems
For information regarding the use of a Bermuda boiler with.a
storage system, contact the appropriate storage system
manufacturer.
Pumped Heating & Gravity Hot Water
The sizes of system pipes should be determined by normal
methods (BS 5449). 28mm pipe is recommended for the
gravity circuits.
The gravity flow pipe should rise vertically as close as
possible to the boiler, avoiding sharp bends and tight
elbows.
The open vent pipe should be a minimum of 22mm and must
rise continuously to a point above the feed and expansion
tank.
The flow pipe from the boiler may form part of the vent pipe.
No part of the open vent should contain a valve.
The cold feed pipe (15mm mm) should be connected to the
boiler return pipework.
The brass injector tee must be fitted to the boiler return
on all systems incorporating a gravity circuit.
The circulating head should not be less than 1 m (3ft.) with a
maximum horizontal run of 3m (10ft.) when using 28mm
pipes. Smaller pipe sizes and longer horizontal runs are
acceptable with suitably increased circulating heads.
The gravity circuit should be designed with a minimum of
restriction, avoiding possible air traps and long horizontal
runs.
The system should be designed to prevent gravity circulation
in the heating system when the pump is not running.
SITE REQUIREMENTS - Page 9
Builders & Fireplace Opening
The boiler unit is designed to fit within a standard builders
opening cavity, the minimum dimensions of which are
343mm(13½in) deep x 584mm(23in) wide x 584mm(23in)
high.
The opening should be soundly constructed of brick, precast concrete or be a proprietary builders opening. The base
of the opening should be sound and non-combustible and
must be flat and level.
The base of the builders opening should be at the same
height as the finished level of the hearth or be the required
height of 100-125mm (4-5 in) above floor level for a wall
mounted firefront installation.
The fireplace opening (i.e. the opening into the cavity) must
be 560mm (22in) high and between 406mm (16in) and
584mm (23in) wide.
Maximum fireplace opening sizes are preferable for ease of
installation and service.
Location
The appliance must be installed in the living space of a
dwelling.
Restrictions to the siting of the appliance are covered by BS
5546. The appliance may not be installed in bathrooms,
shower rooms, bedrooms or bed sitting rooms.
Fireplace Surround
If a fireplace surround is to be used, it must be centrally
placed and have opening sizes and a vertical flat area as
shown in the firefront Installation and Servicing Instructions.
Maximum fireplace opening sizes are preferable for ease of
installation and service.
NO SURROUND
The appliance can be fitted without a surround.
The fireplace opening and vertical flat areas as per above
still apply.
Maximum fireplace opening sizes are preferable for ease of
installation and service.
HEARTH MOUNTING
All Bermuda Firefronts are suitable for hearth mounting. The
hearth must be on the same level as the builders opening.
The hearth must be non-combustible and comply with BS
5871: Pt 1.
WALL MOUNTING
A number of Bermuda Firefronts are aesthetically suitable for
wall mounting above the level of the room floor in instances
where there is no hearth.
The base of the builders opening on which the boiler rests
should be 100-125mm (4-5 in) above floor level.
The following firefronts are suitable for wall mounting:
Bermuda 5P3 Bermuda PW5 Deluxe
Bermuda CS Bermuda RG3
Bermuda C5W Bermuda LFE5 Super
SITE REQUIREMENTS - Page 10
FLUE
Prior to installation it is important to establish that the
flue will perform satisfactorily. Do not proceed with the
installation if the flue does not operate correctly.
The Bermuda is fitted with an Atmospheric sensing
Device that will automatically shut the appliance down
under adverse flue conditions and where insufficient
flue pull exists.
The flue installation must conform to BS 5440 Pt 1. The flue
must have a minimum vertical height of 3m (10ft) measured
from the boiler flue outlet socket and have an internal cross
section area of 12,700 mm2 (20in2), this is satisfied by a flue
of 125mm (5in) internal diameter. If the flue system contains
any bends the vertical height must be increased accordingly.
An approved terminal is required for all installations.
9in X 9in BRICK
Flues previously used for other fuels must be thoroughly
swept. The flue must be protected with a 125mm (5in)
flexible liner. The bottom of the liner should terminate
500mm (20in) above the base of the builders opening. The
flue must be sealed between the liner and the brickwork at
both the top and bottom.
An approved terminal must be installed.
ACID RESISTANT LINERS
A flue constructed of acid resistant liners is satisfactory
provided the size requirements are met.
The boiler flue outlet can be connected to the flue by
means of a short length of 125mm (5in) of flue pipe.
A seal must be made in the annular space between the outer
face of this flue pipe and the acid resistant liner.
An approved terminal must be installed.
PRECAST FLUES
These must conform to BS 5440 Pt 1 and be correctly
designed and installed without intrusion of cement into the
flue passage.
An approved terminal must be installed.
PROPRIETARY FLUES
A flue of this type must meet the size requirements specified
and be installed in accordance with the flue manufacturers
recommendation and relevant codes of practice.
An approved terminal must be installed.
SITE REQUIREMENTS - Page 11
Ventilation
Ventilation air supply to BS 5440 Pt 2 is required.
The permanent ventilation area size requirements are
given in the firefront Installation and Servicing
Instructions.
The permanent vent may be directly into the room containing
the appliance. The vent may also be sited in another room
provided an interconnecting vent is used.
The vent must not be installed inside the builders opening.
The vent should be sited following good practise for a
habitable room. We recommend the use of the Stadium
BM720 “Black Hole” ventilator which is available from your
local merchant.
Gas Supply
The gas installation should be in accordance with BS
6891. The connection at the appliance is Rc ½ (½in
BSPT internal) located at the rear of the gas cock.
Ensure the pipework from the meter to the appliance is of
adequate size and suitably protected. It is preferable to route
the gas supply pipe to the right hand side of the builders
opening. It must be routed so as not to restrict the
installation and servicing of the appliance.
Electrical Supply
External wiring must be correctly earthed, polarised and in
accordance with current lEE wiring regulations. The mains
supply is 230V ~ 50Hz
fused at 5 A.
NOTE: The method of connection to the electrical
supply must facilitate complete electrical isolation of the
appliance, connection may be made via a fused double
pole isolator with a contact separation of at least 3mm
on all poles and serve the appliance and system
controls only.
The cable within the builders opening should be 0.75 mm2 to
lEC 53 Code 227 (heat resistant).
The cable must be routed to avoid contact with the
metal combustion box and hood.
PERMANENT LIVE
A permanent live electrical supply is required for all firefronts
with lighting effects i.e. VP3, 5P3, RG3, 5L3, LFE5 Super
and GF3 Super. The permanent live is also required to
operate the electronic ignition on VP3, 5P3 and RG3
models.
SITE REQUIREMENTS - Page 12
Functional Flow Diagram
It is preferable to route the input cable from the left hand side
of the builders opening.
The cable can be secured to either the boiler base or fire
support plate using the ‘P’ clip supplied in the kit.
NOTE: Polarity of the appliance MUST be correct otherwise
the appliance will not operate correctly.
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