Baxi Neta-tec Combi 24 GA, Neta-tec Combi 28 GA, Neta-tec Combi 33 GA Installation & Servicing Instructions Manual

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Neta-tec Combi GA Range

Gas Fired Wall Mounted Condensing

Combination Boiler

Installation & Servicing Instructions

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

They must be read in conjunction with the Flue Installation Guide.

Model Range

Baxi Neta-tec Combi 24 GA

G.C.N

47-075-51

Baxi Neta-tec Combi 28 GA

G.C.No 47-075-52

Baxi Neta-tec Combi 33 GA

G.C.No47-075-53

© Baxi Heating UK Ltd 2012 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 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 address:

The Company Secretary, Baxi Heating UK Limited, Brooks House, Coventry Road, Warwick. CV34 4LL

Full acknowledgement of author and source must be given.

WARNING: Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages.

The Benchmark Scheme

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote 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. This can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly.

The Health & Safety Executive operates the ‘Gas Safe Register’, a self-certification scheme for gas heating appliances.

These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook (which was then left on site with the customer).

With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn. However, a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions.

This company is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating 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 completed by the installer. The relevant section of Building Regulations only relates to dwellings. Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure.

The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations.

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact a government approved

inspector

LABC will record the data

and will issue a

certificate of compliance

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant 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

the Building Regulations

certificate on members’ behalf

Complete the

Benchmark Checklist

Install and Commission this appliance to manufacturer's

instructions

Competent Person's

Self Certification Scheme

Building Control

Complete the

Benchmark Checklist

Install and Commission this appliance to manufacturer's

instructions

Legislation

Codes of Practice - refer to the most recent version

IMPORTANT - Installation, Commissioning, Service & Repair

This appliance must be installed in accordance with the manufacturer’s instructions and the regulations 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 person as stated in I.S. 813 “Domestic Gas Installations”.

The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty. In GB this could also infringe the Gas Safety (Installation and Use) Regulations.

Warning - Check the information on the data plate is compatible with local supply conditions.

This company declare that no substances harmful to health are contained in the appliance or used during appliance manufacture.

The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force, and only used in a suitably ventilated location.

In GB, the installation must be carried out by a Gas Safe Registered Installer. It must be carried out in accordance with the relevant requirements of the:

• Gas Safety (Installation & Use) Regulations.

• The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland).

• The Water Fittings Regulations or Water Byelaws in Scotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, 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 with inhibitor (see section 6.2).

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations 1993 N

3083” and is deemed to meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by: Notified Body 0085.

Product/Production certified by: Notified Body 0086.

For GB/IE only.

All Gas Safe registered engineers carry an ID card with their licence number and a photograph. You can check your engineer is registered by telephoning 0800 408 5500 or online at www.gassaferegister.co.uk

In GB the following Codes of Practice apply: Standard Scope

BS 6891 Gas Installation. BS 5482 Part 1 Butane & Propane Gas Installation BS 5546 Installation of hot water supplies for domestic

purposes. BS EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings - Calculation of load. BS EN 14336 Installation & commissioning of water based

heating systems. BS 6798 Installation of gas fired hot water boilers. BS 5440 Part 1 Flues. BS 5440 Part 2 Ventilation. BS 7074 Expansion vessels and ancillary equipment for

sealed water systems. BS 7593 Treatment of water in domestic hot water

central heating systems.

In IE the following Codes of Practice apply: Standard Scope

I.S. 813 Domestic Gas Installations. The following standards give valuable additional information; BS 5546 Installation of hot water supplies for domestic

purposes. BS EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings - Calculation of load. BS EN 14336 Installation & commissioning of water based

heating systems. BS 7074 Expansion vessels and ancillary equipment for

sealed water systems. BS 7593 Treatment of water in domestic hot water

central heating systems.

Safe Manual Handling

General

The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.

Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health & Safety is the responsibility of EVERYONE.

There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.

Do not handle or lift unless you feel physically able.

Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.

Preparation

Co-ordinate movements - know where, and when, you are both going.

Minimise the number of times needed to move the boiler - plan ahead.

Always ensure when handling 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 transport the boiler using a sack truck or other suitable trolley.

Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the ‘Installation’ section of these instructions for recommended lift points.

Remember

The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.

If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT ‘work through’ the pain - you may cause further injury.

IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

CONTENTS

1.0 Introduction 7

2.0 General Layout 8

3.0 Appliance Operation 9

4.0 Technical Data 10

5.0 Dimensions and Fixings 11

6.0 System Details 12

7.0 Site Requirements 15

8.0 Flue Options 21

9.0 Installation 23

10.0 Commissioning 28

11.0 Completion & System Draining 30

12.0 Servicing 31

13.0 Changing Components 33

14.0 Combustion & Calibration 42

15.0 Electrical 43

16.0 Short Parts List 44

17.0 Fault Finding & ‘Service Due’ 45

18.0 Optional Outdoor Sensor s 51

Benchmark Checklist 54

Section Page

1.0 Introduction

1.1 Description

1. The Baxi Neta-tec Combi GA Range are fully automatic gas fired wall mounted condensing combination boilers. They are room sealed and fan assisted, and will serve central heating and mains fed domestic hot water.

2. The boiler is set to give a maximum output of :-

24 models - 24 kW DHW

21.2 kW CH (Condensing)

28 models - 28 kW DHW

25.3 kW CH (Condensing)

33 models - 33 kW DHW

29.6 kW CH (Condensing)

3. The boiler is factory set for use on Natural Gas (G20). It can be adapted to operate on Propane (G31) - see Section 10.1 ‘Gas Type Check’.

4. The boiler is suitable for use only on fully pumped sealed heating systems. Priority is given to domestic hot water.

5. The boiler data badge gives details of the model, serial number and Gas Council number and is situated on the control box. It is visible when the case front panel is removed (Fig. 2).

6. The boiler model, serial number and Gas Council number are also shown on the information label behind the boiler control flap (Fig. 1). 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 designed flues such as one of the standard horizontal telescopic flue kits detailed in the Flue Installation Guide .

9. All systems must be thoroughly cleansed, flushed and

treated with inhibitor (see section 6.2).

1.2 Optional Extras

Various timers, external controls, etc. are available as optional extras. Full details are contained in the relevant sales literature.

1.3 Contents of Pack

The pack contains:-

• Boiler

• Wall Plate (including taps)

• Template

• Fittings & Literature Pack

NOTE: These Installation & Servicing Instructions MUST be read in conjunction with the Flue Installation Guide supplied in the Literature Pack.

Fig. 1

Control Flap

Fig. 2

Information Label

Data Badge

Gas Type Label

2.0 General Layout

2.1 Layout

1. Expansion Vessel

2. Boiler Adaptor

3. Primary Heat Exchanger

4. DHW Plate Heat Exchanger

5. Pump with Automatic Air Vent

6. Central Heating System Pressure Gauge

7. Fan Assembly

8. Exp. Vessel Locating Stud

9. Flame Sensing Electrode

10. Air/Gas Collector

11. Spark Ignition Electrode

12. Combustion Box Cover & Burner

13. Control Box Display

14. Condensate Trap

15. Safety Pressure Relief Valve

16. Gas Valve

17. Diverter Valve Motor

18. Boiler Control

19. Optional Timer

20. Boiler Drain Tap

21. Heating Flow Sensor

22. Safety Thermostat

3.0 Appliance Operation

3.1 Central Heating Mode

1. With a demand for heating, the pump circulates water through the primary circuit.

2. Once the burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor.

3. When the flow temperature exceeds the setting temperature, a 3 minute delay occurs before the burner relights automatically (anti-cycling). The pump continues to run during this period.

4. When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes (Pump Overrun).

3.2 Domestic Hot Water Mode

1. Priority is given to the domestic hot water supply. A demand at a tap or shower will override any central heating requirement.

2. The flow of water will operate the Domestic Hot Water Sensor (‘Hall Effect Sensor’) which requests the 3 way valve to change position. This will allow the pump to circulate the primary water through the DHW plate heat exchanger.

3. The burner will light automatically and the temperature of the domestic hot water is controlled by the temperature sensor.

4. When the domestic hot water demand ceases the burner will extinguish and the diverter valve will remain in the domestic hot water mode, unless there is a demand for central heating.

3.3 Boiler Frost Protection Mode

1. The frost protection mode is integral to the appliance and functions as long as there is power to the boiler, as indicated by the standby signal .

2. With CH & DHW or CH only selected, when the boiler temperature falls below 5°C the boiler will fire until a temperature of 30°C is reached.

3. If DHW only is selected, when the boiler CH temperature falls below 5°C the boiler will fire until a temperature of 30°C is reached. When the boiler DHW temperature falls below 5°C the boiler will fire until a temperature of 7°C is reached.

4. Further protection can be incorporated by using a system frost thermostat.

3.4 Pump Protection

1. If the boiler has been inactive for a period of 24 hours the pump will automatically operate for 1 minute to prevent sticking.

Key

1. Pump with Automatic Air Vent

2. Diverter Valve Assembly

3. Diverter Valve motor

4. CH System Pressure Gauge

5. Central Heating Filter

6. Domestic Hot Water Filter

7. Domestic Hot Water Priority Sensor (‘Hall Effect Sensor’)

8. Domestic Hot Water NTC sensor

9. Non-return Valve

10. Hydraulic Pressure Sensor

11. Boiler Drain Tap

12. Pressure Relief Valve

13. Plate Heat Exchanger

14. Condensate Trap

15. Gas Valve

16. Safety Thermostat (105°C)

17. Heating Flow Sensor

18. Flue Sensor

19. Boiler Adaptor

20. Primary Heat Exchanger

21. Spark Ignition Electrode

22. Burner

23. Flame Sensing Electrode

24. Air/Gas Collector

25. Return Heating Sensor

26. Fan

27. Air/Gas Venturi

28. Expansion Vessel

Connections:A – Condensate Drain B – Heating Flow C – Domestic Hot Water Outlet D – Gas Inlet E – Cold Water Inlet On/Off Valve and filter F – Heating Return

Fig. 3

Boiler Schematic Layout

4.0 Technical Data

200 400 600 800 1000 1200

0.5

1.5

2.5

3.5

Metre (wg)

Flow Rate (l/h)

Pump - Available Head

5.5

4.5

4.1

Flue Terminal Diameter 100mm Dimensions Projection 125mm

Outercase Dimensions

Casing Height - 700mm Overall Height Inc Flue Elbow - 860mm Casing Width - 390mm Casing Depth - 300mm

Weights

(24 model)

Packaged Boiler Carton 38.5kg Installation Lift Weight 34 kg

(28 model)

Packaged Boiler Carton 38.5kg Installation Lift Weight 34 kg

(33 model)

Packaged Boiler Carton 40.5kg Installation Lift Weight 36kg

Central Heating Primary Circuit Pressures

bar Safety Discharge 3 Max Operating 2.5 Min Operating 0.5 Recommended Operating Range 1-2

DHW Circuit bar Pressures

Max Operating 8 Min Operating 0.15

Flow Rates (24) (28) (33)

l/min l/min l/min DHW Flow Rate @ 30o CRise 10.9 12.9 15.3

DHW Flow Rate @ 35o CRise 9.8 11.5 13.5

Min Working DHW Flow Rate 2 2 2

Pump

Available Head See graph below

Expansion Vessel - (For Central Heating only. Integral with appliance)

bar

Min Pre-charge Pressure 0.5

(24 & 28) (33)

litre litre

Max Capacity of CH System 100 100

Primary Water Content of Boiler (unpressurised) 2.5 2.8

Connections copper tails Gas Inlet - 22mm Heating Flow - 22mm Heating Return - 22mm Cold Water Inlet - 15mm Hot Water Outlet - 15mm Pressure Relief Discharge - 15mm

Temperatures

C.H. Flow Temp (adjustable)

25°C to 80°C max (± 5°C)

D.H.W. Flow Temp (adjustable)

35°C to 60°C max (± 5°C) dependent upon flow rate

NOxClass 5

Clearances

Above Casing 175mm Min Below Casing 150mm Min* Front 450mm Min(For Servicing) Front 5mm Min (In Operation) L.H. Side 5mm Min R.H. Side 5mm Min :

*This is MINIMUM recommended dimension. Greater clearance will aid installation and maintenance.

Electrical Protection

IPX5D

Internal Fuse Rating F2L

Inlet Pressure (Natural Gas - G20)

mbar 20

Injector

24 model mm 4.4 28 model mm 4.6 33 model mm 4.9

Condensate Drain

To accept 21.5mm (3/4in) plastic waste pipe

External Fuse Rating 3A

Heat Input CH (Net) Max Min

24 model kW 20 3.5 28 model kW 24 3.9 33 model kW 28 4.8

Heat Output CH (Non-Condensing)

Max Min 24 model kW 20 3.4 28 model kW 24 3.8 33 model kW 28 4.7

Appliance Category CAT II

2H 3P

Heat Output CH (Condensing)

Max Min 24 model kW 21.2 3.7 28 model kW 25.3 4.1 33 model kW 29.6 5.1

Heat Input DHW (Net) Max 24 model kW 24.7 28 model kW 28.9 33 model kW 34

Heat Output DHW Max 24 model kW 24 28 model kW 28 33 model kW 33

Max Gas Rate (Natural Gas - G20)

(After 10 mins)

24 model m

/h 2.54

28 model m

/h 2.96

33 model m

/h 3.49

Inlet Pressure (Propane - G31)

mbar 37

Max Gas Rate (Propane - G31)

(After 10 mins) 24 model kg/h 1.92 28 model kg/h 2.25 33 model kg/h 2.64

NA TURAL GAS ONLY !

PROPANE ONLY !

IMPORTANT: Where Low Flow Taps or Fittings are

intended to be used in the DHW system connected it is strongly recommended that the DHW flow rate DOES NOT fall below 2.5l/min. This will ensure reliable operation of the DHW function.

NOTE: All data in this section are nominal values and subject to normal production tolerances.

SAP 2005 Seasonal Efficiency for N. G.

models is 91.1%

SAP 2005 Seasonal Efficiency for L.P.G.

models is 93.2%

SAP 2009 Annual Efficiency for N. G.

models is 89%

SAP 2009 Annual Efficiency for L.P.G.

models is 91%

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 0087.

SEDBUK Declaration

Electrical Supply 230V~ 50H

(Appliance must be connected to an earthed supply)

Power Consumption

24 model W 104 28 model W 116 33 model W 133

Appliance Type C

13 C33 C43 C53

N.G. 9.0% ± 0.7 L.P.G. 10.5% ± 1.0

+ 22 hidden pages

Baxi Neta-tec Combi 24 GA, Neta-tec Combi 28 GA, Neta-tec Combi 33 GA Installation & Servicing Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual