Baxi Potterton BBU 15 HE User Manual

Baxi Bermuda BBU 15 HE

Condensing Back Boiler Unit

These Instructions must be read in conjunction with those for

the separate Valor Dimension electric firefront.

They include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

Installation & Servicing Instructions

Natural Gas

Baxi Bermuda BBU 15 HE

G.C.No. 44 075 09

For use with the following electric firefronts:

Valor Dimension Classica Brass, Pewter or Black BBU Firefront

Valor Dimension Dream Gold, Chrome or Black BBU Firefront

Valor Dimension Innova BBU Firefront

Valor Dimension Regalia BBU Firefront

Valor Dimension Nano Chrome BBU Firefront

Valor Dimension Lyrica BBU Firefront

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 an option to notifying the Local Authority directly. Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006.

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With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn.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.

0086

ISO 9001

FM 00866

This product has an energy rating (A) on a scale of A to G.

For more information see www.boilers.org.uk. This is a certification mark.

© Baxi Heating UK Ltd 2009 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 Ltd, The Wyvern Business Park, Stanier Way, Derby, DE21 6BF.

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.

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Competent Person's

Self Certification Scheme

Install and Commission this appliance to manufacturer's

instructions

Complete the

Benchmark Checklist

If you notify via the ‘Gas Safe

the Building Regulations

certificate on members’ behalf

Building Control

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact a government approved

inspector

Install and Commission this appliance to manufacturer's

instructions

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

or log onto:

www.GasSafeRegister.co.uk

within 10 days

You must ensure that the

certificate number issued by

the ‘Gas Safe Register’ is written

onto the Benchmark Checklist

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant LABC

Complete the

Benchmark Checklist

LABC will record the data

and will issue a

certificate of compliance

Legislation

Codes of Practice, most recent version should be used

In GB the following Codes of Practice apply: Standard Scope

BS 6891 Gas Installation. BS 5546 Installation of hot water supplies for

domestic purposes. BS 5449 Forced circulation hot water systems. BS 6798 Installation of gas fired hot water boilers. BS 5440 Part 1 Chimneys. 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.

Also the following standard includes relevant information about builders openings:

BS 5871 Part 1 Installation of gas fires, convector heaters,

fire/back boilers and heating stoves.

In IE the following Codes of Practice apply: Standard Scope

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

domestic purposes. BS 5449 Forced circulation hot water systems.

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 0087.

Product/Production certified by: Notified Bodies 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

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 !!

Working at Height

In order to reduce the number of fatalities and major accidents attributable to working at height, the Health and Safety Executive has introduced comprehensive regulations and guidance that should be followed by all businesses working at height.

The following paragraphs consider some of the main features of the regulations and guidance. This is, however, only a limited summary and it is recommended that all businesses planning on undertaking air source heat pump heating installations obtain a copy of the regulations and guidance issued by the Health and Safety Executive and carefully consider the contents.

The regulations and guidance state that you are required to carry out a risk assessment for all work conducted at height and to put in place arrangements for:

• Eliminating or minimising risks from work at height.

• Safe systems of work for organising and performing work at height.

• Safe systems for selecting suitable work equipment.

• Safe systems for protecting people from the consequences of work at height.

The regulations and guidance highlight a hierarchy for safe work at height:

• Avoid the risk by not working at height if practicable.

• Prevent falls. Where it is not reasonably practicable to avoid work at height, you are required to take suitable and sufficient steps to prevent the risk of a fall including selecting the most suitable work equipment (in accordance with the regulations).

• Mitigate the consequences of a fall; where the risk of a person or object falling still remains, take suitable and sufficient measures to minimise the distance and consequences of any fall.

Collective protection measures, such as guard rails on scaffold, should be given priority over personal protection measures, such as safety harnesses.

Within the regulations’ framework, you are required to:

1) Assess the risk to help you decide how to work safely.

2) Follow the hierarchy for safe work at height (i.e. avoid, prevent and mitigate).

3) Plan and organise your work properly, taking account of weather conditions and the possibility of emergencies.

4) Make sure those working at height are competent.

5) Make use of appropriate work equipment.

6) Manage the risks from working on or around fragile surfaces and from falling objects.

7) Inspect and maintain the work equipment to be used and inspect the place where the work will be carried out for both access and egress.

1.0 Introduction 7

2.0 General Layout 8

3.0 Technical Data 10

4.0 System Details 11

5.0 Site Requirements 15

6.0 Boiler Internal Wiring 20

7.0 Installation 21

8.0 Completion & Commissioning 25

9.0 Annual Servicing 27

10.0 Changing Components 29

11.0 Setting the Gas Valve 33

12.0 Fault Finding 34

13.0 Short Parts List 38

14.0 Notes 39

Benchmark Checklist 42

Section Page

Contents

1.0 Introduction

1.1 Description

1. The Baxi Bermuda BBU 15 HE is a central heating boiler designed for installation within a builders opening in the living space of a dwelling.

2. The boiler is a fully automatic gas fired condensing boiler. It is room sealed and fan assisted.

3. The boiler output will automatically modulate between:

Max Min 15kW 4.6kW

15.7kW (condensing) 4.83kW (condensing) According to system load

4. It must be fitted in conjunction with one of the available electric firefront units as listed on page 2. The separate electric firefront is intended for hearth mounting. All instructions, fixings etc. needed to fit the firefront are included in the firefront pack.

5. These instructions relate to the central heating boiler section of the appliance (Fig. 1).

6. The appliance is designed for use on NATURAL GAS (G20) only.

7. It can be used on sealed or open vented systems. It must NOT be fitted on any type of gravity system. The boiler is suitable for fully pumped systems ONLY.

8. The boiler is fitted with an integral pump unit for the removal of condensate.

9. The boiler data badge gives details of the model, serial number and Gas Council number and is situated on the front case panel.

10. The boiler is intended to be installed in a residential environment on a governed meter supply only.

11. The boiler must be installed with one of the MULTIIFIT vertical concentric Flexi Flue kits available:10m kit 720101701 or 12.5m kit 720102001.

12. All systems must be thoroughly flushed and

treated with inhibitor (see section 4.2).

1.2 Contents

1. The boiler pack contains:

• Boiler Unit

• Plumbing Kit

• Condensate Pipe & Elbow

• Fixings Kit

• Literature Pack

2. The flue pack contains:

• Terminal Cap

• Flue Duct Adaptor (inc. seal)

• Air Cowl

• Air Duct Collar (inc. 4 screws)

• Air Duct Clamp

• Closure Plate

• Boiler Concentric Adaptor (inc. 2 seals)

• 10m or 12.5m of Concentric Flexible Duct

• 2 x 60mm grey Seals

• 1 x 100mm red Seal

Fig. 1

Fig. 2

2.0 General Layout

2.1 Layout (Fig. 3)

1. Automatic Air Vent

2. Flue Connection

3. Spark Generator

4. Spark & Sensing Electrodes

5. Heat Exchanger

6. Boiler Control Connector

7. Control Wiring Connector

8. Condensate Sump

9. Gas Cock

10. Condensate Pump

11. Fan

12. Drain

13. Return Connection

14. Air Sampling Point

15. Flue Sampling Point

16. Flow Connection

17. Condensate Outlet

18. PCB Control Box (shown removed for clarity)

19. Boiler Control (cover open)

The Boiler Control operates the boiler remotely. This is supplied with the firefront and is fitted, in operation, to the firefront spacer frame.

IMPORTANT: To commission the boiler it is is necessary to remove the Boiler Control from the firefront packaging and connect it to the boiler at the upper right hand side (item 6).

Calibration Controls

Fig. 3

PCB Control Box removed for clarity

PCB Control Box

2.0 General Layout

2.2 Flue Kit (10m & 12.5m) (Fig. 3a)

1. Terminal Cap

2. Flue Duct Adaptor

3. Air Cowl

4. Air Duct Collar

5. Air Duct Clamp

6. Closure Plate

7. Boiler Adaptor

8. 60mm Ø Seal

9. Collar Securing Screws x 4

10. 100mm Ø Seal

11. 60mm Ø Flue Duct

12. 100mm Ø Air Duct

13. ‘C’ Clip

Fig. 3a

Sedbuk Declaration For Bermuda

BBU 15 HE

The seasonal efficiency (SEDBUK) is 90.1%

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.

Appliance Category CAT I

Inlet Pressure (Natural Gas - G20)

mbar 20

Injector (Natural Gas - G20)

420 (4.2 mm)

Appliance Type C

3.0 Technical Data

3.1 Bermuda HE CBBU 15 HE

NOxClass 5 (31mg/kWh)

Heat Input (Net) Max Min

kW 15.4 5.0

Heat Input (Gross) Max Min

kW 17.1 5.7

Heat Output (Non-Condensing)

Max Min

kW 15.0 4.88

Heat Output (Condensing)

Max Min

kW 15.7 5.25

Gas Rate (Natural Gas - G20)

(After 10 mins)

Max Min

m3/h 1.63 0.54

Electrical Supply 230V~ 50H

(Appliance must be connected to an earthed supply)

Boiler Power Consumption

112W

Boiler Electrical Protection

IPX0

Boiler External Fuse Rating 3A

Connections

Gas Supply - 15mm compression Flow - 22mm male copper Return - 22mm male copper

Weights

Packaged Boiler Carton 28 kg Installation Lift Weight 27 kg

Flue Length Max Min

Metres 12.5 3.0

Dimensions

Casing Height - 538mm Casing Width - 383mm Casing Depth - 306mm

Boiler Set Temperature

Max Min

°C 75 25

Firefront

See the instructions supplied with the firefront for all Technical Data

4.0 System Details

4.1 Water Circulating Systems

1. The appliance is suitable for use on fully pumped systems ONLY which may be sealed or open vented.

2. The following conditions should be observed at all

times:

The static head must not exceed 30m of water. The static head must not be less than 1m 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 they do not restrict the servicing of the boiler. Position isolating valves as close as possible to the circulating pump. There is a drain cock supplied in the plumbing kit.

4.2 Treatment of Water Circulating

Systems

All recirculatory water systems will be subject to corrosion unless they are flushed and an appropriate water treatment is applied. To prevent this, follow the guidelines given in BS 7593 “Treatment of Water in Domestic Hot Water Central Heating Systems” and the treatment manufacturers instructions.

Treatment must involve the use of a proprietary cleanser, such as Sentinel X300 or X400, or Fernox F3 and an inhibitor such as Sentinel X100 or Fernox MB-1.

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 service in accordance with the inhibitor manufacturer’s instructions. (Test kits are available from inhibitor stockists.)

For information or advice regarding any of the above contact Technical Enquiries 0844 871 1555.

4.3 Pipework

1. The sizes of the flow and return pipes from the boiler should be determined by normal methods according to the requirements of the system.

2. It is recommended that the system is designed for a drop in temperature across the system of between 11& 20°C.

3. 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. 4).

4.4 System Controls

1. The system in which the appliance is installed should include a control system.

2. Such a system would comprise a timer control and a separate room and/or cylinder thermostat as appropriate.

3. The boiler should be controlled so that it operates on demand only.

4.5 Fully Pumped Open Vent System (Fig. 5)

1. The sizes of the system pipes should be determined by normal methods.

2. The open vent pipe should be a minimum of 22mm and must rise continuously to a point above the feed and expansion tank.

3. The flow pipe from the boiler form part of the vent pipe. No part of the open vent may contain a valve.

4. Inverted pipe runs must be avoided.

5. On low capacity systems with a maximum available flow rate of less than 8.3l/min (temperature differential ›25°C) an external bypass must be fitted .

6. The bypass must be of the automatic pressure operated type.

4.6 Storage Systems

1. For information regarding the use of a Bermuda BBU 15 HE boiler with a storage system, contact the appropriate storage system manufacturer.

4.0 System Details

Air Vent

Boiler

Pump

Radiator Circuit

Fully Pumped System

22mm Open Vent

15mm Cold Feed

Indirect Cylinder

Return

Flow

Fig. 5

Boiler

Flow

Return

Copper

0.5m

Copper

0.5m

Fig. 4

4.0 System Details

4.7 Sealed Systems (Figs. 6, 7 & 8)

1. Installation. The installation must comply with the requirements of BS 6798 and BS EN 12828. The British Gas publication “British Gas Specification for Domestic Wet Central Heating Systems” should also be consulted.

2. Pressure Relief Valve. A non-adjustable spring loaded pressure relief valve, preset to operate at 3 bar (45 lbf/in

) shall be used. It must comply with BS 6759:1 and include a manual testing device. It shall be positioned in the flow pipe either horizontally or vertically upwards and close to the boiler. No shut off valves are to be placed between the boiler and the safety valve. The valve should be installed with a discharge pipe which permits the safe discharge of steam and hot water such that no hazard to persons or damage to electrical components is caused.

3. Pressure Gauge. A pressure gauge incorporating a fill pressure indicator, covering the range 0-4 bar (60 lbf/in

) shall be fitted to the system. It should be connected to the system, preferably at the same point as the expansion vessel. Its location should be visible from the filling point.

Air Vent

Boiler

Pump

Radiator Circuit

Fully Pumped Sealed System

Filling Point

Indirect Cylinder

Return

Flow

Pressure Gauge

Safety Valve

Expansion Vessel

Fig. 6

4.0 System Details

4.7 Sealed Systems (cont)

4. Expansion Vessel. A diaphragm type expansion vessel to BS 4814:1 shall be fitted close to the inlet side of the pump. The connecting pipework should not be less than 15mm. Pipework connecting the expansion vessel should not incorporate valves of any sort.

Methods of supporting the vessel are supplied by the vessel manufacturer.

The nitrogen or air charge pressure of the expansion vessel shall not be less than the hydrostatic head, (height of the top point of the system above the expansion vessel). To size the expansion vessel it is first necessary to calculate the volume of water in the system in litres. The following volumes may be used as a conservative guide to calculating the system volume.

Boiler Heat Exchanger: 1.55 litres Small Bore Pipework: 1 litre per kW of system output Micro Bore Pipework: 7 litre Steel Panel Radiators: 8 litre per kW of system output Low Water Capacity Radiators: 1 litre per kW of system output Hot Water Cylinder: 1 litre per kW of system output

If the system is extended, the expansion vessel volume may have to be increased unless provision has been made for extension. Where a vessel of the calculated size is not available, the next available larger size should be used.

The boiler flow temperature is controlled at approx. 75°C.

The vessel size can now be determined from the information in table 1 where V = System volume in litres.

5. Cylinder. The hot water cylinder must be an indirect coiler type.

6. Method of Make Up. Provision shall be made for replacing water loss from the system either:-

a) From a make up vessel or tank mounted in a position higher than the top point of the system and connected through a non-return valve to the system on the return side of the hot water cylinder or the return side of all heat emitters. or b) Where access to a make up vessel would be difficult by using the mains top up method or a remote automatic pressurisation and make up unit.

7. Mains Connection. There shall be no connection to the mains water supply or to the water storage tank which supplies domestic hot water even through a non-return valve, without the approval of the Local Water Authority.

8. Filling Point. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling.

The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe, provided a ‘Listed’ double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use.

The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment.

Your attention is drawn to: for GB: Guidance G24.2 and recommendation R24.2 of the Water Regulations Guide. for IE: the current edition of IS 813 “Domestic Gas Installations”.

Double Check Valve

Heating System

Temporary Hose

Hose Union

Stop Valve

Mains Water Supply (Service Pipe)

Heating System

Pressure Pump Reducing Valve (if required)

Cistern

Stop Valve

Mains Water Supply

Filling a Sealed Water System (Method 1)

Mains Topping Up Method NOTE: This method of filling a sealed system

may only be used if acceptable to Local Water Undertaking

Filling a Sealed Water System (Method 2)

Cistern Filling Method NOTE: Cistern to be supplied through a

temporary connection from a service pipe or cold water distributing pipe

Vessel Charge Pressure (bar)

Initial System Pressure (bar) Expansion Vessel Volume (litres)

0.5

1.0

V x 0.11

1.5

1.0

V x 0.087

Table 1

Fig. 7

Fig. 8

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