Baxi Bahama 100 Gas Fired Wall Mounted Combination Boiler Installation and Servicing Instructions BAXI
Page 2 Natural Gas Baxi Bahama 100 G.C.Nº 47 075 02 Baxi 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 designed into every Baxi product products which fulfil the demands and needs of customers, offering choice, efficiency and reliability.
Contents – page 3 Section Page 1.0 Introduction 4 2.0 General Layout 5 3.0 Appliance Operation 6 4.0 Technical Data 7 5.0 Dimensions and Fixings 8 6.0 System Details 9 7.0 Site Requirements 12 8.0 installation 17 9.0 Electrical 24 10.0 Commissioning the Boiler 26 11.0 Fitting the Outer Case 28 12.0 Servicing the Boiler 30 13.0 Changing Components 28 14.0 Short Parts List 41 15.0 Fault Finding 42 16.0 Operational Flow Chart 46 17.
1.0 Introduction – page 4 Fig. 1 NOTE: 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. Fig. 2 “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.
2.0 General Layout – page 5 2.1 Layout 1. Backplate 2. Airbox 3. Fan Assembly 4. Primary Heat Exchanger 5. Combustion Chamber 6. Burner Assembly & Electrodes 7. Gas Valve Assembly 8. Automatic Air Vent 9. Flow Switch Heating Circuit 10. Flow Switch DHW Circuit 11. Circulation Pump 12. Facia Box 13. Safety Thermostat 14. CH Thermostat Sensor 15. Three Way Valve 16. DHW Plate Heat Exchanger 17. ON-Off Selector Switch 18. DHW Temperature Adjustment 19.
3.0 Appliance Operation – page 6 NOTE: All delay timers mentioned in 3.1 and 3.2 are overridden by domestic hot water demand. 3.1 Central Heating Mode 1. With a demand for heating, the pump circulates water through the primary circuit. At a flow rate of approximately 125 I/hr the central heating flow switch operates, initiating the ignition sequence. 2. The main burner ignites at low rate, then the gas valve controls the gas rate to maintain the heating temperature measured by the thermostat sensor.
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6.0 System Details – page 9 6.1 Information 1. The Baxi Bahama 100 Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 See text of entry for installation requirements and notes. b) IRN 116 Byelaw 90 and 9l. c) IRN 302 Byelaw 14. 2.
6.0 System Details – page 10 Fig. 3 6.5 System Filling and Pressurising 1. 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. 2. The filling method adopted must be in accordance with all relevant water supply bye-laws and use approved equipment. 3. Your attention is drawn to: IRN 302 and Byelaw 14. 4.
6.0 System Details – page 11 6.8 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply bye-laws. 2. Your attention is drawn to: IRN 116 and Byelaw 90 and 91. Sealed primary circuits and/or secondary hot water systems shall incorporate a means for accommodating the thermal expansion of water to prevent any discharge from the circuit and/or system, except in an emergency situation. 3.
7.0 Fig. 5 Site Requirements – page 12 7.1 Information 1. The installation must be carried out by a CORGI Registered Installer or other registered competent person and be in accordance with the relevant requirements of the current 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.
7.0 Site Requirements – page 13 7.5 1. Ventilation of Compartments Where the appliance is installed in a cupboard or compartment, no air vents are required. NOTE: The ventilation label on the front of the outer case MUST NOT BE REMOVED when the appliance is installed in a compartment or cupboard. 2. Fig. 8 7.6 BS 5440: Part 2 Clause 4.2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. Gas Supply 1.
7.0 Site Requirements – page 14 7.8 Flue Fig. 9 1. 2. 3. 4. 5. An internal fitting kit is available for installations where the flue terminal is inaccessible from the outside. This is available direct from Baxi Heating. Quote Part Nº 236441 when ordering. The following guidelines indicate the general requirements for siting balanced flue terminals. Recommendations for flues are given in BS 5440 Pt.1.
7.0 Site Requirements – page 15 7.9 Flue Dimensions Fig. 11 See Section 1.2. The standard horizontal flue kit allows for flue lengths between 200mm (7 7/8 in) and 1m (39 3/8 in) from elbow to terminal (Fig. 11). The maximum permissible equivalent flue length is: 4 metres. NOTE: Each additional 45º of flue bend will account for an equivalent flue length of 0.5m. eg. 45º = 0.5m, 90º = 2 x 45º = 1m etc. 7.10 Flue Terminal Trim 1. The trim should be fitted once the flue is secure. 2.
7.0 Site Requirements – page 16 7.12 Flue Options 1. The Baxi Bahama 100 can be fitted with flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. 3. Maximum permissible equivalent flue lengths are:Horizontal 4.0 metres Vertical 4.0 metres Vertical (Twin) 22.0 metres 4. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 45º bend 90º bend 0.5 metres 1.
8.0 Installation – page 17 8.1 Initial Preparation Fig. 13 The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.6). NOTE: If the boiler is to be pre-plumbed, follow both these instructions and those on the boiler pack. 1. Remove the fixing template (Fig. 13) from the fixing carton. 2. After considering the site requirements (see Section 7.0) position the template on the wall ensuring it is level both horizontally and vertically.
8.0 Installation – page 18 8.3 Preparing The Boiler Fig. 15 1. Remove the outer carton. 2. Hinge down the lower door panel to the horizontal and gently pull forward to remove (Fig. 15). 3. Remove the outer case fixing screws (Fig. 15). Slide the outercase upwards to disengage the hooks on the backplate and remove (Fig. 16). 4. Remove the sealing plugs from the copper bends (Fig. 16). 5. Stand the boiler on its base by using the rear lower edge as a pivot.
8.0 Installation – page 19 8.4 Fitting The Boiler 1. Fit the central heating return filter (Fig. 18) and flow regulator (Fig. 18a). 2. Lift the boiler using the lower edges of the combustion box. 3. Lift the boiler over the support bracket and engage onto the top hooks (Fig. 17). 4. To gain access to the connections between boiler and valves, release the facia securing screws (¼ turn) and hinge down the facia box. 5. Make the gas connection first (Fig. 19). This will centralise the boiler.
8.0 Installation – page 20 8.6 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths 200mm minimum to 965mm maximum (measured from the edge of the flue elbow outlet). Rear Flue: maximum wall thickness - 865mm Side Flue: maximum wall thickness - 805mm (left or right) 2. If using the optional internal fitting kit, flue extension kit or elbows, refer to the instructions provided with the kits. 3. Fit the captive nuts supplied in the kit to the boiler outlet (Fig.
8.0 Installation – page 21 8.6 Fitting the Flue (Cont) 10. Slide the rubber seal over the air duct with the thicker section outermost (Fig. 25). Align the seal with the end of the air duct. 11. Engage uncut end of the flue duct in the flue elbow using soap solution to ease the engagement (Fig. 26). 12. Insert the flue duct into the air duct and engage it in the terminal (Fig. 27). 13. Slide the rubber sleeve over the joint between the air duct and elbow. 14. Align the clip over the rubber seal.
8.0 Installation – page 22 8.7 Making The Electrical Connections 1. The electrical connections are on the left hand side of the unit. 2. Undo the two screws securing the small cover and remove the cover (Fig. 29). 3. Undo the two screws securing the L/N/E cable clamp and place to one side (Fig. 30). 4. If fitting an integral timer kit please refer to kit instructions at this stage. 5. Route the incoming electrical cable/s over the top edge of the support bracket.
8.0 Fig. 34 Installation – page 23 8.9 1. A 2-wire or 3-wire room thermostat can be fitted to the Baxi Bahama 100 terminal block. 2. To fit a 2-wire thermostat, remove link and wire the thermostat switch between positions 3 & 4 (Fig. 34). To fit a 3-wire thermostat, remove link and wire the thermostat switch between positions 3 & 4. The anticipator should be wired to position 5, as this provides a continuous mains neutral (Fig. 35). 3. 4. 8.10 1. 8.11 A cable clamp is provided for incoming cables.
9.0 Electrical – page 24 9.
9.0 Electrical – page 25 9.
10.0 Commissioning the Boiler – page 26 10.1 Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Open the cold feed to the boiler. 3. Open all hot water taps to purge the DHW system. 4. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. 5. Open the automatic air vent (Fig. 37).
10.0 Commissioning the Boiler – page 27 10.3 Adjusting C.H. Setting Pressure The appliance is preset to supply an output of 80,000 Btu/h (23.45 kW) for central heating. If the system design requires an output other than this, proceed as described below. 1. Fit a pressure test gauge to the burner pressure test point (Fig. 39a). 2. Remove the rubber bung in the facia cover panel, and identify the central heating pressure control potentiometer (Fig. 39c & 39d). 3.
11.0 Fitting the Outer Case – page 28 11.1 Fitting The Outer Case Fig. 40 Fig. 41 1. Position the outercase on the chassis, ensuring that the four slots in the side flanges align with the hooks on the chassis (Fig. 40). 2. Insert the two fixing screws into the sides of the chassis (Fig. 41). 3. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 4. Locate the lower door panel on to its hinges and gently hinge up (Fig. 41). 5.
12.0 Servicing the Boiler – page 29 12.1 Annual Servicing Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended. 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. 2. After servicing, complete the relevant section of the “Benchmark” Installation, Commissioning and Service Record Log Book. This should be in the possession of the user. 3.
13.0 Changing Components – page 30 13.1 Changing Components IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended. 1. Remove the outer case and lower door panel as described under “Installation” Section 8.3. 2. Isolate the water circuits and drain as necessary.
13.0 Changing Components – page 31 To change the heat exchanger - fan - burner and injector manifold - flame sensing probe -spark electrode and return electrode. 1. Remove the airbox door panel by releasing the six ¼ turn screws (Fig. 49). 2. Undo the four screws securing the combustion box door and remove the door (Fig. 49). 13.4 Heat Exchanger (Fig. 50) 1. Remove the air vent connecting pipe by undoing the nuts at the air vent and the return pipe connection. 2.
13.0 Changing Components – page 32 13.6 Burner and Injector Manifold Fig. 52 1. Disconnect the spark, return and flame sensing electrode leads from the electrodes whilst noting their positions (Fig. 53). 2. Loosen the lower burner securing screws and remove the upper securing screws (Fig. 52). 3. Remove the burner (Fig. 52). 4. Remove the injector manifold securing screws and withdraw the manifold from the burner feed “O” ring joint (Fig. 52). 5.
13.0 Changing Components – page 33 To change the gas valve - spark generator -pump (head only) - pump - thermistor & safety thermostat expansion vessel - pressure relief valve - flow switches pressure gauge -diverter valve - domestic hot water filter & flow regulator cartridge - central heating return filter domestic hot water heat exchanger - CVI ignition cartridge - ECS hydraulic control board - Release the two facia securing screws (¼ turn) and hinge down the box. 13.9 Gas Valve (Figs. 54 & 55) 1.
13.0 Changing Components – page 34 13.11 Pump 1. If only the head needs replacing. A standard Grundfos UPS 15-60 pump head is interchangeable (see section 13.13 for details). 2. This must be switched to setting Nº 3 (Fig. 57). 13.12 Pump (Complete) (Fig. 56) 1. Unplug the wiring harness from the pump. 2. Remove the four screws retaining the pump backplate to the hydraulic manifold. 3. Remove the pump. 4. Fit the new pump and reassemble in reverse order. 13.13 Pump (Head Only) (Fig. 58) 1.
13.0 Changing Components – page 35 13.14 Thermistor 1. Remove the thermistor from the flow pipe. 2. Remove the electrical connections from the sensor. 3. Fit the new thermistor and reassemble in reverse order. 13.15 Safety Thermostat 1. Remove the retaining clip from the flow pipe. 2. Remove the electrical connections from the thermostat. 3. Remove the thermostat from the clip. 4. Fit the new thermostat and reassemble in reverse order. 13.16 Expansion Vessel 1.
13.0 Changing Components – page 36 13.18 Pressure Relief Valve (Fig. 62) 1. The pressure relief valve is positioned on the central heating bypass pipe at the diverter valve manifold. 2. Drain the system at an appropriate low point. 3. Disconnect the union between the valve and the discharge pipe. 4. Slacken the grub screw retaining the valve. 5. Pull the valve sideways to disengage it. 6. Fit the new pressure relief valve and reassemble in reverse order. 13.19 Flow Switches (Fig. 63) 1.
13.0 Changing Components – page 37 13.21 Diverter Valve To change the diverter valve actuator: 1. Remove electrical plug (Fig. 65). 2. Depress the locking latch whilst rotating the head anticlockwise through 45º (Fig. 65) and pull forward (Fig. 66). 3. Fit the new diverter valve actuator and reassemble in reverse order. To change the diverter valve cartridge: 1. Remove the diverter valve actuator (Figs 65 & 66). 2.
13.0 Changing Components – page 38 13.22 Domestic Hot Water Filter and Flow Regulator Cartridge (Fig. 69) 1. Isolate the cold water inlet tap. 2. Undo the cold water inlet pipe nut. 3. Swivel the bend to gain access to the filter and flow regulator cartridge. 4. Remove the fibre washer and remove the cartridge. 5. Fit the new filter and regulator cartridge and renew the fibre washer. Reassemble in reverse order. 13.23 Central Heating Return Filter (Fig. 70) 1.
13.0 Changing Components – page 39 13.24 Domestic Hot Water Heat Exchanger 1. Remove the gas valve (see 13.9 Gas Valve section 1-6 incI.). 2. Remove the cold inlet flow switch head (see Section 13.18 1-3 incI.). 3. Remove the two screws securing the plate heat exchanger to the manifolds (Fig. 71). 4. Remove the gas valve outlet retaining clip (see 13.9 Gas Valve section). 5. Push the plate heat exchanger backwards and tilt through 45º anti-clockwise. 6.
13.0 Changing Components – page 40 13.25 Fig. 75 Hydraulic Control Board 1. Remove the facia cover by removing the securing screws and pulling it forwards whilst lifting (Fig. 73). 2. Remove all the connections from the control board (Plugs are removed by springing the retaining clip outwards and withdrawing them vertically). 3. Remove the screws fixing the control board to the facia panel and withdraw the board taking care to leave the temperature control spindles in place (Fig. 75). 4.
14.0 Short Parts List – page 41 Short Parts List Key No. G.C. No. Description Manufacturers Part No.
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16.0 Operational Flow Chart – page 46 16.1 Central Heating Mode 16.
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17.0 Ignition Flow Chart – page 48 17.1 Ignition Phase IGNITION PHASE (From Section 16.0 Operation Flow Chart) 17.
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Page 51 Baxi Limited manufacture a comprehensive range of products for the domestic heating market. Gas Central Heating Boilers (Wall, Floor and Fireside models). Independent Gas Fires. Renewal Firefronts. Gas Wall Heaters. Solid Fuel Fires. If you require information on any of these products, please write, telephone or fax to the Sales Department.
The Baxi Helplines - Page 52 Comp Nº 245528 – Iss 3 – 4/00 For General Enquiries +44 (0)1772 695 555 For After Sales Service +44 (0)1772 695 505 For Technical Enquiries +44 (0)1772 695 504 BAXI Baxi Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www.baxi.
