Installation & Servicing Instructions 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.
Natural Gas Building Regulations and the Benchmark Commissioning Checklist 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 Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department.
Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Self Certification Scheme Building Control Install and Commission this appliance to manufacturer's instructions Contact your relevant Local Authority Building Control (LABC) who will arrange an inspection or contact a government approved inspector Complete the Benchmark Checklist If you notify via the ‘Gas Safe Register’, the register will issue the Building Regulations certificate on members’ behalf
Legislation 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.
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.
Contents Section 6 © Baxi Heating UK Ltd 2014 Page 1.0 Introduction 7 2.0 General Layout 8 3.0 Technical Data 10 4.0 System Details 11 5.0 Site Requirements 14 6.0 Installation 22 7.0 Completion & Commissioning 26 8.0 Annual Servicing 29 9.0 Changing Components 31 10.0 Setting the Gas Valve 35 11.0 Fault Finding 36 12.0 Short Parts List 40 13.
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 4.86kW 15.7kW (condensing) 5.25kW (condensing) according to system load. 4.
2.0 General Layout 2.1 1 2 3 17 4 5 16 15 14 6 13 7 12 8 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.
2.0 General Layout 1 2.2 8 2 3 9 4 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 Concentric 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 5 6 8 11 10 12 7 13 Fig.
3.0 Technical Data 3.1 Sedbuk Declaration For Bermuda BBU 15 HE The seasonal efficiency SEDBUK 2005 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 0086. Bermuda BBU 15 HE Appliance Type C33 Appliance Category CAT I 2H Inlet Pressure (Natural Gas - G20) mbar 20 Injector (Natural Gas - G20) 420 (4.2 mm) NOx Class 5 (31mg/kWh) Heat Input (Net) kW Max 15.
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.
4.0 System Details Copper 0.5m Copper 0.5m 4.3 Flow Boiler Return Copper 1m 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. Fig. 4 22mm Open Vent 3. In systems using non-metallic pipework it is necessary to use copper pipe for the boiler Flow and Return.
Air Vent 3 Litre Top Up Bottle (if required) 4.0 System Details 4.7 Filling Point Pressure Gauge Safety Valve Pump Radiator Circuit Expansion Vessel Boiler System Drains at Low Point Max Boiler Flow Vessel Charge Pressure (Bar) Initial System Pressure (Bar) Multiply Total Water Content Of System By (Litres) 0.5 0.5 1.0 1.5 2.0 0.067 0.112 0.207 0.441 1.0 1.5 2.0 0.087 0.152 0.330 1.5 2.0 0.125 0.265 1.5 Fig.
5.0 Site Requirements IMPORTANT NOTES: If the depth of BUILDERS opening is at the minimum (i.e. 400mm) it will be necessary to use a Spacer Kit (see Section 5.4). 5.1 1. The boiler unit is designed to fit within a standard builders opening, the MINIMUM dimensions of which are as shown. All dimensions in this section are general RECOMMENDATIONS. It may be possible to install & maintain the appliance when some of the dimensions are different.
5.0 Site Requirements 5.5 Flue 1. The following guidelines indicate the general requirements for installation of flues:For GB recommendations are given in BS 5440 Part 1. For IE recommendations are given in the current edition of I.S. 813 “Domestic Gas Installations”. A B C 2. Only one of the three available MULTIIFIT vertical concentric Flexi Flue kits approved for use with the boiler can be used (10m kit 710143901 or 12.5m kit 710144001). Any proprietary flue systems, terminals, adaptors etc.
5.0 Site Requirements 5.6 Overall Depth = Overall Width = 330mm Ventilation 1. No ventilation is required for the boiler in the room of installation. 430mm 5.7 Gas Supply (Fig. 11) 1. The gas installation should be in accordance with relevant standards. In GB this is BS 6891. In IE this is I.S. 813 “Domestic Gas Installations”. The connection at the appliance is 15mm copper tail located at the rear of the gas tap. Overall Height = 550mm 2.
5.0 Site Requirements IMPORTANT NOTES: 5.9 FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER. CAREFUL CONSIDERATION MUST BE GIVEN TO THE POSSIBILITY OF THE PIPEWORK BEING SUBJECT TO FREEZING CONDITIONS AND APPROPRIATE MEASURES TAKEN TO PREVENT BLOCKAGE. CORRECT INSTALLATION IN ACCORDANCE WITH THIS SECTION WILL CONSIDERABLY MINIMISE THE LIKELIHOOD OF BLOCKAGE AND SUBSEQUENT BOILER LOCK-OUT. Condensate Drain - General 1.
5.0 Site Requirements 5.11 Condensate Disposal - Pipe Runs 1. 3.5 metres of flexible 10mm condensate discharge pipe and a 10mm push fit elbow are supplied with the boiler. 2. The 10mm pipe can be routed to a maximum of 2.5 metres vertically as measured from the outlet (equivalent to the total available head of 3 metres) and then discharge via gravity or be routed horizontally (Fig. 12). R100 min. Fig. 13 3.
5.0 Site Requirements 5.11 B Condensate Disposal Pipe Runs (cont.) 7. When A to B at max. (2.5m) B to C can be up to 8m 8. When B to C at max. (10m) A to B can be up to 0.5m See Table for maximum no. of elbows 9. If the entire length of discharge pipe is 10mm diameter pipe the point of discharge into a drain or similar must be a MINIMUM of 150mm above the base of the boiler to prevent syphonic action emptying the sump (Fig. 16). C A Fig.
5.0 Site Requirements 5.11 Condensate Disposal Pipe Runs (cont.) Underfloor Runs 10. On installations where the discharge pipe is routed lower than the outlet connection Point ‘X’ must always be at least 150mm above the baseline of the boiler (Fig. 17). 11. Once larger diameter pipe is used smaller pipe must not be fitted further downstream. 12. There must be no air breaks within the dwelling ! 13. When calculating the vertical run* it is necessary to include the 0.5m from the pump to the boiler outlet.
5.0 Site Requirements Termination via internal discharge branch e.g sink waste - downstream 5.11 Pipe must terminate above water level but below surrounding surface From Boiler Sink Condensate Disposal Pipe Runs (cont.) 14. Ensure that the condensate can discharge freely (without blockage or restriction of the pipe) into the drain. 15.
6.0 Installation INSTALLATION SEQUENCE There are 4 main elements to the installation of the Baxi Bermuda BBU 15 HE:• Preparation of pipework & opening • Inserting the flue into the chimney • Siting & fixing the boiler • Fitting the terminal assembly The sequence in which these are performed may depend upon various factors beyond the scope of these instructions. The above list is intended as a guide based on a typical installation.
6.0 Installation 6.2 Flue System (cont.) 8. It is recommended that the Pull Cone Flue Adaptor (part no. 720111801) is used as shown to ease the fitting of the flue into the chimney and prevent damage to the adaptor. Fig. 27 Fig. 26 9. The cone has two internal lugs that engage on the boiler adaptor in a bayonet action (Figs. 26 & 27). 10. A suitable weight should then be tied to the guide rope fixed to the cone. The weight can then be passed into the chimney and will draw the guide rope down (Fig. 28).
6.0 Installation 6.2 Air Cowl Flue System (cont.) 16. Pass the air duct collar and air cowl over the 60mm flue duct (Fig. 34) and secure the collar to the closure plate with the screws supplied (Fig. 35). The air cowl will fit snugly over the collar. Fig. 35 17. Cut the protruding 60mm flue duct down so that 5 ribs are visible and fit the remaining 60mm lip seal into the first groove (Fig. 36). The flue duct adaptor can now be fitted in the same manner as the boiler adaptor (Fig. 37).
6.0 Installation 6.3 Siting the Boiler IMPORTANT: This product should be lifted and handled by two people. Stooping should be avoided and protective equipment worn where necessary. Carrying & lifting equipment should be used as required, e.g. when installing on another floor. Fixing Slot 1. Lift the boiler from the packing base and place into the opening. 2. Align the boiler centrally as far back in the opening as possible, and ensure the distance between each side and the opening is equal.
Auto Air Vent 7.0 Completion & Commissioning ON/OFF Service Reset Boiler Control 7.1 Completion 1. Seal off any secondary openings within the builders opening after wrapping the gas and water pipes through the brickwork and within the opening itself. (B.S. 5871 Part 1). Reset 2. Take the Boiler Control from the firefront packaging and connect it to the boiler (Fig. 44). 7.2 Commissioning the Boiler On/Off 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. Fig.
7.0 Completion & Commissioning IMPORTANT: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type specified on the appliance data plate. It is still necessary to check combustion as part of commissioning. Do not adjust the air/gas ratio valve. 7.2 Commissioning the Boiler (cont.) Checked: That the boiler has been installed in accordance with these instructions. The integrity of the flue system and the flue seals, as described in Section 6.2.
Set Boiler to Maximum Rate (see 7.2.14) Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser. Verify Flue Integrity Indication that products of combustion & inlet air are mixing - further investigation is required. Check all flue components are correctly assembled, fixed & supported. Check the flue & terminal are unobstructed. Is O2 ≥ 20.6% and CO2 < 0.2% ? No TURN APPLIANCE OFF ! Call 0844 871 1555 for advice.
8.0 Annual Servicing Electrical Test Point This test point must be used to confirm complete isolation of the appliance if a Service Inspection is to be performed (Section 8.2). From left to right the terminals are Switched Live, Live, Neutral and Earth. With the Mains Input Plug removed, check using a suitable multimeter. 8.1 Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually.
8.0 Annual Servicing PCB Control Box Securing Screw 8.2 Annual Servicing - Inspection Reset Switch 1. Ensure that the boiler is cool. PCB Control Box 2. Ensure that the gas supply to the boiler is isolated. 3. Operate the Reset switch (Fig. 51) to activate the condensate pump and then repeat. This will empty most of the condensate from the sump. Isolate the boiler from the electrical supply (see Electrical Test Point, Fig. 48). Off Position Fig. 51 4. Undo & remove the flue sampling plug and washer.
9.0 Changing Components 9.1 Changing Components To change any components on the back boiler it is necessary to remove the firefront. Refer to the Installer Guide that accompanies the firefront for details of removal. After changing any components carry out gas soundness checks. Fig. 45 1. Ensure that the boiler is cool and that the electrical and gas supplies are isolated. 2. Undo & remove the flue sampling plug and washer. Remove the screws retaining the boiler front panel, and lift the panel away.
Spark Generator 9.0 Changing Components 9.5 Fan (Fig. 56) 1. Disconnect the two plugs from the fan motor and remove the sensing pipe from between the gas valve and fan outlet. Plug 2. Remove the gas feed pipe and washers, and extract the injector from the gas/air inlet manifold. Injector 3.
9.0 Changing Components 9.8 Gas Valve (Fig. 58) IMPORTANT:After replacing the valve the CO2 must be checked and adjusted as detailed in Section 10.0 Setting the Gas Valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see Section 8.1 1. Disconnect the plug and earth wire from the gas valve and remove the sensing pipe from between the valve and fan outlet. 2.
9.0 Changing Components Safety Thermostat 9.9 PCB (Fig. 61) 1. Pull off the two control knobs and disengage the securing tabs of the cover. Undo the screws securing the PCB. Flow Pipe 2. Draw the PCB forwards and disconnect the wiring. Transfer the two potentiometer drive pins to the new PCB and replace in reverse order of dismantling. Fig. 59 3. Ensure that the wiring connectors are pushed fully on to the PCB terminals. 9.10 NTC (Fig. 60) 1. Disconnect the 2 pin plug.
10.0 Setting the Gas Valve 10.1 Setting the Gas Valve (CO2 check) IMPORTANT:The CO2 must be only be checked and adjusted to set the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see Section 8.1 Flue Sampling Point 1. The combustion (CO2) may be checked after running the boiler for several minutes. To do this it is necessary to set the boiler to ‘Calibration Mode’. Display 2. Ensure that all external controls are calling for heat.
11.0 Fault Finding 11.1 NOTE: When instructed to operate the reset button, press and hold for 5 seconds to reset the boiler. Initial Fault Finding Checks 1. Check that gas, water and electrical supplies are available at the boiler. 2. Electrical supply = 230V ~ 50 Hz. Check the CH & DHW system. The preferred minimum gas pressure is 20 mbar. 3. Carry out electrical system checks, i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable meter.
11.0 Fault Finding Refer to Section 13.0 “Boiler Internal Wiring” for position of terminals and components Central Heating - Follow operational sequence Turn on Power Supply Display Illuminates NO NOTE: Sections ‘A’ to ‘L’ referred to in the chart opposite are on the following pages Go to section ‘A’ YES Error 110 flashing Error 131 flashing YES Press the Service Reset switch for 5 seconds YES If the error 110 is still flashing.
Fault Finding Solutions Sections 11.0 Fault Finding A Is there 230V at: 1. Main terminals L and N 2. Main terminal fuse NO Check electrical supply NO Replace fuse NO 3. Check wiring PCB - X1 connector terminals 1,2 B Check all system wiring and pump C Service Reset Display illuminated Condensate Pump does not run NO Replace PCB On Reset is there 230V at: 1. PCB - X3 connector terminals 5 & 6 for at least 2 seconds NO Replace PCB 2.
H 1. 2. Check the gas supply pressure: For Natural Gas greater than 10 - 11 mbar 11.0 Fault Finding 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 YES Flame current should be more than 0.5 μA I Overheat Thermostat or Condensate Safety Float Switch operated or faulty NO Replace PCB Replace flame sensing electrode Allow to cool.
12.0 Short Parts List Short Parts List A J B I C G H E F D 40 © Baxi Heating UK Ltd 2014 K Key No. Description Manufacturers Part No. A Burner Assy 720125701 B Injector 720126301 C Ignition Lead 720127501 D Gas Valve 720301001 E P.C.
13.0 Boiler Internal Wiring 13.
GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.
SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. SERVICE 01 Date: SERVICE 02 Engineer name: Engineer name: Company name: Company name: Telephone No: Telephone No: Gas safe register No: Record: At max.
Please complete the boxes below 9.0 Warranty & Service Serial Number Standard Warranty Terms & Conditions To activate your second year free warranty you must register your boiler with heateam the service division of Baxi Heating UK Ltd either by completing and returning the registration card or calling our telephone registration line on 0800 013 7989.
