Please leave these instructions with the user Baxi Bermuda Inset 2 Boiler 50/4 E Fireside Gas Central Heating Unit Installation and Servicing Instructions
Natural Gas Baxi Bermuda Inset 2 Boiler 50/4 E G.C.No. 44 075 03 For use with the following firefronts: Baxi Bermuda Inset 2 BS Super G.C.No. 37 075 40 Baxi Bermuda Inset 2 TS Super G.C.No. 37 075 41 Baxi Bermuda Inset 2 KS Super G.C.No. 37 075 42 Baxi Bermuda Inset 2 FS Super G.C.No. 37 075 43 Baxi Bermuda Inset 2 CS Super G.C.No. 37 075 44 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.
Contents Section Page 1.0 Introduction 4 2.0 Technical Data 5 3.0 System Details 6 Water Circulating Systems Treatment of Water Circulating Systems Pipework System Controls Fully Pumped System Storage Systems Pumped Heating & Gravity Hot Water Safety Limit Kit & Sealed Systems 4.0 Site Requirements 9 Builders Opening Location Fireplace Opening & Surround Frame Extension Kit Flue Ventilation Gas Supply Electrical Supply 5.0 Electrical 12 6.
1.0 Introduction 1.1 Description 1. The Baxi Bermuda Inset 2 is a combined central heating boiler and gas fire designed for installation within a builders opening in the living space of a dwelling. 2. The firefront is intended for hearth mounting. Baxi Bermuda Inset 2 Boiler 50/4 E 3. These instructions relate to the central heating boiler section of the appliance (Fig. 1). 4. The boiler is range rated, with outputs as shown: HEAT OUTPUT Model Max 50/4 E 14.65kW Mid 13.19kW Min 11.
2.0 Technical Data Bermuda Inset 2 Boiler 50/4 E The Boiler is for use with Natural Gas only. mbar Inset 50/4 E hydraulic resistance 22 20 18 16 14 12 10 8 6 4 2 0 0 5 with injector Tee 10 l/min 15 Heat Input kW Btu/h Max 18.79 64,100 Mid Min 17 15.2 58,070 51,850 Heat Output kW Btu/h Max 14.65 50,000 Mid Min 13.19 11.72 45,000 40,000 Burner Pressure mbar in wg Max 17 6.8 Mid 14 5.6 Water Content litres gallons Max 1.6 0.35 Gas Connection Rc 1/2 (1/2 in BSPT) Min 11 4.
3.0 System Details 3.1 Water Circulating Systems 1. The appliance is suitable for open vented systems which are either fully pumped or pumped central heating with gravity domestic hot water. 2. 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.
3.0 System Details 3.3 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. Copper 0.5m Copper 0.5m Flow Boiler Return Copper 1m Fig. 2a 2. It is recommended that the system is designed for an 11°C (20°F) drop in temperature across the system. 3. In systems using non-metallic pipework it is necessary to use copper pipe for the boiler Flow and Return.
3.0 System Details 3.6 Storage Systems 1. For information regarding the use of a Bermuda Inset 2 boiler with a storage system, contact the appropriate storage system manufacturer. 3.7 Pumped Heating & Gravity Hot Water (Fig. 4) 1. The sizes of system pipes should be determined by normal methods. 2. The gravity flow pipe should rise vertically as close as possible to the boiler, avoiding sharp bends and tight elbows. 22mm Open Vent 3.
4.0 Site Requirements 590mm (2315/64in) max Fireplace Opening 560mm (22in) min 584mm (23in) min 4.1 Builders Opening (Fig. 5) 1. The boiler unit is designed to fit within a standard builders opening, the minimum dimensions of which are as shown. Height Width Depth 584mm (23in) 584mm (23in) 375mm (143/4in) 460mm (18in) min 560mm (22in) max 584mm (23in) min 3. The base of the opening should be sound and non-combustible and must be flat and level.
4.0 Site Requirements 4.5 Flue 1. The flue installation must conform to BS 5440 Pt 1. The flue must have a minimum vertical height of 3m (10ft) and have a minimum internal cross section area of 12,700 mm2 (20in2), this is satisfied by a flue of 125mm (5in) internal diameter. A suitable terminal is required for all installations. 2. 9in X 9in Brick Flues previously used for other fuels must be thoroughly swept. The flue must be lined with a 125mm (5in) flexible liner.
4.0 Site Requirements 4.6 Ventilation 1. Ventilation air supply to BS 5440 Pt 2 is required. The permanent ventilation area size requirements are as shown: (12.42in2) 80.1cm2 2. The permanent vent may be directly into the room containing the appliance. The vent may also be sited in another (not a bedroom, toilet, bathroom or kitchen) room provided an interconnecting vent is used. 3. The vent must not be installed inside the builders opening.
5.0 Electrical 5.1 Illustrated Wiring Diagram Key b - blue r - red p - pink w - white or - orange g/y - green & yellow or/bk - orange & black r/b - red & blue y/r - yellow & red Control Potentiometer & Switch y/r or/bk r/b Gas Valve or g/y b r b p p w w Thermostat Sensor Printed Circuit Board Electrode Fig. 7 5.
6.0 Installation Retaining Strip Thermostat Sensor Blanking Disc Boiler Door 6.1 Initial Preparation Rubber Seal ‘P’ Clip Heat Exchanger Baffles 1. Remove the outer carton from the boiler pack. Discard the packing pieces. Remove the boiler hood and fitting kit from it's packing on top of the boiler. 2. The boiler as supplied has the flow and return water connections at the left hand side of the appliance. If this is the required orientation, go to section 6.3. Thermostat Protection Cover 6.
6.0 Installation Adaptor 6.3 Connecting the Sensing Pipe 1. Remove the protection cap from the sensing pipe adaptor on the burner mounting plate. Slacken the screw retaining the sensing pipe ‘P’ clip (Fig. 9b, 9c & 9d). Fig. 9b ‘P’ Clip 2. Manouevre the pipe so that the flared end aligns with the adaptor. Engage the nut on the adaptor and tighten finger tight. Tighten the ‘P’ clip retaining screw and tighten the nut onto the adaptor using a suitable spanner (Fig. 9c & 9d). Sensing Pipe Fig. 9c Fig.
6.0 Installation Plug Remaining Connection 6.7 Pumped Flow Use Either Connection Water Connections 1. The boiler has one return and two flow tappings, Rc1 (1in BSP). The flows are the two upper tappings. The return is the lower position tapping and is marked RETURN. It is essential the flow and return pipes are connected to the correct tappings. 6.8 Fully Pumped Systems (Fig. 16) Pumped Return 1.
6.0 Installation Pumped or Gravity Flow 6.9 Pumped Heating & Gravity Hot Water (Fig. 17) 1. A 1in x 22mm threaded adaptor, two compression nuts and olives and a brass injector tee piece are provided in the kit for the return connection. Pumped Return Gravity Return NOTE: The injector tee must be fitted to the return of all systems with gravity domestic hot water. 2. The 1in x 22mm threaded adaptor provided must be fitted to the lower tapping marked RETURN. Fig. 17 3.
6.0 Installation 6.11 Fig. 20 4 Pin Electrical Plug Electrical Connection 1. The appliance requires an electrical supply from the heating controls system. 2. A permanent live supply is required. WARNING: The appliance must be earthed. The input cable for the appliance should be 0.75mm2 to IEC Code 227 (heat resistant). The system external controls and the appliance must be supplied by the same isolator. 3 Pin Electrical Plug 6.12 Making the Electrical Connection Fig. 21 1.
7.0 Commissioning the Appliance 7.1 Commissioning the Appliance 1. Reference should be made to BS 5449 section 5 when commissioning the boiler and system. 2. Flush the whole system in accordance with BS7593:1992. (See Treatment of Water Circulating Systems section 3.2). Check the system for leaks. 3. Turn the gas service cock 1/4 turn from the off position (Fig. 27). This will supply gas to the boiler only. Purge the air from the gas service pipe in accordance with BS 6891 and test for gas soundness. 4.
8.0 Annual Servicing Off Position 8.1 Annual Servicing 1. To perform annual servicing of the back boiler it is necessary to remove the firefront. Fig. 30 Gas Cock 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. 8.2 Removal of Firefront 1. Isolate the electrical supply to the appliance. Retaining Strip Fig. 31 2. Turn the gas service tap to the off position (Fig. 30).
8.0 Annual Servicing Lint Arrestor 8.4 Cleaning the Lint Arrestor 1. Remove the lint arrestor from its retaining clips on the burner mounting plate and clean away any deposits (Fig. 37). Fig. 37 8.5 Cleaning the Burner & Main Injector 1. Remove the four hexagon headed screws holding the burner to the burner mounting plate (Fig. 38). 2. Carefully clean any deposits from the burner blades and venturi inlet (Fig. 38). 3. Remove the injector and copper sealing washer from the feed pipe.
8.0 Annual Servicing 8.7 Cleaning the Heat Exchanger 1. Remove the top and the centre baffles from the heat exchanger, noting their orientation (Fig. 43). 2. Remove the side and rear insulation pieces by undoing the screws retaining the support brackets and sliding the rear bracket to the left and both side brackets forward (Fig. 44, 45,46 & 47). Fig. 43 Heat Exchanger Baffles 3. Each bracket may then be removed along with the insulation. 4.
9.0 Changing Components 9.1 Changing Components 1. To change any components on the back boiler it is necessary to remove the fire front. Off Position 2. After changing any components carry out gas soundness checks. 9.2 Removal of Firefront Fig. 48 1. Isolate the electrical supply to the appliance. Gas Cock 2. Turn the thermostat knob to the off position (Fig. 52). 3. Turn the gas service tap to the off position (Fig. 50). 4.
9.0 Changing Components 9.6 Printed Circuit Board 1. Remove the controls heat shield from its retaining clips. Control Box Cover 2. Undo the two screws retaining the valve cover assembly and remove the assembly (Fig. 53). 3. Undo the three screws retaining the control box cover and remove the cover (Fig. 52). 4. Disconnect the three multi-pin plugs, flame sensing lead and ignition lead from the PCB, noting their positions (Fig. 52). P.C.B. 5.
9.0 Changing Components Controls Heat Shield 9.8 Gas Valve 1. Remove controls heat shield (Fig. 58). Fig. 58 2. Remove the screws holding the valve cover assembly to the controls mounting bracket and remove the assembly (Fig. 59). Valve Cover Assembly 3. Disconnect the electrical connections from the valve, noting the position of each wire (Fig. 60). 4. Remove the three screws holding the burner feed pipe to the valve, being careful not to lose or damage the "O" ring seal (Fig. 60). Fig.
9.0 Changing Components 9.10 Pilot/A.S.D. Assembly WARNING: The Pilot/A.S.D. Assembly should not be adjusted in anyway. The A.S.D. must not be altered so that it will not operate or be bypassed in anyway. The complete assembly must be replaced in the event of one or other component failure(s). Only use a Genuine Baxi Spare Part. Fig. 63 1. Remove the ignition and sensing leads from the A.S.D. electrodes (Fig. 64). Undo the pilot feed pipe at the A.S.D. (Fig. 63 & 64). Pilot / A.S.D. Assembly 2.
10.0 Fault Finding START Ensure all external controls are calling for heat. Turn the thermostat potentiometer off, wait 10 seconds and turn to HIGH. Is the permanent live neon lit ? Before starting FAULT FINDING carry out preliminary electrical system checks i.e. Earth Continuity, Polarity, Short Circuit and Resistance to Earth.
10.0 Fault Finding WARNING: Where practicable fault finding should be performed with the main electricity supply ISOLATED. Does pilot burner ignite ? YES YES NO YES Does pilot remain alight and ignition sparking stop? NO Check electrode spark gap (2.5 - 4.0mm) Check gas pressure at inlet to valve (20mb) Check gas pressure at inlet to valve (20mb) Replace wiring harness Disconnect red + blue leads & check resistance of pilot solenoid (approx. 1.
10.0 Fault Finding Does main burner ignite ? YES YES With thermostat on high, does boiler switch off at approx. 82oC on flow ? NO YES Replace P.C.B.
11.0 Short parts list Short Parts List Key No. G.C. No. Description Manufacturers Part No. 39 E02-416 Burner 238652 60 378 882 Injector B19 234014 51 E00-121 Ignition Lead 237811 52 E00-122 Sensing Lead 237812 35 193 182 Valve 236579 33 E37 405 Pilot/A.S.D. Assembly 246386 28 E00-118 P.C.
12.
Baxi UK 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 to the Sales Department.
Comp No 245025 - Iss 5 - 6/00 The Baxi Helplines For General Enquiries +44 (0)8706 060 780 For After Sales Service +44 (0)8706 096 096 For Technical Enquiries +44 (0)8706 049 049 Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www.baxi.
