Baxi Bermuda Inset 2 Boiler 50/4 E User manual

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Baxi Bermuda
Inset 2 Boiler 50/4 E
Fireside Gas Central Heating Unit
Installation and
Servicing Instructions
Please leave these instructions with the user

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2
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. Quality is built into every Baxi product -
products which fulfil the demands and needs of
customers, offering choice, efficiency and reliability.
To keep ahead of changing trends, we have made a
commitment to develop new ideas using the
latest technology - with the aim of continuing to
make the products that customers want to buy.
Baxi is also the largest manufacturing partnership in
the country. Everyone who works at the company
has a commitment to quality because, as
shareholders, we know that satisfied customers
mean continued success.
We hope you get a satisfactory service from Baxi. If
not, please let us know.
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 is a BS-EN ISO 9001
Accredited Company

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3
1.0Introduction 4
2.0Technical Data 5
3.0System 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
4.0Site Requirements 9
Builders Opening
Location
Fireplace Opening & Surround
Frame Extension Kit
Flue
Ventilation
Gas Supply
Electrical Supply
5.0Electrical 12
6.0Installation 13
Initial Preparation
Right Hand Water Connections
Connecting the Sensing Pipe
Fitting the Boiler Hood
Siting the Boiler
Securing the Boiler
Water Connections
Fully Pumped Systems
Pumped Heating & Gravity Hot Water
Gas Connection
Electrical Connection
Making the Electrical Connection
Flue Connection
Completion
7.0Commissioning the Appliance 18
8.0Annual Servicing 19
Annual Servicing
Removal of Firefront
Removal of Controls
Cleaning the Lint Arrestor
Cleaning the Burner & Main Injector
Cleaning the Pilot/A.S.D. Assembly
Cleaning the Heat Exchanger
9.0Changing Components 22
Changing Components
Removal of Firefront
Lint Arrestor
Suppression Capacitor
Thermostat
Piezo Igniter Unit
Removal of Controls
Gas Valve
Burner & Main Injector
Pilot/A.S.D. Assembly
Ignition Lead
10.0Fault Finding 26
11.0Short Parts List 29
12.0Notes 30
Section Page
Contents

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1.0 Introduction
41
STANDARD
B.S. 6891
B.S. 5546
B.S. 5449
B.S. 6798
B.S. 5440: Pt 1
B.S. 5440: Pt 2
B.S. 5871: Pt 1
B.S. 6500
SCOPE
Gas Installation.
Installation of hot water supplies for
domestic purposes
Forced circulation hot water systems.
Installation of gas fired hot water
boilers.
Flues.
Air Supply.
Installation of fire/back boilers, gas
appliances.
Cables.
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.
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:
5. The appliance is preset at its MIDRANGE
heat input rate and is designed for use on
NATURAL GAS only. The boiler is suitable for
fully pumped and pumped central heating with
gravity hot water systems.
6. Sealed System applications require an
optional safety limit thermostat kit (Baxi Part No.
245947).
1.2 Installation
1. The appliance is suitable for installation only
in G.B. and I.E. and should be installed in
accordance with the rules in force. For Ireland
install in accordance with I.S. 813 “Installation of
Gas Appliances”.
2. The installation must be carried out by a
CORGI Registered Installer or other competent
person and be in accordance with the relevant
requirements of 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. Where no specific instructions are
given, reference should be made to the relevant
B.S. CODES OF PRACTICE.
3. All systems must be thoroughly flushed
and treated with inhibitor (see section 3.2).
1.3 B.S. Codes of Practice
HEAT OUTPUT
Model Max Mid Min
50/4 E 14.65kW 13.19kW 11.72kW
(50,000 Btu/h) (45,000 Btu/h) (40,000 Btu/h)
Baxi Bermuda Inset 2 Boiler 50/4 E
Fig. 1
The boiler meets requirements of Statutory Instrument
“The Boiler (Efficiency) Regulations 1993 No3083”and
is deemed to meet the requirements of Directive
92/42/EEC on the efficiency requirements for new hot
water boilers fired with liquid or gaseous fuels.
Type test for purpose of Regulation 5 certified by:
Notified Body 0086.
Product/production certified by: Notified Body 0086.
“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. These include sections on the type of
controls employed, flushing the system, burner
operating pressure etc. The details of the Log
Book will be required in the event of any warranty
work. Also, there is a section to be completed at
each subsequent regular service visit.

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2.0 Technical Data
15
Bermuda Inset 2 Boiler 50/4 E
The Boiler is for use with Natural Gas only.
Heat Input Max Mid Min
kW 18.79 17 15.2
Btu/h 64,100 58,070 51,850
Heat Output Max Mid Min
kW 14.65 13.19 11.72
Btu/h 50,000 45,000 40,000
Burner Pressure Max Mid Min
mbar 17 14 11
in wg 6.8 5.6 4.4
Water Content Max
litres 1.6
gallons 0.35
Gas Connection Rc1/2(1/2in BSPT)
Water Connections 3 x 1in BSP
Electricity Supply 230V ~ 50Hz
External fuse - 5 Amp
Appliance Rating - 17 watt
Controls Electronic thermostat
intermittent pilot & timed
electronic flame sensing
with atmospheric sensing
device.
Gas Rate 1.8m3/h
(after 10 mins) (63.57ft3/h)
Lifting Weight 33.2 kg (73.2 lbs)
Dimensions Height 516mm
Width 440mm
Depth 368mm
Flue Diameter
mm 125
in 5
Heat Exchanger Cast Iron
Low Head (Min)
mm 1000
in 393/8
Water Systems Fully pumped or pumped
heating with gravity hot
water. Sealed system with
optional safety limit
thermostat.
0
2
6
10
4
8
12
14
16
18
20
22
0 5 10 15
Inset 50/4 E hydraulic resistance
mbar
20
l/min
with injector Tee without injector Tee
Fig. 2
Sedbuk Declaration For Bermuda
Inset 2 50/4 E
The seasonal efficiency (SEDBUK) is 76.1%
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.

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3.0 System Details
61
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.
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.
3.2 Treatment of Water Circulating
Systems
For optimum performance after installation, this
boiler and its associated central heating system
must be flushed in accordance with the guidelines
given in BS7593:1992 “Treatment of water in
domestic hot water central heating systems”.This
must involve the use of a proprietary cleanser,
such as BetzDearborn’s Sentinel X300 or X400, or
Fernox’s Superfloc.
Full instructions are supplied with the products, but
for immediate information please contact
BetzDearborn ( 0151 420 9563) or Fernox (01799
550811).
For long term protection against corrosion and
scale, after flushing it is recommended that an
inhibitor such as BetzDearborn’s Sentinel X100, or
Fernox’s MB-1 or Copal is dosed in accordance
with the guidelines given in BS7593:1992.
Failure to flush and add inhibitor to the
system may invalidate the appliance warranty.
It is important to check the inhibitor concentration
after installation, system modification and at every
service in accordance with the manufacturer’s
instructions. (Test kits are available from inhibitor
stockists.)
For information or advice regarding any of the
above contact the Baxi Helpline.

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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.
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. The copper must extend at least 1
metre from the boiler and include any branches.
The copper pipe must not be insulated (Fig. 2a).
3.4 System Controls
1. For optimum operating conditions, 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. It is not economical to rely on the boiler
thermostat to control operation of the system.
3.5 Fully Pumped System (Fig. 3)
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 may form part of
the vent pipe. No part of the open vent should
contain a valve.
3.0 System Details
17
Air Vent
Boiler
Pump
Radiator
Circuit
Fully Pumped System
22mm
Open Vent
15mm
Cold
Feed
Indirect
Cylinder
Return
Flow
Fig. 3
Boiler
Flow
Return
Copper
0.5m
Copper
1m
Copper
0.5m
Fig. 2a

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3.0 System Details
81
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.
3. The open vent pipe should be a minimum of
22mm and must rise continuously to a point
above the feed and expansion tank.
4. The flow pipe from the boiler may form part of
the vent pipe.
5. No part of the open vent should contain a
valve.
6. The brass injector tee must be fitted to the
boiler return on all systems incorporating a
gravity circuit.
7. The circulating head should not be less than
1m (3ft) with a maximum horizontal run of 3m
(10ft) when using 28mm pipes. Smaller pipe
sizes and longer horizontal runs are acceptable
with suitably increased circulating heads.
8. The gravity circuit should be designed with a
minimum of restriction, avoiding possible air
traps and long horizontal runs.
9. The system should be designed to prevent
gravity circulation in the heating system when the
pump is not running.
3.8 Safety Limit Kit & Sealed Systems
1. A safety limit thermostat kit is available to
facilitate the installation of a Bermuda Inset 2
boiler to systems incorporating a combined feed
and vent and to flats and dwellings where the
building design prevents the boiler vent pipe
rising continuously to the feed and expansion
tank. (This must not be used on gravity systems.)
Baxi Part No245947.
2. The boiler can be applied to a sealed system
with the use of the safety limit kit.
3. Information regarding the application of the
safety limit thermostat is included with the kit.
Boiler Pump
Radiator
Circuit
Gravity Domestic
Hot Water System
22mm
Open Vent
15mm
Cold
Feed Indirect
Cylinder
Gravity
Return
Gravity
Flow
Pumped
Flow
Pumped
Return
Injector
Tee
Fig. 4

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4.0 Site Requirements
9
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 584mm (23in)
Width 584mm (23in)
Depth 375mm (143/4in)
2. The opening should be soundly constructed of
brick, pre-cast concrete or be a proprietary
builders opening.
3. The base of the opening should be sound
and non-combustible and must be flat and
level.
4. The base of the builders opening should be at
the same height as the finished level of the
hearth.
IMPORTANT: If a false chimney breast is
intended to house the boiler, a simulated
builders opening, within the breast, must be
provided.
5. The builders opening must not communicate
with voids, pipe ducts or spaces other than the
room in which the appliance is situated.
4.2 Location
1. The appliance must be installed in the living
space of a dwelling.
2. Restrictions to the siting of the appliance are
covered by BS 5546. The appliance may not be
installed in bathrooms, shower rooms, bedrooms
or bed sitting rooms.
4.3 Fireplace Opening & Surround
1. If a fireplace surround is to be used, it must be
centrally placed and have opening sizes and a
vertical flat area as detailed in the Installation and
Servicing Instructions for the fire.
4.4 Frame Extension Kit
1. If the depth of the builders opening is less than
the 375mm minimum specified, it can be
increased by the use of the Frame Extension Kit.
2. Kit No234887 is suitable for use with Inset 2
TS, BS and FS models.
For Inset 2 KS & CS, Kit No239341 must be used.
3. Full installation details are included in the kit.
1
560mm (22in) min
SURROUND OR FINISHED
WALL FACE
560mm (22in) minimum 590mm (235/8) maximum
584mm (23in) minimum
375mm (143/4in)
minimum
Solid, non combustible hearth
to support the boiler,
as specified in BS 5871.
HEARTH
LEVEL
When correctly installed the centre line of the boiler flue socket
will be 260mm from the surround or finished wall face.
Fireplace
Opening
460mm (18in) min
560mm (22in) max
584mm (23in) min
590mm (2315/64in) max
584mm (23in) min
NOTE: For builders openings
between 343mm & 374mm the
optional Frame Extension Kit must
be used.
Fig. 5

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4.0 Site Requirements
10 1
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. The bottom of the
liner should terminate 500mm (20in) above the
base of the builders opening. The flue must be
sealed between the liner and the brickwork at
both the top and bottom.
3. Acid Resistant Liner
A flue constructed of acid resistant liners is
satisfactory provided the size requirements are
met. The boiler flue outlet can be connected to
the flue by means of a short length of 125mm
(5in) of flue pipe. A seal must be made in the
annular space between the outer face of this
flue pipe and the acid resistant liner.
4. Precast Flues
These must conform to BS 5440 Pt 1 and be
correctly installed without intrusion of cement
into the flue passage.
5. Proprietary Flues
A flue of this type must meet the size
requirements specified and be installed in
accordance with the flue manufacturers
recommendation and relevant codes of practice.
An approved terminal must be installed.

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4.0 Site Requirements
111
4.6 Ventilation
1. Ventilation air supply to BS 5440 Pt 2 is
required. The permanent ventilation area size
requirements are as shown:
80.1cm2(12.42in2)
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. The vent should be sited
following good practise for a habitable room. We
recommend the use of the Stadium BM720 “Black
Hole”ventilator which is available from your local
merchant.
4.7 Gas Supply (Fig. 6)
1. The gas installation should be in accordance
with BS 6891. The connection at the appliance is
Rc 1/2(1/2in BSPT internal) located at the rear of
the gas cock.
2. Ensure the pipework from the meter to the
appliance is of adequate size. It is necessary to
route the gas supply pipe to the right hand side of
the builders opening. It must be routed so as not
to restrict the installation and servicing of the
appliance.
4.8 Electrical Supply
1. External wiring must be correctly earthed,
polarised and in accordance with current IEE
wiring regulations. The mains supply is 230V ~
50Hz fused at 5A. A permanent live supply is
required for all Super Model Firefronts.
NOTE: The method of connection to the
electrical supply must facilitate complete
electrical isolation of the appliance.
Connection may be made via a fused double
pole isolator with a contact separation of at
least 3mm on all poles and serve the
appliance and system controls only.
2. The cable within the builders opening should
be 0.75mm2to IEC 53 code 227 (heat resistant).
3. It is preferable to route the electrical supply
cable to the left hand side of the builders opening.
If however it must come from the right hand side
it must be routed via the clips provided and not
restrict the servicing of the appliance (Fig. 6).
4. The cable must be routed to avoid contact with
the metal combustion box and hood.
Cable Routing Clips
Gas Cock
165mm
min
Fig. 6

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5.0 Electrical
12
Main Gas Valve
Pilot Gas Valve
Thermostat Sensor
Control
Potentiometer
& Switch
Spark Electrode
N
N
External
Controls S/L
L
230V
L
b
r
b
or
p
p
or/bk
r/b
w
y/r
PCB
Schematic
Wiring
Diagram
Electrode
Printed Circuit Board
Control
Potentiometer
& Switch
Thermostat Sensor
Gas Valve
br
g/y
b
or
y/r or/bk r/b
w
p
p
w
Sensing Probe
w
5.1 Illustrated Wiring Diagram
5.2 Functional Flow 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
Fig. 7
Fig. 8

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6.0 Installation
13
6.1 Initial Preparation
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.
6.2 For installations requiring the water
connections at the right hand side proceed
as follows (Fig. 9 & 9a):
1. Leave the boiler on its back on the carton base.
2. Remove the thermostat lead from its clip.
Withdraw the thermostat sensor and its retaining
strip from the pocket.
3. Unfasten the four screws retaining the boiler
door and remove. Remove the rubber seal and
thermostat protection cover.
4. Lift out the 3 heat exchanger baffles, noting
their orientation (they are marked ‘TOP’and
‘FRONT’).
5. Lift the heat exchanger from the appliance and
remove the side blanking plate.
6. Transfer the 3 sealing rings from the holes in
the left hand side of the boiler to those on the
right.
7. Rotate the heat exchanger to place the water
connections at the right hand side, return the heat
exchanger to the combustion box.
DO NOT TURN THE HEAT EXCHANGER
UPSIDE DOWN
NOTE: The heat exchanger is correctly
oriented when the three water connections line
up with the holes in the right hand side of the
combustion box and the thermostat pocket
aligns with the corresponding hole in the door.
The unfinned heat exchanger water tubes face
the burner.
8. Remove the blanking disc from the left hand
hole in the boiler door and replace with the rubber
seal and thermostat protection cover. Fit the
blanking disc into the right hand hole.
9. Replace the heat exchanger baffles and
blanking plate. Refit boiler door. Refit the
thermostat sensor and its retaining strip into the
pocket.
Side Blanking
Plate
Thermostat
Sensor
Retaining Strip
Thermostat
Protection Cover
Rubber Seal
Heat Exchanger
Baffles
Heat
Exchanger
Sealing
Rings
Blanking Disc
Boiler Door
Fig. 9a
Fig. 9
Carton Base
‘P’Clip

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6.0 Installation
14
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).
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).
IMPORTANT: The sensing pipe must be
connected to enable the appliance to function
safely and correctly.
6.4 Fitting the Boiler Hood
1. Stand the boiler upright on the carton base.
2. The hood may be fitted now or when the boiler
is in situ. Secure using the four nuts and set
screws provided (Fig. 10).
3. If a safety limit thermostat is required, it may be
convenient to fit it at this point of the installation.
6.5 Siting the Boiler
1. The fireplace and builders opening should
be as described under ‘4.0 Site Requirements’
and be clean, sound and level.
2. The flue should be installed as described under
‘4.0 Site Requirements’.
3. It may be desirable to insert the required fittings
into the heat exchanger at this point, depending
on the size of the fireplace opening and whether
or not the gravity injector tee is to be used.
4. Locate and mark the centre line of the finished
opening and hearth (Fig. 15).
5. Hold the boiler by its combustion box at either
side of the heat exchanger, lift from the packing
base and place into the opening.
6. Align the boiler centrally using the "V" mark on
the front centre of the appliance base. Check the
distance between each side of the base and
opening. They should be equal (Fig. 15).
7. The front edge of the base tray must align with
the finished front face of the wall or surround.
This is important for correct installation of the
firefront.
8. Mark the hearth through the two slots in the
base (Fig. 14).
6.6 Securing the Boiler
1. It is important that the boiler is secured to the
base of the builders opening.
2. The hearth should be drilled as follows:
Remove the boiler and drill the hearth. Insert
suitable plugs. Replace the boiler & check the
alignment within the opening is correct. Secure
the boiler with two screws.
X1
X2
NOTE: X1and X2must be equal
‘V’mark - centre line of opening
Fig. 13
Fixing Slot
Fig. 14
Fig. 15
Boiler Hood
Fig. 10
Sensing Pipe
Adaptor
‘P’Clip
Fig. 9b
Fig. 9c Fig. 9d

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6.0 Installation
15
6.7 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)
1. A 1in x 22mm threaded adaptor, compression
nut and olive are provided in the kit for the return
connection.
2. The 1in x 22mm threaded adaptor provided
must be fitted to the lower tapping marked
RETURN. Connect the pumped return into the
adaptor using the nut and olive.
3. Fit a 1in x 22mm threaded adaptor into one of
the higher tapping positions marked FLOW and
connect the pumped flow into the adaptor.
4. Fit a 1in plug to the remaining connection.
6. Follow the instructions under ‘System Details’
as regards the vent pipe and cold feed.
Pumped Flow Use
Either Connection
Pumped Return
Plug Remaining
Connection
Fig. 16

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6.0 Installation
16
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.
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.
3. Fit the injector tee into the adaptor. The
injector tee may be oriented as shown to facilitate
connection to the gravity return pipework.
NOTE: When connections are on the left,
ensure that the injector tee does not encroach
on the shaded area (Fig. 18). This area is
required for the firefront transformer assembly.
4. Connect the pumped return to the 22mm
compression fitting of the injector tee.
5. Take the gravity hot water return pipe to a level
beneath that of the injector tee and connect
upwards to the 28mm branch of the injector tee,
oriented as shown.
6. Connect the pumped flow to one of the
connections marked FLOW. Connect the gravity
flow to the remaining connection.
7. The gravity flow pipes must rise vertically as
close as possible to the appliance. Ensure the
pipework is routed such that it does not introduce
an airlock in the boiler.
8. Follow the instructions under system details as
regards the vent pipe and cold feed.
6.10 Gas Connection (Fig. 19)
1. Connection to the gas supply is Rc 1/2(1/2in
BSPT) internal located at the rear of the gas
cock. The gas supply pipe must be routed from
the right hand side.
2. The positioning of the gas supply pipe must not
restrict the servicing of the appliance or
installation of the fire.
Pumped Return
Gravity Return
Pumped or Gravity Flow
Fig. 17
Fig. 18
Gas Cock
165mm
min
Fig. 19
Transformer Assembly
Fire Front

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6.0 Installation
17
6.11 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
0.75mm2to IEC Code 227 (heat resistant).
The system external controls and the
appliance must be supplied by the same
isolator.
6.12 Making the Electrical Connection
1. Take the 3 pin plug and lead assembly from
the gas fire contents kit and remove the 4 pin
electrical plug from the control PCB.
2. Remove the cover from the 4 pin plug and
undo the cable clamps (Fig. 22).
3. Route the mains inlet cable under the boiler
base through the cutouts (Fig. 23a).
IMPORTANT: The mains inlet cable MUST
be routed under the boiler base to ensure
that it cannot interfere with the transformer
box on the fire front.
4. Connect the cables as indicated (Fig. 23):
Mains Inlet cable:
Permanent live to L
Controls system switched live to SL
Control system neutral to N
Earth to
Fire cable:
Brown (live) to L
Blue (neutral) to N
Green and Yellow (earth) to
Re-fit the cable clamps ensuring that the outer
insulation is securely held and re-fit the plug
cover.
Ensure that all cables are routed away from
the boiler casing and hood.
6.13 Flue Connection (Fig. 24)
1. If not already done so, fit the boiler hood now.
Locate the flue within the flue socket and secure
with the three self tapping screws provided in
the kit.
2. Seal the flue against the flue outlet socket.
6.14 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).
4 Pin Electrical Plug
3 Pin Electrical Plug
Mains Inlet Cable Clamp
Mains Inlet Cable
Boiler Base
Fire Cable Clamp
Inlet Plug
Mains Inlet Cable
Fire Cable
Cutouts
SL L N E
Flue Outlet Socket
Fig. 24
Fig. 20
Fig. 21
Fig. 22
Fig. 23a
Fig. 23

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7.0 Commissioning the Appliance
18
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 1/4turn 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. Turn the boiler thermostat to the off position
(Fig. 26).
5. Ensure that all external controls e.g. room stat,
timer etc are calling for heat and turn on the mains
electrical supply.
6. Slacken the test point sealing screw and connect
a pressure gauge (Fig. 26).
The pilot is intermittent and lights when the boiler
thermostat is calling for heat.
To operate the pilot turn the thermostat to HIGH.
The burner will also light shortly after the pilot has
been established.
The boiler is fitted with a series of diagnostic
indicator lights that indicate the status of the boiler.
Three of these are visible through the top of the
control box cover and two through the front of the
control box. Their sequence of operation is as
follows:-
a) No power-no lights.
b) Permanent live supplied-orange light illuminates.
c) Permanent live & switched live supplied-second
orange light illuminates.
d) Boiler thermostat turned on-third orange light
illuminates and spark generator operates.
e) Pilot established-green light illuminates and power
supplied to main burner solenoid.
f) Boiler fault-orange light illuminates and boiler goes to
lockout.
The pilot flame should be without a yellow tip and
be approximately 20mm long. No adjustment is
possible.
Operate the burner and allow the system to reach
normal operating temperature. Make further checks
for leaks and check the burner setting pressure,
adjusting if necessary.
This is done by removing the governor cover screw
(Fig. 28) and adjusting the governor in either
direction as required:- clockwise to increase,
anticlockwise to decrease (Fig. 29).
Remove the pressure gauge and tighten the
pressure test point sealing screw.
The boiler and system should be run and then
flushed and treated in accordance with BS5793:
1992 and the flushing agent/inhibitor
manufacturers instructions. When all the air has
been removed from the water circuit, the pump and
radiators should be balanced to achieve the design
temperature drop across the system.
Carefully read and complete all sections of the
“Benchmark”Installation, Commissioning and
Service Record Log Book that are relevant to the
appliance and installation. The details of the Log
Book will be required in the event of any warranty
work. The Log Book must be handed to the user
for safe keeping and each subsequent regular
service visit recorded.
Governer Cover Screw
Adjust Governer
in either direction
Fig. 28
Fig. 29
Test Point
Sealing Screw
Viewing
Window
Boiler Thermostat
Knob
Green Pilot
Indicator Light
Off Position
Boiler Lockout
Light
Gas Cock
Fig. 25
Fig. 26
Fig. 27

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8.0 Annual Servicing
19
8.1 Annual Servicing
1. To perform annual servicing of the back boiler
it is necessary to remove the firefront.
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.
2. Turn the gas service tap to the off position
(Fig. 30).
3. Refer to the separate firefront instructions for
the removal of the firefront.
8.3 Removal of Controls
1. Turn the boiler thermostat to "O" position
(Fig. 31).
2. Pull the electrical input plug from the socket
on the P.C.B. (Fig. 33).
3. Disconnect the union at the gas service cock
and remove the fire feed pipe (Fig. 35).
4. Remove the thermostat sensor and retaining
strip from the boiler (Fig. 32).
5. Undo the nut on the sensing pipe at the
adaptor (Fig. 34).
6. Undo the four screws retaining the door and
remove the door (Fig. 36).
7. Undo the two screws retaining the controls to
the combustion box sides (Fig. 35).
8. Undo the screw holding the controls to the
combustion box base tray (Fig. 35).
9. Withdraw the controls from the boiler.
Gas Cock
Off Position
Fig. 30
Fig. 31
Fig. 32
Fig. 34
Thermostat Sensor
Retaining Strip
Input Plug
Thermostat Knob
Base Tray Screw
Securing Screw
Union Nut
Sensing Pipe
Adaptor
Fig. 35
Fig. 36
Fig. 33

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8.0 Annual Servicing
20
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).
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. Clean the injector and
reassemble in reverse order (Fig. 38).
4. Reassemble the burner in reverse order and
refit the lint arrestor.
8.6 Cleaning the Pilot/A.S.D. Assembly
NOTE: No attempt should be made to clean
the device using any hard tools, including pins
or wire.
WARNING: The pilot/A.S.D. assembly must
not be adjusted in any way.
1. The A.S.D. must not be altered so that it will not
operate or be bypassed in any way.
2. Ensure that the pilot burner aeration hole is free
from lint, debris etc (Fig. 41).
3. If necessary clean the electrode and target, and
check that the spark gap is 2.5 - 4.0mm (Fig. 39).
4. The complete assembly must be replaced in the
event of one or other componet failure(s).
5. Only use a Genuine Baxi Spare Part.
Lint Arrestor
Pilot
Burner
Burner Mounting
Plate
Sensing Pipe
Pilot Burner
Aeration Hole
Hexagon
Headed Screws
Injector
Copper Washer
2.5 - 4mm
Fig. 37
Fig. 38
Fig. 39
Fig. 40
Fig. 41
Fig. 42