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Baxi 100 HE Plus Quick Start Manual

1. Central Insulation Panel 100 amp 80 HE Burner amp re D CETTE Combustion Box Base l Securing Bolts Eu Burner Securing Screws Fig 73 48 Baxi Heating UK Limited 2005 13 0 Changing Components Kaa Heat Exchanger Insulation Pads Fig 73 Remove the fan and condensate trap see section 13 21 and 13 24 2 Remove the burner see section 13 25 3 Remove the four bolts securing the combustion box base 4 Remove the combustion box base 5 Pull the central insulation panel down from the centre of the heat exchanger and remove the insulation pads 6 Check combustion box seal for damage replace if necessary 7 Fit the new insulation pads and reassemble in reverse order 14 0 Short Parts List Short Parts List Q Q P P g Key GC Description Manufacturers A No o Part No A E58 933 Flow Thermistor Red Return Thermistor 240670 C E58 912 Safety Thermostat Black Fan Protection 242235 D E06 059 Flow Switch Kit 242459 E DHW Flow Switch Kit 247502 G PCB enclosure 5110991 Pump 240395 K E58 935 Diverter Valve Head 243341 L Fan 133 HE 5109926 Fan 100 amp 80 HE 5109925 M Condensate Trap Kit 5111714 N E78 749 Gas Valve Kit 247222 O E58 900 Burner 133 HE 245199
2. 4mbar and the gas rate is no greater than 4 2m h 133 model 3 1m h 100 model 2 5m h 80 model WARNING The PCB Control and Fan Assembly is 325 Vdc Isolate at supply before Fig 34 Expansion Vessel removed for clarity access Inlet Gas Pressure Test Point Baxi Heating UK Limited 2005 31 Facia Box PCB Connection Cover Remove the Red Jumper labelled CNI2 Fig 35 32 Baxi Heating UK Limited 2005 10 0 Commissioning the Boiler Increasing Central Heating Output To 100 000 Btu hr Fig 35 Combi 133 amp 100 HE Plus only The boiler is factory set for a maximum output of 80 000 Btu hr The boiler will automatically vary its output to match the system load giving the most efficient use of gas and the most comfortable room temperature possible 2 If the CH system is greater than 80 000 Btu hr then to increase the maximum output of the boiler to 100 000 Btu hr proceed as follows a Isolate the mains supply to the boiler b Remove the outer case c Lower the hinge down facia box d Remove the PCB connection cover e At the extreme left hand side of the PCB there are two jumpers Remove the red one labelled CN 12 3 Reassemble in reverse order Facia Box F PCB Connection Cover Remove the Blue amp Red Jumpers labelled CNI I amp CNI2 PCB
3. Appliance Type Ci3 C33 Appliance Category CAT LH Heat Input Gross DHW Max kW 45 45 Btu h 155 000 Heat Input Gross CH Max Factory Set kW 33 7 26 95 Btu h 15 000 92 000 Heat Output CH Non Condensing 70 C Mean Water temp Max Factory Set kW 30 0 239 Btu h 102 000 81 500 Condensing 40 C Mean Water temp Max Factory Set kW 314 25 1 Btu h 107 000 85 600 Max Gas Rate Natural Gas After 10 Mins mh 42 f h 148 3 Inlet Pressure Natural Gas mbar 20 in wg 8 Electrical Supply 230V 50H Appliance must be connected to an earthed supply Power Consumption 200W External Fuse Rating 3A Internal Fuse Rating 3 15A SEDBUK Declaration For Combi 133 HE Plus The efficiency is 90 7 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 Baxi Heating UK Limited 2005 4 0 Technical Data Combi 133 HE Plus Flue Terminal Diameter 110mm Dimensions Projection 150mm Connections compression Gas Supply 2 BSPF Central Heating Flow 22mm Central Heating Return 22mm Cold Water Mains Inlet 5mm DHW Flow 15mm Pressure Relief Discharge 15mm Condensate Drain 1 BSP Outercase Dimensions Casing Height 850mm Overall Height Inc Flue Elbow 1000mm Casing Width
4. NO Fault Finding En F Remove 5 way connector from gas valve Is there 240Vdc between F amp G during ignition NO the larger of the two 6 way PCB connectors Is there continuity from F to amp from G to H YES Replace PCB Replace PCB YES NO Replace gas valve Lead from PCB to gas valve faulty lt 53 15 0 Fault Finding OVERHEAT LOCKOUT Disconnect NO black stat on flow pipe When flow lt 60 C is there continuity across stat Replace Stat Reconnect stat Disconnect fan stat When fan temp lt 60 C is there continuity across stat NO Replace Stat YES Reconnect stat Disconnect the larger of Wiring from PCB to lt the 6 way PCB connectors Is there continuity across M thermostats faulty Disconnect thermistor red sensor on flow pipe Is resistance between 0 5kQ amp 20kQ Replace thermistor combustion chamber Replace combustion chamber door seal amp trim door seal damaged or not in place seal Replace PCB 54 Baxi Heating UK Limited 2005 C of LED s C Flash Lights gt Flash aC On 15 0 Fault Finding FAN NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after the boiler has been electrically isolated NO 3 way PCB connector amp unplug fan Is ther
5. The following guidelines indicate the general requirements for siting balanced flue terminals For GB recommendations are given in BS 5440 Pt For IE recommendations are given in the current edition of l S 813 Domestic Gas Installations 2 If the terminal discharges onto a pathway or passageway check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway 3 Take into consideration the effect the plume of vapour may have on neighbours when siting the flue 4 Adjacent surfaces close to the flue terminal may need protection from the effects of condensation Alternatively a flue deflector kit part no 248167 is available 5 For installation of the flue into an internal corner at the 25mm dimension the flue deflector kit part no 248167 must be fitted 6 Reduction to the boundary is possible down to 25mm but the flue deflector kit part no 248167 must be fitted 7 If required a suitable terminal guard is available from Baxi for use with the flue deflector 8 For fitting under low soffits and eaves it is acceptable for the flue to project upto 500mm from the face of the wall to the inside of the air intake This can be painted if required using a suitable external paint 9 If a terminal is less than 2 metres 787 s in above a balcony above ground or above a flat roof to which people have access then a suitable terminal guar
6. 5 The system must be flushed in accordance with BS 7593 see Section 6 1 and the flushing agent manufacturers instructions further guidance can be obtained from BS 5449 Section 5 6 Refill the system and add inhibitor following the inhibitor manufacturer s instructions Vent air as described in Step 4 7 Complete the label supplied with the inhibitor and attach to the inside of the boiler case Detail of system treatment should be added for future reference 8 Pressurise the system to 1 5 bar then close and disconnect the filling loop 9 Turn the gas supply on and purge according to in GB BS 6891 and in IE IS 813 Domestic Gas Installations 10 Turn the gas service cock anticlockwise to the ON Gas Valve position and check for gas soundness up to the gas valve 1 Run the system and check the boiler for correct operation NOTE These boilers are self regulating and the gas rate will vary continously between maximum and minimum modulation depending on the system or DHW load The maximum CH input is factory set to 26 95kW This can be increased to 33 7kW on the 133 and 100 models see section 10 2 No adjustment of the gas valve is possible DO NOT check gas pressure here 12 After a period of 3 minutes and with all the system controls calling for heat check the gas pressure at the inlet tapping of the gas valve Fig 34 is greater than
7. Remove the airbox door panel by loosening the four la turn screws Fig 64 ERA Spark and Sensing Electrode Fig 65 Disconnect the leads to the electrode noting their positions left to right Spark Opaque Lead Earth Green Yellow Lead Sensing White Lead 2 Remove the two screws securing the electrode to the combustion box door and remove the electrode 3 Fit the new electrode and new gasket reassemble in reverse order ensuring the spark gap of 3 5mm 0 5mm is maintained EPAR Fan and Fan Protection Thermostat Fig 66 WARNING The PCB Control and Fan Assembly is 325 Vdc Isolate at supply before access Remove the electrical connections to the fan protection thermostat on the fan 2 Replacing the thermostat Unscrew the thermostat and replace with the new thermostat Reassemble in reverse order 3 Replacing the fan Remove the wing nuts securing he fan to the base of the combustion box 4 Loosen the screw retaining the gas injector pipe at he venturi 100 amp 80 HE Plus models 5 Lower the fan and disconnect the electrical supply from the right hand front of the fan Remove the fan venturi assembly 6 Remove the screws securing the venturi to the fan and remove the venturi together with the gasket 7 Remove the fan protection thermostat and fix it to the new fan together with the venturi and gasket 8 Fit the new fan and reassemble in revers
8. 3 Drain the boiler see Section 13 1 paragraph 2 amp 3 4 The Schraeder valve is positioned centrally at the side of the appliance Pressurise to 0 bar 5 Open the isolating valves and recharge the system to between 1 0 bar and 2 5 bar Vent the system as necessary 39 Facia Box Pump Setting Eads Hydraulic Fig 52 Manifold Wiring Harness Fig 53 Plug Connector X i Pump Electrical Fig 54 Cover 40 Baxi Heating UK Limited 2005 13 0 Changing Components The pump 3 way diverter valve pressure gauge pressure relief valve plate heat exchanger and DHW flow switch can be accessed after hinging down the facia box Release the facia securing screws 4 turn and hinge down the facia box Fig 51 Pump Fig 51 If only the head needs replacing a standard Grundfos UPS 15 60 pump head is interchangeable see section 13 9 for details 2 This must be switched to setting N 3 Fig 52 Pump Complete Fig 53 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Unplug the wiring harness from the pump 3 Remove the four screws retaining the pump backplate to the hydraulic manifold NOTE Ensure nuts are not dislodged 4 Remove the pump 5 Fit the new pump and reassemble in reverse order Pump Head Only Fig 54 Drain the boiler see Section 13
9. 490mm Casing Depth 320mm Clearances Both Sides 5mm Min Above Casing 200mm Min Below Casing 200mm Min Front 500mm Min For Servicing Front 5mm Min In Operation Weights kg lb Packaged Boiler Carton 58 2 128 3 Packaged Flue Kit 3 8 8 4 Weight Empty 53 2 117 3 Installation Lift Weight 444 98 Central Heating Primary Circuit Pressures bar Ib in Safety Discharge 3 43 5 Max Operating 2 5 36 3 Min Operating 0 7 10 2 Recommend Operating 1 2 14 5 29 Recommended System Temperature Drop Condensing 20 C DHW Circuit bar Ib in Pressures ax Operating 10 145 in Operating 0 1 1 45 in Operating Pressure at 16 l min 6 232 Flow Rates l min gal min DHW Flow Rate 30 CRise 8 7 4 11 DHW Flow Rate 35 CRise 6 3 52 in Working DHW Flow Rate 9 0 43 Pump Available Head See graph below Expansion Vessel For Central Heating only Integral with appliance bar Ib in in Pre charge Pressure 0 95 13 8 ominal Pre charge Pressure l 14 5 litre gal ax Capacity of CH System 125 27 5 Primary Water Content of Boiler unpressurised 35 6 2 DHW Expansion Vessel See Section 6 6 for information Temperatures Flow Temp adjustable 55 C to 82 C max 0 5 C O D H W Flow Temp adjustable 45 C to 55 C max 0 5 C dependent upon flow rate NO Class 5 CO CO Ratio 0 002 Electrical Protection IPX4 Pump Available Head SSSR P
10. Fig 36 Baxi Heating UK Limited 2005 10 0 Commissioning the Boiler Switching Off The Intelligent Pre heat Fig 36 The boiler includes an intelligent pre heat feature This feature ensures that the domestic hot water to the tap is pre heated when and only when the user required domestic hot water the previous week For example if the user only requires hot water between 7 00am and 8 00am on Monday then the boiler will log this demand and then the next week will only pre heat between 7 00am and 8 00am on Monday During the first week of operation from power on no pre heating will occur 2 The pre heat switches the boiler on for approximately minute every 40 minutes whenever it is required 3 The boiler is factory set with the pre heat feature on If the user wishes to disable this feature then proceed as follows solate the mains supply to the boiler amp b Remove the outercase c Lower the hinge down facia box d Remove the PCB connections cover e At the the extreme left hand side of the PCB there are two jumpers one Blue one Red Remove both Blue and Red jumpers 4 Reassemble in reverse order 33 34 Baxi Heating UK Limited 2005 10 0 Commissioning the Boiler Filling the System When filling the system move the diverter valve to the central heating position as follows a Ensure that no DHW taps are on
11. removal of the combustion box door To change the heat exchanger the fan and burner must be removed first see section 13 21 amp 13 25 Remove the combustion box door by undoing the four turn securing screws wees Burner Fig 69 WARNING The burner skin is fragile 133 model HANDLE WITH CARE Remove the two 8mm hex head screws securing the burner to the base of the combustion box 2 Remove the burner carefully from the combustion box base inspect gasket for damage replace if necessary U Fit the new burner and reassemble in reverse order Meme Heat Exchanger Drain the boiler see section 13 1 paragraph 2 amp 3 WARNING The PCB Control and Fan Assembly is 325 Vdc Isolate at supply before access 2 Remove the fan and condensate trap see section 13 21 and 13 24 3 Undo the screws securing the flow switch and return connections Remove the flow switch and return connection Fig 70 4 Undo the screws securing the heat exchanger manifold and remove the manifold Fig 71 5 Undo the screws on the bracket supporting the heat exchanger and remove bracket 6 Lift the heat exchanger assembly Fig 72 and rotate the bottom upwards whilst pulling it forwards out of the airbox 7 Fit the new heat exchanger and reassemble in reverse order 8 Recommission the boiler and check the inhibitor concentration see Section 6 1 and 10 1 47
12. 3 minute Anti cycle 60 Baxi Heating UK Limited 2005 17 0 Notes Baxi Heating UK Limited 2005 6l BENCHMARK No 5111019 1912 9 henchman J GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No NOTIFICATION No CONTROLS To comply with the Building Regulations each section must have a tick in one or other of the boxes TIME amp TEMPERATURE CONTROL TO HEATING ROOM T STAT amp PROGRAMMER TIMER PROGRAMMABLE ROOMSTAT TIME amp TEMPERATURE CONTROL TO HOT WATER CYLINDER T STAT amp PROGRAMMERITIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE gt mh ft hr BURNER OPERATING PRESSURE IF APPLICABLE N A mbar CENTRAL HEATING FLOW TEMPERATURE C CENTRAL HEATING RETURN TEMPERATURE C FOR COMBINATION BOILERS ONLY HAS A WAT
13. Burner 100 amp 80 HE 5107430 P Electrode Kit 5110992 R Plate Heat Exch Kit 247224 5 E06 085 Inspection Window Assy 242484 T E06 097 Heat Exchanger Assy 242497 U Control Knob 5109996 ii M a Na Baxi Heating UK Limited 2005 49 Domestic Hot Water LED Light Green Flame Failure LED Light Red Burner ON ED Light Green T Mains ON seest ie LED Light Green CJ of LED aC Flash Lights a C Of 50 Baxi Heating UK Limited 2005 Reset YES YES YES YES YES Go to Electrical Supply section of the fault finding instructions Live amp Neutral Reversed Incoming Live and Neutral reversed Go to Dry Fire section of the fault finding instructions Go to Ignition Lockout section of the fault finding instructions Go to Overheat Lockout section of the fault finding instructions Go to Fan Lockout section of the fault finding instructions Go to Return Thermistor section of the fault finding instructions Go to Flow Thermistor section of the fault finding instructions 15 0 Fault Finding Before performing fault finding carry out preliminary electrical checks for earth continuity and polarity See Section 8 13 CH works but DHW does not DHW works but CH does not YES YES Go to DHW Flow Switch section of the fau
14. NO Is there 240V at H Wiring from R S 2 to PCB faulty YES O Unplug G Diverter Valve YES N 1 Ensure all DHW taps are M d off so that DHW LED is off Is Diverter Valve faulty qm there 240V from to amp H from K to J NO Is there YES 240V from G to N amp from G Wiring from PCB to Diverter Valve faulty toM NO Diverter Valve Plug when unplugged PCB faulty 0 0 Oo 0 00 PAN 58 Baxi Heating UK Limited 2005 16 0 Operational Flow Chart ES Domestic Hot Water Mode Tap or shower switch dion Standby The diverter valve pump fan spark generator and gas valve are off If a tap or shower is switched on then Fan Pre Purge occurs YES 2 Fan Pre Purge The pump and fan are on while the 5 second diverter valve spark generator and gas valve are off After 5 seconds if the DHW temperature is less than the set point then Ignition occurs Fan Pre Purge 3 Ignition The pump fan spark generator and gas valve are on while the diverter valve is off If a flame is DHW temperature less than set point detected then Burner On occurs If a flame is not detected within 5 seconds and less than 5 ignition Ignition done and less than 5 attempts have been made then Fan Pre Purge occurs If attempts made a flame is not detected within 5 seconds and 5 ignition attempts have been made then Ignition Lockout occurs
15. b Turn power on to the boiler c Ensure that any external controls are calling for heat d After 10 seconds turn the boiler off at the isolation switch e The diverter valve will now be in the central heating position There is no need to reset the position of the diverter valve after filling 11 0 Fitting the Outer Case Lower Door Panel Outercase Fixing Screws Lower Door Panel Baxi Heating UK Limited 2005 Cr Fitting The Outer Case Fit the outercase to the appliance ensuring that the four slots in the side flanges align with the hooks on the chassis Fig 38 2 Insert the two fixing screws into the sides of the chassis Fig 39 3 Close the lower door panel against the retaining magnets Fig 39 4 Instruct the user in the operation of the boiler controls Hand over both the Users Operating and nstallation and Servicing Instructions giving advice on the necessity of regular servicing 5 Advise the user that a plume of vapour from the flue terminal is normal and that there is no need for concern 6 Advise the user that if intelligent pre heat is on pre heating will not occur for the first week of operation 7 Set the User preferences See User Label on lower door panel Fig 38 or user s operating instructions set CH DHW temperatures 8 Carefully read and complete all sections
16. 1 paragraph 2 amp 3 2 Unplug the wiring harness from the pump 3 Remove the four socket head screws securing the pump head and separate it from the housing 4 Remove the screws retaining the pump electrical covers on the original and replacement heads 5 From the replacement UPS 15 60 pump head remove the strain relief cable gland and discard 6 Remove the plug connector from the old pump head and wire it into the UPS 15 60 pump head 7 Replace the electrical cover to the new pump head and assemble with the electrical box at 6 o clock to the housing 8 Check that the pump has been switched to setting N 3 Fig 52 and reconnect the wiring harness plug 13 0 Changing Components EME Three Way Diverter Valve Head Only Fig 55 If only the head needs replacing 1 Unplug the wiring harness from the 3 way diverter valve 2 Depress the clip and revolve the head through 30 and remove 3 Fit replacement head and reassemble in reverse order EARR Three Way Diverter Valve Complete Fig 56 A Drain the boiler see Section 13 1 paragraph 2 amp 3 Three Way Diverter Valve 2 Unplug the wiring harness from the 3 way diverter Head valve 3 Remove the four socket screws retaining the 3 way valve 4 Remove the 3 way valve 5 Fit the new 3 way valve ensuring the gasket is in place and that the spig
17. 31 4 25 1 Front 5mm Min In Operation Pressure 14 5 Btu h 107 000 85 600 Weights kg lb litre gal Packaged Boiler Carton 582 1283 ax Capacity of Max Gas Rate Natural Gas Packaged Flue Kit 38 84 CH System 125 275 After 10 Mins Weight Empty 532 1173 Primary Water Content neh 2il nstallation Lift Weight 444 98 of Boiler unpressurised 35 62 ft h 10 0 DHW Expansion Vessel See Section 6 6 for information Central Heating Primary Circuit Inlet Pressure Natural Gas Pressures mbar 20 bar Ib in Temperatures in wg 8 Safety Discharge 3 43 5 C H Flow Temp adjustable ee Max Operating 2 5 36 3 55 C to 82 C max 0 5 C Electrical Supply 230V 50H Min Operating 07 10 2 DHAN Plow Tempedustebig Appliance must be connected to an Recommend Operating 12 145 29 45 C to 55 C max 0 5 C earthed Supply dependent upon flow rate ST Recommended System P p Power Consumption 200W T emperature Drop iii m o NO Class 5 External Fuse Rating 3A Condensing 20 C Sa CO CO Ratio 0 002 Internal Fuse Rating 3 15A Electrical Protection IPX2 Pump Available Head sarmas a ecard abote aiaia ii obini SEDBUK Declaration For Combi 100 HE Plus The efficiency is 90 8 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 Vh O been calculated has been certified by 0086 gal
18. 5 second 4 Burner On The pump fan and gas valve are on while Ignition Period he diverter valve and spark generator are off DHW emperature is controlled by varying the fan speed and hereby the gas rate to achieve optimum operation If he hot water tap is turned off and the DHW emperature has been reached and there is a Central Ignition done and 5 attempts made Heating demand then CH Burner On occurs If the hot water tap is turned off and the DHW temperature has been reached and there is no CH demand then Pump H ee Overrun occurs If the hot water tap is turned off and ame Detected i he DHW temperature has been exceeded and there is Ignition Lockout no CH demand then Standby occurs 5 Pump Overrun The pump is on while the diverter valve fan spark generator and gas valve are off If a tap Tap or or shower is switched on then Fan Pre Purge occurs shower off amp DHW temperature gt set point Tap or shower off amp DHW temperature set point CH Burner On After minute Standby occurs Burner On 6 Ignition Lockout The diverter valve pump fan spark generator and gas valve are off The boiler can only be reset by manually using the reset button Tap or shower off amp DHW temperature set point minute Tap or shower Pump Overrun switched on Standby Baxi Heating UK Limited 2005 59 Standby 16 0
19. 81 500 Btu h for central heating and 39 0 kW 133 000 Btu h 133 model 30 2 kW 102 000 Btu h 100 model 23 9 kW 81 500 Btu h 80 model for hot water In central heating mode the boiler will automatically adjust down to 10 6 kW 36 000 Btu h 133 model 9 1 kW 31 000 Btu h 100 amp 80 models according to system load 3 They are designed for use on Natural Gas G20 only 4 The boilers are suitable for use only on fully pumped sealed heating systems Priority is given to domestic hot water 5 A label giving details of the model serial number and Gas Council number is situated on the rear of the lower door panel Fig 1 6 The boiler data badge is positioned on the air box door Fig 2 7 The boilers are intended to be installed in residential commercial light industrial E M C environments on a governed meter supply only 8 The boilers must be installed with one of the purpose designed flues such as the standard horizontal flue kit part n 236921 Important Information Man made mineral fibre Some component parts of this appliance insulation pads gaskets and rope seals are manufactured from man made mineral fibre e Prolonged or excessive exposure to this material may result in some irritation to the eyes skin or respiratory tract e It is advisable to wear gloves when handling these items e Irritant dust will only be released from the items if they are broken up or subjected t
20. 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 All CORGI registered installers carry a CORGI identification card and have a registration number You can check your installer is registered by telephoning 0870 4012300 or writing to Elmwood Chineham Business Park Crockford Lane Basingstoke RG24 8WG or check online at www corgi gas safety com 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 otified Body 0087 Product Production certified by otified Body 0086 Ref 86 BL 647 For GB IE only 4 Baxi Heating UK Limited 2005 Legislation Baxi 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 CORGI Registered Installer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation a
21. Heating UK Limited 2005 6 0 System Details GE Central Heating Circuit The appliance is suitable for fully pumped SEALED SYSTEMS ONLY This boiler is fitted with a flow switch interlock that prevents it from firing when the heating demand is satisfied The boiler is designed so that it will heat the house to the desired room temperature as quickly as possible by running at the maximum radiator temperature of 82 C Once this room temperature is achieved the boiler will then reduce the radiator temperature to as low a level as possible while still achieving the desired room temperature thereby giving the most efficient use of gas and the most comfortable room temperature possible The boiler will be able to achieve this performance if a room thermostat is fitted or with a fully TRV d system without a bypass This boiler does not require a bypass To comply with Part LI of the Building Regulations the heating system into which the boiler is installed should include the following a zone controls b timing controls c boiler control interlocks Such a system needs to be fully pumped and must provide independent temperature and time control to both the heating and hot water circuits and have a boiler interlock The boiler should be controlled so that it operates on demand only Where it is proposed to effect control by thermostatic radiator valves a room thermostat or other device such as a flow switch a flow sw
22. Ih O gal min O 5 0 Dimensions and Fixings SIDE FLUE left and right For every Im of horizontal flue length the clearance above the top of the flue elbow should be 55mm to incorporate the 3 in 20 fall in the flue from the terminal to the elbow Ve 3 DIMENSIONS A 850mm I in 20 B 320mm C 490mm D 125mm Min Flue length Y Clearance X up to Im 55mm E oami Im 2m 110mm F 136mm 2m 3m 165mm V a _ D I in 20 The 3 I in 20 fall provided by T the elbow is to allow condensate ube 10mm to run back to the boiler for disposal through the condensate discharge pipe Support Bracket Key To Support Bracket Domestic Hot Water Outlet 4 Central Heating Flow 2 Cold Water Inlet 5 Central Heating Return 3 Gas Supply 6 Pressure Relief Top View of Tap Rail 12 Baxi Heating UK Limited 2005 Information In GB it is necessary to comply with the Water Supply Water Fittings Regulations 1999 or for Scotland The Water Byelaws 2000 Scotland The Baxi Combi 133 100 80 HE Plus Combination Boilers are an Approved Product under the Water Regulations To comply with the Water Regulations your attention is drawn to The Water Regulations Advisory Service WRAS which gives full details of the requirements In IE the requirements
23. Installation of hot water supplies for domestic purposes BS 5449 Forced circulation hot water systems BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7535 Treatment of water in domestic hot water central heating systems Baxi Heating UK Limited 2005 Section Page 1 0 Introduction 6 2 0 General Layout Z 3 0 Appliance Operation 8 4 0 Technical Data 9 5 0 Dimensions and Fixings 12 6 0 System Details 13 7 0 Site Requirements 16 8 0 Installation 22 9 0 Electrical 29 10 0 Commissioning the Boiler 31 11 0 Fitting the Outer Case 35 12 0 Servicing the Boiler 36 13 0 Changing Components 38 14 0 Short Parts List 49 15 0 Fault Finding 50 16 0 Operational Flow Chart 60 Benchmark Checklist 62 6 Fig Lower Door Panel Air Box Door Data Badge Fig 2 Baxi Heating UK Limited 2005 1 0 Introduction This boiler is fitted with a flow switch interlock that prevents it from firing when the heating demand is satisfied m Description The Baxi Combi HE Plus Range are fully automatic gas fired wall mounted condensing combination boilers They are room sealed and fan assisted and will serve central heating and mains fed domestic hot water 2 The boiler is preset to give a maximum output of 23 9 kW
24. PCB Control and Fan Assembly is 325 Vdc Isolate at supply before access 2 Isolate the water circuit and drain the system as necessary There are 4 drain points a Flow Valve b Heat Exchanger Manifold Fig 45 c Return Valve d Cold Water Inlet NOTE When reassembling always fit new O rings ensuring their correct location on the spigot Green O rings are used for gas joints and Black O rings for water joints Use Greasil 4000 Approved Silicone Grease 3 After changing a component re commission the boiler where appropriate and check the inhibitor concentration see Section 6 1 and 10 1 The air vents flowswitch thermistor safety thermostat and expansion vessel can be accessed after removal of the outer case Manual and Automatic Air Vent Fig 46 Drain the boiler 2 Undo the manual air vent from the flow pipe or the automatic air vent from the return pipe and retain the sealing washer 3 Remove the air vent 4 Fit the new air vent and reassemble in reverse order Flow Thermistor Red Body Safety Thermostat Black Body Electrical Connections Fig 48 Return Thermistor Red Body Fig 49 Expansion Vessel Fig 50 Baxi Heating UK Limited 2005 Expansion Vessel Connection Expansion Vessel Securing Screw
25. guard see Section 7 9 VERTICAL FLUEING Only a flue approved with the Baxi Combi HE Plus Boiler Range can be used 2 For information on vertical flues consult the Baxi Flue Guide Brochure or Notes for Guidance supplied with the vertical flue pack Metal Shield Plug Filter 2 way Terminal Block ite ES Electrical Cover Fig 27 PRE EE Cable Clamp Link Wire 2 For External Controls sO PCB Fig 28 External Timer SES O PCB Fig 29 Baxi Heating UK Limited 2005 8 0 Installation Making The Electrical Connections Fig 26a WARNING This appliance must be earthed The electrical connection is on the rear left hand side of the unit 2 Remove the electrical plug and lead assembly from the hardware pack 3 Connect L N amp E of the lead into the fused double pole isolator serving the boiler Connect the plug to the socket at the back left at the bottom of the boiler 4 Remove the metal shield from the hardware pack and connect it over the plug 5 If fitting an integral timer please refer to the instructions supplied with the kit 6 Check the electrical installation for earth continuity short circuits resistance to earth correct polarity and fuse failure see Section 8 13 Electrical System Chec
26. he corner of the room and along the wall to where the flue be drilled Fig 14 The diagram Fig 4a shows the dimensions required to hole wi ensure any horizontal flue is installed with the correct fall to he boiler Mark the offset V dimension and if required mark the position of the gas and water pipes Remove the emplate 6 Cut the hole for the flue preferably with a 125mm 5 diameter core boring tool ensuring that the hole is drill at approx 3 up from the horizontal Both wall faces immediately around the cut hole should be flat 7 Drill and plug the w o ll as previously marked Secure the wallplate to the wall by the top centre hole 8 Ensuring the wallplate is level both horizontally and vertically drill and plug the remaining 4 securing positions at the top and bottom through the wallplate Utilising the slots available ensure the wallplate is square and secure to the wall 9 Connect the gas water and the pressure relief discharge pipes to the valves on the support bracket using the compression fittings supplied 10 Loosely route the condensate discharge pipe to the area previously marked Flushing Insert a tube into the valve outlet furthest from the filling loop Fig 15 2 Flush thoroughly see System Details Section 6 0 Lower Door Panel Fig 16 Fig 17 Outer Case Fixing on inside of panel Baxi Heating UK Limite
27. manufacturer s specified spare part when replacing all controls SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 DATE SERVICE 4 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 5 DATE SERVICE 6 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 7 DATE SERVICE 8 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 9 DATE SERVICE 10 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE Baxi Heating UK Limited 2005 63 All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet A
28. min O 10 Baxi Heating UK Limited 2005 Appliance Type C3 C33 Appliance Category Heat Input Gross DHW Max kW 26 95 Btu h 92 000 Heat Input Gross CH Max kW 26 95 Btu h 92 000 Heat Output CH Non Condensing 70 C Mean Water temp ax kW 23 9 Btu h 81 500 Condensing 40 C Mean Water temp ax kW 25 1 Btu h 85 600 Max Gas Rate Natural Gas After 10 Mins m h 2 5 ft h 87 9 Inlet Pressure Natural Gas mbar 20 in wg 8 Electrical Supply 230V 50H Appliance must be connected to an earthed supply Power Consumption 200W External Fuse Rating 3A Internal Fuse Rating 3 15A SEDBUK Declaration For Combi 80 HE Plus The efficiency is 90 8 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 Baxi Heating UK Limited 2005 4 0 Technical Data Combi 80 HE Plus Flue Terminal Dimensions Diameter Projection 110mm 150mm Connections compression Gas Supply th BSPF Central Heating Flow 22mm Central Heating Return 22mm Cold Water Mains Inlet 15mm DHW Flow 5mm Pressure Relief Discharge 5mm Condensate Drain I BSP Outercase Dimensions Casing Height 850mm Overall Height Inc Flue Elbow 1000mm Casing Width 490mm Casi
29. service is recommended When replacing the combustion box door after servicing it is essential that the retaining screws are tightened fully For reasons of safety and economy it is recommended that the boiler is serviced annually Before servicing please read Section 2 Important Information 2 After servicing complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication 3 Ensure that the boiler is cool 4 Ensure that both the gas and electrical supplies to the boiler are isolated 5 Remove the outercase and lower door panel see Fitting the Outercase Section 1 0 in reverse WARNING The PCB Control and Fan Assembly is 325 Vdc Isolate at supply before access 6 Release the four turn screws securing the air box door panel and remove the door Fig 40 7 Disconnect the three lead terminals from the combustion box door taking note of their positions Fig 40 8 Undo the four screws securing the combustion box door and remove the door Fig 41 9 Visually check for debris damage and clean or replace if necessary the following a Burner Fragile 133 model handle with care b Heat exchanger fins c Fan compartment Check also for condensate leaks d Insulation e Door seals Important Pay particular attention to the condition of the combustion box door seals f Electrodes g The condensate trap must be t
30. 13 0 Changing Components 13 3 Flowswitch Fig 47 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 It may be necessary to remove the expansion vessel see Section 13 5 3 Remove the clip securing the flow pipe to the flowswitch 4 Remove the two screws securing the flow switch to the boiler 5 Disconnect the inline electrical connection 6 Remove the flowswitch 7 Fit the new flowswitch and reassemble in reverse order 8 Recommission the boiler and check the inhibitor concentration see Section 6 1 and 10 1 Flow or Return Temperature Thermistors and Safety Thermostat Figs 48 amp 49 The procedure is the same for both the thermistors and the safety thermostat although the components are not interchangeable 2 Remove the electrical connection from the component 3 Unscrew the component from the pipe 4 Fit the new thermistor or safety thermostat and reassemble in reverse order Expansion Vessel Fig 50 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Loosen the securing screw at the base of the expansion vessel 3 Whilst supporting the vessel undo the expansion vessel connection and retain the sealing washer 4 Remove the expansion vessel 5 Fit the new expansion vessel and reassemble in reverse order Re pressuring Expansion vessel The charge pressure is 1 0 bar 2 Close the central heating flow and return isolating valves
31. AST 2 5 50mm per metre along the entire run AAA NOTE It is unnecessary to fit an air break in the discharge pipe A The condensate outlet terminates in a BSP nut and seal 450mm min for the connection of 21 5mm fin plastic overflow pipe which should generally discharge internally into the household drainage system If this is not possible discharge into an External termination via internal discharge outside drain is acceptable branch e g sink waste downstream 2 Ensure the discharge of condensate complies with any national or local regulations in force BS 6798 2000 amp Part HI of the Building Regulations give f further guidance Pipe must terminate above water level but i ta i below surrounding 3 The discharge pipe should be run in a proprietary drain pipe surface material e g PVC PVC U ABS PVC C or PP Sink 4 Metal pipework is NOT suitable for use in condensate discharge systems 5 The pipe should be a minimum of 21 5mm diameter and must be supported using suitably spaced clips to prevent sagging Termination to a drain or gully 6 It is advisable to keep the condensate pipe internal Boiler 7 External runs greater than 3 metres or runs in cold areas Pipe must terminate above water level but below surrounding surface should use 32mm waste pipe 8 If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treate
32. BAXI Installation amp Servicing Instructions Baxi Combi 133 HE Plus Baxi Combi 100 HE Plus Baxi Combi 80 HE Plus Gas Fired Wall Mounted Condensing Combination Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Baxi Heating UK Limited 2005 Natural Gas Baxi Combi 133 HE Plus G C N 47 075 14 Baxi Combi 100 HE Plus G C N 47 075 15 Baxi Combi 80 HE Plus G C NP 47 075 16 Baxi Heating UK Limited 2005 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 Limited Pentagon House Sir Frank Whittle Road Derby DE21 4XA 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 Building Regulations and the Benchmark C
33. ER SCALE REDUCER BEEN FITTED YES Nol WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE amp RECORD GAS RATE m lhr ft8fhr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE _ NA mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE Its min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS _ IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDED A CO CO2 RATIO READING NA YES CO CO2 RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER COMMISSIONING ENG S NAME PRINT CORGI ID No 62 Baxi Heating UK Limited 2005 SIGN Se DATE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the
34. Operational Flow Chart Central Heating Mode Timer amp Room Stat YES on Standby The diverter valve pump fan spark generator and gas valve are off If the timer and room stat are on then Diverter Valve moving to CH position Occurs 6 second Timer off or Diverter Valve moving to 2 Diverter Valve moving to CH position The diverter ne tat off CH position Me valve moves to the CH position while the pump fan spark generator and gas valve are off After 6 seconds if the flow temperature is less than the set point then Pump On occurs After 6 seconds if the flow Flow temperature temperature is greater than the set point then Pump less than set point Overrun occurs 3 Pump On The diverter valve and pump are on while the fan spark generator and gas valve are off After 10 seconds if the flow switch has made then Fan Pre Purge 10 second occurs After 10 seconds if the flow switch has not P On ee i made then Anti cycle occurs 4 Fan Pre Purge The diverter valve pump and fan are on while the spark generator and gas valve are off After 5 seconds Ignition occurs Primary Flow Switch made 5 Ignition The diverter valve pump fan spark generator and gas valve are on If a flame is detected then Burner On occurs If a flame is not detected within 5 seconds and less than 5 ignition attempts have been Ignition done 3 second and less than 5 made then Fan
35. Purge occurs If a flame is not detected Fan Pre Purge attempts made within 5 seconds and 5 ignition attempts have been made then Ignition Lockout occurs 5 second 6 Burner On The diverter valve pump fan and gas Ignition Period valve are on while the spark generator are off Flow temperature is controlled by varying the fan speed and thereby the gas rate to achieve optimum operation If the flow temperature is greater than the set point or Ignition done and 5 attempts made the timer is off or the room stat is off then Pump Overrun occurs If the TRVs all shut down then Anti cycle occurs Flame Detected 7 Pump Overrun The diverter valve and pump are on p a ignition while the fan spark generator and gas valve are off umer On i Bumer On After minute Anti cycle occurs Lockout All TRVs shut down 8 Anti cycle The diverter valve pump fan spark Timer off or temperature gt set point or room stat off generator and gas valve are off After 3 minutes Diverter Valve moving to CH position occurs 9 Ignition Lockout The diverter valve pump fan spark generator and gas valve are off The boiler can only be reset by manually using the reset button minute NOTE If a tap or shower is switched on during CH Burner On then DHW Burner On occurs If a DHW demand occurs during any other part of CH Pump Overrun operation then DHW Purge occurs
36. S Example DSK V 110mm Horizontal Side Flue Centre Line EXAMPLE Boiler is 2 metres away from corner of wall flue duct hole is 110mm up from horizontal side flue centre line This will maintain the approx 3 backfall to the boiler Wall Plate Template Backfall to the Boiler ie 2m flue offset V position Omm Flue Duct Hole Offset V mm 27 55 110 165 220 mm metres Distance in metres from boiler to the wall For pipe lengths greater than 4m increase the off set by 52mm Fig 14a for every additional metre to maintain approx 3 inclination Plastic Flushing Tube The symbols for each connection are on the support bracket 22 Baxi Heating UK Limited 2005 8 0 Installation ET Initial Preparation Check Site Requirements section 7 0 before commencing The gas supply gas type and pressure must be checked for suitability before connection see Section 7 4 NOTE If the boiler is to be pre plumbed follow both these instructions and those on the boiler pack Remove the fixing template Fig 14 from the fixing carton 2 Position the template on the wall ensuring it is level both horizontally and vertically 3 Mark the position of the top centre hole for the wallplate 4 Mark the condensate discharge pipe area 5 Mark the centre of the flue hole rear exit For side exit project the horizontal side flue centre line into
37. anger fins I Check condition of all seals Important Pay particular attention to the condition of the combustion box door seals m Reassemble in reverse order applying a suitable silicon based grease to O rings and seals Greasil 4000 Approved Silicone Grease 12 Check CO CO ratio at flue sampling point Fig 41a See section 4 0 13 Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user 37 Heat Exchanger Manifold Drain Point Fig 45 Manual Air Vent 38 Baxi Heating UK Limited 2005 13 0 Changing Components Changing Components IMPORTANT When servicing ensure that both the gas and electrical supplies to the boiler are isolated before any work is started The boiler cannot be switched off at the boiler therefore it is important to isolate the electrical supply at the mains fuse Hazardous materials are not used in the construction of Baxi products however reasonable care during service is recommended When replacing the combustion box door after changing components it is essential that the retaining screws are tightened fully Remove the outer case and lower door panel see Fitting the Outercase Section 1 0 WARNING The
38. d 2005 Service Guidance Note Label 8 0 Installation Preparing The Boiler Remove the outer carton 2 Hinge up the lower door panel Fig 16 3 Remove the outer case fixing screws Fig 16 Slide the outercase upwards to disengage the hooks on the backplate and remove Fig 17 NOTE Service Guidance Note Label is fitted to the inside of the outercase Fig 17 4 Remove the sealing plugs from the copper bends 5 Remove cardboard transit packaging at the left hand rear of the boiler before lifting the boiler onto the support bracket 6 Stand the boiler on its base by using the rear lower edge as a pivot NOTE A small amount of water may drain from the boiler in the upright position Baxi declare that no substances harmful to health are contained in the appliance or used during construction of the appliance 23 UN EES aa ANT A A Facia Securing a7 U Screws Facia Box Erei Suggested Lifting Points shown as shaded area DO NOT LIFT USING THE PLASTIC FACIA FLUE PRODUCTS EXHAUST BOX Flow Regulator Water Inlet Filter Outlet Fa gt Cold Water O Inlet ie Gas Connection re 7 Fibre Sealing Central Heating Central Heating ee Washer Flow Return Pressure Relief 24 Baxi Heating UK Limited 2005 Top Hooks Support Bracket 8 0 Installation Fittin
39. d as an external run 9 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used 10 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soil pipes or waste pipes are subjected to internal pressure Termination to a purpose made soak fluctuations when WC s are flushed or sinks emptied then awa y back pressure may force water out of the boiler trap and cause appliance lockout 500mm min Examples are shown of the following methods of termination i to an internal soil amp vent pipe ii via an internal discharge branch e g sink waste iii to a drain or gully Holes in the soak away must iv to a purpose made soakaway face away from the building 18 Baxi Heating UK Limited 2005 Table 2 Terminal Position with Minimum Distance Fig 10 Directly below an opening air brick opening windows etc 300 B Above an opening air brick opening window etc 300 C2 Horizontally to an opening air brick opening window etc 300 D Below gutters soil pipes or drain pipes 25 E Below eaves 25 F Below balconies or car port roof 25 G From a vertical drain pipe or soil pipe 25 H From an internal or external li comer 25 115 Above ground roof or balcony
40. d must be provided 7 0 Site Requirements Flue Dimensions See Section 2 2 The standard horizontal flue kit allows for flue lengths between 270mm and 800mm from elbow to terminal Fig 1 The maximum permissible equivalent flue length is 4 metres horizontal Fig 2 NOTE Each additional 45 of flue bend will account for an equivalent flue length of 0 5m eg 45 0 5m 90 2 x 45 Im etc Terminal Guard Fig 13 Fig 11 When codes of practice dictate the use of terminal guards they can be obtained from most Plumbers and Im Builders Merchants m om Y V 2 There must be a clearance of at least 50mm f f between any part of the terminal and the guard FT y F y A 0 5m 3 When ordering a terminal guard quote the appliance name and model number Fig 12 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated Pictorial examples of flue runs where EQUIVALENT flue length equals 4m Fig 13 20 Baxi Heating UK Limited 2005 A Standard Flue 7 0 Site Requirement Flue options Concentric The maximum equivalent lengths are 4m horizontal or 5m vertical There lengths exclude the standard elbow and flue terminal assembly horizontal and terminal assembly vertical Twin Flue The total maximum equivalent flue length is 40
41. e continuity from K to L amp from M to N Fan PCB Connection Connection K L EE lt N ectify wiring to T amp from StoR Fan PCB Connection Connection O Replace fan Q gt P m Viewed from Wire Entry end DHW FLOW SWITCH Unplug 5 way connector from PCB With all DHW taps off is there continuity NO Replace PCB W Viewed from Wire Entry end across W Is DHW flow switch Unblock DHW flow blocked switch Replace DHW flow switch Baxi Heating UK Limited 2005 55 15 0 Fault Finding FLOW THERMISTOR Unplug flow thermistor Is thermistor resistance between Replace flow thermistor 0 5kQ amp 20kQ Viewed from Wire Entry end Plug in thermistor unplug Sway PCB connecter Wiring from PCB to flow Is resistance at V between thermistor faulty 0 5kQ amp 20kQ Replace PCB RETURN THERMISTOR Unplug return thermistor Is thermistor resistance between Replace return thermistor 0 5kQ amp 20kQ Viewed from Wire Entry end Plug in thermistor unplug 7 8 way PCB connector Wiring from PCB to Is resistance at U between return thermistor faulty 0 5kQ amp 20kQ Replace PCB 56 Baxi Heating UK Limited 2005 DHW Fault x Viewed from Wire Entry end Unplug 5 way connector from PCB With water flowing out of a fully open DHW tap is there contin
42. e 3 Fig A In GB Only Ceiling fa et Sis a fies Outside Zones Zone 2 Tone 3 I mm mm mm mm Outside Zones Zone 3 I Zone 2 Fig B In GB Only 16 Baxi Heating UK Limited 2005 7 0 Site Requirements Location NOTE Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue This should be taken into account when siting the flue terminal The boiler may be fitted to any suitable non flammable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i e garage or outhouse The boiler may be fitted inside a cupboard see Section 7 2 2 lf the boiler is sited in an unheated enclosure then it is recommended to incorporate an appropriate device for frost protection in the system controls 3 If the boiler is fitted in a room containing a bath or shower the 100 HE Plus and 80 HE Plus can only be fitted in zone 3 the 133 HE Plus has a higher protection level and may be fitted in zone 2 Figs A amp B shows zone dimensions for a bathtub For other examples refer to Section 601 of the Current LEE Wiring Regulations reference must be made to the relevant requirements In GB this is the current LEE Wiring Regulations a
43. e order The injector pipe condensate trap and gas valve can be changed after the removal of the fan 45 Injector Pipe 100 amp 80 HE models Injector Pipe Gas Valve Securing Screws Gas Pressure Gasket Pipe Boiler Side Aluminium Spacer Electrical Plug Gas Valve Qa Gas Inlet Pipe Fig 67 E Flange Sensor Leads Securing Nut Condensate Trap A Locknut Condensate Drain Pipe Fig 68 46 Baxi Heating UK Limited 2005 13 0 Changing Components It is necessary to remove the fan before changing the injector pipe condensate trap and gas valve see section 13 21 EPA Injector Pipe Fig 67 Loosen the screw retaining the gas injector pipe at the venturi 100 amp 80 HE Plus models 2 Remove the injector pipe by pulling out from the O ring joint in the gas valve 3 Fit the new injector pipe and reassemble in reverse order applying Greasil 4000 Approved Silicone Grease to both O rings EPEE Gas Valve Fig 67 Release the facia securing screws l 4 turn and hinge down the facia box 2 Loosen nut at gas inlet pipe at tap rail 3 Undo the gas pressure pipe from the gas valve 4 Undo the screw and disconnect the electrical plug from the gas valve 5 Remove the two gas valve
44. e supply then an expansion vessel must be fitted e g Zilmet 160ml R 2 15 bar 3 If the hot water expansion is not provided for then high pressures can develop which may result in damage to fittings and devices on the system 4 The boiler s maximum working mains pressure is 10 bar 150 Ib in2 therefore all pipework connections fittings etc should be suitable for pressures in excess of 10 bar A pressure reducing valve must be fitted for pressures in excess of 10 bar The manufacturer of any outlet fittings such as a shower valve may require a lower maximum pressure The pressure reduction must take account of all fittings connected to the DHW system 5 Optimum hot water delivery of 16 l min 133 model 12 Vmin 100 model 10 l min 80 model may be obtained by fitting the flow regulator supplied Showers If a shower control is supplied from the appliance it should be of the thermostatic or pressure balanced type Thermostatic type shower valves provide the best comfort and guard against water at too high a temperature Existing controls may not be suitable refer to the shower valve manufacturer 16 8 Hard Water Areas If the area of the installation is recognised as a HARD WATER AREA then a suitable device should be fitted to treat the mains water supply to the boiler Contact your Water Distribution Company for advice on suitable devices Window Recess Zone 2 Zon
45. er Condensate Drain see section 7 6 Connect the condensate drain using the 1 BSP nut and seal supplied Ensure the discharge of condensate complies with any national or local regulations in force see British Gas Guidance Notes for the Installation of Domestic Gas Condensing Boilers 2 The condensate outlet terminates in a 1 BSP nut and seal for the connection of 21 5mm fin plastic overflow pipe which should generally discharge internally into the household drainage system If this is not possible discharge into an outside drain is acceptable NOTE To ensure the correct operation and integrity of the condensate drainage system Carefully pour approximately cupful 250ml of water into the flue products exhaust at the top of the heat exchanger Fig 19 to ensure a seal is made in the trap Wall Thickness ZZ o gt 3 I in 20 x Support Bracket 360 Orientation Edge of Support Bracket to Wall Wall Thickness Fig 21 Y Left Exit Z Right Exit Waste X Rear Exit Flue Inner Flue Support Bracket Baxi Heating UK Limited 2005 8 0 Installation ES Fitting The Flue Before fitting the flue check the condensate drain integrity see section 8 5 IMPORTANT The flue should always be installed with a 3 I in 20 fall from terminal to elbow to allow condensate to run back to the b
46. etes Ts ess Vh O gal min O 4 0 Technical Data Combi 100 HE Plus Appliance Type C3 C33 Flue Terminal Diameter 110mm DHW Circuit bar Ib in Dimensions Projection 150mm Pressures Appliance Category CAT 2H ax Operating 10 145 Heat Input Gross DHW Max Connections compression in Operating 0 1 1 45 Gas Supply 1 2 BSPF kW 337 Central Heating Flow 22mm in Operating Pressure Btu h 15 000 Central Heating Return 22mm at 12 l min 0 54 7 83 Cold Water Mains Inlet 5mm a ee Heat Input Gross CH DHW Flow Bim Flow Rates lin gal min Max Factory Set Pressure Relief Discharge 5mm Dee Fow hate j 30 CRise 14 3 08 Condensate Drain BSP kW 33 7 26 95 DHW Flow Rate Btu h 15 000 92 000 Outercase Dimensions 35 CRise 12 2 64 Casing Height 850mm in Working Heat Output CH Overall Height Inc Flue DHW Flow Rate 19 043 Non Condensing 70 C Mean Water temp Elbow 1000mm M Factory Set Casing Width 490mm Pump ax ay S Casing Depth 320mm Available Head See graph below kW 30 0 239 alk 102 000 81 500 Clearances Expansion Vessel For Central Heating Both Sides 5mm Min only Integral with appliance bar Ib in Condensing 40 C Mean Water temp Above Casing 200mm Min in Pres Pr ae Le Below Casing 200mm Min INF Pee CNAMEE Pressure Max Factory Set Front 500mm Min For Servicing ominal Pre charge kW
47. g The Boiler Fig 8 Remove the tape from the tap rail on the support bracket 2 Lift the boiler over the support bracket using the lifting points shown in Fig 18 and engage onto the top hooks see Lifting paragraph page 4 NOTE When installing in Loft Small Compartment access for lifting the boiler from the front can be gained for two people using the lifting points Fig 18 3 To gain access to the connections between boiler and valves release the facia securing screws 4 turn and hinge down the facia box 4 Make the connections in the following sequence a Gas connection first to centralise the boiler The gas sealing washer is an integral part of the gas tap The Combi HE is designed to operate under nominal water supply conditions If the hot water delivery is greater than 18 l min 133 model 14 l min 100 model 12 l min 80 model the flow regulator must be fitted to the Domestic Hot Water inlet b Domestic hot water cold feed if necessary fit the water flow regulator ensuring that it is fitted the correct way round Fig 20 NOTE Ensure water inlet filter is fitted c The remaining connections ensuring the fibre sealing washers are inserted between the valve outlet face and the flange on the copper pipes of the water circuit and pressure relief connections Fig 20 5 Tighten the connections in the sequence listed above Central Heating Return Filt
48. given in the current edition of l S 813 Domestic Gas Installations and the current Building Regulations must be followed Treatment of Water Circulating Systems e All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system risking damage to pump and valves boiler noise and circulation problems e When fitting new systems flux will be evident within the system which can lead to damage of system components e All systems must be thoroughly drained and flushed out Using for example Betz Dearborm Sentinel X300 or X400 or Fernox Superfloc Universal Cleanser They should be used following the flushing agent manufacturer s instructions e System additives corrosion inhibitors and flushing agents descalers should comply to BS7593 requirements e g Betz Dearborn Sentinel X100 and Fernox Copal which should be used following the inhibitor manufacturer s instructions Failure to flush and add inhibitor to the system will invalidate the appliance warranty e 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 e For information or advice regarding any of the above contact Technical Enquiries Baxi
49. horoughly cleaned at every service see section 3 24 for removal NOTE If necessary remove the trap drain plug and place a vessel underneath to catch the condensate care should be taken as this could be hot Clean the trap and refit the drain plug Check for leaks h Top of heat exchanger NOTE General cleaning can be undertaken using a vacuum However debris should only be gently blown off the burner skin due to its fragile nature 133 HE Plus 10 Check system pressure is between and 2 5 bar Flue Sampling Point Burner Fig 4la Injector Pipe Injector Pipe Retaining Screw 100 amp 80 HE models Venturi Sensor E Leads Protection Sensor Leads e s Condensate Wig ju e gt gt k Trap Electrical Supply N Fig 42 Locking Nut gt oy Fig 43 Condensate Central Insulation Drain Pipe Panel 100 amp 80 HE Burner Burner a Combustion Box Base wf Heat Exchanger r Support Bracket Combustion Box Base Burner Securing Securing Screws Screws Fig 44 Baxi Heating UK Limited 2005 12 0 Servicing the Boiler Annual Servicing Cont NOTE The information shown on the display is explained on the label on the inside of the lower door panel see F
50. ig 38 To clean the heat exchanger and burner proceed as follows a we Disconnect the electrical leads to the fan component protection sensor Fig 42 b Loosen the screw retaining the gas injector pipe at the venturi 100 amp 80 HE Plus models c Undo the two wing nuts to disconnect the fan Fig 42 w d Remove the fan and disconnect the electrical supply to it Fig 42 e Remove the gas injector pipe from the gas valve push fit Fig 42 f Undo the condensate trap securing nut lock nut and the condensate drain pipe Remove the condensate trap and disconnect the sensor leads Fig 43 g Remove the two screws securing the burner and remove the burner Visually inspect the internal burner baffle for obstruction Fig 44 NOTE The 133 HE Plus burner skin is fragile handle with care Clean and if necessary replace the burner Fig 44 h Loosen the two screws retaining the heat exchanger support bracket and slide to the left to remove Fig 44 i Remove the four screws securing the heat exchanger combustion box base and withdraw the base j Lower the central insulation panels and check condition Fig 44 Replace the insulation pads if necessary k Ensure the heat exchanger fins are clear of any obstruction use a thin bladed tool to remove debris The use of a torch at the heat exchanger top and a mirror held under the heat exchanger will aid observation of the heat exch
51. itch is integral to this boiler should also be provided to switch off the boiler when there is no demand for heating or hot water The interlock for CH circuit can be provided in either of the following ways a A Room Thermostat with at least the radiator nearest the room stat not TRV d b A fully TRV d system without a bypass A fully TRV d system with a bypass that has not been valved off does not comply with Part LI of the Building Regulations If the system is fully TRV d with a bypass then this feature will not be available in this case the radiator temperature can be reduced to provide more efficient operation see User instructions e The condensate drain and pipes must be free from leaks Mains Inlet Fig 3 Expansion Vessel removed for clarity 14 Baxi Heating UK Limited 2005 Fig 4 Pressure Relief Valve 6 0 System Details System Control The boiler is designed for use in a heating system that incorporates external controls i e a minimum of a timer device 2 Suitable timer kits are available as optional extras System Filling and Pressurising Fig 3 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 a
52. ks Connecting an External Timer Undo the screw securing the electrical cover and remove 133 HE Plus only Fig 27 2 To connect an external timer switch circuit remove the link wire between terminals amp 2 and connect the switch circuit Figs 28 amp 29 3 A cable clamp is provided for incoming cables 27 Electrical Cover Link Wire A 2 l PCB Fig 30 External Room Timer Thermostat PCB Fig 30a Frost Thermostat Fig 31 28 Baxi Heating UK Limited 2005 8 0 Installation EM Fitting a Room Thermostat To fit a 2 wire thermostat remove link and wire the thermostat switch between positions amp 2 Figs 30a A cable clamp is provided for incoming cables EU Fitting a Frost Thermostat The frost thermostat is connected between positions and 2 Fig 31 or between mains isolator and position 2 Secure the incoming cable s with the cable clamp and replace the cover ES Electrical System Checks Earth Continuity Check Isolate the appliance at mains supply Using a multimeter set to ohm s scale test between any appliance earth point and the earth pin on the socket The resistance should be less than ohm If the resistance is greater than then check all earth wires for continuity and ensure that all connecti
53. level 300 From a surface or boundary line facing a terminal 600 From a terminal facing a terminal Horizontal flue 1200 From a terminal facing a terminal Vertical flue 600 L From an opening in carport e g door window into the dwelling 1200 Vertically from a terminal on the same wall 1500 Horizontally from a terminal on the same wall 300 From adjacent wall to flue vertical only 300 S From an adjacent opening window vertical only 1000 4 In addition the terminal should be no nearer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built in element such as a window frame See BS 5440 Pt NOTE The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below Terminal D gt LLU a Assembly 1 1 l c 1 4 i 4 oJ 1 Top View Rear Flue i i Fig 9 W 1 1 Property Boundary Line pK I eal pi Likely flue positions requiring a flue terminal guard Baxi Heating UK Limited 2005 re D vA Of T TE El E JF JK A H H Fig 10 7 0 Site Requirements Flue NOTE Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue This should be taken into account when siting the flue terminal
54. ll goods are sold subject to our standard Conditions of Sale which are available on request BAXI A Trading Division of Baxi Heating UK a division of Baxi Group Brooks House Coventry Road Warwick CV34 4LL After Sales Service 08700 60 30 60 Technical Enquiries 08706 049 049 Website www baxi co uk e amp oe A BAXI GR UP company Baxi Heating UK Limited 2005 Comp N 5109929 Iss 6 10 07
55. ll relevant water supply regulations and use approved equipment 3 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 l S 813 Domestic Gas Installations 4 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 5 To aid removal of air from the system whilst filling move the diverter valve to the CH position by using the installer parameters see Section 10 4 Expansion Vessel CH only Fig 4 The appliance expansion vessel is pre charged to bar 14 5 Ib in Therefore the minimum cold fill pressure is bar The vessel is suitable for correct operation for system capacities up to 125 litres 27 5gal For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt For IE the current edition of LS 813 Domestic Gas Installations Pressure Relief Valve Fig 4 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressures in excess of 3 bar 2 The pressure relief discharge pipe should not be less than 5mm dia run continuously downwa
56. low DC Fan Switch Switch Condensate Fan Trap Overheat Thermostat Diverter Valve Key To Wiring Colours b Blue r Red bk Black g Green gy Grey g y Green Yellow w White o Orange br Brown y Yellow op Opaque Baxi Heating UK Limited 2005 29 9 0 Electrical Key To Wiring Colours b Blue r Red bk Black g Green Illustrated Wiring Diagram gy Grey g y Green Yellow w White o Orange br Brown y Yellow op Opaque Pump Return Thermistor A Flow br b Thermistor bob LD Spark Electrode Flame DZ Detection KO fH Electrode y IMs y VAAD IIIR L N O V7 F o a E AN een ee A C7 rl ml Fan Overheat D Thermostat Flow Overheat Thermostat bk Diverter Valve 30 Baxi Heating UK Limited 2005 10 0 Commissioning the Boiler 10 1 Commissioning the Boiler NOTE The information shown on the display is explained on the label on the inside of the lower door panel see Fig 38 Open the cold feed to the boiler 2 Open all hot water taps to purge the Domestic Hot Water Circuit Manual Air Vent 3 Ensure that the filling loop is connected and open then Fig 32 open the heating flow and return valves on the boiler see Section 10 4 Filling the System 4 Open the manual and automatic air vents Fig 32 ensure all external controls are turned on and calling for heat
57. lt finding instructions Low Electrical Supply Incoming Voltage less than 180V Check System Controls amp System Wiring Otherwise contact Electricity Provider Wiring Harness Ensure 8 way PCB connector securely pushed in If fault persists replace Wiring Harness PCB Fault Replace PCB PCB Fault Replace PCB PCB Fault Replace PCB Go to DHW Fault section of the fault finding instructions Go to CH Fault section of the fault finding instructions 15 0 Fault Finding ELECTRICAL SUPPLY Connect Mains to boiler YES Check wiring from terminal block to PCB YES Check for shorts on pump fan amp gas valve Replace if shorted amp replace fuse F gt PCB fuse OK Replace PCB Ww yy Fuse HUT OCH Baxi Heating UK Limited 2005 5I CD of aC On Lights 4 C Flash C Flash 15 0 Fault Finding DRY FIRE Pump Plug when unplugged Is NO the system Fill system with water and o bleed out all air CETT E Viewed from G Wire Entry end full of water YES Is there 240V at D water flowing out NO Unplug the NO of a fully open DHW tap does the pump pump is there 240V at C NO Replace PCB run YES YES YES Pump fault Wiring from terminal block to PCB faulty YES 5 way PCB connector With water flowing out of a fully open DHW tap is there c
58. m NOTE Each Im of flue duct should be calculated as 2m E Any additional in line bends in the flue system must be 3 taken into consideration Their equivalent lengths are Concentric Pipes 45 bend 0 5 m 93 bend 1 0 m Twin Flue Pipe 45 bend air duct 1 3 m 45 bend flue duct 2 6m 90 bend air duct 48 m 90 bend flue duct 9 6m Plume Displacement 70 110 dia Kit Detailed examples of equivalent flue length calculation are given in the Installation Guidance Notes for each flue system type Documents 243501 and 243502 for concentric and twin pipe respectively Key Accessory Baxi Code Number m a a Concentric Flue System 10mm diameter A Horizontal flue kit 850mm 236921 Straight extension kit 1000mm 241695 500mm 241694 250mm 241692 Bend kit 93 241687 5 DA 2 Bend kit pair 45 241689 d Horizontal flue terminal 24301 3BAX Clamp 10mm 243014BAX Twin Flue System 80mm diameter F Straight extension kit 1000mm 238690 500mm 238692 250mm 238694 G Bend kit 90 246139 H Bend kit pair 45 246138 Universal Vertical Flue Kits Twin flue adaptor kit 242757 Vertical flue terminal 242802 L Universal roof tile 25 50 243015 M Roof cover plate kit 243131 Flat roof flashing 24301 6BAX Boiler connection vertical concentric 242886 Clamp 80mm 238684 Baxi Heating UK Limited 2005 21 Example Edge of Boiler 2m aoa n E
59. moved for clarity Optional Extras x 13 IT PART Ne FLUE EXTENSION KITS 110 70 12 orizontal Flue Kit 4M max Flue Extension 0 25M 241692 Il Flue Extension 0 5M 241694 Flue Extension M Use two kits for 2M etc 241695 Flue Bend 45 Reduce overall length of flue by 0 5m when fitting this bend 241689 23 Flue Bend 90 Reduce overall length of flue 5 by Im when fitting this bend 241687 orizontal Extended Flue 1 75M 5111457 VERTICAL FLUE KITS 110 70 5M max Vertical Flue Terminal 242802 Vertical Boiler Connection 5106888 78 VERTICAL FLUE 80 80 it Boiler Connection Twin 242757 CONTROL ACCESSORIES RF Programmable Room Thermostat 5117204 Electro Mechanical Timer 5117493 Filling Loop Kit 5111095 Plume Displacement Kit 5117383 Baxi Heating UK Limited 2005 7 Baxi Heating UK Limited 2005 3 0 Appliance Operation NOTE All delay timers mentioned in 3 1 and 3 2 are overridden by domestic hot water demand Central Heating Mode With a demand for heating the pump circulates water through the primary circuit At a flow rate of approximately 4 5 l min the central heating flow switch operates initiating the ignition sequence 2 The main burner ignites at a low rate then the fan gas valve and proportionator control the gas rate to maintain the heating temperature measured by the thermistor sensor 3 When the flow temperature exceeds the set temperature a minute pump overru
60. mp 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 LEE 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 LS 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 1 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 Flues 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 In IE the following Codes of Practice apply Standard Scope LS 813 Domestic Gas Installations The following BS standards give valuable additional information BS 5546
61. n occurs followed by 3 minutes anticycle If the flow temperature is low enough the burner will then relight automatically otherwise pump overrun and anticycle will occur again 4 When the demand is satisfied the burner is extinguished and the pump continues to run for a period of minute Pump Overrun Domestic Hot Water Mode Priority is given to the domestic hot water supply A demand at a tap or shower will override any central heating requirement 2 The flow of water will operate the DHW flow switch and the 3 way valve will change position This will allow the pump to circulate the primary water through the DHW plate heat exchanger 3 The burner will light automatically and the temperature of the domestic hot water is controlled by the return thermistor 4 When the domestic hot water demand ceases the burner will extinguish and the diverter valve will remain in the domestic hot water mode unless there is a demand for central heating Boiler Frost Protection The boiler incorporates an integral frost protection feature It will operate in both summer and winter modes If the boiler temperature falls below 8 C 5 then the boiler will fire until a temperature of 15 C 5 is reached Pump Protection The control system continually monitors the time since the pump last operated This will result in the pump being run for minute if it has not run in the last 24 hours to prevent seizure
62. nd Building Regulations In IE reference should be made to the current edition of l S 813 Domestic Gas Installations and the current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing Ventilation of Compartments Where the appliance is installed in a cupboard or compartment no air vents are required The appliance will run sufficiently cool without extra ventilation Minimum Cupboard Size inside dimensions Height 1250mm Width 590mm Depth 400mm 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 BS 5440 Part 2 Clause 4 2 refers to room sealed appliances installed in compartments 7 0 Site Requirements LE Pomi gt lt amiin Clearances Fig 6 amp 7 A A flat vertical area is required for the installation of the boiler N 200mm 2 These dimensions include the necessary clearances y around the boiler for case removal spanner access and air movement Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler Gas Supply The gas installation should be in accordance with the relevant standa
63. ng Depth 320mm Clearances Both Sides 5mm Min Above Casing 200mm Min Below Casing 200mm Min Front 500mm Min For Servicing Front 5mm Min In Operation Weights kg Ib Packaged Boiler Carton 58 2 128 3 Packaged Flue Kit 3 8 8 4 Weight Empty 332 117 3 nstallation Lift Weight 44 4 98 Central Heating Primary Circuit Pressures bar Ib in Safety Discharge 3 435 Max Operating 2 5 36 3 Min Operating 0 7 10 2 Recommend Operating 1 2 14 5 29 Recommended System Temperature Drop Condensing 20 C DHW Circuit bar Ib in Pressures Max Operating 10 145 Min Operating 0 1 1 45 Min Operating Pressure at 10 l min 0 39 232 Flow Rates min gal min DHW Flow Rate 30 CRise 1 7 2 57 DHW Flow Rate 35 CRise 10 2 20 Min Working DHW Flow Rate 1 9 0 43 Pump Available Head See graph below Expansion Vessel For Central Heating only Integral with appliance bar Ib in in Pre charge Pressure 0 95 13 8 ominal Pre charge Pressure 14 5 litre gal ax Capacity of CH System 125 27 5 Primary Water Content of Boiler unpressurised 3 5 6 2 DHW Expansion Vessel See Section 6 6 for information Temperatures CH Flow Temp adjustable 55 C to 82 C max 0 5 C D H W Flow Temp adjustable 45 C to 55 C max 0 5 C dependent upon flow rate NO Class 5 CO CO Ratio 0 002 Electrical Protection IPX2 Pump Available Hea STe ss aaa A ne ES OA
64. ntrol 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 Complete the Benchmark Checklist LABC will record the data and will issue a certificate of compliance IMPORTANT Installation Commissioning Service amp Repair This appliance must be installed in accordance with the manufacturer s instructions and he regulations in force Read the instructions fully before installing or using the appliance n GB this must be carried out by a competent person as stated in the Gas Safety Installation amp Use Regulations Definition of competence A person who works for a CORGI registered company and holding current certificates in the relevant ACS modules is deemed competent n IE this must be carried out by a competent person as stated in I S 813 Domestic Gas Installations Lifting This product should be lifted and handled by two people For recommended hand holds see section 8 4 Stooping should be avoided and protective equipment worn where necessary Carrying amp lifting equipment should be used as required e g when installing in a loft space 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
65. o severe abrasion In these instances a suitable dust mask and goggles should be worn e Always thoroughly wash hands after installation servicing or changing components e When disposing of any items manufactured from man made mineral fibre care must be exercised e If any irritation of the eyes or severe irritation of the skin is experienced seek medical attention NOTE All Illustrations show the Combi 133 HE Plus unless otherwise stated The PCB Connection Cover is removed for clarity 2 0 General Layout Layout l i p Wallplate 2 Flue Elbow 3 Air Box 3 4 Heat Exchanger f 5 Burner 6 Fan Protection Thermostat Fan Assembly 8 DHW Plate Heat Exchanger Le IN f i 19 9 Three Way Valve cy BR Nee eN 0 Facia Box S s s 0 18 Q A Q Kaa L Water Pressure Gauge Go l nee 5 v K Fe Gas Tap ee K i cn 3 Circulation Pump 4 Pressure Relief Valve 16 5 Return Thermistor 6 fi 6 Gas Air Ratio Valve T EE OOR ype 15 E PCB 8 Flow Temperature Safety Thermostat oa 9 Flow Temperature Thermistor 8 teuin 20 Manual Air Vent 2 Automatic Air Vent par 22 Flow Switch Dry Fire Protection 4 23 Condensate Trap 17 N 24 Expansion Vessel lo 8 g Expansion Vessel QS k re
66. of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation These details will be required in the event of any warranty work The publication must be handed to the User for safe keeping and each subsequent regular service visit recorded 9 For IE it is necessary to complete a Declaration of Conformity to indicate compliance to I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 35 Flue Elbow Air Box Door Panel YEA OA alll se all gt Fig 40 Lead Terminals Combustion Box D 4 a SS Door Securing R Ca Screw Ih ii f D Uii F gt dut If Combustion Box Door Panel Fig 41 36 Baxi Heating UK Limited 2005 12 0 Servicing the Boiler Annual Servicing IMPORTANT When servicing ensure that both the gas and electrical supplies to the boiler are isolated before any work is started The boiler cannot be switched off at the boiler therefore it is important to isolate the electrical supply at the mains fuse Hazardous materials are not used in the construction of Baxi products however reasonable care during
67. oiler HORIZONTAL FLUE The standard flue is suitable for lengths 270mm minimum to 800mm maximum measured from the edge of the flue elbow outlet Rear Flue maximum wall thickness 614mm Side Flue maximum wall thickness Right Hand 462mm Left Hand 537mm when installed with minimum side clearances o 5mm 2 For rear exit measure the wall thickness Fig 21 and to this dimension add 201mm This dimension to be known as X ie X wall thickness 201mm 3 Take the flue and mark off X from the terminal end as indicated in the diagram Fig 22 Check your dimensions The flue tubes are fixed together Cut through both tubes whilst resting the flue on the semi circular packing pieces Deburr both tube ends 4 For left hand exit measure the distance from the edge of the support bracket to the inner face of the wall Fig 21 and to this dimension add the wall thickness 268mm This dimension to be known as Y ie Y support bracket to wall wall thickness 268mm 5 Take the flue and mark off Y from the terminal end as indicated Fig 22 6 For right hand exit measure the distance from the edge of the support bracket to the inner face of the wall and to this dimension add the wall thickness 343mm This dimension to be known as Z ie Z support bracket to wall wall thickness 343mm 7 Take the flue and mark off Z from the terminal end as indicated Fig 22 Check you
68. ommissioning Checklist Building Regulations England amp Wales require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department From 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 January 2006 CORGI operate 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 comple
69. ons are clean and tight WARNING If the resistance is still greater than lohm the fault still exists and it could be dangerous to work with the appliance live 2 Short Circuit Check Isolate the control system set all switches and thermostats to calling for heat Set the meter on ohm s scale Test from L to N on control system terminal block if the resistance reads zero there is a short circuit 3 Resistance to Earth Check Isolate the control system set all switches and thermostats to calling for heat Set the meter on ohm s scale Test between L and E the resistance should be greater than mega ohm 4 Polarity Check If all the tests you have carried out so far are OK then reconnect the system to the mains supply Set the meter on Volts AC scale starting at the highest voltage Test at terminals L and N meter should read approx 240 Vac L and E meter should read approx 240 Vac N and E meter should read from 0 to 15 Vac 5 Fuse Check Remove the fuse check fuse on ohm s scale there should be no resistance infinity or maximum reading If no reading is obtained change the fuse Check fuse is 3A 9 0 Electrical Et Schematic Wiring Diagram Earths not shown to aid clarity of diagram Mains Input P External Controls LN Connection r Filter D00000 00000000 EEE Overheat Thermostat W Flame Return Flow Detection Spark 325Vd Thermistor Thermistor Electrode Flectrode DHW F Flow F
70. ontinuity at E Replace PCB NO Disconnect primary flow switch inline connector with a tap open is there continuity across flow switch YES Wires from inline connector to PCB faulty NO Remove flow switch from boiler Is there a physical blockage to the paddle within the flow switch Is I TA M o TION D there a blockage in NO the system NO Replace flow switch 52 Baxi Heating UK Limited 2005 Ignition Lockout Is there gas at gas valve inlet YES Reset lockout Is there gas flow check at the meter YES Is there at least 8mbar dynamic at gas valve inlet YES Is condensate trap blocked or water on terminals NO Is spark or flame detection probe damaged NO Is spark gap between 3 and 4mm YES wiring from PCB to spark probe amp flame detection probe OK NO Rectify wiring Baxi Heating UK Limited 2005 LED sC On Lights s CO of Check isolation valve and gas supply NO NO YES YES NO YES Remove gas valve amp check inlet filter for blockage Otherwise incorrect gas supply to boiler Clear blockage amp dry Sensors Replace spark or flame detection probe Set spark gap to 3 5mm Is the burner blocked or damaged YES Clean burner or replace as Necessary
71. ots are at the top to fit into the recesses on the manifold and reassemble in reverse order Wiring Harness Fits Here JT Gasket Wiring Harness Fits Here Three Way Diverter Valve Baxi Heating UK Limited 2005 41 13 0 Changing Components EAP Pressure Gauge Fig 57 Pressure Gauge Bracket Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Undo the nut retaining the capillary in the connection at the return pipe Fig 58 3 Depress the two lugs on either side of the pressure gauge and feed through the bracket 4 Fit new pressure gauge and reassemble in reverse order EMM Pressure Relief Valve Fig 59 The pressure relief valve is positioned on the Fig 57 hydraulic manifold at the back of the pump 2 Drain the boiler see Section 13 1 paragraph 2 amp 3 Capillary A 3 Disconnect the union between the valve and the A RSS x discharge pipe LS 4 Slacken the screw retaining the valve T Return Pipe 5 Pull the valve upwards to disengage it Fig 58 6 Fit the new pressure relief valve and reassemble in reverse order Pressure Relief Valve Fig 59 Expansion Vessel removed for clarity 42 Baxi Heating UK Limited 2005 13 0 Changing Components EAE DHW Plate Heat Exchanger Drain the boiler see Section 13 1 paragraph 2 am
72. p 3 2 Remove the four screws securing the plate heat exchanger to the manifolds Fig 60 NOTE Ensure nuts are not dislodged from the manifolds 3 Remove the plate heat exchanger cover Fig 61 4 Remove the O rings from the manifolds and replace with new O rings Fig 61 5 Taking care not to displace the O rings fit the new plate heat exchanger ensuring the nuts are retained in the manifolds 6 Refit the plate heat exchanger cover EARE DHW Flow Switch Fig 62 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Remove the DHW plate heat exchanger see section 3 14 3 Disconnect the inline electrical connection Fig 60 Plate Heat Exchanger Securing Screws 4 Remove the clip at right hand side of the flow switch 5 Undo the DHW inlet connection 6 Remove the flow switch assembly and undo the second clip 7 Fit the new flow switch and reassemble in reverse order O Rings 8 Ensure that both clips are fully inserted from the Plate Heat front Exchanger Cover Plate Heat Exchanger 9 Fit the DHW plate heat exchanger Fig 61 Flow Switch Inline Electrical Connection DHW Inlet Connection Fig 62 Baxi Heating UK Limited 2005 43 13 0 Changing Components ERIM PCB Fig 63 WARNING The PCB Control and Fan Assembly is 325 Vdc Isolate at s
73. r dimensions The flue tubes are fixed together Cut through both tubes whilst resting the flue on the semi circular packing pieces Deburr both tube ends IMPORTANT Check all measurements before cutting When cutting ensure the cut does not interfere with the inner flue support bracket Fig 23 25 Inner Flue Support Bracket Flue Flue Elbow Gasket 26 Baxi Heating UK Limited 2005 Flue Trim Fig 26 8 0 Installation 8 6 Fitting the Flue Cont 8 Ensure the inner flue support bracket is positioned in the flue Fig 24 9 Engage the flue into the flue elbow using soap solution to ease the engagement ensuring the flue is assembled as shown Fig 25 0 Place the gasket over the flue exit on the boiler Fig 25 Slide the flue assembly through the hole in the wall Ensure angled inner end slopes downwards Fig 26 2 Engage the elbow on to the flue connection on top of the boiler Secure with the four screws supplied in the kit 13 Make good between the wall and air duct outside the building ensuring the 3 drop between the terminal and elbow 14 The flue trim should be fitted once the installation is complete and the flue secure Fig 26 Apply a suitable mastic to the inside of the trim and press against the wall finish making sure the brickwork is dust free and dry 15 If necessary fit a terminal
74. rd and discharge outside the building preferably over a drain It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components The end of the pipe should terminate facing down and towards the wall 3 The discharge must not be above a window entrance or other public access Consideration must be given to the possibility that boiling water steam could discharge from the pipe Other Tap Outlets NZ Pressure Reducer Expansion Vessel Taps 4 3 2 oe di H Key 2 3 4 5 6 7 8 9 Baxi Heating UK Limited 2005 Expansion Vessel Flow Thermostat Flow Thermistor Flow Switch Primary Heat Exchanger Gas Valve DHW Plate Heat Exchanger DHW Flow DHW Mains Inlet 0 Fl l ow Regulator DHW Flow Switch Gas Inlet C Pum Filling Loop CH Flow Valve Filter Return Valve Pressure Gauge P Pressure Relief Valve Return Thermistor 3 Way Valve 6 0 System Details 66 Domestic Hot Water Circuit All DHW circuits connections fittings etc should be fully in accordance with relevant standards and water supply regulations 2 When installed in accordance with above this appliance does not require a check valve to meet water supply regulations However when the system includes any device which prevents water expanding back towards th
75. rds In GB this is BS 6891 In IE this is the current edition of l S 813 Domestic Gas Installations Cann 2 The connection to the appliance is a 2 BSPF 3 Ensure that the pipework from the meter to the 850mm appliance is of adequate size Do not use pipes of a smaller l diameter than 22mm up to the boiler connection 200mm Electrical Supply ae 2z ee External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current LEE Wiring Regulations In IE reference should be made to the current edition of ETCI rules NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection must be via a fused double pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only 3 I in 20 WARNING The PCB Control and Fan Assembly is 325 Vdc Isolate at supply before access For Servicing Purposes ag 320mm gt 5mm In Operation Fig 7 Baxi Heating UK Limited 2005 17 Termination to an internal soil and 7 0 Site Requirements vent pipe Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER Boiler The condensate discharge pipe MUST NOT RISE at any point along its length There MUST be a fall of AT LE
76. securing screws from inside the air box holding the gas valve 6 Remove the gas valve and inlet pipe from the airbox side 7 Remove the four screws securing the gas inlet pipe to the valve and refit to the new valve 8 Remove the aluminium spacer and its gasket and O ring from the gas valve 9 Fit the aluminium spacer O ring and its gasket to the new valve 10 Fit the new gas valve and reassemble in reverse order Test for gas soundness NOTE It is essential that you ensure gas soundness as they are under negative pressure EPEE Condensate Trap Fig 68 Disconnect the condensate trap from the base of the heat exchanger 2 Disconnect the condensate drain outside the boiler from the condensate trap 3 Undo the condensate trap lock nut 4 Remove the condensate trap from the boiler 5 Disconnect the sensor leads Fit the new condensate trap and reassemble in reverse order 100 amp 80 HE Burner SF Burner Securing Screws Fig 69 Flow Switch es Fig 71 i Heat Exchanger Assembly li ie es ol SA A la EO CEI CSC KE SS if K M Fig 72 Baxi Heating UK Limited 2005 Return Connection Fig 70 Heat Exchanger Manifold 13 0 Changing Components The burner and heat exchanger can be changed after
77. ted 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 recommended 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 Limited 2005 Baxi supports _ hamnehiN Chenchmark Baxi is a BS EN ISO 9001 Accredited Company The code of practice for the installation commissioning amp servicing of central heating systems 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 CORGI Scheme CORGI will then notify the relevant Local Authority Building Control Scheme on member s behalf Scheme Members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist CORGI will record the data and will send a certificate of compliance to the property Baxi Heating UK Limited 2005 Building Co
78. uity With water flowing out of a fully open DHW tap does the DHW LED light NO NO YES YES Replace PCB Unplug diverter valve With DHW LED on is there 240V from YtoZ Unplug 7 way PCB connector With DHW LED on is there 240V from NO YES Wiring from PCB to Diverter Valve faulty Unplug 7 way PCB connector With DHW LED on is there 240V from YES Is there 240V from AtoZ NO YES Diverter Valve faulty PCB faulty Baxi Heating UK Limited 2005 NO 15 0 Unplug DHW F S inline connector With water flowing out of a fully open tap is there continuity across DHW flow switch NO Wiring from PCB to Flow Switch faulty Replace PCB Wiring from PCB to Diverter Valve faulty J 0w MA COTTON oO ONE Fault Finding Replace DHW Flow Switch YES Is DHW flow switch blocked YES Unblock DHW Flow Switch Diverter Valve Plug when unplugged A m 00 00g Zz y 57 15 0 Fault Finding CH Fault NO Wiring in 8 way terminal block from L to Prog faulty Is there 240V at D YES Link Plug NO Check integral timer and Is there 240V at E wiring Check Link Plug if no timer fitted YES NO Is there 240V at F Check external controls wiring Cc YES NO Is there 240V at G Check room stat amp room stat wiring OK YES
79. upply before access Pull the control knobs off their spindles and remove the plastic button covers Refit them onto the new PCB Fig 63a 2 Release the facia securing screws turn and hinge down the facia box 3 Remove the screws securing the PCB connection cover 4 Remove the screws securing the PCB and disconnect the electrical connections noting their positions although they are one way fitting NOTE Check the PCB for the presence of input jumpers see section 10 2 amp 10 3 Set the new PCB as the original 5 Fit the new PCB and reassemble in reverse order Facia Box Facia Securing Screws l Plastic Button Covers PCB Connection Cover ES a Control Knob 44 Baxi Heating UK Limited 2005 Air Box Door Panel Fig 64 Sensing Combustion Box Door Fig 65 Injector Pipe Injector Pipe Retaining Screw 100 amp 80 HE models Fan Protection Venturi Thermostat Black Body Protection Thermostat Leads Wing Nut aaa A Electrical Supply Fig 66 Baxi Heating UK Limited 2005 13 0 Changing Components The fan and venturi gas valve injector pipe condensate trap fan protection thermostat spark and sensing electrode can be accessed and changed on the removal of the airbox door panel

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