baxi 50 HE Plus, 80 HE Plus, 100/2 HE Plus User guide

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Page 1

Installation & Servicing Instructions

Baxi 50 HE Plus Baxi 80 HE Plus

Baxi 100/2 HE Plus

Wall Mounted Powered Flue Condensing Boilers

Gas Fired Central Heating Units

These instructions include the Benchmark Commissioning Checklist and

should be left with the User for safe keeping

Page 2

Natural Gas

Baxi 50 HE Plus

G.C.No41 077 41

Baxi 80 HE Plus

G.C.No41 077 42

Baxi 100/2 HE Plus

G.C.No41 075 34

Building Regulations and the Benchmark Commissioning Checklist

Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 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 1 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With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn.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.

© Baxi Heating UK Ltd 2006 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 Ltd, 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 require that installations should comply with manufacturer's instructions. It is therefore important that the commissioning checklist is completed 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.

“Baxi” supports

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.

BS-EN ISO 9001 Accredited Company

The code of practice for the installation,

commissioning & servicing of central

heating systems.

Baxi Heating UK Ltd is a

Page 3

Choose Building

Regulations Notification

Route

Installer Notification Guidelines

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

Building Control

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

Scheme Members only

Call CORGI on: 0870 88 88 777

www.corgi-notify.com

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

Complete the

Benchmark Checklist

or log onto:

within 10 days

LABC will record the data

and will issue a

certificate of compliance

Page 4

Legislation

IMPORTANT - Installation, Commissioning, Service & Repair

This appliance must be installed in accordance with the manufacturer’s instructions and the regulations in force. Read the instructions fully before installing or using the appliance.

In GB, this must be carried out by a competent person as stated in the Gas Safety (Installation & Use) Regulations.

Definition of competence: A person who works for a CORGI registered company and holding current certificates in the relevant ACS modules, is deemed competent.

In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic Gas Installations”.

NOTE: 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 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.

This company 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 & 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 I.E.E. 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 I.S. 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 6.2).

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:-

1 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: Notified Body 0087.

Product/Production certified by: Notified Body 0086.

For GB/IE only.

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 1 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

I.S. 813 Domestic Gas Installations. The following BS standards give valuable additional information; BS 5546 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 7593 Treatment of water in domestic hot water

central heating systems.

Page 5

Safe Manual Handling

General

The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.

Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health & Safety is the responsibility of EVERYONE.

There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.

Do not handle or lift unless you feel physically able.

Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.

Preparation

Co-ordinate movements - know where, and when, you are both going.

Minimise the number of times needed to move the boiler - plan ahead.

Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care on ladders/into lofts.

Technique

When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible.

Where possible transport the boiler using a sack truck or other suitable trolley.

Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the ‘Installation’ section of these instructions for recommended lift points.

Remember

The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.

If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT ‘work through’ the pain - you may cause further injury.

IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

Page 6

Contents

Section Page

1.0 Introduction 7

2.0 General Layout 8

3.0 Appliance Operation 9

4.0 Technical Data 10

5.0 Dimensions and Fixings 11

6.0 System Details 12

7.0 Site Requirements 16

8.0 Installation 23

9.0 Electrical 29

10.0 Commissioning the Boiler 31

11.0 Fitting the Outer Case 32

12.0 Servicing the Boiler 33

13.0 Changing Components 35

14.0 Short Parts List 42

15.0 Fault Finding 43

Benchmark Checklist 50

Page 7

Fig. 1

Position of Label

1.0 Introduction

1.1 Description

1. The Baxi 50 HE Plus, 80 HE Plus and100/2 HE Plus are gas fired room sealed fan assisted condensing central heating boilers.

2. The maximum output of the Baxi 50 HE Plus is 52,000 Btu/hr. The maximum out put of the 80 HE Plus is 75,000 Btu/hr. The maximum output of the Baxi 100/2 HE Plus is preset at 75,000 Btu/hr but can be set to 100,000 Btu/hr (see section 8.8). All three boilers automatically adjust their outputs down to 30,000 Btu/hr according to the system load.

3. It is designed for use on Natural Gas (G20).

4. The boiler is suitable for fully pumped open vented central heating and domestic hot water systems and sealed systems.

Air Box Door

Fig. 2

Lower Door Panel

Data Badge

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 boiler is intended to be installed in residential / commercial / light industrial E.M.C. environments on a governed meter supply only.

8. The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit, part no 236921.

1.2 Important Information

Man-made mineral fibre

• Some component parts of this appliance (insulation pads, gaskets and rope seals) are manufactured from manmade mineral fibre.

• Prolonged or excessive exposure to this material may result in some irritation to the eyes, skin or respiratory tract.

• It is advisable to wear gloves when handling these items.

• Irritant dust will only be released from the items if they are broken up or subjected to severe abrasion. In these instances a suitable dust mask and goggles should be worn.

• Always thoroughly wash hands after installation, servicing or changing components.

• When disposing of any items manufactured from manmade mineral fibre care must be exercised.

• If any irritation of the eyes or severe irritation of the skin is experienced seek medical attention.

Page 8

2.0 General Layout

2.1 Layout (Figs. 3,4,5 & 6)

1. Wall Plate

2. Flue Elbow

3. Heat Exchanger

4. Burner

5. Air Box

6. Fan Protection Thermostat

Fig. 5

15 14

7. Fan Assembly

8. Condensate Trap

9. PCB Housing Assembly

10. Gas Tap

11. Gas / Air Ratio Valve

12. Flow Pipe Connection

13. Return Pipe Connection

14. Flow Temperature Safety Thermostat - Black

15. Flow Temperature Thermistor - Red

16. Flow Switch (dry fire protection)

2.2 Optional Extras

KIT PART N

FLUE EXTENSION KITS (110/70)

Flue Extension 0.25M 241692

Flue Extension 0.5M 241694

Flue Extension 1M

Flue Bend x 2 - 45°

Flue Bend - 90° (

Horizontal Extended Flue (1.75M) 5111457 Plume Displacement 5117383

(Use two kits for 2M etc.) 241695

(Reduce overall length of flue

by 0.5m when fitting this bend)

Reduce overall length of flue by 1m when fitting each bend)

VERTICAL FLUE (110/70)

Vertical Flue Terminal 242802

Vertical Flue Adaptor 5106888

Fig. 3

241689

241687

Fig. 4

Fig. 6

Page 9

Mains On.

3.0 Appliance Operation

Flow

temperature less

than set point ?

YES

10 second Pump On.

Flow switch made ?

YES

5 second

Fan Pre-Purge.

5 second

Ignition Period.

YES

Ignition done

and less than 5

attempts made ?

3.1

1. Switched Live On: When the switched live switches on if the flow temperature is less than the set point then pump overrun occurs. When the switched live switches on if the flow temperature is greater than the set point then pump overrun occurs.

2. Pump On: The pump is on while the fan, spark generator and gas valve are off. After 10 seconds if the flow switch has made then fan pre-purge occurs. After 10 seconds if the flow switch has not made then anticycle occurs.

3. Fan Pre-Purge: The pump and fan are on while the spark generator and gas valve are off. After 5 seconds ignition occurs.

4. Ignition: The 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 made then fan purge occurs. If a flame is not detected within 5 seconds and 5 ignition attempts have been made then ignition lockout occurs.

Flame Detected ?

shut or Flow temperature

greater than set point ?

Fan Post Purge.

YES

Burner On.

All TRVs

YES

5 second

All TRVs

shut down ?

Ignition done and 5 attempts made ?

YES

Ignition

Lockout.

5. Burner On: The pump, fan and gas valve are on while the spark generator is 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 the TRVs all shut down then fan post purge occurs.

6. Fan Post Purge: The pump and fan are on while the spark generator and gas valve are off. After 5 seconds if the TRVs are not shut down then pump overrun occurs. After 5 seconds if the TRVs are shut down then anti-cycle occurs.

7. Pump Overrun: The pump is on while the fan, spark generator and gas valve are off. After 1 minute anticycle occurs.

8. Anti-cycle: The pump, fan, spark generator and gas valve are off. After 3 minutes if the flow temperature is less than the set point then pump on occurs. After 3 minutes if the flow temperature is greater than the set point then pump overrun occurs.

9. Ignition Lockout: The pump, fan, spark generator and gas valve are off. The boiler can only be reset by manually using the reset button.

1 minute

Pump Overrun.

3 minute

Anti-cycle.

Page 10

4.0 Technical Data

Appliance Type C

Appliance Category CAT I

Heat Input (Q)(Gross) Max Min

50 HE Plus kW 16.88 10.2

Btu/hr 57,600 34,840

80 HE Plus kW 24.50 10.2

Btu/hr 83,600 34,840

100/2 HE Plus kW 33.76 10.2 (see note) Btu/hr 115,200 34,840

Heat Output (P)

(Non Condensing 70° C Mean Water Temp)

Max Min

50 HE Plus kW 15.24 9.14

Btu/hr 52,000 31,180

80 HE Plus kW 22.00 9.14

Btu/hr 75,000 31,180

100/2 HE Plus kW 30.18 9.14

Btu/hr 102,980 31,180

Heat Output (P)

(Condensing 40° C Mean Water Temp)

Max Min

50 HE Plus kW 16.49 10.1

Btu/hr 56,260 34,520

80 HE Plus kW 23.8 10.1

Btu/hr 81,200 34,520

100/2 HE Plus kW 32.61 10.1

Btu/hr 113,280 34,520

Max Gas Rate (2H - G20 - 20mbar) (After 10 Mins)

Btu/hr 52,000 75,000 102,980

m3/hr 1.64 2.31 2.95

ft3/hr 52.1 83.3 104.2

Injector (Natural Gas)

6.5mm Diameter

CO/CO2 Ratio Up to a maximum

of 0.004

CO2 Level 9% ± 1%

Nox Class 5

Horizontal Flue Terminal Diameter 110mm Dimensions Projection 150mm

Connections

Gas Supply Central Heating Flow - 22mm Central Heating Return - 22mm Condensate Drain - 1 in BSP

Outercase Dimensions

Overall Height Casing Height - 600mm Casing Width - 390mm Casing Depth - 320mm

Clearances

(For unventilated compartments see Section 7.2)

Both Sides 5mm Min Above Casing 200mm Min Below Casing 50mm Min Front (For Servicing) 500mm Min Front (In Operation) 5mm Min

Weights kg Packaged Boiler Carton 36.2 Packaged Flue Kit 3.6 Installation Lift Weight 26.0

Recommended System Temperature Drop

Condensing 20°C 36°F

Inc Flue Elbow - 750mm

/2in BSPT

Electrical Supply 230V~ 50Hz

(Appliance must be connected to an

earthed supply)

Power Consumption 80W

External Fuse Rating 3A

Internal Fuse Rating (BS 4265)

Fuse 3.15 AT (PCB)

Electrical Protection IPX2

Water Content

litres 2.6

pints 4.6

Static Head

max 30 metres (100 ft)

min 1 metre (3.25 ft)

Low Head 0.2m (8 in) min

System Detail

fully pumped open vented & sealed systems

Gas Connection

Controls

boiler thermostat, safety thermostat, flow switch, electronic flame sensing, temperature protection thermostat & condensate blockage sensor

Inlet Pressure at Gas Valve (Natural Gas)

Min 18.1 mbar

Max 22.5 mbar

Flow Temperature (adjustable)

55° C to 78° C (± 5° C)

/2” B.S.P. Thread

(see Section 10.1)

NOTE: The maximum output of the 100/2 HE Plus is factory set at 22.0kW (75,000 Btu/hr). This can be altered to

30.18kW (102,980 Btu/hr)

- see section 8.8.

SEDBUK Declaration

For 50 HE Plus - The efficiency is 91.3% For 80 HE Plus - The efficiency is 90.9% For 100/2 HE Plus - The efficiency is 90.9%

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 0087.

Hydraulic Resistance Chart

220 200 180 160 140 120 100

80 60

Pressure Drop (mbar)

40 20

0 10 20 30 40

Water Flow Rate (litres/min)

91 83 75 66 58 50 42 33 25 17 8

Pressure Drop (in wg)

Page 11

5.0 Dimensions and Fixings

DIMENSIONS

3°

(1 in 20)

A 600mm

B 320mm

C 390mm

D 125mm Ø Min.

E 150mm

F 125mm

360° Orientation

The 3° (1 in 20) fall provided by the elbow is to allow condensate to run back to the boiler, for disposal

Tube Ø 110mm

through the condensate discharge pipe.

Fig. 7

Fig. 8

SIDE FLUE (left and right)

3°

(1 in 20)

For every 1m of horizontal flue length, the clearance above the top of the flue elbow should be 55mm to incorporate the 3° (1 in 20) fall in the flue from the terminal to the elbow.

Flue length (Y)

up to 1m

1m - 2m

2m - 3m

Clearance (X)

55mm

110mm

165mm

Page 12

6.0 System Details

6.1 Water Circulating Systems

1. The appliance is suitable for use with open vent fully pumped systems and sealed systems .

The following conditions should be observed on all systems:

• The static head must not exceed 30m (100ft) of water.

• The boiler must not be used with a direct cylinder.

• Drain cocks should be fitted to all system low points.

• All gas and water pipes and electrical wiring must be installed in a way which would not restrict the servicing of the boiler.

• Position isolating valves as close to circulating pump as possible.

• It is recommended that the return pipe is fitted with an automatic air vent as close to the boiler as is practical.

6.2 Treatment of Water Circulating

Systems

• 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.

• When fitting new systems flux will be evident within the system, which can lead to damage of system components.

• All systems must be thoroughly drained and flushed out. Using, for example Betz-Dearborn Sentinel X300 or X400 or Fernox Superfloc Universal Cleanser. They should be used following the flushing agent manufacturer’s instructions.

• System additives - corrosion inhibitors and flushing agents/descalers should be suitable for aluminium and 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.

• It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the manufacturer’s instructions. (Test kits are available from inhibitor stockists.)

• For information or advice regarding any of the above contact Technical Enquiries.

Page 13

Fig. 9

Boiler

Copper

0.5m

Copper

0.5m

Flow

Return

6.0 System Details

6.3 Pipework

1. The sizes of flow and return pipes from the boiler should be determined by normal methods, according to the requirements of the system. The connections to the boiler will accept 22mm pipe.

Fig. 10

Automatic Air

Boiler

500mm

45°

1000mm

Min

150mm

Max

Boiler

Return

Typical Low Head Installation

500mm

45°

Vent

1000mm

Min

15mm Cold Feed

150mm

Max

22mm Open Vent

400mm

Min Head

Pump

22mm Open Vent

400mm

Min Head

Return

Pump

Flow

2. A 20 °C (36°F) drop in temperature across the system is recommended for condensing boilers. Existing radiators may be oversized and so allow this, but where radiator sizing is marginal it may be advisable to retain a system temperature drop of 11°C (20°F).

NOTE: On 100/2 HE Plus models 28mm pipe should be used to connect to the boiler flow and return.

3. In systems using non-metallic pipework it is necessary to use copper pipe for the boiler Flow and Return. The copper must extend at least 1 metre from the boiler and include any branches (Fig. 9).

6.4 Low Head Installation

1. Using a close couple arrangement the minimum head is as shown in the diagrams (Figs. 10 & 11) subject to the following conditions:

a) The pump being adjusted to give a 20°C drop across

the boiler. b) The pump must be fitted on the flow. c) The pump must be fitted in accordance with the

pump manufacturer's instructions. d) The open vent pipe must be taken up from a tee in a

horizontal section of the flow pipe.

An alternative Low Head Installation (Fig. 12)

2. For heads below 400mm then a combined vent and feed pipe may be connected. This must be a minimum of 22mm diameter. It is recommended that an air separator is fitted when using a combined feed and vent pipe.

Fig. 11

Fig. 12

If Conditions Require,

This System Possible

200mm

Min

Boiler

22mm Feed & Vent Pipe

Air

Separator

Pump

Return

Alternative Low Head Installation

6.5 Thermal Stores

1. When the boiler is fitted in conjunction with a thermal store, both jumpers must be removed from the PCB, see Fig. 32 Section 8.8.

Flow

Page 14

230V 50Hz

L NE

g/y

Room

Stat

Cylinder

Stat

Y Plan

Diverter

Valve

Boiler

L N P/FE

Timer

L N

CH on HW on HW off

Pump

LNE

Y Plan, Room Thermostat System, CH Interlocked By Room Thermostat

At least the Radiator(s) near the Room Thermostat not TRV’d Pump run from Switched Live By-pass permitted but not required for Part L1 compliance

230V 50Hz

L NE

Motor

S Plan

Valve

g/y

Room

Stat

Cylinder

Stat

Motor

S Plan

g/y

Valve

Boiler

L N P/FE

Timer

L N

CH on

HW on

Pump

LNE

Key to colours

b - Blue br - Brown w - White o - Orange gr - Grey g/y - Green/Yellow

6.0 System Details

6.6 System Controls

This boiler does not require a bypass. This boiler does not require a permanent live. The pump only needs wiring directly to the boiler for fully TRV’d systems.

1. To comply with Part L1 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

2. 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.

3. 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 switch is integral to this boiler) should also be provided to switch off the boiler when there is no demand for heating or hot water.

4. The interlock for the CH circuit can be provided by either a Room Thermostat or a fully TRV’d system with the pump wired back to the boiler without a bypass. Connection diagrams for both options for Y and S plan systems are shown.

S Plan, Room Thermostat System, CH Interlocked By Room Thermostat

At least the Radiator(s) near the Room Thermostat not TRV’d Pump run from Switched Live By-pass permitted but not required for Part L1 compliance

230V 50Hz

L NE

g/y

Cylinder

Stat

Y Plan

Diverter

Valve

Boiler

L N P/FE

Timer

L N

CH on

HW on

HW off

Pump

LNE

Y Plan, Fully TRV’d System, CH Interlocked By Boiler Flow Switch

Room Thermostat should not be fitted Pump must be run from Boiler P/F connection for Part L1 compliance By-pass not permitted (must be valved) for Part L1 compliance

230V 50Hz

L NE

Motor

S Plan

Valve

g/y

Cylinder

Motor

S Plan

g/y

Valve

Stat

Boiler

L N P/FE

Timer

L N

CH on

HW on

Pump

LNE

S Plan, Fully TRV’d System, CH Interlocked By Boiler Flow Switch

Room Thermostat should not be fitted Pump must be run from Boiler P/F connection for Part L1 compliance By-pass not permitted (must be valved) for Part L1 compliance

Page 15

Table. 1

Safety

Valve

Fig. 13

Air

Vent

Pressure

Gauge

Boiler

System Drains at Low Point

Filling Point

Pump

Expansion Vessel

Max Boiler Flow

Temp = 82° C

Method of determining minimum valve of

expansion vessel volume for sealed systems

using Baxi Boilers

Vessel Charge Pressure (Bar)

Initial System

Pressure (Bar)

0.5

1.0

1.5

2.0

1.0

1.5

2.0

1.5

Example :-

System Volume = 75 litres

1.5

2.0

Vessel Charge Pressure = 1.0 bar Initial System Pressure = 1.5 bar

Then :-

75 x 0.152 = 11.4 litres Expansion Vessel Volume

NOTE

Where a vessel of the calculated size is not obtainable then

the next available larger size should be used.

3 Litre Top Up Bottle (if required)

Radiator Circuit

Multiply Total

Water Content Of

System By (Litres)

0.067

0.112

0.207

0.441

0.087

0.152

0.330

0.125

0.265

6.0 System Details

6.7 Sealed Systems (Fig. 13)

1. SAFETY VALVE - A safety valve complying with the requirements of BS 6750 Part 1 must be fitted close to the boiler on the flow pipe by means of a horizontal or vertically upward connection with no intervening valve or restrictions and should be positioned to facilitate testing. The valve should be pre-set and non-adjustable to operate at a pressure of 3 bar (45 Ibf/in arranged to discharge any water or steam through a pipe to a safe outlet position.

2. PRESSURE GAUGE - A pressure gauge of minimum range 0-4 bar (0-60 Ibf/in

) with a fill pressure indicator must be fitted to the system, preferably at the same point as the expansion vessel in an easily visible position.

3. EXPANSION VESSEL - An expansion vessel complying with the requirements of BS 4814 must be fitted to the system by means of a connection close to the inlet side of the circulating pump in accordance with the manufacturers instructions, the connecting pipe being unrestricted and not less than 15mm ( The volume of the vessel should be suitable for the system water content and the nitrogen or air charge pressure should not be less than the system static head (See Table. 1).

Further details of sealed system design can be obtained from BS 5449 and the British Gas publication entitled 'Specifications for Domestic Wet Central Heating Systems'.

4. FILLING POINT - 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. The sealed primary circuits may be filled or replenished by means of a temporary connection between the primary 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. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment. 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 I.S. 813 “Domestic Gas Installations”.

5. MAKE UP SYSTEM - A method of replacing water lost from the system should be provided either by means of a make up vessel of not more than 3 litres (5 pints) capacity, mounted above the highest point of the system, or by re-pressurisation of the system.

). It must be

/2in) nominal size.

Fig. 14

Stop Valve

DHW Mains Inlet

Double Check Valve

Temporary Hose

Stop Valve

6. VENTING - A method of venting the system during filling and commissioning must be provided by fitting automatic air vents or by venting manually.

7. HOT WATER STORAGE - The hot water storage vessel must be of the indirect coil type. All components used in the system must be suitable for operation at 110°C (230°F) and at the pressure allowed by the safety valve.

CH Return

Page 16

Fig. A

Zone 2

Zone 1

Zone 0

Window Recess

Zone 2

In GB Only

Window Recess

Zone 2

0.6 m

Zone 3

2.4 m

7.0 Site Requirements

7.1 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.

1. The boiler may be fitted to any suitable 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. If 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, it can only be fitted in zone 3, (Figs. A & B shows zone dimensions for a bathtub. For other examples refer to Section 601 of the Current I.E.E. Wiring Regulations) reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules.

3.0 m

Zone 2

Zone 1

Zone 0

Fig. B

Zone 3

Zone 2

0.6 m

Window Recess Zone 2

In GB Only

Outside Zones

Zone 3

2.4 m

2.25 m

Ceiling

Outside Zones

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).

7.2 Ventilation of Compartments

1. Where the boiler is installed in a cupboard or compartment, no air vents are required for cooling purposes providing that the minimum dimensions below are maintained.

Sides 15mm Top 200mm Bottom 50mm Front 30mm

2. If the boiler is installed in a smaller cupboard or compartment it must be ventilated according to BS 5440 Part 2 and the minimum clearances given in section 4.0 “Technical Data” maintained.

3. Any compartment should be large enough to house the boiler only.

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.

Page 17

5mm Min

390mm

5mm Min

7.0 Site Requirements

Fig. 15

200mm

600mm

50mm

7.3 Clearances (Figs. 15 &16)

1. A flat vertical area is required for the installation of the boiler.

2. These dimensions include the necessary clearances 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.

3. For unventilated compartments see Section 7.2.

7.4 Gas Supply

1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891. In IE this is the current edition of I.S. 813 “Domestic Gas Installations”.

2. The connection to the appliance is a

/2in BSPF (Fig. 6).

3. Ensure that the pipework from the meter to the appliance is of adequate size to ensure correct operation.

Do not use pipes of a smaller diameter than the boiler gas connection.

Fig. 16

500mm

For Servicing

Purposes

5mm

In Operation

320mm

3°

(1 in 20)

7.5 Electrical Supply

1. External wiring must be correctly earthed, polarised and in accordance with relevant regulations/rules. In GB this is the current I.E.E. Wiring Regulations. In IE reference should be made to the current edition of ETCI rules.

2. The mains supply is 230V ~ 50Hz fused at 3A.

NOTE: “The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance”.

Note! There is no method of isolating the boiler, at the user interface.

Connection may 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.

WARNING: The PCB Control and Fan

Assembly are 325 Vdc. Isolate at supply

before access.

Page 18

Termination to an internal soil and

vent pipe

7.0 Site Requirements

Boiler

50mm per metre of pipe run

2.5° Minimum fall

Sink

450mm min

External termination via internal discharge

Boiler

50mm per metre of pipe run

2.5° Minimum fall

branch

e.g sink waste - downstream

Pipe must terminate above water level but below surrounding surface

7.6 Condensate Drain

FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER

The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST

2.5° (50mm per metre) along the entire run.

NOTE: It is unnecessary to fit an air break in the discharge pipe.

1. The condensate outlet terminates in a 1” BSP nut and seal for

the connection of 21.5mm (

/4in) 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.

2. Ensure the discharge of condensate complies with any national or local regulations in force.

BS 6798:2000 & Part H1 of the Building Regulations give further guidance.

3. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP.

4. Metal pipework is NOT suitable for use in condensate discharge systems.

Boiler

50mm per metre of pipe run

2.5° Minimum fall

Termination to a purpose made soak-

Termination to a drain or gully

Pipe must terminate above water level but below surrounding surface

away

500mm min

5. The pipe should be a minimum of 21.5mm diameter and must be supported using suitably spaced clips to prevent sagging.

6. It is advisable to keep the condensate pipe internal.

7. External runs greater than 3 metres or runs in cold areas

should use 32mm waste pipe.

8. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated 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 fluctuations when WC's are flushed or sinks emptied then back-pressure may force water out of the boiler trap and cause appliance lockout.

Examples are shown of the following methods of termination:i) to an internal soil & vent pipe ii) via an internal discharge branch (e.g. sink waste) iii) to a drain or gully iv) to a purpose made soakaway

50mm per metre of pipe run

2.5° Minimum fall

Holes in the soak-away must face away from the building

Page 19

7.0 Site Requirements

Table. 2

Terminal Position with Minimum Distance (Fig. 17) (mm)

AaDirectly below an opening, air brick, opening

windows, etc. 300 BaAbove an opening, air brick, opening window etc. 300 CaHorizontally 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 I Above ground, roof or balcony level. 300 J From a surface or boundary line facing a terminal. 600 K 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 M Vertically from a terminal on the same wall. 1500 N Horizontally from a terminal on the same wall. 300

R From adjacent wall to flue (vertical only). 300 S From an adjacent opening window (vertical only). 1000

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. 1.

(i)

or external

(ii)

corner.

(i)

(ii)

115

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 Assembly

300 min

7.7 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.

1. The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendations are given in BS 5440 Pt.1. For IE recommendations are given in the current edition of I.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.

Fig. 16a

Top View Rear Flue

Property Boundar y Line

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 (78

/4in) above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be provided.

IMPORTANT:

• Only ONE 25mm clearance is allowed per installation.

• Under car ports we recommend the use of the plume displacement kit.

• The terminal position must ensure the safe and nuisance - free dispersal of combustion products.

Fig. 17

Page 20

A - Standard Flue

7.0 Site Requirements

7.8 Flue options

Concentric The maximum equivalent lengths are 4m (horizontal) or

(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 150m. NOTE: Each 1m of flue duct should be calculated as 2m.

Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:

Concentric Pipes: 45° bend 0.5 m

93° bend 1.0 m

Plume Displacement 70/110 dia Kit 1M Extensions, 45° & 93° bends are also available - see literature supplied with the kit for details

Twin Flue Pipe: 45° bend (air duct) 1.3 m

45° bend (flue duct) 2.6 m 90° bend (air duct) 4.8 m 90° bend (flue duct) 9.6 m

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 Size Baxi Code

Number

Concentric Flue System 110mm diameter

A Horizontal flue kit 850mm 236921 B Straight extension kit 1000mm 241695

500mm 241694

250mm 241692 C Bend kit 93° 241687 D Bend kit (pair) 45° 241689 E Horizontal flue terminal 243013BAX

Clamp 110mm 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

J Twin flue adaptor kit 242757 K Vertical flue terminal 242802 L Universal roof tile 25°/50° 243015 M Roof cover plate kit 243131 N Flat roof flashing 243016BAX R Vertical flue adaptor 5106888

Clamp 80mm 238684

Q Plume Displacement Kit 5117383

Page 21

7.0 Site Requirements

50 & 80

70Ø Exhaust (metres)

Fig. 17a

7.9 Plume Displacement Kit

NOTE: Please read this section in conjunction with

the instructions supplied in the kit. The table opposite supplements information in the kit literature.

100/2

1. This kit is recommended for installations where the condensate plume emitted from the flue may cause a nuisance or affect the surroundings.

2. The flue consists of two main parts. The concentric part, most of which is fitted inside and the 70Ø part which is entirely outside the building.

3. Full fitting details are supplied with the kit. The table and illustration opposite show the maximum permissible lengths of each part of the flue (Fig 17a).

234

Concentric 70/110 Flue (metres)

4. The required length of one part of the flue affects the maximum permissible length of the other. For example, when fitting a 100/2 HE the table shows that if 14 metres of 70Ø are required outside, up to 2 metres of concentric flue can be used.

5. This is determined by finding the 14 metre mark on the left hand part of the graph, and tracing across to the sloping line marked ‘100/2 HE’. Then trace vertically down to the bottom part of the graph - this gives a concentric maximum of 2 metres.

6. Further worked examples are shown in the literature supplied with the kit.

70Ø Exhaust

Concentric 70/110 Flue (MUST be installed horizontally)

Fig. 17b

IMPORTANT: If fitting a Plume

Displacement Flue Kit, the air inlet must be a minimum of 100mm from any opening windows or doors (see Section 7.9).

Plume Displacement Kit

Air Inlet

Opening Window

or Door

100mm MIN.

Fig. 17c

Page 22

7.0 Site Requirements

7.10 Flue Dimensions

0.5m

Fig. 18

270mm 800mm

0.5m

See Section 2.2. The standard horizontal flue kit allows

for flue lengths between 270mm (10

/8”) and 800mm

(32”) from elbow to terminal (Fig. 18).

The maximum permissible equivalent flue length is: 4 metres (Fig. 18a).

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° = 1m etc.

7.11 Terminal Guard (Fig. 19)

1. When codes of practice dictate the use of terminal guards, they can be obtained from most Plumbers’ and Builders’ Merchants.

2. When ordering a terminal guard, quote the appliance model number.

3. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated.

Fig. 18a

Pictorial examples of flue runs where EQUIVALENT flue length equals 4m

7.12 Vertical Flue

1. Only a flue approved with the Baxi 50, 80 and 100/2 HE Plus 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.

Fig. 19

Page 23

8.0 Installation

Edge of Boiler

Centre Hole

Fig. 20

Example

Horizontal

Side Flue

Centre Line

Wall Plate Template

125mm

Example

V = 110mm

Wall Thickness

up to 227mm

up to 750mm

up to 1200mm

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.

Flue Hole ø

125mm core drill

150mm core drill

175mm core drill

Check Site Requirements (section 7) before commencing.

8.1 Initial Preparation

The gas supply, gas type and pressure must be checked for suitability before connection (see Section

7.4).

NOTE: If the boiler wall plate is to be pre-hung, follow both these instructions and those on the boiler pack.

1. Remove the fixing template (Fig. 20) from the carton.

2. After considering the site requirements (see Section

7.0) position the template on the wall ensuring it is level both horizontally and vertically.

NOTE: When fitting Plume Displacement Kit refer to the instructions supplied for details of installation of the flue.

Flue Duct Hole Offset V (mm)

Fig. 21

Backfall to the Boiler, ie. 2m flue offset (V) position 110mm

27 55 110 165 220

0.5

1.0

2.0

3.0

4.0 (metres)

Distance in metres from boiler to the wall. For pipe lengths greater than 4m increase the off-set by 52mm for every additional metre to maintain approx 3° inclination.

Centralising

Screw

Wall Plate

(mm)

3. Mark the position of the centre hole for the wall plate (Fig. 20).

4. Mark the centre of the flue hole (rear exit).

3°

For side exit: project the horizontal side flue centre line into the corner of the room and along the wall to where the flue hole will be drilled. (Fig. 20). The diagram (Fig. 21) shows the dimensions required to ensure any horizontal flue is installed with the correct fall to the boiler. Mark the offset (V) dimension and if required, mark the position of the gas and water pipes. Remove the template.

5. Cut the hole for the flue (minimum diameter 125mm, see table (Fig. 20) for wall thicknesses and flue diameters).

6. Drill and plug the wall as previously marked. Secure the wall plate using the centre hole (Fig. 22).

7. Ensuring the wall plate is level both horizontally and vertically, drill and plug at least 4 securing positions at the top and bottom through the wall plate. Utilising the slots available ensure the wall plate is square and secure to the wall (Fig. 22).

8. Loosely route the condensate discharge pipe to the lower left hand side of the wall plate.

Fig. 22

Page 24

Lower Door Panel

8.0 Installation

8.2 Preparing The Boiler

1. Remove the outer carton.

2. Remove the internal packaging.

Outercase

3. Lift the outercase upwards and remove (Fig. 23).

Break Off Upper & Lower Pipe Run Options

Fig. 23

Page 25

8.0 Installation

Wall Plate

Spring Clip

Suggested Lifting Points shown as shaded area

Flue Products Exhaust

Retaining Bracket

Remove the red pipe

protection caps

Fig. 24

Wall Plate

Return Pipe Connection

8.3 Fitting The Boiler (Fig. 24)

1. Remove the screw and retaining bracket from the wall plate spring clip.

2. Offer up the boiler to the wall plate using the lifting points shown in Fig. 24 and locate the rear bottom edge onto the self locating support at the base of the wall plate. (See Safe Manual Handling page 5.)

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. 24).

3. Rotate the boiler and engage into temporary spring retaining latch.

4. Ensure the boiler is secured with the retaining bracket and screw previously removed, immediately.

5. Remove red pipe protection caps from the FLOW and RETURN connections.

8.4 Making the Water Connections (Fig. 25)

1. The boiler has two side water connections which are labelled FLOW and RETURN. The front connection is the flow pipe and the rear threaded connection is the return.

2. It is essential that the flow and return pipes are connected to the boiler correctly. The flow connection incorporates the boiler thermostats and a flow switch.

Fig. 25a

Flow Pipe Connection

Fig. 25

3. Only 22mm copper pipe can be connected (by soldering) to the boiler flow and return. Compression fittings cannot be used.

NOTE: On 100/2 HE Plus models 28mm pipe should be used to connect to the boiler flow and return.

4. If the installation requires that the system pipework originates from the bottom of the boiler, then the flow and return pipes will need cutting, as they terminate upwards.

8.5 Making the Condensate Drain Connection

1. Connect the condensate drain using the 1”BSP nut and seal supplied. (see section 7.6).

NOTE: To ensure the correct operation and integrity of the condensate drainage system -

Carefully pour approximately 1 cupful (250ml) of water into the flue products exhaust, at the top of the heat exchanger (Fig. 25a) to ensure a seal is made in the trap.

Page 26

3°

(1 in 20)

Wall Thickness

8.0 Installation

8.6 Making the Gas Connection

1. Connect the gas supply to the G1/2(1/2in BSPT Internal) gas tap. This is located on the lower right side of the boiler, access by hinging down the PCB housing (see Fig. 32).

8.7 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° (1 in 20) fall from terminal to elbow, to allow condensate to run back to the boiler.

HORIZONTAL FLUE

Fig. 26

Fig. 27

Waste

360° Orientation

(Z) Edge of Wall Plate to Wall

Wall Thickness

(Z) = Side Exit

(X) = Rear Exit

Flue

1. 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 - 630mm

Side Flue: maximum wall thickness - 565mm (left or right)

2. For rear exit - measure the wall thickness (Fig. 26) and to this dimension add 210mm. This dimension to be known as (X). i.e.

(X) = wall thickness + 210

3. Take the flue and mark off (X) from the terminal end as indicated in the diagram (Fig. 27).

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 side exit - measure the distance from the edge of the wall plate to the inner face of the wall (Fig. 26) and to this dimension add the wall thickness + 250mm. This dimension to be known as (Z). i.e.

(Z) = wall plate to wall + wall thickness + 250

5. Take the flue and mark off (Z) from the terminal end as indicated (Fig. 27).

Inner Flue Support Bracket

Fig. 27a

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.

IMPORTANT: Check all measurements before cutting.

NOTE: When cutting ensure the cut does not interfere with the inner flue support bracket (Fig. 27a).

Page 27

8.0 Installation

8.7 Fitting the Flue (Cont)

Flue Elbow

Inner Flue Support Bracket

Flue

Apply Lubricant for ease of

assembly. Ensure Flue is fully

Fig. 28

engaged into Flue Elbow.

6. Ensure the inner flue support bracket is positioned in the flue (Fig. 28).

7. Engage the flue into the flue elbow using soap solution to ease the engagement ensuring the flue is assembled as shown (Fig. 29).

8. Place the gasket over the flue exit on the boiler.

9. Slide the flue assembly through the hole in the wall.

10. Engage the elbow on to the flue connection on top of the boiler. Secure with the four screws supplied in the kit.

11. Make good between the wall and air duct outside the building ensuring the 3° drop between the terminal and elbow.

12. The flue trim should be fitted once the installation is complete and the flue secure (Fig. 30). 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.

Fig. 29

13. If necessary fit a terminal guard (see Section 7.9).

Gasket

VERTICAL FLUEING

1. Only a flue approved with the Baxi 50, 80 and 100/2 HE Plus 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.

Fig. 30

Flue Trim

Page 28

Hinge down PCB Housing

8.0 Installation

8.8 Making The Electrical Connections

WARNING: This appliance must be earthed

1. The electrical connections are on the right hand side of the unit.

2. Undo the two screws securing the cable clamp and place to one side (Fig. 31).

3. The Baxi 100/2 HE Plus is factory set to give a maximum output of 22.0 kW (75,000 Btu/hr). The Control PCB jumper positions are as follows:

CN11 (Blue) CN12 (Red)

If the installation requires a greater output to achieve the desired room temperature, this can be increased to 30.18 kW (103,000 Btu/hr) and the boiler can be adjusted as follows (Fig. 32): a) Remove the top right hand securing screw and

hinge down the PCB housing.

b) Remove the Red jumper labelled CN12 from the

bottom left hand side of the PCB.

c) Hinge back up the PCB housing and secure with

screw.

Fig. 31

Cable Clamp

4-way Terminal Block

Blue (CN11) Jumper

Red (CN12) Jumper

Fig. 32

If the boiler is to be used in conjunction with a Thermal Store, the boiler can be adjusted as follows (Fig. 32):

a) Remove the top right hand securing screw and

hinge down the PCB housing.

b) Remove the Blue and Red jumpers labelled CN11

and CN12 from the bottom left hand side of the PCB.

c) Hinge back up the PCB housing and secure with

screw.

4. Route the incoming electrical cable/s through the grommet in the support bracket. This will prevent damage to the cable.

5. Lay the cable through the cable clamp to gauge the length of cable required when it is connected to the 4-way terminal block.

6. Connect the (S/L), (N) and ( ) wires to the 4-way terminal block (Fig. 33) and refit the cable clamp (Fig. 31).

7. Check the electrical installation for; earth continuity, short circuits, resistance to earth, correct polarity and fuse failure.

S/L N

Fig. 33

Optional Pump Feed Connection

P/F

only required for fully TRV’d system

Page 29

Earths not shown to aid

clarity of diagram

9.0 Electrical

9.1 Schematic Wiring Diagram

Flow

Switch

PCB

325 Vdc DC Fan

g/y

Flow

Thermistor

Electrical

g/y

Filter

g/y

LNOptional

g/y

Pump

Feed

Flow

Overheat

Thermostat

Overheat

Thermostat

Fan

Gas

Valve

Condensate

Tr ap

g/y

Flame

Detection

Electrode

g/y

Spark Electrode

Key To Wiring Colours

b - Blue

bk - Black

w - White

br - Brown

gy - Grey

r - Red

g - Green

g/y- Green/Yellow

op - Opaque

y - Yellow

Page 30

CH Flow Switch

Flow Thermistor

g/y

Electrical Filter

9.0 Electrical

9.2 Illustrated Wiring Diagram

Optional Pump Feed

Layout of PCB Pins

g/y

Spark

Electrode

Flame Detection

Electrode

Main PCB

g/y

Condensate Trap

Gas Valve

Fan Overheat Thermostat

Fan

Flow Overheat Thermostat

Wiring Key

b - Blue bk - Black br - Brown r - Red w - White g/y - Green/Yellow g - Green gy - Grey op - Opaque y - Yellow

Page 31

10.0 Commissioning the Boiler

IN OUT

10.1 Commissioning the Boiler

1. Reference should be made to BS 5449 Section 5 when commissioning the boiler.

2. Flush the whole system using a suitable flushing agent (see Section 6.2) and vent the radiators. Check for water leaks.

3. Refill the system with inhibitor following the inhibitor manufacturer’s instructions and BS 7593 Code of Practice for Treatment of Water in Domestic Hot Water Central Heating Systems (see Section 6.2).

4. 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.

Fig. 35

Reset

Gas Service

Cock

BS 6891 and in IE I.S. 813 “Domestic Gas Installations”.

6. Remove the top RH securing screw and hinge down the PCB housing to gain access to the gas service cock (see Fig. 32). Turn the gas service cock anticlockwise to the ON position and check for gas soundness up to the gas valve (Fig. 34).

7. Turn the boiler control knob fully clockwise to ‘HIGH’

5. Turn the gas supply on and purge according to in GB

High

Low

Open

Fig. 34

Control Knob

(Fig. 35) and run the system and check the boiler for correct operation.

NOTE: The boiler is self-regulating dependent upon the system load. The 50 HE Plus will modulate between inputs of 16.88kW and 10.3kW. The 80 HE

Plus will modulate between inputs of 24.9kW and

10.3kW. The 100/2 HE Plus will modulate between inputs of 33.76kW and 10.3kW. The 100/2 HE Plus input is factory set at 24.9kW and can be altered to

33.76kW - see section 8.8. No adjustment of the

gas valve is permissible.

8. With the system cold and all controls calling for heat check the gas pressure at the inlet tapping of the gas valve (Fig. 36). The pressure must be a minimum of 18.1 mbar (Working Pressure). Check that the gas rate is no greater than quoted in Section 4.0 Technical Data.

DO NOT check gas pressure here

Inlet Gas Pressure Test Point

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

Fig. 36

Page 32

11.0 Fitting the Outer Case

Outercase Securing

Screws

Break Off Panel

Fig. 37

11.1 Fitting The Outer Case

1. Position the outercase over the boiler engaging the lugs in the side flanges over the hooks on the wall plate. Break off top or bottom panel as required to accommodate pipework runs (Fig.37).

2. Using the two screws supplied in the kit, secure the outercase to the combustion box (Fig. 37).

3. Replace the lower front door panel (Fig. 38).

4. The “Important Ventilation Information” label can be removed unless the appliance is installed in an unventilated compartment.

5. Carefully read and complete all sections 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.

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.

Lower Door Panel

Fig. 38

6. Instruct the user in the operation of the boiler controls. Hand over the User’s Operating, Installation and Servicing Instructions, giving advice on the necessity of regular servicing.

7. Demonstrate to the user the action required if a gas leak occurs or is suspected. Show them how to turn off the gas supply at the meter control, and advise them not to operate electric light or power switched, and to ventilate the property.

8. Show the user the location of the system control isolation switch, and demonstrate its operation.

9. Advise the user that they may observe a plume of vapour from the flue terminal, and that it is part of the normal operation of the boiler.

10. Complete the label supplied with the inhibitor and stick to the inside of the boiler case. Detail of system treatment must be recorded in the Benchmark Commissioning Checklist.

Page 33

12.0 Servicing the Boiler

12.1 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 service is recommended.

When replacing the combustion box door after servicing it is essential that the retaining screws are tightened fully.

After Annual Servicing a combustion check should be performed (see Section 12.1 paragraph 11).

1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Before servicing please read Section 1.2 Important Information.

2. After servicing, complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication.

Air Box Door Panel

Spark

Sleeve

Earth

Sensing

Fig. 40

Combustion Box

Door Panel

Lead Terminals

Fig. 39

Fig. 41

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 11.0).

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

6. Release the four

/4turn screws securing the air box

door panel and remove the door (Fig. 39).

7. Disconnect the leads from the centre and right hand terminals (earth and flame sensing probe) (Fig. 40). Reconnect in reverse order.

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. b) Heat exchanger fins. c) Fan compartment d) Insulation. e) Door seals-Important: Pay particular attention to

the condition of the combustion box door seals.

f) Electrodes. g) The condensate trap.

NOTE: 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.

(Check also for condensate leaks).

Page 34

Flue Sampling Point

Fig. 41a

12.0 Servicing the Boiler

12.1 Annual Servicing (Cont)

10. To clean the heat exchanger and burner proceed as follows:

a) Disconnect the electrical leads to the fan component protection sensor (Fig. 42).

b) Loosen the screw retaining the gas injector pipe at the venturi (Fig. 42).

c) Undo the two wing nuts to disconnect the fan (Fig. 42).

d) Remove the fan and disconnect the electrical supply to it (Fig. 42).

Injector Pipe

Injector Pipe Retaining

Screw

Protection

Sensor Leads

Fig. 42

Wing Nuts

Central Insulation Panel

Electrical Supply

Burner

Fan

Condensate

Lock Nut

Condensate Drain Pipe

Sensor

Leads

Trap

Fig. 43

Securing Nut

Service Drain Plug

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, check seal around baffle for cracks/damage. Clean with a soft brush.

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 panel and check condition (Fig. 44). Replace the lower insulation pad if necessary.

k) Ensure the heat exchanger fins are clear of any obstruction.

l) Check condition of all seals. Important: Pay particular

attention to the condition of the combustion box door seals.

m) Reassemble in reverse order and check for leaks.

Burner Securing

Screws

Combustion

Box Base

Heat Exchanger Support Bracket

Combustion Box Base

Securing Screws

Fig. 44

11. Check CO/CO

ratio and CO2level at the flue sampling point (Fig.41a) is as quoted in Section 4.0 Technical Data.

12. If the ratio or level is greater than that quoted telephone the Technical Enquires for further advice

IMPORTANT: No adjustment of the gas valve is permissible.

12. 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.

Page 35

Fig. 45

Heat Exchanger

Manifold

13.0 Changing Components

13.1 Changing Components

IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started.

“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.

After Changing Components a combustion check should be performed (see Section 13.8 paragraph 11). This is especially important on gas carrying parts and those that may affect combustion (e.g. fan).

1. Before changing any components please read Section

1.2 Important Information.

2. Remove the outer case and lower door panel (see “Fitting the Outercase” Section 11.0).

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

Electrical

Connections

Safety

Thermostat

Fig. 46

Drain Point

Flow Temperature Thermistor

Tube

3. Isolate the water circuit and drain the system as necessary. A drain point is located on the heat exchanger manifold at the right hand side of the boiler (Fig. 45) to enable the heat exchanger to be drained.

4. Place a tube on the drain point to drain water away from electrics. Turn anticlockwise to open (Fig. 45).

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).

5. After changing a component re-commission the boiler where appropriate and check the inhibitor concentration (see Section 6.2 and 10.1).

The thermistor, safety thermostat, interface PCB and the flow switch can be accessed after removal of the outer case.

13.2 Flow Temperature Thermistor and

Safety Thermostat

(Fig. 46)

1. The procedure is the same for both the thermistor and the safety thermostat.

2. Remove the electrical connections from the sensor.

3. Unscrew the sensor from the pipe.

4. Fit the new thermistor or safety thermostat and reassemble in reverse order.

Page 36

13.0 Changing Components

13.3 Flowswitch (Fig. 47)

1. Drain the boiler (see Section 13.1 paragraph 2 & 3).

2. Remove the two screws on the support bracket.

Support Bracket

Flow Switch

Clip

Flow Pipe

3. Remove the clip securing the flow pipe to the flowswitch.

4. Disconnect the inline electrical connection.

5. Pull pipe away from flowswitch.

6. Remove the two screws securing the flowswitch to the boiler.

7. Remove the flowswitch.

8. Fit the new flowswitch and reassemble in reverse order.

9. Recommission the boiler and check the inhibitor concentration (see Section 6.2 and 10.1).

Fig. 47

Page 37

Control Knob

Plastic Button Cover

13.0 Changing Components

13.4 PCB (Figs. 48 & 49)

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

1. Pull the control knob off the spindle and remove the plastic button cover. Refit them onto the new PCB (Fig. 48).

1. Remove the top right hand securing screw and hinge down the PCB housing and disconnect the electrical connections noting their positions

NOTE: Check the PCB for the presence of input jumpers - see section 8.8. Set the new PCB as the one removed.

Fig. 48

Hinge down PCB Housing

Blue (CN11) Jumper

Red (CN12) Jumper

Fig. 49

PCB Housing Securing Screw

2. Lift Control PCB housing out of hinge housing of metal bracket.

3. Fit the new PCB Housing Assembly and reassemble in reverse order.

Page 38

Air Box Door Panel

Fig. 50

13.0 Changing Components

The fan and venturi, gas valve, injector pipe, condensate trap, fan protection sensor, spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel.

1. Remove the airbox door panel by loosening the four

/4turn screws (Fig. 50).

13.5 Spark and Sensing Electrodes

(Fig. 51)

1. Disconnect all three leads from tabs. Spark - Opaque cable Earth - Green/Yellow cable Sensing - White cable

2. Remove the two screws securing each of the

electrodes to the combustion box door and remove the electrodes.

3. Fit the new electrodes (and new gasket, as required)

and reassemble in reverse order.

Spark

Earth

Injector Pipe

Screw

Sensing

Fig. 51

Combustion

Box Door

Injector

Opening

Gasket

13.6 Fan (Fig. 52)

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

1. Loosen the screw holding the injector pipe into the

venturi.

2. Remove the electrical connections to the fan and

protection sensor on the fan.

3. Remove the wing nuts securing the fan to the base of

the combustion box.

4. Lower the fan and remove.

5. If changing the fan remove the screws securing the

venturi and fan protection sensor bracket, noting the positions of the injector opening and sensor bracket, fix them to the new fan.

Fan

6. Fit the new fan and reassemble in reverse order.

Electrical Connections

Protection

Sensor

The injector pipe, condensate trap and gas valve can be changed after the removal of the fan.

Venturi

Fig. 52

Electrical Connection

Wing Nuts

Page 39

13.0 Changing Components

The removal of the fan is necessary to enable the changing of the injector pipe, condensate trap and gas valve (see section 13.6).

13.7 Injector Pipe (Fig. 53)

1. Remove the injector pipe by pulling out from the ‘O’

ring joint in the gas valve.

2. Fit the new injector pipe and reassemble in reverse

order.

Injector Pipe

Boiler Side

Fig. 53

Gas Valve

Securing Screws

Aluminium

Spacer

Case Pressure Pipe

Gasket

‘O ring’

Electrical Plug

Gas Valve

Gas Tap

13.8 Gas Valve (Fig. 53)

1. Remove the Control PCB (see Section 13.4).

2. Isolate gas supply and disconnect the gas tap by

removing the four screws.

3. Undo the case pressure pipe from the gas valve.

4. Disconnect the electrical plug from the gas valve.

5. Remove the fan (see section 13.6) and injector pipe.

6. Remove the two gas valve securing screws from

inside the air box holding the gas valve.

7. Remove the gas valve from the airbox side.

8. Remove the aluminium spacer and its gasket from

the gas valve.

9. Fit the aluminium spacer and its gasket to the new

valve.

10. Fit the new gas valve and reassemble in reverse

order.

NOTE: Check for gas tightness after replacing gas valve.

Sensor

Leads

Condensate

Trap

Lock Nut

Condensate

Drain Pipe

Securing

Nut

Service Drain Plug

Fig. 54

11. Check CO/CO

ratio and CO2level at the flue sampling point (Fig.41a) is as quoted in Section 4.0 Technical Data.

12. If the ratio or level is greater than that quoted telephone the Technical Enquires for further advice

IMPORTANT: No adjustment of the gas valve is permissible.

13.9 Condensate Trap (Fig. 54)

1. 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.

6. Fit the new condensate trap and reassemble in reverse order.

7. Prime the condensate trap (fill first chamber), check for leaks.

Page 40

13.0 Changing Components

Combustion Box

Door Panel

Burner

Fig. 55

Support

Bracket

Connection

Fig. 57

The burner and heat exchanger can be changed after removal of the combustion box door. To change the heat exchanger, the fan and burner must be removed first (see section 13.6 and 13.10).

1. Remove the combustion box door by removing the four securing screws (Fig. 55).

IMPORTANT: On refitting the combustion box door check the condition of the combustion box door seals.

13.10 Burner (Fig. 56)

1. Remove the two screws securing the burner to the base of the combustion box.

Return

2. Remove the burner carefully from the combustion box base.

3. Check the burner seal on the heat exchanger base, replace if necessary. Fit the new burner and reassemble in reverse order.

Fig. 56

Securing Screws

Fig. 58

Heat Exchanger

Manifold

Flow

Switch

13.11 Heat Exchanger

1. Drain the boiler (see section 13.1 paragraph 2 & 3).

2. Remove all components in the base of the airbox.

3. Undo the screws on the support bracket. Remove the screws securing the flow switch and return connections and remove the connections (Fig. 57).

4. Remove the screws securing the heat exchanger manifold and remove the manifold (Fig. 58).

5. Lift the heat exchanger assembly (Fig. 59) and rotate the bottom upwards whilst pulling it forwards out of the airbox.

6. Fit the new heat exchanger and reassemble in reverse order.

7. Recommission the boiler and check the inhibitor concentration (see Section 6.2 and 10.1).

Heat Exchanger

Assembly

Fig. 59

Page 41

Upper Insulation Pad

Lower Insulation Pad

Central Insulation Panel

Burner

Fig. 60

13.0 Changing Components

13.12 Heat Exchanger Lower Insulation Pad

(Fig. 60)

1. Remove all components in the base of the airbox.

2. Remove the burner (see section 13.10).

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 lower insulation pad.

6. Fit the new insulation pad and reassemble in reverse order.

13.13 Heat Exchanger Upper Insulation Pad

(Fig. 60)

1. Remove all components in the base of the airbox.

Burner Securing

Screws

Combustion Box Base

Support Bracket

Combustion Box Base

Securing Screws

2. Remove the burner (see section 13.10).

3. Remove the heat exchanger (see section 13.11).

4. Remove the four bolts securing the combustion box base.

5. Remove the combustion box base.

6. Pull the central insulation panel down from the centre of the heat exchanger.

7. Fit the new insulation pad and reassemble in reverse order.

Page 42

14.0 Short Parts List

Short Parts List

A BC

Key G.C. Description Manufacturers No. No. Part No.

A E06 058 Flow Temperature

B E06 059 Flow Switch 242459

C E06 060 Safety Thermostat

D PCB 5110991

E Fan 5109925

F Gas Valve 241900

Thermistor (Red) 240670

(Black) 242235

G E06 085 Viewing Window 242484

H Condensate Trap 5111714

I Electrodes Kit 5110992

J Burner Assy 5107430

K E06 097 Heat Exchanger Assy 242497

L Control Knob 5109996

Page 43

Reset

High

15.0 Fault Finding

Lockout

LED Light (Red)

Boiler On

LED Light (Green)

Lights

Off Off Off

Lights

On Off Flash

Lights

On Flash Flash

Lights

On Off On

Lights

Flash Off On

Lights

Flash Flash On

Low

Mains On

LED Light

NOTE: The fan is supplied with 325 Vdc.

Fan Fault Finding should only be carried out after the boiler has been electrically isolated.

General Fault Finding should only be carried out by someone who is appropriately qualified.

(Green)

YES

Go to Electrical Supply

section of the fault finding

instructions.

Live & Neutral Reversed

Incoming Live and Neutral

reversed.

Lights

On Flash On

Lights

Flash Off Flash

YES

Go to Thermistor section

of the fault finding

instructions.

Low Electrical Supply

Incoming Voltage less than

180V. Check System

Controls & System Wiring.

Otherwise contact Electricity

Provider.

YES

Go to Dry-Fire

section of the fault finding

instructions.

Lights

On On On

YES

LV Wiring Harness Ensure 8-

way PCB connector securely

pushed in. If fault persists

replace LV wiring harness.

YES

Go to Ignition Lockout section

of the fault finding instructions.

Lights

Flash On Flash

YES

PCB Fault

Replace PCB.

YES

Go to Overheat Lockout section of the fault finding

instructions.

Lights

On On Flash

YES

PCB Fault

Replace PCB.

YES

Go to Fan Lockout

section of the fault finding

instructions.

Lights

Flash On On

YES

PCB Fault

Replace PCB.

Page 44

ELECTRICAL SUPPLY

Lights

Off Off Off

15.0 Fault Finding

240V at A ?

YES

240V at B ?

YES

PCB fuse OK ?

YES

No Switched Live to

boiler. Check Systems

Controls and System

Wiring.

Check wiring from

terminal block to PCB.

Check for shorts on

pump, fan & gas valve.

Replace if shorted &

replace fuse.

Optional

Pump

Live

Replace PCB.

Fuse

Page 45

DRY-FIRE

Lights

On Flash Flash

15.0 Fault Finding

Are

Flow & Return reversed ?

Is the

system full of water ?

YES

Is the

pump running ?

YES

Swop Flow & Return.

Fill system with water and

bleed out all air.

Optional

Pump

Live

Turn

mains off & on. After 5 sec, is

there 240V

at E?

YES

Pump or Pump Wiring

fault.

Replace PCB.

YES

Turn

mains off, unplug

7-way connector to PCB.

Is there continuity between

F and G ?

Wiring from terminal

block to PCB faulty.

Unplug

5-way PCB

connector. Is there continuity

between H (run pump from

switched live) ?

Disconnect

Flow Switch Inline

connector. With pump running is

there continuity across flow

switch ?

Remove

flow switch from boiler.

Is there a physical blockage to

the paddle within the

flow switch ?

YES

Replace PCB.

Wires from inline

connector to PCB faulty.

Is there a

blockage in the system ?

YES

Viewed from

Wire Entry end

Replace Flow Switch.

7-way Connector

Optional Pump

Live

Replace Blockage.

Page 46

IGNITION LOCKOUT

Is there gas at gas valve inlet

YES

Lights

On Off On

Check isolation valve and

gas supply.

15.0 Fault Finding

5-way Connector

Reset Lockout.

Is there gas flow

(check at meter) ?

YES

there at least

18mbar dynamic at gas valve

inlet ?

YES

Condensate Trap

blocked or water on

terminals ?

YES

Remove Gas Valve & check

inlet filter for blockage.

Otherwise incorrect gas supply

to boiler.

Clear blockage and dry

sensors.

Remove

5-way connector

from gas valve. Is there 240

Vdc between I & J

during ignition ?

Remove

the larger or the

two 6-way PCB connectors.

Is there continuity from I to L

& from J to K ?

YES

Replace PCB.

6-way Connector

YES

Replace Gas Valve.

Lead from PCB to Gas

Valve faulty.

spark or flame detection

probe damaged ?

spark gap between 3 and

4mm ?

YES

wiring from PCB

to spark probe & flame

detection probe OK ?

Rectify wiring.

YES

Replace spark or flame

detection probe and

gaskets.

Set spark gap to 3.5mm.

Is the

burner blocked or

damaged ?

YES

Clean burner or replace as

necessary.

Replace PCB.

Page 47

OVERHEAT LOCKOUT

Lights

Flash Off On

15.0 Fault Finding

Disconnect

black stat on flow pipe.

When flow < 60° C is there

continuity across stat ?

YES

Reconnect stat.

Disconnect fan stat.

When fan temp < 60° C

is there continuity

across stat ?

YES

Reconnect stat.

Disconnect the larger of

the 6-way PCB connectors.

Is there continuity

across M ?

YES

Disconnect

thermistor

(red sensor on flow pipe).

Is resistance between

0.5kΩ & 20kΩ ?

Replace Stat.

Wiring from PCB to

thermostats faulty.

Replace thermistor.

6-way Connector

YES

combustion chamber

door seal damaged or not in

place ?

Replace PCB.

YES

Replace combustion

chamber door seal & trim

seal.

Page 48

FAN LOCKOUT

Lights

Flash Flash On

15.0 Fault Finding

Unplug

3-way PCB connector

& unplug fan. Is there

continuity from N to O &

from P to Q ?

YES

Unplug

the smaller of the

6-way PCB connector. Is there

continuity from R to S & from T

to U & from

V to W ?

YES

Replace fan.

Rectify wiring.

NOTE: The fan is supplied with 325 Vdc.

Fan Fault Finding should only be carried out after the boiler has been electrically isolated.

Fan

Connection

PCB

Connection

Fan

Connection

PCB

Connection

S U W

Viewed from

Wire Entry end

Page 49

THERMISTOR

Lights

On Flash On

15.0 Fault Finding

Unplug

thermistor,

Is thermistor resistance between

0.5kΩ & 20kΩ ?

YES

Plug in

thermistor, leave

8-way connector unplugged.

Is resistance at D between

0.5kΩ & 20kΩ ?

YES

Replace PCB.

Replace thermistor.

Wiring from PCB to

thermistor faulty.

Viewed from

Wire Entry end

Page 50

BENCHMARK No.

5113638

COLLECTIVE MARK

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 & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT

TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER

HEATING ZONE VALVES FITTED NOT REQUIRED

HOT WATER ZONE VALVES FITTED NOT REQUIRED

THERMOSTATIC RADIATOR VALVES FITTED

AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED

COMBI BOILER

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 & RECORD

GAS RATE ft3/hr

BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

CENTRAL HEATING FLOW TEMPERATURE °C

CENTRAL HEATING RETURN TEMPERATURE °C

m3/hr

N/A

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED? YES NO

WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE ft3/hr

MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

COLD WATER INLET TEMPERATURE °C

HOT WATER OUTLET TEMPERATURE °C

WATER FLOW RATE

N/A

/hr

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? N/A 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

lts/min

COMMISSIONING ENG’S NAME PRINT CORGI ID No.

SIGN DATE

Page 51

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 manufacturer’s specified spare part when replacing all controls

SERVICE 1

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 3

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 5

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

DATE

SERVICE 2

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 4

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 6

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

DATE

SIGNATURE

SERVICE 7

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 9

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

DATE

SIGNATURE

SERVICE 8

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 10

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

DATE

Page 52

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. All goods are sold subject to our standard Conditions of Sale

which are available on request.

BAXI

A Trading Division of Baxi Heating UK Ltd

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&oe

Comp No5113638 - Iss 4 - 10/06

baxi 50 HE Plus, 80 HE Plus, 100/2 HE Plus User guide

Specifications and Main Features

Frequently Asked Questions

User Manual