Baxi 80 HE Plus, 100 HE Plus, Combi 133 HE Plus Quick Start Manual

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.

Installation & Servicing Instructions

Natural Gas

Baxi Combi 133 HE Plus

G.C.No47 075 14

Baxi Combi 100 HE Plus

G.C.No47 075 15

Baxi Combi 80 HE Plus

G.C.No47 075 16

Baxi is a BS-EN ISO 9001

Accredited Company

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.

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With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn.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.

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 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.

The code of practice for the installation,

commissioning & servicing of central

heating systems.

“Baxi” supports

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

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

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

Complete the

Benchmark Checklist

LABC will record the data

and will issue a

certificate of compliance

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 & 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 6.1).

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”.

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 & 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 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:-

1 Elmwood,

Chineham Business Park,

Crockford Lane,

Basingstoke. RG24 8WG

or check online at www.corgi-gas-safety.com

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.

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. Ref: 86-BL-647

For GB/IE only.

1.0 Introduction 6

2.0 General Layout 7

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

Section Page

Contents

This boiler is fitted with a flow switch interlock that prevents it from firing when the heating demand is satisfied.

1.1 Description

1. 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 (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 & 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.

1.2 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.

• 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.

1.0 Introduction

Fig. 1

Fig. 2

Lower Door Panel

Air Box Door

Data Badge

NOTE: All Illustrations show the Combi 133 HE Plus unless otherwise stated. The PCB Connection Cover is removed for clarity.

Label

2.0 General Layout

2.1 Layout

1. Wallplate

2. Flue Elbow

3. Air Box

4. Heat Exchanger

5. Burner

6. Fan Protection Thermostat

7. Fan Assembly

8. DHW Plate Heat Exchanger

9. Three Way Valve

10. Facia Box

11. Water Pressure Gauge

12. Gas Tap

13. Circulation Pump

14. Pressure Relief Valve

15. Return Thermistor

16. Gas/Air Ratio Valve

17. PCB

18. Flow Temperature Safety Thermostat

19. Flow Temperature Thermistor

20. Manual Air Vent

21. Automatic Air Vent

22. Flow Switch (Dry Fire Protection)

23. Condensate Trap

24. Expansion Vessel

2.2 Optional Extras

KIT PART N

FLUE EXTENSION KITS (110/70) Horizontal Flue Kit 4M max Flue Extension 0.25M 241692 Flue Extension 0.5M 241694 Flue Extension 1M

(Use two kits for 2M etc.) 241695

Flue Bend - 45°

(Reduce overall length of flue

by 0.5m when fitting this bend)

241689

Flue Bend - 90° (

Reduce overall length of flue

by 1m when fitting this bend)

241687

Horizontal Extended Flue (1.75M) 5111457

VERTICAL FLUE KITS (110/70) 5M max Vertical Flue Terminal 242802 Vertical Boiler Connection 5106888

VERTICAL FLUE (80/80) Kit Boiler Connection Twin 242757

CONTROL ACCESSORIES RF Programmable Room Thermostat 5117204 Electro-Mechanical Timer 5117493

Filling Loop Kit 5111095

Plume Displacement Kit 5117383

Expansion Vessel removed for clarity

3.0 Appliance Operation

NOTE: All delay timers mentioned in 3.1 and 3.2 are overridden by domestic hot water demand.

3.1

Central Heating Mode

1. 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 1 minute pump overrun 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 1 minute (Pump Overrun).

3.2 Domestic Hot Water Mode

1. 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.

3.3 Boiler Frost Protection

1. 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.

3.4 Pump Protection

1. The control system continually monitors the time since the pump last operated. This will result in the pump being run for 1 minute if it has not run in the last 24 hours to prevent seizure.

4.0 Technical Data

Flue Terminal Diameter 110mm Dimensions Projection 150mm

Outercase Dimensions

Casing Height - 850mm Overall Height Inc Flue Elbow - 1000mm Casing Width - 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 44.4 98

Central Heating Primary Circuit Pressures

bar lb/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

DHW Circuit bar lb/in

Pressures

Max Operating 10 145 Min Operating 0.1 1.45

Min Operating Pressure at 16 l/min 1.6 23.2

Flow Rates l/min gal/min DHW Flow Rate @ 30o C Rise 18.7 4.11

DHW Flow Rate @ 35o C Rise 16 3.52

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 lb/in

Min Pre-charge Pressure 0.95 13.8

Nominal Pre-charge Pressure 1 14.5

litre gal Max Capacity of CH System 125 27.5 Primary Water Content of Boiler (unpressurised) 3.5 6.2

Connections compression Gas Supply -1/2” BSPF Central Heating Flow - 22mm Central Heating Return - 22mm Cold Water Mains Inlet - 15mm DHW Flow - 15mm Pressure Relief Discharge - 15mm Condensate Drain - 1” BSP

Recommended System Temperature Drop

Condensing 20°C

Temperatures

C.H. 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

Heat Input Gross DHW Max

kW 45.45

Btu/h 155,000

Heat Output CH

Non Condensing (70°C Mean Water temp)

Max Factory Set

kW 30.0 23.9

Btu/h 102,000 81,500

Condensing (40°C Mean Water temp)

Max Factory Set

kW 31.4 25.1

Btu/h 107,000 85,600

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption 200W

External Fuse Rating 3A

Internal Fuse Rating 3.15A

Appliance Category CAT I

Max Gas Rate (Natural Gas)

(After 10 Mins)

m3/h 4.2

ft3/h 148.3

Inlet Pressure (Natural Gas)

mbar 20

in wg 8

Appliance Type C

NOxClass 5

DHW Expansion Vessel

See Section 6.6 for information

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.

SEDBUK Declaration For

Combi 133 HE Plus

Heat Input Gross CH

Max Factory Set

kW 33.7 26.95

Btu/h 115,000 92,000

CO/CO2Ratio 0.002

4.1 Combi 133 HE Plus

Electrical Protection IPX4

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4.0 Technical Data

Flue Terminal Diameter 110mm Dimensions Projection 150mm

Outercase Dimensions

Casing Height - 850mm Overall Height Inc Flue Elbow - 1000mm Casing Width - 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 44.4 98

Central Heating Primary Circuit Pressures

bar lb/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

DHW Circuit bar lb/in

Pressures

Max Operating 10 145 Min Operating 0.1 1.45

Min Operating Pressure at 12 l/min 0.54 7.83

Flow Rates l/min gal/min DHW Flow Rate @ 30o C Rise 14 3.08

DHW Flow Rate @ 35o C Rise 12 2.64

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 lb/in

Min Pre-charge Pressure 0.95 13.8

Nominal Pre-charge Pressure 1 14.5

litre gal Max Capacity of CH System 125 27.5 Primary Water Content of Boiler (unpressurised) 3.5 6.2

Recommended System Temperature Drop

Condensing 20°C

Temperatures

C.H. 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

Heat Input Gross DHW Max

kW 33.7

Btu/h 115,000

Heat Output CH

Non Condensing (70°C Mean Water temp)

Max Factory Set

kW 30.0 23.9

Btu/h 102,000 81,500

Condensing (40°C Mean Water temp)

Max Factory Set

kW 31.4 25.1

Btu/h 107,000 85,600

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption 200W

External Fuse Rating 3A

Internal Fuse Rating 3.15A

Appliance Category CAT I

Max Gas Rate (Natural Gas)

(After 10 Mins)

m3/h 3.1

ft3/h 110.0

Inlet Pressure (Natural Gas)

mbar 20

in wg 8

Appliance Type C

NOxClass 5

DHW Expansion Vessel

See Section 6.6 for information

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.

SEDBUK Declaration For

Combi 100 HE Plus

Heat Input Gross CH

Max Factory Set

kW 33.7 26.95

Btu/h 115,000 92,000

CO/CO2Ratio 0.002

4.2 Combi 100 HE Plus

Electrical Protection IPX2

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4.0 Technical Data

Flue Terminal Diameter 110mm Dimensions Projection 150mm

Outercase Dimensions

Casing Height - 850mm Overall Height Inc Flue Elbow - 1000mm Casing Width - 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 44.4 98

Central Heating Primary Circuit Pressures

bar lb/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

DHW Circuit bar lb/in

Pressures

Max Operating 10 145 Min Operating 0.1 1.45

Min Operating Pressure at 10 l/min 0.39 23.2

Flow Rates l/min gal/min DHW Flow Rate @ 30o C Rise 11.7 2.57

DHW Flow Rate @ 35o C Rise 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 lb/in

Min Pre-charge Pressure 0.95 13.8

Nominal Pre-charge Pressure 1 14.5

litre gal Max Capacity of CH System 125 27.5 Primary Water Content of Boiler (unpressurised) 3.5 6.2

Recommended System Temperature Drop

Condensing 20°C

Temperatures

C.H. 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

Heat Input Gross DHW Max

kW 26.95

Btu/h 92,000

Heat Output CH

Non Condensing (70°C Mean Water temp)

Max

kW 23.9

Btu/h 81,500

Condensing (40°C Mean Water temp)

Max

kW 25.1

Btu/h 85,600

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption 200W

External Fuse Rating 3A

Internal Fuse Rating 3.15A

Appliance Category CAT I

Max Gas Rate (Natural Gas)

(After 10 Mins)

m3/h 2.5

ft3/h 87.9

Inlet Pressure (Natural Gas)

mbar 20

in wg 8

Appliance Type C

NOxClass 5

DHW Expansion Vessel

See Section 6.6 for information

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.

SEDBUK Declaration For

Combi 80 HE Plus

Heat Input Gross CH

Max

kW 26.95

Btu/h 92,000

CO/CO2Ratio 0.002

4.3 Combi 80 HE Plus

Electrical Protection IPX2

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5.0 Dimensions and Fixings

Key To Support Bracket

1 Domestic Hot Water Outlet 4 Central Heating Flow

2 Cold Water Inlet 5 Central Heating Return

3 Gas Supply 6 Pressure Relief

Support Bracket

1 2 3 4 5

63 mm

62 mm 77 mm 74.5 mm

Tap Rail

Top View of Tap Rail

C/L

50 mm

360° Orientation

Tube Ø 110mm

3°

(1 in 20)

DIMENSIONS

A 850mm

B 320mm

C 490mm

D 125mm Ø Min.

E 150mm

F 136mm

SIDE FLUE (left and right)

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.

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

Flue length (Y)

up to 1m

1m - 2m

2m - 3m

Clearance (X)

55mm

110mm

165mm

3°

(1 in 20)

6.0 System Details

6.1 Central Heating Circuit

1. 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

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

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 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.

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 L1 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).

• The condensate drain and pipes must be free from leaks.

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 given in the current edition of I.S. 813 “Domestic Gas Installations” and the current Building Regulations must be followed.

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 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.

6.0 System Details

6.2 System Control

1. 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.

6.3 System Filling and Pressurising (Fig. 3)

1. 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 all 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 I.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).

6.4 Expansion Vessel - CH only (Fig. 4)

1. The appliance expansion vessel is pre-charged to 1 bar (14.5 lb/in

). Therefore, the minimum cold fill pressure is 1 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 1. For IE, the current edition of I.S. 813 “Domestic Gas Installations”.

6.5 Pressure Relief Valve (Fig. 4 )

1. 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 15mm dia, run continuously downward, 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.

Fig. 3

Stop Valve

Double Check Valve

DHW Mains Inlet

CH Return

Temporary Hose

Pressure Relief Valve

Expansion Vessel removed for clarity

Fig. 4

Expansion Vessel

Stop Valve

6.0 System Details

6.6 Domestic Hot Water Circuit

1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations.

2.When installed in accordance with 1 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 the supply, then an expansion vessel must be fitted (e.g. Zilmet 160ml, R

/215 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 lb/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 l/min (100 model), 10 l/min (80 model) may be obtained by fitting the flow regulator supplied.

6.7 Showers

1. 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.

6.8 Hard Water Areas

1. 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.

Key

1 Expansion Vessel 2 Flow Thermostat 3 Flow Thermistor 4 Flow Switch 5 Primary Heat Exchanger 6 Gas Valve 7 DHW Plate Heat Exchanger 8 DHW Flow 9 DHW Mains Inlet 10 Flow Regulator 11 DHW Flow Switch

Boiler

Other Tap Outlets

Expansion Vessel

To Hot Taps

Check Valve

Pressure Reducer Valve

Stop Tap

12 Gas Inlet 13 Filling Loop 14 CH Flow Valve 15 Filter 16 CH Return Valve 17 Pressure Gauge 18 Pump 19 Pressure Relief Valve 20 Return Thermistor 21 3 Way Valve

129

7.0 Site Requirements

Zone 2

Zone 1

Zone 0

Zone 2

Zone 3

Zone 2

Window Recess

0.6 m

2.4 m

Ceiling

Outside Zones

Zone 3

Zone 2

Zone 1

Zone 0

2.25 m

Zone 2

Window Recess

3.0 m

2.4 m

0.6 m

Fig. A

Fig. B

In GB Only

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 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. 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, 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 & 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.

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 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

7.3 Clearances (Fig. 6 & 7)

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.

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

/2” BSPF.

3. Ensure that the pipework from the meter to the appliance is of adequate size. Do not use pipes of a smaller

diameter than 22mm up to the boiler connection.

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.

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.

WARNING: The PCB Control and Fan Assembly

is 325 Vdc. Isolate at supply before access.

200mm

850mm

490mm

200mm

5mm Min

5mm

500mm

For Servicing

Purposes

Fig. 6

Fig. 7

In Operation

3°

(1 in 20)

320mm

7.0 Site Requirements

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.

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

Boiler

2.5° Minimum fall

Termination to an internal soil and

vent pipe

450mm min

Boiler

2.5° Minimum fall

External termination via internal discharge

branch

e.g sink waste - downstream

Sink

Pipe must terminate above water level but below surrounding surface

Boiler

Pipe must terminate above water level but below surrounding surface

2.5° Minimum fall

Termination to a drain or gully

Boiler

500mm min

2.5° Minimum fall

Termination to a purpose made soak-

away

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

50mm per metre of pipe run

7.0 Site Requirements

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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.

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.

Fig. 10

Fig. 9

300 min

Terminal Assembly

TopViewRear Flue

Property Boundary Line

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

Table. 2

Terminal Position with Minimum Distance (Fig. 10) (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)

or external

(ii)

corner.

(i)

(ii)

115 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.

7.0 Site Requirements

7.8 Flue Dimensions

See Section 2.2. The standard horizontal flue kit allows for flue lengths between 270mm and 800mm from elbow to terminal (Fig. 11).

The maximum permissible equivalent flue length is: 4 metres horizontal (Fig. 12).

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.

7.9 Terminal Guard (Fig. 13)

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

2. There must be a clearance of at least 50mm between any part of the terminal and the guard.

3. When ordering a terminal guard, quote the appliance name and model number.

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

Fig. 11

Fig. 12

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

Fig. 13

270mm

800mm

0.5m

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