Baxi Combi 130 HE Quick Start Manual

Download

Please leave these instructions with the user

Baxi Combi 130 HE

Gas Fired Wall Mounted Condensing

Combination Boiler

Installation & Servicing Instructions

Baxi is one of the leading manufacturers of domestic

heating products in the UK.

Our first priority is to give a high quality service to our

customers. Quality is designed into every Baxi product

- products which fulfil the demands and needs of

customers, offering choice, efficiency and reliability.

To keep ahead of changing trends, we have made a

commitment to develop new ideas using the

latest technology - with the aim of continuing to make

the products that customers want to buy.

Everyone who works at Baxi has a commitment to

quality because we know that satisfied customers

mean continued success.

We hope you get a satisfactory service from Baxi. If

not, please let us know.

Natural Gas

Baxi Combi 130 HE

G.C.No47 075 04

Baxi is a BS-EN ISO 9001

Accredited Company

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 0086.

Product/Production certified by: Notified Body 0086. Ref: 86-BL-647

For GB/IE only.

0.0 Legislation 4

1.0 Introduction 5

2.0 General Layout 6

3.0 Appliance Operation 7

4.0 Technical Data 8

5.0 Dimensions and Fixings 9

6.0 System Details 10

7.0 Site Requirements 13

8.0 Installation 19

9.0 Electrical 26

10.0 Commissioning the Boiler 28

11.0 Fitting the Outer Case 32

12.0 Servicing the Boiler 33

13.0 Changing Components 35

14.0 Short Parts List 46

15.0 Fault Finding 47

16.0 Operational Flow Chart 58

Section Page

Contents

0.0 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 6.0).

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, or valid ACoP equivalents, 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. Stooping should be avoided and protective equipment worn where necessary. Carrying & lifting equipment should be used as required.

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.

“Benchmark” Installation, Commissioning and Service Record Log Book

Please ensure that your installer has completed the Installation and Commissioning sections of the Log Book and hands the Log Book over. The details of the Log Book will be required in the event of any warranty work. Keep the Log Book in a safe place and ensure that the relevant sections are completed at each subsequent regular service visit.

All CORGI registered installers carry a CORGI identification card and have a registration number. Both should be recorded in your boiler Log Book. You can check your installer is registered by telephoning +44 (0)1256 372300 or writing to:-

1 Elmwood,

Chineham Business Park,

Crockford Lane,

Basingstoke. RG24 8WG

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.

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 130 HE is a fully automatic gas fired wall mounted condensing combination boiler. It is 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) for hot water. In central heating mode the boiler will automatically adjust down to 10.6 kW (36,000 Btu/h) according to system load.

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

4. Check the local supply conditions before installation.

5. The boiler is suitable for use only on fully pumped sealed heating systems. Priority is given to domestic hot water.

6. 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).

7. The boiler data badge is positioned on the air box door (Fig. 2).

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

9. The boiler 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 man-made 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

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. Primary Water Pressure Gauge

12. Gas Tap

13. Circulation Pump

14. Pressure Relief Valve

15. Return Thermistor

16. Gas/Air Ratio Valve

17. Transformer

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

VERTICAL FLUE KITS (110/70) 5M max Vertical Flue Terminal 242802 Vertical Boiler Connection 242886

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

CONTROL ACCESSORIES Programmable Room Thermostat (Intellistat) 247495 Electro-Mechanical Timer 247498

Filling Loop Kit 247500

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/hr the central heating flow switch operates, initiating the ignition sequence.

2. The burner ignites at low rate, then the gas control system modulates the heat input to maintain the heating temperature measured by the thermistor sensor.

3. When the boiler reaches 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.

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 automatic integral frost protection feature (see section 10.4). 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 System Frost Protection Mode

1. The boiler incorporates an integral system frost protection feature. This can be activated (see section 10.4) if required. To monitor system temperature the boiler will switch on the pump every four hours in both summer and winter modes. If water returned to the boiler is below 8°C (± 5°) the boiler frost protection mode is automatically activated. Due consideration should be taken to the siting of the appliance when using this option. It may be preferable to fit an external frost thermostat to the system. In this instance the integral system frost protection feature need not be activated.

3.5 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 62.5 137.8 Packaged Flue Kit 3.8 8.4 Weight Empty 55.7 122.8 Installation Lift Weight 45.9 101.2

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 3.5 0.77

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) 1.5 0.33

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

Recommended System Temperature Drop

Normal 11°C Condensing 20°C

Temperatures

C.H. Flow Temp (adjustable)

45° C to 82° C max (± 0.5° C)

D.H.W. Flow Temp (adjustable)

35° 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 2AH

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

(see section 10.1)

Appliance Type C

NOxClass 5

DHW Expansion Vessel

See Section 6.7 for information

Where flow rates are required in excess of 840 l/h

please contact the Baxi

Technical Department for advice (Telephone number on the back cover).

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 130 HE

Heat Input Gross CH

Max Factory Set

kW 33.7 26.95

Btu/h 115,000 92,000

Electrical Protection IP 44

Pump - Available Head

Metre wg

l/h

0 1250

gal/min

0 0.9 1.8 2.75 3.7

250 500 750 1000

4.625

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 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 130 HE Combination Boiler is 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.

6.2 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 boiler flow temperature of 82°C.

When the 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. 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).

• If the hot water delivery is greater than 18 litres/minute the flow regulator must be fitted to the Domestic Hot Water inlet (A pint milk bottle will fill in under 2 seconds).

• If the boiler is to be uprated to 100,000 Btu/hr CH output, an extra standard pump will be required and the commissioning procedure will take approximately 30 minutes longer.

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

• Any timer and thermostat should be removed before installing optional Intellistat as it will override their operation.

• Treatment of Water Circulating Systems

All water circulating systems will be subject to corrosion unless an appropriate water treatment is applied. Without treatment 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.

For optimum performance after installation this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS 7593:1992. “Treatment of water in domestic hot water central heating systems”.

This must involve the use of a proprietary cleanser, such as BetzDearborn Sentinel X300 or X400, Fernox Superfloc or Salamander System Cleanser. Full instructions are supplied with the products, but for immediate information please contact BetzDearborn (0044 (0)151 420 9563), Fernox (0044 (0)1799 550 811) or Salamander (0044 (0)121 378 0952) directly.

For long term protection against corrosion and scale, after flushing it is necessary that an inhibitor such as BetzDearborn Sentinel X100, Fernox MB-1 or Copal or Salamander System Inhibitor is dosed in accordance with the guidelines given in BS 7593:1992.

Failure to flush and add inhibitor to the system will invalidate the appliance warranty.

6.0 System Details

6.3 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.

3. For optimum operating conditions and maximum economy the fitting of the Baxi Intellistat, is recommended.

6.4 System Filling and Pressurising

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 10.5).

6.5 Expansion Vessel - CH only(Fig. 4)

1. The appliance expansion vessel is pre-charged to 1 bar (10 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”.

6.6 Pressure Relief Valve (Fig. 4 & 5)

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 be not 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

Fig. 5

Stop Valve

Double Check Valve

DHW Mains Inlet

CH Return

Temporary Hose

Discharge Pipe

Pressure Relief Valve

Expansion Vessel removed for clarity

Fig. 4

Expansion Vessel

Stop Valve

6.0 System Details

6.7 Domestic Hot Water Circuit

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

2.Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. for IE: the current edition of I.S. 813. "Domestic Gas Installations".

Sealed primary circuits and/or secondary hot water systems shall incorporate a means for accommodating the thermal expansion of water to prevent any discharge from the circuit and/or system, except in an emergency situation.

3.When the system includes any device which prevents water expanding back towards the supply (check valve, loose jumpered stopcock, water meter, water treatment device), then an expansion vessel must be fitted (e.g. Zilmet l6Oml, R1/2 l5 bar). A check valve must also be fitted on the supply as shown, to ensure efficient operation and also to prevent the reverse flow of hot water into the supply pipe.

4. 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.

5. The boiler’s maximum working mains pressure is 10 bar (150 lb/in

), 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.

6.8 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.

6.9 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.

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

1. The boiler may be fitted to any suitable nonflammable 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.

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 22mm copper tail located at the rear of the gas service cock.

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

smaller diameter than the boiler gas connection (22mm).

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.

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

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

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 (3/4in) 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. Any pipe fitted externally must not exceed 3 metres.

7. Any condensate discharge pipework external to the building (or in an unheated part of it e.g. garage) must be insulated to protect against frost. It is also recommended that the pipe diameter is increased to 32mm.

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

7.0 Site Requirements

J,K

D E

Likely flue positions requiring a flue terminal guard

J,K

7.7 Flue

NOTE: Due to the high efficiency of the boiler

a plume of water vapour will be discharged from the flue. Take into consideration the effect the plume of vapour may have on neighbours when siting the flue.

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. 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.

4. For installation of the flue into an internal corner at the 25mm dimension the flue deflector kit (part no. 248167) must be fitted.

5. * Reduction to the boundary is possible down to 25mm but the flue deflector kit (part no.

248167) must be fitted.

6. 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.

7. 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

Top View Rear 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. 1

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 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

7.0 Site Requirement

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 Boiler connection vertical concentric 242886

Clamp 80mm 238684

7.10 Flue options

Concentric The maximum equivalent lengths are 4m (horizontal) or 5m (vertical). These lengths exclude the standard elbow and flue/terminal assembly (horizontal) and terminal assembly (vertical).

Twin Flue The total maximum equivalent flue length is 40m. 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: 45º bend 0.5 m

93º bend 1.0 m

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

45º bend (flue duct) 2.6 m 90º bend (air duct) 4.8 m 90º 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).

A - Standard Flue

8.0 Installation

Check Site Requirements (section 7.0) before commencing.

Fitting an Extra Pump

To extract 100,000 Btu/hr from the boiler in central heating mode an extra pump will need to be fitted to increase flow. It must be fitted in parallel to the existing pump and in the return pipe. See Pages 24 & 25 for wiring details.

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 is to be pre-plumbed, follow

both these instructions and those on the boiler pack.

1. Remove the fixing template (Fig. 14) from the fixing carton.

2. Position the template on the wall ensuring it is level both horizontally and vertically.

3. Mark the position of the top centre hole for the wallplate.

4. Mark the condensate discharge pipe area.

5. Mark the centre of the flue hole (rear exit). For side exit, mark as shown. If required, mark the position of the gas and water pipes. Remove the template.

6. Cut the hole for the flue (minimum diameter 125mm) (see table opposite for wall thickness flue diameters).

7. Drill and plug the wall as previously marked. Secure the wallplate to the wall by the top centre hole.

8. Ensuring the wallplate is level both horizontally and vertically, drill and plug the remaining 4 securing positions at the top and bottom through the wallplate. Utilising the slots available ensure the wallplate is square and secure to the wall.

9. Connect the gas,water and the pressure relief discharge pipes to the valves on the support bracket using the copper tails supplied. Ensure the sealing washers are fitted correctly to the water connections.

10. Loosely route the condensate discharge pipe to the area previously marked.

8.2 Flushing

1. Insert a tube into the valve outlet furthest from the filling loop (Fig. 15).

2. Flush thoroughly (see System Details, Section

6.0).

Wall Thickness

up to 227mm

up to 750mm

up to 1200mm

Flue Hole ø

125mm core drill

150mm core drill

175mm core drill

Plastic Flushing Tube

Fig. 15

Fig. 14

Centre for dia 125mm (5") hole for wall thickness upto 227mm (9")

Centre for dia 150mm (6") hole for wall thickness 227mm (9") to 750mm (30")

Note: For each 1m of horizontal flue add 55mm of clearance

Centre line of flue at 3

General area for electrical supply

5mm Minimum clearance each side

Appliance outline

Gas Supply

Central Heating

Return

Central Heating

Flow

Cold Water

Inlet

Domestic Hot

Water Out

Condensate

Drain

Pressure

Relief

Combi 130 HE

TEMPLATE

Boiler

Centre Line

200mm Minimum Clearance

37.5mm Offset

The symbols for each connection are on the support bracket.

8.0 Installation

Fig. 16

Fig. 17

Outer Case Fixing Screw

Lower Door Panel

Service Guidance Note Label on inside of panel

8.3 Preparing The Boiler

1. Remove the outer carton.

2. Remove the lower door panel (Fig. 16).

3. Remove the outer case fixing screws (Fig. 16). Slide the outercase upwards to disengage the hooks on the backplate and remove (Fig. 17).

NOTE: Service Guidance Note Label is fitted to the inside of the outercase (Fig. 17).

4. Remove the sealing plugs from the copper bends.

5. Stand the boiler on its base by using the rear lower edge as a pivot.

NOTE: A small amount of water may drain from the boiler in the upright position.

Baxi declare that no substances harmful to health are contained in the appliance or used during construction of the appliance.

8.0 Installation

8.4 Fitting The Boiler (Fig. 18)

1. Remove the tape from the tap rail on the support bracket.

2. Lift the boiler using the lower edges of the combustion box.

3. Lift the boiler over the support bracket and engage onto the top hooks.

4. To gain access to the connections between boiler and valves, release the facia securing screws (

/4turn) and hinge down the facia box.

5. Make the connections in the following

sequence:

a) Gas connection first to centralise the boiler. The gas sealing washer is an integral part of the gas tap.

The Combi 130 HE is designed to operate under nominal water supply conditions. If the hot water delivery is greater than 18 litres/minute the flow regulator must be fitted to the Domestic Hot Water inlet (A pint milk bottle must fill in under 2 seconds).

b) Domestic hot water cold feed, if necessary fit the water flow regulator ensuring that it is fitted the correct way round (Fig. 20). NOTE: Ensure water inlet filter is fitted.

c) The remaining connections ensuring the fibre sealing washers are inserted between the valve outlet face and the flange on the copper pipes of the water circuit and pressure relief connections (Fig. 20).

6. Tighten the connections in the sequence listed above.

8.5 Condensate Drain (see section 7.6)

1. Connect the condensate drain using the 1” BSP nut and seal supplied.

Ensure the discharge of condensate complies with any national or local regulations in force (see British Gas “ Guidance Notes for the Installation of Domestic Gas Condensing Boilers”.

2. The condensate outlet terminates in a 1” BSP nut and seal for the connection of 21.5mm (

/4in)

plastic overflow pipe (See section 7.6 for details

of recommended condensate drain methods).

Top Hooks

Support Bracket

Facia Box

Facia Securing Screws

Gas Connection

Tap Rail

Fig. 18

Fig. 20

FLUE PRODUCTS EXHAUST

Tap Rail

Central Heating Return Filter

Fig. 19

Fibre Sealing Washer

Flow Regulator

Water Inlet Filter

Hot Water Outlet

Cold Water Inlet

Central Heating Flow

Central Heating Return

Pressure Relief

8.0 Installation

8.6 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

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 - 614mm Side Flue: maximum wall thickness - Right Hand 462mm,

Left Hand 537mm when installed with minimum side clearances of 5mm.

2. For rear exit - measure the wall thickness (Fig. 21) and to this dimension add 201mm. This dimension to be known as (X). i.e. (X) = wall thickness + 201mm

3. Take the flue and mark off (X) from the terminal end as indicated in the diagram (Fig. 22).

Check your dimensions.

The flue tubes are fixed together. Cut through both tubes whilst resting the flue on the semicircular packing pieces. Deburr both tube ends.

4. For left hand exit - measure the distance from the edge of the support bracket to the inner face of the wall (Fig. 21) and to this dimension add the wall thickness + 268mm. This dimension to be known as (Y). i.e. (Y) = support bracket to wall + wall thickness + 268mm

5. Take the flue and mark off (Y) from the terminal end as indicated (Fig. 22).

6. For right hand exit - measure the distance from the edge of the support bracket to the inner face of the wall and to this dimension add the wall thickness + 343mm. This dimension to be known as (Z). i.e. (Z) = support bracket to wall + wall thickness + 343mm

7. Take the flue and mark off (Z) from the terminal end as indicated (Fig. 22).

Check your dimensions.

The flue tubes are fixed together. Cut through both tubes whilst resting the flue on the semicircular packing pieces. Deburr both tube ends.

IMPORTANT: Check all measurements before cutting. When cutting ensure the cut does not interfere with the inner flue support bracket (Fig. 23).

360° Orientation

Inner Flue Support Bracket

Wall Thickness

Edge of Support Bracket to Wall

Wall Thickness

(Y) = Left Exit (Z) = Right Exit (X) = Rear Exit

Flue

Waste

Fig. 21

Fig. 22

Fig. 23

3°

(1 in 20)

Support Bracket

8.0 Installation

8.6 Fitting the Flue (Cont)

8. Ensure the inner flue support bracket is positioned in the flue (Fig. 24).

9. Engage the flue into the flue elbow using soap solution to ease the engagement ensuring the flue is assembled as shown (Fig. 25).

10. Place the gasket over the flue exit on the boiler (Fig. 25).

11. Slide the flue assembly through the hole in the wall. Ensure angled inner end slopes downwards (Fig. 26).

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

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

14. The flue trim should be fitted once the installation is complete and the flue secure (Fig. 26). Making sure the brickwork is dust free and dry apply a suitable mastic to the inside of the trim and press against the wall finish,

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

VERTICAL FLUEING

Only flues approved with the Baxi Combi 130 HE Boiler can be used.

For information on vertical flues consult the Baxi Combination Boilers Brochure or Notes for Guidance supplied with the vertical flue pack.

Gasket

Flue Trim

Inner Flue Support Bracket

Flue

Flue Elbow

Fig. 24

Fig. 26

Fig. 25

8.0 Installation

8.7 Making The Electrical Connections

WARNING: This appliance must be earthed.

1. A plug is supplied with the boiler and the electrical connection is at the rear left hand side of the unit.

2. Remove the electrical plug from the kit pack.

3. Connect L, N & E into the plug and connect it to the socket at the rear left at the bottom of the boiler.

4. Remove the metal shield from the kit pack and connect it over the plug (Fig. 26a).

5. If fitting an integral timer please refer to the instructions supplied with the kit.

8. Remove the electrical box cover and check the electrical installation for; earth continuity, short circuits, resistance to earth, correct polarity and fuse failure (see Section 8.13 Electrical System Checks).

9. Replace the electrical box cover and secure.

8.8 Connecting an External Timer

1. Undo the two screws securing the small electrical cover and remove (Fig. 27).

2. To connect an external timer switch circuit, remove the link wire between terminals 3 & 4 and connect the switch circuit (Figs. 28 & 29 or 29a).

3. A cable clamp is provided for incoming cables.

Filter

Isolator

N L

1LN2345

Filter

Isolator

N L

1LN2345

External Timer

Small Electrical Cover

Fig. 27

Fig. 28

Fig. 29

Optional Live Feed For An External Pump

L/N/E Cable Clamp

8-way Terminal Block

Mains Input

Fig. 26a

Filter

Plug

Metal Shield

Filter

Isolator

N L

1LN2345

External Timer

Mains Input

Optional Live Feed For An External Pump

Fig. 29a

Link Wire

8.0 Installation

8.9 Fitting a Room Thermostat

1. To fit a 2-wire thermostat, remove link and wire the thermostat switch between positions 1 & 2 (Figs. 30 or 31a). A cable clamp is provided for incoming cables.

8.10 Fitting a Baxi Intellistat

1. Refer to the Baxi Intellistat instructions.

2. The boiler installation parameters must be set to recognise that the Intellistat will operate in conjunction with the boiler (see section 10.6).

8.11 Fitting a Frost Thermostat

1. The frost thermostat is connected between positions 1 and 4 (Figs. 31 or 31a). Secure the incoming cable/s with the cable clamp and replace the cover.

8.12 Fitting an Additional Pump

1. To extract 100,000 Btu/hr from the boiler in central heating mode an additional pump will need to be fitted to the system. Connect pump Live to terminal 5 and use any available neutral.

8.13 Electrical System Checks

1. Earth Continuity Check: Isolate the appliance at mains supply. Using a multimeter set to ohm’s scale, test between any appliance earth point and the earth pin on the socket. The resistance should be less than 1ohm. If the resistance is greater than 1 then check all earth wires for continuity and ensure that all connections are clean and tight.

WARNING: If the resistance is still greater than 1ohm the fault still exists and it may be dangerous to work with the appliance live.

2. Short Circuit Check: Isolate the control system, set all switches and thermostats to calling for heat. Set the meter on ohm’s scale. Test from L to N on control system terminal block - if the resistance reads zero there is a short circuit.

3. Resistance to Earth Check: Isolate the control system, set all switches and thermostats to calling for heat. Set the meter on ohm’s scale. Test between L and E - the resistance should be greater than 1 mega ohm.

4. Polarity Check: If all the tests carried out so far are satisfactory, then reconnect the system to the mains supply. Set the meter on Volts AC scale (starting at the highest voltage).Test at terminals:

L and N - meter should read approx 240 Vac L and E - meter should read approx 240 Vac N and E - meter should read from 0 to 15 Vac

5. Fuse Check: Remove the fuse, and check resistance. There should be no resistance or maximum reading. If no reading is obtained change the fuse. Check fuse is 3A.

Filter

Isolator

N L

1LN2345

External

Timer

Room

Thermostat

Optional Live Feed For An External Pump

Fig. 30

Filter

Isolator

N L

1LN2345

Frost

Thermostat

Fig. 31

Optional Live Feed For An External Pump

Mains Input

Filter

Isolator

N L

1LN2345

External

Timer

Room

Thermostat

Optional Live Feed For An External Pump

Fig. 30a

Mains Input

Filter

Isolator

N L

1LN2345

Frost

Thermostat

Fig. 31a

Optional Live Feed For An External Pump

Mains Input

9.0 Electrical

9.1 Schematic Wiring Diagram

Primary Flow Switch

Fan Overheat Thermostat

Flow Overheat Thermostat

Condensate Tra p

DHW Flow Switch

Flow Thermistor

Return Thermistor

Baxi Intellistat Terminal Block

- s + Grey

Ribbon Cable

Display PCB

Fan PCB

DC Fan

Main PCB

Transformer

Flame Detection Electrode

Spark Electrodes

Programmer

Room

Thermostat

Mains Input

Fault Neon

Burner ON Neon

Pump

Diverter Valve

Gas Valve

Auxiliary

Pump Connection

(31.8kW CH Output)

IEC

Inlet Filter

g/y

Plug

Key To Wiring Colours b - Blue

bk - Black gr - Grey w - White br - Brown

r - Red g - Green g/y- Green/Yellow o - Orange y - Yellow

9.0 Electrical

9.2 Illustrated Wiring Diagram

Pump

Diverter Valve

Gas Valve

Fan PCB

Fan

Display PCB

Condensate Trap

Safety Thermostat

g/y

Flow Switch DHW

Flow Switch

Flow Thermistor

Return Thermistor

Fan Protection Thermostat

Transformer

Electrode

Sensing Electrode

g/y

Main PCB

Filter

Plug

Key To Wiring Colours b - Blue

bk - Black gr - Grey w - White br - Brown

r - Red g - Green g/y- Green/Yellow o - Orange y - Yellow

10.0 Commissioning the Boiler

10.1 Commissioning the Boiler

NOTE: The information shown on the display

is explained on the label on the inside of the lower door panel (see Fig. 48).

1. Open the cold feed to the boiler.

2. Open all hot water taps to purge the Domestic Hot Water Circuit.

3. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler (see Section 10.5 Filling the System).

4. Open the manual and automatic air vents (Fig. 32). To help purge the primary circuit turn the pump on & off several times by using the Summer/Winter button (Fig. 33) (ensure all external controls are turned on and calling for heat).

5. The system must be flushed in accordance with BS 7593 (see Section 6.2) and the flushing agent manufacturers instructions, further guidance can be obtained from BS 5449 Section

6. Refill the system and add inhibitor following the inhibitor manufacturer’s instructions. Vent air as described in section 10.1 paragraph 4.

7. Complete the label supplied with the inhibitor and attach to the inside of the boiler case. Detail of system treatment should be added for future reference.

8. Pressurise the system to 1.5 bar then close and disconnect the filling loop.

9. Turn the gas supply on and purge according to in GB BS 6891 and in IE IS 813 "Domestic Gas Installations".

10. Turn the gas service cock anticlockwise to the ON position and check for gas soundness up to the gas valve.

11. Run the system and check the boiler for correct operation.

12. After a period of 3 minutes and with all the system controls calling for heat, check that the gas pressure at the inlet tapping of the gas valve (Fig. 34) is greater than 14 mbar and the gas rate is no greater than 4.1m

/h.

IN OUT

Reset

Summer/Winter Button

Control Panel

Fig. 33

Automatic Air Vent

Manual Air Vent

Fig. 32

Gas Valve

DO NOT check gas pressure here

Inlet Gas Pressure Test Point

Fig. 34

Expansion Vessel removed for clarity

10.0 Commissioning the Boiler

10.2 Increasing Central Heating Output

To 100,000 Btu/hr

1. The boiler is factory set for a maximum output of 80,000 Btu/hr. The boiler will automatically vary its output to match the system load giving the most efficient use of gas and the most comfortable room temperature possible.

2. If the CH system requirement is greater than 80,000 Btu/hr then to increase the maximum output of the boiler to 100,000 Btu/hr proceed as follows:

a) While On or OF is shown on the display ie: no CH or DHW demand ongoing. Depress the “+” and “-” Temperature Control Buttons at the same time for 5 seconds. The display will show “18” (Fig. 35) where the “1” indicates that the installer parameter for range rating has been accessed and the “8” indicates that the boiler is presently set for a maximum Central Heating output of 80,000 Btu/hr.

b) Press the “+” Temperature Control Button twice so that the display shows “10” (Fig. 36) with the “0” indicating that the boiler is set for a maximum Central Heating output of 100,000 Btu/hr. 1 minute after the parameter has been set the display will revert to normal operation.

NOTE: The boiler will need to run in CH for 30 minutes after this is done to change to 100,000 Btu/hr. i.e. Turn all CH controls to max and ensure no DHW demand is activated, during this setting period. To extract 100,000 Btu/hr from the boiler an additional pump will need to be fitted to the system (see the electrical installation section of these instructions).

10.3 Switching Off The Intelligent Pre-

heat

1. The boiler includes an intelligent pre-heat feature. This feature ensures that the domestic hot water to the tap is pre-heated only when the user required domestic hot water the previous week. For example, if the user only requires hot water between 7.00am and 8.00am on Monday then the boiler will log this demand and then the next week will only pre-heat between 7.00am and

8.00am on Monday. During the first week of operation from power on no pre-heating will occur.

2. The pre-heat switches the boiler on for approximately 1 minute every 40 minutes whenever it is required.

3. The boiler is factory set with the pre-heat feature on. If it is required to disable this feature then depress the “+” and “-” Temperature Control Buttons at the same time for 5 seconds. The display will show “18 or 10” (Fig. 35 or 36). Press the Summer/Winter Mode Button marked ( ) and the display will show “21” (Fig. 37). The “2” indicates that the installer parameter for pre-heat has been selected. The “1” indicates that the pre-heat is switched on.

4. Press the “-” Temperature Control Button to change this to “20” (Fig. 38), with the “0” indicating that the pre-heat is switched off. One minute after the parameter has been set the display will revert to normal operation.

Reset

Fig. 35

Fig. 36

Fig. 37

Fig. 38

Temperature Control Buttons

Reset Button

10.0 Commissioning the Boiler

10.3 Switching Off Intelligent Pre-heat

(cont)

5. To switch the pre-heat feature back on depress the “+” and “-” Temperature Control Buttons at the same time for 5 seconds. The display will show “18 or 10” (Fig. 39).

6. Press the Summer/Winter Mode Button marked ( ) and the display will show “20” (Fig. 40). The “2” indicates that the installer parameter for pre-heat has been selected. The “0” indicates that the pre-heat is switched off. Press the “+” Temperature Control Button to change this to “21” (Fig. 41), with the “1” indicating that the pre-heat is switched on. 1 minute after the parameter has been set the display will revert to normal operation.

10.4 Switching On System Frost

Protection

1. The boiler has an automatic boiler frost protection feature which will bring the boiler on in Central Heating mode if the flow thermistor senses a temperature of less than 8° ±5°C and remain on until the temperature reaches 15° ±5°C. This feature is not adjustable.

2. The boiler also has a system frost protection feature. As supplied this feature is not activated. The system frost protection will switch the diverter valve to the Central Heating position and operate the pump every 4 hours. In conjunction with the boiler frost protection feature (which operates the burner) this will prevent frost damage to the system.

3. To switch the system frost protection on: depress the “+” and “-” Temperature Control Buttons at the same time for 5 seconds. The display will show “18 or 10” (Fig. 39).

4. Press the Summer/Winter Mode Button marked ( ) until the display shows “30” (Fig. 42). The “3” indicates that the installer parameter for system frost protection has been selected. The “0” indicates that the system frost protection is switched off. Press the “+” Temperature Control Button until the display shows “31” (Fig. 43). The “1” indicates that the system frost protection is switched on. 1 minute after the parameter has been set the display will revert to normal operation.

5. To switch the system frost protection off depress the “+” and “-” Temperature Control Buttons at the same time for 5 seconds. The display will show “18 or 10” (Fig. 39).

6. Press the Summer/Winter Mode Button marked ( ) until the display shows “31” (Fig. 43). The “3” indicates that the installer parameter for system frost protection has been selected. The “1” indicates that the system frost protection is switched on. Press the “-” Temperature Control Button until the display shows “30” (Fig. 42). The “0” indicates that the system frost protection is switched off. 1 minute after the parameter has been set the display will revert to normal operation.

Reset

Fig. 42

Reset

Temperature Control Buttons

Fig. 39

Reset

Fig. 40

Reset

Fig. 41

Fig. 43

Summer/Winter Mode Button

Temperature Control Buttons

Summer/Winter Mode Button

10.0 Commissioning the Boiler

10.5 Filling the System

1. When filling the system move the diverter valve to the central heating position as follows (to ensure

air is removed from manifold, wait until display shows

‘Of’):-

NOTE: If an additional pump has been fitted (see

Section 8.12) disconnect the wiring until the system is filled and fully vented.

2. With mains switched on to the boiler press the “+” and “-” Temperature Control Buttons at the same time for 5 seconds. The display will show “18 or 10” (Fig. 44).

3. Repeatedly press the Summer/Winter Mode Button marked ( ) until the display shows “40” (Fig. 45). The “4” indicates that the installer parameter for filling the system has been selected. The “0” indicates that the installer parameter for filling the system is switched off. Press the “+” Temperature Control Button so that the display shows “41” (Fig. 46). The “1” indicates that the installer parameter for filling the system is switched on. The diverter valve will now move to the central heating position and stay there until reset as below. Purge through manual air vent on boiler and radiators, ensure auto air vent is open and manually bleed pump before continuing with paragraph 4 (NOTE: The boiler will not fire until section 10.5 paragraph 4 has been carried out).

4. Press the “-” Temperature Control Button so that the display shows “40” (Fig. 45). The “0” indicates that the installer parameter for filling the system is switched off. The diverter valve will now return to normal operation.

The display will revert to normal operation 1 minute after the parameter has been set.

10.6 Switching on the Intellistat

1. For optimum efficiency, this boiler can be controlled by an optional control accessary, the Baxi Intellistat (Part No. 247495). To activate the Intellistat, the boiler installer parameter No 6 requires switching from “60” to “61” (Figs 47a & b).

2. With the Intellistat connected to the 3-way terminal block at the boiler and the mains switched on to the boiler, press the “+” and “-” Temperature Control Buttons at the same time for 5 seconds. The display will show “18” or “10”.

3. Press the Summer/Winter Mode Button marked ( ) until the display shows “60” (Fig. 47a). The “6” indicates that the installer parameter for switching on/off the Intellistat has been selected. The “0” indicates that this parameter is switched off. Press the “+” Temperature Control Button so that the display shows “61” (Fig. 47b). The “1” indicates that the installer parameter for activating the Intellistat is switched on. One minute after the parameter has been set, the display will revert to the normal operation.

NOTE: This parameter must only be selected when installed in conjunction with Baxi Intellistat, not when connected to any other room thermostat or programmer, otherwise the boiler will not function.

Reset

Temperature Control Buttons

Fig. 44

Fig. 45

Summer/Winter Mode Button

Temperature Control Buttons

Fig. 46

Reset

Temperature Control Buttons

Fig. 47

Temperature Control Buttons

Reset

Fig. 47a

Fig. 47b

Temperature Control Buttons

Summer/Winter Mode Button

11.0 Fitting the Outer Case

11.1 Fitting The Outer Case

1. Fit the outercase to the appliance ensuring

that the four slots in the side flanges align with the hooks on the chassis (Fig. 48).

2. Insert the two fixing screws into the sides of

the chassis (Fig. 49).

3. Locate the lower door panel on the studs on

the case (Fig. 49).

4. Instruct the user in the operation of the boiler

controls. Hand over both the Users Operating and Installation and Servicing Instructions, giving advice on the necessity of regular servicing.

5. Advise the user that a plume of vapour from

the flue terminal is normal, and that there is no need for concern.

6. Advise the user that if intelligent pre-heat is

on, pre-heating will not occur for the first week of operation.

7. Set the User preferences. See User Label on

lower door panel (Fig. 48) or user’s operating instructions (set CH/DHW temperatures).

8. Carefully read and complete all sections of

the “Benchmark” Installation, Commissioning and Service Record Log Book that are relevant to the appliance and installation. The details of the Log Book will be required in the event of any warranty work. The Log Book must be handed to the User for safe keeping and each subsequent regular service visit recorded.

9. For IE, it is necessary to complete a

“Declaration of Conformity” to indicate compliance to I.S. 813. An example of this is given in I.S. 813 “Domestic Gas Installations”. This is in addition to the “Benchmark” logbook.

Fig. 48

Fig. 49

Lower Door Panel

Outercase Fixing Screws

Lower Door Panel

User Label on back of Lower Door Panel

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.

Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended.

1. For reasons of safety and economy, it is recommended that the boiler is serviced annually.

2. After servicing, complete the relevant section of the “Benchmark” Installation, Commissioning and Service Record Log Book. This should be in the possession of the user.

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.

6. Release the four

/4turn screws securing the

air box door panel and remove the door (Fig. 51).

7. Disconnect the three lead terminals from the combustion box door taking note of their positions (Fig. 51).

8. Undo the four screws securing the combustion box door and remove the door (Fig. 52).

9. Visually check for debris/damage and clean or replace if necessary the following:

a) Burner (Fragile - handle with care). b) Heat exchanger fins. c) Fan compartment (Check also for condensate leaks). d) Insulation. e) Door seals. f) Electrodes. g) Check condensate trap for debris. NOTE: If

necessary remove the trap drain plug and place a vessel underneath to catch the condensate (care should be taken as this could be hot). Clean the trap and refit the drain plug.

h) Top of heat exchanger.

NOTE: General cleaning can be undertaken using a vacuum. However debris should only be gently blown off the burner skin due to its fragile nature.

10. Check system pressure is between 1 and 2.5 bar.

Flue Elbow

Lead Terminals

Fig. 51

Air Box Door Panel

Fig. 52

Combustion Box Door Panel

12.0 Servicing the Boiler

12.1 Annual Servicing (Cont)

NOTE: The information shown on the display

is explained on the label on the inside of the lower door panel (see Fig. 48).

12. To clean the heat exchanger and burner

proceed as follows:

a) Disconnect the electrical leads to the fan component protection sensor (Fig. 53).

b) Undo the two wing nuts to disconnect the fan (Fig. 53).

c) Remove the fan and disconnect the electrical supply to it (Fig. 53).

d) Remove the gas injector pipe from the gas valve (push-fit) (Fig. 53).

e) Undo the condensate trap securing nut, lock nut and the condensate drain pipe. Remove the condensate trap and disconnect the sensor leads (Fig. 54).

f) Remove the two screws securing the burner and remove the burner. Visually inspect the internal burner baffle for obstruction (Fig. 55).

NOTE: The burner skin is fragile - handle with care. Clean and if necessary replace the burner (Fig. 55).

g) Loosen the two screws retaining the heat exchanger support bracket and slide to the left to remove (Fig. 55).

h) Remove the four screws securing the heat exchanger/combustion box base and withdraw the base.

i) Lower the central insulation panels and check condition (Fig. 55). Replace the insulation pads if necessary.

j) Ensure the heat exchanger fins are clear of any obstruction, use a thin bladed tool to remove debris. The use of a torch at the heat exchanger top and a mirror held under the heat exchanger will aid observation of the heat exchanger fins.

k) Check condition of all seals.

l) Reassemble in reverse order, applying a suitable silicon based grease to “O” rings and seals - Greasil 4000 (Approved Silicone Grease).

12. Complete the relevant section of the

“Benchmark” Installation, Commissioning and Service Record Log Book and hand it back to the user.

Fig. 53

Burner

Fig. 54

Electrical Supply

Fig. 55

Wing Nuts

Protection Sensor Leads

Fan

Injector Pipe

Central Insulation Panel

Burner

Combustion Box Base

Heat Exchanger Support Bracket

Combustion Box Base Securing Screws

Burner Securing Screws

Lock Nut

Condensate

Trap

Condensate Drain Pipe

Securing Nut

Sensor

Leads

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.

Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended.

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

2. Isolate the water circuit and drain the system as necessary. There are 5 drain points:

a) Flow Valve b) Heat Exchanger Manifold c) Return Valve d) Cold Water Inlet e) Hot Water Outlet

NOTE: Do not use the Pressure Relief Valve to drain the circuit.

NOTE: When reassembling always fit new ‘O’ rings, ensuring their correct location on the spigot. Green “O” rings are used for gas joints and Black “O” rings for water joints. Use Greasil 4000 (Approved Silicone Grease).

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

The air vents, flowswitch, thermistor, safety thermostat and expansion vessel can be accessed after removal of the outer case.

13.2 Manual and Automatic Air Vent

(Fig. 57)

1. Drain the boiler.

2. Undo the manual air vent from the flow pipe or the automatic air vent from the return pipe and retain the sealing washer.

3. Remove the air vent.

4. Fit the new air vent and reassemble in reverse order.

Fig. 56

Heat Exchanger Manifold

Drain Point

Tube

Fig. 57

Automatic Air Vent

Sealing Washer

Manual Air Vent

13.0 Changing Components

13.3 Flowswitch (Fig. 58)

1. Drain the boiler

(see Section 13.1 paragraph 2 & 3).

2. It may be necessary to remove the expansion vessel (see Section 13.5).

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

4. Remove the two screws securing the flow switch to the boiler.

5. Disconnect the inline electrical connection.

6. Remove the flowswitch.

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

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

13.4 Flow or Return Temperature

Thermistors and Safety Thermostat

(Figs. 59 & 59a)

1. The procedure is the same for both the thermistors and the safety thermostat, although the components are not interchangeable.

2. Remove the electrical connections from the component.

3. Unscrew the component from the pipe.

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

13.5 Expansion Vessel (Fig. 60)

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

2. Loosen the securing screw at the base of the expansion vessel.

3. Whilst supporting the vessel undo the expansion vessel connection and retain the sealing washer.

4. Remove the expansion vessel.

5. Fit the new expansion vessel and reassemble in reverse order.

13.6 Re-pressuring Expansion vessel

1. The charge pressure is 1.0 bar.

2. Close the central heating flow and return isolating valves.

3. Drain the boiler

(see Section 13.1 paragraph 2 & 3).

4. The “Schraeder” valve is positioned centrally at the side of the appliance. Pressurise to 1.0 bar.

5. Open the isolating valves and recharge the system to between 1.0 bar and 2.5 bar. Vent the system as necessary.

Fig. 58

Flowswitch

Clip

Fig. 59

Fig. 60

Flow Pipe

Electrical Connections

Expansion Vessel

Expansion Vessel Securing Screw

Flow Thermistor (Red Body) Safety Thermostat (Black Body)

Expansion Vessel Connection

ReturnThermistor (Red Body)

Fig. 59a

13.0 Changing Components

The pump, 3-way diverter valve, pressure gauge, pressure relief valve, plate heat exchanger and DHW flow switch can be accessed after hinging down the facia box.

1. Release the facia securing screws (

/4turn)

and hinge down the facia box (Fig. 61).

13.7 Pump (Fig. 61)

1. If only the head needs replacing, a standard Grundfos UPS 15-60 pump head is interchangeable (see section 13.9 for details).

2. This must be switched to setting N

3 (Fig. 62).

13.8 Pump (Complete) (Fig. 63)

1. Drain the boiler

(see Section 13.1 paragraph 2 & 3).

2. Unplug the wiring harness from the pump.

3. Remove the four screws retaining the pump backplate to the hydraulic manifold. NOTE: Ensure nuts are not dislodged.

4. Remove the pump.

5. Fit the new pump and reassemble in reverse order.

13.9 Pump (Head Only) (Fig. 64)

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

2. Unplug the wiring harness from the pump.

3. Remove the four socket head screws securing the pump head and separate it from the housing.

4. Remove the screws retaining the pump electrical covers on the original and replacement heads.

5. From the replacement UPS 15-60 pump head remove the strain relief cable gland and discard.

6. Remove the plug connector from the old pump head and wire it into the UPS 15-60 pump head.

7. Replace the electrical cover to the new pump head and assemble with the electrical box at 6 o’clock to the housing.

8. Check that the pump has been switched to setting N

3 (Fig. 62) and reconnect the wiring

harness plug.

Fig. 61

Facia Box

Fig. 63

Facia Securing Screws

Fig. 62

Pump Setting

Fig. 64

Plug Connector

Hydraulic Manifold

Wiring Harness

Pump

Pump Head

Pump Electrical Cover

13.0 Changing Components

13.10 Three-Way Diverter Valve (Head

Only) (Fig. 65)

If only the head needs replacing:

1. Unplug the wiring harness from the 3-way diverter valve.

2.Depress the clip and revolve the head through 30° and remove.

3. Fit replacement head and reassemble in reverse order.

13.11 Three-Way Diverter Valve

(Complete) (Fig. 66)

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

2. Unplug the wiring harness from the 3-way diverter valve.

3. Remove the four socket screws retaining the 3-way valve.

4. Remove the 3-way valve.

5. Fit the new 3-way valve ensuring the gasket is in place and that the spigots are at the top to fit into the recesses on the manifold and reassemble in reverse order.

Fig. 65

Wiring Harness

Fits Here

Fig. 66

Clip

Three-Way Diverter Valve Head

Wiring Harness

Fits Here

Three-Way Diverter Valve

Spigot

Gasket

13.0 Changing Components

13.12 Pressure Gauge (Fig. 67)

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

2. Undo the nut retaining the capillary in the connection at the return pipe (Fig. 68).

3. Depress the two lugs on either side of the pressure gauge and feed through the bracket.

4. Fit new pressure gauge and reassemble in reverse order.

13.13 Pressure Relief Valve (Fig. 69)

1. The pressure relief valve is positioned on the hydraulic manifold at the back of the pump.

2. Drain the boiler

(see Section 13.1 paragraph 2 & 3).

3. Disconnect the union between the valve and the discharge pipe.

4. Slacken the screw retaining the valve.

5. Pull the valve upwards to disengage it.

6. Fit the new pressure relief valve and reassemble in reverse order.

Fig. 67

Lug

Pressure Gauge

Pressure Gauge Bracket

Fig. 68

Capillary

Return Pipe

Fig. 69

Pressure Relief Valve

Expansion Vessel removed for clarity

13.0 Changing Components

13.14 DHW Plate Heat Exchanger

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

2. Remove the four screws securing the plate heat exchanger to the manifolds (Fig. 70). NOTE: Ensure nuts are not dislodged from the manifolds.

3. Remove the plate heat exchanger cover (Fig. 71)

4. Remove the ’O’ rings from the manifolds and replace with new ‘O’ rings (Fig. 71).

5. Taking care not to displace the ‘O’ rings fit the new plate heat exchanger ensuring the nuts are retained in the manifolds.

6. Refit the plate heat exchanger cover.

13.15 DHW Flow Switch (Fig. 72)

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

2. Remove the DHW plate heat exchanger (see section 13.14).

3. Disconnect the inline electrical connection.

4. Remove the clip at right hand side of the flow switch.

5. Undo the DHW inlet connection.

6. Remove the flow switch assembly and undo the second clip.

7. Fit the new flow switch and reassemble in reverse order.

8. Ensure that both clips are fully inserted from the front.

9. Fit the DHW plate heat exchanger.

Fig. 70

Plate Heat Exchanger Securing Screws

Fig. 71

Plate Heat Exchanger Cover

‘O’ Rings

Fig. 72

Inline Electrical Connection

Clip

Flow Switch

Manifold to Pump

Clip

DHW Inlet Connection

Plate Heat Exchanger

13.0 Changing Components

The control, display and fan driver boards can be accessed on the removal of the main electrical box cover.

1. Release the facia securing screws (

/4turn) and

hinge down the facia box.

2. Remove the screws securing the main electrical box cover (Fig. 73) and rotate the cover upwards to gain access.

13.16 Control Board (Fig. 73)

1. Remove the screws securing the control board and disconnect the electrical connections noting their positions although they are one way fitting.

2. Fit the new control board and reassemble in reverse order.

13.17 Display Board (Fig. 73)

1. Remove control board as in 13.16.

2. Remove the screws securing the display board and disconnect the electrical connection.

3. Fit the new display board and reassemble in reverse order.

13.18 Fan Driver Board (Fig. 73)

1. Remove the screws securing the fan driver board and disconnect the electrical connections noting their positions.

2. Fit the new fan driver board and reassemble in reverse order.

13.19 Transformer (Fig. 74)

1. Remove the transformer connection from the control board (Fig. 73).

2. The transformer is mounted to the right of the combustion box.

3. Remove the two transformer mounting screws and remove the transformer.

4. Fit the new transformer and reassemble in reverse order.

Fig. 73

Fig. 74

Main Electrical Box Cover

Control Board

Transformer connected here

Transformer

Fan Driver Board

Display Board

Facia Box

Facia Securing Screws

Main Electrical Box Cover Removed For Clarity

13.0 Changing Components

The fan and venturi, gas valve, injector pipe, condensate trap, fan protection thermostat, 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. 75).

13.20 Spark and Sensing Electrodes

(Fig. 76)

1. Disconnect the leads to the electrodes noting their positions (left to right):

Spark - Opaque Lead Spark - Opaque Lead Sensing - White Lead

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 gaskets, reassemble in reverse order, ensuring the spark gap of 3.5mm ± 0.5mm is maintained.

13.21 Fan and Fan Protection Thermostat

(Fig. 77)

1. Remove the electrical connections to the fan protection thermostat on the fan.

2. Replacing the thermostat:- Unscrew the thermostat and replace with the new thermostat. Reassemble in reverse order.

3. Replacing the fan:- Remove the wing nuts securing the fan to the base of the combustion box.

4. Lower the fan and disconnect the electrical supply from the right hand rear of the fan. Remove the fan/venturi assembly.

5. Remove the two screws securing the venturi to the fan and remove the venturi together with the gasket.

6. Remove the fan protection thermostat and fix it to the new fan, together with the venturi and gasket.

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

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

Fig. 75

Air Box Door Panel

Fig. 76

Fig. 77

Combustion Box Door

Sensing Electrode

Spark Electrode

Fan Protection Thermostat (Black Body)

Electrical Supply

Wing Nuts

Protection Thermostat Leads

Fan

Injector Pipe

Spark Electrode Leads

Gaskets

Venturi

13.0 Changing Components

It is necessary to remove the fan before changing the injector pipe, condensate trap and gas valve (see section 13. 21).

13.22 Injector Pipe (Fig. 78)

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, applying Greasil 4000 (Approved Silicone Grease) to both “O” rings.

13.23 Gas Valve (Fig. 78)

1. Release the facia securing screws 1/4turn and hinge down the facia box.

2. Loosen nut at gas inlet pipe at tap rail.

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

4. Undo the screw and disconnect the electrical plug from the gas valve.

5. Remove the two gas valve securing screws from inside the air box holding the gas valve.

6. Remove the gas valve and inlet pipe from the airbox side.

7. Remove the four screws securing the gas inlet pipe to the valve and refit to the new valve.

8. Remove the aluminium spacer and its gasket and “O” ring from the gas valve.

9. Fit the aluminium spacer, “O” ring and its gasket to the new valve.

10. Fit the new gas valve and reassemble in reverse order. Test for gas soundness. Note: It is essential that these ensure gas soundness as they are under negative pressure.

13.24 Condensate Trap (Fig. 79)

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.

Fit the new condensate trap and reassemble in reverse order.

Fig. 78

Injector Pipe

Gas Valve Securing Screws

Boiler Side

Gas Valve

Gasket

Gas Pressure Pipe

‘O’ Ring

Aluminium Spacer

Electrical Plug

Gas Inlet Pipe Flange

Fig. 79

Lock Nut

Condensate

Trap

Condensate Drain Pipe

Securing Nut

Sensor

Leads

13.0 Changing Components

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. 21 & 13. 25).

1. Remove the combustion box door by undoing the four

/4turn securing screws.

13.25 Burner (Fig. 80)

WARNING: The burner skin is fragile:

(HANDLE WITH CARE)

1. Remove the two 8mm hex head screws securing the burner to the base of the combustion box.

2. Remove the burner carefully from the combustion box base, inspect gasket for damage, replace if necessary..

3. Fit the new burner and reassemble in reverse order.

13.26 Heat Exchanger

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

2. Remove the fan and condensate trap (see section 13.21 and 13.24).

3. Undo the screws securing the flow switch and return connections. Remove the flow switch and return connection (Fig. 81).

4. Undo the screws securing the heat exchanger manifold and remove the manifold (Fig. 82).

5. Undo the M6 Hex Headed bolt on the left hand side of the combustion box.

6. Undo the screws on the bracket supporting the heat exchanger and remove bracket.

7. Lift the heat exchanger assembly (Fig. 83) and rotate the bottom upwards whilst pulling it forwards out of the airbox.

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

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

Fig. 80

Securing Screws

Fig. 81

Burner

Flow Switch

Return Connection

Heat Exchanger Manifold

Fig. 82

Fig. 83

Heat Exchanger Assembly

Heat Exchanger Support Bolt

13.0 Changing Components

13.27 Heat Exchanger Insulation Pads

(Fig. 84)

1. Remove the fan and condensate trap (see section 13.21 and 13.24).

2. Remove the burner (see section 13. 25).

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

4. Remove the combustion box base.

5. Pull the central insulation panel down from the centre of the heat exchanger and remove the insulation pads.

6. Check combustion box seal for damage, replace if necessary.

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

Fig. 84

Central Insulation Panel

Lower Insulation Panel

Upper Insulation Panel

Burner

Combustion Box Base

Support Bracket

Burner Securing Screws

Combustion Box Base Securing Bolts

14.0 Short Parts List

Short Parts List

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

A E58 933 Flow Thermistor (Red) /

Return Thermistor 240670

C E58 912 Safety Thermostat (Black) /

Fan Protection 242235

D E06 059 Flow Switch Kit 242459

E DHW Flow Switch Kit 247502

F E58 989 Fan Driver PCB 239230

G E58 987 Control Board PCB 244878

H E58 991 Display PCB 244880

I Pump 240395

J E58 919 Transformer 247155

K E58 935 Diverter Valve Head 243341

L E58 913 Fan 246557

M Condensate Trap Kit 242485

N Gas Valve Kit 247222

O E58 900 Burner 245199

P Spark Electrode Kit 247215

Q Sensing Electrode Kit 249099

R Plate Heat Exch. Kit 247224

S E06 085 Inspection Window Assy 242484

T E06 097 Heat Exchanger Assy 242497

Display Blank ?

15.0 Fault Finding

Go to No Display

section of the fault

finding instructions.

Display Showing 00 ?

Check stats at top right

of boiler. Red wires go to

red stat, black wires to

black stat.Check integral

timer wires exit PCB

cover at right hand side

(not run over Main PCB).

Display Showing OF ?

Central Heating switched

off. To turn Central Heating

on press Summer/Winter

mode button.

Display Flashing L0

or Loud Ignitions ?

Go to Ignition Lockout

section of the fault

finding instructions.

Display Flashing

L2 or L3 ?

Go to Thermistor section

of the fault finding

instructions.

Display Flashing

L7 or L8 ?

Go to Dry-Fire section of

the fault finding

instructions.

Display flashing L9 ?

Go to Fan section of the fault finding instructions.

Display Flashing 41 ?

Press the - button. The

display will show 40 and

after 60sec will revert to

normal operation (the

boiler was set for filling

the Central Heating

circuit).

Display Flashing

Ld or LE ?

Go to Overheat

Lockout section of the

fault finding instructions.

YES

Display Flashing Lh ?

Replace Display PCB.

Display shows 13

continuously ?

Check if Live & Neutral to

boiler reversed or Live &

Neutral from boiler

electrical filter to boiler

terminal block reversed.

Otherwise Main PCB

faulty.

Display

repeatedly shows 21 for

10sec & then 26 for

3mins ?

Check if Live & Neutral

to boiler reversed.

Otherwise there is a

blockage in the central

heating system.

Is the Burner or Heat

Exchanger noisy ?

Go to Burner or Heat

Exchanger Noisy

section of the fault

finding instructions.

Central

Heating Run continues

after Room Stat

switches off ?

Check if Installer

Parameters set for 61

(Intellistat). If Intellistat not

fitted change to 60.

Burner

lights for 3sec then goes

straight to 25 (Pump

Overrun) ?

If Intellistat connected

check if Installer

Parameters set for 60

(Room Stat). If so

change to 61.

works OK, DHW works

but temperature is too

low ?

Check flow restrictor if

fitted. If fitted try smaller

flow restrictor. If still not

OK got to Domestic Hot

Water section of the fault

finding instructions.

CH works

but DHW does not ?

Go to Domestic Hot

Water section of the fault

finding instructions.

YES

Before performing fault finding carry out preliminary electrical checks for earth, continuity and polarity. See Section 8.13

YES

NOTE: The information shown on the display is

explained on the label on the inside of the outer case (see Fig. 17).

Display Flashing

LF or Lt ?

Go to Condensate Trap

or DHW Flow Switch

section of the fault

finding instructions.

YES

DHW works

but Central Heating

does not ?

Go to Central Heating

section of the fault

finding instructions.

YES

15.0 Fault Finding

240 V at A ?

Ensure that mains is

securely connected to

incoming plug and that

wiring from electrical filter

to boiler 8-way terminal

block is OK.

240 V at B ?

Check wiring from boiler

8-way terminal block to

PCB is OK.

Main PCB Fuse OK ?

Check for shorts on

Pump, Diverter Valve,

Fan and Gas Valve,

then replace fuse.

240 V at C ?

Replace Main PCB.

24Vac at D ?

Replace Transformer.

5Vdc at E ?

Replace Main PCB.

YES

Replace Display PCB.

No Display

Mains Input

Transformer

Burner On & Fault Neons

Pump

Diverter Valve

Gas Valve

Modem PCB

Room Thermostat

Flow & Return

Thermistors

Overheat

Thermostats

Flow Switches

Condensate Trap

Room Control

Display PCB

Fan

Prog

Prog R/S R/S

Extra

Pump

YES

15.0 Fault Finding

Is there gas at gas valve

inlet ?

Check isolation valve

and gas supply.

YES

Ignition Lockout

Reset Lockout.

When the Burner On light

is on, is there gas flow

(check at meter) ?

Unplug

Gas Valve,

is there 215 Vdc at F

when the Burner On light

is on ?

spark or flame detection

probe damaged ?

Have

boot lace seals

inside combustion box

door grown outwards so door

held away from

heat exchanger ?

the burner

damaged or the burner

gaskets missing/damaged or

the wrong burner

fitted ?

Replace Main PCB.

Set spark gap to

3.5mm.

Replace Gas Valve.

Trim back seals

Replace Burner or

burner Gaskets.

Rectify wiring and check

spades and receptacles

for a firm fit.

Replace PCB if fault

persists. Replace gas

valve.

YES

Remove Gas Valve & check

inlet filter for blockage.

Check gas feed pipe seals,

venturi gasket & fan seals

are fited and not damaged.

Otherwise incorrect gas

supply to boiler.

there at least

18mbar dynamic at gas

valve inlet ?

Gas Valve Plug (when unplugged)

there 240Vac at G

when the Burner On

light is on ?

Lead from PCB to Gas

Valve faulty.

spark gap between 3 and

4mm ?

Replace spark or flame

detection probe and

gaskets.

wiring from PCB

to spark probe & flame

detection probe OK & are

terminals tight ?

Mains Input

Transformer

Burner On & Fault Neons

Pump

Diverter Valve

Gas Valve

Modem PCB

Room Thermostat

Flow & Return

Thermistors

Overheat

Thermostats

Flow Switches

Condensate Trap

Room Control

Display PCB

Fan

YES

Remove blockage. If

bypass fitted to system pipework open up fully to prove operation of boiler.

15.0 Fault Finding

Fill system with water

and bleed out all air.

Replace PCB.

YES

Dry-Fire Fault (L7 or L8)

YES

Is the

system full of water ?

With

water flowing out of a

full open DHW tap, does

the Pump run ?

Wires from inline

connector to PCB

faulty.

Disconnect

primary flow switch

inline connector, with a tap

open, is there continuity

across flow switch ?

Remove blockage. Check flow switch operation after removing blockage before

replacing flow switch.

Remove

flow switch from boiler.

Is there a physical blockage

to the paddle within the

flow switch ?

Replace Flow Switch.

YES

Mains Input

Transformer

Burner On & Fault Neons

Pump

Diverter Valve

Gas Valve

Modem PCB

Room Thermostat

Flow & Return

Thermistors

Overheat

Thermostats

Flow Switches

Condensate Trap

Room Control

Display PCB

Fan

Unplug

the pump, is there 240V

at J?

Is there 240V at K?

Replace PCB.

Pump Fault (water in

pump housing

terminals ?).

Wiring from terminal

block to PCB faulty (or

water ingress).

With

water flowing out of

a fully open DHW tap, is

there continuity at L ?

Is there a

blockage in the system ?

YES

Plug from PCB to Pump (when unplugged)

15.0 Fault Finding

Replace Main PCB.

Wiring from Main PCB

to Fan PCB faulty.

YES

Fan (L9)

YES

Is there at

least 24Vdc at M ?

Replace Fan PCB.

YES

When

display shows 12 or 22,

is there at least

2Vdc at N ?

Is there at

least 24Vdc at O ?

Wiring from Fan PCB

to Fan faulty.

Is continuity

of all 5 wires from Fan

PCB to Fan OK ?

Replace Fan.

Does fan run ?

YES

Mains Input

Transformer

Burner On & Fault Neons

Pump

Diverter Valve

Gas Valve

Modem PCB

Room Thermostat

Flow & Return

Thermistors

Overheat

Thermostats

Flow Switches

Condensate Trap

Room Control

Display PCB

Fan

Fan PCB

When

display shows 12 or 22,

is there at least

2Vdc at P ?

Wiring from Main PCB

to Fan PCB faulty.

When

display shows 12 or 22,

is there at least

12Vdc at Q ?

Is there continuity from

R to S ?

Wiring from Fan PCB

to Main PCB faulty.

Replace Main PCB.

YES

RGW

Fan Connection

Fan PCB Connection

Key to Wire Colours

R - Red

Br - Brown

W - White

G - Green

B - Blue

15.0 Fault Finding

Replace stat.

Wiring from PCB to

thermostats faulty.

YES

Display flashing Ld ?

Disconnect

black stat on flow pipe.

When flow < 60° C, is there

continuity across stat ?

Flow Temperature Overheat Lockout (Ld) or Fan Temperature Overheat Lockout (LE)

Replace PCB.

Reconnect

stat. Disconnect 9-way

PCB connector. Is there

continuity across T ?

YES

Replace stat.

Wiring from PCB to

thermostats faulty.

YES

Display flashing LE ?

Disconnect

Fan Stat.

When Fan temperature < 60° C,

is there continuity

across stat ?

Replace PCB.

Reconnect

stat. Disconnect 9-way

PCB connector. Is there

continuity across U ?

YES

Are Boot

Lace seals holding door

away from heat

exchanger ?

Trim seals back.

Replace door seals if

damaged.

YES

15.0 Fault Finding

Clear blockage and dry

sensors. Fit secondary

trap and air break if

connected to internal

stack/soil pipe.

Disconnect drain and run

boiler to prove. If fault

persists change

condensate trap faulty.

Wires from Main PCB

to condensate trap

faulty.

YES

Display flashing LF ?

Replace PCB.

Condensate Trap

blocked or water on

terminals ?

Unplug

9-way PCB connector.

Is there continuity from

V to earth ?

YES

Condensate Trap (LF) or DHW Flow Switch (Lt)

Unblock DHW Flow

Switch.

YES

Display flashing Lt ?

Replace DHW Flow

Switch.

DHW Flow Switch

blocked ?

Unplug

9-way connector from

PCB. With all DHW taps off

is there continuity across

W ?

YES

Replace PCB.

Display flashing L2 ?

Replace Flow

Thermistor.

Unplug

flow thermistor, is

thermistor resistance

between 0.5kΩ

and 20kΩ ?

Wiring from PCB to

Flow Thermistor faulty.

Return Thermistor (L3) or Flow Thermistor (L2)

Replace PCB.

YES

Reconnect

thermistor Unplug 7-way PCB connector. Is resistance at H between

0.5kΩ & 20kΩ?

Display flashing L3 ?

Replace Return

Thermistor.

Unplug

return thermistor, is

thermistor resistance

between 0.5kΩ

and 20kΩ ?

Wiring from PCB to

Return Thermistor

faulty.

Replace PCB.

YES

Reconnect

thermistor Unplug

7-way PCB connector. Is

resistance at I between

0.5kΩ & 20kΩ?

YES

Unblock filter or

incoming gas pipe.

Purge out before

reconnecting to boiler.

YES

Tighten Fan

connections.

YES

Replace Fan

connection seal.

YES

Tighten Burner

connections.

YES

Fit new Burner Seal.

YES

15.0 Fault Finding

YES

Is the

noise coming from the

burner ?

Replace Burner.

Is the Burner damaged ?

YES

Burner or Heat Exchanger Noisy

Is the

Burner Seal missing or

damaged ?

Is the

Burner loose ?

Is the

Fan connection seal

damaged ?

Is the

Fan loose ?

Are Gas feed

pipe O rings

damaged ?

Gas Valve inlet

filter or incoming gas pipe

partially blocked ?

Smear new O rings with

silicon grease before

fitting and ensure

positive location in Gas

Valve/Venturi.

Change Gas Valve and

Venturi.

YES

Recharge Expansion

Vessel to correct

pressure (1 bar

nominal).

YES

Is the

noise coming from the

heat exchanger ?

Ensure that there is no

air in the heat

exchanger or system.

Is the

Heat Exchanger still

noisy ?

Is the

Expansion Vessel

charged (1 bar nominal) ?

Add extra inhibitor to

system.

Flush out system, add

inhibitor again and

ensure all air removed.

YES

15.0 Fault Finding

Replace PCB.

YES

Set to

summer mode

(display shows Of).

With water flowing out of a fully

open DHW tap does

display show

Of ?

Is there 240V

from B to D ?

Diverter Valve faulty.

YES

DHW Fault

Mains Input

Transformer

Burner On & Fault Neons

Pump

Diverter Valve

Gas Valve

Modem PCB

Room Thermostat

Flow & Return

Thermistors

Overheat

Thermostats

Flow Switches

Condensate Trap

Room Control

Display PCB

Fan

Diverter Valve Plug (when unplugged)

YES

Unplug

9-way connector

from PCB. With water flowing

out of a fully open DHW tap is

there continuity

across A ?

Unplug

DHW F/S inline connector. With water flowing out of a fully open tap is there

continuity across

A ?

Is DHW Flow Switch

blocked ?

Replace DHW Flow

Switch.

Wiring from PCB to Flow Switch faulty.

Unblock DHW Flow

Switch.

Unplug

Diverter Valve.

With water flowing

out of a fully open DHW tap is

there 240V from

B to C ?

Unplug

4-way PCB

connector. With water flowing

out of a fully open DHW tap is

there 240V from

E to F ?

Replace PCB.

Wiring from PCB to

Diverter Valve faulty.

Unplug

4-way PCB connector. With water flowing out of a fully open DHW tap is

there 240V from

F to G ?

Wiring from PCB to

Diverter Valve faulty.

PCB faulty.

YES

15.0 Fault Finding

Is there an Intellistat

connected to the boiler ?

Is there 240V from

Neutral to H ?

PCB faulty.

Is there 240V from

Neutral to I ?

Is there 240V from

Neutral to J ?

Check Programmer &

Programmer wiring OK.

Is there 240V from

Neutral to K ?

Wiring from Prog 2 to

R/S 1 faulty.

Is there 240V from

Neutral to L ?

Check Room Stat &

Room Stat wiring OK.

YES

Central Heating

Wiring from PCB to

Prog 1 faulty.

Mains Input

Transformer

Burner On & Fault Neons

Pump

Diverter Valve

Gas Valve

Modem PCB

Room Thermostat

Flow & Return

Thermistors

Overheat

Thermostats

Flow Switches

Condensate Trap

Room Control

Display PCB

Fan

Is there 240V from

Neutral to M ?

Wiring from R/S 2 to

PCB faulty.

Unplug

Diverter Valve.

Ensure all DHW taps are off.

Is there 240V from N to P &

from O to P ?

Diverter Valve faulty.

Is there 240V from

Q to R & from R to S ?

Wiring from PCB to

Diverter Valve faulty.

Go to Intellistat

section of the fault

finding instructions.

PCB faulty.

YES

R S

Prog

1 2 1 2

Prog R/S R/S

Extra

Pump

Diverter Valve Plug (when unplugged)

KJI

15.0 Fault Finding

YES

there a Sun

symbol near the bottom

right of the Intellistat

display ?

Intellistat

Hinge

down the flap below

the Intellistat display. Press

the Intellistat Reset Button. Is

the display still

blank ?

Is there 5V from

D to F ?

Wiring from boiler to

Intellistat faulty.

PCB faulty.

YES

Is the Intellistat

display blank ?

Is there 5V from

A to B ?

With the hinge down flap located below the display

in the shut position,

press the right arrow

button on the Intellistat

until the Sun symbol appears and read the Intellistat instructions.

Is the

temperature in the

middle of the display at least

2° C less than the temperature

at the top of the

display ?

Turn the knob at the

bottom right of the

Intellistat fully clockwise

and read the Intellistat

instructions.

Is there at least 4Vdc

from E to F ?

Is there continuity from

C to E ?

Wiring from boiler to

Intellistat faulty.

Unplug

Diverter Valve.

Ensure all DHW taps are off.

Is there 240V from G to I &

from H to I ?

Diverter Valve faulty.

Is there 240V from

J to K & from J to L ?

Wiring from PCB to

Diverter Valve faulty.

PCB faulty.

Mains Input

Transformer

Burner On & Fault Neons

Pump

Diverter Valve

Gas Valve

Modem PCB

Room Thermostat

Flow & Return

Thermistors

Overheat

Thermostats

Flow Switches

Condensate Trap

Room Control

Display PCB

Fan

Diverter Valve Plug (when unplugged)

FED

Terminal Block

in Boiler

Intellistat

Terminal Block

CBA

YES

16.0 Operational Flow Chart

16.1 Domestic Hot Water Mode

Purge done and DHW

Flow Switch Off and

Flow temp above set

point.

PURGE

Pump on

Fan on

Purge done & primary Flow

Switch made & DHW temp

below set point.

DHW Flow Switch on

or Flow temp below

preheat level.

OFF

(Overrun done & DHW

Flow Switch off) or

(DHW Flow Switch off

& Flow temp ≥ 55°C).

DHW OVERRUN

Pump on

DHW Flow Switch on &

DHW temp below set

point.

(DHW Flow Switch off &

Flow temp below 55°C & Flow temp above preheat level) or DHW temp 10°C

above set point

IGNITION

Pump on

Fan on

Spark Generator on

Gas Valve on

Flame detected

STABILISATION

Pump on

Fan on

Gas Valve on

Stabilisation done

DHW RUN

Pump on

Fan speed variable

Gas Valve on

DHW Flow Switch off &

Flow temp above 55°C

16.0 Operational Flow Chart

16.2 Central Heating Mode

Pump Overrun done or

primary Flow Switch

not made.

WAIT FOR DIVERTER

VALVE TO MOVE

Diverter Valve on

Diverter Valve moved

Programmer on &

Room Thermostat on &

Anticycle done

OFF

Programmer off or

Room Thermostat off

or Flow temp above

set point

CH RUN

Diverter Valve on

Pump on

Fan Speed Variable

Gas Valve on

Programmer on &

Room Thermostat on &

Flow temp below set point & primary Flow

Switch made

PUMP OVERRUN

Diverter Valve on

Pump on

PURGE

Diverter Valve on

Pump on

Fan on

Purge done

IGNITION

Diverter Valve on

Pump on

Fan on

Spark Generator on

Gas Valve on

Primary Flow Switch

not made

Flame detected

CH STABILISATION

Diverter Valve on

Pump on

Fan on

Gas Valve on

Stabilisation done

Comp No245736 - Iss 04 - 11/03

BAXI POTTERTON

A Trading Division of Baxi Heating UK Ltd

Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www.baxi.co.uk

company

Baxi Combi 130 HE Quick Start Manual

Specifications and Main Features

Frequently Asked Questions

User Manual