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

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Page 1

Baxi Combi 133 HE Plus

Baxi Combi 100 HE Plus

Baxi Combi 80 HE Plus

Gas Fired Wall Mounted Condensing

Combination Boiler

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

Installation & Servicing Instructions

Page 2

Natural Gas

Baxi Combi 133 HE Plus

G.C.No47 075 14

Baxi Combi 100 HE Plus

G.C.No47 075 15

Baxi Combi 80 HE Plus

G.C.No47 075 16

Baxi is a BS-EN ISO 9001

Accredited Company

This product has an energy rating (A) on a scale of A to G.

For more information see www.boilers.org.uk. This is a certification mark.

Building Regulations and the Benchmark Commissioning Checklist

Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly. Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006.

CORGI operate a Self Certification Scheme for gas heating appliances.

These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook (which was then left on site with the customer).

With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn. However, a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions.

This company is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

Building Regulations require that installations should comply with manufacturer's instructions. It is therefore important that the commissioning checklist is completed by the installer. The relevant section of Building Regulations only relates to dwellings. Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure.

The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations.

© Baxi Heating UK Limited 2005 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988.

Applications for the copyright owner’s permission to reproduce or make other use of any part of this publication should be made, giving details of the proposed use, to the following address:

The Company Secretary, Baxi Heating UK Limited, Pentagon House, Sir Frank Whittle Road, Derby, DE21 4XA.

Full acknowledgement of author and source must be given.

WARNING: Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages.

The code of practice for the installation,

commissioning & servicing of central

heating systems.

“Baxi” supports

Page 3

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Competent Person's

Self Certification Scheme

Install and Commission this appliance to manufacturer's

instructions

Complete the

Benchmark Checklist

If you notify via CORGI Scheme,

CORGI will then notify the

relevant Local Authority

Building Control Scheme

on member's behalf

Building Control

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact a government approved

inspector

Install and Commission this appliance to manufacturer's

instructions

Scheme Members only

Call CORGI on: 0870 88 88 777

or log onto:

www.corgi-notify.com

within 10 days

You must ensure that the

notification number issued by

CORGI is written onto the

Benchmark Checklist

CORGI will record the data and

will send a certificate of

compliance to the property

Complete the

Benchmark Checklist

LABC will record the data

and will issue a

certificate of compliance

Page 4

Legislation

Baxi declare that no substances harmful to health are

contained in the appliance or used during appliance

manufacture.

The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force, and only used in a suitably ventilated location.

In GB, the installation must be carried out by a CORGI Registered Installer. It must be carried out in accordance with the relevant requirements of the:

• Gas Safety (Installation & Use) Regulations.

• The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland).

• The Water Fittings Regulations or Water Byelaws in Scotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent person and installed in accordance with the current edition of I.S. 813 ‘Domestic Gas Installations’, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

All systems must be thoroughly flushed and treated with inhibitor (see section 6.1).

IMPORTANT - Installation, Commissioning, Service & Repair

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

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

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

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

Lifting - This product should be lifted and handled by two people. For recommended hand holds see section 8.4. Stooping should be avoided and protective equipment worn where necessary. Carrying & lifting equipment should be used as required, e.g. when installing in a loft space.

The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty. In GB this could also infringe the Gas Safety (Installation and Use) Regulations.

Warning - Check the information on the data plate is compatible with local supply conditions.

All CORGI registered installers carry a CORGI identification card and have a registration number. You can check your installer is registered by telephoning 0870 4012300 or writing to:-

1 Elmwood,

Chineham Business Park,

Crockford Lane,

Basingstoke. RG24 8WG

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

Codes of Practice, most recent version should be used

In GB the following Codes of Practice apply: Standard Scope

BS 6891 Gas Installation. BS 5546 Installation of hot water supplies for domestic

purposes. BS 5449 Forced circulation hot water systems. BS 6798 Installation of gas fired hot water boilers. BS 5440 Part 1 Flues. BS 5440 Part 2 Ventilation. BS 7074 Expansion vessels and ancillary equipment for

sealed water systems. BS 7593 Treatment of water in domestic hot water

central heating systems.

In IE the following Codes of Practice apply: Standard Scope

I.S. 813 Domestic Gas Installations. The following BS standards give valuable additional information; BS 5546 Installation of hot water supplies for domestic

purposes. BS 5449 Forced circulation hot water systems. BS 7074 Expansion vessels and ancillary equipment for

sealed water systems. BS 7593 Treatment of water in domestic hot water

central heating systems.

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations 1993 N

3083” and is deemed to meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by: Notified Body 0087.

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

For GB/IE only.

Page 5

1.0 Introduction 6

2.0 General Layout 7

3.0 Appliance Operation 8

4.0 Technical Data 9

5.0 Dimensions and Fixings 12

6.0 System Details 13

7.0 Site Requirements 16

8.0 Installation 22

9.0 Electrical 29

10.0 Commissioning the Boiler 31

11.0 Fitting the Outer Case 35

12.0 Servicing the Boiler 36

13.0 Changing Components 38

14.0 Short Parts List 49

15.0 Fault Finding 50

16.0 Operational Flow Chart 60

Benchmark Checklist 62

Section Page

Contents

Page 6

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

1.1 Description

1. The Baxi Combi HE Plus Range are fully automatic gas fired wall mounted condensing combination boilers. They are room sealed and fan assisted, and will serve central heating and mains fed domestic hot water.

2. The boiler is preset to give a maximum output of 23.9 kW (81,500 Btu/h) for central heating and (39.0 kW (133,000 Btu/h) 133 model) (30.2 kW (102,000 Btu/h) 100 model) (23.9 kW (81,500 Btu/h) 80 model) for hot water. In central heating mode the boiler will automatically adjust down to (10.6 kW (36,000 Btu/h) 133 model) 9.1 kW (31,000 Btu/h) 100 & 80 models) according to system load.

3. They are designed for use on Natural Gas (G20) only.

4. The boilers are suitable for use only on fully pumped sealed heating systems. Priority is given to domestic hot water.

5. A label giving details of the model, serial number and Gas Council number is situated on the rear of the lower door panel (Fig. 1).

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

7. The boilers are intended to be installed in residential / commercial / light industrial E.M.C. environments on a governed meter supply only.

8. The boilers must be installed with one of the purpose designed flues such as the standard horizontal flue kit, part n

236921.

1.2 Important Information

Man-made mineral fibre

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

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

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

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

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

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

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

1.0 Introduction

Fig. 1

Fig. 2

Lower Door Panel

Air Box Door

Data Badge

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

Label

Page 7

2.0 General Layout

2.1 Layout

1. Wallplate

2. Flue Elbow

3. Air Box

4. Heat Exchanger

5. Burner

6. Fan Protection Thermostat

7. Fan Assembly

8. DHW Plate Heat Exchanger

9. Three Way Valve

10. Facia Box

11. Water Pressure Gauge

12. Gas Tap

13. Circulation Pump

14. Pressure Relief Valve

15. Return Thermistor

16. Gas/Air Ratio Valve

17. PCB

18. Flow Temperature Safety Thermostat

19. Flow Temperature Thermistor

20. Manual Air Vent

21. Automatic Air Vent

22. Flow Switch (Dry Fire Protection)

23. Condensate Trap

24. Expansion Vessel

2.2 Optional Extras

KIT PART N

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

(Use two kits for 2M etc.) 241695

Flue Bend - 45°

(Reduce overall length of flue

by 0.5m when fitting this bend)

241689

Flue Bend - 90° (

Reduce overall length of flue

by 1m when fitting this bend)

241687

Horizontal Extended Flue (1.75M) 5111457

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

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

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

Filling Loop Kit 5111095

Plume Displacement Kit 5117383

Expansion Vessel removed for clarity

Page 8

3.0 Appliance Operation

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

3.1

Central Heating Mode

1. With a demand for heating, the pump circulates water through the primary circuit. At a flow rate of approximately 4.5 l/min the central heating flow switch operates, initiating the ignition sequence.

2. The main burner ignites at a low rate, then the fan/gas valve and proportionator control the gas rate to maintain the heating temperature measured by the thermistor sensor.

3. When the flow temperature exceeds the set temperature, a 1 minute pump overrun occurs followed by 3 minutes anticycle. If the flow temperature is low enough the burner will then relight automatically otherwise pump overrun and anticycle will occur again.

4. When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 1 minute (Pump Overrun).

3.2 Domestic Hot Water Mode

1. Priority is given to the domestic hot water supply. A demand at a tap or shower will override any central heating requirement.

2. The flow of water will operate the DHW flow switch and the 3-way valve will change position. This will allow the pump to circulate the primary water through the DHW plate heat exchanger.

3. The burner will light automatically and the temperature of the domestic hot water is controlled by the return thermistor.

4. When the domestic hot water demand ceases the burner will extinguish and the diverter valve will remain in the domestic hot water mode, unless there is a demand for central heating.

3.3 Boiler Frost Protection

1. The boiler incorporates an integral frost protection feature. It will operate in both summer and winter modes. If the boiler temperature falls below 8°C (± 5°) then the boiler will fire until a temperature of 15°C (± 5°) is reached.

3.4 Pump Protection

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

Page 9

4.0 Technical Data

Flue Terminal Diameter 110mm Dimensions Projection 150mm

Outercase Dimensions

Casing Height - 850mm Overall Height Inc Flue Elbow - 1000mm Casing Width - 490mm Casing Depth - 320mm

Clearances

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

Weights kg lb Packaged Boiler Carton 58.2 128.3 Packaged Flue Kit 3.8 8.4 Weight Empty 53.2 117.3 Installation Lift Weight 44.4 98

Central Heating Primary Circuit Pressures

bar lb/in

Safety Discharge 3 43.5 Max Operating 2.5 36.3 Min Operating 0.7 10.2 Recommend Operating 1-2 14.5-29

DHW Circuit bar lb/in

Pressures

Max Operating 10 145 Min Operating 0.1 1.45

Min Operating Pressure at 16 l/min 1.6 23.2

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

DHW Flow Rate @ 35o C Rise 16 3.52

Min Working DHW Flow Rate 1.9 0.43

Pump

Available Head See graph below

Expansion Vessel - (For Central Heating only. Integral with appliance)

bar lb/in

Min Pre-charge Pressure 0.95 13.8

Nominal Pre-charge Pressure 1 14.5

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

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

Recommended System Temperature Drop

Condensing 20°C

Temperatures

C.H. Flow Temp (adjustable)

55° C to 82° C max (± 0.5° C)

D.H.W. Flow Temp (adjustable)

45° C to 55° C max (± 0.5° C) dependent upon flow rate

Heat Input Gross DHW Max

kW 45.45

Btu/h 155,000

Heat Output CH

Non Condensing (70°C Mean Water temp)

Max Factory Set

kW 30.0 23.9

Btu/h 102,000 81,500

Condensing (40°C Mean Water temp)

Max Factory Set

kW 31.4 25.1

Btu/h 107,000 85,600

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption 200W

External Fuse Rating 3A

Internal Fuse Rating 3.15A

Appliance Category CAT I

Max Gas Rate (Natural Gas)

(After 10 Mins)

m3/h 4.2

ft3/h 148.3

Inlet Pressure (Natural Gas)

mbar 20

in wg 8

Appliance Type C

NOxClass 5

DHW Expansion Vessel

See Section 6.6 for information

The efficiency is 90.7 %

This value is used in the UK Government’s

Standard Assessment Procedure (SAP) for energy

rating of dwellings. The test data from which it has

been calculated has been certified by 0086.

SEDBUK Declaration For

Combi 133 HE Plus

Heat Input Gross CH

Max Factory Set

kW 33.7 26.95

Btu/h 115,000 92,000

CO/CO2Ratio 0.002

4.1 Combi 133 HE Plus

Electrical Protection IPX4

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Page 10

4.0 Technical Data

Flue Terminal Diameter 110mm Dimensions Projection 150mm

Outercase Dimensions

Casing Height - 850mm Overall Height Inc Flue Elbow - 1000mm Casing Width - 490mm Casing Depth - 320mm

Clearances

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

Weights kg lb Packaged Boiler Carton 58.2 128.3 Packaged Flue Kit 3.8 8.4 Weight Empty 53.2 117.3 Installation Lift Weight 44.4 98

Central Heating Primary Circuit Pressures

bar lb/in

Safety Discharge 3 43.5 Max Operating 2.5 36.3 Min Operating 0.7 10.2 Recommend Operating 1-2 14.5-29

DHW Circuit bar lb/in

Pressures

Max Operating 10 145 Min Operating 0.1 1.45

Min Operating Pressure at 12 l/min 0.54 7.83

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

DHW Flow Rate @ 35o C Rise 12 2.64

Min Working DHW Flow Rate 1.9 0.43

Pump

Available Head See graph below

Expansion Vessel - (For Central Heating only. Integral with appliance)

bar lb/in

Min Pre-charge Pressure 0.95 13.8

Nominal Pre-charge Pressure 1 14.5

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

Recommended System Temperature Drop

Condensing 20°C

Temperatures

C.H. Flow Temp (adjustable)

55° C to 82° C max (± 0.5° C)

D.H.W. Flow Temp (adjustable)

45° C to 55° C max (± 0.5° C) dependent upon flow rate

Heat Input Gross DHW Max

kW 33.7

Btu/h 115,000

Heat Output CH

Non Condensing (70°C Mean Water temp)

Max Factory Set

kW 30.0 23.9

Btu/h 102,000 81,500

Condensing (40°C Mean Water temp)

Max Factory Set

kW 31.4 25.1

Btu/h 107,000 85,600

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption 200W

External Fuse Rating 3A

Internal Fuse Rating 3.15A

Appliance Category CAT I

Max Gas Rate (Natural Gas)

(After 10 Mins)

m3/h 3.1

ft3/h 110.0

Inlet Pressure (Natural Gas)

mbar 20

in wg 8

Appliance Type C

NOxClass 5

DHW Expansion Vessel

See Section 6.6 for information

The efficiency is 90.8 %

This value is used in the UK Government’s

Standard Assessment Procedure (SAP) for energy

rating of dwellings. The test data from which it has

been calculated has been certified by 0086.

SEDBUK Declaration For

Combi 100 HE Plus

Heat Input Gross CH

Max Factory Set

kW 33.7 26.95

Btu/h 115,000 92,000

CO/CO2Ratio 0.002

4.2 Combi 100 HE Plus

Electrical Protection IPX2

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Page 11

4.0 Technical Data

Flue Terminal Diameter 110mm Dimensions Projection 150mm

Outercase Dimensions

Casing Height - 850mm Overall Height Inc Flue Elbow - 1000mm Casing Width - 490mm Casing Depth - 320mm

Clearances

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

Weights kg lb Packaged Boiler Carton 58.2 128.3 Packaged Flue Kit 3.8 8.4 Weight Empty 53.2 117.3 Installation Lift Weight 44.4 98

Central Heating Primary Circuit Pressures

bar lb/in

Safety Discharge 3 43.5 Max Operating 2.5 36.3 Min Operating 0.7 10.2 Recommend Operating 1-2 14.5-29

DHW Circuit bar lb/in

Pressures

Max Operating 10 145 Min Operating 0.1 1.45

Min Operating Pressure at 10 l/min 0.39 23.2

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

DHW Flow Rate @ 35o C Rise 10 2.20

Min Working DHW Flow Rate 1.9 0.43

Pump

Available Head See graph below

Expansion Vessel - (For Central Heating only. Integral with appliance)

bar lb/in

Min Pre-charge Pressure 0.95 13.8

Nominal Pre-charge Pressure 1 14.5

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

Recommended System Temperature Drop

Condensing 20°C

Temperatures

C.H. Flow Temp (adjustable)

55° C to 82° C max (± 0.5° C)

D.H.W. Flow Temp (adjustable)

45° C to 55° C max (± 0.5° C) dependent upon flow rate

Heat Input Gross DHW Max

kW 26.95

Btu/h 92,000

Heat Output CH

Non Condensing (70°C Mean Water temp)

Max

kW 23.9

Btu/h 81,500

Condensing (40°C Mean Water temp)

Max

kW 25.1

Btu/h 85,600

Electrical Supply 230V~ 50H

(Appliance must be connected to an

earthed supply)

Power Consumption 200W

External Fuse Rating 3A

Internal Fuse Rating 3.15A

Appliance Category CAT I

Max Gas Rate (Natural Gas)

(After 10 Mins)

m3/h 2.5

ft3/h 87.9

Inlet Pressure (Natural Gas)

mbar 20

in wg 8

Appliance Type C

NOxClass 5

DHW Expansion Vessel

See Section 6.6 for information

The efficiency is 90.8%

This value is used in the UK Government’s

Standard Assessment Procedure (SAP) for energy

rating of dwellings. The test data from which it has

been calculated has been certified by 0086.

SEDBUK Declaration For

Combi 80 HE Plus

Heat Input Gross CH

Max

kW 26.95

Btu/h 92,000

CO/CO2Ratio 0.002

4.3 Combi 80 HE Plus

Electrical Protection IPX2

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Page 12

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)

Page 13

6.0 System Details

6.1 Central Heating Circuit

1. The appliance is suitable for fully pumped SEALED SYSTEMS ONLY.

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

The boiler is designed so that it will heat the house to the desired room temperature as quickly as possible by running at the maximum radiator temperature of 82°C. Once this room temperature is achieved the boiler will then reduce the radiator temperature to as low a level as possible, while still achieving the desired room temperature, thereby giving the most efficient use of gas and the most comfortable room temperature possible.

The boiler will be able to achieve this performance if a room

thermostat is fitted or with a fully TRV’d system without a bypass.

This boiler does not require a bypass. To comply with Part

L1 of the Building Regulations the heating system into which the boiler is installed should include the following:

a) zone controls b) timing controls c) boiler control interlocks

Such a system needs to be fully pumped and must provide independent temperature and time control to both the heating and hot water circuits and have a boiler interlock.

The boiler should be controlled so that it operates on demand only. Where it is proposed to effect control by thermostatic radiator valves, a room thermostat (or other device such as a flow switch - a flow switch is integral to this boiler) should also be provided to switch off the boiler when there is no demand for heating or hot water.

The interlock for CH circuit can be provided in either of the following ways:

a) A Room Thermostat with at least the radiator

nearest the room stat not TRV’d.

b) A fully TRV’d system without a bypass.

A fully TRV’d system with a bypass that has not been valved off does not comply with Part L1 of the Building Regulations.

If the system is fully TRV’d with a bypass then this feature will not be available, in this case the radiator temperature can be reduced to provide more efficient operation. (see User instructions).

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

Information

In GB it is necessary to comply with the Water Supply (Water Fittings) Regulations 1999 (or for Scotland, The Water Byelaws 2000, Scotland). The Baxi Combi 133, 100, 80 HE Plus Combination Boilers are an Approved Product under the Water Regulations.

To comply with the Water Regulations your attention is drawn to The Water Regulations Advisory Service (WRAS) which gives full details of the requirements.

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

Treatment of Water Circulating Systems

• All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems.

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

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

• System additives - corrosion inhibitors and flushing agents/descalers should comply to BS7593 requirements, e.g. Betz-Dearborn Sentinel X100 and Fernox-Copal which should be used following the inhibitor manufacturer’s instructions.

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

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

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

Page 14

6.0 System Details

6.2 System Control

1. The boiler is designed for use in a heating system that incorporates external controls, i.e. a minimum of a timer device.

2. Suitable timer kits are available as optional extras.

6.3 System Filling and Pressurising (Fig. 3)

1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling.

2. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment.

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

4. The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe, provided a 'Listed' double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use.

5. To aid removal of air from the system whilst filling, move the diverter valve to the CH position by using the installer parameters (see Section 10.4).

6.4 Expansion Vessel - CH only (Fig. 4)

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

). Therefore, the minimum cold fill pressure is 1 bar. The vessel is suitable for correct operation for system capacities up to 125 litres (27.5gal). For greater system capacities an additional expansion vessel must be fitted. For GB refer to BS 7074 Pt 1. For IE, the current edition of I.S. 813 “Domestic Gas Installations”.

6.5 Pressure Relief Valve (Fig. 4 )

1. The pressure relief valve is set at 3 bar, therefore all pipework, fittings, etc. should be suitable for pressures in excess of 3 bar.

2. The pressure relief discharge pipe should not be less than 15mm dia, run continuously downward, and discharge outside the building, preferably over a drain. It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components. The end of the pipe should terminate facing down and towards the wall.

3. The discharge must not be above a window, entrance or other public access. Consideration must be given to the possibility that boiling water/steam could discharge from the pipe.

Fig. 3

Stop Valve

Double Check Valve

DHW Mains Inlet

CH Return

Temporary Hose

Pressure Relief Valve

Expansion Vessel removed for clarity

Fig. 4

Expansion Vessel

Stop Valve

Page 15

6.0 System Details

6.6 Domestic Hot Water Circuit

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

2.When installed in accordance with 1 above this appliance does not require a check valve to meet water supply regulations. However when the system includes any device which prevents water expanding back towards the supply, then an expansion vessel must be fitted (e.g. Zilmet 160ml, R

/215 bar).

3. If the hot water expansion is not provided for, then high pressures can develop which may result in damage to fittings and devices on the system.

4. The boiler’s maximum working mains pressure is 10 bar (150 lb/in2), therefore all pipework, connections, fittings, etc. should be suitable for pressures in excess of 10 bar. A pressure reducing valve must be fitted for pressures in excess of 10 bar. The manufacturer of any outlet fittings, such as a shower valve, may require a lower maximum pressure. The pressure reduction must take account of all fittings connected to the DHW system.

5. Optimum hot water delivery of 16 l/min (133 model), 12 l/min (100 model), 10 l/min (80 model) may be obtained by fitting the flow regulator supplied.

6.7 Showers

1. If a shower control is supplied from the appliance it should be of the thermostatic or pressure balanced type. Thermostatic type shower valves provide the best comfort and guard against water at too high a temperature. Existing controls may not be suitable refer to the shower valve manufacturer.

6.8 Hard Water Areas

1. If the area of the installation is recognised as a HARD WATER AREA then a suitable device should be fitted to treat the mains water supply to the boiler. Contact your Water Distribution Company for advice on suitable devices.

Key

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

Boiler

Other Tap Outlets

Expansion Vessel

To Hot Taps

Check Valve

Pressure Reducer Valve

Stop Tap

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

129

Page 16

7.0 Site Requirements

Zone 2

Zone 1

Zone 0

Zone 2

Zone 3

Zone 2

Window Recess

0.6 m

2.4 m

Ceiling

Outside Zones

Zone 3

Zone 2

Zone 1

Zone 0

2.25 m

Zone 2

Window Recess

3.0 m

2.4 m

0.6 m

Fig. A

Fig. B

In GB Only

7.1 Location

NOTE: Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal.

1. The boiler may be fitted to any suitable non-flammable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard - see Section 7.2).

2. If the boiler is sited in an unheated enclosure then it is recommended to incorporate an appropriate device for frost protection in the system controls.

3. If the boiler is fitted in a room containing a bath or shower, the 100 HE Plus and 80 HE Plus can only be fitted in zone 3, the 133 HE Plus has a higher protection level and may be fitted in zone 2 (Figs. A & B shows zone dimensions for a bathtub. For other examples refer to Section 601 of the Current I.E.E. Wiring Regulations) reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules.

4. If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE/UP/7 (Gas Installations in Timber Framed Housing.

7.2 Ventilation of Compartments

1. Where the appliance is installed in a cupboard or compartment, no air vents are required. The appliance

will run sufficiently cool without extra ventilation.

Minimum Cupboard Size (inside dimensions) Height - 1250mm Width - 590mm Depth - 400mm

NOTE: The ventilation label on the front of the outer case MUST NOT BE REMOVED when the appliance is installed in a compartment or cupboard.

2. BS 5440: Part 2 Clause 4.2 refers to room sealed appliances installed in compartments.

Page 17

7.0 Site Requirements

7.3 Clearances (Fig. 6 & 7)

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

2. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement. Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler.

7.4 Gas Supply

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

2. The connection to the appliance is a

/2” BSPF.

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

diameter than 22mm up to the boiler connection.

7.5 Electrical Supply

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

NOTE: The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance. Connection must be via a fused double-pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only.

WARNING: The PCB Control and Fan Assembly

is 325 Vdc. Isolate at supply before access.

200mm

850mm

490mm

200mm

5mm Min

5mm

500mm

For Servicing

Purposes

Fig. 6

Fig. 7

In Operation

3°

(1 in 20)

320mm

Page 18

7.0 Site Requirements

7.6 Condensate Drain

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

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

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

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

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

/4in) plastic overflow pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable.

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

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

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

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

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

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

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

should use 32mm waste pipe.

8. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run.

9. In all cases discharge pipe must be installed to aid disposal of the condensate. To reduce the risk of condensate being trapped, as few bends and fittings as possible should be used.

10. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC's are flushed or sinks emptied then back-pressure may force water out of the boiler trap and cause appliance lockout.

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

Boiler

2.5° Minimum fall

Termination to an internal soil and

vent pipe

450mm min

Boiler

2.5° Minimum fall

External termination via internal discharge

branch

e.g sink waste - downstream

Sink

Pipe must terminate above water level but below surrounding surface

Boiler

Pipe must terminate above water level but below surrounding surface

2.5° Minimum fall

Termination to a drain or gully

Boiler

500mm min

2.5° Minimum fall

Termination to a purpose made soak-

away

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

50mm per metre of pipe run

Page 19

7.0 Site Requirements

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7.7 Flue

NOTE: Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal.

1. The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendations are given in BS 5440 Pt 1. For IE recommendations are given in the current edition of I.S. 813 “Domestic Gas Installations”.

2. If the terminal discharges onto a pathway or passageway, check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway.

3. Take into consideration the effect the plume of vapour may have on neighbours when siting the flue.

4. Adjacent surfaces close to the flue terminal may need protection from the effects of condensation. Alternatively a flue deflector kit (part no. 248167) is available.

5. For installation of the flue into an internal corner at the 25mm dimension the flue deflector kit (part no.

248167) must be fitted.

6. * Reduction to the boundary is possible down to 25mm but the flue deflector kit (part no. 248167) must be fitted.

7. If required a suitable terminal guard is available from Baxi for use with the flue deflector.

8. For fitting under low soffits and eaves it is acceptable for the flue to project upto 500mm from the face of the wall to the inside of the air intake. This can be painted if required using a suitable external paint.

9. If a terminal is less than 2 metres (78

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

Fig. 10

Fig. 9

300 min

Terminal Assembly

TopViewRear Flue

Property Boundary Line

NOTE: The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below

Table. 2

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

AaDirectly below an opening, air brick, opening

windows, etc. 300 BaAbove an opening, air brick, opening window etc. 300 CaHorizontally to an opening, air brick, opening window etc. 300 D Below gutters, soil pipes or drain pipes. 25 E Below eaves. 25 F Below balconies or car port roof. 25 G From a vertical drain pipe or soil pipe. 25 H From an internal

(i)

or external

(ii)

corner.

(i)

(ii)

115 I Above ground, roof or balcony level. 300 J From a surface or boundary line facing a terminal. 600 K From a terminal facing a terminal (Horizontal flue). 1200

From a terminal facing a terminal (Vertical flue). 600

L From an opening in carport (e.g. door, window)

into the dwelling. 1200 M Vertically from a terminal on the same wall. 1500 N Horizontally from a terminal on the same wall. 300

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

In addition, the terminal should be no nearer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame. See BS 5440 Pt. 1.

Page 20

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

Page 21

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). There 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

Plume Displacement 70/110 dia Kit

Page 22

8.0 Installation

8.1 Initial Preparation

Check Site Requirements (section 7.0) before commencing.

The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4).

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

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: project the horizontal side flue centre line into the corner of the room and along the wall to where the flue hole will be drilled (Fig. 14). The diagram (Fig.14a) shows the dimensions required to ensure any horizontal flue is installed with the correct fall to the boiler. Mark the offset (V) dimension and if required, mark the position of the gas and water pipes. Remove the template.

6. Cut the hole for the flue (preferably with a 125mm/5” diameter core boring tool), ensuring that the hole is drill at approx 3° up from the horizontal. Both wall faces immediately around the cut hole should be flat.

7. Drill and plug the 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 compression fittings supplied.

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).

Plastic Flushing Tube

Fig. 15

Fig. 14

The symbols for each connection are on the support bracket.

0.5

1.0

2.0

3.0

4.0

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

Flue Duct Hole Offset V (mm)

27 55 110 165 220

(metres)

(mm)

3°

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

Horizontal

Side Flue

Centre Line

EXAMPLE: Boiler is 2 metres away from corner of wall, flue duct hole is 110mm up from horizontal side flue centre line. This will maintain the approx 3° backfall to the boiler.

Wall Plate Template

Edge of Boiler

Example

V = 110mm

Centre Hole

Fig. 14a

Page 23

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. Hinge up the lower door panel (Fig. 16).

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

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

4. Remove the sealing plugs from the copper bends.

5. Remove cardboard transit packaging at the left hand rear of the boiler before lifting the boiler onto the support bracket.

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

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

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

Page 24

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 over the support bracket using the lifting points shown in Fig. 18 and engage onto the top hooks (see Lifting paragraph page 4).

NOTE: When installing in Loft/Small Compartment access for lifting the boiler from the front can be gained for two people using the lifting points (Fig. 18).

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

/4turn) and

hinge down the facia box.

4. Make the connections in the following sequence:

a) Gas connection first to centralise the boiler. The gas

sealing washer is an integral part of the gas tap.

The Combi HE is designed to operate under nominal water supply conditions. If the hot water delivery is greater than 18 l/min (133 model), 14 l/min (100 model), 12 l/min (80 model) the flow regulator must be fitted to the Domestic Hot Water inlet.

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

fitted.

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

5. Tighten the connections in the sequence listed above.

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 which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable.

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

Carefully pour approximately 1 cupful (250ml) of water into the flue products exhaust, at the top of the heat exchanger (Fig. 19) to ensure a seal is made in the trap.

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

Suggested Lifting Points shown as shaded area.

DO NOT LIFT USING THE PLASTIC FACIA BOX.

Page 25

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 semi-circular packing pieces. Deburr both tube ends.

4. For left hand exit - measure the distance from the edge of the support bracket to the inner face of the wall (Fig. 21) and to this dimension add the wall thickness + 268mm. This dimension to be known as (Y). 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 semi-circular packing pieces. Deburr both tube ends.

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

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

Page 26

8.0 Installation

8.6 Fitting the Flue (Cont)

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

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

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). Apply a suitable mastic to the inside of the trim and press against the wall finish, making sure the brickwork is dust free and dry.

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

VERTICAL FLUEING

1. Only a flue approved with the Baxi Combi HE Plus Boiler Range can be used.

2. For information on vertical flues consult the Baxi Flue Guide Brochure or Notes for Guidance supplied with the vertical flue pack.

Gasket

Flue Trim

Inner Flue Support Bracket

Flue

Flue Elbow

Fig. 24

Fig. 26

Fig. 25

Page 27

8.0 Installation

8.7 Making The Electrical Connections

(Fig. 26a)

WARNING: This appliance must be earthed.

1. The electrical connection is on the rear left hand side of the unit.

2. Remove the electrical plug and lead assembly from the hardware pack.

3. Connect L, N & E of the lead into the fused double pole isolator serving the boiler. Connect the plug to the socket at the back left at the bottom of the boiler.

4. Remove the metal shield from the hardware pack and connect it over the plug.

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

6. Check the electrical installation for; earth continuity, short circuits, resistance to earth, correct polarity and fuse failure (see Section 8.13 Electrical System Checks).

8.8 Connecting an External Timer

1. Undo the screw securing the electrical cover and remove (133 HE Plus only) (Fig. 27).

2. To connect an external timer switch circuit, remove the link wire between terminals 1 & 2 and connect the switch circuit (Figs. 28 & 29).

3. A cable clamp is provided for incoming cables.

Fig. 27

Fig. 28

Fig. 29

Cable Clamp

2-way Terminal Block

Link Wire

External Timer

Fig. 26a

Filter

Plug

Metal Shield

Electrical Cover

1 2

PCB

For External Controls

Page 28

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. 30a). A cable clamp is provided for incoming cables.

8.10 Fitting a Frost Thermostat

1. The frost thermostat is connected between positions 1 and 2 (Fig. 31) or between mains isolator and position

2. Secure the incoming cable/s with the cable clamp and replace the cover.

8.11 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 could be dangerous to work with the appliance live.

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

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

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

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

5. Fuse Check: Remove the fuse, check fuse on ohm’s scale there should be no resistance (infinity) or maximum reading. If no reading is obtained change the fuse. Check fuse is 3A.

Fig. 30

Fig. 31

Fig. 30a

External Timer

Electrical Cover

Link Wire

1 2

PCB

Room Thermostat

PCB

Frost Thermostat

Page 29

9.0 Electrical

9.1 Schematic Wiring Diagram

Earths not shown to aid

Key To Wiring Colours b - Blue

bk - Black gy - Grey w - White br - Brown op - Opaque

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

clarity of diagram

DHW

Flow

Switch

Filter

Mains Input

g/y

External Controls Connection

g/y

Detection

Electrode

Flame

g/y

Spark Electrode

PCB

Switch

Flow

g/y

325 Vdc

DC Fan

Return

Thermistor

Flow

Thermistor

Thermostat

Flow

Overheat

Gas

Valve

g/y

Condensate

Tr ap

Diverter

Valve

Pump

Fan

Overheat

Thermostat

Page 30

9.0 Electrical

9.2 Illustrated Wiring Diagram

Key To Wiring Colours b - Blue

bk - Black gy - Grey w - White br - Brown op - Opaque

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

Return Thermistor

CH Flow Switch

DHW Flow Switch

Pump

Flow Thermistor

g/y

Main PCB

Plug

g/y

Filter

Spark Electrode

Flame Detection Electrode

g/y

Layout of PCB Pins

Fan

g/y

Condensate Trap

Gas Valve

Fan Overheat Thermostat

Diverter Valve

Flow Overheat Thermostat

Page 31

10.0 Commissioning the Boiler

10.1 Commissioning the Boiler

NOTE: The information shown on the display is explained on the label on the inside of the lower door panel (see Fig. 38).

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 10.4 Filling the System).

4. Open the manual and automatic air vents (Fig. 32) (ensure all external controls are turned on and calling for heat).

5. The system must be flushed in accordance with BS 7593 (see Section 6.1) and the flushing agent manufacturers instructions, further guidance can be obtained from BS 5449 Section 5.

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

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

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

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

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

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

NOTE: These boilers are self-regulating and the gas rate will vary continously between maximum and minimum modulation depending on the system or DHW load. The maximum CH input is factory set to 26.95kW. This can be increased to 33.7kW on the 133 and 100 models - see section 10.2.

No adjustment of the gas valve is possible.

12. After a period of 3 minutes and with all the system controls calling for heat, check the gas pressure at the inlet tapping of the gas valve (Fig. 34) is greater than 14mbar and the gas rate is no greater than 4.2m

/h (133

model) 3.1m

/h (100 model) 2.5m3/h (80 model).

WARNING: The PCB Control and Fan

Assembly is 325 Vdc. Isolate at supply before

access.

IN OUT

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

Page 32

10.0 Commissioning the Boiler

10.2 Increasing Central Heating Output

To 100,000 Btu/hr (Fig. 35)

(Combi 133 & 100 HE Plus only)

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 is greater than 80,000 Btu/hr then to increase the maximum output of the boiler to 100,000 Btu/hr proceed as follows:

a) Isolate the mains supply to the boiler.

b) Remove the outer case.

c) Lower the hinge down facia box.

d) Remove the PCB connection cover.

e) At the extreme left hand side of the PCB there are two jumpers. Remove the red one labelled CN12.

3. Reassemble in reverse order.

Fig. 35

Remove the Red Jumper labelled

CN12

Facia Box

PCB

PCB Connection Cover

Page 33

10.0 Commissioning the Boiler

10.3 Switching Off The Intelligent Pre-heat

(Fig. 36)

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

8.00am on Monday then the boiler will log this demand and then the next week will only pre-heat between

7.00am and 8.00am on Monday. During the first week of operation from power on no pre-heating will occur.

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

3. The boiler is factory set with the pre-heat feature on. If the user wishes to disable this feature then proceed as follows:

a) Isolate the mains supply to the boiler.

b) Remove the outercase.

c) Lower the hinge down facia box.

d) Remove the PCB connections cover.

e) At the the extreme left hand side of the PCB there are two jumpers (one Blue, one Red). Remove both Blue and Red jumpers.

4. Reassemble in reverse order.

Facia Box

Fig. 36

Remove the Blue & Red Jumpers

labelled

CN11 & CN12

PCB

PCB Connection Cover

Page 34

10.0 Commissioning the Boiler

10.4

Filling the System

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

a) Ensure that no DHW taps are on.

b) Turn power on to the boiler.

c) Ensure that any external controls are calling for heat.

d) After 10 seconds turn the boiler off at the isolation switch.

e) The diverter valve will now be in the central heating position. There is no need to reset the position of the diverter valve after filling.

Page 35

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. 38).

2. Insert the two fixing screws into the sides of the

chassis (Fig. 39).

3. Close the lower door panel against the retaining

magnets (Fig. 39).

4. Instruct the user in the operation of the boiler

controls. Hand over both the Users Operating and 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. 38) or user’s operating instructions (set CH/DHW temperatures).

8. Carefully read and complete all sections of the

Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation. These details will be required in the event of any warranty work. The publication must be handed to the User for safe keeping and each subsequent regular service visit recorded.

9. For IE, it is necessary to complete a “Declaration of

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

Fig. 38

Fig. 39

Lower Door Panel

Outercase Fixing Screws

Lower Door Panel

Retaining Magnet

User Label

Page 36

12.0 Servicing the Boiler

12.1 Annual Servicing

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

“The boiler cannot be switched off at the boiler, therefore it is important to isolate the electrical supply at the mains fuse.”

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

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

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

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

3. Ensure that the boiler is cool.

4. Ensure that both the gas and electrical supplies to the

boiler are isolated.

5. Remove the outercase and lower door panel (see Fitting the Outercase, Section 11.0 in reverse).

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

6. Release the four

/4turn screws securing the air box

door panel and remove the door (Fig. 40).

7. Disconnect the three lead terminals from the combustion box door taking note of their positions (Fig. 40).

8. Undo the four screws securing the combustion box door and remove the door (Fig. 41).

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

a) Burner (Fragile (133 model) - handle with care). b) Heat exchanger fins. c) Fan compartment (Check also for condensate leaks). d) Insulation. e) Door seals - Important: Pay particular attention to

the condition of the combustion box door seals.

f) Electrodes. g) The condensate trap must be thoroughly cleaned at

every service (see section 13.24 for removal).

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

h) Top of heat exchanger.

NOTE: General cleaning can be undertaken using a vacuum. However debris should only be gently blown off the burner skin due to its fragile nature (133 HE Plus).

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

Flue Elbow

Lead Terminals

Fig. 40

Air Box Door Panel

Fig. 41

Combustion Box Door Panel

Combustion Box Door Securing Screw

/4Turn

Screw

Page 37

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. 38).

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

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

b) Loosen the screw retaining the gas injector pipe at the venturi (100 & 80 HE Plus models)

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

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

e) Remove the gas injector pipe from the gas valve (pushfit) (Fig. 42).

f) Undo the condensate trap securing nut, lock nut and the condensate drain pipe. Remove the condensate trap and disconnect the sensor leads (Fig. 43).

g) Remove the two screws securing the burner and remove the burner. Visually inspect the internal burner baffle for obstruction (Fig. 44).

NOTE: The 133 HE Plus burner skin is fragile handle with care. Clean and if necessary replace the burner (Fig. 44).

h) Loosen the two screws retaining the heat exchanger support bracket and slide to the left to remove (Fig. 44).

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

j) Lower the central insulation panels and check condition (Fig. 44). Replace the insulation pads if necessary.

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

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

attention to the condition of the combustion box door seals.

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

12. Check CO/CO

ratio at flue sampling point (Fig. 41a).

See section 4.0.

13. Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user.

Fig. 42

Burner

Fig. 43

Electrical Supply

Fig. 44

Wing Nuts

Protection Sensor Leads

Fan

Injector Pipe

Securing Nut

Condensate Trap

Sensor Leads

Locking Nut

Condensate Drain Pipe

Central Insulation Panel

Burner

Combustion Box Base

Heat Exchanger Support Bracket

Combustion Box Base Securing Screws

Burner Securing Screws

Venturi

Injector Pipe Retaining Screw (100 & 80 HE models)

100 & 80 HE

Burner

Fig. 41a

Flue Sampling Point

Page 38

13.0 Changing Components

13.1 Changing Components

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

“The boiler cannot be switched off at the boiler, therefore it is important to isolate the electrical supply at the mains fuse.”

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

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

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

WARNING: The PCB Control and Fan

Assembly is 325 Vdc. Isolate at supply before

access.

2. Isolate the water circuit and drain the system as necessary. There are 4 drain points:

a) Flow Valve b) Heat Exchanger Manifold (Fig. 45) c) Return Valve d) Cold Water Inlet

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

3. After changing a component re-commission the boiler where appropriate and check the inhibitor concentration (see Section 6.1 and 10.1).

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

13.2 Manual and Automatic Air Vent (Fig. 46)

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. 45

Heat Exchanger Manifold

Drain Point

Tube

Fig. 46

Automatic Air Vent

Sealing Washer

Manual Air Vent

Page 39

13.0 Changing Components

13.3 Flowswitch (Fig. 47)

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 6.1 and 10.1).

13.4 Flow or Return Temperature

Thermistors and Safety Thermostat

(Figs. 48 & 49)

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

2. Remove the electrical connection from the component.

3. Unscrew the component from the pipe.

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

13.5 Expansion Vessel (Fig. 50)

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. 47

Flowswitch

Clip

Fig. 48

Fig. 50

Flow Pipe

Electrical Connections

Expansion Vessel

Expansion Vessel Securing Screw

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

Expansion Vessel Connection

Return Thermistor (Red Body)

Fig. 49

Page 40

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. 51).

13.7 Pump (Fig. 51)

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. 52).

13.8 Pump (Complete) (Fig. 53)

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. 54)

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. 52) and reconnect the wiring harness plug.

Fig. 51

Facia Box

Fig. 53

Facia Securing Screws

Fig. 52

Pump Setting

Fig. 54

Plug Connector

Hydraulic Manifold

Wiring Harness

Pump

Pump Head

Pump Electrical Cover

Page 41

13.0 Changing Components

13.10 Three-Way Diverter Valve (Head Only)

(Fig. 55)

If only the head needs replacing:

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

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

3. Fit replacement head and reassemble in reverse order.

13.11 Three-Way Diverter Valve (Complete)

(Fig. 56)

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. 55

Wiring Harness

Fits Here

Fig. 56

Clip

Three-Way Diverter Valve Head

Wiring Harness

Fits Here

Three-Way Diverter Valve

Spigot

Gasket

Page 42

13.0 Changing Components

13.12 Pressure Gauge (Fig. 57)

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. 58).

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

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

13.13 Pressure Relief Valve (Fig. 59)

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. 57

Lug

Pressure Gauge

Pressure Gauge Bracket

Fig. 58

Capillary

Return Pipe

Fig. 59

Pressure Relief Valve

Expansion Vessel removed for clarity

Page 43

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. 60). NOTE: Ensure nuts are not dislodged from the manifolds.

3. Remove the plate heat exchanger cover (Fig. 61)

4. Remove the ’O’ rings from the manifolds and replace with new ‘O’ rings (Fig. 61).

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

6. Refit the plate heat exchanger cover.

13.15 DHW Flow Switch (Fig. 62)

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. 60

Plate Heat Exchanger Securing Screws

Fig. 61

Plate Heat Exchanger Cover

‘O’ Rings

Fig. 62

Inline Electrical Connection

Clip

Flow Switch

Manifold to Pump

Clip

DHW Inlet Connection

Plate Heat Exchanger

Page 44

13.0 Changing Components

13.16 PCB (Fig. 63)

WARNING: The PCB Control and Fan

Assembly is 325 Vdc. Isolate at supply before

access.

1. Pull the control knobs off their spindles and remove the plastic button covers. Refit them onto the new PCB (Fig. 63a).

2. Release the facia securing screws (

/4turn) and hinge

down the facia box.

3. Remove the screws securing the PCB connection cover.

4. Remove the screws securing the PCB and disconnect the electrical connections noting their positions although they are one way fitting.

NOTE: Check the PCB for the presence of input jumpers - see section 10.2 & 10.3. Set the new PCB as the original.

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

Fig. 63

Facia Box

Facia Securing Screws

PCB

Control Knob

Fig. 63a

PCB Connection Cover

Plastic Button Covers

Page 45

13.0 Changing Components

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

1. Remove the airbox door panel by loosening the four

/4turn screws (Fig. 64).

13.20 Spark and Sensing Electrode

(Fig. 65)

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

Spark - Opaque Lead Earth - Green/Yellow Lead Sensing - White Lead

2. Remove the two screws securing the electrode to the combustion box door and remove the electrode.

3. Fit the new electrode and new gasket, reassemble in reverse order, ensuring the spark gap of 3.5mm ±

0.5mm is maintained.

13.21 Fan and Fan Protection Thermostat

(Fig. 66)

WARNING: The PCB Control and Fan

Assembly is 325 Vdc. Isolate at supply before

access.

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. Loosen the screw retaining the gas injector pipe at the venturi (100 & 80 HE Plus models)

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

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

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

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

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

Fig. 64

Air Box Door Panel

Fig. 65

Fig. 66

Combustion Box Door

Sensing

Spark

Fan Protection Thermostat (Black Body)

Electrical Supply

Wing Nuts

Protection Thermostat Leads

Fan

Injector Pipe

Earth

Gasket

Venturi

Injector Pipe Retaining Screw (100 & 80 HE models)

Page 46

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. 67)

1. Loosen the screw retaining the gas injector pipe at the venturi (100 & 80 HE Plus models)

2. Remove the injector pipe by pulling out from the ‘O’ ring joint in the gas valve.

3. Fit the new injector pipe and reassemble in reverse order, applying Greasil 4000 (Approved Silicone Grease) to both “O” rings.

13.23 Gas Valve (Fig. 67)

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 you ensure gas soundness as they are under negative pressure.

13.24 Condensate Trap (Fig. 68)

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. 67

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. 68

Securing Nut

Condensate Trap

Sensor Leads

Locknut

Condensate Drain Pipe

Injector Pipe

(100 & 80 HE models

Page 47

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. 69)

WARNING: The burner skin is fragile (133 model): (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).

WARNING: The PCB Control and Fan

Assembly is 325 Vdc. Isolate at supply before

access.

2. Remove the fan and condensate trap (see section

13.21 and 13.24).

3. Undo the screws securing the flow switch and return connections. Remove the flow switch and return connection (Fig. 70).

4. Undo the screws securing the heat exchanger manifold and remove the manifold (Fig. 71).

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

6. Lift the heat exchanger assembly (Fig. 72) and rotate the bottom upwards whilst pulling it forwards out of the airbox.

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

8. Recommission the boiler and check the inhibitor concentration (see Section 6.1 and 10.1).

Fig. 69

Securing Screws

Fig. 70

Burner

Flow Switch

Return Connection

Heat Exchanger Manifold

Fig. 71

Fig. 72

Heat Exchanger Assembly

100 & 80 HE

Burner

Page 48

13.0 Changing Components

13.27 Heat Exchanger Insulation Pads (Fig. 73)

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. 73

Central Insulation Panel

Lower Insulation Panel

Upper Insulation Panel

Burner

Combustion Box Base

Support Bracket

Burner Securing Screws

Combustion Box Base Securing Bolts

100 & 80 HE

Burner

Page 49

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

G PCB - enclosure 5110991

I Pump 240395

K E58 935 Diverter Valve Head 243341

L Fan (133 HE 5109926

Fan (100 & 80 HE) 5109925

M Condensate Trap Kit 5111714

N E78 749 Gas Valve Kit 247222

O E58 900 Burner (133 HE) 245199

Burner (100 & 80 HE) 5107430

P Electrode Kit 5110992

R Plate Heat Exch. Kit 247224

S E06 085 Inspection Window Assy 242484

T E06 097 Heat Exchanger Assy 242497

U Control Knob 5109996

Page 50

15.0 Fault Finding

Low Electrical Supply

Incoming Voltage less than

180V. Check System Controls

& System Wiring. Otherwise

contact Electricity Provider.

Live & Neutral Reversed

Incoming Live and Neutral

reversed.

Wiring Harness

Ensure 8-way PCB

connector securely pushed

in. If fault persists replace

Wiring Harness.

Go to Return Thermistor

section of the fault finding instructions.

Go to Flow Thermistor

section of the fault finding

instructions.

CH works but

DHW does not.

Go to DHW Flow Switch

section of the fault finding instructions.

DHW works but

CH does not.

Go to DHW Fault

section of the fault finding

instructions.

Go to Fan Lockout

section of the fault finding

instructions.

Go to Ignition Lockout

section of the fault finding

instructions.

Go to Overheat Lockout

section of the fault finding instructions.

PCB Fault

Replace PCB.

YES

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

YES

Go to Electrical Supply

section of the fault finding

instructions.

Domestic Hot Water

LED Light - Green

Burner ON

LED Light - Green

Mains ON

LED Light - Green

Flame Failure

LED Light - Red

Off

LED

Lights

Off

Flash

LED

Lights

Go to Dry-Fire

section of the fault finding

instructions.

Off

Flash

LED

Lights

Off

LED

Lights

Off

Flash

Off

LED

Lights

Off

Flash

LED

Lights

Flash

LED

Lights

Off

Flash

LED

Lights

Flash

LED

Lights

Off

Flash

Off

Flash

LED

Lights

Off

LED

Lights

Off

Flash

LED

Lights

PCB Fault

Replace PCB.

PCB Fault

Replace PCB.

Off

Flash

LED

Lights

Off

Flash

LED

Lights

Go to CH Fault

section of the fault finding

instructions.

YES

Low

High

Reset

High

Low

Page 51

15.0 Fault Finding

Connect Mains to boiler.

240V at B ?

Check wiring from

terminal block to PCB.

Check for shorts on

pump, fan & gas valve.

Replace if shorted &

replace fuse.

YES

Replace PCB.

YES

ELECTRICAL SUPPLY

240V at A ?

PCB fuse OK ?

Fuse

Off

LED

Lights

Page 52

15.0 Fault Finding

the system

full of water ?

Fill system with water and

bleed out all air.

YES

With

water flowing out

of a fully open DHW tap

does the pump

run ?

Unplug the

pump is there

240V at C ?

there 240V at D ?

Replace PCB.

Wiring from terminal

block to PCB faulty.

Pump fault.

Wires from inline

connector to PCB faulty.

Remove blockage.

YES

Unplug

5-way PCB connector.

With water flowing out of a fully

open DHW tap is there

continuity at

E ?

DRY-FIRE

Replace PCB.

Disconnect

primary flow switch

inline connector, with a tap open

is there continuity

across flow

switch ?

Remove

flow switch from boiler.

Is there a physical blockage to the

paddle within the

flow switch ?

there a blockage in

the system ?

Remove blockage.

Replace flow switch.

YES

Viewed from

Wire Entry end

Pump Plug (when unplugged)

Off

Flash

LED

Lights

Page 53

15.0 Fault Finding

Check isolation valve and

gas supply.

Remove gas valve & check inlet

filter for blockage. Otherwise

incorrect gas supply to boiler.

YES

Ignition Lockout

YES

Is there

gas at gas valve inlet ?

Reset lockout.

Is there gas flow ?

(check at the meter)

Replace spark or flame

detection probe.

Is spark or

flame detection probe

damaged ?

Is there at

least 18mbar dynamic

at gas valve inlet ?

Set spark gap to 3.5mm.

Is spark gap

between 3 and 4mm ?

YES

Rectify wiring.

wiring from PCB

to spark probe & flame

detection probe

OK ?

YES

Replace gas valve.

YES

Replace PCB.

Remove

5-way connector

from gas valve. Is there 240Vdc

between F & G during ignition ?

Remove

the larger of the two

6-way PCB connectors. Is there

continuity from F to I

& from G to H ?

Lead from PCB to gas

valve faulty.

YES

Off

LED

Lights

Clear blockage & dry

sensors.

Is condensate

trap blocked or water on

terminals ?

YES

Is the burner

blocked or damaged ?

Replace PCB.

Clean burner or replace

as necessary.

YES

Page 54

15.0 Fault Finding

Replace Stat.

Wiring from PCB to

thermostats faulty.

YES

Disconnect

black stat on flow pipe.

When flow < 60° C is there

continuity across stat ?

Replace combustion

chamber door seal & trim

seal.

YES

Reconnect stat.

Disconnect fan stat.

When fan temp < 60° C

is there continuity

across stat ?

Reconnect stat.

Disconnect the larger of

the 6-way PCB connectors.

Is there continuity

across M ?

Disconnect

thermistor

(red sensor on flow pipe).

Is resistance between

0.5kΩ & 20kΩ ?

combustion chamber

door seal damaged or not in

place ?

Replace PCB.

YES

OVERHEAT LOCKOUT

Replace thermistor.

Off

Flash

Off

LED

Lights

Page 55

15.0 Fault Finding

Rectify wiring.

YES

Unplug

3-way PCB connector

& unplug fan. Is there

continuity from K to L &

from M to N ?

Unplug

the smaller of the

6-way PCB connectors. Is there

continuity from O to P & from Q

to T & from

S to R ?

Replace fan.

FAN

Rectify wiring.

YES

Viewed from

Wire Entry end

Fan

Connection

PCB

Connection

Fan

Connection

PCB

Connection

DHW FLOW SWITCH

Replace PCB.

Unplug

5-way connector

from PCB. With all DHW taps

off is there continuity

across W ?

DHW flow switch

blocked ?

Unblock DHW flow

switch.

Replace DHW flow

switch.

YES

Viewed from

Wire Entry end

Off

Flash

LED

Lights

NOTE: The fan is supplied with 325 Vdc. Fan Fault Finding should only be carried out after the boiler has been electrically isolated.

Flash

LED

Lights

Page 56

15.0 Fault Finding

Replace flow thermistor.

Wiring from PCB to flow

thermistor faulty.

YES

Replace PCB.

FLOW THERMISTOR

Unplug

flow thermistor,

Is thermistor resistance between

0.5kΩ & 20kΩ ?

Plug in

thermistor, unplug

8-way PCB connector.

Is resistance at V between

0.5kΩ & 20kΩ ?

Viewed from

Wire Entry end

RETURN THERMISTOR

YES

Wiring from PCB to

return thermistor faulty.

YES

Replace return thermistor.

Replace PCB.

Viewed from

Wire Entry end

Off

Flash

LED

Lights

Flash

LED

Lights

Unplug

return thermistor,

Is thermistor resistance between

0.5kΩ & 20kΩ ?

Plug in

thermistor, unplug

8-way PCB connector.

Is resistance at U between

0.5kΩ & 20kΩ ?

Page 57

15.0 Fault Finding

YES

With water

flowing out of a fully

open DHW tap, does the

DHW LED light ?

Unplug

diverter valve.

With DHW LED on, is

there 240V from

Y to Z ?

DHW Fault

Unplug

5-way connector

from PCB. With water flowing

out of a fully open DHW tap,

is there continuity

across X ?

Unplug

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

continuity across DHW

flow switch ?

Is DHW flow switch

blocked ?

Replace DHW Flow

Switch.

Unblock DHW Flow

Switch.

Wiring from PCB to Flow

Switch faulty.

Replace PCB.

YES

Unplug

7-way PCB connector.

With DHW LED on, is

there 240V from

B to C ?

Replace PCB.

Wiring from PCB to

Diverter Valve faulty.

YES

Is there 240V from

A to Z ?

YES

Unplug

7-way PCB connector.

With DHW LED on, is

there 240V from

B to D ?

Wiring from PCB to

Diverter Valve faulty.

Diverter Valve faulty. PCB faulty.

YES

Viewed from

Wire Entry end

Diverter Valve Plug (when unplugged)

B C

Page 58

15.0 Fault Finding

Wiring in 8-way terminal

block

from L to Prog 1 faulty.

Is there 240V at D ?

YES

CH Fault

Check integral timer and

wiring. Check Link Plug if

no timer fitted.

Is there 240V at E ?

Check external controls

wiring.

Is there 240V at F ?

Check room stat & room

stat wiring OK.

Is there 240V at G ?

Wiring from R/S 2 to PCB

faulty.

Is there 240V at H ?

Diverter Valve faulty.

Unplug

Diverter Valve.

Ensure all DHW taps are

off so that DHW LED is off. Is

there 240V from I to J &

from K to J ?

Wiring from PCB to

Diverter Valve faulty.

Is there

240V from G to N & from G

to M ?

PCB faulty.

YES

Diverter Valve Plug (when unplugged)

G N

M H

E F

YES

Link Plug

Page 59

16.0 Operational Flow Chart

16.1 Domestic Hot Water Mode

1. Standby: The diverter valve, pump, fan, spark generator and gas valve are off. If a tap or shower is switched on then Fan Pre-Purge occurs.

2. Fan Pre-Purge: The pump and fan are on while the diverter valve, spark generator and gas valve are off. After 5 seconds if the DHW temperature is less than the set point then Ignition occurs.

3. Ignition: The pump, fan, spark generator and gas valve are on while the diverter valve is off. If a flame is detected then Burner On occurs. If a flame is not detected within 5 seconds and less than 5 ignition attempts have been made then Fan Pre-Purge occurs. If a flame is not detected within 5 seconds and 5 ignition attempts have been made then Ignition Lockout occurs.

4. Burner On: The pump, fan and gas valve are on while the diverter valve and spark generator are off. DHW temperature is controlled by varying the fan speed (and thereby the gas rate) to achieve optimum operation. If the hot water tap is turned off and the DHW temperature has been reached and there is a Central Heating demand then CH Burner On occurs. If the hot water tap is turned off and the DHW temperature has been reached and there is no CH demand then Pump Overrun occurs. If the hot water tap is turned off and the DHW temperature has been exceeded and there is no CH demand then Standby occurs.

5. Pump Overrun: The pump is on while the diverter valve, fan, spark generator and gas valve are off. If a tap or shower is switched on then Fan Pre-Purge occurs. After 1 minute Standby occurs.

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

Standby.

Tap or shower

switched on ?

YES

5 second

Fan Pre-Purge.

Flame Detected ?

Burner On.

Ignition

Lockout.

5 second

Ignition Period.

Ignition done and 5 attempts made ?

Ignition done

and less than 5

attempts made ?

DHW temperature less than set point ?

YES

1 minute

Pump Overrun.

YES

Tap or

shower off & DHW

temperature >

set point ?

Standby.

Tap or shower

switched on ?

Tap or

shower off & DHW

temperature =

set point ?

CH Burner On.

Tap or

shower off & DHW

temperature =

set point ?

YES

Page 60

16.0 Operational Flow Chart

16.2 Central Heating Mode

1. Standby: The diverter valve, pump, fan, spark generator and gas valve are off. If the timer and room stat are on then Diverter Valve moving to CH position occurs.

2. Diverter Valve moving to CH position: The diverter valve moves to the CH position while the pump, fan, spark generator and gas valve are off. After 6 seconds if the flow temperature is less than the set point then Pump On occurs. After 6 seconds if the flow temperature is greater than the set point then Pump Overrun occurs.

3. Pump On: The diverter valve and pump are on while the fan, spark generator and gas valve are off. After 10 seconds if the flow switch has made then Fan Pre-Purge occurs. After 10 seconds if the flow switch has not made then Anti-cycle occurs.

4. Fan Pre-Purge: The diverter valve, pump and fan are on while the spark generator and gas valve are off. After 5 seconds Ignition occurs.

5. Ignition: The diverter valve, pump, fan, spark generator and gas valve are on. If a flame is detected then Burner On occurs. If a flame is not detected within 5 seconds and less than 5 ignition attempts have been made then Fan Purge occurs. If a flame is not detected within 5 seconds and 5 ignition attempts have been made then Ignition Lockout occurs.

6. Burner On: The diverter valve, pump, fan and gas valve are on while the spark generator are off. Flow temperature is controlled by varying the fan speed (and thereby the gas rate) to achieve optimum operation. If the flow temperature is greater than the set point or the timer is off or the room stat is off then Pump Overrun occurs. If the TRVs all shut down then Anticycle occurs.

7. Pump Overrun: The diverter valve and pump are on while the fan, spark generator and gas valve are off. After 1 minute Anti-cycle occurs.

8. Anti-cycle: The diverter valve, pump, fan, spark generator and gas valve are off. After 3 minutes Diverter Valve moving to CH position occurs.

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

NOTE: If a tap or shower is switched on during CH Burner On then DHW Burner On occurs. If a DHW demand occurs during any other part of CH operation then DHW Purge occurs.

Standby.

Timer & Room Stat

on ?

6 second

Diverter Valve moving to

CH position

Burner On.

Ignition

Lockout.

10 second Pump On.

Ignition done and

5 attempts made ?

Ignition done

and less than 5

attempts made ?

Flow temperature

less than set point ?

YES

1 minute

Pump Overrun.

YES

Timer off

or temperature >

set point or room

stat off ?

Primary Flow

Switch made ?

5 second

Fan Pre-Purge.

Flame Detected ?

5 second

Ignition Period.

3 minute

Anti-cycle.

All TRVs

shut down ?

Timer off or

room stat off ?

YES

Page 61

17.0 Notes

Page 62

CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes

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

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

COMBI BOILER

HEATING ZONE VALVES FITTED NOT REQUIRED

HOT WATER ZONE VALVES FITTED NOT REQUIRED

THERMOSTATIC RADIATOR VALVES FITTED

AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS?

THE SYSTEM CLEANER USED

THE INHIBITOR USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE ft3/hr

BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

CENTRAL HEATING FLOW TEMPERATURE °C

CENTRAL HEATING RETURN TEMPERATURE °C

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED? YES NO

WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE ft3/hr

MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar

COLD WATER INLET TEMPERATURE °C

HOT WATER OUTLET TEMPERATURE °C

WATER FLOW RATE

lts/min

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS? YES

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS

THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS

IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2 RATIO READING? N/A YES CO/CO2 RATIO

THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER

THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

m3/hr

/hr

COMMISSIONING ENG’S NAME PRINT CORGI ID No.

SIGN DATE

BOILER SERIAL No. NOTIFICATION No.

BENCHMARK No.

GAS BOILER COMMISSIONING CHECKLIST

COLLECTIVE MARK

N/A

5109929

Page 63

SERVICE 1

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 2

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 3

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 4

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 5

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 6

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 7

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 8

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 9

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE 10

DATE

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID CARD SERIAL No.

COMMENTS

SIGNATURE

SERVICE INTERVAL RECORD

It is recommended that your heating system is serviced regularly

and that you complete the appropriate Service Interval Record Below.

Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service

as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls

Page 64

Comp No5109929 - Iss 6 - 10/07

BAXI

A Trading Division of Baxi Heating UK, a division of Baxi Group

Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 08700 60 30 60 Technical Enquiries 08706 049 049 Website www.baxi.co.uk e&oe

company

All descriptions and illustrations provided in this leaflet have been

carefully prepared but we reserve the right to make changes and

improvements in our products which may affect the accuracy of the

information contained in this leaflet. All goods are sold subject to our

standard Conditions of Sale which are available on request.