Baxi Combi 80 Eco Quick Start Manual

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Baxi Combi 80Eco

Gas Fired Wall Mounted Combination Boiler

Installation and Servicing Instructions

Please leave these instructions with the user

Baxi UK Limited is one of the leading manufacturers

of domestic heating products in the UK.

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

customers. Quality is designed into every Baxi product

- products which fulfil the demands and needs of

customers, offering choice, efficiency and reliability.

To keep ahead of changing trends, we have made a

commitment to develop new ideas using the

latest technology - with the aim of continuing to make

the products that customers want to buy.

Everyone who works at Baxi has a commitment to

quality because we know that satisfied customers

mean continued success.

We hope you get a satisfactory service from Baxi. If

not, please let us know.

Natural Gas

Baxi Combi 80Eco

G.C.No47 075 05

Baxi is a BS-EN ISO 9001

Accredited Company

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

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

Type test for purpose of Regulation 5 certified by: Notified Body 0051.

Product/Production certified by: Notified Body 0051.

For GB/IE only.

1.0 Introduction 4

2.0 General Layout 5

3.0 Appliance Operation 6

4.0 Technical Data 7

5.0 Dimensions and Fixings 8

6.0 System Details 9

7.0 Site Requirements 12

8.0 Installation 17

9.0 Commissioning the Boiler 22

10.0 Completion 24

11.0 Servicing the Boiler 25

12.0 Changing Components 27

13.0 Illustrated Wiring Diagram 36

14.0 Fault Finding 37

15.0 Short Parts List 42

Section Page

Contents

Baxi UK Limited declare that no substances harmful to health are contained in the appliance or used during appliance manufacture.

1.1 Description

1. The Baxi Combi 80Eco is a fully automatic gas fired wall mounted combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water.

2. The boiler is set to give a maximum output of

24.0 kW.

3. It is designed for use on Natural Gas (G20) and can be converted to use Propane or Butane.

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

5. The boiler data badge gives details of the model, serial number and Gas Council number and is situated on the control box. It is visible when the case front panel is removed (Fig. 1).

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

7. The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit, part no. 247719.

8. All systems must be thoroughly flushed and

treated with inhibitor (see section 6.2).

1.2 Installation

1. The appliance is suitable for installation only in G.B. and I.E. and should be installed in accordance with the rules in force. For Ireland install in accordance with I.S.813 “I

NSTALLATION OF

GAS APPLIANCES”. The installation must be carried out by a

CORGI Registered Installer or other competent person and be in accordance with the relevant requirements of G

AS SAFETY

(Installation and Use) REGULATIONS, the BUILDING REGULATIONS (Scotland) (Consolidation), the LOCAL BUILDING REGULATIONS, the C

URRENT I.E.E. WIRING REGULATIONS and the bye laws of the

Local Water Undertaking. Where no specific instructions are given, reference should be made to the relevant BRITISH

STANDARD CODES OF PRACTICE.

1.3 Optional Extras

Various flue extensions, bends, vertical flue kits, control accessories etc. are available as optional extras. These are detailed in a separate publication.

1.0 Introduction

Data Badge

Fig. 1

Control Box

Case Front Panel

“Benchmark” Log Book

As part of the industry-wide “Benchmark” initiative all Baxi boilers now include an Installation, Commissioning and Service Record Log Book. Please read the Log Book carefully and complete all sections relevant to the appliance and installation. These include sections on the type of controls employed, flushing the system, burner operating pressure etc. The details of the Log Book will be required in the event of any warranty work. Also, there is a section to be completed at each subsequent regular service visit. The Log Book must be left with the user.

NOTE: 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.

2.0 General Layout

2.1 Layout

1. Air Pressure Switch

2. Expansion Vessel

3. Burner Manifold

4. Automatic Air Vent

5. DHW Plate Heat Exchanger

6. Circulation Pump

7. Drain Off Point

8. Pressure Relief Valve

9. Optional Integral Timer Position

10. Central Heating System Pressure Gauge

11. Control PCB

12. Control Box

13. 3-Way Valve Assembly

14. Spark Generator

15. Flame Sensing Electrode

16. Spark Electrode

17. Burner

18. Primary Heat Exchanger

19. Fan Assembly

20. On / Off / Reset Selector Switch

21. Burner On Neon

22. Power On Neon

23. Flame Failure Neon

24. Central Heating Temperature Control

25. Hot Water Temperature Control

20 21 22 23 24 25 10 9

bar

Fig. 2

Fig. 3

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 (Fig. 4)

1. With a demand for heating, the pump circulates water through the primary circuit. At a predetermined flow rate the central heating flow switch operates, initiating the ignition sequence.

2. The main burner ignites at low rate, then the gas valve controls the gas rate to maintain the heating temperature measured by the temperature sensor.

3. When the flow temperature exceeds the setting temperature, a 3 minute delay occurs before the burner relights automatically (anti-cycling). The pump continues to run during this period.

3.2 Domestic Hot Water Mode (Fig. 5)

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 which requests the 3 way valve to 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 temperature sensor.

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.

IMPORTANT: When the selector switch is in the ‘0’ (Off) position the electrical supply to the boiler is isolated. The boiler will not operate and the integral timer (if fitted) will require resetting once the selector switch is turned to either the DHW or CH position.

5 6

1213141516

1 Primary Heat Exchanger 2 Burner 3 Ignition Electrode 4 Flame Sensing Electrode 5 Gas Valve 6Pump 7 Automatic Air Vent 8 Plate Heat Exchanger 9 Flow Sensor with Filter 10 Pressure Relief Valve 11 Boiler Drain Point 12 Heating Return 13 Cold Water Inlet On/Off Valve and Filter

14 Gas Inlet 15 Domestic Hot Water Outlet 16 Heating Flow 17 Pressure Gauge 18 Hydraulic Differential Pressure Sensor Microswitch 19 Automatic By-Pass 20 Hydraulic Differential Pressure Sensor 21 Diverter Valve Assembly 22 Domestic Hot Water Flow Priority Assembly 23 Domestic Hot Water Flow Priority Microswitch 24 Temperature Sensor 25 Overheat Thermostat 26 Expansion Vessel

Key

Central Heating Circuit

Domestic Hot Water Circuit

Fig. 4

Fig. 5

5 6

1213141516

4.0 Technical Data

Flue Terminal Diameter 100mm Dimensions Projection 95mm

Outercase Dimensions

Casing Height - 780mm Overall Height Inc Flue Elbow - 980mm Casing Width - 450mm Casing Depth - 345mm

Clearances

Both Sides 5 mm Min Above Casing 200 mm Min Below Casing 200 mm Min Front 450 mm Min (For Servicing) Front 5 mm Min (In Operation)

Weights kg Packaged Boiler Carton 46 Packaged Flue Kit 3 Installation Lift Weight 38.5

Central Heating Primary Circuit Pressures

bar

Safety Discharge 3 Max Operating 2.5 Min Operating 0.5 Recommend Operating 1-2

DHW Circuit bar Pressures

Max Operating 8 Min Operating 0.2

Min Operating Pressure at 9.8 l/min 0.9

Flow Rates l/min DHW Flow Rate @ 30o C Rise 11.4

DHW Flow Rate @ 35o C Rise 9.8

Min Working DHW Flow Rate 2.5

Pump

Available Head See graph below

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

bar

Min Pre-charge Pressure 0.5

litre Max Capacity of CH System 125 Primary Water Content of Boiler (unpressurised) 1.0

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

Temperatures

C.H. Flow Temp (adjustable)

35°C to 85°C max (± 5°C)

D.H.W. Flow Temp (adjustable)

35°C to 65°C max (± 5°C) dependent upon flow rate

Heat Input C/H & DHW (Gross)

Max Min

kW 26.3 10.6

Btu/h 89,739 36,167

Heat Output Max Min

kW 24.0 9.3

Btu/h 81,891 31,732

Electrical Supply 230V~ 50H

(Appliance must be connected to an earthed supply)

Power Consumption 170W

External Fuse Rating 3A

Internal Fuse Rating

Fuse 2A Fast Blow to BS 4265

Appliance Category CAT II

2H 3+

Max Gas Rate (Natural Gas - G20)

(After 10 Mins)

m3/h 2.78

ft3/h 98.12

Inlet Pressure (Natural Gas - G20)

mbar 20

in wg 8

Burner Injector (Natural Gas - G20)

12 x 1.28mm Diameter

Burner Pressure (Natural Gas - G20)

Max Rate Min Rate

mbar 12.2 ± 0.5 2.5 ± 0.2

in wg 4.88 ± 0.2 1.0 ± 0.2

Appliance Type C

NOxClass 3

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 have been

certified by 0051.

SEDBUK Declaration For Combi 80Eco

The seasonal efficiency (SEDBUK) is 78.6%

Electrical Protection

IPX4D

LPG Gases - Propane G31 Butane G31

Burner Injector

12 x 0.77mm diameter

Burner Pressure

Propane mbar

in wg

Butane mbar

in wg

Inlet Pressures

mbar in wg

Butane

11.2

Max Rate

36.2

14.5

28.3

11.3

Min Rate

6.4

2.6

5.3

2.1

Propane

14.8

3.5

2.5

Metre wg

1.5

0.5

l/h

Pump - Available Head

200 400 600 800 1000 1200

5.0 Dimensions and Fixings

Dimensions

A 780mm

B 345mm

C 450mm

D 107mm Ø Min.

E 200mm

F 190mm

G 143mm

360° Orientation

Tube Ø 100mm

65mm 65mm 65mm 65mm

Wall

View from under the appliance

Gas Inlet

Heating

Flow

Domestic Hot

Water Outlet

Cold Water

Inlet

Heating

Return

130mm

165.7mm

95mm

Left Hand Side

of Boiler

Fig. 6

Fig. 7

6.0 System Details

6.1 Information

1. The Baxi Combi 80Eco Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN).

a) IRN 001 - See text of entry for installation

requirements and notes.

b) IRN 302 - Byelaw 14.

2. Reference to the WRC publications, ‘Water fittings and materials directory’ and ‘Water supply byelaws guide’ give full details of byelaws and the IRNs.

6.2 Central Heating Circuit

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

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.

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

• This must involve the use of a proprietary cleanser, such as BetzDearborn Sentinel X300 or X400, or Fernox Superfloc. Full instructions are supplied with the products, but for immediate information please contact BetzDearborn (0151 420 9563) or Fernox (01799 550 811) directly.

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

Failure to flush and add inhibitor to the system may 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 the Baxi Helpline.

6.3 Bypass

1. The boiler is fitted with an automatic integral bypass.

6.4 System Control

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

2. Suitable timer kits are available as optional extras.

3. For optimum operating conditions and maximum economy the fitting of a programmable thermostat, such as one of the Baxi Combi 80Eco Controllers, is recommended.

Stop Valve

Double Check Valve

DHW Mains Inlet

CH Return

Temporary Hose

6.0 System Details

6.5 System Filling and Pressurising

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

2. There are connection points on the mains cold water inlet and central heating return isolating taps to which the optional filling loop kit (Part No.

248221) can be assembled.

3. The filling method adopted must be in accordance with the Water Supply (Water Fittings) regulations and the Water Bylaws (Scotland).

4. Your attention is drawn to: Paragraph 24 of Schedule 2 Section 8 of the publication Water Regulations Guide which gives recommendations and guidance on approved methods for filling sealed systems.

5. The sealed primary circuits may be filled or replenished by means of a temporary connection between the primary circuit and a supply pipe provided the arrangement in accordance with Diagram R24.2a of the Water Regulations Guide.

6. The temporary hose must be completely removed at both ends after use.

6.6 Expansion Vessel

(Central Heating only)

1. The appliance expansion vessel is pre-charged to 0.5 bar. Therefore, the minimum cold fill pressure is 0.5 bar. The vessel is suitable for correct operation for system capacities up to 125 litres. For greater system capacities an additional expansion vessel must be fitted - refer to BS 7074 Pt 1.

6.7 Pressure Relief Valve (Fig. 9)

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

2. The pressure relief discharge pipe should be not less than 15mm dia, run continuously downward, and discharge outside the building, preferably over a drain (Fig. 10). 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. 8

Fig. 9

Fig. 10

Pressure Relief Valve

Discharge Pipe

Stop Valve

6.0 System Details

6.8 Domestic Hot Water Circuit

1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards, the Water Supply (water fittings) Regulations and the Water Bylaws (Scotland).

2. Your attention is drawn to: Schedule 2, Section 6 of the publication Water Regulations Guide which relates to backflow prevention.

3. A single check valve must be fitted as shown in Fig. 11 to prevent backflow to the supply pipe and to ensure the efficient operation of the expansion vessel which is required to accommodate the thermal expansion of the water.

4. When the domestic water system includes any device which prevents water expanding back towards the supply (check valve, loose jumpered stopcock, water meter, water treatment device) then an expansion vessel must be fitted (eg. Zilmet 160ml, R

/215bar).

5. 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.

6. The boiler’s maximum working mains pressure is 8 bar, therefore all pipework, connections, fittings, etc. should be suitable for pressures in excess of 8 bar. A pressure reducing valve must be fitted for pressures in excess of 8 bar. The manufacturer of any outlet fittings, such as a shower valve, may require a lower maximum pressure. The pressure reduction must take account of all fittings connected to the DHW system.

6.9 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.

6.10 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.

Boiler

Other Tap Outlets

Expansion Vessel

To Hot Taps

Check Valve

Pressure Reducing Valve

Stop Tap

Fig. 11

7.0 Site Requirements

7.1 Information

1. The installation must be carried out by a CORGI Registered Installer or other registered competent person and be in accordance with the relevant requirements of the current G

AS SAFETY (Installation

and Use) R

EGULATIONS, the BUILDING REGULATIONS

(Scotland)(Consolidation), the LOCAL BUILDING REGULATIONS, the current I.E.E. WIRING REGULATIONS

and the bye laws of the LOCAL WATER UNDERTAKING. Where no specific instruction is given reference should be made to the relevant BRITISH STANDARD CODES OF PRACTICE. For Ireland install in accordance with IS 813 “I

NSTALLATION OF

GAS APPLIANCES”.

7.2 B.S. Codes of Practice

Standard Scope

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

domestic purposes. BS 5449 Part 1 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.

WARNING - The addition of anything that may interfere with the normal operation of the appliance without the express written permission of Baxi UK Limited could invalidate the appliance warranty and infringe the G

AS SAFETY

(Installation and Use) REGULATIONS.

7.3 Clearances (Fig. 12 & 13)

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 Location

1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard - see Section 7.5).

2. If the boiler is sited in an unheated enclosure then it is recommended to leave the ON/OFF/RESET Selector Switch in the domestic hot water and central heating position to give frost protection.

3. If the boiler is fitted in a room containing a bath or shower reference must be made to the current

I.E.E. W

IRING REGULATIONS and BUILDING

REGULATIONS. 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).

200mm Min

780mm

450mm

200mm Min

5mm Min

5 mm Min

450mm Min

For Servicing

Purposes

Fig. 12

Fig. 13

In Operation

7.0 Site Requirements

7.5 Ventilation of Compartments

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

2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.

7.6 Gas Supply

1. The gas installation should be in accordance with BS6891.

2. The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock (Fig. 14).

3. Ensure that the pipework from the meter to the appliance is of adequate size. Do not use pipes of a smaller diameter than the boiler gas connection (22mm).

7.7 Electrical Supply

1. External wiring must be correctly earthed, polarised and in accordance with current I.E.E.

IRING REGULATIONS.

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

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

Connection may be via a fused double-pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only.

Fig. 14

Gas Service Cock

7.0 Site Requirements

Fig. 16

7.8 Flue

1. The flue terminal position must be in accordance with the current editions of B.S. 5440 Part 1, and either Part J of the Building Regulations England and Wales or Part F of the Building Standards (Scotland) Regulations as appropriate.

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. If a terminal is less than 2 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be provided.

Terminal Position with Minimum Distance (Fig. 16) (mm)

A Directly below an openable window, air vent or any other

ventilation opening. 300 B Below gutter, drain/soil pipe. 25 C Below eaves. 25 D Below a balcony/car port roof. 25 E From vertical drain pipes and soil pipes. 25 F From internal or external corners. 25 G Above adjacent ground or balcony level. 300 H From a surface facing a terminal. 600 I Facing a terminals. 1200 J From opening (door/window) in carport into dwelling. 1200 K Vertically from a terminal on the same wall. 1500 L Horizontally from a terminal on the same wall. 300 M Above an opening, air brick, opening window etc. 300 N Horizontally to an opening, air brick, opening window etc. 300

H,I

B,C

Likely flue positions requiring a flue terminal guard

300 min

Terminal Assembly

Top View Rear Flue

Property Boundary Line

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