Home

Baxi 80e Quick Start Manual

1. Section Page 1 0 Introduction 4 2 0 General Layout 5 3 0 Appliance Operation 6 4 0 Technical Data 7 5 0 Dimensions and Fixings 9 6 0 System Details 10 7 0 Site Requirements 13 8 0 Installation 18 9 0 Commissioning the Boiler 23 10 0 Completion 25 11 0 Servicing the Boiler 26 12 0 Changing Components 28 13 0 Illustrated Wiring Diagram 37 14 0 Fault Finding 38 15 0 Short Parts List 43 CM Front Panel Control Box Fig 1 Data Badge 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 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 1 0 Introduction Baxi UK Limited declare that no substances harmful to health are contained in the appliance or u
2. 3 Note the position of all plugs and wires on the P C B and disconnect them 4 Undo the securing screws and remove the P C B Transfer the control knob drive pins to the new P C B and turn them fully anticlockwise 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions EEZ Selector Switch 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Remove the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pin 3 Note the position of the electrical connections and the orientation of the switch Remove the electrical connections 4 Remove the screws securing the switch to the facia panel 5 Fit the new switch ensuring that it is correctly positioned and reassemble in reverse order Plate Heat Exchanger Fig 64 Sensing Pipes Microswitch Bracket Grub Screws DHW Pressure Fig 65 i Differential Valve Diaphragm Diaphragm 12 0 Changing Components ERA Plate Heat Exchanger Fig 64 1 Drain the primary circuit 2 While supporting the heat exchanger undo the screws securing it to the brass manifolds 3 Withdraw the heat exchanger upwards and to the left of the gas valve taking care not to damage any wires or controls Seals 4 There are four ru
3. seconds NO sections H amp K YES Replace PCB Burner on d negn Ag Go to section F illuminated YES Burner extinguishes YES A neon flashing after 10 seconds Go to section I yo NO Burner output modulates until set Go to section G temperature is reached YES YES YES YES Operation sequence Burner goes out Fan stops Pump stops correct 38 14 0 Fault Finding Domestic Hot Water Follow operational sequence Replace diaphragm YES DHW flow valve diaphragm damaged Go to section A Is mains water YES filter and differential assembly clean YES NO DHW flow rate more than DHW flow valve rod 2 5I min obstructed n Replace DHW flow from CH system to DHW NO flow microswitch terminals heat exchanger and flow and PCB A5 connector microswitch operated terminals 5 amp 6 Replace PCB neon illuminated YES NO neon flashing YES Primary flow switch neon flashing operated Go to section C YES Turn selector to reset position If regular Fan runs at max speed YES Turn selector to Q neon illuminated YES amp neon flashing resetting is required or Go to section J appliance still does not NO operate investigation is amp amp WW neons flashing necessary Go to section D Air pressure switch NO B neon flashing proved Go to section E YES Turn the selector to the Spark at ignition YES re electrodes for
4. 1 The frost protection mode is integral to the appliance and functions only with the selector switch see Section 2 1 in the domestic hot water and central heating position If the system temperature falls below 5 C then the boiler will fire on its minimum setting until a flow temperature of 30 C is reached Further protection can be incorporated by using a system frost thermostat EX Pump Protection 1 With the selector switch see Section 2 1 in either the central heating or central heating and domestic hot water position the pump will automatically operate for 1 minute in every 24 hours to prevent sticking 4 0 Technical Data ESM Combi 80e Appliance Type C42 Cao NO Class 3 DHW Circuit bar Pressures Appliance Category CATI 213 Flue Terminal Diameter 100mm Max Operating 8 Dimensions Projection 95mm i i Heat Input C H amp DHW Gross Min Operating 0 2 Max Min i i Connections copper tails i cm Pressure 0 9 kW 26 3 10 6 Gas Supply 22mm ape mn Btu h 89 739 31 738 Central Heating Flow 22mm Flow Rates l min Central Heating Return 22mm DHW Flow Rate Heat Output Max Min Cold Water Mains Inlet 15mm 30 CRise 13 7 kW 240 93 bM MM ae DHW Flow Rate Btu h 81 891 31 738 Pressure Relief Discharge 15mm 35 C Rise 98 Max Gas Rate Natural Gas G20 Outercase Dimensions Min Working After 10 Mins Casing Height 780mm DHW Flow Rate 2
5. LPG Gases Propane G31 Burner Injector 15 x 0 77mm diameter Metre wg Burner Pressure Max Rate Min Rate Propane mbar 36 2 6 4 in wg 14 5 2 6 Inlet Pressures mbar in wg Ih O 200 400 600 800 1000 1200 5 0 Dimensions and Fixings A 780mm B 345mm C 450mm D 107mm Min E 200mm F 190mm G 143mm Tube 100mm Tap Rail 65 mm 65 mm 65 mm 65 mm 65 mm re Heating Domestic Hot Gas Cold Water Heating Pressure Relief Flow Water Outlet Inlet Inlet Return Valve 22mm 15mm 22mm 15mm 22mm 15mm m 4 G ta m 10 6 0 System Details EB Information 1 The Baxi Combi 80e and 105e Combination Boilers are Water Byelaws Scheme Approved Products To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes IRN a IRN001 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 ENB 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 corrosi
6. Sensing Pipe By pass Diaphragm en Pipe Heating Flow Pipe Diverter Manifold Fig 67 Pressure Gauge Capillary Cartridge Body Filter Gauze 7 Flow Q Regulator J S Venturi Fig 68 Inlet Return Manifold 36 12 0 Changing Components ERA Diverter Valve Assembly Cont Pressure Differential Valve Fig 67 1 Remove the pressure differential valve as described above 2 From the brass diverter manifold undo the nut on the heating flow pipe Remove the screw securing the diverter manifold to the appliance lower bracket 3 Disconnect the pressure gauge capillary from the diverter manifold and remove the two wires from the microswitch 4 Prise off the spring clip securing the by pass pipe to the diverter manifold and disconnect the sensing pipe 5 Ease the diverter manifold out of the plate heat exchanger manifold Remove the assembly from the appliance 6 Undo the screw securing the microswitch bracket to the valve body The sensor may now be dismantled to examine the diaphragm 7 To examine the diaphragm hold the assembly securely and carefully remove the four screws The diaphragm spring will force the two halves of the valve apart 8 Carefully examine the diaphragm and replace it if there is any damage 9 Reassemble in reverse order CH Pressure Microswitch Fig 67 1 Remove the two wires from the Pressure microswitch 2 Un
7. 1 Note the positions of the two sensing tubes and three wires and remove them 2 Remove the two screws holding the pressure switch to the combustion box top panel 3 Fit the new pressure switch and reassemble all components in reverse order of dismantling EE Fan Figs 46 amp 47 1 Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them Fan Wires 2 Slacken the screws on the outlet sealing collar Ease the collar upwards as far as possible 3 Remove the four screws securing the combustion box door and remove the door ZR o ZA XT Etc oe Fan and Hood NC Tubes Assembly t Outlet Sealing Collar 5 Undo the screws securing the fan hood to the Fig 46 appliance back panel and draw the fan and hood assembly forwards 4 Remove the spring clips retaining the air box side baffle plates Disengage the tabs on the baffles from the slots in the fan hood 6 Remove the screws and spring washers securing the fan to the hood ren 7 Fit the new fan to the hood using the screws and spring washers previously removed m 8 Reassemble in reverse order of dismantling m Spring Washer Securing Screw Fig 47 Fan Hood 28 Heat Exchanger 80e model Pipe Connecting Clips fe Heat Exchanger A 105e model Pipe Connecting Clips Electrodes ig amp G ATi 2 i Electrode c we
8. 15mm DHW Flow 15mm Pressure Relief Discharge 15mm 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 49 Packaged Flue Kit 3 Installation Lift Weight 41 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 12 7 l min 0 96 Flow Rates l min DHW Flow Rate 30 C Rise 14 8 DHW Flow Rate 35 C Rise 12 7 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 1 2 of Boiler unpressurised 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 Pump Available Head The seasonal efficiency SEDBUK is 78 5 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
9. A small amount of water may drain from the boiler in the upright position Baxi UK Limited declare that no substances harmful to health are contained in the appliance or used during construction of the appliance Wall Plate p 8 0 Installation ZH Fitting The Boiler 1 Remove the sealing caps from the boiler connections 2 Lift the boiler using the lower edges Engage the slots at the top rear of the boiler on the wall plate Fig 18 3 Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections The rubber washers must be used on the gas connection 4 Tighten all the connections 5 Secure the boiler side panels to the boiler wall plate flanges using the screws provided Fig 18 a EXE Fitting the Pressure Relief Discharge Pipe Fig 19 1 Remove the discharge pipe from the kit 2 Determine the routing of the discharge pipe in the vicinity of the boiler Make up as much of the pipework as is practical including the discharge pipe supplied 3 The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPORTANT Make all
10. pieces carefully out of their carriers 3 To replace the rear insulation piece it is necessary to remove the heat exchanger as Rear insulation described in Section 12 3 and slide out the side pieces Side Insulation 4 The combustion box door insulation piece can be replaced by carefully bending up the two retaining tabs 5 Replace all insulation pieces and reassemble in reverse order Side Insulation Combustion Box Door Front Insulation Fig 51 30 Gas Valve Electrical Plug Ze Earth Wire Wes Inlet Pipe 8 Gas Feed Pipe Fig 52 Flow Pipe Central Heating Temperature Sensor IPD 9 aN st Safety Thermostat Fig 53 Fig 53a DHW Temperature Sensor 12 0 Changing Components EAJ Gas Valve Fig 52 1 Undo the nut on the gas feed pipe under the boiler 2 Remove the securing screws and hinge the facia panel down 3 Disconnect the earth wire and pressure sensing pipe from the valve Undo the screw securing the electrical plug to the valve and disconnect the plug Disconnect the wires from the valve modulator 4 Remove the screws securing the inlet pipe flange to the boiler bottom panel and those securing the outlet manifold to the burner manifold 5 Remove the valve from the boiler 6 Note the orientation of the inlet pipe and outlet manifold Undo the securing screws and remove the pi
11. soldered joints before connecting to the pressure relief valve Fig 19 19 Wall Thickness Fig 20 x Waste s A Air Duct Waste E Fig 21 VILL Flue Duct 20 8 0 Installation EXE Fitting The Flue HORIZONTAL FLUE 1 The standard flue is suitable for lengths 100mm minimum to 1m maximum measured from the edge of the flue elbow outlet 80e model only If the optional rear flue kit is to be used refer to the instructions supplied Rear Flue maximum wall thickness 900mm Side Flue maximum wall thickness 870mm 2 If using the optional internal fitting kit flue extension kit or elbows refer to the instructions provided with the kits 3 Locate the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation rear right or left 4 Measure the distance from the outside wall face to the elbow Fig 20 This dimension will be known as X 5 Taking the air duct mark dimension X as shown Fig 21 Measure the length of waste material and transfer the dimension to the flue duct Fig 21 6 Remove the waste from both ducts Ensure that the cut ends are square and free from burrs 7 Remove the flue elbow from the adaptor IMPORTANT Check all measurements before cutting Restrictor Elbow f Adaptor E Fig 22 Clip Fig 23 Flue Duct Clamp Fi
12. the retaining clips 6 Reassemble in reverse order Fully recommission the appliance and system IPAE Spark Generator Fig 60 1 Pull the electrode lead off the spark generator Remove the screws and spring washers securing the generator to it s mounting bracket 2 Pull the rubber shroud off the generator input plug and disconnect the plug 3 Reassemble in reverse order 33 Grub Screw Pressure Relief Valve Fig 61 Control Box Cover Fig 62 P C B Selector Switch a bn Drive Pins Facia Selector Switch Knob adi Q2 Temperature Control Knobs 34 Fig 63 O lt 12 0 Changing Components KENT Pressure Relief Valve Fig 61 1 Drain the primary circuit 2 Disconnect the discharge pipe from the valve Using a suitable hexagon key undo the grub screw sufficiently to release the valve 3 Note the orientation of the valve rotate it and withdraw it from the manifold 4 Fit the new valve and O ring seal and set to the previously noted orientation Reassemble in reverse order EERE P c B Fig 63 1 Note the settings of the temperature control knobs Rotate the knobs fully anticlockwise and carefully pull them off the drive pins 2 Remove the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pin Fig 62
13. timer device 2 Suitable timer kits are available as optional extras 3 For optimum operating conditions and maximum economy the fitting of a programmable room thermostat such as the Baxi Combi Controller is recommended Double Stop Check Stop Valve Valve Temporary Hose Mains Inlet Fig 4 Fig 5 Pressure Relief Valve Discharge Pipe 6 0 System Details XE 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 Fig 4a 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 t
14. 5 m h 2 78 Overall Height Inc Flue ft h 98 12 Elbow 980mm Pump Casing Width 450mm Available Head See graph below Burner Pressure Natural Gas G20 iib halal id Expansion Vessel For Central Heating oe i Tu Clearances only Integral with appliance ee EM ops Both Sides 5 mm Min bar in wg 4 88 0 2 1 0 0 2 Above Casing 200 mm Min Min Pre charge Pressure 0 5 Below Casing 200 mm Min Inlet Pressure Natural Gas G20 Front 450 mm Min For Servicing litre mbar 20 Front 5 mm Min In Operation Max Capacity of i CH System 125 ae 3 Weights kg Burner Injector Natural Gas G20 Packaged Boiler Carton 47 Primary Water Content 10 12 x 1 28mm Diameter Packaged Flue Kit 3 of Boiler unpressurised Installation Lift Weight 39 Electrical Supply 230V 50H T t Appliance musti connectedito an Central Heating Primary Circuit VL AE earthed supply Pressuros C H Flow Temp adjustable 35 C to 85 C max 5 C Power Consumption 170W bar Vaid moti i 5 D H W Flow Temp adjustable External Fuse Rating 3A ax perating 35 C to 65 C max 5 C Min Operating 0s dependent upon flow rate Recommend Operating 1 2 Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 Electrical Protection IPX5D SEDBUK Declaration For Combi 80e Pump Available Head The seasonal efficiency SEDBUK is 78 6 This value is used in the UK Government s Standard Assessment Procedure SAP for energy ra
15. Continuity across flow microswitch and PCB A5 connector terminals 7 amp 8 Replace microswitch 2 Primary temperature sensor faulty Cold resistance approx 11K ohms resistance reduces with increase in temp Replace sensor Fan connections correct at fan PCB A2 connector is 230V across terminals 5 amp 7 YES Fan jammed or faulty winding Replace fan Replace PCB 40 14 0 Fault Finding Check and correct if necessary 1 Electrical and pressure tube connections No z Replace air 2 Blockage of pressure tubes NE pressure switch 3 Restriction in flue 4 Venturi F NO Ensure gas is on and purged PCB A1 connector has 230V AC YES across terminals 2 amp 4 NO YES neon iflashing NO Replace PCB Replace gas valve Turn selector switch to reset position R Check the burner setting pressure of the gas valve see Section of Commissioning Voltage at modulating coil of gas valve is Max burner press approx 9V DC 13V DC LPG Min burner press approx 1V DC Replace gas valve Current at modulating coil of gas valve is Use an instrument with average function for this measure 30 230 mA DC 45 310 mA DC LPG Replace PCB Check and correct if necessary NO Replace PCB 1 Ignition electrode and lead yes 230V Maln des Al 2 Electrode connection sae c c nini SS YES ar 3 Spark gap and position oper Replace igniter 41 42 Ensure tha
16. Domestic Hot Water Mode A Z Central Heating Mode 32 Burner On Q 4 When neons 23 to 28 are constantly illuminated A A A A they indicate the temperature of the central heating water Z 9 8 DD wos HO Bos 20 D e 8 b 20 21 22 10 9 Central Heating Circuit 23 22 11 16 Fig 2 Key 1 Primary Heat Exchanger 14 Gas Inlet 2 Burner 15 Domestic Hot Water Outlet 3 Ignition Electrode 16 Heating Flow 4 Flame Sensing Electrode 17 Pressure Gauge 5 Gas Valve 18 Hydraulic Differential Pressure Sensor Microswitch 6 Pump 19 Automatic By Pass 7 Automatic Air Vent 20 Hydraulic Differential Pressure Sensor 8 Plate Heat Exchanger 21 Diverter Valve Assembly 9 Flow Sensor with Filter 22 Domestic Hot Water Flow Priority Assembly 10 Pressure Relief Valve 23 Domestic Hot Water Flow Priority Microswitch 11 Boiler Drain Point 24 Safety Thermostat 12 Heating Return 25 Central Heating Temperature Sensor 13 Cold Water Inlet On Off Valve and Filter 26 Expansion Vessel 27 Domestic Hot Water Temperature Sensor Domestic Hot Water Circuit 23 22 T3 16 Fig 3 3 0 Appliance Operation NOTE All delay timers mentioned in 3 1 and 3 2 are overridden by domestic hot water demand ERJ Central Heating Mode Fig 2 1 With a demand for heating the pump circulates water through the primary circuit At a pre determined flow rate the central heating flow switch operates initiating the ignition sequence 2 The main b
17. Please leave these instructions with the user Baxi Combi 80e amp 105e Gas Fired Wall Mounted Combination Boiler Installation and Servicing Instructions Natural Gas Baxi Combi 80e G C N 47 075 06 Baxi Combi 105e G C N 47 075 08 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 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
18. and servicing the boiler and system controls only 7 0 Site Requirements 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 QS Likely flue positions requiring a flue terminal guard Fig 11 Terminal Position with Minimum Distance Fig 11 A Directly below an openable window air vent or any other ventilation opening 300 B Below gutter drain soil pipe 25 Terminal 300 min C Below eaves 25 Assembly i i D Below a balcony car port roof 25 N i E From vertical drain pipes and soil pipes 25 i E F From internal or external corners 25 1 i G Above adjacent ground or balcony level 300 i i H From a surface facing a terminal 600 Facing a terminals 1200 i J From opening door window in carport into dwelling 1200 f K Vertically from a terminal on the same wall 1500 i L Horizontally from a
19. bber seals between the manifolds and heat exchanger which may need replacement 5 Ease the seals out of the manifold Replace carefully ensuring that the seal is inserted into the manifold parallel and pushed fully in 6 When fitting the new heat exchanger note that the left hand location stud is offset towards the centre more than the right hand one 7 Reassemble in reverse order KEEZ Diverter Valve Assembly Figs 65 amp 66 The diverter valve assembly comprises of a central heating pressure differential valve and a domestic hot water pressure differential valve These are connected to a manifold which is joined to the plate heat exchanger DHW Pressure Differential Valve Fig 66 1 Drain the primary circuit 2 Undo the screw securing the microswitch bracket to the valve Fig 65 3 Disconnect the two sensing pipes and slacken the grub screws securing the valve to the diverter manifold 4 Draw the valve away from the diverter manifold The valve may now be replaced or split to examine the diaphragm 5 To examine the diaphragm hold the valve body securely and carefully remove the six screws The diaphragm spring will force apart the two halves of the valve 6 Remove the plastic disc and pushrod assembly Carefully examine the diaphragm and replace it if there is any damage 7 Reassemble in reverse order 35 Central Heating Pressure Differential Microswitch Bracket Valve
20. be checked for suitability before connection see Section 7 6 1 After considering the site requirements see Section 7 0 position the fixing template Fig 16 on the wall ensuring it is level both horizontally and vertically 2 Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes It is preferable to use the horizontal fixing slots 3 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown 4 Note the shaded area on the template Pipework may be routed upwards behind the boiler providing it does not conflict with the shaded area 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 107mm 7 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 8 Using a spirit level ensure that the plate is level before finally tightening the screws 9 Connect the gas and water pipes to the valves on the wall plate using the copper tails supplied Ensure that the sealing washers are fitted between the connections EJ Flushing 1 Connect a tube to the central heating flow or return pipe Fig 17 2 Flush thoroughly see System Details Section 6 2 8 3 Preparing The Boiler 1 Remove all packaging 2 Stand the boiler on its base by using the rear lower edge as a pivot NOTE
21. ct Natural Gas 20mbar Butane 30mbar and Propane 37mbar 9 The pressure can be adjusted if required Selector Switch Pressure Fig 35 i Gauge 10 To check minimum pressure first remove one of the modulator wires Adjusting the Pressure Fig 34a 11 Prise apart the spring clip retaining the modulator Draw the modulator off the valve Power On n a 12 Slacken the adjuster tube locknut Rotate the Neon Central Heating Hot Water tube until the correct maximum pressure is Temperature Control Temperature Control achieved Tighten the locknut Fig 36 13 Rotate the minimum rate adjuster screw until the correct minimum pressure is achieved 14 Once the pressure has been set turn the boiler off and disconnect the pressure gauge 15 Tighten the pressure test screw and refit the modulator to the valve Reassemble in reverse order 24 Facia Panel CRI Front Panel CA 10 0 Completion EAN Completion 1 Hinge the facia panel upwards and refit the case front panel Secure them with the screws previously removed Fig 37 2 Instruct the user in the operation of the boiler and system explaining the operational sequence 3 Carefully read and complete all sections of the Benchmark Installation Commissioning and Service Record Log Book that are relevant to the appliance and installation The details of the Log Book will be required in the event of any warrant
22. do the screw securing the microswitch bracket to the valve body 3 Reassemble in reverse order KEEPER Flow Regulator Figs 68 amp 69 1 Undo the filter cartridge from the inlet return manifold 2 Unscrew the venturi and remove the flow regulator 3 Check the cleanliness of the filter gauze rinsing thoroughly in clean water as necessary Fit the new flow regulator and reassemble in reverse order 13 0 Illustrated Wiring Diagram Air Pressure Switch Central Heating Temperature Sensor Domestic Hot Water Temperature Sensor Domestic Hot Water Flow 2 Priority Pressure Switch Hydraulic Differential Pressure Switch CONAnAWY o Control PCB Sensing Electrode b b wo Oo r br bk b 1 2 b 4 b 12 3 4 1 2 3 4 ee t t o L A2 5 vul 6 7 8 9 b br b b b bk br bk Spark Generator br brown g green bk black g y green yellow b blue w white r red Optional Timers 37 14 0 Fault Finding Carry out initial fault finding checks 1 Check that gas water and electrical supplies are available at the boiler Electrical supply 230V 50 Hz CH water system pressurised to 0 5 bar when the boiler is cold The preferred minimum gas pressure is 19 5mbar natural gas 27mbar butane or 36mbar propane 2 Carry out electrical system checks i e Ground Continuity Resistance to Ground Short Circuit and Polarity with a suitab
23. e Grommets 1 7 Fig 49 Electrode Leads 12 0 Changing Components 12 3 Heat Exchanger Fig 48 1 Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them 2 Slacken the screws on the outlet sealing collar Ease the collar upwards as far as possible 3 Remove the four screws securing the combustion box door and remove the door 4 Remove the spring clips retaining the air box side baffle plates Disengage the tabs on the baffles from the slots in the fan hood 5 Undo the screws securing the fan hood to the appliance back panel and draw the fan and hood assembly forwards 6 Drain the primary circuit Prise the two pipe connecting clips off the joints in the flow and return pipes 7 Lift the heat exchanger to disconnect the flow and return pipe joints Withdraw it from the appliance taking care not to damage the rear insulation piece 8 Fit the new heat exchanger 9 Reassemble in reverse order of dismantling and repressurise the system 12 4 Burner Fig 49 1 Remove the four screws securing the combustion box door and remove the door 2 Undo the screws securing the burner to the injector manifold 105e model only Draw the burner out of the combustion box pulling the electrode grommets from the slots in the combustion box lower panel 3 Disconnect the electrode leads and grommets from th
24. e control box to drop down Tighten the cable clamp s on the boiler chassis 9 If the optional integral timer is to be used it should be fitted at this point Refer to the instructions supplied with the timer NOTE An external frost thermostat cannot be used with the integral timer Preliminary Electrical Checks 1 Prior to commissioning the boiler preliminary electrical system checks should be carried out 2 These should be performed using a suitable meter and include checks for Ground Continuity Resistance to Ground Short Circuit and Polarity 7 Automatic Air Vent Selector Switch Pressure Fig 32 Gauge 9 0 Commissioning the Boiler EX Commissioning the Boiler 1 Reference should be made to BS 5449 Section 5 when commissioning the boiler 2 Open the mains water supply to the boiler 3 Open all hot water taps to purge the DHW system 4 Ensure that the filling loop is connected and open then open the heating flow and return valves on the boiler 5 Open the screw on the automatic air vent Fig 31 6 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 7 Pressurise the system to 1 0 bar then close and disconnect the filling loop 8 Turn the gas supply on and purge the system according to BS 6891 9 Test for gas soundness 10 If at any time during comm
25. e electrodes Completely remove the burner 4 Undo the screws securing the electrodes to the burner Examine the condition of the electrodes replacing if necessary Fit the electrodes to the new burner 5 Engage the burner location brackets over the studs on the injector manifold and reassemble in reverse order 29 12 0 Changing Components EEG Injectors Fig 50 Injector Manifold Inlet Elbow 1 Remove the burner as described in Section 12 4 Gasket 2 Undo the screws securing the injector manifold to the inlet elbow and remove the manifold 3 Unscrew and replace injectors as required and examine the sealing gasket replacing as necessary Reassemble in reverse order Burner amp 5 Fig 50 12 6 Electrodes Fig 50 K l Electrode vi mE rey 1 Remove the four screws securing the Grommets 7j combustion box door and remove the door Electrode 2 Undo the screws securing the burner to the Leads injector manifold 105e model only Draw the burner out of the combustion box pulling the electrode grommets from the slots in the combustion box lower panel 3 Disconnect the lead and grommet from the electrode being replaced Undo the securing screw and withdraw the electrode to the burner 4 Reassemble in reverse order Insulation Fig 51 1 Remove the four screws securing the combustion box door and remove the door 2 Slide the side insulation
26. emporary hose must be completely removed at both ends after use l66 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 Pressure Relief Valve Fig 5 1 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressures in excess of 3 bar 2 The pressure relief discharge pipe should be not less than 15mm dia run continuously downward and discharge outside the building preferably over a drain It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components The end of the pipe should terminate facing down and towards the wall 3 The discharge must not be above a window entrance or other public access Consideration must be given to the possibility that boiling water steam could discharge from the pipe 11 12 Other Tap Outlets Expansion Vessel Pressure JN Reducer Valve To Hot Taps Fig 6 6 0 System Details XE Domestic Hot Water Circuit Fig 6 1 All DHW circuits connections fittings etc should be fully in accordance with relevant standards the Water Supply water fittin
27. g 24 Clip ios Fig 25 8 0 Installation EXE Fitting the Flue Cont IMPORTANT If the equivalent flue length is greater than 1 5m the restrictor MUST be removed from the adaptor Fig 22 8 Insert the flue duct into the air duct and pass them through the hole in the wall 9 Take one of the rubber seals and position it on the boiler flue adaptor Engage the flue elbow on the adaptor and pull the sleeve up so that it equally covers the joint Fig 22 10 Remove the screws from one of the clips provided Prise the clip apart and fit it over the seal Fig 23 Set the elbow to the required angle 11 Refit the screws to the clip and tighten them to secure the elbow Take the second rubber seal and position it on the flue elbow 12 Locate the flue duct clamp on the flue outlet elbow Draw the flue duct out of the air duct engage it in the clamp and tighten the screws Fig 24 13 Draw the air duct out of the wall and align it with the elbow Position the seal so that it equally covers the joint Fig 25 14 Remove the screws from the second clip provided Prise the clip apart and fit it over the seal Refit the screws to the clip and tighten them Fig 25 15 Where possible position the clips so that the screws are not visible 16 Make good between the wall and air duct outside the building 17 Fit the circular flue trim outside if required and if necessary fit a termina
28. g a bath or shower reference must be made to the current I E E WiRING 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 13 14 Gas Service Cock 7 0 Site Requirements Ventilation of Compartments 1 Where the appliance is installed in a cupboard or compartment no air vents are required 2 BS 5440 Part 2 Clause 4 2 refers to room sealed appliances installed in compartments The appliance will run sufficiently cool without ventilation 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 9 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 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with current I E E WiRING REGULATIONS 2 The mains supply is 230V 50H fused 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
29. gs 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 6 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 z 15bar 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 XE 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 wa
30. he pump wiring cover and remove the cover Using a suitable flat bladed Screw driver press the cable securing levers downwards to release each wire after noting their position 3 A standard Grundfos replacement head can now be fitted A Grundfos 15 50 head is suitable for the Combi 80e The Combi 105e requires a 15 60 head Connect the wiring to the new head The pump speed must be set to 3 Fig 55 4 Reassemble in reverse order Pump Wiring Cover 12 13 Pump Complete Fig 56 1 Drain the primary circuit and unscrew the automatic air vent from the pump body Undo the two screws securing the body to the pipe and manifold and draw the pump forwards 2 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position Socket Headed gt Screw Pump Head 3 Connect the wiring to the new pump Examine Fig 54 l the O ring seals on the return pipe and manifold i replacing if necessary 4 Fit the air vent to the pump body and reassemble in reverse order Pump Setting EAE Automatic Air Vent Fig 56 Automatic Fig 55 Air ven E 1 Drain the primary circuit and unscrew the e automatic air vent from the pump body Pump Wirin 2 Examine the O ring seal replacing if aie necessary and fit it to the new automatic air vent 3 Reassemb
31. issioning it is required to terminate a particular cycle e g the pump overrun period turn the selector to the OFF position and then back to either or fff Fig 33 Power On Neon Central Heating Hot Water Temperature Control Temperature Control Fig 33 23 9 0 Commissioning the Boiler 19 2 Checking the Burner Pressure Pressure Test Point Sealing Screw 1 Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for heat 2 Set the temperature controls to maximum and the selector switch to the Off position Fig 36 3 Slacken the pressure test point sealing screw on the gas valve and connect a pressure gauge Fig 33 4 Undo the screws securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case 5 Turn the selector switch fully anticlockwise against the spring pressure to the reset position Minimum fate z and hold for 2 seconds to reset the boiler Adjuster Screw 6 Turn the selector switch to the Cental Heating and Domestic Hot Water position ij The power On neon Q will illuminate Fig 36 7 Turn a hot water tap on to give a flow rate of at QM least 10l min Modulator Seino 8 The pressure should be Fig 34a 80e 105e NG 12 2mbar 13 4mbar Butane 28 3mbar n a Propane 36 2mbar 35 8mbar If not check that the gas supply pressure is corre
32. l Flues Rear Flue 80e only Vertical Flues Twin Pipe Maximum Length 14m inc 4 x 45 bends Q Vertical Flues Maximum Length 2m inc 2 x 90 bends ALP 7 0 Site Requirements Flue Options 1 The Baxi Combi 80e and 105e can be fitted with flue systems as illustrated 2 The standard flue is suitable only for horizontal applications 3 The 80e model ONLY can also be fitted with a flue system that exits horizontally from the rear of the appliance dispensing with the need for the top flue elbow 4 Maximum permissible equivalent flue lengths are 80e 105e Concentric 5m 4m Vertical 4m 4m Vertical Two Pipe 15m 12m 5 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 45 bend 0 5 metres 90 bend 1 0 metres Twin Flue Pipe 45 bend 0 25 metres 90 bend 0 50 metres The elbow supplied with the standard horizontal flue is not included in any equivalent length calculations 6 The illustrations opposite show examples of maximum equivalent lengths 7 Full details of part numbers and descriptions of all optional flue components and kits can be found in the Baxi Gas Central Heating Boilers Installers Guide 8 Instructions for guidance and fitting are included in each kit where appropriate 17 Fixing Template ry 200 mm Minimu
33. l guard see Section 7 10 amp 7 11 VERTICAL FLUE 1 Only a flue approved with the Baxi Combi 80e and 105e can be used 2 For information on vertical flues consult the Baxi Combi Installer Guide or Notes for Guidance supplied with the vertical flue pack 21 Control Box Cover Fig 27 Fig 28 Cable Clamp Frost Thermostat Fuse N External Clock Fused supply 3A Always fit fast 230V 50Hz Ablow 2A fuse Live brown Neutral blue Earth green yellow Room Thermostat Fig 26 Facia Panel IMPORTANT If an integral timer is fitted to the boiler an external frost thermostat wired as shown will not operate correctly Only external timers may be used in such installations as in the diagram Terminal Block Fig 29 Functional Flow Diagram External Controls Selector Reset Switch Fig 30 Pump b t N Safety Overheat Thermostat c Central Heating i NTC Sensor 1 9 bk jg DHW NTC Sensor PCB b br Gas Valve bk K to Wiri bk Gas Valve Modulator ey to Iring b i blue T J4 x Flame Sensing Electrode br brown br r Spark Electrode bk black b N Spark r red Generator T tr g green L Hydraulic Differential Pressure Switch T r 22 4 9 a DHW Flow Priority Microswitch T 8 8 0 In
34. le in reverse order Fig 56 Pressure Gauge Capillary Gauge Retaining Bracket been Pressure Gauge Expansion Vessel Vessel Outlet E Spigot Boiler ros pig SA Chassis as E Lock Nut Spring Washer Fig 59 Mounting Bracket Spark Generator A Fig 60 Electrode Lead 12 0 Changing Components EAH Pressure Gauge Figs 57 amp 58 1 Drain the primary circuit and undo the nut on the pressure gauge capillary 2 Remove the timer cover and ease the timer wiring aside Undo the screws securing the gauge retaining bracket 3 Remove the bracket and gauge assembly Depress the barbs on the side of the gauge and remove the retaining bracket 4 Reassemble in reverse order EAN Expansion Vessel Fig 59 1 To replace the expansion vessel it is necessary to remove the boiler from the wall Note Alternatively a vessel of equivalent capacity can be fitted on the system return pipe as close as possible to the boiler 2 Drain the system and undo all gas and water connections Remove the flue elbow 3 Lift the boiler off the wall plate and lay it on it s side on a clean flat surface 4 Undo the nut on the vessel outlet spigot and remove the locknut and spring washer securing the spigot to the boiler chassis 5 Undo the screws and remove the appliance upper cross member Slide the expansion vessel out of
35. le meter NOTE These checks must be repeated after any servicing or fault finding 3 Ensure all external controls are calling for heat and check all external and internal fuses Before any servicing or replacement of parts ensure the gas and electrical supplies are isolated Refer to Section 13 0 Illustrated Wiring Diagram for position of numbered terminals Central Heating Follow operational sequence NOTE When instructed to turn the selector to the reset position turn the b selector to Me NO Go to section A selector switch fully anticlockwise neon illuminated against the spring pressure to position R and hold for 2 seconds to neon flashing reset the boiler Go to section B YES YES Turn fff thermostat External controls and Ensure controls are set to to max where fitted integral timer demand and verify the Pump runs calling for heat contacts are closed S Primary flow switch NO Q3 neon flashing operated Go to section C YES Turn selector to reset position If regular Fan runs at max speed NO amp neon flashing reseting es required or Go to section J appliance still does not YES NO operate investigation is necessary BA amp ig neons flashing Go to section D NO Air pressure neon flashing Switch proved Go to section E YES Spark at ignition electrodes for up to 10 Turn selector to the reset position If the neon does neo flashing not extinguish go to
36. llar upwards as far as possible Fig 41 9 Remove the four screws securing the combustion box door and remove the door Fig 40 Y tm Sensing T Tubes Fan EN EN Fig 41 Inner Door i Outlet Sealing Panel Collar Combustion Box Door r 80e models meN Sy Combustion i SN Box Door 105e models yj Nu Inner Door Panel 26 11 0 Servicing the Boiler EERE Annual Servicing Cont 10 Remove the spring clips retaining the air box side baffle plates Disengage the tabs on the baffles from the slots in the fan hood Fig 42 11 Undo the screws securing the fan and hood to the appliance back panel Draw the assembly forwards Fig 42a 12 Undo the screws securing the burner to the injector manifold 105e model only Draw the burner out of the combustion box pulling the electrode grommets from the slots in the combustion box lower panel Fig 43 13 Disconnect the electrode leads and grommets from the electrodes Completely remove the burner Fig 43 14 Brush any deposits from the injectors Do not use a pin or wire to clean them 15 Brush the burner blades and venturis and clean the combustion box 16 Ensure that the heat exchanger fins are clear of any obstruction DHW Filters Fig 44 17 If the flow of domestic hot water is diminished it may be necessary to clean the filters 18 Initially check the c
37. m Centre Line D Vertical Flue Centre Line Horizontal Side Flue Appliance Wall Plate 7 Boiler Mounting Bracket Fixing Slots r Drill 8 mm diameter x 50 mm deep i I 80e Model Only Alternative Flue perature s Using Rear Flue Kit Part No 247940 BAXI Combi For Side Flue Exit FIXING TEMPLATE 5 mm Minimum 5mm Minimum Side Clearance Side Clearance i i i i _ Profile of IMPORTANT Outercase Keep rear routed pipework clips and electrical cables clear of all shaded areas to allow the correct fitting of the boiler chassis i General Area For j Electrical Boiler Lower Fixing Holes i supply Drill 8 mm diameter x 50 mm deep Hm 1 i 1 i 1 i M Cr x x a 1 t T T T T 1 1 l 1 1 1 l 1 l 1 95 mm 65mm 65mm 65mm 65mm i 65mm i He iaiia t it gt lt lt gt Heating Hot Water Gas Cold Water Heating Pressure Relief Flow Outlet Inlet Inlet Return Valve 22mm 15mm 22mm 15mm 22mm 15mm 200 mm Minimum cewa VL d 6500 ta tm gt Fig 16 Wall Plate Flushing Tube s Central Heating Return Fig 17 18 8 0 Installation EXBl Initial Preparation The gas supply gas type and pressure must
38. nd be in accordance with the relevant requirements of Gas Sarety Installation and Use REGuLATIONS the BuiLpiNG 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 instructions are given reference should be made to the relevant BRITISH STANDARD CODES OF PRACTICE E Optional Extras Various flue extensions bends vertical flue kits control accessories etc are available as optional extras These are detailed in a separate publication 2 0 General Layout ES Layout 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 10 Central Heating System Pressure Gauge 11 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 Central Heating Temperature Control 22 Hot Water Temperature Control 23 Flame Failure 24 Safety Thermostat 25 Fault on Fan or Flue 26 Fault on Pump or Low System Pressure oo ee des 28 zd 28 27 Fault on Hot Water Sensor Y Y Y Vv Y 28 Fault on Central Heating Sensor 30 40 50 60 70 80 Power On 9 9 9 9 9 9
39. old water inlet tap filter 19 Turn the tap off Undo the blanking cap and remove the threaded bush Fig 43a 20 Extract the filter and rinse thoroughly in clean water Reassemble and check the flow If required clean the manifold filter as described below 21 Undo the filter cartridge from the inlet return manifold 22 Dismantle the cartridge and carefully remove the flow regulator and filter gauze Rinse them thoroughly in clean water and reassemble in reverse order 23 Check that the pressure vessel charge is 0 5bar reassemble in reverse order of dismantling and recommission 24 Turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 2 seconds to reset the boiler 25 Complete the relevant section of the Benchmark Installation Commissioning and Service Record Log Book and hand it back to the user Inlet Return Manifold 27 12 0 Changing Components IMPORTANT When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started When the new component has Pressure Switch been fitted turn the selector switch fully anticlockwise against the spring pressure to position R and hold for 2 seconds to reset the boiler before recommissioning See Section 11 1 Annual Servicing for removal of case panel door etc EAN Pressure Switch Fig 45 Pressure Switch Wires
40. on 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 e t 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 EEE Bypass 1 The boiler is fitted with an automatic integral bypass ZE System Control 1 The boiler is designed for use in a heating system that incorporates external controls i e a minimum of a
41. pe and manifold 7 Examine the O ring seals for damage replacing as necessary 8 Fit the inlet pipe and outlet manifold to the new valve ensuring that the O ring seals are in place 9 Reassemble in reverse order and check the burner pressure Section 9 2 12 9 Central Heating Temperature Sensor Fig 53 1 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way 12 10 Safety Thermostat Fig 53 1 Pull the electrical connections off the thermostat 2 Remove the screws securing the thermostat to the mounting plate on the flow pipe 3 Reassemble in reverse order The thermostat is not polarised either wire can fit either terminal on the thermostat EAE DHW Temperature Sensor Fig 53a 1 Turn off the mains water supply and draw off the residual domestic hot water 2 Ease the retaining tab on the sensor away and disconnect the electrical plug 3 Unscrew the sensor from the plate heat exchanger manifold Examine the sealing washer replacing if necessary 4 Reassemble in reverse order The plug will only fit one way 31 12 0 Changing Components EAA Pump Head Only Fig 54 1 Drain the primary circuit and remove the Socket head screws securing the pump head to the body and draw the head away 2 Undo the screw on t
42. sed during appliance manufacture 11 Description 1 The Baxi Combi 80e or 105e 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 80e or 31 0 kW 105e 3 It is designed for use on Natural Gas G20 and can be converted to use Propane 80e and 105e or Butane 80e 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 FEE 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 1 S 813 INSTALLATION OF GAS APPLIANCES The installation must be carried out by a CORGI Registered Installer or other competent person a
43. ssels 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 Gas Sarety Installation and Use REGULATIONS Clearances Figs 7 amp 8 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 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 Selector Switch in the domestic hot water and central heating position to give frost protection 3 If the boiler is fitted in a room containin
44. ssure Gauge 248090 LY 9 7 Dy My 6778 LY J j fj Wy Ay J Nir yy Ly DA QT Ay 77 779 LU ii 2 B Lyi iy Ui DS 7777777779770 QU Ny r JP i ij Diy Dis lt a Uy H LU Z 32 105e models 43 Comp N 247938 Iss 5 5 02 After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 BAXI Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www baxi com 921 660 3
45. stallation Making The Electrical Connections To connect the mains input cable proceed as follows 1 Slacken the facia securing screws and lift the outercase panel so that its locating tabs are clear of the facia Remove the panel 2 Remove the screws securing the facia panel and hinge it down Fig 26 3 Remove the control box cover securing screws Disengage the barbs on the control box from the cover Remove the cover Fig 27 4 Slacken the cable clamp on the LH side of the boiler chassis Fig 28 Insert the cable through the clamp and route it to the terminal block 5 Slacken the screws in the terminal block connect the input cable and tighten the screws 6 If an external control is to be connected it can be done at this point Run the input cable from the external control through the second cable clamp on the boiler chassis Refer to the instructions supplied with the control 7 To connect external control s remove the link between terminals 1 amp 2 The 230V supply at terminal 1 must be connected to the external control The switched output from the external control must be connected to terminal 2 Fig 29 NOTE If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Fig 29 IMPORTANT The external control MUST be suitable for 230V switching 8 Ensure that both mains input and where fitted external control input cables have sufficient slack to allow th
46. t mains input terminal L is Live 230V and N is Neutral OV Check and correct if necessary 1 Flame sensing electrode and lead connections 2 Electrode position Flame current should be 1 pA approx 14 0 Fault Finding Replace PCB Replace flame sensing electrode Overheat thermostat operated Allow to cool Continuity n Replace safety or faulty i e continuity across across thermostat terminals thermostat thermostat terminals more than 1 5 ohm Replace PCB Check terminal 1 of ON OFF RESET selector is in connection with PCB A4 connector terminal 2 Check electrical continuity across terminals 1 amp a of ON OFF RESET selector when turned to position R NO o YES o Replace ON OFF RESET selector Replace PCB 15 0 Short Parts List Short Parts List gt Key GC Description Manufacturers 44 No No Part No 22 E66 383 Fan 80e 248001 E66 527 Fan 105e 248002 23 393 974 Pressure Switch 247380 32 E66 393 Heat Exchanger 80e 248016 E66 535 Heat Exchanger 105e 248017 131 135 CF 41 E66 398 Burner 80e 248029 z E66 399 Burner 105e 248030 63 E66 402 Injector 248210 E66 408 Electrode Lead 248037 E66 411 Spark or Sensing Electrode 247384 E66 431 Pump 80e 248041 E66 539 Pump 105e 248042 E66 432 3 Way Valve Assy 248061 342 571 Temperature Sensor 247394 E66 439 Safety Thermostat 248079 343 560 Gas Valve 248085 E66 459 PCB 248074 E66 453 Pre
47. ter at too high a temperature Existing controls may not be suitable refer to the shower valve manufacturer EAD 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 5mm Min 450mm Fig 7 450mm Min F1 For Servicing Purposes In Operation Fig 8 5mm Min 780mm Y 200mm Min y 7 0 Site Requirements 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 Gas SareTY Installation and Use REGULATIONS 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 INSTALLATION OF Gas APPLIANCES 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 ve
48. terminal on the same wall 300 Top en mear Eue i M Above an opening air brick opening window etc 300 N Horizontally to an opening air brick opening window etc 300 i l 1 Property Boundary Line 15 7 0 Site Requirements Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 1m from elbow to terminal Fig 12 The maximum permissible equivalent flue length is 80e 5 metres 105e 4 metres 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 Flue Terminal Trim 1 Once the flue is secure the trim can be fitted if Flue Trim required 2 Remove the protective backing from the adhesive seal Apply the seal to the rear of the trim flange Fig 13 3 Locate the trim over the flue terminal and push it back to the wall to compress the seal Fig 14 Adhesive Seal Terminal Guard Fig 15 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 15 16 Horizonta
49. ting of dwellings The test data from which it has been calculated have been certified by 0051 LPG Gases Propane G31 and Butane G30 Burner Injector 12 x 0 77mm diameter Burner Pressure Max Rate Min Rate Propane mbar 36 2 6 4 in wg 14 5 2 6 Butane mbar 28 3 5 3 in wg 11 3 23 1000 1200 Inlet Pressures Propane Butane mbar 37 28 in wg 14 8 11 2 Appliance Type C12 C32 Appliance Category CATI 54 ap Heat Input C H amp DHW Gross Max Min kW 34 3 11 9 Btu h 117 086 40 610 Heat Output Max Min kW 31 0 10 4 Btu h 105 776 35 490 Max Gas Rate Natural Gas G20 After 10 Mins m h 3 63 ft h 128 12 Burner Pressure Natural Gas G20 Max Rate Min Rate mbar 13 4 x 0 5 1 8x0 2 in wg 5 36 0 2 0 72 0 2 Inlet Pressure Natural Gas G20 mbar 20 in wg 8 Burner Injector Natural Gas G20 15 x 1 28mm Diameter Electrical Supply 230V 50H Appliance must be connected to an earthed supply Power Consumption 190W External Fuse Rating 3A Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 Electrical Protection IPX5D SEDBUK Declaration For Combi 105e 4 0 Technical Data EE Combi 105e NO Class 3 Flue Terminal Diameter 100mm Dimensions Projection 95mm Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Cold Water Mains Inlet
50. up to 10 neon flashing edad dis r seconds g g NO section H amp K YES Replace PCB NO Burner on 4 neon illuminated Go to section F YES Burner extinguishes YES neon flashing after 10 seconds Go to section 1 NO Reduce the DHW flow rate If burner does not modulate clean DHW temperature sensor and Burner output modulates to maintain temperature set at thermostat YES DHW heat exchanger If modulation does not occur Close DHW tap go to section G YES DHW flow valve senses no flow Primary water diverted to Diverter valve spindle CH system DHW flow assembly faulty Switch released off YES NO YE i 39 14 0 Fault Finding Fault Finding Solutions Sections A to E A Is there 230V at 1 Main terminals L and N NO 2 Main terminal fuse NO 3 Selector terminals a amp b and a amp 3 PCB A4 Check electrical supply Replace fuse Check wiring Replace selector neon NO Repl PCB illuminated connector terminals 4 amp 5 B Is there 230V at 1 NO Tr pump jammed release Replace pump PCB A4 connector terminals 3 amp 6 No Replace PCB YES Change pump supply cable O CH system pressure 0 5 to 1 5 bar No Re pressurise system x Gen His tap of the automatic NO Open the automatic air vent air vent is opened YES 3 Primary flow valve diaphragm damaged Replace diaphragm NO Flow valve rod obstructed D 1
51. urner 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 4 When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes Pump Overrun EENB Domestic Hot Water Mode Fig 3 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 set to either Position i or Position ii Frost Protection Mode
52. y work The Log Book must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 Hand over the Users Operating Installation and Servicing Instructions and the Log Book giving advice on the necessity of regular servicing 25 11 0 Servicing the Boiler Case Front Panel ERN Annual Servicing 1 For reasons of safety and economy it is recommended that the boiler is serviced annually Servicing must be performed by a competent person 2 After servicing complete the relevant section of the Benchmark Installation Commissioning and Service Record Log Book This should be in the possession of the user 3 Ensure that the boiler is cool 4 Ensure that both the gas and electrical supplies to the boiler are isolated 5 Slacken the screws securing the facia panel Fig 39 LA US IX Y Lift the outercase panel so that its securing tabs are clear of the facia Remove the panel Fig 39 Facia Panel i77 i Securing Screws 6 Remove the screws 2 on 80e 4 on 105e securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 40 Fan Wires Ease Outlet Sealing 7 Note the positions of the in sensing tubes on Collar Upwards the outlet elbow and three wires on the fan motor and remove them Fig 41 8 Slacken the screws on the outlet sealing collar Ease the co

Baxi 80e Quick Start Manual

Contents

Download Pdf Manuals

Related Search

Related Contents