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Baxi Combi 130 HE Quick Start Manual

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1. R N b Yn Or yA E C OF lt gt TE il l 5 l e l Qs H F i L A A A a f G H H TASS l Likely flue positions requiring Fig 10 a flue terminal guard 7 0 Site Requirements Flue NOTE Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue Take into consideration the effect the plume of vapour may have on neighbours when siting the flue 1 The following guidelines indicate the general requirements for siting balanced flue terminals For GB recommendations are given in BS 5440 Pt 1 For IE recommendations are given in the current edition of I S 813 Domestic Gas Installations 2 If the terminal discharges onto a pathway or passageway check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway 3 Adjacent surfaces close to the flue terminal may need protection from the effects of condensation Alternatively a flue deflector kit part no 248167 is available 4 For installation of the flue into an internal corner at the 25mm dimension the flue deflector kit part no 248167 must be fitted 5 Reduction to the boundary is possible down to 25mm but the flue deflector kit part no 248167 must be fitted 6 For fitting under low soffits and eaves it is acceptable for the flue to project upto 500mm from the face of the wall to the inside of the air intake This can b
2. A Directly below an opening air brick opening windows etc 300 B Above an opening air brick opening window etc 300 C4 Horizontally 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 or external corner i 25 il 115 Above ground roof or balcony level 300 J From a surface facing a terminal 600 K From a terminal facing a terminal Horizontal flue 1200 From a terminal facing a terminal Vertical flue 600 L From an opening in carport e g door window into the dwelling 1200 M Vertically from a terminal on the same wall 1500 N Horizontally from a terminal on the same wall 300 R From adjacent wall to flue vertical only 300 S From an adjacent opening window vertical only 1000 a 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 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 Terminal dead me Assembly St lt i i Top View Rear Flue i Fig 9 i Property Boundary Line pK 16
3. Unplug Diverter Valve With water flowing out of a fully open DHW tap i there 240V from BtoC Unplug 4 way PCB connector With water flowing out of a fully open DHW tap i there 240V from EtoF NO YES Wiring from PCB to Diverter Valve faulty Transformer Mains Input Flow amp YES Return Thermistors Wiring from PCB to Diverter Valve faulty Burner On amp Fault Neons Overheat Thermostats amp Flow Switches amp Condensate Trap Unplug 4 way PCB connector With water flowing out of a fully open DHW tap i there 240V from FtoG YES Is there 240V from B to D YES E Diverter Valve G Diverter Valve faulty PCB faulty Diverter Valve Plug when unplugged Gas Valve Modem PCB Display PCB Room Thermostat oOo o soo o o oo Ww Room Control 55 56 Central Heating Is there an Intellistat connected to the boiler NO Is there 240V from Neutral to H YES Is there 240V from Neutral to YES Is there 240V from Neutral to J YES Is there 240V from Neutral to K YES Is there 240V from Neutral to L YES Is there 240V from Neutral to M YES Unplug Diverter Valve Ensure all DHW taps are off Is there 240V from N to P amp fromOtoP YES NO NO YES Go to Intellistat section of the fault finding instructions PCB
4. 13 0 Changing Components GERD Three Way Diverter Valve Head Only Fig 65 If only the head needs replacing 1 Unplug the wiring harness from the 3 way diverter valve 2 Depress the clip and revolve the head through 30 and remove 3 Fit replacement head and reassemble in reverse order 13 11 Three Way Diverter Valve Complete Fig 66 1 Drain the boiler see Section 13 1 paragraph 2 amp 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 13 0 Changing Components ERA Pressure Gauge Fig 67 Pressure Gauge Bracket w 1 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Undo the nut retaining the capillary in the connection at the return pipe Fig 68 3 Depress the two lugs on either side of the pressure gauge and feed through the bracket 4 Fit new pressure gauge and reassemble in reverse order Lug Grashiite Gauge KEXE Pressure Relief Valve Fig 69 i 1 The pressure relief valve is positioned on the Fig 67 hydraulic manifold at the back of the pump 2 Drain the boiler see Section 13 1 paragraph 2 amp 3 Capillary a
5. 7 The boiler data badge is positioned on the air box door Fig 2 8 The boiler is intended to be installed in residential commercial light industrial E M C environments on a governed meter supply only 9 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit part n 236921 KEN Important Information Man made mineral fibre e Some component parts of this appliance insulation pads gaskets and rope seals are manufactured from man made mineral fibre e Prolonged or excessive exposure to this material may result in some irritation to the eyes skin or respiratory tract e It is advisable to wear gloves when handling these items e 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 e Always thoroughly wash hands after installation servicing or changing components e When disposing of any items manufactured from man made mineral fibre care must be exercised e If any irritation of the eyes or severe irritation of the skin is experienced seek medical attention 2 0 General Layout EX Layout 1 gt A Wallplate 2 EN 2 Flue Elbow 3 Air Box 3 7 4 Heat Exchanger Ree A e i
6. and remove the burner Visually inspect the Sensor internal burner baffle for obstruction Fig 55 Leads Wing Nut Z Trap Z NOTE The burner skin is fragile handle with Electrical Supply care Clean and if necessary replace the Fig 53 Lock Nuts gt burner Fig 55 Condensate Drain Pipe g Loosen the two screws retaining the heat Central Insulation i exchanger support bracket and slide to the left to Panel Fig 54 remove Fig 55 h Remove the four screws securing the heat exchanger combustion box base and withdraw the base i Lower the central insulation panels and check LJ condition Fig 55 Replace the insulation pads if necessary Burner Combustion Box Base j Ensure the heat exchanger fins are clear of any obstruction use a thin bladed tool to remove debris The use of a torch at the heat exchanger top and a mirror held under the heat exchanger Hl will aid observation of the heat exchanger fins Heat Exchanger k Check condition of all seals Reassemble in reverse order applying a suitable silicon based grease to O rings and a seals Greasil 4000 Approved Silicone Grease Combustion Box Base Burner Securing Securing Screws Screws 12 Complete the relevant section of the Benchmark Installation Commissioning and Service Record Log Book and hand
7. 3 Locate the lower door panel on the studs on the case Fig 49 4 Instruct the user in the operation of the boiler controls Hand over both the Users Operating and Installation and Servicing Instructions giving advice on the necessity of regular servicing 5 Advise the user that a plume of vapour from the flue terminal is normal and that there is no need for concern 6 Advise the user that if intelligent pre heat is on pre heating will not occur for the first week of operation 7 Set the User preferences See User Label on lower door panel Fig 48 or user s operating instructions set CH DHW temperatures Fig 48 User Label on back of Lower Door Panel 8 Carefully read and complete all sections of the Benchmark Installation Commissioning and Service Record Log Book that are relevant to the appliance and installation The details of the Log Book will be required in the event of any warranty work The Log Book must be handed to the User for safe keeping and each subsequent regular service visit recorded Lower Door Panel 9 For IE it is necessary to complete a Declaration of Conformity to indicate compliance to I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark logbook Outercase Fixing Screws Lower Door Panel Fig 49 32 Air Box Do
8. ES IX A AS a Y KEYS Spacer Gas Valve 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 EA Injector Pipe Fig 78 1 Remove the injector pipe by pulling out from the O ring joint in the gas valve 2 Fit the new injector pipe and reassemble in reverse order applying Greasil 4000 Approved Silicone Grease to both O rings EER Gas valve Fig 78 1 Release the facia securing screws 4 turn and hinge down the facia box 2 Loosen nut at gas inlet pipe at tap rail 3 Undo the gas pressure pipe from the gas valve 4 Undo the screw and disconnect the electrical plug from the gas valve 5 Remove the two gas valve securing screws from inside the air box holding the gas valve 6 Remove the gas valve and inlet pipe from the airbox side 7 Remove the four screws securing the gas inlet pipe to the valve and refit to the new valve 8 Remove the aluminium spacer and its gasket and O ring from the gas valve 9 Fit the aluminium spacer O ring and its gasket to the new valve 10 Fit the new gas valve and reassemble in reverse order Test for gas soundness Note It is essential that these ensure gas soundness as they are under negative pressure
9. eae 1m 2m 110mm 136mm 2m 3m 165mm 1 in 20 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 Support Bracket 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 Top View of Tap Rail 10 e Treatment of Water Circulating Systems All water circulating systems will be subject to corrosion unless an appropriate water treatment is applied Without treatment the efficiency of the system will deteriorate as corrosion sludge accumulates within the system risking damage to pump and valves boiler noise and circulation problems For optimum performance after installation this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS 7593 1992 Treatment of water in domestic hot water central heating systems This must involve the use of a proprietary cleanser such as BetzDearborn Sentinel X300 or X400 Fernox Superfloc or Salamander System Cleanser Full instructions are supplied with the products but for immediate information please contact BetzDearborn 0044 0 151 420 9563 Fernox 0044 0 1799 550 811 or Salamander 0044 0 121 378 0952 directly For long term
10. Drill and plug the wall as previously marked Secure the wallplate to the wall by the top centre up to 750mm 150mm core drill hale j de p up to 1200mm 175mm core drill 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 Plastic Flushing Tube 9 Connect the gas water and the pressure relief discharge pipes to the valves on the support bracket using the copper tails supplied Ensure the sealing washers are fitted correctly to the water connections 10 Loosely route the condensate discharge pipe to the area previously marked EZ Flushing 1 Insert a tube into the valve outlet furthest from the filling loop Fig 15 The symbols for each connection are on the support bracket 2 Flush thoroughly see System Details Section 6 0 19 Lower Door Panel Outer Case ww Fixing Screw Fig 16 Service Guidance Note Label on inside of panel Fig 17 20 8 0 Installation EEN Preparing The Boiler 1 Remove the outer carton 2 Remove the lower door panel Fig 16 3 Remove the outer case fixing screws Fig 16 Slide the outercase upwards to disengage the hooks on the backplate and remove Fig 17 NOTE Service Guidance Note Label is fitted to the inside of the outercase Fig 17
11. In Operation Fig 7 pore 14 p 850mm 200mm 3 1 in 20 7 0 Site Requirements Clearances Fig 6 amp 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 Gas Supply 1 The gas installation should be in accordance with the relevant standards In GB this is BS 6891 In IE this is the current edition of I S 813 Domestic Gas Installations 2 The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock 3 Ensure that the pipework from the meter to the appliance is of adequate size Do not use pipes of a smaller diameter than the boiler gas connection 22mm Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current 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
12. 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
13. feature is not adjustable 2 The boiler also has a system frost protection feature As supplied this feature is not activated The system frost protection will switch the diverter valve to the Central Heating position and operate the pump every 4 hours In conjunction with the boiler frost protection feature which operates the burner this will prevent frost damage to the system 3 To switch the system frost protection on depress the and Temperature Control Buttons at the same time for 5 seconds The Fig 39 R display will show 18 or 10 Fig 39 Summer Winter i Mode Button 4 Press the Summer Winter Mode Button marked s s until the display shows 30 Fig 42 The 3 indicates that the installer parameter for system frost protection has been selected The 0 indicates that the system frost protection is switched off Press the Temperature Control Button until the display shows 31 Fig 43 The 1 indicates that the system frost protection is switched on 1 minute after the parameter has been set the display will revert to normal operation Fig 40 Temperature 5 To switch the system frost protection off Control Buttons depress the and Temperature Control Buttons at the same time for 5 seconds The display will show 18 or 10 Fig 39 Fig 41 6 P
14. gr gr MO O tte E Fan PCB Main PCB Y b O brb Diverter Fault Burner Valve Neon ON Neon Programmer Room Thermostat Inlet Filter Auxiliary Pump Connection 31 8kW CH Output Key To Wiring Colours b Blue r Red bk Black g Green gr Grey g y Green Yellow w White o Orange br Brown y Yellow 26 9 0 Electrical 9 2 Illustrated Wiring Diagram T D O E oO E 2 E D Os 2 S lo 2 e WW 2 2 5 2 TINSEN TE o Be 10 a 5 S BENENE 03852 2 a E AS ALA o Ooruvr 5 e Y JS E LODO gt S i 3 gt 4 CI E 3 Sa gt e rE A YS 2 S DDO gt s 5 o TD c D O Oo 2 x og oo rz o D gt OLO de _ Fonosa gt y 1 1 f b 0 x la ozs Display PCB Diverter Valve Fan PCB Gas Valve 27 Fig 32 Control Panel Fig 33 Gas Valve LY Os LX DO NOT check gas pressure here Fig 34 Inlet Gas Pressure Test Point 28 Summer Winter Button Expansion Vessel removed for clarity 10 0 Commissioning the Boiler EA Commissioning the Boiler NOTE The information shown on the display is explained on the label on the inside of the lower door panel see Fig 48 1 Open the cold feed to the boiler 2 Open al
15. 4 Remove the sealing plugs from the copper bends 5 Stand the boiler on its base by using the rear lower edge as a pivot NOTE A small amount of water may drain from the boiler in the upright position Baxi declare that no substances harmful to health are contained in the appliance or used during construction of the appliance Top Hooks Screws Facia Box Support Bracket Fig 18 FLUE PRODUCTS EXHAUST Flow Regulator Water Inlet Filter Hot Water Outlet a Cold Water Inlet j Central Heating Return Filter Gas Connection 3 gt ha Fibre Sealing Central Central Washer Heating Flow Heating Return Pressure Relief 8 0 Installation EX Fitting The Boiler Fig 18 1 Remove the tape from the tap rail on the support bracket 2 Lift the boiler using the lower edges of the combustion box 3 Lift the boiler over the support bracket and engage onto the top hooks 4 To gain access to the connections between boiler and valves release the facia securing screws 4 turn and hinge down the facia box 5 Make the connections in the following sequence a Gas connection first to centralise the boiler The gas sealing washer is an integral part of the gas tap The Combi 130 HE is designed to operate under nominal water supply conditions If the hot water delivery is greater than
16. Display Showing 00 cover at right hand side not run over Main PCB NO Central Heating switched YES off To turn Central Heating on press Summer Winter mode button Display Showing OF NO YES Go to Ignition Lockout section of the fault finding instructions Display Flashing LO or Loud Ignitions NO YES Go to Thermistor section of the fault finding instructions Display Flashing L2 or L3 NO YES Go to Dry Fire section of the fault finding instructions Display Flashing L7 or L8 NO YES Go to Fan section of the P z 2 Display ali id fault finding instructions NO Press the button The display will show 40 and YES after 60sec will revert to normal operation the boiler was set for filling the Central Heating circuit Display Flashing 41 NO YES Go to Overheat Lockout section of the fault finding instructions Display Flashing Ld or LE NO YES Go to Condensate Trap Display Flashing or DHW Flow Switch LF or Lt section of the fault finding instructions 15 0 Fault Finding NOTE The information shown on the display is explained on the label on the inside of the outer case see Fig 17 YES Display Flashing Lh Replace Display PCB NO Check if Live amp Neutral to boiler reversed or Live amp YES Neutral from boiler electrical filter to boiler terminal block reversed Otherwise Main PCB faulty Display shows 1
17. Heating Mode 1 With a demand for heating the pump circulates water through the primary circuit At a flow rate of approximately 4 5 l hr the central heating flow switch operates initiating the ignition sequence 2 The burner ignites at low rate then the gas control system modulates the heat input to maintain the heating temperature measured by the thermistor sensor 3 When the boiler reaches temperature a 1 minute pump overrun occurs followed by 3 minutes anticycle If the flow temperature is low enough the burner will then relight automatically otherwise pump overrun and anticycle will occur again ER 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 Boiler Frost Protection 1 The boiler incorporates an automatic integral frost protection feature see section 10 4 It will operate in both summer and winter modes
18. Intellistat Part No 247495 To activate the Intellistat the boiler installer parameter No 6 requires switching from 60 to 61 Figs 47a 8 b 2 With the Intellistat connected to the 3 way terminal block at the boiler and the mains switched on to the boiler press the and Temperature Control Buttons at the same time for 5 seconds The display will show 18 or 10 3 Press the Summer Winter Mode Button marked 2 4M until the display shows 60 Fig 47a The 6 indicates that the installer parameter for switching on off the Intellistat has been selected The 0 indicates that this parameter is switched off Press the Temperature Control Button so that the display shows 61 Fig 47b The 1 indicates that the installer parameter for activating the Intellistat is switched on One minute after the parameter has been set the display will revert to the normal operation NOTE This parameter must only be selected when installed in conjunction with Baxi Intellistat not when connected to any other room thermostat or programmer otherwise the boiler will not function 31 11 0 Fitting the Outer Case EERE Fitting The Outer Case 1 Fit the outercase to the appliance ensuring that the four slots in the side flanges align with the hooks on the chassis Fig 48 AS 2 Insert the two fixing screws into the sides of the chassis Fig 49
19. charged 1 bar nominal pressure 1 bar YES Fit new Burner Seal nominal NO Add extra inhibitor to system Is the Burner loose YES Tighten Burner connections NO Is the Heat Exchanger still Is the noisy Fan connection seal damaged YES Replace Fan connection seal NO Flush out system add inhibitor again and ensure all air removed Is the Fan loose YES Tighten Fan connections NO NO YES Unblock filter or incoming gas pipe Are Gas feed pipe O rings damaged Gas Valve inlet filter or incoming gas pipe partially blocked Purge out before reconnecting to boiler YES NO Smear new O rings with silicon grease before fitting and ensure Change Gas Valve and Venturi positive location in Gas Valve Venturi 15 0 Fault Finding DHW Fault Replace DHW Flow Switch Unplug 9 way connector from PCB With water flowing out of a fully open DHW tap i there continuity across A Unplug DHW F S inline connector With water flowing out of a fully open tap is there continuity across A summer mode NO display shows Of With water flowing out of a fully open DHW tap does display show YES NO Is DHW Flow Switch blocked YES YES YES Replace PCB Wiring from PCB to Flow Switch faulty Unblock DHW Flow NO Switch Replace PCB NO
20. 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 SS AF Aa a Facia Securing Screws Main Electrical Box Cover Removed For Clarity Oe P Main Electrical e Box Cover Transformer Board 8 e connected here e Fan Driver Board Display Board Fig 74 13 0 Changing Components The control display and fan driver boards can be accessed on the removal of the main electrical box cover 1 Release the facia securing screws s turn and hinge down the facia box 2 Remove the screws securing the main electrical box cover Fig 73 and rotate the cover upwards to gain access 13 16 Control Board Fig 73 1 Remove the screws securing the control board and disconnect the electrical connections noting their positions although they are one way fitting 2 Fit the new control board and reassemble in reverse order Display Board Fig 73 1 Remove control board as in 13 16 2 Remove the screws securing the display board and disconnect the electrical connection 3 Fit the new display board and reassembl
21. lengths are 4m horizontal or 5m vertical These lengths exclude the standard elbow and flue terminal assembly horizontal and terminal assembly vertical Twin Flue The total maximum equivalent flue length is 40m NOTE Each 1m of flue duct should be calculated as 2m Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 45 bend 0 5m 93 bend 1 0m Twin Flue Pipe 45 bend air duct 1 3m 45 bend flue duct 2 6m 90 bend air duct 4 8m 90 bend flue duct 9 6m 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 Key Accessory Concentric Flue System 110mm diameter A Horizontal flue kit 850mm B Straight extension kit 1000mm 500mm 250mm 93 45 C Bend kit D Bend kit pair E Horizontal flue terminal Clamp 110mm Twin Flue System 80mm diameter 1000mm 500mm 250mm 90 45 F Straight extension kit G Bend kit H Bend kit pair Universal Vertical Flue Kits Twin flue adaptor kit Vertical flue terminal Universal roof tile Roof cover plate kit Flat roof flashing Boiler connection vertical concentric Clamp 80mm 25 50 Baxi Code Number 236921 241695 241694 241692 241687 241689 243013BAX 243014BAX 238690 238692 238694 2461
22. only Section Page 0 0 Legislation 4 1 0 Introduction 5 2 0 General Layout 6 3 0 Appliance Operation 7 4 0 Technical Data 8 5 0 Dimensions and Fixings 9 6 0 System Details 10 7 0 Site Requirements 13 8 0 Installation 19 9 0 Electrical 26 10 0 Commissioning the Boiler 28 11 0 Fitting the Outer Case 32 12 0 Servicing the Boiler 33 13 0 Changing Components 35 14 0 Short Parts List 46 15 0 Fault Finding 47 16 0 Operational Flow Chart 58 IMPORTANT Installation Commissioning Service amp 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 amp Use Regulations Definition of competence A person who works for a CORGI registered company and holding current certificates in the relevant ACS modules or valid ACoP equivalents is deemed competent In IE this must be carried out by a competent person as stated in I S 813 Domestic Gas Installations Lifting This product should be lifted and handled by two people Stooping should be avoided and protective equipment worn where necessary Carrying amp lifting equipment should be used as required The addition of anything that may interfere with the norm
23. pipe material e g PVC PVC U ABS PVC C or PP 4 Metal pipework is NOT suitable for use in condensate discharge systems 5 The pipe should be a minimum of 21 5mm diameter and must be supported using suitably spaced clips to prevent sagging 6 Any pipe fitted externally must not exceed 3 metres 7 Any condensate discharge pipework external to the building or in an unheated part of it e g garage must be insulated to protect against frost It is also recommended that the pipe diameter is increased to 32mm 8 If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run 9 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used 10 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC s are flushed or sinks emptied then back pressure may force water out of the boiler trap and cause appliance lockout Examples are shown of the following methods of termination i to an internal soil amp vent pipe ii via an internal discharge branch e g sink waste iii to a drain or gully iv to a purpose made soakaway 15 Table 1 Terminal Position with Minimum Distance Fig 10
24. protection against corrosion and scale after flushing it is necessary that an inhibitor such as BetzDearborn Sentinel X100 Fernox MB 1 or Copal or Salamander System Inhibitor is dosed in accordance with the guidelines given in BS 7593 1992 Failure to flush and add inhibitor to the system will invalidate the appliance warranty 6 0 System Details EX Information In GB it is necessary to comply with the Water Supply Water Fittings Regulations 1999 or for Scotland The Water Byelaws 2000 Scotland The Baxi Combi 130 HE Combination Boiler is an Approved Product under the Water Regulations To comply with the Water Regulations your attention is drawn to The Water Regulations Advisory Service WRAS which gives full details of the requirements In IE the requirements given in the current edition of I S 813 Domestic Gas Installations and the current Building Regulations must be followed EE Central Heating Circuit 1 The appliance is suitable for fully pumped SEALED SYSTEMS ONLY This boiler is fitted with a flow switch interlock that prevents it from firing when the heating demand is satisfied The boiler is designed so that it will heat the house to the desired room temperature as quickly as possible by running at the maximum boiler flow temperature of 82 C When the room temperature is achieved the boiler will then reduce the radiator temperature to as lowa level as possible while still achieving the
25. raul YES Br G YES y B WIR Does fan run Is there continuity from Wiring from Fan PCB RtoS to Main PCB faulty 0101 Fan Connection NO YES Br G Key to Wire Colours RIWI B Replace Fan Replace Main PCB R Red Br Brown Ws White a G Green Fan PCB Connection B Blue 51 52 Flow Temperature Overheat Lockout Ld or Fan Temperature Overheat Lockout LE Display flashing Ld Disconnect black stat on flow pipe When flow lt 60 C is there continuity across stat NO Replace stat Reconnect stat Disconnect 9 way PCB connector Is there continuity across T Wiring from PCB to thermostats faulty Replace PCB 15 0 Fault Finding Display flashing LE Disconnect Fan Stat When Fan temperature lt 60 C is there continuity across stat NO Replace stat Reconnect stat Disconnect 9 way PCB connector Is there continuity across U Wiring from PCB to thermostats faulty Are Boot NO Lace seals holding door away from heat exchanger Replace PCB Trim seals back Replace door seals if damaged Condensate Trap LF or DHW Flow Switch Lt Display flashing LF Clear blockage and dry sensors Fit secondary trap and air break if connected to internal stack soil pipe Condensate Trap blocked or water on terminals boiler to prove If fault persists change condensate trap faulty Wires from Main
26. refer to BS 7074 Pt 1 For IE the current edition of 1 S 813 Domestic Gas Installations Expansion Vessel EN Pressure Relief Valve Fig 4 amp 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 Discharge Pipe 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 5 11 6 0 System Details Domestic Hot Water Circuit Other Tap Outlets 1 All DHW circuits connections fittings etc should be fully in accordance with relevant standards and water supply regulations Expansion Vessel 2 Your attention is drawn to for GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide for IE the current edition of I S 813 Domestic Gas Installations Sealed primary circuits and or secondary hot water systems shall incorporate a means for accommodating the thermal expansion of
27. the shower valve manufacturer GE Hard Water Areas ES Jasin SSA caida 1 If the area of the installation is recognised as a X BY Blow Miemmestal 8 Filling Loop HARD WATER AREA then a suitable device 3 Flow Thermistor 14 CH Flow Valve should be fitted to treat the mains water supply to 4 Flow Switch 15 Filter 5 Primary Heat Exchanger 16 CH Return Valve the boiler 6 Gas Valve 17 Pressure Gauge 7 DHW Plate Heat Exchanger 18 Pump 8 DHW Flow 19 Pressure Relief Valve 9 DHW Mains Inlet 20 Return Thermistor 10 Flow Regulator 21 3 Way Valve 11 DHW Flow Switch 12 Fig A Zone 2 Zone1 4 Fig B zone pl Window Recess 1 In GB Only r Zone3 I Window Recess Zone 2 I I I I I Zone 2 1 I I I I In GB Only m m Outside Zones 2 25 m Ceiling Outside Zones 7 0 Site Requirements Location 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 incorpor
28. 13 24 Condensate Trap Fig 79 1 Disconnect the condensate trap from the base of the heat exchanger 2 Disconnect the condensate drain outside the boiler from the condensate trap 3 Undo the condensate trap lock nut 4 Remove the condensate trap from the boiler 5 Disconnect the sensor leads Fit the new condensate trap and reassemble in reverse order 43 Heat Exchanger Support Bolt Burner Screws Fig 80 a q RT Return Flow Connection Switch Fig 81 Manifold Fig 82 Heat Exchanger Assembly een yal iG To kG Fig 83 44 Heat Exchanger 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 amp 13 25 1 Remove the combustion box door by undoing the four a turn securing screws EJ Burner Fig 80 WARNING The burner skin is fragile HANDLE WITH CARE 1 Remove the two 8mm hex head screws securing the burner to the base of the combustion box 2 Remove the burner carefully from the combustion box base inspect gasket for damage replace if necessary 3 Fit the new burner and reassemble in reverse order 113 26 Heat Exchanger 1 Drain the boiler see section 13 1 paragrap
29. 18 litres minute the flow regulator must be fitted to the Domestic Hot Water inlet A pint milk bottle must fill in under 2 seconds b Domestic hot water cold feed if necessary fit the water flow regulator ensuring that it is fitted the correct way round Fig 20 NOTE Ensure water inlet filter is fitted c The remaining connections ensuring the fibre sealing washers are inserted between the valve outlet face and the flange on the copper pipes of the water circuit and pressure relief connections Fig 20 6 Tighten the connections in the sequence listed above EEN 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 sin plastic overflow pipe See section 7 6 for details of recommended condensate drain methods 21 Wall Thickness A 3 Val 1 in 20 X o gt aap _ Support Bracket Fig 21 Y Left Exit Z Right Exit X Rear Exit 360 Orientation Edge of Support Bracket to Wall Wall Thickness Flue 22 8 0 Installation EG Fitting The Flue Before fitting the flue
30. 3 Disconnect the union between the valve and lA the discharge pipe El 4 Slacken the screw retaining the valve Return Pipe 5 Pull the valve upwards to disengage it Fig 68 6 Fit the new pressure relief valve and reassemble in reverse order Pressure Relief Valve Fig 69 Expansion Vessel removed for clarity 39 Fig 70 Plate Heat Exchanger Cover Fig 71 40 Inline Electrical Connection DHW Inlet Connection Plate Heat Exchanger Securing Screws l O Rings Plate Heat Exchanger Flow Switch 13 0 Changing Components EERE DHW Plate Heat Exchanger 1 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Remove the four screws securing the plate heat exchanger to the manifolds Fig 70 NOTE Ensure nuts are not dislodged from the manifolds 3 Remove the plate heat exchanger cover Fig 71 4 Remove the O rings from the manifolds and replace with new O rings Fig 71 5 Taking care not to displace the O rings fit the new plate heat exchanger ensuring the nuts are retained in the manifolds 6 Refit the plate heat exchanger cover EXE DHW Flow Switch Fig 72 1 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Remove the DHW plate heat exchanger see section 13 14 3 Disconnect the inline
31. 3 continuously NO Check if Live amp Neutral YES to boiler reversed Otherwise there is a blockage in the central heating system Display repeatedly shows 21 for 10sec amp then 26 for 3mins NO Go to Burner or Heat YES Exchanger Noisy section of the fault finding instructions Is the Burner or Heat Exchanger noisy NO Central Heating Run continues after Room Stat switches off YES Check if Installer Parameters set for 61 Intellistat If Intellistat not fitted change to 60 NO If Intellistat connected YES check if Installer Parameters set for 60 Room Stat If so change to 61 Burner lights for 3sec then goes straight to 25 Pump Overrun NO Check flow restrictor if fitted If fitted try smaller YES flow restrictor If still not OK got to Domestic Hot Water section of the fault finding instructions works OK DHW works but temperature is too NO YES Go to Domestic Hot Water section of the fault finding instructions CH works but DHW does not NO DHW works but Central Heating does not YES Go to Central Heating section of the fault finding instructions 47 48 No Display 240 VatA Y ES ES Y Main PCB Fuse OK YES lt gt YES YES YES as Replace Display PCB Ensure that mains is securely connected to incoming plug and that wiring from electrical filter to boiler 8 way
32. 39 246138 242757 242802 243015 243131 243016BAX 242886 238684 8 0 Installation Check Site Requirements section 7 0 before commencing gt lt 37 5mm Offset Fitting an Extra Pump To extract 100 000 Btu hr from the boiler in central heating mode an extra pump will need to be fitted to increase flow It must be fitted in parallel to the existing pump and in the return pipe See Pages 24 amp 25 for wiring details EAN Initial Preparation Combi 130 HE TEMPLATE The gas supply gas type and pressure must be d checked for suitability before connection see me Section 7 4 sentiment aso NOTE If the boiler is to be pre plumbed follo both these instructions and those on the boiler pack j j j 1 Remove the fixing template Fig 14 from the fixing carton j j j 2 Position the template on the wall ensuring it is level both horizontally and vertically on Ho i eo 3 Mark the position of the top centre hole for the os me wallplate 4 Mark the condensate discharge pipe area 5 Mark the centre of the flue hole rear exit For Fig 14 side exit mark as shown If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 125mm see table opposite for wall thickness flue A diameters Wall Thickness Flue Hole y up to 227mm 125mm core drill 7
33. 5 Burner S gt a 20 6 Fan Protection Thermostat 7 Te Fan Assembly ii 8 DHW Plate Heat Exchanger Pe Mi he al 9 Three Way Valve Uy Dy 10 Facia Box a 11 Primary Water Pressure Gauge 30 X is 12 Gas Tap Me 13 Circulation Pump 14 Pressure Relief Valve 15 Return Thermistor 16 Gas Air Ratio Valve e A Dana 17 Transformer 18 Flow Temperature Safety Thermostat 19 Flow Temperature Thermistor Bell Dy 20 Manual Air Vent l N 21 Automatic Air Vent lt tr 22 Flow Switch Dry Fire Protection 23 Condensate Trap lt 24 Expansion Vessel e 2 i a Expansion Vessel i ES E i mus for clarity ER Optional Extras 9 x 1 3 KIT PART N E FLUE EXTENSION KITS 110 70 12 Horizontal Flue Kit 4M max Flue Extension 0 25M 241692 Flue Extension 0 5M 241694 Flue Extension 1M Use two kits for 2M etc 241695 Flue Bend 45 Reduce overall length of flue by 0 5m when fitting this bend 241689 Flue Bend 90 Reduce overall length of flue by 1m when fitting this bend 241687 VERTICAL FLUE KITS 110 70 5M max Vertical Flue Terminal 242802 Vertical Boiler Connection 242886 VERTICAL FLUE 80 80 Kit Boiler Connection Twin 242757 CONTROL ACCESSORIES Programmable Room Thermostat Intellistat 247495 Electro Mechanical Timer 247498 Filling Loop Kit 247500 3 0 Appliance Operation NOTE All delay timers mentioned in 3 1 and 3 2 are overridden by domestic hot water demand EXI Central
34. 57 1 Drain the boiler 2 Undo the manual air vent from the flow pipe or the automatic air vent from the return pipe and retain the sealing washer 3 Remove the air vent 4 Fit the new air vent and reassemble in reverse order 35 13 0 Changing Components KEEN Flowswitch Fig 58 1 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 It may be necessary to remove the expansion vessel see Section 13 5 3 Remove the clip securing the flow pipe to the flowswitch 4 Remove the two screws securing the flow switch to the boiler 5 Disconnect the inline electrical connection 6 Remove the flowswitch 7 Fit the new flowswitch and reassemble in reverse order 8 Recommission the boiler and check the inhibitor concentration see Section 6 2 and 10 1 Flow Thermistor Red Body Safety Thermostat Black Body KEN Flow or Return Temperature Thermistors and Safety Thermostat Figs 59 8 59a 1 The procedure is the same for both the thermistors and the safety thermostat although the components are not interchangeable 2 Remove the electrical connections from the Expansion Vessel component Connection Electrical 3 Unscrew the component from the pipe Connections 4 Fit the new thermistor or safety thermostat and reassemble in reverse order Fig 59 ReturnThermistor Red Body LES Expan
35. BAXI Installation amp Servicing Instructions TS Baxi Combi 130 HE Gas Fired Wall Mounted Condensing Combination Boiler Please leave these instructions with the user Natural Gas Baxi Combi 130 HE G C N 47 075 04 Baxi is one of the leading manufacturers of domestic heating products in the UK Our first priority is to give a high quality service to our customers Quality is designed into every Baxi product products which fulfil the demands and needs of customers offering choice efficiency and reliability To keep ahead of changing trends we have made a commitment to develop new ideas using the latest technology with the aim of continuing to make the products that customers want to buy Everyone who works at Baxi has a commitment to quality because we know that satisfied customers mean continued success We hope you get a satisfactory service from Baxi If not please let us know RECOMMENDED henchman 7 Baxi is a BS EN ISO 9001 Accredited Company The boiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 N 3083 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0086 Product Production certified by Notified Body 0086 Ref 86 BL 647 For GB IE
36. Bamber Bridge Preston Lancashire PR5 6SN After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www baxi co uk A BAXI GROUP company Comp N 245736 Iss 04 11 03
37. 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 Data Badge Fig 2 Air Box Door 1 0 Introduction This boiler is fitted with a flow switch interlock that prevents it from firing when the heating demand is satisfied ERN Description 1 The Baxi Combi 130 HE is a fully automatic gas fired wall mounted condensing combination boiler It is room sealed and fan assisted and will serve central heating and mains fed domestic hot water 2 The boiler is preset to give a maximum output of 23 9 kW 81 500 Btu h for central heating and 39 0 kW 133 000 Btu h for hot water In central heating mode the boiler will automatically adjust down to 10 6 kW 36 000 Btu h according to system load 3 It is designed for use on Natural Gas G20 only 4 Check the local supply conditions before installation 5 The boiler is suitable for use only on fully pumped sealed heating systems Priority is given to domestic hot water 6 A label giving details of the model serial number and Gas Council number is situated on the rear of the lower door panel Fig 1
38. Hinge down the flap below the Intellistat display Press the Intellistat Reset Button Is the display still blank NO YES Is there 5V from DtoF Is there 5V from AtoB YES NO Intellistat faulty PCB faulty Terminal Block Intellistat With the hinge down flap located below the display NO in the shut position press the right arrow button on the Intellistat until the Sun symbol appears and read the in Boiler Terminal Block Intellistat instructions ape os S 000000 Turn the knob at the NO bottom right of the AB C Intellistat fully clockwise and read the Intellistat instructions Wiring from boiler to Intellistat faulty Transformer Mains Input Flow amp Return Thermistors Is there continuity from CtoE Burner On amp Fault Neons YES Overheat Thermostats amp Flow Switches amp Condensate Trap Intellistat faulty Diverter Valve faulty YES K Diverter Valve J L Gas Valve YES Wiring from PCB to Modem PCB Diverter Valve faulty Diss PCB isplay Room Thermostat Diverter Valve Plug when unplugged Room Control O O O a pel O 58 DHW Flow Switch on or Flow temp below preheat level PURGE Pump on Fanon Purge done amp primary Flow Switch made amp DHW temp below set point Purge done and DHW Flow Switch Off and Flow temp above set point Overrun done amp DHW Flow Switch off or DHW Flow Swit
39. If the boiler temperature falls below 8 C 5 then the boiler will fire until a temperature of 15 C 5 is reached EZ System Frost Protection Mode 1 The boiler incorporates an integral system frost protection feature This can be activated see section 10 4 if required To monitor system temperature the boiler will switch on the pump every four hours in both summer and winter modes If water returned to the boiler is below 8 C 5 the boiler frost protection mode is automatically activated Due consideration should be taken to the siting of the appliance when using this option It may be preferable to fit an external frost thermostat to the system In this instance the integral system frost protection feature need not be activated EE Pump Protection 1 The control system continually monitors the time since the pump last operated This will result in the pump being run for 1 minute if it has not run in the last 24 hours to prevent seizure 4 0 Technical Data Appliance Type Ci3 C33 Flue Terminal Diameter 110mm DHW Circuit bar Ib in Dimensions Projection 150mm Pressures Appliance Category CAT I 2H Max Operating 10 145 Heat Input Gross DHW Max Connections copper tails Min Operating 0 1 1 45 Gas Supply 22mm kW 45 45 Central Heating Flow 22mm Min Operating Pressure Btu h 155 000 Central Heating Re
40. N SLO o Oo Sa N Optional Live Feed For An External Pump iS 5 Fig 31 Mains Input Isolator FL Filter Optional Live Feed For An External Pump Fig 31a N 8 0 Installation EU Fitting a Room Thermostat 1 To fit a 2 wire thermostat remove link and wire the thermostat switch between positions 1 amp 2 Figs 30 or 31a A cable clamp is provided for incoming cables EXO Fitting a Baxi Intellistat 1 Refer to the Baxi Intellistat instructions 2 The boiler installation parameters must be set to recognise that the Intellistat will operate in conjunction with the boiler see section 10 6 ERIN Fitting a Frost Thermostat 1 The frost thermostat is connected between positions 1 and 4 Figs 31 or 31a Secure the incoming cable s with the cable clamp and replace the cover EXP Fitting an Additional Pump 1 To extract 100 000 Btu hr from the boiler in central heating mode an additional pump will need to be fitted to the system Connect pump Live to terminal 5 and use any available neutral 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
41. PCB to condensate trap faulty 9 way PCB connector Is there continuity from Replace PCB Return Thermistor L3 or Flow Thermistor L2 Display flashing L2 Unplug flow thermistor is thermistor resistance between 0 5kQ and 20kQ Replace Flow Thermistor Reconnect thermistor Unplug 7 way PCB connector Is resistance at H between 0 5kQ amp 20kQ2 Wiring from PCB to Flow Thermistor faulty Replace PCB Disconnect drain and run 15 0 Fault Finding Display flashing Lt 9 way connector from PCB With all DHW taps off is there continuity across Replace PCB Is DHW Flow Switch blocked Unblock DHW Flow Switch Replace DHW Flow Switch Display flashing L3 Unplug return thermistor is thermistor resistance between 0 5kQ and 20kQ Replace Return Thermistor Reconnect thermistor Unplug 7 way PCB connector Is resistance at betwee 0 5kQ amp 20k22 Wiring from PCB to Return Thermistor faulty Replace PCB 53 54 Burner or Heat Exchanger Noisy 15 0 Fault Finding Is the noise coming from the burner Is the noise coming from the heat exchanger YES YES Ensure that there is no Is the Burner damaged Replace Burner air in the heat exchanger or system NO Is the Burner Seal missing or damaged a ion V i Recharge Expansion panel yesse Vessel to correct
42. al operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty In GB this could also infringe the Gas Safety Installation and Use Regulations Warning Check the information on the data plate is compatible with local supply conditions Benchmark Installation Commissioning and Service Record Log Book Please ensure that your installer has completed the Installation and Commissioning sections of the Log Book and hands the Log Book over The details of the Log Book will be required in the event of any warranty work Keep the Log Book in a safe place and ensure that the relevant sections are completed at each subsequent regular service visit All CORGI registered installers carry a CORGI identification card and have a registration number Both should be recorded in your boiler Log Book You can check your installer is registered by telephoning 44 0 1256 372300 or writing to 1 Elmwood Chineham Business Park Crockford Lane Basingstoke RG24 8WG 0 0 Legislation Baxi declare that no substances harmful to health are contained in the appliance or used during appliance manufacture The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force and only used in a suitably ventilated location In GB the installation must be carried out by a CORGI Registered Installer It must be carrie
43. and system controls only Termination to an internal soil and vent pipe Boiler AAA 450mm min t External termination via internal discharge branch e g sink waste downstream Boiler Pipe must terminate above water level but below surrounding surface Sink Termination to a drain or gully Boiler Pipe must terminate above water level but below surrounding surface Termination to a purpose made soak away Boiler 500mm min Holes in the soak away must face away from the building 7 0 Site Requirements Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length There MUST be a fall of AT LEAST 2 5 50mm per metre along the entire run NOTE It is unnecessary to fit an air break in the discharge pipe 1 The condensate outlet terminates in a 1 BSP nut and seal for the connection of 21 5mm 3 4in plastic overflow pipe which should generally discharge internally into the household drainage system If this is not possible discharge into an outside drain is acceptable 2 Ensure the discharge of condensate complies with any national or local regulations in force BS 6798 2000 amp Part H1 of the Building Regulations give further guidance 3 The discharge pipe should be run in a proprietary drain
44. as valve Fig 34 is greater than 14 mbar and the gas rate is no greater than 4 1m h 10 0 Commissioning the Boiler KN increasing Central Heating Output To 100 000 Btu hr 1 The boiler is factory set for a maximum output of 80 000 Btu hr The boiler will automatically vary its output to match the system load giving the most efficient use of gas and the most comfortable room temperature possible 2 If the CH system requirement is greater than 80 000 Btu hr then to increase the maximum output of the boiler to 100 000 Btu hr proceed as follows a While On or OF is shown on the display ie no CH or DHW demand ongoing Depress the and Temperature Control Buttons at the same time for 5 seconds The display will show 18 Fig 35 where the 1 indicates that the installer parameter for range rating has been accessed and the 8 indicates that the boiler is presently set for a maximum Central Heating output of 80 000 Btu hr oi b Press the Temperature Control Button twice so that the display shows 10 Fig 36 with the 0 indicating that the boiler is set for a maximum Central Heating output of 100 000 Btu hr 1 minute after the parameter has been set the display will revert to normal operation Temperature Control Buttons NOTE The boiler will need to run in CH for 30 minutes after this is done t
45. ate an appropriate device for frost protection in the system controls 3 If the boiler is fitted in a room containing a bath or shower it can only be fitted in zone 3 Figs A amp B shows zone dimensions for a bathtub For other examples refer to Section 601 of the Current 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 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 13 5mm Min 490mm 5mm Min A 7 AN 200mm Fig 6 For Servicing Purposes lt lt 320mm 5mm
46. ce PCB there continuity at L Transformer NO Mains Input Flow amp Return Thermistors primary flow switch YES Wires from inline lios a conector to POB Faut Neons across flow switch faulty L Overheat Thermostats K amp Flow Switches amp NO Condensate Trap Diverter Valve F YES Remove blockage Check Is ea pa flow switch operation after to the paddle within the removing blockage before flow switch replacing flow switch z Gas Valve NO Modem PCB Is there a YES Remove blockage If Display PCB blockage in the system ABRES Mena System 9 y j pipework open up fully to prove operation of boiler Room Thermostat NO Room Control E Replace Flow Switch Fan L9 15 0 Fault Finding least 24Vdc at M Replace Main PCB Transformer Mains Input Flow amp Return Thermistors YES Burner On amp Fault Neons When NO display shows 12 or 22 Replace Main PCB aot is there at least 8 2Vdc at N Flow eS Condensate Trap YES Diverter Valve NO Is there at Wiring from Main PCB least 24Vdc at O to Fan PCB faulty Gas Valve YES Modem PCB Display PCB When NO we display shows 12 or 22 Wiring from Main PCB is there at least to Fan PCB faulty Room Thermostat 2Vdc at P Room Control YES When display shows 12 or 22 NO pi y Replace Fan PCB is there at least 12Vdc at Q 2 YES Is continuity NO of all 5 wires from Fan Wiring from Fan PCB PCB to Fan OK ofan
47. ch off 8 Flow temp gt 55 C DHW OVERRUN Pump on DHW Flow Switch on amp DHW temp below set point IGNITION Pump on Fan on Spark Generator on Gas Valve on 16 0 Operational Flow Chart EAN Domestic Hot Water Mode DHW Flow Switch off amp Flow temp above 55 C DHW Flow Switch off amp Flow temp below 55 C amp Flow temp above preheat level or DHW temp 10 C above set point DHW RUN Pump on Fan speed variable Gas Valve on Stabilisation done STABILISATION Pump on Flame detected Fan on Gas Valve on Programmer on amp Room Thermostat on amp Anticycle done WAIT FOR DIVERTER VALVE TO MOVE Diverter Valve on Diverter Valve moved Primary Flow Switch not made Programmer off or Room Thermostat off or Flow temp above set point PUMP OVERRUN Diverter Valve on Pump on Pump Overrun done or primary Flow Switch not made 16 0 Operational Flow Chart I Central Heating Mode CH RUN Diverter Valve on Pump on Fan Speed Variable Gas Valve on Programmer on amp Room Thermostat on amp Flow temp below set point amp primary Flow Switch made Stabilisation done CH STABILISATION Diverter Valve on Pump on Fan on Gas Valve on Flame detected IGNITION Diverter Valve on Pump on Fan on Spark Generator on Gas Valve on Purge done PURGE Diverter Valve on Pump on Fan on 59 BAXI POTTERTON A Trading Division of Baxi Heating UK Ltd Brownedge Road
48. check all earth wires for continuity and ensure that all connections are clean and tight WARNING If the resistance is still greater than 10hm the fault still exists and it may be dangerous to work with the appliance live 2 Short Circuit Check Isolate the control system set all switches and thermostats to calling for heat Set the meter on ohm s scale Test from L to N on control system terminal block if the resistance reads zero there is a short circuit 3 Resistance to Earth Check Isolate the control system set all switches and thermostats to calling for heat Set the meter on ohm s scale Test between L and E the resistance should be greater than 1 mega ohm 4 Polarity Check If all the tests carried out so far are satisfactory then reconnect the system to the mains supply Set the meter on Volts AC scale starting at the highest voltage Test at terminals Land N meter should read approx 240 Vac L and E meter should read approx 240 Vac N and E meter should read from 0 to 15 Vac 5 Fuse Check Remove the fuse and check resistance There should be no resistance or maximum reading If no reading is obtained change the fuse Check fuse is 3A 25 9 0 Electrical 91 Schematic Wiring Diagram Primary Fan Overheat Flow Overheat Flow Switch Thermostat Thermostat Display PCB Condensate BR bk _ Flow Return 7 l Baxi Intellistat Thermistor Thermistor gr Terminal Block DHW Flow
49. d out in accordance with the relevant requirements of the e Gas Safety Installation amp Use Regulations e The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland e The Water Fittings Regulations or Water Byelaws in Scotland e The Current 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 1 S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation All systems must be thoroughly flushed and treated with inhibitor see section 6 0 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 l S 813 Domestic
50. desired room temperature thereby giving the most efficient use of gas and the most comfortable room temperature possible The boiler will be able to achieve this performance if a room thermostat is fitted or with a fully TRV d system without a bypass If the system is fully TRV d with a bypass then this feature will not be available in this case the radiator temperature can be reduced to provide more efficient operation see User instructions e If the hot water delivery is greater than 18 litres minute the flow regulator must be fitted to the Domestic Hot Water inlet A pint milk bottle will fill in under 2 seconds e If the boiler is to be uprated to 100 000 Btu hr CH output an extra standard pump will be required and the commissioning procedure will take approximately 30 minutes longer e The condensate drain and pipes must be free from leaks e Any timer and thermostat should be removed before installing optional Intellistat as it will override their operation 6 0 System Details CEN System Control 1 The boiler is designed for use in a heating system that incorporates external controls i e a minimum of a timer device 2 Suitable timer kits are available as optional extras 3 For optimum operating conditions and maximum economy the fitting of the Baxi Intellistat is recommended 16 4 System Filling and Pressurising DEW Temporary CH 1 A filling point connection on the central heat
51. e insulation pads 6 Check combustion box seal for damage replace if necessary 7 Fit the new insulation pads and reassemble in reverse order 45 14 0 Short Parts List Short Parts List 2 O 2 P na Key G C Description Manufacturers A No No Part No A E58 933 Flow Thermistor Red Return Thermistor 240670 Cc E58 912 Safety Thermostat Black Fan Protection 242235 D E06 059 Flow Switch Kit 242459 E DHW Flow Switch Kit 247502 F E58 989 Fan Driver PCB 239230 G E58 987 Control Board PCB 244878 H E58 991 Display PCB 244880 Pump 240395 J E58 919 Transformer 247155 K E58 935 Diverter Valve Head 243341 L E58 913 Fan 246557 M Condensate Trap Kit 242485 N Gas Valve Kit 247222 O E58 900 Burner 245199 P Spark Electrode Kit 247215 E Q Sensing Electrode Kit 249099 CK Xd d ay R Plate Heat Exch Kit 247224 GO S E06 085 Inspection Window Assy 242484 T E06 097 Heat Exchanger Assy 242497 vl mn a OMG a OMG en KY La RS ISS A i CN 46 Before performing fault finding carry out preliminary electrical checks for earth continuity and polarity See Section 8 13 YES Go to No Display section of the fault finding instructions Display Blank NO Check stats at top right of boiler Red wires go to YES red stat black wires to black stat Check integral timer wires exit PCB
52. e in reverse order KEXO Fan Driver Board Fig 73 1 Remove the screws securing the fan driver board and disconnect the electrical connections noting their positions 2 Fit the new fan driver board and reassemble in reverse order BES Transformer Fig 74 1 Remove the transformer connection from the control board Fig 73 2 The transformer is mounted to the right of the combustion box 3 Remove the two transformer mounting screws and remove the transformer 4 Fit the new transformer and reassemble in reverse order 41 e SS umn y iC Air Box Door Panel ih Fig 75 Gaskets park b i Zz Electrode Po 2 2 2 4 a A fA ES a d Sensing Electrode i a Combustion A Box Door Spark Fig 76 Electrode Leads Injector Pipe Venturi Fan Protection Thermostat Black Body Protection Thermostat Leads Wing Nut Electrical Supply Fig 77 42 13 0 Changing Components The fan and venturi gas valve injector pipe condensate trap fan protection thermostat spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel 1 Remove the airbox door panel by loosening the four s turn screws Fig 75 KEEN Spark and Sensing Electrodes Fig 76 1 Disconnect the leads to the electrodes noting their posi
53. e painted if required using a suitable external paint 7 Ifa terminal is less than 2 metres 78 4 in above a balcony above ground or above a flat roof to which people have access then a suitable terminal guard must be provided 7 0 Site Requirements 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 Terminal Guard Fig 13 Fig 11 1 When codes of practice dictate the use of terminal guards they can be obtained from most 1m Plumbers and Builders Merchants 0 5m es 7 2 There must be a clearance of at least 50mm la between any part of the terminal and the guard im ee 4 2 y F 0 5m 3 When ordering a terminal guard quote the appliance name and model number Fig 12 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated Pictorial examples of flue runs where EQUIVALENT flue length equals 4m Fig 13 17 18 A Standard Flue 7 0 Site Requirement Flue options Concentric The maximum equivalent
54. eat has been selected The 1 indicates that the pre heat is switched on 4 Press the Temperature Control Button to change this to 20 Fig 38 with the 0 indicating that the pre heat is switched off One minute after the parameter has been set the display will revert to normal operation 29 10 0 Commissioning the Boiler Switching Off Intelligent Pre heat cont 5 To switch the pre heat feature back on depress the and Temperature Control Buttons at the same time for 5 seconds The display will show 18 or 10 Fig 39 6 Press the Summer Winter Mode Button marked 8 8 and the display will show 20 Fig 40 The 2 indicates that the installer parameter for pre heat has been selected The 0 indicates that the pre heat is switched off Press the Temperature Control Button to change this to 21 Fig 41 with the 1 indicating that the pre heat is switched on 1 minute after the parameter has been set the display will revert to normal operation 110 4 Switching On System Frost Protection 1 The boiler has an automatic boiler frost protection feature which will bring the boiler on in Central Heating mode if the flow thermistor senses Temperature a temperature of less than 8 5 C and remain on Control Buttons i until the temperature reaches 15 5 C This
55. faulty Wiring from PCB to Prog 1 faulty Check Programmer amp Programmer wiring OK Wiring from Prog 2 to R S 1 faulty Check Room Stat amp Room Stat wiring OK Wiring from R S 2 to PCB faulty Diverter Valve faulty NO 15 0 Fault Finding YES Is there 240V from Q to R amp from Rto S Wiring from PCB to Diverter Valve faulty Diverter Valve Plug NO when unplugged O O O TT ps Zz P O i Prog Prog R S R S Extra N E il 2 1 2 Pump AAA SS l oJ KOOL Transformer Mains Input Flow amp Return Thermistors Burner On amp Fault Neons Overheat Thermostats amp Flow Switches amp Condensate Trap Q Diverter Valve R S Gas Valve Modem PCB Display PCB H r M Room Thermostat Room Control Intellistat Is the Intellistat display blank NO Is there a Sun symbol near the bottom right of the Intellistat display YES temperature in the middle of the display at least 2 C less than the temperature at the top of the display YES Is there at least 4Vdc from E to F YES Unplug Diverter Valve Ensure all DHW taps are off Is there 240V from G tol amp from H to NO Is there 240V from Jto K amp from J toL NO PCB faulty YES NO 15 0 Fault Finding Wiring from boiler to Intellistat faulty YES
56. fins c Fan compartment Check also for condensate leaks d Insulation e Door seals f Electrodes Check condensate trap for debris NOTE If necessary remove the trap drain plug and place a vessel underneath to catch the condensate care should be taken as this could be hot Clean the trap and refit the drain plug Top of heat exchanger Q En NOTE General cleaning can be undertaken using a vacuum However debris should only be gently blown off the burner skin due to its fragile nature 10 Check system pressure is between 1 and 2 5 bar 33 12 0 Servicing the Boiler EES Annual Servicing Cont NOTE The information shown on the display is explained on the label on the inside of the lower door panel see Fig 48 Burner 12 To clean the heat exchanger and burner proceed as follows a Disconnect the electrical leads to the fan component protection sensor Fig 53 b Undo the two wing nuts to disconnect the fan Fig 53 Injector Pipe c Remove the fan and disconnect the electrical supply to it Fig 53 d Remove the gas injector pipe from the gas valve push fit Fig 53 e Undo the condensate trap securing nut lock nut and the condensate drain pipe Remove the condensate trap and disconnect the sensor leads Fig 54 f Remove the two screws securing the burner Protection
57. h 2 amp 3 2 Remove the fan and condensate trap see section 13 21 and 13 24 3 Undo the screws securing the flow switch and return connections Remove the flow switch and return connection Fig 81 4 Undo the screws securing the heat exchanger manifold and remove the manifold Fig 82 5 Undo the M6 Hex Headed bolt on the left hand side of the combustion box 6 Undo the screws on the bracket supporting the heat exchanger and remove bracket 7 Lift the heat exchanger assembly Fig 83 and rotate the bottom upwards whilst pulling it forwards out of the airbox 8 Fit the new heat exchanger and reassemble in reverse order 9 Recommission the boiler and check the inhibitor concentration see Section 6 2 and 10 1 Central Insulation Panel Upper Insulation Panel Lower Insulation Panel Burner Combustion Box Base _ Support Bracket B ei ts Combustion Box Base A Securing Bolts ES Burner Securing Screws Fig 84 13 0 Changing Components EY74 Heat Exchanger Insulation Pads Fig 84 1 Remove the fan and condensate trap see section 13 21 and 13 24 2 Remove the burner see section 13 25 3 Remove the four bolts securing the combustion box base 4 Remove the combustion box base 5 Pull the central insulation panel down from the centre of the heat exchanger and remove th
58. ing Hose return pipework must be provided to facilitate initial Hl Retu filling and pressurising and also any subsequent water loss replacement refilling Fig 3 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 SS N for GB Guidance G24 2 and recommendation ON R24 2 of the Water Regulations Guide for IE the current edition of I S 813 Domestic Gas Installations LW 7 A T a L OP 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 Expansion Vessel removed for clarity 5 To aid removal of air from the system whilst filling move the diverter valve to the CH position by using the installer parameters see Section 10 5 65 Expansion Vessel CH only Fig 4 1 The appliance expansion vessel is pre charged to 1 bar 10 Ib in Therefore the minimum cold fill pressure is 1 bar The vessel is suitable for correct J operation for system capacities up to 125 litres 78 27 5gal For greater system capacities an Valve additional expansion vessel must be fitted For GB
59. it back to the user Fig 55 34 13 0 Changing Components Changing Components IMPORTANT When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started Hazardous materials are not used in the construction of Baxi products however reasonable care during service is recommended Heat Exchanger Manifold 1 Remove the outer case and lower door panel see Fitting the Outercase Section 11 0 2 Isolate the water circuit and drain the system as necessary There are 5 drain points Flow Valve Heat Exchanger Manifold Return Valve Cold Water Inlet Hot Water Outlet NOTE Do not use the Pressure Relief Valve to drain the circuit NOTE When reassembling always fit new O rings ensuring their correct location on the w oo A AI Drain Point Q 9 Fig 56 spigot Green O rings are used for gas joints and Black O rings for water joints Use Greasil Automatic Air 4000 Approved Silicone Grease 3 After changing a component re commission the boiler where appropriate and check the inhibitor concentration see Section 6 2 and 10 1 Manual Air Vent The air vents flowswitch thermistor safety thermostat and expansion vessel can be accessed after removal of the outer case Manual and Automatic Air Vent Fig
60. l hot water taps to purge the Domestic Hot Water Circuit 3 Ensure that the filling loop is connected and open then open the heating flow and return valves on the boiler see Section 10 5 Filling the System 4 Open the manual and automatic air vents Fig 32 To help purge the primary circuit turn the pump on amp off several times by using the Summer Winter button Fig 33 ensure all external controls are turned on and calling for heat 5 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions further guidance can be obtained from BS 5449 Section 5 6 Refill the system and add inhibitor following the inhibitor manufacturer s instructions Vent air as described in section 10 1 paragraph 4 7 Complete the label supplied with the inhibitor and attach to the inside of the boiler case Detail of system treatment should be added for future reference 8 Pressurise the system to 1 5 bar then close and disconnect the filling loop 9 Turn the gas supply on and purge according to in GB BS 6891 and in IE IS 813 Domestic Gas Installations 10 Turn the gas service cock anticlockwise to the ON position and check for gas soundness up to the gas valve 11 Run the system and check the boiler for correct operation 12 After a period of 3 minutes and with all the system controls calling for heat check that the gas pressure at the inlet tapping of the g
61. lock 1 Undo the two screws securing the small a electrical cover and remove Fig 27 Mains Input asia 2 To connect an external timer switch circuit remove the link wire between terminals 3 amp 4 and connect the switch circuit Figs 28 amp 29 or NL 29a Link Wire ij x Optional Live Feed 3 A cable clamp is provided for incoming cables Y For An External y t ma ma Pump SS SOS O O ggg gg e TCT N L 1 2 3 4 5 Fig 28 Mains Input Mains Input Isolator O Isolator External External Timer 5 N L 4 2 3 4 5 a SIGO A O 9 A JO N L NEL a Optional Live Feed dee Optional Live Feed For An External For An External N L Sig Pump N t eo Pump iS S 4 19 Ot O O 9 Ot O 9 O 0 O O Fig 29a 24 Mains Input Isolator S Room Thermostat N L Filter Optional Live Feed For An External Pump y E SSA OOOO A A O A A 9 A O E Fig 30 N 2 L 1 2 3 4 5 Mains Input Isolator External Timer Filter Optional Live Feed For An External Pump SLsLsLoLeLeLels A ATA ATA A O Fig 30a N L 1 bar 4 5 Mains Input Isolator NFL Filter
62. n Temperatures in wg 8 Safety Discharge 3 43 5 C H Flow Temp adjustable see section 10 1 Max Operating 25 36 3 45 C to 82 C max 0 5 C Min Operating 0 7 10 2 D H W Flow Temp adjustable Electrical Supply 230V 50H Recommend Operating 1 2 14 5 29 35 C to 55 C max 0 5 C Appliance must be connected to an dependent upon flow rate earthed supply Recommended System ew Temperature Drop Power Consumption 200W Normal 11 C NO Class 5 _ ST Condensin 20 C A A External Fuse Rating 3A g Electrical Protection IP 44 Internal Fuse Rating 2AH Pump Available Head pa qee PAra qee qn MES aa ARA iii PA SEDBUK Declaration For Combi 130 HE 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 h O which it has been calculated has been certified by 0086 gal min O Where flow rates are required in excess of 840 I h please contact the Baxi Technical Department for advice Telephone number on the back cover 5 0 Dimensions and Fixings 3 Nas DIMENSIONS SIDE FLUE left and right 1 in 20 For every 1m of horizontal flue 850mm length the clearance above the top of the flue elbow should be 320mm 55mm to incorporate the 3 1 in 20 fall in the flue from the 490mm terminal to the elbow N 125mm Min Flue length Y Clearance X up to 1m 55mm
63. o change to 100 000 Btu hr i e Turn all CH controls to max and ensure no DHW demand is activated during this setting period To extract 100 000 Btu hr from the boiler an additional pump will need to be fitted to the system see the electrical installation section of these instructions KEN Switching Off The Intelligent Pre Fig 35 Fig 36 heat 1 The boiler includes an intelligent pre heat feature This feature ensures that the domestic hot water to the tap is pre heated only when the user required domestic hot water the previous week For example if the user only requires hot water between 7 00am and 8 00am on Monday then the boiler will log this demand and then the next week will only pre heat between 7 00am and 8 00am on Monday During the first week of operation from power on no pre heating will occur 2 The pre heat switches the boiler on for approximately 1 minute every 40 minutes whenever it is required 3 The boiler is factory set with the pre heat feature on If it is required to disable this feature then depress the and Temperature Control Buttons at the same time for 5 seconds The a display will show 18 or 10 Fig 35 or 36 Press Fig 37 Reset Fig 38 the Summer Winter Mode Button marked Button 8481 and the display will show 21 Fig 37 The 2 indicates that the installer parameter for pre h
64. on probe damaged wiring from PCB to spark probe amp flame detection probe OK amp are terminals tight Replace PCB if fault persists Replace gas valve Set spark gap to 3 5mm Remove Gas Valve amp check when the Burner On 15 0 Fault Finding Gas Valve Plug when unplugged F E L Unplug Gas Valve YES is there 215 Vdc at F Replace Gas Valve when the Burner On light is on NO YES there 240Vac at G Lead from PCB to Gas Valve faulty light is on NO Replace Main PCB Transformer Mains Input Flow amp Return Thermistors Burner On amp Fault Neons Overheat Thermostats amp Flow Switches amp Condensate Trap Diverter Valve G Gas Valve Modem PCB Display PCB Room Thermostat Room Control Rectify wiring and check spades and receptacles for a firm fit 49 Dry Fire Fault L7 or L8 15 0 Fault Finding Plug from PCB to Pump when unplugged Is the NO EN m O ill system with water system full of water a y and bleed out all air J YES water flowing out of NO Unplug NO NO full open DHW tap does the pump is there 240V Is there 240V at K Replace PCB at J YES YES YES Fume de water i Wiring from terminal pump nousng block to PCB faulty or terminals water ingress water flowing out o YES a fully open DHW tap is Repla
65. only the head needs replacing a standard Grundfos UPS 15 60 pump head is interchangeable see section 13 9 for details 2 This must be switched to setting N 3 Fig 62 Pump Complete Fig 63 1 Drain the boiler see Section 13 1 paragraph 2 amp 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 Pump Head Only Fig 64 1 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Unplug the wiring harness from the pump 3 Remove the four socket head screws securing the pump head and separate it from the housing 4 Remove the screws retaining the pump electrical covers on the original and replacement heads 5 From the replacement UPS 15 60 pump head remove the strain relief cable gland and discard 6 Remove the plug connector from the old pump head and wire it into the UPS 15 60 pump head 7 Replace the electrical cover to the new pump head and assemble with the electrical box at 6 o clock to the housing 8 Check that the pump has been switched to setting N 3 Fig 62 and reconnect the wiring harness plug 37 Ta Three Way Diverter Valve Head Wiring Harness Fits Here Wiring Harness Fits Here Three Way Diverter Valve 38
66. or Panel Combustion Box Door Panel Fig 51 Flue Elbow Lead Terminals 12 0 Servicing the Boiler EES Annual Servicing IMPORTANT When servicing ensure that both the gas and electrical supplies to the boiler are isolated before any work is started Hazardous materials are not used in the construction of Baxi products however reasonable care during service is recommended 1 For reasons of safety and economy it is recommended that the boiler is serviced annually 2 After servicing complete the relevant section of the Benchmark Installation Commissioning and Service Record Log Book This should be in the possession of the user 3 Ensure that the boiler is cool 4 Ensure that both the gas and electrical supplies to the boiler are isolated 5 Remove the outercase and lower door panel 6 Release the four s turn screws securing the air box door panel and remove the door Fig 51 7 Disconnect the three lead terminals from the combustion box door taking note of their positions Fig 51 8 Undo the four screws securing the combustion box door and remove the door Fig 52 9 Visually check for debris damage and clean or replace if necessary the following a Burner Fragile handle with care b Heat exchanger
67. ress the Summer Winter Mode Button marked 2 2 until the display shows 31 Fig 43 The 3 indicates that the installer parameter for system frost protection has been selected The 1 indicates that the system frost protection is switched on Press the Temperature Control Button until the display shows 30 Fig 42 The 0 indicates that the system frost protection is switched off 1 minute after the parameter has been set the display will revert to Fig 42 Summer Winter Fig 43 Summer Winter Normal operation Mode Button Mode Button 30 Temperature Temperature Control Buttons i Control Buttons Fig 44 E Fig 45 Summer Winter Temperature Mode Button Temperature Ontol Buttons Control Buttons Fig 46 Fig 47 Temperature Temperature Control Buttons Control Buttons 0 00 Fig 47a Fig 47b Summer Winter Mode Button 10 0 Commissioning the Boiler EEN Filling the System 1 When filling the system move the diverter valve to the central heating position as follows to ensure air is removed from manifold wait until display shows Of NOTE If an additional pump has been fitted see Section 8 12 disconnect the wiring until the system is filled and f
68. sion Vessel Fig 60 1 Drain the boiler see Section 13 1 paragraph 2 amp 3 2 Loosen the securing screw at the base of the expansion vessel Fig 59a 3 Whilst supporting the vessel undo the expansion vessel connection and retain the sealing washer 4 Remove the expansion vessel 5 Fitthe new expansion vessel and reassemble in reverse order EEJ 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 amp 3 4 The Schraeder valve is positioned centrally at Expansion Vessel the side of the appliance Pressurise to 1 0 bar Expansion Vessel Fig 60 Securing Screw 5 Open the isolating valves and recharge the system to between 1 0 bar and 2 5 bar Vent the system as necessary 36 Pump Setting idea Hydraulic Fig 62 Manifold Wiring wer Harness Fig 63 e Plug Connector 8 y Pump Electrical Fig 64 Cover 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 4 turn and hinge down the facia box Fig 61 Pump Fig 61 1 If
69. sure the brickwork is dust free and dry apply a suitable mastic to the inside of the trim and press against the wall finish 15 If necessary fit a terminal guard see Section 7 9 VERTICAL FLUEING Only flues approved with the Baxi Combi 130 HE Boiler can be used For information on vertical flues consult the Baxi Combination Boilers Brochure or Notes for Guidance supplied with the vertical flue pack 23 8 0 Installation Making The Electrical Connections WARNING This appliance must be earthed 1 A plug is supplied with the boiler and the electrical connection is at the rear left hand side of the unit Filter 2 Remove the electrical plug from the kit pack 3 Connect L N amp E into the plug and connect it to the socket at the rear left at the bottom of the boiler 4 Remove the metal shield from the kit pack and connect it over the plug Fig 26a Fig 26a 5 If fitting an integral timer please refer to the instructions supplied with the kit L N E Cable Clamp 8 Remove the electrical box cover and check 4 the electrical installation for earth continuity short circuits resistance to earth correct polarity and fuse failure see Section 8 13 Electrical System Checks 9 Replace the electrical box cover and secure 8 way Terminal Connecting an External Timer B
70. terminal block is OK Check wiring from boiler 8 way terminal block to PCB is OK Check for shorts on Pump Diverter Valve Fan and Gas Valve then replace fuse Replace Main PCB Replace Transformer Replace Main PCB 15 0 Fault Finding i Prog Prog R S R S Extra N L 1 2 1 2 Pump SLisLisLsLisLsLisUs Transformer Mains Input Flow amp Return Thermistors Burner On Fault Neons Overheat Thermostats amp Flow Switches Condensate Trap Diverter Valve Gas Valve Modem PCB Display PCB Room Thermostat Room Control Ignition Lockout NO Check isolation valve Is there gas at gas valve inlet and gas supply YES Reset Lockout NO hen the Burner On light is on is there gas flow check at meter YES inlet filter for blockage Check gas feed pipe seals venturi gasket amp fan seals there at least 18mbar dynamic at gas valve inlet are fited and not damaged Otherwise incorrect gas supply to boiler YES boot lace seals inside combustion box door grown outwards so door held away from eat exchanger 2 YES Trim back seals NO Is the burner damaged or the burner gaskets missing damaged or the wrong burner fitted YES Replace Burner or burner Gaskets NO ls YES Replace spark or flame detection probe and gaskets spark or flame detecti
71. 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 Inner Flue Support Bracket Flue Elbow Gasket Flue Trim Fig 26 8 0 Installation EGM Fitting the Flue Cont 8 Ensure the inner flue support bracket is positioned in the flue Fig 24 9 Engage the flue into the flue elbow using soap solution to ease the engagement ensuring the flue is assembled as shown Fig 25 10 Place the gasket over the flue exit on the boiler Fig 25 11 Slide the flue assembly through the hole in the wall Ensure angled inner end slopes downwards Fig 26 12 Engage the elbow on to the flue connection on top of the boiler Secure with the four screws supplied in the kit 13 Make good between the wall and air duct outside the building ensuring the 3 drop between the terminal and elbow 14 The flue trim should be fitted once the installation is complete and the flue secure Fig 26 Making
72. tions left to right Spark Opaque Lead Spark Opaque Lead Sensing White Lead 2 Remove the two screws securing each of the electrodes to the combustion box door and remove the electrodes 3 Fit the new electrodes and new gaskets reassemble in reverse order ensuring the spark gap of 3 5mm 0 5mm is maintained KM Fan and Fan Protection Thermostat Fig 77 1 Remove the electrical connections to the fan protection thermostat on the fan 2 Replacing the thermostat Unscrew the thermostat and replace with the new thermostat Reassemble in reverse order 3 Replacing the fan Remove the wing nuts securing the fan to the base of the combustion box 4 Lower the fan and disconnect the electrical supply from the right hand rear of the fan Remove the fan venturi assembly 5 Remove the two screws securing the venturi to the fan and remove the venturi together with the gasket 6 Remove the fan protection thermostat and fix it to the new fan together with the venturi and gasket 7 Fit the new fan and reassemble in reverse order The injector pipe condensate trap and gas valve can be changed after the removal of the fan q Sl lt A g Injector Pipe f B E ANg y Gas Valve Te Boiler Side T Electrical Plug Gas Inlet Pipe Fig 78 Flange Sensor Leads Trap Condensate Drain Pipe Securing Screws XY
73. turn 22mm at 16 l min 1 6 23 2 AAA Cold Water Mains Inlet 15mm Heat Input Gross CH DHW Flow 22mm Flow Rates l min gal min Max Factory Set Pressure Relief Discharge 15mm eee Rate 18 7 4 11 kW 33 7 26 95 Condensate Drain T BSP b i DHW Flow Rate Btu h 115 000 92 000 Outercase Dimensions 35 C Rise 16 3 52 Casing Height 850mm Min Working Heat Output CH Overall Height Inc Flue DHW Flow Rate 3 5 0 77 Non Condensing 70 C Mean Water temp Elbow 1000mm Mi omsdi Casing Width 490mm Pump ax ado gt e Casing Depth 320mm Available Head See graph below kW 30 0 23 9 2 E ion V For Central Heati Btu h 102 000 81 500 Clearances xpansion Vesse ror Central Heating Both Sides 5mm Min only Integral with appliance 5 Above Casing 200mm Min bar Ib in Condensing 40 C Mean Water temp Below Casing 200mm Min Min Pre charge Pressure 0 95 13 8 Max Factory Set Front 500mm Min For Servicing Nominal Pre charge kW 31 4 25 1 Front 5mm Min In Operation Pressure 1 14 5 Btu h 107 000 85 600 Weights kg Ib litre gal Packaged Boiler Carton 62 5 137 8 Max Capacity of Max Gas Rate Natural Gas Packaged Flue Kit 3 8 8 4 CH System 125 27 5 After 10 Mins Weight Empty 55 7 122 8 Primary Water Content m h 4 2 Installation Lift Weight 45 9 101 2 of Boiler unpressurised 1 5 0 33 3 Eee Central Heating Primary Circuit DHW Expansion Vessel Inlet Pressure Natural Gas Pressures See Section 6 7 for information mbar 20 bar Ib i
74. ully vented 2 With mains switched on to the boiler press the and Temperature Control Buttons at the same time for 5 seconds The display will show 18 or 10 Fig 44 3 Repeatedly press the Summer Winter Mode Button marked 3 21 until the display shows 40 Fig 45 The 4 indicates that the installer parameter for filling the system has been selected The O indicates that the installer parameter for filling the system is switched off Press the Temperature Control Button so that the display shows 41 Fig 46 The 1 indicates that the installer parameter for filling the system is switched on The diverter valve will now move to the central heating position and stay there until reset as below Purge through manual air vent on boiler and radiators ensure auto air vent is open and manually bleed pump before continuing with paragraph 4 NOTE The boiler will not fire until section 10 5 paragraph 4 has been carried out 4 Press the Temperature Control Button so that the display shows 40 Fig 45 The O indicates that the installer parameter for filling the system is switched off The diverter valve will now return to normal operation The display will revert to normal operation 1 minute after the parameter has been set DO Switching on the Intellistat 1 For optimum efficiency this boiler can be controlled by an optional control accessary the Baxi
75. water to prevent any discharge from the circuit and or system except in an emergency situation Ny Pressure ZN Reducer Valve To Hot Taps Stop Ta di 3 When the system includes any device which prevents water expanding back towards the supply check valve loose jumpered stopcock water meter water treatment device then an expansion vessel must be fitted e g Zilmet I6Oml R1 2 15 bar A check valve must also be fitted on the supply as shown to ensure efficient Operation and also to prevent the reverse flow of hot water into the supply pipe 4 If the hot water expansion is not provided for then high pressures can develop which may result in damage to fittings and devices on the system 5 The boilers maximum working mains pressure is 10 bar 150 lb in therefore all pipework connections fittings etc should be suitable for pressures in excess of 10 bar A pressure reducing valve must be fitted for pressures in excess of 10 bar The manufacturer of any outlet fittings such as a shower valve may require a lower maximum pressure The pressure reduction must take account of all fittings connected to the DHW system CE 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

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