Baxi
Інструкція Baxi Instruction Baxi 200 and 400 Combi Installation and Service Manual
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Сторінка 1
These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping.They must be read in conjunction with the Flue Installation Guide. United Kingdom en Installation and Service Manual High Efficiency Wall Hung Condensing Gas Boiler Baxi Combi 224 — 228 — 424 — 428 428 LPG
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Dear Customer, Thank you very much for buying this appliance. Please read through the manual carefully before using the product, and keep it in a safe place for later reference. In order to ensure continued safe and efficient operation we recommend that the product is serviced regularly. Our service and customer service organisation can assist with this. We hope you enjoy years of problem-free operation with the product.
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Contents 1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1 Benchmark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1.1 Building Regulations and the Benchmark Commissioning Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 1.1.2 The Benchmark Scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 1.1.3 Installer Notification Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.3 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.4 Specific safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.4.1 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 1.5 Liabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.5.1 Manufacturer's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.5.2 Installer's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.5.3 User's liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 2 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.2 Additional documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.3 Symbols used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.3.1 Symbols used in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 2.4 Abbreviations/Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 3 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1 Homologations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1.1 Safety, Performance & Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1.2 Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1.3 Gas category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.1.4 Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 3.2 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 3.2.1 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 3.2.2 Technical parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 3.3 Dimensions and connections/clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 3.4 Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4 Description of the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 4.2 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.2.1 Air-gas adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 4.2.2 Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.2.3 Central heating and domestic hot water production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.3 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.4 Control panel description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.4.1 Description of the keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 4.4.2 Description of the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 4.5 Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4.5.1 Contents of the carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4.6 Accessories and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 4.6.1 Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5 Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.1 Installation regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 5.2 Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 5.2.1 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 5.2.2 Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 5.2.3 Hard water area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 5.2.4 Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 5.2.5 System control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 5.2.6 Treatment of water circulating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 5.2.7 Showers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 5.2.8 Expansion vessel (CH only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 5.2.9 Pump available head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.2.10 Safety pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3 Choice of the location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3.1 Location of the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3.2 Data plate and service label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Contents 7696317 - 1 - 21032018 3
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5.3.3 Bath and shower rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 5.3.4 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5.3.5 Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.3.6 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 5.3.7 Flue/chimney location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5.3.8 Horizontal flue/chimney systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 5.3.9 Flue/chimney trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 5.3.10 Terminal guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 5.3.11 Flue/chimney deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 5.3.12 Flue/chimney accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 5.4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 5.5 Unpacking & initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 5.5.1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 5.5.2 Initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 5.6 Connecting diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 5.6.1 Filling information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 5.6.2 Domestic hot water circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 6.2.1 Fitting the pressure relief discharge pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 6.3 Air supply/flue gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6.3.1 Connecting the flue/chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 6.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 6.4.1 Panel removal to make electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 6.4.2 Electrical connections of the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.4.3 Connecting a room thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.4.4 Connecting & setting outdoor weather sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 6.5 Filling the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 6.5.1 Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 6.5.2 Fill the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.2 Checklist before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.2.1 Preliminary electrical checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 7.2.2 Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 7.3 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.3.1 De-Aeration function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.4 Gas settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.4.1 Check the operational (working gas inlet pressure and gas rate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 7.4.2 Checking combustion - chimney sweep mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 7.5 Configuring the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 7.5.1 System draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 7.6 Final instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 7.6.1 Handover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 8.1 Use of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8.1.1 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8.2 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8.3 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8.4 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 9 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 9.1 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 9.2 Information menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 10.2 Standard inspection and maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 10.2.1 Periodic check and maintenance procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 10.2.2 Checking the water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 10.2.3 Checking the expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 10.2.4 Checking the automatic air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Contents 4 7696317 - 1 - 21032018
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10.2.5 Checking the burner and cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 10.3 Specific maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 10.3.1 Detection/spark ignition electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 10.3.2 NTC flue sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57 10.3.3 Flow and return sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 10.3.4 Safety overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 10.3.5 HMI control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 10.3.6 Burner/combustion chamber door assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 10.3.7 Air/gas unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 10.3.8 Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 10.3.9 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 10.4 Hydraulics maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 10.4.1 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61 10.4.2 Pump - complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 10.4.3 Auto air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 10.4.4 Plate heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 10.4.5 Hydraulic pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 10.4.6 DHW flow sensor (hall effect sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 10.4.7 DHW flow regulator and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63 10.4.8 Diverter valve motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 10.4.9 Diverter valve cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 10.4.10 Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 11.1 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 11.2 Fault finding — temporary faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 11.3 Fault finding - permanent faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 11.4 Accessing the information menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 11.5 Reading out operating parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 11.6 Statuses and sub-statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 12 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 12.1 Decommissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 13 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 13.1 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 14 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 14.1 Combustion check on small heating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 14.2 LPG model supplement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 14.2.1 Technical information - LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 14.2.2 Technical parameters - LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 14.2.3 Gas Category - LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 14.2.4 Setting the gas valve - LPG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 14.2.5 LPG spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 14.3 Benchmark commissioning checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 14.4 Service records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Contents 7696317 - 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1 Safety 1.1 Benchmark 1.1.1 Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. This can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly. The Health & Safety Executive operates the ’Gas Safe Register’, a selfcertification scheme for gas heating appliances. This company is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency. Building Regulations require that installations should comply with manufacturer’s instructions. It is therefore important that the commissioning checklist is completed by the installer. The relevant section of Building Regulations only relates to dwellings. Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure. The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations. 1.1.2 The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.centralheating.co.uk for more information. Fig.1 Benchmark AD-3000725-01 1 Safety 6 7696317 - 1 - 21032018
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1.1.3 Installer Notification Guidelines Fig.2 Installer Notification Guidelines AD-3000696-01 Choose Building Regulations Notification Route Contact your relevant Local Authority Building Control (LABC) who will arrange an inspection or contact a government approved inspector LABC will record the data and will issue a certificate of compliance ‘Gas Safe Register’ will issue a Building Regulations Compliance Certificate to the property owner and inform the relevant LABC You must ensure that the certificate number issued by the ‘Gas Safe Register’ is written onto the Benchmark Checklist Scheme Members only Call ‘Gas Safe Register’ on: 0800 408 5577 or log onto: www.gassaferegister.co.uk within 10 days If you notify via the ‘Gas Safe Register’, the register will issue the Building Regulations certificate on members’ behalf Complete the Benchmark Checklist Install and Commission this appliance to manufacturer's instructions Competent Person's Self Certification Scheme Building Control Complete the Benchmark Checklist Install and Commission this appliance to manufacturer's instructions 1 Safety 7696317 - 1 - 21032018 7
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1.2 General safety instructions Danger This boiler can be used by children aged 8 years and above and by persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge when they have been given supervision or instruction concerning the safe use of the device and understand the resulting risks. Children must not be allowed to play with the appliance. Cleaning and user maintenance must not be carried out by children without supervision. Danger If you smell gas: 1. Do not use a naked flame, do not smoke, do not operate electrical contacts or switches (doorbell, light, motor, lift, etc.). 2. Shut off gas supply. 3. Open the windows. 4. Trace possible leaks and seal them immediately. 5. If the gas leak is before the gas meter, contact the supplier 6. Telephone the National Gas Emergency Service on:- 0800 111 999. Danger If you smell flue gases: 1. Switch off the boiler. 2. Open the windows. 3. Trace possible leaks and seal them immediately. Warning Do not touch the flue gas pipes. Depending on the boiler settings, the temperature of the flue gas pipes may exceed 60oC. Warning Do not touch the radiators for long periods. Depending on the boiler settings, the temperature of the radiators may exceed 60oC. Warning Take precautions with the domestic hot water. Depending on the boiler settings, the domestic hot water temperature may exceed 65oC. Danger Before any work, switch off the mains supply to the boiler. Caution After maintenance or repair work, check the entire heating installation to ensure that there are no leaks. 1.3 Recommendations Warning Installation and maintenance of the boiler must be carried out by a qualified installer in accordance with local and national regulations. Warning If the mains lead is damaged, it must be replaced by the original manufacturer, the manufacturer's dealer or another suitably skilled person to prevent hazardous situations from arising. Warning Always disconnect the mains supply and close the main gas tap when working on the boiler. 1 Safety 8 7696317 - 1 - 21032018
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Caution Make sure the boiler can be reached at all times. The boiler must be installed in a frost-free area. In the case of a fixed connection to the power cord, you must always install a main double pole switch with an opening gap of at least 3 mm (EN 60335-1). Drain the boiler and central heating system if you are not going to use your home for a long time and there is a chance of frost. The frost protection does not work if the boiler is out of operation. The boiler protection only protects the boiler, not the system. Check the water pressure in the system regularly. If the water pressure is lower than 0.8 bar, the system must be topped up (recommended water pressure between 1 and 2 bar). Important Keep this document near to the boiler. Important Casing panels may only be removed for maintenance and servicing purposes. Refit all panels when maintenance work and servicing are complete. Note Instruction and warning labels must never be removed or covered and must be clearly legible throughout the entire service life of the boiler. Replace damaged or illegible instruction and warning labels immediately. Note The boiler must not be modified in any way. 1.4 Specific safety instructions 1.4.1 Handling General The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance. Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health & Safety is the responsibility of EVERYONE. There is no "safe" limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE. Do not handle or lift unless you feel physically able. Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc. Preparation Co-ordinate movements - know where, and when, you are both going. Minimise the number of times needed to move the boiler - plan ahead. Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care on ladders/into lofts. Technique When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible. Where possible transport the boiler using a sack truck or other suitable trolley. 1 Safety 7696317 - 1 - 21032018 9
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Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the "Installation" section of these instructions for recommended lift points. Remember The circumstances of each installation are different. Always assess the risks associated with handling and lifting according to the individual conditions. If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT "work through" the pain - you may cause further injury. IF IN ANY DOUBT DO NO HANDLE OR LIFT THE BOILER — OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING ! 1.5 Liabilities 1.5.1 Manufacturer's liability Our products are manufactured in compliance with the requirements of the various Directives applicable. They are therefore delivered with the marking and any documents necessary. In the interests of the quality of our products, we strive constantly to improve them. We therefore reserve the right to modify the specifications given in this document. Our liability as manufacturer may not be invoked in the following cases: Failure to abide by the instructions on installing the appliance. Failure to abide by the instructions on using the appliance. Faulty or insufficient maintenance of the appliance. 1.5.2 Installer's liability The installer is responsible for the installation and initial commissioning of the appliance. The installer must abide by the following instructions: Read and follow the instructions given in the manuals provided with the appliance. Install the appliance in compliance with prevailing legislation and standards. Carry out initial commissioning and any checks necessary. Explain the installation to the user. If maintenance is necessary, warn the user of the obligation to check the appliance and keep it in good working order. Give all the instruction manuals to the user. 1.5.3 User's liability To guarantee optimum operation of the system, you must abide by the following instructions: Read and follow the instructions given in the manuals provided with the appliance. Call on a qualified professional to carry out installation and initial commissioning. Get your installer to explain your installation to you. Have the required inspections and maintenance carried out by a qualified installer. Keep the instruction manuals in good condition close to the appliance. 1 Safety 10 7696317 - 1 - 21032018
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2 About this manual 2.1 General This manual is intended for the installer of a Baxi Combi boiler. 2.2 Additional documentation These Installation & Service Instructions must be read in conjunction with the Flue Accessories Fitting Guide supplied in the Literature Pack. Various timers, external controls, etc. are available as optional extras. Full details are contained in the relevant sales literature. 2.3 Symbols used 2.3.1 Symbols used in the manual This manual uses various danger levels to draw attention to special instructions. We do this to improve user safety, to prevent problems and to guarantee correct operation of the appliance. Danger Risk of dangerous situations that may result in serious personal injury. Danger of electric shock Risk of electric shock. Warning Risk of dangerous situations that may result in minor personal injury. Caution Risk of material damage. Important Please note: important information. See Reference to other manuals or pages in this manual. 2.4 Abbreviations/Glossary BS British Standard CH Central heating DHW Domestic hot water GB Great Britain Hi Lower heating value (LHV) Hs Higher heating value (HHV) IE Ireland PCU PCB for managing burner operation Pn Nominal output Pnc Condensing output PWM Pulse wide modulation Qn Nominal input SU Safety PCB 2 About this manual 7696317 - 1 - 21032018 11
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3 Technical specifications 3.1 Homologations 3.1.1 Safety, Performance & Quality This boiler has been assessed by an appropriate Notified Body and shown to meet the requirements of all Directives and Regulations as applicable. These Directives and Regulations lay down requirements for the safety and efficiency of the appliance, together with its design, construction and use of materials. They also require the production process to be covered by an approved and monitored system of quality assurance. 3.1.2 Certifications Tab.1 Certifications CE certificate number 0085CQ0192 NOx class 6 Boiler type C13, C33 3.1.3 Gas category Tab.2 Gas category, type and supply pressure Gas category Gas type Supply pressure (mbar) I2H G20 20 3.1.4 Standards Codes of Practice — refer to the most recent version Tab.3 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 EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings — Calculation of load. BS EN 14336 Installation & commissioning of water based heating sys tems. 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 wa ter systems. BS 7593 Treatment of water in domestic hot water central heating systems. BS 4814 Specification for Expansion Vessels using an internal dia phragm, for sealed hot water systems. IGE/UP/ 7/1998 Guide for gas installations in timber framed housing. 3 Technical specifications 12 7696317 - 1 - 21032018
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Tab.4 In IE the following Code of Practice apply: Standard Scope IS 813 Domestic Gas Installations. The following standards give valuable additional information: BS 5546 Installation of hot water supplies for domestic purposes. BS EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings — Calculation of load. BS EN 14336 Installation & commissioning of water based heating sys tems. BS 7074 Expansion vessels and ancillary equipment for sealed wa ter systems. BS 7593 Treatment of water in domestic hot water central heating systems. 3.2 Technical data 3.2.1 Technical information Important All data in these sections are nominal and subject to normal production tolerances. Important LPG information can be found in Technical information - LPG, page 75 Tab.5 General Baxi Combi 224 228 424 428 Gas Council Numbers 47–077–21 47–077–22 47–077–23 47–077–24 Nominal heat input Domes tic Hot Water — Maximum Rate Nett (Qn Hi) kW 24.7 28.9 24.7 28.9 Gross (Qn Hs) kW 27.4 32.1 27.4 32.1 Nominal Heat Input Central Heating — Maximum Rate Nett (Qn Hi) kW 20.6 24.7 20.6 24.7 Gross (Qn Hs) kW 22.9 27.4 22.9 27.4 Nominal Heat Input — Min imum Rate Nett (Qn Hi) kW 4.9 4.9 4.9 4.9 Gross (Qn Hs) kW 5.4 5.4 5.4 5.4 Nominal heat output 80/60°C — Domestic Hot Water — Maximum Rate Pn kW 24.0 28.0 24.0 28.0 Nominal heat output 80/60°C — Central Heating — Maximum Rate Pn kW 20.0 24.0 20.0 24.0 Nominal heat output 80/60°C — Central Heating — Factory Setting Pn kW 20.0 20.0 20.0 20.0 Nominal heat output 80/60°C — Minimum Rate Pn kW 4.8 4.8 4.8 4.8 3 Technical specifications 7696317 - 1 - 21032018 13
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Baxi Combi 224 228 424 428 Nominal heat output 50/30°C — Central Heating — Maximum Rate Pnc kW 21.8 26.1 21.8 26.1 Nominal heat output 50/30°C — Central Heating — Minimum Rate Pnc kW 5.2 5.2 5.2 5.2 Tab.6 Central heating circuit specifications Baxi Combi 224 228 424 428 Maximum pressure bar 3 3 3 3 Minimum pressure bar 0.5 0.5 0.5 0.5 Central heating temperature adjust ment ±5°C °C 25/80 25/80 25/80 25/80 Expansion vessel water capacity litres 7.0 7.0 7.0 7.0 Expansion vessel pre charge pres sure bar 1.0 1.0 1.0 1.0 Maximum capacity of central heat ing system litres 120 120 120 120 Primary water content of boiler (un pressurised) litres 2.5 2.5 2.5 2.5 Tab.7 Domestic hot water circuit specifications Baxi Combi 224 228 424 428 Maximum pressure bar 8.0 8.0 8.0 8.0 Dynamic minimum pressure bar 0.5 0.5 0.5 0.5 Minimum working water flow rate l/min 2.0 2.0 2.0 2.0 Specific flow rate (D) l/min 11.5 13.4 11.5 13.4 Domestic hot water temperature range adjustment ±5°C °C 35/60 35/60 35/60 35/60 Production of domestic water with ΔT = 30°C l/min 11.4 13.3 11.4 13.3 Production of domestic water with ΔT = 35°C l/min 9.8 11.5 9.8 11.5 Where low flow taps or fittings are intended to be used in the DHW system connected to the boiler, it is strongly recommended that the DHW flow rate DOES NOT fall below 2.5 l/min. This will ensure reliable operation of the DHW function. Tab.8 Characteristics of combustion Baxi Combi 224 228 424 428 Natural gas rate (G20) Qmax m3/h 2.61 3.06 2.61 3.06 Natural gas rate (G20) Qmin m3/h 0.52 0.52 0.52 0.52 Diameter of coaxial discharge pipes mm 60/100 & 80/125 60/100 & 80/125 60/100 & 80/125 60/100 & 80/125 Important Dynamic (nominal) inlet pressure (Natural gas — G20) 20mbar with a CV of 37.78 MJ/m3 Tab.9 Electrical specifications Baxi Combi 224 228 424 428 Nominal electrical power supply voltage V 230 230 230 230 Nominal electrical power supply frequency Hz 50 50 50 50 3 Technical specifications 14 7696317 - 1 - 21032018
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Baxi Combi 224 228 424 428 Nominal power consumption when firing W 84 94 84 94 External fuse rating Amp 3 3 3 3 F2 Internal fuse rating — Connec tion board ’B’ Amp 0.5 0.5 0.5 0.5 F1 Internal fuse rating — Main PCB board ‘A’ Amp 1.6 1.6 1.6 1.6 Important Boiler must be connected to an earth supply. Tab.10 Other specifications Baxi Combi 224 228 424 428 Degree of protection against hu midity (EN 60529) without plug-in timer / receiver fitted IP IPX5D IPX5D IPX5D IPX5D Degree of protection against hu midity (EN 60529) with plug-in tim er / receiver fitted IP IPXO IPXO IPXO IPXO Dimensions (height/width/depth) mm 700/395/279 700/395/279 700/395/279 700/395/279 Tab.11 Connections (copper tails) Baxi Combi 224 228 424 428 Gas inlet mm 22 22 22 22 Heating flow mm 22 22 22 22 Heating return mm 22 22 22 22 Cold water inlet mm 15 15 15 15 Hot water outlet mm 15 15 15 15 Pressure relief discharge mm 15 15 15 15 Condensate discharge drain plastic waste pipe mm 21.5 21.5 21.5 21.5 Tab.12 Clearances Baxi Combi 224 228 424 428 Above casing mm 183 183 183 183 Below casing (min) Below casing (recommended) mm mm 200 250 200 250 200 250 200 250 Front — for servicing (min) Front — for servicing (recommen ded) mm mm 450 1000 450 1000 450 1000 450 1000 Front — for operation mm 6 6 6 6 Sides LH mm 5 5 5 5 Sides RH mm 5 5 5 5 Tab.13 Weights Baxi Combi 224 228 424 428 Packaged boiler kg 30.0 30.0 30.5 30.5 Boiler lift weight (dry) kg 26.0 26.0 26.0 26.0 Installed weight (dry) kg 28.0 28.0 28.5 28.5 Installed weight when filled with wa ter kg 30.5 30.5 31.0 31.0 3 Technical specifications 7696317 - 1 - 21032018 15
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3.2.2 Technical parameters Tab.14 Technical parameters for boiler combination heaters Baxi Combi 224 228 424 428 Condensing boiler Yes Yes Yes Yes Low-temperature boiler(1) No No No No B1 boiler No No No No Cogeneration space heater No No No No Combination heater Yes Yes Yes Yes Rated heat output Prated kW 20 24 20 24 Useful heat output at rated heat output and high temperature regime(2) P4 kW 20.0 24.0 20.0 24.0 Useful heat output at 30% of rated heat output and low temperature regime P1 kW 6.7 8.0 6.7 8.0 Seasonal space heating energy efficiency ƞs % 93 93 93 93 Useful efficiency at rated heat output and high temperature regime ƞ4 % 88.1 88.0 88.1 88.0 Useful efficiency at 30% of rated heat output and low temperature regime ƞ1 % 97.8 97.8 97.8 97.8 Auxiliary electricity consumption Full load elmax kW 0.028 0.038 0.028 0.038 Part load elmin kW 0.011 0.011 0.011 0.011 Standby mode PSB kW 0.003 0.003 0.003 0.003 Other items Standby heat loss Pstby kW 0.069 0.069 0.069 0.069 Ignition burner power consumption Pign kW 0.000 0.000 0.000 0.000 Annual energy consumption QHE GJ 62 74 62 74 Sound power level, indoors LWA dB 48 50 48 50 Emissions of nitrogen oxides NOX mg/kWh 38 40 38 40 Domestic hot water parameters Declared load profile XL XL XL XL Daily electricity consumption Qelec kWh 0.151 0.151 0.151 0.151 Annual electricity consumption AEC kWh 33 33 33 33 Water heating energy efficiency ƞwh % 86 85 86 85 Daily fuel consumption Qfuel kWh 22.770 22.930 22.770 22.939 Annual fuel consumption AFC GJ 17 17 17 17 (1) Low temperature means for condensing boilers 30°C, for low temperature boilers 37°C and for other heaters 50°C return temperature (at heater inlet). (2) High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet. See The back cover for contact details. 3 Technical specifications 16 7696317 - 1 - 21032018
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3.3 Dimensions and connections/clearances Fig.3 Dimensions and connections 1 2 3 4 5 6 7 8 700 279 395 PN-0000501 1 Safety valve 2 Heating circuit water flow 3 Condensate discharge 4 Heating system/boiler drain tap 5 Domestic hot water outlet 6 Gas inlet 7 Mains cold water inlet 8 Heating circuit water return A* Clearances below — 200mm minimum, 250mm recommended B* Clearances in front — 450mm minimum, 1000mm recommended The clearances shown in the diagram are minimum requirements to allow for case removal, spanner access and air movement. These should be observed at all times and kept clear of obstructions. Fig.4 Clearances A* 5.0 6 B* 285 700 395 PN-0000503 5.0 183 3 Technical specifications 7696317 - 1 - 21032018 17
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Fig.5 Paper template Ø 8 34 33.5 65 65 65 65 67.5 198 198 50 MIN 82.5 32 116 Dia Minimum Aperture For Flue Tube Vertical Flue Centre Line Ø 22 Heating Return (22mm) Heating Flow (22mm) Hot Water Outlet (15mm) Combi Only Not System Cold Water Inlet (15mm) Combi Only Not System Side Clearance 5 Side Clearance 5 Clearance below 250 Clearance above 183 Wall View from under boiler PN-0000504 3 Technical specifications 18 7696317 - 1 - 21032018
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3.4 Electrical diagram Fig.6 Electrical diagram HMI 1 1 1 GND 1 1 PWM - P L-BUS E 1 1 1 L N G/Y G/Y W Br Bl DV PN-0000505 Bl Br Bl Br P 230V - 50Hz Gy R W Bk Vt Br Bl 13 R R R R Gn W Br R Bl Gn Br Bl Y Bk Bk R R Vt Vt Vt Vt Br Br Br Br R R Bk Bk W Br 1 2 3 4 5 1 2 3 4 5 6 7 1 2 1 1 2 3 Br Br Bl Bk Bk Gy Bl W Gy Vt Br Bk W Gn Br R Bl R L-BUS Bk R W Gn Gn Wk Bk Br R 16 F1 F1 (1,6A) L N L(CH) L(DW) N GV W8-1 W8-2 W8-4 W8-3 ST HS WPS DS RS FS X6-A X9-1 X14-A X4-A W8 X5-A X1-A X3-A X2-A A JP1 G/Y G/Y SERVICE X7 X6 F2 0.5A X14 OS X13 J X9 L-BUS 3 On B X12 X11 X10 X3 TIMER X2 X5 Off 230V - 50Hz L N 2 1 X1 MAINS X4 RT X8 OT Gn Bk W4 W3 + C2 C1 SIG W2 W1 W5 F 1 2 1 Circuit board ‘A’ 2 Circuit board ‘B’ Tab.15 Circuit board wiring Br Brown Gy Grey Gn Green Bl Blue R Red W White G/Y Green/Yellow Vt Violet Mains (230V) Bk Black 3 Technical specifications 7696317 - 1 - 21032018 19
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Tab.16 Electrical connections inside the boiler (A) X1–A Electrical power supply 230 V — 50 Hz 1: Earthing connector 2: L (230 V) 3: N X2–A Pump 1: Earth connection 2: L (230 V) 3: N X3–A 3-way valve 1: L (CH) 230 V — Heating circuit opening command 2: L (DW) 230 V — Domestic water circuit opening command 3: N — Common X4–A Pump PWM signal X5–A Sensor connection HS: domestic water request RS: heating circuit water return DS: heating circuit water flow FS: flue gas WPS: hydraulic pressure switch ST: safety thermostat X6–A Boiler PCB and control panel connection (electrical connection board) X13–A Not used X14–A Connection L-BUS Tab.17 Electrical connections to be made to the boiler (B) X1–B Electrical power supply 230 V — 50 Hz 1: Earthing connector 2: L (230 V) 3: N X4–B Room thermostat/timer (230V) X6–B Not used X7–B Solar probe connection X8–B On-Off/R-Bus - Room thermostat connection (the jumper must be REMOVED to connect a device) X9–B Service connection (SERVICE) X13–B Connection L-BUS X14–B Outside sensor connection (OS) J Dip-Switch 1: Maximum heating temperature OFF = 80°C - ON = 45°C (floor system) 2: OFF = Maximum output (heating) - ON = Boiler output 50% (heating) 3: DO NOT ADJUST 3 Technical specifications 20 7696317 - 1 - 21032018
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4 Description of the product 4.1 General description The Baxi Combi condensing boiler is a gas-fuelled boiler. The purpose of this boiler is to heat water to a temperature that is lower than boiling point at atmospheric pressure. It must be connected to a heating installation and to a domestic hot water distribution system that is compatible with its power and performance ratings. Features of this boiler: Low pollutant emissions. High-efficiency heating. Combustion products discharged through a coaxial connector. Front control panel with display. Lightweight and compact. 4.2 Operating principle 4.2.1 Air-gas adjustment The air is drawn in by the fan and gas injected directly at the top of the mixer valve. The fan rotation speed is regulated automatically by the electronic board based on temperature adjustment and other parameters. The gas and air are mixed in the manifold. The gas/air ratio ensures that the quantity of gas and air are adjusted correctly to always obtain optimal combustion. The gas/air mixture is fed into the burner at the front of the heat exchanger. The mixture is ignited by the spark electrode. 4.2.2 Combustion The burner heats the heating water circulating in the heat exchanger. When the temperature of the combustion gas is lower than the dew point (around 55 °C), the water vapour contained in the combustion gas condenses in the flue gas side of the heat exchanger. The heat recovered during this condensation process (the latent heat or condensing heat) is also transferred to the heating water. Once cooled, the combustion gases are discharged through the flue exhaust. The condensed water is discharged through a trap. 4.2.3 Central heating and domestic hot water production In boilers used for heating and for producing domestic hot water, an integrated plate heat exchanger heats the domestic water. The heated water is then channelled to the heating installation or to the plate heat exchanger via a diverter valve. A flow sensor detects that a hot water tap has been turned on and communicates this to the printed circuit board (PCB), which switches the diverter valve to the hot water position and activates the pump. The diverter valve is spring-loaded but only consumes electricity when switching from one position to another. Priority is given to domestic hot water. 4 Description of the product 7696317 - 1 - 21032018 21
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4.3 Main components 1 Boiler case 2 Mounting slots for wall bracket 3 Flue adaptor 4 Expansion vessel air control/filling valve 5 Expansion vessel 6 Burner door 7 Detection/ignition electrode 8 Water circuit-expansion vessel connection pipe 9 Air-gas assembly (control board, fan, mixer valve) 10 Automatic air vent 11 Gas valve 12 Pump 13 3-way valve 14 Pressure gauge (fitted on the panel) 15 Domestic hot water priority sensor 16 Boiler electrical connection board 17 Domestic hot water plate heat exchanger fastening screws 18 Domestic hot water plate heat exchanger 19 Pressure relief valve 20 Condensate trap 21 Hydraulic pressure sensor 22 Silencer 23 Trap quick connection (with gaskets) 24 Heating circuit water flow sensor 25 Overheat safety thermostat 26 Heating circuit water return sensor (behind the silencer) 27 Heat exchanger 28 Flue gas temperature sensor 4.4 Control panel description 4.4.1 Description of the keys Heating temperature control knob Level access button: Information, Installer or Chimney Sweep Manual reset button Domestic hot water temperature control knob 4.4.2 Description of the display Hour run meter Malfunction Maintenance Reset necessary Burner status Heating mode Outside temperature sensor Domestic hot water mode Fig.7 Component description 1 3 2 4 5 6 7 8 9 10 12 13 11 21 22 23 25 26 24 28 27 15 16 17 18 19 20 14 PN-0000506 Fig.8 Control panel PN-0000509 Fig.9 Display screen PN-0000510 4 Description of the product 22 7696317 - 1 - 21032018
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4.5 Standard delivery 4.5.1 Contents of the carton The boiler is delivered in a carton comprising: a wall-hung gas boiler; a bracket for fastening the boiler to the wall; a paper template; an installation and service manual; a user manual. a fitting kit, including taps and tail pipes. 4.6 Accessories and options 4.6.1 Optional accessories The table below shows the accessories available for this boiler range. Tab.18 Optional accessories Part number Accessory 7658276 Baxi plug-in 24 hr mechanical timer combi - RH 7658523 Baxi plug-in 7 day digital timer combi - RH 7658781 Baxi plug-in receiver 24 hr RF programmable mech room thermostat-combi 7658789 Baxi plug-in receiver 7 day RF digital programmable room thermostat-combi 7212438 Baxi single channel wired programmable room thermostat 7212444 Baxi single channel wired timer 720971601 Baxi room thermostat 720330001 Baxi wired weather sensor 720648301 Multifit condensate & PRV combined pump 720644401 Multifit 1m condensate drain pipe 'trace heating' element 720664101 Multifit 2m Condensate drain pipe 'trace heating' element 720664201 Multifit 3m condensate drain pipe 'trace heating' element 720664401 Multifit 5m condensate drain pipe 'trace heating' element 7659335 Baxi 200-400 stand off kit 5121379 Multifit remote secondary PRV kit 248221 Multifit filling loop (Not required for 424 and 428) For Flue Accessories (elbows, extensions, clamps etc.) refer to the Flue Installation Guide supplied in the literature pack. Any of the above MUST be fitted ONLY by a qualified competent person. Further details can be found in the relevant sales literature and at www.baxi.co.uk 4 Description of the product 7696317 - 1 - 21032018 23
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5 Before installation 5.1 Installation regulations Warning Installation, repair and maintenance must only be carried out by a competent person. This document is intended for use by competent persons. Installation must be carried out in accordance with the prevailing regulations, the code of practice and the recommendations in these instructions. Installation must also respect the following points: This instruction manual and any other applicable documentation Building Regulations British Standards Gas Safety Regulations Water Supply Regulations 5.2 Installation requirements 5.2.1 Gas supply 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 IS 813 Domestic Gas Installations. The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock. Ensure that the pipework from the meter to the appliance is of adequate size, and the demands of any other gas appliances in the property are taken into consideration. Do not use pipes of a smaller diameter than the boiler gas connection (22mm) UNLESS the stated gas rate can be achieved with pipe of lesser diameter and with all other gas appliances operating at maximum rate. 5.2.2 Electrical supply External wiring must be correctly earthed, polarised and in accordance with relevant regulations/rules. In GB this is the current IEE Wiring Regulations. In IE reference should be made to the current edition of ETCI rules. The mains supply is 230V ~ 50Hz fused at 3A. Important The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance. Connection may be via a fused double-pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only. The boiler must be connected to the mains fused 3A 230V 50HZ supply & control system using cable of 3 core 0.75mm 3183Y multi strand flexible type. 5 Before installation 24 7696317 - 1 - 21032018
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Important Any wiring to the boiler, from either the mains or an external control, MUST be cable of the following specification:- 0.75mm 3183/4/5Y (depending on installation) multi strand flexible cable conforming to BS 50525-2-11. Cable of the above specification is sufficiently flexible to withstand normal regular opening and closing of the facia/ control box as expected during routine servicing and other maintenance work. Use ONLY cable glands supplied with the boiler, or provided as spares by the manufacturer. Under no circumstances must solid core cable be used as it is not intended for applications where movement may occur. The use of solid core cable could result in situations potentially hazardous to health. These points must be considered when initially wiring the boiler to the installation, and if replacing any wiring during the service life of the boiler. 5.2.3 Hard water area Important Only water that has NOT been artificially softened must be used when filling or re-pressurising the primary system. If the mains cold water to the property is fitted with an artificial softening/ treatment device the source utilised to fill or re-pressurise the system must be upstream of such a device. 5.2.4 Bypass The boiler is fitted with an automatic integral bypass. 5.2.5 System control Further external controls (e.g. room thermostat sensors) MUST be fitted to optimise the economical operation of the boiler in accordance with Part L of the Building Regulations. A range of optional controls is available. Full details are contained in the relevant Sales Literature. Any proprietary OpenTherm control MUST allow individual adjustment of CH and DHW temperature. 5.2.6 Treatment of water circulating systems All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems. When fitting new systems flux will be evident within the system, which can lead to damage of system components. BS 7593 gives extensive recommendations on system cleansing and water treatment. All systems must be thoroughly drained and flushed out using appropriate proprietary flushing agent. A suitable inhibitor must then be added to the system. All system additives (flushing agents, cleansers, inhibitors etc.) must comply with the requirements of BS 7593. Full instructions are supplied with the products and for further information contact the additive manufacturer directly or consult their website. 5 Before installation 7696317 - 1 - 21032018 25
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Important Failure to flush and add inhibitor to the system will invalidate the appliance warranty. It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the inhibitor manufacturer. (Test kits are available from inhibitor stockists.) For information or advice regarding any of the above contact Baxi Customer Support 0344 871 1545. 5.2.7 Showers If a shower control is supplied from the appliance it should be of the thermostatic or pressure balanced type. Thermostatic type shower valves provide the best comfort and guard against water at too high a temperature. Existing controls may not be suitable - refer to the shower valve manufacturer. 5.2.8 Expansion vessel (CH only) The appliance expansion vessel is pre-charged to 1.0 bar. Therefore, the minimum cold fill pressure is 1.0 bar. The vessel is suitable for correct operation for system capacities up to 120 litres. For greater system capacities an additional expansion vessel must be fitted. For GB refer to BS 7074 Pt 1. For IE, the current edition of IS 813 Domestic Gas Installations. Checking the charge pressure of the vessel - to check the charge accurately ensure the system is cold. It is also necessary to relieve the pressure by draining the boiler. Using a suitable gauge check the pressure at the valve on the underside of the vessel. Adjust the pressure as required and repressurise the system. 5.2.9 Pump available head This is a two-speed (85% CH and 100% DHW) high static head pump fit for installation on any type of single or double pipe CH system. The automatic air valve incorporated in the pump allows quick venting of the heating systems. Tab.19 Pump head Q Flow 85% Speed in the CH mode H Head 100% Speed in the DHW mode Fig.10 Available pump head graph PN-0000511 600 400 85% 100% 200 6.0 5.5 4.5 3.5 2.5 1.5 5.0 4.0 3.0 3.0 0 Q (l/h) H (mH 20) 800 1000 5 Before installation 26 7696317 - 1 - 21032018
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5.2.10 Safety pressure relief valve 1 Discharge pipe 2 Pressure relief valve A The end of the pipe should terminate facing down and towards the wall See See BS 6798 for full details. The pressure relief valve is set at 3 bar, therefore all pipework, fittings, etc. should be suitable for pressures in excess of 3 bar and temperature in excess of 100°C. The pressure relief discharge pipe should be not less than 15mm diameter, 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. If it is anticipated that any part of the pipe may be subject to freezing it should be suitably insulated. The end of the pipe should terminate facing down and towards the wall. 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. Important The relief valve must never be used to drain the system. A remote relief valve kit is available to enable the boiler to be installed in cellars or similar locations below outside ground level. A boiler discharge pump is available which will dispose of both condensate & high temperature water from the relief valve. It has a maximum head of 5 metres. 5.3 Choice of the location 5.3.1 Location of the boiler The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard.) Where the boiler is sited in an unheated enclosure and during periods when the heating system is to be unused it is recommended that the permanent live is left on to give BOILER frost protection. NOTE: THIS WILL NOT PROTECT THE SYSTEM ! If the boiler is fitted in a room containing a bath or shower reference must be made to the relevant requirements. In GB this is the current IEE Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of IS 813 Domestic Gas Installations and the current ETCI rules. 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). Fig.11 Discharge pipe 1 PN-0000553 1 2 A 5 Before installation 7696317 - 1 - 21032018 27
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5.3.2 Data plate and service label The data plate is located on the top inner part of the boiler. To see it, remove the front panel of the boiler. The data plate provides important information about the boiler. Tab.20 Description of the data plate "BRAND" Commercial brand "Product name" Model name "Code" Product code Qn Hi Nominal input Pn Effective rated output (delivery 80° C return 60° C) PMS Maximum heating circuit pressure (bar) Maximum domestic water circuit pressure (bar) D Specific flow rate (l/min) NOx NOx class IP Protection rating V-Hz-W Power supply and output Cxx/Bxx Flue gas exhaust type II2HM3B/P — IT (example) Gas category used (depends on the country of destination) C1/C2 Factory parameters s/n Serial number The service label is at the base of the cover of the terminal block under the control panel. Tab.21 Description of the service label "Code" Product code "Product name" Model name "s/n" Serial number Fig.12 Data plate position Qn Hi Pn 80/60°C Pn 50/30°C PMS PMW D NOx 4,9-24,7 4,8-24 kW kW kW kW kW kW 4,9-20,6 4,8-20 5,2-21,8 3 bar <95 °C 8 bar 10,9 l/min 5 3P - G31 - 37 mbar 2H - G20 - 20 mbar GB I2H X 0085 C13 C33 230 V~50 Hz - 84 W - IP X5D 72xxxxx.xx s/n: 143800001 CN1=1 CN2=1 “Code” “Product name” “ BRAND ” PN-0000512 Fig.13 Service label position BO-0000011 Fig.14 Service label BO-0000012 “Code” “Product name” “s/n” 5 Before installation 28 7696317 - 1 - 21032018
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5.3.3 Bath and shower rooms A Zone 0 B Zone 1 C Zone 2 D Window recess Zone 2 E Ceiling F Outside zones Important Where an optional plug-in integral timer, RF receiver or thermostat is NOT FITTED the boiler has a protection rating of IPX5D and if installed in a room containing a bath or shower can be within Zone 2 (but not 0 or 1). Important A boiler fitted with an optional plug-in integral timer, RF receiver or thermostat CANNOT be fitted in any zone. Bathroom 1 and 2 ( in GB only) shows zone dimensions for a bathtub. For other examples refer to the Current IEE Wiring Regulations). Reference must be made to the relevant requirements. In GB this is the current IEE. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of IS 813 “Domestic Gas Installations” and the current ETCI rules. 5.3.4 Ventilation Where the appliance is installed in a cupboard or compartment, no air vents are required. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. Fig.15 Bathroom 1 and 2 PN-0000400 A B C D D 0.6m A B C D E F 0.6m 2.25m 5 Before installation 7696317 - 1 - 21032018 29
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5.3.5 Condensate drain It is strongly recommended to discharge internally into the household drainage system. If connecting to a rain water drain, that drain MUST discharge into a foul drain. 1 Pipework. 2 Insulation. 3 50mm per metre of pipe run — 2.5° minimum run. 4 450mm minimum is applicable to properties up to 3 storeys. For multi-storey building installations consult BS 6798. 5 Boiler. 6 Sink. 7 Pipe must terminate above water level but below surrounding surface. Cut end at 45°. 8 Holes in the soak-away must face away from the building. 9 500mm mimimum. 10 Basement or similar (heated) 11 Condensate pump 12 Unheated Location (e.g. Garage) Tab.22 Examples are shown of the following methods of termination Key Description A Termination to an internal soil and vent pipe. B External termination via internal discharge branch e.g. sink waste — downstream (It is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle!) C Termination to a drain or gully. D Termination to a purpose made soakaway Further specific re quirements for soakaway design are referred to in BS 6798 E Pumped into an internal discharge branch (e.g. sink waste) down stream of the trap. F Pumped into an external soil and vent pipe. G Termination to a drain or gully with extended external run and trace heating. The "Trace Heating" element must be installed in accordance with the instructions supplied. External runs and those in unheated locations still require insulation. Fig.16 Pipework and method of termination PN-0000389 A B C D 3 3 3 3 4 6 5 5 5 5 7 7 8 9 21.5mm 32mm 2 5 Before installation 30 7696317 - 1 - 21032018
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Important Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler. Careful consideration must be given to the possibility of the pipework being subject to freezing conditions and appropriate measures taken to prevent blockage. Correct installation in accordance with this section will considerably minimise the likelihood of blockage and subsequent boiler lock-out. A condensate discharge pump and pipe "Trace Heating" are available as accessories. 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 EXCEPT when employing a suitable condensate pump in basement and cellar or similar applications. The boiler condensate trap incorporates a seal of 75mm, therefore it is unnecessary to install an air break and trap in the discharge pipework. The condensate outlet will accept 21.5mm (3/4in) plastic overflow pipe. It is strongly recommended that this discharges internally into the household drainage system. Where this is not possible, discharge into an outside drain is permissible providing every possible precaution is taken to prevent freezing. Ensure the discharge of condensate complies with any national or local regulations in force. BS 6798 & Part H1 of the Building Regulations give further detailed guidance. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP. Metal pipework is NOT suitable for use in condensate discharge systems. The pipe should be a minimum of 21.5mm diameter and must be supported using suitably spaced clips of the correct design to prevent sagging. It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres. Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe. External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external use. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly. 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 and any burrs on cut pipe removed. 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 backpressure may force water out of the boiler trap and cause appliance lockout. A boiler discharge pump is available which will dispose of both condensate & high temperature water from the relief valve. It has a maximum head of 5 metres. Follow the instructions supplied with the pump. Condensate Drain Pipe "Trace Heating" Elements are available in various lengths, 1, 2, 3 & 5 metres. Where the drain is between 3 & 5 metres a 5 metre kit can be used and "doubled back" upon itself. It is possible to fit the element externally on the condensate drain or internally as detailed in the instructions provided. Fig.17 Methods of termination continued PN-0000455 E 3 5 F G 3 3 5 5 7 7 10 11 11 10 12 6 5 Before installation 7696317 - 1 - 21032018 31
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The fitting of a "Trace Heating" Element is NOT a substitute for correct installation of the condensate drain. ALL requirements in this section must still be adhered to. 5.3.6 Clearances A flat vertical area is required for the installation of the boiler and it should be capable of bearing the weight of the boiler when full of water. 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. A* Clearance below — 200mm minimum, 250mm recommended B* Clearance in front — 450mm minimum, 1000mm recommended 5.3.7 Flue/chimney location 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. Important Due to the nature of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. Fig.19 Flue outlets R T U J,K J,K A D E C I I I A A S F H H B G F I I L N M PN-0000456 1 1 Flue positions marked require a flue terminal guard. Fig.18 Clearances A* 5.0 6 B* 285 700 395 PN-0000503 5.0 183 5 Before installation 32 7696317 - 1 - 21032018
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Tab.23 Terminal position with minimum distance Key Description mm Key Description mm A (1) Directly below an opening, air brick open ing window etc. 300 J From a surface or boundary line facing a terminal 600 B (1) Above an opening, air brick, opening win dow etc. 300 K From a terminal facing a terminal (Horizontal flue) 1200 From a terminal facing a terminal (Ver tical flue) 600 C (1) Horizontally to an opening, air brick, opening window etc. 300 L From an opening in carport (e.g. door, window) into the dwelling 1200 D (2) Below gutters, soil pipes or drain pipes 25 (75) M Vertically from a terminal on the same wall 1500 E (2) Below eaves 25 (200) N Horizontally from a terminal on the same wall 300 F (2) Below balconies or car port roof 25 (200) R From adjacent wall to flue (vertical on ly) 300 G (2) From a vertical drain pipe or soil pipe 25 (150) S From an adjacent opening window (vertical only) 1000 H (2) From an internal or external corner 25 (300) T Adjacent to windows or openings on pitched and flat roofs 600 I Above ground, roof, or balcony level 300 U Below windows or openings on pitch ed roofs 2000 (1) In addition, the terminal should be no nearer than 150mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame. (2) Only ONE 25mm clearance is allowed per installation. If one of the dimension D,E,F,G or H is 25mm then the remainder MUST be as shown in brackets, in accordance with BS 5440–1. Important Under car ports we recommend the use of the plume displacement kit. The terminal position must ensure the safe and nuisance - free dispersal of combustion products. 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. If a terminal is less than 2 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be provided. 1 Property boundary line 2 Terminal assembly 3 Top view rear flue A 300mm minimum* *Reduction to the boundary is possible down to 25mm but the flue deflector must be used. Important The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram opposite. Fig.20 Property boundary PN-0000457 3 1 2 A* 5 Before installation 7696317 - 1 - 21032018 33
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1 Opening window or door 2 Air inlet 3 Plume displacement kit A 150mm minimum Important If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 150mm from any opening windows or doors. Important The Plume Displacement flue gas discharge terminal and air inlet must always terminate in the same pressure zone i.e. on the same facing wall. 5.3.8 Horizontal flue/chimney systems 1 315mm to 500mm 2 Flue trims 3 This bend is equivalent to 1 metre Total equivalent length = A+B+C+2x90° bends Important Horizontal flue extensions should always be installed with a fall of at least 1.5° from the terminal to allow condensate to run back to the boiler. The standard telescopic flue is suitable only for horizontal termination applications. It allows for lengths between 315mm and 500mm from elbow to terminal without the need for cutting. Extensions of 250mm, 500mm and 1m are available. All fittings should be fully engaged. The approximate engagement is 40mm. Apply the lubricant supplied to the seal on each fitting to aid assembly. Tab.24 Maximum permissible equivalent flue lengths are:- Horizontal concentric 60/100 Diameter 80/125 Diameter 10 metres 20 metres Any additional "in line" bends in the flue system must be taken into consideration. Tab.25 Their equivalent lengths are:- Concentric pipes 135° bend 0.5 metres 93° bend 1.0 metres The elbow supplied with the standard horizontal telescopic flue kit is not included in any equivalent length calculations. Important Flue length is measured from point (i) to (ii) as shown. See Read this section in conjunction with the Flue Installation Guide supplied with the boiler. This document includes details of vertical flue/chimney systems and plume displacement kits. Fig.21 Plume displacement kit PN-0000458 3 1 2 A Fig.22 Horizontal flues PN-0000459 3 1 2 A 3 C B (i) (ii) 5 Before installation 34 7696317 - 1 - 21032018
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Warning SUPPORT - All flue systems MUST be securely supported at a MINIMUM of once every metre & every change of direction. It is recommended that every straight piece is supported irrespective of length. Additional supports are available as accessories. VOIDS - Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual inspection. 5.3.9 Flue/chimney trim The flexible flue trims supplied can be fitted on the outer and inner faces of the wall of installation. 5.3.10 Terminal guard 1 ENSURE THAT NO PART OF THE WHITE OUTER CHIMNEY DUCT IS VISIBLE. When codes of practice dictate the use of terminal guards Multifit accessory part no. 720627901 can be used Important This guard is not compatible with Flue Deflector referred to below. There must be a clearance of at least 50mm between any part of the terminal and the guard. When ordering a terminal guard, quote the appliance name and model number. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated. 5.3.11 Flue/chimney deflector 1 Flue deflector Push the flue deflector over the terminal end. It may point upwards as shown, or up to 45° either way from vertical. Secure the deflector to the terminal with screws provided. 5.3.12 Flue/chimney accessories See For full details of Flue Accessories (elbows, extensions, clamps etc.) refer to the Flue Installation Guide supplied in the literature pack. Fig.23 Flexible flue trims PN-0000390 Fig.24 Terminal guard PN-0000460 1 Fig.25 Flue deflector PN-0000461 1 5 Before installation 7696317 - 1 - 21032018 35
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5.4 Transport This product should be lifted and handled by two people. When lifting always keep your back straight and wear protective equipment where necessary. Carrying and lifting equipment should be used as required. e.g. when install in a loft. 5.5 Unpacking & initial preparation 5.5.1 Unpacking Important RISK ASSESSMENT - Before commencing the installation it is recommended that the "Five Steps to Risk Assessment" document published by the HSE is consulted, and an assessment performed as described. GAS SUPPLY - The gas supply, gas type and pressure must be checked for suitability before connection. See Handling, page 9 before unpacking or lifting the boiler. Follow the procedure on the carton or see the diagrams below to unpack the boiler. Lift the boiler to a vertical position (1). Remove the straps and the strip of tape (2)-(3)-(4). Remove the accessories (5). Remove the polystyrene by slipping it off upwards (6). Remove the carton by pulling it upwards (7). Snap off the rear part of the polystyrene at the bottom (8). Important Polystyrene base should be removed completely if fitting the boiler into a space with minimum side clearances of 5mm each side. If removing the polystyrene base the sealing caps can also be removed at this stage. Important Care must be taken to avoid damage from any residual water in the boiler 5 Before installation 36 7696317 - 1 - 21032018
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Fig.26 Unpacking 5 1 2 3 4 6 7 8 PN-0000513 5.5.2 Initial preparation 1. After considering the location position the fixing template on the wall ensuring it is level both horizontally and vertically. 2. Mark the position of the fixing slots for the wall bracket indicated on the template. 3. Mark the position of the centre of the flue hole (rear exit). For side flue exit, mark as shown. 4. If required, mark the position of the gas and water pipes. Remove the template. 5. Cut the hole for the flue (minimum diameter 116mm). 6. Drill the wall as previously marked to accept suitable wall plugs. Secure the wall bracket using appropriate fixing screws. Fig.27 Template Ø 8 34 33.5 65 65 65 65 67.5 198 198 50 MIN 82.5 32 116 Dia Minimum Aperture For Flue Tube Vertical Flue Centre Line Ø 22 Heating Return (22mm) Heating Flow (22mm) Hot Water Outlet (15mm) Combi Only Not System Cold Water Inlet (15mm) Combi Only Not System Side Clearance 5 Side Clearance 5 Clearance below 250 Clearance above 183 Wall View from under boiler PN-0000514 5 Before installation 7696317 - 1 - 21032018 37
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7. Using a spirit level ensure that the wall bracket is level before finally tightening the screws 8. Lift the boiler by gripping "a" and "b" and hook the boiler onto the wall bracket (9). 9. Remove the polystyrene by slipping it off downwards (10). 10. Remove the sealing caps from the pipes underneath the boiler Warning Some residual water may escape when removing the sealing caps. Take precautions to avoid damage to components! . 5.6 Connecting diagrams 5.6.1 Filling information A Domestic hot water mains inlet B Central heating return C Stop valve D Double check valve E Temporary loop A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. A Filling loop B Flow and return taps A filling loop is supplied with the 424 and 428 models. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment. Your attention is drawn to: for GB: Guidance G24.2 and recommendation R24.2 of the Water Regulations Guide. for IE: the current edition of I.S. 813 Domestic Gas Installations. 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. Fig.28 Mounting the boiler 10 9 b a PN-0000515 Fig.29 System filling circuit PN-0000347 A B C C D E Fig.30 Filling loop PN-0000517 A B 5 Before installation 38 7696317 - 1 - 21032018
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5.6.2 Domestic hot water circuit A Boiler B Expansion vessel C Check valve D Pressure reducer E Stop tap F To hot tap G Other tap outlets All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations. 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 IS 813 Domestic Gas Installations. The Water Regulations recommendations for England and Wales prohibits backflow from appliances into the wholesome water supply due to thermal expansion. However this type of instantaneous combination boiler, with less than 15 litres of stored capacity, does not require any backflow prevention device as any thermal expansion is accommodated within the appliance. It is possible in certain circumstances that other cold water demands (e.g. washing machines, flushing of WCs) may affect the DHW function of the boiler. In these instances the fitting of a backflow prevention device and expansion vessel is recommended. Important In instances where the mains water supply incorporates a non- return backflow prevention device, or any other device that includes one*, it is possible for a build-up of pressure to occur. This may result in damage to the boiler and other appliances. To prevent damage to the boiler it is strongly recommended that a suitable mini expansion vessel is fitted on the mains water inlet between the boiler and the non-return device. *(The manufacturer of the device should be consulted if there is any doubt regarding the presence of a non-return feature). Even in circumstances where a non-return device is not fitted any future modifications to the mains inlet (e.g. fitting of a water meter) should be considered and an expansion vessel fitted. Baxi cannot accept any responsibility for damage to the boiler if these recommendations are not followed. The boiler’s maximum working mains pressure is 8 bar, therefore all pipework, connections, fittings, etc. should be suitable for pressures in excess of 8 bar. A pressure reducing valve must be fitted for pressures in excess of 8 bar. The manufacturer of any outlet fittings, such as a shower valve, may require a lower maximum pressure. The pressure reduction must take account of all fittings connected to the DHW system. Fig.31 Circuit plan PN-0000350 A B G C D E F 5 Before installation 7696317 - 1 - 21032018 39
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6 Installation 6.1 General Installation must be carried out in accordance with the prevailing regulations, codes of practice and the recommendations in this manual. Danger If the boiler is installed in a compartment do not use it for storage purposes. Do not obstruct any purpose provided ventilation openings. Caution Where the boiler is sited in an unheated enclosure provision must be made to protect against frost, e.g. frost thermostat, pipe thermostat. Important If the boiler stand-off kit has been used the copper tails are reversible and can be used here. Ensure the sealing caps are removed from the boiler connections under the boiler (including the condensate trap). Important A small amount of water may drain from the boiler once the caps are removed. Remove the taps, elbow and sealing washers from the fitting kit. Connect the appropriate tap to the heating flow and return pipework, gas supply and mains cold inlet. The elbow must be connected to the DHW flow pipe. Using the sealing washers provided connect the taps and elbow to the boiler. Ensure all joints are tight. 6.2 Assembly 6.2.1 Fitting the pressure relief discharge pipe 1. Remove the discharge pipe from the kit. 2. Determine the routing of the discharge pipe in the vicinity of the boiler. Make up as much of the pipework as is practical, including the discharge pipe supplied. Important Make all soldered joints before connecting to the pressure relief valve. Do not adjust the position of the valve. The discharge pipe must be installed before pressurising the system. 3. The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building. 4. Firmly engage the flange on the pipe into the pressure relief valve outlet grommet, ensuring it is pushed fully in. 5. Complete the discharge pipework and route it to the outside discharge point. 6. The pipework must be clipped at suitable intervals to support it, commencing as close to the boiler as possible. Fig.32 Pressure relief pipe connection PN-0000554 6 Installation 40 7696317 - 1 - 21032018
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6.3 Air supply/flue gas connections 6.3.1 Connecting the flue/chimney HORIZONTAL TELESCOPIC FLUE (concentric 60/100) 1 315mm to 500mm 2 Connection assembly 3 Terminal assembly There are two telescopic sections, the terminal assembly and the connection assembly, a roll of sealing tape and two self tapping screws. A 93° elbow is also supplied. The two sections can be adjusted to provide a length between 315mm and 500mm when measured from the flue elbow (there is 40mm engagement into the elbow). 1. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation. Important The flue elbow is angled at 93° to ensure a fall back to the boiler. 2. Measure the distance from the outside wall face to the elbow. This dimension will be known as " X" . 3. If the distance from the flue elbow to the outside face of the wall is less than 250mm the connection assembly can be discarded and the terminal assembly fitted directly into the elbow. 4. In instances where the dimension " X" is between 250mm and 315mm it will be necessary to shorten the terminal assembly by careful cutting to accommodate walls of these thicknesses. 5. To dimension " X" add 40mm. This dimension to be known as "Y" . 1 TOP label 2 Sealing tape 3 Securing screw 4 Peak to be uppermost 6. Adjust the two telescopic sections to dimension "Y" and seal the joint with the tape provided. Ensure that the labels marked "TOP" on the terminal and connection assemblies are uppermost. 7. Using the clearance holes in the connection assembly secure it to the terminal assembly using the screws supplied with the telescopic flue. Fig.33 Telescopic flue PN-0000462 3 1 2 Fig.34 Flue dimension X PN-0000463 X X Fig.35 Flue dimension Y PN-0000464 Y 1 2 1 3 4 6 Installation 7696317 - 1 - 21032018 41
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8. Remove the flue elbow and insert the flue through the hole in the wall. Fit the flue trims if required, and refit the elbow to the boiler adaptor, ensuring that it is pushed fully in. Secure the elbow with the screws supplied in the boiler fitting kit. 1 Flue elbow 2 Boiler adaptor 3 Telescopic flue 4 Flue trim 5 Securing screw A Apply the lubricant supplied for ease of assembly (do not use any other type). Ensure flue is fully engaged into elbow. B Apply the lubricant supplied for ease of assembly (do not use any other type). Ensure elbow is fully engaged into boiler adaptor. C Peak to be uppermost 9. Draw the flue back through the wall and engage it in the elbow. It may be necessary to lubricate to ease assembly of the elbow and flue. 10. Ensure that the terminal is positioned with the slots to the bottom. Secure to the elbow with the screws supplied with the telescopic flue. Important It is essential that the flue terminal is fitted as shown to ensure correct boiler operation and prevent water entering the flue. 11. Make good between the wall and air duct outside the building, appropriate to the wall construction and fire rating. 12. If necessary fit a terminal guard. Important There must be no part of the air duct (white tube) visible outside the property. 6.4 Electrical connections See Electrical supply, page 24 for details of the electrical supply. Warning Check that the total nominal consumption of the accessories connected to the appliance is less than 1 amp. If it is higher, a relay must be installed between the accessories and the electronic board. 6.4.1 Panel removal to make electrical connection Remove the plastic protective coating from the front of the boiler. Unscrew the two screws retaining the electrical cover at the bottom of the front panel and then remove the cover. Fig.36 Attaching the flue PN-0000465 1 2 3 4 4 5 A B C 6 Installation 42 7696317 - 1 - 21032018
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6.4.2 Electrical connections of the boiler Access the connection board located below the control panel to make the electrical connections by: 1. Fully unscrewing the two screws retaining the electrical cover at the bottom of the front panel and then remove the cover. 2. Connect the electrical power supply to the X1 terminal on the connection board as shown on the label located on the inside of the electrical cover. Route the cables to the rear using the integral channel guides. Additional cable ties can be used if 5–core cable is used. Important The blue X1 Mains terminal block can be removed to ease the access for wiring. X1 Electrical power supply 230V~50Hz X4 230V Room thermostat (remove the link) X6 Not used X7 Not used X8 On/Off — R-Bus — Low voltage/voltage free Room thermostat (remove the link) X9 Service connection (PC) X13 L-Bus connection X14 Outside sensor (OS) connection 1 . X14 – 1. Outside sensor 2 . X14 – 2. Common J Dip-switch 1 . J1. Maximum heating temperature: OFF = 80°C = 45°C (floor system) 2 . J2. OFF = Maximum output (heating) — ON = Boiler output 50% (heating) 3 . J3. DO NOT ADJUST! See Electrical diagram, page 19 for more information. 6.4.3 Connecting a room thermostat The terminals can be accessed by removing the electrical cover as described in Electrical connections of the boiler, page 43. 230V Room Thermostat When using a 230V Room Thermostat it must be connected to Terminal X4 on circuit board B. See diagram. The X4 link wire must be removed from the terminal. Important The X4 terminal block for the 230V Room Thermostat can be removed to ease the access for wiring. Low Voltage/Voltage Free Room Thermostat These connections are not polarity sensitive. When using a Low voltage/Voltage free Open Therm type room thermostat it must be connected to Terminal X8 on connection board B. See diagram. The X8 link wire must be removed from the terminal. Replace the electrical cover and secure with the 2 screws. Fig.37 Electrical connections PN-0000518 1 2 3 4 5 1 2 3 4 5 6 7 1 2 1 1 2 3 Br Br Bl Bk Gy Bl Bk W Gn Br R G/Y SERVICE X7 X6 F2 0.5A X14 OS X13 J X9 L-BUS B X12 X11 X10 X3 TIMER X2 X5 230V - 50Hz L N X1 MAINS X4 RT X8 OT Bk W Gy Vt Br Bl R 3 On Off 2 1 B 6 Installation 7696317 - 1 - 21032018 43
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6.4.4 Connecting & setting outdoor weather sensor See Please read the instructions supplied with the sensor. They give information about positioning the sensor and routing the sensor cable. 1. Ensure the electrical supply to the boiler is isolated. Fully undo the two screws retaining the electical cover at the bottom of the front panel and remove the cover. 2. Connect the sensor cable to the grey T-OUT connector (X14). There is no polarity. Refit the cover. 3. Ensure that there is power to the boiler (though it is not necessary for there to be any heating demand). 4. The central heating control knob should be turned clockwise until the value which corresponds with the desired slope (as shown on the graph) is displayed. Important If a Baxi uSense smart thermostat is connected to the boiler the slope must be set using the uSense App. The boiler display will not show the slope but will still be active. 5. Normally the display will show the current temperature of the water in the boiler. As the knob is turned the display will show the selected slope. For example if slope ‘12’ is selected at an outside temperature of 0°C the boiler flow temperature will be 80°C. Consider the type of dwelling and discuss with the user their requirements to determine the most appropriate curve. 6. Explain to the user how to select a different temperature slope. Fig.38 Connect to X14 PN-0000644 1 2 3 4 5 1 2 3 4 5 6 7 1 1 2 1 2 3 Br Br Bl Bk Gy Bl Bk W Gn Br R G/Y X7 X6 F2 0.5A X13 J X9 X12 X11 X10 X3 TIMER X2 X5 230V - 50Hz N L X1 MAINS X4 X8 Bk W Gy Vt Br Bl R X14 3 On Off 2 1 Fig.39 Graph of slopes PN-0000645 20° 30° 25° 20° 35° 40° 45° 50° 55° 60° 65° 70° 75° 80° 15° 10° 5° 0° -5° Slope 30 Slope 20 Slope 12 Slope 5 Fig.40 Display & control knobs OFF MAX OFF MAX RESET OFF MAX OFF MAX OFF MAX OFF MAX PN-0000646 Slope 30 Slope 20 Slope 5 6 Installation 44 7696317 - 1 - 21032018
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6.5 Filling the installation 6.5.1 Flushing the system Flush thoroughly and treat the system according to guidance given in BS 7593. 6.5.2 Fill the installation A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. 1. A filling loop is supplied with the 424/428 models. It can be fitted to the cold mains inlet and the CH return isolation taps. 2. Fill the installation using approved equipment and in accordance with all relevant water supply regulations. Important Your attention is drawn to: for GB: Guidance G24.2 and recommendation R24.2 of the Water Regulations Guide. for IE: The current edition of IS 813 “Domestic Gas Installations”. 3. 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. 4. Fill or replenish the sealed primary circuits by means of a temporary connection between the circuit and a supply pipe: — Permanently connect a "Listed" double check valve or some other no less effective backflow prevention device at the inlet to the circuit. — Remove the temporary connection after use 6 Installation 7696317 - 1 - 21032018 45
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7 Commissioning 7.1 General Reference should be made to BS:EN 12828, 12831 & 14336 when commissioning the boiler. Ensure that the condensate drain trap has been primed. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publication. Open the mains water supply to the boiler and all hot water taps to purge the DHW system. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. Ensure that the cap on the automatic air vent on the pump body is opened. The system must be flushed in accordance with BS 7593 and the flushing agent manufacturer’s instructions. Pressurise the system to 1.5 bar then close and disconnect the temporary filling loop except where a permanent loop is fitted. Test for gas tightness, turn the gas supply on and purge according to GB BS 6891 and in IE I.S. 813 "Domestic Gas Installations" . 7.2 Checklist before commissioning 7.2.1 Preliminary electrical checks Important Consideration must be given to Health & Safety Document 635 (The Electricity at Work Regulations, 1989). Prior to commissioning the boiler preliminary electrical system checks should be carried out. These should be performed using a suitable meter, and include checks for Earth Continuity, Resistance to Earth, Short Circuit and Polarity. 7.2.2 Checks Check: That the boiler has been installed in accordance with these instructions. The integrity of the flue system and the flue seals. The integrity of the boiler combustion circuit and the relevant seals. That the condensate trap has been primed. That the electrical cover has been refitted. 7 Commissioning 46 7696317 - 1 - 21032018
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7.3 Commissioning procedure 7.3.1 De-Aeration function Before turning on the power to the boiler, rotate the Central Heating control knob fully clockwise. The purpose of the function is to remove as much air as possible from the heating system. It operates automatically on the boiler’s first power up and lasts approximately 5 minutes. Turn on the power to the boiler. The display shows an initialisation sequence briefly before displaying t.17 to indicate the sequence has started. At the end of the de-aeration process the flame symbol is seen in the display whilst the boiler does a flame ionisation check. A Initialisation sequence before de-aeration starts Important If during this first commissioning process the power to the boiler is interrupted the de-aeration function will restart automatically. Caution Only the initial de-aeration process during commissioning is performed automatically. Any subsequent de-aeration carried out, for example after a system drain down, must be done manually. To start the process manually, press the RESET button for approximately 5 seconds and release. The display will show dAf briefly and then t.17 to indicate that the process has started. Caution If the power is lost to the boiler during a manual de-aeration the process does NOT restart automatically! Re-establish the power and manually restart the de-aeration. 7.4 Gas settings 7.4.1 Check the operational (working gas inlet pressure and gas rate) A If the pressure drops are greater than shown in the diagram opposite, a problem with the pipework or connections is indicated. Permissible pressure drop across system pipework ≤ 1mbar. Important The system MUST be cold to ensure the boiler is operating under full demand. To obtain an accurate measurement on smaller capacity systems it may be necessary to open one or more hot taps and remove the diverter valve motor in order to maintain the boiler output. Fig.41 Initialisation process PN-0000519 A Fig.42 Gas meter to valve EV1 EV2 P. OUT 1 2 3 4 VENT RQ ADJ. 17-21 mbar PN-0000361 19-23 mbar 18-22 mbar A 7 Commissioning 7696317 - 1 - 21032018 47
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A Gas inlet test point 1. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point is in accordance with BS 6798 & BS 6891. This must be AT LEAST 17mb ! 2. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working. The pressure should be measured at the test point on the gas cock. 3. Measure the gas rate — With any other appliances & pilot lights turned OFF the gas rate can be measured. It should be:- Tab.26 Natural gas 224 model 2.61 m3/h 228 model 3.06 m3/h 424 model 2.61 m3/h 428 model 3.06 m3/h See Technical information - LPG, page 75 for LPG values 7.4.2 Checking combustion - chimney sweep mode See If the appliance cannot be operated on central heating for more than 10 minutes without reaching maximum temperature refer to Combustion check on small heating systems, page 74. The case front panel must be fitted when checking combustion. Ensure the system is cold and the gas and electric supplies are turned on. Important The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results. 1 Combustion test point 2 Incoming air for combustion test point Important Allow the combustion to stabilise before inserting the Combustion Analyser Probe into the Test Point (1). This will prevent saturation of the analyser. The combustion must be measured and recorded at the Maximum and Minimum heat inputs. Fig.43 Gas inlet test point A PN-0000362 Fig.44 Flue adaptor test points PN-0000363 1 2 7 Commissioning 48 7696317 - 1 - 21032018
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Measuring the combustion Important The system MUST be cold to ensure the boiler is operating under full demand. 1. Turn the Central Heating and Domestic Hot Water control knobs fully clockwise. 2. Activate the Chimney Sweep mode by pressing the Chimney Sweep button for 3 seconds (A). The display will show the activation sequence (B) then a "P" with 3 bars alongside it alternating with the current water temperature (C). This indicates the Maximum Domestic Hot Water rate. 3. Check the CO and CO2 levels at the Maximum rate and record the result in the Benchmark log at the back of this manual. 4. Press the Chimney Sweep button (A) again to set the boiler to its minimum rate. The display shows a "P" with 1 bar alongside it alternating with the current water temperature (D). 5. Check the CO and CO2 levels at the Minimum rate and record the result in the Benchmark log at the back of this manual. 6. A further press of the Chimney Sweep button (A) will set the boiler to its Maximum Central Heating Rate. The display shows a "P" with 2 bars alongside it alternating with the current water temperature (E). 7. To exit the Chimney sweep function press and hold the Chimney sweep button for approximately 3 seconds and release. 8. Replace the plug in the flue adaptor test point. Fig. 42. See If the appliance cannot be operated on central heating for more than 10 minutes without reaching maximum temperature refer to Combustion check on small heating systems, page 74. Fig.45 Chimney sweep procedure PN-0000516 C D E B A A 7 Commissioning 7696317 - 1 - 21032018 49
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Fig.46 Combustion procedure Set Boiler to Maximum Rate Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser. Perform Flue Integrity Combustion Check Insert the analyser probe into the air inlet test point, allowing the reading to stabilise. Is O2 ≥ 20.6% and CO2 < 0.2% ? Verify Flue Integrity Indication that products of combustion & inlet air are mixing - further investigation is required. Check all flue components are correctly assembled, fixed & supported. Check the flue & terminal are unobstructed. Is O2 ≥ 20.6% and CO2 < 0.2% ? TURN APPLIANCE OFF ! Call 0344 871 1545 for advice. The appliance MUST NOT be commissioned until all problems are identified and resolved. Check CO & Combustion Ratio at Maximum Rate Whilst the boiler is still operating at maximum insert the analyser probe into the flue gas test point, allowing the reading to stabilise. Is CO < 350ppm and CO/CO2 ratio < 0.004 ? Verify Integrity of Seals Check all burner seals, internal flue seals, door & case seals. Replace any seals that appear unsound. Is CO < 350ppm and CO/CO2 ratio < 0.004 ? TURN APPLIANCE OFF ! Call 0344 871 1545 for advice. The appliance MUST NOT be commissioned until all problems are identified and resolved. If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with the GSIUR. Note: Check & record the CO & combustion ratio at both maximum & minimum rates before calling 0344 871 1545. Set Boiler to Minimum Rate Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser. Yes No No Yes No Yes Check CO & Combustion Ratio at Minimum Rate Whilst the boiler is operating at minimum insert the analyser probe into the flue gas test point, allowing the reading to stabilise. Yes No Is CO < 350ppm and CO/CO2 ratio < 0.004 ? No Yes BOILER OPERATING SATISFACTORILY. NO FURTHER ACTION REQUIRED Ensure test points are capped, the boiler case front panel is correctly fitted & secured and all other commissioning procedures completed. Complete the ‘Benchmark’ Checklist, recording the CO & combustion ratio readings as required. PN-0000466 7 Commissioning 50 7696317 - 1 - 21032018
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7.5 Configuring the system 7.5.1 System draining If at any time after installation it is necessary to drain and refill the central heating system (e.g. when replacing a radiator) the De-Aeration function must be activated to avoid air being trapped in the system. See De-Aeration function, page 47. Once De-Aeration is complete recommission the boiler and check that the inhibitor concentration is sufficient. 7.6 Final instructions 7.6.1 Handover 1. Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the boiler and installation. These details will be required in the event of any warranty work. Important The warranty will be invalidated if the Benchmark section is incomplete. 2. The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded. 3. Complete the Package Fiche in the User Guide. 4. Hand over the User Guide and Installation and Servicing Instructions, giving advice on the necessity of regular servicing. 5. For IE, it is necessary to complete a "Declaration of Conformity" to indicate compliance with I.S. 813. An example of this is given in I.S. 813 "Domestic Gas Installations" . This is in addition to the Benchmark Commissioning Checklist. 6. Set the central heating and hot water temperatures to the requirements of the user. Instruct the user in the operation of the boiler and system. 7. Instruct the user in the operation of the boiler controls. 8. Demonstrate to the user the action required if a gas leak occurs or is suspected. Show them how to turn off the gas supply at the meter control, and advise them not to operate electric light or power switched, and to ventilate the property. 9. Show the user the location of the system control isolation switch, and demonstrate its operation. 10. Advise the user that they may observe a plume of vapour from the flue terminal, and that it is part of the normal operation of the boiler. Fig.47 People PN-0000333 7 Commissioning 7696317 - 1 - 21032018 51
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8 Operation 8.1 Use of the control panel 8.1.1 Control The controls are operated by the buttons and knobs shown. 1 Central heating water temperature control 2 Domestic Hot Water temperature control 3 Reset button Where an outdoor sensor (weather compensation) device is connected to the boiler the central heating control (item 1) adjusts the setting of the curve, not the boiler flow temperature. It will have been set by the installer who should be consulted for advice if you require other settings. 8.2 Start up If there is no power to the boiler, switch on at the fused spur unit and ensure that the time control is in the on position and any other controls (e.g. room thermostat) are calling for heat. Press the RESET button once to bring the boiler out of Standby mode. The boiler will begin its start sequence. This procedure performs a series of tests, after which the installation is purged (this takes approximately five minutes). 8.3 Shutdown Isolate the mains power supply at the fused spur unit. Isolate the gas supply at the boiler valve. Protect the boiler from frost. Important The boiler is not protected against frost once it has been shut down. 8.4 Frost protection Where possible, draining the system should be avoided. If the system is to be unused during winter months several precautions must be taken: A suitable antifreeze solution added to the system. Any parts of the system that are in unheated areas of the dwelling fitted with a device such as a pipe thermostat or frost thermostat. Power must remain supplied to the boiler and controls. Gas must remain supplied to the boiler. The boiler pump will operate if the system temperature drops below 7°C. If the temperature falls to 4°C the burner will ignite and remain lit until the temperature reaches 10°C. At this temperature the burner will extinguish but the pump will continue to operate for 15 minutes. This feature will protect the boiler and to some extent adjacent parts of the system but additional devices must be incorporated to guarantee frost protection. Fig.48 Operating the controls 1 2 3 PN-0000520 8 Operation 52 7696317 - 1 - 21032018
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9 Settings 9.1 Functions The operating functions of the boiler have been factory set to suit most systems. See table below for a list of display functions. See Accessing the information menu, page 69 for further information. 9.2 Information menu Tab.27 Information list Information Description Status Sub-status °C Heating water temperature (°C) The symbol flashes °C Domestic hot water temperature (°C) The symbol flashes If no domestic hot water sensor connected: display — — — °C Outside temperature (°C) The symbol flashes. Burner status Energy meter on the heating water circuit The symbol flashes. The displayed value flashes. Energy meter on the domestic hot water circuit The symbol flashes. The displayed value flashes. Information on the boiler not available 9 Settings 7696317 - 1 - 21032018 53
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10 Maintenance 10.1 General Warning When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed recommission the boiler. Always examine any seals or gaskets, replacing where necessary. The case front panel MUST seal effectively against the boiler side panels. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person in accordance with BS 7967-4. After servicing, complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication. Important During routine servicing, and after any maintenance or change of part of the combustion circuit, the following must be checked:- The integrity of the complete flue system and the flue seals by checking air inlet sample to eliminate the possibility of recirculation. O2 ≥ 20.6% & CO2< 0.2% The integrity of the boiler combustion circuit and relevant seals. The operational gas inlet pressure and the gas rate. The combustion performance as described in "Check the Combustion Performance" below. Competence to carry out checking combustion performance BS 6798 "Specification for Installation & Maintenance of Gas Fired Boilers not exceeding 70kWh" advises that:- The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results. The flue gas analyser used should be one meeting the requirements of BS 7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturers’ requirements. Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS 7967, Parts 1 to 4. Check the Combustion Performance (CO/CO2 ratio) Set the boiler to operate at maximum rate. See Checking combustion - chimney sweep mode, page 48 for details. Remove the plug from the flue sampling point, insert the analyser probe and obtain the CO/CO2 ratio. This must be less than 0.004. If the combustion reading (CO/CO2 ratio) is greater than this, and the integrity of the complete flue system and combustion circuit seals has been verified, and the inlet gas pressure and gas rate are satisfactory either:- Perform the "Standard Inspection and Maintenance" . Perform "Setting the Gas Valve" . Replace and set the gas valve. 10 Maintenance 54 7696317 - 1 - 21032018
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10.2 Standard inspection and maintenance operations 10.2.1 Periodic check and maintenance procedure Warning Before performing any operation, make sure the boiler is not powered on. Once the maintenance operations are complete, reset the original boiler operating parameters if they were changed. Warning Wait for the combustion chamber and pipes to cool down. Important The appliance must not be cleaned using abrasive, aggressive and/or easily flammable substances (e.g. petrol or acetone). The following checks must be performed every year in order to ensure efficient boiler operation: 1. Check the appearance and seal of the gaskets in the gas circuit and the combustion circuit; 2. Check the condition and correct position of the flame detection and ignition electrode; 3. Check the condition of the burner and that it is correctly fastened; 4. Check for any impurities located inside the combustion chamber. To do so, use a vacuum cleaner or the cleaning kit available as an accessory; 5. Check the pressure of the heating system; 6. Check the pressure of the expansion vessel; 7. Check that the fan is working correctly; 8. Check that the intake and exhaust pipes are not obstructed; 9. Check for any impurities inside the siphon; 10.2.2 Checking the water pressure In order for the boiler to operate correctly, the pressure of the water in the heating circuit must be between 1.0 and 1.5 bar. Restore the water pressure if necessary. 10.2.3 Checking the expansion vessel Check the expansion vessel and replace it if necessary. Check its pre- charge every year and restore the pressure to 1 bar if necessary. 10.2.4 Checking the automatic air vent Check that the pump venting valve is working. In the event of a leak, replace the valve. 10.2.5 Checking the burner and cleaning the heat exchanger 1. Isolate the unit from the gas & electrical supplies. 2. Remove the front panel. 3. Remove the silencer. Important Reposition the silencer inside the boiler before refitting the air-gas unit. 4. Open the air/gas cover and remove all the connectors from the PCB. Fig.49 PN-0000382 10 Maintenance 7696317 - 1 - 21032018 55
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5. Close the air/gas cover. 6. Completely remove the air/gas and burner/unit by unscrewing the four M6 nuts and undoing the 3/4” nut below the gas valve. 7. Check that the detection/spark electrode is not worn. Replace the electrode if necessary. 8. Check the condition of the burner, the gasket and the insulation board. 9. Any loose deposits in the heat exchanger should be removed using a vacuum cleaner. 10. A brush with plastic bristles can be used to dislodge any stubborn deposits, which should then also be removed by vacuum. 11. Do not use any chemicals to clean the heat exchanger. 12. The burner does not require any maintenance as it is self-cleaning. Check that there are no cracks and/or other damage on the surface of the burner. If the burner is damaged, replace it. 13. Reassemble in reverse order. 10.3 Specific maintenance instructions Warning When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed recommission the boiler. Always examine any seals or gaskets, replacing where necessary. The case front panel MUST seal effectively against the boiler side panels. To remove the case front panel proceed as follows: Remove the two screws retaining the electrical cover. Remove the electrical cover. Disengage the two clips on the case front panel and lift the panel slightly to remove it from the lip on top of the case. Fig.50 Remove front panel PN-0000521 10 Maintenance 56 7696317 - 1 - 21032018
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10.3.1 Detection/spark ignition electrode 1. Disconnect the electrode lead and earthing cable. 2. Using a T15 Torx key, remove the retaining screws securing the electrode to the combustion chamber door and remove the electrode, noting its orientation. 3. Fit the new electrode with the sealing gasket. 4. Reassemble in reverse order. 10.3.2 NTC flue sensor 1. Turn the sensor 90° anticlockwise to remove — it is a bayonet connection. 2. Ease the retaining tab on the sensor away and disconnect the electrical plug. 3. Fit new sensor and reassemble in reverse order. 10.3.3 Flow and return sensors There is one sensor on the flow (red wires) and one sensor on the return (black wires). 1. Remove the air/gas unit. See Air/gas unit, page 58 to remove. 2. After noting the position prise the sensor clip off the pipe and disconnect the plug. 3. Connect the plug to the new sensor and ease the clip onto the pipe in its original position. 10.3.4 Safety overheat thermostat 1. Pull the two spade connections off the safety overheat thermostat. 2. Prise the thermostat clip with the safety overheat thermostat off the pipe 3. Fit new safety thermostat on the pipe using heat-sink paste. 4. Connect the two spade connections to the safety overheat thermostat ensuring that they are pushed fully on. Fig.51 Remove detection/spark ignition electrode PN-0000331 Fig.52 Remove NTC flue sensor PN-0000332 Fig.53 Removing the flow and return sensors PN-0000522 Fig.54 Removing the safety overheat thermostat PN-0000523 10 Maintenance 7696317 - 1 - 21032018 57
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10.3.5 HMI control 1. Remove the screws from the link/timer 2. Hinge the control box downwards. 3. Disengage the optional timer plug and ease the cable out of its housing. 4. Unclip the back cover of the control box and remove it. 5. Unplug the wire harness on the HMI control. 6. Release the clips securing the HMI control and remove it. 7. Fit the new HMI control and reassemble in reverse order ensuring all plugs and cables are seated correctly. Important Ensure that wiring is correctly routed with no wires trapped during reassembly. 10.3.6 Burner/combustion chamber door assembly 1. Remove the detection/spark electrode. See Detection/spark ignition electrode, page 57 2. Hinge the control box down. 3. Hinge down the air/gas cover and disconnect all wiring plugs from the PCB, noting their positions. Close the air/gas cover. 4. Using a 10mm spanner/socket, undo the 4 nuts holding the combustion chamber door cover to the heat exchanger. 5. Undo the gas valve nut (30mm A/F). 6. Draw the combustion chamber/burner door assembly with the air/gas unit away. 7. Remove the two Torx T30 screws holding the combustion chamber/ burner door assembly to the air/gas unit and disengage the tab on the cover from the air/gas unit. 8. Fit new combustion chamber/burner door assembly to the air/gas unit and reassemble in reverse order. 10.3.7 Air/gas unit 1. Disconnect the electrode lead and earthing cable. 2. Hinge the control box down. 3. Hinge down the air/gas cover and disconnect all wiring plugs from the PCB, noting their positions. Close the air/gas cover. 4. Disconnect the silencer from behind the air/gas unit. 5. Undo the gas valve nut. 6. Remove the two Torx T30 screws securing the air/gas unit to the burner combustion chamber door assembly. 7. Push the flexible gas pipe downwards and ease the air/gas unit away from the burner combustion chamber door assembly. 8. Fit the new air/gas unit to the burner combustion chamber door assembly and reassemble in reverse order. Important Ensure the silencer is correctly positioned. Setting the gas valve Important The CO2 must only be checked and adjusted to set the valve if a suitable calibrated combustion analyser is available, operated by a responsible person. Fig.55 HMI removal 1 1 2 2 PN-0000524 Fig.56 Removing the burner PN-0000525 Fig.57 Removing the air gas unit PN-0000526 10 Maintenance 58 7696317 - 1 - 21032018
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A Minimum rate (offset) adjustment screw. B Maximum rate adjustment screw. C Burner gas pressure outlet. D Gas supply pressure outlet. Important The case front panel must be fitted when checking combustion. Run the boiler for several minutes before checking the CO and CO2. To do this it is necessary to operate the boiler in Chimney sweep mode. Ensure the boiler is at Maximum rate. Insert the test probe in the flue sample point and allow the reading to stabilise. See Checking combustion - chimney sweep mode, page 48. If the appliance cannot be operated on central heating for more than 10 minutes without reaching maximum temperature refer to Combustion check on small heating systems, page 74. See Technical information - LPG, page 75 for details of LPG CO and CO2 values The CO2 at MAXIMUM rate should be 9% +0.4, –0.2. Alter the CO2 if necessary by adjusting the gas valve. Use the Maximum rate adjustment screw (B) to alter the CO2. Turn anti- clockwise (B1) to increase the CO2 or clockwise (B2) to reduce the CO2. Important Do not turn the adjustment screw more than 1/8 of a turn at a time. Allow the analyser reading to settle before any further adjustment. Set the boiler to Minimum rate and check the CO2. The CO2 at MINIMUM rate should be 8.5% +0.1, –0.4. Alter the CO2 if necessary by adjusting the gas valve. Use the Minimum rate adjustment screw (A) to alter the CO2. Turn clockwise (A2) to increase the CO2 or anti-clockwise (A1) to decrease the CO2. Check the combustion performance (CO/CO2 ratio). This must be less than 0.004. Important If the CO2 is reset at minimum rate it must be rechecked at maximum rate again and adjusted if required. If the CO2 is reset at maximum rate it must be rechecked at minimum rate and adjusted if required. Press the Chimney sweep button for 3 seconds to exit the function. Refit the sampling point plug and ensure there is no leakage of products. Fig.58 Adjusting the gas valve A C D 1 2 B 1 2 PN-0000527 10 Maintenance 7696317 - 1 - 21032018 59
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10.3.8 Insulation 1. Remove the Detection/spark ignition electrode. See Detection/spark ignition electrode, page 57. 2. Hinge the control box down. 3. Hinge down the air/gas cover and disconnect all wiring plugs from the PCB, noting their positions. Close the air/gas cover. 4. Undo the nuts holding the combustion chamber/burner door cover to the heat exchanger. 5. Undo the gas valve nut. 6. Draw the combustion chamber/burner door with the air/gas unit away. 7. Remove the cover insulation piece. 8. Fit the new insulation piece carefully over the burner and align it with the slot for the electrode. 9. If the rear insulation requires replacement, remove it and all debris from the heat exchanger. 10. Examine the cover seal and replace if necessary. Reassemble in reverse order. 10.3.9 Heat exchanger 1. Remove the boiler front panel. 2. Hinge down the controls door. Warning Ensure all wiring and electronics are protected before draining down. 3. Close the flow and return isolation taps. 4. Drain the primary circuit using the drain point provided. 5. Remove the flue thermistor. 6. Remove the condensate trap by lifting clear and pulling forward. 7. Disconnect the flow and return overheat thermistor. 8. Disengage the wires from the securing clip and move to one side. 9. Hinge down the air/gas cover and disconnect the wiring from the PCB. Remove the air gas unit. 10. Remove the flow pipe by disengaging the clips and easing the pipe down. Warning Care must be taken to avoid damage due to residual water in the heat exchanger. 11. Remove the return pipe by disengaging the clip to the heat exchanger and the screw at the rear of the pump. Rotate the pipe to allow removal of heat exchanger. 12. Disconnect the condensate pipe from the condensate trap spigot. Important Disconnecting the condensate system may ease trap removal. 13. Ease the rear condensate trap from the heat exchanger and remove. 14. Whilst supporting the heat exchanger, disengage the clip from the front. Ease the heat exchanger down and away from the boiler. 15. Reassemble in reverse order. Warning Care must be taken with the heat exchanger support/spring clip when reassembling. Ensure the guides on the rear of the heat exchanger engage fully with the 2 retaining tags on the boiler chassis. Fig.59 Removing the insulation PN-0000528 Fig.60 Heat exchanger location bracket PN-0000529 10 Maintenance 60 7696317 - 1 - 21032018
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10.4 Hydraulics maintenance 10.4.1 Expansion vessel Warning Take precautions to protect other components from water damage when removing the expansion vessel. 1. Close the flow and return isolation taps and drain the primary circuit. 2. Relieve the pressure from the expansion vessel. 3. Prise off the securing clips and disconnect the braided hose from the vessel and hydraulic inlet assembly, taking care as water may still be in the vessel. 4. Ensure that the braided hose is free of restriction, as a boiler with a blocked hose will exhibit symptoms similar to one with a failed vessel. Important Where the hose is found to be blocked it must be cleared or replaced and the vessel re-charged to 1 bar. 5. If the hose is clear support the vessel, undo the locknut and manoeuvre the vessel out of the boiler. 6. Reassemble in reverse order and recharge to 1 bar. 10.4.2 Pump - complete Warning Take precautions to protect other components from water damage when removing the pump and auto air vent. 1. Hinge the control box down. 2. Close the flow and return isolation taps and drain the boiler primary circuit. Disconnect the electrical plugs from the pump motor. 3. Undo the screws securing the body to the pipe and manifold and draw the pump forward to remove. 4. Examine the "O" ring seals on the return pipe and manifold, replacing if necessary. 5. Reassemble in reverse order. Fig.61 Removing the expansion vessel PN-0000530 Fig.62 Removing the pump PN-0000531 10 Maintenance 7696317 - 1 - 21032018 61
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10.4.3 Auto air vent Warning Take precautions to protect other components from water damage when removing the air vent. 1. Close the flow and return isolation taps and drain the boiler primary circuit. 2. Unscrew the automatic air vent anti-clockwise and lift away from the pump body. 3. Fit the new air vent and O-ring seal. 4. Reassemble in reverse order. 10.4.4 Plate heat exchanger Important It is recommended to isolate the cold water mains stop cock to the dwelling. 1. Close the flow and return isolation taps and the cold mains inlet. 2. Drain the primary circuit and draw off any residual DHW. 3. Hinge the control box downwards. 4. Remove the air/gas unit. See Air/gas unit, page 58, paragraph 1 to 6 to remove. 5. Undo the screws securing the plate heat exchanger to the hydraulic assembly. 6. Withdraw the plate heat exchanger by manoeuvring it to the rear of the boiler, then upwards and to the left to remove. Seals 7. There are four rubber seals between the hydraulic assembly and heat exchanger which may need replacement. 8. Ease the seals out of the hydraulic assembly. Replace carefully, ensuring that the each seal is inserted parallel and pushed fully in. 9. Reassemble in reverse order. Fig.63 Removing the auto air vent PN-0000532 Fig.64 Removing the plate heat exchanger PN-0000533 10 Maintenance 62 7696317 - 1 - 21032018
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10.4.5 Hydraulic pressure sensor 1. Close the flow and return isolation taps. 2. Drain the primary circuit. 3. Hinge the control box down. 4. Remove the air/gas unit. See Air/gas unit, page 58, paragraph 1 to 6 to remove. 5. Pull the two spade connections off the hydraulic pressure sensor. 6. Draw the securing clip forwards to release the sensor and remove. 7. Fit new sensor and reassemble in reverse order. 10.4.6 DHW flow sensor (hall effect sensor) 1. Hinge the control box down. 2. Remove the air/gas unit. See Air/gas unit, page 58, paragraph 1 to 6 to remove. 3. Pull the sensor off the DHW inlet manifold. 4. Disconnect the plug from the sensor and connect it to the new component. 5. Fit the new sensor, ensuring it is correctly oriented and fully engaged over the manifold. 10.4.7 DHW flow regulator and filter Important It is recommended to isolate the cold water mains stop cock to the dwelling. 1. Close the cold mains inlet. 2. Drain off any residual DHW. 3. Hinge the control box down. 4. Remove the air/gas unit. See Air/gas unit, page 58, paragraph 1 to 6 to remove. 5. Pull out the securing clip and prise the regulator and filter assembly out of the hydraulic inlet assembly. 6. Twist the body to unlock the bayonet connection on the filter and remove the regulator. 7. Examine and clean the filter or replace. 8. Fit the new regulator and reassemble in reverse order. Fig.65 Removing the hydraulic pressure sensor PN-0000534 Fig.66 Removing the DHW flow sensor (Hall effect sensor) PN-0000535 Fig.67 Removing the DHW flow regulator and filter PN-0000536 10 Maintenance 7696317 - 1 - 21032018 63
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10.4.8 Diverter valve motor 1. Hinge the control box down. 2. Remove the air/gas unit. See Air/gas unit, page 58, paragraph 1 to 6 to remove. 3. Undo the screw securing the electrical plug to the motor unit. Disconnect the plug. 4. Hold the motor in place against the spring pressure of the valve and removing the securing clip. 5. Remove the motor. 6. When fitting the new motor it will be necessary to hold the unit firmly while depressing the valve return spring. 7. Reassemble in reverse order. 10.4.9 Diverter valve cartridge 1. Close the flow and return isolation taps. 2. Drain the primary circuit. 3. Hinge the HMI control box down. 4. Remove the air/gas unit. 5. Remove the diverter valve motor. See Diverter valve motor, page 64 6. Remove the pressure gauge clip and ease the pressure gauge away from its housing. Important It is recommended to completely remove the pressure gauge to ease the access to the diverter cartridge. Push the plastic retaining spring clips away and press the gauge out. 7. Remove the clip securing the central heating filter. 8. Grip the central heating filter firmly and pull away. Note the orientation of the o-ring seal. 9. Remove the diverter valve cartridge clip. 10. Grip the cartridge firmly and pull away from the o-ring seal. 11. Reassemble in reverse order. 10.4.10 Pressure relief valve Important It may be necessary to dismantle the PRV pipework. 1. Remove the pipe from the pressure relief valve outlet by gripping firmly and pulling down. 2. Reassemble in reverse order. Fig.68 Removing the diverter valve motor PN-0000537 Fig.69 Removing the diverter cartridge PN-0000538 Fig.70 Removing the pressure relief valve PN-0000539 10 Maintenance 64 7696317 - 1 - 21032018
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11 Troubleshooting 11.1 Error codes Error messages are displayed according to the type of fault. Temporary fault A temporary fault is indicated by an ‘H’ followed by a two-digit code number (e.g. .02). This code flashes and alternates with a second two-digit code (e.g. .06) that indicates the specific fault. A temporary fault prevents the boiler operating but will automatically reset once the cause of the fault has been resolved. See Fault finding — temporary faults, page 65 for a list of temporary faults and their possible solutions. Permanent fault A permanent fault ‘Lock out’ is indicated by an ‘E’ followed by a two-digit code number (e.g. .02). This code flashes and alternates with a second two-digit code (e.g. .07) which indicates the specific fault. A permanent fault prevents the boiler operating and will not automatically reset. Once the fault condition has been rectified the RESET button must be pressed for 3 seconds to restart the boiler. Warning Pressing the RESET button for 5 seconds will start the de-aeration process! The boiler will run in de-aeration for approximately 5 minutes before restarting. See Fault finding - permanent faults, page 66 for a list of permanent faults and their possible solutions. 11.2 Fault finding — temporary faults Tab.28 Temporary fault finding guide Group code Specific code Description Probable cause Check/Reason H:01 .00 Communication error between gas valve and PCB Fault in air/gas unit Loose connection to gas valve Replace air gas unit Check gas valve connection from PCB H:01 .05 Maximum difference between the flow and return temperature exceeded Non-existent or insufficient circu lation Sensor error Check circulation/pump Check water pressure Check sensors are operating correctly Check that the sensor has been correctly fitted Check the cleanliness of the heat exchanger H:01 .08 CH Flow temperature increasing too fast Non-existent or insufficient circu lation Sensor error Check circulation Check water pressure Check sensors are operating correctly Check that the sensor has been correctly fitted Check the cleanliness of the heat exchanger H:01 .14 Maximum flow temperature ex ceeded Non-existent or insufficient circu lation Check circulation. 11 Troubleshooting 7696317 - 1 - 21032018 65
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Group code Specific code Description Probable cause Check/Reason H:01 .18 No circulation of water Non-existent or insufficient circu lation Sensor error Check circulation Check water pressure Check sensors are operating correctly Check that the sensor has been correctly fitted Check the cleanliness of the heat exchanger Check pump H:01 .21 DHW flow temperature increas ing too fast Non-existent or insufficient circu lation Sensor error Check circulation Check water pressure Check sensors are operating correctly Check that the sensor has been correctly fitted Check the cleanliness of the heat exchanger H:02 .02 No input of parameters C1/C2 PCB not configured Input C1/C2 H:02 .03 Incorrect configuration settings C1/C2 Incorrect C1/C2 Reset C1/C2 H:02 .04 Parameter error Incorrect parameters Reset C1/C2 H:02 .06 Low system water pressure Water leak on boiler Water leak on system Check boiler Check system Repressurise system H:03 .00 Communication error with NTC flue sensor Sensor not, or badly connected Bad connection Sensor fault Check wiring Check sensors are operating correctly Check that the sensor has been correctly fitted Replace the sensor if necessary H:03 .01 Communication error with the HMI PCB HMI not connected Check wiring H:03 .02 No flame during operation No ionization current Purge gas supply to remove air Check gas valve is fully opened Check supply pressure Check operation and setting of the gas valve unit Check air inlet and flue gas dis charge flues are not blocked Check that there is no recircula tion of flue gases 11.3 Fault finding - permanent faults Tab.29 Permanent fault finding guide Group code Specific code Description Probable cause Check/Reason E:00 .04 Return temperature sensor open-circuit Sensor not or badly connected Bad connection Sensor fault Check the wiring Check that the sensors are oper ating correctly Check that the sensor has been correctly fitted Replace the sensor if necessary E:00 .05 Return temperature sensor short-circuit Sensor not or badly connected Bad connection Sensor fault Check the wiring Check that the sensors are oper ating correctly Check that the sensor has been correctly fitted Replace the sensor if necessary 11 Troubleshooting 66 7696317 - 1 - 21032018
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Group code Specific code Description Probable cause Check/Reason E:01 .04 5 x flame loss in 24 hours with burner on No ionization current Purge the gas supply to remove air Check that the gas valve is fully opened Check the supply pressure Check the operation and setting of the gas valve unit Check that the air inlet and flue gas discharge flues are not blocked Check that there is no recircula tion of flue gases E:01 .11 Incorrect fan speed External draught over the boiler Defective gas/air unit Check for adequate draw on the chimney connection Check the gas/air unit and re place if necessary E:01 .12 Temperature measured by re turn sensor greater than flow sensor Bad connection Sensor fault Sensor not or badly connected Water circulation direction re versed Flow and return pipes reversed Replace the sensor if necessary Check the circulation (direction, pump, valves) Check that the sensors are oper ating correctly Check that the sensor has been correctly fitted Check pipework configuration E:01 .17 No circulation No circulation Sensor not or badly connected Sensor fault Vent the air in the heating sys tem Check the water pressure Check the wiring Check the circulation (direction, pump, valves) Check the cleanliness of the heat exchanger Check that the sensors are oper ating correctly Check that the sensor has been correctly fitted Replace the sensor if necessary E:01 .20 Maximum flue gas temperature reached (> 140 Deg C) No circulation Sensor fault Vent the air in the heating sys tem Check the water pressure Check the wiring Check the circulation (direction, pump, valves) Check the cleanliness of the heat exchanger Check that the sensors are oper ating correctly Check that the sensor has been correctly fitted Replace the sensor if necessary E:02 .00 Boiler reset in progress Reset button pushed Boiler carrying out reset (Infor mation only) E:02 .07 Low system water pressure Water leak on boiler Water leak on system Check boiler Check system Repressurise system E:02 .16 On board CSU time-out Check PCB for damage Replace the PCB if necessary E:02 .17 Permanent loss of communica tion between gas valve and boil er PCB Fault in air/gas unit Loose connection to gas valve Replace air/gas unit Check gas valve connection from PCB E:02 .19 Jumper 1 changed Check position of jumper 1 Put jumper 1 to the off position E:02 .20 Jumper 2 changed Check position of jumper 2 Put jumper 2 to the off position 11 Troubleshooting 7696317 - 1 - 21032018 67
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Group code Specific code Description Probable cause Check/Reason E:02 .21 Jumper 3 changed Check position of jumper 3 Put jumper 3 to the off position E:02 .47 Connection to external device unsuccessful Check wiring to external device Check wiring E:02 .48 Configuration to external device unsuccessful Check pairing to external Pair the devices E:04 .00 Gas Valve fault Gas valve not detected Check the wiring Check resistance across gas valve terminals Replace gas valve if necessary E:04 .01 Flow temperature sensor short- circuited Sensor not or badly connected Bad connection Sensor fault Check the wiring Check that the sensors are oper ating correctly Check that the sensor has been correctly fitted Replace the sensor if necessary E:04 .02 Flow temperature sensor open- circuited Sensor not or badly connected Bad connection Sensor fault Check the wiring Check that the sensors are oper ating correctly Check that the sensor has been correctly fitted Replace the sensor if necessary E:04 .03 Critical flow temperature reached Non-existent or insufficient circu lation Check circulation E:04 .04 Flue temperature sensor short- circuited Sensor not or badly connected Bad connection Sensor fault Check the wiring Check the sensors are operating correctly Check the sensor has been cor rectly fitted Replace the sensor if necessary E:04 .05 Flue temperature sensor open- circuited Sensor not or badly connected Bad connection Sensor fault Check the wiring Check the sensors are operating correctly Check the sensor has been cor rectly fitted Replace the sensor if necessary E:04 .06 Critical flue gas temperature reached No circulation Sensor fault Vent the air in the heating sys tem Check the water pressure Check the wiring Check the circulation (direction, pump, valves) Check the cleanliness of the heat exchanger Check that the sensors are oper ating correctly Check that the sensor has been correctly fitted Replace the sensor if necessary E:04 .08 Maximum safe temperature reached (Safety thermostat open-circuited) No circulation Sensor not or badly connected Bad connection Sensor fault Vent the air in the heating sys tem Check the water pressure Check the wiring Check the circulation (direction, pump, valves) Check the cleanliness of the heat exchanger Check that the sensors are oper ating correctly Check that the sensor has been correctly fitted Replace the sensor if necessary 11 Troubleshooting 68 7696317 - 1 - 21032018
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Group code Specific code Description Probable cause Check/Reason E:04 .10 5 burner start-up failures No ignition Check cabling of ignition trans former Replace the ionization/ignition electrode Check the breakdown to earth Check the condition of the burn er set Check the earthing Defective gas/air unit Ignition arc but no flame forma tion Check that the gas valve is fully opened Check the supply pressure Purge the gas supply to remove air Check the operation and setting of the gas valve unit Check that the air inlet and flue gas discharge flues are not blocked Check the wiring on the gas valve Defective gas/air unit Presence of flame but insuffi cient ionization (<1μA) Check that the gas valve is fully opened Check the supply pressure Replace the ionization/ignition electrode Check the earthing Check the wiring on the ioniza tion/ignition electrode E:04 .12 False flame signal Short-term fluctuation of the mains Ionization current present even though there is no flame The burner remains very hot (CO2 too high) Defective gas/air unit Press the RESET button for 5 seconds Replace the ionization/ignition electrode Set the CO2 Check the gas/air unit and re place if necessary E:04 .13 Fan rotor blocked Fan seized Wiring to fan damaged Replace air/gas unit E:04 .17 Problem on the gas valve Defective gas/air unit Replace gas/air unit 11.4 Accessing the information menu 1. The key is used to access the various menus and to scroll up and down the information in the Information menu. Fig.71 Press the key MW-3000237-2 11 Troubleshooting 7696317 - 1 - 21032018 69
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2. To access the Information menu, briefly press the key once. Caution A long press (approximately 3 seconds) of the button will activate functions intended only for your installer or service engineer. If this occurs, press the button again for 3 seconds to exit the function. Important Five minutes after the key is pressed for the last time, the display goes back to the main display, once the venting cycle has been completed. 11.5 Reading out operating parameters Pressing the button enables you to view information about how the boiler is working. 1. Press this button for one second to view the operating mode (e.g. "t.17" = purging in progress). 2. Press this button for one second again to view the operating sub- status or the corresponding function that is active (e.g. "u.00" = boiler in standby mode). 3. Press this button for one second again to view the operating temperature in the heating system: The symbol followed by the temperature in °C will flash. 4. Press this button for one second again to view the operating temperature in the domestic water system: The symbol followed by the temperature in °C will flash. 5. Press this button for one second again to view the power level from 0 to 100: The symbol and the number relating to the level of operating power will flash. Press and hold the button for more than three seconds to exit this menu. 11.6 Statuses and sub-statuses The STATUS is the instantaneous operating phase of the boiler at the moment of display. The SUB-STATUS is the instantaneous operating phase of the boiler within the STATUS at the moment of display. Tab.30 List of statuses STATUS DISPLAY Standby t00 Heat request t01 Burner on t02 Operating in heating mode t03 Operating in domestic water mode t04 Burner off t05 Pump post circulation t06 Burner off to reach the temperature setpoint t08 Temporary fault t09 Permanent fault (fault to be reset manually) t10 Chimney sweep function at minimum output t11 Chimney sweep function at maximum output in heating mode t12 Chimney sweep function at maximum output in domestic water mode t13 Manual heat request t15 Frost protection function active t16 Fig.72 Accessing the information menu PN-0000540 11 Troubleshooting 70 7696317 - 1 - 21032018
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STATUS DISPLAY Venting function active t17 Electronic board overheated (wait for it to cool) t18 Boiler in reset phase t19 Tab.31 List of sub-statuses SUB-STATUS DISPLAY Standby U00 Wait time until next ignition in heating mode U01 Pre-ventilation U13 Burner pre-ignition U17 Burner ignition U18 Flame check U19 Fan operation with active request U20 Operation at set temperature setpoint U30 Operation at limited temperature setpoint U31 Operation at maximum output available U32 Level 1 gradient detected U33 Level 2 gradient detected U34 Level 3 gradient detected U35 Flame protection active U36 Stabilisation time U37 Boiler start at minimum output U38 Post ventilation U41 Fan off U44 Output reduction due to high flue gas temperature U45 Pump post circulation U60 11 Troubleshooting 7696317 - 1 - 21032018 71
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12 Decommissioning 12.1 Decommissioning procedure Disconnect the gas & electric supplies and isolate them. Drain the primary circuit and disconnect the filling device. Dismantle the chimney system and remove the boiler from the wall mounting frame. 12 Decommissioning 72 7696317 - 1 - 21032018
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13 Spare parts 13.1 Short parts list The following spares are available: See LPG spare parts, page 77 Tab.32 Part number and description of spare parts Key No. Description Part Number 135 Safety thermostat 7661894 63 Detection/Spark ignition electrode 7661804 528 Flow sensor and Return sensor 7662085 242 NTC flue sensor 7662034 624 Hall effect sensor 7662101 154 Air/Gas unit 24kW Natural Gas only Air/Gas unit 28kW Natural Gas only 7661938 7661952 347 HMI control 7662052 408 Burner assembly 7662070 29 Insulation rear 7661741 30 Insulation front 7661745 72 Pump assembly 7220533 340 Hydraulic pressure sensor 7662048 337 Diverter valve motor 7662047 120 3–way valve cartridge 7661857 76 Plate heat exchanger 24kW Plate heat exchanger 28kW 7661816 7661819 35 Expansion vessel 7661749 409 Auto air vent 720777601 Fig.73 Spare parts PN-0000541 242 135 347 154 72 409 29 30 35 76 337 624 528 63 340 120 408 13 Spare parts 7696317 - 1 - 21032018 73
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14 Appendix 14.1 Combustion check on small heating systems 1. Use the procedure shown below to carry out the combustion check. Fig.74 Small system combustion check Combustion Check Turn DHW knob to MAX & open DHW taps to create demand Press button 5 times until load value displayed No Open more DHW taps to increase to maximum load Close all DHW taps Yes Start Chimney Sweep mode - see section 7. Measure & record combustion • If incorrect at commissioning call Baxi Customer Support 0344 871 1545 • If incorrect when changing gas valve adjust & re-check as described in Section 10 Measure & record combustion • If incorrect at commissioning call Baxi Customer Support 0344 871 1545 • If incorrect when changing gas valve adjust & re-check Stop chimney sweep mode by pressing button for 3 seconds Is load reading 100? Is load reading 100? Load reading Yes Start Chimney Sweep mode - see Section 7 - and set to minimum load. If changing gas valve adjust & re-check as described in section 10. Yes No PN-0000542 Can the appliance be operated on central heating for 10 mins without reaching maximum temp? 14 Appendix 74 7696317 - 1 - 21032018
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14.2 LPG model supplement 14.2.1 Technical information - LPG Important All data in these sections are nominal and subject to normal production tolerances. Tab.33 General Baxi Combi 428 LPG Gas Council Numbers 47–077–27 Nominal heat input Domestic Hot Water — Maxi mum Rate Nett (Qn Hi) kW 28.9 Gross (Qn Hs) kW 31.4 Nominal Heat Input Central Heating — Maximum Rate Nett (Qn Hi) kW 24.7 Gross (Qn Hs) kW 26.9 Nominal Heat Input — Minimum Rate Nett (Qn Hi) kW 4.9 Gross (Qn Hs) kW 5.3 Nominal heat output 80/60°C — Domestic Hot Water — Maximum Rate Pn kW 28.0 Nominal heat output 80/60°C — Central Heating — Maximum Rate Pn kW 24.0 Nominal heat output 80/60°C — Central Heating — Factory Setting Pn kW 20.0 Nominal heat output 80/60°C — Minimum Rate Pn kW 4.8 Nominal heat output 50/30°C — Central Heating — Maximum Rate Pnc kW 26.1 Nominal heat output 50/30°C — Central Heating — Minimum Rate Pnc kW 5.2 Tab.34 Characteristics of combustion Baxi Combi 428 LPG LPG gas rate (G31) Qmax kg/h 2.25 Diameter of coaxial discharge pipes mm 60/100 & 80/125 14.2.2 Technical parameters - LPG Tab.35 Technical parameters for boiler combination heaters Baxi Combi 428 LPG Condensing boiler Yes Low-temperature boiler(1) No B1 boiler No Cogeneration space heater No Combination heater Yes Rated heat output Prated kW 24 Useful heat output at rated heat output and high temperature re gime(2) P4 kW 24.0 Useful heat output at 30% of rated heat output and low tempera ture regime P1 kW 8.0 Seasonal space heating energy efficiency ƞs % 93 Useful efficiency at rated heat output and high temperature re gime ƞ4 % 88.0 Useful efficiency at 30% of rated heat output and low temperature regime ƞ1 % 97.8 Auxiliary electricity consumption 14 Appendix 7696317 - 1 - 21032018 75
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Baxi Combi 428 LPG Full load elmax kW 0.038 Part load elmin kW 0.011 Standby mode PSB kW 0.003 Other items Standby heat loss Pstby kW 0.069 Ignition burner power consumption Pign kW 0.000 Annual energy consumption QHE GJ 74 Sound power level, indoors LWA dB 50 Emissions of nitrogen oxides NOX mg/kWh 40 Domestic hot water parameters Declared load profile XL Daily electricity consumption Qelec kWh 0.151 Annual electricity consumption AEC kWh 33 Water heating energy efficiency ƞwh % 85 Daily fuel consumption Qfuel kWh 22.939 Annual fuel consumption AFC GJ 17 (1) Low temperature means for condensing boilers 30°C, for low temperature boilers 37°C and for other heaters 50°C return temperature (at heater inlet). (2) High temperature regime means 60°C return temperature at heater inlet and 80°C feed temperature at heater outlet. See The back cover for contact details. 14.2.3 Gas Category - LPG Tab.36 LPG gas category, type and supply pressure Gas category Gas Type Supply pressure (mbar) CAT II 2H 3P G31 37 14.2.4 Setting the gas valve - LPG 1. Disconnect the electrode lead and earthing cable. 2. Hinge the control box down. 3. Hinge down the air/gas cover and disconnect all wiring plugs from the PCB, noting their positions. Close the air/gas cover. 4. Disconnect the silencer from behind the air/gas unit. 5. Undo the gas valve nut. 6. Remove the two Torx T30 screws securing the air/gas unit to the burner combustion chamber door assembly. 7. Push the flexible gas pipe downwards and ease the air/gas unit away from the burner combustion chamber door assembly. 8. Fit the new air/gas unit to the burner combustion chamber door assembly and reassemble in reverse order. Important Ensure the silencer is correctly positioned. Setting the gas valve Important The CO2 must only be checked and adjusted to set the valve if a suitable calibrated combustion analyser is available, operated by a responsible person. Fig.75 Removing the air/gas unit PN-0000526 14 Appendix 76 7696317 - 1 - 21032018
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A Minimum rate (offset) adjustment screw. B Maximum rate adjustment screw. C Burner gas pressure outlet. D Gas supply pressure outlet. Important The case front panel must be fitted when checking combustion. Run the boiler for several minutes before checking the CO and CO2. To do this it is necessary to operate the boiler in Chimney sweep mode. Ensure the boiler is at Maximum rate. Insert the test probe in the flue sample point and allow the reading to stabilise. See Checking combustion - chimney sweep mode, page 48. If the appliance cannot be operated on central heating for more than 10 minutes without reaching maximum temperature refer to Combustion check on small heating systems, page 74. The CO2 at MAXIMUM rate should be 10.3% +0.5, –0.1. Alter the CO2 if necessary by adjusting the gas valve. Use the Maximum rate adjustment screw (B) to alter the CO2. Turn anti- clockwise (B1) to increase the CO2 or clockwise (B2) to reduce the CO2. Important Do not turn the adjustment screw more than 1/8 of a turn at a time. Allow the analyser reading to settle before any further adjustment. Set the boiler to Minimum rate and check the CO2. The CO2 at MINIMUM rate should be 9.7% +0.1, –0.5. Alter the CO2 if necessary by adjusting the gas valve. Use the Minimum rate adjustment screw (A) to alter the CO2. Turn clockwise (A2) to increase the CO2 or anti-clockwise (A1) to decrease the CO2. Check the combustion performance (CO/CO2 ratio). This must be less than 0.004. Important If the CO2 is reset at minimum rate it must be rechecked at maximum rate again and adjusted if required. If the CO2 is reset at maximum rate it must be rechecked at minimum rate and adjusted if required. Press the Chimney sweep button for 3 seconds to exit the function. Refit the sampling point plug and ensure there is no leakage of products. 14.2.5 LPG spare parts The following spares item is available for the 28kW LPG Combi model. Key No. Description Part number 154 Air/Gas unit — 28kW LPG only 7679781 Fig.76 Adjusting the gas valve A C D 1 2 B 1 2 PN-0000527 Fig.77 Spare parts — LPG 154 PN-0000543 14 Appendix 7696317 - 1 - 21032018 77
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14.3 Benchmark commissioning checklist CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer’s instructions and/or s e Y 8 9 7 6 S B / 6 4 5 5 S B COMBINATION BOILERS ONLY Is the installation in a hard water area (above 200ppm)? Yes No Yes No DOMESTIC HOT WATER MODE Measure and Record: Gas rate m³/hr OR ft³/hr Burner operating pressure (at maximum r a b m ) e t a r OR Gas inlet pressure at maximum r a b m e t a r Cold water inlet temperature °C Hot water has been checked at all outlets Yes Temperature °C I/min CENTRAL HEATING MODE measure and record: Gas rate m³/hr OR ft³/hr Burner operating pressure (if applicabl r a b m ) e OR Gas inlet r a b m e r u s s e r p °C Central heating return temperature °C ALL SYSTEMS ’s s e Y s n oitc u rts ni What system cleaner was used? What inhibitor was used? Quantity litres Yes No CONTROLS (tick the appropriate boxes) Time and temperature control to heating Room thermostat and b a m m a r g o r P r e m it/r e m m a r g o r p le room thermostat Load/weather m u m it p O n oit a s n e p m o c start control Time and temperature control to hot water Cylinder thermostat and n oit a nib m o C r e m it/r e m m a r g o r p Boiler Heating zone valves t o N d e tti F required Hot water zone valves t o N d e tti F required Thermostatic radiator val t o N d e tti F s e v required Automatic bypass to t o N d e tti F m e ts y s required Boiler interlock Provided Customer e T : e m a n lephone number: Address: Boiler make and model: Boiler serial number: Commissioned by (PRINT s a G :) E M A N Safe register number: Company e T : e m a n lephone number: Company address: Commissioning date: This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights. 14 Appendix 78 7696317 - 1 - 21032018
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www.centralheating.co.uk www.centralheating.co.uk *All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer. © Heating and Hotwater Industry Council (HHIC) Commissioning Engineer’s Signature Customer’s Signature ALL INSTALLATIONS Record the following: At max. rate: CO ppm AND CO/CO² Ratio At min. rate: (where possible) CO ppm AND CO/CO² Ratio The heating and hot water system complies with the appropriate Building Regul s e Y s n oit a The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s s e Y s n oitc u rts ni The operation of the boiler and system controls have been demonstrated to and understood by the s e Y r e m o ts u c The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the s e Y r e m o ts u c 14.4 Service records SERVICE 01 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature SERVICE 02 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature SERVICE 03 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature SERVICE 04 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature SERVICE 05 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature SERVICE 06 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. 14 Appendix 7696317 - 1 - 21032018 79
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www.centralheating.co.uk *All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer. © Heating and Hotwater Industry Council (HHIC) SERVICE 07 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature SERVICE 08 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature SERVICE 09 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature SERVICE 10 Date: Engineer name: Company name: Telephone No: Gas safe register No: Record: At max. rate: CO ppm AND CO² % At min. rate: (Where Possible) CO ppm AND CO² % Comments: Signature 14 Appendix 80 7696317 - 1 - 21032018
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© Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical descriptions supplied, remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations.
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Baxi Customer Support 0344 871 1545 Opening hours Monday - Friday, 8.00am-6.00pm Weekends and Bank Holidays, 8.30am-2.00pm Please note calls may be recorded for training and monitoring purposes baxi.co.uk Register now to activate your warranty: www.baxi.co.uk/registration For the warranty to be maintained, please make sure... Benchmark checklist is completed Warranty is registered within 30 days The boiler has an annual service 1 2 3 For full terms and conditions, visit www.baxi.co.uk/terms. Failure to adhere to terms and conditions will void your manufacturer’s warranty. Baxi Brooks House, Coventry Road, Warwick, CV34 4LL Please ensure the boiler is installed in accordance with these installation instructions and that you adhere to the Building Regulations. e&oe All descriptions and illustrations provided in this document have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet. All goods are sold subject to our standard Conditions of Sale which are available on request. 7696317 - 1 - 21032018
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