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Инструкция Baxi Instruction Baxi Combi 80e 105e Installation and Service Manual
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Baxi Combi 80e & 105e Gas Fired Wall Mounted Combination Boiler Installation & Servicing Instructions Please leave these instructions with the user
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2 Natural Gas Baxi Combi 80e G.C.No 47 075 06 Baxi Combi 105e G.C.No 47 075 08 Baxi is a BS-EN ISO 9001 Accredited Company The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations 1993 No 3083” and is deemed to meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels:- Type test for purpose of Regulation 5 certified by: Notified Body 0051. Product/Production certified by: Notified Body 0086. For GB/IE only. Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly. Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006. CORGI operate a Self Certification Scheme for gas heating appliances. These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook (which was then left on site with the customer). With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn. However, a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions. Potterton 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.
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Installer Notification Guidelines 3 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 CORGI will record the data and will send a certificate of compliance to the property You must ensure that the notification number issued by CORGI is writen onto the Benchmark Checklist Scheme Members only Call CORGI on: 0870 88 88 777 or log onto: www.corgi-notify.com within 10 days If you notify via CORGI Scheme, CORGI will then notify the relevant Local Authority Building Control Scheme on member's behalf Complete the Benchmark Checklist Install and Commission this appliance to manufacturer's instructions Competent Person's Self Certification Scheme Building Control
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Legislation 4 Codes of Practice, most recent version should be used IMPORTANT - Installation, Commissioning, Service & Repair This appliance must be installed in accordance with the manufacturer’s instructions and the regulations in force. Read the instructions fully before installing or using the appliance. In GB, this must be carried out by a competent person as stated in the Gas Safety (Installation & Use) Regulations. Definition of competence: A person who works for a CORGI registered company and holding current certificates in the relevant ACS modules, is deemed competent. In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic Gas Installations”. Lifting - This product should be lifted and handled by two people. Stooping should be avoided and protective equipment worn where necessary. Carrying & lifting equipment should be used as required, when installing in a loft space. The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty. In GB this could also infringe the Gas Safety (Installation and Use) Regulations. Warning - Check the information on the data plate is compatible with local supply conditions. All CORGI registered installers carry a CORGI identification card and have a registration number. You can check your installer is registered by telephoning 0870 4012300 or writing to:- 1 Elmwood, Chineham Business Park, Crockford Lane, Basingstoke. RG24 8WG or check online at www.corgi-gas-safety.com Baxi declare that no substances harmful to health are contained in the appliance or used during appliance manufacture. The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force, and only used in a suitably ventilated location. In GB, the installation must be carried out by a CORGI Registered Installer. It must be carried out in accordance with the relevant requirements of the: • Gas Safety (Installation & Use) Regulations. • The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland). • The Water Fittings Regulations or Water Byelaws in Scotland. • The Current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice. In IE, the installation must be carried out by a competent Person and installed in accordance with the current edition of I.S. 813 ‘Domestic Gas Installations’, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation. All systems must be thoroughly flushed and treated with inhibitor (see section 6.2). In GB the following Codes of Practice apply: Standard Scope BS 6891 Gas Installation. BS 5546 Installation of hot water supplies for domestic purposes. BS 5449 Forced circulation hot water systems. BS 6798 Installation of gas fired hot water boilers. BS 5440 Part 1 Flues. BS 5440 Part 2 Ventilation. BS 7074 Expansion vessels and ancillary equipment for sealed water systems. BS 7593 Treatment of water in domestic hot water central heating systems. In IE the following Codes of Practice apply: Standard Scope I.S. 813 Domestic Gas Installations. The following BS standards give valuable additional information; BS 5546 Installation of hot water supplies for domestic purposes. BS 5449 Forced circulation hot water systems. BS 7074 Expansion vessels and ancillary equipment for sealed water systems. BS 7593 Treatment of water in domestic hot water central heating systems.
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5 1.0 Introduction 6 2.0 General Layout 7 3.0 Appliance Operation 8 4.0 Technical Data 9 5.0 Dimensions and Fixings 11 6.0 System Details 13 7.0 Site Requirements 15 8.0 Installation 20 9.0 Commissioning the Boiler 25 10.0 Completion 27 11.0 Servicing the Boiler 28 12.0 Changing Components 30 13.0 Illustrated Wiring Diagram 39 14.0 Fault Finding 40 15.0 Short Parts List 44 Benchmark Checklist 46 Section Page Contents
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1.1 Description 1. The Baxi Combi 80e or 105e is a fully automatic gas fired wall mounted combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water. 2. The boiler is set to give a maximum output of 24.0 kW (80e) or 31.0 kW (105e). 3. It is designed for use on Natural Gas (G20) and can be converted to use Propane (80e and 105e) or Butane (80e). 4. The boiler is suitable for use only on fully pumped sealed heating systems. Priority is given to domestic hot water. 5. The boiler data badge gives details of the model, serial number and Gas Council number and is situated on the control box. It is visible when the case front panel is removed (Fig. 1). 6. The boiler is intended to be installed in residential / commercial / light industrial E.M.C. environments on a governed meter supply only. 7. The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit, part no. 247719. 8. All systems must be thoroughly flushed and treated with inhibitor (see section 6.2). 1.2 Optional Extras Various flue extensions, bends, vertical flue kits, control accessories etc. are available as optional extras. These are detailed in a separate publication. 1.0 Introduction 6 Data Badge Fig. 1 Control Box Case Front Panel
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2.0 General Layout 7 2.1 Layout 1. Air Pressure Switch 2. Expansion Vessel 3. Burner Manifold 4. Automatic Air Vent 5. DHW Plate Heat Exchanger 6. Circulation Pump 7. Drain Off Point 8. Pressure Relief Valve 9. Optional Integral Timer 10. Central Heating System Pressure Gauge 11. PCB 12. Control Box 13. 3-Way Valve Assembly 14. Flame Sensing Electrode 15. Spark Electrode 16. Burner 17. Primary Heat Exchanger 18. Fan Assembly 19. On/Off/Reset Selector Switch 20. Central Heating Temperature Control 21. Hot Water Temperature Control 22. Flame Failure 23. Safety Thermostat 24. Fault on Fan or Flue 25. Fault on Pump or Low System Pressure 26. Fault on Hot Water Sensor 27. Fault on Central Heating Sensor 28. Power On 29. Domestic Hot Water Mode 30. Central Heating Mode 31. Burner On When neons 22 to 27 are constantly illuminated, they indicate the temperature of the central heating water. 18 17 16 14 15 13 12 11 10 9 19 20 21 10 9 7 6 3 4 5 8 2 1 30° 40° 50° 60° 70° 80° 2 1 0 4 3 bar 30° 40° 50° 60° 70° 80° 22 23 24 25 26 27 28 29 30 31
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3.0 Appliance Operation 8 NOTE: All delay timers mentioned in 3.1 and 3.2 are overridden by domestic hot water demand. 3.1 Central Heating Mode (Fig. 2) 1. With a demand for heating, the pump circulates water through the primary circuit. At a pre-determined flow rate the central heating flow switch operates, initiating the ignition sequence. 2. The main burner ignites at low rate, then the gas valve controls the gas rate to maintain the heating temperature measured by the temperature sensor. 3. When the flow temperature exceeds the setting temperature, a 3 minute delay occurs before the burner relights automatically (anti-cycling). The pump continues to run during this period. 4. When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes (Pump Overrun). 3.2 Domestic Hot Water Mode (Fig. 3) 1. Priority is given to the domestic hot water supply. A demand at a tap or shower will override any central heating requirement. 2. The flow of water will operate the DHW flow switch which requests the 3 way valve to change position. This will allow the pump to circulate the primary water through the DHW plate heat exchanger. 3. The burner will light automatically and the temperature of the domestic hot water is controlled by the temperature sensor. 4. When the domestic hot water demand ceases the burner will extinguish and the diverter valve will remain in the domestic hot water mode, unless there is a demand for central heating. IMPORTANT: When the selector switch is in the ‘0’ (Off) position the electrical supply to the boiler is isolated. The boiler will not operate and the integral timer (if fitted) will require resetting once the selector switch is set to either Position (i) or Position (ii). 3.3 Frost Protection Mode 1. The frost protection mode is integral to the appliance and functions only with the selector switch (see Section 2.1) in the domestic hot water and central heating position. If the system temperature falls below 5° C then the boiler will fire on its minimum setting until a flow temperature of 30° C is reached. Further protection can be incorporated by using a system frost thermostat. 3.4 Pump Protection 1. With the selector switch (see Section 2.1) in either the central heating or central heating and domestic hot water position the pump will automatically operate for 1 minute in every 24 hours to prevent sticking. 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 3 1 Primary Heat Exchanger 2 Burner 3 Ignition Electrode 4 Flame Sensing Electrode 5 Gas Valve 6 Pump 7 Automatic Air Vent 8 Plate Heat Exchanger 9 Flow Sensor with Filter 10 Pressure Relief Valve 11 Boiler Drain Point 12 Heating Return 13 Cold Water Inlet On/Off Valve and Filter 14 Gas Inlet 15 Domestic Hot Water Outlet 16 Heating Flow 17 Pressure Gauge 18 Hydraulic Differential Pressure Sensor Microswitch 19 Automatic By-Pass 20 Hydraulic Differential Pressure Sensor 21 Diverter Valve Assembly 22 Domestic Hot Water Flow Priority Assembly 23 Domestic Hot Water Flow Priority Microswitch 24 Safety Thermostat 25 Central Heating Temperature Sensor 26 Expansion Vessel 27 Domestic Hot Water Temperature Sensor Key Central Heating Circuit Domestic Hot Water Circuit Fig. 3 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 3 Fig. 2 27 27
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4.0 Technical Data 9 Flue Terminal Diameter 100mm Dimensions Projection 95mm Outercase Dimensions Casing Height - 780mm Overall Height Inc Flue Elbow - 980mm Casing Width - 450mm Casing Depth - 345mm Clearances Both Sides 5 mm Min Above Casing 200 mm Min Below Casing 200 mm Min Front 450 mm Min (For Servicing) Front 5 mm Min (In Operation) Weights kg Packaged Boiler Carton 47 Packaged Flue Kit 3 Installation Lift Weight 39 Central Heating Primary Circuit Pressures bar Safety Discharge 3 Max Operating 2.5 Min Operating 0.5 Recommend Operating 1-2 DHW Circuit bar Pressures Max Operating 8 Min Operating 0.2 Min Operating Pressure at 9.8 l/min 0.9 Flow Rates l/min DHW Flow Rate @ 30°CRise 13.7 DHW Flow Rate @ 35°CRise 9.8 Min Working DHW Flow Rate 2.5 Pump Available Head See graph below Expansion Vessel - (For Central Heating only. Integral with appliance) bar Min Pre-charge Pressure 0.5 litre Max Capacity of CH System 125 Primary Water Content 1.0 of Boiler (unpressurised) Connections copper tails Gas Supply - 22mm Central Heating Flow - 22mm Central Heating Return - 22mm Cold Water Mains Inlet - 15mm DHW Flow - 15mm Pressure Relief Discharge - 15mm Temperatures C.H. Flow Temp (adjustable) 35°C to 85°C max (± 5°C) D.H.W. Flow Temp (adjustable) 35°C to 65°C max (± 5°C) dependent upon flow rate Heat Input C/H & DHW (Gross) Max Min kW 26.3 10.6 Btu/h 89,739 31,738 Heat Output Max Min kW 24.0 9.3 Btu/h 81,891 31,738 Electrical Supply 230V~ 50Hz (Appliance must be connected to an earthed supply) Power Consumption 170W External Fuse Rating 3A Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 Appliance Category CAT II 2H 3+ Max Gas Rate (Natural Gas - G20) (After 10 Mins) m3/h 2.78 ft3/h 98.12 Inlet Pressure (Natural Gas - G20) mbar 20 in wg 8 Burner Injector (Natural Gas - G20) 12 x 1.28mm Diameter Burner Pressure (Natural Gas - G20) Max Rate Min Rate mbar 12.2 ± 0.5 2.5 ± 0.2 in wg 4.88 ± 0.2 1.0 ± 0.2 0 200 400 600 800 1000 1200 0.5 1 1.5 2 2.5 3 3.5 4.5 5 5.5 4 Metre wg l/h Pump - Available Head 0 Appliance Type C12 C32 NOx Class 3 This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by 0051. SEDBUK Declaration For Combi 80e The seasonal efficiency (SEDBUK) is 78.6 % Electrical Protection IPX5D 4.1 Combi 80e LPG Gases Propane - G31 and Butane - G30 Burner Injector 12 x 0.77mm diameter Burner Pressure Propane mbar in wg Butane mbar in wg Inlet Pressures mbar in wg Max Rate 36.2 14.5 28.3 11.3 Min Rate 6.4 2.6 5.3 2.1 Propane 37 14.8 Butane 28 11.2
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4.0 Technical Data 10 4.2 Combi 105e Flue Terminal Diameter 100mm Dimensions Projection 95mm Outercase Dimensions Casing Height - 780mm Overall Height Inc Flue Elbow - 980mm Casing Width - 450mm Casing Depth - 345mm Clearances Both Sides 5 mm Min Above Casing 200 mm Min Below Casing 200 mm Min Front 450 mm Min (For Servicing) Front 5 mm Min (In Operation) Weights kg Packaged Boiler Carton 49 Packaged Flue Kit 3 Installation Lift Weight 41 Central Heating Primary Circuit Pressures bar Safety Discharge 3 Max Operating 2.5 Min Operating 0.5 Recommend Operating 1-2 DHW Circuit bar Pressures Max Operating 8 Min Operating 0.2 Min Operating Pressure at 12.7 l/min 0.96 Flow Rates l/min DHW Flow Rate @ 30°CRise 14.8 DHW Flow Rate @ 35°CRise 12.7 Min Working DHW Flow Rate 2.5 Pump Available Head See graph below Expansion Vessel - (For Central Heating only. Integral with appliance) bar Min Pre-charge Pressure 0.5 litre Max Capacity of CH System 125 Primary Water Content 1.2 of Boiler (unpressurised) Connections copper tails Gas Supply - 22mm Central Heating Flow - 22mm Central Heating Return - 22mm Cold Water Mains Inlet - 15mm DHW Flow - 15mm Pressure Relief Discharge - 15mm Temperatures C.H. Flow Temp (adjustable) 35°C to 85°C max (± 5°C) D.H.W. Flow Temp (adjustable) 35°C to 65°C max (± 5°C) dependent upon flow rate Heat Input C/H & DHW (Gross) Max Min kW 34.3 11.9 Btu/h 117,036 40,610 Heat Output Max Min kW 31.0 10.4 Btu/h 105,776 35,490 Electrical Supply 230V~ 50Hz (Appliance must be connected to an earthed supply) Power Consumption 190W External Fuse Rating 3A Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 Appliance Category CAT II 2H 3P Max Gas Rate (Natural Gas - G20) (After 10 Mins) m3/h 3.63 ft3/h 128.12 Inlet Pressure (Natural Gas - G20) mbar 20 in wg 8 Burner Injector (Natural Gas - G20) 15 x 1.28mm Diameter Burner Pressure (Natural Gas - G20) Max Rate Min Rate mbar 13.4 ± 0.5 1.8 ± 0.2 in wg 5.36 ± 0.2 0.72 ± 0.2 Appliance Type C12 C32 NOx Class 3 Electrical Protection IPX5D This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by 0051. SEDBUK Declaration For Combi 105e The seasonal efficiency (SEDBUK) is 78.5 % 0 200 400 600 800 1000 1200 0.5 1 1.5 2 2.5 3 3.5 4 Metre wg l/h Pump - Available Head 0 5 4.5 5.5 6 LPG Gases Propane - G31 Burner Injector 15 x 0.77mm diameter Burner Pressure Propane mbar in wg Inlet Pressures mbar in wg Max Rate 36.2 14.5 Min Rate 6.4 2.6 37 14.8
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5.0 Dimensions and Fixings 11 Dimensions A 780mm B 345mm C 450mm D 107mm Ø Min. E 200mm F 190mm G 143mm 360° Orientation Tube Ø 100mm D C B A E G F Domestic Hot Water Outlet (15mm) Cold Water Inlet (15mm) Heating Return (22mm) Heating Flow (22mm) Pressure Relief Valve (15mm) Gas Inlet (22mm) 65 mm 65 mm 65 mm 65 mm 65 mm Tap Rail
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6.0 System Details 12 6.1 Information 1. The Baxi Combi 80e and 105e Combination Boilers are ‘Water Byelaws Scheme - Approved Products’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 - See text of entry for installation requirements and notes. b) IRN 302 - Byelaw 14. 2. Reference to the WRc publications, ‘Water fittings and materials directory’ and ‘Water supply byelaws guide’ give full details of byelaws and the IRNs. 6.2 Central Heating Circuit 1. The appliance is suitable for fully pumped SEALED SYSTEMS ONLY. Treatment of Water Circulating Systems • All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems. • When upgrading existing systems that exhibit evidence of sludging, it is advisable to clean the system prior to treatment in order to remove any sludge and reduce the likelihood of these deposits damaging new components. • When fitting new systems flux will be evident within the system, which can lead to damage of system components. • All systems must be thoroughly drained and flushed out. The recommended flushing and cleansing agents are Betz-Dearborn Sentinel X300 or X400 and Fernox Superfloc Universal Cleanser which should be used following the flushing agent manufacturer’s instructions. • System additives - corrosion inhibitors and flushing agents/descalers should be suitable for aluminium and comply to BS7593 requirements. The only system additives recommended are Betz-Dearborn Sentinel X100 and Fernox-Copal which should be used following the inhibitor manufacturer’s instructions. Failure to flush and add inhibitor to the system may invalidate the appliance warranty. • It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the manufacturer’s instructions. (Test kits are available from inhibitor stockists.) • For information or advice regarding any of the above contact Technical Enquiries. 6.3 Bypass 1. The boiler is fitted with an automatic integral bypass. 6.4 System Control 1. The boiler is designed for use in a heating system that incorporates external controls, i.e. a minimum of a timer device. 2. Suitable timer kits are available as optional extras. 3. For optimum operating conditions and maximum economy the fitting of a programmable room thermostat is recommended.
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6.0 System Details 13 6.5 System Filling and Pressurising 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. 2. There are connection points on the mains cold water inlet and central heating return isolating taps Fig. 4a) to which the optional filling loop kit (Part No. 248221) can be assembled. 3. The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment. 4. 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”. 5. The sealed primary circuits may be filled or replenished by means of a temporary connection between the primary circuit and a supply pipe provided the arrangement in accordance with Diagram R24.2a of the Water Regulations Guide. 6. The temporary hose must be completely removed at both ends after use. 6.6 Expansion Vessel (Central Heating only) 1. The appliance expansion vessel is pre-charged to 0.5 bar. Therefore, the minimum cold fill pressure is 0.5 bar. The vessel is suitable for correct operation for system capacities up to 125 litres. For greater system capacities an additional expansion vessel must be fitted. For GB refer to BS 7074 Pt 1. For IE, the current edition of I.S. 813 “Domestic Gas Installations”. 6.7 Pressure Relief Valve (Fig. 5) 1. The pressure relief valve is set at 3 bar, therefore all pipework, fittings, etc. should be suitable for pressures in excess of 3 bar. 2. The pressure relief discharge pipe should be not less than 15mm dia, run continuously downward, and discharge outside the building, preferably over a drain. It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components. The end of the pipe should terminate facing down and towards the wall. 3. The discharge must not be above a window, entrance or other public access. Consideration must be given to the possibility that boiling water/steam could discharge from the pipe. Fig. 4 Fig. 5 Stop Valve Double Check Valve DHW Mains Inlet CH Return Temporary Hose Pressure Relief Valve Discharge Pipe Filling Loop Fig. 4a Stop Valve
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6.0 System Details 14 6.8 Domestic Hot Water Circuit (Fig. 6) 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations. 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. for IE: the current edition of I.S. 813. “domestic Gas Installations”. 3. A single check valve must be fitted as shown in Fig. 6 to prevent backflow to the supply pipe and to ensure the efficient operation of the expansion vessel which is required to accommodate the thermal expansion of the water. 4. When the domestic water system includes any device which prevents water expanding back towards the supply (check valve, loose jumpered stopcock, water meter, water treatment device) then an expansion vessel must be fitted (eg. Zilmet 160ml, R1/2 15bar). 5. If the hot water expansion is not provided for, then high pressures can develop which may result in damage to fittings and devices on the system. 6. The boiler’s maximum working mains pressure is 8 bar, therefore all pipework, connections, fittings, etc. should be suitable for pressures in excess of 8 bar. A pressure reducing valve must be fitted for pressures in excess of 8 bar. The manufacturer of any outlet fittings, such as a shower valve, may require a lower maximum pressure. The pressure reduction must take account of all fittings connected to the DHW system. 6.9 Showers 1. If a shower control is supplied from the appliance it should be of the thermostatic or pressure balanced type. Thermostatic type shower valves provide the best comfort and guard against water at too high a temperature. Existing controls may not be suitable - refer to the shower valve manufacturer. 6.10 Hard Water Areas 1. If the area of the installation is recognised as a HARD WATER AREA then a suitable device should be fitted to treat the mains water supply to the boiler. Contact your Water Distribution Company for advice on suitable devices. Boiler Other Tap Outlets Expansion Vessel To Hot Taps Check Valve Pressure Reducer Valve Stop Tap Fig. 6
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7.0 Site Requirements 15 7.1 Location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard-see Section 7.3). 2. If the boiler is sited in an unheated enclosure then it is recommended to leave the ON/OFF Selector Switch in the domestic hot water and central heating position to give frost protection. 3. If the boiler is fitted in a room containing a bath or shower reference must be made to the relevant requirements. In GB this is the current I.E.E. Wiring Regulations and Building Regulations. In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules. 4. If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE/UP/7 (Gas Installations in Timber Framed Housing). 7.2 Clearances (Figs. 7 & 8) 1. A flat vertical area is required for the installation of the boiler. 2. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement. Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler. 200mm Min 780mm 450mm 200mm Min 5mm Min 5mm Min 5mm Min 450mm Min For Servicing Purposes Fig. 7 Fig. 8 In Operation
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7.0 Site Requirements 16 7.3 Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. The appliance will run sufficiently cool without ventilation. 2. Minimum clearances must be maintained and the compartment should be large enough to house the boiler and any ancillary equipment only. 7.4 Gas Supply 1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891. In IE this is the current edition of I.S. 813 “Domestic Gas Installations”. 2. The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock (Fig. 9). 3. Ensure that the pipework from the meter to the appliance is of adequate size. Do not use pipes of a smaller diameter than the boiler gas connection (22mm). 7.5 Electrical Supply 1. External wiring must be correctly earthed, polarised and in accordance with relevant regulations/rules. In GB this is the current I.E.e. Wiring Regulations. In IE reference should be made to the current edition of ETCI rules. 2. The mains supply is 230V ~ 50Hz fused at 3A. NOTE: The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance. Connection may be via a fused double-pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only. Fig. 9 Gas Service Cock
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7.0 Site Requirements 17 Fig. 11 7.6 Flue 1. The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendations are given in BS 5440 PT.1. For IE recommendations are given in the current edition of I.S. 813 “Domestic Gas Installations”. 2. If the terminal discharges onto a pathway or passageway, check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway. 3. If a terminal is less than 2 metres above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be provided. Terminal Position with Minimum Distance (Fig. 11) (mm) A* Directly below an openable window, air vent or any other ventilation opening. 300 B Below gutter, drain/soil pipe. 25 C Below eaves. 25 D Below a balcony/car port roof. 25 E From vertical drain pipes and soil pipes. 25 F From internal or external corners. 25 G Above adjacent ground or balcony level. 300 H From a surface facing a terminal. 600 I Facing a terminals. 1200 J From opening (door/window) in carport into dwelling. 1200 K Vertically from a terminal on the same wall. 1500 L Horizontally from a terminal on the same wall. 300 M* Above an opening, air brick, opening window etc. 300 N* Horizontally to an opening, air brick, opening window etc. 300 L G G E J D K G A A D F H,I B,C F Likely flue positions requiring a flue terminal guard M N 300 min Terminal Assembly Top View Rear Flue Property Boundary Line * 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. See BS 5440 Pt. 1.
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7.0 Site Requirements 18 7.7 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 1m from elbow to terminal (Fig. 12). The maximum permissible equivalent flue length is: 80e 5 metres 105e 4 metres NOTE: Each additional 45° of flue bend will account for an equivalent flue length of 0.5m. eg. 45° = 0.5m, 90° = 2 x 45° = 1m etc. 7.8 Flue Terminal Trim 1. Once the flue is secure the trim can be fitted if required. 2. Remove the protective backing from the adhesive seal. Apply the seal to the rear of the trim flange (Fig. 13). 3. Locate the trim over the flue terminal and push it back to the wall to compress the seal (Fig. 14). 7.9 Terminal Guard (Fig. 15) 1. When codes of practice dictate the use of terminal guards, they can be obtained from most Plumbers’ and Builders’ Merchants. 2. There must be a clearance of at least 50mm between any part of the terminal and the guard. 3. When ordering a terminal guard, quote the appliance name and model number. 4. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated. Fig. 12 Fig. 15 100mm 1m Fig. 14 Fig. 13 Flue Trim Adhesive Seal
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19 7.0 Site Requirements 7.10 Flue Options 1. The Baxi Combi 80e and 105e can be fitted with flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. 3. The 80e model ONLY can also be fitted with a flue system that exits horizontally from the rear of the appliance, dispensing with the need for the top flue elbow. 4. Maximum permissible equivalent flue lengths are:- 80e 105e Concentric 5m 4m Vertical 4m 4m Vertical Two-Pipe 15m 12m 5. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:- Concentric Pipes: 45° bend 0.5 metres 90° bend 1.0 metres Twin Flue Pipe 45° bend 0.25 metres 90° bend 0.50 metres The elbow supplied with the standard horizontal flue is not included in any equivalent length calculations 6. The illustrations opposite show examples of maximum equivalent lengths. 7. Full details of part numbers and descriptions of all optional flue components and kits can be found in the Baxi Flue Guide. 8. Instructions for guidance and fitting are included in each kit where appropriate. Horizontal Flues Vertical Flues Vertical Flues (Twin Pipe) Rear Flue (80e only) Maximum Length = 3m inc. 2 x 45° bends Maximum Length = 14m inc. 4 x 45° bends Maximum Length = 2m inc. 2 x 90° bends
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8.0 Installation 20 8.1 Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). 1. After considering the site requirements (see Section 7.0) position the fixing template (Fig. 16) on the wall ensuring it is level both horizontally and vertically. 2. Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes. It is preferable to use the horizontal fixing slots. 3. Mark the position of the centre of the flue hole (rear exit). For side flue exit, mark as shown. 4. Note the shaded area on the template. Pipework may be routed upwards behind the boiler, providing it does not conflict with the shaded area. 5. If required, mark the position of the gas and water pipes. Remove the template. 6. Cut the hole for the flue (minimum diameter 107mm). 7. Drill the wall as previously marked to accept the wall plugs supplied. Secure the wall plate using the fixing screws. 8. Using a spirit level ensure that the plate is level before finally tightening the screws. 9. Connect the gas and water pipes to the valves on the wall plate using the copper tails supplied. Ensure that the sealing washers are fitted between the connections. 8.2 Flushing 1. Connect a tube to the central heating flow or return pipe (Fig. 17). 2. Flush thoroughly (see System Details, Section 6.2). 8.3 Preparing The Boiler 1. Remove all packaging. 2. Stand the boiler on its base by using the rear lower edge as a pivot. NOTE: A small amount of water may drain from the boiler in the upright position. Fig. 16 Fig. 17 Combi FIXING TEMPLATE 5 mm Minimum Side Clearance 5 mm Minimum Side Clearance Horizontal Side Flue Centre Line 107mm Dia Minimum Aperture For Flue Tube 200 mm Minimum Clearance 200 mm Minimum Clearance Profile of Outercase Vertical Flue Centre Line General Area For Electrical Supply Hot Water Outlet (15mm) Cold Water Inlet (15mm) Heating Return (22mm) Heating Flow (22mm) Pressure Relief Valve (15mm) Gas Inlet (22mm) 95 mm 65 mm Boiler Mounting Bracket Fixing Slots Drill 8 mm diameter x 50 mm deep 65 mm 65 mm 65 mm 65 mm Boiler Lower Fixing Holes Drill 8 mm diameter x 50 mm deep 922.400.1 Comp No 247934 - Iss 5 - 3/02 80e Model Only Alternative Flue Aperature Using Rear Flue Kit Part No. 248220 IMPORTANT Keep rear routed pipework, clips and electrical cables clear of all shaded areas to allow the correct fitting of the boiler chassis Fixing Template Appliance Wall Plate 190mm For Side Flue Exit Central Heating Return Flushing Tube Wall Plate
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8.0 Installation 21 8.4 Fitting The Boiler 1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate (Fig. 18). 3. Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections. The rubber washers must be used on the gas connection. 4. Tighten all the connections. 8.5 Fitting the Pressure Relief Discharge Pipe (Fig. 19) 1. Remove the discharge pipe from the kit. 2. Determine the routing of the discharge pipe in the vicinity of the boiler. Make up as much of the pipework as is practical, including the discharge pipe supplied. 3. The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building. See section 6.7 for further details. 4. Utilising one of the sealing washers, connect the discharge pipe to the adaptor and tighten the nut. 5. Complete the discharge pipework and route it to the outside discharge point. IMPORTANT: Make all soldered joints before connecting to the pressure relief valve. Fig. 19 Fig. 18 Pressure Relief Valve Wall Plate Discharge Pipe
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8.0 Installation 22 8.6 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths 100mm minimum to 1m maximum (measured from the edge of the flue elbow outlet). 80e model only If the optional rear flue kit is to be used, refer to the instructions supplied. Rear Flue: maximum wall thickness - 900mm Side Flue: maximum wall thickness - 870mm 2. If using the optional internal fitting kit, flue extension kit or elbows, refer to the instructions provided with the kits. 3. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (rear, right or left). 4. Measure the distance from the outside wall face to the elbow (Fig. 20). This dimension will be known as ‘X’. 5. Taking the air duct, mark dimension ‘X’ as shown (Fig. 21). Measure the length of waste material, and transfer the dimension to the flue duct (Fig. 21). 6. Remove the waste from both ducts. Ensure that the cut ends are square and free from burrs. 7. Remove the flue elbow from the adaptor. IMPORTANT: Check all measurements before cutting. Wall Thickness (X) Wall Thickness (X) Fig. 20 Waste (X) Waste Fig. 21 Air Duct Flue Duct
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8.0 Installation 23 8.6 Fitting the Flue (Cont) IMPORTANT: If the equivalent flue length is greater than 1.5m the restrictor MUST be removed from the adaptor (Fig. 22). 8. Insert the flue duct into the air duct and pass them through the hole in the wall. 9. Take one of the rubber seals and position it on the boiler flue adaptor. Engage the flue elbow on the adaptor and pull the sleeve up so that it equally covers the joint (Fig. 22). 10. Remove the screws from one of the clips provided. Prise the clip apart and fit it over the seal (Fig. 23). Set the elbow to the required angle. 11. Refit the screws to the clip and tighten them to secure the elbow. Take the second rubber seal and position it on the flue elbow. 12. Locate the flue duct clamp on the flue outlet elbow. Draw the flue duct out of the air duct, engage it in the clamp and tighten the screws (Fig. 24). 13. Draw the air duct out of the wall and align it with the elbow. Position the seal so that it equally covers the joint (Fig. 25). 14. Remove the screws from the second clip provided. Prise the clip apart and fit it over the seal. Refit the screws to the clip and tighten them (Fig. 25). 15. Where possible position the clips so that the screws are not visible. 16. Make good between the wall and air duct outside the building. 17. Fit the circular flue trim outside if required, and if necessary fit a terminal guard (see Section 7.8 & 7.9). VERTICAL FLUE 1. Only a flue approved with the Baxi Combi 80e and 105e can be used. 2. For information on vertical flues consult the Baxi Flue Guide Brochure or Notes for Guidance supplied with the vertical flue pack. Fig. 22 Fig. 23 Fig. 24 Seal Adaptor Seal Clip Screws Flue Duct Clamp Flue Duct Air Duct Seal Clip Screws Fig. 25 Restrictor Elbow
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8.0 Installation 24 8.7 Making The Electrical Connections To connect the mains input cable proceed as follows:- 1. Slacken the facia securing screws and lift the outercase panel so that its locating tabs are clear of the facia. Remove the panel. 2. Remove the screws securing the facia panel and hinge it down (Fig. 26). 3. Remove the control box cover securing screws. Disengage the barbs on the control box from the cover. Remove the cover (Fig. 27). 4. Slacken the cable clamp on the LH side of the boiler chassis (Fig. 28). Insert the cable through the clamp and route it to the terminal block. 5. Slacken the screws in the terminal block, connect the input cable, and tighten the screws. 6. If an external control is to be connected it can be done at this point. Run the input cable from the external control through the second cable clamp on the boiler chassis. Refer to the instructions supplied with the control. 7. To connect external control(s) remove the link between terminals 1 & 2. The 230V supply at terminal 1 must be connected to the external control. The switched output from the external control must be connected to terminal 2 (Fig. 29). NOTE: If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Fig. 29. IMPORTANT: The external control MUST be suitable for 230V switching. 8. Ensure that both mains input and, where fitted, external control input cables have sufficient slack to allow the control box to drop down. Tighten the cable clamp(s) on the boiler chassis. 9. If the optional integral timer is to be used it should be fitted at this point. Refer to the instructions supplied with the timer. NOTE: An external frost thermostat cannot be used with the integral timer. 8.8 Preliminary Electrical Checks 1. Prior to commissioning the boiler preliminary electrical system checks should be carried out. 2. These should be performed using a suitable meter, and include checks for Ground Continuity, Resistance to Ground, Short Circuit and Polarity. Always fit fast blow 2A fuse Fused supply 3A 230V ~ 50Hz Live (brown) Neutral (blue) Earth (green/yellow) 1 2 230V br b g/y bk bk b br bk bk g/y 1 N L Frost Thermostat Room Thermostat External Clock 2 N 230 V N L SL L 230 V Selector / Reset Switch External Controls N br b Pump Hydraulic Differential Pressure Switch r r DHW Flow Priority Microswitch g g Safety Overheat Thermostat b b Central Heating NTC Sensor r r Gas Valve Spark Electrode Flame Sensing Electrode N br b Fan b br bk bk bk Pressure Switch b br bk PCB b b br r bk bk br DHW NTC Sensor g g Gas Valve Modulator Fig. 28 Fig. 27 Fig. 29 Fig. 30 Fig. 26 Terminal Block Fuse Cable Clamp Control Box Cover Facia Panel Functional Flow Diagram Key to Wiring b - blue br - brown bk - black r - red g - green IMPORTANT: If an integral timer is fitted to the boiler an external frost thermostat wired as shown will not operate correctly. Only external timers may be used in such installations, as in the diagram.
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9.0 Commissioning the Boiler 25 9.1 Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Open the mains water supply to the boiler. 3. Open all hot water taps to purge the DHW system. 4. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. 5. Open the screw on the automatic air vent (Fig. 31). 6. The system must be flushed in accordance with BS 7593 (see Section 6.2) and the flushing agent manufacturers instructions. 7. Pressurise the system to 1.0 bar then close and disconnect the filling loop. 8. Turn the gas supply on and purge according to in GB BS 6891 and in IE I.S. 813 “Domestic Gas Installations”. 9. Test for gas soundness. 10. If at any time during commissioning it is required to terminate a particular cycle, e.g. the pump overrun period, turn the selector to the OFF position and then back to either ( ) or ( ) (Fig. 33). Automatic Air Vent Pressure Gauge Screw 2 1 0 4 3 bar Fig. 31 Selector Switch Central Heating Temperature Control Hot Water Temperature Control Fig. 32 30° 40° 50° 60° 70° 80° 2 1 0 4 3 bar Pump Fig. 33 Power On Neon
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9.0 Commissioning the Boiler 26 OUT MIN Pressure Test Point Sealing Screw Gas Valve Fig. 34 Selector Switch Central Heating Temperature Control Hot Water Temperature Control 30° 40° 50° 60° 70° 80° 2 1 0 4 3 bar Fig. 36 Power On Neon Pressure Gauge 2 1 0 4 3 bar Fig. 35 9.2 Checking the Burner Pressure 1. Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for heat. 2. Set the temperature controls to maximum and the selector switch to the Off position (Fig. 36). 3. Slacken the pressure test point sealing screw on the gas valve and connect a pressure gauge (Fig. 33). 4. Undo the screws securing the inner door panel. Lift the panel slightly to disengage it from the studs on top of the case. 5. IMPORTANT: Turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for at least 3 seconds to reset the boiler. 6. Turn the selector switch to the Cental Heating and Domestic Hot Water position ( ). The power On neon ( ) will illuminate (Fig. 36). 7. Turn a hot water tap on to give a flow rate of at least 10l/min. 8. The pressure should be :- 80e 105e NG 12.2mbar 13.4mbar Butane 28.3mbar n/a Propane 36.2mbar 35.8mbar If not, check that the gas supply pressure is correct (Natural Gas 20mbar, Butane 30mbar and Propane 37mbar). 9. The pressure can be adjusted if required. 10. To check and set minimum pressure first remove one of the modulator wires. Adjusting the Pressure (Fig 34a) 11. Remove the plastic protection cap from the pressure adjustment nuts on the valve. 12. The smaller nut (5mm) adjusts minimum pressure and the larger nut (8mm) maximum pressure. 13. Using a suitable spanner adjust the relevant nut until the correct pressure is achieved. 14. Once the pressure has been set turn the boiler off and disconnect the pressure gauge. 15. Tighten the pressure test screw and refit the modulator to the valve. Reassemble in reverse order. Fig. 34a Plastic Protection Cap Modulator Wire Maximum Rate Adjustment Nut Minimum Rate Adjustment Nut NOTE: Gas Valve Electrical Plug shown removed for clarity.
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10.0 Completion 27 10.1 Completion 1. Hinge the facia panel upwards and refit the case front panel. Secure them with the screws previously removed (Fig. 37). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3. Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation. These details will be required in the event of any warranty work. The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded. 4. 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. 5. Hand over the Users Operating, Installation and Servicing Instructions, giving advice on the necessity of regular servicing. Fig. 37 Facia Panel Case Front Panel
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11.0 Servicing the Boiler 28 11 .1 Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person. 2. After servicing, complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication. 3. Ensure that the boiler is cool. 4. Ensure that both the gas and electrical supplies to the boiler are isolated. 5. Slacken the screws securing the facia panel. Lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel (Fig. 39). 6. Remove the screws (2 on 80e, 4 on 105e) securing the inner door panel. Lift the panel slightly to disengage it from the studs on top of the case (Fig. 40). 7. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them (Fig. 41). 8. Slacken the screws on the outlet sealing collar. Ease the collar upwards as far as possible (Fig. 41). 9. Remove the four screws securing the combustion box door and remove the door (Fig. 40). Fan Wires Fan Sensing Tubes Outlet Sealing Collar Combustion Box Door Inner Door Panel Case Front Panel Ease Outlet Sealing Collar Upwards Fig. 39 Facia Panel Securing Screws Fig. 40 Fig. 41 Inner Door Panel Combustion Box Door 80e models 105e models
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11.0 Servicing the Boiler 29 11 .1 Annual Servicing (Cont) 10. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood (Fig. 42). 11. Undo the screws securing the fan and hood to the appliance back panel. Draw the assembly forwards (Fig. 42a). 12. Undo the screws securing the burner to the injector manifold (105e model only). Draw the burner out of the combustion box, pulling the electrode grommets from the slots in the combustion box lower panel (Fig. 43). 13. Disconnect the electrode leads and grommets from the electrodes. Completely remove the burner (Fig. 43). 14. Brush any deposits from the injectors. Do not use a pin or wire to clean them. 15. Brush the burner blades and venturis and clean the combustion box. 16. Ensure that the heat exchanger fins are clear of any obstruction. DHW Filters (Fig. 44) 17. If the flow of domestic hot water is diminished, it may be necessary to clean the filters. 18. Initially check the cold water inlet tap filter. 19. Turn the tap off. Undo the blanking cap and remove the thread bush (Fig. 43a). 20. Extract the filter and rinse thoroughly in clean water. Reassemble and check the flow. If required clean the manifold filter as described below. 21. Undo the filter cartridge from the inlet/return manifold. 22. Dismantle the cartridge and carefully remove the flow regulator and filter gauze. Rinse them thoroughly in clean water and reassemble in reverse order. 23. Check that the pressure vessel charge is 0.5bar and reassemble in reverse order of dismantling and recommission. 24. Turn the selector switch fully anticlockwise against the spring pressure to the reset position (R) and hold for at least 3 seconds to reset the boiler. 25. Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user. Spring Clip Fan and Hood Assembly Baffle Tab Burner Electrode Grommets Fig. 42 Fig. 43 Fig. 42a Fig. 43a Threaded Bush Cold Water Inlet Tap Blanking Cap Cartridge Body Filter Gauze Flow Regulator Venturi Inlet/Return Manifold Fig. 44
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12.0 Changing Components 30 IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the new component has been fitted turn the selector switch fully anticlockwise against the spring pressure to position R and hold for at least 3 seconds to reset the boiler before recommissioning. See Section 11.1 “Annual Servicing” for removal of case panel, door etc. 12.1 Pressure Switch (Fig. 45) 1. Note the positions of the two sensing tubes and three wires and remove them. 2. Remove the two screws holding the pressure switch to the combustion box top panel. 3. Fit the new pressure switch and reassemble all components in reverse order of dismantling. 12.2 Fan (Figs. 46 & 47) 1. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them. 2. Slacken the screws on the outlet sealing collar. Ease the collar upwards as far as possible. 3. Remove the four screws securing the combustion box door and remove the door. 4. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood. 5. Undo the screws securing the fan hood to the appliance back panel, and draw the fan and hood assembly forwards. 6. Remove the screws and spring washers securing the fan to the hood. 7. Fit the new fan to the hood using the screws and spring washers previously removed. 8. Reassemble in reverse order of dismantling. Spring Clip Fan Fan Hood Spring Washer Securing Screw Baffle Tab Fan Wires Fan and Hood Assembly Sensing Tubes Outlet Sealing Collar Pressure Switch Sensing Tubes Pressure Switch Wires Fig. 45 Fig. 46 Fig. 47
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12.0 Changing Components 31 12.3 Heat Exchanger (Fig. 48) 1. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them. 2. Slacken the screws on the outlet sealing collar. Ease the collar upwards as far as possible. 3. Remove the four screws securing the combustion box door and remove the door. 4. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood. 5. Undo the screws securing the fan hood to the appliance back panel, and draw the fan and hood assembly forwards. 6. Drain the primary circuit. Prise the two pipe connecting clips off the joints in the flow and return pipes. 7. Lift the heat exchanger to disconnect the flow and return pipe joints. Withdraw it from the appliance, taking care not to damage the rear insulation piece. 8. Fit the new heat exchanger. 9. Reassemble in reverse order of dismantling, and repressurise the system. 12.4 Burner (Fig. 49) 1. Remove the four screws securing the combustion box door and remove the door. 2. Undo the screws securing the burner to the injector manifold (105e model only). Draw the burner out of the combustion box, pulling the electrode grommets from the slots in the combustion box lower panel. 3. Disconnect the electrode leads and grommets from the electrodes. Completely remove the burner. 4. Undo the screws securing the electrodes to the burner. Examine the condition of the electrodes, replacing if necessary. Fit the electrodes to the new burner. 5. Engage the burner location brackets over the studs on the injector manifold and reassemble in reverse order. Burner Electrode Grommets Electrode Leads Electrodes Heat Exchanger (80e model) Fig. 48 Heat Exchanger (105e model) Pipe Connecting Clips Pipe Connecting Clips Fig. 49
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12.0 Changing Components 32 12.5 Injectors (Fig. 50) 1. Remove the burner as described in Section 12.4. 2. Undo the screws securing the injector manifold to the inlet elbow and remove the manifold. 3. Unscrew and replace injectors as required and examine the sealing gasket, replacing as necessary. Reassemble in reverse order. 12.6 Electrodes (Fig. 50) 1. Remove the four screws securing the combustion box door and remove the door. 2. Undo the screws securing the burner to the injector manifold (105e model only). Draw the burner out of the combustion box, pulling the electrode grommets from the slots in the combustion box lower panel. 3. Disconnect the lead and grommet from the electrode being replaced. Undo the securing screw and withdraw the electrode to the burner. 4. Reassemble in reverse order. 12.7 Insulation (Fig. 51) 1. Remove the four screws securing the combustion box door and remove the door. 2. Slide the side insulation pieces carefully out of their carriers. 3. To replace the rear insulation piece it is necessary to remove the heat exchanger as described in Section 12.3 and slide out the side pieces. 4. The combustion box door insulation piece can be replaced by carefully bending up the two retaining tabs. 5. Replace all insulation pieces and reassemble in reverse order. 13.8 Injector Manifold Inlet Elbow Gasket Injector Burner Electrode Grommets Electrode Leads Side Insulation Rear Insulation Front Insulation Combustion Box Door Side Insulation Electrodes Fig. 50 Fig. 51
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12.0 Changing Components 33 12.8 Gas Valve (Fig. 52) 1. Undo the nut on the gas feed pipe under the boiler. 2. completely undo the securing screws and hinge the facia panel down. 3. Disconnect the earth wire and pressure sensing pipe from the valve. Undo the screw securing the electrical plug to the valve and disconnect the plug. Disconnect the wires from the valve modulator. 4. Pull the earth wire off the spade terminal on the valve. 5. Remove the screws securing the inlet pipe flange to the boiler bottom panel and those securing the outlet manifold to the burner manifold. 6. Remove the valve from the boiler. 7. Note the orientation of the inlet pipe and outlet manifold. Undo the securing screws and remove the pipe and manifold. 8. Examine the ‘O’ ring seals for damage, replacing as necessary. 9. Fit the inlet pipe and outlet manifold to the new valve, ensuring that the ‘O’ ring seals are in place. 10. Reassemble in reverse order and check the burner pressure (Section 9.2). 12.9 Central Heating Temperature Sensor (Fig. 53) 1. Ease the retaining tab on the sensor away and disconnect the electrical plug. 2. Unscrew the sensor from it’s pocket and reassemble in reverse order. The plug will only fit one way. 12.10 Safety Thermostat (Fig. 53) 1. Pull the electrical connections off the thermostat. 2. Remove the screws securing the thermostat to the mounting plate on the flow pipe. 3. Reassemble in reverse order. The thermostat is not polarised - either wire can fit either terminal on the thermostat. 12.11 DHW Temperature Sensor (Fig. 53a) 1. Turn off the mains water supply and draw off the residual domestic hot water. 2. Ease the retaining tab on the sensor away and disconnect the electrical plug. 3. Unscrew the sensor from the plate heat exchanger manifold. Examine the sealing washer,replacing if necessary. 4. Reassemble in reverse order. The plug will only fit one way. Gas Valve Inlet Pipe Gas Feed Pipe Earth Wire Electrical Plug Central Heating Temperature Sensor Safety Thermostat Flow Pipe Fig. 52 Fig. 53 DHW Temperature Sensor Fig. 53a Plate Heat Exchanger Modulator Wires Electrode Lead Earth Wire
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12.0 Changing Components 34 12.12 Pump - Head Only (Fig. 54) 1. Drain the primary circuit and remove the socket head screws securing the pump head to the body and draw the head away. 2. Undo the screw on the pump wiring cover and remove the cover. Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position. 3. A standard Grundfos replacement head can now be fitted. A Grundfos 15-50 head is suitable for the Combi 80e. The Combi 105e requires a 15-60 head. Connect the wiring to the new head. The pump speed must be set to 3 (Fig. 55). 4. Reassemble in reverse order. 12.13 Pump - Complete (Fig. 56) 1. Drain the primary circuit and unscrew the automatic air vent from the pump body. Undo the two screws securing the body to the pipe and manifold and draw the pump forwards. 2. Undo the screw on the pump wiring cover and remove the cover. Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position. 3. Connect the wiring to the new pump. Examine the ‘O’ ring seals on the return pipe and manifold, replacing if necessary. 4. Fit the air vent to the pump body and reassemble in reverse order. 12.14 Automatic Air Vent (Fig. 56) 1. Drain the primary circuit and unscrew the automatic air vent from the pump body. 2. Examine the ‘O’ ring seal, replacing if necessary, and fit it to the new automatic air vent. 3. Reassemble in reverse order. Pump Setting Pump Wiring Cover Socket Headed Screw Pump Head Pump Body Pump Wiring Cover Automatic Air Vent Fig. 54 Fig. 56 Fig. 55
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12.0 Changing Components 35 12.15 Pressure Gauge (Figs. 57 & 58) 1. Drain the primary circuit and undo the nut on the pressure gauge capillary. 2. Remove the timer cover and ease the timer wiring aside. Undo the screws securing the gauge retaining bracket. 3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining bracket. 4. Reassemble in reverse order. 12.16 Expansion Vessel (Fig. 59) 1. To replace the expansion vessel it is necessary to remove the boiler from the wall. NOTE: Alternatively a vessel of equivalent capacity can be fitted on the system return pipe as close as possible to the boiler. 2. Drain the system and undo all gas and water connections. Remove the flue elbow. 3. Lift the boiler off the wall plate and lay it on it’s side on a clean flat surface. 4. Undo the nut on the vessel outlet spigot, and remove the locknut and spring washer securing the spigot to the boiler chassis. 5. Undo the screws and remove the appliance upper cross member. Slide the expansion vessel out of the retaining clips. 6. Reassemble in reverse order. Fully recommission the appliance and system. 12.17 Gas Valve Plug/Spark Generator (Fig. 60) 1. The valve electrical plug, spark generator and lead are combined in one unit. 2. Disconnect the earth wire and electrode lead from the plug/generator. Undo the screw securing the plug/generator to the valve and disconnect it. 3. Remove the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear tabs of the cover from the control box hinge pin. 4. Remove the plug lead from the cable clip and disconnect the multi-pin plug from the PCB. 5. Reassemble in reverse order. Pressure Gauge Timer Cover Pressure Gauge Capillary Gauge Retaining Bracket Expansion Vessel Retaining Clip Vessel Outlet Spigot Boiler Chassis Lock Nut Spring Washer Fig. 57 Fig. 58 Fig. 59 Fig. 60 Gas Valve Plug/ Spark Generator Electrode Lead Earth Wire
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12.0 Changing Components 36 12.18 Pressure Relief Valve (Fig. 61) 1. Drain the primary circuit. 2. Disconnect the discharge pipe from the valve. Using a suitable hexagon key undo the grub screw sufficiently to release the valve. 3. Note the orientation of the valve, rotate it and withdraw it from the manifold. 4. Fit the new valve and ‘O’ ring seal and set to the previously noted orientation. Reassemble in reverse order. 12.19 P.C.B. (Fig. 63) 1. Note the settings of the temperature control knobs. Rotate the knobs fully anticlockwise and carefully pull them off the drive pins. 2. Remove the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear of the cover from the control box hinge pin (Fig. 62). 3. Note the position of all plugs and wires on the P.C.B. and disconnect them. 4. Undo the securing screws and remove the P.C.B. Transfer the control knob drive pins to the new P.C.B. and turn them fully anticlockwise. 5. Reassemble in reverse order, ensuring that the temperature controllers are reset to their previous positions. 6. IMPORTANT: Turn the selector switch fully anticlockwise against the spring pressure to the reset position (R) and hold for at least 3 seconds to reset the boiler. 12.20 Selector Switch (Fig. 63) 1. Note the setting of the selector switch knob and carefully pull it off the facia. 2. Remove the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear of the cover from the control box hinge pin. 3. Note the position of the electrical connections and the orientation of the switch. Remove the electrical connections. 4. Remove the screws securing the switch to the facia panel. 5. Fit the new switch, ensuring that it is correctly positioned and reassemble in reverse order. Pressure Relief Valve Grub Screw ‘O’ ring seal Discharge Pipe Control Box Cover P.C.B. Selector Switch Facia Selector Switch Knob Temperature Control Knobs Fig. 61 Fig. 62 Fig. 63 Drive Pins
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12.0 Changing Components 37 12.21 Plate Heat Exchanger (Fig. 64) 1. Drain the primary circuit. 2. While supporting the heat exchanger undo the screws securing it to the brass manifolds. 3. Withdraw the heat exchanger upwards and to the left of the gas valve, taking care not to damage any wires or controls. Seals 4. There are four rubber seals between the manifolds and heat exchanger which may need replacement. 5. Ease the seals out of the manifold. Replace carefully, ensuring that the seal is inserted into the manifold parallel and pushed fully in. 6. When fitting the new heat exchanger note that the left hand location stud is offset towards the centre more than the right hand one. 7. Reassemble in reverse order. 12.22 Diverter Valve Assembly (Figs. 65 & 66) The diverter valve assembly comprises of a central heating pressure differential valve and a domestic hot water pressure differential valve. These are connected to a manifold which is joined to the plate heat exchanger. DHW Pressure Differential Valve (Fig. 66) 1. Drain the primary circuit. 2. Undo the screw securing the microswitch bracket to the valve (Fig. 65). 3. Disconnect the two sensing pipes and slacken the grub screws securing the valve to the diverter manifold. 4. Draw the valve away from the diverter manifold. The valve may now be replaced or split to examine the diaphragm. 5. To examine the diaphragm hold the valve body securely and carefully remove the six screws. The diaphragm spring will force apart the two halves of the valve. 6. Remove the plastic disc and pushrod assembly. Carefully examine the diaphragm and replace it if there is any damage. 7. Reassemble in reverse order. Plate Heat Exchanger Rubber Seal DHW Pressure Differential Valve Microswitch Bracket Grub Screws Diverter Manifold Sensing Pipes Plastic Disc Pushrod Diaphragm Spring Diaphragm Fig. 64 Fig. 65 Fig. 66
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12.0 Changing Components 38 12.22 Diverter Valve Assembly (Cont) Pressure Differential Valve (Fig. 67) 1. Remove the pressure differential valve as described above. 2. From the brass diverter manifold undo the nut on the heating flow pipe. Remove the screw securing the diverter manifold to the appliance lower bracket. 3. Disconnect the pressure gauge capillary from the diverter manifold and remove the two wires from the microswitch. 4. Prise off the spring clip securing the by-pass pipe to the diverter manifold and disconnect the sensing pipe. 5. Ease the diverter manifold out of the plate heat exchanger manifold. Remove the assembly from the appliance. 6. Undo the screw securing the microswitch bracket to the valve body. The sensor may now be dismantled to examine the diaphragm. 7. To examine the diaphragm hold the assembly securely and carefully remove the four screws. The diaphragm spring will force the two halves of the valve apart. 8. Carefully examine the diaphragm and replace it if there is any damage. 9. Reassemble in reverse order. CH Pressure Microswitch (Fig. 67) 1. Remove the two wires from the Pressure microswitch. 2. Undo the screw securing the microswitch bracket to the valve body. 3. Reassemble in reverse order. 12.23 Flow Regulator (Figs. 68 & 69) 1. Undo the filter cartridge from the inlet/return manifold. 2. Unscrew the venturi and remove the flow regulator. 3. Check the cleanliness of the filter gauze, rinsing thoroughly in clean water as necessary. Fit the new flow regulator and reassemble in reverse order. Pressure Gauge Capillary Heating Flow Pipe Spring Clip By-pass Pipe Sensing Pipe Diaphragm Diverter Manifold Microswitch / Bracket Central Heating Pressure Differential Valve Fig. 67 Cartridge Body Filter Gauze Flow Regulator Venturi Inlet/Return Manifold Fig. 68 Fig. 69
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13.0 Illustrated Wiring Diagram 39 - brown - black - blue - red br bk b r - green - green / yellow - white g g/y w Optional Timers Domestic Hot Water Temperature Sensor Reset Selector Switch Control PCB A1 A2 A3 A4 A5 F2 1 bk bk r r g g g r g r 2 1 2 3 3 4 1 1 2 3 4 5 6 10 9 8 7 6 5 4 3 2 1 2 3 4 4 5 5 6 7 8 9 Central Heating Temperature Sensor Fan Gas Valve Overheat Stat Hydraulic Differential Pressure Switch Domestic Hot Water Flow Priority Pressure Switch Air Pressure Switch Flame Mains Input Fuse Link g/y g/y b br bk br b bk Sensing Electrode Pump b b b bk b b b br br b b r bk bk br bk br br br 1 2 3 4
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40 14.0 Fault Finding Carry out initial fault finding checks 1. Check that gas, water and electrical supplies are available at the boiler. Electrical supply = 230V ~ 50 Hz. CH water system pressurised to 0.5 bar when the boiler is cold. The preferred minimum gas pressure is 19.5mbar (natural gas), 27mbar (butane) or 36mbar (propane). 2. Carry out electrical system checks, i.e. Ground Continuity, Resistance to Ground, Short Circuit and Polarity with a suitable meter. NOTE: These checks must be repeated after any servicing or fault finding. 3. Ensure all external controls are calling for heat and check all external and internal fuses. Before any servicing or replacement of parts ensure the gas and electrical supplies are isolated. Refer to Section 13.0 “Illustrated Wiring Diagram” for position of numbered terminals Central Heating - Follow operational sequence Turn selector to neon illuminated Primary flow switch operated Fan runs at max speed Burner goes out Turn thermostat to max. Pump runs Air pressure switch proved neon flashing Burner on neon illuminated Burner output modulates until set temperature is reached Spark at ignition electrodes for up to 10 seconds Go to section ‘A’ neon flashing Go to section ‘B’ neon flashing Go to section ‘C’ Go to section ‘J’ neons flashing Go to section ‘D’ neon flashing Go to section ‘E’ Replace PCB Turn selector to the reset position. If the neon does not extinguish go to sections H & K Go to section ‘F’ neon flashing Go to section ‘I’ Go to section ‘G’ Fan stops Pump stops Operation sequence correct neon flashing Turn selector to reset position. If regular resetting is required or appliance still does not operate investigation is necessary External controls and, where fitted, integral timer calling for heat Ensure controls are set to demand and verify the contacts are closed Burner extinguishes after 10 seconds YES YES YES YES YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO NO NO NO NO NO NO YES NO NOTE: When instructed to turn the selector to the reset position turn the selector switch fully anticlockwise against the spring pressure to position R and hold for at least 3 seconds to reset the boiler.
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41 14.0 Fault Finding Domestic Hot Water - Follow operational sequence Turn selector to neon illuminated Primary flow switch operated Fan runs at max speed Pump runs Turn thermostat to max. Open DHW tap fully. DHW flow switch operated Primary water is diverted from CH system to DHW heat exchanger and flow microswitch operated neon illuminated Continuity across DHW flow microswitch terminals and PCB - A5 connector terminals 5 & 6 Air pressure switch proved neon flashing Burner on neon illuminated Spark at ignition electrodes for up to 10 seconds Go to section ‘A’ neon flashing Go to section ‘B’ neon flashing Go to section ‘C’ Go to section ‘J’ neons flashing Go to section ‘D’ Replace PCB Turn the selector to the reset position. If the light does not extinguish go to section H & K Go to section ‘F’ neon flashing Go to section ‘I’ DHW flow valve senses no flow. Primary water diverted to CH system. DHW flow switch released off Close DHW tap Burner goes out Diverter valve spindle assembly faulty Pump stops Operation sequence correct neon flashing Turn selector to reset position. If regular resetting is required or appliance still does not operate investigation is necessary neon flashing Go to section ‘E’ Burner extinguishes after 10 seconds YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES NO Fan stops NO YES YES YES YES NO NO DHW flow rate more than 2.5l/min. Is mains water filter and differential assembly clean? DHW flow valve diaphragm damaged DHW flow valve rod obstructed Replace DHW flow microswitch Replace PCB Replace diaphragm NO NO NO YES NO NO NO NO NO NO NO NO Reduce the DHW flow rate. If burner does not modulate clean DHW temperature sensor and DHW heat exchanger. If modulation does not occur go to section ‘G’ Burner output modulates to maintain temperature set at thermostat NO NO
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42 14.0 Fault Finding Fault Finding Solutions Sections A to E Is there 230V at: Is there 230V at: Main terminals L and N Check electrical supply 1. NO Main terminal fuse Replace fuse Replace PCB neon illuminated 2. YES Selector terminals a & b and a & 3. PCB - A4 connector terminals 4 & 5 Check wiring Replace selector 3. NO NO A Pump Replace pump 1. NO PCB - A4 connector terminals 3 & 6 Replace PCB 2. NO Change pump supply cable YES B CH system pressure 0.5 to 1.5 bar Re-pressurise system 1. NO Primary flow valve diaphragm damaged Replace diaphragm Flow valve rod obstructed 3. YES Check the tap of the automatic air vent is opened Open the automatic air vent 2. NO NO C YES Continuity across flow microswitch and PCB -A5 connector terminals 7 & 8 Replace microswitch 1. NO NO Primary temperature sensor faulty. Cold resistance approx. 11K ohms (resistance reduces with increase in temp.) Replace sensor 2. YES Fan connections correct at fan. PCB - A2 connector, is 230V across terminals 5 & 7 Fan jammed or faulty winding Replace PCB Replace fan YES 3. D If pump jammed, release Check and correct if necessary 1. Electrical and pressure tube connections 2. Blockage of pressure tubes 3. Restriction in flue 4. Venturi NO E Replace air pressure switch
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43 14.0 Fault Finding Gas at burner Ensure gas is on and purged Replace PCB Replace gas valve neon flashing PCB - A1 connector has 230V AC across terminals 3 & 4 YES Turn selector switch to reset position R YES NO NO NO F Replace PCB G Check and correct if necessary 1. Ignition electrode and lead 2. Electrode connection 3. Spark gap and position 230V at Main PCB - A1 connector across terminals 2 & 4. Check wiring YES NO Replace gas valve electrical plug/spark generator YES H YES Check the burner setting pressure of the gas valve (see Section 9.2 of Commissioning) 1. Voltage at modulating coil of gas valve is: Max. burner press.approx 9V DC (13V DC LPG) Min. burner press.approx 1V DC Current at modulating coil of gas valve is: (Use an instrument with average function for this measure) 30 ÷ 230 mA DC (45 ÷ 310 mA DC LPG) Replace gas valve NO Replace PCB 2. Check and correct if necessary 1. Flame sensing electrode and lead connections 2. Electrode position Flame current should be 1 μA approx. Replace PCB Replace PCB YES YES Replace flame sensing electrode NO YES Ensure that mains input terminal L is Live (230V) and N is Neutral (0V) I Check terminal 1 of ON/OFF/RESET selector is in connection with PCB - A4 connector terminal 2 Check electrical continuity across terminals 1 & a of ON/OFF/RESET selector when turned to position R Replace ON/OFF/RESET selector NO Replace PCB YES K Replace safety thermostat YES NO Overheat thermostat operated or faulty, i.e. continuity across thermostat terminals Allow to cool. Continuity across thermostat terminals more than 1.5 ohm J
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15.0 Short Parts List 44 Short Parts List Key G.C. Description Manufacturers No. No. Part No. 22 E66 383 Fan 80e 248001 E66 527 Fan 105e 248002 23 393 974 Pressure Switch 247380 32 E66 393 Heat Exchanger 80e 248016 E66 535 Heat Exchanger 105e 248017 41 E66 398 Burner 80e 248029 E66 399 Burner 105e 248030 44 E66 402 Injector 248210 59 E66 408 Electrode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 E66 431 Pump 80e 248041 E66 539 Pump 105e 248042 101 E66 432 3-Way Valve Assy. 248061 131 342 571 Temperature Sensor 247394 135 E66 439 Safety Thermostat 248079 140 Gas Valve 5107339 154 PCB 5112380 169 E66 453 Pressure Gauge 248090 A Gas Valve Plug/Spark 5112385 Generator & Lead 22 140 44 63 154 72 135 59 41 101 32 169 131 23 32 80e models 105e models A
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16.0 Notes 45
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CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS? THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE, MEASURE & RECORD GAS RATE ft3/hr BURNER OPERATING PRESSURE (IF APPLICABLE) mbar CENTRAL HEATING FLOW TEMPERATURE °C CENTRAL HEATING RETURN TEMPERATURE °C FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED? YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED? FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD GAS RATE ft3/hr MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar COLD WATER INLET TEMPERATURE °C HOT WATER OUTLET TEMPERATURE °C WATER FLOW RATE lts/min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS? YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2 RATIO READING? N/A YES CO/CO2 RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER m3/hr m3/hr COMMISSIONING ENG’S NAME PRINT CORGI ID No. SIGN DATE BOILER SERIAL No. NOTIFICATION No. BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K N/A N/A 5 1 1 3 9 3 1 46
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SERVICE 1 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 7 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls 47
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Comp No 5113931 - Iss 2 - 03/05 BAXI POTTERTON A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www.baxi.co.uk
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