Installation and servicing manual

United Kingdom
en
Installation and Service Manual
High Efficiency Wall Hung Condensing Gas Boiler
Baxi Combi
624 — 630
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.
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.
Contents
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
Directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4
Description of the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 Operating principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.1
Air-gas adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
4.2.2
Combustion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.3
Central heating and domestic hot water production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.4
Central heating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.5
Domestic hot water mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.6
Frost protection mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.7
Pump protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.3 Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.3.1
List of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.4 Control panel description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.4.1
Description of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5 Standard delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.1
Contents of the carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6 Accessories and options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.1
Optional accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Installation regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2 Installation requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.2.1
Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.2.2
Electrical supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
5.2.3
Hard water area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.4
Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.5
System control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.6
Treatment of water circulating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.7
Showers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.2.8
Expansion vessel (CH only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.2.9
Safety pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7679306 - 1 - 10082017
3
Contents
5.3
5.4
5.5
5.6
Choice of the location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3.1
Location of the boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3.2
Bath and shower rooms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
5.3.3
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3.4
Condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.5
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5.3.6
Flue/chimney location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3.7
Horizontal flue/chimney systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.3.8
Flue/chimney trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3.9
Terminal guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.3.10 Flue/chimney deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
5.3.11 Flue/chimney accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Unpacking & initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5.1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.5.2
Initial preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Connecting diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.6.1
Filling information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
5.6.2
Domestic hot water circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6.2.1
Fitting the pressure relief discharge pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
6.2.2
Connecting the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3 Air supply/flue gas connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3.1
Connecting the flue/chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.4 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.4.1
Making the electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.4.2
Connecting outdoor sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4.3
Identifying label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4.4
Outdoor sensor graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4.5
Setting outdoor sensor curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
6.5 Filling the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.5.1
Flushing the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
6.5.2
Fill the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.5.3
Filling the condensate trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
7
Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2 Checklist before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2.1
Preliminary electrical checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.2.2
Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
7.3 Commissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.3.1
De-Aeration function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.4 Gas settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.4.1
Check the operational (working gas inlet pressure and gas rate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.4.2
Checking combustion - chimney sweep mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.5 Configuring the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.5.1
System draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.6 Final instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
7.6.1
Handover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8.1 Use of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.1.1
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.2 Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.3 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
9.2 Standard inspection and maintenance operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2.1
Annual Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
9.2.2
Checking the water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2.3
Checking the expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
9.2.4
Checking the automatic air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4
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Contents
9.3
9.2.5
Checking the burner and cleaning the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Specific maintenance instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
9.3.1
Detection/spark ignition electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
9.3.2
NTC flue sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
9.3.3
Flow and return sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.3.4
Safety overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.3.5
DHW temperature sensor (NTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
9.3.6
Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
9.3.7
Hall effect sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.3.8
DHW flow regulator and filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
9.3.9
Safety pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
9.3.10 Diverter valve motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.3.11 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.3.12 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.3.13 Pump - head only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
9.3.14 Pump - complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.1 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.1.1 Initial error fault finding checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.1.2 Display of error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.2 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.2.1 Central heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.2.2 Domestic hot water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10.2.3 Fault finding solutions sections A to E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.2.4 Fault finding solutions sections F to H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.2.5 Fault finding solutions sections I to M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
11 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
11.1 Decommissioning procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
12.1 Disposal and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
13 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
13.1 Short parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
14 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
14.1 Benchmark commissioning checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
14.2 Service records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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5
1 Safety
1
1.1
Safety
Benchmark
1.1.1
Building Regulations and the Benchmark Commissioning
Checklist
Building Regulations (England & Wales) require notification of the installa­
tion of a heating appliance to the relevant Local Authority Building Control
Department. This can be achieved via a Competent Persons Self Certifica­
tion Scheme as an option to notifying the Local Authority directly.
The Health & Safety Executive operates the ’Gas Safe Register’, a selfcer­
tification 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 installa­
tion and commissioning of central heating systems in the UK and to en­
courage the regular servicing of all central heating systems to ensure safe­
ty and efficiency.
Building Regulations require that installations should comply with manu­
facturer’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 neces­
sary to ensure compliance with Building Regulations.
1.1.2
Fig.1
Benchmark
AD-3000725-01
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 ref­
erence.
Installers are required to carry out installation, commissioning and servic­
ing 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 infor­
mation.
6
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1 Safety
1.1.3
Fig.2
Installer Notification Guidelines
Installer Notification Guidelines
Choose Building
Regulations Notification
Route
Competent Person's
Self Certification Scheme
Building Control
Install and Commission this
appliance to manufacturer's
instructions
Contact your relevant Local
Authority Building Control
(LABC) who will arrange
an inspection or contact
a government approved
inspector
Complete the
Benchmark Checklist
If you notify via the ‘Gas Safe
Register’, the register will issue
the Building Regulations
certificate on members’ behalf
Install and Commission this
appliance to manufacturer's
instructions
Scheme Members only
Call ‘Gas Safe Register’ on:
0800 408 5577
or log onto:
www.gassaferegister.co.uk
within 10 days
Complete the
Benchmark Checklist
You must ensure that the
certificate number issued by
the ‘Gas Safe Register’ is written
onto the Benchmark Checklist
‘Gas Safe Register’ will issue a
Building Regulations Compliance
Certificate to the property owner
and inform the relevant LABC
LABC will record the data
and will issue a
certificate of compliance
AD-3000696-01
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7
1 Safety
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 elec­
trical 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 boil­
er 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 installa­
tion 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 regula­
tions.
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.
8
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1 Safety
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 al­
ways 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 opera­
tion.
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 servic­
ing purposes. Refit all panels when maintenance work and servic­
ing 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 should­
ers, arms and hands. Health & Safety is the responsibility of EVERY­
ONE.
There is no "safe" limit for one man - each person has different capabili­
ties. 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 unobstruc­
ted. 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 pos­
sible.
Where possible transport the boiler using a sack truck or other suitable
trolley.
7679306 - 1 - 10082017
9
1 Safety
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 recom­
mended lift points.
Remember
The circumstances of each installation are different. Always assess the
risks associated with handling and lifting according to the individual con­
ditions.
If at any time when installing the boiler you feel that you may have in­
jured 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 observe 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 stand­
ards.
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 fol­
lowing 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 com­
missioning.
Get your installer to explain your installation to you.
Have the required inspections and maintenance carried out by a quali­
fied installer.
Keep the instruction manuals in good condition close to the appliance.
10
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2 About this manual
2
2.1
About this manual
General
This manual is intended for the installer of a Baxi Combi boiler.
2.2
Additional documentation
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 in­
structions. 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 in­
jury.
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
CH
DHW
GB
HHIC
Hi
Hs
IE
PCU
Pn
Pnc
SU
7679306 - 1 - 10082017
British Standard
Central heating
Domestic hot water
Great Britain
Heating and Hotwater Industry Council
Lower heating value (LHV)
Higher heating value (HHV)
Ireland
PCB for managing burner operation
Nominal output
Condensing output
Safety PCB
11
3 Technical specifications
3
Technical specifications
3.1
Homologations
3.1.1
Directives
Our company declares that these products are provided with the CE mark­
ing in compliance with the essential requirements of the following direc­
tives:
Gas Directive 2009/142/EC;
Electromagnetic Compatibility Directive 2014/30/EU General standards:
EN 61000-6-3, EN 61000-6-1 Standard in reference to: EN 55014;
Electromagnetic Compatibility Directive 2014/30/EU General standards:
EN 61000-6-3, EN 61000-6-1 Standard in reference to: EN 55014.
For appliances connected to the electricity network: Comply with the
prevailing provisions for low-voltage electrical equipment;
Low Voltage Directive 2014/35/EU General standard: EN 60335–1
Standard in reference to: EN 60335–2-102;
Efficiency Directive 92/42/EC
Ecodesign Directive 2009/125/EC;
Directive on energy consumption 2010/30/EC; Regulation (EU) No.
813/2013 and 814/2013.
Energy Labelling Directive 2010/30/EU: Regulation 811/2013 and
812/2013
In addition to the provisions and legal directives, also the complementary
directives described in these instructions must be observed. All the sup­
plements and additional requirements are applicable at the moment of in­
stallation.
3.1.2
Tab.1
Certifications
Certifications
CE certificate number
NOx class
5
Boiler type
C13, C33
3.1.3
Tab.2
Gas category
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
12
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.
7679306 - 1 - 10082017
3 Technical specifications
Standard
Scope
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.
Tab.4
In IE the following Code of Practice apply:
Standard
Scope
IS 813
Domestic Gas Installations.
The following standards give valuable additional information:
3.2
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.
Technical data
3.2.1
Technical information
Important
All data in these sections are nominal and subject to normal pro­
duction tolerances.
Tab.5
General
Baxi Combi
624
630
Gas council numbers
47 077 28
47 077 29
Nominal heat input domestic hot water —
Maximum rate
7679306 - 1 - 10082017
Net (Qn Hi)
kW
25.77
30.93
Gross (Qn Hs)
kW
28.58
34.26
13
3 Technical specifications
Baxi Combi
Nominal heat input central heating — Maxi­
mum rate
624
630
Net (Qn Hi)
kW
20.6
20.6
Gross (Qn Hs)
kW
22.86
22.86
Net (Qn Hi)
kW
6.2
6.2
Gross (Qn Hs)
kW
6.87
6.87
Nominal heat output 80/60°C — domestic hot
water — Maximum rate
Pn
kW
25
30
Nominal heat output 80/60°C — central heat­
ing — Maximum rate
Pn
kW
20
20
Nominal heat output 80/60°C — central heat­
ing — Factory setting
Pn
kW
20
20
Nominal heat output 80/60°C — Minimum
rate
Pn
kW
6.2
6.2
Nominal heat output 50/30°C — central heat­
ing — Maximum rate
Pnc
kW
21.16
21.16
Nominal heat output 50/30°C — central heat­
ing — Minimum rate
Pnc
kW
6.7
6.7
Nominal heat input — Minimum rate
Tab.6
Central heating circuit specifications
Baxi Combi
624
630
Maximum pressure
bar
3
3
Minimum pressure
bar
0.5
0.5
Central heating temperature adjustment (±5°C)
°C
25 / 80
25 / 80
litres
7.0
7.0
bar
1.0
1.0
Maximum capacity of central heating system
litres
100
100
Primary water content of boiler (unpressurised)
litres
2.5
2.5
624
630
bar
8
8
bar
0.5
0.5
l/min
2.0
2.0
l/min
10.2
12.2
35 / 60
35 / 60
Expansion vessel water capacity
Expansion vessel pre charge pressure
Tab.7
Domestic hot water circuit specifications
Baxi Combi
Maximum pressure
Dynamic minimum pressure
Minimum working water flow rate
(1)
Specific flow rate (D)
Domestic hot water temperature range adjustment
±5°C
°C
Production of domestic hot water with ΔT = 30°C
l/min
12
14.3
Production of domestic hot water with ΔT = 35°C
l/min
10.2
12.2
(1) 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
624
630
Natural gas rate (G20) Qmax
m3/h
2.71
3.26
Natural gas rate (G20) Qmin
m3/h
0.67
0.67
14
7679306 - 1 - 10082017
3 Technical specifications
Important
Dynamic (nominal) inlet pressure (Natural gas — G20) 20mbar
with a CV of 37.78 MJ/m3
Tab.9
Electrical specifications
Baxi Combi
624
630
Nominal electrical power supply voltage
V
230
230
Nominal electrical power supply frequency
Hz
50
50
Nominal power consumption when firing
W
100
100
External fuse rating
Amp
3
3
Internal fuse rating
Amp
F2A H250V
F2A H250V
Important
Boiler must be connected to an earth supply.
Tab.10
Other specifications
Baxi Combi
Degree of protection against humidity (EN 60529)
Dimensions (height / width / depth)
Tab.11
IP
mm
624
630
IPX5D
IPX5D
H 700/W 390/D 285
H 700/W 390/D 285
624
630
Connections
Baxi Combi
Gas inlet
mm
22
22
Heating flow
mm
22
22
Heating return
mm
22
22
Cold water inlet
mm
15
15
Hot water outlet
mm
15
15
Pressure relief discharge
mm
15
15
Condensate discharge drain plastic waste pipe
mm
21.5
21.5
624
630
Tab.12
Clearances
Baxi Combi
Above casing
mm
178
178
Below casing (min)
mm
200
200
Front — for servicing
mm
450
450
Front — for operation
mm
5
5
Sides LH
mm
5
5
Sides RH
mm
5
5
624
630
Tab.13
Weights
Baxi Combi
Packaged boiler
kg
32.2
32.2
Boiler lift weight (dry)
kg
29.2
29.2
Installed weight (dry)
kg
30.2
30.2
7679306 - 1 - 10082017
15
3 Technical specifications
Baxi Combi
Installed weight when filled with water
kg
3.2.2
Tab.14
624
630
32.5
32.5
Technical parameters
Technical parameters for boiler combination heaters
Baxi Combi
624
630
Condensing boiler
Yes
Yes
Low-temperature boiler(1)
No
No
B1 boiler
No
No
Cogeneration space heater
No
No
Combination heater
Yes
Yes
Prated
kW
20
20
Useful heat output at rated heat output and high tem­
perature regime(2)
P4
kW
20
20
Useful heat output at 30% of rated heat output and low
temperature regime
P1
kW
6.0
7.5
ƞs
%
93
93
Useful efficiency at rated heat output and high temper­
ature regime
ƞ4
%
97.9
97.9
Useful efficiency at 30% of rated heat output and low
temperature regime
ƞ1
%
108.7
108.7
Full load
elmax
kW
68
78
Part load
elmin
kW
50
53
Standby mode
PSB
kW
0.003
0.003
Standby heat loss
Pstby
kW
0.069
0.069
Ignition burner power consumption
Pign
kW
0
0
Annual energy consumption
QHE
GJ
62
77
Sound power level, indoors
LWA
dB
51
54
Emissions of nitrogen oxides
NOX
mg/kWh
29.7
28.3
XL
XL
Rated heat output
Seasonal space heating energy efficiency
Auxiliary electricity consumption
Other items
Domestic hot water parameters
Declared load profile
Daily electricity consumption
Qelec
kWh
0.195
0.196
Annual electricity consumption
AEC
kWh
43
43
Water heating energy efficiency
ƞwh
%
83.8
83.9
Daily fuel consumption
Qfuel
kWh
23.2
23.1
Annual fuel consumption
AFC
GJ
18
18
(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.
16
7679306 - 1 - 10082017
3 Technical specifications
See
The back cover for contact details.
3.3
Fig.3
Dimensions and connections/clearances
Dimensions and connections / clearances
5
390
11
5
178
1
2
700
10
3
285
450
200
4
5
5
6
7
8
9
PN-0000605
1
2
3
4
5
6
7
8
9
10
11
Condensate trap sump
Condensate drain
Heating circuit water flow
Hot water outlet
Gas inlet
Pressure relief pipe
Cold water inlet
Heating circuit water return
Pump drain point
Boiler drain point on flow isolation tap
Cable entry points
The clearances shown in the diagram are minimum requirements to allow
for case removal, spanner access and air movement. These should be ob­
served at all times and kept clear of obstructions.
7679306 - 1 - 10082017
17
3 Technical specifications
3.4
Electrical diagram
Fig.4
Electrical wiring diagram
A
M
B
C
D
E
N
F
g g
r
b w
M1
L
N
G
E
g
b g b
br bk br
r
g
b
g
r
b
r
b r
g
g
br
bk
b
X3
br
L
X23
X37
X36
X22
X20
br
10
M2
9
8
7
6 H
5
4
3
2
1
X24
X10
g/y
b
bk
w
P
X13
r
bk
bk
X31
b
b
br
br
X11
g/y
X12
X1
X2
g/y
g/y
g/y
I
K
J
O
PN-0000341
bk — black
br — brown
b — blue
r — red
w — while
g/y — green/
yellow
g — green
Key
Description
Key
Description
A
Gas valve
I
Spark ignition electrode
B
Hall effect sensor
J
Diverter valve motor
C
Flue sensor
K
Pump
D
Hydraulic pressure switch
L
Terminal strip
E
Heating return sensor
M
Fan
F
Heating flow sensor
N
Safety thermostat
G
DHW NTC sensor
O
Earth point on boiler chassis
H
M2 low voltage external control connection P
18
Printed circuit board (PCB)
7679306 - 1 - 10082017
4 Description of the product
4
4.1
Description of the product
General description
The Baxi Combi range are fully automatic gas fired wall mounted condens­
ing boilers. They are room sealed and fan assisted and will serve central
heating and mains fed domestic hot water.
Tab.15
Fig.5
Information label
The boiler is set to give a maximum output of :-
624 models
25 kW DHW
21.16 kW CH Pnc (Condensing)
630 models
30 kW DHW
21.16 kW CH Pnc (Condensing)
The boiler is factory set for use on Natural Gas (G20).
The boiler is suitable for use only on fully pumped sealed heating systems.
Priority is given to domestic hot water.
An information label giving details of the model, serial number and Gas
Council number is situated on the front middle underside of the outercase
and is accessed by swinging forward gently.
A
Information label
The boiler data badge is positioned on the control box and can be seen
when the outercase panel is removed.
A
PN-0000606
The boiler is intended to be installed in residential / domestic environments
on a governed meter supply only.
The boiler must be installed with one of the purpose designed flues such
as one of the standard horizontal telescopic flue kits detailed in the Flue
Accessories and Fitting Guide.
Important
All systems must be thoroughly cleansed, flushed and treated with
inhibitor.
Note
These installation and servicing instructions must be read in con­
junction with the Flue Accessories and Fitting Guide supplied in
the literature pack.
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 elec­
tronic 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 con­
denses 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 dis­
charged through a trap.
7679306 - 1 - 10082017
19
4 Description of the product
4.2.3
Central heating and domestic hot water production
In boilers used for heating and for producing domestic hot water, an inte­
grated 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.
4.2.4
Fig.6
Operating scheme (combi)
With a demand for heating the pump circulates water through the primary
circuit.
15
14
Once the main burner ignites the fan speed controls the gas rate to main­
tain the heating temperature measured by the temperature sensor.
16
17
When the flow temperature exceeds the set temperature, a 3 minute delay
occurs before the burner relights automatically (anti-cycling). The pump
continues to run during this period.
18
When the demand is satisfied the burner is extinguished and the pump
continues to run for a period of 3 minutes (Pump Overrun).
19
Key to components
20
21
23
13
12
22
11
8
10
1
7
9
5
3
6
4
2
A B
C D
Central heating mode
E
F
PN-0000309
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Pump with automatic air vent
Boiler drain tap
Pressure gauge
Safety pressure relief valve
DHW flow sensor / filter / restrictor
DHW priority sensor
DHW NTC sensor
Hydraulic pressure switch
Diverter valve and motor
Plate heat exchanger
Gas valve
Safety thermostat
Heating flow sensor
Flue sensor
Flue adaptor
Primary heat exchanger
Burner / door assembly
Electrode
Air / gas collector
Heating return sensor
Fan
Air / gas venturi
Expansion vessel
Key to connections
A
B
C
D
E
F
4.2.5
Condensate drain
Heating flow
DHW outlet
Gas inlet
Cold water inlet on/off valve and filter
Heating return
Domestic hot water mode
Priority is given to the domestic hot water supply. A demand at a tap or
shower will override any central heating requirement.
The flow of water will operate the Hall Effect Sensor which requests the
diverter valve to change position. This will allow the pump to circulate the
primary water through the DHW plate heat exchanger.
20
7679306 - 1 - 10082017
4 Description of the product
The burner will light automatically and the temperature of domestic hot wa­
ter is controlled by the temperature sensor.
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.
4.2.6
Frost protection mode
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 per­
manent live is left on to give boiler frost protection.
When the boiler temperature falls below 5° C, the boiler will fire until a
temperature of 30° C is reached.
Important
This will not protect the system !
Further protection can be incorporated by using a system frost thermostat.
4.2.7
Pump protection
If the boiler has been inactive for a period of 24 hours the pump will auto­
matically operate for 1 minute to prevent sticking.
7679306 - 1 - 10082017
21
4 Description of the product
4.3
Main components
4.3.1
Fig.7
List of components
Component descriptions
17
2
9
3
8
22
1
10
7
11
5
16
6
Fig.8
PN-0000612
Hydraulic layout
18
19
4
23
15
20
12
21
13
14
PN-0000388
Tab.16
Component descriptions
Key
Description
Key
Description
Key
Description
1
Expansion vessel
9
Flue sensor
17
Flue adaptor
2
Expansion vessel valve
10
Spark ignition electrode
18
Heating flow sensor
3
Primary heat exchanger
11
Control box
19
Safety thermostat
4
DHW plate heat exchanger (not 12
on System Models)
Condensate trap
20
Water Pressure Switch
5
Pump with automatic air vent
13
Safety pressure relief valve
21
Condensate outlet
6
CH system pressure gauge
14
Gas valve
22
Silencer
7
Fan assembly
15
Diverter valve motor (not on
System Models)
23
Hall effect sensor (not on Sys­
tem Models)
8
Burner / door assembly
16
Boiler controls
22
7679306 - 1 - 10082017
4 Description of the product
4.4
Control panel description
4.4.1
Fig.9
Control panel
1
1
2
3
4
5
6
2
R
Mi n
Description of the control panel
Display
Reset button
Central heating temperature control
Service diagnostic port
DHW temperature control
System water pressure gauge
Min
Reset
2
1
3
4
0
bar
M
M
x
a
a
x
3
4
5
6
PN-0000607
Fig.10
Display screen
Display description
The following symbols may be seen on the display
OFF (frost protection still enabled)
R
Indicates errors that prevent the burner from starting
Error — not resettable by user
Water pressure too low
Indicates a resettable error
R
Not applicable
Not applicable
Generic error
Burner lit
DHW request
Heating mode
Units for temperature
Units for pressure
PN-0000336
4.5
Standard delivery
4.5.1
Contents of the carton
The boiler is delivered in a carton comprising:
Wall hung gas boiler
Wall bracket for fastening the boiler to the wall
Clipping bracket for running pipes upwards
Fitting kit, including taps
Literature pack containing:
Installation and service manual
User guide manual
Template
Flue accessories fitting guide
Warranty documentations
ErP product and package leaflets
System additives leaflets
Important
These installation and service instructions MUST be read in con­
junction with the flue accessories fitting guide supplied in the liter­
ature pack.
7679306 - 1 - 10082017
23
4 Description of the product
4.6
Accessories and options
4.6.1
Optional accessories
The table shows the accessories available for this boiler range.
Tab.17
Optional accessories
Part number
Accessory
7212438
Baxi single channel wired programmable room thermostat
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
5121379
Multifit remote secondary PRV kit
248221
Multifit filling loop
7682790
Multifit rear pipework kit
7682545
Multifit pre-plumbing jig
7209714
Multifit wall mounted 24 hour timeclock
720030501
RF Single Channel Room Thermostat
7212444
Single channel wired timer
For flue accessories (elbows, extensions, clamps etc.) refer to the Flue Ac­
cessories Fitting 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
24
7679306 - 1 - 10082017
5 Before installation
5
5.1
Before installation
Installation regulations
Warning
Installation, repair and maintenance must only be carried out by a
competent person. This document is intended for use by compe­
tent persons.
Installation must be carried out in accordance with the prevailing regula­
tions, 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 (NG). In IE this is the current edition of IS 813 Do­
mestic 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 tak­
en into consideration. Do not use pipes of a smaller diameter than the boil­
er 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 Regula­
tions. 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.
7679306 - 1 - 10082017
25
5 Before installation
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 with­
stand 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 haz­
ardous 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/treat­
ment device the source utilised to fill or re-pressurise the system
must be upstream of such a device.
5.2.4
Bypass
The boiler utilises the primary side of the DHW plate heat exchanger as 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 ap­
propriate 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 wa­
ter 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 com­
ply 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.
26
7679306 - 1 - 10082017
5 Before installation
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 manufac­
turer. (Test kits are available from inhibitor stockists.)
For information or advice regarding any of the above contact Baxi Custom­
er Support 0344 871 1545.
5.2.7
Showers
If a shower control is supplied from the appliance it should be of the ther­
mostatic or pressure balanced type. Thermostatic type shower valves pro­
vide the best comfort and guard against water at too high a temperature.
Existing controls may not be suitable - refer to the shower valve manufac­
turer.
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 op­
eration for system capacities up to 120 litres. For greater system capaci­
ties an additional expansion vessel must be fitted.
For GB refer to BS 7074 Pt 1. For IE, the current edition of IS 813 Domes­
tic Gas Installations.
Checking the charge pressure of the vessel - to check the charge accu­
rately ensure the system is cold. It is also necessary to relieve the pres­
sure 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
Fig.11
Discharge pipe
1
2
A
Discharge pipe
Pressure relief valve
The end of the pipe should terminate facing down and towards the
wall
See
BS 6798 for full details.
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 and temperature in ex­
cess of 100°C.
2
A
Safety pressure relief valve
1
PN-0000604
The pressure relief discharge pipe should be not less than 15mm diame­
ter, run continuously downward, and discharge outside the building, pref­
erably 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 ac­
cess. 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.
7679306 - 1 - 10082017
27
5 Before installation
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 permit­
ting satisfactory removal of combustion products and providing an ade­
quate air supply. The boiler should be fitted within the building unless oth­
erwise 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 per­
manent 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 Engi­
neers Publication IGE/UP/7 (Gas Installations in Timber Framed Housing).
28
7679306 - 1 - 10082017
5 Before installation
5.3.2
Fig.12
Bathroom 1 and 2
B
A
B
C
D
E
F
D
Bath and shower rooms
Zone 0
Zone 1
Zone 2
Window recess Zone 2
Ceiling
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).
C
A
0.6m
Important
A boiler fitted with an optional plug-in integral timer, RF receiver or
thermostat CANNOT be fitted in any zone.
D
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.
E
D
In IE reference should be made to the current edition of IS 813 “Domestic
Gas Installations” and the current ETCI rules.
F
2.25m
B
C
A
0.6m
PN-0000400
5.3.3
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 in­
stalled in compartments. The appliance will run sufficiently cool without
ventilation.
7679306 - 1 - 10082017
29
5 Before installation
5.3.4
Fig.13
Pipework and method of termination
21.5mm
32mm
2
It is strongly recommended to discharge internally into the household
drainage system. If connecting to a rain water drain, that drain MUST dis­
charge into a foul drain.
1
2
3
4
5
6
7
5
A
8
9
10
11
12
3
4
Condensate drain
Pipework.
Insulation.
50mm per metre of pipe run — 2.5° minimum run.
450mm minimum is applicable to properties up to 3 storeys. For
multi-storey building installations consult BS 6798.
Boiler.
Sink.
Pipe must terminate above water level but below surrounding sur­
face. Cut end at 45°.
Holes in the soak-away must face away from the building.
500mm mimimum.
Basement or similar (heated)
Condensate pump
Unheated Location (e.g. Garage)
5
Tab.18
B
6
3
7
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.
5
C
3
7
5
D
9
3
Examples are shown of the following methods of termination
8
PN-0000389
30
7679306 - 1 - 10082017
5 Before installation
Fig.14
Methods of termination continued
6
3
7
10
5
E
11
3
12
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.
10
5
F
11
5
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.
G
3
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 pipe­
work being subject to freezing conditions and appropriate meas­
ures taken to prevent blockage. Correct installation in accordance
with this section will considerably minimise the likelihood of block­
age and subsequent boiler lock-out.
A condensate discharge pump and pipe "Trace Heating" are avail­
able 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 suita­
ble condensate pump in basement and cellar or similar applica­
tions.
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 discharge pipe should be run in a proprietary drain pipe material e.g.
PVC, PVC-U, ABS, PVC-C or PP.
7
Metal pipework is NOT suitable for use in condensate discharge systems.
PN-0000455
The pipe should be a minimum of 21.5mm diameter and must be suppor­
ted 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 ma­
terial suitable for external use.
If the boiler is fitted in an unheated location the entire condensate dis­
charge 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 conden­
sate. 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 sub­
jected 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 inter­
nally as detailed in the instructions provided.
The fitting of a "Trace Heating" Element is NOT a substitute for correct in­
stallation of the condensate drain. ALL requirements in this section must
still be adhered to.
7679306 - 1 - 10082017
31
5 Before installation
5.3.5
Fig.15
Clearances
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.
5
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.
390
5
178
In the diagram these are MINIMUM recommended dimensions. Greater
clearance will aid installation and maintenance.
700
200
285
450
5
PN-0000613
5.3.6
Flue/chimney location
The following guidelines indicate the general requirements for siting bal­
anced 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 Do­
mestic Gas Installations.
Important
Due to the nature of the boiler a plume of water vapour will be dis­
charged from the flue. This should be taken into account when sit­
ing the flue terminal.
Fig.16
Flue outlets
J,K
T
U
N
R
M
I
I
A
D
E
C
I
F
S
I
F
J,K
B
L
A
A
G
H
H
I
1
PN-0000456
1
Tab.19
Flue positions marked
require a flue terminal guard.
Terminal position with minimum distance
Key
Description
A (1)
B (1)
mm
Key
Description
mm
Directly below an opening, air brick open­ 300
ing window etc.
J
From a surface or boundary line facing 600
a terminal
Above an opening, air brick, opening win­ 300
dow etc.
K
From a terminal facing a terminal
(Horizontal flue)
1200
From a terminal facing a terminal (Ver­ 600
tical flue)
32
7679306 - 1 - 10082017
5 Before installation
Key
Description
mm
Key
Description
mm
C (1)
Horizontally to an opening, air brick,
opening window etc.
300
L
From an opening in carport (e.g. door, 1200
window) into the dwelling
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 300
ly)
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 displace­
ment 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 com­
bustion 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.
Fig.17
Property boundary
1
2
3
A
A*
2
Property boundary line
Terminal assembly
Top view rear flue
300mm minimum*
*Reduction to the boundary is possible down to 25mm but the flue deflec­
tor 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.
3
1
PN-0000457
7679306 - 1 - 10082017
33
5 Before installation
Fig.18
Plume displacement kit
1
2
3
A
3
Opening window or door
Air inlet
Plume displacement kit
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.
2
1
A
PN-0000458
5.3.7
Fig.19
Horizontal flues
Horizontal flue/chimney systems
1
2
3
1
315mm to 500mm
Flue trims
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.
2
The standard telescopic flue is suitable only for horizontal termination ap­
plications. 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 as­
sembly.
Tab.20
Maximum permissible equivalent flue lengths are:-
Horizontal concentric
3
C
A
60/100 Diameter
80/125 Diameter
10 metres
20 metres
Any additional "in line" bends in the flue system must be taken into consid­
eration.
B
3
Tab.21
(i)
(ii)
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.
PN-0000459
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.
34
7679306 - 1 - 10082017
5 Before installation
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.
5.3.8
Fig.20
Flexible flue trims
Flue/chimney trim
The flexible flue trims supplied can be fitted on the outer and inner faces of
the wall of installation.
PN-0000390
5.3.9
Fig.21
Terminal guard
Terminal guard
1
1
ENSURE THAT NO PART OF THE WHITE OUTER CHIMNEY
DUCT IS VISIBLE.
When codes of practice dictate the use of terminal guards Multifit accesso­
ry 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 ter­
minal and the guard.
When ordering a terminal guard, quote the appliance name and model
number.
PN-0000460
The flue terminal guard should be positioned centrally over the terminal
and fixed as illustrated.
5.3.10
Fig.22
Flue deflector
1
1
Flue/chimney deflector
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.
PN-0000461
5.3.11
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.
5.4
Transport
This product should be lifted and handled by two people. When lifting al­
ways keep your back straight and wear protective equipment where nec­
7679306 - 1 - 10082017
35
5 Before installation
essary. Carrying and lifting equipment should be used as required. e.g.
when install in a loft.
5.5
Unpacking & initial preparation
5.5.1
Fig.23
Unpacking the boiler
Unpacking
Caution
RISK ASSESSMENT - Before commencing the installation it is
recommended that the "Five Steps to Risk Assessment" docu­
ment published by the HSE is consulted, and an assessment per­
formed 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.
To unpack the boiler:
1. Remove the banding and the cardboard sleeve.
2. Remove the polystyrene top piece and installation kit.
3. Snap off the rear part of the polystyrene bottom piece.
Important
Polystyrene base should be removed completely if fitting the boiler
into a space with minimum side clearances of 5 mm each side.
PN-0000345
Important
If removing the polystyrene base, the sealing caps can also be re­
moved at this stage. Care must be taken to avoid damage from
any residual water in the boiler.
5.5.2
Fig.24
Template
Clearance above 178mm
116mm Dia Minimum
Aperture For
Flue Tube
mm
50
150 mm
N
MI
Ø
Side Clearance 5mm
8m
m
Side Clearance 5mm
195.5mm
195.5mm
Pipework run to rear of boiler.
If it is desired to route pipework vertically behind the boiler the
5 position clip bracket must be used. This guides the gas pipe
and one of the DHW pipes to one side of the flue. They may be
set to the right or left. To engage in the bracket the gas pipe must
be offset by 70mm and the DHW by 35mm. Compression fittings
cannot be used behind the boiler. The use of 90o elbows is not
recommended. The clip bracket is retained using the same screws
that fasten the wall plate in position. DO NOT ROUTE THE PRV
OR CONDENSATE DISCHRGE UPWARDS !
Pipe Profiles. (Where copper tails are not supplied with the boiler)
To ensure that the vertical pipework is at the optimum distance (whether
piping up or down) make up in accordance with these exactly sized profiles.
This leg into tap
22mm CH F & R
22mm Gas
This leg into tap
15mm DHW
In/Out
Clip
Bracket
View from
under boiler
Condensate
Safety Pressure Relief
Primary Drain
Wall
Condensate
Drain
Pressure
Relief
Initial preparation
1. After considering the site requirements position the fixing template
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.
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 the wall plugs supplied.
Secure the wall plate using the fixing screws.
7. Using a spirit level ensure that the plate is level before finally tight­
ening the screws.
Ø 22mm
65mm
Heating
Flow
(22mm)
65mm
65mm
Hot Water
Outlet
(15mm)
Combi Only
Not System
65mm
Cold Water
Inlet
(15mm)
Gas
(22mm)
Heating
Return
(22mm)
Combi Only
Not System
Clearance below
200mm
7664094-02
PN-0000346
36
7679306 - 1 - 10082017
5 Before installation
5.6
Connecting diagrams
5.6.1
Fig.25
"Easy-Fill" permanent filling link
Filling information
The Baxi 600 Combi is supplied with an "Easy-Fill" permanent filling link.
The permanent filling link is a device to allow filling and repressurising of
the heating system. The link has been tested and approved to be left con­
nected after use. It is not necessary to remove any temporary loop or oth­
er part of the device after filling and repressurising.
Filling & repressurising is achieved by the operation of a spring loaded
green lever incorporated in the cold mains inlet part of the link. Full fitting
and operating instructions are included with the permanent filling link.
If not using the "Easy-Fill" permanent filling link normal regulations apply.
PN-0000633
Fig.26
System filling circuit
D
C
A
B
C
D
E
C
Domestic hot water mains inlet
Central heating return
Stop valve
Double check valve (Not supplied)
Loop (Temporary or Permanent)
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.
E
A
B
The filling method adopted must be in accordance with all relevant water
supply regulations and use approved equipment.
PN-0000347
Your attention is drawn to:
for GB: Guidance G24.2 and recommendation R24.2 of the Water Regu­
lations Guide.
for IE: the current edition of I.S. 813 Domestic Gas Installations.
A
B
Cold mains in
Heat return
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 pre­
vention device is permanently connected at the inlet to the circuit and the
temporary connection is removed after use.
When the optional permanent filling link is fitted it is not necessary to re­
move any part of it after filling or re-pressurising.
5.6.2
Fig.27
Circuit plan
A
B
C
D
E
F
G
G
B
A
C
D
Domestic hot water circuit
Boiler
Expansion vessel
Check valve
Pressure reducer
Stop tap
To hot tap
Other tap outlets
All DHW circuits, connections, fittings, etc. should be fully in accordance
with relevant standards and water supply regulations.
F
E
Your attention is drawn to:
PN-0000350
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.
7679306 - 1 - 10082017
37
5 Before installation
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 pre­
vention device as any thermal expansion is accommodated within the ap­
pliance. It is possible in certain circumstances that other cold water de­
mands (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-re­
turn backflow prevention device, or any other device that includes
one*, it is possible for a build-up of pressure to occur. This may re­
sult 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 recom­
mendations are not followed.
The boiler’s maximum working mains pressure is 8 bar, therefore all pipe­
work, 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.
38
7679306 - 1 - 10082017
6 Installation
6
Installation
6.1
General
Mounting the boiler
Fig.28
Installation must be carried out in accordance with the prevailing regula­
tions, 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 open­
ings.
Caution
Where the boiler is sited in an unheated enclosure provision must
be made to protect against frost, e.g. frost thermostat, pipe ther­
mostat.
b
1. Lift the boiler by gripping "a" and "b" and hook the boiler onto the wall
plate.
2. Remove the polstyrene bottom piece by slipping it off downwards.
a
c
PN-0000614
Fig.29
3. Remove the sealing caps from the boiler connections under the boiler
(including the condensate trap).
c
Sealing caps
Warning
Some residual water may escape when removing the sealing
caps. Take precautions to avoid damage to components !
4. Remove the taps, elbow and sealing washers from the fitting kit. The
taps and elbow accept the 15mm or 22mm copper tails supplied.
5. Using the sealing washers provided connect the appropriate tap to the
heating flow and return, gas supply and mains cold inlet. Connect the
elbow to the DHW flow outlet.
6. Always fit the tap with the drain point to the heating flow.
7. Ensure all joints are tight.
Important
Connect the pressure relief discharge pipe first before any other
pipework.
PN-0000630
6.2
Assembly
6.2.1
Fig.30
Pressure relief pipe connection
Fitting the pressure relief discharge pipe
1. The valve and discharge pipe are assembled to the boiler, terminat­
ing in a threaded male coupling.
2. Determine the routing of the discharge pipe in the vicinity of the boil­
er. Make up as much of the pipework as is practical, including the
15mm elbow and nut 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.
PN-0000632
7679306 - 1 - 10082017
3. The pipework must be at least 15mm diameter and run continuously
downwards to a discharge point outside the building.
4. Complete the discharge pipework and route it to the outside dis­
charge point.
5. The pipework must be clipped at suitable intervals to support it, com­
mencing as close to the boiler as possible.
39
6 Installation
6.2.2
Fig.31
Pour 300ml of water into flue spigot
Connecting the condensate drain
1. Remove the blanking cap, and using the straight rubber coupling
supplied, connect the condensate drain pipework to the boiler con­
densate trap outlet pipe.
See
Ensure the discharge of condensate complies with any national or
local regulations in force (see HHIC recommendations).
See
Condensate drain, page 30.
2. The straight rubber coupling will accept 21.5mm (3/4 in) plastic over­
flow pipe which should generally discharge internally into the house­
hold drainage system. If this is not possible, discharge into an out­
side drain is acceptable.
PN-0000602
Important
The boiler condensate trap should be primed by pouring approxi­
mately 300ml of water into the flue spigot. Do not allow any water
to fall into the air inlet.
6.3
Air supply/flue gas connections
6.3.1
Fig.32
Telescopic flue
Connecting the flue/chimney
HORIZONTAL TELESCOPIC FLUE (concentric 60/100)
1
2
3
1
315mm to 500mm
Connection assembly
Terminal assembly
There are two telescopic sections, the terminal assembly and the connec­
tion assembly, a roll of sealing tape and two self tapping screws. A 93° el­
bow is also supplied.
3
2
PN-0000462
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.
Fig.33
Flue dimension X
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.
X
X
PN-0000463
40
7679306 - 1 - 10082017
6 Installation
Fig.34
Flue dimension Y
1
4
2
Y
1
3
PN-0000464
Fig.35
Attaching the flue
C
4
4
A
3
B
1
2
5
PN-0000465
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.
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, ap­
propriate 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.
7679306 - 1 - 10082017
41
6 Installation
6.4
Electrical connections
See
Electrical supply, page 25 for details of the electrical supply.
Warning
Check that the total nominal consumption of the accessories con­
nected 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
Fig.36
Making the electrical connection
Remove terminal cover
Low Voltage
Controls
(OpenTherm)
1
2
3
Outdoor
Weather
Sensor
M2
4
5
6
7
H
8
9
10
1
2
3
4
G
M1
5
PN-0000395
Important
When fitting external controls remove the yellow link wire from the
Mains Terminal Block M1.
Note
Consideration must be given to Health and Safety Document 635
(The Electricity at Work Regulations, 1989).
1. Remove the front panel.
See
Specific maintenance instructions, page 57 to remove the front
panel.
2. Hinge down the control box and unclip the terminal block cover.
3. Slacken both gland nuts in the bottom of the boiler lower panel and
insert the mains cable and the external control system cable through
them.
4. Leave sufficient slack in the cables to allow the control box to be
hinged fully open. Tighten both gland nuts.
42
7679306 - 1 - 10082017
6 Installation
Fig.37
Typical electrical connections
D
A
ELN
A
N
B
ELN
B
N
G
F
230V
G
b 1
b 1
bk 2
230V
230V
g/y
E
C
E
b
N
N
br
L
L
bk 2
g/y
b
br
PN-0000396
5. Connect the earth, permanent live and neutral wires to the terminal
block.
Note
Both the permanent live and neutral connections are fused.
Key
Description
Key
Description
A
Fused Spur
b
Blue
B
Room Thermostat
bk
Black
C
External Clock
br
Brown
D
Frost Thermostat
g/y
Green/Yellow
F
Pipe Thermostat
E
Earth
G
Mains Terminal Block M1
N
Neutral
H
Low Voltage Terminal Block M2
L
Live
6.
7.
8.
9.
Refer to the instructions supplied with the external control(s).
Remove the link between terminals 1 and 2.
The 230V supply at terminal 2 must be connected to the thermostat.
The switched output from the thermostat must be connect to termi­
nal 1.
Important
The 230V switched signal for external controls (frost thermostat —
room thermostat — timer) must always be taken from terminal 2 at
the boiler. Live, Neutral and Earth to power these controls must be
taken from the Fused Spur.
10. Reclip the terminal block cover back into position and hinge back the
control box.
Important
When an OpenTherm controller is connected adjustment of the
boiler, e.g. heating temperature, is made using the OpenTherm
controller rather than the boiler controls. The boiler controls are
overridden by the OpenTherm control. Please check the function­
ality with the manufacturer of the OpenTherm controller.
Preliminary electrical checks
Prior to commissioning the boiler preliminary electrical system checks
should be carried out.
7679306 - 1 - 10082017
43
6 Installation
These should be performed using a suitable meter, and include checks
for Earth Continuity, Resistance to Eart, Short Circuit and Polarity.
6.4.2
Fig.38
Sensor position
Connecting outdoor sensor
The sensor must be fixed to an external wall surface of the property it is
serving. The wall must face north or west. Under no circumstance must it
be fixed to a south facing wall in direct sunlight.
The sensor must be positioned approximately at half the height of the liv­
ing space of the property, and a minimum of at least 2.5 metres above
ground level.
To ensure accurate operation do not position the sensor in the proximity of
any heat or cooling source (e.g. a flue terminal). Siting above doors & win­
dows, adjacent to vents and close to eaves should be avoided.
1/2 H
2.5m Min
H
West
North
N
W
E X
S X
PN-0000626
44
1. Once the position has been determined, prise the cover off the sen­
sor and mark through the sensor body the two fixing holes and the
larger hole for the wiring.
2. Drill & plug the two fixing holes (plugs and screws are supplied with
the sensor). Also drill the hole for the sensor wiring.
3. Insert the sensor wiring through the hole in the wall, leaving suffi­
cient length outside to allow connection. Seal the hole. Note: 0.5mm
2 core cable is recommended (the sensor is a low voltage device).
This wiring is NOT supplied in the kit.
4. If it is not possible to pass the wiring through the wall directly behind,
remove the circular ‘knock-out’ panel in the sensor base to allow
connection.
5. Using the screws provided fit the body to the wall. Insert the wires in
the two-way terminal block and secure them. Replace the sensor
cover.
6. Ensure the electrical supply to the boiler is isolated and remove the
front panel.
7. Hinge down the control box and unclip the terminal block cover.
8. Pass the wires from the sensor through one of the gland nuts in the
bottom of the boiler lower panel, leaving sufficient slack to allow the
control box to be hinged fully open. Tighten the nut.
9. Connect the wires from the sensor to positions 4 & 5 of low voltage
terminal block M2. Refit the cover and front panel.
10. Reinstate the electrical supply to the boiler.
11. From the graph determine which is the most appropriate curve for
the installation and the expectations of the user. For example if
curve 50 is selected, at an outside temperature of 10°C the boiler
flow temperature will be 65°C. In the event of the outside tempera­
ture falling to 0°C the boiler flow will increase to 85°C.
7679306 - 1 - 10082017
6 Installation
6.4.3
Identifying label
Important
The identifying label (7221476-01) supplied with the outdoor sen­
sor must be signed and affixed on or adjacent to the boiler. The
label must be readily accessible without removing the boiler cas­
ing or any other disassembly. This label is required to enable SAP
and energy assessors to identify that a weather compensation de­
vice is installed and connected .
6.4.4
Fig.39
Outdoor sensor graph
Graph showing available curves
90 80 70
60
50
40
30
85°
80°
75°
70°
20
65°
60°
55°
50°
10
45°
40°
35°
00
30°
20°
15°
10°
5°
0°
-5°
-10°
-15°
-20°
PN-0000627
There are 9 available curves. It is essential that expected outdoor temper­
atures and the user requirements are considered before selecting the
curve.
Boiler flow temperature is shown on the vertical axis. The outside tempera­
ture is along the horizontal axis.
6.4.5
Fig.40
Control knob and setting curve
00
10
Min
20
30
40
ax
M
50
90
1. Ensure that there is power to the boiler (though it is not necessary
for there to be any heating demand).
2. The central heating control knob should be turned clockwise to the
position which corresponds with the desired curve as shown on the
graph.
3. Curve 50 is recommended as the most suitable for the normal range
of conditions expected in the UK. Consider the type of dwelling and
discuss with the user their requirements — one of the other curves
may be more appropriate.
4. 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
curve.
5. Once the curve is set the installation and commissioning of the boil­
er can be completed.
Note
Explain to the user how to select a different temperature curve
and how the outdoor sensor regulates the boiler flow temperature.
60
80
Setting outdoor sensor curve
70
PN-0000628
Important
When an OpenTherm controller is connected adjustment of the
boiler, e.g. heating temperature, is made using the OpenTherm
controller rather than the boiler controls. The boiler controls are
overridden by the OpenTherm control. Please check the function­
ality with the manufacturer of the OpenTherm controller.
7679306 - 1 - 10082017
45
6 Installation
Fig.41
Example — setting to curve 50
Min
ax
M
Curve 50
PN-0000629
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. 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 Wa­
ter Regulations Guide.
for IE: the current edition of I.S. 813 "Domestic Gas Installa­
tions" .
2. The sealed primary circuits may be filled or replenished by means of
a temporary connection between the circuit and a supply pipe, provi­
ded 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.
3. 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 cir­
cuit.
Remove the temporary connection after use except if where a per­
manent connection is used.
6.5.3
Filling the condensate trap
1. Check that the boiler condensate trap has been primed before com­
missioning the boiler.
46
7679306 - 1 - 10082017
7 Commissioning
7
7.1
Commissioning
General
Reference should be made to BS:EN 12828, 12831 & 14336 when com­
missioning the boiler. Ensure that the condensate drain trap has been
primed.
At the time of commissioning, complete all relevant sections of the Bench­
mark 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
Note
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
Checked:
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.
7679306 - 1 - 10082017
47
7 Commissioning
7.3
Commissioning procedure
7.3.1
Fig.42
Setting de-aeration
Before turning on the power to the boiler, rotate the CH control knob (
fully anticlockwise.
R
Mi n
Reset
2
1
3
4
0
bar
M
M
a
a
x
Mi n
R
Ma
x
R
Mi n
)
The purpose of the function is to remove as much air as possible from the
heating system. To assist this it is essential that all precautions are taken
to remove air manually before enabling the function. Ensure that all radia­
tors are fully bled, starting on the lowest floor in properties of more than
one storey. Any high points in the system should be fitted with a suitable
venting device. On the boiler’s first power up de-aeration lasts approxi­
mately 7 minutes. The boiler will not operate during this process.
Min
x
De-Aeration function
x2
Ma
x
PN-0000608
1. Turn on the power to the boiler. The display shows "000" .
2. Turn the CH control knob ( ) 1/4 turn clockwise twice in quick succes­
sion (within 2 seconds).
3. Display shows "312" while de-aeration is taking place (approximately
7 minutes).
4. When de-aeration has completed, the display will show the primary
flow temperature and both the CH ( ) and DHW ( ) symbols.
Important
If during the first commissioning process the power to the boiler is
interrupted the de-aeration function will re-start automatically at
the point which it stopped once power is restored.
Caution
If the system is drained in the future (even partly, when replacing
a radiator for example) the de-aeration function must be repeated.
Also the inhibitor concentration must be checked and replenished
if necessary.
7.4
Gas settings
7.4.1
Gas meter to valve
Note
If the pressure drops are greater than shown in the diagram oppo­
site, a problem with the pipework or connections is indicated. Per­
missible pressure drop across system pipework ≤ 1mbar. Carry
out chimney sweep.
RQ
ADJ.
VENT
P. OUT
Fig.43
EV2
17-21 mbar
Check the operational (working gas inlet pressure and
gas rate)
1
2
3
EV1
4
A
See
Checking combustion - chimney sweep mode, page 49.
18-22 mbar
19-23 mbar
PN-0000361
48
7679306 - 1 - 10082017
7 Commissioning
Fig.44
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 18mb !
2. Ensure that this inlet pressure can be obtained with all other gas ap­
pliances in the property working. The pressure should be measured
at the gas test point on the gas inlet (A).
3. Measure the gas rate— With any other appliances & pilot lights
turned OFF the gas rate can be measured. It should be:-
A
PN-0000362
Tab.22
7.4.2
Fig.45
Flue adaptor test points
Natural gas
624 model
2.71 m3/h
630 model
3.26 m3/h
Checking combustion - chimney sweep mode
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
1
2
2
PN-0000363
Combustion test point
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.
7679306 - 1 - 10082017
49
7 Commissioning
Warning
Ensure that both flue test point plugs are in place after checking
combustion.
Fig.46
Setting maximum and minimum output
Setting chimney sweep mode
R
Mi n
Min
Reset
2
1
3
4
0
bar
M
M
x
a
a
x
[
Min
Min
M
Measuring the combustion
Turn on the domestic hot water tap. Carry out inlet working gas pressure
gas rate and combustion checks.
x
a
a
M
x
1. Turn both control knobs fully anticlockwise and leave for 10 sec­
onds.
2. Turn the DHW knob ( ) 1/ 4 turn twice in quick succession (within 2
seconds).
3. "304" will appear in the display.
4. Turn the CH knob ( ) fully clockwise. "100" will appear in the dis­
play, indicating maximum output.
5. After checking at maximum turn the CH knob ( ) fully anticlock­
wise. "0" will appear in the display, indicating minimum output.
Once all relevant tests are completed, take out of chimney sweep mode by
turning the DHW control knob clockwise.
R
Boiler is now ready to use.
Min
M
a
x
Min
M
a
x
PN-0000609
50
7679306 - 1 - 10082017
7 Commissioning
Fig.47
Combustion procedure
Set Boiler to Maximum Rate
Allow the combustion to
stabilise. Do not insert probe
to avoid ‘flooding’ the analyser.
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% ?
Perform Flue Integrity
Combustion Check
Insert the analyser probe into
the air inlet test point, allowing
the reading to stabilise.
No
Is O2 ≥ 20.6% and
CO2 < 0.2% ?
Yes
Yes
No
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 ?
Yes
No
TURN APPLIANCE OFF !
Call 0344 871 1545 for
advice.
The appliance MUST NOT
be commissioned until all
problems are identified
and resolved.
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 ?
No
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.
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 ?
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
7679306 - 1 - 10082017
51
7 Commissioning
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 48.
Once De-Aeration is complete recommission the boiler and check that the
inhibitor concentration is sufficient.
7.6
Final instructions
7.6.1
Fig.48
People
Handover
1. Carefully read and complete all sections of the Benchmark Commis­
sioning 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 in­
complete.
PN-0000333
52
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 Instruc­
tions, 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 Bench­
mark Commissioning Checklist.
6. Set the central heating and hot water temperatures to the require­
ments 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.
7679306 - 1 - 10082017
8 Operation
8
Operation
8.1
Use of the control panel
8.1.1
Control panel
The controls are operated by the control knobs and a reset button.
Fig.49
Control panel
1
1
2
3
4
5
6
2
R
Mi n
Min
Reset
2
1
3
4
0
bar
M
M
x
a
a
x
3
4
5
6
PN-0000607
8.2
Display screen
Reset button
CH temperature control knob
Service diagnostic port
DHW temperature control knob
System water pressure gauge
Important
When an OpenTherm controller is connected adjustment of the
boiler, e.g. heating temperature, is made using the OpenTherm
controller rather than the boiler controls. The boiler controls are
overridden by the OpenTherm control. Please check the function­
ality with the manufacturer of the OpenTherm controller.
Start up
If there is no power to the boiler, switch on at the fused spur unit and en­
sure that the time control is in the on position and any other controls (e.g.
room thermostat) are calling for heat. The boiler will begin its start se­
quence. This procedure performs a series of tests, after which the installa­
tion is purged (this takes approximately five minutes).
8.3
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:
Any parts of the system that are in unheated areas of the dwelling
should be fitted with a device such as a pipe thermostat or frost thermo­
stat.
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 pro­
tect the boiler and to some extent adjacent parts of the system but addi­
tional devices must be incorporated to guarantee frost protection.
7679306 - 1 - 10082017
53
9 Maintenance
9
9.1
Maintenance
General
Warning
When changing components ensure that both the gas and electri­
cal 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.
Warning
After servicing or performing any maintenance on the boiler en­
sure that
Both flue test point plugs are in place
The front cover is correctly fitted
The front cover securing screws are fully tightened
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 ex­
ceeding 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 inter­
pretation 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 an­
alyser 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 49 for details.
54
7679306 - 1 - 10082017
9 Maintenance
Flue adaptor test points
Fig.50
Remove the plug from the combustion test point, insert the analyser probe
and obtain the CO/CO2 ratio. This must be less than 0.004. If the combus­
tion 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.
1
1
2
2
Combustion test point
Incoming air for combustion test point
Warning
Ensure that both flue test point plugs are in place after checking
combustion.
PN-0000363
9.2
Standard inspection and maintenance operations
9.2.1
Annual Servicing
Warning
Ensure that the boiler is cool. Ensure that both the gas and electri­
cal supplies to the boiler are isolated.
Caution
Always examine any seals or gaskets, replacing where necessary.
Where a seal or gasket is supplied with a spare part it should be
used, irrespective of the condition of the original. Use only original
spare parts that are intended for use with this type of boiler.
Important
When performing any inspection or maintenance, personal protec­
tive equipment must be used where appropriate.
Fig.51
Remove the condensate trap
1. Ensure that both the gas and electrical supplies to the boiler are iso­
lated and that the boiler is cool.
2. Remove the case front panel and hinge down the control panel.
See
Specific maintenance instructions, page 57
PN-0000381
3. Disconnect the pipe from the top of the condensate trap and the
drain pipe from the condensate drain pipe connection. Undo the
screw securing the bracket and trap to the boiler lower panel.
4. Remove the trap. Take care not to spill any residual condensate on
the controls and P.C.B. Thoroughly rinse the trap and examine the
gasket on the trap base, replacing if necessary.
5. Remove the clip securing the gas feed pipe to the air/gas venturi on
the fan. Disconnect the pipe. Do not break the joint between the pipe
ang gas valve unless necessary.
6. Disconnect the electrode lead and the fan electrical plug.
7. Undo the four nuts retaining the burner / door assembly to the heat
exchanger.
8. Carefully draw the burner / door assembly forward and remove.
See
Checking the burner and cleaning the heat exchanger, page 56
9. Clean any debris from the heat exchanger and check that the gaps
between the tubes are clear.
10. Inspect the burner, insulation and position and condition of the elec­
trode, cleaning or replacing if necessary. Clean any dirt or dust from
the airbox.
7679306 - 1 - 10082017
55
9 Maintenance
11. Carefully examine all seals and gaskets, replacing if necessary.
Look for any evidence of leaks or corrosion and if found determine
and rectify the cause.
12. Reassemble in reverse order.
13. Complete the relevant Service Interval Record section of the Bench­
mark Commissioning Checklist at the rear of this publication and
then hand it back to the user.
9.2.2
Fig.52
Restore water pressure
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 pres­
sure if necessary.
PN-0000382
9.2.3
Checking the expansion vessel
Check the expansion vessel and recharge or replace it if necessary.
Check its pre-charge every year and restore the pressure to 1 bar if nec­
essary.
9.2.4
Checking the automatic air vent
Check that the boiler pump venting valve is working. In the event of a leak,
replace the valve.
9.2.5
Fig.53
Remove burner / door assembly
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
PN-0000394
13.
56
Checking the burner and cleaning the heat exchanger
Isolate the boiler from the gas & electrical supplies.
Remove the front panel.
Remove the silencer.
Disconnect the spark electrode lead and earth wire from the detec­
tion / spark electrode.
Remove the clip securing the gas feed pipe to the fan. Disconnect
the pipe.
Completely remove the combustion chamber / burner door assembly
by unscrewing the four M6 nuts and drawing it forwards to disen­
gage it from the heat exchanger..
Check that the detection/spark electrode is not worn. Replace the
electrode if necessary.
Check the condition of the burner, the gasket and the insulation
board.
Any loose deposits in the heat exchanger should be removed using
a vacuum cleaner.
A brush with plastic bristles can be used to dislodge any stubborn
deposits, which should then also be removed by vacuum.
Do not use any chemicals to clean the heat exchanger.
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.
Reassemble in reverse order.
7679306 - 1 - 10082017
9 Maintenance
9.3
Fig.54
Specific maintenance instructions
Panel removal
Warning
When changing components ensure that both the gas and electri­
cal 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 font panel MUST seal effectively against the boiler side
panels.
To remove the case front panel proceed as follows:
Unscrew the two screws located on the bottom of the front panel.
Slide the bottom of the front panel forward and lift upwards to disengage
the panel.
Hinge down the control panel.
PN-0000611
9.3.1
Fig.55
Remove detection/spark ignition
electrode
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 elec­
trode, noting its orientation.
3. Fit the new electrode with the sealing gasket.
4. Reassemble in reverse order.
PN-0000331
9.3.2
Fig.56
Remove NTC flue sensor
NTC flue sensor
1. Turn the sensor 90° anticlockwise to remove — it is a bayonet con­
nection.
2. Ease the retaining tab on the sensor away and disconnect the elec­
trical plug.
3. Fit new sensor and reassemble in reverse order.
PN-0000332
7679306 - 1 - 10082017
57
9 Maintenance
9.3.3
Fig.57
Remove flow and return sensors
Flow and return sensors
There is one sensor on the flow (red wires) and one sensor on the return
(blue wires).
1. After noting the position of each sensors, prise the sensor clip off the
pipe and disconnect the plug.
2. Connect the plug to the new sensor and ease the clip onto the pipe
in its original position.
PN-0000329
9.3.4
Fig.58
Removing safety overheat thermo­
stat
Safety overheat thermostat
1. Pull the two spade connections off the safety overheat thermostat.
2. Remove the screws securing the thermostat to the mounting plate
on the flow pipe and remove it.
3. Fit the new safety overheat thermostat to the mounting plate with the
two screw previously removed.
4. Connect the two spade connections to the safety overheat thermo­
stat ensuring that they are pushed fully on.
PN-0000328
9.3.5
Fig.59
Remove DHW temperature sensor
DHW temperature sensor (NTC)
1. Turn off the mains cold water supply tap and draw off the residual
domestic hot water.
2. Ease the retaining tab on the sensor away and disconnect the elec­
trical plug.
3. Unscrew the sensor from the plate heat exchanger manifold. Exam­
ine the sealing washer, replacing if necessary.
4. Reassemble in reverse order with the new sensor. The plug will only
fit one way.
PN-0000330
9.3.6
Pressure Gauge
1. Drain the primary circuit and undo the nut on the pressure gauge ca­
pillary.
2. Ease the two retaining tabs holding the pressure gauge bracket
away and remove the bracket.
3. Remove the gauge assembly.
4. Examine the sealing washer on the pressure gauge capillary, re­
place if necessary.
5. Reassemble in reverse order with the new pressure gauge.
58
7679306 - 1 - 10082017
9 Maintenance
9.3.7
Fig.60
Remove hall effect sensor
Hall effect sensor
1. Ease the sensor upwards off the hydraulic inlet manifold assembly.
2. Disconnect the electrical plug from the sensor.
3. Connect the plug to the new sensor. Carefully fit the new sensor to
the hydraulic assembly, ensuring it is fully down.
PN-0000314
9.3.8
Fig.61
Remove flow regulator and filter
DHW flow regulator and filter
1. Close the cold mains inlet and draw off any residual DHW.
2. Pull off the hall effect sensor.
3. Unscrew the filter assembly from the inlet / return manifold.
PN-0000313
9.3.9
Fig.62
Remove safety pressure relief valve
2
1
Safety pressure relief valve
1
Safety pressure relief valve
2
"O" ring seal
3
Sealing grommet
4
Discharge pipe
5
Grub screw
3
4
5
PN-0000312
7679306 - 1 - 10082017
1. Drain the primary circuit.
2. Disconnect the discharge pipe from the valve and remove the seal­
ing grommet.
3. Using a suitable hexagon key undo the grub screw sufficiently to re­
lease the valve.
4. Note the orientation of the valve, rotate it and withdraw it from the
manifold.
5. Fit the new valve and ‘O’ ring seal and set to the previously noted
orientation. Tighten the grub screw.
6. Reconnect the discharge pipe ensuring the sealing grommet is in
place to maintain the integrity of the case seal.
59
9 Maintenance
9.3.10
Fig.63
Remove diverter valve
Diverter valve motor
1. Disconnect the multi-pin plug from the diverter valve motor.
2. Hold the motor in place against the spring pressure of the valve as­
sembly, remove the securing clip.
3. Remove the motor.
4. When fitting the new motor it will be necessary to hold the unit firmly
while depressing the valve assembly spring to refit the securing clip.
5. Reconnect the multi-pin plug.
PN-0000311
9.3.11
Fig.64
Remove expansion vessel
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 boiler primary
circuit.
2. Relieve the pressure from the expansion vessel.
3. Remove the silencer.
4. 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.
5. 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 ves­
sel.
PN-0000378
Important
Where the hose is found to be blocked, it must be cleared or re­
placed and the vessel recharged to 1 bar.
6. If the hose is clear support the vessel, undo the locknut and ma­
noeuvre the vessel out of the boiler.
7. Replace the expansion vessel with the new one and reassemble in
reverse order and recharge to 1 bar.
9.3.12
Tab.23
Gas valve
Characteristics of combustion
Baxi Combi
CO2
Diameter of coaxial discharge pipes
60
624
630
% (maximum)
9.0 + 0.3 – 0.2
9.0 + 0.3 – 0.2
% (minimum)
8.5 + 0.1 – 0.4
8.5 + 0.1 – 0.4
60/100 & 80/125
60/100 & 80/125
mm
7679306 - 1 - 10082017
9 Maintenance
Fig.65
Removing the gas valve
Important
After replacing the gas valve the CO2 must be checked and adjus­
ted. Only change the valve if a suitable calibrated combustion an­
alyer is available, operated by a competent person.
1. Undo the screw and disconnect the electrical plug.
2. Turn the gas cock off and undo the nut on the gas valve inlet under­
neath the boiler.
3. Undo the nut on the gas valve outlet. Ease the pipe aside.
Important
The gas nozzle injector is inserted in the gas valve outlet.
4. Remove the screws securing the gas valve to the boiler bottom pan­
el. Remove the valve.
5. Transfer the gas nozzle injector to the new valve, ensuring it sits in
the valve outlet. Examine the sealing washers, replacing if necessa­
ry.
6. Reassemble in reverse order.
Important
Check gas tightness and combustion.
PN-0000308
7679306 - 1 - 10082017
61
9 Maintenance
Fig.66
Setting the gas valve (CO2)
Setting the gas valve
Important
The CO2 must be only checked and adjusted to set the valve if a
suitable calibrated combustion analyser is available, operated by a
competent person.
R
Min
Min
Reset
2
1
3
4
0
See
Annual Servicing, page 55
bar
M
M
x
a
a
x
[
Min
Min
M
x
a
a
M
x
Mi n
R
M
a
x
1
2
A
RQ
ADJ.
VENT
1
Combustion test point
2
Incoming air for combustion test point
A
Throttle Adjustment Screw
B
Offset Adjustment Screw
5. Remove the plug from the flue sampling test point. Insert the analyser
probe and allow sufficient time for the reading to settle.
Baxi Combi
P.
P. OUT
ADJ
.
R.
B
1. The combustion (CO2) may be checked after running the boiler for
several minutes. To do this it is necessary to set the boiler to "Calibra­
tion Mode" .
2. Ensure that all external controls are calling for heat. The actual current
boiler temperature is shown on the display.
3. Turn both control knobs fully anticlockwise, then quickly turn the right
hand knob 1/4 clockwise twice and back in quick succession (within 2
seconds). "304" will appear in the display screen.
4. Turn the left hand knob fully clockwise. "100" will appear in the display
screen, indicating maximum output.
EV2
1
CO2
2
3
EV1
4
Mi n
M
a
x
PN-0000610
% (maximum)
624
630
9.0 + 0.3 – 0.2
9.0 + 0.3 – 0.2
6. It is possible to alter the CO2 by adjustment of the gas valve. Remove
the plastic cover from the Throttle Adjustment Screw. At maximum
rate the throttle adjustment screw should be turned, using a suitable
hexagon key, until the correct reading is obtained.
Turning clockwise will reduce the CO2.
Turning anticlockwise will increase the CO2.
7. The CO2 must then be checked at minimum rate. Turn the left hand
knob fully anticlockwise. As the knob is turned the display will change,
indicating the fan speed. When the display reads "0" the boiler runs at
minimum rate.
Baxi Combi
CO2
624
% (minimum)
630
8.5 + 0.1 — 0.4 8.5 + 0.1 — 0.4
8. With the boiler on minimum, the Offset Adjustment Screw must be al­
tered, using a suitable hexagon key, after removing the cap.
Turning clockwise will increase the CO2.
Turning anticlockwise will reduce the CO2.
9. The calibration function is maintained for 20 minutes unless the maxi­
mum central heating temperature is exceeded. The function can be
disabled at any time by turning the right hand knob.
10. Check the combustion performance (CO/CO2 ratio). This must be less
than 0.004.
62
7679306 - 1 - 10082017
9 Maintenance
Warning
Ensure that both flue test point plugs are in place after checking
combustion.
9.3.13
Fig.67
Remove pump head only
Pump - head only
To remove the pump head only.
1. Drain the boiler primary circuit and disconnect the electrical plug
from the pump
2. Remove the socket head screws securing the pump head to the
body and draw the head away.
3. Fit the new pump head and reassemble in reverse order.
PN-0000380
9.3.14
Pump - complete
Warning
Take precautions to protect other components from water damage
when removing the pump and auto air vent.
Fig.68
Remove pump
PN-0000379
7679306 - 1 - 10082017
1. Hinge the control box down.
2. Close the flow and return isolation taps and drain the boiler primary
circuit.
3. Disconnect the electrical plugs from the pump motor.
4. Prise off the securing clip that is holding the pump return pipe in po­
sition. Pull away the pipe.
5. Pull out the securing clip that is holding the pump body to the hy­
draulic inlet assembly.
6. Prise off the securing clip and disconnect the braided hose from the
pump body, taking care as water may still be in the hose.
7. Remove the screws securing the pump to the boiler bottom panel.
8. The pump should now be able to be remove.
9. Pull out the securing clip and remove the automatic air vent, trans­
fering it to the new pump body.
10. Examine all ‘O’ ring seals, replace if necessary and reassemble in
reverse order.
63
10 Troubleshooting
10 Troubleshooting
10.1
Error codes
10.1.1
Initial error fault finding checks
Check that gas, water and electrical supplies are available at the boiler.
Electrical supply = 230V ~ 50 Hz.
The minimum gas pressure at the meter is 19mb.
Carry out electrical system checks, i.e. Earth Continuity, Resistance to
Earth, Short Circuit and Polarity with a suitable meter.
Ensure all external controls are calling for heat and check all external
and internal fuses.
Important
These checks must be repeated after any servicing or fault find­
ing.
10.1.2
Fig.69
Display of error codes
(UURUFRGH
Display of error codes
If a fault occurs on the boiler an error code may be shown by the display
screen.
The codes are a flashing number, either two or three digit, preceded by
the symbol
:-
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*DVYDOYHFRQQHFWLRQFDEOH
*DVYDOYHIDXOW
&HQWUDOKHDWLQJ17&IDXOW
)OXH17&IDXOW
&HQWUDOKHDWLQJUHWXUQ17&IDXOW
&RPPXQLFDWLRQHUURU
3UHFLUFXODWLRQIDXOW
6DIHW\WKHUPRVWDWRSHUDWHG
3ULPDU\V\VWHPZDWHUSUHVVXUHWRRORZ
&LUFXODWLRQIDXOWSULPDU\
)ODPHIDLOXUH
)OXH17&RSHUDWHG
,QWHUUXSWLRQRIJDVVXSSO\RUIODPHIDLOXUH
,QWHUUXSWLRQRIJDVVXSSO\LQWHUQDOHUURU
)ORZUHWXUQVHQVRUWHPSHUDWXUHWHVW
)DQRUIDQZLULQJIDXOW
&LUFXODWLRQIDXOW'U\ILUH
+RWZDWHU17&IDXOW
)DOVHIODPH
followed by 20, 28, 40, 160 or 321 indicates possible faulty compo­
nents.
110 indicates overheat of the primary system water.
118 is displayed when the primary water pressure is less than 0.5
bar.
133, 134 and 135 indicates that the gas supply has been interrup­
ted, ignition has failed or the flame has not been detected.
128 is displayed if there has been a flame failure during normal op­
eration.
125 is displayed in either of two situations:If between 15 and 30 seconds of the burner lighting, the primary
water temperature has not changed by 1° C.
If within 10 minutes of the burner lighting, the primary water tem­
perature actual temperature twice exceeds the selected temper­
ature by 30°. In these instances poor primary circulation is indi­
cated.
By pressing the Reset button for 1 to 3 seconds when
09, 15, 110, 125,
128, 133, 134, 135, 384 are displayed it is possible to relight the boiler.
If this does not have any effect, or the codes are displayed regularly fur­
ther investigation is required.
PN-0000377
64
7679306 - 1 - 10082017
10 Troubleshooting
10.2
Fault finding
10.2.1
Fig.70
Central heating
Central heating — Follow operational sequence
Turn on mains power
The display illuminates
NO
If
09, 15, 110 or 384 is flashing or re-occurs
regularly, check all PCB connections. If this
has no effect replace the PCB.
Go to section ‘A’
YES
09, 15, 110, 125, 133,
134, 135 or 384 flashing
YES
Press the reset button for
1 to 3 seconds
If 110 is still flashing
go to section ‘H’
NO
20, 28, 40 or 321 flashing
YES
Go to section ‘D’
NO
YES
118 flashing
NO
Go to section ‘I’
Ensure controls are set to
demand and verify the
contacts are closed
NO
Set Central Heating
temperature to Maximum.
symbol flashing,
pump runs
NO
Ensure all controls and
programmers are calling
for heat
YES
Go to section ‘B’
YES
Fan runs after up to
3 minutes
NO
160 flashing
Go to section ‘C’
NO
160 flashing
Go to section ‘C’
YES
Fan runs at correct speed
YES
Spark at ignition electrodes
up to 5 seconds & for
3 attempts
NO
YES
YES
133 flashing
Go to section ‘F’.
Press the reset button
for 1 to 3 seconds
Go to section ‘E’
NO
Burner lights
YES
YES
Burner goes out after
5 seconds
128 flashing
Go to section ‘G’
YES
YES
109 flashing
Go to section ‘J’
125 flashing after 1 min
NO
YES
Go to section ‘H’
110 flashing
NO
Diverter valve open to
Central Heating circuit
NO
Go to section ‘K’
YES
Burner modulates to
maintain set temperature
NO
Check Heating flow sensor.
Go to section ‘D’
NO
YES
Go to section ‘M’
130 flashing
NO
Burner goes out
YES
Fan stops after 10 seconds
YES
Boiler operation correct
PN-0000315
See
Electrical diagram, page 18 for position of terminals and compo­
nents.
7679306 - 1 - 10082017
65
10 Troubleshooting
10.2.2
Fig.71
Domestic hot water
Domestic hot water — Follow operational sequence
Turn on mains power
The display illuminates
NO
If
09, 15, 110 or 384 is flashing or re-occurs
regularly, check all PCB connections. If this
has no effect replace the PCB.
Go to section ‘A’
YES
09, 15, 110, 125, 133,
134, 135 or 384 flashing
YES
Press the reset button for
1 to 3 seconds
If
110 is still flashing
go to section ‘H’
NO
20, 28, 40 or 321 flashing
YES
Go to section ‘D’
NO
YES
118 flashing
Go to section ‘I’
Go to section ‘L’
NO
NO
Set Hot Water temperature to
Maximum & fully open hot tap
NO
symbol flashing, pump
runs.
NO
DHW flow rate greater
than 2litres/min
YES
Fan runs after up to
3 minutes
Burner lights
YES
YES
NO
160 flashing
Go to section ‘C’
NO
160 flashing
Go to section ‘C’
NO
133 flashing
Go to section ‘L’
Go to section ‘B’
YES
Fan runs at correct speed
YES
Spark at ignition electrodes
up to 5 seconds & for
3 attempts
YES
YES
Go to section ‘F’.
Press the reset button for
1 to 3 seconds
YES
128 flashing
Go to section ‘G
’
Go to section ‘E
’
NO
Burner lights
YES
Burner goes out after
5 seconds
YES
109 flashing
YES
125 flashing after 1 min
Go to section ‘J’
NO
110 flashing
YES
Go to section ‘H’
NO
Diverter Valve open to
Domestic Hot Water circuit
NO
Go to section ‘K’
YES
Burner modulates to
maintain set temperature
NO
Check CH NTC sensor.
Go to section ‘D’
NO
130 flashing
YES
Go to section ‘M’
NO
Burner goes out
YES
Fan stops after 10 seconds
YES
Boiler operation correct
PN-0000316
66
7679306 - 1 - 10082017
10 Troubleshooting
10.2.3
Fig.72
Fault finding solutions sections A to E
Solutions sections A to E
A
Is there 230V at:
1.
2.
3.
B
NO
Main terminals L and N
Check electrical supply
NO
Main terminal fuse
Replace fuse
NO
Check wiring
PCB - X10 connector
Main terminals L and N
Display
illuminated
NO
Display or
Main PCB fault
Switch to DHW mode maximum flow and press reset.
During next 3 minutes check:-
230V at PCB - X13 connector
(between blue & brown - see Wiring
Diagram)
YES
NO
230V between PCB - X13
connector (blue) and PCB - X11
connector (black) - see Wiring
Diagram
NO
Replace PCB
C
Connection
OK at X41
YES
230V at pump
YES
Replace pump
NO
Check wiring
Replace PCB
Fan connections correct at fan &
PCB X11 and X23 connectors see Wiring Diagram
NO
Make connections
YES
230V at PCB - X11 connector
YES
(between blue & brown - see Wiring
Diagram)
Fan jammed or YES
faulty wiring
Replace fan or wire
NO
Replace PCB
D
Temperature sensor faulty.
Check correct location and wiring.
YES
Cold resistance approximately
10kΩ @ 25° C (DHW and CH sensors)
(resistance reduces with increase in
temp.)
E
Gas at burner
NO
NO
Replace sensor
Ensure gas is on and purged
Check wiring and PCB - X36 connector YES
see Wiring Diagram
Replace gas valve
NO
Replace PCB
PN-0000317
7679306 - 1 - 10082017
67
10 Troubleshooting
10.2.4
Fig.73
Fault finding solutions sections F to H
Solutions sections F to H
Check and correct if necessary
1. Ignition electrode and lead
2. Electrode connection
3. Spark gap and position
YES
Check wiring - see Electrical
Wiring Diagram page 18
NO
Replace PCB
4 ±0.5
F
10 ±1
G
1.
Check supply pressure at the
gas valve:Natural Gas - Minimum 17 mbar
2.
Check and correct if necessary
1. The set of the gas valve
(CO2 values - see instruction)
2. Flame sensing electrode and lead connections
3. Flame sensing electrode position
Replace flame sensing electrode or PCB
H
Safety thermostat operated
or faulty
YES
Check for and correct any
system faults
NO
Allow to cool. Continuity
across thermostat terminals
more than 1.5 ohm
YES
Replace safety thermostat
NO
Check Flow & Return Sensors
- see section ‘D’
YES
Is
110 still flashing ?
YES
Replace PCB
PN-0000318
68
7679306 - 1 - 10082017
10 Troubleshooting
10.2.5
Fig.74
Fault finding solutions sections I to M
Solutions sections I to M
I
YES
CH system pressure less than
0.5 bar
NO
J
Restore system pressure
Check wiring and PCB - X22
connector for approx. 5V DC
between green & black - see
Wiring Diagram
NO
Ensure that the boiler and
system are fully vented
YES
YES
Replace hydraulic pressure switch
NO
Replace PCB
System fault - correct
Check flow temperature sensor connections
and position.
NO
Cold resistance approximately
10k Ω @ 25° C (CH sensors)
(resistance reduces with increase in temp.)
Replace sensor
YES
Go to section ‘B’
K
Is there 230V at:
1.
PCB - X13 connector terminals between:Blue & Black (central heating mode)
Blue & Brown (domestic hot water mode)
see Wiring Diagram
NO
Replace PCB
YES
Check diverter valve cable
2.
L
Diverter valve motor
YES
Is mains water filter & assembly
clean, and rotor moving freely ?
Replace motor
YES
NO
Check wiring and PCB - X22
connector for approx. 5V DC
between red & blue from Hall
Effect sensor see Wiring Diagram
YES
Replace Hall Effect Sensor
NO
Clean or replace
Replace PCB
M
1.
2.
Temperature sensors faulty.
Cold resistance approximately
10k Ω @ 25° C (CH sensor)
20k Ω @ 25° C (Flue sensor)
(resistance reduces with increase in temp.)
If pump is running the heat exchanger
could be obstructed
NO
Replace sensor
YES
Replace heat exchanger
PN-0000319
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69
11 Decommissioning
11 Decommissioning
11.1
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 mount­
ing frame.
70
7679306 - 1 - 10082017
12 Disposal
12 Disposal
12.1
Disposal and recycling
Caution
Removal and disposal of the boiler must be carried out by a quali­
fied person in accordance with local and national regulations.
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71
13 Spare parts
13 Spare parts
13.1
Short parts list
The following spares are available:
Fig.75
Tab.24
Spare parts
B
A
C
D
E
F
R
G
K
H
J
Part number and description of spare parts
Key No.
Description
Manufacturer’s Spare
Part No.
A
Safety thermostat
7207653
B
Detection / spark ignition electrode
7686344
C
Flow sensor and return sensor
7207471
D
NTC flue sensor
7207892
E
Diverter valve motor
7216534
F
Auto air vent
7207776
G
Burner / door assembly
7686323
H
Insulation rear
7661741
J
Insulation front
7661745
K
Pump assembly
7684006
L
Expansion vessel
7683801
M
Plate heat exchanger (25 & 30)
7683965
N
Hall effect sensor
7207880
O
Hydraulic pressure switch
5114748
P
Gas valve
7683968
R
Pump head
7686336
Q
Fan
7683926
M
L
N
P
O
Q
PN-0000365
72
7679306 - 1 - 10082017
14 Appendix
14 Appendix
14.1
Benchmark commissioning checklist
Warning
After servicing or performing any maintenance on the boiler
ensure that
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7KHIURQWFRYHULVFRUUHFWO\ILWWHGWKHVHFXULQJVFUHZVDUHIXOO\WLJKWHQHG
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.
Customer name:
Telephone number:
Address:
Boiler make and model:
Boiler serial number:
Commissioned by (PRINT NAME):
Gas Safe register number:
Company name:
Telephone number:
Company address:
Commissioning date:
CONTROLS (tick the appropriate boxes)
Time and temperature control to heating
Room thermostat and programmer/timer
Programmable room thermostat
Load/weather compensation
Optimum start control
Cylinder thermostat and programmer/timer
Combination Boiler
Heating zone valves
Fitted
Not required
Hot water zone valves
Fitted
Not required
Thermostatic radiator valves
Fitted
Not required
Automatic bypass to system
Fitted
Not required
Time and temperature control to hot water
Boiler interlock
Provided
ALL SYSTEMS
’s instructions
Yes
What system cleaner was used?
What inhibitor was used?
Quantity
Yes
litres
No
CENTRAL HEATING MODE measure and record:
Gas rate
m³/hr
OR
ft³/hr
Burner operating pressure (if applicable)
mbar
OR Gas inlet pressure
mbar
°C
Central heating return temperature
°C
COMBINATION BOILERS ONLY
Is the installation in a hard water area (above 200ppm)?
Yes
No
Yes
No
DOMESTIC HOT WATER MODE Measure and Record:
OR
Gas rate
m³/hr
Burner operating pressure (at maximum rate)
mbar OR Gas inlet pressure at maximum rate
ft³/hr
mbar
Cold water inlet temperature
Hot water has been checked at all outlets
°C
Yes
Temperature
°C
I/min
CONDENSING BOILERS ONLY
The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798
7679306 - 1 - 10082017
Yes
73
14 Appendix
ALL INSTALLATIONS
Record the following:
At max. rate:
CO
ppm AND
At min. rate: (where possible)
CO
ppm AND
CO/CO²
CO/CO²
Ratio
Ratio
The heating and hot water system complies with the appropriate Building Regulations
Yes
The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions
Yes
The operation of the boiler and system controls have been demonstrated to and understood by the customer
Yes
The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer
Yes
Commissioning Engineer’s Signature
Customer’s Signature
*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)
14.2
www.centralheating.co.uk
Service records
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.
SERVICE 01
Date:
SERVICE 02
Engineer name:
Engineer name:
Company name:
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Record:
Gas safe register No:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
CO² %
CO² %
Record:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
Comments:
Signature
Signature
SERVICE 03
Date:
SERVICE 04
Engineer name:
Engineer name:
Company name:
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Record:
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
CO² %
CO² %
Record:
CO
ppm
AND
ppm
AND
Comments:
Signature
Signature
SERVICE 05
Date:
SERVICE 06
Engineer name:
Engineer name:
Company name:
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Record:
CO² %
CO² %
Date:
Gas safe register No:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
CO² %
CO² %
Record:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
Comments:
Signature
Signature
74
Date:
At min. rate: (Where Possible) CO
At max. rate:
Comments:
At max. rate:
CO² %
CO² %
Gas safe register No:
CO
At max. rate:
Date:
CO² %
CO² %
7679306 - 1 - 10082017
14 Appendix
SERVICE 07
Date:
SERVICE 08
Engineer name:
Engineer name:
Company name:
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Record:
Gas safe register No:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
CO² %
CO² %
Record:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
Comments:
Signature
Signature
SERVICE 09
Date:
SERVICE 10
Engineer name:
Engineer name:
Company name:
Company name:
Telephone No:
Telephone No:
Gas safe register No:
Record:
CO² %
CO² %
Date:
Gas safe register No:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Date:
CO² %
CO² %
Record:
CO
ppm
AND
At min. rate: (Where Possible) CO
ppm
AND
At max. rate:
Comments:
Comments:
Signature
Signature
CO² %
CO² %
to Local Authority Building Control (LABC) either directly or through a
*All installations in England and Wales must be
Competent Persons Scheme. A Building Regulations Compliance
will then be issued to the customer.
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
Warning
After servicing or performing any maintenance on the boiler
ensure that
%RWKIOXHWHVWSRLQWSOXJVDUHLQSODFH
7KHIURQWFRYHULVFRUUHFWO\ILWWHGWKHVHFXULQJVFUHZVDUHIXOO\WLJKWHQHG
7679306 - 1 - 10082017
75
14 Appendix
76
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14 Appendix
7679306 - 1 - 10082017
77
14 Appendix
78
7679306 - 1 - 10082017
© Copyright
All technical and technological information contained in these technical instructions, as well as any drawings and technical de­
scriptions supplied, remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations.
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...
1
2
3
Benchmark checklist is completed
Warranty is registered within 30 days
The boiler has an annual service
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.
7679306 - 1 - 10082017
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