Installation & Servicing Instructions Baxi System 100 HE Plus Wall Mounted Powered Flue Condensing Gas Fired Central Heating Boiler Please leave these instructions with the user
Natural Gas Baxi System 100 HE Plus G.C.No 41 075 43 Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly.
Installer Notification Guidelines Install and Commission this appliance to manufacturer's instructions Complete the Benchmark Checklist Choose Building Regulations Notification Route Competent Person's Self Certification Scheme If you notify via CORGI Scheme, CORGI will then notify the relevant Local Authority Building Control Scheme on member's behalf Building Control Contact your relevant Local Authority Building Control (LABC) who will arrange an inspection or contact a government approved inspect
Legislation IMPORTANT - Installation, Commissioning, Service & Repair This appliance must be installed in accordance with the manufacturer’s instructions and the regulations in force. Read the instructions fully before installing or using the appliance. In GB, this must be carried out by a competent person as stated in the Gas Safety (Installation & Use) Regulations.
Contents Section Page 1.0 Introduction 6 2.0 General Layout 7 3.0 Appliance Operation 8 4.0 Technical Data 9 5.0 Dimensions and Fixings 10 6.0 System Details 11 7.0 Site Requirements 14 8.0 Installation 20 9.0 Electrical 26 10.0 Commissioning 28 11.0 Outer Case 29 12.0 Servicing 30 13.0 Changing Components 32 14.0 Short Parts List 41 15.
1.0 Introduction 1.1 Description 1. The Baxi System 100 HE Plus is a gas fired room sealed fan assisted condensing central heating system boiler. 2. The maximum output of the boiler is preset at 75,000 Btu/hr. The boiler will automatically adjust down to 30,000 Btu/hr according to the system load. If required, the output can be set to 100,000 Btu/hr. Please refer to section 8.7. 3. It is designed for use on Natural Gas (G20). 4.
2.0 General Layout 15 2.1 1 Fig. 6 2 Fig. 5 13/14 3 4 17 6 Layout (Figs. 3,4 & 5) 1. Wall Plate 2. Flue Elbow 3. Heat Exchanger 4. Burner 5. Air Box 6. Fan Protection Thermostat 7. Fan Assembly 8. Condensate Trap 9. Gas Tap 10. Gas / Air Ratio Valve 13. Flow Temperature Safety Thermostat - Black 14. Flow Temperature Thermistor - Red 15. Flow Switch (dry fire protection) 16. Circulation Pump 17. Manual Air Vent 18. Pressure Relief Valve 19.
3.0 Appliance Operation Switched Live to Boiler On. 3.1 Flow temperature less than set point ? NO 2. Pump On: The pump is on while the fan, spark generator and gas valve are off. After 10 seconds if the flow switch has made then fan pre-purge occurs. After 10 seconds if the flow switch has not made then anticycle occurs. YES 10 second Pump On. 3. Fan Pre-Purge: The pump and fan are on while the spark generator and gas valve are off. After 5 seconds ignition occurs.
4.0 Technical Data Appliance Type C13 Appliance Category C33 CAT I 2H Heat Input Gross Max Min kW 33.76 10.2 Btu/h 115,200 34,840 Heat Output (Non Condensing 70° C Mean Water Temp) Max Min kW 30.18 9.
5.0 Dimensions and Fixings DIMENSIONS A 850mm E 3° (1 in 20) B 320mm C 490mm A D 125mm Ø Min. E 150mm F 125mm B 360° Orientation C D Tube Ø 110mm The 3° (1 in 20) fall provided by the elbow is to allow condensate to run back to the boiler, for disposal through the condensate discharge pipe. Fig. 7 F Y X 3° (1 in 20) Fig.
6.0 System Details 6.1 Hot water Switch live from programmer, etc. S/L N Central heating load Filter Optional Pump Feed S/L Boiler N Live feed to pump Boiler Connections Fig. A Wiring an extra pump to the pump feed connection of boiler Water Circulating Systems 1. The appliance is suitable for fully pumped sealed systems only. The following conditions should be observed on all systems: • The boiler must not be used with a direct cylinder. • Drain cocks should be fitted to all system low points.
230V 50Hz L N E w Cylinder Stat b br w o gr g/y gr 1 Room Stat Key to colours Y Plan Diverter Valve b g/y o C 2 - Blue Brown White Orange Grey Green/Yellow 6.0 System Details 6.3 This boiler does not require a bypass. This boiler does not require a permanent live. An additional external pump is required if a boiler output of greater than 75,000 Btu/hr is required. The additional external pump only needs wiring directly to the boiler for fully TRV’d systems.
6.0 System Details 6.4 Copper 0.5m Boiler Fig. 9 1. The sizes of flow and return pipes from the boiler should be determined by normal methods, according to the requirements of the system. The connection to the boiler is 22mm compression fitting. Copper 0.5m Flow Return Copper 1m Pipework 2. Due to space requirements at the rear of the tap bracket, pipework should comprise of solder fittings. 3. A 20 °C (36°F) drop in temperature across the system is recommended for condensing boilers.
6.0 System Details 6.6 Stop Valve Cold Mains Double Check Valve System Filling and Pressurising (Fig. 10) 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. Stop Valve 2. The filling method adopted must be in accordance with the Water Supply (Water Fittings) regulations and the Water Bylaws (Scotland). Temporary Hose CH Return Fig. 10 3.
7.0 Site Requirements 7.1 Location NOTE: Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. Zone 2 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply.
7.0 Site Requirements 490mm 5mm Min 5mm Min 7.3 Clearances (Figs. 13 &14) 1. A flat vertical area is required for the installation of the boiler. 200mm 2. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement. Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler. 3. For unventilated compartments see Section 7.2. 850mm 7.4 Gas Supply 1.
Termination to an internal soil and vent pipe 7.0 Site Requirements 7.6 Boiler Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER 50mm per me 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. tre of p 2.5° M inimum ipe run fall NOTE: It is unnecessary to fit an air break in the discharge pipe.
7.0 Site Requirements Terminal Position with Minimum Distance (Fig. 16) (mm) Aa Directly below an opening, air brick, opening windows, etc. 300 Ba Above an opening, air brick, opening window etc. 300 Ca Horizontally to an opening, air brick, opening window etc. 300 D Below gutters, soil pipes or drain pipes. 25 E Below eaves. 25 F Below balconies or car port roof. 25 G From a vertical drain pipe or soil pipe. 25 (i) 25 (ii) 115 H From an internal (i) or external (ii) corner.
7.0 Site Requirements 7.8 Flue Dimensions See Section 2.2. The standard horizontal flue kit allows for flue lengths between 270mm (105/8”) and 800mm (32”) from elbow to terminal (Fig. 17). m 0m 80 m 0m 27 The maximum permissible equivalent flue length is: 4 metres (Fig. 18). NOTE: Each additional 45° of flue bend will account for an equivalent flue length of 0.5m. eg. 45° = 0.5m, 90° = 2 x 45° = 1m etc. Fig. 17 7.9 Terminal Guard (Fig. 19) 1.
A - Standard Flue 7.0 Site Requirements D 7.11 Flue options Concentric The maximum equivalent lengths are 4m (horizontal) or (vertical). There lengths exclude the standard elbow and flue/terminal assembly (horizontal) and terminal assembly (vertical). Twin Flue The total maximum equivalent flue length is 150m. NOTE: Each 1m of flue duct should be calculated as 2m. E Any additional “in line” bends in the flue system must be taken into consideration.
Example 2m Edge of Boiler 8.0 Installation Example V = 110mm Check Site Requirements (section 7.0) before commencing. Horizontal Side Flue Centre Line Centre Hole 8.1 Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). EXAMPLE: Boiler is 2 metres away from corner of wall, flue duct hole is 110mm up from horizontal side flue centre line. This will maintain the approx 3° backfall to the boiler.
8.0 Installation Lower Door Panel Outer Case Fixing Screw 8.3 Preparing The Boiler 1. Remove the outer carton. 2. Hinge up the lower door panel (Fig. 22). 3. Remove the outer case fixing screws (Fig. 22). Slide the outercase upwards to disengage the hooks on the backplate and remove (Fig. 23). NOTE: Service Guidance Note Label is fitted to the inside of the outercase (Fig. 23). 4. Remove the sealing plugs from the copper bends. 5.
8.0 Installation Top Hooks 8.4 Fitting The Boiler (Fig. 24) 1. Remove the tape from the tap rail on the support bracket and fit the central heating return filter (Fig. 26). 2. Lift the boiler over the support bracket using the lifting points shown in Fig. 24 and engage onto the top hooks (see Lifting paragraph page 4). NOTE: When installing in Loft/Small Compartment access for lifting the boiler from the front can be gained for two people using the lifting points (Fig. 24). 3.
8.0 Installation Wall Thickness 8.6 Fitting The Flue Before fitting the flue, check the condensate drain integrity (see section 8.5). IMPORTANT: The flue should always be installed with a 3° (1 in 20) fall from terminal to elbow, to allow condensate to run back to the boiler. 3° (1 in 20) HORIZONTAL FLUE 1. The standard flue is suitable for lengths 270mm minimum to 800mm maximum (measured from the edge of the flue elbow outlet).
8.0 Installation 8.6 Inner Flue Support Bracket Fitting the Flue (Cont) 6. Ensure the inner flue support bracket is positioned in the flue (Fig. 30). 7. Engage the flue into the flue elbow using soap solution to ease the engagement ensuring the flue is assembled as shown (Fig. 31). Fig. 30 8. Place the gasket over the flue exit on the boiler. 9. Slide the flue assembly through the hole in the wall. Flue 10. Engage the elbow on to the flue connection on top of the boiler.
8.0 Installation 8.7 Making The Electrical Connections WARNING: This appliance must be earthed 1. The electrical connection is on the rear left hand side of the unit (Fig 33). N L 2. Remove the electrical plug from the hardware pack. 3. Connect S/L, N & E into the plug and connect it to the socket at the back left at the bottom of the boiler. Metal Shield Plug 4. Remove the metal shield from the hardware pack and connect it over the plug. Filter 5.
9.0 Electrical 9.
9.0 Electrical 9.
Automatic Air Vent 10.0 10.1 Commissioning Commissioning the Boiler 1. Ensure that the filling loop is connected. Open the cold mains stop valve. 2. Ensure that the heating flow and return valves are open. Manual Air Vent 3. Open the system side stop valves. Fig. 35 4. Open the manual and automatic air vents (Fig. 35). To help purge the primary circuit turn the pump on & off several times by using the Reset button (Fig. 36) (ensure all external controls are turned on and calling for heat). 5.
11.0 11.1 Outercase Fitting The Outer Case 1. Position the outercase on the chassis, ensuring that the four slots in the side flanges align with the hooks on the chassis (Fig. 38). 2. Insert the two fixing screws into the sides of the chassis (Fig. 39). 3. Close the door against the retaining magnets (Fig. 39). 4. Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation.
12.0 12.1 Servicing Annual Servicing IMPORTANT: When servicing ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended. Flue Sampling Point 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. 2.
12.0 Servicing Flue Sampling Point 12.1 Annual Servicing (Cont) 12. To clean the heat exchanger and burner proceed as follows: a) Disconnect the electrical leads to the fan component protection sensor (Fig. 42). b) Loosen the screw retaining the gas injector pipe at the venturi (Fig. 42). c) Undo the two wing nuts to disconnect the fan (Fig. 42). Injector Pipe d) Remove the fan and disconnect the electrical supply to it (Fig. 42).
13.0 13.1 Changing Components Changing Components IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended. Heat Exchanger Manifold When replacing the combustion box door after changing components it is essential that the retaining screws are tightened fully. 1.
13.0 Flowswitch 13.3 Changing Components Flowswitch (Fig. 47) 1. Drain the boiler (see Section 13.1 paragraph 2 & 3). Flow Pipe 2. It may be necessary to remove the expansion vessel (see Section 13.5). 3. Remove the clip securing the flow pipe to the flowswitch. 4. Remove the two screws securing the flow switch to the boiler. Fig. 47 Clip 5. Disconnect the inline electrical connection. 6. Remove the flowswitch. 7. Fit the new flowswitch and reassemble in reverse order. 8.
13.0 Changing Components The Pump, interface PCB, pressure gauge and pressure relief valve can be accessed after hinging down the facia panel. 1. Release the facia securing screws (1/4 turn) and hinge down the facia panel. 13.7 Pump (Fig. 50) Facia Panel 1. If only the head needs replacing. A standard Grundfos UPS 15-60 pump head is interchangeable (see section 13.13 for details). 2. This must be switched to setting No 3 (Fig. 51). 13.8 Pump (Complete) (Fig. 52) 1. Drain the boiler (see Section 13.
13.0 Pressure Gauge Bracket 13.10 Changing Components Pressure Gauge 1. Drain the boiler (see Section 13.1 paragraph 2 & 3). 2. Undo the nut retaining the capillary in the connection at the return pipe (Fig. 55). 3. Depress the two lugs on either side of the pressure gauge and feed through facia (Fig. 54). Pressure Gauge 4. Fit new pressure gauge and reassemble in reverse order. Lug 13.11 Fig. 54 Pressure Relief Valve (Fig. 56) 1.
13.0 13.12 Changing Components PCB (Fig. 57) WARNING: The PCB Control and Fan Assembly is 325 Vdc. Isolate at supply before access. 1. Pull the control knob off its spindle and remove the plastic button cover. Refit them onto the new PCB (Fig. 57a). 2. Release the facia securing screws (1/4 turn) and hinge down the facia panel. 3. Remove the screws securing the PCB connection cover. Facia Panel 4.
13.0 Changing Components The fan and venturi, gas valve, injector pipe, condensate trap, fan protection sensor, spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel. 1. Remove the airbox door panel by loosening the four 1 /4 turn screws. 13.13 Spark and Sensing Electrodes (Fig. 58) 1. Disconnect all three leads from tabs. Spark Opaque cable Earth Green/Yellow cable Sensing White cable Air Box Door Panel 2.
13.0 Changing Components The removal of the fan is necessary to enable the changing of the injector pipe, condensate trap and gas valve (see section 13.14). 13.15 Injector Pipe (Fig. 60) 1. Remove the injector pipe by pulling out from the ‘O’ ring joint in the gas valve. 2. Fit the new injector pipe and reassemble in reverse order. Injector Pipe 13.16 Gas Valve Securing Screws Gas Valve (Fig. 60) 1. Remove the four screws securing the gas inlet pipe flange to the gas valve. Case Pressure Pipe 2.
13.0 Changing Components The burner and heat exchanger can be changed after removal of the combustion box door. To change the heat exchanger, the fan and burner must be removed first (see section 13.14 & 13.18). Combustion Box Door Panel 1. Remove the combustion box door by removing the four securing screws. 13.18 Burner (Fig. 62) 1. Remove the two screws securing the burner to the base of the combustion box. 2. Remove the burner carefully from the combustion box base. 3.
13.0 13.20 Changing Components Heat Exchanger Lower Insulation Pad (Fig. 66) WARNING: The PCB Control and Fan Assembly is 325 Vdc. Isolate at supply before access. 1. Remove the fan and condensate trap (see section 13.14 and 13.17). 2. Remove the burner (see section 13.18). 3. Remove the four bolts securing the combustion box base. 4. Remove the combustion box base. Central Insulation Panel 5. Pull the central insulation panel down from the centre of the heat exchanger and remove the lower insulation pad.
14.0 Short Parts List Short Parts List A B Key No. G.C. No. Description A E06 058 Flow Temperature Manufacturers Part No.
15.0 Lockout Fault Finding Light (Red) Reset NOTE: The fan is supplied with 325 Vdc. Boiler On Light (Green) Fan Fault Finding should only be carried out after the boiler has been electrically isolated. ON High Low Mains On General Fault Finding should only be carried out by someone who is appropriately qualified. Light (Green) Lights ON Off Off Off YES Go to Electrical Supply section of the fault finding instructions.
ELECTRICAL SUPPLY Lights ON NO 240V at A ? Off Off Off 15.0 Fault Finding No Switched Live to boiler. Check Systems Controls and System Wiring. YES NO 240V at B ? A Check wiring from terminal block to PCB. YES L NO PCB fuse OK ? Optional Pump Live Check for shorts on pump, fan & gas valve. Replace if shorted & replace fuse. YES Replace PCB.
DRY-FIRE Lights ON 15.0 On Flash Flash Fault Finding E Is the system full of water ? NO Fill system with water and bleed out all air. L N Optional Pump Replace PCB. Live YES YES Is the pump running ? NO YES Unplug 5-way PCB connector. Is there continuity between H (run pump from switched live) ? Is the pump run off the switched live? NO Turn mains off & on. After 5 sec, is there 240V at E? YES YES Pump or Pump Wiring fault. Pump or Pump Wiring fault.
IGNITION LOCKOUT Lights ON 15.0 On Off On Fault Finding I NO Is there gas at gas valve inlet ? Check isolation valve and gas supply. J 5-way Connector YES Remove 5-way connector from gas valve. Is there 240 Vdc between I & J during ignition ? NO Reset Lockout. Is there gas flow (check at meter) ? YES Replace Gas Valve. NO YES Is there at least 18mbar dynamic at gas valve inlet ? NO Remove the larger or the two 6-way PCB connectors.
OVERHEAT LOCKOUT Lights ON Disconnect black stat on flow pipe. When flow < 60° C is there continuity across stat ? Flash Off On 15.0 Fault Finding NO Replace Stat. YES Reconnect stat. Disconnect fan stat. When fan temp < 60° C is there continuity across stat ? NO Replace Stat. YES Reconnect stat. Disconnect the larger of the 6-way PCB connectors. Is there continuity across M ? NO YES Disconnect thermistor (red sensor on flow pipe). Is resistance between 0.
FAN LOCKOUT 15.0 Flash Flash On Lights ON Fault Finding NOTE: The fan is supplied with 325 Vdc. Fan Fault Finding should only be carried out after the boiler has been electrically isolated. Fan Connection Unplug 3-way PCB connector & unplug fan. Is there continuity from N to O & from P to Q ? PCB Connection NO O N Rectify wiring. Q P YES Unplug the smaller of the 6-way PCB connector.
16.
BENCHMARK No. 5 1 1 0 4 8 1 GAS BOILER COMMISSIONING CHECKLIST COLLECTIVE MARK BOILER SERIAL No. NOTIFICATION No.
SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing all controls SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No.
B A X I P OTTERTO N A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www.baxi.co.
