Please leave these instructions with the user Baxi Combi 80e & 105e Gas Fired Wall Mounted Combination Boiler Installation and Servicing Instructions
Natural Gas Baxi Combi 80e G.C.No 47 075 06 Baxi Combi 105e G.C.No 47 075 08 Baxi UK Limited is one of the leading manufacturers of domestic heating products in the UK. Our first priority is to give a high quality service to our customers. Quality is designed into every Baxi product - products which fulfil the demands and needs of customers, offering choice, efficiency and reliability.
Contents Section Page 1.0 Introduction 4 2.0 General Layout 5 3.0 Appliance Operation 6 4.0 Technical Data 7 5.0 Dimensions and Fixings 9 6.0 System Details 10 7.0 Site Requirements 13 8.0 Installation 18 9.0 Commissioning the Boiler 23 10.0 Completion 25 11.0 Servicing the Boiler 26 12.0 Changing Components 28 13.0 Illustrated Wiring Diagram 37 14.0 Fault Finding 38 15.
1.0 Introduction Baxi UK Limited declare that no substances harmful to health are contained in the appliance or used during appliance manufacture. Case Front Panel 1.1 Description 1. The Baxi Combi 80e or 105e is a fully automatic gas fired wall mounted combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water. 2. The boiler is set to give a maximum output of 24.0 kW (80e) or 31.0 kW (105e). 3.
2.0 General Layout 2.1 Layout 1. Air Pressure Switch 2. Expansion Vessel 3. Burner Manifold 4. Automatic Air Vent 5. DHW Plate Heat Exchanger 6. Circulation Pump 7. Drain Off Point 8. Pressure Relief Valve 9. Optional Integral Timer 10. Central Heating System Pressure Gauge 16 11. PCB 15 12. Control Box 13. 3-Way Valve Assembly 14. Spark Generator 15.
3.0 Appliance Operation 1 NOTE: All delay timers mentioned in 3.1 and 3.2 are overridden by domestic hot water demand. Central Heating Circuit 3.1 2 3 4 7 26 5 6 25 24 23 9 27 21 11 17 10 18 19 15 14 13 12 Fig. 2 3.2 Key 1 2 3 4 5 6 7 8 9 10 11 12 13 3. When the flow temperature exceeds the setting temperature, a 3 minute delay occurs before the burner relights automatically (anti-cycling). The pump continues to run during this period. 4.
4.0 Technical Data 4.1 Appliance Type C12 Appliance Category C32 CAT II 2H 3+ Heat Input C/H & DHW (Gross) Max Min kW 26.3 10.6 Btu/h 89,739 31,738 Heat Output Max Min kW 24.0 9.3 Btu/h 81,891 31,738 Max Gas Rate (Natural Gas - G20) (After 10 Mins) m3/h 2.78 ft3/h 98.12 Burner Pressure (Natural Gas - G20) Max Rate Min Rate mbar 12.2 ± 0.5 2.5 ± 0.2 in wg 4.88 ± 0.2 1.0 ± 0.2 Inlet Pressure (Natural Gas - G20) mbar 20 in wg 8 Burner Injector (Natural Gas - G20) 12 x 1.
4.0 Technical Data 4.2 Appliance Type C12 Appliance Category C32 CAT II 2H 3P Heat Input C/H & DHW (Gross) Max Min kW 34.3 11.9 Btu/h 117,036 40,610 Heat Output Max Min kW 31.0 10.4 Btu/h 105,776 35,490 Max Gas Rate (Natural Gas - G20) (After 10 Mins) m3/h 3.63 ft3/h 128.12 Burner Pressure (Natural Gas - G20) Max Rate Min Rate mbar 13.4 ± 0.5 1.8 ± 0.2 in wg 5.36 ± 0.2 0.72 ± 0.2 Inlet Pressure (Natural Gas - G20) mbar 20 in wg 8 Burner Injector (Natural Gas - G20) 15 x 1.
5.0 Dimensions and Fixings Dimensions G A 780mm E B 345mm C 450mm A D 107mm Ø Min.
6.0 System Details 6.1 Information 1. The Baxi Combi 80e and 105e Combination Boilers are ‘Water Byelaws Scheme - Approved Products’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 - See text of entry for installation requirements and notes. b) IRN 302 - Byelaw 14. 2. Reference to the WRc publications, ‘Water fittings and materials directory’ and ‘Water supply byelaws guide’ give full details of byelaws and the IRNs. 6.
6.0 System Details 6.5 System Filling and Pressurising 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. Double Stop Check Valve Valve DHW Mains Inlet Fig. 4 Temporary Hose 2. There are connection points on the mains cold water inlet and central heating return isolating taps Fig. 4a) to which the optional filling loop kit (Part No. 248221) can be assembled.
6.0 System Details Other Tap Outlets 6.8 Expansion Vessel Boiler Stop Tap Fig. 6 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards, the Water Supply (water fittings) Regulations and the Water Bylaws (Scotland). 2. Your attention is drawn to: Schedule 2, Section 6 of the Publication Water Regulations Guide which relates to backflow prevention. Check Valve Pressure Reducer Valve Domestic Hot Water Circuit (Fig. 6) To Hot Taps 3.
7.0 Site Requirements 450mm 5mm Min 5mm Min 7.1 200mm Min 1. The installation must be carried out by a CORGI Registered Installer or other registered competent person and be in accordance with the relevant requirements of the current GAS SAFETY (Installation and Use) REGULATIONS, the BUILDING REGULATIONS (Scotland)(Consolidation), the LOCAL BUILDING REGULATIONS, the current I.E.E. WIRING REGULATIONS and the bye laws of the LOCAL WATER UNDERTAKING.
7.0 Site Requirements 7.5 Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. BS 5440: Part 2 Clause 4.2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. 7.6 Gas Supply 1. The gas installation should be in accordance with BS6891. 2. The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock (Fig. 9). 3.
7.0 Site Requirements 7.8 Flue 1. The flue terminal position must be in accordance with the current editions of B.S. 5440 Part 1, and either Part J of the Building Regulations England and Wales or Part F of the Building Standards (Scotland) Regulations as appropriate. 2. If the terminal discharges onto a pathway or passageway, check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway. 3.
7.0 Site Requirements 7.9 Flue Dimensions 1m The standard horizontal flue kit allows for flue lengths between 100mm and 1m from elbow to terminal (Fig. 12). m 0m 10 The maximum permissible equivalent flue length is: 80e 5 metres 105e 4 metres NOTE: Each additional 45° of flue bend will account for an equivalent flue length of 0.5m. eg. 45° = 0.5m, 90° = 2 x 45° = 1m etc. Fig. 12 7.10 Flue Terminal Trim 1. Once the flue is secure the trim can be fitted if required. Flue Trim 2.
7.0 Site Requirements 7.12 Flue Options 1. The Baxi Combi 80e and 105e can be fitted with flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. Maximum Length = 3m inc. 2 x 45° bends 3. The 80e model ONLY can also be fitted with a flue system that exits horizontally from the rear of the appliance, dispensing with the need for the top flue elbow. Horizontal Flues Rear Flue (80e only) 4.
Fixing Template 8.0 Installation 921.724.1 200 mm Minimum Clearance 107mm Dia Minimum Aperture For Flue Tube Horizontal Side Flue Centre Line 8.1 The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.6). Vertical Flue Centre Line Appliance Wall Plate 1. After considering the site requirements (see Section 7.0) position the fixing template (Fig. 16) on the wall ensuring it is level both horizontally and vertically.
Wall Plate 8.0 Installation 8.4 Fitting The Boiler 1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate (Fig. 18). 3. Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections. The rubber washers must be used on the gas connection. 4. Tighten all the connections. 5.
8.0 Installation Wall Thickness 8.6 Fitting The Flue HORIZONTAL FLUE (X) 1. The standard flue is suitable for lengths 100mm minimum to 1m maximum (measured from the edge of the flue elbow outlet). 80e model only If the optional rear flue kit is to be used, refer to the instructions supplied. Rear Flue: maximum wall thickness - 900mm Side Flue: maximum wall thickness - 870mm 2. If using the optional internal fitting kit, flue extension kit or elbows, refer to the instructions provided with the kits. 3.
8.0 Installation Elbow 8.6 Fitting the Flue (Cont) IMPORTANT: If the equivalent flue length is greater than 1.5m the restrictor MUST be removed from the adaptor (Fig. 22). Seal Restrictor Adaptor 8. Insert the flue duct into the air duct and pass them through the hole in the wall. Fig. 22 9. Take one of the rubber seals and position it on the boiler flue adaptor. Engage the flue elbow on the adaptor and pull the sleeve up so that it equally covers the joint (Fig. 22). 10.
8.0 Installation 8.7 Making The Electrical Connections To connect the mains input cable proceed as follows:1. Slacken the facia securing screws and lift the outercase panel so that its locating tabs are clear of the facia. Remove the panel. Control Box Cover 2. Remove the screws securing the facia panel and hinge it down (Fig. 26). Fig. 27 3. Remove the control box cover securing screws. Disengage the barbs on the control box from the cover. Remove the cover (Fig. 27). 4.
9.0 9.1 Screw Commissioning the Boiler Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Open the mains water supply to the boiler. Automatic Air Vent 3. Open all hot water taps to purge the DHW system. 4. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. 5. Open the screw on the automatic air vent (Fig. 31). 6. The system must be flushed in accordance with BS 7593 (see Section 6.
9.0 Commissioning the Boiler OUT Pressure Test Point Sealing Screw 9.2 1. Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for heat. Gas Valve MIN Checking the Burner Pressure 2. Set the temperature controls to maximum and the selector switch to the Off position (Fig. 36). 3. Slacken the pressure test point sealing screw on the gas valve and connect a pressure gauge (Fig. 33). Fig. 34 4. Undo the screws securing the inner door panel.
10.0 Completion Case Front Panel 10.1 Completion 1. Hinge the facia panel upwards and refit the case front panel. Secure them with the screws previously removed (Fig. 37). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3. Carefully read and complete all sections of the “Benchmark” Installation, Commissioning and Service Record Log Book that are relevant to the appliance and installation.
11.0 Servicing the Boiler 11 .1 Case Front Panel Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person. 2. After servicing, complete the relevant section of the “Benchmark” Installation, Commissioning and Service Record Log Book. This should be in the possession of the user. 3. Ensure that the boiler is cool. 4. Ensure that both the gas and electrical supplies to the boiler are isolated. 5.
Baffle Tab Spring Clip 11.0 11.1 Servicing the Boiler Annual Servicing (Cont) 10. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood (Fig. 42). 11. Undo the screws securing the fan and hood to the appliance back panel. Draw the assembly forwards (Fig. 42a). Fig. 42 Fan and Hood Assembly 12. Undo the screws securing the burner to the injector manifold (105e model only).
12.0 Changing Components IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the new component has been fitted turn the selector switch fully anticlockwise against the spring pressure to position R and hold for 2 seconds to reset the boiler before recommissioning. Pressure Switch Sensing Tubes See Section 11.1 “Annual Servicing” for removal of case panel, door etc. Fig. 45 12.
12.0 Changing Components 12.3 Heat Exchanger (Fig. 48) Heat Exchanger 1. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them. (80e model) 2. Slacken the screws on the outlet sealing collar. Ease the collar upwards as far as possible. 3. Remove the four screws securing the combustion box door and remove the door. Pipe Connecting Clips 4. Remove the spring clips retaining the air box side baffle plates.
12.0 Changing Components Injector Manifold Inlet Elbow 12.5 Injectors (Fig. 50) 1. Remove the burner as described in Section 12.4. Gasket Injector Burner Electrodes Fig. 50 2. Undo the screws securing the injector manifold to the inlet elbow and remove the manifold. 3. Unscrew and replace injectors as required and examine the sealing gasket, replacing as necessary. Reassemble in reverse order. 12.6 Electrodes (Fig. 50) 1.
12.0 Changing Components 12.8 Gas Valve (Fig. 52) 1. Undo the nut on the gas feed pipe under the boiler. 2. Remove the securing screws and hinge the facia panel down. Gas Valve 3. Disconnect the earth wire and pressure sensing pipe from the valve. Undo the screw securing the electrical plug to the valve and disconnect the plug. Disconnect the wires from the valve modulator. Electrical Plug 4.
12.0 Changing Components 12.12 Pump - Head Only (Fig. 54) 1. Drain the primary circuit and remove the socket head screws securing the pump head to the body and draw the head away. 2. Undo the screw on the pump wiring cover and remove the cover. Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position. 3. A standard Grundfos replacement head can now be fitted. A Grundfos 15-50 head is suitable for the Combi 80e.
12.0 Changing Components 12.15 Pressure Gauge (Figs. 57 & 58) 1. Drain the primary circuit and undo the nut on the pressure gauge capillary. 2. Remove the timer cover and ease the timer wiring aside. Undo the screws securing the gauge retaining bracket. Fig. 57 3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining bracket. Pressure Gauge Capillary Gauge Retaining Bracket 4. Reassemble in reverse order. 12.16 Expansion Vessel (Fig.
12.0 Changing Components 12.18 Pressure Relief Valve (Fig. 61) 1. Drain the primary circuit. 2. Disconnect the discharge pipe from the valve. Using a suitable hexagon key undo the grub screw sufficiently to release the valve. 3. Note the orientation of the valve, rotate it and withdraw it from the manifold. 4. Fit the new valve and ‘O’ ring seal and set to the previously noted orientation. Reassemble in reverse order. ‘O’ ring seal 12.19 P.C.B. (Fig. 63) 1.
12.0 Changing Components Plate Heat Exchanger 12.21 Plate Heat Exchanger (Fig. 64) 1. Drain the primary circuit. 2. While supporting the heat exchanger undo the screws securing it to the brass manifolds. 3. Withdraw the heat exchanger upwards and to the left of the gas valve, taking care not to damage any wires or controls. Rubber Seal Seals 4. There are four rubber seals between the manifolds and heat exchanger which may need replacement. Fig. 64 5. Ease the seals out of the manifold.
12.0 Changing Components Central Heating Pressure Differential Valve Microswitch / Bracket 12.22 Diverter Valve Assembly (Cont) Sensing Pipe Pressure Differential Valve (Fig. 67) 1. Remove the pressure differential valve as described above. By-pass Pipe Diaphragm Spring Clip Heating Flow Pipe 2. From the brass diverter manifold undo the nut on the heating flow pipe. Remove the screw securing the diverter manifold to the appliance lower bracket. 3.
13.
14.0 Fault Finding Carry out initial fault finding checks 1. Check that gas, water and electrical supplies are available at the boiler. Electrical supply = 230V ~ 50 Hz. CH water system pressurised to 0.5 bar when the boiler is cold. The preferred minimum gas pressure is 19.5mbar (natural gas), 27mbar (butane) or 36mbar (propane). 2. Carry out electrical system checks, i.e. Ground Continuity, Resistance to Ground, Short Circuit and Polarity with a suitable meter.
14.0 Fault Finding Domestic Hot Water - Follow operational sequence Turn selector to neon illuminated NO Replace diaphragm Go to section ‘A’ YES YES Is mains water filter and differential assembly clean? YES NO YES Turn thermostat to max. Open DHW tap fully. DHW flow switch operated NO DHW flow valve diaphragm damaged DHW flow rate more than 2.5l/min.
14.0 Fault Finding Fault Finding Solutions Sections A to E A Is there 230V at: 1. 2. 3. B Main terminals L and N Main terminal fuse NO Check electrical supply YES Selector terminals a & b and a & 3. PCB - A4 connector terminals 4 & 5 Replace fuse NO Check wiring Replace selector neon illuminated NO Is there 230V at: NO 1. Pump 2. PCB - A4 connector terminals 3 & 6 If pump jammed, release Replace pump NO Replace PCB YES Change pump supply cable C NO 1. CH system pressure 0.5 to 1.
14.0 Fault Finding E F Check and correct if necessary 1. Electrical and pressure tube connections 2. Blockage of pressure tubes 3. Restriction in flue 4. Venturi Gas at burner NO NO Replace air pressure switch Ensure gas is on and purged PCB - A1 connector has 230V AC across terminals 2 & 4 YES Replace gas valve NO neon iflashing YES Turn selector switch to reset position R NO Replace PCB G 1. Check the burner setting pressure of the gas valve (see Section of Commissioning) 2.
14.0 Fault Finding I Ensure that mains input terminal L is Live (230V) and N is Neutral (0V) YES Check and correct if necessary 1. Flame sensing electrode and lead connections 2. Electrode position YES Flame current should be 1 µA approx. J Overheat thermostat operated or faulty, i.e. continuity across thermostat terminals NO NO Replace PCB Replace flame sensing electrode Allow to cool. Continuity across thermostat terminals more than 1.
15.0 Short Parts List Short Parts List 44 22 140 Key No. G.C. No. Description 22 E66 383 Fan 80e 248001 E66 527 Fan 105e 248002 393 974 Pressure Switch 247380 248016 23 32 Manufacturers Part No.
Comp No 247938 - Iss 5 - 5/02 After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www.baxi.com 921.660.
