Please leave these instructions with the user Baxi Combi 80Eco Gas Fired Wall Mounted Combination Boiler Installation and Servicing Instructions
Natural Gas Baxi Combi 80Eco G.C.No 47 075 05 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 8 6.0 System Details 9 7.0 Site Requirements 12 8.0 Installation 17 9.0 Commissioning the Boiler 22 10.0 Completion 24 11.0 Servicing the Boiler 25 12.0 Changing Components 27 13.0 Illustrated Wiring Diagram 36 14.0 Fault Finding 37 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 80Eco 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. 3.
2.0 General Layout 2.1 19 18 1 17 2 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 Position 10. Central Heating System Pressure Gauge 11. Control PCB 12. Control Box 16 13. 3-Way Valve Assembly 15 14. Spark Generator 15. Flame Sensing Electrode 16. Spark Electrode 17. Burner 18.
3.0 Appliance Operation 1 Central Heating Circuit NOTE: All delay timers mentioned in 3.1 and 3.2 are overridden by domestic hot water demand. 2 3.1 Central Heating Mode (Fig. 4) 3 4 7 26 5 6 25 24 2. The main burner ignites at low rate, then the gas valve controls the gas rate to maintain the heating temperature measured by the temperature sensor. 8 23 9 22 21 11 17 10 20 Fig. 4 18 16 19 15 14 13 1. With a demand for heating, the pump circulates water through the primary circuit.
4.0 Technical Data 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 36,167 Heat Output Max Min kW 24.0 9.3 Btu/h 81,891 31,732 Burner Pressure (Natural Gas - G20) Max Rate Min Rate mbar 12.2 ± 0.5 2.5 ± 0.2 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.
5.0 Dimensions and Fixings G E A Dimensions A 780mm B 345mm B C 450mm D 107mm Ø Min. 360° Orientation E 200mm D F 190mm C G 143mm Tube Ø 100mm Fig. 6 F Gas Inlet Heating Flow 95mm Domestic Hot Water Outlet 65mm Cold Water Inlet 65mm 65mm Heating Return 65mm 165.7mm View from under the appliance Left Hand Side of Boiler 130mm Wall Fig.
6.0 System Details 6.1 Information 1. The Baxi Combi 80Eco Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. 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. Stop Valve Double Check Valve DHW Mains Inlet Temporary Hose Stop Valve 2. There are connection points on the mains cold water inlet and central heating return isolating taps to which the optional filling loop kit (Part No. 248221) can be assembled. 3.
6.0 System Details Other Tap Outlets 6.8 Expansion Vessel Boiler 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 Reducing Valve Domestic Hot Water Circuit To Hot Taps Stop Tap Fig. 11 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 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. 14). 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 1metre from elbow to terminal (Fig. 17). m 0m 10 The maximum permissible equivalent flue length is: 5 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. 17 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 80Eco can be fitted with flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. Maximum Length = 4m inc. 2 x 45° bends Horizontal Flues 3. Maximum permissible equivalent flue lengths are:Horizontal 5 metres Vertical 4 metres Vertical (Twin Pipe) 15 metres 4. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:Concentric Pipes: 45° bend 0.
Fixing Template 8.0 Installation 107mm diameter minimum aperture for flue tube 8.1 Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.6). Appliance Wall Plate 1. After considering the site requirements (see Section 7.0) position the fixing template on the wall ensuring it is level both horizontally and vertically. 190mm Combi 80Eco FIXING TEMPLATE For Side Flue Exit 2.
Wall Plate 8.0 Installation 8.4 Fitting The Boiler 1. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate hooks (Fig. 23). 2. Ensure that the boiler is level and sits against the wall. 3. Take the two steel washers and remaining screws. Using the previously drilled and plugged holes, secure the bottom of the boiler to the wall (Fig. 24). Fig. 23 4. Remove the elbows, valves and sealing washers from the packaging.
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). Rear Flue: maximum wall thickness - 900mm Side Flue: maximum wall thickness - 870mm 2. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (rear, right or left). 3. Measure the distance from the outside wall face to the elbow (Fig. 27).
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. 29). Seal Restrictor Adaptor 7. Insert the flue duct into the air duct and pass them through the hole in the wall. Fig. 29 8. 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. 29). 9.
8.0 Installation 8.7 Making The Electrical Connections Fig. 33 To connect the mains input cable proceed as follows:1. Slacken the facia securing screws and lift the outercase panel so that it’s securing 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. 35). 3. Remove the control box cover securing screws. Disengage the barbs on the control box from the cover. Remove the cover (Fig. 33). 4.
9.0 9.1 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. 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. 40). 6. The system must be flushed in accordance with BS 7593 (see Section 6.
9.0 Commissioning the Boiler Selector Switch 9.2 Checking the Burner Pressure 1. Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for heat. 2 1 3 2. Set the hot water and central heating temperature controls to maximum and the selector switch to the OFF position (Fig. 42). 4 0 bar Fig. 42 Central Heating Temperature Control Hot Water Temperature Control 3.
10.0 Completion 10.1 Case Front Panel Completion 1. Hinge the facia panel upwards and refit the case front panel. Secure them with the screws previously removed (Fig. 45). 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 Case Front Panel 11 .1 Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person. 2. After servicing, complete the relevant 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. Fig.
Baffle Tab Spring Clip 11.0 11.1 Fig. 52 Fig. 51 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. 52). 11. Undo the screws securing the fan hood assembly to the appliance back panel, and draw the fan and hood assembly forwards (Fig. 51). Fan and Hood Assembly 12.
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. Pressure Switch Fig. 57 See Section 11.1 “Annual Servicing” for removal of case panel, door etc. Sensing Tubes 12.1 Pressure Switch 1. Note the positions of the two sensing tubes and three wires and remove them (Fig. 57). 2. Remove the two screws holding the pressure switch to the combustion box top panel. Pressure Switch Wires 3.
12.0 Changing Components 12.3 Heat Exchanger (Fig. 62) 1. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them (Figs. 58 to 61). 2. Slacken the screws on the outlet sealing collar. Ease the collar upwards as far as possible. Fig. 62 3. Remove the four screws securing the combustion box door and remove the door. 4. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood.
12.0 Changing Components Injector Manifold Inlet Elbow Injectors (Fig. 64) 1. Remove the burner as described in Section 12.4. Fig. 64 Gasket Injector Electrodes 12.5 Burner 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. 64) 1.
12.0 Changing Components 12.8 Fig. 66 Gas Valve (Fig. 66) 1. Undo the nut on the gas feed pipe at the tap rail under the boiler. Gas Valve 2. Remove the securing screws and hinge the facia panel down. 3. Disconnect the earth wire and pressure sensing pipe from the valve. Undo the screw securing the electrical plug to the valve and disconnect the plug. Electrical Plug 4. Remove the screws securing the inlet pipe flange to the tap rail and those securing the outlet manifold to the burner manifold.
12.0 Changing Components 12.11 Pump - Head Only (Figs. 68 & 69) 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 15-50 replacement head can now be fitted. Connect the wiring to the new head.
12.0 Changing Components 12.14 Pressure Gauge Fig. 71 1. Drain the primary circuit and undo the nut on the pressure gauge capillary (Fig. 71). 2. Remove the timer cover and ease the timer wiring aside. Undo the screws securing the gauge retaining bracket (Fig. 72). 3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining bracket (Fig. 73). Pressure Gauge Capillary Gauge Retaining Bracket Fig. 72 4. Reassemble in reverse order. 12.
12.0 Changing Components 12.17 Pressure Relief Valve (Fig. 78) 1. Drain the primary circuit. 2. Disconnect the discharge pipe from the valve. Using a suitable hexagon key slacken 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 12.18 P.C.B. 1. Note the settings of the temperature control knobs.
12.0 Changing Components Plate Heat Exchanger 12.20 Plate Heat Exchanger (Fig. 81) Fig. 81 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. 5. Ease the seals out of the manifold.
12.0 Changing Components Central Heating Pressure Differential Valve Microswitch & Bracket 12.21 Diverter Valve Assembly (Cont) Sensing Pipe Pressure Differential Valve (Fig. 84) 1. Remove the pressure differential valve as described above. By-pass Pipe Diaphragm Spring Clip 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 rate more than 2.5l/min.
14.0 Fault Finding Fault Finding Solutions Sections A to E A Is there 230V at: 1. Main terminals L and N 2. Main terminal fuse 3. B NO Check electrical supply YES Selector terminals a & b and a & 3. PCB - M1 connector terminals 9 & 10 Replace fuse NO Check wiring Replace selector neon illuminated NO Replace PCB Is there 230V at: 1. 2. Pump NO If pump jammed, release PCB - M1 connector terminals 8 & 15 Replace pump NO Replace PCB YES Change pump supply cable C NO 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 - M4 connector is approx 70-140V DC, terminals 23 & 24 YES Replace gas valve NO YES neon illuminated Turn selector switch to reset position R NO Replace PCB G H 40 1. Check the burner setting pressure of the gas valve (see Section 9.
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 140 Short Parts List 44 22 Key G.C. No. No. Description Manufacturers Part No. 22 E66 383 Fan 248001 23 393-497 Pressure Switch 247380 32 E66 393 Heat Exchanger 248016 41 E66 398 Burner 248029 44 E66 402 Injector - 1.28 NG 248210 Injector - 0.
Baxi UK Limited manufacture a comprehensive range of products for the domestic heating market. Gas Central Heating Boilers (Wall, Floor and Fireside models). Independent Gas Fires. Renewal Firefronts. Gas Wall Heaters. Solid Fuel Fires. If you require information on any of these products, please write, telephone or fax to the Sales Department.
Comp No 247936 - Iss 6 - 6/02 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 921.648.
