Baxi Combi Instant 80e Installation & Servicing Instructions Manual
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Baxi Combi Instant 80e Installation & Servicing Instructions Manual

Baxi Combi Instant 80e Installation & Servicing Instructions Manual

Gas fired wall mounted combination boiler
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Installation & Servicing Instructions
Baxi Combi Instant 80e & 105e
Gas Fired Wall Mounted Combination Boiler
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Summary of Contents for Baxi Combi Instant 80e

  • Page 1 Installation & Servicing Instructions Baxi Combi Instant 80e & 105e Gas Fired Wall Mounted Combination Boiler Please leave these instructions with the user...

  • Page 2: Natural Gas

    Type test for purpose of Regulation 5 certified by: Notified Body 0051. Product/Production certified by: Notified Body 0051. For GB/IE only. Baxi is a BS-EN ISO 9001 Accredited Company...
  • Page 3 Installer Notification Guidelines Install and Commission this appliance to manufacturer's instructions Complete the Benchmark Checklist Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme If you notify via CORGI Scheme, Contact your relevant Local CORGI will then notify the Authority Building Control relevant Local Authority (LABC) who will arrange...
  • Page 4 Legislation IMPORTANT - Installation, Commissioning, Service & Repair Baxi declare that no substances harmful to health are contained in the appliance or used during appliance This appliance must be installed in accordance with the manufacturer’s instructions and manufacture. the regulations in force. Read the instructions fully before installing or using the appliance.

  • Page 5: Table Of Contents

    Contents Section Page Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Installation Commissioning the Boiler 10.0 Completion 11.0 Servicing the Boiler 12.0 Changing Components 13.0 Illustrated Wiring Diagram 14.0 Fault Finding 15.0 Short Parts List Benchmark Checklist...

  • Page 6: Introduction

    1.0 Introduction Description Case Front Panel 1. The Baxi Combi Instant 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.

  • Page 7: General Layout

    2.0 General Layout Layout Air Pressure Switch Expansion Vessel & Pre-Heat Store Burner Manifold Automatic Air Vent DHW Plate Heat Exchanger Circulation Pump Drain Off Point Pressure Relief Valve Position for Optional Integral Timer Central Heating System Pressure Gauge Control Box 3-Way Valve Assembly Spark Generator Flame Sensing Electrode...

  • Page 8: Appliance Operation

    Central Heating Mode 3.0 Appliance Operation NOTE: All delay timers mentioned in 3.1 and 3.2 are overridden by domestic hot water demand. Central Heating Mode (Fig. 2) 1. With a demand for heating, the pump circulates water through the primary circuit. At a pre-determined flow rate the central heating flow switch operates, initiating 20 22 the ignition sequence.
  • Page 9 3.0 Appliance Operation Domestic Hot Water Mode Domestic Hot Water Mode (Fig. 3A) 1. Priority is given to the domestic hot water supply. A demand at a tap or shower will override any central heating requirement. 2. The flow of water will operate the DHW flow switch which requests the 3 way valve to change position.

  • Page 10: Technical Data

    Fuse 2A Fast Blow to BS 4265 dependent upon flow rate Electrical Protection IPX5D SEDBUK Declaration For Combi Instant 80e Pump - Available Head The seasonal efficiency (SEDBUK) is 78.6 % This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings.
  • Page 11 4.0 Technical Data Combi Instant 105e Appliance Type DHW Circuit NO x Class Pressures Appliance Category CAT II Flue Terminal Diameter 100mm Max Operating 2H 3P Dimensions Projection 95mm Min Operating Heat Input C/H & DHW (Net) Min Operating Pressure Connections copper tails at 12.7 l/min...

  • Page 12: Dimensions And Fixings

    5.0 Dimensions and Fixings Dimensions A 780mm B 345mm C 450mm D 107mm Ø Min. E 200mm F 190mm G 143mm 360° Orientation Tube Ø 100mm Tap Rail 65 mm 65 mm 65 mm 65 mm 65 mm Heating Pressure Relief Heating Domestic Hot Cold Water...

  • Page 13: System Details

    6.0 System Details Information 1. The Baxi Combi Instant 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.
  • Page 14 6.0 System Details 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 Stop Check 2. There are connection points on the mains cold water Valve Valve Valve...
  • Page 15 6.0 System Details Other Tap Domestic Hot Water Circuit (Fig. 6) Outlets 1. All DHW circuits, connections, fittings, etc. should be Boiler Expansion fully in accordance with relevant standards, the water Vessel supply regulations. 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Check Regulations Guide.

  • Page 16: Site Requirements

    7.0 Site Requirements 450mm 5mm Min 5mm Min Location 1. The boiler may be fitted to any suitable wall with the 200mm Min 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.
  • Page 17 7.0 Site Requirements Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required as the appliance will run sufficiently cool without ventilation. Gas Supply 1. The gas installation should be in accordance with the relevant standards.
  • Page 18 7.0 Site Requirements Flue 1. The following guidelines indicate the general requirements for siting flue terminals. For GB recommendations are given in BS 5440 Pt.1. For IE recommendations are given in the current edition of I.S. 813 “Domestic Gas Installations”. 2.
  • Page 19 7.0 Site Requirements Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 1m from elbow to terminal (Fig. 12). The maximum permissible equivalent flue length is: Instant 80e 5 metres Instant 105e 4 metres NOTE: Each additional 45° of flue bend will Fig.
  • Page 20 7.0 Site Requirements 7.10 Flue Options 1. The Baxi Combi Instant 80e and 105e can be fitted with flue systems as illustrated. 2. The standard flue Kit No 247719 is suitable only for horizontal applications. 3. Maximum permissible equivalent flue lengths are:-...

  • Page 21: Installation

    Comp No 248740 - Iss 1 - 1/01 pipe (Fig. 17). 2. Flush thoroughly (see System Details, Section 6.2). Fig. 16 3. The use of the optional Baxi Filling Loop Kit (Part No. 248221) will simplify the flushing and soundness Wall Plate checking.
  • Page 22 Wall Plate 8.0 Installation 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.
  • Page 23 8.0 Installation Wall Thickness Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths 100mm minimum to 1m maximum (measured from the edge of the flue elbow outlet). Rear Flue: maximum wall thickness - 900mm Side Flue: maximum wall thickness - 870mm 2.
  • Page 24 8.0 Installation Elbow Fitting the Flue (Cont) IMPORTANT: If the equivalent flue length is greater Seal than 1.5m the restrictor MUST be removed from Restrictor the adaptor (Fig. 22). Adaptor 8. Take one of the rubber seals and position it on the boiler flue adaptor.
  • Page 25 8.0 Installation Making The Electrical Connections To connect the mains input cable proceed as follows:- 1. Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel. 2.

  • Page 26: Commissioning The Boiler

    Commissioning the Boiler Commissioning the Boiler Screw 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 3. Open all hot water taps to purge the DHW system. Vent 4.
  • Page 27 Commissioning the Boiler Burner Pressure Test Point Sealing Screw Checking the Burner Pressure Inlet Pressure Test 1. Turn on the gas and electrical supplies to the boiler Point Sealing Screw and ensure that all external controls are calling for heat. Gas Valve 2.

  • Page 28: Completion

    10.0 Completion 10.1 Completion Case Front Panel 1. Hinge the facia panel upwards and refit the case front panel. Secure them with the screws previously removed (Fig. 38). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3.

  • Page 29: Servicing The Boiler

    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 Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication.
  • Page 30 Baffle 11.0 Servicing the Boiler Spring Clip 11.1 Annual Servicing (Cont) 10. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood (Fig. 42). 11. Undo the screws securing the fan and hood to the appliance back panel.

  • Page 31: Changing Components

    12.0 Changing Components IMPORTANT: When changing components ensure Pressure that both the gas and electrical supplies to the Switch 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 Sensing seconds to reset the boiler before...
  • Page 32 12.0 Changing Components Heat Exchanger 12.3 Heat Exchanger (Fig. 48) (Instant 80e model) 1. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them. 2. Slacken the screws on the outlet sealing collar. Ease the collar upwards as far as possible.
  • Page 33 12.0 Changing Components Injector Inlet Elbow Manifold 12.5 Injectors (Fig. 50) 1. Remove the burner as described in Section 12.4. 2. Undo the screws securing the injector manifold to the inlet elbow and remove the manifold. Gasket 3. Unscrew and replace injectors as required and examine the sealing gasket, replacing as necessary.
  • Page 34 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 Modulator from the valve.
  • Page 35 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.
  • Page 36 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.
  • Page 37 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.
  • Page 38 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.
  • Page 39 12.0 Changing Components Diverter Valve Operating Head 12.22 Diverter Valve Assembly (Cont) CH Pressure Differential Valve Diaphragm (Fig. 67) Spring Clip 3-pin Plug 1. Isolate the boiler from the central heating flow and return pipes and drain the boiler primary circuit. Diverter Valve 2.

  • Page 40: Illustrated Wiring Diagram

    13.0 Illustrated Wiring Diagram Air Pressure Switch Central Heating Temperature Sensor Domestic Hot Water Temperature Sensor Optional Timers Microswitch Microswitch Control PCB Flame Sensing Electrode Diverter Valve Operating Head Mains Input Link Fuse Pump Overheat Stat Gas Valve Spark Generator - brown - green - black...

  • Page 41: Fault Finding

    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).
  • Page 42 14.0 Fault Finding Domestic Hot Water - Follow operational sequence Turn On/Off/Reset selector to position. Go to section ‘A’. neon illuminated. Primary water diverted to Go to section ‘M’. DHW preheating circuit. Go to section ‘L’. Turn preheat control to on. External controls and where Ensure controls are set to Preheating function starts after...
  • Page 43 14.0 Fault Finding Central Heating - Follow operational sequence Turn selector to Go to section ‘A’. neon illuminated. Ensure controls are set to demand and verify the contacts are closed. Turn Central Heating External controls calling for neon flashing thermostat to maximum. heat and where fitted, internal Go to section ‘B’.
  • Page 44 14.0 Fault Finding Central Heating - Follow operational sequence (Continued) Continued from previous page Does the burner remain lit ? CH temperature higher than set point of CH thermostat control. When CH temperature decreases cycle continues. Turn the selector to reset. If regular resetting is required Go to section ‘J’.
  • Page 45 14.0 Fault Finding Fault Finding Solutions Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse neon Replace main PCB illuminated Selector terminals a & b and a Check wiring & 3. PCB - A4 connector Replace selector terminals 4 &...
  • Page 46 14.0 Fault Finding Fault Finding Solutions Check and correct if necessary 1. Electrical and pressure tube connections Replace air pressure 2. Blockage of pressure tubes switch 3. Restriction in flue 4. Venturi Gas at burner Ensure gas is on and purged PCB - A1 connector has 230V across Replace gas valve terminals 2 &...
  • Page 47 14.0 Fault Finding Fault Finding Solutions Ensure that mains input terminal L is Live (230V) and N is Neutral (0V) Check and correct if necessary 1. Flame sensing electrode and lead connections 2. Flame sensing electrode position Replace main PCB Flame current should be 1 µA approx.

  • Page 48: Short Parts List

    15.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. E66 527 248002 393 974 Pressure Switch 247380 E66 393 Heat Exchanger (80e) 248016 E66 535 Heat Exchanger (105e) 248017 E66 398 Burner (80e) 248029 E66 399 Burner (105e) 248030 E66 402 Injector...
  • Page 49 16.0 Notes...

  • Page 50: Benchmark Checklist

    2 4 8 7 4 1 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...

  • Page 51: Service Interval Record

    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.
  • Page 52 BAX I POTT ER TON 922.555.3 A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www.baxi.co.uk company Comp N 248741 - Iss 7 - 4/05...

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Combi instant 105e

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