Baxi 100/2 HE Plus Installation & Servicing Instructions Manual
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Baxi 100/2 HE Plus Installation & Servicing Instructions Manual

Baxi 100/2 HE Plus Installation & Servicing Instructions Manual

Wall mounted powered flue condensing boiler, gas fired central heating unit
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Installation & Servicing Instructions
Baxi 100/2 HE Plus
Wall Mounted Powered Flue Condensing Boiler
Gas Fired Central Heating Unit
Please leave these instructions with the user

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Summary of Contents for Baxi 100/2 HE Plus

  • Page 1 Installation & Servicing Instructions Baxi 100/2 HE Plus Wall Mounted Powered Flue Condensing Boiler Gas Fired Central Heating Unit Please leave these instructions with the user...
  • Page 2 Notified Body 0087. success. Product/Production certified by: Notified Body 0086. We hope you get a satisfactory service from Baxi. If not, please let us know. For GB/IE only. Baxi is a BS-EN ISO 9001 Accredited Company This product has an energy rating (A) on a scale of A to G.

  • Page 3: Table Of Contents

    Contents Section Page Legislation Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Installation Electrical 10.0 Commissioning the Boiler 11.0 Fitting the Outer Case 12.0 Servicing the Boiler 13.0 Changing Components 14.0 Short Parts List 15.0 Fault Finding...

  • Page 4: Legislation

    0.0 Legislation IMPORTANT - Installation, Commissioning, Service & Repair Baxi declare that no substances harmful to health are contained in the appliance or used during This appliance must be installed in accordance with the manufacturer’s instructions and appliance manufacture. the regulations in force. Read the instructions fully before installing or using the appliance.

  • Page 5: Introduction

    1.0 Introduction Description 1. The Baxi 100/2 HE Plus is a gas fired room sealed fan assisted condensing central heating 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.

  • Page 6: General Layout

    2.0 General Layout Layout (Figs. 3,4,5 & 6) Wall Plate Flue Elbow Heat Exchanger Burner Air Box Fan Protection Thermostat Fan Assembly Fig. 5 Condensate Trap PCB Housing Assembly Gas Tap Gas / Air Ratio Valve Flow Pipe Connection Return Pipe Connection Flow Temperature Safety Thermostat - Black Flow Temperature Thermistor - Red Flow Switch (dry fire protection)

  • Page 7: Appliance Operation

    Mains On. 3.0 Appliance Operation Flow temperature less 1. Switched Live On: When the switched live switches than set point ? on if the flow temperature is less than the set point then pump overrun occurs. When the switched live switches on if the flow temperature is greater than the set point then pump overrun occurs.

  • Page 8: Technical Data

    22.0kW (75,000 Btu/hr). This can be altered to 30.18kW (102,980 Btu/hr) - see section 8.8. SEDBUK Declaration For 100/2 HE Plus The efficiency is 90.9% This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings.

  • Page 9: Dimensions And Fixings

    5.0 Dimensions and Fixings DIMENSIONS A 600mm 3° (1 in 20) B 320mm C 390mm D 125mm Ø Min. E 150mm F 125mm 360° Orientation 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 Tube Ø...

  • Page 10: System Details

    • It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the manufacturer’s instructions. (Test kits are available from inhibitor stockists.) • For information or advice regarding any of the above contact the Baxi Helpline.
  • Page 11 Thermal Stores If Conditions Require, Fig. 11 This System Possible 1. When the 100/2 HE Plus is fitted in conjunction with a thermal store, both jumpers must be removed from the PCB, see Fig. 32 Section 8.8. 22mm 200mm Feed &...
  • Page 12 230V Key to colours 50Hz - Blue Y Plan L N E 6.0 System Details - Brown Diverter Valve - White Cylinder Stat - Orange System Controls - Grey Room g/y - Green/Yellow Stat This boiler does not require a bypass. Boiler This boiler does not require a permanent live.
  • Page 13 15mm ( in) nominal size. using Baxi Boilers The volume of the vessel should be suitable for the system water content and the nitrogen or air charge Multiply Total pressure should not be less than the system static head (See Table.

  • Page 14: Site Requirements

    7.0 Site Requirements 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. 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 Zone 2...
  • Page 15 5mm Min 390mm 5mm Min 7.0 Site Requirements Clearances (Figs. 15 &16) 200mm 1. A flat vertical area is required for the installation of the boiler. 2. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement.
  • Page 16 7.0 Site Requirements Termination to an internal soil and vent pipe Boiler Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5°...
  • Page 17 25mm but the flue deflector kit (part no. 248167) must be fitted. 7. If required a suitable terminal guard is available from Baxi for use with the flue deflector. Top View Rear Flue Fig. 16a 8. For fitting under low soffits and eaves it is acceptable...
  • Page 18 7.10 Vertical Flue Fig. 18a 1. Only a flue approved with the Baxi 100/2 HE Plus Pictorial examples of flue runs where EQUIVALENT flue length equals 4m can be used. 2. For information on vertical flues consult the Baxi Flue Guide Brochure or Notes for Guidance supplied with the vertical flue pack.
  • Page 19 Detailed examples of equivalent flue length calculation are given in the Installation Guidance Notes for each flue system type. (Documents 243501 and 243502 for concentric and twin pipe respectively). Accessory Size Baxi Code Number Concentric Flue System 110mm diameter Horizontal flue kit 850mm 236921 Straight extension kit...

  • Page 20: Installation

    8.0 Installation Example Edge of Boiler 125mm Check Site Requirements (section 7) before commencing. EXAMPLE: Boiler is 2 metres away Initial Preparation from corner of wall, flue duct hole is 110mm up from horizontal side flue Example centre line. This will maintain the V = 110mm The gas supply, gas type and pressure must be approx 3°...
  • Page 21 1. Remove the outer carton. 2. Remove the internal packaging. 3. Lift the outercase upwards and remove (Fig. 23). Outercase Baxi declare that no substances harmful to health are contained in the appliance or used during appliance manufacture. Break Off Upper &...
  • Page 22 8.0 Installation Fitting The Boiler (Fig. 24) Retaining Bracket 1. Remove the screw and retaining bracket from the wall plate spring clip. 2. Offer up the boiler to the wall plate using the lifting points shown in Fig. 24 and locate the rear bottom edge onto the self locating support at the base of the wall plate.
  • Page 23 8.0 Installation Wall Thickness Making the Gas Connection 1. Connect the gas supply to the G in BSPT Internal) gas tap. This is located on the lower right side 3° of the boiler, access by hinging down the PCB housing (1 in 20) (see Fig.
  • Page 24 13. If necessary fit a terminal guard (see Section 7.9). Gasket VERTICAL FLUEING 1. Only a flue approved with the Baxi 100/2 HE Plus can be used. 2. For information on vertical flues consult the Baxi Flue Guide Brochure or Notes for Guidance supplied with the vertical flue pack.
  • Page 25 8.0 Installation Making The Electrical Connections WARNING: This appliance must be earthed 1. The electrical connections are on the right hand side of the unit. 2. Undo the two screws securing the cable clamp and place to one side (Fig. 31). 3.

  • Page 26: Electrical

    9.0 Electrical Schematic Wiring Diagram Key To Wiring Colours b - Blue r - Red bk - Black g - Green w - White g/y- Green/Yellow br - Brown op - Opaque gy - Grey y - Yellow...
  • Page 27 9.0 Electrical Illustrated Wiring Diagram Flow Thermistor Optional Pump Feed Flow Switch Spark Flame Electrode Detection Electrode Main Layout of PCB Pins Condensate Trap Gas Valve Fan Overheat Thermostat Flow Overheat Thermostat Wiring Key - Blue bk - Black br - Brown - Red w - White g/y - Green/Yellow...

  • Page 28: Commissioning The Boiler

    10.0 Commissioning the Boiler 10.1 Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Flush the whole system using a suitable flushing agent (see Section 6.2) and vent the radiators. Check for water leaks.

  • Page 29: Fitting The Outer Case

    11.0 Fitting the Outer Case 11.1 Fitting The Outer Case Break Off Panel 1. Position the outercase over the boiler engaging the lugs in the side flanges over the hooks on the wall plate. Break off top or bottom panel as required to accommodate pipework runs (Fig.37).

  • Page 30: Servicing The Boiler

    Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended. When replacing the combustion box door after servicing it is essential that the retaining screws are tightened fully.
  • Page 31 12.0 Servicing the Boiler 12.1 Annual Servicing (Cont) Flue Sampling Point 10. To clean the heat exchanger and burner proceed as follows: a) Disconnect the electrical leads to the fan component protection sensor (Fig. 42). Fig. 41a b) Loosen the screw retaining the gas injector pipe at the venturi (Fig.

  • Page 32: Changing Components

    Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended. When replacing the combustion box door after changing components, it is essential that the retaining screws are tightened fully.
  • Page 33 13.0 Changing Components 13.3 Flowswitch (Fig. 47) 1. Drain the boiler (see Section 13.1 paragraph 2 & 3). 2. Disconnect pipework, loosen elbow locking nut and undo screws on support bracket. 3. Remove the clip securing the flow pipe to the Support Bracket flowswitch.
  • Page 34 13.0 Changing Components 13.4 (Figs. 48 & 49) Control Knob WARNING: The PCB Control and Fan Assembly is 325 Vdc. Isolate at supply before access. 1. Pull the control knob off the spindle and remove the Plastic plastic button cover. Refit them onto the new PCB Button (Fig.
  • Page 35 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 turn screws (Fig.
  • Page 36 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 13.6). 13.7 Injector Pipe (Fig. 53) 1. Remove the injector pipe by pulling out from the ‘O’ ring joint in the gas valve.
  • Page 37 13.0 Changing Components Combustion Box The burner and heat exchanger can be changed after Door Panel removal of the combustion box door. To change the heat exchanger, the fan and burner must be removed first (see section 13.6 and 13.10). 1.
  • Page 38 13.0 Changing Components 13.12 Heat Exchanger Lower Insulation Pad (Fig. 60) 1. Remove all components in the base of the airbox. 2. Remove the burner (see section 13.10). 3. Remove the four bolts securing the combustion box base. 4. Remove the combustion box base. 5.

  • Page 39: Short Parts List

    14.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. E06 058 Flow Temperature Thermistor (Red) 240670 E06 059 Flow Switch 242459 E06 060 Safety Thermostat (Black) 242235 PCB (100/2HE) 5110991 5109925 Gas Valve 241900 E06 085 Viewing Window 242484 Condensate Trap 5111714...

  • Page 40: Fault Finding

    15.0 Fault Finding High Reset NOTE: The fan is supplied with 325 Vdc. Fan Fault Finding should only be carried out after the boiler has been electrically isolated. General Fault Finding should only be carried out by Lockout Boiler On Mains On someone who is appropriately qualified.
  • Page 41 Lights 15.0 Fault Finding Off Off Off ELECTRICAL SUPPLY No Switched Live to boiler. Check Systems 240V at A ? Controls and System Wiring. Check wiring from 240V at B ? terminal block to PCB. Optional Pump Live Check for shorts on pump, fan &...
  • Page 42 Lights 15.0 Fault Finding On Flash Flash DRY-FIRE Is the Fill system with water and system full of water ? bleed out all air. Optional Pump Replace PCB. Live Turn Turn Is the mains off, unplug Is the mains off & on. After 5 sec, is 7-way connector to PCB.
  • Page 43 Lights 15.0 Fault Finding On Off On IGNITION LOCKOUT Check isolation valve and Is there gas at gas valve inlet ? gas supply. 5-way Connector Remove 5-way connector Reset Lockout. from gas valve. Is there 240 Is there gas flow Replace Gas Valve.
  • Page 44 Lights 15.0 Fault Finding Flash Off On OVERHEAT LOCKOUT Disconnect black stat on flow pipe. Replace Stat. When flow < 60° C is there continuity across stat ? Reconnect stat. Disconnect fan stat. Replace Stat. When fan temp < 60° C is there continuity across stat ? Reconnect stat.
  • Page 45 Lights 15.0 Fault Finding Flash Flash On FAN LOCKOUT NOTE: The fan is supplied with 325 Vdc. Fan Fault Finding should only be carried out after the boiler has been electrically isolated. Connection Connection Unplug 3-way PCB connector & unplug fan. Is there Rectify wiring.
  • Page 46 15.0 Fault Finding Lights On Flash On THERMISTOR Unplug thermistor, Is thermistor resistance between Replace thermistor. 0.5kΩ & 20kΩ ? Plug in thermistor, leave Wiring from PCB to 8-way connector unplugged. thermistor faulty. Viewed from Is resistance at D between 0.5kΩ...
  • Page 47 Baxi 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...
  • Page 48 BAX I POTTE RT ON 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 Comp N 5109941 - Iss 2 - 09/04...

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