High-efficiency wall-hung condensing gas boiler (36 pages)
Summary of Contents for Baxi Combi 428 LPG
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United Kingdom Installation and Service Manual High Efficiency Wall Hung Condensing Gas Boiler Baxi Combi 224 — 228 — 424 — 428 428 LPG These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping.They must be read in conjunction with the Flue Installation Guide.
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Dear Customer, Thank you very much for buying this appliance. Please read through the manual carefully before using the product, and keep it in a safe place for later reference. In order to ensure continued safe and efficient operation we recommend that the product is serviced regularly. Our service and customer service organisation can assist with this.
1 Safety Safety Benchmark 1.1.1 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. This can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly.
1 Safety 1.1.3 Installer Notification Guidelines Fig.2 Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme Contact your relevant Local Install and Commission this Authority Building Control appliance to manufacturer's (LABC) who will arrange instructions an inspection or contact a government approved...
1 Safety General safety instructions Danger This boiler can be used by children aged 8 years and above and by persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge when they have been given supervision or instruction concerning the safe use of the device and understand the resulting risks.
1 Safety Caution Make sure the boiler can be reached at all times. The boiler must be installed in a frost-free area. In the case of a fixed connection to the power cord, you must always install a main double pole switch with an opening gap of at least 3 mm (EN 60335-1).
1 Safety Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the "Installation" section of these instructions for recommended lift points. Remember The circumstances of each installation are different. Always assess the risks associated with handling and lifting according to the individual conditions.
2 About this manual About this manual General This manual is intended for the installer of a Baxi Combi boiler. Additional documentation These Installation & Service Instructions must be read in conjunction with the Flue Accessories Fitting Guide supplied in the Literature Pack.
3 Technical specifications Technical specifications Homologations 3.1.1 Safety, Performance & Quality This boiler has been assessed by an appropriate Notified Body and shown to meet the requirements of all Directives and Regulations as applicable. These Directives and Regulations lay down requirements for the safety and efficiency of the appliance, together with its design, construction and use of materials.
All data in these sections are nominal and subject to normal production tolerances. Important LPG information can be found in Technical information - LPG, page 75 Tab.5 General Baxi Combi Gas Council Numbers 47–077–21 47–077–22 47–077–23 47–077–24 Nominal heat input Domes...
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3 Technical specifications Baxi Combi Nominal heat output 21.8 26.1 21.8 26.1 50/30°C — Central Heating — Maximum Rate Nominal heat output 50/30°C — Central Heating — Minimum Rate Tab.6 Central heating circuit specifications Baxi Combi Maximum pressure Minimum pressure Central heating temperature adjust...
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3 Technical specifications Baxi Combi Nominal power consumption when firing External fuse rating F2 Internal fuse rating — Connec tion board ’B’ F1 Internal fuse rating — Main PCB board ‘A’ Important Boiler must be connected to an earth supply.
3 Technical specifications Dimensions and connections/clearances Fig.3 Dimensions and connections PN-0000501 Fig.4 Clearances Safety valve Heating circuit water flow Condensate discharge Heating system/boiler drain tap Domestic hot water outlet Gas inlet Mains cold water inlet Heating circuit water return Clearances below — 200mm minimum, 250mm recommended Clearances in front —...
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3 Technical specifications Fig.5 Paper template Clearance above 183 116 Dia Minimum Aperture For Flue Tube Vertical Flue Centre Line Ø 8 Side Clearance 5 Side Clearance 5 View from under boiler Wall 82.5 33.5 67.5 Hot Water Cold Water Heating Heating Outlet...
Description of the product General description The Baxi Combi condensing boiler is a gas-fuelled boiler. The purpose of this boiler is to heat water to a temperature that is lower than boiling point at atmospheric pressure. It must be connected to a heating installation and to a domestic hot water distribution system that is compatible with its power and performance ratings.
4 Description of the product Main components Fig.7 Component description Boiler case Mounting slots for wall bracket Flue adaptor Expansion vessel air control/filling valve Expansion vessel Burner door Detection/ignition electrode Water circuit-expansion vessel connection pipe Air-gas assembly (control board, fan, mixer valve) Automatic air vent Gas valve Pump...
5 Before installation Before installation Installation regulations Warning Installation, repair and maintenance must only be carried out by a competent person. This document is intended for use by competent persons. Installation must be carried out in accordance with the prevailing regulations, the code of practice and the recommendations in these instructions.
5 Before installation Important Any wiring to the boiler, from either the mains or an external control, MUST be cable of the following specification:- 0.75mm 3183/4/5Y (depending on installation) multi strand flexible cable conforming to BS 50525-2-11. Cable of the above specification is sufficiently flexible to withstand normal regular opening and closing of the facia/ control box as expected during routine servicing and other maintenance work.
It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the inhibitor manufacturer. (Test kits are available from inhibitor stockists.) For information or advice regarding any of the above contact Baxi Customer Support 0344 871 1545. 5.2.7...
5 Before installation 5.2.10 Safety pressure relief valve Fig.11 Discharge pipe Discharge pipe Pressure relief valve The end of the pipe should terminate facing down and towards the wall See BS 6798 for full details. The pressure relief valve is set at 3 bar, therefore all pipework, fittings, etc. should be suitable for pressures in excess of 3 bar and temperature in excess of 100°C.
5 Before installation 5.3.2 Data plate and service label Fig.12 Data plate position The data plate is located on the top inner part of the boiler. To see it, remove the front panel of the boiler. The data plate provides important information about the boiler.
5 Before installation 5.3.3 Bath and shower rooms Fig.15 Bathroom 1 and 2 Zone 0 Zone 1 Zone 2 Window recess Zone 2 Ceiling Outside zones Important Where an optional plug-in integral timer, RF receiver or thermostat is NOT FITTED the boiler has a protection rating of IPX5D and if installed in a room containing a bath or shower can be within Zone 2 (but not 0 or 1).
5 Before installation 5.3.5 Condensate drain Fig.16 Pipework and method of termination It is strongly recommended to discharge internally into the household drainage system. If connecting to a rain water drain, that drain MUST discharge into a foul drain. 32mm 21.5mm Pipework.
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5 Before installation Fig.17 Methods of termination continued Important Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler. Careful consideration must be given to the possibility of the pipework being subject to freezing conditions and appropriate measures taken to prevent blockage.
5 Before installation The fitting of a "Trace Heating" Element is NOT a substitute for correct installation of the condensate drain. ALL requirements in this section must still be adhered to. 5.3.6 Clearances Fig.18 Clearances A flat vertical area is required for the installation of the boiler and it should be capable of bearing the weight of the boiler when full of water.
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5 Before installation Tab.23 Terminal position with minimum distance Description Description Directly below an opening, air brick open From a surface or boundary line facing ing window etc. a terminal Above an opening, air brick, opening win From a terminal facing a terminal 1200 dow etc.
5 Before installation Fig.21 Plume displacement kit Opening window or door Air inlet Plume displacement kit 150mm minimum Important If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 150mm from any opening windows or doors. Important The Plume Displacement flue gas discharge terminal and air inlet must always terminate in the same pressure zone i.e.
5 Before installation Warning SUPPORT - All flue systems MUST be securely supported at a MINIMUM of once every metre & every change of direction. It is recommended that every straight piece is supported irrespective of length. Additional supports are available as accessories. VOIDS - Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual inspection.
5 Before installation Transport This product should be lifted and handled by two people. When lifting always keep your back straight and wear protective equipment where necessary. Carrying and lifting equipment should be used as required. e.g. when install in a loft. Unpacking &...
5 Before installation Fig.26 Unpacking PN-0000513 5.5.2 Initial preparation Fig.27 Template 1. After considering the location position the fixing template on the wall ensuring it is level both horizontally and vertically. 2. Mark the position of the fixing slots for the wall bracket indicated on the template.
5 Before installation Fig.28 Mounting the boiler 7. Using a spirit level ensure that the wall bracket is level before finally tightening the screws 8. Lift the boiler by gripping "a" and "b" and hook the boiler onto the wall bracket (9).
Even in circumstances where a non-return device is not fitted any future modifications to the mains inlet (e.g. fitting of a water meter) should be considered and an expansion vessel fitted. Baxi cannot accept any responsibility for damage to the boiler if these recommendations are not followed.
6 Installation Installation General Installation must be carried out in accordance with the prevailing regulations, codes of practice and the recommendations in this manual. Danger If the boiler is installed in a compartment do not use it for storage purposes. Do not obstruct any purpose provided ventilation openings.
6 Installation Air supply/flue gas connections 6.3.1 Connecting the flue/chimney Fig.33 Telescopic flue HORIZONTAL TELESCOPIC FLUE (concentric 60/100) 315mm to 500mm Connection assembly Terminal assembly There are two telescopic sections, the terminal assembly and the connection assembly, a roll of sealing tape and two self tapping screws. A 93°...
6 Installation Fig.36 Attaching the flue 8. Remove the flue elbow and insert the flue through the hole in the wall. Fit the flue trims if required, and refit the elbow to the boiler adaptor, ensuring that it is pushed fully in. Secure the elbow with the screws supplied in the boiler fitting kit.
6 Installation 6.4.2 Electrical connections of the boiler Fig.37 Electrical connections Access the connection board located below the control panel to make the electrical connections by: 1. Fully unscrewing the two screws retaining the electrical cover at the bottom of the front panel and then remove the cover. 2.
(as shown on the graph) is displayed. 80° 75° 70° Important 65° If a Baxi uSense smart thermostat is connected to the boiler the Slope 30 60° slope must be set using the uSense App. The boiler display will 55° Slope 20 50°...
6 Installation Filling the installation 6.5.1 Flushing the system Flush thoroughly and treat the system according to guidance given in BS 7593. 6.5.2 Fill the installation 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.
7 Commissioning Commissioning General Reference should be made to BS:EN 12828, 12831 & 14336 when commissioning the boiler. Ensure that the condensate drain trap has been primed. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publication. Open the mains water supply to the boiler and all hot water taps to purge the DHW system.
7 Commissioning Commissioning procedure 7.3.1 De-Aeration function Fig.41 Initialisation process Before turning on the power to the boiler, rotate the Central Heating control knob fully clockwise. The purpose of the function is to remove as much air as possible from the heating system.
7 Commissioning Fig.43 Gas inlet test point Gas inlet test point 1. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point is in accordance with BS 6798 & BS 6891. This must be AT LEAST 17mb ! 2.
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7 Commissioning Fig.45 Chimney sweep procedure Measuring the combustion Important The system MUST be cold to ensure the boiler is operating under full demand. 1. Turn the Central Heating and Domestic Hot Water control knobs fully clockwise. 2. Activate the Chimney Sweep mode by pressing the Chimney Sweep button for 3 seconds (A).
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7 Commissioning Fig.46 Combustion procedure Set Boiler to Maximum Rate Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser. Perform Flue Integrity Combustion Check Insert the analyser probe into Verify Flue Integrity the air inlet test point, allowing Indication that products of Check CO &...
7 Commissioning Configuring the system 7.5.1 System draining If at any time after installation it is necessary to drain and refill the central heating system (e.g. when replacing a radiator) the De-Aeration function must be activated to avoid air being trapped in the system. De-Aeration function, page 47.
8 Operation Operation Use of the control panel 8.1.1 Control The controls are operated by the buttons and knobs shown. Fig.48 Operating the controls Central heating water temperature control Domestic Hot Water temperature control Reset button Where an outdoor sensor (weather compensation) device is connected to the boiler the central heating control (item 1) adjusts the setting of the curve, not the boiler flow temperature.
9 Settings Settings Functions The operating functions of the boiler have been factory set to suit most systems. See table below for a list of display functions. Accessing the information menu, page 69 for further information. Information menu Tab.27 Information list Information Description Status...
10 Maintenance 10 Maintenance 10.1 General Warning When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed recommission the boiler. Always examine any seals or gaskets, replacing where necessary. The case front panel MUST seal effectively against the boiler side panels.
10 Maintenance 10.2 Standard inspection and maintenance operations 10.2.1 Periodic check and maintenance procedure Warning Before performing any operation, make sure the boiler is not powered on. Once the maintenance operations are complete, reset the original boiler operating parameters if they were changed.
10 Maintenance 5. Close the air/gas cover. 6. Completely remove the air/gas and burner/unit by unscrewing the four M6 nuts and undoing the ” nut below the gas valve. 7. Check that the detection/spark electrode is not worn. Replace the electrode if necessary.
10 Maintenance 10.3.1 Detection/spark ignition electrode Fig.51 Remove detection/spark ignition 1. Disconnect the electrode lead and earthing cable. electrode 2. Using a T15 Torx key, remove the retaining screws securing the electrode to the combustion chamber door and remove the electrode, noting its orientation.
10 Maintenance 10.3.5 HMI control Fig.55 HMI removal 1. Remove the screws from the link/timer 2. Hinge the control box downwards. 3. Disengage the optional timer plug and ease the cable out of its housing. 4. Unclip the back cover of the control box and remove it. 5.
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10 Maintenance Fig.58 Adjusting the gas valve Minimum rate (offset) adjustment screw. Maximum rate adjustment screw. Burner gas pressure outlet. Gas supply pressure outlet. Important The case front panel must be fitted when checking combustion. Run the boiler for several minutes before checking the CO and CO .
10 Maintenance 10.3.8 Insulation Fig.59 Removing the insulation 1. Remove the Detection/spark ignition electrode. Detection/spark ignition electrode, page 57. 2. Hinge the control box down. 3. Hinge down the air/gas cover and disconnect all wiring plugs from the PCB, noting their positions. Close the air/gas cover. 4.
10 Maintenance 10.4 Hydraulics maintenance 10.4.1 Expansion vessel Warning Take precautions to protect other components from water damage when removing the expansion vessel. Fig.61 Removing the expansion vessel 1. Close the flow and return isolation taps and drain the primary circuit. 2.
10 Maintenance 10.4.3 Auto air vent Warning Take precautions to protect other components from water damage when removing the air vent. Fig.63 Removing the auto air vent 1. Close the flow and return isolation taps and drain the boiler primary circuit.
10 Maintenance 10.4.5 Hydraulic pressure sensor Fig.65 Removing the hydraulic pressure 1. Close the flow and return isolation taps. sensor 2. Drain the primary circuit. 3. Hinge the control box down. 4. Remove the air/gas unit. Air/gas unit, page 58, paragraph 1 to 6 to remove. 5.
10 Maintenance 10.4.8 Diverter valve motor Fig.68 Removing the diverter valve motor 1. Hinge the control box down. 2. Remove the air/gas unit. Air/gas unit, page 58, paragraph 1 to 6 to remove. 3. Undo the screw securing the electrical plug to the motor unit. Disconnect the plug.
11 Troubleshooting 11 Troubleshooting 11.1 Error codes Error messages are displayed according to the type of fault. Temporary fault A temporary fault is indicated by an ‘H’ followed by a two-digit code number (e.g. .02). This code flashes and alternates with a second two-digit code (e.g.
11 Troubleshooting Group Specific Description Probable cause Check/Reason code code H:01 No circulation of water Non-existent or insufficient circu Check circulation lation Check water pressure Sensor error Check sensors are operating correctly Check that the sensor has been correctly fitted Check the cleanliness of the heat exchanger Check pump...
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11 Troubleshooting Group Specific Description Probable cause Check/Reason code code E:01 5 x flame loss in 24 hours with No ionization current Purge the gas supply to remove burner on Check that the gas valve is fully opened Check the supply pressure Check the operation and setting of the gas valve unit Check that the air inlet and flue...
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11 Troubleshooting Group Specific Description Probable cause Check/Reason code code E:02 Jumper 3 changed Check position of jumper 3 Put jumper 3 to the off position E:02 Connection to external device Check wiring to external device Check wiring unsuccessful E:02 Configuration to external device Check pairing to external Pair the devices...
11 Troubleshooting Group Specific Description Probable cause Check/Reason code code E:04 5 burner start-up failures No ignition Check cabling of ignition trans former Replace the ionization/ignition electrode Check the breakdown to earth Check the condition of the burn er set Check the earthing Defective gas/air unit Ignition arc but no flame forma...
11 Troubleshooting Fig.72 Accessing the information menu 2. To access the Information menu, briefly press the key once. Caution A long press (approximately 3 seconds) of the button will activate functions intended only for your installer or service engineer. If this occurs, press the button again for 3 seconds to exit the function.
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11 Troubleshooting STATUS DISPLAY Venting function active Electronic board overheated (wait for it to cool) Boiler in reset phase Tab.31 List of sub-statuses SUB-STATUS DISPLAY Standby Wait time until next ignition in heating mode Pre-ventilation Burner pre-ignition Burner ignition Flame check Fan operation with active request Operation at set temperature setpoint Operation at limited temperature setpoint...
12 Decommissioning 12 Decommissioning 12.1 Decommissioning procedure Disconnect the gas & electric supplies and isolate them. Drain the primary circuit and disconnect the filling device. Dismantle the chimney system and remove the boiler from the wall mounting frame. 7696317 - 1 - 21032018...
13 Spare parts 13 Spare parts 13.1 Short parts list The following spares are available: LPG spare parts, page 77 Fig.73 Spare parts Tab.32 Part number and description of spare parts Key No. Description Part Number Safety thermostat 7661894 Detection/Spark ignition electrode 7661804 Flow sensor and Return sensor 7662085...
If changing gas valve adjust & re-check as described in section 10. Measure & record combustion • If incorrect at commissioning call Baxi Customer Support 0344 871 1545 • If incorrect when changing gas valve adjust & re-check Stop chimney sweep mode by pressing...
Technical information - LPG Important All data in these sections are nominal and subject to normal production tolerances. Tab.33 General Baxi Combi 428 LPG Gas Council Numbers 47–077–27 Nominal heat input Domestic Hot Water — Maxi Nett (Qn Hi) 28.9...
14 Appendix Baxi Combi 428 LPG elmax Full load 0.038 elmin Part load 0.011 Standby mode 0.003 Other items Standby heat loss 0.069 stby Ignition burner power consumption 0.000 Annual energy consumption Sound power level, indoors Emissions of nitrogen oxides...
14 Appendix Fig.76 Adjusting the gas valve Minimum rate (offset) adjustment screw. Maximum rate adjustment screw. Burner gas pressure outlet. Gas supply pressure outlet. Important The case front panel must be fitted when checking combustion. Run the boiler for several minutes before checking the CO and CO .
14 Appendix 14.3 Benchmark commissioning checklist This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty.
14 Appendix ALL INSTALLATIONS At max. rate: ppm AND CO/CO ² Ratio Record the following: At min. rate: (where possible) ppm AND CO/CO ² Ratio The heating and hot water system complies with the appropriate Building Regul The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s The operation of the boiler and system controls have been demonstrated to and understood by the The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the Commissioning Engineer’s Signature...
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14 Appendix SERVICE 07 SERVICE 08 Date: Date: Engineer name: Engineer name: Company name: Company name: Telephone No: Telephone No: Gas safe register No: Gas safe register No: At max. rate: ppm AND CO ² % At max. rate: ppm AND CO ²...
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For the warranty to be maintained, please make sure... Benchmark checklist is completed Warranty is registered within 30 days The boiler has an annual service For full terms and conditions, visit www.baxi.co.uk/terms. Failure to adhere to terms and conditions will void your manufacturer’s warranty. Baxi Brooks House,...
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