Baxi Combi 80 Maxflue Installation And Servicing Instructions
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Baxi Combi 80 Maxflue Installation And Servicing Instructions

Baxi Combi 80 Maxflue Installation And Servicing Instructions

Gas fired wall mounted combination boiler
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Baxi Combi 80 Maxflue
Gas Fired Wall Mounted Combination Boiler
Installation and
Servicing Instructions
Please leave these instructions with the user

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  • Page 1 Please leave these instructions with the user Baxi Combi 80 Maxflue Gas Fired Wall Mounted Combination Boiler Installation and Servicing Instructions...
  • Page 2 Notified Body 0051. mean continued success. Product/Production certified by: Notified Body 0051. 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...

  • Page 3: 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...

  • Page 4: Introduction

    Description 1. The Baxi Combi 80 Maxflue 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 5: General Layout

    2.0 General Layout Layout Air Pressure Switch Expansion Vessel 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 Flame Sensing Electrode Spark Electrode Burner...

  • Page 6: Appliance Operation

    3.0 Appliance Operation Central Heating Circuit 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 flow rate of approximately 125 l/hr the central heating flow switch operates, initiating the ignition sequence.

  • Page 7: Technical Data

    Recommend Operating Fuse 2A Fast Blow to BS 4265 Electrical Protection IPX5D SEDBUK Declaration For Combi 80 Maxflue Pump - Available Head The seasonal efficiency (SEDBUK) is 78.5 % This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings.

  • Page 8: Dimensions And Fixings

    5.0 Dimensions and Fixings Dimensions A 780mm B 345mm C 450mm Tap Rail 65 mm 65 mm 65 mm 65 mm 65 mm Heating Pressure Relief Heating Domestic Hot Cold Water Return Valve Flow Water Outlet Inlet Inlet (22mm) (22mm) (15mm) (22mm) (15mm)

  • Page 9: System Details

    6.0 System Details Information 1. The Baxi Combi 80 Maxflue Combination Boiler is a ‘Water Bylaws Scheme - Approved Product’. To comply with the Water Bylaws 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 10 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 Valve Valve Valve...
  • Page 11 6.0 System Details Other Tap Domestic Hot Water Circuit (Fig. 6) Outlets 1. All DHW circuits, connections, fittings, etc. Boiler Expansion should be fully in accordance with relevant Vessel standards, the Water Supply (water fittings) Regulations and the Water Bylaws (Scotland). 2.

  • Page 12: Site Requirements

    WARNING - The addition of anything that may interfere with the normal operation of the 200mm Min appliance without the express written permission of Baxi UK Limited could invalidate the appliance warranty and infringe the G (Installation Fig. 7 AFETY...
  • Page 13 7.0 Site Requirements Location 1. The boiler may be fitted to any suitable internal or external wall. It is primarily intended for use with a twin flue system using separate horizontal terminals. It may also be fitted with a vertical twin flue system connected to a single vertical terminal.
  • Page 14 7.0 Site Requirements Separation in mm from Flue & Air Terminals Air Terminal Appliance another terminal Position Input (kW) Fanned Natural 1. The flue terminal position must always be Draught Draught in accordance with the current edition of B.S. 5440 Part 1, and either Part J of the Building Above a Regulations England and Wales or Part F of 7-14...
  • Page 15 7.0 Site Requirements Condensate Collector Flue Connections 90° Male - Male 1. The flue duct adaptor, air duct adaptor, 90° Elbow male - male elbow and condensate collector are supplied in a separate pack (Fig. 12). Also in the Flue Duct Adaptor pack are two terminals and fixing screws for use with separate termination installations (see Air Duct Adaptor...
  • Page 16 Terminal 7.0 Site Requirements 7.12 Flue Components 1,2,3 1,2,3 1,2,3 Terminal 1,2,3 1,2,3 Condensate 1,2,3 Condensate Collector Collector 1,2,3 90° Male-Male 90° Male-Male 1,2,3 Elbow Elbow 1,2,3 Flue and Air Flue and Air Duct Adaptors Duct Adaptors Items marked are supplied with each boiler in a separate pack marked Twin Flue Adaptor Kit (Maxflue) Part No 248338 Description Part No.
  • Page 17 7.0 Site Requirements 7.13 Flue Options 1. The Baxi Combi 80 Maxflue can be fitted with flue systems as illustrated (Figs. 15 & 16). 2. Maximum permissible equivalent flue lengths = 70m Max are:- = 15m Max) Vertical Roof Terminal...

  • Page 18: Installation

    2. Stand the boiler on its base by using the rear lower edge as a pivot. NOTE: A small amount of water may drain from the boiler in the upright position. Baxi UK Limited declare that no substances Fig. 18 Central Heating Return harmful to health are contained in the appliance or used during construction of the appliance.
  • Page 19 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. 19). 3.
  • Page 20 8.0 Installation Blanking Pipe Fitting The Flue Gasket 1. Sections 7.12 and 7.13 give details of available flue components, equivalent flue lengths etc. 2. The flue and air duct adaptors must be fitted to the boiler outlet adaptor and boiler top panel Boiler Outlet Adaptor (Fig.
  • Page 21 8.0 Installation Fitting the Flue (Cont) Condensate Collector 10. The flue system can now be fitted. All burrs must be removed from any cut pipes to prevent damage to joint seals. Soap solution can be used to ease assembly of flue components. 90°...
  • Page 22 8.0 Installation 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 securing tabs are clear of the facia. Remove the panel. Control Box Cover 2.

  • Page 23: Commissioning The Boiler

    Commissioning the Boiler Screw Commissioning the Boiler 1. Reference should be made to BS 5449 when commissioning the boiler. Automatic 2. Open the mains water supply to the boiler. Air Vent 3. Open all hot water taps to purge the DHW system.
  • Page 24 Commissioning the Boiler 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. Set the hot water temperature control to maximum and the selector switch to the OFF Pressure Test position (Fig.

  • Page 25: 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 26: 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 section of the “Benchmark”...
  • Page 27 Baffle 11.0 Servicing the Boiler Spring Clip 11.1 Annual Servicing (Cont) 11. 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). 12. Undo the screws securing the fan hood to the appliance back panel, and draw the fan and hood Fig.

  • Page 28: Changing Components

    12.0 Changing Components IMPORTANT: When changing components Pressure ensure that both the gas and electrical Switch 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 Sensing position R and hold for 2 seconds to reset the Tubes...
  • Page 29 12.0 Changing Components 12.3 Heat Exchanger (Fig. 49) 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 30 12.0 Changing Components Injector Inlet Elbow Manifold 12.5 Injectors (Fig. 51) 1. Remove the burner as described in Section 12.4. 2. Undo the screws securing the injector Gasket manifold to the inlet elbow and remove the manifold. 3. Unscrew and replace injectors as required Injector and examine the sealing gasket, replacing as necessary.
  • Page 31 12.0 Changing Components 12.8 Gas Valve (Fig. 53) 1. Undo the nut on the gas feed pipe under the boiler. 2. Disconnect the two wires from the valve modulator and the ignition lead from the NAC plug. Gas Valve 3. Disconnect the earth wire from the NAC plug and spade terminal on the gas valve body.
  • Page 32 12.0 Changing Components 12.12 Pump - Head Only (Fig. 56) 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 33 12.0 Changing Components 12.15 Pressure Gauge (Figs. 59 & 60) 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 34 12.0 Changing Components 12.18 Pressure Relief Valve (Fig. 63) 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 35 12.0 Changing Components Plate Heat Exchanger 12.21 Plate Heat Exchanger (Fig. 66) 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 36 12.0 Changing Components 12.22 Diverter Valve Assembly (Cont) Pressure Differential Valve (Fig. 69) 1. Remove the DHW Flow Sensor as described above. 2. From the brass diverter manifold undo the nut on the heating flow valve. Remove the screw securing the diverter manifold to the appliance lower bracket.

  • Page 37: Illustrated Wiring Diagram

    13.0 Illustrated Wiring Diagram Pump Air Pressure Switch Domestic Hot Water Flow Priority Pressure Switch Hydraulic Differential Pressure Switch Control PCB Domestic Hot Water NTC Sensor Flame Sensing Central Heating Electrode NTC Sensor Mains Input Link - brown - black - blue - red - green...

  • Page 38: 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 39 14.0 Fault Finding Domestic Hot Water - Follow operational sequence Turn selector to Replace diaphragm Go to section ‘A’ neon illuminated Is mains water DHW flow valve filter and differential diaphragm damaged assembly clean? Turn thermostat to DHW flow rate more than DHW flow valve rod max.
  • Page 40 14.0 Fault Finding Fault Finding Solutions Sections A to E Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse neon Replace PCB illuminated Selector terminals a & b Check wiring and a & 3. PCB - A4 Replace selector connector terminals 4 &...
  • Page 41 14.0 Fault Finding Check and correct if necessary 1. Electrical and pressure tube connections Replace air 2. Blockage of pressure tubes pressure switch 3. Restriction in flue 4. Venturi Gas at burner Ensure gas is on and purged PCB - A1 connector has 230V AC Replace gas valve across terminals 2 &...
  • Page 42 14.0 Fault Finding 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. Electrode position Replace PCB Flame current should be 1 µA approx. Replace flame sensing electrode Overheat thermostat operated Allow to cool.

  • Page 43: Short Parts List

    15.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. E66 383 248001 E66 385 Pressure Switch 248466 E66 393 Heat Exchanger 248016 E66 399 Burner 248030 E03 659 Injector 247439 E66 408 Electrode Lead 248467 E66 411 Spark or Sensing Electrode 247384...

  • Page 44: After Sales Service

    Comp N 248465 - Iss 4 - 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 921.731.3...
  • Page 45 BAXI COMBI 80 MAXFLUE 47 075 07 Page 1 of 9 Iss 1 - 11/00 X018 BAXI UK LIMITED Data Badge: On control box behind front panel...
  • Page 46 BAXI COMBI 80 MAXFLUE 47 075 07 Page 2 of 9 Iss 1 - 11/00 X018 BAXI UK LIMITED Outer Case...
  • Page 47 BAXI COMBI 80 MAXFLUE 47 075 07 Page 3 of 9 Iss 1 - 11/00 X018 BAXI UK LIMITED Combustion Box...
  • Page 48 BAXI COMBI 80 MAXFLUE 47 075 07 Page 4 of 9 Iss 1 - 11/00 X018 BAXI UK LIMITED Hydraulics 137 138...
  • Page 49 BAXI COMBI 80 MAXFLUE 47 075 07 Page 5 of 9 Iss 1 - 11/00 X018 BAXI UK LIMITED Controls...
  • Page 50 BAXI COMBI 80 MAXFLUE 47 075 07 Page 6 of 9 Iss 1 - 11/00 X018 BAXI UK LIMITED Wall Jig & Hydraulic Connections Key No. 200 Vacuum Pack...
  • Page 51 BAXI COMBI 80 MAXFLUE 47 075 07 Page 7 of 9 Iss 1 - 11/00 X018 BAXI UK LIMITED Key No 269 - Flue Kit...
  • Page 52 BAXI COMBI 80 MAXFLUE 47 075 07 Page 8 of 9 Iss 1 - 11/00 X018 BAXI UK LIMITED Wiring Harnesses...
  • Page 53 BAXI COMBI 80 MAXFLUE 47 075 07 Page 9 of 9 Iss 1 - 11/00 X018 BAXI UK LIMITED Short Parts List...
  • Page 54 Please keep these instructions safe. Should you move house, please hand them over to the next occupier. Baxi Combi 80 Maxflue Gas Fired Wall Mounted Combination Boiler User’s Operating Instructions...
  • Page 55 Notified Body 0051. customers mean continued success. Product/Production certified by: Notified Body 0051. 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...
  • Page 56 IN AN EMERGENCY appliance without the express written permission of Baxi UK Limited could invalidate If a water or gas leak occurs or is suspected, the boiler can be the appliance warranty and infringe the G isolated at the inlet valves as follows;...
  • Page 57 2.0 Introduction Introduction 1. Your Baxi Combi 80 Maxflue is a gas fired, room sealed, powered flue combination boiler, providing central heating for your home and mains fed domestic hot water to taps and shower. It is fully automatic and does not have a pilot light.

  • Page 58: Operating The Boiler

    3.0 Operating the Boiler Operating the Boiler 1. Ensure that the electricity and gas supplies are turned on. Check that the central heating pressure is in the green area on the gauge (Fig. 4). 2. Turn the On/Off/Reset selector switch either anti-clockwise from the off position (Fig.
  • Page 59 Safety Thermostat Fig. 11 1. Your Baxi Combi 80 Maxflue is fitted with an additional safety device, which shuts down the boiler in the event of the system or the boiler overheating. The safety thermostat neon ( ) will light in this instance (Fig.
  • Page 60 3.0 Operating the Boiler Air Flow Monitor Pump/Low Sensor Fault Pressure Neon Neons 1. The boiler is fitted with an air pressure sensing Air Flow Monitor Neon device. This monitors the flue system. 2. If the neon illuminates ( ) it indicates that 30°...
  • Page 61 3.0 Operating the Boiler Pressure Gauge Central Heating System Pressure 1. The water pressure in the central heating system is indicated by the pressure gauge. 2. With the system cold and the boiler not operating the pressure should be between 0.5 Fig.
  • Page 62 4.0 Clearances and Check List 5mm Min 450mm 5mm Min Clearances around the Boiler (Figs. 21 & 22) 5mm both sides recommended for 1. The minimum clear spaces needed around ease of installation 200mm Min and service. the boiler measured from the casing are as follows: 200mm Bottom...
  • Page 63 (Fig. 23). Fig. 23 Guarantee 1. Your Baxi Combi 80 Maxflue is designed and Information Label produced to meet all the relevant Standards. 2. Baxi UK Limited provide a 12 month guarantee on the boiler.
  • Page 64 6.0 Notes...
  • Page 65 Comp N 248463 - Iss 2 - 9/01 After Sales Service 08706 096 096 Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www.baxi.com 921.730.1...

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