Please
leave
these
instructions
with
the
user
Baxi
Combi
80e
& 105e
Gas
Fired
Wall
Mounted
Combination
Boiler
Installation
and
Servicing
Instructions


Page
1
Natural
Gas
Baxi
Combi
80e
G
.C
.N
o
47
075
06
Baxi
Combi
105e
G
.C
.N
o
47
075
08
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
.
To
keep
ahead
of
changing
trends
, we
have
made
a
commitment
to
develop
new
ideas
using
the
latest
technology
-
with
the
aim
of
continuing
to
make
the
products
that
customers
want
to
buy
.
Everyone
who
works
at
Baxi
has
a
commitment
to
quality
because
we
know
that
satisfied
customers
mean
continued
success
.
We
hope
you
get
a
satisfactory
service
from
Baxi
. If
not
, please
let
us
know
.
The
boiler
meets
the
requirements
of
Statutory
Instrument
" The
Boiler
(Efficiency
) Regulations
1993
N
o
3083
" and
is
deemed
to
meet
the
requirements
of
Directive
92/42/EEC
on
the
energy
efficiency
requirements
for
new
hot
water
boilers
fired
with
liquid
or
gaseous
fuels
:-
Type
test
for
purpose
of
Regulation
5
certified
by
: Notified
Body
0051
.
Product/Production
certified
by
: Notified
Body
0051
.
For
GB/IE
only
.

Page
2
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 |
9 |
|
6. 0 |
System Details |
10 |
|
7. 0 |
Site Requirements |
13 |
|
8. 0 |
Installation |
18 |
|
9. 0 |
Commissioning the Boiler |
23 |
|
10. 0 |
Completion |
25 |
|
11. 0 |
Servicing the Boiler |
26 |
|
12. 0 |
Changing Components |
28 |
|
13. 0 |
Illustrated Wiring Diagram |
37 |
|
14. 0 |
Fault Finding |
38 |
|
15. 0 |
Short Parts List |
43 |
|
Page
3
1
.0
Introduction
Baxi
UK
Limited
declare
that
no
substances
harmful
to
health
are
contained
in
the
appliance
or
used
during
appliance
manufacture
.
1
.1
Description
1
. The
Baxi
Combi
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
.
2
. The
boiler
is
set
to
give
a
maximum
output
of
24
.0
kW
(80e
) or
31
.0
kW
(105e
).
3
. It
is
designed
for
use
on
Natural
Gas
(G20
) and
can
be
converted
to
use
Propane
(80e
and
105e
) or
Butane
(80e
).
4
. The
boiler
is
suitable
for
use
only
on
fully
pumped
sealed
heating
systems
. Priority
is
given
to
domestic
hot
water
.
5
. The
boiler
data
badge
gives
details
of
the
model
, serial
number
and
Gas
Council
number
and
is
situated
on
the
control
box
. It
is
visible
when
the
case
front
panel
is
removed
(Fig
. 1
).
6
. The
boiler
is
intended
to
be
installed
in
residential
/
commercial
/
light
industrial
E
.M
.C
. environments
on
a
governed
meter
supply
only
.
7
. The
boiler
must
be
installed
with
one
of
the
purpose
designed
flues
such
as
the
standard
horizontal
flue
kit
, part
no
. 247719
.
8
. All
systems
must
be
thoroughly
flushed
and
treated
with
inhibitor
(see
section
6
.2
).
1
.2
Installation
1
. The
appliance
is
suitable
for
installation
only
in
G
.B
. and
I
.E
. and
should
be
installed
in
accordance
with
the
rules
in
force
. For
Ireland
install
in
accordance
with
I
.S
.813
"INSTALLATION
OF
GAS
APPLIANCES
". The
installation
must
be
carried
out
by
a
CORGI
Registered
Installer
or
other
competent
person
and
be
in
accordance
with
the
relevant
requirements
of
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
. Where
no
specific
instructions
are
given
, reference
should
be
made
to
the
relevant
BRITISH
STANDARD
CODES
OF
PRACTICE
.
1
.3
Optional
Extras
Various
flue
extensions
, bends
, vertical
flue
kits
, control
accessories
etc
. are
available
as
optional
extras
. These
are
detailed
in
a
separate
publication
.
Fig
. 1
NOTE
: This
appliance
must
be
installed
in
accordance
with
the
manufacturer
’s
instructions
and
the
regulations
in
force
.Read
the
instructions
fully
before
installing
or
using
the
appliance
.
"Benchmark
" Log
Book
As
part
of
the
industry-wide
"Benchmark
" initiative
all
Baxi
boilers
now
include
an
Installation
, Commissioning
and
Service
Record
Log
Book
. Please
read
the
Log
Book
carefully
and
complete
all
sections
relevant
to
the
appliance
and
installation
. These
include
sections
on
the
type
of
controls
employed
, flushing
the
system
, burner
operating
pressure
etc
. The
details
of
the
Log
Book
will
be
required
in
the
event
of
any
warranty
work
. Also
, there
is
a
section
to
be
completed
at
each
subsequent
regular
service
visit
. The
Log
Book
must
be
left
with
the
user
.
Page
4
2
.0
General
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
10
. Central
Heating
System
Pressure
Gauge
11
. PCB
12
. Control
Box
13
. 3-Way
Valve
Assembly
14
. Spark
Generator
15
. Flame
Sensing
Electrode
16
. Spark
Electrode
17
. Burner
18
. Primary
Heat
Exchanger
19
. Fan
Assembly
20
. On/Off/Reset
Selector
Switch
21
. Central
Heating
Temperature
Control
22
. Hot
Water
Temperature
Control
23
. Flame
Failure
24
. Safety
Thermostat
25
. Fault
on
Fan
or
Flue
26
. Fault
on
Pump
or
Low
System
Pressure
27
. Fault
on
Hot
Water
Sensor
28
. Fault
on
Central
Heating
Sensor
29
. Power
On
30
. Domestic
Hot
Water
Mode
31
. Central
Heating
Mode
32
. Burner
On
When
neons
23
to
28
are
constantly
illuminated
, they
indicate
the
temperature
of
the
central
heating
water
.


Page
5
NOTE
: All
delay
timers
mentioned
in
3
.1
and
3
.2
are
overridden
by
domestic
hot
water
demand
.
3
.1
Central
Heating
Mode
(Fig
. 2
)
1
. With
a
demand
for
heating
, the
pump
circulates
water
through
the
primary
circuit
. At
a
predetermined
flow
rate
the
central
heating
flow
switch
operates
, initiating
the
ignition
sequence
.
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
.
3
. When
the
flow
temperature
exceeds
the
setting
temperature
, a
3
minute
delay
occurs
before
the
burner
relights
automatically
(anti-cycling
). The
pump
continues
to
run
during
this
period
.
4
. When
the
demand
is
satisfied
the
burner
is
extinguished
and
the
pump
continues
to
run
for
a
period
of
3
minutes
(Pump
Overrun
).
3
.2
Domestic
Hot
Water
Mode
(Fig
. 3
)
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
. This
will
allow
the
pump
to
circulate
the
primary
water
through
the
DHW
plate
heat
exchanger
.
3
. The
burner
will
light
automatically
and
the
temperature
of
the
domestic
hot
water
is
controlled
by
the
temperature
sensor
.
4
. When
the
domestic
hot
water
demand
ceases
the
burner
will
extinguish
and
the
diverter
valve
will
remain
in
the
domestic
hot
water
mode
, unless
there
is
a
demand
for
central
heating
.
IMPORTANT
: When
the
selector
switch
is
in
the
‘0
’ (Off
) position
the
electrical
supply
to
the
boiler
is
isolated
. The
boiler
will
not
operate
and
the
integral
timer
(if
fitted
) will
require
resetting
once
the
selector
switch
is
set
to
either
Position
(i
) or
Position
(ii
).
3
.3
Frost
Protection
Mode
1
. The
frost
protection
mode
is
integral
to
the
appliance
and
functions
only
with
the
selector
switch
(see
Section
2
.1
) in
the
domestic
hot
water
and
central
heating
position
. If
the
system
temperature
falls
below
5
° C
then
the
boiler
will
fire
on
its
minimum
setting
until
a
flow
temperature
of
30
° C
is
reached
. Further
protection
can
be
incorporated
by
using
a
system
frost
thermostat
.
3
.4
Pump
Protection
1
. With
the
selector
switch
(see
Section
2
.1
) in
either
the
central
heating
or
central
heating
and
domestic
hot
water
position
the
pump
will
automatically
operate
for
1
minute
in
every
24
hours
to
prevent
sticking
.
Fig
. 2
Key |
||||
1 |
Primary Heat Exchanger |
14 |
Gas Inlet |
|
2 |
Burner |
15 |
Domestic Hot Water Outlet |
|
3 |
Ignition Electrode |
16 |
Heating Flow |
|
4 |
Flame Sensing Electrode |
17 |
Pressure Gauge |
|
5 |
Gas Valve |
18 |
Hydraulic Differential Pressure Sensor Microswitch |
|
6 |
Pump |
19 |
Automatic By-Pass |
|
7 |
Automatic Air Vent |
20 |
Hydraulic Differential Pressure Sensor |
|
8 |
Plate Heat Exchanger |
21 |
Diverter Valve Assembly |
|
9 |
Flow Sensor with Filter |
22 |
Domestic Hot Water Flow Priority Assembly |
|
10 |
Pressure Relief Valve |
23 |
Domestic Hot Water Flow Priority Microswitch |
|
11 |
Boiler Drain Point |
24 |
Safety Thermostat |
|
12 |
Heating Return |
25 |
Central Heating Temperature Sensor |
|
13 |
Cold Water Inlet On/Off Valve and Filter |
26 |
Expansion Vessel |
|
27 |
Domestic Hot Water Temperature Sensor |
|||
Fig
. 3
Page
6
4
.0
Technical
Data
4
.1
Combi
80e
Appliance Type |
C 12 |
C 32 | |||||||||||||||||||
Appliance Category |
CAT II 2H 3+ | ||||||||||||||||||||
Heat Input C/H& DHW( Gross) | |||||||||||||||||||||
Max |
Min |
||||||||||||||||||||
kW |
26. 3 |
10. 6 |
|||||||||||||||||||
Btu/h |
89, 739 |
31, 738 |
|||||||||||||||||||
Heat Output |
Max |
Min |
|||||||||||||||||||
kW |
24. 0 |
9. 3 |
|||||||||||||||||||
Btu/h |
81, 891 |
31, 738 |
|||||||||||||||||||
Max Gas Rate |
(Natural Gas - G20) | ||||||||||||||||||||
(After 10 Mins) | |||||||||||||||||||||
m 3 /h |
2. 78 |
||||||||||||||||||||
ft 3 /h |
98. 12 |
||||||||||||||||||||
Burner Pressure( Natural Gas - G20) | |||||||||||||||||||||
Max Rate |
Min Rate | ||||||||||||||||||||
mbar |
12. 2+ - 0. 5 |
2. 5+ - 0. 2 | |||||||||||||||||||
in wg |
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. 28mm Diameter |
|||||||||||||||||||||
Electrical Supply |
230V~ 50Hz | ||||||||||||||||||||
(Appliance must be connected to an | |||||||||||||||||||||
earthed supply) |
|||||||||||||||||||||
Power Consumption |
170W |
||||||||||||||||||||
External Fuse Rating |
3A |
||||||||||||||||||||
Internal Fuse Rating |
|||||||||||||||||||||
Fuse 2A Fast Blow to BS 4265 |
|||||||||||||||||||||
Electrical Protection |
|||||||||||||||||||||
IPX5D |
|||||||||||||||||||||
NOx Class |
3 |
||||||||||||||||||||
Flue Terminal |
Diameter |
100mm | |||||||||||||||||||
Dimensions |
Projection |
95mm | |||||||||||||||||||
Connections |
copper tails | ||||||||||||||||||||
Gas Supply |
- |
22mm | |||||||||||||||||||
Central Heating Flow |
- |
22mm | |||||||||||||||||||
Central Heating Return |
- |
22mm | |||||||||||||||||||
Cold Water Mains Inlet |
- |
15mm | |||||||||||||||||||
DHW Flow |
- |
15mm | |||||||||||||||||||
Pressure Relief Discharge |
- |
15mm | |||||||||||||||||||
Outercase Dimensions |
|||||||||||||||||||||
Casing Height |
- |
780mm | |||||||||||||||||||
Overall Height Inc Flue |
|||||||||||||||||||||
Elbow |
- |
980mm | |||||||||||||||||||
Casing Width |
- |
450mm | |||||||||||||||||||
Casing Depth |
- |
345mm | |||||||||||||||||||
Clearances |
|||||||||||||||||||||
Both Sides |
5 mm Min | ||||||||||||||||||||
Above Casing |
200 mm Min | ||||||||||||||||||||
Below Casing |
200 mm Min | ||||||||||||||||||||
Front |
450 mm Min( For Servicing) | ||||||||||||||||||||
Front |
5 mm Min( In Operation) | ||||||||||||||||||||
Weights |
kg | ||||||||||||||||||||
Packaged Boiler Carton |
47 | ||||||||||||||||||||
Packaged Flue Kit |
3 | ||||||||||||||||||||
Installation Lift Weight |
39 | ||||||||||||||||||||
Central Heating Primary Circuit | |||||||||||||||||||||
Pressures |
|||||||||||||||||||||
bar | |||||||||||||||||||||
Safety Discharge |
3 | ||||||||||||||||||||
Max Operating |
2. 5 | ||||||||||||||||||||
Min Operating |
0. 5 | ||||||||||||||||||||
Recommend Operating |
1-2 | ||||||||||||||||||||
DHW Circuit |
bar | ||||||||||||||||||||
Pressures |
|||||||||||||||||||||
Max Operating |
8 | ||||||||||||||||||||
Min Operating |
0. 2 | ||||||||||||||||||||
Min Operating Pressure |
|||||||||||||||||||||
at 9. 8 l/min |
0. 9 | ||||||||||||||||||||
Flow Rates |
l/min | ||||||||||||||||||||
DHW Flow Rate |
|||||||||||||||||||||
@ 30° C Rise |
13. 7 | ||||||||||||||||||||
DHW Flow Rate |
|||||||||||||||||||||
@ 35° C Rise |
9. 8 | ||||||||||||||||||||
Min Working |
|||||||||||||||||||||
DHW Flow Rate |
2. 5 | ||||||||||||||||||||
Pump |
|||||||||||||||||||||
Available Head |
See graph below | ||||||||||||||||||||
Expansion Vessel -( For Central Heating | |||||||||||||||||||||
only. Integral with appliance) | |||||||||||||||||||||
bar | |||||||||||||||||||||
Min Pre-charge Pressure |
0. 5 | ||||||||||||||||||||
litre | |||||||||||||||||||||
Max Capacity of |
|||||||||||||||||||||
CH System |
125 | ||||||||||||||||||||
Primary Water Content |
1. 0 | ||||||||||||||||||||
of Boiler( unpressurised) |
|||||||||||||||||||||
Temperatures |
|||||||||||||||||||||
C. H. Flow Temp( adjustable) |
|||||||||||||||||||||
35° C to 85° C max(+ - 5° C) | |||||||||||||||||||||
D. H. W. Flow Temp( adjustable) | |||||||||||||||||||||
35° C to 65° C max(+ - 5° C) | |||||||||||||||||||||
dependent upon flow rate | |||||||||||||||||||||
SEDBUK
Declaration
For
Combi
80e
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
. The
test
data
from
which
it
has
been
calculated
have
been
certified
by
0051
.
LPG Gases |
Propane - G31 and | |||
Butane - G30 | ||||
Burner Injector 12 x 0. 77mm diameter | ||||
Burner Pressure |
|
| ||
Propane |
mbar |
|
| |
in wg |
|
| ||
Butane |
mbar |
|
| |
in wg |
|
| ||
Inlet Pressures |
|
| ||
mbar |
|
| ||
in wg |
|
| ||

Page
7
4
.2
Combi
105e
Appliance Type |
C 12 |
C 32 | ||||||||||||||||
Appliance Category |
CAT II 2H 3P | |||||||||||||||||
Heat Input C/H& DHW( Gross) |
||||||||||||||||||
Max |
Min |
|||||||||||||||||
kW |
34. 3 |
11. 9 |
||||||||||||||||
Btu/h |
117, 036 |
40, 610 |
||||||||||||||||
Heat Output |
Max |
Min |
||||||||||||||||
kW |
31. 0 |
10. 4 |
||||||||||||||||
Btu/h |
105, 776 |
35, 490 |
||||||||||||||||
Max Gas Rate |
(Natural Gas - G20) | |||||||||||||||||
(After 10 Mins) |
||||||||||||||||||
m 3 /h |
3. 63 |
|||||||||||||||||
ft 3 /h |
128. 12 |
|||||||||||||||||
Burner Pressure( Natural Gas - G20) | ||||||||||||||||||
Max Rate |
Min Rate | |||||||||||||||||
mbar |
13. 4+ - 0. 5 |
1. 8+ - 0. 2 | ||||||||||||||||
in wg |
5. 36+ - 0. 2 |
0. 72+ - 0. 2 | ||||||||||||||||
Inlet Pressure |
(Natural Gas - G20) | |||||||||||||||||
mbar |
20 |
|||||||||||||||||
in wg |
8 |
|||||||||||||||||
Burner Injector( Natural Gas - G20) | ||||||||||||||||||
15 x 1. 28mm Diameter |
||||||||||||||||||
Electrical Supply |
230V~ 50Hz | |||||||||||||||||
(Appliance must be connected to an | ||||||||||||||||||
earthed supply) |
||||||||||||||||||
Power Consumption |
190W |
|||||||||||||||||
External Fuse Rating |
3A |
|||||||||||||||||
Internal Fuse Rating |
||||||||||||||||||
Fuse 2A Fast Blow to BS 4265 |
||||||||||||||||||
Electrical Protection |
||||||||||||||||||
IPX5D |
||||||||||||||||||
NOx Class |
3 |
|||||||||||||||||
Flue Terminal |
Diameter |
100mm | ||||||||||||||||
Dimensions |
Projection |
95mm | ||||||||||||||||
Connections |
copper tails | |||||||||||||||||
Gas Supply |
- |
22mm | ||||||||||||||||
Central Heating Flow |
- |
22mm | ||||||||||||||||
Central Heating Return |
- |
22mm | ||||||||||||||||
Cold Water Mains Inlet |
- |
15mm | ||||||||||||||||
DHW Flow |
- |
15mm | ||||||||||||||||
Pressure Relief Discharge |
- |
15mm | ||||||||||||||||
Outercase Dimensions |
||||||||||||||||||
Casing Height |
- |
780mm | ||||||||||||||||
Overall Height Inc Flue |
||||||||||||||||||
Elbow |
- |
980mm | ||||||||||||||||
Casing Width |
- |
450mm | ||||||||||||||||
Casing Depth |
- |
345mm | ||||||||||||||||
Clearances |
||||||||||||||||||
Both Sides |
5 mm Min |
|||||||||||||||||
Above Casing |
200 mm Min | |||||||||||||||||
Below Casing |
200 mm Min | |||||||||||||||||
Front |
450 mm Min( For Servicing) | |||||||||||||||||
Front |
5 mm Min( In Operation) | |||||||||||||||||
Weights |
kg | |||||||||||||||||
Packaged Boiler Carton |
49 | |||||||||||||||||
Packaged Flue Kit |
3 | |||||||||||||||||
Installation Lift Weight |
41 | |||||||||||||||||
Central Heating Primary Circuit | ||||||||||||||||||
Pressures |
||||||||||||||||||
bar | ||||||||||||||||||
Safety Discharge |
3 | |||||||||||||||||
Max Operating |
2. 5 | |||||||||||||||||
Min Operating |
0. 5 | |||||||||||||||||
Recommend Operating |
1-2 | |||||||||||||||||
DHW Circuit |
bar | |||||||||||||||||
Pressures |
||||||||||||||||||
Max Operating |
8 | |||||||||||||||||
Min Operating |
0. 2 | |||||||||||||||||
Min Operating Pressure |
||||||||||||||||||
at 12. 7 l/min |
0. 96 | |||||||||||||||||
Flow Rates |
l/min | |||||||||||||||||
DHW Flow Rate |
||||||||||||||||||
@ 30° C Rise |
14. 8 | |||||||||||||||||
DHW Flow Rate |
||||||||||||||||||
@ 35° C Rise |
12. 7 | |||||||||||||||||
Min Working |
||||||||||||||||||
DHW Flow Rate |
2. 5 | |||||||||||||||||
Pump |
||||||||||||||||||
Available Head See graph below | ||||||||||||||||||
Expansion Vessel -( For Central Heating | ||||||||||||||||||
only. Integral with appliance) | ||||||||||||||||||
bar | ||||||||||||||||||
Min Pre-charge Pressure |
0. 5 | |||||||||||||||||
litre | ||||||||||||||||||
Max Capacity of |
||||||||||||||||||
CH System |
125 | |||||||||||||||||
Primary Water Content |
1. 2 | |||||||||||||||||
of Boiler( unpressurised) |
||||||||||||||||||
Temperatures |
||||||||||||||||||
C. H. Flow Temp( adjustable) |
||||||||||||||||||
35° C to 85° C max(+ - 5° C) | ||||||||||||||||||
D. H. W. Flow Temp( adjustable) | ||||||||||||||||||
35° C to 65° C max(+ - 5° C) | ||||||||||||||||||
dependent upon flow rate | ||||||||||||||||||
SEDBUK
Declaration
For
Combi
105e
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
. The
test
data
from
which
it
has
been
calculated
have
been
certified
by
0051
.
LPG Gases Propane - G31 | ||||
Burner Injector 15 x 0. 77mm diameter | ||||
Burner Pressure |
|
| ||
Propane |
mbar |
|
| |
in wg |
|
| ||
Inlet Pressures |
||||
mbar |
|
|||
in wg |
||||

Page
8

Page
9
6
.0
System
Details
6
.1
Information
1
. The
Baxi
Combi
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
.
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
.
1
. The
appliance
is
suitable
for
fully
pumped
SEALED
SYSTEMS
ONLY
.
Treatment
of
Water
Circulating
Systems
All
recirculatory
water
systems
will
be
subject
to
corrosion
unless
an
appropriate
water
treatment
is
applied.
This
means
that
the
efficiency
of
the
system
will
deteriorate
as
corrosion
sludge
accumulates
within
the
system,
risking
damage
to
pump
and
valves,
boiler
noise
and
circulation
problems.
For
optimum
performance
after
installation
this
boiler
and
its
associated
central
heating
system
must
be
flushed
in
accordance
with
the
guidelines
given
in
BS
7593"
Treatment
of
water
in
domestic
hot
water
central
heating
systems".
This
must
involve
the
use
of
a
proprietary
cleanser,
such
as
BetzDearborn
Sentinel
X300
or
X400,
or
Fernox
Superfloc.
Full
instructions
are
supplied
with
the
products,
but
for
immediate
information
please
contact
BetzDearborn(
0151
420
9563)
or
Fernox(
01799
550
811)
directly.
For
long
term
protection
against
corrosion
and
scale,
after
flushing
it
is
recommended
that
an
inhibitor
such
as
BetzDearborn
Sentinel
X100,
or
Fernox
MB-1
or
Copal
is
dosed
in
accordance
with
the
guidelines
given
in
BS
7593.
Failure
to
flush
and
add
inhibitor
to
the
system
may
invalidate
the
appliance
warranty
.
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.
6
.3
Bypass
1
. The
boiler
is
fitted
with
an
automatic
integral
bypass
.
6
.4
System
Control
1
. The
boiler
is
designed
for
use
in
a
heating
system
that
incorporates
external
controls
, i
.e
. a
minimum
of
a
timer
device
.
2
. Suitable
timer
kits
are
available
as
optional
extras
.
3
. For
optimum
operating
conditions
and
maximum
economy
the
fitting
of
a
programmable
room
thermostat
, such
as
the
Baxi
Combi
Controller
, is
recommended
.
Page
10
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
.
2
. There
are
connection
points
on
the
mains
cold
water
inlet
and
central
heating
return
isolating
taps
Fig
. 4a
) to
which
the
optional
filling
loop
kit
(Part
No
. 248221
) can
be
assembled
.
3
. The
filling
method
adopted
must
be
in
accordance
with
the
Water
Supply
(Water
Fittings
) regulations
and
the
Water
Bylaws
(Scotland
).
4
. Your
attention
is
drawn
to
: Paragraph
24
of
Schedule
2
Section
8
of
the
publication
Water
Regulations
Guide
which
gives
recommendations
and
guidance
on
approved
methods
for
filling
sealed
systems
.
5
. The
sealed
primary
circuits
may
be
filled
or
replenished
by
means
of
a
temporary
connection
between
the
primary
circuit
and
a
supply
pipe
provided
the
arrangement
in
accordance
with
Diagram
R24
.2a
of
the
Water
Regulations
Guide
.
6
. The
temporary
hose
must
be
completely
removed
at
both
ends
after
use
.
6
.6
Expansion
Vessel
(Central
Heating
only
)
1
. The
appliance
expansion
vessel
is
pre-charged
to
0
.5
bar
. Therefore
, the
minimum
cold
fill
pressure
is
0
.5
bar
. The
vessel
is
suitable
for
correct
operation
for
system
capacities
up
to
125
litres
. For
greater
system
capacities
an
additional
expansion
vessel
must
be
fitted
-
refer
to
BS
7074
Pt
1
.
6
.7
Pressure
Relief
Valve
(Fig
. 5
)
1
. The
pressure
relief
valve
is
set
at
3
bar
, therefore
all
pipework
, fittings
, etc
. should
be
suitable
for
pressures
in
excess
of
3
bar
.
2
. The
pressure
relief
discharge
pipe
should
be
not
less
than
15mm
dia
, run
continuously
downward
, and
discharge
outside
the
building
, preferably
over
a
drain
. It
should
be
routed
in
such
a
manner
that
no
hazard
occurs
to
occupants
or
causes
damage
to
wiring
or
electrical
components
. The
end
of
the
pipe
should
terminate
facing
down
and
towards
the
wall
.
3
. The
discharge
must
not
be
above
a
window
, entrance
or
other
public
access
. Consideration
must
be
given
to
the
possibility
that
boiling
water/steam
could
discharge
from
the
pipe
.
Fig
. 4
, 4a
, 5
Page
11
6
.8
Domestic
Hot
Water
Circuit
(Fig
. 6
)
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
.
3
. A
single
check
valve
must
be
fitted
as
shown
in
Fig
. 6
to
prevent
backflow
to
the
supply
pipe
and
to
ensure
the
efficient
operation
of
the
expansion
vessel
which
is
required
to
accommodate
the
thermal
expansion
of
the
water
.
4
. When
the
domestic
water
system
includes
any
device
which
prevents
water
expanding
back
towards
the
supply
(check
valve
, loose
jumpered
stopcock
, water
meter
, water
treatment
device
) then
an
expansion
vessel
must
be
fitted
(eg
. Zilmet
160ml
, R
1
/
2
15bar
).
5
. If
the
hot
water
expansion
is
not
provided
for
, then
high
pressures
can
develop
which
may
result
in
damage
to
fittings
and
devices
on
the
system
.
6
. The
boiler
’s
maximum
working
mains
pressure
is
8
bar
, therefore
all
pipework
, connections
, fittings
, etc
. should
be
suitable
for
pressures
in
excess
of
8
bar
. A
pressure
reducing
valve
must
be
fitted
for
pressures
in
excess
of
8
bar
. The
manufacturer
of
any
outlet
fittings
, such
as
a
shower
valve
, may
require
a
lower
maximum
pressure
. The
pressure
reduction
must
take
account
of
all
fittings
connected
to
the
DHW
system
.
6
.9
Showers
1
. If
a
shower
control
is
supplied
from
the
appliance
it
should
be
of
the
thermostatic
or
pressure
balanced
type
. Thermostatic
type
shower
valves
provide
the
best
comfort
and
guard
against
water
at
too
high
a
temperature
. Existing
controls
may
not
be
suitable
-
refer
to
the
shower
valve
manufacturer
.
6
.10
Hard
Water
Areas
1
. If
the
area
of
the
installation
is
recognised
as
a
HARD
WATER
AREA
then
a
suitable
device
should
be
fitted
to
treat
the
mains
water
supply
to
the
boiler
.
Fig
. 6
Page
12
7
.1
Information
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
. Where
no
specific
instruction
is
given
reference
should
be
made
to
the
relevant
BRITISH
STANDARD
CODES
OF
PRACTICE
. For
Ireland
install
in
accordance
with
IS
813
"I
NSTALLATION
OF
GAS
APPLIANCES
".
7
.2
B
.S
. Codes
of
Practice
Standard |
Scope |
|
BS 6891 |
Gas Installation. |
|
BS 5546 |
Installation of hot water supplies for |
|
domestic purposes. |
||
BS 5449 Part 1 |
Forced circulation hot water systems. |
|
BS 6798 |
Installation of gas fired hot water boilers. |
|
BS 5440 Part 1 |
Flues. |
|
BS 5440 Part 2 |
Ventilation. |
|
BS 7074 |
Expansion vessels and ancillary |
|
equipment for sealed water systems. |
||
BS 7593 |
Treatment of water in domestic hot water |
|
central heating systems. |
WARNING
-
The
addition
of
anything
that
may
interfere
with
the
normal
operation
of
the
appliance
without
the
express
written
permission
of
Baxi
UK
Limited
could
invalidate
the
appliance
warranty
and
infringe
the
GAS
SAFETY
(Installation
and
Use
) REGULATIONS
.
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
. Additional
clearances
may
be
required
for
the
passage
of
pipes
around
local
obstructions
such
as
joists
running
parallel
to
the
front
face
of
the
boiler
.
7
.4
Location
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
satisfactory
removal
of
combustion
products
and
providing
an
adequate
air
supply
. The
boiler
should
be
fitted
within
the
building
unless
otherwise
protected
by
a
suitable
enclosure
i
.e
. garage
or
outhouse
. (The
boiler
may
be
fitted
inside
a
cupboard-see
Section
7
.5
).
2
. If
the
boiler
is
sited
in
an
unheated
enclosure
then
it
is
recommended
to
leave
the
ON/OFF
Selector
Switch
in
the
domestic
hot
water
and
central
heating
position
to
give
frost
protection
.
3
. If
the
boiler
is
fitted
in
a
room
containing
a
bath
or
shower
reference
must
be
made
to
the
current
I
.E
.E
. WIRING
REGULATIONS
and
BUILDING
REGULATIONS
. If
the
boiler
is
to
be
fitted
into
a
building
of
timber
frame
construction
then
reference
must
be
made
to
the
current
edition
of
Institute
of
Gas
Engineers
Publication
IGE/UP/7
(Gas
Installations
in
Timber
Framed
Housing
).
Fig
. 7
, 8
Page
13
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
Clause
4
.2
refers
to
room
sealed
appliances
installed
in
compartments
. The
appliance
will
run
sufficiently
cool
without
ventilation
.
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
. 9
).
3
. Ensure
that
the
pipework
from
the
meter
to
the
appliance
is
of
adequate
size
. Do
not
use
pipes
of
a
smaller
diameter
than
the
boiler
gas
connection
(22mm
).
7
.7
Electrical
Supply
1
. External
wiring
must
be
correctly
earthed
, polarised
and
in
accordance
with
current
I
.E
.E
. WIRING
REGULATIONS
.
2
. The
mains
supply
is
230V
~ 50Hz
fused
at
3A
.
NOTE
: The
method
of
connection
to
the
electricity
supply
must
facilitate
complete
electrical
isolation
of
the
appliance
.
Connection
may
be
via
a
fused
double-pole
isolator
with
a
contact
separation
of
at
least
3mm
in
all
poles
and
servicing
the
boiler
and
system
controls
only
.
Fig
. 9
Page
14
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
. If
a
terminal
is
less
than
2
metres
above
a
balcony
, above
ground
or
above
a
flat
roof
to
which
people
have
access
, then
a
suitable
terminal
guard
must
be
provided
.
Fig
. 11
Terminal Position with Minimum Distance( Fig. 11) |
(mm) |
||
A |
Directly below an openable window, air vent or any other |
||
ventilation opening. |
300 |
||
B |
Below gutter, drain/soil pipe. |
25 |
|
C |
Below eaves. |
25 |
|
D |
Below a balcony/car port roof. |
25 |
|
E |
From vertical drain pipes and soil pipes. |
25 |
|
F |
From internal or external corners. |
25 |
|
G |
Above adjacent ground or balcony level. |
300 |
|
H |
From a surface facing a terminal. |
600 |
|
I |
Facing a terminals. |
1200 |
|
J |
From opening( door/window) in carport into dwelling. |
1200 |
|
K |
Vertically from a terminal on the same wall. |
1500 |
|
L |
Horizontally from a terminal on the same wall. |
300 |
|
M |
Above an opening, air brick, opening window etc. |
300 |
|
N |
Horizontally to an opening, air brick, opening window etc. |
300 |

Page
15
7
.9
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
: 80e
5
metres
105e
4
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
.
1
. Once
the
flue
is
secure
the
trim
can
be
fitted
if
required
.
2
. Remove
the
protective
backing
from
the
adhesive
seal
. Apply
the
seal
to
the
rear
of
the
trim
flange
(Fig
. 13
).
3
. Locate
the
trim
over
the
flue
terminal
and
push
it
back
to
the
wall
to
compress
the
seal
(Fig
. 14
).
1
. When
codes
of
practice
dictate
the
use
of
terminal
guards
, they
can
be
obtained
from
most
Plumbers
’ and
Builders
’ Merchants
.
2
. There
must
be
a
clearance
of
at
least
50mm
between
any
part
of
the
terminal
and
the
guard
.
3
. When
ordering
a
terminal
guard
, quote
the
appliance
name
and
model
number
.
4
. The
flue
terminal
guard
should
be
positioned
centrally
over
the
terminal
and
fixed
as
illustrated
.
Fig
. 12
, 13
, 14
, 15
Page
16
7
.12
Flue
Options
1
. The
Baxi
Combi
80e
and
105e
can
be
fitted
with
flue
systems
as
illustrated
.
2
. The
standard
flue
is
suitable
only
for
horizontal
applications
.
3
. The
80e
model
ONLY
can
also
be
fitted
with
a
flue
system
that
exits
horizontally
from
the
rear
of
the
appliance
, dispensing
with
the
need
for
the
top
flue
elbow
.
4
. Maximum
permissible
equivalent
flue
lengths
are
:-
80e |
105e | |
Concentric |
5m |
4m |
Vertical |
4m |
4m |
Vertical Two-Pipe |
15m |
12m |
5
. Any
additional
"in
line
" bends
in
the
flue
system
must
be
taken
into
consideration
. Their
equivalent
lengths
are
:-
Concentric
Pipes
:
45
° bend
0
.5
metres
90
° bend
1
.0
metres
Twin
Flue
Pipe
45
° bend
0
.25
metres
90
° bend
0
.50
metres
The
elbow
supplied
with
the
standard
horizontal
flue
is
not
included
in
any
equivalent
length
calculations
6
. The
illustrations
opposite
show
examples
of
maximum
equivalent
lengths
.
7
. Full
details
of
part
numbers
and
descriptions
of
all
optional
flue
components
and
kits
can
be
found
in
the
Baxi
Gas
Central
Heating
Boilers
Installers
’ Guide
.
8
. Instructions
for
guidance
and
fitting
are
included
in
each
kit
where
appropriate
.


Page
17
8
.0
Installation
8
.1
Initial
Preparation
The
gas
supply
, gas
type
and
pressure
must
be
checked
for
suitability
before
connection
(see
Section
7
.6
).
1
. After
considering
the
site
requirements
(see
Section
7
.0
) position
the
fixing
template
(Fig
. 16
) on
the
wall
ensuring
it
is
level
both
horizontally
and
vertically
.
2
. Mark
the
position
of
the
two
most
suitable
fixing
slots
for
the
wall
plate
and
boiler
lower
fixing
holes
. It
is
preferable
to
use
the
horizontal
fixing
slots
.
3
. Mark
the
position
of
the
centre
of
the
flue
hole
(rear
exit
). For
side
flue
exit
, mark
as
shown
.
4
. Note
the
shaded
area
on
the
template
. Pipework
may
be
routed
upwards
behind
the
boiler
, providing
it
does
not
conflict
with
the
shaded
area
.
5
. If
required
, mark
the
position
of
the
gas
and
water
pipes
. Remove
the
template
.
6
. Cut
the
hole
for
the
flue
(minimum
diameter
107mm
).
7
. Drill
the
wall
as
previously
marked
to
accept
the
wall
plugs
supplied
. Secure
the
wall
plate
using
the
fixing
screws
.
8
. Using
a
spirit
level
ensure
that
the
plate
is
level
before
finally
tightening
the
screws
.
9
. Connect
the
gas
and
water
pipes
to
the
valves
on
the
wall
plate
using
the
copper
tails
supplied
. Ensure
that
the
sealing
washers
are
fitted
between
the
connections
.
8
.2
Flushing
1
. Connect
a
tube
to
the
central
heating
flow
or
return
pipe
(Fig
. 17
).
2
. Flush
thoroughly
(see
System
Details
, Section
6
.2
).
8
.3
Preparing
The
Boiler
1
. Remove
all
packaging
.
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
harmful
to
health
are
contained
in
the
appliance
or
used
during
construction
of
the
appliance
.
Fig
. 16
, 17
Page
18
8
.4
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
. Insert
the
sealing
washers
between
the
valves
and
pipes
on
the
wall
plate
and
the
boiler
connections
. The
rubber
washers
must
be
used
on
the
gas
connection
.
4
. Tighten
all
the
connections
.
5
. Secure
the
boiler
side
panels
to
the
boiler
wall
plate
flanges
using
the
screws
provided
(Fig
. 18
).
8
.5
Fitting
the
Pressure
Relief
Discharge
Pipe
(Fig
. 19
)
1
. Remove
the
discharge
pipe
from
the
kit
.
2
. Determine
the
routing
of
the
discharge
pipe
in
the
vicinity
of
the
boiler
. Make
up
as
much
of
the
pipework
as
is
practical
, including
the
discharge
pipe
supplied
.
3
. The
pipework
must
be
at
least
15mm
diameter
and
run
continuously
downwards
to
a
discharge
point
outside
the
building
. See
section
6
.7
for
further
details
.
4
. Utilising
one
of
the
sealing
washers
, connect
the
discharge
pipe
to
the
adaptor
and
tighten
the
nut
.
5
. Complete
the
discharge
pipework
and
route
it
to
the
outside
discharge
point
.
IMPORTANT
: Make
all
soldered
joints
before
connecting
to
the
pressure
relief
valve
.
Fig
. 18
Fig
. 19
Page
19
8
.6
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
).
80e
model
only
If
the
optional
rear
flue
kit
is
to
be
used
, refer
to
the
instructions
supplied
.
Rear
Flue
: maximum
wall
thickness
-
900mm
Side
Flue
: maximum
wall
thickness
-
870mm
2
. If
using
the
optional
internal
fitting
kit
, flue
extension
kit
or
elbows
, refer
to
the
instructions
provided
with
the
kits
.
3
. Locate
the
flue
elbow
on
the
adaptor
at
the
top
of
the
boiler
. Set
the
elbow
to
the
required
orientation
(rear
, right
or
left
).
4
. Measure
the
distance
from
the
outside
wall
face
to
the
elbow
(Fig
. 20
). This
dimension
will
be
known
as
‘X
’.
5
. Taking
the
air
duct
, mark
dimension
‘X
’ as
shown
(Fig
. 21
). Measure
the
length
of
waste
material
, and
transfer
the
dimension
to
the
flue
duct
(Fig
. 21
).
6
. Remove
the
waste
from
both
ducts
. Ensure
that
the
cut
ends
are
square
and
free
from
burrs
.
7
. Remove
the
flue
elbow
from
the
adaptor
.
IMPORTANT
: Check
all
measurements
before
cutting
.
Fig
. 20
Fig
. 21
Page
20
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
. 22
).
8
. Insert
the
flue
duct
into
the
air
duct
and
pass
them
through
the
hole
in
the
wall
.
9
. 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
. 22
).
10
. Remove
the
screws
from
one
of
the
clips
provided
. Prise
the
clip
apart
and
fit
it
over
the
seal
(Fig
. 23
). Set
the
elbow
to
the
required
angle
.
11
. Refit
the
screws
to
the
clip
and
tighten
them
to
secure
the
elbow
. Take
the
second
rubber
seal
and
position
it
on
the
flue
elbow
.
12
. Locate
the
flue
duct
clamp
on
the
flue
outlet
elbow
. Draw
the
flue
duct
out
of
the
air
duct
, engage
it
in
the
clamp
and
tighten
the
screws
(Fig
. 24
).
13
. Draw
the
air
duct
out
of
the
wall
and
align
it
with
the
elbow
. Position
the
seal
so
that
it
equally
covers
the
joint
(Fig
. 25
).
14
. Remove
the
screws
from
the
second
clip
provided
. Prise
the
clip
apart
and
fit
it
over
the
seal
. Refit
the
screws
to
the
clip
and
tighten
them
(Fig
. 25
).
15
. Where
possible
position
the
clips
so
that
the
screws
are
not
visible
.
16
. Make
good
between
the
wall
and
air
duct
outside
the
building
.
17
. Fit
the
circular
flue
trim
outside
if
required
, and
if
necessary
fit
a
terminal
guard
(see
Section
7
.10
& 7
.11
).
VERTICAL
FLUE
1
. Only
a
flue
approved
with
the
Baxi
Combi
80e
and
105e
can
be
used
.
2
. For
information
on
vertical
flues
consult
the
Baxi
Combi
Installer
Guide
or
Notes
for
Guidance
supplied
with
the
vertical
flue
pack
.
Fig
. 22
, 23
, 24
, 25
Page
21
8
.7
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
locating
tabs
are
clear
of
the
facia
. Remove
the
panel
.
2
. Remove
the
screws
securing
the
facia
panel
and
hinge
it
down
(Fig
. 26
).
3
. Remove
the
control
box
cover
securing
screws
. Disengage
the
barbs
on
the
control
box
from
the
cover
. Remove
the
cover
(Fig
. 27
).
4
. Slacken
the
cable
clamp
on
the
LH
side
of
the
boiler
chassis
(Fig
. 28
). Insert
the
cable
through
the
clamp
and
route
it
to
the
terminal
block
.
5
. Slacken
the
screws
in
the
terminal
block
, connect
the
input
cable
, and
tighten
the
screws
.
6
. If
an
external
control
is
to
be
connected
it
can
be
done
at
this
point
. Run
the
input
cable
from
the
external
control
through
the
second
cable
clamp
on
the
boiler
chassis
. Refer
to
the
instructions
supplied
with
the
control
.
7
. To
connect
external
control
(s
) remove
the
link
between
terminals
1
& 2
. The
230V
supply
at
terminal
1
must
be
connected
to
the
external
control
. The
switched
output
from
the
external
control
must
be
connected
to
terminal
2
(Fig
. 29
).
NOTE
: If
the
room
thermostat
being
used
incorporates
an
anticipator
it
MUST
be
wired
as
shown
in
Fig
. 29
IMPORTANT
: The
external
control
MUST
be
suitable
for
230V
switching
.
8
. Ensure
that
both
mains
input
and
, where
fitted
, external
control
input
cables
have
sufficient
slack
to
allow
the
control
box
to
drop
down
. Tighten
the
cable
clamp
(s
) on
the
boiler
chassis
.
9
. If
the
optional
integral
timer
is
to
be
used
it
should
be
fitted
at
this
point
. Refer
to
the
instructions
supplied
with
the
timer
. NOTE
: An
external
frost
thermostat
cannot
be
used
with
the
integral
timer
.
8
.8
Preliminary
Electrical
Checks
1
. Prior
to
commissioning
the
boiler
preliminary
electrical
system
checks
should
be
carried
out
.
2
. These
should
be
performed
using
a
suitable
meter
, and
include
checks
for
Ground
Continuity
, Resistance
to
Ground
, Short
Circuit
and
Polarity
.
Fig
. 26
, 27
, 28
, 29
, 30
Page
22
9
.1
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
. 31
).
6
. The
system
must
be
flushed
in
accordance
with
BS
7593
(see
Section
6
.2
) and
the
flushing
agent
manufacturers
instructions
.
7
. Pressurise
the
system
to
1
.0
bar
then
close
and
disconnect
the
filling
loop
.
8
. Turn
the
gas
supply
on
and
purge
the
system
according
to
BS
6891
.
9
. Test
for
gas
soundness
.
10
. If
at
any
time
during
commissioning
it
is
required
to
terminate
a
particular
cycle
, e
.g
. the
pump
overrun
period
, turn
the
selector
to
the
OFF
position
and
then
back
to
either
(
) or
(
) (Fig
. 33
).
Fig
. 31
, 32
, 33
Page
23
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
. Set
the
temperature
controls
to
maximum
and
the
selector
switch
to
the
Off
position
(Fig
. 36
).
3
. Slacken
the
pressure
test
point
sealing
screw
on
the
gas
valve
and
connect
a
pressure
gauge
(Fig
. 33
).
4
. Undo
the
screws
securing
the
inner
door
panel
. Lift
the
panel
slightly
to
disengage
it
from
the
studs
on
top
of
the
case
.
5
. Turn
the
selector
switch
fully
anticlockwise
against
the
spring
pressure
to
the
reset
position
and
hold
for
2
seconds
to
reset
the
boiler
.
6
. Turn
the
selector
switch
to
the
Cental
Heating
and
Domestic
Hot
Water
position
(
). The
power
On
neon
(
) will
illuminate
(Fig
. 36
).
7
. Turn
a
hot
water
tap
on
to
give
a
flow
rate
of
at
least
10l/min
.
8
. The
pressure
should
be
:-
80e |
105e | |
NG |
12. 2mbar |
13. 4mbar |
Butane |
28. 3mbar |
n/a |
Propane |
36. 2mbar |
35. 8mbar |
If
not
, check
that
the
gas
supply
pressure
is
correct
(Natural
Gas
20mbar
, Butane
30mbar
and
Propane
37mbar
).
9
. The
pressure
can
be
adjusted
if
required
.
10
. To
check
minimum
pressure
first
remove
one
of
the
modulator
wires
.
Adjusting
the
Pressure
(Fig
. 34a
)
11
. Prise
apart
the
spring
clip
retaining
the
modulator
. Draw
the
modulator
off
the
valve
.
12
. Slacken
the
adjuster
tube
locknut
. Rotate
the
tube
until
the
correct
maximum
pressure
is
achieved
. Tighten
the
locknut
.
13
. Rotate
the
minimum
rate
adjuster
screw
until
the
correct
minimum
pressure
is
achieved
.
14
. Once
the
pressure
has
been
set
turn
the
boiler
off
and
disconnect
the
pressure
gauge
.
15
. Tighten
the
pressure
test
screw
and
refit
the
modulator
to
the
valve
. Reassemble
in
reverse
order
.
Fig
. 34
, 34a
, 35
, 36
Page
24
10
.0
Completion
10
.1
Completion
1
. Hinge
the
facia
panel
upwards
and
refit
the
case
front
panel
. Secure
them
with
the
screws
previously
removed
(Fig
. 37
).
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
. The
details
of
the
Log
Book
will
be
required
in
the
event
of
any
warranty
work
. The
Log
Book
must
be
handed
to
the
user
for
safe
keeping
and
each
subsequent
regular
service
visit
recorded
.
4
. Hand
over
the
Users
Operating
, Installation
and
Servicing
Instructions
and
the
Log
Book
, giving
advice
on
the
necessity
of
regular
servicing
.
Fig
. 37
Page
25
11
.0
Servicing
the
Boiler
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
.
5
. Slacken
the
screws
securing
the
facia
panel
. Lift
the
outercase
panel
so
that
its
securing
tabs
are
clear
of
the
facia
. Remove
the
panel
(Fig
. 39
).
6
. Remove
the
screws
(2
on
80e
, 4
on
105e
) securing
the
inner
door
panel
. Lift
the
panel
slightly
to
disengage
it
from
the
studs
on
top
of
the
case
(Fig
. 40
).
7
. Note
the
positions
of
the
two
sensing
tubes
on
the
outlet
elbow
and
three
wires
on
the
fan
motor
and
remove
them
(Fig
. 41
).
8
. Slacken
the
screws
on
the
outlet
sealing
collar
. Ease
the
collar
upwards
as
far
as
possible
(Fig
. 41
).
9
. Remove
the
four
screws
securing
the
combustion
box
door
and
remove
the
door
(Fig
. 40
).
Fig
. 39
, 40
, 41
Page
26
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
. Draw
the
assembly
forwards
(Fig
. 42a
).
12
. Undo
the
screws
securing
the
burner
to
the
injector
manifold
(105e
model
only
). Draw
the
burner
out
of
the
combustion
box
, pulling
the
electrode
grommets
from
the
slots
in
the
combustion
box
lower
panel
(Fig
. 43
).
13
. Disconnect
the
electrode
leads
and
grommets
from
the
electrodes
. Completely
remove
the
burner
(Fig
. 43
).
14
. Brush
any
deposits
from
the
injectors
. Do
not
use
a
pin
or
wire
to
clean
them
.
15
. Brush
the
burner
blades
and
venturis
and
clean
the
combustion
box
.
16
. Ensure
that
the
heat
exchanger
fins
are
clear
of
any
obstruction
.
DHW
Filters
(Fig
. 44
)
17
. If
the
flow
of
domestic
hot
water
is
diminished
, it
may
be
necessary
to
clean
the
filters
.
18
. Initially
check
the
cold
water
inlet
tap
filter
.
19
. Turn
the
tap
off
. Undo
the
blanking
cap
and
remove
the
threaded
bush
(Fig
. 43a
).
20
. Extract
the
filter
and
rinse
thoroughly
in
clean
water
. Reassemble
and
check
the
flow
. If
required
clean
the
manifold
filter
as
described
below
.
21
. Undo
the
filter
cartridge
from
the
inlet/return
manifold
.
22
. Dismantle
the
cartridge
and
carefully
remove
the
flow
regulator
and
filter
gauze
. Rinse
them
thoroughly
in
clean
water
and
reassemble
in
reverse
order
.
23
. Check
that
the
pressure
vessel
charge
is
0
.5bar
, reassemble
in
reverse
order
of
dismantling
and
recommission
.
24
. Turn
the
selector
switch
fully
anticlockwise
against
the
spring
pressure
to
the
reset
position
and
hold
for
2
seconds
to
reset
the
boiler
.
25
. Complete
the
relevant
section
of
the
"Benchmark
" Installation
, Commissioning
and
Service
Record
Log
Book
and
hand
it
back
to
the
user
.
Fig
. 42
, 42a
, 43
, 43a
, 44
Page
27
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
. When
the
new
component
has
been
fitted
turn
the
selector
switch
fully
anticlockwise
against
the
spring
pressure
to
position
R
and
hold
for
2
seconds
to
reset
the
boiler
before
recommissioning
.
See
Section
11
.1
"Annual
Servicing
" for
removal
of
case
panel
, door
etc
.
12
.1
Pressure
Switch
(Fig
. 45
)
1
. Note
the
positions
of
the
two
sensing
tubes
and
three
wires
and
remove
them
.
2
. Remove
the
two
screws
holding
the
pressure
switch
to
the
combustion
box
top
panel
.
3
. Fit
the
new
pressure
switch
and
reassemble
all
components
in
reverse
order
of
dismantling
.
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
.
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
.
5
. Undo
the
screws
securing
the
fan
hood
to
the
appliance
back
panel
, and
draw
the
fan
and
hood
assembly
forwards
.
6
. Remove
the
screws
and
spring
washers
securing
the
fan
to
the
hood
.
7
. Fit
the
new
fan
to
the
hood
using
the
screws
and
spring
washers
previously
removed
.
8
. Reassemble
in
reverse
order
of
dismantling
.
Fig
. 45
, 46
, 47
Page
28
12
.3
Heat
Exchanger
(Fig
. 48
)
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
.
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
.
5
. Undo
the
screws
securing
the
fan
hood
to
the
appliance
back
panel
, and
draw
the
fan
and
hood
assembly
forwards
.
6
. Drain
the
primary
circuit
. Prise
the
two
pipe
connecting
clips
off
the
joints
in
the
flow
and
return
pipes
.
7
. Lift
the
heat
exchanger
to
disconnect
the
flow
and
return
pipe
joints
. Withdraw
it
from
the
appliance
, taking
care
not
to
damage
the
rear
insulation
piece
.
8
. Fit
the
new
heat
exchanger
.
9
. Reassemble
in
reverse
order
of
dismantling
, and
repressurise
the
system
.
1
. Remove
the
four
screws
securing
the
combustion
box
door
and
remove
the
door
.
2
. Undo
the
screws
securing
the
burner
to
the
injector
manifold
(105e
model
only
). Draw
the
burner
out
of
the
combustion
box
, pulling
the
electrode
grommets
from
the
slots
in
the
combustion
box
lower
panel
.
3
. Disconnect
the
electrode
leads
and
grommets
from
the
electrodes
. Completely
remove
the
burner
.
4
. Undo
the
screws
securing
the
electrodes
to
the
burner
. Examine
the
condition
of
the
electrodes
, replacing
if
necessary
. Fit
the
electrodes
to
the
new
burner
.
5
. Engage
the
burner
location
brackets
over
the
studs
on
the
injector
manifold
and
reassemble
in
reverse
order
.
Fig
. 48
, 49
Page
29
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
.
3
. Unscrew
and
replace
injectors
as
required
and
examine
the
sealing
gasket
, replacing
as
necessary
. Reassemble
in
reverse
order
.
12
.6
Electrodes
(Fig
. 50
)
1
. Remove
the
four
screws
securing
the
combustion
box
door
and
remove
the
door
.
2
. Undo
the
screws
securing
the
burner
to
the
injector
manifold
(105e
model
only
). Draw
the
burner
out
of
the
combustion
box
, pulling
the
electrode
grommets
from
the
slots
in
the
combustion
box
lower
panel
.
3
. Disconnect
the
lead
and
grommet
from
the
electrode
being
replaced
. Undo
the
securing
screw
and
withdraw
the
electrode
to
the
burner
.
4
. Reassemble
in
reverse
order
.
12
.7
Insulation
(Fig
. 51
)
1
. Remove
the
four
screws
securing
the
combustion
box
door
and
remove
the
door
.
2
. Slide
the
side
insulation
pieces
carefully
out
of
their
carriers
.
3
. To
replace
the
rear
insulation
piece
it
is
necessary
to
remove
the
heat
exchanger
as
described
in
Section
12
.3
and
slide
out
the
side
pieces
.
4
. The
combustion
box
door
insulation
piece
can
be
replaced
by
carefully
bending
up
the
two
retaining
tabs
.
5
. Replace
all
insulation
pieces
and
reassemble
in
reverse
order
.
Fig
. 50
, 51
Page
30
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
.
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
. Disconnect
the
wires
from
the
valve
modulator
.
4
. Remove
the
screws
securing
the
inlet
pipe
flange
to
the
boiler
bottom
panel
and
those
securing
the
outlet
manifold
to
the
burner
manifold
.
5
. Remove
the
valve
from
the
boiler
.
6
. Note
the
orientation
of
the
inlet
pipe
and
outlet
manifold
. Undo
the
securing
screws
and
remove
the
pipe
and
manifold
.
7
. Examine
the
‘O
’ ring
seals
for
damage
, replacing
as
necessary
.
8
. Fit
the
inlet
pipe
and
outlet
manifold
to
the
new
valve
, ensuring
that
the
‘O
’ ring
seals
are
in
place
.
9
. Reassemble
in
reverse
order
and
check
the
burner
pressure
(Section
9
.2
).
12
.9
Central
Heating
Temperature
Sensor
(Fig
. 53
)
1
. Ease
the
retaining
tab
on
the
sensor
away
and
disconnect
the
electrical
plug
.
2
. Unscrew
the
sensor
from
it
’s
pocket
and
reassemble
in
reverse
order
. The
plug
will
only
fit
one
way
.
12
.10
Safety
Thermostat
(Fig
. 53
)
1
. Pull
the
electrical
connections
off
the
thermostat
.
2
. Remove
the
screws
securing
the
thermostat
to
the
mounting
plate
on
the
flow
pipe
.
3
. Reassemble
in
reverse
order
. The
thermostat
is
not
polarised
-
either
wire
can
fit
either
terminal
on
the
thermostat
.
12
.11
DHW
Temperature
Sensor
(Fig
. 53a
)
1
. Turn
off
the
mains
water
supply
and
draw
off
the
residual
domestic
hot
water
.
2
. Ease
the
retaining
tab
on
the
sensor
away
and
disconnect
the
electrical
plug
.
3
. Unscrew
the
sensor
from
the
plate
heat
exchanger
manifold
. Examine
the
sealing
washer
,replacing
if
necessary
.
4
. Reassemble
in
reverse
order
. The
plug
will
only
fit
one
way
.
Fig
. 52
, 53
, 53a
Page
31
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
. 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
replacement
head
can
now
be
fitted
. A
Grundfos
15-50
head
is
suitable
for
the
Combi
80e
. The
Combi
105e
requires
a
15-60
head
. Connect
the
wiring
to
the
new
head
. The
pump
speed
must
be
set
to
3
(Fig
. 55
).
4
. Reassemble
in
reverse
order
.
12
.13
Pump
-
Complete
(Fig
. 56
)
1
. Drain
the
primary
circuit
and
unscrew
the
automatic
air
vent
from
the
pump
body
. Undo
the
two
screws
securing
the
body
to
the
pipe
and
manifold
and
draw
the
pump
forwards
.
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
. Connect
the
wiring
to
the
new
pump
. Examine
the
‘O
’ ring
seals
on
the
return
pipe
and
manifold
, replacing
if
necessary
.
4
. Fit
the
air
vent
to
the
pump
body
and
reassemble
in
reverse
order
.
12
.14
Automatic
Air
Vent
(Fig
. 56
)
1
. Drain
the
primary
circuit
and
unscrew
the
automatic
air
vent
from
the
pump
body
.
2
. Examine
the
‘O
’ ring
seal
, replacing
if
necessary
, and
fit
it
to
the
new
automatic
air
vent
.
3
. Reassemble
in
reverse
order
.
Fig
. 54
, 55
, 56
Page
32
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
.
3
. Remove
the
bracket
and
gauge
assembly
. Depress
the
barbs
on
the
side
of
the
gauge
and
remove
the
retaining
bracket
.
4
. Reassemble
in
reverse
order
.
12
.16
Expansion
Vessel
(Fig
. 59
)
1
. To
replace
the
expansion
vessel
it
is
necessary
to
remove
the
boiler
from
the
wall
.
Note
: Alternatively
a
vessel
of
equivalent
capacity
can
be
fitted
on
the
system
return
pipe
as
close
as
possible
to
the
boiler
.
2
. Drain
the
system
and
undo
all
gas
and
water
connections
. Remove
the
flue
elbow
.
3
. Lift
the
boiler
off
the
wall
plate
and
lay
it
on
it
’s
side
on
a
clean
flat
surface
.
4
. Undo
the
nut
on
the
vessel
outlet
spigot
, and
remove
the
locknut
and
spring
washer
securing
the
spigot
to
the
boiler
chassis
.
5
. Undo
the
screws
and
remove
the
appliance
upper
cross
member
. Slide
the
expansion
vessel
out
of
the
retaining
clips
.
6
. Reassemble
in
reverse
order
. Fully
recommission
the
appliance
and
system
.
12
.17
Spark
Generator
(Fig
. 60
)
1
. Pull
the
electrode
lead
off
the
spark
generator
. Remove
the
screws
and
spring
washers
securing
the
generator
to
it
’s
mounting
bracket
.
2
. Pull
the
rubber
shroud
off
the
generator
input
plug
and
disconnect
the
plug
.
3
. Reassemble
in
reverse
order
.
Fig
. 57
, 58
, 59
, 60
Page
33
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
.
4
. Fit
the
new
valve
and
‘O
’ ring
seal
and
set
to
the
previously
noted
orientation
. Reassemble
in
reverse
order
.
12
.19
P
.C
.B
. (Fig
. 63
)
1
. Note
the
settings
of
the
temperature
control
knobs
. Rotate
the
knobs
fully
anticlockwise
and
carefully
pull
them
off
the
drive
pins
.
2
. Remove
the
screws
securing
the
control
box
cover
and
release
the
cover
retaining
barbs
from
their
slots
. Disengage
the
rear
of
the
cover
from
the
control
box
hinge
pin
(Fig
. 62
).
3
. Note
the
position
of
all
plugs
and
wires
on
the
P
.C
.B
. and
disconnect
them
.
4
. Undo
the
securing
screws
and
remove
the
P
.C
.B
. Transfer
the
control
knob
drive
pins
to
the
new
P
.C
.B
. and
turn
them
fully
anticlockwise
.
5
. Reassemble
in
reverse
order
, ensuring
that
the
temperature
controllers
are
reset
to
their
previous
positions
.
12
.20
Selector
Switch
1
. Note
the
setting
of
the
selector
switch
knob
and
carefully
pull
it
off
the
facia
.
2
. Remove
the
screws
securing
the
control
box
cover
and
release
the
cover
retaining
barbs
from
their
slots
. Disengage
the
rear
of
the
cover
from
the
control
box
hinge
pin
.
3
. Note
the
position
of
the
electrical
connections
and
the
orientation
of
the
switch
. Remove
the
electrical
connections
.
4
. Remove
the
screws
securing
the
switch
to
the
facia
panel
.
5
. Fit
the
new
switch
, ensuring
that
it
is
correctly
positioned
and
reassemble
in
reverse
order
.
Fig
. 61
, 62
, 63
Page
34
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
.
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
. Replace
carefully
, ensuring
that
the
seal
is
inserted
into
the
manifold
parallel
and
pushed
fully
in
.
6
. When
fitting
the
new
heat
exchanger
note
that
the
left
hand
location
stud
is
offset
towards
the
centre
more
than
the
right
hand
one
.
7
. Reassemble
in
reverse
order
.
12
.22
Diverter
Valve
Assembly
(Figs
. 65
& 66
)
The
diverter
valve
assembly
comprises
of
a
central
heating
pressure
differential
valve
and
a
domestic
hot
water
pressure
differential
valve
. These
are
connected
to
a
manifold
which
is
joined
to
the
plate
heat
exchanger
.
DHW
Pressure
Differential
Valve
(Fig
. 66
)
1
. Drain
the
primary
circuit
.
2
. Undo
the
screw
securing
the
microswitch
bracket
to
the
valve
(Fig
. 65
).
3
. Disconnect
the
two
sensing
pipes
and
slacken
the
grub
screws
securing
the
valve
to
the
diverter
manifold
.
4
. Draw
the
valve
away
from
the
diverter
manifold
. The
valve
may
now
be
replaced
or
split
to
examine
the
diaphragm
.
5
. To
examine
the
diaphragm
hold
the
valve
body
securely
and
carefully
remove
the
six
screws
. The
diaphragm
spring
will
force
apart
the
two
halves
of
the
valve
.
6
. Remove
the
plastic
disc
and
pushrod
assembly
. Carefully
examine
the
diaphragm
and
replace
it
if
there
is
any
damage
.
7
. Reassemble
in
reverse
order
.
Fig
. 64
, 65
, 66
Page
35
12
.22
Diverter
Valve
Assembly
(Cont
)
Pressure
Differential
Valve
(Fig
. 67
)
1
. Remove
the
pressure
differential
valve
as
described
above
.
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
. Disconnect
the
pressure
gauge
capillary
from
the
diverter
manifold
and
remove
the
two
wires
from
the
microswitch
.
4
. Prise
off
the
spring
clip
securing
the
by-pass
pipe
to
the
diverter
manifold
and
disconnect
the
sensing
pipe
.
5
. Ease
the
diverter
manifold
out
of
the
plate
heat
exchanger
manifold
. Remove
the
assembly
from
the
appliance
.
6
. Undo
the
screw
securing
the
microswitch
bracket
to
the
valve
body
. The
sensor
may
now
be
dismantled
to
examine
the
diaphragm
.
7
. To
examine
the
diaphragm
hold
the
assembly
securely
and
carefully
remove
the
four
screws
. The
diaphragm
spring
will
force
the
two
halves
of
the
valve
apart
.
8
. Carefully
examine
the
diaphragm
and
replace
it
if
there
is
any
damage
.
9
. Reassemble
in
reverse
order
.
CH
Pressure
Microswitch
(Fig
. 67
)
1
. Remove
the
two
wires
from
the
Pressure
microswitch
.
2
. Undo
the
screw
securing
the
microswitch
bracket
to
the
valve
body
.
3
. Reassemble
in
reverse
order
.
12
.23
Flow
Regulator
(Figs
. 68
& 69
)
1
. Undo
the
filter
cartridge
from
the
inlet/return
manifold
.
2
. Unscrew
the
venturi
and
remove
the
flow
regulator
.
3
. Check
the
cleanliness
of
the
filter
gauze
, rinsing
thoroughly
in
clean
water
as
necessary
. Fit
the
new
flow
regulator
and
reassemble
in
reverse
order
.
Fig
. 67
, 68
, 69
Page
36
13
.0
Illustrated
Wiring
Diagram

Page
37
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
. NOTE
: These
checks
must
be
repeated
after
any
servicing
or
fault
finding
.
3
. Ensure
all
external
controls
are
calling
for
heat
and
check
all
external
and
internal
fuses
. Before
any
servicing
or
replacement
of
parts
ensure
the
gas
and
electrical
supplies
are
isolated
.
Refer
to
Section
13
.0
"Illustrated
Wiring
Diagram
" for
position
of
numbered
terminals
Central
Heating
-
Follow
operational
sequence

Page
38
Domestic
Hot
Water
-
Follow
operational
sequence

Page
39
Fault
Finding
Solutions
Sections
A
to
E

Page
40

Page
41

Page
42
15
.0
Short
Parts
List
Short
Parts
List
Key |
G. C. |
Description |
Manufacturers |
No. |
No. |
Part No. | |
22 |
E66 383 |
Fan 80e |
248001 |
E66 527 |
Fan 105e |
248002 | |
23 |
393 974 |
Pressure Switch |
247380 |
32 |
E66 393 |
Heat Exchanger 80e |
248016 |
E66 535 |
Heat Exchanger 105e |
248017 | |
41 |
E66 398 |
Burner 80e |
248029 |
E66 399 |
Burner 105e |
248030 | |
44 |
E66 402 |
Injector |
248210 |
59 |
E66 408 |
Electrode Lead |
248037 |
63 |
E66 411 |
Spark or Sensing |
|
Electrode |
247384 | ||
72 |
E66 431 |
Pump 80e |
248041 |
E66 539 |
Pump 105e |
248042 | |
101 |
E66 432 |
3-Way Valve Assy. |
248061 |
131 |
342 571 |
Temperature Sensor |
247394 |
135 |
E66 439 |
Safety Thermostat |
248079 |
140 |
343 560 |
Gas Valve |
248085 |
154 |
E66 459 |
PCB |
248074 |
169 |
E66 453 |
Pressure Gauge |
248090 |


Page
43
Comp
N
o
247938
-
Iss
5
-
5/02

Page
44