Baxi Combi 105 HE Page 48 Installation & Servicing Instructions Manual Download

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12.0

Changing Components

12.21

Plate Heat Exchanger

(Fig. 67)

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. 68 & 69)

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. 69)

1. Drain the primary circuit.

2. Undo the screw securing the microswitch bracket to

the valve (Fig. 68).

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.

Plate Heat Exchanger

Rubber Seal

DHW Pressure

Differential Valve

Microswitch

Bracket

Grub Screws

Diverter Manifold

Sensing Pipes

Plastic Disc

Pushrod

Diaphragm

Spring

Diaphragm

Fig. 67

Fig. 68

Fig. 69

Summary of Contents for Combi 105 HE

Page 1: ...2005 Baxi Combi 105 HE Gas Fired Wall Mounted Condensing Combination Boiler Installation Servicing Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the User for safe keeping ...

Page 2: ...lding Regulations only relates to dwellings Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations Legislation 4 1 0 Introduction 5 2 0 General Layout 6 3 0 Appliance Operation 7 4 0 Technical Data 8 5 0 Dimensions an...

Page 3: ...K Limited 2005 Baxi Combi 105 HE Gas Fired Wall Mounted Condensing Combination Boiler User s Operating Instructions Please keep these instructions safe Should you move house please hand them over to the next occupier ...

Page 4: ...rrange a visit convenient to you Benchmark Commissioning Check List Please ensure that your installer hands you the boiler Installation Service Instructions with the Benchmark Commissioning Checklist sections completed The details in the Checklist will be required in the event of any warranty work Keep the instructions in a safe place and ensure that the Service Interval Record at the back is comp...

Page 5: ...ockford Lane Basingstoke RG24 8WG or check online at www corgi gas safety com Baxi declare that no substances harmful to health are contained in the appliance or used during appliance manufacture The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force and only used in a suitably ventilated location In GB the installation must be ca...

Page 6: ...owards the wall Fig 2 4 Call your Installer or Service Engineer as soon as possible 1 2 In case of gas leaks 1 If a gas leak is found or suspected turn off the gas supply at the meter immediately and at the isolating valve on the boiler if possible Contact your Gas Supplier immediately 1 3 Servicing your Appliance 1 For reasons of safety and economy your appliance should be serviced annually Servi...

Page 7: ...rol knobs and pressure gauge the facia incorporates ten neon indicator lights 2 Neons 12 to 15 indicate the operational status of the boiler Neons 6 to 11 have a dual function indicating the temperature of the central heating water when constantly illuminated If a fault develops the appropriate neon will begin to flash Refer to Sections 3 3 to 3 7 30o 40o 50o 60o 70o 80o Reset Fig 3 30o 40o 50o 60...

Page 8: ... illuminate as the temperature rises 5 Position ii In this position hot water will be provided when a tap or shower is turned on Fig 8 The hot water neon will illuminate Fig 5 6 The boiler will light automatically on demand 7 The orange burner on neon will illuminate when the boiler is operating and the main burner is on Fig 5 IMPORTANT When the selector switch is in the 0 Off position the electri...

Page 9: ...he selector switch fully anti clockwise against the spring pressure to the Reset position for at least two seconds and release Fig 12 Set the selector to the required position to light the boiler 3 If the flame failure light illuminates repeatedly a fault is indicated with either the boiler the gas supply or the condensate drain Your installer or Service Engineer should be contacted as soon as pos...

Page 10: ... system pressure drops below the minimum requirement Fig 12 2 Check the pressure gauge as described in Section 3 9 If the pressure is in the normal range a pump fault is indicated Contact your Installer or Service Engineer to determine the nature of the fault 3 7 Sensor Fault 1 When the or neon is illuminated a fault on the hot water or central heating temperature sensor is indicated Fig 12 Contac...

Page 11: ...riods during cold weather the boiler and whole system should be drained unless there is additional frost protection 3 Your installer will advise you about frost protection and draining the system 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 sel...

Page 12: ...f gas are vented to the outside through the flue terminal which must be kept free from obstruction as this would interfere with the correct operation of the boiler 4 The boiler may be installed in a cupboard if these minimum clearances are kept The compartment should be large enough to house the boiler and ancillary equipment only 5 IT SHOULD NOT BE USED AS A STORAGE CUPBOARD 4 2 Check List 1 If a...

Page 13: ... 08706 096 096 open Monday to Friday 8am 6pm weekends and bank holidays 8 30am 2pm closed on Christmas and New Years Day An appointment convenient for you can be arranged It will help if you have your boiler serial number when you call the serial number is shown on the back cover of this guide 5 3 Spare Parts 1 Once outside the guarantee period any spare parts may be obtained through approved Baxi...

Page 14: ...e the boiler serial number heateam will verify the boiler age via the serial number and offer a free warranty service within 12 months of installation of the boiler If you are unable to provide this information or the boiler has been installed for over 15 months heateam will charge a competitive rate for the repair The engineer when visiting will verify if the boiler is under the free 12 months wa...

Page 15: ...and will send a certificate of compliance to the property You must ensure that the notification number issued by CORGI is writen onto the Benchmark Checklist Scheme Members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days If you notify via CORGI Scheme CORGI will then notify the relevant Local Authority Building Control Scheme on member s behalf Complete the Benchm...

Page 16: ... by a CORGI Registered Installer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation Use Regulations The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland The Water Fittings Regulations or Water Byelaws in Scotland The Current I E E Wiring Regulations Where no speci...

Page 17: ...l 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 5111073 8 All systems ...

Page 18: ...ry Heat Exchanger 21 On Off Reset Selector Switch 22 Central Heating Temperature Control 23 Hot Water Temperature Control 24 Flame Failure or Blocked Condensate Drain 25 Safety Thermostat Activated Boiler or Flue 26 Fault on Fan or Flue 27 Fault on Pump or Low System Pressure 28 Fault on Hot Water Sensor 29 Fault on Central Heating Sensor 30 Power On 31 Domestic Hot Water Mode 32 Central Heating M...

Page 19: ...o 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...

Page 20: ...Content 1 2 of Boiler unpressurised 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 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 Heat Input CH Max Min kW 30 5 11 9 Heat Output CH Non Condensing...

Page 21: ... C 450mm D 116mm Ø Min E 185mm F 190mm G 131mm 360 Orientation Tube Ø 100mm D C B A E G F Domestic Hot Water Outlet 15mm Cold Water Inlet 15mm Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 65 mm 65 mm 65 mm 65 mm 65 mm Tap Rail 3o 28mm Condensate Drain ...

Page 22: ... new systems flux will be evident within the system which can lead to damage of system components All systems must be thoroughly drained and flushed out The recommended flushing and cleansing agents are Betz Dearborn Sentinel X300 or X400 and Fernox Superfloc Universal Cleanser which should be used following the flushing agent manufacturer s instructions System additives corrosion inhibitors and f...

Page 23: ...emoved 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 For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Dom...

Page 24: ...velop 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 ...

Page 25: ...3 Domestic Gas Installations and the current ETCI rules 4 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 7 2 Clearances Figs 8 9 1 A flat vertical area is required for the installation of the boiler 2 These dimensions include t...

Page 26: ...e rear of the gas service cock Fig 10 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 5 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current I E e Wiring Regulations In IE reference should be made ...

Page 27: ... pipe diameter is increased to 32mm 8 If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run 9 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used 10 When discharging condensate into a soil stack or waste ...

Page 28: ...h 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 o...

Page 29: ...9 Flue Trim 1 The rubber flue trim supplied may be fitted to either the outside wall or on the inner wall of installation 7 10 Terminal Guard 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 quo...

Page 30: ...gths are Concentric Pipes 45 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 45 bend 0 25 metres 91 5 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 fou...

Page 31: ... 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 116mm 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 ...

Page 32: ...ards 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 8 6 Condensate Drain see section 7 6 1 Connect the conde...

Page 33: ...ate the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 21 NOTE The flue elbow is angled at 93 degrees to ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 22 4 To dimension X add 50mm This dimension to be known as Y IMPORTANT Check all dimensions before cutting Wall...

Page 34: ...ducts and ease assembly Fig 24 8 Insert the flue through the hole in the wall Fit the elbow to the boiler adaptor ensuring that it is pushed fully in 9 Draw the flue back through the wall and engage it in the elbow It may be necessary to use soap solution or similar to ease assembly of the elbow adaptor and flue Fig 25 10 Make good between the wall and air duct outside the building 11 Fit the flue...

Page 35: ...rnal 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 9 Preliminary Electrical Checks 1 Prior to commissioning the...

Page 36: ...593 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 according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 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 t...

Page 37: ...37 6 Turn the selector switch to the Cental Heating and Domestic Hot Water position The power On neon will illuminate Fig 37 7 Turn a hot water tap on to give a flow rate of at least 10l min 8 The pressure should be NG 12 1mbar Propane 32 3mbar If not check that the gas supply pressure is correct Natural Gas 20mbar and Propane 37mbar 9 The pressure can be adjusted if required 10 To check and set m...

Page 38: ...o the appliance and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to t...

Page 39: ...l so that its securing tabs are clear of the facia Remove the panel Fig 39 6 Remove the screws 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 fan spigot and three wires on the fan motor and remove them Fig 41 8 Slacken the screws on the fan spigot outlet pipe clamps Ease the clamps ...

Page 40: ...water is diminished it may be necessary to clean the filters 19 Initially check the cold water inlet tap filter 20 Turn the tap off Undo the blanking cap and remove the thread bush Fig 45 21 Extract the filter and rinse thoroughly in clean water Reassemble and check the flow If required clean the manifold filter as described below 22 Undo the filter cartridge from the inlet return manifold 23 Dism...

Page 41: ...e the front edge of the left hand baffle upwards disengaging the spring clip Disengage the tab on the baffle from the slot in the fan hood 6 Undo the screws securing the fan hood to the appliance back panel and draw the fan and hood assembly forwards 7 Remove the screws and spring washers securing the fan to the hood 8 Fit the new fan to the hood using the screws and spring washers previously remo...

Page 42: ...he four screws securing the combustion box door and remove the door 2 Undo the screws securing the burner to the injector manifold 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 bur...

Page 43: ...onnect 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 53 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 e...

Page 44: ...Reassemble in reverse order and check the burner pressure Section 9 2 12 9 Central Heating Temperature Sensor Fig 55 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 55 1 Pull the electrical connections off the thermostat 2 Remove the screws...

Page 45: ...ent 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 manifo...

Page 46: ...he 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 Condensate Trap Fig 63 1 Disconnect the two sensing wires from the trap connections 2 Squeeze tog...

Page 47: ... 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 Fig 66 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely un...

Page 48: ...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 69 1 Drain the primary circuit 2 Undo the screw securing the microswitch bracket to the valve Fig 68 3 Disconnect the two sensing pipes and slacken the grub screws securing the valve to the diverte...

Page 49: ... 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 70 1 Remove the two wires from the Pressure microswitch 2 Undo the screw securing the microswitch bracket to the...

Page 50: ...hanger from the outer drum by easing it forward 7 Reassemble in reverse order of dismantling 12 25 Flue Overheat Thermostat Fig 74 NOTE The flue overheat thermostat includes a reset button Check that the thermostat will not reset before replacing 1 Remove the fan spigot outlet pipe from the fan and elbow 2 Pull the two wires off the terminals on the flue overheat thermostat Unscrew the thermostat ...

Page 51: ...5 F2 1 bk bk r r g g g r g r 2 1 2 3 3 4 1 1 2 3 4 5 6 10 9 8 7 6 5 4 3 2 1 2 3 4 4 5 5 6 7 8 9 Central Heating Temperature Sensor Fan Gas Valve Overheat Stat Hydraulic Differential Pressure Switch Domestic Hot Water Flow Priority Pressure Switch Air Pressure Switch Flame Mains Input Fuse Link g y g y b br bk br b bk Sensing Electrode Pump b b b bk b b b br br b b r bk bk br bk br br br Flue Stat ...

Page 52: ...t to max Pump runs Air pressure switch proved neon flashing Burner on neon illuminated Burner output modulates until set temperature is reached Spark at ignition electrodes for up to 10 seconds Go to section A neon flashing Go to section B neon flashing Go to section C Go to sections J M neons flashing Go to section D neon flashing Go to section E Replace PCB Turn selector to the reset position If...

Page 53: ... F neon flashing Go to sections I L DHW flow valve senses no flow Primary water diverted to CH system DHW flow switch released off Close DHW tap Burner goes out Diverter valve spindle assembly faulty Pump stops Operation sequence correct neon flashing Turn selector to reset position If regular resetting is required or appliance still does not operate investigation is necessary neon flashing Go to ...

Page 54: ...cable YES B CH system pressure 0 5 to 1 5 bar Re pressurise system 1 NO Primary flow valve diaphragm damaged Replace diaphragm Flow valve rod obstructed 3 YES Check the tap of the automatic air vent is opened Open the automatic air vent 2 NO NO C YES Continuity across flow microswitch and PCB A5 connector terminals 7 8 Replace microswitch 1 NO NO Primary temperature sensor faulty Cold resistance a...

Page 55: ...place PCB G Check and correct if necessary 1 Ignition electrode and lead 2 Electrode connection 3 Spark gap and position 230V at Main PCB A1 connector across terminals 3 4 Check wiring YES NO Replace gas valve electrical plug igniter assembly YES H YES Check the burner setting pressure of the gas valve see Section 9 2 of Commissioning 1 Voltage at modulating coil of gas valve is Max burner press a...

Page 56: ...ESET selector when turned to Reset position Replace ON OFF RESET selector NO Replace PCB YES K Replace safety thermostat YES NO Overheat thermostat operated or faulty i e continuity across thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm J If checks in section I are completed successfully blockage of the condensate drain or trap may have occurred L If che...

Page 57: ...ctor 5112376 59 E66 408 Electrode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 Pump 248042 101 E66 432 3 Way Valve Assy 248061 131 342 571 Temperature Sensor 247394 135 E66 439 Safety Thermostat 248079 140 Gas Valve 5107339 154 PCB 5112380 169 E66 453 Pressure Gauge 248090 327 Igniter Gas Valve Cable 5112385 A Flue Overheat Thermostat 5112395 22 140 44 63 154 72 135 59 41 101 169 13...

Page 58: ...CER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE...

Page 59: ...ANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE INTERVAL RECORD It is recommended that your heating syst...

Page 60: ...nquiries 08706 049 049 Website www baxi co uk company All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request ...

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