Baxi System 100 HE Plus, Installation & Servicing Instructions Manual

Page 1: ...Please leave these instructions with the user Baxi System 100 HE Plus Wall Mounted Powered Flue Condensing Gas Fired Central Heating Boiler Installation Servicing Instructions ...

Page 2: ... a Self Certification Scheme for gas heating appliances These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook which was then left on site with the customer With the introduction of Self Certification Schemes the Benchmark Logbook is being withdrawn However a similar document in...

Page 3: ... 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 Benchmark Checklist I...

Page 4: ...nt 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 specific instructions are given reference should be made to the relevant British Standard ...

Page 5: ... 0 Dimensions and Fixings 10 6 0 System Details 11 7 0 Site Requirements 14 8 0 Installation 20 9 0 Electrical 26 10 0 Commissioning 28 11 0 Outer Case 29 12 0 Servicing 30 13 0 Changing Components 32 14 0 Short Parts List 41 15 0 Fault Finding 42 Benchmark Checklist 50 Section Page Contents ...

Page 6: ...ust be installed with one of the purpose designed flues such as the standard horizontal flue kit part no 236921 1 2 Important Information Man made mineral fibre Some component parts of this appliance insulation pads gaskets and rope seals are manufactured from man made mineral fibre Prolonged or excessive exposure to this material may result in some irritation to the eyes skin or respiratory tract...

Page 7: ... Gauge 20 Expansion Vessel 1 2 3 4 5 6 7 8 9 10 13 14 17 16 Fig 4 Fig 3 Fig 5 15 18 19 20 Fig 6 2 2 Optional Extras KIT PART No FLUE EXTENSION KITS 110 70 Flue Extension 0 25M 241692 Flue Extension 0 5M 241694 Flue Extension 1M Use two kits for 2M etc 241695 Flue Bend x 2 45 Reduce overall length of flue by 0 5m when fitting this bend 241689 Flue Bend 90 Reduce overall length of flue by 1m when fi...

Page 8: ...Burner On The pump fan and gas valve are on while the spark generator is off Flow temperature is controlled by varying the fan speed and thereby the gas rate to achieve optimum operation If the flow temperature is greater than the set point then pump overrun occurs If the TRVs all shut down then anti cycle occurs 6 Pump Overrun The pump is on while the fan spark generator and gas valve are off Aft...

Page 9: ...in Front In Operation 5mm Min Appliance Type C13 C33 Nox Class 5 Heat Output Condensing 40 C Mean Water Temp Max Min kW 32 61 10 1 Btu h 111 280 34 520 Water Content litres 3 5 pints 6 2 Controls boiler thermostat safety thermostat flow switch electronic flame sensing temperature protection thermostat condensate blockage sensor Central Heating Primary Circuit Pressures bar lb in2 Safety Discharge ...

Page 10: ...f the flue elbow should be 55mm to incorporate the 3 1 in 20 fall in the flue from the terminal to the elbow The 3 1 in 20 fall provided by the elbow is to allow condensate to run back to the boiler for disposal through the condensate discharge pipe Flue length Y up to 1m 1m 2m 2m 3m Clearance X 55mm 110mm 165mm 360 Orientation Tube Ø 110mm D C B A E F Y 3 1 in 20 X 3 1 in 20 Fig 7 Fig 8 ...

Page 11: ...ump and valves boiler noise and circulation problems When upgrading existing systems that exhibit evidence of sludging it is advisable to clean the system prior to treatment in order to remove any sludge and reduce the likelihood of these deposits damaging new components When fitting new systems flux will be evident within the system which can lead to damage of system components All systems must b...

Page 12: ...own Y Plan Diverter Valve Cylinder Stat Room Stat Pump Timer 230V 50Hz L N E L N CH on HW on HW off L N E b g y w o gr 1 C 2 Electrical Filter L E N g y S Plan Valve Cylinder Stat Room Stat Pump Timer 230V 50Hz L N E L N CH on HW on L N E Motor S Plan Valve Motor o o gr b g y b gr br br Electrical Filter L E N Y Plan Diverter Valve Cylinder Stat Pump Timer 230V 50Hz L N E L N CH on HW on HW off L ...

Page 13: ...ondensing boilers Existing radiators may be oversized and so allow this but where radiator sizing is marginal it may be advisable to retain a system temperature drop of 11 C 20 F 4 In systems using non metallic pipework it is necessary to use copper pipe for the boiler Flow and Return The copper must extend at least 1 metre from the boiler and include any branches Fig 9 6 5 Thermal Stores 1 When t...

Page 14: ... charged to 1 bar 10 lb in2 Therefore the minimum cold fill pressure is 1 bar The vessel is suitable for correct operation for system capacities up to 125 litres 27 5 gal For greater system capacities an additional expansion vessel must be fitted refer to BS 7074 Pt 1 6 8 Pressure Relief Valve Fig 11 1 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable...

Page 15: ... E E Wiring Regulations and Building Regulations In IE reference should be made to the current edition of I S 813 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 Ventil...

Page 16: ...r to the appliance is of adequate size 22mm recommended at the appliance Do not use pipes of a smaller diameter than 22mm up to the boiler connection 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 to the current edition of ETCI rules 2 The...

Page 17: ...otect against frost It is also recommended that the 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...

Page 18: ...be painted if required using a suitable external paint 9 If a terminal is less than 2 metres 783 4 in above a balcony above ground or above a flat roof to which people have access then a suitable terminal guard must be provided Fig 16 Fig 15 300 min Terminal Assembly TopView Rear Flue Property Boundary Line NOTE The distance from a fanned draught appliance terminal installed parallel to a boundary...

Page 19: ...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 model number 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated 7 10 Vertical Flue 1 Only a flue approved with the Baxi System 100 HE Plus can be us...

Page 20: ...ation are given in the Installation Guidance Notes for each flue system type Documents 243501 and 243502 for concentric and twin pipe respectively A Standard Flue D C B E K L M D J F J N H G R Key Accessory Size Baxi Code Number Concentric Flue System 110mm diameter A Horizontal flue kit 850mm 236921 B Straight extension kit 1000mm 241695 500mm 241694 250mm 241692 C Bend kit 93 241687 D Bend kit p...

Page 21: ... Both wall faces immediately around the cut hole should be flat 7 Drill and plug the wall as previously marked Secure the wallplate to the wall by the top centre hole 8 Ensuring the wallplate is level both horizontally and vertically drill and plug the remaining 4 securing positions at the top and bottom through the wallplate Utilising the slots available ensure the wallplate is square and secure ...

Page 22: ... Fig 23 NOTE Service Guidance Note Label is fitted to the inside of the outercase Fig 23 4 Remove the sealing plugs from the copper bends 5 Remove cardboard transit packaging at the left hand rear of the boiler before lifting the boiler onto the support bracket 6 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 uprig...

Page 23: ...on see section 7 6 1 Connect the condensate drain using the 1 BSP nut and seal supplied Ensure the discharge of condensate complies with any national or local regulations in force see British Gas Guidance Notes for the Installation of Domestic Gas Condensing Boilers 2 The condensate outlet terminates in a 1 BSP nut and seal for the connection of 21 5mm 3 4in plastic overflow pipe which should gene...

Page 24: ...indicated in the diagram Fig 28 Check your dimensions The flue tubes are fixed together Cut through both tubes whilst resting the flue on the semi circular packing pieces Deburr both tube ends 4 For left hand exit measure the distance from the edge of the support bracket to the inner face of the wall Fig 27 and to this dimension add the wall thickness 268mm This dimension to be known as Y i e Y su...

Page 25: ...good between the wall and air duct outside the building ensuring the 3 drop between the terminal and elbow 12 The flue trim should be fitted once the installation is complete and the flue secure Apply a suitable mastic to the inside of the trim and press against the wall finish making sure the brickwork is dust free and dry Fig 32 If necessary fit a terminal guard see section 7 9 VERTICAL FLUEING ...

Page 26: ...8 kW 103 000 Btu hr and the boiler can be adjusted as follows a Release the facia securing screws 1 4 turn and hinge down the facia panel Remove the PCB connection cover Fig 34 b Remove the Red jumper labelled CN12 from the bottom left hand side of the PCB If the boiler is to be used in conjunction with a Thermal Store the boiler can be adjusted as follows a Release the facia securing screws 1 4 t...

Page 27: ...9 0 Electrical 27 9 1 Schematic Wiring Diagram Key To Wiring Colours b Blue bk Black w White br Brown gy Grey r Red g Green g y Green Yellow op Opaque y Yellow ...

Page 28: ...de Flame Detection Electrode Main PCB r r gy gy r b br g w Flow Overheat Thermostat Fan Overheat Thermostat bk bk bk r bk w w op g y g y b Layout of PCB Pins Optional Pump Feed g y br g y br Pump y b y g y L N Filter Plug br b g y Wiring Key b Blue bk Black br Brown r Red w White g y Green Yellow g Green gy Grey op Opaque ...

Page 29: ...or following the inhibitor manufacturer s instructions Vent air as described in Step 4 7 Complete the label supplied with the inhibitor and attach to the inside of the boiler case Detail of system treatment should be added for future reference 8 Pressurise the system to 1 5 bar then close and disconnect the filling loop 9 Turn the gas supply on and purge according to in GB BS 6891 and in IE IS 813...

Page 30: ...mplete a Declaration of Conformity to indicate compliance to I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 5 The Important Ventilation Information label can be removed unless the appliance is installed in an unventilated compartment 6 Instruct the user in the operation of the boiler controls Hand over the User...

Page 31: ...crews securing the air box door panel and remove the door Fig 40 7 Disconnect the three lead terminals from the combustion box door taking note of their positions Fig 40 8 Undo the four screws securing the combustion box door and remove the door Fig 41 9 Visually check for debris damage and clean or replace if necessary the following a Burner Fragile handle with care b Heat exchanger fins c Fan co...

Page 32: ...e heat exchanger support bracket and slide to the left to remove Fig 44 i Remove the four screws securing the heat exchanger combustion box base and withdraw the base j Lower the central insulation panel and check condition Fig 44 Replace the lower insulation pad if necessary k Ensure the heat exchanger fins are clear of any obstruction l Check condition of all seals Important Pay particular atten...

Page 33: ...sary There are 3 drain points a Flow Valve b Heat Exchanger Manifold Fig 45 c Return Valve NOTE When reassembling always fit new O rings ensuring their correct location on the spigot Green O rings are used for gas joints and Black O rings for water joints Use Greasil 4000 Approved Silicone Grease 3 After changing a component re commission the boiler where appropriate and check the inhibitor concen...

Page 34: ...e sensor from the pipe 4 Fit the new thermistor or safety thermostat and reassemble in reverse order 13 5 Expansion Vessel Fig 49 1 Drain the boiler see Section 13 1 paragraph 2 3 2 Loosen the securing screw at the base of the expansion vessel 3 Whilst supporting the vessel undo the expansion vessel connection and retain the sealing washer 4 Remove the expansion vessel 5 Fit the new expansion vess...

Page 35: ... the new pump and reassemble in reverse order 13 9 Pump Head Only Fig 53 1 Drain the boiler see Section 13 1 paragraph 2 3 2 Unplug the wiring harness from the pump 3 Remove the four socket head screws securing the pump head and separate it from the housing 4 Remove the screws retaining the pump electrical covers on the original and replacement heads 5 From the replacement UPS 15 60 pump head remo...

Page 36: ...3 11 Pressure Relief Valve Fig 56 1 The pressure relief valve is positioned on the hydraulic manifold at the back of the pump 2 Drain the boiler see Section 13 1 paragraph 2 3 3 Disconnect the union between the valve and the discharge pipe 4 Slacken the screw retaining the valve 5 Pull the valve upwards to disengage it 6 Fit the new pressure relief valve and reassemble in reverse order Expansion V...

Page 37: ...nd hinge down the facia panel 3 Remove the screws securing the PCB connection cover 4 Remove the screws securing the control board and disconnect the electrical connections noting their positions although they are one way fitting NOTE Check the PCB for the presence of input jumpers see section 8 7 Set the new PCB as the original 5 Fit the new PCB and reassemble in reverse order Fig 57 Facia Panel ...

Page 38: ...n Fig 59 WARNING The PCB Control and Fan Assembly is 325 Vdc Isolate at supply before access 1 Loosen the screw holding the injector pipe into the venturi 2 Remove the electrical connections to the fan and protection sensor on the fan 3 Remove the wing nuts securing the fan to the base of the combustion box 4 Lower the fan and remove 5 If changing the fan remove the screws securing the venturi and...

Page 39: ...lve 5 Remove the gas valve from the airbox side 6 Remove the nut union aluminium spacer and its gasket from the gas valve 7 Fit the nut union aluminium spacer and its gasket to the new valve 8 Fit the new gas valve and reassemble in reverse order 13 17 Condensate Trap Fig 61 1 Disconnect the condensate trap from the base of the heat exchanger 2 Disconnect the condensate drain outside the boiler fr...

Page 40: ...WARNING The PCB Control and Fan Assembly is 325 Vdc Isolate at supply before access 2 Remove the fan and condensate trap see section 13 14 and 13 17 3 Remove the screws securing the flow switch and return connections and remove the connections Fig 63 4 Remove the screws securing the heat exchanger manifold and remove the manifold Fig 64 5 Lift the heat exchanger assembly Fig 65 and rotate the bott...

Page 41: ...ove the lower insulation pad 6 Fit the new insulation pad and reassemble in reverse order 13 21 Heat Exchanger Upper Insulation Pad Fig 66 WARNING The PCB Control and Fan Assembly is 325 Vdc Isolate at supply before access 1 Remove the fan and condensate trap see section 13 14 and 13 17 2 Remove the burner see section 13 18 3 Remove the heat exchanger see section 13 19 4 Remove the four bolts secu...

Page 42: ... B E06 059 Flow Switch 242459 C E06 060 Safety Thermostat Black 242235 D PCB enclosure 5110991 E Fan 5109925 F E78 749 Gas Valve 242473 G E06 085 Viewing Window 242484 H Condensate Trap 5111714 J Electrodes Kit 5110992 K Burner Assy 5107430 L E06 097 Heat Exchanger Assy 242497 M Pump 240395 N Control Knob 5109996 A B C E F G H K L J D M N ...

Page 43: ...ess PCB Fault Replace PCB PCB Fault Replace PCB PCB Fault Replace PCB YES YES YES YES YES YES YES YES YES YES YES YES Go to Electrical Supply section of the fault finding instructions ON Go to Dry Fire section of the fault finding instructions Go to Overheat Lockout section of the fault finding instructions NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after th...

Page 44: ...ols and System Wiring 240V at B Check wiring from terminal block to PCB Check for shorts on pump fan gas valve Replace if shorted replace fuse YES NO Replace PCB YES YES NO NO ELECTRICAL SUPPLY 240V at A PCB fuse OK B Fuse A Optional Pump Live N L Off Off Off ON Lights ...

Page 45: ...ive Turn mains off on After 5 sec is there 240V at E Pump or Pump Wiring fault Is there a blockage in the system NO NO YES YES YES E Optional Pump Live N L F Optional Pump Live N L Turn mains off unplug 7 way connector to PCB Is there continuity between F and G Wiring from terminal block to PCB faulty NO YES Pump or Pump Wiring fault Replace PCB Wires from inline connector to PCB faulty Remove flo...

Page 46: ...ry YES YES NO NO YES Remove Gas Valve check inlet filter for blockage Otherwise incorrect gas supply to boiler Is there at least 18mbar dynamic at gas valve inlet Lead from PCB to Gas Valve faulty Is spark gap between 3 and 4mm Replace spark or flame detection probe and gaskets Is wiring from PCB to spark probe flame detection probe OK NO YES NO NO YES YES NO NO I Remove the larger or the two 6 wa...

Page 47: ...er door seal trim seal NO YES NO YES Reconnect stat Disconnect fan stat When fan temp 60 C is there continuity across stat Reconnect stat Disconnect the larger of the 6 way PCB connectors Is there continuity across M Disconnect thermistor red sensor on flow pipe Is resistance between 0 5kΩ 20kΩ Is combustion chamber door seal damaged or not in place Replace PCB YES Replace thermistor M 6 way Conne...

Page 48: ...d S W Fan Connection PCB Connection Fan Connection PCB Connection NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after the boiler has been electrically isolated Flash Flash On ON Lights THERMISTOR Replace thermistor Wiring from PCB to thermistor faulty YES NO NO YES Replace PCB Unplug thermistor Is thermistor resistance between 0 5kΩ 20kΩ Plug in thermistor leav...

Page 49: ...16 0 Notes 49 ...

Page 50: ...E OF SCALE REDUCER 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 INSTALLATI...

Page 51: ...INEER NAME COMPANY 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 yo...

Page 52: ... Iss 3 03 05 BAXI POTTERTON A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www baxi co uk ...