Baxi Combi 624 Installation And Service Manual
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Baxi Combi 624 Installation And Service Manual

High efficiency wall hung condensing gas boiler
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United Kingdom
en
Installation and Service Manual
High Efficiency Wall Hung Condensing Gas Boiler
Baxi Combi
624 - 630 - 636
624 LPG - 630 LPG
These instructions include the Benchmark Commissioning Checklist and should be left with the
user for safe keeping.They must be read in conjunction with the Flue Installation Guide.

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  • Page 1 United Kingdom Installation and Service Manual High Efficiency Wall Hung Condensing Gas Boiler Baxi Combi 624 - 630 - 636 624 LPG - 630 LPG These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping.They must be read in conjunction with the Flue Installation Guide.
  • Page 2 Dear Customer, Thank you very much for buying this appliance. Please read through the manual carefully before using the product, and keep it in a safe place for later reference. In order to ensure continued safe and efficient operation we recommend that the product is serviced regularly. Our service and customer service organisation can assist with this.

  • Page 3: Table Of Contents

    Contents Contents Safety ................... . 6 Benchmark .
  • Page 4 Contents Choice of the location ................28 5.3.1 Location of the boiler .
  • Page 5 Contents 9.2.5 Checking the burner and cleaning the heat exchanger ......... 56 Specific maintenance instructions .

  • Page 6: Safety

    1 Safety Safety Benchmark 1.1.1 Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installa­ tion of a heating appliance to the relevant Local Authority Building Control Department. This can be achieved via a Competent Persons Self Certifica­ tion Scheme as an option to notifying the Local Authority directly.

  • Page 7: Installer Notification Guidelines

    1 Safety 1.1.3 Installer Notification Guidelines Fig.2 Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme Contact your relevant Local Install and Commission this Authority Building Control appliance to manufacturer's (LABC) who will arrange instructions an inspection or contact a government approved...

  • Page 8: General Safety Instructions

    1 Safety General safety instructions Danger This boiler can be used by children aged 8 years and above and by persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge when they have been given supervision or instruction concerning the safe use of the device and understand the resulting risks.

  • Page 9: Specific Safety Instructions

    1 Safety Caution Make sure the boiler can be reached at all times. The boiler must be installed in a frost-free area. In the case of a fixed connection to the power cord, you must al­ ways install a main double pole switch with an opening gap of at least 3 mm (EN 60335-1).

  • Page 10: Liabilities

    1 Safety Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the "Installation" section of these instructions for recom­ mended lift points. Remember The circumstances of each installation are different. Always assess the risks associated with handling and lifting according to the individual con­...

  • Page 11: About This Manual

    2 About this manual About this manual General This manual is intended for the installer of a Baxi Combi boiler. Additional documentation Various timers, external controls, etc. are available as optional extras. Full details are contained in the relevant sales literature.

  • Page 12: Technical Specifications

    3 Technical specifications Technical specifications IMPORTANT: For detail of LPG versions, where different, please see section 14.3. Unless otherwise stated all data & procedures are the same for NG & LPG. Homologations Safety, Performance & Quality 3.1.1 This boiler has been assessed by an appropriate Notified Body and shown to meet the requirements of all Directives and Regulations as applicable.

  • Page 13: Technical Data

    Technical information Important All data in these sections are nominal and subject to normal pro duction tolerances. Tab.5 General Baxi Combi Gas council numbers 47 077 28 47 077 29 47 077 30 Nominal heat input domestic hot water —...
  • Page 14 3 Technical specifications Baxi Combi 63 3 6 Nominal heat input central heating — Maxi Net (Qn Hi) 20.6 20.6 25.8 mum rate Gross (Qn Hs) 22.9 22.9 28.6 Nominal heat input — Minimum rate Net (Qn Hi) Gross (Qn Hs) Nominal heat output 80/60°C —...
  • Page 15 Important Dynamic (nominal) inlet pressure (Natural gas — G20) 20mbar with a CV of 37.78 MJ/m Tab.9 Electrical specifications Baxi Combi Nominal electrical power supply voltage Nominal electrical power supply frequency Nominal power consumption when firing External fuse rating F2A H250V...

  • Page 16: Technical Parameters

    3 Technical specifications Baxi Combi Installed weight when filled with water 32.5 32.5 33.8 3.2.2 Technical parameters Tab.14 Technical parameters for boiler combination heaters Baxi Combi Condensing boiler Low-temperature boiler B1 boiler Cogeneration space heater Combination heater Rated heat output...

  • Page 17: Dimensions And Connections/Clearances

    3 Technical specifications The back cover for contact details. Dimensions and connections/clearances Fig.3 Dimensions and connections / clearances PN-0000605 Condensate trap sump Condensate drain Heating circuit water flow Hot water outlet Gas inlet Pressure relief pipe Cold water inlet Heating circuit water return Pump drain point Boiler drain point on flow isolation tap Cable entry points...

  • Page 18: Electrical Diagram

    3 Technical specifications Electrical diagram Fig.4 Electrical wiring diagram br bk PN-0000341 bk — black br — brown b — blue g — green r — red w — while g/y — green/ yellow Description Description Gas valve Spark ignition electrode Hall effect sensor Diverter valve motor Flue sensor...

  • Page 19: Description Of The Product

    4 Description of the product Description of the product General description The Baxi Combi range are fully automatic gas fired wall mounted condens ing boilers. They are room sealed and fan assisted and will serve central heating and mains fed domestic hot water.

  • Page 20: Central Heating And Domestic Hot Water Production

    4 Description of the product 4.2.3 Central heating and domestic hot water production In boilers used for heating and for producing domestic hot water, an inte­ grated plate heat exchanger heats the domestic water. The heated water is then channelled to the heating installation or to the plate heat exchanger via a diverter valve.

  • Page 21: Frost Protection Mode

    4 Description of the product The burner will light automatically and the temperature of domestic hot wa­ ter is controlled by the temperature sensor. 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.

  • Page 22: Main Components

    4 Description of the product Main components 4.3.1 List of components Fig.7 Component descriptions PN-0000612 Fig.8 Hydraulic layout PN-0000388 Tab.16 Component descriptions Description Description Description Expansion vessel Flue sensor Flue adaptor Expansion vessel valve Spark ignition electrode Heating flow sensor Primary heat exchanger Control box Safety thermostat...

  • Page 23: Control Panel Description

    4 Description of the product Control panel description 4.4.1 Description of the control panel Fig.9 Control panel Display Reset button Central heating temperature control Service diagnostic port DHW temperature control System water pressure gauge Reset PN-0000607 Fig.10 Display screen Display description The following symbols may be seen on the display OFF (frost protection still enabled) Indicates errors that prevent the burner from starting...

  • Page 24: Accessories And Options

    The table shows the accessories available for this boiler range. Tab.17 Optional accessories Part number Accessory 7212438 Baxi single channel wired programmable room thermostat 720971601 Baxi room thermostat 720330001 Baxi wired weather sensor 720648301 Multifit condensate & PRV combined pump...

  • Page 25: Before Installation

    5 Before installation Before installation Installation regulations Warning Installation, repair and maintenance must only be carried out by a competent person. This document is intended for use by compe­ tent persons. Installation must be carried out in accordance with the prevailing regula­ tions, the code of practice and the recommendations in these instructions.

  • Page 26: Hard Water Area

    5 Before installation Important Any wiring to the boiler, from either the mains or an external control, MUST be cable of the following specification:- 0.75mm 3183/4/5Y (depending on installation) multi strand flexible cable conforming to BS 50525-2-11. Cable of the above specification is sufficiently flexible to with­ stand normal regular opening and closing of the facia/control box as expected during routine servicing and other maintenance work.

  • Page 27: Showers

    It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the inhibitor manufac­ turer. (Test kits are available from inhibitor stockists.) For information or advice regarding any of the above contact Baxi Custom­ er Support 0344 871 1545. 5.2.7 Showers If a shower control is supplied from the appliance it should be of the ther­...

  • Page 28: Choice Of The Location

    5 Before installation A boiler discharge pump is available which will dispose of both condensate & high temperature water from the relief valve. It has a maximum head of 5 metres. Choice of the location 5.3.1 Location of the boiler 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 permit­...

  • Page 29: Bath And Shower Rooms

    5 Before installation 5.3.2 Bath and shower rooms Fig.12 Bathroom 1 and 2 Zone 0 Zone 1 Zone 2 Window recess Zone 2 Ceiling Outside zones Important Where an optional plug-in integral timer, RF receiver or thermostat is NOT FITTED the boiler has a protection rating of IPX5D and if installed in a room containing a bath or shower can be within Zone 2 (but not 0 or 1).

  • Page 30: Condensate Drain

    5 Before installation 5.3.4 Condensate drain Fig.13 Pipework and method of termination It is strongly recommended to discharge internally into the household drainage system. If connecting to a rain water drain, that drain MUST dis­ charge into a foul drain. 32mm 21.5mm Pipework.
  • Page 31 5 Before installation Fig.14 Methods of termination continued Important Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler. Careful consideration must be given to the possibility of the pipe­ work being subject to freezing conditions and appropriate meas­ ures taken to prevent blockage.

  • Page 32: Clearances

    5 Before installation 5.3.5 Clearances Fig.15 Clearances A flat vertical area is required for the installation of the boiler and it should be capable of bearing the weight of the boiler when full of water. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement.
  • Page 33 5 Before installation Description Description Horizontally to an opening, air brick, From an opening in carport (e.g. door, 1200 opening window etc. window) into the dwelling Below gutters, soil pipes or drain pipes 25 (75) Vertically from a terminal on the same 1500 wall Below eaves...

  • Page 34: Horizontal Flue/Chimney Systems

    5 Before installation Fig.18 Plume displacement kit Opening window or door Air inlet Plume displacement kit 150mm minimum Important If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 150mm from any opening windows or doors. Important The Plume Displacement flue gas discharge terminal and air inlet must always terminate in the same pressure zone i.e.

  • Page 35: Flue/Chimney Trim

    5 Before installation Warning SUPPORT - All flue systems MUST be securely supported at a MINIMUM of once every metre & every change of direction. It is recommended that every straight piece is supported irrespective of length. Additional supports are available as accessories. VOIDS - Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual inspection.

  • Page 36: Unpacking & Initial Preparation

    5 Before installation essary. Carrying and lifting equipment should be used as required. e.g. when install in a loft. Unpacking & initial preparation 5.5.1 Unpacking Fig.23 Unpacking the boiler Caution RISK ASSESSMENT - Before commencing the installation it is recommended that the "Five Steps to Risk Assessment" docu­ ment published by the HSE is consulted, and an assessment per­...

  • Page 37: Connecting Diagrams

    Fig.25 "Easy-Fill" permanent filling link The Baxi 600 Combi is supplied with an "Easy-Fill" permanent filling link. The permanent filling link is a device to allow filling and repressurising of the heating system. The link has been tested and approved to be left con­...
  • Page 38 Even in circumstances where a non-return device is not fitted any future modifications to the mains inlet (e.g. fitting of a water meter) should be considered and an expansion vessel fitted. Baxi cannot accept any responsibility for damage to the boiler if these recom­...

  • Page 39: Installation

    6 Installation Installation General Fig.28 Mounting the boiler Installation must be carried out in accordance with the prevailing regula­ tions, codes of practice and the recommendations in this manual. Danger If the boiler is installed in a compartment do not use it for storage purposes.

  • Page 40: Connecting The Condensate Drain

    6 Installation 6.2.2 Connecting the condensate drain Fig.31 Pour 300ml of water into flue spigot 1. Remove the blanking cap, and using the straight rubber coupling supplied, connect the condensate drain pipework to the boiler con­ densate trap outlet pipe. Ensure the discharge of condensate complies with any national or local regulations in force (see HHIC recommendations).
  • Page 41 6 Installation Fig.34 Flue dimension Y 5. To dimension " X" add 40mm. This dimension to be known as "Y" . TOP label Sealing tape Securing screw Peak to be uppermost 6. Adjust the two telescopic sections to dimension "Y" and seal the joint with the tape provided.

  • Page 42: Electrical Connections

    6 Installation Electrical connections Electrical supply, page 25 for details of the electrical supply. Warning Check that the total nominal consumption of the accessories con­ nected to the appliance is less than 1 amp. If it is higher, a relay must be installed between the accessories and the electronic board.
  • Page 43 6 Installation Fig.37 Typical electrical connections 230V 230V 230V PN-0000396 5. Connect the earth, permanent live and neutral wires to the terminal block. Note Both the permanent live and neutral connections are fused. Description Description Fused Spur Blue Room Thermostat Black External Clock Brown...

  • Page 44: Connecting Outdoor Sensor

    6 Installation These should be performed using a suitable meter, and include checks for Earth Continuity, Resistance to Eart, Short Circuit and Polarity. 6.4.2 Connecting outdoor sensor Fig.38 Sensor position The sensor must be fixed to an external wall surface of the property it is serving.

  • Page 45: Identifying Label

    6 Installation 6.4.3 Identifying label Important The identifying label (7221476-01) supplied with the outdoor sen­ sor must be signed and affixed on or adjacent to the boiler. The label must be readily accessible without removing the boiler cas­ ing or any other disassembly. This label is required to enable SAP and energy assessors to identify that a weather compensation de­...

  • Page 46: Filling The Installation

    6 Installation Fig.41 Example — setting to curve 50 Curve 50 PN-0000629 Filling the installation 6.5.1 Flushing the system Flush thoroughly and treat the system according to guidance given in BS 7593. 6.5.2 Fill the installation A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling.

  • Page 47: Commissioning

    7 Commissioning Commissioning General Reference should be made to BS:EN 12828, 12831 & 14336 when com­ missioning the boiler. Ensure that the condensate drain trap has been primed. At the time of commissioning, complete all relevant sections of the Bench­ mark Checklist at the rear of this publication.

  • Page 48: Commissioning Procedure

    7 Commissioning Commissioning procedure 7.3.1 De-Aeration function Fig.42 Setting de-aeration Before turning on the power to the boiler, rotate the CH control knob ( fully anticlockwise. The purpose of the function is to remove as much air as possible from the heating system.

  • Page 49: Checking Combustion - Chimney Sweep Mode

    7 Commissioning Fig.44 Gas inlet test point 1. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point is in accordance with BS 6798 & BS 6891. This must be AT LEAST 18mb ! 2.
  • Page 50 7 Commissioning Warning Ensure that both flue test point plugs are in place after checking combustion. Fig.46 Setting chimney sweep mode Setting maximum and minimum output 1. Turn both control knobs fully anticlockwise and leave for 10 sec­ onds. 2. Turn the DHW knob ( turn twice in quick succession (within 2 seconds).
  • Page 51 7 Commissioning Fig.47 Combustion procedure Set Boiler to Maximum Rate Allow the combustion to stabilise. Do not insert probe to avoid ‘flooding’ the analyser. Perform Flue Integrity Combustion Check Insert the analyser probe into Verify Flue Integrity the air inlet test point, allowing Indication that products of Check CO &...

  • Page 52: Configuring The System

    7 Commissioning Configuring the system 7.5.1 System draining If at any time after installation it is necessary to drain and refill the central heating system (e.g. when replacing a radiator) the De-Aeration function must be activated to avoid air being trapped in the system. De-Aeration function, page 48.

  • Page 53: Operation

    8 Operation Operation Use of the control panel 8.1.1 Control panel The controls are operated by the control knobs and a reset button. Fig.49 Control panel Display screen Reset button CH temperature control knob Service diagnostic port DHW temperature control knob System water pressure gauge Important Reset...

  • Page 54: Maintenance

    9 Maintenance Maintenance General Warning When changing components ensure that both the gas and electri­ cal supplies to the boiler are isolated before any work is started. When the component has been changed recommission the boiler. Always examine any seals or gaskets, replacing where necessary. The case front panel MUST seal effectively against the boiler side panels.

  • Page 55: Standard Inspection And Maintenance Operations

    9 Maintenance Fig.50 Flue adaptor test points Remove the plug from the combustion test point, insert the analyser probe and obtain the CO/CO ratio. This must be less than 0.004. If the combus­ tion reading (CO/CO ratio) is greater than this, and the integrity of the complete flue system and combustion circuit seals has been verified, and the inlet gas pressure and gas rate are satisfactory either:- Perform the "Standard Inspection and Maintenance"...

  • Page 56: Checking The Water Pressure

    9 Maintenance 11. Carefully examine all seals and gaskets, replacing if necessary. Look for any evidence of leaks or corrosion and if found determine and rectify the cause. 12. Reassemble in reverse order. 13. Complete the relevant Service Interval Record section of the Bench­ mark Commissioning Checklist at the rear of this publication and then hand it back to the user.

  • Page 57: Specific Maintenance Instructions

    9 Maintenance Specific maintenance instructions Fig.54 Panel removal Warning When changing components ensure that both the gas and electri­ cal supplies to the boiler are isolated before any work is started. When the component has been changed recommission the boiler. Always examine any seals or gaskets, replacing where necessary.

  • Page 58: Flow And Return Sensors

    9 Maintenance 9.3.3 Flow and return sensors Fig.57 Remove flow and return sensors There is one sensor on the flow (red wires) and one sensor on the return (blue wires). 1. After noting the position of each sensors, prise the sensor clip off the pipe and disconnect the plug.

  • Page 59: Hall Effect Sensor

    9 Maintenance 9.3.7 Hall effect sensor Fig.60 Remove hall effect sensor 1. Ease the sensor upwards off the hydraulic inlet manifold assembly. 2. Disconnect the electrical plug from the sensor. 3. Connect the plug to the new sensor. Carefully fit the new sensor to the hydraulic assembly, ensuring it is fully down.

  • Page 60: Diverter Valve Motor

    1 bar. 9.3.12 Gas valve Tab.23 Characteristics of combustion Baxi Combi % (maximum) 9.0 + 0.3 – 0.2 9.0 + 0.3 – 0.2 9.0 + 0.3 – 0.2 % (minimum) 8.5 + 0.1 – 0.4 8.5 + 0.1 –...
  • Page 61 9 Maintenance Fig.65 Removing the gas valve Important After replacing the gas valve the CO must be checked and adjus­ ted. Only change the valve if a suitable calibrated combustion an­ alyer is available, operated by a competent person. 1. Undo the screw and disconnect the electrical plug. 2.
  • Page 62 Offset Adjustment Screw 5. Remove the plug from the flue sampling test point. Insert the analyser probe and allow sufficient time for the reading to settle. Baxi Combi 624 - 630 - 636 % (maximum) 9.0 + 0.3 – 0.2 6.

  • Page 63: Pump - Head Only

    9 Maintenance Warning Ensure that both flue test point plugs are in place after checking combustion. 9.3.13 Pump - head only Fig.67 Remove pump head only To remove the pump head only. 1. Drain the boiler primary circuit and disconnect the electrical plug from the pump 2.

  • Page 64: 10 Troubleshooting

    10 Troubleshooting 10 Troubleshooting 10.1 Error codes 10.1.1 Initial error fault finding checks Check that gas, water and electrical supplies are available at the boiler. Electrical supply = 230V ~ 50 Hz. The minimum gas pressure at the meter is 19mb. Carry out electrical system checks, i.e.

  • Page 65: Fault Finding

    10 Troubleshooting 10.2 Fault finding 10.2.1 Central heating Fig.70 Central heating — Follow operational sequence Turn on mains power 09, 15, 110 or 384 is flashing or re-occurs Go to section ‘A’ The display illuminates regularly, check all PCB connections. If this has no effect replace the PCB.

  • Page 66: Domestic Hot Water

    10 Troubleshooting 10.2.2 Domestic hot water Fig.71 Domestic hot water — Follow operational sequence 09, 15, 110 or 384 is flashing or re-occurs Turn on mains power Go to section ‘A’ regularly, check all PCB connections. If this The display illuminates has no effect replace the PCB.

  • Page 67: Fault Finding Solutions Sections A To E

    10 Troubleshooting 10.2.3 Fault finding solutions sections A to E Fig.72 Solutions sections A to E Is there 230V at: Main terminals L and N Check electrical supply Connection OK at X41 Main terminal fuse Replace fuse Check wiring PCB - X10 connector Display Display or Main terminals L and N...

  • Page 68: Fault Finding Solutions Sections F To H

    10 Troubleshooting 10.2.4 Fault finding solutions sections F to H Fig.73 Solutions sections F to H Check and correct if necessary 1. Ignition electrode and lead Check wiring - see Electrical Replace PCB 2. Electrode connection Wiring Diagram page 18 3.

  • Page 69: Fault Finding Solutions Sections I To M

    10 Troubleshooting 10.2.5 Fault finding solutions sections I to M Fig.74 Solutions sections I to M CH system pressure less than Restore system pressure 0.5 bar Check wiring and PCB - X22 Replace hydraulic pressure switch connector for approx. 5V DC between green &...

  • Page 70: 11 Decommissioning

    11 Decommissioning 11 Decommissioning 11.1 Decommissioning procedure Disconnect the gas & electric supplies and isolate them. Drain the primary circuit and disconnect the filling device. Dismantle the chimney system and remove the boiler from the wall mount­ ing frame.

  • Page 71: 12 Disposal

    12 Disposal 12 Disposal 12.1 Disposal and recycling Caution Removal and disposal of the boiler must be carried out by a quali­ fied person in accordance with local and national regulations.

  • Page 72: 13 Spare Parts

    13 Spare parts 13 Spare parts 13.1 Short parts list The following spares are available: Fig.75 Spare parts Tab.24 Part number and description of spare parts Key No. Description Manufacturer’s Spare Part No. Safety thermostat 7207653 Detection / spark ignition electrode 7686344 Flow sensor and return sensor 7207471...

  • Page 73: 14 Appendix

    14 Appendix 14 Appendix 14.1 Benchmark commissioning checklist Warning After servicing or performing any maintenance on the boiler ensure that This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

  • Page 74: Service Records

    14 Appendix ALL INSTALLATIONS At max. rate: ppm AND CO/CO ² Ratio Record the following: At min. rate: (where possible) ppm AND CO/CO ² Ratio The heating and hot water system complies with the appropriate Building Regul The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s The operation of the boiler and system controls have been demonstrated to and understood by the The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the Commissioning Engineer’s Signature...
  • Page 75 14 Appendix SERVICE 07 SERVICE 08 Date: Date: Engineer name: Engineer name: Company name: Company name: Telephone No: Telephone No: Gas safe register No: Gas safe register No: At max. rate: ppm AND CO ² % At max. rate: ppm AND CO ²...
  • Page 76 Tab.2 Gas category, type and supply pressure Gas category Gas type Supply pressure (mbar) 2H 3P 3.2.1 Technical information Baxi Combi 624 LPG 630 LPG Gas council numbers 47 077 33 47 077 32 General description Tab.15 The boiler is set to give a maximum output of :-...
  • Page 77 14 Appendix...
  • Page 78 14 Appendix...
  • Page 79 © Copyright All technical and technological information contained in these technical instructions, as well as any drawings and technical de­ scriptions supplied, remain our property and shall not be multiplied without our prior consent in writing. Subject to alterations.
  • Page 80 For the warranty to be maintained, please make sure... Benchmark checklist is completed Warranty is registered within 30 days The boiler has an annual service For full terms and conditions, visit www.baxi.co.uk/terms. Failure to adhere to terms and conditions will void your manufacturer’s warranty. Baxi Brooks House,...

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