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Baxi Duo-tec Installation & Servicing Instructions Manual Download Page 1

© Baxi Heating UK Ltd 2008

Duo-tec Combi HE LPG

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.

Summary of Contents for Duo-tec

Page 1: ...Duo tec Combi HE LPG Gas Fired Wall Mounted Condensing Combination Boiler Installation Servicing Instructions These instructions include the Benchmark Commissioning Checklist and should be left with...

Page 2: ...ld comply with manufacturer s instructions It is therefore important that the commissioning checklist is completed by the installer The relevant section of Building Regulations only relates to dwellin...

Page 3: ...rty You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist Scheme Members only Call CORGI on 0800 408 1007 or log onto www corgi notify com within 10 days...

Page 4: ...stallation Use Regulations The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland The Water Fittings Regulations o...

Page 5: ...clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep...

Page 6: ...d Fixings 11 6 0 System Details 12 7 0 Site Requirements 15 8 0 Flue Options 19 9 0 Plume Displacement 24 10 0 Installation 28 11 0 Commissioning 33 12 0 Completion 35 13 0 Servicing 36 14 0 Changing...

Page 7: ...ble when the case front panel is removed Fig 1 6 The boiler model name and serial number are also shown on the information label on the underside of the facia This is for user reference 7 The boiler i...

Page 8: ...ate Trap 13 Flame Sensing Electrode 14 Spark Electrode 15 Primary Heat Exchanger 16 Fan Assembly 17 On Off Reset Selector Switch 18 Central Heating Temperature Control 19 Hot Water Temperature Control...

Page 9: ...not operate and the integral timer 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...

Page 10: ...5mm Temperatures C H Flow Temp adjustable 25 C to 80 C max 5 C D H W Flow Temp adjustable 35 C to 60 C max 5 C dependent upon flow rate NOx Class 5 Clearances Above Casing 200 mm Min Below Casing 200...

Page 11: ...m for 80 125mm flue systems F 145mm G 131mm H 180mm J 270mm Domestic Hot Water Outlet 15mm Cold Water Inlet 15mm Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 65 mm 6...

Page 12: ...hen fitting 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 Using for example Betz Dearborn Sent...

Page 13: ...ssel 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...

Page 14: ...op 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 pressu...

Page 15: ...lations 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...

Page 16: ...lations In IE reference should be made to the current edition of ETCI rules 2 The mains supply is 230V 50Hz fused at 3A NOTE The method of connection to the electricity supply must facilitate complete...

Page 17: ...ocation 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 bei...

Page 18: ...oundary may not be less than 300mm in accordance with the diagram below Terminal Position with Minimum Distance Fig 12 mm Aa Directly below an opening air brick opening windows etc 300 Ba Above an ope...

Page 19: ...t lengths are Concentric Pipes 135 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 135 bend 0 25 metres 91 5 bend 0 50 metres The elbow supplied with the standard horizontal telescopic flue kit is n...

Page 20: ...as shown The total equivalent length for this example is 6 5 metres 1m extension 135 bend 91 5 bend 1m 0 25m 0 5m 5 2 2 5 0m 0 5m 1 0m AIR DUCT No of fittings pipes Sub total Equivalent Length Value E...

Page 21: ...ll Liner 5111067 S Flue Terminal Deflector 5111068 FLUE GROUP N Twin Flue System 80mm diameter E Flue Extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend 2 pair 135 5111086 J Vertica...

Page 22: ...in the kit One marked 23 one marked 27 an a third unmarked The unmarked one must be used with this boiler Discard the other two Position the unmarked restrictor as shown below 3 Take one of the gasket...

Page 23: ...If the boiler is not fitted immediately after the flue system temporary precautions must be taken to prevent rain entry into the room of installation Any precautionary measures must be removed prior...

Page 24: ...crease with the addition of extensions the length of either or both the 60 100 concentric and 60 exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the termina...

Page 25: ...d and the 60 exhaust needed to be 4 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Whe...

Page 26: ...re that the concentric assembly and any extensions fall back to the boiler at an angle of at least 1 5 and that the external air inlet is to the bottom 8 Use suitable brackets to support the concentri...

Page 27: ...extension at 30mm as shown in two positions directly opposite each other Fig 27 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The r...

Page 28: ...xing slots 4 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 32 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the...

Page 29: ...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 detai...

Page 30: ...lue elbow is angled at 93 degrees to ensure a fall back to the boiler 4 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 38 5 If the distance from the...

Page 31: ...rect boiler operation and prevent water entering the flue 13 Make good between the wall and air duct outside the building 14 Fit the flue trim if required and if necessary fit a terminal guard see Sec...

Page 32: ...0V supply at terminal 2 must be connected to the thermostat The switched output from the thermostat must be connected to terminal 1 Figs 49 50 If the room thermostat being used incorporates an anticip...

Page 33: ...g agent manufacturers instructions 7 Pressurise the system to 1 5 bar then close and disconnect the filling loop 8 Turn the gas supply on and purge according to in GB BS 5482 1 and in IE I S 813 Domes...

Page 34: ...ise then quickly turn the DHW temperature knob 1 4 clockwise twice and back fully anticlockwise Fig 55 6 The display will now alternate between SF and the current boiler temperature and both green LED...

Page 35: ...e relevant to 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 se...

Page 36: ...must be performed see below Carefully check items such as the burner injector and heat exchanger for blockage or damage rectifying as necessary Re check the combustion Once satisfactory readings have...

Page 37: ...clean the filter 17 Initially check the cold water inlet tap filter 18 Turn the tap off and draw off from a hot tap Undo the blanking cap and remove the threaded bush Fig 67 19 Extract the filter and...

Page 38: ...ter Fig 69 1 Disconnect the igniter feed plug and the electrode leads noting their positions 2 Undo the screw securing the bracket to the boiler 3 Remove the igniter and transfer the bracket to the ne...

Page 39: ...or is in place and the sensing pipe is connected to the fan 14 4 Venturi Fig 71 1 Remove the collector and fan assembly as described in section 14 3 2 Extract the injector from the venturi 3 Undo the...

Page 40: ...14 2 2 Undo the screws securing the collector to the venturi and the nuts holding the cover to the heat exchanger Draw the collector and cover assembly away 3 Remove the cover insulation piece 4 Fit...

Page 41: ...nnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way 14 11 Safety Thermostat Fig 77 1 Pull the plug off the thermostat 2 Remov...

Page 42: ...the body to the pipe and manifold and draw the pump forwards 3 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers d...

Page 43: ...e 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 14 18 Pressure Relief Valve Fig 85 1 Drain the p...

Page 44: ...reverse order 14 20 Diverter Valve Motor Unit Assembly Figs 87 88 1 To replace the motor unit disconnect the multi pin plug 2 Pull off the retaining clip and remove the motor unit 3 The motor unit ca...

Page 45: ...5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 14 22 Selector Switch Fig 90 1 Note the setting of the selector switch knob and carefully...

Page 46: ...ssary 6 Reassemble in reverse order NOTE To assist the boiler to light prior to final setting use a suitable hexagon key to wind out the Gas Air adjustment screw until it is flush with the valve body...

Page 47: ...emove the plastic cover from the Max Rate adjustment screw At maximum rate the Max Rate adjustment screw should be turned using a suitable hexagon key until the correct reading is obtained Fig 100 Tur...

Page 48: ...Stat Flame Sensing Electrode Pump Flue Sensor X400 X401 g g b b r r b b b b b br bk g b br b br b br br b b b br br br b b br r bk r bk Water Pressure Switch Spark Generator Ignition Electrode 9 8 7 6...

Page 49: ...e 5114702 316 Sensing Electrode 5114703 422 Gas Valve 5119647 624 Hall Effect Sensor 5114767 306 Burner 5114697 419 Water Pressure Switch 5114748 400 Plate Heat Exchanger 5114708 415 Pump 248042 302 F...

Page 50: ...E133 will be displayed by E1 alternating with 33 E50 is shown as E then 50 E20 E28 E50 indicate faulty components E110 shows overheat of the primary water and E130 overheat of the flue system E119 is...

Page 51: ...lashing Burner does not stay alights after 5 seconds Error 133 flashing Go to section I Operation sequence successful If the error 110 is still flashing Go to section J Fan runs at correct speed YES Y...

Page 52: ...g Burner does not stay alights after 5 seconds Error 133 flashing Go to section I Operation sequence successful Turn the selector switch to reset position for 5 seconds If the error 110 is still flash...

Page 53: ...nnector terminals 3 4 Replace PCB 2 NO Change pump supply cable YES B CH system pressure less than 0 5 bar Re pressurise system 1 YES Check the tap of the automatic air vent is opened Open the automat...

Page 54: ...ad 2 Electrode connection 3 Spark gap and position Voltage at PCB X2 connector is at least 100V DC across terminals 2 5 Note from multimeter connect common to 2 volts to 5 Check wiring YES NO Replace...

Page 55: ...cool Continuity across thermostat terminals more than 1 5 ohm J L M Is there 230V at Motor 3 way valve Replace motor 3 way valve 1 YES PCB X3 connector terminals 5 6 central heating mode 5 7 domestic...

Page 56: ...56 19 0 Notes Baxi Heating UK Ltd 2008...

Page 57: ...57 19 0 Notes Baxi Heating UK Ltd 2008...

Page 58: ...FITTED YES NO WHAT TYPE 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 TEMPERATUR...

Page 59: ...NGINEER 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 COM...

Page 60: ...Technical Enquiries 08706 049 049 Website www baxi co uk e oe All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and imp...

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