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Baxi Duo-tec Combi HE LPG Installation & Servicing Instructions Manual

Gas fired wall mounted condensing combination boiler
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Installation & Servicing Instructions
Duo-tec Combi HE LPG
Gas Fired Wall Mounted Condensing
Combination Boiler
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2008

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  • Page 1 Installation & Servicing Instructions Duo-tec Combi HE LPG Gas Fired Wall Mounted Condensing Combination Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2008...
  • Page 2 Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure. © Baxi Heating UK Ltd 2008 All rights reserved. No part of this publication may The flowchart opposite gives guidance for installers on the...
  • Page 3 CORGI is written onto the Benchmark Checklist CORGI will record the data and LABC will record the data will send a certificate of and will issue a compliance to the property certificate of compliance © Baxi Heating UK Ltd 2008...
  • Page 4 BS 5449 Forced circulation hot water systems. For GB/IE only. BS 7074 Expansion vessels and ancillary equipment for sealed water systems. BS 7593 Treatment of water in domestic hot water central heating systems. © Baxi Heating UK Ltd 2008...
  • Page 5 If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT ‘work through’ the pain - you may cause further injury. IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !! © Baxi Heating UK Ltd 2008...

  • Page 6: Table Of Contents

    Dimensions and Fixings System Details Site Requirements Flue Options Plume Displacement 10.0 Installation 11.0 Commissioning 12.0 Completion 13.0 Servicing 14.0 Changing Components 15.0 Combustion Check 16.0 Electrical 17.0 Short Parts List 18.0 Fault Finding Benchmark Checklist © Baxi Heating UK Ltd 2008...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Baxi Duo-tec Combi HE LPG is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve central heating and Case Front Panel mains fed domestic hot water.

  • Page 8: General Layout

    Central Heating Temperature Control Hot Water Temperature Control Venturi Air/Gas Collector Combustion Box Cover & Burner Igniter Burner On Light Central Heating Mode Light Domestic Hot Water Mode Light Display Position of Optional Integral Timer © Baxi Heating UK Ltd 2008...

  • Page 9: Appliance Operation

    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. 3 © Baxi Heating UK Ltd 2008...

  • Page 10: Technical Data

    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 has been certified by 0085. 1000 1200 Flow Rate (l/h) © Baxi Heating UK Ltd 2008...

  • Page 11: Dimensions And Fixings

    32.5 mm Condensate Drain 65 mm 65 mm 65 mm 65 mm 65 mm Heating Heating Domestic Hot Cold Water Pressure Relief Return Valve Flow Water Outlet Inlet Inlet (22mm) (22mm) (15mm) (22mm) (15mm) (15mm) © Baxi Heating UK Ltd 2008...

  • Page 12: System Details

    6.0 System Details Information 1. The Baxi Duo-tec Combi HE LPG Condensing Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN).
  • Page 13 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. 6 Pressure Relief Valve Discharge Pipe © Baxi Heating UK Ltd 2008...
  • Page 14 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. Contact your Water Distribution Company for advice on suitable devices. © Baxi Heating UK Ltd 2008...

  • Page 15: Site Requirements

    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. 450mm Min For Servicing Purposes 5mm Min In Operation Fig. 9 © Baxi Heating UK Ltd 2008...
  • Page 16 Zone 0 Building Regulations. In IE reference should be made to the current edition of I.S. 0.6 m 2.4 m 813 “Domestic Gas Installations” and the current ETCI rules. Fig. B In GB Only © Baxi Heating UK Ltd 2008...
  • Page 17 Boiler ii) via an internal discharge branch (e.g. sink waste) iii) to a drain or gully 500mm min iv) to a purpose made soakaway Holes in the soak-away must face away from the building © Baxi Heating UK Ltd 2008...
  • Page 18 Top View Rear Flue any opening windows or doors (see Section 9.0). Fig. 11 Property Boundary Line Air Inlet Opening Window or Door 100mm Fig. 12a MIN. Likely flue positions requiring Fig. 12 a flue terminal guard © Baxi Heating UK Ltd 2008...

  • Page 19: Flue Options

    NOTE: Horizontal flue pipes should always be installed with a fall of at least 1.5° from the terminal to allow condensate to run back to the boiler. This bend is equivalent to 1 metre This bend is equivalent to 1 metre Total equivalent length = A+B+C+2 x 90°Bends © Baxi Heating UK Ltd 2008...
  • Page 20 This bend is equivalent to Equivalent Length Air Duct = 6.5m 1 metre FLUE DUCT Equivalent Sub total Length Value fittings/pipes 1m extension 5.0m 135°bend 0.5m 0.25m 91.5°bend 1.0m 0.5m Equivalent Length Flue Duct = 6.5m © Baxi Heating UK Ltd 2008...
  • Page 21 91.5° 5118588 FLUE GROUP A, N, G Vertical Flue Kits Vertical Flue Terminal 5111078 (use with 5111070) Vertical Flue Terminal 5118576 Pitch Roof Flashing 25°/50° 5122151 Roof Cover Plate 246143 Flat Roof Flashing 246144 © Baxi Heating UK Ltd 2008...
  • Page 22 5. Using the screws previously removed secure the inlet adaptor to the top panel. 6. Continue to fit the twin flue system. Air Duct Adaptor Position of Restrictor Gasket Restrictor Gasket © Baxi Heating UK Ltd 2008...
  • Page 23 8.10 Flue Deflector Fig. 14 1. If required, push the flue deflector over the terminal end and rotate to the optimum angle for deflecting plume. Secure the deflector to the terminal with screws provided. © Baxi Heating UK Ltd 2008...

  • Page 24: Plume Displacement

    Installation & Servicing Instructions and BS5440 Pt. 1. It is NOT necessary to fit a terminal guard over the air inlet or the plume outlet. © Baxi Heating UK Ltd 2008...
  • Page 25 After consulting the table in Example 3 it can be determined that the concentric flue could be up to 2.5 metres long. Additional Accessories 93° Elbow 5121369 45° Elbow (Pair) 5121370 Fig. 18 1 metre 60Ø Extension 5121368 © Baxi Heating UK Ltd 2008...
  • Page 26 14. Fit the 93° elbow/plume outlet and secure with the two remaining screws supplied. Ensure the plume outlet is at least 45° to the wall and that the ‘peak’ is uppermost (Fig. 24). Fig. 24 © Baxi Heating UK Ltd 2008...
  • Page 27 25. All other minimum & maximum dimensions must be adhered to, and the air inlet positioned such that it will not be subject to rain entry. Fig. 28 70° Concentric Flue Length (shown end-on) Outlet Spigot Fig. 29 © Baxi Heating UK Ltd 2008...

  • Page 28: Installation

    Wall Plate supplied with it. 10.2 Flushing 1. Connect a tube to the central heating flow or return pipe (Fig. 34). Fig. 34 Central Heating Return 2. Flush thoroughly (see System Details, Section 6.2). © Baxi Heating UK Ltd 2007...
  • Page 29 Condensing Boilers”. 2. The connection will accept 21.5mm ( in) plastic overflow pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable. © Baxi Heating UK Ltd 2008...
  • Page 30 250mm and 315mm it will be necessary to shorten the Terminal Assembly by careful cutting to accommodate walls of these thicknesses. 7. To dimension ‘X’ add 50mm. This dimension to be known as ‘Y’. Fig. 39 Wall Thickness Fig. 38 © Baxi Heating UK Ltd 2008...
  • Page 31 Extension Tape Cut End Adaptor Fig. 45 Apply Lubricant for ease of assembly. Ensure Extension is fully engaged into Boiler Adaptor Fig. 46 © Baxi Heating UK Ltd 2008...
  • Page 32 NOTE: The 230V switched signal for external controls (Frost Stat - Room Stat - Timer) must always be taken from terminal 2 at the boiler. Live, Neutral and Earth to power these controls must be taken from the Fused Spur. © Baxi Heating UK Ltd 2008...

  • Page 33: Commissioning

    After a few seconds the display reverts to show the current boiler temperature (Fig. 54). Central Heating Domestic Hot Water Temperature Control Temperature Control Fig. 54 © Baxi Heating UK Ltd 2008...
  • Page 34 9. The ‘Calibration Function’ is active for 20 minutes unless the maximum CH temperature is exceeded. 10. The function can be disabled at any time by turning the Fig. 56 Fig. 57 DHW temperature knob. Fig. 58 Fig. 60 Fig. 59 © Baxi Heating UK Ltd 2008...

  • Page 35: Completion

    I.S. 813 “Domestic Gas Installations”. This is in addition to the Benchmark Commissioning Checklist. 5. Hand over the Users Operating, Installation and Servicing Instructions giving advice on the necessity of regular servicing. Facia Panel Fig. 61 © Baxi Heating UK Ltd 2008...

  • Page 36: Servicing

    (Fig. 63). 7. Unscrew the sump from the bottom of the condensate trap assembly (Fig. 64). 8. Remove any deposits from the sump and trap. Clean as Sump necessary and replace the sump. Fig. 64 © Baxi Heating UK Ltd 2008...
  • Page 37 23. Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this Restrictor publication and then hand it back to the user. (not on 40 models) Hydraulic Inlet Assembly Fig. 68 Filter © Baxi Heating UK Ltd 2008...

  • Page 38: Changing Components

    3. Check the condition of the sealing gaskets and replace if necessary. Reassemble in reverse order. Spark Electrode Electrode Leads Sensing Electrode Fig. 70 © Baxi Heating UK Ltd 2008...
  • Page 39 1. Remove the collector and fan assembly as described in Injector section 14.3. Collector Fig. 71 2. Extract and replace the injector and reassemble in reverse order. Fig. 73 When fitting the venturi ensure that the arrow is pointing forward © Baxi Heating UK Ltd 2008...
  • Page 40 6. Examine the cover seal and replace if necessary. Heat Exchanger Rear Insulation Spark Electrode Venturi Cover Insulation Seal Fig. 75 Collector Electrode Sensing Leads Electrode © Baxi Heating UK Ltd 2008...
  • Page 41 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. Pressure Sensor Plate Heat Exchanger Fig. 78 DHW Temperature Sensor © Baxi Heating UK Ltd 2008...
  • Page 42 Pump Setting Fig. 80 2. Examine the ‘O’ ring seal, replacing if necessary, and fit it Automatic Air to the new automatic air vent. Vent 3. Reassemble in reverse order. Pump Wiring Cover © Baxi Heating UK Ltd 2008...
  • Page 43 4. Fit the new valve and ‘O’ ring seal and set to the previously noted orientation. Reassemble in reverse order. Fig. 84 ‘O’ ring seal Grub Screw Pressure Relief Valve Fig. 85 Discharge Pipe © Baxi Heating UK Ltd 2008...
  • Page 44 7. Remove the valve assembly. Examine any seals or washers, replacing if necessary. Transfer the DHW NTC to the new valve and reassemble in reverse order. Bypass Pipe Spring Clip Fig. 88 Securing Screw © Baxi Heating UK Ltd 2008...
  • Page 45 4. Remove the screws securing the switch to the facia panel. Facia 5. Fit the new switch, ensuring that it is correctly positioned and reassemble in reverse order. Selector Switch Knob Temperature Control Knobs Fig. 90 © Baxi Heating UK Ltd 2008...
  • Page 46 3. Remove the bracket and vessel from the boiler. 4. Locate the retaining bracket on the upper flange of the Expansion Vessel vessel and fit to the boiler. 5. Reassemble in reverse order. Boiler Chassis Lock Nut Fig. 92 © Baxi Heating UK Ltd 2008...

  • Page 47: Combustion Check

    11. The ‘Calibration Function’ is maintained for 20 minutes unless the maximum CH temperature is exceeded. The function can be disabled at any time by turning the DHW knob. Gas Valve Fig. 100 © Baxi Heating UK Ltd 2008...

  • Page 48: Electrical

    Control PCB X501 Flame Pump Sensing Electrode Spark Generator Diverter Valve Gas Valve Link Ignition Electrode Mains Input Cable - green - brown - green / yellow - black - red - blue - white © Baxi Heating UK Ltd 2008...

  • Page 49: Short Parts List

    Sensing Electrode 5114703 Gas Valve 5119647 Hall Effect Sensor 5114767 Burner 5114697 Water Pressure Switch 5114748 Plate Heat Exchanger 5114708 Pump 248042 Flue Thermostat 5114747 NTC Sensor 5114725 Overheat Thermostat 5114729 Pressure Gauge 248090 5132042 © Baxi Heating UK Ltd 2008...

  • Page 50: Fault Finding

    5 seconds when E110, E130 & E133 are displayed it is possible to relight the boiler. 4. If this does not have any effect, or the codes are displayed regularly further investigation is required. © Baxi Heating UK Ltd 2008...
  • Page 51 Burner output modulates to Error 130 flashing maintain the temperature set Go to section ‘M’ Pump continues to run for 3 Operation sequence Burner goes out Fan stops after 10 seconds minutes successful (room thermostat open) © Baxi Heating UK Ltd 2008...
  • Page 52 Error 130 flashing Go to section ‘M’ Close DHW tap DHW flow sensor senses no Operation sequence Fan stops after 10 seconds Pump runs for 30 seconds flow. Burner goes out successful © Baxi Heating UK Ltd 2008...

  • Page 53: Fault Finding Solutions Sections

    Open the automatic air vent vent is opened Fan connections correct at fan. PCB - X2 connector, is 230V AC across Fan jammed or faulty winding Replace fan terminals 3 & 4 Replace PCB © Baxi Heating UK Ltd 2008...
  • Page 54 (Note: from multimeter connect 2. Electrode connection ‘common’ to 2 & ‘volts’ to 5). Replace igniter 3. Spark gap and position Check wiring Burner Viewing Window 7.5 ± 1 4 ± 0.5 10 ± 1 Electrode Position © Baxi Heating UK Ltd 2008...
  • Page 55 Cold resistance approximately 10kΩ @ 25° C (CH sensor) Replace sensor 20kΩ @ 25° C (Flue sensor) (resistance reduces with increase in temp.) Replace heat exchanger If pump is running the heat exchanger could be obstructed © Baxi Heating UK Ltd 2008...
  • Page 56 19.0 Notes © Baxi Heating UK Ltd 2008...
  • Page 57 19.0 Notes © Baxi Heating UK Ltd 2008...

  • Page 58: Benchmark Checklist

    CO/CO RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER COMMISSIONING ENG’S NAME PRINT CORGI ID No. SIGN DATE © Baxi Heating UK Ltd 2008...

  • Page 59: Service Interval Record

    SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
  • Page 60 Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 08700 60 30 60 Technical Enquiries 08706 049 049 Website www.baxi.co.uk e&oe IT Comp N 925.738.1 UK Comp N 5131787 - Iss 1 - 4/08 © Baxi Heating UK Ltd 2008...

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