Baxi Solo 2 RS Quick Start Manual
Contents
1. CONTENTS PAGE 5 PAGE 6 7 PAGE 8 11 Water Circulating Systems System Controls Pipework Fully Pumped Open Vented Systems Low Head Installation Sealed Systems Gravity Systems Hydraulic Charts PAGE 12 14 r O O D en O 2 Clearances Flue Position Flue Dimensions Ventilation of Compartments Gas Supply Electrical Supply PAGE 15 25 Initial Preparation Flue Preparation Fitting the Wall Mounting Plate Fitting the Flue Duct Terminal Guard Fitting a Terminal Guard Fitting the Boiler Water Connections Pipe Routes Gravity Hot Water System Gas Connection Electrical Supply PAGE 26 27 PAGE 28 PAGE 29 PAGE 30 32 Dismantling the Boiler Cleaning the Burner Injectors Cleaning the Combustion Box PAGE 33 40 Eco Interrupter Leads Piezo Igniter Solenoid Operator Thermocouple Spark Electrode amp Lead Pilot Injector Pilot Bracket amp Gasket Overheat Thermostat Main Thermostat Pump Overrun Timer Removal of Combustion Chamber Door Burner and Injectors Gas Valve Insulation Panels PAGE 41 PAGE 42 Benchmark Log Book As part of the industry wide Benchmark initiative all Baxi boilers now include an Installation Commissioning and Service Record Log Book Please read the Log Book carefully and complete all sections relevant to the appliance and installation These include sections on the type of controls employed flushing the system burner operating pressu2. Main Thermostat Loosen the screw on the capillary retaining washer allowing the washer to move freely Free the capillaries from the clips on the left hand side of the combustion box Withdraw both thermostat phials from the thermostat pocket Disconnect the electrical plug and cable on the gas valve Carefully pull off the thermostat knob Loosen the securing screw sufficiently for the electrical box cover to be removed remove cover A Disconnect the wires of the input and pump outlet cables from the terminal strips Loosen the screws on the cable clamps Boilers converted for use on gravity D H W will have wiring only to the left hand terminal strip 5 Unfasten the screws holding the thermostat box to its bracket on jM the boiler combustion box The thermostat box is now free of the boiler Remove the rear part of the thermostat box by removing the screws at the side Release the locknut securing the main boiler thermostat to the mounting plate da Pull off the spade connectors from the rear of the thermostat taking note of their orientation Remove thermostat taking care not to damage the PCB Fit the new thermostat to the mounting plate and reconnect the spade connectors to the appropriate terminals Heassemble all components in reverse order See pages 24 and 25 for electrical Pump Overrun Timer To change circuit board proceed as if to change Main Thermostat 1 to
3. Panel Bottom Panel Door Lower Assy Valve Honeywell Stepped Ignition Injector Boiler Injector Boiler Burner Boiler Burner Boiler Burner Boiler Burner Boiler Burner Pilot Assy Injector Pilot Thermocouple Electrode Pilot Ign Thermostat Boiler Knob Thermostat Thermostat Overheat Pump Overrun Circuit Kit Spark Generator All models All models All models All models All models All models 30 40 50 60 30 40 50 60 All models All models All models All models All models All models All models All models All Models 364 983 364 984 170 508 364 986 364 987 E04 788 364 989 364 990 170 530 170 531 170 532 170 533 379 300 379 301 379 302 379 303 379 306 364 988 379 305 170 525 183 936 SHORT PARTS LIST Manuf rs Part N 233700 230675 231770 230690 232111 241857 232446 232445 232515 232514 232513 232512 233122 232150 232159 232151 232156 232171 231825 232510 040456 Baxi UK Limited manufacture a comprehensive range of products for the domestic heating market Gas Central Heating Boilers Wall Floor and Fireside models Independent Gas Fires Renewal Firefronts Gas Wall Heaters Solid Fuel Fires If you require information on any of these products please write to the Sales Department Comp N 232184 Iss 11 6 00 The Baxi Helplines F
4. Ren PM 164 9cm Ke MEAT 25 56in FREE AREA FREE AREA 82 5cm 12 78in SIIcISM NN 197 9cm FREE AREA 99 0cm FREE AREA KoA ESAR 30 67in 15 34in Gas Supply The gas installation should be in accordance with BS 6891 The connection on the appliance is RC 2 in BSPT internal located at the bottom right hand side of the appliance Ensure that the pipework from the meter to the appliance is of adequate size Do not use pipes of a smaller diameter than the appliance gas connection Electrical Supply External wiring must be correcty earthed polarized and in accordance with CURRENT I E E WIRING REGULATIONS The mains supply is 230V 50Hz fused at 3A NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance preferably by the use of a fused three pin plug and unswitched shuttered socket outlet both complying with the requirements of BS 1363 Alternatively connection may be made via a fused double pole isolator with a contact separation of a least 3mm in all poles and serving the appliance and system controls only INSTALLATION Initial Preparation Unpack the contents of carton leaving the combustion box and mounting plate assembled on the base tray Place the outer case in a safe place until required Detach the fixing template from the packaging Remove the two wing nuts securing the combustion box to th
5. 02 approximately 3 minutes and then stop HII 8 0 0 5 The boiler and system should be run and then flushed and treated in accordance with BS7593 1992 and the M flushing agent inhibitor manufacturers instructions Minimum 10 3505 4 10 2 When all the air has been removed from the water circuit the pump and radiators should be balanced to achieve the design temperature drop across the Maximum 16 3 0 5 Maximum 16 3 0 5 Minimum 11 2 0 5 4 50 2 system Recheck for water leaks Maximum 16 0505 64 02 Carefully read and complete all sections of the Minimum 12 0 0 5 4 Benchmark Installation Commissioning and Service Record Log Book that are relevant to the appliance and installation The details of the Log Book will be required in the event of any warranty work The Log Book must be handed to the user for safe keeping and each subsequent regular service visit recorded FITTING THE OUTER CASE Remove the lower door panel from the ready assembled outer case by following the sequence of diagrams If the appliance is to be fitted on a gravity system remove the two infill panels Offer the outer case up to the hooks on the top of the combustion box ensuring that it engages Secure the outer case using the two screws and washers that are supplied Replace the lower front door panel cp Instruct the user in the operation of the boiler Hand over the User s and Installation Instructions and the Log Book to th
6. B A radiator fitted with lockshield valves The radiator output should be a minimum of 800 watts 2 700 Btu h Typically a convector type radiator with an area of 3750 cm Aft is adequate C By including an automatic bypass valve in the system see diagram D Any circuit that provides the same operating conditions as option A or option B iui System Controls Return For optimum operating conditions the heating system into which the boiler is installed should include a control system Such a system will comprise of timer control and a separate room or cylinder thermostat as appropriate The boiler should be controlled so that it operates on demand only 1000mm Min Operation of the system under control of the boiler thermostat only does not produce the best results The sizes of flow and return pipes from the boiler should be determined by normal methods according to the requirements of the system Return It is recommended that the system is designed for an 11 C 20 F drop in temperature across the system 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 The copper pipe must not be insulated Fully Pumped Open Vented Systems Low Head Installation Using a close couple arrangement the minimum head is as shown in the diagram subject to the foll
7. and the bye laws of the LOCAL WATER UNDERTAKING Where no specific instruction is given reference should be made to the relevant BRITISH STANDARD CODES OF PRACTICE STANDARD SCOPE Important Information Gas Installation Installation of hot water supplies for domestic purposes Forced circulation hot water BS 6891 BS 5546 BS 5449 Part 1 systems BS 6798 Installation of gas fired hot water boilers BS 5440 Part 1 Flues BS 5440 Part 2 Air Supply The addition of anything that may interfere with the normal operation of the appliance e g FLUE DAMPERS ECONOMISERS etc without the express written permission of BAXI could invalidate the appliance warranty and infringe the GAS SAFETY Installation and Use REGULATIONS This product contains Refractory Ceramic Fibres R C F which are man made vitreous silicate fibres Excessive exposure to these materials may cause temporary irritation to eyes skin and respiratory tract Care must be taken when handling these articles to ensure the release of dust or fibres is kept to a minimum To ensure that the release of fibres from these articles is kept to a minimum during installation and servicing it is recommended that a H E P A filtered vacuum is used to remove any dust soot or other debris accumulated in and around the appliance This should be performed before and after working on the installation It is recommended that any replaced item s are not broken up but sealed within
8. designed to prevent reverse circulation Pipes should be laid to maximum fall avoiding points of possible air lock If the domestic hot water temperature is controlled by a cylinder thermostat and zone valve it is recommended that a bypass is installed in the gravity circuit One method is to install a bathroom radiator fitted with two lock shield valves Mechanical valves which allow the boiler to operate when the valve is closed should not be used Note If the above conditions cannot be met then pumped primaries must be used oee page 25 for wiring of boiler when installed with gravity hot water Hydraulic Charts Hydraulic Resistance Chart or Gravity Systems with injector wash in wg gt Hydraulic Resistance Chart For Fully Pumped Systems Q O Q E Q O G Q 0 Q 5 WY Uu Vv e Ay Pressure Drop 4 5 9 0 13 5 18 0 I T E 9 0 13 5 18 0 1 2 3 4 1 2 3 4 Water Flow litres min gal mi Water Flow litres min gal SITE REQUIREMENTS The appliance may be fitted to any suitable wall with the flue passing through an outside wall and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply The appliance should be fitted within the building unless other wise protected by a suitable enclosure ie garage or outhouse The appliance may be fitted inside a cupboard provided that ventilation requirements and comb
9. heavy duty polythene bags and clearly labelled R C F waste This is not classified as hazardous waste and may be disposed of at a tipping site licensed for the disposal of industrial waste Protective clothing is not required when handling these articles but it is recommended that gloves are worn and the normal hygiene rules of not smoking eating or drinking in the work area are followed and always wash hands before eating or drinking TECHNICAL DATA 30 RS Heat Input Max Min Lifting Weight 37 3 kg 82 1 Ibs kW 11 00 7 69 Btu h 37 500 26 250 Heat Output Max Min kW 8 79 6 15 Water Content 2 1 litres 0 46 gals Static Head metres feet Max 100 Min 1 3 25 Btu h 30 000 21 000 Low Head Min 0 15m 6in Burner Pressure Max Min 15 4 0 5 80 0 5 6 2 0 2 82202 System Design gravity hot water fully pumped open vented and sealed systems mbar in wg Heat Exchanger cast iron monobloc Gas Connection RC in BSPT Gas Rate Electrical Supply 230V 50Hz after 10 mins fused 3A 1 05m h 37 0ft5 h 5 inside cupboard 600mm 420mm 287mm Outercase Dimensions for Servicing Height Width Depth Controls on off boiler thermostat with pilot thermocouple cut out overheat thermostat on fully pumped applications only mum Clearances 293mm 173mm Flue Terminal Dimensions Height Width Depth 2 x 22mm and a kit for gr
10. in BS PT 112205 Electrical Supply 230V 50Hz Controls out overheat thermostat on fully fused 3A on off boiler thermostat with pilot thermocouple pumped applications only Connections 2 x 22mm and a kit for gravity cut Heat Input Max Min kW 21 98 18 68 Btu h 75 000 63 750 Lifting Weight Heat Output Max Min kW 17 58 14 95 Btu h 60 000 Burner Pressure mbar in wg Gas Connection 51 000 Max Min 16 0 0 5 64 02 48 02 12 0 0 5 RC in BSPT Electrical Supply 230V 50Hz fused 3A Controls out overheat on off boiler thermostat with pilot thermocouple thermostat on fully pumped applications only cut Connections 2 x 22mm and a kit for gravity Lifting Weight 37 3 kg 82 1 Ibs Water Content 2 1 litres 0 46 gals Static Head metres feet Max Min 1 100 3 25 Low Head System Design Heat Exchanger Gas Rate after 10 mins Outercase Dimensions Min 0 15m Gin gravity hot water fully pumped open vented and sealed systems cast iron monobloc 1 75m h 61 6ft h 600mm 420mm 287mm Height Width Depth Flue Terminal Dimensions 208mm 293mm 173mm Height Width Depth 5 inside cupboard p for servicing Clearances NOTE On gravity applications a clearance of 80mm 3 in is required from the top panel 60 RS Water Content Static Head m
11. marked L Secure the cable in place with the left hand cable clamp Replace the electrical cover and securing screw A cable clip is supplied in the kit to secure the cable to the bottom of the combustion box In the event of an electrical fault after installation of the appliance preliminary electrical system checks should be carried out earth continuity polarity and resistance to earth FOR GRAVITY D H W AND PUMPED C H When the boiler is to be used on a system with gravity D H W ensure that the overheat thermostat has been disconnected as shown The overheat thermostat is now by passed and will allow the appliance to perform satisfactorily on gravity circulation NOTE Even though the overheat thermostat is not operational it must not be removed from the pocket in the heat exchanger The recommended cable for connection to the Eon appliance terminal strip is 3 core 0 75mm Fuse oiler Gas 24 x 0 2mm P V C IEC 53 code 227 heat resistant Thermostat Valve WARNING This appliance must be earthed Loosen securing screw sufficiently for the electrical cover to be removed from the thermostat box Bare back input cable to dimensions shown Fit input cable to terminal block on left passing through the grip provided The pump should be wired to the junction box or programmer Replace electrical cover and securing screw A cable clip is supplied in the kit to secure the cable
12. small screwdriver Pilot Supply Tube at Gas Valve Pilot Bracket amp Gasket Disconnect thermocouple spark electrode and pilot feed pipe from pilot bracket DO NOT remove pilot viewing window Carefully remove pilot injector Undo the four screws retaining the bracket to the door and remove Check pilot gasket and replace if necessary Fit new pilot bracket Reassemble in reverse order Overheat Thermostat NOTE On boilers converted for use with gravity D H W the overheat thermostat will have been rendered inoperable and will never need changing Loosen the screw on the capillary retaining washer allowing the washer to move freely Free the capillaries from the clips on the left hand side of the combustion box Withdraw the two thermostat phials from the thermostat pocket Remove the locknut and withdraw the overheat thermostat from the bracket Disconnect the two wires from the overheat thermostat and refit them to the new component Heassemble in reverse order Care must be taken to align the overheat thermostat capillary with the groove in the main thermostat phial NOTE The overheat thermostat capillary may be somewhat longer than necessary Excess length should be tidied up by making a neat coil Contact with the side of the combustion box should be avoided Heassemble all components in the reverse order to dismantling ZA
13. to the bottom of the combustion box In the event of an electrical fault after installation of the appliance preliminary electrical system checks should be carried out earth continuity polarity and resistance to earth COMMISSIONING THE APPLIANCE Fill the whole system in accordance with BS 7593 1992 See Treatment of Water Circulating Systems in the System Details section Check for water leaks Purge air from supply pipe at gas service tap BS 6891 7 SS XV AV Turn gas service tap anticlockwise to M Y ON position Check for gas soundness up to gas valve Ensure that all external controls e g room thermostat timer etc are calling for heat oT JUS XO 9 Oo E D D era E 40 Fit thermostat control knob packed with the contents in plastic bag Turn anticlockwise to OFF position marked O Burner Pressure Slacken burner pressure test point screw Connect Test Point pressure gauge Press gas control knob fully inwards and hold Press in igniter button and release Repeat until pilot ignites Continue to hold in gas control knob for approximately 15 seconds and then release Pilot should stay alight Check the appearance of the pilot flame to ensure that it envelops the tip of the thermocouple and is approximately 25mm long Check that the thermocouple output is between 10 15 mV closed circuit The pilot pressure is factory set and canno
14. using 28 x 22 Elbow or 28 x 28 Elbow witha reducing set or 28 x 22 x 22 Tee directly on the tail marked F Pumped Flow 22mm Gravity Flow 28mm Gravity Hot Water System For gravity domestic hot water and pumped central heating system connect tee supplied in kit to the tail marked R Ensure that the injector washer is positioned correctly as shown Failure to fit the injector washer will result in reverse circulation in the D H W circuit The gravity circuit should be installed in 28mm diameter copper pipe as shown Ensure that pipes run perpendicular to the wall to allow fitting of the outercase Pumped Return 22mm Gravity Return 28mm Tee with Injector Washer Gas Connection Gas connection is made on the union gas service tap female in B S P thread Dimension shown will ensure that gas pipe does not interfere with outer case or any downward routed pipes or 220 240V 3A KEY b o e Electrical Supply g y green yellow or orange The electrical supply for this Solo 2 RS depends on r red the design of the central heating system i e w white Gravity DHW and Pumped Central Heating 3 core cable Fully Pumped Open Vented with rising primaries 4 core cable However 3 core cable can be used if the timed pump overrun and overheat thermostat are disconnected Overheat Sealed Systems and Fully Pumped thermostat Gas valve Systems with dropp
15. 6 page 37 then Disconnect the molex plug from the circuit board Remove the circuit board from the two supports Fit the new circuit board to the mounting plate and reconnect the molex plug Reassemble all components in reverse order Wiring removed for clarity Remove Combustion Chamber Door To change burner burner injectors gas valve and insulation panels proceed as follows Turn off gas supply at the service tap and disconnect the union 2 Disconnect the electrical plug on the gas valve by removing screw and pulling forward 3 Disconnect the two wires from the overheat thermostat 4 Loosen the screw on the capillary retaining washer allowing the washer to move freely Release the capillaries from the clips on the side of the combustion box Remove both phials from the thermostat pocket 5 Loosen the six screws sufficiently for the removal of the combustion chamber door Remove the combustion chamber door complete with the burner NOTE When re assembling care must be taken to align the overheat thermostat capillary with the groove in the main thermostat phial Burner and Injectors Remove the two nuts fixing the burner manifold to the burner feed pipe Remove the two nuts fixing the burner manifold to the combustion chamber door Remove the two screws fixing the burner brackets to the combustion chamber door Hemove burner assem
16. Please leave these Instructions with the User Baxi Solo 2 RS Range Wall Mounted Room Sealed Gas Fired Central Heating Boilers Installation and Servicing Instructions Natural Gas Baxi Solo 2 60 RS G C No 41 077 79 Baxi Solo 2 50 RS G C No 41 077 78 Baxi Solo 2 40 RS G C No 41 077 77 Baxi Solo 2 30 RS G C No 41 077 76 Baxi UK Limited is one of the leading manufacturers of domestic heating products in the U K Our first priority is to give a high quality service to our customers Quality is built into every Baxi product products which fulfil the demands and needs of customers offering choice efficiency and reliability To keep ahead of changing trends we have made a commitment to develop new ideas using the latest technology with the aim of continuing to make the products that customers want to buy Baxi is also the largest manufacturing partnership in the country Everyone who works at the company has a commitment to quality because as shareholders we know that satisfied customers mean continued success We hope you get a satisfactory service from Baxi If not please let us know C Baxi is a BS EN ISO 9001 Accredited Company Introduction Technical Data System Details and By pass Requirements Site Requirement Installation Commissioning the Appliance Fitting the Outer Case Overheat Cut Off Device Annual Servicing Changing Components Fault Finding Short Parts List
17. Specifications for Domestic Wet Central Heating Systems IBN CH A filling point and an approved stop valve to BS 1010 must be fitted at low level and the method used for filling the system should be approved by the local water undertaking For further details see BS 6798 A method of replacing water lost from the system should be provided either by means of a make up vessel of not more than 3 litres 5 pints capacity mounted above the highest point of the system or by pre pressurisation of the system A method of venting the system during filling and commissioning must be provided by fitting automatic air vents or by venting manually The hot water storage vessel must be of the indirect coil type All components used in the system must be suitable for operation at 110 C 230 F and at the pressure allowed by the safety valve Gravity Systems When the boiler is to be installed to an existing or new gravity domestic hot water and pumped central heating system the following considerations should be given to the design of the gravity domestic hot water flow and return pipes The minimum circulating head should not be less than 1m 3ft with a maximum horizontal run of 3m 10ft when using 28mm pipes Smaller pipe sizes and longer horizontal runs are acceptable with suitably increased circulating heads Bathroom Radiator used as Gravity Circuit Byp amp s when a Zone Valve is uf The system must be
18. Where a vessel of the calculated size is not then the next available larger size should Air Top Up Bottl If Required lt Radiator Circuit Sealed Systems SAFETY VALVE A safety valve complying with the requirements of BS 6750 Part 1 must be fitted close to the boiler on the flow pipe by means of a horizontal or vertically upward connection with no intervening valve or restrictions and should be positioned to facilitate testing The valve should be pre set and non adjustable to operate at a pressure of 3 bar 45 Ibf in It must be arranged to discharge any water or steam through a pipe to a safe outlet position PRESSURE GAUGE A pressure gauge of minimum range 0 4 bar 0 60 Ibf in with a fill pressure indicator must be fitted to the system preferably at the same point as the expansion vessel in an easily visible position EXPANSION VESSEL An expansion vessel complying with the requirements of BS 4814 must be fitted to the system by means of a connection close to the inlet side of the circulating pump in accordance with the manufacturers instructions the connecting pipe being unrestricted and not less than 15mm in nominal size The volume of the vessel should be suitable for the system water content and the nitrogen or air charge pressure should not be less than the system static head Further details of sealed system design can be obtained from BS 5449 Part 1 and the British Gas publication entitled
19. avity Connections NOTE On gravity applications a clearance of 80mm 3 in is required from the top 40 RS Heat Input kW Btu h Heat Output Max 14 65 50 000 Min 11 36 38 750 Max Min kW 11 72 9 09 Lifting Weight Water Content Static Head metres feet 37 3 kg 82 1 Ibs 2 1 litres 0 46 gals Max 30 100 Min 1 3 25 Btu h 40 000 31 000 Low Head Min 0 15m 6in Burner Pressure Max Min 16 3405 103 0 5 6 5 0 2 4 1 0 2 System Design gravity hot water fully pumped open vented and sealed systems mbar in wg Heat Exchanger cast iron monobloc Gas Connection RC hin BSPT Gas Rate Electrical Supply 230V 50Hz after 10 mins fused 3A 1 40m h 49 3ft h 5 inside cupboard 600mm 420mm 287mm Outercase Dimensions panel p for Servicing Height Wiath Depth Controls on off boiler thermostat with pilot thermocouple cut out overheat thermostat on fully pumped applications only Clearances 208mm 293mm 173mm Flue Terminal Dimensions Height Width Depth 2 x 22mm and a kit for gravity Connections NOTE On gravity applications a clearance of 80mm 3 in is required from the top panel Heat Input Max Min kW 18 32 15 02 Btu h 62 500 Heat Output 51 250 Max Min kW 14 65 12 02 Btu h 50 000 Burner Pressure mbar in wg Gas Connection 41 000 Max Min 16 3 0 5 65 02 45702 RC
20. ble in reverse order To replace rear insulation panel remove the side insulation panels by removing fixing screws Slide rear insulation panel down and away from location Fit new rear insulation panel and reassemble in reverse order Gas Leak FAULT FINDING Gas le ak at joi solution t Joint on valy te Maged valve eine Or fittings pipe casting at joint defective O defective p ring urner feed IIO NR Pilot on but burner will not ignite External controls or boiler thermostat not calling for heat blown fuse defective power supply or external controls solenoid open circuit test for continuity at solenoid terminals injector blocked inadequate gas supply faulty gas valve Pilot established and main burner will ignite Dirty or loose thermocouple connections defective but system liable to nuisance shut down thermocouple defective flame safety magnet incorrect or faulty wiring overheat cut off device defective adverse wind conditions incorrectly fitted terminal partially blocked pilot injector Main burner will not shut down in response to external controls Short circuit in external controls Or wiring defective solenoid faulty main thermostat Check continuity between S L on terminal strip and 1 L on plug on gas valve O verheat Ther Main burner pressure mostat incorrect Throttle screw requir
21. bly noting position of pilot shield O ring and gasket Check the O ring and gasket replace if necessary A replacement burner can be fitted by reassembling in reverse order ensuring that the pilot shield is refitted in the correct position If only the injectors are being replaced then proceed as follows Remove the two screws fixing the mounting brackets Remove the four screws to separate the manifold from the blade assembly Unscrew injectors and fit new ones Reassemble the burner and attach to controls door in reverse order The gas valve fitted to the appliance is of the stepped ignition type Helease fixing nuts on pilot feed pipe and thermocouple at gas valve which releases the Eco interrupter Hemove screws holding burner feed pipe to gas valve Hemove the piezo igniter assembly Hemove screws on gas valve inlet support bracket Hemove gas valve Undo Eco interrupter from GP rear of valve Fit new gas valve and reassemble using the O ring from the original valve If however the O ring has become damaged or worn replace Insulation Panels To replace the combustion chamber door insulation undo the five screws holding the insulation carrier assembly in place Replace with new carrier assembly and reassemble in reverse order To replace side insulation panels remove fixing screws Slide panel down and away from location Fit new side insulation panel and reassem
22. by removing the wire with the black sleeve and attaching it to the wire with the red sleeve as shown The overheat thermostat is now by passed and will allow the appliance to perform satisfactorily on gravity circulation NOTE Even though the overheat thermostat is not operational it must not be removed from the pocket in the heat exchanger except during servicing Lift boiler and engage centrally the back bottom edge into the hook bracket on the mounting plate Rotate the boiler back to the mounting plate to engage two studs and spring latch Fit the two wing nuts Tighten to compress rear flue seal Water Connections The boiler is supplied ready for fully pumped and sealed systems The boiler has 2 connection tails to accept capillary or compression fittings 22mm tail marked F for Flow 22mm tail marked R for Return Pipe Routes Pipework should be routed to the back plate Pipes may also be routed to drop down within outer case Spaces are available at both sides If pipes are routed to drop down within the outercase vents are required It is recommended that fittings A are of copper capillary type It is recommended that fittings B are compression type Fully Pumped System For fully pumped system connect to tails marked F and R sealed System For sealed system connect to tails marked F and R Injector Washer IMPORTANT Start Gravity Flow Pipe in 28mm at this point
23. culating Systems The appliance is suitable for use with fully pumped open vented systems small bore and micro bore gravity domestic hot water with pumped central heating systems and sealed systems The following conditions should be observed on all systems e The static head must not exceed 30m 100ft of water e The boiler must only be used with an indirect cylinder Drain points should be fitted to the lowest points in the system e All electrical wiring gas and water pipes must be installed in a way which would not restrict the servicing of the boiler e Position isolating valves as close to circulating pump as practicable e For fuel economy and best boiler performance the system should be designed so that gravity circulation does not take place in the heating system when the pump is not running Treatment of Water Circulating Systems For optimum performance after installation this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS7593 1992 Treatment of water in domestic hot water central heating systems This must involve the use of a proprietry cleanser such as BetzDearborn s Sentinel X300 or X400 or Fernox s Superfloc Full instructions are supplied with the products but for immediate information please contact BetzDearborn on 0151 420 9563 or Fernox on 01799 550811 For long term protection against corrosion and scale after flushing it is recommende
24. d O ring and gasket Hemove the two screws fixing the mounting bracket Remove the four screws to separate the manifold from the blade assembly Clean venturies Unscrew injectors clean carefully and replace Check seal around the door and replace if necessary Heassemble burner to door and feed pipe ensuring the pilot shield is in the correct position Cleaning the Combustion Box Slide baffle forward 30 40 and 50 models only Side insulation panels and rear insulation panel should be removed to avoid brush damage To remove side panel remove one screw per panel Slide panel down and away from location TOS Rear insulation panel can now be removed The heat exchanger can now be easily cleaned thoroughly Remove any obstructions from flue outlet and air inlet Remove dirt and debris from bottom of combustion box Reassemble all components in reverse order Check burner setting pressure and gas rate Recommission the boiler before use checking for gas soundness and ensuring all controls are working correctly Complete the relevant section of the Benchmark Installation Commissioning and Service Record Log Book and hand it back to the user CHANGING COMPONENTS Before changing any components please read the Important Information section on page 5 When changing components ensure that electrical and gas supplies are isolated before the work is started Re
25. d that an inhibitor such as BetzDearborn s Sentinel X100 or Fernox s MB 1 or Copal is dosed in accordance with the guidelines given in BS7593 1992 Failure to flush and add inhibitor to the system may invalidate the appliance warranty BYPASS REQUIREMENTS The boiler is fitted with a pump overrun device which allows the removal of residual heat from the boiler NOTE The pump overrun will operate for approximately 3 minutes The system design must therefore always provide an open circuit for water to circulate between the boiler flow and return Qf a system has an open circuit a bypass is not required A system using a 3 port diverter valve does not normally require a bypass and therefore this system is recommended The exception to this is where all radiators in the system are fitted with thermostatic valves in which case a bypass would be required However if one radiator in such a system was fitted with 2 lockshield valves a bypass would not be required A system controlled by non electrical valves e g mechanical thermostatic control valves both on the radiators and the hot water circuit and systems using twin zone valves e g Honeywell S Plan will require a bypass The bypass circuit can be A A minimum of 9 metres of 22mm pipe measured between the boiler flow and return connections It should be fitted with a lockshield valve opened at least 1 full turn to give a minimum flow rate of 8 litres min 1 8 gal min
26. e mounting plate Disengage the spring latch and lift the combustion box away from the airbox Place the combustion box on its back Choose a flat vertical area to position the boiler making necessary allowances for required minimum clearances If fitting between wall cupboards ensure that the minimum available width is as shown Hold the wall template against the wall at the required boiler location Ensure that the top of the template is level The template represents the outer limits of the appliance plus the required minimum clearances NOTE On gravity applications a clearance of 80mm 3 sin is required from the top panel If fitting the appliance between or adjacent to kitchen wall units ensure that the line on the template indicating the lower edge of the boiler is level with the lower edge of the units and is correctly spaced If fitting the appliance in a compartment or cupboard with suitable air vents see Ventilation of Compartments ensure that the bottom edge of the template is level with the lower edge of the units and is correctly spaced S outline of n Two holes are provided on the template to allow gas Outer Casp E ky and electrical supplies to be brought directly into the na La cds rp boiler from the wall The grommet provided must be used when the electrical cable is routed through the wall mounting plate Mark the position of the flue hole and four good anchorage points Where possible use the upperm
27. e user giving advice on the necessity of regular servicing OVERHEAT CUT OFF DEVICE The overheat cut off device is of the manual reset type and therefore it is important that the user knows how to reset the control should it ever cut out Remove the lower door panel by following the sequence of diagrams Reach into the outer case and locate the reset button adjacent to the control box Press the button to reset the overheat thermostat The boiler must be reignited manually NOTE Any interruption to the electricity supply may cause the device to operate ANNUAL SERVICING 2 Dismantling the Boiler To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals 3 The frequency of servicing will depend upon the particular installation conditions and usage but in general once per year should be adequate It is the law that all servicing work is carried out by a competent person such as British Gas or other AO i f CORGI registered personnel zd Before servicing please read the Important Information section on page 5 After servicing complete the relevant section of the Benchmark Installation Commissioning and Service Record Log Book This should be in the possession of the user ISOLATE THE ELECTRICAL SUPPLY TO THE BOILER Remove lower door panel following the seque
28. es adjustment after adjustment recheck pressure Overh eat the be reigniteg rMostat reset b IN i Ut boiler cannot correct use i poor OVerhea overheat ho a t faulty gas valve faulty or Pilot will not light Main gas tap off ignition restart interlock is still engaged gas control knob not fully depressed pilot feed not purged of air pilot teed blocked pilot injector blocked electrode lead or ignitor faulty overheat cut off device has operated if on gravity overheat thermostat wires may not be piggybacked Pilot established when gas control knob Incorrect or faulty pilot injector fitted pilot injector partially released but pilot flame does not fully blocked envelop the thermocouple Gas control knob released too SOON dirty or loose connections defective thermocouple Of flame safety magnet overheat cut off device activated partially plocked pilot injector Pilot lights but goes out when gas control knob is released ite but pilot flame is Incorrect pilot injector 985 supply too small or restricted adverse wind conditions incorrectly fitted terminal partially plocked pilot injector Main burner will ign immediately extinguished Ol cO 65 Key Description 49 50 45 46 47 48 60 59 63 64 29 38 30 34 65 Panel Front Panel Side 2 off Panel Top
29. etres feet 37 3 kg 82 1 Ibs 2 1 litres 0 46 gals Max Min 1 100 3 25 Low Head System Design Heat Exchanger Min 0 15m 6in gravity hot water fully pumped open vented and sealed systems cast iron monobloc Gas Rate after 10 mins 2 09m h 74 0ft h Outercase Dimensions 600mm 420mm 287mm Height Width Depth Flue Terminal Dimensions 208mm 293mm 173mm Height Wiath Depth 5 inside cupboard p for Servicing Clearances NOTE On gravity applications a clearance of 80mm 3 in is required from the top panel Examples of Open Circuits Radiator Circuit P at T Air Vent s 4 N m I I I I I I I I I I I I Pump l I I i I 7 EA I i HA Radiatof optional Gi Bypass A 5 j 1 XN i P d Fully Pumped System A By pass is required with this system Twin Zone Valve System Mu Length Pump Boiler ERE M length ZA B C EE Radiator Circuit Typical Systems Arrangement ir Bypass Incorporating Automatic Valve 3 Port Diverter Valve System eni Radiator Circuit This system is unlikely to require a By pass unless all radiators are thermostatically controlled Flow from boiler A D H W Zone valve B C H Zone valve C Automatic Bypass valve SYSTEM DETAILS and By pass Requirements Water Cir
30. from a terminal on the same wall 300 L Foran opening in a car port e g door window into a dwelling 1200 Flue Dimensions Recommendations for flues are given in BS 5440 1 The standard flue terminal supplied with the appliance is suitable for use with wall thickness between 100mm 4in and 356mm 14in A flue terminal extension kit is available as an optional extra for wall thickness between 356mm 14in and 610mm 24in from the manufacturer Quote appliance Model N when ordering Ventilation of Compartments Where the appliance is installed in a cupboard or compartment air vents are required for cooling purposes in the cupboard or compartment at high and low level which may communicate with a room or direct to outside air Detailed recommendations for air supply are given in BS 5440 Part 2 An existing cupboard or compartment may be used provided that it is modified for the purpose Hecommendations for air supplies and details of essential cupboard compartment design are given in BS 5440 Part 2 NOTE Both air vents must communicate with the same room or both be on the same wall to outside air MINIMUM AIR VENT FREE AREA Position of Air from Air direct Air Vent Room from Outside HiGH AND 09 0cm KoA ESAR 15 35in FREE AREA 49 5cm FREE AREA 7 68in Sen PN 131 9cm KoA ESAN 20 44in FREE AREA 66 0cm FREE AREA 10 22in
31. ing pipework 4 core cable must be used Detail of the electrical supply for the various system designs can be found below view in arrow direction Pump Overrun Circuit FOR FULLY PUMPED AND SEALED SYSTEMS li ani The recommended cable for connection to the appliance terminal strip is 4 core 0 75mme w 24 x 0 2mm dia P V C IEC 53 code 227 heat resistant gemeas DI External wiring must be correctly earthed and polarised and in accordance with current I E E wiring External Boiler regulations Programmer Thermostat N The mains supply required is 230V 50Hz fused at 3A ene WARNI NG THIS APPLIANCE MUST BE EARTHED NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Loosen the securing screw sufficiently for the electrical cover to be removed from the thermostat box Bare back the input cable to the dimensions shown Fit the electrical input cable as follows Connect the switched live to the terminal marked S L Connect the permanent live to the terminal marked P L Connect the supply neutral to the terminal marked N and the supply earth to the terminal masked l Secure the cable in place with the right hand cable clamp Fit the pump outlet as follows Connect the pump earth to the terminal marked Connect the pump neutral to the terminal marked N Connect the pump live to the terminal
32. move the outer case lower door panel by following the sequence of diagrams unscrewing the two screws and washers lift the case to clear the two hooks at the top of the combustion box Draw the outer case clear of the boiler ey Eco Interrupter Leads Disconnect the leads at the overheat thermostat One lead is removed by unscrewing the connection from the rear of the gas valve The other lead can be removed after slackening off the thermocouple connection at the gas valve Reassemble in reverse order CAUTION Do not overtighten Piezo Igniter Withdraw and disconnect electrode lead Remove retaining nut holding piezo igniter to bracket Exchange igniter for new and reassemble Solenoid Operator Ensure electrical supply is isolated Disconnect the electrical plug by removing the screw and pulling forward Remove solenoid operator by unscrewing fixing screws Exchange solenoid for new and reassemble Thermocouple Release nuts holding thermocouple in place Bend new thermocouple to required shape fit in place and tighten retaining nuts Caution Do not overtighten nuts Thermocouple at Gas Valve Spark Electrode amp Lead Unclip the electrode from the pilot bracket and remove lead from piezo igniter Replace with new spark electrode ensuring it is fully engaged TU C Pilot Injector Disconnect nuts on pilot supply tube and remove Extract injector using a
33. nce of diagrams To remove the outer case from the boiler take out the two screws and washers Draw outer case forward and clear of the boiler Turn off gas supply at the service tap and disconnect the union 2 Disconnect the electrical plug on the gas valve by removing screw and pulling forward Disconnect the two wires from the overheat thermostat 4 Loosen the screw on the capillary retaining washer allowing the washer to move freely Release the capillaries from the clips on the side of the combustion box Remove both phials from the thermostat pocket British Gas Service a Test Point For use by B G personnel Remove brass sealing plug with fibre washer EN Em Loosen the six screws sufficiently for the removal of the combustion chamber door Remove the combustion chamber door complete with the burner NOTE When re assembling care must be taken to align the overheat thermostat capillary with the groove in the main thermostat phial Cleaning the Burner Injectors Lightly brush any debris from top of burner blades and ensure that ports are free of obstructions Remove the two nuts fixing the burner manifold to the burner feed pipe Remove the two nuts fixing the burner manifold to the combustion chamber door Remove the two screws fixing the burner brackets to the combustion chamber door Hemove burner assembly noting position of pilot shiel
34. or General Enquiries 44 0 8706 060 780 For After Sales Service 44 0 8706 096 096 For Technical Enquiries 44 0 8706 049 049 BAXI Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www baxi com
35. ost and lowest fixing hole positions otherwise space the fixing holes as far apart as possible Mark gas and electrical supply access holes if required Cut out hole for flue Drill anchorage holes 7mm in diameter by 63mm 2 2 in deep to accept wall plugs 8 Slots Centre o 10 x 6 Sri 150 175 Centre of Connectlon 184 184 Gas Connection Fixing Template Make good internal masonry up to edges of flue cut out Flue Preparation Unpack flue duct flue trim and air duct Flue Trim a Flue Duct s Air Duct Measure overall wall thickness If this is between 280mm 11in and 355mm 14in use flue as supplied without alteration N N N N N N N M i For wall thickness between 102mm 4in and 280mm 11in air duct and flue duct are required to be shortened Using the indication on the duct mark accordingly to table below Cut off Wall Thickness 203mm 280mm 8in 11in 127mm 208mm bin 8in 102mm 127mm 4in bin Bend tabs as shown Using tin snips cut around ducts at appropriate mark Remove any sharp edges Fitting the Wall Mounting Plate Secure plate to wall using 68mm 2 2 in screws From outside building pass air duct through wall opening The two tabs should be positioned at the bottom Inner Duct Slide air duct over inner duct until tabs contact wall surface Ensure air duct is horizon
36. owing conditions 22mm Open Vent 15mm Cold Feed 400mm Min Head 1 The correct heat input 2 The pump being adjusted to give an 11 C drop across the boiler 3 The pump must be fitted on the flow 4 The pump must be fitted in accordance with the pump manufacturer s instructions 5 The open vent pipe must be taken up from a tee in a horizontal section of the flow pipe Alternative Low Head Installation for all Solo 2 RS If less height is available then a combined vent and feed pipe may be connected This must be a minimum of 22mm diameter It is recommended that an air separator is fitted when using a combined feed and vent pipe 22mm Feed amp Vent Return Alternative Low Head Installation 3 Litre Vent Filling Pressure Point Gauge sat Pump Expansion Vessel A System Drains at Low Point Max Boiler Flow Temp 82 C Method of determining minimN value of expansion vessel volumw for Sealed systems using Baxi Boile o Multiply Total Initial Systef Water Content df Pressure Bar System By Lites Vessel Charge Pressure Bar 0 5 0 067 1 0 0 112 Va 1 5 0 207 2 0 0 441 1 0 0 087 1 0 La 9 0 152 2 0 0 330 1 5 0 125 vos Gn ae 0 265 Example System Volume 75 litres Vessel Charge Pressure Initial System Pressure 3775 x 0 152 11 4 litres Expansion Vessel Volumg Then NOTE
37. re etc The details of the Log Book will be required in the event of any warranty work Also there is a section to be completed at each subsequent regular service visit B S Codes of Practice INTRODUC TION Description The Baxi Solo 2 RS is a wall mounted gas fired room sealed natural draught central heating boiler with range rated outputs as shown in the table below HEAT OUTPUT Max 8 79kW 30 000 Btu h 11 72kW 40 000 Btu h 14 65kW 50 000 Btu h 17 58kW 60 000 Btu h 6 15kW 21 000 Btu h 9 09kW 31 000 Btu h 12 02kW 41 000 Btu h 14 95kW 51 000 Btu h Each appliance is preset at its MAXIMUM heat input rating and is designed for use on NATURAL GAS only They are suitable for gravity domestic hot water with pumped central heating fully pumped open vented central heating and domestic hot water and sealed systems The standard flue assembly supplied is suitable for wall thicknesses between 100mm 4in and 356mm 14in An optional flue extension kit is available for walls of 356mm 14in and 610mm 24in thickness The appliance data badge is fitted to the combustion chamber door above the gas valve Installation The installation must be carried out by a CORGI Registered Installer and be in accordance with the relevant requirements of GAS SAFETY Installation and Use REGULATIONS the BUILDING REGULATIONS Scotland Consolidation the LOCAL BUILDING REGULATIONS the current I E E WIRING REGULATIONS
38. rminal is fitted within 1 metre 39in of a plastic Shield Z gutter within 500mm 19 in of a painted eave or a painted gutter an aluminium shield of at least 1 metre 39in long should be fitted to the underside of the gutter or painted surface An air space of 5mm 8 16 in should be left between shield and gutter If the terminal discharges onto a pathway or passageway check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway If the outer surface of an outside wall is of combustible material it should be protected by fitting a non combustible plate so that it extends not less than 50mm 2in around the terminal VVZANINTINIE If a terminal is less than 2 metres 78 in above a balcony above ground or above a flat roof to which people have access then a suitable terminal guard must be provided Likely positions requiring a flue terminal guard Terminal Position with Minimum Distance mm A Directly below an openable window or other opening e g an air brick 300 B Below gutters soil pipes or drain pipes 300 C Below eaves 300 D Below balconies or car port roof 600 E From vertical drain pipes and soil pipes 75 F From internal or external corners 600 G Above ground roof or balcony level 300 H From a surface facing a terminal 600 From a terminal facing a terminal 600 J Vertically from a terminal on the same wall 1500 K Horizontally
39. t be adjusted Fi If pilot fails to remain alight repeat from start of paragraph above Turn on main electricity supply Light burner by turning thermostat knob to high setting fully clockwise Check pressure after 10 minutes Adjust if necessary to the relevant figures for the corresponding model shown in the chart below To set the main burner pressure adjust the throttle as shown To increase the burner pressure turn the adjustment screw in either direction until the required pressure is obtained A Set any timer control room thermostats etc to the customer s specific requirements Turn the boiler thermostat knob to the OFF position marked O Screw home the pressure test point screw Turn the boiler thermostat knob to the required setting Make a final check for gas soundness of all gas carrying joints on boiler Check operation of flame failure device Turn gas control knob clockwise in the direction marked O The control knob cannot be depressed until ignition restart interlock device in gas valve has disengaged This takes 60 seconds approximately Pilot must not be relit for 3 minutes after shut down The appliance is fitted with a pump overrun timer which keeps the pump running fully pumped systems only when any external control switches the appliance off Setting Pressure To check the operation of this turn programmer time mbar in wg switch off the pump should continue to run for ME 154 05 62
40. tal and square to wall face Using sealing tape supplied make good the joint on inside of the two ducts I ealing Tape e hl Make good with cement mortar between the outside wall and Fitting the Flue Duct Fit flue trim over air duct Flue Trim Sealing Tape Air Duct Tabs x Slide flue duct inside air duct to engage flue duct on boiler noting correct positioning as labelled Flue Duct Air Duct Secure flue duct flue trim to air duct with four screws provided in the kit Remove label from duct Terminal Guard When codes of practice dictate the use of terminal guards they can be obtained from most plumbers and builders merchants nationwide When ordering a terminal guard quote the appliance model number The guard manufacturers listed below can be contacted for terminal sizes and guard model numbers Quinnell Barrett amp Quinnell 884 Old Kent Road London SE15 1NL Tel 071 639 1357 Tower Flue Components Ltd Tower House Vale Rise Tonbridge Kent Tel 0732 351555 Fitting a Terminal Guard Position the guard over the terminal on the outside wall Ensure guard is equally spaced about terminal Mark fixing positions Drill and plug fixing positions then secure guard to wall Fitting the Boiler When the boiler is to be used on a system with gravity D H W it is necessary to disconnect the overheat thermostat
41. ustible material standards are adhered to If the appliance is fitted in a room containing a bath or shower reference must be made to the Current E E Wiring Regulations and Building Regulations If the appliance is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of British Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing Recommendations for flues are given in BS 5440 Pt1 Clearances A flat vertical area is required for the installation of the boiler measuring as shown A space above the boiler should also be left clear as indicated by the dotted lines These dimensions include the necessary clearances around the appliance for case removal spanner access and air movement Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the appliance If fitted inside a cupboard the clearance of 300mm shown is only necessary when the cupboard door is open A clearance of 5mm in is required from the front of the casing when the door is closed NOTE On gravity applications a clearance of 80mm 3 sin is required from the top panel ee Flue Position x T e N The following guide lines indicate the general Z gt 9m requirements for siting balanced flue terminals e N Aluminium If the te
Download Pdf Manuals
Related Search