Baxi Solo 2 PF Quick Start Manual
Contents
1. 35 9 0 Annual Servicing Baffles 30 40 50 60 70 models KEJ Cleaning the Combustion Box 1 Remove the burner assembly by pulling it forward Fig 94 2 Lightly brush any dirt from the top of the burner blades and ensure that the ports are free from obstruction 3 Lift the baffles out of the heat exchanger using the corner tabs on 30 40 50 60 70 models Fig 94 LEJ Cleaning the Heat Exchanger 1 The heat exchanger may be cleaned by insertion of a thin metal strip e g a hack saw blade or steel rule from above or below taking care not to damage any insulation 2 Clean the front and rear fin sections and ensure that any blockages are cleared EX Cleaning the Burner Injector 1 Remove the injector which is screwed into the burner feed manifold Fig 95 2 Examine and clean carefully then replace ensuring that the copper washer is in position Tighten the injector fully EGR Cleaning the Pilot Y P d 60 70 amp 80 PF Fig 96 1 Disconnect the spark electrode lead at the Models Only electrode Fig 96 Fig 95 2 Unscrew the electrode from the manifold and withdraw the electrode Fig 96 Qo A 3 Remove the right hand side insulation carrier an L e bracket by releasing the screw Remove the side Pilot Hood 7 TOON A insulation Fig 94 Pilot Injector di GS ie 4 Release the screw securing the pilot hood and Seal i j remove Fig 96a2. after 10 mins Lifting Weight kg Ibs Water Content litres pints Outercase Height Dimensions Width Depth 100mm Flue Terminal Diameter Dimensions Depth 65mm Static Head VEXI 30 metres 100 ft Min 1 metres 3 25 ft Connections Flow 22mm Cu tail Return 22mm Cu elbow Heat Exchanger Cast iron monobloc Low Head 0 2m 8 in System Design fully pumped open vented and sealed systems Gas Connection RC 2 in BSPT Electrical Supply 230V 50Hz fused 5A 90W Controls frost protection thermostat Internal Fuse 4AF 250V to BS4256 situated on control board 2 0 Technical Data 80 23 45 80 000 20 8 71 000 29 91 100 000 26 01 88 750 16 0 0 5 6 4 0 2 11 5 40 5 4 4 0 2 2 78m h 98 1ft h 34 2 75 5 1 3 2 3 600mm 462mm 28 mm boiler thermostat pilot amp electronic flame sensing timed pump over run Hydraulic Resistance Charts a mm Oo z E 3 E S fas o D D a 2 4 6 8 1012141618 2022242628 30 Water Flow Rate litres min 30 40 and 50 PF models Templates 107 Dia without with internal internal fitting fitting Centre of Gas Connection Layout of Fixing Points 30 40 and 50 PF models Clearances 50mm 600mm 100mm 5mm 350mm 30 40 50 models 462mm 60 70 80 models 2 0 Technical Data Pressure Drop mbar in wg 2 4 6 8 10121416 182022 242628 30 Water Flow Rate litres min 60 70 and 80 PF models without with in
3. Changing Components Cont 1 To change Fan Pressure Switch Burner Burner Injector Pilot Burner Injector Gas Manifold proceed as follows 2 Release the four latches holding the combustion box door Fig 108 Remove the combustion box door by pulling forward from the bottom and unhooking its top edge Fig 110 3 Release the 5 pin electrical plug connecting the pressure switch and fan Fig 109 Withdraw the fan assembly by pulling forwards from the top edge Fig 110 EYE Fan Fig 111 IMPORTANT 80 PF Models Only On appliances up to serial n 8999 use replacement fan Baxi Part N 229422 G C N 364 979 From serial n 9000 use replacement fan Baxi Part N 237578 G C No 170 615 1 Disconnect sensing probe from the pressure switch at rubber tube connector 2 Disconnect the 2 fan wires from the connection on the electrical plug Unscrew bracket securing sensing probe into top of fan and remove the sensing probe Remove the 3 screws securing the fan to the fan hood 3 Remove the two screws securing the fan outlet flange to the fan and remove Clean all sealing Outlet Flange mastic from the outlet flange 4 Fit the outlet flange onto the new fan fix with the 2 screws and seal the outside gap between the fan body and the outlet fan with the mastic provided Sensin Tube 3 5 Fit the new fan and re assemble all components Fig 111 in reverse order of disman
4. 1 NOTE There are two options for fitting the flue and back plate they are Method A Fitting the flue and back plate as an assembly usually used where there are no side clearance problems Method B Pre fitting the flue through the wall fitting the back plate to its position on the wall and then connecting the two together usually used where side clearances are restrictive EXE Method A 1 Remove the left or right hand air box blanking plate as appropriate from the back plate air box by releasing the three screws Fig 46 2 Rotate the turret to face the selected opening Fig 47 and remove the side blanking cap by pushing in and turning anti clockwise to release the bayonet fitting Fig 48 3 Locate the swaged end of the flue duct over the bayonet fitting on the turret taking care not to damage the O ring Lock the flue in place by pressing in and turning clockwise Fig 49 4 Ensure all seams of the air duct sections are uppermost and that the O ring seal is in position against the sealing flange 5 Fit the air duct over the flue duct and draw towards the air box on the back plate ensuring that the flue duct locates into position in the terminal end of the air duct Engage the bayonet slots of the air duct over the location lugs of the back plate opening and press and turn clockwise to secure the air duct to the air box Fig 50 6 In order to increase security of the flue the bayonet tags
5. 6 Engage the bayonet slots of the air duct over the location lugs of the back plate opening and press and turn clockwise to secure the air duct to the back plate Fig 30 7 In order to increase security of the flue the bayonet tags may be deformed to secure the flue in position Fig 32 Fig 33 5 0 Installation Fitting the Back Plate 1 Engage the assembly into the hole previously cut in the wall and slide in place Fig 31 2 Secure the assembly to the wall at the previously drilled anchorage points with suitable screws Fig 31 Before finally tightening the screws check that the assembly is level 3 Make good between the wall and the air duct outside the building if the internal fitting kit has not been used Fig 32 4 The flue trim provided may be fitted if required to neaten up the make up around the terminal This plate may also be used as a protection plate on outside walls of combustible material 5 Fit the trim over the flue terminal and mark through the four securing holes Remove the trim drill holes 63mm 2 2 in deep to accept suitable wall plugs Fit the trim over the flue terminal and secure using suitable screws Fig 33 Fig 35 Fig 36 Fig 37 Fig 39 5 0 Installation EX Left or Right Flue NOTE If the flue terminal is inaccessible from outside the building it is necessary to fix the internal fitting kit in position before con
6. Is YES Is there mains voltage Boiler On at P L input light on YES NO YES Is there mains voltage at S L input S there mains voltage at Pump L output NO Check external NO Check fuse on YES Change circuit board potentiometer Change PCB YES No continuity across fuse change fuse YES Note This can occur if the boiler has overheated Check pump wiring YES Investigate PE Reset by turning control knob OFF wait 10 seconds then turn Does lockout light go out NO Is there continuity across the overheat thermostat NO Replace thermostat i 42 YES 12 0 Fault Finding Is YES there a clear YES Does fan run constant spark at the electrode NO NO Is Is lockout light Pilot On on light on YES NO NO Check amp clean electrode Check gap amp lead Is YES Fan On light on Change PCB NO Note Under cold conditions fan Up time may excee Check control knob 1 Lae is turned on Check pressure switch pipes for leaking or Check that the wires blockage are connected to the thermostat sensor YES Is there a Sic Check that the fan amp erminals pressure switch plug is 4 e dep connected YES Check continuity NO across sensor 1 M OHM at 20 C Replace pressure switch No continuity change sensor Check continuity Replace fan across pilot solenoid 1 5 K OHM No cont
7. Pigi P Vent Radiator Circuit P Shir S pu midi rr X N NS T Twin Zone N Valve System i ML Fig 3 r I I l l l l l l l l l l l l N Fig 4 Air SM A d f Typical Systems Arrangement d 3 Port Divertor Valve System by e os Radiator Circuit 4 4 4 oe a e uA A e o ae N Y Y l l l I l l l l l l I Radiator Circuit I Fi e e e c M n 1 3 0 System Details ESM Water Circulating Systems 1 The appliance is suitable for use with open vent fully pumped systems sealed systems and where additional control protection is required The following conditions should be observed on all systems The static head must not exceed 30m 100ft of water The boiler must not be used with a direct cylinder The boiler is fitted with a timed pump overrun that will operate for approximately 8 minutes Drain cocks should be fitted to all system low points e All gas and water pipes and electrical wiring must be installed in a way which would not restrict the servicing of the boiler Position isolating valves as close to circulating pump as possible Treatment of Water Circulating Systems All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is app
8. an outside wall and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply Fig 9 The appliance should be fitted within the building unless otherwise protected by a suitable enclosure ie garage or outhouse The appliance may be fitted inside a cupboard Cooling ventilation and insulation of the cupboard are not required see section 4 5 2 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 British Gas document DM2 3 Recommendations for flues are given in BS 5440 Part 1 EPR Clearances Fig 10 1 A flat vertical area is required for the installation of the boiler measuring as shown in the table below for each model 2 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 3 If fitted inside a cupboard the clearance of 300mm shown is only necessary when the cupboard door is open A clearance of 5mm e in is required when the door is closed FE Flue Position 1 For installations where the flue termina
9. feed pipe the control box may be pulled forward to give greater access Overheat Q Overheat Neon Warning O Boiler On O Burner On O Fig 80 6 0 Commissioning the Appliance CA Commissioning the Appliance 1 Flush the whole system in accordance with BS 5793 1992 see Section 3 1 Water Circulating Systems Check for water leaks 2 Purge away air from the supply pipe at the gas service cock BS 6891 1988 Fig 79 3 Ensure that the electrical supply is isolated 4 Check the electrical supply for earth continuity polarity short circuit and resistance to earth 5 Turn the gas service cock anti clockwise to the ON position and check for gas soundness up to the gas valve 6 Loosen the pressure test point screw on the right hand side of the gas control valve there is no need to completely remove this screw to obtain a pressure reading and connect a pressure gauge 7 Turn the boiler thermostat control knob fully anti clockwise to the OFF position marked 0 Fig 80 8 Ensure that the electricity supply is turned ON and set any external controls to the ON position 9 Turn the boiler thermostat knob fully clockwise 10 The fan will start running and after approximately 5 seconds the ignition spark will commence NOTE This may increase up to 1 minute in extremely cold weather 11 The sparking will continue until the pilot light is established Fig 81 and then the main burner wi
10. from the boiler NOTE The pump overrun will operate for approximately 8 minutes The system design must therefore always provide an open circuit for water to circulate between the boiler flow and return 22mm Open Vent 1000mm Min Flow Return Fig 5 Typical Low Head Installation 22mm Open Vent Automatic Air Vent Flow If Conditions Require Fig 6 This System Possible 22mm Flow Return Alternative Low Head Installation Fig 7 3 0 System Details EXT Pipework 1 The sizes of flow and return pipes from the boiler should be determined by normal methods according to the requirements of the system 2 An 11 C 20 F drop in temperature across the system is recommended EZ System Controls 1 For optimum operating conditions the heating system into which the boiler is installed should include a control system 2 Such a system will comprise of a timer control and separate room or cylinder thermostats as appropriate 3 The boiler should be controlled so that it operates on demand only 4 Operation of the system under control of the boiler thermostat only does not produce the best results 5 A frost thermostat is fitted integrally to the appliance controls and will protect the boiler from frost damage by operating the burner when the water temperature in the boiler drops towards freezing point The boiler will fire as necessary to maintain a tempera
11. may be deformed to secure the flue in position 21 22 Fig 52 Fig 53 Fig 51 5 0 Installation ESE Method A Cont 7 Engage the assembly into the hole previously cut in the wall and slide into place 8 Secure the assembly to the wall at the previously drilled anchorage points with suitable screws Before finally tightening the screws check that the assembly is level Fig 51 9 Make good between the wall and the air duct inside and outside the building if the internal fitting kit has not been used Fig 52 10 The flue trim provided may be fitted if required to neaten up the make up around the terminal This plate may also be used as a protection plate on outside walls of combustible material 11 Fit the trim over the flue terminal and mark through the four securing holes Remove the trim drill holes 63mm 2 2 in deep to accept suitable wall plugs Fit the trim over the flue terminal and secure using suitable screws Fig 53 Air Box Blanking Plate Fig 54 Blanking Cap Fig 55a Fig 56 60mm 27 2 in EME Support Clamps D Flue Duct Fig 58 Air Duct Fig 57 5 0 Installation ESP Method B 1 Remove the left or right hand air box blanking plate as appropriate from the back plate air box by releasing the three screws Fig 54 2 Rotate the turret to face the selected opening Fig 55 and remove the side bla
12. screw in either direction until the required pressure is obtained 5 Turn the boiler thermostat to the OFF position marked 0 Screw home the pressure test point screw Turn the boiler thermostat knob to the required setting 6 The boiler and system should be run and then flushed and treated in accordance with BS 5793 1992 and the flushing agent inhibitor manufacturers instructions 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 system 7 Make a final check for gas soundness and set any timer control room thermostats etc to the customer s specific requirements 8 The boiler is protected by an integral frost stat but if the boiler is not to be used for a long period of time the system should be drained Burner Pressure Test Point NOTE The frost thermostat operates even if Fig 82 the boiler thermostat is in the OFF position and it is necessary therefore if the system is drained for the external electrical and gas supplies to be isolated It is recommended that a label be affixed to the appliance to draw attention to the fact that the system has been drained WARNING If the system is filled with very cold water and the boiler lit the action of the frost protection thermostat will prevent the boiler Regulator from shutting down before the water temperature reaches 10 C 32 7 0 Fi
13. the mains cables from the cable clamps and unplug the mains connection blocks from the circuit board Fig 101 4 Remove the screw retaining the thermostat control panel and slide the circuit board from the box 5 Carefully withdraw the centre pin from the retaining rivet which then allows the retaining rivet to be removed Remove the thermostat control panel Fig 102 On reassembling ensure the control panel is located over the retaining rivet body before inserting the centre pin 6 Disconnect the plugs from the sockets on the circuit board Fig 103 7 Replace new circuit board in reverse order checking that the connections are correct as shown in the diagram See Electrical Connections section 5 17 of these instructions and that the harness is retained in the strain reliefs 3 10 0 Changing Components EME ignition Electrode Fig 104 1 Disconnect the spark electrode lead at the electrode 2 Unscrew the electrode from the manifold and withdraw the electrode 3 Replace the new electrode in reverse order ensuring that the sleeving is pushed over the end of the electrode EEI Gas Valve Fig 105 1 Disconnect the inlet gas cock union 2 Remove the cover from the front face of the gas valve and remove the electrical connections from the tags on the gas valve Fig 104 3 Disconnect the gas valve by unscrewing the three screws on the top face of the gas manifold If access
14. to these screws is dificult the valve can be removed with the manifold 4 Remove the gas valve being careful not to damage the gasket 5 Fit the new gas valve by re assembling all components in reverse order ensuring that the gasket is properly positioned EQ Thermostat Sensor Fig 106 1 Disconnect the two electrical tags from the sensor 2 Unscrew the sensor from the top flow water connection 3 Screw in the new sensor with the plastic shroud in place as a cover guard Make sure that the Thermostat Clip sensor is fully tightened into the top flow water e connection and connect the two electrical tags either wire can be connected onto either connection there is no polarity Plastic Shroud in place IDE Over Heat Thermostat Figs 106 amp 107 Fig 106 Overheat 1 Disconnect the two electrical tags from the Thermostat overheat thermostat 2 Remove the clip and thermostat from the pipe noting its position Remove the retaining O ring if one is fitted and discard disengage the thermostat from the clip If the clip is a metal one discard and use the plastic clip supplied in the kit 3 Engage the new thermostat in the clip Prise the clip over the flow pipe ensuring it is positioned as previously Connect the two electrical tags to the Orange Leads terminals on the overheat thermostat either wire can be connected onto either terminal there is no 38 polarity 10 0 Changing Components
15. 70 80 364 878 364 879 Manuf rs Part N 231708 231709 30 40 50 60 70 80 364 880 364 881 364 882 364 873 E01 623 364 981 231354 231355 228104 231776 239619 231777 All models 170 558 236142 All models 364 745 225826 All models 364 886 230981 All models 364 588 224183 All models 3 9 033 230068 All models 364 889 230653 All models 364 890 230652 All models 364 891 230817 All models 379 202 231857 All models E03 921 241792 All models 364 892 231402 30 40 50 60 80 up to serial n 8999 364 979 after serial n 9000 170 615 70 from serial n 00001 170 615 229421 229422 23 5 78 23 5 78 All models 379 030 230204 All models 379 031 231711 30 40 50 60 70 80 364 893 364 894 230442 230863 30 40 50 60 70 80 364 895 170 602 230443 229428 30 40 50 60 70 80 364 897 364 898 231406 231429 30 40 50 60 70 80 364 899 364 900 230446 230868 All models 364 901 230439 All models 364 902 230951 All models 379 960 237140 Before starting FAULT FINDING carry out preliminary electrical system checks i e Earth Continuity Polarity Short Circuit and Resistance to Earth START Does pump run Ensure external controls are calling for heat NO
16. C on the efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0086 Product Production certified by Notified Body 0086 Section Page 1 0 Introduction 4 2 0 Technical Data 5 3 0 System Details 7 4 0 Site Requirement 10 5 0 Installation 13 6 0 Commissioning the Appliance 31 7 0 Fitting the Outercase 33 8 0 Overheat Cut Off Device 34 9 0 Annual Servicing 35 8 0 Changing Components 37 9 0 Short Parts List 41 10 0 Fault Finding 42 B S Codes of Practice STANDARD SCOPE B S 6891 Gas Installation B S 5546 Installation of hot water supplies for domestic purposes B S 5449 Forced circulation hot water systems B S 6798 Installation of gas fired hot water boilers B S 5440 Pt 2 Ventilation 1 0 Introduction ERM Description 1 The Baxi Solo 2 PF is a gas fired room sealed fan assisted central heating boiler with range rated outputs as shown in the table below HEAT OUTPUT Min Max 5 86kW 20 000 Btu h 8 79kW 30 000 Btu h 9 09kW 31 000 Btu h 11 72kW 40 000 Btu h 12 02kW 41 000 Btu h 14 65kW 50 000 Btu h 14 95kW 51 000 Btu h 17 58kW 60 000 Btu h 17 88kW 61 000 Btu h 20 5kW 70 000 Btu h 20 8kW 71 000 Btu h 23 45kW 80 000 Btu h 2 Each appliance is preset at a MID RANGE heat input rating and is desi
17. Mark the fixing positions 2 Drill and plug fixing the positions then secure the guard to wall Fig 60 ey 24 4 N M N N N a N N r N Fig 61 Fig 62 Wall Thickness 10 Fig 63 5 0 Installation EXE internal Fitting Kit 1 The internal fitting kit available from merchants free of charge quoting Baxi Part N 226441 is suitable for walls between 100mm 4in and 280mm 11in in thickness 2 TO INSTALL THE KIT Mark the flue hole centre as described in section 5 4 or 5 8 Cut a hole in the masonry approximately 117mm 4 s in diameter for the internal fitting kit The use of a core drill is recommended When using a core drill it is important to keep the drill level and square 3 Measure the wall thickness and from this dimension subtract 10mm s in Fig 61 4 Remove the wall liner from its packing and remove the end piece Fig 62 5 Mark off the dimension wall thickness 10mm 3 s in measuring from the beaded end of the duct and cut off the remaining length of the duct Ensure that the cut is square and reasonably straight Fig 63 25 26 Fig 65 Fig 68 5 0 Installation EARN internal Fitting Kit Cont 6 Refit the end piece to the liner and open out to the thickness of the wall Seal the two pieces together using the tape provided with the kit Fig 64 7 Slide the assembled wall liner into the hole in the
18. Please leave these instructions with the user BaxiSolo 2 PF Wall Mounted Powered Flue Gas Fired Central Heating Unit Installation and Servicing Instructions BAXI HEATING Natural Gas Baxi Solo 2 30 PF G C No 41 077 71 Baxi Solo 2 40 PF G C No 41 077 72 Baxi Solo 2 50 PF G C No 41 077 73 Baxi Solo 2 60 PF G C No 41 077 74 Baxi Solo 2 70 PF G C No 41 075 01 Baxi Solo 2 80 PF G C No 41 077 75 Baxi Heating Ltd is one of the leading manufacturers of domestic heating products in the UK 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 consumers 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 Baxi is a BS EN ISO 9001 Accredited Company The boiler meets requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 N 3083 and is deemed to meet the requirements of Directive 92 42 EE
19. a terminal on the same wall For an opening in a car port e g door window into a dwelling Flue Terminal Dimensions Fig 12 LEN Flue Position Cont WARNING 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 Heating Ltd could invalidate the appliance warranty and infringe the GAS SAFETY Installation and Use REGULATIONS 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 6 Table 2 and the accompanying diagram show the positioning of the flue terminal relative to buildings and other structures 7 The dimensions of the flue terminal are shown in Fig 12 YU Flue Dimensions 1 The standard flue supplied with the appliance is suitable for use with flue lengths between 100mm 4in and 685mm 27in NOTE Maximum flue length when flued to the left or right is 584mm 23in 30 40 50 PF 533mm 21in 60 70 80 PF 2 Flue extension kits are available as an optional extra for installations up to 1 metre 39 s in and up to 2 metres 79 in 2 metre kit is not available for the 70 and 80 PF model 3 A vertical flue kit with flue breaker is also available as an optional extra Sol Ver Kit 4 Where it is intended to pass the flue through a c
20. ault Finding 43 Comp N 230988 Issue 22 11 98 The Baxi Helplines For General Enquiries 44 0 1772 D 95535 For After Sales Service 44 0 1772 695505 For Technical Enquiries 44 0 1772 695504 BAXI Baxi Heating Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www baxiheating co uk
21. cket by releasing the screw Remove the side insulation panel 2 Release the screw securing the pilot hood and remove Carefully remove the pilot injector Fit the new pilot injector ensuring the new sealing washer is in position Tighten the injector fully 3 Re assemble all components in reverse order EDEE Gas Manifold Fig 116 1 Remove the right hand side insulation carrier bracket by releasing the screw Remove the side insulation panel Fig 113 2 Remove the two screws securing the manifold from the inside of the combustion box and slide the manifold forward from under the two rear locating studs 3 Remove valve and ancillary components from manifolds as necessary 4 Replace all ancillary components onto manifold and replace manifold by sliding rear edge backwards under the two rear locating studs and securing from inside the combustion box using the two screws previously removed Ensure that the sealing gasket is properly positioned and undamaged 11 0 Short parts list Description Burner Burner Injector Ignition Pilot Kit Electrode Lead Control Knob Viewing Window Kit Pressure Switch Insulation R H Insulation L H Retaining Brackets Control Valve Overheat Thermostat Fuse Fan Thermostat Sensor Control Board Panel Top Panel Upper Panel Lower Panel Bottom Panel L H Panel R H Potentiometer amp Leads EERI Short Parts List 30 40 50 60
22. ctrical isolation of the appliance 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 Fig 14 Fig 15 5 0 Installation ES initial Preparation 1 Unpack contents of carton 2 Remove the lower door panel from the outer case Remove the 2 screws holding the outer case to the combustion box 3 Place the ready assembled outer case in a safe place until required 4 Release the H clips from the two latches securing the combustion box to the back plate and release the latches Fig 14 5 Lift and remove the combustion box from the back plate Fig 15 Place the combustion box on its back IMPORTANT When installing a Solo 2 with a rear flue see section 5 2 before continuing the installation 6 Proceed to the relevant section for flueing the appliance either to the Rear Left Right or Vertically NOTE For Vertical flueing or flue lengths above the standard 610mm 24 in the relevant optional extra kits must be obtained and their instructions followed 14 Fig 17 Fig 18 Fig 16a Fan Outlet Restrictor 5 0 Installation EEJ Fan Outlet Restrictor 30 40 50 60 70 and 80 Rear Flue only up to 686mm 27 in 1 Release the four latches holding the combustion box door Fig 16a Remove the combustion box door by pulling forward from the b
23. e boiler Turn the boiler thermostat control knob fully anti clockwise to the OFF position marked 0 Fig 88 Wait ten seconds turn the control knob clockwise to the required thermostat setting the red neon goes out the boiler will start automatically 4 No adjustment to the gas controls or main thermostat are required 5 If the overheat thermostat drops out repeatedly refer to the fault finding chart at the rear of this booklet or consult a competent service engineer 9 0 Annual Servicing EX Dismantling the Boiler 1 To ensure its continued safe and efficient operation it is important that the appliance is regularly serviced For location of British Gas service test point see Changing Components section of these instructions 2 Before servicing the boiler please read Section 1 3 Important Information 3 Isolate the electrical supply to the boiler 4 Remove the outer case lower door panel by following the sequence of diagrams Fig 89 5 Remove the outer case from the boiler by unscrewing the two screws and lift the case clear Fig 90 6 Release the four latches holding the combustion box door Fig 91 Remove the combustion box door by pulling forward from the bottom and unhooking its top edge Fig 93 7 Release the 5 pin electrical plug connecting the pressure switch and fan Fig 92 Withdraw the fan assembly by pulling forwards from the top edge Fig 93
24. ealing Washer d 5 Carefully remove the pilot injector Fig 96a E d PF gt Examine and clean it as necessary Do not use a Yi wire or pin to clean the injector orifice Fig 96a 6 Examine the sealing washer Fig 96a and replace if it is damaged in any way Reassemble in reverse order Baffles 80 models only 7 Replace all components in reverse order On Battle 30 40 50 60 70 models refit the rear baffle by a 90 40700 60 70 MOLES holding it at an angle and locating the lower fingers between the heat exchanger and rear insulation Lower it into position as shown Fig 97 8 Check that the seal to the combustion box door is good 9 Re commission the boiler before use checking for gas soundness and ensuring all controls are 36 Fig 97 working correctly Fig 102 Retaining Rivet Centre Pin 10 0 Changing Components EAI Changing Components 1 When changing components ensure that the gas and electrical supplies are isolated before the work is started 2 Before changing any components please read Section 1 3 Important Information 3 Remove the outer case lower door panel Fig 98 4 Remove the outer case from the boiler by unscrewing the two screws and lift the case clear Fig 99 EEJ Replacing the Circuit Board 1 Ensure that the electrical supply is isolated 2 Remove the cover from the front of the controls box Fig 100 3 Release
25. er to the on position the multimeter s audible alarm should now be sounding to indicate continuity Does the main burner light NO Is Burner On light on NO Are live amp neutral reversed Indicator light inside box will be lit Check pilot flame for correct size Check amp clean electrode Check spark gap Check electrode lead Check there is 20mbar gas pressure at the inlet to gas valve Replace PCB YES Does the boiler shut down when the water flow reaches 80 84 C NO YES Check there is 20mbar gas pressure at the inlet to gas valve Is there the correct burner pressure at the test point NO YES Check main injector is not blocked YES Check pilot injector is not blocked YES Check pilot flame size YES Check pilot hood position and pilot air flow YES Check continuity across mains solenoid 5 K OHM NO Change gas valve Warning YES Does pump run on YES Boiler satisfactory Replace sensor Check Potentiometer see table Replace PCB Set pressure regulator Change PCB It is important that both the air and flue ducts are cut to their correct lengths also ensure that the flue duct is fully engaged in the flue terminal Failure to comply with the recommended fitting instructions will adversly affect the operation of the appliance 12 0F
26. gned for use on NATURAL GAS only 3 All boilers are suitable for fully pumped open vented central heating and domestic hot water systems and sealed systems 4 The appliance data badge is fitted to the combustion box door EEB installation 1 The appliance is suitable for installation only in G B and I E and should be installed in accordance with the rules in force For Ireland install in accordance with S 813 INSTALLATION OF Gas APPLIANCES The installation must be carried out by a CORGI Registered Installer or other competent person 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 and the bye laws of the Local Water Undertaking Where no specific instructions are given reference should be made to the relevant BRITISH STANDARD CODES OF PRACTICE 2 All systems must be thoroughly flushed and treated with inhibitor see Section 3 1 EES Important Information This product contains Refractory Ceramic Fibres R C F which are man made vitreous silicate fibres Excessive exposure to these materials may cause tempory 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 mi
27. gth R W 224mm 87s in 6 Mark off the appropriate length from the swaged end of the flue duct Cut the duct to length and dispose of the unwanted length Use the tape provided to give an accurate cutting guide by wrapping it around the flue duct with the edge marking the cutting line Fig 42 7 Take the telescopic air duct from its pack Open the air duct out to the length 30 40 50 PF R W 91mm 39 16 in 60 70 80 PF R W 147mm 53 4 in 8 Using the tape provided seal the joints of the three sections of the air duct ensuring an overlap of at least 30mm 1 e in at each joint Fig 43 NOTE The seams of all three sections must be in line 9 If the wall thickness W plus the distance from the wall to the side of the boiler case R is less than 202mm 8 in it will be necessary to cut the components of the air duct to make up the appropriate size Dispose of the centre section as this is not required Fig 44 30 40 50 PF R W 91mm 3 in 60 70 80 PF R W 147mm 5 s in 10 Engage the sections one inside the other then open the assembly out to wall thickness Tape the sections together using the tape provided ensuring that the seal is good Fig 45 NOTE The seams of both sections must be in line Air Blanking Plate Blanking Cap Box Fig 46 Fig 47 Air Duct Fig 50 Turret 5 0 Installation END Fitting the Flue and Back Plate
28. inuity change pilot solenoid Is there mains at the fan ion Check Potentiometer EORITISeUBR see table NO Replace harness YES Replace fan YES Does the pilot burner light NO Check there is 20mbar gas pressure at the inlet to gas valve Check the pilot injector is not blocked partially blocked or damaged Replace the gas valve Testing Potentiometer Three Pin Connector Set multimeter to the 2 M OHM scale Turn potentiometer to the OFF position connect the multimeter leads to the blue red wire and centre black yellow wire of three pin connector The reading on the multimeter should indicate approx 1 M OHM switch potentiometer to the ON position the reading on the multimeter should be approx 1 M OHM Slowly turn potentiometer knob to the FULL ON position the reading on the multimeter should decrease proportionally down to O OHMs Connect multimeter to centre black yellow wire and red yellow wire turn potentiometer knob to fully OFF position reading on multimeter should be 0 OHM Switch potentiometer to ON position slowly turn potentiometer knob to the fully ON position the reading on multimeter should increase proportionally to 1 M OHM turn potentiometer off Reading on multimeter should indicate 0 OHM Two Pin Connector Check potentiometer is in OFF position Set multimeter to continuity connect multimeter leads to both potentiometer leads Turn potentiomet
29. l is inaccesible from the outside an internal fitting kit is available This can be obtained free of charge from your local merchant 2 The following guide lines indicate the general requirements for siting balanced flue terminals 3 If the terminal is fitted within 1 metre 39in of a plastic 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 in should be left between shield and gutter Fig 11 4 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 5 If the outer surface of an outside wall is of combustible material it should be protected by fitting the flue trim provided 4 0 Site Requirements gt T Ac rTQGnriuo Ou Table 2 X Likely positions requiring a flue terminal guard Terminal Position with Minimum Distance Directly below an openable window or other opening e g an air brick Below gutters Below eaves soil pipes or drain pipes Below balconies or car port roof From vertical drain pipes and soil pipes From internal or external corners Above ground roof or balcony level From a surface facing a terminal From a terminal facing a terminal Vertically from a terminal on the same wall Horizontally from
30. lied This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system risking damage to pump and valves boiler noise and circulation problems e For optimum performance after installation this boiler and its associated central heating system must be flushed in accordance with the guidelines given in BS 5793 1992 Treatment of water in domestic hot water central heating systems This must involve the use of a proprietary cleanser such as BetzDearborn Sentinel X300 or X400 or Fernox Superfloc Full instructions are supplied with the products but for immediate information please contact BetzDearborn 0151 420 9563 or Fernox 01799 550 811 directly For long term protection against corrosion and scale after flushing it is recommended that an inhibitor such as BetzDearborn Sentinel X100 or Fernox MB 1 or Copal is dosed in accordance with the guidelines given in BS 5793 1992 Failure to flush and add inhibitor to the system may invalidate the appliance warranty e tis important to check the inhibitor concentration after installation system modification and at every service in accordance with the manufacturer s instructions Test kits are available from inhibitor stockists For information or advice regarding any of the above contact the Baxi Helpline EP Bypass Requirements 1 The boiler is fitted with a pump overrun device which allows the removal of residual heat
31. line between the two marks The intersection of the vertical and horizontal lines is the centre of the flue hole Fig 38 11 For installations where the flue terminal is inaccessible from the outside an internal fitting kit is available This can be obtained free of charge from your local merchant 12 If using the internal fitting kit a 117mm 4 in diameter hole is required 13 Cut a hole approximately 107mm 4 4 in diameter in the masonry for the 100mm 4 in diameter flue duct Fig 39 Use of a core drill is recommended When using a core drill it is important to keep the drill level and square particularly with the wall onto which the boiler is to be fitted 14 Drill the anchorage holes 63mm 2 in deep to accept suitable wall plugs 20 Fig 40 30 40 50 R W 168mm 60 70 80 R W 224mm 30 40 50 R W 91mm 60 70 80 R W 147mm Wall Thickness 30mm Fig 44 5 0 Installation EE Side Flue Preparation 1 For both Left and Right Hand Flue Measure the distance from the wall to the nearest line marked from the template This will be known as distance R Fig 40 2 Measure the thickness of the wall from the inside This will be known as distance W Fig 41 3 Add these two figures together plus 168mm 65 s in for 30 40 50 PF and 224mm 87 s in for 60 70 80 PF 4 30 40 50 PF Flue Duct Length R W 168mm 65 in 5 60 70 80 PF Flue Duct Len
32. ll light from the pilot flame 12 Check that both the main burner and the pilot are alight by observing through the viewing window The indicator lights should also be illuminated 13 Should this sequence not occur then refer to the fault finding section of these instructions NOTE The pilot rate for this appliance is factory set sealed and therefore non adjustable 31 6 0 Commissioning the Appliance Input Setting Pressure kW Btu h mbar in wg Maximum 10 99 37 500 Minimum 7 33 25 000 XB Commissioning the Appliance Cont 1 From the table opposite check that the main burner pressure is correct after the appliance has been running for 10 minutes Maximum 14 65 50 000 Minimum 11 36 38 750 ks Co gt 29 oe O I l olt oP nt C101 C1 KO Ceo I I Maximum 18 32 62 500 Minimum 15 02 51 250 2 Check for gas soundness with main burner alight using leak detection fluid Maximum 21 98 75 000 Minimum 18 68 63 750 k k C a r C oo oaol oo I I pH C1 oo Jooj os alCalan loan WO RO AD TRO A oR oA AR TARR ORI DA I I ocoo oo oo oo oo oo Maximum 25 64 87 500 Minimum 22 35 76 250 3 If necessary adjustment to main burner pressure can be made by altering the regulator as shown Fig 82 Maximum 29 31 100 000 Minimum 22 35 76 250 MNI NNI NN INNI DNI PYN 4 To alter the burner pressure turn the adjustment
33. nimum 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 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 Model Heat Output Max Heat Output Min kW 25 64 Heat Input Max 10 99 14 65 18 32 21 98 Btu h 87 500 37 500 50 000 62 500 75 000 Heat Input Min kW 7 33 11 36 15 02 18 68 22 35 Btu h 25 000 38 750 51 250 63 750 76 250 16 0 0 5 16 0 0 5 Burner Pressure Max mbar 16 0 0 5 16 0 0 5 16 0 0 5 6 4 0 2 6 4 0 2 6 4 0 2 6 4 0 2 6 4 0 2 in wg Burner Pressure Min mbar 8 0 40 5 10 0 0 5 11 9 280 5 11 9 40 5 12 1 0 5 4 8 0 2 in wg 3 2 20 2 4 0 0 2 4 4 0 2 4 4 0 2 1 74m h 2 78m h Gas Rate CV 38MUm 1 04m h 1 39m h 2 08m h 36 86ft h 49 0ft h 61 3ft h 7 3 5ft h 98 1ft h
34. nking cap by pushing in and turning anti clockwise to release the bayonet fitting Fig 55a 3 Fit the support clamp provided 60mm 2 in from the plain end of the flue tube and tighten with the two screws Fig 56 4 Fit the air duct over the flue duct ensuring that the flue duct locates into position in the terminal end of the air duct 5 Ensuring all seams of the air duct are uppermost engage the air duct into the hole previously cut in the wall and through holes in other partitions cupboards walls etc Ensure that the bayonet ends of the air duct and flue are clear of the previously marked back plate area or that they overhang it by no more than 50mm 2in Ensure that the O ring seal is in position against the sealing flange of the air duct Fig 57 6 Secure the back plate to the wall at the previously drilled anchorage points with suitable screws Before finally tightening the screws check that the assembly is level Fig 57 7 Draw the flue duct towards the back plate air box and locate the swaged end of the flue duct over the bayonet fitting on the turret taking care not to damage the O ring Lock the flue in place by pressing in and turning clockwise 8 Draw the air duct towards the air box on the back plate ensuring that the flue duct is located into position in the terminal end of the air duct Engage the bayonet slots of the air duct over the location lugs of the air box opening and press and
35. nnecting pipe being unrestricted and not less than 15mm 2 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 See Table 1 Further details of sealed system design can be obtained from BS 5449 and the British Gas publication entitled Specifications for Domestic Wet Central Heating Systems 4 FILLING POINT 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 5 MAKE UP SYSTEM 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 6 VENTING A method of venting the system during filling and commissioning must be provided by fitting automatic air vents or by venting manually 7 HOT WATER STORAGE 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 10 Fig 11 Fig 9 Fig 10 Aluminium ERR Location 1 The appliance may be fitted to any suitable wall with the flue passing through
36. ombustible wall or timber framed dwelling reference should be made to British Gas publication DM2 5 If the flue is more than 1 8 metres 707 s in long it is required that it is supported 6 All above dimensions are taken from the respective faces of of the outer case 11 4 0 Site Requirements 90000000000000000000000000000000000000000099 oo 4 0 Site Requirements DEN Ventilation of Compartments 1 Where the appliance is installed in a cupboard or compartment no air vents are required NOTE The ventilation label on the front of the outer case MUST NOT BE REMOVED when the appliance is installed in a compartment or cupboard 2 B S 5440 Part 2 Clause 4 2 refers to room sealed appliances installed in compartments The Solo 2 PF will run sufficiently cool without ventilation EYJ Gas Supply Fig 13 1 The gas installation should be in accordance with BS 6891 2 The connection of the appliance is a RC 2 in BSPT internal located at the rear of the gas COCk 3 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 correctly earthed polarized and in accordance with CURRENT Il E E WIRING REGULATIONS The mains supply is 230V 50Hz fused at 5A NOTE The method of connection to the electricity supply must facilitate complete ele
37. ottom and unhooking its top edge Fig 16 2 Release the 5 pin electrical plug connecting the pressure switch and fan Fig 17 Withdraw the fan assembly by pulling forwards from the top edge Fig 16 3 Take the sheetmetal restrictor Supplied in the kit of parts check that the number stamped on the restrictor matches the appliance e g 50 stamped on the restrictor is for 50 PF appliance 4 Fit the restrictor to the fan outlet flange bending the 3 lugs equally over the flange to secure Fig 18 5 Re assemble the fan assembly and combustion box door 5 0 Installation EER Position the Boiler Fig 19 1 Choose a suitable position for the boiler making necessary allowances for the minimum clearances required as shown in the table below Model A 610 40 50 60 70 80 2 Hold the wall template against the wall at the required boiler location Ensure that the top of the template is level Fig 20 3 The template represents the outer limits of the appliance plus the required minimum side clearance 4 Mark the position of the flue hole centre and the inward pointing corners of the two triangular cutouts in the template Mark the position of the four fixing holes Where possible use the uppermost and lowest fixing hole positions otherwise space the fixing holes as far apart as possible Fig 20 EZI near Flue 1 For installations where the flue terminal is inaccessible from the ou
38. r y or Overheat or Thermostat or bk O or bk o Control r b Potentiometer amp Switch y bk o y r Spark Electrode Spar Hegroe n 28 5 0 Installation Electrical Connections 4 Pressure Switch o 9 A Overheat Thermostat Key Control Potentiometer br brown b blue amp Switch r red w white bk black or orange AL 72 gy grey y yellow g green ja KAT g y green amp yellow a EY or bk orange amp black r b red amp blue y bk yellow amp black y r yellow amp red NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection may be made via a fused double pole isolator with a contact separation of at least 3mm s in in all poles and serving the appliance and system controls only All cables should be routed to avoid hot surfaces WARNING THIS APPLIANCE MUST BE EARTHED 4 core input cable for connection to the appliance must be not less than 0 75mm 24 x 0 2mm PVC grade to IEC 227 code 53 heat resisting External controls and the appliance MUST be supplied via the same isolator NOTE Polarity of the appliance MUST be correct otherwise the appliance will not operate correctly Fig 72 5 0 Installation EXE Making the Electrical Connections 1 Remove the cover from the control box by removing the 2 screws Fig 72 2 Slide the bo
39. rheat thermostat and a venting point Fig 76 4 A copper elbow compression nut and olive are provided in the kit for the return connection NOTE Drain cocks should be fitted to all the system s low points 5 Connect the two electrical tags of the thermostat lead to the connections on the thermostat either wire can be connected onto either connection there is no polarity Fig 76 6 Remove the overheat thermostat and clip from the plastic kit bag Engage the thermostat in the clip as shown Fig 76 Prise the clip over the flow pipe as near to the vent as possible Fig 76 amp 77 7 Connect the two electrical tags from the wiring harness to the terminals on the overheat thermostat Fig 77 either wire can be connected onto either terminal there is no polarity EET Pipe Routes 1 Ensure that any pipework is routed so as to leave the boiler via the spaces at the rear of the outer case either at the top or at the bottom 2 Pipes may be dropped down within the outer case in the spaces between the back plate and the combustion box NOTE It is important that the pipework does not interfere with the correct fitting of the outer case and a space of 14mm clearance must be left between any vertical pipes and the outer edge of the back plate EXAM Gas Connection 1 Connection to the gas supply is RC 2 in BSPT internal located at the rear of the gas cock Fig 78 2 When connecting the gas
40. ternal internal fitting fitting Centre of Layout of Fixing Points 60 70 and 80 PF models 5mm 28 mm 300mm for servicing 5mm during operation Option C Fig 1 Examples of systems which require a bypass are a A system controlled by non electrical valves e g mechanical thermostatic control valves both on the radiators and the hot water circuit b A system using twin zone valves e g Honeywell S Plan Fig 3 C A system using a 3 port divertor valve Fig 4 does not normally require a bypass therefore this system is recommended The exception to this is where thermostatic radiator valves are used and then a bypass is required The bypass circuit can be a For 30 40 50 PF a minimum of 8 metres of 22mm pipe for 60 70 80 PF a minimum of 8 metres of 28mm pipe measured between the boiler flow and return connections It should be fitted with a lock shield valve opened at least 1 full turn to give a minimum flow rate of 8 litres min 1 8 gal min Option C Fig 1 amp Option A Fig 2 b A radiator fitted with lock shield 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 4 sq ft is adequate Option B Fig 1 C Any circuit that provides the same operating conditions as option A or option B Figs 1 amp 2 T Radiator Circuit A mT
41. tinuing with the installation See section 5 15 Internal Fitting Kit of these instructions 1 The procedure for fitting the appliance flued to the left or right hand side is the same 2 30 40 50 PF Left Right Hand Side maximum flue 584mm 23 in 3 60 70 80 PF Left Right Hand Side maximum flue 533mm 21 in 4 Using the previously marked flue hole centre and the two marks made at the triangular cutouts of the template mark the horizontal centre line for the flue assembly Fig 34 5 Extend this line either left or right as required to the corner of the room Fig 34 6 Extend the horizontal centre line around the corner for approximately 300mm 12 in Ensure that the line remains horizontal by checking with a spirit level Fig 35 7 From the wall template remove the detachable section outlined and marked Using this as a template line up the horizontal triangular cut outs with the extended 300mm 12 in line and make sure that the flat of the template is butted up against the corner of the wall Fig 36 8 If the appliance mounting wall is out of true use string or a straight edge to determine the true corner position and mark a vertical line to accommodate the flat edge of the template 9 Holding the template firmly mark the vertical centre line for the flue assembly by marking the point at the outer corners of the upper and lower cut outs Fig 37 10 Remove the template and draw a vertical
42. tling reconnect the new fan wires into the connections on the electrical plug either wire can be connected into either connection Sensing Tube KE Pressure Switch Fig 112 oy Grey S ae 1 Disconnect sensing tube emm uu Black e 2 Remove the screw securing the pressure switch to its bracket and unhook the pressure switch 3 Disconnect the 3 electrical terminals from the pressure switch Note the position of the tags before removal and reconnect in correct order Fig 112 4 Fit new pressure switch and re assemble all components in reverse order of dismantling ensuring that the electrical terminals are connected to their correspondingly marked tags 39 40 Fig 114 Fig 116 60 70 amp 80 PF Models Only Co A 26 gt Pilot Hood y Pilot Injector pe x lt Sealing Washer Fig 115 a TOM OK Changing Components EAJ Burner Fig 113 1 Remove the burner assembly by pulling it forward 2 Fit new burner and re assemble all components in reverse order of dismantling EAEN Burner Injector Fig 114 1 Release and remove the burner injector which is screwed into the burner feed manifold 2 Fit the new burner injector ensuring that the copper washer is in position Tighten the injector fully 3 Re assemble all components in reverse order EQ SPY Pilot Burner Injector Fig 115 1 Remove the right hand side insulation carrier bra
43. tside an internal fitting kit is available This can be obtained free of charge from your local merchant quoting Baxi Part N 226441 2 If using the internal fitting kita 117mm 45 s in diameter hole is required 3 Drill the anchorage holes 63mm 2 2 in deep to accept suitable wall plugs Fig 21 4 Using the previously marked flue hole centre cut a hole approximately 107mm 4 4 in diameter in the masonry for the 100mm 4 in diameter flue duct When using a core drill it is important to keep the drill level and square Fig 22 Fig 23 Wall Thickness 30mm Fig 25 EG Rear Flue Preparation 1 Measure the wall thickness Fig 22 and to this dimension add 60mm 2 s in 2 Take the flue duct and mark off wall thickness 60mm 23 s in from the swaged end of the duct and cut to size Fig 23 Use the tape provided to give an accurate cutting guide by wrapping it around the flue duct with the edge marking the cutting line 3 Wall Thickness 280mm 685mm 11in 27in Take the telescopic air duct from its pack Open the air duct out to the wall thickness Using the tape provided seal the joints of the three sections of the air duct ensuring an overlap of at least 30mm 1 in at each joint Fig 24 NOTE The seams of all three sections must be in line 4 Wall Thickness 100mm 280mm 4in 11in If the wall thickness is less than 280mm 11 in it will be necessar
44. tting the Outercase Fitting the Outercase 1 The warning label may be removed unless the boiler is to be fitted within a cupboard 2 Taking the ready assembled outercase the front door of which has already been removed proceed as follows 3 If the appliance is flued to the left or to the right remove the relevant infill panel by removing the retaining clips and fixing screws Fig 83 4 Offer the outer case up to the hooks on the top of the back plate Fig 85 5 Ensure that the outer case is located over the lower tabs on the back plate on both sides Fig 86 6 Using the two screws previously removed secure the outer case to the combustion box Fig 84 7 Replace the lower front door panel 8 Instruct the user in the operation of the boiler controls Hand over both the Users Operating and Installation Instructions giving advice on the necessity of regular servicing Fig 85 e q99999000009000900000000009090000000000000090009009000000009000000000900000000000000009 amp Fig 86 33 Overheat O Overheat Neon Warning 34 Boiler On O Fig 88 Burner On O O 8 0 Overheat Cut off Device EX Operation 1 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 2 Remove the lower door panel by following the sequence of diagrams Fig 87 3 To reset th
45. ture above freezing NOTE The frost thermostat operates even if the boiler thermostat is in the OFF 0 position and it is necessary therefore if the system is drained for the external electrical and gas supplies to be isolated It is recommended that a label be affixed to the appliance to draw attention to the fact that the system has been drained ENS Low Head Installation For boilers up to 50 000 Btu h output 1 Using a close couple arrangement the minimum head is as shown in the diagrams Figs 5 amp 6 subject to the following conditions a The correct heat input b The pump being adjusted to give an 11 C drop across the boiler c The pump must be fitted on the flow d The pump must be fitted in accordance with the pump manufacturer s instructions e 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 PF Fig 7 2 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 3 Litre Ai Top Up Bottle if required Vent uereg Filling s Pressure Point alely Gauge pe ae Valve x Pump ii Expansion Radiator Vessel Circuit i System Drains at Low Point Max Boiler Flow Fig 8 Temp 82 C Method of determining minimum value of expansion
46. turn clockwise to secure the air box to the air duct 9 n order to increase security of the flue the bayonet tags may be deformed to secure the flue in position 10 Make good between the wall and the air duct inside and outside the building if the internal fitting kit has not been used Fig 58 11 The flue trim provided may be fitted if required to neaten up the make up around the terminal This plate may also be used as a protection plate on outside walls of combustible material Fit the trim over the flue terminal and mark through the four securing holes Remove the trim drill holes 63mm 2 2 in deep to accept suitable wall plugs Fit the trim over the flue terminal and secure using suitable screws Fig 59 23 5 0 Installation EREN Terminal Guard 1 When codes of practice dictate the use of terminal guards they can be obtained from most plumbers and builders merchants nationwide 2 When ordering a terminal guard quote the appliance model number 3 The guard manufacturers listed below can be contacted for terminal sizes and guard model numbers Tower Flue Components Ltd Tower House Vale Rise Tonbridge Kent Tel 01732 351555 Quinnell Barrett amp Quinnell 884 Old Kent Road London SE15 1NL Tel 0171 639 1357 ESEI Fitting a Terminal Guard Fig 60 1 Position the guard over the terminal on the outside wall Ensure the guard is equally spaced about the terminal
47. vessel volume for sealed systems using Baxi Boilers Multiply Total Water Content Of System By Litres Vessel Charge Pressure Bar Initial System Pressure Bar Example Volume 75 litres Vessel Charge Pressure 1 0 bar Initial System Pressure 1 5 bar Then 75 x 0 152 11 4 litres Expansion Vessel Volume Table 1 NOTE Where a vessel of the calculated size is not obtainable then the next available larger size should be used 3 0 System Details ECHO Sealed Systems Fig 8 1 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 2 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 3 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 co
48. wall until the tags stop against the inner wall with the seam of the liner uppermost Mark the positions of the holes in the tags on the wall and then rotate liner so that tags reveal marks Fig 65 8 Drill and plug the wall in these positions Fig 66 9 Rotate liner back until the tags align with the holes drilled and secure it to the wall using suitable screws Fig 67 10 Make good between the edge of the liner and the outside wall with cement mortar or a similar substance by reaching through the liner and pressing the mortar between liner and the outside brick work Fig 68 Make good between the liner and the inside wall Apply soap solution to the O ring inside the liner 11 The rest of the installation may now proceed as described 5 0 Installation ESTE Fitting the Combustion Box 1 Offer up the combustion box to the back plate and locate the rear bottom edge of the combustion box onto the self locating support at the base of the wall plate Fig 69 2 Swing the top of the combustion box backwards against the top air box Fig 70 3 Engage the two retaining latches and secure with the R clips previously removed Fig 71 2 Spark Electrode CC s Thermostat Sensor 7 Ke 230V ue EE seo Main Gas Valve e O o Pilot Gas Valve r Jt N Fan br b gt N Pressure Switch W Schematic Wiring bk Diagram o y O Thermostat Senso
49. x forward for easier access 3 The terminal strips may be removed by carefully pulling them forward Connect the supply cable and the pump cable to the terminal strips Fig 74 IMPORTANT When installing in conjunction with a thermal store or heat store please refer to the store manufacturers installation instructions when wiring the boiler 4 The pump must be connected to the boiler terminals 5 A permanent live must be connected to the L terminal 6 The switched live must be connected to the S L terminal 7 Clamp the cables in the grips provided Ensure that the lengths of the supply cables are such that the current carrying wires become taut before the earth wires if the cable should pull out of the cable clamp Fig 73 8 Tuck the cables under the box and clip to the wall where necessary Make sure sufficient slack is left to allow the box to slide forward for future access 9 A cable clip is provided in the base of the box 29 Boiler Thermostat Fig 76 Overheat Thermostat Orange Leads 009900000000000000090000000000900000000000000009099 30 5 0 Installation ERE Water Connections 1 The boiler has two side water connections the top connection being FLOW and the bottom connection being RETURN Fig 75 2 Itis essential that FLOW and RETURN pipes are connected to the correct fittings 3 The top flow connection incorporates the boiler thermostat ove
50. y to cut the components of the air duct to the appropriate size Dispose of the centre section as this is not required Fig 25 5 Measure the wall thickness and subtract 30mm 13e in from this dimension Cut the remaining sections to this length measuring from the positions indicated in the diagram Fig 25 6 Engage the sections one inside the other then open the assembly out to wall thickness Tape the sections together using the tape provided ensuring that the seal is good Fig 26 NOTE The seams of both sections must be in line 5 0 Installation Rear Air Box Blanking Plate Fig 27 Fig 28 Blanking Cap Fig 30 Air Duct 5 0 Installation EC Assembly of Rear Flue 1 Remove the rear air box blanking plate from the back plate by releasing the three screws Fig 27 2 Remove the blanking cap at the rear of the turret by pushing and turning anti clockwise to release the bayonet fitting Fig 28 3 Locate the swaged end of the flue duct over the bayonet fitting on the turret taking care not to damage the O ring Lock the flue duct in place by pressing in and turning clockwise Fig 29 4 Ensure all seams of the air duct sections are uppermost and that the O ring seal is in position against the sealing flange 5 Fit the air duct over the flue duct and draw towards the back plate ensuring that the flue duct locates into position in the terminal end of the air duct
Download Pdf Manuals
Related Search