Baxi Solo 3 30 PF, Installation And Servicing Instructions

Page 1: ...Baxi Solo 3 PF Wall Mounted Powered Flue Gas Fired Central Heating Unit Installation and Servicing Instructions Please leave these instructions with the user ...

Page 2: ...fied customers mean continued success We hope you get a satisfactory service from Baxi If not please let us know Natural Gas Baxi Solo 3 30 PF G C No 41 075 04 Baxi Solo 3 40 PF G C No 41 075 05 Baxi Solo 3 50 PF G C No 41 075 06 Baxi Solo 3 60 PF G C No 41 075 07 Baxi Solo 3 70 PF G C No 41 075 08 Baxi Solo 3 80 PF G C No 41 075 09 Baxi is a BS EN ISO 9001 Accredited Company The boiler meets requ...

Page 3: ...Site Requirement 10 5 0 Installation 14 6 0 Commissioning the Appliance 32 7 0 Fitting the Outercase 34 8 0 Overheat Cut Off Device 35 9 0 Annual Servicing 36 10 0 Changing Components 38 11 0 Fault Finding 42 12 0 Short Parts List 44 13 0 Notes 45 Section Page Contents ...

Page 4: ...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 current BRITISH STANDARD CODES OF PRACTICE 2 All systems must be thoroughly flushed and treated with inhibitor see Section 3 1 1 3 Important Information M...

Page 5: ... 1 04m3 h 1 39m3 h 1 74m3 h 2 08m3 h 2 43m3 h 2 78m3 h after 10 mins 36 86ft3 h 49 0ft3 h 61 3ft3 h 73 5ft3 h 86 75ft3 h 98 1ft3 h Lifting Weight kg 23 1 23 1 23 1 32 2 32 2 32 2 lbs 51 51 51 71 71 71 Water Content litres 1 1 1 1 1 1 1 6 1 6 1 6 pints 1 9 1 9 1 9 2 8 2 8 2 8 Outercase Height 600mm 600mm 600mm 600mm 600mm 600mm Dimensions Width 350mm 350mm 350mm 462mm 462mm 462mm Depth 287mm 287mm ...

Page 6: ...21416182022 Water Flow Rate litres min Pressure Drop mbar in wg 242628 30 52 130 30 40 and 50 PF models 60 70 and 80 PF models Templates Hydraulic Resistance Charts This appliance is only intended for installation on a governed supply PMS 3 bar pressure class 2 Max CH water pressure 3 bar Type C12 C32 C52 Nox class 2 Appliance category I2H 2H G20 20mbar Ref 86 AU 588 Burner Injector Sizes 30 B12 4...

Page 7: ...ly 8 minutes Drain cocks should be fitted to all system low points 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...

Page 8: ...nd 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 3 5 Low Head Installation For boilers up to 50 000 Btu h output 1 Using a close coupled arrangement the minimum head is as shown in the diagrams Figs 5 6 subject to...

Page 9: ...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 poi...

Page 10: ...round 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 3 16 in is required when the door is closed 4 3 Flue Position 1 For installations where the flue terminal is inaccessible from the outside an internal fitting kit is available This ...

Page 11: ...in NOTE Maximum flue length when flued to the left or right is 410mm 16in 30 40 50 PF 355mm 14in 60 70 80 PF 4 Where it is intended to pass the flue through a combustible wall or timber framed dwelling reference should be made to the Institute of Gas Engineers document UP7 Guide for Gas Installations in Timber Framed Dwellings 5 If the flue is more than 1 metre 39 in long it is required that it is...

Page 12: ...connection of the appliance is a RC1 2 1 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 4 7 Electrical Supply External wiring must be correctly earthed polarized and in accordance with CURRENT I E E WIRING REGULATIONS The mains supply is 23...

Page 13: ...s Twin Flue Pipes Air Duct Flue Duct 45 bend 1 3 metres 3 3 metres 90 bend 4 8 metres 12 0 metres 5 The illustrations opposite show examples of maximum equivalent lengths 6 Full details of part numbers and descriptions of all optional flue components and kits can be found in Baxi Gas Central Heating Boilers Installers Guide 7 Instructions for guidance and fitting are included in each kit IMPORTANT...

Page 14: ... box to the back plate and release both 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 3 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 len...

Page 15: ...tal 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 ensuring the restrictor seals against the fan outlet flange Fig 19 5 Re assemble the fan assembly and combustion box door ensuring that the flexible tubes fr...

Page 16: ...erwise space the fixing holes as far apart as possible Fig 20 5 4 Rear Flue Concentric flue kits are available to allow 3 metres horizontal and 4 metres vertical flueing Twin flue at 80mm diameter will allow up to 15 metres vertical flueing 1 For installations where the flue terminal is inaccessible from the outside an internal fitting kit is available This can be obtained from your local merchant...

Page 17: ...ly and measure from the terminal end the wall thickness and subtract 40mm Fig 23a Cut the waste off the plain end Wall Thickness 40mm all boilers 3 The cardboard support should be installed onto the flue tubes to ensure the assembly is supported during cutting Fig 25 26 4 Measure the same amount from the flange end of the Air Duct and cut the waste off the plain end Fig 24 Wall Thickness 40mm all ...

Page 18: ...nd turning clockwise Fig 28 4 Engage the bayonet slots of the air duct over the location lugs on the back plate opening and press and turn clockwise to secure the air duct to the back plate Fig 29 5 In order to increase security of the flue the bayonet tags may be deformed to secure the flue in position 6 Take the flue terminal assembly and engage on the flue and air ducts Slide the flues together...

Page 19: ...tting kit has not been used Fig 32 4 The flue trim provided may be fitted if required to neaten the make up around the terminal Fig 33 5 To fit the flue terminal trim a The trim should be fitted once the flue is secure b Take the three edge clips from the kit and fit them equi spaced onto the inner flange of the trim Fig 32a c With the flanges towards the wall pass the trim over the terminal If re...

Page 20: ...ection 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...

Page 21: ...below from the flared end Cut the waste off the plain end Fig 42 Wall Thickness X 90mm 30 40 50 PF Wall Thickness X 145mm 60 70 80 PF 5 Take the Flue Terminal Assembly and measure from the terminal end the dimension below Fig 43 Cut the waste off the plain end Wall Thickness X 50mm 30 40 50 PF Wall Thickness X 105mm 60 70 80 PF 6 Measure the same amount from the flange end of the Air Duct and cut ...

Page 22: ... fitting Fig 46 3 Locate the flared 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 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 Engage the bayonet slots of the air duct ov...

Page 23: ...ing kit has not been used Fig 52 10 The flue trim provided may be fitted if required to neaten the make up around the terminal Fig 53 11 To fit the flue terminal trim a The trim should be fitted once the flue is secure b Take the three edge clips from the kit and fit them equi spaced onto the inner flange of the trim Fig 52a c With the flanges towards the wall pass the trim over the terminal If re...

Page 24: ...that the assembly is level 7 Take the flue terminal assembly and pass through the cut hole from outside Engage on the flue and air ducts Slide the flues together to the desired wall thickness tape the outer duct sections together with the tape provided ensuring a good seal is made 8 In order to increase security of the flue the bayonet tags may be deformed to secure the flue in position 9 Make goo...

Page 25: ...minal guard quote the appliance name and model number 3 There must be a clearance of at least 50mm between any part of the terminal and the guard 5 14 Fitting a Terminal Guard Fig 61 1 Position the guard over the terminal on the outside wall Ensure the guard is equally spaced about the terminal Mark the fixing positions 2 Drill and plug fixing the positions then secure the guard to wall Fig 61 ...

Page 26: ...eter 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 3 8 in Fig 62 4 Remove the wall liner from its packing and remove the end piece Fig 63 5 Mark off the dimension wall thickness 10mm 3 8 in measuring from the beaded end of the duct and ...

Page 27: ... liner so that tags reveal marks Fig 66 8 Drill and plug the wall in these positions Fig 67 9 Rotate liner back until the tags align with the holes drilled and secure it to the wall using suitable screws Fig 68 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...

Page 28: ...locate the rear bottom edge of the combustion box onto the self locating support at the base of the wall plate Fig 70 2 Swing the top of the combustion box backwards against the top air box Fig 71 3 Engage the two retaining latches and secure with the R clip previously removed Fig 72 Fig 71 Fig 70 Fig 72 ...

Page 29: ...UST be supplied via the same isolator NOTE Polarity of the appliance MUST be correct otherwise the appliance will not operate correctly or b r g y w br b gy bk w y y or bk y r y bk r b or or g w bk gy br b Pump N Main Gas Valve Pilot Gas Valve Fan Pressure Switch Thermostat Sensor Overheat Thermostat Control Potentiometer Switch Spark Electrode N N N External Controls S L L 230V L b r b or b br gy...

Page 30: ... 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 74 8 Tuck the cables ...

Page 31: ...e ribs on the clip Connect the electrical tags to the thermostats The overheat thermostat has the larger terminals The thermostats have no polarity either tag can go on either terminal Ensure that the area of the flow pipe to which the thermostats are fitted is free of excess solder and debris 5 20 Pipe Routes 1 Ensure that any pipework is routed so as to leave the boiler via the spaces at the rea...

Page 32: ...uge 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 10 seconds the ignition spark will commence 11 The sparking will continue until the pilot ligh...

Page 33: ...ostat 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...

Page 34: ...s 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...

Page 35: ...reset the 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...

Page 36: ...oning and Service Record Log Book This should be in the possession of the user 4 Isolate the electrical supply to the boiler 5 Remove the outer case lower door panel by following the sequence of diagrams Fig 89 6 Remove the outer case from the boiler by unscrewing the two screws and lift the case clear Fig 90 7 Release the four latches holding the combustion box door Fig 91 Remove the combustion b...

Page 37: ...lectrode from the manifold and withdraw the electrode Fig 96 3 Remove the right hand side insulation carrier bracket by releasing the screw Remove the side insulation Fig 94 4 Release the screw securing the pilot hood and remove Fig 96a 5 Carefully remove the pilot injector Fig 96a Examine and clean it as necessary Do not use a wire or pin to clean the injector orifice 6 Examine the sealing washer...

Page 38: ...bles 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 loc...

Page 39: ...ags from the sensor 2 Prise the clip and sensor off the flow manifold 3 Clip the new sensor to the manifold and reconnect the wires Either wire can be connected to either spade terminal there is no polarity 10 6 Over Heat Thermostat Figs 106 107 1 Disconnect the two electrical tags from the overheat thermostat 2 Cut off the cable tie securing the clip to the pipe 3 Prise the clip and thermostat fr...

Page 40: ...models only When fitted unbend the tabs securing the fan outlet restrictor to the outlet flange on the original fan 6 Fit the outlet restrictor to the new fan outlet flange Bend the tabs over the flange to secure the restrictor 7 Fit the new fan and re assemble all components in reverse order of dismantling reconnect the new fan wires into the connections on the electrical plug either wire can be ...

Page 41: ...he new pilot injector ensuring the new sealing washer is in position Tighten the injector fully 3 Re assemble all components in reverse order 10 13 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 forw...

Page 42: ...pipes for leaking or blockage Note Under cold conditions fan run up time may exceed 1 min Ensure external controls are calling for heat Does pump run Is Pilot On light on Is lockout light on Is Boiler On light on Is there mains voltage at P L input Is there mains at the fan connection Is there continuity across the overheat thermostat YES NO YES YES YES YES YES NO YES YES NO NO NO NO NO YES YES YE...

Page 43: ...heck pilot hood position and pilot air flow Check continuity across mains solenoid 5 K OHM Change gas valve NO Change PCB YES 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 ...

Page 44: ... 745 225826 90 Control Knob All models 364 886 230981 42 Viewing Window Kit All models 364 588 224183 34 Insulation R H All models 364 889 230653 33 Insulation L H All models 364 890 230652 35 Retaining Clips All models 364 891 230817 77 Gas Valve All models E24 690 245122 98 Overheat Thermostat All models E03 921 241792 84 Fuse All models 364 892 231402 64 Fan 30 40 50 E26 180 246051 60 70 80 E26...

Page 45: ...13 0 Notes 45 ...

Page 46: ...13 0 Notes 46 ...

Page 47: ...ts 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 47 ...

Page 48: ...Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www baxi com After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Comp No 244096 Iss 5 4 01 ...