Baxi Solo 3 PFL 30, Installation & Servicing Instructions Manual

Page 1: ...axi Solo 3 PFL Range Wall Mounted Powered Flue Gas Fired Central Heating Units Installation Servicing Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping ...

Page 2: ...of hot water supplies for domestic purposes BS 5449 Part 1 Forced circulation hot water systems BS 7593 Treatment of water in domestic hot water central heating systems IMPORTANT The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty In GB this could also in...

Page 3: ...etails 7 4 0 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: ...given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Read the instructions before installing or usin...

Page 5: ... 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 287mm 287mm 287mm 287mm Flue Terminal Diameter 100mm Dimensions Depth 70mm Static Head Max 30 metres 100 ft Min 1 metre 3 25 ft Connections Flow 22mm Cu tail Ret...

Page 6: ... 2 4 6 8 10121416182022 Water Flow Rate litres min Pressure Drop mbar in wg 242628 30 52 130 30 40 and 50 models 60 70 and 80 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 1 Appliance category I2H 2H G20 20mbar Ref 86 AU 588 Burner Injector Sizes 30...

Page 7: ... 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 All gas and water pipes and electrical wiring must be installed in a way which would not restrict the ser...

Page 8: ...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 3 5 Low Head Installation For boilers up to 50 000 Btu h output 1 Using a close coupled ...

Page 9: ...sted double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment Your attention is drawn to for GB Guidance G24 2 and recommendation R24 2 of the Water Regulati...

Page 10: ...uired 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 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 interna...

Page 11: ...ng 5 If the flue is more than 1 metre long it is required that it is supported 6 All above dimensions are taken from the respective faces of the outer case Table 2 Fig 13 Fig 12 Maximum lengths for side flues using the standard telescopic flue kit 410mm 30 40 50 410mm 30 40 50 355mm 60 70 80 355mm 60 70 80 Terminal Position with Minimum Distance mm Aa Directly below an opening air brick opening wi...

Page 12: ...s 2 The 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 the relevant regulations rules In GB this is th...

Page 13: ...r equivalent lengths are Concentric Pipes 45 bend 0 5 metres 90 bend 1 0 metres 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 Instructions for guidance and fitting are included in each kit IMPORTANT All flue systems must be securely supported at least once every metre Suitab...

Page 14: ... combustion box to the back plate and release both latches Fig 15 5 Lift and remove the combustion box from the back plate Fig 16 Place the combustion box on its back IMPORTANT When installing a Solo 3 PFL 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 flue...

Page 15: ...e kit of parts check that the number stamped on the restrictor matches the appliance e g 50 stamped on the restrictor is for PFL 50 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 20 5 Re assemble the fan assembly and combustion box door ensuring that the flexible tubes from the fan unit to the press...

Page 16: ...positions otherwise space the fixing holes as far apart as possible Fig 22 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 l...

Page 17: ...erminal Assembly and measure from the terminal end the wall thickness and subtract 40mm Fig 26 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 28 29 4 Measure the same amount from the flange end of the Air Duct and cut the waste off the plain end Fig 27 Wall Thickn...

Page 18: ...pressing in and turning clockwise Fig 31 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 32 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 f...

Page 19: ...he internal fitting kit has not been used Fig 35 4 The flue trim provided may be fitted if required to neaten the make up around the terminal Fig 37 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 36 c With the flanges towards the wall pass the trim over the t...

Page 20: ...ut the D shaped section 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 41 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 t...

Page 21: ...mension below from the flared end Cut the waste off the plain end Fig 48 Wall Thickness X 90mm 30 40 50 models Wall Thickness X 145mm 60 70 80 models 5 Take the Flue Terminal Assembly and measure from the terminal end the dimension below Fig 49 Cut the waste off the plain end Wall Thickness X 50mm 30 40 50 models Wall Thickness X 105mm 60 70 80 models 6 Measure the same amount from the flange end ...

Page 22: ...e the bayonet fitting Fig 53 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 55 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 th...

Page 23: ... internal fitting kit has not been used Fig 58 10 The flue trim provided may be fitted if required to neaten the make up around the terminal Fig 60 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 59 c With the flanges towards the wall pass the trim over the t...

Page 24: ... screws check 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 posit...

Page 25: ...rdering a terminal 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 68 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 wa...

Page 26: ... 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 3 8 in Fig 69 4 Remove the wall liner from its packing and remove the end piece Fig 70 5 Mark off the dimension wall thickness 10mm 3 8 in measuring from the beaded end of the duct...

Page 27: ...d then rotate liner so that tags reveal marks Fig 73 8 Drill and plug the wall in these positions Fig 74 9 Rotate liner back until the tags align with the holes drilled and secure it to the wall using suitable screws Fig 75 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 an...

Page 28: ...ck plate and locate the rear bottom edge of the combustion box onto the self locating support at the base of the wall plate Fig 77 2 Swing the top of the combustion box backwards against the top air box Fig 78 3 Engage the two retaining latches and secure with the R clip previously removed Fig 79 Fig 78 Fig 77 Fig 79 ...

Page 29: ...e appliance MUST 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...

Page 30: ... 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 81 8 Tuc...

Page 31: ...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 ...

Page 32: ...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 8 Turn the boiler thermostat control knob fully anti clockwise to the OFF position marked 0 Fig 88 9 Ensure that the electricity supply is turned ON and set any external controls to the ON position 10 Turn the boiler thermostat knob fully clockwise 11 ...

Page 33: ...TE The frost thermostat operates even if 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 a...

Page 34: ...ng the retaining clips and fixing screws Fig 91 4 Offer the outer case up to the hooks on the top of the back plate Fig 93 5 Ensure that the outer case is located over the lower tabs on the back plate on both sides Fig 94 6 Using the two screws previously removed secure the outer case to the combustion box Fig 92 7 Replace the lower front door panel 8 Instruct the user in the operation of the boil...

Page 35: ... Fig 95 3 To reset the boiler Turn the boiler thermostat control knob fully anti clockwise to the OFF position marked 0 Fig 96 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 ...

Page 36: ...chmark Commissioning Checklist at the rear of this publication and then hand it back to 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 97 6 Remove the outer case from the boiler by unscrewing the two screws and lift the case clear Fig 98 7 Release the four latches holding the combustion box door Fig 99 Remov...

Page 37: ... 2 Unscrew the electrode from the manifold and withdraw the electrode Fig 105 3 Remove the right hand side insulation carrier bracket by releasing the screw Remove the side insulation Fig 103 4 Release the screw securing the pilot hood and remove Fig 106 5 Carefully remove the pilot injector Fig 106 Examine and clean it as necessary Do not use a wire or pin to clean the injector orifice 6 Examine ...

Page 38: ...se the mains cables from the cable clamps and unplug the mains connection blocks from the circuit board Fig 111 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 112 On reassembling ensure the contr...

Page 39: ... Check Burner pressure is 16mbar 0 5 See section 6 1 paragraph 2 if burner pressure needs adjusting 10 5 Thermostat Sensor Fig 116 1 Disconnect the two electrical tags from the sensor 2 Prise the clip and sensor off the flow manifold 3 Clip the new sensor to the pipe and reconnect the wires Either wire can be connected to either spade terminal there is no polarity 10 6 Over Heat Thermostat Figs 11...

Page 40: ...ed 5 60 70 80 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 eithe...

Page 41: ...jector 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 10 13 Gas Manifold Fig 127 1 Remove the right hand side insulation carrier bracket by releasing the screw Remove the side insulation panel Fig 124 2 Remove the two screws securing the manifold from the inside of the combustion box and slide the m...

Page 42: ...ssure switch 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 ...

Page 43: ... YES YES YES YES Check 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 ...

Page 44: ...36142 100 Electrode Lead All models 364 745 225826 90 Control Knob All models 364 886 230981 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 5106746 84 Fuse All models 364 892 231402 64 Fan 30 40 50 E26 180 246051 60 70 80 E26 213 246052 94 T...

Page 45: ... Baxi Heating UK Ltd 2009 13 0 Notes 45 ...

Page 46: ...h t i w e c n a d r o c c a n i d e l l a t s n i n e e b s a h n i a r d e t a s n e d n o c e h T ALL INSTALLATIONS O C g n i w o l l o f e h t d r o c e r r e r u t c a f u n a m e h t y b d e r i u q e r f I 2 OR CO ppm OR CO CO2 Ratio s e Y s n o i t a l u g e R g n i d l i u B e t a i r p o r p p a e h t h t i w s e i l p m o c m e t s y s r e t a w t o h d n a g n i t a e h e h T s e Y s n ...

Page 47: ...phone Number Comments Signature SERVICE 9 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 2 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 4 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature...

Page 48: ...cal Enquiries 0844 871 1555 Website www baxi co uk e oe All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request ...