Installation & Servicing Instructions Baxi Solo 3 PFL Range Wall Mounted Powered Flue Gas Fired Central Heating Units These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping.
Natural Gas Codes of Practice, most recent version should be used Baxi Solo 3 PFL 30 G.C.No. 41 075 20 In GB the following Codes of Practice apply: Standard Scope BS 6891 Gas Installation. BS 5546 Installation of hot water supplies for domestic purposes. BS 5449 Part 1 Forced circulation hot water systems. BS 6798 Installation of gas fired hot water boilers. BS 5440 Part 1 Flues. BS 5440 Part 2 Ventilation. BS 7593 Treatment of water in domestic hot water central heating systems.
Contents Section © Baxi Heating UK Ltd 2009 Page 1.0 Introduction 4 2.0 Technical Data 5 3.0 System Details 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.
1.0 Introduction 1.1 Description 1. The Baxi Solo 3 PFL is a gas fired room sealed fan assisted central heating boiler with outputs as shown in the table below Model 30 40 50 60 70 80 Heat Output 8.79kW (30,000 Btu/h) 11.72kW (40,000 Btu/h) 14.65kW (50,000 Btu/h) 17.58kW (60,000 Btu/h) 20.5kW (70,000 Btu/h) 23.44kW (80,000 Btu/h) 2. Each appliance is preset at a heat input rating and is designed for use on NATURAL GAS only. 3.
2.0 Technical Data Model 30 40 50 60 70 80 kW 8.79 11.72 14.65 17.58 20.5 23.44 Btu/h 30,000 40,000 50,000 60,000 70,000 80,000 kW 10.99 14.65 18.32 21.98 25.64 29.31 Btu/h 37,500 50,000 62,500 75,000 87,500 100,000 mbar 16.0 ±0.5 16.0 ±0.5 16.0 ±0.5 16.0 ±0.5 16.0 ±0.5 16.0 ±0.5 in wg 6.4 ±0.2 6.4 ±0.2 6.4 ±0.2 6.4 ±0.2 6.4 ±0.2 6.4 ±0.2 1.04m3/h 1.39m3/h 1.74m3/h 2.08m3/h 2.43m3/h 2.78m3/h 36.86ft3/h 49.0ft3/h 61.3ft3/h 73.5ft3/h 86.75ft3/h 99.
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3.0 System Details 3.1 Option B Water Circulating Systems 1. The appliance is suitable for use with open vent fully pumped systems and sealed systems where additional control protection is required. The following conditions should be observed on all systems: Option C Radiator Circuit • 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.
3.0 System Details Copper 0.5m Copper 0.5m 3.3 Flow Boiler Return Pipework 1. If this appliance is being fitted to a system containing plastic pipework, the flow switch kit part no 5107297 must be fitted. Copper 1m 2. The sizes of flow and return pipes from the boiler should be determined by normal methods, according to the requirements of the system. Fig. 5 mm 500 45° 1000mm Min 22mm Open Vent 15mm Cold Feed 3. An 11 °C (20°F) drop in temperature across the system is recommended. 4.
3 Litre Top Up Bottle (if required) Air Vent Pressure Gauge Safety Valve Filling Point Pump Radiator Circuit Expansion Vessel Boiler System Drains at Low Point Temp = 82° C Method of determining minimum value of expansion vessel volume for sealed systems using Baxi Boilers Vessel Charge Pressure (Bar) Initial System Pressure (Bar) Multiply Total Water Content Of System By (Litres) 0.5 1.0 1.5 2.0 1.0 1.5 2.0 1.5 2.0 0.5 1.0 1.5 3.6 Sealed Systems (Fig. 9) 1.
4.0 Site Requirements 4.1 Location 1. The appliance may be fitted to any suitable wall with the flue passing through an outside wall and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The appliance should be fitted within the building unless otherwise protected by a suitable enclosure ie. garage or outhouse. (The appliance may be fitted inside a cupboard, see section 4.5.) 5mm 5mm 2.
J,K 4.0 Site Requirements 4.3 R M I D E C I A I F S I F J,K WARNING - The addition of anything that may interfere with the normal operation of the appliance without the express written permission from the manufacturer or his agent could invalidate the appliance warranty and infringe the GAS SAFETY (Installation and Use) REGULATIONS. B L A A G H H I Likely flue positions requiring a flue terminal guard Fig.
4.0 Site Requirements 4.5 Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. The Solo 3 PFL will run sufficiently cool without ventilation. 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 refers to room sealed appliances installed in compartments. 4.6 Gas Supply (Fig. 14) 1.
4.0 Site Requirement 4.8 Flue Options 1. The Baxi Solo 3 PFL can be fitted with flue systems as illustrated. 2, The standard flue is suitable only for horizontal applications. Maximum Length = 2m inc. 2 x 45° bends 3. Maximum permissible equivalent flue lengths are:Horizontal 3.0 metres Vertical 4.0 metres Vertical (Twin) 20.0 metres 4. Any additional “in line” bends in the flue system must be taken into consideration.
5.0 Installation 5.1 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 R clip from the top latch securing the 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.
5.0 Installation 5.2 Fan Outlet Restrictor Rear Flue only up to 500mm (195/8 in) 1. Release the four latches holding the combustion box door (Fig 18). Remove the combustion box door by pulling forward (Fig. 17). Fig. 18 Fig. 19 2. Release the 5-pin electrical plug connecting the pressure switch and fan (Fig. 19). Withdraw the fan assembly by pulling forwards from the top edge (Fig. 17). Combustion Box Door 3.
5.0 Installation 5.3 Position the Boiler 1. Choose a suitable position for the boiler making necessary allowances for the minimum clearances required (see page 10). 2. Hold the wall template against the wall at the required boiler location. Ensure that the top of the template is level (Fig. 22). Fig. 22 3. The template represents the outer limits of the appliance plus the required minimum side clearance. 4.
5.0 Installation Wall Thickness 5.5 Rear Flue Preparation Wall thickness 285mm - 500mm (115/16 - 193/8) go to section 5.6. Fig. 24 Wall thickness 100mm - 284mm (4 in - 113/16 in). Waste If the wall thickness is less than 285mm (113/16 in), it will be necessary to cut the components of the flue to the appropriate size. Wall Thickness 1. Measure the wall thickness (Fig. 24). Mark this dimension on the Flue Duct from the flared end and cut the waste off the plain end (Fig. 25). Flue Duct Fig.
5.0 Installation Blanking Cap 5.6 Assembly of Rear Flue 1. Remove the rear air box blanking plate from the back plate by releasing the three screws (Fig. 30). 2. Remove the blanking cap at the rear of the turret, by pushing and turning anti-clockwise to release the bayonet fitting (Fig. 30). 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 duct in place by pressing in and turning clockwise (Fig. 31).
5.0 Installation 5.7 Fitting the Back Plate 1. Engage the assembly into the hole previously cut in the wall and slide in place (Fig. 34). 2. Secure the assembly to the wall at the previously drilled anchorage points with suitable screws (Fig. 34). 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. 35). 4.
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) 5.0 Installation 5.8 Left or Right 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.
Wall Thickness 5.0 Installation 5.9 X 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 dimension X (Fig. 45). Fig. 46 Fig. 45 Side Flue Preparation Total Flue Length Wall Thickness X 2. Measure the thickness of the wall from the inside. This will be known as Wall Thickness (Fig 46). 90mm (30, 40, 50) 145mm (60, 70, 80) 3.
5.0 Installation 5.10 Fitting the Flue and Back Plate 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). Blanking Cap Air Box Blanking Plate Turret Fig. 54 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). Fig. 53 5.
5.0 Installation 5.11 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. 57). 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. 58). 10.
5.0 Installation 5.12 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. 61). Blanking Cap Air Box Blanking Plate Turret Fig. 62 2. Rotate the turret to face the selected opening (Fig. 62) and remove the side blanking cap by pushing in and turning anti-clockwise to release the bayonet fitting (Fig. 61). 3.
5.0 Installation 5.13 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 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.
5.0 Installation 5.15 Wall Thickness Internal Fitting Kit 1. A internal fitting kit (available from merchants, quote Baxi Part No. 236441BAX) is suitable for walls between 100mm (4in) and 285mm (113/16in) 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 (45/8 in) diameter for the internal fitting kit. The use of a core drill is recommended.
5.0 Installation 5.15 Fig. 72 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 72). 7. Slide the assembled wall liner into the hole in the 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. 73). 8.
5.0 Installation 5.16 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. 77). 2. Swing the top of the combustion box backwards against the top air box (Fig. 78). Fig. 78 Fig. 77 Fig. 79 28 © Baxi Heating UK Ltd 2009 3. Engage the two retaining latches and secure with the 'R' clip previously removed (Fig. 79).
5.0 Installation Fan 5.
5.0 Installation 5.18 Making the Electrical Connections 1. Remove the cover from the control box by removing the 2 screws (Fig. 80). 2. Slide the box 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. 82). 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.
5.0 Installation 5.19 Water Connections 1. The boiler has two side water connections, the top connection being FLOW and the bottom connection being RETURN (Fig. 83). 2. It is essential that FLOW and RETURN pipes are connected to the correct fittings. 3. The top flow connection incorporates the boiler thermostat and overheat thermostat (Fig. 85). Fig. 83 4. A copper elbow, compression nut and olive are provided in the kit for the return connection.
6.0 Commissioning the Appliance 6.1 Commissioning the Appliance 1. The system must be flushed in accordance with BS 7593 (see Section 3.1 Water Circulating Systems) and the flushing agent manufacturers instructions, further guidance can be obtained from BS 5449 section 5. 2. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publications. 3. Turn the gas supply on and purge according to in GB BS 6891 and in IE the current edition of I.S.
6.0 Commissioning the Appliance Model kW Input P Btu/h Setting Pressure mbarin wg 30 10.99 37, 500 16.0 + 0.5 6.4 + 0.2 40 14.65 50, 000 16.0 + 0.5 6.4 + 0.2 50 18.32 62, 500 16.0 + 0.5 6.4 + 0.2 60 21.98 75, 000 16.0 + 0.5 6.4 + 0.2 70 25.64 87, 500 16.0 + 0.5 6.4 + 0.2 80 29.31 100,000 16.0 + 0.5 6.4 + 0.2 6.1 Commissioning the Appliance (Cont) 15. The burner pressure is factory set. 16.
7.0 Fitting the Outercase 7.1 Fitting the Outercase 1. The warning label may be removed unless the boiler is to be fitted within a cupboard. Fig. 91 Infill Panel 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. 91). 4. Offer the outer case up to the hooks on the top of the back plate (Fig. 93). 5.
8.0 Overheat Cut-off Device 1 8.1 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. NOTE: Cut-out is indicated by illumination of the neon light on the control box. 2 2. Remove the lower door panel by following the sequence of diagrams (Fig 95). 3. To reset the boiler - Turn the boiler thermostat control knob fully anti-clockwise to the OFF position marked ‘0’ (Fig. 96).
9.0 Annual Servicing 1 9.1 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. 2 Fig. 98 3.
9.0 Annual Servicing Baffle Retension Clip 9.2 Fig. 102 Cleaning the Combustion Box 1. Remove the burner assembly by pulling it forward (Fig. 103). 2. Lightly brush any dirt from the top of the burner blades and ensure that the ports are free from obstruction. Baffles 3. Remove the baffle retension clip (Fig. 102). 4. Lift the baffles out of the heat exchanger (Fig. 103). 9.3 Cleaning the Heat Exchanger 1. The heat exchanger may be cleaned by insertion of a thin metal strip e.g.
10.0 1 10.1 Changing Components 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. 2 3. Remove the outer case lower door panel (Fig. 108). Fig. 109 10.2 British Gas Service Test Point. 3 4. Remove the outer case from the boiler by unscrewing the two screws and lift the case clear (Fig 109). Replacing the Circuit Board 1.
British Gas Service Test Point. 10.0 For use by B.G. Personnel only 10.3 Changing Components Ignition Electrode (Fig. 114) 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. 10.4 Gas Valve (Fig. 115) 1. Disconnect the inlet gas cock union. 2.
10.0 10.7 Changing Components Changing Components (Cont) 1. To change Fan - Pressure Switch - Burner - Burner Injector - Pilot Burner Injector - Gas Manifold, proceed as follows:Fig. 119 2. Release the four latches holding the combustion box door (Fig. 118). Remove the combustion box door by pulling forward (Fig. 120). 3. Release the 5-pin electrical plug connecting the pressure switch and fan (Fig. 119). Withdraw the fan assembly by pulling forwards from the top edge (Fig. 120). Fig. 118 10.
10.0 10.10 Changing Components Burner (Fig. 124) 1. Remove the burner assembly by pulling it forward. 2. Fit new burner and re-assemble all components in reverse order of dismantling. 10.11 Burner Injector (Fig. 125) 1. Release and remove the burner injector which is screwed into the burner feed manifold. Fig. 124 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. 10.12 Pilot Burner Injector (Fig.
11.0 Before starting FAULT FINDING carry out preliminary electrical system checks i.e. Earth Continuity, Polarity, Short Circuit and Resistance to Earth. START Is there a clear constant spark at the electrode ? YES YES Does pump run ? Fault Finding Does fan run ? Ensure external controls are calling for heat NO YES Is there mains voltage at P/L input ? NO Is "Boiler On" light on ? NO YES NO Is lockout light on ? YES NO Is "Pilot On" light on ? YES NO Check & clean electrode.
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12.0 12.1 59 Short Parts List Short Parts List 53 Key No Description Model G.C. No Manuf'rs Part No 53 Burner 30-40-50 364 878 231708 60-70-80 364 879 231709 30 364 880 231354 40 364 881 231355 50 364 882 228104 60 364 873 231776 70 E01 623 239619 80 369 981 231777 Pilot Kit All models 170 558 236142 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.
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GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.
SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. Always use the manufacturer’s specified spare part when replacing controls.
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. BAXI A Trading Division of Baxi Heating UK Ltd Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 0844 871 1525 Technical Enquiries 0844 871 1555 Website www.
