Installation & Servicing Instructions

Baxi Solo 15 HE

Baxi Solo 24 HE

Baxi Solo 30 HE

Wall Mounted Powered Flue Condensing Boilers Gas Fired Central Heating Units

These instructions include the Benchmark Commissioning Checklist and should be left with the User for safe keeping

© BAXI Heating UK 2006

Page 1


Natural Gas

Baxi Solo 15 HE

G.C.N° 41 075 46

Baxi Solo 24 HE

G.C.N° 41 075 45

Baxi Solo 30 HE

G.C.N° 41 075 44

© BAXI Heating UK 2006 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any retrieval system of any nature (including in any database), in each case whether electronic, mechanical, recording or otherwise, without the prior written permission of the copyright owner, except for permitted fair dealing under Copyrights, Designs and Patents Act 1988.

Applications for the copyright owner's permission to reproduce or make other use of any part of this publication should be made, giving details of the proposed use, to the following address:

The Company Secretary, BAXI Heating UK, Pentagon House, Sir Frank Whittle Road, Derby, DE21 4XA.

Full acknowledgement of author and source must be given.

WARNING: Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages.

Building Regulations and the Benchmark Commissioning Checklist

Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly. Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006.

CORGI operate a Self Certification Scheme for gas heating appliances.

These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook (which was then left on site with the customer).

With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn. However, a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions.

This company is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

Building Regulations require that installations should comply with manufacturer's instructions. It is therefore important that the commissioning checklist is completed by the installer. The relevant section of Building Regulations only relates to dwellings. Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure.

The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations.

This product has an energy rating (A) on a scale of A to G. For more information see www.boilers.org.uk. This is a certification mark.

BAXI Heating UK is a BS-EN ISO 9001 Accredited Company

"Baxi" supports

The code of practice for the installation, commissioning & servicing of central heating systems.

Page 2


Installer Notification Guidelines

Page 3


IMPORTANT - Installation, Commissioning, Service & Repair

This appliance must be installed in accordance with the manufacturer's instructions and the regulations in force. Read the instructions fully before installing or using the appliance.

In GB, this must be carried out by a competent person as stated in the Gas Safety (Installation & Use) Regulations.

Definition of competence: A person who works for a CORGI registered company and holding current certificates in the relevant ACS modules, is deemed competent.

In IE, this must be carried out by a competent person as stated in I.S. 813 "Domestic Gas Installations".

NOTE: 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 infringe the Gas Safety (Installation and Use) Regulations.

Warning - Check the information on the data plate is compatible with local supply conditions.

All CORGI registered installers carry a CORGI identification card and have a registration number. You can check your installer is registered by telephoning 0870 4012300 or writing to:-

I Elmwood,
Chineham Business Park,
Crockford Lane,
Basingstoke. RG24 8WG

or check online at www.corgi-gas-safety.com

The boiler meets the requirements of Statutory Instrument " The Boiler (Efficiency) Regulations 1993 No 3083" and is deemed to meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by:

Notified Body 0087.

Product/Production certified by:

Notified Body 0086.

For GB/IE only.

Legislation

Baxi declare that no substances harmful to health are contained in the appliance or used during appliance manufacture.

The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force, and only used in a suitably ventilated location.

In GB, the installation must be carried out by a CORGI Registered Installer. It must be carried out in accordance with the relevant requirements of the:

Where no specific instructions are 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.

All systems must be thoroughly flushed and treated with inhibitor (see section 6.2).

Codes of Practice, most recent version should be used

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 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 7074 Expansion vessels and ancillary equipment for sealed water systems.
BS 7593 Treatment of water in domestic hot water central heating systems.

In IE the following Codes of Practice apply:

Standard Scope
I.S. 813 Domestic Gas Installations.
The following BS standards give valuable additional information;
BS 5546 Installation of hot water supplies for domestic purposes.
BS 5449 Forced circulation hot water systems.
BS 7074 Expansion vessels and ancillary equipment for sealed water systems.
BS 7593 Treatment of water in domestic hot water central heating systems.

Page 4


Safe Manual Handling

General

The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.

Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health & Safety is the responsibility of EVERYONE.

There is no 'safe' limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.

Do not handle or lift unless you feel physically able.

Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.

Preparation

Co-ordinate movements - know where, and when, you are both going.

Minimise the number of times needed to move the boiler - plan ahead.

Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care on ladders/into lofts.

Technique

When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don't twist - move your feet, avoid bending forwards and sideways and keep the load as close to your body as possible.

Where possible transport the boiler using a sack truck or other suitable trolley.

Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See section 8.3 of these instructions for recommended lift points.

Remember

The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.

If at any time when installing the boiler you feel that you may have injured yourself STOP !! DONOT 'work through' the pain - you may cause further injury.

IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

Page 5


Contents

Section

1.0 Introduction
2.0 General Layout
3.0 Appliance Operation
4.0 Technical Data
5.0 Dimensions and Fixings
6.0 System Details
7.0 Site Requirements
8.0 Installation
9.0 Electrical
10.0 Commissioning the Boiler
11.0 Fitting the Outer Case
12.0 Servicing the Boiler
13.0 Changing Components
14.0 Short Parts List
15.0 Fault Finding
Benchmark Checklist

Page 6


1.0 Introduction

1.1 Description

1. The Baxi Solo 15 HE, 24 HE and 30 HE are gas fired room sealed fan assisted condensing central heating boilers.

2. The maximum output of the Baxi Solo 15 HE is 52,000 Btu/hr. The maximum out put of the 24 HE is 75,000 Btu/hr. The maximum output of the 30 HE is preset at 75,000 Btu/hr but can be set to 100,000 Btu/hr (see section 8.8). All three boilers automatically adjust their outputs down to 30,000 Btu/hr according to the system load.

3. It is designed for use on Natural Gas (G20).

4. The boiler is suitable for fully pumped open vented central heating and domestic hot water systems and sealed systems.

5. A label giving details of the model, serial number and Gas Council number is situated on the rear of the lower door panel (Fig. 1).

 

Fig. 1

6. The boiler data badge is positioned on the air box door (Fig. 2).

 

Fig. 2

7. The boiler is intended to be installed in residential / commercial / light industrial E.M.C. environments on a governed meter supply only.

8. The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit, part no 236921.

1.2 Important Information

Man-made mineral fibre

Page 7


2.0 General Layout

2.1 Layout (Figs. 3,4,5 & 6)

 

1. Wall Plate

2. Flue Elbow

3. Heat Exchanger

4. Burner

5. Air Box

6. Fan Protection Thermostat

7. Fan Assembly

8. Condensate Trap

9. PCB Housing Assembly

10. Gas Tap

11. Gas / Air Ratio Valve

12. Flow Pipe Connection

13. Return Pipe Connection

14. Flow Temperature Safety Thermostat - Black

15. Flow Temperature Thermistor - Red

16. Flow Switch (dry fire protection)

2.2 Optional Extras

KIT PART N°
FLUE EXTENSION KITS (110/70)
Flue Extension 0.25M 241692
Flue Extension 0.5M 241694
Flue Extension 1M (Use two kits for 2M etc.) 241695
Flue Bend × 2 - 45° (Reduce overall length of flue by 0.5m when fitting this bend) 241689
Flue Bend - 90° (Reduce overall length of flue by 1m when fitting each bend) 241687
Horizontal Extended Flue (1.75M) 5111457
Plume Displacement 5117383
VERTICAL FLUE (110/70)
Vertical Flue Terminal 242802
Vertical Flue Adaptor 5106888

Page 8


3.0 Appliance Operation

3.1

1. Switched Live On: When the switched live switches on if the flow temperature is less than the set point then pump overrun occurs. When the switched live switches on if the flow temperature is greater than the set point then pump overrun occurs.

2. Pump On: The pump is on while the fan, spark generator and gas valve are off. After 10 seconds if the flow switch has made then fan pre-purge occurs. After 10 seconds if the flow switch has not made then anticycle occurs.

3. Fan Pre-Purge: The pump and fan are on while the spark generator and gas valve are off. After 5 seconds ignition occurs.

4. Ignition: The pump, fan, spark generator and gas valve are on. If a flame is detected then burner on occurs. If a flame is not detected within 5 seconds and less than 5 ignition attempts have been made then fan purge occurs. If a flame is not detected within 5 seconds and 5 ignition attempts have been made then ignition lockout occurs.

5. Burner On: The pump, fan and gas valve are on while the spark generator is off. Flow temperature is controlled by varying the fan speed (and thereby the gas rate) to achieve optimum operation. If the flow temperature is greater than the set point or the TRVs all shut down then fan post purge occurs.

6. Fan Post Purge: The pump and fan are on while the spark generator and gas valve are off. After 5 seconds if the TRVs are not shut down then pump overrun occurs. After 5 seconds if the TRVs are shut down then anti-cycle occurs.

7. Pump Overrun: The pump is on while the fan, spark generator and gas valve are off. After 1 minute anticycle occurs.

8. Anti-cycle: The pump, fan, spark generator and gas valve are off. After 3 minutes if the flow temperature is less than the set point then pump on occurs. After 3 minutes if the flow temperature is greater than the set point then pump overrun occurs.

9. Ignition Lockout: The pump, fan, spark generator and gas valve are off. The boiler can only be reset by manually using the reset button.

Page 9


4.0 Technical Data

Appliance Type C13 C33 C53
Appliance Category CATI2H
Heat Input (Q)(Gross) Max Min
15 HE kW 16.88 10.2
  Btu/hr 57,600 34,840
24 HE kW 24.50 10.2
  Btu/hr 83,600 34,840
30 HE kW 33.76 10.2
(see note) Btu/hr 115,200 34,840
Heat Output (P)
(Non Condensing 70° C Mean Water Temp)
    Max Min
15 HE kW 15.24 9.14
  Btu/hr 52,000 31,180
24 HE kW 22.00 9.14
  Btu/hr 75,000 31,180
30 HE kW 30.18 9.14
  Btu/hr 102,980 31,180
Heat Output (P)
(Condensing 40° C Mean Water Temp)
    Max Min
15 HE kW 16.49 10.1
  Btu/hr 56,260 34,520
24 HE kW 23.8 10.1
  Btu/hr 81,200 34,520
30 HE kW 32.61 10.1
  Btu/hr 113,280 34,520
Max Gas Rate (2H - G20 - 20mbar)
(After 10 Mins)
Btu/hr 52,000 75,000 102,980
m3/hr 1.64 2.31 2.95
ft3/hr 52.1 83.3 104.2
Injector (Natural Gas)
6.5mm Diameter
CO/CO2 Ratio 0.001
Nox Class 5
Horizontal
Flue Terminal Diameter 110mm
Dimensions Projection 150mm
Connections
Gas Supply - ½in BSPT
Central Heating Flow - 28mm
Central Heating Return - 28mm
Condensate Drain - 1 in BSP
Outercase Dimensions
Overall Height Inc Flue Elbow - 750mm
Casing Height - 600mm
Casing Width - 390mm
Casing Depth - 320mm
Clearances
(For unventilated compartments see Section 7.2)
Both Sides   5mm Min
Above Casing   200mm Min
Below Casing   50mm Min
Front (For Servicing)   500mm Min
Front (In Operation)   5mm Min
Weights   kg
Packaged Boiler Carton   36.2
Packaged Flue Kit   3.6
Installation Lift Weight   26.0
Recommended System
Temperature Drop
Condensing 20°C 36°F
Electrical Supply   230V~ 50Hz
(Appliance must be connected to an earthed supply)
Power Consumption   80W
External Fuse Rating   3A
Internal Fuse Rating (BS 4265)
Fuse 3.15 AT (PCB)
Electrical Protection   IPX2
Water Content
litres 2.6
pints 4.6
Static Head
max 30 metres (100 ft)
min 1 metre (3.25 ft)
Low Head 0.2m (8 in) min
System Detail
fully pumped open vented & sealed systems
Gas Connection
  G½" B.S.P. Thread
Controls
boiler thermostat, safety thermostat, flow switch, electronic flame sensing, temperature protection thermostat & condensate blockage sensor
Inlet Pressure at Gas Valve (Natural Gas)
Min 18.1 mbar
Max 22.5 mbar
  (see Section 10.1)
Flow Temperature (adjustable)
55° C to 78° C5° C)
NOTE: The maximum output of the 30 HE is factory set at 22.0kW (75,000 Btu/hr). This can be altered to 30.18kW (102,980 Btu/hr) - see section 8.8.

SEDBUK Declaration

For 15 HE - The efficiency is 91.3%

For 24 HE - The efficiency is 90.9%

For 30 HE - The efficiency is 90.9%

This value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated has been certified by 0087.

Page 10


5.0 Dimensions and Fixings

Fig. 7

DIMENSIONS
A 600mm
B 320mm
C 390mm
D 125mm Ø Min.
E 150mm
F 125mm

The 3° (1 in 20) fall provided by the elbow is to allow condensate to run back to the boiler, for disposal through the condensate discharge pipe.

Fig. 8

SIDE FLUE (left and right)

For every 1m of horizontal flue length, the clearance above the top of the flue elbow should be 55mm to incorporate the 3° (1 in 20) fall in the flue from the terminal to the elbow.

Flue length (Y) Clearance (X)
up to 1m 55mm
1m - 2m 110mm
2m - 3m 165mm

Page 11


6.0 System Details

6.1 Water Circulating Systems

1. The appliance is suitable for use with open vent fully pumped systems and sealed systems .

The following conditions should be observed on all systems:

6.2 Treatment of Water Circulating Systems

Failure to flush and add inhibitor to the system will invalidate the appliance warranty.

Page 12


6.3 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. The connection to the boiler is 28mm (compression).

2. Due to space requirements within the boiler outercase, pipework should comprise of solder fittings.

3. A 20 °C (36°F) drop in temperature across the system is recommended for condensing boilers. Existing radiators may be oversized and so allow this, but where radiator sizing is marginal it may be advisable to retain a system temperature drop of 11°C (20°F).

4. In systems using non-metallic pipework it is necessary to use copper pipe for the boiler Flow and Return. The copper must extend at least 1 metre from the boiler and include any branches (Fig. 9).

 

Fig. 9

6.4 Low Head Installation

1. Using a close couple arrangement the minimum head is as shown in the diagrams (Figs. 10 & 11) subject to the following conditions:

 

Fig. 10

 

Fig. 11

a) The pump being adjusted to give a 20°C drop across the boiler.

b) The pump must be fitted on the flow.

c) The pump must be fitted in accordance with the pump manufacturer's instructions.

d) The open vent pipe must be taken up from a tee in a horizontal section of the flow pipe.

An alternative Low Head Installation (Fig. 12)

 

Fig. 12

2. For heads below 400mm 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.

6.5 Thermal Stores

1. When the boiler is fitted in conjunction with a thermal store, both jumpers must be removed from the PCB, see Fig. 32 Section 8.8.

Page 13


Key to colours

b - Blue
br - Brown
w - White
o - Orange
gr - Grey
g/y - Green/Yellow

Y Plan, Room Thermostat System, CH Interlocked By Room Thermostat

At least the Radiator(s) near the Room Thermostat not TRV'd

Pump run from Switched Live

By-pass permitted but not required for Part L1 compliance

S Plan, Room Thermostat System, CH Interlocked By Room Thermostat

At least the Radiator(s) near the Room Thermostat not TRV'd

Pump run from Switched Live

By-pass permitted but not required for Part L1 compliance

Y Plan, Fully TRV'd System, CH Interlocked By Boiler Flow Switch

Room Thermostat should not be fitted

Pump must be run from Boiler P/F connection for Part L1 compliance

By-pass not permitted (must be valved off) for Part L1 compliance

S Plan, Fully TRV'd System, CH Interlocked By Boiler Flow Switch

Room Thermostat should not be fitted

Pump must be run from Boiler P/F connection for Part L1 compliance

By-pass not permitted (must be valved off) for Part L1 compliance

6.5 System Controls

This boiler does not require a bypass.

This boiler does not require a permanent live.

The pump only needs wiring directly to the boiler for fully TRV'd systems.

1. To comply with Part L1 of the Building Regulations the heating system into which the boiler is installed should include the following:

a) zone controls

b) timing controls

c) boiler control interlocks

2. Such a system needs to be fully pumped and must provide independent temperature and time control to both the heating and hot water circuits and have a boiler interlock.

3. The boiler should be controlled so that it operates on demand only. Where it is proposed to effect control by thermostatic radiator valves, a room thermostat (or other device such as a flow switch - a flow switch is integral to this boiler) should also be provided to switch off the boiler when there is no demand for heating or hot water.

4. The interlock for the CH circuit can be provided by either a Room Thermostat or a fully TRV'd system with the pump wired back to the boiler without a bypass. Connection diagrams for both options for Y and S plan systems are shown.

Page 14


6.7 Sealed Systems (Fig. 13)

 

Fig. 13

Fig. 14

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/in2). 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/in2) 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 connecting pipe being unrestricted and not less than 15mmin) 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).

 

Table. 1

Method of determining minimum valve 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 0.5 0.067
1.0 0.112
1.5 0.207
2.0 0.441
1.0 1.0 0.087
1.5 0.152
2.0 0.330
1.5 1.5 0.125
2.0 0.265

Example :- System 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

NOTE

Where a vessel of the calculated size is not obtainable then the next available larger size should be used.

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 connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement / refilling. The sealed primary circuits may be filled or replenished by means of a temporary connection between the primary circuit and a supply pipe provided a 'Listed' 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 Regulations Guide. for IE: the current edition of I.S. 813 "Domestic Gas Installations".

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 re-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.

Page 15


7.0 Site Requirements

7.1 Location

NOTE: Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal.

1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (The boiler may be fitted inside a cupboard - see Section 7.2).

2. If the boiler is sited in an unheated enclosure then it is recommended to incorporate an appropriate device for frost protection in the system controls.

3. If the boiler is fitted in a room containing a bath or shower, it can only be fitted in zone 3, (Figs. A & B shows zone dimensions for a bathtub. For other examples refer to Section 601 of the Current I.E.E. Wiring Regulations) reference must be made to the relevant requirements.

 

Fig. A

 

Fig. B

In GB this is the current I.E.E. Wiring Regulations and Building Regulations.

In IE reference should be made to the current edition of I.S. 813 "Domestic Gas Installations" and the current ETCI rules.

4. If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE/UP/7 (Gas Installations in Timber Framed Housing).

7.2 Ventilation of Compartments

1. Where the boiler is installed in a cupboard or compartment, no air vents are required for cooling purposes providing that the minimum dimensions below are maintained.

  Sides 15mm
  Top 200mm
  Bottom 50mm
  Front 30mm

2. If the boiler is installed in a smaller cupboard or compartment it must be ventilated according to BS 5440 Part 2 and the minimum clearances given in section 4.0 "Technical Data" maintained.

3. Any compartment should be large enough to house the boiler only.

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.

Page 16


7.3 Clearances (Figs. 15 & 16)

 

Fig. 15

 

Fig. 16

1. A flat vertical area is required for the installation of the boiler.

2. These dimensions include the necessary clearances around the boiler 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 boiler.

3. For unventilated compartments see Section 7.2.

7.4 Gas Supply

1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891. In IE this is the current edition of I.S. 813 "Domestic Gas Installations".

2. The connection to the appliance is a ½in BSP Internal Threaded Connection located at the rear of the gas service cock (Fig. 6).

3. Ensure that the pipework from the meter to the appliance is of adequate size. (22mm pipework must be connected to the appliance gas service cock. This should extend for at least 3 meters back towards the gas meter). Do not use pipes of a smaller diameter than the boiler gas connection.

7.5 Electrical Supply

1. External wiring must be correctly earthed, polarised and in accordance with relevant regulations/rules. In GB this is the current I.E.E. Wiring Regulations. In IE reference should be made to the current edition of ETCI rules.

2. The mains supply is 230V ~ 50Hz fused at 3A.

NOTE: "The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance".

Note! There is no method of isolating the boiler, at the user interface.

Connection may be via a fused double-pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only.

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

Page 17


Termination to an internal soil and vent pipe

External termination via internal discharge branch e.g sink waste - downstream

Termination to a drain or gully

Termination to a purpose made soakaway

7.6 Condensate Drain

FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER

The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run.

NOTE: It is unnecessary to fit an air break in the discharge pipe.

1. The condensate outlet terminates in a 1" BSP nut and seal for the connection of 21.5mmin) plastic overflow pipe which should generally discharge internally into the household drainage system. If this is not possible, discharge into an outside drain is acceptable.

2. Ensure the discharge of condensate complies with any national or local regulations in force.

BS 6798:2000 & Part H1 of the Building Regulations give further guidance.

3. The discharge pipe should be run in a proprietary drain pipe material e.g. PVC, PVC-U, ABS, PVC-C or PP.

4. Metal pipework is NOT suitable for use in condensate discharge systems.

5. The pipe should be a minimum of 21.5mm diameter and must be supported using suitably spaced clips to prevent sagging.

6. It is advisable to keep the condensate pipe internal.

7. External runs greater than 3 metres or runs in cold areas should use 32mm waste pipe.

8. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run.

9. In all cases discharge pipe must be installed to aid disposal of the condensate. To reduce the risk of condensate being trapped, as few bends and fittings as possible should be used.

10. When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC's are flushed or sinks emptied then back-pressure may force water out of the boiler trap and cause appliance lockout.

Examples are shown of the following methods of termination:-

i) to an internal soil & vent pipe

ii) via an internal discharge branch (e.g. sink waste)

iii) to a drain or gully

iv) to a purpose made soakaway

Page 18


Table. 2

Terminal Position with Minimum Distance (Fig. 17) (mm)
Aa Directly below an opening, air brick, opening windows, etc. 300
Ba Above an opening, air brick, opening window etc. 300
Ca Horizontally to an opening, air brick, opening window etc. 300
D Below gutters, soil pipes or drain pipes. 25
E Below eaves. 25
F Below balconies or car port roof. 25
G From a vertical drain pipe or soil pipe. 25
H From an internal (i) or external (ii) corner. (i) 115 (ii)
I Above ground, roof or balcony level. 300
J From a surface or boundary line facing a terminal. 600
K From a terminal facing a terminal (Horizontal flue). 1200
  From a terminal facing a terminal (Vertical flue). 600
L From an opening in carport (e.g. door, window) into the dwelling. 1200
M Vertically from a terminal on the same wall. 1500
N Horizontally from a terminal on the same wall. 300
R From adjacent wall to flue (vertical only). 300
S From an adjacent opening window (vertical only). 1000

a In addition, the terminal should be no nearer than 150 mm to an opening in the building fabric formed for the purpose of accommodating a built-in element such as a window frame. See BS 5440 Pt. 1.

 

NOTE: The distance from a fanned draught appliance terminal installed parallel to a boundary may not be less than 300mm in accordance with the diagram below

7.7 Flue

NOTE: Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal.

1. The following guidelines indicate the general requirements for siting balanced flue terminals.

For GB recommendations are given in BS 5440 Pt.1.

For IE recommendations are given in the current edition of I.S. 813 "Domestic Gas Installations".

2. 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.

3. Take into consideration the effect the plume of vapour may have on neighbours when siting the flue.

4. Adjacent surfaces close to the flue terminal may need protection from the effects of condensation.

Alternatively a flue deflector kit (part no. 248167) is available.

5. For installation of the flue into an internal corner at the 25mm dimension the flue deflector kit (part no. 248167) must be fitted.

6. * Reduction to the boundary is possible down to 25mm but the flue deflector kit (part no. 248167) must be fitted.

7. If required a suitable terminal guard is available from Baxi for use with the flue deflector.

8. For fitting under low soffits and eaves it is acceptable for the flue to project upto 500mm from the face of the wall to the inside of the air intake. This can be painted if required using a suitable external paint.

9. If a terminal is less than 2 metres (78¾ in) above a balcony, above ground or above a flat roof to which people have access, then a suitable terminal guard must be provided.

Page 19


7.8 Flue Dimensions

See Section 2.2. The standard horizontal flue kit allows for flue lengths between 270mm (105/8") and 800mm (32") from elbow to terminal (Fig. 18).

 

Fig. 18

The maximum permissible equivalent flue length is: 4 metres (Fig. 18a).

 

Fig. 18a

NOTE: Each additional 45° of flue bend will account for an equivalent flue length of 0.5m. eg. 45° = 0.5m, 90° = 2 × 45° = 1m etc.

7.9 Terminal Guard (Fig. 19)

 

Fig. 19

1. When codes of practice dictate the use of terminal guards, they can be obtained from most Plumbers' and Builders' Merchants.

2. When ordering a terminal guard, quote the appliance model number.

3. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated.

7.10 Vertical Flue

1. Only a flue approved with the Baxi Solo 15, 24 and 30 HE can be used.

2. For information on vertical flues consult the Baxi Flue Guide Brochure or Notes for Guidance supplied with the vertical flue pack.

Page 20


Key Accessory Size Baxi Code Number
Concentric Flue System 110mm diameter
A Horizontal flue kit 850mm 236921
B Straight extension kit 1000mm 241695
    500mm 241694
    250mm 241692
C Bend kit 93° 241687
D Bend kit (pair) 45° 241689
E Horizontal flue terminal   243013BAX
  Clamp 110mm 243014BAX
Twin Flue System 80mm diameter
F Straight extension kit 1000mm 238690
    500mm 238692
    250mm 238694
G Bend kit 90° 246139
H Bend kit (pair) 45° 246138
Universal Vertical Flue Kits
J Twin flue adaptor kit   242757
K Vertical flue terminal   242802
L Universal roof tile 25°/50° 243015
M Roof cover plate kit   243131
N Flat roof flashing   243016BAX
R Vertical flue adapter   5106888
  Clamp 80mm 238684

7.11 Flue options

Concentric

The maximum equivalent lengths are 4m (horizontal) or (vertical). There lengths exclude the standard elbow and flue/terminal assembly (horizontal) and terminal assembly (vertical).

Twin Flue

The total maximum equivalent flue length is 150m.

NOTE: Each 1m of flue duct should be calculated as 2m.

Any additional "in line" bends in the flue system must be taken into consideration. Their equivalent lengths are:

Concentric Pipes: 45° bend 0.5 m
  93° bend 1.0 m
Twin Flue Pipe: 45° bend (air duct) 1.3 m
  45° bend (flue duct) 2.6 m
  90° bend (air duct) 4.8 m
  90° bend (flue duct) 9.6 m

Detailed examples of equivalent flue length calculation are given in the Installation Guidance Notes for each flue system type.

(Documents 243501 and 243502 for concentric and twin pipe respectively).

Page 21


8.0 Installation

Check Site Requirements (section 7) before commencing.

8.1 Initial Preparation

The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4).

NOTE: If the boiler wall plate is to be pre-hung, follow both these instructions and those on the boiler pack.

1. Remove the fixing template (Fig. 20) from the carton.

 

Wall Thickness Flue Hole ø
up to 227mm 125mm core drill
up to 750mm 150mm core drill
up to 1200mm 175mm core drill

Fig. 20

2. After considering the site requirements (see Section 7.0) position the template on the wall ensuring it is level both horizontally and vertically.

NOTE: When fitting Plume Displacement Kit refer to the instructions supplied for details of installation of the flue.

3. Mark the position of the centre hole for the wall plate (Fig. 20).

4. Mark the centre of the flue hole (rear exit).

For side exit: project the horizontal side flue centre line into the corner of the room and along the wall to where the flue hole will be drilled. (Fig. 20).

The diagram (Fig. 21) shows the dimensions required to ensure any horizontal flue is installed with the correct fall to the boiler. Mark the offset (V) dimension and if required, mark the position of the gas and water pipes. Remove the template.

 

Fig. 21

5. Cut the hole for the flue (minimum diameter 125mm, see table (Fig. 20) for wall thicknesses and flue diameters).

6. Drill and plug the wall as previously marked. Secure the wall plate using the centre hole (Fig. 22).

 

Fig. 22

7. Ensuring the wall plate is level both horizontally and vertically, drill and plug at least 4 securing positions at the top and bottom through the wall plate. Utilising the slots available ensure the wall plate is square and secure to the wall (Fig. 22).

8. Loosely route the condensate discharge pipe to the lower left hand side of the wall plate.

Page 22


8.2 Preparing The Boiler

1. Remove the outer carton.

2. Remove the internal packaging.

3. Hinge down the lower door panel and unscrew the securing screws. Lift the outercase upwards and remove (Fig. 23).

 

Fig. 23

Baxi declare that no substances harmful to health are contained in the appliance or used during appliance manufacture.

Page 23


8.3 Fitting The Boiler (Fig. 24)

 

Fig. 24

1. Remove the screw and retaining bracket from the wall plate spring clip.

2. Offer up the boiler to the wall plate using the lifting points shown in Fig. 24 and locate the rear bottom edge onto the self locating support at the base of the wall plate. (See Safe Manual Handling page 5.)

NOTE: When installing in a Loft/Small Compartment, access for lifting the boiler from the front can be gained for two people using the lifting points. (Fig. 24).

3. Rotate the boiler and engage into temporary spring retaining latch.

4. Ensure the boiler is secured with the retaining bracket and screw previously removed, immediately.

5. Remove thread protection caps from the FLOW and RETURN connections.

8.4 Making the Water Connections (Fig. 25)

 

1. The boiler has two side water connections, the front connection being FLOW and the rear connection being RETURN.

2. It is essential that Flow and Return pipes are connected to the correct fittings. The flow connection incorporates the boiler thermostats and a flow switch. To avoid damage to the flow switch when tightening the flow connection the use of two spanners is recommended.

3. A copper elbow, compression nut and olive are provided in the kit for the return connection.

NOTE: Drain cocks should be fitted to all system's low points and vents to all high points.

4. 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. Break Off panels are provided, top and bottom. Pipework within the confines of the outercase should consist of solder fittings.

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 wall plate.

8.5 Making the Condensate Drain Connection

1. Connect the condensate drain using the 1"BSP nut and seal supplied. (see section 7.6).

NOTE: To ensure the correct operation and integrity of the condensate drainage system - Carefully pour approximately 1 cupful (250ml) of water into the flue products exhaust, at the top of the heat exchanger (Fig. 25a) to ensure a seal is made in the trap.

Page 24


8.6 Making the Gas Connection

1. Connect the gas supply to the G½ (½in BSPT Internal) gas tap. This is located on the lower right side of the boiler, access by hinging down the PCB housing (see Fig. 32).

8.7 Fitting The Flue

Before fitting the flue, check the condensate drain integrity (see section 8.5).

IMPORTANT: The flue should always be installed with a 3° (1 in 20) fall from terminal to elbow, to allow condensate to run back to the boiler.

HORIZONTAL FLUE

1. The standard flue is suitable for lengths 270mm minimum to 800mm maximum (measured from the edge of the flue elbow outlet).

Rear Flue: maximum wall thickness - 630mm

Side Flue: maximum wall thickness - 565mm (left or right)

2. For rear exit - measure the wall thickness (Fig. 26) and to this dimension add 210mm. This dimension to be known as (X).

 

Fig. 26

i.e.

(X) = wall thickness + 210

3. Take the flue and mark off (X) from the terminal end as indicated in the diagram

(Fig. 27).

 

Fig. 27

Check your dimensions.

The flue tubes are fixed together. Cut through both tubes whilst resting the flue on the semi-circular packing pieces. Deburr both tube ends.

4. For side exit - measure the distance from the edge of the wall plate to the inner face of the wall (Fig. 26) and to this dimension add the wall thickness + 250mm. This dimension to be known as (Z).

i.e.

(Z) = wall plate to wall + wall thickness + 250

5. Take the flue and mark off (Z) from the terminal end as indicated (Fig. 27).

Check your dimensions.

The flue tubes are fixed together. Cut through both tubes whilst resting the flue on the semi-circular packing pieces. Deburr both tube ends.

IMPORTANT: Check all measurements before cutting.
NOTE: When cutting ensure the cut does not interfere with the inner flue support bracket (Fig. 27a).
 

Fig. 27a

Page 25


6. Ensure the inner flue support bracket is positioned in the flue (Fig. 28).

 

Fig. 28

7. Engage the flue into the flue elbow using soap solution to ease the engagement ensuring the flue is assembled as shown (Fig. 29).

 

Fig. 29

8. Place the gasket over the flue exit on the boiler.

9. Slide the flue assembly through the hole in the wall.

10. Engage the elbow on to the flue connection on top of the boiler. Secure with the four screws supplied in the kit.

11. Make good between the wall and air duct outside the building ensuring the 3° drop between the terminal and elbow.

12. The flue trim should be fitted once the installation is complete and the flue secure (Fig. 30). Apply a suitable mastic to the inside of the trim and press against the wall finish, making sure the brickwork is dust free and dry.

 

Fig. 30

13. If necessary fit a terminal guard (see Section 7.9).

VERTICAL FLUEING

1. Only a flue approved with the Baxi 50, 80 and 100/2 HE Plus can be used.

2. For information on vertical flues consult the Baxi Flue Guide Brochure or Notes for Guidance supplied with the vertical flue pack.

Page 26


8.8 Making The Electrical Connections

WARNING: This appliance must be earthed

1. The electrical connections are on the right hand side of the unit.

2. Undo the two screws securing the cable clamp and place to one side (Fig. 31).

 

3. The Baxi Solo 30 HE is factory set to give a maximum output of 22.0 kW (75,000 Btu/hr). The Control PCB jumper positions are as follows:

  CN11 (Blue) CN12 (Red)

If the installation requires a greater output to achieve the desired room temperature, this can be increased to 30.18 kW (103,000 Btu/hr) and the boiler can be adjusted as follows (Fig. 32):

a) Remove the top right hand securing screw and hinge down the PCB housing.

b) Remove the Red jumper labelled CN12 from the bottom left hand side of the PCB.

c) Hinge back up the PCB housing and secure with screw.

If the boiler is to be used in conjunction with a Thermal Store, the boiler can be adjusted as follows (Fig. 32):

a) Remove the top right hand securing screw and hinge down the PCB housing.

b) Remove the Blue and Red jumpers labelled CN11 and CN12 from the bottom left hand side of the PCB.

c) Hinge back up the PCB housing and secure with screw.

4. Route the incoming electrical cable/s through the grommet in the support bracket. This will prevent damage to the cable.

5. Lay the cable through the cable clamp to gauge the length of cable required when it is connected to the 4-way terminal block.

6. Connect the (S/L), (N) and () wires to the 4-way terminal block (Fig. 33) and refit the cable clamp (Fig. 31).

7. Check the electrical installation for;

earth continuity, short circuits, resistance to earth, correct polarity and fuse failure.

Page 27


9.0 Electrical

9.1 Schematic Wiring Diagram

Key To Wiring Colours
b - Blue r - Red
bk - Black g - Green
w - White g/y - Green/Yellow
br - Brown op - Opaque
gy - Grey y - Yellow

Page 28


9.2 Illustrated Wiring Diagram

Wiring Key

b - Blue

bk - Black

br - Brown

r - Red

w - White

g/y - Green/Yellow

g - Green

gy - Grey

op - Opaque

y - Yellow

Page 29


10.0 Commissioning the Boiler

10.1 Commissioning the Boiler

1. Reference should be made to BS 5449 Section 5 when commissioning the boiler.

2. Flush the whole system using a suitable flushing agent (see Section 6.2) and vent the radiators. Check for water leaks.

3. Refill the system with inhibitor following the inhibitor manufacturer's instructions and BS 7593 Code of Practice for Treatment of Water in Domestic Hot Water Central Heating Systems (see Section 6.2).

4. Complete the label supplied with the inhibitor and attach to the inside of the boiler case. Detail of system treatment should be added for future reference.

5. Turn the gas supply on and purge according to in GB BS 6891 and in IE I.S. 813 "Domestic Gas Installations".

6. Remove the top RH securing screw and hinge down the PCB housing to gain access to the gas service cock (see Fig. 32). Turn the gas service cock anticlockwise to the ON position and check for gas soundness up to the gas valve (Fig. 34).

 

Fig. 34

7. Turn the boiler control knob fully clockwise to 'HIGH' (Fig. 35) and run the system and check the boiler for correct operation.

 

NOTE: The boiler is self-regulating dependent upon the system load. The 15 HE will modulate between inputs of 16.88kW and 10.3kW. The 24 HE will modulate between inputs of 24.9kW and 10.3kW. The 30 HE will modulate between inputs of 33.76kW and 10.3kW. The 30 HE input is factory set at 24.9kW and can be altered to 33.76kW - see section 8.8. No adjustment of the gas valve is permissible.

8. With the system cold and all controls calling for heat check the gas pressure at the inlet tapping of the gas valve (Fig. 36). The pressure must be a minimum of 18.1 mbar (Working Pressure). Check that the gas rate is no greater than 3.3m3/h.

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

Page 30


11.0 Fitting the Outer Case

11.1 Fitting The Outer Case

1. Position the outercase over the boiler engaging the lugs in the side flanges over the hooks on the wall plate. Break off top or bottom panel as required to accommodate pipework runs (Fig. 37).

 

Fig. 37

2. Using the two screws supplied in the kit, secure the outercase to the combustion box (Fig. 37).

3. Hinge up the lower door panel (Fig. 38).

 

Fig. 38

4. The "Important Ventilation Information" label can be removed unless the appliance is installed in an unventilated compartment.

5. Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation. These details will be required in the event of any warranty work. The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded.

For IE, it is necessary to complete a "Declaration of Conformity" to indicate compliance to I.S. 813. An example of this is given in I.S. 813 "Domestic Gas Installations". This is in addition to the Benchmark Commissioning Checklist.

6. Instruct the user in the operation of the boiler controls. Hand over the User's Operating, Installation and Servicing Instructions, giving advice on the necessity of regular servicing.

7. Demonstrate to the user the action required if a gas leak occurs or is suspected. Show them how to turn off the gas supply at the meter control, and advise them not to operate electric light or power switched, and to ventilate the property.

8. Show the user the location of the system control isolation switch, and demonstrate its operation.

9. Advise the user that they may observe a plume of vapour from the flue terminal, and that it is part of the normal operation of the boiler.

10. Complete the label supplied with the inhibitor and stick to the inside of the boiler case. Detail of system treatment must be recorded in the Benchmark Commissioning Checklist.

Page 31


12.0 Servicing the Boiler

12.1 Annual Servicing

IMPORTANT: When servicing ensure that both the gas and electrical supplies to the boiler are isolated before any work is started.

"The boiler cannot be switched off at the boiler, therefore it is important to isolate the electrical supply at the mains fuse."

Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended.

When replacing the combustion box door after servicing it is essential that the retaining screws are tightened fully.

1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Before servicing please read Section 1.2 Important Information.

2. After servicing, complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication.

3. Ensure that the boiler is cool.

4. Ensure that both the gas and electrical supplies to the boiler are isolated.

5. Remove the outercase and lower door panel (see Fitting the Outercase, Section 11.0).

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

6. Release the four ¼ turn screws securing the air box door panel and remove the door (Fig. 39).

 

Fig. 39

7. Disconnect the leads from the centre and right hand terminals (earth and flame sensing probe) (Fig. 40). Reconnect in reverse order.

 

Fig. 40

8. Undo the four screws securing the combustion box door and remove the door (Fig. 41).

9. Visually check for debris/damage and clean or replace if necessary the following:

a) Burner.

b) Heat exchanger fins.

c) Fan compartment (Check also for condensate leaks).

d) Insulation.

e) Door seals-Important: Pay particular attention to the condition of the combustion box door seals.

f) Electrodes.

g) The condensate trap must be thoroughly cleaned at every service (see section 13.9 for removal).

NOTE: Remove the trap drain plug and place a vessel underneath to catch the condensate (care should be taken as this could be hot). Clean the trap and refit the drain plug. Check for leaks.

h) Top of heat exchanger.

Page 32


10. To clean the heat exchanger and burner proceed as follows:

a) Disconnect the electrical leads to the fan component protection sensor (Fig. 42).

 

b) Loosen the screw retaining the gas injector pipe at the venturi (Fig. 42).

c) Undo the two wing nuts to disconnect the fan (Fig. 42).

d) Remove the fan and disconnect the electrical supply to it (Fig. 42).

e) Remove the gas injector pipe from the gas valve (push-fit) (Fig. 42).

f) Undo the condensate trap securing nut, lock nut and the condensate drain pipe. Remove the condensate trap and disconnect the sensor leads (Fig. 43).

g) Remove the two screws securing the burner and remove the burner. Visually inspect the internal burner baffle for obstruction, check seal around baffle for cracks/damage. Clean with a soft brush.

h) Loosen the two screws retaining the heat exchanger support bracket and slide to the left to remove (Fig. 44).

 

Fig. 44

i) Remove the four screws securing the heat exchanger/combustion box base and withdraw the base.

j) Lower the central insulation panel and check condition (Fig. 44). Replace the lower insulation pad if necessary.

k) Ensure the heat exchanger fins are clear of any obstruction.

l) Check condition of all seals. Important: Pay particular attention to the condition of the combustion box door seals.

m) Reassemble in reverse order and check for leaks.

11. Check CO/CO2 ratio at flue sampling point (Fig. 41a). See section 4.0.

12. Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user.

Page 33


13.0 Changing Components

13.1 Changing Components

IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started.

"The boiler cannot be switched off at the boiler, therefore it is important to isolate the electrical supply at the mains fuse."

Hazardous materials are not used in the construction of Baxi products, however reasonable care during service is recommended.

When replacing the combustion box door after changing components, it is essential that the retaining screws are tightened fully.

1. Before changing any components please read Section 1.2 Important Information.

2. Remove the outer case and lower door panel (see "Fitting the Outercase" Section 11.0).

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

3. Isolate the water circuit and drain the system as necessary. A drain point is located on the heat exchanger manifold at the right hand side of the boiler (Fig. 45) to enable the heat exchanger to be drained.

 

Fig. 45

4. Place a tube on the drain point to drain water away from electrics. Turn anticlockwise to open (Fig. 45).

NOTE: When reassembling always fit new 'O' rings, ensuring their correct location on the spigot. Green "O" rings are used for gas joints and Black "O" rings for water joints. Use Greasil 4000 (Approved Silicone Grease).

5. After changing a component re-commission the boiler where appropriate and check the inhibitor concentration (see Section 6.2 and 10.1).

The thermistor, safety thermostat, interface PCB and the flow switch can be accessed after removal of the outer case.

13.2 Flow Temperature Thermistor and Safety Thermostat (Fig. 46)

 

Fig. 46

1. The procedure is the same for both the thermistor and the safety thermostat.

2. Remove the electrical connections from the sensor.

3. Unscrew the sensor from the pipe.

4. Fit the new thermistor or safety thermostat and reassemble in reverse order.

Page 34


13.3 Flowswitch (Fig. 47)

 

Fig. 47

1. Drain the boiler (see Section 13.1 paragraph 2 & 3).

2. Disconnect pipework, loosen elbow locking nut and undo screws on support bracket.

3. Remove the clip securing the flow pipe to the flowswitch.

4. Remove the two screws securing the flow switch to the boiler.

5. Disconnect the inline electrical connection.

6. Remove the flowswitch.

7. Fit the new flowswitch and reassemble in reverse order.

8. Recommission the boiler and check the inhibitor concentration (see Section 6.2 and 10.1).

Page 35


13.4 PCB (Figs. 48 & 49)

 

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

1. Pull the control knob off the spindle and remove the plastic button cover. Refit them onto the new PCB (Fig. 48).

1. Remove the top right hand securing screw and hinge down the PCB housing and disconnect the electrical connections noting their positions

NOTE: Check the PCB for the presence of input jumpers - see section 8.8. Set the new PCB as the one removed.

2. Lift Control PCB housing out of hinge housing of metal bracket.

3. Fit the new PCB Housing Assembly and reassemble in reverse order.

Page 36


The fan and venturi, gas valve, injector pipe, condensate trap, fan protection sensor, spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel.

1. Remove the airbox door panel by loosening the four ¼ turn screws (Fig. 50).

 

13.5 Spark and Sensing Electrodes (Fig. 51)

1. Disconnect all three leads from tabs.

  Spark - Opaque cable
  Earth - Green/Yellow cable
  Sensing - White cable

2. Remove the two screws securing each of the electrodes to the combustion box door and remove the electrodes.

3. Fit the new electrodes (and new gasket, as required) and reassemble in reverse order.

13.6 Fan (Fig. 52)

WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access.

1. Loosen the screw holding the injector pipe into the venturi.

2. Remove the electrical connections to the fan and protection sensor on the fan.

3. Remove the wing nuts securing the fan to the base of the combustion box.

4. Lower the fan and remove.

5. If changing the fan remove the screws securing the venturi and fan protection sensor bracket, noting the positions of the injector opening and sensor bracket, fix them to the new fan.

6. Fit the new fan and reassemble in reverse order.

The injector pipe, condensate trap and gas valve can be changed after the removal of the fan.

Page 37


The removal of the fan is necessary to enable the changing of the injector pipe, condensate trap and gas valve (see section 13.6).

13.7 Injector Pipe (Fig. 53)

 

Fig. 53

1. Remove the injector pipe by pulling out from the 'O' ring joint in the gas valve.

2. Fit the new injector pipe and reassemble in reverse order.

13.8 Gas Valve (Fig. 53)

1. Remove the Control PCB (see Section 13.4).

2. Isolate gas supply and disconnect the gas tap by removing the four screws.

3. Undo the case pressure pipe from the gas valve.

4. Disconnect the electrical plug from the gas valve.

5. Remove the fan (see section 13.6) and injector pipe.

6. Remove the two gas valve securing screws from inside the air box holding the gas valve.

7. Remove the gas valve from the airbox side.

8. Remove the aluminium spacer and its gasket from the gas valve.

9. Fit the aluminium spacer and its gasket to the new valve.

10. Fit the new gas valve and reassemble in reverse order.

NOTE: Check for gas tightness after replacing gas valve.

13.9 Condensate Trap (Fig. 54)

 

Fig. 54

1. Disconnect the condensate trap from the base of the heat exchanger.

2. Disconnect the condensate drain (outside the boiler) from the condensate trap.

3. Undo the condensate trap lock nut.

4. Remove the condensate trap from the boiler.

5. Disconnect the sensor leads.

6. Fit the new condensate trap and reassemble in reverse order.

7. Prime the condensate trap (fill first chamber), check for leaks.

Page 38


The burner and heat exchanger can be changed after removal of the combustion box door. To change the heat exchanger, the fan and burner must be removed first (see section 13.6 and 13.10).

1. Remove the combustion box door by removing the four securing screws (Fig. 55).

 

IMPORTANT: On refitting the combustion box door check the condition of the combustion box door seals.

13.10 Burner (Fig. 56)

1. Remove the two screws securing the burner to the base of the combustion box.

2. Remove the burner carefully from the combustion box base.

3. Check the burner seal on the heat exchanger base, replace if necessary. Fit the new burner and reassemble in reverse order.

13.11 Heat Exchanger

1. Drain the boiler (see section 13.1 paragraph 2 & 3).

2. Remove all components in the base of the airbox.

3. Undo the screws on the support bracket. Remove the screws securing the flow switch and return connections and remove the connections (Fig. 57).

4. Remove the screws securing the heat exchanger manifold and remove the manifold (Fig. 58).

 

Fig. 58

5. Lift the heat exchanger assembly (Fig. 59) and rotate the bottom upwards whilst pulling it forwards out of the airbox.

 

Fig. 59

6. Fit the new heat exchanger and reassemble in reverse order.

7. Recommission the boiler and check the inhibitor concentration (see Section 6.2 and 10.1).

Page 39


13.12 Heat Exchanger Lower Insulation Pad (Fig. 60)

 

Fig. 60

1. Remove all components in the base of the airbox.

2. Remove the burner (see section 13.10).

3. Remove the four bolts securing the combustion box base.

4. Remove the combustion box base.

5. Pull the central insulation panel down from the centre of the heat exchanger and remove the lower insulation pad.

6. Fit the new insulation pad and reassemble in reverse order.

13.13 Heat Exchanger Upper Insulation Pad (Fig. 60)

1. Remove all components in the base of the airbox.

2. Remove the burner (see section 13.10).

3. Remove the heat exchanger (see section 13.11).

4. Remove the four bolts securing the combustion box base.

5. Remove the combustion box base.

6. Pull the central insulation panel down from the centre of the heat exchanger.

7. Fit the new insulation pad and reassemble in reverse order.

Page 40


14.0 Short Parts List

Short Parts List

Key No. G.C. No. Description Manufacturers Part No.
A E06 058 Flow Temperature Thermistor (Red) 240670
B E06 059 Flow Switch 242459
C E06 060 Safety Thermostat (Black) 242235
D   PCB 5110991
E   Fan 5109925
F   Gas Valve 241900
G E06 085 Viewing Window 242484
H   Condensate Trap 5111714
I   Electrodes Kit 5110992
J   Burner Assy 5107430
K E06 097 Heat Exchanger Assy 242497
L   Control Knob 5109996
 

A

 

B

 

C

 

D

 

E

 

F

 

G

 

H

 

I

 

J

 

K

 

L

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15.0 Fault Finding

NOTE: The fan is supplied with 325 Vdc.

Fan Fault Finding should only be carried out after the boiler has been electrically isolated.

General Fault Finding should only be carried out by someone who is appropriately qualified.

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ELECTRICAL SUPPLY

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DRY-FIRE

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IGNITION LOCKOUT

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OVERHEAT LOCKOUT

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FAN LOCKOUT

NOTE: The fan is supplied with 325 Vdc.

Fan Fault Finding should only be carried out after the boiler has been electrically isolated.

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THERMISTOR

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16.0 Notes

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GAS BOILER COMMISSIONING CHECKLIST

BOILER SERIAL No. __________________________ NOTIFICATION No. ______________________________

CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes

TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER __ PROGRAMMABLE ROOMSTAT __
TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER __ COMBI BOILER __
HEATING ZONE VALVES FITTED __ NOT REQUIRED __
HOT WATER ZONE VALVES FITTED __ NOT REQUIRED __
THERMOSTATIC RADIATOR VALVES FITTED __  
AUTOMATIC BYPASS TO SYSTEM FITTED __ NOT REQUIRED __

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER'S INSTRUCTIONS? __
THE SYSTEM CLEANER USED  
THE INHIBITOR USED  

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE ____ m3/hr ____ ft3/hr
BURNER OPERATING PRESSURE (IF APPLICABLE) __ N/A ____ mbar
CENTRAL HEATING FLOW TEMPERATURE     ____ ºC
CENTRAL HEATING RETURN TEMPERATURE     ____ ºC

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED? YES __ NO __
WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?    

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE ____ m3/hr ____ ft3/hr
MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) __ N/A ____ mbar
COLD WATER INLET TEMPERATURE     ____ ºC
HOT WATER OUTLET TEMPERATURE     ____ ºC
WATER FLOW RATE     ____ lts/min

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS? YES __

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS     __
THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS     __
IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2 RATIO READING? N/A __ YES ____ CO/CO2 RATIO
THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER     __
THE MANUFACTURER'S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER     __
COMMISSIONING ENG'S NAME PRINT ______________________ CORGI ID No. _____________________
  SIGN _______________________ DATE ____________________________

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SERVICE INTERVAL RECORD

It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below.

Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer's instructions. Always use the manufacturer's specified spare part when replacing all controls

SERVICE 1 DATE SERVICE 2 DATE
ENGINEER NAME ENGINEER NAME
COMPANY NAME COMPANY NAME
TEL No. TEL No.
CORGI ID CARD SERIAL No. CORGI ID CARD SERIAL No.
COMMENTS COMMENTS
SIGNATURE SIGNATURE
SERVICE 3 DATE SERVICE 4 DATE
ENGINEER NAME ENGINEER NAME
COMPANY NAME COMPANY NAME
TEL No. TEL No.
CORGI ID CARD SERIAL No. CORGI ID CARD SERIAL No.
COMMENTS COMMENTS
SIGNATURE SIGNATURE
SERVICE 5 DATE SERVICE 6 DATE
ENGINEER NAME ENGINEER NAME
COMPANY NAME COMPANY NAME
TEL No. TEL No.
CORGI ID CARD SERIAL No. CORGI ID CARD SERIAL No.
COMMENTS COMMENTS
SIGNATURE SIGNATURE
SERVICE 7 DATE SERVICE 8 DATE
ENGINEER NAME ENGINEER NAME
COMPANY NAME COMPANY NAME
TEL No. TEL No.
CORGI ID CARD SERIAL No. CORGI ID CARD SERIAL No.
COMMENTS COMMENTS
SIGNATURE SIGNATURE
SERVICE 9 DATE SERVICE 10 DATE
ENGINEER NAME ENGINEER NAME
COMPANY NAME COMPANY NAME
TEL No. TEL No.
CORGI ID CARD SERIAL No. CORGI ID CARD SERIAL No.
COMMENTS COMMENTS
SIGNATURE SIGNATURE

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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 Heating UK

Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP

After Sales Service 08706 096 096 Technical Enquiries 08706 049 049

Website www.baxi.co.uk

A BAXI GROUP company

Comp N° 5117935 - Iss 1 - 4/06

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