Baxi BOSTON 40 OF Installation And Servicing Instructions Download Page 6 | Manualshive

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Page 4

Fitting the Appliance

PREPARATION

1) A sound and level floor which conforms to the requirements of the Local Authorities and Building
Regulations must be provided.

2) Select the most suitable position for the boiler taking due account of any clearances required for
the safe and proper functions of the boiler and its associated controls.

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Summary of Contents for BOSTON 40 OF

Page 1: ...ALLATION AND SERVICING INSTRUCTIONS GAS TYPE G20 Natural Gas BAXI BOSTON 80 OF G C No 41 077 65 BAXI BOSTON 70 OF G C No 41 077 64 BAXI BOSTON 60 OF G C No 41 077 63 BAXI BOSTON 50 OF G C No 41 077 62 BAXI BOSTON 40 OF G C No 41 077 61 Please leave these Instructions with the User ...

Page 2: ...rols 2 OUTER CASE Installation Requirements GENERAL The installation must be carried out by a competent installer and be in accordance with relevant BS Codes of Practice I E E Regulations Gas Safety Regulations Building Regulations and by laws of the Local Water Undertaking References should be made to BS 6891 BS 6798 BS 5440 Part 1 2 and BS 5449 SITING These appliances must be fitted on a suitabl...

Page 3: ... compartment air vents are based upon the rated input of the appliance Ventilation areas required APPLIANCE HIGH LEVEL VENT AREA LOW LEVEL VENT AREA cm 2 in 2 cm 2 in 2 80 OF Compartment 271 42 542 84 70 OF vented to 232 36 464 72 60 OF adjacent 212 33 423 67 50 OF room 176 27 353 55 40 OF 140 22 281 44 80 OF Compartment 136 21 271 42 70 OF vented to 116 18 232 36 60 OF outside 106 17 212 33 50 OF...

Page 4: ... in measured vertically from the flow connection on the boiler to the flow connection on the cylinder At this head the maximum horizontal distance measured along the run of the pipe should not exceed 3 metres 10ft Greater horizontal distances and smaller pipe sizes are acceptable with suitably increased heads Allowances must be made for pipe bends where necessary b If the above conditions are not ...

Page 5: ...T 900mm 35 1 2 in WIDTH 395mm 15 1 2 in FORWARD PROJECTION FROM THE WALL 535mm 21 in BOILER TAPPINGS 4 x Rp1 1in BSP internal and 1 x Rp3 4 3 4 in BSP internal ELECTRICAL SUPPLY 240v 50Hz 3 amp fuse GAS CONNECTION Rc1 2 1 2 in BSPT internal MAX WORKING HEAD 30m 100ft THERMOCOUPLE OUTPUT 10 15mv APPLIANCE WEIGHT EMPTY WATER CONTENT 80 OF 98 kg 7 litres 70 OF 216 lbs 1 54 gallons 60 OF 50 OF 79 2 kg...

Page 6: ...ch conforms to the requirements of the Local Authorities and Building Regulations must be provided 2 Select the most suitable position for the boiler taking due account of any clearances required for the safe and proper functions of the boiler and its associated controls ...

Page 7: ...URN CONNECTION ON ALL INSTALLATIONS THE MARKS ON THE SPREADER MUST BE BETWEEN THE TWO MARKERS ON THE COMBUSTION CHAMBER Fig 4 The spreader has one mark on the 80 70 and has two marks on the 60 50 40 When installing the pipework ensure that a Suitable union fittings are used at the first joint of all boiler connections b The pipework will run through the cutouts provided in the outer case Fig 2 c D...

Page 8: ...LH side panel 4 Secure the hinges of the facia panel to the two side panels using two of the six screws provided 5 At this point the electrical connections to the facia panel can be made and the appliance can be commissioned See Electrical Connections and Commissioning the Appliance 6 Swing the facia panel upwards and secure to the side panels using the two screws retained to the control facia 7 L...

Page 9: ...fig 1 Pump in Casing Page 5 fig 2 Outer Case ...

Page 10: ...fig 3 Boiler Connections Fig 4 Spreader in Pumped Return Connection fig 5 Clearances Work Tops ...

Page 11: ...sed and be in accordance with I E E Regulations Electrical supply to controls The recommended cable for connection to the appliance is 0 5 sq mm 16 0 20 PVC heat resistant grade to BS 6500 1990 The input cable should be secured with the cable clips provided and be laid to avoid contact with hot surfaces The length of the supply conductors between the cable grip and the terminals must be such that ...

Page 12: ... surfaces 3 Connect the 2 green and yellow earth wires halfway down the appliance wiring harness to the combustion chamber earth point on the outer case support bracket 4 Fit the socket at the end of the wiring harness to the plug attached to the burner feed pipe and clip the wire to the cable clips provided 5 Refit the thermostat cover to the facia panel 6 Push the thermostat phial into the therm...

Page 13: ...opriate wiring diagrams ALLOWING THE BOILER TO CYCLE ON THE BOILER THERMOSTAT DOES NOT PRODUCE THE BEST RESULTS SIMILARLY FOR ECONOMY AND BOILER PERFORMANCE THE SYSTEM SHOULD BE DESIGNED SO THAT GRAVITY CIRCULATION IN THE HEATING CIRCUIT DOES NOT TAKE PLACE WHEN THE PUMP IS NOT RUNNING Control Systems FULLY PUMPED SYSTEMS One Zone Valve Fig A Zone valve with auxiliary switch fitted at point V A cy...

Page 14: ...In both cases the cold feed pipe which is the neutral point of the system is shown directly behind the pump to avoid sub atmospheric pressure air entrainment in the system ...

Page 15: ...Page 8 Fig A One Zone Valve Fully Pumped System ...

Page 16: ...Fig B Sundial Gravity System ...

Page 17: ...Fig C 2 Zones Valve Fully Pumped System ...

Page 18: ...position Turn on the mains electrical supply and ensure that all external controls e g room thermostat timer etc are calling for heat Remove the burner pressure test point screw and connect a pressure gauge Hold in the grey ON OFF button on the gas control valve Fig 7 Press the piezo unit button Fig 7 and release Repeat until pilot lights Hold in the grey ON OFF button for a further 20 seconds and...

Page 19: ...e length The system should now be flushed again whilst hot refilled vented and checked for water leaks Make a final check for gas soundness Replace the burner pressure test point screw and then turn the boiler thermostat to the required setting Complete the assembly of the outer case as described in Outer Case Fig 6 Instruct the user in the use of the unit Please leave these instructions with the ...

Page 20: ...fig 7 Burner Controls fig 8 Boiler Thermostat Page 10 ...

Page 21: ...tion panel 12 80 70 OF ONLY Clean the burner as follows a Pull and release the lint arrester from the front of the combustion box panel held in position by two spring clips This can be cleaned by thoroughly washing and then allowed to dry b Remove the two nuts securing the burner tie plate to the burners Fig 12 c Remove the burners by removing the securing screws 2 per burner Fig 12 d Remove the s...

Page 22: ...hen release The pilot should then stay alight IF THE PILOT FAILS TO REMAIN ALIGHT TURN THE GREY ON OFF BUTTON FULLY CLOCKWISE AND RELEASE WAIT 3 MINUTES AND START AGAIN FROM THE BEGINNING OF THE PARAGRAPH The flame should be without a yellow tip and be approximately 25mm 1 in long No adjustment of the pilot flame is necessary as with the restrictor screw fully open the pilot jet is sized to give t...

Page 23: ...Fig 9 Insulation Combustion Box Door Fig 10 Baffle Securing Screws ...

Page 24: ...fig 11 Door Burner 60 50 40 fig 12 Door Burner 80 70 ...

Page 25: ...move the outer case front panel by pulling forwards at the top and lifting upwards 2 Turn off the gas supply at the service tap or at the grey ON OFF button on the gas valve 3 Release the thermocouple nut at the side of the gas valve Fig 15 4 Release the thermocouple nut at the pilot bracket 5 Re assemble in reverse order of dismantling THERMOCOUPLE RE ROUTE DEVICE ...

Page 26: ...ove the 3 screws securing the burner to the door panel and remove the burner Fig 11 4 Unscrew the injector from the inlet manifold 5 Re assemble in reverse order of dismantling BURNERS 80 70 OF ONLY 1 Remove the burner and controls assembly as described in steps 1 to 6 Servicing the Unit 2 Remove the lint arrester 3 Remove the two nuts securing the burner tie plate to the burners Fig 12 4 Remove t...

Page 27: ...ing the electrical terminal cover to the gas valve Disconnect the electrical connections 6 Remove the valve complete with the heat shield and inlet pipe by disconnecting the flanged injector manifold 7 Disconnect the flanged inlet pipe Retain the O rings for re assembly but replace if damaged 8 Remove the heat shield by undoing the retaining screw 9 Release the thermocouple re route nut and remove...

Page 28: ...he Unit 2 Disconnect the electrode lead at the piezo unit 3 Remove the nut securing the piezo unit to the heat shield and remove the piezo unit 4 Re assemble in reverse order of dismantling SPARK ELECTRODE Fig 15 1 Remove the burner and controls assembly as described in steps 1 to 6 Servicing the Unit 2 Disconnect the electrode lead at the electrode 3 Remove the nut securing the electrode and remo...

Page 29: ...fig 16 Insulation Page 14 Short Parts List ...

Page 30: ......

Page 31: ... 50 Injector Stereomatic 6 x 1 2mm 70 OF 364 339 112050 55 Injector Stereomatic 6 x 1 55mm 60 OF 364 330 112040 56 Injector Stereomatic 6 x 1 4mm 50 OF 364 331 112060 57 Injector Stereomatic 6 x 1 3mm 40 OF 364 332 112051 59 52 Valve Control Honeywell V4600 C 393 180 062623 65 Burner Pilot 364 341 110028 59 Burner Pilot Honeywell Q359A 1058 391 707 082211 68 61 Injector Pilot Honeywell 0 38 0 35 A...

Page 32: ... 110069 80 74 Thermostat Ranco GI P1004 382 387 112025 81 75 Knob Thermostat 364 287 231212 Page 15 7 94 BAXI manufacture a comprehensive range of products for the domestic heating market Gas Central Heating Boilers Wall Floor and Fireside models Independent Gas Fires Gas Heaters Solid Fuel Fires ...

Page 33: ...roducts please write to the Sales Department at the address below Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN Main Switchboard 0772 695555 Order Office 0772 695454 Literature Office 0772 695500 Technical Enquiries 0772 695504 Page 16 ...

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