Baxi Solo 3 Installation And Servicing Instructions Download

Page: 40 / 48

Supplied By www.heating spares.co Tel. 0161 620 6677

11.0 Changing Components

11.7

Changing Components

(Cont)

1. To change Fan - Pressure Switch - Burner -

Burner Injector - Pilot Burner Injector - Gas

Manifold, proceed as follows:-

2. Release the four latches holding the combustion

box door. Remove the combustion box door by

pulling forward from the bottom and unhooking its

top edge (Fig. 115).

3. Disconnect the 5-pin pressure switch and fan

plug (Fig. 114). Withdraw the fan assembly by

pulling forwards from the top edge (Fig. 115).

11.8

Fan

(Fig. 116)

1. Disconnect the two flexible tubes from the

venturi situated on the fan.

2. Disconnect the 2 fan wires from the connection

on the electrical plug. Remove the 3 screws

securing the fan to the fan hood.

3. Remove the two screws securing the fan outlet

flange to the fan and remove. Clean all sealing

mastic from the outlet flange.

4. Fit the outlet flange onto the new fan, fix with the

2 screws and seal the outside gap between the fan

body and the outlet fan with the mastic provided.

5. Fit the new fan and re-assemble all components

in reverse order of dismantling ensuring that the

flexible tubes from the fan unit to the pressure

switch are routed correctly and that they are not

kinked or flattened (Fig. 115), reconnect the new

fan wires into the connections on the electrical plug

- either wire can be connected into either

connection.

11.9

Pressure Switch

(Fig. 117)

1. Disconnect flexible tubes noting their positions.

2. Remove the screw securing the pressure switch

to its bracket and unhook the pressure switch.

3. Disconnect the 3 electrical terminals from the

pressure switch. Note the position of the tags

before removal and reconnect in correct order.

4. Fit new pressure switch and re-assemble all

components ensuring that the flexible tubes from

the fan unit to the pressure switch are routed

correctly and that they are not kinked or flattened

(Fig. 115). Ensure that the electrical terminals are

connected to their correspondingly marked tags.

Fig. 116

Fig. 115

Fig. 114

Fig. 117

Outlet Flange

Flexible Tubes

Grey

Pressure Switch

Fan

Flexible Tubes

Black

White

Fan

Assembly

Combustion Box Door

Summary of Contents for Solo 3

Page 1: ... heating spares co Tel 0161 620 6677 Baxi Solo 3 PFL System Wall Mounted Powered Flue System Boiler Gas Fired Central Heating Unit Installation and Servicing Instructions Please leave these instructions with the user ...

Page 2: ...stomers mean continued success We hope you get a satisfactory service from Baxi If not please let us know Natural Gas Baxi Solo 3 PFL System 30 G C No 41 075 25 Baxi Solo 3 PFL System 40 G C No 41 075 26 Baxi Solo 3 PFL System 50 G C No 41 075 27 Baxi Solo 3 PFL System 60 G C No 41 075 28 Baxi Solo 3 PFL System 70 G C No 41 075 29 Baxi Solo 3 PFL System 80 G C No 41 075 31 Baxi is a BS EN ISO 9001...

Page 3: ... Technical Data 6 4 0 System Details 8 5 0 Site Requirement 11 6 0 Installation 14 7 0 Commissioning the Appliance 32 8 0 Fitting the Outercase 34 9 0 Overheat Cut Off Device 35 10 0 Annual Servicing 36 11 0 Changing Components 38 12 0 Short Parts List 44 13 0 Fault Finding 45 Section Page Contents ...

Page 4: ... systems must be thoroughly flushed and treated with inhibitor see Section 4 2 1 3 Important Information Man Made Mineral Fibre a Some component parts of this appliance insulation pads gaskets and rope seals are manufactured from man made mineral fibre b Prolonged or excessive exposure to this material may result in some irritation to the eyes skin or respiratory tract c It is advisable to wear gl...

Page 5: ...ve 12 Burner 13 Heat Exchanger 14 Fan Assembly 15 Pressure Switch 16 Overheat Thermostat 17 Thermostat Sensor 1 2 Fig 4 Fig 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 STANDARD B S 6891 B S 5546 B S 5449 B S 6798 B S 5440 Pt 1 B S 5440 Pt 2 B S 7074 Pt 1 SCOPE Gas Installation Installation of hot water supplies for domestic purposes Forced circulation hot water systems Installation of gas fired hot wa...

Page 6: ...t3 h 86 75ft3 h 99 24ft3 h Lifting Weight kg 40 40 40 49 1 49 1 49 1 lbs 88 88 88 108 108 108 Water Content litres 2 1 2 1 2 1 2 6 2 6 2 6 pints 3 2 3 2 3 2 4 5 4 5 4 5 Outercase Height 850mm 850mm 850mm 850mm 850mm 850mm Dimensions Width 490mm 490mm 490mm 490mm 490mm 490mm Depth 320mm 320mm 320mm 320mm 320mm 320mm Flue Terminal Diameter 100mm Dimensions Depth 70mm Connections Flow 22mm Cu tail Re...

Page 7: ...pliance is only intended for installation on a governed supply PMS 3 bar pressure class 2 Max CH water pressure 3 bar Type C12 C32 C52 Nox class 1 Appliance category I2H 2H G20 20mbar Ref 86 AU 588 Burner Injector Sizes 30 B31 40 B32 50 B33 60 B34 70 B35 80 B36 This boiler is designed to operate at a maximum water temperature of 85 C 68mm Model Seasonal Efficiency SEDBUK 30 79 4 40 78 4 50 78 0 60...

Page 8: ...er installation system modification and at every service in accordance with the manufacturer s instructions Test kits are available from inhibitor stockists For information or advice regarding any of the above contact the Baxi Helpline 4 3 Bypass Requirements 1 The boiler is fitted with a pump overrun device which allows the removal of residual heat from the boiler NOTE The pump overrun will opera...

Page 9: ...m Controls 1 For optimum operating conditions the heating system into which the boiler is installed should include a control system 2 Such a system will comprise of a timer control and separate room or cylinder thermostats as appropriate An integral twin channel programmer is available as an optional extra 3 The boiler should be controlled so that it operates on demand only 4 Operation of the syst...

Page 10: ...the minimum cold fill pressure is 1 bar The vessel is suitable for correct operation for system capacities up to 125 litres 27 5gal For greater system capacities an additional expansion vessel must be fitted refer to BS 7074 Pt 1 4 10 Pressure Relief Valve Figs 6 7 1 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressures in excess of 3 bar 2 ...

Page 11: ...emoval 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 appliance 3 If fitted inside a cupboard the clearance of 500mm shown is only necessary when the cupboard door is open A clearance of 5mm 3 16 in is required when the door is closed 5 3 Flue Position 1 For installati...

Page 12: ...n 4 Where it is intended to pass the flue through a combustible wall or timber framed dwelling reference should be made to the Institute of Gas Engineers document UP7 Guide for Gas Installations in Timber Framed Dwellings 5 If the flue is more than 1 metre 393 8 in long it is required that it is supported 6 All above dimensions are taken from the respective faces of the outer case Fig 11 Maximum l...

Page 13: ...891 2 The connection of the appliance is a 22mm copper tail on the tap rail Fig 12 3 The pipework should be sized to account for the distance of the appliance from the meter the pipe routing and maximum input of the appliance 5 7 Electrical Supply External wiring must be correctly earthed polarized and in accordance with CURRENT I E E WIRING REGULATIONS The mains supply is 230V 50Hz fused at 5A NO...

Page 14: ...s Fig 14a 14b 5 Lift and remove the combustion box and backplate from the wall plate Fig 14 Place the combustion box and backplate on its back IMPORTANT When installing a Solo 3 System with a rear flue see section 6 2 Fan Outlet Restrictor before continuing the installation 6 Proceed to the relevant section for flueing the appliance either to the Rear Left Right or Vertically NOTE For Vertical flu...

Page 15: ...he anchorage holes 63mm 21 2in deep to accept suitable wall plugs 5 Mark the centre of the flue hole rear exit For side exit mark as shown If required mark the position of the gas water and pressure relief discharge pipes Remove the template 6 Cut the hole for the flue minimum diameter 107mm 7 For rear flue applications continue as described in Section 6 4 Side flue installations are covered in Se...

Page 16: ...ctor supplied in the kit of parts check that the number stamped on the restrictor matches the appliance e g 50 stamped on the restrictor is for 50 PF appliance 4 Fit the restrictor to the fan outlet flange bending the 3 lugs equally ensuring the restrictor seals against the fan outlet flange Fig 17 5 Re assemble the fan assembly and combustion box door ensuring that the flexible tubes from the fan...

Page 17: ...2 Take the Flue Terminal Assembly and measure from the terminal end the wall thickness and subtract 40mm Fig 21 Cut the waste off the plain end Wall Thickness 40mm all boilers 3 The cardboard support should be installed onto the flue tubes to ensure the assembly is supported during cutting Fig 23 24 4 Measure the same amount from the flange end of the Air Duct and cut the waste off the plain end F...

Page 18: ...amage the O ring Lock the flue duct in place by pressing in and turning clockwise Fig 26 4 Engage the bayonet slots of the air duct over the location lugs on the back plate opening and press and turn clockwise to secure the air duct to the back plate Fig 27 5 In order to increase security of the flue the bayonet tags may be deformed to secure the flue in position 6 Take the flue terminal assembly ...

Page 19: ...lding if the internal fitting kit has not been used Fig 29 4 The flue trim provided may be fitted if required to neaten the wall around the terminal Fig 30 5 To fit the flue terminal trim a The trim should be fitted once the flue is secure b Take the three edge clips from the kit and fit them equi spaced onto the inner flange of the trim Fig 29a c With the flanges towards the wall pass the trim ov...

Page 20: ...t of the template is butted up against the corner of the wall Fig 33 9 If the appliance mounting wall is out of true use string or a straight edge to determine the true corner position and mark a vertical line to accommodate the flat edge of the template 10 Holding the template firmly mark the vertical centre line for the flue assembly by marking the point at the outer corners of the upper and low...

Page 21: ...easure the dimension below from the flared end Cut the waste off the plain end Fig 40 Wall Thickness X 145mm L H Flue Wall Thickness X 165mm R H Flue 5 Take the Flue Terminal Assembly and measure from the terminal end the dimension below Fig 41 Cut the waste off the plain end Wall Thickness X 110mm L H Flue Wall Thickness X 130mm R H Flue 6 Measure the same amount from the flange end of the Air Du...

Page 22: ...urning anti clockwise to release the bayonet fitting Fig 46 3 Locate the swaged end of the flue duct over the bayonet fitting on the turret taking care not to damage the O ring Lock the flue in place by pressing in and turning clockwise Fig 47 4 Ensure that the O ring seal is in position against the sealing flange 5 Fit the air duct over the flue duct and draw towards the air box on the back plate...

Page 23: ...ding if the internal fitting kit has not been used Fig 51 10 The flue trim provided may be fitted if required to neaten up the make up around the terminal Fig 52 11 To fit the flue terminal trim a The trim should be fitted once the flue is secure b Take the three edge clips from the kit and fit them equi spaced onto the inner flange of the trim Fig 51a c With the flanges towards the wall pass the ...

Page 24: ... Before finally tightening the screws check that the assembly is level 7 Take the flue terminal assembly and pass through the cut hole from outside Engage on the flue and air ducts Slide the flues together to the desired wall thickness Tape the outer duct sections together with the tape provided ensuring a good seal is made Fig 57 8 In order to increase security of the flue the bayonet tags may be...

Page 25: ...ationwide 2 When ordering a terminal guard quote the appliance model number 3 There must be a clearance of at least 50mm between any part of the terminal and the guard 6 13 Fitting a Terminal Guard Fig 60 1 Position the guard over the terminal on the outside wall Ensure the guard is equally spaced about the terminal Mark the fixing positions 2 Drill and plug fixing the positions then secure the gu...

Page 26: ...117mm 45 8 in diameter for the internal fitting kit The use of a core drill is recommended When using a core drill it is important to keep the drill level and square 3 Measure the wall thickness and from this dimension subtract 10mm 3 8 in Fig 61 4 Remove the wall liner from its packing and remove the end piece Fig 62 5 Mark off the dimension wall thickness 10mm 3 8 in measuring from the beaded en...

Page 27: ...n the wall and then rotate liner so that tags reveal marks Fig 65 8 Drill and plug the wall in these positions Fig 66 9 Rotate liner back until the tags align with the holes drilled and secure it to the wall using suitable screws Fig 67 10 Make good between the edge of the liner and the outside wall with cement mortar or a similar substance by reaching through the liner and pressing the mortar bet...

Page 28: ... Connect the gas water and pressure relief discharge pipes to the valves on the wall plate using the copper tails supplied Ensure that the sealing washers are fitted correctly to the water connections 2 Connect the filling loop and fill and thoroughly flush the system see system details section 4 2 4 7 ...

Page 29: ...e taken not to damage the boiler pipework and fittings 4 Engage the two retaining latches and secure the right hand one with the R clip previously removed Fig 69 72 5 Take the three washers from the kit and insert them between the water flow and return pipes pressure relief discharge pipe and their corresponding taps The pressure relief washer is the smaller of the three 6 Tighten all the nuts to ...

Page 30: ...he appliance MUST be supplied via the same isolator NOTE Polarity of the appliance MUST be correct otherwise the appliance will not operate correctly or b r g y w br g w bk gy br b Pump N Main Gas Valve Pilot Gas Valve Fan Pressure Switch Thermostat Sensor Overheat Thermostat Control Potentiometer Switch Spark Electrode N N N External Controls S L L 230V L b r b or b br br gy w y bk y or or or bk ...

Page 31: ...ng the boiler 5 The pump is connected to the boiler P C B terminals 6 A permanent live must be connected to the L terminal 7 The switched live must be connected to the S L terminal 8 Clamp the cable in the grip provided Ensure that the length of the supply cable is such that the current carrying wires become taut before the earth wires if the cable should pull out of the cable clamp Fig 76 9 Tuck ...

Page 32: ... thermostat control knob fully anti clockwise to the OFF position marked 0 Fig 79 8 Ensure that the electricity supply is turned ON and set any external controls to the ON position 9 Turn the boiler thermostat knob fully clockwise 10 The fan will start running and after approximately 10 seconds the ignition spark will commence 11 The sparking will continue until the pilot light is established Fig ...

Page 33: ... s specific requirements 8 The boiler is protected by an integral frost stat but if the boiler is not to be used for a long period of time the system should be drained NOTE The frost thermostat operates even if the boiler thermostat is in the OFF position and it is necessary therefore if the system is drained for the external electrical and gas supplies to be isolated It is recommended that a labe...

Page 34: ...ts in the case over the hooks on the back plate Ensure that the case is positively located Fig 86 4 Using the two screws previously removed secure the outer case to the combustion box Fig 85 5 Replace the lower front door panel relocate the door stay and hinge upwards ensuring it is secured by the two magnets Fig 87 88 6 Instruct the user in the operation of the boiler controls Hand over the Users...

Page 35: ...rol box 2 Hinge the lower door panel down Fig 89 3 To reset the boiler Turn the boiler thermostat control knob fully anti clockwise to the OFF position marked 0 Fig 90 Wait ten seconds then turn the control knob clockwise to the required thermostat setting The red neon will go out and the boiler will start automatically 4 If the overheat cut off operates repeatedly refer to the fault finding chart...

Page 36: ...possession of the user 4 Isolate the gas and electrical supplies to the boiler 5 Open the hinged lower door panel and carefully disengage the door stay Remove the door by opening it 90 and pulling forward Fig 93 6 Remove the outer case from the boiler by unscrewing the two screws and lifting the case clear Fig 91 7 Release the four latches retaining the combustion box door and remove the door Fig ...

Page 37: ...trode from the manifold and withdraw the electrode Fig 100 3 Remove the right hand side insulation carrier bracket by releasing the screw Remove the side insulation Fig 101 4 Release the screw securing the pilot hood and remove Fig 102 5 Carefully remove the pilot injector Fig 102 Examine and clean it as necessary Do not use a wire or pin to clean the injector orifice 6 Examine the sealing washer ...

Page 38: ... from the circuit board Fig 105 5 Remove the screw retaining the thermostat control panel and slide the circuit board from the box 6 Carefully withdraw the centre pin from the retaining rivet which then allows the retaining rivet to be removed Remove the thermostat control panel Fig 106 107 On reassembling ensure the control panel is located over the retaining rivet body before inserting the centr...

Page 39: ...in reverse order of dismantling ensuring that the gaskets and washer are correctly fitted 12 Check burner pressure is 16mbar 0 5 See section 7 1 paragraph 2 if burner pressure needs adjusting 11 5 Thermostat Sensor Fig 112 113 1 Disconnect the two electrical tags from the sensor 2 Prise the clip and sensor off the flow manifold 3 Clip the new sensor to the pipe and reconnect the wires Either wire ...

Page 40: ... and the outlet fan with the mastic provided 5 Fit the new fan and re assemble all components in reverse order of dismantling ensuring that the flexible tubes from the fan unit to the pressure switch are routed correctly and that they are not kinked or flattened Fig 115 reconnect the new fan wires into the connections on the electrical plug either wire can be connected into either connection 11 9 ...

Page 41: ...s in reverse order 11 13 Gas Manifold Fig 123 1 Undo the 1 4 turn screws and drop the facia panel down 2 Pull the electrode lead off the electrode 3 Remove the right hand side insulation carrier bracket by slackening the screw Remove the burner Remove the side insulation panel Fig 122 4 Undo the three screws securing the brass inlet adaptor to the manifold 5 Remove the two screws securing the mani...

Page 42: ...t UPS 15 60 pump head remove the strain relief cable gland and discard 10 Remove the plug connector from the old pump head and wire it into the UPS 15 60 pump head 11 Replace the electrical cover to the new pump head and assemble with the electrical box at 6 o clock to the housing 12 Reconnect the wiring harness plug 13 Repressurise and recommission the system 11 16 Pump Complete Fig 125 127 1 Iso...

Page 43: ...om the water system by closing the flow and return taps 2 Drain the boiler of water 3 Undo the 1 4 turn screws and drop the facia panel down 4 Undo the nut on the pressure relief pipe and slacken the screw holding the valve to the manifold 5 Fit the new valve in reverse order and recommission the appliance 11 18 Re pressurising Expansion Vessel 1 The charge pressure is 1 0 bar 2 Close the central ...

Page 44: ...81 14 Viewing Window Kit All models 364 588 224183 101 Pressure Switch 30 40 50 246053 60 70 246054 80 E26 221 246055 17 Insulation R H All models 364 889 230653 16 Insulation L H All models 364 980 230652 18 Retaining Clip All models 364 891 230817 32 Gas Valve All models E24 690 245122 72 Overheat Thermostat All models 5106746 121 Fuse All models 364 892 231402 97 Fan 30 40 50 246051 60 70 80 24...

Page 45: ...h pipes for leaking or blockage Note Under cold conditions fan run up time may exceed 1 min Ensure external controls are calling for heat Does pump run Is Pilot On light on Is lockout light on Is Boiler On light on Is there mains voltage at P L input Is there mains at the fan connection Is there continuity across the overheat thermostat YES NO YES YES YES YES YES NO YES YES NO NO NO NO NO YES YES ...

Page 46: ...ot flame size YES YES YES YES Check pilot hood position and pilot air flow Check continuity across mains solenoid 5 K OHM Change gas valve NO Change PCB YES Testing Potentiometer Three Pin Connector Set multimeter to the 2 M OHM scale Turn potentiometer to the OFF position connect the multimeter leads to the blue red wire and centre black yellow wire of three pin connector The reading on the multi...

Page 47: ...nsive range of products for the domestic heating market Gas Central Heating Boilers Wall Floor and Fireside models Independent Gas Fires Renewal Firefronts Gas Wall Heaters Solid Fuel Fires If you require information on any of these products please write telephone or fax to the Sales Department ...

Page 48: ... heating spares co Tel 0161 620 6677 Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN www baxi com After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Comp No 5106278 Iss 1 11 01 ...

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