Baxi Solo 3 30 PF User guide

Baxi Solo 3 PF

Wall Mounted Powered Flue

Gas Fired Central Heating Unit

Installation and

Servicing Instructions

Please leave these instructions with the user

Baxi UK Limited is one of the leading manufacturers

of domestic heating products in the UK.

Our first priority is to give a high quality service to our

customers. Quality is built into every Baxi product -

products which fulfil the demands and needs of

customers, offering choice, efficiency and reliability.

To keep ahead of changing trends, we have made a

commitment to develop new ideas using the

latest technology - with the aim of continuing to

make the products that customers want to buy.

Everyone who works at Baxi has a commitment to

quality because we know that satisfied customers

mean continued success.

We hope you get a satisfactory service from Baxi. If

not, please let us know.

Natural Gas

Baxi Solo 3 30 PF

G.C.No. 41 075 04

Baxi Solo 3 40 PF

G.C.No. 41 075 05

Baxi Solo 3 50 PF

G.C.No. 41 075 06

Baxi Solo 3 60 PF

G.C.No. 41 075 07

Baxi Solo 3 70 PF

G.C.No. 41 075 08

Baxi Solo 3 80 PF

G.C.No. 41 075 09

Baxi is a BS-EN ISO 9001

Accredited Company

The boiler meets requirements of Statutory

Instrument “The Boiler (Efficiency) Regulations

1993 No3083” and is deemed to meet the

requirements of Directive 92/42/EEC on the

efficiency requirements for new hot water boilers

fired with liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by:

Notified Body 0086.

Product/Production certified by:

Notified Body 0086.

For GB / IE only.

1.0Introduction 4

2.0Technical Data 5

3.0System Details 7

4.0Site Requirement 10

5.0Installation 14

6.0 Commissioning the Appliance 32

7.0 Fitting the Outercase 34

8.0 Overheat Cut-Off Device 35

9.0Annual Servicing 36

10.0Changing Components 38

11.0Fault Finding 42

12.0Short Parts List 44

13.0Notes 45

Section Page

Contents

1.0 Introduction

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. 7593

B.S. 4814

B.S. 6283

SCOPE

Gas Installation.

Installation of hot water supplies for

domestic purposes.

Forced circulation hot water systems.

Installation of gas fired hot water

boilers.

Flues.

Ventilation.

Water Treatment.

Expansion vessels for hot water

systems.

Safety and control devices for use in

hot water systems.

HEAT OUTPUT Q

Model Min Max

30 5.86kW (20,000 Btu/h) 8.79kW (30,000 Btu/h)

40 9.09kW (31,000 Btu/h) 11.72kW (40,000 Btu/h)

50 12.02kW (41,000 Btu/h) 14.65kW (50,000 Btu/h)

60 14.95kW (51,000 Btu/h) 17.58kW (60,000 Btu/h)

70 17.88kW (61,000 Btu/h) 20.5kW (70,000 Btu/h)

80 20.8kW (71,000 Btu/h) 23.45kW (80,000 Btu/h)

B.S. Codes of Practice, most recent

version should be used

1.1 Description

1. The Baxi Solo 3 PF is a gas fired room sealed

fan assisted central heating boiler with range rated

outputs as shown in the table below

2. Each appliance is preset at a MID RANGE heat

input rating and is designed for use on NATURAL

GAS only.

3. All boilers are suitable for fully pumped open

vented central heating and domestic hot water

systems and sealed systems.

4. The appliance data badge is fitted to the

combustion box door.

1.2 Installation

1. The appliance is suitable for installation only in

G.B. and I.E. and should be installed in

accordance with the rules in force. For Ireland

install in accordance with I.S.813 “INSTALLATION OF

GAS APPLIANCES”. The installation must be carried

out by a CORGI Registered Installer or other

competent person and be in accordance with the

relevant requirements of the current GAS SAFETY

(Installation and Use) REGULATIONS, the BUILDING

REGULATIONS (Scotland) (Consolidation), the

LOCAL BUILDING REGULATIONS, the CURRENT I.E.E.

WIRING REGULATIONS and the bye laws of the Local

Water Undertaking. Where no specific instructions

are given, reference should be made to the

relevant current BRITISH STANDARD CODES

OF PRACTICE.

2. All systems must be thoroughly flushed and

treated with inhibitor (see Section 3.1).

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 gloves when handling

these items.

d) Irritant dust will only be released from the items

if they are broken up or subjected to severe

abrasion. In these instances a suitable dust mask

and goggles should be worn.

e) Always thoroughly wash hands after

installation, servicing or changing components.

f) When disposing of any items manufactured from

man-made mineral fibre care must be exercised.

g) If any irritation of the eyes or severe irritation of

the skin is experienced seek medical attention.

IMPORTANT: State of adjustment - Check that

the state of adjustment given on the data plate

is compatible with local supply conditions.

“Benchmark”Log Book

As part of the industry-wide “Benchmark”intiative all Baxi boilers now

include an Installation, Commissioning and Service Record Log Book.

Please read the Log Book carefully and complete all sections relevant to

the appliance and installation. These include sections on the type of

controls employed, flushing the system, burner operating pressure etc.

The details of the Log Book will be required in the event of any warranty

work. Also, there is a section to be completed at each subsequent regular

service visit.

2.0 Technical Data

Model 30 40 50 60 70 80

P Heat Output (Max) kW 8.79 11.72 14.65 17.58 20.5 23.45

Btu/h 30,000 40,000 50,000 60,000 70,000 80,000

P Heat Output (Min) kW 5.86 9.09 12.02 14.95 17.88 20.8

Btu/h 20,000 31,000 41,000 51,000 61,000 71,000

Q Heat Input (Max) kW 10.99 14.65 18.32 21.98 25.64 29.31

Btu/h 37,500 50,000 62,500 75,000 87,500 100,000

Q Heat Input (Min) kW 7.33 11.36 15.02 18.68 22.35 26.01

Btu/h 25,000 38,750 51,250 63,750 76,250 88,750

Burner Pressure (Max) mbar 16.0 ±0.5 16.0 ±0.5 16.0 ±0.5 16.0 ±0.5 16.0 ±0.5 16.0 ±0.5

in wg 6.4 ±0.2 6.4 ±0.2 6.4 ±0.2 6.4 ±0.2 6.4 ±0.2 6.4 ±0.2

Burner Pressure (Min) mbar 8.0 ±0.5 10.0 ±0.5 11.5 ±0.5 11.5 ±0.5 12.1 ±0.5 11.5 ±0.5

in wg 3.2 ±0.2 4.0 ±0.2 4.4 ±0.2 4.4 ±0.2 4.8 ±0.2 4.4 ±0.2

Gas Rate CV 38mj/m31.04m3/h 1.39m3/h 1.74m3/h 2.08m3/h 2.43m3/h 2.78m3/h

(after 10 mins) 36.86ft3/h 49.0ft3/h 61.3ft3/h 73.5ft3/h 86.75ft3/h 98.1ft3/h

Lifting Weight kg 23.1 23.1 23.1 32.2 32.2 32.2

lbs 51 51 51 71 71 71

Water Content litres 1.1 1.1 1.1 1.6 1.6 1.6

pints 1.9 1.9 1.9 2.8 2.8 2.8

Outercase Height 600mm 600mm 600mm 600mm 600mm 600mm

Dimensions Width 350mm 350mm 350mm 462mm 462mm 462mm

Depth 287mm 287mm 287mm 287mm 287mm 287mm

Flue Terminal Diameter 100mm

Dimensions Depth 70mm

Static Head Max 30 metres (100 ft)

Min 1 metre (3.25 ft)

Connections Flow 22mm Cu tail

Return 22mm Cu elbow

Heat Exchanger Cast iron monobloc

Low Head Min 0.2m (8 in)

System Design fully pumped open vented and sealed systems

Gas Connection RC1/2(1/2in BSPT)

Electrical Supply 230V ~ 50Hz fused 5A - 90W

Controls boiler thermostat, intermittent pilot & electronic flame sensing,

timed pump over-run, frost protection thermostat

Internal Fuse 4AF 250V to BS4256 situated on control board

2.0 Technical Data

75 121

392

439

442

268

144144

107 Dia

without

internal

fitting

117 Dia

with

internal

fitting

Centre of

Gas Connection

8 Slots

20 x 6

Layout of Fixing Points

30, 40 and 50 PF models

75 121

392

439

442

380

196196

107 Dia

without

internal

fitting

117 Dia

with

internal

fitting

Centre of

Gas Connection

8 Slots

20 x 6

Layout of Fixing Points

60, 70 and 80 PF models

(4) 10

(8) 20

(16) 40

(24) 60

(12) 30

(20) 50

(28) 70

(32) 80

(36) 90

(40) 100

(44) 110

(48) 120

2 4 6 8 1012141618 2022

Water Flow Rate litres / min

Pressure Drop mbar (in wg)

242628 30

(52) 130

(4) 10

(8) 20

(16) 40

(24) 60

(12) 30

(20) 50

(28) 70

(32) 80

(36) 90

(40) 100

(44) 110

(48) 120

2 4 6 8 1012141618 2022

Water Flow Rate litres / min

Pressure Drop mbar (in wg)

242628 30

(52) 130

30, 40 and 50 PF models 60, 70 and 80 PF models

Templates

Hydraulic Resistance Charts

•This appliance is only intended for installation on a governed supply.

•PMS = 3 bar pressure class 2

•Max CH water pressure 3 bar

•Type C12, C32, C52

•Nox class 2

•Appliance category I2H 2H - G20 - 20mbar

•Ref: 86/AU/588

•Burner Injector Sizes: 30=B12 40=B13 50=B14 60=B15 70=B30 80=B16

•This boiler is designed to operate at a maximum water temperature of 85°C.

61.3mm

Model Seasonal Efficiency

(SEDBUK) (%)

30 78.8

40 77.8

50 76.7

60 77.8

70 77.7

80 77.8

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 have been certified by 0086.

SEDBUK Declaration For Solo 3 PF

All Models

121mm

Top of Outercase

3.0 System Details

Typical Systems

Arrangement

Option A

Boiler

Pump

Air Vent

Radiator

Circuit

Fully Pumped System

Air

Vent

Radiator

Circuit

Twin Zone

Valve System

Air

Vent

Radiator

Circuit

3 Port Divertor

Valve System

Option B

Radiator

Circuit

Option C

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Examples of systems which require a

bypass are:-

a) A system controlled by non-electrical

valves e.g. mechanical thermostatic control

valves both on the radiators and the hot

water circuit.

b) A system using twin zone valves (e.g.

Honeywell 'S' Plan) (Fig. 3).

c) A system using a 3 port divertor valve

(Fig. 4) does not normally require a bypass

therefore this system is recommended. The

exception to this is where thermostatic

radiator valves are used and then a bypass

is required.

NOTE: For ‘S’Plan systems the bypass

flow circuit must be situated between

pump and zone valves as option A

shows (Fig. 2).

The bypass circuit can be:-

a) For all boilers a minimum of 6 metres of

22mm copper pipe, (measured between the

boiler flow and return connections). It

should be fitted with a lock shield valve

opened at least 1 full turn or a proprietary

bypass valve set to give a minimum flow

rate of 8 litres/min (1.8 gal/min) (Option C,

Fig. 1 & Option A, Fig.2).

b) A radiator fitted with lock shield valves.

The radiator output should be a minimum of

800 watts (2,700 Btu/h). Typically a

convector type radiator with an area of

3750 cm2(4 sq ft) is adequate (Option B,

Fig. 1).

c) Any circuit that provides the same

operating conditions as option A or option B

(Figs. 1 & 2).

3.1 Water Circulating Systems

1. The appliance is suitable for use with open

vent fully pumped systems and sealed systems

where additional control protection is required.

The following conditions should be observed

on all systems:

•The static head must not exceed 30m (100ft) of

water.

•The boiler must not be used with a direct cylinder.

•The boiler is fitted with a timed pump overrun that

will operate for approximately 8 minutes.

•Drain cocks should be fitted to all system low

points.

•All gas and water pipes and electrical wiring must

be installed in a way which would not restrict the

servicing of the boiler.

•Position isolating valves as close to circulating

pump as possible.

Treatment of Water Circulating Systems

•All recirculatory water systems will be subject to

corrosion unless an appropriate water treatment is

applied. This means that the efficiency of the system

will deteriorate as corrosion sludge accumulates

within the system, risking damage to pump and

valves, boiler noise and circulation problems.

•For optimum performance after installation this

boiler and its associated central heating system

must be flushed in accordance with the guidelines

given in BS 7593:1992 “Treatment of water in

domestic hot water central heating systems”.

•This must involve the use of a proprietary

cleanser, such as BetzDearborn Sentinel X300 or

X400, or Fernox Superfloc. Full instructions are

supplied with the products, but for immediate

information please contact BetzDearborn (0151 420

9563) or Fernox (01799 550 811) directly.

•For long term protection against corrosion and

scale, after flushing it is recommended that an

inhibitor such as BetzDearborn Sentinel X100, or

Fernox MB-1 or Copal is dosed in accordance with

the guidelines given in BS 7593:1992.

Failure to flush and add inhibitor to the system

may invalidate the appliance warranty.

•It is important to check the inhibitor concentration

after installation, system modification and at every

service in accordance with the inhibitor

manufacturer’s instructions. (Test kits are available

from inhibitor stockists.)

•For information or advice regarding any of the

above contact the Baxi Helpline.

3.2 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 operate for

approximately 8 minutes. The system design

must therefore, always provide an open circuit for

water to circulate between the boiler flow and

return.

2. See information opposite “Examples of systems

which require a bypass are”.

3.0 System Details

3.3 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.

2. An 11 °C (20°F) drop in temperature across the

system is recommended.

3. 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. 4a). The copper pipe must not be insulated.

3.4 System 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.

3. The boiler should be controlled so that it

operates on demand only.

4. Operation of the system under control of the

boiler thermostat only does not produce the best

results.

5. A frost thermostat is fitted integrally to the

appliance controls and will protect the boiler from

frost damage by operating the burner when the

water temperature in the boiler drops towards

freezing point. The boiler will fire as necessary to

maintain a temperature above freezing.

NOTE: The frost thermostat operates even if

the boiler thermostat is in the OFF ('0') position

and it is necessary therefore, if the system is

drained, for the external electrical and gas

supplies to be isolated. It is recommended that

a label be affixed to the appliance to draw

attention to the fact that the system has been

drained.

3.5 Low Head Installation

For boilers up to 50,000 Btu/h output

1. Using a close coupled arrangement the

minimum head is as shown in the diagrams

(Figs. 5 & 6) subject to the following conditions:

a) The correct heat input.

b) The pump being adjusted to give an 11oC

drop across the boiler.

c) The pump must be fitted on the flow.

d) The pump must be fitted in accordance with

the pump manufacturer's instructions.

e) The open vent pipe must be taken up from a

tee in a horizontal section of the flow pipe.

Alternative Low Head Installation for all Solo 3 PF

(Fig. 7)

2. If less height is available 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.

Typical Low Head Installation

If Conditions Require,

This System Possible

Alternative Low Head Installation

Boiler

500mm

45°

22mm

Open Vent

1000mm

Min

150mm

Max

15mm

Cold

Feed

400mm

Min Head

Return

Pump

Flow

Boiler

500mm

45°

22mm

Open Vent

400mm

Min Head

1000mm

Min

Automatic

Air Vent 15mm

Cold

Feed

150mm

Max

Return

Pump

Flow

Return

Pump

Flow

Boiler

200mm

Min

Air

Separator

22mm

Feed & Vent

Pipe

Fig. 5

Fig. 6

Fig. 7

Boiler

Flow

Return

Copper

0.5m

Copper

0.5m

Fig. 4a

3.0 System Details

3.6 Sealed Systems (Fig. 8)

1. SAFETY VALVE - A safety valve complying

with the requirements of BS 6283 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 15mm (1/2in) 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).

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 and an

approved stop valve to BS 1010 must be fitted at

low level and the method used for filling the

system should be approved by the local water

undertaking. For further details see BS 6798.

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 pre-

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.

8. SYSTEM COMPONENTS - 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.

Initial System

Pressure (Bar)

Vessel Charge

Pressure (Bar)

Multiply Total

Water Content Of

System By (Litres)

0.067

0.112

0.207

0.441

0.087

0.152

0.330

0.125

0.265

0.5

1.0

1.5

2.0

1.0

1.5

2.0

1.5

2.0

0.5

1.0

1.5

Example :-

Then :-

System Volume = 75 litres

Vessel Charge Pressure = 1.0 bar

Initial System Pressure = 1.5 bar

75 x 0.152 = 11.4 litres

Expansion Vessel Volume

Method of determining minimum

value of expansion vessel volume for

sealed systems using Baxi Boilers

NOTE

Where a vessel of the calculated size is not obtainable

then the next available larger size should be used.

Safety

Valve

Pressure

Gauge

Pump

Filling

Point

Air

Vent

3 Litre

Top Up Bottle

(if required)

Radiator

Circuit

Expansion

Vessel

System Drains

at Low Point

Max Boiler Flow

Temp = 82°C

Boiler

Fig. 8

Table. 1

4.0 Site Requirements

4.1 Location

1. The appliance may be fitted to any suitable wall

with the flue passing through an outside wall and

discharging to atmosphere in a position permitting

satisfactory removal of combustion products and

providing an adequate air supply. The appliance

should be fitted within the building unless otherwise

protected by a suitable enclosure ie. garage or

outhouse. (The appliance may be fitted inside a

cupboard. Cooling ventilation and insulation of the

cupboard are not required, see section 4.5.)

2. If the appliance is fitted in a room containing a bath

or shower reference must be made to the Current

I.E.E. Wiring Regulations and Building Regulations. If

the appliance is to be fitted into a building of timber

frame construction then reference must be made to

the Institute of Gas Engineers document UP7 - Guide

for Gas Installations in Timber Framed Dwellings.

3. Recommendations for flues are given in BS 5440

Part 1.

4.2 Minimum Clearances (Fig. 9)

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

the boiler measuring as shown in the table below for

each model.

2. These dimensions include the necessary

clearances around the appliance 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 appliance.

3. If fitted inside a cupboard the clearance of 300mm

shown is only necessary when the cupboard door is

open. A clearance of 5mm (3/16 in) is required when

the door is closed.

4.3 Flue Position

1. For installations where the flue terminal is

inaccessible from the outside, an internal fitting kit is

available. This can be obtained free of charge from

your local merchant.

2. The following guide lines indicate the general

requirements for siting balanced flue terminals.

3. If the terminal is fitted within 1 metre (39in) of a

plastic gutter, within 500mm (191/2in) of a painted

eave or a painted gutter, an aluminium shield of at

least 1 metre (39in) long should be fitted to the

underside of the gutter or painted surface. An air

space of 5mm (3/16 in) should be left between shield

and gutter (Fig. 10).

4. 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.

5. If the outer surface of an outside wall is of

combustible material, it should be protected by fitting

the flue trim provided.

Fig. 9

Fig. 10

300mm for servicing

5mm during operation

5mm5mm

350mm (30,40,50 models)

600mm

50mm

100mm

462mm (60,70,80 models)

Aluminium

Shield

Model Height Width

mm (in) mm (in)

30 750 (291/2) 360 (141/8)

40 750 (291/2) 360 (141/8)

50 750 (291/2) 360 (141/8)

60 750 (291/2) 472 (185/8)

70 750 (291/2) 472 (185/8)

80 750 (291/2) 472 (185/8)

287mm

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