Baxi Solo 3 Installation And Servicing Instructions

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Baxi Solo 3 PFL System
Wall Mounted Powered Flue System Boiler Gas Fired Central Heating Unit
Installation and Servicing Instructions
Supplied By www.heating spares.co Tel. 0161 620 6677
2
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 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 Accredited Company
The boiler meets the requirements of Statutory Instrument “The Boiler (Efficiency) Regulations 1993 N
o
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 0086.
Product/Production certified by: Notified Body 0086.
For use in GB/IE only
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3
1.0 Introduction 4
2.0 General Layout 5
3.0 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
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Model Heat Output
30
8.79kW (30,000 Btu/h)
40 11.72kW (40,000 Btu/h) 50 14.65kW (50,000 Btu/h) 60 17.58kW (60,000 Btu/h) 70 20.5kW (70,000 Btu/h)
80 23.44kW (80,000 Btu/h)
1.0 Introduction
4 1
1.1 Description
1. The Baxi Solo 3 PFL System is a gas fired room sealed fan assisted central heating system boiler with outputs as shown in the table below.
2. Each appliance is preset at a heat input rating and is designed for use on NATURAL GAS only.
3. All boilers are suitable for sealed fully pumped systems only.
4. The appliance incorporates a circulating pump and expansion vessel.
5. The appliance data badge is fitted to the combustion box door, an abbreviated version is on the inside of the front panel.
6. All illustrations show the Solo 3 PFL System 50 boiler.
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 “I
NSTALLATION 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 G
AS 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
BRITISH STANDARD CODES OF PRACTICE.
2. All 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 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.
Users Operating Label
Data Badge
Combustion Box Door
Fig. 1
Fig. 2
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. The Log Book must be left with the user.
IMPORTANT:
STATEMENT OF ADJUSTMENT. Check that the state of adjustment given on the data plate is compatible with local supply conditions
British Gas Service Test Point.
For use by B.G. Personnel only
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2.0 General Layout
5
2.1 Layout (Figs. 3 & 4)
1. Wall Plate
2. Automatic Air Vent
3. Expansion Vessel
4. Pressure Relief Valve
5. Circulation Pump
6. Water Pressure Gauge
7. Position of Optional Timer
8. Gas Tap
9. Control Knob
10. Electronics Housing
11. Gas Valve
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 water boilers. Flues. Ventilation. Sealed Systems
B.S. Codes of Practice, most recent
version should be used
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3.0 Technical Data
6
Model 30 40 50 60 70 80
Heat Output kW 8.79 11.72 14.65 17.58 20.5 23.44
Btu/h 30,000 40,000 50,000 60,000 70,000 80,00
Heat Input 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
Burner Pressure 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
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 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
Return 22mm Cu elbow
Heat Exchanger Cast iron monobloc
System Design fully pumped sealed systems only
Gas Connection 22mm Cu tail
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
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3.0 Technical Data
7
(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 10121416182022
Water Flow Rate litres / min
Pressure Drop mbar (in wg)
24262830
(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 10121416182022
Water Flow Rate litres / min
Pressure Drop mbar (in wg)
24262830
(52) 130
30, 40 and 50 models
60, 70 and 80 models
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 C
12C32C52
Nox class 1
Appliance category
I
2H
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 78.5 70 78.2 80 78.7
This value is used in the UK Governments 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 PFL System
All Models
Top of Outercase
120mm
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4.0 System Details
8
4.1 Water Circulating Systems
Water Circulating Systems
1. The appliance is suitable for fully pumped sealed systems only.
The following conditions should be observed on all systems:
The boiler must not be used with a direct cylinder.
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.
Air vents should be fitted to all system high points.
All components used in the system must be suitable for operation at 110°C (230°F).
4.2 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 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 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.
Typical Systems Arrangement
Option A
Boiler
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. 4a
Fig. 4b
Fig. 4c
Fig. 4d
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. 4c).
c) A system using a 3 port divertor valve (Fig. 4d) 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. 4b).
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. 4a & Option A, Fig. 4b).
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. 4a).
c) Any circuit that provides the same operating conditions as option A or option B (Figs. 4a & 4b).
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4.0 System Details
9
4.4 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. The connections to the boiler are 22mm copper tails.
4.5 System Components
1. 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.
4.6 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. (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 system under control of the boiler thermostat & TRVs only does not produce the best results.
4.7 Thermal Stores & Heat Stores
1. If a thermal store or heat store is being used, it should be one approved for use with the Baxi Solo 3 PFL System Boiler.
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4.0 System Details
10
4.8 System Filling and Pressurising
1. 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.
2. The filling method adopted must be in accordance with all relevant water supply bye-laws and use approved equipment.
3. Your attention is drawn to: IRN 302 and Byelaw
14.
4. The sealed primary circuits may be filled or replenished by means of a temporary connection (Filling Loop) between the circuit and a supply pipe, provided a WRC approved 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 (Filling Loop) is removed after use (Fig. 5).
4.9 Expansion Vessel
1. The appliance expansion vessel is pre-charged to 1 bar (10 lb/in
2
). Therefore, 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. The pressure relief discharge pipe should be not less than 15mm dia, run continuously downward, and discharge outside the building, preferably over a drain. It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components. The end of the pipe should terminate facing down and towards the wall.
3. The discharge must not be above a window, entrance or other public access. Consideration must be given to the possibility that under fault conditions boiling water/steam could discharge from the pipe.
4. The pressure relief valve must not be used for draining the system/boiler.
Discharge Pipe
Fig. 5
Stop Valve
Double Check Valve
Mains
CH Return
Filling Loop
Fig. 7
Fig. 6
Pressure Relief Valve
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5.0 Site Requirements
11
5.1 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 5.5.)
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 Installation in Timber Framed Dwellings).
3. Recommendations for flues are given in BS 5440 Part 1.
5.2 Minimum Clearances (Fig. 8)
1. A flat vertical area is required for the installation of the boiler.
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 500mm shown is only necessary when the cupboard door is open. A clearance of 5mm (3/16in) is required when the door is closed.
5.3 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 (3/16in) should be left between shield and gutter (Fig. 9).
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. 8
Fig. 9
500mm for servicing
5mm during operation
5mm5mm
850mm
50mm
100mm
Aluminium
Shield
490mm
320mm
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5.0 Site Requirements
12
5.3 Flue Position (Cont)
WARNING - The addition of anything that may
interfere with the normal operation of the appliance (e.g. FLUE DAMPERS, ECONOMISERS,etc.) without the express written permission of Baxi UK Limited could invalidate the appliance warranty and infringe the GAS SAFETY (Installation and Use) REGULATIONS. If a terminal is less than 2 metres (78
3
/4in) above a balcony, above ground or above a flat roof to which people have access then a suitable terminal guard must be provided.
6. The flue terminal position must always be
in accordance with the current edition of B.S. 5440 Part 1, and either Part J of the Building Regulations England and Wales or Part F of the Building Standards (Scotland) Regulations as appropriate.
7. Table 2 and Fig. 10 show the positioning of the flue terminal relative to buildings and other structures.
8. The dimensions of the flue terminal are shown in Section 3.0 Technical Data.
5.4 Flue Dimensions
1. Flue extensions are available as optional extras for installations up to 3 metres horizontal.
2. Vertical flue kits are available up to 4 metres in length. Vertical twin flue kits are available up to 15 metres in length.
3. The standard telescopic flue is suitable for use with rear flue lengths between 100mm (4in) and 500mm (19
5
/8in).
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 (39
3
/8in) 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 lengths for side flue using the standard telescopic flue kit
355mm
335mm
Table. 2
Fig. 10
L
G
G
E
J
D
K
G
A
A
D
F
H,I
B,C
F
Likely flue positions requiring a flue terminal guard
M
N
Horizontal Terminal Position with Minimum Distance (mm)
A Directly below an openable window, air vent or any other
ventilation opening. 300 B Below gutter, drain/soil pipe. 150 C Below eaves. 200 D Below a balcony/car port roof. 200 E From vertical drain pipes and soil pipes. 150 F From internal or external corners. 300 G Above adjacent ground or balcony level. 300 H From a surface or boundary facing a terminal. 600 I Facing a terminal. 1200 J From opening (door/window) in carport into dwelling. 1200 K Vertically from a terminal on the same wall. 1500 L Horizontally from a terminal on the same wall. 300 M Above an opening, air brick, opening window etc. 300 N Horizontally to an opening, air brick, opening window etc. 300
NOTE: Scotland Only - The distance from a fanned draught appliance terminal installed at right angles to a boundary may not be less than 300mm in accordance with the diagram below.
300 min
Terminal Assembly
Top View Rear Flue
Property Boundary Line
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5.0 Site Requirements
13
5.5 Ventilation of Compartments
1. Where the appliance is installed in a cupboard or compartment, no air vents are required.
NOTE: The ventilation label on the front of the outer case MUST NOT BE REMOVED when the appliance is installed in a compartment or cupboard.
2. B.S. 5440 Part 2 Clause 4.2 refers to room sealed appliances installed in compartments. This appliance will run sufficiently cool without ventilation.
5.6 Gas Supply
1. The gas installation should be in accordance with BS 6891.
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.
NOTE: The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance.
Connection may be made via a fused double­pole isolator with a contact separation of a least 3mm in all poles and serving the appliance and system controls only.
Fig. 12
Gas Connection
Flow Connection
Return Connection
Pressure Relief Connection
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6.0 Installation
14
6.1 Initial Preparation
1. Open the hinged lower door panel and carefully disengage the door stay. Remove the door by opening it 90° and pulling forward (Fig. 13).
2. Remove the 2 screws holding the outer case to the combustion box (Fig. 13).
3. Place the outer case in a safe place until required.
4. Remove the R clip from the latch securing the combustion box to the back plate and release the latches (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 flueing or flue lengths greater than standard, the relevant optional extra kits must be obtained and their instructions followed.
Fig. 13
Lower Door Panel
Outer Case Fixing Screw
Retaining Latch
Wall Plate
Back Plate Slots
Hooks
R Clip
Fig. 14
Fig. 14a
Fig. 14b
Door Stay
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6.0 Installation
15
6.2 Initial Preparation (continued)
1. Remove the fixing template (Fig. 14c) from the carton.
2. After considering the site requirements (see Section 5.2) position the template on the wall ensuring it is level both horizontally and vertically. If it is desired that the appliance is positioned centrally between two points, mark the wall accordingly and align the template centreline with this mark.
3. Mark at least four suitable fixing holes for the wall plate. Preferably the two at either side of the flue airbox should be used. Fixing points X and Y can be used for additional securing of the combustion box assembly to the wall. Points X must be used when the optional security kit is used.
4. Drill the anchorage holes 63mm (2
1
/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 Section 6.7.
Fig. 14c
Vertical Flue Centre Line
Horizontal Flue Centre Line
Solo 3 System Boiler
GAS SUPPLY FLOW RETURN PRESSURE
RELIEF
100 mm
Minimum
Clearance
50 mm
Minimum Clearance
5 mm Minimum Clearance From Outercase To
Edge Of Template
Fixing Points marked X and Y can be
used for additional securing of the
combustion box to the wall.
Points X must be used when optional
security bolts are fitted
TEMPLATE
Boiler
Center Line
Profile of
Outercase
5 mm Minimum Clearance From Outercase To
Edge Of Template
Side And Top
Flue Template
X
X
X
X
Y
Y
Fixing Template
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