Baxi Solo HE A Quick Start Manual

Installation & Servicing Instructions

Solo HE A Range

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.

Natural Gas

Baxi Solo 12 HE A

G.C.No41 075 65

Baxi Solo 15 HE A

G.C.No41 075 66

Baxi Solo 18 HE A

G.C.No41 075 67

Baxi Solo 24 HE A

G.C.No41 075 68

Baxi Solo 30 HE A

G.C.No41 075 69

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.

The Health & Safety Executive operates the ‘Gas Safe Register’, 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With the introduction of Self Certification Schemes, the Benchmark Logbook is being withdrawn.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.

The Benchmark Scheme

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Visit www.centralheating.co.uk for more information.

© Baxi Heating UK Ltd 2014 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 Ltd, Brooks House, Coventry Road, Warwick. CV34 4LL

Full acknowledgement of author and source must be given.

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.

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.

0086

ISO 9001

FM 00866

Choose Building

Regulations Notification

Route

Installer Notification Guidelines

Competent Person's

Self Certification Scheme

Install and Commission this appliance to manufacturer's

instructions

Complete the

Benchmark Checklist

If you notify via the ‘Gas Safe

the Building Regulations

certificate on members’ behalf

Building Control

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact a government approved

inspector

Install and Commission this appliance to manufacturer's

instructions

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

or log onto:

www.gassaferegister.co.uk

within 10 days

You must ensure that the

certificate number issued by

the ‘Gas Safe Register’ is written

onto the Benchmark Checklist

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant LABC

Complete the

Benchmark Checklist

LABC will record the data

and will issue a

certificate of compliance

Legislation

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 Gas Safe 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”.

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 Gas Safe registered engineers carry an ID card with their licence number and a photograph. You can check your engineer is registered by telephoning 0800 408 5500 or online at www.gassaferegister.co.uk

This company 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 Gas Safe Registered Installer. It must be carried out in accordance with the relevant requirements of the:

• Gas Safety (Installation & Use) Regulations.

• The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland).

• The Water Fittings Regulations or Water Byelaws in Scotland.

• The Current I.E.E. Wiring Regulations.

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).

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)

Regulations 1993 N

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 GB/IE only.

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 EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings - calculations of load BS EN 14336 Installation & commissioning of water based

heating 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 EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings - calculations of load BS EN 14336 Installation & commissioning of water based

heating systems. BS 7074 Expansion vessels and ancillary equipment for

sealed water systems. BS 7593 Treatment of water in domestic hot water

central heating systems.

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 !! DO NOT ‘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 !!

Contents

Section Page

1.0 Introduction 7

2.0 General Layout 8

3.0 Appliance Operation 9

4.0 Technical Data 10

5.0 Dimensions and Fixings 11

6.0 System Details 12

7.0 Site Requirements 16

8.0 Flue Options 21

9.0 Plume Displacement 26

10.0 Installation 30

11.0 Electrical 36

12.0 Commissioning the Boiler 38

13.0 Fitting the Outer Case 41

14.0 Servicing the Boiler 42

15.0 Changing Components 45

16.0 Short Parts List 51

17.0 Fault Finding 52

Benchmark Checklist 58

Contents of Pack

The pack contains:-

• Boiler

• Wall Plate

• Template & ‘Quick Fit’ Guide

• Literature Pack

• Fittings Pack

Fig. 1

1.0 Introduction

1.1 Description

1. The Baxi Solo HE A range are gas fired room sealed fan assisted condensing central heating boilers.

2. The maximum outputs of the Baxi Solo models are:-

A - 11.82 kW (Non Condensing)

12 HE

12.81 kW (Condensing)

A - 15.24 kW (Non Condensing)

15 HE

16.49 kW (Condensing)

A - 17.81 kW (Non Condensing)

18 HE

19.27 kW (Condensing)

A - 22.0 kW (Non Condensing)

24 HE

23.8 kW (Condensing)

A - 30.18 kW (Non Condensing)

30 HE

32.61 kW (Condensing) Note: 30 HE adjustment details. All boilers automatically adjust output according to system load.

A is pre-set at 22.0/23.8 kW - see section 10.8 for

Air Box Door

Fig. 2

Lower Door Panel

Position of Label

Data Badge

3. The boiler 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).

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

7. The boiler is intended to be installed in residential / domestic 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

• Some component parts of this appliance (insulation pads, gaskets and rope seals) are manufactured from man-made mineral fibre.

• Prolonged or excessive exposure to this material may result in some irritation to the eyes, skin or respiratory tract.

• It is advisable to wear gloves when handling these items.

• 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.

• Always thoroughly wash hands after installation, servicing or changing components.

• When disposing of any items manufactured from man-made mineral fibre care must be exercised.

• If any irritation of the eyes or severe irritation of the skin is experienced seek medical attention.

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

Fig. 5

15 14

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)

Fig. 3

Fig. 4

Fig. 6

Mains On.

3.0 Appliance Operation

Flow

temperature less

than set point ?

YES

10 second Pump On.

Flow switch made ?

YES

5 second

Fan Pre-Purge.

5 second

Ignition Period.

YES

Ignition done

and less than 5

attempts made ?

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.

Flame Detected ?

shut or Flow temperature

greater than set point ?

Fan Post Purge.

YES

Burner On.

All TRVs

YES

5 second

All TRVs

shut down ?

Ignition done and 5 attempts made ?

YES

Ignition

Lockout.

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.

1 minute

Pump Overrun.

3 minute

Anti-cycle.

4.0 Technical Data

Appliance Type C

Appliance Category CAT I

Heat Input (Q)(Gross) Max Min

12 model kW 13.34 10.2

15 model kW 16.88 10.2

18 model kW 20.18 10.2

24 model kW 24.50 10.2

30 model kW 33.76 10.2 (see note)

Heat Output (P)

(Non Condensing 70° C Mean Water Temp)

12 model kW 11.82 9.14

15 model kW 15.24 9.14

18 model kW 17.81 9.14

24 model kW 22.00 9.14

30 model kW 30.18 9.14

Heat Output (P)

(Condensing 40° C Mean Water Temp)

12 model kW 12.81

15 model kW 16.49 10.1

18 model kW 19.27

24 model kW 23.8 10.1

30 model kW 32.61 10.1

Max Gas Rate (2H - G20 - 20mbar) (After 10 Mins)

(12) (15) (18) (24) (30)

m3/hr 1.34 1.64 1.94 2.31 2.95

Max Min

Injector (Natural Gas)

6.5mm Diameter

Nox Class 5

Horizontal Flue Terminal Diameter 110mm Dimensions Projection 150mm

Connections

Gas Supply -1/2in BSPT Central Heating Flow - 22mm Central Heating Return - 22mm Condensate Drain - 1 in BSP

Outercase Dimensions

Overall Height Inc Flue Elbow - 750mm Casing Height - 600mm Casing Width - 390mm Casing Depth - 285 mm

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

CO/CO2 Ratio Up to a maximum

of 0.004

CO2 Level 9% ± 1%

NOTE: All data in this section are nominal values

and subject to normal production tolerances

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

G1/2” 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 12.1)

Flow Temperature (adjustable)

55° C to 78° C (± 5° C)

Recommended System Temperature Drop

Condensing 20°C 36°F

NOTE: The maximum output of the 30 model is factory set at 22.0kW. This can be altered to 30.18kW - see section 10 .8.

SEDBUK Declaration

For 12 model - The efficiency is 90.5% For 15 model - The efficiency is 91.3% For 18 model - The efficiency is 90.4% For 24 model - The efficiency is 90.9% For 30 model - 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 0086.

Hydraulic Resistance Chart

220 200 180 160 140 120 100

80 60

Pressure Drop (mbar)

40 20

010203040

Water Flow Rate (litres/min)

91 83 75 66 58 50 42 33 25 17 8

Pressure Drop (in wg)

5.0 Dimensions and Fixings

DIMENSIONS

At least

1.5°

A 600mm

B 285mm

C 390mm

D 125mm Ø Min.

E 150mm

F 96mm

360° Orientation

The 1.5° fall provided by the elbow is to allow condensate to run back to the boiler, for disposal through the

Tube Ø 110mm

condensate discharge pipe.

Fig. 7

Fig. 8

At least

1.5°

SIDE FLUE (left and right)

For every 1m of horizontal flue length, the clearance above the top of the flue elbow should be 27.5mm to incorporate the 1.5° fall in the flue from the terminal to the elbow.

Flue length (Y)

up to 1m

1m - 2m

2m - 3m

Clearance (X)

27.5mm

55mm

82.5mm

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:

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

• 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.

• Position isolating valves as close to circulating pump as possible.

• It is recommended that the return pipe is fitted with an automatic air vent as close to the boiler as is practical.

6.2 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.

• When fitting new systems flux will be evident within the system, which can lead to damage of system components.

• All systems must be thoroughly drained and flushed out using, for example, Sentinel X300 or X400 or Fernox F3. They should be used following the flushing agent manufacturer’s instructions.

• System additives - corrosion inhibitors and flushing agents/descalers should comply to BS7593 requirements, e.g. Sentinel X100 and Fernox MB-1 which should be used following the inhibitor manufacturer’s instructions.

• Full instructions are supplied with the products, for further information contact Sentinel (0800 389 4670) or Fernox (0870 870 0362)

Failure to flush and add inhibitor to the system will 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 Technical Enquiries.

Boiler

Fig. 9

Copper

0.5m

Copper

0.5m

Flow

Return

6.0 System Details

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 on the boiler are 22mm.

Fig. 10

Automatic Air

Boiler

500mm

45°

1000mm

Min

150mm

Max

Boiler

Return

Typical Low Head Installation

500mm

45°

Vent

1000mm

Min

15mm Cold Feed

150mm

Max

22mm Open Vent

400mm

Min Head

Pump

22mm Open Vent

400mm

Min Head

Return

Pump

Flow

2. 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).

NOTE: On Solo 30 HE

A models 28mm pipe should

be used to connect to the boiler flow and return.

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. 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:

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)

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.

Fig. 11

Fig. 12

If Conditions Require,

This System Possible

200mm

Min

Boiler

22mm Feed & Vent Pipe

Air

Separator

Pump

Return

Alternative Low Head Installation

6.5 Pump

1. Providing that the cold feed and open vent pipe are positioned correctly (e.g. the system is not prone to pumping over, air entrainment etc.) the pump may be fitted on the primary return pipe.

Flow

Y Plan

Diverter

Valve

Cylinder

Stat

Room

Stat

Boiler

Pump

Timer

230V 50Hz

LNE

L N

CH on HW on HW off

LNE

L N P/FE

g/y

S Plan Valve

Cylinder

Stat

Room

Stat

Boiler

Pump

Timer

230V 50Hz

LNE

L N

CH on HW on

LNE

L N P/FE

Motor

S Plan

Valve

Motor

g/y

Y Plan

Diverter

Valve

Cylinder

Stat

Boiler

Pump

Timer

230V 50Hz

LNE

L N

CH on HW on

HW off

LNE

L N P/FE

g/y

S Plan

Valve

Cylinder

Stat

Boiler

Pump

Timer

230V 50Hz

LNE

L N

CH on

HW on

LNE

L N P/FE

Motor

S Plan

Valve

Motor

g/y

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

Key to colours

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

6.0 System Details

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.

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

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.

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

Table. 1

Safety

Valve

Fig. 13

Air

Vent

Pressure

Gauge

Boiler

System Drains at Low Point

Filling Point

Pump

Expansion Vessel

Max Boiler Flow

Temp = 82° C

Method of determining minimum valve of

expansion vessel volume for sealed systems

using Baxi Boilers

Vessel Charge Pressure (Bar)

Initial System

Pressure (Bar)

0.5

1.0

1.5

2.0

1.0

1.5

2.0

1.5

Example :-

System Volume = 75 litres

1.5

2.0

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.

3 Litre Top Up Bottle (if required)

Radiator Circuit

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

6.0 System Details

6.7 Sealed Systems (Fig. 13)

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/in 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/in

) 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 ( 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 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.

). It must be

/2in) nominal size.

Fig. 14

Stop Valve

Double Check Valve

Temporary Hose

Stop Valve

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.

CH Return

Zone 1

Zone 2

Window Recess

Zone 2

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).

Fig. A

Zone 1

Zone 0

Window Recess

Zone 2

Fig. B

0.6 m

In GB Only

Window Recess Zone 2

Zone 2

0.6 m

In GB Only

2.25 m

Ceiling

Outside Zones

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 MUST NOT BE fitted in zone 0, 1 or 2, ONLY within the shaded area (Figs. A & B shows zone dimensions for a bathtub. For other examples refer to the Current I.E.E. Wiring Regulations) reference must be made to the relevant requirements. 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.

5mm Min

390mm

5mm Min

7.0 Site Requirements

Fig. 15

200mm

600mm

50mm

7.3 Clearances (Figs. 15 &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

/2in BSPF.

3. Ensure that the pipework from the meter to the appliance is of adequate size to ensure correct operation.

Do not use pipes of a smaller diameter than the boiler gas connection.

Fig. 16

500mm

For Servicing

Purposes

5mm

In Operation

285mm

At least

1.5°

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.

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) downstream of the trap iii) to a drain or gully iv) to a purpose made soakaway v) pumped into an internal discharge branch (e.g. sink waste) downstream of the trap vi) pumped into an external soil & vent pipe vii) to a drain or gully with extended external run & trace heating

It is strongly recommended to discharge internally into the household drainage system. If connecting to a rain water drain, that drain MUST discharge into a foul drain.

Insulation

Pipe must terminate above water level but below surrounding surface. Cut end at 45°

*It is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle !

50mm per metre of pipe run

2.5° Minimum fall

Boiler

Sink

Boiler

50mm per metre of pipe run

2.5° Minimum fall

iii) Termination to a drain or gully

50mm per metre of pipe run

2.5° Minimum fall

21.5mm

i) Termination to an internal soil and vent pipe

450mm min*

ii) External termination via internal discharge branch

32mm

*450mm is applicable to properties up to 3 storeys. For multi-storey building installations consult BS 6798.

e.g sink waste - downstream*

Pipe must terminate above water level but below surrounding surface. Cut end at 45°

7.0 Site Requirements

7.6 Condensate Drain

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

CAREFUL CONSIDERATION MUST BE GIVEN TO THE POSSIBILITY OF THE PIPEWORK BEING SUBJECT TO FREEZING CONDITIONS AND APPROPRIATE MEASURES TAKEN TO PREVENT BLOCKAGE. CORRECT INSTALLATION IN ACCORDANCE WITH THIS SECTION WILL CONSIDERABLY MINIMISE THE LIKELIHOOD OF BLOCKAGE AND SUBSEQUENT BOILER LOCK-OUT.

A CONDENSATE DISCHARGE PUMP AND PIPE ‘TRACE HEATING’ ARE AVAILABLE AS ACCESSORIES - see paragraphs 7.7.12 to 7.715 for further details.

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 EXCEPT when employing a suitable condensate pump in basement and cellar or similar applications.

The boiler condensate trap incorporates a seal of 75mm, therefore it is unnecessary to install an air break and trap in the discharge pipework.

1. The condensate outlet will accept 21.5mm ( overflow pipe. It is strongly recommended that this discharges internally into the household drainage system. Where this is not possible, discharge into an outside drain is permissible providing every possible precaution is taken to prevent freezing.

2. Ensure the discharge of condensate complies with any national or local regulations in force. BS 6798 & Part H1 of the

Building Regulations give further detailed 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 of the correct design to prevent sagging.

6. It is advisable that the full length of condensate pipe is run

internally and preferably be less than 3 metres.

/4in) plastic

Boiler

iv) Termination to a purpose made soakaway

Further specific requirements for soakaway design are referred to in BS 6798.

50mm per metre of pipe run

2.5° Minimum fall

500mm min

Holes in the soak-away must face away from the building

7. Internal runs greater than 3 metres or runs in cold areas

should use 32mm waste pipe.

8. External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external use.

9. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly.

10. 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 and any burrs on cut pipe removed.

11. 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.

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