Baxi Solo 2 60 RS User guide

Please leave these Instructions with the User.
Baxi Solo 2 RS Range
Wall Mounted Room Sealed
Gas Fired Central Heating Boilers
Installation and
Servicing Instructions

2
Natural Gas
Baxi Solo 2 60 RS
G.C.No. 41 077 79
Baxi Solo 2 50 RS
G.C.No. 41 077 78
Baxi Solo 2 40 RS
G.C.No. 41 077 77
Baxi Solo 2 30 RS
G.C.No. 41 077 76

Baxi UK Limited is one of the leading manufacturers of
domestic heating products in the U.K.
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.
Baxi is also the largest manufacturing partnership in the
country. Everyone who works at the company has a
commitment to quality because, as shareholders, we
know that satisfied customers mean continued success.
We hope you get a satisfactory service from Baxi. If
not, please let us know.
3
Baxi is a BS-EN ISO 9001
Accredited Company

CONTENTS
Introduction
Technical Data
System Details
(and By-pass Requirements)
Site Requirement
Installation
Commissioning the Appliance
Fitting the Outer Case
Overheat Cut-Off Device
Annual Servicing
Changing Components
Fault Finding
Short Parts List
PAGE 5
PAGE 6 - 7
PAGE 8 - 11
Water Circulating Systems
System Controls
Pipework
Fully Pumped, Open Vented Systems
Low Head Installation
Sealed Systems
Gravity Systems
Hydraulic Charts
PAGE 12 - 14
Location
Clearances
Flue Position
Flue Dimensions
Ventilation of Compartments
Gas Supply
Electrical Supply
PAGE 15 - 25
Initial Preparation
Flue Preparation
Fitting the Wall Mounting Plate
Fitting the Flue Duct
Terminal Guard
Fitting a Terminal Guard
Fitting the Boiler
Water Connections
Pipe Routes
Fully Pumped System
Sealed System
Gravity Hot Water System
Gas Connection
Electrical Supply
PAGE 26 - 27
PAGE 28
PAGE 29
PAGE 30 - 32
Dismantling the Boiler
Cleaning the Burner/Injectors
Cleaning the Combustion Box
PAGE 33 - 40
Eco Interrupter Leads
Piezo Igniter
Solenoid Operator
Thermocouple
Spark Electrode & Lead
Pilot Injector
Pilot Bracket & Gasket
Overheat Thermostat
Main Thermostat
Pump Overrun Timer
Removal of Combustion Chamber Door
Burner and Injectors
Gas Valve
Insulation Panels
PAGE 41
PAGE 42
4

INTRODUCTION
Description
The Baxi Solo 2 RS is a wall mounted gas
fired room sealed natural draught central
heating boiler with range rated outputs as
shown in the table below.
Each appliance is preset at its MAXIMUM
heat input rating and is designed for use on
NATURAL GAS only. They are suitable for
gravity domestic hot water with pumped
central heating, fully pumped open vented
central heating and domestic hot water and
sealed systems.
The standard flue assembly supplied is suitable
for wall thicknesses between 100mm (4in) and
356mm (14in). An optional flue extension kit is
available for walls of 356mm (14in) and 610mm (24in)
thickness.
The appliance data badge is fitted to the combustion
chamber door above the gas valve.
Installation
The installation must be carried out by a CORGI
Registered Installer and be in accordance with the
relevant requirements of 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
instruction is given reference should be made to the
relevant BRITISH STANDARD CODES OF
PRACTICE.)
Important Information
This product contains Refractory Ceramic Fibres (R.C.F.) which are
man-made vitreous silicate fibres. Excessive exposure to these
materials may cause temporary irritation to eyes, skin and respiratory
tract. Care must be taken when handling these articles to ensure the
release of dust or fibres is kept to a minimum. To ensure that the
release of fibres from these articles is kept to a minimum, during
installation and servicing it is recommended that a H.E.P.A. filtered
vacuum is used to remove any dust, soot or other debris
accumulated in and around the appliance. This should be performed
before and after working on the installation. It is recommended that
any replaced item(s) are not broken up but sealed within heavy duty
polythene bags and clearly labelled “R.C.F. waste”. This is not
classified as “hazardous waste” and may be disposed of at a tipping
site licensed for the disposal of industrial waste. Protective clothing is
not required when handling these articles but it is recommended that
gloves are worn and the normal hygiene rules of not smoking, eating
or drinking in the work area are followed and always wash hands
before eating or drinking.
HEAT OUTPUT
Model Min Max
30 6.15kW (21,000 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)
5
B.S. Codes of Practice
STANDARD SCOPE
BS 6891 Gas Installation.
BS 5546 Installation of hot water supplies
for domestic purposes.
BS 5449 Part 1 Forced circulation hot water
systems.
BS 6798 Installation of gas fired hot water
boilers.
BS 5440 Part 1 Flues.
BS 5440 Part 2 Air Supply.
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 could invalidate the
appliance warranty and infringe the GAS SAFETY
(Installation and Use) REGULATIONS.
“Benchmark” Log Book
As part of the industry-wide “Benchmark”initiative
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.

TECHNICAL DATA
30 RS
40 RS
Heat Input Max Min
kW 11.00 7.69
Btu/h 37,500 26,250
Heat Output Max Min
kW 8.79 6.15
Btu/h 30,000 21,000
Burner Pressure Max Min
mbar 15.4 +0.5 8.0 +0.5
in wg 6.2 +0.2 3.2 +0.2
Gas Connection RC1/2(1/2in BSPT)
Electrical Supply 230V~50Hz
fused 3A
Controls on/off boiler thermostat
with pilot/thermocouple cut
out/overheat
thermostat on fully
pumped applications only
Heat Exchanger cast iron monobloc
Lifting Weight 37.3 kg (82.1 lbs)
Water Content 2.1 litres (0.46 gals)
Static Head Max Min
metres 30 1
feet 100 3.25
Low Head Min 0.15m (6in)
System Design gravity hot water fully
pumped open vented
and sealed systems
Connections 2 x 22mm and a kit for
gravity
Gas Rate
(after 10 mins) 1.05m3/h (37.0ft3/h)
Outercase Height 600mm
Dimensions Width 420mm
Depth 287mm
Flue Terminal Height 208mm
Dimensions Width 293mm
Depth 173mm
Heat Input Max Min
kW 14.65 11.36
Btu/h 50,000 38,750
Heat Output Max Min
kW 11.72 9.09
Btu/h 40,000 31,000
Burner Pressure Max Min
mbar 16.3 +0.5 10.3 +0.5
in wg 6.5 +0.2 4.1 +0.2
Gas Connection RC1/2(1/2in BSPT)
Electrical Supply 230V~50Hz
fused 3A
Controls on/off boiler thermostat
with pilot/thermocouple cut
out/overheat
thermostat on fully
pumped applications only
Heat Exchanger cast iron monobloc
Lifting Weight 37.3 kg (82.1 lbs)
Water Content 2.1 litres (0.46 gals)
Static Head Max Min
metres 30 1
feet 100 3.25
Low Head Min 0.15m (6in)
System Design gravity hot water fully
pumped open vented
and sealed systems
Connections 2 x 22mm and a kit for
gravity
Gas Rate
(after 10 mins) 1.40m3/h (49.3ft3/h)
Outercase Height 600mm
Dimensions Width 420mm
Depth 287mm
Flue Terminal Height 208mm
Dimensions Width 293mm
Depth 173mm
50
50
5
5
300
80
for
ravity
for
servicing
5
inside
cupboard
Clearances
50
50
5
5
300
80
for
ravity
for
servicing
5
inside
cupboard
Clearances
NOTE: On gravity applications a clearance
of 80mm (31/8in) is required from the top
panel
NOTE: On gravity applications a clearance
of 80mm (31/8in) is required from the top
panel
6

50 RS
60 RS
Heat Input Max Min
kW 18.32 15.02
Btu/h 62,500 51,250
Heat Output Max Min
kW 14.65 12.02
Btu/h 50,000 41,000
Burner Pressure Max Min
mbar 16.3 +0.5 11.2 +0.5
in wg 6.5 +0.2 4.5 +0.2
Gas Connection RC1/2(1/2in BSPT)
Electrical Supply 230V~50Hz
fused 3A
Controls on/off boiler thermostat
with pilot/thermocouple cut
out/overheat
thermostat on fully
pumped applications only
Heat Exchanger cast iron monobloc
Lifting Weight 37.3 kg (82.1 lbs)
Water Content 2.1 litres (0.46 gals)
Static Head Max Min
metres 30 1
feet 100 3.25
Low Head Min 0.15m (6in)
System Design gravity hot water fully
pumped open vented
and sealed systems
Connections 2 x 22mm and a kit for
gravity
Gas Rate
(after 10 mins) 1.75m3/h (61.6ft3/h)
Outercase Height 600mm
Dimensions Width 420mm
Depth 287mm
Flue Terminal Height 208mm
Dimensions Width 293mm
Depth 173mm
Heat Input Max Min
kW 21.98 18.68
Btu/h 75,000 63,750
Heat Output Max Min
kW 17.58 14.95
Btu/h 60,000 51,000
Burner Pressure Max Min
mbar 16.0 +0.5 12.0 +0.5
in wg 6.4 +0.2 4.8 +0.2
Gas Connection RC1/2(1/2in BSPT)
Electrical Supply 230V~50Hz
fused 3A
Controls on/off boiler thermostat
with pilot/thermocouple cut
out/overheat
thermostat on fully
pumped applications only
Heat Exchanger cast iron monobloc
Lifting Weight 37.3 kg (82.1 lbs)
Water Content 2.1 litres (0.46 gals)
Static Head Max Min
metres 30 1
feet 100 3.25
Low Head Min 0.15m (6in)
System Design gravity hot water fully
pumped open vented
and sealed systems
Connections 2 x 22mm and a kit for
gravity
Gas Rate
(after 10 mins) 2.09m3/h (74.0ft3/h)
Outercase Height 600mm
Dimensions Width 420mm
Depth 287mm
Flue Terminal Height 208mm
Dimensions Width 293mm
Depth 173mm
50
50
5
5
300
80
for
ravity
for
servicing
5
inside
cupboard
Clearances
50
50
5
5
300
80
for
ravity
for
servicing
5
inside
cupboard
Clearances
NOTE: On gravity applications a clearance
of 80mm (31/8in) is required from the top
panel
NOTE: On gravity applications a clearance
of 80mm (31/8in) is required from the top
panel
7

This system is unlikely to
require a By-pass unless all
radiators are thermostatically
controlled
Water Circulating Systems
The appliance is suitable for use with fully pumped
open vented systems (small bore and micro-bore),
gravity domestic hot water with pumped central heating
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 only be used with an indirect
cylinder.
Drain points should be fitted to the lowest points in
the system.
All electrical wiring, gas and water pipes must be
installed in a way which would not restrict the servicing
of the boiler.
Position isolating valves as close to circulating pump
as practicable.
For fuel economy and best boiler performance, the
system should be designed so that gravity circulation
does not take place in the heating system when the
pump is not running.
Treatment of Water Circulating Systems
For optimum performance after installation, this boiler and its
associated central heating system must be flushed in
accordance with the guidelines given in BS7593:1992
“Treatment of water in domestic hot water central heating
systems”.
This must involve the use of a proprietry cleanser, such as
BetzDearborn’s Sentinel X300 or X400, or Fernox’s Superfloc. Full
instructions are supplied with the products but for immediate
information please contact BetzDearborn on 0151 420 9563, or
Fernox on 01799 550811.
For long term protection against corrosion and scale, after flushing it
is recommended that an inhibitor such as BetzDearborn’s Sentinel
X100, or Fernox’s MB-1 or Copal is dosed in accordance with the
guidelines given in BS7593:1992.
Failure to flush and add inhibitor to the system may
invalidate the appliance warranty.
BYPASS REQUIREMENTS
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 3 minutes. The system design must
therefore always provide an open circuit for water to circulate
between the boiler flow and return.
If a system has an open circuit a bypass is not required.
A system using a 3 port diverter valve does not normally require a
bypass and therefore this system is recommended. The exception to
this is where all radiators in the system are fitted with thermostatic
valves, in which case a bypass would be required. However, if one
radiator in such a system was fitted with 2 lockshield valves a bypass
would not be required.
A system controlled by non-electrical valves e.g. mechanical
thermostatic control valves both on the radiators and the hot water
circuit and systems using twin zone valves (e.g. Honeywell 'S' Plan)
will require a bypass.
The bypass circuit can be:-
A) A minimum of 9 metres of 22mm pipe (measured between the
boiler flow and return connections). It should be fitted with a
lockshield valve opened at least 1 full turn to give a minimum flow rate
of 8 litres/min (1.8 gal/min).
B) A radiator fitted with lockshield 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(4ft2) is adequate.
C) By including an automatic bypass valve in the system (see
diagram).
D) Any circuit that provides the same operating conditions as option A
or option B.
Radiator Circuit
Examples of
Open Circuits
By-pass
Loops
SYSTEM DETAILS
(and By-pass Requirements)
Air Vent
Boiler
Pump
Radiator
Circuit
Fully Pumped System
Optional
Bypass
8
A By-pass is
required with
this system
Air
Vent
Radiator
Circuit
Twin Zone
Valve System
Air
Vent
Radiator
Circuit
3 Port Diverter
Valve System
Typical Systems Arrangement
B
F
R
BC
C
A
A
Flow from boiler
Boiler
Pump
Valve
A = D. H. W. Zone valve
B = C. H. Zone valve
C = Automatic Bypass valve
Bypass length = A + B + C
Bypass Incorporating
Automatic Valve
Bypass Length

Boiler Pump
Flow
Return
400mm
Min Head
22mm
Open Vent
15mm
Cold
Feed
1000mm
Min
150mm
Max
500mm
45o
Boiler Pump
Flow
Return
22mm
Feed & Vent
Pipe
200mm
Min
Air
Separator
Boiler Pump
Flow
Return
22mm
Open Vent
15mm
Cold
Feed
1000mm
Min
150mm
Max
500mm
45o
Automatic
Air
Vent
400mm
Min Head
Typical Low Head Installation
Alternative Layout
Alternative Low Head Installation
9
System Controls
For optimum operating conditions, the heating system
into which the boiler is installed should include a
control system.
Such a system will comprise of timer control and a
separate room or cylinder thermostat as appropriate.
The boiler should be controlled so that it operates on
demand only.
Operation of the system under control of the boiler
thermostat only, does not produce the best results.
Pipework
The sizes of flow and return pipes from the boiler
should be determined by normal methods, according to
the requirements of the system.
It is recommended that the system is designed for an
11 °C (20°F) drop in temperature across the
system.
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. The copper pipe must not
be insulated.
Fully Pumped, Open Vented Systems
Low Head Installation
Using a close couple arrangement the minimum head
is as shown in the diagram, subject to the following
conditions:
1) The correct heat input.
2) The pump being adjusted to give an 11oC drop
across the boiler.
3) The pump must be fitted on the flow.
4) The pump must be fitted in accordance with the
pump manufacturer's instructions.
5) 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 2 RS
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.
Boiler
Flow
Return
Copper
0.5m
Copper
1m
Copper
0.5m
Copper Pipe In Non-Metallic System

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
then the next available larger size should
Sealed Systems
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/in2). It must be arranged to
discharge any water or steam through a pipe to a safe
outlet position.
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.
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.
Further details of sealed system design can be
obtained from BS 5449: Part 1 and the British Gas
publication entitled 'Specifications for Domestic Wet
Central Heating Systems'.
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.
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.
VENTING
A method of venting the system during filling and
commissioning must be provided by fitting automatic
air vents or by venting manually.
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 110OC (230OF) and at the
pressure allowed by the safety valve.
Boiler
Safety
Valve
System Drains
at Low Point
Expansion
Vessel
Pump
Pressure
Gauge
Filling
Point
Air
Vent
3 Litre
Top Up Bottle
(If Required)
Radiator
Circuit
Max Boiler Flow
Temp = 82OC
10

4.5 9.0 13.5 18.0 22.5
(1) (2) (3) (4) (5)
(12)30
(8)20
(4)10
0
Water Flow litres/min (gal/mi
n
Pressure Drop mbar (in wg)
30 RS
40 RS
50 RS
60 RS
Hydraulic Resistance Chart
For Gravity Systems - with injector wash
e
(16)40
(20)50
Gravity Systems
When the boiler is to be installed to an existing or new
gravity domestic hot water and pumped central heating
system, the following considerations should be given
to the design of the gravity domestic hot water flow
and return pipes.
The minimum circulating head should not be less
than 1m (3ft) with a maximum horizontal run of
3m (10ft) when using 28mm pipes. Smaller pipe
sizes and longer horizontal runs are acceptable
with suitably increased circulating heads.
The system must be designed to prevent
reverse circulation.
Pipes should be laid to maximum fall avoiding
points of possible air lock.
If the domestic hot water temperature is controlled by a
cylinder thermostat and zone valve, it is recommended
that a bypass is installed in the gravity circuit. One
method is to install a bathroom radiator, fitted with two
lock shield valves. Mechanical valves which allow the
boiler to operate when the valve is closed should not
be used.
Note: If the above conditions cannot be met, then
pumped primaries must be used.
See page 25 for wiring of boiler when installed with
gravity hot water.
Hydraulic Charts
Boiler
Bathroom Radiator used
as Gravity Circuit Bypass
when a Zone Valve is used
4.5 9.0 13.5 18.0 22.5
(1) (2) (3) (4) (5)
(12)30
(8)20
(4)10
0
Water Flow litres/min (gal/
m
Pressure Drop mbar (in wg)
30 RS
40 RS
50 RS
60 RS
Hydraulic Resistance Chart
(For Fully Pumped Systems)
11

SITE REQUIREMENTS
Location
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 other-wise protected
by a suitable enclosure ie. garage or outhouse. The
appliance may be fitted inside a cupboard provided that
ventilation requirements and combustible material
standards are adhered to.
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
current edition of Institute of British Gas Engineers
Publication IGE/UP/7 (Gas Installations in Timber
Framed Housing).
Recommendations for flues are given in BS 5440 Pt1.
Clearances
A flat vertical area is required for the installation of the
boiler measuring as shown. A space above
the boiler should also be left clear as
indicated by the dotted lines.
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.
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 from the
front of the casing when the door is closed.
NOTE: On gravity applications a clearance of 80mm
(31/8 in) is required from the top panel.
Flue Position
The following guide lines indicate the general
requirements for siting balanced flue terminals.
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.
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.
If the outer surface of an outside wall is of combustible
material, it should be protected by fitting a non-
combustible plate so that it extends not less than 50mm
(2in) around the terminal.
Aluminium
Shield
600
420
50
50
5
5
300
12

Terminal Position with Minimum Distance (mm)
A Directly below an openable window or other
opening, e.g. an air brick. 300
B Below gutters, soil pipes or drain pipes. 300
C Below eaves. 300
D Below balconies or car port roof 600
E From vertical drain pipes and soil pipes. 75
F From internal or external corners. 600
G Above ground, roof or balcony level. 300
H From a surface facing a terminal. 600
I From a terminal facing a terminal. 600
J Vertically from a terminal on the same wall. 1500
K Horizontally from a terminal on the same wall. 300
L For an opening in a car port (e.g. door, window)
into a dwelling. 1200
WARNING
If a terminal is less than 2 metres (783/4in) above a
balcony, above ground or above a flat roof to which
people have access then a suitable
terminal guard must be provided.
Flue Dimensions
Recommendations for flues are given in BS 5440:1.
The standard flue terminal supplied with the appliance
is suitable for use with wall thickness between 100mm
(4in) and 356mm (14in).
A flue terminal extension kit is available as an optional
extra for wall thickness between 356mm (14in) and
610mm (24in) from the manufacturer. Quote appliance
Model Nowhen ordering.
D
F
F
G
B,C
A
G
E
G
J
K
D
L
H,I
Likely positions requiring
a flue terminal guard
D
A
293
208
173
13

Ventilation of Compartments
Where the appliance is installed in a cupboard or
compartment, air vents are required (for cooling
purposes) in the cupboard or compartment at high
and low level which may communicate with a room
or direct to outside air.
Detailed recommendations for air supply are given
in BS 5440: Part 2.
An existing cupboard or compartment may be used,
provided that it is modified for the purpose.
Recommendations for air supplies and details of
essential cupboard compartment design are given in
BS 5440: Part 2.
NOTE: Both air vents must communicate with the
same room or both be on the same wall to outside
air.
MINIMUM AIR VENT FREE AREA
Gas Supply
The gas installation should be in accordance with
BS 6891.
The connection on the appliance is RC1/2
(1/2in BSPT internal) located at the bottom right
hand side of the appliance.
Ensure that the pipework from the meter to the
appliance is of adequate size. Do not use pipes
of a smaller diameter than the appliance gas
connection.
Electrical Supply
External wiring must be correcty earthed, polarized
and in accordance with CURRENT I.E.E. WIRING
REGULATIONS.
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, preferably by the use of a fused three pin
plug and unswitched shuttered socket outlet, both
complying with the requirements of BS 1363.
Alternatively, connection may be made via a fused
double-pole isolator with a contact separation of a
least 3mm in all poles and serving the appliance and
system controls only.
Model Position of Air from Air direct
Air Vent Room from Outside
30 HIGH AND 99.0cm2FREE AREA 49.5cm2FREE AREA
LOW LEVEL (15.35in2) (7.68in2)
40 HIGH AND 131.9cm2FREE AREA 66.0cm2FREE AREA
LOW LEVEL (20.44in2) (10.22in2)
50 HIGH AND 164.9cm2FREE AREA 82.5cm2FREE AREA
LOW LEVEL (25.56in2) (12.78in2)
60 HIGH AND 197.9cm2FREE AREA 99.0cm2FREE AREA
LOW LEVEL (30.67in2) (15.34in2)
14

Unpack the contents of carton leaving the combustion
box and mounting plate assembled on the base tray.
Place the outer case in a safe place until required.
Detach the fixing template from the packaging.
Remove the two wing nuts securing the
combustion box to the mounting plate.
Disengage the spring latch and lift the
combustion box away from the airbox. Place
the combustion box on its back.
Choose a flat vertical area to position the boiler,
making necessary allowances for required
minimum clearances. If fitting between wall
cupboards ensure that the minimum available width is
as shown.
Hold the wall template against the wall at the required
boiler location. Ensure that the top of the template is
level. The template represents the outer limits of the
appliance, plus the required minimum clearances.
NOTE: On gravity applications a clearance of 80mm
(31/8 in) is required from the top panel.
If fitting the appliance between or adjacent to kitchen
wall units, ensure that the line on the template
indicating the lower edge of the boiler is level with the
lower edge of the units and is correctly spaced.
If fitting the appliance in a compartment or cupboard
with suitable air vents (see Ventilation of
Compartments), ensure that the bottom edge of the
template is level with the lower edge of the units and
is correctly spaced.
Two holes are provided on the template to allow gas
and electrical supplies to be brought directly into the
boiler from the wall. The grommet provided must be
used when the electrical cable is routed through the
wall mounting plate.
Mark the position of the flue hole and four good
anchorage points. Where possible use the
uppermost and lowest fixing hole positions,
otherwise space the fixing holes as far
apart as possible. Mark gas and
electrical supply access holes if
required. Cut out hole for flue. Drill
anchorage holes 7mm (9/32 in)
diameter by 63mm (2l/2in) deep to
accept wall plugs.
Make good internal masonry up to edges of
flue cut-out.
INSTALLATION
Initial Preparation
430
50
50
700
27
77 144
156
324
374
360
184184
Outline of
Outer Case Outline of
Wall Aperture
Centre of
Gas Connection
8 Slots
10 x 6
175150
Centre of
Electrical
Connection
414
207
292
Fixing Template
15

Flue Preparation
Unpack flue duct, flue trim and air duct.
Measure overall wall thickness. If this is between
280mm (11in) and 355mm (14in), use flue as
supplied without alteration.
For wall thickness between 102mm (4in) and 280mm
(11in), air duct and flue duct are required to be
shortened.
Using the indication on the duct, mark accordingly to
table below.
Bend tabs as shown.
Using tin snips, cut around ducts at appropriate
mark. Remove any sharp edges.
Wall Thickness
Air Duct
Flue Duct
Flue Trim
Cut off Wall Thickness
3in 203mm - 280mm
(8in) - (11in)
6in 127mm - 203mm
(5in) - (8in)
7in 102mm - 127mm
(4in) - (5in)
16

Fitting the Wall Mounting Plate
Secure plate to wall using 63mm (21/2in) screws.
From outside building, pass air duct
through wall opening. The two tabs
should be positioned at the bottom.
Slide air duct over inner
duct until tabs contact
wall surface.
Ensure air duct is horizontal and square to wall face.
Using sealing tape supplied make good the joint on
inside of the two ducts.
Make good with
cement mortar
between the
outside wall and
duct.
Sealing Tape
Air Duct
Tab
Inner Duct
17

Fitting the Flue Duct
Fit flue trim over air duct.
Slide flue duct inside air duct to
engage flue duct on boiler, noting
correct positioning as labelled.
Secure flue duct, flue trim to
air duct with four screws
provided in the kit.
Remove label from duct.
Flue Trim Sealing
Tape
Air Duct
Tabs
Air Duct
Flue Duct
18
Label

Terminal Guard
When codes of practice dictate the use of terminal
guards, they can be obtained from most plumbers and
builders merchants nationwide.
When ordering a terminal guard, quote the appliance
model number.
The guard manufacturers listed below can be
contacted for terminal sizes and guard model
numbers.
Quinnell, Barrett & Quinnell,
884 Old Kent Road,
London, SE15 1NL.
Tel: [phone].
Tower Flue Components Ltd.,
Tower House,
Vale Rise,
Tonbridge,
Kent.
Tel: [phone]
Fitting a Terminal Guard
Position the guard over the terminal on the outside
wall. Ensure guard is equally spaced about
terminal. Mark fixing positions.
Drill and plug fixing positions, then
secure guard to wall.
19

Fitting the Boiler
When the boiler is to be used on a system with gravity
D.H.W. it is necessary to disconnect the overheat
thermostat by removing the wire with the black sleeve
and attaching it to the wire with the red sleeve as
shown.
The overheat thermostat is now by-passed and will
allow the appliance to perform satisfactorily on gravity
circulation.
NOTE: Even though the overheat thermostat is not
operational, it must not be removed from the pocket in
the heat exchanger except during servicing.
Lift boiler and engage centrally the back bottom edge
into the hook bracket on the mounting plate.
Rotate the boiler back to the mounting plate to
engage two studs and spring latch.
Fit the two wing nuts. Tighten to compress rear
flue seal.
20