Baxi Solo 2 PF User guide

Baxi Solo 2 PF Please leave these instructions with
the user.
Wall Mounted Powered Flue
Gas Fired Central Heating Unit
Comp No230988 - Iss 22 – 11/98
Installation and
Servicing Instructions

2
Page 2
Natural Gas
Baxi Solo 2 30 PF
G.C. No41 077 71
Baxi Solo 2 40 PF
G.C. No41 077 72
Baxi Solo 2 50 PF
G.C. No41 077 73
Baxi Solo 2 60 PF
G.C. No41 077 74
Baxi Solo 2 70 PF
G.C. No41 075 01
Baxi Solo 2 80 PF
G.C. No41 077 75
Baxi 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.
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.
The boiler meets requirements of Statutory Instrument “The Boiler
(Efficiency) Regulations 1993 No3083” and is deemed to meet the
requirements of Directive 92/42/EEC on the efficiency requirements for
new hot water boilers fired with liquid or gaseous fuels:-
Type test for purpose of Regulation 5 certified by:
Notified Body 0086.
Product/Production certified by:
Notified Body 0086.
Baxi is a BS-EN ISO 9001
Accredited Company

3
Contents - Page 3
Section
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
Introduction
Technical Data
System Details
Site Requirements
Installation
Commissioning the Appliance
Fitting the Outercase
Overhead Cut-Off device
Annual Servicing
Changing Components
Short Parts List
Fault Finding
Page
4
5
7
10
13
31
33
34
35
37
41
42

4
1.0 Introduction – Page 4
B.S. Codes of Practice
1.1 Description
1. The Baxi Solo 2 PF is a gas fired room sealed fan
assisted central heating boiler with range rated outputs as
shown In the table below
2. Each appliance is preset at a MID RANGE heat input
rating and is designed for use on NATURAL GAS only.
3. All boilers are suitable for fully pumped open vented
central heating and domestic hot water systems and
sealed systems.
4. The appliance data badge is fitted to the combustion
box door.
1.2 Installation
1. The appliance is suitable for installation only in G.B.
and I.E. and should be installed in accordance with the
rules in force. For Ireland install in accordance with
I.S.813 “INSTALLATION OF GAS APPLIANCES”. The
installation must be carried out by a CORGI Registered
Installer or other competent person and be in accordance
with the relevant requirements of GAS SAFETY (Installation
and Use) REGULATIONS, the BUILDING REGULATIONS
(Scotland) (Consolidation), the LOCAL BUILDING
REGULATIONS, the CURRENT I.E.E. WIRING REGULATIONS
and the bye laws of the Local Water Undertaking. WHERE
no specific instructions are given, reference should be
made to the relevant BRITISH STANDARD CODES OF
PRACTICE.
2. All systems must be thoroughly flushed and
treated with inhibitor (see Section 3.1).
1.3 Important Information
STANDARD
B S. 6891
B S. 5546
B S. 5449
B S. 6798
B S. 5440: Pt 1
B S. 5440: Pt 2
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
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.

5
2.0 Technical Data – Page 5
Model 30 40 50 60 70 80
Heat Output (Max)
Heat Output (Min)
kW
Btu/h
kW
Btu/h
8.9
30,000
5.86
20,000
11.72
40.000
9.09
31,000
14.65
50,000
12.02
41,000
17.58
60,000
14.95
51,000
20.5
70,000
17.88
61,000
23.45
80,000
20.8
71,000
Heat Input (Max)
Heat Input (Min)
kW
Btu/h
kW
Btu/h
10.99
37,500
7.33
25.000
14.65
50.000
11.36
38,750
18.32
62,500
15.02
51.250
21.98
75,000
18.68
63.750
25.64
87,500
22.35
76,250
29.31
100,000
26.01
88,750
Burner Pressure
(Max)
Burner Pressure
(Min)
mbar
in wg
mbar
in wg
16.0 ± 0.5
6.4 ± 0.2
8.0 ± 0.5
3.2 ± 0.2
16.0 ± 0.5
6.4 ± 0.2
10.0 ± 0.5
4.0 ± 0.2
16.0 ± 0.5
6.4 ± 0.2
11.5 ± 0.5
4.4 ± 0.2
16.0 ± 0.5
6.4 ± 0.2
11.5 ± 0.5
4.4 ± 0.2
16.0 ± 0.5
6.4 ± 0.2
12.1 ± 0.5
4.8 ± 0.2
16.0 ± 0.5
6.4 ± 0.2
11.5 ± 0.5
4.4 ± 0.2
Gas Rate CV 38MJm31.04m3/h 1.39m3/h 1.74m3/h 2.08m3/h 2.78m3/h 2.78m3/h
(after 10 mins) 36.86ft3/h 49.0ft3/h 61.3ft3/h 73.5ft3/h 98.1ft3/h 98.1ft3/h
Lifting Weight kg
lbs
23.1
51
23.1
51
23.1
51
32.2
71
32.2
71
34.2
75.5
Water Content Litres
pints
1.1
1.9
1.1
1.9
1.1
1.9
1.6
2.8
1.6
2.8
1.3
2.3
Outercase
Dimensions
Height
Width
Depth
600mm
350mm
287mm
600mm
350mm
287mm
600mm
350mm
287mm
600mm
462mm
287mm
600mm
462mm
287mm
600mm
462mm
287mm
Flue Terminal
Dimensions
Diameter
Depth
100mm
65mm
Static Head Max
Min
30 metres (100 ft)
1 metres (3.25 ft)
Connections Flow
Return
22mm Cu tail
22mm Cu elbow
Heat Exchanger Cast iron monobloc
Low Head Min 0.2m (8 in)
System Design fully pumped open vented and sealed systems
Gas Connection RC ½ ( ½ in BSPT)
Electrical Supply 230V - 50Hz fused 5A - 90W
Controls boiler thermostat, pilot & electronic flame sensing, timed pump over-run,
frost protection thermostat
Internal Fuse 4AF 250V to BS4256 situated on control board

6
2.0 Technical Data – Page 6

7
3.0 System Details – Page 7
3.1 Water Circulating Systems
1. The appliance Is suitable for use with open vent fully
pumped systems, sealed systems and where additional
control protection is required. The following conditions
should be observed on all systems:
•The static head must not exceed 30m (100ft) of
water.
•The boiler must not be used with a direct cylinder.
•The boiler Is fitted with a timed pump overrun that will
operate for approximately 8 minutes.
•Drain cocks should be fitted to all system low points.
•All gas and water pipes and electrical wiring must be
installed in a way which would not restrict the
servicing of the boiler.
•Position isolating valves as close to circulating pump
as possible.
Treatment of Water Circulating Systems
•All recirculatory water systems will be subject to
corrosion unless an appropriate water treatment is
applied. This means that the efficiency of the system
will deteriorate as corrosion sludge accumulates
within the system, risking damage to pump and
valves, boiler noise and circulation problems.
•For optimum performance after installation this boiler
and its associated central heating system must be
flushed in accordance with the guidelines given in BS
5793:1992 “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 Femox
(01799 550 811) directly.
•For long term protection against corrosion and scale,
after flushing it is recommended that an inhibitor such
as BetzDearborn Sentinel X1 00, or Femox MB-1 or
Copal is dosed in accordance with the guidelines
given in BS 5793:1 992.
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.
3.2 Bypass Requirements
1. The boiler is fitted with a pump overrun device which
allows the removal of residual heat from the boiler.
NOTE: The pump overrun will operate for
approximately 8 minutes. The system design must
therefore, always provide an open circuit for water to
circulate between the boiler flow and return.

8
3.0 System Details – Page 8
3.3 Pipework
1. The sizes of flow and return pipes from the boiler
should be determined by normal methods, according to
the requirements of the system.
2. An 11º C (20ºF) drop in temperature across the
system is recommended.
3.4 System Controls
1. For optimum operating conditions, the heating system
into which the boiler is installed should include a control
system.
2. Such a system will comprise of a timer control and
separate room or cylinder thermostats as appropriate.
3. The boiler should be controlled so that it operates on
demand only.
4. Operation of the system under control of the boiler
thermostat only does not produce the best results.
5. A frost thermostat is fitted integrally to the appliance
controls and will protect the boiler from frost damage by
operating the burner when the water temperature in the
boiler drops towards freezing point. The boiler will fire as
necessary to maintain a temperature above freezing.
NOTE: The frost thermostat operates even if the
boiler thermostat is in the OFF (‘0’) position and it is
necessary therefore, if the system is drained, for the
external electrical and gas supplies to be isolated. It
is recommended that a label be affixed to the
appliance to draw attention to the fact that the system
has been drained.
3.5 Low Head Installation
For boilers up to 50,000 Btu/h output
1. Using a close couple arrangement the minimum head
is as shown in the diagrams (Figs. 5 & 6) subject to the
following conditions:
a) The correct heat input.
b) The pump being adjusted to give an 11º C drop
across the boiler.
c) The pump must be fitted on the flow.
d) The pump must be fitted in accordance with the
pump manufacturers instructions.
e) The open vent pipe must be taken up from a tee in a
horizontal section of the flow pipe.
Alternative Low Head Installation for all Sole 2 PF
(Fig. 7)
2. If less height is available then a combined vent and
feed pipe may be connected. This must be a minimum of
22mm diameter. It is recommended that an air separator
is fitted when using a combined feed and vent pipe.

9
3.0 System Details – Page 9
Method of determining minimum value of expansion vessel
volume for sealed systems using Baxi Boilers
Table 1 NOTE
Where a vessel of the calculated size is not obtainable then the
next available larger size should be used
3.6 Sealed Systems (Fig. 8)
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 lbf/in2). It must be
arranged to discharge any water or steam through a pipe
to a safe outlet position.
2. PRESSURE GAUGE - A pressure gauge of minimum
range 0-4 bar (0-60 lbf/in2) with a fill pressure indicator
must be fitted to the system, preferably at the same point
as the expansion vessel in an easily visible position.
3. EXPANSION VESSEL - An expansion vessel
complying with the requirements of BS 4814 must be
fitted to the system by means of a connection close to the
inlet side of the circulating pump in accordance with the
manufacturers instructions, the connecting pipe being
unrestricted and not less than 15mm ( ½ in) nominal size.
The volume of the vessel should be suitable for the
system water content and the nitrogen or air charge
pressure should not be less than the system static head
(See Table. 1).
Further details of sealed system design can be obtained
from BS 5449 and the British Gas publication entitled
‘Specifications for Domestic Wet Central Heating
Systems’.
4. FILLING POINT - A filling point and an approved stop
valve to BS 1010 must be fitted at low level and the
method used for filling the system should be approved by
the local water undertaking. For further details see BS
6798.
5. MAKE UP SYSTEM - A method of replacing water lost
from the system should be provided either by means of a
make up vessel of not more than 3 litres (5 pints)
capacity, mounted above the highest point of the system,
or by pre-pressurisation of the system.
6. VENTING - A method of venting the system during
filling and commissioning must be provided by fitting
automatic air vents or by venting manually.
7. HOT WATER STORAGE - The hot water storage
vessel must be of the indirect coil type. All components
used in the system must be suitable for operation at
110ºC (230ºF) and at the pressure allowed by the safety
valve.

10
4.0 Site Requirements – Page 10
4.1 Location
1. The appliance may be tilted 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 (Fig. 9). The appliance should be
fitted within the building unless otherwise protected by a
suitable enclosure ie. garage or outhouse. (The appliance
may be fitted inside a cupboard. Cooling ventilation and
insulation of the cupboard are not required,
see section 4.5.)
2. If the appliance is fitted in a room containing a bath or
shower reference must be made to the Current l.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 British Gas
document DM2.
3. Recommendations for flues are given in BS 5440 Part
1.
4.2 Clearances (Fig. 10)
1. A flat vertical area is required for the installation of the
boiler measuring as shown in the table below for each
model.
2. These dimensions include the necessary clearances
around the appliance for case removal, spanner access
and air movement. Additional clearances may. Be
required for the passage of pipes around local
obstructions such as joists running parallel to the front
face of the appliance.
3. If fitted inside a cupboard the clearance of 300mm
shown is only necessary when the cupboard door is
open. A clearance of 5mm (3/16 in) is required when the
door is dosed.
4.3 Flue Position
1. For installations where the flue terminal is inaccesible
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 (19½ in) of a painted eave or a
painted gutter, an aluminium shield of at least 1 metre
(39in) long should be fitted to the underside of the gutter
or painted surface. An air space of 5mm (3/16 in) should
be left between shield and gutter (Fig. 11).
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 wail is of combustible
material, it should be protected by fitting the flue trim
provided.

11
4.0 Site Requirements – Page 11
4.3 Flue Position (Ctd)
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 Heating Ltd
could invalidate the appliance warranty and infringe
the GAS SAFETY (Installation and Use)
REGULATIONS.
If a terminal is less than 2 metres (78 ¾ in) above a
balcony, above ground or above a fiat roof to which
people have access then a suitable terminal guard
must be provided.
6. Table 2 and the accompanying diagram show the
positioning of the flue terminal relative to buildings and
other structures.
7. The dimensions of the flue terminal are shown in
Fig. 12.
A
B
C
D
E
F
G
H
I
J
K
L
Terminal Position with Minimum Distance
Directly below an openable window or other
opening, e.g. an air brick.
Below gutters.
Below eaves, soil pipes or drain pipes.
Below balconies or car port roof
From vertical drain pipes and soil pipes.
From internal or external corners.
Above ground, roof or balcony level.
From a surface facing a terminal.
From a terminal facing a terminal.
Vertically from a terminal on the same wall.
Horizontally from a terminal on the same wall.
For an opening in a car port (e.g. door, window)
into a dwelling.
(mm)
300
25
75
200
75
25
300
600
1200
1500
300
1200
4.4 Flue Dimensions
1. The standard flue supplied with the appliance is
suitable for use with flue lengths between 100mm (4in)
and 685mm (27in).
NOTE: Maximum flue length when flued to the left or
right is
584mm (23 n) - 30, 40, 50 PF
533mm (21 in) - 60, 70, 80 PF
2. Flue extension kits are available as an optional extra
for installations up to 1 metre (39 3/8in) and up to 2
metres (79 ¾ in). 2 metre kit is not available for the 70
and 80 PF model.
Table 2 3. A vertical flue kit, with flue breaker, is also available as
an optional extra (Sol-Ver Kit).
4. Where it is intended to pass the flue through a
combustible wall or timber framed dwelling, reference
should be made to British Gas publication DM2.
5. If the flue is more than 1.8 metres (70 7/8in) long, it is
required that it is supported.
6. All above dimensions are taken from the
respective faces of the outer case.

12
4.0 Site Requirements – Page 12
4.5 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. The Solo 2 PF will
run sufficiently cool without ventilation
4.6 Gas Supply (Fig. 13)
1. The gas installation should be in accordance with BS
6891.
2. The connection of the appliance is a RC ½ ( ½ in
BSPT internal) located at the rear of the gas cock.
3. 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.
4.7 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 5k
NOTE: The method of connection to the electricity
supply must facilitate complete electrical isolation of
the appliance.
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.

13
5.0 Installation – Page 13
5.1 Initial Preparation
1. Unpack contents of carton.
2. Remove the lower door panel from the outer case.
Remove the 2 screws holding the outer case to the
combustion box.
3. Place the ready assembled outer case in a safe place
until required.
4. Release the R clips from the two latches securing the
combustion box to the back plate and release the latches
(Fig. 14).
5. Lift and remove the combustion box from the back
plate (Fig. 15). Place the combustion box on its back.
IMPORTANT - When installing a Solo 2 with a rear flue
see section 5.2 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 above the
standard 610mm (24 in) the relevant optional extra
kits must be obtained and their instructions followed.

14
5.0 Installation – Page 14
5.2 Fan Outlet Restrictor (30, 40, 50. 60, 70 and 80)
Rear Flue only up to 686mm (27 in)
1. Release the four latches holding the combustion box
door (Fig 16a). Remove the combustion box door by
pulling forward from the bottom and unhooking its top
edge (Fig. 16).
2. Release the 5-pin electrical plug connecting the
pressure switch and fan (Fig. 17). Withdraw the fan
assembly by pulling forwards from the top edge (Fig. 16).
3. Take the sheetmetal restrictor (supplied in the kit of
parts), check that the number stamped on the restrictor
matches the appliance (e.g. 50 stamped on the restrictor
is for 50 PF appliance)
4. Fit the restrictor to the fan outlet flange, bending the 3
lugs equally over the flange to secure (Fig. 18).
5. Re-assemble the fan assembly and combustion box
door.

15
5.0 Installation – Page 15
5.3 Position the Boiler (Fig. 19)
1. Choose a suitable position for. the boiler making
necessary allowances for the minimum clearances
required as shown in the table below.
ModeI A
30 360
40 360
50 360
60 472
70 472
80 472
2. Hold the wall template against the wall at the required
boiler location. Ensure that the top of the template is level
(Fig. 20).
3. The template represents the outer limits of the appliance
plus the required minimum side clearance.
4. Mark the position of the flue hole centre and the inward
pointing corners of the two triangular cut-outs in the
template. Mark the position of the four fixing holes. Where
possible use the uppermost and lowest fixing hole
positions, otherwise space the fixing holes as far apart as
possible (Fig. 20).
5.4 Rear Flue
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
quoting Baxi Part Nº 226441.
2. If using the internal fitting kit a 117mm (4 5/8in)
diameter hole is required.
3. Drill the anchorage holes 63mm (2 ½ in) deep to accept
suitable wall plugs (Fig. 21).
4. Using the previously marked flue hole centre, cut a hole
approximately 107mm (4 ¼ in) diameter in the masonry for
the 100mm (4 in) diameter flue duct. (When using a core
drill, it is important to keep the drill level and square).

16
5.0 Installation – Page 16
5.5 Rear Flue Preparation
1. Measure the wall thickness (Fig. 22) and to this
dimension add 60mm (2 3/8in).
2. Take the flue duct and mark off wall thickness + 60mm
(2 3/8in) from the swaged end of the duct and cut to size
(Fig. 23). (Use the tape provided to give an accurate
cutting guide by wrapping it around the flue duct with the
edge marking the cutting line).
3. Wall Thickness 280mm - 685mm (11in - 27in) -Take
the telescopic air duct from its pack. Open the air duct out
to the wall thickness. Using the tape provided seal the
joints of the three sections of the air duct, ensuring an
overlap of at least 30mm (1 3/16 in) at each joint (Fig. 24).
NOTE: The seams of all three sections must be in line.
4. Wall Thickness 100mm - 280mm (4in - 11in) if the
wall thickness is less than 280mm (11 in), it will be
necessary to cut the components of the air duct to the
appropriate size. Dispose of the centre section, as this is
not required (Fig. 25).
5. Measure the wall thickness and subtract 30mm (1 3/16
in) from this dimension. Cut the remaining sections to this
length, measuring from the positions indicated in the
diagram (Fig. 25).
6. Engage the sections, one inside the other, then open
the assembly out to wall thickness. Tape the sections
together using the tape provided, ensuring that the seal is
good (Fig. 26).
NOTE: The seams of both sections must be in line.

17
5.0 Installation – Page 17
5.6 Assembly of Rear Flue
1. Remove the rear air box blanking plate from the back
plate by releasing the three screws (Fig. 27).
2. Remove the blanking cap at the rear of the turret, by
pushing and turning anti-clockwise to release the bayonet
fitting (Fig. 28).
3. Locate the swaged end of the flue duct over the
bayonet fitting on the turret, taking care not to damage
the ‘0’ ring. Lock the flue duct in place by pressing in and
turning clockwise (Fig. 29).
4. Ensure all seams of the air duct sections are
uppermost and that the ‘0’ ring seal is in position against
the sealing flange.
5. Fit the air duct over the flue duct and draw towards the
back plate, ensuring that the flue duct locates into
position in the terminal end of the air duct.
6. Engage the bayonet slots of the air duct over the
location lugs of the back plate opening and press and turn
clockwise to secure the air duct to the back plate (Fig.
30).
7. In order to increase security of the flue, the bayonet
tags may be deformed to secure the flue in position.

18
5.0 Installation – Page 18
5.7 Fitting the Back Plate
1. Engage the assembly into the hole previously cut in
the wall and slide in place (Fig. 31).
2. Secure the assembly to the wall at the previously
drilled anchorage points with suitable screws (Fig. 31).
Before finally tightening the screws, check that the
assembly is level.
3. Make good between the wall and the air duct outside
the building if the internal fitting kit has not been used
(Fig. 32).
4. The flue trim provided may be fitted if required, to
neaten up the make-up around the terminal. This plate
may also be used as a protection plate on outside walls of
combustible material.
5. Fit the trim over the flue terminal and mark through the
four securing holes. Remove the trim, drill holes 63mm (2
½ in) deep to accept suitable wall plugs. Fit the trim over
the flue terminal and secure using suitable screws (Fig.
33).

19
5.0 Installation – Page 19
5.8 Left or Right Flue
NOTE: if the flue terminal is inaccessible from outside
the building, it is necessary to fix the internal fitting
kit in position before continuing with the installation.
(See section 5.15 Internal Fitting Kit of these
instructions).
1. The procedure for fitting the appliance flued to the left
or right hand side is the same.
2. 30-40-50 PF- Left/Right Hand Side maximum flue
584mm (23 in).
3. 60-70-80 PF - Left/Right Hand Side maximum flue
533mm (21 in).
4. Using the previously marked flue hole centre and the
two marks made at the triangular cutouts of the template,
mark the horizontal centre line for the flue assembly (Fig.
34).
5. Extend this line either left or right as required, to the
corner of the room (Fig. 34).
6. Extend the horizontal centre line around the corner for
approximately 300mm (12 in). Ensure that the line
remains horizontal by checking with a spirit level (Fig. 35).
7. From the wall template remove the detachable section
outlined and marked. Using this as a template, line up the
horizontal triangular cut outs with the extended 300mm
(12 in) line and make sure that the flat of the template is
butted up against the corner of the wall (Fig. 36).
8. If the appliance mounting wall is out of true, use string
or a straight edge to determine the true corner position
and mark a vertical line to accommodate the flat edge of
the template.
9. Holding the template firmly, mark the vertical centre
line for the flue assembly by marking the point at the
outer corners of the upper and lower cut outs (Fig. 37).
10. Remove the template and draw a vertical line
between the two marks. The intersection of the vertical
and horizontal lines is the centre of the flue hole (Fig. 38).
11. 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.
12. If using the internal fitting kit a 117mm (4 5/8in)
diameter hole is required.
13. Cut a hole approximately 107mm (4 ¼ in) diameter in
the masonry for the 100mm (4 in) diameter flue duct (Fig.
39). (Use of a core drill is recommended. When using a
core drill, it is important to keep the drill level and square,
particularly with the wall onto which the boiler is to be
fitted).
14. Drill the anchorage holes 63mm (2 ½ in) deep to
accept suitable wall plugs.

20
5.0 Installation – Page 20
5.9 Side Flue Preparation
1. For both Left and Right Hand Flue – Measure the
distance from the wall to the nearest line marked from the
template. This will be known as distance R (Fig. 40).
2. Measure the thickness of the wall from the inside. This
will be known as distance W (Fig 41).
3. Add these two figures together plus 168mm (6 5/8in) for
30-40-50 PF and 224mm (8 7/8in) for 60-70-80 PF
4. 30-40-50 PF:
Flue Duct Length = R + W + 168mm (6 5/8in)
5. 60-70-80 PF:
Flue Duct Length = R + W + 224mm (8 7/8in)
6. Mark oft the appropriate length from the swaged end of
the flue duct. Cut the duct to length and dispose of the
unwanted length. (Use the tape provided to give an
accurate cutting guide by wrapping it around the flue duct
with the edge marking the cutting line) (Fig. 42).
7. Take the telescopic air duct from its pack.
Open the air duct out to the length:-
(30-40-50 PF) R + W + 91mm (3 9/16 in)
(60-70-80 PF) R + W + 147mm (5 ¾ in)
8. Using the tape provided seal the joints of the three
sections of the air duct, ensuring an overlap of at least
30mm (1 3/16 in) at each joint (Fig. 43).
NOTE: The seams of all three sections must be in line.
9. If the wall thickness (W) plus the distance from the wall
to the side of the boiler case (R) is less than 202mm (8 in),
it will be necessary to cut the components of the air duct to
make up the appropriate size. Dispose of the centre
section as this is not required (Fig. 44).
(30-40-50 PF) R + ‘N + 91mm (3 9/16 in)
(60-70-80 PF) R + ‘N + 147mm (5 ¾ in)
10. Engage the sections, one inside the other, then open
the assembly out to wall thickness. Tape the sections
together using the tape provided, ensuring that the seal is
good (Fig. 45).
NOTE: The seams of both sections must be in line.