Baxi Barcelona System User guide

Baxi Barcelona
Wall Mounted Powered Flue Condensing Boiler
Gas Fired Central Heating Unit
Installation and
Servicing Instructions
BAXI

Page 2
Natural Gas
Baxi Barcelona
G.C.Nº 41 075 02
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 designed 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 the requirements of Statutory Instrument
“The Boiler (Efficiency) Regulations 1993 Nº 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.
Baxi is a BS-EN ISO 9001
Accredited Company

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
13.0
14.0
15.0
Introduction
General Layout
Appliance Operation
Technical Data
Dimensions and Fixings
System Details
Site Requirements
Installation
Electrical
Commissioning the Boiler
Fitting the Outer Case
Servicing the Boiler
Changing Components
Short Parts List
Fault Finding
Page
4
5
6
7
8
9
12
16
22
24
25
26
28
35
36

1.0 Introduction – page 4
Fig.1
Fig. 2
“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.
Baxi Limited declare that no substances harmful to health
are contained in the appliance or used during appliance
manufacture.
NOTE: This appliance must be installed in accordance with
the manufacturer’s instructions and the regulations in force,
and only used in a suitably ventilated location.
All systems must be thoroughly flushed and treated
with inhibitor (see Section 6.2).
Read the instructions fully before installing or using the
appliance
1.1 Description
1. The Baxi Barcelona is a gas fired room sealed fan
assisted condensing central heating boiler.
2. The maximum output of the boiler is preset at 80,000
Btu/hr. The boiler will automatically adjust down to
30,000 Btu/hr according to the system load. If required,
the output can be set to 100,000 Btu/hr. Please refer to
section 8.8.
3. It 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 /
commercial / light industrial E.M.C. 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
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 HEPA. 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.

2.0 General Layout – page 5
2.1 Layout (Figs. 3,4 & 5)
1. Wall Plate
2. Flue Elbow
3. Heat Exchanger
4. Burner
5. Air Box
6. Fan Protection Thermostat
7. Fan Assembly
8. Condensate Trap
9. User Interface (optional timer available)
10. Gas Tap
11. Gas / Air Ratio Valve
12. Electronics Housing
13. Transformer
14. Flow Pipe Connection
15. Return Pipe Connection
16. Flow Temperature Safety Thermostat - Black
17. Flow Temperature Thermistor - Red
18. Flow Switch (dry fire protection)
2.2 Optional Extras
KIT PART Nº
FLUE EXTENSION KITS (110/70)
Flue Extension 0.25M 241692
Flue Extension 0.5M 241694
Flue Extension 1 M (Use two kits for 2M etc.) 241695
Flue Bend x 2 – 45º (Reduce overall length
of flue by 0.5m when fitting this bend) 241689
Flue Bend – 90º (Reduce Overall length of
flue by 1m when fitting each bend) 241687
VERTICAL FLUE (110/70)
Vertical Flue Terminal 242802
Vertical Boiler Connection 242886
CONTROL ACCESSORIES
Integral Electronic Twin Channel Timer Kit 242834

3.0 Appliance Operation – page 6
3.1
1. Pump Overrun: When the switched live to the boiler
switches on or the flow temperature is greater than the
set point or anti-cycle finishes then Pump Overrun
occurs for 10 seconds (cold) or 60 seconds (hot). The
pump is on while the fan, spark generator and gas
valve are off.
2. Fan Purge: When pump overrun has finished if the flow
temperature is less than that set on the thermostat
knob then Fan Purge occurs. The pump and fan are on
while the spark generator and gas valve are off.
3. Ignition: When fan purge has finished Ignition occurs.
The pump, fan, spark generator and gas valve are on.
The burner ignites at mid rate.
4. Burner On: When a flame is detected during the
ignition period then Burner On occurs. 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.
5. Anti-cycle: When all the TRVs shut down during
Burner On or Pump Overrun finishes and flow
temperature is greater than set point then Anti-cycle
occurs. The pump, fan, spark generator and gas valve
are switched off.
6. Ignition Lockout: When 5 ignition attempts have been
made without a flame being detected then Ignition
Lockout occurs. The pump, fan, spark generator and
gas valve are switched off. The lockout light flashes
once a second. The boiler can only be reset manually
using the thermostat knob.
7. No Water Flow: When there is No Water Flow through
the boiler (indicated by the flow switch) then a
continuous cycle of Pump Overrun and Anti-cycle
occurs.

4.0 Technical Data – page 7

5.0 Dimensions and Fixings – page 8
Fig. 6
Fig 7
DIMENSIONS
A 600mm
B 320mm
C 390mm
D l25mm Ø Min.
E 150mm
F 125mm
The 3º (1 in 20) fall provided by the elbow is
to allow condensate to run back to the boiler,
for disposal through the condensate
discharge pipe.
SIDE FLUE (left and right)
For every 1 m of horizontal flue length,
the clearance above the top of the flue
elbow should be 55mm to incorporate
the 3º (1 in 20) fall in the flue from the
terminal to the elbow.
Flue length (Y) Clearance (X)
Up to1m 55mm
1m-2m 110mm
2m-3m 165mm

6.0 System Details – page 9
Fig. A Wiring to the pump feed connection of boiler
Fig. B Providing a 3 l/mm bypass
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.
NOTE: Full TRV Systems (refer to section 6.4) Where all
the radiators are controlled by TRV’s then pump protection
will be required. This can be done by either of the options
opposite (see Fig A & B). The option shown in Fig. A
should only be used on a full TRV system without a
bypass. Fig. B shows a system with a bypass that must
be capable of allowing a flow of at least 3 l/mm.
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 upgrading existing systems that exhibit evidence
of sludging, it is advisable to clean the system prior to
treatment in order to remove any sludge and reduce the
likelihood of these deposits damaging new
components.
•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. The recommended flushing and cleansing agents
are Betz-Dearborn Sentinel X300 or X400 and Fernox
Superfloc Universal Cleanser which should be used
following the flushing agent manufacturer’s instructions.
•System additives - corrosion inhibitors and flushing
agents/descalers should be suitable for aluminium and
comply to BS7593 requirements. The only system
additives recommended are Betz-Dearborn Sentinel
X100 and Fernox-Copal which should be used following
the inhibitor manufacturer’s instructions.
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 the Baxi Helpline.

6.0 System Details – page 10
Fig. 7a
Fig. 8 Typical Low Head Installation
Fig. 9 If Conditions Require,
This System Possible
Fig. 10 Alternative Low Head Installation
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 to the
boiler is 28mm (compression).
2. Due to space requirements within the boiler outercase,
pipework should comprise of solder fittings.
3. A 20ºC (36ºF) 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 11ºC (20ºF).
4. 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. 7a).
6.4 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.
(An integral twin channel programmer is available as an
optional extra).
3. The boiler should be controlled so that it operates on
demand only.
4. Operation of the system under control of the boiler
thermostat & TRV’s only does not produce the best
results.
6.5 Low Head Installation
1. Using a close couple arrangement the minimum head is
as shown in the diagrams (Figs. 8 & 9) subject to the
following conditions:
a) The pump being adjusted to give an 20ºC drop across
the boiler.
b) The pump must be fitted on the flow.
c) The pump must be fitted in accordance with the pump
manufacturers 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. 10)
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.
6.6 Thermal Stores
1. The Barcelona must not be fitted to thermal stores
which override the boiler control system.

6.0 System Details – page 11
Fig 11
Table 1
NOTE
Where a vessel of the calculated size is not obtainable
then the next available larger size should be used.
6.7 Sealed Systems (Fig. 11)
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 re-pressurisation of the system.
6. VENTING - A method of venting the system during
filling and commissioning must be provided by fining
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.

7.0 Site Requirements – page 12
Fig. 12
Fig. 13
7.1 Information
WARNING - Check the information on the data plate is compatible
with local supply conditions
1. The installation must be carried out by a CORGI Registered
Installer or other registered competent person and be in
accordance with the relevant requirements of the current GAS
SAFETY (Installation and Use) REGULATIONS, the
BUILDING REGULATIONS (Scotland)(Consolidation), the
LOCAL BUILDING REGULATIONS, the current I.E.E.
WIRING REGULATIONS and the bye laws of the LOCAL
WATER UNDERTAKING. Where no specific instruction is
given reference should be made to the relevant BRITISH
STANDARD CODES OF PRACTICE. For Ireland install in
accordance with IS 813 “INSTALLATION OF GAS
APPLIANCES”. Reference should also be made to BRITISH
GAS GUIDANCE NOTES FOR THE INSTALLATION OF
DOMESTIC GAS CONDENSING BOILERS.
7.2 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 Ventilation
BS 7074 Expansion vessels and ancillary equipment for
sealed water systems.
BS 7593 Treatment of water in domestic hot water
central heating systems
WARNING - The addition of anything that may interfere with the
normal operation of the appliance without the express written
permission of Baxi Limited could invalidate the appliance warranty
and infringe the GAS SAFETY (Installation and Use)
REGULATIONS.
7.3 Clearances (Figs. 12 &13)
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.
7.4 Location
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 7.5).
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
reference must be made to the current I.E.E.WIRING
REGULATIONS and BUILDING REGULATIONS, If the boiler
is to be fitted into a building of timber frame construction then
reference must be made to the Institute of Gas Engineers
document UP 7.

7.0 Site Requirements – page 13
Fig14
Fig. 15
7.5 Ventilation of Compartments (Fig. 14)
1. Where the boiler 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.
NOTE: Both air vents must communicate with the same
room or both be on the same wall to outside air
2. Detailed recommendations for air supply are given in
BS 5440: Part 2.
3. 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.
7.6 Gas Supply
1. The gas installation should be in accordance with
BS6891.
2. The connection to the appliance is a ½in BSPT internal
threaded connection located at the rear of the gas
service cock (Fig. 15).
3. Ensure that the pipework from the meter to the
appliance is of adequate size. (22mm pipework must be
connected to the appliance gas service cock. This
should extend for at least 3 meters back towards the
gas meter).
Do not use pipes of a smaller diameter than the
boiler gas connection.
7.7 Electrical Supply
1. External wiring must be correctly earthed, polarised and
in accordance with current l.E.E. WIRING
REGULATIONS.
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.
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.
7.8 Condensate Drain
NOTE: Ensure the discharge of condensate complies with
any national or local regulations in force.
1. The condensate outlet terminates in a 1” BSP nut and
seal for the connection of 21.5mm (¾in) plastic
overflow pipe which should generally discharge
internally into the household drainage system. If this is
not possible, discharge into an outside drain is
acceptable.
2. The pipe should run internally as much as possible and
with a 10º (1 in 6) fall to dispose of condensate quickly
to avoid freezing.

7.0 Site Requirements – page 14
Fig. 16 7.9 Flue
NOTE:Due to the nature 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 following guidelines indicate the general
requirements for siting balanced flue terminals.
Recommendations for flues are given in BS 5440 Pt.1.
2. If the terminal is fitted within 1 metre (39 in) of a plastic
gutter, within 500mm (19½ in) of a painted eave or a
painted gutter, an aluminium shield of at least 1 metre
(39 in) 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. 16).
3. 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.
4. Take into consideration the effect the plume of vapour
may have on neighbours when siting the flue.
5. If a terminal is less than 2 metres (78¾ in) above a
balcony, above ground or above a flat roof to which
people have access, then a suitable terminal guard
must be provided.
Fig. 17
Terminal Position with Minimum Distance Fig 17 mm
ADirectly below an openable window or other opening,
e.g. an air brick.
BBelow gutters, soil pipes or drain pipes.
CBelow eaves.
DBelow balconies or car port roof.
EFrom vertical drain pipes and soil pipes.
FFrom internal or external corners.
GAbove ground, roof or balcony level.
HFrom a surface facing a terminal.
IFrom a terminal facing a terminal.
JVertically from a terminal on the same wall.
KHorizontally from a terminal on the same wall.
LFor an opening in a car port (e.g. door, window) into a
dwelling.
300
75
200
200
75
300
300
600
1200
1500
300
1200

7.0 Site Requirements – page 15
Fig. 18
Fig 18a
Pictorial examples of flue runs where EQUIVALENT flue
length equals 4m
Fig. 19
7.10 Flue Dimensions
See Section 1.2. The standard horizontal flue kit allows for
flue lengths between 270mm (10 5/8”) and 800mm (32”)
from elbow to terminal
(Fig. 18).
The maximum permissible equivalent flue length is:
4metres (Fig. 18a).
NOTE: Each additional 45º of flue bend will account for an
equivalent flue length of 0.5m
eg. 45º = m, 90º = 2 x 45º = 1m etc.
7.11 Terminal Guard (Fig. 19)
1. When codes of practice dictate the use of terminal
guards, they can be obtained from most Plumbers’ and
Builders’ Merchants.
2. When ordering a terminal guard, quote the appliance
model number.
3. The guard manufacturers listed below can be contacted
for terminal sizes and guard model numbers.
Tower Flue Components Ltd.,
Tower House,
Vale Rise,
Tonbridge,
Kent.
Tel: [phone].
Quinnell, Barrett & Quinnell,
884 Old Kent Road,
London,
SE15 1NL.
Tel: [phone].
4. The flue terminal guard should be positioned centrally
over the terminal and fixed as illustrated
7.12 Vertical Flue
1. Only a flue approved with the Baxi Barcelona can be
used.
2. For information on vertical flues consult the Baxi
Barcelona Installer Guide or Notes for Guidance
supplied with the vertical flue pack.

8.0 Installation – page 16
Fig. 20
Fig. 21
Fig. 22
Check Site Requirements (section 7) before
commencing.
8.1 Initial Preparation
The gas supply, gas type and pressure must be checked
for suitability before connection (see Section 7.6).
NOTE: If the boiler wall plate is to be pre-hung, follow both
these instructions and those on the boiler pack.
1. Remove the fixing template (Fig. 20) from the carton.
2. After considering the site requirements (see Section 7.0
) position the template on the wall ensuring it is level
both horizontally and vertically.
3. Mark the position of the centre hole for the wall plate
(Fig. 20).
4. Mark the centre of the flue hole (rear exit). For side exit,
mark as shown (Fig. 21). If required, mark the position
of the gas and water pipes. Remove the template.
5. Cut the hole for the flue (minimum diameter 125mm,
see table for wall thicknesses and flue diameters).
6. Drill and plug the wall as previously marked. Secure the
wall plate using the centre hole.
7. Ensuring the wall plate is level both horizontally and
vertically, drill and plug at least 4 securing positions at
the top and bottom through the wall plate. Utilising the
slots available ensure the wall plate is square and
secure to the wall (Fig. 22).
8. Loosely route the condensate discharge pipe to the
lower left hand side of the wall plate.

8.0 Installation – page 17
Fig. 23 8.2 Preparing The Boiler
1. Remove the outer carton.
2. Remove the internal packaging.
3. Lift the outercase upwards and remove (Fig. 23).
Baxi Limited declare that no substances harmful to
health are contained in the appliance or used during
appliance manufacture.

8.0 Installation – page 18
Fig. 24 8.3 Fitting The Boiler (Fig. 24)
1. Remove the screw and retaining bracket from the wall
plate spring clip.
2. Offer up the boiler to the wall plate and locate the rear
bottom edge onto the self locating support at the base
of the wall plate.
3. Rotate the boiler and engage into temporary spring
retaining latch.
4. Ensure the boiler is secured with the retaining
bracket and screw previously removed,
immediately.
5. Remove thread protection caps from the FLOW and
RETURN connections.
8.4 Making the Water Connections (Fig. 25)
1. The boiler has two side water connections, the front
connection being FLOW and the rear connection being
RETURN.
2. It is essential that Flow and Return pipes are connected
to the correct fittings. The flow connection incorporates
the boiler thermostats and a flow switch. To avoid
damage to the flow switch when tightening the flow
connection the use of two spanners is recommended.
3. A copper elbow, compression nut and olive are
provided in the kit for the return connection.
NOTE: Drain cocks should be fitted to all system’s low
points and vents to all high points.
4. Ensure that any pipework is routed so as to leave the
boiler via the spaces at the rear of the outer case,
either at the top or at the bottom.
Pipework within the confines of the outercase should
consist of solder fittings.
NOTE: It is important that the pipework does not interfere
with the correct fitting of the outer case and a space of 14
mm clearance must be left between any vertical pipes and
the outer edge of the wall plate.
8.5 Making the Condensate Drain Connection
1. Connect the condensate drain using the 1 “BSP nut
and seal supplied. (see section 7.8.).
NOTE: To ensure the correct operation and integrity of
the condensate drainage system
- Carefully pour approximately 1 cupful (250ml) of water into
the flue products exhaust, at the top of the heat exchanger
(Fig. 25a) to ensure a seal is made in the trap.

8.0 Installation – page 19
Fig. 26
Fig. 27
Fig. 27a
8.6 Making the Gas Connection
1. Connect the gas supply to the RC½ (½in BSPT
internal) gas tap located on the lower right side of the
boiler.
8.7 Fitting The Flue
Before fitting the flue, check the condensate drain
integrity (see section 8.5).
IMPORTANT: The flue should always be installed with a 3º
(1 in 20) fall from terminal to elbow, to allow condensate to
run back to the boiler.
HORIZONTAL FLUE
1. The standard flue is suitable for lengths 270mm
minimum to 800mm maximum (measured from the
edge of the flue elbow outlet).
Rear Flue: maximum wall thickness - 630mm
Side Flue: maximum wall thickness - 565mm (left or right)
2. For rear exit - measure the wall thickness (Fig. 26) and
to this dimension add 235mm. This dimension to be
known as (X).
i.e. (X) = wall thickness + 235
3. Take the flue and mark off (X) from the terminal end as
indicated in the diagram (Fig. 27).
Check your dimensions.
The flue tubes are fixed together. Cut through both
tubes whilst resting the flue on the semicircular packing
pieces. Deburr both tube ends.
4. For side exit - measure the distance from the edge of
the wall plate to the inner face of the wall (Fig. 26) and
to this dimension add the wall thickness + 275mm. This
dimension to be known as (Z).
i.e. (Z) = wall plate to wall + wall thickness + 275
5. Take the flue and mark off (Z) from the terminal end as
indicated (Fig. 27).
Check your dimensions.
The flue tubes are fixed together. Cut through both
tubes whilst resting the flue on the semicircular packing
pieces. Deburr both tube ends.
IMPORTANT: Check all measurements before cutting
NOTE: When cutting ensure the cut does not interfere with
the inner flue support bracket (Fig. 27a).

8.0 Installation – page 20
Fig 28 8.7 Fitting the Flue (Cont)
6. Ensure the inner flue support bracket is positioned in
the flue (Fig. 28).
7. Engage the flue into the flue elbow using soap solution
to ease the engagement ensuring the flue is assembled
as shown (Fig. 29).
8. Place the gasket over the flue exit on the boiler.
9. Slide the flue assembly through the hole in the wall.
10. Engage the elbow on to the flue connection on top of
the boiler. Secure with the four screws supplied in the
kit.
11. Make good between the wall and air duct outside the
building ensuring the 3º drop between the terminal and
elbow.
12. The flue trim should be fitted once the installation is
complete and the flue secure (Fig. 30). Apply a suitable
mastic to the inside of the trim and press against the
wall finish, making sure the brickwork is dust free and
dry.
13. If necessary fit a terminal guard (see Section 7.11).
VERTICAL FLUEING
1. Only a flue approved with the Baxi Barcelona can be
used.
2. For information on vertical flues consult the Baxi Gas
Central Heating Boilers Installer Guide or Notes for
Guidance supplied with the vertical flue pack.