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.