Baxi Barcelona System Page 5 Installation And Servicing Instructions Download

Page: 5 / 46

2.0

General Layout - Page 5

2.1 Layout

(Figs. 3,4 & 5)

Wall Plate

Flue Elbow

Heat Exchanger

Burner

Air Box

Fan Protection Thermostat

Fan Assembly

Condensate Trap

User Interface (optional timer available)

10. Gas Tap

11. Gas / Air Ratio Valve

12. Electronics Housing

13. Transformer

14. Flow Temperature Safety Thermostat - Black

15. Flow Temperature Thermistor - Red

16. Flow Switch (dry fire protection)

17. Circulation Pump

18. Automatic Air Vent

19. Pressure Relief Valve

20. Water Pressure Gauge

21. Expansion Vessel

Summary of Contents for Barcelona System

Page 1: ...ase leave these Instructions with the User Baxi Barcelona System Wall Mounted Powered Flue Condensing Boiler Gas Fired Central Heating Unit Comp No 243612 Iss 5 4 00 Installation and Servicing Instructions ...

Page 2: ... 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 ...

Page 3: ...ction 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 Fault Finding Short Parts List Page 4 5 6 7 8 9 12 17 23 25 26 27 29 38 46 ...

Page 4: ...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 Optional Extras Benchmark Log Book As part of the industry wide Benchmark intiative all Baxi boilers now include an Installa...

Page 5: ... Condensate Trap 9 User Interface optional timer available 10 Gas Tap 11 Gas Air Ratio Valve 12 Electronics Housing 13 Transformer 14 Flow Temperature Safety Thermostat Black 15 Flow Temperature Thermistor Red 16 Flow Switch dry fire protection 17 Circulation Pump 18 Automatic Air Vent 19 Pressure Relief Valve 20 Water Pressure Gauge 21 Expansion Vessel ...

Page 6: ...ected 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 sp...

Page 7: ...4 0 Technical Data Page 7 ...

Page 8: ...5 0 Dimensions and Fixings Page 8 ...

Page 9: ... 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 ...

Page 10: ...ng 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 8a 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 t...

Page 11: ...1 The appliance expansion vessel is pre charged to 1 bar 10 lb in2 Therefore the minimum cold fill pressure is 1 bar The vessel is suitable for correct operation for system capacities up to 125 litres 27 5gal For greater system capacities an additional expansion vessel must be fitted refer to BS 7074 Pt 1 6 8 Pressure Relief Valve Figs 10 11 1 The pressure relief valve is set at 3 bar therefore al...

Page 12: ... 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 ca...

Page 13: ... appliance is of adequate size 22mm recommended at the appliance 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 I 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 electric...

Page 14: ...ill 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 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 Terminal Position with Minimum Distance Fig 17 ...

Page 15: ...rom 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 01732 351555 Quinnell Barrett Quinnell 884 Old Kent Road London SE15 1NL Tel 0171 639 1357 4 The flue terminal guard should be ...

Page 16: ...ration Their equivalent lengths are Concentric Pipes 45o bend 0 5 metres 90o bend 1 0 metres Twin Flue Pipes Air Duct Flue Duct 45o bend 1 3 metres 2 6 metres 90o bend 4 8 metres NOTE The elbow supplied with the standard horizontal flue is not included in any equivalent length calculations 5 The illustrations opposite show examples of maximum equivalent lengths 6 Full details of part numbers and d...

Page 17: ...f the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 125mm see table opposite for wall thickness flue diameter s 7 Drill and plug the wall as previously marked Secure the wallplate to the wall by the top centre hole 8 Ensuring the wallplate is level both horizontally and vertically drill and plug the remaining 4 securing positions at the top and bottom through...

Page 18: ...the outercase upwards to disengage the hooks on the backplate and remove Fig 23 4 Remove the sealing plugs from the copper bends 5 Stand the boiler on its base by using the rear lower edge as a pivot NOTE A small amount of water may drain from the boiler in the upright position Baxi Limited declare that no substances harmful to health are contained in the appliance or used during construction of t...

Page 19: ...he gas tap 6 Insert the fibre sealing washers between the valve outlet face and the flange on the copper bends of the water circuit connections 7 Tighten the connections 8 5 Making the Condensate Drain Connection 1 Connect the condensate drain using the 1 BSP nut and seal supplied see section 7 8 2 For better access loosen the left hand electrical box transformer mounting plate securing screws and...

Page 20: ...whilst resting the flue on the semi circular packing pieces Deburr both tube ends 4 For left hand 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 Y i e Y wall plate to wall wall thickness 275mm 5 Take the flue and mark off Y from the terminal end as indicated Fig 27 6 For...

Page 21: ...upplied 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 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 Fig 30 If necessary fit a terminal guard see s...

Page 22: ...x the control PCB is the right hand board b Pull off the two jumper connections at the top rear corner of the PCB Fig 32a c Replace the PCB and continue with the installation 6 Lay the cable through the cable clamp to gauge the length of cable required when it is connected to the 4 way terminal block Fig 32 7 Connect the S L N and wires to the 4 way terminal block and refit the cable clamp Fig 33 ...

Page 23: ...9 0 Electrical Page 23 ...

Page 24: ...9 0 Electrical Page 24 9 2 Illustrated Wiring Diagram ...

Page 25: ...ge the system according to BS 6891 5 Turn the gas service cock anticlockwise to the ON position and check for gas soundness up to the gas valve 6 Turn the boiler control knob fully clockwise to HIGH Fig 34 and run the system and check the boiler for correct operation NOTE The boiler is self regulating and the gas rate will modulate between inputs of 33 76kW and 10 2kW dependent upon the system loa...

Page 26: ...rs Operating Installation and Servicing Instructions and the Log Book giving advice on the necessity of regular servicing 5 Advise the user that a plume of vapour from the flue terminal is normal and that there is no need for concern IMPORTANT This boiler is fitted with an aluminium alloy heat exchanger It is important that the system is thoroughly flushed in accordance with BS 7593 and that one o...

Page 27: ...CO2 ratio is greater than 0 02 then a more extensive service and investigation will be required If the CO CO2 ratio is less than 0 02 proceed as follows 4 Ensure that the boiler is cool 5 Ensure that both the gas and electrical supplies to the boiler are isolated 6 Remove the outercase and lower door panel see Fitting the Outercase Section 11 0 7 Release the four turn screws securing the air box d...

Page 28: ...d disconnect the sensor leads Fig 42 g Remove the two screws securing the burner and remove the burner Visually inspect the internal burner baffle for obstruction NOTE The burner skin is fragile handle with care Clean and if necessary replace the burner Fig 43 see note page 26 h Loosen the two screws retaining the heat exchanger support bracket and slide to the left to remove Fig 43 i Remove the f...

Page 29: ...2 Isolate the water circuit and drain the system as necessary There are 3 drain points a Flow Valve b Heat Exchanger Manifold c Return Valve NOTE Do not use the Pressure Relief Valve to drain the circuit NOTE When reassembling always fit new O rings ensuring their correct location on the spigot Green O rings are used for gas joints and Black O rings for water joints Use Greasil 4000 Approved Silic...

Page 30: ...ctrical connections from the sensor 3 Unscrew the sensor from the pipe 4 Fit the new thermistor or safety thermostat and reassemble in reverse order 13 5 Expansion Vessel Fig 48 1 Drain the boiler see Section 13 1 paragraph 2 3 2 Loosen the securing screw at the base of the expansion vessel 3 Whilst supporting the vessel undo the expansion vessel connection and retain the sealing washer 4 Remove t...

Page 31: ...lic manifold 4 Remove the pump 5 Fit the new pump and reassemble in reverse order 13 9 Pump Head Only Fig 52 1 Drain the boiler see Section 13 1 paragraph 2 3 2 Unplug the wiring harness from the pump 3 Remove the four socket head screws securing the pump head and separate it from the housing 4 Remove the screws retaining the pump electrical covers on the original and replacement heads 5 From the ...

Page 32: ...in the connection at the return pipe Fig 56 3 Depress the two lugs on either side of the pressure gauge and feed through facia Fig 57 4 Fit new pressure gauge and reassemble in reverse order 13 12 Pressure Relief Valve Fig 58 1 The pressure relief valve is positioned on the hydraulic manifold at the back of the pump 2 Drain the boiler see Section 13 1 paragraph 2 3 3 Disconnect the union between t...

Page 33: ... If so remove the jumpers from the new control board 3 Fit the new control board and reassemble in reverse order 13 14 Ignition Board Fig 61 1 Remove the control board 13 5 and slide out the ignition board left hand side and disconnect the electrical connections noting their positions 2 Fit the new ignition board and reassemble in reverse order 13 15 Transformer Fig 62 1 Remove the transformer con...

Page 34: ... door and remove the electrodes 3 Fit the new electrodes and reassemble in reverse order 13 17 Fan Fig 65 1 Loosen the screw holding the injector pipe into the venturi 2 Remove the electrical connections to the fan protection sensor on the fan 3 Remove the wing nuts securing the fan to the base of the combustion box 4 Lower the fan and remove 5 Disconnect the electrical supply from the right hand ...

Page 35: ...do the screw and disconnect the electrical plug from the gas valve 5 Remove the two gas valve securing screws from inside the air box holding the gas valve 6 Remove the gas valve from the airbox side 7 Remove the nut union aluminium spacer and its gasket from the gas valve 8 Fit the nut union aluminium spacer and its gasket to the new valve 9 Fit the new gas valve and reassemble in reverse order 1...

Page 36: ...base 3 Fit the new burner and reassemble in reverse order Fig 70 13 22 Heat Exchanger 1 Drain the boiler see section 13 1 paragraph 2 3 2 Remove all components in the base of the airbox 3 Remove the screws securing the flow switch and return connections and remove the connections Fig 70 4 Remove the electrical connections from the P C B s 5 Remove the screws securing the heat exchanger manifold an...

Page 37: ... heat exchanger and remove the lower insulation pad 6 Fit the new insulation pad and reassemble in reverse order 13 24 Heat Exchanger Upper Insulation Pad Fig 73 1 Remove all components in the base of the airbox 2 Remove the burner see section 13 21 3 Remove the heat exchanger see section 13 22 4 Remove the four bolts securing the combustion box base 5 Remove the combustion box base 6 Pull the cen...

Page 38: ...14 0 Fault Finding Page 38 ...

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Page 44: ...Barcelona System Baxi Heating Ltd 44 45 14 0 Fault Finding Page 44 45 ...

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Page 46: ...06 060 E06 093 E06 097 E02 762 Description Flow Temperature Thermistor Red Flow Switch Safety Thermostat Black Control PCB Ignition PCB Transformer Fan Gas Valve Interface PCB Viewing Window Condensate Trap Electrode Burner Sensing Electrode Thermostat Burner Assy Heat Exchanger Assy Pump Manufacturers Part No 242458 242459 242460 242463 242464 242465 242472 242473 242477 242484 242485 244736 2447...

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