Potterton Promax System HE Plus A Range, Installation & Service Instructions Manual

Page 1: ...014 Installation Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Promax System HE Plus A Range Condensing System Boiler You can rely on ...

Page 2: ... accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information Building Regulations and the Benchmark Commissioning Checklist Building Regulations England Wales require notification of the installation of a heating appliance to the relevant Local Authority Buildi...

Page 3: ...elevant LABC You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www gassaferegister co uk within 10 days If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Complete the Benchmark Checklist Instal...

Page 4: ...en reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation All systems must be thoroughly flushed and treated...

Page 5: ...s clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straight bend your knees Don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible transport the boiler using a sack ...

Page 6: ...6 0 System Details 12 7 0 Site Requirements 14 8 0 Flue Options 20 9 0 Plume Displacement 25 10 0 Installation 29 11 0 Commissioning 34 12 0 Completion 37 13 0 Servicing 38 14 0 Changing Components 40 15 0 Setting the Gas Valve 48 16 0 Electrical 49 17 0 Short Parts List 50 18 0 Fault Finding 51 19 0 Pages for Notes 56 Benchmark Checklist 58 Section Page ...

Page 7: ... is situated on the inner door panel It is visible when the case front panel is removed Fig 1 6 The boiler model name and serial number are also shown on the information label on the rear of the lower door panel This is for user reference 7 The boiler is intended to be installed in residential domestic environments on a governed meter supply only 8 The boiler must be installed with one of the purp...

Page 8: ... 10 Gas Valve 11 Condensate Trap 12 Flame Sensing Electrode 13 Spark Electrode 14 Primary Heat Exchanger 15 Fan Assembly 16 On Off Reset Selector Switch 17 Central Heating Temperature Control 18 Calibration Control 19 Venturi 20 Air Gas Collector 21 Combustion Box Cover Burner 22 Igniter 23 Burner On Light 24 Central Heating Mode Light 25 Display 1 16 17 18 7 Reset bar 0 1 2 3 4 21 2 3 4 5 6 7 8 9...

Page 9: ... mode is integral to the appliance and functions when the selector switch see Section 2 1 is in the ON position If the system temperature falls below 5 C then the boiler will fire on its minimum setting until a flow temperature of 30 C is reached Further protection can be incorporated by using a system frost thermostat 3 3 Pump Protection 1 With the selector switch see Section 2 1 in the ON positi...

Page 10: ... Side 5 mm Min In Operation This is MINIMUM recommended dimension Greater clearance will aid installation and maintenance Heat Input Net Max Min 12 model kW 12 4 4 15 model kW 15 4 3 9 18 model kW 18 5 4 3 24 model kW 24 7 7 32 model kW 32 8 9 7 Heat Output Non Condensing Max Min 12 model kW 12 3 9 15 model kW 15 3 9 18 model kW 18 4 2 24 model kW 24 6 8 32 model kW 32 9 4 Electrical Supply 230V 5...

Page 11: ...00mm D C B A E G F At least 1 5 H Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 130 mm 130 mm 65 mm Condensate Drain 32 5 mm Tap Rail Dimensions A 780mm B 345mm C 450mm D 116mm Ø Min E 185mm 207mm for 80 125mm flue systems F 145mm G 131mm H 180mm ...

Page 12: ... and Fernox MB 1 which should be used following the inhibitor manufacturer s instructions Full instructions are supplied with the products for further information contact Sentinel 0800 389 4670 or Fernox 0870 870 0362 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 an...

Page 13: ...itable for correct operation for system capacities up to 125 litres For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Domestic Gas Installations 6 6 Pressure Relief Valve Fig 4 1 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressures in excess of 3 ba...

Page 14: ...ng Regulations In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing This is the MINIMUM recommended dimension Gr...

Page 15: ...t edition of ETCI rules 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 3 When the system includes an indirect domestic hot water...

Page 16: ...diameter and must be supported using suitably spaced clips of the correct design to prevent sagging 6 It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres 7 Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe 8 External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external us...

Page 17: ... emptied then back pressure may force water out of the boiler trap and cause appliance lockout Boiler 2 5 Minimum fall iii Termination to a drain or gully Boiler 500mm min 2 5 Minimum fall iv Termination to a purpose made soakaway Holes in the soak away must face away from the building 50mm per metre of pipe run 50mm per metre of pipe run Further specific requirements for soakaway design are refer...

Page 18: ...e Heating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to Boiler vi pumped into an external soil vent pipe 2 5 Minimum fall 50mm per metre of pipe run Condensate Pump Unheated Location e g Garage Basement or similar heated Boiler 2 5 Minimum fall 50mm per metre of pipe run Pipe must terminate above water level b...

Page 19: ...ram below Opening Window or Door 150mm MIN IMPORTANT If fitting a Plume Displacement Flue Kit the air inlet must be a minimum of 150mm from any opening windows or doors see Section 9 0 Plume Displacement Kit Air Inlet Fig 10 Terminal Position with Minimum Distance Fig 9 mm A1 Directly below an opening air brick opening windows etc 300 B1 Above an opening air brick opening window etc 300 C1 Horizon...

Page 20: ... 135 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 135 bend 0 25 metres 91 5 bend 0 50 metres The elbow connected to the boiler adaptor is not included in any equivalent length calculations 5 The illustrations opposite show examples of permissible flue systems NOTE Flue length is measured from point i to ii as shown IMPORTANT All flue systems must be securely supported at least once every metr...

Page 21: ...nt Length Value Equivalent Length Air Duct 6 5m 1m extension 45 bend 91 5 bend 1m 0 25m 0 5m 5 2 2 5 0m 0 5m 1 0m FLUE DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Flue Duct 6 5m ii i C Roof Terminal A B 660mm This bend is equivalent to 1 metre Total Equivalent Length A B C 1x90 Bend All vertical and angled runs must be included measured from the boiler adaptor poi...

Page 22: ... N Twin Flue System 80mm diameter E Flue Extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend 2 pair 135 5111086 J Vertical Flue Boiler Adaptor Kit 720089801 H Vertical Flue Adaptor 5111084 W Pipe Support pair 80mm 5111081 Y Flue Termination Kit horizontal termination 80mm 5120172 Z Single Terminal 80mm 5121791 Q Adaptor 60 80 5121792 T Pitched Roof Terminal 25 45 5106164 FLUE GRO...

Page 23: ...tor 8 5 Twin Flue Connection 1 Engage the twin flue duct adaptor in the boiler adaptor making sure that it is pushed down as far as possible 2 Ensure that the air flue ducts are connected correctly and that they are adequately supported at least once every metre using the available pipe supports 3 Ensure that all joints and elbows are fully engaged and cannot become disconnected during operation ...

Page 24: ...ted immediately after the flue system temporary precautions must be taken to prevent rain entry into the room of installation Any precautionary measures must be removed prior to commissioning the boiler 8 7 Flue Dimensions The standard horizontal telescopic flue kit allows for lengths between 100mm and 685mm from elbow to terminal Fig 11 The maximum permissible equivalent flue length is 10 metres ...

Page 25: ... with the addition of extensions the length of either or both the 60 100 concentric and 60Ø exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow IMPORTANT The maximum equivalent length of concentric flue is 8 metres 24 32 models 14 metres 1...

Page 26: ...ic flue assembly and any extensions and the 60Ø exhaust and any extensions or additional bends Example 1 Not Permissible If for instance a concentric length of 5 metres was required and the 60Ø exhaust needed to be 6 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Where both lengths hav...

Page 27: ... that the concentric assembly and any extensions fall back to the boiler at an angle of at least 1 5 and that the external air inlet is to the bottom 8 Use suitable brackets to support the concentric assembly and any extensions and make good inside and outside 9 The 60Ø exhaust can now be fitted Slide the adaptor over the plain end of the 60Ø exhaust Fig 22 and engage the exhaust in the terminal S...

Page 28: ...the extension at 30mm as shown in two positions directly opposite each other Fig 27 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The remaining screw must be used to secure the adaptor to the concentric terminal 22 When the plume outlet is positioned under a balcony or other projection Fig 28 it must protrude at least 200mm it is ...

Page 29: ...t is preferable to use the vertical fixing slots 4 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 32 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 116mm 7 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 8 ...

Page 30: ...scharge pipe supplied 3 The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPORTANT Make all soldered joints before co...

Page 31: ...tween the terminal and air duct Fig 36 2 Locate the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 37 NOTE The flue elbow is angled at 93 degrees to ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 39 4 To dimension X add 50mm This dimension to be known as Y IMPORT...

Page 32: ...essary to use soap solution or similar to ease assembly of the elbow adaptor and flue Fig 42 10 Ensure that the terminal is positioned with the slots to the bottom Fig 43 IMPORTANT It is essential that the flue terminal is fitted as shown to ensure correct boiler operation and prevent water entering the flue 11 Make good between the wall and air duct outside the building 12 Fit the flue trim if re...

Page 33: ...tions supplied with the control IMPORTANT The external control MUST be suitable for 230V switching and fused 3A maximum 6 Remove the link between terminals 1 2 The switched output from the external control must be connected to terminal 2 Fig 48 7 Ensure that the external control input cable s have sufficient slack to allow the control box to drop down Tighten the cable clamp on the boiler chassis ...

Page 34: ...he integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals Proceed to put the boiler into operation as follows 11 The Combustion Check procedure as shown by the chart in 11 2 is mandatory from April 2014 The method of setting the boiler to operate at maximum and minimum rates to comply with the procedure is described below 12 Ensure tha...

Page 35: ...eals that appear unsound Is CO 350ppm and CO CO2 ratio 0 004 TURN APPLIANCE OFF Call 0844 871 1555 for advice The appliance MUST NOT be commissioned until all problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with the GSIUR Note Check record the CO combustion ratio at both maximum minimum rates befor...

Page 36: ...g in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point Fig 53a is in accordance with B S 6798 B S 6891 7 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Measure the Gas Rate 8 With any other appliances pilot lights turned OFF the gas rate can be measured It should be between 15 model...

Page 37: ...e relevant to the appliance and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in a...

Page 38: ...ing the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Check the Combustion Performance CO CO2 ratio 4 Set the boiler to operate at maxim...

Page 39: ...d cover assembly forward being careful to retain the injector in the venturi Figs 63 64 10 Clean any debris from the heat exchanger and check that the gaps between the tubes are clear 11 Inspect the burner electrodes position and insulation cleaning or replacing if necessary Clean any dirt or dust from the air box 12 Reassemble in reverse order NOTE The sensing pipe must be reconnected to the fan ...

Page 40: ...iter Fig 65 1 Disconnect the igniter feed plug and the electrode leads noting their positions 2 Undo the screw securing the bracket to the boiler 3 Remove the igniter and transfer the bracket to the new component 4 Reassemble in reverse order 14 2 Spark and Sensing Electrodes Fig 66 1 Disconnect the electrode leads noting their positions 2 Remove the retaining screws securing each of the electrode...

Page 41: ... that the injector is in place and the sensing pipe is connected to the fan 14 4 Venturi Fig 67 1 Remove the collector and fan assembly as described in section 14 3 2 Extract the injector from the venturi 3 Undo the screws securing the fan to the venturi and the venturi to the collector IMPORTANT When fitting the new venturi ensure the arrows on it s base point into the collector Fig 69 4 Examine ...

Page 42: ...ing their positions Also remove the electrodes as described in section 14 2 2 Undo the screws securing the collector to the venturi and the nuts holding the cover to the heat exchanger Draw the collector and cover assembly away 3 Remove the cover insulation piece 4 Fit the new insulation carefully over the burner and align it with the slots for the electrodes 5 If the rear insulation requires repl...

Page 43: ...e Sensor NTC Fig 73 1 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way 14 11 Safety Thermostat Fig 73 1 Pull the plug off the thermostat 2 Remove the screws securing the thermostat to the mounting plate on the flow pipe 3 Reassemble in reverse order ensuring that the plu...

Page 44: ...the body to the pipe and manifold and draw the pump forwards 3 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 4 Unscrew the automatic air vent from the pump body 5 Connect the wiring to the new pump Examine the O ring seals on the return pipe and manifo...

Page 45: ...sher replace if necessary 5 Reassemble in reverse order 14 17 Pressure Relief Valve Fig 81 1 Drain the primary circuit 2 Disconnect the discharge pipe from the valve Using a suitable hexagon key undo the grub screw sufficiently to release the valve 3 Note the orientation of the valve rotate it and withdraw it from the manifold 4 Fit the new valve and O ring seal and set to the previously noted ori...

Page 46: ...e 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 14 19 Selector Switch Fig 83 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pi...

Page 47: ...ry 6 Reassemble in reverse order ensuring that all seals are in place NOTE To assist the boiler to light prior to final setting use a suitable hexagon key to wind out the Throttle adjustment screw until it is flush with the valve body then turn the screw 4 full turns clockwise Fig 85 If the boiler will not light or the correct CO2 cannot be achieved contact the heateam technical helpline 14 21 Exp...

Page 48: ...g to settle Fig 93 The CO2 should be 8 7 0 2 8 It is possible to alter the CO2 by adjustment of the gas valve Remove the plastic cover from the Throttle Adjustment Screw At maximum rate the Throttle Adjustment Screw should be turned using a suitable hexagon key until the correct reading is obtained Fig 94 Turning clockwise will reduce the CO2 Anticlockwise will increase the CO2 9 The CO2 must then...

Page 49: ...Gas Valve Overheat Stat Flame Sensing Electrode Pump Flue Sensor X401 r r b b b b b br bk g b br g y b br b br br b b b br br br b b br r bk r bk Spark Generator Ignition Electrode 9 10 8 7 6 5 4 3 2 1 N L w g or w 1 4 2 5 3 1 2 a b Link bk b g y br Mains Input Cable br b X9 Return Heating Temperature Sensor X400 g g b b Water Pressure Switch 9 8 7 6 5 4 3 2 1 b w 16 1 Illustrated Wiring Diagram ...

Page 50: ...1 Fan 5121447 315 Igniter Electrode 720222801 316 Sensing Electrode 720222901 415 Pump 248042 419 Water Pressure Switch 5114748 420 Overheat Thermostat 5114729 421 NTC Sensor 5114725 422 Gas Valve 720301001 434 NTC Sensor Return 5114726 503 PCB 12 5122455 PCB 15 5122457 PCB 18 5122458 PCB 24 720045201 PCB 32 5122459 504 Pressure Gauge 248090 306 315 316 311 422 419 415 302 421 420 503 504 434 ...

Page 51: ... For example code E133 will be displayed by E1 alternating with 33 E20 is shown as E then 20 E20 and E28 indicate faulty components E110 shows overheat of the primary water and E130 overheat of the flue system E119 is displayed when the primary water pressure is less than 0 5 bar E133 indicates that the gas supply has been interrupted ignition has failed or the flame has not been detected E125 is ...

Page 52: ...flashing Burner does not stay alights after 5 seconds Error 133 flashing Go to section I Operation sequence successful If the error 110 is still flashing Go to section J Fan runs at correct speed YES YES NO NO NO YES YES YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO NO Burner output modulates to maintain the temperature set Burner goes out Go to section C Ensure controls are set to demand...

Page 53: ...onnector terminals 3 4 Replace PCB 2 NO Change pump supply cable YES B CH system pressure less than 0 5 bar Re pressurise system 1 YES Check the tap of the automatic air vent is opened Open the automatic air vent 2 NO C 1 NO YES Fan connections correct at fan PCB X2 connector is 230V AC across terminals 5 7 Fan jammed or faulty winding Replace PCB Replace fan YES D If pump jammed release NO NO Rep...

Page 54: ... 230V AC across terminals 1 2 YES NO NO F Replace PCB G Check and correct if necessary 1 Ignition electrode and lead 2 Electrode connection 3 Spark gap and position YES NO Replace igniter YES Check and correct the connection of the tube between the venturi and gas valve 1 2 Voltage at PCB X2 connector is at least 100V DC across terminals 2 5 Note from multimeter connect common to 2 volt to 5 Check...

Page 55: ...he gas valve Minimum 17 mbar I Replace safety thermostat YES NO Overheat thermostat operated or faulty i e continuity across thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm J K Fan connections correct at fan PCB X401 connector terminals 5 6 7 8 1 YES Replace fan Temperature sensors faulty Cold resistance approximately 10kΩ 25 C CH sensor 20kΩ 25 C Flue s...

Page 56: ...56 19 0 Pages for Notes Baxi Heating UK Ltd 2014 ...

Page 57: ...57 19 0 Pages for Notes Baxi Heating UK Ltd 2014 ...

Page 58: ...uired Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL SYSTEMS s instructions Yes What system cleaner was used What inhibitor was used Quantity litres Yes No CENTRAL HEATING MODE measure and record Gas rate m hr OR ft hr Burner operating pressure if applicable mbar OR Gas inlet pressure mbar C Central heating return tempe...

Page 59: ...ompany name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 06 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 07 Date Engineer name Company name Telephone No Gas safe register No Record At max ...

Page 60: ...ements in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request POTTERTON A Trading Division of Baxi Heating UK Ltd 3879156 Brooks House Coventry Road Warwick CV34 4LL After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555 Website www potterton co uk e oe ...