Potterton Promax Ultra Combi 24 Installation And Service Manual
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Potterton Promax Ultra Combi 24 Installation And Service Manual

Condensing combination boiler
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United Kingdom
en
Installation and Service Manual
Condensing Combination Boiler
P P romax Ultra Combi
24 - 28 - 33 - 40
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.

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Summary of Contents for Potterton Promax Ultra Combi 24

  • Page 1 United Kingdom Installation and Service Manual Condensing Combination Boiler P P romax Ultra Combi 24 - 28 - 33 - 40 These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping.
  • Page 2 Model Range Building Regulations and the Benchmark Commissioning Checklist Potterton Promax Ultra 24 Combi ErP G.C.N 47-393-54 Building Regulations (England & Wales) require notification of Potterton Promax Ultra 28 Combi ErP the installation of a heating appliance to the relevant Local G.C.N...
  • Page 3 Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme Install and Commission this Contact your relevant Local appliance to manufacturer's Authority Building Control instructions (LABC) who will arrange an inspection or contact a government approved inspector Complete the Benchmark Checklist...
  • Page 4 BS EN 12828 Heating systems in buildings. BS EN 12831 Heating systems in buildings - Calculation of load. Potterton Promax Ultra 24 - 28 - 33 - 40 Combi ErP BS EN 14336 Installation & commissioning of water based heating systems.
  • Page 5 Safe Manual Handling General The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance. Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands. Health &...

  • Page 6: Table Of Contents

    CONTENTS Section Page Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Flue Options Installation 10.0 Commissioning 11.0 Completion 12.0 Servicing 13.0 Changing Components 14.0 Combustion & Calibration 15.0 Electrical 16.0 Short Parts List 17.0 Fault Finding 18.0 External Low Voltage Controls...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Potterton Promax Ultra Combi Range are fully automatic gas fired wall mounted condensing combination boilers. It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water. 2. The boiler is set to give a maximum output of :- 24 models - 24 kW DHW 21.2 kW CH Pnc (Condensing)

  • Page 8: General Layout

    2.0 General Layout Layout Expansion Vessel Expansion Vessel Valve Primary Heat Exchanger DHW Plate Heat Exchanger Pump with Automatic Air Vent (NOTE: T he boiler can be fitted with one of two alternative pumps, Grundfos or Wilo. All boiler illustrations show Grundfos.

  • Page 9: Appliance Operation

    3.0 Appliance Operation Central Heating Mode 1. With a demand for heating, the pump circulates water through the primary circuit. 2. Once main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor.

  • Page 10: Technical Data

    4.0 Technical Data Promax Ultra 24, 28, 33, 40 Combi NO x Class Appliance Type Electrical Supply 230V~ 50H z (Appliance must be connected to an Appliance Category CAT I Central Heating Primary Circuit 2H 3P earthed supply) Pressures Heat Input CH Qn Hs (Gross) Power Consumption Safety Discharge 24 model...
  • Page 11 4.0 Technical Data Technical parameters for boiler combination heaters Potterton Promax Ultra Combi ErP Condensing boiler Low-temperature boiler B1 boiler Cogeneration space heater Combination heater Prated Rated heat output 20.0 24.0 28.0 32.0 Useful heat output at rated heat output...

  • Page 12: Dimensions And Fixings

    5.0 Dimensions and Fixings NOTE: There must be no part of the air duct (white tube) visible outside the property after installation. The flue seal should fit neatly and effect a good seal. For full detail refer to Section 9.7 “Fitting the Flue”. Dimensions A 763mm B 355mm*...

  • Page 13: System Details

    6.0 System Details Information 1. The Potterton Promax Ultra Condensing Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 - See text of entry for installation requirements and notes.
  • Page 14 6.0 System Details System Filling and Pressurising 1. A filling point connection on the central heating return Double Stop Stop Check pipework must be provided to facilitate initial filling and Valve Valve Valve pressurising and also any subsequent water loss replacement/refilling.
  • Page 15 Fittings are intended to be used in the DHW therefore all pipework, connections, fittings, etc. should be system connected to a Potterton Promax Ultra suitable for pressures in excess of 8 bar. A pressure reducing it is strongly recommended that the DHW flow rate DOES NOT fall below 2.5l/min.

  • Page 16: Site Requirements

    7.0 Site Requirements 5mm Min 450mm 5mm Min Location 175 mm Min (300mm Min if using 80/125mm 1. The boiler may be fitted to any suitable wall with the flue flueing system) 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.
  • Page 17 7.0 Site Requirement Gas Supply 1. The gas installation should be in accordance with the relevant standards. In GB this is BS 6891 (NG) or BS 5482 Pt. 1 (LPG). In IE this is the current edition of I.S. 813 “Domestic Gas Installations”.
  • Page 18 Examples are shown of the following methods of termination:- i) to an internal soil & vent pipe 7.0 Site Requirements ii) via an internal discharge branch (e.g. sink waste) downstream of the trap iii) to a drain or gully iv) to a purpose made soakaway Condensate Drain v) pumped into an internal discharge branch (e.g.
  • Page 19 v) pumped into an internal discharge branch 7.0 Site Requirements (e.g. sink waste) downstream of the trap Pipe must terminate above Sink Condensate Drain (cont.) water level but below surrounding surface. Cut end at 45° 12. A boiler discharge pump is available, ‘MULTIFIT’ part no.
  • Page 20 Terminal Position with Minimum Distance (Fig. 12) (mm) A 1 Directly below an opening, air brick, opening 7.0 Site Requirements windows, etc. B 1 Above an opening, air brick, opening window etc. C 1 Horizontally to an opening, air brick, opening window etc. Flue D 2 Below gutters, soil pipes or drain pipes.

  • Page 21: Flue Options

    8.0 Flue Options Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination applications. (ii) 2. All fittings should be fully engaged. The approximate engagement is 40mm. Apply the lubricant supplied to the seal on each fitting to aid assembly. 3.
  • Page 22 8.0 Flue Options Flue Lengths The standard horizontal telescopic flue kit allows for lengths between 315mm and 500mm from elbow to terminal without the need for cutting (Fig. 14). Extensions of 250mm, 500mm & 1m are available. The maximum permissible equivalent flue length is: 10 metres (60/100 system - vertical &...

  • Page 23: Installation

    9.0 Installation Unpacking & Initial Preparation IMPORTANT RISK ASSESSMENT - Before commencing the installation it is recommended that the ‘Five Steps to Risk Assessment’ document published by the HSE is consulted, and an assessment performed as described. GAS SUPPLY - The gas supply, gas type and pressure must be checked for suitability before connection (see Fig.
  • Page 24 9.0 Installation Fitting the Filling Loop Kit Note: Full instructions are provided in the Filling Loop Kit pack. 1. The filling loop kit supplied with the boiler can be connected to the taps on the wall plate at this point. (Either one of two types of loop kit will be supplied - both function in the same way, differing only in detail).
  • Page 25 9.0 Installation Boiler Mounting Bracket Fitting The Boiler 1. Remove the sealing caps from the boiler connections. NOTE: A small amount of water may drain from the boiler once the caps are removed. Sealing Washers 2. Lift the boiler as indicated by the shaded areas. The boiler should be lifted by TWO PEOPLE.
  • Page 26 9.0 Installation Fitting The Flue HORIZONTAL TELESCOPIC FLUE Terminal Assembly 1. There are two telescopic sections, the Terminal Assembly and the Connection Assembly, a roll of sealing tape and two self tapping screws. A 93° elbow is also supplied. Connection Assembly Fig.
  • Page 27 9.0 Installation Apply the lubricant Flue Elbow supplied for ease of assembly (do not use any other type). Fitting the Flue (Cont) Ensure Flue Elbow is fully engaged into 10. Remove the flue elbow and insert the flue through the Boiler Boiler Adaptor Adaptor...
  • Page 28 9.0 Installation Making The Electrical Connections 1. Undo the securing screws and lift the case front panel off. 2. Disengage the securing tab and hinge the control box downwards. Undo the terminal block cover securing screw and remove the cover (Fig. 34). 3.

  • Page 29: Commissioning

    10.0 Commissioning 10.1 Commissioning the Boiler 1. Reference should be made to BS:EN 12828, 12831 & 14336 when commissioning the boiler. Ensure that the trap has been Automatic Air primed -see Section 9.5.3. Vent 2. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publication.
  • Page 30 10.0 Commissioning 10.2 Checking the Combustion - ‘Chimney Sweep’ Function Flue Sampling Point 1. To set the boiler to operate at MAXIMUM and MINIMUM, Plug press & together and hold for at least 6 seconds. ‘On’ will be displayed briefly, followed by ‘304’ then Analyser Probe the boiler output expressed as percentage i.e.
  • Page 31 Set Boiler to Maximum Rate 10.0 Introduction (see 10.3.1) Allow the combustion to stabilise. Do not insert probe to 10.2 Checking the Combustion - ‘Chimney Sweep’ avoid ‘flooding’ the analyser. Function (cont) 1. Follow the flow chart opposite. Perform Flue Integrity Combustion Check Insert the analyser probe into the air inlet test point, allowing the...
  • Page 32 10.0 Commissioning 10.3 Check the Operational (Working) Gas Inlet Pressure & Gas Rate Note: The system MUST be cold to ensure the boiler is operating under full demand. To obtain an accurate measurement on smaller capacity systems it may be necessary to open one or more hot taps in order to maintain the boiler at full rate.

  • Page 33: Completion

    11.0 Completion & System Draining 11.1 Completion 1. Replace the case front panel, and secure with the screws previously removed. 2. This publication must be handed to the user for safe keeping and each subsequent regular service visit recorded. 3. Set the central heating and hot water temperatures to the requirements of the user.

  • Page 34: Servicing

    Flue Sampling 12.0 Servicing Point 12 .1 Performance Safety Check & Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by Air Sampling a competent person in accordance with B.S. 7967-4. Point 2.
  • Page 35 12.0 Servicing 12.2 Annual Servicing Inspection (Cont) 5. Remove the clip securing the gas feed pipe to the air/gas venturi. Disconnect the pipe. Do not break the joint between the pipe and gas valve unless necessary. Flame 6. Disconnect the electrode leads, noting their position, and Sensing Spark Ignition Electrode...

  • Page 36: Changing Components

    13.0 Changing Components IMPORTANT: When changing components ensure that Spark Ignition both the gas and electrical supplies to the boiler are Electrode isolated before any work is started. When the component has been changed recommission the boiler as described in Section 10.0.
  • Page 37 Cover 13.0 Changing Components Burner 13.4 Burner (Fig. 52) Gasket 1. Undo the securing screw and remove the airbox, Extension Piece disengaging it from the fan venturi. Remove the clip securing (24 & 28 only) the gas feed pipe to the air/gas venturi and disconnect the fan electrical plugs.
  • Page 38 13.0 Changing Components 13.6 Flue Sensor (Fig. 54) Electrical Plug 1. Ease the retaining tab on the sensor away and disconnect Flue Sensor the electrical plug. 2. Turn the sensor 90° anticlockwise to remove - it is a bayonet connection. 3.
  • Page 39 13.0 Changing Components 13.11 Pump - Complete (Figs. 57 & 58) 1. Drain the boiler primary circuit and disconnect the electrical plug from the pump motor. 2. Undo the two screws securing the body to the pipe and manifold and draw the pump forwards. 3.
  • Page 40 13.0 Changing Components 13.14 Hall Effect Sensor (Fig. 59) 1. Ease the sensor upwards off the hydraulic inlet manifold assembly. 2. Disconnect the electrical plug from the sensor. 3. Connect the plug to the new sensor. Carefully fit the new sensor to the hydraulic assembly, ensuring it is fully down.
  • Page 41 13.0 Changing Components 13.17 Plate Heat Exchanger (Fig. 62) 1. Close the flow & return isolation taps and the cold mains inlet. Drain the primary circuit and draw off any residual DHW. 2. Remove the gas valve as described in Section 13.20. and disconnect the pressure gauge capillary.
  • Page 42 13.0 Changing Components 13.19 P.C.B. & R.D.S. (Removable Data Stick) (Fig. 64) NOTE: Both P.C.B. and R.D.S. are available as spare parts. The P.C.B. is suitable for any boiler model. An R.D.S. specific to the boiler model output & gas type will be required if the R.D.S.
  • Page 43 13.0 Changing Components NOTE: The Injector Washer MUST be fitted as shown between the Valve & Pipe. DO NOT fit the 13.20 Gas Valve (Fig. 65) Injector Washer between the Gas Gas Feed Pipe Cock & Valve IMPORTANT: After replacing the valve the CO must be calibrated as detailed in Section 14.0 Combustion &...

  • Page 44: Combustion & Calibration

    14.0 Combustion & Calibration 14.1 Checking the Combustion IMPORTANT: DO NOT insert the Analyser Probe into the Test Point immediately. This will 1. Combustion should be:- prevent saturation of the analyser. Natural Gas 9.0% CO ± 0.7 Propane 10.5% CO ±...

  • Page 45: Electrical

    15.0 Electrical 15.1 Illustrated Wiring Diagram Valve Overheat Safety Thermostat Hall Effect Heat Exchanger Sensor Flue Sensor Water Pressure Switch Return Temperature Sensor CH Flow Temperature Sensor Temperature Sensor Terminal Strip g br Low Voltage External Control Connection Flame Sensing Electrode Spark Ignition...

  • Page 46: Short Parts List

    16.0 Short Parts List Short Parts List Description Manufacturers Part No. 720768101 Burner (24/28/33) 720767901 Burner (40) 720785201 Spark Ignition Electrode 720767301 Flame Sensing Electrode 720767101 Gas Valve 720752301 Hall Effect Sensor 720788001 Plate Heat Exchanger (24 & 28) 720852401 Plate Heat Exchanger (33 &...

  • Page 47: Fault Finding

    Table Of Error Codes 17.0 Fault Finding Gas Valve Connection Cable Gas Valve Fault Central Heating NTC Fault 17.1 Initial Fault Finding Checks Flue NTC Fault Central Heating Return NTC Fault 1. Check that gas, water and electrical supplies are available at the boiler.
  • Page 48 17.0 Fault Finding Refer to “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence 09, 15, 110 or 384 is flashing or re-occurs Turn on mains power Go to section ‘A’ regularly, check all PCB connections. If this has no The display illuminates effect replace the PCB.
  • Page 49 17.0 Fault Finding Domestic Hot Water - Follow operational sequence 09, 15, 110 or 384 is flashing or re-occurs Turn on mains power Go to section ‘A’ regularly, check all PCB connections. If this has no The display illuminates effect replace the PCB. 09, 15, 110, 125, 133, 134, 110 is still flashing go to Press the reset button for 1 to...
  • Page 50 17.0 Fault Finding Fault Finding Solutions Sections Is there 230V at: Main terminals L and N Check electrical supply Connection OK at X41 Main terminal fuse Replace fuse Check wiring PCB - X10 connector Display Display or Main terminals L and N Main PCB fault illuminated Switch to DHW mode maximum flow and press reset.
  • Page 51 17.0 Fault Finding Check and correct if necessary 1. Ignition electrode and lead Replace PCB Check wiring - see Diagram 2. Electrode connection 3. Spark gap and position Burner Viewing Window Flame Sensing Spark Ignition Electrode Electrode Electrode Position Check supply pressure at the gas valve:- Natural Gas - Minimum 17 mbar Propane - Minimum 37 mbar...
  • Page 52 17.0 Fault Finding CH system pressure less than Restore system pressure 0.5 bar or greater than 2.7 bar Check wiring and PCB - X22 Replace hydraulic pressure sensor connector for approx. 5V DC between green & black - see Replace PCB Wiring Diagram Ensure that the boiler and system System fault - correct...

  • Page 53: External Low Voltage Controls

    18.0 External Low Voltage Controls Optional Outdoor Sensor 1/2 H 2.5m Min West North Boiler Flow Temperature Outdoor Temperature © Baxi Heating UK Ltd 2016...
  • Page 54 18.0 External Low Voltage Controls Optional 7 Day Wired Sensor 1. Press Securing Tab 18.4 Connecting the Optional 7 Day Wired Sensor NOTE: The yellow link wire between terminals 1 & 2 on 2. Ease away from Backplate terminal block M1 MUST be removed when fitting the 7 Day Wired Sensor.
  • Page 55 18.0 External Low Voltage Controls Optional 7 Day Wireless Sensor & 24hr Wireless Sensor 18.5 Connecting the Optional 7 Day Wireless Sensor & 24hr Wireless Sensor (kit includes a Sensor & 1. Press Securing Tab. Receiver - the Receiver is wired into the boiler). NOTE: The yellow link wire between terminals 1 &...

  • Page 56: Notes

    19.0 Notes © Baxi Heating UK Ltd 2016...
  • Page 57 19.0 Notes © Baxi Heating UK Ltd 2016...

  • Page 58: Benchmark Checklist

    GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty.

  • Page 59: Service Record

    SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions. SERVICE 01 SERVICE 02 Date:...

  • Page 60: Description

    Baxi Customer Support 0344 871 1545 Opening hours Monday - Friday, 8.00am-6.00pm Weekends and Bank Holidays, 8.30am-2.00pm Please note calls may be recorded for training and monitoring purposes baxi.co.uk Register now to activate your warranty: www.baxi.co.uk/registration For the warranty to be maintained, please make sure... Benchmark checklist is completed Warranty is registered within 30 days The boiler has an annual service...

This manual is also suitable for:

Promax ultra combi 28Promax ultra combi 33Promax ultra combi40

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