Potterton Promax HE Store Installation & Servicing Instructions Manual
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Potterton Promax HE Store Installation & Servicing Instructions Manual

Promax he store series condensing boilers with integrated hot water storage
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You can rely on
Installation & Servicing
Promax HE Store
Instructions
Range
Condensing Boilers with
Integrated Hot Water
Storage
Please keep these instructions in a safe place.
If you move house, please hand them over to the next occupier
© Baxi Heating UK Ltd 2012

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Summary of Contents for Potterton Promax HE Store

  • Page 1 You can rely on Installation & Servicing Promax HE Store Instructions Range Condensing Boilers with Integrated Hot Water Storage Please keep these instructions in a safe place. If you move house, please hand them over to the next occupier © Baxi Heating UK Ltd 2012...
  • Page 2 Natural Gas Building Regulations and the Benchmark Commissioning Checklist Potterton HE Store Building Regulations (England & Wales) require notification G.C.N 41 601 24 (90 litre) of the installation of a heating appliance to the relevant G.C.N 41 591 76 (115 litre) Local Authority Building Control Department.

  • Page 3: Installer Notification Guidelines

    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: Table Of Contents

    Commission the Boiler........Hand Over to the User........Safety, Performance & Quality Promax HE Store boilers have been assessed by a Government appointed Notified Body and shown to 4. Service & Replacement of Parts....meet the 'Essential Requirements' of the European Gas General Access..........

  • Page 5: Panel Removal

    Panel Removal Important: Refer to Page 8 for Storage, Unpacking and Handling Instructions. Top & Bottom Section Top Section Lift Heat Engine onto Rollers Cylinder. Ensure the rollers engage into location channels. Tilt and slide until front location pegs drop into position on the cylinder.

  • Page 6: Technical Data

    Technical Data Unless indicated, data shown relevant to all models 90 litre 115 litre 150 litre Classifications Appliance category CAT I 2 H Flue Type C 13 - C 33 - C 53 (as supplied) NOx Class 5 (< 70 mg/kWh) Cylinder Insulation CFC, HCFC = 0% Input (hot water/central heating) - gross...
  • Page 7 Note: Note: Cupboard At these minimum clearances above Removable Top Panel intended the appliance, adequate working to provide access MUST be provided. access. 650 max Removable Top Panel Door Frame 400 mm 400 mm Recommended Recommended Typical Bulkhead Installation Typical Cupboard Installation with rearwards horizontal concentric flue with twin vertical air/flue pipes Fig.

  • Page 8: Introduction

    (1) the heat engine and unvented accessory kit, (2) the hot water cylinder and (3) the flue kit. The Samples of the Promax HE Store gas boilers have been flue kit must be ordered/specified additionally to the examined by DVGW Technologies Limited, a EU Notified boiler.

  • Page 9: Codes Of Practice

    Codes of Practice In GB the following Codes of Practice apply: Standard Scope The appliance is suitable only for installation in GB and BS6891 Specification for low pressure gas pipework IE and should be installed in accordance with the rules in in domestic premises.

  • Page 10: Storage, Unpacking And Handling

    Bottom (cylinder) under cover in dry conditions. the current edition of I.S. 813 "Domestic Gas Installations". Remove the Promax HE Store unvented Accessory Kit from above the heat engine to reduce lift weight. (The The whole of the gas installation must be checked for...

  • Page 11: Compartment Installation & Ventilation

    General guidance for cupboard/compartment Flue Systems installations, including airing cupboards, is contained in BS 6798. Specific requirements for Promax HE Store All boilers are supplied to accept either the concentric are given below. horizontal flue system or the Promax 80 mm dia. twin flue system, however several flue system options are 1.
  • Page 12 General Requirements for Horizontal Flue aluminium shield at least 750 mm long must be fitted Terminations to the underside of the plastic or painted surface. Detailed recommendations for flueing are given in g) Where installation will be in an unusual location, BS5440: Part 1.
  • Page 13 Plume Displacement Kit IMPORTANT: If fitting a Plume Displacement Flue Kit, the air inlet must be a minimum of 100mm from any opening windows or doors Air Inlet Opening Window or Door 150mm MIN. Likely flue positions requiring a flue terminal guard Terminal Position with Minimum Distance (mm) For IE, refer to I.S.
  • Page 14 Flue Options 1. The Promax Store can be fitted with flue systems as illustrated. 2. The standard flue kit, Part No. 5118489 comprises a concentric 100/60 terminal and a 93° bend. It is suitable only for horizontal termination applications. 3. Maximum permissible equivalent flue lengths are:- Horizontal Concentric 10 metres...
  • Page 15 600mm Min Mini Terminal apart (sited in loft) Vertical Flues (Twin Pipe) 1m Min 15m Max For terminal position see literature provided with kit 1m Min Vertical Flues 15m Max Total Equivalent Length = A+B+C+1x90°Bend Roof Terminal All vertical and angled runs must be included, measured from the boiler adaptor (point X) to The total equivalent length for this the joint with the flue terminal (point Y).
  • Page 16 Flue Accessories Key Accessory Size Code No FLUE GROUP A Concentric Flue System 100mm diameter Horizontal Flue Terminal 5118489 (inc. elbow) Flue Extension 1000mm 5111074 Flue Bend 93° 5111075 Flue Bend 135° 5111085 (pair) Pipe Support 100Ømm 5111080 (painted) Vertical Flue Adaptor 5111070 Wall Liner 5111067...
  • Page 17 For Twin Flue Systems fit the adaptors as follows:- Flue Duct Adaptor Flue Duct Adaptor 1. Engage the flue duct adaptor on the boiler Boiler Adaptor adaptor, making sure that it is pushed down Blanking Plate as far as possible. Air duct adaptor 1.
  • Page 18 Flue Deflector (Fig. 5b) 1. If required a flue deflector is available from your Potterton stockist. 2. Push the flue deflector over the teminal end and rotate to the optimum angle for deflecting plume.
  • Page 19 Plume Displacement Kit (Fig. 6a) Kit No 5118638 Content of kit 1 0.9m 60/100 Concentric Flue 1 1m 60 Dia Exhaust Flue Pipe 93° Elbow/Plume 1 Adaptor Outlet Assembly 2 60 Dia Support Brackets 1 93° Elbow/Plume Outlet Assembly 60Ø Support 1 Flexible Flue Trim O Ring Bracket...
  • Page 20 Support 60Ø Exhaust Bracket 45° Elbow Flue Length - Worked Example Potterton Promax Store 93° Elbow In diagram opposite an additional 93° bend and pair of 45° elbows have been included in the 60Ø exhaust. 1 metre Extension Concentric 60/100 Flue Also 3 straight extension pieces have been used.
  • Page 21 General Fitting Notes 1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall back to the boiler at an angle of at least 1.5°. 2. When completed the terminal must be at least 2 metres above ground level (Fig.
  • Page 22 Plume Outlet Elbow General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air. 16. It is also possible to separate the plume outlet from the 93°...

  • Page 23: Water Supply & Systems

    1.6 Water Supply be effective in reducing limescale but require correct siting and regular replenishment to remain operational. They should generally not be fitted where heat could Mains Supply Requirements impair their perfomance. Other types of device can It is essential that the mains supply pressure and inhibit scale formation but their effectiveness may vary.

  • Page 24: Discharge Pipework

    This includes the 4 litre primary circuit volume Fig. 8, Table 1 and the worked example. within the Promax HE Store boiler - thus radiator and pipework volume should not exceed 94 litres. An alternative approach for sizing discharge pipes...
  • Page 25 • The cold water Inlet Control Group must be Discharge fitted to the mains water supply to the 300mm min. above Promax HE Store when it is operated as an Fixed unvented system. Grate • Control and safety valves MUST NOT be tampered with.

  • Page 26: Installation

    2. Installation 2.1 Install the boiler 5. Release DHW temperature sensor and un-roll cable. Route cable behind cylinder pipes and push sensor fully home (approx. 310mm - 12”) into the pocket in Before starting an installation, check that the correct flue the cylinder.
  • Page 27 Tundish Domestic Hot Water Sensor Isolating Valve Plumbing 'NO GO' Area Pressure Gauge Immersion Filling Loop Heater Potterton Promax Store Pipework shown as this 150 litre model shown NOT SUPPLIED D.H.W. CH Flow Outlet Gas Inlet Discharge Pipe CH Return Mains Cold Inlet Fig.
  • Page 28 2.4 Condensate Drain Pipe Before fitting, fill the condensate trap with water. Fit the steady bracket (with round hole) for the condensate trap to the lower pair of holes in the left hand cylinder side panel. Snap the C-shaped bracket into the groove in the condensate connector.
  • Page 29 Ø240mm Wall Bolts & Plugs Secondary Washer Threaded Expansion Vessel 300mm Expansion Vessel Support Bracket Nut & 22mm Balanced 15mm Washer Cold Feed Expansion Vessel Support Strap To Shower Stop Valve Mains Cold Inlet 22mm 22mm and cold feed to kitchen Combination tap.

  • Page 30: Connect The Power Supply Cable

    2.5 Connect the Water System Read and observe recommendations in Section 1.6 and see Fig. 11. Secure the combination reducing valve - a wall Graph of Central Heating Head vs. Flow bracket is provided in the accessory pack. 22mm copper tube is recommended for both the inlet and outlet connections.
  • Page 31 Making The Electrical Connections To connect the mains input cable proceed as follows:- 1. Remove all the outer panels. Always fit fast 2. Completely undo the screws securing the blow 2A fuse Fused supply 3A facia panel and hinge it down. 230V ~ 50Hz Live (brown) 3.
  • Page 32 2.7 Immersion Heater The immersion heater is rated 3kW at 240V and must be wired to a separate, suitably rated electrical supply. THERE MUST BE NO INTERCONNECTION WITH THE WIRING TO THE BOILER. WARNING: THE IMMERSION HEATER MUST BE EARTHED. Promax Store It should be installed in accordance with the current IEE Wiring Regulations and be wired through a double pole isolating...

  • Page 33: How To Drain Hot Water Storage Cylinder

    How to Drain Hot Water Storage Cylinder Isolate mains water supply at stop valve on Inlet Control Group and close -turn valve (handle at 90° to valve body) on double check valve - see Fig. 14. Fit a hosepipe to the tail of the drain valve (secure with “Jubilee” clip), and run open end to a low level where water can be safely drained.

  • Page 34: Commissioning

    When checking for gas soundness open only be carried out by a suitably qualified all windows and doors in the room. person. Potterton offer this service Extinguish all naked lights, cigarettes, pipes, etc. on a chargeable basis. © Baxi Heating UK Ltd 2012...

  • Page 35: Commission The Boiler

    3.1 Commission the Boiler Sealed Primary System Automatic Air Vent: This is built into the pump. Leave 1. Ensure that gas supply is turned OFF at the gas the cap open during and after commissioning. cock. Manual Air Vent: This must be used to remove as much 2.

  • Page 36: Hand Over To The User

    Commissioning Checks N.B. Leave the cap on the auto air vent (above the pump) partially unscrewed so that the vent remians 1. The gas valve is factory set and the burner pressure operational - note that the burner control goes to safety changes as the fan modulates when demand on the shut-down if the system pressure drops below 0.5 bar.

  • Page 37: Service & Replacement Of Parts

    4. Service & Replacement of Parts To ensure safe, efficient operation of the boiler, it is 6. Turn off the mains water supply at the Inlet Control necessary to carry out routine servicing at regular Group and release system pressure by opening a intervals.

  • Page 38: General Access

    4.1 General Access WARNING: Before attempting to remove any component from the boiler first disconnect the mains electricity supply by removing the plug from the wall General Access socket or by switching off the boiler at the external isolating switch. Pull forward Front Panel at the bottom and lift off IMPORTANT: After removal or replacement of any...

  • Page 39: Expansion Vessel/Pump

    4.3 Expansion Vessel, Pump & Pressure Switch Re-assemble all parts in reverse order. 1. Check that the cap on the auto air vent is open. Turn the 3 isolating valves OFF and Expansion Vessel locally drain the boilers circuit by opening the primary pressure relief valve.

  • Page 40: Pressure Sensor/Pressure Relief Valve

    4.4 Pressure Sensor/PRV Re-assemble all parts in reverse order. 1. Perform 4.1 General Access. Isolating Valve 2. Isolate three valves as shown and open the cap on the auto air vent. 3. Release pressure by opening the pressure relief valve. Gas Cock 4.

  • Page 41: Air/Gas Valve/Injector/Fan

    Gas Valve Venturi Inlet 1. Turn the gas cock OFF and disconnect Pipe the electrical plug. Sealing Washer 2. Pull off the earth lead and sensing pipe. Sensing 3. Undo the nuts on the venturi inlet pipe Pipe and valve inlet pipe. Remove the gas valve. Gas Valve 4.
  • Page 42 Igniter Bracket 1. Remove the air box front cover. 2. Disconnect the igniter feed plug and the Igniter electrode leads, noting their positions. 3. Undo the screw securing the bracket to the boiler. Igniter Feed Plug 4. Remove the igniter and transfer the bracket to the new component.

  • Page 43: Burner

    4.10 Burner 1. Remove the fan/manifold assembly - see Section 4.6. 2. Undo the screws securing the spacer to the cover. Cover 3. Withdraw the burner from the cover and replace with the new one. Gasket 4. Replace the burner gasket. Extension Piece 5.

  • Page 44: Diverter Valve Actuator

    4.12 Diverter Valve Actuator Re-assemble all parts in reverse order. 1. Perform 4.1 General Access. 2. Disconnect the electrical connector at the actuator. 3. Release the locking catch and twist the actuator until it unlocks from the valve and remove from the boiler. Diverter Valve Complete Re-assemble all parts in reverse order.

  • Page 45: Heat Exchanger

    4.14 Heat Exchanger NOTE: Replacing the heat exchanger involves disconnecting the appliance from the flue and air pipes. It is essential that the flue system is fully reinstated and tested so we recommend that the appropriate replacement flue pipe and fittings be obtained before starting this work.

  • Page 46: Immersion Heater And Immersion Heater Combined Thermostat/Thermal Cut Out

    4.15 Replacement of Immersion Heater and Immersion Heater Combined Thermostat/Thermal Cut-out The cylinder must be fully drained prior to removing the immersion heater. Refer to Section 2.8 for the procedure to drain the unit. Important: Ensure ALL power supplies are isolated before starting work on the boiler. Perform the actions detailed in section 4.1 General Access.

  • Page 47: Gas/Air Valve Setup Procedure

    4.16 Gas/Air Valve Setup Procedure Flue Adaptor Checking the CO Test Point 1. The combustion (CO ) may be checked at maximum rate using a suitably calibrated analyser after running the boiler for several minutes. 2. To do this it is necessary to set the boiler to Calibration Mode .

  • Page 48: Wiring Diagrams

    5. Wiring Diagrams Wiring/Functional Flow Diagram Fig. 27 © Baxi Heating UK Ltd 2012...
  • Page 49 Flow Cylinder Thermistor Thermistor Overheat Stat Water Pressure Flue Thermistor Switch X400 Timer X401 9 8 7 8 7 6 5 4 3 2 1 Control PCB X501 Flame Pump Sensing Electrode Diverter Valve Spark Generator Mains Input Link Gas Valve Ignition Electrode Reset Selector Switch...

  • Page 50: Error Codes

    6. Fault Finding Guide Boiler Fault Finding Initial Fault Finding Checks 1. Check that gas, water and electrical supplies are available at the boiler. 2. Electrical supply = 230V ~ 50 Hz. 3. CH water system pressurised to 0.5 bar minimum when the boiler is cold.
  • Page 51 Refer to Section “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence Turn selector switch to Go to section A The display illuminates Error 110 flashing If the error 110 is still Turn the selector switch to Error 130 flashing flashing.
  • Page 52 Domestic Hot Water - Follow operational sequence Turn selector switch to Select HW On All Day or Go to section A The display illuminates 24Hr at programmer Error 110 flashing Turn the selector switch to If the error 110 is still Error 133 flashing reset position for 5 seconds flashing.

  • Page 53: Fault Finding Solutions Sections

    Fault Finding Solutions Sections Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse Display Replace PCB illuminated Check wiring PCB - X1 connector terminals 1,2 Is there 230V at: Pump If pump jammed, release Replace pump PCB - X3 connector terminals 3 &...
  • Page 54 Temperature sensors faulty. Cold resistance approximately 10k @ 25° C (DHW and CH sensors) Replace sensor 20k @ 25° C (Flue sensor) (resistance reduces with increase in temp.) Check and correct the connection of the tube between the venturi and gas valve Gas at burner Ensure gas is on and purged...
  • Page 55 Check the gas supply pressure: For Natural Gas greater than 10 - 11 mbar Check and correct if necessary 1. The mechanical set of the gas valve (CO2 values - see instruction) 2. Flame sensing electrode and lead connections 3. Flame sensing electrode position Replace PCB Flame current should be more than 0.5 A Replace flame sensing electrode...

  • Page 56: Short List Of Spare Parts

    7. Short List Of Spare Parts Short Parts List G.C. Description Manufacturers Part No. 5129230 Igniter Electrode 5114702 Sensing Electrode 5117275 Gas Valve 720301001 Burner 5114697 Water Pressure Switch 5114748 Pump 248042 Flue Thermostat 5114747 NTC Sensor 5114725 Overheat Thermostat 5106291 Pressure Gauge 248090...
  • Page 57 Notes © Baxi Heating UK Ltd 2012...

  • Page 58: Litres

    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 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.
  • Page 60 A T r a d i n g D i v i s i o n o f B a x i H e a t i n g U K L t d ( 3 8 7 9 1 5 6 ) Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 0844 871 1525 Technical Enquiries 0844 871 1555 Website www.potterton.co.uk e&oe © Baxi Heating UK Ltd 2012...

This manual is also suitable for:

Promax he store 115Promax he store 150Promax he store 90 litres

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