Potterton Promax System HE Plus LPG Installation & Service Instructions Manual
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Potterton Promax System HE Plus LPG Installation & Service Instructions Manual

Potterton Promax System HE Plus LPG Installation & Service Instructions Manual

Condensing system boiler
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You can rely on
Installation & Service Instructions
Promax System
HE Plus LPG
Condensing
System Boiler
These instructions include the Benchmark Commissioning
Checklist and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2008

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  • Page 1 You can rely on Installation & Service Instructions Promax System HE Plus LPG Condensing System Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2008...
  • Page 2 Propane Building Regulations and the Benchmark Commissioning Checklist Potterton Promax System 24 HE Plus LPG G.C.N 41 592 11 Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly.
  • Page 3 Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme Contact your relevant Local Install and Commission this Authority Building Control appliance to manufacturer's (LABC) who will arrange instructions an inspection or contact a government approved inspector Complete the Benchmark Checklist...

  • Page 4: Systems

    Legislation IMPORTANT - Installation, Commissioning, Service & Repair This company declare that no substances harmful to health are contained in the appliance or used during appliance This appliance must be installed in accordance with the manufacturer’s instructions and manufacture. the regulations in force. Read the instructions fully before installing or using the appliance.
  • 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 Plume Displacement 10.0 Installation 11.0 Commissioning 12.0 Completion 13.0 Servicing 14.0 Changing Components 15.0 Combustion Check 16.0 Electrical 17.0 Short Parts List 18.0 Fault Finding Benchmark Checklist...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Potterton Promax System HE Plus LPG is a fully automatic gas fired wall mounted condensing system boiler. It is room sealed and fan assisted. Case Front Panel 2. The boiler is set to give a maximum output of :- 24 kW 25.9 kW (Condensing)

  • Page 8: General Layout

    2.0 General Layout Layout Expansion Vessel Automatic Air Vent Circulation Pump Drain Off Point Pressure Relief Valve Selector Switch Central Heating System Pressure Gauge Control Box Gas Valve Condensate Trap Flame Sensing Electrode Spark Electrode Primary Heat Exchanger Fan Assembly On/Off/Reset Selector Switch Central Heating Temperature Control Calibration Control...

  • Page 9: Appliance Operation

    3.0 Appliance Operation Operating Mode (Fig. 2) Boiler Primary Circuit 1. With a demand for heating or hot water, the pump circulates water through the primary circuit. If the pressure is at least 0.5 bar and the ignition sequence will start. 2.

  • Page 10: Technical Data

    4.0 Technical Data Promax System 24 HE Plus LPG Electrical Protection Appliance Type NO x Class IPX5D Appliance Category CAT I I Central Heating Primary Circuit 2H3P External Fuse Rating Pressures Heat Input (Net) Internal Fuse Rating 24 model 24.7 Safety Discharge Max Operating Condensate Drain...

  • Page 11: Dimensions And Fixings

    5.0 Dimensions and Fixings Dimensions A 780mm At least 1.5° B 345mm C 450mm D 116mm Ø Min. E 185mm (207mm for 80/125mm flue systems) F 145mm G 131mm 360° Orientation H 180mm Tube Ø 100mm Tap Rail 32.5 mm Condensate Drain 130 mm...

  • Page 12: System Details

    6.0 System Details Central Heating Circuit 1. The appliance is suitable for fully pumped SEALED SYSTEMS ONLY. 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.
  • Page 13 6.0 System Details System Filling and Pressurising Sealed Systems Double Stop Stop Check 1. A filling point connection on the central heating return Valve Valve Valve pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling.

  • Page 14: Site Requirements

    7.0 Site Requirements 5mm Min 450mm 5mm Min Location 1. The boiler may be fitted to any suitable wall with the flue 200mm Min passing through an outside wall or roof and discharging to (300mm Min if using 80/125mm atmosphere in a position permitting satisfactory removal of flueing system) combustion products and providing an adequate air supply.
  • Page 15 7.0 Site Requirements Ventilation of Compartments Gas Service Cock 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.
  • Page 16 7.0 Site Requirements Condensate Drain Termination to an internal soil and Boiler vent pipe FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length.
  • Page 17 Terminal Position with Minimum Distance (Fig. 9) (mm) 7.0 Site Requirements A a Directly below an opening, air brick, opening windows, etc. B a Above an opening, air brick, opening window etc. Flue C a Horizontally to an opening, air brick, opening window etc. D Below gutters, soil pipes or drain pipes.

  • Page 18: Flue Options

    8.0 Flue Options Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination applications. 2. Maximum permissible equivalent flue lengths are:- 60/100 80/125 Horizontal Concentric 10 metres 20 metres 3. Any additional “in line” bends in the flue system must be taken into consideration.
  • Page 19 Vertical Flues 8.0 Flue Options (Twin Pipe) Twin & Vertical Flue Systems 1. Maximum permissible equivalent flue lengths are:- (60/100) (80/125) Vertical Concentric 10 metres 20 metres Vertical Twin Pipe 15 metres 2. Any additional “in line” bends in the flue system must be taken into consideration.
  • Page 20 8.0 Flue Options Flue Accessories Accessory Size Code No FLUE GROUP A Concentric Flue System 100mm diameter Horizontal Flue Terminal (incl elbow) 5118489 Telescopic Flue (inc. elbow) 315-500mm 5119654 Telescopic Internal Flue Kit 315-500mm 5119654 Flue Extension 1000mm 5111074 Flue Bend 93°...
  • Page 21 8.0 Flue Options For Twin Flue Systems fit the adaptors as follows:- Flue Duct Adaptor 1. Engage the flue duct adaptor on the boiler flue adaptor, making sure that it is pushed down as far as possible. Air duct adaptor 1.
  • Page 22 8.0 Flue Options For Roof Terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead Approx tile to replace/flash over existing roof tiling. Make an aperture in 1425mm the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained.

  • Page 23: Plume Displacement

    93° Elbow/Plume 9.0 Plume Displacement Outlet Assembly 60Ø Support Plume Displacement Kit (Fig. 14) O Ring Bracket Kit No 5118638 (5121367 without elbow) Content of kit 0.9 metres 0.9m 60/100 Concentric Flue 1m 60 Dia Exhaust Flue Pipe 60Ø Exhaust Adaptor Flue Pipe 60 Dia Support Brackets...
  • Page 24 9.0 Plume Displacement Determining Permissible Lengths In the graph the solid line diagonal represents the relationship between the concentric flue assembly (and any extensions) and the 60Ø exhaust (and any extensions or additional bends). Concentric 60/100 Flue (metres) Y Concentric 60/100 Flue (metres) Y Example 1 Example 2 Example 1 - Not Permissible...
  • Page 25 9.0 Plume Displacement 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 least1.5°. 2.
  • Page 26 9.0 Plume Displacement 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 27: Installation

    10.0 Installation 10.1 Unpacking & Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). NOTE: a small amount of water may drain from the boiler in the upright position. 1. Remove staples, open flaps and remove the cardboard sheet.
  • Page 28 10.0 Installation Wall Plate 10.3 Fitting The Boiler 1. Lift the boiler using the Lifting Points as shown by the shaded areas (Fig. 34). The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig.
  • Page 29 10.0 Installation 10.6 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the Fig. 36 edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 36). 2.
  • Page 30 10.0 Installation Inner Flue Support Bracket 10.6 Fitting the Flue (Cont) 6. The inner flue duct support bracket may be in the waste portion of the flue. In this case retrieve the bracket before discarding the waste. 7. Take the inner flue support bracket (if not already fitted) Fig.
  • Page 31 10.0 Installation 10.7 Making The Electrical Connections The boiler is fitted with a 1.3m length of 3 core of cable. This can be connected to the fused 3A 230V 50H supply. NOTE: Both the Live and Neutral connections are fused. To connect an external control proceed as follows:- 1.

  • Page 32: Commissioning

    Heat Exchanger 11.0 Commissioning Automatic Air Vent Fig. 49 11.1 Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. IMPORTANT: The heat exchanger air vent on top of the boiler (Fig. 49) MUST be opened before filling the primary Screw system.
  • Page 33 11.0 Commissioning 11.2 Checking 1. The gas valve is factory set and the burner pressure cannot be measured as it is altered by suction of the fan and modulates as demand on the boiler alters. The gas supply pressure should be 37mb. 2.

  • Page 34: Completion

    12.0 Completion 12.1 Completion Case Front Panel 1. Instruct the user in the operation of the boiler and system including extenal controls, explaining the operational sequence. 2. Set the central heating and hot water temperature control knobs to the requirements of the user. 3.

  • Page 35: Servicing

    13.0 Servicing 13 .1 Annual Servicing Case Front Panel 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4:2007. If a suitably calibrated combustion analyser is available it may not be necessary to perform a full strip down of the appliance.
  • Page 36 13.0 Servicing 13.1 Annual Servicing (Cont) Burner Viewing Window 9. Undo the nut on the gas inlet pipe to the venturi (Fig. 63) and pull the sensing pipe off the fan. 7.5 ± 1 10. Disconnect the electrode leads, noting their position, and the fan electrical plugs (Fig.

  • Page 37: Changing Components

    14.0 Changing Components IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are Bracket isolated before any work is started. When the component has been changed turn the selector switch fully anticlockwise against the spring pressure to the Igniter reset position and hold for 5 seconds to reset the boiler before recommissioning.
  • Page 38 14.0 Changing Components 14.3 Fan (Fig. 67) 1. Undo the nut on the gas inlet pipe to the venturi (Fig. 68) and pull the sensing pipe off the fan. 2. Disconnect the electrode leads, noting their position and disconnect the fan electrical plugs. 3.
  • Page 39 14.0 Changing Components Cover 14.6 Burner (Fig. 70) Burner 1. Undo the screws securing the collector to the venturi and extension piece. Remove this extension piece from the Gasket cover. Extension Piece 2. Withdraw the burner from the cover and replace with the new one.
  • Page 40 14.0 Changing Components 14.8 Flue/Heat Exchanger Thermostat Sensor Electrical (Fig. 72) Plug Flue/Heat Exchanger Thermostat Sensor 1. Ease the retaining tab on the sensor away and disconnect the electrical plug. 2. Turn the sensor 90 anticlockwise to remove - it is a bayonet connection.
  • Page 41 14.0 Changing Components 14.13 Pump - Head Only (Fig. 76) 1. Drain the primary circuit and remove the socket head screws securing the pump head to the body and draw the head away. 2. Undo the screw on the pump wiring cover and remove the cover.
  • Page 42 14.0 Changing Components 14.16 Pressure Gauge (Figs. 79 & 80) Gauge Retaining Bracket 1. Drain the primary circuit and undo the nut on the pressure gauge capillary. 2. Undo the screws securing the gauge retaining bracket. 3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining bracket.
  • Page 43 14.0 Changing Components 14.18 P.C.B. (Fig. 82) 1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins. 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 pin (Fig.
  • Page 44 Venturi Inlet Pipe 14.0 Changing Components Outlet Adaptor 14.20 Gas Valve (Fig. 84) IMPORTANT: After replacing the valve the CO must be Gas Valve Sensing Pipe checked and adjusted as detailed in Section 15.0 Combustion Check. Only change the valve if a suitable calibrated combustion analyser is available 1.

  • Page 45: Combustion Check

    15.0 Combustion Check 15.1 Checking the CO IMPORTANT: The CO must be only be checked and adjusted if a suitable calibrated combustion analyser is available. 1. The combustion (CO ) may be checked after running the boiler for several minutes. To do this it is necessary to set the boiler to ‘Calibration Mode’.

  • Page 46: Electrical

    16.0 Electrical 16.1 Illustrated Wiring Diagram Central Heating NTC Sensor Overheat Stat Water Pressure Microswitch Return Heating Temperature Sensor Flue Sensor X400 X401 9 8 7 6 5 4 3 2 1 10 8 7 6 5 4 3 2 1 Control PCB X501 6 7 8 9...

  • Page 47: Short Parts List

    17.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. Flue Thermostat 5114747 Burner 5114697 5121447 Igniter Electrode 5114702 Sensing Electrode 5114703 Pump 248042 Water Pressure Switch 5114748 Overheat Thermostat 5114729 NTC Sensor 5114725 Gas Valve 5119647 NTC Sensor (Return) 5114725 5129836 Pressure Gauge...

  • Page 48: Fault Finding

    18.0 Fault Finding 18.1 Initial Fault Finding Checks NOTE: When instructed to turn the 1. Check that gas, water and electrical supplies are available selector to the reset position turn the at the boiler. selector switch fully anticlockwise against the spring pressure to the reset position 2.
  • Page 49 18.0 Fault Finding Refer to Section 16.0 “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 Turn the selector switch to If the error 110 is still flashing.

  • Page 50: Fault Finding Solutions Sections

    18.0 Fault Finding 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...
  • Page 51 18.0 Fault Finding Temperature sensors faulty. Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) Replace sensor 20kΩ @ 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 PCB - X3 connector is 230V AC across...
  • Page 52 18.0 Fault Finding Check the gas supply pressure: Propane LPG should be 37 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 μA Replace flame sensing electrode...
  • Page 53 19.0 Notes © Baxi Heating UK Ltd 2008...

  • Page 54: Benchmark Checklist

    5 1 3 1 7 9 1 BENCHMARK No. 1.0 Introduction GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...

  • Page 55: Service Interval Record

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

  • Page 56: Description

    A D iv i s i o n o f B a x i G ro up Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 08706 017 017 Technical Enquiries 08706 049 049 Website www.potterton.co.uk e&oe 925.736.1 Comp N 5131791 - Iss 1 - 4/08 ©...

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