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Potterton Promax Combi 24 HE Plus Installation & Service Instructions Manual

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See also: User Manual
Installation & Service Instructions
Promax Combi
24, 28 & 33
HE Plus
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2007

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Summary of Contents for Potterton Promax Combi 24 HE Plus

  • Page 1 Installation & Service Instructions Promax Combi 24, 28 & 33 HE Plus These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2007...
  • Page 2 Natural Gas Building Regulations and the Benchmark Commissioning Checklist Potterton Promax Combi 24 HE Plus G.C.N 47 393 17 Building Regulations (England & Wales) require notification of Potterton Promax Combi 28 HE Plus 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 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 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 19.0...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Potterton Promax Combi is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed Case Front Panel domestic hot water.

  • Page 8: General Layout

    2.0 General Layout Layout Expansion Vessel Automatic Air Vent DHW Plate Heat Exchanger Circulation Pump Drain Off Point Pressure Relief Valve Optional Integral Timer Position Central Heating System Pressure Gauge Control Box 3-Way Valve Assembly Condensate Trap Flame Sensing Electrode Spark Electrode Primary Heat Exchanger Fan Assembly...

  • Page 9: Appliance Operation

    3.0 Appliance Operation Central Heating Mode (Fig. 2) Central Heating Circuit 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 Combi 24, 28 & 33 Appliance Type NO x Class Inlet Pressure (Natural Gas - G20) mbar Appliance Category CAT I Central Heating Primary Circuit Pressures Injector (Natural Gas - G20) Heat Input CH (Net) 7.5mm (24&28 model) 12mm(33 model) 24 model 20.5...

  • 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 H 180mm 360° Orientation Tube Ø 100mm Tap Rail 32.5 mm Condensate Drain 65 mm...

  • Page 12: System Details

    6.0 System Details Information 1. The Promax Combi 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 13 6.0 System Details System Filling and Pressurising (Fig. 4) 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 14 6.0 System Details Domestic Hot Water Circuit (Fig. 7) 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations. Other Tap Outlets 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to Boiler Expansion R24 of the Water Regulations Guide.

  • Page 15: 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 16 7.0 Site Requirement Gas Service Cock Ventilation of Compartments 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 17 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 18 Terminal Position with Minimum Distance (Fig. 18) (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 19: Flue Options

    8.0 Flue Options Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination applications. 2. All fittings should be fully engaged. The approximate engagement is 40mm. Apply soap solution to the seal on each fitting to aid assembly. 3.
  • Page 20 8.0 Flue Options Vertical Twin & Vertical Flue Systems Flues (Twin Pipe) 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 21 8.0 Flue Options Flue Accessories Accessory Size Code No FLUE GROUP A Concentric Flue System 100mm diameter Horizontal Flue Terminal (inc. elbow) 5118489 Telescopic Flue (inc. elbow) 315-500mm 5118069 Telescopic Internal Flue Kit 315-500mm 5119654 Flue Extension 1000mm 5111074 Flue Bend 93°...
  • Page 22 8.0 Flue Options For Twin Flue Systems fit the adaptors as follows:- Flue Duct Adaptor Flue Duct Adaptor 1. Engage the flue duct adaptor on the boiler adaptor, Blanking Plate making sure that it is pushed down as far as possible. Air duct adaptor Boiler Adaptor 1.
  • Page 23 4. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated. 8.10 Flue Deflector (Fig. 20) 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 Fig. 21 optimum angle for deflecting plume.

  • Page 24: Plume Displacement

    93° Elbow/Plume 9.0 Plume Displacement Outlet Assembly 60Ø Support Plume Displacement Kit (Fig. 23) O Ring Bracket Kit No 5118638 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 93°...
  • Page 25 Support 60Ø Exhaust Bracket 45° Elbow Flue Length - Worked Example Potterton Promax Combi 33HE 93° Elbow In Fig. 27 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 26 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 least 1.5°. 2.
  • Page 27 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 28: 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). Fig. 39 Method 1 a) Remove the outer packaging and literature, and stand the boiler and inner packaging upright. Remove the base tray Fig.
  • Page 29 10.0 Installation 10.3 Fitting The Boiler 1. Lift the boiler using the Lifting Points as shown by the shaded areas (Figs. 44a or 45). The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate(see Safe Manual Handling page 5).
  • Page 30 10.0 Installation 10.6 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths between 100mm Fig. 48 minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 48). 2.
  • Page 31 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 32 10.0 Installation 10.7 Making The Electrical Connections The boiler is fitted with a 1.3m length of 3 core 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:- Terminal Block Cover 1.

  • Page 33: Commissioning

    Heat Exchanger 11.0 Commissioning Automatic Air Vent Fig. 62 11.1 Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Open the mains water supply to the boiler. IMPORTANT: The heat exchanger air vent on top of the Screw boiler (Fig.
  • Page 34 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 20mb. 2.

  • Page 35: Completion

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

  • Page 36: 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. If a combustion analyser is available the CO can be checked and adjusted - see Section 15.0.
  • Page 37 13.0 Servicing 13.1 Annual Servicing (Cont) 9. Undo the nut on the gas inlet pipe to the venturi (Fig. 77) Fan, Collector and Cover and pull the sensing pipe off the fan. Assembly 10. Disconnect the electrode leads, noting their position, and the fan electrical plugs.

  • Page 38: Changing Components

    14.0 Changing Components IMPORTANT: When changing components ensure that Bracket both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed turn the selector switch Igniter fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler Igniter Feed before recommissioning.
  • Page 39 14.0 Changing Components 14.3 Fan (Fig. 83) 1. Undo the nut on the gas inlet pipe to the venturi (Fig. 62) and pull the sensing pipe off the fan. 2. Disconnect the electrode leads, noting their position and disconnect the fan electrical plugs. 3.
  • Page 40 14.0 Changing Components Cover 14.6 Burner (Fig. 85) Burner 1. Undo the screws securing the collector to the cover and Gasket venturi (On 28 models there is an extension piece fitted to the cover, remove this also. Extension Piece (On 28 models only) 2.
  • Page 41 14.0 Changing Components Electrical Plug 14.8 Flue/Heat Exchanger Thermostat Sensor Flue/Heat Exchanger (Fig. 87) 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 42 14.0 Changing Components Heat Exchanger Air Vent 14.11 Heat Exchanger Automatic Air Vent (Fig. 90) 1. Drain the boiler primary circuit and unscrew the automatic air vent from the pump body. 2. Examine the ‘O’ ring seal, replacing if necessary, and fit it to the new automatic air vent.
  • Page 43 14.0 Changing Components 14.15 Pressure Gauge (Figs. 94 & 95) Gauge Retaining Bracket 1. Drain the boiler 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 44 14.0 Changing Components 14.18 Plate Heat Exchanger (Fig. 98) 1. Drain the boiler primary circuit and remove the gas valve Plate Heat Exchanger as described in section 13.22. 2. While supporting the heat exchanger undo the screws securing it to the brass manifolds. 3.
  • Page 45 14.0 Changing Components 14.20 P.C.B. (Fig. 102) 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 46 14.0 Changing Components 14.22 Gas Valve (Fig. 103) IMPORTANT: After replacing the valve the CO must be Venturi Inlet checked and adjusted as detailed in Section 15.0 Pipe Combustion Check. Only change the valve if a suitable calibrated combustion analyser is available Outlet Adaptor 1.

  • Page 47: Combustion Check

    15.0 Combustion Check 15.1 Checking the CO IMPORTANT: The must only be checked and adjusted if a suiutable calibrated combustion analyser is available. 1. The combustion (CO ) may be checked using a suitably calibrated analyser after running the boiler for several minutes.

  • Page 48: Electrical

    16.0 Electrical 16.1 Illustrated Wiring Diagram Central Heating NTC Sensor NTC Sensor Overheat Stat Hall Effect Sensor Water Pressure Flue Sensor Switch X400 X401 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Timer Control PCB X501...

  • Page 49: Short Parts List

    17.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. 5121447 Motor 3way Valve 248733 Igniter Electrode 5114702 Sensing Electrode 5114703 Gas Valve 5114734 Hall Effect Sensor 5114767 Burner 24 5122149 Burner 28 5114697 Burner 33 5114698 Water Pressure Switch 5114748 Plate Heat Exchanger 24 248048...

  • Page 50: 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 51 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 If the error 110 is still flashing. Turn the selector switch to Error 130 flashing reset position for 5 seconds...
  • Page 52 18.0 Fault Finding Domestic Hot Water - 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. Error 133 flashing Go to section ‘J’ reset position for 5 seconds Error 20, 28 or 50 flashing Go to section ‘E’...

  • Page 53: 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 54 18.0 Fault Finding E20 or E50 - Temperature sensors faulty. Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) Replace sensor or PCB (E28) 20kΩ @ 25° C (Flue sensor) (resistance reduces with increase in temp.) E28 - Incorrect PCB fitted Check and correct the connection of the tube between the venturi and gas valve Gas at burner...
  • Page 55 18.0 Fault Finding 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.

  • Page 56: Pages For Notes

    19.0 Notes © Baxi Heating UK Ltd 2007...
  • Page 57 19.0 Notes © Baxi Heating UK Ltd 2007...

  • Page 58: Benchmark Checklist

    5 1 1 4 4 4 4 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 59: 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 60: Description

    A T r a d in g D i v i s ion of B a x i He at i ng U K Ltd 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 ompany IT Comp N 925.096.2...

This manual is also suitable for:

Promax combi 28 he plusPromax combi he plus lpgPromax combi 33 he plus

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