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Benchmark Procombi A Series Installation & Servicing Instructions Manual

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Installation & Servicing Instructions
Installation & Servicing Instructions
Installation & Servicing Instructions
Installation & Servicing Instructions
Installation & Servicing Instructions
THESE INSTRUCTIONS
TO BE RETAINED
BY USER
0694
0694BR1207
G.C. NUMBER
PROCOMBI A28
N° 47 094 96
PROCOMBI A32
N° 47 094 97
PROCOMBI A36
N° 47 094 98

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Summary of Contents for Benchmark Procombi A Series

  • Page 1 Installation & Servicing Instructions Installation & Servicing Instructions Installation & Servicing Instructions Installation & Servicing Instructions Installation & Servicing Instructions 0694 0694BR1207 G.C. NUMBER PROCOMBI A28 N° 47 094 96 PROCOMBI A32 N° 47 094 97 PROCOMBI A36 N° 47 094 98 THESE INSTRUCTIONS TO BE RETAINED BY USER...

  • Page 2: Table Of Contents

    10.5 Gas supply installation Preparation for mounting the appliance 10.6 Adjusting the gas valve Fitting the flue 10.7 Appliance fan speed Connecting the gas & water Electrical connections Benchmark 32-33 Commissioning Page Gas supply installation The heating system Initial filling of the system...
  • Page 3 INTRODUCTION The Procombi A comprises a range of high-efficiency The Procombi A is approved for use with C13 & C33 type combination boilers with outputs to DHW of 28kW, 32kW, flue applications. and 36kW respectively. These appliances – by design These appliances are designed for use with a sealed –...
  • Page 4 GREEN LED RED LED HEATING TEMPERATURE TEMPERATURE SELECTOR SELECTOR HYDROMETRE 2-digit LED display CLOCK MODE SELECTOR SWITCH Fig. 1A Hot water only Select this position if you want the boiler to supply hot water only (no heating) Boiler at OFF/standby Select this position when you want the boiler to be switched off for short periods (days) or if the boiler requires to be reset (refer to users handbook) Heating &...

  • Page 5: Design Principles & Operating Sequence

    SECTION 1 DESIGN PRINCIPLES AND OPERATING SEQUENCE PRINCIPLE COMPONENTS In the event of the appliance exceeding the de- • A fully integrated electronic control board featur- sired temperature (set point) the burner will shut ing electronic temperature control, anti-cycle down until the temperature drops. When the re- control, pump over-run, self-diagnostic fault in- quest for DHW has been satisfied the appliance dicator, full air/gas modulation.

  • Page 6: Technical Data

    SECTION 2 TECHNICAL DATA 2.1 Central Heating Heat input (kW) Maximum heat output (kW) 60/80°C 19.6 24.45 29.31 Minimum heat output (kW) 60/80°C 6.84 Maximum heat output (kW) 30/50°C 21.00 26.30 31.83 Minimum heat output (kW) 30/50°C 6.40 7.47 7.41 Minimum working pressure 0.5 bar Maximum working pressure...

  • Page 7: Pump Duty

    2.12 PUMP DUTY Fig. 3 shows the flow-rate available – after allowing for pressure loss through the appliance – for system requirements. When using this graph, apply only the pressure loss of the system. The graph is based on a 20 C temperature differential.

  • Page 8: General Requirements (Uk)

    SECTION 3 GENERAL REQUIREMENTS (UK) This appliance must be installed by a competent FLUE SYSTEM person in accordance with the Gas Safety (In- The terminal should be located where the disper- stallation & Use) Regulations. sal of combustion products is not impeded and with due regard for the damage and discoloration RELATED DOCUMENTS that may occur to building products located nearby.

  • Page 9: Electrical Supply

    3.6.5 EXPANSION VESSEL Make-up vessel The appliance has an integral expansion vessel to or tank accommodate the increased volume of water when the system is heated. It can accept up to 8 Automatic (28HE) or 10 (32 & 36HE) litres of expansion from air-vent within the system, generally this is sufficient, however if the system has an unusually high water...

  • Page 10: Installation

    SECTION 4 INSTALLATION DELIVERY Due to the weight of the appliance it may be Reduction for additional bends necessary for two people to lift and attach the Bend Reduction in maximum flue length for appliance to its mounting. The appliance is con- each bend tained within a heavy-duty cardboard carton.
  • Page 11 FITTING THE HORIZONTAL FLUE KIT Carefully measure the distance from the centre of the appliance flue outlet to the edge of the finished outside wall (dimension X). Add 65mm to dimen- sion X to give you Dimension Y (see fig 9A). Measure dimension Y from the terminal end of the concentric flue pipe and cut off the excess ensur- ing any burrs are removed.

  • Page 12: Connecting The Gas & Water

    CONNECTING THE GAS AND WATER KIT “X” The appliance is supplied with an accessory pack 28/32/36 HE = 218 mm that includes service valves. The service valves are of the compression type. The accessories “X” pack contains sealing washers etc., for use with 12/15/20HE = 202mm the service valves.

  • Page 13: Electrical Connections

    4.6.5 SAFETY VALVE (fig. 12) Connect the safety valve connection pipe to the safety valve outlet. Connect a discharge pipe to the other end of the safety valve connection pipe and tighten. The discharge pipe must have a continuous fall away from the appliance to outside and allow any water to drain away thereby eliminat- ing the possibility of freezing.

  • Page 14: Commissioning

    SECTION 5 COMMISSIONING GAS SUPPLY INSTALLATION INITIAL FLUSHING OF THE SYSTEM Inspect the entire installation including the gas The whole of the heating system must be flushed meter, test for soundness and purge. Refer to BS both cold and hot as detailed in 5.8. Open all 6891 for specific instruction.

  • Page 15: Final Flushing Of The Heating System

    The DHW outlet temperature can be adjusted Complete details of the boiler, controls, installa- between 35 °C - 60 °C via the DHW thermostat tion and commissioning in the Benchmark check- knob (see fig.1). list at the back of this book. It is important that 5.10...

  • Page 16: General

    SECTION 6 SERVICING INSTRUCTIONS GENERAL content from the appliance via the drain valve. To ensure the continued safe and efficient opera- Ensure some water absorbent cloths are avail- tion of the appliance, it is recommended that it is able to catch any residual water that may drip checked and serviced at regular intervals.

  • Page 17: Safety Valve

    SAFETY VALVE (fig. 19) 6.11 PRINTED CIRCUIT BOARD (fig. 21) Carry out component removal procedure as de- Carry out component removal procedure as de- scribed in 6.4. Disconnect the outlet pipe (A) from scribed in 6.4. Pull the control fascia forward and the safety valve, remove safety valve locking pin lower it.

  • Page 18: Electrodes And Condense Sensor

    6.13 ELECTRODES & CONDENSE SENSOR (fig. 23) (D). Disconnect the electrode leads and ancillary Carry out component removal procedure as de- wiring from their respective connectors. Remove scribed in 6.4. Unclip and remove the air chamber the retaining screws (A, fig. 25) for sensing front and RH side covers.

  • Page 19: Automatic By-Pass

    Fig. 27: To remove the fan burner assembly (A) locate and remove the 3 external nuts (B). Replace in the reverse order. Ensure all seals are in good condition, taking care to ensure they are replaced correctly. 6.17 AUTOMATIC BY-PASS & DHW NON-RETURN VALVE (fig.
  • Page 20 6.20.1 DHW FLOW RESTRICTOR (fig. 32A) 6.20.4 DHW THERMISTOR (fig. 32B) Carry out the component removal procedure as Carry out component removal procedure as de- described in 6.4. scribed in 6.4. Disconnect the cold water inlet pipe at the DHW Locate and remove the thermistor locking pin (H).

  • Page 21: Checks, Adjustments And Fault Finding

    SECTION 7 CHECKS, ADJUSTMENTS AND FAULT FINDING economy by ensuring the boiler remains in the CHECKING APPLIANCE OPERATION modulation phase during any heating requests. When carrying out any repairs or servicing to the This reduces the amount of ON/OFF periods appliance, the relevant commissioning procedure and therefore increases fuel efficiency.

  • Page 22: Appliance Fan Speed

    whereby fan speed will increase relative to the 7.3.3 ABSOLUTE MIN FAN SPEED output required. When the boiler has reached Locate the MIN trimmer (fig. 36) and gently adjust the set point (+ hysterisis), the burner will switch clockwise or counter clockwise to achieve the off.

  • Page 23: Combustion Analysis Test

    7.7.1 INSTALLATION FAULTS Maximum Symptom Possible cause screw Compensation No display/ignition Check wiring/check electrical pipe connection supply No hot water Check pipe-work No heating Check external controls Minimum screw Fault code Possible cause fig. 37 Check gas supply, check flue system, check polarity 7.4.2 GAS VALVE MINIMUM SETTING...

  • Page 24: Fault Finding

    7.12 COMPONENT VALUES & CHARACTERISTICS These series of checks must be carried out be- fore attempting any faultfinding procedures on the COMPONENT VALUE appliance. On completion of any task that required 230Vac the disconnection and re-connection of any elec- Pump 230Vac trical wiring or component, these checks must be Valve actuator (Combi only)

  • Page 25: Wiring Diagrams

    SECTION 8 WIRING DIAGRAMS EXTERNAL WIRING IMPORTANT • The boiler must always be supplied with a per- The appliance comes with a factory fitted (TA) link to allow basic operation of the boiler via the manent 230V electrical supply. mode selector switch. If external controls are to •...
  • Page 26 FUNCTIONAL DIAGRAM Fig. 38 NOTE: L-N-E connection is advisable F Hv Fan power supply 230 V M3-M5 Terminal strip for supply in / clock / room thermostat F Lv Fan signal control M3a-M4 Terminal strip for esternal sensor / condense pump / low temperature Pump thermostat Fuse 3.15A F (fast)

  • Page 27: Exploded Diagrams

    SECTION 9 EXPLODED DIAGRAMS Table 1 POS. DESCRIPTION Frame R01005415 R01005416 R01005416 Water gauge carrier R10029105 R10029105 R10029105 Pressure gauge R2564 R2564 R2564 Cover assembly R10028554 R10028554 R10028554 Printed circuit board 20001116 20001116 20001116 Led light guide R10028557 R10028557 R10028557 Instrumental panel 20005205 20005205...

  • Page 28: Table 2

    Table 2 POS. DESCRIPTION Exchanger R8037 R1957 R10024627 Connection R10030114 R10030114 R10030114 Pressure water switch R10028141 R10028141 R10028141 Non return valve R10025056 R10025056 R10025056 By-pass casing R10024642 R10024642 R10024642 Heating by-pass valve R2047 R2047 R2047 Pipe R10026193 R10026193 R10026193 Heating manifold R10026506 R10026506 R10026506...

  • Page 29: Table 3

    Table 3 POS. DESCRIPTION Expansion vessel R2204 R2573 R2573 Pipe R10025188 R10025188 R10025188 Pump R10027571 R10027571 R10027571 Pipe R10030440 R10026552 R10026552 Pipe R10026267 R10026267 R10026267 Pipe R10029476 R10029457 R10029458 Pipe R10030441 R10030477 R10030477 Air venting plug R10029306 R10029306 R10029306 Siphon R10028405 R10028405 R10028405...

  • Page 30: Table 4

    Table 4 POS. DESCRIPTION Roomsealed chamber R10028479 R10028447 R10028447 Roomsealed chamber side R10026231 R10026231 R10026231 R10028456 R10028456 R10028456 Burner assembly R10028537 R10028642 R10028537 Spark / ignition electrode R10027864 R10027864 R10027864 Condense electrode R10026316 R10026316 R10026316 Gas pipe R10029096 R10030387 R10030387 Gas valve R10028538 R10028538...

  • Page 31: Table 5

    Table 5 POS. DESCRIPTION Condensing exchanger assembly R01005443 R01005366 R01005369 Conveyor R10028536 R10028623 R10028623 Flue drain connection R10028421 R10028421 R10028421 Nut screw R10020625 R10020625 R10020625 Washer Ø 125 R10026323 R10026323 R10026323 Washer R10026366 R10026366 R10026366 Washer Ø 60 R10026345 R10026345 R10026345 Washer Ø...

  • Page 32: Related Documents

    SECTION 10 LPG INSTRUCTIONS 10.1 RELATED DOCUMENTS BS 5440 PARTS 1 & 2 FLUES & VENTILATION REQUIREMENTS BS 5449 PART 1 FORCED CIRCULATION OF HOT WATER SYSTEMS BS 5482 PART 1 DOMESTIC BUTANE & PROPANE GAS BURNERS IN PERMAMENT DWELLINGS BS 5546 INSTALLATION OF GAS HOT WATER SUPPLIES FOR DOMESTIC PURPOSES...

  • Page 33: Appliance Fan Speed

    10.6.3 COMPLETION On completion of the combustion analysis check and/or any gas valve adjustment, set the HTG trimmer to the corresponding value as detailed in the fan speed table. Refit the 3-selector knobs and move the mode selector to the OFF position. Remove the test probe from the test point and refit.

  • Page 34: Benchmark

    The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Commissioning Engineer’s Signature Customer’s Signature...
  • Page 35 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 36 Heating Services provides after-sales assistance and Technical advice for Procombi A Boilers Service & Technical Helpline: 0870-264-1220 Heating Services, PO BOX 167, BRADFORD, BD19 4WL. We reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected...

This manual is also suitable for:

Procombi a28Procombi a32Procombi a36

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