Potterton Promax SL range Installation & Service Instructions Manual
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Potterton Promax SL range Installation & Service Instructions Manual

Promax sl series condensing central heating boiler
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You can rely on
Installation & Service Instructions
Promax SL
Range
Condensing
Central Heating
Boiler
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2014

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Summary of Contents for Potterton Potterton Promax SL range

  • Page 1 You can rely on Installation & Service Instructions Promax SL Range Condensing Central Heating Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2014...

  • Page 2: Natural Gas

    The flowchart opposite gives guidance for installers on the © Baxi Heating UK Ltd 2014 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, or stored in any...
  • Page 3 Benchmark Checklist ‘Gas Safe Register’ will issue a LABC will record the data Building Regulations Compliance and will issue a Certificate to the property owner certificate of compliance and inform the relevant LABC © Baxi Heating UK Ltd 2014...
  • Page 4 BS EN 14336 Installation & commissioning of water based heating systems. BS 7074 Expansion vessels and ancillary equipment for sealed water systems. BS 7593 Treatment of water in domestic hot water central heating systems. © Baxi Heating UK Ltd 2014...
  • Page 5 If at any time when installing the boiler you feel that you may have injured yourself STOP !! DO NOT ‘work through’ the pain - you may cause further injury. IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !! © Baxi Heating UK Ltd 2014...

  • Page 6: Table Of Contents

    Site Requirements Flue Options Plume Displacement 10.0 Installation 11.0 Electrical 12.0 Commissioning the Boiler 13.0 Fitting the Outer Case 14.0 Servicing the Boiler 15.0 Changing Components 16.0 Short Parts List 17.0 Fault Finding Benchmark Checklist © Baxi Heating UK Ltd 2014...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Potterton Promax SL range are gas fired room sealed fan assisted condensing central heating boilers. 2. The maximum output of the Potterton Promax 12 SL is 40,330 Btu/hr,15 SL model is 52,000 Btu/hr, 18 SL model is 60,770 Btu/hr and 24 SL model is 75,000 Btu/hr.

  • Page 8: General Layout

    Gas Tap Gas / Air Ratio Valve Flow Pipe Connection Return Pipe Connection Flow Temperature Safety Thermostat - Black Flow Temperature Thermistor - Red Flow Switch (dry fire protection) Fig. 3 Fig. 4 Fig. 6 © Baxi Heating UK Ltd 2014...

  • Page 9: Appliance Operation

    ? 9. Ignition Lockout: The pump, fan, spark generator and gas valve are off. The boiler can only be reset by manually using the reset button. 1 minute Pump Overrun. 3 minute Anti-cycle. © Baxi Heating UK Ltd 2014...

  • Page 10: Technical Data

    This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been Water Flow Rate (litres/min) calculated has been certified by 0087. © Baxi Heating UK Ltd 2014...

  • Page 11: Dimensions And Fixings

    27.5mm to incorporate the 1.5° fall in the flue from the terminal to the elbow. Flue length (Y) Clearance (X) up to 1m 27.5mm 1m - 2m 55mm 2m - 3m 82.5mm Fig. 8 © Baxi Heating UK Ltd 2014...

  • Page 12: System Details

    • It is important to check the inhibitor concentration after installation, system modification and at every service in accordance with the manufacturer’s instructions. (Test kits are available from inhibitor stockists.) • For information or advice regarding any of the above contact Technical Enquiries. © Baxi Heating UK Ltd 2014...
  • Page 13 (e.g. the system is not prone to pumping over, air entrainment etc.) the pump may be fitted 22mm on the primary return pipe. 200mm Feed & Vent Pipe Separator Boiler Pump Flow Return Fig. 12 Alternative Low Head Installation © Baxi Heating UK Ltd 2014...
  • Page 14 Pump must be run from Boiler P/F connection for Part L1 compliance By-pass not permitted (must be valved off) for Part L1 compliance By-pass not permitted (must be valved off) for Part L1 compliance © Baxi Heating UK Ltd 2014...
  • Page 15 All components Valve Valve Valve used in the system must be suitable for operation at 110°C (230°F) and at the pressure allowed by the safety valve. Temporary Cold Hose Mains Return Fig. 14 Inlet © Baxi Heating UK Ltd 2014...

  • Page 16: Site Requirements

    3. Any compartment should be large enough to house the boiler only. NOTE: The ventilation label on the front of the outer case MUST NOT BE REMOVED when the appliance is installed in a compartment or cupboard. © Baxi Heating UK Ltd 2014...
  • Page 17 3mm in all poles and servicing the boiler and system controls only. WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access. 280mm In Operation Fig. 16 © Baxi Heating UK Ltd 2014...
  • Page 18 *It is NOT RECOMMENDED to connect upstream of the sink or other waste water receptacle ! © Baxi Heating UK Ltd 2014...
  • Page 19 45° iv) Termination to a purpose made soakaway Further specific requirements for soakaway Boiler design are referred to in BS 6798. 500mm min Holes in the soak-away must face away from the building © Baxi Heating UK Ltd 2014...
  • Page 20 Boiler External runs & those in unheated locations still require insulation. Condensate Pump Pipe must terminate above water level but below surrounding surface. Cut end at 45° © Baxi Heating UK Ltd 2014...
  • Page 21 150mm from any opening windows or doors (see Section 9.0). Plume Displacement Kit Air Inlet Likely flue positions requiring Fig. 17 Opening Window a flue terminal guard or Door 150mm MIN. Fig. 17b © Baxi Heating UK Ltd 2014...

  • Page 22: Flue Options

    NOTE: Horizontal flue pipes should always be installed with a 1.5° fall from the terminal to allow condensate to run back to the boiler. This bend is equivalent to 0.5 metre This bend is equivalent to 0.5 metre Total equivalent length (up to 4m) = A+B+2x45°Bends © Baxi Heating UK Ltd 2014...
  • Page 23 This bend is equivalent to Equivalent Length Air Duct = 17.2m 1 metre FLUE DUCT Equivalent Sub total Length Value fittings/pipes 1m extension 10.0m 135°bend 2.6m 5.2m 91.5°bend 19.2m 9.6m Equivalent Length Flue Duct = 34.4m © Baxi Heating UK Ltd 2014...
  • Page 24 Vertical Flue Boiler Adaptor Kit 242757 Pipe Support (pair) 80mm 5111081 FLUE GROUP B,P Vertical Flue Kits Vertical Flue Terminal 242802 Pitched Roof Flashing 25°/50° 243015 Roof Cover Plate 243131 Flat Roof Flashing 243016BAX © Baxi Heating UK Ltd 2014...
  • Page 25 Discard the plate. 2. Fix both the air and flue adaptors with their gaskets onto the boiler top panel. Secure with screws. For Twin Flues Air Duct Adaptor Flue Duct Adaptor Gasket Gasket © Baxi Heating UK Ltd 2014...
  • Page 26 Flue Deflector (Fig. 18a) 1. If required, push the flue deflector over the terminal end and rotate to the optimum angle for deflecting plume. Fig. 19 Secure the deflector to the terminal with screws provided. © Baxi Heating UK Ltd 2014...

  • Page 27: Plume Displacement

    Installation & Outlet Connection Servicing Instructions and BS5440 Pt. 1. It is NOT upwards necessary to fit a terminal guard over the air inlet or the plume outlet. Fig. B © Baxi Heating UK Ltd 2014...
  • Page 28 Additional Accessories that the concentric flue could be up to approximately 3.25 A - 93° Elbow 5121373 metres long. B - 45° Elbow (Pair) 5121374 C - 1 metre 70Ø Extension 5121372 Fig. D © Baxi Heating UK Ltd 2014...
  • Page 29 Fit the 93° elbow and plume outlet. Ensure the plume outlet is at least 45° to the wall and that the ‘peak’ is uppermost. 15. Continue with installation and commissioning of the boiler. © Baxi Heating UK Ltd 2014...
  • Page 30 18. When the plume outlet is positioned under a balcony or other projection (Figs. I & J) it must protrude at least Fig. H 200mm (it is not necessary to extend it further than this). 200mm Min. Fig. I 200mm Min. Fig. J © Baxi Heating UK Ltd 2014...

  • Page 31: Installation

    1.5° inclination. as shown on template (Fig. 22). Fig. 21 8. Loosely route the condensate discharge pipe to the lower left hand side of the wall plate. Relief Holes Wall Plate Fig. 22 © Baxi Heating UK Ltd 2014...
  • Page 32 1. Remove the outer carton and packaging. 2. Lift the outercase upwards and remove. 3. Remove the internal packaging. Fig. 22a Internal Polystyrene Packaging Piece Lower Door Panel Outercase Break Off Upper & Lower Pipe Run Options Fig. 23 © Baxi Heating UK Ltd 2014...
  • Page 33 - Carefully pour approximately 1 cupful (250ml) of water into the flue products exhaust, at the top of the heat exchanger (Fig. 25a) to ensure a seal is made in the trap. © Baxi Heating UK Ltd 2014...
  • Page 34 Inner Flue Support Bracket pieces. Deburr both tube ends. IMPORTANT: Check all measurements before cutting. NOTE: When cutting ensure the cut does not interfere with the inner flue support bracket Fig. 27a (Fig. 27a). © Baxi Heating UK Ltd 2014...
  • Page 35 Apply Lubricant for ease of assembly. Ensure Flue is fully engaged into Flue Elbow VERTICAL FLUEING 1. Only a flue approved with the Potterton Promax SL range can be used. Gasket Fig. 30 Flue Trim Fig. 29 © Baxi Heating UK Ltd 2014...
  • Page 36 (Fig. 31). 7. Check the electrical installation for; earth continuity, short circuits, resistance to earth, correct polarity and fuse failure. 4-way Terminal Block Optional Pump Feed Connection only required for fully TRV’d system Fig. 33 © Baxi Heating UK Ltd 2014...

  • Page 37: Electrical

    Trap Key To Wiring Colours b - Blue r - Red bk - Black g - Green w - White g/y- Green/Yellow br - Brown op - Opaque gy - Grey y - Yellow © Baxi Heating UK Ltd 2014...
  • Page 38 Fan Overheat Thermostat Flow Overheat Thermostat Wiring Key - Blue bk - Black br - Brown - Red w - White g/y - Green/Yellow - Green gy - Grey op - Opaque - Yellow © Baxi Heating UK Ltd 2014...

  • Page 39: Commissioning The Boiler

    •The integrity of the flue system and the flue seals. •The integrity of the boiler combustion circuit and the DO NOT check gas pressure here relevant seals. Proceed to put the boiler into operation as follows: Fig. 36 Inlet Gas Pressure Test Point © Baxi Heating UK Ltd 2014...
  • Page 40 & a low rate before correctly fitted & secured and calling 0844 871 1555. all other commissioning procedures completed. Complete the ‘Benchmark’ Checklist, recording the CO & combustion ratio readings as required. © Baxi Heating UK Ltd 2014...
  • Page 41 Fig. 36a Conformity” to indicate compliance with I.S. 813. An example of this is given in I.S. 813 “Domestic Gas Inlet Gas Pressure Test Point Installations”. This is in addition to the Benchmark Commissioning Checklist. © Baxi Heating UK Ltd 2014...

  • Page 42: Fitting The Outer Case

    10. Complete the label supplied with the inhibitor and stick to the inside of the boiler case. Detail of system Fig. 38 Lower Door Panel treatment must be recorded in the Benchmark Commissioning Checklist. © Baxi Heating UK Ltd 2014...

  • Page 43: Servicing The Boiler

    • Perform the ‘Annual Servicing - Inspection’ (Section 14.2) & re-check. • Replace the gas valve (Section 15.8) & re-check. © Baxi Heating UK Ltd 2014...
  • Page 44 (care should be taken as this could be hot). Clean the trap and refit the drain plug. Check for leaks. h) Top of heat exchanger. Fig. 41 Combustion Box Door Panel © Baxi Heating UK Ltd 2014...
  • Page 45 14. Complete the relevant Service Interval Record Securing Screws section of the Benchmark Commissioning Checklist at Burner Securing Screws the rear of this publication and then hand it back to the Fig. 44 user. © Baxi Heating UK Ltd 2014...

  • Page 46: Changing Components

    1. The procedure is the same for both the thermistor and the safety thermostat. 2. Remove the electrical connections from the sensor. 3. Unscrew the sensor from the pipe. 4. Fit the new thermistor or safety thermostat and reassemble in reverse order. © Baxi Heating UK Ltd 2014...
  • Page 47 7. Remove the flowswitch. 8. Fit the new flowswitch and reassemble in reverse order. Flow Switch 9. Recommission the boiler and check the inhibitor concentration (see Section 6.2 and 12.1). Flow Pipe Fig. 47 Clip © Baxi Heating UK Ltd 2014...
  • Page 48 2. Lift Control PCB housing out of hinge housing of metal bracket. Fig. 48 PCB Housing Securing 3. Fit the new PCB Housing Assembly and reassemble Screw in reverse order. Hinge down PCB Housing Blue (CN11) Jumper Red (CN12) Jumper Fig. 49 © Baxi Heating UK Ltd 2014...
  • Page 49 6. Fit the new fan and reassemble in reverse order. Gasket The injector pipe, condensate trap and gas valve can be changed after the removal of the fan. Protection Sensor Venturi Electrical Connections Fig. 52 Electrical Connection Wing Nuts © Baxi Heating UK Ltd 2014...
  • Page 50 Disconnect the sensor leads. Lock Nut 4. Fit the new condensate trap and reassemble in Service Drain reverse order. Plug Condensate Drain Pipe 5. Prime the condensate trap (fill first chamber), check Fig. 54 for leaks. © Baxi Heating UK Ltd 2014...
  • Page 51 6. Fit the new heat exchanger and reassemble in reverse order. Fig. 58 7. Recommission the boiler and check the inhibitor concentration (see Section 6.2 and 12.1). Heat Exchanger Manifold Heat Exchanger Assembly Fig. 59 © Baxi Heating UK Ltd 2014...
  • Page 52 5. Remove the combustion box base. Combustion Box Base Securing Screws 6. Pull the central insulation panel down from the Burner Securing centre of the heat exchanger. Screws 7. Fit the new insulation pad and reassemble in reverse order. © Baxi Heating UK Ltd 2014...

  • Page 53: Short Parts List

    Flow Switch 242459 E06 060 Safety Thermostat (Black) 242235 5129147 5109925 Gas Valve 241900 E06 085 Viewing Window 242484 Condensate Trap 5111714 Electrodes Kit 5132097 Burner Assy 5107430 E06 097 Heat Exchanger Assy 242497 © Baxi Heating UK Ltd 2014...

  • Page 54: Fault Finding

    Lights On On Flash PCB Fault Replace PCB. Lights Go to Fan Lockout Flash Flash On section of the fault finding instructions. Lights Flash On On PCB Fault Replace PCB. © Baxi Heating UK Ltd 2014...
  • Page 55 Check wiring from 240V at B ? terminal block to PCB. Optional Pump Live Check for shorts on pump, fan & gas valve. PCB fuse OK ? Replace if shorted & replace fuse. Replace PCB. Fuse © Baxi Heating UK Ltd 2014...
  • Page 56 Live Remove Is there a flow switch from boiler. Replace Flow Switch. Is there a physical blockage to blockage in the system ? the paddle within the flow switch ? Remove Blockage. Remove Blockage. © Baxi Heating UK Ltd 2014...
  • Page 57 3 and 4mm ? Is the wiring from PCB to spark probe & flame burner blocked or Replace PCB. detection probe OK ? damaged ? Clean burner or replace as Rectify wiring. necessary. © Baxi Heating UK Ltd 2014...
  • Page 58 (red sensor on flow pipe). Replace thermistor. Is resistance between 0.5k & 20k Replace combustion combustion chamber chamber door seal & trim door seal damaged or not in seal. place ? Replace PCB. © Baxi Heating UK Ltd 2014...
  • Page 59 6-way PCB connector. Is there Rectify wiring. continuity from R to S & from T to U & from V to W ? Viewed from Wire Entry end Replace fan. © Baxi Heating UK Ltd 2014...
  • Page 60 Is thermistor resistance between Replace thermistor. 0.5k & 20k Plug in thermistor, leave Wiring from PCB to 8-way connector unplugged. thermistor faulty. Viewed from Is resistance at D between 0.5k & 20k Wire Entry end Replace PCB. © Baxi Heating UK Ltd 2014...
  • Page 61 18.0 Pages for Notes © Baxi Heating UK Ltd 2014...

  • Page 62: 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 63: 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 64 A T r a d i n g D i v is i o n o f B axi H eat i ng U K Ltd ( 387 91 56 ) Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555 Website www.potterton.co.uk e&oe © Baxi Heating UK Ltd 2014 Comp N 5121908 - Iss 17 - 4/14...

This manual is also suitable for:

Promax 24 slPromax 30 slPromax sl seriesPromax 12 slPromax 15 slPromax 18 sl

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