Potterton Promax FSB 30 HE Installation & Service Instructions Manual
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Potterton Promax FSB 30 HE Installation & Service Instructions Manual

Floor standing fanned flue condensing boiler
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See also: Instructions for Installation and Servicing
You can rely on
Installation & Service Instructions
Promax
FSB 30 HE
Floor Standing
Fanned Flue
Condensing Boiler
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2010

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Summary of Contents for Potterton Promax FSB 30 HE

  • Page 1 You can rely on Installation & Service Instructions Promax FSB 30 HE Floor Standing Fanned Flue Condensing Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2010...

  • Page 2: Natural Gas

    Natural Gas Building Regulations and the Benchmark Commissioning Checklist Potterton Promax FSB 30 HE G.C. No 41 595 39 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 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 Legislation This company declare that no substances harmful to IMPORTANT - Installation, Commissioning, Service & Repair health are contained in the appliance or used during appliance manufacture. This appliance must be installed in accordance with the manufacturer’s instructions and the regulations in force. Read the instructions fully before installing or using the The appliance is suitable only for installation in GB and IE appliance.

  • Page 5: Table Of Contents

    Contents Section Page Introduction General Layout Boiler Operation Technical Data Dimensions and Fixings System Details Site Requirements Flue Options Plume Displacement 10.0 Installation 11.0 Electrical 12.0 Commissioning the Boiler 13.0 Completion 14.0 Servicing the Boiler 15.0 Changing Components 16.0 Short Parts List 17.0 Fault Finding Benchmark Checklist...

  • Page 6: Introduction

    1.0 Introduction Description Optional Integral Timer 1. The Potterton Promax FSB 30 HE is a gas fired room sealed fan assisted condensing central heating boiler. 2. The maximum output of the boiler is 30.18 kW. The boiler automatically adjusts the output down to 9.2 kW Position of Label according to system load.

  • Page 7: General Layout

    2.0 General Layout Layout (Figs. 3, 4, 5 & 6) Condensate Pump Flue Elbow (supplied in std. flue kit) Heat Exchanger Burner Air Box Fan Protection Thermostat - Black Fan Assembly Fig. 5 Condensate Trap PCB Housing Assembly Gas Tap Gas / Air Ratio Valve Flow Pipe Connection Return Pipe Connection...

  • Page 8: Boiler Operation

    3.0 Boiler Operation Boiler Operation Mains On. Condensate Pump will 1. Switched Live On: When switched live is supplied to operate as necessary (3.1.9) the boiler and the flow temperature is less than the set point the sequence below commences. Flow 2.

  • Page 9: Technical Data

    4.0 Technical Data Appliance Type Horizontal Electrical Supply 230V~ 50Hz Flue Terminal Diameter - 110mm The boiler must be connected to an earthed Appliance Category CAT I Dimensions Projection - 150mm supply. A permanent and switched live are required. The boiler has a 4 wire connection. Heat Input (Q)(Gross) Connections Power Consumption...

  • Page 10: Dimensions And Fixings

    5.0 Dimensions and Fixings DIMENSIONS At least A 850mm 1.5° B 520mm C 390mm D 125mm Ø Min. E 175mm F 150mm The 1.5° fall provided by the elbow is to allow condensate to run back to the boiler, for discharge through the condensate disposal system.

  • Page 11: System Details

    6.0 System Details Water Circulating Systems 1. The boiler is suitable for use with open vent fully pumped systems and sealed systems . The following conditions should be observed on all systems: • The static head must not exceed 30m of water. •...
  • Page 12 Boiler Air Vent 6.0 System Details Copper Copper 0.5m 0.5m Flow Pipework Boiler Return Copper 1. The sizes of flow and return pipes from the boiler should be determined by normal methods, according to Fig. 9 the requirements of the system. 2.
  • Page 13 Key to colours - Blue 6.0 System Details - Brown - White - Orange System Controls & Wiring - Grey g/y - Green/Yellow This boiler requires a permanent live for operation of the condensate pump and frost protection. 230V 1. To comply with Part L1 of the Building Regulations the 50Hz Y Plan L N E...
  • Page 14 6.0 System Details 3 Litre Top Up Bottle Sealed Systems (if required) (Fig. 13) Vent 1. SAFETY VALVE - A safety valve complying with the requirements of BS 6750 Part 1 must be fitted close to Filling Pressure the boiler on the flow pipe by means of a horizontal or Point Safety Gauge...

  • Page 15: Site Requirements

    7.0 Site Requirements Location NOTE: Due to the high efficiency of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. 1. The boiler must be fitted on a suitable flat and level surface capable of supporting the weight.
  • Page 16 7.0 Site Requirements 5mm Min 5mm Min 390mm Clearances (Figs. 15 &16) 15mm Min 1. These dimensions include the necessary clearances (25mm if under around the boiler for case removal, spanner access and air non removable worktop) movement. Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler.
  • Page 17 7.0 Site Requirements Condensate Pump Flow Graph Condensate Drain - General Failure to install the condensate discharge pipework correctly will affect the reliable operation of the boiler. 1. Ensure the discharge of condensate complies with any national or local regulations in force. BS 6798 &...
  • Page 18 7.0 Site Requirement Termination via internal discharge branch e.g Condensate Disposal (cont.) sink waste - downstream Pipe must terminate Direct Connect Fitting above water level but 9. Ensure that the condensate can discharge freely (without below surrounding surface blockage or restriction of the pipe) into the drain. Sink 10.

  • Page 19: Flue Plume Deflector Kit

    Assembly 8. If required a suitable terminal guard (part no. 248484) is available from Potterton for use with the flue deflector. See also Section 7.11. 9. For fitting under low soffits and eaves the Plume Displacement Kit or Flue Deflector Kit is recommended.

  • Page 20: Flue Options

    8.0 Flue Options Horizontal Flue Systems Only a flue approved with the Potterton Promax FSB 30 HE Plus can be used. (ii) Concentric The maximum equivalent lengths are 4m (horizontal) or (vertical). Their lengths exclude the standard elbow and flue/terminal assembly (horizontal) and terminal assembly (vertical).
  • Page 21 Vertical Flue System 8.0 Flue Options Examples (Twin Pipe) Twin & Vertical Flue Systems Concentric The maximum equivalent lengths are 4m (vertical). Their (ii) lengths exclude the standard elbow and terminal assembly (vertical). Twin Flue The total maximum equivalent flue length is 150m. NOTE: Each 1m of flue duct should be calculated as 2m.

  • Page 22: Vertical Flue Terminal

    8.0 Flue Options Flue Accessories Accessory Size Code No FLUE GROUP B Concentric Flue System 110mm diameter Horizontal Flue Terminal 850mm 243013BAX Horizontal Flue Terminal (incl elbow) 236921 Flue Extension 1000mm 241695 500mm 241694 250mm 241692 Flue Bend 93° 241687 Flue Bend (pair) 135°...

  • Page 23: Vertical Flue Adaptor

    8.0 Flue Options For Vertical Flues For Vertical Flue Systems Vertical Flue Adaptor 1. Undo the screws securing the blanking plate to the boiler top panel. Discard the plate. Gasket 2. Fix the vertical adaptor and gasket to the top panel with the previously removed screws.
  • Page 24 8.0 Flue Options For Roof Terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make Approx 1425mm an aperture in the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained.

  • Page 25: Plume Displacement

    9.0 Plume Displacement Plume Outlet (‘Peak’ MUST be Uppermost) Plume Displacement Kit (P.D.K.) Kit No 5121371 Content of kit 70/110 Concentric Flue 1m 70 Dia Exhaust Flue Pipe 0.94 metre Support Brackets 93° Elbow/Plume Outlet Assembly Flue Trim “O” Rings Elbow with Gasket 1.
  • Page 26 9.0 Plume Displacement Determining Permissible Lengths - P.D.K. In the graph the solid line diagonal represents the relationship between the concentric flue assembly (and any extensions) and the 70Ø exhaust (and any extensions or additional bends). Example 1 - Not Permissible If, for instance, a concentric length of 3.25 metres was required and the 70Ø...
  • Page 27 9.0 Plume Displacement General Fitting Notes - P.D.K. 1. Cut a hole in the external wall which the horizontal This section of the concentric flue assembly will pass through. flue MUST be horizontal 2. When completed the terminal must be at least 2 metres Min.
  • Page 28 9.0 Plume Displacement Plume Outlet General Fitting Notes - P.D.K. (cont.) Elbow 16. For aesthetic purposes it is permissible to route the 70Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air. 17.

  • Page 29: Installation

    10.0 Installation Example Edge of Boiler 125mm Check Site Requirements before commencing. EXAMPLE: If the boiler is 2 metres away from corner of wall the flue 10.1 Initial Preparation & Installation duct hole will be 55mm higher than Example the horizontal side flue centre line. 1.
  • Page 30 10.0 Installation Wall Thickness 10.5 Fitting the Standard Flue IMPORTANT: The flue should always be installed with at least 1.5° fall from terminal to elbow, to At least allow condensate to run back to the boiler. 1.5° 1. The standard flue is suitable for lengths 270mm minimum to 800mm maximum (measured from the edge of the flue elbow outlet).
  • Page 31 10.0 Installation 10.5 Fitting the Standard Flue (Cont) Inner Flue Support Bracket 7. Ensure the inner flue support bracket is positioned in the flue (Fig. 28). 8. Engage the flue into the flue elbow using soap solution to ease the engagement, ensuring the flue terminal is positioned as shown (Fig.
  • Page 32 Min. radius 100mm 10.0 Installation Gravity Drain min. fall 3° Point ‘A’ 10.6 Making the Condensate Drain Note: The point of discharge from Connection the pumped length of condensate Max. Head pipe (point ‘A’) must not be below Boiler 3 metres the level of the pump, whether 1.
  • Page 33 10.0 Installation 10.7 Making The Electrical Connections WARNING: This boiler must be earthed IMPORTANT: Four core cable is required to supply the boiler as a permanent live is necessary for the operation of the condensate pump and frost protection. 1. The electrical connections are on the right hand side of the boiler.

  • Page 34: Electrical

    11.0 Electrical 11.1 Schematic Wiring Diagram Condensate Removal System Condensate Condensate Level Switch Condensate Pump Over-Level Switch Overheat Condensate Thermostat Trap 325 Vdc Flow DC Fan Switch Spark Flame Flow Electrode Detection Thermistor Valve Electrode Flow Overheat Thermostat Optional Internal Timer Electrical Earths not shown to aid Filter...
  • Page 35 11.0 Electrical 11.2 Illustrated Wiring Diagram Flow Thermistor Flow Switch Electrical Filter Spark Electrode Flame Detection Electrode Main Layout of PCB Pins Condensate Trap Gas Valve Fan Overheat Thermostat Flow Overheat Thermostat Wiring Key - Blue bk - Black br - Brown - Red w - White g/y - Green/Yellow...

  • Page 36: Commissioning The Boiler

    12.0 Commissioning the Boiler 12.1 Commissioning the Boiler WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access. 1. Reference should be made to BS:EN 12828 & 14336 when commissioning the boiler. Flue Sampling Point 2.
  • Page 37 12.0 Commissioning the Boiler 12.3 Check the Operational (Working) Gas Inlet Pressure 1. Ensure that all controls are calling for heat and maximum load is applied to the system. 2. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point is in accordance with B.S.

  • Page 38: Completion

    13.0 Completion 13.1 Fitting The Case Panels & Facia 1. Refit the case top panel and front door, securing with the screws previously removed (Fig.37). 2. Locate the facia panel and secure with the screws previously removed (Fig. 38). 3. The “Important Ventilation Information” label can be removed unless the boiler is installed in an unventilated compartment.

  • Page 39: Servicing The Boiler

    14.0 Servicing the Boiler 14.1 Annual Servicing WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate system controls before access. IMPORTANT: When servicing ensure that both the gas and electrical supplies, including Switched and Permanent Live to the boiler are isolated before any work is started.
  • Page 40 14.0 Servicing the Boiler 14.2 Annual Servicing - Inspection WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate system controls before access 1. Ensure that the boiler is cool. 2. Remove the facia and front door panel. 3. Release the four turn screws securing the air box door panel and remove the panel (Fig.
  • Page 41 14.0 Servicing the Boiler 14.2 Annual Servicing - Inspection (Cont) Flue Sampling Point 7. To clean the heat exchanger and burner proceed as follows: a) Disconnect the electrical leads to the fan component protection sensor (Fig. 42). Fig. 41a b) Loosen the screw retaining the gas injector pipe at the venturi (Fig.

  • Page 42: Changing Components

    15.0 Changing Components 15.1 Changing Components & Preparation WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate system controls before access. IMPORTANT: Ensure that both the gas and electrical supplies, including Switched and Permanent Live to the boiler are isolated before any work is started. The four facia LEDs will be all OFF.
  • Page 43 15.0 Changing Components Pipe Access Panel 15.3 Flowswitch (Fig. 47) 1. Drain the boiler (see Section 13.1 paragraph 2 & 3). 2. Remove the pipe access panel and remove the securing clip from the ‘O’ ring joint between the flow pipe and the system.
  • Page 44 15.0 Changing Components 15.6 (Figs. 48 & 49) Control Knob WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate system controls before access. 1. Pull the control knob off the spindle and remove the plastic button cover. Refit them onto the new PCB (Fig.
  • Page 45 15.0 Changing Components The fan and venturi, gas valve, injector pipe, condensate trap, fan protection sensor, spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel. 1. Remove the airbox door panel by loosening the four turn screws (Fig.
  • Page 46 15.0 Changing Components The removal of the fan is necessary to enable the changing of the injector pipe, condensate trap and gas valve (see section 13.6). 15.9 Injector Pipe (Fig. 53) 1. Remove the injector pipe by pulling out from the ‘O’ ring joint in the gas valve.
  • Page 47 15.0 Changing Components Combustion Box The burner and heat exchanger can be changed after Door Panel removal of the combustion box door. To change the heat exchanger, the fan and burner must be removed first (see section 13.6 and 13.10). 1.
  • Page 48 15.0 Changing Components 15.14 Heat Exchanger Lower Insulation Pad (Fig. 60) 1. Remove all components in the base of the airbox. 2. Remove the burner (see section 13.10). 3. Remove the four bolts securing the combustion box base. 4. Remove the combustion box base. 5.

  • Page 49: Short Parts List

    16.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. E06 058 Flow Temperature Thermistor (Red) 240670 E06 059 Flow Switch 242459 E06 060 Safety Thermostat (Black) 242235 5129147 5109925 Gas Valve 241900 E06 085 Viewing Window 242484 Condensate Trap 5111714 Electrodes Kit...

  • Page 50: Fault Finding

    17.0 Fault Finding NOTE: The fan is supplied with 325 Vdc. Fan Fault Finding should only be carried out after the boiler has been electrically isolated. Mains On Boiler On Lockout General Fault Finding should only be carried out by LED Light LED Light LED Light...
  • Page 51 17.0 Fault Finding Lights Off Off Off ELECTRICAL SUPPLY No Permanent Live to boiler. Check Mains Fuse 240V at A ? System Wiring. No Switched Live to boiler. Check System 240V at B ? Controls and System Wiring. Check P/L wiring from 240V at C ? terminal block to PCB.
  • Page 52 17.0 Fault Finding Lights DRY-FIRE Is the Fill system with water and system full of water ? bleed out all air. Is the Pump or Pump Wiring pump running ? fault. Unplug 5-way PCB Replace PCB. connector. Is there continuity between H Viewed from Wire Entry end...
  • Page 53 17.0 Fault Finding Lights On Off On IGNITION LOCKOUT Gas Valve 5-way Is there Connector Plug Check isolation valve and gas at gas valve inlet ? gas supply. Remove 5-way connector Reset Lockout. from gas valve. Is there 240 Is there gas flow Replace Gas Valve.
  • Page 54 17.0 Fault Finding Lights On Off onn OVERHEAT LOCKOUT Disconnect black stat on flow pipe. Replace Stat. When flow < 60° C is there continuity across stat ? Reconnect stat. Disconnect fan stat. Replace Stat. When fan temp < 60° C is there continuity across stat ? Reconnect stat.
  • Page 55 17.0 Fault Finding Lights On on on FAN LOCKOUT NOTE: The fan is supplied with 325 Vdc. Fan Fault Finding should only be carried out after the boiler has been electrically isolated. Connection Connection Unplug 3-way PCB connector & unplug fan. Is there Rectify wiring.
  • Page 56 17.0 Fault Finding Lights THERMISTOR Unplug thermistor, Is thermistor resistance between Replace thermistor. 0.5kΩ & 20kΩ ? Plug in thermistor, leave Wiring from PCB to 8-way connector unplugged. thermistor faulty. Viewed from Is resistance at D between 0.5kΩ & 20kΩ ? Wire Entry end Replace PCB.
  • Page 57 17.0 Fault Finding CONDENSATE PUMP Lights Lights On Off On Reset boiler Condensate pump level switch Condensate pump over level and add approx. 1 litre activated for longer than 3 switch activated - pump tap water to the condensate minutes - boiler locks out. reservoir level too high system via the flue or Boiler will try to relight 4 times...

  • Page 58: 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 this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

  • 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 Ad iv is i o n of B a x i G ro up 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 Limited 2010 5117331 - Iss.

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