Potterton Promax 12 SL Installation And Service Instructions Manual
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Potterton Promax 12 SL Installation And Service Instructions Manual

Potterton Promax 12 SL Installation And Service Instructions Manual

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See also: User Manual
Installation & Service Instructions
Promax SL
Range
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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  • Page 1 Installation & Service Instructions Promax SL Range 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

    Natural Gas Building Regulations and the Benchmark Commissioning Checklist Potterton Promax 12 SL G.C.N 41 591 79 Building Regulations (England & Wales) require notification of Potterton Promax 15 SL 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 declares that no substances harmful to health are contained in the appliance or used This appliance must be installed in accordance with the manufacturer’s instructions and during appliance 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.

  • 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 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...

  • Page 7: Introduction

    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. The maximum output of the 30 SL model is preset at 75,000 Btu/hr but can be set to 100,000 Btu/hr (see section 10.8).

  • Page 8: General Layout

    2.0 General Layout Layout (Figs. 3,4,5 & 6) Wall Plate Flue Elbow Heat Exchanger Burner Air Box Fan Protection Thermostat Fan Assembly Fig. 5 Condensate Trap PCB Housing Assembly 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)

  • Page 9: Appliance Operation

    Mains On. 3.0 Appliance Operation Flow temperature less 1. Switched Live On: When the switched live switches than set point ? on if the flow temperature is less than the set point then pump overrun occurs. When the switched live switches on if the flow temperature is greater than the set point then pump overrun occurs.

  • Page 10: Technical Data

    4.0 Technical Data Max Gas Rate (2H - G20 - 20mbar) Appliance Type Electrical Supply 230V~ 50Hz (After 10 Mins) (Appliance must be connected to an Appliance Category CAT I earthed supply) (12) (15) (18) (24) (30) Btu/hr 40,950 52,000 61,400 75,000 102,980 Heat Input (Q)(Gross) Power Consumption...

  • Page 11: Dimensions And Fixings

    5.0 Dimensions and Fixings DIMENSIONS A 600mm 1.5° B 280mm C 390mm D 150mm Ø Min. E 162.5mm F 96mm 360° Orientation The 1.5° fall provided by the elbow is to allow condensate to run back to the boiler, for disposal through the Tube Ø...

  • Page 12: System Details

    6.0 System Details Water Circulating Systems 1. The appliance 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 (100ft) of water. •...
  • Page 13 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 the Fig. 9 requirements of the system. The connections on the boiler are 22mm.
  • Page 14 230V Key to colours 50Hz - Blue Y Plan 6.0 System Details L N E - Brown Diverter Valve - White Cylinder Stat - Orange System Controls - Grey Room g/y - Green/Yellow Stat This boiler does not require a bypass. This boiler does not require a permanent live.
  • Page 15 15mm ( in) nominal size. using Potterton Boilers The volume of the vessel should be suitable for the system water content and the nitrogen or air charge Multiply Total pressure should not be less than the system static head (See Table.

  • Page 16: 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 may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting Zone 2...
  • Page 17 5mm Min 390mm 5mm Min 7.0 Site Requirements Clearances (Figs. 15 &16) 200mm 1. A flat vertical area is required for the installation of the boiler. 2. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement.
  • Page 18 7.0 Site Requirements Termination to an internal soil and vent pipe Boiler Condensate Drain 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. There MUST be a fall of AT LEAST 2.5°...
  • Page 19 Terminal Position with Minimum Distance (Fig. 17) (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. C a Horizontally to an opening, air brick, opening window etc. Flue D Below gutters, soil pipes or drain pipes.

  • Page 20: Flue Options

    8.0 Flue Options Horizontal Flue Systems 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). Any additional “in line” bends in the flue system must be taken into consideration.
  • Page 21 Vertical Flue System Examples (Twin Pipe) 8.0 Flue Options Twin & Vertical Flue Systems Concentric The maximum equivalent lengths are 4m (vertical). Their 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 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 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 Support 70Ø Exhaust Bracket 45° Elbow Flue Length - Worked Example Potterton Promax 30 SL 93° Elbow In Fig. D opposite an additional 93° elbow and pair of 45° elbows have been included in the 70Ø exhaust. 1 metre Extension Also 3 straight extension pieces have been used.
  • 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

    Template Literature Pack 10.0 Installation Wall Plate Check Site Requirements (section 7) before commencing. 10.1 Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). Fig. 19a 1. Cut the banding and remove the fixing template, wall plate and literature pack (Fig.
  • Page 30 10.0 Installation 10.2 Preparing The Boiler 1. Remove the outer carton and packaging. 2. Lift the outercase upwards and remove. 3. Remove the internal packaging. Fig. 22a Internal Polysterene Packaging Piece Lower Door Panel Outercase Break Off Upper & Lower Pipe Run Options Fig.
  • Page 31 10.0 Installation 10.3 Fitting The Boiler (Fig. 24) Retaining Bracket 1. Obtain retaining bracket and two M6 nuts from fitting bag. 2. Offer up the boiler to the wall plate using the lifting points shown in Fig. 24 and locate the rear bottom edge onto the self locating support at the base of the wall plate.
  • Page 32 10.0 Installation Wall Thickness 10.6 Making the Gas Connection 1. Connect the gas supply to the G in BSPT Internal) gas tap. This is located on the lower right side 1.5° of the boiler, access by hinging down the PCB housing (see Fig.
  • Page 33 13. If necessary fit a terminal guard (see Section 8.8). 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.
  • Page 34 10.0 Installation 10.8 Making The Electrical Connections WARNING: This appliance must be earthed 1. The electrical connections are on the right hand side of the unit. 2. Undo the two screws securing the cable clamp and place to one side (Fig. 31). 3.

  • Page 35: Electrical

    11.0 Electrical 11.1 Schematic Wiring Diagram Earths not shown to aid clarity of diagram w g br Flow Electrical Overheat Filter Thermostat Flow Valve Thermistor Flame 325 Vdc Spark Detection Flow DC Fan Electrode Electrode Switch Optional Pump Feed Overheat Condensate Thermostat Trap...
  • Page 36 11.0 Electrical 11.2 Illustrated Wiring Diagram Optional Flow Pump Thermistor Feed 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...

  • Page 37: Commissioning The Boiler

    12.0 Commissioning the Boiler 12.1 Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Flush the whole system using a suitable flushing agent (see Section 6.2) and vent the radiators. Check for water leaks.

  • Page 38: Fitting The Outer Case

    13.0 Fitting the Outer Case 13.1 Fitting The Outer Case Break Off Panel 1. Position the outercase over the boiler engaging the lugs in the side flanges over the hooks on the wall plate. Break off top or bottom panel as required to accommodate pipework runs (Fig.37).

  • Page 39: Servicing The Boiler

    14.0 Servicing the Boiler 14.1 Annual Servicing If a combustion analyser is available the CO/CO2 can be checked (for levels see Section 4.0). If the the reading is acceptable, and a visual inspection of the appliance is satisfactory, it is not necessary to perform a full strip- down.
  • Page 40 14.0 Servicing the Boiler 14.1 Annual Servicing (Cont) Flue Sampling Point 10. 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 41: Changing Components

    15.0 Changing Components 15.1 Changing Components IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. “The boiler cannot be switched off at the boiler, therefore it is important to isolate the electrical supply at the mains fuse.”...
  • Page 42 15.0 Changing Components 15.3 Flowswitch (Fig. 47) 1. Drain the boiler (see Section 15.1 paragraph 2 & 3). 2. Remove the two screws on the support bracket. 3. Remove the clip securing the flow pipe to the flowswitch. Support Bracket 4.
  • Page 43 15.0 Changing Components 15.4 (Figs. 48 & 49) WARNING: The PCB Control and Fan Assembly are 325 Vdc. Isolate at supply before access. 1. Remove the plastic button cover. Refit them onto Plastic the new PCB (Fig. 48). Button Cover 1.
  • Page 44 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 45 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 15.6). 15.7 Injector Pipe (Fig. 53) 1. Remove the injector pipe by pulling out from the ‘O’ ring joint in the gas valve.
  • Page 46 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 15.6 and 15.10). 1.
  • Page 47 15.0 Changing Components 15.12 Heat Exchanger Lower Insulation Pad (Fig. 60) 1. Remove all components in the base of the airbox. 2. Remove the burner (see section 15.10). 3. Remove the four bolts securing the combustion box base. 4. Remove the combustion box base. 5.

  • Page 48: 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 5110991 5109925 Gas Valve 241900 E06 085 Viewing Window 242484 Condensate Trap 5111714 Electrodes Kit...

  • Page 49: Fault Finding

    17.0 Fault Finding High Reset NOTE: The fan is supplied with 325 Vdc. Fan Fault Finding should only be carried out after the boiler has been electrically isolated. General Fault Finding should only be carried out by Lockout Boiler On Mains On someone who is appropriately qualified.
  • Page 50 Lights 17.0 Fault Finding Off Off Off ELECTRICAL SUPPLY No Switched Live to boiler. Check Systems 240V at A ? Controls and System Wiring. Check wiring from 240V at B ? terminal block to PCB. Optional Pump Live Check for shorts on pump, fan &...
  • Page 51 Lights 17.0 Fault Finding On Flash Flash DRY-FIRE Swop Flow & Return. Flow & Return reversed ? Is the Fill system with water and system full of water ? bleed out all air. Optional Pump Replace PCB. Live Turn Turn mains off, unplug Is the mains off &...
  • Page 52 Lights 17.0 Fault Finding On Off On IGNITION LOCKOUT Check isolation valve and Is there gas at gas valve inlet gas supply. 5-way Connector Remove 5-way connector Reset Lockout. from gas valve. Is there 240 Is there gas flow Replace Gas Valve. Vdc between I &...
  • Page 53 Lights 17.0 Fault Finding Flash Off On 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 54 Lights 17.0 Fault Finding Flash Flash 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 55 17.0 Fault Finding Lights On Flash On 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...
  • Page 56 18.0 Notes © Baxi Heating UK Ltd 2007...
  • Page 57 18.0 Notes © Baxi Heating UK Ltd 2007...

  • Page 58: Benchmark Checklist

    5 1 2 1 9 0 8 BENCHMARK No. 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: Boiler

    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 Ad iv is i o n of 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 ompany © Baxi Heating UK Ltd 2007...

This manual is also suitable for:

Promax 15 slPromax 18 slPromax 30 slPromax 24 sl

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