Potterton Promax FSB 30 HE Installation And Servicing Instructions
  1. Manuals
  2. Brands
  3. Potterton Manuals
  4. Boiler
  5. Promax FSB 30 HE
  6. Installation and servicing instructions

Potterton Promax FSB 30 HE Installation And Servicing Instructions

Floor standing fanned flue condensing boiler
Hide thumbs Also See for Promax FSB 30 HE:
Table of Contents

Advertisement

Quick Links

Installation & Service Instructions
Benchmark Commissioning Checklist
The boiler meets the requirements of Statutory Instrument " The Boiler (Efficiency) Regulations 1993 N
meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water boilers fired with liquid or
gaseous fuels:-
Type test for purpose of Regulation 5 certified by:
Notified Body 0087.
Product/Production certified by:
Notified Body 0086.
For GB/IE only.
Only a flue approved for the Promax FSB 30 HE can be used.
These instructions include the Benchmark Commissioning Checklist and should be left with the User for safe keeping.
© Baxi Heating UK Limited 2005
Promax FSB 30 HE
Floor Standing Fanned Flue

Condensing Boiler

o
3083" and is deemed to

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Promax FSB 30 HE and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Potterton Promax FSB 30 HE

Summary of Contents for Potterton Promax FSB 30 HE

  • Page 1: Condensing Boiler

    Notified Body 0086. For GB/IE only. Only a flue approved for the Promax FSB 30 HE can be used. These instructions include the Benchmark Commissioning Checklist and should be left with the User for safe keeping. © Baxi Heating UK Limited 2005...

  • 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 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 Potterton declare that no substances harmful to health are contained in the boiler or used during This appliance must be installed in accordance with the manufacturer’s instructions and boiler manufacture. the regulations in force. Read the instructions fully before installing or using the appliance.

  • Page 5: Table Of Contents

    Contents Section Page Introduction General Layout Boiler Operation Technical Data Dimensions and Fixings System Details Site Requirements Installation Electrical 10.0 Commissioning the Boiler 11.0 Completion 12.0 Servicing the Boiler 13.0 Changing Components 14.0 Short Parts List 15.0 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 A 850mm 3° (1 in 20) B 520mm C 390mm D 125mm Ø Min. E 175mm F 150mm The 3° (1 in 20) fall provided by the elbow is to allow condensate to run back to the boiler, for discharge through the condensate disposal Tube Ø...

  • 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 6798:2000 &...
  • 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

    7.0 Site Requirements Flue Terminal Position with Minimum Distance (Fig. 17) (mm) A a Directly below an opening, air brick, opening NOTE: Due to the high efficiency of the boiler a windows, etc. plume of water vapour will be discharged from the B a Above an opening, air brick, opening window etc.
  • Page 20 7.0 Site Requirements 7.10 Standard Flue Dimensions The standard horizontal flue kit allows for flue lengths between 270mm and 800mm from elbow to terminal (Fig. 18). The maximum permissible equivalent concentric flue length is: 4 metres (Fig. 18a). NOTE: Each additional 45° flue bend will account for an equivalent flue length of 0.5m.

  • Page 21: Terminal Guard (Suitable For Use With Above)

    A - Standard Flue 7.0 Site Requirement 7.12 Flue options Only a flue approved with the Potterton Promax FSB 30 HE Plus can be used. Concentric The maximum equivalent length is 4m horizontal or vertical. This does not include the standard elbow and flue/terminal assembly (horizontal) and terminal assembly (vertical).

  • Page 22: Installation

    8.0 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 Initial Preparation & Installation duct hole will be 110mm higher Example than the horizontal side flue centre 1.
  • Page 23 8.0 Installation Wall Thickness Fitting the Standard Flue IMPORTANT: The flue should always be installed with a 3° (1 in 20) fall from terminal to elbow, to 3° allow condensate to run back to the boiler. (1 in 20) 1. The standard flue is suitable for lengths 270mm minimum to 800mm maximum (measured from the edge of the flue elbow outlet).
  • Page 24 8.0 Installation 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 25 Min. radius 100mm 8.0 Installation Gravity Drain min. fall 3° Point ‘A’ 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 26 8.0 Installation 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 27: Electrical

    9.0 Electrical 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 28 9.0 Electrical 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 29: Commissioning The Boiler

    10.0 Commissioning the Boiler 10.1 Commissioning the Boiler For correct operation of the flow switch the boiler and system MUST be completely vented. The boiler flow pipe incorporates a manual air vent. 1. Reference should be made to BS 5449 Section 5 when Flue Sampling Point commissioning the boiler.

  • Page 30: Completion

    11.0 Completion 11.1 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 31: Servicing The Boiler

    12.0 Servicing the Boiler 12.1 Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. 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 32 12.0 Servicing the Boiler 12.1 Annual Servicing (Cont) Flue Sampling Point 9. 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 33: Changing Components

    13.0 Changing Components 13.1 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 34 13.0 Changing Components Pipe Access Panel 13.3 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 35 13.0 Changing Components 13.6 (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 36 13.0 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 37 13.0 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). 13.9 Injector Pipe (Fig. 53) 1. Remove the injector pipe by pulling out from the ‘O’ ring joint in the gas valve.
  • Page 38 13.0 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 39 13.0 Changing Components 13.14 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 40: Short Parts List

    14.0 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 5117224 5109925 Gas Valve 241900 E06 085 Viewing Window 242484 Condensate Trap 5111714 Electrodes Kit...

  • Page 41: Fault Finding

    15.0 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 Condensate General Fault Finding should only be carried out by LED Light LED Light LED Light...
  • Page 42 15.0 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 43 15.0 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 44 15.0 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 45 15.0 Fault Finding Lights On Off 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 46 15.0 Fault Finding Lights 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 47 15.0 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 48 15.0 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 49 16.0 Notes © Baxi Heating UK Limited 2005...

  • Page 50: Benchmark Checklist

    5 1 1 7 3 3 1 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 51: 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 52 5117331 - Iss. 1 Publication No. (01/2006) General Enquiries (GB) 08706 060 780 Tel. Technical (GB) 08706 049 049 Tel. Service (GB) 08706 096 096 Tel. 01926 410 006 Fax. Literature Request (GB) 08706 060 623 Tel. Technical (IE) 1850 560570 Tel.

Table of Contents

Save PDF