Potterton Promax HE Store 90 Litres Installation & Servicing Instructions Manual
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Potterton Promax HE Store 90 Litres Installation & Servicing Instructions Manual

Potterton Promax HE Store 90 Litres Installation & Servicing Instructions Manual

Condensing boilers with integrated hot water storage
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Installation & Servicing Instructions
About the Boiler
See page 4 for models covered by these instructions.
This is a Floor Mounted Fan Assisted Balanced Flue Gas Boiler.
This boiler is for use with Natural Gas (G20) only at 20 mbar and for use in GB/IE only.
About Safety
The Gas Safety (Installation and Use) Regulations.
'' In your own interest, and that of safety, it is law that all gas appliances are installed by
competent persons, in accordance with the above regulations. Failure to install appliances
correctly could lead to prosecution.''
Installation must be in accordance with the Installation & Service Instructions and the rules in
force.
Read these Instructions before installing or lighting the boiler
These Instructions include the Benchmark Commissioning Checklist and should be left
with the user for safe keeping.
© Baxi Heating UK Ltd 2006
Promax HE Store
Condensing Boilers with
Integrated Hot Water Storage
Promax Store

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Summary of Contents for Potterton Promax HE Store 90 Litres

  • Page 1 Installation & Servicing Instructions Promax HE Store Condensing Boilers with Integrated Hot Water Storage Promax Store About the Boiler See page 4 for models covered by these instructions. This is a Floor Mounted Fan Assisted Balanced Flue Gas Boiler. This boiler is for use with Natural Gas (G20) only at 20 mbar and for use in GB/IE only. About Safety The Gas Safety (Installation and Use) Regulations.
  • Page 2 Natural Gas Building Regulations and the Benchmark Commissioning Checklist Potterton HE Store G.C.N 41 601 24 (90 litre) Building Regulations (England & Wales) require G.C.N 41 591 76 (115 litre) notification of the installation of a heating appliance to G.C.N...

  • Page 3: Installer Notification Guidelines

    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: Table Of Contents

    Benchmark Commissioning Checklist Location of Boiler.......... Compartment Installation & Ventilation..........Potterton is a member of the Benchmark initiative and Flue Systems..........fully supports the aims of the programme. Benchmark Water Supply & Systems......has been introduced to improve the standards of Discharge Pipework........

  • Page 5: Panel Removal

    Panel Removal Important: Refer to Page 8 for Storage, Unpacking and Handling Instructions. Top & Bottom Section Top Section Lift Heat Engine onto Rollers Cylinder. Ensure the rollers engage into location channels. Tilt and slide until front location pegs drop into position on the cylinder.

  • Page 6: Technical Data

    Technical Data Unless indicated, data shown relevant to all models 90 litre 115 litre 150 litre Classifications Appliance category CAT I 2 H Flue Type C 13 - C 33 - C 53 (as supplied) NOx Class 5 (< 70 mg/kWh) Cylinder Insulation CFC, HCFC = 0% Input (hot water/central heating) - gross...
  • Page 7 Note: Note: Cupboard At these minimum clearances above Removable Top Panel intended the appliance, adequate working to provide access MUST be provided. access. 650 max Removable Top Panel Door Frame 400 mm 400 mm Recommended Recommended Typical Bulkhead Installation Typical Cupboard Installation with rearwards horizontal concentric flue with twin vertical air/flue pipes Fig.

  • Page 8: Introduction

    Introduction Important - Installation, Commissioning, Service & Operation Repair The boiler control works on the principle of “hot water priority” so the central heating output may be This appliance must be installed in accordance with the temporarily delayed if the hot water temperature manufacturer’s instructions and the regulations in force.

  • Page 9: Codes Of Practice

    Codes of Practice In GB the following Codes of Practice apply: Standard Scope The appliance is suitable only for installation in GB and IE BS6891 Specification for low pressure gas pipework and should be installed in accordance with the rules in in domestic premises.

  • Page 10: Storage, Unpacking And Handling

    1. Installation Requirements Storage, Unpacking & Handling from any other appliances in the house and must be governed at the meter. This boiler is delivered in two sections for safety and The gas installation should be in accordance with the ease of handling.

  • Page 11: Compartment Installation & Ventilation

    I.S. 813 "Domestic Gas Installations" and the current ETCI rules. This is a “room sealed” condensing boiler. Flue systems are supplied in kits, or components can be ordered individually from Potterton. Only Promax HE Store flue Compartment Installation and components (which are designed for condensing Ventilation operation) can be used.
  • Page 12 General Requirements Horizontal Flue Terminations g) Where installation will be in an unusual location, special procedures may be necessary. BS 6798 gives Detailed recommendations for flueing are given in detailed guidance on this aspect. BS5440: Part 1. The following notes give general guidance.
  • Page 13 Flue Options 1. The Potterton Store can be fitted with flue systems as illustrated. 2. The standard flue kit, Part No. 5118489 comprises a concentric 100/60 terminal and a 93° bend. It is suitable only for horizontal termination applications. 3. Maximum permissible equivalent flue...
  • Page 14 IMPORTANT: If fitting a Plume Plume Displacement Flue Kit, the air inlet Displacement Kit must be a minimum of 100mm from any opening windows or doors Air Inlet Opening Window or Door 100mm MIN. Likely flue positions requiring a flue terminal guard Terminal Position with Minimum Distance (mm) Concentric For IE, refer to I.S.

  • Page 15: Water Supply & Systems

    Water Supply can be effective in reducing limescale but require correct siting and regular replenishment to remain operational. They should generally not be fitted where heat could Mains Supply Requirements impair their perfomance. Other types of device can It is essential that the mains supply pressure and inhibit scale formation but their effectiveness may vary.

  • Page 16: Discharge Pipework

    Building discharges a wire cage or similar guard is Control Officer or Potterton. positioned to prevent contact, whilst maintaining visibility. G3 Requirement “...there shall be precautions ... to ensure that the hot water discharged from safety iii.
  • Page 17 T.P.R. Valve Warnings • Under No circumstances should the factory Tundish Overflow fitted Temperature/Pressure Relief Valve be Pipework removed other than by Authorised Potterton Discharge personnel. To do so will invalidate any 300mm min. above warranty or claim. Fixed • The cold water Inlet Control Group must be...

  • Page 18: Installation

    2. Installation Install the boiler 5. Release DHW temperature sensor and un-roll cable. Route cable behind cylinder pipes and push sensor fully home (approx. 310mm - 12”) into the pocket in Before starting an installation, check that the correct flue the cylinder.
  • Page 19 Tundish Domestic Hot Water Sensor Isolating Valve Plumbing 'NO GO' Area Pressure Gauge Immersion Filling Loop Heater Potterton Promax Store Pipework shown as this 150 litre model shown NOT SUPPLIED D.H.W. CH Flow Outlet Gas Inlet Discharge Pipe CH Return Mains Cold Inlet Fig.
  • Page 20 Condensate Drain Pipe Before fitting, fill the condensate trap with water. Fit the steady bracket (with round hole) for the condensate trap to the lower pair of holes in the left hand cylinder side panel. Snap the C-shaped bracket into the groove in the condensate connector.
  • Page 21 Ø240mm Wall Bolts & Plugs Secondary Threaded Washer Expansion Vessel 300mm Expansion Vessel Support Bracket Nut & Balanced 22mm 15mm Washer Cold Feed Expansion Vessel Support Strap To Shower Stop Valve Mains Cold Inlet 22mm 22mm and cold feed to kitchen Combination tap.

  • Page 22: Connect The Water Supply

    Connect the Water System Read and observe recommendations in Section 1.6 and see Fig. 11. Graph of Central Heating Head vs. Flow Secure the combination reducing valve - a wall bracket is provided in the accessory pack. 22mm copper tube is recommended for both the inlet and outlet connections.
  • Page 23 Making The Electrical Connections To connect the mains input cable proceed as follows:- 1. Remove all the outer panels. Always fit fast blow 2A fuse 2. Completely undo the screws securing the Fused supply 3A 230V ~ 50Hz facia panel and hinge it down. Live (brown) 3.
  • Page 24 2.7 Immersion Heater The immersion heater is rated 3kW at 240V and must be wired to a separate, suitably rated electrical supply. THERE MUST BE NO INTERCONNECTION WITH THE WIRING TO THE BOILER. WARNING: THE IMMERSION HEATER MUST BE Promax Store EARTHED.

  • Page 25: How To Drain Hot Water Storage Cylinder

    How to Drain Hot Water Storage Cylinder Isolate mains water supply at stop valve on Inlet Control Group and close ⁄-turn valve (handle at 90° to valve body) on double check valve - see Fig. 14. Fit a hosepipe to the tail of the drain valve (secure with “Jubilee” clip), and run open end to a low level where water can be safely drained.

  • Page 26: Commissioning

    When checking for gas soundness open only be carried out by a suitably qualified all windows and doors in the room. person. Potterton offer this service Extinguish all naked lights, cigarettes, pipes, etc. on a chargeable basis. © Baxi Heating UK Ltd 2006...

  • Page 27: Commission The Boiler

    3.1 Commission the Boiler Sealed Primary System Automatic Air Vent: This is built into the pump. Leave the 1. Ensure that gas supply is turned OFF at the gas cap open during and after commissioning. cock. Manual Air Vent: This must be used to remove as much 2.

  • Page 28: Hand Over To The User

    Commissioning Checks N.B. Leave the cap on the auto air vent (above the pump) partially unscrewed so that the vent remians 1. The gas valve is factory set and the burner pressure operational - note that the burner control goes to safety changes as the fan modulates when demand on the shut-down if the system pressure drops below 0.5 bar.

  • Page 29: Service & Replacement Of Parts

    4. Service & Replacement of Parts To ensure safe, efficient operation of the boiler, it is 6. Turn off the mains water supply at the Inlet Control necessary to carry out routine servicing at regular Group and release system pressure by opening a intervals.

  • Page 30: General Access

    General Access Warning: Before attempting to remove any component from the boiler first disconnect the mains General Access electricity supply by removing the plug from the wall Pull forward Front Panel socket or by switching off the boiler at the external at the bottom and lift off isolating switch.

  • Page 31: Expansion Vessel/Pump

    Expansion Vessel, Pump & Pressure Switch Re-assemble all parts in reverse order. Expansion Vessel 1. Check that the cap on the auto air vent is open. Turn the 3 isolating valves OFF and locally drain the boilers’ circuit by opening the primary pressure relief valve.

  • Page 32: Pressure Sensor/Pressure Relief Valve

    Pressure Sensor/PRV Re-assemble all parts in reverse order. Isolating Valve 1. Perform 4.1 General Access. 2. Isolate three valves as shown and open the cap on the auto air vent. Gas Cock 3. Release pressure by opening the pressure relief valve. 4.

  • Page 33: Air/Gas Valve/Injector/Fan

    Venturi Inlet Gas Valve Pipe 1. Turn the gas cock OFF and undo the Outlet Adaptor screw on the bracket below the valve. 2. Pull off the earth lead and sensing pipe. Gas Valve 3. Undo the nut on the venturi inlet pipe and slacken the nut on the venturi.
  • Page 34 Bracket Igniter 1. Remove the air box front cover. Igniter 2. Disconnect the igniter feed plug and the electrode leads, noting their positions. Igniter Feed 3. Undo the screw securing the bracket to Plug the boiler. 4. Remove the igniter and transfer the bracket to the new component.

  • Page 35: Burner

    4.10 Burner 1. Remove the fan/manifold assembly - see Section 4.6. 2. Undo the screws securing the spacer to Cover the cover. 3. Withdraw the burner from the cover and Gasket replace with the new one. Extension Piece 4. Replace the burner gasket. 5.

  • Page 36: Diverter Valve Actuator

    4.12 Diverter Valve Actuator Re-assemble all parts in reverse order. 1. Perform 4.1 General Access. 2. Disconnect the electrical connector at the actuator. 3. Release the locking catch and twist the actuator until it unlocks from the valve and remove from the boiler. Diverter Valve Complete Re-assemble all parts in reverse order.

  • Page 37: Heat Exchanger

    4.14 Heat Exchanger Note: Replacing the heat exchanger involves disconnecting the appliance from the flue and air pipes. It is essential that the flue system is fully reinstated and tested so recommend that appropriate replacement flue pipe and fittings be obtained before starting this work.

  • Page 38: Immersion Heater And Immersion Heater Combined Thermostat/Thermal Cut Out

    4.15 Replacement of Immersion Heater and Immersion Heater Combined Thermostat/Thermal Cut-out The cylinder must be fully drained prior to removing the immersion heater. Refer to Section 2.8 for the procedure to drain the unit. Important: Ensure ALL power supplies are isolated before starting work on the boiler. Perform the actions detailed in section 4.1 General Access.

  • Page 39: Gas/Air Valve Setup Procedure

    4.16 Gas/Air Valve Setup Procedure Flue Adaptor Test Point Checking the CO 1. The combustion (CO ) may be checked at maximum rate using a suitably calibrated analyser after running the boiler for several minutes. 2. To do this it is necessary to set the boiler to ‘Calibration Mode’.

  • Page 40: Wiring Diagrams

    5. Wiring Diagrams Wiring/Functional Flow Diagram Fig. 27 © Baxi Heating UK Ltd 2006...
  • Page 41 Flow Cylinder Thermistor Thermistor Overheat Stat Water Pressure Flue Thermistor Switch X400 Timer X401 9 8 7 8 7 6 5 4 3 2 1 Control PCB X501 Flame Pump Sensing Electrode Diverter Valve Spark Generator Mains Input Link Gas Valve Ignition Electrode Reset Selector Switch...

  • Page 42: Fault Finding

    6. Fault Finding Guide Boiler Fault Finding Initial Fault Finding Checks 1. Check that gas, water and electrical supplies are available at the boiler. 2. Electrical supply = 230V ~ 50 Hz. 3. CH water system pressurised to 0.5 bar minimum when the boiler is cold.
  • Page 43 Refer to Section “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence Turn selector switch to Go to section ‘A’ The display illuminates Error 110 flashing If the error 110 is still Turn the selector switch to Error 130 flashing flashing.
  • Page 44 Domestic Hot Water - Follow operational sequence Turn selector switch to Select HW ‘On All Day’ or Go to section ‘A’ The display illuminates 24Hr at programmer Error 110 flashing If the error 110 is still Turn the selector switch to Error 133 flashing flashing.

  • Page 45: Fault Finding Solutions Sections

    Fault Finding Solutions Sections Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse Display Replace PCB illuminated Check wiring PCB - X1 connector terminals 1,2 Is there 230V at: Pump If pump jammed, release Replace pump PCB - X3 connector terminals 3 &...
  • Page 46 Temperature sensors faulty. Cold resistance approximately 10kΩ @ 25° C (DHW and CH sensors) Replace sensor 20kΩ @ 25° C (Flue sensor) (resistance reduces with increase in temp.) Check and correct the connection of the tube between the venturi and gas valve Gas at burner Ensure gas is on and purged...
  • Page 47 Check the gas supply pressure: For Natural Gas greater than 10 - 11 mbar Check and correct if necessary 1. The mechanical set of the gas valve (CO2 values - see instruction) 2. Flame sensing electrode and lead connections 3. Flame sensing electrode position Replace PCB Flame current should be more than 0.5 μA Replace flame sensing electrode...

  • Page 48: Short List Of Spare Parts

    7. Short List Of Spare Parts Short Parts List G.C. Description Manufacturers Part No. 5119648 Igniter Electrode 5114702 Sensing Electrode 5117275 Gas Valve 5119647 Burner 5114697 Water Pressure Switch 5114748 Pump 248042 Flue Thermostat 5114747 NTC Sensor 5114725 Overheat Thermostat 5106291 Pressure Gauge 248090...
  • Page 49 Notes © Baxi Heating UK Ltd 2006...
  • Page 50 5 1 2 0 0 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 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 A Tr a d i n g D i v i s i o n o f B a x i H e a t i n g U K L t d , a d i v i s i o n o f B a x i G r o u p 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 Publication No.

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