Potterton Promax 24 Combi ErP Installation And Service Manual
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Potterton Promax 24 Combi ErP Installation And Service Manual

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See also: Installation and Servicing Manual , User Manual
United Kingdom
en
Installation and Service Manual
Condensing Combination Boiler
P P romax Combi
24 - 28 - 33
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.

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Summary of Contents for Potterton Promax 24 Combi ErP

  • Page 1 United Kingdom Installation and Service Manual Condensing Combination Boiler P P romax Combi 24 - 28 - 33 These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping.

  • Page 2: Natural Gas

    Natural Gas Building Regulations and the Benchmark Commissioning Checklist Potterton Promax 24 Combi ErP G.C.N 47 393 47 Building Regulations (England & Wales) require notification of Potterton Promax 28 Combi ErP 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 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 BS 7593 Treatment of water in domestic hot water Potterton Promax 24 - 28 - 33 Combi ErP central heating systems. declare that the above is in conformity with the provisions of the Council Directive In IE the following Codes of Practice apply:...
  • 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. Health &...

  • Page 6: Table Of Contents

    CONTENTS Section Page Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Flue Options Installation 10.0 Commissioning 11.0 Completion 12.0 Servicing 13.0 Changing Components 14.0 Setting the Gas Valve 15.0 Electrical 16.0 Short Parts List 17.0 Fault Finding 18.0...

  • Page 7: Introduction

    1.0 Introduction Description 1. The Potterton Promax Combi is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed Case Front Panel domestic hot water.

  • Page 8: General Layout

    2.0 General Layout Layout Expansion Vessel Automatic Air Vent DHW Plate Heat Exchanger / Automatic Bypass Circulation Pump (NOTE: T he boiler can be fitted with one of two alternative pumps, Grundfos or Wilo. All boiler illustrations show Grundfos. Section 13.14 details both types). Drain Off Point Pressure Relief Valve Optional Integral Timer Position...

  • Page 9: Appliance Operation

    3.0 Appliance Operation Central Heating Mode (Fig. 2) Central Heating Circuit 1. With a demand for heating, the pump circulates water through the primary circuit. 2. Once main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor.

  • Page 10: Technical Data

    4.0 Technical Data Promax 24, 28 & 33 Combi ErP Appliance Type Inlet Pressure (Natural Gas - G20) Central Heating Primary Circuit mbar Pressures Appliance Category CAT I Injector (Natural Gas - G20) Safety Discharge Heat Input CH Qn Hs (Gross) 7.5mm (24 &...
  • Page 11 4.0 Technical Data Technical Parameters Technical parameters for boiler combination heaters Potterton Promax Combi ErP Condensing boiler Low-temperature boiler B1 boiler Cogeneration space heater Combination heater Prated Rated heat output Useful heat output at rated heat output 20.6 24.7 28.9...

  • Page 12: Dimensions And Fixings

    5.0 Dimensions and Fixings NOTE: There must be no part of the air duct (white tube) visible outside the property after installation. The flue seal should fit neatly and effect a good seal. For full detail refer to Section 9.7 “Fitting the Flue”. Dimensions A 780mm B 345mm...

  • Page 13: System Details

    6.0 System Details Information 1. The Promax Combi Condensing Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 - See text of entry for installation requirements and notes.
  • Page 14 6.0 System Details System Filling and Pressurising (Fig. 4) 1. A filling point connection on the central heating return Double Stop Stop pipework must be provided to facilitate initial filling and Check Valve Valve Valve pressurising and also any subsequent water loss replacement/refilling.
  • Page 15 6.0 System Details Domestic Hot Water Circuit (Fig. 7) 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations. Other Tap Outlets 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to Boiler Expansion R24 of the Water Regulations Guide.

  • Page 16: Site Requirements

    7.0 Site Requirements 5mm Min 450mm 5mm Min Location 1. The boiler may be fitted to any suitable wall with the flue 175mm Min passing through an outside wall or roof and discharging to (300mm Min if using 80/125mm atmosphere in a position permitting satisfactory removal of flueing system) combustion products and providing an adequate air supply.
  • Page 17 7.0 Site Requirement Gas Service Cock Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.
  • Page 18 Examples are shown of the following methods of termination:- i) to an internal soil & vent pipe 7.0 Site Requirements ii) via an internal discharge branch (e.g. sink waste) downstream of the trap iii) to a drain or gully iv) to a purpose made soakaway Condensate Drain v) pumped into an internal discharge branch (e.g.
  • Page 19 iii) Termination to a drain or gully 7.0 Site Requirements Boiler Condensate Drain (cont.) Pipe must terminate above water level but below 11. When discharging condensate into a soil stack or waste pipe surrounding surface. Cut end at 45° the effects of existing plumbing must be considered. If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC's are flushed or sinks emptied then back-pressure may force water out of the boiler trap and cause appliance...
  • Page 20 Terminal Position with Minimum Distance (Fig. 13) (mm) 7.0 Site Requirements Directly below an opening, air brick, opening windows, etc. Above an opening, air brick, opening window etc. Horizontally to an opening, air brick, opening window etc. Flue Below gutters, soil pipes or drain pipes. 25 (75) Below eaves.

  • Page 21: Flue Options

    8.0 Flue Options Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination applications. 2. All fittings should be fully engaged. The approximate engagement is 40mm. Apply soap solution to the seal on each fitting to aid assembly. 3.
  • Page 22 These Guidance Notes cover the following boiler models: Baxi EcoBlue Combi & System ErP Duo-tec Combi ErP Platinum Combi ErP Megaflo System ErP Potterton Promax Combi & System ErP Gold Combi & System ErP Titanium Combi ErP Promax Ultra Combi ErP Main Eco Elite Combi &...

  • Page 23: Installation

    1.0 Introduction 9.0 Installation Unpacking & Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). NOTE: a small amount of water may drain from the boiler in the upright position. 1.
  • Page 24 9.0 Installation Fitting the Filling Loop Kit Note: Full instructions are provided in the Filling Loop Kit pack. 1. The filling loop kit supplied with the boiler can be connected to the taps on the wall plate at this point. (Either one of two types of loop kit will be supplied - both function in the same way, differing only in detail).
  • Page 25 9.0 Installation Fitting The Boiler (Fig. 20) 1. Remove the sealing caps from the boiler connections. Remove Sealing Caps from NOTE: A small amount of water may drain from the boiler under the Boiler after lifting once the caps are removed. into position 2.
  • Page 26 9.0 Installation Fitting The Flue HORIZONTAL TELESCOPIC FLUE 1. There are two telescopic sections, the Terminal Terminal Assembly Assembly and the Connection Assembly, a roll of sealing tape and two self tapping screws. A 93° elbow is also supplied. Connection Assembly 2.
  • Page 27 Flue Elbow 9.0 Installation Apply Lubricant for ease of assembly. Ensure Elbow is fully Fitting the Flue (Cont) engaged into Boiler Adaptor Adaptor 10. Remove the flue elbow and insert the flue through the hole in the wall. 11. Refit the elbow to the boiler adaptor, ensuring that it is pushed fully in (Fig.
  • Page 28 9.0 Installation Making The Electrical Connections The boiler is fitted with a 1.3m length of 3 core cable. This can be connected to the fused 3A 230V 50H supply. NOTE: Both the Live and Neutral connections are fused. To connect an external control proceed as follows:- Terminal Block Cover 1.

  • Page 29: Commissioning

    10.0 Commissioning 10.1 Commissioning the Boiler 1. Reference should be made to BS:EN 12828 & 14336 when commissioning the boiler. 2. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publications. 3.
  • Page 30 Set Boiler to Maximum Rate 10.0 Commissioning (see 10.1.13) Allow the combustion to stabilise. Do not insert probe to 10.2 Checking Combustion avoid ‘flooding’ the analyser. 1. Follow the flow chart opposite. Perform Flue Integrity Combustion Check Insert the analyser probe into the air inlet test point, allowing the reading to stabilise.
  • Page 31 10.0 Commissioning 10.3 Check the Operational (Working) Gas Inlet Pressure 1. Ensure that all controls are calling for heat, and the selector switch is in the central heating and hot water position ( The current boiler temperature is shown on the display. Central Heating Domestic Hot Water 2.

  • Page 32: Completion

    10.0 Commissioning 10.3 Check the Operational (Working) Gas Inlet Pressure (cont.) Gas Valve 13. Working Gas Pressures If the pressure drops are greater than shown in Fig. 43a a 17-21 mbar problem with the pipework or connections is indicated. Permissible pressure drop across system pipework ¿ 1 mbar. Gas Cock 19-23 mbar Gas Meter...

  • Page 33: Servicing

    12.0 Servicing 12 .1 Annual Servicing 1. For reasons of safety and economy, it is recommended that Case Front Panel the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4. 2. After servicing, complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication.
  • Page 34 12.0 Servicing Burner 12.2 Annual Servicing - Inspection (Cont) Viewing Window 6. Undo the nut on the gas inlet pipe to the venturi (Fig. 48) and pull the sensing pipe off the fan. 7. Disconnect the electrode leads, noting their position, and the fan electrical plugs.

  • Page 35: Changing Components

    13.0 Changing Components Bracket Igniter IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the Igniter Feed Plug component has been changed turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler before recommissioning.
  • Page 36 13.0 Changing Components 13.4 Fan (Fig. 53) 1. Undo the nut on the gas inlet pipe to the venturi (Fig. 53) and pull the sensing pipe off the fan. 2. Disconnect the electrode leads, noting their position and disconnect the fan electrical plugs. Disconnect the sensing pipe and wires from the air pressure switch.
  • Page 37 13.0 Changing Components Cover 13.7 Burner (Fig. 56) Burner 1. Undo the screws securing the collector to the venturi and Gasket extension piece. Allow the air pressure switch to rest on the air box lower panel. Remove the extension piece from Extension Piece the cover (on 24 and 28 models).
  • Page 38 13.0 Changing Components Electrical Plug 13.9 Flue/Heat Exchanger Thermostat Sensor Flue/Heat Exchanger (Fig. 58) Thermostat Sensor 1. Ease the retaining tab on the sensor away and disconnect the electrical plug. 2. Turn the sensor 90 ° anticlockwise to remove - it is a bayonet connection.
  • Page 39 13.0 Changing Components 13.14 Pump - Complete (Figs. 61 & 62) 1. Drain the boiler primary circuit and disconnect the electrical plug from the pump motor. 2. Undo the two screws securing the body to the pipe and manifold and draw the pump forwards. 3.
  • Page 40 13.0 Changing Components 13.17 Pressure Gauge (Figs. 63 & 64) Gauge Retaining Bracket 1. Drain the boiler primary circuit and undo the nut on the pressure gauge capillary. 2. Undo the screws securing the gauge retaining bracket. 3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining bracket.
  • Page 41 13.0 Changing Components 13.20 Plate Heat Exchanger (Fig. 67) 1. Drain the boiler primary circuit and remove the gas valve Plate Heat Exchanger as described in section 13.25. 2. While supporting the heat exchanger undo the screws securing it to the brass manifolds. 3.
  • Page 42 13.0 Changing Components 13.22 P.C.B. (Fig. 69 & 70) 1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins. 2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots. 3.
  • Page 43 Venturi Inlet 13.0 Changing Components Pipe 13.25 Gas Valve (Fig. 71) IMPORTANT: After replacing the valve the CO must be Gas Valve checked and adjusted as detailed in Section 14.0 Setting the Gas Valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see section 12.1.

  • Page 44: Setting The Gas Valve

    14.0 Setting the Gas Valve 14.1 Setting the Gas Valve ( check) IMPORTANT: The CO must be only be checked and adjusted to set the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see Section 12.1 Central Heating Domestic Hot Water Temperature Control...

  • Page 45: Electrical

    15.0 Electrical 15.1 Illustrated Wiring Diagram Pressure Switch Central Heating NTC Sensor NTC Sensor Overheat Stat Hall Effect Sensor Water Pressure Flue Sensor Switch Flame X400 X401 Sensing 9 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1 Electrode Timer (where fitted) Pump...

  • Page 46: Short Parts List

    16.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. 505a 5121447 Motor 3 way Valve 7216534 Igniter Electrode 720222801 Sensing Electrode 720222901 Gas Valve 720301001 Hall Effect Sensor 5114767 Burner 24 5122149 Burner 28 5122149 Burner 33 5114697 Water Pressure Switch 5114748...

  • Page 47: Fault Finding

    17.0 Fault Finding 17.1 Initial Fault Finding Checks NOTE: When instructed to turn the 1. Check that gas, water and electrical supplies are available selector to the reset position turn the at the boiler. selector switch fully anticlockwise against the spring pressure to the reset position 2.
  • Page 48 17.0 Fault Finding Refer to Section 16.0 “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 flashing. Turn the selector switch to Error 130 flashing reset position for 5 seconds...
  • Page 49 17.0 Fault Finding Domestic Hot Water - Follow operational sequence Turn selector switch to Go to section ‘A’ The display illuminates Error 110 flashing Turn the selector switch to If the error 110 is still flashing. Error 133 flashing Go to section ‘J’ reset position for 5 seconds Error 20, 28 or 50 flashing Go to section ‘E’...
  • Page 50 17.0 Fault Finding 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: X3 Connection Pump PCB Check incoming wiring X2 Connection Pump PCB...
  • Page 51 17.0 Fault Finding Temperature sensors faulty. Cold resistance approximately Replace sensor 10kî @ 25° C (DHW and CH sensors) 20kî @ 25° C (Flue sensor) (resistance reduces with increase in temp.) Air Pressure Switch faulty. Replace switch Check for continuity across terminals 1 & 2 Unblock or repair flue Flue blocked or damaged Unblock...
  • Page 52 17.0 Fault Finding Check supply pressure at the gas valve:- Minimum 17 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 –...

  • Page 53: Notes

    18.0 Notes © Baxi Heating UK Ltd 2016...

  • Page 54: 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 55: 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 56: Description

    Baxi Customer Support 0344 871 1525 Opening hours Monday - Friday, 8.00am-6.00pm Weekends and Bank Holidays, 8.30am-2.00pm Please note calls may be recorded for training and monitoring purposes baxi.co.uk Register now to activate your warranty: www.baxi.co.uk/registration For the warranty to be maintained, please make sure... Benchmark checklist is completed Warranty is registered with Baxi The boiler has an annual service...

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