Potterton Heatmax Combi 24 HE Installation & Service Instructions Manual Download Page 56

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18.0 Fault Finding

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

Flame current should be more than 0.5

Replace PCB

YES

Replace flame sensing electrode

Check supply pressure at the

gas valve:-

Minimum 17mbar

Replace safety thermostat

YES

Overheat thermostat operated or

faulty, i.e. continuity across

thermostat terminals

Allow to cool. Continuity

across thermostat terminals

more than 1.5 ohm

Is there 230V at:

Motor 3-way valve

Replace motor 3-way valve

YES

PCB - X3 connector terminals
5 & 6 central heating mode
5 & 7 domestic hot water mode

Replace PCB

Change pump supply cable

YES

Fan connections correct at fan.
PCB - X401 connector terminals 5,6,7 & 8

YES

Replace fan

Temperature sensors faulty.
Cold resistance approximately
10k

@ 25° C (CH sensor)

20k

@ 25° C (Flue sensor)

(resistance reduces with increase in temp.)

Replace sensor

YES

If pump is running the heat exchanger could be
obstructed

Replace heat exchanger

Summary of Contents for Heatmax Combi 24 HE

Page 1: ...2012 Installation Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Heatmax Combi HE Range Condensing Combination Boiler You can rely on ...

Page 2: ...ble from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information Building Regulations and the Benchmark Commissioning Checklist 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 vi...

Page 3: ...elevant LABC You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www gassaferegister co uk within 10 days If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Complete the Benchmark Checklist Instal...

Page 4: ...ings BS EN 12831 Heating systems in buildings Calculation of load BS EN 14336 Installation commissioning of water based heating systems BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems The boiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 No 3083 and is deem...

Page 5: ...s clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straight bend your knees Don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible transport the boiler using a sack ...

Page 6: ...6 0 System Details 12 7 0 Site Requirements 15 8 0 Flue Options 21 9 0 Plume Displacement 25 10 0 Installation 29 11 0 Commissioning 34 12 0 Completion 36 13 0 Servicing 37 14 0 Changing Components 39 15 0 Setting the Gas Valve 48 16 0 Electrical 49 17 0 Short Parts List 50 18 0 Fault Finding 51 19 0 Pages for Notes 57 Benchmark Checklist 58 Section Page ...

Page 7: ...el is removed Fig 1 6 The boiler model name and serial number are also shown on the information label on the back of the facia door This is for user reference 7 The boiler is intended to be installed in residential commercial light industrial E M C environments on a governed meter supply only 8 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue...

Page 8: ...alve Assembly 12 Condensate Trap 13 Flame Sensing Electrode 14 Spark Electrode 15 Primary Heat Exchanger 16 Fan Assembly 17 On Off Reset Selector Switch Knob 18 Central Heating Temperature Control 19 Hot Water Temperature Control 20 Venturi 21 Air Gas Collector 22 Combustion Box Cover Burner 23 Igniter 24 Burner On Light 25 Central Heating Mode Light 26 Domestic Hot Water Mode Light 27 Display 28 ...

Page 9: ...ted The boiler will not operate and the integral timer if fitted will require resetting once the selector switch is set to either Position or Position 3 3 Frost Protection Mode 1 The frost protection mode is integral to the appliance and functions only with the selector switch see Section 2 1 in the domestic hot water and central heating position If the system temperature falls below 5 C then the ...

Page 10: ... 24 model kW 20 5 7 28 model kW 24 7 9 33 model kW 28 9 9 7 Heat Output CH Non Condensing Max Min 24 model kW 20 6 8 28 model kW 24 8 7 33 model kW 28 9 4 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 155W 24 28 model 160W 33 model Electrical Protection IPX5D Internal Fuse Rating F2L Appliance Category CAT I 2H Inlet Pressure Natural Gas G20 mbar 20...

Page 11: ... 207mm for 80 125mm flue systems F 145mm G 131mm H 180mm 360 Orientation Tube Ø 100mm ØD C B A E G F At Least 1 5 H Domestic Hot Water Outlet 15mm Cold Water Inlet 15mm Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 65 mm 65 mm 65 mm 65 mm 65 mm 32 5 mm Condensate Drain Tap Rail ...

Page 12: ...They should be used following the flushing agent manufacturer s instructions System additives corrosion inhibitors and flushing agents descalers should comply to BS7593 requirements e g Sentinel X100 and Fernox MB 1 which should be used following the inhibitor manufacturer s instructions Full instructions are supplied with the products for further information contact Sentinel 0800 389 4670 or Fern...

Page 13: ...el Central Heating only 1 The appliance expansion vessel is pre charged to 0 5 bar Therefore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Domestic Gas Installations 6 7 Safety ...

Page 14: ...the boiler domestic hot water DHW inlet supply then a suitable expansion device may be required 5 If the hot water expansion is not provided for then high pressures can develop which may result in damage to fittings and devices on the system 6 The boiler s maximum working mains pressure is 8 bar therefore all pipework connections fittings etc should be suitable for pressures in excess of 8 bar A p...

Page 15: ... Wiring Regulations and Building Regulations In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE UP 7 Gas Installations in Timber Framed Housing This is the MI...

Page 16: ...ions In IE reference should be made to the current edition of ETCI rules 2 The mains supply is 230V 50Hz fused at 3A NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection may be via a fused double pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only 7 6 Bath...

Page 17: ...diameter and must be supported using suitably spaced clips of the correct design to prevent sagging 6 It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres 7 Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe 8 External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external us...

Page 18: ... emptied then back pressure may force water out of the boiler trap and cause appliance lockout Boiler 2 5 Minimum fall iii Termination to a drain or gully Boiler 500mm min 2 5 Minimum fall iv Termination to a purpose made soakaway Holes in the soak away must face away from the building 50mm per metre of pipe run 50mm per metre of pipe run Further specific requirements for soakaway design are refer...

Page 19: ...ce Heating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to Boiler vi pumped into an external soil vent pipe 2 5 Minimum fall 50mm per metre of pipe run Condensate Pump Unheated Location e g Garage Basement or similar heated Boiler 2 5 Minimum fall 50mm per metre of pipe run Pipe must terminate above water level ...

Page 20: ...ance with the diagram below Opening Window or Door 150mm MIN IMPORTANT If fitting a Plume Displacement Flue Kit the air inlet must be a minimum of 150mm from any opening windows or doors see Section 9 0 Plume Displacement Kit Air Inlet Fig 18a Terminal Position with Minimum Distance Fig 18 mm A1 Directly below an opening air brick opening windows etc 300 B1 Above an opening air brick opening windo...

Page 21: ...valent flue lengths are 60 100 80 125 Horizontal Concentric 10 metres 20 metres 4 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 135 bend 0 5 metres 93 bend 1 0 metres 5 The elbow connected to the boiler adaptor is not included in any equivalent length calculations 6 The illustrations opposite show examples of permissi...

Page 22: ...amounts 1 metre for each 91 5 bend 0 5 metre for each 135 bend 8 2 Vertical Flue Systems 1 Maximum permissible equivalent flue lengths are 60 100 80 125 Vertical Concentric 10 metres 20 metres 2 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 135 bend 0 5 metres 93 bend 1 0 metres The elbow supplied with the standard ho...

Page 23: ...85 U Pipe Support painted 100Ømm 5111080 R Vertical Flue Adaptor 5111070 P Wall Liner 5111067 S Flue Terminal Deflector 5111068 FLUE GROUP G Concentric Flue System 80 125mm diameter A4 Horizontal Flue Kit 5118580 B Straight Extension Kit 1000mm 5118584 D Bend Kit pair 135 5118597 C Bend 91 5 5118588 U Pipe support 125mm 5118610 FLUE GROUP A G Vertical Flue Kits K Vertical Flue Terminal use with 51...

Page 24: ...nto the flashing making sure the collar of the flue locates securely with the flashing A mastic seal may be necessary From inside the roof adjust the flue to a vertical position and secure to the roof structure with the clamp supplied 8 7 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 685mm from elbow to terminal Fig 19 The maximum permissible equivalent...

Page 25: ... increase with the addition of extensions the length of either or both the 60 100 concentric and 60Ø exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow IMPORTANT The maximum equivalent length of concentric flue is 8 metres Additional bend...

Page 26: ...e 60Ø exhaust and any extensions or additional bends Example 1 Not Permissible If for instance a concentric length of 5 metres was required and the 60Ø exhaust needed to be 6 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Where both lengths have been determined they can be applied to t...

Page 27: ... that the concentric assembly and any extensions fall back to the boiler at an angle of at least 1 5 and that the external air inlet is to the bottom 8 Use suitable brackets to support the concentric assembly and any extensions and make good inside and outside 9 The 60Ø exhaust can now be fitted Slide the adaptor over the plain end of the 60Ø exhaust Fig 31 and engage the exhaust in the terminal S...

Page 28: ...the extension at 30mm as shown in two positions directly opposite each other Fig 36 20 Using a suitable bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The remaining screw must be used to secure the adaptor to the concentric terminal 22 When the plume outlet is positioned under a balcony or other projection Fig 37 it must protrude at least 200mm it is ...

Page 29: ...s for the wall plate and boiler lower fixing holes It is preferable to use the vertical fixing slots 4 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 41 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the flue minimum diameter 116mm 7 Drill the wall as previously marked to accept suitable plugs and s...

Page 30: ...e up as much of the pipework as is practical including the discharge pipe supplied 3 The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building See section 6 7 for further details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside...

Page 31: ...or to the indicator line Fig 46 NOTE The flue elbow is angled at 93 degrees to ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 48 4 To dimension X add 50mm This dimension to be known as Y IMPORTANT Check all dimensions before cutting 5 Mark dimension Y on the flue as shown Fig 49 Carefully cut the waste material ...

Page 32: ...ect boiler operation and prevent water entering the flue 11 Make good between the wall and air duct outside the building 12 Fit the flue trim if required and if necessary fit a terminal guard see Section 8 8 8 9 CONCENTRIC VERTICAL FLUE 13 Once the length of the vertical concentric extension has been determined mark and carefully cut off the excess material The cut end MUST be square and free of b...

Page 33: ...s 1 2 The 230V supply at terminal 2 must be connected to the thermostat The switched output from the thermostat must be connected to terminal 1 Fig 57 If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Fig 57 7 Ensure that the external control input cable s have sufficient slack to allow the control box to drop down Tighten the cable clamp on the boiler chas...

Page 34: ...ing loop 9 Turn the gas supply on and purge according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 10 Test for gas tightness 11 Hinge the facia panel upwards and refit the case front panel Tighten the securing screws IMPORTANT The combustion for this appliance has been checked adjusted and preset at the factory for operation on the gas type specified on the appliance data plate No...

Page 35: ... with the current boiler temperature Figs 66 67 6 With the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point Fig 62a is in accordance with B S 6798 B S 6891 7 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Measure the Gas Rate 8 With any other appliances pilot li...

Page 36: ...the appliance and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the...

Page 37: ...requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts 1 to 4 Check the Combustion Performance CO CO2 ratio 4 Set the boiler to operate at maximum rate ...

Page 38: ...ny dirt or dust from the air box 12 Reassemble in reverse order NOTE The sensing pipe must be reconnected to the fan not the venturi DHW Filter Fig 75 13 If the flow of domestic hot water is diminished it may be necessary to clean the filter 14 Initially check the cold water inlet tap filter 15 Turn the tap off and draw off from a hot tap Undo the blanking cap and remove the threaded bush Fig 74 1...

Page 39: ...iter Fig 76 1 Disconnect the igniter feed plug and the electrode leads noting their positions 2 Undo the screw securing the bracket to the boiler 3 Remove the igniter and transfer the bracket to the new component 4 Reassemble in reverse order 14 2 Spark and Sensing Electrodes Fig 77 1 Disconnect the electrode leads noting their positions 2 Remove the retaining screws securing each of the electrode...

Page 40: ...securing the fan to the venturi and fit the new fan replacing the seal if necessary 6 Examine the burner gasket and replace if necessary 7 Reassemble in reverse order ensuring that the injector is in place and the sensing pipe is connected to the fan 14 4 Venturi Fig 78 1 Remove the collector and fan assembly as described in section 14 3 2 Extract the injector from the venturi 3 Undo the screws se...

Page 41: ...h the new one 3 Examine the gasket replacing if necessary 4 Reassemble in reverse order 14 7 Insulation Fig 82 1 Remove the electrode leads noting their positions Also remove the electrodes as described in section 14 2 2 Undo the screws securing the collector to the venturi and the nuts holding the cover to the heat exchanger Draw the collector and cover assembly away 3 Remove the cover insulation...

Page 42: ...Reassemble in reverse order The component is not polarised either wire will fit each terminal 14 10 Central Heating Temperature Sensor NTC Fig 84 1 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way 14 11 Safety Thermostat Fig 85 1 Pull the plug off the thermostat 2 Remove...

Page 43: ...ing the body to the pipe and manifold and draw the pump forwards 3 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 4 Unscrew the automatic air vent from the pump body 5 Connect the wiring to the new pump Examine the O ring seals on the return pipe and ma...

Page 44: ...lectrical plug from the sensor 3 Connect the plug to the new sensor Carefully fit the new sensor to the hydraulic assembly ensuring it is fully down 14 19 Safety Pressure Relief Valve Fig 93 1 Drain the boiler primary circuit 2 Disconnect the discharge pipe from the valve Using a suitable hexagon key undo the grub screw sufficiently to release the valve 3 Note the orientation of the valve rotate i...

Page 45: ...t hand location stud is offset towards the centre more than the right hand one 7 Reassemble in reverse order 14 21 Diverter Valve Motor Unit Assembly Fig 95 1 To replace the motor unit disconnect the multi pin plug 2 Pull off the retaining clip and remove the motor unit 3 The motor unit can now be replaced or the valve assembly removed 4 Drain the primary circuit and draw off any hot water once th...

Page 46: ...e 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 14 23 Selector Switch Fig 98 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pi...

Page 47: ...als are in place and the injector is fitted NOTE To assist the boiler to light prior to final setting use a suitable hexagon key to wind out the throttle adjustment screw until it is flush with the valve body then turn the screw 4 full turns clockwise Fig 100 If the boiler will not light or the correct CO2 cannot be achieved contact the heateam technical helpline 14 25 Expansion Vessel Fig 101 1 D...

Page 48: ...knob 1 4 clockwise twice and back fully anticlockwise Fig 102 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 103 104 5 Turn the left hand knob fully clockwise As the knob is turned the display will change indicating the fan speed 6 The display will show 00 indicating maximum rate then revert to P alternating with the current boile...

Page 49: ...NTC Sensor Fan GasValve Overheat Stat Flame Sensing Electrode Pump Flue Sensor X400 X401 g g b b r r b b b b b br bk g b br b br b br br b b b br br br b b br r bk r bk Water Pressure Switch Spark Generator Ignition Electrode 9 8 7 6 5 4 3 2 1 9 10 8 7 6 5 4 3 2 1 Hall Effect Sensor r w b w r bk bk r w DiverterValve OptionalTimer 1 2 3 4 1 2 3 4 bk br bk b N L w g 1 4 2 5 3 1 2 a b Link bk b g y b...

Page 50: ... Valve 720301001 404 Hall Effect Sensor 5114767 306 Burner 24 28 5122149 Burner 33 5114697 302 Flue Sensor 720851401 419 Water Pressure Switch 5114748 400 Plate Heat Exchanger 24 248048 Plate Heat Exchanger 28 33 5114708 415 Pump 248042 421 NTC Sensor 5114725 420 Overheat Thermostat 5114729 504 Pressure Gauge 248090 503 PCB 24 5121862 PCB 28 720043401 PCB 33 720795201 306 426 315 316 311 422 404 4...

Page 51: ...133 will be displayed by E1 alternating with 33 E50 is shown as E then 50 E20 E28 E50 indicate faulty or incorrect components E110 shows overheat of the primary water and E130 overheat of the flue system E119 is displayed when the primary water pressure is less than 0 5 bar E133 indicates that the gas supply has been interrupted ignition has failed or the flame has not been detected E125 is displa...

Page 52: ...r 133 flashing Burner does not stay alights after 5 seconds Error 133 flashing Go to section I Operation sequence successful If the error 110 is still flashing Go to section J Fan runs at correct speed YES YES NO NO NO YES YES YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO NO Burner output modulates to maintain the temperature set Burner goes out Go to section C Ensure controls are set to ...

Page 53: ...hts after 5 seconds Error 133 flashing Go to section I Operation sequence successful Turn the selector switch to reset position for 5 seconds If the error 110 is still flashing Go to section J Fan runs at correct speed YES YES NO NO NO YES YES YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO NO Burner output modulates to maintain the temperature set DHW flow sensor senses no flow Burner goes...

Page 54: ...onnector terminals 3 4 Replace PCB 2 NO Change pump supply cable YES B CH system pressure less than 0 5 bar Re pressurise system 1 YES Check the tap of the automatic air vent is opened Open the automatic air vent 2 NO C 1 NO YES Fan connections correct at fan PCB X2 connector is 230V AC across terminals 5 7 Fan jammed or faulty winding Replace PCB Replace fan YES D If pump jammed release NO NO Rep...

Page 55: ...Ignition electrode and lead 2 Electrode connection 3 Spark gap and position YES NO Replace igniter YES H YES 1 Ensure that the Hall Effect Sensor is in position Check the connection between the PCB X400 connector terminals 3 6 7 and the electronic sensor Check the voltage between red wire and blue wire is more than 5V DC NO Replace PCB Check and correct the connection of the tube between the ventu...

Page 56: ...aulty i e continuity across thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm J L M Is there 230V at Motor 3 way valve Replace motor 3 way valve 1 YES PCB X3 connector terminals 5 6 central heating mode 5 7 domestic hot water mode Replace PCB 2 NO Change pump supply cable YES Fan connections correct at fan PCB X401 connector terminals 5 6 7 8 1 YES Replace...

Page 57: ...19 0 Notes 57 ...

Page 58: ...em cleaner was used Gas Rate Burner Operating Pressure if applicable Central Heating Flow Temperature Central Heating Return Temperature Gas Rate Burner Operating Pressure at maximum rate Cold Water Inlet Temperature Hot Water has been checked at all outlets If required by the manufacturer record the following The heating and hot water system complies with the appropriate Building Regulations The ...

Page 59: ...r Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Signature Date Engineer Name Company Name Telephone No Operative ID No Comments Signature Date Engineer Name Company Name Telephone No Gas Safe Register No Comments Si...

Page 60: ...ents in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request POTTERTON A Trading Division of Baxi Heating UK Ltd 3879156 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 ...

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Summary of Contents for Heatmax Combi 24 HE

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