Potterton Promax 24 Combi ErP Page 28 Installation And Service Manual Download

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9.0 Installation

g/y

‘

Stat

Fused

Spur

230V

Fig. 36

Fig. 34

Control Box

g/y

herm

stat

Externa

herm

stat

‘

Stat

Fused

Spur

230V

NOTE:

The 230V switched signal for external controls

(Frost Stat - Room Stat - Timer) must always be taken
from terminal 2 at the boiler. Live, Neutral and Earth to
power these controls must be taken from the Fused Spur.

Fig. 35

9.8

Making The Electrical Connections

1. Undo the securing screws and lift the case front panel off.

2. Disengage the securing tab and hinge the control box

downwards. Undo the terminal block cover securing screw

and remove the cover (Fig. 34).

3. Slacken the gland nut in the left of the boiler lower panel

and pass the mains cable through it. Remove the grommet

adjacent to the gland nut, pierce the diaphragm and insert

the cable from the external control system.

4. Leave sufficient slack in the cables to allow the Control

Box to be hinged fully open. Tighten the gland nut and refit

the grommet.

5. Connect the Earth, Permanent Live and Neutral wires to

the terminal strip.

NOTE:

Both the Permanent Live and Neutral

connections are fused.

6. Refer to the instructions supplied with the external

control(s).

IMPORTANT:

Any thermostat

MUST

be suitable for

230V switching.

7. Remove the link between terminals 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. (Figs. 35 & 36). If the room

thermostat being used incorporates an anticipator it MUST

be wired as shown in Figs. 35 & 36.

NOTE:

When only Low Voltage controls are being used

(connected to Terminal M2) it is still necessary to

remove the link wire !

8. Replace the terminal block cover.

9. See Section 18.0 for details of fitting the Optional

Outdoor Sensor.

9.9

Preliminary Electrical Checks

1. Prior to commissioning the boiler preliminary electrical

system checks should be carried out.

2. These should be performed using a suitable meter, and

include checks for Earth Continuity,

Resistance to Earth, Short Circuit and Polarity.

Summary of Contents for Promax 24 Combi ErP

Page 1: ...a Combi Installation and Service Manual Condensing Combination Boiler 24 28 33 40 en United Kingdom These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping ...

Page 2: ...M 00866 Model Range Potterton Promax Ultra 24 Combi ErP G C No 47 393 54 Potterton Promax Ultra 28 Combi ErP G C No 47 393 55 Potterton Promax Ultra 33 Combi ErP G C No 47 393 56 Potterton Promax Ultra 40 Combi ErP G C No 47 393 57 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England Wales require notification of the installation of a heating appliance to the...

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: ...nd reference should be made to the current ETCI rules for electrical installation All systems must be thoroughly flushed and treated with inhibitor see section 6 2 All Gas Safe registered engineers carry an ID card with their licence number and a photograph You can check your engineer is registered by telephoning 0800 408 5500 or online at www gassaferegister co uk In GB the following Codes of Pra...

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: ... 0 System Details 13 7 0 Site Requirements 16 8 0 Flue Options 21 9 0 Installation 23 10 0 Commissioning 29 11 0 Completion 33 12 0 Servicing 34 13 0 Changing Components 36 14 0 Combustion Calibration 44 15 0 Electrical 45 16 0 Short Parts List 46 17 0 Fault Finding 47 18 0 External Low Voltage Controls 53 19 0 Notes 56 Benchmark Checklist 58 Section Page ...

Page 7: ...er door panel It is visible when the case front panel is removed Fig 2 6 The boiler model serial number and Gas Council number are also shown on the information label behind the boiler control flap Fig 1 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 wit...

Page 8: ... show Grundfos Section 13 11 details both types 6 Central Heating System Pressure Gauge 7 Fan Assembly 8 Air Gas Collector 9 Flue Sensor 10 Flame Sensing Electrode 11 Spark Ignition Electrode 12 Combustion Box Cover Burner 13 Control Box Display 14 Condensate Trap 15 Safety Pressure Relief Valve 16 Drain Off Point 17 Gas Valve 18 Diverter Valve Motor 19 Boiler Controls 20 Boiler Adaptor 21 Heating...

Page 9: ...on mode is integral to the appliance and functions as long as there is power to the boiler as indicated by the standby signal 2 With CH DHW or CH only selected when the boiler temperature falls below 5 C the boiler will fire until a temperature of 30 C is reached 3 If DHW only is selected when the boiler CH temperature falls below 5 C the boiler will fire until a temperature of 30 C is reached Whe...

Page 10: ...Gross Max Min 24 model kW 22 20 3 89 28 model kW 26 64 4 32 33 model kW 31 08 5 33 40 model kW 35 52 6 55 Heat Output CH Non Condensing Max Min 24 model kW 20 0 3 4 28 model kW 24 0 3 8 33 model kW 28 0 4 7 40 model kW 32 0 5 7 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Electrical Protection IPX5D Internal Fuse Rating F2L Appliance Category CAT I 2H 3P Injector 24...

Page 11: ...kWh GJ Sound power level indoors LWA dB Emissions of nitrogen oxides NOX Daily electricity consumption Domestic hot water parameters Declared load profile Water heating energy efficiency Qelec kWh Annual electricity consumption AEC kWh Šwh Daily fuel consumption Qfuel kWh Annual fuel consumption AFC GJ 1 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for oth...

Page 12: ... 100mm D C B A E G F At least 1 5 H J Boiler Side Boiler Side Heating Flow 22mm Hot Water Outlet 15mm Gas Inlet 22mm Cold Water Inlet 15mm Heating Return 22mm Pressure Relief Valve 15mm Condensate Drain 65 mm 65 mm 65 mm 65 mm 95 mm 45 mm 192 mm 50 mm Tap Rail 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 e...

Page 13: ... of a proprietary cleanser such as Sentinel X300 or X400 or Fernox F3 and an inhibitor such as Sentinel X100 or Fernox MB 1 3 Full instructions are supplied with the products for further information contact Sentinel 0800 389 4670 or Fernox 0870 870 0362 Failure to flush and add inhibitor to the system will invalidate the appliance warranty 4 It is important to check the inhibitor concentration aft...

Page 14: ...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 Pressure Relief Valve Fig 6 1 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressures in excess of 3 bar and temperature in excess of 100 C 2 The pressur...

Page 15: ...uitable expansion device may be required 5 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 pressure reducing valve must be fitted for pressures in excess of 8 bar The manufacturer of any outlet fittings such as a shower valve may require a lower maximum pressure The pressure reduction must ta...

Page 16: ...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 7 2 Clearances Figs 8 9 1 A flat vertical area is required for the installation of the boiler 2 These dimensions include the necessar...

Page 17: ...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 Shower Rooms 1 If the boiler is fitted in ...

Page 18: ... with material suitable for external use 9 If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly 10 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used and any burrs on...

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: ...ng window etc 300 C1 Horizontally to an opening air brick opening window etc 300 D2 Below gutters soil pipes or drain pipes 25 75 E2 Below eaves 25 200 F2 Below balconies or car port roof 25 200 G2 From a vertical drain pipe or soil pipe 25 150 H2 From an internal or external corner 25 300 I Above ground roof or balcony level 300 J From a surface or boundary line facing a terminal 600 K From a ter...

Page 21: ...lue length is measured from point i to ii as shown IMPORTANT SUPPORT All flue systems MUST be securely supported a MINIMUM of once every metre It is recommended that every straight piece is supported irrespective of length Additional supports are available as accessories VOIDS Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual i...

Page 22: ... terminal guards Multifit accessory part no 720627901 can be used Note This is not compatible with Flue Deflector referred to below 2 There must be a clearance of at least 50mm between any part of the terminal and the guard 3 When ordering a terminal guard quote the appliance name and model number 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated 8...

Page 23: ...m 7 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 8 Using a spirit level ensure that the plate is level before finally tightening the screws 9 Connect the gas and water pipes to the valves on the wall plate using the copper tails supplied Ensure that the sealing washers are fitted between the connections NOTE 40kW models ONLY en...

Page 24: ...onnect them to the central heating flow and return taps and the cold inlet tap The system can now be filled by opening the cold inlet supply and stop valves 8 If desired a suitable gauge can be connected to one of the taps so that the system may be accurately pressurised 9 All joints fittings and system components can now be examined for soundness at operating pressure 10 The system can be flushed...

Page 25: ...er details 4 Utilising one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut hand tight plus 1 4 turn to seal 5 Complete the discharge pipework and route it to the outside discharge point 9 6 Condensate Drain see section 7 7 Fig 23 1 Using the short piece of rubber hose supplied connect the condensate drain pipework to the boiler condensate trap outlet pipe When ...

Page 26: ...om the flue elbow to the outside face of the wall X in Fig 25 is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into the elbow 6 In instances where the dimension X Fig 25 is between 250mm and 315mm it will be necessary to shorten the Terminal Assembly by careful cutting to accommodate walls of these thicknesses 7 To dimension X add 40mm This dime...

Page 27: ...the internal trim is being used it is first fitted over the elbow to allow access to the securing screws and then manoeuvred into place against the wall 14 Draw the flue back through the wall and engage it in the elbow It may be necessary to lubricate to ease assembly of the elbow and flue Fig 30 15 Ensure that the terminal is positioned with the slots to the bottom Fig 31 Secure the flue to the e...

Page 28: ... to allow the Control Box to be hinged fully open Tighten the gland nut and refit the grommet 5 Connect the Earth Permanent Live and Neutral wires to the terminal strip NOTE Both the Permanent Live and Neutral connections are fused 6 Refer to the instructions supplied with the external control s IMPORTANT Any thermostat MUST be suitable for 230V switching 7 Remove the link between terminals 1 2 Th...

Page 29: ...peed e g 33 or 43 Note Each boiler model will display a different figure 12 The boiler is factory set for Natural Gas On a Natural Gas Supply will be displayed and the boiler is ready for the Inlet Pressure Gas Rate to be checked Section 10 2 13 IMPORTANT In cases where the supplied gas is Propane gas will be displayed Press for at least 6 seconds to confirm that this is the intended gas type for ...

Page 30: ...d as percentage i e 100 2 Press until 00 is displayed indicating minimum input 3 To exit the function press together for 6 seconds 4 The combustion CO level and CO CO2 ration must be measured and recorded at MAXIMUM DHW input and MINIMUM input 5 Follow the flow chart on the next page to comply with the requirement to check combustion on commissioning 6 The system MUST be cold to ensure the boiler ...

Page 31: ...oor case seals Replace any seals that appear unsound Is CO 350ppm and CO CO2 ratio 0 004 TURN APPLIANCE OFF Call 0344 871 1545 for advice The appliance MUST NOT be commissioned until all problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with the GSIUR Note Check record the CO combustion ratio at both...

Page 32: ...orking gas pressure at the inlet gas pressure test point on the gas cock or valve is in accordance with B S 6798 B S 6891 This must be AT LEAST 17mb LPG 37mb 3 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Measure the Gas Rate 4 With any other appliances pilot lights turned OFF the gas rate can be measured It should be Natural Gas 24 model 2 ...

Page 33: ...operation of the boiler 11 2 System Draining 1 If at any time after installation it is necessary to drain the central heating system e g after replacing a radiator the De Aeration Function should be activated 2 On refilling the system ensure that there is no heating or hot water demand but that there is power to the boiler 3 Press together and hold for at least 6 seconds The De Aeration Function w...

Page 34: ...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 as described in Section 14 1 1 to 14 1 6 5 Remove the plug from the flue sampling point insert the analyser probe and obtain the CO CO2 ratio This mus...

Page 35: ... Reassemble in reverse order ensuring the front case panel is securely fitted DHW Filter Turbine Assy Fig 48 13 If the flow of domestic hot water is diminished it may be necessary to clean the filter In areas of harder water it is recommended that this is performed annually 14 Turn the DHW isolation cock Fig 47 off and draw off from a hot tap 15 Remove the retaining clip and extract the filter car...

Page 36: ... gas venturi Disconnect the pipe 2 Undo the screws securing the air gas collector to the cover 33 40 or extension piece 24 28 and disconnect the fan electrical plugs 3 Remove the collector and fan assembly being careful to retain the gasket 4 Undo the screws securing the fan to the collector Retain the gasket 5 Undo the screws securing the venturi to the fan noting its position and transfer to the...

Page 37: ...lectrodes as described in section 13 1 3 Undo the nuts holding the cover to the heat exchanger Draw the air gas collector fan and cover assembly away 4 Remove the cover insulation piece 5 Fit the new insulation carefully over the burner and align it with the slots for the electrodes 6 If the rear insulation requires replacement remove it and all debris from the heat exchanger Also it may be necess...

Page 38: ...eassemble in reverse order ensuring that the terminals are pushed fully on 13 9 DHW NTC Sensor Fig 56 1 Turn off the mains cold water supply tap and draw off the residual domestic hot water 2 Ease the retaining tab on the sensor away and disconnect the electrical plug 3 Unscrew the sensor from the hydraulic outlet assembly Examine the sealing washer replacing if necessary 4 Reassemble in reverse o...

Page 39: ... 13 12 Automatic Air Vent Grundfos Fig 57 1 Drain the boiler primary circuit and unscrew the automatic air vent from the pump body 2 Examine the O ring seal replacing if necessary and fit it to the new automatic air vent 3 Reassemble in reverse order 13 13 Automatic Air Vent Wilo Fig 58 1 Drain the boiler primary circuit and remove the U clip securing the automatic air vent to the pump body 2 Pull...

Page 40: ...e inlet assembly 4 On reassembly ensure that the O ring is in place and the sealing grommet is correctly refitted to maintain the integrity of the case seal 13 16 Heating Pressure Gauge Figs 61 61a 1 Close the flow and return isolation taps and drain the primary circuit 2 Remove the gauge from the boiler lower panel 3 Remove the clip securing the pressure gauge capillary 4 Fit the new gauge ensuri...

Page 41: ...ing the new heat exchanger note that the right hand location stud is offset more towards the centre 8 Reassemble in reverse order 13 18 Diverter Valve Motor Valve Assembly Fig 63 1 To replace the motor disconnect the multi pin plug 2 Pull off the retaining clip and remove the motor 3 The motor can now be replaced or the valve assembly removed 4 Drain the primary circuit and draw off any hot water ...

Page 42: ...their slots 3 Note the position of all plugs and wires on the P C B and disconnect them 4 Undo the securing screws and remove the P C B IMPORTANT If only the P C B is being replaced transfer the R D S from the original board to the new one Where both P C B and R D S are being replaced ensure the new R D S is on new the board 5 Reassemble in reverse order Ensure that the ignition lead is connected ...

Page 43: ...n place and perform the Calibration Function Combustion Check see Sections 14 1 14 2 NOTE Check for gas tightness after replacing gas valve 13 21 Expansion Vessel Fig 66 1 Close the flow and return isolation taps and drain the primary circuit 2 Undo the nut on the pipe connection at the bottom of the vessel and slacken the nut on the hydraulic inlet assembly 3 Remove the screws securing the suppor...

Page 44: ...e Ignition Phase speed then 00 These represent the percentage of MAXIMUM fan speed i e 00 is MINIMUM fan speed Once the boiler has stabilised and self calibrated at each fan speed the and symbols will be displayed before the next speed is automatically set 4 When self calibration is complete the boiler will run at MINIMUM fan speed 00 displayed The following symbols will also be displayed flashing...

Page 45: ...ture Sensor X3 X31 b g br w b b g br br bk g g b b br b b bk g y bk r w b br g y g y bk br M1 Terminal Strip br bk M2 LowVoltage External Control Connection Pump Grundfos Pump Wilo X22 Heat Exchanger Flue Sensor Return Temperature Sensor CH Flow Temperature Sensor Water Pressure Switch Hall Effect Sensor b r w b b r r r bk g b b Key To Wiring Colours b Blue bk Black br Brown w White gr Grey r Red ...

Page 46: ...ensor 720747101 N DHW NTC Sensor 720789201 O Pump Automatic Air Vent 720787601 P Hydraulic Pressure Sensor 720789001 Q Heating Pressure Gauge 720787201 R Flue Sensor 720851401 S PCB only R D S not inc 7224738 T R D S 24 720843201 R D S 28 720843501 R D S 33 720843801 R D S 40 720844101 R D S 24 LPG 720844401 R D S 28 LPG 720844701 R D S 33 LPG 720845001 R D S 40 LPG 720845301 U Injector Washer 24 ...

Page 47: ...isplayed when the primary water pressure is less than 0 5 bar 133 134 and 135 indicate that the gas supply has been interrupted ignition has failed or the flame has not been detected 128 is displayed if there has been a flame failure during normal operation 125 is displayed in either of two situations i If between 15 and 30 seconds of the burner lighting the boiler temperature has not changed by 1...

Page 48: ...ton for 1 to 3 seconds NO Fan runs after up to 3 minutes 160 flashing Go to section C NO If 09 15 110 or 384 is flashing or re occurs regularly check all PCB connections If this has no effect replace the PCB Fan runs at correct speed 160 flashing Go to section C Spark at ignition electrodes up to 5 seconds for 3 attempts Go to section F Press the reset button for 1 to 3 seconds YES Burner lights G...

Page 49: ...NO If 09 15 110 or 384 is flashing or re occurs regularly check all PCB connections If this has no effect replace the PCB Fan runs at correct speed 160 flashing Go to section C Spark at ignition electrodes up to 5 seconds for 3 attempts Go to section F Press the reset button for 1 to 3 seconds YES Burner lights Go to section E Burner goes out after 5 seconds 133 flashing Go to section G YES YES NO...

Page 50: ...et During next 3 minutes check 230V at PCB X13 connector between blue brown see Wiring Diagram NO Replace PCB YES 230V between PCB X13 connector blue and PCB X11 connector black see Wiring Diagram NO Replace PCB YES 230V at pump YES Replace pump NO Check wiring 230V at PCB X11 connector between blue brown see Wiring Diagram YES NO Replace PCB Replace fan or wire YES YES Temperature sensor faulty C...

Page 51: ... The set of the gas valve CO2 values see instruction 2 Flame sensing electrode and lead connections 3 Flame sensing electrode position 1 2 G Replace flame sensing electrode or PCB Replace PCB YES Replace safety thermostat YES NO Safety thermostat operated or faulty Check for and correct any system faults H Allow to cool Continuity across thermostat terminals more than 1 5 ohm NO Check Flow Return ...

Page 52: ... sensor NO System fault correct NO YES Ensure that the boiler and system are fully vented Check flow temperature sensor connections and position Cold resistance approximately 10k 25 C CH sensors resistance reduces with increase in temp YES Go to section B K Is there 230V at Diverter valve motor Replace 3 way valve motor 1 YES PCB X13 connector terminals between Blue Black central heating mode Blue...

Page 53: ...he grommet 5 Connect the wires from the Outdoor Sensor to positions 4 5 on M2 as shown Refit the cover 18 3 Setting the Sensor Curve 1 Ensure that there is power to the boiler 2 The Central Heating temperature buttons are used to select the desired curve as shown on the graph 3 Normally the display will show the current temperature of the water in the boiler e g 41 C As the buttons are pressed the...

Page 54: ...iterature supplied with it 4 Pass the wiring through the slots in the backplate and connect as shown opposite to 2 3 on the sensor backplate and 1 2 of boiler terminal M2 5 Complete fitting as described in the sensor literature turn the power back on and set the controls to the requirements of the user Optional 7 Day Wired Sensor 1 Press SecuringTab 2 Ease away from Backplate 1 2 3 Programmer Room...

Page 55: ...t by pressing down on the rear tab and easing apart 3 Locate the receiver and use wiring as described in the literature supplied with it 4 Pass the wiring through the slots in the backplate and connect as shown opposite to the OT connection on the receiver backplate and 1 2 of boiler terminal M2 5 Complete fitting as described in the sensor receiver literature turn the power back on and set the co...

Page 56: ...56 Baxi Heating UK Ltd 2016 19 0 Notes ...

Page 57: ...57 Baxi Heating UK Ltd 2016 19 0 Notes ...

Page 58: ...uired Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL SYSTEMS s instructions Yes What system cleaner was used What inhibitor was used Quantity litres Yes No CENTRAL HEATING MODE measure and record Gas rate m hr OR ft hr Burner operating pressure if applicable mbar OR Gas inlet pressure mbar C Central heating return tempe...

Page 59: ...ompany name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 06 Date Engineer name Company name Telephone No Gas safe register No Record At max rate CO ppm AND CO At min rate Where Possible CO ppm AND CO Comments Signature SERVICE 07 Date Engineer name Company name Telephone No Gas safe register No Record At max ...

Page 60: ... terms and conditions visit www baxi co uk terms Failure to adhere to terms and conditions will void your manufacturer s warranty Baxi Brooks House Coventry Road Warwick CV34 4LL Please ensure the boiler is installed in accordance with these installation instructions and that you adhere to the Building Regulations e oe All descriptions and illustrations provided in this document have been carefull...

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