Potterton Promax FSB 30 HE Installation And Servicing Instructions Download

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Installer Notification Guidelines

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Scheme Members only

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Complete the

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Install and Commission this
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Install and Commission this
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Summary of Contents for Promax FSB 30 HE

Page 1: ...nd is deemed to 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 Commi...

Page 2: ...d via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006 CORGI operate a Self Certification Scheme for gas heating appliances These arrangements represent a change from the situation whereby compliance with Building Regulations was accepted as being...

Page 3: ...perty You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist Scheme Members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days If you notify via CORGI Scheme CORGI will then notify the relevant Local Authority Building Control Scheme on member s behalf Complete the Benchmark Checklist Install and Commission this appliance...

Page 4: ...ting systems In IE the installation must be carried out in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and 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 Failure to flush and add inhibitor to the system will invalidate the ...

Page 5: ... 5 0 Dimensions and Fixings 10 6 0 System Details 11 7 0 Site Requirements 15 8 0 Installation 22 9 0 Electrical 27 10 0 Commissioning the Boiler 29 11 0 Completion 30 12 0 Servicing the Boiler 31 13 0 Changing Components 33 14 0 Short Parts List 40 15 0 Fault Finding 41 Benchmark Checklist 50 Section Page Contents ...

Page 6: ...ues such as the standard horizontal flue kit part no 236921 1 2 Important Information Man made mineral fibre Some component parts of this boiler insulation pads gaskets and rope seals are manufactured from man made mineral fibre Prolonged or excessive exposure to this material may result in some irritation to the eyes skin or respiratory tract It is advisable to wear gloves when handling these ite...

Page 7: ...3 4 5 6 7 9 8 10 11 15 14 12 13 16 Fig 4 Fig 3 Fig 5 2 2 110Ø Concentric Flues Optional Extras KIT PART No Standard Flue Kit 850mm inc elbow 236921 Extended Flue Kit 1 75M inc elbow 5111457 Flue Plume Deflector Kit 248167 Terminal Guard suitable for use with above 248484 FLUE EXTENSION KITS 110 70 Flue Extension 250mm 241692 Flue Extension 500mm 241694 Flue Extension 1000mm Use two kits for 2M etc...

Page 8: ...eby the gas rate to achieve optimum operation If the flow temperature is greater than the set point or the TRVs all shut down then fan post purge occurs 6 Fan Post Purge The fan is on while the spark generator and gas valve are off After 5 seconds if the TRVs are shut down then anti cycle occurs 7 Anti cycle The fan spark generator and gas valve are off 8 Ignition Lockout The fan spark generator a...

Page 9: ...ter 6 5mm Minimum Clearances For unventilated compartments see Section 7 2 Both Sides 5mm Above Casing 15mm Above Casing Under fixed worktop It is recommended that any worktop is removable 25mm Front For Servicing 500mm Front In Operation 5mm 0 10 20 30 40 20 40 60 80 100 120 140 160 180 200 220 Water Flow Rate litres min Pressure Drop mbar 8 17 25 33 42 50 58 66 75 83 91 Pressure Drop in wg Boile...

Page 10: ...55mm to incorporate the 3 1 in 20 fall in the flue from the terminal to the elbow It is especially important to consider this when fitting the boiler under a work top 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 system Flue length Y up to 1m 1m 2m 2m 3m 3m 4m Clearance X 55mm 110mm 165mm 220mm Tube Ø 110mm D...

Page 11: ...ence of sludging it is advisable to clean the system prior to treatment in order to remove any sludge and reduce the likelihood of these deposits damaging new components When fitting new systems flux will be evident within the system which can lead to damage of system components All systems must be thoroughly drained and flushed out Using for example Betz Dearborn Sentinel X300 or X400 or Fernox S...

Page 12: ...iler b The pump must be fitted on the flow c The pump must be fitted in accordance with the pump manufacturer s instructions d The open vent pipe must be taken up from a tee in a horizontal section of the flow pipe 2 For heads below 400mm then an alternative utilising a combined vent and feed pipe may be connected Fig 12 This must be a minimum of 22mm diameter It is recommended that an air separat...

Page 13: ... be provided to switch off the boiler when there is no demand for heating Y Plan Diverter Valve Cylinder Stat Room Stat Boiler Connection 4 Core Wire Pump Timer 230V 50Hz L N E L N CH on HW on HW off L N E S L N E b g y w o gr 1 C 2 P L System Control Wiring Centre g y S Plan Valve Cylinder Stat Room Stat Boiler Connection 4 Core Wire Pump Timer 230V 50Hz L N E L N CH on HW on L N E S L N E Motor ...

Page 14: ... supply pipe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment Your attention is drawn to for GB Guidance G24 2 and recommendation R...

Page 15: ... shows zone dimensions for a bathtub For other examples refer to Section 601 of the Current I E E Wiring Regulations Reference must be made to the relevant requirements In GB this is the current I E E 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 6 If the boiler is to be fitted into...

Page 16: ...e that the pipework from the meter to the boiler is of adequate size If the boiler is further than 3 metres from the Gas Meter 22mm pipe should be used Do not use pipes of a smaller diameter than the boiler gas connection 7 5 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current I E E Wiring Regulations I...

Page 17: ...d connect to 21 5mm overflow pipe is also supplied 4 The 10mm pipe can be routed to a maximum of 3 metres vertically and then discharge via gravity or be routed horizontally Fig A A combination of vertical and horizontal runs is permissible 5 The pipe must be supported either using suitably spaced clips or run within larger diameter pipe When using clips take care not to deform the pipe 6 When rou...

Page 18: ...eely without blockage or restriction of the pipe into the drain iv to a soakaway Fig F From Boiler Termination to an internal soil and vent pipe Termination via internal discharge branch e g sink waste downstream Sink Pipe must terminate above water level but below surrounding surface Pipe must terminate above water level but below surrounding surface Termination to a drain or gully Termination to...

Page 19: ...ee also Section 7 11 9 For fitting under low soffits and eaves it is acceptable for the flue to project up to 500mm from the face of the wall to the inside of the air intake This can be painted if required using a suitable external paint Fig 17 Fig 16a 300 min Terminal Assembly TopView Rear Flue Property Boundary Line NOTE The distance from a fanned draught boiler terminal installed parallel to a ...

Page 20: ... practice dictate the use of terminal guards they can be obtained from most Plumbers and Builders Merchants 2 When ordering a terminal guard quote the boiler model name and type Tower Flue Components Tel 01732 351555 part no CGDK6BR is suitable 3 There must be a clearance of at least 50mm between any part of the terminal and the guard The guard should be positioned centrally over the terminal and ...

Page 21: ... Vertical flue adaptor concentric 5106888 Clamp 80mm 238684 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 Twin Flue The total maximum equivalent flue length is 150m NOTE Each...

Page 22: ... therefore some pipe movement will be evident even though a water tight seal has been achieved Excessive force could result in damage to the connection 3 Make all soldered joints before connecting the tails to the boiler to avoid damaging the O rings 4 Refit the pipe access panel 8 3 Making the Gas Connection 1 The connection to the boiler is a 15mm tail on the gas service cock The tail protrudes ...

Page 23: ... X from the terminal end as indicated in the diagram Fig 27 4 For side exit measure the distance from the edge of the boiler case to the inner face of the wall Fig 26 and to this dimension add the wall thickness 280mm This dimension to be known as Z i e Z case to wall wall thickness 280 5 Take the flue and mark off Z from the terminal end as indicated Fig 27 Before cutting check your dimensions 6 ...

Page 24: ...onnection on top of the boiler Secure with the four screws supplied in the kit 12 Make good between the wall and air duct outside the building ensuring the 3 drop between the terminal and elbow 13 The flue trim should be fitted once the installation is complete and the flue secure Fig 30 Apply a suitable mastic to the inside of the trim and press against the wall finish making sure the brickwork i...

Page 25: ...f the boiler is fitted in an unheated location the entire length of condensate pipe should be treated as external and run within insulated larger diameter pipe 9 Ensure that the condensate can discharge freely without blockage or restriction of the pipe into the drain 10 Examples are shown of condensate pipe methods of termination i via an internal discharge branch e g sink waste Fig B ii to an in...

Page 26: ...ystem control wiring centre through the grommet in rear of the boiler and the grommet in the support bracket This will prevent damage to the cable s 4 Lay the cable through the cable clamp to gauge the length of wire required when it is connected to the 4 way terminal block 5 Connect the S L N and P L wires to the 4 way terminal block Fig 33 and refit the cable clamp Fig 31 INTEGRAL PROGRAMMER 6 I...

Page 27: ... Condensate Trap Flow Overheat Thermostat Fan Overheat Thermostat g y r b r r Flow Thermistor 325Vdc DC Fan CH Flow Switch gy gy w g br PCB Earths not shown to aid clarity of diagram g y Electrical Filter CH Out DHW Out DHW Off Out Permanent Live Neutral Earth Switched Live Optional InternalTimer br b g y br b y v o Condensate Pump Condensate Over Level Switch Condensate Level Switch L N gy gy br ...

Page 28: ...ue y Yellow 9 2 Illustrated Wiring Diagram GasValve Fan CondensateTrap CH Flow Switch Flow Thermistor Spark Electrode Flame Detection Electrode Main PCB N P L S L r r gy gy b br g w Flow Overheat Thermostat Fan Overheat Thermostat bk bk bk r bk w w op g y g y b Layout of PCB Pins g y o br g y Electrical Filter br g y b r w b br gy gy g y ...

Page 29: ...apping of the gas valve Fig 36 The pressure must be a minimum of 18 1 mbar Working Pressure NOTE The boiler is self regulating dependent upon the system load It will modulate between inputs of 33 76kW and 10 3kW No adjustment of the gas valve is permissible 10 2 Priming the Condensate Pump 1 Using a funnel and tube carefully pour approximately 1litre of tap water into the flue products exhaust at ...

Page 30: ...essary to complete a Declaration of Conformity to indicate compliance to I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 11 3 Handover 1 Instruct the user in the operation of the boiler and system controls Hand over the User s Operating Installation and Servicing Instructions giving advice on the necessity of re...

Page 31: ...er servicing it is essential that the retaining screws are tightened fully After servicing complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication 2 Ensure that the boiler is cool 3 Remove the facia and front door panel 4 Release the four 1 4 turn screws securing the air box door panel and remove the panel Fig 39 5 Disconnect t...

Page 32: ...rush i Loosen the two screws retaining the heat exchanger support bracket and slide to the left to remove Fig 44 j Remove the four screws securing the heat exchanger combustion box base and withdraw the base k Lower the central insulation panel and check condition Fig 44 Replace the lower insulation pad if necessary l Ensure the heat exchanger fins are clear of any obstruction m Check condition of...

Page 33: ... 1 Isolate the water circuit and drain the system as necessary A drain point is located on the heat exchanger manifold at the right hand side of the boiler Fig 45 to enable the heat exchanger to be drained 2 Place a tube on the drain point to drain water away from the electrics Turn anticlockwise to open Fig 45 3 After changing a component recommission the boiler where appropriate and check the in...

Page 34: ...e 3 Connect the condensate outlet pipe to the new pump using the new clip provided 4 With the new pump in place on the studs refit the trap discharge pipe ensuring the O ring is in place Reconnect the electrical plug 5 Neatly coil the excess condensate outlet pipe adjacent to the pump ensuring that it is not kinked or restricted 6 Check operation of the pump See Section 10 2 13 5 Condensate Pump L...

Page 35: ...nd securing screw and swing out the PCB housing Remove the PCB cover and disconnect the electrical plugs noting their positions 3 Remove the screw securing the PCB to the housing The PCB can be removed from the housing 4 Ensure that the two jumpers are fitted to the new PCB as shown Fig 49 5 Reconnect the plugs fit the new PCB to the housing and reassemble in reverse order PCB Housing Securing Scr...

Page 36: ...WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate system controls before access 1 Loosen the screw holding the injector pipe into the venturi 2 Remove the electrical connections to the fan and protection sensor on the fan 3 Remove the wing nuts securing the fan to the base of the combustion box 4 Lower the fan and remove 5 If changing the fan remove the screws securing the venturi and f...

Page 37: ...ket from the gas valve 7 Fit the aluminium spacer and its gasket to the new valve 8 Fit the new gas valve and reassemble in reverse order NOTE Check for gas tightness after replacing gas valve 13 11 Condensate Trap Fig 54 1 Disconnect the condensate trap from the base of the heat exchanger 2 Disconnect the condensate drain O ring connection from the condensate trap and condensate pump For ease of ...

Page 38: ...ction 13 1 paragraph 2 3 2 Remove all components in the base of the airbox 3 Undo the screws on the support bracket Remove the screws securing the flow switch and return connections and remove the connections Fig 57 4 Remove the screws securing the heat exchanger manifold and remove the manifold Fig 58 5 Ease the combustion box left hand side panel to clear the stud lift the heat exchanger assembl...

Page 39: ...changer and remove the lower insulation pad 6 Fit the new insulation pad and reassemble in reverse order 13 15 Heat Exchanger Upper 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 heat exchanger see section 13 11 4 Remove the four bolts securing the combustion box base 5 Remove the combustion box base 6 Pull the central ins...

Page 40: ... Flow Switch 242459 C E06 060 Safety Thermostat Black 242235 D PCB 5117224 E Fan 5109925 F Gas Valve 241900 G E06 085 Viewing Window 242484 H Condensate Trap 5111714 I Electrodes Kit 5110992 J Burner Assy 5107430 K E06 097 Heat Exchanger Assy 242497 L Control Knob 5109996 M Condensate Pump 5117661 N Level Switch 5117591 O Over Level Switch 5117592 A B C E F G H I J K D L M N O ...

Page 41: ...B PCB Fault Replace PCB PCB Fault Replace PCB YES YES YES YES YES YES YES YES YES YES YES YES Go to Electrical Supply section of the fault finding instructions Go to Dry Fire section of the fault finding instructions Go to Overheat Lockout section of the fault finding instructions NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after the boiler has been electrica...

Page 42: ...block to PCB Check for short circuit on condensate pump fan gas valve Replace if shorted replace fuse YES NO Replace PCB YES YES NO NO ELECTRICAL SUPPLY 240V at B PCB fuse OK C Fuse B N S L Lights Off Off Off Off P L A D No Permanent Live to boiler Check Mains Fuse and System Wiring 240V at D Check S L wiring from terminal block to PCB YES NO NO 240V at A YES ...

Page 43: ... Disconnect Flow Switch Inline connector With pump running is there continuity across flow switch Remove Blockage NO YES NO YES Pump or Pump Wiring fault Is there a blockage in the system YES Replace PCB Wires from inline connector to PCB faulty Remove flow switch from boiler Is there a physical blockage to the paddle within the flow switch Replace Flow Switch Remove Blockage YES NO Viewed from Wi...

Page 44: ...et filter for blockage Otherwise incorrect gas supply to boiler Is there at least 18mbar dynamic at gas valve inlet Lead from PCB to Gas Valve faulty Is spark gap between 3 and 4mm Replace spark or flame detection probe and gaskets Is wiring from PCB to spark probe flame detection probe OK NO YES NO NO YES YES NO NO I Remove the larger of the two 6 way PCB connectors Is there continuity from I to ...

Page 45: ... combustion chamber door seal trim seal NO YES NO YES Reconnect stat Disconnect fan stat When fan temp 60 C is there continuity across stat Reconnect stat Disconnect the larger of the 6 way PCB connectors Is there continuity across M Disconnect thermistor red sensor on flow pipe Is resistance between 0 5kΩ 20kΩ Is combustion chamber door seal damaged or not in place Replace PCB YES Replace thermis...

Page 46: ... the smaller of the 6 way PCB connector Is there continuity from R to S from T to U from V to W Replace fan Rectify wiring YES N P R V T Q O U Viewed from Wire Entry end S W Fan Connection PCB Connection Fan Connection PCB Connection NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after the boiler has been electrically isolated Lights On Off ...

Page 47: ... thermistor Wiring from PCB to thermistor faulty YES NO NO YES Replace PCB Unplug thermistor Is thermistor resistance between 0 5kΩ 20kΩ Plug in thermistor leave 8 way connector unplugged Is resistance at D between 0 5kΩ 20kΩ D Viewed from Wire Entry end Lights On On Off ...

Page 48: ...blocked or frozen at drain Rectify fault replacing pipe if necessary YES NO Condensate pipe has high resistance too long or restricted head greater than 3 metres Rectify fault replacing or re routing pipe if necessary YES NO Pump motor or impellor worn replace pump assembly Does pump motor stop as level in reservoir falls NO Mechanical fault on float linkage or level switch After 3 mins boiler wil...

Page 49: ...49 Baxi Heating UK Limited 2005 16 0 Notes ...

Page 50: ...CER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE...

Page 51: ...ANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE INTERVAL RECORD It is recommended that your heating syst...

Page 52: ... provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements 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 General Enquiries GB Tel 08706 060 780 Technical GB Tel 08706 049 049 Service GB Tel 08706 096 096 Fax ...

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Potterton Promax FSB 30 HE, Installation And Servicing Instructions

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