Potterton Promax HE Store Page 9 Installation & Servicing Instructions Manual Download | Manualshive

Page: 9 / 60

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9

Condensate

Trap

3 Way

Diverter Valve

Flow Sensor

Combustion

Analyser

Test Point

Flue

Air

Automatic

Bypass

Primary E

x

pansion Vessel

Automatic
Air Vent

Gas
Valve

I

solation Valve

I

solation

Valve

Pump

Primary
Relief
Valve

Heat E

x

changer

Combination Valve

Tundish

Cross/Check
Valve

Tundish

Gas

Gas Cock

D.H.W. Sensor

Hot Water

Cylinder

CH

Return

CH

Flo

w

Schematic Diagram

Filling Loop

Double
Check
Valve

DHW

Cold Main

Stopcock

Balanced Cold
Feed to Shower

Pressure Relief Valve

Secondary
E

x

pansion

Vessel

Fan

A B

T.P.R.V.

Codes of Practice

The appliance is suitable only for installation in GB and
IE and should be installed in accordance with the rules in
force.
In GB, the installation must be carried out by a Gas Safe
Registered Installer. It must be carried out in accordance
with the relevant requirements of the:

• Gas Safety (Installation & Use) Regulations.
• The appropriate Building Regulations either The

Building Regulations, The Building Regulations
(Scotland), Building Regulations (Northern Ireland).

• The Water Fittings Regulations or Water Byelaws in

Scotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference
should be made to the relevant British Standard Codes
of Practice.

In IE, the installation must be carried out by a Competent
Person and installed 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.

Fig. 4

In GB the following Codes of Practice apply:
Standard

Scope

BS6891

Specification for low pressure gas pipework

in domestic premises.

BS5440 Pt.1

Specification for installation of flues.

BS5440 Pt.2

Specification for installation of ventilation for

gas appliances (except that compartment

ventilation is amended in section 8 of these

instructions).

BS5546

Specification for installation of gas hot water

supplies.

BS5449

Specification for forced circulation hot water

central heating systems.

BS6798

Specification for installation of gas fired hot

water boilers of rated input not exceeding

70kW.

In IE:
I.S. 813

Domestic Gas Installations.

The following BS standards give valuable additional information:

BS6891

Specification for low pressure gas pipework

in domestic premises.

BS5546

Specification for installation of gas hot water

supplies.

BS5449

Specification for forced circulation hot water

central heating systems.

© Baxi Heating UK Ltd 2012

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Summary of Contents for Promax HE Store

Page 1: ...tallation Servicing Instructions Please keep these instructions in a safe place If you move house please hand them over to the next occupier Promax HE Store Range Condensing Boilers with Integrated Hot Water Storage You can rely on ...

Page 2: ...tive and fully supports the aims of the programme Its aim is to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency Building Regulations require that installations should comply with manufacturer s instructions It is therefore important that the commissioni...

Page 3: ...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 Install and Commission this appliance to...

Page 4: ...24 115 Litres 41 591 76 150 Litres 41 591 77 Important Refer to Page 8 for Storage Unpacking and Handling Instructions Benchmark Commissioning Checklist Potterton is a member of the Benchmark initiative and fully supports the aims of the programme Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regul...

Page 5: ... Panel at the bottom and lift off General Access Plumbing Access 1 Pull forward Bottom Panel Unscrew Upper Panel at the bottom and pull away Retaining Screws Upper Panel Condensate outlet hole Top Section Lift Heat Engine onto Cylinder Ensure the rollers engage into location channels Tilt and slide until front location pegs drop into position on the cylinder Location Peg Location Channel Rollers F...

Page 6: ...sure 2 5 bar expansion relief valve set 8 0 bar Filling Loop 15 mm 1 2 union accessible behind lower front panel Secondary Expansion Vessel 12 litre pre charge 2 5 2 7 bar supplied separately Automatic bypass Built in Pressure loss warning Gauge on facia Built in programmer 2 channel pre programmed battery back up separate times for HW CH advance button CH off selector External programmer Built in...

Page 7: ...min Removable Top Panel 450 min 250 min 650 max Door Frame 400 mm Recommended 400 mm Recommended Concentric Flue Ø80 Air Tube No Clearance required Ø80 Flue Tube 145 145 Side Flue Rear Flue 300 min All dimensions in mm 600 Twin Flue MAX0008B Ø100 Air Tube Ø60 Flue Tube C L Inner Wall Outer Wall Inner Wall Outer Wall C L 550 Fig 2 Fig 3 Promax Store Promax Store Promax Store 1544 mm 150 Litre Model...

Page 8: ...and shows compliance with the Electro Magnetic Compatibility Directive 89 336 EEC the Boiler Efficiency Directive 92 42 EEC and are therefore permitted to carry the CE Mark Operation The boiler control works on the principle of hot water priority so the central heating output may be temporarily delayed if the hot water temperature drops below the selected temperature e g after drawing a hot bath T...

Page 9: ... instructions are given reference should be made to the relevant British Standard Codes of Practice In IE the installation must be carried out by a Competent Person and installed 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 Fig 4 In GB the following Co...

Page 10: ...m gas inlet connection is provided at the front and gas supply pipework of not less than 22 mm diameter should be run to the boiler The meter and supply pipes must be capable of delivering this quantity of gas in addition to the demand from any other appliances in the house and must be governed at the meter The gas installation should be in accordance with the relevant standards In GB this is BS 6...

Page 11: ...ayouts safely provide sufficient flexibility If the boiler is to be fitted in a room containing a bath or shower 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 1 4 Compartment Installation and Ventila...

Page 12: ...that the position of the terminal allows free passage of air across it at all times c It is ESSENTIAL TO ENSURE that products of combustion discharging from the terminal cannot re enter the building or any other adjacent building through ventilators windows doors other sources of natural air infiltration or forced ventilation air conditioning d The minimum permissible dimensions between the flue t...

Page 13: ... Plume Displacement Kit Air Inlet IMPORTANT Under car ports we recommend the use of the plume displacement kit The terminal position must ensure the safe and nuisance free dispersal of combustion products 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 window etc 300 C1 Horizontally to an opening...

Page 14: ...in Flue Pipe 45 bend 0 25 metres 91 5 bend 0 50 metres The elbow attached to the boiler is not included in any equivalent length calculations 5 The illustrations opposite show examples of permissible flue systems NOTE Flue length is measured from point X to Y as shown IMPORTANT All flue systems must be securely supported at least once every metre Suitable pipe supports are available as accessories...

Page 15: ... 135 bend 91 5 bend 1m 0 25m 0 5m 5 2 2 5 0m 0 5m 1 0m FLUE DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Flue Duct 6 5m Y X C Roof Terminal A B This bend is equivalent to 1 metre Total Equivalent Length A B C 1x90 Bend All vertical and angled runs must be included measured from the boiler adaptor point X to the joint with the flue terminal point Y One 91 5 bend or ...

Page 16: ...eter E Flue Extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend 2 pair 135 5111086 J Vertical Flue Boiler Adaptor Kit 5111079 H Vertical Flue Adaptor 5111084 W Pipe Support pair 80mm 5111081 Y Twin Flue Termination Kit horizontal termination 80mm 5120172 Z Single Terminal 80mm 5121791 Q Adaptor 60 80 5121792 T Pitched Roof Terminal 25 45 5106164 FLUE GROUP A N G Vertical Flue Kit...

Page 17: ... and one marked 27 these can be discarded The third restrictor MUST be positioned as shown in the diagrams below 3 Take one of the gaskets supplied in the kit and place on the boiler top panel 4 Align the appropriate restrictor as shown Position the second gasket over the restrictor 5 Using the screws previously removed secure the inlet adaptor to the top panel 6 Continue to fit the twin flue syst...

Page 18: ...re 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 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 685mm from elbow to terminal Fig 5a The maximum permissible equivalent flue length is 10 metres 60 1...

Page 19: ...tensions 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 bends may be fitted in the concentric...

Page 20: ...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 10 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 the graph to check tha...

Page 21: ...tensions 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 7c and engage the exhaust in the terminal Slide the adaptor down over the spigot Ma...

Page 22: ...at 30mm as shown in two positions directly opposite each other Fig 7h 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 7j it must protrude at least 200mm it is not necessary ...

Page 23: ... grade polyphosphates can be effective in reducing limescale but require correct siting and regular replenishment to remain operational They should generally not be fitted where heat could impair their perfomance Other types of device can inhibit scale formation but their effectiveness may vary The manufacturers of any water conditioning device should be consulted regarding its suitability for the...

Page 24: ... pipe D2 from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge preferably be of metal and a be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long i e discharge pipes between 9m and 18m equivalent resistance length shoul...

Page 25: ...ipe sizing The example below is for a G1 2 temperature relief valve with a discharge pipe D2 having 4 No elbows and length of 7 m from the tundish to the point of discharge From Table 1 Maximum resistance allowed for a straight length of 22mm copper discharge pipe D2 from a G1 2 temperature relief valve is 9 0 m Subtract the resistance for 4 No 22 mm elbows at 0 8m each 3 2 m Therefore the permitt...

Page 26: ...er if fitted or to the condensate trap 3 Move boiler into position The need to move as Top and Bottom sections or as a complete assembly will depend on the individual installation The Top has 4 downward facing dowel pins which provide accurate location on to the cylinder Take care to avoid trapping hands and fingers during assembly 4 Apply sealant to cone faces of both 22mm Union Nuts see Fig 10 R...

Page 27: ...ischarge Pipe Pressure Gauge Pipework shown as this NOT SUPPLIED Filling Loop Potterton Promax Store 150 litre model shown Mains Cold Inlet CH Return Gas Inlet CH Flow MAX0002D 22mm Union Nuts 15mm Branch Pipe Promax Store Display Selector Reset Switch CH Control Knob DHW Control PCB Enclosure Gas Valve Diverter Valve Manual Air Vent Flue Outlet Programmer Pressure Gauge Pump Expansion Vessel Fan ...

Page 28: ... no smaller than 32 mm Ideally the condensate pipe should be run internally to the house soil and vent stack or to a waste pipe Alternatively the condensate may be discharged into the rainwater system or a purpose built soakaway All connecting drainage pipework must have a fall of at least 50 mm per metre run It is recommended that the pipe is insulated if run externally to minimise the effects of...

Page 29: ... CH Flow Gas CH Return Pipework shown as this NOT SUPPLIED RWC Important Do Not fit any valve in line between the storage cylinder and the Inlet Control Group or between cylinder and an independent relief valve Double Check Valve Promax Store Secondary Expansion Vessel Expansion Relief Valve 8 0 bar Stop Valve DHW Mains Cold Inlet and cold feed to kitchen tap Tundish 22mm 22mm 22mm 22mm 15mm 15mm ...

Page 30: ...pe supplied with the cylinder provides clearance for future maintenance of the immersion heater Ensure this pipe is pushed fully home into the Techtite joint The return connection is low down at the front centre Pressure Relief Valve Primary A pressure relief valve set at 3 0 bar is fitted to the Heat Engine s primary circuit Trim the supplied 15mm branch pipe to length before fitting See Fig 10 2...

Page 31: ...ng used incorporates an anticipator it MUST be wired as shown in the diagram 8 Ensure that both mains input and where fitted external control input cables have sufficient slack to allow the control box to drop down 9 The boiler is fitted with a programmer that is powered up when the selector switch is in the combined heating hot water or hot water only positions Although unpowered when the selecto...

Page 32: ...g nut and pulling the cap away from the cylinder The Live Brown conductor should be connected directly to the thermostat terminal marked A The Neutral Blue conductor should be connected directly to the thermostat terminal marked B The earth conductor should be connected to the threaded post on the bracket marked The supply cable outer sheath must be routed through the cable gland supplied and secu...

Page 33: ... pre charge pressure is between 2 5 to 2 7 bar and allow water to flow freely before closing tap s 2 9 Control Panel Displays Diagnostics The boiler control fitted to Promax Store has been designed to provide safe reliable and economical operation of the boiler see Fig 15 for a guide to the control panel Fault finding during both commissioning and subsequent maintenance is much simplified by the c...

Page 34: ... naked lights cigarettes pipes etc Important The commissioning and boiler adjustment must only be carried out by a suitably qualified person Potterton offer this service on a chargeable basis Fig 16 Manual Vent for Heat Exchanger Combustion Test Port Automatic Air Vent On Pump Diverter Valve Indicator Lever Isolating Valve on by pass link ...

Page 35: ...e store are Unit Heat up Recovery 90 Litre 18 min 15 min 115 Litre 22 min 18 min 150 Litre 30 min 23 min From previous draw off of 70 of volume Sealed Primary System 1 Ensure that gas supply is turned OFF at the gas cock 2 Leave the boiler switched OFF at the selector switch but turn both the CH and DHW control knobs clockwise 3 Move the indicator lever on the diverter valve head to the mid positi...

Page 36: ...below 0 5 bar IMPORTANT Do not vent the boiler with the burner running or damage to the heat exchanger may result 5 Wait until the central heating circuit has reached its normal temperature of approx 80 C before balancing the radiators in the usual way to achieve a temperature drop of 10 C 6 Allow system to reach full temperature all radiators at working temp and note hot system pressure Switch bo...

Page 37: ...mooth and visually inspect flame Continue to draw water until maximum fan speed is attained Check combustion see Combustion Testing 6 Turn off the mains water supply at the Inlet Control Group and release system pressure by opening a hot tap Using hexagon key provided remove the pressure reducing cartridge from the Inlet Control Group Clean the cartridge and strainer in running cold water Re fit t...

Page 38: ...s must be made and functional check of the controls carried out IMPORTANT Any O rings seals gaskets or washers disturbed during replacement of parts must be visually inspected and replaced if worn or damaged Re assemble all parts in reverse order 1 Follow stages 1 3 opposite to remove the outer panels Internal Access 2 Remove the screws securing the top engine box cover and lift the cover away fro...

Page 39: ...and remove the socket head screws securing the pump head to the body and draw the head away 2 Detach the pump cable 3 A standard replacement Grundfos 15 60 head can now be fitted Connect the pump wiring to the new head 4 Reassemble in reverse order Pump Complete 1 Drain the primary circuit 2 Undo the two screws securing the body to the pipe fittings and draw the pump forwards 3 Detach the pump cab...

Page 40: ... below the sensor body remove securing clip and pull valve out from assembly 4 By pass Valve This valve is part of the complete cross unit and cannot be replaced separately Remove the pressure relief valve as shown above then release the Techtite unions and remove the cross unit RWC MAX0002D Promax Store Pull out Clip to release Pressure Relief Valve Pressure Relief Valve Remove Cross Pressure Rel...

Page 41: ... washer and replace if necessary 3 Undo the screws securing the manifold to the extension piece 4 Partially remove the manifold and fan assembly being careful to retain the injector in the venturi Disconnect the fan electrical plugs before completely removing the assembly 5 Undo the screws securing the fan to the venturi and fit the new fan replacing the seal if necessary 6 Examine the gasket behi...

Page 42: ...ect the electrode leads noting their positions 2 Remove the retaining screws securing each of the electrodes to the combustion box cover and remove the electrodes 3 Check the condition of the sealing gaskets and replace if necessary Reassemble in reverse order 4 9 Overheat Thermostat Re assemble all parts in reverse order 1 Perform 4 1 General Access 2 Disconnect electrical connections and unscrew...

Page 43: ...g the cover to the heat exchanger Draw the cover assembly away 3 Remove the cover insulation piece 4 Fit the new insulation carefully over the burner and align it with the slots for the electrodes 5 The rear insulation is retained by a screw and large washer remove these and draw the insulation out of the heat exchanger 6 Examine the cover seal and replace if necessary Heat Exchanger Rear Insulati...

Page 44: ...e from primary system and drain down until water level is below the valve NOTE A convenient way to check the water level is to drain all water to the level of the primary expansion relief valve NOTE The markings on the valve body are an aid to correct installation See Fig 23 4 Remove the three spring clips from the connections and remove the valve from the boiler Manual Air Vent 5 Unscrew vent fro...

Page 45: ...previous sections Remove flow and return pipework from the push fit connections on the manifold underneath the heat exchanger Retain securing clips for re use 4 Disengage the flue air inlet duct elbow on top of the boiler Unscrew the 4 c sunk screws and remove the flue connector fitting 5 Disconnect wiring from temperature sensors and overheat thermostat Remove the spark generator and leads Remove...

Page 46: ...d of the immersion heater should be tilted towards the floor for ease of withdrawal 6 Insert the immersion heater into the boss ensuring the right angled element hangs vertically downwards towards the base of the unit Push the immersion heater mounting plate into the boss so the gasket seats on the flange at the base of the boss It may be helpful to support the immersion heater using a round blade...

Page 47: ... the reading to settle The CO2 should be 8 9 0 2 9 It is possible to alter the CO2 by adjustment of the gas valve At maximum rate the Max Rate throttle adjustment screw should be turned clockwise to decrease CO2 anti clockwise to increase CO2 using a suitable 2 5mm hexagon key until the correct reading is obtained 10 The CO2 must then be checked at minimum rate Turn the CH temperature knob fully a...

Page 48: ...48 Baxi Heating UK Ltd 2012 5 Wiring Diagrams Fig 27 Wiring Functional Flow Diagram ...

Page 49: ... Gas Valve Overheat Stat Flame Sensing Electrode Pump Mains Input Link g y b br Flue Thermistor X400 X401 g g b b r r b b b b b br bk g b br g y b br b br br b b b br br br b b br r o r o o br b b br Water Pressure Switch Spark Generator Ignition Electrode 9 8 7 5 4 2 1 9 10 8 7 6 5 4 3 2 1 br bk b b bk br Diverter Valve 1 2 3 4 N L w g 1 4 2 5 3 1 2 a b r o br o b b w Timer 6 3 Baxi Heating UK Lt...

Page 50: ...g with 33 E50 is shown as E then 50 E20 E28 E50 indicate faulty components or wiring harness 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 displayed in either of two situations i...

Page 51: ...ts after 5 seconds Error 133 flashing Go to section H Operation sequence successful If the error 110 is still flashing Go to section I 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 demand and verify the contacts are closed...

Page 52: ...ner does not stay alights after 5 seconds Error 133 flashing Go to section H Operation sequence successful Turn the selector switch to reset position for 5 seconds If the error 110 is still flashing Go to section I Fan runs at correct speed YES NO NO NO YES YES YES YES YES YES NO YES YES YES YES NO NO NO NO Go to section C Error 160 flashing Go to section K YES Go to section G Turn the selector sw...

Page 53: ... 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 Replace water pressure switch Check c...

Page 54: ...CB X3 connector is 230V AC across terminals 1 2 YES NO NO F Replace PCB Check and correct if necessary 1 Ignition electrode and lead 2 Electrode connection 3 Spark gap and position Voltage at PCB X2 connector is 110V DC across terminals 2 5 Note from multimeter connect common to 2 volts to 5 Check wiring YES NO Replace igniter YES G Check and correct the connection of the tube between the venturi ...

Page 55: ...thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm I K L Is there 230V at Motor 3 way valve Replace diverter valve actuator 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 fan Temperature senso...

Page 56: ... Sensing Electrode 5117275 480 Gas Valve 720301001 410 Burner 5114697 535 Water Pressure Switch 5114748 520 Pump 248042 402 Flue Thermostat 5114747 531 NTC Sensor 5114725 530 Overheat Thermostat 5106291 235 Pressure Gauge 248090 205 PCB 5117086 220 Selector Switch 248095 215 Battery Programmer 5118231 231 Knob 5116069 410 441 442 490 480 535 520 402 531 530 205 235 215 231 220 ...

Page 57: ...57 Notes Baxi Heating UK Ltd 2012 ...

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: ...Comments Signature SERVICE 9 Date Energy Efﬁciency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 2 Date Energy Efﬁciency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 4 Date Energy Efﬁciency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 6 Date ...

Page 60: ...the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request Publication No 5120008 Iss 9 5 12 Baxi Heating UK Ltd 2012 POTTERTON A Trading Division of Baxi Heating UK Ltd 3879156 Brooks House Coventry Road Warwick CV34 4LL After Sales Service 0844 871 1525 Technical Enquiries 0844 871 1555 Website www potterton co uk e oe ...

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