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Potterton Promax System HE Plus LPG, Installation & Service Instructions Manual

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Potterton Promax System HE Plus LPG Installation & Service Instructions Manual Download Page 21

21

8.0 Flue Options

© Baxi Heating UK Ltd 2008

For Twin Flue Systems fit the adaptors as follows:-

8.4

Flue Duct Adaptor

1. Engage the flue duct adaptor on the boiler flue adaptor,

making sure that it is pushed down as far as possible.

8.5

Air duct adaptor

1. Undo the screws securing the blanking plate to the boiler

top panel. Discard the plate.

2. There are three restrictor plates supplied in the kit. One

marked ‘23’, one marked ‘27’ and a third unmarked. The

unmarked one must be used with this 24kW boiler. Discard

the other two. Position the unmarked restrictor as shown

below.

3. Take one of the gaskets supplied in the kit and place on

the boiler top panel.

4. Align the 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 system.

Flue Duct Adaptor

Inlet Adaptor

Gasket

Restrictor

Gasket

Blanking Plate

24 kW model

Position of Restrictor

Summary of Contents for Promax System HE Plus LPG

Page 1: ... 2008 Installation Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Promax System HE Plus LPG Condensing System Boiler You can rely on ...

Page 2: ...mportant that the commissioning checklist is completed by the installer The relevant section of Building Regulations only relates to dwellings Therefore the checklist only applies if the appliance is being installed in a dwelling or some related structure The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations Baxi Heating UK Ltd...

Page 3: ...erty You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist Scheme Members only Call CORGI on 0800 408 1007 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 t...

Page 4: ...itish Standard Code 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 All systems must be thoroughly flushed and treated with inhibitor see section 6 2 In GB the foll...

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: ...nd Fixings 11 6 0 System Details 12 7 0 Site Requirements 14 8 0 Flue Options 18 9 0 Plume Displacement 23 10 0 Installation 27 11 0 Commissioning 32 12 0 Completion 34 13 0 Servicing 35 14 0 Changing Components 37 15 0 Combustion Check 45 16 0 Electrical 46 17 0 Short Parts List 47 18 0 Fault Finding 48 Benchmark Checklist 54 Section Page ...

Page 7: ...the inner door panel It is visible when the case front panel is removed Fig 1 6 The boiler model name and serial number are also shown on the information label on the rear of the lower door panel 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...

Page 8: ... 10 Gas Valve 11 Condensate Trap 12 Flame Sensing Electrode 13 Spark Electrode 14 Primary Heat Exchanger 15 Fan Assembly 16 On Off Reset Selector Switch 17 Central Heating Temperature Control 18 Calibration Control 19 Venturi 20 Air Gas Collector 21 Combustion Box Cover Burner 22 Igniter 23 Burner On Light 24 Central Heating Mode Light 25 Display 1 16 17 18 7 Reset 2 1 0 4 3 bar 21 2 3 4 5 6 7 8 9...

Page 9: ... mode is integral to the appliance and functions when the selector switch see Section 2 1 is in the ON position If the system temperature falls below 5 C then the boiler will fire on its minimum setting until a flow temperature of 30 C is reached Further protection can be incorporated by using a system frost thermostat 3 3 Pump Protection 1 With the selector switch see Section 2 1 in the ON positi...

Page 10: ...ating Flow 22mm Central Heating Return 22mm Pressure Relief Discharge 15mm Temperatures Flow Temp adjustable 25 C to 80 C max 5 C NOx Class 5 0 200 400 600 800 1000 1200 0 5 1 1 5 2 2 5 3 3 5 4 Metre wg Flow Rate l h Pump Available Head 0 5 5 5 4 5 Clearances Above Casing 200 mm Min Below Casing 200 mm Min Front 450 mm Min For Servicing Front 5 mm Min In Operation L H Side 5 mm Min R H Side 5 mm M...

Page 11: ...00mm D C B A E G F At least 1 5 H Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 130 mm 130 mm 65 mm Condensate Drain 32 5 mm Tap Rail Dimensions A 780mm B 345mm C 450mm D 116mm Ø Min E 185mm 207mm for 80 125mm flue systems F 145mm G 131mm H 180mm ...

Page 12: ...hing agents descalers should comply to BS7593 requirements e g Betz Dearborn Sentinel X100 and Fernox Copal which should be used following the inhibitor manufacturer s instructions Failure to flush and add inhibitor to the system will invalidate the appliance warranty It is important to check the inhibitor concentration after installation system modification and at every service in accordance with...

Page 13: ...to provide sufficient head in order to ensure a minimum system pressure of 0 2 bar 3 A suitable non return valve must be fitted in the pipework between the header tank and heating system 6 5 Expansion Vessel 1 The appliance expansion vessel is pre charged to 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres For greater system capacities an additional expan...

Page 14: ...ns 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 5 In accordance with BS6798 LPG fuelled appliances shall...

Page 15: ...ly 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 3 When the system includes an indirect domestic hot water cylinder it is recommended that a cylin...

Page 16: ...location the entire condensate discharge pipe should be treated as an external run 9 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 10 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soil pipes or was...

Page 17: ...boundary may not be less than 300mm in accordance with the diagram below Terminal Position with Minimum Distance Fig 9 mm Aa Directly below an opening air brick opening windows etc 300 Ba Above an opening air brick opening window etc 300 Ca Horizontally to an opening air brick opening window etc 300 D Below gutters soil pipes or drain pipes 25 E Below eaves 25 F Below balconies or car port roof 25...

Page 18: ...en into consideration Their equivalent lengths are Concentric Pipes 135 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 135 bend 0 25 metres 91 5 bend 0 50 metres The elbow connected to the boiler adaptor 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 Y X This ben...

Page 19: ...s shown The total equivalent length for this example is 6 5 metres 1m extension 45 bend 91 5 bend 1m 0 25m 0 5m 5 2 2 5 0m 0 5m 1 0m AIR DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Air Duct 6 5m 1m extension 45 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 R...

Page 20: ...diameter 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 FLUE GROUP G Concentric Flue System 80 125mm diameter A4 Horizontal Flue Kit 5118580 B Straight Extension Kit 1000mm 511858...

Page 21: ...supplied in the kit One marked 23 one marked 27 and a third unmarked The unmarked one must be used with this 24kW boiler Discard the other two Position the unmarked restrictor as shown below 3 Take one of the gaskets supplied in the kit and place on the boiler top panel 4 Align the restrictor as shown Position the second gasket over the restrictor 5 Using the screws previously removed secure the i...

Page 22: ...T If the boiler is not fitted immediately after the flue system temporary precautions must be taken to prevent rain entry into the room of installation Any precautionary measures must be removed prior to commissioning the boiler 8 7 Flue Dimensions The standard horizontal telescopic flue kit allows for lengths between 100mm and 685mm from elbow to terminal Fig 11 The maximum permissible equivalent...

Page 23: ... reduce or 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 Addit...

Page 24: ...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 that the installation is permissible For example if it was known that 2 metres of concentric flue and 6 metr...

Page 25: ...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 22 and engage the exhaust in the terminal Sl...

Page 26: ...the extension at 30mm as shown in two positions directly opposite each other Fig 27 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 28 it must protrude at least 200mm it is ...

Page 27: ...t 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 32 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 the wall plugs supplied Secure the wall plate using the fixing screws 8 ...

Page 28: ... 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 discharge point IMPORTANT Make al...

Page 29: ...e the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 37 The elbow is fully engaged when there is a distance of 20mm from the adaptor to the indicator line Fig 38 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 39 4 To...

Page 30: ...essary to use soap solution or similar to ease assembly of the elbow adaptor and flue Fig 42 10 Ensure that the terminal is positioned with the slots to the bottom Fig 43 IMPORTANT It is essential that the flue terminal is fitted as shown to ensure correct 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 re...

Page 31: ...tions supplied with the control IMPORTANT The external control MUST be suitable for 230V switching and fused 3A maximum 6 Remove the link between terminals 1 2 The switched output from the external control must be connected to terminal 2 Fig 48 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 chassis ...

Page 32: ...tem to 1 5 bar then close and disconnect the filling loop On semi sealed systems ensure that the gauge is showing at least 0 2 bar 6 Turn the gas supply on and purge the system according to in GB BS 5482 1 and in IE I S 813 Domestic Gas Installations 7 Test for gas soundness 8 Hinge the facia panel upwards and refit the case front panel Tighten the securing screws 9 Turning the temperature control...

Page 33: ... anticlockwise then quickly turn the Calibration Control knob 1 4 clockwise twice and back fully anticlockwise Fig 53 6 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 54 55 7 Turn CH temperature control knob fully clockwise As the knob is turned the display will change from 0 to 00 Fig 58 indicating maximum rate then revert to P alt...

Page 34: ...e relevant to 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 a...

Page 35: ... must be performed see below Carefully check items such as the burner injector and heat exchanger for blockage or damage rectifying as necessary Re check the combustion Once satisfactory readings have been achieved and any other defects corrected complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication Where no suitable analyser...

Page 36: ...or and cover assembly forward being careful to retain the injector in the venturi Figs 63 64 13 Clean any debris from the heat exchanger and check that the gaps between the tubes are clear 14 Inspect the burner electrodes position and insulation cleaning or replacing if necessary Clean any dirt or dust from the air box 15 Reassemble in reverse order NOTE The sensing pipe must be reconnected to the...

Page 37: ...iter Fig 65 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 66 1 Disconnect the electrode leads noting their positions 2 Remove the retaining screws securing each of the electrode...

Page 38: ...or is in place and the sensing pipe is connected to the fan 14 4 Venturi Fig 67 1 Remove the collector and fan assembly as described in section 14 3 2 Extract the injector from the venturi 3 Undo the screws securing the fan to the venturi and the venturi to the collector IMPORTANT When fitting the new venturi ensure the arrows on it s base point into the collector Fig 69 4 Examine the seals and bu...

Page 39: ...n 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 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 t...

Page 40: ...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 73 1 Pull the plug off the thermostat 2 Remove the screws securing the thermostat to the mounting plate on the flow pipe 3 Reassemble in reverse order ensuring that the plug is pushed fully on 14 12 Return Heating Temperature Sensor Fig 75 1 Ease the ...

Page 41: ...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 manifo...

Page 42: ...sher replace if necessary 5 Reassemble in reverse order 14 17 Pressure Relief Valve Fig 81 1 Drain the 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 it and withdraw it from the manifold 4 Fit the new valve and O ring seal and set to the previously noted ori...

Page 43: ...e 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 14 19 Selector Switch Fig 83 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 44: ...cessary 6 Reassemble in reverse order NOTE To assist the boiler to light prior to final setting use a suitable hexagon key to wind out the Gas Air adjustment screw until it is flush with the valve body then turn the screw 4 full turns clockwise Fig 85 If the boiler will not light or the correct CO2 cannot be achieved contact the heateam technical helpline 14 21 Expansion Vessel Fig 86 1 Drain the ...

Page 45: ...e gas valve Remove the plastic cover from the Max Rate adjustment screw At maximum rate the Max Rate adjustment screw should be turned using a suitable hexagon key until the correct reading is obtained Fig 94 Turning clockwise will reduce the CO2 Anti clockwise will increase the CO2 9 The CO2 must then be checked at minimum rate Turn the CH temperature knob fully anticlockwise As the knob is turne...

Page 46: ...n GasValve Overheat Stat Flame Sensing Electrode Pump Flue Sensor X401 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 bk r bk Spark Generator Ignition Electrode 9 10 87 6 5 4 3 2 1 N L w g 1 4 2 5 3 1 2 a b Link bk b g y br Mains Input Cable br b X9 Return Heating Temperature Sensor X400 g g b b Water Pressure Microswitch 9 87 6 5 4 3 2 1 b w 16 1 Illustrated Wiring Diagram ...

Page 47: ...306 Burner 5114697 311 Fan 5121447 315 Igniter Electrode 5114702 316 Sensing Electrode 5114703 415 Pump 248042 419 Water Pressure Switch 5114748 420 Overheat Thermostat 5114729 421 NTC Sensor 5114725 422 Gas Valve 5119647 434 NTC Sensor Return 5114725 503 PCB 5129836 504 Pressure Gauge 248090 306 315 316 311 422 419 415 302 421 420 503 504 434 ...

Page 48: ...For example code E133 will be displayed by E1 alternating with 33 E20 is shown as E then 20 E20 and E28 indicate faulty 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 d...

Page 49: ...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 demand...

Page 50: ...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 51: ...ve PCB X3 connector is 230V AC across terminals 1 2 YES NO NO F Replace PCB G Check and correct if necessary 1 Ignition electrode and lead 2 Electrode connection 3 Spark gap and position YES NO Replace igniter YES Check and correct the connection of the tube between the venturi and gas valve 1 2 4 0 5 10 1 7 5 1 Electrode Position Viewing Window Burner Voltage at PCB X2 connector is at least 100V ...

Page 52: ... Propane LPG should be 37 mbar I Replace safety thermostat YES NO Overheat thermostat operated or faulty i e continuity across thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm J K Fan connections correct at fan PCB X401 connector terminals 5 6 7 8 1 YES Replace fan Temperature sensors faulty Cold resistance approximately 10kΩ 25 C CH sensor 20kΩ 25 C Flue...

Page 53: ...53 19 0 Notes Baxi Heating UK Ltd 2008 ...

Page 54: ... FITTED YES NO WHAT TYPE OF SCALE REDUCER 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...

Page 55: ...ENGINEER NAME COMPANY 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...

Page 56: ...ucts 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 925 736 1 POTTERTON A Trading Division of Baxi Heating UK Ltd 3879156 A Division of Baxi Group Brooks House Coventry Road Warwick CV34 4LL After Sales Service 08706 017 017 Technical Enquiries 08706 049 049 Website www potterto...

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