Potterton PROMAX 24 Installation And Service Manual Download

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Promax Store

Installation and Service Manual

Condensing Boiler with Integrated Hot Water Storage

United Kingdom

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

Summary of Contents for PROMAX 24

Page 1: ...nstallation and Service Manual Condensing Boiler with Integrated Hot Water Storage 24 en United Kingdom These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping ...

Page 2: ...ion 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 commissioning checklist is completed by the installer The relevant section of Building Regulations only relat...

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: ... C No 90 Litres 41 592 47 115 Litres 41 592 48 150 Litres 41 592 49 Important Refer to Page 11 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 an...

Page 5: ...nel 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 Fig ...

Page 6: ...ss 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 room thermostat Dedicated connectors on user terminal block Built in frost protection Boiler protected below 5 C Optional Immersion Heater Heatrae Mega 3 kW at 240V Advantica Approved Electricity supply 23...

Page 7: ...y consumption QHE 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 boiler...

Page 8: ...n 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 1...

Page 9: ...tted 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 The selected temperature is user adjustable in the range 45 to 65 C To suit conventional radiator based central heating systems the boiler will norm...

Page 10: ...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 ins...

Page 11: ...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 6891 In...

Page 12: ...uts 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 Ventilatio...

Page 13: ...erminal 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 terminal and obstructions a...

Page 14: ...ume 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 ai...

Page 15: ...ot included in any equivalent length calculations 4 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 Horizontal Flues Y X Plume Displacement Kit 60 100 Ø 1M Extensions 45 93 bends are also ava...

Page 16: ...hown or up to 45 either way from vertical Secure the deflector to the terminal with screws provided Flue Accessories Fig 5d 1 For full details of Flue Accessories elbows extensions clamps etc refer to the Flue Installation Guide supplied in the literature pack Flue Deflector Fig 5b Ensure that no part of the white outer chimney duct is visible Baxi Heating UK Ltd 2011 G U I D A N C E N OT E S Flue...

Page 17: ...ade 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 performance 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 a...

Page 18: ... 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 should be at ...

Page 19: ... for 4 No 22 mm elbows at 0 8m each 3 2 m Therefore the permitted length equates to 5 8 m 5 8 m is less than the actual length of 7 m therefore calculate the next largest size Maximum resistance allowed for a straight length of 28 mm pipe D2 from a G1 2 temperature relief valves equates to 18 m Subtract the resistance of 4 No 28 mm elbows at 1 0 m each 4 0 m Therefore the maximum permitted length ...

Page 20: ...ard 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 Remove cardboard pipework support Attach the 15mm x 90 branch pipe joining the two relief valves tundish 5 Remove the DHW temperature sensor from the boiler fitting kit and uncoil it 6 Drop down the b...

Page 21: ...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 22: ...eally 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 freezing NOTE Connection...

Page 23: ... 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 24: ...nder 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 6 Connect the Power Supp...

Page 25: ...g 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 selector...

Page 26: ... 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 secured by tightening the gla...

Page 27: ...rsion heater before removing the cover Open the cover to the immersion heater housing and disconnect wiring from immersion heater Carefully remove the thermostat capillaries Remove the terminal shroud Unscrew immersion heater backnut and remove immersion heater from the unit A key spanner is supplied with the cylinder unit for easy removal tightening of the immersion heater Over time the immersion...

Page 28: ...e 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 clea...

Page 29: ...es 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 29 Baxi Heating UK Ltd 2015 ...

Page 30: ...tore 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 position ...

Page 31: ... external controls are calling for heat The actual current boiler temperature is shown on the display 6 Turn both control knobs fully anticlockwise then quickly turn the right hand knob 1 4 clockwise twice and back fully anticlockwise 7 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash 8 To set to maximum rate Turn the left hand knob fully ...

Page 32: ...eplace any seals that appear unsound Is CO 350ppm and CO CO2 ratio 0 004 TURN APPLIANCE OFF Call 0344 871 1525 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 maximum minimum...

Page 33: ...e cap on the auto air vent above the pump partially unscrewed so that the vent remains operational note that the burner control goes to safety shut down if the system pressure drops 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 balanc...

Page 34: ...th 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 the ...

Page 35: ...l 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 from the boiler 3 Remove the sc...

Page 36: ...rews securing the pump head to the body and draw the head away 3 Reassemble in reverse order 4 3b Pump Complete 1 Drain the primary circuit and disconnect the electrical plug from the pump motor 2 Undo the two screws securing the body to the pipe and manifold and draw the pump forwards 3 Unscrew the automatic air vent from the pump body 4 Examine the O ring seals on the return pipe and manifold re...

Page 37: ...e 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 Relief Valve Assembly By pass V...

Page 38: ...sher 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 behind ...

Page 39: ...ng 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 the thermostat Polarity of ...

Page 40: ...he 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 Insulation ...

Page 41: ...ain 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 from its mounting See Commissio...

Page 42: ...vious 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 th...

Page 43: ...ould 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 bladed screwdriver inserted into ...

Page 44: ...e 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 anti...

Page 45: ...ssure Switch Flue Thermistor Overheat Thermostat X900 X501 X300 X400 X401 X500 X1 X2 X3 X9 M 1 1 3 2 4 5 Ignition Electrode br b b b b b b b b g g b r r g bk bk o o w b br b g w br b br br b b bk br N E L o o o b r br b br b br b br b br r Wiring Colour Key b blue r red bk black g green w white o orange br brown 6 Way Connector g y Wiring Functional Flow Diagram 45 Baxi Heating UK Ltd 2015 br w ...

Page 46: ...lame Sensing Electrode Pump Mains Input Link g y b br FlueThermistor X400 X401 br w b b r r b b b b b br bk g b br g y b br br b b br 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 DiverterValve 1 2 3 4 N L w g 1 4 2 5 3 1 2 a b r br o o b b w Timer 6 3 g g g y X1 X2 X3 b br b br b br Pump PCB 6 Way Connector b b...

Page 47: ...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 If within 15 seconds of the...

Page 48: ...fter 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 Err...

Page 49: ...ter 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 switch to the reset position f...

Page 50: ...nt 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 NO Replace water pressure switch Check connection water pressure switch terminal COM NO and PCB connector X400 terminals 3 4 YES 50 Baxi Heating UK Ltd 2015 Is there 230V at X3 Connection Pump PCB 1 NO YES B Check incoming wiring X2 Connectio...

Page 51: ...cross 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 and gas valve 1 2 5 5 8 5 13...

Page 52: ...rmostat 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 sensors ...

Page 53: ...e 720301001 410 Burner 5114697 535 Water Pressure Switch 5114748 520 Pump 7220533 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 A Pump PCB 7222704 410 441 442 490 480 535 520 402 531 530 205 235 215 231 220 53 Baxi Heating UK Ltd 2015 A ...

Page 54: ...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 55: ...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 56: ...erms 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 carefully ...

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