Baxi Potterton G.C.No 47 393 21 manual

© Baxi Heating UK Ltd 2011 Installation & Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. Promax Combi HE Plus A Range Condensing Combination Boiler You can rely on[...]

2 © Baxi Heating UK Ltd 2011 Natural Gas Potterton Promax Combi 24 HE Plus A G.C.N o 47 393 21 Potterton Promax Combi 28 HE Plus A G.C.N o 47 393 22 Potterton Promax Combi 33 HE Plus A G.C.N o 47 393 23 Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation[...]

3 Installer Notification Guidelines © Baxi Heating UK Ltd 2011 Choose Building Regulations Notification Route Contact your rele v ant Local A uthor ity Building Control (LABC) who will arrange an inspection or contact a gov er nment approv ed inspector LABC will record the data and will issue a cer tificate of compliance ‘Gas Safe Register’ wi[...]

4 Legislation © Baxi Heating UK Ltd 2011 Codes of Practice - refer to the most recent version IMPORTANT - Installation, Commissioning, Service & Repair This appliance must be installed in accordance with the manufacturer’s instructions and the regulations in force. Read the instructions fully before installing or using the appliance. In GB, [...]

5 Safe Manual Handling © Baxi Heating UK Ltd 2011 General The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance. Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable , particularly sho[...]

6 © Baxi Heating UK Ltd 2011 CONTENTS 1.0 Introduction 7 2.0 General Layout 8 3.0 Appliance Operation 9 4.0 Technical Data 10 5.0 Dimensions and Fixings 11 6.0 System Details 12 7.0 Site Requirements 15 8.0 Flue Options 19 9.0 Plume Displacement 24 10.0 Installation 28 11.0 Commissioning 33 12.0 Completion 35 13.0 Servicing 36 14.0 Changing Compon[...]

7 1.0 Intr oduction © Baxi Heating UK Ltd 2011 1.1 Description 1. The Potterton Promax Combi HE Plus A is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water. 2. The boiler is set to give a maximum output of :- 24 models - 24 kW [...]

8 2.0 General La yout © Baxi Heating UK Ltd 2011 2.1 Layout 1. Expansion Vessel 2. Automatic Air Vent 3. DHW Plate Heat Exchanger / Automatic Bypass 4. Circulation Pump 5. Drain Off Point 6. Pressure Relief Valve 7. Optional Integral Timer Position 8. Central Heating System Pressure Gauge 9. PCB 10. Control Box 11. 3-Way Valve Assembly 12. Condens[...]

9 3.0 Appliance Operation © Baxi Heating UK Ltd 2011 3.1 Central Heating Mode (Fig. 2) 1. With a demand for heating, the pump circulates water through the primary circuit. 2. Once main burner ignites the fan speed controls the gas rate to maintain the heating temperature measured by the temperature sensor. 3. When the flow temperature exceeds the [...]

10 4.0 T echnical Data © Baxi Heating UK Ltd 2011 4.1 Promax Combi 24, 28 & 33 Flue Terminal Diameter 100mm Dimensions Projection 125mm Outercase Dimensions Casing Height - 780mm Overall Height Inc Flue Elbow - 965mm Casing Width - 450mm Casing Depth - 345mm Central Heating Primary Circuit Pressures bar Safety Discharge 3 Max Operating 2.5 Min[...]

11 5.0 Dimensions and Fixings © Baxi Heating UK Ltd 2011 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 Domestic Hot W ater Outlet (15mm) Cold W ater Inlet (15mm) Heating Return (22mm) Heating Flow (22mm) Pressur e Relief V alve (15mm) Gas Inlet (22mm) 65 mm 65 mm 65 mm 65 mm 65[...]

12 6.0 System Details © Baxi Heating UK Ltd 2011 6.1 Information 1. The Promax Combi Condensing Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 - See text of entry for installation requirements and [...]

13 6.0 System Details © Baxi Heating UK Ltd 2011 6.5 System Filling and Pressurising (Fig. 4) 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. 2. There are connection points on the mains cold water inlet and[...]

14 6.0 System Details © Baxi Heating UK Ltd 2011 6.8 Domestic Hot Water Circuit (Fig. 7) 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and water supply regulations. 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. for IE[...]

15 7.0 Site Requirements © Baxi Heating UK Ltd 2011 7.1 Location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply. The boiler should be fitted within the build[...]

16 7.0 Site Requirement © Baxi Heating UK Ltd 2011 7.3 Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. BS 5440: Part 2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation. 7.4 Gas Supply 1. The gas instal[...]

17 7.0 Site Requirements © Baxi Heating UK Ltd 2011 7.7 Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5° (50mm per metre) along the entire run. 1. The cond[...]

18 © Baxi Heating UK Ltd 2011 7.0 Site Requirements 7.8 Flue NOTE: Due to the nature of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. 1. The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendations are gi[...]

19 © Baxi Heating UK Ltd 2011 8.0 Flue Options Horizontal Flues (ii) (i) Plume Displacement Kit 60 /100 Ø 1M Extensions, 45° & 93° bends are also available - see Section 9.0 (ii) (i) This bend is equivalent to 1 metre Total equivalent length = A+B+C+2x90°Bends B A C This bend is equivalent to 1 metre 8.1 Horizontal Flue Systems 1. The stan[...]

20 © Baxi Heating UK Ltd 2011 8.0 Flue Options Vertical Flues (ii) (i) The total equivalent length for this example is = 6.5 metres. 1m extension 135°bend 91.5°bend 1m 0.25m 0.5m 5 2 2 5.0m 0.5m 1.0m AIR DUCT N o of fittings/pipes Sub total Equivalent Length Value Equivalent Length Air Duct = 6.5m 1m extension 135°bend 91.5°bend 1m 0.25m 0.5m [...]

21 © Baxi Heating UK Ltd 2011 8.0 Flue Options B K,K1 R D C N U,W S L H M E G F P Key Accessory Size Code No FLUE GROUP A Concentric Flue System 100mm diameter A Horizontal Flue Terminal (inc. elbow) 5118489 A2 Telescopic Flue (inc. elbow) 315-500mm 5118069 A3 Telescopic Internal Flue Kit 315-500mm 5119654 B Flue Extension 1000mm 5111074 C Flue Be[...]

22 © Baxi Heating UK Ltd 2011 8.0 Flue Options 8.4 Twin Flue Duct Adaptor 1. The kit allows connection of a twin flue system to the boiler adaptor. 8.5 Twin Flue Connection 1. Engage the twin flue duct adaptor in the boiler adaptor, making sure that it is pushed down as far as possible. 2. Ensure that the air & flue ducts are connected correct[...]

23 © Baxi Heating UK Ltd 2011 8.0 Flue Options Fig. 19 Fig. 21 100mm 685mm Push Fit Adaptor Air Duct Flue Duct Cut the same amount off the Air Duct & Flue Duct Approx 1425mm 8.6 For Roof Terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make an aperture in the roof su[...]

24 9.0 Plume Displacement © Baxi Heating UK Ltd 2011 9 .1 Plume Displacement Kit (Fig. 23) Kit No 5118638 Content of kit 1 0.9m 60/100 Concentric Flue 1 1m 60 Dia Exhaust Flue Pipe 1 Adaptor 2 60 Dia Support Brackets 1 93° Elbow/Plume Outlet Assembly 1 Flexible Flue Trim 3 “O” Rings 1 ‘Jubilee Clip 1 Boiler Elbow 1. This kit is recommended [...]

25 9.0 Plume Displacement © Baxi Heating UK Ltd 2011 Concentric 60/100 Flue 60Ø Exhaust X Y Fig. 26 2 0 2 4 6 8 10 12 14 60 Ø Exhaust (metres) X Concentric 60/100 Flue (metres) Y 0 16 1 34 6 57 9 8 24 28/33 Fig. 27 2 0 2 4 6 8 10 12 14 60 Ø Exhaust (metres) X Concentric 60/100 Flue (metres) Y 0 16 1 34 6 57 9 8 24 28/33 2 0 2 4 6 8 10 12 14 60 [...]

26 © Baxi Heating UK Ltd 2011 9.0 Plume Displacement Min. 2 metres Fig. 28 50mm Flue Trim Position of ‘Jubilee’ Clip screw Fig. 33 30mm 30mm Fig. 30 Fig. 32 Fig. 29 Fig. 31 Adaptor Spigot 9.3 General Fitting Notes 1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall bac[...]

27 9.0 Plume Displacement © Baxi Heating UK Ltd 2011 9.3 General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air. 16. It is also possible to separate the plume outlet from the 93° elbow to allow the flue to be installed as s[...]

28 10.0 Installation © Baxi Heating UK Ltd 2011 Fig. 42 145mm For Side Flue Exit Central Heating Return Flushing Tube Wall Plate Fig. 41 10.1 Unpacking & Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). NOTE: a small amount of water may drain from the boiler in the u[...]

29 10.0 Installation © Baxi Heating UK Ltd 2011 10.3 Fitting The Boiler 1. Lift the boiler using the Lifting Points as shown by the shaded areas (Fig. 43). The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate(see Safe Manual Handling page 5). 2. Pull the lower polystyrene cap off the boiler (w[...]

30 10.0 Installation © Baxi Heating UK Ltd 2011 10.6 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 45). 2. Locate the flue elbow on the adaptor at the top of the boiler. Se[...]

31 10.0 Installation © Baxi Heating UK Ltd 2011 10.6 Fitting the Flue (Cont) 6. The inner flue duct support bracket may be in the waste portion of the flue. In this case retrieve the bracket before discarding the waste. 7. Take the inner flue support bracket (if not already fitted) and engage it over the flue duct. This will centralise the flue an[...]

32 10.0 Installation © Baxi Heating UK Ltd 2011 Fig. 56 Fig. 55 Cable Clamp Facia Panel Terminal Block Cover 10.7 Making The Electrical Connections The boiler is fitted with a 1.3m length of 3 core cable. This can be connected to the fused 3A 230V 50H Z supply. NOTE: Both the Live and Neutral connections are fused. To connect an external control p[...]

33 11.0 Commissioning © Baxi Heating UK Ltd 2011 11.1 Commissioning the Boiler 1. Reference should be made to BS:EN 12828 & 14336 when commissioning the boiler. 2. At the time of commissioning, complete all relevant sections of the Benchmark Checklist at the rear of this publications. 3. Open the mains water supply to the boiler. 4. Open all h[...]

34 11.0 Commissioning © Baxi Heating UK Ltd 2011 11.2 Check the Operational (Working) Gas Inlet Pressure 1. Ensure that all controls are calling for heat, and the selector switch is in the central heating and hot water position ( ). The current boiler temperature is shown on the display. 2. It is necessary to set the boiler to ‘Calibration Mode?[...]

35 12.0 Completion © Baxi Heating UK Ltd 2011 12.1 Completion 1. Instruct the user in the operation of the boiler and system explaining the operational sequence. 2. Set the central heating and hot water temperature control knobs to the requirements of the user. 3. Carefully read and complete all sections of the Benchmark Commissioning Checklist at[...]

36 13.0 Ser vicing © Baxi Heating UK Ltd 2011 Case Front Panel Fig. 69 Facia Panel Securing Screws Fig. 70 Inner Door Panel Fig. 71 Sump 13 .1 Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person in accordance with B.S. 7967-4. 2. After serv[...]

37 13.0 Ser vicing © Baxi Heating UK Ltd 2011 13.2 Annual Servicing - Inspection (Cont) 6. Undo the nut on the gas inlet pipe to the venturi (Fig. 73) and pull the sensing pipe off the fan. 7. Disconnect the electrode leads, noting their position, and the fan electrical plugs. 8. Undo the four nuts retaining the combustion box cover to the heat ex[...]

38 14.0 Changing Components © Baxi Heating UK Ltd 2011 IMPORTANT: When changing components ensure that both the gas and electrical supplies to the boiler are isolated before any work is started. When the component has been changed turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds [...]

39 14.0 Changing Components © Baxi Heating UK Ltd 2011 Cover Gas Inlet Fan Venturi Injector Collector Burner Gasket When fitting the venturi ensure that the arrow is pointing forward Fig. 78 Fig. 79 Gas Inlet Pipe Venturi Injector Fig. 80 14.3 Fan (Fig. 79) 1. Undo the nut on the gas inlet pipe to the venturi (Fig. 79) and pull the sensing pipe of[...]

40 14.0 Changing Components © Baxi Heating UK Ltd 2011 Fig. 81 Cover Burner Gasket Extension Piece (On 28 models only) Collector Venturi Heat Exchanger Rear Insulation Cover Insulation Seal Collector Spark Electrode Sensing Electrode Electrode Leads Venturi Fig. 82 14.6 Burner (Fig. 81) 1. Undo the screws securing the collector to the cover and ve[...]

41 14.0 Changing Components © Baxi Heating UK Ltd 2011 Central Heating Temperature Sensor Safety Thermostat Flow Pipe Fig. 84 DHW Temperature Sensor Fig. 85 Plate Heat Exchanger Pressure Sensor Flue/Heat Exchanger Thermostat Sensor Electrical Plug Fig. 83 14.8 Flue/Heat Exchanger Thermostat Sensor (Fig. 83) 1. Ease the retaining tab on the sensor [...]

42 14.0 Changing Components © Baxi Heating UK Ltd 2011 14.14 Pump - Head Only (Fig. 87) 1. Drain the boiler primary circuit and remove the socket head screws securing the pump head to the body and draw the head away. 2. Undo the screw on the pump wiring cover and remove the cover. Using a suitable flat bladed screw driver press the cable securing [...]

43 14.0 Changing Components © Baxi Heating UK Ltd 2011 14.17 Pressure Gauge (Figs. 90 & 91) 1. Drain the boiler primary circuit and undo the nut on the pressure gauge capillary. 2. Undo the screws securing the gauge retaining bracket. 3. Remove the bracket and gauge assembly. Depress the barbs on the side of the gauge and remove the retaining [...]

44 14.0 Changing Components © Baxi Heating UK Ltd 2011 14.20 Plate Heat Exchanger (Fig. 94) 1. Drain the boiler primary circuit and remove the gas valve as described in section 14.24. 2. While supporting the heat exchanger undo the screws securing it to the brass manifolds. 3. Withdraw the heat exchanger upwards, taking care not to damage any wire[...]

45 14.0 Changing Components © Baxi Heating UK Ltd 2011 14.22 P.C.B. (Fig. 98) 1. Note the settings of the temperature control knobs, rotate them fully anticlockwise and carefully pull them off the drive pins. 2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots. Disengage the rear of t[...]

46 14.0 Changing Components © Baxi Heating UK Ltd 2011 14.24 Gas Valve (Fig. 99) IMPORTANT: After replacing the valve the CO 2 must be checked and adjusted as detailed in Section 15.0 Setting the Gas Valve. Only change the valve if a suitable calibrated combustion analyser is available, operated by a competent person - see section 13.1. 1. Turn th[...]

47 15.0 Setting the Gas V alve © Baxi Heating UK Ltd 2011 Selector Switch Display Reset bar 0 1 2 3 4 Central Heating Temperature Control Domestic Hot Water Temperature Control Fig. 103 Fig. 104 Fig. 105 Fig. 106 Fig. 107 Central Heating Temperature Control Domestic Hot Water Temperature Control Fig. 102 x 2 Fig. 108 Throttle Adjustment Screw (cov[...]

48 16.0 Electrical © Baxi Heating UK Ltd 2011 16.1 Illustrated Wiring Diagram - bro wn - black - blue - white br bk b w - green - green / y ellow - red g g/y r Control PCB X2 X3 X9 X501 12 12 3 3 4 4 5 5 678 9 X1 12 DHW NTC Sensor Central Heating NTC Sensor Fan Gas V alve Overheat Stat Flame Sensing Electrode Pump Flue Sensor X400 X401 g g b b r r[...]

49 17.0 Short Par ts List © Baxi Heating UK Ltd 2011 Short Parts List Key G.C. Description Manufacturers No. No. Part No. 311 Fan 5121447 426 Motor 3way Valve 5132452 315 Igniter Electrode 720222801 316 Sensing Electrode 720222901 422 Gas Valve 720301001 404 Hall Effect Sensor 5114767 306 Burner 24 5122149 Burner 28 5122149 Burner 33 5114697 419 W[...]

50 18.0 Fault Finding © Baxi Heating UK Ltd 2011 NOTE: When instructed to turn the selector to the reset position turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 5 seconds to reset the boiler. 18.1 Initial Fault Finding Checks 1. Check that gas, water and electrical supplies are available[...]

51 18.0 Fault Finding © Baxi Heating UK Ltd 2011 Refer to Section 16.0 “Illustrated Wiring Diagram” for position of terminals and components Central Heating - Follow operational sequence Turn selector switch to The display illuminates Error 20, 28 or 50 flashing Error 119 flashing Burner lights Error 110 flashing Error 130 flashing Error 133 f[...]

52 18.0 Fault Finding © Baxi Heating UK Ltd 2011 Turn selector switch to The display illuminates Error 20, 28 or 50 flashing Error 119 flashing Burner lights Error 110 flashing Error 133 flashing Turn Domestic Hot Water thermostat to Maximum. Open DHW tap fully. DHW Hall Effect sensor operated (red neon on the sensor illuminated Fan runs Spark at [...]

53 18.0 Fault Finding © Baxi Heating UK Ltd 2011 Fault Finding Solutions Sections Is there 230V at: Is there 230V at: Main terminals L and N Check electrical supply 1. NO Main terminal fuse Replace fuse Replace PCB Display illuminated 2. NO PCB - X1 connector terminals 1,2 Check wiring 3. NO NO A Pump Replace pump 1. YES PCB - X3 connector termina[...]

54 18.0 Fault Finding © Baxi Heating UK Ltd 2011 E20 or E50 - Temperature sensors faulty. Cold resistance approximately 10k Ω @ 25° C (DHW and CH sensors) 20k Ω @ 25° C (Flue sensor) (resistance reduces with increase in temp.) E28 - Incorrect PCB fitted NO E Replace sensor or PCB (E28) Gas at burner Ensure gas is on and purged Replace PCB Repl[...]

55 © Baxi Heating UK Ltd 2011 18.0 Fault Finding Check and correct if necessary 1. The mechanical set of the gas valve (CO2 values - see instruction) 2. Flame sensing electrode and lead connections 3. Flame sensing electrode position Flame current should be more than 0.5 μ A Replace PCB Replace PCB YES YES Replace flame sensing electrode NO I K R[...]

56 19.0 Notes © Baxi Heating UK Ltd 2011[...]

57 © Baxi Heating UK Ltd 2011 19.0 Notes[...]

Failure to install and commission accor ding to the manufacturer’ s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty . This does not affect the customer’ s statutory rights. If yes, and if required by the manufactur er , has a water scale reducer been fitted? CONDENSING BOILERS ONL Y The condensate [...]

Service Record It is recommended that your heating system is serviced r egularly and that the appropriate Service Interval Record is completed. Service Provider Before completing the appr opriate Service Record below , please ensure you have carried out the service as described in the manufacturer’ s instructions. Always use the manufacturer’ s[...]

© Baxi Heating UK Ltd 2011 UK Comp N o 5114444 - Iss 15 - 6/11 All descriptions and illustrations 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 Cond[...]