Potterton Promax System HE Benutzerhandbuch

Installation and

Servicing Instructions

Please leave these instructions with the user

Promax System HE

Wall Mounted Powered Flue Condensing Boiler

Gas Fired Central Heating Unit

Natural Gas

Potterton Promax System HE

G.C.No41 590 69

The boiler meets the requirements of Statutory

Instrument “ The Boiler (Efficiency) Regulations

1993 No3083” and is deemed to meet the

requirements of Directive 92/42/EEC on the energy

efficiency requirements for new hot water boilers

fired with liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by:

Notified Body 0086.

Product/Production certified by:

Notified Body 0086.

For GB/IE only.

Guarantee

Your Potterton Promax System HE is

designed and produced to meet all the

relevant Standards.

Potterton provide a 12 month

guarantee on the boiler. The guarantee

operates from the date installation is

completed for the customer who is the

original user.

To maximise the benefit from our

guarantee we urge you to return the

reply-paid guarantee registration.

This does not in any way prejudice

your rights at Common Law. Such

rights between the customer and the

installer or supplier from whom the unit

was purchased remain intact.

Any component or part which becomes

defective during the guarantee period

as a result of faulty workmanship or

material whilst in normal use will be

repaired or replaced free of charge.

B.S. Codes of Practice

Standard Scope

BS 6891 Gas Installation.

BS 5546 Installation of hot water supplies for

domestic purposes.

BS 5449 Part 1 Forced circulation hot water systems.

BS 6798 Installation of gas fired hot water boilers.

BS 5440 Part 1 Flues.

BS 5440 Part 2 Ventilation.

BS 7074 Expansion vessels and ancillary

equipment for sealed water systems.

BS 7593 Treatment of water in domestic hot water

central heating systems.

IMPORTANT - Care must be

exercised when lifting and handling

this product. Seek assistance where

appropriate and avoid stooping.

Protective equipment (e.g. gloves)

should be worn as necessary.

1.0 Introduction 4

2.0 General Layout 5

3.0 Appliance Operation 6

4.0 Technical Data 7

5.0 Dimensions and Fixings 8

6.0 System Details 9

7.0 Site Requirements 12

8.0 Installation 17

9.0 Electrical 23

10.0 Commissioning the Boiler 25

11.0 Fitting the Outer Case 26

12.0 Servicing the Boiler 27

13.0 Changing Components 29

14.0 Fault Finding 38

15.0 Short Parts List 46

Section Page

Contents

Potterton declare that no substances

harmful to health are contained in the

appliance or used during appliance

manufacture.

NOTE: This appliance must be installed in

accordance with the manufacturer’s

instructions and the regulations in force, and

only used in a suitably ventilated location.

All systems must be thoroughly flushed

and treated with inhibitor (see Section 6.2).

Read the instructions fully before installing or

using the appliance.

1.1 Description

1. The Potterton Promax System HE is a gas

fired room sealed fan assisted condensing

central heating system boiler.

2. The maximum output of the boiler is preset at

75,000 Btu/hr. The boiler will automatically adjust

down to 30,000 Btu/hr according to the system

load. If required, the output can be set to 100,000

Btu/hr. Please refer to section 8.7.

3. It is designed for use on Natural Gas (G20).

4. The boiler is suitable for sealed central heating

and domestic hot water systems.

5. A label giving details of the model, serial

number and Gas Council number is situated on

the rear of the lower door panel (Fig. 1).

6. The boiler data badge is positioned on the air

box door (Fig. 2).

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 the

purpose designed flues such as the standard

horizontal flue kit, part no236921.

1.2 Optional Extras

KIT PART No

FLUE EXTENSION KITS (110/70)

Flue Extension 0.25M 241692

Flue Extension 0.5M 241694

Flue Extension 1M (Use two kits for 2M etc.) 241695

Flue Bend x 2 - 45°(Reduce overall length of flue

by 0.5m when fitting this bend) 241689

Flue Bend - 90°(Reduce overall length of flue

by 1m when fitting each bend) 241687

VERTICAL FLUE (110/70)

Vertical Flue Terminal 242802

Vertical Boiler Connection 242886

VERTICAL FLUE (80/80)

Kit Boiler Connection Twin 242757

1.0 Introduction

Fig. 1

Data Badge

Air Box Door

Lower Door Panel

Fig. 2

“Benchmark” Log Book

As part of the industry-wide “Benchmark”initiative all Potterton boilers now

include an Installation, Commissioning and Service Record Log Book.

Please read the Log Book carefully and complete all sections relevant to

the appliance and installation. These include sections on the type of

controls employed, flushing the system, burner operating pressure etc.

The details of the Log Book will be required in the event of any warranty

work. Also, there is a section to be completed at each subsequent regular

service visit.

2.0 General Layout

2.1 Layout (Figs. 3,4 & 5)

1. Wall Plate

2. Flue Elbow

3. Heat Exchanger

4. Burner

5. Air Box

6. Fan Protection Thermostat

7. Fan Assembly

8. Condensate Trap

9. Gas Tap

10. Gas / Air Ratio Valve

11. Electronics Housing

12. Transformer

13. Flow Temperature Safety Thermostat - Black

14. Flow Temperature Thermistor - Red

15. Flow Switch (dry fire protection)

16. Circulation Pump

17. Automatic Air Vent

18. Pressure Relief Valve

19. Water Pressure Gauge

20. Expansion Vessel

11 12

13/14

Fig. 4

Fig. 3

Fig. 5

Fig. 6

3.0 Appliance Operation

3.1

1. Switched Live On: When the switched live

switches on pump overrun occurs.

2. Pump Overrun: The pump is on while the fan,

spark generator and gas valve are off. If at any

stage during pump overrun the flow temperature

is less than the set point and the flow switch is

made then fan purge occurs. After 1 minute of

pump overrun anti-cycle occurs.

3. Fan Purge: The pump and fan are on while

the spark generator and gas valve are off. After 5

seconds ignition occurs.

4. Ignition: The pump, fan, spark generator and

gas valve are on. If a flame is detected then

burner on occurs. If a flame is not detected within

5 seconds and less than 5 ignition attempts have

been made then fan purge occurs. If a flame is

not detected within 5 seconds and 5 ignition

attempts have been made the ignition lockout

occurs.

5. Burner On: The pump, fan and gas valve are

on while the spark generator is off. Flow

temperature is controlled by varying the fan

speed (and thereby the gas rate) to achieve

optimum operation. If the flow temperature is

greater than the set point then pump overrun

occurs. If the TRVs all shut down then anti-cycle

occurs.

6. Anti-cycle: The pump, fan, spark generator

and gas valve are switched off. After 3 minutes

pump overrun occurs.

7. Ignition Lockout: The pump, fan, spark

generator and gas valve are switched off. The

boiler can only be reset by manually using the

thermostat knob.

Mains On.

Flow

temperature less

than set point and flow

switch made ?

YES

5 second

Fan Purge.

Flame Detected ?

Burner On. Ignition

Lockout.

5 second

Ignition Period.

All TRVs

shut down ?

Flow temperature

greater than set

point ?

Ignition done and

5 attempts made ?

Ignition done

and less than 5

attempts made ?

Pump Overrun

Anti-cycle.

Pump Overrun

for 1 minute ?

YES

Appliance Category CAT I 2H

4.0 Technical Data

Horizontal

Flue Terminal Diameter 110mm

Dimensions Projection 150mm

Outercase Dimensions

Overall Height Inc Flue Elbow - 1000mm

Casing Height - 850mm

Casing Width - 490mm

Casing Depth - 325mm

Weights kg lb

Packaged Boiler Carton 54.7 120.6

Packaged Flue Kit 3.6 8.0

Weight Empty 49.4 108.9

Installation Lift Weight 41 90.4

Connections copper tails

Gas Supply - 22mm

Central Heating Flow - 22mm

Central Heating Return - 22mm

Pressure Relief Discharge - 15mm

Condensate Drain - 1 in BSP

Recommended System

Temperature Drop

Normal 11°C20°F

Condensing 20°C36°F

Heat Input Max Min

kW 33.76 10.2

Btu/h 115,200 34,840

Heat Output

(Non Condensing 70°C Mean Water Temp)

Max Min

kW 30.18 9.14

Btu/h 102,980 31,180

Electrical Supply 230V~ 50Hz

(Appliance must be connected to an

earthed supply)

Power Consumption 200W

External Fuse Rating 3A

Internal Fuse Rating (BS 4265)

Fuse (2) 4 AT (Control Board)

Fuse (3) 2 AT (Ignition Board)

Inlet Pressure (Natural Gas)

Min 18.1 mbar

Max 22.5 mbar

(see Section 10.1)

Injector (Natural Gas)

6.3mm Diameter

Clearances

(For unventilated compartments see Section 7.5)

Both Sides 5mm Min

Above Casing 200mm Min

Below Casing 200mm Min

Front (For Servicing) 500mm Min

Front (In Operation) 5mm Min

Appliance Type C13 C33

Nox Class 5

Heat Output

(Condensing 40°C Mean Water Temp)

Max Min

kW 32.61 10.1

Btu/h 111,280 34,520

Water Content

litres 3.5

pints 6.2

Controls

boiler thermostat, safety thermostat,

flow switch, electronic flame sensing,

temperature protection thermostat &

condensate blockage sensor.

Central Heating Primary

Circuit Pressures

bar lb/in2

Safety Discharge 3 43.5

Max Operating 2.5 36.3

Min Operating 1 10.9

Recommend Operating 1-2 14.5-29

Expansion Vessel - (For Central Heating

only. Integral with appliance)

bar lb/in2

Min Pre-charge Pressure 0.95 13.6

Nominal Pre-charge

Pressure 1 14.5

litre gal

Max Capacity of

CH System 125 27.5

120 240 360 480

100

200

300

400

500

600

Pump Head (mbar)

Flow Rate (l/h)

Central Heating Circuit available Pump Head

0 600 720 840

Where flow rates are required in excess of 840 l/h, please refer to page 21.

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been

certified by 0086.

SEDBUK Declaration For

Potterton Promax System HE

The seasonal efficiency (SEDBUK) is 90.9 %

Max Gas Rate (Natural Gas)

(After 10 Mins)

Btu/hr 102,980 75,000

m3/h 2.95 2.36

ft3/h 104.2 83.3

NOTE: The maximum output of the

boiler is factory set at 22.0kW

(75,000 Btu/hr). This can be altered

to 30.18kW (102,980 Btu/hr)

- see section 8.7.

5.0 Dimensions and Fixings

DIMENSIONS

A850mm

B325mm

C490mm

D125mm ØMin.

E150mm

F125mm

SIDE FLUE (left and right)

For every 1m of horizontal flue

length, the clearance above the

top of the flue elbow should be

55mm to incorporate the 3°

(1 in 20) fall in the flue from the

terminal to the elbow.

The 3°(1 in 20) fall provided by

the elbow is to allow condensate

to run back to the boiler, for

disposal through the condensate

discharge pipe.

Flue length (Y)

up to 1m

1m - 2m

2m - 3m

Clearance (X)

55mm

110mm

165mm

360°Orientation

Tube Ø110mm

3°

(1 in 20)

3°

(1 in 20)

Fig. 7

Fig. 8

6.0 System Details

6.1 Water Circulating Systems

1. The appliance is suitable for fully pumped

sealed systems only.

The following conditions should be observed

on all systems:

•The boiler must not be used with a direct

cylinder.

•Drain cocks should be fitted to all system low

points.

•All gas and water pipes and electrical wiring

must be installed in a way which would not

restrict the servicing of the boiler.

•Air vents should be fitted to all system high

points.

•Best practice recommends that an appropriate

size air separator is fitted, to expel the air from

the system. This will reduce corrosion potential

and maximise the efficiency within the system.

6.2 Treatment of Water Circulating

Systems

•All recirculatory water systems will be subject to

corrosion unless an appropriate water treatment

is applied. This means that the efficiency of

the system will deteriorate as corrosion sludge

accumulates within the system, risking damage

to pump and valves, boiler noise and circulation

problems.

•When upgrading existing systems that exhibit

evidence of sludging, it is advisable to clean the

system prior to treatment in order to remove any

sludge and reduce the likelihood of these

deposits damaging new components.

•When fitting new systems flux will be evident

within the system, which can lead to damage of

system components.

•All systems must be thoroughly drained and

flushed out. The recommended flushing and

cleansing agents are Betz-Dearborn Sentinel

X300 or X400 and Fernox Superfloc Universal

Cleanser which should be used following the

flushing agent manufacturer’s instructions.

•System additives - corrosion inhibitors and

flushing agents/descalers should be suitable for

aluminium and comply to BS7593 requirements.

The only system additives recommended are

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 the manufacturer’s instructions. (Test kits are

available from inhibitor stockists.)

•For information or advice regarding any of the

above contact the Potterton Helpline.

Boiler

Hot water

Central

heating

load

Live feed

to pump

Switch live from

programmer, etc.

S/L N P/F

Fig. A Wiring an extra pump to the pump feed

connection of boiler

Boiler

Connections

6.0 System Details

6.3 Pipework

1. The sizes of flow and return pipes from the

boiler should be determined by normal methods,

according to the requirements of the system. The

connection to the boiler is 22mm (copper tail).

2. Due to space requirements at the rear of the tap

bracket, pipework should comprise of solder

fittings.

3. A 20 °C (36°F) drop in temperature across the

system is recommended for condensing boilers.

Existing radiators may be oversized and so allow

this, but where radiator sizing is marginal it may be

advisable to retain a system temperature drop of

11°C (20°F).

4. In systems using non-metallic pipework it is

necessary to use copper pipe for the boiler Flow

and Return. The copper must extend at least 1

metre from the boiler and include any branches

(Fig. 8a).

6.4 System Controls

1. For optimum operating conditions, the heating

system into which the boiler is installed should

include a control system.

2. Such a system will comprise of a timer control

and separate room or cylinder thermostats as

appropriate.

3. The boiler should be controlled so that it

operates on demand only.

4. Operation of the system under control of the

boiler thermostat & TRV’s only does not produce

the best results.

6.5 Thermal Stores

1. When the Potterton Promax System HE is fitted

in conjunction with a thermal store, jumper 2 must

be removed from the Control PCB, see Fig. 32a

Section 8.7.

Boiler

Flow

Return

Copper

0.5m

Copper

0.5m

Fig. 8a

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