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Promax system installation and servicing manual

1. 1 2 2 3 4 5 L 2 3 4 5 6 7 8 Pump xI xa x3 gLIgLIeLIe o PCB l r NN br br ewe BE EN LO j Ignition Electrode Mains Input Cable Baxi Heating UK Ltd 2015 43 16 0 Short Parts List Short Parts List Key Description Manufacturers No Part No 302 Flue Thermostat 5114747 306 Burner 12 15 18 24 5122149 Burner 32 5114698 311 Fan 5121447 315 gniter Electrode 720222801 316 Sensing Electrode 720222901 415 Pump 7222703 419 Water Pressure Switch 5114748 420 Overheat Thermostat 5114729 421 NTC Sensor 5114725 422 Gas Valve 720301001 419 434 NTC Sensor Return 5114726 A 503 Yy A PCB 12 5122455 LR D eS PCB 15 5122457 S PCB 18 5122458 PCB 24 720045201 PCB 32 5122459 504 Pressure Gauge 248090 517 Pump PCB 7222704 44 Baxi Heating UK Ltd 2015 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 Table Of Error Codes Central Heating NTC Fault Flue NTC Fault Safety Thermostat Operated Water Pressure Switch Not Operated Circulation Fault Primary Circuit Flue NTC Operated Interruption Of Gas Supply or Flame Failure Fan or Fan Wiring Fault Pre Circulation Fault Baxi Heating UK Ltd
2. 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 8 Replace the terminal block cover routing the external control input cable s through the second cut out 98 Preliminary Electrical Checks Prior to commissioning the boiler preliminary electrical system checks should be carried out 2 These should be performed using a suitable meter and include checks for Earth Continuity Resistance to Earth Short Circuit and Polarity 27 Pump Automatic Air Vent Fig 31 Selector Switch Fig 32 i Display t X Central Heating Calibration Control Temperature Control Fig 33 28 Q Baxi Heating UK Ltd 2015 Pressure Gauge 10 0 Commissioning I Commissioning the Boiler Reference should be made to BS EN 12828 amp 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 Ensure that the filling loop is connected and open then open the heating flow and return valves on the boiler 4 Open the screw on the automatic air vent on the pump body Fig 31 5 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 6 Pressurise the system to 1 5 bar then close and disco
3. Baxi Heating UK Ltd 2015 39 13 0 Changing Components ENTE P C B Fig 62 Note the settings of the temperature control knobs rotate them fully anticlockwise and carefully pull them off the drive pins f 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 pin Fig 82 3 Note the position of all plugs and wires on the P C B and disconnect them 4 Undo the securing screws and remove the P C B Transfer Control Box Cover the control knob drive pins to the new P C B and turn them Fig 62 fully anticlockwise P C B gt f 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions EN Pump P C B Fig 63 Selector Switch 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 Drive Pins pin Fig 82 2 Note the position of all plugs and wires on the P C B and disconnect them Undo the securing screws and remove the P C B 3 Reassemble in reverse order EP Selector Switch Fig 63 Note the setting of the selector switch knob and carefully pull it off the facia Fig 63 2 Completely undo the screws securing the
4. Vertically from a terminal on the same wall Horizontally from a terminal on the same wall R From adjacent wall to flue vertical only S From an adjacent opening window vertical only T Adjacent to windows or openings on pitched and flat roofs U Below windows or openings on pitched roofs In ad 2 Only ONE 25mm clearance is allowed per installa be as shown i NOTE The distance from a fanned draught appliance termina ion If one of 300 300 300 25 75 25 200 25 200 25 150 25 300 300 600 200 600 200 500 300 300 000 600 2000 n brackets in installed parallel to a boundary may not be less than 300mm in accordance with the diagram below 300 mi min Terminal Assembly Plume dition the terminal should be no nearer than 150 mm to an opening in the building fabric a window frame formed for the purpose of accommodating a built in element such as the dimensions re 2 i K Displacement Kit ge Top View Rear Flue i Fig 8 1 Property Boundary Line T JK j Air Inlet Uo tee cg r4 N R D A l de Q F L C l A Isl G A STH D ec l Fig 9 Likely flue positions requiring a flue terminal guard 20 Q Baxi Heating UK Ltd 2015 7 0 Site Requirement
5. water level but below surrounding surface Cut end at 45 cause appliance lockout fluctuations when WC s are flushed or sinks emptied then back pressure may force water out of the boiler trap and iv Termination to a purpose made soakaway Further specific requirements for soakaway design are referred to in BS 6798 Boiler E 500mm min Holes in the soak away must face away from the building 18 Baxi Heating UK Ltd 2015 v pumped into an internal discharge branch e g sink waste downstream of the trap Basement or similar heated f Boiler Condensate Pump vi pumped into an external soil amp vent pipe Unheated Location e g Garage Basement or similar heated f Condensate Pump Baxi Heating UK Ltd 2015 MM per Metre of n Pipe must terminate above water level but below surrounding surface Cut end at 45 7 0 Site Requirent Condensate Drain cont 2 A boiler discharge pump is available MULTIFIT part no 720648301 This pump will dispose of both condensate amp high temperature water from the relief valve It has a maximum head of 5 metres Follow the instructions supplied with the pump 3 Condensate Drain Pipe Trace Heating Elements are available in various lengths MULTIFIT part nos metre 72064440 1 2 metre 720664101 3 metre 720664201 5 metre 720664401 Where the drain is between 3 amp 5 met
6. 5 mm Min In Operation This is MINIMUM recommended dimension Greater clearance will aid installation and maintenance Metre wg NOX Class 5 Central Heating Primary Circuit Pressures bar Safety Discharge 3 Max Operating 2 5 Min Operating 0 5 Recommended Operating Range 1 2 Pump Available Head See graph below Expansion Vessel Integral with appliance bar in Pre charge Pressure 0 5 litre ax Capacity of CH System 125 Primary Water Content of Boiler unpressurised 2 5 Temperatures Flow Temp adjustable 25 C to 80 C max 5 C Inlet Pressure Natural Gas G20 mbar 20 Injector Natural Gas G20 12 mode 4mm 15 mode 4 5mm 18 mode 5 mm 24 mode 7 5mm 32 mode 12mm Weights kg 12 15 amp 18 24 Packaged Boiler Carton 41 5 43 0 Installation Lift Weight 36 4 349 32 Packaged Boiler Carton 43 5 Installation Lift Weight 484 Pump Available Head 400 600 800 1000 1200 Flow Rate l h Technical parameters for boiler space heaters 4 0 Technical Data Technical Parameters Potterton Promax System ErP 12 15 18 24 32 Condensing boiler Yes Yes Yes Yes Yes Low temperature boiler No No No No No B1 boiler No No No No No Cogeneration space heater No No No No No Combination heater No No No No No Rated heat output Prated kW 12 15 19 25 33 Useful heat output at rated heat output P4 kW and high
7. Additional supports are available as accessories VOIDS Consideration must be given to flue systems in voids and the provision of adequate access for subsequent periodic visual inspection 6 Read this section in conjunction with the Flue Installation Guide supplied with the boiler 21 8 0 Flue Options Flue Lengths The standard horizontal telescopic flue kit allows for lengths between 315mm and 500mm from elbow to terminal without the need for cutting Fig 11 Extensions of 250mm 500mm amp m are available The maximum permissible equivalent flue length is 10 metres 60 100 system vertical amp horizontal 20 metres 80 125 system vertical amp horizontal 15 metres 80 80 twin pipe Flue Trim Flue Deflector The flexible flue trims supplied can be fitted on the outer and inner faces of the wall of installation Terminal Guard Fig 12 When codes of practice dictate the use of terminal guards Multifit accessory part no 720627901 can be used Note This is not compatible with Flue Deflector referred to below Ensure that no part of the white outer chimney duct is visible 2 There must be a clearance of at least 50mm between any part of the terminal and the guard 3 When ordering a terminal guard quote the appliance name and model number 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated Flue De
8. Dimensions and Fixings Dimensions 16m 60m 207mm for 80 125mm ue systems 45mm 06mm 80mm 130 mm 65 mm Gas Heating Pressure Relief Inlet Return Valve 22mm 22mm 15mm G fm D 6 0 System Details 6 1 Central Heating Circuit The appliance is suitable for fully pumped SEALED SYSTEMS ONLY 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 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 using for example Sentinel X300 or X400 or Fernox F3 They should be used following the flushing agent manufacturer s instructions System additives corrosion inhibitors and flushing agents descalers should comply to BS7593 requirements e g Sentinel X100 and Fernox MB which should be used following the inhibitor manufacturer s instructions Full instructions are supplied with the products for further information contact Sentinel 0800 389 4670 or Fernox 0870 870 0362 Failure to flush and add inhibitor to the system will invalidate the appliance warranty It
9. Selector Switch Central Heating System Pressure Gauge PCB M 0 M Qo YH EWN Control Box oD Gas Valve Condensate Trap Flame Sensing Electrode Spark Electrode Primary Heat Exchanger Fan Assembly On Off Reset Selector Switch Central Heating Temperature Control Calibration Control SD 700 AU ON OT en Ud vba Venturi N e Air Gas Collector N Combustion Box Cover amp Burner N N Igniter N w Burner On Light N A Central Heating Mode Light N En Display 3 0 Appliance Operation Operating Mode Fig 2 Boiler Primary Circuit With a demand for heating or hot water the pump circulates water through the primary circuit If the pressure is at least 0 5 bar and the ignition sequence will start 0000060900000 2 When the flow temperature exceeds the setting temperature a 3 minute delay occurs before the burner relights automatically anti cycling The pump continues to run during this period 3 When the demand is satisfied the burner is extinguished and the pump continues to run for a period of 3 minutes 19 Pump Overrun IMPORTANT When the selector switch is in the 0 Off position the electrical supply to the boiler is isolated The boiler will not operate Frost Protection Mode The frost protection mode is integral to the appliance and functions when the selector switch see Section 2 1 is in the ON position ff
10. all outlets Yes Temperature Water flow rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 ALL INSTALLATIONS At max rate co ppm CO CO At min rate where possible CO ppm CO CO Record the following The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a 0 en Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 50 Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE RECORD It is recommended that your heating system is servic
11. and towards the wall 3 The discharge must not be above a window entrance or other public access Consideration must be given to the possibility that boiling water steam could discharge from the pipe 4 A remote relief valve kit is available to enable the boiler to be installed in cellars or similar locations below outside ground level kit no 5121379 7 0 Site Requirements Location E Min The boiler may be fitted to any suitable wall with the flue 300mm Min if passing through an outside wall or roof and discharging to using 80 125mm atmosphere in a position permitting satisfactory removal of flueing system combustion products and providing an adequate air supply H The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i e garage or outhouse The boiler may be fitted inside a cupboard see Section 7 3 2 If the boiler is sited in an unheated enclosure then it is recommended to leave the ON OFF Selector Switch in the On position 780mm 3 If the boiler is 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 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current Y
12. mode m3 h 1 3 15 mode m h 1 69 18 mode m3 h 1 95 24 mode m3 h 2 6 32 model m3 h 3 48 NOTE All data in this section are nominal values and subject to normal production tolerances Product Characteristic Database SEDBUK SAP 2009 Annual Efficiency All models 89 0 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 has been certified by 0085 IO Baxi Heating UK Ltd 2015 4 0 Technical Data Promax 12 15 18 24 amp 32 System ErP Electrical Supply 230V 50H Appliance must be connected to an earthed supply Power Consumption Watts 12 model 1 10W 15 model 95W 18 model 105W 24 model 15W 32 model 125W Electrical Protection IPX5D External Fuse Rating 3A Internal Fuse Rating FAL Condensate Drain To accept 21 5mm s in plastic waste pipe Flue Terminal Diameter 100mm Dimensions Projection 125mm Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Pressure Relief Discharge 5mm Outercase Dimensions Casing Height 80mm Overall Height Inc Flue Elbow 965mm Casing Width 450mm Casing Depth 345mm Clearances Above Casing Below Casing Front Front L H Side R H Side 175 mm Min 150 mm Min 450 mm Min For Servicing 5 mm Min In Operation 5 mm Min
13. necessary to separately remove the spring clip from the pin in the centre of the heat exchanger and the L shaped clips embedded in the insulation 6 DO NOT remove the shrink wrapped coating from the replacement rear insulation Keep the insulation vertical and Heat press firmly into position Exchanger 7 Examine the cover seal and replace if necessary Rear Insulation Spark Electrode Insulation m Fig 52 Collector Electrode Sensing Leads Electrode 36 Baxi Heating UK Ltd 2015 Electrical Plug Flue Heat Exchanger Thermostat Sensor Fig 53 Flow Pipe Central Heating Temperature Sensor Safety Thermostat Fig 54 Return Heating Temperature Sensor Baxi Heating UK Ltd 2015 13 0 Changing Components Flue Heat Exchanger Thermostat Sensor Fig 53 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Turn the sensor 90 anticlockwise to remove it is a bayonet connection 3 Reassemble in reverse order Water Pressure Sensor Fig 55 Drain the primary circuit 2 Disconnect the two wires from the sensor 3 Undo the nut on the flow pipe securing and sealing the sensor 4 Remove the sensor examine the sealing washer replacing if necessary 5 Reassemble in reverse order The component is not polarised either w
14. quickly turn the Calibration Control knob clockwise twice and back fully anticlockwise Fig 34 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 35 amp 36 5 Turn CH temperature control knob fully clockwise As the knob is turned the display will change from 0 to 00 Fig 37 indicating maximum rate then revert to P alternating with the current boiler temperature Figs 38 amp 39 6 With the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point Fig 34 is in accordance with B S 6798 amp BS 6891 7 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Measure the Gas Rate 8 With any other appliances amp pilot lights turned OFF the gas rate can be measured It should be between 12 model 1 31 m h 15 model 1 69 m h 18 model 1 95 m3 h 24 model 2 61 m3 h 32 model 3 48 m h 9 The Calibration Function is active for 20 minutes unless the maximum CH temperature is exceeded 10 The function can be disabled at any time by turning the Calibration Control knob Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation These details will be required in the event of an
15. temperature regime 12 4 154 18 5 24 7 32 8 output and low temperature regime 40 50 60 8 amp 0 106 Seasonal space heating energy efficiency 77 91 92 92 92 92 Useful efficiency at rated heat output and 7 high temperature regime 90 0 90 0 90 0 90 0 90 0 Useful efficiency at 30 of rated heat MN output and low temperature regime 96 7 96 8 96 8 96 8 96 7 Auxiliary electricity consumption Full load elmax kW 0 050 0 037 0 065 0 042 0 043 Part load elmin kW 0 015 0 014 0 014 0 014 0 015 Standby mode Psg kW 0 003 0 003 0 003 0 003 0 003 Other items Standby heat loss Pstpy kw 0 040 0 040 0 040 0 040 0 040 Ignition burner power consumption Pig kW s Annual energy consumption QHE kWh 10901 13391 16087 21478 28522 GJ 39 48 58 77 103 Sound power level indoors Lwa dB 55 52 53 58 54 Emissions of nitrogen oxides NOx mg kWh 15 25 29 20 24 1 Low temperature means for condensing boilers 30 C for low temperature boilers 37 C and for other heaters 50 C return temperature at heater inlet 2 High temperature regime means 60 C return temperature at heater inlet and 80 C feed temperature at heater outlet Baxi Heating UK Ltd 2015 See The back cover for contact details At least 1 5 360 Orienta 132 5 MMI Heating Flow 22mm Vu 12 Baxi Heating UK Ltd 2015 Condensate Drain 130 mm Flue 100mm 5 0
16. 0 dia Kit M Extensions 45 amp 93 bends are also available NOTE Horizontal flue pipes should always be installed with a fall of at least 1 5 from the terminal to allow condensate to run back to the boiler This bend is equivalent to metre This bend is equivalent to metre Total equivalent length Z A B C 2x90 Bends Baxi Heating UK Ltd 2015 8 0 Flue Options Em Horizontal Flue Systems The standard flue is suitable only for horizontal termination applications 2 All fittings should be fully engaged The approximate engagement is 40mm Apply soap solution to the seal on each fitting to aid assembly 3 Maximum permissible equivalent flue lengths are 60 100 80 125 Horizontal Concentric 10 metres 20 metres 4 Any additional in line bends in the flue system must be taken 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 4 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 IMPORTANT SUPPORT All flue systems MUST be securely supported a MINIMUM of once every metre It is recommended that every straight piece is supported irrespective of length
17. 2015 17 0 Fault Finding Initial Fault Finding Checks Check that gas water and electrical supplies are available at the boiler 2 Electrical supply 230V 50 Hz 3 CH water system pressurised to 0 5 bar minimum when the boiler is cold 4 The preferred minimum gas pressure is 20 mbar 5 Carry out electrical system checks i e Earth Continuity Resistance to Earth Short Circuit and Polarity with a suitable meter NOTE These checks must be repeated after any servicing or fault finding 6 Ensure all external controls are calling for heat and check all external and internal fuses Before any servicing or replacement of parts ensure the gas and electrical supplies are isolated 17 2 Error Codes If a fault occurs on the boiler an error code may be shown by the facia display 2 The codes are either two or three digit preceded by the etter E For example code E133 will be displayed by EI alternating with 33 E20 is shown as E then 20 E20 and E28 indicate faulty components EI 10 shows overheat of the primary water and E130 overheat of the flue system EII9 is displayed when the primary water pressure is less han 0 5 bar 33 indicates that the gas supply has been interrupted gnition has failed or the flame has not been detected E125 is displayed in either of two situations i If within 15 seconds of the burner lighting the boiler emperature has not changed b
18. ONTROLS tick the appropriate boxes Room thermostat and programmer timer Programmable room thermostat Time and temperature control to heating Load weather compensation Optimum start control Time and temperature control to hot water Cylinder thermostat and programmer timer Combination Boiler Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions What system cleaner was used What inhibitor was used Quantity Has a primary water system filter been installed CENTRAL HEATING MODE measure and record Gas rate OR Burner operating pressure if applicable OR Gas inlet pressure Central heating flow temperature Central heating return temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate OR Burner operating pressure at maximum rate OR Gas inlet pressure at maximum rate Cold water inlet temperature Hot water has been checked at
19. and 500mm Fig 20 when measured from the flue elbow there is 50mm engagement into the elbow 3 Locate the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 21 NOTE The flue elbow is angled at 93 degrees to ensure a fall back to the boiler 4 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 21 5 If the distance from the flue elbow to the outside face of the wall X in Fig 21 is less than 250mm the Connection Assembly can be discarded and the Terminal Assembly fitted directly into the elbow 6 In instances where the dimension X Fig 21 is between 250mm and 315mm it will be necessary to shorten the Terminal Assembly by careful cutting to accommodate walls of these thicknesses 7 To dimension X add 40mm This dimension to be known as Y 8 Adjust the two telescopic sections to dimension Y and seal the joint with the tape provided Fig 23 Ensure that the labels marked TOP on the Terminal and Connection Assemblies are uppermost 9 Using the clearance holes in the Connection Assembly secure it to the Terminal Assembly using the screws supplied Fig 24 25 Flue Elbow Apply Lubricant for ease of assembly Ensure Elbow is fully engaged into Boiler Adaptor Fig 25 Apply the lubricant supplied for ease of assembly do not use any other type E
20. and expansion vessel s suitable for use only on fully pumped sealed systems 5 The boiler data badge gives details of the model serial number and Gas Council number and is situated on the inner door panel It is visible when the case front panel is removed md X Fig 1 Control Box 6 The boiler model name and serial number are also shown on the information label on the rear of the lower door panel This Facia Door is for user reference F 7 The boiler is intended to be installed in residential domestic Fig Data Badge Fa environments on a governed meter supply only POE 8 The boiler must be installed with one of the purpose Information Label 4 designed flues such as the standard horizontal telescopic flue kit part no 720598701 9 All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Important If the boiler is installed at a high point in the system it is strongly recommended that Automatic Air Vent Kit 720004701 is fitted Contents of Pack The pack contains Boiler Wall Plate including taps Set of Pipe Connections Template Literature Pack Baxi Heating UK Ltd 2015 7 8 16 Baxi Heating UK Ltd 2015 25 23 2 0 General Layout Layout Expansion Vessel Automatic Air Vent Circulation Pump Drain Off Point Pressure Relief Valve
21. as Safety Installation amp Use Regulations Definition of competence A person who works for a Gas Safe registered company and holding current certificates in the relevant ACS modules is deemed competent In IE this must be carried out by a competent person as stated in l S 813 Domestic Gas Installations The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty In GB this could also infringe the Gas Safety Installation and Use Regulations Warning Check the information on the data plate is compatible with local supply conditions All Gas Safe registered engineers carry an ID card with their licence number and a photograph You can check your engineer is registered by telephoning 0800 408 5500 or online at www gassaferegister co uk Homologations CE Marking EC Declaration of Conformity Baxi Heating UK Limited being the manufacturer distributor within the European Economic Area of the following Potterton Promax 12 15 18 24 32 System ErP declare that the above is in conformity with the provisions of the Council Directive 2009 142 EC 92 42 EEC 2004 108 EC 2006 95 EC 2009 125 EC 2010 30 EU and has been subject to the following conformity procedures laid down in Annex 2 Article 3 of 2009 142 EC under the supervision of the British Standards Institution a Notifi
22. conds and for 3 Error 133 flashing Tum the selector switch to attempts reset i YES i Burner lights Burner does not stay alights Error 133 flashing after 5 seconds Go to section Check the Central Heating NTC sensor Ensure controls are set to demand and verify the contacts are closed Go to section E Burner output modulates to Error 130 flashing maintain the temperature set Go to section M YES Pump continues to run for 3 YES YES P Bumergossout Fan stops after lO seconds minutes Operation into room thermostat open PERS 46 Baxi Heating UK Ltd 2015 17 0 Fault Finding Fault Finding Solutions Sections A Is there 230V at Main terminals L and N iis 2 NO NO M ns je Check electrical supply Replace fuse Check wiring Display illuminated Replace PCB PCB XI connector terminals 2 B Is there 230V at Check incoming wiring Replace Pump PCB Check wiring Replace Control PCB Replace Pump PCB YES Replace Pump CH system pressure less than 0 5 bar YES Check connection water pressure switch terminal YES Replace water COM NO and PCB connector pressure switch X400 terminals 3 4 2 ic ai NO Tm Check the tap of the automatic air Open the automatic air vent vent is opened D i Fan connections correct at fan PCB YES X2 connector is 230V AC across Fan jammed or fault
23. control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hinge pin Fig 82 3 Note the position of the electrical connections and the orientation of the switch Remove the electrical connections 4 Remove the screws securing the switch to the facia panel 5 Fit the new switch ensuring that it is correctly positioned and reassemble in reverse order 40 Q Baxi Heating UK Ltd 2015 Venturi Inlet Pipe 13 0 Changing Components EPAR Gas Valve Fig 64 IMPORTANT After replacing the valve the CO must be checked and adjusted as detailed in Section 14 0 Setting the Gas Valve Only change the valve if a suitable calibrated combustion analyser is available operated by a competent person see section 12 1 Turn the gas cock off and undo the nut on the gas feed elbow under the boiler 2 Remove the screws securing the gas valve to the boiler bottom panel 3 Pull off the power lead earth lead and sensing pipe il Gas Feed Farth Lead Elbow 4 Undo the nut on the gas pipe at the gas air inlet and the gas valve Remove the pipe taking care not to lose the sealing washers Remove the valve Fig 64 5 Examine the O ring seals replace if necessary 6 Reassemble in reverse order ensuring that all seals are in place Throttle Adjustment Screw NOTE To assist the boiler to light prior to f
24. cover removed the display will change indicating the fan speed When the display reads O the boiler runs at minimum rate The CO should be 8 476 0 2 10 With the boiler on minimum the Offset Adjustment CN Screw must be altered using a suitable hexagon key after Reduce CO Increase CO removing the cap Fig 74 Turning anti clockwise will reduce at max rate at max rate the CO Clockwise will increase the CO D A Reduce CO2 Increase CO2 at min rate at min rate Fig 74 Gas Valve The Calibration Function is maintained for 20 minutes If the CO is reset at minimum rate it must be rechecked at maximum rate again and adjusted if required If the CO is reset at unless the maximum CH temperature is exceeded The Do not turn the adjustment function can be disabled at any time by turning the right screws more than 1 8 of a turn at hand knob a time Allow the analyser reading maximum rate it must be rechecked at minimum rate and adjusted if required to settle before any further 12 Check the Combustion Performance CO CO ratio adjustment This must be less than 0 004 42 Baxi Heating UK Ltd 2015 15 0 Electrical Illustrated Wiring Diagram Central Heating NTC Sensor Overheat Stat Return Heating Water Pressure Temperature Sensor Switch Flame Sensing Electrode 9 87865432 Control PCB x501 10987654321
25. d fire rating 18 If necessary fit a terminal guard see Section 8 4 Cable Clamp Fig 29 Terminal Block Cover Facia Panel Always fit fast blow 2A fuse pese Rs en 230V pk Fused supply 3A N bk 230V 50Hz Earth green yellow gly Fuses Neutral blue Live brown Fig 30 Terminal Block Baxi Heating UK Ltd 2015 9 0 Installation Making The Electrical Connections The boiler is fitted with a 1 3m length of 3 core of cable This can be connected to the fused 3A 230V 50Hz supply NOTE Both the Live and Neutral connections are fused To connect an external control proceed as follows Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia Remove the panel 2 Completely undo the screws securing the facia panel and hinge it down Fig 28 3 Undo the terminal block cover securing screw and remove the cover Fig 28 4 Slacken the unused cable c boiler chassis Fig 29 Insert through the clamp and route amp on the LH side of the he external control wiring it to the terminal block 5 Refer to the instructions supplied with the control IMPORTANT The external control MUST be suitable for 230V switching and fused 3A maximum 6 Remove the link between terminals amp 2 The switched output from the external control must be connected to terminal 2 Fig 30
26. ed Body authorized by the United Kingdom Competent Authority and carrying the Notified Body umber 0086 Type test for purpose of Regulation 5 certified by otified Body 0085 Product Production certified by otified Body 0086 For GB IE only Baxi Heating UK Ltd 2015 Legislation This company declare that no substances harmful to health are contained in the appliance or used during appliance manufacture The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force and only used in a suitably ventilated location 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 amp 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 LEE Wiring Regulations Where no specific instructions are given reference should be made to the relevant British 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 LS 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical ins
27. ed regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate AND CO At max rate Record Record At min rate Where Possible AND CO 96 At min rate Where Possible Comments Comments Signature SERVICE 03 SERVICE 04 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate At max rate Record Record At min rate Where Possible At min rate Where Possible Comments Comments Signature SERVICE 05 SERVICE 06 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate At max rate Record F Record At min rate Where Possible At min rate Where Possible Comments Comments Signature SERVICE 07 SERVICE 08 Engineer name E
28. edition of Institute of Gas Engineers Publication IGE UP 7 5mm Min 450mm Gas Installations in Timber Framed Housing 150mm Min Fig 5 Low This is the MINIMUM recommended dimension Greater Clearance will aid installation and maintenance Clearances Figs 5 amp 6 f least 1 5 A flat vertical area is required for the installation of the boiler 2 These dimensions include the necessary clearances around the boiler for case removal spanner access and air movement Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler 450mm Min For Servicing Purposes Sn Min In i e Fig 6 Baxi Heating UK Ltd 2015 I5 Gas Service Cock Fig 7 Zone 2 LL LL d Window Recess Window Recess Zone 2 o 99 In GB Only Ceiling Window Recess Outside Zones ee Aa a 0 6 m Fig B In GB Only 16 Baxi Heating UK Ltd 2015 7 0 Site Requirements Ventilation of Compartments 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 Gas Supply The gas installation should be in accordance with the relevant standard
29. ements represent a change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook which was then left on site with the customer With the introduction of Self Certification Schemes the Benchmark Logbook is being withdrawn However a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions This company is a member of the Benchmark initiative 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 he 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 BSI amp benchmar COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS ISO 9001 FM 00866 Insta
30. en POTTESTON Installation and Service Manual Condensing System Boiler Promax System 12 15 18 24 3 These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Natural Gas Potterton Promax 12 System ErP G C NP 41 592 42 Potterton Promax 15 System ErP G C N 41 592 43 Potterton Promax 18 System ErP G C NP 41 592 44 Potterton Promax 24 System ErP G C Ne 41 592 45 Potterton Promax 32 System ErP G C N 41 592 46 The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference Installers are required to carry out installation commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme Visit www centralheating co uk for more information Baxi Heating UK Ltd 2015 Al rights reserved No part of this publication may be reproduced or transmitted in any form or by any means
31. ensions for a bathtub For other examples refer to the Current LEE Wiring Regulations reference must be made to the relevant requirements In GB this is the current LEE 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 Examples are shown of the following methods of termination i lt It il to a drain or gully v to a purpose made soakaway v pumped into an internal discharge branch e g sink waste downstream of the trap to an internal soil amp vent pipe il via an internal discharge branch e g sink waste downstream of the trap pumped into an external soil amp vent pipe i to a drain or gully with extended external run amp trace heating is strongly recommended to discharge internally into the household drainage system If connecting to a rain water drain that drain MUST discharge into a foul drain 21 5mm 32mm Insulation i Termination to an internal soil and vent pipe AAA 450mm min 450mm is applicable to properties up to 3 storeys For multi storey building installations consult BS 6798 ii External termination via internal discharge branch e g sink waste downstream Pipe must terminate above water level but below surrounding surface Cut end at 45 cr It is NOT RECOMMENDED to connect upstream of the si
32. f d amp 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 EL D 8 can be incorporated by using a system frost thermostat Pump Protection With the selector switch see Section 2 1 in the ON T 0 2 position ff the pump will automatically operate for minute in every 24 hours to prevent sticking Key Fig 2 Heat Exchanger Burner gnition Electrode Flame Sensing Electrode Gas Valve Pump Automatic Air Vent Pressure Relief Valve Oo MAN AUNT w a Boiler Drain Point Gas Inlet Boiler Flow Boiler Return Pressure Gauge Automatic By Pass Water Pressure Sensor Safety Thermostat Temperature Sensor Expansion Vessel DO AN AYN KRWNYN Return Temperature Sensor N e Fan Baxi Heating UK Ltd 2015 9 Appliance Type Ci5 C35 Cs Appliance Category CAT LH Heat Input Qn Hs Gross Max Min 12 model kW 13 8 44 15 model kW 17 1 40 18 model kW 20 5 45 24 model kW 274 7 8 32 model kW 364 0 8 Heat Output Pn Non Condensing Max in 12 mode W 12 4 39 15 mode W 15 4 39 18 mode W 18 5 4 2 24 mode W 24 7 6 8 32 mode W 32 8 94 Heat Output Pnc Condensing Max Min 12 mode W 13 0 42 15 mode W 16 2 42 18 mode W 19 4 45 24 mode W 259 74 32 mode W 344 10 2 Max Gas Rate Natural Gas G20 After 10 mins 12
33. facia to hinge down Fig 41 4 Remove the screws securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 42 5 Unscrew the sump from the bottom of the condensate trap assembly Fig 43 and remove any deposits from the sump and trap Clean as necessary and replace the sump uu Ze Burner Viewing Window Sensing Electrode Spark Ignition Electrode Electrode Position Fan Collector and Cover Assembly Electrode Leads Fig 45 Injector Gas Inlet Pipe Fig 44 Baxi Heating UK Ltd 2015 12 0 Servicing Annual Servicing Inspection Cont Undo the nut on the gas inlet pipe to the venturi Fig 44 and pull the sensing pipe off the fan 7 he fan e Disconnect the electrode leads noting their position and ectrical plugs Fig 45 8 Undo to the heat exchanger he four nuts retaining the combustion box cover 9 Carefu forward being careful to re Figs 44 amp 45 ly draw the fan collector and cover assembly ain the injector in the venturi 0 Clean any debris from the heat exchanger and check hat the gaps between the tubes are clear Inspect the burner electrodes position and insulation cleaning or replacing if necessary Clean any dirt or dust from the air box 12 Reassemble in reverse order NOTE The sensing pipe must be recon
34. flector Fig 13 Push the flue deflector over the terminal end It may point upwards as shown or up to 45 either way from vertical Secure the deflector to the terminal with screws provided 86 Flue Accessories Fig 13a For full details of Flue Accessories elbows extensions clamps etc refer to the Flue Installation Guide supplied in the literature pack 22 Baxi Heating UK Ltd 2015 LIFT HERE BOTH SIDES Pre plumbing Ii To remove only the wall jig slide Slide the wall jig out of carton then banding to the edge and open flaps close the flaps Slide banding back on Fig 15 For Side Flue Exit Fig 16 Flushing Tube Fig 17 Central Heating Return Baxi Heating UK Ltd 2015 9 0 Installation ES Unpacking amp 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 upright position See section Safe Manual Handling before unpacking or lifting the boiler RISK ASSESSMENT Before commencing the installation it is recommended that the Five Steps to Risk Assessment document published by the HSE is consulted and an assessment performed as described 2 Follow the procedure on the carton to unpack the boiler or see Fig 14 3 If pre plumb
35. gt A w li B le ENS i SK D dise gt P N ElectrodeL i a eads SD Sensing Electrode Fig 47 34 Baxi Heating UK Ltd 2015 Venturi Injector Fan Inlet Flange gia enteteb uis d ce y iedie 18 model ONLY Gas Inlet Venturi Injector Collector Fig 50 Fig 48 When fitting the venturi ensure that the arrow is pointing forward Baxi Heating UK Ltd 2015 13 0 Changing Components Fan Fig 50 Undo the nut on the gas inlet pipe to the venturi Fig 49 and pull the sensing pipe off the fan 2 Disconnect the electrode leads noting their position and di sconnect the fan electrical plugs 3 Undo the screws securing the collector to the extension piece 4 Remove the collector and fan assembly being careful to retain the injector in the venturi 5 Undo the screws securing the fan to the venturi and fit the new fan On 18 models ONLY transfer the fan inlet flange to the new fan Replace the seal if necessary 6 Examine the burner gasket and replace if necessary 7 Reassemble in reverse order ensuring that the injector is in place and the sensing pipe is connected to the fan ESS Venturi Fig 50 Remove the collector and fan assembly as described in section 13 3 2 Extract the injector from the venturi 3 Undo the screws securing the fan to the venturi and the ven
36. he left hand knob fully anti clockwise As the knob is turned the display will change indicating the fan speed When the display reads 0 the boiler runs at minimum rate 18 This function is maintained for 20 minutes unless the maximum CH temperature is exceeded The function can be disabled at any time by turning the right hand knob 10 0 Commissioning Checking Combustion Follow the flow chart opposite Is O2 2 20 676 and CO lt 0 2 Is CO lt 350ppm and CO CO ratio 0 004 Is O2 2 20 6 and CO2 lt 0 2 Is CO 350ppm and CO CO ratio lt 0 004 Is CO lt 350ppm and CO CO ratio lt 0 004 Baxi Heating UK Ltd 2015 29 Central Heating Temperature Control Fig 34 Selector Switch Display We f O i IUE CHE Central Heating O 4 v Temperature Control Gas Pressure Test Point Fig 35 Fig 38 30 Baxi Heating UK Ltd 2015 Gas Valve Calibration Control Calibration Control Fig 34 2 10 0 Commissioning Check the Operational Working Gas Inlet Pressure Ensure that all controls are calling for heat and the selector switch is in the central heating and hot water position iJ The current boiler temperature is shown on the display 2 To check the gas rate it is necessary to set the boiler to Calibration Mode 3 Turn both temperature control knobs fully anticlockwise then
37. inal setting a use a suitable hexagon key to wind out the Throttle adjustment screw until it is flush with the valve body then turn the screw 4 full turns clockwise Fig 65 If the boiler will not light or the correct CO cannot be achieved contact the heateam technical helpline EPP Expansion Vessel Fig 66 Drain the primary circuit and undo the nut on the vessel connection pipe 2 Undo and remove the locknut securing the vessel spigot to EN A the boiler air box Expansion Vessel 3 Remove the bracket and vessel from the boiler 4 Locate the retaining bracket on the upper flange of the vessel and fit to the boiler 5 Reassemble in reverse order Boiler Chassis Baxi Heating UK Ltd 2015 41 IMPORTANT The CO must be only be checked and adjusted to set the valve if a suitable calibrated x2 14 0 Setting the Gas Valve W e Setting the Gas Valve CO check combustion analyser is available operated by a competent person see Section 12 1 Central Heating Calibration Temperature Control Fig 67 Control The combustion CO2 may be checked after running the Selector Switch Display boiler for several minutes To do this it is necessary to se f the boiler to Calibration Mode we WE b Eis 2 Ensure that all external controls are calling for heat The actual current boiler temperatu
38. ing Fig 15 the wall jig and fitting kit can be removed without removing the carton sleeve Simply slide banding to the edge and open the perforated flap lift out the jig fitting kit and instructions If the boiler is to be installed at a later date close the flap and reposition the banding straps the boiler can now be stored safely away 4 After considering the site requirements see Section 7 0 position the fixing template on the wall ensuring it is level both horizontally and vertically 5 Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes It is preferable to use the vertical fixing slots 6 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown Fig 16 7 If required mark the position of the gas and water pipes Remove the template 8 Cut the hole for the flue minimum diameter 6mm 9 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 10 Using a spirit level ensure that the plate is level before finally tightening the screws Connect the gas and water pipes to the valves on the wall plate using the copper tails supplied Ensure that the sealing washers are fitted between the connections Flushing Connect a tube to the central heating flow or return pipe Fig 17 2 Flush thoroughly see System Details Secti
39. ire will fit each terminal EMI Central Heating Temperature Sensor NTC Fig 54 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way EM Safety Thermostat Fig 54 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 EAP Return Heating Temperature Sensor Fig 56 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Prise the sensor retaining clip off the pipe and remove the sensor from the clip 3 Reassemble in reverse order 37 13 0 Changing Components EMM Pump Head Only Fig 57 Drain the primary circuit and disconnect the electrical plug from the pump motor 2 Remove the socket head screws securing the pump head to the body and draw the head away 3 Reassemble in reverse order EACS Pump Complete Fig 58 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 replacing if necessar
40. 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 Technical Enquiries Bypass The boiler is fitted with an automatic integral bypass System Control 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 amp TRV s only does not produce the best results Baxi Heating UK Ltd 2015 13 Double StOP Check Stop Valve Valve Valve I v ar Mains Temporary Cold Hose Inlet Fig 3 Pressure Relief Valve Discharge Pipe 14 Baxi Heating UK Ltd 2015 6 0 System Details System Filling and Pressurising I 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 The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment 3 Your atte
41. k must be at least 5mm 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 all soldered joints before connecting to the pressure relief valve Condensate Drain see section 7 7 Connect the condensate drain to the trap outlet pipe Ensure the discharge of condensate complies with any national or local regulations in force see British Gas Guidance Notes for the Installation of Domestic Gas Condensing Boilers 2 The connection will accept 21 5mm in plastic overflow pipe which should generally discharge internally into the household drainage system If this is not possible discharge into an outside drain is acceptable Terminal Assembly Connection Assembly Fig 20 Wall Thickness Z Wall Fig 21 Thickness Peak to be uppermost T Sealing Tape Fig 23 TOP Label Baxi Heating UK Ltd 2015 9 0 Installation EG Fitting The Flue HORIZONTAL TELESCOPIC FLUE There are two telescopic sections the Terminal Assembly and the Connection Assembly a roll of sealing tape and two self tapping screws A 93 elbow is also supplied 2 The two sections can be adjusted to provide a length between 315mm
42. lations in force BS 6798 amp Part HI of the Building Regulations give further detailed guidance 3 The discharge pipe should be run in a proprietary drain pipe material e g PVC PVC U ABS PVC C or PP 4 Metal pipework is NOT suitable for use in condensate discharge systems 5 The pipe should be a minimum of 21 5mm diameter and must be supported using suitably spaced clips of the correct design to prevent sagging 6 It is advisable that the full length of condensate pipe is run internally and preferably be less than 3 metres 7 Internal runs greater than 3 metres or runs in cold areas should use 32mm waste pipe 8 External runs MUST be a MINIMUM of 32mm and fully insulated with material suitable for external use 9 If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run and sized and insulated accordingly 10 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 and any burrs on cut pipe removed 7 0 Site Requirement Condensate Drain cont iii Termination to a drain or gully Boiler 1 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soil pipes or waste pipes are subjected to internal pressure Pipe must terminate above
43. ller Notification Guidelines Choose Building Regulations Notification Route Competent Person s Self Certification Scheme Install and Commission this appliance to manufacturer s instructions Complete the Benchmark Checklist If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www gassaferegister co uk within 10 days You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Gas Safe Register will issue a Building Regulations Compliance Certificate to the property owner and inform the relevant LABC Baxi Heating UK Ltd 2015 Building Control Contact your relevant Local Authority Building Control LABC who will arrange an inspection or contact a government approved inspector Install and Commission this appliance to manufacturer s instructions Complete the Benchmark Checklist LABC will record the data and will issue a certificate of compliance 4 IMPORTANT Installation Commissioning Service amp 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 this must be carried out by a competent person as stated in the G
44. n the necessity of regular servicing 3l Panel NE Front SS Fig 41 Facia Panel Securing Screws Inner Door Panel Fig 42 Condensate Trap Fig 43 32 Q Baxi Heating UK Ltd 2015 12 0 Servicing Annual Servicing 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 servicing complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication IMPORTANT During routine servicing and after any maintenance or change of part of the combustion circuit the following must be checked The integrity of the complete flue system and the flue seals The integrity of the boiler combustion circuit and relevant seals as described in Section 13 The operational gas inlet pressure as described in Section 10 3 1 to 10 3 7 and the gas rate as described in 11 3 8 The combustion performance as described in Check the Combustion Performance 13 1 4 to 13 1 6 below 3 Competence to carry out Checking Combustion Performance B S 6798 Specification for Installation amp Maintenance of Gas Fired Boilers not exceeding 70kW advises that The person carrying out a combustion measurement should have been assessed a
45. nected to the fan not the venturi 13 Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user 33 13 0 Changing Components IMPORTANT When changing components ensure that both the gas and electrical supplies to the boiler are Bracket e d 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 to reset the boiler Igniter before recommissioning Igniter Feed Plug See Section 12 2 Annual Servicing for removal of case panel door etc EA Igniter Fig 46 Electrode Leads Disconnect the igniter feed plug and the electrode leads noting their positions Fig 46 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 Spark and Sensing Electrodes Fig 47 Disconnect 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 ES N Electrode iW Iu Ir ut IE
46. ngineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate At max rate Record Record At min rate Where Possible At min rate Where Possible Comments Comments SERVICE 09 SERVICE 10 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate At max rate Record Record At min rate Where Possible At min rate Where Possible Comments Comments All installations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a enchmarn Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 5 Heating and Hotwater Industry Council HHIC www centralheating co uk Baxi Customer Support 0344 871 1525 Opening hours Monday Friday 8 00am 6 00pm Weekends and Bank Holidays 8 30am 2 00pm Please note calls may be recorded for training and monitoring purposes baxi co uk Register now to activate your warranty www baxi co uk registration For the warranty to be maintained please make sure B Benchmark checklis
47. nk or other waste water receptacle Baxi Heating UK Ltd 2015 7 0 Site Requirements Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER CAREFUL CONSIDERATION MUST BE GIVEN TO THE POSSIBILITY OF THE PIPEWORK BEING SUBJECT TO FREEZING CONDITIONS AND APPROPRIATE MEASURES TAKEN TO PREVENT BLOCKAGE CORRECT INSTALLATION IN ACCORDANCE WITH THIS SECTION WILL CONSIDERABLY MINIMISE THE LIKELIHOOD OF BLOCKAGE AND SUBSEQUENT BOILER LOCK OUT A CONDENSATE DISCHARGE PUMP AND PIPE TRACE HEATING ARE AVAILABLE AS ACCESSORIES see paragraphs 7 7 12 to 7 715 for further details 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 EXCEPT when employing a suitable condensate pump in basement and cellar or similar applications The boiler condensate trap incorporates a seal of 75mm therefore it is unnecessary to install an air break and trap in the discharge pipework The condensate outlet will accept 21 5mm 4in plastic overflow pipe It is strongly recommended that this discharges internally into the household drainage system Where this is not possible discharge into an outside drain is permissible providing every possible precaution is taken to prevent freezing 2 Ensure the discharge of condensate complies with any national or local regu
48. nnect the filling loop 7 Turn the gas supply on and purge the system according to in GB BS 6891 and in IE LS 813 Domestic Gas Installations 8 Test for gas tightness 9 Hinge the facia panel upwards and refit the case front panel Tighten the securing screws 10 Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals Proceed to put the boiler into operation as follows The Combustion Check procedure as shown by the chart in 10 2 is mandatory The method of setting the boiler to operate at maximum and minimum rates to comply with the procedure is described below 12 Ensure that all external controls are calling for heat The actual current boiler temperature is shown on the display 13 Turn both control knobs fully anticlockwise then quickly turn the right hand knob 1 4 clockwise twice and back fully anticlockwise 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash 5 To set to maximum rate Turn the left hand knob fully clockwise As the knob is turned the display will change indicating the fan speed 6 The display will show OO indicating maximum rate then revert to P alternating with the current boiler temperature 7 To set to minimum rate Turn t
49. nsure Flue is fully engaged into Elbow Fig 26 Flue to elbow securing screws Elbow to adaptor securing screws Slots at bottom 26 Q Baxi Heating UK Ltd 2015 Fig 27 9 0 Installation Ea Fitting the Flue Cont 0 Remove the flue elbow and insert the flue through the hole in the wall Refit the elbow to the boiler adaptor ensuring that it is pushed fully in Fig 25 2 Two flue trims are supplied one for internal use the other for outside The internal trim is packaged and identified as such it should not be used externally 13 It is recommended that if the internal trim is being used it is first fitted over the elbow to allow access to the securing screws and then manouvered into place against the wall 14 Draw the flue back through the wall and engage it in the elbow It may be necessary to lubricate to ease assembly of the elbow and flue Fig 26 15 Ensure that the terminal is positioned with the slots to the bottom Fig 27 Secure the flue to the elbow with the screws supplied Fig 26 1 6 Secure the elbow flue to the boiler adaptor with the screws supplied in the boiler fittings pack Fig 26 IMPORTANT It is essential that the flue terminal is fitted as shown to ensure correct boiler operation and prevent water entering the flue 7 Make good between the wall and air duct outside the building appropriate to the wall construction an
50. ntion is drawn to for GB Guidance G24 2 and recommendation R24 2 of the Water Regulations Guide for IE the current edition of I S 813 Domestic Gas Installations 4 The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use Expansion Vessel The appliance expansion vessel is pre charged to 0 5 bar Therefore the minimum cold fill pressure is 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres For greater system capacities an additional expansion vessel must be fitted For GB refer to BS 7074 Pt I For IE the current edition of I S 813 Domestic Gas Installations 66 Pressure Relief Valve Fig 4 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressures in excess of 3 bar and temperature in excess of 100 C 2 The pressure relief discharge pipe should be not less than I 5mm dia run continuously downward and discharge outside the building preferably over a drain It should be routed in such a manner that no hazard occurs to occupants or causes damage to wiring or electrical components The end of the pipe should terminate facing down
51. on 6 2 23 Remove Sealing Caps from under the Boiler after lifting into position i Wall Plate 5 Suggested Lifting Points shown as shaded area sed 4 Bottom Polystyrene When the Boiler Mounting Bracket on the Boiler is in position on the Retaining Lugs the bottom polystyrene may be discarded allowing the boiler to swing into position Pressure Relief Valve Discharge Pipe 24 Baxi Heating UK Ltd 2015 9 0 Installation Fitting The Boiler Lift the boiler using the Lifting Points as shown by the shaded areas Fig 18 The boiler should be lifted by TWO PEOPLE Engage the slots at the top rear of the boiler on the wall plate Fig 18 see Safe Manual Handling page 5 2 Ease the boiler forwards and remove the sealing caps from the boiler connections NOTE A small amount of water may drain from the boiler once the caps are removed 3 Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections 4 Tighten all the connections Fitting the Pressure Relief Discharge Pipe Fig 19 Remove the discharge pipe from the kit 2 Determine the routing of the discharge pipe in the vicinity of the boiler Make up as much of the pipework as is practical including the discharge pipe supplied 3 The pipewor
52. onditions If at any time when installing the boiler you feel that you may have injured yourself STOP DO NOT work through the pain you may cause further injury IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING Baxi Heating UK Ltd 2015 5 CONTENTS Section Page 1 0 Introduction 7 2 0 General Layout 8 3 0 Appliance Operation 9 4 0 Technical Data 0 5 0 Dimensions and Fixings 2 6 0 System Details 3 7 0 Site Requirements 5 8 0 Flue Options 21 9 0 Installation 23 10 0 Commissioning 28 11 0 Completion 3l 12 0 Servicing 32 13 0 Changing Components 34 14 0 Setting the Gas Valve 42 15 0 Electrical 43 16 0 Short Parts List 44 17 0 Fault Finding 45 Benchmark Checklist 50 Baxi Heating UK Ltd 2015 1 0 Introduction EJ Description The Potterton Promax System ErP is a fully automatic gas fired wall mounted condensing system boiler It is room sealed and fan assisted Case Front Panel 2 The boiler is set to give a maximum output of 12 models 12 kW 13 KW Pnc Condensing 15 models 15 kW 16 2 kW Pnc Condensing 18 models 18 kW 19 4 KW Pnc Condensing 24 models 24 kW 25 9 KW Pnc Condensing 32 models 32 kW 34 4 KW Pnc Condensing 3 It is designed for use on Natural Gas G20 4 The boiler incorporates a circulating pump
53. or stored in any retrieval system of any nature including in any database in each case whether electronic mechanical recording or otherwise without the prior written permission of the copyright owner except for permitted fair dealing under Copyrights Designs and Patents Act 1988 Applications for the copyright owner s permission to reproduce or make other use of any part of this publication should be made giving details of the proposed use to the following address The Company Secretary Baxi Heating UK Ltd Brooks House Coventry Road Warwick CV34 4LL Full acknowledgement of author and source must be given WARNING Any person who does any unauthorised act in relation to a copyright work may be liable to criminal prosecution and civil claims for damages C oc 2 Baxi Heating UK Ltd 2015 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England amp Wales require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department From April 2005 this can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly Similar arrangements will follow for Scotland and will apply in Northern Ireland from January 2006 The Health amp Safety Executive operates the Gas Safe Register a self certification scheme for gas heating appliances These arrang
54. ore than 1 5 ohm Replace safety thermostat Replace PCB Fan connections correct at fan YES Replace fi PCB X401 connector terminals 5 6 7 amp 8 K Temperature sensors faulty Cold resistance approximately 10KQ 25 C CH sensor 20kQ 25 C Flue sensor resistance reduces with increase in temp YES 2 Ir pump is running the heat exchanger could be Replace Neat excnanger obstructed Baxi Heating UK Ltd 2015 49 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer name Telephone number Address Boiler make and model Boiler serial number Commissioned by PRINT NAME Gas Safe register number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable C
55. re is shown on the display y 2 gt X Ke O b 4 v 3 Turn both control knobs fully anticlockwise then quickly turn the right hand knob 4 clockwise twice and back fully Central Heating Calibration Control anticlockwise Fig 67 Temperature Control 4 The display will now alternate between SF and the current boiler temperature and both green LEDs will flash Figs 68 amp 69 5 Turn the left hand knob fully clockwise As the knob is turned the display will change indicating the fan speed 6 The display will show 00 indicating maximum rate then revert to P alternating with the current boiler temperature Figs 70 71 amp 72 7 Remove the plug from the flue sampling test point Insert the analyser probe and allow sufficient time for the reading Fig 70 Fig 71 Fig 72 to settle Fig 73 The CO should be 8 776 0 2 Flue Adaptor Test 8 It is possible to alter the CO by adjustment of the gas Plug valve Remove the plastic cover from the Throttle Adjustment Screw At maximum rate the Throttle Adjustment Screw should be turned using a suitable Analyser Probe hexagon key until the correct reading is obtained Fig 74 Turning clockwise will reduce the CO Anticlockwise will increase the CO Offset Throttle 9 The CO must then be checked at minimum rate Turn ee ee Adjustment Screw the left hand knob fully anti clockwise As the knob is turned
56. res a 5 metre kit can be used and doubled back upon itself 14 It is possible to fit the element externally on the condensate drain or internally as detailed in the instructions provided 15 The fitting of a Trace Heating Element is NOT a substitute for correct installation of the condensate drain ALL requirements in this section must still be adhered to vii to a drain or gully with extended external run amp trace heating The Trace Heating element must be installed in accordance with the instructions supplied External runs amp those in unheated locations still require insulation Pipe must terminate above water level but below surrounding surface Cut end at 45 D E F G or H is 25mm then the remainder MUST accordance with B S 5440 Terminal Position with Minimum Distance Fig 9 Directly below an opening air brick opening windows etc Above an opening air brick opening window etc Horizontally to an opening air brick opening window etc Below gutters soil pipes or drain pipes E Below eaves Below balconies or car port roof From a vertical drain pipe or soil pipe From an internal or external corner Above ground roof or balcony level From a surface or boundary line facing a terminal K Froma terminal facing a terminal Horizontal flue From a terminal facing a terminal Vertical flue L From an opening in carport e g door window into the dwelling
57. s 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 The following guidelines indicate the general requirements for siting balanced flue terminals For GB recommendations are given in BS 5440 Pt For IE recommendations are given in the current edition of l S 813 Domestic Gas Installations 2 If the terminal discharges onto a pathway or passageway check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway 3 If a terminal is less than 2 metres above a balcony above ground or above a flat roof to which people have access then a suitable terminal guard must be provided 4 Reduction to the boundary is possible down to 25mm but the flue deflector kit part no 5111068 must be fitted 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 IMPORTANT If fitting a Plume Displacement Flue Kit the air inlet must be a minimum of 50mm from any opening windows or doors V A Opening Window or Door 150mm MI Horizontal Flues Plume Displacement 60 10
58. s In GB this is BS 6891 In IE this is the current edition of I S 813 Domestic Gas Installations 2 The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock Fig 7 3 Ensure that the pipework from the meter to the appliance is of adequate size and the demands of any other gas appliances in the property are taken into consideration Do not use pipes of a smaller diameter than the boiler gas connection 22mm Electrical Supply External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current E E Wiring Regulations In IE reference should be made to the current edition of ETCI rules 2 The mains supply is 230V 50H 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 cylinder thermostat is used in conjunction with a 3 port 2 position valve or 2 port zone valve Bath amp Shower Rooms If the boiler is fitted in a room containing a bath or shower and NOT FITTED with any optional integral timer or thermostat it can be fitted in zone 2 Figs A amp B shows zone dim
59. s competent in the use of a flue gas analyser and the interpretation of the results he flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements Competence can be demonstrated by satisfactory completion of the CPA ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 Parts to 4 Check the Combustion Performance CO CO ratio 4 Set the boiler to operate at maximum rate as described in Section 14 1 1 to 14 1 6 5 Remove the plug from the flue sampling point insert the analyser probe and obtain the CO CO ratio This must be less than 0 004 6 If the combustion reading CO CO ratio is greater than this and the integrity of the complete flue system and combustion circuit seals has been verified and the inlet gas pressure and gas rate are satisfactory either Perform the Annual Servicing Inspection Section 12 2 amp re check Adjust the gas valve Section 14 0 amp re check Replace the gas valve Section 13 24 amp re check Annual Servicing Inspection Ensure that the boiler is cool 2 Ensure that both the gas and electrical supplies to the boiler are isolated 3 Slacken the screws securing the facia panel Lift the outercase panel so that its securing tabs are clear of the facia Remove the panel allowing the
60. t is completed B warranty is registered with Baxi Eb The boiler has an annual service For full terms and conditions visit www baxi co uk terms Failure to adhere to terms and conditions will void your manufacturer s warranty SE Baxi if Brooks House Coventry Road Warwick CV34 4LL C benchmar COLLE M THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING n kr a n AND SERVICING OF DOMESTIC HEATING AND HOY WATER SYSTEMS Please ensure the boiler is installed in accordance with these installation L instructions and that you adhere to the Building Regulations e amp oe n All descriptions and illustrations provided in this document 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 Conditions of Sale which are available on request part of 7219681 OI 5 15
61. tallation All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Codes of Practice refer to the most recent version In GB the following Codes of Practice apply Standard Scope BS 6891 Gas Installation BS 5546 Installation of hot water supplies for domestic purposes BS EN 12828 Heating systems in buildings BS EN 14336 Installation amp commissioning of water based heating systems BS 6798 Installation of gas fired hot water boilers BS 5440 Part 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 In IE the following Codes of Practice apply Standard Scope LS 813 Domestic Gas Installations The following standards give valuable additional information BS 5546 Installation of hot water supplies for domestic purposes BS EN 12828 Heating systems in buildings BS EN 14336 Installation amp commissioning of water based heating systems BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems Safe Manual Handling The following advice should be adhered to from when first handling the boiler to the final stages of installation and also during maintenance General Most injuries as a result of inappropriate handling and lifting are to the back b
62. turi to the collector IMPORTANT When fitting the new venturi ensure the arrows on it s base point into the collector Fig 48 4 Examine the seals and burner gasket replace if necessary 5 Reassemble in reverse order ensuring that the injector is in place Injector Fig 50 Remove the collector and fan assembly as described in section 13 3 2 Extract and replace the injector and reassemble in reverse order 35 13 0 Changing Components Burner Fig 51 Undo the screws securing the collector to the venturi and Cover Burner Ene extension piece Remove this extension piece from the x cover not 32 models Extension Piece Not on 32 model l Notion mone 2 Withdraw the burner from the cover and replace with the new one 3 Examine the gasket replacing if necessary B 4 Reassemble in reverse order Venturi Insulation Fig 52 Remove the electrode leads noting their positions Also remove the electrodes as described in section 13 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 f the rear insulation requires replacement remove it and all debris from the heat exchanger Also it may be
63. ut all other parts of the body are vulnerable particularly shoulders arms and hands Health amp Safety is the responsibility of EVERYONE There is no safe limit for one man each person has different capabilities The boiler should be handled and lifted by TWO PEOPLE Do not handle or lift unless you feel physically able Wear appropriate Personal Protection Equipment e g protective gloves safety footwear etc Preparation Co ordinate movements know where and when you are both going Minimise the number of times needed to move the boiler plan ahead Always ensure when handling or lifting the route is 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 truck or other suitable trolley Always grip the boiler firmly and before lifting feel where the weight is concentrated to establish the centre of gravity repositioning yourself as necessary See the installation section of these instructions for recommended lift points Remember The circumstances of each installation are different Always asses the risks associated with handling and lifting according to the individual c
64. y 5 Fit the air vent to the pump body and reassemble in reverse order Socket Headed Screw EMEN Automatic Air Vent Fig 58 Drain the primary circuit and unscrew the automatic air vent from the pump body 2 Examine the O ring seal replacing if necessary and fit it to the new automatic air vent Fig 57 3 Reassemble in reverse order Automatic Air Vent Fig 58 38 Baxi Heating UK Ltd 2015 13 0 Changing Components EALE Pressure Gauge Figs 59 amp 60 Gauge Retaining Bracket Drain the 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 bracket Pressure Gauge Fig 59 4 Examine the sealing washer replace if necessary 5 Reassemble in reverse order EMFA Pressure Relief Valve Fig 61 Drain the primary circuit 2 Disconnect the discharge pipe from the valve Using a Pressure Gauge f suitable hexagon key undo the grub screw sufficiently to Capillary 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 orientation Reassemble in reverse order
65. y 1 ii If within 10 minutes of the burner lighting the boiler emperature twice exceeds the selected temperature by 30 n these instances poor primary circulation is indicated 3 By turning the selector switch to the Reset position for a minimum of 5 seconds when EI10 E130 amp E133 are displayed it is possible to relight the boiler 4 If this does not have any effect or the codes are displayed regularly further investigation is required 45 17 0 Fault Finding Refer to Section 16 0 Illustrated Wiring Diagram for position of terminals and components Central Heating Follow operational sequence Go to section A Turn selector switch to flf The display illuminates Error 110 flashing Error 30 flashing Error 33 flashing NO NO Turn the selector switch to If the error 10 is still flashing reset position for 5 seconds Go to section J Go to section E Go to section C Turn Central Heating Ensure all controls and thermostat to Maximum integral clock are calling for Go to section B Pump runs heat Ensure that primary Error E125 or E193 flashing circulation is OK amp that there is no blockage 3 way valve is open to Central YES mpm NGA gt Go to section K Heating circuit NO F Error 160 flashing Ducis Go to section D YES Error 160 flashing Fan runs at correct speed re Go to section L YES Spark at ignition electrodes for YES Go to section H up to 5 se
66. y warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 12 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with LS 813 An example of this is given in LS 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist Case Front Panel y Facia Panel Fig 40 Baxi Heating UK Ltd 2015 11 0 Completion mE Completion Instruct the user in the operation of the boiler and system including extenal controls 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 the rear of this publication that are 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 addition to the Benchmark Commissioning Checklist 5 Hand over the Users Operating Installation and Servicing Instructions giving advice o
67. y winding Replace fan terminals 5 amp 7 Replace PCB Baxi Heating UK Ltd 2015 47 17 0 Fault Finding E Temperature sensors faulty Cold resistance approximately 10kQ 25 C DHW and CH sensors 20kQ 25 C Flue sensor resistance reduces with increase in temp Check and correct the connection of the tube between the venturi and gas valve 2 Gesta Fe PCB X3 connector is 230V AC across terminals amp 2 Ensure gas is on and purged Replace gas valve Replace PCB Voltage at PCB X2 connector is at least 100V DC across terminals 2 amp 5 Note from multimeter connect common to 2 amp volt to 5 Check wiring Check and correct if necessary Ignition electrode and lead 2 Electrode connection 3 Spark gap and position Burner Sensing Electrode Spark Ignition JD Electrode j y TL os Electrode Position 48 Baxi Heating UK Ltd 2015 17 0 Fault Finding H k Check supply pressure at the gas valve Minimum 7 mbar 2 Check and correct if necessary The mechanical set of the gas valve CO2 values see instruction 2 Flame sensing electrode and lead connections 3 Flame sensing electrode position Replace PCB Replace flame sensing electrode Flame current should be more than 0 5 u A Overheat thermostat operated or Allow to cool Continuity faulty i e continuity across across thermostat terminals thermostat terminals m

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