Potterton Promax 24 Combi ErP Manual

P
Promax Ultra Combi
Installation and Service Manual
Condensing Combination Boiler
24 - 28 - 33 - 40
en
United Kingdom
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.

2© Baxi Heating UK Ltd 2016
© Baxi Heating UK Ltd 2016 All rights reserved. No part of this publication may
be reproduced or transmitted in any form or by any means, 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 Limited,
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.
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.
0085
ISO 9001
FM 00866
Model Range
Potterton Promax Ultra 24 Combi ErP
G.C.No 47-393-54
Potterton Promax Ultra 28 Combi ErP
G.C.No 47-393-55
Potterton Promax Ultra 33 Combi ErP
G.C.No 47-393-56
Potterton Promax Ultra 40 Combi ErP
G.C.No47-393-57
Building Regulations and the Benchmark Commissioning
Checklist
Building Regulations (England & Wales) require notification of
the installation of a heating appliance to the relevant Local
Authority Building Control Department. This can be achieved
via a Competent Persons Self Certification Scheme as an
option to notifying the Local Authority directly.
The Health & Safety Executive operates the ‘Gas Safe Register’,
a self-certification scheme for gas heating appliances.
These arrangements 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
the commissioning checklist is completed by the installer. The
relevant section of Building Regulations only relates to
dwellings. Therefore the checklist only applies if the appliance is
being installed in a dwelling or some related structure.
The flowchart opposite gives guidance for installers on the
process necessary to ensure compliance with Building
Regulations.

3
Installer Notification Guidelines
© Baxi Heating UK Ltd 2016
Choose Building
Regulations Notification
Route
Contact your relevant Local
Authority Building Control
(LABC) who will arrange
an inspection or contact
a government approved
inspector
LABC will record the data
and will issue a
certificate of compliance
‘Gas Safe Register’ will issue a
Building Regulations Compliance
Certificate to the property owner
and inform the relevant LABC
You must ensure that the
certificate number issued by
the ‘Gas Safe Register’ is written
onto the Benchmark Checklist
Scheme Members only
Call ‘Gas Safe Register’ on:
0800 408 5577
or log onto:
www.gassaferegister.co.uk
within 10 days
If you notify via the ‘Gas Safe
Register’, the register will issue
the Building Regulations
certificate on members’ behalf
Complete the
Benchmark Checklist
Install and Commission this
appliance to manufacturer's
instructions
Competent Person's
Self Certification Scheme
Building Control
Complete the
Benchmark Checklist
Install and Commission this
appliance to manufacturer's
instructions

4
Legislation
© Baxi Heating UK Ltd 2016
Codes of Practice - refer to the most recent version
IMPORTANT - Installation, Commissioning, Service & Repair
This appliance must be installed in accordance with the manufacturer’s instructions and
the regulations in force. Read the instructions fully before installing or using the
appliance.
In GB, this must be carried out by a competent person as stated in the Gas Safety
(Installation & 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 I.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.
This company declares 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 & 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 I.E.E. 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
I.S. 813 ‘Domestic Gas Installations’, the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
All systems must be thoroughly flushed and treated with
inhibitor (see section 6.2).
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
In GB the following Codes of Practice apply:
Standard Scope
BS 6891 Gas Installation.
BS 5482 Part 1 Butane & Propane Gas Installation
BS 5546 Installation of hot water supplies for domestic
purposes.
BS EN 12828 Heating systems in buildings.
BS EN 12831 Heating systems in buildings - Calculation of load.
BS EN 14336 Installation & commissioning of water based
heating 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.
In IE the following Codes of Practice apply:
Standard Scope
I.S. 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 12831 Heating systems in buildings - Calculation of load.
BS EN 14336 Installation & 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.
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 Ultra 24 - 28 - 33 - 40 Combi 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 Notified Body authorized
by the United Kingdom Competent Authority, and carrying the Notified Body
Number 0086.
Type test for purpose of Regulation 5 certified by:
Notified Body 0085.
Product/Production certified by:
Notified Body 0086.
For GB/IE only.

5
Safe Manual Handling
© Baxi Heating UK Ltd 2016
General
The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.
Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands.
Health & 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 conditions.
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 !!

6© Baxi Heating UK Ltd 2016
CONTENTS
1.0 Introduction 7
2.0 General Layout 8
3.0 Appliance Operation 9
4.0 Technical Data 10
5.0 Dimensions and Fixings 12
6.0 System Details 13
7.0 Site Requirements 16
8.0 Flue Options 21
9.0 Installation 23
10.0 Commissioning 29
11.0 Completion 33
12.0 Servicing 34
13.0 Changing Components 36
14.0 Combustion & Calibration 44
15.0 Electrical 45
16.0 Short Parts List 46
17.0 Fault Finding 47
18.0 External Low Voltage Controls 53
19.0 Notes 56
Benchmark Checklist 58
Section Page

7
1.0 Introduction
© Baxi Heating UK Ltd 2016
Fig. 1
1.1 Description
1. The Potterton Promax Ultra Combi Range are fully
automatic gas fired wall mounted condensing combination
boilers. It is room sealed and fan assisted, and will serve central
heating and mains fed domestic hot water.
2. The boiler is set to give a maximum output of :-
24 models - 24 kW DHW
21.2 kW CH Pnc (Condensing)
28 models - 28 kW DHW
25.3 kW CH Pnc (Condensing)
33 models - 33 kW DHW
29.6 kW CH Pnc (Condensing)
40 models - 40 kW DHW
33.8 kW CH Pnc (Condensing)
3. The boiler is factory set for use on Natural Gas (G20). It can
be converted to operate on Propane (G31) - see Section
10.1.11 ‘Gas Type Check’.
4. The boiler is suitable for use only on fully pumped sealed
heating systems. Priority is given to domestic hot water.
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
(Fig. 2).
6. The boiler model, serial number and Gas Council number
are also shown on the information label behind the boiler
control flap (Fig. 1). This is for user reference.
7. The boiler is intended to be installed in residential /
commercial / light industrial E.M.C. environments on a
governed meter supply only.
8. The boiler must be installed with one of the purpose
designed flues such as one of the standard horizontal
telescopic flue kits detailed in the Flue Installation Guide.
9. All systems must be thoroughly cleansed, flushed and
treated with inhibitor (see section 6.2).
1.2 Optional Extras
Various timers, external controls, etc. are available as optional
extras. Full details are contained in the relevant sales literature.
1.3 Contents of Pack
The pack contains:-
• Boiler
• Wall Plate inc. Taps
• Template
• Fittings & Literature Pack
NOTE: These Installation & Servicing Instructions MUST be
read in conjunction with the Flue Installation Guide
supplied in the Literature Pack.
Fig. 2
Data Badge
Gas Type Label
Control Flap
Information Label

8
2.0 General Layout
© Baxi Heating UK Ltd 2016
2.1 Layout
1. Expansion Vessel
2. Expansion Vessel Valve
3. Primary Heat Exchanger
4. DHW Plate Heat Exchanger
5. Pump with Automatic Air Vent
(NOTE: The boiler can be fitted with one of two alternative
pumps, Grundfos or Wilo. All boiler illustrations show
Grundfos. Section 13.11 details both types).
6. Central Heating System Pressure Gauge
7. Fan Assembly
8. Air/Gas Collector
9. Flue Sensor
10. Flame Sensing Electrode
11. Spark Ignition Electrode
12. Combustion Box Cover & Burner
13. Control Box Display
14. Condensate Trap
15. Safety Pressure Relief Valve
16. Drain Off Point
17. Gas Valve
18. Diverter Valve Motor
19. Boiler Controls
20. Boiler Adaptor
21. Heating Flow Sensor
22. Safety Thermostat
1
23
4
5
6
7
8
10
11
12
13
19
14
15
16
17
18
9
20
21
22

9
3.0 Appliance Operation
© Baxi Heating UK Ltd 2016
3.1 Central Heating Mode
1. With a demand for heating, the pump circulates water
through the primary circuit.
2. Once main burner ignites the fan speed controls the gas
rate to maintain the heating temperature measured by the
temperature sensor.
3. When the flow temperature exceeds the setting
temperature, a 3 minute delay occurs before the burner
relights automatically (anti-cycling). The pump continues to
run during this period.
4. When the demand is satisfied the burner is extinguished
and the pump continues to run for a period of 3 minutes
(Pump Overrun).
3.2 Domestic Hot Water Mode
1. Priority is given to the domestic hot water supply. A
demand at a tap or shower will override any central heating
requirement.
2. The flow of water will operate the Hall Effect Sensor
which requests the 3 way valve to change position. This will
allow the pump to circulate the primary water through the
DHW plate heat exchanger.
3. The burner will light automatically and the temperature of
the domestic hot water is controlled by the temperature
sensor.
4. When the domestic hot water demand ceases the burner
will extinguish and the diverter valve will remain in the
domestic hot water mode, unless there is a demand for
central heating.
3.3 Boiler Frost Protection Mode
1. The frost protection mode is integral to the appliance and
functions as long as there is power to the boiler, as indicated
by the standby signal .
2. With CH & DHW or CH only selected, when the boiler
temperature falls below 5°C the boiler will fire until a
temperature of 30°C is reached.
3. If DHW only is selected, when the boiler CH temperature
falls below 5°C the boiler will fire until a temperature of
30°C is reached. When the boiler DHW temperature falls
below 5°C the boiler will fire until a temperature of 7°C is
reached.
4. Further protection can be incorporated by using a system
frost thermostat.
3.4 Pump Protection
1. If the boiler has been inactive for a period of 24 hours the
pump will automatically operate for 1 minute to prevent
sticking.
Key
1. Pump with Automatic Air Vent
2. Boiler Drain Tap
3. Pressure Gauge
4. Safety Pressure Relief Valve
5. DHW Flow Sensor/Filter/Restrictor
6. Domestic Hot Water Priority Sensor
7. Domestic Hot Water NTC Sensor
8. Hydraulic Pressure Switch
9. Three Way Valve & Motor
10. Plate Heat Exchanger
11. Gas Valve
12. Safety Thermostat (105° C)
13. Heating Flow Sensor
14. Flue Sensor
15. Boiler Adaptor
16. Primary Heat Exchanger
17. Spark Ignition Electrode
18. Burner
19. Flame Sensing Electrode
20. Air/Gas Collector
21. Heating Return Sensor
22. Fan
23. Air/Gas Venturi
24. Expansion Vessel
Connections:-
A – Condensate Drain
B – Heating Flow
C – Domestic Hot Water Outlet
D – Gas Inlet
E – Cold Water Inlet On/Off Valve and filter
F – Heating Return
Fig. 3
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
14
17
18
19
21
22
23
24
ABCDEF
20

10
4.0 Technical Data
© Baxi Heating UK Ltd 2016
0
200 400 600 800 1000 1200
0.5
1
1.5
2
2.5
3
3.5
4
Metre (wg)
Flow Rate (l/h)
Pump - Available Head
0
5
5.5
6
4.5
4.1 Promax Ultra 24, 28, 33, 40 Combi
Flue Terminal Diameter 100mm
Dimensions Projection 125mm
Outercase Dimensions
Casing Height - 763mm
Overall Height Inc Flue Elbow - 923mm
Casing Width - 450mm
Casing Depth - 355mm
Weights
(24/28)
Packaged Boiler Carton 41.5kg
Installation Lift Weight 36kg
(33)
Packaged Boiler Carton 43.5kg
Installation Lift Weight 38kg
(40)
Packaged Boiler Carton 44.5kg
Installation Lift Weight 39kg
Central Heating Primary Circuit
Pressures
bar
Safety Discharge 3
Max Operating 2.5
Min Operating 0.5
Recommended Operating Range 1-2
DHW Circuit bar
Pressures
Max Operating 8
Min Operating 0.15
Flow Rates (24) (28) (33) (40)
l/min l/min l/min l/min
DHW Flow Rate
@ 30o C Rise 10.9 12.9 15.3 18.3
DHW Flow Rate
@ 35o C Rise 9.8 11.5 13.5 16.4
Min Working
DHW Flow Rate 2 2 2 2
Pump
Available Head See graph below
Expansion Vessel - (For Central Heating only.
Integral with appliance)
bar
Min Pre-charge Pressure 0.5
(24 & 28) (33 & 40)
litre litre
Max Capacity of
CH System 125 125
Primary Water Content
of Boiler (unpressurised) 2.5 2.8
Connections copper tails
Gas Inlet - 22mm
Heating Flow - 22mm
Heating Return - 22mm
Cold Water Inlet - 15mm
Hot Water Outlet - 15mm
Pressure Relief Discharge - 15mm
Temperatures
C.H. Flow Temp (adjustable)
25°C to 80°C max (± 5°C)
D.H.W. Flow Temp (adjustable)
35°C to 60°C max (± 5°C)
dependent upon flow rate
NOxClass 5
Clearances
Above Casing 175 mm Min
Below Casing 150 mm* Min
Front 450 mm Min (For Servicing)
Front 5 mm Min (In Operation)
L.H. Side 5 mm Min
R.H. Side 5 mm Min
*This is MINIMUM recommended dimension. Greater
clearance will aid installation and maintenance.
Heat Input CH Qn Hs (Gross)
Max Min
24 model kW 22.20 3.89
28 model kW 26.64 4.32
33 model kW 31.08 5.33
40 model kW 35.52 6.55
Heat Output CH (Non-Condensing)
Max Min
24 model kW 20.0 3.4
28 model kW 24.0 3.8
33 model kW 28.0 4.7
40 model kW 32.0 5.7
Electrical Supply 230V~ 50Hz
(Appliance must be connected to an
earthed supply)
Electrical Protection
IPX5D
Internal Fuse Rating F2L
Appliance Category CAT I 2H 3P
Injector
24 model mm 4.4
28 model mm 4.6
33 model mm 4.9
40 model mm 5.8
Heat Output CH (Condensing) Pnc
Max Min
24 model kW 21.2 3.7
28 model kW 25.3 4.1
33 model kW 29.6 5.1
40 model kW 33.8 6.2
Heat Input DHW Qnw Hs (Gross)
Max
24 model kW 27.4
28 model kW 32.1
33 model kW 37.8
40 model kW 45.8
Heat Output DHW Max
24 model kW 24
28 model kW 28
33 model kW 33
40 model kW 40
Condensate Drain
To accept 21.5mm (3/4in) plastic waste pipe
External Fuse Rating 3A
Power Consumption
24 model W 85
28 model W 90
33 model W 95
40 model W 100
Inlet Pressure (Natural Gas - G20)
mbar 20
Max Gas Rate (Natural Gas - G20)
(After 10 mins)
24 model m3/h 2.61
28 model m3/h 3.05
33 model m3/h 3.59
40 model m3/h 4.35
Inlet Pressure (Propane - G31)
mbar 37
NATURAL GAS ONLY !
PROPANE ONLY !
Max Gas Rate (Propane - G31)
(After 10 mins)
24 model kg/h 1.96
28 model kg/h 2.29
33 model kg/h 2.70
40 model kg/h 3.27
NOTE: All data in this section are nominal values
and subject to normal production tolerances.
IMPORTANT: Where Low Flow Taps or Fittings are
intended to be used in the DHW system connected it is
strongly recommended that the DHW flow rate DOES
NOT fall below 2.5l/min. This will ensure reliable
operation of the DHW function.
SAP 2009 Annual Efficiency for N. G.
models is 89.1%
SAP 2009 Annual Efficiency for L.P.G.
models is 90.1%
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.
Product Characteristics Database (SEDBUK)
Appliance Type C13 C33 C43 C53

11
© Baxi Heating UK Ltd 2016
4.0 Technical Data
Technical parameters for boiler combination heaters
Condensing boiler
24
PottertonPromax Ultra Combi ErP
Rated heat output
Seasonal spaceheating energy efficiency
Auxiliary electricity consumption
Other items
28 33 40
Low-temperatureboiler(1)
B1 boiler
Cogeneration spaceheater
Combination heater
Prated
kW
Useful heatoutputatrated heatoutput
and high temperatureregime(2)
P4
kW
Useful heatoutputat30% of rated heat
outputand low temperatureregime(1)
P1
kW
Šs
%
Useful efficiency atrated heatoutputand
high temperatureregime(2)
Š4
%
Useful efficiency at30% of rated heat
outputand low temperatureregime(1)
Š1
%
Full load
elmax
kW
Partload
elmin
kW
Standby mode
PSB
kW
Standby heatloss
Pstby
kW
Ignition burner power consumption
Pign
kW
Annual energy consumption
QHE
kWh
GJ
Sound power level, indoors
LWA
dB
Emissions of nitrogen oxidesNO
X
Daily electricity consumption
Domestic hot water parameters
Declared load profile
Water heating energy efficiency
Qelec
kWh
Annual electricity consumption
AEC
kWh
Šwh
%
Daily fuel consumption
Qfuel
kWh
Annual fuel consumption
AFC
GJ
(1) Low temperaturemeans for condensing boilers 30°C, for low temperatureboilers 37°C and for other heaters 50°C returntemperature(at
heater inlet).
(2) High temperatureregime means 60°C returntemperatureatheater inlet and 80°C feed temperatureatheater outlet.
S
See
Theback cover for contactdetails.
mg/kWh
YesYesYes
NoNoNo
YesYesYes
NoNoNo
NoNoNo
20 3224
20.0 32.024.0
6.7 10.78.0
93 9393
88.0 87.987.9
98.0 98.098.0
0.030 0.0350.042
0.013 0.0130.013
0.003 0.0030.003
0.035 0.0450.035
---
17204 2752720645
62 9974
49 5150
15 2417
XL XXLXL
0.162 0.2760.232
36 6151
88 8586
22 2822
17 22
Yes
No
Yes
No
No
28
28.0
9.4
93
88.1
98.1
0.041
0.013
0.003
0.040
-
24086
87
53
15
XXL
0.214
47
87
28
2217

12
5.0 Dimensions and Fixings
© Baxi Heating UK Ltd 2016
Dimensions
A763mm
B355mm*
*This can be reduced to 345mm by
removing the boiler control access flap
C450mm
D116mm Ø Min.
E160mm
(207mm for 80/125mm
flue systems)
F150mm
G106mm
H170mm
J280mm
360° Orientation
Flue Ø 100mm
D
C
B
A
E
G
F
At least 1.5°
H
J
Boiler
Side
Boiler
Side
Heating
Flow
(22mm)
Hot Water
Outlet
(15mm)
Gas
Inlet
(22mm)
Cold Water
Inlet
(15mm)
Heating
Return
(22mm)
Pressure
Relief
Valve
(15mm)
Condensate
Drain
65 mm 65 mm 65 mm 65 mm 95 mm45 mm
192 mm
50 mm
Tap Rail
NOTE: There must be no part of the air duct (white
tube) visible outside the property after installation. The
flue seal should fit neatly and effect a good seal. For full
detail refer to Section 9.7 “Fitting the Flue”.

13
6.0 System Details
© Baxi Heating UK Ltd 2016
6.1 Information
1. The Potterton Promax Ultra Condensing Combination
Boiler is a ‘Water Byelaws Scheme - Approved Product’.
To comply with the Water Byelaws your attention is drawn
to the following installation requirements and notes (IRN).
a) IRN 001 - See text of entry for installation
requirements and notes.
b) IRN 302 - Byelaw 14.
2. Reference to the WRc publications, ‘Water fittings and
materials directory’ and ‘Water supply byelaws guide’ give full
details of byelaws and the IRNs.
6.2 Treatment of Water Circulating Systems
1. All recirculatory water systems will be subject to corrosion
unless they are flushed and an appropriate water treatment is
applied. To prevent this, follow the guidelines given in BS
7593 “Treatment of Water in Domestic Hot Water Central
Heating Systems” and the treatment manufacturers
instructions.
2. Treatment must involve the use of a proprietary cleanser,
such as Sentinel X300 or X400, or Fernox F3 and an inhibitor
such as Sentinel X100 or Fernox MB-1.
3. 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.
4. It is important to check the inhibitor concentration after
installation, system modification and at every service in
accordance with the inhibitor manufacturer’s instructions.
(Test kits are available from inhibitor stockists.)
5. For information or advice regarding any of the above
contact Baxi Customer Support 0344 871 1545.
6.3 Bypass
1. The boiler is fitted with an automatic integral bypass. Some
systems may require an additional external bypass.
6.4 System Control
1. Further external controls (e.g. room thermostat sensors)
MUST be fitted to optimise the economical operation of the
boiler in accordance with Part L of the Building Regulations
(2010). A range of optional controls is available. Full details
are contained in the relevant Sales Literature.

14
6.0 System Details
© Baxi Heating UK Ltd 2016
Fig. 4
Fig. 6
Pressure Relief Valve
Discharge Pipe
Fig. 5
6.5 System Filling and Pressurising
1. A filling point connection on the central heating return
pipework must be provided to facilitate initial filling and
pressurising and also any subsequent water loss
replacement/refilling.
2. A filling loop is supplied with the boiler. Follow the
instructions provided with it.
3. The filling method adopted must be in accordance with all
relevant water supply regulations and use approved equipment.
4. Your attention 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”.
5. 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.
6.6 Expansion Vessel (Central Heating only)
1. The appliance expansion vessel is pre-charged to 1.0 bar.
Therefore, the minimum cold fill pressure is 1.0 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 1. For IE, the
current edition of I.S. 813 “Domestic Gas Installations”.
6.7 Safety Pressure Relief Valve (Fig. 6)
1. 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
15mm 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 and towards the wall (Fig. 6a).
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).
5. A boiler discharge pump is available, part no. 720648301.
This pump will dispose of both condensate & high temperature
water from the relief valve. It has a maximum head of 5 metres.
Control Box removed
for clarity
Filling Loop
Connections
Stop
Valve
Double
Check
Valve
DHW
Mains
Inlet
CH
Return
Temporary
Loop
Stop
Valve
Fig. 6a
The end of the pipe should
terminate facing down and
towards the wall

15
6.0 System Details
© Baxi Heating UK Ltd 2016
6.8 Domestic Hot Water Circuit (Fig. 7)
1. All DHW circuits, connections, fittings, etc. should be fully
in accordance with relevant standards and water supply
regulations.
2. Your attention is drawn to:
for GB: Guidance G17 to G24 and recommendation R17 to
R24 of the Water Regulations Guide.
for IE: the current edition of I.S. 813 “Domestic Gas
Installations”.
3. The Water Regulations recommendations for England and
Wales prohibits backflow from appliances into the
wholesome water supply due to thermal expansion.
However this type of instantaneous combination boiler, with
less than 15 litres of stored capacity, does not require any
backflow prevention device as any thermal expansion is
accommodated within the appliance.
It is possible in certain circumstances that other cold water
demands (e.g. washing machines, flushing of W.C.s) may
affect the DHW function of the boiler. In these instances the
fitting of a backflow prevention device and expansion vessel
is recommended.
4. Also if there is an existing check valve, loose jumpered
stop cock, water meter or water treatment device already
fitted to the wholesome water supply connected to the
boiler domestic hot water (DHW) inlet supply then a
suitable expansion device may be required.
5. The boiler’s maximum working mains pressure is 8 bar,
therefore all pipework, connections, fittings, etc. should be
suitable for pressures in excess of 8 bar. A pressure reducing
valve must be fitted for pressures in excess of 8 bar. The
manufacturer of any outlet fittings, such as a shower valve,
may require a lower maximum pressure. The pressure
reduction must take account of all fittings connected to the
DHW system.
6.9 Showers
1. If a shower control is supplied from the appliance it
should be of the thermostatic or pressure balanced type.
Thermostatic type shower valves provide the best comfort
and guard against water at too high a temperature. Existing
controls may not be suitable - refer to the shower valve
manufacturer.
6.10 Hard Water Areas
1. If the area of the installation is recognised as a HARD
WATER AREA then a suitable device should be fitted to
treat the mains water supply to the boiler. Contact your
Water Distribution Company for advice on suitable devices.
Boiler
Other Tap
Outlets
Expansion
Vessel*
To Hot
Taps
Check
Valve*
Pressure Reducer
Valve*
Stop Tap
Fig. 7
*See 6.8 for instances when
these items may be required
IMPORTANT: Where Low Flow Taps or
Fittings are intended to be used in the DHW
system connected to a Potterton Promax Ultra
it is strongly recommended that the DHW flow
rate DOES NOT fall below 2.5l/min. This will
ensure reliable operation of the DHW function.

16
7.0 Site Requirements
© Baxi Heating UK Ltd 2016
7.1 Location
1. The boiler may be fitted to any suitable wall with the flue
passing through an outside wall or roof and discharging to
atmosphere in a position permitting satisfactory removal of
combustion products and providing an adequate air supply.
The boiler should be fitted within the 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. Where the boiler is sited in an unheated enclosure and
during periods when the heating system is to be unused it is
recommended that the permanent live is left on to give
BOILER frost protection. NOTE: THIS WILL NOT PROTECT
THE SYSTEM !
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
edition of Institute of Gas Engineers Publication IGE/UP/7
(Gas Installations in Timber Framed Housing).
7.2 Clearances (Figs. 8 & 9)
1. 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.
*This is MINIMUM recommended dimension. Greater
clearance will aid installation and maintenance.
7.3 Ventilation of Compartments
1. Where the appliance is installed in a cupboard or
compartment, no air vents are required.
2. BS 5440: Part 2 refers to room sealed appliances installed
in compartments. The appliance will run sufficiently cool
without ventilation.
150mm* Min
763mm
450mm
175mm Min (300mm
Min if using 80/125mm
flueing system)
5mm Min
5mm Min
450mm Min
For Servicing
Purposes
Fig. 8
Fig. 9
In Operation
5mm Min
At least 1.5°
355mm
(345mm with flap removed)

17
7.0 Site Requirement
© Baxi Heating UK Ltd 2016
7.4 Gas Supply
1. The gas installation should be in accordance with the
relevant standards. In GB this is BS 6891 (NG) or BS 5482
Pt. 1 (LPG). 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. 10).
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).
7.5 Electrical Supply
1. External wiring must be correctly earthed, polarised and
in accordance with relevant regulations/rules. In GB this is
the current I.E.E. Wiring Regulations. In IE reference should
be made to the current edition of ETCI rules.
2. The mains supply is 230V ~ 50Hzfused 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.
7.6 Bath & Shower Rooms
1. If the boiler is fitted in a room containing a bath or
shower it can be fitted in zone 2, (Figs. A & B shows zone
dimensions for a bathtub. For other examples refer to the
Current I.E.E. Wiring Regulations) 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.
Fig. 10
Gas Service Cock
Zone 2
Zone 1
Zone 0
Zone 2
Zone 2
Window
Recess
Window
Recess
0.6 m
Ceiling
Outside Zones
Zone 2
Zone 1
Zone 0
2.25 m
Window Recess
Zone 2
0.6 m
Fig. A
Fig. B
In GB Only
In GB Only

18
7.0 Site Requirements
© Baxi Heating UK Ltd 2016
7.7 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.
1. The condensate outlet will accept 21.5mm (3/4in) 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 regulations in force. BS 6798 & Part H1 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.
11. 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 fluctuations
when WC's are flushed or sinks emptied then back-pressure
may force water out of the boiler trap and cause appliance
lockout.
21.5mm
2.5° Minimum fall
i) Termination to an internal soil and
vent pipe
450mm min*
Boiler
2.5° Minimum fall
ii) External termination via internal discharge branch
e.g sink waste - downstream*
Sink
Pipe must terminate above
water level but below
surrounding surface. Cut
end at 45°
50mm per metre of pipe run
50mm per metre of pipe run
*450mm is applicable to properties
up to 3 storeys.
For multi-storey building installations
consult BS 6798.
Examples are shown of the following methods of termination:-
i) to an internal soil & vent pipe
ii) via an internal discharge branch (e.g. sink waste) downstream of the trap
iii) to a drain or gully
iv) to a purpose made soakaway
v) pumped into an internal discharge branch (e.g. sink waste) downstream of the trap
vi) pumped into an external soil & vent pipe
vii) to a drain or gully with extended external run & trace heating
It 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.
*It is NOT RECOMMENDED
to connect upstream of the
sink or other waste water
receptacle !
32mm Insulation
Boiler
2.5° Minimum fall
iii) Termination to a drain or gully
50mm per metre of pipe run
Pipe must terminate above
water level but below
surrounding surface. Cut
end at 45°
Boiler
500mm min
2.5° Minimum fall
iv) Termination to a purpose made soakaway
Holes in the soak-away must
face away from the building
50mm per metre of pipe run
Further specific requirements for soakaway
design are referred to in BS 6798.

19
7.0 Site Requirements
© Baxi Heating UK Ltd 2016
7.7 Condensate Drain (cont.)
12. A boiler discharge pump is available, ‘MULTIFIT’
part no. 720648301. This pump will dispose of both
condensate & high temperature water from the relief valve.
It has a maximum head of 5 metres. Follow the instructions
supplied with the pump.
13. Condensate Drain Pipe ‘Trace Heating’ Elements are
available in various lengths. ‘MULTIFIT’ part nos.:-
1 metre 720644401
2 metre 720664101
3 metre 720664201
5 metre 720664401*
*Where the drain is between 3 & 5 metres 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.
Boiler
vi) pumped into an external soil & vent pipe
2.5° Minimum fall
50mm per metre of pipe run
Condensate Pump
Unheated Location
(e.g. Garage)
Basement or similar
(heated)
Boiler
2.5° Minimum fall
50mm per metre of pipe run
Pipe must terminate above
water level but below
surrounding surface. Cut
end at 45°
The ‘Trace Heating’ element
must be installed in accordance
with the instructions supplied.
External runs & those in
unheated locations still require
insulation.
vii) to a drain or gully with extended
external run & trace heating
Boiler
v) pumped into an internal discharge branch
(e.g. sink waste) downstream of the trap
Pipe must terminate above
water level but below
surrounding surface. Cut
end at 45°
2.5° Minimum fall
50mm per metre of pipe run
Condensate Pump
Sink
Basement or similar
(heated)

20
7.0 Site Requirements
© Baxi Heating UK Ltd 2016
7.8 Flue
NOTE: Due to the nature of the boiler a plume of water
vapour will be discharged from the flue. This should be
taken into account when siting the flue terminal.
1. The following guidelines indicate the general requirements
for siting balanced flue terminals. For GB recommendations
are given in BS 5440 Pt 1. For IE recommendations are given
in the current edition of I.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.
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.
*4. Reduction to the boundary is possible down to 25mm
but flue deflector part no. 5111068 must be used.
N
I
I
G
F
M
I
AAF
H
J,K
D
E
H
Likelyflue positions requiring
aflue terminal guard
C
RA
I
J,K
I
L
S
B
T
U
Fig. 12
Fig. 11
300 min
Terminal
Assembly
Top View Rear Flue
Property Boundary Line
Terminal Position with Minimum Distance (Fig. 12) (mm)
A1Directly below an opening, air brick, opening
windows, etc. 300
B1Above an opening, air brick, opening window etc. 300
C1Horizontally to an opening, air brick, opening window etc. 300
D2Below gutters, soil pipes or drain pipes. 25 (75)
E2Below eaves. 25 (200)
F2Below balconies or car port roof. 25 (200)
G2From a vertical drain pipe or soil pipe. 25 (150)
H2From an internal or external corner. 25 (300)
I Above ground, roof or balcony level. 300
JFrom a surface or boundary line facing a terminal. 600
K From a terminal facing a terminal (Horizontal flue). 1200
From a terminal facing a terminal (Vertical flue). 600
L From an opening in carport (e.g. door, window)
into the dwelling. 1200
M Vertically from a terminal on the same wall. 1500
N Horizontally from a terminal on the same wall. 300
R From adjacent wall to flue (vertical only). 300
S From an adjacent opening window (vertical only). 1000
T Adjacent to windows or openings on pitched and flat roofs 600
U Below windows or openings on pitched roofs 2000
Opening Window
or Door
150mm
MIN.
IMPORTANT: If fitting a Plume
Displacement Flue Kit, the air inlet
must be a minimum of 150mm
from any opening windows or
doors (see Fig. 13).
Plume
Displacement Kit
Air Inlet
Fig. 13
1In addition, the terminal should be no nearer than 150 mm to an opening in the
building fabric formed for the purpose of accommodating a built-in element such as
a window frame.
2Only ONE 25mm clearance is allowed per installation. If one of the dimensions
D, E, F, G or H is 25mm then the remainder MUST be as shown in brackets, in
accordance with B.S.5440-1.
NOTE: The distance from a fanned draught appliance terminal
installed parallel to a boundary may not be less than 300mm in
accordance with the diagram below
*