Potterton PROMAX 24 Manual

P
Promax Store
Installation and Service Manual
Condensing Boiler with Integrated Hot Water Storage
24
en
United Kingdom
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.

Natural Gas
Potterton Promax 24 Store ErP
G.C.No41 592 47 (90 litre)
G.C.No41 592 48 (115 litre)
G.C.No41 592 49 (150 litre)
© Baxi Heating UK Ltd 2015 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 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.
0086
ISO 9001
FM 00866
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. From 1 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 & 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Benchmark Logbook is being withdrawn.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.
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.
About the Boiler
See page 4 for models covered by these instructions.
This is a Floor Mounted Fan Assisted Balanced Flue Gas Boiler.
This boiler is for use with Natural Gas (G20) only at 20 mbar and for use
in GB/IE only.
About Safety
The Gas Safety (Installation and Use) Regulations.
 In your own interest, and that of safety, it is law that all gas appliances
are installed by competent persons, in accordance with the above
regulations. Failure to install appliances correctly could lead to
prosecution.
Installation must be in accordance with the Installation & Service
Instructions and the rules in force.
Read these Instructions before installing or lighting the boiler
These Instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
IMPORTANT
Please read and understand all these instructions before commencing installation.
Please leave this manual with the customer for future reference.
2© Baxi Heating UK Ltd 2015

3
© Baxi Heating UK Ltd 2015
Choose Building
Regulations Notification
Route
Contact your relevant Local
Authority Building Control
(LABC)who will arrange
an inspection or contact
agovernment 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 10days
Ifyou 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
SelfCertification Scheme
Building Control
Complete the
Benchmark Checklist
Install and Commission this
appliance to manufacturer's
instructions
Installer Notification Guidelines

4© Baxi Heating UK Ltd 2015
Contents
Panel Removal
Technical Data
Technical Parameters
Introduction
Installation, Commissioning, Service & Repair
Health & Safety Information
Codes of Practice
1. Installation Requirements
Storage, Unpacking and Handling
1.1Gas Supply
1.2 Electricity Supply
1.3 Location of Boiler
1.4 Compartment Installation & Ventilation
1.5Flue Systems
1.6 Water Supply & Systems
1.7Discharge Pipework
2. Installation
2.1Install the Boiler
2.2 Connect the Flue System
2.3 Connect the Gas Supply
2.4 Connect the Condensate Pipe
2.5Connect the Water Supply
2.6 Connect the Power Supply Cable
2.7Optional Immersion Heater
2.8How to Drain Hot Water Storage Cylinder
2.9 Control Panel, Display & Diagnostics
3. Commissioning
3.1Commission the Boiler
3.2 Hand Over to the User
4. Service & Replacement of Parts
4.1General Access
4.2 Automatic Air Vent
4.3 Expansion Vessel/Pump & Pressure Switch
4.3a Pump - Head Only
4.3b Pump - Complete
4.3c Automatic Air Vent
4.4 Pressure Sensor/Pressure Relief Valve
4.5Gas Valve
4.6 Fan
4.7Igniter
4.8Sparkand Sensing Electrodes
4.9 Overheat Thermostat
4.10 Burner
4.11 Insulation
4.12 Diverter Valve Actuator
4.13 Temperature Flow & Dry Fire Sensors
4.14 Heat Exchanger
4.15 Replacement of Immersion Heater etc
4.16 Gas/Air Valve Setup Procedure
5. Wiring Diagrams
6. Fault Finding
Diagnostic Codes
7. Short List of Spares
The models covered by these instructions are:-
Promax 24 Store G.C. No.
90 Litres 41592 47
115 Litres 41592 48
150 Litres 41592 49
Important
Refer to Page 11 for Storage, Unpacking and
Handling Instructions.
Benchmark Commissioning Checklist
Potterton is a member of the Benchmarkinitiative and
fully supports the aims of the programme. Benchmark
has been introduced to improve the standards of
installation and commissioning of central heating
systems in the UK and to encourage the regular
servicing of all central heating systems to ensure safety
and efficiency.
Important – Failure to install and commission this
appliance to manufacturers instructions may invalidate
the warranty. This note does not affect your statutory
rights.
Gas Safe
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 4085500 or online at www.gassaferegister.co.uk
Safety, Performance & Quality
Promax Store boilers have been assessed by a
Government appointed Notified Body and shown to
meet the 'Essential Requirements'of the European Gas
Appliance Directive 90/396/EEC.
The Directive lays down requirements for the safety and
efficiency of the appliance, together with its design,
construction, and use of materials.
It also requires the production process to be covered by
an approved and monitored system of quality
assurance.
Warning - The addition of anything that may interfere
with the normal operation of the appliance without
explicit 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.

Panel Removal
MAX0006B
Bottom Section
Union Nuts
(remain with
Bottom Section)
DHW Sensor Pocket
(310mm deep)
Top & Bottom Section
Handholds
(Underneath boiler)
Lifting and
plumbing
access
each side
Mains power
supplyand
Immersion Heater
cableentry holes
Pull up and away Top Panel
2
4
3
Pull forward Front Panel at the bottom and lift off
General AccessPlumbing Access
1
Pull forward Bottom Panel
Unscrew Upper Panel at the bottom and pull away
Retaining Screws (Upper Panel)
Condensate
outlet hole
Top Section
Lift Heat Engine onto
Cylinder. Ensure the
rollers engage into
location channels.
Tiltand slide until front
location pegs drop into
position on the cylinder.
Location Peg
Location Channel
Rollers
Fig. 1
Important: Refer to Page 11 for Storage, Unpacking and Handling Instructions.
5
© Baxi Heating UK Ltd 2015

Technical Data
Unless indicated, data shown relevant to all models 90 litre 115 litre 150 litre
Classifications Appliance category CAT I2H
Flue Type C13- C33 - C53(as supplied)
NOx Class 5
Cylinder Insulation CFC, HCFC= 0%
Input Qn Hs (hot water/central heating) - gross 7.8- 27.4 kW
Output to CH Pn (non-condensing) 6.8- 24.0 kW
Output to CH Pnc (condensing) 7.6 - 25.9 kW
Inlet pressure 20 mbar
Gas rate (after 10 mins.) 2.6 m3/hr max.
Gas control differential (offset) -3 Pa to - 8Pa (- 0.03 to - 0.08mbar)
CO (approx average) 70 ppm
Ventilation Requirements: No Compartment Ventilation Required
Connections CH Flow & Return 22 mm Techtite/compression
DHW Inlet & Outlet 22 mm tube end
Gas 22 mm compression
Temperature/Press. Relief Valve 22 mm compression from tundish.
Condensate Outlet Flexible Pipe 500 mm long (fits 21.5mm PP overflow systems)
Inlet Control Group 22 mm compression inlet & outlet
Set reduced pressure 2.5bar, expansion relief valve set 8.0 bar
Filling Loop 15 mm /1/2” union (accessible behind lower front panel)
Secondary Expansion Vessel 12 litre, pre-charge 2.5- 2.7bar (supplied separately)
Automatic bypass Built in
Pressure loss warning Gauge on facia
Built in programmer 2-channel, pre-programmed, battery back-up, separate times for HW
& CH, advance button, CH off selector
External programmer
Built-in room thermostat Dedicated connectors on user terminal block
Built in frost protection Boiler protected below 5°C
Optional Immersion Heater Heatrae Mega. 3 kW at 240V, Advantica Approved
Electricity supply 230v ~ 3A fused supply,
Power Consumption (maximum) 126W
Working pressures Primary 0.9 - 2.5bar
DHW 1.0 - 2.5bar
Mains Supply 1.0 - 16.0 bar
Pressure Relief Valve (Primary) 3.0 bar
Temperature/Press. Relief Valve Pre-set 95°C, 10.0 bar opening
DHW temperature 30 °Cto 60 °C
DHW flow rate (Practical maximum assuming suitable mains supply) 25l/m max. 25l/m max. 25l/m max.
Weights Lift Weight Heat Engine 45kg
Cylinder 37kg 41kg 49 kg
Full Weight 171 kg 202 kg 246 kg
Cylinder Maximum Mains Pressure 1.6MPa (16 bar)
Operational Operating Pressure/PRV 0.25MPa (2.5bar)
Summary Maximum Design Pressure 0.8MPa (8bar)
Expansion Vessel Charge Pressure 0.25MPa (2.5bar)
Expansion Relief Valve Setting 0.8MPa (8bar)
T & PRelief Valve Setting 90 - 95°C/1.0MPa (10 bar)
Pressure Drop (Primary Coil) 0.02MPa (0.2 bar)
Cylinder Standing Heat Loss 90L0.93kW/24hrs
115L 1.04kW/24hrs
150L1.39kW/24hrs
6© Baxi Heating UK Ltd 2015

Technical Parameters
Technical parameters for boiler combination heaters
Condensing boiler
90
PottertonPromax 24 StoreErP
Rated heat output
Seasonal spaceheating energy efficiency
Auxiliary electricity consumption
Other items
115 150
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(atheater inlet).
(2) High temperatureregime means 60°C returntemperatureatheater inlet and 80°C feed temperatureatheater outlet.
S
See
Theback cover for contactdetails.
mg/kWh
YesYesYes
YesYesYes
NoNoNo
NoNoNo
NoNoNo
24 24 24
24.0 24.0 24.0
8.0 8.0 8.0
92 92 92
87.2 87.2 87.2
96.8 96.8 96.8
0.049 0.049 0.049
0.019 0.019 0.019
0.003 0.003 0.003
0.040 0.040 0.040
---
20870 20870 20870
75 75 75
18 18 18
XL XL XL
0.192 0.224 0.246
42 49 54
90 92 77
21.234 20.621 25.856
16 16 19
57 57 57
7
© Baxi Heating UK Ltd 2015

MAX0007A
Note:
At these minimum clearances above
the appliance, adequate working
access MUST be provided.
Note:
Cupboard
intended
to provide
access.
RemovableTop Panel
Typical Cupboard Installation
with twin vertical air/flue pipes
Typical Bulkhead Installation
with rearwards horizontal concentric flue
250
min
RemovableTop Panel450
min
250
min 650max
Door
Frame
400 mm
Recommended
*
*
*400 mm
Recommended
*
Concentric
Flue
Ø80
Air
Tube
No
Clearance
required
Ø80
Flue
Tube
145
145
Side Flue
Rear Flue
(300 min.)
All dimensions
in mm
600
Twin
Flue
MAX0008B
Ø100 Air Tube
&
Ø60 Flue Tube
C/L
Inner Wall
Outer Wall
Inner Wall
Outer Wall
C/L
550
Fig. 2
Fig. 3
Promax Store
Promax Store
PromaxStore
1544 mm
150 Litre
Model
115 Litre
Model
90 Litre
Model
1344 mm
1264 mm
25mm 25mm
25mm
25mm
25mm
25mm
8© Baxi Heating UK Ltd 2015

Introduction
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".
Read the instructions fully before installing or lighting the
boiler.
Promax 24 Store is a floor standing condensing
combination boiler which incorporates a hot water store
to provide domestic hot water (DHW) and central heating
(CH). The DHW temperature is user adjustable (e.g. for
summer/winter operation). Operation is automatic and the
fully modulating pre-mixed burner ensures that gas is
burned cleanly and efficiently within the condensing heat
exchanger. An advanced burner control includes flame
monitoring, pressure monitoring and other safety
features, plus status and diagnostic displays which are
large and easy to read.
Installation of this boiler as an unvented hot water system
falls within the scope of the Building Regulations 1995
(Part G). These require that installation of an unvented
system shall be notified to the local authority Building
Control Department; also that the workmust be carried
out by a competent person as defined in the Approved
Document G3. The above requirements do not apply if
hot water is obtained via an open vented feed tank.
Samples of the Promax Store gas boilers have been
examined by DVGW Technologies Limited, a EU Notified
Body. The range is certified to comply with the essential
requirements of the Gas Appliance Directive 90/396/EEC,
the Low Voltage Directive 72/23/EECand shows
compliance with the Electro Magnetic Compatibility
Directive 89/336/EEC, the Boiler Efficiency Directive
92/42/EECand are therefore permitted to carry the CE
Mark.
Operation
The boiler control works on the principle of “hot water
priority” so the central heating output may be
temporarily delayed if the hot water temperature
drops below the selected temperature e.g. after
drawing a hot bath. The selected temperature is
user adjustable in the range 45° to 65°C
To suit conventional radiator based central heating
systems, the boiler will normally provide a flow
temperature of around 80 °C. The boiler control
automatically responds to lower central heating loads
by reducing the boiler output (which saves wasteful
on-off cycling).
This boiler must be installed into a sealed
(pressurised) primary system.
Provision is made for fitting both room and frost
thermostats if required. Note: The boiler has its own
in-built frost protection which will seekto prevent the
boiler temperature dropping below 5°C
For summer operation the user can switch off the
central heating at the control panel.
Visible Pluming
The efficient condensing operation of Promax Store
will naturally cause condensate to form in the flue
pipe and pluming of the condensing gases will be
visible during all but the most favourable atmospheric
conditions. In installations with long flue runs, some
condensate may be discharged from the terminal.
The flue terminal must, therefore, be sited to avoid
nuisance from either phenomenon.
Delivery & Kits Available
Promax Store boilers are delivered in three packages
(1) the heat engine and unvented accessory kit, (2)
the hot water cylinder and (3) the flue kit. The flue kit
must be ordered/specified additionally to the boiler.
Health and Safety Information for the Installer
and Service Engineer
Under the Consumer Protection Act 1987 and Section
6 of the Health and Safety at WorkAct 1974, we are
required to provide information on substances
hazardous to health.
This boiler does not contain substances harmful to
health; it does not contain asbestos. Small quantities
of adhesives and sealants used in the product are
cured and present no known hazards.
Checklist of supplied components:
Cold water control packincluding:
Expansion Vessel
Expansion Vessel Bracket
Expansion Vessel Braided Hose with Seals
Pressure Reducing Valve (2.5bar)
Pressure Relief Valve (8bar)
Nuts and Olives
Tundish
Bracket
9
© Baxi Heating UK Ltd 2015

Condensate
Trap
3Way
Diverter Valve
Flow Sensor
Combustion
Analyser
Test Point Flue Air
Automatic
Bypass
Primary Expansion Vessel
Automatic
Air Vent
Gas
Valve
Isolation Valve
Isolation
Valve
Pump
Primary
Relief
Valve
Heat Exchanger
Combination Valve
Tundish
Cross/Check
Valve
Tundish
Gas
Gas Cock
D.H.W. Sensor
Hot Water
Cylinder
CH
Return
CH
Flow
Schematic Diagram
Filling Loop
Double
Check
Valve
DHW
Cold Main
Stopcock
Balanced Cold
Feed to Shower
Pressure Relief Valve
Secondary
Expansion
Vessel
Fan
AB
T.P.R.V.
Codes of Practice
The appliance is suitable only for installation in GB and
IE and should be installed in accordance with the rules in
force.
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 Codes
of Practice.
In IE, the installation must be carried out by a Competent
Person and installed in accordance with the current
edition of I.S. 813 "Domestic Gas Installations", the
current Building Regulations and reference should be
made to the current ETCI rules for electrical installation.
Fig. 4
In GB the following Codes of Practice apply:
Standard Scope
BS6891Specification for low pressure gas pipework
in domestic premises.
BS5440 Pt.1Specification for installation of flues.
BS5440 Pt.2 Specification for installation of ventilation for
gas appliances.
BS5546 Specification for installation of gas hot water
supplies.
BS5449 Specification for forced circulation hot water
central heating systems.
BS6798Specification for installation of gas fired hot
water boilers of rated input not exceeding
70kW.
In IE:
I.S. 813 Domestic Gas Installations.
The following BS standards give valuable additional information:
BS6891Specification for low pressure gas pipework
in domestic premises.
BS5546 Specification for installation of gas hot water
supplies.
BS5449 Specification for forced circulation hot water
central heating systems.
10© Baxi Heating UK Ltd 2015