Potterton Promax FSB 30 HE Installation and maintenance instructions

© Baxi Heating UK Ltd 2010
Installation & Service Instructions
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
Promax
FSB 30 HE
Floor Standing
Fanned Flue
Condensing Boiler
You can rely on

2© Baxi Heating UK Limited 2010
Natural Gas
Potterton Promax FSB 30 HE
G.C. No 41 595 39
© Baxi Heating UK Ltd 2010 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, The Wyvern Business Park,
Stanier Way, Derby, DE21 6BF.
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.
This product has an energy rating (A) on a scale of A to G.
For more information see www.boilers.org.uk. This is a certification mark.
0086
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.
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 1 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.

Installer Notification Guidelines
3
© Baxi Heating UK Limited 2010
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

Legislation
4© Baxi Heating UK Limited 2010
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 & 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).
Codes of Practice, most recent version should be used
The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)
Regulations 1993 No3083” and is deemed to meet the requirements of Directive
92/42/EEC on the energy efficiency requirements for new hot water boilers fired with
liquid or gaseous fuels:-
Type test for purpose of Regulation 5 certified by:
Notified Body 0087.
Product/Production certified by:
Notified Body 0086.
For GB/IE only.
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.
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 5546 Installation of hot water supplies for domestic
purposes.
BS EN 12828 Heating systems in buildings.
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 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.

5
© Baxi Heating UK Limited 2010
1.0 Introduction 6
2.0 General Layout 7
3.0 Boiler Operation 8
4.0 Technical Data 9
5.0 Dimensions and Fixings 10
6.0 System Details 11
7.0 Site Requirements 15
8.0 Flue Options 20
9.0 Plume Displacement 25
10.0 Installation 29
11.0 Electrical 34
12.0 Commissioning the Boiler 36
13.0 Completion 38
14.0 Servicing the Boiler 39
15.0 Changing Components 42
16.0 Short Parts List 49
17.0 Fault Finding 50
Benchmark Checklist 58
Section Page
Contents

1.1 Description
1. The Potterton Promax FSB 30 HE is a gas fired room
sealed fan assisted condensing central heating boiler.
2. The maximum output of the boiler is 30.18 kW. The
boiler automatically adjusts the output down to 9.2 kW
according to system load.
3. The boiler is designed for use on Natural Gas (G20)
only.
4. The boiler is suitable for fully pumped open vented and
sealed systems, providing heating and hot water.
5. A label giving details of the model, serial number and
Gas Council number is situated on the rear of the drop
down facia panel (Fig. 1).
6. The boiler data badge is positioned on the air box door
(Fig. 2).
7. The boiler is intended to be installed in residential /
commercial / light industrial E.M.C. environments on a
governed meter supply only.
8. The boiler must be installed with one of the purpose
designed flues such as the standard horizontal flue kit, part
no 236921.
1.2 Important Information
Man-made mineral fibre
• Some component parts of this boiler (insulation pads,
gaskets and rope seals) are manufactured from man-made
mineral fibre.
• Prolonged or excessive exposure to this material may
result in some irritation to the eyes, skin or respiratory
tract.
• It is advisable to wear gloves when handling these items.
• Irritant dust will only be released from the items if they
are broken up or subjected to severe abrasion. In these
instances a suitable dust mask and goggles should be
worn.
• Always thoroughly wash hands after installation,
servicing or changing components.
• When disposing of any items manufactured from man-
made mineral fibre care must be exercised.
• If any irritation of the eyes or severe irritation of the skin
is experienced seek medical attention.
1.0 Introduction
6© Baxi Heating UK Limited 2010
Fig. 1
Data Badge
Air Box Door
Position of Label
Fig. 2
Optional Integral Timer
Facia Securing Screws
Case Securing Screws

2.0 General Layout
7
© Baxi Heating UK Limited 2010
2.1 Layout (Figs. 3, 4, 5 & 6)
1. Condensate Pump
2. Flue Elbow (supplied in std. flue kit)
3. Heat Exchanger
4. Burner
5. Air Box
6. Fan Protection Thermostat - Black
7. Fan Assembly
8. Condensate Trap
9. PCB Housing Assembly
10. Gas Tap
11. Gas / Air Ratio Valve
12. Flow Pipe Connection
13. Return Pipe Connection
14. Flow Temperature Safety Thermostat - Black
15. Flow Temperature Thermistor - Red
16. Flow Switch (dry fire protection)
17. Position of Optional Integral Timer Wiring
18. Pipe Access Panel
19. Manual Air Vent
2
3
4
5
6
7
9
8
10
11
15 14
12
13
16
Fig. 4
Fig. 3
Fig. 5
2.2 110Ø Concentric Flues & Optional Extras
KIT PART No
Standard Flue Kit 850mm (inc. elbow) 236921
Extended Flue Kit - 1.75M ( inc. elbow) 5111457
Flue Plume Deflector Kit 248167
Terminal Guard (suitable for use with above) 248484
FLUE EXTENSION KITS (110/70)
Flue Extension 250mm 241692
Flue Extension 500mm 241694
Flue Extension 1000mm (Use two kits for 2M etc.) 241695
Flue Bend x 2 - 45° (Reduce overall length of flue
by 0.5m when fitting this bend) 241689
Flue Bend - 93° (Reduce overall length of flue
by 1m when fitting each bend) 241687
VERTICAL FLUE
Vertical Flue Terminal 242802
Vertical Flue Adaptor 5106888
See Section 7.12 for more flue option details
Integral Twin Channel Timer 5117455
Fig. 6
1
17
18
19

3.1 Boiler Operation
1. Switched Live On: When switched live is supplied to
the boiler and the flow temperature is less than the set
point the sequence below commences.
2. Flow Switch: After 10 seconds if the flow switch has
made then fan pre-purge occurs. After 10 seconds if
the flow switch has not made then anti-cycle occurs.
3. Fan Pre-Purge: The flow switch is made and the fan
is on while the spark generator and gas valve are off.
After 5 seconds ignition occurs.
4. Ignition: The flow switch is made, fan, spark
generator and gas valve are on. If a flame is detected
then burner on occurs. If a flame is not detected within
5 seconds and less than 5 ignition attempts have been
made then fan purge occurs. If a flame is not detected
within 5 seconds and 5 ignition attempts have been
made then ignition lockout occurs.
5. Burner On: The flow switch is made, fan and gas
valve are on while the spark generator is off. Flow
temperature is controlled by varying the fan speed (and
thereby the gas rate) to achieve optimum operation. If
the flow temperature is greater than the set point or
the TRVs all shut down then fan post purge occurs.
6. Fan Post Purge: The fan is on while the spark
generator and gas valve are off. After 5 seconds if the
TRVs are shut down then anti-cycle occurs.
7. Anti-cycle: The fan, spark generator and gas valve
are off.
8. Ignition Lockout: The fan, spark generator and gas
valve are off. The boiler can only be reset by manually
using the reset button.
9. Condensate Pump: Condensate accumulates in a
reservoir within the pump assembly. The pump may
run at any time, independent of boiler operation, to
discharge the condensate to drain.
3.0 Boiler Operation
8© Baxi Heating UK Limited 2010
Mains On.
Flow
temperature less
than set point ?
YES
5 second
Fan Pre-Purge.
Flame Detected ?
Burner On.
Ignition
Lockout.
5 second
Ignition Period.
All TRVs
shut down ?
Ignition done and
5 attempts made ?
Ignition done
and less than 5
attempts made ?
System Pump
Running and Flow
switch made ?
NO
YES
YES
YES
All TRVs
shut or Flow temperature
greater than set point ?
5 second
Fan Post Purge.
3 minute
Anti-cycle.
YES
YES
YES
Condensate Pump will
operate as necessary (3.1.9)

Appliance Category CAT I 2H
4.0 Technical Data
9
© Baxi Heating UK Limited 2010
Horizontal
Flue Terminal Diameter - 110mm
Dimensions Projection - 150mm
Outercase Dimensions
Casing Height - 850mm
Casing Width - 390mm
Casing Depth - 520mm
Weights kg
Packaged Boiler Carton - 49.5
Packaged Flue Kit - 3.6
Installation Lift Weight - 37.5
Installed Weight (dry) - 44.5
Connections
Gas Supply - 15mm
Central Heating Flow - 28mm
Central Heating Return - 28mm
Condensate Drain (Pump) - 10mm o.d.
Recommended System
Temperature Drop
Condensing 20°C
Heat Input (Q)(Gross) Max Min
kW 33.76 10.3
Heat Output (P)
(Non Condensing 70° C Mean Water Temp)
Max Min
kW 30.18 9.2
Electrical Supply 230V~ 50Hz
The boiler must be connected to an earthed
supply. A permanent and switched live are
required. The boiler has a 4 wire connection.
Power Consumption 80W
External Fuse Rating 3A
Internal Fuse Rating (BS 4265)
Fuse 3.15 AT (PCB)
Max Gas Rate (2H - G20 - 20mbar)
(After 10 Mins)
kW Input 33.76
m3/hr 3.4
Inlet Pressure at Gas Valve (Natural Gas)
Min 18.1 mbar
Max 22.5 mbar
(see Section 10.1)
Injector (Natural Gas)
Diameter 6.5mm
Minimum Clearances
(For unventilated compartments see Section 7.2)
Both Sides - 5mm
Above Casing - 15mm
Above Casing
Under fixed worktop -
(It is recommended that any
worktop is removable) - 25mm
Front (For Servicing) - 500mm
Front (In Operation) - 5mm
010203040
20
40
60
80
100
120
140
160
180
200
220
Water Flow Rate (litres/min)
Pressure Drop (mbar)
8
17
25
33
42
50
58
66
75
83
91
Pressure Drop (in wg)
Boiler Hydraulic Resistance Chart
Appliance Type C13 C33
NOxClass 5
Heat Output (P)
(Condensing 40° C Mean Water Temp)
Max Min
kW 32.61 10.0
Water Content
litres 2.6
Static Head
max 30 metres
min 1 metre
Low Head 0.2m min
System Detail
Fully pumped open vented & sealed systems.
No bypass required.
Controls
boiler thermostat, safety thermostat,
flow switch, electronic flame sensing,
temperature protection thermostat &
condensate blockage and level sensors
The efficiency is 90.9%
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 0087.
SEDBUK Declaration
Electrical Protection IPXX
CO/CO2 Ratio 0.001
Boiler Flow Temperature (adjustable)
55° C to 78° C (± 5° C)
Condensate Pump
Head 3 metres
Flow Rate 1.8 l/min
Connection 10mm o.d. (pipe supplied)

5.0 Dimensions and Fixings
10 © Baxi Heating UK Limited 2010
DIMENSIONS
A850mm
B520mm
C390mm
D125mm Ø Min.
E175mm
F150mm
SIDE FLUE (left and right)
For every 1m of horizontal flue
length, the clearance above the top
of the flue elbow should be 27.5mm
to incorporate the 1.5° fall in the flue
from the terminal to the elbow. It is
especially important to consider
this when fitting the boiler under a
work top !
The 1.5° fall provided by the elbow
is to allow condensate to run back to
the boiler, for discharge through the
condensate disposal system.
Flue length (Y)
up to 1m
1m - 2m
2m - 3m
3m - 4m
Clearance (X)
27.5mm
55mm
82.5mm
110mm
Tube Ø 110mm
DC
B
A
E
Y
At least
1.5°
X
At least
1.5°
Fig. 7
Fig. 8
F