Installation & Servicing Instructions: Powermax HE

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Installation & Servicing Instructions Powermax HE

85, 115 & 150 Litre


Condensing Boilers with
Integrated Hot Water Storage

Powermax HE
MON TUE WED THU FRI SAT SUN
P.M
OFF OFF
TIMED TIMED
ONCE ONCE
ON ON
TIME ON 1 ON 2 ON 3
A DAY OFF 1 OFF 2 OFF 3

About the Boiler See inside cover 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


Leave these Instructions and the Benchmark Log Book with the user for use on future
calls.
Contents
Panel Removal.....................................................3 The models covered by these instructions are:-
Technical Data......................................................4
Powermax HE 85 Litre G.C. No. 41 389 15
Introduction..........................................................6 Powermax HE 115 Litre G.C. No. 41 389 16
Health & Safety Information......................................6 Powermax HE 150 Litre G.C. No. 41 389 17
Codes of Practice......................................................7
Storage, Unpacking and Handling............................8
Important
1. Installation Requirements..............................8 Refer to Page 8 for Storage, Unpacking and Handling
1.1 Gas Supply......................................................8 Instructions.
1.2 Electricity Supply.............................................8
1.3 Location of Boiler..........................................8 Benchmark Installation, Commissioning and Service
1.4 Compartment Installation & Record Log Book TM

Ventilation..................................................9
1.5 Flue Systems..................................................9 Potterton is a member of the Benchmark initiative and
1.6 Water Supply & Systems...............................13 fully supports the aims of the programme. Benchmark
1.7 Discharge Pipework......................................14 has been introduced to improve the standards of
installation and commissioning of central heating
systems in the UK and to encourage the regular
2. Installation...................................................16 servicing of all central heating systems to ensure safety
2.1 Install the Boiler.............................................16 and efficiency.
2.2 Connect the Flue System..............................16
2.3 Connect the Gas Supply...............................16 Important – Failure to install and commission this
2.4 Connect the Water Supply.............................18 appliance to manufacturer’s instructions may invalidate
2.5 Connect the Condensate Pipe......................20 the warranty. This note does not affect your statutory
2.6 Connect the Power Supply Cable..................20 rights.
2.7 Optional Immersion Heater...........................22
2.8 How to Drain Hot Water Storage Cylinder.....22 CORGI
2.9 Control Panel, Display & Diagnostics............23 All CORGI registered installers carry a CORGI
identification card and have a registration number. Both
3. Commissioning............................................24 should be recorded in your boiler Log Book.
3.1 Commission the Boiler..................................25
3.2 Hand Over to the User...................................26 You can check your installer is registered by telephoning
+44 (0) 1256 372300 or writing to:-
4. Service & Replacement of Parts..................27
4.1 General Access.............................................28 CORGI. 1 Elmwood, Chineham Business Park,
4.2 Automatic Air Vent.........................................28 Crockford Lane, Basingstoke, RG24 8WG.
4.3 Expansion Vessel/Pump...............................29
4.4 Pressure Sensor/Pressure Relief Valve........30 Safety, Performance & Quality
4.5 Air/Gas Valve/Injector/Fan.............................31 Powermax HE boilers have been assessed by a
4.6 Spark Generator/Ignition Electrode...............32 Government appointed Notified Body and shown to meet
4.7 Burner...........................................................32 the 'Essential Requirements' of the European Gas
4.8 Boiler Control Assembly................................33 Appliance Directive 90/396/EEC.
4.9 Diverter Valve Actuator..................................34
4.10 Overheat Thermostat....................................34 The Directive lays down requirements for the safety and
4.11 Diverter Valve Complete, Manual Air Vent and efficiency of the appliance, together with its design,
Temperature Flow & Return Sensors........34 construction, and use of materials.
4.12 Heat Exchanger............................................35
It also requires the production process to be covered by
5. Wiring Diagrams............................................36 an approved and monitored system of quality assurance.
6. Fault Finding..................................................38
Diagnostic Codes..........................................39 Warning - The addition of anything that may interfere
7. Short List of Spares......................................40 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
Gas/Air Valve Setup Procedure.........................42 could also infringe the GAS SAFETY (Installation and
Use) REGULATIONS.

2 Contents Publication No. 5106226


Panel Removal
Important: Refer to Page 8 for Storage, Unpacking and Handling Instructions.

Top & Bottom Section

Handholds
Top Section
Manual Air Vent (below Top Panel)
Pipes connected to
Serial Number/Data Badge Bottom Section:

Auto Air Vent (access panel) DHW Sensor Cable


(in carrying position)
Electrical Diagram
Drain Connection

Location Cylinder Return Connection


Dowels
Cylinder Flow Connection

Bottom Section

Union Nuts
(remain with
Bottom Section)

DHW Sensor Pocket


MAX0006B

Handholds
(Underneath boiler)

Plumbing Access General Access


1 Pull forward Front Panel at the bottom and lift off

Mains power
2 Pull up and away Top Panel
supply and
Immersion Heater
cable entry holes 4 Unscrew Upper Panel at the bottom and pull away
Condensate
outlet hole
Lifting and
plumbing Retaining Screws (Upper Panel)
access
each side
3 Pull forward Bottom Panel

Fig. 1

Publication No. 5106226 Panel Removal 3


Technical Data
Unless indicated, data shown relevant to all models 85 litre 115 litre 150 litre

Classifications Appliance catergory CAT I2H


Flue Type C13 - C33 - C53 (as supplied)
NOx Class 5 (< 70 mg/kWh)
Cylinder Insulation CFC, HCFC = 0%

Input (hot water/central heating) - gross 7.8 - 25.8 kW


Output to CH (non-condensing) 6.7 - 22.6 kW
Output to CH (condensing) 7.6 - 24.0 kW

Inlet pressure 20 mbar


Gas rate (after 10 mins.) 2.55 m3/hr max.

Gas control differential (offset) 0 Pa to - 5 Pa


CO (average) 50 ppm

Noise 48 DbA (maximum)

Ventilation Requirements: High Level 80 cm2 to internal space - 40 cm2 to outside


Low Level 80 cm2 to internal space - 40 cm2 to outside

Connections CH Flow & Return 22 mm 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 21.5 mm PP overflow systems)
Inlet Control Group 22 mm compression inlet & outlet
Set reduced pressure 2.5 bar, expansion relief valve set 8.0 bar
Filling Loop 15 mm /1/2” union (accessible behind lower front panel)

Secondary Expansion Vessel 18 litre, pre-charge 2.5 - 2.7 bar (supplied separately)
Automatic bypass Built in

Pressure loss warning Linked to diagnostic display


Built in programmer 2-channel, pre-programmed, back lit display, battery back-up
Separate times for HW & CH, advance button, CH off selector
External programmer Optional connectors on user terminal block
Built-in room thermostat Dedicated connectors on user terminal block
Built in frost protection Boiler protected below 5 °C plus external frost ‘stat connection

Optional Immersion Heater 11” Heatrae ‘Mega’ G1 3/4. 3 kW at 240V, BEAB Approved

Electricity supply 230v ~ 3A fused supply,


Power Consumption (maximum) 166 Watts (Grundfos pump) 156 Watts (Wilo pump)

Working pressures Primary 0.9 - 2.5 bar


DHW 1.0 - 2.5 bar
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 45 °C to 65 °C
DHW flow rate (Practical maximum assuming suitable mains supply) 30 l/m max. 36 l/m max. 48 l/m max.

Weights Lift Weight Heat Engine 38 kg


Cylinder 37 kg 41 kg 49 kg
Full Weight 166 kg 202 kg 246 kg

4 Technical Data Publication No. 5106226


Note: Note:
450 Cupboard At these minimum clearances above
Removable Top Panel min intended the appliance, adequate working
to provide access MUST be provided.
250 access.
min * 650 max

Removable Top Panel

200
min *

Door
Frame

* 400 mm

MAX0007A
Recommended

Typical Bulkhead Installation Typical Cupboard Installation


with rearwards horizontal concentric flue with twin vertical air/flue pipes
Fig. 2

550 550

215 215 215 215 215


2˚ 120 120
165 approx.

CH HW CH HW CH HW
- + - + - +
H.W. TEMP H.W. TEMP H.W. TEMP

SEL + SEL SEL + SEL SEL + SEL


POWER POWER POWER

MAINS ON BURNER LOCK OUT RESET C.H. ADVANCE PROG - PROG MAINS ON BURNER LOCK OUT RESET C.H. ADVANCE PROG - PROG MAINS ON BURNER LOCK OUT RESET C.H. ADVANCE PROG - PROG

1110
1270
85 litre 115 litre 150 litre
model model model 1470

5 5

5 5

5 5
105 Minimum
with rear C/L
facing
Concentric Rear Flue No
Flue (300 min.) Clearance C/L
required
Outer Wall
All dimensions Outer Wall
Inner Wall in mm Inner Wall

Side Flue
40 Ø60 Ø60 65
Ø100 Air Tube 65 Flue Air
Clearance
& Tube Tube 600
MAX0008B

Ø60 Flue Tube


Twin
Concentric
Flue
Flue
Fig. 3

Publication No. 5106226 Technical Data 5


Introduction
Important - Installation, Commissioning, Service & Operation
Repair
The boiler control works on the principle of “hot water
This appliance must be installed in accordance with the priority” so the central heating output may be
manufacturer’s instructions and the regulations in force. temporarily delayed if the hot water temperature
Read the instructions fully before installing or using the drops below the selected temperature e.g. after
appliance. drawing a hot bath. The selected temperature is user
adjustable in the range 45° to 65 °C
In GB this must be carried out by a competent person as
stated in the Gas Safety (Installation & Use) Regulations. To suit conventional radiator based central heating
systems, the boiler will normally provide a flow
Definition of competence: A person who works for a CORGI temperature of around 80 °C. The boiler control
registered company and holding current certificates in the automatically responds to lower central heating loads
relevant ACS modules, or valid ACoP equivalents, is by reducing the boiler output (which saves wasteful
deemed competent. on-off cycling).
In IE this must be carried out by a competent person as This boiler must be installed into a sealed
stated in I.S. 813. "Domestic Gas Installations". (pressurised) primary system.
Read the instructions fully before installing or lighting the
Provision is made for fitting both room and frost
boiler. See also the separate Installation Instructions for the
thermostats if required. Note: The boiler has its own
Powermax HE Flue (Part No. 5106227).
in-built frost protection which will seek to prevent the
boiler temperature dropping below 5 °C
Powermax HE is a floor standing condensing combination
boiler which incorporates a hot water store to provide
For summer operation the user can switch off the
domestic hot water (DHW) and central heating (CH). The
central heating at the control panel.
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 Visible Pluming
efficiently within the condensing heat exchanger. An
advanced burner control includes flame monitoring, The efficient condensing operation of Powermax HE
pressure monitoring and other safety features, plus status will naturally cause condensate to form in the flue
and diagnostic displays which are large and easy to read. pipe and pluming of the condensing gases will be
visible during all but the most favourable atmospheric
A small diameter twin pipe flue system has been designed conditions. In installations with long flue runs, some
for a length of up to 12.0 metres (including the separate flue condensate may be discharged from the terminal. The
and air terminals) through which to draw inlet air and expel flue terminal must, therefore, be sited to avoid
exhaust gases. The standard concentric terminal suits a wall nuisance from either phenomenon.
thickness of 300 mm to 500 mm.
Delivery & Kits Available
Installation of this boiler as an unvented hot water system
falls within the scope of the Building Regulations 1995 (Part Powermax HE boilers are delivered in three packages
G). These require that installation of an ‘unvented’ system (1) the heat engine and unvented accessory kit, (2) the
shall be notified to the local authority Building Control hot water cylinder and (3) the flue kit. The flue kit must
Department; also that the work must be carried out by a be ordered/specified additionally to the boiler.
competent person as defined in the Approved Document G3.
The above requirements do not apply if hot water is obtained Health and Safety Information for the Installer
via an open vented feed tank. and Service Engineer
Samples of the Powermax HE gas boilers have been Under the Consumer Protection Act 1987 and Section
examined by Advantica Technologies Limited, a United 6 of the Health and Safety at Work Act 1974, we are
Kingdom Notified Body. The range is certified to comply with required to provide information on substances
the essential requirements of the Gas Appliance Directive hazardous to health.
90/396/EEC, the Low Voltage Directive 72/23/EEC and
This boiler does not contain substances harmful to
shows compliance with the Electro Magnetic Compatibility
health; it does not contain asbestos. Small quantities of
Directive 89/336/EEC, the Boiler Efficiency Directive
adhesives and sealants used in the product are cured
92/42/EEC and are therefore permitted to carry the CE
and present no known hazards.
Mark.

6 Introduction Publication No. 5106226


Codes of Practice In GB the following Codes of Practice apply:
Standard Scope
The appliance is suitable only for installation in GB and IE
BS6891 Specification for low pressure gas pipework
and should be installed in accordance with the rules in
in domestic premises.
force. BS5440 Pt.1 Specification for installation of flues.
In GB, the installation must be carried out by a CORGI BS5440 Pt.2 Specification for installation of ventilation for
Registered Installer. It must be carried out in accordance gas appliances (except that compartment
with the relevant requirements of the: ventilation is amended in section 8 of these
instructions).
• Gas Safety (Installation & Use) Regulations. BS5546 Specification for installation of gas hot water
• The appropriate Building Regulations either The supplies.
Building Regulations, The Building Regulations BS5449 Specification for forced circulation hot water
central heating systems.
(Scotland), Building Regulations (Northern Ireland).
BS6798 Specification for installation of gas fired hot
• The Water Fittings Regulations or Water Byelaws in water boilers of rated input not exceeding
Scotland. 70kW.
• The Current I.E.E. Wiring Regulations.
In IE:
Where no specific instructions are given, reference I.S. 813 Domestic Gas Installations.
should be made to the relevant British Standard Codes of
Practice. The following BS standards give valuable additional information:

BS6891 Specification for low pressure gas pipework


In IE, the installation must be carried out by a Competent
in domestic premises.
Person and installed in accordance with the current BS5546 Specification for installation of gas hot water
edition of I.S. 813 "Domestic Gas Installations", the supplies.
current Building Regulations and reference should be BS5449 Specification for forced circulation hot water
made to the current ETCI rules for electrical installation. central heating systems.

Schematic Diagram

Combustion Flue Air Return Sensor


Analyser Isolation Valve
Test Point
Primary Expansion Vessel
Heat Exchanger

3 Way
Diverter Valve Flow Sensor

A B Fan Automatic Air Vent


Secondary
Pump Expansion
Gas
Valve Vessel

Automatic Bypass Primary Secondary


Condensate Relief
Trap Relief
Valve Valve
T.P.R.V. Isolation
Hot Water Stopcock &
Valve
Cylinder Checkvalve
Tundish
Gas Cock Cold Main
D.H.W. Sensor
Double Tundish
Check
Valve Inlet PRV & Strainer
MAX0009A

Control
Group
Filling Loop
CH CH Gas DHW COLD
Flow Return (balanced pressure to shower)
Fig. 4

Publication No. 5106226 Introduction 7


1. Installation Requirements
Storage, Unpacking & Handling from any other appliances in the house and must be
governed at the meter.
This boiler is delivered in two sections for safety and
ease of handling. Store both the Top (heat engine) and The gas installation should be in accordance with the
the Bottom (cylinder) under cover in dry conditions. relevant standards. In GB this is BS 6891. In IE this is the
current edition of I.S. 813 "Domestic Gas Installations".
Remove the Powermax HE unvented Accessory Kit
from above the heat engine to reduce lift weight. (The The whole of the gas installation must be checked for
front and top panels can also be removed if required - soundness and purged in accordance with, in GB, BS
see Fig. 1 on page 3). 6891 and in IE, I.S. 813 “Domestic Gas Installations”.

Handholds are provided at the top rear of the heat 1.2 Electricity Supply
engine and will assist with removing it from the transport
tray. Handholds are provided at both sides and The boiler requires a 230V ~ 50Hz single-phase 3A fused
underneath the cylinder. electrical supply. External wiring must be correctly
earthed, polarised and in accordance with relevant
Use a handling device e.g. sack truck, to manually move regulations/rules. In GB this is the current I.E.E. Wiring
either section over long distances. Trucking must be Regulations. In IE reference should be made to the
done from the rear. Take particular care to avoid current edition of the ETCI rules.
damaging outer panels or programmer.
Detailed wiring instructions are given in Section 10.
These items should be lifted and handled by two Power consumption is approximately 90 - 166 W.
people. Stooping should be avoided and protective
clothing worn when necessary. Carrying and lifting WARNING: THIS BOILER MUST BE EARTHED
equipment should be used as required for moving Top
and Bottom to where they will be assembled and In the event of an electrical fault after installation of the
installed.. boiler, preliminary electrical systems checks must be
carried out i.e. Earth Continuity, Short Circuit, Polarity and
Determine beforehand whether the Top and Bottom Resistance to Earth.
should be assembled to enable the complete unit to be
moved into position, or whether to fit the cylinder and
then lift the heat engine into position. 1.3 Location of Boiler

The Top has 4 downward facing dowel pins which The boiler must not be sited outside or in any outhouse
provide accurate location on to the cylinder. Take care where it could be exposed to the weather. Avoid siting the
to avoid trapping hands and fingers during assembly. boiler at the highest part of the system.

Take great care when manoeuvring the boiler into its The boiler must be installed on a flat floor capable of
final location and avoid twisting movements of the body. supporting the weight of the unit when full of water – up
Do not attempt to carry the complete boiler as the to 250 kg for the 150 litre model.
Top is only dowelled to the Bottom.
It should be sited to minimise the length of flue and to
Dispose of packaging in accordance with environmental avoid long hot water pipe runs.
guidelines.
The extended flueing capability enables the boiler to be
1.1 Gas Supply sited well away from an outside wall, thus installation in a
first floor cupboard or compartment, basement, utility
Entry holes are provided in the base and via knockouts room or kitchen are all feasible locations.
in the side panels.
The location chosen must permit the provision of a
This boiler requires a natural gas supply of 2.6 cubic satisfactory external flue termination. The location must
metres per hour. A 22 mm gas inlet connection is also provide adequate space for servicing and air
provided at the front and gas supply pipework of not circulation.
less than 22 mm diameter should be run to the boiler.
The meter and supply pipes must be capable of
delivering this quantity of gas in addition to the demand

8 Installation Requirements Publication No. 5106226


If floor settlement is likely due to the weight of the boiler, VENTILATION
ensure that both the flueing and pipework layouts safely
provide sufficient flexibility. 1. When the boiler is installed in a room or habitable
internal space, there are no specific ventilation
If the boiler is to be fitted in a room containing a bath or requirements.
shower reference must be made to the relevant
requirements. 2. When the boiler is installed in a compartment it is
essential that permanent high and low vents are
In GB this is the current I.E.E. Wiring Regulations and provided for the circulation of cooling air. Purpose
Building Regulations. made vents must have a non-adjustable free area not
less than the minimum specified in the table below.
In IE reference should be made to the current edition of
I.S. 813 "Domestic Gas Installations" and the current Note: These are approximately 30% of BS 5440:2
ETCI rules. recommendations.

1.4 Compartment Installation and Minimum effective area of compartment air vents
Ventilation
Position of opening Ventilated Area of
General guidance for cupboard/compartment to each vent
installations, including airing cupboards, is contained in
BS 6798. Specific requirements for Powermax are given
High and low level Room 80 cm2
below.
High and low level Outside 40
1. The compartment should be a fixed rigid structure
large enough to allow it and the boiler to be
inspected and serviced. A minimum width between
the door jambs of 560 mm must be provided.
1.5 Flueing
2. Minimum clearances are indicated in Fig.3. A full
height compartment door must be at least 15 mm This is a “room sealed” condensing boiler. Flue systems
from the front of the boiler and provide 200 mm are supplied in kits, or components can be ordered
access height above the boiler. individually from Potterton. Only Powermax flue
components (which are designed for condensing
3. The compartment must be ventilated at high and low operation) can be used.
level as detailed below.
Flue Systems
4. The flue pipe must be protected by the ducting
supplied by Potterton or by another no less suitable All boilers are supplied to accept the Powermax 60 mm
non-combustible enclosure. dia. twin flue system, however several flue system
options are available.
5. With the flue protection duct fitted, additional
partitioning is not required. However householders Each system is room sealed and offers a choice of flue
should be discouraged from storing clothes etc. on type and termination method, see Fig. 2.
the boiler itself. A removable shelf at least 75 mm
above the boiler is acceptable. • Concentric balanced flue with horizontal terminal
• Twin flue with vertical terminal *
6. The internal surfaces of an understairs cupboard • Twin flue with pitched roof terminal *
must be lined with non-combustible materials. The • Twin flue with horizontal mini terminal
door shall have a BS 476 fire resistance of not less
than 0.5 hour. Air vents as opposite must be direct to Flue kits are available for each of the above options
outside air if the building has two or more storeys. and each kit contains all of the components needed for
connection to the boiler and terminal. Flue extension
lengths and bends should be purchased separately, as
required.

* These terminals must be ordered/specified separately.

Publication No. 5106226 Installation Requirements 9


Flue Protection cause nuisance and that the terminal will not obstruct
the passageway.
When using an extended flue system it is essential to fit
protective ducting (such as that supplied in the extended f) Where terminals are fitted within 850 mm of a plastic
flue kits) in order to prevent direct contact with the hot or painted gutter, or 450 mm of painted eaves, an
flue pipe. aluminium shield at least 750 mm long must be fitted
to the underside of the plastic or painted surface.
General Requirements for Horizontal Flue
Terminations g) Where installation will be in an unusual location,
special procedures may be necessary. BS 6798 gives
Detailed recommendations for flueing are given in detailed guidance on this aspect.
BS5440: Part 1. The following notes give general
guidance. The horizontal balanced flue terminal must be h) As the Powermax is a condensing boiler the flue duct
installed so that it is exposed to external air, preferably must have a fall back to the boiler of nominally 2°.
on a clear expanse of wall. Acceptable positions are
indicated in Fig. 3. Avoid positions where the terminal is j) The efficient condensing operation of the Powermax
adjacent to projections; particularly immediately under a HE will naturally give rise to condensation in the flue
balcony, inside a re-entrant position, or immediately gases and pluming will occur in all but the most
adjacent to a drain pipe. If the boiler is fitted under a favourable atmospheric conditions. Some
ventilator or opening window, the terminal must be at condensate may also be discharged from the terminal.
least 300 mm from any part of the window or ventilator The terminal must, therefore, be sited to avoid
and in accordance with BS5440: Part 1. nuisance from either phenomenon.

The flue pipe must not be closer than 25 mm to k) Where the lowest part of the terminal is less than 2 m
combustible material. Additional clearance must be above the level of any ground, balcony, flat roof or
provided when passing the flue through timber walls. place to which people have access, the terminal must
Advice on gas installations in timber framed buildings is be protected by a guard of durable material. A Terminal
contained in IGE technical publication IGE/UP/7 Guard, Part No. P210 is available from Potterton. The
available from the Institution of Gas Engineers, 21 guard requires a flat wall surface of approximately 330
Portland Place, London W1N 3AF. mm diameter, concentric with the terminal assembly.

Guidance notes for Flue Installation


Horizontal Extended Terminal
Read these Installation Instructions before installing
the boiler. Before starting an installation, check that the
correct flue kit has been supplied with the boiler. Horizontal Extended Terminal

Detailed recommendations for flue installations are given


in BS 5440:1: 2000. The following notes are for general
guidance only.
92˚ Bend
a) The flue system must be constructed using only
Powermax approved components. 92˚ Bend

b) It is important that the position of the terminal allows Extension


free passage of air across it at all times. 1m min
92˚ Bend
to
c) It is ESSENTIAL TO ENSURE that products of
12m max Air Pipe
combustion discharging from the terminal cannot re-
enter the building, or any other adjacent building, Flue Pipe
through ventilators, windows, doors, other sources of
natural air infiltration, or forced ventilation / air
Flue Duct
conditioning.

d) The minimum acceptable dimensions from the flue


terminal to obstructions and ventilation openings are
specified in Figs. 3 & 4 on Page 4 of these instructions.
MAX2002A

e) If the flue terminal discharges into a pathway or


passageway check that combustion products will not

10 Installation Requirements Publication No. 5106226


Concentric Flue Horizontal Terminal Twin Flue Vertical Terminal

300mm min Vertical Pitched Flat Roof


to Terminal Roof Flashing
2.5m max Flashing

360˚

Air
Flue Roof

Reducer
(Ø80 to Ø60) Flue Air

Concentric
Elbow 135˚ Extension
1.5m max
Adaptor Bend
Box Assy. 1m min
Flue Pipe Ø60
to
Concentric
12m max
Terminal Flue Duct

Concentric
Extension Elbow Air Pipe Ø60

Twin Flue Pitched Roof Terminal Twin Flue Mini Horizontal Terminal
Twin Pitched Roof Terminals 600 mm
can be fitted min Mini Terminal
360 mm
apart
min
Pitched Roof apart 92˚ Bend
Terminal
(135˚ elbow fitted)
Extension
Mini Terminal (sited in loft)
92˚ Bend
Extension Extension
1.5m min 1m min
135˚ Bend 92˚ Bend
to to
12m max 12m max Air Pipe
Flue Pipe
Flue Pipe
Warning Air Pipe
Note that the length
of the Air Inlet Pipe Flue Duct
MUST be at least Flue Duct
0.75 x length
of the Flue Pipe
MAX2003A

Fig. 5

Publication No. 5106226 Installation Requirements 11


Twin Flue
Pitched Roof
Terminal

Twin Flue
Vertical
Terminal
Twin Flue Flue Air Flue Air Flue Air

Double
Pitched Roof
Terminals

J,K

Twin Flue Mini


Terminals

MAX0033B
Rear Concentric
Terminal Side Concentric
N
R D Terminal
M C E T
S A
I I I I

F B
F J,K
L A
A
G H H
I

Likely flue positions requiring a flue terminal guard

Mini Terminal Assembly Terminal Position with Minimum Distance (mm)


300 min. 300 min. For IE, refer to I.S. 813 "Domestic Gas Installation".

Air Flue Fanned Draught Balanced Flue

Aa Directly below an opening, air brick, 300


opening windows, etc.
Ba Above an opening, air brick, opening window, etc. 300
Property Ca Horizontally to an opening, air brick,
300
Boundary opening window, etc.
Line D Below gutters, soil pipes or drain pipes.
75
E Below eaves.
200
High Level F Below balconies or car port roof.
200
G From a vertical drain pipe or soil pipe.
Side Twin Flue Top View
H From an internal or external corner.
150
300
I Above ground, roof or balcony level.
300
Concentric J From a surface facing a terminal.
600
K From a terminal facing the terminal.
Terminal 1200
300 min. 300 min. L From an opening in a carport (e.g. door, window)
Assembly 1200
into the dwelling.
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).
210
S From internal corner to flue (vertical only).
230
T Below eaves or balcony (vertical only).
Top 600
View
a In addition, the terminal should not be nearer than 150 mm to an opening
MAX0027A

Top View
in the building fabric formed for the purpose of accommodating a built-in
element such as a window frame. See BS 5440 Pt. 1.

Rear Side Concentric


Concentric Flue Note: The distance from a fanned draught appliance terminal installed
Flue parallel to a boundary may not be less than 300 mm in accordance with
Property the diagram on the left.
Fig. 6 Boundary Line

12 Installation Requirements Publication No. 5106226


1.6 Water Supply siting and regular replenishment to remain operational.
They should generally not be fitted where heat could
Mains Supply Requirements impair their perfomance. Other types of device can
It is essential that the mains supply pressure and flow inhibit scale formation but their effectiveness may vary.
availability are capable of meeting both the hot and cold The manufacturers of any water conditioning device
water services demand. should be consulted regarding its suitability for the
application and the particular water supply to the
Unless consistently high mains pressures are available, installation address.
it is unlikely that a mains service pipe of less than 22
mm OD (copper) or 25 mm OD (Blue MDPE) will Record the type of conditioner being used in
provide an adequate flow rate to the system. “Benchmark” log book.

A multi-function Inlet Control Group is supplied with Treatment of Water Circulating Systems
every Powermax HE. To ensure safe and splash free All water circulating systems will be subject to corrosion
operation, mains water must be supplied to the boiler unless an appropriate water treatment is applied.
via the Inlet Control Group as indicated in Fig. 11 on Without treatment the efficiency of the system will
Page 18. deteriorate as corrosion sludge accumulates within the
system, risking damage to pump and valves, boiler
Powermax HE is not recommended for unvented use noise and circulation problems.
where the prevailing mains pressure is below 1.0 bar. It
is recommended that a 22 mm draw-off is provided from For optimum performance after installation this boiler
which 15 mm or smaller pipes can then be used to and its associated central heating system must be
supply hot water services to individual terminations to flushed in accordance with the guidelines given in BS
give a balanced distribution system. 7593:1992. “Treatment of water in domestic hot water
central heating systems”. This must involve the use of a
Terminal Water Fittings proprietary cleanser, such as GE Betz Sentinel X300 or
Always tee the cold feed to shower fittings (and other X400, Fernox Superfloc or Salamander System
mixer fittings) into the pipe supplying the hot water store Cleanser. Full instructions are supplied with the
i.e. downstream of the Inlet Control Group. This will products, but for immediate information please contact
ensure a balanced pressure supply to the shower(s). GE Betz (0044 (0)151 420 9563), Fernox (0044 (0)1799
550 811) or Salamander (0044 (0)121 378 0952)
Taps - Ensure that all terminal fittings will withstand directly.
mains pressure.
Showers - Thermostatic shower mixers are For long term protection against corrosion and scale,
recommended to optimise performance; these must be after flushing dose the system with an inhibitor such as
suitable for use at mains pressure. The ‘Showermax’ GE Betz Sentinel X100, Fernox MB-1 or Copal or
thermostatic shower kit is recommended for use with Salamander System Inhibitor in accordance with the
this boiler. guidelines given in BS 7593:1992.

Note: Shower fittings should comply with the backflow Failure to flush and add inhibitor to the system will
prevention requirements (Para. 15, Schedule 2) of the invalidate the appliance warranty.
Water Supply Regulations 1999.
Sealed Primary Systems
Use in Hard Water Areas This boiler must be installed into a sealed primary
In the UK., water is drawn from diverse sources some system. As a general guide systems of up to 7-9
of which have high levels of natural hardness. If not radiators will operate satisfactorily with the 12 litre
dealt with effectively, the scaling associated with hard expansion vessel built into the boiler.
waters can adversly affect hot water performance. As a
general guide, if the temporary hardness exceeds 200 • Guidance on expansion vessel sizing
mg/l, then some form of water treatment device is
required. The ultimate solution is an ion-exchange (salt These notes explain how to calculate the total
regenerated) water softener. In addition to protecting expansion vessel volume required, based on the size
the Powermax heat exchanger against the effects of and the initial cold fill pressure of the system. If the
limescale, an ion-exchange softener offers users other required volume exceeds that of the vessel fitted to the
benefits and should be specified with an appropriate boiler then an additional vessel should be installed, on
flow rate capacity. the return connection from the heating system. The
charge pressure of any additional vessel is assumed
Water “conditioning” devices such as those which dose to be 1.0 bar, the same as the vessel fitted to the
the incoming water with food grade polyphosphates can boiler.
be effective in reducing limescale but require correct

Publication No. 5106226 Installation Requirements 13


If the initial cold fill pressure is 1.0 bar: a.be at least one pipe size larger than the nominal
expansion vessel size = 0.11 x system volume outlet size of the safety device unless its total
equivalent hydraulic resistance exceeds that of a
This fill pressure will allow the maximum expansion straight pipe 9m long i.e. discharge pipes between 9m
capacity, though any minor loss of water will result in and 18m equivalent resistance length should be at
a rapid pressure drop. An additional expansion vessel least two sizes larger than the nominal Outlet size of
is only required if the total system volume exceeds the safety device, between 18 and 27m at least 3 sizes
106 litres. larger, and so on. Bends must be taken into account in
calculating the flow resistance. Refer to Fig. 7, Table 1
This includes the 5.5 litre primary circuit volume and the worked example.
within the Powermax HE boiler - thus radiator and
pipework volume should not exceed 100 litres. An alternative approach for sizing discharge pipes
would be to follow BS 6700:1987 Specification for
Pipework above boiler design installation, testing and maintenance of
Air vents must be fitted at the highest positions on flow services supplying water for domestic use within
and return pipes and at any point where air is likely to buildings and their curtilages. Appendix E. section E2
collect. and table 21.

TRV’s in System b. have a vertical section of pipe at least 300 mm long,


An automatic bypass valve is built into the boiler to below the tundish before any elbows or bends in the
allow thermostatic radiator valves to be fitted. This can pipework.
be switched into or out of circuit as required.
c. be installed with a continuous fall.
1.7 Discharge Pipework
d.have discharges visible at both the tundish and the
It is a requirement of Building Regulation G3 that any final point of discharge, but where this is not possible
discharge from an unvented system is conveyed to or practical, there should be clear visibility at one or
where it is visible, but will not cause danger to persons other of these locations. Examples of acceptable
in or about the building. The tundish and discharge discharge arrangements are:
pipes should be fitted in accordance with the
requirements and guidance notes of Building i. ideally below a fixed grating and above the water
Regulation G3. The G3 Requirements and Guidance seal in a trapped gully.
section 3.9 are reproduced in the following sections.
Information Sheet No. 33 available from the British ii. downward discharges at low level; i.e. up to
Board of Agrement gives further advice on discharge 100mm above external surfaces such as car
pipe installation. For discharge pipe arrangements not parks, hard standings, grassed areas etc. are
covered by G3 Guidance or BBA Info Sheet No.33 acceptable providing that where children may
advice should be sought from either your local Building play or otherwise come into contact with
Control Officer or Potterton. discharges a wire cage or similar guard is
positioned to prevent contact, whilst maintaining
G3 Requirement “...there shall be precautions ... to visibility.
ensure that the hot water discharged from safety
devices is safely conveyed to where it is visible but will iii. discharges at high level; e.g. into a metal hopper
not cause danger to persons in or about the building.” and metal down pipe with the end of the
discharge pipe clearly visible (tundish visible or
G3 Guidance SECTION 3.9 not) or onto a roof capable of withstanding high
The discharge pipe (D1) from the vessel up to and temperature discharges of water and 3m from
including the tundish is generally supplied by the any plastic guttering system that would collect
manufacturer of the hot water storage system. Where such discharges (tundish visible).
otherwise, the installation should include the discharge
pipe(s) (D1) from the safety device(s). In either case the iv. where a single pipe serves a number of
tundish should be vertical, located in the same space discharges, such as in blocks of flats, the number
as the unvented hot water storage system and be fitted served should be limited to not more than 6
as close as possible and within 500 mm of the safety systems so that any installation discharging can
device e.g. the temperature relief valve. Note: The be traced reasonably easily. The single common
tundish is factory fitted during manufacture of the discharge pipe should be at least one pipe size
Powermax HE. The discharge pipe (D2) from the larger than the largest individual discharge pipe
tundish should terminate in a safe place where there is (D2) to be connected. If unvented hot water
no risk to persons in the vicinity of the discharge, storage systems are installed where discharges
preferably be of metal and: from safety devices may not be apparent i.e. in

14 Installation Requirements Publication No. 5106226


dwellings occupied by blind, infirm or
disabled people, consideration should be Valve Minimum Minimum Maximum Resistance
given to the installation of an electronically outlet dischage discharge resistance created by
operated device to warn when discharge size pipe D1 pipe D2 allowed, each elbow
takes place. from expressed or bend
tundish as a length
Note: The discharge will consist of scalding of straight
water and steam. Asphalt, roofing felt and pipe (i.e. no
non-metallic rainwater goods may be elbows or
damaged by such discharges. bends)
Worked example of discharge pipe sizing 22 mm up to 9 m 0.8 m
The example below is for a G1/2 temperature G1/2 15 mm 28 mm up to 18 m 1.0 m
relief valve with a discharge pipe (D2) having 4 35 mm up to 27 m 1.4 m
No. elbows and length of 7 m from the tundish to
the point of discharge.
28 mm up to 9 m 1.0 m
G3/4 22 mm 35 mm up to 18 m 1.4 m
From Table 1:
42 mm up to 27 m 1.7 m
Maximum resistance allowed for a straight length
of 22mm copper discharge pipe (D2) from a G1/2
35 mm up to 9 m 1.4 m
temperature relief valve is 9.0 m.
G1 28 mm 42 mm up to 18 m 1.7 m
54 mm up to 27 m 2.4 m
Subtract the resistance for 4 No. 22 mm elbows at
0.8m each = 3.2 m.
Table 1. Sizing of copper discharge pipe (D2) for common temperature
relief valve outlet sizes. Note: shaded area is reproduced for completeness
Therefore the permitted length equates to: 5.8 m. but does not apply to this boiler.

5.8 m is less than the actual length of 7 m


therefore calculate the next largest size.

Maximum resistance allowed for a straight length


of 28 mm pipe (D2) from a G1/2 temperature
relief valves equates to 18 m. Typical Discharge Pipe Arrangement
Subtract the resistance of 4 No. 28 mm elbows at Condensate Trap
1.0 m each - 4.0 m. Internal
S.V.P. 500 mm
Therefore the maximum permitted length equates Flexible Tube
to: 14 m. supplied
21.5 mm T.P.R. Valve
As the actual length is 7 m, a 28 mm min. (D2) PVC
copper pipe will be satisfactory. Overflow Tundish
Pipework
Warnings
Discharge
• Under No circumstances should the factory
300mm min. above
fitted Temperature/Pressure Relief Valve be
Fixed
removed other than by Authorised Potterton
Grate
personnel. To do so will invalidate any
warranty or claim. 450mm min.
• The cold water Inlet Control Group must be Fixed
fitted to the mains water supply to the Metal discharge pipe from
Tundish with continuous fall Grate
Powermax HE when it is operated as an
unvented system.
• Control and safety valves MUST NOT be
MAX0011A

tampered with.
• The discharge pipe MUST NOT be blocked
or used for any other purpose.
• The tundish must not be removed but can be
sited outside the RH panel using the opening Trapped Gulley
provided.
• Electrical components must not be sited near
the tundish. Fig. 7

Publication No. 5106226 Installation Requirements 15


2. Installation
2.1 Install the boiler 5. Release DHW temperature sensor and un-roll cable.
Route cable behind cylinder pipes and push sensor
Before starting an installation, check that the correct flue fully home (approx. 310mm - 12”) into the pocket in the
kit and correct capacity cylinder have been supplied. cylinder.
6. Remove small knock-outs as required either side of
Important: When soldering plumbing fittings, do not casing for plumbing access. The handholds in the side
allow flame from blowtorch to come into contact with panels can also be used. Further access holes allow
the insulating foam or other non-metallic parts. the condensate to be routed via the LH panel and the
DHW to be plumbed via the RH panel.
Guidance on where to locate the boiler is given in Sections
1.3 and 1.5. In some instances it will be advantageous 2.2 Connect the Flue System
to pre-plumb pipework or to pre-fix terminal, air/flue
pipes and duct.
1. Unless already fitted, install the flue system as shown
in the Installation Instructions supplied with the flue kit.
1. Remove top and front panels (see Page 3) and
carefully set aside.
2. Determine boiler final position. The cutaway in the
2.3 Connect the Gas Supply
cylinder base allows pipework to be brought up from
below floor level. Use the dimensions below or the 1. Ensure that the gas supply is isolated.
template on the reverse of the Installation Guide to pre- 2. The gas connection to the boiler is 22 mm.
drill any holes. Pipes must not obstruct service access Refer to Section 1.1 for information on the required gas
to the immersion heater (if fitted) or to the condensate supply. Do not turn the gas supply on at this stage.
trap.
3. Move boiler into position. The need to move as Top and POWER

MAINS ON BURNER LOCK OUT RESET


-
H.W. TEMP

C.H. ADVANCE
+

SEL

PROG
+

-
SEL

PROG

Bottom sections or as a complete assembly will

Must Be Earthed
This Appliance
N L TR TL N 2 L 2 FR HWR HWL CHR CH L

Gas
depend on the individual installation. The Top has 4 Cock
downward facing dowel pins which provide accurate (0pen)
location on to the cylinder. Take care to avoid trapping RWC

hands and fingers during assembly.


4. Apply sealant to cone faces of both 22mm Union
Nuts (see Fig. 10). Remove cardboard pipework

MAX0023C
support. Attach the 15mm x 90° branch pipe joining the
two relief valves/tundish.
22mm Gas
Connection

Double arrows are from rear of boiler Fig. 8

Outline of insulation
550 Overall

46 70 43 119 122 35 60 54
514
600 overall
572

512
507
567

544

560

536

MAX0021B

C/H Flow DHW


TPRV
Discharge
Cold
Condensate
Feed
39 Alternate
C/H Return
C/H Flow or
Condensate Gas
Dimensions are approximate
All pipes are 22mm Outline of front panels Outline of base plate
Fig. 9

16 Installation Requirements Publication No. 5106226


Component & Connection Identification

Flue Test Point Manual Air Vent - Bleed


Ø60 Flue Ø60 Air
Air Manifold
Fan
Air - Gas Ratio Valve
Ignition Electrode
Isolating Valve
Viewing Window
"Schraeder" Valve
Heat Exchanger

Burner Primary Expansion Vessel

Ionisation Probe
-
H.W. TEMP
+ Auto Air Vent - Pump
SEL + SEL
POWER

Control Box MAINS ON BURNER LOCK OUT RESET C.H. ADVANCE PROG - PROG

Wiring Cover
Must Be Earthed
This Appliance

Cable Bushing N L TR TL N 2 L 2 FR HWR HWL CHR CH L


D.H.W. Outlet
Wiring Terminal Primary Pressure Sensor

Condensate Trap Pressure Relief Valve (3 bar)


Isolating Valve
By-pass Valve
Gas Cock 15mm Branch Pipe
Union Joints TPR Valve (Temperature
RWC & Pressure Relief)
Condensate Outlet
(500mm supplied)

Tundish
Domestic Hot
Water Sensor
Isolating Valve

Plumbing
'NO GO' Area Pressure Gauge

Immersion
Heater (Optional) Filling Loop

Potterton Powermax HE
Pipework shown as this
NOT SUPPLIED 150 litre model shown
MAX0002C

CH Flow D.H.W.
Outlet
Gas Inlet
Discharge Pipe
CH Return
Mains Cold Inlet

Fig. 10

Publication No. 5106226 Installation Requirements 17


2.4 Connect the Water System For most systems, pump speed 2 will suffice. Using
speed 1 will impair domestic hot water recovery. Speed
See Figs. 10 and 11. Observe guidance provided in 3 will be required for high resistance systems such
Section 1.6. Always tee the cold feed to shower fittings as those controlled by TRVs and/or utilising plastics
(and other mixer fittings) into the pipe supplying the hot minibore pipework.
water store i.e. downstream of the Inlet Control Group. Graph of Central Heating Head vs. Flow
This will ensure a balanced pressure supply to the
m
shower(s).
4

3
Future maintenance and servicing operations will be
simplified if the Inlet Control Group can be mounted 3

Pump Head
2
above the DHW store as indicated in Fig. 11. Both the
Inlet Control Group and the expansion vessel can be 2
sited away from the boiler e.g. to supply reduced
pressure to all the system, but it is essential that no valve 1
is fitted in-line between the store and either of these
components.
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
Solder Flux Flow litres/min. MAX0063A

Use water-soluble flux for making soldered capillary Secondary Circulation


joints in the primary circuit. Traditional grease-based flux
containing zinc chloride must not be used. A pumped secondary circuit, if required, can be
connected by teeing into the 22 mm DHW Outlet pipe
CH System Connections and the 22 mm Cold Inlet pipe. Note: This is not
recommended for models having a secondary store of
The flow connection is on the LH side of the unit as less than 150 litres.
indicated. The return connection is low down at the front
centre. Pipework can be run inside the casing but must A single check valve (spring loaded type) should be fitted
not prevent the removal of the immersion heater (if fitted) in the return from the secondary circuit. All component
or obstruct access to condensate trap. parts of a secondary circuit must be suitable for
operation at temperatures up to 65 °C and pressures up
Pressure Relief Valve to 8 bar.
Must Be Earthed
This Appliance

A pressure relief valve set at 3.0 bar is fitted to the N L TR TL N 2 L 2 FR HWR HWL CHR CH L

primary pipework near the top of the tank. See Fig. 10.

Manual Air Vent

Using the manual air vent, thoroughly vent air from top To secondary circuit
of the heat exchanger when filling the system to save
RWC
time during the boiler commissioning. Note: 1/4” dia.
manometer tube fits the manual vent.

Central Heating Pump & System By-pass

The central heating pump is factory fitted and an


automatic system by-pass is provided. The boiler can be
used in systems controlled by thermostatic radiator
valves (TRVs) but it is essential that the by-pass isolating
valve is fully open.

The circulating pressure and flowrate available for the


central heating system is shown opposite with the by-
pass in circuit.

From secondary circuit


Check Valve

18 Installation Publication No. 5106226


Ø240mm
Wall Bolts & Plugs
Threaded Washer Secondary
Rod Expansion
Vessel
Nut 400mm

Expansion Vessel
Support Bracket
Nut &
Washer
Expansion Vessel Support Strap

15mm
Inlet Control Group
(set pressure 2.5 bar)

Expansion Relief
Valve (8.0 bar)

Stop DHW
15mm Valve Mains
22mm 22mm Cold Inlet
POWER
-
H.W. TEMP
+

SEL + SEL
and cold
feed to
MAINS ON BURNER LOCK OUT RESET C.H. ADVANCE PROG - PROG
Must Be Earthed

kitchen
This Appliance

N L TR TL N 2 L 2 FR HWR HWL CHR CH L


Tundish
140 310mm tap.
mm

RWC

If possible mount above the storage


cylinder for ease of servicing
Cold feed
to showers
only

22mm Discharge Pipe

Double
Check Valve Important
300mm Do Not fit any valve in-line
CH Flow Minimum between the storage cylinder
Gas and the Inlet Control Group
CH Return

Schematic ONLY:
Discharge Pipes can
Floor
be combined as shown
MAX0003D

Pipework shown as this


NOT SUPPLIED

Fig. 11

Publication No. 5106226 Installation 19


2.5 Condensate Drain Pipe
Washer Seal
Before fitting, fill the condensate trap with water.

The condensate pipe should be run in 21.5/22.0


mm diameter plastic material suitable for
Boiler operation at 60° C. Solvent weld PVC overflow is
Condensate recommended or a PP system can be used.
Connection Copper tube must not be used. Do not use push-
Condensate
fit plastic pipe.
Drain Pipe
Fill up the Condensate 500mm supplied
Trap with water, then (suitable for 21.5mm Use the flexible pipe provided to connect to
fit to the boiler overflow pipe) 21.5mm PVC pipe; alternatively a Marley or
Plumb Center elbow can be used to direct the
condensate pipe through the LH side panel (see
Fig. 12). When using the Osma PVC overflow
system, a 3/4 -to-22mm adaptor No. 158 may be
required.
- +

POWER

MAINS ON BURNER LOCK OUT RESET


H.W. TEMP

C.H. ADVANCE
SEL

PROG
+

-
SEL

PROG
Internal pipework should have a bore diameter no
smaller than 14 mm.
Optional
Must Be Earthed
This Appliance

N L TR TL N 2 L 2 FR HWR HWL CHR CH L


External pipework should be kept to a minimum,
Route -
and have a bore diameter no smaller than 32 mm.
Condensate
Ideally the condensate pipe should be run
internally to the house soil and vent stack or to a
waste pipe.
Alternatively, the condensate may be discharged
RWC Optional into the rainwater system, or a purpose-built
Route - soakaway.
DHW All connecting drainage pipework must have a fall
of at least 50 mm per metre run.
It is recommended that the pipe is insulated if run
externally to minimise the effects of freezing, and
that a plastic insert is fitted that provides a
siphon/weir action to encourage the water to flow
in intermittent bursts rather than dripping
continuously.
Note: Connection of a condensate pipe to a drain
may be subject to local building regulations.
See Page 19 for a typical example.
MAX0022C

2.6 Connect the Power Supply


Fig. 12
WARNING – THIS BOILER MUST BE EARTHED

Wiring must comply with the current IEE Wiring


Regulations. The supply cable must be 3-core
0.75sq. mm (24/0.2 mm) to BS6500 Table 16.
The supply must be of 230V – 50Hz. A 3A-fused
double pole-isolating switch may be used, having
a minimum contact separation of 3 mm in both
poles, providing it serves only the boiler and its
system controls. Alternatively a 3A 3 pin fused
plug may be used.

The wiring diagram is shown in Fig. 25, Page 36.


Note that the boiler control is fitted with two
internal 3.15A “slow blow” fuses (20 mm x 5 mm).

20 Installation Publication No. 5106226


1. Connect the incoming electricity supply cable
to the user terminal as shown below ensuring Fig. 13
that the green/yellow earth conductor is WARNING
DISCONNECT
ELECTRICITY
BEFORE
REMOVING

longer than the blue neutral and brown live THIS COVER

conductors. Secure the cable to the Front View of Control Box


anchorage clamp and route via the bushing
in the L.H. side panel.

2. Connect the cable from any external control


e.g. room thermostat, or frost thermostat and
route via lower LH side of unit. Programmer Off Programmer On

Control Box Integral Programmer Disable Switch

MAX0068A

N L T T N
R L 2

- +
'Stat Neutral

H.W. TEMP
'Stat Return

SEL + SEL
POWER

BL MAINS ON BURNER LOCK OUT RESET C.H. ADVANCE PROG - PROG


'Stat Live

Must Be Earthed
This Appliance
G/Y BR
N L TR TL N 2 L 2 FR HWR HWL CHR CH L

Bushing for
electrical cable

MAINS

ROOM 'STAT

RWC

3. The integral programmer can be replaced by


one sited away from the boiler if required. It is
recommended that it should be of a type

MAX0013C
having volt free contacts. Wiring connections
are indicated in Fig. 25, Page 36. When using
an external programmer, the integral
programmer must be disabled, see Fig. 13. Mains Cable Clamp Earth Post

4. If a combined clock thermostat is being used


Must Be Earthed

to control the central heating, it should be of a


This Appliance

type having voltage free contacts. Permanent


live and additional neutral connections are
available as shown (Fig. 13) for supplying
power to the clock. N L TR TL N 2 L 2 FR HWR HWL CHR CH L

Important: Be certain before switching on for the


first time that Earth, Live, Neutral and Mains Room Frost/Pipe Remote
Thermostat connections are correctly 'Stat 'Stat Programmer
connected and identified. (see wiring diagram)

Important: If wired incorrectly, the boiler control Installer Options


may fail when power is applied. This is not
covered by the warranty and is replaceable on a
Important: If you intend to use an external
chargeable basis.
programmer to control this boiler then the integral
programmer must be switched off as shown above
5. After completing the electrical connections,
perform the following electrical system safety
checks: If a frost thermostat is situated in an outhouse or
A - EARTH CONTINUITY garage, it is advisable to use a pipe ‘stat, wired in
B - POLARITY parallel, to switch off the boiler
C - RESISTANCE TO EARTH
D - SHORT CIRCUIT Fig. 13

Publication No. 5106226 Installation 21


2.7 Optional Immersion Heater

This heater is rated 3 kW at 240 V only and must be wired to a


totally separate, suitably rated main supply. THERE MUST BE
NO INTERCONNECTION WITH THE WIRING TO THE
BOILER.

Warning: THIS HEATER MUST BE EARTHED.


- +
H.W. TEMP

SEL + SEL
POWER

MAINS ON BURNER LOCK OUT RESET C.H. ADVANCE PROG - PROG

It should be installed in accordance with the current IEE wiring


regulations and be wired through a double pole isolating switch
Must Be Earthed
This Appliance

N L TR TL N 2 L 2 FR HWR HWL CHR CH L

or a suitable controller. The heater must be fully immersed and


not switched on dry. Secure cable grip using only screws
provided.

This immersion heater has a special 1 3/4 “ BSP thread. It is not


interchangeable with standard immersion heaters. Use only the
RWC
‘O’ ring seal provided. The use of any sealant on the ‘O’ ring is
not recommended.

The heater must be wired with 85 °C rubber insulated HOFR


sheathed flexible cable 1.5 mm2 complying with BS 6141 Table
8. The outer sheathing should be secured using the cable grip
fitted and routed away from the boiler through one of the
bushings provided.

The heater is controlled by the rod type thermostat fitted.


Drain
Valve A temperature setting of 65 °C is recommended and is factory
pre-set. This should be reduced to 55 °C (No. 3 on dial) in hard
water areas.

The thermostat incorporates a thermal cutout which cuts the


power to the immersion heater in an overheat situation. Should
this operate it can be manually reset by pressing the red button
Double to the side of the temperature adjustment dial.
Optional
Check
Immersion Heater
Valve Note: Investigate the cause of the overheating prior to resetting.

Immersion Heater Wiring Should the immersion heater require replacement, use only the
Powermax spare part P3223/5106143.
Element (connections Temperature
under thermostat) Adjustment
2.8 How to Drain Hot Water Storage Cylinder
Thermostat
L
Isolate mains water supply at stop valve on Inlet Control Group
and close ⁄-turn valve (handle at 90° to valve body) on double
check valve - see Fig. 14.
N
Fit a hosepipe to the tail of the drain valve (secure with “Jubilee”
clip), and run open end to a low level where water can be safely
drained.

Cut-out Earth
Post Open nearest tap(s) fully (to allow air to enter cylinder) before
Reset Button opening the drain valve above hose. Note: The lower the open
L N E end of the hose, the faster will be the draining effect.
MAX0014C

Cable
Grip When refilling: check that the secondary expansion vessel pre-
charge pressure is between 2.5 to 2.7 bar and allow water to
Fig. 14 flow freely before closing tap(s).

22 Installation Publication No. 5106226


2.9 Control Panel, Displays & Diagnostics

The boiler control fitted to Powermax HE has been designed to provide safe, reliable and economical operation of the
boiler - see Fig. 15 for a guide to the control panel.

Fault finding, during both commissioning and subsequent maintenance is much simplified by the clear display of lockout
and error codes which appear in the ‘Status/Error Code Display’. What the codes represent and the remedial actions
required are explained on Page 39.

During normal operation, the ‘Status/Error Code Display’ can be set to show either:

System pressure e.g. P 1.5 (in bar)


or The selected temperature of the DHW e.g. U 55 (in °C)
or The flow temperature to the CH circuit e.g. c 80 (in °C)

by pressing the reset button to scroll from one display to the next.

The ‘Programmer Display Window’ shows time of day and, when implemented, is used for setting and checking the timed
on periods.

Programmer Display Window

MON TUE WED THU FRI SAT SUN


P.M
OFF OFF
TIMED TIMED
ONCE ONCE
ON ON
TIME ON 1 ON 2 ON 3
A DAY OFF 1 OFF 2 OFF 3 A

C.Heating 'ON' D.H.W. 'ON'


Boiler ON- OFF Status/Error Code D.H.W. Temperature Indicator Indicator
Switch Display Window Control Light (Green) Light (Green)

MAX0010A

Mains 'ON' Burner 'ON' Lock Out Lock Out


Indicator Indicator Indicator Reset Integral Programmer
Light (Amber) Light (Green) Light (Red) Button Controls

Fig. 15

Publication No. 5106226 Installation 23


3. Commissioning

Ionisation Fan Heat Overheat Manual Air Flow Air


Probe Assembly Exchanger Thermostat Vent - Bleed Sensor Manifold
(Remove to
add inhibitor)
Burner Flue Test Return
Spark
Assembly Point Sensor
Generator
Diverter
Valve

PCB/ Controls
Assembly

POWE
R -
MAINS H.W.
+ CH
BURN TEMP
ON ER
LOCK HW
OU
T
RESE SEL
T

Indicator Lever C.H.


ADVA
NCE
PROG
+
SEL
Pow
erma
-
x
MAX0001C
PRO
G

Off
On

Integral
Programmer
Disable
Switch

Condensate Isolating Gas Primary Air/Gas E. Vessel Ignition


Trap Valve Cock Pressure Sensor Valve "Schraeder" Valve Electrode
Automatic Air Pressure Relief Pump Isolating Expansion
Vent - Bleed Valve Valve Vessel

Fig. 16

Important Important
The commissioning and boiler adjustment must When checking for gas soundness open
only be carried out by a suitably qualified all windows and doors in the room.
person. Potterton offer this service Extinguish all naked lights, cigarettes, pipes, etc.
on a chargeable basis.

24 Commissioning Publication No. 5106226


3.1 Commission the Boiler Top up if required. Loosen bleed screw for pump
spindle to remove air and re-tighten.
Important - An automatic air vent is built into the pump 10.Use the programmer CH and HW buttons to
and the cap on the air bleed valve should be closed after alternately select central heating and hot water.
air has been removed from the system. Observe that indicator on diverter valve moves
forward (hot water) and back (central heating).
Flush the System Check that air is expelled from both circuits.
11. Consult the diagnostic codes on Page 39 to
The system must be flushed in accordance with BS check that control display shows a normal or
7593 and the flushing agent manufacturers instructions, indicative code, switch off.
further guidance can be obtained from BS 5449 Section 12.The whole of the gas installation must be checked
5. for soundness and purged in accordance with, in
GB BS 6891 and in IE I.S. 813 “Domestic Gas
Use the manual air vent connection on top of the heat Installations”. Loosen screw in gas valve inlet
exchanger to add inhibitor - See Fig. 16. pressure test point and attach a suitable gauge to
monitor inlet gas pressures. Turn on gas supply at
Warning: Do not attempt to start this boiler unless meter and turn the service gascock on (indicated
the primary circuit has been filled with water. by screwdriver slot being in-line – see Fig. 10,
Page 18.
Preliminary Electrical System Checks
Unvented Domestic Hot Water System
These checks must be carried out prior to attempting to
start the boiler. They are, Earth Continuity, Short Circuit, 1. With no water pressure on the system, check and
Polarity & Resistance to Earth. if necessary adjust the secondary expansion
vessel pressure to approx. 2.5 to 2.8 bar (36 to 40
Sealed Primary System psi). Note: Vessel pressure can not be accurately
set with water pressure in system.
1. With no water pressure on the system, check and if 2. Open one or more hot water taps.
necessary adjust expansion vessel pressure to 3. Turn on mains water supply and observe air free
approx. 1.0 to 1.2 bar (15 to 16 psi). water issuing from tap(s)
Note: Vessel pressure cannot be accurately set with 4. Close tap(s) and check mains water pipework for
water pressure in system. leaks
2. Attach a length of hose to the outlet of the manual 5. Check that all factory-made plumbing connections
vent so that a copious volume of air water mix can are tight and leak free (and have not loosened in
be discharged. Open vent using radiator key. transit).
3. Loosen cap on automatic air vent on pump. Check 6. Manually operate both the Temperature &
that filling loop is connected. Pressure Relief Valve and the secondary pressure
4. Open stopvalves (including filling loop) and fill relief valve and ensure that the discharge from
system with water. Allow water to continue flowing these valves emerges safely. Close them again
from the manual air vent until air is no longer with a “snap” action.
discharged.
5. Close manual vent and, using the gauge on the Guideline times for the initial heat-up and recovery
lower pipework, set the system pressure to approx. for a nominal 50 °C temperature rise (e.g. 15 °C -
1.5 bar. 65 °C) within the store are:
6. Open one or more hot water taps to ensure the
cylinder is full of water and all air has been Unit Heat-up Recovery*
expelled. 85 Litre 18 min. 15 min.
7. Thoroughly check water connections on boiler and 115 Litre 22 min. 18 min.
inspect radiator valves, unions, etc. for leaks. 150 Litre 30 min. 23 min.
8. Switch on mains electricity supply. Check that
integral programmer is switched on and set so that * From previous draw-off of 70% of volume.
either/both CH and HW channels (and CH
thermostat) are calling for heat, (green neons on). Starting (Lighting) the Boiler
Note: If remote programmer is being used, the
integral programmer should be disabled by moving 1. Switch electricity supply on at the isolating switch
slider switch to left. and switch the boiler on (‘I’ position on On/Off
9. Check that pump starts immediately (free spindle if switch).
it appears to be sticking). Air should be expelled 2. Move the boiler on-off switch to the ‘I’ (on) position.
from auto air vent and the control display will warn Note that displays are visible in both windows of the
if system pressure falls below 0.5 bar. control panel.

Publication No. 5106226 Commissioning 25


3. Press the DHW select button to switch hot water on 4. With flow to the CH circuit, bleed every radiator and
(green neon stays on). the pipework high points until all air or air/water mix
4. Press reset button to scroll through LH window until has been removed.
display shows “p 1.5” to check that system pressure 5. Vent the boiler again if necessary - note that the
is between 0.9 to 2.5 bar. Adjust as necessary. The burner control goes to safety shut-down if the
fan starts to rotate after a slight delay and a few system pressure drops below 0.5 bar.
seconds later the automatic ignition sequence will 6. Wait until the central heating circuit has reached its
be initiated. The green burner neon will indicate when normal temperature of approx. 80 °C before
the burner lights. balancing the radiators in the usual way to achieve
5. If the burner fails to light, the ignition sequence will a temperature drop of 10 °C.
be automatically repeated until either the burner 7. Allow system to reach full temperature (all radiators
lights or a safety LOCK-OUT condition is signalled by at working temp.) and note “hot system” pressure.
the red neon. If red neon shows, press the reset Switch boiler off, drain and flush the system.
button indicated. 8. Refill (using a suitable inhibitor) and remove all air
6. With the boiler operating check the flame is stable. and air/water mix. Check the relief valve is not
Note: After first filling with cold water some noise “letting” by observing pipe outlet for several minutes.
may occur within the combustion chamber as the (“Letting” is usually due to debris on valve seat.
flame settles on the burner. This is normal and will Snapping the valve open-shut a few times will
soon disappear. normally cure this).
7. Record the “working” inlet gas pressure at inlet 9. Check that the system final pressure equals “hot
pressure test nipple in “Benchmark” logbook. system” pressure as noted in 7. above. Adjust if
8. Check gas valve differential (offset) - See Fig. 28, necessary.
Page 42 10.Set the room thermostat or programmer according
Note: This valve has been factory pre-set and to the manufacturer’s instructions.
adjustment is not normally required. 11.Disconnect filling loop flexible hose and leave in a
a. Loosen screw in outlet pressure test point and secure place for householder.
connect to “+” (positive) side of differential micro-
manometer. Domestic Hot Water System
b. Tee the “-” (negative) side of the micro-manomter
into the air signal tube as shown in Fig. 28. 1. With the cylinder fully heated, check DHW output
c. Switch on central heating using CH select button temperature is approximately 45 to 65 °C (as
and switch off hot water. The boiler will re-start in selected) using nearest tap and a flow rate of
CH mode after approx. 1 minute. approximately 5 l/min. Record inlet and outlet
d. After boiler has been operating in CH mode for temperatures in “Benchmark” log book.
several minutes, simultaneously press the “+” and 2. Measure hot water flow rate at bath rap (fully open)
“STEP” buttons and hold down for 5 to 6 seconds. and record in “Benchmark” log book.
After a minute the boiler will be operating at low 3. Refit outer covers in reverse order.
input and the differential can be checked.
e. Ensure micro-manometer has been zeroed (if in 3.2 Hand Over to the User
doubt re-zero).
f. Check the differential reading. This should be zero 1. Explain the boiler controls
to minus 5 Pa (0.00 to - 0.05 mbar). If adjustment 2. Give guidance if the system is to be shut down for
is required refer to Page 42. long periods when freezing is possible
g. Disconnect micro-manometer, re-instate signal 3. Advise the User that for continued efficient and safe
tube between air duct and gas valve, and test operation of the boiler it is important that adequate
for gas soundness. servicing is carried out.
9. Turn boiler off, remove gauge, tighten test screws 4. Explain how to re-start boiler if red neon indicates
and test for gas soundness. lockout.
5. Hand over the User’s Instructions.
6. Carefully read and complete all sections of the
Central Heating System
“Benchmark” Installation, Commissioning and
Service Record Log Book that are relevant to the
1. Press button to select heating (indicated by stable
appliance and installation. The details of the Log
green neon). Book will be required in the event of any warranty
2. Check that any connected room thermostat is calling work. The Log Book must be handed to the user for
for heat. safe keeping and each subsequent regular service
3. Note that the 3-way diverter valve does not allow visit recorded. For IE, it is necessary to complete a
circulation to the CH circuit until the storage cylinder “Declaration of Conformity” to indicate compliance to
contents have reached the selected temperature. I.S. 813. An example of this is given in I.S. 813
After filling with cold water, this will normally take “Domestic Gas Installations”. This is in addition to the
between 20 to 25 minutes. “Benchmark” Log Book.

26 Commissioning Publication No. 5106226


4. Service & Replacement of Parts
To ensure safe, efficient operation of the boiler, it is pressure to approx. 2.5 to 2.8 bar (36 to 40 psi).
necessary to carry out routine servicing at regular Note: Vessel pressure can not be accurately set with
intervals. The frequency of servicing will depend upon the water pressure in system.
particular installation conditions and the use to which the
boiler is put. 7. Restore pressure to DHW system. Manually
operate, in turn, the expansion relief valve (part of
Important: Before commencing any servicing or Inlet Control Group) and the temperature & pressure
exchange of components, always turn off the gas relief valve (Fig. 10). Check that the discharge
supply and isolate the electricity supplies (i.e. to route(s) is unobstructed and that water flows freely
boiler and immersion heater). to a safe, visible location. Check that both valves
close correctly.
An annual inspection is recommended with servicing
every other year. After completing any service work 8. Release CH system pressure via relief valve and
always test for gas soundness and Remember to fill in check primary expansion vessel pre-charge
the Benchmark Log Book. pressure is between 1.0 to 1.2 bar. Adjust if required
and top up system to same pressure.
To gain access to the boiler for servicing, remove front
panel and top cover as described in Section 4.1 on Page 9. Check for gas soundness and re-assemble in
28. reverse order.

Annually Every Second Year

Important: Any 'O' rings, seals, gaskets or washers 1. Additionally to the above.
disturbed during service or replacement of parts must
be visually inspected and replaced if worn or Remove the heat exchanger door complete with
damaged. burner, see Section 4.7 - Burner. Inspect the burner,
combustion chamber and heat exchanger, carefully
1. Remove outer and inner top covers to gain access clean using a vacuum cleaner. Check the tightness
to heat exchanger etc. Inspect components within of the nuts securing the burner to the heat
compartment, checking that joints are dry etc. exchanger door. DO NOT separate the burner from
the heat exchanger door. Inspect the electrode
2. Withdraw the ionisation probe and clean the condition and check gap which should be 3.5 - 4.0
electrode with wire wool or similar abraisive. mm.

3. Partially open vent on top of heat exchanger and Combustion Testing


release any trapped air. Partially unscrew cap on
auto air vent (on top of pump) and release air. A combustion analysis test point is provided on the flue
outlet (just above heat exchanger). The test point is
4. Draw hot water from a bath tap if necessary to tapped ⁄ BSP and is sealed by a special screw/’O’ ring
cause burner to light. Check ignition is smooth and assembly. For a correctly installed boiler typical values
visually inspect flame. Continue to draw water until to be expected are:
maximum fan speed is attained. Check combustion, CO <80 ppm C02 <9.5 % at maximum input
see ‘Combustion Testing’.
Levels significantly above these should be investigated
5. Turn off the mains water supply at the Inlet Control and may indicate a defective component or faulty
Group and release system pressure by opening a installation. Ensure the test point is FULLY GAS
hot tap. Using hexagon key provided, remove the TIGHT. Do not substitute any other screw for the
pressure reducing cartridge from the Inlet Control special Powermax screw (Part No. 5106046).
Group. Clean the cartridge and strainer in running
cold water (A replacement cartridge/strainer Electrical Safety Testing
element is available - Part No. 5106018). Re-fit the
cartridge ensuring that the strainer is correctly It may be necessary to carry out electrical test work to
located. ensure the safety of the boiler circuits after overhaul
or as part of an inspection programme. This should be
6. With no water pressure in the system, check and if carried out to latest edition IEE regulations for Class 1
necessary adjust the secondary expansion vessel appliances with the flash test set at 1500 volts.

Publication No. 5106226 Service & Replacement of Parts 27


4.1 General Access

Warning: Before attempting to remove any


General Access component from the boiler first disconnect the mains
electricity supply by removing the plug from the wall
Uunscrew Top Panel
2 and lift away
socket or by switching off the boiler at the external
isolating switch.
Pull forward Front
Warning: The fan operating voltage is 325V d.c. Take
1 Panel at the bottom appropriate precautions. Allow at least 40 seconds to
and lift off elapse before handling the PCB within the boiler
Retaining Screws - Top Panel control assembly.

Unscrew Upper Panel at Important: After removal or replacement of any gas


4 the bottom and pull away carrying component a test for gas soundness must
be made and functional check of the controls carried
out.

Retaining Screws - Upper Panel Important: Any 'O' rings, seals, gaskets or washers
disturbed during replacement of parts must be
visually inspected and replaced if worn or damaged.

3 Pull forward Bottom Panel Re-assemble all parts in reverse order.

1. Follow stages 1 - 4 (opposite) to remove the


outer panels.
Internal Access
Internal Access
2. Remove the screws securing the top engine
Remove Front box cover and lift the cover away from the
Engine boiler.
Box Cover 3. Remove the screws securing the front engine
Retaining box cover and lift the cover away from the
Screws - boiler.
Top Panel
Access Panel 4.2 Automatic Air Vent
for Automatic
Air Vent - Bleed Re-assemble all parts in reverse order.
Front
Fascia 1. Perform 4.1 General Access, remove the
access panel rather than the front engine box
cover.
2. Pull away the securing clip and lift out the air
POW
ER -
MAIN H.W.
+ CH
BUR TEMP
S ON NER
LOC HW
K OUT
RESE SEL
T
C.H. +
ADVA
NCE
PRO
SEL
Pow
G
ermax
vent parts as shown.
-
PROG

Pull out
Auto Air Auto Air
Vent Parts Vent
Remove Front Fascia Securing Screws Front
Fascia
Removal
Pow
erma
x Pull away
Securing
Side Support Clip
MAX0004C

Pump Body
Lift Off
Front Fascia Location Peg

Fig. 17

28 Replacement of Parts Publication No. 5106226


4.3 Expansion Vessel/Pump
Isolating
Isolating Valve
Re-assemble all parts in reverse order. Valve
Open
1. Perform 4.1 General Access. Also remove Auto
the moulded facsia panel (2 screws). Air
Vent
2. Isolate three valves as shown and open Gas Cock Cap
the cap on the auto air vent.

3. Release pressure by opening the


pressure relief valve.
Open
4. Remove expansion vessel
Remove securing screws and support Pump
bracket. Disconnect flexible pipe at the Closed
vessel. Pull vessel forwards and out of the Isolating
boiler. Valve
POW
ER -
MAIN H.W.
+ CH
BUR TEMP
S ON NER
LOC HW
K OUT
RESE SEL
T

5a.Pump Motor
C.H. +
ADVA
NCE
PRO
G
SEL
Power
-
PROG
max

Loosen the top pipe union nut at the Expansion Vessel


pump.
Disconnect electrical connector from the Loosen when removing pump
pump motor. The pump can now be complete
rotated so the motor retaining screws can Pressure Relief
be removed Valve

5b.Pump Complete
Disconnect the top pipe union nut at the Open Pressure
pump. Disconnect electrical connector Relief Valve
from the pump motor. Loosen 22 mm
compression nut on cross fitting, lift the Isolating
pump up and it will disconnect (complete Disconnect Valve Disconnect
with pipe) from the push fit elbow. Pump Flexible Pipe
Washer
Connector
Important: Ensure that the metal washer
is located between the push fit elbow and Pump Top
the bulkhead and also above the rubber Pipe Washer
washers on top of the bulkhead. This will 2 Fibre
ensure that the pump can be easily Washers
removed in the future.

Lift Out
Disconnect Rotate Pump Pump Pump
Pump to Access Motor Pull
Pump
Connector the Pump forward
Bottom
Motor Expansion
Pipe
Vessel

Remove Expansion
Vessel Support Bracket

Bulkhead
MAX0015C

Metal Washers
Remove 4
Securing Screws Push Fit Elbow

Fig. 18

Publication No. 5106226 Replacement of Parts 29


4.4 Pressure Sensor/PRV
Isolating
Isolating Valve Re-assemble all parts in reverse order.
Valve
Open 1. Perform 4.1 General Access.
Auto
Air 2. Isolate three valves as shown and open
Vent the cap on the auto air vent.
Gas Cock Cap
3. Release pressure by opening the
pressure relief valve.

Open 4. Primary Pressure Sensor


Disconnect the electrical connector and
unscrew the sensor.
Pump
Closed
4. Pressure Relief Valve (PRV)
Isolating Release union nut below the sensor body,
Valve remove securing clip and pull valve out
POW
ER -
+

from assembly.
CH
MAIN H.W.
BUR TEMP
S ON NER
LOC HW
K OUT
RESE SEL
T
C.H. +
ADVA
NCE
PRO
SEL
Pow
G

- ermax
PROG

Expansion
Vessel 4. By-pass Valve
This valve is part of the complete ‘cross’
Pressure unit and cannot be replaced separately.
Relief Valve Remove the pressure relief valve as
shown above then release the unions and
remove the ‘cross’ unit.
Open
Pressure
Relief Valve

Remove Primary
Pressure Sensor
Disconnect
'O' Ring Electrical
Connector

Pull out Clip to


By-pass
release Pressure
Valve
Relief Valve

Pressure
Relief Valve
Remove Cross/Pressure
MAX0016C

Relief Valve Assembly


(By-pass Valve part of assy.)

Fig. 19

30 Replacement of Parts Publication No. 5106226


4.5 Air/Gas Valve/Injector/Fan
CH Flow
Re-assemble all parts in reverse order.

1. Perform 4.1 General Access. Fan Venturi Flue Gas


Test Point
2. Isolate the gas cock.
Gas Cock
3. Air/Gas Valve
Gas Pipe Air/Gas
Important: DO NOT attempt to replace Valve
the air/gas valve unless a combustion
analyser is available. See Page 42 for
Air
setup procedure.
Manifold
Remove the screws securing the gas pipe
securing plate to the air/gas valve.
Remove the screw securing the injector to
the venturi body. POW

MAIN
ER

S ON BUR
NER
LOC
K OUT
RESE
-
H.W.
TEMP
+ CH

HW

SEL

Disconnect all electrical connections to


T
C.H. +
ADVA
NCE
PRO
G
SEL
Power
-
PROG
max

the valve and the air pressure sensing


tube.
Pull the air/gas valve complete with
injector forward and away from the venturi
Top View of Air/Gas Ratio Valve Air
body.
Manifold
Fan
4. Injector Mounting Gasket Venturi
Remove the screws securing the plate to Venturi
Fan Securing Injector Connector
the air/gas valve and pull out the injector.
On re-assembly, leave the securing plate Screws
slightly loose so the injector can be turned
to allow the flat to line up with the flat
on the inside of the venturi body. Fan Injector Locking
Use an 8 mm A/F spanner to ‘nip’ the 'O' Ring Grub Screw

screws when in position.

5. Fan Injector Securing


Fan Plate & Screws (3 off)
Disconnect the electrical connections at
the fan.
Remove the 3 bolts securing the fan to the
venturi and the 4 screws and nuts
securing the fan to the burner. Gas Gas Pipe Air/Gas
Carefully lift the fan out and away from the Pipe Securing Plate Valve
boiler.
Be careful not to lose the large ‘O’ ring Venturi-Injector
Inlet Pressure Test Point Location Flat
between the fan and venturi.
Inspect and if necessary replace gasket Outlet Pressure Test Point
behind the fan outlet flange. Air Signal
Transfer large ‘O’ ring on fan intake to new Connection
fan.
Offset 'O'
Adjustment Rings
MAX0018C

Air/Gas Ratio Valve Injector

Fig. 20

Publication No. 5106226 Replacement of Parts 31


4.6 Spark Generator/Ignition
CH Flow
Electrode

Re-assemble all parts in reverse order.


Fan Burner Heat
Exchanger 1. Perform 4.1 General Access.

Gas Cock 2. Isolate the gas cock.


Spark
Generator 3. Spark Generator
Carefully disconnect the electrode lead
from the spark generator.
Remove supply cable from top of boiler
control - see Fig. 22.
Remove the screws securing the spark
generator to its bracket (ensure earth wire
is re-connected on re-assembly).

- 3. Ignition Electrode
- Powe
rmax Carefully disconnect the earth lead at the
electrode.
Remove the screws securing the
electrode to the heat exchanger.
Electrode Earth Lead Ignition Electode Carefully remove the electrode from the
heat exchanger.
Heat Exchanger On re-assembly check that the spark gap
between the tips is 3.5 - 4.0 mm.

3. Ionisation Probe
Alternative Fan Carefully disconnect the ionisation probe
Ignition Electode Support lead at the boiler control.
Remove the screws securing the probe to
the heat exchanger.
Ionisation
Probe Carefully remove the probe from the heat
exchanger.

Heat Exchanger
Door & 4.7 Burner
Securing Nuts
Re-assemble all parts in reverse order.

Supply Cable Ionisation 1. Perform 4.1 General Access.


Burner
& Earth to Probe to When cleaning burner
Control Box Control Box DO NOT unscrew from
2. Isolate the gas cock.
Heat Exchanger Door
Spark Generator 3. Remove the Fan (Section 4.5, Air/Gas
Heat Valve/Injector/Fan).
Spark Securing Exchanger 4mm
Generator Screws Door Spark 4. Disconnect the ionisation probe,
Gap electrode lead and earth lead.
Electrode (between
Lead wires) 5. Remove the nuts securing the heat
exchanger door to the heat exchanger.

6. Carefully remove the door complete with


MAX0017D

Electrode burner from the heat exchanger.


Earth Earth
Supply Cable Lead Lead
Important: Do not separate the burner
from the heat exchanger door.
Fig. 21

32 Replacement of Parts Publication No. 5106226


4.8 Boiler Control Assembly
Front Fascia

Warning: The fan operating voltage is 325V


d.c. Take appropriate precautions. Allow at
Remove Front Fascia
least 40 seconds to elapse before handling Power
max

the PCB within the boiler control assembly. Side Support


Remove Front Fascia
Re-assemble all parts in reverse order. Securing Screws

1. Perform 4.1 General Access.


Pow
erma
x
2. Isolate the electricity supply to the boiler. MAINS
ON

BURNE
R
LOCK
OUT
RESET
TEMP

SEL

ADVANC SEL
E

PROG

STEP

3. Remove wiring cover plate. Boiler


Control
4. Remove securing screws from fascia, Boiler
note how it fits and with great care, Control
Lift Off
remove it from the boiler. Support Front Fascia
Plate Location Peg
5. Disconnect all electrical connectors at the
control box. On re-assembly, connect as
shown on the wiring diagram.

6. Remove the two screws securing the


control box to the support plate, note how
it fits and carefully remove it from the
boiler. Boiler Control Disconnect Boiler Control
Support Electrical Securing
Plate Connectors Screws Remove Cover
Fuse: This is located on the control board
Plate
as shown opposite.

Front View of Boiler Control


Flow/Return
Generator

Fuse Lift Off


Pressure
Ionisation Probe

Sensors
Sensor

(3.15A Control Box


Spark

Pump

& Gas Valve

Slow Blow)
O/heat 'Stat

DHW Temp
Diverter

Top
Valve
Earth

Diagnostic
Fan

Electrical
Port
Connectors
J4 Spare

MAX0019C

J16 J10

J5 J12 J8 JP2 J7 J4 J11 J13 J15

High Voltage Connectors Low Voltage Connectors

Fig. 22

Publication No. 5106226 Replacement of Parts 33


4.9 Diverter Valve Actuator
Temp. Flow Sensor Overheat Thermostat Re-assemble all parts in reverse order.

Electrical Electrical 1. Perform 4.1 General Access.


Cable (Red) Cable (White) 2. Disconnect the electrical connector at the
actuator.
3. Release the locking catch and twist the
actuator until it unlocks from the valve and
remove from the boiler.
Flow Overheat
Sensor Thermostat
4.10 Overheat Thermostat

Manual Air Vent - Re-assemble all parts in reverse order.


Bleed
1. Perform 4.1 General Access.
Refer to Fig. 24, Page 35.
Manual 2. Disconnect electrical connections and
Air Vent - unscrew the thermostat. Polarity of the
Bleed wires is not important.
Extension
4.11 Diverter Valve Complete, Manual
Temp. Return Sensor Air Vent, Temperature Flow &
Return Sensors
Electrical
Cable (Blue) Re-assemble all parts in reverse order.
TEMP

MAINS
ON

BURNER

1. Perform 4.1 General Access.


LOCK SEL
OUT
RESET

ADVANC SEL
E

PROG

STEP
Powe
rmax

2. Check that the boiler primary system is


Return isolated from mains water supply.
Sensor 3. Release pressure from primary system and
drain down until water level is below the
valve.
Note: A convenient way to check the water
Remove level is to drain all water to the level of the
Electrical
'O' Securing primary expansion relief valve.
Connector Clips
Ring
Diverter Valve Complete

Note: The markings on the valve body are


A an aid to correct installation (See Fig. 23,
AB
Page 34).
'O' Rings
Remove B 4. Remove the three spring clips from the
the Release connections and remove the valve from the
complete Locking boiler.
Diverter Latch
Valve Manual Air Vent

Diverter Valve A 4. Unscrew vent from its mounting.


AB

B Temperature Flow & Return Sensors

4. Disconnect the electrical connector and


Diverter Valve Actuator unscrew the sensor. Sensors are inter-
MAX0024B

Twist the Actuator to the left & pull away


changable.
5. See Commissioning Instructions, Page 25
for procedure to re-fill and vent the sealed
primary system.

Fig. 23

34 Replacement of Parts Publication No. 5106226


4.12 Heat Exchanger
Heat Exchanger
Note: Replacing the heat exchanger
involves disconnecting the appliance from
the flue and air pipes. It is essential that the
flue system is fully reinstated and tested so
we recommend that the appropriate
replacement flue pipe and fittings be
obtained before starting this work. The slip
fitting Part No.5106807 will be helpful in
reinstating extended twin pipe flue systems.
'O' Rings/Seals Kit
POW
ER - Gas (Part No. 5106295)
Re-assemble all parts in reverse order. MAIN H.W.
+ CH
BUR TEMP
S ON NER
LOCK HW
OUT
RESE SEL
T
C.H. +
ADVA
NCE
PRO
G
SEL
Powe
-
PROG
rmax

'O' Rings/Seals Kit


1. Perform 4.1 General Access. Water (Part No. 5106296)

2. Check that the boiler primary system is


isolated from the mains water supply.
Release pressure from the primary
system and drain down.

3. Remove expansion vessel, pump, gas


valve, fan/venturi, diverter valve and heat Flue
Diecasting
exchanger door (complete with burner) all
as detailed in previous sections. Remove Side View
flow and return pipework from the push-fit of
To remove Heat Condensate
connections on RH manifold of heat
Heat Exchanger Exchanger Transfer
exchanger. Retain securing clips for re-
use. swing bottom forward Pipe

bottom of case Saddle


4. Disengage air inlet duct from elbow on top
RH side of boiler and set aside. Unscrew
3 c/sunk screws and remove air inlet Condensate Trap
elbow. Condensate Pipe
(not supplied Grommet
5. Disconnect wiring from temperature with Heat Exchanger)
sensors and overheat thermostat. Flue Seal
Carefully remove HT lead from spark Disconnect Flue
generator. H. Exchanger Diecasting
from LH
6. Disconnect flue pipe. Remove “hidden” Support Brackets Disconnect
M6 nut - see Fig. 24, at RH rear of heat HE
exchanger and remove two M6 flanged from RH
set screws securing the LH suspension Support
bracket. Support weight of heat Bracket
(which is
exchanger before removing the clip and
part of case)
saddle beneath.
Burner
Assembly Flow &
7. Lift heat exchanger vertically about 19mm removed
(3/4”) to disengage condensate spigot Heat Return
from its socket in the base panel; then tilt Exchanger Pipe
Securing
forward from the bottom to remove.
Clips
Remove bottom
MAX0025B

Disconnect Flow
Clip from the Saddle
& Return Pipes
Saddle

Fig. 24

Publication No. 5106226 Replacement of Parts 35


36 Wiring Diagrams

Fig. 25

Wiring/Functional Flow Diagram

5. Wiring Diagrams
G/Y

G/Y

IONISATION DIVERTER
VALVE 'HUBA' PRESSURE D.H.W.
PROBE PUMP GAS VALVE FAN TRANSMITTER TEMP RETURN FLOW
BL BR BK SENSOR SENSOR
O/HEAT BR BL
SENSOR
Y BL R Y
G/Y BK BR
BL BK W BR
BK CONN
W W LATCHES
R BL R
BL BL BK W
G/Y G/Y BR R
HT LEADS W W V V Y R W BL R
G/Y G/Y
G/Y BL BR BL BK BL BK BR Y BK R W BL V BK BR BL R DIAGNOSTIC
C1206
G/Y C1212 C1176 C1205 C1203 C1204 C1202 C1515 SPARE C1211 PORT
G/Y

J5 J16 J12 J8 JP2 J7 J4 J11 J14 J13 J10 J15


HIGH VOLTAGE CONNECTIONS LOW VOLTAGE CONNECTIONS
0
R
R
I
P.H.C. 129 - R2
R CONTROL UNIT
O POWER
SPARK R
GENERATOR
W
J1 J6 JP3 J9 S9

Programmer Programmer
OFF ON

NOTE! INTERNAL FUSE DISABLE INTEGRAL


(NOTE! NOT TO BE PROGRAMMER SWITCH
ALL CONNECTIONS ARE G/Y BL BR O O BL BR BK P BK L
CHANGED BY USER)
VIEWED FROM THE W Y N OUTSIDE
BR W P SENSOR INTERNAL FUSE SPECIFICATION:
CABLE - ENTRY SIDE. O BL BR
G/Y BL 3.15A "SLOW BLOW" (20mm X 5mm)
O BK Y BK
KEY
G/Y = GREEN/YELLOW
W= WHITE BL G/Y
G/Y
G= GREEN
BL = BLUE
BL = BLACK N L TR TL N2 L2 FR HWR HWL CHR CHL N L TR TL N2 L2 FR HWR HWL CHR CHL
BR = BROWN
R= RED
O= ORANGE BL BK
Publication No. 5106226

Y
Y= YELLOW BL R W P
V= VIOLET G/Y BR
O P Y
P= PURPLE
LIVE
DHW C/H
COM COM
MAINS ROOM FROST ROOM 'STAT
STAT STAT
MAX0020B NEUTRAL
REMOTE PROGRAMMER DHW ON C/H ON
Wiring Visual Reference

Alternative
Ignition
Electrode
Cable
Alternative
Ionisation
Probe
Lead Ignition Gas Gas Temperature Temperature
Electrode Valve Valve Flow Sensor Return Sensor
Ignition
Earth Earth Connector
Electrode
Cable

Ionisation
Probe
Cable

Fan
Cable
Fan Overheat
Earth Thermostat
Pump
Diverter Cable
Valve
Cable
Spark Temperature
Generator Return & Flow
Sensor
Cable
Gas Valve &
Overheat
Primary Thermostat
Pressure Sensor Cable
Spare
Primary Pressure
J12
Earth Cable Sensor Cable DHW Sensor
Cable
J8
Battery JP2 J7

J16 J4
J11
J5 J14 J13
Internal Fuse J10
(3.15) Cable Grommet
Boiler Control Support Panel
Cover Plate
J1 Boiler Control Box
J6 Bottom Connectors
JP3

Insulation
Must Be Earthed
This Appliance

Cover Plate
Securing Screw Boiler Control Box
N L T
R T
L N
2 L
Mains 2 F
R HW
R HWL C
Cable H
R CH L
MAX0061A

Clip Terminal Connector


See Wiring Diagram opposite for colour key (12 way)
Earth Point

Fig. 26

Publication No. 5106226 Wiring Diagrams 37


6. Fault Finding Guide
Boiler Fault Finding

Status/Error Code Display A 01 - Burner fails to light


- Lock out light 'ON'
- Reset & check

Is there negative pressure developed of at least Live Change


NO NO
150 Pa (1.5 mbar) at the gas valve outlet pressure point. to fan? Boiler Control
YES YES

Is there gas pressure during cycle? Change fan


YES NO

Check differential pressure Check inlet Check


as page 42. pressure to gas NO gas
valve - 20 mbar supply
NO
YES
Set
differential Check gas valve Check
YES
Change
240v NO overheat NO
Boiler Control
(JP2 BL & BK) stat
Check live to spark Check
NO YES
generator spark
NO YES YES
Replace
NO
Change Change Check coil
control spark electrode
& reset YES
box unit
spark gap
spark Change
gas valve
YES

Check Check gas supply If burner lights for


Remove condensate continuity 3 seconds & goes out.
YES NO NO
blockage trap is NOT ie. meter Check ionisation
blocked governor etc probe & lead.

Status/Error Code Display A 15 - Reset & check

Check dial Check sensor for damage/blockages


gauge pressure YES & electrical connections
1 - 2.9 bar etc replace as necessary
NO

Is pressure relief
YES Replace pressure relief valve
valve leaking?

NO

Release pressure on system


Repressurise & check
check internal (primary) YES
system for leaks
expansion vessel is 1 bar
NO
MAX0056A

Recharge (replace)
vessel to 1 bar

38 Fault Finding Guide Publication No. 5106226


Publication No. 5106226

Fault Finding Diagnostic Codes


DISPLAY MESSAGE ACTION / REMEDY FURTHER ACTIONS
CODE (INFORMATION / FAULT)

A 01 Burner failed to light Check gas supply and gas valve operation Check fan and spark operation. Check flue for blockage
Clean or replace ionisation probe & lead Check condensate outlet not blocked & vent tube is clear

A 03 Over temp. lock-out or circulation failure Check pump, 3-way valve & CH water pressure Replenish system & purge air/water via manual vent
A 04 Overheat 'stat open/gas valve failure Check wires/re-set 'stat. Test valve coils. Test for 230V and Neutral at PCB & plug on gas valve
A 05 Safety relay failure (in boiler control) Switch OFF/ON - press RESET Replace boiler control Part No. 5107535
A 07 Heat exchanger monitoring fault Check/adjust gas valve differential (page 42) Clean/replace ionisation probe & lead Part No. 5106941
Test combustion at high and low input (page 42) Check boiler control responds to flow & ret.sensors
A 15 CH pressure loss/pressure sensor faulty. Check/replenish CH system pressure. Find leaks. Check/replace pressure transmitter and cable.
A 19 Flame detected after gas valve shut Relight, check gas valve closes promptly Check for electric mains problem. Replace gas valve
A 20 Flame detected during ignition cycle Check gas valve closes fully. Replace Check ionisation probe & condensate outlet
A 33 Fan speed incorrect Check fan wiring and connections Replace fan Part No. 5106068 or boiler control
A 40 System response fault Check pump operation and speed setting Check 3-way valve operation. Purge air from H/E
Check by-pass and other water valves open. Check boiler control responds to flow & ret.sensors
A 41 System flow fault Check pump operation and speed setting Check by-pass isolating valve is open

b 52 ¡C Indicative cylinder temperature O.K. Cylinder being re-heated Press RESET button to scroll display
c 80 ¡C Indicative flow temperature to CH O.K. Scroll to pressure display "P" Press RESET button to scroll display

E 01 Primary pressure too high Reduce CH system pressure Check/adjust/replace primary expansion vessel 5106287
E 03 Flow temperature abnormally high Check pump, 3-way valve & CH system pressure Replenish system, adjust pump speed & bleed air
E 04 Flow sensor open circuit Check cable/connections not damaged Renew sensor/cable. Check connections on control
E 06 Flow sensor short circuit Check cable/connections not damaged Renew sensor/cable. Check connections on control
E 07 DHW sensor open circuit Check cable/connections not damaged Renew DHW cable /sensor assy. Part No. 5106290
E 08 DHW sensor short circuit Check cable/connections not damaged Renew DHW cable /sensor assy. Part No. 5106290
E 20 Flame detected with closed gas valve Check ionization probe/cable Check condensate outlet not blocked & vent tube clear
E 21 Live & Neutral supply reversed Correct the electrical supply
E 22 Electrical supply not 50Hz Correct the electrical supply
E 29 Fault in link on 6-way plug J11 Replace (pressure sensor) cable assy. Part No. 5107534
E 40 Return sensor open circuit Check cable/connections not damaged Renew sensor/cable. Check connections on control
E 41 Return sensor short circuit Check cable/connections not damaged Renew sensor/cable. Check connections on control
E 42 Internal control error Switch OFF/ON at mains isolator Replace boiler control Part No. 5107535

P 0.1 - 0.4 (bar) Boiler off because pressure too low Replenish CH system & purge air Find leak(s) and repair.
P 0.5 - 0.9 (bar) Water pressure in CH system low Replenish CH system & purge air Find leak(s) and repair. Compare analogue gauge pressure.
P 1.0 - 2.9 (bar) Normal pressure, system warm/hot O.K.
Fault Finding Guide 39

P 3.0 - 3.5 (bar) Primary pressure over 3 bar, boiler off Reduce CH system pressure Check/adjust/replace primary expansion vessel

t 80 ¡C Indicative flow temperature to DHW O.K. Scroll to pressure display "P" Press RESET button to scroll display
U 60 ¡C DHW temperature selected (by knob) Adjust if required - 55¡C recommended Range: 65¡C (winter) - 45¡C (summer) MAX0062D

Other codes not listed above indicate a faulty boiler control


7. Short List Of Spare Parts

3
1 2

4 5

10

8
9 7 8

12
13

9
22

11

14

18

19
23

20
6

16

17
MAX0046A

21
15 24

Fig. 27

40 Short List of Spare Parts Publication No. 5106226


Drg. No. G.C. No. Description Qty. Part No.

1 E83 458 Fan Assembly c/w ‘O’ Ring & Gasket 1 5106279
2 E83 462 Gas Valve Assembly c/w 3 off ‘O’ Rings 1 5106280
3 E83 465 Boiler Control Assembly 1 5106281
(Use with ‘Ranco’ sensor only)
H00 266 Boiler Control Assembly 1 5107535
(Use with ‘Huba’ pressure transmitter only)
4 E83 466 Boiler Control On/Off Switch 1 5106229
5 E85 802 Fuse 3.15A “Slow Blow” 1 5106872
6 E83 467 Spark Generator c/w Flying Lead 1 5106282
7 E83 468 Electrode/Ionization Kit Incl. key no’s 8 & 9 1 5106283
8 E85 739 Ignition Electrode & leadc/w Gasket & 2 screws 1 5106940
9 E85 740 Ionization Probe & lead c/w Gasket & 2 screws 1 5106941
10 E83 476 HT Lead 1 5106284
11 E83 477 Ionization Lead 1 5106285
12 E85 752 3 Way Valve Assembly (Body, ‘O’ Rings, Clips & key no. 13) 1 5106931
13 E85 753 Actuator Head 1 5107000
14 E85 761 Pump c/w auto air vent & 2 off washers 1 5106286
E85 762 Automatic Air Vent 1 5106932
15 E83 481 Expansion Vessel 12 Litre (Primary) 1 5106287
16 E83 482 PRV Assembly 1 5106288
17 E83 483 Immersion NTC Sensors 2 5106289
18 E83 484 DHW NTC Sensor c/w cable 1.25 m 1 5106290
19 E83 485 Overheat Thermostat 1 5106291
20 E83 486 Pressure Sensor ‘Ranco’ Black 1 5106292
H00 269 Pressure Transmitter ‘Huba’ Red 1 5107764
21 E85 901 Unvented Inlet Control Group 1 5106293
22 E83 488 ‘O’ Rings/Seals Kit - Gas Components 1 5106295
23 E83 489 ‘O’ Rings/Seals Kit - Water Components 1 5106296
24 E83 491 Programmer Battery 1 5106294

Publication No. 5106226 Short List of Spare Parts 41


Gas/Air Valve Setup Procedure

Procedure to correctly set new Air/Gas Valve


Fan Venturi Flue Gas using a micro-manometer.
Test Point

1. Loosen screw in outlet pressure test point


and connect to ‘+’ (positive) side of
Air/Gas differential micro-manometer.
Valve
Tee the ‘-’ (negative) side of the micro-
manometer into the air signal tube.
Air
Manifold
2. Remove special ⁄ BSP screw from flue
gas outlet (above heat exchanger) and
insert probe of combustion analyser
approximately 50 mm.
POW
ER -
MAIN H.W.
+ CH
BUR TEMP
S ON NER
LOC HW
K OUT
RESE SEL
T

Temporarily seal probe into flue gas test


C.H. +
ADVA
NCE
PRO
G
SEL
Power
-
PROG
max

point.

3. Press ‘ADVANCE’ or central heating


‘SELECT’ button to obtain ON display in
Top View Air Manifold programmer screen. Ensure any
connected room thermostat is calling for
Outlet Pressure Air Signal Signal sensing tube
heat. Observe burner lights and allow
Test Point Connection connected to Gas Valve
boiler to operate in central heating mode
for several minutes.
Inlet Pressure
Test Point
Air/Gas Tee inserted 4. Simultaneously press ‘+’ and ‘STEP’
Ratio Valve into signal buttons and hold down for 5 to 6 seconds.
sensing tube After one minute, the boiler will be
operating at the correct reduced input rate
Do Not use to enable the differential pressure to be set.
this point
5. Ensure micro-manometer is in Pa or mbar
Offset scale and has zeroed correctly. If in doubt,
Adjustment re-zero the instrument.

Throttle 6. Check differential pressure reading.


Adjustment
This should be zero or a negative (gas
relative to signal) value of 0 to - 5 Pa (0.00
to - 0.05 mbar).

MANOMETER
Use zero adjustment screw (below central
Venturi dust cover) to reset differential if
P200UL
Connector necessary.

Manometer Note: Turning adjustment screw clockwise


0.0 UNIT
V reduces negative differential; anti-
V AUTO
clockwise increases negative differential. A
HOLD Condensate Vent
4 mm hexagon key should be used to make
(Do Not disturb this vent tube)
MAX0031B

the adjustment.

Fig. 28

42 Gas/Air Valve Setup Procedure Publication No. 5106226


7. After 2 minutes, the boiler control will
return to normal operation. Maintain full
central heating demand (or if this is not
possible, draw hot water from a bath tap) to
cause the fan speed to increase to
maximum.

8. Check CO2 content of the flue gas


indicated by combustion analyser.

At maximum fan speed, this should be 9.0


to 9.2% CO2.

For values other than this, use throttle


adjustment screw to obtain correct
setting.

Note: Turning screw clockwise reduces


CO2; anti-clockwise increases CO2.

Ensure fan does not modulate by


maintaining a CH or DHW demand during
the above sequence.

As a double check, the expected CO


content should be in the range of 65 to 85
ppm when CO2 is 9.1%.

Check that gas rate is approximately 2.55


m3/hr.

9. Replace dust cover, re-instate air signal


tube between air duct and gas valve,
checking that tube has not physically
deteriorated or been damaged e.g. cracked.

Carefully replace special sealing screw in


flue gas test point.

Publication No. 5106226 Gas/Air Valve Setup Procedure 43


Publication No. 5106226 - Iss. 07 (09/2004)

General Enquiries (GB)

Tel. 08706 060 780


Sales (GB)

Tel. 08706 060 403


Fax. 01772 695 416
Technical (GB)

Tel. 08706 060 955


Service (GB)

Tel. 08706 060 933


Fax. 08706 060 966
Literature Request (GB)

Tel. 08706 060 623


Spares (GB)

Tel. 08706 000 454


Technical (IE)

Tel. 1850 560570


All descriptions and illustrations provided in this leaflet 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.

BAXI POTTERTON
A Trading Division of Baxi Heating UK Ltd
Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP
Website www.potterton.co.uk

company

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