Installation & Servicing Instructions: Powermax HE
Installation & Servicing Instructions: Powermax HE
Installation & Servicing Instructions: Powermax HE
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.
‘‘ 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.
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.
Handholds
Top Section
Manual Air Vent (below Top Panel)
Pipes connected to
Serial Number/Data Badge Bottom Section:
Bottom Section
Union Nuts
(remain with
Bottom Section)
Handholds
(Underneath boiler)
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
Secondary Expansion Vessel 18 litre, pre-charge 2.5 - 2.7 bar (supplied separately)
Automatic bypass Built in
Optional Immersion Heater 11” Heatrae ‘Mega’ G1 3/4. 3 kW at 240V, BEAB Approved
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.
200
min *
Door
Frame
* 400 mm
MAX0007A
Recommended
550 550
CH HW CH HW CH HW
- + - + - +
H.W. TEMP H.W. TEMP H.W. TEMP
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
Schematic Diagram
3 Way
Diverter Valve Flow Sensor
Control
Group
Filling Loop
CH CH Gas DHW COLD
Flow Return (balanced pressure to shower)
Fig. 4
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
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.
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.
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
Twin Flue
Vertical
Terminal
Twin Flue Flue Air Flue Air Flue Air
Double
Pitched Roof
Terminals
J,K
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
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.
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
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
C.H. ADVANCE
+
SEL
PROG
+
-
SEL
PROG
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
MAX0023C
support. Attach the 15mm x 90° branch pipe joining the
two relief valves/tundish.
22mm Gas
Connection
Outline of insulation
550 Overall
46 70 43 119 122 35 60 54
514
600 overall
572
512
507
567
544
560
536
MAX0021B
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
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
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
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.
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.
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
RWC
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
Fig. 11
POWER
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
longer than the blue neutral and brown live THIS COVER
MAX0068A
N L T T N
R L 2
- +
'Stat Neutral
H.W. TEMP
'Stat Return
SEL + SEL
POWER
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
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
SEL + SEL
POWER
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).
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:
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.
MAX0010A
Fig. 15
PCB/ Controls
Assembly
POWE
R -
MAINS H.W.
+ CH
BURN TEMP
ON ER
LOCK HW
OU
T
RESE SEL
T
Off
On
Integral
Programmer
Disable
Switch
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.
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.
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.
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
5a.Pump Motor
C.H. +
ADVA
NCE
PRO
G
SEL
Power
-
PROG
max
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
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
Pressure
Relief Valve
Remove Cross/Pressure
MAX0016C
Fig. 19
MAIN
ER
S ON BUR
NER
LOC
K OUT
RESE
-
H.W.
TEMP
+ CH
HW
SEL
Fig. 20
- 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.
BURNE
R
LOCK
OUT
RESET
TEMP
SEL
ADVANC SEL
E
PROG
STEP
Sensors
Sensor
Pump
Slow Blow)
O/heat 'Stat
DHW Temp
Diverter
Top
Valve
Earth
Diagnostic
Fan
Electrical
Port
Connectors
J4 Spare
MAX0019C
J16 J10
Fig. 22
MAINS
ON
BURNER
ADVANC SEL
E
PROG
STEP
Powe
rmax
Fig. 23
Disconnect Flow
Clip from the Saddle
& Return Pipes
Saddle
Fig. 24
Fig. 25
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
Programmer Programmer
OFF ON
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
Fig. 26
Is pressure relief
YES Replace pressure relief valve
valve leaking?
NO
Recharge (replace)
vessel to 1 bar
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
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
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
point.
MANOMETER
Use zero adjustment screw (below central
Venturi dust cover) to reset differential if
P200UL
Connector necessary.
the adjustment.
Fig. 28
BAXI POTTERTON
A Trading Division of Baxi Heating UK Ltd
Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP
Website www.potterton.co.uk
company