Potterton 15 HE Plus, Installation & Service Instructions Manual

Page 1: ... Installation Service Instructions These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping Promax 15 2 24 2 30 HE Plus Condensing Central Heating Boiler You can rely on ...

Page 2: ...change from the situation whereby compliance with Building Regulations was accepted as being demonstrated by completion of the Benchmark Logbook which was then left on site with the customer With the introduction of Self Certification Schemes the Benchmark Logbook is being withdrawn However a similar document in the form of a commissioning checklist and service interval record is incorporated at t...

Page 3: ...elevant LABC You must ensure that the certificate number issued by the Gas Safe Register is written onto the Benchmark Checklist Scheme Members only Call Gas Safe Register on 0800 408 5577 or log onto www GasSafeRegister co uk within 10 days If you notify via the Gas Safe Register the register will issue the Building Regulations certificate on members behalf Complete the Benchmark Checklist Instal...

Page 4: ...ied out by a competent person as stated in I S 813 Domestic Gas Installations NOTE The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty In GB this could also infringe the Gas Safety Installation and Use Regulations Warning Check the information on the data...

Page 5: ...oute is clear and unobstructed If possible avoid steps wet or slippery surfaces unlit areas etc and take special care on ladders into lofts Technique When handling or lifting always use safe techniques keep your back straight bend your knees Don t twist move your feet avoid bending forwards and sideways and keep the load as close to your body as possible Where possible transport the boiler using a...

Page 6: ... Options 20 9 0 Plume Displacement 25 10 0 Installation 29 11 0 Electrical 35 12 0 Commissioning the Boiler 37 13 0 Fitting the Outer Case 38 14 0 Servicing the Boiler 39 15 0 Changing Components 41 16 0 Short Parts List 48 17 0 Fault Finding 49 Benchmark Checklist 58 Section Page Contents 6 Contents of Pack The pack contains Boiler Wall Plate Template Quick Fit Guide Literature Pack Fittings Pack...

Page 7: ...ments on a governed meter supply only 8 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit part no 236921 1 2 Important Information Man made mineral fibre Some component parts of this appliance insulation pads gaskets and rope seals are manufactured from man made mineral fibre Prolonged or excessive exposure to this material may result in s...

Page 8: ... Protection Thermostat 7 Fan Assembly 8 Condensate Trap 9 PCB Housing Assembly 10 Gas Tap 11 Gas Air Ratio Valve 12 Flow Pipe Connection 13 Return Pipe Connection 14 Flow Temperature Safety Thermostat Black 15 Flow Temperature Thermistor Red 16 Flow Switch dry fire protection 1 2 3 4 5 6 7 9 8 10 11 15 14 12 13 16 Fig 4 Fig 3 Fig 5 Fig 6 ...

Page 9: ...and thereby the gas rate to achieve optimum operation If the flow temperature is greater than the set point or the TRVs all shut down then fan post purge occurs 6 Fan Post Purge The pump and fan are on while the spark generator and gas valve are off After 5 seconds if the TRVs are not shut down then pump overrun occurs After 5 seconds if the TRVs are shut down then anti cycle occurs 7 Pump Overrun...

Page 10: ...For Servicing 500mm Min Front In Operation 5mm Min 0 10 20 30 40 20 40 60 80 100 120 140 160 180 200 220 Water Flow Rate litres min Pressure Drop mbar 8 17 25 33 42 50 58 66 75 83 91 Pressure Drop in wg Hydraulic Resistance Chart Appliance Type C13 C33 C53 Nox Class 5 Heat Output P Condensing 40 C Mean Water Temp Max Min 15 2 HE Plus kW 16 49 10 1 Btu hr 56 260 34 520 24 2 HE Plus kW 23 8 10 1 Btu...

Page 11: ...ove the top of the flue elbow should be 27 5mm to incorporate the 1 5 fall in the flue from the terminal to the elbow The 1 5 fall provided by the elbow is to allow condensate to run back to the boiler for disposal through the condensate discharge pipe Flue length Y up to 1m 1m 2m 2m 3m Clearance X 27 5mm 55mm 82 5mm 360 Orientation Tube Ø 110mm D C B A E F Y X At Least 1 5 Fig 7 Fig 8 At Least 1 ...

Page 12: ...tems will be subject to corrosion unless they are flushed and an appropriate water treatment is applied To prevent this follow the guidelines given in BS 7593 Treatment of Water in Domestic Hot Water Central Heating Systems and the treatment manufacturers instructions 2 Treatment must involve the use of a proprietary cleanser such as Sentinel X300 or X400 or Fernox F3 and an inhibitor such as Sent...

Page 13: ...ive a 20 C drop across the boiler b The pump must be fitted on the flow c The pump must be fitted in accordance with the pump manufacturer s instructions d The open vent pipe must be taken up from a tee in a horizontal section of the flow pipe An alternative Low Head Installation Fig 12 2 For heads below 400mm then a combined vent and feed pipe may be connected This must be a minimum of 22mm diame...

Page 14: ...L N CH on HW on HW off L N E L N P F E b g y w o gr 1 C 2 g y S Plan Valve Cylinder Stat Room Stat Boiler Pump Timer 230V 50Hz L N E L N CH on HW on L N E L N P F E Motor S Plan Valve Motor o o gr b g y b gr br br Y Plan Diverter Valve Cylinder Stat Boiler Pump Timer 230V 50Hz L N E L N CH on HW on HW off L N E L N P F E b g y o gr 1 C 2 w g y S Plan Valve Cylinder Stat Boiler Pump Timer 230V 50Hz...

Page 15: ...pe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment Your attention is drawn to for GB Guidance G24 2 and recommendation R24 2 of th...

Page 16: ... must be made to the relevant requirements In GB this is the current I E E Wiring Regulations and Building Regulations In IE reference should be made to the current edition of I S 813 Domestic Gas Installations and the current ETCI rules 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publ...

Page 17: ...ce is of adequate size to ensure correct operation Do not use pipes of a smaller diameter than the boiler gas connection 7 5 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current I E E Wiring Regulations In IE reference should be made to the current edition of ETCI rules 2 The mains supply is 230V 50Hz fu...

Page 18: ... the entire condensate discharge pipe should be treated as an external run 9 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used 10 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soil pipes or waste pipes...

Page 19: ... must be provided IMPORTANT Only ONE 25mm clearance is allowed per installation Under car ports we recommend the use of the plume displacement kit The terminal position must ensure the safe and nuisance free dispersal of combustion products Fig 17 Fig 16a 300 min Terminal Assembly TopView Rear Flue Property Boundary Line NOTE The distance from a fanned draught appliance terminal installed parallel...

Page 20: ...3 bend 1 0 m NOTE Flue length is measured from point X to Y as shown IMPORTANT All flue systems must be securely supported at least once every metre Suitable pipe supports are available as accessories X Y X Y Plume Displacement 70 110 dia Kit 1M Extensions 45 93 bends are also available see Section 9 0 NOTE Horizontal flue pipes should always be installed with a 1 5 fall from the terminal to allow...

Page 21: ...tal equivalent length for this example is 17 2 34 4 51 6 metres 1m extension 135 bend 91 5 bend 1m 1 3m 4 8m 5 2 2 5 0m 2 6m 9 6m AIR DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Air Duct 17 2m 1m extension 135 bend 91 5 bend 2m 2 6m 9 6m 5 2 2 10 0m 5 2m 19 2m FLUE DUCT No of fittings pipes Sub total Equivalent Length Value Equivalent Length Flue Duct 34 4m Y X C ...

Page 22: ...m 243014BAX T Vertical Flue Boiler Adaptor 5106888 S Flue Terminal Deflector 248167 FLUE GROUP P Twin Flue System 80mm diameter E Flue Extension pair 1000mm 246137 500mm 246136 250mm 246135 F Flue Bend pair 90 5121560 G Flue Bend 2 pair 135 5121561 J Vertical Flue Boiler Adaptor Kit 242757 W Pipe Support pair 80mm 5111081 FLUE GROUP B P Vertical Flue Kits K Vertical Flue Terminal 242802 L Pitched ...

Page 23: ...te 2 Fix the vertical adaptor and gasket to the top panel with the previously removed screws 8 5 For Twin Flue Systems 1 Undo the screws securing the blanking plate to the boiler top panel Discard the plate 2 Fix both the air and flue adaptors with their gaskets onto the boiler top panel Secure with screws For Vertical Flues For Twin Flues Air Duct Adaptor Flue Duct Adaptor Gasket Gasket ...

Page 24: ...and secure to the roof structure with the clamp supplied IMPORTANT If the boiler is not fitted immediately after the flue system temporary precautions must be taken to prevent rain entry into the room of installation Any precautionary measures must be removed prior to commissioning the boiler 8 7 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 270mm 105 8 and 800mm...

Page 25: ...h the 70 110 concentric and 70Ø exhaust 5 Standard concentric flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the boiler flue elbow There is a further 45mm engagement into the elbow IMPORTANT The maximum equivalent length of concentric flue is 4 metres Additional elbows may be fi...

Page 26: ...ional bends Example 1 Not Permissible If for instance a concentric length of 3 25 metres was required and the 70Ø exhaust needed to be 10 metres the graph shows that this combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Where both lengths have been determined they can be applied to the graph to check that the installati...

Page 27: ...support the concentric assembly and any extensions and make good inside and outside Secure the flue trim to the wall 9 The 70Ø exhaust can now be fitted to the spigot at the terminal end 10 If it is necessary to shorten the 70Ø exhaust or any of the extensions the excess material must be cut from the plain end of the pipe 11 Determine the position of the 70Ø exhaust and mark on the wall a suitable...

Page 28: ...t in an enclosed box but the air inlet and plume outlet MUST remain in free air 17 It is also possible to separate the plume outlet from the 93 elbow to allow the flue to be installed as shown in Fig H 18 When the plume outlet is positioned under a balcony or other projection Figs I J it must protrude at least 200mm it is not necessary to extend it further than this 200mm Min Fig H Fig I Fig J ...

Page 29: ...e Fig 20 for wall thicknesses and flue diameters 6 Drill and plug the wall as previously marked Secure the wall plate using the centre hole Fig 22 7 Ensuring the wall plate is level both horizontally and vertically drill and plug at least 4 securing positions at the top and bottom through the wall plate Utilising the slots available ensure the wall plate is square and secure to the wall Fig 22 8 A...

Page 30: ...ating UK Ltd 2009 10 2 Preparing The Boiler 1 Remove the outer carton and packaging 2 Lift the outercase upwards and remove 3 Remove the internal packaging Lower Door Panel Outercase Fig 22a Break Off Upper Lower Pipe Run Options ...

Page 31: ...low pipe and the rear threaded connection is the return 2 It is essential that the flow and return pipes are connected to the boiler correctly The flow connection incorporates the boiler thermostats and a flow switch 3 The boiler connection will accept 22mm fittings NOTE On Promax 30 HE Plus models 28mm pipe should be used to connect to the boiler flow and return 4 If the installation requires tha...

Page 32: ...hickness 210 3 Take the flue and mark off X from the terminal end as indicated in the diagram Fig 27 Check your dimensions The flue tubes are fixed together Cut through both tubes whilst resting the flue on the semi circular packing pieces Deburr both tube ends 4 For side exit measure the distance from the edge of the wall plate to the inner face of the wall Fig 26 and to this dimension add the wa...

Page 33: ...supplied in the kit 11 Make good between the wall and air duct outside the building ensuring at least a 1 5 drop between the terminal and elbow 12 The flue trim should be fitted once the installation is complete and the flue secure Fig 30 Apply a suitable mastic to the inside of the trim and press against the wall finish making sure the brickwork is dust free and dry 13 If necessary fit a terminal...

Page 34: ...hand securing screw and hinge down the PCB housing b Remove the Red jumper labelled CN12 from the bottom left hand side of the PCB c Hinge back up the PCB housing and secure with screw 4 Route the incoming electrical cable s through the grommet in the support bracket This will prevent damage to the cable 5 Lay the cable through the cable clamp to gauge the length of cable required when it is conne...

Page 35: ...een g y Green Yellow op Opaque y Yellow Gas Valve g op Spark Electrode g y bk bk bk bk r w w Flame Detection Electrode Condensate Trap Flow Overheat Thermostat Fan Overheat Thermostat g y r b r r Flow Thermistor 325Vdc DC Fan CH Flow Switch gy gy w g br PCB Earths not shown to aid clarity of diagram g y b y L N Optional Pump Feed br g y br b op op ...

Page 36: ...p Opaque y Yellow 11 2 Illustrated Wiring Diagram GasValve Fan CondensateTrap CH Flow Switch Flow Thermistor Spark Electrode Flame Detection Electrode Main PCB N L r r gy gy r b br g w Flow Overheat Thermostat Fan Overheat Thermostat bk bk bk r bk w w op g y g y Layout of PCB Pins Optional Pump Feed g y br y g y b br b y b br br ...

Page 37: ...the gas service cock see Fig 32 Turn the gas service cock anticlockwise to the ON position and check for gas soundness up to the gas valve Fig 34 7 Turn the flow temperature adjustment screw fully clockwise Fig 35 and run the system and check the boiler for correct operation NOTE The 15 2 24 2 are self regulating dependent upon the system load The 30 HE Plus will modulate between inputs of 33 76kW...

Page 38: ...mplete a Declaration of Conformity to indicate compliance to I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 6 Instruct the user in the operation of the boiler controls Hand over the User s Operating Installation and Servicing Instructions giving advice on the necessity of regular servicing 7 Demonstrate to the ...

Page 39: ...val Record section of the Benchmark Commissioning Checklist at the rear of this publication 3 Ensure that the boiler is cool 4 Ensure that both the gas and electrical supplies to the boiler are isolated 5 Remove the outercase and lower door panel see Fitting the Outercase Section 13 0 WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate at supply before access 6 Release the four 1 4 turn s...

Page 40: ...n box base and withdraw the base j Lower the central insulation panel and check condition Fig 44 Replace the lower insulation pad if necessary k Ensure the heat exchanger fins are clear of any obstruction l Check condition of all seals Important Pay particular attention to the condition of the combustion box door seals m Reassemble in reverse order and check for leaks 11 Check CO CO2 ratio and CO2...

Page 41: ...upply before access 3 Isolate the water circuit and drain the system as necessary A drain point is located on the heat exchanger manifold at the right hand side of the boiler Fig 45 to enable the heat exchanger to be drained 4 Place a tube on the drain point to drain water away from electrics Turn anticlockwise to open Fig 45 NOTE When reassembling always fit new O rings ensuring their correct loc...

Page 42: ...ring the flow pipe to the flowswitch 4 Disconnect the inline electrical connection 5 Pull pipe away from flowswitch 6 Remove the two screws securing the flowswitch to the boiler 7 Remove the flowswitch 8 Fit the new flowswitch and reassemble in reverse order 9 Recommission the boiler and check the inhibitor concentration see Section 6 2 and 12 1 Flow Switch Clip Flow Pipe Fig 47 Support Bracket ...

Page 43: ...ring screw and hinge down the PCB housing and disconnect the electrical connections noting their positions NOTE Check the PCB for the presence of input jumpers see section 10 8 Set the new PCB as the one removed 2 Lift Control PCB housing out of hinge housing of metal bracket 3 Fit the new PCB Housing Assembly and reassemble in reverse order PCB Housing Securing Screw Fig 48 Blue CN11 Jumper Red C...

Page 44: ... WARNING The PCB Control and Fan Assembly are 325 Vdc Isolate at supply before access 1 Loosen the screw holding the injector pipe into the venturi 2 Remove the electrical connections to the fan and protection sensor on the fan 3 Remove the wing nuts securing the fan to the base of the combustion box 4 Lower the fan and remove 5 If changing the fan remove the screws securing the venturi and fan pr...

Page 45: ... its gasket to the new valve 10 Fit the new gas valve and reassemble in reverse order NOTE Check for gas tightness after replacing gas valve 11 Check CO CO2 ratio and CO2 level at the flue sampling point Fig 41a is as quoted in Section 4 0 Technical Data 12 If the ratio or level is greater than that quoted telephone the Technical Enquires for further advice IMPORTANT No adjustment of the gas valve...

Page 46: ...it the new burner and reassemble in reverse order 15 11 Heat Exchanger 1 Drain the boiler see section 15 1 paragraph 2 3 2 Remove all components in the base of the airbox 3 Undo the screws on the support bracket Remove the screws securing the flow switch and return connections and remove the connections Fig 57 4 Remove the screws securing the heat exchanger manifold and remove the manifold Fig 58 ...

Page 47: ...anger and remove the lower insulation pad 6 Fit the new insulation pad and reassemble in reverse order 15 13 Heat Exchanger Upper Insulation Pad Fig 60 1 Remove all components in the base of the airbox 2 Remove the burner see section 15 10 3 Remove the heat exchanger see section 15 11 4 Remove the four bolts securing the combustion box base 5 Remove the combustion box base 6 Pull the central insul...

Page 48: ...058 Flow Temperature Thermistor Red 240670 B E06 059 Flow Switch 242459 C E06 060 Safety Thermostat Black 242235 D PCB 5129147 E Fan 5109925 F Gas Valve 241900 G E06 085 Viewing Window 242484 H Condensate Trap 5111714 I Electrodes Kit 5132097 J Burner Assy 5107430 K E06 097 Heat Exchanger Assy 242497 A B C E F G H I J K D ...

Page 49: ...ts replace LV wiring harness PCB Fault Replace PCB PCB Fault Replace PCB PCB Fault Replace PCB YES YES YES YES YES YES YES YES YES YES YES YES Go to Electrical Supply section of the fault finding instructions ON Go to Dry Fire section of the fault finding instructions Go to Overheat Lockout section of the fault finding instructions NOTE The fan is supplied with 325 Vdc Fan Fault Finding should onl...

Page 50: ...Systems Controls and System Wiring 240V at B Check wiring from terminal block to PCB Check for shorts on pump fan gas valve Replace if shorted replace fuse YES NO Replace PCB YES YES NO NO ELECTRICAL SUPPLY 240V at A PCB fuse OK B Fuse A N L Lights Off Off Off ON Optional Pump Live ...

Page 51: ...off on After 5 sec is there 240V at E Pump or Pump Wiring fault Is there a blockage in the system NO YES YES E Optional Pump Live N L F N L Turn mains off unplug 7 way connector to PCB Is there continuity between F and G Wiring from terminal block to PCB faulty NO YES Replace PCB Wires from inline connector to PCB faulty Remove flow switch from boiler Is there a physical blockage to the paddle wit...

Page 52: ...e as necessary YES YES NO NO YES Remove Gas Valve check inlet filter for blockage Otherwise incorrect gas supply to boiler Is there at least 18mbar dynamic at gas valve inlet Lead from PCB to Gas Valve faulty Is spark gap between 3 and 4mm Replace spark or flame detection probe and gaskets Is wiring from PCB to spark probe flame detection probe OK NO YES NO NO YES YES NO NO I Remove the larger or ...

Page 53: ...bustion chamber door seal trim seal NO YES NO YES Reconnect stat Disconnect fan stat When fan temp 60 C is there continuity across stat Reconnect stat Disconnect the larger of the 6 way PCB connectors Is there continuity across M Disconnect thermistor red sensor on flow pipe Is resistance between 0 5kΩ 20kΩ Is combustion chamber door seal damaged or not in place Replace PCB YES Replace thermistor ...

Page 54: ...ller of the 6 way PCB connector Is there continuity from R to S from T to U from V to W Replace fan Rectify wiring YES N P R V T Q O U Viewed from Wire Entry end S W Fan Connection PCB Connection Fan Connection PCB Connection NOTE The fan is supplied with 325 Vdc Fan Fault Finding should only be carried out after the boiler has been electrically isolated Lights Flash Flash On ON ...

Page 55: ...mistor Wiring from PCB to thermistor faulty YES NO NO YES Replace PCB Unplug thermistor Is thermistor resistance between 0 5kΩ 20kΩ Plug in thermistor leave 8 way connector unplugged Is resistance at D between 0 5kΩ 20kΩ D Viewed from Wire Entry end Lights On Flash On ON ...

Page 56: ...18 0 Notes 56 Baxi Heating UK Ltd 2009 ...

Page 57: ...18 0 Notes 57 Baxi Heating UK Ltd 2009 ...

Page 58: ... a d r o c c a n i d e l l a t s n i n e e b s a h n i a r d e t a s n e d n o c e h T ALL INSTALLATIONS O C g n i w o l l o f e h t d r o c e r r e r u t c a f u n a m e h t y b d e r i u q e r f I 2 OR CO ppm OR CO CO2 Ratio s e Y s n o i t a l u g e R g n i d l i u B e t a i r p o r p p a e h t h t i w s e i l p m o c m e t s y s r e t a w t o h d n a g n i t a e h e h T s e Y s n o i t c u r t...

Page 59: ...Comments Signature SERVICE 9 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 2 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 4 Date Energy Efficiency Checklist completed Yes No Engineer Name Company Name Telephone Number Comments Signature SERVICE 6 Da...

Page 60: ... 871 1560 Technical Enquiries 0844 871 1555 Website www potterton co uk e oe 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 ...