Potterton Promax 15 HE, Installation & Service Instructions Manual

Page 1: ...The Boiler Efficiency Regulations 1993 No 3083 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0086 Product Production certified by Notified Body 0086 For use with Natural Gas G20 only at 20mbar and for use in GB IE only ...

Page 2: ...Publication No 5106451 2 Natural Gas Potterton Promax 15 HE G C No 41 590 58 Potterton Promax 24 HE G C No 41 590 62 ...

Page 3: ...liance Operation 7 4 0 Technical Data 8 5 0 Dimensions and Fixings 9 6 0 System Details 10 7 0 Site Requirements 13 8 0 Installation 19 9 0 Electrical 25 10 0 Commissioning 27 11 0 Outer Case 28 12 0 Servicing 29 13 0 Changing Components 31 14 0 Fault Finding 38 15 0 Short Parts List 43 Section Page ...

Page 4: ... recorded in your boiler Log Book You can check your installer is registered by telephoning 44 0 1256 372300 or writing to 1 Elmwood Chineham Business Park Crockford Lane Basingstoke RG24 8WG Potterton declare that no substances harmful to health are contained in the appliance or used during appliance manufacture The appliance is suitable only for installation in GB and IE and should be installed ...

Page 5: ...ht industrial E M C environments on a governed meter supply only 8 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit part no 236921 1 2 Important Information Man made mineral fibre Some component parts of this appliance insulation pads gaskets and rope seals are manufactured from man made mineral fibre Prolonged or excessive exposure to th...

Page 6: ...ack 17 Flow Temperature Thermistor Red 18 Flow Switch dry fire protection 1 2 3 4 5 6 7 9 8 10 11 12 13 17 16 14 15 18 Fig 4 Fig 3 Fig 5 2 2 Optional Extras KIT PART No FLUE EXTENSION KITS 110 70 Flue Extension 0 25M 241692 Flue Extension 0 5M 241694 Flue Extension 1M Use two kits for 2M etc 241695 Flue Bend x 2 45 Reduce overall length of flue by 0 5m when fitting this bend 241689 Flue Bend 90 Re...

Page 7: ...ttempts have been made the ignition lockout occurs 5 Burner On The pump fan and gas valve are on while the spark generator is off Flow temperature is controlled by varying the fan speed and thereby the gas rate to achieve optimum operation If the flow temperature is greater than the set point then pump overrun occurs If the TRVs all shut down then anti cycle occurs 6 Anti cycle The pump fan spark ...

Page 8: ...ral Gas After 10 Mins Btu hr 75 000 52 000 m3 h 2 31 1 64 ft3 h 83 3 52 1 Inlet Pressure at Gas Valve Natural Gas Min 18 1 mbar Max 22 5 mbar see Section 10 1 Injector Natural Gas 6 3mm Diameter Clearances Both Sides 5mm Min Above Casing 200mm Min Below Casing 130mm Min Front 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 li...

Page 9: ...e the top of the flue elbow should be 55mm to incorporate the 3 1 in 20 fall in the flue from the terminal to the elbow The 3 1 in 20 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 55mm 110mm 165mm 360 Orientation Tube Ø 110mm D C B A E F Y 3 1 in 20 X 3 1 in 20 Fig 6 Fig ...

Page 10: ...and reduce the likelihood of these deposits damaging new components When fitting new systems flux will be evident within the system which can lead to damage of system components All systems must be thoroughly drained and flushed out The recommended flushing and cleansing agents are Betz Dearborn Sentinel X300 or X400 and Fernox Superfloc Universal Cleanser which should be used following the flushi...

Page 11: ...t boiler thermostat TRV s only does not produce the best results 6 5 Low Head Installation 1 Using a close couple arrangement the minimum head is as shown in the diagrams Figs 8 9 subject to the following conditions a The pump being adjusted to give an 20o 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 instruction...

Page 12: ...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 the W...

Page 13: ...d 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 Publication IGE UP 7 Gas Installations in Timber Framed Housing 7 2 Ventilation of Compartments 1 Where the boiler is installed in a cupboard or...

Page 14: ...nternal threaded connection located at the rear of the gas service cock 3 Ensure that the pipework from the meter to the appliance is of adequate size 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...

Page 15: ...lated to protect against frost It is also recommended that the pipe diameter is increased to 32mm 8 If the boiler is fitted in an unheated location 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 u...

Page 16: ...the face of the wall to the inside of the air intake This can be painted if required using a suitable external paint 9 If a terminal is less than 2 metres 783 4 in above a balcony above ground or above a flat roof to which people have access then a suitable terminal guard must be provided Fig 17 Fig 16 300 min Terminal Assembly Top View Rear Flue Property Boundary Line NOTE The distance from a fan...

Page 17: ...hey can be obtained from most Plumbers and Builders Merchants 2 There must be a clearance of at least 50mm between any part of the terminal and the guard 3 When ordering a terminal guard quote the appliance name and model number 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated 7 10 Vertical Flue 1 Only a flue approved with the Potterton Promax 15 ...

Page 18: ...r vertical flue adaptor 5106888 Clamp 80mm 238684 7 11 Flue options Concentric The maximum equivalent lengths are 4m horizontal or vertical These lengths exclude the standard elbow and flue terminal assembly horizontal and terminal assembly vertical Twin Flue The total maximum equivalent flue length is 150m NOTE Each 1m of flue duct should be calculated as 2m Any additional in line bends in the fl...

Page 19: ... minimum diameter 125mm see table for wall thicknesses and flue diameters 6 Drill and plug the wall as previously marked Secure the wall plate using the centre hole 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 t...

Page 20: ...g The Boiler 1 Remove the outer carton 2 Remove the internal packaging 3 Lift the outercase upwards and remove Fig 23 Potterton declare that no substances harmful to health are contained in the appliance or used during appliance manufacture Outercase Fig 23 ...

Page 21: ...he flow switch when tightening the flow connection the use of two spanners is recommended 3 A copper elbow compression nut and olive are provided in the kit for the return connection NOTE Drain cocks should be fitted to all system s low points and vents to all high points 4 Ensure that any pipework is routed so as to leave the boiler via the spaces at the rear of the outer case either at the top o...

Page 22: ...d 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 wall thickness 250mm This dimensi...

Page 23: ...op of the boiler Secure with the four screws supplied in the kit 11 Make good between the wall and air duct outside the building ensuring the 3 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 an...

Page 24: ... the boiler can be adjusted as follows a Draw the control PCB forwards out of the electrical box the control PCB is the right hand board b Remove jumper no 3 c Replace the PCB and continue with the installation 5 Route the incoming electrical cable s through the grommet in the support bracket This will prevent damage to the cable Fig 31a 6 Lay the cable through the cable clamp to gauge the length ...

Page 25: ...een g y Green Yellow y Yellow o Orange Spark Electrode Ignition PCB Control PCB Condensate Trap Detection Electrode Gas Valve Mains Input Optional Pump Feed Transformer Safety Stat Fan Protection Stat Thermistor Dry Fire Flow Switch DC Fan On Off Switch br r br w g y g y br b b b b b bk br br bk bk bk bk bk r r r br g w N P F bk S L v w g y bk ...

Page 26: ...ed Wiring Diagram Ignition PCB Condensate Trap Sensing Electrode bk bk w w br r b br b br br br bk bk bk b w v bk b bk r r b bk g y g y g y Flow Switch Fan Control PCB On Off Switch Mains Input Transformer Safety Thermostat Fan Protection Thermostat Flow Temperature Thermistor Gas Valve Spark and Earth Electrode Earth Earth r r br w w g g br b v w ...

Page 27: ...ic Gas Installations 5 Turn the gas service cock anticlockwise to the ON position and check for gas soundness up to the gas valve Fig 34 6 Switch on the on off switch Fig 35 and run the system and check the boiler for correct operation NOTE The boiler is self regulating dependent upon the system load The 15 HE will modulate between inputs of 16 88kW and 10 2kW The 24 HE will modulate between input...

Page 28: ... Book must be handed to the user for safe keeping and each subsequent regular service visit recorded For IE it is necessary to complete 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 Log Book 4 Instruct the user in the operation of the boiler controls Hand over the User s Operating...

Page 29: ... the Outercase Section 11 0 6 Release the four 1 4 turn screws securing the air box door panel and remove the door Fig 40 7 Disconnect the leads from the centre and right hand terminals earth and flame sensing probe The spark electrode lead is permanently fixed to the electrode Undo the re usable cable tie and pull down the sleeving to expose the joint in the electrode lead Disconnect the lead Fig...

Page 30: ...burner skin is fragile handle with care Clean and if necessary replace the burner Fig 44 see note above h Loosen the two screws retaining the heat exchanger support bracket and slide to the left to remove Fig 44 i Remove the four screws securing the heat exchanger combustion box base and withdraw the base j Lower the central insulation panel and check condition Fig 44 Replace the lower insulation ...

Page 31: ...er 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 location on the spigot Green O rings are used for gas joints and Black O rings for water joints Use Greasil 4000 Approved Silicone Grease 5 After changing a component re commi...

Page 32: ...t bracket 3 Remove the clip securing the flow pipe to the flowswitch 4 Remove the two screws securing the flow switch to the boiler 5 Disconnect the inline electrical connection 6 Remove the flow switch 7 Fit the new flow switch and reassemble in reverse order 8 Recommission the boiler and check the inhibitor concentration see Section 6 2 and 10 1 Flow Switch Clip Flow Pipe Fig 47 Support Bracket ...

Page 33: ...ion board left hand side and disconnect the electrical connections noting their positions 2 Fit the new ignition board and reassemble in reverse order 13 6 Transformer Fig 51 1 After the removal of the control and ignition boards the transformer can be accessed Loosen the two electrical box mounting plate securing screws remove the front drip tray securing screw and lift the assembly to clear the ...

Page 34: ...d reassemble in reverse order NOTE The spark electrode sleeve should always cover the joint in the electrode lead to prevent tracking 13 8 Fan Fig 54 1 Loosen the screw holding the injector pipe into the venturi 2 Remove the electrical connections to the fan protection thermostat 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 Disco...

Page 35: ...he air box holding the gas valve 6 Remove the gas valve from the airbox side 7 Remove the nut union aluminium spacer and its gasket from the gas valve 8 Fit the nut union aluminium spacer and its gasket to the new valve 9 Fit the new gas valve and reassemble in reverse order 13 11 Condensate Trap Fig 56 1 Disconnect the condensate trap from the base of the heat exchanger 2 Disconnect the condensat...

Page 36: ...Undo the screws on the support bracket Remove the screws securing the flow switch and return connections and remove the connections Fig 61 4 Remove the electrical connections from the P C B s see section 13 4 13 5 5 Loosen the two screws securing the electrical box mounting plate and remove the assembly Fig 59 6 Undo the M6 hex headed bolt on the left hand side of the combustion box 7 Remove the s...

Page 37: ...nger and remove the lower insulation pad 6 Fit the new insulation pad and reassemble in reverse order 13 15 Heat Exchanger Upper Insulation Pad Fig 62 1 Remove all components in the base of the airbox 2 Remove the burner see section 13 12 3 Remove the heat exchanger see section 13 13 4 Remove the four bolts securing the combustion box base 5 Remove the combustion box base 6 Pull the central insula...

Page 38: ...not in lockout There is an adequate gas supply pressure at the inlet A minimum pressure of 18 1 mb is required at the inlet All isolating valves are open and both the boiler and the system are vented Check installation is correct including the flue system Is there 230V sL to N NO Does a spark occur Go to IGNITION LOCKOUT section of the fault finding instructions Go to IGNITION LOCKOUT section of t...

Page 39: ... for short circuits on control PCB and fan If OK replace fuse Replace control PCB YES NO Is there 24 Vac at control PCB transformer 24V connection C NO NO NO NO YES YES YES YES No Switched Live Spark Electrode Ignition PCB Control PCB Condensate Trap Detection Electrode Gas Valve Mains Input Optional Pump Feed Transformer Overheat Stat Casing Stat Thermistor Dry Fire Flow Switch DC Fan On Off Swit...

Page 40: ... box door seal damaged or not in place Replace combustion box door seal Is Safety Thermostat open circuit NO YES NO NO YES YES NO No Pump Feed Is thermistor resistance between 0 5kΩ and 20kΩ Is Fan Protection Thermostat open circuit Go to IGNITION LOCKOUT section of the fault finding instructions Is condensate trap blocked Clear blockage and dry sensors YES NO YES ...

Page 41: ...aulty Is spark gap between 3 and 5mm Set spark gap to 4mm Is there 230V at ignition PCB connection to gas valve O Is there 230Vdc at the end of the gas valve lead P Is sensing tube blocked Unblock tube Replace ignition PCB Replace gas valve lead Replace gas valve Is the detection probe damaged Is wiring from ignition PCB to detection probe OK Is there 230V ignition PCB burner on pin to control PCB...

Page 42: ...h Remove blockage Is there water in system and pump on Is flow switch short circuit G Is flow switch blocked Dry fire Lockout NO NO NO YES NO YES Replace thermistor Is thermistor short circuit YES No Fan Run YES NO Is thermistor between 0 5kΩ and 20kΩ Replace flow temperature thermistor red Replace control PCB YES ...

Page 43: ...06 060 Safety Thermostat Black 242235 8 Control PCB 24 HE 5106588 Control PCB 15 HE 5106791 9 E06 065 Ignition PCB 241838 10 E06 066 Transformer 240236 21 E06 074 Fan 242472 23 E06 075 Gas Valve 242473 38 E06 085 Viewing Window 242484 39 Condensate Trap 5111714 44 E06 091 Electrodes Kit 242490 47 E06 093 Burner Assy 242492 52 E06 097 Heat Exchanger Assy 242497 1 2 3 8 9 10 21 23 38 39 44 47 52 ...

Page 44: ... are sold subject to our standard Conditions of Sale which are available on request General Enquiries GB Tel 08706 060 780 Technical GB Tel 08706 049 049 Service GB Tel 08706 096 096 Fax 01926 410 006 Literature Request GB Tel 08706 060 623 Technical IE Tel 1850 560570 BAXI POTTERTON A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Servi...