Potterton 15 HE Plus Montage- und Wartungsanleitung

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

2© Baxi Heating UK Ltd 2009

Natural Gas

Potterton Promax 15/2 HE Plus

G.C.No41 605 52

Potterton Promax 24/2 HE Plus

G.C.No41 601 17

Potterton Promax 30 HE Plus

G.C.No41 601 22

be reproduced or transmitted in any form or by any means, or stored in any

retrieval system of any nature (including in any database), in each case whether

electronic, mechanical, recording or otherwise, without the prior written

permission of the copyright owner, except for permitted fair dealing under

Copyrights, Designs and Patents Act 1988.

Applications for the copyright owner’s permission to reproduce or make other

use of any part of this publication should be made, giving details of the proposed

use, to the following address:

The Company Secretary, Baxi Heating UK Ltd, The Wyvern Business Park,

Stanier Way, Derby, DE21 6BF.

Full acknowledgement of author and source must be given.

WARNING: Any person who does any unauthorised act in relation to a

This product has an energy rating (A) on a scale of A to G.

For more information see www.boilers.org.uk. This is a certification mark.

0086

ISO 9001

FM 00866

Building Regulations and the Benchmark Commissioning

Checklist

Building Regulations (England & Wales) require notification of

the installation of a heating appliance to the relevant Local

Authority Building Control Department. From 1 April 2005 this

can be achieved via a Competent Persons Self Certification

Scheme as an option to notifying the Local Authority directly.

Similar arrangements will follow for Scotland and will apply in

Northern Ireland from 1 January 2006.

The Health & Safety Executive operates the ‘Gas Safe Register’,

a self-certification scheme for gas heating appliances.

These arrangements represent a change from the situation

whereby compliance with Building Regulations was accepted as

being demonstrated by completion of the Benchmark Logbook

(which was then left on site with the customer).

With the introduction of Self Certification Schemes, the

Benchmark Logbook is being withdrawn. However, a similar

document in the form of a commissioning checklist and service

interval record is incorporated at the back of these instructions.

This company is a member of the Benchmark initiative and fully

supports the aims of the programme. Its aim is to improve the

standards of installation and commissioning of central heating

systems in the UK and to encourage the regular servicing of all

central heating systems to ensure safety and efficiency.

Building Regulations require that installations should comply

with manufacturer's instructions. It is therefore important that

the commissioning checklist is completed by the installer. The

relevant section of Building Regulations only relates to

dwellings. Therefore the checklist only applies if the appliance is

being installed in a dwelling or some related structure.

The flowchart opposite gives guidance for installers on the

process necessary to ensure compliance with Building

Regulations.

The Benchmark Scheme

Benchmark places responsibilities on both manufacturers and installers. The

purpose is to ensure that customers are provided with the correct equipment for

their needs, that it is installed, commissioned and serviced in accordance with the

manufacturer’s instructions by competent persons and that it meets the

requirements of the appropriate Building Regulations. The Benchmark Checklist

can be used to demonstrate compliance with Building Regulations and should be

provided to the customer for future reference.

Installers are required to carry out installation, commissioning and servicing work

in accordance with the Benchmark Code of Practice which is available from the

Heating and Hotwater Industry Council who manage and promote the Scheme.

Visit www.centralheating.co.uk for more information.

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact

a government approved

inspector

LABC will record the data

and will issue a

certificate of compliance

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant LABC

You must ensure that the

certificate number issued by

the ‘Gas Safe Register’ is written

onto the Benchmark Checklist

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

or log onto:

www.GasSafeRegister.co.uk

within 10 days

If you notify via the ‘Gas Safe

the Building Regulations

certificate on members’ behalf

Complete the

Benchmark Checklist

Install and Commission this

appliance to manufacturer's

instructions

Competent Person's

Self Certification Scheme

Building Control

Complete the

Benchmark Checklist

Install and Commission this

appliance to manufacturer's

instructions

Legislation

4© Baxi Heating UK Ltd 2009

This company declares that no substances harmful

to health are contained in the appliance or used

during appliance manufacture.

The appliance is suitable only for installation in GB and IE

and should be installed in accordance with the rules in

force, and only used in a suitably ventilated location.

In GB, the installation must be carried out by a Gas Safe

Registered Installer. It must be carried out in accordance

with the relevant requirements of the:

• Gas Safety (Installation & Use) Regulations.

• The appropriate Building Regulations either The Building

Regulations, The Building Regulations (Scotland), Building

Regulations (Northern Ireland).

• The Water Fittings Regulations or Water Byelaws in

Scotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should

be made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a competent

Person and installed in accordance with the current edition

of I.S. 813 ‘Domestic Gas Installations’, the current Building

Regulations and reference should be made to the current

ETCI rules for electrical installation.

All systems must be thoroughly flushed and treated

with inhibitor (see section 6.2).

IMPORTANT - Installation, Commissioning, Service & Repair

This appliance must be installed in accordance with the manufacturer’s instructions and

the regulations in force. Read the instructions fully before installing or using the

appliance.

In GB, this must be carried out by a competent person as stated in the Gas Safety

(Installation & Use) Regulations.

Definition of competence: A person who works for a Gas Safe registered company

and holding current certificates in the relevant ACS modules, is deemed competent.

In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic

Gas Installations”.

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 plate is compatible with local supply

conditions.

Codes of Practice, most recent version should be used

In GB the following Codes of Practice apply:

Standard Scope

BS 6891 Gas Installation.

BS 5546 Installation of hot water supplies for domestic

purposes.

BS 5449 Forced circulation hot water systems.

BS 6798 Installation of gas fired hot water boilers.

BS 5440 Part 1 Flues.

BS 5440 Part 2 Ventilation.

BS 7074 Expansion vessels and ancillary equipment for

sealed water systems.

BS 7593 Treatment of water in domestic hot water

central heating systems.

In IE the following Codes of Practice apply:

Standard Scope

I.S. 813 Domestic Gas Installations.

The following BS standards give valuable additional information;

BS 5546 Installation of hot water supplies for domestic

purposes.

BS 5449 Forced circulation hot water systems.

BS 7074 Expansion vessels and ancillary equipment for

sealed water systems.

BS 7593 Treatment of water in domestic hot water

central heating systems.

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)

Regulations 1993 No3083” and is deemed to meet the requirements of Directive

92/42/EEC on the energy efficiency requirements for new hot water boilers fired with

liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by:

Notified Body 0087.

Product/Production certified by:

Notified Body 0086.

For GB/IE only.

All Gas Safe registered engineers carry an ID card with their licence number and a

photograph. You can check your engineer is registered by telephoning

0800 408 5500 or online at www.GasSafeRegister.co.uk

Safe Manual Handling

General

The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.

Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and

hands. Health & Safety is the responsibility of EVERYONE.

There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.

Do not handle or lift unless you feel physically able.

Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.

Preparation

Co-ordinate movements - know where, and when, you are both going.

Minimise the number of times needed to move the boiler - plan ahead.

Always ensure when handling or lifting the route 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 sack truck or other suitable trolley.

Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary.

See section 8.3 of these instructions for recommended lift points.

Remember

The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.

If at any time when installing the boiler you feel that you may have injured yourself STOP !!

DO NOT ‘work through’ the pain - you may cause further injury.

IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

1.0 Introduction 7

2.0 General Layout 8

3.0 Appliance Operation 9

4.0 Technical Data 10

5.0 Dimensions and Fixings 11

6.0 System Details 12

7.0 Site Requirements 16

8.0 Flue 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

Contents of Pack

The pack contains:-

• Boiler

• Wall Plate

• Template & ‘Quick Fit’ Guide

• Literature Pack

• Fittings Pack

1.1 Description

1. The Potterton Promax HE Plus are gas fired room

sealed fan assisted condensing central heating boilers.

2. The maximum output of the Potterton Promax 15/2

HE Plus is 52,000 Btu/hr, 24/2 HE Plus is 75,000 Btu/hr.

The maximum output of the 30 HE Pus is preset at

75,000 Btu/hr but can be set to 100,000 Btu/hr (see

section 8.8). All boilers automatically adjust their outputs

according to the system load.

3. It is designed for use on Natural Gas (G20).

4. The boiler is suitable for fully pumped open vented

central heating and domestic hot water systems and

sealed systems.

5. A label giving details of the model, serial number and

Gas Council number is situated on the rear of the lower

door panel (Fig. 1).

6. The boiler data badge is positioned on the air box door

(Fig. 2).

7. The boiler is intended to be installed in residential /

commercial / light industrial E.M.C. environments on a

governed meter supply only.

8. The boiler must be installed with one of the purpose

designed flues such as the standard horizontal flue kit, part

no 236921.

1.2 Important Information

Man-made mineral fibre

• Some component parts of this appliance (insulation

pads, gaskets and rope seals) are manufactured from man-

made mineral fibre.

• Prolonged or excessive exposure to this material may

result in some irritation to the eyes, skin or respiratory

tract.

• It is advisable to wear gloves when handling these items.

• Irritant dust will only be released from the items if they

are broken up or subjected to severe abrasion. In these

instances a suitable dust mask and goggles should be

worn.

• Always thoroughly wash hands after installation,

servicing or changing components.

• When disposing of any items manufactured from man-

made mineral fibre care must be exercised.

• If any irritation of the eyes or severe irritation of the skin

is experienced seek medical attention.

1.0 Introduction

Fig. 1

Data Badge

Air Box Door

Lower Door Panel Position of Label

Fig. 2

2.0 General Layout

8© Baxi Heating UK Ltd 2009

2.1 Layout (Figs. 3,4,5 & 6)

1. Wall Plate

2. Flue Elbow

3. Heat Exchanger

4. Burner

5. Air Box

6. Fan 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)

15 14

Fig. 4

Fig. 3

Fig. 5

Fig. 6

3.0 Appliance Operation

3.1

1. Switched Live On: When the switched live switches

on if the flow temperature is less than the set point

then pump overrun occurs. When the switched live

switches on if the flow temperature is greater than the

set point then pump overrun occurs.

2. Pump On: The pump is on while the fan, spark

generator and gas valve are off. After 10 seconds if the

flow switch has made then fan pre-purge occurs. After

10 seconds if the flow switch has not made then anti-

cycle occurs.

3. Fan Pre-Purge: The pump and fan are on while the

spark generator and gas valve are off. After 5 seconds

ignition occurs.

4. Ignition: The pump, fan, spark generator and gas

valve are on. If a flame is detected then burner on

occurs. If a flame is not detected within 5 seconds and

less than 5 ignition attempts have been made then fan

purge occurs. If a flame is not detected within 5

seconds and 5 ignition attempts have been made then

ignition lockout occurs.

5. Burner On: The 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 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: The pump is on while the fan, spark

generator and gas valve are off. After 1 minute anti-

cycle occurs.

8. Anti-cycle: The pump, fan, spark generator and gas

valve are off. After 3 minutes if the flow temperature is

less than the set point then pump on occurs. After 3

minutes if the flow temperature is greater than the set

point then pump overrun occurs.

9. Ignition Lockout: The pump, fan, spark generator

and gas valve are off. The boiler can only be reset by

manually using the reset button.

Mains On.

Flow

temperature less

than set point ?

YES

5 second

Fan Pre-Purge.

Flame Detected ?

Burner On.

Ignition

Lockout.

5 second

Ignition Period.

All TRVs

shut down ?

Ignition done and

5 attempts made ?

Ignition done

and less than 5

attempts made ?

Flow switch made ?

YES

10 second

Pump On.

All TRVs

shut or Flow temperature

greater than set point ?

5 second

Fan Post Purge.

1 minute

Pump Overrun.

3 minute

Anti-cycle.

YES

Appliance Category CAT I 2H

4.0 Technical Data

10 © Baxi Heating UK Ltd 2009

Horizontal

Flue Terminal Diameter 110mm

Dimensions Projection 150mm

Outercase Dimensions

Overall Height Inc Flue Elbow - 750mm

Casing Height - 600mm

Casing Width - 390mm

Casing Depth - 320mm

Weights kg

Packaged Boiler Carton 36.2

Packaged Flue Kit 3.6

Installation Lift Weight 26.0

Connections

Gas Supply - 1/2in BSPT

Central Heating Flow - 22mm

Central Heating Return - 22mm

Condensate Drain - 1 in BSP

Recommended System

Temperature Drop

Condensing 20°C 36°F

Heat Input (Q)(Gross) Max Min

15/2 HE Plus kW 16.88 10.2

Btu/hr 57,600 34,840

24/2 HE Plus kW 24.50 10.2

Btu/hr 83,600 34,840

30 HE Plus kW 33.76 10.2

(see note) Btu/hr 115,200 34,840

Heat Output (P)

(Non Condensing 70° C Mean Water Temp)

Max Min

15/2 HE Plus kW 15.24 9.14

Btu/hr 52,000 31,180

24/2 HE Plus kW 22.00 9.14

Btu/hr 75,000 31,180

30 HE Plus kW 30.18 9.14

Btu/hr 102,980 31,180

Electrical Supply 230V~ 50Hz

(Appliance must be connected to an

earthed supply)

Power Consumption 80W

External Fuse Rating 3A

Internal Fuse Rating (BS 4265)

Fuse 3.15 AT (PCB)

Inlet Pressure at Gas Valve (Natural Gas)

Min 18.1 mbar

Max 22.5 mbar

(see Section 10.1)

Injector (Natural Gas)

6.5mm Diameter

Clearances

(For unventilated compartments see Section 7.2)

Both Sides 5mm Min

Above Casing 200mm Min

Below Casing 50mm Min

Front (For Servicing) 500mm Min

Front (In Operation) 5mm Min

010203040

100

120

140

160

180

200

220

Water Flow Rate (litres/min)

Pressure Drop (mbar)

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/hr 81,200 34,520

30 HE Plus kW 32.61 10.1

Btu/hr 113,280 34,520

Water Content

litres 2.6

pints 4.6

Static Head

max 30 metres (100 ft)

min 1 metre (3.25 ft)

Low Head 0.2m (8 in) min

System Detail

fully pumped open vented & sealed systems

Gas Connection

G1/2” B.S.P. Thread

Controls

boiler thermostat, safety thermostat,

flow switch, electronic flame sensing,

temperature protection thermostat &

condensate blockage sensor

NOTE: The maximum output of the 30 HE

Plus is factory set at 22.0kW (75,000

Btu/hr). This can be altered to 30.18kW

(102,980 Btu/hr) - see section 8.8.

For 15/2 HE Plus - The efficiency is 91.3%

For 24/2 HE Plus - The efficiency is 90.9%

For 30 HE Plus - The efficiency is 90.9%

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of

dwellings. The test data from which it has been

calculated has been certified by 0087.

SEDBUK Declaration

Electrical Protection IPX2

CO/CO2 Ratio Up to a maximum

of 0.004

Flow Temperature (adjustable)

55° C to 78° C (± 5° C)

Max Gas Rate (2H - G20 - 20mbar)

(After 10 Mins)

(15/2) (24/2) (30)

Btu/hr 52,000 75,000 102,980

m3/hr 1.64 2.31 2.95

ft3/hr 52.1 83.3 104.2

CO2 Level 9% ± 1%

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