Potterton IHE 150 Versionshinweis

M6500

iHE

Indirect High Eﬃciency Boiler & Water Heater

Installation & Servicing Instructions

Models

iHE 100

iHE 150

This manual must be kept with the appliance

PERFORMANCE Unit 100 150

Category gas types II2H G20 @ 20 mbar

Qn Nominal Heat Input net (gross) kW 94.0 (102.2) 140.0 (152.1)

Qn Minimum Heat Input net (gross) kW 9.8 (11.1) 9.8 (11.1)

Pn Nominal Heat Output Max (50/30) kW 99.0 147.4

Pn Nominal Heat Output Min (50/30) kW 10.0 10.0

V Gas Consumption (G20) m3/h 9.9 14.8

Flue gas temperature max (min) oC 79 (50) 79 (50)

CO2 at max output (min output) % 9.3 (8.7) 9.3 (8.7)

CO at max output (min output) ppm 150 (3) 150 (3)

NOx emission at 0% 02 (dry) ppm (mg/kWh) 36.8 (56.7) 36.8 (56.7)

NOx Class 5 5

HEATING

Eﬃciency max heat output 50/30 net % 105.3 105.3

Eﬃciency min heat output 50/30 net % 102.5 102.5

Eﬃciency max heat output 80/60 net % 96.6 96.6

Eﬃciency min heat output 80/60 net % 95.2 95.2

Eﬃciency at 30% heat output net % 108.5 108.5

Seasonal eﬃciency gross % 95.6 95.6

PMS Operating pressure max (min) bar 3.0 (0.5) 3.0 (0.5)

Tmax Max permitted operating temperature oC82 82

Flow / Return connections BSP 2” 2”

Low Loss Header resistance kPa 0.5 0.5

HOT WATER

Tank capacity litres 300 300

Recovery rate through 50oC l/h 1520 2240

Time to recover tank through 50oC mins 12 9

PMS Operating pressure max (min) bar 6.0 (0.2) 6.0 (0.2)

In / Out connections BSP M 11/2”M1

1/2”

Water return connection BSP M 1” M 1”

ELECTRICAL

Electrical supply voltage / Hz V / Hz 230 / 50 230 / 50

Power consumption - standby A (W) 0.15 (34) 0.2 (40)

Power consumpion - maximum A (W) 3.3 (760) 3.82 (880)

Fuse rating on mains supply A 5 5

Insulation protection rating IP 20 20

FLUE

Flue connection - single mm 130 130

Flue connection - concentric mm 130 / 200 130 / 200

Max ﬂue equivalent length - single m 30 30

Max ﬂue equivalent length - concentric m 14 14

Flue systems permitted type B23, C13, C33 & C53

Approx ﬂue gas volume @ 90oCm

3/h 160 242

OTHER CONNECTIONS

Gas BSP F 1” F 1”

Condensate mm 40 40

Immersion Heater BSP 2 1/4” 2 1/4”

Tank drain mm 28 28

WEIGHTS & CLEARANCES

Weight empty (full) kg 290 (608) 320 (641)

Service clearance - rear mm 0 0

Service clearance - right (with immersion) mm 300 (600) 300 (600)

Service clearance - top mm 350 350

Service clearance - left mm 800 800

GB, IE

iHE 1 GB/IE

TECHNICAL INFORMATION

Performance & measurement data Inside cover

1.0 GENERAL & SAFETY INFORMATION

1.1 Symbols used in this manual 2

1.2 Data plate & CE Marking 3

1.3 General warnings 4

1.4 Safety 4

1.5 Health 4

1.6 Description of appliance 5

1.7 General dimensions 6

2.0 INSTALLATION

2.1 Unpacking and location 7

2.2 New & existing heating systems 8

2.3 Water connections 9

2.4 Open vent design 9

2.5 Unvented design 10

2.6 Secondary return design 11

2.7 Condensate removal 11

2.8 Immersion Heater 12

2.9 Mixer Valve & actuator control 12

2.10 Flue systems & ventilation 13

2.11 Open ﬂue type (B23)13

2.12 Room sealed type (Cxy)14

2.13 Flue terminal positions 15

2.14 Maximum ﬂue lengths 16

2.15 Gas connections 17

2.16 Electrical connections 18

2.17 System schematic 19

2.18 Application drawings 20

2.19 Wiring diagrams 23

2.20 Wired room units & outside sensor 25

2.21 AGU2.5 Expansion modules 28

3.0 COMMISSIONING

3.1 Filling & starting the appliance 29

3.2 Running the circulation pumps 29

3.3 Commissioning the heat engines 30

3.4 Final checks & user handover 32

3.5 Frost protection & anti-legionella 32

3.6 Fault ﬁnding 33

4.0 SERVICE & MAINTENANCE

4.1 Recommended servicing 34

4.2 Changing components 35

4.3 Spare parts list 38

4.4 Appliance components identiﬁcation 39

4.5 Fault codes list 42

CONTENTS

iHE 2 GB/IE

CORRECT USE OF APPLIANCE

This Potterton Commercial heating product has been designed and manufactured to comply with

current International standards of safety. However, following an improper use, dangers could

arise concerning the safety and life of the user or of other people, or damage could be caused to

the appliance or other object. The appliance is designed to be used in a pumped hot water central

heating system and potable hot water supply and storage. Any other use of this appliance will be

considered improper. Potterton Commercial declines any responsibility for any damage or injuries

caused by an improper use. In order to use the appliance according to its designed scope, it is es-

sential to carefully follow the instructions given in this guide.

DANGER!

INDICATES SERIOUS DANGER

TO PERSONAL SAFETY AND LIFE

WARNING!

INDICATES APOTENTALLY DANGER-

OUS SITUATION FOR THE APPLIANCE

AND THE ENVIRONMENT

NOTE!

SUGGESTIONS TO ASSIST THE USER

IN IMPLEMENTING INSTRUCTIONS IN

THIS GUIDE

1.1 SYMBOLS USED IN THIS GUIDE

SMELL OF GAS

If you smell gas - follow these safety instructions:

- Do NOT turn oﬀor on any electrical switches (including light switches)

- Do NOT smoke

- Do NOT use the telephone

- DO evacuate persons away from the source of the gas smell

- DO close the main gas shutoﬀvalve

- DO open all the windows and doors where the gas leakage has occurred

- DO inform the gas authority or a competent specialist as soon as possible

OPERATOR COMPETENCY

This boiler is not intended for use by persons (including children) with reduced physical,

sensory or mental capabilities, or lack of experience and knowledge, unless they are given

supervision or instruction concerning the use of it by a person responsible for their safety.

Children should be supervised to ensure they do not play with the appliance.

BEWARE

The installation, adjustment & servicing of this appliance must be carried out by a competent

person (In the UK by a Gas Safe Registered Engineer and in IE by a (RGII) Registered Gas Installer)

and installed in accordance with current standards and regulations. Failure to correctly install or

maintain this appliance could cause injury to persons or damage to property. The manufacturer

shall not be held liable for any such injury and/or damage.

FLAMMABLE SUBSTANCES

Do not store or use explosive or easily inﬂammable material (such as petrol, paint or paper) in the

same room where the appliance has been installed.

Potterton Commercial’s policy is one of continuous improvement, and therefore the information

in this manual, whilst correct at the time of publication, may be subject to revision without prior

notice.

1.0 GENERAL & SAFETY INFORMATION

iHE 3 GB/IE

1.2 DATA PLATE & CE MARKING

There are two data plates located on the appliance . One is mounted on the inside of the electrical assembly

(which becomes visible when the left hand door is opened) and the other is on the outside casing just below

the electrical installation panel.

The CE marking documents that the appliance complies with the essential requirements of the following

directives:

- Gas appliance directive (2009/142/EC)

- Eﬃciency requirements directive (Council Directive 92/42/EEC) for condensing boilers

KEY

1 Type approval designation

2 Gas type and pressure

3 Model Name

4 Heat, gas ﬂow & CO ² data

5 Technical data

6 Serial number

This manual is an integral and indispensable part of the appliance and it is suggested that this

manual is kept in a safe place for future reference.

iHE 4 GB/IE

1.3 GENERAL WARNINGS

The appliance has been designed for use with G20 gas and is manufactured to give an eﬃcient, reliable

and long service life.To ensure continued trouble-free operation of the appliance at maximum eﬃciency, it

is essential that correct installation, commissioning, operation and annual service procedures are carried out

strictly in accordance with the instructions given in this manual.

Only original parts and accessories from the manufacturer must be used on all appliances. Using non-approved

parts may compromise the safety of the appliance and invalidate any warranty.

The installation, commissioning and repair of this appliance must be carried out by a competent

person, in accordance with the manufacturers instructions and complying with the National Laws in

force at the time. (In the UK a competent person must be a Gas Safe registered Engineer or in IE by a

Registered Gas Installer (RGII)).

In the event of failure and/or suspected faulty functioning of the appliance. Switch oﬀthe appliance and con-

tact suitable qualiﬁed technicians. Do not attempt to make any repairs unless you are suitably qualiﬁed and

competent to do so.

1.4 SAFETY

This appliance must be installed in accordance with local building regulations, national standards and bye laws

in force. Attention should be given to the following standards and guidance notes:

GAS SAFETY (INSTALLATION AND USE) REGULATIONS

BUILDING REGULATIONS

THE WATER SUPPLY (WATER FITTINGS) REGULATIONS

Detailed recommendations are contained in the following codes of practice:

BS 6880: Low temperature hot water heating systems of output greater than 45kW.

Part 1 Fundamental Design

Part 2 Selection of equipment

Part 3 Installation, commissioning and maintenance

BS 6644: Speciﬁcation for installation of gas-ﬁred hot water boilers of rated inputs of between 70kW (net)

and 1.8MW (net) (2nd & 3rd family gases)

BS EN 12897 Speciﬁcation for indirectly heated unvented (closed) storage water heaters.

The following could be relevant dependent upon the installation:

IGE/UP/1 - 1A -1B Strength & tightness testing of industrial and commercial gas installations.

IGEM/UP/2 Gas installation pipework, boosters and compressors on industrial and commercial premises.

IGEM/UP/4 Commissioning of gas ﬁred plant on industrial and commercial premises.

IGE/UP/7 Gas installations in timber frame buildings.

IGE/UP/10 Gas Installations in industrial and commercial premises.

IEE Wiring Regulations for electrical installations (BS7671)

NOTE: Consideration should be given to amendments or updates to the above standards.

1.5 HEALTH

It is the duty of manufacturers and suppliers of products to ensure, so far as is practicable, that such products

are safe and without risk to health when properly used and to make available to users, adequate information

about their safe and proper operation.

This appliance should only be used in the manner and purpose for which it was intended and in accordance

with the instructions in this manual. Although the boiler has been manufactured with paramount considera-

tion to safety, certain basic precautions speciﬁed in this manual must be taken by the user. It is imperative

that all users of it must be provided with all the information and instruction necessary to ensure correct and

safe operation.

iHE 5 GB/IE

COMBATTING LEGIONELLA

Water systems in buildings have been associated with outbreaks of Legionnaires’ Disease, particularly in health

care facilities where occupants are signiﬁcantly more susceptible to infection. In recognition of the risks in hos-

pitals, a Code of Practice for the Control of Legionella in Health Care premises has been issued by the Depart-

ment of Health.

Codes of Practice applicable to other premises have been published by other organisations, principally the

Health and Safety Executive (HS) (G70) and the Chartered Institute of Building Services Engineers (CIBSE,

TM13). All Codes of Practice draw attention to the design and operation of water systems with reference

to avoidance of factors that favour colonisation by Legionella bacteria. These factors include stagnation,

lukewarm conditions (20ºC to 45ºC) and the accumulation of debris, scale and corrosion in the base of tanks and

caloriﬁers.

An independent evaluation of our products was commissioned to investigate their resistance to the build-up of

Legionella bacteria. Experiments were conducted to determine whether, following a substantial challenge by

Legionella Pneumophilia, after overnight and stagnation conditions, the system was rendered free from viable

recoverable Legionella. It was found that at 61ºC, following a challenge of approximately 107 organisms per

litre, within one hour, more than 99.999% of organisms had been killed. After a subsequent stagnation period,

sampling did not reveal any residual contamination. The design of the base of the integral water tank precludes

Legionella colonisation, even after build-up of debris. The heating process ensures that the water at the bottom

of the tank reaches the same temperature as in the rest. In addition the controls of the appliance provide anti-

legionella routines to provide additional protection.

Based on data obtained through experiment, this appliance can be described as Legionella resistant as it is

considered unlikely that, at the temperature tested, the organism would colonise the water heater and present

a possible health risk.

1.6 DESCRIPTION OF APPLIANCE

The Potterton iHE is a gas ﬁred, low No×, multi-heat engine cascading boiler system, with an integrated 5” Low

Loss Header for the supply of a low temperature hot water space heating system. The Sirius Advance range of

boilers also features an integrated stainless steel tank and plate heat exchanger for the supply of hot water.

Fully automatic electronic controls are integrated into the appliance, with a wide range of control and sensor

options available. The controls also provides voltage free outputs for Enable, Burner On, Fault and 0-10V input

for remote BMS use.

Each heat engine module consists of a stainless steel combustion chamber, premix burner, modulating fan, gas

valve, ignition and ﬂame detection electrodes and a NTC ﬂue sensor for safety supervision.

Each heat engine module is equipped with NTC sensors for precise temperature control on ﬂow and return mani-

folds. Fully premixed, radiating, modulating burner, integrated with gas valve to deliver precise gas/air mixture

throughout the full modulation range.

Common combustion air intake manifold, takes air from boiler room (type B23 ﬂue) or directly from outside via

a combined ﬂue system (C13 & C33). An air control non-return ﬂap is integrated into the air supply of each heat

engine, to ensure that ﬂue products cannot contaminate the air supply, when the heat engine is not in use.

The safety and operation functions of each heat engine are managed by micro processor controlled circuit

boards, one for each heat engine. The upper controller also acts as the cascade controller, switching/modulat-

ing the heat engines according to the demand and data from the systems sensors. Control is performed using

comparison parameters between the requested temperature and the global ﬂow temperature.

CONTROL LOGIC:

At full demand, each heat engine is ignited one at a time, until all heat engines are operating at full output. As

ﬂow and return temperatures increase, all heat engines will begin to modulate down together, until all are oper-

ating at minimum input rate. As ﬂow temperatures begin to approach the calculated set point, one of the heat

engines will stop, leaving the others operating at minimum input rate. This will continue until all heat engines

have stopped and temperature ﬂow requirements have been fully satisﬁed.

iHE 6 GB/IE

Fig 1.1

1450

678

515

105

812

1033

1708

253

540

1970

1987-REMOVEABLEAIRDUCTSPIGOTFORINSTALLATION

127

Safety Valve

& Tundish

3/4" BSP F

Condensate

Trap

41mm

Low Loss Header

Return

2" BSP F

Low Loss Header

Flow

2" BSP F

Gas Inlet

1" BSP F

Wiring Centre

Door

Front

LH Door

Front

RH Door

RH Side

Upper

LH Side

Lower

LH Side

Top

Multiple Cable

entry point

1941

192

104

Low Loss Header

Air vent

User Display

268

190

179

149

191

238

Cylinder Hot Water Supply

1.5" BSP M

Cylinder Return

1" BSP M

Air/Flue Duct

200mm/130mm

Pressure Gauge

Fill/Drain 15mm

497

132

Cylinder Drain

28mm

701

302

Immersion Heater Boss

2.25" BSP F

1871

PT Valve exits

100kW - 1 x 28mm

150kW - 1 x 28mm & 1 x 22mm

1.7 GENERAL DIMENSIONS

Minimim Service Clearances (mm)

Rear 0

Right (without immersion)

Right (with immersion)

300

600

Left 600

Top 350

iHE 7 GB/IE

The appliance is delivered assembled and

protected by a plastic bag, inside a strong

wooden crate. The packaging is designed

to be handled by a forklift or pallet truck.

The complete crated appliance can go

through a door of 2,320mm high. Without

packaging it can go through a door

1,970mm high.

Remove nails ﬁxing crate sides to the base. Remove

nails from one end of the crate. Remove end of crate

and slide the main body of the crate oﬀthe oppo-

site end.

Remove plastic wrapping once the appliance has

reached its intended installation area.

Dispose of plastic packaging carefully.

Keep out of the reach of children and

animals.

LOCATION

The location selected for installation of the appli-

ance must allow the provision of a satisfactory ﬂue,

an adequate air supply (for type B23), a drain and

be well illuminated. A purpose built plant room or

compartment is strongly recommended.

If a purpose built plant room is not available, meas-

ures should be taken to protect the appliance from

damage and prevent any extraneous matter from

being stored on or around the Heater. See BS 6644

Clauses 4, 5 and 6 for details. Any combustible ma-

terial adjacent to the appliance must be so placed

and shielded as to ensure that it’s temperature does

not exceed 66ºC (150ºF).

There must be easy access to the plant room and

boiler at all times. The appliance must be located in

an area where leakage from the tank, water con-

nections or the combined temperature and pres-

sure safety valve will not result in damage to the

area adjacent to it. When such locations cannot

be avoided, a suitable drain tray must be installed

under the Heater. The drain tray must be no deeper

than 38mm and must be 100mm wider and longer

than the boiler. It should be piped to an adequate

drain using 20mm (0.75in) diameter pipe, angled for

proper drainage.

Access must be provided to the front of the boiler

with adequate clearance for servicing and opera-

tion. (Fig 1.1)

The ﬂoor on which the boiler is installed must be

ﬂat, level and of suﬃcient strength to withstand

the weight of it when ﬁlled with water, and should

satisfy the requirements of the Local Authority &

Building Regulations.

Whether connecting to an existing or a new

heating system, a ﬁlter/strainer (with two

isolation valves) must be ﬁtted in the return

pipe. When necessary it can be removed

and cleaned, which will help protect the

appliance from contaminants, from within

the heating system.

APPLIANCE FLOOR FIXING KIT

This appliance has been supplied with plates to fas-

ten the appliance securely to the ﬂoor.

There are four ﬂoor ﬁxing plates (M6644) included

with this unit. Two have been packed separately with

the Air Duct kit that includes these instructions and

another two plates have been used to fasten the

appliance to the pallet.

Central Floor ﬁxing method (two plates required)

Once the appliance has been located on a level sur-

face, ﬁx the appliance to the ﬂoor using the follow-

ing method.

1) Slide plate into position so that it interlocks onto

the LH central base support . Mark ﬂoor

with hole position and remove plate (Fig 2.1).

2) Drill marked position on ﬂoor to allow installers

preferred method of ﬁxing.

3) Reﬁt plate and fasten through using preferred

ﬁxing method.

4) Repeat method at the RH end of the central

base support.

Fig 2.1

2.0 INSTALLATION

2.1 UNPACKING AND APPLIANCE LOCATION

iHE 8 GB/IE

Central Floor ﬁxing method (four plates required)

If the central ﬁxing positions are unsuitable for the

installation, alternative positions can be utilised in

the corners. (Fig 2.2) This method can only be used

if the installer has kept the pallet ﬁxing plates and

has four plates in total.

Follow points 1 - 4 above for ﬁxing instructions.

2.2 NEW AND EXISTING HEATING

SYSTEMS

EXISTING SYSTEMS

Before replacement of an existing boiler, it

is necessary to thoroughly clean out the

old system ﬁrst. This is best achieved intro

ducing a basic cleaning solution 4 weeks

before the substitution.

When the appliance is installed on existing systems,

please ensure you have considered the following

before commissioning:

- If you intend to use the existing ﬂue on a B23

category system, check that ﬂue outlet is suitable

for condensing boilers, is the correct size, is correct

for the temperature of the products of combustion

and is manufactured according to current

regulations. It must be tested for soundness and

must not have any restrictions or defects. Also

ensure that the ﬂue outlet pipe has a connection for

the discharge of condensate. For all other ﬂue

types, it is recommended that a completely new

ﬂue system is installed.

- The boiler room has a suitable outlet for the

discharge of condensate produced.

- The electrical connections comply with the current

electrical standards and the work has been carried

out by a suitably qualiﬁed person.

- The gas supply pipework is constructed to the

current regulations in force.

-The expansion vessels and associated ﬁttings are

correctly sized to absorb the total expansion of the

system and in tested working order.

- The circulation pump’ s output, the head and ﬂow

direction are suitable.

- The complete system has been cleaned of

impurities and lime scale.

NEW SYSTEMS

It is recommended to thoroughly clean out the new

system with a system ﬂush product, before commis-

sioning the appliance.

SYSTEM INHIBITORS & PH LEVELS

After cleaning and ﬂushing of the system, it should

be ﬁlled with an appropriate inhibitor/antifreeze

treatment to maintain pH levels of between 7.5 &

9.5pH.

The following system treatments have been tested

and are recommended for use in this appliance:

FERNOX SENTINEL

Inhibitors Protector/

Alphi 11

X100, X500

Noise reducer X200

Universal cleaner Restorer X300

Sludge remover Protector,

Restorer

X400

Antifreeze Alphi 11 X500

Fig 2.2

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