Potterton Promax 15 HE Benutzerhandbuch

Supplied By www.heating spares.co Tel. 0161 620 6677

Installation and

Servicing Instructions

Please leave these instructions with the user

Promax 15 HE & 24 HE

Wall Mounted Powered Flue Condensing Boiler

Gas Fired Central Heating Unit

Supplied By www.heating spares.co Tel. 0161 620 6677

Natural Gas

Potterton Promax 15 HE

G.C.No41 590 58

Potterton Promax 24 HE

G.C.No41 590 62

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 0051.

Product/Production certified by:

Notified Body 0086.

For GB/IE only.

Guarantee

Your Potterton Promax 15 HE or 24 HE

are designed and produced to meet all

the relevant Standards.

Potterton provide a 12 month

guarantee on the boiler.The guarantee

operates from the date installation is

completed for the customer who is the

original user.

To maximise the benefit from our

guarantee we urge you to return the

reply-paid guarantee registration.

This does not in any way prejudice

your rights at Common Law. Such

rights between the customer and the

installer or supplier from whom the unit

was purchased remain intact.

Any component or part which becomes

defective during the guarantee period

as a result of faulty workmanship or

material whilst in normal use will be

repaired or replaced free of charge.

B.S. Codes of Practice

Standard Scope

BS 6891 Gas Installation.

BS 5546 Installation of hot water supplies for

domestic purposes.

BS 5449 Part 1 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.

IMPORTANT - Care must be

exercised when lifting and handling

this product. Seek assistance where

appropriate and avoid stooping.

Protective equipment (e.g. gloves)

should be worn as necessary.

Supplied By www.heating spares.co Tel. 0161 620 6677

1.0 Introduction 4

2.0 General Layout 5

3.0 Appliance Operation 6

4.0 Technical Data 7

5.0 Dimensions and Fixings 8

6.0 System Details 9

7.0 Site Requirements 12

8.0 Installation 17

9.0 Electrical 23

10.0 Commissioning the Boiler 25

11.0 Fitting the Outer Case 26

12.0 Servicing the Boiler 27

13.0 Changing Components 29

14.0 Short Parts List 36

15.0 Fault Finding 37

Section Page

Contents

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Potterton declare that no substances harmful to

health are contained in the appliance or used

during appliance manufacture.

NOTE: This appliance must be installed in

accordance with the manufacturer’s instructions

and the regulations in force, and only used in a

suitably ventilated location.

All systems must be thoroughly flushed and

treated with inhibitor (see Section 6.2).

Read the instructions fully before installing or

using the appliance.

1.1 Description

1. The Potterton Promax 15 HE and 24 HE are gas

fired room sealed fan assisted condensing central

heating boilers.

2. The maximum output of the Potterton Promax 15

HE is 52,000 Btu/hr. The maximum output of the

Potterton Promax 24 HE is 75,000 Btu/hr. Both

boilers automatically adjust their outputs down to

30,000 Btu/hr 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 top of

the outercase (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 no236921.

1.2 Important Information

This product contains Refractory Ceramic Fibres

(R.C.F.) which are man-made vitreous silicate fibres.

Excessive exposure to these materials may cause

temporary irritation to eyes, skin and respiratory tract.

Care must be taken when handling these articles to

ensure the release of dust or fibres is kept to a

minimum.

To ensure that the release of fibres from these articles

is kept to a minimum, during installation and servicing

it is recommended that a H.E.P.A. filtered vacuum is

used to remove any dust, soot or other debris

accumulated in and around the appliance. This should

be performed before and after working on the

installation.

It is recommended that any replaced item(s) are not

broken up but sealed within heavy duty polythene

bags and clearly labelled “R.C.F. waste”. This is not

classified as “hazardous waste”and may be disposed

of at a tipping site licensed for the disposal of

industrial waste.

Protective clothing is not required when handling

these articles but it is recommended that gloves are

worn and the normal hygiene rules of not smoking,

eating or drinking in the work area are followed and

always wash hands before eating or drinking.

1.0 Introduction

Fig. 1

Data Badge

Air Box Door

Fig. 2

“Benchmark” Log Book

As part of the industry-wide “Benchmark”initiative all Potterton boilers now

include an Installation, Commissioning and Service Record Log Book.

Please read the Log Book carefully and complete all sections relevant to

the appliance and installation. These include sections on the type of

controls employed, flushing the system, burner operating pressure etc.

The details of the Log Book will be required in the event of any warranty

work. Also, there is a section to be completed at each subsequent regular

service visit. The Log Book must be left with the user.

Label

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2.0 General Layout

2.1 Layout (Figs. 3,4 & 5)

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. On/Off/Lockout Reset Switch

10. Gas Tap

11. Gas / Air Ratio Valve

12. Electronics Housing

13. Transformer

14. Flow Pipe Connection

15. Return Pipe Connection

16. Flow Temperature Safety Thermostat - Black

17. Flow Temperature Thermistor - Red

18. Flow Switch (dry fire protection)

17 16

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°(Reduce overall length of flue

by 1m when fitting each bend) 241687

VERTICAL FLUE (110/70)

Vertical Flue Terminal 242802

Vertical Boiler Connection 242886

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3.0 Appliance Operation

3.1

1. Switched Live On: When the switched live

switches on pump overrun occurs.

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

spark generator and gas valve are off. If at any

stage during pump overrun the flow temperature

is less than the set point and the flow switch is

made then fan purge occurs. After 1 minute of

pump overrun anti-cycle occurs.

3. Fan 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 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 generator

and gas valve are switched off. After 3 minutes

pump overrun occurs.

7. Ignition Lockout: The pump, fan, spark

generator and gas valve are switched off. The

boiler can only be reset by manually using the

thermostat knob.

Mains On.

Flow

temperature less

than set point and flow

switch made ?

YES

5 second

Fan Purge.

Flame Detected ?

Burner On. Ignition

Lockout.

5 second

Ignition Period.

All TRVs

shut down ?

Flow temperature

greater than set

point ?

Ignition done and

5 attempts made ?

Ignition done

and less than 5

attempts made ?

Pump Overrun

Anti-cycle.

Pump Overrun

for 1 minute ?

YES

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Appliance Category CAT I2H

4.0 Technical Data

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 lb

Packaged Boiler Carton 40.7 89.6

Packaged Flue Kit 3.6 8.0

Weight Empty 38.2 84.1

Installation Lift Weight 31.5 69.3

Connections

Gas Supply - 1/2in BSPT

Central Heating Flow (HE15) - 28mm

Central Heating Flow (HE24) - 28mm

Central Heating Return (HE15)- 28mm

Central Heating Return (HE24)- 28mm

Condensate Drain - 1 in BSP

Recommended System

Temperature Drop

Normal 11°C20°F

Condensing 20°C36°F

Heat Input (see note) Max Min

15 HE kW 16.88 10.2

Btu/hr 57,600 34,840

24 HE kW 24.50 10.2

Btu/hr 83,600 34,840

Heat Output

(Non Condensing 70°C Mean Water Temp)

Max Min

15 HE kW 15.24 9.14

Btu/h 52,000 31,180

24 HE kW 22.0 9.14

75,000 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 (2) 4 AT (Control Board)

Fuse (3) 2 AT (Ignition Board)

Max Gas Rate (Natural 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 10203040

100

120

140

160

180

200

220

Water Flow Rate (litres/min)

Pressure Drop (mbar)

0.8

1.7

2.5

3.3

4.2

5.0

5.8

6.6

7.5

8.3

9.1

Pressure Drop (in wg)

Hydraulic Resistance Chart

Appliance Type C13 C33

Nox Class 5

Heat Output

(Condensing 40°C Mean Water Temp)

Max Min

15 HE kW 16.49 10.1

Btu/h 56,260 34,520

24 HE kW 23.8 10.1

81.200 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 RC1/2(1/2in BSPT)

Controls

installer preset boiler thermostat, safety

thermostat, flow switch, electronic flame

sensing,temperature protection thermostat

& condensate blockage sensor

The efficiency is

Promax 15 HE - 91.3%

Promax 24 HE - 91.0%

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 0086.

SEDBUK Declaration For

Potterton Promax 15 HE & 24 HE

Supplied By www.heating spares.co Tel. 0161 620 6677

5.0 Dimensions and Fixings

DIMENSIONS

A600mm

B320mm

C390mm

D125mm ØMin.

E150mm

F125mm

SIDE FLUE (left and right)

For every 1m of horizontal flue

length, the clearance above 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 Ø110mm

3°

(1 in 20)

3°

(1 in 20)

Fig. 6

Fig. 7

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6.0 System Details

6.1 Water Circulating Systems

1. The appliance is suitable for use with open vent

fully pumped systems and sealed systems .

The following conditions should be observed

on all systems:

•The static head must not exceed 30m (100ft)

of water.

•The boiler must not be used with a direct

cylinder.

•Drain cocks should be fitted to all system low

points.

•All gas and water pipes and electrical wiring

must be installed in a way which would not

restrict the servicing of the boiler.

•Position isolating valves as close to circulating

pump as possible.

•It is recommended that the return pipe is fitted

with an automatic air vent as close to the boiler

as is practical.

NOTE: Full TRV Systems (refer to section 6.4)

Where all the radiators are controlled by TRV’s

then pump protection will be required. This can be

done by either of the options opposite (see Fig A &

B). The option shown in Fig. A should only be

used on a full TRV system without a bypass.

Fig. B shows a system with a bypass that must

be capable of allowing a flow of at least 3 l/min.

6.2 Treatment of Water Circulating

Systems

•All recirculatory water systems will be subject to

corrosion unless an appropriate water treatment

is applied. This means that the efficiency of

the system will deteriorate as corrosion sludge

accumulates within the system, risking damage

to pump and valves, boiler noise and circulation

problems.

•When upgrading existing systems that exhibit

evidence of sludging, it is advisable to clean the

system prior to treatment in order to remove any

sludge 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

flushing agent manufacturer’s instructions.

•System additives - corrosion inhibitors and

flushing agents/descalers should be suitable for

aluminium and comply to BS7593 requirements.

The only system additives recommended are

Betz-Dearborn Sentinel X100 and Fernox-Copal

which should be used following the inhibitor

manufacturer’s instructions.

Failure to flush and add inhibitor to the

system will invalidate the appliance warranty.

•It is important to check the inhibitor

concentration after installation, system

modification and at every service in accordance

with the manufacturer’s instructions. (Test kits

are available from inhibitor stockists.)

•For information or advice regarding any of the

above contact the Potterton Helpline.

Boiler

No demand

for hot water

Central

heating

load

All TRV’s shut down

(boiler flow switch

causes pump to stop)

Live feed

to pump

Switch live from

programmer, etc.

S/L N P/F

Fig. A Wiring to the pump feed connection of boiler

Fig. B Providing a 3 l/min bypass

Boiler

No demand

for hot water

Central

heating

load

All TRV’s shut down

(pump continues

around bypass)

Switch live from

programmer,

room stat, etc.

S/L

junction

S/L N P/F 3 l/min

bypass

Boiler

Connections

Boiler

Connections

NOTE: This boiler does not require a bypass.

This boiler does not require a permanent live.

These diagrams only refer to pump protection for fully TRV’d systems.

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6.0 System Details

6.3 Pipework

1. The sizes of flow and return pipes from the

boiler should be determined by normal methods,

according to the requirements of the system. The

connection to the boiler is 28mm (compression).

2. Due to space requirements within the boiler

outercase, pipework should comprise of solder

fittings.

3. A 20 °C (36°F) drop in temperature across

the system is recommended for condensing

boilers. Existing radiators may be oversized and

so allow this, but where radiator sizing is marginal

it may be advisable to retain a system temperature

drop of 11°C (20°F).

4. In systems using non-metallic pipework it is

necessary to use copper pipe for the boiler Flow

and Return. The copper must extend at least 1

metre from the boiler and include any branches

(Fig. 7a).

6.4 System Controls

1. For optimum operating conditions, the heating

system into which the boiler is installed should

include a control system.

2. Such a system will comprise of a timer control

and separate room or cylinder thermostats as

appropriate.

3. The boiler should be controlled so that it

operates on demand only.

4. Operation of the system under control of the

preset 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 20oC

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. 10)

2. For heads below 400mm then a combined vent

and feed pipe may be connected. This must be a

minimum of 22mm diameter. It is recommended

that an air separator is fitted when using a

combined feed and vent pipe.

6.6 Thermal Stores

1. The Promax 24 HE is suitable for fitting with a

Thermal Store, for details please contact

Technical Enquires (08706 049 049). The Promax

15 HE is not suitable for fitting with a thermal

store.

Typical Low Head Installation

If Conditions Require,

This System Possible

Alternative Low Head Installation

Boiler

500mm

45°

22mm

Open Vent

1000mm

Min

150mm

Max

15mm

Cold

Feed 400mm

Min Head

Return

Pump Flow

Boiler

500mm

45°

22mm

Open Vent

400mm

Min Head

1000mm

Min

Automatic

Air Vent 15mm

Cold

Feed

150mm

Max

Return

Pump

Flow

Return

Pump

Flow

Boiler

200mm

Min

Air

Separator

22mm

Feed & Vent

Pipe

Fig. 8

Fig. 9

Fig. 10

Boiler

Flow

Return

Copper

0.5m

Copper

0.5m

Fig. 7a

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