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Potterton Promax 15 HE Installation & Service Instructions Manual

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See also: Instructions for Installation and Servicing
Installation & Service Instructions
Promax
15 HE & 24 HE
This is a Wall Mounted Powered Flue Condensing Boiler Gas Fired Central Heating Unit.
The boiler meets the requirements of Statutory Instrument " The Boiler (Efficiency) Regulations 1993 N
o
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.

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  • Page 1 Installation & Service Instructions Promax 15 HE & 24 HE This is a Wall Mounted Powered Flue Condensing Boiler Gas Fired Central Heating Unit. The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations 1993 N 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:...
  • Page 2 Natural Gas Potterton Promax 15 HE G.C.N 41 590 58 Potterton Promax 24 HE G.C.N 41 590 62 Publication No. 5106451...

  • Page 3: Table Of Contents

    CONTENTS Section Page Legislation Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Installation Electrical 10.0 Commissioning 11.0 Outer Case 12.0 Servicing 13.0 Changing Components 14.0 Fault Finding 15.0 Short Parts List Publication No. 5106451...

  • Page 4: Legislation

    Codes of Practice, most recent version should “Benchmark” Log Book be used As part of the industry-wide “Benchmark” initiative all Potterton boilers now In GB the following Codes of Practice apply: Standard Scope include an Installation, Commissioning and Service Record Log Book. Please BS 6891 Gas Installation.

  • Page 5: Introduction

    INTRODUCTION Description 1. The Potterton Promax 15 HE and 24 HE are gas fired room sealed fan assisted condensing central heating boilers. Label 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.

  • Page 6: General Layout

    GENERAL LAYOUT Layout (Figs. 3,4 & 5) Wall Plate Flue Elbow Heat Exchanger Burner Air Box Fan Protection Thermostat Fan Assembly Fig. 5 Condensate Trap On/Off/Lockout Reset Switch Gas Tap Gas / Air Ratio Valve Electronics Housing Transformer Flow Pipe Connection Return Pipe Connection Flow Temperature Safety Thermostat - Black Flow Temperature Thermistor - Red...

  • Page 7: Appliance Operation

    APPLIANCE OPERATION 1. Switched Live On: When the switched live Mains On. 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 Pump Overrun Pump Overrun for 1 minute ? during pump overrun the flow temperature is less...

  • Page 8: Technical Data

    20°F Condensing 20°C 36°F Hydraulic Resistance Chart SEDBUK Declaration For Potterton Promax 15 HE & 24 HE 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.

  • Page 9: Dimensions And Fixings

    DIMENSIONS AND FIXINGS DIMENSIONS A 600mm 3° (1 in 20) B 320mm C 390mm D 125mm Ø Min. E 150mm F 125mm 360° Orientation 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 Tube Ø...

  • Page 10: System Details

    SYSTEM DETAILS NOTE: This boiler does not require a bypass. Water Circulating Systems This boiler does not require a permanent live. These diagrams only refer to pump protection for fully TRV’d systems. 1. The appliance is suitable for use with open vent fully pumped systems and sealed systems .
  • Page 11 SYSTEM DETAILS Pipework 1. The sizes of flow and return pipes from the boiler Copper should be determined by normal methods, according Copper 0.5m to the requirements of the system. The connection to 0.5m the boiler is 28mm (compression). Flow Boiler Return 2.
  • Page 12 SYSTEM DETAILS 3 Litre Top Up Bottle (if required) Sealed Systems (Fig. 11) Vent 1. SAFETY VALVE - A safety valve complying with the requirements of BS 6750 Part 1 must be fitted Filling Pressure close to the boiler on the flow pipe by means of a Point Safety Gauge...

  • Page 13: Site Requirements

    SITE REQUIREMENTS Location 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and Zone 2 providing an adequate air supply. The boiler should Window be fitted within the building unless otherwise Recess...
  • Page 14 SITE REQUIREMENTS 5mm Min 390mm 5mm Min Clearances (Figs. 12 &13) 1. A flat vertical area is required for the installation of the boiler. 200mm 2. These dimensions include the necessary clearances around the boiler for case removal, spanner access and air movement. Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler.
  • Page 15 SITE REQUIREMENTS Condensate Drain Termination to an internal soil FAILURE TO INSTALL THE CONDENSATE Boiler and vent pipe DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5°...
  • Page 16 25mm but the flue deflector kit (part no. 248167) must be fitted. 7. If required a suitable terminal guard is available from Potterton for use with the flue deflector. Top View Rear Flue 8. For fitting under low soffits and eaves it is Fig.
  • Page 17 Pictorial examples of flue runs where EQUIVALENT flue length equals 4m 7.10 Vertical Flue 1. Only a flue approved with the Potterton Promax 15 HE & 24 HE can be used. 2. For information on vertical flues consult the Potterton Flue Guide Brochure or Guidance Notes supplied with the vertical flue pack.
  • Page 18 SITE REQUIREMENTS A - Standard Flue 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 Any additional “in line”...

  • Page 19: Installation

    INSTALLATION Check Site Requirements (section 7.0) before commencing. Example Edge of Boiler 125mm Initial Preparation EXAMPLE: Boiler is 2 metres The gas supply, gas type and pressure must be away from corner of wall, flue checked for suitability before connection (see duct hole is 60mm up from Example Section 7.4).
  • Page 20 1. Remove the outer carton. 2. Remove the internal packaging. 3. Lift the outercase upwards and remove Outercase (Fig. 23). Potterton declare that no substances harmful to health are contained in the appliance or used during appliance manufacture. Fig. 23 Publication No. 5106451...
  • Page 21 INSTALLATION Fitting The Boiler (Fig. 24) Retaining Bracket 1. Remove the screw and retaining bracket from the wall plate spring clip. 2. Offer up the boiler to the wall plate using the lifting points shown in Fig. 24 and locate the rear bottom edge onto the self locating support at the base of the wall plate (See Lifting paragraph page 4).
  • Page 22 INSTALLATION Wall Thickness Making the Gas Connection 1. Connect the gas supply to the RC in BSPT internal) gas tap located on the lower right side of the boiler. 3° (1 in 20) Fitting The Flue Before fitting the flue, check the condensate drain integrity (see section 8.5).
  • Page 23 13. If necessary fit a terminal guard (see Section Gasket 7.9). VERTICAL FLUEING 1. Only flues approved with the Potterton Promax 15 HE & 24 HE can be used. Fig. 30 Flue Trim Fig. 29...
  • Page 24 (Fig. 32). 4. The boiler is factory set to give a flow temperature set point of 82°C. The Control PCB jumper positions are as follows: Promax 15 HE J1 Out J2 In J3 In...

  • Page 25: Electrical

    ELECTRICAL Schematic Wiring Diagram Control bk bk b bk Ignition Dry Fire Flow Switch Detection Electrode Transformer On/Off Valve Thermistor Switch Condensate Fan Protection Trap Stat Spark Electrode Safety Stat N P/F Mains Optional Input Pump Feed Key To Wiring Colours b - Blue r - Red bk - Black...
  • Page 26 ELECTRICAL Illustrated Wiring Diagram On/Off Switch Flow Switch Sensing Electrode Flow Temperature Thermistor Control Condensate Trap Fan Protection Thermostat Ignition Safety Thermostat Valve Earth Transformer Mains Input Spark and Earth Electrode Wiring Key - Blue bk - Black br - Brown - Red Earth w - White...

  • Page 27: Commissioning

    10.0 COMMISSIONING 10.1 Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Flush the whole system using a suitable flushing agent (see Section 6.2) and vent the radiators. Check for water leaks. 3.

  • Page 28: Outer Case

    11.0 OUTER CASE 11.1 Fitting The Outer Case 1. Position the outercase over the boiler engaging the lugs in the side flanges over the hooks on the wall plate (Fig. 37). 2. Carefully centralise the On/Off switch through the cut-out on the facia. Using the screw supplied in the kit, secure the outercase from the bottom (Fig.

  • Page 29: Servicing

    PCB remains live. Therefore it is important to isolate the electrical supply. Hazardous materials are not used in the construction of Potterton products, however reasonable care during service is recommended. When replacing the combustion box door after servicing it is essential that the retaining screws are tightened fully.
  • Page 30 12.0 SERVICING 12.1 Annual Servicing (Cont) NOTE: General cleaning can be undertaken using a vacuum. However debris should only be gently blown off the burner skin due to its fragile nature. 10. To clean the heat exchanger and burner proceed as follows: a) Disconnect the electrical leads to the fan component protection sensor (Fig.

  • Page 31: Changing Components

    PCB remains live. Therefore it is important to isolate the electrical supply. Hazardous materials are not used in the construction of Potterton products, however reasonable care during service is recommended. When replacing the combustion box door after changing components, it is essential that the retaining screws are tightened fully.
  • Page 32 13.0 CHANGING COMPONENTS 13.3 Flow Switch (Fig. 47) 1. Drain the boiler (see Section 13.1 paragraph 2 & 3). 2. Disconnect pipework, loosen elbow locking nut and undo screws on support bracket. 3. Remove the clip securing the flow pipe to the flowswitch.
  • Page 33 13.0 CHANGING COMPONENTS The control and ignition boards can be accessed on the removal of the main electrical box cover. Electrical Box Cover 1. Remove the two screws securing the main electrical box cover (Fig. 48). 13.4 Control Board (Fig. 49) 1.
  • Page 34 13.0 CHANGING COMPONENTS The fan and venturi, gas valve, injector pipe, condensate trap, fan protection sensor, spark and sensing electrodes can be accessed and changed on the removal of the airbox door panel. 1. Remove the airbox door panel by loosening the four turn screws (Fig.
  • Page 35 13.0 CHANGING COMPONENTS The removal of the fan is necessary to enable the changing of the injector pipe, condensate trap and gas valve (see section 13.8). 13.9 Injector Pipe (Fig. 55) 1. Remove the injector pipe by pulling out from the ‘O’...
  • Page 36 13.0 CHANGING COMPONENTS The burner and heat exchanger can be changed after removal of the combustion box door. To change the heat exchanger, the fan and burner must be removed first (see section 13.8). Combustion Box 1. Remove the combustion box door by removing the Door Panel four securing screws (Fig.
  • Page 37 13.0 CHANGING COMPONENTS 13.14 Heat Exchanger Lower 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 four bolts securing the combustion box base. 4. Remove the combustion box base. 5.

  • Page 38: Fault Finding

    14.0 FAULT FINDING Is On/Off switch Switch On/Off switch on. On ? Go to Does the fan Is there 230V NO SWITCHED LIVE run ? sL to N ? section of the fault finding instructions. Go to Does a spark IGNITION LOCKOUT occur ? section of the fault...
  • Page 39 14.0 FAULT FINDING No Switched Live boiler supply Replace with 3A fuse. fuse OK ? Is there 230 V at mains No mains supply to input terminal boiler. block (A) ? there 230 V at control PCB transformer Replace control PCB. mains connection (B) ? Is there...
  • Page 40 14.0 FAULT FINDING No Pump Feed Replace safety Safety Thermostat thermostat (black) open circuit ? Fan Protection Replace fan Thermostat protection thermostat. open circuit ? Replace flow thermistor resistance temperature between 0.5kΩ and thermistor (red) 20kΩ ? combustion box door Replace combustion seal damaged or not box door seal.
  • Page 41 Ignition Lockout 14.0 FAULT FINDING Does Does control PCB fan Reset lockout, Replace fan. connection have connection have does fan run ? 12 Vac across it 12 Vac across it (L) ? (K) ? Replace ignition PCB. Wiring from control Replace control PCB.
  • Page 42 14.0 FAULT FINDING Dry-fire Lockout No Fan Run Is there water in system Fill system and switch pump on. and pump on ? Replace flow thermistor between temperature 0.5kΩ and 20kΩ ? thermistor (red) thermistor short Replace thermistor. circuit ? Replace control PCB.

  • Page 43: Short Parts List

    15.0 SHORT PARTS LIST Short Parts List Key G.C. Description Manufacturers Part No. E06 058 Flow Temperature Thermistor (Red) 240670 E06 059 Flow Switch 242459 E06 060 Safety Thermostat (Black) 242235 Control PCB 5106588 (24 HE) Control PCB 5106791 (15 HE) E06 065 Ignition PCB 241838...
  • Page 44 B A X I P O T T E R T O N A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www.potterton.co.uk company...

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Promax 24 he

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