Table of Contents
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Installation & Servicing Instructions
About the Boiler
See inside cover for models covered by these instructions.
This is a Floor Mounted Fan Assisted Balanced Flue Gas Boiler.
This boiler is for use with Natural Gas (G20) only at 20 mbar and for use in GB/IE only.
About Safety
The Gas Safety (Installation and Use) Regulations.
'' In your own interest, and that of safety, it is law that all gas appliances are installed by
competent persons, in accordance with the above regulations. Failure to install appliances
correctly could lead to prosecution.''
Installation must be in accordance with the Installation & Service Instructions and the rules in
force.
Read these Instructions before installing or lighting the boiler
Leave these Instructions and the Benchmark Log Book with the user for use on future
calls.
Powermax HE
85, 115 & 150 Litre
Condensing Boilers with
Integrated Hot Water Storage
MON
TUE WED THU FRI SAT SUN
P.M
OFF
OFF
TIMED
TIMED
ONCE
ONCE
ON
ON
TIME ON 1 ON 2 ON 3
A
DAY
OFF 1
OFF 2
OFF 3
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Table of Contents
Related Manuals for Potterton Powermax HE 85 Litre
Summary of Contents for Potterton Powermax HE 85 Litre
- Page 1 Installation & Servicing Instructions Powermax HE 85, 115 & 150 Litre Condensing Boilers with Integrated Hot Water Storage TUE WED THU FRI SAT SUN TIMED TIMED ONCE ONCE TIME ON 1 ON 2 ON 3 OFF 1 OFF 2 OFF 3 About the Boiler See inside cover for models covered by these instructions.
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Page 2: Table Of Contents
Location of Boiler..........8 Record Log Book Compartment Installation & Ventilation..........9 Potterton is a member of the Benchmark initiative and Flue Systems..........9 fully supports the aims of the programme. Benchmark Water Supply & Systems.......13 has been introduced to improve the standards of Discharge Pipework........14... -
Page 3: Panel Removal
Panel Removal Important: Refer to Page 8 for Storage, Unpacking and Handling Instructions. Top & Bottom Section Handholds Top Section Manual Air Vent (below Top Panel) Pipes connected to Serial Number/Data Badge Bottom Section: Auto Air Vent (access panel) DHW Sensor Cable (in carrying position) Electrical Diagram Drain Connection... -
Page 4: Technical Data
Technical Data Unless indicated, data shown relevant to all models 85 litre 115 litre 150 litre Classifications Appliance catergory CAT I 2 H Flue Type C 13 - C 33 - C 53 (as supplied) NOx Class 5 (< 70 mg/kWh) Cylinder Insulation CFC, HCFC = 0% Input (hot water/central heating) - gross... - Page 5 Note: Note: Cupboard At these minimum clearances above Removable Top Panel intended the appliance, adequate working to provide access MUST be provided. access. min * 650 max Removable Top Panel min * Door Frame * 400 mm Recommended Typical Bulkhead Installation Typical Cupboard Installation with rearwards horizontal concentric flue with twin vertical air/flue pipes...
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Page 6: Introduction
Introduction Important - Installation, Commissioning, Service & Operation Repair The boiler control works on the principle of “hot water This appliance must be installed in accordance with the priority” so the central heating output may be manufacturer’s instructions and the regulations in force. temporarily delayed if the hot water temperature Read the instructions fully before installing or using the drops below the selected... -
Page 7: Codes Of Practice
Codes of Practice In GB the following Codes of Practice apply: Standard Scope The appliance is suitable only for installation in GB and IE BS6891 Specification for low pressure gas pipework and should be installed in accordance with the rules in in domestic premises. -
Page 8: Storage, Unpacking And Handling
1. Installation Requirements Storage, Unpacking & Handling from any other appliances in the house and must be governed at the meter. This boiler is delivered in two sections for safety and The gas installation should be in accordance with the ease of handling. -
Page 9: Compartment Installation
Flue Systems 4. The flue pipe must be protected by the ducting All boilers are supplied to accept the Powermax 60 mm supplied by Potterton or by another no less suitable dia. twin flue system, however several flue system non-combustible enclosure. - Page 10 A Terminal contained in IGE technical publication IGE/UP/7 Guard, Part No. P210 is available from Potterton. The available from the Institution of Gas Engineers, 21 guard requires a flat wall surface of approximately 330 Portland Place, London W1N 3AF.
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Page 11: Mini Terminal (500 Mm) (Each)
Concentric Flue Horizontal Terminal Twin Flue Vertical Terminal 300mm min Vertical Pitched Flat Roof Terminal Roof Flashing 2.5m max Flashing 360˚ Flue Roof Reducer (Ø80 to Ø60) Flue Concentric Extension Elbow 135˚ 1.5m max Bend Adaptor 1m min Box Assy. Flue Pipe Ø60 Concentric 12m max... - Page 12 Twin Flue Pitched Roof Terminal Twin Flue Vertical Terminal Flue Air Flue Air Flue Air Twin Flue Double Pitched Roof Terminals Twin Flue Mini Terminals Rear Concentric Terminal Side Concentric Terminal Likely flue positions requiring a flue terminal guard Mini Terminal Assembly Terminal Position with Minimum Distance (mm) For IE, refer to I.S.
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Page 13: Water Supply & Systems
Water Supply siting and regular replenishment to remain operational. They should generally not be fitted where heat could impair their perfomance. Other types of device can Mains Supply Requirements inhibit scale formation but their effectiveness may vary. It is essential that the mains supply pressure and flow The manufacturers of any water conditioning device availability are capable of meeting both the hot and cold should be consulted regarding its suitability for the... -
Page 14: Discharge Pipework
Building discharges a wire cage or similar guard is Control Officer or Potterton. positioned to prevent contact, whilst maintaining visibility. G3 Requirement “...there shall be precautions ... to ensure that the hot water discharged from safety iii. - Page 15 • Under No circumstances should the factory 300mm min. above fitted Temperature/Pressure Relief Valve be Fixed removed other than by Authorised Potterton Grate personnel. To do so will invalidate any warranty or claim. 450mm min. • The cold water Inlet Control Group must be...
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Page 16: Installation
2. Installation Install the boiler 5. Release DHW temperature sensor and un-roll cable. Route cable behind cylinder pipes and push sensor fully home (approx. 310mm - 12”) into the pocket in the Before starting an installation, check that the correct flue cylinder. - Page 17 Domestic Hot Water Sensor Isolating Valve Plumbing Pressure Gauge 'NO GO' Area Immersion Filling Loop Heater (Optional) Potterton Powermax HE Pipework shown as this 150 litre model shown NOT SUPPLIED D.H.W. CH Flow Outlet Gas Inlet Discharge Pipe CH Return Mains Cold Inlet Fig.
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Page 18: Connect The Water Supply
Connect the Water System For most systems, pump speed 2 will suffice. Using speed 1 will impair domestic hot water recovery. Speed 3 will be required for high resistance systems such See Figs. 10 and 11. Observe guidance provided in as those controlled by TRVs and/or utilising plastics Section 1.6. - Page 19 Ø240mm Wall Bolts & Plugs Washer Threaded Secondary Expansion Vessel 400mm Expansion Vessel Support Bracket Nut & Washer Expansion Vessel Support Strap 15mm Inlet Control Group (set pressure 2.5 bar) Expansion Relief Valve (8.0 bar) Stop 15mm Valve Mains 22mm 22mm Cold Inlet and cold...
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Page 20: Connect The Condensate Pipe
Condensate Drain Pipe Washer Seal Before fitting, fill the condensate trap with water. The condensate pipe should be run in 21.5/22.0 mm diameter plastic material suitable for operation at 60° C. Solvent weld PVC overflow is Boiler recommended or a PP system can be used. Condensate Copper tube must not be used. - Page 21 1. Connect the incoming electricity supply cable to the user terminal as shown below ensuring Fig. 13 that the green/yellow earth conductor is WARNING DISCONNECT ELECTRICITY BEFORE REMOVING longer than the blue neutral and brown live THIS COVER conductors. Secure the cable to the Front View of Control Box anchorage clamp and route via the bushing in the L.H.
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Page 22: Optional Immersion Heater
Optional Immersion Heater This heater is rated 3 kW at 240 V only and must be wired to a totally separate, suitably rated main supply. THERE MUST BE NO INTERCONNECTION WITH THE WIRING TO THE BOILER. Warning: THIS HEATER MUST BE EARTHED. H.W. -
Page 23: Control Panel, Display & Diagnostics
Control Panel, Displays & Diagnostics The boiler control fitted to Powermax HE has been designed to provide safe, reliable and economical operation of the boiler - see Fig. 15 for a guide to the control panel. Fault finding, during both commissioning and subsequent maintenance is much simplified by the clear display of lockout and error codes which appear in the ‘Status/Error Code Display’. -
Page 24: Commissioning
When checking for gas soundness open only be carried out by a suitably qualified all windows and doors in the room. person. Potterton offer this service Extinguish all naked lights, cigarettes, pipes, etc. on a chargeable basis. Publication No. 5106226... -
Page 25: Commission The Boiler
3.1 Commission the Boiler Top up if required. Loosen bleed screw for pump spindle to remove air and re-tighten. Important - An automatic air vent is built into the pump 10.Use the programmer CH and HW buttons to and the cap on the air bleed valve should be closed after alternately select central heating and hot water. -
Page 26: Hand Over To The User
3. Press the DHW select button to switch hot water on 4. With flow to the CH circuit, bleed every radiator and (green neon stays on). the pipework high points until all air or air/water mix 4. Press reset button to scroll through LH window until has been removed. -
Page 27: Service & Replacement Of Parts
4. Service & Replacement of Parts To ensure safe, efficient operation of the boiler, it is pressure to approx. 2.5 to 2.8 bar (36 to 40 psi). necessary to carry out routine servicing at regular Note: Vessel pressure can not be accurately set with intervals. -
Page 28: General Access
General Access Warning: Before attempting to remove any General Access component from the boiler first disconnect the mains electricity supply by removing the plug from the wall Uunscrew Top Panel socket or by switching off the boiler at the external and lift away isolating switch. -
Page 29: Expansion Vessel/Pump
Expansion Vessel/Pump Isolating Isolating Valve Valve Re-assemble all parts in reverse order. Open 1. Perform 4.1 General Access. Also remove Auto the moulded facsia panel (2 screws). Vent 2. Isolate three valves as shown and open Gas Cock the cap on the auto air vent. 3. -
Page 30: Pressure Sensor/Pressure Relief Valve
Pressure Sensor/PRV Isolating Isolating Valve Re-assemble all parts in reverse order. Valve Open 1. Perform 4.1 General Access. Auto 2. Isolate three valves as shown and open Vent the cap on the auto air vent. Gas Cock 3. Release pressure by opening the pressure relief valve. -
Page 31: Air/Gas Valve/Injector/Fan
Air/Gas Valve/Injector/Fan CH Flow Re-assemble all parts in reverse order. 1. Perform 4.1 General Access. Venturi Flue Gas Test Point 2. Isolate the gas cock. Gas Cock 3. Air/Gas Valve Air/Gas Gas Pipe Valve Important: DO NOT attempt to replace the air/gas valve unless a combustion analyser is available. -
Page 32: Spark Generator/Ignition Electrode
Spark Generator/Ignition CH Flow Electrode Re-assemble all parts in reverse order. Burner Heat 1. Perform 4.1 General Access. Exchanger Gas Cock 2. Isolate the gas cock. Spark 3. Spark Generator Generator Carefully disconnect the electrode lead from the spark generator. Remove supply cable from top of boiler control - see Fig. -
Page 33: Boiler Control Assembly
Boiler Control Assembly Front Fascia Warning: The fan operating voltage is 325V d.c. Take appropriate precautions. Allow at Remove Front Fascia least 40 seconds to elapse before handling Side Support the PCB within the boiler control assembly. Remove Front Fascia Securing Screws Re-assemble all parts in reverse order. -
Page 34: Diverter Valve Actuator
Diverter Valve Actuator Overheat Thermostat Temp. Flow Sensor Re-assemble all parts in reverse order. Electrical Electrical 1. Perform 4.1 General Access. Cable (Red) Cable (White) 2. Disconnect the electrical connector at the actuator. 3. Release the locking catch and twist the actuator until it unlocks from the valve and remove from the boiler. -
Page 35: Heat Exchanger
4.12 Heat Exchanger Heat Exchanger Note: Replacing the heat exchanger involves disconnecting the appliance from the flue and air pipes. It is essential that the flue system is fully reinstated and tested so recommend that appropriate replacement flue pipe and fittings be obtained before starting this work. -
Page 36: Wiring Diagrams
DIVERTER IONISATION 'HUBA' PRESSURE VALVE D.H.W. PROBE PUMP GAS VALVE TRANSMITTER TEMP RETURN FLOW SENSOR SENSOR O/HEAT SENSOR CONN LATCHES G/Y G/Y HT LEADS G/Y G/Y BL BR DIAGNOSTIC C1206 C1212 C1176 C1205 C1203 C1204 C1202 C1515 SPARE C1211 PORT J14 J13 HIGH VOLTAGE CONNECTIONS LOW VOLTAGE CONNECTIONS... - Page 37 Wiring Visual Reference Alternative Ignition Electrode Cable Alternative Ionisation Probe Lead Temperature Ignition Temperature Electrode Valve Valve Return Sensor Flow Sensor Ignition Earth Earth Connector Electrode Cable Ionisation Probe Cable Cable Overheat Earth Thermostat Pump Diverter Cable Valve Cable Spark Temperature Generator Return &...
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Page 38: Fault Finding Guide
6. Fault Finding Guide Boiler Fault Finding A 01 Status/Error Code Display - Burner fails to light - Lock out light 'ON' - Reset & check Is there negative pressure developed of at least Live Change 150 Pa (1.5 mbar) at the gas valve outlet pressure point. to fan? Boiler Control Is there gas pressure during cycle? -
Page 39: Diagnostic Codes
DISPLAY MESSAGE ACTION / REMEDY FURTHER ACTIONS CODE (INFORMATION / FAULT) A 01 Burner failed to light Check gas supply and gas valve operation Check fan and spark operation. Check flue for blockage Clean or replace ionisation probe & lead Check condensate outlet not blocked &... -
Page 40: Short List Of Spares
7. Short List Of Spare Parts Fig. 27 Publication No. 5106226 Short List of Spare Parts... - Page 41 Drg. No. G.C. No. Description Qty. Part No. E83 458 Fan Assembly c/w ‘O’ Ring & Gasket 5106279 E83 462 Gas Valve Assembly c/w 3 off ‘O’ Rings 5106280 E83 465 Boiler Control Assembly 5106281 (Use with ‘Ranco’ sensor only) H00 266 Boiler Control Assembly 5107535...
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Page 42: Gas/Air Valve Setup Procedure
Gas/Air Valve Setup Procedure Procedure to correctly set new Air/Gas Valve using a micro-manometer. Venturi Flue Gas Test Point 1. Loosen screw in outlet pressure test point and connect to ‘+’ (positive) side of Air/Gas differential micro-manometer. Valve Tee the ‘-’ (negative) side of the micro- manometer into the air signal tube. - Page 43 7. After 2 minutes, the boiler control will return to normal operation. Maintain full central heating demand (or if this is not possible, draw hot water from a bath tap) to cause the fan speed to increase to maximum. 8. Check CO 2 content of the flue gas indicated by combustion analyser.
- Page 44 All goods are sold subject to our standard Conditions of Sale which are available on request. BAXI POTTERTON A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP Website www.potterton.co.uk...
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Page 45: Contents
Installation Instructions - Powermax HE Flue Systems 85, 115 & 150 Litre Condensing Boilers with Integrated Hot Water Storage These instructions cover the installation of the following kits and their options: Concentric Flue - Horizontal Terminal, Page 5 Twin Flue - Vertical Terminal, Page 10 Twin Flue - Pitched Roof Terminal, Page 12 Twin Flue - Mini Horizontal Terminal, Page 13 Contents... - Page 46 A Terminal Advice on gas installations in timber framed buildings is Guard, Part No. P210 is available from Potterton. The contained in IGE technical publication IGE/UP/7...
- Page 47 Concentric Flue Horiz. Term. (System 1) Twin Flue Vertical Term. (System 2) 300mm min Vertical Pitched Flat Roof Terminal Roof Flashing Flashing 2.5m max 360˚ Flue Roof Reducer (Ø80 to Ø60) Flue Concentric Extension Elbow 135˚ 1.5m max Bend Adaptor 1m min Box Assy.
- Page 48 Mini Terminal Assembly Horizontal Terminal Position with Minimum Distance (mm) 300 min. 300 min. Fanned Draught Balanced Flue Flue A Directly below an opening, air brick, opening window etc. B Above an opening, air brick, opening window, etc. Property C Horizontally to an opening, air brick, opening window etc.
- Page 49 Concentric Balanced Flue System 105mm Minimum Dimensions in mm with rear The concentric balanced flue system is facing Concentric Rear Flue recommended for use with appliances sited near Concentric Flue (300 min.) an outside wall. The Concentric Flue Kit (Part Flue 5106273) includes all the components Outer Wall...
- Page 50 Guidance Notes on Twin Flue Installations Twin Flue Pitched Roof Terminal The air pipe MUST NOT BE LESS than 3/4 of the length of the flue pipe. See Fig. 7. Warning Cutting Extensions Note that the length of the Air Inlet Pipe MUST not be less than 0.75 x length All flue components contain rubber lip seals to ensure both ease of the Flue Pipe...
- Page 51 Flue Duct This kit covers pipe lengths from 0.5 m to 1.45 m Fixing Flue Bracket Pack Pipe Rail Part No. 5106207 Wall Clamps 1. Measure length of flue/air pipes to be Wood Screw Ø60 covered. Set the short and long covers to the Cut Threaded Rod to required length required length and secure through the...
- Page 52 Twin Flue Vertical Terminal Kit Twin Flue Pitched Roof Kit Vertical Concentric Pitched Roof Pitched Roof Terminal (25˚- 45˚) Part No.5106164 Terminal Flashing Pitched Roof Part No. Part No.5106213 Terminal 15-25˚= P231 25-45˚= P232 35-55˚= P233 Terminal Stabilising Bracket 4.5m Twin Flue Pipe Kit (for Pitched Roof Term) Part No.5106259 Mini Terminal...
- Page 53 Twin Flue Mini Terminal Kits Pitched Roof Terminal (25˚- 45˚) Part No.5106164 2 Mini Mini Terminals Part No. Terminals Matt Black = 5106261 (standard finish) Pitched Roof Terminal Stone = 5106262 Light Brick = 5106263 Red Brick = 5106264 500mm Twin Flue Options Slate = 5106265...
- Page 54 Twin Flue with Vertical Balanced Flue Vertical Concentric Terminal Terminal Vertical Part No.5106213 Used in conjunction with the standard 60 mm twin Terminal pipe system the Powermax Vertical system offers Ø390 an unobtrusive balanced flue terminal as an easy Flat Roof Flashing to fit option for both pitched and flat roofs.
- Page 55 Note: Damage to the seals could result in Flat Roof Flashing condensate/flue products leakage from the flue Felt Roof system. 100mm Felt Collar Top Felt Layer Note: Due to the high efficiency and reduced Bitumen flue gas temperature of the Powermax HE, little Bottom Felt or no buoyancy is generated in a vertical length of the 60 mm Ø...
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Page 56: Pitched Roof Terminal
Twin Flue with Pitched Roof Terminal Used in conjunction with the standard 60 mm diameter twin pipe flue system, the Powermax Pitched Roof Terminal (Part No. 5106164) provides an unobtrusive alternative where horizontal mini terminals are not practical. This terminal is supplied with a 0.5 m x 0.5 m universal lead slate;... - Page 57 Twin Flue with Horizontal Mini Terminal Flue The Mini Terminal flue system provides an 2˚ Angle unobtrusive arrangement. Separate 60 mm diameter air inlet and flue terminal assemblies can be positioned in different locations on the same wall Flue Air Twin Flue Mini subject to similar wind conditions.
- Page 58 Installing Mini Terminal Flues a. Measure and cut the first pair of flue pipes away from the appliance. Push pipes fully into the sockets on top Mark the positions of the air/flue terminals and core drill 70 of the boiler whilst also fitting the flue duct prepared as mm (2¾) diameter holes.
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Page 59: Fittings Factor
Guidance on Unusual Twin Flue Installations Table of Flue Resistance Factors : Component factor The following notes offer guidance regarding the relationship between the maximum flue length and the Mini Terminal (500 mm) (each) number of bends allowed in a twin flue system. Pitched Roof Terminal Vertical Terminal (inc. - Page 60 All goods are sold subject to our standard Conditions of Sale which are available on request. BAXI POTTERTON A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN Website www.potterton.co.uk...
- Page 61 Red neon - indicates that the boiler has gone to lock out Benchmark Log Book and Potterton Warranty Envelope. and needs to be reset by pressing the Lock-Out reset button.
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Page 62: About The Boiler
Record Log Book gas supplier or service engineer. Potterton is a member of the Benchmark initiative and fully • Flammable materials must not be stored in close supports the aims of the programme. Benchmark has proximity to the boiler. - Page 63 Lighting How your boiler Works Check that the mains electricity and gas supply are both Control of the Boiler turned ON. The amber neon on the control will light The boiler is fitted with a control panel which indicates when electricity is being supplied. Set the boiler On/Off basic functions and also contains a programmer.
- Page 64 Things you need to be aware of during periods of cold weather we recommend leaving your boiler on and adjusting your control system (e.g thermostat) to suit. Air Locks The boiler pump is fitted with an automatic air vent and Condensate Outlet Pipe will bleed air from the boiler when required.
- Page 65 How to set the Programmer This section is relevant only if your programmer has If you wish to return to the built in time periods, after been enabled. Refer to 'Programmer not working' on changes have been made to them, firstly ensure the Page 7 if unsure.
- Page 66 How to set the Programmer 1.0 Normal Operation 1.1 During normal operation the display will show the day, time TIMED TIMED ONCE ONCE and programme option selected e.g. OFF, TIMED, ONCE or ON. 2.0 Setting the Time & Day 2.1 Press SET/RUN. The time will be now be displayed and the hours will flash.
- Page 67 * If repeated, renew sensor or cable E 42 Internal boiler control error Switch electricity off - on. Try re-starting If repeated, call Powermax service * Work to be performed by Baxi Potterton/Corgi technician only MAX0055C User’s Instructions Publication No. 5106228...
- Page 68 5106228 - Iss. 04 Publication No. (02/2004) When contacting Baxi Potterton please have the General Enquiries (GB) following information to hand: 08706 060 780 Tel. Appliance Name Model Number Sales (GB) Serial Number 08706 060 403 Tel. The Label (detailing serial and G.C. numbers) is 01772 695 416 behind the top front panel.