Potterton Promax 15 HE Installation And Servicing Instructions
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Potterton Promax 15 HE Installation And Servicing Instructions

Wall mounted powered flue condensing boiler gas firel central heating unit
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Promax 15 HE & 24 HE
Wall Mounted Powered Flue Condensing Boiler
Gas Fired Central Heating Unit
Installation and
Servicing Instructions
Please leave these instructions with the user
Supplied By www.heating spares.co Tel. 0161 620 6677

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Summary of Contents for Potterton Promax 15 HE

  • Page 1: Installation And Servicing Instructions

    Promax 15 HE & 24 HE Wall Mounted Powered Flue Condensing Boiler Gas Fired Central Heating Unit Installation and Servicing Instructions Please leave these instructions with the user Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 2 41 590 62 Guarantee The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations Your Potterton Promax 15 HE or 24 HE 1993 N 3083” and is deemed to meet the requirements of Directive 92/42/EEC on the energy are designed and produced to meet all the relevant Standards.

  • Page 3: Table Of Contents

    Contents Section Page Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Installation Electrical 10.0 Commissioning the Boiler 11.0 Fitting the Outer Case 12.0 Servicing the Boiler 13.0 Changing Components 14.0 Short Parts List 15.0 Fault Finding Supplied By www.heating spares.co Tel.

  • Page 4: Introduction

    Read the instructions fully before installing or using the appliance. 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.

  • Page 5: General Layout

    2.0 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 6: Appliance Operation

    3.0 Appliance Operation Mains On. 1. Switched Live On: When the switched live switches on pump overrun occurs. Pump Overrun Pump Overrun 2. Pump Overrun: The pump is on while the fan, for 1 minute ? 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.

  • Page 7: 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 8: Dimensions And Fixings

    5.0 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 9: System Details

    (Test kits are available from inhibitor stockists.) • For information or advice regarding any of the above contact the Potterton Helpline. Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 10 6.0 System Details Copper Copper 0.5m 0.5m Flow Pipework Boiler Return Copper 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 Fig. 7a connection to the boiler is 28mm (compression). 2.
  • Page 11 6.0 System Details Sealed Systems (Fig. 11) 1. SAFETY VALVE - A safety valve complying with the requirements of BS 6750 Part 1 must be 3 Litre fitted close to the boiler on the flow pipe by Top Up Bottle means of a horizontal or vertically upward (if required) Vent...

  • Page 12: Site Requirements

    WARNING - The addition of anything that may interfere with the normal operation of the Fig. 12 appliance without the express written permission of Potterton could invalidate the appliance warranty and infringe the G AFETY (Installation and Use) R EGULATIONS Clearances (Figs.
  • Page 13 7.0 Site Requirements Ventilation of Compartments (Fig. 14) 1. Where the boiler is installed in a cupboard or compartment, no air vents are required for cooling purposes providing that the minimum dimensions below are maintained. Sides 15mm 200mm Bottom 130mm Front 30mm 2.
  • Page 14 7.0 Site Requirements Flue NOTE: Due to the nature of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. 1. The following guidelines indicate the general requirements for siting balanced flue terminals.
  • Page 15 Pictorial examples of flue runs where EQUIVALENT flue length equals 4m 7.12 Vertical Flue 1. Only a flue approved with the Potterton Promax 15 HE & 24 HE can be used. Fig. 19 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 16 Standard Flue 7.0 Site Requirement 7.13 Flue options Concentric The maximum equivalent lengths are 4m (horizontal) or (vertical). There 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 2m.

  • Page 17: Installation

    8.0 Installation Rear Flue R/H Side Flue Template Check Site Requirements (section 7) before Template commencing. Flow & Return Initial Preparation Pipe Positions The gas supply, gas type and pressure must Centre Hole be checked for suitability before connection Vertical Flue (see Section 7.6).
  • Page 18 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...
  • Page 19 8.0 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 and locate the rear bottom edge onto the self locating support at the base of the wall plate.
  • Page 20 8.0 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 3° the boiler. (1 in 20) Fitting The Flue Before fitting the flue, check the condensate drain integrity (see section 8.5).
  • Page 21 Gasket 13. If necessary fit a terminal guard (see Section 7.11). VERTICAL FLUEING 1. Only a flue approved with the Potterton Promax 15 HE & 24 HE can be used. Fig. 30 Flue Trim Fig. 29...
  • Page 22 (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 23: Electrical

    9.0 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 24 9.0 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 Spark and Input Earth Electrode Wiring Key - Blue bk - Black br - Brown - Red Earth w - White...

  • Page 25: Commissioning The Boiler

    10.0 Commissioning the Boiler 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 26: Fitting The Outer Case

    11.0 Fitting the 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.

  • Page 27: Servicing The Boiler

    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 28 12.0 Servicing the Boiler 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 29: Changing Components

    When the boiler on/off switch is switched off the control 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 30 13.0 Changing Components 13.3 Flowswitch (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. Support Bracket 3. Remove the clip securing the flow pipe to the flowswitch.
  • Page 31 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 32 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 33 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 34 13.0 Changing Components Combustion Box The burner and heat exchanger can be Door Panel 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). 1. Remove the combustion box door by removing the four securing screws (Fig.
  • Page 35 13.0 Changing Components 13.14 Heat Exchanger Lower Insulation (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 36: Short Parts List

    14.0 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 37: Fault Finding

    15.0 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 38 No Switched Live 15.0 Fault Finding 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 39 15.0 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 40 Ignition Lockout 15.0 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 41 15.0 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 42 16.0 Notes Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 43 Baxi UK Limited manufacture a comprehensive range of products for the domestic heating market. Gas Central Heating Boilers (Wall, Floor and Fireside models). Independent Gas Fires. Renewal Firefronts. Gas Wall Heaters. Solid Fuel Fires. If you require information on any of these products, please write, telephone or fax to the Sales Department.
  • Page 44 Potterton, Baxi UK Limited, Brownedge Road, Bamber Bridge, Preston, Lancashire. PR5 6SN After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 www.baxi.com Comp N 5106451 - Iss H - 12/01 Supplied By www.heating spares.co Tel. 0161 620 6677...

This manual is also suitable for:

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