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Potterton 15 HE Plus User Manual

Potterton 15 HE Plus
60 pages
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© Baxi Heating UK Ltd 2009
Installation & Service Instructions
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
Promax
15/2,24/2 & 30
HE Plus
Condensing
Central Heating Boiler
You can rely on
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Potterton 15 HE Plus Specifications

General IconGeneral
Output15 kW
DHW Output15 kW
ErP RatingA
Central Heating Flow Temperature Range30 - 80 °C
Hot Water Flow Rate at 35°C Rise6.1 l/min
Fuel TypeNatural Gas
MountingWall Mounted
CH Output15 kW
TypeCondensing Combination Boiler

Summary

Benchmark Scheme and Regulatory Compliance

The Benchmark Scheme

Explains the purpose and responsibilities of the Benchmark Scheme for installers and manufacturers.

Building Regulations and the Benchmark Commissioning Checklist

Details how Building Regulations compliance is achieved via the Benchmark Checklist and self-certification schemes.

Installer Notification Guidelines

Provides guidance on notifying local authorities or using self-certification schemes for installations.

Installation, Commissioning, Service & Repair Importance

Highlights the critical importance of following manufacturer instructions and regulations for installation and service.

Legislation and Codes of Practice

Outlines relevant UK and IE legislation and codes of practice for gas appliance installation.

Safe Manual Handling Practices

Provides essential advice on safely handling and lifting boilers to prevent injury.

1.0 Introduction and Overview

1.1 Description of Promax HE Plus

Details the boiler's features, output, gas type, and suitability for different heating systems.

1.2 Important Information: Mineral Fibre

Advises on precautions when handling components made from man-made mineral fibre to avoid irritation.

2.0 General Layout and Appliance Operation

2.1 Layout Diagrams

Provides detailed diagrams showing the arrangement of key boiler parts.

3.0 Appliance Operation

Explains the sequence of operation for the boiler during heating and hot water cycles.

4.0 Technical Data and System Details

4.0 Technical Data

Presents comprehensive technical specifications including heat input, output, electrical data, and dimensions.

5.0 Dimensions and Fixings

Details the physical dimensions and fixing requirements for boiler installation.

6.0 System Details

Covers essential information regarding water circulating systems and their treatment.

6.1 Water Circulating Systems

Outlines suitability for open vent and sealed systems and general system conditions.

6.2 Treatment of Water Circulating Systems

Advises on flushing and treating systems to prevent corrosion and maintain warranty.

6.3 Pipework Requirements

Specifies pipe sizing for flow and return, and material requirements for non-metallic pipework.

6.4 Low Head Installation Guidance

Provides instructions for low head installations, including pump placement and vent pipes.

6.5 Pump Installation and System Details

Discusses pump positioning and system configurations for optimal performance.

6.5 System Controls

Explains boiler control requirements for compliance with Building Regulations.

6.7 Sealed Systems Design

Details design considerations and components for sealed central heating systems.

7.0 Site Requirements and Flue Options

7.1 Location Considerations

Discusses suitable locations for boiler installation, including wall mounting and compartment fitting.

7.2 Ventilation of Compartments

Provides minimum dimensions for ventilation when installing the boiler in a cupboard or compartment.

7.3 Clearance Requirements

Details necessary clearances around the boiler for installation and servicing access.

7.4 Gas Supply Specifications

Outlines requirements for gas supply type, pressure, and connection.

7.5 Electrical Supply Requirements

Specifies electrical supply voltage, frequency, and earthing requirements.

7.6 Condensate Drain Installation

Details the correct installation procedure for the condensate discharge pipe.

7.7 Flue Installation Guidelines

Provides crucial guidelines for siting flue terminals and ensuring safe dispersal of combustion products.

8.0 Flue Options Overview

Introduces the available flue systems and their configurations.

8.1 Horizontal Flue Systems

Explains the installation and limitations of horizontal flue systems, including equivalent lengths.

8.2 Twin & Vertical Flue Systems

Details installation requirements and equivalent lengths for twin and vertical flue systems.

8.3 Flue Accessories

Lists available accessories for concentric, twin, and vertical flue systems.

8.4 Vertical Flue System Installation

Describes the process for fitting vertical flue adaptors and terminals.

8.5 Twin Flue System Installation

Outlines the procedure for connecting air and flue adaptors for twin flue systems.

8.6 For Roof Terminals

Provides instructions for installing flue terminals on pitched and flat roofs.

8.7 Flue Dimensions and Equivalencies

Explains how to calculate equivalent flue lengths, considering bends and extensions.

8.8 Terminal Guard Installation

Advises on the use and ordering of terminal guards for flue terminals.

8.9 Flue Deflector Installation

Details how to fit and position the flue deflector for plume management.

9.0 Plume Displacement and 10.0 Installation

9.1 Plume Displacement Kit (P.D.K.)

Lists the contents of the P.D.K. and its recommended use for plume management.

9.2 Determining Permissible Flue Lengths

Uses graphs to help determine permissible concentric and 700 exhaust flue lengths.

9.3 General P.D.K. Fitting Notes

Provides step-by-step instructions for fitting the Plume Displacement Kit.

10.0 Installation Guide

A comprehensive guide to the installation process of the boiler.

10.1 Initial Preparation for Installation

Details essential pre-installation checks, including gas supply suitability.

10.2 Preparing the Boiler for Installation

Outlines the steps to unpack and prepare the boiler unit for mounting.

10.3 Fitting the Boiler to the Wall Plate

Describes the process of mounting the boiler onto the prepared wall plate.

10.4 Making Water Connections

Guides on correctly connecting the flow and return water pipes to the boiler.

10.5 Condensate Drain Connection

Details how to connect the condensate drain pipe and prime the trap.

10.6 Making the Gas Connection

Explains how to safely connect the gas supply to the boiler's gas tap.

10.7 Fitting the Flue Assembly

Provides instructions on how to cut, assemble, and fit the flue system correctly.

10.8 Making Electrical Connections

Details the procedure for making electrical connections to the boiler's control system.

11.0 Electrical and 12.0 Commissioning

11.0 Electrical Schematics

Covers the electrical aspects of the boiler, including diagrams and connections.

11.1 Schematic Wiring Diagram

Shows the detailed electrical connections between components and the PCB.

11.2 Illustrated Wiring Diagram

Provides a visual representation of the boiler's wiring harness and connections.

12.0 Commissioning the Boiler

Outlines the necessary steps and checks for commissioning the boiler after installation.

12.1 Commissioning Procedure

Details the step-by-step process for commissioning, including system checks and adjustments.

13.0 Fitting Outer Case and 14.0 Servicing

13.0 Fitting the Outer Case

Guides on how to refit the boiler's outer casing after installation or servicing.

13.1 Outer Case Fitting Instructions

Specific steps for correctly attaching the outer case and lower door panel.

14.0 Servicing the Boiler

Provides instructions for routine annual servicing of the boiler to ensure safe operation.

14.1 Annual Servicing Steps

Details the procedures for performing annual maintenance and safety checks.

15.0 Component Replacement Procedures

15.1 Component Replacement Safety

Emphasizes isolating gas and electrical supplies before changing any components.

15.2 Flow Temperature Thermistor and Safety Thermostat

Instructions for replacing the flow temperature thermistor and safety thermostat.

15.3 Flowswitch Replacement

Details the procedure for removing and replacing the boiler's flow switch.

15.4 PCB Replacement

Guides on how to replace the Printed Circuit Board (PCB) and its housing.

15.5 Spark and Sensing Electrodes

Instructions for replacing the spark and flame detection electrodes.

15.6 Fan Replacement

Steps for removing and replacing the boiler's fan assembly.

15.7 Injector Pipe Replacement

Procedure for changing the injector pipe connecting to the gas valve.

15.8 Gas Valve Replacement

Instructions for replacing the gas valve, including safety checks.

15.9 Condensate Trap Replacement

Details on how to remove and replace the condensate trap.

15.10 Burner Replacement

Steps for removing and replacing the boiler's burner assembly.

15.11 Heat Exchanger Replacement

Procedure for removing and replacing the heat exchanger and manifold.

15.12 Heat Exchanger Lower Insulation Pad

Instructions for replacing the lower insulation pad within the heat exchanger assembly.

15.13 Heat Exchanger Upper Insulation Pad

Steps for replacing the upper insulation pad in the heat exchanger assembly.

16.0 Short Parts List

17.0 Fault Finding

ELECTRICAL SUPPLY Faults

Guides on diagnosing and resolving issues related to electrical supply problems.

DRY-FIRE Fault Diagnosis

Provides a flowchart for troubleshooting dry-fire conditions and pump faults.

IGNITION LOCKOUT Troubleshooting

Steps to diagnose and resolve ignition lockout errors, including gas and spark issues.

OVERHEAT LOCKOUT Diagnosis

Flowchart for troubleshooting overheat lockout errors, checking thermostats and seals.

FAN LOCKOUT Troubleshooting

Steps to diagnose and resolve fan lockout errors, checking wiring and fan components.

THERMISTOR Fault Diagnosis

Guide for troubleshooting issues related to the thermistor and its wiring.

18.0 Notes

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

SERVICE RECORD

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