Potterton HE Plus Installation and maintenance instructions

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© Baxi Heating UK Ltd 2007
Installation & Service Instructions Promax System
HE Plus
Range
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.

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2© Baxi Heating UK Ltd 2007
Natural Gas
Potterton Promax System 12 HE Plus
G.C.No41 591 90
Potterton Promax System 15 HE Plus
G.C.No41 591 91
Potterton Promax System 18 HE Plus
G.C.No41 591 92
Potterton Promax System 24 HE Plus
G.C.No41 601 21
Potterton Promax System 32 HE Plus
G.C.No41 591 93
Building Regulations and the Benchmark Commissioning
Checklist
Building Regulations (England & Wales) require notification of
the installation of a heating appliance to the relevant Local
Authority Building Control Department. From 1 April 2005 this
can be achieved via a Competent Persons Self Certification
Scheme as an option to notifying the Local Authority directly.
Similar arrangements will follow for Scotland and will apply in
Northern Ireland from 1 January 2006.
CORGI operate a Self Certification Scheme for gas heating
appliances.
These arrangements represent a change from the situation
whereby compliance with Building Regulations was accepted as
being demonstrated by completion of the Benchmark Logbook
(which was then left on site with the customer).
With the introduction of Self Certification Schemes, the
Benchmark Logbook is being withdrawn. However, a similar
document in the form of a commissioning checklist and service
interval record is incorporated at the back of these instructions.
This company is a member of the Benchmark initiative and fully
supports the aims of the programme. Its aim is to improve the
standards of installation and commissioning of central heating
systems in the UK and to encourage the regular servicing of all
central heating systems to ensure safety and efficiency.
Building Regulations require that installations should comply
with manufacturer's instructions. It is therefore important that
the commissioning checklist is completed by the installer. The
relevant section of Building Regulations only relates to
dwellings. Therefore the checklist only applies if the appliance is
being installed in a dwelling or some related structure.
The flowchart opposite gives guidance for installers on the
process necessary to ensure compliance with Building
Regulations.
Baxi Heating UK Ltd is a
BS-EN ISO 9001 Accredited Company
The code of practice for the installation,
commissioning & servicing of central
heating systems.
“Potterton” supports
© Baxi Heating UK Ltd 2007 All rights reserved. No part of this publication may
be reproduced or transmitted in any form or by any means, or stored in any
retrieval system of any nature (including in any database), in each case whether
electronic, mechanical, recording or otherwise, without the prior written
permission of the copyright owner, except for permitted fair dealing under
Copyrights, Designs and Patents Act 1988.
Applications for the copyright owner’s permission to reproduce or make other
use of any part of this publication should be made, giving details of the proposed
use, to the following address:
The Company Secretary, Baxi Heating UK Ltd, Pentagon House,
Sir Frank Whittle Road, Derby, DE21 4XA.
Full acknowledgement of author and source must be given.
WARNING: Any person who does any unauthorised act in relation to a
copyright work may be liable to criminal prosecution and civil claims for damages.
This product has an energy rating (A) on a scale of A to G.
For more information see www.boilers.org.uk. This is a certification mark.

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3
Installer Notification Guidelines
© Baxi Heating UK Ltd 2007
Choose Building
Regulations Notification
Route
Contact your relevant Local
Authority Building Control
(LABC) who will arrange
an inspection or contact
a government approved
inspector
LABC will record the data
and will issue a
certificate of compliance
CORGI will record the data and
will send a certificate of
compliance to the property
You must ensure that the
notification number issued by
CORGI is written onto the
Benchmark Checklist
Scheme Members only
Call CORGI on: 0870 88 88 777
or log onto:
www.corgi-notify.com
within 10 days
If you notify via CORGI Scheme,
CORGI will then notify the
relevant Local Authority
Building Control Scheme
on member's behalf
Complete the
Benchmark Checklist
Install and Commission this
appliance to manufacturer's
instructions
Competent Person's
Self Certification Scheme Building Control
Complete the
Benchmark Checklist
Install and Commission this
appliance to manufacturer's
instructions

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4
Legislation
© Baxi Heating UK Ltd 2007
Codes of Practice - refer to the most recent version
IMPORTANT - Installation, Commissioning, Service & Repair
This appliance must be installed in accordance with the manufacturer’s instructions and
the regulations in force. Read the instructions fully before installing or using the
appliance.
In GB, this must be carried out by a competent person as stated in the Gas Safety
(Installation & Use) Regulations.
Definition of competence: A person who works for a CORGI registered company and
holding current certificates in the relevant ACS modules, is deemed competent.
In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic
Gas Installations”.
The addition of anything that may interfere with the normal operation of the appliance
without express written permission from the manufacturer or his agent could invalidate
the appliance warranty. In GB this could also infringe the Gas Safety (Installation and
Use) Regulations.
Warning - Check the information on the data plate is compatible with local supply
conditions.
All CORGI registered installers carry a CORGI identification card and have a
registration number. You can check your installer is registered by telephoning 0870
4012300 or writing to:-
1 Elmwood,
Chineham Business Park,
Crockford Lane,
Basingstoke. RG24 8WG
or check online at www.corgi-gas-safety.com
This company declare that no substances harmful to health
are contained in the appliance or used during appliance
manufacture.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force, and
only used in a suitably ventilated location.
In GB, the installation must be carried out by a CORGI
Registered Installer. It must be carried out in accordance with
the relevant requirements of the:
• Gas Safety (Installation & Use) Regulations.
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
• The Water Fittings Regulations or Water Byelaws in
Scotland.
• The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a competent
Person and installed in accordance with the current edition of
I.S. 813 ‘Domestic Gas Installations’, the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
All systems must be thoroughly flushed and treated with
inhibitor (see section 6.2).
In GB the following Codes of Practice apply:
Standard Scope
BS 6891 Gas Installation.
BS 5546 Installation of hot water supplies for domestic
purposes.
BS 5449 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.
In IE the following Codes of Practice apply:
Standard Scope
I.S. 813 Domestic Gas Installations.
The following standards give valuable additional information;
BS 5546 Installation of hot water supplies for domestic
purposes.
BS 5449 Forced circulation hot water systems.
BS 7074 Expansion vessels and ancillary equipment for
sealed water systems.
BS 7593 Treatment of water in domestic hot water
central heating systems.
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 0085.
Product/Production certified by:
Notified Body 0085.
For GB/IE only.

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5
Safe Manual Handling
© Baxi Heating UK Ltd 2007
General
The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.
Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands.
Health & Safety is the responsibility of EVERYONE.
There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.
Do not handle or lift unless you feel physically able.
Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.
Preparation
Co-ordinate movements - know where, and when, you are both going.
Minimise the number of times needed to move the boiler - plan ahead.
Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care
on ladders/into lofts.
Technique
When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and
sideways and keep the load as close to your body as possible.
Where possible transport the boiler using a sack truck or other suitable trolley.
Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the
‘Installation’ section of these instructions for recommended lift points.
Remember
The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.
If at any time when installing the boiler you feel that you may have injured yourself STOP !!
DO NOT ‘work through’ the pain - you may cause further injury.
IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

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6© Baxi Heating UK Ltd 2007
CONTENTS
1.0 Introduction 7
2.0 General Layout 8
3.0 Appliance Operation 9
4.0 Technical Data 10
5.0 Dimensions and Fixings 11
6.0 System Details 12
7.0 Site Requirements 14
8.0 Flue Options 18
9.0 Plume Displacement 23
10.0 Installation 27
11.0 Commissioning 32
12.0 Completion 34
13.0 Servicing 35
14.0 Changing Components 37
15.0 Combustion Check 45
16.0 Electrical 46
17.0 Short Parts List 47
18.0 Fault Finding 48
Benchmark Checklist 54
Section Page

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1.0 Introduction
© Baxi Heating UK Ltd 2007
1.1 Description
1. The Potterton Promax System HE Plus is a fully automatic
gas fired wall mounted condensing system boiler. It is room
sealed and fan assisted.
2. The boiler is set to give a maximum output of :-
12 models - 12 kW
13 kW (Condensing)
15 models - 15 kW
16.2 kW (Condensing)
18 models - 18 kW
19.4 kW (Condensing)
24 models - 24 kW
25.9 kW (Condensing)
32 models - 32 kW
34.4 kW (Condensing)
3. It is designed for use on Natural Gas (G20).
4. The boiler incorporates a circulating pump and expansion
vessel. It is suitable for use only on fully pumped sealed
systems.
5. The boiler data badge gives details of the model, serial
number and Gas Council number and is situated on the inner
door panel. It is visible when the case front panel is removed
(Fig. 1).
6. The boiler model name and serial number are also shown
on the information label on the rear of the lower door panel.
This is for user reference.
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 no.
5118489.
9. All systems must be thoroughly flushed and treated with
inhibitor (see section 6.2).
1.2 Contents of Pack
The pack contains:-
• Boiler
• Wall Plate (including taps)
• Set of Pipe Connections
• Template
• Literature Pack
Fig. 1
Control Box
Case Front Panel
Data Badge
Information Label

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2.0 General Layout
© Baxi Heating UK Ltd 2007
2.1 Layout
1. Expansion Vessel
2. Automatic Air Vent
3. Circulation Pump
4. Drain Off Point
5. Pressure Relief Valve
6. Selector Switch
7. Central Heating System Pressure Gauge
8. PCB
9. Control Box
10. Gas Valve
11. Condensate Trap
12. Flame Sensing Electrode
13. Spark Electrode
14. Primary Heat Exchanger
15. Fan Assembly
16. On/Off/Reset Selector Switch
17. Central Heating Temperature Control
18. Calibration Control
19. Venturi
20. Air/Gas Collector
21. Combustion Box Cover & Burner
22. Igniter
23. Burner On Light
24. Central Heating Mode Light
25. Display
1
16 17 18 7
Reset
bar
0
1
2
3
4
21
2
3
4
5
6
7
8
9
10
11
12
13
14
15
19
20
22
23
24
25

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3.0 Appliance Operation
© Baxi Heating UK Ltd 2007
3.1 Operating Mode (Fig. 2)
1. With a demand for heating or hot water, the pump
circulates water through the primary circuit. If the pressure is
at least 0.5 bar and the ignition sequence will start.
2. When the flow temperature exceeds the setting
temperature, a 3 minute delay occurs before the burner
relights automatically (anti-cycling). The pump continues to
run during this period.
3. When the demand is satisfied the burner is extinguished
and the pump continues to run for a period of 3 minutes
(Pump Overrun).
IMPORTANT: When the selector switch is in the ‘0’
(Off) position the electrical supply to the boiler is
isolated. The boiler will not operate.
3.2 Frost Protection Mode
1. The frost protection mode is integral to the appliance and
functions when the selector switch (see Section 2.1) is in the
ON position ( ). If the system temperature falls below
5° C then the boiler will fire on its minimum setting until a
flow temperature of 30° C is reached. Further protection
can be incorporated by using a system frost thermostat.
3.3 Pump Protection
1. With the selector switch (see Section 2.1) in the ON
position ( ) the pump will automatically operate for 1
minute in every 24 hours to prevent sticking.
1
2
4
5
6
7
8
19
18
9
10 1211
14
13
15
16
17
3
Key
1 Heat Exchanger
2 Burner
3 Ignition Electrode
4 Flame Sensing Electrode
5 Gas Valve
6 Pump
7 Automatic Air Vent
8 Pressure Relief Valve
9 Boiler Drain Point
10 Gas Inlet
11 Boiler Flow
12 Boiler Return
13 Pressure Gauge
14 Automatic By-Pass
15 Water Pressure Sensor
16 Safety Thermostat
17 Temperature Sensor
18 Expansion Vessel
19 Return Temperature Sensor
20 Fan
Boiler Primary Circuit
Fig. 2
20

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10 © Baxi Heating UK Ltd 2007
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 have been certified by 0085.
SEDBUK Declaration For Promax System HE Plus
The seasonal efficiency (SEDBUK) is:-
90.2% (15, 18 & 24) 90.1% (12 & 32) Band A
4.0 Technical Data
4.1 Promax System 12,15,18, 24, & 32 HE
Flue Terminal Diameter 100mm
Dimensions Projection 125mm
Outercase Dimensions
Casing Height - 780mm
Overall Height Inc Flue Elbow - 965mm
Casing Width - 450mm
Casing Depth - 345mm
Central Heating Primary Circuit
Pressures
bar
Safety Discharge 3
Max Operating 2.5
Min Operating 0.5
Recommended Operating Range 1-2
Pump
Available Head See graph below
Expansion Vessel - (Integral with appliance)
bar
Min Pre-charge Pressure 0.5
litre
Max Capacity of
CH System 125
Primary Water Content
of Boiler (unpressurised) 2.5
Connections copper tails
Gas Supply - 22mm
Central Heating Flow - 22mm
Central Heating Return - 22mm
Pressure Relief Discharge - 15mm
Temperatures
Flow Temp (adjustable)
25°C to 80°C max (± 5°C)
NOxClass 5
0
200 400 600 800 1000 1200
0.5
1
1.5
2
2.5
3
3.5
4
Metre (wg)
Flow Rate (l/h)
Pump - Available Head
0
5
5.5
4.5
Clearances
Above Casing 200 mm Min
Below Casing 200 mm Min
Front 450 mm Min (For Servicing)
Front 5 mm Min (In Operation)
L.H. Side 5 mm Min
R.H. Side 5 mm Min (In Operation)
Heat Input (Net) Max Min
12 model kW 12.4 4
15 model kW 15.4 3.9
18 model kW 18.5 4.3
24 model kW 24.7 7
32 model kW 32.8 9.7
Heat Output (Non-Condensing)
Max Min
12 model kW 12 3.9
15 model kW 15 3.9
18 model kW 18 4.2
24 model kW 24 6.8
32 model kW 32 9.4
Electrical Supply 230V~ 50Hz
(Appliance must be connected to an
earthed supply)
Power Consumption
12 model 145W
15 model 130W
18 model 140W
24 model 150W
32 model 160W
Electrical Protection
IPX5D
Internal Fuse Rating F2L
Appliance Category CAT I 2H
Inlet Pressure (Natural Gas - G20)
mbar 20
Injector (Natural Gas - G20)
12 model 4mm
15 model 4.5mm
18 model 5.7mm
24 model 7.5mm
32 model 12mm
Appliance Type C13 C33 C53
Heat Output (Condensing)
Max Min
12 model kW 13 4.2
15 model kW 16.2 4.2
18 model kW 19.4 4.5
24 model kW 25.9 7.4
32 model kW 34.4 10.2
Max Gas Rate (Natural Gas - G20)
(After 10 mins)
12 model m3/h 1.31
15 model m3/h 1.69
18 model m3/h 1.95
24 model m3/h 2.61
32 model m3/h 3.48
Condensate Drain
To accept 21.5mm (3/4in) plastic waste pipe
Heat Input (Gross) Max Min
12 model kW 13.8 4.4
15 model kW 17.1 4
18 model kW 20.5 4.5
24 model kW 27.4 7.8
32 model kW 36.4 10.8
External Fuse Rating 3A
Weights
12, 15 &18 24
Packaged Boiler Carton 52.5kg 53.5kg
Installation Lift Weight 43kg 44kg
32
Packaged Boiler Carton 54.5kg
Installation Lift Weight 45kg