Potterton iHE 100/300 Installation And Servicing Instructions Download Page 3

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iHE

TECHNICAL DATA

Inside cover

SERVICING & MAINTENANCE

GENERAL & SAFETY INFORMATION

COMMISSIONING

Symbols used in this manual

Data plate and CE marking

General

warnings

Safety

Health

Description

appliance

General

Dimensions

INSTALLER INSTRUCTIONS

Unpacking

Location

Water

Connections

Open

vent

Unvented 10

Secondary

return

Condensate

removal

Flue systems & ventilation:

Open

ue type (B

) 12

Room sealed type (C

) 13

Flue

terminal

positions 14

Maximum

lengths

Flue parts identi

cation 16

Gas

connections 17

Electrical

connections

Wiring

diagram

PCB1

Wiring diagram PCB 2 & 3

System

schematic

Filling

the

appliance 22

Starting

the

appliance

Running the circulation pumps

Commissioning the heat engines

Final

checks

User

handover

Frost

protection

Anti-legionella

Fault

nding

Recommended

servicing

Changing

components 28

Cleaning

the

appliance 30

Spare parts identi

cation

Appliance

components 32

Appliance

components 33

Appliance components internal

Fault

codes

(table

Summary of Contents for iHE 100/300

Page 1: ...M6500 M6500 ...

Page 2: ...5 Max permitted operating temperature o C 82 82 Flow Return connections BSP F 2 F 2 Fill drain connection BSP M M HOT WATER Tank capacity litres 300 300 Recovery rate through 50 C l h 1 520 2 240 Time to recover tank through 50o C mins 12 9 Operating pressure max min bar 6 0 0 2 6 0 0 2 In Out connections BSP M 1 M 1 Water return connection BSP M 1 M 1 ELECTRICAL Electrical supply voltage V 230 23...

Page 3: ... Room sealed type Cxy 13 Flue terminal positions 14 Maximum flue lengths 15 Flue parts identification 16 Gas connections 17 Electrical connections 18 Wiring diagram PCB1 19 Wiring diagram PCB 2 3 20 System schematic 21 Filling the appliance 22 Starting the appliance 22 Running the circulation pumps 22 Commissioning the heat engines 23 Final checks 25 User handover 25 Frost protection 25 Anti legio...

Page 4: ... persons away from the source of the gas smell DO close the main gas shutoff valve DO open all the windows and doors where the gas leakage has occurred DO inform the gas authority or a competent specialist as soon as possible OPERATOR COMPETENCY This boiler is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge...

Page 5: ...es with the essential requirements of the following directives Gas appliance directive 90 396 EEC Electromagnetic compatibility directive 89 336 CEE Low voltage directive 2006 95 EEC Efficiency requirements directive Council Directive 92 42 EEC for condensing boilers KEY 1 Type approval designation 2 Gas type and pressure 3 Model Name 4 Heat gas flow CO data 5 Technical data 6 Serial number This m...

Page 6: ... of practice BS 6880 Low temperature hot water heating sys tems of output greater than 45kW Part 1 Fundamental Design Part 2 Selection of equipment Part 3 Installation commissioning and mainte nance BS 6644 Specification for installation of gas fired hot water boilers of rated inputs of between 70kW net and 1 8MW net 2nd 3rd family gases BS EN 12897 Specification for indirectly heated unvented clo...

Page 7: ...alth risk DESCRIPTION OF APPLIANCE The iHE is a gas fired low No multi heat engine cascading boiler system with an integrated 5 Low Loss Header for the supply of a low temperature hot water heating system The iHE range of boilers also features an integrated stainless steel tank and plate heat exchanger for the supply of hot water Fully automatic electronic controls are integrated into the applianc...

Page 8: ...n 2 BSP F Low Loss Header Flow 2 BSP F Gas Inlet 1 BSP F PT Valve exits 28mm Wiring Centre Door Front LH Door Front RH Door RH Side Upper LH Side Lower LH Side Top Multiple Cable entry point 1941 192 104 Low Loss Header Air vent User Display 43 268 190 179 149 191 238 Cylinder Hot Water Supply 1 5 BSP M Cylinder Return 1 BSP M Air Flue Duct 200mm 130mm Air vent Pressure Gauge Fill Drain 15mm 497 1...

Page 9: ... such locations cannot be avoided a suitable drain tray must be installed under the Heater The drain tray must be no deeper than 38mm and must be 100mm wider and longer than the boiler It should be piped to an adequate drain using 20mm 0 75in diameter pipe angled for proper drainage Access must be provided to the front of the boiler with adequate clearance for servicing and opera tion Fig 1 1 The ...

Page 10: ... discharge of condensate For all other flue types it is recommended that a completely new flue system is installed The boiler room has a suitable outlet for the discharge of condensate produced The electrical connections comply with the current electrical standards and the work has been carried out by a suitably qualified person The gas supply pipework is constructed to the current regulations in ...

Page 11: ...tment is usually recommended when the hardness levels measures greater than 150 ppm For this reason base exchange water treatment is strongly recom mended in hard water areas OPEN VENTED DESIGN FIG 2 3 The tank must be supplied from a cold water feed cistern and the hot water supply pipe must be fitted with an open vent pipe in accordance with BS 5546 and BS 6644 The Water Supply Water Fittings Re...

Page 12: ...eturn Valve ensure that the flow arrows marked on the components are pointing in the direction of flow that is towards the Heater The relief valves fitted to this appliance must not be used for any other purpose No fitting should be installed between the expansion valve and the cylinder The cold water for services may be drawn from the 22mm compression port on Pressure Reduc ing Valve The water pr...

Page 13: ...al can be used for the discharge pipe work 40mm pipe with a drop of at least 30 mm for every metre of pipework should be used A trap is sup plied which should be connected into a drain via a tundish or air break External pipework and that passing through a wall to the outside should be run in a minimum of iHE SECONDARY RETURN DESIGN Fig 2 5 40mm diameter External pipework should be insulat ed to p...

Page 14: ...s to be operated at 75 then an additional 1cm2 will be required per kW at low and high level If this appliance is to be operated 100 of the time during the summer an additional 2cm2 free area per kW will be required at low and high level There must be sufficient clearance around the appliance to allow proper circulation of ventilation air The clearances required for Installation and Servicing will...

Page 15: ...e 13 VENTILATION REQUIREMENTS TYPE C13 C33 C53 Where the appliance is installed in a ROOM or COMPARTMENT no additional ventilation is re quired MAXIMUM FLUE LENGTHS The combustion fan fitted to the appliance moves the air and flue products through the system and can provide sufficient capacity for a Flue Equiva lent Length FEL of 18 metres for type C13 and C33 systems and 30 metres for type B23 sy...

Page 16: ... opening window etc 300 D Below a gutter or sanitary pipework 75 E Below the eaves 200 F Below a balcony or carport roof 200 G From vertical drain soil pipework 150 H From an internal or external corner 300 I Above ground roof or balcony level 300 J From a surface facing terminal 600 K From a terminal facing the terminal 1200 L From a opening in a carport e g door windows into the building 1200 M ...

Page 17: ...90 bends 3 0 2 x 45o bends 1 0 1 x Horizontal Terminal 1 0 Total within 18m limit 15 0 Concentric Flue Type C33 A system that rises from the Heater and uses seven straight lengths four 45 bends and a verti cal terminal 7 x 1m straight lengths 7 0 4 x 45 bends 2 0 Vertical Terminal 1 6 Total within 18m limit 10 6 Open Flue Type B23 The maximum FEL of flue in this configuration is 25 metres The air ...

Page 18: ...d 0 5 FEL P N E216 Fig 3 5 CONCENTRIC FLUE PARTS Debris Guard 0 0 FEL Vertical Terminal kit 1 6 FEL P N E670 Horizontal Terminal kit 1 0 FEL P N E240 CONVENTIONAL SINGLE FLUE PARTS 1m Length 1 0 FEL 45 Bend 0 5 FEL 90 Bend 1 0 FEL Horizontal Terminal 1 0 FEL Fig 3 6 ...

Page 19: ...equirements Where the Boiler is installed in a plant room or pur pose built compartment a manually operated valve must be fitted in accordance with the Gas Safety Installation and Use Regulations The valve must be easily identified and readily accessible GAS CONNECTION The 1 Galvanised steel gas connection is provided at the top of the Heater A minimum of 20mb G20 running pressure must be availabl...

Page 20: ...n of the appliance can be achieved by connecting to the volt free Remote Enable terminals after removing the link wire Fig 4 2 REMOTE INDICATORS The appliance has a volt free or can be used with voltages up to 230v output which can be con nected to a Building Management System or a remote indicator panel This input is connected to the BMS COMMON INPUT terminal FAULT Five minutes after any fault oc...

Page 21: ...iHE 19 Fig 4 3 WIRING DIAGRAM PCB 1 ...

Page 22: ...iHE 20 WIRING DIAGRAM PCB 2 3 Fig 4 4 ...

Page 23: ...OR TEMP SENSOR DIRECT HEATING CIRCUIT ZONE 1 MIXED HEATING CIRCUIT ZONE 2 B7 R Q1 B2 F B7 R Q1 B2 F H5 SYSTEM SCHEMATIC TEMPERATURE SENSORS CIRCULATION PUMPS B2 Heat engine fl ow Q1 Heat engine B3 DHW cylinder Q3 DHW Primary B7 Heat engine return Q6 Mixed heating external B8 Heat engine fl ue Q14 Direct heating external B9 Outdoor Q33 DHW Secondary B10 Low Loss Header fl ow B12 Mixed heating circu...

Page 24: ...on below regarding running the appliance pumps 7 Open the vent at the top of the hot water outlet until all air has been expelled 8 After initial filling open each hot water draw off tap in succession and check that all the air is vented from the system 9 Check for leaks STARTING THE APPLIANCE Turn on the switched spur supplying electricity to the appliance Turn on the appliance A green light with...

Page 25: ... set point can be altered by performing the following actions from the default screen 1 Press the OK button 2 Using the scroll wheel select Domestic Hot Water press OK 3 Press OK the temperature should now be flashing Use the scroll wheel to set desired temperature press OK 4 Press ESC twice to return to default display See seperate User Guide for more detail on setting both heating and hot water ...

Page 26: ...igure should be within the range 9 1 to 9 3 If adjustment is required pull off the black rubber cover from the Throttle Screw and adjust Screw clockwise to reduce CO2 anti clockwise to increase the CO2 Fig 5 4 13 When the correct combustion readings are achieved replace the cover plug over the Throttle Screw 14 Press and hold the heating demand button for more than 3 seconds to turn off the contro...

Page 27: ... provide Space Heating and DHW in equal quantities However if this appliance is used primarily for the supply of DHW and has very little or no Space heating demand there is a small efficiency benefit if the circulation pump on each heat engine see fig 7 3 is moved from speed 3 to speed 2 FINAL CHECKS Check the individual heat engines maximum rate and combustion are to specification See Table 1 0 a...

Page 28: ... run It is delivered with a link between them which can be removed if a Timer or Remote Switch is used To run the Heater you must have a Mains supply Gas and a Tank or Central Heating temperature below their set point If all the above are correct then the Gas Ignition Control starts the Ignition sequence 1 The Fan runs as a pre purge of the Heat Exchanger 2 After a few seconds a spark is created a...

Page 29: ...exchanger Undo the four nuts holding the heat exchanger front and pull the whole assembly forwards Replace silicone door seal if there are any signs of damage and in any case every 2 years Heat exchanger deposits can be removed using a non metalic brush and vacuum cleaner Assembly is the reverse SERVICING SPARK ELECTRODE OR SENSE ELECTRODE Turn off the Boiler Pull off the Lead s Undo the two screw...

Page 30: ...e Heat Ex changer They are removed by turning anti clockwise a quarter turn and withdrawing Replacement is the reverse AVS 37 HMI DISPLAY Use a small flat edged screwdriver to release the HMI from its mounting bracket by springing off its four plastic edge clips Remove the cable from the HMI Display Replacement is reverse LMS14 PCB 1 TO 3 These are located on Control Panel It is important that the...

Page 31: ...sing the compression fitting Disconnect all electrical connections to the flue sensor spark generator both fan connections and gas valve Fig 6 4 Unscrew to remove heat exchanger both sets Unscrew to remove burner system both sets The Air tube connecting the Venturi to the flue system contains a one way valve at the end of the flexible tube It is essential that the two screws holding it in position...

Page 32: ...much of the primary water as is nec essary to ensure the Pump is empty Remove the lid of the pump wiring box and disconnect the supply lead Undo the two water connections and remove the pump Transfer the supply lead to the new Pump Replacement is the reverse Refill and check for leaks SECONDARY DHW PUMPS These are located on the pipes from the Plate Heat Exchanger going to the Tank see Fig 7 2 Tur...

Page 33: ...ndish 1 inch 5139811 18 Tank Access Hatch c w O Ring Dip Tube 5139809 19 Tank Dip Tube Sensor E664 20 Low Loss Header Sensor G077 21 DHW Pressure Temperature Relief Valve 5139805 22 300ltr Tank E652 23 Tank DHW Flow Sensor 5139797 24 Pressure Relief Valve 3 bar 5139807 25 Condensate Trap E211 26 Plate Heat Exchanger c w Fittings 5139775 27 DHW Primary Pump 5139803 28 Heat Exchanger Pump 5139802 29...

Page 34: ...iHE 32 APPLIANCE COMPONENTS Fig 7 1 21 20 17 22 19 18 16 24 25 26 27 28 29 23 ...

Page 35: ...iHE 33 APPLIANCE COMPONENTS Fig 7 2 2 3 5 4 6 14 13 12 7 11 8 10 1 15 9 31 32 34 35 36 30 37 33 ...

Page 36: ...ion Fan 6 12 5 Spark Electrode 1 Flue Temp Sensor 300ltr Tank DHW Secondary Pumps DHW Pump Isolation Cocks G G G G F Fa F Fa S S S S S Sp Sp Sp Sp Sp Sp p E E E E E E E El El E E E E E E I I I I I I I I I I I I I Io o o o o o o o o o o o o o on n n n n n n n n E E El El E e DHW Primary Pump 10 Heat Exchanger Pump Heat Exchanger Pump 28 28 Plate Heat Exchanger Air control valve 29 27 26 ...

Page 37: ...lision Duplicate LPB address Check all PCBs function 6600 84 BSB address collision Room unit incorrectly configured see function 40 98 Extension module 1 error Module 1 configuration error Check parameters 99 Extension module 2 error Module 2 configuration error Check parameters 100 2 Clock time masters Only PCB no 1 is set as time master see Function 6640 110 STB lockout Check connector X18a and ...

Page 38: ... parameters 331 Sensor input BX2 without function BX2 connected but not defined check parameters 332 Sensor input BX3 without function BX3 connected but not defined check parameters 333 Sensor input BX4 without function BX4 connected but not defined check parameters 335 Sensor input BX21 without function BX21 connected but not defined check parameters 336 Sensor input BX22 without function BX22 co...

Page 39: ...NOTES ...

Page 40: ...Publication Date 01 09 12 ...

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Potterton iHE 100/300, Installation And Servicing Instructions

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