Potterton iHE 100 Installation & Servicing Instructions Manual Download

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M6500

iHE

Indirect High E

ﬃ

ciency Boiler & Water Heater

Installation & Servicing Instructions

Models

iHE 100
iHE 150

This manual must be kept with the appliance

Summary of Contents for iHE 100

Page 1: ...M6500 iHE Indirect High Eﬃciency Boiler Water Heater Installation Servicing Instructions Models iHE 100 iHE 150 This manual must be kept with the appliance ...

Page 2: ...BSP 2 2 Low Loss Header resistance kPa 0 5 0 5 HOT WATER Tank capacity litres 300 300 Recovery rate through 50o C l h 1520 2240 Time to recover tank through 50o C mins 12 9 PMS Operating pressure max min bar 6 0 0 2 6 0 0 2 In Out connections BSP M 11 2 M 11 2 Water return connection BSP M 1 M 1 ELECTRICAL Electrical supply voltage Hz V Hz 230 50 230 50 Power consumption standby A W 0 15 34 0 2 40...

Page 3: ...stems ventilation 13 2 11 Open flue type B23 13 2 12 Room sealed type Cxy 14 2 13 Flue terminal positions 15 2 14 Maximum flue lengths 16 2 15 Gas connections 17 2 16 Electrical connections 18 2 17 System schematic 19 2 18 Application drawings 20 2 19 Wiring diagrams 23 2 20 Wired room units outside sensor 25 2 21 AGU2 5 Expansion modules 28 3 0 COMMISSIONING 3 1 Filling starting the appliance 29 ...

Page 4: ...ay 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 unless they...

Page 5: ...uments that the appliance complies with the essential requirements of the following directives Gas appliance directive 2009 142 EC 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 manual is an integral and indispensable part of the app...

Page 6: ...es of practice BS 6880 Low temperature hot water heating systems of output greater than 45kW Part 1 Fundamental Design Part 2 Selection of equipment Part 3 Installation commissioning and maintenance 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: ...ION OF APPLIANCE The Potterton 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 space heating system The Sirius Advance 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...

Page 8: ...pper 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 Pressure Gauge Fill Drain 15mm 497 132 Cylinder Drain 28mm 701 302 Immersion Heater Boss 2 25 BSP F 1871 80 PT Valve exits 100kW 1 x 28mm 150kW 1 x 28mm 1 x 22mm 1 7 GENERAL DIME...

Page 9: ...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 floor on which the boiler is insta...

Page 10: ...s a connection for the 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 c...

Page 11: ...reater than 150 ppm For this reason base exchange water treatment is strongly recom mended in hard water areas 2 4 OPEN VENT DESIGN 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 Regulations must be observed when installing the system The cold water f...

Page 12: ... the Pressure Reducing Valve and Double Non Return 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 ...

Page 13: ...ate rial 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 40mm Fig 2 5 diameter External pipework should be insulated to protect against frost an...

Page 14: ...tional purchased AGU2 5 module 3 would require to be defined under parameter 6022 as Multi functional The output QX23 and other settings would be defined according to the following table Menu Line no Setting Config QX23 6038 El imm heater DHW K6 To configure as a backup heater DHW storage tank 5060 5061 5062 Substitute Time program 4 DHW External thermostat To configure as a summer heater DHW stor...

Page 15: ... 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 no...

Page 16: ... FLUE AND AIR DUCTS TERMINATE EITHER HORIZONTALLY OR VERTICALLY IN THE SAME POSITION Flue and air ducts are supplied to a concentric design 130 200mm See Fig 3 5 for component choices Flues should slope back to the Heater by 3 degrees Terminal positions must comply with the requirements detailed in section 2 12 VENTILATION REQUIREMENTS TYPE C13 C33 C53 Where the appliance is installed in a ROOM or...

Page 17: ...nal 600 K From a terminal facing a terminal Horizontal flue 1200 K From a terminal facing a terminal Vertical flue 600 L From a opening in a carport e g door windows into the building 1200 M Vertically from a terminal on the same wall 1500 N Horizontally from a terminal on the same wall 300 R From an adjacent wall to flue Vertical only 300 S From an adjacent opening window vertical only 1000 T Adj...

Page 18: ...allation requirement and then calculate the FEL of the system this must not be greater than that stated above Examples Concentric Flue Type C13 A flue system that uses ten straight lengths three 90 bends two 45o bends and a horizontal terminal 10 x 1m straight length 10 0 3 x 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 th...

Page 19: ...te require ments Where this appliance is installed in a plant room or purpose 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 appliance A minimum of 20mb G20 running pressure must ...

Page 20: ...nected to the appliance Automatic timed or remote operation 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 connected to a Building Management System or a remote indica tor panel This input is connected to the AGU2 ...

Page 21: ...TERNAL CONTROLS RC HC1 Room controller H5 HC2 Room thermostat MIXING VALVE Y1 Open Valve 230V 1A Max Y2 Close valve 230V 1A Max OPTIONAL HEAT ENGINE 1 HEAT ENGINE 2 HEAT ENGINE 3 150kW ONLY 300 LT DWH CYLINDER LOW LOSS HEADER DHW PLATE HT EX DHW DRAIN DHW PUMPS LTHW R MCWS DHW R DHW F FILL DRAIN PRV P T RELIEF B7 R B8 Q1 B2 F B8 B8 B3 B36 Q33 Q33 Q3 B10 RC AV AV AV AV AV Q6 Q2 Y1 Y2 B1 LTHW F DIRE...

Page 22: ...iHE 20 GB IE Fig 4 4 WEATHER COMPENSATING MIXING HC1 OPTIONAL HC2 BMS 2 18 APPLICATION DRAWINGS ...

Page 23: ...iHE 21 GB IE Fig 4 5 HC1 OPTIONAL HC2 ...

Page 24: ...iHE 22 GB IE Fig 4 6 HC1 IMMERSION HEATER BMS ...

Page 25: ...iHE 23 GB IE Fig 4 7 2 19 WIRING DIAGRAMS PCB 1 ...

Page 26: ...iHE 24 GB IE Fig 4 8 PCB 2 3 ...

Page 27: ...ately as possible without getting adversely aﬀected by direct solar radiation or other heat or refrigeration sources about 1 5 metres above the floor The base provides the power for QAA55 and QAA75 When the units are removed from the base power is cut oﬀ i e the units are out of operation QAA75 ROOM UNIT CONNECTIONS Termi nal Designa tion QAA55 QAA75 1 CL BSB data BSB data 2 CL BSB ground BSB grou...

Page 28: ... following example illustrates applications avail able using the settings Used as operating line 40 together with Heating circuit assignment operat ing lines 42 to 48 Existing heating circuits 1 and 2 are controlled centrally from room unit 1 for logistical reasons The room temperature sensor in room unit 1 is relevant to only heating circuit 1 since climatic conditions for heating circuit 2 may d...

Page 29: ...justment with the knob is adopted either by pressing the operating mode button or without any further confirmation timeout MANUAL THERMOSTAT USING H2 INPUT Using the Main HMI on the appliance enter Commisioning mode see User Levels section in Users Operating and Programming guide and select Configuration menu Depending on which AGU2 5 being used the setup is as follows Line Display Notes 6046 6062...

Page 30: ...h a mixing valve e g underfloor heating then you have no choice but to define the AGU2 5 as a heating circuit As soon as a 10K sensor is connected to BX21 the LMS14 controls will detect it and activate the extra functions QX21 QX22 These two outputs can be connected to a 230v max 1A 3 point control actuator to accurately control the temperature of the flow around this heating circuit There are fiv...

Page 31: ...garding running the appliance pumps 7 After initial filling open each hot water draw oﬀ tap in succession and check that all the air is vented from the system 8 Check for leaks STARTING THE APPLIANCE Turn on the switched spur supplying electricity to the appliance Turn on the appliance A green light within the switch should illuminate to indicate that power is now available to the appliance and th...

Page 32: ...efault 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 temperatures and times 3 3 COMMISSIONING THE HEAT ENGINES The gas mixtur...

Page 33: ...uce CO2 anti clockwise to increase the CO2 Fig 5 3 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 controller stop function 15 Press the DHW demand button to turn oﬀ the appliance and when the burner has stopped firing remove the Gas Valve electrical connector of t...

Page 34: ...ation pump on each heat engine see fig 7 3 is moved from speed 3 to speed 2 CLEANING THE APPLIANCE The casing is finished with a polyester coating and will mark if abrasive cleaners are used It should be cleaned using standard non abrasive cleaning products 3 4 FINAL CHECKS Check the individual heat engines maximum rate and com bustion are to specification See Table 1 0 and Data table Inside Cover...

Page 35: ...z electricity supply and a valid demand from either the DHW or the space heating system If all the above are correct then the Gas Ignition Control starts the Ignition sequence 1 The Fan operates on one heat engine as a pre purge of the heat exchanger 2 After a 20 seconds a spark is created at the electrode and the gas valve is opened 3 The burner should light within 5 seconds 4 The burner flame is...

Page 36: ...f there are any signs of damage and in any case replacement every 2 years is recommended Heat exchanger deposits can be removed using a non metalic brush and vacuum cleaner or loose deposits can be flushed away into the condense line using water Assembly is the reverse 2 SPARK ELECTRODE AND FLAME SENSE ELECTRODE Turn oﬀ the appliance and pull oﬀ the lead s Undo the two screws retaining the spark e...

Page 37: ...ated at the Flue outlet of the 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 pa...

Page 38: ... and unscrew the oﬀset connector small blue threaded tube and transfer to the new gas valve Release the gas valve from the venturi by undoing three screws see fig 6 5 Transfer the rubber gasket to the new gas valve Replacement is the reverse Fire the boiler and check for gas leaks After five minutes check the rate and combustion is correct to the Datatable inside cover Adjust using the throttle on...

Page 39: ...rse Refill and check for leaks PRIMARY DHW PUMP This single pump is located between the Low Loss Header and the plate heat exchanger see Fig 7 1 item 27 Drain as much of the primary water as is neces sary to ensure the pump is empty Remove the lid of the pump wiring box and disconnect the power supply lead Undo the two water connections and remove the pump Transfer the supply lead to the new pump ...

Page 40: ... 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 DHW secondary pump 5139804 30 AGU2 5 clip in extension 5139793 31 AVS37 HMI display 5139788 32 On Oﬀ Switch 5139801 33 Reset PCB 5139800 34 iHE LMS14 PCB 1 5139789 35 iH...

Page 41: ...iHE 39 GB IE Fig 7 1 20 17 22 18 16 24 25 26 27 28 29 23 39 4 4 APPLIANCE COMPONENTS IDENTIFICATION 21 40 20 19 ...

Page 42: ...iHE 40 GB IE 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 4 4 APPLIANCE COMPONENTS IDENTIFICATION CONTINUED ...

Page 43: ...n fan 6 12 5 Spark elec trode 1 Flue temp sensor 300ltr tank DHW secondary pumps DHW pump isolation cocks DHW primary pump Ionisation electrode 10 Heat exchanger pump Heat exchanger pump 28 28 Plate Heat Exchanger Air control flap assembly 29 27 26 Non return valve 39 4 4 APPLIANCE COMPONENTS IDENTIFICATION CONTINUED Control sensor 20 s s s se ...

Page 44: ...all flow return sensors 111 Shutdown limit thermostat Heat exchanger temperatures have been exceeded 119 Shutd water pressure switch Check for condensate or flue blockage 121 Flow temperature heating circuit 1 not reached Htg Circuit 1 time temp parameter not reached 122 Flow temperature heating circuit 2 not rached Htg Circuit 2 time temp parameter not reached 126 DHW charging temperature not rea...

Page 45: ...er system pump address error Htg Pump Q14 not configured on PCB1 353 Cascade flow sensor B10 missing Check connections and configuration of sensor B10 384 Extraneous Light Ionisation current detected before ignition 385 Mains under voltage Mains voltage below 185v check electrical installation 386 Fan speed tolerance Fan outside allowed speed tolerance level 388 DHW sensor no function Tank tempera...

Page 46: ...iHE 44 GB IE NOTES ...

Page 47: ...Notes ...

Page 48: ...ax 0845 070 1059 e mail enquiries pottertoncommercial co uk web pottertoncommercial co uk Sales 0845 070 1056 Technical 0845 070 1057 Wood Lane Erdington Birmingham B24 9QP Publication date February 2015 ...

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Potterton iHE 100, Installation & Servicing Instructions Manual

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