Potterton Performa 24 Installation & Servicing Instructions Manual
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Potterton Performa 24 Installation & Servicing Instructions Manual

Potterton Performa 24 Installation & Servicing Instructions Manual

Gas fired wall mounted combination boiler
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Performa 24
Gas Fired Wall Mounted Combination Boiler
Installation and
Servicing Instructions
Please leave these instructions with the user

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Summary of Contents for Potterton Performa 24

  • Page 1 Performa 24 Gas Fired Wall Mounted Combination Boiler Installation and Servicing Instructions Please leave these instructions with the user...
  • Page 2 Natural Gas Potterton Performa 24 G.C.N 47 393 06 The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency) Regulations 1993 N 3083” and is deemed to meet the requirements of Directive 92/42/EEC on the energy efficiency requirements for new hot water boilers...

  • Page 3: Table Of Contents

    Contents Section Page Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Installation Commissioning the Boiler 10.0 Completion 11.0 Servicing the Boiler 12.0 Changing Components 13.0 Illustrated Wiring Diagram 14.0 Fault Finding 15.0 Short Parts List...

  • Page 4: Introduction

    Description 1. The Potterton Performa 24 is a fully automatic gas fired wall mounted combination boiler. It is room sealed and fan assisted, and will provide central heating and mains fed domestic hot water.

  • Page 5: General Layout

    2.0 General Layout Layout Air Pressure Switch Expansion Vessel Burner Manifold Automatic Air Vent DHW Plate Heat Exchanger Circulation Pump Drain Off Point Pressure Relief Valve Optional Integral Timer Position Central Heating System Pressure Gauge Control PCB Control Box 3-Way Valve Assembly Spark Generator Flame Sensing Electrode Spark Electrode...

  • Page 6: Appliance Operation

    3.0 Appliance Operation Central Heating Circuit NOTE: All delay timers mentioned in 3.1 and 3.2 are overridden by domestic hot water demand. Central Heating Mode (Fig. 4) 1. With a demand for heating, the pump circulates water through the primary circuit. At a pre- determined flow rate the central heating flow switch operates, initiating the ignition sequence.

  • Page 7: Technical Data

    4.0 Technical Data Appliance Type DHW Circuit Nox Class Pressures Appliance Category Flue Terminal Diameter 100mm Max Operating 2H 3+ Dimensions Projection 95mm Min Operating Heat Input C/H & DHW (Gross) Min Operating Pressure Connections copper tails at 9.8 l/min 26.3 10.6 Gas Supply...

  • Page 8: Dimensions And Fixings

    5.0 Dimensions and Fixings Dimensions A 780mm B 345mm C 450mm D 107mm Ø Min. 360° Orientation E 200mm F 190mm G 143mm Tube Ø 100mm Fig. 6 Gas Inlet Heating Domestic Hot Cold Water Heating Flow Water Outlet Inlet Return 95mm 65mm...

  • Page 9: System Details

    6.0 System Details Information 1. The Potterton Performa 24 Combination Boiler is a ‘Water Byelaws Scheme - Approved Product’. To comply with the Water Byelaws your attention is drawn to the following installation requirements and notes (IRN). a) IRN 001 - See text of entry for installation requirements and notes.
  • Page 10 6.0 System Details System Filling and Pressurising 1. A filling point connection on the central heating return pipework must be provided to facilitate Double initial filling and pressurising and also any Check subsequent water loss replacement/refilling. Valve 2. The filling method adopted must be in Stop Valve accordance with all relevant water supply bye- laws and use approved equipment.
  • Page 11 6.0 System Details Other Tap Domestic Hot Water Circuit Outlets 1. All DHW circuits, connections, fittings, etc. Boiler Expansion should be fully in accordance with relevant Vessel standards and water supply bye-laws. 2. Your attention is drawn to: IRN 116 and Byelaw 90 and 91. Check Sealed primary circuits and/or secondary hot Valve...

  • Page 12: Site Requirements

    7.0 Site Requirements 450mm 5mm Min 5mm Min Information 1. The installation must be carried out by a CORGI Registered Installer or other competent person and be in accordance with the relevant requirements of 200mm Min the current G (Installation and Use) AFETY , the B EGULATIONS...
  • Page 13 7.0 Site Requirements Ventilation of Compartments 1. Where the appliance is installed in a cupboard or compartment, no air vents are required. 2. BS 5440: Part 2 Clause 4.2 refers to room sealed appliances installed in compartments. The appliance will run sufficiently cool without ventilation.
  • Page 14 7.0 Site Requirements Flue 1. The following guidelines indicate the general requirements for siting balanced flue terminals. Recommendations for flues are given in BS 5440 Aluminium Shield Pt.1. 2. If the terminal is fitted within 1 metre of a plastic gutter, within 500mm of a painted eave or a painted gutter, an aluminium shield of at least 1 metre long should be fitted to the underside of the gutter or painted surface.
  • Page 15 7.0 Site Requirements Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 1metre from elbow to terminal (Fig. 17). The maximum permissible flue length is: 5 metres. 7.10 Flue Terminal Trim Fig. 17 1. Once the flue is secure the trim can be fitted if required.
  • Page 16 7.0 Site Requirements 7.12 Flue Options 1. The Potterton Performa 24 can be fitted with flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. 3. Maximum permissible equivalent flue lengths Maximum Length = 4m inc. 2 x 45° bends...

  • Page 17: Installation

    2. Mark the position of the two most suitable fixing slots for the wall plate and boiler lower Performa 24 fixing holes. It is preferable to use the horizontal For Side Flue Exit fixing slots. For side flue exit, mark as shown.
  • Page 18 Wall Plate 8.0 Installation Fitting The Boiler 1. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate hooks (Fig. 23). 2. Ensure that the boiler is level and sits against the wall.
  • Page 19 8.0 Installation Wall Thickness Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths 100mm minimum to 1m maximum (measured from the edge of the flue elbow outlet). Rear Flue: maximum wall thickness - 900mm Side Flue: maximum wall thickness - 870mm 2.
  • Page 20 8.0 Installation Elbow Fitting the Flue (Cont) IMPORTANT: If the flue length is greater than Seal 1.5m the restrictor MUST be removed from Restrictor the adaptor (Fig. 29). Adaptor 7. Insert the flue duct into the air duct and pass Fig.
  • Page 21 8.0 Installation Making The Electrical Connections Fig. 33 To connect the mains input cable proceed as follows:- 1. Slacken the facia panel securing screws and lift the outercase panel so that its securing tabs are clear of the facia. Remove the panel. Control Box Cover 2.

  • Page 22: Commissioning The Boiler

    Commissioning the Boiler Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Open the mains water supply to the boiler. 3. Open all hot water taps to purge the DHW system. 4.
  • Page 23 Commissioning the Boiler Selector Switch Checking the Burner Pressure 1. Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for heat. Reset Burner On 2. Set the hot water and central heating Flame Failure Power On temperature controls to maximum and the...

  • Page 24: Completion

    10.0 Completion Case Front Panel 10.1 Completion 1. Hinge the facia panel upwards and engage the securing screws. Refit the case front panel and tighten the screws (Fig. 45). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3.

  • Page 25: Servicing The Boiler

    11.0 Servicing the Boiler Case Front Panel 11 .1 Annual Servicing 1. For reasons of safety and economy, it is recommended that the boiler is serviced annually. Servicing must be performed by a competent person. 2. After servicing, complete the relevant section of the “Benchmark”...
  • Page 26 Baffle 11.0 Servicing the Boiler Spring Clip 11.1 Annual Servicing (Cont) 10. Remove the spring clips retaining the air box side baffle plates. Disengage the tabs on the baffles from the slots in the fan hood (Fig. 52). Fig. 52 Fig.

  • Page 27: Changing Components

    12.0 Changing Components IMPORTANT: When changing components Pressure ensure that both the gas and electrical Switch supplies to the boiler are isolated before any work is started. See Section 11.1 “Annual Servicing” for removal Fig. 57 Sensing of case panel, door etc. Tubes 12.1 Pressure Switch...
  • Page 28 12.0 Changing Components 12.3 Heat Exchanger (Fig. 62) 1. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them (Figs. 58 to 61). 2. Slacken the screws on the outlet sealing collar. Ease the collar upwards as far as possible.
  • Page 29 12.0 Changing Components Injector Inlet Elbow Manifold 12.5 Injectors (Fig. 64) 1. Remove the burner as described in Section 12.4. Fig. 64 2. Undo the screws securing the injector Gasket manifold to the inlet elbow and remove the manifold. 3. Unscrew and replace injectors as required Injector and examine the sealing gasket, replacing as necessary.
  • Page 30 12.0 Changing Components 12.8 Gas Valve (Fig. 66) Fig. 66 1. Undo the nut on the gas feed pipe at the tap rail under the boiler. 2. Remove the securing screws and hinge the Gas Valve facia panel down. 3. Disconnect the earth wire and pressure sensing Electrical pipe from the valve.
  • Page 31 12.0 Changing Components 12.11 Pump - Head Only (Figs. 68 & 69) 1. Drain the primary circuit and remove the socket head screws securing the pump head to the body and draw the head away. 2. Undo the screw on the pump wiring cover and remove the cover.
  • Page 32 12.0 Changing Components 12.14 Pressure Gauge Fig. 71 1. Drain the primary circuit and undo the nut on the pressure gauge capillary (Fig. 71). 2. Remove the timer cover and ease the timer wiring aside. Undo the screws securing the gauge retaining bracket (Fig.
  • Page 33 12.0 Changing Components 12.17 Pressure Relief Valve (Fig. 78) 1. Drain the primary circuit. 2. Disconnect the discharge pipe from the valve. Using a suitable hexagon key undo the grub sufficiently to release the valve. 3. Note the orientation of the valve, rotate it and withdraw it from the manifold.
  • Page 34 12.0 Changing Components Plate Heat Exchanger 12.20 Plate Heat Exchanger (Fig. 81) Fig. 81 1. Drain the primary circuit. 2. While supporting the heat exchanger undo the screws securing it to the brass manifolds. 3. Withdraw the heat exchanger upwards and to the left of the gas valve, taking care not to damage any wires or controls.
  • Page 35 12.0 Changing Components Central Heating Microswitch & Pressure Differential 12.21 Diverter Valve Assembly (Cont) Bracket Valve Pressure Differential Valve (Fig. 84) Sensing Pipe 1. Remove the pressure differential valve as described above. By-pass 2. From the brass diverter manifold undo the nut Pipe Diaphragm on the heating flow pipe.

  • Page 36: Illustrated Wiring Diagram

    13.0 Illustrated Wiring Diagram Pump Mains Input Link On/Off/Reset Selector Switch Fuse Temperature Sensor Hydraulic Differential Pressure Switch Optional Timers Control PCB Gas Valve Safety Thermostat 3-Way Valve Air Pressure Switch Microswitch Flame Sensing Electrode Igniter - brown - black - blue - red - yellow...

  • Page 37: Fault Finding

    14.0 Fault Finding Carry out initial fault finding checks 1. Check that gas, water and electrical supplies are available at the boiler. Electrical supply = 230V ~ 50 Hz. CH water system pressurised to 0.5 bar when the boiler is cold. The preferred minimum gas pressure is 19.5mbar (natural gas), 27mbar (butane) or 36mbar (propane).
  • Page 38 14.0 Fault Finding Domestic Hot Water - Follow operational sequence Turn selector to Replace diaphragm Go to section ‘A’ neon illuminated Is mains water DHW flow valve filter and differential diaphragm damaged assembly clean? Turn thermostat to DHW flow rate more than DHW flow valve rod max.
  • Page 39 14.0 Fault Finding Fault Finding Solutions Sections A to E Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse neon Replace PCB illuminated Selector terminals a & b Check wiring and a & 3. PCB - M1 Replace selector connector terminals 9 &...
  • Page 40 14.0 Fault Finding Check and correct if necessary 1. Electrical and pressure tube connections Replace air 2. Blockage of pressure tubes pressure switch 3. Restriction in flue 4. Venturi Gas at burner Ensure gas is on and purged PCB - M4 connector is approx 70-140V DC, Replace gas valve terminals 23 &...
  • Page 41 14.0 Fault Finding Ensure that mains input terminal L is Live (230V) and N is Neutral (0V) Check and correct if necessary 1. Flame sensing electrode and lead connections 2. Electrode position Replace PCB Flame current should be 1 µA approx. Replace flame sensing electrode Overheat thermostat operated Allow to cool.

  • Page 42: Short Parts List

    15.0 Short Parts List Short Parts List Key G.C. Description Manufacturers Part No. E66 383 Fan 248001 393-497 Pressure Switch 247380 E66 393 Heat Exchanger 248016 E66 398 Burner 248029 E66 402 Injector - 1.28 NG 248210 Injector - 0.77 LPG 248211 E66 408 Electrode Lead 248037...
  • Page 43 16.0 Notes...
  • 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 922.031.1 Comp N 249083 - Iss 1 - 3/01...

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