Potterton Performa 24 Eco HE Installation & Service Instructions Manual
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Potterton Performa 24 Eco HE Installation & Service Instructions Manual

Condensing combination boiler
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See also: User Manual
You can rely on
Installation & Service Instructions
Performa
24 Eco HE
Condensing
Combination Boiler
2
Reset
Burner On
1
3
Flame Failure
0
4
Power On
bar
These instructions include the Benchmark Commissioning
Checklist and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2009

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  • Page 1 You can rely on Installation & Service Instructions Performa 24 Eco HE Condensing Combination Boiler Reset Burner On Flame Failure Power On These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2009...

  • Page 2: Table Of Contents

    Natural Gas Contents Potterton Performa 24 Eco HE Section Page G.C.N 47 393 11 Legislation Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings Building Regulations and the Benchmark System Details Commissioning Checklist Site Requirements Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Flue Options Authority Building Control Department.
  • Page 3 Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme Install and Commission this Contact your relevant Local appliance to manufacturer's Authority Building Control instructions (LABC) who will arrange an inspection or contact a government approved inspector Complete the Benchmark Checklist...

  • Page 4: Legislation

    Legislation IMPORTANT - Installation, Commissioning, Service & Repair This company declare that no substances harmful to health are contained in the appliance or used during appliance This appliance must be installed in accordance with the manufacturer’s instructions and manufacture. the regulations in force. Read the instructions fully before installing or using the appliance.
  • Page 5 Safe Manual Handling 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 &...

  • Page 6: Introduction

    1.0 Introduction Description Case Front Panel 1. The Potterton Performa 24 Eco HE is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water. 2.

  • Page 7: 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 Safety Pressure Relief Valve Optional Integral Timer Position Central Heating System Pressure Gauge Control PCB Control Box 3-Way Valve Assembly Condensate Trap Flame Sensing Electrode...

  • Page 8: 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. 2) 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 9: Technical Data

    4.0 Technical Data Appliance Type Electrical Protection IPX4D Central Heating Primary Circuit Pressures Appliance Category CAT II 2H 3P NO x Class Safety Discharge Heat Input CH Condensate Drain 1” BSP Max Operating Min Operating Flue Terminal Diameter 100mm 24.8 10.6 Recommend Operating Dimensions...

  • Page 10: Dimensions And Fixings

    5.0 Dimensions and Fixings Dimensions At Least 1.5° A 780mm B 345mm C 450mm D 116mm Ø Min. E 185mm F 190mm G 131mm 360° Orientation Tube Ø 100mm Tap Rail 28mm Condensate Drain 65 mm 65 mm 65 mm 65 mm 65 mm Heating...

  • Page 11: System Details

    6.0 System Details Information Potterton Performa 24 Eco HE 1. The Condensing Combination Boiler is ‘Water Byelaws Scheme - Approved Products’. 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 12 6.0 System Details System Filling and Pressurising 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling. Double 2. There are connection points on the mains cold water Stop Check Stop...
  • Page 13 6.0 System Details Other Tap Domestic Hot Water Circuit (Fig. 7) Outlets 1. All DHW circuits, connections, fittings, etc. should be Boiler Expansion fully in accordance with relevant standards and water Vessel* supply regulations. 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 Check to R24 of the Water Regulations Guide.

  • Page 14: Site Requirements

    7.0 Site Requirements 20mm/5mm Min See * NOTE: 450mm 5mm Min Location 1. The boiler may be fitted to any suitable wall with the 200mm Min flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply.
  • Page 15 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 16 7.0 Site Requirements Termination to an internal soil and vent pipe Boiler Condensate Drain FAILURE TO INSTALL THE CONDENSATE DISCHARGE PIPEWORK CORRECTLY WILL AFFECT THE RELIABLE OPERATION OF THE BOILER The condensate discharge pipe MUST NOT RISE at any point along its length. There MUST be a fall of AT LEAST 2.5°...
  • Page 17 Terminal Position with Minimum Distance (Fig. 11) (mm) 7.0 Site Requirements A a Directly below an opening, air brick, opening windows, etc. B a Above an opening, air brick, opening window etc. Flue C a Horizontally to an opening, air brick, opening window etc. D Below gutters, soil pipes or drain pipes.

  • Page 18: Flue Options

    8.0 Flue Options Horizontal Flue Systems 1. The standard flue is suitable only for horizontal termination applications. 2. All fittings should be fully engaged. The approximate engagement is 40mm. Apply soap solution to the seal on each fitting to aid assembly. 3.
  • Page 19 8.0 Flue Options Vertical Twin & Vertical Flue Systems Flues (Twin Pipe) 1. Maximum permissible equivalent flue lengths are:- Vertical Concentric Vertical Twin Pipe 12m* * Both the air and flue duct can be up to 12 metres long each. 2.
  • Page 20 8.0 Flue Options Flue Accessories Accessory Size Code No FLUE GROUP A Concentric Flue System 100mm diameter Horizontal Flue Terminal 5111073 Horizontal Flue Terminal (incl elbow) 5118489 Flue Extension 1000mm 5111074 Flue Bend 93° 5111075 Flue Bend (pair) 135° 5111085 Pipe Support (painted) 100mmØ...
  • Page 21 8.0 Flue Options For Twin Flue Systems fit the adaptors as follows:- Flue Duct Adaptor Flue Duct Adaptor 1. Engage the flue duct adaptor on the boiler adaptor, Blanking Plate making sure that it is pushed down as far as possible. Air duct adaptor Boiler Adaptor 1.
  • Page 22 8.0 Flue Options For Roof Terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead Approx tile to replace/flash over existing roof tiling. Make an aperture in 1425mm the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained.

  • Page 23: Plume Displacement

    93° Elbow/Plume 9.0 Plume Displacement Outlet Assembly 60Ø Support Plume Displacement Kit (Fig. 14b) O Ring Bracket Kit No 5118638 Content of kit 0.9 metres 0.9m 60/100 Concentric Flue 1m 60 Dia Exhaust Flue Pipe 60Ø Exhaust Adaptor Flue Pipe 60 Dia Support Brackets 93°...
  • Page 24 9.0 Plume Displacement Determining Permissible Lengths In the graph the solid line diagonal represents the relationship between the concentric flue assembly (and any extensions) and the 60Ø exhaust (and any extensions or additional bends). Example 1 - Not Permissible If, for instance, a concentric length of 2 metres was required Concentric 60/100 Flue (metres) Y Concentric 60/100 Flue (metres) Y and the 60Ø...
  • Page 25 9.0 Plume Displacement General Fitting Notes 1. Cut a hole in the external wall which the concentric flue assembly will pass through. The hole should allow the flue to fall back to the boiler at an angle of 1.5° to 3°. 2.
  • Page 26 9.0 Plume Displacement Plume Outlet Elbow General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø exhaust in an enclosed box, but the air inlet and plume outlet MUST remain in free air. 16. It is also possible to separate the plume outlet from the 93°...

  • Page 27: Installation

    10.0 Installation 10.1 Initial Preparation The gas supply, gas type and pressure must be checked for suitability before connection (see Section 7.4). 1. After considering the site requirements (see Section 7.0) position the fixing template on the wall ensuring it is level both horizontally and vertically. 2.
  • Page 28 10.0 Installation Wall Plate 10.4 Fitting The Boiler 1. Remove the sealing caps from the boiler connections. NOTE: A small amount of water may drain from the boiler once the caps are removed. 2. Lift the boiler as indicated by the shaded areas. The boiler should be lifted by TWO PEOPLE.
  • Page 29 10.0 Installation 10.6 Condensate Drain (see section 7.6) 1. Connect the condensate drain using the 1” BSP nut and seal supplied. Ensure the discharge of condensate complies with any national or local regulations in force (see British Gas “Guidance Notes for the Installation of Domestic Gas Condensing Boilers”.
  • Page 30 10.0 Installation 10.7 Fitting the Flue (Cont) Waste 5. Mark dimension ‘Y’ on the flue as shown (Fig. 37). Carefully cut the waste material from the flue, ensuring that the ducts are square and free from burrs. 6. The inner flue duct support bracket may be in the waste portion of the flue.
  • Page 31 10.0 Installation 10.8 Making The Electrical Connections To connect the mains input cable proceed as follows:- 1. Slacken the facia securing screws and lift the outercase panel so that its locating tabs are clear of the facia. Remove the panel. 2.

  • Page 32: Commissioning The Boiler

    11.0 Commissioning the Boiler 11.1 Commissioning the Boiler Screw 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. At the time of commissioning complete all relevant Automatic Air sections of the Benchmark Commissioning Checklist at Vent the rear of this publication.
  • Page 33 11.0 Commissioning the Boiler Pressure Test Point Sealing Screw 11.2 Checking the Burner Pressure 1. Turn on the gas and electrical supplies to the boiler and ensure that all external controls are calling for Gas Valve heat. 2. Set the temperature controls to maximum and the selector switch to the Off position (Fig.

  • Page 34: Completion

    12.0 Completion 12.1 Completion Case Front Panel 1. Refit the case front panel and tighten the securing screws (Fig. 52). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3. Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation.

  • Page 35: Servicing The Boiler

    13.0 Servicing the Boiler 13 .1 Annual Servicing Case Front Panel 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 Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication.
  • Page 36 Baffle 13.0 Servicing the Boiler Spring Clip 13.1 Annual Servicing (Cont) 10. Ease the front edge of the left hand baffle upwards, disengaging the spring clip. Disengage the tab on the baffle from the slot in the fan hood (Fig. 56). 11.

  • Page 37: Changing Components

    14.0 Changing Components IMPORTANT: When changing components ensure Pressure that both the gas and electrical supplies to the Switch boiler are isolated before any work is started. When the new component has been fitted turn the selector switch fully anticlockwise against the spring pressure to the ‘Reset’...
  • Page 38 14.0 Changing Components 14.3 Heat Exchanger (Fig. 64) 1. Remove the fan as described in section 14.1. 2. Drain the primary circuit. Prise the three pipe connecting clips off the joints in the flow and return pipes. Remove the heat exchanger return pipe. 3.
  • Page 39 14.0 Changing Components Injector Inlet Elbow Manifold 14.5 Injectors (Fig. 66) 1. Remove the burner as described in Section 14.4. 2. Undo the screws securing the injector manifold to the inlet elbow and remove the manifold. Gasket 3. Unscrew and replace injectors as required and examine the sealing gasket, replacing as necessary.
  • Page 40 14.0 Changing Components 14.8 Gas Valve (Fig. 68) 1. Undo the nut on the gas feed pipe under the boiler. Modulator Wires 2. Completely undo the securing screws and hinge the Ignition facia panel down. Lead Gas Valve 3. Disconnect the wires from the valve modulator and the ignition lead from the spark generator.
  • Page 41 14.0 Changing Components 14.11 Pump - Head Only (Fig. 71) 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 42 14.0 Changing Components 14.14 Pressure Gauge (Figs. 74 & 75) 1. Drain the primary circuit and undo the nut on the pressure gauge capillary. 2. Remove the timer cover and ease the timer wiring aside. Undo the screws securing the gauge retaining Fig.
  • Page 43 14.0 Changing Components 14.17 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 screw sufficiently to release the valve. 3. Note the orientation of the valve, rotate it and withdraw it from the manifold.
  • Page 44 14.0 Changing Components Plate Heat Exchanger 14.20 Plate Heat Exchanger (Fig. 67) 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 45 14.0 Changing Components Central Heating Pressure Differential Valve Microswitch / Bracket 14.21 Diverter Valve Assembly (Cont) Sensing Pipe Pressure Differential Valve (Fig. 84) 1. Remove the pressure differential valve as described above. By-pass Pipe Diaphragm 2. From the brass diverter manifold undo the nut on the heating flow pipe.
  • Page 46 14.0 Changing Components Secondary 14.23 Secondary Heat Exchanger (Fig. 87) Heat Exchanger 1. Drain the primary circuit Pipe Connecting Clip 2. Undo the four screws securing the right hand case panel. Remove the panel. 3. Prise the connecting clips from the heat exchanger return pipe and the boiler return pipe.

  • Page 47: Illustrated Wiring Diagram

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

  • Page 48: Fault Finding

    16.0 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), or 36mbar (propane).
  • Page 49 16.0 Fault Finding Domestic Hot Water - Follow operational sequence Turn selector to Go to section ‘A’ Replace diaphragm neon illuminated Is mains water DHW flow valve diaphragm filter and differential damaged assembly clean? Turn thermostat to max. DHW flow rate more than DHW flow valve rod Open DHW tap fully.
  • Page 50 Fault Finding Solutions Sections A to F 16.0 Fault Finding 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 and a Check wiring &...
  • Page 51 Fault Finding Solutions Sections G to L 16.0 Fault Finding Check the burner setting pressure of the gas valve (see Section 11.2 of Commissioning) Voltage at modulating coil of gas valve is: Max. burner press.approx 9V DC (13V DC LPG) Replace gas valve Min.

  • Page 52: Fault Indication Display

    17.0 Fault Indication Display 17.0 Fault Indication Display 1. The boiler has three neon indicators. The upper two function as boiler on and fault indicators. 2. Depending on the nature of the fault the upper two neons Burner On will illuminate, go off or flash. Flame Failure Fast Flashing (2 every second) 3.

  • Page 53: Short Parts List

    18.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. 5112627 Pressure Switch 5112999 Heat Exchanger 5112431 Burner 5112770 E66 402 Injector - 1.18 NG 248210 E66 408 Electrode Lead 248037 E66 411 Spark or Sensing Electrode 247384 Pump 248042 E66 432...

  • Page 54: Benchmark Checklist

    GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

  • Page 55: Service Record

    SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
  • Page 56 All descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet. All goods are sold subject to our standard Conditions of Sale which are available on request.

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