Potterton Performa 30 HE Installation & Service Instructions Manual
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Potterton Performa 30 HE Installation & Service Instructions Manual

Potterton Performa 30 HE Installation & Service Instructions Manual

Condensing combination boiler
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See also: User Manual
You can rely on
Installation & Service Instructions
Performa 30 HE
Condensing
Combination Boiler
These instructions include the Benchmark Commissioning
Checklist and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2008

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Summary of Contents for Potterton Performa 30 HE

  • Page 1 You can rely on Installation & Service Instructions Performa 30 HE Condensing Combination Boiler These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2008...

  • Page 2: Table Of Contents

    Natural Gas Contents Potterton Performa 30 HE G.C.N 47 393 13 Section Page Legislation Introduction The Benchmark Scheme Benchmark places responsibilities on both manufacturers and installers. The purpose is to General Layout ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions...
  • 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 30 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.

  • 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 Pressure Relief Valve Optional Integral Timer Central Heating System Pressure Gauge Control Box 3-Way Valve Assembly Condensate Trap Flame Sensing Electrode Spark Electrode Burner...

  • 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

    Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 Pump - Available Head SEDBUK Declaration For Performa 30 HE The seasonal efficiency (SEDBUK) is 87.3% (89.4% LPG) Band B This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings.

  • 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 1. The Potterton Performa 30 HE 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 Stop Stop 2. There are connection points on the mains cold water Check Valve Valve...
  • 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. C a Horizontally to an opening, air brick, opening window etc. Flue D Below gutters, soil pipes or drain pipes.

  • Page 18: Flue Options

    8.0 Flue Options The Potterton Performa 30 HE can be fitted with either horizontal, vertical or twin flue systems. Horizontal Flue Systems 1. The standard flue is suitable only for horizontal applications. 2. All fittings should be fully engaged. The approximate engagement is 40mm.
  • 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 Baxi 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 100mm...
  • 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, making sure that it is pushed down as far as possible. Blanking Plate Air duct adaptor Boiler Adaptor 1.
  • Page 22 4. The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated. 8.10 Flue Deflector (Fig. 13a) 1. If required a flue deflector is available from your Potterton stockist. Fig. 14 2. Push the flue deflector over the teminal end and rotate to the optimum angle for deflecting plume.

  • 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 60Ø Exhaust Support Flue Length - Worked Example 93° Elbow Bracket Potterton Performa 30 HE In Fig. 18 opposite an additional 93° bend has been included Extension in the 60Ø exhaust. with 2 x 1metre extensions which have Concentric 60/100 Flue been cut to 0.25metres and fitted.
  • 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 at least 1.5°. 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 Wall Plate 10.0 Installation 10.4 Fitting The Boiler 1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. The boiler should be lifted by TWO PEOPLE. Engage the slots at the top rear of the boiler on the wall plate (Fig. 32). See ‘Safe Manual Handling’...
  • Page 29 10.0 Installation 10.7 Fitting The Flue HORIZONTAL FLUE 1. The standard flue is suitable for lengths between 100mm minimum and 685mm maximum, as measured from the edge of the flue elbow outlet to the joint between the terminal and air duct (Fig. 34). 2.
  • Page 30 Fig. 38 11. Fit the flue trim if required, and if necessary fit a terminal guard (see Section 8.8 & 8.9). VERTICAL FLUE 1. Only a flue approved with the Potterton Performa 30 HE can be used. Flue Elbow Fig. 39...
  • 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 Checklist at the rear of this Vent publications.
  • 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 heat. Gas Valve 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. Hinge the facia panel upwards and refit the case front panel. Tighten the securing screws (Fig. 52). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3.

  • 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) 11. 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). 12.

  • 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 2. Completely undo the securing screws and hinge the Wires facia panel down. Ignition 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 14.12 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 14.15 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 14.18 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 14.21 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 14.22 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 14.24 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. Fan Spigot Outlet Pipe Clamp 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 Air Pressure Switch Central Heating Temperature Sensor Domestic Hot Water Temperature Sensor Domestic Hot Water Flow Priority Pressure Switch Hydraulic Differential Pressure Switch Pump Control PCB Flame Sensing Electrode Mains Input Link Fuse Overheat Stat Flue Stat Gas Valve Condensate Trap...

  • 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). 2.
  • Page 49 16.0 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 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 16.0 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 and a Check wiring &...
  • Page 51 16.0 Fault Finding Check and correct if necessary 1. Electrical and pressure tube connections Replace air pressure 2. Blockage of pressure tubes switch 3. Restriction in flue 4. Venturi Gas at burner Ensure gas is on and purged PCB - A1 connector has 230V AC Replace gas valve across terminals 2 &...
  • Page 52 16.0 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 or Allow to cool.

  • Page 53: Short Parts List

    17.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. 5112430 Pressure Switch 248466 Heat Exchanger 5112431 Burner 5112770 Injector 5112376 E66 408 Electrode Lead 248037 E66 411 Spark or Sensing Electrode 247384 Pump 248042 E66 432 3-Way Valve Assy. 248061 342 571 Temperature Sensor...

  • 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 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 D i v i s i o n o f B a x i G r o u p Brooks House, Coventry Road, Warwick. CV34 4LL After Sales Service 0844 871 1560 Technical Enquiries 0844 871 1555 Website www.potterton.co.uk e&oe UK Comp N 5111815 - Iss 7 - 7/09 ©...

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