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

Potterton Performa SL HE Installation & Service Instructions Manual

Condensing central heating boiler
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Installation & Service Instructions
Performa SL
HE Range
Condensing
Central Heating
Boiler
Only a flue approved for the Performa SL HE can be used.
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 SL HE

  • Page 1 HE Range Condensing Central Heating Boiler Only a flue approved for the Performa SL HE can be used. 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

    Flush the System..........32 the back of these instructions. Final Adjustments.........33 Advise the User..........33 Potterton is a member of the Benchmark initiative and Documentation..........33 fully supports the aims of the programme. Its aim is to 7. Control Sequence.........34 improve the standards of installation and commissioning 8.
  • Page 3 Installer Notification Guidelines Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme Contact your relevant Local Install and Commission this Authority Building Control appliance to manufacturer's (LABC) who will arrange instructions an inspection or contact a government approved inspector Complete the Benchmark Checklist...

  • Page 4: Introduction

    Performa SL HE boilers meet the requirements of For the boiler to operate correctly all air must be Statutory Instrument “The...
  • Page 5 Health and Safety Information for the Installer and Service Engineer Under the Consumer Protection Act 1987 and Section 6 of the Health and Safety at Work Act 1974, we are required to provide information on substances hazardous to health. Small quantities of adhesives and sealants used in the product are cured and present no known hazards.

  • Page 6: Technical Data

    IP20 Boiler Type Boiler Category CAT 1 2H - G20 - 20 mbar SEDBUK Declaration for Model Seasonal Efficiency Performa SL HE (SEDBUK) (%) This value is used in the UK 9 SL 86.1 Government's Standard Assessment 12 SL 86.4...
  • Page 7 Return Connection Flow Connection Flow Sensor Overheat Sensor Casting Sensor Air Pressure Switch 'O' Ring and Clip Joints Fan and Flue Hood Secondary Heat Exchanger Primary Heat Exchanger Burner & Electrodes Data Label Wiring Centre PCB Enclosure Condensate Trap 75 mm Gas Connection 410 mm overall Gas Valve...

  • Page 8: Installation Requirements

    3. Installation Requirements General Information Important – Failure to install and commission this boiler to manufacturer’s instructions may invalidate the warranty. This does not affect your statutory rights. Optional Extras In IE, the installation must be carried out by a competent person and installed in accordance with the Various flue extensions, bends, vertical flue kits, control current edition of:...

  • Page 9: Electricity Supply

    Electricity Supply Bath or Shower Room If the boiler is fitted in a room containing a bath or shower, it can only be fitted in Zone 3, Figs. 2 & 3 show Zone 230V ~ 50Hz via a fused double pole switch with dimensions for a bathtub.

  • Page 10: Condensate Disposal

    Condensate Disposal Termination via internal discharge branch e.g sink waste - downstream This boiler incorporates a 75 mm trap. Boiler Ensure the disposal of condensate complies with Pipe must terminate any national or local regulations in force. above water level but Sink below surrounding Failure to install the condensate disposal pipework...

  • Page 11: Air Supply

    Air Supply Flue Systems The room in which the boiler is installed does not require Horizontal a purpose provided air vent. The standard flue/terminal assembly can be cut and 3.7.1 Ventilated Cupboard/Compartment is suitable for an installed length from 160 mm up to 700 mm.
  • Page 12 Terminal Position with Minimum Distance (Fig. 8) (mm) A a Directly below an opening, air brick, opening windows, etc B a Above an opening, air brick, opening window etc. NOTE: The distance from a fanned draught appliance C a Horizontally to an opening, air brick, opening window etc. terminal installed parallel to a boundary may not be less D Below gutters, soil pipes or drain pipes.
  • Page 13 3.8.2 Horizontal Flue Systems 1. The standard flue is suitable only for horizontal applications. 2. Maximum permissible equivalent flue lengths is:- Horizontal Concentric 3.55m 3. Any additional “in line” bends in the flue system must be taken into consideration. Their equivalent lengths are:- Concentric Pipes: 135°...
  • Page 14 Vertical 3.8.3 Twin & Vertical Flue Systems Flues (Twin Pipe) 1. Maximum permissible equivalent flue lengths are:- Vertical Concentric 1.9m Vertical Twin Pipe * Both the air and flue duct can be up to 6 metres long each. 2. Any additional “in line” bends in the flue system must be taken into consideration.
  • Page 15 3.8.4 Flue Accessories Key Accessory Size Baxi Code FLUE GROUP A Concentric Flue System 100mm diameter Telescopic Internal Flue Kit 315-500mm 5119654 Telescopic Flue 5118069 (incl elbow) Horizontal flue Terminal 5118489 (incl elbow) Flue extension 1000mm 5111074 Flue Bend 93° 5111075 Flue Bend 135°...
  • Page 16 For Twin Flue Systems fit the adaptors as follows:- 3.8.5 Vertical Flue Duct Adaptor (Fig. 11) Vertical Flue 1. Remove the flue elbow from top of the boiler and Boiler Adaptor replace with the vertical flue duct adaptor ensuring the existing gasket is still in place.
  • Page 17 3.8.7 For Roof Terminals 1. In the case of a pitched roof 25 - 50 degrees, position the lead tile to replace/flash over existing roof tiling. Make an Approx 1425mm aperture in the roof suitable for the lower tube of the roof terminal and ensure the integrity of the roof cover is maintained.

  • Page 18: Plume Displacement

    93° Elbow/Plume Outlet Assembly Plume Displacement Kit (Fig. 14b) 60Ø Support O Ring Bracket Kit No 5118638 Content of kit 0.9m 60/100 Concentric Flue 1m 60 Dia Exhaust Flue Pipe 0.9 metres 60Ø Exhaust Adaptor Flue Pipe 60 Dia Support Brackets 93°...
  • Page 19 1 metre, each 45° elbow to 0.5 metres. 60Ø Exhaust Flue Length - Worked Example Support Bracket Potterton Performa 24 SL HE 93° Elbow In Fig. 18 opposite an additional 93° elbow has been included in the 60Ø exhaust. with 2 x 1metre Extension Concentric 60/100 Flue extensions which have been cut to 0.25metres and...
  • Page 20 3.9.2 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. When completed the terminal must be at least 2 metres above ground level (Fig.
  • Page 21 Plume Outlet Elbow 3.9.2 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 22: Water Circulating Systems

    3.10 Water Circulating Systems To ensure correct circulation, it is essential to vent all air from the system prior to commissioning the boiler. The boiler is suitable for use with fully pumped open System Drain Off Points vented and sealed systems with an indirect coil type Drain off points should be fitted in the pipework close to high efficiency cylinder.
  • Page 23 3.10.5 Boiler Protection ydraulic resistance • A frost thermostat is fitted within the boiler controls which operates even if the temperature control knob is at the ( ) position. The boiler will operate as necessary to maintain the boiler temperature above freezing.
  • Page 24 3.10.6 Sealed Systems The vessel size can now be determined from the information in Table 3 where V = System size in litres. System Components All components used in the sealed system must be Vessel Charge Pressure (bar) suitable for operation at 110°C and at the maximum pressure allowed by the pressure relief valve (normally Initial System Pressure (bar) 3 bar).
  • Page 25 Indirect HE Cylinder Auto air vent Pressure gauge visible from filling point Optional Safety 2 port Optional valve 3 port valves Pump with valve isolating valves Flow Automatic Expansion Alternative existing by-pass or vessel by-pass arrangement existing using the bathroom by-pass Auto air vent radiator fitted with two...

  • Page 26: Installation

    4. Installation Unpack & Prepare the Wall & Boiler Cut with MINIMUM CLEARANCE MINIMUM CLEARANCE 3° Rise Core Drill Flue Hole Centre Line Centre Line 105mm (4")minimum Flow Return These instructions assume you have chosen a 127mm (5") mimimum for Internal Fitment Kit suitable boiler location which will also allow STAND OFF KIT-...

  • Page 27: Install The Flue

    Install the Flue Standard Horizontal Flue These instructions are for standard horizontal Minimum dimension X including wall rear and side flue applications which have a thickness = 160 mm maximum horizontal installed length of 700 mm Rear flue when fitted. Maximum dimension X = 700 mm The flue elbow is supplied set to the rear.

  • Page 28: Electrical Connections

    The wiring must be routed through the supplied cable clamp. from boiler Connect the power supplies as follows; Typical Potterton Permanent Live to 'Mains L'. External To System Wiring Neutral to 'Mains N'. Programmer Earth to 'Mains E'. Fused 3A Switched Live (from system) to ‘SwL’...

  • Page 29: Connect The Gas Supply

    Connect the Gas Supply 1. Ensure that the gas supply is isolated at Gas cock Open the meter. 2. Solder the gas tail (supplied) to main gas supply before connecting the tail to the gas cock. Securing screws To prevent blow lamp damage to the wiring and condensate trap, any soldering of gas pipework must be done away from the boiler.

  • Page 30: Wiring Diagrams

    5. Wiring Diagrams Boiler Wiring Fig. 39 © Baxi Heating UK Ltd 2008...
  • Page 31 Typical System Wiring Fig. 40 © Baxi Heating UK Ltd 2008...

  • Page 32: Commissioning

    6. Commissioning 6.1 Commission the Water, Electrical and Gas 9. Turn the temperature control knob to ( ) position and check that the burner shuts down. Systems 10. Remove the pressure gauge, re-fit the screws and Water check for gas soundness. The system should be cold flushed.

  • Page 33: Final Adjustments

    Final Adjustments Temperature Control Turn the temperature control knob to adjust the radiator surface temperature and hot water tap temperature between approximately 63°C and 82°C. Overheat Thermostat The boiler will require re-setting if an overheat condition occurs (the ‘Lockout’ (Red) light will flash). Other Boiler Controls No further setting or checking is necessary as all boiler mounted controls are fail safe.

  • Page 34: Control Sequence

    7. Control Sequence Standby Switched live - ON On/Off switch - ON Check thermistors Indicate thermistor fault give valid readings Flow temperature > 100C Pump ON Pump overrun Overheat Lockout Check 2 mins thermistors Indicate thermistor fault read within 8C Flow temperature >...

  • Page 35: Fault Finding Guide

    8. Fault Finding Guide Lockout Codes = off = flashing = on FAULT CONTROL DISPLAY RESET Lockout Burner Mains Electrical Supply Fault Lockout Burner Mains Ignition LOCKOUT Manual Lockout Burner Mains Overheat LOCKOUT Manual Lockout Burner Mains False Flame Fault Automatic Lockout Burner...
  • Page 36 Electrical Supply Fault Lockout Burner Mains Refer to the boiler wiring diagram This boiler requires both a permanent live and a switched live. Both need to be a minimum of 190V to function Is there 230V No Permanent Live to boiler at boiler terminal block Check systems controls (Mains L and N) ?
  • Page 37 Ignition Lockout Lockout Burner Mains Refer to the boiler wiring diagram Is more than 17 mbar dynamic Incorrect gas supply pressure at the to boiler gas valve inlet ? Are Live and Correct the Live and Neutral to boiler Neutral connections reversed ? Replace PCB Replace gas valve...
  • Page 38 Overheat Lockout Lockout Burner Mains Refer to the boiler wiring diagram flashing Wait until the temperature at the flow pipe is <60C Unplug the 8 way connector from PCB. Check as the Is there continuity 'Water Circulation Lockout' fault between the 2 black wires ? Remove...
  • Page 39 Water Circulation Lockout Lockout Burner Mains Refer to the boiler wiring diagram This indication can be activated by two faults: flashing flashing 1) Flow direction is checked after 1 minute of burner fire. If the casting thermistor reads a higher temperature than the flow thermistor, the fault occurs. This does not cause a lockout. 2) Adequate circulation is checked continuously during burner fire.
  • Page 40 Air Pressure Switch Stuck Fault Lockout Burner Mains Refer to the boiler wiring diagram flashing Switch the boiler on Replace PCB Refit the Unplug Open circuit on 12 way the 12 way After 15 the wiring. Rectify connector to PCB. connector from PCB.
  • Page 41 Thermistor Fault - Flow and Casting Lockout Burner Mains Refer to the boiler wiring diagram flashing There are two types of fault which can occur: Flow thermistor fault 1) The thermistors are reading outside of limits (this is checked before the PUMP is switched on and during Burner on).

  • Page 42: Servicing & Parts Replacement

    Condensate trap - remove if required, see 9.13. • Ensure you are using the correct Potterton approved Place a vessel underneath to catch the spare part when replacing any items as incorrect or condensate then remove the trap drain plug.
  • Page 43 Return Connection Flow Connection Flow Sensor Overheat Sensor Flue Sample Point Casting Sensor Air Pressure Switch 'O' Ring and Clip Joints Fan and Flue Hood Secondary Heat Exchanger Primary Heat Exchanger Burner & Electrodes Data Label Wiring Centre PCB Enclosure Condensate Trap Gas Connection Gas Valve...

  • Page 44: Parts Replacement

    9. Parts Replacement 9.2 General Access 1. Isolate the supplies as detailed in 9.1.2. 2. Pull the door panel down and remove the two screws. Carefully slide the bottom cover out and away from the boiler. 3. Remove the three screws and carefully lift the outer case away from the boiler.

  • Page 45: Air Pressure Switch

    9.5 Air Pressure Switch Ease bracket open Disconnect tubes 1. Perform General Access - See 9.2. 2. Disconnect the wires at the switch. 3. Note how they are fitted then disconnect the sensing tubes at the switch. 4. Ease the front of the bracket forwards and carefully prise the switch out of the bracket.

  • Page 46: Fan & Flue Hood

    9.9 Fan and Flue Hood Warning 325V d.c a.c fan - 9 to 18 models Isolate the d.c. fan - 21 and 24 models mains supply. 1. Perform General Access - See 9.2. Sensing tubes 2. Remove the screw securing the front combustion chamber cover.

  • Page 47: Electrodes/Burner

    9.10 Electrodes/Burner 1. Perform General Access - See 9.2. 2. Remove the combustion chamber cover - Ignition electrode Sensing electrode See 9.9. Remove screw 3. Disconnect the ignition lead from the ignition electrode and the sensing lead and earth lead from the sensing electrode. If replacing electrode(s), remove securing screw(s) as appropriate.

  • Page 48: Combustion Chamber Insulation

    9.12 Combustion Chamber Insulation Important: See Section 3.1, Health and Safety information before handling insulation. 1. Perform General Access - See 9.2. 2. Remove the screw securing the front combustion chamber cover. Pull the cover out slightly then down to unhook and lift away from the boiler.

  • Page 49: Condensate Trap

    9.13 Condensate Trap 1. Perform General Access - See 9.2. Place a vessel underneath to catch the condensate then remove the drain plug. Take care as the condensate could be hot. Spring clip 2. Disconnect condensate disposal pipework from the flat faced union on the trap and swing pipework away from boiler.

  • Page 50: Primary Heat Exchanger

    9.14 Primary Heat Exchanger Screw 1. Perform General Access - See 9.2. Flue duct securing bracket 2. Drain the system as necessary. 3. Remove the combustion chamber cover - See 9.9. 4. Drain the heat exchanger, a drain point is located on the left hand side bottom of the Bolt Screw...

  • Page 51: Secondary Heat Exchanger

    9.15 Secondary Heat Exchanger 1. Perform General Access - See 9.2. 2. Drain the system as necessary. 3. Drain the Heat Exchanger - See 9.14, 4. Pipe clips 4. Remove the Spark Igniter - See 9.6. To ease removal of the secondary heat exchanger it may be necessary to:- Remove the Air Pressure Switch - See 9.5.

  • Page 52: Short Spares List

    10. Short Spares [18 to 24] [9 to 15] [18 to 24] [9 to 15] [21 to 24] [9 to 18] Fig. 64 © Baxi Heating UK Ltd 2008...
  • Page 53 Drg. Ref. G.C. No. Description Part No. 114-852 Sight glass mica 238162 114-872 Mica retainer outer 238106 Fan and gasket kit 9 SL HE 5112318 Fan and gasket kit 12 SL HE 5112319 Fan and gasket kit 15 & 18 SL HE 5112320 Fan and gasket kit 21 &...

  • Page 54: Benchmark Commissioning Checklist

    BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...

  • Page 55: Service Interval Record

    SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
  • Page 56 A Tr a d in g D i v i si o n o f B a xi He at i ng U K L td ( 3 8 7 9 1 5 6 ) A D ivis ion of B a xi Gro 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 ompany © Baxi Heating UK Ltd 2008 5131110 - Iss 1 Publication No.

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