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Potterton Performa 28 Installation And Servicing Instruction

Gas fired wall mounted combination boiler
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Performa 28
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 28

  • Page 1 Performa 28 Gas Fired Wall Mounted Combination Boiler Installation and Servicing Instructions Please leave these instructions with the user...
  • Page 2 Natural Gas Potterton Performa 28 G.C.N 47 393 07 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

    “Benchmark” Log Book Undertaking. Where no specific instructions are given, reference should be made to the relevant As part of the industry-wide “Benchmark” initiative all Potterton boilers now BRITISH STANDARD CODES OF PRACTICE. include an Installation, Commissioning and Service Record Log Book.

  • 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 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. 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 7: Technical Data

    4.0 Technical Data Performa 28 Appliance Type DHW Circuit NO x Class Pressures Appliance Category CAT II Flue Terminal Diameter 100mm Max Operating 2H 3P Dimensions Projection 95mm Min Operating Heat Input C/H & DHW (Gross) Min Operating Pressure Connections copper tails at 12.7 l/min...

  • Page 8: Dimensions And Fixings

    5.0 Dimensions and Fixings Dimensions A 780mm B 345mm C 450mm D 107mm Ø Min. E 200mm F 190mm G 143mm 360° Orientation Tube Ø 100mm Tap Rail 65 mm 65 mm 65 mm 65 mm 65 mm Heating Pressure Relief Heating Domestic Hot Cold Water...

  • Page 9: System Details

    6.0 System Details Information 1. The Potterton Performa 28 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 (Fig. 6) 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 the Water Supply (Water Fittings) Check Regulations 1999 Schedule 2, Section 8,...

  • 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 registered competent person and be in accordance with the relevant 200mm Min requirements of the current G (Installation AFETY and Use) R...
  • 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 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 flue terminal position must be in accordance with the current editions of B.S. 5440 Part 1, and either Part J of the Building Regulations England and Wales or Part F of the Building Standards (Scotland) Regulations as appropriate.
  • Page 15 7.0 Site Requirements Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 1m from elbow to terminal (Fig. 12). The maximum permissible equivalent flue length is: 4 metres 7.10 Flue Terminal Trim Fig. 12 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 28 can be fitted with flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. Maximum Length = 3m inc. 2 x 45° bends 3. Maximum permissible equivalent flue lengths...

  • Page 17: Installation

    NOTE: A small amount of water may drain from the boiler in the upright position. Fig. 17 Central Heating Return Potterton declare that no substances harmful to health are contained in the appliance or used during construction of the appliance.
  • Page 18 Wall Plate 8.0 Installation Fitting The Boiler 1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate (Fig. 18). 3.
  • 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 equivalent flue length is Seal greater than 1.5m the restrictor MUST be Restrictor removed from the adaptor (Fig. 22). Adaptor 8. Take one of the rubber seals and position it on Fig.
  • Page 21 8.0 Installation Making The Electrical Connections 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 Screw 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Open the mains water supply to the boiler. Automatic Air Vent 3. Open all hot water taps to purge the DHW system.
  • Page 23 Commissioning the Boiler Pressure Test Point Sealing Screw 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 24: Completion

    10.0 Completion 10.1 Completion Case Front Panel 1. Hinge the facia panel upwards and refit the case front panel. Secure them with the screws previously removed (Fig. 37). 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. 42). 11. Undo the screws securing the fan and hood to the appliance back panel.

  • 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. When the component has been changed turn the selector switch fully Sensing anticlockwise against the spring pressure to Tubes the reset position and hold for 2 seconds to reset the boiler before recommissioning.
  • Page 28 12.0 Changing Components 12.3 Heat Exchanger (Fig. 48) 1. Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them. 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. 50) 1. Remove the burner as described in Section 12.4. 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. 52) 1. Undo the nut on the gas feed pipe under the boiler. 2. Remove the securing screws and hinge the facia panel down. Gas Valve 3. Disconnect the earth wire and pressure sensing pipe from the valve.
  • Page 31 12.0 Changing Components 12.12 Pump - Head Only (Fig. 54) 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 12.15 Pressure Gauge (Figs. 57 & 58) 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 bracket.
  • Page 33 12.0 Changing Components 12.18 Pressure Relief Valve (Fig. 61) 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 34 12.0 Changing Components Plate Heat Exchanger 12.21 Plate Heat Exchanger (Fig. 64) 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 Pressure Differential Microswitch / Bracket 12.22 Diverter Valve Assembly (Cont) Valve Sensing Pipe Pressure Differential Valve (Fig. 67) 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 36: Illustrated Wiring Diagram

    13.0 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 Gas Valve Spark Generator - brown - green...

  • 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 - A4 Replace selector connector terminals 4 &...
  • 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 - A1 connector has 230V AC Replace gas valve across terminals 2 &...
  • 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 G.C. Description Manufacturers Part No. E66 527 248002 393 974 Pressure Switch 247380 E66 535 Heat Exchanger 248017 E66 399 Burner 248030 E66 402 Injector 248210 E66 408 Electrode Lead 248037 E66 411 Spark or Sensing Electrode 247384...
  • 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 922.049.2 Comp N 249110 - Iss 2 - 7/01...

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