Potterton Performa System 12 HE Installation & Service Instructions Manual

Wall mounted powered flue condensing boiler gas fired central heating unit

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Page 1 Installation & Service Instructions Performa System HE This is a Wall Mounted Powered Flue Condensing Boiler Gas Fired Central Heating Unit. 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 fired with liquid or gaseous fuels:- Type test for purpose of Regulation 5 certified by: Notified Body 0051.
Page 2 Potterton is a member of the Benchmark initiative and fully supports the aims of the programme. Its aim is to improve the standards of installation and commissioning...
Page 3 INSTALLER NOTIFICATION GUIDELINES Install and Commission this appliance to manufacturer's instructions Complete the Benchmark Checklist Choose Building Regulations Notification Route Competent Person's Building Control Self Certification Scheme If you notify via CORGI Scheme, Contact your relevant Local CORGI will then notify the Authority Building Control relevant Local Authority (LABC) who will arrange...
Page 4 LEGISLATION IMPORTANT - Installation, Commissioning, Service & Repair Potterton declare that no substances harmful to health are contained in the appliance or used This appliance must be installed in accordance with the manufacturer’s during appliance manufacture. instructions and the regulations in force. Read the instructions fully before installing or using the appliance.
Page 5: Table Of Contents
CONTENTS Section Page Introduction General Layout Appliance Operation Technical Data Dimensions and Fixings System Details Site Requirements Installation Commissioning 10.0 Completion 11.0 Servicing 12.0 Changing Components 13.0 Electrical 14.0 Short Parts List 15.0 Fault Finding Benchmark Checklist Publication No. 5111817...
Page 6: Introduction
INTRODUCTION Description 1. The Potterton Performa System HE range are fully automatic gas fired wall mounted system boilers. They are room sealed and fan assisted. Case Front Panel 2. The boilers are set to give a maximum output of 12.5kW, 18.9kW, 25.2kW or 29.3kW when in condensing mode.
Page 7: General Layout
GENERAL LAYOUT Layout Air Pressure Switch Expansion Vessel Burner Manifold Automatic Air Vent Circulation Pump Drain Off Point Pressure Relief Valve System Pressure Gauge Control Box Condensate Trap Flame Sensing Electrode Spark Electrode Burner Primary Heat Exchanger Fan Assembly Secondary Heat Exchanger On/Off/Reset Selector Switch Temperature Control Flame Failure or Blocked Condensate Drain...
Page 8: Appliance Operation
APPLIANCE OPERATION Operating Mode (Fig. 2) Boiler Primary Circuit 1. With a demand for heating, the pump circulates water through the primary circuit. At a pre-determined flow rate the hydraulic differential pressure switch operates, initiating the ignition sequence. 2. The main burner ignites at low rate, then the gas valve controls the gas rate to maintain the heating temperature measured by the temperature sensor.
Page 9: Technical Data
Installation Lift Weight Electrical Protection IPX5D Pump - Available Head SEDBUK Declaration For Performa System 12 HE The seasonal efficiency (SEDBUK) is 86.8% (86.6% LPG) Band B This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by 0051.
Page 10 TECHNICAL DATA System 18 HE Appliance Type NO x Class Central Heating Primary Circuit Pressures Appliance Category CAT II 2H 3P Condensate Drain 1” BSP Safety Discharge Heat Input Max Operating Flue Terminal Diameter 100mm Min Operating Dimensions Projection 125mm 18.7 10.6 Recommend Operating...
Page 11 TECHNICAL DATA System 24 HE Appliance Type NO x Class Central Heating Primary Circuit Pressures Appliance Category CAT II 2H 3P Condensate Drain 1” BSP Safety Discharge Heat Input Max Operating Flue Terminal Diameter 100mm Min Operating Dimensions Projection 125mm 24.8 10.6 Recommend Operating...
Page 12 TECHNICAL DATA System 28 HE Appliance Type NO x Class Central Heating Primary Circuit Pressures Appliance Category CAT II 2H 3P Condensate Drain 1” BSP Safety Discharge Heat Input Max Operating Flue Terminal Diameter 100mm Min Operating Dimensions Projection 125mm 28.9 11.9 Recommend Operating...
Page 13: Dimensions And Fixings
DIMENSIONS AND FIXINGS Dimensions A 780mm 3° B 345mm C 450mm D 107mm Ø Min. E 185mm F 190mm G 131mm 360° Orientation Tube Ø 100mm Tap Rail 28mm Condensate Drain 130 mm 130 mm 65 mm Heating Heating Pressure Relief Return Flow Inlet...
Page 14: System Details
SYSTEM DETAILS Central Heating Circuit 1. The appliance is suitable for fully pumped SEALED SYSTEMS ONLY. Treatment of Water Circulating Systems • All recirculatory water systems will be subject to corrosion unless an appropriate water treatment is applied. This means that the efficiency of the system will deteriorate as corrosion sludge accumulates within the system, risking damage to pump and valves, boiler noise and circulation problems.
Page 15 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 Check Stop 2. The filling method adopted must be in accordance Valve Valve Valve...
Page 16: Site Requirements
SITE REQUIREMENTS 20mm/5mm Min Location see *NOTE: 5mm Min 450mm 1. The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and discharging to atmosphere in a position permitting satisfactory removal of combustion products and 200mm Min providing an adequate air supply.
Page 17 SITE REQUIREMENT 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. Gas Supply 1.
Page 18 SITE REQUIREMENTS Condensate Drain Termination to an internal soil Boiler FAILURE TO INSTALL THE CONDENSATE and vent pipe 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 19 SITE REQUIREMENTS Flue NOTE: Due to the nature of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. Terminal Position with Minimum Distance (Fig. 9) (mm) 1.
Page 20 SITE REQUIREMENTS Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 685 from elbow to terminal (Fig. 10). The maximum permissible equivalent flue length System 12 &18 HE 5 metres System 24 HE 4 metres System 28 HE 3 metres Flue Trim...
Page 21 SITE REQUIREMENTS 7.11 Flue Options 1. The Potterton Performa System HE range can be fitted with flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. 3. Maximum permissible equivalent flue lengths are:- 12,18 Concentric Vertical...
Page 22: Installation
INSTALLATION 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 23 INSTALLATION Fitting The Boiler Wall Plate 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. 14). 3. Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections.
Page 24 INSTALLATION 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. 16). 2.
Page 25 11. Fit the flue trim if required, and if necessary fit a terminal guard (see Section 7.9 & 7.10). VERTICAL FLUE 1. Only a flue approved with the Potterton Performa System HE range can be used. 2. For information on vertical flues consult the Potterton Flue Guide brochure.
Page 26: Condensate Trap
INSTALLATION 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 securing tabs are clear of the facia. Remove the panel. Control Box Cover Fig.
Page 27: Commissioning
COMMISSIONING Commissioning the Boiler 1. Reference should be made to BS 5449 when commissioning the boiler. Screw 2. Ensure that the filling loop is connected and open, then open the heating flow and return valves on the boiler. Automatic 3. Open the screw on the automatic air vent Air Vent (Fig.
Page 28: Burner
COMMISSIONING 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. Pressure Test Point Sealing Screw 2. Set the temperature control to maximum and the selector switch to the Off position (Fig.
Page 29: Completion
10.0 COMPLETION 10.1 Completion Case Front Panel 1. Hinge the facia panel upwards and refit the case front panel. Tighten the securing screws (Fig. 34). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3.
Page 30: Servicing
11.0 SERVICING 11 .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 31 11.0 SERVICING 11.1 Annual Servicing (Cont) Baffle 12. Ease the front edge of the left hand baffle Spring Clip upwards, disengaging the spring clip. Disengage the tabs on the baffle from the slots in the fan hood (Fig. 38). 13. Undo the screws securing the fan and hood to the appliance back panel.
Page 32: Changing Components
12.0 CHANGING COMPONENTS IMPORTANT: When changing components Pressure ensure that both the gas and electrical supplies to Switch the 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 33 12.0 CHANGING COMPONENTS 12.3 Heat Exchanger (Fig. 44) 1. Remove the fan as described in section 12.1. 2. Drain the primary circuit. Prise the pipe connecting clips off the joints in the flow and return pipes. Remove the heat exchanger return pipe. 3.
Page 34 12.0 CHANGING COMPONENTS 12.5 Injectors (Fig. 46) Injector Inlet Elbow Manifold 1. Remove the burner as described in Section 12.4. Injector 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 35 12.0 CHANGING COMPONENTS 12.8 Gas Valve (Fig. 48) 1. Undo the nut on the gas feed pipe under the boiler. 2. Completely undo the securing screws and hinge Modulator Wires the facia panel down. Ignition 3. Disconnect the wires from the valve modulator and Gas Valve Lead the ignition lead from the spark generator.
Page 36 12.0 CHANGING COMPONENTS 12.12 Pump - Head Only (Fig. 51) 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 37 12.0 CHANGING COMPONENTS Pressure Gauge 12.15 Pressure Gauge (Figs. 54 & 55) Capillary 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 38 12.0 CHANGING COMPONENTS 12.18 Main PCB (Fig. 59) 1. Note the setting of the temperature control knob. Rotate the knob fully anticlockwise and carefully pull it off the drive pin. 2. Completely undo the screws securing the control box cover and release the cover retaining barbs from their slots.
Page 39 12.0 CHANGING COMPONENTS 12.20 Central Heating Differential Valve (Figs. 60 & 61) 1. Drain the primary circuit. 2. Undo the screw securing the microswitch to the differential valve. Allow the microswitch to rest to one side. 3. Undo the pressure gauge capillary nut and heating flow pipe nut from the valve.
Page 40 12.0 CHANGING COMPONENTS 12.23 Secondary Heat Exchanger) (Fig. 63) 1. Drain the primary circuit Secondary Heat Exchanger 2. Undo the four screws securing the right hand case panel. Remove the panel. Pipe Connecting Clip 3. Prise the connecting clips from the heat exchanger return pipe and the boiler return pipe.
Page 41: Electrical
13.0 ELECTRICAL 13.1 Illustrated Wiring Diagram Pump Air Pressure Switch Hydraulic Differential Pressure Switch Control PCB Return Heating Temperature Sensor Flame Sensing Central Heating Electrode NTC Sensor Mains Input Link Fuse Overheat Stat Flue Stat - brown - black - blue Reset Selector Switch - red Gas Valve...
Page 42: Short Parts List
14.0 SHORT PARTS LIST Key G.C. Description Manufacturers No. No. Part No. Fan (12,18 HE) 5113278 Fan (24 HE) 5112627 Fan (28 HE) 5112430 Pressure Switch (12 HE) 5113279 Pressure Switch (18 HE) 5113280 Pressure Switch (24,28 HE) 248466 Heat Exchanger (12,18 HE) 5113284 Heat Exchanger (24,28 HE) 5112431...
Page 43: Fault Finding
15.0 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 44 15.0 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 45 15.0 FAULT FINDING Check the burner setting pressure of the gas valve (see Section 9.2 of Commissioning) Voltage at modulating coil of gas valve is: Max. burner press.approx 9V DC (13V DC LPG) Replace gas valve Min. burner press.approx 1V DC Current at modulating coil of gas valve is: (Use an instrument with average function for this measure)
Page 46: Benchmark Checklist
5 1 1 1 8 1 7 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 47: 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 48 B A X I P O T T E R T O N A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www.potterton.co.uk 923.690.2 company...

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