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Potterton Performa 24i HE Installation And Service Instructions Manual

Wall mounted powered flue condensing combination boiler gas fired central heating unit
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See also: User Manual
Installation & Service Instructions
Performa
24i HE
This is a Wall Mounted Powered Flue Condensing Combination Boiler Gas Fired Central Heating Unit.
The boiler meets the requirements of Statutory Instrument " The Boiler (Efficiency) Regulations 1993 N
o
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.
Product/Production certified by:
Notified Body 0051.
For use in GB/IE only.

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  • Page 1 Installation & Service Instructions Performa 24i HE This is a Wall Mounted Powered Flue Condensing Combination 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:...

  • Page 2: Natural Gas

    Natural Gas Potterton Performa 24i HE G.C.N 47 393 12 This product has an energy rating (B) on a scale of A to G. For more information see www.boilers.org.uk. This is a certification mark. Publication No. 5111813...

  • Page 3: Table Of Contents

    CONTENTS Section Page Legislation 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 Publication No. 5111813...

  • Page 4: Legislation

    Codes of Practice, most recent version should “Benchmark” Log Book be used As part of the industry-wide “Benchmark” initiative all Potterton boilers now In GB the following Codes of Practice apply: Standard Scope include an Installation, Commissioning and Service Record Log Book. Please BS 6891 Gas Installation.

  • Page 5: Introduction

    INTRODUCTION Description 1. The Potterton Performa 24i 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. Case Front Panel 2.The unit incorporates a small storage cylinder built...

  • Page 6: General Layout

    GENERAL LAYOUT Layout Air Pressure Switch Expansion Vessel & Pre-Heat Store Burner Manifold Automatic Air Vent DHW Plate Heat Exchanger Circulation Pump Drain Off Point Pressure Relief Valve Position for Optional Integral Timer Central Heating System Pressure Gauge Control Box 3-Way Valve Assembly Condensate Trap Flame Sensing Electrode...

  • Page 7: Appliance Operation

    APPLIANCE OPERATION NOTE: All delay timers mentioned in 3.1 and 3.2 are Central Heating Mode 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 8 APPLIANCE OPERATION Domestic Hot Water Mode (Fig. 4) Domestic Hot Water Mode 1. Priority is given to the domestic hot water supply. A demand at a tap or shower will override any central heating requirement. 2. The flow of water will operate the DHW flow switch which requests the 3 way valve to change position.

  • Page 9: Technical Data

    Max Operating Fuse 2A Fast Blow to BS 4265 Min Operating Recommend Operating SEDBUK Declaration For Performa 24i HE Pump - Available Head The seasonal efficiency (SEDBUK) is 87.3% (89.3% 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

    DIMENSIONS AND FIXINGS Dimensions 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 Heating Domestic Hot...

  • Page 11: System Details

    SYSTEM DETAILS Information 1. The Potterton Performa 24i 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 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 Check 2. There are connection points on the mains cold Valve Valve Valve...
  • Page 13 SYSTEM DETAILS Domestic Hot Water Circuit (Fig. 8) 1. All DHW circuits, connections, fittings, etc. should be fully in accordance with relevant standards and Other Tap water supply regulations. Outlets 2. Your attention is drawn to: Boiler Expansion for GB: Guidance G17 to G24 and recommendation Vessel R17 to R24 of the Watert Regulations Guide.

  • Page 14: Site Requirements

    SITE REQUIREMENTS 20mm/5mm Min see *NOTE: Location 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 200mm Min satisfactory removal of combustion products and providing an adequate air supply.
  • Page 15 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. Gas Supply 1.
  • Page 16 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 17 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. 1. The following guidelines indicate the general requirements for siting balanced flue terminals.
  • Page 18 SITE REQUIREMENTS Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 685mm from elbow to terminal (Fig. 14). The maximum permissible equivalent flue length 4 metres. NOTE: Each additional 45° of flue bend will account for an equivalent flue length of 0.5m. eg.
  • Page 19 SITE REQUIREMENTS 7.11 Flue Options 1. The Potterton Performa 24i HE 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:- Horizontal Concentric Vertical Concentric Vertical Twin Pipe 4.

  • Page 20: 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.
  • Page 21 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. 18). 3. Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections.
  • Page 22 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. 20). 2.
  • Page 23 11. Fit the flue trim if required, and if necessary fit a terminal guard (see Section 7.9 & 7.10). VERTICAL FLUE 1. 1. Only a flue approved with the Potterton Performa 24i HE can be used. 2. For information on vertical flues consult the Potterton Flue Guide brochure.
  • Page 24 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 25: Commissioning

    COMMISSIONING Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. Screw 2. Open the mains water supply to the boiler. 3. Open all hot water taps to purge the DHW system. Automatic 4.
  • Page 26 COMMISSIONING Pressure Test Point Checking the Burner Pressure Sealing Screw 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 control to maximum and the selector switch to the OFF position (Fig.

  • Page 27: Completion

    10.0 COMPLETION 10.1 Completion 1. Hinge the facia panel upwards and refit the case Case Front Panel front panel. Tighten the securing screws (Fig. 38). 2. Instruct the user in the operation of the boiler and system, explaining the operational sequence. 3.

  • Page 28: Servicing

    11.0 SERVICING 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 29 11.0 SERVICING Baffle 11.1 Annual Servicing (Cont) Spring Clip 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. 42). 12. Undo the screws securing the fan and hood to the appliance back panel.

  • Page 30: 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 component has been changed turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 2 Sensing seconds to reset the boiler before...
  • Page 31 12.0 CHANGING COMPONENTS 12.3 Heat Exchanger (Fig. 50) 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 32 12.0 CHANGING COMPONENTS Injector Inlet Elbow Manifold 12.5 Injectors (Fig. 52) 1. Remove the burner as described in Section 12.4. 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 33 12.0 CHANGING COMPONENTS 12.8 Gas Valve (Fig. 54) 1. Undo the nut on the gas feed pipe under the boiler. Modulator 2. Completely undo the securing screws and hinge Wires the facia panel down. Ignition 3. Disconnect the wires from the valve modulator and Lead Gas Valve the ignition lead from the spark generator.
  • Page 34 12.0 CHANGING COMPONENTS 12.12 Pump - Head Only (Fig. 57) 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 35 12.0 CHANGING COMPONENTS 12.15 Pressure Gauge (Figs. 60 & 61) 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 36 12.0 CHANGING COMPONENTS 12.18 Pressure Relief Valve (Fig. 64) 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 37 12.0 CHANGING COMPONENTS 12.21 Plate Heat Exchanger (Fig. 67) Plate Heat Exchanger 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 38 12.0 CHANGING COMPONENTS 12.22 Diverter Valve Assembly (Cont) Diverter Valve Operating Head CH Pressure Differential Valve Diaphragm (Fig. 70) Spring Clip 3-pin Plug 1. Isolate the boiler from the central heating flow and return pipes and drain the boiler primary circuit. Diverter Valve 2.
  • Page 39 12.0 CHANGING COMPONENTS 12.24 Secondary Heat Exchanger (Fig. 73) 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 40: Electrical

    13.0 ELECTRICAL 13.1 Illustrated Wiring Diagram Air Pressure Switch Central Heating Temperature Sensor Domestic Hot Water Temperature Sensor Optional Timers Microswitch Microswitch Control PCB Flame Sensing Electrode Diverter Valve Operating Head Mains Input Link Fuse Overheat Stat Flue Stat Pump Gas Valve Condensate Trap - brown...

  • Page 41: Short Parts List

    14.0 SHORT PARTS LIST Short Parts List G.C. Description Manufacturers Part No. 5112627 Pressure Switch 5112999 Heat Exchanger 5112431 Burner 5112770 Injector 1.18 NG 248210 E66 408 Electrode Lead 248037 E66 411 Spark or Sensing Electrode 247384 E66 539 Pump Complete 248042 342 571 Temperature Sensor...

  • Page 42: 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), 27mbar (butane) or 36mbar (propane).
  • Page 43 15.0 FAULT FINDING Turn On/Off/Reset selector position. Go to section ‘A’. Domestic Hot Water - Follow operational sequence neon illuminated. Primary water diverted to Go to section ‘M’. DHW preheating circuit. Go to section ‘L’. Turn preheat control to on. External controls and Ensure controls are set to Preheating function starts...
  • Page 44 15.0 FAULT FINDING Central Heating - Follow operational sequence Turn selector to Go to section ‘A’. neon illuminated. Ensure controls are set to demand and verify the contacts are closed. External controls calling for Turn Central Heating heat and where fitted, neon flashing thermostat to maximum.
  • Page 45 15.0 FAULT FINDING Central Heating - Follow operational sequence (Continued) Continued from previous page Does the burner remain lit ? CH temperature higher than set point of CH thermostat control. When CH temperature decreases cycle continues. Turn the selector to reset. If regular resetting is Go to section ‘J’.
  • Page 46 15.0 FAULT FINDING Fault Finding Solutions Is there 230V at: Main terminals L and N Check electrical supply Main terminal fuse Replace fuse neon Replace main PCB illuminated Selector terminals a & b Check wiring and a & 3. PCB - A4 Replace selector connector terminals 4 &...
  • Page 47 15.0 FAULT FINDING Fault Finding Solutions 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 Replace gas valve across terminals 2 &...
  • Page 48 15.0 FAULT FINDING Fault Finding Solutions 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. Flame sensing electrode position Replace main PCB Flame current should be 1 µA approx.
  • Page 49 16.0 NOTES Publication No. 5111813...
  • Page 50 16.0 NOTES Publication No. 5111813...
  • Page 51 Publication No. 5111813...
  • Page 52 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 6SN After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www.potterton.co.uk 923.628.1 company...

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