Potterton Performa System 12e, Installation And Servicing Instructions

Page 1: ...Performa System 12e 18e 24e 28e Gas Fired Wall Mounted System Boilers Installation and Servicing Instructions Please leave these instructions with the user ...

Page 2: ... The boiler meets the requirements of Statutory Instrument The Boiler Efficiency Regulations 1993 No 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 GB IE on...

Page 3: ...nd Fixings 11 6 0 System Details 12 7 0 Site Requirements 14 8 0 Installation 19 9 0 Commissioning the Boiler 24 10 0 Completion 26 11 0 Servicing the Boiler 27 12 0 Changing Components 29 13 0 Illustrated Wiring Diagram 37 14 0 Fault Finding 38 15 0 Short Parts List 41 16 0 Notes 42 Section Page Contents ...

Page 4: ...3 INSTALLATION OF GAS APPLIANCES The installation must be carried out by a CORGI Registered Installer or other competent person and be in accordance with the relevant requirements of GAS SAFETY Installation and Use REGULATIONS the BUILDING REGULATIONS Scotland Consolidation the LOCAL BUILDING REGULATIONS the CURRENT I E E WIRING REGULATIONS and the bye laws of the Local Water Undertaking Where no ...

Page 5: ...Fan Assembly 18 On Off Reset Selector Switch 19 Central Heating Temperature Control 20 Flame Failure 21 Safety Thermostat 22 Fault on Fan or Flue 23 Fault on Pump or Low System Pressure 24 Temperature Indication Only 25 Fault on Central Heating Sensor 26 Power On 27 Hot Water Mode 28 Central Heating Mode 29 Burner On When neons 20 to 25 are constantly illuminated they indicate the temperature of t...

Page 6: ... 1 The frost protection mode is integral to the appliance and functions only with the selector switch see Section 2 1 in the domestic hot water and central heating position If the system temperature falls below 5 C then the boiler will fire on its minimum setting until a flow temperature of 30 C is reached Further protection can be incorporated by using a system frost thermostat 3 4 Pump Protectio...

Page 7: ...4 23 888 Heat Output Max Min kW 12 4 6 3 Btu h 42 309 21 496 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 120W External Fuse Rating 3A Maximum Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 Appliance Category CAT II 2H 3 Max Gas Rate Natural Gas G20 After 10 Mins m3 h 1 46 ft3 h 51 57 Inlet Pressure Natural Gas G20 mbar 20 in wg 8 Burner Injecto...

Page 8: ...200 36 170 Heat Output Max Min kW 17 5 9 3 Btu h 59 720 31 740 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 170W External Fuse Rating 3A Maximum Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 Appliance Category CAT II 2H 3 Max Gas Rate Natural Gas G20 After 10 Mins m3 h 2 05 ft3 h 72 4 Inlet Pressure Natural Gas G20 mbar 20 in wg 8 Burner Inject...

Page 9: ...39 36 170 Heat Output Max Min kW 24 0 9 3 Btu h 81 891 31 740 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 170W External Fuse Rating 3A Maximum Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 Appliance Category CAT II 2H 3 Max Gas Rate Natural Gas G20 After 10 Mins m3 h 2 78 ft3 h 98 12 Inlet Pressure Natural Gas G20 mbar 20 in wg 8 Burner Inject...

Page 10: ... Input Gross Max Min kW 32 6 11 9 Btu h 111 250 40 610 Heat Output Max Min kW 29 4 10 4 Btu h 100 330 35 490 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 190W External Fuse Rating 3A Maximum Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 Appliance Category CAT II 2H 3P Max Gas Rate Natural Gas G20 After 10 Mins m3 h 3 45 ft3 h 122 Inlet Pressure...

Page 11: ... 11 Dimensions A 780mm B 345mm C 450mm D 107mm Ø Min E 200mm F 190mm G 143mm 360 Orientation Tube Ø 100mm D C B A E G F Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 130 mm 130 mm 65 mm Tap Rail ...

Page 12: ...cts but for immediate information please contact BetzDearborn 0151 420 9563 or Fernox 01799 550 811 directly For long term protection against corrosion and scale after flushing it is recommended that an inhibitor such as BetzDearborn Sentinel X100 or Fernox MB 1 or Copal is dosed in accordance with the guidelines given in BS 7593 Failure to flush and add inhibitor to the system may invalidate the ...

Page 13: ... Expansion Vessel 1 The appliance expansion vessel is pre charged to 0 5 bar The vessel is suitable for correct operation for system capacities up to 125 litres For greater system capacities an additional expansion vessel must be fitted refer to BS 7074 Pt 1 6 6 Pressure Relief Valve Fig 4 1 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressu...

Page 14: ...ONS 7 3 Clearances Figs 5 6 1 A flat vertical area is required for the installation of the boiler 2 These dimensions include the necessary clearances around the boiler for case removal spanner access and air movement Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler 7 4 Location 1 The boiler may ...

Page 15: ...not use pipes of a smaller diameter than the boiler gas connection 22mm 7 7 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with current I E E Wiring Regulations 2 The mains supply must be 230V 50Hz and fused at 3A maximum NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection may b...

Page 16: ...nimum Distance Fig 9 mm A Directly below an openable window air vent or any other ventilation opening 300 B Below gutter drain soil pipe 25 C Below eaves 25 D Below a balcony car port roof 25 E From vertical drain pipes and soil pipes 25 F From internal or external corners 25 G Above adjacent ground or balcony level 300 H From a surface facing a terminal 600 I Facing a terminals 1200 J From openin...

Page 17: ...the rear of the trim flange Fig 11 3 Locate the trim over the flue terminal and push it back to the wall to compress the seal Fig 12 7 11 Terminal Guard Fig 13 1 When codes of practice dictate the use of terminal guards they can be obtained from most Plumbers and Builders Merchants 2 There must be a clearance of at least 50mm between any part of the terminal and the guard 3 When ordering a termina...

Page 18: ...r equivalent lengths are Concentric Pipes 45 bend 0 5 metres 90 bend 1 0 metres Twin Flue Pipe 45 bend 0 25 metres 90 bend 0 50 metres The elbow supplied with the standard horizontal flue is not included in any equivalent length calculations 5 The illustrations opposite show examples of maximum equivalent lengths 6 Instructions for guidance and fitting are included in each kit where appropriate Ho...

Page 19: ...ails supplied Ensure that the sealing washers are fitted between the connections 8 2 Flushing 1 Connect a tube to the central heating flow or return pipe Fig 15 2 Flush thoroughly see System Details Section 6 2 8 3 Preparing The Boiler 1 Remove all packaging 2 Stand the boiler on its base by using the rear lower edge as a pivot NOTE A small amount of water may drain from the boiler in the upright ...

Page 20: ...ssure Relief Discharge Pipe Fig 17 1 Remove the discharge pipe from the kit 2 Determine the routing of the discharge pipe in the vicinity of the boiler Make up as much of the pipework as is practical including the discharge pipe supplied 3 The pipework must be at least 15mm diameter and run continuously downwards to a discharge point outside the building See section 6 6 for further details 4 Utili...

Page 21: ...sure the distance from the outside wall face to the elbow Fig 18 This dimension will be known as X 4 Taking the air duct mark dimension X as shown Fig 19 Measure the length of waste material and transfer the dimension to the flue duct Fig 19 IMPORTANT Check all measurements before cutting 5 Remove the waste from both ducts Ensure that the cut ends are square and free from burrs 6 Remove the flue e...

Page 22: ...rews to the clip and tighten them Fig 23 14 Where possible position the clips so that the screws are not visible 15 Make good between the wall and air duct outside the building 16 Fit the circular flue trim outside if required and if necessary fit a terminal guard see Section 7 10 7 11 8 7 Extensions Additional Elbows 1 The method of connecting any flue extensions or additional elbows is the same ...

Page 23: ...2 Fig 27 IMPORTANT The external control MUST be suitable for 230V switching and fused 3A maximum 8 Ensure that both mains input and where fitted external control input cables have sufficient slack to allow the control box to drop down Tighten the cable clamp s on the boiler chassis 8 9 Preliminary Electrical Checks 1 Prior to commissioning the boiler preliminary electrical system checks should be ...

Page 24: ...manufacturers instructions 5 Pressurise the system to 0 2 bar then close and disconnect the filling loop 6 Turn the gas supply on and purge the system according to BS 6891 7 Test for gas soundness 8 If at any time during commissioning it is required to terminate a particular cycle e g the pump overrun period turn the selector to the Off position and then back to the On position Fig 32 Automatic Ai...

Page 25: ...pressure should be as quoted in Section 4 0 Technical Data If not check that the gas supply pressure is correct Natural Gas 20mbar Butane 30mbar and Propane 37mbar 8 The pressure can be adjusted if required 9 To check and set minimum pressure first remove one of the modulator wires Adjusting the Pressure Fig 34 10 Remove the plastic protection cap from the pressure adjustment nuts on the valve 11 ...

Page 26: ...ons of the Benchmark Installation Commissioning and Service Record Log Book that are relevant to the appliance and installation The details of the Log Book will be required in the event of any warranty work The Log Book must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 Hand over the Users Operating Installation and Servicing Instructions and the Log B...

Page 27: ...the panel Fig 38 6 Remove the facia securing screws and hinge the panel down 7 Remove the screws 2 on 12e 18e 24e 4 on 28e securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 39 8 Note the positions of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them Fig 40 9 Slacken the screws on the outlet sealing c...

Page 28: ...ets from the electrodes Completely remove the burner Fig 43 15 Brush any deposits from the injectors Do not use a pin or wire to clean them 16 Brush the burner blades and venturis and clean the combustion box 17 Ensure that the heat exchanger fins are clear of any obstruction 18 Check that the pressure vessel charge is 0 5bar and reassemble in reverse order of dismantling 19 Turn the selector swit...

Page 29: ... 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 3 Remove the four screws securing the combustion box door and remove the door 4 Remove the spring clips retaining the air box side baffle plates Disengage the tabs on the baffles from the slots...

Page 30: ...ppliance taking care not to damage the rear insulation piece 8 Fit the new heat exchanger 9 Reassemble in reverse order of dismantling and repressurise the system 12 4 Burner Fig 48 1 Remove the four screws securing the combustion box door and remove the door 2 Undo the screws securing the burner to the injector manifold 28e model only Draw the burner out of the combustion box pulling the electrod...

Page 31: ...the lead and grommet from the electrode being replaced Undo the securing screw and withdraw the electrode to the burner 4 Reassemble in reverse order 12 7 Insulation Fig 50 1 Remove the four screws securing the combustion box door and remove the door 2 Slide the side insulation pieces carefully out of their carriers 3 To replace the rear insulation piece it is necessary to remove the heat exchange...

Page 32: ...rder and check the burner pressure as described in Section 9 2 12 9 Central Heating Temperature Sensor Fig 52 1 Ease the retaining tab on the sensor away and disconnect the electrical plug 2 Unscrew the sensor from it s pocket and reassemble in reverse order The plug will only fit one way 12 10 Safety Thermostat Fig 52 1 Pull the electrical connections off the thermostat 2 Remove the screws securi...

Page 33: ...and unscrew the automatic air vent from the pump body Undo the two screws securing the body to the pipe and manifold and draw the pump forwards 2 Undo the screw on the pump wiring cover and remove the cover Using a suitable flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 3 Connect the wiring to the new pump Examine the O ring seal...

Page 34: ... boiler off the wall plate and lay it on either side on a clean flat surface 4 Undo the nut on the vessel outlet spigot and remove the locknut and spring washer securing the spigot to the boiler chassis 5 Undo the screws and remove the appliance upper cross member Slide the expansion vessel out of the retaining clips 6 Reassemble in reverse order Fully recommission the appliance and system 12 17 S...

Page 35: ...oller is reset to the previous position 6 Ensure that the DHW potentiometer is fully anticlockwise once the new PCB is fitted 12 19 Selector Switch Fig 62 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Remove the screws securing the control box cover and release the cover retaining barbs from their slots Disengage the rear of the cover from the control box hin...

Page 36: ...omplete valve assembly can be replaced 7 Examine the sealing washers and O ring on the pipes and capillary replacing as necessary 12 21 Central Heating Differential Valve Microswitch Fig 64 1 Remove the two wires from the microswitch 2 Undo the screw securing the microswitch to the valve body 3 Reassemble in reverse order 12 22 Pressure Relief Valve Fig 65 1 Drain the primary circuit 2 Disconnect ...

Page 37: ...A4 A5 F2 1 bk bk r r g g 2 1 2 3 3 4 1 1 2 3 4 5 6 7 8 9 10 2 3 4 1 2 3 6 4 5 4 5 5 6 7 8 9 Central Heating NTC Sensor Fan Gas Valve Overheat Stat Hydraulic Differential Pressure Switch Air Pressure Switch Flame Mains Input Fuse Link g y g y b br bk br b bk r g r g Sensing Electrode Pump b b b br b b br br b b r bk br br b br Spark Generator Optional Timers 1 2 3 4 bk br bk b ...

Page 38: ...temperature control to max Pump runs Air pressure switch proved neon flashing Burner on neon illuminated Burner output modulates until set temperature is reached Spark at ignition electrodes for up to 10 seconds Go to section A neon flashing Go to section B neon flashing Go to section C Go to section J neons flashing Go to section D neon flashing Go to section E Replace PCB Turn selector to the re...

Page 39: ...nt is opened Open the automatic air vent 2 NO NO C YES Continuity across flow microswitch and PCB A5 connector terminals 7 8 Replace microswitch 1 NO NO Primary temperature sensor faulty Cold resistance approx 11K ohms resistance reduces with increase in temp Replace sensor 2 YES Fan connections correct at fan PCB A2 connector is 230V across terminals 5 7 Fan jammed or faulty winding Replace PCB R...

Page 40: ...310 mA DC LPG Replace gas valve NO Replace PCB 2 Check and correct if necessary 1 Flame sensing electrode and lead connections 2 Electrode position Flame current should be 1 µA approx Replace PCB Replace PCB YES YES Replace flame sensing electrode NO YES Ensure that mains input terminal L is Live 230V and N is Neutral 0V I Check terminal 1 of On Off Reset selector is in connection with PCB A4 conn...

Page 41: ... 248029 E66 399 Burner 28e 248030 44 Injector 248210 59 E66 408 Electrode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 E66 431 Pump 12e 18e 24e 248041 E66 539 Pump 28e 248042 102 Hydraulic Outlet Assy 248490 131 342 571 Temperature Sensor 247394 135 E66 439 Safety Thermostat 248079 140 Gas Valve 154 PCB 248074 169 E66 453 Pressure Gauge 248090 528 Return Heating 248497 Temperature S...

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Page 43: ...16 0 Notes 43 ...

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 Comp No 5107333 Iss 1 6 02 922 516 1 ...