Potterton Performa SL HE, Installation & Service Instructions Manual

Page 1: ...lude the Benchmark Commissioning Checklist and should be left with the user for safe keeping Performa SL HE Range Condensing Central Heating Boiler You can rely on U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 w w w h e a t i n g s p a r e s 2 4 7 c o m ...

Page 2: ...his can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly Similar arrangements will follow for Scotland and will apply in Northern Ireland from 1 January 2006 CORGI operate a Self Certification Scheme for gas heating appliances These arrangements represent a change from the situation whereby compliance with Building Regulations was...

Page 3: ...nly Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days If you notify via CORGI Scheme CORGI will then notify the relevant Local Authority Building Control Scheme on member s behalf Complete the Benchmark Checklist Install and Commission this appliance to manufacturer s instructions Competent Person s Self Certification Scheme Building Control Complete the Benchmark Checkl...

Page 4: ...cy cylinder The gas type supply size and pressure must be checked for suitability before connection Failure to install the condensate discharge pipework correctly could affect the reliable operation of the boiler For the boiler to operate correctly all air must be vented from the system prior to commissioning and the system itself must be suitably vented The system must be designed to always provi...

Page 5: ...xposure to this material may result in some irritation to the eyes skin or respiratory tract c It is advisable to wear gloves when handling these items d Irritant dust will only be released from the items if they are broken up or subjected to severe abrasion In these instances a suitable dust mask and goggles should be worn e Always thoroughly wash hands after installation servicing or changing co...

Page 6: ...Content litres 2 3 9 12 15 2 7 18 21 24 Boiler Weight kg 39 0 9 12 15 42 8 18 21 24 Lift Installed Dry Nox Class 2 2 2 2 2 2 Maximum Working Head 30 5m 100 ft Minimum Working Head 150mm 6 in Flow Temperature Range 63 C 82 C Gas Supply Connection 15 mm Tail Flow Return Connections 22 mm Copper Condensate System Connection 21 5 mm PP Electricity Supply 230v 50Hz External Fuse 3A Internal Fuse Type 3...

Page 7: ...p 75 mm Gas Valve Primary Heat Exchanger PCB Enclosure Burner Electrodes Flow Connection Return Connection Spark Igniter Flow Sensor Overheat Sensor Casting Sensor 610 mm servicing clearance 260 mm 15 mm clearance Condensate Connection Wiring Centre Data Label O Ring and Clip Joints Gas Connection Fig 1 U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r...

Page 8: ...RING REGULATIONS Where no specific instructions are given reference should be made to the relevant BRITISH STANDARD CODES OF PRACTICE Reference should also be made to BRITISH GAS GUIDANCE NOTES FOR THE INSTALLATION OF DOMESTIC GAS CONDENSING BOILERS Definition of competence A person who works for a CORGI registered company and holding current certificates in the relevant ACS modules is deemed comp...

Page 9: ...ide a 25 mm annular space Further guidance is given in BS5440 Pt 1 Timber Frame If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institution of Gas Engineers Publication IGE UP 7 Gas Installation in Timber Framed Housing Zone 2 Zone 1 Zone 0 Zone 2 Zone 3 Zone 3 Zone 2 Window Recess Window Recess 0 6 m 2 4 m In GB Only...

Page 10: ...oiler 5 Any condensate pipework external to the building or in an unheated part of it e g garage should not exceed 3 metres in length and when in an exposed position waterproof insulation is recommended It is also recommended that the pipe diameter is increased to 32 mm If the boiler is fitted in an unheated location the entire condensate pipe should be treated as an external run Examples are show...

Page 11: ...le Maximum straight flue length 3 55 m 3 extensions equivalent resistance 3 55 m It is recommended that the flue is supported at least once per metre All lengths quoted exclude the boiler elbow Example layouts are shown on the Page 13 Bends A 93 bend is equivalent to a 1m length of flue A 135 bend is equivalent to a 0 5m length of flue Vertical For information on vertical flues consult the instruc...

Page 12: ...orner 25 I Above ground roof or balcony level 300 J From a surface or boundary line facing a terminal 600 K From a terminal facing a terminal Horizontal flue 1200 From a terminal facing a terminal Vertical flue 600 L From an opening in carport e g door window into the dwelling 1200 M Vertically from a terminal on the same wall 1500 N Horizontally from a terminal on the same wall 300 R From adjacen...

Page 13: ...s not included in any equivalent length calculations NOTE Flue length is measured from point X to Y as shown Horizontal Flues Y X Plume Displacement Kit 60 100 Ø 1M Extensions 45 93 elbows are also available see Plume Displacement Section 3 9 NOTE Horizontal flue pipes should always be installed with at least a 1 5 fall from the terminal to allow condensate to run back to the boiler Y X This bend ...

Page 14: ...ed without reduction of the flue length If further elbows are required the flue length must be reduced by the following amounts 1 metre for each 91 5 bend 0 5 metre for each 135 bend 3 8 3 Twin Vertical Flue Systems 1 Maximum permissible equivalent flue lengths are Vertical Concentric 1 9m Vertical Twin Pipe 6m Both the air and flue duct can be up to 6 metres long each 2 Any additional in line ben...

Page 15: ...Deflector 5111068 FLUE GROUP N Twin Flue System 80mm diameter E Flue extension pair 1000mm 5111087 F Flue Bend pair 90 5111072 G Flue Bend 2 pair 135 5111086 O Vertical flue boiler adaptor kit 5111071 H Vertical flue adaptor 5111084 W Pipe support pair 80mm 5111081 FLUE GROUP A N Vertical Flue Kits K Vertical flue terminal use with 5111070 5111078 L Lead tile 25 45 246141 Lead tile 35 55 246142 M ...

Page 16: ...nsuring the existing gasket is still in place 2 Attach the rubber spacer to the base of the adaptor 3 Fit the adaptor to the top of the boiler and secure it to the four hole fixing plate using the long screws supplied 4 Continue to fit the twin flue system Vertical Flue Boiler Adaptor Gasket Gasket Original seal Four hole fixing plate Screw Stick rubber spacer here Position of Adaptor Twin Vertica...

Page 17: ...ion and secure to the roof structure with the clamp supplied 3 8 8 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 685mm from elbow to terminal Fig 13 The maximum permissible equivalent flue length is 3 55 metres NOTE Each additional 45 of flue bend will account for an equivalent flue length of 0 5m eg 45 0 5m 90 2 x 45 1m etc 3 8 9 Flue Trim 1 The rubber...

Page 18: ...ic flue extension kits may be added between the boiler elbow and the terminal assembly 6 The minimum length of the concentric flue is 100mm when measured from the edge of the flue elbow IMPORTANT The maximum equivalent length of concentric flue is 3 55 metres Performa 9 12 15 18 SL 3 0 metres Performa 21 24 SL Additional bends may be fitted in the concentric flue but the equivalent length must be ...

Page 19: ...combination would NOT be permissible as the intersection point would be above the solid diagonal line Example 2 Flue Lengths OK Where both lengths have been determined they can be applied to the graph to check that the installation is permissible For example if it was known that 1 metre of concentric flue and 6 metres of 60Ø exhaust were required the values could be applied to the graph as shown i...

Page 20: ... 5 and that the external air inlet is to the bottom 8 Use suitable brackets to support the concentric assembly and any extensions and make good inside and outside 9 The 60Ø exhaust can now be fitted Slide the adaptor over the plain end of the 60Ø exhaust Fig 22 and engage the exhaust in the terminal Slide the adaptor down over the spigot Mark and drill the adaptor using a 2mm bit as shown in Fig 2...

Page 21: ...table bit e g 2mm drill through the extension and outlet Secure using two of the screws supplied 21 The remaining screw must be used to secure the adaptor to the concentric terminal 22 When the plume outlet is positioned under a balcony or other projection Fig 28 it must protrude at least 200mm it is not necessary to extend it further than this 23 When under balconies or projections it is permissi...

Page 22: ...o ensure correct circulation it is essential to vent all air from the system prior to commissioning the boiler System Drain Off Points Drain off points should be fitted in the pipework close to the boiler and in the low points of the system Plastic Pipework If plastic pipe is used for the central heating circuit there must be a run of at least 2 metres of uninsulated copper pipe from the boiler fl...

Page 23: ...ble 2 3 10 5 Boiler Protection 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 The boiler is fitted with a timed pump overrun that will operate for around 2 minutes after boiler shutdown The boiler control will operate the pump for ar...

Page 24: ...litres The following volumes may be used as a conservative guide to calculating the system volume Boiler Heat Exchanger 2 7 litres Small Bore Pipework 1 litre per kW of system output Micro Bore Pipework 7 litres Steel Panel Radiators 8 litres per kW of system output Low Water Capacity Radiators 2 litres per kW of system output Hot Water Cylinder 2 litres The vessel size can now be determined from ...

Page 25: ...ing by pass balancing valve Optional 3 port valve Auto air vent Pressure gauge visible from filling point Safety valve Expansion vessel Alternative existing by pass arrangement using the bathroom radiator fitted with two lockshield valves Pump with isolating valves Manual Filling and Make Up Point Sealed system manual filling and make up point requirements Stop Valve Temporary Hose Stop Valve Doub...

Page 26: ... BRACKET Drill and plug 7 mm Secure using woodscrews supplied 50mm per metre 2 5 Minim um Fall Boiler Mounting Bracket Boiler Mounting Bracket Woodscrews Boiler Securing Point Woodscrew or Anti theft kit Lifting points in base of packing Fig 33 4 Installation 4 1 Unpack Prepare the Wall Boiler These instructions assume you have chosen a suitable boiler location which will also allow correct instal...

Page 27: ...flush with the outer Deburr both tube ends 3 Slide the wall seal along the flue and into position behind the terminal 4 To ease assembly of the flue system apply the silicone grease provided to the inner seal of the flue elbow Pass the flue through the wall and push firmly into the flue elbow The flue is correctly located when the visual check holes are blocked 5 Ensure the terminal shroud is vert...

Page 28: ...ut preliminary electrical system checks i e Earth Continuity Short Circuit Polarity and Resistance to Earth For safety leave the electrical supply switched off and isolated until boiler installation is complete See Page 31 for typical system wiring Optional Integral Programmer Schematic wiring with boiler interlock There must be both mains Permanent Live and Switched Live from the system to the bo...

Page 29: ...e connections Heat from a blowlamp could damage the case seals 4 6 Connect the Condensate System 1 The condensate connection is a 21 5 mm PP pipe To allow access for servicing we recommend the first connection to the system is a push fit type 2 Prime the condensate system to seal the trap Method 1 Pour 1 2 litre of water down through the flue products inner tube at the terminal Method 2 Pour 1 2 l...

Page 30: ...h to Burner L N E SwL L N E Mains Pump g y g y g y g y g y g y b br y r b w p p br b bk bk bk r bk y y b b or or b blue bk black br brown g y green yellow or orange p purple y yellow r red w white Boiler Wiring Fig 39 U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 w w w h e a t i n g s p a r e s 2 4 7 c o m ...

Page 31: ...al block b blue br brown g y green yellow Boiler PCB NC C N HW on E HW off L CH on Pump Mains T h i s A p p l i a n c e m u s t b e E a r t h e d N N L E E SwL L 7 8 9 4 10 5 E N L 1 7 2 8 3 9 4 10 5 6 6 11 11 12 12 Optional external programmer Fused 3A Mains Supply Frost stat Not used Typical wiring centre 12 way shown Room stat Cyl stat CH Zone valve DHW Zone valve NO C br br b b g y g y Pump su...

Page 32: ...r pressure is required follow Section 9 4 8 Check that the burner flames are blue and stable 9 Turn the temperature control knob to position and check that the burner shuts down 10 Remove the pressure gauge re fit the screws and check for gas soundness 11 Re fit the controls cover assembly and secure with the screws previously removed 6 3 Flush the system 1 Drain the system whilst still hot 2 Re f...

Page 33: ...mage to the system and to the building in the event of the system remaining inoperative during frost conditions Advise the user that this boiler has frost protection pump overrun and pump anti seize features See 3 9 4 Advise the User that for continued efficient and safe operation of the boiler it is important that adequate servicing is carried out at least once a year 6 6 Documentation Carefully ...

Page 34: ...ame On Air Proving Lockout APS Off 4 times in 15 mins Circulation Lockout Indicate APS fault Safety shutdown 5 mins Overheat stat Off Check thermistors give valid readings Switched live On On Off switch On Overheat Lockout Check flow thermistor casting thermistor Flow temperature setpoint Post purge 5 secs Flow temperature 100C Flow temperature 100C or overheat stat Off Ignition attempt or casting...

Page 35: ...s Air Proving LOCKOUT Manual Lockout Burner Mains PCB Fault Replace PCB Automatic Lockout Burner Mains False Flame Fault Automatic Lockout Burner Mains APS Stuck Fault Automatic Lockout Burner Mains Flow Thermistor Fault Automatic Lockout Burner Mains Casting Thermistor Fault Automatic off flashing on Key Lockout Codes U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a...

Page 36: ... pump fan and gas valve Replace if shorted and replace fuse No No This boiler requires both a permanent live and a switched live Both need to be a minimum of 190V to function Yes Check wiring from terminal block to PCB No Replace PCB Yes Is there 230V at 6 way plug to PCB Mains L and N off off off Fig 44 U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o ...

Page 37: ...en extinguish Is flame detection electrode damaged No Is wiring to the detection electrode OK Yes Yes Replace electrode No Set gap to correct position over falme strip No Rectify wiring No Is there a spark Is spark electrode damaged Is the electrode gap between 3 and 4 mm No Is wiring from spark generator to electrode OK No Yes No No Is the flame detection gap between 3 and 4 mm Yes Yes Check the ...

Page 38: ...ipe is 60C Check as the Water Circulation Lockout fault Unplug the 8 way connector from PCB Is there continuity between the 2 black wires Replace the overheat thermostat Remove connectors from overheat thermostat Is there continuity across the terminals Wiring faulty between the PCB and the overheat thermostat Is the flame detection electrode un damaged Is the electrode gap between 3 and 4 mm Yes ...

Page 39: ...s A lockout is activated if this happens 4 times Water Circulation Lockout Refer to the boiler wiring diagram Yes No Fill system with water and bleed out all air Is the system full of water Yes No Is the pump running Yes No Reset lockout Is there 230V at the terminal block Pump L and N Pump or pump wiring fault Yes No Check the continuity of the Pump L and N wiring from the terminal block to PCB W...

Page 40: ...the APS APS stuck in the On position Replace Short circuit on the wiring rectify No Yes Rectify fault Switch off Unplug the 12 way connector and both APS leads Is there continuity between the 2 orange wires Open circuit on the APS wiring rectify Yes Check the tubes from venturi to the APS Check for blockages in condensate system flue and heat exch APS stuck in Off position Replace No No flashing o...

Page 41: ...thermistors Do resistances vary from ones previously measured Wiring from PCB to thermistor faulty Replace Faulty Thermistor This can be identified by removing both thermistors and holding the brass probe between your fingers The resistance should be approximately 8kΩ There are two types of fault which can occur 1 The thermistors are reading outside of limits this is checked before the PUMP is swi...

Page 42: ... Burner remove if required see 9 10 Brush the burner top and check that the flame ports are clear Any blockage may be removed with a fine wire brush Turn the burner upside down and tap gently to remove any debris Protect the electrodes d Electrodes remove if required see 9 10 If the electrodes require cleaning wipe the surface using a solvent e Injector remove if required see 9 11 Omit this operat...

Page 43: ...low Connection Return Connection Spark Igniter Flow Sensor Overheat Sensor Casting Sensor Wiring Centre Data Label Condensate Connection O Ring and Clip Joints Gas Connection Flue Sample Point Fig 50 U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 w w w h e a t i n g s p a r e s 2 4 7 c o m ...

Page 44: ...curing screws to improve access to the gas valve 4 Using the service spanner supplied with the new valve remove the front screw and loosen the two rear screws securing the gas valve to the manifold 5 Slide the valve backwards and carefully remove from the boiler 6 Re assemble in reverse order using a new O ring Remember to re tighten the condensate trap and ensure the electrical plug to the gas va...

Page 45: ...isconnect ignition lead if required 4 Re assemble in reverse order 9 7 Flow Casting Sensors 1 Perform General Access See 9 2 2 Disconnect the electrical plug from the sensor and unscrew the sensor from the pocket 3 Re assemble in reverse order Use a heat sink compound on the sensor shaft insert and tighten to finger tight and a quarter turn 9 8 Overheat Sensor 1 Perform General Access See 9 2 2 Di...

Page 46: ...Remove all traces of gasket from the flue hood then attach new gasket Fit the fan to the flue hood and secure using four screws previously removed Fit the venturi assembly to the replacement fan Ensure that the flue hood locates under the clips at the rear of the chassis The front of the flue hood will rise slightly under the pressure of the clips Re assemble all remaining parts in reverse order P...

Page 47: ...tween the electrode tip and the burner face is 3 4 mm adjustment can be made by careful use of pliers 9 11 Injector 1 Remove the Burner See 9 10 Use a 13 mm A F or 1 2 A F socket spanner to remove the injector 2 Unscrew the injector 3 Re assemble in reverse order Use a new sealing washer on the injector and test for gas soundness Remove screw Ignition electrode Sensing electrode Fig 58 Fig 59 9 11...

Page 48: ... front of the chassis 5 Pull the assembly forwards and away from the boiler Replace insulation pieces as required replace any securing clip if damaged 6 Re assemble in reverse order ensure the insulation assembly has located correctly over the tabs at the rear of the casing below the casting and is NOT hanging down Insulation assembly correctly fitted and held in location tabs Insulation assembly ...

Page 49: ...ew securing the trap to the boiler 5 Slide the trap to the right to release from the left hand screw then pull the unit complete with tube down and away from the boiler 6 Re assemble in reverse order using a new case seal Pour half a litre of water into the trap to prime it before re fitting Ensure the tube and spring clip locate correctly onto the sump 7 Re connect condensate disposal pipework Di...

Page 50: ...mary heat exchanger 9 Release the flow and return unions at the heat exchanger and lift the pipes clear 10 Remove the screw from the top right hand side and bolt and nut from the left hand side mounting brackets 11 Support the heat exchanger spring out the left hand mounting bracket to clear the stud and withdraw the heat exchanger 12 Re assemble in reverse order Ensure all seals are replaced as n...

Page 51: ...bracket 10 Manoeuvre the heat exchanger out to disconnect the gaitor and flue duct from the hood pull down to release the pipe O ring connections and lift away from the boiler 11 Check and replace seals washers O rings etc as necessary Lubricate O rings prior to fitting 12 Re assemble as follows Align the flow and return pipes lift the heat exchanger slightly to engage the O ring joints and locate...

Page 52: ... 18 206 18 to 24 206 9 to 15 216 9 to 15 216 18 to 24 200 21 to 24 217 306 332 329 330 318 202 219 121 120 209 U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e y R o a d B r a d f o r d B D 8 9 H Q 0 1 2 7 4 4 8 8 3 8 8 w w w h e a t i n g s p a r e s 2 4 7 c o m ...

Page 53: ...ondensate trap assembly 1 5111451 305 PCB assembly 1 5110550 306 364 866 Temperature control knob 1 230981 308 Igniter assembly 1 5111922 313 Air pressure switch 9 SL HE 1 5112195 Air pressure switch 12 SL HE 1 5112196 Air pressure switch 15 SL HE 1 5110350 Air pressure switch 18 SL HE 1 5112197 Air pressure switch 21 SL HE 1 5112198 Air pressure switch 24 SL HE 1 5110393 318 Heat exchanger second...

Page 54: ...TE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDIN...

Page 55: ... ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service In...

Page 56: ... descriptions and illustrations provided in this leaflet have been carefully prepared but we reserve the right to make changes and improvements in our products which may affect the accuracy of the information contained in this leaflet All goods are sold subject to our standard Conditions of Sale which are available on request U n i t 3 A T h o r n t o n R o a d I n d E s t a t e O f f H o c k n e ...