Baxi Potterton 24 Eco HE Boiler User Manual
Contents
1. Q Likely flue positions requiring a flue terminal guard Fig 14 Terminal Position with Minimum Distance Fig 14 A Directly below an openable window air vent or any other ventilation opening 300 B Below gutters drain soil pipe 25 C Below eaves 25 300 min D Below balcony car port roof 25 Hine as E From vertical drain pipes and soil pipes 25 ml F From internal or external corners 25 d i 7 gt G Above adjacent ground or balcony level 300 i T H From a surface or boundary facing the terminal 600 gt l i 4 Facing terminals 1200 m i J_ For opening door window in car port into dwelling 1200 OU K Vertically from a terminal on the same wall 1500 i L Horizontally from a terminal on the same wall 300 1 M Above an opening air brick opening window etc 300 Top View Rear Flue i N Horizontally to an opening air brick opening window etc i 300 i l In addition the terminal should be no nearer than 150mm to an Fig 15 WYN Property Boundary Line opening in the building fabric formed for the purpose of accommodating a built in element such as a window frame See BS 5440 Pt 1 Publication No 5111811 7 0 SITE REQUIREMENTS 7 8 Flue Dimensions The standard horizontal flue kit allows for flue lengths between 100mm and 685mm from elbow to terminal Fig 16 The maximum permissible flue length is 4 metres 7 9 Flue Trim 1 The2. Facia Panel Frost Thermostat L O 9 br N mpb N C External Clock a g y bk bk Room Thermostat IMPORTANT If an integral timer is fitted to the boiler an external frost thermostat wired as shown will not operate correctly Only external timers may be used in such installations as in the diagram Fig 32 Selector Reset Switch Key to Wiring b blue br brown bk black r red g green w white Functional Flow Diagram Pump b N b Pressure Switch br 4 br O b N b 4 b a NTC Sensor dabi Abk Flue Thermostat Safety Overheat Thermostat r r PCB Gas Valve Modulator p H Spark Electrode br Gas Valve bk a Condensate Trap r Flame Sensing Electrode 4r D Hydraulic Differential Pressure Switch r DHW Flow Priority Microswitch 9 9 Publication No 5111811 23 24 Central Heating Temperature Control Hot Water Temperature Control 9 0 COMMISSIONING 9 1 Commissioning the Boiler 1 Reference should be made to BS 5449 Section 5 when commissioning the boiler 2 Open the mains water supply to the boiler 3 Open all hot water taps to purge the DHW system 4 Ensure that the filling loop is connected and open then open the heating flow and return valves on th
3. TIME amp TEMPERATURE CONTROL TO HEATING ROOM T STAT amp PROGRAMMER TIMER PROGRAMMABLE ROOMSTAT TIME amp TEMPERATURE CONTROL TO HOT WATER CYLINDER T STAT amp PROGRAMMERITIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE mihr _ hr BURNER OPERATING PRESSURE IF APPLICABLE C NA mbar CENTRAL HEATING FLOW TEMPERATURE C Ga CENTRAL HEATING RETURN TEMPERATURE dee FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE amp RECORD GAS RATE ar ft hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE N A mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE Its 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 H
4. 4 Pull the earth wire off the spade terminal on the valve 5 Remove the screws securing the inlet pipe flange to the tap rail and those securing the outlet manifold to the burner manifold 6 Remove the valve from the boiler 7 Note the orientation of the inlet pipe and outlet manifold Undo the securing screws and remove the pipe and manifold 8 Examine the O ring seals for damage replacing as necessary 9 Fit the inlet pipe and outlet manifold to the new valve ensuring that the O ring seals are in place 10 Reassemble in reverse order and check the burner pressure Section 9 2 12 9 Temperature Sensor Fig 57 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 57 1 Pull the two electrical connections off the thermostat 2 Remove the screws securing the thermostat to the mounting plate on the flow pipe 3 Reassemble in reverse order The thermostat is not polarised either wire can fit either terminal on the thermostat 32 Publication No 5111811 12 0 CHANGING COMPONENTS 12 11 Pump Head Only Figs 58 amp 59 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 Using a suit
5. 7 Fit the new fan to the hood using the screws and spring washers previously removed Fig 50 8 Reassemble in reverse order of dismantling 12 2 Pressure Switch Fig 49 1 Remove the fan as described in section 12 1 2 Note the positions of the sensing tubes and wires and remove them Tab Spring Clip 3 Remove the two screws holding the pressure switch to the bracket on the combustion box top panel 4 Fit the new pressure switch and reassemble all components in reverse order of dismantling Oe ae om 7P Spring Washer 4 YO P Securing Screw Publication No 5111811 29 12 0 CHANGING COMPONENTS 12 3 Heat Exchanger Fig 52 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 Lift the heat exchanger to disconnect the flow pipe joint Withdraw it from the appliance taking care not to damage the rear insulation piece 4 Fit the new heat exchanger ensuring that the tabs on the side insulation carriers engage in the slots in the heat exchanger side plates 5 Reassemble in reverse order of dismantling and repressurise the system 12 4 Burner Fig 53 1 Remove the four screws securing the combustion box door and remove the door 2 Draw the burner out of the combustion box j pulling the electrode grommets from the sl
6. components e All systems must be thoroughly drained and flushed out Using for example Betz Dearborn Sentinel X300 or X400 or Fernox Superfloc Universal Cleanser which should be used following the flushing agent manufacturer s instructions e System additives corrosion inhibitors and flushing agents descalers should be suitable for aluminium and comply to BS7593 requirements e g Betz Dearborn Sentinel X100 and Fernox Copal which should be used following the inhibitor manufacturer s instructions Failure to flush and add inhibitor to the system will invalidate the appliance warranty e t is important to check the inhibitor concentration after installation system modification and at every service in accordance with the manufacturer s instructions Test kits are available from inhibitor stockists e For information or advice regarding any of the above contact the Potterton Helpline 6 3 Bypass 1 The boiler is fitted with an automatic integral bypass 6 4 System Control 1 The boiler is designed for use in a heating system that incorporates external controls i e a minimum of a timer device 2 An integral electro mechanical or electronic timer is available as an optional extra 3 For optimum operating conditions and maximum economy the fitting of a programmable thermostat is recommended Publication No 5111811 6 0 SYSTEM DETAILS 6 5 System Filling and Pressurising 1 A filling point conn
7. supply pipe and to ensure the efficient operation of the expansion vessel which is required to accommodate the thermal expansion of the water 4 When the domestic water system includes any device which prevents water expanding back towards the supply check valve loose jumpered stopcock water meter water treatment device then an expansion vessel must be fitted eg Zilmet 160ml R 2 15bar 5 If the hot water expansion is not provided for then high pressures can develop which may result in damage to fittings and devices on the system 6 The boiler s maximum working mains pressure is 8 bar therefore all pipework connections fittings etc should be suitable for pressures in excess of 8 bar A pressure reducing valve must be fitted for pressures in excess of 8 bar The manufacturer of any outlet fittings such as a shower valve may require a lower maximum pressure The pressure reduction must take account of all fittings connected to the DHW system 6 9 Showers 1 If a shower control is supplied from the appliance it should be of the thermostatic or pressure balanced type Thermostatic type shower valves provide the best comfort and guard against water at too high a temperature Existing controls may not be suitable refer to the shower valve manufacturer 6 10 Hard Water Areas 1 If the area of the installation is recognised as a HARD WATER AREA then a suitable device should be fitted to treat the mains water suppl
8. 0 amp Part H1 of the Building Regulations give further guidance 3 The discharge pipe should be run in a proprietary drain pipe material e g PVC PVC U ABS PVC C or PP 4 Metal pipework is NOT suitable for use in condensate discharge systems 5 The pipe should be a minimum of 21 5mm diameter and must be supported using suitably spaced clips to prevent sagging 6 Any pipe fitted externally must not exceed 3 metres 7 Any condensate discharge pipework external to the building or in an unheated part of it e g garage must be insulated to protect against frost It is also recommended that the pipe diameter is increased to 32mm 8 If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run 9 In all cases discharge pipe must be installed to aid disposal of the condensate To reduce the risk of condensate being trapped as few bends and fittings as possible should be used 10 When discharging condensate into a soil stack or waste pipe the effects of existing plumbing must be considered If soil pipes or waste pipes are subjected to internal pressure fluctuations when WC s are flushed or sinks emptied then back pressure may force water out of the boiler trap and cause appliance lockout Examples are shown of the following methods of termination i to an internal soil amp vent pipe ii via an internal discharge branch e g sink waste iii to a drain o
9. 9 1 The pressure relief valve is set at 3 bar therefore all pipework fittings etc should be suitable for pressures in excess of 3 bar 2 The pressure relief discharge pipe should be not less than 15mm dia run continuously downward and discharge outside the building preferably over a drain It should be routed in such a manner that no hazard occurs or causes damage to wiring or electrical components The end of the pipe should terminate facing down and towards the wall 3 The discharge must not be above a window entrance or other public access Consideration must be given to the possibility that boiling water steam could discharge from the pipe Double Stop Check Stop Valve Valve Tem porary Hose CH Mains Return Inlet Fig 8 Fig 9 Discharge Pipe Publication No 5111811 Other Tap Outlets Expansion Vessel Pressure JN Reducing Valve To Hot Taps Stop Tap Fig 10 6 0 SYSTEM DETAILS 6 8 Domestic Hot Water Circuit 1 All DHW circuits connections fittings etc should be fully in accordance with relevant standards and water supply regulations 2 Your attention is drawn to for GB Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide for IE the current edition of I S 813 Domestic Gas Installations 3 A single check valve must be fitted as shown in Fig 10 to prevent backflow to the
10. D rofar Q Powerton Performa 24 Eco HE Fig 3 21 22 23 24 25 26 10 9 Publication No 5111811 3 0 APPLIANCE OPERATION NOTE All delay timers mentioned in 3 1 and 3 2 are overridden by domestic hot water demand 3 1 Central Heating Mode Fig 4 Central Heating Circuit 27 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 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 3 When the flow temperature exceeds the setting temperature a 3 minute delay occurs before the burner relights automatically anti cycling The pump 23 continues to run during this period j9 11 21 3 2 Domestic Hot Water Mode Fig 5 1 Priority is given to the domestic hot water supply Fig 4 16 A demand at a tap or shower will override any central heating requirement Key 2 The flow of water will operate the DHW flow switch a 1 Primary Heat Exchanger 14 Gas Inlet which causes the 3 way valve to change position 2 Bumer 15 Domestic Hot Water Outlet This will allow the pump to circulate the primary water 3 Ignition Electrode 16 Heating Flow 4 Flame Sensing Electrode 17 Pressure Gauge through the DHW plate heat exchanger 5 Gas Valve 18 Hydraulic Differential Pressure Sensor Mi
11. Department From 1 April 2005 this 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 accepted as being demonstrated by completion of the Benchmark Logbook which was then left on site with the customer With the introduction of Self Certification Schemes the Benchmark Logbook is being withdrawn However a similar document in the form of a commissioning checklist and service interval record is incorporated at the back of these instructions This company 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 of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency Building Regulations require that installations should comply with manufacturer s instructions It is therefore important that the commissioning checklist is completed by the installer The relevant section of Building Regulations only relates to dwellings Therefore the checklist only applies if the appliance is being installed in a dwelling or some re
12. Heat Output DHW Max kW 24 Max Gas Rate Natural Gas G20 After 10 mins m h 2 62 Burner Pressure Natural Gas G20 Max Rate Min Rate 10 2 0 5 2 02 mbar Inlet Pressure Natural Gas G20 mbar 20 Burner Injector Natural Gas G20 15 x 1 18mm Diameter Electrical Supply 230V 50H Appliance must be connected to an earthed supply 170W Power Consumption External Fuse Rating 3A Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 SEDBUK Declaration For Performa 24 Eco HE 4 0 Electrical Protection IPX4D NO Class 3 Condensate Drain 1 BSP Flue Terminal Diameter 100mm Dimensions Projection 125mm Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Cold Water Mains Inlet 15mm DHW Flow 15mm Pressure Relief Discharge 15mm Outercase Dimensions Casing Height 780mm Overall Height Inc Flue Elbow 965mm Casing Width 450mm Casing Depth 345mm Clearances Above Casing 200 mm Min Below Casing 200 mm Min Front 450 mm Min For Servicing Front 5 mm Min In Operation L H Side 5 mm Min R H Side 5 mm Min In Operation 20 mm Min See Note NOTE The boiler can be operated with a clearance of 5mm at the right This is also sufficient for routine maintenance However a clearance of 20mm is required if it is necessary to remove the secondary heat exchanger This
13. Installation amp Service Instructions Performa 24 Eco 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 Notified Body 0051 Product Production certified by Notified Body 0086 For use in GB IE only These instructions include the Benchmark Commissioning Checklist and should be left with the User for safe keeping Natural Gas Potterton Performa 24 Eco HE G C N 47 393 11 CONTENTS Section Page Legislation 4 1 0 Introduction 5 2 0 General Layout 6 3 0 Appliance Operation 7 4 0 Technical Data 8 5 0 Dimensions and Fixings 9 6 0 System Details 10 7 0 Site Requirements 13 8 0 Installation 19 9 0 Commissioning 24 10 0 Completion 26 11 0 Servicing the Boiler 27 12 0 Changing Components 29 13 0 Electrical 39 14 0 Short Parts List 40 15 0 Fault Finding 41 Benchmark Checklist 46 Building Regulations and the Benchmark Commissioning Checklist Building Regulations England amp Wales require notification of the installation of a heating appliance to the relevant Local Authority Building Control
14. OT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDED A CO CO RATIO READING N A YES CO CO RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER COMMISSIONING ENG S NAME PRINT CORGI ID No SIGN DATE 46 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 Always use the manufacturer s specified spare part when replacing all controls SERVICE 1 DATE SERVICE 2 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 DATE SERVICE 4 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 5 DATE SE
15. RVICE 6 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 7 DATE SERVICE 8 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 9 DATE SERVICE 10 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE 47 BAXI Heating UK Brownedge Road Bamber Bridge Preston Lancashire PR5 6UP After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 Website www baxi co uk A BAXI GR UP company Tel Tel Tel Fax Tel Tel Publication No 5111811 Iss 4 04 2006 General Enquiries GB 08706 060 780 Technical GB 08706 049 049 Service GB 08706 096 096 01926 410 006 Literature Request GB 08706 060 623 Technical IE 1850 560570 All 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 requ
16. able flat bladed screw driver press the cable securing levers downwards to release each wire after noting their position 3 A standard Grundfos 15 60 replacement head can now be fitted Connect the wiring to the new head The pump speed must be set to 3 4 Reassemble in reverse order 12 12 Pump Complete Figs 59 amp 60 1 Drain the primary circuit 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 seals on the return pipe and manifold replacing if necessary 4 Fit the air vent to the pump body and reassemble in reverse order 12 13 Automatic Air Vent Fig 60 1 Drain the primary circuit and unscrew the automatic air vent from the pump body 2 Examine the O ring seal replacing if necessary and fit it to the new automatic air vent 3 Reassemble in reverse order Pump Wiring Cover Socket Headed gt Screw Pump Head Fig 58 Pump Setting Automatic Fig 59 Air Vent Qi Pump Wiring Cover Publication No 5111811 33 Pressure Gauge Capillary Gauge Retaining Bracket sages Pr
17. able 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 23 Flue Elbow 2 Locate the flue elbow on the adaptor at the top of Wall Thickness the boiler Set the elbow to the required orientation BA Fig 24 GG NOTE The flue elbow is angled at 93 degrees to x ensure a fall back to the boiler 3 Measure the distance from the outside wall face to the elbow This dimension will be known as X Fig 25 4 To dimension X add 50mm This dimension to be known as Y IMPORTANT Check all dimensions before cutting Fig 24 Wall Thickness Publication No 5111811 22 Waste Fig 26 Flue Elbow Flue Fig 28 Flue Trim 8 0 INSTALLATION 8 7 Fitting the Flue Cont 5 Mark dimension Y on the flue as shown Fig 26 Carefully cut the waste material from the flue ensuring that the ducts are square and free from burrs 6 The inner flue duct support bracket may be in the waste portion of the flue In this case retrieve the bracket before discarding the waste 7 Take the inner flue support bracket if not already fitted and engage it over the flue duct This will centralise the flue and air ducts and ease assembly Fig 27 8 Insert the flue through the hole in the wall Fit the elbow to the boiler adaptor e
18. age the securing screws Refit the case front panel and tighten the screws Fig 40 2 Instruct the user in the operation of the boiler and system explaining the operational sequence 3 Carefully read and complete all sections of the Benchmark Commissioning Checklist at the rear of this publication that are relevant to the appliance and installation These details will be required in the event of any warranty work The publication must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 For IE it is necessary to complete a Declaration of Conformity to indicate compliance with I S 813 An example of this is given in I S 813 Domestic Gas Installations This is in addition to the Benchmark Commissioning Checklist 5 Hand over the Users Operating Installation and Servicing Instructions giving advice on the necessity of regular servicing Publication No 5111811 11 0 SERVICING THE BOILER 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 Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication 3 Ensure that the boiler is cool 4 Ensure that both the gas and electrical supplies to the boiler are isolated 5 Slacken the screws securing the facia panel Li
19. an Spigot outlet pipe forwards Outlet Pipe 6 Remove the secondary heat exchanger from the outer drum by easing it forward 7 Reassemble in reverse order of dismantling 12 24 Flue Overheat Thermostat Fig 74 NOTE The flue overheat thermostat includes a reset button Check that the thermostat will not reset before replacing 1 Remove the fan spigot outlet pipe from the fan and elbow 2 Pull the two wires off the terminals on the flue overheat thermostat Unscrew the thermostat from the adaptor in the outlet elbow 3 Reassemble in reverse order of dismantling Ease Fan Spigot Outlet Pipe Clamp Inwards Fan Spigot Outlet Pipe Fig 74 Overheat Thermostat 38 Publication No 5111811 13 0 ELECTRICAL 13 1 Illustrated Wiring Diagram On Off Reset Selector Switch Temperature Sensor Hydraulic Differential Pressure Switch EN Valve gt N Gas DON Control PCB M2 A 3 pe M7 Safety Thermostat 44 HK 43 bk 42 Air Pressure Switch 3 Way Valve Microswitch Sensing Electrode Condensate Trap br brown bk black b blue r red y yellow g y green yellow w white gr grey Publication No 5111811 39 14 0 SHORT PARTS LIST Short Parts List Key G C Description Manufacturers No No Part No 22 Fan 5112627 M 23 Pressure Switch 5112999 A 32 Heat Exc
20. and disconnect them Pull the drive pins off the P C B 4 Undo the securing screws and remove the P C B 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 12 19 Selector Switch Fig 67 1 Note the setting of the selector switch knob and carefully pull it off the facia 2 Completely undo 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 hinge pin Fig 66 3 Note the position of the electrical connections and the orientation of the switch Remove the electrical connections 4 Remove the screws securing the switch to the facia panel 5 Fit the new switch ensuring that it is correctly positioned and reassemble in reverse order Grub Screw Pressure Relief Valve Selector Switch Drive Pins Selector Switch Knob Knobs Publication No 5111811 Plate Heat Exchanger Rubber Seal On Sensing Pipes Manifold Microswitch Bracket DHW Pressure Differential Valve Fig 69 Diaphragm Diaphragm apaa GQ gt A D we a astic Disc s Ra D Ky Pushrod Se P a Fig 70 w F 12 0 CHANGING COMPONENTS 12 20 Plate Heat Exchanger Fig 68 1 Drain the primary circuit 2 While supporting t
21. croswitch 6 Pump 19 Automatic By Pass PTET 7 Automatic Air Vent 20 Hydraulic Differential Pressure Sensor 3 The burner will light automaticaly ang the 8 Plate Heat Exchanger 21 Diverter Valve Assembly temperature of the domestic hot water is controlled 9 Flow Sensor with Filter 22 Domestic Hot Water Flow Priority Assembly by the temperature sensor 10 Pressure Relief Valve 23 Domestic Hot Water Flow Priority Microswitch 11 Boiler Drain Point 24 Temperature Sensor 12 Heating Return 25 Overheat Thermostat 4 When the domestic hot water demand ceases the 13 Cold Water Inlet On Off Valve and Filter 26 Expansion Vessel burner will extinguish and the diverter valve will 2r pocondary Hear Exenanger remain in the domestic hot water mode unless there 1 is a demand for central heating Domestic Hot Water Circuit IMPORTANT When the selector switch is in the 0 Off position the electrical supply to the boiler is isolated The boiler will not operate and the integral timer if fitted will require resetting once the selector switch is turned to either the DHW or CH position Publication No 5111811 T Appliance Type C42 C32 Appliance Category CAT Il 2H 3p Heat Input CH Max Min kW 24 8 10 6 Heat Output CH Non Condensing Max Min kW 24 9 8 Heat Output CH Condensing Max Min kW 25 2 10 1 Heat Input DHW Max kW 24 8
22. e boiler 5 Open the screw on the automatic air vent Fig 35 6 The system must be flushed in accordance with BS 7593 see Section 6 2 and the flushing agent manufacturers instructions 7 Pressurise the system to at least 0 5 bar then close and disconnect the filling loop Fig 34 8 Turn the gas supply on and purge the system according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 9 Test for gas soundness 10 If at any time during commissioning it is required to terminate a particular cycle turn the selector to the OFF position and then back to either or J Fig 36 Publication No 5111811 9 0 COMMISSIONING 9 2 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 2 Set the hot water and central heating temperature controls to maximum and the selector switch to the OFF position Fig 37 3 Slacken the pressure test point sealing screw on the gas valve and connect a pressure gauge Fig 38 4 Disconnect the sensing tube from the gas valve 5 Turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 2 seconds to reset the boiler 6 Turn the selector switch to the Cental Heating and Domestic Hot Water position W The power ON light G will illuminate Fig 37 7 Turn on a hot water tap to give a flow rate of at
23. e selector to the e ak Aaa Go to section F illuminated YES Burner extinguishes YES PE T after 10 seconds o to section NO Reduce the DHW flow rate If burner does not modulate clean temperature sensor and DHW heat exchanger If modulation does not YES Close DHW tap occur go to section G YES DHW flow valve __ Senses no flow Diverter valve spindle Primary water diverted to assembly faulty CH system DHW flow Burner output modulates to maintain temperature set at thermostat switch released off YES NO YES i Pump stops P ect 42 Publication No 5111811 15 0 FAULT FINDING Fault Finding Solutions Sections A to E A Is there 230V at 1 Main terminals L and N NO e 2 Main terminal fuse YES NO 3 Selector terminals a amp b and a amp 3 PCB M1 connector terminals 9 amp 10 B Is there 230V at ile If pump jammed release ue PCB M1 connector terminals 8 amp 15 ne YES Change pump supply cable C 1 CH system pressure 0 5 to 1 5 bar Me Check the tap of the NO automatic air vent is opened Primary flow valve diaphragm damaged YES NO N D 1 Continuity across flow microswitch and PCB M2 connector terminals 3 amp 4 2 Primary temperature sensor faulty YES Cold resistance approx 11K ohms resistance reduces with increase in temp Fan connections correct at fan PCB M5 connector is 230V across termi
24. ear lower edge as a pivot NOTE A small amount of water may drain from the boiler in the upright position For Side Flue Exit Fig 18 Flushing Tube Koa Fig 19 Central Heating Return Publication No 5111811 Wall Plate Fig 20 Securing Screw 7 i Washer Fig 21 Discharge Pipe 8 0 INSTALLATION 8 4 Fitting The Boiler 1 Lift the boiler using the lower edges Engage the slots at the top rear of the boiler on the wall plate hooks Fig 20 2 Ensure that the boiler is level and sits against the wall 3 Take the two steel washers and remaining screws Using the previously drilled and plugged holes secure the bottom of the boiler to the wall Fig 21 4 Remove the elbows valves and sealing washers from the packaging The 3 4 in valve with internal filter must be fitted to the central heating return The filter is visible through the branch connection of the valve 5 Using the sealing washers provided connect the valves to the heating flow and return and the cold water inlet 6 Connect the elbows to the gas service cock and hot water outlet pipe and then connect the elbows to the boiler Connect the elbows with flared ends to the valves 7 Ensure that the sealing washers are used on all connections The rubber washers must be used on the gas connections 8 The gas and water supplies central heating flow and retur
25. ection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement refilling 2 There are connection points on the mains cold water inlet and central heating return isolating taps to which the optional filling loop kit Part No 248221 can be assembled 3 The filling method adopted must be in accordance with all relevant water supply regulations and use approved equipment 4 Your attention is drawn to for GB Guidance G24 2 and recommendation R24 2 of the Water Regulations Guide for IE the current edition of I S 813 Domestic Gas Installations 5 The sealed primary circuits may be filled or replenished by means of a temporary connection between the circuit and a supply pipe provided a Listed double check valve or some other no less effective backflow prevention device is permanently connected at the inlet to the circuit and the temporary connection is removed after use 6 6 Expansion Vessel Central Heating only 1 The appliance expansion vessel is pre charged to 0 5 bar Therefore the minimum cold fill pressure is 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 For GB refer to BS 7074 Pt 1 For IE the current edition of I S 813 Domestic Gas Installations 6 7 Pressure Relief Valve Fig
26. essure Gauge Fig 62 Expansion Vessel 12 0 CHANGING COMPONENTS 12 14 Pressure Gauge Figs 61 amp 62 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 3 Remove the bracket and gauge assembly Depress the barbs on the side of the gauge and remove the retaining bracket 4 Reassemble in reverse order 12 15 Expansion Vessel Fig 63 1 To replace the expansion vessel it is necessary to remove the boiler from the wall NOTE Alternatively a vessel of equivalent capacity can be fitted on the system return pipe as close as possible to the boiler 2 Drain the system and undo all gas water and condensate drain connections Remove the flue elbow 3 Lift the boiler off the wall bracket and lay it on it s 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 Fig 63 L retaining clips j Vessel Outlet 6 Reassemble in reverse order Fully recommission ae Spigot the appliance and system Boiler S Chassis a 4 is 12 16 Condensate Trap Fig 64 Spring ant Washer 1 Disconnect t
27. est
28. ft the outercase panel so that its securing tabs are clear of the facia Remove the panel Fig 41 6 Remove the screws securing the inner door panel Lift the panel slightly to disengage it from the studs on top of the case Fig 43 7 Note the positions of the three wires on the fan motor and remove them Remove the sensing tube from the fan spigot Fig 42 8 Slacken the screws on the fan spigot outlet pipe clamp Ease the clamp inwards over the pipe 9 Remove the four screws securing the combustion box door and remove the door Fig 43 Publication No 5111811 Case Front Panel Fig 41 Facia Panel Fan Wires Sensing i Tube Ease Fan Spigot Outlet Pipe Clamp Inwards Fan Spigot Outlet Pipe Combustion Box Door Inner Door Panel Fan 27 Tab Fan and Hood Assembly Fig 46 Electrode Grommets Burner Electrode Leads Gas Supply Pipe Blanking Cold Water Cap Inlet Tap Cartridge ue Body Filter Gauze Fig 55 Regulator S34 Inlet Return Manifold Flow e Venturi 11 0 SERVICING THE BOILER 11 1 Annual Servicing Cont 10 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 44 11 Undo the screws securing the fan hood asse
29. gulator Figs 71 amp 72 1 Undo the filter cartridge from the inlet return manifold 2 Unscrew the venturi and remove the flow regulator 3 Check the cleanliness of the filter gauze rinsing thoroughly in clean water as necessary Fit the new flow regulator and reassemble in reverse order Microswitch amp Bracket Central Heating Pressure Differential Valve ra Sensing Pipe o CN Ka e E By pass Diaphragm C n Pipe 0 Yy e Spring Clip Heating Flow Pipe 4 Fig 71 Fig 85 Diverter Manifold Cartridge we Body Pressure Gauge Capillary Filter Gauze i Inlet Return Manifold Flow e Regulator A Met Fig 72 Venturi Publication No 5111811 12 0 CHANGING COMPONENTS Secondary Heat Exchanger 12 23 Secondary Heat Exchanger Fig 73 1 Drain the primary circuit Pipe Connecting Clip E 2 Undo the four screws securing the right hand case panel Remove the panel Fan Spigot Outlet Pipe Clamp A 3 Prise the connecting clips from the heat Outer Drum exchanger return pipe and the boiler return pipe Remove the pipes 4 Slacken the screws on the fan spigot outlet Boiler Return Pipe pipe clamp Ease the clamp to the left Undo the screw at the left hand end of the pipe Heat Exchanger 5 Remove the nut securing the elbow to the Return Pipe secondary heat exchanger Draw the elbow and F
30. h mbar 37 8 Publication No 5111811 5 0 DIMENSIONS AND FIXINGS Dimensions A 780mm B 345mm C 450mm D 116mm Min E 185mm F 190mm G 131mm Gas Inlet Heating Domestic Hot Cold Water Heating Flow Water Outlet Inlet Return 165 7mm View from under the appliance Left Hand Side 130mm of Boiler Publication No 5111811 6 0 SYSTEM DETAILS 6 1 Information 1 The Potterton Performa 24 Eco HE Condensing 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 b IRN 302 Byelaw 14 2 Reference to the WRc publications Water fittings and materials directory and Water supply byelaws guide give full details of byelaws and the IRNs 6 2 Central Heating Circuit 1 The appliance is suitable for fully pumped SEALED SYSTEMS ONLY Treatment of Water Circulating Systems e 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 e When fitting new systems flux will be evident within the system which can lead to damage of system
31. hanger 5112431 gt Le 41 Burner 5112770 AD 131 135 SI A 44 E66 402 Injector 1 18 NG 248210 63 59 E66 408 Electrode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 Pump Complete 248042 101 E66 432 Hydraulic Outlet Assembly 248061 102 E66 434 Valve 3 Way Assembly 248062 103 343 619 Pressure Differential Assy 248063 131 Temperature Sensor 5108265 135 E66 697 Safety Limit Thermostat 248078 140 Gas Valve 5107339 154 PCB 5112657 169 E66 453 Pressure Gauge 248090 371 Igniter Gas Valve Cable 5112385 A Flue Overheat Thermostat 5112395 D Y D IE in L LLL iii W DE i ip np ip ap De W Ly Ly Y Ly U 4 i Uy ST Dy Di iy D Ly p y a y gt Sip Ui yy Ny MyM Lips STP gt yy 169 32 40 Publication No 5111811 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 Carry out electrical system checks i e Ground Continuity Resistance to Ground Short Circuit and Polarity with a suitable meter NOTE These checks must be repeated after any servicing or fault finding Ensure all external controls are calling for heat and check all external and internal fuses Befo
32. he 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 Seals 4 There are four rubber seals between the manifolds and heat exchanger which may need replacement 5 Ease the seals out of the manifold Replace carefully ensuring that when the seal is inserted into the manifold it is parallel and pushed fully in 6 When fitting the new heat exchanger note that the left hand location stud is offset towards the centre more than the right hand one 7 Reassemble in reverse order 12 21 Diverter Valve Assembly Fig 69 The diverter valve assembly comprises of a central heating pressure differential valve and a domestic hot water pressure differential valve These are connected to a manifold which is joined to the plate heat exchanger DHW Pressure Differential Valve Fig 70 1 Drain the primary circuit 2 Undo the screw securing the microswitch bracket to the valve Fig 69 3 Disconnect the two sensing pipes and slacken the grub screws securing the valve to the diverter manifold 4 Draw the valve away from the diverter manifold The valve may now be replaced or split to examine the diaphragm 5 To examine the diaphragm hold the valve body securely and carefully remove the six screws The diaphragm spring will force apart the two halves of the valve 6 Remove the plastic disc a
33. he two sensing wires from the trap connections Sensing Wires Inlet Pipe 2 Squeeze together the wire spring clip to release eo ge and ease the inlet pipe from the trap spigot a _ Wire Spring DS Clip 3 Undo the nut securing the condensate drain pipe aet to the trap Disconnect the pipe and sealing washer TON Condensate 4 From underneath the boiler remove the screws Trap securing the trap bracket Dya Bracket 5 Remove the trap and bracket from the boiler Undo the locknut securing the trap to the bracket amp 6 Reassemble in reverse order Fig 64 Ex Condensate Tee Drain Pipe 34 Publication No 5111811 12 0 CHANGING COMPONENTS 12 17 Pressure Relief Valve Fig 65 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 4 Fit the new valve and O ring seal and set to the previously noted orientation Reassemble in reverse order 12 18 P C B Fig 67 1 Note the settings of the temperature control knobs Rotate the knobs fully anticlockwise and pull them off the drive pins 2 Completely undo 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 hinge pin Fig 66 3 Note the position of all plugs and wires on the P C B
34. ing or using the appliance In GB this must be carried out by a competent person as stated in the Gas Safety Installation amp Use Regulations Definition of competence A person who works for a CORGI registered company and holding current certificates in the relevant ACS modules is deemed competent In IE this must be carried out by a competent person as stated in I S 813 Domestic Gas Installations Lifting This product should be lifted and handled by two people Stooping should be avoided and protective equipment worn where necessary Carrying amp lifting equipment should be used as required e g when installing in a loft space The addition of anything that may interfere with the normal operation of the appliance without express written permission from the manufacturer or his agent could invalidate the appliance warranty In GB this could also infringe the Gas Safety Installation and Use Regulations Warning Check the information on the data plate is compatible with local supply conditions All CORGI registered installers carry a CORGI identification card and have a registration number You can check your installer is registered by telephoning 0870 4012300 or writing to 1 Elmwood Chineham Business Park Crockford Lane Basingstoke RG24 8WG or check online at www corgi gas safety com LEGISLATION Potterton declare that no substances harmful to health are contained in the appliance or used during ap
35. ion electrical 230V at Main PCB M4 Replace PCB plug igniter assy Publication No 5111811 15 0 FAULT FINDING l Ensure that mains input terminal L is Live 230V and N is Neutral OV Check and correct if necessary 1 Flame sensing electrode and lead connections 2 Electrode position Replace PCB Replace flame sensing electrode Flame current should be 1 pA approx J Boiler overheat thermostat Allow to cool Continuity operated or faulty i e continuity across thermostat terminals across thermostat terminals more than 1 5 ohm Replace boiler overheat thermostat Replace PCB Check terminal 1 of ON OFF RESET selector is in NO Replace ON OFF RESET selector connection with PCB M1 connector terminal 16 Check electrical continuity across terminals 1 amp a of YES ON OFF RESET selector when turned to Reset position Replace PCB L Press the reset button on the flue overheat thermostat If the boiler does not relight or repeatedly cuts out check the operation of the flue system or replace the flue overheat thermostat If the flue overheat thermostat has not been activated see section D Publication No 5111811 BENCHMARK No 5 1 1 1 8 1 1 benchmar J GAS BOILER COMMISSIONING CHECKLIST 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
36. lated structure The flowchart opposite gives guidance for installers on the process necessary to ensure compliance with Building Regulations Publication No 5111811 INSTALLER NOTIFICATION GUIDELINES Choose Building Regulations Notification Route Competent Person s Self Certification Scheme Install and Commission this appliance to manufacturer s instructions Complete the Benchmark Checklist If you notify via CORGI Scheme CORGI will then notify the relevant Local Authority Building Control Scheme on member s behalf Scheme Members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist CORGI will record the data and will send a certificate of compliance to the property Publication No 5111811 Building Control Contact your relevant Local Authority Building Control LABC who will arrange an inspection or contact a government approved inspector Install and Commission this appliance to manufacturer s instructions Complete the Benchmark Checklist LABC will record the data and will issue a certificate of compliance IMPORTANT Installation Commissioning Service amp Repair This appliance must be installed in accordance with the manufacturer s instructions and the regulations in force Read the instructions fully before install
37. least 10 l min 8 The pressure should be NG 10 2 mbar Propane 21 8 mbar If not check that the gas supply pressure is correct Natural Gas 20mbar and Propane 37mbar 9 The pressure can be adjusted if required 10 To check and set minimum pressure first remove one of the modulator wires Adjusting the Pressure Fig 39 11 Remove the plastic protection cap from the pressure adjustment nuts on the valve 12 The smaller nut 6mm adjusts minimum pressure and the larger nut 8mm maximum pressure 13 Using a suitable spanner adjust the relevant nut until the correct pressure is achieved 14 Once the pressure has been set turn the boiler off and disconnect the pressure gauge 15 Tighten the pressure test screw and refit the modulator to the valve Reassemble in reverse order Selector Switch Performa 24 Eco HE Central Heating Hot Water Temperature Control Temperature Control Pressure Test Point Sealing Screw Gas Valve Minimum Pressure Screw Fig 38 Plastic Protection Cap Wire Maximum Rate era Adjustment Nut Minimum Rate Adjustment Nut NOTE Gas Valve Electrical Fig 39 ig 3 Plug Igniter not shown for clarity Publication No 5111811 25 26 Facia Panel Case Front Panel 5 Fig 40 10 0 COMPLETION 10 1 Completion 1 Hinge the facia panel upwards and eng
38. mbly to the appliance back panel and draw the fan and hood assembly forwards Fig 45 12 Draw the burner out of the combustion box pulling the electrode grommets from the slots in the combustion box lower panel Fig 46 13 Disconnect the electrode leads and grommets from the electrodes Completely remove the burner Fig 46 14 Brush any deposits from the injectors Do not use a pin or wire to clean them 15 Brush the burner blades and venturis and clean the combustion box 16 Ensure that the heat exchanger fins are clear of any obstruction NOTE If necessary the secondary heat exchanger may be dismantled see section 12 23 D H W Filters Fig 48 17 If the flow of domestic hot water is diminished it may be necessary to clean the filters 18 Initially check the cold water inlet tap filter 19 Turn the tap off Undo the blanking cap and remove the threaded bush Fig 47 20 Extract the filter and rinse thoroughly in clean water Reassemble and check the flow If required clean the manifold filter as described below 21 Undo the filter cartridge from the inlet return manifold 22 Dismantle the cartridge and carefully remove the flow regulator and filter gauze Rinse them thoroughly in clean water and reassemble in reverse order 23 Check that the pressure vessel charge is 0 5bar reassemble in reverse order of dismantling 24 Turn the selector switch fully anticlockwise against the spring pre
39. mmercial light industrial E M C environments on a governed meter supply only 7 The boiler must be installed with one of the purpose designed flues such as the standard horizontal flue kit part no 5111073 8 All systems must be thoroughly flushed and treated with inhibitor see section 6 2 1 2 Optional Extras 1 Various flue extensions bends vertical flue kits control accessories etc are available as optional extras These are detailed in a separate publication Publication No 5111811 Control Box Fig 1 Case Front Panel Data Badge 2 0 GENERAL LAYOUT 2 1 Layout 4 Air Pressure Switch 2 Expansion Vessel 3 Burner Manifold 4 Automatic Air Vent 5 DHW Plate Heat Exchanger 6 Circulation Pump ce Drain Off Point 8 Pressure Relief Valve 9 Optional Integral Timer Position 10 Central Heating System Pressure Gauge ti Control PCB 12 Control Box 13 3 Way Valve Assembly 14 Condensate Trap 15 Flame Sensing Electrode 16 Spark Electrode 17 Burner 18 Primary Heat Exchanger 19 Fan Assembly 20 Secondary Heat Exchanger 21 On Off Reset Selector Switch 22 Burner amp Fault Indicator Neon 23 Power Neon 24 Flame Failure amp Fault Indicator Neon 25 Central Heating Temperature Control 26 Hot Water Temperature Control p gt Burner on A L
40. n the boiler chassis Refer to the instructions supplied with the control 7 To connect external control s remove the link between terminals 1 amp 2 The 230V supply at terminal 1 can be connected to the external control as shown The switched output from the external control must be connected to terminal 2 Figs 32 NOTE If the room thermostat being used incorporates an anticipator it MUST be wired as shown in Fig 32 IMPORTANT The external control MUST be suitable for 230V switching 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 9 If an optional integral timer is to be used it should be fitted at this point Refer to the instructions supplied with the timer NOTE An external frost thermostat cannot be used with the integral timer 8 9 Preliminary Electrical Checks 1 Prior to commissioning the boiler preliminary electrical system checks should be carried out 2 These should be performed using a suitable meter and include checks for Ground Continuity Resistance to Ground Short Circuit and Polarity Control Box Cover Fig 31 Cable Clamp Fuse Fused supply 3A 230V 50Hz Live brown External Controls Fig 33 Neutral blue Earth green yellow EA Always fit fast a blow 2A fuse Terminal Block
41. n and domestic hot water flow can now be connected 8 5 Fitting the Pressure Relief Discharge Pipe Fig 22 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 7 for further details 4 Using one of the sealing washers connect the discharge pipe to the adaptor and tighten the nut 5 Complete the discharge pipework and route it to the outside discharge point IMPORTANT Make all soldered joints before connecting to the pressure relief valve Publication No 5111811 8 0 INSTALLATION 8 6 Condensate Drain see section 7 6 1 Connect the condensate drain using the 1 BSP nut and seal supplied Ensure the discharge of condensate complies with any national or local regulations in force see British Gas Guidance Notes for the Installation of Domestic Gas Condensing Boilers 2 The condensate outlet terminates in a 1 BSP nut and seal for the connection of 21 5mm sin plastic overflow pipe which should generally discharge internally into the household drainage system If this is not possible discharge into an outside drain is acceptable 8 7 Fitting The Flue HORIZONTAL FLUE 1 The standard flue is suit
42. nals 28 amp 29 Check electrical supply Replace fuse Check wiring Replace selector Replace pump Replace PCB Re pressurise system Open the automatic air vent Replace diaphragm Flow valve rod obstructed Replace microswitch Replace sensor Fan jammed or faulty winding Replace PCB Q neon illuminated Replace PCB Replace fan Publication No 5111811 43 F Gasatbumer PS 44 15 0 FAULT FINDING Check and correct if necessary 1 Electrical and pressure tube connections NO Replace air 2 Blockage of pressure tubes A pressure switch 3 Restriction in flue 4 Venturi Ensure gas is on and purged PCB M4 connector is approx 230V AC terminals 36 amp 38 O N YES A neon illuminated NO Replace PCB Replace gas valve Turn selector switch to Reset position 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 XES 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 NO measure gt Replace PCB 30 230 mA DC 45 310 mA DC LPG Check and correct if necessary 1 Ignition electrode and lead connector across terminals 2 Electrode connection 37 amp 38 Check wiring Replace gas valve 3 Spark gap and posit
43. nd pushrod assembly Carefully examine the diaphragm and replace it if there is any damage 7 Reassemble in reverse order 36 Publication No 5111811 12 0 CHANGING COMPONENTS 12 21 Diverter Valve Assembly Cont CH Pressure Differential Valve Fig 71 1 Remove the DHW pressure differential valve as described above 2 From the brass diverter manifold undo the nut on the heating flow pipe Remove the screw securing the diverter manifold to the appliance lower bracket 3 Disconnect the pressure gauge capillary from the diverter manifold and remove the two wires from the microswitch 4 Prise off the spring clip securing the by pass pipe to the diverter manifold and disconnect the sensing pipe 5 Ease the diverter manifold out of the plate heat exchanger manifold Remove the assembly from the appliance 6 Undo the screw securing the microswitch bracket to the valve body The sensor may now be dismantled to examine the diaphragm 7 To examine the diaphragm hold the assembly securely and carefully remove the four screws The diaphragm spring will force the two halves of the valve apart 8 Carefully examine the diaphragm and replace it if there is any damage 9 Reassemble in reverse order CH Pressure Microswitch Fig 71 1 Remove the two wires from the pressure microswitch 2 Undo the screw securing the microswitch bracket to the valve body 3 Reassemble in reverse order 12 22 Flow Re
44. nsuring that it is pushed fully in 9 Draw the flue back through the wall and engage it in the elbow It may be necessary to use soap solution or similar to ease assembly of the elbow adaptor and flue Fig 28 10 Make good between the wall and air duct outside the building 11 Fit the flue trim if required and if necessary fit a terminal guard see Section 7 9 amp 7 10 VERTICAL FLUE 1 Only a flue approved with the Potterton Performa 24 Eco HE can be used 2 For information on vertical flues consult the Potterton Flue Guide brochure Publication No 5111811 8 0 INSTALLATION 8 8 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 2 Completely undo the screws securing the facia panel and hinge it down Fig 29 3 Remove the control box cover securing screws Disengage the barbs on the control box from the cover Remove the cover Fig 30 4 Slacken the cable clamp on the LH side of the boiler chassis Fig 31 Insert the cable through the clamp and route it to the terminal block 5 Slacken the screws in the terminal block connect the input cable and tighten the screws 6 If an external control is to be connected it can be done at this point Run the input cable from the external control through the second cable clamp o
45. o section G temperature is reached YES YES YES YES Operation sequence Burner goes out Fan stops Pump stops correct Publication No 5111811 41 15 0 FAULT FINDING Replace diaphragm ES Y Is mains water filter and differential di ss se VANE d assembly clean AP Agi Caled NO YES Domestic Hot Water Follow operational sequence Turn selector to Q neon illuminated YES Go to section A Turn thermostat to DHW flow rate more than DHW flow valve rod nas Open DENN tap fully 2 5l min obstructed DHW flow switch operated er Continuity across DHW a DAWN flow Primary water is diverted fow micr switch microswitch from CH system to DHW NO Replace PCB heat exchanger and flow terminals a dPGB M1 microswitch operated connector terminals 13 amp YES 14 terminals 12 14 open YES YES Primary flow switch Go te section C operated YES Turn the selector switch to the Reset position an Ep go g Epp Fan runs at max speed andihold forat least 2 Go to section J L amp D YES seconds If regular resetting is required or appliance still does not operate investigation is necessary Air pressure switch Goto scion E proved YES Spark at ignition i YES i electrodes for up to 10 A neon illuminated roset position ome light does not extinguish go to seconds section H amp K NO Replace PCB Turn th
46. ork from the meter to the appliance is of adequate size Do not use pipes of a smaller diameter than the boiler gas connection 22mm 7 5 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with relevant regulations rules In GB this is the current I E E Wiring Regulations In IE reference should be made to the current edition of ETCI rules 2 The mains supply is 230V 50Hz fused at 3A maximum NOTE The method of connection to the electricity supply must facilitate complete electrical isolation of the appliance Connection may be via a fused double pole isolator with a contact separation of at least 3mm in all poles and servicing the boiler and system controls only Publication No 5111811 7 0 SITE REQUIREMENTS 7 6 Condensate Drain FAILURE TO INSTALL THE CONDENSATE 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 50mm per metre along the entire run 1 The condensate outlet terminates in a 1 BSP nut and seal for the connection of 21 5mm sin plastic overflow pipe which should generally discharge internally into the household drainage system If this is not possible discharge into an outside drain is acceptable 2 Ensure the discharge of condensate complies with any national or local regulations in force BS 6798 200
47. ots in the Heat Exchanger combustion box lower panel 3 Disconnect the electrode leads and grommets from the electrodes Completely remove the burner 4 Undo the screws securing the electrodes to the burner Examine the condition of the electrodes replacing if necessary Fit the electrodes to the new burner 5 Engage the burner location brackets over the studs on the injector manifold and reassemble in reverse order Electrodes r N Burner eS 6 2 Electrode 4 ee gt Fig 53 Grommets A 5 Electrode Leads 30 Publication No 5111811 12 0 CHANGING COMPONENTS 12 5 Injectors Fig 54 Injector Inlet Elbow 1 Remove the burner as described in Section 12 4 Injector Manifold 2 Undo the screws securing the injector manifold to the inlet elbow and remove the manifold Fig 54 3 Unscrew and replace injectors as required and examine the sealing gasket replacing as necessary Reassemble in reverse order Gasket 12 6 Electrodes Fig 54 1 Remove the four screws securing the combustion box door and remove the door Electrodes eS 2 Draw the burner out of the combustion box E as pulling the electrode grommets from the slots in the Electrode s Gales yd i combustion box lower panel Grommets x 3 Disconnect the lead and grommet from the Sissies electrode being replaced Undo the securing screw Leads and withdraw the electrode to the burner 4 Reassemble in
48. pliance manufacture The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force and only used in a suitably ventilated location In GB the installation must be carried out by a CORGI Registered Installer It must be carried out in accordance with the relevant requirements of the e Gas Safety Installation amp Use Regulations e The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland e The Water Fittings Regulations or Water Byelaws in Scotland e The Current I E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a competent Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation All systems must be thoroughly flushed and treated with inhibitor see section 6 2 Codes of Practice most recent version should be used In GB the following Codes of Practice apply Standard Scope BS 6891 Gas Installation BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Forced circulation hot water systems BS 6798 Installation of gas fired hot water boiler
49. r gully iv to a purpose made soakaway Termination to an internal soil and vent pipe AWA 450mm min External termination via internal Boiler discharge branch e g sink waste downstream Pipe must terminate above water level but below surrounding surface Sink External termination to a drain or gully Pipe must terminate above water level but below surrounding surface External termination to a purpose made soak away Boiler gt lt lt _ 500mm min Holes in the soak away must face away from the building Publication No 5111811 15 7 0 SITE REQUIREMENTS 7 7 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 For GB recommendations are given in BS 5440 Pt 1 For IE recommendations are given in the current edition of I S 813 Domestic Gas Installations 2 If the terminal discharges onto a pathway or passageway check that combustion products will not cause a nuisance and that the terminal will not obstruct the passageway 3 If a terminal is less than 2 metres above a balcony above ground or above a flat roof to which people have access then a suitable terminal guard must be provided
50. re any servicing or replacement of parts ensure the gas and electrical supplies are isolated Refer to Section 13 1 Illustrated Wiring Diagram for position of numbered terminals Central Heating Follow operational sequence Turn selector to iJ Q neon illuminated YES NOTE When instructed to turn the Selector Go to section A to the reset position turn the Selector Go to section B Switch fully anticlockwise against the spring pressure and hold for 2 seconds to reset the boiler YES Turn iff thermostat External controls and Ensure controls are set to to max where fitted integral timer demand and verify the Pump runs calling for heat contacts are closed Go to section C YES Primary flow switch operated YES Turn the selector switch NO to the Reset position Go to sections J L amp Fan runs at max speed and hold for at least 2 D YES seconds If regular resetting is required or appliance still does not operate investigation is necessary Air pressure Ne Go to section E switch proved YES Spark at ignition electrodes for up to 10 A illuminated seconds YES Turn selector to the reset position If the light does not extinguish go to sections H amp K zZ O Replace PCB Bumer on d nean No Go to section F illuminated YES Burner extinguishes YES T i after 10 seconds Goto section il NO Burner output modulates until set Go t
51. reverse order 12 7 Insulation Fig 55 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 exchanger as described in Section 12 3 and slide out the side pieces 4 The combustion box door insulation piece can be replaced by carefully bending up the two retaining Side Insulation tabs Rear Insulation 5 Replace all insulation pieces and reassemble in reverse order Side Insulation Combustion Box Door Front Insulation Fig 55 Publication No 5111811 31 Modulator 6 Wires ag a Ignition kee Lead ig oO i j R Gas Valve SSE Electrical Plug Earth Wire 3 Inlet Pipe Gas Feed Pipe Fig 56 Flow Pipe Safety Thermostat Temperature Sensor Fig 57 12 0 CHANGING COMPONENTS 12 8 Gas Valve Fig 56 1 Undo the nut on the gas feed pipe at the tap rail under the boiler 2 Completely undo the securing screws and hinge the facia panel down 3 Disconnect the wires from the valve modulator and the ignition lead from the spark generator Disconnect the pressure sensing pipe from the valve Undo the screw securing the spark generator electrical plug to the valve and disconnect the plug
52. rubber flue trim supplied may be fitted to either the outside wall or on the inner wall of installation 7 10 Terminal Guard Fig 17 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 terminal guard quote the appliance name and model number 4 The flue terminal guard should be positioned centrally over the terminal and fixed as illustrated Publication No 5111811 Fig 17 17 Horizontal Flues Vertical Flues Twin Pipe Vertical g Flues 18 7 0 SITE REQUIREMENTS 7 11 Flue Options 1 The Potterton Performa 24 Eco 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 4 metres Vertical Concentric 4 metres Vertical Twin Pipe 12 metres 4 Any additional in line bends in the flue system must be taken into consideration Their equivalent lengths are Concentric Pipes 45 bend 0 5 metres 93 bend 1 0 metres Twin Flue Pipe 45 bend 0 25 metres 91 5 bend 0 50 metres The elbow supplied with the standard horizontal flue is not included in any equivalent length calculations 5 The illustrations opposi
53. s BS 5440 Part 1 Flues BS 5440 Part 2 Ventilation BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems In IE the following Codes of Practice apply Standard Scope l S 813 Domestic Gas Installations The following BS standards give valuable additional information BS 5546 Installation of hot water supplies for domestic purposes BS 5449 Forced circulation hot water systems BS 7074 Expansion vessels and ancillary equipment for sealed water systems BS 7593 Treatment of water in domestic hot water central heating systems Publication No 5111811 1 0 INTRODUCTION 1 1 Description 1 The Potterton Performa 24 Eco HE is a fully automatic gas fired wall mounted condensing combination boiler It is room sealed and fan assisted and will provide central heating and mains fed domestic hot water 2 The boiler is set to give a maximum output of 25 2 kW condensing 3 It is designed for use on Natural Gas G20 and can be converted to use Propane 4 The boiler is suitable for use only on fully pumped sealed heating systems Priority is given to domestic hot water 5 The boiler data badge gives details of the model serial number and Gas Council number and is situated on the control box It is visible when the case front panel is removed Fig 1 6 The boiler is intended to be installed in residential co
54. should be considered when siting the appliance and in the event of any subsequent alterations in the area of installation Weights kg Packaged Boiler Carton 50 Installation Lift Weight 43 5 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 The test data from TECHNICAL DATA Central Heating Primary Circuit Pressures bar Safety Discharge 3 Max Operating 2 5 Min Operating 0 5 Recommend Operating 1 2 DHW Circuit bar Pressures Max Operating 8 Min Operating 0 2 Min Operating Pressure at 11 1 I min 0 9 Flow Rates l min DHW Flow Rate 30 C Rise 11 5 DHW Flow Rate 35 C Rise 9 8 Min Working DHW Flow Rate 2 5 Pump Available Head See graph below Expansion Vessel For Central Heating only Integral with appliance bar Min Pre charge Pressure 0 5 litre Max Capacity of CH System 125 Primary Water Content 1 0 of Boiler unpressurised Temperatures C H Flow Temp adjustable 35 C to 85 C max 5 C D H W Flow Temp 35 C to 65 C max 5 C dependent upon flow rate Pump Available Head which it has been calculated have been certified by 0051 B g 3 LPG Propane G31 Burner Injector 15 x 0 77mm diameter Burner Pressure Max Rate Min Rate Propane mbar 21 8 os 4 4 0 2 600 800 1000 1200 Inlet Pressures Flow Rate
55. ssure to position R and hold for 2 seconds to reset the boiler before recommissioning 25 Complete the relevant Service Interval Record section of the Benchmark Commissioning Checklist at the rear of this publication and then hand it back to the user 28 Publication No 5111811 12 0 CHANGING COMPONENTS IMPORTANT When changing components ensure that both the gas and electrical supplies to the Pressure Switch boiler are isolated before any work is started See Section 11 1 Annual Servicing for removal of case panel door etc Fig 49 12 1 Fan Figs 50 amp 51 1 Note the positions of the three wires on the fan motor and remove them Remove the sensing tube from the fan spigot f Pressure Switch Wires 2 Slacken the screws on the fan spigot outlet pipe clamp Ease the clamp inwards over the pipe 3 Remove the four screws securing the combustion box door and remove the door Fan Wires i s Fan 4 Ease the front edge of the left hand baffle upwards TA disengaging the spring clip Disengage the tab on the baffle from the slot in the fan hood s pa 7 5 Undo the screws securing the fan hood to the appliance back panel and draw the fan and hood Wie assembly forwards s Sensing l 6 Remove the screws and spring washers securing Tube the fan to the hood Transfer the flue spigot outlet pipe Ease Fan Spi ot O tlet to the new fan pa Pipe Clamp Inwards
56. te show examples of maximum equivalent lengths 6 Instructions for guidance and fitting are included in each kit where appropriate NOTE Flue length is measured from point A to B as shown Publication No 5111811 8 0 INSTALLATION 8 1 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 Mark the position of the two most suitable fixing slots for the wall plate and boiler lower fixing holes It is preferable to use the horizontal fixing slots For side flue exit mark as shown Fig 18 3 Mark the position of the centre of the flue hole rear exit For side flue exit mark as shown 4 If required mark the position of the gas and water pipes Remove the template 5 Cut the hole for the flue minimum diameter 116mm 6 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using two of the fixing screws 7 Using a spirit level ensure that the plate is level before finally tightening the screws 8 2 Flushing 1 Connect a tube to the central heating flow or return pipe Fig 19 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 r
57. the boiler Fig 11 y 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 NOTE The boiler can be operated with a clearance of 5mm at the right This is also sufficient for routine maintenance However a clearance of 20mm is required if it is necessary to remove the secondary heat exchanger This should be considered when siting the appliance and in the event of any subsequent alteration in the area of installation 450mm Min e For Servicing Purposes 5mm Min In Operation Fig 12 Publication No 5111811 13 Gas Service Cock 7 0 SITE REQUIREMENTS 7 3 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 7 4 Gas Supply 1 The gas installation should be in accordance with the relevant standards In GB this is BS 6891 In IE this is the current edition of I S 813 Domestic Gas Installations 2 The connection to the appliance is a 22mm copper tail located at the rear of the gas service cock Fig 13 3 Ensure that the pipew
58. y to the boiler Contact your Water Distribution Company for advice on suitable devices Publication No 5111811 7 0 SITE REQUIREMENTS 7 1 Location 20mm 5mm Min 5mm Min 450mm see NOTE gt 1 The boiler may be fitted to any suitable wall with the flue passing through an outside wall or roof and aa discharging to atmosphere in a position permitting satisfactory removal of combustion products and providing an adequate air supply The boiler should be fitted within the building unless otherwise protected by a suitable enclosure i e garage or outhouse The boiler may be fitted inside a cupboard see Section 7 3 2 If the boiler is sited in an unheated enclosure then it is recommended that frost protection is incorporated in the control system 3 If the boiler is fitted in a room containing a bath or shower reference must be made to the relevant requirements In GB this is the current I E E Wiring Regulations and Building Regulations In IE reference should be made to the current edition of l S 813 Domestic Gas Installations and the current ETCI rules 780mm 4 If the boiler is to be fitted into a building of timber frame construction then reference must be made to the current edition of Institute of Gas Engineers Publication GE UP 7 Gas Installations in Timber Framed Housing 7 2 Clearances Fig 11 amp 12 200mm Min 1 A flat vertical area is required for the installation of
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