Potterton Performa 30 HE Installation & Service Instructions Manual
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Potterton Performa 30 HE Installation & Service Instructions Manual

Potterton performa 30 he installation guide
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Installation & Service Instructions
Performa 30 HE
These instructions include the Benchmark Commissioning Checklist
and should be left with the user for safe keeping.
© Baxi Heating UK Ltd 2007

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  • Page 1 Installation & Service Instructions Performa 30 HE These instructions include the Benchmark Commissioning Checklist and should be left with the user for safe keeping. © Baxi Heating UK Ltd 2007...

  • Page 2: Table Of Contents

    Natural Gas Potterton Performa 30 HE G.C.N 47 393 13 Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control 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.

  • Page 3: Installer Notification Guidelines

    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...

  • Page 4: Legislation

    Crockford Lane, Basingstoke. RG24 8WG or check online at www.corgi-gas-safety.com 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...
  • Page 5 Where possible transport the boiler using a sack truck or other suitable trolley. Always grip the boiler firmly, and before lifting feel where the weight is concentrated to establish the centre of gravity, repositioning yourself as necessary. See the ‘Installation’ section of these instructions for recommended lift points.

  • Page 6: Introduction

    Data Badge 1.0 Introduction Description 1. The Potterton Performa 30 HE is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water.

  • Page 7: General Layout

    On/Off/Reset Selector Switch Central Heating Temperature Control Hot Water Temperature Control Flame Failure or Blocked Condensate Drain Safety Thermostat Activated (Boiler or Flue) Fault on Fan or Flue Fault on Pump or Low System Pressure Fault on Hot Water Sensor...

  • Page 8: Appliance Operation

    2.1) in the domestic hot water and central heating position. If the system temperature falls below 5° C then the boiler will fire on its minimum setting until a flow temperature of 30° C is reached. Further protection can be incorporated by using a system frost thermostat.

  • Page 9: Technical Data

    180W External Fuse Rating Internal Fuse Rating Fuse 2A Fast Blow to BS 4265 SEDBUK Declaration For Performa 30 HE The seasonal efficiency (SEDBUK) is 87.3% (89.4% LPG) Band B This value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings.

  • Page 10: Dimensions And Fixings

    1.5° to 3 65 mm Heating Flow (22mm) © Baxi Heating UK Ltd 2007 360° Orientation Tube Ø 100mm Tap Rail 65 mm 65 mm Domestic Hot Cold Water Water Outlet Inlet Inlet (15mm) (22mm) (15mm) 5.0 Dimensions and Fixings Dimensions A 780mm B 345mm...

  • Page 11: System Details

    Bypass 1. The boiler is fitted with an automatic integral bypass. 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. Suitable timer kits are available as optional extras.
  • Page 12 Double Stop Check Valve Valve Mains Inlet Fig. 4 Fig. 5 Filling Loop Fig. 6 Pressure Relief Valve Discharge Pipe © Baxi Heating UK Ltd 2007 Stop Valve Temporary Hose Return 6.0 System Details System Filling and Pressurising 1. A filling point connection on the central heating return pipework must be provided to facilitate initial filling and pressurising and also any subsequent water loss replacement/refilling.

  • Page 13: Hard Water Areas

    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.

  • Page 14: Site Requirements

    In IE reference should be made to the current edition of I.S. 813 “Domestic Gas Installations” and the current ETCI rules. 4. If the boiler is to be fitted into a building of timber frame 200mm Min construction then reference must be made to the current edition of Institute of Gas Engineers Publication IGE/UP/7 (Gas Installations in Timber Framed Housing).
  • Page 15 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.
  • Page 16 6. It is advisable to keep the condensate pipe internal. 7. External runs greater than 3 metres or runs in cold areas should use 32mm waste pipe. 8. If the boiler is fitted in an unheated location the entire condensate discharge pipe should be treated as an external run.
  • Page 17 Fig. 11 7.0 Site Requirements Flue NOTE: Due to the nature of the boiler a plume of water vapour will be discharged from the flue. This should be taken into account when siting the flue terminal. 1. The following guidelines indicate the general requirements for siting balanced flue terminals.

  • Page 18: Flue Options

    This bend is equivalent to 1 metre 8.0 Flue Options Horizontal Flue Systems 1. The Potterton Performa 30 HE can be fitted with either horizontal, vertical or twin flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications.
  • Page 19 Total Equivalent Length = A+B+C+1x90°Bend All vertical and angled runs must be included, measured from the boiler adaptor (point X) to the joint with the flue terminal (point Y). One 91.5° bend or two 45° bends can be included without reduction of the flue length.
  • Page 20 Flue Terminal Deflector Twin Flue System 80mm diameter Flue extension (pair) 1000mm Flue Bend (pair) 90° Flue Bend (pair) 135° Vertical flue boiler adaptor kit Vertical flue adaptor Pipe support (pair) 80mm Vertical Flue Kits Vertical flue terminal Lead tile 25°/45°...
  • Page 21 Flue Duct Adaptor 1. Insert the inner sleeve into the flue duct outlet of the boiler flue adaptor. Engage the outer sleeve in the boiler flue adaptor. Ensure that it is pushed fully in. Take the air duct blank and fit into the outer sleeve and over the inner sleeve.
  • Page 22 Cut the same amount off the Air Duct & Flue Duct Fig. 14 © Baxi Heating UK Ltd 2007 Approx 1425mm Air Duct Flue Duct Push Fit Adaptor Flue Deflector Fig. 13 Fig. 13a 8.0 Flue Options For Roof Terminals 1.

  • Page 23: Plume Displacement

    There must be a constant fall along the entire length of the flue system from the outlet back to the boiler. 4. It is possible to reduce or increase (with the addition of extensions) the length of either or both the 60/100 concentric and 60Ø...
  • Page 24 93° bends are equal to 1 metre, each 45° bend to 0.5 metres. Flue Length - Worked Example Potterton Performa 30 HE In Fig. 18 opposite an additional 93° bend has been included in the 60Ø exhaust. with 2 x 1metre extensions which have been cut to 0.25metres and fitted.
  • Page 25 7. Ensure that the concentric assembly and any extensions fall back to the boiler at an angle of 3° 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.
  • Page 26 Plume Outlet Fig. 25 Fig. 26 30mm Fig. 27 200mm Min. Fig. 28 © Baxi Heating UK Ltd 2007 Elbow 70° Outlet Spigot 9.0 Plume Displacement General Fitting Notes (cont.) 15. For aesthetic purposes it is permissible to route the 60Ø...

  • Page 27: Installation

    2. Flush thoroughly (see System Details, Section 6.2). 10.3 1. Remove all packaging. 2. Stand the boiler on its base by using the rear lower edge as a pivot. NOTE: A small amount of water may drain from the boiler in the upright position.

  • Page 28: Fitting The Boiler

    1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate (Fig. 32). 3. Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections.
  • Page 29 (Fig. 34). 2. Locate the flue elbow on the adaptor at the top of the boiler. Set the elbow to the required orientation (Fig. 35). NOTE: The flue elbow is angled at 91.5 degrees to ensure a fall back to the boiler.
  • Page 30 (Fig. 38). 8. Insert the flue through the hole in the wall. Fit the elbow to the boiler adaptor, ensuring that it is pushed fully in. Inner Flue Support Bracket 9. Draw the flue back through the wall and engage it in the elbow.

  • Page 31: Making The Electrical Connections

    Disengage the barbs on the control box from the cover. Remove the cover (Fig. 41). 4. Slacken the cable clamp on the LH side of the boiler chassis (Fig. 42). Insert the cable through the clamp and route it to the terminal block.

  • Page 32: 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 the boiler.
  • Page 33 Commissioning the Boiler 11.2 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 temperature controls to maximum and the selector switch to the Off position (Fig. 51).

  • Page 34: Completion

    1. Hinge the facia panel upwards and refit the case front panel. Tighten the securing screws (Fig. 52). 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...

  • Page 35: Commissioning Checklist

    8. Slacken the screws on the fan spigot outlet pipe clamps. Ease the clamps inwards over the pipe. 9. Draw the outlet pipe away from the boiler. 10. Remove the four screws securing the combustion box door and remove the door (Fig. 54).
  • Page 36 25. Turn the selector switch fully anticlockwise against the spring pressure to the reset position and hold for 2 seconds to reset the boiler. 26. 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...

  • Page 37: Changing Components

    2. Slacken the screws on the fan spigot outlet pipe clamps. Ease the clamps inwards over the pipe. 3. Draw the outlet pipe away from the boiler. 4. Remove the four screws securing the combustion box door and remove the door.
  • Page 38 Pipe Connecting Clips Heat Exchanger Return Pipe Flow Pipe Heat Exchanger Electrodes Electrode Grommets Electrode Leads © Baxi Heating UK Ltd 2007 Fig. 64 Burner Fig. 65 14.0 Changing Components 14.3 Heat Exchanger (Fig. 64) 1. Remove the fan as described in section 14.1. 2.
  • Page 39 Electrodes Electrode Grommets Electrode Leads Side Insulation Combustion Box Door Front Insulation Fig. 67 © Baxi Heating UK Ltd 2007 Injector Inlet Elbow Manifold Gasket Injector Burner Fig. 66 Rear Insulation Side Insulation 14.0 Changing Components 14.5 Injectors (Fig. 66) 1.
  • Page 40 Changing Components 14.8 Gas Valve (Fig. 68) 1. Undo the nut on the gas feed pipe 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.
  • Page 41 Pump Wiring Cover Socket Headed Screw Pump Setting Fig. 72 Pump Wiring Cover © Baxi Heating UK Ltd 2007 Pump Body Pump Head Fig. 71 Automatic Air Vent Fig. 73 14.0 Changing Components 14.12 Pump - Head Only (Fig. 71) 1.
  • Page 42 2. Drain the system and undo all gas, water and condensate drain connections. Remove the flue elbow. 3. Lift the boiler off the wall plate and lay it on it’s side on a clean flat surface. 4. Undo the nut on the vessel outlet spigot, and...
  • Page 43 ‘O’ ring seal Grub Screw Pressure Relief Valve Fig. 78 Discharge Pipe Control Box Cover Fig. 79 P.C.B. Selector Switch Facia Fig. 80 Selector Switch Knob © Baxi Heating UK Ltd 2007 14.0 14.18 Pressure Relief Valve (Fig. 78) 1. Drain the primary circuit. 2.
  • Page 44 Plate Heat Exchanger Rubber Seal Fig. 81 Sensing Pipes Microswitch Bracket Fig. 82 Diaphragm Diaphragm Spring Pushrod Fig. 83 © Baxi Heating UK Ltd 2007 Diverter Manifold Grub Screws DHW Pressure Differential Valve Plastic Disc 14.0 Changing Components 14.21 Plate Heat Exchanger (Fig. 67) 1.
  • Page 45 Central Heating Pressure Microswitch / Bracket Diaphragm Heating Flow Pipe Diverter Manifold Fig. 84 Pressure Gauge Capillary Cartridge Body Filter Gauze Fig. 85 Flow Regulator Venturi © Baxi Heating UK Ltd 2007 Differential Valve Sensing Pipe By-pass Pipe Spring Clip Fig.
  • Page 46 2. Undo the four screws securing the right hand case panel. Remove the panel. 3. Prise the connecting clips from the heat exchanger return pipe and the boiler return pipe. Remove the Outer Drum pipes. 4. Slacken the screws on the left hand fan spigot outlet pipe clamp.

  • Page 47: Illustrated Wiring Diagram

    Control PCB Flame Sensing Electrode Overheat Stat Gas Valve Condensate Trap - brown - black - blue - red - green - green / yellow - white © Baxi Heating UK Ltd 2007 Air Pressure Switch Flue Stat Optional Timers 15.0 Illustrated Wiring Diagram Central Heating Temperature Sensor...

  • Page 48: Fault Finding

    1. Check that gas, water and electrical supplies are available at the boiler. Electrical supply = 230V ~ 50 Hz. CH water system pressurised to 0.5 bar when the boiler is cold. The preferred minimum gas pressure is 19.5mbar (natural gas), or 36mbar (propane).
  • Page 49 Domestic Hot Water - Follow operational sequence Turn selector to neon illuminated Turn thermostat to max. Open DHW tap fully. DHW flow switch operated Primary water is diverted Continuity across DHW flow from CH system to DHW heat exchanger and flow microswitch operated neon illuminated Pump runs...

  • Page 50: Fault Finding Solutions Sections A To E

    Fault Finding Solutions Sections A to E Is there 230V at: Main terminals L and N Main terminal fuse Selector terminals a & b and a & 3. PCB - A4 connector terminals 4 & 5 Is there 230V at: Pump If pump jammed, release PCB - A4 connector terminals 3 &...
  • Page 51 Check and correct if necessary 1. Electrical and pressure tube connections 2. Blockage of pressure tubes 3. Restriction in flue 4. Venturi Gas at burner Ensure gas is on and purged PCB - A1 connector has 230V AC Check the burner setting pressure of the gas valve (see Section 9.2 of Commissioning) Voltage at modulating coil of gas valve is:...
  • Page 52 If checks in section J are completed successfully, the flue overheat thermostat may have operated. 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 ©...

  • Page 53: Short Parts List

    © Baxi Heating UK Ltd 2007 17.0 Short Parts List Short Parts List G.C. Description Manufacturers Part No. 5112430 Pressure Switch 248466 Heat Exchanger 5112431 Burner 5112770 Injector 5112376 E66 408 Electrode Lead 248037 E66 411 Spark or Sensing Electrode 247384 Pump 248042...

  • Page 54: Gas Boiler Commissioning Checklist

    THERMOSTATIC RADIATOR VALVES AUTOMATIC BYPASS TO SYSTEM 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 & RECORD...

  • Page 55: Service Interval Record

    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...
  • Page 56 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 request.

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