Potterton Performa 24i HE Installation And Service Instructions Manual Download Page 25

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9.0

COMMISSIONING

Publication No. 5111813

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 the

boiler.

5. Open the screw on the automatic air vent

(Fig. 31).

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 1.0 bar then close and

disconnect the filling loop.

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”. BS 6891.

9. Test for gas soundness.

10. If at any time during commissioning it is required

to terminate a particular cycle, e.g. the pump overrun

period, turn the selector to the OFF position and then

back to either ( ) or ( ) (Fig. 33).

Automatic

Air Vent

Pressure

Gauge

Screw

bar

Fig. 31

Selector Switch

Central Heating

Temperature Control

Hot Water

Temperature Control

Fig. 32

bar

Reset

Off

Preheat

Pump

Fig. 33

Power On

Neon

Summary of Contents for Performa 24i HE

Page 1: ...nts of Statutory Instrument The Boiler Efficiency Regulations 1993 No 3083 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0051 Product Production certified by Notified Body 0051 For use in GB IE only ...

Page 2: ...blication No 5111813 Natural Gas Potterton Performa 24i HE G C No 47 393 12 This product has an energy rating B on a scale of A to G For more information see www boilers org uk This is a certification mark ...

Page 3: ...ance Operation 7 4 0 Technical Data 9 5 0 Dimensions and Fixings 10 6 0 System Details 11 7 0 Site Requirements 14 8 0 Installation 20 9 0 Commissioning 25 10 0 Completion 27 11 0 Servicing 28 12 0 Changing Components 30 13 0 Electrical 40 14 0 Short Parts List 41 15 0 Fault Finding 42 Section Page ...

Page 4: ...r Log Book You can check your installer is registered by telephoning 44 0 1256 372300 or writing to 1 Elmwood Chineham Business Park Crockford Lane Basingstoke RG24 8WG Potterton declare that no substances harmful to health are contained in the appliance or used during appliance manufacture The appliance is suitable only for installation in GB and IE and should be installed in accordance with the ...

Page 5: ...gned flues such as the standard horizontal flue kit part no 5111073 9 All systems must be thoroughly flushed and treated with inhibitor see section 6 2 1 2 Instant Domestic Hot Water Expansion Vessel Pre Heat Store 1 The boiler expansion vessel incorporates a small volume of stored primary hot water 2 When the boiler has been off and there is then a demand for domestic hot water the stored primary...

Page 6: ...y Heat Exchanger 21 On Off Reset Selector Switch 22 Central Heating Temperature Control 23 Domestic Hot Water Pre Heat Control 24 Flame Failure or Blocked Condensate Drain 25 Safety Thermostat Activated Boiler or Flue 26 Fault on Fan or Flue 27 Fault on Pump or Low System Pressure 28 Fault on Hot Water Sensor 29 Fault on Central Heating Sensor 30 Power On 31 Domestic Hot Water Mode 32 Central Heat...

Page 7: ...ows the pump to circulate hot water to the store and back to the primary heat exchanger via the bypass pipe 3 The automatic ignition sequence commences after approximately 25 seconds and the burner will light 4 When the store reaches the desired temperature the burner is extinguished The pump continues to run for a period of 30 seconds 5 Following a demand for domestic hot water or the end of a ce...

Page 8: ...liance and functions only with the selector switch Section 2 1 in the domestic hot water and central heating position If the system temperature falls below 5 C then the boiler will fire on its minimum setting until a flow temperature of 30 C is reached Further protection can be incorporated by using a system frost thermostat 3 5 Pump Protection 1 With the selector switch see Section 2 1 in either ...

Page 9: ...ve 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 20mm 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 should be...

Page 10: ...450mm D 116mm Ø Min E 185mm F 190mm G 131mm 360 Orientation Tube Ø 100mm D C B A E G F Domestic Hot Water Outlet 15mm Cold Water Inlet 15mm Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 65 mm 65 mm 65 mm 65 mm 65 mm Tap Rail 3o 28mm Condensate Drain ...

Page 11: ...systems flux will be evident within the system which can lead to damage of system components All systems must be thoroughly drained and flushed out The recommended flushing and cleansing agents are Betz Dearborn Sentinel X300 or X400 and Fernox Superfloc Universal Cleanser which should be used following the flushing agent manufacturer s instructions System additives corrosion inhibitors and flushi...

Page 12: ...oved 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 80 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 Domest...

Page 13: ...lop 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 Th...

Page 14: ... S 813 Domestic Gas Installations and the current ETCI rules 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 IGE UP 7 Gas Installations in Timber Framed Housing 7 2 Clearances Figs 9 10 1 A flat vertical area is required for the installation of the boiler 2 These dimensions inc...

Page 15: ...ear of the gas service cock Fig 11 3 Ensure that the pipework 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 ...

Page 16: ...at 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 ...

Page 17: ...Distance Fig 12 mm A Directly below an openable window air vent or any other ventilation opening 300 B Below gutter drain soil pipe 25 C Below eaves 25 D Below a balcony car port roof 25 E From vertical drain pipes and soil pipes 25 F From internal or external corners 25 G Above adjacent ground or balcony level 300 H From a surface facing a terminal 600 I Facing a terminals 1200 J From opening doo...

Page 18: ...lue Trim 1 The rubber flue trim supplied may be fitted to either the outside wall or on the inner wall of installation 7 10 Terminal Guard Fig 15 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 ...

Page 19: ...lue 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 opposite show examples of maximum equivalent lengths 6 Instructions for guidance and fit...

Page 20: ... flue minimum diameter 116mm 7 Drill the wall as previously marked to accept the wall plugs supplied Secure the wall plate using the fixing screws 8 Using a spirit level ensure that the plate is level before finally tightening the screws 9 Connect the gas and water pipes to the valves on the wall plate using the copper tails supplied Ensure that the sealing washers are fitted between the connectio...

Page 21: ...s to a discharge point outside the building See section 6 7 for further details 4 Utilising 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 8 6 Condensate Drain see section 7 6 1 Connect the condensa...

Page 22: ... the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 21 NOTE The flue elbow is angled at 93 degrees to 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 22 4 To dimension X add 50mm This dimension to be known as Y IMPORTANT Check all dimensions before cutting Fig 22 ...

Page 23: ...ease assembly Fig 24 8 Insert the flue through the hole in the wall Fit the elbow to the boiler adaptor ensuring 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 25 10 Make good between the wall and air duct outside the building 11 Fit the flue trim if r...

Page 24: ...rnal 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 the 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...

Page 25: ...e flushing agent manufacturers instructions 7 Pressurise the system to 1 0 bar then close and disconnect the filling loop 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 BS 6891 9 Test for gas soundness 10 If at any time during commissioning it is required to terminate a particular cycle e g the pump overrun period turn the sele...

Page 26: ...min 8 the pressure should be as quoted in Section 4 0 Technical Data 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 35 11 Remove the plastic protection cap from the pressure adjustment nuts on the valve 12 The...

Page 27: ...d installation The details of the Log Book will be required in the event of any warranty work The Log Book must be handed to the user for safe keeping and each subsequent regular service visit recorded 4 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 In addition it is necessary to ...

Page 28: ...l so that its securing tabs are clear of the facia Remove the panel Fig 39 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 40 7 Note the positions of the three wires on the fan motor and remove them Remove the sensing tube from the fan spigot Fig 41 8 Slacken the screws on the fan spigot outlet pipe clamps Ease the cla...

Page 29: ...may be necessary to clean the filters 19 Initially check the cold water inlet tap filter 20 Turn the tap off Undo the blanking cap and remove the threaded bush Fig 45 21 Extract the filter and rinse thoroughly in clean water Reassemble and check the flow If required clean the manifold filter as described below 22 Undo the filter cartridge from the inlet return manifold 23 Dismantle the cartridge a...

Page 30: ...t edge of the left hand baffle upwards disengaging the spring clip Disengage the tab on the baffle from the slot in the fan hood 6 Undo the screws securing the fan hood to the appliance back panel and draw the fan and hood assembly forwards 7 Remove the screws and spring washers securing the fan to the hood 8 Fit the new fan to the hood using the screws and spring washers previously removed 9 Reas...

Page 31: ...se the system 12 4 Burner Fig 51 1 Remove the four screws securing the combustion box door and remove the door 2 Draw the burner out of the combustion box pulling the electrode grommets from the slots in the 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 co...

Page 32: ...ect the lead and grommet from the electrode being replaced Undo the securing screw and withdraw the electrode to the burner 4 Reassemble in reverse order 12 7 Insulation Fig 53 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 exch...

Page 33: ...reverse order and check the burner pressure Section 9 2 12 9 Central Heating Temperature Sensor Fig 55 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 electrical plug will only fit one way 12 10 Safety Thermostat Fig 55 1 Pull the electrical connections off the thermostat 2 Remove the screws se...

Page 34: ... 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 ...

Page 35: ...ssel spigot to the boiler chassis 6 Undo the screws and remove the appliance upper cross member Slide the expansion vessel and insulation out of the retaining clips 7 Reassemble in reverse order using new sealing washers Fully recommission the appliance and system 12 17 Condensate Trap Fig 63 1 Disconnect the two sensing wires from the trap connections 2 Squeeze together the wire spring clip to re...

Page 36: ... B and disconnect them 4 Undo the securing screws and remove the P C B Transfer the control knob drive pins to the new P C B and turn them fully anticlockwise 5 Reassemble in reverse order ensuring that the temperature controllers are reset to their previous positions 12 20 Selector Switch Fig 66 1 Turn the selector switch knob to the off position and carefully pull it off the facia 2 Completely u...

Page 37: ... 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 Diaphragm Figs 68 69 1 Turn off the mains water inlet tap and drain the domestic hot water by turning on a hot tap 2 Prise off the spring clip retain...

Page 38: ...off the operating head and prise off the spring clip retaining the head to the valve body 2 Lift the operating head away from the valve body 3 Fit the new head and reassemble in reverse order 12 23 Flow Regulator Figs 71 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...

Page 39: ...changer from the outer drum by easing it forward 7 Reassemble in reverse order of dismantling 12 25 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...

Page 40: ... 5 4 3 2 1 4 5 5 6 7 8 9 Central Heating Temperature Sensor Fan Gas Valve Overheat Stat Microswitch Air Pressure Switch Flame Mains Input Fuse Link g y b br br b g y Sensing Electrode b b b bk b b bk br br Flue Stat br Microswitch Pump Diverter Valve Operating Head bk bk w bk r b br br bk br b br b bk b bk br bk b br bk w r br b bk b r b bk br r bk bk w A5 A4 A8 A3 A2 A1 1 2 3 4 r r g g bk w r r C...

Page 41: ...ode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 E66 539 Pump Complete 248042 131 342 571 Temperature Sensor 247394 135 E66 439 Safety Thermostat 248079 140 Gas Valve 5107339 154 PCB 248731 169 E66 453 Pressure Gauge 248090 387 E68 349 Motor 3way Valve 248733 390 E68 350 Differential Valve DHW 248734 371 Igniter Gas Valve Cable 5112385 A Flue Overheat Thermostat 5112395 22 140 44 63...

Page 42: ...DHW preheating circuit Pump runs Primary flow switch operated Fan runs at maximum speed Air pressure switch proved Spark at ignition electrode for up to 10 seconds Burner lights Burner output modulates to minimum heat input until a temperature of 75 C is detected by central heating NTC sensor Burner extinguishes Go to section A External controls and where fitted integral timer calling for heat Go ...

Page 43: ...low DHW flow switch released off Preheating function restarts neon flashing Go to section A Go to section M External controls and where fitted integral timer calling for heat Go to section L Ensure controls are set to demand and verify the contacts are closed DHW flow rate more than 2 5 l min Is mains water filter and differential assembly clean DHW flow valve diaphragm damaged Replace diaphragm D...

Page 44: ...onds Preheating function starts after 25 seconds neon flashing see DHW preheating function Primary water is diverted from preheating circuit to CH system neon illuminated Go to section M neon flashing Go to section B neon flashing Go to section C neons flashing Go to section D Turn the selector to reset If regular resetting is required or appliance still does not operate investigation is necessary...

Page 45: ... speed Air pressure switch proved Spark at ignition electrodes for up to 10 seconds neon illuminated Burner extinguishes after 10 seconds neons flashing Go to section D Turn the selector to reset If regular resetting is required or appliance still does not operate investigation is necessary Go to section J NO YES neon flashing Go to section E neon flashing Turn selector to the reset position If th...

Page 46: ...ble YES B CH system pressure 0 5 to 1 5 bar Re pressurise system 1 NO Primary flow valve diaphragm damaged Replace diaphragm Flow valve rod obstructed clean reset 3 YES Check automatic air vent is open Open the automatic air vent 2 NO NO C YES Continuity across flow microswitch and PCB A5 connector terminals 7 8 Replace microswitch 1 NO NO Temperature sensor faulty Cold resistance approx 11 kΩ res...

Page 47: ...k and correct if necessary 1 Ignition electrode and lead 2 Electrode connection 3 Spark gap and position 230V at Main PCB A1 connector across terminals 3 5 Check wiring YES NO Replace gas valve electrical plug igniter assembly YES H YES Check the burner setting pressure at the gas valve see Section 9 2 of Commissioning 1 Voltage at modulating coil of gas valve is Max burner press approx 9V DC 13V ...

Page 48: ... electrical continuity across terminals 1 a on reset selector when turned to the reset position Replace ON OFF RESET selector NO Replace main PCB YES K Replace overheat thermostat YES NO Overheat thermostat operated or faulty i e continuity across thermostat terminals Allow to cool Continuity across thermostat terminals more than 1 5 ohm J Check continuity of loop on A10 connector L Replace main P...

Page 49: ...49 16 0 NOTES Publication No 5111813 ...

Page 50: ...16 0 NOTES 50 Publication No 5111813 ...

Page 51: ...51 Publication No 5111813 ...

Page 52: ...sold subject to our standard Conditions of Sale which are available on request General Enquiries GB Tel 08706 060 780 Technical GB Tel 08706 049 049 Service GB Tel 08706 096 096 Fax 01926 410 006 Literature Request GB Tel 08706 060 623 Technical IE Tel 1850 560570 BAXI POTTERTON A Trading Division of Baxi Heating UK Ltd Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN After Sales Service 08...

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