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Potterton Performa 28i, Installation And Servicing Instructions, Page: 3 / 48

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Potterton Performa 28i Installation And Servicing Instructions Download Page 3

3

1.0

Introduction

4

2.0

General Layout

6

3.0

Appliance 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

19

9.0

Commissioning the Boiler

24

10.0 Completion

26

11.0 Servicing the Boiler

27

12.0 Changing Components

29

13.0 Illustrated Wiring Diagram

38

14.0 Fault Finding

39

15.0 Short Parts List

46

Section

Page

Contents

Summary of Contents for Performa 28i

Page 1: ...Installation and Servicing Instructions Please leave these instructions with the user Performa 28i Gas Fired Wall Mounted Combination Boiler ...

Page 2: ...ciency Regulations 1993 No 3083 and is deemed to meet the requirements of Directive 92 42 EEC on the energy efficiency requirements for new hot water boilers fired with liquid or gaseous fuels Type test for purpose of Regulation 5 certified by Notified Body 0051 Product Production certified by Notified Body 0051 For GB IE only ...

Page 3: ...sions and Fixings 10 6 0 System Details 11 7 0 Site Requirements 14 8 0 Installation 19 9 0 Commissioning the Boiler 24 10 0 Completion 26 11 0 Servicing the Boiler 27 12 0 Changing Components 29 13 0 Illustrated Wiring Diagram 38 14 0 Fault Finding 39 15 0 Short Parts List 46 Section Page Contents ...

Page 4: ...suitable for installation only in G B and I E and should be installed in accordance with the rules in force For Ireland install in accordance with I S 813 INSTALLATION OF GAS APPLIANCES The installation must be carried out by a CORGI Registered Installer or other competent person and be in accordance with the relevant requirements of GAS SAFETY Installation and Use REGULATIONS the BUILDING REGULAT...

Page 5: ... domestic hot water which is fresh mains water heated by a heat exchanger within the boiler 4 The stored primary hot water temperature is maintained whilst the boiler is in operation During a period when there is no demand for heating or hot water the temperature of the stored primary hot water will eventually fall The boiler will operate occasionally in order to maintain the temperature This is i...

Page 6: ...ger 19 Fan Assembly 20 On Off Reset Selector Switch 21 Central Heating Temperature Control 22 Domestic Hot Water Pre Heat Control 23 Flame Failure 24 Safety Thermostat 25 Fault on Fan or Flue 26 Fault on Pump or Low System Pressure 27 Fault on Hot Water Sensor 28 Fault on Central Heating Sensor 29 Power On 30 Domestic Hot Water Mode 31 Central Heating Mode 32 Burner On When neons 23 to 28 are cons...

Page 7: ...allows 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...

Page 8: ...ppliance 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 eithe...

Page 9: ...ended System Temperature Drop 11 C 20 F 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 50 C Pre heat OFF 65 C Pre heat ON 5 C dependent upon flow rate Heat Input C H DHW Gross Max Min kW 32 6 11 9 Btu h 111 250 40 610 Heat Output Max Min kW 29 4 10 4 Btu h 100 330 35 490 Electrical Supply 230V 50Hz Appliance must be connecte...

Page 10: ... 450mm D 107mm Ø Min E 200mm F 190mm G 143mm 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 ...

Page 11: ...he guidelines given in BS 7593 Treatment of water in domestic hot water central heating systems This must involve the use of a proprietary cleanser such as BetzDearborn Sentinel X300 or X400 or Fernox Superfloc Full instructions are supplied with the products but for immediate information please contact BetzDearborn 0151 420 9563 or Fernox 01799 550 811 directly For long term protection against co...

Page 12: ...essel 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 refer to BS 7074 Pt 1 6 7 Pressure Relief Valve Fig 5 1 The pressure relief valve is set at 3 bar there...

Page 13: ...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 5 The boiler s maximum working mains pressure is 8 bar therefore all pipework connections fittings etc should be suitable for pressures in excess of 10 bar A pressure reducing valve must be fitted for pressures in excess of 10 bar The manufacturer of any o...

Page 14: ...ONS 7 3 Clearances Figs 7 8 1 A flat vertical area is required for the installation of the boiler 2 These dimensions include the necessary clearances around the boiler for case removal spanner access and air movement Additional clearances may be required for the passage of pipes around local obstructions such as joists running parallel to the front face of the boiler 7 4 Location 1 The boiler may ...

Page 15: ...e gas service cock Fig 9 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 7 Electrical Supply 1 External wiring must be correctly earthed polarised and in accordance with current I E E WIRING REGULATIONS 2 The mains supply is 230V 50Hz fused at 3A NOTE The method of connection to the electric...

Page 16: ...on opening 300 B Below gutter drain soil pipe 150 C Below eaves 200 D Below a balcony car port roof 200 E From vertical drain pipes and soil pipes 150 F From internal or external corners 300 G Above adjacent ground or balcony level 300 H From a surface facing a terminal 600 I Facing a terminals 1200 J From opening door window in carport into dwelling 1200 K Vertically from a terminal on the same w...

Page 17: ...om the adhesive seal Apply the seal to the rear of the trim flange Fig 13 3 Locate the trim over the flue terminal and push it back to the wall to compress the seal Fig 14 7 11 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 ...

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

Page 19: ...ushing 1 Connect a tube to the central heating flow or return pipe Fig 17 2 Flush thoroughly see System Details Section 6 2 3 The use of the optional Filling Loop Kit Part No 248221 will simplify the flushing and soundness checking 8 3 Preparing The Boiler 1 Remove all packaging 2 Stand the boiler on its base by using the rear lower edge as a pivot NOTE A small amount of water may drain from the b...

Page 20: ...f Discharge Pipe Fig 19 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 Utilising one of...

Page 21: ...sure the distance from the outside wall face to the elbow Fig 20 This dimension will be known as X 4 Taking the air duct mark dimension X as shown Fig 21 Measure the length of waste material and transfer the dimension to the flue duct Fig 21 IMPORTANT Check all measurements before cutting 5 Remove the waste from both ducts Ensure that the cut ends are square and free from burrs 6 Remove the flue e...

Page 22: ...ews to the clip and tighten them Fig 25 14 Where possible position the clips so that the screws are not visible 15 Make good between the wall and air duct outside the building 16 Fit the circular flue trim outside if required and if necessary fit a terminal guard see Section 7 10 7 11 8 7 Extensions Additional Elbows 1 The method of connecting any flue extensions or additional elbows is the same a...

Page 23: ...ig 29 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 the optional integral timer is to be used it should be fitted at this point Refer to the instructions supplied with the timer 8 9 Prelim...

Page 24: ... 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 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 ba...

Page 25: ...st 10 l 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 Butane 30mbar and Propane 37mbar 9 The pressure can be adjusted if required 10 To check minimum pressure first remove one of the modulator wires Adjusting the Pressure Fig 35 11 Prise apart the spring clip retaining the modulator Draw the modulator of...

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

Page 27: ...rcase panel 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 two sensing tubes on the outlet elbow and three wires on the fan motor and remove them Fig 41 8 Slacken the screws on the outlet sealing collar Ease the col...

Page 28: ...e 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 43a 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 inl...

Page 29: ...ons of the two sensing tubes on the outlet elbow and three wires on the fan motor and remove them 2 Slacken the screws on the outlet sealing collar Ease the collar upwards as far as possible 3 Remove the four screws securing the combustion box door and remove the door 4 Remove the spring clips retaining the air box side baffle plates Disengage the tabs on the baffles from the slots in the fan hood...

Page 30: ...eturn pipe joints Withdraw it from the appliance taking care not to damage the rear insulation piece 8 Fit the new heat exchanger 9 Reassemble in reverse order of dismantling and repressurise the system 12 4 Burner Fig 49 1 Remove the four screws securing the combustion box door and remove the door 2 Undo the screws securing the burner to the injector manifold Draw the burner out of the combustion...

Page 31: ... 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 51 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 des...

Page 32: ... 12 9 Central Heating Temperature Sensor Fig 53 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 53 1 Pull the electrical connections off the thermostat 2 Remove the screws securing the thermostat to the mounting plate on the flow...

Page 33: ...mp 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...

Page 34: ...nd remove the pipe Fig 59 5 Undo the union on pipe B connected to the vessel Fig 59 and remove the locknut securing the vessel 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 Spark G...

Page 35: ...nd 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 1 Turn the selector switch knob to the off position and carefully pull it off the facia 2 Remove the screws secur...

Page 36: ...r 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 65 66 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 retaining the micr...

Page 37: ...rating 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 68 69 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 wate...

Page 38: ...3 4 5 6 10 9 8 7 6 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 Spark Generator Mains Input Fuse Link g y b br br b g y Sensing Electrode b b b b br b bk br br b 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 br b w A5 A4 A8 A3 A...

Page 39: ...ng 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 to section L...

Page 40: ...w 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 DHW flow val...

Page 41: ...ing 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 Go to secti...

Page 42: ...ressure 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 the neon does ...

Page 43: ...H 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 resistance red...

Page 44: ...G Check 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 igniter 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 DC LPG Min burner press appro...

Page 45: ...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 PCB Is there ...

Page 46: ...9 E66 408 Electrode 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 E02 286 Gas Valve 248085 141 343 560 Modulation Coil 248086 154 E68 347 PCB 248074 169 E66 453 Pressure Gauge 248090 387 E68 349 Motor 3way Valve 248733 390 E68 350 Differential Valve DHW 248734 22 140 44 63 154 ...

Page 47: ...16 0 Notes 47 ...

Page 48: ...Potterton Baxi UK Limited Brownedge Road Bamber Bridge Preston Lancashire PR5 6SN After Sales Service 08706 096 096 Technical Enquiries 08706 049 049 www baxi com Comp No 249111 Iss 2 9 01 922 055 2 ...

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