Potterton Performa System 12 HE Installation & Service Instructions Manual Download Page 25

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8.0

INSTALLATION

Publication No. 5111817

8.8

Making The Electrical Connections

To connect the mains input cable proceed as

follows:-

1. Slacken the facia 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. 22).

3. Remove the control box cover securing screws.

Disengage the barbs on the control box from the

cover. Remove the cover (Fig. 23).

4. Slacken the cable clamp on the LH side of the

boiler chassis (Fig. 24). 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 on

the boiler chassis. Refer to the instructions supplied

with the control.

7. To connect external control(s) remove the link

between terminals 1 & 2. The switched output from

the external control must be connected to terminal 2

(Fig. 25).

IMPORTANT:

The external control

MUST

suitable for 230V switching and fused 3A maximum

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.

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.

Always fit fast

blow 2A fuse

230V ~ 50Hz

fused 3A maximum

Live (brown)

Neutral (blue)

Earth (green/yellow)

230V S/L from

external control

g/y

230 V

Selector /

Reset Switch

External
Controls

Pump

Hydraulic Differential Pressure Switch

Safety Overheat Thermostat

Flue Thermostat

Central Heating Flow

NTC Sensor

Gas Valve

Spark Electrode

Condensate Trap

Flame Sensing Electrode

Fan

bk
bk

Pressure Switch

PCB

Central Heating Return

NTC Sensor

Gas Valve Modulator

Fig. 24

Fig. 23

Fig. 25

Fig. 26

Fig. 22

Terminal Block

Internal Fuse

Cable Clamp

Control Box Cover

Facia Panel

Functional Flow Diagram

Key to Wiring

b - blue
br - brown
bk - black
r - red
g - green

Summary of Contents for Performa System 12 HE

Page 1: ...ments 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: ...91 24 Potterton Performa System 18 HE G C No 41 591 25 Potterton Performa System 24 HE G C No 41 591 26 Potterton Performa System 28 HE G C No 41 591 27 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 8 5 0 Dimensions and Fixings 12 6 0 System Details 13 7 0 Site Requirements 15 8 0 Installation 21 9 0 Commissioning 26 10 0 Completion 28 11 0 Servicing 29 12 0 Changing Components 31 13 0 Electrical 40 14 0 Short Parts List 41 15 0 Fault Finding 42 Section Page ...

Page 4: ...er 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: ...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 commercial 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 mu...

Page 6: ...Exchanger 18 On Off Reset Selector Switch 19 Central Heating Temperature Control 20 Flame Failure or Blocked Condensate Drain 21 Safety Thermostat Activated Boiler or Flue 22 Fault on Fan or Flue 23 Fault on Pump or Low System Pressure 24 Temperature Indication Only 25 Fault on Central Heating Sensor 26 Power On 27 Boiler On 28 Burner On When neons 20 to 25 are constantly illuminated they indicate...

Page 7: ...ill not operate 3 2 Frost Protection Mode 1 The frost protection mode is integral to the appliance and functions when the selector switch see Section 2 1 is in the ON 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 3 Pump Protec...

Page 8: ...iler unpressurised 1 2 Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Pressure Relief Discharge 15mm Temperatures Flow Temp adjustable 35 C to 85 C max 5 C Heat Input Max Min kW 12 6 7 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 140W External Fuse Rating 3A Internal Fuse Rating Fuse 2A Fast Blow to B...

Page 9: ...iler unpressurised 1 2 Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Pressure Relief Discharge 15mm Temperatures Flow Temp adjustable 35 C to 85 C max 5 C Heat Input Max Min kW 18 7 10 6 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 140W External Fuse Rating 3A Internal Fuse Rating Fuse 2A Fast Blow t...

Page 10: ...ler unpressurised 1 2 Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Pressure Relief Discharge 15mm Temperatures Flow Temp adjustable 35 C to 85 C max 5 C Heat Input Max Min kW 24 8 10 6 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 170W External Fuse Rating 3A Internal Fuse Rating Fuse 2A Fast Blow to...

Page 11: ...er unpressurised 1 2 Connections copper tails Gas Supply 22mm Central Heating Flow 22mm Central Heating Return 22mm Pressure Relief Discharge 15mm Temperatures Flow Temp adjustable 35 C to 85 C max 5 C Heat Input Max Min kW 28 9 11 9 Electrical Supply 230V 50Hz Appliance must be connected to an earthed supply Power Consumption 180W External Fuse Rating 3A Internal Fuse Rating Fuse 2A Fast Blow to ...

Page 12: ...17 Dimensions A 780mm B 345mm C 450mm D 107mm Ø Min E 185mm F 190mm G 131mm Heating Return 22mm Heating Flow 22mm Pressure Relief Valve 15mm Gas Inlet 22mm 130 mm 130 mm 65 mm Tap Rail 360 Orientation Tube Ø 100mm D C B A E G F 3 28mm Condensate Drain ...

Page 13: ...300 or X400 and Fernox Superfloc Universal Cleanser which should be used following the flushing agent manufacturer s instructions System additives corrosion inhibitors and flushing agents descalers should be suitable for aluminium and comply to BS7593 requirements The only system additives recommended are Betz Dearborn Sentinel X100 and Fernox Copal which should be used following the inhibitor man...

Page 14: ...liance expansion vessel is pre charged to 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 6 Pressure Relief Valve Fig 4 1 The pressure relief valve is set at 3 bar therefore all pipewo...

Page 15: ...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 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 5 6 1 A flat vertical area is required for the installation of the boiler 2 These dimensions ...

Page 16: ... 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 must be 230V 50Hz and fused at 3A maximum NOTE The meth...

Page 17: ...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 18: ... Distance Fig 9 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 19: ...im supplied may be fitted to either the outside wall or on the inner wall of installation 7 10 Terminal Guard Fig 11 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 ...

Page 20: ... 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 opposite show examples of maximum equivalent lengths 6 Instructions for guidanc...

Page 21: ...ea 5 If required mark the position of the gas and water pipes Remove the template 6 Cut the hole for the 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 wal...

Page 22: ...s to a discharge point outside the building See section 6 6 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 23: ... the flue elbow on the adaptor at the top of the boiler Set the elbow to the required orientation Fig 17 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 18 4 To dimension X add 50mm This dimension to be known as Y IMPORTANT Check all dimensions before cutting Wall Th...

Page 24: ...mbly Fig 20 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 21 10 Make good between the wall and air duct outside the building 11 Fit the flue trim if required a...

Page 25: ...al 2 Fig 25 IMPORTANT The external control MUST be suitable for 230V switching and fused 3A maximum 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 8 9 Preliminary Electrical Checks 1 Prior to commissioning the boiler preliminary electrical system checks should ...

Page 26: ...uctions 5 Pressurise the system to 0 2 bar then close and disconnect the filling loop 6 Turn the gas supply on and purge the system according to in GB BS 6891 and in IE I S 813 Domestic Gas Installations 7 Test for gas soundness 8 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 the...

Page 27: ...ld 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 8 The pressure can be adjusted if required 9 To check and set minimum pressure first remove one of the modulator wires Adjusting the Pressure Fig 31 10 Remove the plastic protection cap from the pressure adjustment nuts on the valve 11 The smaller nut 5mm adjusts...

Page 28: ...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 29: ...clear of the facia Remove the panel allowing the facia to hinge down Fig 35 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 37 7 Note the positions of the two sensing tubes on the fan spigot and three wires on the fan motor and remove them Fig 36 8 Slacken the screws on the fan spigot outlet pipe clamps Ease the clamps...

Page 30: ...emove the burner Fig 40 16 Brush any deposits from the injectors Do not use a pin or wire to clean them 17 Brush the burner blades and venturis and clean the combustion box 18 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 19 Check that the pressure vessel charge is 0 5bar and reassemble in reverse...

Page 31: ...of the left hand baffle upwards disengaging the spring clip Disengage the tabs on the baffle from the slots 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 Reassembl...

Page 32: ...e the four screws securing the combustion box door and remove the door 2 On 28 HE models undo the screws securing the burner to the injector manifold 3 Draw the burner out of the combustion box pulling the electrode grommets from the slots in the combustion box lower panel 4 Disconnect the electrode leads and grommets from the electrodes Completely remove the burner 5 Undo the screws securing the ...

Page 33: ...he 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 47 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...

Page 34: ...suring that the O ring seals are in place 10 Reassemble in reverse order and check the burner pressure as described in Section 9 2 12 9 Central Heating Temperature Sensor Fig 49 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 49 1 Pull the ...

Page 35: ...nt 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 manifol...

Page 36: ...utlet 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 retaining clips 6 Reassemble in reverse order Fully recommission the appliance and system 12 17 Condensate Trap Fig 57 1 Disconnect the two sensing wires from the trap connections 2 Squeeze together the w...

Page 37: ...re controller is reset to the previous position 6 Ensure that the DHW potentiometer is fully anticlockwise once the new PCB is fitted 12 19 Selector Switch Fig 59 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 th...

Page 38: ...uired the complete valve assembly can be replaced 7 Examine the sealing washers and O ring on the pipes and capillary replacing as necessary 12 21 Central Heating Differential Valve Microswitch Fig 61 1 Remove the two wires from the microswitch 2 Undo the screw securing the microswitch to the valve body 3 Reassemble in reverse order 12 22 Pressure Relief Valve Fig 62 1 Drain the primary circuit 2 ...

Page 39: ... outer drum by easing it forward 7 Reassemble in reverse order of dismantling 12 24 Flue Overheat Thermostat Fig 64 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 adapto...

Page 40: ...2 A3 A4 A5 F2 1 bk bk r r g g 2 1 2 3 3 4 1 1 2 3 4 5 6 7 8 9 10 2 3 4 1 2 3 6 4 5 4 5 5 6 7 8 9 Central Heating NTC Sensor Fan Gas Valve Overheat Stat Hydraulic Differential Pressure Switch Air Pressure Switch Flame Mains Input Fuse Link g y g y b br bk br b bk r g r g Sensing Electrode Pump b b b b bk b br br b b r bk br br Flue Stat br g y g y 13 1 Illustrated Wiring Diagram ...

Page 41: ...r 24 28 HE 44 Injector 248210 59 E66 408 Electrode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 E66 539 Pump 248042 102 Hydraulic Outlet Assy 248490 131 342 571 Temperature Sensor 247394 135 E66 439 Safety Thermostat 248079 140 Gas Valve 5107339 154 PCB 5112380 169 E66 453 Pressure Gauge 248090 528 Return Heating 248497 Temperature Sensor 371 Igniter Gas Valve Cable 5112385 A Flue O...

Page 42: ... temperature control to max Pump runs Air pressure switch proved neon flashing Burner on neon illuminated Burner output modulates until set temperature is reached Spark at ignition electrodes for up to 10 seconds Go to section A neon flashing Go to section B neon flashing Go to section C Go to section J neons flashing Go to section D neon flashing Go to section E Replace PCB Turn selector to the r...

Page 43: ...ic air vent is opened 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 Flow or Return temperature sensor faulty Cold resistance approx 11K ohms resistance reduces with increase in temp Replace sensor 2 YES Fan connections correct at fan PCB A2 connector is 230V across terminals 5 7 Fan jammed or faulty windi...

Page 44: ... 1 µA approx Replace PCB Replace PCB NO YES Replace flame sensing electrode NO YES Ensure that mains input terminal L is Live 230V and N is Neutral 0V I Check terminal 1 of On Off Reset selector is in connection with PCB A4 connector terminal 2 Check electrical continuity across terminals 1 a of On Off Reset selector when turned to position R Replace On Off Reset selector NO Replace PCB YES K Repl...

Page 45: ...45 16 0 NOTES Publication No 5111817 ...

Page 46: ...16 0 NOTES 46 Publication No 5111817 ...

Page 47: ...47 Publication No 5111817 ...

Page 48: ...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 6UP After Sales Service 08...

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