Potterton Performa 30 HE Instrucciones de instalación y mantenimiento

Installation & Service Instructions Performa 30 HE

These instructions include the Benchmark Commissioning Checklist

and should be left with the user for safe keeping.

2© Baxi Heating UK Ltd 2007

Natural Gas

Potterton Performa 30 HE

G.C.No47 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.

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Benchmark Logbook is being withdrawn.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.

Potterton 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 related structure.

The flowchart opposite gives guidance for installers on the

process necessary to ensure compliance with Building

Regulations.

Legislation 4

1.0 Introduction 6

2.0 General Layout 7

3.0 Appliance Operation 8

4.0 Technical Data 9

5.0 Dimensions and Fixings 10

6.0 System Details 11

7.0 Site Requirements 14

8.0 Flue Options 18

9.0 Plume Displacement 23

10.0 Installation 27

11.0 Commissioning the Boiler 32

12.0 Completion 34

13.0 Servicing the Boiler 35

14.0 Changing Components 37

15.0 Illustrated Wiring Diagram 47

16.0 Fault Finding 48

17.0 Short Parts List 53

Benchmark Checklist 54

Section Page

Contents

be reproduced or transmitted in any form or by any means, or stored in any

retrieval system of any nature (including in any database), in each case whether

electronic, mechanical, recording or otherwise, without the prior written

permission of the copyright owner, except for permitted fair dealing under

Copyrights, Designs and Patents Act 1988.

Applications for the copyright owner’s permission to reproduce or make other

use of any part of this publication should be made, giving details of the proposed

use, to the following address:

The Company Secretary, Baxi Heating UK Ltd, Pentagon House,

Sir Frank Whittle Road, Derby, DE21 4XA.

Full acknowledgement of author and source must be given.

WARNING: Any person who does any unauthorised act in relation to a

Baxi Heating UK Ltd is a

BS-EN ISO 9001 Accredited Company

The code of practice for the installation,

commissioning & servicing of central

heating systems.

“Potterton” supports

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact

a government approved

inspector

LABC will record the data

and will issue a

certificate of compliance

CORGI will record the data and

will send a certificate of

compliance to the property

You must ensure that the

notification number issued by

CORGI is written onto the

Benchmark Checklist

Scheme Members only

Call CORGI on: 0870 88 88 777

or log onto:

www.corgi-notify.com

within 10 days

If you notify via CORGI Scheme,

CORGI will then notify the

relevant Local Authority

Building Control Scheme

on member's behalf

Complete the

Benchmark Checklist

Install and Commission this

appliance to manufacturer's

instructions

Competent Person's

Self Certification Scheme

Building Control

Complete the

Benchmark Checklist

Install and Commission this

appliance to manufacturer's

instructions

Legislation

4© Baxi Heating UK Ltd 2007

Codes of Practice, most recent version should be used

This company 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 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:

• Gas Safety (Installation & Use) Regulations.

• The appropriate Building Regulations either The

Building Regulations, The Building Regulations

(Scotland), Building Regulations (Northern Ireland).

• The Water Fittings Regulations or Water Byelaws in

Scotland.

• 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).

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 boilers.

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

I.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.

The boiler meets the requirements of Statutory Instrument “ The Boiler (Efficiency)

Regulations 1993 No3083” 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 GB/IE only.

IMPORTANT - Installation, Commissioning, Service & Repair

This appliance must be installed in accordance with the manufacturer’s instructions and

the regulations in force. Read the instructions fully before installing or using the

appliance.

In GB, this must be carried out by a competent person as stated in the Gas Safety

(Installation & 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”.

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

Safe Manual Handling

General

The following advice should be adhered to, from when first handling the boiler to the final stages of installation, and also during maintenance.

Most injuries as a result of inappropriate handling and lifting are to the back, but all other parts of the body are vulnerable, particularly shoulders, arms and hands.

Health & Safety is the responsibility of EVERYONE.

There is no ‘safe’ limit for one man - each person has different capabilities. The boiler should be handled and lifted by TWO PEOPLE.

Do not handle or lift unless you feel physically able.

Wear appropriate Personal Protection Equipment e.g. protective gloves, safety footwear etc.

Preparation

Co-ordinate movements - know where, and when, you are both going.

Minimise the number of times needed to move the boiler - plan ahead.

Always ensure when handling or lifting the route is clear and unobstructed. If possible avoid steps, wet or slippery surfaces, unlit areas etc. and take special care

on ladders/into lofts.

Technique

When handling or lifting always use safe techniques - keep your back straight, bend your knees. Don’t twist - move your feet, avoid bending forwards and

sideways and keep the load as close to your body as possible.

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.

Remember

The circumstances of each installation are different. Always asses the risks associated with handling and lifting according to the individual conditions.

If at any time when installing the boiler you feel that you may have injured yourself STOP !!

DO NOT ‘work through’ the pain - you may cause further injury.

IF IN ANY DOUBT DO NOT HANDLE OR LIFT THE BOILER - OBTAIN ADVICE OR ASSISTANCE BEFORE PROCEEDING !!

1.1 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.

2. The boiler is set to give a maximum output of

31.0 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 /

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 must be thoroughly flushed and treated

with inhibitor (see section 6.2).

1.2 Optional Extras

Various flue extensions, bends, vertical flue kits,

control accessories etc. are available as optional

extras. These are detailed in a separate publication.

1.0 Introduction

6© Baxi Heating UK Ltd 2007

Data Badge

Fig. 1

Control Box

Case Front Panel

2.0 General Layout

2.1 Layout

1. Air Pressure Switch

2. Expansion Vessel

3. Burner Manifold

4. Automatic Air Vent

5. DHW Plate Heat Exchanger

6. Circulation Pump

7. Drain Off Point

8. Pressure Relief Valve

9. Optional Integral Timer

10. Central Heating System Pressure Gauge

11. 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. Central Heating Temperature Control

23. Hot Water Temperature 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 Heating Mode

33. Burner On

When neons 24 to 29 are constantly illuminated, they

indicate the temperature of the central heating water.

12 11

10 9

21 22 23 10 9

bar

Reset

30°40°50°60°70°80°

24 25 26 27 28 29

30 31 32 33

3.0 Appliance Operation

8© Baxi Heating UK Ltd 2007

NOTE: All delay timers mentioned in 3.1 and 3.2 are

overridden by domestic hot water demand.

3.1 Central Heating Mode (Fig. 2)

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 continues

to run during this period.

4. When the demand is satisfied the burner is

extinguished and the pump continues to run for a

period of 3 minutes (Pump Overrun).

3.2 Domestic Hot Water Mode (Fig. 3)

1. Priority is given to the domestic hot water supply. A

demand at a tap or shower will override any central

heating requirement.

2. The flow of water will operate the DHW flow switch

which requests the 3 way valve to change position. This

will allow the pump to circulate the primary water

through the DHW plate heat exchanger.

3. The burner will light automatically and the

temperature of the domestic hot water is controlled by

the temperature sensor.

4. When the domestic hot water demand ceases the

burner will extinguish and the diverter valve will remain

in the domestic hot water mode, unless there is a

demand for central heating.

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 set to either Position (i) or

Position (ii).

3.3 Frost Protection Mode

1. The frost protection mode is integral to the appliance

and functions only with the selector switch (see 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.

3.4 Pump Protection

1. With the selector switch (see Section 2.1) in either

the central heating or central heating and domestic hot

water position the pump will automatically operate for 1

minute in every 24 hours to prevent sticking.

5 6

10 11

1213141516

1 Primary Heat Exchanger

2 Burner

3 Ignition Electrode

4 Flame Sensing Electrode

5 Gas Valve

6 Pump

7 Automatic Air Vent

8 Plate Heat Exchanger

9 Flow Sensor with Filter

10 Pressure Relief Valve

11 Boiler Drain Point

12 Heating Return

13 Cold Water Inlet On/Off Valve and Filter

14 Gas Inlet

15 Domestic Hot Water Outlet

16 Heating Flow

17 Pressure Gauge

18 Hydraulic Differential Pressure Sensor Microswitch

19 Automatic By-Pass

20 Hydraulic Differential Pressure Sensor

21 Diverter Valve Assembly

22 Domestic Hot Water Flow Priority Assembly

23 Domestic Hot Water Flow Priority Microswitch

24 Safety Thermostat

25 Central Heating Temperature Sensor

26 Expansion Vessel

27 Domestic Hot Water Temperature Sensor

28 Secondary Heat Exchanger

Key

Central Heating Circuit

Domestic Hot Water Circuit

Fig. 3

5 6

10 11

1213141516

Fig. 2

4.0 Technical Data

4.1 Performa 30 HE

Flue Terminal Diameter 100mm

Dimensions Projection 125mm

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)

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 considered when siting the appliance

and in the event of any subsequent alterations in

the area of installation

Weights kg

Packaged Boiler Carton 54

Installation Lift Weight 44

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 13.2 l/min 0.96

Flow Rates l/min

DHW Flow Rate

@ 30°C Rise 14.1

DHW Flow Rate

@ 35°C Rise 12.1

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 1.2

of Boiler (unpressurised)

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

Temperatures

C.H. Flow Temp (adjustable)

35°C to 85°C max (± 5°C)

D.H.W. Flow Temp (adjustable)

35°C to 65°C max (± 5°C)

dependent upon flow rate

Heat Input CH

Max Min

kW 30.5 11.9

Heat Output CH (Non-Condensing)

Max Min

kW 29.6 11

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 BS 4265

Appliance Category CAT II 2H 3P

Inlet Pressure (Natural Gas - G20)

mbar 20

Burner Injector (Natural Gas - G20)

15 x 1.25mm Diameter

Burner Pressure (Natural Gas - G20)

Max Rate Min Rate

mbar 12.1 ± 0.5 2.1 ± 0.2

Appliance Type C12 C32 C52

NOxClass 3

Electrical Protection IPX5D

This value is used in the UK Government’s Standard Assessment

Procedure (SAP) for energy rating of dwellings. The test data from

which it has been calculated have been certified by 0051.

SEDBUK Declaration For Performa 30 HE

The seasonal efficiency (SEDBUK) is 87.3% (89.4% LPG)

Band B

200 400 600 800 1000 1200

0.5

1.5

2.5

3.5

Metre (wg)

Flow Rate (l/h)

Pump - Available Head

4.5

LPG Propane - G31

Burner Injector 15 x 0.77mm diameter

Burner Pressure

Propane mbar

Inlet Pressures

mbar

Max Rate

32.3 ± 0.5

Min Rate

5.2 ± 0.2

Heat Output CH (Condensing)

Max Min

kW 31 11.3

Heat Input DHW

Max

kW 30.5

Heat Output DHW

Max

kW 29.6

Condensate Drain 1” BSP

Max Gas Rate (Natural Gas - G20)

(After 10 mins)

m3/h 3.22

5.0 Dimensions and Fixings

Dimensions

A780mm

B345mm

C450mm

D116mm Ø Min.

E185mm

F190mm

G131mm

360° Orientation

Tube Ø 100mm

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

1.5° to 3o

28mm

Condensate

Drain

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