Baxi Potterton Performa 24 Eco HE User Manual

You can rely on

Installation & Service Instructions

Performa

24 Eco HE

Condensing

Combination Boiler

Burner On

Reset

Flame Failure

Power On

bar

These instructions include the Benchmark Commissioning

Checklist and should be left with the user for safe keeping.

Installer Notification Guidelines

Choose Building

Regulations Notification

Route

Competent Person's

Building Control

Self Certification Scheme

Install and Commission this

appliance to manufacturer's

instructions

Contact your relevant Local

Authority Building Control

(LABC) who will arrange

an inspection or contact

a government approved

inspector

Complete the

Benchmark Checklist

If you notify via the ‘Gas Safe

the Building Regulations

Install and Commission this

appliance to manufacturer's

instructions

certificate on members’ behalf

Scheme Members only

Call ‘Gas Safe Register’ on:

0800 408 5577

Complete the

Benchmark Checklist

or log onto:

www.GasSafeRegister.co.uk

within 10 days

You must ensure that the

certificate number issued by

the ‘Gas Safe Register’ is written

onto the Benchmark Checklist

‘Gas Safe Register’ will issue a

Building Regulations Compliance

Certificate to the property owner

and inform the relevant LABC

LABC will record the data

and will issue a

certificate of compliance

Legislation

IMPORTANT - Installation, Commissioning, Service & Repair

This company declare that no substances harmful to health

are contained in the appliance or used during appliance

manufacture.

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.

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

(Installation & Use) Regulations.

In GB, the installation must be carried out by a Gas Safe

Registered Installer. It must be carried out in accordance with

the relevant requirements of the:

Definition of competence: A person who works for a Gas Safe registered company

and holding current certificates in the relevant ACS modules, is deemed competent.

• 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.

All Gas Safe registered engineers carry an ID card with their licence number and a

photograph. You can check your engineer is registered by telephoning

0800 408 5500 or online at www.GasSafeRegister.co.uk

• The Current I.E.E. Wiring Regulations.

In IE, this must be carried out by a competent person as stated in I.S. 813 “Domestic

Gas Installations”.

Where no specific instructions are given, reference should be

made to the relevant British Standard Code of Practice.

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.

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.

Warning - Check the information on the data plate is compatible with local supply

All systems must be thoroughly flushed and treated with

inhibitor (see section 6.2).

conditions.

Codes of Practice, most recent version should be used

In GB the following Codes of Practice apply:

Standard

BS 6891

BS 5546

Scope

Gas Installation.

Installation of hot water supplies for

domestic purposes.

BS 5449

BS 6798

BS 5440 Part 1

BS 5440 Part 2

BS 7074

Forced circulation hot water systems.

Installation of gas fired hot water boilers.

Flues.

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

Ventilation.

Regulations 1993 N 3083” and is deemed to meet the requirements of Directive

Expansion vessels and ancillary equipment

for sealed water systems.

Treatment of water in domestic hot water

central heating systems.

92/42/EEC on the energy efficiency requirements for new hot water boilers fired with

liquid or gaseous fuels:-

BS 7593

In IE the following Codes of Practice apply:

Type test for purpose of Regulation 5 certified by:

Notified Body 0051.

Standard

I.S. 813

Scope

Domestic Gas Installations.

The following BS standards give valuable additional information;

BS 5546

Installation of hot water supplies for

domestic purposes.

Product/Production certified by:

Notified Body 0086.

BS 5449

BS 7074

Forced circulation hot water systems.

Expansion vessels and ancillary equipment

for sealed water systems.

BS 7593

Treatment of water in domestic hot water

central heating systems.

For GB/IE only.

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 !!

1.0 Introduction

1.1

Description

Case Front Panel

1. The Potterton Performa 24 Eco 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

25.2 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.

Control Box

7. The boiler must be installed with one of the purpose

designed flues such as the standard horizontal flue kit,

part no. 5118489.

Fig. 1

Data Badge

8. All systems must be thoroughly flushed and treated

with inhibitor (see section 6.2).

1.2

Contents of Pack

The pack contains:-

Boiler

Wall Plate (inc. taps)

Set of Connections

Template

Literature Pack

2.0 General Layout

2.1

Layout

Air Pressure Switch

Expansion Vessel

Burner Manifold

Automatic Air Vent

DHW Plate Heat Exchanger

Circulation Pump

Drain Off Point

Safety Pressure Relief Valve

Optional Integral Timer Position

Central Heating System Pressure Gauge

Control PCB

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

Control Box

3-Way Valve Assembly

Condensate Trap

Flame Sensing Electrode

Spark Electrode

Burner

Primary Heat Exchanger

Fan Assembly

Secondary Heat Exchanger

On/Off/Reset Selector Switch

Burner & Fault Indicator Neon

Power Neon

Flame Failure & Fault Indicator Neon

Central Heating Temperature Control

Hot Water Temperature Control

Burner On

Flame Failure

Power On

Reset

bar

3.0 Appliance Operation

NOTE: All delay timers mentioned in 3.1 and 3.2 are

overridden by domestic hot water demand.

Central Heating Circuit

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.

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.

Fig. 2

Key

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.

Primary Heat Exchanger

Burner

Ignition Electrode

Flame Sensing Electrode

Gas Valve

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

Pump

Automatic Air Vent

Plate Heat Exchanger

Flow Sensor with Filter

3. The burner will light automatically and the

temperature of the domestic hot water is controlled by

the temperature sensor.

10 Pressure Relief Valve

11 Boiler Drain Point

12 Heating Return

13 Cold Water Inlet On/Off Valve and Filter

14 Gas Inlet

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.

27 Secondary Heat Exchanger

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 turned to either the DHW

or CH position.

Domestic Hot Water Circuit

Fig. 3

4.0 Technical Data

Appliance Type

C₁₂

C₃₂

C₅₂

Electrical Protection

IPX4D

Central Heating Primary Circuit

Pressures

Appliance Category

Heat Input CH

CAT II

2H 3P

NO Class

bar

2.5

0.5

1-2

Safety Discharge

Max Operating

Min Operating

Condensate Drain

1” BSP

Max

24.8

Min

Flue Terminal

Dimensions

Diameter

Projection

100mm

125mm

10.6

Recommend Operating

Heat Output CH (Non-Condensing)

DHW Circuit

Pressures

Max Operating

Min Operating

bar

Max

Min

Connections

Gas Supply

Central Heating Flow

Central Heating Return

Cold Water Mains Inlet

DHW Flow

copper tails

22mm

15mm

0.2

9.8

Heat Output CH (Condensing)

Min Operating Pressure

at 11.1 l/min

Max

Min

0.9

25.2

10.1

15mm

Pressure Relief Discharge

Flow Rates

DHW Flow Rate

@ 30°CRise

l/min

Heat Input DHW

Max

Outercase Dimensions

Casing Height

Overall Height Inc Flue

Elbow

Casing Width

Casing Depth

11.5

9.8

24.8

780mm

DHW Flow Rate

@ 35°CRise

Heat Output DHW

Max

965mm

450mm

345mm

Min Working

DHW Flow Rate

2.5

Pump

Available Head

Max Gas Rate

(Natural Gas - G20)

(After 10 mins)

2.62

Clearances

See graph below

- (For Central Heating

Above Casing

Below Casing

Front

L.H. Side

R.H. Side

200 mm Min

m /h

Expansion Vessel

only. Integral with appliance)

450 mm Min (For Servicing)

5 mm Min (In Operation)

5 mm Min

5 mm Min (In Operation)

20mm Min (See Note*)

Burner Pressure

(Natural Gas - G20)

Max Rate

10.2 0.5

Min Rate

0.2

bar

0.5

mbar

Min Pre-charge Pressure

Inlet Pressure (Natural Gas - G20)

mbar 20

litre

125

1.0

*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

Max Capacity of

CH System

Burner Injector (Natural Gas - G20)

15 x 1.18mm Diameter

Primary Water Content

of Boiler (unpressurised)

Electrical Supply

(Appliance must be connected to an

earthed supply)

230V~ 50H

Temperatures

C.H. Flow Temp (adjustable)

Power Consumption

External Fuse Rating

170W

35°C to 85°C max ( 5°C)

Weights

Packaged Boiler Carton

Installation Lift Weight

43.5

D.H.W. Flow Temp (adjustable)

35°C to 65°C max ( 5°C)

dependent upon flow rate

Internal Fuse Rating

Fuse 2A Fast Blow to BS 4265

Pump - Available Head

4.5

LPG Propane - G31

Burner Injector 15 x 0.77mm diameter

3.5

Burner Pressure

Propane

Max Rate Min Rate

mbar

21.8 0.5 4.4 0.2

Inlet Pressures

2.5

mbar

1.5

0.5

200

400

600

800

1000

1200

Flow Rate (l/h)

5.0 Dimensions and Fixings

Dimensions

A 780mm

At Least 1.5°

B 345mm

C 450mm

D 116mm Ø Min.

E 185mm

F 190mm

G 131mm

360° Orientation

Tube Ø 100mm

Tap Rail

28mm

Condensate

Drain

65 mm

Heating

Return

(22mm)

Pressure Relief

Heating

Flow

(22mm)

Domestic Hot

Water Outlet

(15mm)

Gas

Inlet

(22mm)

ColdWater

Inlet

(15mm)

Valve

(15mm)

6.0 System Details

6.1

Information

1. The Potterton Performa 24 Eco HE Condensing Combination

Boiler is ‘Water Byelaws Scheme - Approved Products’.

To comply with the Water Byelaws your attention is drawn to the

following installation requirements and notes (IRN).

a) IRN 001 -

See text of entry for installation

requirements and notes.

Byelaw 14.

b) IRN 302 -

2. Reference to the WRc publications, ‘Water fittings and materials

directory’ and ‘Water supply byelaws guide’ give full details of

byelaws and the IRNs.

6.2

Central Heating Circuit

1. The appliance is suitable for fully pumped SEALED SYSTEMS

ONLY.

Treatment of Water Circulating Systems

• All recirculatory water systems will be subject to

corrosion unless an appropriate water treatment is

applied. This means that the efficiency of the system will

deteriorate as corrosion sludge accumulates within the system,

risking damage to pump and valves, boiler noise and circulation

problems.

• When fitting new 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. Using,

for example Betz-Dearborn Sentinel X300 or X400 or Fernox

Superfloc Universal Cleanser. They should be used following the

flushing agent manufacturer’s instructions.

• System additives - corrosion inhibitors and flushing

agents/descalers should comply to BS7593 requirements, e.g. Betz-

Dearborn Sentinel X100 and Fernox-Copal which should be used

following the inhibitor manufacturer’s instructions.

Failure to flush and add inhibitor to the system will invalidate

the appliance warranty.

• It is important to check the inhibitor concentration after

installation, system modification and at every service in accordance

with the manufacturer’s instructions. (Test kits are available from

inhibitor stockists.)

• For information or advice regarding any of the above contact

Technical Enquiries.

6.3

Bypass

1. The boiler is fitted with an automatic integral bypass.

6.4

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.

3. For optimum operating conditions and maximum economy

the fitting of a programmable room thermostat is

recommended.

6.0 System Details

6.5

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.

Double

Check

Valve

2. There are connection points on the mains cold water

inlet and central heating return isolating taps (Fig. 5) to

which the optional filling loop kit (Part No. 248221) can

be assembled.

Stop

Valve

Stop

Valve

3. The filling method adopted must be in accordance

with all relevant water supply regulations and use

approved equipment.

Temporary

Hose

DHW

Mains

Inlet

Return

4. Your attention is drawn to,

for GB: guidance G24.2 and recommendation R24.2 of

the Water Regulations Guide.

Fig. 4

for IE: the current edition of I.S. 813. “Domestic Gas

Installations”.

5. The sealed primary circuits may be filled or

replenished by means of a temporary connection

between the circuit and a supply pipe provided a

‘Listed’ double check valve or some other no less

effective backflow prevention device is permanently

connected at the inlet to the circuit and the temporary

connection is removed after use.

Fig. 5

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 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”.

Filling Loop

6.7

Safety Pressure Relief Valve (Fig. 6)

1. The pressure relief valve is set at 3 bar, therefore all

pipework, fittings, etc. should be suitable for pressures in

excess of 3 bar.

2. The pressure relief discharge pipe should be not less

than 15mm dia, run continuously downward, and

discharge outside the building, preferably over a drain. It

should be routed in such a manner that no hazard

occurs to occupants or causes damage to wiring or

electrical components. The end of the pipe should

terminate facing down and towards the wall.

Fig. 6

Pressure Relief Valve

Discharge Pipe

3. The discharge must not be above a window,

entrance or other public access. Consideration must be

given to the possibility that boiling water/steam could

discharge from the pipe.

4. A remote relief valve kit is available to enable the

boiler to be installed in cellars or similar locations below

outside ground level (kit no. 5121379).

6.0 System Details

Other Tap

Outlets

6.8

Domestic Hot Water Circuit (Fig. 7)

1. All DHW circuits, connections, fittings, etc. should be

fully in accordance with relevant standards and water

supply regulations.

Boiler

Expansion

Vessel*

2. Your attention is drawn to:

for GB: Guidance G17 to G24 and recommendation R17

to R24 of the Water Regulations Guide.

for IE: the current edition of I.S. 813. “domestic Gas

Installations”.

Check

Valve*

Pressure Reducer

Valve*

3. The Water Regulations recommendations for England

and Wales prohibits backflow from appliances into the

wholesome water supply due to thermal expansion.

However this type of instantaneous combination boiler,

with less than 15 litres of stored capacity, does not

require any backflow prevention device as any thermal

expansion is accommodated within the appliance.

It is possible in certain circumstances that other cold

water demands (e.g. washing machines, flushing of W.C.s)

may affect the DHW function of the boiler. In these

instances the fitting of a backflow prevention device and

expansion vessel is recommended.

To Hot

Taps

Stop Tap

*See 6.8 for instances when

these items may be required

Fig. 7

4. Also if there is an existing check valve, loose jumpered

stop cock, water meter or water treatment device

already fitted to the wholesome water supply connected

to the boiler domestic hot water (DHW) inlet supply

then a suitable expansion device may be required.

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 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.

The pressure reduction must take account of all fittings

connected to the DHW system.

6.9

Showers

1. If a shower control is supplied from the appliance it

should be of the thermostatic or pressure balanced type.

Thermostatic type shower valves provide the best

comfort and guard against water at too high a

temperature. Existing controls may not be suitable - refer

to the shower valve manufacturer.

6.10

Hard Water Areas

1. If the area of the installation is recognised as a HARD

WATER AREA then a suitable device should be fitted to

treat the mains water supply to the boiler. Contact your

Water Distribution Company for advice on suitable

devices.

7.0 Site Requirements

20mm/5mm Min

See * NOTE:

450mm

5mm Min

7.1

Location

1. The boiler may be fitted to any suitable wall with the

flue passing through an outside wall or roof and discharging

to atmosphere in a position permitting satisfactory removal

of combustion products and providing an adequate air

supply. The boiler should be fitted within the building

unless otherwise protected by a suitable enclosure i.e.

garage or outhouse. (The boiler may be fitted inside a

cupboard-see Section 7.3).

200mm Min

2. If the boiler is sited in an unheated enclosure then it is

recommended to leave the ON/OFF Selector Switch in

the domestic hot water and central heating position to

give frost protection.

780mm

3. If the boiler is fitted in a room containing a bath or

shower reference must be made to the relevant

requirements.

In GB this is the current I.E.E. Wiring Regulations and

Building Regulations.

In IE reference should be made to the current edition of

I.S. 813 “Domestic Gas Installations” and the current ETCI

rules.

Burner On

Flame Failure

Power On

Reset

bar

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).

200mm Min

Fig. 8

7.2

Clearances (Figs. 8 & 9)

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, access during routine

maintenance 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.

* 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

450mm Min

For Servicing

Purposes

subsequent alteration in the area of installation.

5mm Min

In Operation

Fig. 9

7.0 Site Requirements

7.3

Ventilation of Compartments

1. Where the appliance is installed in a cupboard or

compartment, no air vents are required.

2. BS 5440: Part 2 Clause 4.2 refers to room sealed

appliances installed in compartments. The appliance will

run sufficiently cool without ventilation.

7.4

Gas Supply

1. The gas installation should be in accordance with the

relevant standards. In GB this is BS 6891. In IE this is the

current edition of I.S. 813 “Domestic Gas Installations”.

2. The connection to the appliance is a 22mm copper

tail located at the rear of the gas service cock (Fig. 10).

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 the current edition of

ETCI rules.

2. The mains supply is 230V ~ 50H fused at 3A.

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.

Fig. 10

Gas Service Cock

7.0 Site Requirements

Termination to an internal soil and vent pipe

Boiler

7.6

Condensate Drain

FAILURE TO INSTALL THE CONDENSATE

DISCHARGE PIPEWORK CORRECTLY WILL AFFECT

THE RELIABLE OPERATION OF THE BOILER

The condensate discharge pipe MUST NOT RISE at any

point along its length. There MUST be a fall of AT LEAST

2.5° (50mm per metre) along the entire run.

1. The condensate outlet terminates in a 1” BSP nut and seal

for the connection of 21.5mm ( /⁴in) plastic overflow pipe

450mm min

which should generally discharge internally into the household

drainage system. If this is not possible, discharge into an

outside drain is acceptable.

2. Ensure the discharge of condensate complies with any

national or local regulations in force.

External termination via internal

discharge branch

e.g sink waste - downstream

Boiler

BS 6798:2000 & Part H1 of the Building Regulations give

further guidance.

3. The discharge pipe should be run in a proprietary drain pipe

material e.g. PVC, PVC-U, ABS, PVC-C or PP.

Pipe must terminate

above water level but

below surrounding

surface

Sink

4. Metal pipework is NOT suitable for use in condensate

discharge systems.

5. The pipe should be a minimum of 21.5mm diameter and

must be supported using suitably spaced clips to prevent

sagging.

6. It is advisable to keep the condensate pipe internal.

7. External runs greater than 3 metres or runs in cold areas

External termination to a drain or gully

should use 32mm waste pipe.

Boiler

8. If the boiler is fitted in an unheated location the entire

condensate discharge pipe should be treated as an external

run.

Pipe must terminate above

water level but below

surrounding surface

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 waste

pipe the effects of existing plumbing must be considered. If soil

pipes or waste pipes are subjected to internal pressure

fluctuations when WC's are flushed or sinks emptied then

back-pressure may force water out of the boiler trap and

cause appliance lockout.

External termination to a purpose made soak-away

Examples are shown of the following methods of termination:-

i) to an internal soil & vent pipe

Boiler

ii) via an internal discharge branch (e.g. sink waste)

iii) to a drain or gully

500mm min

iv) to a purpose made soakaway

Holes in the soak-away must

face away from the building

Terminal Position with Minimum Distance (Fig. 11)

(mm)

7.0 Site Requirements

Directly below an opening, air brick, opening

windows, etc.

Above an opening, air brick, opening window etc.

Horizontally to an opening, air brick, opening window etc.

Below gutters, soil pipes or drain pipes.

Below eaves.

Below balconies or car port roof.

From a vertical drain pipe or soil pipe.

From an internal or external corner.

300

7.7

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.

Above ground, roof or balcony level.

300

600

1200

600

1. The following guidelines indicate the general requirements

for siting balanced flue terminals. For GB recommendations

are given in BS 5440 Pt 1. For IE recommendations are given

in the current edition of I.S. 813 “Domestic Gas

Installations”.

From a surface or boundary line facing a terminal.

From a terminal facing a terminal (Horizontal flue).

From a terminal facing a terminal (Vertical flue).

From an opening in carport (e.g. door, window)

into the dwelling.

Vertically from a terminal on the same wall.

Horizontally from a terminal on the same wall.

From adjacent wall to flue (vertical only).

From an adjacent opening window (vertical only).

Adjacent to windows or openings on pitched and flat roofs

Below windows or openings on pitched roofs

1200

1500

300

1000

600

2. If the terminal discharges onto a pathway or passageway,

check that combustion products will not cause a nuisance

and that the terminal will not obstruct the passageway.

2000

3. If a terminal is less than 2 metres above a balcony, above

ground or above a flat roof to which people have access,

then a suitable terminal guard must be provided.

In addition, the terminal should be no nearer than 150 mm to an

opening in the building fabric formed for the purpose of accommodating

a built-in element such as a window frame. See BS 5440 Pt. 1.

IMPORTANT:

• Only ONE 25mm clearance is allowed per installation.

• Under car ports we recommend the use of the plume

displacement kit.

• The terminal position must ensure the safe and

nuisance - free dispersal of combustion products.

NOTE: The distance from a fanned draught appliance terminal

installed parallel to a boundary may not be less than 300mm in

accordance with the diagram below

300 min

Terminal

Assembly

Plume

Displacement Kit

IMPORTANT: If fitting a Plume

Displacement Flue Kit, the air inlet

must be a minimum of 100mm from

any opening windows or doors (see

Section 9.0).

TopView Rear Flue

Fig. 12

Property Boundary Line

J,K

Air Inlet

Opening Window

or Door

100mm

MIN.

Fig. 12a

J,K

Likely flue positions requiring

a flue terminal guard

Fig. 11

8.0 Flue Options

8.1

Horizontal Flue Systems

1. The standard flue is suitable only for horizontal

termination applications.

2. All fittings should be fully engaged. The approximate

engagement is 40mm. Apply soap solution to the seal on

each fitting to aid assembly.

3. Maximum permissible equivalent flue lengths are:-

Horizontal Concentric 4 metres

4. Any additional “in line” bends in the flue system must be

taken into consideration.

Their equivalent lengths are:-

Concentric Pipes:

Horizontal

Flues

135° bend

93° bend

0.5 metres

1.0 metres

Twin Flue Pipe

135° bend

91.5° bend

0.25 metres

0.50 metres

The elbow supplied with the standard horizontal telescopic

flue kit is not included in any equivalent length calculations

Plume Displacement Kit 60 /100 Ø

1M Extensions, 45° & 93° bends are

also available - see Section 9.0

NOTE: Flue length is measured from point X to Y as

shown.

IMPORTANT: All flue systems must be securely

supported at least once every metre. Suitable pipe

supports are available as accessories.

NOTE: Horizontal flue pipes should always be installed with a 1.5° fall from the

terminal to allow condensate to run back to the boiler.

This bend is equivalent to

1 metre

This bend is equivalent to

1 metre

Total equivalent length (up to 3m) =

A+B+C+2x90°Bends

8.0 Flue Options

Vertical

Flues

8.2

Twin & Vertical Flue Systems

(Twin Pipe)

1. Maximum permissible equivalent flue lengths are:-

Vertical Concentric

Vertical Twin Pipe

12m*

* Both the air and flue duct can be up to 12 metres

long each.

2. Any additional “in line” bends in the flue system must

be taken into consideration. Their equivalent lengths

are:-

Concentric Pipes:

45° bend

93° bend

0.5 metres

1.0 metres

Twin Flue Pipe

Vertical

Flues

45° bend

0.25 metres

0.50 metres

91.5° bend

The elbow supplied with the standard horizontal flue is

not included in any equivalent length calculations

NOTE: Flue length is measured from point X to Y

as shown.

IMPORTANT: All flue systems must be securely

supported at least once every metre. Suitable pipe

supports are available as accessories.

Total Equivalent Length =

A+B+C+1x90°Bend

Roof

Terminal

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 135° bends can be included without

reduction of the flue length.

660mm

The total equivalent

length for this example

is = 6.5 metres.

If further elbows are required the flue length must

be reduced by the following amounts:-

1 metre for each 91.5° bend

0.5 metre for each 135° bend

AIR DUCT

N of

fittings/pipes

Equivalent

Length Value

Sub total

1m extension

45°bend

5.0m

0.5m

1.0m

0.25m

0.5m

91.5°bend

This bend is equivalent to

1 metre

Equivalent Length Air Duct = 6.5m

FLUE DUCT

N of

fittings/pipes

Equivalent

Sub total

Length Value

1m extension

45°bend

5.0m

0.5m

1.0m

0.25m

0.5m

91.5°bend

Equivalent Length Flue Duct = 6.5m

8.0 Flue Options

8.3

Flue Accessories

Key Accessory

FLUE GROUP A

Concentric Flue System 100mm diameter

Size

Code No

Horizontal Flue Terminal

Horizontal Flue Terminal (incl elbow)

Flue Extension

5111073

5118489

1000mm 5111074

Flue Bend

93°

135°

5111075

5111085

Flue Bend (pair)

Pipe Support (painted)

Vertical Flue Adaptor

Wall Liner

100mmØ 5111080

5111070

5111067

Flue Terminal Deflector

5111068

FLUE GROUP N

Twin Flue System 80mm diameter

Flue Extension (pair)

Flue Bend (pair)

1000mm 5111087

90°

135°

5111072

5111086

5111079

5111084

5111081

K, K1

Flue Bend (2 pair)

Vertical Flue Boiler Adaptor Kit

Vertical Flue Adaptor

Pipe Support (pair)

80mm

FLUE GROUP A, N, G

Vertical Flue Kits

Vertical Flue Terminal (use with 5111070)

Vertical Flue Terminal

5111078

5118576

5122151

246143

246144

Pitched Roof Flashing

Roof Cover Plate

Flat Roof Flashing

25°/50°

U,W

8.0 Flue Options

For Twin Flue Systems fit the adaptors as follows:-

8.4

Flue Duct Adaptor

Boiler Adaptor

1. Engage the flue duct adaptor on the boiler adaptor,

making sure that it is pushed down as far as possible.

Blanking Plate

8.5

Air duct adaptor

1. Undo the screws securing the blanking plate to the boiler

top panel. Discard the plate.

2. There are three restrictor plates supplied in the kit. One

marked ‘23’ and one marked ‘27’, these can be discarded

The third restrictor MUST be positioned as shown in the

diagram below.

3. Take one of the gaskets supplied in the kit and place on

the boiler top panel.

4. Align the restrictor as shown. Position the second gasket

over the restrictor.

5. Using the screws previously removed secure the inlet

adaptor to the top panel.

6. Continue to fit the twin flue system.

Position of Restrictor

Air Duct Adaptor

Gasket

Restrictor

Gasket

8.0 Flue Options

8.6

For Roof Terminals

1. In the case of a pitched roof 25 - 50 degrees, position the lead

tile to replace/flash over existing roof tiling. Make an aperture in

the roof suitable for the lower tube of the roof terminal and

ensure the integrity of the roof cover is maintained. The

Approx

1425mm

adjustable plastic collar can either be positioned on the lead tile

or the lower tube of the roof terminal prior to the final

positioning of the vertical flue through the tile. Check the collar is

correctly located to suit required roof pitch (either 25° to 38° or

37° to 50°). From inside the roof adjust the flue to a vertical

position and secure to the roof structure with the clamp supplied.

2. For flat roof installations the aluminium flashing must be

incorporated into the roof covering and the appropriate aperture

made in the roof decking. The vertical flue is lowered onto the

flashing making sure the collar of the flue locates securely with the

flashing. (A mastic seal may be necessary). From inside the roof,

adjust the flue to a vertical position and secure to the roof

structure with the clamp supplied.

Cut the same

amount off the

Air Duct &

Air Duct

Flue Duct

Push Fit Adaptor

8.7

Flue Dimensions

1. The standard horizontal flue kit allows for flue lengths between

100mm and 685mm from elbow to terminal (Fig. 13).

The maximum permissible equivalent flue length is: 4 metres

NOTE: Each additional 45° of flue bend will account for an

equivalent flue length of 0.5m.

eg. 45° = 0.5m,

90° = 2 x 45° = 1m etc.

Flue Deflector

8.8

Flue Trim

1. The rubber flue trim supplied may be fitted to either the

outside wall or on the inner wall of installation.

Fig. 13

8.9

Terminal Guard (Fig. 14)

1. When codes of practice dictate the use of terminal guards, they

can be obtained from most Plumbers’ and Builders’ Merchants.

Fig. 13a

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 number.

4. The flue terminal guard should be positioned centrally over the

terminal and fixed as illustrated.

8.10

Flue Deflector (Fig. 13a)

1. If required a flue deflector is available from your Potterton

stockist.

Fig. 14

2. Push the flue deflector over the terminal end and rotate to the

optimum angle for deflecting plume. Secure the deflector to the

terminal with screws provided.

93° Elbow/Plume

Outlet Assembly

9.0 Plume Displacement

60Ø Support

Bracket

9.1

Plume Displacement Kit (Fig. 14b)

O Ring

Kit No 5118638

Content of kit

0.9 metres

0.9m 60/100 Concentric Flue

1m 60 Dia Exhaust Flue Pipe

Adaptor

60Ø Exhaust

Flue Pipe

60 Dia Support Brackets

93° Elbow/Plume Outlet Assembly

Flexible Flue Trim

60Ø Support

Bracket

“O” Rings

‘Jubilee Clip

O Ring

Adaptor

O Ring

Fig. 14a

Boiler Elbow

Flexible Flue

Trim

1. This kit is recommended for installations where the

condensate plume emitted from the flue may cause a nuisance

or affect the surroundings.

‘Jubilee’ Clip

2. The terminal must be positioned outside the building with

the air inlet facing downward and outlet connection upwards.

Elbow

3. The plume outlet must always be at least 45° to the wall,

with the ‘peak’ uppermost to prevent rain entry (Figs. 15 &

16), and be at least 2 metres above ground level. It must be

secured as shown in Fig. 12a. The plume outlet must also be

at least 500mm from the air inlet in any direction (Fig. 16).

60/100Ø

Concentric Flue

Fig. 14b

Outlet must be at

least 45° from

wall face

NOTE: The outlet must be positioned so that any

condensate plume is directed away from adjacent surfaces.

There must be a constant fall along the entire length of the

flue system from the outlet back to the boiler.

45°

‘Peak’ Uppermost

45°

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 exhaust.

5. Standard concentric flue extension kits may be added

between the boiler elbow and the terminal assembly.

6. The minimum length of the concentric flue is 100mm when

measured from the edge of the flue elbow.

500mm Min.

IMPORTANT: The maximum equivalent length of

concentric flue is:- 2.5 metres

Additional bends may be fitted in the concentric flue, but

the equivalent length must be reduced by 1 metre (93°

bend) or 0.5 metres (45° bend).

Fig. 15

Air Inlet at Bottom

7. 60Ø 1 metre extensions (including support bracket), and

additional 93° & 45° elbows are available. Any additional 93°

& 45° elbows must be accounted for when calculating flue

lengths.

Fig. 16

NOTE: Permitted positions of the plume outlet relative to

doors, windows etc. are the same as for conventional

concentric flues as detailed in the main Installation &

Servicing Instructions and BS5440 Pt. 1. It is NOT

necessary to fit a terminal guard over the air inlet or the

plume outlet.

9.0 Plume Displacement

9.2

Determining Permissible Lengths

In the graph the solid line diagonal represents the

relationship between the concentric flue assembly (and any

extensions) and the 60Ø exhaust (and any extensions or

additional bends).

Example 1 - Not Permissible

If, for instance, a concentric length of 2 metres was required

and the 60Ø exhaust needed to be 1.5 metres the graph

shows that this combination would NOT be permissible as

the intersection point would be above the solid diagonal line.

Concentric 60/100 Flue (metres)Y

Example 1

Example 2

Flue Lengths - Not Permissible

Flue Lengths - OK

Example 2 - Flue Lengths OK

Where both lengths have been determined they can be

applied to the graph to check that the installation is

permissible. For example, if it was known that 1 metre of

concentric flue and 1.5 metres of 60Ø exhaust were

required, the values could be applied to the graph as shown

in Example 2.. As the point of intersection of the dotted lines

is below the solid diagonal line, the combination of lengths is

shown to be acceptable.

Example 3 - Flue Lengths OK

In the example shown, assume that the concentric part of

the flue needs to be 1 metres long. Find the position of ‘1’ on

the horizontal axis of the graph and then project upwards to

the solid diagonal line. This is represented by the vertical

thick dotted line. Where this dotted line intersects with the

solid diagonal line on the graph, project across to the vertical

axis. As can be seen this corresponds with 2 metres.

Therefore, the total equivalent length of the 60Ø exhaust

can be up to 2 metres. Any bend equivalencies must be

accounted for i.e. 93° bends are equal to 1 metre, each 45°

bend to 0.5 metres.

Concentric 60/100 Flue (metres)Y

Example 3

Flue Lengths - OK

60Ø Exhaust

Support

Bracket

Flue Length - Worked Example

Potterton Performa 24 Eco HE

93° Elbow

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. The waste is discarded.

Extension

Concentric 60/100 Flue

Concentric Flue

To calculate total length:-

Fig. 17

2 x 0.25 metre Lengths =

1 x 93° Elbow =

0.5 metres

1 metre

Total 60Ø Exhaust =

1.5 metres

After consulting the table in Example 3 it can be determined

that the concentric flue could be up to approximately 0.5

metres long.

Additional Accessories

A - 93° Elbow

B - 45° Elbow (Pair)

5117381

5117382

Fig. 18

C - 1 metre 60Ø Extension 5117380

9.0 Plume Displacement

9.3

General Fitting Notes

1. Cut a hole in the external wall which the concentric flue

assembly will pass through. The hole should allow the flue

to fall back to the boiler at an angle of 1.5° to 3°.

2. When completed the terminal must be at least 2 metres

above ground level (Fig. 19).

Min. 2 metres

3. Measure and cut to size the concentric assembly and any

extensions that are being used.

4. Insert the concentric assembly through the hole from

outside the building.

5. If required, the flexible flue trim should be fitted prior to

this as it cannot be fitted after. Use the large ‘Jubilee’ clip to

secure the trim to the flue (See Fig. 20, trim shown

dotted), with the screw part of the clip at the bottom.

Fig. 19

6. Connect any extensions or elbows that are being used

to the concentric assembly. Engage the extension, elbow

or concentric assembly in the boiler flue elbow. Fit the

boiler flue elbow to the boiler adaptor.

Flue Trim

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.

Spigot

9. The 60Ø exhaust can now be fitted. Slide the adaptor

over the plain end of the 60Ø exhaust (Fig. 22) and engage

the exhaust in the terminal. Slide the adaptor down over

the spigot. Mark and drill the adaptor, using a 2mm bit, as

shown in Fig. 21. Secure the adaptor to the spigot using

one of the screws supplied.

Position of ‘Jubilee’ Clip

screw

Fig. 20

50mm

Adaptor

10. If it is necessary to shorten the 60Ø exhaust or any of

the extensions, the excess material must be cut from the

plain end of the pipe.

Fig. 22

11. Determine the position of the 60Ø exhaust and mark

on the wall a suitable position for the support bracket. If

extensions are being used, a support bracket is supplied in

each kit.

30mm

Fig. 21

12. Drill the wall, and fit the bracket(s) using the plug and

screw provided.

30mm

13. Mark and drill the 60Ø exhaust, using a 2mm bit, as

shown in Fig. 23. Complete the installation of the 60Ø

exhaust, securing in the brackets.

Fig. 23

14. Fit the 93° elbow/plume outlet and secure with the

two remaining screws supplied. Ensure the plume outlet is

at least 45° to the wall and that the ‘peak’ is uppermost

(Fig. 24).

Fig. 24

9.0 Plume Displacement

Plume Outlet

Elbow

9.3

General Fitting Notes (cont.)

15. For aesthetic purposes it is permissible to route the

60Ø exhaust in an enclosed box, but the air inlet and

plume outlet MUST remain in free air.

16. It is also possible to separate the plume outlet from the

93° elbow to allow the flue to be installed as shown in

Fig. 25.

17. To do this, first slacken the two screws retaining the

plume outlet to the elbow, and remove the outlet (Fig. 26).

The elbow can now be used to connect the vertical to

horizontal 60Ø exhaust (Fig. 25). Retighten the screws in

the elbow.

Fig. 25

18. The outlet can now be fitted into the female end of an

60Ø extension piece. It must be secured using two of the

screws supplied in the bag with the ‘Jubilee’ clip.

19. Mark the female end of the extension at 30mm as

shown in two positions, directly opposite each other

(Fig. 27).

Fig. 26

30mm

20. Using a suitable bit (e.g. 2mm), drill through the

extension and outlet. Secure using two of the screws

supplied.

21. The remaining screw must be used to secure the

adaptor to the concentric terminal.

Fig. 27

22. When the plume outlet is positioned under a balcony

or other projection (Fig. 28) it must protrude at least

200mm (it is not necessary to extend it further than this).

200mm Min.

23. When under balconies or projections it is permissible to

rotate the concentric flue length up to 70°, clockwise or

anti-clockwise (Fig. 29), if there is insufficient space to

connect vertically.

24.This will allow the connection of the exhaust to the

outlet spigot.

25. All other minimum & maximum dimensions must be

adhered to, and the air inlet positioned such that it will not

be subject to rain entry.

Fig. 28

70°

Concentric Flue Length

(shown end-on)

Outlet Spigot

Fig. 29

10.0 Installation

10.1

Initial Preparation

The gas supply, gas type and pressure must be

checked for suitability before connection (see Section

7.4).

1. After considering the site requirements

(see Section 7.0) position the fixing template on the

wall ensuring it is level both horizontally and vertically.

2. Mark the position of the two most suitable fixing slots

for the wall plate and boiler lower fixing holes. It is

preferable to use the horizontal fixing slots.

190mm

3. Mark the position of the centre of the flue hole (rear

exit). For side flue exit, mark as shown (Fig. 30).

4. Note the shaded area on the template. Pipework

may be routed upwards behind the boiler, providing it

does not conflict with the shaded area.

5. If required, mark the position of the gas and water

pipes. Remove the template.

For Side Flue Exit

6. Cut the hole for the flue (minimum diameter

116mm).

Fig. 30

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 connections.

10.2

Flushing

1. Connect a tube to the central heating flow or return

pipe (Fig. 31).

2. Flush thoroughly (see System Details, Section 6.2).

10.3

Preparing The Boiler

Flushing Tube

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.

Fig. 31

Central Heating Return

10.0 Installation

Wall Plate

10.4

Fitting The Boiler

1. Remove the sealing caps from the boiler connections.

NOTE: A small amount of water may drain from the

boiler once the caps are removed.

2. Lift the boiler as indicated by the shaded areas. The

boiler should be lifted by TWO PEOPLE. Engage the slots

at the top rear of the boiler on the wall plate (Fig. 35)

(see Safe Manual Handling page 5).

3. Insert the sealing washers between the valves and

pipes on the wall plate and the boiler connections. The

rubber washers must be used on the gas connection.

Fig. 32

4. Tighten all the connections.

10.5

Fitting the Safety Pressure Relief

Discharge Pipe (Fig. 33)

Suggested Lifting Points

shown as shaded area

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 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 safety pressure relief valve.

Pressure Relief Valve

Fig. 33

Discharge Pipe

10.0 Installation

10.6

Condensate Drain (see section 7.6)

1. Connect the condensate drain using the 1” BSP nut

and seal supplied.

Ensure the discharge of condensate complies with

any national or local regulations in force (see British

Gas “Guidance Notes for the Installation of

Domestic Gas Condensing Boilers”.

Fig. 34

2. The condensate outlet terminates in a 1” BSP nut and

seal for the connection of 21.5mm ( /⁴in) plastic

overflow pipe which should generally discharge internally

into the household drainage system. If this is not

possible, discharge into an outside drain is acceptable.

10.7

Fitting The Flue

HORIZONTAL FLUE

Wall Thickness

1. The standard flue is suitable for lengths between

100mm minimum and 685mm maximum, as measured

from the edge of the flue elbow outlet to the joint

between the terminal and air duct (Fig. 34).

Flue Elbow

(X)

2. Locate the flue elbow on the adaptor at the top of

the boiler. Set the elbow to the required orientation

(Fig. 35).

Adaptor

NOTE: The flue elbow is angled at 91.5 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. 36).

4. To dimension ‘X’ add 50mm. This dimension to be

known as ‘Y’.

IMPORTANT: Check all dimensions before cutting.

Fig. 35

(X)

Wall Thickness

Fig. 36

10.0 Installation

10.7

Fitting the Flue (Cont)

Waste

5. Mark dimension ‘Y’ on the flue as shown (Fig. 37).

Carefully cut the waste material from the flue, ensuring

that the ducts are square and free from burrs.

6. The inner flue duct support bracket may be in the

waste portion of the flue. In this case retrieve the

bracket before discarding the waste.

Flue

Fig. 37

7. Take the inner flue support bracket (if not already

fitted) and engage it over the flue duct. This will

centralise the flue and air ducts, and ease assembly

(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. It may be necessary to use soap solution or

similar to ease assembly of the elbow adaptor and flue

(Fig. 39).

10. Make good between the wall and air duct outside

the building.

Fig. 38

11. Fit the flue trim if required, and if necessary fit a

terminal guard (see Section 8.8 & 8.9).

VERTICAL FLUE

1. Only a flue approved with the Potterton Performa 24

Eco HE can be used.

Flue Elbow

Fig. 39

10.0 Installation

10.8

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 locating tabs are clear of the

facia. Remove the panel.

2. Completely undo the screws securing the facia panel

and hinge it down (Fig. 40).

Control Box Cover

Fig. 41

3. Remove the control box cover securing screws.

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.

5. Slacken the screws in the terminal block, connect

the input cable, and tighten the screws.

Fig. 40

Fig. 42

Facia Panel

Cable Clamp

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.

Frost Thermostat

Fuse

External Clock

g/y

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

between terminals 1 & 2. The 230V supply at terminal

1 must be connected to the external control. The

switched output from the external control must be

connected to terminal 2 (Fig. 43).

Fused supply 3A

230V ~ 50Hz

Always fit fast

blow 2A fuse

230 V

Live (brown)

Neutral (blue)

g/y

Earth (green/yellow)

Room Thermostat

NOTE: If the room thermostat being used

incorporates an anticipator it MUST be wired as

shown in Fig. 43

230V

IMPORTANT: If an integral timer is fitted to the boiler

an external frost thermostat wired as shown will not

operate correctly. Only external timers may be used in

such installations, as in the diagram.

IMPORTANT: The external control MUST be

suitable for 230V switching.

Terminal Block

Fig. 43

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.

Functional Flow Diagram

Pump

Fan

External

Controls

230 V

Pressure Switch

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.

Selector /

Reset Switch

Flue Thermostat

Safety Overheat Thermostat

Central Heating

NTC Sensor

DHW

NTC Sensor

10.9

Preliminary Electrical Checks

PCB

Gas Valve Modulator

Spark Electrode

Gas Valve

1. Prior to commissioning the boiler preliminary

electrical system checks should be carried out.

Key to Wiring

b - blue

br - brown

bk - black

r - red

Condensate Trap

2. These should be performed using a suitable meter,

and include checks for Ground Continuity,

Flame Sensing Electrode

Hydraulic Differential Pressure Switch

DHW Flow Priority Microswitch

g - green

Resistance to Ground, Short Circuit and Polarity.

Fig. 44

11.0 Commissioning the Boiler

11.1

Commissioning the Boiler

Screw

1. Reference should be made to BS 5449 Section 5

when commissioning the boiler.

2. At the time of commissioning complete all relevant

sections of the Benchmark Commissioning Checklist at

the rear of this publication.

Automatic Air

Vent

3. Open the mains water supply to the boiler.

4. Open all hot water taps to purge the DHW system.

5. Ensure that the filling loop is connected and open,

then open the heating flow and return valves on the

boiler.

6. Open the screw on the automatic air vent

(Fig. 45).

7. The system must be flushed in accordance with BS

7593 (see Section 6.2) and the flushing agent

manufacturers instructions.

Pump

Fig. 45

8. Pressurise the system to 1.0 bar then close and

disconnect the filling loop.

9. Turn the gas supply on and purge according to in GB

BS 6891 and in IE I.S. 813 “Domestic Gas Installations”.

10. Test for gas soundness.

bar

11. 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

Selector Switch

Fig. 46

Pressure Gauge

back to either ( ) or (

) (Fig. 47).

Burner On

Reset

Flame Failure

Power On

bar

Power On

Neon

Hot Water

Temperature Control

Central Heating

Temperature Control

Fig. 47

11.0 Commissioning the Boiler

Pressure Test Point

Sealing Screw

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.

Gas Valve

2. Set the temperature controls to maximum and the

selector switch to the Off position (Fig. 51).

3. Slacken the pressure test point sealing screw on the

gas valve and connect a pressure gauge (Fig. 48).

Fig. 48

4. Undo the screws securing the inner door panel. Lift

the panel slightly to disengage it from the studs on top

of the case.

Plastic

Protection

Cap

5. Turn the selector switch fully anticlockwise against

the spring pressure to the reset position and hold for

2 seconds to reset the boiler (Fig. 51).

6. Turn the selector switch to the Cental Heating and

Domestic Hot Water position (

neon ( ) will illuminate (Fig. 51).

). The power On

Modulator

Wire

Maximum Rate

Adjustment Nut

7. Turn a hot water tap on to give a flow rate of at

least 10l/min.

Minimum Rate

Adjustment Nut

Fig. 49

NOTE: Gas Valve Electrical

Plug/Igniter not shown for clarity.

8. The pressure should be :-

Propane

10.2mbar

21.8mbar

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.

bar

Selector Switch

Pressure Gauge

Fig. 50

Adjusting the Pressure (Fig 49)

11. Remove the plastic protection cap from the

pressure adjustment nuts on the valve.

Burner On

Reset

Flame Failure

Power On

bar

12. The smaller nut (5mm) adjusts minimum pressure

and the larger nut (8mm) maximum pressure.

Power On

Neon

13. Using a suitable spanner adjust the relevant nut

until the correct pressure is achieved.

Central Heating

Temperature Control

Hot Water

Temperature Control

Fig. 51

14. Once the pressure has been set turn the boiler off

and disconnect the pressure gauge.

15. Tighten the pressure test screw and refit the

modulator to the valve. Reassemble in reverse order.

12.0 Completion

12.1

Completion

Case Front Panel

1. Refit the case front panel and 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

Benchmark Commissioning Checklist at the rear of this

publication that are relevant to the appliance and

installation. These details will be required in the event of

any warranty work. The publication 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”. This is in addition to the Benchmark

Commissioning Checklist.

5. Hand over the Users Operating, Installation and

Servicing Instructions, giving advice on the necessity of

regular servicing.

Facia Panel

Fig. 52

13.0 Servicing the Boiler

Case Front Panel

13 .1 Annual Servicing

1. For reasons of safety and economy, it is

recommended that the boiler is serviced annually.

Servicing must be performed by a competent person.

2. After servicing, complete the relevant Service Interval

Record section of the Benchmark Commissioning

Checklist at the rear of this publication.

3. Ensure that the boiler is cool.

4. Ensure that both the gas and electrical supplies to

the boiler are isolated.

5. Slacken the screws securing the facia panel. Lift the

outercase panel so that its securing tabs are clear of the

facia. Remove the panel (Fig. 53).

Fig. 53

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. 54).

Facia Panel Securing

Screws

7. Note the positions of the three wires on the fan

motor and remove them. Remove the sensing tube

from the fan spigot (Fig. 55).

Fan Wires

Fan

8. Slacken the screws on the fan spigot outlet pipe

clamp. Ease the clamp to the left over the pipe.

9. Remove the four screws securing the combustion

box door and remove the door (Fig. 54).

Sensing

Tube

Ease Outlet Pipe Clamp

To The Left

Fig. 55

Combustion

Box Door

Fig. 54

Inner Door

Panel

Baffle

Tab

Spring Clip

13.0

Servicing the Boiler

13.1

Annual Servicing (Cont)

10. Ease the front edge of the left hand baffle upwards,

disengaging the spring clip. Disengage the tab on the

baffle from the slot in the fan hood (Fig. 56).

11. Undo the screws securing the fan and hood to the

appliance back panel. Draw the assembly forwards

(Fig. 57).

Fig. 56

12. Undo the screws securing the burner to the injector

manifold. Draw the burner out of the combustion box,

pulling the electrode grommets from the slots in the

combustion box lower panel (Fig. 58).

Fan and Hood

Assembly

Fig. 57

13. Disconnect the electrode leads and grommets from

the electrodes. Completely remove the burner (Fig. 58).

14. Brush any deposits from the injectors. Do not use a

pin or wire to clean them.

15. Brush the burner blades and venturis and clean the

combustion box.

16. Ensure that the heat exchanger fins are clear of any

obstruction.

Electrode

Grommets

NOTE: If necessary the secondary heat exchanger

may be dismantled - see section 14.24.

DHW Filters (Fig. 60)

17. If the flow of domestic hot water is diminished, it

may be necessary to clean the filters.

18. Initially check the cold water inlet tap filter.

Fig. 58

Threaded

Bush

19. Turn the tap off. Undo the blanking cap and remove

the thread bush (Fig. 59).

Fig. 59

Burner

20. Extract the filter and rinse thoroughly in clean water.

Reassemble and check the flow. If required clean the

manifold filter as described below.

Cartridge

Body

21. Undo the filter cartridge from the inlet/return

manifold.

Filter Gauze

22. Dismantle the cartridge and carefully remove the

flow regulator and filter gauze. Rinse them thoroughly in

clean water and reassemble in reverse order.

Blanking Cap

Cold Water

Inlet Tap

23. Check that the pressure vessel charge is 0.5bar and

reassemble in reverse order of dismantling and

recommission.

Flow

Regulator

Venturi

24. Turn the selector switch fully anticlockwise against

the spring pressure to the reset position and hold for 2

seconds to reset the boiler.

Fig. 60

25. 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

user.

Inlet/Return Manifold

14.0 Changing Components

IMPORTANT: When changing components ensure

that both the gas and electrical supplies to the

boiler are isolated before any work is started.

When the new component has been fitted turn the

selector switch fully anticlockwise against the spring

pressure to the ‘Reset’ position and hold for 2

seconds to reset the boiler before recommissioning.

Pressure

Switch

Sensing

Tubes

See Section 13.1 “Annual Servicing” for removal of case

panel, door etc.

14.1

Fan (Figs. 62 & 63)

Fig. 61

1. Note the positions of the sensing tube on the outlet

elbow and three wires on the fan motor and remove

them.

Pressure

Switch Wires

2. Slacken the screw on the fan spigot outlet pipe clamp.

Ease the clamp to the left over the pipe.

3. Remove the four screws securing the combustion box

door and remove the door.

Fan Wires

Fan

4. Ease the front edge of the left hand baffle upwards,

disengaging the spring clip. Disengage the tab on the

baffle from the slot in the fan hood.

5. Undo the screws securing the fan hood to the

appliance back panel, and draw the fan and hood

assembly forwards.

Sensing

Tube

6. Remove the screws and spring washers securing the

fan to the hood, and the screw securing the outlet pipe.

Ease Outlet Pipe Clamp

To The Left

7. Transfer the outlet pipe and clamp to the new fan.

8. Fit the new fan to the hood using the screws and

spring washers previously removed.

Fig. 62

9. Reassemble in reverse order of dismantling.

14.2

Pressure Switch (Fig. 61)

Fan Spigot

Outlet Pipe

1. Remove the fan and hood assembly as described in

section 14.1.

2. Note the positions of the two sensing tubes and

wires and remove them.

Baffle

Tab

Spring Clip

3. Remove the two screws holding the pressure switch

to the bracket on the combustion box top panel.

Fan

4. Fit the new pressure switch and reassemble all

components in reverse order of dismantling.

Fan Hood

Fig. 63

Spring Washer

Securing Screw

14.0 Changing Components

14.3

Heat Exchanger (Fig. 64)

1. Remove the fan as described in section 14.1.

2. Drain the primary circuit. Prise the three pipe

connecting clips off the joints in the flow and return

pipes. Remove the heat exchanger return pipe.

3. Lift the heat exchanger to disconnect the flow pipe

joint. Withdraw it from the appliance, taking care not to

damage the rear insulation piece.

Pipe Connecting

Clips

Heat Exchanger

Return Pipe

4. Fit the new heat exchanger.

5. Reassemble in reverse order of dismantling, and

repressurise the system.

14.4

Burner (Fig. 65)

1. Remove the four screws securing the combustion box

door and remove the door.

Flow Pipe

2. Undo the screws securing the burner to the injector

manifold. Draw the burner out of the combustion box,

pulling the electrode grommets from the slots in the

combustion box lower panel.

Fig. 64

Heat Exchanger

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 condition of the electrodes,

replacing if necessary. Fit the electrodes to the new

burner.

5. Engage the burner location brackets over the studs on

the injector manifold and reassemble in reverse order.

Burner

Electrodes

Electrode

Grommets

Fig. 65

Electrode

Leads

14.0 Changing Components

Injector

Manifold

Inlet Elbow

14.5

Injectors (Fig. 66)

1. Remove the burner as described in Section 14.4.

2. Undo the screws securing the injector manifold to

the inlet elbow and remove the manifold.

Gasket

3. Unscrew and replace injectors as required and

examine the sealing gasket, replacing as necessary.

Reassemble in reverse order.

Injector

14.6

Electrodes (Fig. 66)

Burner

Electrodes

1. Remove the four screws securing the combustion

box door and remove the door.

Fig. 66

Electrode

Grommets

2. Undo the screws securing the burner to the

injector manifold. Draw the burner out of the

combustion box, pulling the electrode grommets from

the slots in the combustion box lower panel.

Electrode

Leads

3. Disconnect 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.

14.7

Insulation (Fig. 67)

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 described in Section

14.3 and slide out the side pieces.

Side Insulation

4. The combustion box door insulation piece can be

replaced by carefully bending up the two retaining

tabs.

Rear Insulation

5. Replace all insulation pieces and reassemble in

reverse order.

13.8

Side Insulation

Combustion Box

Door

Front Insulation

Fig. 67

14.0 Changing Components

14.8

Gas Valve (Fig. 68)

1. Undo the nut on the gas feed pipe under the boiler.

Modulator

Wires

2. Completely undo the securing screws and hinge the

facia panel down.

Ignition

Lead

Gas Valve

3. Disconnect the wires from the valve modulator and

the ignition lead from the spark generator. Disconnect

the pressure sensing pipe from the valve. Undo the

screw securing the spark generator electrical plug to the

valve and disconnect the plug.

4. Pull the earth wire off the spade terminal on the valve.

5. Remove the screws securing the inlet pipe flange to

the boiler bottom panel and those securing the outlet

manifold to the burner manifold.

Electrical Plug

6. Remove the valve from the boiler.

Earth Wire

Inlet Pipe

7. Note the orientation of the inlet pipe and outlet

manifold. Undo the securing screws and remove the

pipe and manifold.

Gas Feed

Pipe

8. Examine the ‘O’ ring seals for damage, replacing as

necessary.

Fig. 68

9. Fit the inlet pipe and outlet manifold to the new valve,

ensuring that the ‘O’ ring seals are in place.

10. Reassemble in reverse order and check the burner

pressure (Section 11.2).

Flow Pipe

14.9

Temperature Sensor (Fig. 69)

1. Ease the retaining tab on the sensor away and

disconnect the electrical plug.

Safety Thermostat

2. Unscrew the sensor from it’s pocket and reassemble

in reverse order. The plug will only fit one way.

14.10 Safety Thermostat (Fig. 69)

1. Pull the electrical connections off the thermostat.

2. Remove the screws securing the thermostat to the

mounting plate on the flow pipe.

Temperature

Sensor

3. Reassemble in reverse order. The thermostat is not

polarised - either wire can fit either terminal on the

thermostat.

Fig. 69

14.0 Changing Components

14.11 Pump - Head Only (Fig. 71)

1. Drain the primary circuit and remove the socket

head screws securing the pump head to the body and

draw the head away.

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. A standard Grundfos 15-60 replacement head can

now be fitted. Connect the wiring to the new head.

The pump speed must be set to 3 (Fig. 72).

4. Reassemble in reverse order.

14.12 Pump - Complete (Fig. 73)

1. Drain the primary circuit and unscrew the automatic

air vent from the pump body. Undo the two screws

securing the body to the pipe and manifold and draw

the pump forwards.

Pump Wiring

Cover

Pump Body

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.

Socket Headed

Screw

3. Connect the wiring to the new pump. Examine the

‘O’ ring seals on the return pipe and manifold, replacing

if necessary.

Pump Head

4. Fit the air vent to the pump body and reassemble in

reverse order.

Fig. 71

14.13 Automatic Air Vent (Fig. 73)

1. Drain the primary circuit and unscrew the automatic

air vent from the pump body.

Pump Setting

Automatic Air

Vent

2. Examine the ‘O’ ring seal, replacing if necessary, and

fit it to the new automatic air vent.

Fig. 72

3. Reassemble in reverse order.

Pump Wiring

Cover

Fig. 73

14.0 Changing Components

14.14 Pressure Gauge (Figs. 74 & 75)

1. Drain the primary circuit and undo the nut on the

pressure gauge capillary.

2. Remove the timer cover and ease the timer wiring

aside. Undo the screws securing the gauge retaining

bracket.

Fig. 74

Pressure Gauge

Capillary

3. Remove the bracket and gauge assembly. Depress

the barbs on the side of the gauge and remove the

retaining bracket.

Gauge Retaining

Bracket

4. Reassemble in reverse order.

14.15 Expansion Vessel (Fig. 76)

Timer Cover

1. To replace the expansion vessel it is necessary to

remove the boiler from the wall.

Pressure Gauge

Fig. 75

Note: Alternatively a vessel of equivalent

capacity can be fitted on the system return

pipe as close as possible to the boiler.

Expansion Vessel

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

remove the locknut and spring washer securing the

spigot to the boiler chassis.

Retaining Clip

5. Undo the screws and remove the appliance upper

cross member. Slide the expansion vessel out of the

retaining clips.

Vessel Outlet Spigot

Boiler Chassis

Lock Nut

6. Reassemble in reverse order. Fully recommission

the appliance and system.

Spring

Washer

14.16 Condensate Trap (Fig. 77)

Fig. 76

1. Disconnect the two sensing wires from the trap

connections.

Inlet Pipe

Sensing Wires

2. Squeeze together the wire spring clip to release and

ease the inlet pipe from the trap spigot.

Wire Spring

Clip

3. Undo the nut securing the condensate drain pipe to

the trap. Disconnect the pipe and sealing washer.

Condensate

Trap

4. From underneath the boiler remove the screws

securing the trap bracket.

Bracket

5. Remove the trap and bracket from the boiler. Undo

the locknut securing the trap to the bracket.

Fig. 77

Condensate

Drain Pipe

6. Reassemble in reverse order.

14.0 Changing Components

14.17 Pressure Relief Valve (Fig. 78)

1. Drain the primary circuit.

2. Disconnect the discharge pipe from the valve. Using a

suitable hexagon key undo the grub screw sufficiently to

release the valve.

3. Note the orientation of the valve, rotate it and

withdraw it from the manifold.

4. Fit the new valve and ‘O’ ring seal and set to the

previously noted orientation. Reassemble in reverse

order.

‘O’ ring seal

14.18 P.C.B. (Fig. 80)

1. Note the settings of the temperature control knobs.

Rotate the knobs fully anticlockwise and carefully pull

them off the drive pins.

Grub Screw

Pressure Relief Valve

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 the control

box hinge pin (Fig. 79).

Fig. 78

Discharge Pipe

3. Note the position of all plugs and wires on the P.C.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.

Control Box Cover

P.C.B.

Fig. 79

14.19 Selector Switch (Fig. 80)

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 the control

box hinge pin (Fig. 79).

Selector

Switch

Drive Pins

3. Note the position of the electrical connections and

the orientation of the switch. Remove the electrical

connections.

4. Remove the screws securing the switch to the facia

panel.

5. Fit the new switch, ensuring that it is correctly

positioned and reassemble in reverse order.

Facia

Fig. 80

Selector Switch Knob

Temperature Control Knobs

14.0 Changing Components

Plate Heat Exchanger

14.20 Plate Heat Exchanger (Fig. 67)

1. Drain the primary circuit.

2. While supporting the heat exchanger undo the

screws securing it to the brass manifolds.

3. Withdraw the heat exchanger upwards and to the

left of the gas valve, taking care not to damage any

wires or controls.

Rubber Seal

Seals

4. There are four rubber seals between the manifolds

and heat exchanger which may need replacement.

Fig. 81

5. Ease the seals out of the manifold. Replace carefully,

ensuring that the seal is inserted into the manifold

parallel and pushed fully in.

6. When fitting the new heat exchanger note that the

left hand location stud is offset towards the centre

more than the right hand one.

7. Reassemble in reverse order.

14.21 Diverter Valve Assembly

(Figs. 82 & 83)

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.

Sensing Pipes

Diverter Manifold

DHW Pressure Differential Valve (Fig. 83)

1. Drain the primary circuit.

Microswitch

Bracket

2. Undo the screw securing the microswitch bracket to

the valve (Fig. 82).

Grub Screws

3. Disconnect the two sensing pipes and slacken the

grub screws securing the valve to the diverter manifold.

DHW Pressure

Differential Valve

Fig. 82

4. Draw the valve away from the diverter manifold. The

valve may now be replaced or split to examine the

diaphragm.

Diaphragm

5. To examine the diaphragm hold the valve body

securely and carefully remove the six screws. The

diaphragm spring will force apart the two halves of the

valve.

Diaphragm

Spring

6. Remove the plastic disc and pushrod assembly.

Carefully examine the diaphragm and replace it if there

is any damage.

Plastic Disc

Pushrod

7. Reassemble in reverse order.

Fig. 83

14.0 Changing Components

Central Heating Pressure

Differential Valve

Microswitch / Bracket

14.21 Diverter Valve Assembly (Cont)

Sensing Pipe

Pressure Differential Valve (Fig. 84)

1. Remove the pressure differential valve as described

above.

By-pass Pipe

Diaphragm

2. From the brass diverter manifold undo the nut on

the heating flow pipe. Remove the screw securing the

diverter manifold to the appliance lower bracket.

Spring Clip

3. Disconnect the pressure gauge capillary from the

diverter manifold and remove the two wires from the

microswitch.

Heating Flow

Pipe

4. Prise off the spring clip securing the by-pass pipe to

the diverter manifold and disconnect the sensing pipe.

Diverter Manifold

5. Ease the diverter manifold out of the plate heat

exchanger manifold. Remove the assembly from the

appliance.

Fig. 84

Pressure Gauge

Capillary

6. Undo the screw securing the microswitch bracket

to the valve body. The sensor may now be dismantled

to examine the diaphragm.

7. To examine the diaphragm hold the assembly

securely and carefully remove the four screws. The

diaphragm spring will force the two halves of the valve

apart.

8. Carefully examine the diaphragm and replace it if

there is any damage.

9. Reassemble in reverse order.

CH Pressure Microswitch (Fig. 84)

1. Remove the two wires from the Pressure

microswitch.

2. Undo the screw securing the microswitch bracket

to the valve body.

3. Reassemble in reverse order.

Cartridge

Body

14.22 Flow Regulator (Figs. 85 & 86)

Filter Gauze

1. Undo the filter cartridge from the inlet/return

manifold.

Fig. 85

2. Unscrew the venturi and remove the flow regulator.

Flow

Regulator

Fig. 86

3. Check the cleanliness of the filter gauze, rinsing

thoroughly in clean water as necessary. Fit the new

flow regulator and reassemble in reverse order.

Venturi

Inlet/Return Manifold

14.0

Changing Components

Secondary

Heat Exchanger

14.23 Secondary Heat Exchanger (Fig. 87)

1. Drain the primary circuit

Pipe Connecting Clip

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

pipes.

Outer Drum

4. Remove the fan and hood assembly as described in

Section 14.1

Boiler Return Pipe

5. Remove the nut securing the elbow to the secondary

heat exchanger. Draw the elbow and outlet pipe

forwards.

Heat Exchanger

Return Pipe

Elbow

Fig. 87

6. Remove the secondary heat exchanger from the

outer drum by easing it forward.

7. Reassemble in reverse order of dismantling.

14.24 Flue Overheat Thermostat (Fig. 88)

NOTE: The flue overheat thermostat includes a

reset button. Check that the thermostat will not

reset before replacing.

1. Remove the fan and hood assembly as described in

Section 14.1

2. Pull the two wires off the terminals on the flue

overheat thermostat. Unscrew the thermostat from the

adaptor in the outlet elbow.

3. Reassemble in reverse order of dismantling.

Fig. 88

Overheat Thermostat

15.0 Illustrated Wiring Diagram

Pump

Mains Input

Link

g/y

On/Off/Reset

Selector Switch

Fuse

Temperature Sensor

g/y

Hydraulic Differential

Pressure Switch

Flue Thermostat

Optional Timers

Gas Valve

Control PCB

Safety Thermostat

Air Pressure

Switch

3-Way Valve

Microswitch

g/y

FA2

Fan

g/y

Flame

Sensing

Electrode

Condensate

Trap

br - brown

bk - black

- blue

- red

- yellow

g/y - green / yellow

w - white

gr - grey

16.0 Fault Finding

Carry out initial fault finding checks

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).

2. Carry out electrical system checks, i.e. Ground Continuity, Resistance to Ground, Short Circuit and Polarity with a suitable meter.

NOTE: These checks must be repeated after any servicing or fault finding.

3. Ensure all external controls are calling for heat and check all external and internal fuses. Before any servicing or replacement of parts

ensure the gas and electrical supplies are isolated.

Refer to Section 13.1 “Illustrated Wiring Diagram” for position of numbered terminals

Central Heating - Follow operational sequence

NOTE: When instructed to turn the Selector to

Turn selector to

neon illuminated

the reset position turn the Selector Switch fully

anticlockwise against the spring pressure and hold

for 2 seconds to reset the boiler.

Go to section ‘A’

YES

Go to section ‘B’

YES

Turn

thermostat

to max.

Pump runs

External controls and, where

fitted, integral timer calling for

heat

Ensure controls are set to

demand and verify the

contacts are closed

YES

Primary flow switch operated

YES

Go to section ‘C’

Turn the selector switch to

the ‘Reset’ position and hold

for at least 2 seconds. If

regular resetting is required,

or appliance still does not

operate, investigation is

necessary

Go to sections ‘J’, ‘L’ & ‘D’

Fan runs at max speed

YES

Air pressure

switch proved

Go to section ‘E’

YES

Spark at ignition electrodes

for up to 10 seconds

Turn selector to the reset

position. If the light does not

extinguish go to sections

H & K

illuminated

YES

Replace PCB

YES

Burner on

neon

Go to section ‘F’

Go to section ‘I’

illuminated

YES

Burner extinguishes

after 10 seconds

Burner output

modulates until set

temperature is reached

YES

Go to section ‘G’

Fan stops

YES

Operation sequence correct

Burner goes out

Pump stops

16.0 Fault Finding

Domestic Hot Water - Follow operational sequence

Turn selector to

neon illuminated

Replace diaphragm

Go to section ‘A’

YES

Is mains water

filter and differential

assembly clean?

YES

DHW flow valve diaphragm

damaged

YES

Turn

thermostat to max.

DHW flow rate more than

2.5l/min.

DHW flow valve rod

obstructed

Open DHW tap fully. DHW

flow switch operated

YES

Replace DHW flow

microswitch

Continuity across DHW flow

microswitch terminals and

PCB - M1 connector

terminals 13 & 14 (terminals

12-14 open)

Primary water is diverted

from CH system to DHW

heat exchanger and flow

microswitch operated

Replace PCB

YES

Pump runs

YES

Go to section ‘B’

Go to section ‘C’

Primary flow switch operated

YES

Turn the selector switch to

the ‘Reset’ position and hold

for at least 2 seconds. If

regular resetting is required,

or appliance still does not

operate investigation is

necessary

Go to section ‘J’, ‘L’ & ‘D’

Fan runs at max speed

YES

Go to section ‘E’

Air pressure switch proved

YES

Turn the selector to the reset

position. If the light does not

extinguish go to section

H & K

YES

neon illuminated

Spark at ignition electrodes

for up to 10 seconds

YES

Replace PCB

YES

Burner on

neon

Go to section ‘F’

Go to section ‘I’

illuminated

YES

Burner extinguishes

after 10 seconds

Reduce the DHW flow rate.

If burner does not modulate

clean temperature sensor and

DHW heat exchanger. If

modulation does not occur

go to section ‘G’

Burner output modulates to

maintain temperature set at

thermostat

YES

Close DHW tap

YES

DHW flow valve

senses no flow.

Primary water diverted to

CH system. DHW flow

switch released off

Diverter valve spindle

assembly faulty

YES

Operation sequence correct

Burner goes out

Fan stops

Pump stops

Fault Finding Solutions Sections A to F

16.0 Fault Finding

Is there 230V at:

Main terminals L and N

Main terminal fuse

Check electrical supply

Replace fuse

YES

neon

illuminated

Replace PCB

Selector terminals a & b and a

& 3. PCB - M1 connector

terminals 9 & 10

Check wiring

Replace selector

Is there 230V at:

Pump

If pump jammed, release

Replace pump

Replace PCB

PCB - M1 connector terminals 8 & 15

YES

Change pump supply cable

CH system pressure 0.5 to 1.5 bar

Re-pressurise system

Check the tap of the automatic air

vent is opened

Open the automatic air vent

YES

Primary flow valve diaphragm damaged

Replace diaphragm

Flow valve rod obstructed

Continuity across flow

Replace microswitch

Replace sensor

microswitch and PCB M2

connector terminals 3 & 4

Primary temperature sensor faulty.

Cold resistance approx. 11K ohms

(resistance reduces with increase in temp.)

YES

Fan connections correct at fan.

YES

PCB - M5 connector, is 230V

Fan jammed or faulty winding

Replace PCB

Replace fan

across terminals 28 & 29

Check and correct if necessary

1. Electrical and pressure tube connections

2. Blockage of pressure tubes

3. Restriction in flue

Replace air pressure

switch

4. Venturi

Gas at burner

Ensure gas is on and purged

YES

PCB - M4 connector is approx 230V AC, terminals

36 & 38

Replace gas valve

YES

Turn selector switch to

‘Reset’ position

neon illuminated

Replace PCB

Fault Finding Solutions Sections G to L

16.0 Fault Finding

Check the burner setting pressure of the

gas valve

(see Section 11.2 of Commissioning)

Voltage at modulating coil of gas valve is:

Max. burner press.approx 9V DC (13V DC LPG)

Min. burner press.approx 1V DC

YES

Replace gas valve

Replace PCB

Current at modulating coil of gas valve is:

(Use an instrument with average function for this

measure)

30 ÷ 230 mA DC (45 ÷ 310 mA DC LPG)

Check and correct if necessary

1. Ignition electrode and lead

2. Electrode connection

Replace PCB

230V at Main PCB - M4

connector across terminals

37 & 38. Check wiring

YES

Replace gas valve

electrical plug/igniter

assy

3. Spark gap and position

Ensure that mains input terminal L

is Live (230V) and N is Neutral

(0V)

YES

Check and correct if necessary

1. Flame sensing electrode and lead connections

2. Electrode position

YES

Replace PCB

Flame current should be 1 μA approx.

Replace flame sensing electrode

Boiler overheat thermostat operated

Allow to cool. Continuity across

thermostat terminals more than

1.5 ohm

YES

Replace boiler overheat

thermostat

or faulty, i.e. continuity across

thermostat terminals

YES

Replace PCB

Check terminal 1 of ON/OFF/RESET selector is in connection

with PCB - M1 connector terminal 16

Check electrical continuity across terminals 1 & a of

ON/OFF/RESET selector when turned to ‘Reset’ position

Replace ON/OFF/RESET selector

YES

Replace PCB

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. If the

flue overheat thermostat has not been activated see section ‘D’

17.0 Fault Indication Display

17.0

Fault Indication Display

1. The boiler has three neon indicators. The upper two

function as boiler on and fault indicators.

2. Depending on the nature of the fault the upper two neons

will illuminate, go off or flash.

Burner On

Flame Failure

Power On

Off

Fast Flashing (2 every second)

3. There are five possible combinations, each indicating one

or more fault conditions. These are described below.

The flue or flue terminal is blocked or obstructed in some

way, or there is an internal fault.

Burner On

Flame Failure

Power On

Off

Slow Flashing (1 every 2 seconds)

The circulating pump is faulty or the system pressure has

dropped. Check the system pressure. If the pressure is in the

normal range a pump fault is indicated.

A fault on the boiler temperature sensor is indicated.

The primary system or the boiler has overheated. Allow the

boiler to cool. Turn the selector switch fully anti-clockwise

against the spring pressure to the ‘Reset’ position and hold for

at least 2 seconds.

Burner On

Flame Failure

Power On

Slow Flashing (1 every 2 seconds)

If the boiler does not relight after resetting it is possible that

the flue has overheated.

The burner has failed to light, or incomplete lighting of the

burner has occurred. Turn the selector switch fully anti-

clockwise against the spring pressure to the ‘Reset’ position

and hold for at least 2 seconds.

Burner On

Flame Failure

Power On

Slow Flashing (1 every 2 seconds)

If the boiler does not relight after resetting blockage of the

condensate drain or trap has occurred.

Burner On

Flame Failure

Power On

Off

18.0 Short Parts List

Short Parts List

Key

No.

G.C.

No.

Description

Manufacturers

Part No.

140

Fan

5112627

5112999

5112431

5112770

248210

Pressure Switch

Heat Exchanger

Burner

131

135

E66 402

E66 408

E66 411

Injector - 1.18 NG

Electrode Lead

248037

Spark or Sensing

Electrode

247384

248042

Pump

101

102

103

131

135

140

154

169

371

E66 432

E66 434

343 619

Hydraulic Outlet Assy. 248061

154

Valve - 3 Way Assy.

248062

Pressure Differential Assy.248063

Temperature Sensor

5108265

E66 697

Safety Limit Thermostat 248078

Gas Valve

PCB

5107339

5112657

248090

E66 453

Pressure Gauge

Igniter/Gas Valve Cable 5112385

101

Flue Overheat

Thermostat

5112395

102

103

371

169

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating

compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

Customer Name

Address

Telephone Number

Boiler Make and Model

Boiler Serial Number

Commissioned by (print name)

Company Name

CORGI ID Number

Telephone Number

Company Address

Commissioning Date

To be completed by the customer on receipt of a Building Regulations Compliance Certiﬁcate :

Building Regulations Notiﬁcation Number (if applicable)

CONTROLS Tick the appropriate boxes

Time and Temperature Control to Heating

Room Thermostat and

Programmer/Timer

Programmable

Room Thermostat

Load/Weather

Compensation

Optimum Start

Control

Time and Temperature Control to Hot Water

Heating Zone Valves

Cylinder Thermostat and Programmer/Timer

Combination Boiler

Not Required

Provided

Fitted

Hot Water Zone Valves

Thermostatic Radiator Valves

Automatic Bypass to System

Boiler Interlock

ALL SYSTEMS

The system has been ﬂushed and cleaned in accordance with BS7593 and boiler manufacturer’s instructions

Yes

What system cleaner was used?

What inhibitor was used?

Quantity

litres

ft³/hr

CENTRAL HEATING MODE Measure and Record:

m³/hr

mbar

Gas Rate

Burner Operating Pressure (if applicable)

Central Heating Flow Temperature

Central Heating Return Temperature

Gas Inlet Pressure

mbar

°C

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)?

If yes, has a water scale reducer been ﬁtted?

What type of scale reducer has been ﬁtted?

DOMESTIC HOT WATER MODE Measure and Record:

Gas Rate

Yes

ft³/hr

m³/hr OR

mbar OR

Burner Operating Pressure (at maximum rate)

Cold Water Inlet Temperature

Gas Inlet Pressure (at maximum rate)

mbar

°C

Hot water has been checked at all outlets

Water Flow Rate

Yes

Temperature

°C

l/min

CONDENSING BOILERS ONLY

The condensate drain has been installed in accordance with the manufacturer’s instructions and/or BS5546/BS6798

Yes

ALL INSTALLATIONS

If required by the manufacturer, record the following

CO₂

OR CO

ppm OR CO/CO₂Ratio

The heating and hot water system complies with the appropriate Building Regulations

Yes

The boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instructions

The operation of the boiler and system controls have been demonstrated to and understood by the customer

The manufacturer’s literature, including Benchmark Checklist and Service Record, has been explained and left with the customer

Commissioning Engineer’s Signature

Customer’s Signature

(To conﬁrm satisfactory demonstration and receipt of manufacturer’s literature)

All installations in England and Wales must be notiﬁed to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme.

A Building Regulations Compliance Certiﬁcate will then be issued to the customer.

www.centralheating.co.uk

SERVICE RECORD

It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed.

Service Provider

Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s

instructions.

Always use the manufacturer’s speciﬁed spare part when replacing controls.

SERVICE 1 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 2 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Yes

Company Name

Telephone Number

CORGI ID Number

Comments

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 3 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 4 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 5 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 6 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 7 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 8 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Telephone Number

CORGI ID Number

Comments

Signature

SERVICE 9 Date

Energy Efﬁciency Checklist completed?

Engineer Name

SERVICE 10 Date

Energy Efﬁciency Checklist completed?

Engineer Name

Company Name

Telephone Number

CORGI ID Number

Comments

Telephone Number

CORGI ID Number

Comments

Signature

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.

POTTERTON

A Trading Division of Baxi Heating UK Ltd (3879156)

A Division of Baxi Group

Brooks House, Coventry Road, Warwick. CV34 4LL

After Sales Service 08706 017 017 Technical Enquiries 08706 049 049

Website www.potterton.co.uk

e&oe

Comp N 5111811 - Iss 6 - 3/09

Alpine Electronics Car Video System IVE W535HD User Manual
Audiovox Jensen Phase Linear UMP400 User Manual
Audiovox VBP500 User Manual
Cuisinart BFM 1000 User Manual
Custom Brackets Two Way System Horizontal Configuration CSC2264H User Manual
Eizo CG223W User Manual
Focal Polyglass 100 CVX User Manual
Hitachi LL 401 User Manual
HP (Hewlett Packard) HP 19 INch LCD Monitor LP1965 User Manual
JVC GR DVL355 User Manual