Baxi Potterton 30 HE manual

© Baxi Heating UK Ltd 2007 Installation & Ser vice Instructions P erforma 30 HE These instructions include the Benchmark Commissioning Checklist and should be left with the user for saf e k eeping.[...]

2 © Baxi Heating UK Ltd 2007 Natural Gas Potterton Performa 30 HE G.C.N o 47 393 13 Building Regulations and the Benchmark Commissioning Checklist Building Regulations (England & Wales) require notification of the installation of a heating appliance to the relevant Local Authority Building Control Department. From 1 April 2005 this can be achi[...]

Installer Notification Guidelines 3 © Baxi Heating UK Ltd 2007 Choose Building Regulations Notification Route Contact your rele vant Local A uthority Building Control (LABC) who will arrange an inspection or contact a gov er nment approv ed inspector LABC will record the data and will issue a cer tificate of compliance CORGI will record the data a[...]

Legislation 4 © Baxi Heating UK Ltd 2007 Codes of Practice, most recent version should be used This company declare that no substances harmful to health are contained in the appliance or used during appliance manufacture. The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force, and[...]

Safe Manual Handling 5 © Baxi Heating UK Ltd 2007 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 shou[...]

1.1 Description 1. The Potterton Performa 30 HE is a fully automatic gas fired wall mounted condensing combination boiler. It is room sealed and fan assisted, and will serve central heating and mains fed domestic hot water. 2. The boiler is set to give a maximum output of 31.0 kW (condensing). 3. It is designed for use on Natural Gas (G20) and can [...]

2.0 General La yout 7 © Baxi Heating UK Ltd 2007 2.1 Layout 1. Air Pressure Switch 2. Expansion Vessel 3. Burner Manifold 4. Automatic Air Vent 5. DHW Plate Heat Exchanger 6. Circulation Pump 7. Drain Off Point 8. Pressure Relief Valve 9. Optional Integral Timer 10. Central Heating System Pressure Gauge 11. PCB 12. Control Box 13. 3-Way Valve Asse[...]

3.0 Appliance Operation 8 © Baxi Heating UK Ltd 2007 NOTE: All delay timers mentioned in 3.1 and 3.2 are overridden by domestic hot water demand. 3.1 Central Heating Mode (Fig. 2) 1. With a demand for heating, the pump circulates water through the primary circuit. At a pre-determined flow rate the central heating flow switch operates, initiating t[...]

4.0 T echnical Data 9 © Baxi Heating UK Ltd 2007 4.1 Performa 30 HE Flue Terminal Diameter 100mm Dimensions Projection 125mm Outercase Dimensions Casing Height - 780mm Overall Height Inc Flue Elbow - 965mm Casing Width - 450mm Casing Depth - 345mm Clearances Above Casing 200 mm Min Below Casing 200 mm Min Front 450 mm Min (For Servicing) Front 5 m[...]

5.0 Dimensions and Fixings 10 © Baxi Heating UK Ltd 2007 Dimensions A 780mm B 345mm C 450mm D 116mm Ø Min. E 185mm F 190mm G 131mm 360° Orientation Tube Ø 100mm D C B A E G F Domestic Hot W ater Outlet (15mm) Cold W ater Inlet (15mm) Heating Return (22mm) Heating Flow (22mm) Pressur e Relief Va l v e (15mm) Gas Inlet (22mm) 65 mm 65 mm 65 mm 65[...]

6.0 System Details 11 © Baxi Heating UK Ltd 2007 6.1 Information 1. The Baxi Combi 105 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 [...]

6.0 System Details 12 © Baxi Heating UK Ltd 2007 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. 2. There are connection points on the mains cold water inlet and central [...]

6.0 System Details 13 © Baxi Heating UK Ltd 2007 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. 2. Your attention is drawn to: for GB: Guidance G17 to G24 and recommendation R17 to R24 of the Water Regulations Guide. for IE[...]

7.0 Site Requirements 14 © Baxi Heating UK Ltd 2007 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 build[...]

7.0 Site Requirements 15 © Baxi Heating UK Ltd 2007 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. Th[...]

7.0 Site Requirements 16 © Baxi Heating UK Ltd 2007 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 cond[...]

7.0 Site Requirements 17 © Baxi Heating UK Ltd 2007 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. 1. The following guidelines indicate the general requirements for siting balanced flue terminals. For GB recommendations are gi[...]

8.0 Flue Options 18 © Baxi Heating UK Ltd 2007 8.1 Horizontal Flue Systems 1. The Potterton Performa 30 HE can be fitted with either horizontal, vertical or twin flue systems as illustrated. 2. The standard flue is suitable only for horizontal applications. 3. Maximum permissible equivalent flue lengths are:- Horizontal Concentric 3m Vertical Conc[...]

8.0 Flue Options 19 © Baxi Heating UK Ltd 2007 Vertical Flues (Twin Pipe) Y X Vertical Flues Y X The total equivalent length for this example is = 6.5 metres. 1m extension 45°bend 91.5°bend 1m 0.25m 0.5m 5 2 2 5.0m 0.5m 1.0m AIR DUCT N o of fittings/pipes Sub total Equivalent Length Value Equivalent Length Air Duct = 6.5m 1m extension 45°bend 9[...]

8.0 Flue Options 20 © Baxi Heating UK Ltd 2007 Key Accessory Size Baxi Code No Concentric Flue System 100mm diameter A1 Horizontal flue Terminal 5111073 A Horizontal flue Terminal (incl elbow) 5118489 B Flue extension 1000mm 5111074 C Flue Bend 93° 5111075 D Flue Bend (pair) 135° 5111085 U Pipe support 100mm 5111080 R Vertical flue adaptor 51110[...]

21 © Baxi Heating UK Ltd 2007 8.0 Flue Options Inner Sleeve For Twin Flue Systems fit the adaptors as follows:- 8.4 Flue Duct Adaptor 1. Insert the inner sleeve into the flue duct outlet of the boiler flue adaptor. Engage the outer sleeve in the boiler flue adaptor. Ensure that it is pushed fully in. Take the air duct blank and fit into the outer [...]

8.0 Flue Options 22 © Baxi Heating UK Ltd 2007 Fig. 13 Fig. 14 100mm 685mm Push Fit Adaptor Air Duct Flue Duct Cut the same amount off the Air Duct & Flue Duct Approx 1425mm 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 su[...]

9.0 Plume Displacement 23 © Baxi Heating UK Ltd 2007 9.1 Plume Displacement Kit (Fig. 14b) Kit No 5117379, or 5118638 (incl. boiler elbow) Content of kit 1 0.9m 60/100 Concentric Flue 1 1m 60 Dia Exhaust Flue Pipe 1 Adaptor 2 60 Dia Support Brackets 1 93° Elbow/Plume Outlet Assembly 1 Flexible Flue Trim 3 “O” Rings 1 ‘Jubilee Clip 1 Boiler [...]

9.0 Plume Displacement 24 © Baxi Heating UK Ltd 2007 Concentric 60/100 Flue 60Ø Exhaust X Y Fig. 17 2 0 1 60 Ø Exhaust (metres) Concentric 60/100 Flue (metres) 0 2 1 30HE Fig. 18 2 0 1 60 Ø Exhaust (metres) Concentric 60/100 Flue (metres) 0 2 1 30HE 2 0 1 60 Ø Exhaust (metres) Concentric 60/100 Flue (metres) 0 2 1 30HE Flue Length - Worked Exa[...]

9.0 Plume Displacement 25 © Baxi Heating UK Ltd 2007 Min. 2 metres Fig. 19 Flue Trim Position of ‘Jubilee’ Clip screw Fig. 24 30mm 30mm Fig. 21 Fig. 23 Fig. 20 Fig. 22 Adaptor Spigot 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 [...]

9.0 Plume Displacement 26 © Baxi Heating UK Ltd 2007 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 s[...]

10.0 Installation 27 © Baxi Heating UK Ltd 2007 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 [...]

10.0 Installation 28 © Baxi Heating UK Ltd 2007 10.4 Fitting The Boiler 1. Remove the sealing caps from the boiler connections. 2. Lift the boiler using the lower edges. Engage the slots at the top rear of the boiler on the wall plate (Fig. 32). 3. Insert the sealing washers between the valves and pipes on the wall plate and the boiler connections[...]

10.0 Installation 29 © Baxi Heating UK Ltd 2007 10.7 Fitting The Flue HORIZONTAL FLUE 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). 2. Locate the flue elbow on the adaptor at the top of the boiler. Se[...]

10.0 Installation 30 © Baxi Heating UK Ltd 2007 10.7 Fitting the Flue ( Cont) 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 bra[...]

10.0 Installation 31 © Baxi Heating UK Ltd 2007 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 ([...]

11.0 Commissioning the Boiler 32 © Baxi Heating UK Ltd 2007 11.1 Commissioning the Boiler 1. Reference should be made to BS 5449 Section 5 when commissioning the boiler. 2. Open the mains water supply to the boiler. 3. Open all hot water taps to purge the DHW system. 4. Ensure that the filling loop is connected and open, then open the heating flow[...]

11.0 Commissioning the Boiler 33 © Baxi Heating UK Ltd 2007 OUT MIN Pressure Test Point Sealing Screw Gas Valve Fig. 48 Selector Switch Central Heating Temperature Control Hot Water Temperature Control 2 1 0 4 3 bar Reset Fig. 51 Power On Neon Pressure Gauge 2 1 0 4 3 bar Fig. 50 11.2 Checking the Burner Pressure 1. Turn on the gas and electrical [...]

12.0 Completion 34 © Baxi Heating UK Ltd 2007 12.1 Completion 1. Hinge the facia panel upwards and refit the case front panel. 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 Checkli[...]

13.0 Ser vicing the Boiler 35 © Baxi Heating UK Ltd 2007 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 re[...]

13.0 Ser vicing the Boiler 36 © Baxi Heating UK Ltd 2007 13.1 Annual Servicing (Cont) 11. 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). 12. Undo the screws securing the fan and hood to the appliance back panel. Draw the assembly forwards (F[...]

14.0 Changing Components 37 © Baxi Heating UK Ltd 2007 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[...]

14.0 Changing Components 38 © Baxi Heating UK Ltd 2007 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. Wi[...]

14.0 Changing Components 39 © Baxi Heating UK Ltd 2007 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. 3. Unscrew and replace injectors as required and examine the sealing gasket, replacing as necessary. Reassemble in reverse o[...]

14.0 Changing Components 40 © Baxi Heating UK Ltd 2007 14.8 Gas Valve (Fig. 68) 1. Undo the nut on the gas feed pipe under the boiler. 2. Completely undo the securing screws and hinge the facia panel down. 3. Disconnect the wires from the valve modulator and the ignition lead from the spark generator. Disconnect the pressure sensing pipe from the [...]

14.0 Changing Components 41 © Baxi Heating UK Ltd 2007 14.12 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 [...]

14.0 Changing Components 42 © Baxi Heating UK Ltd 2007 14.15 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. 3. Remove the bracket and gauge assembly. Depress the barbs o[...]

14.0 Changing Components 43 © Baxi Heating UK Ltd 2007 14.18 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[...]

14.0 Changing Components 44 © Baxi Heating UK Ltd 2007 14.21 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. Seals 4. There[...]

14.0 Changing Components 45 © Baxi Heating UK Ltd 2007 14.22 Diverter Valve Assembly (Cont) Pressure Differential Valve (Fig. 84) 1. Remove the pressure differential valve as described above. 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. 3.[...]

14.0 Changing Components 46 © Baxi Heating UK Ltd 2007 14.24 Secondary Heat Exchanger (Fig. 87) 1. Drain the primary circuit 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. 4. Slacken the screws on the left [...]

15.0 Illustrated Wiring Diagram 47 © Baxi Heating UK Ltd 2007 - brown - black - blue - red br bk b r - green - green / yellow - white g g/y w Optional Timers Domestic Hot Water T emperature Sensor Reset Selector Switch Control PCB A1 A2 A3 A4 A5 F2 1 bk bk r r g g g r g r 2 12 3 3 41 1 2 3 4 5 6 10 9 8 7 6 5 4 3 2 1 23 4 4 5 5 678 9 Central Heatin[...]

48 © Baxi Heating UK Ltd 2007 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.[...]

49 © Baxi Heating UK Ltd 2007 16.0 Fault Finding Domestic Hot Water - Follow operational sequence Turn selector to neon illuminated Primary flow switch operated Fan runs at max speed Pump runs Turn thermostat to max. Open DHW tap fully. DHW flow switch operated Primary water is diverted from CH system to DHW heat exchanger and flow microswitch ope[...]

50 © Baxi Heating UK Ltd 2007 16.0 Fault Finding Fault Finding Solutions Sections A to E Is there 230V at: Is there 230V at: Main terminals L and N Check electrical supply 1. NO Main terminal fuse Replace fuse Replace PCB neon illuminated 2. YES Selector terminals a & b and a & 3. PCB - A4 connector terminals 4 & 5 Check wiring Replace[...]

51 © Baxi Heating UK Ltd 2007 16.0 Fault Finding Check and correct if necessary 1. Electrical and pressure tube connections 2. Blockage of pressure tubes 3. Restriction in flue 4. Venturi NO E Replace air pressure switch Gas at burner Ensure gas is on and purged Replace PCB Replace gas valve neon flashing PCB - A1 connector has 230V AC across term[...]

52 © Baxi Heating UK Ltd 2007 16.0 Fault Finding Check and correct if necessary 1. Flame sensing electrode and lead connections 2. Electrode position Flame current should be 1 μA approx. Replace PCB Replace PCB YES YES Replace flame sensing electrode NO YES Ensure that mains input terminal L is Live (230V) and N is Neutral (0V) I Check terminal 1[...]

17.0 Short Par ts List 53 © Baxi Heating UK Ltd 2007 Short Parts List Key G.C. Description Manufacturers No. No. Part No. 22 Fan 5112430 23 Pressure Switch 248466 32 Heat Exchanger 5112431 41 Burner 5112770 44 Injector 5112376 59 E66 408 Electrode Lead 248037 63 E66 411 Spark or Sensing Electrode 247384 72 Pump 248042 101 E66 432 3-Way Valve Assy.[...]

CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WA[...]

SERVICE 1 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERI[...]

© Baxi Heating UK Ltd 2007 Comp N o 5111815 - Iss 4 - 1/07 POTTERTON A Trading Division of Baxi Heating UK Ltd 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 All descriptions and illustrations provided in this leaflet have been carefully prepar[...]