Potterton Performa 24 Release note

Performa 24

Gas Fired Wall Mounted Combination Boiler

Installation and

Servicing Instructions

Please leave these instructions with the user

Natural Gas

Potterton Performa 24

G.C.No47 393 06

The boiler meets the requirements of Statutory

Instrument “ The Boiler (Efficiency) Regulations

1993 No3083” and is deemed to meet the

requirements of Directive 92/42/EEC on the energy

efficiency requirements for new hot water boilers

fired with liquid or gaseous fuels:-

Type test for purpose of Regulation 5 certified by:

Notified Body 0051.

Product/Production certified by:

Notified Body 0051.

For GB/IE only.

1.0 Introduction 4

2.0 General Layout 5

3.0 Appliance Operation 6

4.0 Technical Data 7

5.0 Dimensions and Fixings 8

6.0 System Details 9

7.0 Site Requirements 12

8.0 Installation 17

9.0 Commissioning the Boiler 22

10.0 Completion 24

11.0 Servicing the Boiler 25

12.0 Changing Components 27

13.0 Illustrated Wiring Diagram 36

14.0 Fault Finding 37

15.0 Short Parts List 42

Section Page

Contents

Potterton declare that no substances

harmful to health are contained in the

appliance or used during appliance

manufacture.

1.1 Description

1. The Potterton Performa 24 is a fully automatic

gas fired wall mounted combination boiler. It is

room sealed and fan assisted, and will provide

central heating and mains fed domestic hot water.

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

24.0 kW.

3. It is designed for use on Natural Gas (G20) and

can be converted to use Propane or Butane.

4. The boiler is suitable for use only on fully

pumped sealed heating systems. Priority is given

to domestic hot water.

5. The boiler data badge gives details of the

model, serial number and Gas Council number

and is situated on the control box. It is visible when

the case front panel is removed (Fig. 1).

6. The boiler is intended to be installed in

residential / commercial / light industrial E.M.C.

environments on a governed meter supply only.

7. The boiler must be installed with one of the

purpose designed flues such as the standard

horizontal flue kit, part no. 247719.

8. All systems must be thoroughly flushed and

treated with inhibitor (see section 6.2).

1.2 Installation

1. The appliance is suitable for installation only in

G.B. and I.E. and should be installed in

accordance with the rules in force. For Ireland

install in accordance with I.S.813 “INSTALLATION OF

GAS APPLIANCES”. The installation must be carried

out by a CORGI Registered Installer or other

competent person and be in accordance with the

relevant requirements of GAS SAFETY (Installation

and Use) REGULATIONS, the BUILDING REGULATIONS

(Scotland) (Consolidation), the LOCAL BUILDING

REGULATIONS, the CURRENT I.E.E. WIRING

REGULATIONS and the bye laws of the Local Water

Undertaking. Where no specific instructions are

given, reference should be made to the relevant

BRITISH STANDARD CODES OF PRACTICE.

1.3 Optional Extras

1. Various flue extensions, bends, vertical flue kits,

control accessories etc. are available as optional

extras. These are detailed in a separate

publication.

1.0 Introduction

Data Badge

Fig. 1

Control Box

Case Front Panel

“Benchmark”Log Book

As part of the industry-wide “Benchmark”initiative all boilers now include

an Installation, Commissioning and Service Record Log Book. Please read

the Log Book carefully and complete all sections relevant to the appliance

and installation. These include sections on the type of controls employed,

flushing the system, burner operating pressure etc. The details of the Log

Book will be required in the event of any warranty work. Also, there is a

section to be completed at each subsequent regular service visit. The Log

Book must be left with the user.

NOTE: 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.

2.0 General Layout

2.1 Layout

1. Air Pressure Switch

2. Expansion Vessel

3. Burner Manifold

4. Automatic Air Vent

5. DHW Plate Heat Exchanger

6. Circulation Pump

7. Drain Off Point

8. Pressure Relief Valve

9. Optional Integral Timer Position

10. Central Heating System Pressure Gauge

11. Control PCB

12. Control Box

13. 3-Way Valve Assembly

14. Spark Generator

15. Flame Sensing Electrode

16. Spark Electrode

17. Burner

18. Primary Heat Exchanger

19. Fan Assembly

20. On / Off / Reset Selector Switch

21. Burner Neon

22. Power Neon

23. Reset Neon

24. Central Heating Temperature Control

25. Hot Water Temperature Control

12 11

10 9

20 21 22 23 24 25 10 9

bar

Reset Burner On

Flame Failure

Power On

Fig. 2

Fig. 3

3.0 Appliance Operation

NOTE: All delay timers mentioned in 3.1 and

3.2 are overridden by domestic hot water

demand.

3.1 Central Heating Mode (Fig. 4)

1. With a demand for heating, the pump circulates

water through the primary circuit. At a pre-

determined flow rate the central heating flow

switch operates, initiating the ignition sequence.

2. The main burner ignites at low rate, then the

gas valve controls the gas rate to maintain the

heating temperature measured by the

temperature sensor.

3. When the flow temperature exceeds the setting

temperature, a 3 minute delay occurs before the

burner relights automatically (anti-cycling). The

pump continues to run during this period.

4. When the demand is satisfied the burner is

extinguished and the pump continues to run for a

period of 30 seconds (Pump Overrun).

3.2 Domestic Hot Water Mode (Fig. 5)

1. Priority is given to the domestic hot water

supply. A demand at a tap or shower will override

any central heating requirement.

2. The flow of water will operate the DHW flow

switch which causes the 3 way valve to change

position. This will allow the pump to circulate the

primary water through the DHW plate heat

exchanger.

3. The burner will light automatically and the

temperature of the domestic hot water is

controlled by the temperature sensor.

4. When the domestic hot water demand ceases

the burner will extinguish and the diverter valve

will remain in the domestic hot water mode,

unless there is a demand for central heating.

IMPORTANT: When the selector switch is in the

‘0’(Off) position the electrical supply to the boiler

is isolated. The boiler will not operate and the

integral timer (if fitted) will require resetting once

the selector switch is turned to either the DHW

or CH position.

5 6

1213141516

1 Primary Heat Exchanger

2 Burner

3 Ignition Electrode

4 Flame Sensing Electrode

5 Gas Valve

6Pump

7 Automatic Air Vent

8 Plate Heat Exchanger

9 Flow Sensor with Filter

10 Pressure Relief Valve

11 Boiler Drain Point

12 Heating Return

13 Cold Water Inlet On/Off Valve and Filter

14 Gas Inlet

15 Domestic Hot Water Outlet

16 Heating Flow

17 Pressure Gauge

18 Hydraulic Differential Pressure Sensor Microswitch

19 Automatic By-Pass

20 Hydraulic Differential Pressure Sensor

21 Diverter Valve Assembly

22 Domestic Hot Water Flow Priority Assembly

23 Domestic Hot Water Flow Priority Microswitch

24 Temperature Sensor

25 Overheat Thermostat

26 Expansion Vessel

Key

Central Heating Circuit

Domestic Hot Water Circuit

Fig. 4

Fig. 5

5 6

1213141516

Burner Pressure (Natural Gas - G20)

Max Rate Min Rate

mbar 12.2 ± 0.5 2.5 ± 0.2

in wg 4.88 ± 0.2 1.0 ± 0.2

4.0 Technical Data

Flue Terminal Diameter 100mm

Dimensions Projection 95mm

Outercase Dimensions

Casing Height - 780mm

Overall Height Inc Flue

Elbow - 980mm

Casing Width - 450mm

Casing Depth - 345mm

Clearances

Both Sides 5 mm Min

Above Casing 200 mm Min

Below Casing 200 mm Min

Front 450 mm Min (For Servicing)

Front 5 mm Min (In Operation)

Weights kg

Packaged Boiler Carton 46

Packaged Flue Kit 3

Installation Lift Weight 38.5

Central Heating Primary Circuit

Pressures

bar

Safety Discharge 3

Max Operating 2.5

Min Operating 0.5

Recommend Operating 1-2

DHW Circuit bar

Pressures

Max Operating 8

Min Operating 0.2

Min Operating Pressure

at 9.8 l/min 0.9

Flow Rates l/min

DHW Flow Rate

@ 30o C Rise 11.4

DHW Flow Rate

@ 35o C Rise 9.8

Min Working

DHW Flow Rate 2.5

Pump Grundfos 15-50

Available Head See graph below

Expansion Vessel - (For Central Heating

only. Integral with appliance)

bar

Pre-charge Pressure 0.5

litre

Max Capacity of

CH System 125

Primary Water Content

of Boiler (unpressurised) 1.0

Connections copper tails

Gas Supply - 22mm

Central Heating Flow - 22mm

Central Heating Return - 22mm

Cold Water Mains Inlet - 15mm

DHW Flow - 15mm

Pressure Relief Discharge - 15mm

Recommended System

Temperature Drop 11°C20°F

Temperatures

C.H. Flow Temp (adjustable)

35°C to 85°C max (± 5°C)

D.H.W. Flow Temp (adjustable)

35°C to 65°C max (± 5°C)

dependent upon flow rate

Heat Input C/H & DHW (Gross)

Max Min

kW 26.3 10.6

Btu/h 89,739 36,167

Heat Output Max Min

kW 24.0 9.3

Btu/h 81,891 31,732

Electrical Supply 230V~ 50Hz

(Appliance must be connected to an

earthed supply)

Power Consumption 170W

External Fuse Rating 3A

Internal Fuse Rating

Fuse 2A Fast Blow to BS 4265

Appliance Category CAT 2H 3+

Max Gas Rate (Natural Gas - G20)

(After 10 Mins)

m3/h 2.78

ft3/h 98.12

Inlet Pressure (Natural Gas - G20)

mbar 20

in wg 8

Burner Injector (Natural Gas - G20)

12 x 1.28mm Diameter

200 400 600 800 1000 1200

0.5

1.5

2.5

3.5

Metre wg

l/h

Pump - Available Head

Appliance Type C12 C32 Nox Class 3

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been

certified by 0051.

SEDBUK Declaration

The seasonal efficiency (SEDBUK) is 78.6%

Electrical Protection

IPX4D

LPG Gases - Propane G31 Butane G31

Burner Injector 12 x 0.77mm diameter

Burner Pressure

Propane mbar

in wg

Butane mbar

in wg

Inlet Pressures

mbar

in wg

Butane

Max Rate

36.2

14.5

28.3

11.3

Min Rate

6.4

2.6

5.3

2.1

Propane

14.8

5.0 Dimensions and Fixings

Dimensions

A780mm

B345mm

C450mm

D107mm ØMin.

E200mm

F190mm

G143mm

360°Orientation

Tube Ø100mm

65mm 65mm 65mm 65mm

Wall

View from under the appliance

Gas Inlet

Heating

Flow

Domestic Hot

Water Outlet

Cold Water

Inlet

Heating

Return

130mm

165.7mm

95mm

Left Hand Side

of Boiler

Fig. 6

Fig. 7

6.0 System Details

6.1 Information

1. The Potterton Performa 24 Combination Boiler is a

‘Water Byelaws Scheme - Approved Product’.

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.

b) IRN 116 - Byelaw 90 and 91.

c) IRN 302 - Byelaw 14.

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.

•For optimum performance after installation this

boiler and its associated central heating system

must be flushed in accordance with the guidelines

given in BS 7593 “Treatment of water in domestic

hot water central heating systems”.

•This must involve the use of a proprietary

cleanser, such as BetzDearborn Sentinel X300 or

X400, or Fernox Superfloc. Full instructions are

supplied with the products, but for immediate

information please contact BetzDearborn (0151

420 9563) or Fernox (01799 550 811) directly.

•For long term protection against corrosion and

scale, after flushing it is recommended that an

inhibitor such as BetzDearborn Sentinel X100, or

Fernox MB-1 or Copal is dosed in accordance with

the guidelines given in BS 7593.

Failure to flush and add inhibitor to the system

may 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.)

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. An integral electro-mechanical or electronic

timer is available as an optional extra.

3. For optimum operating conditions and maximum

economy the fitting of a programmable 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.

2. The filling method adopted must be in

accordance with all relevant water supply bye-

laws and use approved equipment.

3. Your attention is drawn to: IRN 302 and Byelaw

14.

4. 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. 8).

5. There are connection points on the mains cold

water inlet and central heating return isolation

taps to which the optional Filling Loop Kit (Part No

248221) can be fitted.

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 - refer to BS 7074

Pt 1.

6.7 Pressure Relief Valve (Fig. 9)

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 (Fig. 10). It should be

routed in such a manner that no hazard occurs or

causes damage to wiring or electrical

components. The end of the pipe should

terminate facing down and towards the wall.

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.

Fig. 8

Fig. 9

Fig. 10

Stop Valve

Double

Check

Valve

DHW

Mains

Inlet

Return

Temporary

Hose

Pressure Relief Valve

Discharge Pipe

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