Potterton Performa 24i HE Quick guide

Installation & Service Instructions Performa

24i HE

This is a Wall Mounted Powered Flue Condensing Combination Boiler Gas Fired Central Heating Unit.

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 use in GB/IE only.

2Publication No. 5111813

Natural Gas

Potterton Performa 24i HE

G.C.No47 393 12

This product has an energy rating (B) on a scale of A to G.

For more information see www.boilers.org.uk. This is a certification mark.

CONTENTS

Publication No. 5111813

Legislation 4

1.0 Introduction 5

2.0 General Layout 6

3.0 Appliance Operation 7

4.0 Technical Data 9

5.0 Dimensions and Fixings 10

6.0 System Details 11

7.0 Site Requirements 14

8.0 Installation 20

9.0 Commissioning 25

10.0 Completion 27

11.0 Servicing 28

12.0 Changing Components 30

13.0 Electrical 40

14.0 Short Parts List 41

15.0 Fault Finding 42

Section Page

LEGISLATION

4Publication No. 5111813

Codes of Practice, most recent version should

be used

IMPORTANT - Installation, Commissioning, Service & Repair

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

instructions and the regulations in force. Read the instructions fully before

installing or using the appliance.

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

Safety (Installation & Use) Regulations.

Definition of competence: A person who works for a CORGI registered

company and holding current certificates in the relevant ACS modules, or

valid ACoP equivalents, is deemed competent.

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

“Domestic Gas Installations”.

Lifting - This product should be lifted and handled by two people. Stooping

should be avoided and protective equipment worn where necessary. Carrying

& lifting equipment should be used as required, e.g. when installing in a loft

space.

The addition of anything that may interfere with the normal operation of the

appliance without express written permission from the manufacturer or his

agent could invalidate the appliance warranty. In GB this could also infringe

the Gas Safety (Installation and Use) Regulations.

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

supply conditions.

“Benchmark” Log Book

As part of the industry-wide “Benchmark”initiative all Potterton 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.

All CORGI registered installers carry a CORGI identification card and have a

registration number. Both should be recorded in your boiler Log Book. You

can check your installer is registered by telephoning +44 (0)1256 372300 or

writing to:-

1 Elmwood,

Chineham Business Park,

Crockford Lane,

Basingstoke. RG24 8WG

Potterton declare that no substances harmful to

health are contained in the appliance or used

during appliance manufacture.

The appliance is suitable only for installation in GB

and IE and should be installed in accordance with

the rules in force, and only used in a suitably

ventilated location.

In GB, the installation must be carried out by a CORGI

Registered Installer. It must be carried out in accordance

with the relevant requirements of the:

•Gas Safety (Installation & Use) Regulations.

•The appropriate Building Regulations either The

Building Regulations, The Building Regulations

(Scotland), Building Regulations (Northern Ireland).

•The Water Fittings Regulations or Water Byelaws in

Scotland.

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

Where no specific instructions are given, reference

should be made to the relevant British Standard Code of

Practice.

In IE, the installation must be carried out by a competent

Person and installed in accordance with the current

edition of I.S. 813 ‘Domestic Gas Installations’, the

current Building Regulations and reference should be

made to the current ETCI rules for electrical installation.

All systems must be thoroughly flushed and

treated with inhibitor (see section 6.2).

In GB the following Codes of Practice apply:

Standard Scope

BS 6891 Gas Installation.

BS 5546 Installation of hot water supplies for

domestic purposes.

BS 5449 Forced circulation hot water systems.

BS 6798 Installation of gas fired hot water boilers.

BS 5440 Part 1 Flues.

BS 5440 Part 2 Ventilation.

BS 7074 Expansion vessels and ancillary equipment

for sealed water systems.

BS 7593 Treatment of water in domestic hot water

central heating systems.

In IE the following Codes of Practice apply:

Standard Scope

I.S. 813 Domestic Gas Installations.

The following BS standards give valuable additional information;

BS 5546 Installation of hot water supplies for

domestic purposes.

BS 5449 Forced circulation hot water systems.

BS 7074 Expansion vessels and ancillary equipment

for sealed water systems.

BS 7593 Treatment of water in domestic hot water

central heating systems.

1.0 INTRODUCTION

Publication No. 5111813

1.1 Description

1. The Potterton Performa 24i 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 unit incorporates a small storage cylinder built

into the boiler providing hot water the moment the tap

is turned on.

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

29.4 kW in both modes.

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

be converted to use Propane.

5. The boiler is suitable for use only on fully pumped

sealed heating systems. Priority is given to domestic

hot water.

6. 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).

7. The boiler is intended to be installed in residential /

commercial / light industrial E.M.C. environments on a

governed meter supply only.

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

designed flues such as the standard horizontal flue kit,

part no. 5111073.

9. All systems must be thoroughly flushed and

treated with inhibitor (see section 6.2).

1.2 Instant Domestic Hot Water

(Expansion Vessel & Pre-Heat Store)

1. The boiler expansion vessel incorporates a small

volume of stored primary hot water.

2. When the boiler has been off and there is then a

demand for domestic hot water the stored primary hot

water ensures that domestic hot water is supplied

instantly at temperature.

3. The stored hot water is part of the primary circuit.

This is not supplied as domestic hot water, which is

fresh mains water heated by a heat exchanger within

the boiler.

4. The stored primary hot water temperature is

maintained whilst the boiler is in operation. During a

period when there is no demand for heating or hot

water the temperature of the stored primary hot water

will eventually fall. The boiler will operate occasionally

in order to maintain the temperature. This is indicated

by the domestic hot water mode neon flashing.

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.

Data Badge

Fig. 1

Control Box

Case Front Panel

2.0 GENERAL LAYOUT

6Publication No. 5111813

2.1 Layout

1. Air Pressure Switch

2. Expansion Vessel & Pre-Heat Store

3. Burner Manifold

4. Automatic Air Vent

5. DHW Plate Heat Exchanger

6. Circulation Pump

7. Drain Off Point

8. Pressure Relief Valve

9. Position for Optional Integral Timer

10. Central Heating System Pressure Gauge

11. PCB

12. Control Box

13. 3-Way Valve Assembly

14. Condensate Trap

15. Flame Sensing Electrode

16. Spark Electrode

17. Burner

18. Primary Heat Exchanger

19. Fan Assembly

20. Secondary Heat Exchanger

21. On/Off/Reset Selector Switch

22. Central Heating Temperature Control

23. Domestic Hot Water Pre-Heat Control

24. Flame Failure or Blocked Condensate Drain

25. Safety Thermostat Activated (Boiler or Flue)

26. Fault on Fan or Flue

27. Fault on Pump or Low System Pressure

28. Fault on Hot Water Sensor

29. Fault on Central Heating Sensor

30. Power On

31. Domestic Hot Water Mode

32. Central Heating Mode

33. Burner On

When neons 24 to 29 are constantly illuminated, they

indicate the temperature of the central heating water.

12 11

10 9

21 22 23 10 9

bar

30°40°50°60°70°80°

Reset

Off

On Preheat

30°40°50°60°70°80°

24 25 26 27 28 29

30 31 32 33

3.0 APPLIANCE OPERATION

Publication No. 5111813

NOTE: All delay timers mentioned in 3.1 and 3.2 are

overridden by domestic hot water demand.

3.1 Central Heating Mode (Fig. 2)

1. With a demand for heating, the pump circulates

water through the primary circuit. At a pre-determined

flow rate the central heating flow switch operates,

initiating the ignition sequence.

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

valve controls the gas rate to maintain the heating

temperature measured by the temperature sensor.

3. When the flow temperature exceeds the setting

temperature, a 3 minute delay occurs before the

burner relights automatically (anti-cycling). The pump

continues to run during this period.

4. When the demand is satisfied the burner is

extinguished and the pump continues to run for a

period of 3 minutes (Pump Overrun).

5. If there is no other demand the pre-heat function

will operate if switched on (see Section 3.2).

3.2 Domestic Hot Water - Preheat Mode

(Fig. 3)

1. With the pre-heat function switched on (pre-heat

control fully clockwise), priority is given to the

replenishment of the pre-heat store. The DHW mode

neon ( ) will flash during this function.

2. The diverter valve remains in the DHW priority

position. This allows the pump to circulate hot water

to the store and back to the primary heat exchanger

via the bypass pipe.

3. The automatic ignition sequence commences after

approximately 25 seconds and the burner will light.

4. When the store reaches the desired temperature

the burner is extinguished. The pump continues to run

for a period of 30 seconds.

5. Following a demand for domestic hot water or the

end of a central heating ON period, the pre-heat

function restarts.

27 19

16 15 14 13 12

20 22

1 Primary Heat Exchanger

2 Burner

3 Ignition Electrode

4 Flame Sensing Electrode

5 Gas Valve

6 Pump

7 Automatic Air Vent

8 Plate Heat Exchanger

9 Flow Sensor with Filter

10 Pressure Relief Valve

11 Boiler Drain Point

12 Heating Return

13 Cold Water Inlet On/Off Valve and Filter

14 Gas Inlet

15 Domestic Hot Water Outlet

16 Heating Flow

17 Pressure Gauge

18 Hydraulic Pressure Sensor Microswitch

19 Automatic By-Pass

20 Hydraulic 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 & Pre-Heat Store

27 Domestic Hot Water Temperature Sensor

28 Secondary Heat Exchanger

Key

Central Heating Mode

Fig. 2

27 19

16 15 14 13 12

20 22

Domestic Hot Water - Preheat Mode

Fig. 3

3.0 APPLIANCE OPERATION

8Publication No. 5111813

3.3 Domestic Hot Water Mode (Fig. 4)

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

demand at a tap or shower will override any central

heating requirement.

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

which requests the 3 way valve to change position.

This will allow the pump to circulate the primary water

through the DHW plate heat exchanger and take the

stored water to give instant hot water.

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.

5. If there is no other demand the pre-heat function

will operate if switched on (see Section 3.2)

IMPORTANT: When the selector switch is in the

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

isolated. The boiler will not operate and the

integral timer (if fitted) will require resetting once

the selector switch is set to either Position (i) or

Position (ii).

3.4 Frost Protection Mode

1. The frost protection mode is integral to the

appliance and functions only with the selector switch

(Section 2.1) in the domestic hot water and central

heating position. If the system temperature falls below

5°C then the boiler will fire on its minimum setting

until a flow temperature of 30°C is reached. Further

protection can be incorporated by using a system

frost thermostat.

3.5 Pump Protection

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

the central heating or central heating and domestic

hot water position the pump will automatically operate

for 1 minute in every 24 hours to prevent sticking.

27 19

16 15 14 13 12

20 22

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 Pressure Sensor Microswitch

19 Automatic By-Pass

20 Hydraulic 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 & Pre-Heat Store

27 Domestic Hot Water Temperature Sensor

28 Secondary Heat Exchanger

Key

Fig. 4

Domestic Hot Water Mode

4.0 TECHNICAL DATA

Publication No. 5111813

4.1 Performa 24i HE

Flue Terminal Diameter 100mm

Dimensions Projection 95mm

Outercase Dimensions

Casing Height - 780mm

Overall Height Inc Flue

Elbow - 965mm

Casing Width - 450mm

Casing Depth - 345mm

Weights kg

Packaged Boiler Carton 57.5

Installation Lift Weight 47

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 11.1 l/min 0.9

Flow Rates l/min

DHW Flow Rate

@ 30o C Rise 11.5

DHW Flow Rate

@ 35o C Rise 9.8

Min Working

DHW Flow Rate 2.5

Pump - Grundfos UP 15-60

Available Head See graph below

Expansion Vessel - (For Central Heating

only. Integral with appliance)

bar

Min Pre-charge Pressure 0.5

litre

Max Capacity of

CH System 80

Primary Water Content

of Boiler (unpressurised) 3.2

Connections copper tails

Gas Supply - 22mm

Central Heating Flow - 22mm

Central Heating Return - 22mm

Cold Water Mains Inlet - 15mm

DHW Flow - 15mm

Pressure Relief Discharge - 15mm

Temperatures

C.H. Flow Temp (adjustable)

35°C to 85°C max (± 5°C)

D.H.W. Flow Temp

35°C to 65°C max (± 5°C)

dependent upon flow rate

50°C Pre-heat OFF

65°C Pre-heat ON ± 5°C

dependent upon flow rate

NOxClass 3

Electrical Protection IPX5D

200 400 600 800 1000 1200

0.5

1.5

2.5

3.5

Metre (wg)

Flow Rate (l/h)

Pump - Available Head

4.5

Clearances

Above Casing 200 mm Min

Below Casing 200 mm Min

Front 450 mm Min (For Servicing)

Front 5 mm Min (In Operation)

L.H. Side 5 mm Min

R.H. Side 5 mm Min (In Operation)

20mm Min (See Note*)

*NOTE: The boiler can be operated with a

clearance of 5mm at the right. This is also

sufficient for routine maintenance.

However a clearance of 20mm is required

if it is necessary to remove the secondary

heat exchanger. This should be

considered when siting the appliance and

in the event of any subsequent alterations

in the area of installation

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

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

which it has been calculated have been certified by 0051.

SEDBUK Declaration For Performa 24i HE

The seasonal efficiency (SEDBUK) is 87.3% (89.3% LPG)

Band B

Heat Input CH

Max Min

kW 24.8 10.6

Heat Output CH (Non-Condensing)

Max Min

kW 24 9.8

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 II 2H 3P

Inlet Pressure (Natural Gas - G20)

mbar 20

Burner Injector (Natural Gas - G20)

15 x 1.18mm Diameter

Burner Pressure (Natural Gas - G20)

Max Rate Min Rate

mbar 10.2 ± 0.5 2 ± 0.2

Appliance Type C12 C32

Heat Output CH (Condensing)

Max Min

kW 25.2 10.1

Heat Input DHW

Max

kW 24.8

Heat Output DHW

Max

kW 24

LPG Propane - G31

Burner Injector 15 x 0.77mm diameter

Burner Pressure

Propane mbar

Inlet Pressures

mbar

Max Rate

21.8 ± 0.5

Min Rate

4.4 ± 0.2

Max Gas Rate (Natural Gas - G20)

(After 10 mins)

m3/h 2.62

Condensate Drain 1”BSP

5.0 DIMENSIONS AND FIXINGS

10 Publication No. 5111813

Dimensions

A780mm

B345mm

C450mm

D116mm ØMin.

E185mm

F190mm

G131mm

360°Orientation

Tube Ø100mm

Domestic Hot

Water Outlet

(15mm)

Cold Water

Inlet

(15mm)

Heating

Return

(22mm)

Heating

Flow

(22mm)

Pressure Relief

Valve

(15mm)

Gas

Inlet

(22mm)

65 mm 65 mm 65 mm 65 mm 65 mm

Tap Rail

28mm

Condensate

Drain

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