Potterton Performa System 12e User guide

Performa System

12e, 18e, 24e & 28e

Gas Fired Wall Mounted System Boilers

Installation and

Servicing Instructions

Please leave these instructions with the user

Natural Gas

Potterton Performa System 12e

G.C.No41 590 88

Potterton Performa System 18e

G.C.No41 590 89

Potterton Performa System 24e

G.C.No41 590 90

Potterton Performa System 28e

G.C.No41 590 91

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 11

6.0 System Details 12

7.0 Site Requirements 14

8.0 Installation 19

9.0 Commissioning the Boiler 24

10.0 Completion 26

11.0 Servicing the Boiler 27

12.0 Changing Components 29

13.0 Illustrated Wiring Diagram 37

14.0 Fault Finding 38

15.0 Short Parts List 41

16.0 Notes 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 System are fully

automatic gas fired wall mounted system boilers.

They are room sealed and fan assisted.

2. The boilers are set to give a maximum output of

12kW, 18kW, 24kW or 28kW.

3. They are designed for use on Natural Gas

(G20) and can be converted to use Propane (12e,

18e, 24e & 28e) or Butane (12e, 18e & 24e).

4. The boiler incorporates a circulating pump and

expansion vessel. It is suitable for use only on fully

pumped sealed systems.

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 6.1).

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

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

“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.

Case Front Panel

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. Circulation Pump

6. Drain Off Point

7. Pressure Relief Valve

8. Optional Integral Timer Position

9. System Pressure Gauge

10. PCB

11. Control Box

12. Spark Generator

13. Flame Sensing Electrode

14. Spark Electrode

15. Burner

16. Primary Heat Exchanger

17. Fan Assembly

18. On/Off/Reset Selector Switch

19. Central Heating Temperature Control

20. Flame Failure

21. Safety Thermostat

22. Fault on Fan or Flue

23. Fault on Pump or Low System Pressure

24. Temperature Indication Only

25. Fault on Central Heating Sensor

26. Power On

27. Hot Water Mode

28. Central Heating Mode

29. Burner On

When neons 20 to 25 are constantly illuminated,

they indicate the temperature of the central heating

water.

11 10

18 19 9

bar

30°40°50°60°70°80°

Reset

30°40°50°60°70°80°

20 21 22 23 25

26 28 29

3.0 Appliance Operation

3.1 Operating Mode (Fig. 2)

1. With a demand for heating, the pump circulates

water through the primary circuit. At a pre-

determined flow rate the hydraulic differential

pressure 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).

IMPORTANT: When the selector switch is in

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

boiler is isolated. The boiler will not operate.

3.3 Frost Protection Mode

1. The frost protection mode is integral to the

appliance and functions only with the selector

switch (see Section 2.1) in the domestic hot water

and central heating position. If the system

temperature falls below 5°C then the boiler will

fire on its minimum setting until a flow temperature

of 30°C is reached. Further protection can be

incorporated by using a system frost thermostat.

3.4 Pump Protection

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

either the central heating or central heating and

hot water position the pump will automatically

operate for 1 minute in every 24 hours to prevent

sticking.

5 6

10 1211

Key

1 Heat Exchanger

2 Burner

3 Ignition Electrode

4 Flame Sensing Electrode

5 Gas Valve

6 Pump

7 Automatic Air Vent

8 Pressure Relief Valve

9 Boiler Drain Point

10 Gas Inlet

11 Boiler Flow

12 Boiler Return

13 Pressure Gauge

14 Automatic By-Pass

15 Hydraulic Differential Pressure Sensor

16 Safety Thermostat

17 Central Heating Temperature Sensor

18 Expansion Vessel

19 Water Heating Sensor

Boiler Primary Circuit

Fig. 2

4.0 Technical Data

4.1 System 12e

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 45

Packaged Flue Kit 3

Installation Lift Weight 37

Central Heating Primary Circuit

Pressures

bar

Safety Discharge 3

Max Operating 2.5

Min Operating 0.2

Recommend Operating 1-2

Pump - Grundfos UP 15-50

Available Head See graph below

Expansion Vessel - (For Central Heating

only. Integral with appliance)

bar

Min Pre-charge Pressure 0.5

litre

Max Capacity of

CH System 125

Primary Water Content

of Boiler (unpressurised) 1.1

Connections copper tails

Gas Supply - 22mm

Central Heating Flow - 22mm

Central Heating Return - 22mm

Pressure Relief Discharge - 15mm

Temperatures

C.H. Flow Temp (adjustable)

35°C to 85°C max (± 5°C)

Heat Input (Gross)

Max Min

kW 13.8 7

Btu/h 47,094 23,888

Heat Output Max Min

kW 12.4 6.3

Btu/h 42,309 21,496

Electrical Supply 230V~ 50Hz

(Appliance must be connected to an

earthed supply)

Power Consumption 120W

External Fuse Rating 3A Maximum

Internal Fuse Rating

Fuse 2A Fast Blow to BS 4265

Appliance Category CAT II 2H 3+

Max Gas Rate (Natural Gas - G20)

(After 10 Mins)

m3/h 1.46

ft3/h 51.57

Inlet Pressure (Natural Gas - G20)

mbar 20

in wg 8

Burner Injector (Natural Gas - G20)

12 x 1.28mm Diameter

Burner Pressure (Natural Gas - G20)

Max Rate Min Rate

mbar 6.9 ± 0.5 2.5 ± 0.5

in wg 2.8 ± 0.2 1.0 ± 0.2

Appliance Type C12 C32 NOxClass 3

Electrical Protection

IPX5D

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been

certified by 0051.

SEDBUK Declaration For System Boiler 12e

The seasonal efficiency (SEDBUK) is 78.8%

200 400 600 800 1000 1200

0.5

1.5

2.5

3.5

4.5

Metre wg

l/h

Pump - Available Head

LPG Gases Propane - G31 and

Butane - G30

Burner Injector 12 x 0.65mm diameter

Burner Pressure

Propane mbar

in wg

Butane mbar

in wg

Inlet Pressures

mbar

in wg

Max Rate

36.2 ± 0.5

14.5 ± 0.2

28.8 ± 0.5

11.5 ± 0.2

Min Rate

10.8 ± 0.5

4.3 ± 0.2

7.7 ± 0.5

3.1 ± 0.2

Propane

14.8

Butane

28/30

11.2

4.0 Technical Data

4.2 System 18e

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 45

Packaged Flue Kit 3

Installation Lift Weight 37

Central Heating Primary Circuit

Pressures

bar

Safety Discharge 3

Max Operating 2.5

Min Operating 0.2

Recommend Operating 1-2

Pump - Grundfos UP 15-50

Available Head See graph below

Expansion Vessel - (For Central Heating

only. Integral with appliance)

bar

Min Pre-charge Pressure 0.5

litre

Max Capacity of

CH System 125

Primary Water Content

of Boiler (unpressurised) 1.1

Connections copper tails

Gas Supply - 22mm

Central Heating Flow - 22mm

Central Heating Return - 22mm

Pressure Relief Discharge - 15mm

Temperatures

C.H. Flow Temp (adjustable)

35°C to 85°C max (± 5°C)

Heat Input (Gross)

Max Min

kW 19.4 10.6

Btu/h 66,200 36,170

Heat Output Max Min

kW 17.5 9.3

Btu/h 59,720 31,740

Electrical Supply 230V~ 50Hz

(Appliance must be connected to an

earthed supply)

Power Consumption 170W

External Fuse Rating 3A Maximum

Internal Fuse Rating

Fuse 2A Fast Blow to BS 4265

Appliance Category CAT II 2H 3+

Max Gas Rate (Natural Gas - G20)

(After 10 Mins)

m3/h 2.05

ft3/h 72.4

Inlet Pressure (Natural Gas - G20)

mbar 20

in wg 8

Burner Injector (Natural Gas - G20)

12 x 1.28mm Diameter

Burner Pressure (Natural Gas - G20)

Max Rate Min Rate

mbar 6.9 ± 0.5 2.5 ± 0.5

in wg 2.8 ± 0.2 1.0 ± 0.2

Appliance Type C12 C32 NOxClass 3

Electrical Protection

IPX5D

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been

certified by 0051.

SEDBUK Declaration For System Boiler 18e

The seasonal efficiency (SEDBUK) is 78.7%

200 400 600 800 1000 1200

0.5

1.5

2.5

3.5

4.5

Metre wg

l/h

Pump - Available Head

LPG Gases Propane - G31 and

Butane - G30

Burner Injector 12 x 0.65mm diameter

Burner Pressure

Propane mbar

in wg

Butane mbar

in wg

Inlet Pressures

mbar

in wg

Max Rate

36.2 ± 0.5

14.5 ± 0.2

28.8 ± 0.5

11.5 ± 0.2

Min Rate

10.8 ± 0.5

4.3 ± 0.2

7.7 ± 0.5

3.1 ± 0.2

Propane

14.8

Butane

28/30

11.2

4.0 Technical Data

4.3 System 24e

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 45

Packaged Flue Kit 3

Installation Lift Weight 37

Central Heating Primary Circuit

Pressures

bar

Safety Discharge 3

Max Operating 2.5

Min Operating 0.2

Recommend Operating 1-2

Pump - Grundfos UP 15-50

Available Head See graph below

Expansion Vessel - (For Central Heating

only. Integral with appliance)

bar

Min Pre-charge Pressure 0.5

litre

Max Capacity of

CH System 125

Primary Water Content

of Boiler (unpressurised) 1.1

Connections copper tails

Gas Supply - 22mm

Central Heating Flow - 22mm

Central Heating Return - 22mm

Pressure Relief Discharge - 15mm

Temperatures

C.H. Flow Temp (adjustable)

35°C to 85°C max (± 5°C)

Heat Input (Gross)

Max Min

kW 26.3 10.6

Btu/h 89,739 36,170

Heat Output Max Min

kW 24.0 9.3

Btu/h 81,891 31,740

Electrical Supply 230V~ 50Hz

(Appliance must be connected to an

earthed supply)

Power Consumption 170W

External Fuse Rating 3A Maximum

Internal Fuse Rating

Fuse 2A Fast Blow to BS 4265

Appliance Category CAT II 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

Burner Pressure (Natural Gas - G20)

Max Rate Min Rate

mbar 12.2 ± 0.5 2.5 ± 0.5

in wg 4.88 ± 0.2 1.0 ± 0.2

Appliance Type C12 C32 NOxClass 3

Electrical Protection

IPX5D

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been

certified by 0051.

SEDBUK Declaration For System Boiler 24e

The seasonal efficiency (SEDBUK) is 78.5%

200 400 600 800 1000 1200

0.5

1.5

2.5

3.5

4.5

Metre wg

l/h

Pump - Available Head

LPG Gases Propane - G31 and

Butane - G30

Burner Injector 12 x 0.65mm diameter

Burner Pressure

Propane mbar

in wg

Butane mbar

in wg

Inlet Pressures

mbar

in wg

Max Rate

36.2 ± 0.5

14.5 ± 0.2

28.3 ± 0.5

11.3 ± 0.2

Min Rate

6.4 ± 0.5

2.6 ± 0.2

5.3 ± 0.5

2.1 ± 0.2

Propane

14.8

Butane

28/30

11.2

4.0 Technical Data

4.4 System 28e

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 47

Packaged Flue Kit 3

Installation Lift Weight 39

Central Heating Primary Circuit

Pressures

bar

Safety Discharge 3

Max Operating 2.5

Min Operating 0.2

Recommend Operating 1-2

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 125

Primary Water Content

of Boiler (unpressurised) 1.1

Connections copper tails

Gas Supply - 22mm

Central Heating Flow - 22mm

Central Heating Return - 22mm

Pressure Relief Discharge - 15mm

Temperatures

C.H. Flow Temp (adjustable)

35°C to 85°C max (± 5°C)

Heat Input (Gross)

Max Min

kW 32.6 11.9

Btu/h 111,250 40,610

Heat Output Max Min

kW 29.4 10.4

Btu/h 100,330 35,490

Electrical Supply 230V~ 50Hz

(Appliance must be connected to an

earthed supply)

Power Consumption 190W

External Fuse Rating 3A Maximum

Internal Fuse Rating

Fuse 2A Fast Blow to BS 4265

Appliance Category CAT II 2H 3P

Max Gas Rate (Natural Gas - G20)

(After 10 Mins)

m3/h 3.45

ft3/h 122

Inlet Pressure (Natural Gas - G20)

mbar 20

in wg 8

Burner Injector (Natural Gas - G20)

15 x 1.28mm Diameter

Burner Pressure (Natural Gas - G20)

Max Rate Min Rate

mbar 12.5 ± 0.5 1.8 ± 0.5

in wg 5.0 ± 0.2 0.7 ± 0.2

Appliance Type C12 C32 NOxClass 3

Electrical Protection

IPX5D

This value is used in the UK Government’s Standard

Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been

certified by 0051.

SEDBUK Declaration For System Boiler 28e

The seasonal efficiency (SEDBUK) is 78.2 %

LPG Gases Propane - G31

Burner Injector 15 x 0.77mm diameter

Burner Pressure

Propane mbar

in wg

Inlet Pressures

mbar

in wg

Max Rate

34.4 ± 0.5

13.8 ± 0.2

Min Rate

5.1 ± 0.5

2.0 ± 0.2

14.8

200 400 600 800 1000 1200

0.5

1.5

2.5

3.5

4.5

5.5

Metre wg

l/h

Pump - Available Head

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