Potterton Performa System 18 HE Installation and maintenance instructions

Installation & Service Instructions Performa
System 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.

Publication No. 5111817
2
Natural Gas
Potterton Performa System 12 HE
G.C.No41 591 24
Potterton Performa System 18 HE
G.C.No41 591 25
Potterton Performa System 24 HE
G.C.No41 591 26
Potterton Performa System 28 HE
G.C.No41 591 27
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.

3
CONTENTS
Publication No. 5111817
Legislation 4
1.0 Introduction 5
2.0 General Layout 6
3.0 Appliance Operation 7
4.0 Technical Data 8
5.0 Dimensions and Fixings 12
6.0 System Details 13
7.0 Site Requirements 15
8.0 Installation 21
9.0 Commissioning 26
10.0 Completion 28
11.0 Servicing 29
12.0 Changing Components 31
13.0 Electrical 40
14.0 Short Parts List 41
15.0 Fault Finding 42
Section Page

LEGISLATION
4Publication No. 5111817
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 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 [phone] 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.

5
1.0 INTRODUCTION
Publication No. 5111817
1.1 Description
1. The Potterton Performa System HE 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
12.5kW, 18.9kW, 25.2kW or 29.3kW when in
condensing mode.
3. They are designed for use on Natural Gas (G20)
and can be converted to use Propane.
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. 5111073
8. All systems must be thoroughly flushed and
treated with inhibitor (see section 6.1).
1.2 Optional Extras
Various flue extensions, bends, vertical flue
kits,control accessories etc. are available as optional
extras. These are detailed in a separate publication.
NOTE: All illustrations show the Performa System
28 HE unless otherwise stated.
Data Badge
Fig. 1
Control Box
Case Front Panel

2.0 GENERAL LAYOUT
6Publication No. 5111817
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. System Pressure Gauge
9. PCB
10. Control Box
11. Condensate Trap
12. Flame Sensing Electrode
13. Spark Electrode
14. Burner
15. Primary Heat Exchanger
16. Fan Assembly
17. Secondary Heat Exchanger
18. On/Off/Reset Selector Switch
19. Central Heating Temperature Control
20. Flame Failure or Blocked Condensate Drain
21. Safety Thermostat Activated (Boiler or Flue)
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. Boiler On
28. Burner On
When neons 20 to 25 are constantly illuminated, they
indicate the temperature of the central heating water.
16
15
14
11
12
13
10 9
8
18 19 8
6
5
3
4
7
2
1
2
1
0
4
3
bar
30°40°50°60°70°80°
Reset
30°40°50°60°70°80°
20 21 22 23 25
26 27 28
24
17

7
3.0 APPLIANCE OPERATION
Publication No. 5111817
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.
3.2 Frost Protection Mode
1. The frost protection mode is integral to the
appliance and functions when the selector switch (see
Section 2.1) is in the ON 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.
3.3 Pump Protection
1. With the selector switch (see Section 2.1) in the
ON position ( ) the pump will automatically
operate for 1 minute in every 24 hours to prevent
sticking.
1
2
4
5 6
7
8
19
18
9
10 1211
14
13
15
16
17
3
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
20 Secondary Heat Exchanger
Boiler Primary Circuit
Fig. 2
20

4.0 TECHNICAL DATA
8Publication No. 5111817
4.1 System 12 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 mm Min (In Operation)
L.H. Side 5mm Min
R.H. Side 5mm 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
Weights kg
Packaged Boiler Carton 48.5
Installation Lift Weight 38
Central Heating Primary Circuit
Pressures
bar
Safety Discharge 3
Max Operating 2.5
Min Operating 0.5
Recommend Operating 1-2
Pump
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) 1.2
Connections copper tails
Gas Supply - 22mm
Central Heating Flow - 22mm
Central Heating Return - 22mm
Pressure Relief Discharge - 15mm
Temperatures
Flow Temp (adjustable)
35°C to 85°C max (± 5°C)
Heat Input
Max Min
kW 12.6 7
Electrical Supply 230V~ 50Hz
(Appliance must be connected to an
earthed supply)
Power Consumption 140W
External Fuse Rating 3A
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 1.33
Inlet Pressure (Natural Gas - G20)
mbar 20
Burner Injector (Natural Gas - G20)
10 x 1.18mm Diameter
Burner Pressure (Natural Gas - G20)
Max Rate Min Rate
mbar 5.7 ± 0.5 1.9 ± 0.5
Appliance Type C12 C32 NOxClass 3
Electrical Protection
IPX5D
Heat Output (Non-Condensing)
Max Min
kW 12 6.5
Heat Output (Condensing)
Max Min
kW 12.5 6.7
Condensate Drain 1”BSP
0
200 400 600 800 1000 1200
0.5
1
1.5
2
2.5
3
3.5
4
Metre (wg)
Flow Rate (l/h)
Pump - Available Head
0
5
4.5
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 System 12 HE
The seasonal efficiency (SEDBUK) is 86.8% (88.9% LPG)
Band B
LPG Propane - G31
Burner Injector 0.69mm diameter
Burner Pressure
Propane mbar
Inlet Pressure
mbar
Max Rate
23.4 ± 0.5
Min Rate
7.4 ± 0.2
37

9
4.0 TECHNICAL DATA
Publication No. 5111817
4.2 System 18 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 mm Min (In Operation)
L.H. Side 5mm Min
R.H. Side 5mm 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
Weights kg
Packaged Boiler Carton 49
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
Pump
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) 1.2
Connections copper tails
Gas Supply - 22mm
Central Heating Flow - 22mm
Central Heating Return - 22mm
Pressure Relief Discharge - 15mm
Temperatures
Flow Temp (adjustable)
35°C to 85°C max (± 5°C)
Heat Input
Max Min
kW 18.7 10.6
Electrical Supply 230V~ 50Hz
(Appliance must be connected to an
earthed supply)
Power Consumption 140W
External Fuse Rating 3A
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 1.98
Inlet Pressure (Natural Gas - G20)
mbar 20
Burner Injector (Natural Gas - G20)
12 x 1.18mm Diameter
Burner Pressure (Natural Gas - G20)
Max Rate Min Rate
mbar 8.6 ± 0.5 3 ± 0.5
Appliance Type C12 C32 NOxClass 3
Electrical Protection
IPX5D
Heat Output (Non-Condensing)
Max Min
kW 18 9.9
Heat Output (Condensing)
Max Min
kW 18.9 10.2
Condensate Drain 1”BSP
0
200 400 600 800 1000 1200
0.5
1
1.5
2
2.5
3
3.5
4
Metre (wg)
Flow Rate (l/h)
Pump - Available Head
0
5
4.5
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 System 18 HE
The seasonal efficiency (SEDBUK) is 87.4% (89.5% LPG)
Band B
LPG Propane - G31
Burner Injector 0.77mm diameter
Burner Pressure
Propane mbar
Inlet Pressure
mbar
Max Rate
20 ± 0.5
Min Rate
6.6 ± 0.2
37

4.0 TECHNICAL DATA
10 Publication No. 5111817
4.3 System 24 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 mm Min (In Operation)
L.H. Side 5mm Min
R.H. Side 5mm 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
Weights kg
Packaged Boiler Carton 51
Installation Lift Weight 40.5
Central Heating Primary Circuit
Pressures
bar
Safety Discharge 3
Max Operating 2.5
Min Operating 0.5
Recommend Operating 1-2
Pump
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) 1.2
Connections copper tails
Gas Supply - 22mm
Central Heating Flow - 22mm
Central Heating Return - 22mm
Pressure Relief Discharge - 15mm
Temperatures
Flow Temp (adjustable)
35°C to 85°C max (± 5°C)
Heat Input
Max Min
kW 24.8 10.6
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
Max Gas Rate (Natural Gas - G20)
(After 10 Mins)
m3/h 2.62
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 ± 0.5
Appliance Type C12 C32 NOxClass 3
Electrical Protection
IPX5D
Heat Output (Non-Condensing)
Max Min
kW 24 9.8
Heat Output (Condensing)
Max Min
kW 25.2 10.1
Condensate Drain 1”BSP
0
200 400 600 800 1000 1200
0.5
1
1.5
2
2.5
3
3.5
4
Metre (wg)
Flow Rate (l/h)
Pump - Available Head
0
5
4.5
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 System 24 HE
The seasonal efficiency (SEDBUK) is 87.4% (89.4% LPG)
Band B
LPG Propane - G31
Burner Injector 0.77mm diameter
Burner Pressure
Propane mbar
Inlet Pressure
mbar
Max Rate
21.8 ± 0.5
Min Rate
4.4 ± 0.2
37