Table Of Contents; Contents - Potterton Ultra 2 Installation & Service Instructions Manual

Contents - Page 2
Technical Data ...................................................................3
Introduction........................................................................4
1. Installation Requirements.........................................4
1.1 Health & Safety Information................................4
1.2 Codes of Practice ...............................................4
1.3 Gas Supply .........................................................5
1.4 Electricity Supply ................................................5
1.5 Location of Boiler................................................5
1.6 Air Supply ...........................................................8
1.7 Flue System........................................................8
1.8 Water Connections .............................................8
1.9 Sealed System requirements..............................8
2. Installation................................................................10
2.1 Unpack and Prepare the Boiler.........................10
2.2 Options available for Ultra 2 .............................11
2.3 Fit the Optional Wall Spacing Kit ......................12
2.4 Install the Boiler & Rear Flue............................13
2.5 Install the Boiler & Side Flue.............................15
2.6 Flue Extension..................................................17
2.7 Fit the Optional Vertical Balanced Flue ............18
2.8 Fit the Optional Vertex Flue..............................21
2.9 Fit the Optional Fit From the Inside Flue ..........24
2.10 Connect the Power Supply Cable.....................29
2.11 Install the Ultra 2 Programmer..........................30
2.12 Connect the Gas Supply...................................30
2.13 Connect the Water System & Vent the Boiler...31
3. Commissioning........................................................32
3.1 Commission the Boiler......................................32
3.2 Check the Water System..................................34
3.3 Balance the System..........................................34
3.4 Complete the Boiler ..........................................34
3.5 Light the Boiler..................................................34
3.6 Advise the User ................................................35
4. Annual Service.........................................................35
5. Routine Maintenance ..............................................36
5.1 Remove the Case.............................................36
5.2 Dismantle the Boiler..........................................36
5.3 Cleaning the Boiler ...........................................36
5.4 Re-assemble the Boiler ....................................36
6. Replacement Of Parts .............................................38
6.1 General Access ................................................38
6.2 Gas Valve .........................................................39
6.3 Gas Valve Solenoids ........................................39
6.4 Pump ................................................................40
6.5 Air Flow Pressure Switch..................................40
6.6 Diverter Valve Head (Ultra 2 Dv Models)..........41
6.7 Pressure Gauge................................................41
6.8 Pressure Relief Valve .......................................42
6.9 By-Pass Valve ..................................................42
6.10 Ignition Circuit Board ........................................43
6.11 Re-Set Switch...................................................43
6.12 Potterton Internal Programmer (If Fitted) ......... 43
6.13 Test Switch....................................................... 44
6.14 Overheat Cut-Off Device .................................. 44
6.15 Spark Electrode/Electrode Lead....................... 45
6.16 Main Burner...................................................... 46
Pilot Burner....................................................... 46
Pilot Injector...................................................... 46
Main Burner Injector......................................... 46
6.17 Fan ................................................................... 47
6.18 Combustion Chamber Insulation Panels .......... 48
6.19 Boiler Thermostat ............................................. 48
6.25 Heat Exchanger................................................ 49
6.26 Expansion Vessel............................................. 50
7. Wiring Diagrams...................................................... 51
Functional Flow Wiring Diagram ............................... 51
Wiring Diagrams - Ultra 2Dv...................................... 52
Wiring Diagrams - Ultra 2 .......................................... 53
8. Fault Finding............................................................ 54
9. Short List of Spares ................................................ 58
Important
The Ultra 2 range of boilers can
only be used with the Ultra 2
range of flue systems.
The models covered by these instructions
Ultra 2 30Dv - G.C. No. 41 607 50
Ultra 2 40Dv - G.C. No. 41 607 51
Ultra 2 50Dv - G.C. No. 41 607 52
Ultra 2 60Dv - G.C. No. 41 607 53
Ultra 2 80Dv - G.C. No. 41 607 54
Ultra 2 30 - G.C. No. 41 607 55
Ultra 2 40 - G.C. No. 41 607 56
Ultra 2 50 - G.C. No. 41 607 57
Ultra 2 60 - G.C. No. 41 607 58
Ultra 2 80 - G.C. No. 41 607 59
Ultra 2 30DvP - G.C. No. 41 607 65
Ultra 2 40DvP - G.C. No. 41 607 66
Ultra 2 50DvP - G.C. No. 41 607 67
Ultra 2 60DvP - G.C. No. 41 607 68
Ultra 2 80DvP - G.C. No. 41 607 69
Ultra 2 30P - G.C. No. 41 607 70
Ultra 2 40P - G.C. No. 41 607 71
Ultra 2 50P - G.C. No. 41 607 72
Ultra 2 60P - G.C. No. 41 607 73
Ultra 2 80P - G.C. No. 41 607 74
Dv = Diverter Valve P = Programmer fitted
are:-