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Installation & Servicing Manual
Ultra range of wall mounted
fan assisted balanced flue gas boilers
FOR USE WITH NATURAL GAS ONLY
Read these instructions thoroughly before working on the boiler.
Leave these instructions with the User for use on future calls.
Supplied By www.heating spares.co Tel. 0161 620 6677
for the
G.C. Appliance No's.
Ultra 30
41 494 78
Ultra 40
41 494 79
Ultra 50
41 494 80
Ultra 60
41 494 81
Ultra 80
41 494 82
IMPORTANT
405/0302 - 03
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Table of Contents
Related Manuals for Potterton Ultra 30
Summary of Contents for Potterton Ultra 30
- Page 1 405/0302 - 03 Installation & Servicing Manual for the Ultra range of wall mounted fan assisted balanced flue gas boilers G.C. Appliance No's. Ultra 30 41 494 78 Ultra 40 41 494 79 Ultra 50 41 494 80 Ultra 60...
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Page 2: Table Of Contents
LIST OF CONTENTS TECHNICAL DATA................................4 GENERAL ..................................5 Introduction................................5 Regulatory Requirements............................5 Delivery & Kits Available............................5 Gas Supply................................5 Electricity Supply..............................5 Air Supply ................................6 Flue System................................6 Location of Boiler ..............................6 Boiler Dimensions and Gas Connection ........................8 2.10 Water System Schematics ............................ - Page 3 If you have any reason to complain of any shortage of components listed in Figs 6, 7 or 29, supply a list of the item(s) concerned, boiler model, your name, address and any information which may help us avoid further error. Address for return: Supplies Manager Potterton Interpart. Brooks House Coventry Road Warwick. CV34 4LL Tel: 0926 493471 Supplied By www.heating spares.co Tel.
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Page 4: Technical Data
The boiler model and serial No. are given on the Serial No. label on the front of the control box. The boiler data label is on the left hand side of the chassis next to the gas valve. Boiler model Ultra 30 Ultra 40 Ultra 50... -
Page 5: General
The Ultra Dv boilers are range rated at the following outputs: Ultra 30: 5.9 to 8.8 kW (20 000 to 30 000 Btu/h) Ultra 40: 8.8 to 11.7 kW (30 000 to 40 000 Btu/h) Ultra 50: 11.7 to 14.7 kW (40 000 to 50 000 Btu/h) Ultra 60: 14.7 to 17.6 kW (50 000 to 60 000 Btu/h) Ultra 80: 17.6 to 23.4 kW (60 000 to 80 000 Btu/h) -
Page 6: Air Supply
Both the high level and low level vent must each have a free area as stated below. The free area of each vent may be halved if the ventilation is provided directly from outside. Ultra 30: 110 cm² Ultra 40: 140 cm²... - Page 7 GENERAL - PAGE 7 Fig. 1 Dimension Terminal Position (Fanned Balanced Flue models) Min. Spacing Directly below an opening, air brick, window, etc. Below gutters, soil pipes or drain pipes 75 * Below eaves 200 * Below balconies or car port roof From a vertical drain pipe or soil pipe From an internal corner From an external corner...
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Page 8: Boiler Dimensions And Gas Connection
GENERAL - PAGE 8 BOILER DIMENSIONS AND GAS CONNECTION Refer to Fig. 2. Overall cased dimensions. Height: 800 mm Width: 450 mm Depth: 350 mm Clearance required for servicing. Top: 50 mm Bottom: 150 mm Front: 500 mm Side: 10 mm Note: Additional clearances for installation may be required, these are to be left to the discretion of the installer. -
Page 9: Sealed System Requirements
GENERAL - PAGE 9 2.11 SEALED SYSTEM REQUIREMENTS Refer to Fig. 4. The installation must comply with the requirements of BS6798 and BS5449. Maximum water temperature is 82°C ± 3°C. A safety valve set to operate at 3 bar and a pressure gauge covering the range 0 to 6 bar are incorporated within the boiler. A 10 litre expansion vessel to BS4841 is fitted and pre-charged to 0.5 bar. -
Page 10: Installation
INSTALLATION - PAGE 10 UNPACK THE BOILER Refer to Fig. 6. Carefully unpack the boiler. Do not discard any packaging until all the items are accounted for, see Fig. 6. Place the case pack and foam seal to one side so as not to damage the case parts before fitting them. -
Page 11: Rear Flue - Prepare The Wall
INSTALLATION - PAGE 11 IMPORTANT Sections 3.3 to 3.6 are for rear flue applications. Sections 3.7 to 3.12 are for side flue applications. REAR FLUE - PREPARE THE WALL Refer to Figs. 8 and 9. Remove the four screws and sealing plate from the wall mounting plate. -
Page 12: Rear Flue - Fit The Flue/Terminal Assembly
INSTALLATION - REAR FLUE - PAGE 12 REAR FLUE - FIT THE FLUE/TERMINAL ASSEMBLY Refer to Figs. 11 and 12. Note: As the flue/terminal assembly is not physically secured to the boiler or wall mounting plate, the outer wall plate and outer sealing plate must be used to secure the flue/terminal assembly to the wall. - Page 13 INSTALLATION - REAR FLUE - PAGE 13 Remove the four screws (two at the top and two at the bottom) securing the inner case front panel and lift off the panel. See Fig. Note: When the inner case front panel is removed, the four case seal housing channels are not secured to the boiler as they are retained in position by the front panel.
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Page 14: Side Flue - Prepare The Wall
INSTALLATION - SIDE FLUE - PAGE 14 SIDE FLUE - PREPARE THE WALL Refer to Figs. 15 and 16. Decide upon the position of the boiler, ensuring that the position of the flue terminal will meet the requirements given in section 2.6. Using the wall mounting plate as a template and adding the following dimensions to the raised edges of the mounting plate will give the space necessary for the boiler including the... -
Page 15: Side Flue - Flue Extension
INSTALLATION - SIDE FLUE - PAGE 15 SIDE FLUE - FLUE EXTENSION Refer to Fig. 18. The finished wall thickness plus (+) the distance from the inside wall to the side of the white case plus (+) 30 mm will give the length of the flue/terminal assembly required. - Page 16 INSTALLATION - SIDE FLUE - PAGE 16 Remove the four screws (two at the top and two at the bottom) securing the inner case front panel and lift off the panel. See Fig. Note: When the inner case front panel is removed, the four case seal housing channels are not secured to the boiler as they are retained in position by the front panel.
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Page 17: Side Flue - Fit The Flue/Terminal Assembly
INSTALLATION - SIDE FLUE - PAGE 17 3.11 SIDE FLUE - FIT THE FLUE/TERMINAL ASSEMBLY Refer to Figs. 21 and 22. Note: As the flue/terminal assembly is not physically secured to the boiler the outer wall plate, the outer sealing plate must be used to secure the flue/terminal assembly to the wall. -
Page 18: Connect The Gas Supply
INSTALLATION - PAGE 18 3.13 CONNECT THE GAS SUPPLY Refer to Fig. 24. Connect a 15 mm gas supply, using a suitable adaptor, to the service cock. It is recommended that a 22 mm supply be used for the 80 model. Note: The gas supply must be from below, as the boiler chassis extends below the service cock, see Fig. -
Page 19: Replace The Expansion Vessel
INSTALLATION - PAGE 19 3.15 REPLACE THE EXPANSION VESSEL Refer to Fig. 26. Remove the two tie rods from the retaining clips on the front of the expansion vessel frame and remove the split pins from the ends of the rods. With the control box lowered, locate the bottom of the expansion vessel frame into its pivoting point in the boiler chassis as shown in Fig. -
Page 20: Commissioning
COMMISSIONING - PAGE 20 BOILER CONTROLS Refer to Fig. 28. (Case and inner case front panel shown removed, expansion vessel and frame omitted for clarity). Note: Pilot position varies slightly between boiler models. Fig. 28 PREPARE THE BOILER FOR COMMISSIONING Refer to Fig. - Page 21 COMMISSIONING - PAGE 21 Check the ignition sequence With the gas supply isolated check the ignition sequence as follows: Set the test switch on the top of the control box to 1 (on) and check that all system controls are calling for heat. Switch on the electricity supply and turn the boiler thermostat fully clockwise [ ].
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Page 22: Check The Water System
COMMISSIONING - PAGE 22 CHECK THE WATER SYSTEM When the system has been tested, ensure that the boiler is off, drain the water while it is still hot in order to complete the flushing process. Where the boiler is used on an old system, special care is required. The system should be drained and flushed out, ensuring that all the radiators are drained. -
Page 23: Fit The Case
FIT THE CASE - PAGE 23 Refer to Figs. 29 and 30. Locate the side panel(s) over the two fixings at the side of the boiler chassis against the wall. Secure each panel in position to the front of the boiler, at the top and bottom, using two of the No.8 x 12 lg. -
Page 24: Final Assembly
FINAL ASSEMBLY - PAGE 24 If a programmer is fitted, set the timer to the correct time and the programme to the required settings. See separate Programmer instructions. Hand the User instructions (and Programmer instructions if fitted) to the User and instruct in the safe operation of the boiler and controls. -
Page 25: Annual Service
ANNUAL SERVICE - PAGE 25 To ensure continued efficient operation of the appliance, it is recommended that it is checked and cleaned as necessary at regular intervals. The frequency of servicing will depend upon the particular installation conditions and usage but in general once per year should be adequate. -
Page 26: Dismantling Prior To Servicing
ANNUAL SERVICE - PAGE 26 DISMANTLING PRIOR TO SERVICING Refer to Figs. 32, 33 and 34. Turn off the gas supply at the gas service cock (bottom L.H. corner). Remove the screw securing the control box, see Fig. 25 and lower the control box. -
Page 27: Cleaning The Boiler
ANNUAL SERVICE - PAGE 27 CLEANING THE BOILER Brush the heat exchanger from above and below using a suitable brush. Brush back to front NOT sideways. Remove any fallen deposits from the base of the chassis. Brush the burner top and check that the flame ports are clear. Any blockage may be removed with a fine wire brush. Turn the burner open end down and tap gently to remove any debris. -
Page 28: Replace The Case
ANNUAL SERVICE - PAGE 28 REPLACE THE CASE Refer to Fig. 30, if necessary. If a programmer is used, ensure that the test switch on the top of the control box is set to O (off). Carefully slide the bottom panel assembly into position (the bottom panel goes above the returns on the case side panels), clip the neon, see Fig. -
Page 29: Lighting Instructions
LIGHTING INSTRUCTIONS - PAGE 29 See section 4.1 for boiler controls. For access to the controls open the control panel cover (hinges down), if the internal programmer is fitted lower the left hand cover after first opening the right hand one. If a programmer is fitted refer to Programmer instructions to set the programmer. -
Page 30: Replacement Of Parts
REPLACEMENT OF PARTS - PAGE 30 WARNING: Before commencing work open the control panel cover (hinges down) and turn the boiler thermostat to O. Allow the boiler to cool and isolate the electricity supply. IMPORTANT: Always test for gas soundness after completing any exchange of gas carrying components and carry out functional checks of controls. -
Page 31: To Replace The Spark Electrode Or Electrode Lead
REPLACEMENT OF PARTS - PAGE 31 Raise the control box and secure in position with the screw previously removed. Turn on the gas supply at the gas service cock. If a programmer is used, ensure that the test switch on the top of the control box is set to O (off). Place the outer case front panel in position over the four fixings (two on each side panel) and push the panel back to engage the fixing pins into the front panel. -
Page 32: To Replace The Pilot Burner
REPLACEMENT OF PARTS - PAGE 32 TO REPLACE THE PILOT BURNER Refer to Fig. 34. Gain general access as described in section 9.1. Remove the screws (four on the 80 model, six on the other models) securing the combustion chamber front cover and remove the cover. -
Page 33: To Replace The Fan
REPLACEMENT OF PARTS - PAGE 33 TO REPLACE THE FAN Gain general access as described in section 9.1. Remove the two screws securing the fan assembly to the flue hood, see Fig. 33. Carefully slide the fan assembly away from the flue to disengage the flue tube sleeve from the flue. -
Page 34: To Replace The Boiler Thermostat
REPLACEMENT OF PARTS - PAGE 34 9.11 TO REPLACE THE BOILER THERMOSTAT Refer to Fig. 37. Remove the case as described in section 7.1. Remove the boiler thermostat control knob from the front of the control box (pulls off). Remove the thermostat fixing nut and washer from the front of the control box. -
Page 35: To Replace The Heat Exchanger
REPLACEMENT OF PARTS - PAGE 35 9.13 TO REPLACE THE HEAT EXCHANGER Ensure that the system is drained. Remove the case and completely dismantle the boiler as described in sections 7.1 and 7.2. Drain the system. Remove the two screws securing the overheat cut-off device to the heat exchanger. Undo the two tubing nuts at the bottom of the heat exchanger and remove it from the boiler - lift it up slightly to disengage the pipes and to clear the combustion chamber then withdraw it forwards. -
Page 36: To Replace The Gas Valve Solenoids
REPLACEMENT OF PARTS - PAGE 36 9.16 TO REPLACE THE GAS VALVE SOLENOIDS Refer to Fig. 40. Gain general access as described in section 9.1, paragraph Disconnect the gas valve electrical plug from the valve. Remove the screw securing the solenoids mounting bracket and carefully withdraw the mounting bracket, complete with solenoids, from the valve. -
Page 37: To Replace The Pressure Gauge
REPLACEMENT OF PARTS - PAGE 37 9.19 TO REPLACE THE PRESSURE GAUGE Refer to Fig. 42. Gain general access as described in section 9.1, paragraph Remove the screw securing the control box, see Fig. 25 and lower the control box. Drain the system. -
Page 38: To Replace The By-Pass Valve
REPLACEMENT OF PARTS - PAGE 38 9.21 TO REPLACE THE BY-PASS VALVE Ensure that the system is drained. The by-pass valve is positioned to the left of the pump. The valve is pre-set for each particular model, ensure the boiler model is quoted when ordering a spare. -
Page 39: To Replace The Expansion Vessel
REPLACEMENT OF PARTS - PAGE 39 9.24 TO REPLACE THE EXPANSION VESSEL Ensure that the system is drained. Gain general access as described in section 9.1, paragraph 1. Drain the system. Remove the screw securing the control box, see Fig. 25 and lower the control box. Remove the two tie rods from the retaining clips on the front of the expansion vessel frame and remove the split pins from the ends of the tie rods. -
Page 40: Wiring Diagrams
WIRING DIAGRAMS - PAGE 40 a. Illustrated wiring diagram External diverter valve connections Note: Always set the Test Switch to the O (off) position if a programmer is used before the case is fitted. Supplied By www.heating spares.co Tel. 0161 620 6677... - Page 41 WIRING DIAGRAMS - PAGE 41 b. Functional flow wiring diagram Note: Always set the Test Switch to the O (off) position if a programmer is used before the case is fitted. Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 42 WIRING DIAGRAMS - PAGE 42 c. Room thermostat, cylinder thermostat and diverter valve connections Supplied By www.heating spares.co Tel. 0161 620 6677...
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Page 43: Fault Finding Guide
FAULT FINDING GUIDE - PAGE 43 Preliminary electrical system checks i.e. Earth Continuity, Short Circuit, Polarity and Resistance to Earth are the first electrical checks to be carried out during a fault finding procedure. On completion of the service / fault finding task which has required the breaking and remaking of electrical connections, then the checks –... -
Page 44: Exploded View
EXPLODED VIEW - PAGE 44 Ultra 50 shown - other models similar Supplied By www.heating spares.co Tel. 0161 620 6677... -
Page 45: Short List Spare Parts
SHORT LIST SPARE PARTS - PAGE 45 See next page for list of parts Supplied By www.heating spares.co Tel. 0161 620 6677... - Page 46 SHORT LIST SPARE PARTS - PAGE 46 Key No. GC No. Description Qty. Part No. Thermostat Knob 929079 Fan Assembly - 30 929013 Fan Assembly - 40 929014 Fan Assembly - 50 929015 Fan Assembly - 60 929016 Fan Assembly - 80 929017 Pressure Switch 929020...
- Page 47 SHORT LIST SPARE PARTS - PAGE 47 This page intentionally left blank Backpage Supplied By www.heating spares.co Tel. 0161 620 6677...