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THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994.
'' In your own interest, and that of safety, it is law that all gas appliances are installed by competent persons,
in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution.''
The polythene bags used for packaging are a potential hazard to babies and young children and
Installation must be in accordance with the Installation & Service Instructions and the rules in force.
LEAVE THESE INSTRUCTIONS WITH THE USER FOR USE ON FUTURE CALLS
For Use With Natural Gas
(G20) Only At 20mbar
For Use in GB & IE
Installation & Service Instructions
Wall Mounted Fan Assisted Balanced Flue
Gas System Boilers
MUST BE DISPOSED OF IMMEDIATELY.
See inside cover for models covered by these instructions
IMPORTANT
PLEASE READ THIS BOOK
BEFORE INSTALLING,
OPERATING OR SERVICING
THIS BOILER.
405/0522 - 03
Part No.
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Table of Contents
Related Manuals for Potterton Ultra 2
Summary of Contents for Potterton Ultra 2
- Page 1 405/0522 - 03 Part No. See inside cover for models covered by these instructions Installation & Service Instructions Wall Mounted Fan Assisted Balanced Flue Gas System Boilers THE GAS SAFETY (INSTALLATION AND USE) REGULATIONS 1994. ‘‘ In your own interest, and that of safety, it is law that all gas appliances are installed by competent persons, in accordance with the above regulations.
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Page 2: Table Of Contents
Commissioning............32 are:- Commission the Boiler........32 Check the Water System........34 Ultra 2 30Dv - G.C. No. 41 607 50 Balance the System..........34 Ultra 2 40Dv - G.C. No. 41 607 51 Complete the Boiler ..........34 Ultra 2 50Dv - G.C. No. 41 607 52 Ultra 2 60Dv - G.C. -
Page 3: Technical Data
Technical Data - Page 3 The boiler model and serial number are given on the data badge. The boiler data label is on the left hand side of the chassis next to the gas valve. Boiler models Burner type (Aeromatic) AC13/112508 AC13/112509 AC13/112510... -
Page 4: Introduction
A 1m Flue Extension Kit is available (the total flue length must not exceed 3 m). The Ultra 2 boilers are range ratable and are factory set to the maximum output. An Internal Programmer is also available that fits into the facia. -
Page 5: Gas Supply
“Guide for Gas Installation in Timber Framed Housing” reference DM2. If in doubt advice must be sought from the local region of British Gas or from Potterton Myson. The boiler may be installed in any room, although particular attention is drawn to the requirements of the current IEE Wiring Regulations and, in Scotland, the electrical provisions of the Building Standards applicable in Scotland with respect to the installation of the boiler in a room containing a bath or shower. - Page 6 Installation Requirements - Page 6 Fig 1...
- Page 7 Installation Requirements - Page 7 Fig 2...
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Page 8: Air Supply
Installation Requirements - Page 8 Air Supply The room in which the boiler is installed does not require a purpose provided air vent. If the boiler is installed in a cupboard or compartment, permanent air vents are required in the cupboard or compartment, one at high level and one at low level, either direct to the outside air or to a room. - Page 9 Installation Requirements - Page 9...
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Page 10: Installation
2. Installation - Page 10 Unpack & Prepare the Boiler These instructions assume you have decided on the where the boiler will be located and the type of flue system to be used. Carefully unpack the boiler. Do not discard any packaging until all the items are accounted for. -
Page 11: Options Available For Ultra 2
Installation - Page 11 Options Available for Ultra 2 Rubber Gasket Outer Wall Plate Outer Plate Outer Outer Flue Inner Wall Wall Seal Screws & Plugs Sealing Wall Terminal Lining (4 off) Plate Plate T ube Flue Liner Wall Liner Screws &... -
Page 12: Fit The Optional Wall Spacing Kit
Installation - Page 12 Dim. 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 roofs From a vertical drain pipe or soil pipe From an internal or external corner Above ground, roof or balcony level... -
Page 13: Install The Boiler & Rear Flue
Installation - Page 13 Install the Boiler and Rear Flue Having noted the clearances needed for installation (flue terminal & boiler), position the wall mounting plate against the wall (ensure it is level) and mark the position of the flue hole and centre, plus a minimum of four of the mounting holes. - Page 14 Installation - Page 14 Remove the clamping plate & sealing ring from the rear boiler chassis flue hole, place to one side. Measure the wall thickness from the edge of the outer wall to the flue hole in the boiler chassis. Add 15mm (9mm for 80 model)and mark this distance on the flue from the terminal flange.
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Page 15: Install The Boiler & Side Flue
Installation - Page 15 Install the Boiler and Side Flue Having noted the clearances needed for installation 227mm Spirit Level (flue terminal & boiler), position the wall mounting plate (267mm with wall spacer) against the wall (ensure it is level) and mark the 70mm Top Clearance position of the flue hole and centre, plus a minimum of... - Page 16 Installation - Page 16 11. Remove the cover plate from the white case side and attach the panel to the boiler. 12. Locate the outer wall plate and rubber gasket onto the die cast flue terminal. 13. From the outside, insert the flue through the hole in the wall.
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Page 17: Flue Extension
Installation - Page 17 Flue Extension The total length must not exceed 3 m. If the length of the flue/terminal assembly is to be more than 600 mm, one, two or three flue extensions will have to be used as follows: Carefully unpack the flue extension. -
Page 18: Fit The Optional Vertical Balanced Flue
Installation - Page 12 Fit the Optional Vertical Balanced Flue This Vertical Balanced Flue kit is only for use with the Ultra 2 Boiler and allows the flue to run vertically from the boiler, terminating above either a flat or pitched roof. - Page 19 Installation - Page 19 Carefully unpack the kit, do not discard the packaging until all the items are found. The sealing ring and clamping plate supplied with the boiler are not required when the Vertical Balanced Flue kit is used and should be discarded. Having noted the clearances needed for installation (flue terminal &...
- Page 20 Installation - Page 20 Retain the adaptor for connection of the flue system to the boiler. 13. The Vertical Balanced Flue MUST be installed from the roof ! Carefully lower the flue assembly, complete with collar and flashing, down through the previously prepared holes in the roof, internal ceilings and floors.
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Page 21: Fit The Optional Vertex Flue
Fit the Optional Vertex Flue This Vertex Flue kit is only for use with the Ultra 2 Boiler and allows the flue to be run vertically from the boiler. The kit may be used as supplied or with one, two or three flue extension kits. - Page 22 Installation - Page 22 10. If a flue extension is to be used, secure and seal this to the bottom half of the Vertex Flue as follows:- Locate the flared end of the extension over the open end of the Vertex Flue. Ensure that the inner flue tubes Mark the centre line up to the ceiling are engaged.
- Page 23 Installation - Page 23 Connect The SECONDARY FLUE To The VERTEX FLUE Always use compatible flue pipes, sockets, connectors, etc. for the complete flue system. Do not mix components from different manufacturers. The secondary flue must comply with BS5440:1 in respect to routing, supporting, weather proofing, fire precautions and must be connected to a suitable ridge or roof terminal.
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Page 24: Fit The Optional Fit From The Inside Flue
Installation - Page 24 Fit the Optional Fit From The Inside Flue Kit The Fit From the Inside Flue Kit allows the flue/terminal assembly to be fitted entirely from inside the building and is suitable for rear or side exit flue. The kit is only suitable for walls 100 - 375 mm thick and requires a 152 mm diameter hole to be cut through the wall. - Page 25 Installation - Page 25 Fit the flue terminal in the wall liner. Attach the wall plate to the wall. Ensure it is level. Slide the flue assembly back into the room, so the flue terminal disengages from the outer wall plate. The flue assembly will then be angled downward ready to accept the boiler chassis.
- Page 26 Installation - Page 26 To Fit The FIT FROM THE INSIDE FLUE KIT With SIDE Exit Flue With side exit flue a minimum of 25 mm clearance is required on the opposite side to the flue for installation. The rubber seal, inner plate, wall liner and outer wall plate supplied with the horizontal flue terminal are not required with this kit.
- Page 27 Installation - Page 27 Put wedges in the end of the flue to stop the outer flue compressing onto the inner. Cut squarely through both the inner and outer tubes. Remove all burrs. 10. Mark one of the boiler fixing points, then drill and plug to accept a 1"...
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Page 28: Connect The Power Supply Cable
Installation - Page 28 21. Remove the screw and unhook the base plate - DO NOT discard these items. 2.10 Connect the Power Supply Cable Remove the screw securing the control box to the thermostat mounting bracket. Swing the control box out. Two cable clamps are provided on the back of the control box, use one just for the mains supply and the other for any other external wiring. - Page 29 Installation - Page 29 Wiring Diagrams: With External Programmer Fitted (2 Channel Programmer) With Room & Cylinder Thermostats MAINS Rear Of Cable Clamp (Use For (Fuse at Control Box Sensomatic - PRT 2 Mains Cable Only) 3 amp, min Honeywell - T6160B Room 0.5mm cable) Remove Link When...
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Page 30: Install The Ultra 2 Programmer
Installation - Page 30 2.11 Install the Optional Ultra 2 Programmer Connect the programmers electrical plug onto the socket on the back of the control box. Carefully remove the blanking panel from the facia (the facia label is self adhesive), locate the programmer into the cut out, position the retaining bracket and secure using the screws supplied with the programmer. -
Page 31: Connect The Water System & Vent The Boiler
Installation - Page 31 2.13 Connect the Water System & Vent the Boiler Ensure that the plastic plugs are removed from the pipe ends and attach the isolation valves. Check the valves are open. Install the pressure relief valve discharge pipe (min. 15mm dia.) and connect to the pressure relief outlet using a 15mm compression fitting. -
Page 32: Commissioning
3. Commissioning - Page 32 Flexible Tube F an Cable Clips Flue Sampling Point Vertical L.H. Flue Outlet Flue Outlet F an & Diverter Heat Exchanger Assembly Overheat Thermostat R.H. Flue (R.H. Side On 60 Outlet & 80 Models) Insulation Flue Hood Thermostat Phial... - Page 33 Commissioning - Page 33 Check the ignition sequence. With the gas supply isolated check the ignition sequence as follows: Set the test switch to 'Override'. Note: Three indicator lamps are included on the ignition board to aid electrical commissioning. The correct sequence of lights when there is a call for heat is: Permanent Live 'On', Switched Live 'On', Reversed Polarity 'Off'.
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Page 34: Check The Water System
Commissioning - Page 34 Check the Water System When the system has been tested, ensure that the boiler is turned 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 35: Advise The User
If a programmer is fitted, set the timer to the correct time and programme the required settings. For a wall mounted programer, see separate programmer instructions. For the Ultra 2 programmer, see the boiler Instructions for Use. Hand the Instructions for Use, these Installation & Service Instructions (and the programmer instructions) to the User and instruct in the safe operation of the boiler and controls. -
Page 36: Routine Maintenance
5. Routine Maintenance - Page 36 Remove the Case Ensure that the electricity supply is off. Pull down the control cover flap to expose the facia. Remove the 2 screws securing the facia to the side panels and remove the facia/control cover carefully unclipping the two neons as you pull the facia away. Note: If required, disconnect the programmer harness from the rear of the control box. - Page 37 Routine Maintenance - Page 37...
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Page 38: Replacement Of Parts
6. Replacement Of Parts - Page 38 WARNING: Before commencing work open, the control panel cover (hinges down) and turn the thermostat knob to O (Off). Allow the boiler to cool and isolate the electricity supply. Turn off the gas at the gas service cock. IMPORTANT: Always test for gas soundness after completing any exchange of gas carrying components and carry out functional checks of controls. -
Page 39: Gas Valve
Replacement of Parts - Page 39 Gas Valve Gain General Access - See Section 6.1, Paragraph 1. Slacken the retaining screw and disconnect the gas valve electrical plug from the valve. Disconnect the pilot supply from the top of the gas valve. -
Page 40: Pump
Replacement of Parts - Page 40 Pump Head/Pump Complete Pump Head Gain General Access - See Section 6.1, Paragraph 1. Remove the screw securing the pressure switch to the chassis and move the switch out of the way. Remove the two screws securing the thermostat bracket to the chassis and move it out of the way. -
Page 41: Diverter Valve Head (Ultra 2 Dv Models)
Replacement of Parts - Page 41 Diverter Valve Head Dv Models Only Gain General Access - See Section 6.1, Paragraph 1. Disconnect the diverter valve head wiring harness plug from the ignition circuit board. Remove the two screws securing the diverter valve head to the main body and lift off the head. -
Page 42: Pressure Relief Valve
Replacement of Parts - Page 42 Pressure Relief Valve Gain General Access - See Section 6.1, Paragraph 1. Drain the system by removing the pressure gauge connection from the water manifold. Note: When the system is drained, filled or vented, the manual lever on the left hand side of the diverter valve must be moved to the 'MID' (manual override) position. -
Page 43: Ignition Circuit Board
Compress the clips on the side and pull the reset button through the chassis. Re-assemble in reverse order. 6.12 Potterton Internal Ultra 2 Programmer (If Fitted) Gain General Access - See Section 6.1, Paragraph 1. Note how it fits and unplug the programmer wiring harness plug from the back of the control box. -
Page 44: Test Switch
Replacement of Parts - Page 44 6.13 Test Switch Gain General Access - See Section 6.1, Paragraph 1. Disconnect the two electrical (spade) connectors from the switch. Note which way the switch is fitted, compress the clips on the switch body and push it out of the control box. Fit the new switch as shown with the spade connectors to the bottom. -
Page 45: Spark Electrode/Electrode Lead
Replacement of Parts - Page 45 6.15 Electrode Lead/Electrode Spark Electrode. Gain General Access - See Section 6.1 complete. Disconnect the electrode lead from the spark electrode. Undo the securing nut and pull the electrode from the pilot burner. Fit the new spark electrode to the pilot burner and secure using the nut. -
Page 46: Main Burner
Replacement of Parts - Page 46 6.16 Main Burner, Pilot Burner, Main Injector, Pilot Injector Pilot Injector Gain General Access - See Section 6.1 complete. Pull the electrode lead off the electrode. Undo the pilot supply pipe tubing nut at the pilot burner and gas valve. -
Page 47: Fan
Replacement of Parts - Page 47 6.17 Fan Gain General Access - See Section 6.1 complete. Disconnect the overheat thermostat leads. Remove the two screws securing the fan assembly to the flue hood. Carefully slide the fan assembly away from the flue to disengage the flue tube sleeve from the flue. -
Page 48: Combustion Chamber Insulation Panels
Replacement of Parts - Page 48 6.18 Combustion Chamber Insulation Panels Gain General Access - See Section 6.1 complete. Remove the fan/diverter assembly - see Section 6.17. Remove the four remaining screws securing the combustion chamber insulation cover and remove the cover. -
Page 49: Heat Exchanger
Replacement of Parts - Page 49 6.20 Heat Exchanger Note: When removing the heat exchanger it will discharge some remaining water, suitably protect the electronics. Gain General Access - See Section 6.1 complete. Remove the Main Burner - See Section 6.16 Remove the Fan/Diverter Assembly - See Section 6.17 Remove the flue hood by taking out two long screws at... -
Page 50: Expansion Vessel
Replacement of Parts - Page 50 6.21 Expansion Vessel Depending on ease of access, the expansion vessel can be removed from the left, right or from above the boiler. Alternatively, the boiler can be taken off the wall and the vessel removed from the boiler. -
Page 51: Wiring Diagrams
7. Wiring Diagrams - Page 51... -
Page 52: Wiring Diagrams - Ultra 2Dv
Wiring Diagrams - Page 52 Ultra 2Dv... -
Page 53: Wiring Diagrams - Ultra 2
Wiring Diagrams - Page 53 Ultra 2... -
Page 54: Fault Finding
8. Fault Finding Guide - Page 54 54 Fault Finding Part No. 405/0522... - Page 55 Fault Finding Guide - Page 55 Part No. 405/0522 Fault Finding 55...
- Page 56 Fault Finding Guide - Page 56 56 Fault Finding Part No. 405/0522...
- Page 57 Fault Finding Guide - Page 57 Part No. 405/0522 Fault Finding 57...
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Page 58: Short List Of Spares
9. Short List Of Spare Parts - Page 58... - Page 59 Short List Spare Parts - Page 59 Drg. Ref. G.C. No. Description Part No. 289 911 Fan Assembly - 30, 40 & 50 Models 405/0792 289 912 Fan Assembly - 60, 80 Models 405/0730 379 789 Pressure Switch (0.5bar Setting) 642223 379 983 Bypass Valve 28mm...