Check The Water System; Replace The Inner Case Front Panel And Expansion Vessel; Balance The System And Adjust The By-Pass Valve - Potterton Ultra DV 40 Installation & Service Manual

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4.4

CHECK THE WATER SYSTEM

1. 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.
2. 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.
3. In areas with hard or aggressive water we recommend that an inhibitor, suitable for use with copper tube boilers, should
be used in accordance with the manufactures instructions.
4. Refill, vent the system, boiler and pump, see section 3.16.
5. Pressurise the system to 1.5 bar (see section 2.11, paragraph 4) and check for leaks, rectifying where necessary.
6. If a programmer is not to be fitted, the manual lever, see Fig. 27, on the right hand side of the diverter valve must be
moved to the 'MAN OPEN' (top) position, ensure it is locked in position.
If a programmer is to be fitted, the lever must be moved to the 'AUTO' (bottom) position.
4.5

REPLACE THE INNER CASE FRONT PANEL AND EXPANSION VESSEL

1. Ensure that the inner case seals are intact and in position in the seal housing channels and that the channels are
correctly located over the sides of the boiler chassis. Replace the inner case front panel (expansion vessel frame fixing
brackets nearest the top), securing it in position with four screws. Tighten sufficiently to form a seal.
2. Remove the split pins from the ends of the tie rods and unhook them from the support frame, raise the expansion vessel
assembly and secure the frame to the inner case front panel using the two screws previously removed.
3. Unhook the tie rods from the sides of the boiler, replace the split pins into the rods and position them in the retaining
clips on the front of the expansion vessel frame.
4. Raise the control box and secure in position with the screw previously removed.
4.6 BALANCE THE SYSTEM
1. Fully open all the radiator lock shield valves and set any thermostatic radiator valves to maximum.
2. With the electricity supply on and the test switch set to 1, turn the boiler thermostat fully clockwise (
boiler.
3. Balance the system using the radiator lock shield valves to give a temperature drop of 11°C across the individual
radiators - start with the radiator nearest to the boiler.
4. Turn the boiler thermostat fully anticlockwise (
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) to turn the boiler off.
) to light the
Manual No. 405/0101