Potterton Ultra DV 30 Installation & Service Manual Download

Page: 1 / 46

Supplied By www.heating spares.co Tel. 0161 620 6677

405/0101 - 03

Installation & Servicing Manual

for the

Ultra Dv range of wall mounted

fan assisted balanced flue gas boilers

G.C. Appliance No's.

Ultra Dv 30

41 494 73

Ultra Dv 40

41 494 74

Ultra Dv 50

41 494 75

Ultra Dv 60

41 494 76

Ultra Dv 80

41 494 77

IMPORTANT

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.

Summary of Contents for Ultra DV 30

Page 1: ...fan assisted balanced flue gas boilers G C Appliance No s Ultra Dv 30 41 494 73 Ultra Dv 40 41 494 74 Ultra Dv 50 41 494 75 Ultra Dv 60 41 494 76 Ultra Dv 80 41 494 77 IMPORTANT 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 ...

Page 2: ...12 3 7 Side Flue Prepare the Wall 14 3 8 Side Flue Cut the Flue Terminal Assembly to Length 14 3 9 Side Flue Flue Extension 15 3 10 Side Flue Prepare and Fit the Boiler 15 3 11 Side Flue Fit the Flue Terminal Assembly 17 3 12 Side Flue Replace the Fan Assembly 17 3 13 Connect the Gas Supply 18 3 14 Connect the Power Supply Cable 18 3 15 Replace the Expansion Vessel 19 3 16 Connect the Water System...

Page 3: ...Gas Valve Solenoids 36 9 17 To Replace the Ignition Circuit Board 36 9 18 To Replace the Pump 36 9 19 To Replace the Diverter Valve Head 37 9 20 To Replace the Pressure Gauge 37 9 21 To Replace the Safety Valve 38 9 22 To Replace the By Pass Valve 38 9 23 To Replace the Test Switch 39 9 24 To Replace the Neon Indicator 39 9 25 To Replace the Expansion Vessel 39 9 26 To Replace the Programmer if fi...

Page 4: ... 1 min 15 0 1 min 19 2 1 min 22 8 1 min 30 6 1 min Pump head 4 6 m water 3 8 m water 2 8 m water 1 8 m water 1 7 m water Maximum flow temperature 82 C Design water temperature rise 11 C Height 800 mm Width 450 mm Depth 350 mm Clearance Top 50 mm 150 mm if Vertex flue kit is to be fitted required Bottom 150 mm for Front 500 mm servicing Sides 10 mm Flue terminal size 100 mm dia x 65 mm deep Water c...

Page 5: ...with 2 3 DELIVERY KITS AVAILABLE The unit is delivered in two packages 1 the uncased boiler with casing panels and 2 the flue terminal assembly A 1 m flue extension kit is available the total flue length must not exceed 3 m An integral programmer kit is also available to fit within the boiler casing A Vertex Flue kit is available which allows the flue to exit vertically from the boiler maximum len...

Page 6: ...e duct is not closer than 25 mm to combustible material A metal sleeve should be installed to surround the flue duct to provide a 25 mm annular space Further guidance is given in BS5440 1 1990 sub clauses 3 3 and 4 2 5 If the boiler is to be installed in a timber framed building it should be fitted in accordance with the British Gas publication Guide for Gas Installation in Timber Framed Housing r...

Page 7: ...window into dwelling 1200 L Vertically from a terminal on the same wall 1500 M Horizontally from a terminal on the same wall 300 If the terminal is fitted within 850 mm of a plastic or painted gutter pipe or 450 mm of painted eaves an aluminium shield of at least 750 mm in length should be fitted to the underside of the gutter pipe or painted surface If the terminal is fitted less than 2 m above a...

Page 8: ... WATER CONNECTIONS Refer to Fig 3 Fig 3 Compression fittings are supplied loose with the boiler to accept 22 mm and 28 mm copper tubing to BS2871 Common return 28 mm Hot water cylinder supply 22 mm Central heating supply 28 mm A 15 mm nut and olive are fitted to the safety valve discharge ready to accept a 15 mm pipe All water connections are centred 40 mm from the wall Note The supply and return ...

Page 9: ...ed to 0 5 bar This is suitable for a system with a maximum water content of 140 litres 4 Water lost from the system shall be replaced from a make up vessel and double check valve mounted higher than the top of the system and connected as shown in Fig 4a or manually by a temporary hose connection as shown in Fig 4b remove the temporary hose after use Note Stop valves must comply with the requiremen...

Page 10: ... parts before fitting them See Fig 29 for case parts 4 Check that the boiler fixings pack contains Four No 8 x 12 lg c sk hd screws Six No 6 x 10 lg pan hd screws Two M4 x 10 lg c sk hd screws Four M6 x 10 lg hex hd screws One 22 mm nut and olive Two 28 mm nuts and olives Fig 6 3 2 UNPACK THE FLUE TERMINAL Refer to Fig 7 1 Carefully unpack the flue terminal assembly 2 Do not discard any packaging ...

Page 11: ... finished wall thickness this is very important and is required for section 3 4 when cutting the flue terminal assembly to length 6 Place the rubber sealing ring supplied with the flue terminal assembly in position in the opening in the wall mounting plate as shown in Fig 9 it does not matter what position the cut away is in Ensure that the groove in it is located correctly over the mounting plate...

Page 12: ...mbly over the terminal as shown in Fig 12 and mark the position of the four fixing holes 5 Remove the sealing plate and drill and plug the holes suitable for 1 lg No 8 woodscrews Note The terminal should be covered before drilling to prevent debris entering the terminal 6 Remove any covering from the terminal Position the sealing plate over the terminal and secure it to the wall with four 1 lg No ...

Page 13: ...ight of the boiler 5 Secure the boiler to the wall mounting plate using the four M6 hex hd screws supplied with the boiler 6 Remove the four screws securing the transit cover to the bottom of the boiler see Fig 13 and discard the cover and screws 7 Ensure that the O ring is in position on the fan outlet then fit the flue tube sleeve supplied with the boiler over the fan outlet and push it fully ho...

Page 14: ...l and continue it around onto the side wall as shown in Fig 16 Ensure these lines are level 4 Mark the position of the hole for the flue duct as shown in Fig 16 5 Cut the 115 mm dia hole in the wall and drill and plug the fixing holes to accept 2 lg No 12 woodscrews 6 Make a note of the finished wall thickness this is very important and is required in section 3 8 when cutting the flue terminal ass...

Page 15: ...al assembly using the three screws supplied with the extension Seal the joint with the tape supplied with the extension If the length of the flue terminal assembly is to be more than 1500 mm fit another flue extension to the one just fitted in the same way Similarly if the assembly is to more than 2500 mm fit another flue extension 4 Mark the flue terminal assembly to the required length measure f...

Page 16: ...supplied with the boiler 6 Remove the four screws securing the transit cover to the bottom of the boiler see Fig 19 and discard the cover and screws 7 Remove the four screws and sealing plate from the side of the chassis from which the flue is to exit Discard the sealing plate but retain the four screws 8 Place the rubber sealing ring supplied with the flue terminal assembly in position in the ope...

Page 17: ...the terminal Position the sealing plate over the terminal and secure it to the wall with four 1 lg No 8 screws supplied with the flue terminal assembly Fig 21 Fig 22 3 12 SIDE FLUE REPLACE THE FAN ASSEMBLY Refer to Fig 23 1 Ensure that the O ring is in position on the fan outlet then fit the flue tube sleeve supplied with the boiler over the fan outlet and push it fully home 2 Place the fan assemb...

Page 18: ...ut of the cable clamp the live and neutral wires become taut before the earth wire Fig 25 3 Feed the cylinder thermostat wires room thermostat wires and any other external controls wiring into the boiler through the hole marked wiring in the bottom of the chassis then into the control box through the other cable clamp and connect them to the terminal block Refer to the tables on page 42 for variou...

Page 19: ...ction 2 11 paragraph 4 Ensure that all valves are open The pump isolating valves are open when the operating slots are horizontal The manual lever on the right hand side of the diverter valve see Fig 27 must be moved to the MAN OPEN top position when filling venting or draining the system Thoroughly flush the system through A radiator type air vent is positioned on the left hand side at the front ...

Page 20: ...s provided on the top of the control box which will allow the boiler to operate during commissioning without the programmer connected Before the case is fitted this switch must be set to the O off position if a programmer is used 3 Ensure the control box front is secured in position 4 3 COMMISSION THE BOILER 1 Test for gas soundness and purge the supply a With the boiler service cock closed the co...

Page 21: ... check that all system controls are calling for heat b Turn the boiler thermostat fully clockwise The unit will go through the automatic ignition sequence and the pilot will light A second or so after the pilot is lit the main gas solenoid will open and the main burner will light c Test the main burner manifold connection at the gas valve for gas soundness using a suitable leak detecting fluid 5 C...

Page 22: ...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 ...

Page 23: ...it the programmer to the back of the control panel locating the top two hinge pins into the brackets above the opening then lowering it against the panel and securing it at the bottom using the two screws supplied with the programmer Retain the Programmer instructions to hand to the User 5 Ensure that the boiler thermostat control knob is in position on the front of the control box 6 Carefully sli...

Page 24: ...ration of the boiler and controls 3 Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frost conditions 4 Advise the User that for continued efficient and safe operation of the boiler it is important that adequate servicing is carried out at least once a year by the local Gas Region or a C O R G I...

Page 25: ... sufficiently large pilot flame cannot be achieved examine the pilot injector orifice to ensure it is clear and undamaged 5 When refitting the inner case front panel check that the seals are in good condition and compress satisfactorily On completion of the service run the boiler and ensure that it operates satisfactorily The boiler model and serial No are given on the Serial No label on the front...

Page 26: ...e 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 Withdraw the fan assembly disconnecting the fan motor and pressure switch leads Note If a Vertex Flue is fitted slide the flue tube sleeve up into the flue to disengage it from the fan outlet 6 Remove the push rod assembly and the leads from the overheat cu...

Page 27: ...the flue hood to the combustion chamber 7 All models except 80 Secure the flue hood to the combustion chamber with the four screws previously removed two at the back extended screws and two at the front 8 Reconnect the overheat cut off device leads the polarity is not important and connect the push rod to the cut off device the rubber sleeve locates over the cut off device button 9 Ensure that the...

Page 28: ... previously removed Note If a programmer is fitted it will be necessary to connect the programmer wiring harness to the rear of the programmer as the bottom panel assembly is slid into position 3 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 Note Types of screws used a Small machine s...

Page 29: ...to 0 2 Switch on the electricity supply set the programmer to continuous if a programmer is fitted and check that all system controls are calling for heat 3 Turn the boiler thermostat to 7 The automatic ignition sequence will start The fan will start and after a purge period of about 10 seconds a click will be heard indicating that the start gas solenoid has opened the ignition sparks will also be...

Page 30: ...he expansion vessel frame and remove the split pins from the ends of the rods Remove the two screws securing the expansion vessel support frame to the inner case front panel Hook the plain ends of the tie rods into the brackets on the sides of the boiler Carefully lower the expansion vessel and frame hinged at the bottom Locate the other ends of the tie rods in the brackets on the expansion vessel...

Page 31: ...de Ensure that the pilot supply and electrode lead are in position in the cut out in the bottom of the chassis and replace the seal housing channel over the bottom of the chassis ensure it is pushed fully home 4 Replace the inner case front cover and expansion vessel as described in section 9 2 paragraphs 1 to 5 5 Remove the four screws securing the control box front cover and carefully swing down...

Page 32: ...f the chassis and replace the seal housing channel over the bottom of the chassis ensure it is pushed fully home 13 Replace the combustion chamber front cover and secure in position with the screws four or six previously removed 14 Refer to the Commissioning Instructions section 4 Light the pilot check the pilot flame and test the pilot supply for gas soundness 15 Reassemble the boiler as describe...

Page 33: ...of the flue hood For side exit flue locate the base of the fan assembly under the returns first then slide the fan across into the flue Note If a Vertex Flue is fitted slide the flue tube sleeve down out of the flue and over the fan outlet Secure the front of the fan assembly to the flue hood with the two screws previously removed 5 Reassemble the boiler as described in section 9 2 6 Refer to the ...

Page 34: ...stat control knob 10 Remove the fixing retaining the thermostat phial and remove the old thermostat 11 Position the new thermostat phial so it is in contact with the pipe along its full length and retain in position with the fixing previously removed 12 Replace the case as described in section 7 5 13 Refer to the Lighting Instructions section 8 Light the boiler and allow it to heat up Check that t...

Page 35: ...ove the two screws securing the thermostat to the chassis 4 Fit the new thermostat and secure with two screws 5 Connect the wires to the thermostat red to terminal 1 yellow to terminal 2 and brown to terminal 3 6 Reassemble the boiler as described in section 9 2 paragraphs 5 to 9 7 Refer to the Lighting Instructions section 8 and light the boiler Allow the boiler to heat up fully then switch it of...

Page 36: ... the side of the control box and secure it in position with the four screws previously removed 7 Reassemble the boiler as described in section 9 2 paragraphs 6 to 9 8 Refer to the Lighting Instructions section 8 and light the boiler Fig 41 9 18 TO REPLACE THE PUMP 1 Gain general access as described in section 9 1 paragraph 1 2 Remove the screw securing the control box see Fig 25 and lower the cont...

Page 37: ...of the old one 10 Connect the diverter valve head wires to the terminal block on the top of the control box See wiring diagram on page 41 11 Re engage the control box hinge pins and raise the control box securing it in position with the screw previously removed 12 Reassemble the boiler as described in section 9 2 paragraphs 6 to 9 13 Refer to the Lighting Instructions section 8 and light the boile...

Page 38: ...r as described in section 9 2 paragraphs 5 to 9 15 Refer to the Lighting Instructions section 8 and light the boiler 9 22 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 1 Gain general access as described in section 9 1 paragr...

Page 39: ...E THE EXPANSION VESSEL Ensure that the system is drained 1 Gain general access as described in section 9 1 paragraph 1 2 Drain the system Note When the system is drained filled or vented the manual lever on the right hand side of the diverter valve see Fig 27 must be moved to the MAN OPEN top position Return it to its original position after the system has been filled and vented 3 Remove the screw...

Page 40: ...clip it from the top brackets 4 Fit the new programmer to the back of the control panel locating the top two hinge pins into the brackets above the opening then lowering it against the panel and securing it at the bottom using the two screws supplied with the programmer 5 Carefully slide the bottom panel assembly into position the bottom panel goes above the returns on the case side panels clip th...

Page 41: ...spares co Tel 0161 620 6677 Manual No 405 0101 WIRING DIAGRAMS 41 10 WIRING DIAGRAMS PAGE 41 a Illustrated wiring diagram Note Always set the Test Switch to the O off position if a programmer is used before the case is fitted ...

Page 42: ...Supplied By www heating spares co Tel 0161 620 6677 Manual No 405 0101 WIRING DIAGRAMS 42 WIRING DIAGRAMS PAGE 42 b Functional flow wiring diagram ...

Page 43: ...Supplied By www heating spares co Tel 0161 620 6677 Manual No 405 0101 FAULT FINDING GUIDE 43 11 FAULT FINDING GUIDE PAGE 43 ...

Page 44: ...Supplied By www heating spares co Tel 0161 620 6677 44 EXPLODED VIEW Manual No 405 0101 12 EXPLODED VIEW PAGE 44 Ultra Dv 50 shown other models similar ...

Page 45: ...Supplied By www heating spares co Tel 0161 620 6677 Manual No 405 0101 SHORT LIST SPARE PARTS 45 13 SHORT LIST SPARE PARTS PAGE 45 See next page for list of parts ...

Page 46: ...4073A1098 DV30 60 1 929035 68 Diverter Valve 28mm Honeywell V4073A1104 DV80 1 929036 79 Pilot Injector 1 929001 81 Spark Electrode 1 929008 82 Electrode Lead 1 929009 83 386 674 Gas Control Valve SIT 0 830 020 1 929010 87 O Ring 2 929011 88 Burner Injector DV30 Bray 23 800 1 929002 88 Burner Injector DV40 Bray 23 1100 1 929003 88 Burner Injector DV50 Bray 23 1350 1 929004 88 Burner Injector DV60 B...

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Potterton Ultra DV 30, Installation & Service Manual

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