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Potterton Ultra 2 User Manual

Potterton Ultra 2
59 pages
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Part No. 405/0522 - 03
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. 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
MUST BE DISPOSED OF IMMEDIATELY.
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
IMPORTANT
PLEASE READ THIS BOOK
BEFORE INSTALLING,
OPERATING OR SERVICING
THIS BOILER.

Table of Contents

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Potterton Ultra 2 Specifications

General IconGeneral
TypeCombi
Fuel TypeNatural Gas
MountingWall Mounted
FuelNatural Gas
Boiler typeCombination boiler

Summary

Introduction to Potterton Ultra 2 Boilers

Installation and Service Overview

General introduction to the installation and service instructions for the Ultra 2 boiler range.

Gas Safety Regulations Compliance

Highlights the legal requirement to follow Gas Safety (Installation and Use) Regulations 1994.

Installation Requirements and Safety

Health and Safety Information for Installers

Details on hazardous substances and necessary safety precautions for installation personnel.

Codes of Practice for Installation

Outlines the relevant standards, regulations, and codes of practice for boiler installation.

Gas Supply Requirements

Specifications and checks required for the natural gas supply connection.

Electricity Supply Requirements

Details on electrical connections, power supply, and safety measures.

Boiler Location Guidelines

Recommendations and restrictions for choosing a suitable location to install the boiler.

Air Supply and Ventilation

Requirements for air supply and ventilation in the room where the boiler is installed.

Horizontal Flue System Installation

Instructions for installing the standard horizontal flue system.

Water Connections and System

Guidance on connecting the boiler to the water system and isolation valves.

Sealed System Requirements

Specifications and considerations for installing a sealed central heating system.

Boiler Installation Procedures

Unpacking and Boiler Preparation

Steps for unpacking the boiler and initial preparation before installation.

Optional Flue System Kits

Overview of available flue kits for different installation configurations.

Fitting the Wall Spacing Kit

Instructions for installing the optional wall spacing kit for pipework clearance.

Installing with Rear Flue

Step-by-step guide for installing the boiler with a rear-exit flue.

Installing with Side Flue

Step-by-step guide for installing the boiler with a side-exit flue.

Flue Extension Installation

Instructions for fitting flue extensions to achieve the required flue length.

Optional Vertical Balanced Flue Kit

Guide for installing the vertical balanced flue system.

Optional Vertex Flue Kit Installation

Instructions for installing the optional Vertex flue system vertically.

Fit From Inside Flue Kit

Guide for fitting the flue kit entirely from inside the building.

Connecting the Power Supply

Procedure for connecting the main power supply cable to the boiler.

Installing the Ultra 2 Programmer

Steps for installing the optional internal programmer accessory.

Connecting the Gas Supply

Instructions for connecting the natural gas supply to the boiler.

Connecting Water System and Venting

Procedures for connecting the water system and venting the boiler.

Boiler Commissioning and Initial Setup

Commissioning the Boiler

Detailed steps for initial boiler setup, including gas checks and ignition sequence.

Checking the Water System

Verifying the integrity and operation of the water system after installation.

Balancing the Heating System

Adjusting radiator valves to ensure balanced heat distribution.

Completing Boiler Assembly

Final steps for assembling the boiler's internal and external components.

Lighting the Boiler

Procedures for the initial ignition and operation of the boiler.

User Guidance on Operation

Advice for the end-user on boiler operation, controls, and frost protection.

Annual Service Recommendations

Routine Maintenance Procedures

Removing the Boiler Case

Instructions for safely removing the boiler casing for access.

Dismantling Boiler Components

Procedures for disassembling internal boiler parts for maintenance.

Cleaning Boiler Components

Guidelines for cleaning key components like the heat exchanger and burner.

Re-assembling the Boiler

Steps for correctly reassembling the boiler after maintenance.

Replacement of Boiler Parts

Gaining General Access to Components

Steps to gain access to internal components for part replacement.

Replacing the Gas Valve

Detailed instructions for replacing the main gas valve.

Replacing Gas Valve Solenoids

Instructions for replacing the gas valve solenoids.

Replacing Pump Head or Pump

Procedures for replacing the boiler's pump or pump head.

Replacing the Air Pressure Switch

Guide for replacing the air pressure switch.

Replacing the Diverter Valve Head

Steps for replacing the diverter valve head on DV models.

Replacing the Pressure Gauge

Instructions for replacing the system pressure gauge.

Replacing the Pressure Relief Valve

Procedure for replacing the pressure relief valve.

Replacing the By-Pass Valve

Instructions for replacing the system by-pass valve.

Replacing the Ignition Circuit Board

Detailed steps for replacing the ignition circuit board.

Replacing Reset Button and Neons

Instructions for replacing the reset button and neon indicator assembly.

Replacing Internal Programmer

Guide for fitting or replacing the optional internal programmer.

Replacing the Test Switch

Instructions for replacing the test switch on the control panel.

Replacing the Overheat Cut-Off Device

Procedure for replacing the overheat thermostat.

Replacing Electrode Lead and Electrode

Steps for replacing the spark electrode and its lead.

Replacing Main Burner Components

Procedures for replacing the main burner, pilot burner, and injectors.

Replacing the Fan Assembly

Instructions for replacing the boiler's fan assembly.

Replacing Combustion Chamber Insulation

Guide for replacing insulation panels in the combustion chamber.

Replacing the Boiler Thermostat

Steps for replacing the boiler's main thermostat.

Replacing the Heat Exchanger

Detailed procedure for replacing the heat exchanger.

Replacing the Expansion Vessel

Instructions for removing and replacing the expansion vessel.

Wiring Diagrams and Electrical Connections

Ultra 2 Functional Flow Diagram

Diagram showing the functional flow of signals within the boiler control system.

Boiler Fault Finding Guides

Fault Finding Group 1: Initial Checks

Troubleshooting steps for initial electrical checks and ignition sequence.

Fault Finding Group 2: Pilot Issues

Diagnostic steps for pilot light and gas supply problems.

Fault Finding Group 3: Burner and Pump Issues

Troubleshooting steps for main burner, pump, and thermostat related problems.

Fault Finding Group 4: System Operation

Diagnostic steps for system operation and heat distribution issues.

Short List of Spare Parts

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