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 Ultra Dv 40 Ultra Dv 50 Ultra Dv 60 Ultra Dv 80 41 494 73 41 494 74 41 494 75 41 494 76 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.
LIST OF CONTENTS 1. 2. 3. 4. 5. 6. 7. TECHNICAL DATA .........................................................................................................................................................4 GENERAL .......................................................................................................................................................................5 2.1 Introduction...........................................................................................................
8. 9. 10. 11. 12. 13. LIGHTING INSTRUCTIONS..........................................................................................................................................29 REPLACEMENT OF PARTS ........................................................................................................................................30 9.1 General Access Prior to Replacement of Parts ...................................................................................................30 9.
1. TECHNICAL DATA - PAGE 4 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 Burner type (Aeromatic) Burner injector Pilot injector Pilot flame Spark gap Ignition Weight (empty) Max.
2. GENERAL - PAGE 5 2.1 INTRODUCTION These fanned draught room-sealed wall mounted boilers are for use on natural gas only. The Ultra Dv boilers are range rated at the following outputs: Ultra Dv 30: 5.9 to 8.8 kW (20 000 to 30 000 Btu/h) Ultra Dv 40: 8.8 to 11.7 kW (30 000 to 40 000 Btu/h) Ultra Dv 50: 11.7 to 14.7 kW (40 000 to 50 000 Btu/h) Ultra Dv 60: 14.7 to 17.6 kW (50 000 to 60 000 Btu/h) Ultra Dv 80: 17.6 to 23.4 kW (60 000 to 80 000 Btu/h) All models are factory set to the maximum output.
GENERAL - PAGE 6 In the event of an electrical fault after installation of the appliance, preliminary electrical systems checks must be carried out i.e. Earth Continuity, Short Circuit, Polarity and Resistance to Earth. 2.6 AIR SUPPLY The room in which the boiler is installed does not require a purpose provided air vent.
GENERAL - PAGE 7 Fig. 1 Dimension Terminal Position (Fanned Balanced Flue models) Min. Spacing A B Directley below an openig, air brick, window, etc.
GENERAL - PAGE 8 2.9 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. 150 mm is required above the boiler if the Vertex flue kit is fitted. Fig. 2 2.10 WATER CONNECTIONS Refer to Fig. 3. Fig.
GENERAL - PAGE 9 2.11 SEALED SYSTEM REQUIREMENTS Refer to Fig. 4. 1. The installation must comply with the requirements of BS6798 and BS5449. Maximum water temperature is 82°C ± 3°C. 2. 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. 3. A 10 litre expansion vessel to BS4841 is fitted and pre-charged to 0.5 bar. This is suitable for a system with a maximum water content of 140 litres. 4.
3. INSTALLATION - PAGE 10 3.1 UNPACK THE BOILER Refer to Fig. 6. 1. Carefully unpack the boiler. 2. Do not discard any packaging until all the items are accounted for, see Fig. 6. 3. Place the case pack and foam seal to one side so as not to damage the case 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.
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. 3.3 REAR FLUE - PREPARE THE WALL Refer to Figs. 8 and 9. 1. Remove the four screws and sealing plate from the wall mounting plate. Discard the sealing plate but retain the four screws. 2. Decide upon the position of the boiler, ensuring that the position of the flue terminal will meet the requirements given in section 2.6.
INSTALLATION - REAR FLUE - PAGE 12 3.5 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. 1. Fit the outer wall plate, supplied with the flue/terminal assembly, over the flue/terminal assembly as shown in Fig. 11. 2.
INSTALLATION - REAR FLUE - PAGE 13 2. 3. front panel just below the depression. See Fig. 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. 13. 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. Ensure that they are correctly fitted over the chassis edges before the front panel is replaced.
INSTALLATION - SIDE FLUE - PAGE 14 3.7 SIDE FLUE - PREPARE THE WALL Refer to Figs. 15 and 16. 1. 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 minimum clearances required for servicing:Top 107 mm, Bottom 528 mm, Each side 78 mm.
INSTALLATION - SIDE FLUE - PAGE 15 3.9 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. This length must not exceed 3 m. If the length of the flue/terminal assembly is to be more than 500 mm, one, two or three flue extensions will have to be used as follows: 1. Carefully unpack the flue extension.
INSTALLATION - SIDE FLUE - PAGE 16 front panel just below the depression. See Fig. 19. 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. 19. 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. Ensure that they are correctly fitted over the chassis edges before the front panel is replaced. 3.
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. 1. Fit the outer wall plate, supplied with the flue/terminal assembly, over the flue/terminal assembly as shown in Fig. 21. 2.
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. 2. Do not turn the gas supply on at this stage. Fig.24 3.14 CONNECT THE POWER SUPPLY CABLE Refer to Fig. 25. 1.
INSTALLATION - PAGE 19 3.15 REPLACE THE EXPANSION VESSEL Refer to Fig. 26. 1. 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. 2. 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. 26. 3.
4. COMMISSIONING - PAGE 20 4.1 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 4.2 PREPARE THE BOILER FOR COMMISSIONING Refer to Fig. 28 for boiler controls. 1. For a new boiler it will be necessary to fit the boiler thermostat control knob (supplied in the case pack). Place the control knob in position on the spindle on the front of the control box. 2.
COMMISSIONING - PAGE 21 2. 3. 4. 5. 6. 7. 8. 9. Check the ignition sequence With the gas supply isolated check the ignition sequence as follows: a. Set the test switch on the top of the control box to 1 (on) and check that all system controls are calling for heat. b. Switch on the electricity supply and turn the boiler thermostat fully clockwise [ ]. The automatic ignition sequence will start.
COMMISSIONING - PAGE 22 4.4 1. 2. 3. 4. 5. 6. 4.5 1. 2. 3. 4. 4.6 1. 2. 3. 4. 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.
5. FIT THE CASE - PAGE 23 Refer to Figs. 29 and 30. 1. 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. countersunk hd. screws supplied with the boiler. 2. If a programmer is used, ensure that the test switch on the top of the control box is set to O (off). 3.
6. FINAL ASSEMBLY - PAGE 24 1. 2. 3. 4. 5. 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. 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.
7. 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. It is the law that any service work must be carried out by a competent person such as British Gas or other C.O.R.G.I. registered personnel.
ANNUAL SERVICE - PAGE 26 7.2 DISMANTLING PRIOR TO SERVICING Refer to Figs. 32, 33 and 34. 1. Turn off the gas supply at the gas service cock (bottom L.H. corner). 2. Remove the screw securing the control box, see Fig. 25 and lower the control box. 3. 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. Remove the two screws securing the expansion vessel support frame to the inner case front panel.
ANNUAL SERVICE - PAGE 27 7.3 1. 2. 3. 4. 5. 6. 7. 7.4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 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.
ANNUAL SERVICE - PAGE 28 7.5 REPLACE THE CASE Refer to Fig. 30, if necessary. 1. If a programmer is used, ensure that the test switch on the top of the control box is set to O (off). 2. 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. 31, into its holder on the back of the control panel as the bottom panel is slid into position.
8. 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. Do not attempt to light the boiler if the system pressure (see pressure gauge) is less than 0.5 bar. Repressurise the system to 1.5 bar (see section 2.
9. 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. 9. 1 GENERAL ACCESS PRIOR TO REPLACEMENT OF PARTS Refer to Figs. 32 and 35. Ensure that the electricity supply is off. 1.
REPLACEMENT OF PARTS - PAGE 31 6. 7. 8. 9. 9.3 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. 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.
REPLACEMENT OF PARTS - PAGE 32 9. 5 TO REPLACE THE PILOT BURNER Refer to Fig. 34. 1. Gain general access as described in section 9.1. 2. Remove the screws (four on the 80 model, six on the other models) securing the combustion chamber front cover and remove the cover. 3. Remove the bottom case seal housing channel (lifts off the chassis). 4. Undo the securing nut and remove the spark electrode, see Fig. 34, from the pilot assembly. 5.
REPLACEMENT OF PARTS - PAGE 33 9.8 1. 2. 3. 4. 5. 6. 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. 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.
REPLACEMENT OF PARTS - PAGE 34 9.11 TO REPLACE THE BOILER THERMOSTAT Refer to Fig. 37. 1. Remove the case as described in section 7.1. 2. Remove the boiler thermostat control knob from the front of the control box (pulls off). 3. Remove the thermostat fixing nut and washer from the front of the control box. 4. Remove the four screws securing the control box front cover and carefully swing down the cover. 5. Withdraw the boiler thermostat and disconnect the three leads, noting their position.
REPLACEMENT OF PARTS - PAGE 35 9. 13 TO REPLACE THE HEAT EXCHANGER Ensure that the system is drained. 1. Remove the case and completely dismantle the boiler as described in sections 7.1 and 7.2. 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.
REPLACEMENT OF PARTS - PAGE 36 9.16 TO REPLACE THE GAS VALVE SOLENOIDS Refer to Fig. 40. 1. Gain general access as described in section 9.1, paragraph 1. 2. Disconnect the gas valve electrical plug from the valve. 3. Remove the screw securing the solenoids mounting bracket and carefully withdraw the mounting bracket, complete with solenoids, from the valve. 4. Position the new solenoids in the mounting bracket, see Fig. 40 and replace the mounting bracket. 5.
REPLACEMENT OF PARTS - PAGE 37 9.19 TO REPLACE THE DIVERTER VALVE HEAD Refer to Fig. 42. 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 control box. To gain extra clearance, disengage the control box hinge pins. 3. Note the position of the manual lever on the right hand side of the diverter valve, then move it to 'MAN OPEN' (top position).
REPLACEMENT OF PARTS - PAGE 38 9.21 TO REPLACE THE SAFETY VALVE Refer to Fig. 44. 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 control box. 3. 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.
REPLACEMENT OF PARTS - PAGE 39 9.23 TO REPLACE THE TEST SWITCH Ensure that the electricity supply is off. 1. Remove the case as described in section 7.1. 2. Remove the four screws securing the control box front cover and carefully swing down the cover. 3. Disconnect the push-on terminals from the switch. 4. Note which way the switch is fitted (the end terminal should be at the right hand side, next to the 1 on the label), then compress the clips on the switch body and push it out of the control box. 5.
REPLACEMENT OF PARTS - PAGE 40 9.26 TO REPLACE THE PROGRAMMER (IF FITTED) Ensure that the electricity supply is off. 1. With the control panel cover open, remove the two screws (one each side) securing the control panel to the case side panels. 2. Remove the four screws securing the bottom panel assembly (two each side) to the case side panels. Carefully slide out the assembly away from the boiler, unclipping the neon from the back of the control panel, see Fig. 35, before fully withdrawing the assembly.
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. Manual No.
WIRING DIAGRAMS - PAGE 42 b. Functional flow wiring diagram Manual No.
11. FAULT FINDING GUIDE - PAGE 43 Manual No.
12. EXPLODED VIEW - PAGE 44 Ultra Dv 50 shown - other models similar 44 EXPLODED VIEW Manual No.
13. SHORT LIST SPARE PARTS - PAGE 45 See next page for list of parts Manual No.
SHORT LIST SPARE PARTS - PAGE 46 Key No. 15 27 27 27 27 27 28 38 38 38 38 38 63 65 65 66 68 68 79 81 82 83 87 88 88 88 88 88 89 90 95 96 98 104 108 109 122 123 GC No.
