Potterton Ultra DV 40 Supplement

Supplied By www.heating spares.co Tel. [phone]
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.

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2LIST OF CONTENTS Manual No. 405/0101
LIST OF CONTENTS
1. TECHNICAL DATA .........................................................................................................................................................4
2. GENERAL .......................................................................................................................................................................5
2.1 Introduction............................................................................................................................................................5
2.2 Regulatory Requirements......................................................................................................................................5
2.3 Delivery & Kits Available........................................................................................................................................5
2.4 Gas Supply............................................................................................................................................................5
2.5 Electricity Supply ...................................................................................................................................................5
2.6 Air Supply ..............................................................................................................................................................6
2.7 Flue System...........................................................................................................................................................6
2.8 Location of Boiler...................................................................................................................................................6
2.9 Boiler Dimensions and Gas Connection................................................................................................................8
2.10 Water System Schematics ....................................................................................................................................8
2.11 Sealed System Requirements...............................................................................................................................9
3. INSTALLATION.............................................................................................................................................................10
3.1 Unpack the Boiler ................................................................................................................................................10
3.2 Unpack the Flue Terminal....................................................................................................................................10
3.3 Rear Flue - Prepare the Wall...............................................................................................................................11
3.4 Rear Flue - Cut the Flue/Terminal Assembly to Length.......................................................................................11
3.5 Rear Flue - Fit the Flue/Terminal Assembly........................................................................................................12
3.6 Rear Flue - Prepare and Fit the Boiler.................................................................................................................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 and Vent the Boiler..................................................................................................19
4. COMMISSIONING.........................................................................................................................................................20
4.1 Boiler Controls.....................................................................................................................................................20
4.2 Prepare the Boiler for Commissioning.................................................................................................................20
4.3 Commission the Boiler.........................................................................................................................................20
4.4 Check the Water System.....................................................................................................................................22
4.5 Replace the Inner Case Front Panel and Expansion Vessel...............................................................................22
4.6 Balance the System and Adjust the By-pass Valve.............................................................................................22
5. FIT THE CASE..............................................................................................................................................................23
6. FINAL ASSEMBLY .......................................................................................................................................................24
7. ANNUAL SERVICE.......................................................................................................................................................25
7.1 Remove the Case................................................................................................................................................25
7.2 Dismantling Prior to Servicing..............................................................................................................................26
7.3 Cleaning the Boiler ..............................................................................................................................................27
7.4 Reassemble the Boiler.........................................................................................................................................27
7.5 Replace the Case................................................................................................................................................28

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Manual No. 405/0101 LIST OF CONTENTS 3
8. LIGHTING INSTRUCTIONS..........................................................................................................................................29
9. REPLACEMENT OF PARTS ........................................................................................................................................30
9.1 General Access Prior to Replacement of Parts...................................................................................................30
9.2 Reassemble the Boiler After Replacement of Parts............................................................................................30
9.3 To Replace the Spark Electrode or Electrode Lead ............................................................................................31
9.4 To Replace the Pilot Injector ...............................................................................................................................31
9.5 To Replace the Pilot Burner.................................................................................................................................32
9.6 To Replace the Main Burner................................................................................................................................32
9.7 To Replace the Overheat Cut-Off Device............................................................................................................32
9.8 To Replace the Fan.............................................................................................................................................33
9.9 To Replace the Air Flow Pressure Switch ...........................................................................................................33
9.10 To Replace the Main Burner Injector...................................................................................................................33
9.11 To Replace the Boiler Thermostat.......................................................................................................................34
9.12 To Replace the Combustion Chamber Insulation Panels....................................................................................34
9.13 To Replace the Heat Exchanger..........................................................................................................................35
9.14 To Replace the Pump Overrun Thermostat.........................................................................................................35
9.15 To Replace the Gas Valve...................................................................................................................................35
9.16 To Replace the 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 fitted).................................................................................................................40
10. WIRING DIAGRAMS.....................................................................................................................................................41
11. FAULT FINDING GUIDE...............................................................................................................................................43
12. EXPLODED VIEW.........................................................................................................................................................44
13. SHORT LIST SPARE PARTS.......................................................................................................................................45
If you have any reason to complain of any shortage of components listed in Figs 6, 7 or 29, supply a list of the item(s)
concerned, boiler model, your name, address and any information which may help us avoid further error.
Address for return:
Supplies Manager
Potterton Interpart.
Brooks House
Coventry Road
Warwick. CV34 4LL
Tel: [phone]
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.

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4TECHNICAL DATA Manual No. 405/0101
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 Ultra Dv 30 Ultra Dv 40 Ultra Dv 50 Ultra Dv 60 Ultra Dv 80
Burner type (Aeromatic) AC13/112503 AC13/112504 AC13/112505 AC13/112506 AC13/112507
Burner injector Bray 23/800 Bray 23/1100 Bray 23/1350 Bray 23/1700 Bray 23/2400
Pilot injector SIT 0.977.142 marked 33
Pilot flame 35 to 40 mm
Spark gap 5.0 mm ±2 mm
Ignition Intermittent pilot
Weight (empty) 47.7 kg 48.2 kg 48.8 kg 49.3 kg 50.7 kg
Max. lifting weight (installing) 24.0 kg 24.5 kg 25.1 kg 25.6 kg 27.0 kg
Water content 1.65 litre 1.70 litre 1.75 litre 1.80 litre 2.15 litre
Pump (Myson SMC) SD51 SD61
System expansion vessel 10 litre (charge pressure 0.5 mbar)
*Water flow rate 11.4 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 connections Compression fittings to accept 22 mm and 28 mm copper tubing to BS2871
Gas connection Rp ½ (bottom left hand side)
Mid position zone valve Honeywell 22 mm 28 mm
*Water flow rate and pump head available for a system temperature differential of 11°C.
NOMINAL BOILER RATINGS
Boiler model Output Input Burner setting pressure
kW Btu/h kW Btu/h mbar in wg
Ultra Dv 30 5.9 20 000
8.8 30 000 7.5 25 500 11.0 37 500 6.4 2.6 13.5 5.4
Ultra Dv 40 8.8 30 000
11.7 40 000 11.1 37 900 14.7 50 000 7.9 3.2 13.7 5.5
Ultra Dv 50 11.7 40 000
14.7 50 000 14.7 50 000 18.3 62 500 9.0 3.6 14.2 5.7
Ultra Dv 60 14.7 50 000
17.6 60 000 18.8 64 000 22.0 75 000 9.7 3.9 13.5 5.4
Ultra Dv 80 17.6 60 000
23.4 80 000 22.3 76 000 29.3 100 000 8.3 3.3 14.7 5.9

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5GENERAL Manual No. 405/0101
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.
The boilers are designed for use on sealed water systems only, with an indirect hot water cylinder.
THEY MUST NOT BE CONNECTED TO A DIRECT CYLINDER.
2.2 REGULATORY REQUIREMENTS
The boiler must be installed in accordance with: The Gas Safety (Installation and Use) Regulations 1990 and the current
issue of: the Building Regulations, Building Standards (Scotland) Regulations, Local Building Regulations, Model and local
Water Undertaking Bye-laws, IEE Wiring Regulations and Health & Safety Document No. 635 "The Electrician At Work
Regulations 1989".
Detailed recommendations are stated in the following British Standards: BS6891:1988, BS6798:1987, BS5546:1990,
BS5440:1:1990, BS5440:2:1989 and BS5449:1990.
Note: Gas Safety (Installation and Use) Regulations 1990: It is the 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. It is in
your own interest, and that of safety to ensure that the law is complied 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 length is 4 m).
A vertical balanced flue kit is available which allows the flue to exit vertically from the boiler (maximum length 3.15m).
A fit from the inside flue kit is available which allows the flue/terminal assembly to be fitted from inside the building.
Note: Read any kit instructions before installing the boiler.
2.4 GAS SUPPLY
The natural gas requirements are as follows:
Ultra Dv 30: 1.1 m³/h Ultra Dv 40: 1.4 m³/h
Ultra Dv 50: 1.8 m³/h Ultra Dv 60: 2.1 m³/h Ultra Dv 80: 2.8 m³/h
The meter and supply pipes must be capable of delivering this quantity of gas in addition to the demand from any other
appliances in the house.
The complete installation must be tested for gas soundness and purged as described in BS6891.
2.5 ELECTRICITY SUPPLY
240V ~ 50Hz via a fused double pole switch with a contact separation of at least 3 mm in both poles adjacent to the boiler.
There must be only one common isolator for the boiler and its control system and it must provide complete electrical
isolation.
Fuse the supply at 3 A. The minimum requirement for the power supply cable is that it should be a PVC sheathed cord at
least 0.75 mm² (24 x 0.2 mm) (code designation HO5 VV-F or HO5 VVH2-F) as specified in table 16 of BS6500:1984.
All wiring external to the boiler shall comply with the latest IEE Wiring Regulations, and any local regulations which apply.
WARNING: THIS APPLIANCE MUST BE EARTHED.

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6GENERAL Manual No. 405/0101
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.
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. Both high level and low level air vents
must communicate with the same room or must be on the same wall to outside air. Both the high level and low level vent
must each have a free area as stated below. The free area of each vent may be halved if the ventilation is provided directly
from outside.
Ultra Dv 30: 110 cm² Ultra Dv 40: 140 cm²
Ultra Dv 50: 180 cm² Ultra Dv 60: 210 cm² Ultra Dv 80: 264 cm²
If the boiler is installed in a cupboard or compartment with a door, allow at least 50 mm clearance between the front of the
boiler and the door for air movement.
2.7 FLUE SYSTEM
The flue/terminal assembly supplied with the boiler is 500 mm long.
A 1 m flue extension is available, if required.
Under no circumstances should the total flue length exceed 3 m. A 3 m length flue would comprise of three 1m kits, one of
which would be cut down to 500mm.
The following method should be used to determine the flue length.
Rear flue A = C + 28 mm
Side flue A = B + C
where: A = Required flue length.
B = Inside wall to the side of the white case plus (+) 30 mm.
C = Finished wall thickness.
2.8 LOCATION OF BOILER
The boiler is not suitable for external installation.
The boiler must be mounted on a flat wall which is sufficiently robust to take the weight of the boiler.
The boiler is suitable for installation to a combustible wall e.g. wood cladding, provided that the flue 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” 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.
Where a room-sealed appliance is installed in a room containing a bath or shower, any electrical switch or appliance control,
utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower.
Where the installation of the boiler will be in an unusual position, special procedures may be necessary and BS6798 and
BS5546 give detailed guidance on this aspect.
A cupboard or compartment used to enclose the boiler must be designed and constructed specifically for this purpose. An
existing cupboard or compartment may be used provided that it is modified for the purpose. Details of essential features of
cupboard/compartment design including airing cupboard installations are given in BS6798 and BS5546 and should be
complied with.
The boiler requires only the clearances stated in the Technical Data, page 4, after installation. If it is felt that extra space is
required for installation any adjacent kitchen units or fitments may have to be removed.
The boiler must be installed so that the flue terminal is exposed to the external air. It is important that the position of the
terminal allows the free passage of air across it at all times.
The minimum acceptable spacings from the terminal to obstructions, corners and ventilation openings are shown on the
following page.

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7GENERAL Manual No. 405/0101
GENERAL - PAGE 7
Fig. 1
Dimension Terminal Position (Fanned Balanced Flue models) Min. Spacing
ADirectley below an openig, air brick, window, etc. 300
BBelow gutters, soil pipes or drain pipes 75 *
CBelow eaves 200 *
DBelow balconies or car port roof 200
EFrom a vertical drain pipe or soil pipe 75
FFrom an internal corner 25
GFrom an external corner 25
HAbove ground, roof or balcony level 300 **
IFrom a surface facing the terminal 600
JFrom a terminal facing the terminal 1200
KFrom an opening in the car port (e.g. door, window) into dwelling 1200
LVertically from a terminal on the same wall 1500
MHorizontally 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 balcony, above ground or above a flat roof
to which people have access then a suitable terminal guard must be provided and fitted.
A type K1 (G.C. No. 393 552) protective guard is available from Tower Flue Components Ltd. at: Vale Rise, Tonbridge, Kent
TN9 1TB, Tel: [phone].
The guard must be securely fitted to the wall and centrally located over the flue terminal. Refer to the manufacturers
instructions.

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8GENERAL Manual No. 405/0101
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. 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 connections at the base of the boiler have been temporarily sealed with plastic plugs. Remove
ALL THREE plugs before connecting any pipework.
Fit one or more draining taps (BS2879) to enable the water system to be fully drained.
A factory set by-pass is built into the boiler and must not be adjusted.

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9GENERAL Manual No. 405/0101
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. 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 requirements of BS1010:2.
5. The hot water cylinder shall either be the indirect coil type or a cylinder fitted with an immersion calorifier.
6. An automatic air vent should be fitted at the highest point in the system.
2.12 SYSTEM SCHEMATIC
Refer to Fig. 5.
Fig. 5

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10 INSTALLATION Manual No. 405/0101
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.
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 until all the items are
accounted for, see Fig. 7.
3. Bend the cutting jig to shape as shown in Fig. 7. The jig is
easily bent by hand.
Fig. 7

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11 INSTALLATION Manual No. 405/0101
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.
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.
The side of the white case is 68 mm from the raised edge
of the mounting plate. Fig. 8
3. Again using the mounting plate as a template mark the
position of the hole for the flue duct and the five mounting
plate fixing holes as shown in Fig. 8.
Ensure the plate is level and the right way up.
4. Cut the 115 mm dia. hole in the wall and drill and plug the
fixing holes to accept 2½” lg. No.12 woodscrews.
5. Make a note of the 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 and that the
holes line up with the fixing holes in the mounting plate.
7. Secure the sealing ring in position with the clamping
plate, supplied with the flue/terminal assembly, using the
four M4 x 10 lg. screws previously removed from the
mounting plate.
Fig. 9
8. Secure the mounting plate in position with five 2½” lg. No.12 woodscrews (not supplied). Ensure it is level, the right way up
and that the hole for the flue is centralised over the hole cut in the wall.
3.4 REAR FLUE - CUT THE FLUE/TERMINAL ASSEMBLY TO LENGTH
Refer to Fig. 10.
1. Using the measurement noted in section 3.3 mark the
flue/terminal assembly so that it is 28 mm plus (+)
finished wall thickness, from the back of the terminal
flange to the end of the tubes.
2. With the cutting jig, supplied with the flue/terminal
assembly, in position over the flue/terminal assembly as
shown in Fig. 10, cut the tubes to the correct length.
Using the cutting jig should ensure that the tubes are cut
square.
3. Clean up the edges of the cut tubes and discard the
cutting jig.
Fig. 10

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12 INSTALLATION - REAR FLUE Manual No. 405/0101
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. From outside the building insert the flue/terminal
assembly into the wall and carefully push it fully home.
3. If necessary make good the outside wall around the flue
duct.
4. Place the outer sealing plate assembly, supplied with the
flue/terminal assembly, 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.8 screws, supplied with the
flue/terminal assembly.
Fig. 11
Fig. 12
3.6 REAR FLUE - PREPARE AND FIT THE BOILER
Refer to Figs. 13 and 14.
1. Disconnect the flexible pipe connection to the bottom of the expansion vessel, take care not to lose the washer.
Remove the two screws securing the expansion vessel support frame to the inner case front panel. Holding the vessel
and frame swing them out to clear the boiler. Remove the frame and vessel from the boiler by lifting the frame out of its
bottom pivoting point. See Fig. 13. Cut the foam seal in two and stick onto the inner case
Fig. 13

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13 INSTALLATION - REAR FLUE Manual No. 405/0101
INSTALLATION - REAR FLUE - PAGE 13
front panel just below the depression. See Fig. 13.
2. 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.
3. Remove the two screws securing the fan assembly to the flue hood. Withdraw the assembly, disconnecting
Fig. 14
the fan motor and pressure switch leads. See Fig. 14.
4. Lift the boiler into position over the wall mounting plate. The boiler has two brackets on the back of the chassis at the
top, these should be located on top of the wall mounting plate to take the weight 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 home.
8. Place the fan assembly on top of the flue hood with the
outlet facing to the rear and reconnect the leads, see Fig.
14a, as follows:
Two violet leads to the fan motor.
Yellow lead to pressure switch No connection.
Red lead to pressure switch Nc connection.
Black lead to pressure switch C connection.
9. With the fan assembly resting on the flue hood push it
towards the rear of the boiler, locate the flue tube sleeve
on the fan outlet into the inner tube of the flue/terminal
assembly and push the fan assembly fully home until the
base is located under the returns at the rear of the flue
hood, see Fig. 14.
10. Secure the front of the fan assembly to the flue hood with
the two screws previously removed.
11. Proceed to section 3.13. Fig. 14a

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14 INSTALLATION - SIDE FLUE Manual No. 405/0101
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.
The side of the white case is 68 mm from the raised edge
of the mounting plate.
Note that the maximum distance from the side of the
white case to the OUTSIDE wall surface is 2970 mm.
2. Again using the mounting plate as a template mark the
positions of the five mounting plate fixing holes, the side
of the boiler and the horizontal centre line of the flue as
shown in Figs. 15 and 16.
Ensure the plate is level and the right way up.
3. Continue the horizontal flue centre line across the wall
until it reaches the side wall 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 2½" 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 assembly to length.
7. Secure the mounting plate in position with five 2½" lg.
No.12 woodscrews (not supplied). Ensure it is level and
the right way up.
Fig. 15
Fig. 16
3.8 SIDE FLUE - CUT THE FLUE /TERMINAL ASSEMBLY TO LENGTH
Refer to Fig. 17.
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.
If the length required is less than 500 mm proceed as follows,
if it is more go straight to section 3.9.
1. Mark the flue/terminal assembly to the required length,
measure from the back of the terminal flange.
2. With the cutting jig, supplied with the flue/terminal
assembly, in position over the flue/terminal assembly as
shown in Fig. 17, cut the tubes to the correct length.
Using the cutting jig should ensure that the tubes are cut
square.
3. Clean up the edges of the cut tubes and discard the
cutting jig.
Fig. 17

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15 INSTALLATION - SIDE FLUE Manual No. 405/0101
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.
Supplied with the extension tube are three No.8 x 10 lg.
screws and a small roll of sealing tape.
2. Locate the flared end of the extension over the open end
of the flue/terminal assembly as shown in Fig. 18. Ensure
that the inner flue tubes are engaged. Fig. 18
3. Using the pilot holes in the flared end of the extension, drill three 2.8 mm dia. holes into the outer tube of the
flue/terminal assembly. Take care not to damage the inner flue tube with the drill.
Secure the extension to the flue/terminal 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 from the back of the terminal flange.
5. With the cutting jig, supplied with the flue/terminal assembly, in position over the flue/terminal assembly as shown in
Fig. 17, cut the tubes to the correct length.
Using the cutting jig should ensure that the tubes are cut square.
6. Clean up the edges of the cut tubes and discard the cutting jig.
3.10 SIDE FLUE - PREPARE AND FIT THE BOILER
Refer to Figs. 19 and 20.
1. Disconnect the flexible pipe connection to the bottom of the expansion vessel, take care not to lose the washer.
Remove the two screws securing the expansion vessel support frame to the inner case front panel. Holding the vessel
and frame swing them out to clear the boiler. Remove the frame and vessel from the boiler by lifting the frame out of its
bottom pivoting point. See Fig. 19. Cut the foam seal in two and stick onto the inner case
Fig. 19

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16 INSTALLATION - SIDE FLUE Manual No. 405/0101
INSTALLATION - SIDE FLUE - PAGE 16
front panel just below the depression. See Fig. 19.
2. 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. Remove the two screws securing the fan assembly to the flue hood. Withdraw the assembly, disconnecting the fan
motor and pressure switch leads. See Fig. 20.
4. Lift the boiler into position over the wall mounting plate. The boiler has two brackets on the back of the chassis at the
top, these should be located on top of the wall mounting plate to take the weight 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. 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 opening in the chassis side as
shown in Fig. 20. Ensure that the cut-away is at the bottom, that the groove in it is located correctly over the chassis
side and that the holes line up with the fixing holes in the chassis side.
9. Secure the sealing ring in position with the clamping plate, supplied with the flue/terminal assembly, using the four
screws previously removed from the chassis side. Ensure that the cut-away is at the bottom.
10. Select the appropriate side panel, see Fig. 29, through which the flue is to exit, remove the edge clips and push out the
round infill panel.
Locate the side panel over the two fixings at the side of the boiler chassis against the wall. Secure the 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.
Fig. 20

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17 INSTALLATION - SIDE FLUE Manual No. 405/0101
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. From outside the building insert the flue/terminal
assembly into the wall and carefully push it fully home.
3. If necessary make good the outside wall around the flue
duct.
4. Place the outer sealing plate assembly, supplied with the
flue/terminal assembly, over the terminal as shown in Fig.
22 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.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 assembly on top of the flue hood with the
outlet facing to the side from which the flue is to exit (for
right hand exit the fan will be at the front, for left hand exit
the fan will be at the back) and reconnect the leads, see
Fig. 14a, as follows:
Two violet leads to the fan motor.
Yellow lead to pressure switch No connection.
Red lead to pressure switch Nc connection.
Black lead to pressure switch C connection.
3. With the fan assembly resting on the flue hood push it
towards the rear of the boiler locating the base of the fan
assembly under the returns at the rear of the heat
exchanger top frame (1 in Fig. 23), then slide it to the Fig. 23
left or right to locate the flue tube sleeve on the fan outlet into the inner tube of the flue/terminal assembly (2 in Fig.
23).
4. Secure the front of the fan assembly to the flue hood with the two screws previously removed.

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18 INSTALLATION Manual No. 405/0101
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. Remove the five screws securing the control box and its
front cover, carefully swing down the cover and lower the
control box. Take care not to damage the boiler
thermostat capillary.
2. 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. Slacken the necessary cable
clamp screws. Feed the power supply cable into the
boiler through the hole (marked 'wiring') in the bottom of
the chassis, then into the control box through a clamp
and connect the wires, brown to L and blue to N on the
terminal block and green and yellow to the earthing screw
(). Ensure correct polarity.
Note: When connecting the power supply cable, ensure
that the length of the earth wire is such, that if the power
supply cable slips out 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 various room and cylinder thermostat connections.
Note: The cylinder thermostat must be a 240 V type.
4. If the optional programmer kit is not fitted and other external controls are used (e.g. programmer, room thermostat).
The switched live must be connected to terminal ON on the terminal block.
5. Take up excess slack in the power supply cable between the terminal block and the cable clamp, then tighten the
cable clamp screws. Repeat for any wires through the other cable clamp.
6. Raise the control box and replace the control box front, ensuring that the boiler thermostat capillary is located in the cut
out in the side of the control box. Secure in position with four of the screws previously removed. Check that the control
box can be raised and lowered freely, without straining any of the wiring.
Ensure that all external control cables are secured.
Do not secure the control box in its raised position at this stage.
7. Carry out preliminary electrical system checks i.e. Earth Continuity, Short Circuit, Polarity and Resistance to Earth.
Do not switch on the electricity supply at this stage.

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19 INSTALLATION Manual No. 405/0101
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. Hook the plain ends of the tie rods into the brackets on the
sides of the boiler, then locate the other ends in the
brackets on the expansion vessel frame. Pass the split
pins through the ends of the rods to secure them in place
at the expansion vessel end. See Fig. 26.
4. Position the expansion vessel in the frame with the
connection point uppermost and towards the boiler.
5. Reconnect the flexible connection to expansion vessel.
Ensure that the washer is in position between the flexible
connection and expansion tank.
6. Leave the expansion vessel in the lowered position.
Fig. 26
3.16 CONNECT THE WATER SYSTEM AND VENT THE BOILER
Refer to Fig. 27 (expansion vessel, frame and control box omitted for clarity).
1. Ensure that the three plastic plugs are removed from the
pipe ends.
2. Make the connections as shown in Fig. 27.
For dimensions see section 2.10.
For system schematic see section 2.12.
3. Fill the system, see section 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) of the
heat exchanger, and is accessible through a hole in the
blanking plate connected to the flue hood. Use this to
vent the boiler. Fig. 27
4. Refill and vent the system.
5. The pump bearings and shaft rely on system water to provide lubrication. It is important therefore to ensure that the
bearings have been properly vented and that the pump is not run dry otherwise damage may occur to the bearings.
Unscrew the pump manual restart knob, see Fig. 27 and withdraw it to engage in the motor shaft. Rotate the knob and
check that the motor shaft rotates freely. Apply a sideways pressure to the knob until a small amount of water becomes
visible. The pump is now vented. After use the manual restart knob should be screwed back into its original position, finger
tight. Take care not to allow any water to drip onto the control box or other electrics.
6. Pressurise the system to 1.5 bar and check for leaks, rectifying where necessary.
Set the red adjustable pointer on the pressure gauge to 1.5 bar.
Note: Any discharge from the safety valve must be directed clear of the boiler to a drain in such a manner that it may be seen,
but cannot cause injury to persons or property.

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20 COMMISSIONING Manual No. 405/0101
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. A test switch is 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 cock is closed when the operating spindle is turned fully clockwise [ ]),
pressure test the gas supply and inlet pipework connection to the boiler service cock for soundness in accordance with
BS6891.
b. Remove the gas inlet pressure test point screw. Ensure the gas supply is on and open the boiler service cock to purge
in accordance with BS6891. Replace the test point screw and test for gas soundness.