Zanussi ULTRA+ COMBI 30 Installation And Servicing
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Zanussi ULTRA+ COMBI 30 Installation And Servicing

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INSTALLATION
AND SERVICING
ULTRA+ COMBI 30 35
FOR USER GUIDE SEE REVERSE OF BOOK
Manufactured by Ideal Boilers for Zanussi.
When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require.
Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
For the very latest copy of literature for specification and maintenance practices visit our website
www.zanussi-boilers.co.uk where you can download the relevant information in PDF format.
March 2017
UIN 216371 A03
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  • Page 1 Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers. For the very latest copy of literature for specification and maintenance practices visit our website www.zanussi-boilers.co.uk where you can download the relevant information in PDF format. March 2017...
  • Page 2 ERP DATA MODEL SYMBOL UNITS Condensing Boiler Low Temperature Boiler B1 Boiler Cogeneration Space Heater Equipped with a Supplementary Heater Combination Heater Nominal Heat Output for Space Heating Full Load 24.3 24.3 Part Load Auxiliary Electricity Consumption Full Load 0.032 0.029 Part Load 0.013...
  • Page 3 PRODUCT FICHE ULTRA+ COMBI BOILER ZANUSSI ERP DATA SYMBOL UNITS MODEL Condensing boiler Seasonal Space heating efficiency class Rated heat output ƞ Seasonal space heating energy efficiency Annual energy consumption Sound power level, indoors Water heating energy efficiency class Seasonal Space Heating Energy Efficiency of the Boiler...
  • Page 4 Installation and Servicing...
  • Page 5 NOTES FOR THE INSTALLER FOR ANY TECHNICAL QUERIES PLEASE RING THE INSTALLER SUPPORT HELPLINE : 01482 498663 NOTE. BOILER RESTART PROCEDURE - To restart the boiler press the RESTART button. The boiler will repeat the ignition sequence if a heat demand is present.
  • Page 6 Installation and Servicing...

  • Page 7: Table Of Contents

    CONTENTS GENERAL ..............8 SERVICING ............... 39 Introduction ..............10 Servicing Schedule ............ 39 Operation ..............10 Boiler Front Panel Removal / Replacement ....40 Safe Handling ............. 10 Fan And Venturi Assembly Removal And Cleaning ..40 Optional Extra Kits ............. 11 Burner Removal &...

  • Page 8: General

    SECTION 1 - GENERAL Table 1 - General Data Gas supply 2H - G20 - 20mbar Gas Supply Connection 15mm copper compression Injector Size 4.65 Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection Central Heating 22mm copper compression...
  • Page 9 SECTION 1 - GENERAL ZANUSSI ULTRA+ COMBI Natural Gas only Boiler size G.C. Appliance No. PI No. (Benchmark No.) 47-002-03 86CR16 47-002-04 86CR16 Destination Country: GB, IE For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the manufacturer’s instructions.

  • Page 10: Introduction

    SECTION 1 - GENERAL 1.1 INTRODUCTION 1.2 OPERATION The Zanussi Ultra+ Combi range of boilers are wall mounted, full With no demand for CH, the boiler fires only when DHW is drawn sequence, automatic spark ignition, low water content, fanned off, or periodically for a few seconds without any DHW draw-off, flue, high efficiency, condensing, combination gas boilers.

  • Page 11: Optional Extra Kits

    SECTION 1 - GENERAL 1.4 OPTIONAL EXTRA KITS 1.5 SAFETY • Horizontal Flue Terminal 600mm long Current Gas Safety (installation and use) regulations or rules in force: • Horizontal Telescopic Flue 600mm long The appliance is suitable only for installation in GB and IE and •...

  • Page 12: Location Of Boiler

    It is the responsibility of the Gas Installer to size the gas Bathroom Installations installation pipework in accordance with BS.6891. Whilst the principle of the 1:1 gas valve ensures the Zanussi range is This appliance is rated IP20. able to deliver its full output at inlet pressures as low as 14mb, The boiler may be installed in any room or internal space, although other gas appliances in the property may not be as tolerant.

  • Page 13: Terminal

    SECTION 1 - GENERAL 1.10 TERMINAL 2. It is important that the position of the terminal allows the free passage of air across it at all times. The terminal assembly can be adapted to accommodate various 3. Minimum acceptable spacing from the terminal to obstructions wall thicknesses.

  • Page 14: Boiler Dimensions, Services & Clearances

    SECTION 1 - GENERAL 1.16 BOILER DIMENSIONS, SERVICES & CLEARANCES The boiler connections are made on the boiler connection tails. drill, the flue can be installed from inside the building where Refer to Section 2.17. wall thicknesses do not exceed 600mm. Where the space into which the boiler is going to be installed is less than the length The following minimum clearances must be maintained for of flue required the flue must be fitted from the outside.

  • Page 15: System Requirements

    SECTION 1 - GENERAL 1.17 SYSTEM REQUIREMENTS - Central Heating Safety valve setting Notes Vessel charge pressure 0.5 to 0.75 a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose System pre-charge pressure bar None connection is only allowed if acceptable to the local water...

  • Page 16: Domestic Hot Water

    SECTION 1 - GENERAL ..SYSTEM REQUIREMENTS - CONT 1.18 SYSTEM BALANCING Domestic Hot Water The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load 1. The DHW service must be in accordance with BS.5546 & BS.6700. of at least 10% of the minimum boiler output, must 2.

  • Page 17: Installation

    SECTION 2 - INSTALLATION 2.1 BOILER ASSEMBLY - Exploded View Note that item numbers are linked to the spares list CH Return Valve Return Group Manifold Burner Thermistor Flow CH Flow Valve Flow Group Manifold Gasket - Burner Ignition Lead DHW Inlet &...

  • Page 18: Unpacking

    SECTION 2 - INSTALLATION 2.2 UNPACKING The boiler is supplied fully assembled in Pack A. A telescopic or non-telescopic flue assembly for rear or side flue outlet in Pack B is supplied as a separate order. Unpack and check the contents. Pack A Contents Boiler Hardware Pack Box...

  • Page 19: Unpacking Cont'd

    SECTION 2 - INSTALLATION 2.3 UNPACKING CONT’D Note. This flue system incorporates a removable flue outlet nose that utilises a push fit location system. This enables the installation of deflector, high level or balcony outlet flue kits without the removal of the whole ‘B’ pack terminal. The appliance must not be operated without the desired outlet nose correctly fitted in place.

  • Page 20: Wall Mounting Template

    SECTION 2 - INSTALLATION 2.5 WALL MOUNTING TEMPLATE Extended centre line 1 5 5 (2 0 0 ) The wall mounting template is located on the internal protective A** - See Diagram in Section 1.16 packaging. The template shows the position of the fixing and rear flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled.

  • Page 21: Determining The Flue Length & Flue Packs Req'd

    SECTION 2 - INSTALLATION 2.9 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT. The boiler must be installed in a vertical position in recommended that a support bracket is fitted on every 1 metre of accordance to the installation instructions. pipe work used and the bracket is located as close to the collar as possible.
  • Page 22 SECTION 2 - INSTALLATION ..DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED, CONT’D FIGURE 1 Edge of turret Edge of turret Edge of turret to outside face of wall plus to outside face of wall plus to outside face of wall plus 44mm = ue length 44mm = ue length 44mm = ue length...

  • Page 23: Cutting & Setting The Flue Length

    SECTION 2 - INSTALLATION 2.10 CUTTING & SETTING THE FLUE LENGTH TELESCOPIC FLUES TELESCOPIC FLUE B PACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT HORIZONTAL FLUE TERMINAL (1000MM LONG) B PACK (TELESCOPIC) MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 &...

  • Page 24: Installing The Flue

    SECTION 2 - INSTALLATION 2.11 INSTALLING THE FLUE FITTING FLUE THROUGH THE WALL 1. Measure wall thickness and add 14mm. 2. Measure from the outer terminal lip towards the end of outer flue, place a small location mark at the dimension acquired at point 1. 3.

  • Page 25: Fitting The Optional Roof Flue Kit

    SECTION 2 - INSTALLATION 2.12 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched) & SOFFIT FLUE KIT Note. A flat or pitched roof flashing plate (not supplied) is required before proceeding with the installation of this kit. This kit is suitable for both flat and pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level.

  • Page 26: Flue Terminal Position

    SECTION 2 - INSTALLATION 2.14 FLUE TERMINAL POSITION The terminal should be positioned so that products of combustion can safely disperse at all times. Pluming may occur at the termination so, where possible, terminal positions where this could cause a nuisance should be avoided.

  • Page 27: Assembling The Roof Flue Kit

    SECTION 2 - INSTALLATION 2.15 ASSEMBLING THE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied.

  • Page 28: Condensate Drain

    SECTION 2 - INSTALLATION 2.16 CONDENSATE DRAIN Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer Condensate should be used terminating into a suitable internal foul water...
  • Page 29 SECTION 2 - INSTALLATION ..CONDENSATE DRAIN - CONT’D Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to Method (see manufacturer’s detailed instructions) External Soil & Vent Stack Boiler Water/weather Visible air break with 75mm proof insulation Boiler...

  • Page 30: Connections & Filling

    SECTION 2 - INSTALLATION 2.17 CONNECTIONS & FILLING NOTES. Note. The domestic hot water flow rate is Ensure all boss blanking plugs are removed before connecting hardware. Each automatically regulated to a maximum: valve must be fitted to the correct boss as shown in the picture. 30 = 12.4 (2.8 gpm) Ensure each union is fitted with fibre seals provided.
  • Page 31 SECTION 2 - INSTALLATION ..CONNECTIONS & FILLING CONT FILLING IMPORTANT - when filling: When filling there may be a slight water leak from the air vent therefore electrical connections should be protected. Filling Top Up Ensure filling loop is connected and all washers in place. Ensure filling loop is connected and all washers in place.

  • Page 32: Electrical Connections

    SECTION 2 - INSTALLATION 2.18 ELECTRICAL CONNECTIONS Wiring should be 3 core PVC insulated cable, not less than WARNING. This appliance MUST be earthed. 0.75mm (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for A mains supply of 230Vac ~ 50 Hz is required.

  • Page 33: External Wiring

    SECTION 2 - INSTALLATION 2.20 EXTERNAL WIRING External Controls – 230V 50Hz Optional External Controls – Extra Low Frost Protection Voltage If parts of the pipework run outside the Wiring a 230V 50Hz Room Thermostat, DIAGRAM A: DIAGRAM B: house or if the boiler will be left off for more Diagram A (with optional timer, Diagram Wiring OpenTherm Room Control or other than a day or so then a frost thermostat...

  • Page 34: Wiring Diagram

    SECTION 2 - INSTALLATION 2.22 WIRING DIAGRAM Installation and Servicing...

  • Page 35: Commissioning And Testing

    SECTION 2 - INSTALLATION 2.23 COMMISSIONING AND TESTING A. Electrical Installation B. Gas Installation 1. Checks to ensure electrical safety should be carried out by 1. The whole of the gas installation, including the meter, a competent person. should be inspected and tested for tightness and purged in accordance with the recommendations of BS.6891.

  • Page 36: Initial Lighting

    SECTION 2 - INSTALLATION 2.24 INITIAL LIGHTING BOILER Legend ºC A. Domestic Hot Water Temperature Knob HOT WATER PREHEAT B. Central Heating Temperature Knob C. Mode Knob MODE PREHEAT RESTART D. Boiler Status Display E. Burner ‘on’ Indicator Central Heating Economy Setting G.

  • Page 37: General Checks

    SECTION 2 - INSTALLATION 2.25 GENERAL CHECKS Make the following checks for correct operation: WATER CIRCULATION SYSTEM 1. With the system COLD, check that the initial pressure is 1. Fully open all DHW taps in turn and ensure that water flows correct to the system design requirements.

  • Page 38: Restart Procedure

    SECTION 2 - INSTALLATION 2.26 RESTART PROCEDURE To restart the boiler, press the RESTART button (F). Legend A. Domestic Hot Water Temperature Knob BOILER B. Central Heating Temperature Knob ºC C. Mode Knob D. Boiler status Display HOT WATER PREHEAT E.

  • Page 39: Servicing

    SECTION 3 - SERVICING 3.1 SERVICING SCHEDULE For the very latest copy of literature for specification & maintenance practices, visit www.zanussi-boilers.co.uk where you will be able to download the relevant information. WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing.

  • Page 40: Boiler Front Panel Removal / Replacement

    SECTION 3 - SERVICING 3.2 BOILER FRONT PANEL REMOVAL / REPLACEMENT REMOVAL REPLACEMENT 1. Loosen the two screws retaining the front panel. 3. Hook the panel onto the top retaining clips. 2. Pull the two clips down to disengage and pull panel forward 4.

  • Page 41: Burner Removal & Cleaning

    SECTION 3 - SERVICING 3.4 BURNER REMOVAL AND CLEANING 1. Ensure the sump is fully drained 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 3. Lift the manifold to clear the bottom sealing gasket and remove manifold.

  • Page 42: Cleaning The Heat Exchanger

    SECTION 3 - SERVICING 3.6 CLEANING THE HEAT EXCHANGER Note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Section 3.18. 1. Remove ignition and flame detection electrodes. Refer to Section 3.13 & 3.14. 2.

  • Page 43: Replacement Of Components

    SECTION 3 - SERVICING 3.8 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When work is complete, the front panel must be correctly When replacing ANY component refitted - ensuring that a good seal is made. 1. Isolate the electricity supply. Notes. 1. In order to assist fault finding, the control panel has 2.

  • Page 44: Burner Injector Replacement

    SECTION 3 - SERVICING 3.10 BURNER INJECTOR REPLACEMENT 1. Refer to Section 3.8. 2. Disconnect the electrical leads from the fan. 3. Remove the clip from the gas valve to venturi pipe and ease the pipe upwards, rotate and ease down to remove. 4.

  • Page 45: Return Thermistor Renewal

    SECTION 3 - SERVICING 3.12 RETURN THERMISTOR REPLACEMENT 1. Refer to Section 3.8. 2. Unclip the return thermistor from the return pipe and withdraw it from the boiler. 3. Disconnect the electrical lead from the thermistor. 4. Reconnect the electrical lead to the new thermistor and reassemble in reverse order, ensuring that the thermistor is securely fitted to the pipe on the thermistor locator tab as shown.

  • Page 46: Flame Detection Electrode Replacement

    SECTION 3 - SERVICING 3.14 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Section 3.8. Flame Detection Electrode 2. Remove the burner. Refer to Section 3.4. 3. Unplug the flame detection lead from the electrode. 4. Remove the 2 screws retaining the detection electrode.

  • Page 47: Diverter Valve Actuator Replacement

    SECTION 3 - SERVICING 3.17 DIVERTER VALVE ACTUATOR REPLACEMENT Refer to Section 3.8. To remove the motor: 1. Remove the condensate trap/siphon. Refer to Section 3.5. 2. Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator. 3.

  • Page 48: Pcb Replacement

    SECTION 3 - SERVICING 3.19 PCB REPLACEMENT Note. Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis. 1. Refer to Section 3.8. 2. Ensure the control knobs are in the 12 o’ clock position. 3.

  • Page 49: Draining The Boiler

    SECTION 3 - SERVICING 3.21 DRAINING THE BOILER Filling Loop CENTRAL HEATING CIRCUIT 1. Refer to Section 3.8. 2. Close all the CH water isolating valves on the boiler inlet. 3. To drain the primary heat exchanger circuit: Open the drain valve and attach a length of hose to the CH drain point.

  • Page 50: Safety Relief Valve Renewal

    SECTION 3 - SERVICING 3.23 SAFETY RELIEF VALVE REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.21. 3. Remove the clip on return thermistor. Refer to Section 3.12. 4. Pull out and remove the clip (positioned behind the safety valve) retaining the safety valve.

  • Page 51: Diverter Valve Body Assembly Replacement

    SECTION 3 - SERVICING 3.26 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT To remove the valve body assembly: 16. Twist and remove the DHW manifold. 1. Refer to Section 3.8. 17. Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly. 2.

  • Page 52: Ch Water Pressure Switch Replacement

    SECTION 3 - SERVICING 3.29 CH WATER PRESSURE SWITCH REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.21. 3. Pull off the two electrical connections. 4. Using a suitable tool, pull out the metal retaining clip.

  • Page 53: Heat Engine Renewal

    SECTION 3 - SERVICING 3.31 HEAT ENGINE REPLACEMENT Refer also to Section 2.1 - ‘Boiler Exploded View’ IMPORTANT Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. 1. Refer to Section 3.8. 13.

  • Page 54: Expansion Vessel Recharging & Replacement

    SECTION 3 - SERVICING 3.32 EXPANSION VESSEL RECHARGING & REPLACEMENT RECHARGING Recharge Point 1. Refer to Section 3.8. 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order. 5. Check that the boiler operates in both DHW & CH modes.

  • Page 55: Fault Finding

    SECTION 4 - FAULT FINDING 4.1 FAULT FINDING CHART MAIN MENU GO TO SECTION 4.2 - ‘L1’ FLOW TEMPERATURE OVERHEAT LOCKOUT GO TO SECTION 4.3 - ‘L2’ IGNITION LOCKOUT 5 RESETS WITHIN 15 MINS - ‘LC’ TURN POWER OFF AND ON GO TO SECTION 4.4 - ‘L6’...

  • Page 56: L1' - Flow Temp Overheat Lockout

    SECTION 4 - FAULT FINDING 4.2 ‘L1’ - FLOW TEMPERATURE OVERHEAT LOCKOUT Is the Boiler and CH System filled with water and all Fill and vent the system and open all isolation and radiator valves open? isolation valves, then restart boiler Is the Flow/Return Differential across the Boiler in Check that the Pump is rotating freely.

  • Page 57: L6' - False Flame Lockout

    SECTION 4 - FAULT FINDING 4.4 ‘L6’ - FALSE FLAME LOCKOUT Check routing and integrity of internal boiler wiring is OK. Check Restart the boiler, does Boiler Work OK? condition of Flame Sense Electrode and replace if deteriorated. Replace Flame Detection Electrode Separate the flame detection electrode in-line connector.

  • Page 58: F3' - Fan Fault

    SECTION 4 - FAULT FINDING 4.7 ‘F3’ - FAN FAULT Does the wiring from the Fan to the PCB have Rectify Wiring & secure connections at both ends and has not connections deteriorated? Does the wiring have continuity? Replace PCB Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan? Replace Fan...

  • Page 59: F6' - Outside Sensor Fault

    SECTION 4 - FAULT FINDING 4.10 ‘F6’ - OUTSIDE SENSOR FAULT Securely connect the wiring at both the Is the wiring securely connected at both the boiler and boiler and Outside Sensor Outside Sensor? Disconnect the wires to the outside sensor. Check the resistance using a suitable multimeter connected across the Outside Sensor’s terminal pins.

  • Page 60: No Hw But Ch On

    SECTION 4 - FAULT FINDING 4.12 NO HW BUT CH ON Does the display shows a “Tap symbol” when Is hot and cold pipework crossed? a tap is on? Adjust flow rates to achieve 35ºC Are the flow rates correct as per Section 1.2. Is the wiring connected temp rise and check filter fitted in between PCB and DHW...

  • Page 61: Spare Parts

    SECTION 5 - SPARE PARTS When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers. Failure to do so could affect safety or performance of this appliance.

  • Page 62: Benchmark & Commissioning

    SECTION 6 - BENCHMARK & COMMISSIONING Installation and Servicing...
  • Page 63 SECTION 6 - BENCHMARK & COMMISSIONING Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturer’s instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation.

  • Page 64: Gas Boiler System Commissioning Checklist

    GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Programmable room thermostat Optimum start control...

  • Page 65: Service Record

    SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % (Where Possible) (Where Possible) Signature Signature SERVICE 03 SERVICE 04...
  • Page 66 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING. If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) separate guidance is provided with the conversion kit supplied and this must be followed.
  • Page 67 Start Set Boiler to Maximum Gas Rate Carry Out Flue Integrity Check Using Analyser In accordance with boiler instructions, Insert analyser probe into air inlet test point (where available) and allow set boiler to operate at maximum rate readings to stabilise. (full load condition).
  • Page 68 NOTES Installation and Servicing...
  • Page 69 NOTES Installation and Servicing...
  • Page 70 NOTES Installation and Servicing...
  • Page 71 NOTES Installation and Servicing...
  • Page 72 Ideal Boilers provides after-sales assistance and Technical advice for Zanussi Ultra+ Boilers Installer Support Helpline: 01482 498663 Customer Helpline: 01482 498660 Ideal Boilers P.O. Box 103, National Avenue, Kingston Upon Hull. HU5 4JN We reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected...

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Ultra+ combi 35

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