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Zanussi ULTRA SYSTEM 15 Installation And Servicing
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Zanussi ULTRA SYSTEM 15 Installation And Servicing

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INSTALLATION
AND SERVICING
ULTRA SYSTEM 15 18 24 30
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 2016
UIN 214119 A01

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Summary of Contents for Zanussi ULTRA SYSTEM 15

  • 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 2016...
  • 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 Part Load Auxiliary Electricity Consumption Full Load 0.021 0.026 0.042 0.048 Part Load 0.012...
  • Page 3 PRODUCT FICHE ULTRA SYSTEM 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 46.0 56.0 74.0 93.0 Sound power level, indoors 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 HELPLINE : 01482 498663 NOTE. BOILER RESTART PROCEDURE - To restart boiler, turn mode knob to restart position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence if a heat demand is present . DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level ......
  • Page 6 GENERAL Table 1 - General Data Gas supply 2H - G20 - 20mbar Gas Supply Connection 15mm copper compression Injector Size (mm) 4.15 4.15 4.15 4.65 Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter mm (in) 100 (4)
  • Page 7 GENERAL CONTENTS Natural Gas only Air Supply ..............11 Boiler size G.C. Appliance No. PI No. Benchmark Commissioning Checklist ..... 58 (Benchmark No.) Boiler Clearances ............12 41-002-01 86 CL 08 Boiler Exploded Diagram ........... 15 41-002-02 86 CL 08 Condensate Drain ..........26,27 41-002-03 86 CL 08 Commissioning &...
  • Page 8 GENERAL INTRODUCTION The Logic System range of boilers are wall mounted, full During all manoeuvres and handling actions, every attempt should sequence, automatic spark ignition, low water content, fanned be made to ensure the following unless unavoidable and/or the flue, high efficiency, condensing, system gas boilers. weight is light.
  • Page 9 GENERAL SAFETY LOCATION OF BOILER Current Gas Safety (installation and use) regulations or rules The boiler must be installed on a flat and vertical internal wall, in force: capable of adequately supporting the weight of the boiler and any ancillary equipment. The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force.
  • Page 10 GENERAL GAS SUPPLY 4. Where the lowest part of the terminal is fitted less than 2m (6’6”) above a balcony, above ground or above a flat roof The local gas supplier should be consulted, at the installation to which people have access then the terminal MUST be planning stage, in order to establish the availability of an adequate protected by a purpose designed guard.
  • Page 11 GENERAL TERMINAL The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Frame 13 . AIR SUPPLY It is NOT necessary to have a purpose-provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation;...
  • Page 12 GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm The boiler connections are made on the boiler connection tails. Refer to Frame 23. wall thicknesses do not exceed 600mm (24”). Where the The following minimum clearances must be maintained for space into which the boiler is going to be installed is less operation and servicing.
  • Page 13 GENERAL SYSTEM REQUIREMENTS - Central Heating Notes a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection Safety valve setting is only allowed if acceptable to the local water authority. Vessel charge pressure 0.5 to 0.75 b.
  • Page 14 GENERAL SYSTEM BALANCING The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of the minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available. See note regarding thermostatic radiator valves on page 11.
  • Page 15 INSTALLATION BOILER ASSEMBLY - Exploded View Note that item numbers are linked to the spares list CH RETURN VALVE PIPE - GAS INJECTOR ELECTRODE IGNITION CH FLOW VALVE INJECTOR ASSEMBLY ELECTRODE DETECTION PUMP HEAD VENTURI IGNITER UNIT PUMP AUTO AIR VENT THERMISTOR CONTROL/NO FLOW PRESSURE RELIEF VALVE BURNER...
  • Page 16 INSTALLATION 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 suppled as a separate order. Unpack and check the contents. Pack A Contents Boiler Hardware Pack Box Wall Mounting Plate...
  • Page 17 INSTALLATION 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 18 INSTALLATION WALL MOUNTING TEMPLATE Extended centre line 1 5 5 The wall mounting template is located on the internal protective (2 0 0 ) V - See Diagram packaging. The template shows the position of the fixing and rear in frame 1 flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled.
  • Page 19 INSTALLATION 13 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT. The boiler must be installed in a vertical position pipe work used and the bracket is located as close to the collar in accordance to the installation instructions. as possible. The bracketing must ensure a 1.5 degree fall back to the appliance.
  • Page 20 INSTALLATION 14 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 21 INSTALLATION 15 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 22 INSTALLATION 16 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 23 INSTALLATION 17 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched) 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 24 INSTALLATION 19 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. 3 0 0 m m Minimum dimensions are shown below m i n...
  • Page 25 INSTALLATION 20 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 26 INSTALLATION 21 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 Drain...
  • Page 27 INSTALLATION 22 CONDENSATE DRAIN - CONT’D..Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to Method (see manufacturers detailed instructions) External Soil & Vent Stack Boiler Water/weather Visible air break with 75mm proof insulation Boiler sealed...
  • Page 28 INSTALLATION 23 CONNECTIONS & FILLING NOTES. Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown in the picture. Ensure each union is fitted with fibre seals provided. Do not subject any of the isolating valves to heat as the seals may be damaged.
  • Page 29 INSTALLATION 25 INTERNAL WIRING The Logic System boiler comes pre-fitted with 1.8m of mains cable. This must be connected to a permanent live supply and NOT switched by thermostats/ programmers. If the supply cord is damaged, it must be replaced by the manufacturer, service agent or similarly qualified persons in order to avoid hazard.
  • Page 30 INSTALLATION 26 REPLACING PRE-FITTED MAINS CABLE If it is necessary to use an alternative mains cable to the one pre-fitted then use the following guide. Replacement wiring should comply with notes in Frame 24. 1. Isolate the mains supply to the boiler. 2.
  • Page 31 INSTALLATION 28 WIRING DIAGRAM Installation and Servicing...
  • Page 32 INSTALLATION 29 COMMISSIONING AND TESTING A. Electrical Installation B. Gas Installation 1. Checks to ensure electrical safety should be carried out by a 1. The whole of the gas installation, including the meter, competent person. should be inspected and tested for tightness and purged in accordance with the recommendations of BS.
  • Page 33 INSTALLATION 30 INITIAL LIGHTING Legend A. Central Heating Temperature Knob B. Mode Knob C. Boiler Status D. Burner ‘on’ indicator E. Central Heating Economy Setting CH Flow Isolating Valve G. System Pressure Gauge H. Gas Inlet Pressure Test Point Gas Service Cock K.
  • Page 34 INSTALLATION 31 GENERAL CHECKS Make the following checks for correct operation: CENTRAL HEATING (CH) MODE WATER CIRCULATION SYSTEM 1. Ensure that the CH external controls are 1. With the system COLD, check that the initial pressure is correct to the calling for heat.
  • Page 35 SERVICING 34 SERVICING SCHEDULE For the very latest copy of literature for specification & maintenance practices, visit our website 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 36 SERVICING 35 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 spring clips down to disengage and pull panel 4.
  • Page 37 SERVICING 37 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 38 SERVICING 39 CLEANING THE HEAT EXCHANGER Note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Frame 50. 1. Remove ignition and flame detection electrodes. Refer to Frames 46 & 47. 2. It is advisable to replace the sump cover prior to the water flush process.
  • Page 39 SERVICING 41 REPLACEMENT OF COMPONENTS GENERAL After replacing ANY component check operation of the boiler, including gas soundness, gas rate and combustion When replacing ANY component test. 1. Isolate the electricity supply. IMPORTANT. When work is complete, the front panel must be correctly 2.
  • Page 40 SERVICING 43 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 41. 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 41 SERVICING 45 RETURN THERMISTOR REPLACEMENT 1. Refer to Frame 41. 2. Unclip the return thermistor from the return pipe and withdraw it from the boiler. 3. Disconnect the electrical leads 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 42 SERVICING 47 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Frame 41. 2. Remove the burner. Refer to Frame 44. 3. Unplug the flame detection lead from the Flame Detection Electrode electrode. 4. Remove the 2 screws retaining the detection electrode. 5.
  • Page 43 SERVICING 49 GAS CONTROL VALVE REPLACEMENT 1. Refer to Frame 41. 2. Unplug the electrical lead connection from the gas control valve. 3. Disconnect the earth wire. 4. Remove the outlet gas valve clip and slide the pipe upwards 5. Undo the gas inlet pipe union at the inlet to the gas valve.
  • Page 44 SERVICING 51 MAIN PCB REPLACEMENT Note that production boiler PCBs are factory pre-set to operate for boiler range and output, but when ordering Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specific boiler range and output. Note.
  • Page 45 SERVICING 52 USER CONTROL PCB REPLACEMENT Note. Fit the earth strap provided with the PCB to your wrist and a suitable earth on the boiler chassis. 1. Refer to Frame 41. 2. Remove the main PCB, refer to Frame 51. 3.
  • Page 46 SERVICING 54 PRESSURE GAUGE REPLACEMENT 1. Refer to Frame 41. 2. Drain the heating system. Refer to Frame 53. 3. Unscrew the pressure gauge and discard. 4. Fit new pressure gauge, using suitable jointing compound. 5. Refill the boiler. Refer to Frame 23. 6.
  • Page 47 SERVICING 57 PUMP HEAD REPLACEMENT 1. Refer to Frame 41. 2. Drain the boiler. Refer to Frame 53. 3. Disconnect the two electrical leads from the pump. 4. Remove the 4 Allen screws retaining the pump head. 5. Remove the pump head. 6.
  • Page 48 SERVICING 60 HEAT ENGINE REPLACEMENT Refer also to Frame 5 - ‘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 Frame 41. 13. Remove the condensate rubber pipe. Refer to Frame 50, no. 2. 2.
  • Page 49 SERVICING 61 EXPANSION VESSEL RECHARGING & REPLACEMENT RECHARGING 1. Remove the charge point cover. Recharge Point 2. Recharge the tank pressure to 0.75 bar. 3. Re-assemble in reverse order 4. Check operation of the boiler. Refer to Frames 30 & 31. REPLACEMENT 5.
  • Page 50 FAULT FINDING 63 FAULT FINDING CHART MAIN MENU In order to assist fault finding the boiler has a 7 segment display. The key to the display codes is as follows: GO TO FRAME 64 - ALTERNATING ‘L’ and ‘1’ FLOW TEMPERATURE OVERHEAT LOCKOUT or NO WATER FLOW LOCKOUT GO TO FRAME 65 - ALTERNATING ‘L’...
  • Page 51 FAULT FINDING 64 ALTERNATING ‘L’ AND ‘1’ - FLOW TEMPERATURE OVERHEAT LOCKOUT OR NO WATER FLOW 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 If the PCB has been replaced check a BCC has been fitted then restart the boiler.
  • Page 52 FAULT FINDING 66 ALTERNATING ‘L’ AND ‘6’ - FALSE FLAME LOCKOUT Check routing and integrity of internal boiler Restart the boiler, does Boiler Work OK? wiring is OK. Check condition of Flame Sense Electrode and replace if deteriorated. Separate the flame detection electrode in-line Replace Flame Detection Electrode connector.
  • Page 53 FAULT FINDING 70 ALTERNATING ‘F’ AND ‘4’ - CONTROL / NO FLOW THERMISTOR FAULT Fit a new Thermistor Remove the Control/No Flow Thermistor from the Heat Exchanger and disconnect the wires. Check the resistance using a suitable multimeter connected across the thermistors terminal pins. Is there continuity between the PCB and Thermistor? At 25 expect...
  • Page 54 FAULT FINDING 74 NO CH OPERATION Move the mode knob to the ON position Is the mode knob in the ON position? Switch the Timer, Room Stat and Cylinder Stat On Are the Timer and the Room Thermostat or cylinder thermostat switched on? Open the Radiator Valves Are the Radiator Valves Open?
  • Page 55 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. Failure to do so could affect safety or performance of this appliance.
  • Page 56 SHORT LIST OF PARTS Installation and Servicing...
  • Page 57 Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturers 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 58 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 59 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 60 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) sepa- rate guidance is provided with the conversion kit supplied and this must be followed.
  • Page 61 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 62 NOTES Installation and Servicing...
  • Page 63 NOTES Installation and Servicing...
  • Page 64 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...

This manual is also suitable for:

Ultra system 18Ultra system 24Ultra system 30