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Zanussi ULTRA COMBI 35 Installation And Servicing
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Zanussi ULTRA COMBI 35 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.
April 2016
UIN 214118 A02

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Summary of Contents for Zanussi ULTRA COMBI 35

  • 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. April 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 24.2 24.2 Part Load Auxiliary Electricity Consumption Full Load 0.032 0.042 Part Load 0.013...
  • Page 3 PRODUCT FICHE ULTRA COMBINATION 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 74.9 Sound power level, indoors Water heating energy efficiency class...
  • 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 reset 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) 4.65 Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection Central Heating 22mm copper compression Return Connection...
  • Page 7 GENERAL CONTENTS Natural Gas only Boiler Air Supply ..............11 Boiler size G.C. Appliance No. PI No. Benchmark Commissioning Checklist ....64-65 (Benchmark No.) Boiler Clearances ............12 47-002-01 86 CL 08 Boiler Exploded Diagram ........... 15 47-002-02 86 CL 08 Condensate Drain .........11,26,27,40 Electrical Connections ..........
  • Page 8 GENERAL INTRODUCTION OPERATION This range of boilers are wall mounted, full sequence, automatic With no demand for CH, the boiler fires only when DHW is drawn spark ignition, low water content, fanned flue, high efficiency, off, or periodically for a few seconds without any DHW draw-off, condensing, combination gas boilers.
  • Page 9 GENERAL OPTIONAL EXTRA KITS SAFETY • Horizontal Flue Terminal 1000mm long Current Gas Safety (installation and use) regulations or rules in force: Horizontal Flue Terminal 600mm long • The appliance is suitable only for installation in GB and IE and Horizontal Flue Terminal 600mm long (Weather Protection) •...
  • Page 10 GENERAL GAS SUPPLY LOCATION OF BOILER The local gas supplier should be consulted, at the installation The boiler must be installed on a flat and vertical internal wall, planning stage, in order to establish the availability of an adequate capable of adequately supporting the weight of the boiler and any supply of gas.
  • Page 11 GENERAL 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 12 GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm The boiler connections are made on the boiler connection tails. Refer to Frame 24. 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 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 System volume...
  • Page 14 GENERAL SYSTEM REQUIREMENTS - CONT 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 BS5546 & BS6700. of at least 10% of the minimum boiler output, must 2.
  • Page 15 INSTALLATION BOILER ASSEMBLY - Exploded View Note that item numbers are linked to the spares list CH Return Valve Flow Group Manifold Sump Clean Out Cover Ignition Lead CH Flow Valve Plate Heat Exchanger Flue Manifold Control Box Lens DHW Inlet & Outlet Flow Regulator Flue Manifold Top Detection Lead...
  • 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 10 WALL MOUNTING TEMPLATE Extended centre line 1 5 5 The wall mounting template is located on the internal protective (2 0 0 ) “A” - See Diagram in packaging. The template shows the position of the fixing and rear Frame 1 flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled.
  • Page 19 INSTALLATION 14 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 20 INSTALLATION 15 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 16 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 17 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 18 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 24 INSTALLATION 20 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 21 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 22 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 23 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 24 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. Ensure each union is fitted with fibre seals provided.
  • Page 29 INSTALLATION 24A 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 30 INSTALLATION 25 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 31 INSTALLATION 26 INTERNAL WIRING This 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 32 INSTALLATION 27 INTERNAL WIRING DIAGRAM B DIAGRAM A Room External Internal Timer or Room Stat or Timer Programmable Room Stat Stat Prog. Room Stat ROOM ROOM STAT/ STAT/ TIMER TIMER Optional Optional Frost Stat Frost Stat FROST FROST STAT STAT OPTIONAL OPTIONAL Separate Timer and Room Stat...
  • Page 33 INSTALLATION 30 WIRING DIAGRAM Installation and Servicing...
  • Page 34 INSTALLATION 31 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.
  • Page 35 INSTALLATION 32 INITIAL LIGHTING Legend A. Domestic Hot Water Preheat On/Off Knob B. Domestic Hot Water Temperature Knob C. Central Heating Temperature Knob D. Mode Knob E. Boiler Status Burner ‘on’ Indicator H. Central Heating Economy Setting CH Flow Isolating Valve CH Flow K.
  • Page 36 INSTALLATION 33 GENERAL CHECKS Make the following checks for correct operation in: 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. freely from them.
  • Page 37 INSTALLATION 34 RESET PROCEDURE To restart boiler, turn the mode knob (D) to restart position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence if a heat demand is present. Legend D. Mode Knob E.
  • Page 38 SERVICING 36 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 39 SERVICING 37 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 40 SERVICING 39 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 41 SERVICING 41 CLEANING THE HEAT EXCHANGER Note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Frame 40. 1. Remove ignition and flame detection electrodes. Refer to Frames 48 & 49. 2. It is advisable to replace the sump cover prior to the water flush process.
  • Page 42 SERVICING 43 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 43 SERVICING 45 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 43. 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 44 SERVICING 47 RETURN THERMISTOR RENEWAL 1. Refer to Frame 43. 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 45 SERVICING 49 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Frame 43. Flame Detection Electrode 2. Remove the burner. Refer to Frame 46. 3. Unplug the flame detection lead from the electrode. 4. Remove the 2 screws retaining the detection electrode. 5.
  • Page 46 SERVICING 52 DIVERTER VALVE ACTUATOR REPLACEMENT To remove the motor: 2. Remove the condensate trap/siphon. Refer to Frame 40. 3. Disconnect the inline connector block. 4. Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator. 5.
  • Page 47 SERVICING 54 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 Note. Fit the earth strap provided with the PCB to (BCC) MUST also be purchased for your specific boiler range and output.
  • Page 48 SERVICING 56 DHW FLOW TURBINE SENSOR REPLACEMENT 1. Refer to Frame 43. 2. Drain the DHW system. Refer to Frame 57. 3. Pull off the electrical connection. 4. Using a suitable tool, lift and remove the retaining clip. 5. Use the clip to ease the turbine sensor from its housing.
  • Page 49 SERVICING 59 SAFETY RELIEF VALVE RENEWAL 1. Refer to Frame 43. 2. Drain the boiler. Refer to Frame 57. 3. Remove the clip on return thermistor. Refer to frame 47. 4. Pull out and remove the clip (positioned behind the safety valve) retaining the safety valve.
  • Page 50 SERVICING 62 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT To remove the valve body assembly: 18. Fit the new diverter valve body assemble and replace the two fixing screws. 1. Refer to Frame 43. 19. Refit the DHW manifold, fit the assembly back to the boiler 2.
  • Page 51 SERVICING 65 CH WATER PRESSURE SWITCH REPLACEMENT 1. Refer to Frame 43. 2. Drain the boiler. Refer to frame 57. 3. Pull off the two electrical connections. 4. Using a suitable tool, pull out the metal retaining clip. 5. Carefully withdraw the pressure switch. 6.
  • Page 52 SERVICING 68 HEAT ENGINE RENEWAL Refer also to Frame 6 - ‘Boiler Exploded View’ IMPORTANT Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. 13. Remove the condensate rubber pipe. Refer to Frame 53, no. 2. 14.
  • Page 53 SERVICING 69 EXPANSION VESSEL RECHARGING & REPLACEMENT Recharge RECHARGING Point 1. Refer to Frame 43. 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order 5. Check operation of the boiler. Refer to Frames 32 &...
  • Page 54 FAULT FINDING 71 FAULT FINDING CHART MAIN MENU GO TO FRAME 72 - ALTERNATING ‘L’ and ‘1’ FLOW TEMPERATURE OVERHEAT LOCKOUT GO TO FRAME 73 - ALTERNATING ‘L’ and ‘2’ IGNITION LOCKOUT 5 RESETS WITHIN 15 MINS - ALTERNATING ‘L’ and ‘5’ TURN POWER OFF AND ON GO TO FRAME 74 - ALTERNATING ‘L’...
  • Page 55 FAULT FINDING 72 ALTERNATING ‘L’ AND ‘1’ - 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 56 FAULT FINDING 74 ALTERNATING ‘L’ AND ‘6’ - 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 57 FAULT FINDING 77 ALTERNATING ‘F’ AND ‘3’ - 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 58 FAULT FINDING 80 ALTERNATING ‘F’ AND ‘6’ - 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 59 FAULT FINDING 82 NO CH OPERATION BUT HW WORKS OK Move the mode knob to the Winter position Is the mode knob in the Winter position? Are the Timer and the Room Thermostat switched Switch the Timer and Room Thermostat On Open the Radiator Valves Are the Radiator Valves Open? There is no Voltage from the Timer/Room Stat.
  • Page 60 FAULT FINDING 83 NO HW BUT CH ON Does the display show “d” when a tap is on? Is hot and cold pipework crossed? Adjust flow rates to achieve 35º Are the flow rates correct as per Frame 2. Is the wiring connected temp rise and check filter fitted in between PCB and DHW turbine is not blocked with debris.
  • Page 61 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 63 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 64 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 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) sepa- rate 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 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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