Zanussi ULTRA COMBI 30 Manuale utente
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
2
Installation and Servicing
MODEL
SYMBOL UNITS 30 35
Condensing Boiler n/a n/a yes yes
Low Temperature Boiler n/a n/a no no
B1 Boiler n/a n/a no no
Cogeneration Space Heater n/a n/a no no
Equipped with a Supplementary Heater n/a n/a no no
Combination Heater n/a n/a yes yes
Nominal Heat Output for Space Heating
Full Load P4kW 24.3 24.3
Part Load P1kW 8.0 8.0
Auxiliary Electricity Consumption
Full Load elmax kW 0.032 0.029
Part Load elmin kW 0.013 0.013
Standby PSB kW 0.005 0.005
Seasonal Space Heating Energy Efciency
Full Load ƞ4% 90.0 90.0
Part Load ƞ1% 98.7 98.7
Standby Loss Pstby kW 0.050 0.050
Ignition Pign kW 0 0
Emissions NOxmg/kWh 28 33
Annual Energy Consumption QHE GJ 75 75
Sound Power Level, Indoors LWA dB 46 44
Domestic Hot Water
Qelec kWh 0.075 0.074
ƞWH % 78 78
Qfuel kWh 7.700 7.700
AEC kWh 16 16
AFC GJ 6 6
ERP DATA
3
Installation and Servicing
ULTRA+ COMBI BOILER
ZANUSSI
ERP DATA
SYMBOL UNITS MODEL
30 35
Condensing boiler YES
Seasonal Space heating efciency class A
Rated heat output kW 24
Seasonal space heating energy efciency ƞs% 94*
Annual energy consumption QHE GJ 75
Sound power level, indoors LWA dB 46 44
Water heating energy efciency class A
Seasonal Space Heating Energy Efciency of the Boiler *%
Temperature control (from che of temperature control) %
Class I Class II Class III Class IV Class V Class VI Class VII Class VIII
1% 2% 1.5% 2% 3% 4% 3.5% 5%
PRODUCT FICHE
The energy efciency of the package of products provided for in this document may not correspond to its actual energy efciency once installed in a
building, as the efciency is inuenced by further factors such as heat loss in the products in relation to the building size and its characteristics
Collector Size
(in m2)
Tank Volume
(in m3)
Collector
Efciency
(in %)
Tank rating
A* = 0.95
A = 0.91
B = 0.86
C = 0.83
D-G = 0.81
Solar Contribution (from che of solar device)
Seasonal Space Heating Energy Efciency of Package TOTAL: A+B+C=
Seasonal Space Heating Energy Efciency Class of Package
= (‘III ’x + ‘IV ’ x ) x 0.9 x ( / 100 x = %
%
GG F E D C B A A+ A++ A+++
< 30% ≥ 30% ≥ 34% ≥ 36% ≥ 75% ≥ 82% ≥ 90% ≥ 98% ≥ 125% ≥ 150%
A
B
C
4
Installation and Servicing
5
Installation and Servicing
DOCUMENT AMENDMENTS
Relevant Installation changes implemented in this book from Mod Level......................... A02 (Oct 16) to A03 (Mar 17)
The Manufacturer reserve the right to vary specication without notice
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.
NOTES FOR THE INSTALLER
Page 2 - ERP Data Table
Update to Table
Page 3 - Product FICHE
Update to ERP Data
Section 2.9 - Determining the Flue Length and Flue Packs Required
Update to Powered Vertical Flue table
Section 2.15 - Assembling the Roof Flue Kit
Image updated showing new min & max angles
Section 3.1 - Servicing Schedule
Servicing Producedure updated
Section 4.1 - Fault Finding Chart
Fault Code “FA” added.
USER GUIDE
Section 8 - Fault Codes
Fault Code “FA” added.
6
Installation and Servicing
7
Installation and Servicing
1 GENERAL.................................................................... 8
1.1 Introduction ................................................................ 10
1.2 Operation ................................................................... 10
1.3 Safe Handling............................................................. 10
1.4 Optional Extra Kits ..................................................... 11
1.5 Safety ......................................................................... 11
1.6 Safe Handling Of Substances .................................... 11
1.7 Location of Boiler ...................................................... 12
1.8 Gas Supply................................................................. 12
1.9 Flue Installation .......................................................... 12
1.10 Terminal...................................................................... 13
1.11 Air Supply................................................................... 13
1.12 Water Circulation System........................................... 13
1.13 Boiler Control Interlocks ............................................. 13
1.14 Electrical Supply......................................................... 13
1.15 Condensate Drain ...................................................... 13
1.16 Boiler Dimensions, Services & Clearances................ 14
1.17 System Requirements................................................ 15
1.18 Water Treatment......................................................... 16
1.19 System Balancing ...................................................... 16
2 INSTALLATION ......................................................... 17
2.1 Boiler Assembly - Exploded View............................... 17
2.2 Unpacking .................................................................. 18
2.3 Unpacking Cont’d....................................................... 19
2.4 Front Panel Removal ................................................. 19
2.5 Wall Mounting Template ............................................. 20
2.6 Preparing The Wall..................................................... 20
2.7
Fitting The Wall Mounting Plate .................................... 20
2.8 Mounting The Boiler ................................................... 20
2.9 Determining The Flue Length & Flue Packs Req’d ... 21
2.10 Cutting & Setting The Flue Length ............................. 23
2.11 Installing The Flue...................................................... 24
2.12 Fitting The Optional Roof Flue Kit .............................. 25
2.13 Roof Flue Kit Contents / Options................................ 25
2.14 Flue Terminal Position................................................ 26
2.15 Assembling The Roof Flue Kit.................................... 27
2.16 Condensate Drain ...................................................... 28
2.17 Connections & Filling ................................................. 30
2.18 Electrical Connections................................................ 32
2.19 Installer Wiring ........................................................... 32
2.20 External Wiring........................................................... 33
2.21 Replacing Pre-Fitted Mains Cable ............................. 33
2.22 Wiring Diagram .......................................................... 34
2.23 Commissioning And Testing ....................................... 35
2.24 Initial Lighting ............................................................. 36
2.25 General Checks ......................................................... 37
2.26 Restart Procedure ...................................................... 38
2.27 Accessing The Installer Mode .................................... 38
2.28 Handing Over ............................................................. 38
3 SERVICING ............................................................... 39
3.1 Servicing Schedule .................................................... 39
3.2 Boiler Front Panel Removal / Replacement ............... 40
3.3 Fan And Venturi Assembly Removal And Cleaning.... 40
3.4 Burner Removal & Cleaning....................................... 41
3.5 Cleaning the Condensate Trap/Siphon ...................... 41
3.6 Cleaning the Heat Exchanger .................................... 42
3.7 Reassembly ............................................................... 42
3.8 Replacement Of Components.................................... 43
3.9 Fan Replacement....................................................... 43
3.10 Burner Injector Replacement ..................................... 44
3.11 Burner Replacement .................................................. 44
3.12 Return Thermistor Renewal ....................................... 45
3.13 Ignition Electrode Replacement ................................. 45
3.14 Flame Detection Electrode Replacement................... 46
3.15 Spark Generator Replacement .................................. 46
3.16 Gas Control Valve Replacement ................................ 46
3.17 Diverter Valve Actuator Replacement ........................ 47
3.18 Condensate Trap/Siphon Replacement ..................... 47
3.19 PCB Replacement...................................................... 48
3.20 DHW Flow Turbine Sensor Replacement .................. 48
3.21 Draining The Boiler .................................................... 49
3.22 Pressure Gauge Renewal .......................................... 49
3.23 Safety Relief Valve Renewal ...................................... 50
3.24 Pump Automatic Air Vent Replacement ..................... 50
3.25 DHW Filter & Flow Reg Cleaning/Replacement......... 50
3.26 Diverter Valve Body Assembly Replacement............. 51
3.27 DHW Plate Heat Exch. Replacement......................... 51
3.28 Pump Head Replacement .......................................... 51
3.29 CH Water Pressure Switch Replacement .................. 52
3.30 Flow Thermistor Replacement ................................... 52
3.31 Heat Engine Renewal ................................................ 53
3.32 Expansion Vessel Recharging & Replacement.......... 54
4 FAULT FINDING ........................................................ 55
4.1 Fault Finding Chart Main Menu.................................. 55
4.2 ‘L1’ - Flow Temp Overheat Lockout............................ 56
4.3 ‘L2’ - Ignition Lockout ................................................. 56
4.4 ‘L6’ - False Flame Lockout ........................................ 57
4.5 ‘F1’ - Low Water Pressure.......................................... 57
4.6 ‘F2 Or Fn Or Ln’ - Flame Loss.................................... 57
4.7 ‘F3’ - Fan Fault ........................................................... 58
4.8 ‘F4 Or L4’ - Flow Thermistor Fault.............................. 58
4.9 ‘F5 Or L5’ - Return Thermistor Fault .......................... 58
4.10 ‘F6’ - Outside Sensor Fault......................................... 59
4.11 No CH Operation but HW Works OK ......................... 59
4.12 No HW But CH On ..................................................... 60
4.13 No Display.................................................................. 60
5 SPARE PARTS .......................................................... 61
6 BENCHMARK & COMMISSIONING ......................... 62
CONTENTS
8
Installation and Servicing
SECTION 1 - GENERAL
30 35
Gas supply 2H - G20 - 20mbar
Gas Supply Connection 15mm copper compression
Injector Size mm 4.65 4.9
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 Central Heating 22mm copper compression
Flue Terminal Diameter mm 100
Average Flue Temp-Mass Flow Rate (DHW) 68ºC - 13g/s 73ºC - 15g/s
Maximum Working Pressure (Sealed Systems) bar 2.5
Maximum Domestic Hot Water Inlet Pressure bar 10.0
Minimum Domestic Hot Water Inlet Pressure* bar 1.3 1.3**
Minimum DHW Inlet Pressure to operate at 0.6bar system pressure All Model sizes 0.5 bar
Electrical Supply 230 V ~ 50 Hz
Power Consumption W 101 114
Fuse Rating External : 3A Internal : T4A HRC L250 V
Water content Central Heating litre 1.2
Domestic Hot Water litre 0.5
Packaged Weight kg 33.8 33.9
Maximum Installation Weight kg 29 29.1
Boiler Casing Size Height mm 700
Width mm 395
Depth mm 278
Table 1 - General Data
Note. Gas consumption is calculated using a
caloric value of 38.7 MJ/m3 gross or 34.9 MJ/m3
nett
To obtain the gas consumption at a different caloric
value:
a. For l/s - divide the gross heat input (kW) by the
gross C.V. of the gas (MJ/m3)
b. For Btu/h - multiply the gross heat input (kW) by
26.8
c. For ft3/h - divide the gross heat input (Btu/h) by
the gross C.V. of the gas (Btu/ft3)
d. For m3/h - multiply l/s by 3.6
Key to symbols
GB = United Kingdom IE = Ireland (Countries of destination)
PMS = Maximum operating pressure of water
C13 C33 C53
= A room sealed appliance designed for connection via ducts to a
horizontal or vertical terminal, which admits fresh air to the burner
and discharges the products of combustion to the outside through
orices which, in this case, are concentric. The fan is up stream of
the combustion chamber.
I2H = An appliance designed for use on 2nd Family gas, Group H only.
* The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from
which it has been calculated have been certied by a notied body.
*Required for maximum ow rate. Boiler operates down to 2 l/min DHW delivery
** In areas of low water pressure the DHW restrictor can be removed
Maximum DHW Input : 30 35
Nett CV kW 30.4 35.4
Gross CV kW 33.7 39.3
Gas Consumption m3/h 3.135 3.657
Maximum kW 30.3 35.3
DHW Output
DHW Flow Rate l/min 12.4 14.5
at 35°C temp. rise.
DHW Specic Rate l/min 14.5 16.9
Boiler Input : Max. Min.
30 35
Boiler Input ‘Q’ Nett CV kW 24.3 6.1 7.1
Gross CV kW 27.0 6.7 7.9
Gas Consumption m3/h 2.512 0.627 0.734
Boiler Output :
Non Condensing kW 24.2 6.1 7.1
70oC Mean Water temp.
Condensing kW 25.6 6.4 7.5
40oC Mean Water temp.
Seasonal efciency* SEDBUK 2005 91.1% 91.1%
Seasonal efciency* SEDBUK 2009 89.6% 89.6%
NOx Classication CLASS 5
Table 2 - Performance Data - Central Heating Table 3 - Performance Data - Domestic Hot Water
9
Installation and Servicing
SECTION 1 - GENERAL
Boiler Page
Make and model......................................................... 9
Appliance serial no. on data badge .......... Front Cover
SEDBUK No. %.......................................................... 8
Controls
Time and temperature control to heating ................. 32
Time and temperature control to hot water ............. 32
Heating zone valves................................................ n/a
TRV’s........................................................................ 13
Auto bypass ............................................................. 13
Boiler interlock.......................................................... 13
For .................................................................... all boilers
Flushing to BS.7593................................................. 16
Inhibitor .................................................................... 16
Central heating mode
Heat input...................................................to be calculated
For assistance see Technical Helpline on the back page
Page
Burner operating pressure ...................................... n/a
Central heating ow temp. ...........measure and record
Central heating return temp. ........measure and record
For combination boilers only
Scale reducer ........................................................... 16
Hot water mode
Heat input............................................to be calculated
Max. operating burner pressure .............................. n/a
Max. operating water pressure........ measure & record
Cold water inlet temp ...................... measure & record
Hot water outlet temp. ..................... measure & record
Water ow rate at max. setting........ measure & record
For condensing boilers only
Condensate drain................................................28-29
For all boilers: complete, sign & hand over to customer
For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be tted in accordance with the
manufacturer’s instructions. Self-certication that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Commissioning Checklist.
Before installing this boiler, read the Code of Practice sheet at the rear of this book.
BENCHMARK COMMISSIONING CHECKLIST DETAILS
NOTE TO THE INSTALLER:
COMPLETE
THE BENCHMARK COMMISSIONING
CHECKLIST AND LEAVE THESE
INSTRUCTIONS WITH APPLIANCE
Boiler size G.C. Appliance No. PI No.
(Benchmark No.)
30 47-002-03 86CR16
35 47-002-04 86CR16
Natural Gas only
Destination Country: GB, IE
ZANUSSI ULTRA+ COMBI
10
Installation and Servicing
SECTION 1 - GENERAL
1.1 INTRODUCTION
The Zanussi Ultra+ Combi range of boilers are wall mounted, full
sequence, automatic spark ignition, low water content, fanned
ue, high efciency, condensing, combination gas boilers.
Note. Due to the high efciency of the boiler a plume of water
vapour will form at the terminal during operation.
Central heating (CH) output is fully modulating with a range of:
30 6.1 to 24.2kW
35 7.1 to 24.2kW
Instantaneous domestic hot water (DHW) output is also fully
modulating with a maximum of :
30 30.3kW
35 35.3kW
The boiler is supplied fully assembled with DHW plate heat
exchanger, diverter valve, circulating pump, pressure gauge,
safety valve and CH expansion vessel.
Variable CH and DHW temperature controls are tted on the user
control and the boiler features a DHW preheat facility.
The boiler includes as standard:
- Automatic bypass
- Boiler frost protection
- Daily pump and diverter valve exercise.
The boiler casing is of white painted mild steel with a white
polymer front panel.
The boiler temperature controls are visibly located in the control
panel on the front of the boiler.
The heat exchanger is manufactured from cast aluminium.
The boiler is suitable for connection to fully pumped, sealed
heating systems ONLY. Adequate arrangements for completely
draining the system by provision of drain cocks MUST be provided
in the installation pipework.
Pipework from the boiler is routed downwards.
Data Plate
The boiler model and serial number can be located on the
bottom of the boiler casing, shown in Section 1.16 - Water & Gas
Connection Diagram.
1.2 OPERATION
With no demand for CH, the boiler res only when DHW is drawn
off, or periodically for a few seconds without any DHW draw-off,
in order to maintain the DHW plate heat exchanger in a heated
condition. This only occurs if the “PREHEAT” button is pressed
and the display reads “HOT WATER PREHEAT ON”.
When there is a demand for CH, the heating system is supplied
at the selected temperature of between 30oC and 80oC, until
DHW is drawn off. The full output from the boiler is then directed
via the diverter valve to the plate heat exchanger to supply a
nominal DHW draw-off of
30 12.4 l/min at 35ºC temperature rise.
35 14.5 l/min at 35ºC temperature rise.
The DHW draw off rate specied above is the nominal that the
boiler ow regulator will give. Due to system variations and
seasonal temperature uctuations DHW ow rates/temperature
rise will vary, requiring adjustment at the draw off tap.
At low DHW draw-off rates the maximum temperature may
exceed 65ºC.
The boiler features a comprehensive diagnostic system which
gives detailed information on the boiler status when operating,
and performance of key components to aid commissioning and
fault nding.
1.3 SAFE HANDLING
This boiler may require 2 or more operatives to move it to its
installation site, remove it from its packaging base and during
movement into its installation location. Manoeuvring the boiler
may include the use of a sack truck and involve lifting, pushing
and pulling.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques
when performing these tasks and the following precautions
should be considered:
• Grip the boiler at the base.
• Be physically capable.
• Use personal protective equipment as appropriate, e.g.
gloves, safety footwear.
During all manoeuvres and handling actions, every attempt
should be made to ensure the following unless unavoidable and/
or the weight is light.
• Keep back straight.
• Avoid twisting at the waist.
• Avoid upper body/top heavy bending.
• Always grip with the palm of the hand.
• Use designated hand holds.
• Keep load as close to the body as possible.
• Always use assistance if required.
Altri manuali per ULTRA COMBI 30
1
Questo manuale è adatto per i seguenti modelli
1
Indice
Altri manuali Zanussi Caldaia
