Zanussi ULTRA SYSTEM 15 User Manual Download

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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

Summary of Contents for ULTRA SYSTEM 15

Page 1: ...t 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 ...

Page 2: ...pace Heating Full Load P4 kW 15 18 24 30 Part Load P1 kW 4 8 5 8 7 9 11 Auxiliary Electricity Consumption Full Load elmax kW 0 021 0 026 0 042 0 048 Part Load elmin kW 0 012 0 013 0 013 0 013 Standby PSB kW 0 005 0 005 0 005 0 005 Seasonal Space Heating Energy Efficiency Full Load ƞ4 89 7 89 6 89 6 89 8 Part Load ƞ1 97 7 97 4 98 98 Standby Loss Pstby kW 0 055 0 055 0 055 0 055 Ignition Pign kW 0 0...

Page 3: ...s VII Class VIII 1 2 1 5 2 3 4 3 5 5 PRODUCT FICHE The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installed in a building as the efficiency is influenced 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...

Page 4: ...4 Installation and Servicing ...

Page 5: ...rve the right to vary specification without notice 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 NOTES FOR THE INSTALLER ...

Page 6: ...nation 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 orifices 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 Gr...

Page 7: ...to BS 7593 14 Inhibitor 14 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 flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reducer 14 Hot water mode Heat input to be calculated Max operating burner pressure n a Max operating water...

Page 8: ...nding 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 ...

Page 9: ... direct connection of a control device not approved by the manufacturer could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations SAFE HANDLING OF SUBSTANCES No asbestos mercury or CFCs are included in any part of the boiler or its manufacture LOCATION OF BOILER The boiler must be installed on a flat and vertica...

Page 10: ...gs are specified in Table 4 Only one reduction down to 25mm is allowable per installation otherwise BS5440 1 2008 dimensions must be followed Flue Terminal Positions Min Spacing 1 Directly below above or alongside an opening window air vent or other ventilation opening 300mm 12 2 Below guttering drain pipes or soil pipes 25mm 1 BS5440 1 2008 75mm 3 3 Below eaves 25mm 1 BS5440 1 2008 200mm 8 4 Belo...

Page 11: ... are used the space heating temperature control over a living dining area or hallway having a heating requirement of at least 10 of the minimum boiler heat output should be achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves However if the system employs thermostatic radiator valves on all radiators or two port valves then a bypass circui...

Page 12: ... g with a core drill the flue can be installed from inside the building where wall thicknesses do not exceed 600mm 24 Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside Installation from inside ONLY b If a core boring tool is to be used inside the building the space in which the boiler is to be installed ...

Page 13: ...e return to the boiler Guidance on vessel sizing is given in table opposite 5 Filling The system may be filled by the following method Through a temporary hose connection from a draw off tap supplied from a service pipe under mains pressure Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling When installing the filling device it must be connected as b...

Page 14: ...atment is used the manufacturer recommend only the use of Scalemaster Gold 100 FERNOX MB 1 ADEY MC1 SENTINEL X100 or CALMAG CM100 inhibitors and associated water treatment products which must be used in accordance with the manufacturers instructions Notes 1 It is most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers instruc...

Page 15: ... INJECTOR ASSEMBLY 214 VENTURI 215 FAN 217 BURNER 218 GASKET BURNER 219 SUMP CLEAN OUT COVER 223 FLUE MANIFOLD 224 FLUE MANIFOLD TOP 227 CLAMP RETAINING FLUE TURRET 228 HOSE CONDENSATE INTERNAL 229 SIPHON TRAP 231 CONDENSATE OUTLET CONNECTION 301 CONTROLS BOX FIXINGS HINGE SPRING 302 PRIMARY PCB 303 CUI BOARD 304 CONTROL THERMISTOR RETURN 306 ELECTRODE IGNITION 307 ELECTRODE DETECTION 308 IGNITER ...

Page 16: ...n Users Instructions E Wall Mounting Template located on internal protective packaging F Boiler Guarantee Registration Pack C A D B E F Boiler Guarantee HARDWARE PACK CONTENTS Gas Valve Pack 1 Pipe Gas Inlet 2 Washer Gas blue 3 Gas Cock Return Valve Pack 1 Pipe CH Return 2 Washer CH 3 Valve Return Accessory Pack 1 Screw x2 2 Wallplug x2 3 Turret Clamp Screw spare x1 Flow Valve Pack 1 Pipe CH Flow ...

Page 17: ... 1 Loosen the 2 screws retaining the front panel 2 Pull the two spring clips downwards to disengage 3 Pull the front panel forward and upwards to remove 1 2 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 app...

Page 18: ...L IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Cut the flue hole preferably with a 5 core boring tool ensuring that the hole is square to the wall Both wall faces immediately around the cut hole should be flat 2 Drill 2 mounting holes marked from template with a 7 5mm 8mm masonry drill and insert the plastic p...

Page 19: ... in the B Pack has an upper combustion sample point with a screw cap seal and a lower air sample point with an air stopper seal Ensure all caps seals are in place Additional Termination Kits available for use with these B packs Flue Deflector Kit The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from any maximum flue length High Level Flue Outlet Kit The maxim...

Page 20: ...minal 1000mm long B Pack Telescopic Cut 75mm Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum B Pack Standard 171 556 286 484 601 816 526 741 Plus 1 1m D pack 1121 1506 1236 1434 1551 1766 1476 1691 Plus 2 1m D pack 2071 2456 2186 2384 2501 2716 2426 2641 Plus 3 1m D pack 3021 3406 3136 3334 3451 3666 3376 3591 Plus 4 1m D pack 3971 4356 4086 4284 4401 4616 4326 4541 Plus 5 1m D pac...

Page 21: ...rminal is upper most 4 Drill a 3 5mm hole through one of the 2 outer side holes in the outer flue section into the inserted outer flue as shown Take care not to pierce the inner plastic flue Fit screw provided 5 Seal the joint on the outer air duct with the tape provided 6 Fit internal and external wall seals see installing flue CUTTING HORIZONTAL FLUE TERMINAL 600MM LONG B PACK 1 Measure the requ...

Page 22: ... refitted 9 When 1st mark is in line with the wall whilst holding the flue firmly push the white wall sealing flange to the wall until the 2nd of the two marks is just visible If the last location mark is clearly passed the white inner wall seal then the outer wall seal will have been dislodged from its mounting and will need to be re fitted 10 Ensure the seam and the outlet terminal are at the to...

Page 23: ...lat roof weather collar or Universal weather collar ACCESSORIES Flue Duct Extension Kits are available for flue lengths extending beyond 1m These packs contain 500mm 1000mm or 2000mm extension ducts and may be cut to the desired length If the offset vertical option is used an elbow Kit is required For a full accessories list refer to page 8 Optional Extras Flue duct support Vertical Connector Flue...

Page 24: ...ate the shaded area of the roof Note The equivalent flue length resistance of the elbow kits are 90o elbow kit 1m 45o elbow kit 0 6m If chimney penetrates dotted area such that A is less than 300mm B shall not be less than 300mm Where two or more vertical fanned draught chimney configurations terminate in close proximity at the same height they shall be separated by at least 300mm Where any one ve...

Page 25: ...nstructions provided with the vertical connector kit 3 Secure the vertical connector by applying downward pressure on the connector 4 Position the clamp on the top face of the flue manifold and push it horizontally backwards Locate both clamp lugs into the flue manifold and secure to the flue manifold with the M5 retaining screw 5 Push fit extension duct if required supplied separately into vertic...

Page 26: ...rain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose designed soak away If an external system is chosen then the following measures must be adopted The external pipe run should be kept to a minimu...

Page 27: ...m connection height up to 3 storeys Soil vent stack 450 Boiler with 75mm sealed condensate trap Min Ø 19mm Internal pipe Min Ø 30mm Internal pipe Water weather proof insulation 75 Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break Visible air break at plug hole Min Ø 19mm Internal pipe Sink basin bath or shower with integral overflow and 75mm trap Min...

Page 28: ... comprssion joint on the end of the stub pipe This assists with pipe removal when servicing The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring Note An optional safety valve wall outlet kit is available if required FILLING IMPORTANT when filling A Ensure the dust cap o...

Page 29: ...e servicing position 5 Route incoming cable through a grommet in the bottom panel note that the grommets are blind and will require puncturing and secure using the clamp 6 Connect the switched live to the terminal block as shown FROST THERMOSTAT WIRING If parts of the system are vulnerable to freezing or the programmer is likely to be left off during cold weather a frost stat should be fitted in c...

Page 30: ... then use the following guide Replacement wiring should comply with notes in Frame 24 1 Isolate the mains supply to the boiler 2 Remove the front panel Refer to Frame 35 3 Swing the control box down into the service position Refer to frame 41 4 Remove the live neutral and earth wires from the terminal block 5 Loosen the cable clamp and withdraw the mains cable 6 Route replacement cable back throug...

Page 31: ...p bk r bk PCB Earth y g br b bk bk b b br y g blue black brown red pink yellow white yellow green grey orange violet b bk br r p y w y g g or v KEY p y bk bk b y g br y g y g bk b bk y g X13 1 2 3 sL E N L bk y p bk y p Water pressure Switch Flow Thermistor Return Thermistor Service Connector Flame Sensor Electrode Fan Spark Electrode Spark Generator Gas Valve Pump br b y g bk INSTALLATION ...

Page 32: ...een checked adjusted and preset at the factory for operation on the gas type defined on the appliance data plate DO NOT adjust the air gas ratio valve Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals as described in the Flue Installation section Proceed to put the boiler into operation as follows CHECK THE O...

Page 33: ...r to Frame 35 3 Check that the drain valve L is closed and that the CH isolating valve F and K are OPEN 4 Check that the electrical supply is OFF 5 Check that the boiler mode control knob B is off 6 Check that the gas service cock J is OPEN 7 Slacken the screw in the inlet pressure test point H and connect a gas pressure gauge via a flexible tube 8 Switch the electricity supply ON and check all ex...

Page 34: ...ator A B E C D Knob Setting CH Flow Temp ºC ºF Max 80 176 Min 30 86 33 HANDING OVER 8 Loss of system water pressure Explain that the dial underneath the boiler indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated Explain the re pressurising procedure and if unable to re pressurise o...

Page 35: ...ied out in sequence IMPORTANT 6 After completing the servicing or exchange of components always test for gas tightness 7 When work is complete the front panel MUST be correctly refitted ensuring that a good seal is made Do NOT OPERATE the boiler if the front panel is not fitted 8 If for any reason the condensate trap siphon has been removed ensure the trap is refilled with water before reassemblin...

Page 36: ...the front panel 5 Re tighten the two retaining screws 36 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING 1 Disconnect the electrical leads from the fan 2 Remove the clip from the gas control valve outlet and ease the pipe upwards rotate and then ease down to remove 3 Remove the extended nut on the fan mounting bracket 4 Lift off fan and venturi assembly 5 Undo the two M4 screws and release the nozzl...

Page 37: ...ngle the burner as shown IMPORTANT The burner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic 6 Brush off any deposits that may be on the ceramic with a SOFT brush 7 Inspect the sealing gasket around the burner for any signs of damage Replace as necessary 1 Pull off the rubber pipe noting th...

Page 38: ...on gaps are correct Refer to Frames 46 47 1 Ignition Electrode Flame Detection Reassemble the boiler in the following order 1 Ensure that the condensate trap siphon is full of water 2 Refit the burner ensuring the sealing gasket is correctly positioned and free from damage tighten the 4 fixing screws in the sequence shown below 3 Refit the fan venturi assembly ensuring the retaining tabs are corre...

Page 39: ...NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 42 FAN REPLACEMENT 1 Refer to Frame 41 2 Disconnect the electrical leads from the fan 3 Remove the clip from the gas control valve outlet 4 Remove the extended nut retaining the fan mounting bracket 5 Lift and remove the fan and venturi assembly 6 Remove the screw and twist venturi anti clockwise to remove venturi assembly noting the orientation of th...

Page 40: ...er ensuring that the new gas seal supplied is located correctly in the injector housing 10 Check operation of the boiler Refer to Frames 30 31 44 BURNER REPLACEMENT 5 5 6 1 See Frame 37 2 Refer to Frame 41 3 Undo the two screws and remove the sump cover 4 Lift the manifold to clear the bottom sealing gasket and remove manifold 5 Remove the 2 front fixing screws and loosen the 2 rear extended nuts ...

Page 41: ...ns as shown 8 Reassemble in reverse order 9 Check the operation of the boiler Refer to Frames 30 31 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 therm...

Page 42: ...ark generator and re assemble in reverse order ensuring that the the earth lead is replaced 6 Check operation of the boiler Refer to Frames 30 31 Flame Detection Electrode 12 5mm Straight edge 1 Refer to Frame 41 2 Remove the burner Refer to Frame 44 3 Unplug the flame detection lead from the electrode 4 Remove the 2 screws retaining the detection electrode 5 Remove the electrode 6 Fit the new fla...

Page 43: ...ards 7 Fit the new gas control valve ensuring that the O ring and sealing washer are in place and reconnect gas and electrical connections 8 Check operation of the boiler Refer to Frames 30 31 1 Refer to Frame 41 Note Ensure condensate trap is fully drained before removal 2 Pull off the rubber pipe at the sump drain 3 Disconnect the condensate drain pipe 4 Turn the siphon clockwise to disengage an...

Page 44: ...ew Primary PCB and attach the appropriate Boiler Chip Card BCC to it this should correspond to the output of the boiler 15kW 18kW 24kW or 30kW Note Ensure the correct orientation of BCC by placing TOP side up as shown 8 Re connect all plug connections 9 Reassemble in reverse order 10 a Turn power on b Displays 8 blue light on off first digit input second digit input 1st letter appliance type i e 2...

Page 45: ...ROL PCB REPLACEMENT 3 Potentiometer spindle Control Knobs to be in vertical position PCB 4 53 DRAINING THE BOILER CENTRAL HEATING CIRCUIT 1 Refer to Frame 41 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 4 After replacing any component on the boiler remove the hose c...

Page 46: ...sure gauge using suitable jointing compound 5 Refill the boiler Refer to Frame 23 6 Check operation of the boiler Refer to Frames 30 31 54 PRESSURE GAUGE REPLACEMENT 56 PUMP AUTOMATIC AIR VENT REPLACEMENT 1 Refer to Frame 41 2 Drain the boiler Refer to Frame 53 3 Remove the expansion vessel Refer to Frame 61 4 Firstly increase access area by disconnecting the 22mm pipe connection at top of pump ch...

Page 47: ...off the two electrical connections 4 Using a suitable tool pull out the metal retaining clip 5 Carefully withdraw the pressure switch 6 Fit the new pressure switch and re assemble in reverse order 7 Refill the boiler 8 Check operation of the boiler Refer to Frames 30 31 1 Refer to Frame 41 2 Drain down the boiler Refer to Frame 53 3 Unplug the electrical lead 4 Unscrew the thermistor to facilitate...

Page 48: ...s if any sign of damage is evident When replacing the spring clips located on the return pipe connection ensure clip is oriented to correctly match connecting pipe diameters 18 Ensure the trap siphon is filled with water Refer to Frame 50 19 Refill the boiler Refer to Frame 23 20 Check operation of the boiler Refer to Frames 30 31 1 Refer to Frame 41 2 Drain the boiler Refer to Frame 53 3 Remove t...

Page 49: ...the charge point cover 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 Refer to Frame 41 6 Drain the boiler CH circuit Refer to Frame 53 7 Remove the retaining clip on the vessel water connection pipe 8 Support the expansion vessel and unscrew the 2 screws from the securing clamp located on the top of the b...

Page 50: ...70 CONTROL NO FLOW THERMISTOR FAULT GO TO FRAME 71 RETURN THERMISTOR FAULT GO TO FRAME 72 OUTSIDE SENSOR FAULT LOW MAINS VOLTAGE CONTACT ELECTRICITY PROVIDER PCB FAULT REPLACE PCB RESTART BOILER NO CH NO HW GO TO FRAME 74 GO TO FRAME 76 If PCB replaced as a spare ensure that the BCC boiler chip card small plastic part is fitted to the PCB otherwise replace PCB ALTERNATING L and 5 5 RESTARTS WITHIN...

Page 51: ...ly available at the Gas Valve See note YES Check spark generator and associated harness for continuity and visual condition Refer to Frame 48 Are these functioning correctly YES Check ignition electrode and associated harness for continuity visual condition and position Refer to Frame 46 Are these functioning correctly NO Check siphon and condensate drain pipe work for blockage and rectify if nece...

Page 52: ...hile the flame is on See note YES Check spark generator and associated harness for continuity and visual condition Refer to Frame 48 Are these functioning correctly YES Check ignition electrode and associated harness for continuity visual condition and position Refer to Frame 46 Are these functioning correctly YES Check siphon and condensate drain pipe work for blockage and rectify if necessary Bo...

Page 53: ... 6 OUTSIDE SENSOR FAULT Disconnect the wires to the outside sensor Check the resistance using a suitable multimeter connected across the Outside Sensors terminal pins At 0 o C expect 31 000 35 000 Ohms At 15 o C expect 15 000 16 500 Ohms At 30 o C expect 7 700 8 500 Ohms Is the Outside Sensor value correct Replace PCB Fit a new Outside Sensor Is the wiring securely connected between the incoming t...

Page 54: ...NO DISPLAY Is there 230Vac to the boiler at L and N see Frame 74 NO Supply power to the boiler Is the wiring from the terminal block to the Main PCB connected securely NO Connect the wiring from the terminal block to the Main PCB securely Is the ribbon cable from the main PCB to the User Interface PCB connected securely NO Connect the ribbon from the main PCB to the User Interface PCB securely Rep...

Page 55: ...deal Failure to do so could affect safety or performance of this appliance Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www idealparts com The Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665 When calling and to ensure we can provide you with the most accurate parts information please ensure you ...

Page 56: ...56 SHORT LIST OF PARTS Installation and Servicing ...

Page 57: ... 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 To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed The service details should be recorded on the Bench...

Page 58: ...opriate Building Regulations and then handed to the customer to keep for future reference GAS BOILER SYSTEM COMMISSIONING CHECKLIST CONTROLS Programmable room thermostat Optimum start control Combination Boiler Fitted Fitted Fitted Automatic bypass to system Fitted Boiler interlock ALL SYSTEMS Yes Yes CENTRAL HEATING MODE OR mbar OR mbar Central heating return temperature COMBINATION BOILERS ONLY ...

Page 59: ...ularly and that the appropriate Service Interval Record is completed Service Provider SERVICE RECORD SERVICE 01 AND Where Possible AND Signature SERVICE 02 AND Where Possible AND Signature SERVICE 03 AND Where Possible AND Signature SERVICE 04 AND Where Possible AND Signature SERVICE 05 AND Where Possible AND Signature SERVICE 06 AND Where Possible AND Signature SERVICE 07 AND Where Possible AND S...

Page 60: ...d e g Gas Safe Register Technical Bulletin TB 008 where chimney flues are in voids The ECGA should be of the correct type as specified by BS 7967 Prior to its use the ECGA should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser Check and zero the analyser IN FRESH AIR in accordance with the analyser manufac...

Page 61: ...ssembled fixed and supported as per instructions Check that flue and flue terminal are not obstructed Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary Turn off appliance and call Ideal Technical Helpline for advice The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed...

Page 62: ...62 NOTES Installation and Servicing ...

Page 63: ...63 NOTES Installation and Servicing ...

Page 64: ...nussi 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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