Zanussi ULTRA COMBI 35 User manual

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

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 24.2 24.2
Part Load P1kW 7.9 7.9
Auxiliary Electricity Consumption
Full Load elmax kW 0.032 0.042
Part Load elmin kW 0.013 0.013
Standby PSB kW 0.004 0.004
Seasonal Space Heating Energy Efciency
Full Load ƞ4% 89.6 89.6
Part Load ƞ1% 98 98
Standby Loss Pstby kW 0.005 0.005
Ignition Pign kW 0 0
Emissions NOxmg/kWh 26.3 31.2
Annual Energy Consumption QHE GJ 74.9 74.9
Sound Power Level, Indoors LWA dB 45.5 44.2
Domestic Hot Water
Qelec kWh 0.177 0.173
ƞWH % 75.6 76.3
Qfuel kWh 7.615 7.486
AEC kWh 31.4 31.6
AFC GJ 5.8 5.8
ERP DATA

3
Installation and Servicing
ULTRA COMBINATION BOILER
ZANUSSI
ERP DATA
SYMBOL UNITS MODEL
30 35
Condensing boiler Yes
Seasonal Space heating efciency class A
Rated heat output kW 24
Seasonal space heating energy efciency ƞs% 93*
Annual energy consumption QHE GJ 74.9
Sound power level, indoors LWA dB 45 44
Water heating energy efciency class A
Seasonal Space Heating Energy Efciency 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 efciency of the package of products provided for in this document may not correspond to its actual energy efciency once installed in a
building, as the efciency is inuenced 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
Efciency
(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 Efciency of Package TOTAL: A+B+C=
Seasonal Space Heating Energy Efciency 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........ A01 (Mar 16) to A02 (Apr 16)
The manufacturer reserves the right to vary specication without notice
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.
NOTES FOR THE INSTALLER
Page 2 - ERP DATA TABLE
DHW information updated.

6
Installation and Servicing
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 (in) 100 (4)
Average Flue Temp-Mass Flow Rate (DHW) 68oC - 13g/s 73oC - 15g/s
Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.5 (36.3)
Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) (kPa) 10.0 (145) (1000)
Minimum Domestic Hot Water Inlet Pressure* bar (lb/in2) (kPa) 1.3 (18.9) (130) 1.3 (18.9)** (130)
Electrical Supply 230 V ~ 50 Hz.
Power Consumption W 101 114
Fuse Rating External : 3A Internal : T4H HRC L250 V
Water content Central Heating litre (gal) 1.2 (0.26)
Domestic Hot Water litre (gal) 0.5 (0.11)
Packaged Weight kg (lb) 36.5 (80.6) 36.5 (80.6)
Maximum Installation Weight kg (lb) 32 (70.8) 32 (70.8)
Boiler Casing Size Height mm (in) 700 (27.5)
Width mm (in) 395 (15.5)
Depth mm (in) 278 (11)
Table 1 - General Data
Note. Gas consumption is calculated using a
caloric value of 38.7 MJ/m3 (1038 Btu/ft3) gross
or 34.9 MJ/m3 (935 Btu/ft3) nett
To obtain the gas consumption at a different
caloric value:
a. For l/s - divide the gross heat input
(kW) by the gross C.V. of the gas (MJ/m3)
b. For ft3/h - divide the gross heat input (Btu/h)
by the gross C.V. of the gas (Btu/ft3)
c. 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
orices 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 certied by a notied 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
(Btu/h) (103,600) (120,900)
Gross CV kW 33.7 39.3
(Btu/h) (115,000) (134,200)
Gas Consumption m3/h 3.135 3.657
(ft3/h) (111) (129)
Maximum kW 30.3 35.3
DHW Output (Btu/h) (103,300) (120,500)
DHW Flow Rate l/min 12.4 14.5
at 35°C temp. rise. (gpm) (2.8) (3.2)
DHW Specic Rate l/min 14.5 16.9
(gpm) (3.2) (3.7)
Boiler Input : Max. Min.
30 35
Boiler Input ‘Q’ Nett CV kW 24.3 6.1 7.1
(Btu/h) (82,900) (20,700 (24,100)
Gross CV kW 27.0 6.7 7.9
(Btu/h) (92,000) (23,000) (26,900)
Gas Consumption m3/h 2.512 0.627 0.734
(ft3/h) (89) (22) (25.9)
Boiler Output :
Non Condensing kW 24.2 6.1 7.1
70oC Mean Water temp. (Btu/h) (82,600) (20,700) (24,100)
Condensing kW 25.6 6.4 7.5
40oC Mean Water temp. (Btu/h) (87,400) (21,800) (25,500)
Seasonal efciency* SEDBUK 2005 91.1% 91%
Seasonal efciency* SEDBUK 2009 89% 88.9%
NOx Classication CLASS 5
Table 2 - Performance Data - Central Heating Table 3 - Performance Data - Domestic Hot Water

7
Installation and Servicing
GENERAL
Boiler size G.C. Appliance No. PI No.
(Benchmark No.)
30 47-002-01 86 CL 08
35 47-002-02 86 CL 08
CONTENTS
Air Supply .....................................................................11
Benchmark Commissioning Checklist ................ 64-65
Boiler Clearances ....................................................... 12
Boiler Exploded Diagram ........................................... 15
Condensate Drain .........................................11,26,27,40
Electrical Connections ............................................... 31
Electrical Supply ..........................................................11
Fault Finding .......................................................... 54-60
Flue Fitting ............................................................. 19-25
Flue Installation .......................................................... 10
Gas Safety Regulations ............................................... 9
Gas Supply .................................................................. 10
Installation .............................................................. 15-37
Pump ........................................................................... 50
Safe Handling ................................................................ 8
Servicing ................................................................ 38-53
Spare Parts Info .......................................................... 61
Thermostatic Radiator Valves ....................................11
Water and Systems ..........................................11,13,14
Water & Gas Connections .................................... 28-29
Water Treatment ........................................................ 14
Wiring Diagram ........................................................... 33
Natural Gas only Boiler
Destination Country: GB, IE
Boiler Page
Make and model......................................................... 7
Appliance serial no. on data badge .......... Front Cover
SEDBUK No. %.......................................................... 6
Controls
Time and temperature control to heating ................. 31
Time and temperature control to hot water ............. 31
Heating zone valves................................................ n/a
TRV’s........................................................................ 11
Auto bypass ............................................................. 11
Boiler interlock.......................................................... 11
For .................................................................... all boilers
Flushing 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 ow 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 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................................................26-27
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-certication 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

8
Installation and Servicing
GENERAL
INTRODUCTION
This range of boilers are wall mounted, full sequence, automatic
spark ignition, low water content, fanned ue, high efciency,
condensing, combination gas boilers.
Note. Due to the high efciency 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 (20,700 to 82,600 Btu/h)
35 7.1 to 24.2kW (24,100 to 82,600 Btu/h)
Instantaneous domestic hot water (DHW) output is also fully
modulating with a maximum of :
30 30.3kW (103,300 Btu/h)
35 35.3kW (120,500 Btu/h)
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.
The boiler temperature controls are visible 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 Frame 1 - Water & Gas Connection
Diagram.
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 pre-heat knob is in the ‘ON’ period.
When there is a demand for CH, the heating system is supplied
at the selected temperature of between 45oC 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 35 oC temperature rise.
35 14.5 l/min at 35 oC temperature rise.
The DHW draw off rate specied 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 rate the maximum temperature is limited to
64 oC by the modulating gas control.
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.
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.

9
Installation and Servicing
GENERAL
OPTIONAL EXTRA KITS
• Horizontal Flue Terminal 1000mm long
• Horizontal Flue Terminal 600mm long
•
Horizontal Flue Terminal 600mm long (Weather Protection)
• Horizontal Telescopic Flue
• Flue Finishing Kit
• Flue Extension Ducts (1000mm long)
• Flue Extension Ducts (2000mm long)
• Flue Extension Ducts (500mm long)
30-up to 8m
35-up to 6m
• 90o Elbow Kit (maximum per installation).
30-upto 6 elbows
35-upto 4 elbows
• 45o Elbow Kit (maximum per installation).
30-upto 6 elbows
35-upto 4 elbows
• Concentric Flue Screw Retaining Kit
• Roof Flue Kit (to a maximum of 7.5m)
• Powered Vertical Flue Kit (5m primary and 17m secondary
is a typical maximum length. For alternative details refer to
Powered Vertical Instructions)
• Weather Collar
• High Level Flue Outlet Kit
• Flue Deector Kit
• Balcony Flue Kit
• Soft Flue Kit
• Raised Horizontal Flue Outlet Kit
• Adjustable Flue Support Bracket
• Mechanical Timer (24 hr) Kit
• Electronic Timer (7 day) kit
• RF Mechanical Programmable Room Thermostat (24 hr)
kit
• RF Electronic Programmable Room Thermostat (7 day)
kit
• Weather Compensation Kit
• Stand-Off Kit
• Stand-Off Kit (inc. pipes)
• DHW Expansion Vessel Kit
• Pre-Piping Frame Kit
• Condensate Pump Kit
• Security Bracket Kit
• PRV Wall Outlet Kit
• Pressure Gauge Extension Kit
• RF Mechanical Timer and Room Thermostat Kit
• OpenTherm Harness Kit
• Outside Sensor Kit
SAFETY
Current Gas Safety (installation and use) regulations or rules
in force:
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a Gas Safe
Registered Engineer. It must be carried out in accordance with
the relevant requirements of the:
• Gas Safety (Installation and Use) Regulations
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
• The Water Fittings Regulations or Water byelaws in Scotland.
• The Current I.E.E. Wiring Regulations.
Where no specic instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a Registered Gas
Installer (RGII) and installed in accordance with the current edition
of I.S.813 “Domestic Gas Installations”, the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
Detailed recommendations are contained in the following British
Standard Codes of Practice:
BS. 5440:1 Flues (for gas appliances of rated input not
exceeding 70 kW).
BS. 5440:2 Ventilation (for gas appliances of rated input not
exceeding 70 kW).
BSEN. 12828:2003 Heating Systems in buildings: Design for
water based heating systems.
BSEN 12831:2003 Heating Systems in buildings: Method for
calculation of the design heat load.
BSEN 14336:2004 Heating Systems in buildings: Installation
and commissioning of water based heating
systems.
BS. 5546 Installation of gas hot water supplies for domestic
purposes (2nd Family Gases)
BS. 6798 Installation of gas red hot water boilers of rated
input not exceeding 70 kW.
BS. 6891 Low pressure installation pipes.
Health & Safety Document No. 635.
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
IMPORTANT. These appliances are CE certicated for safety
and performance. It is, therefore, important that no external
control devices, e.g. ue dampers, economisers etc., are
directly connected to these appliances unless covered by
these Installation and Servicing Instructions or as otherwise
recommended by the manufacturer in writing. If in doubt please
enquire.
Any direct connection of a control device not approved by the
manufacturer could invalidate the certication 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.

10
Installation and Servicing
GENERAL
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
The boiler MUST be installed on a gas supply with a governed
meter only.
A gas meter can only be connected by the local gas supplier or
by a Gas Safe Registered Engineer. In IE by a Registered Gas
Installer (RGII).
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the rate
of gas supply required.
It is the responsibility of the Gas Installer to size the gas
installation pipework in accordance with BS6891:2005. Whilst
the principle of the 1:1 gas valve ensures this boiler range is
able to deliver it’s full output at inlet pressures as low as 14mb,
other gas appliances in the property may not be as tolerant.
When operating pressures are found to be below the minimum
meter outlet of 19mb these should be checked to ensure this is
adequate for correct and safe operation.
Allowing for the acceptable pressure loss of 1mb across the
installation pipework, it can be assumed that a minimum permitted
operating pressure of 18mb will be delivered to the inlet of
the appliance. (Reference BS 6400-1 Clause 6.2 Pressure
Absorption).
The external gas cock could further reduce the operating pressure
when measured at its test point. The pressure drop is relative to
the heat input to the boiler (kW), refer to graph below.
0
0.5
1
1.5
2
2.5
3
010 20 30 40 50
Pressure drop (mbar )
Heat Input to Boiler (kW)
Gas Cock Pressure Drop
IMPORTANT.
Installation pipes must be tted in accordance with BS.6891. In IE
refer to IS.813:2002.
The complete installation MUST be tested for gas tightness and
purged as described in the above code.
FLUE INSTALLATION
Pluming will occur at the terminal so terminal positions where this
could cause a nuisance should be avoided.
The ue must be installed in accordance with the
recommendations of BS. 5440-1: 2008.
In IE refer to I.S. 813:2002.
The following notes are intended for general guidance:
1. The boiler MUST be installed so that the terminal is exposed
to external air.
LOCATION OF BOILER
The boiler must be installed on a at and vertical internal wall,
capable of adequately supporting the weight of the boiler and any
ancillary equipment.
The boiler may be tted on a combustible wall and insulation
between the wall and the boiler is not necessary, unless required
by the local authority.
For electrical safety reasons there must be no access available
from the back of the boiler.
The boiler must not be tted outside.
Timber Framed Buildings
If the boiler is to be tted in a timber framed building it should be
tted in accordance with the Institute of Gas Engineering document
IGE/UP/7:2006 Edition 2.
Bathroom Installations
This appliance is rated IP20.
The boiler may be installed in any room or internal space, although
particular attention is drawn to the requirements of the current
IEE (BS.7671) Wiring Regulations and the electrical provisions
of the building regulations applicable in Scotland, with respect to
the installation of the boiler in a room or internal space containing
a bath or shower. For IE reference should be made to the current
ETCI rules for electrical installations and I.S. 813:2002.
If the appliance is to be installed in a room containing a bath or
shower then, providing water jets are not going to be used for
cleaning purposes (as in communal baths/showers), the appliance
must be installed beyond Zone 2, as detailed in BS.7671.
Compartment Installations
0.6m
Zone 0
Recessed
window
Zone 2
Ceiling
3G8913a
2.25m
Zone 1
A compartment used to enclose the boiler should be designed and
constructed specially for this purpose.
An existing cupboard or compartment may be used, provided that
it is modied for the purpose.
In both cases, details of essential features of cupboard /
compartment design, including airing cupboard installation, are to
conform to the following:
• BS 6798 (No cupboard ventilation is required - see ‘Air Supply’
for details).
• The position selected for installation MUST allow adequate
space for servicing in front of the boiler.
• For the minimum clearances required for safety and
subsequent service, see the wall mounting template and
Frame 1. In addition, sufcient space may be required to
allow lifting access to the wall mounting plate.