Zanussi ULTRA SYSTEM 15 User manual

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

2
Installation and Servicing
MODEL
SYMBOL UNITS 15 18 24 30
Condensing Boiler n/a n/a yes yes yes yes
Low Temperature Boiler n/a n/a no no no no
B1 Boiler n/a n/a no no no no
Cogeneration Space Heater n/a n/a no no no no
Equipped with a Supplementary Heater n/a n/a no no no no
Combination Heater n/a n/a no no no no
Nominal Heat Output for Space Heating
Full Load P4kW 15 18 24 30
Part Load P1kW 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 Efciency
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 0 0
Emissions NOxmg/kWh 27 24 34 36
Annual Energy Consumption QHE GJ 46.0 56.0 74.0 93.0
Sound Power Level, Indoors LWA dB 41 42 45 45
ERP DATA

3
Installation and Servicing
ULTRA SYSTEM BOILER
ZANUSSI
ERP DATA
SYMBOL UNITS MODEL
15 18 24 30
Condensing boiler Yes
Seasonal Space heating efciency class A
Rated heat output kW 15 18 24 30
Seasonal space heating energy efciency ƞs% 93* 92* 93* 93*
Annual energy consumption QHE GJ 46.0 56.0 74.0 93.0
Sound power level, indoors LWA dB 41 42 45 45
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 (March 16)
The manufacturer reserve the right to vary specication 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

6
Installation and Servicing
GENERAL
15 18 24 30
Gas supply 2H - G20 - 20mbar
Gas Supply Connection 15mm copper compression
Injector Size (mm) 4.15 4.15 4.15 4.65
Flow Connection Central Heating 22mm copper compression
Return Connection Central Heating 22mm copper compression
Flue Terminal Diameter mm (in) 100 (4)
Average Flue Temp-Mass Flow Rate 56oC - 6g/s 58ºC - 8 g/s 63oC - 10g/s 69oC - 13g/s
Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.5 (36.3)
Electrical Supply 230 V ~ 50 Hz.
Power Consumption W 73 78 94 100
Fuse Rating External : 3A Internal : T4H HRC L250 V
Water content litre (gal) 1.2 (0.26)
Packaged Weight kg (lb) 34.1 (75.3) 34.1 (75.3) 34.1 (75.3) 34.1 (75.3)
Maximum Installation Weight kg (lb) 27.7 (61.0) 27.7 (61.0) 27.7 (61.0) 27.7 (61.0)
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.
15 18 24 30
MIN MAX MIN MAX MIN MAX MIN MAX
Boiler Input :
Boiler Input ‘Q’ Nett CV kW 4.9 15.1 4.9 18.1 4.9 24.3 6.1 30.4
(Btu/h) (16,600) (51,520) (16,600) (61,800) (16,600) (82,900) (20,700) (103.600)
Gross CV kW 5.4 16.6 5.4 20.1 5.4 27.0 6.7 33.7
(Btu/h) (18,400) (56,800) (18,400) (68,600) (18,400) (92,000) (23,000) (115,000)
Gas Consumption m3/h 0.500 1.537 0.500 1.872 0.500 2.512 0.622 3.135
(ft3/h) (17.8) (54.7) (17.8) (66.1) (17.8) (89) (22) (111)
Boiler Output :
Non Condensing kW 4.8 15.0 4.8 18.0 4.8 24.2 6.1 30.3
70oC Mean Water temp. (Btu/h) (16,500) (51,300) (16,500) (61,600) (16,500) (82,600) (20,700) (103,300)
Condensing kW 5.1 15.9 5.1 19.1 5.1 25.6 6.4 31.0
40oC Mean Water temp. (Btu/h) (17,500) (54,250) (17,500) (65,100) (17,500) (87,400) (21,800) (105,800)
Seasonal efciency* SEDBUK 2005 91.1% 91% 91% 91.1%
Seasonal efciency* SEDBUK 2009 89.3 89.2% 89.5% 89.6%
NOx Classication CLASS 5
Table 2 - Performance Data - Central Heating

7
Installation and Servicing
GENERAL
Boiler size G.C. Appliance No. PI No.
(Benchmark No.)
15 41-002-01 86 CL 08
18 41-002-02 86 CL 08
24 41-002-03 86 CL 08
30 41-002-04 86 CL 08
CONTENTS
Air Supply .....................................................................11
Benchmark Commissioning Checklist ..................... 58
Boiler Clearances ....................................................... 12
Boiler Exploded Diagram ........................................... 15
Condensate Drain .................................................. 26,27
Commissioning & Testing ......................................... 34
Electrical Connections ............................................... 30
Electrical Supply ..........................................................11
Fault Finding .......................................................... 50-54
Flue Fitting .................................................................. 19
Flue Installation .......................................................... 10
Gas Safety Regulations ............................................... 9
Gas Supply .................................................................. 10
Initial Lighting ............................................................ 33
Installation ............................................................. 15-34
Pump ........................................................................... 47
Safe Handling ................................................................ 8
Servicing ................................................................ 35-49
Spare Parts Info .......................................................... 55
Thermostatic Radiator Valves ....................................11
Water and Systems ......................................... 11,13-14
Water Connections ................................................ 12,28
Water Treatment ........................................................ 14
Wiring Diagram ........................................................... 31
Natural Gas only
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 ................. 30
Time and temperature control to hot water ........... N/A
Heating zone valves................................................. 30
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
The Logic System range of boilers are wall mounted, full
sequence, automatic spark ignition, low water content, fanned
ue, high efciency, condensing, system 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:
15 4.8 to 15kW (16,500 to 51,300 Btu/h)
18 4.8 to 18kW (16,500 to 61,600 Btu/h)
24 4.8 to 24.2kW (16,500 to 82,600 Btu/h)
30 6.1 to 30.3kW (20,700 to 103,300 Btu/h)
The boiler is supplied fully assembled with circulating pump,
pressure gauge, safety valve and CH expansion vessel.
A variable CH temperature control is tted on the user control.
The boiler includes as standard:
- Boiler frost protection
- Daily pump exercise.
Note. The appliance must be wired with a permanent live supply,
or the boiler frost protection will not operate. The boiler warranty
will be invalid if this requirement is not complied with.
The boiler casing is of white painted mild steel.
The boiler temperature control is 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 Frame 1 - Water & Gas Connection
Diagram.
OPERATION
When there is a demand for CH, the heating system is supplied at
the selected temperature of between 30oC and 80oC.
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.
OPTIONAL EXTRA KITS
• Horizontal Flue Terminal 600mm long
• Horizontal Flue Terminal 600mm long Weather Protection
• Horizontal Flue Terminal 1000mm long
• Horizontal Flue Telescopic
• Flue Extension Ducts 1000mm long
• Flue Extension Ducts 2000mm long
• Flue Extension Ducts 500mm long
15-up to 9m
18-up to 9m
24-up to 9m
30-up to 8m
• 90o Elbow Kit (maximum per installation).
15-up to 6 elbows
18-up to 6 elbows
24-up to 6 elbows
30-up to 6 elbows
• 45o Elbow Kit (maximum per installation).
15-up to 6 elbows
18-up to 6 elbows
24-up to 6 elbows
30-up to 6 elbows
• 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)
• Flue Finishing Kit
• High Level Flue Outlet Kit
• Flue Deector Kit
• Adjustable Flue Support Bracket
• Balcony Flue Kit
• Soft Kit
• Raised Horizontal Flue Outlet Kit
• Concentric Flue Screw Retaining Kit
• Weather Collar (Universal)
• Weather Collar (Flat Roof)
• Stand-Off Kit
• Stand-Off Kit (inc. pipes)
• Pre-Piping Frame Kit
• Condensate Pump Kit
• Weather Compensation Kit
• Security Bracket Kit
• PRV Wall Outlet Kit
• Pressure Gauge Extension Kit

9
Installation and Servicing
GENERAL
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.
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.

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 the Logic 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.
2. It is important that the position of the terminal allows the free
passage of air across it at all times.
3. Minimum acceptable spacing from the terminal to obstructions
and ventilation openings are specied 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. Below balconies or a car port roof. 25mm (1”)*
BS5440-1 2008 200mm (8”)
5. From vertical drain pipes or soil pipes. 25mm (1”)*
BS5440-1 2008 150mm (6”)
6. From an internal or external corner or to a 25mm (1”)*
boundary along side the terminal. BS5440-1 2008 300mm (12”)
7. Above adjacent ground, roof or balcony level. 300mm (12”)
8. From a surface or a boundary facing the terminal.600mm (24”)
9. From a terminal facing a terminal. 1,200mm (48”)
10. From an opening in a car port
(e.g. door or window) into dwelling. 1,200mm (48”)
11. Vertically from a terminal on the same wall. 1,500mm (60”)
12. Horizontally from a terminal on the wall. 300mm (12”)
Vertical Terminals
13. Above the roof pitch with roof slope of all angles.300mm (12”)
Above at roof. 300mm (12”)
14. From a single wall face. 300mm (12”)
From corner walls. 300mm (12”)
15. Below velux window 2000mm (79”)
16. Above or side of velux window 600mm (24”)
Table 4 - Balanced Flue Terminal Position
4. Where the lowest part of the terminal is tted less than 2m
(6’6”) above a balcony, above ground or above a at roof
to which people have access then the terminal MUST be
protected by a purpose designed guard.
Terminal guards are available from boiler suppliers. (Ask for
TFC ue guard model no. K6 - round, plastic coated). In case
of difculty contact:
TFC Group Ltd. Tel. + 44 (0) 01732 351 680
Tower House, Vale Rise Fax. + 44 (0) 01732 354 445
Tonbridge. Kent TN9 1TB www.tfc-group.co.uk
Ensure that the guard is tted centrally.
5. The ue assembly shall be so placed or shielded as to prevent
ignition or damage to any part of any building.
6. The air inlet/products outlet duct and the terminal of the boiler
MUST NOT be closer than 25mm (1”) to combustible material.
Detailed recommendations on the protection of combustible
material are given in BS. 5440-1:2008.
IMPORTANT. It is essential to ensure, in practice, that products
of combustion discharging from the terminal cannot re-enter the
building or buildings through any openings into the building such
as ventilators, windows, doors, or other sources of natural air
inltration, such as forced ventilation openings etc.
If products of combustion re-entry is identied or suspected this
should be immediately investigated and corrected following the
guidance provided in the current Gas Industry Unsafe Situation
Procedure.

11
Installation and Servicing
GENERAL
TERMINAL
The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frame 13 .
AIR SUPPLY
It is NOT necessary to have a purpose-provided air vent in the
room or internal space in which the boiler is installed. Neither
is it necessary to ventilate a cupboard or compartment in which
the boiler is installed, due to the low surface temperatures of the
boiler casing during operation; therefore the requirements of BS
6798, Clause 12, and BS 5440:2 may be disregarded.
WATER CIRCULATION SYSTEM
IMPORTANT.
A minimum length of 1 metre of copper pipe MUST be tted
to both ow and return connections from the boiler before
connection to any plastic piping.
The central heating system should be in accordance with BS.6798
and, in addition, for smallbore and microbore systems, BS.5449.
WATER TREATMENT - see Frame 4
BOILER CONTROL INTERLOCKS
Central heating systems controls should be installed to ensure
the boiler is switched off when there is no demand for heating, in
compliance with Building Regulations.
Heating systems utilising full thermostatic radiator valve control
of temperature in individual rooms should also be tted with a
room thermostat controlling the temperature in a space served by
radiators not tted with such a valve.
When thermostatic radiator valves 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 circuit must be tted
with an automatic bypass valve to ensure a ow of water should
all valves be in the closed position.
ELECTRICAL SUPPLY
WARNING.
This appliance must be earthed.
Wiring external to the appliance MUST be in accordance with
the current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply. For IE reference should be made to the
current ETCI rules for electrical installations.
The mains supply to the boiler and system wiring centre shall be
through one common fused double pole isolator. For new heating
systems, and where practicable replacement boiler installations,
the isolator shall be situated adjacent to the appliance.
CONDENSATE DRAIN
Refer to Frames 21, 22 & 38
A condensate drain is provided on the boiler. This drain must be
connected to a drainage point on site. All pipework and ttings in
the condensate drainage system MUST be made of plastic - no
other materials may be used.
IMPORTANT.
Any external runs must be in accordance with BS 6798.
The drain outlet on the boiler is sized for standard 21.5mm (3/4”)
overow pipe. It is a universal tting to allow use of different
brands of pipework.

12
Installation and Servicing
GENERAL
3952.5 2.5
from case
700
Side flue
dim. A
CH FLOW
DATA PLATE
COND. DRAIN
GAS INLET
CH RETURN
PRV
43.5 93.5 28.5 135.6 37.556.4
Underside View - Pipe Dimensions to Wall
Water Connections and Gas Connection
30.9
PRV PIPE
23.4
CH RETURN
148.3
CONDENSATE DRAIN
19.4
GAS INLET
23.4
CH FLOW
1 BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm
The boiler connections are made on the boiler connection tails.
Refer to Frame 23.
The following minimum clearances must be maintained for
operation and servicing.
Additional space will be required for installation, depending upon
site conditions.
Side and Rear Flue
a. Provided that the ue hole is cut accurately, e.g. with a core
drill, the ue 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 ue required the ue must be tted 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 must be at least
wide enough to accommodate the tool.
Front clearance
The minimum front clearance when built in to a
cupboard is 5mm from the cupboard door but
450mm overall clearance is still required, with the
cupboard door open, to allow for servicing.
* Bottom clearance
Bottom clearance after installation can be
reduced to 5mm.
This must be obtained with an easily removable
panel, to enable the consumer to view the
system pressure gauge, and to provide the
100mm clearance required for servicing.

13
Installation and Servicing
GENERAL
Model 15 18 24 30
Max CH uutput kW 15 18 24.2 30.3
(Btu/h) (51,300) (61,600) (82,600) (103,300)
Water ow rate l/min 10.7 13 17.2 21.5
(gal/min) (2.4) (2.8) (3.8) (4.7)
Temp differential oC 20 20 20 20
(oF) (36) (36) (36 (36)
Head available m.w.g. 5 4.5 3.3 1.9
for system (ft.w.g.) (16.2) (14.7) (10.8) (6.2)
General
1. The installation must comply with all relevant national and local
regulations.
2. The installation should be designed to work with flow
temperatures of up to 86 oC.
3. All components of the system must be suitable for a working
pressure of 3 bar and temperature of 110 oC. Extra care should
be taken in making all connections so that the risk of leakage is
minimised.
The following components are incorporated within the appliance:
a. Circulating pump.
b. Safety valve, with a non-adjustable preset lift pressure of 3
bar.
c. Pressure gauge, covering a range of 0 to 4 bar.
d. An 8-litre expansion vessel, with an initial charge pressure
of 0.75 bar.
4. ‘Make-up’ Water. Provision must be made for replacing water
loss from the system, either :
a. From a manually lled ‘make-up’ vessel with a readily visible
water level. The vessel should be mounted at least 150mm
above the highest point of the system and be connected
through a non-return valve to the system, tted at least
150mm below the ‘make-up’ vessel on the return side of
the radiators. or
b. Where access to a ‘make-up’ vessel would be difcult, by
pre-pressurisation of the system.
The maximum cold water capacity of the system should
not exceed 143 litres. This is the maximum system
volume for the boiler expansion vessel. If the capacity of
the vessel is not considered sufcient for this, or for any
other reason, an additional vessel MUST be installed on
the return to the boiler.
Guidance on vessel sizing is given in table opposite.
5. Filling
The system may be lled 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 lling. When installing the lling device, it must
be connected as below to fully comply with the water regulations.
This may involve the tting of an additional WRAS approved
isolator valve to the mains supply.
i. Thoroughly ush out the whole system with cold water.
ii. Fill and vent the system until the pressure gauge registers 1.5
bar, and examine for leaks.
iii. Check the operation of the safety valve by raising the water
pressure until the valve lifts. This should occur within 0.3 bar
of the preset lift pressure.
iv. Release water from the system until the minimum system
design pressure is reached; 1.0 bar if the system is to be pre-
pressurised.
Notes
a. The method of lling, relling, topping up or ushing sealed primary
hot water circuits from the mains via a temporary hose connection
is only allowed if acceptable to the local water authority.
b. Antifreeze uid, corrosion and scale inhibitor uids suitable for use
with boilers having aluminium heat exchangers may be used in the
central heating system.
2 SYSTEM REQUIREMENTS - Central Heating
Safety valve setting bar 3.0
Vessel charge pressure bar 0.5 to 0.75
System pre-charge pressure bar None 1.0
System volume Expansion vessel
(litres) volume (litres)
25 1.6 1.8
50 3.1 3.7
75 4.7 5.5
100 6.3 7.4
125 7.8 9.2
150 9.4 11.0
175 10.9 12.9
190 11.9 14.0
200 12.5 14.7
250 15.6 18.4
300 18.8 22.1
For other system volumes
multiply by the factor across 0.063 0.074
CH Return
Ecl 6053
Hose unions
Mains
water supply
Temporary hose
(disconnect after filling)
Additional
stop valve
Double check valve
assembly
(
note direction of flow )

14
Installation and Servicing
GENERAL
The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of the
minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available. See
note regarding thermostatic radiator valves on page 11.
Note. Systems incorporating zone valves which could completely cut off the ow through the system must also include a bypass.
BALANCING
3 SYSTEM BALANCING
1. Set the programmer to ON.
Close the manual or thermostatic valves on all radiators,
leaving the twin lockshield valves (on the radiators referred
to above) in the OPEN position.
Turn up the room thermostat and adjust the lockshield
valve to give an uninterrupted ow through the radiator.
These valves should now be left as set.
2. Open all manual or thermostatic radiator valves and adjust
the lockshield valves on the remaining radiators, to give
4 WATER TREATMENT
CENTRAL HEATING
The Logic System range of boilers have an ALUMINIUM
alloy heat exchanger.
IMPORTANT.
The application of any other treatment to this product may
render the guarantee of Invalid.
The manufacturer recommends Water Treatment in accordance
with the Benchmark Guidance Notes on Water Treatment in
Central Heating Systems.
If water treatment 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’ instructions.
2. If the boiler is installed in an existing system any unsuitable
additives MUST be removed by thorough cleansing. BS
7593:2006 details the steps necessary to clean a domestic
heating system.
3. In hard water areas, treatment to prevent lime scale may be
necessary - however the use of articially softened water is
NOT permitted.
4. Under no circumstances should the boiler be red before the
system has been thoroughly ushed.
For further information contact:
Fernox Cookson Electronics
Forsyth Road
Sheerwater
Woking
Surrey GU21 5RZ
[phone]
Sentinel Performance Solutions
The Heath Business & Technical Park
Runcorn
Cheshire WA7 4QX
Tel: [phone]
www.sentinel-solutions.net
Scalemaster Water Treatment Products
Emerald Way
Stone
Staffordshire ST15 0SR
Tel: [phone]
Calmag Ltd.
Unit 3-6, Crown Works
Bradford Road
Sandbeds, Keighley
West Yorkshire BD20 5LN
Tel: [phone]
Adey Professional Heating Solutions
Gloucester Road,
Cheltenham GL51 8NR
Tel: [phone]
around 20oC temperature drop at each radiator.
3. Adjust the room thermostat and programmer to NORMAL
settings.

15
INSTALLATION
Installation and Servicing
Note that item numbers are linked to the spares list
104 CH RETURN VALVE
105 CH FLOW VALVE
108 PUMP HEAD
110 PUMP AUTO AIR VENT
113 PRESSURE RELIEF VALVE
114 PIPE - PRV OUTLET
115 PIPE - FLOW
116 PIPE - RETURN
117 PIPE - EXPANSION VESSEL
118 EXPANSION VESSEL
120 FLOW GROUP MANIFOLD
121 BY-PASS KIT
131 WATER PRESSURE SWITCH
135 PRESSURE GAUGE
203 GAS COCK
204 PIPE - GAS INLET
205 GAS VALVE
5 BOILER ASSEMBLY - Exploded View
504 227
224
503
505
313
215
309
308
306
217
307 401
218
211
304
214
223
325
302
104
BCC
114
117
118
507
203
135
105
231
228
229
303
304
116
115
219
301
324
314
110
113
120
108
121
206
205
204
506
131
206 PIPE - GAS INJECTOR
211 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 UNIT
309 THERMISTOR CONTROL/NO FLOW
313 IGNITION LEAD
314 CONTROL BOX LENS
324 CONTROLS BOX LID
325 CONTROL BOX FRONT
401 HEAT ENGINE
503 WALL MOUNTING BRACKET
504 FRONT PANEL
505 FASCIA
506 BRACKET - GAS VALVE
507 BRACKET - EXPANSION VESSEL
* Note that production boiler PCBs are factory
pre-set to operate for boiler range and output,
but when ordering Primary PCB as a spare, an
additional Boiler Chip Card (BCC) MUST also
be purchased for your specic boiler range and
output.
INSTALLATION

16
INSTALLATION
Installation and Servicing
6 UNPACKING
The boiler is supplied fully assembled in Pack A. A telescopic or non-telescopic ue assembly for rear or side ue outlet in Pack
B is suppled as a separate order.
Unpack and check the contents.
Pack A Contents
A Boiler
B Hardware Pack Box
C Wall Mounting Plate
D These Installation/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
2. Washer CH
3. Valve Flow (with gauge)
Gas Valve Pack Accessory Pack
Flow Valve Pack
Return Valve Pack
11
1
1
2
33
2
2
2
3
3
INSTALLATION

17
INSTALLATION
Installation and Servicing
7 UNPACKING....CONT’D
Pack B Contents Telescopic
A Telescopic ue terminal
B Flue turret
C Rubber terminal wall seal
D Screw
E Sealing Tape
F Wall Seal (white)
D
C
A
E
F
B
Pack B Contents Non-Telescopic
A Flue terminal
B Flue turret
C Rubber terminal wall seal
D Cutting Aid
E Wall Seal (white)
A
D
B
CE
8 FRONT PANEL REMOVAL
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 ue system incorporates a removable ue outlet nose that utilises a push t location system. This enables the
installation of deector, high level or balcony outlet ue kits without the removal of the whole ‘B’ pack terminal. The appliance
must not be operated without the desired outlet nose correctly tted in place.
Note. Location dimples must be aligned with terminal mounting frame.
INSTALLATION

18
INSTALLATION
Installation and Servicing
205552-10139
V - See Diagram
in frame 1
Extended centre line
155
(200)
3G9495
X
Section
through wall
Note. Check all of the hole
positions before drilling.
Side flue only
5" diameter hole
Rear flue only
5" diameter hole
The wall mounting template is located on the internal protective
packaging. The template shows the position of the xing and rear
ue centre holes for a standard installation
Care MUST be taken to ensure the correct holes are drilled.
1. Tape template into the required position, ensuring its squareness
by hanging a plumbline as shown.
2. If tting a side ue, extend the ue centreline onto the side by
155mm on a standard wall x or 200mm if using a stand-off
bracket.
3. Mark the following on to the wall:
a The selected group of wall mounting screw holes.
b. The centre position of the ue duct. Marking both the centre
and the circumference of the ue duct.
4. Remove the template plate from the wall.
9 WALL MOUNTING TEMPLATE
10 PREPARING THE WALL
IMPORTANT.
Ensure that, during the cutting operation, masonry falling
outside of the building does not cause damage or personal
injury.
1. Cut the ue 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
at.
2. Drill 2 mounting holes (marked from template) with a 7.5mm
/ 8mm masonry drill and insert the plastic plugs, provided,
for the wall mounting plate.
3. Locate 2 No.14 x 50mm screws in the wall mounting plate
(one at each side, in any of the 3 holes provided at each
side) and screw home. Ensure mounting bracket is level.
12 MOUNTING THE BOILER 11 FITTING THE WALL MOUNTING PLATE
3G9948
Example of fixing
1. Ensure the plastic plug is removed from the CH
connections before mounting the boiler.
Caution: Water may discharge from open pipes.
2. Lift the boiler onto the wall mounting plate (refer to the
Introduction section for safe handling advice), locating it
over the two tabs.
Screw the wall mounting plate to the wall using 2 wall
plugs (previously tted) with the 2 screws provided.
Choose one of the 2 sets of slots in left and right bank.
Ensuring that at least one of the screws is tted into a top
slot.
INSTALLATION

19
INSTALLATION
Installation and Servicing
FLUE OUTLET
13 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED
IMPORTANT. The boiler must be installed in a vertical position
in accordance to the installation instructions.
FLUE KITS
Telescopic Flue‘B’ Pack - contains: Flue turret, telescopic ue
incorporating a terminal and rubber wall seals.
Horizontal Flue Terminal (600mm long) ‘B’ Pack - contains:
Flue turret, non telescopic single piece ue incorporating a
terminal and rubber wall seals.
Horizontal Flue Terminal (1000mm long) ‘B’ Pack - Flue turret,
telescopic ue incorporating a terminal, rubber wall seals and instructions.
Note. If ‘B’ packs are used on their own (either 1 piece or
telescopic), then they can be tted horizontally as the ue
inside is designed to slope 1.5 degrees.
Flue Kit 203129 - D Pack Flue Extension 100mm DIA 1000mm long
Flue Kit 211037 - D Pack Flue Extension 100mm DIA 500mm long
Flue Kit 211038 - D Pack Flue Extension 100mm Dia 2000mm long
Flue Kit 211039 - Roof Flue Kit with Vertical Connector
When extension ‘D’ Packs are used the ue duct must incline
1.5 degrees away from the appliance, to allow the condensate
to drain back to the boiler and out of the condensate drain. It is
recommended that a support bracket is tted on every 1 metre of
pipe work used and the bracket is located as close to the collar
as possible. The bracketing must ensure a 1.5 degree fall back
to the appliance.
Optional Flue Finishing Kit - UIN 155988 & Concentric Flue
Screw Retaining Kit (Optional Kit of mechanical xing of ue
joints)
Only use water as a lubricant during assembly.
The ‘B’ pack terminal is classed as part of the maximum ue
length.
These ue systems incorporates a removable ue outlet
nose that utilises a push t location system. This enables the
installation of deector, high level or balcony ue kits without
the removal of the whole ‘B’ pack terminal. The appliance must
not be operated without the desired outlet nose correctly tted
in place, ensuring the side location dimples are in line with the
mounting face allowing the correct sealing of the components.
It is IMPORTANT that all attachments are tted in accordance
to the installation instructions provided with them.
The TURRET supplied 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 Deector Kit The resistance is the equivalent of 1 metre of ue pipe and therefore must be deducted from
any maximum ue length
High Level Flue Outlet Kit The maximum permissible concentric ue length when using a standard (500mm) kit is 4.5 metres
Balcony Flue Outlet Kit The maximum permissible concentric ue length when using this kit is dependant on the length
of the balcony ue outlet run which combined with the concentric run must not exceed the
maximum ue length requirement of the appliance it is to be tted to
Soft Kit This kit enables tment of an external ue below softs.
Total Maximum Permissible Horizontal Concentric Flue Length combining both ‘B’ Packs and ‘D’ Packs
(Measured from centreline of the turret to the outside of the wall terminal)
15, 18 & 24 kW appliances Total Maximum: 9 metres - minus any ue kit options or bends
30 kW Appliances Total Maximum: 8 metres - minus any ue kit options or bends
Total Maximum Permissible Vertical Flue Length combining both Roof Terminal and ‘D’ Packs
15, 18, 24 & 30kW Appliances Total Maximum: 7.5 Metres - minus any bends
Powered Vertical Flue
15, 18, 24 & 30kW Appliances Total Maximum: 5 Metres - Concentric Flue and 17m ue pipe only. For additional details
refer to the powered Vertical Instructions
90º Elbow Kit 60/100 - (Equivalent ue length resistance = 1M)
45º Elbow Kit 60/100 - (Equivalent ue length resistance = 0.6M)
Minimum Horizontal Flue Lengths (Centre line of turret to outside of wall terminal)
Telescopic Flue ‘B’ Pack = 400mm
Horizontal Flue terminal (600mm long) ‘B’ Pack = 285mm
Wall Thickness Std Metric Brick 102.5mm wide
‘B’ Pack Flue Type 60/100 Minimum permissible Wall Thickness Maximum permissible Wall Thickness
Rear Flue Rear Flue + Std-Off Side Flue Rear Flue Rear Flue + Std-Off Side Flue
Horizontal Flue Terminal
(600mm long) B Pack
116 102.5 102.5 501 456 456
Telescopic Flue B Pack 231 186 186 429 384 384
Horizontal Flue Terminal
(1000mm long) B Pack
546 501 501 761 716 716
Horizontal Flue Terminal
(1000mm long) B Pack cut 75mm
471 426 426 686 641 641
For Flue lengths between 658 & 708 use a Horizontal Flue Terminal (1000mm long) B Pack, cut 75mm off the end of the
terminal section of the telescopic ue only.

20
INSTALLATION
Installation and Servicing
FLUE OUTLET
100mm
Edge of turret
to outside face of wall plus
44mm = ue length
Centre of turret to edge of turret = 100mm
Turret has a ue insertion of 30mm
The compressed outer wall seal has protruding wall to seal mounting lip - 14mm
From centreline of turret to wall. Rear mount 155mm, side (including clearance) 200mm
NOTES
REAR
Fit
to wall
A
WALL
Edge of turret
to outside face of wall plus
44mm = ue length
Flue length measured from outer terminal lip
to end of outer ue
A+ 44mm
REAR
Fit
to wall
inc. Stand
o Frame
A
WALL
Edge of turret
to outside face of wall plus
44mm = ue length
SIDE
Fit
to wall
A
WALL
Minimum clearance 5mm
14 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED, CONT’D
Shows the ue required when measured from outside edge of turret to the outside face of the wall (to obtain cut length add 44mm)
Minimum & Maximum nished ue lengths obtainable (dimension ‘A’ +44mm)
Horizontal Flue Terminal
(600mm long) B Pack
Telescopic Flue B Pack Horizontal Flue
Terminal (1000mm long)
B Pack (Telescopic)
Horizontal Flue Terminal
(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 pack) 4921 5306 5036 5234 5351 5566 5276 5491
Plus 6 (1m D pack) 5871 6256 5986 6184 6301 6516 6226 6441
Plus 7 (1m D pack) 6821 7206 6936 7134 7251 7466 7176 7391
Plus 8 (1m D pack) 7771 8186 7886 8084 8201 8416 8126 8341
Plus 9 (1m D pack) 8721 9000 8836 9000 9000 9000 9000 9000
Max output 30 kW
Max output 15, 18 & 24 kW
FIGURE 1
FIGURE 2
Note. Maximum permissible
ue length is measured from
centre line of appliance ue
outlet to outside wall face.
Note; Telescopic ue B Pack or attached “D” pack extensions do not need to be cut between minimum and maximum values
shown above (except where specied). Horizontal Flue Terminal (600mm long) B Pack ue will require cutting on values below
maximum values shown in the table above.
If using the 2000mm D Pack , the maximum usable length per extension is 1950mm
If using the 500mm D Pack, the maximum usable length per extension is 450mm.