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.