Table Of Contents - Zanussi ULTRA+ COMBI 30 Installation And Servicing

1 GENERAL .................................................................... 8
1.1 Introduction ................................................................ 10
1.2 Operation ................................................................... 10
1.3 Safe Handling ............................................................. 10
1.4 Optional Extra Kits ..................................................... 11
1.5 Safety ......................................................................... 11
1.6 Safe Handling Of Substances .................................... 11
1.7 Location of Boiler ...................................................... 12
1.8 Gas Supply ................................................................. 12
1.9 Flue Installation .......................................................... 12
1.10 Terminal ...................................................................... 13
1.11 Air Supply ................................................................... 13
1.12 Water Circulation System ........................................... 13
1.13 Boiler Control Interlocks ............................................. 13
1.14 Electrical Supply ......................................................... 13
1.15 Condensate Drain ...................................................... 13
1.16 Boiler Dimensions, Services & Clearances ................ 14
1.17 System Requirements ................................................ 15
1.18 Water Treatment......................................................... 16
1.19 System Balancing ...................................................... 16
2 INSTALLATION ......................................................... 17
2.1 Boiler Assembly - Exploded View ............................... 17
2.2 Unpacking .................................................................. 18
2.3 Unpacking Cont'd ....................................................... 19
2.4 Front Panel Removal ................................................. 19
2.5 Wall Mounting Template ............................................. 20
2.6 Preparing The Wall ..................................................... 20
2.7 Fitting The Wall Mounting Plate .................................... 20
2.8 Mounting The Boiler ................................................... 20
2.9 Determining The Flue Length & Flue Packs Req'd ... 21
2.10 Cutting & Setting The Flue Length ............................. 23
2.11 Installing The Flue ...................................................... 24
2.12 Fitting The Optional Roof Flue Kit .............................. 25
2.13 Roof Flue Kit Contents / Options ................................ 25
2.14 Flue Terminal Position ................................................ 26
2.15 Assembling The Roof Flue Kit .................................... 27
2.16 Condensate Drain ...................................................... 28
2.17 Connections & Filling ................................................. 30
2.18 Electrical Connections ................................................ 32
2.19 Installer Wiring ........................................................... 32
2.20 External Wiring ........................................................... 33
2.21 Replacing Pre-Fitted Mains Cable ............................. 33
2.22 Wiring Diagram .......................................................... 34
2.23 Commissioning And Testing ....................................... 35
2.24 Initial Lighting ............................................................. 36
2.25 General Checks ......................................................... 37
2.26 Restart Procedure ...................................................... 38
2.27 Accessing The Installer Mode .................................... 38
2.28 Handing Over ............................................................. 38
Installation and Servicing
CONTENTS
3 SERVICING ............................................................... 39
3.1 Servicing Schedule .................................................... 39
3.2 Boiler Front Panel Removal / Replacement ............... 40
3.3 Fan And Venturi Assembly Removal And Cleaning .... 40
3.4 Burner Removal & Cleaning ....................................... 41
3.5 Cleaning the Condensate Trap/Siphon ...................... 41
3.6 Cleaning the Heat Exchanger .................................... 42
3.7 Reassembly ............................................................... 42
3.8 Replacement Of Components .................................... 43
3.9 Fan Replacement ....................................................... 43
3.10 Burner Injector Replacement ..................................... 44
3.11 Burner Replacement .................................................. 44
3.12 Return Thermistor Renewal ....................................... 45
3.13 Ignition Electrode Replacement ................................. 45
3.14 Flame Detection Electrode Replacement ................... 46
3.15 Spark Generator Replacement .................................. 46
3.16 Gas Control Valve Replacement ................................ 46
3.17 Diverter Valve Actuator Replacement ........................ 47
3.18 Condensate Trap/Siphon Replacement ..................... 47
3.19 PCB Replacement ...................................................... 48
3.20 DHW Flow Turbine Sensor Replacement .................. 48
3.21 Draining The Boiler .................................................... 49
3.22 Pressure Gauge Renewal .......................................... 49
3.23 Safety Relief Valve Renewal ...................................... 50
3.24 Pump Automatic Air Vent Replacement ..................... 50
3.25 DHW Filter & Flow Reg Cleaning/Replacement ......... 50
3.26 Diverter Valve Body Assembly Replacement ............. 51
3.27 DHW Plate Heat Exch. Replacement ......................... 51
3.28 Pump Head Replacement .......................................... 51
3.29 CH Water Pressure Switch Replacement .................. 52
3.30 Flow Thermistor Replacement ................................... 52
3.31 Heat Engine Renewal ................................................ 53
3.32 Expansion Vessel Recharging & Replacement .......... 54
4 FAULT FINDING ........................................................ 55
4.1 Fault Finding Chart Main Menu .................................. 55
4.2 'L1' - Flow Temp Overheat Lockout ............................ 56
4.3 'L2' - Ignition Lockout ................................................. 56
4.4 'L6' - False Flame Lockout ........................................ 57
4.5 'F1' - Low Water Pressure .......................................... 57
4.6 'F2 Or Fn Or Ln' - Flame Loss.................................... 57
4.7 'F3' - Fan Fault ........................................................... 58
4.8 'F4 Or L4' - Flow Thermistor Fault .............................. 58
4.9 'F5 Or L5' - Return Thermistor Fault .......................... 58
4.10 'F6' - Outside Sensor Fault......................................... 59
4.11 No CH Operation but HW Works OK ......................... 59
4.12 No HW But CH On ..................................................... 60
4.13 No Display .................................................................. 60
5 SPARE PARTS .......................................................... 61
6 BENCHMARK & COMMISSIONING ......................... 62
7