INSTALLATION
AND SERVICING
LOGIC COMBI ESP1
24 30 35
For Users Guide see reverse of book
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.
For the very latest copy of literature for specification and maintenance practices visit our
website www.idealboilers.com where you can download the relevant information in PDF format.
June 2016
UIN 215120 A01
ERP DATA
MODEL
Condensing Boiler
Low Temperature Boiler
B1 Boiler
Cogeneration Space Heater
Equipped with a Supplementary Heater
Combination Heater
Nominal Heat Output for Space Heating
Full Load
Part Load
Auxiliary Electricity Consumption
Full Load
Part Load
Standby
Seasonal Space Heating Energy Efficiency
Full Load
Part Load
Standby Loss
Ignition
Emissions
Annual Energy Consumption
Sound Power Level, Indoors
Domestic Hot Water
SYMBOL
n/a
n/a
n/a
n/a
n/a
n/a
UNITS
n/a
n/a
n/a
n/a
n/a
n/a
24
yes
no
no
no
no
yes
30
yes
no
no
no
no
yes
35
yes
no
no
no
no
yes
P4
P1
kW
kW
24.2
7.8
24.2
7.8
24.2
7.8
elmax
elmin
PSB
kW
kW
kW
0.029
0.012
0.005
0.032
0.013
0.005
0.042
0.013
0.005
ƞ4
ƞ1
Pstby
Pign
%
%
kW
kW
90
98.6
0.05
0
90
98.6
0.05
0
90
98.6
0.05
0
NOx
QHE
LWA
mg/kWh
GJ
dB
31.5
74.1
48
27.8
74.1
46
33.1
74.1
44
Qelec
ƞWH
kWh
%
kWh
kWh
GJ
0.075
84.1
7.11
16.30
5.32
0.075
84.1
7.10
16.30
5.32
0.074
84.40
7.01
16.10
5.31
Qfuel
AEC
AFC
2
Installation and Servicing

PRODUCT FICHE
LOGIC ESP1 COMBINATION BOILER
Ideal Boilers
ERP DATA SYMBOL
Condensing boiler
Seasonal Space heating efficiency class
Rated heat output
Seasonal space heating energy efficiency
UNITS
30
GJ
dB
QHE
LWA
35
Yes
A
24
94*
kW
%
ƞs
Annual energy consumption
Sound power level, indoors
Water heating energy efficiency class
MODEL
24
74.1
46
A
48
Seasonal Space Heating Energy Efficiency of the Boiler
44
*%
A
Temperature control (from fiche 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%
B
Solar Contribution (from fiche of solar device)
Tank Volume
(in m3)
Collector Size
(in m2)
= (‘III ’x
+ ‘IV ’ x
Collector
Efficiency
(in %)
) x 0.9 x (
Tank rating
A* = 0.95
A = 0.91
B = 0.86
C = 0.83
D-G = 0.81
/ 100 x
%
=
%
TOTAL: A+B+C=
Seasonal Space Heating Energy Efficiency of Package
C
Seasonal Space Heating Energy Efficiency Class of Package
G

< 30%
F
E
≥ 30%
≥ 34%
D
≥ 36%
C
≥ 75%
B
≥ 82%
A
≥ 90%
A+
A++
A+++
≥ 98%
≥ 125%
≥ 150%
The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installed in a
building, as the efficiency is influenced by further factors such as heat loss in the products in relation to the building size and its characteristics
Installation and Servicing
3
4
Installation and Servicing
NOTES FOR THE INSTALLER
FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL
INSTALLER HELPLINE : 01482 498704
NOTE. BOILER RESTART PROCEDURE To restart the boiler press the RESTART button. The boiler will repeat the ignition sequence if a heat
demand is present.
DOCUMENT AMENDMENTS
Relevant Installation changes implemented in this book from Mod Level........................... A01 (JUNE 2016)
Ideal Boilers reserve the right to vary specification without notice
Installation and Servicing
5
6
Installation and Servicing
CONTENTS
1GENERAL................................................................... 10
3SERVICING................................................................ 39
1.1Introduction................................................................. 10
3.1
Servicing Schedule..................................................... 39
1.2Operation.................................................................... 10
3.2
Boiler Front Panel Removal / Replacement................ 40
1.3
Safe Handling.............................................................. 10
3.3
Fan And Venturi Assembly Removal And Cleaning..... 40
1.4
Optional Extra Kits...................................................... 11
3.4
Burner Removal & Cleaning........................................ 41
1.5Safety.......................................................................... 11
3.5
Cleaning the Condensate Trap/Siphon....................... 41
1.6
Safe Handling Of Substances..................................... 11
3.6
Cleaning the Heat Exchanger..................................... 42
1.7
Location of Boiler ....................................................... 11
3.7Reassembly................................................................ 42
1.8
Gas Supply.................................................................. 12
3.8
Replacement Of Components..................................... 43
1.9
Flue Installation........................................................... 12
3.9
Fan Replacement........................................................ 43
1.10Terminal....................................................................... 13
1.11
Air Supply.................................................................... 13
3.10 Burner Injector Replacement...................................... 44
3.11
Burner Replacement................................................... 44
1.12 Water Circulation System............................................ 13
3.12 Return Thermistor Renewal........................................ 45
1.13 Boiler Control Interlocks.............................................. 13
3.13 Ignition Electrode Replacement.................................. 45
1.14 Electrical Supply.......................................................... 13
3.14 Flame Detection Electrode Replacement.................... 46
1.15 Condensate Drain....................................................... 13
3.15 Spark Generator Replacement................................... 46
1.16 Boiler Dimensions, Services & Clearances................. 14
3.16 Gas Control Valve Replacement................................. 46
1.17 System Requirements................................................. 16
3.17 Diverter Valve Actuator Replacement......................... 47
1.18 System Balancing....................................................... 16
3.18 Condensate Trap/Siphon Replacement...................... 47
1.19 Water Treatment......................................................... 16
3.19 PCB Replacement....................................................... 48
2INSTALLATION.......................................................... 17
2.1
Boiler Assembly - Exploded View................................ 17
2.2Unpacking................................................................... 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
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
2.13 Flue Terminal Position................................................. 26
4
FAULT FINDING......................................................... 55
2.14 Assembling The Roof Flue Kit..................................... 27
4.1
Fault Finding Chart Main Menu................................... 55
2.15 Condensate Drain....................................................... 28
4.2
‘L1’ - Flow Temp Overheat Lockout............................. 56
2.16 Connections & Filling.................................................. 30
4.3
‘L2’ - Ignition Lockout.................................................. 56
2.17 Electrical Connections................................................. 32
4.4
‘L6’ - False Flame Lockout ......................................... 57
2.18 Installer Wiring............................................................ 32
4.5
‘F1’ - Low Water Pressure........................................... 57
2.19 External Wiring............................................................ 33
4.6
‘F2 Or Fn Or Ln’ - Flame Loss.................................... 57
2.20 Replacing Pre-Fitted Mains Cable.............................. 33
4.7
‘F3’ - Fan Fault............................................................ 58
2.21 Wiring Diagram........................................................... 34
4.8
‘F4 Or L4’ - Flow Thermistor Fault............................... 58
‘F5 Or L5’ - Return Thermistor Fault........................... 58
2.22 Commissioning And Testing........................................ 35
4.9
2.23 Initial Lighting.............................................................. 36
4.10 ‘F6’ - Outside Sensor Fault......................................... 59
2.24 General Checks.......................................................... 37
4.11
2.25 Restart Procedure....................................................... 38
4.12 No HW But CH On...................................................... 60
2.26 Accessing The Installer Mode..................................... 38
4.13 No Display................................................................... 60
2.27 Handing Over.............................................................. 38
Installation and Servicing
No CH Operation but HW Works OK.......................... 59
5
SPARE PARTS........................................................... 61
6
BENCHMARK & COMMISSIONING.......................... 62
7
SECTION 1 - GENERAL
Table 1 - General Data
2430 35
Gas supply
2H - G20 - 20mbar
Gas Supply Connection
15mm copper compression
Injector Size
mm
4.15
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
100
Average Flue Temp-Mass Flow Rate
(DHW)
63ºC - 11g/s
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)
2
Minimum Domestic Hot Water Inlet Pressure*
bar (lb/in ) (kPa)
0.8 (11.6) (80) 1.3 (18.9) (130) 1.3 (18.9)** (130)
Minimum DHW Inlet Pressure to operate at 0.6bar system pressure All Model sizes 0.5 bar
Electrical Supply
230 V ~ 50 Hz
Power Consumption
W
94 101 114
Fuse RatingExternal : 3A Internal : T4A HRC L250 V
Water content
Central Heating
litre (gal)
1.2 (0.26)
Domestic Hot Water litre (gal)
Packaged Weight
kg
Maximum Installation Weight
Boiler Casing Size
Height
Width
Depth
0.5 (0.11)
33.7
kg
28.9
mm
mm
mm
33.8
33.9
29
700
395
278
29.1
*Required for maximum flow rate. Boiler operates down to 2 l/min DHW delivery
** In areas of low water pressure the DHW restrictor can be removed
Table 2 - Performance Data - Central Heating
Table 3 - Performance Data - Domestic Hot Water
Boiler Input :
Max.
Min.
243035
Boiler Input ‘Q’
Nett CV
kW
24.3
4.9
6.1
7.1
Gross CV kW
27.05.46.77.9
Maximum DHW Input :
24
30
35
Nett CV
kW
24.3
30.4
35.4
Gross CV
kW
27.0
33.7
39.3
Gas Consumption
m /h2.512
3.135
3.657
(ft3/h)(89)
(111)
(129)
Maximum DHW Output
30.3
35.3
Non Condensing kW
24.24.86.17.1
70oC Mean Water temp.
DHW Flow Rate
l/min
9.9
12.4
14.5
Condensing kW
25.65.16.47.5
at 35°C temp. rise.
(gpm)
(2.2)
(2.8)
(3.2)
40oC Mean Water temp.
DHW Specific Rate
l/min
11.5
Seasonal efficiency* SEDBUK 2005 91.1% 91.1% 91.1%
(gpm) (2.5)
Seasonal efficiency* SEDBUK 2009 89.6% 89.6% 89.6%
Gas Consumption
m3/h
2.5120.5000.6270.734
(ft3/h)(89)(17.8)(22)(25.9)
Boiler Output :
3
kW
24.2
14.5
16.9
(3.2)
(3.7)
NOx Classification CLASS 5
* 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 certified by a notified body.
Note. Gas consumption is calculated using a
calorific 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
calorific value:
Key to symbols
GB = United Kingdom
c. For ft3/h - divide the gross heat input (Btu/h)
by the gross C.V. of the gas (Btu/ft3)
(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
orifices which, in this case, are concentric. The fan is up stream of
the combustion chamber.
a. For l/s - divide the gross heat input (kW) by
the gross C.V. of the gas (MJ/m3)
b. For Btu/h - multiply the gross heat input (kW)
by 26.8
IE = Ireland
I2H
=An appliance designed for use on 2nd Family gas, Group H only.
d. For m3/h - multiply l/s by 3.6
8
Installation and Servicing
SECTION 1 - GENERAL
LOGIC COMBI ESP1
Natural Gas only
Boiler size
G.C. Appliance No.
(Benchmark No.)
24
30
35
Destination Country:
PI No.
47-349-2186CR16
47-349-2286CR16
47-349-2386CR16
GB, IE
For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the
manufacturer’s instructions. Self-certification 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
Boiler
Page
Make and model.......................................................... 9
Appliance serial no. on data badge ........... Front Cover
SEDBUK No. %........................................................... 8
Controls
Time and temperature control to heating.................. 32
Time and temperature control to hot water .............. 32
Heating zone valves................................................. n/a
TRV’s........................................................................ 13
Auto bypass.............................................................. 13
Boiler interlock........................................................... 13
For ..................................................................... all boilers
Flushing to BS.7593.................................................. 16
Inhibitor..................................................................... 16
Central heating mode
Heat input....................................................to be calculated
Page
Burner operating pressure....................................... n/a
Central heating flow temp.............measure and record
Central heating return temp..........measure and record
For combination boilers only
Scale reducer............................................................ 16
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 flow rate at max. setting......... measure & record
For condensing boilers only
Condensate drain.................................................28-29
For all boilers: complete, sign & hand over to customer
For assistance see Technical Helpline on the back page
NOTE TO THE INSTALLER: COMPLETE
THE BENCHMARK COMMISSIONING
CHECKLIST AND LEAVE THESE
INSTRUCTIONS WITH APPLIANCE
Installation and Servicing
9
SECTION 1 - GENERAL
1.1INTRODUCTION
1.2OPERATION
The Logic Combi ESP1 range of boilers are wall mounted, full
sequence, automatic spark ignition, low water content, fanned
flue, high efficiency, condensing, combination gas boilers.
With no demand for CH, the boiler fires only when DHW is
drawn off, 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
Note. Due to the high efficiency 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:
24
4.8 to 24.2kW
30
6.1 to 24.2kW
35
7.1 to 24.2kW
Instantaneous domestic hot water (DHW) output is also fully
modulating with a maximum of :
2424.2kW
3030.3kW
3535.3kW
24
9.9 l/min at 35ºC temperature rise.
30
12.4 l/min at 35ºC temperature rise.
35
14.5 l/min at 35ºC temperature rise.
The DHW draw off rate specified above is the nominal that the
boiler flow regulator will give. Due to system variations and
seasonal temperature fluctuations DHW flow rates/temperature
rise will vary, requiring adjustment at the draw off tap.
At low DHW draw-off rates the maximum temperature may
exceed 65ºC.
The boiler is supplied fully assembled with DHW plate heat
exchanger, diverter valve, circulating pump, pressure gauge,
safety valve and CH expansion vessel.
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 finding.
Variable CH and DHW temperature controls are fitted on the user
control..
1.3 SAFE HANDLING
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 with a white
polymer front panel.
The boiler temperature controls are 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 Section 1.16 - Water & Gas
Connection Diagram.
10
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.
Installation and Servicing
SECTION 1 - GENERAL
1.4 OPTIONAL EXTRA KITS
1.6 SAFE HANDLING OF SUBSTANCES
Please visit www.idealboilers.com to access the Flue and
Accessories Guide for this boiler.
No asbestos, mercury or CFCs are included in any part of the
boiler or its manufacture.
1.5SAFETY
1.7 LOCATION OF BOILER
Current Gas Safety (installation and use) regulations or
rules in force:
The boiler must be installed on a flat and vertical internal wall,
capable of adequately supporting the weight of the boiler and any
ancillary equipment.
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
• Appropriate Building Regulations, either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
• Water Fittings Regulations or Water byelaws in Scotland.
• Current I.E.E. Wiring Regulations.
Where no specific 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).
The boiler may be fitted 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 fitted outside.
Timber Framed Buildings
If the boiler is to be fitted in a timber framed building it should
be fitted 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.
Ceiling
BSEN. 12828 Heating Systems in buildings: Design for water
based heating systems.
BSEN 12831 BSEN 14336
BS.5546
BS.6798
Heating Systems in buildings: Method for
calculation of the design heat load.
Heating Systems in buildings: Installation and
commissioning of water based heating
systems.
Installation of gas hot water supplies for domestic
purposes (2nd Family Gases)
Installation of gas fired hot water boilers of rated
input not exceeding 70 kW.
BS.6891Low pressure installation pipes.
Health & Safety Document No. 635.
Recessed
window
Zone 2
2.25m
Zone 1
0.6m
Zone 0
3G8913a
The Electricity at Work Regulations, 1989.
Compartment Installations
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
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 modified 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, This can be by means
of an opening door
• For the minimum clearances required for safety and
subsequent service, see the wall mounting template and
Section 1.16. In addition, sufficient space may be required to
allow lifting access to the wall mounting plate.
IMPORTANT. These appliances are CE certificated for safety
and performance. It is, therefore, important that no external
control devices, e.g. flue dampers, economisers etc., are
directly connected to these appliances unless covered by
these Installation and Servicing Instructions or as otherwise
recommended by Ideal Boilers in writing. If in doubt please
enquire.
Any direct connection of a control device not approved by
Ideal Boilers could invalidate the certification and the normal
appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.
Installation and Servicing
11
SECTION 1 - GENERAL
1.8 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.
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 specified in
Table 4.
4. Where the lowest part of the terminal is fitted less than 2m
above a balcony, above ground or above a flat 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 flue guard model no. K6 - round, plastic coated). In case
of difficulty contact:
TFC Group.
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
It is the responsibility of the Gas Installer to size the gas installation
pipework in accordance with BS.6891. Whilst the principle of the
1:1 gas valve ensures the Logic range is able to deliver it is full
5.
output at inlet pressures as low as 14mb, other gas appliances in
the property may not be as tolerant. When operating pressures
6.
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.
Gas Cock Pressure Drop
Pressure drop (mbar )
2
1.5
1
0.5
0
20
30
40
50
Heat Input to Boiler (kW)
IMPORTANT.
Installation pipes must be fitted 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.
1.9 FLUE INSTALLATION
Pluming will occur at the terminal so terminal positions where this
could cause a nuisance should be avoided.
The flue must be installed in accordance with the recommendations
of BS.5440-1.
In IE refer to I.S. 813.
The following notes are intended for general guidance:
1. The boiler MUST be installed so that the terminal is exposed to
external air.
12
The air inlet/products outlet duct and the terminal of the boiler
MUST NOT be closer than 25mm to combustible material.
Detailed recommendations on the protection of combustible
material are given in BS.5440-1.
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
infiltration, such as forced ventilation openings etc.
If products of combustion re-entry is identified or suspected this
should be immediately investigated and corrected following the
guidance provided in the current Gas Industry Unsafe Situation
Procedure.
Flue Terminal Positions
2.5
10
The flue assembly shall be so placed or shielded as to prevent
ignition or damage to any part of any building.
Table 4 - Balanced Flue Terminal Position
3
0
Ensure that the guard is fitted centrally.
Min. Spacing*
1. Directly below, above or alongside an open
window, air vent or other ventilation opening.
300mm
2. Below guttering, drain pipes or soil pipes.
BS5440-1
25mm*
75mm
3. Below eaves.
BS5440-1
25mm*
200mm
4. Below balconies or a car port roof.
BS5440-1
25mm*
200mm
5. From vertical drain pipes or soil pipes.
BS5440-1
25mm*
150mm
6. From an internal or external corner or to a boundary alongside the terminal.
BS5440-1
25mm*
300mm
7. Above adjacent ground, roof or balcony level.
300mm
8. From a surface or a boundary facing the terminal.
600mm
9. From a terminal facing a terminal.
1,200mm
10. From an opening in a car port
(e.g. door or window) into dwelling.
1,200mm
11. Vertically from a terminal on the same wall.
1,500mm
12. Horizontally from a terminal on the wall.
300mm
Vertical Terminals
13. Above the roof pitch with roof slope of all angles.
Above flat roof.
300mm
300mm
14. From a single wall face.
From corner walls.
300mm
300mm
15. Below velux window
2000mm
16. Above or side of velux window
600mm
* Only one reduction down to 25mm is allowable per installation
otherwise BS5440-1 dimensions must be followed.
Installation and Servicing
SECTION 1 - GENERAL
1.10TERMINAL
The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Section 2.9.
1.11 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.
1.12 WATER CIRCULATION SYSTEM
IMPORTANT.
A minimum length of 1 metre of copper pipe MUST be fitted
to both flow 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 - Refer to Section 1.19.
1.13 BOILER CONTROL INTERLOCKS
Central heating system controls should be installed to ensure that
the boiler has no demand when there is no requirement from the
system, in compliance with Building Regulations.
Heating systems utilising full thermostatic radiator valve control
of temperature in individual rooms should also be fitted with a
room thermostat controlling the temperature in a space served by
radiators not fitted 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 fitted
with an automatic bypass valve to ensure a flow of water should
all valves be in the closed position.
1.14 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 and for new
heating systems, and where practical replacement installations,
the isolator shall be situated adjacent to the appliance.
1.15 CONDENSATE DRAIN (Refer to Section 2.15)
A condensate drain is provided on the boiler. This drain must be
connected to a drainage point on site. All pipework and fittings 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
overflow pipe. It is a universal fitting to allow use of different
brands of pipework.
Installation and Servicing
13
SECTION 1 - GENERAL
1.16 BOILER DIMENSIONS, SERVICES & CLEARANCES
The boiler connections are made on the boiler connection tails.
Refer to Section 2.16.
drill, the flue can be installed from inside the building where
wall thicknesses do not exceed 600mm. Where the space into
which the boiler is going to be installed is less than the length
of flue required the flue must be fitted from the outside.
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 flue hole is cut accurately, e.g. with a core
2.5
from case
2.5
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.
395
WALL
Side flue
dim. A
700
Underside View - Dimensions to Wall
Filling Loop
PRV
56.4 37.5
CH RETURN
75
DHW INLET
GAS INLET
28.5 28.5 60.6
DHW OUTLET
65
COND. DRAIN
43.5
CH FLOW
DATA PLATE
Centre line
of boiler
CH
Flow
DHW
Outlet
Gas
DHW
Inlet
WALL
CH
Return
CH Circuit
Drain
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
14
Bottom clearance after
installation can be
reduced to 5mm. This
must be obtained with
an easily removable
panel to provide the
100mm clearance
required for servicing.
Installation and Servicing
SECTION 1 - GENERAL
1.17 SYSTEM REQUIREMENTS - Central Heating
Notes
Safety valve settingbar
a. The method of filling, refilling, topping up or flushing sealed
primary hot water circuits from the mains via a temporary hose
connection is only allowed if acceptable to the local water
authority.
Vessel charge pressure
b. Antifreeze fluid, corrosion and scale inhibitor fluids suitable for
use with boilers having aluminium heat exchangers may be used
in the central heating system.
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 84 oC.
bar
0.5 to 0.75
System pre-charge pressurebar
System volume
(litres)
3.0
None
1.0
Expansion vessel
volume (litres)
25
1.61.8
50
3.13.7
75
4.75.5
100
6.37.4
125
7.89.2
150
9.411.0
175
10.912.9
190
11.914.0
200
12.514.7
250
15.618.4
300
18.822.1
For other system volumes
multiply by the factor across
0.0630.074
3. All components of the system must be suitable for a working
pressure of 3 bar and a maximum design 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:
Water Flow Rate and Pressure Loss
a. Circulating pump.
Max CH Output
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.
Water flow rate
Temperature Differential
Head available for
system
kW
24.2
l/min
17.3
(gal/min)(3.8)
o
C20
m.w.g.
3.4
(ft.w.g.)(11.1)
4. ‘Make-up’ Water. Provision must be made for replacing water
loss from the system, either :
a. From a manually filled ‘make-up’ vessel with a readily visible
5.Filling
water level. The vessel should be mounted at least 150mm
above the highest point of the system and be connected The system may be filled by the following method:
through a non-return valve to the system, fitted at least
Where the mains pressure is excessive a pressure
150mm below the ‘make-up’ vessel on the return side of
reducing valve must be used to facilitate filling.
the radiators. or
a. Thoroughly flush out the whole system with cold
b. Where access to a ‘make-up’ vessel would be difficult, by
water.
pre-pressurisation of the system.
b.
Fill and vent the system until the pressure gauge
The maximum cold water capacity of the system should
registers 1bar and examine for leaks. Refer to
not exceed 143 litres, if not pressurized. However, if
Section 2.16 for filling detail.
the system is to be pressurized, the efficiency of the
expansion vessel will be reduced and a larger vessel
c.
Check the operation of the safety valve by raising the
(or smaller system volume) may be necessary. If the
water pressure until the valve lifts. This should occur
capacity of the vessel is not considered sufficient for this,
within 0.3bar of the preset lift pressure.
or for any other reason, an additional vessel MUST be
d. Release water from the system until the installed on the return to the boiler.
minimum system design pressure is reached; Guidance on vessel sizing is given in table above.
1.0 bar if the system is to be pre-pressurised.
continued . . . . . .
Installation and Servicing
15
SECTION 1 - GENERAL
........ SYSTEM REQUIREMENTS - CONT
Domestic Hot Water
1.18 SYSTEM BALANCING
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 13.
1. The DHW service must be in accordance with BS.5546 & BS.6700.
2. Refer to Table 1 for minimum and maximum working pressures. In
areas of low mains water pressures the domestic hot water regulator
may be removed from the DHW flow turbine cartridge. Refer to
Section 3.20. The boiler will require the flow rate to be set to obtain
a temperature rise of 35oC at the tap furthest from the boiler.
Note. Systems incorporating zone valves which could
completely cut off the flow through the system must
also include a bypass.
3. The boilers are suitable for connection to most types of washing
machine and dishwasher appliances.
BALANCING
4. When connecting to suitable showers, ensure that:
a. The cold inlet to the boiler is fitted with an approved antivacuum or syphon non-return valve.
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 flow
through the radiator.
IMPORTANT. Provision must be made to accommodate the expansion
of DHW contained within the appliance. If the DHW inlet contains a
back flow prevention device or non-return valve, e.g. a water meter,
then a mini expansion vessel should be fitted between the device and
the boiler in the cold inlet pipe.
These valves should now be left as set.
Cold water, rising main and pipework in exposed areas need to
be suitably lagged to prevent freezing.
Note. DHW Expansion Vessel kit available from Ideal.
3. Adjust the room thermostat and programmer to
NORMAL settings.
b. Hot and cold water supplies to the shower are of equal pressure.
5. Hard Water Areas
Where the water hardness exceeds 200mg/litre (200 ppm), it is
recommended that a proprietary scale reducing device is fitted into the
boiler cold supply within the requirements of the local water company.
2. Open all manual or thermostatic radiator valves
and adjust the lockshield valves on the remaining
radiators, to give around 20oC temperature drop at
each radiator.
1.19 WATER TREATMENT
CENTRAL HEATING
The Logic range of boilers have an ALUMINIUM alloy heat
exchanger.
IMPORTANT.
The application of any other treatment to this product
may render the guarantee of Ideal Boilers Invalid.
Ideal Boilers recommend Water Treatment in accordance
with the Benchmark Guidance Notes on Water Treatment
in Central Heating Systems.
If water treatment is used Ideal Boilers recommend only
the use of SCALEMASTER GOLD 100, FERNOX, MBI, ADEY
MC1, SENTINEL X100 or CALMAG CM100 inhibitors and
associated water treatment products, which must be used
in accordance with the manufacturers’ instructions.
DOMESTIC HOT WATER
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 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 artificially
softened water is NOT permitted.
4. Under no circumstances should the boiler be fired
before the system has been thoroughly flushed.
16
In hard water areas where mains water can exceed 200ppm
Total Hardness (as defined by BS 7593 Table 2) a scale reducing
device should be fitted into the boiler cold supply within the
requirements of the local water company. The use of artificially
softened water, however, is not permitted.
Ideal Boilers recommend the use of Fernox Quantomat, Sentinel
Combiguard,Calmag CalPhos I scale reducing devices or
Scalemaster In-line Scale Inhibitor branded Ideal, which must be
used in accordance with the manufacturers’ instructions.
Notes.
For further information contact:
Fernox Cookson Electronics
Forsyth Road, Sheerwater, Woking, Surrey GU21 5RZ
+44 (0) 8706 015000
Sentinel Performance Solutions
The Heath Business & Technical Park
Runcorn, Cheshire WA7 4QX
Tel: 0800 389 4670
Scalemaster Water Treatment Products
Emerald Way, Stone, Staffordshire ST15 0SR
Tel: +44 (0) 1785 811636
Calmag Ltd.
Unit 3-6, Crown Works, Bradford Road,
Sandbeds, Keighley, West Yorkshire BD20 5LN
Tel: +44 (0) 1535 210320
Adey Professional Heating Solutions
Gloucester Road, Cheltenham GL51 8NR
Tel: +44 (0) 1242 546700
Installation and Servicing
SECTION 2 - INSTALLATION
104
105
106
107
108
110
111
112
113
114
115
116
117
118
119
120
121
124
127
131
135
203
204
205
206
211
214
215
CH Return Valve
CH Flow Valve
DHW Inlet & Outlet
Filling Loop Pipe
Pump Head
Auto Air Vent
Diverter Valve Motor
Diverter Valve Body & Paddle
Pressure Relief Valve
Pipe - PRV Outlet
Pipe - Flow
Pipe - Return
Pipe - Expansion Vessel
Expansion Vessel
Note that item numbers are linked to the spares list
217
218
219
223
224
227
228
229
231
302
304
306
307
308
Return Group Manifold
Flow Group Manifold
Plate Heat Exchanger
Flow Regulator
Flow Sensor/Turbine
Water Pressure Switch
Pressure Gauge
Gas Cock
Pipe - Gas Inlet
Gas Valve
Pipe - Gas Injector
Injector Assy
Venturi
Fan
Burner
Gasket - Burner
Sump Clean Out Cover
Flue Manifold
Flue Manifold Top
Clamp Retaining Flue Turret
Hose Condensate Internal
Siphon Trap
Condensate Outlet Connection
Primary PCB
Control Thermistor (Return)
Electrode Ignition
Electrode Detection
Ignitor Unit
504
Thermistor Flow
Ignition Lead
Detection Lead
Control Box Lid
Control Box Front
Blank Insert
Heat Engine
Wall Mounting Bracket
Front Panel
Fascia
Bracket - Gas Valve
Bracket - Expansion Vessel
227
224
505
215
503
214
217
206
218
205
309
313
320
324
325
326
401
503
504
505
506
507
INSTALLATION
2.1 BOILER ASSEMBLY - Exploded View
118
313
211
306
320
507
309
401
307
204
506
308
223
231
115
228
116
111
110
121
135
219
105
324
304
229
106
203
106
120
112
131
104
113
127
107
124
326
325
Installation and Servicing
302
119
114
117
108
17
INSTALLATION
SECTION 2 - INSTALLATION
2.2UNPACKING
The boiler is supplied fully assembled in Pack A. A telescopic or non-telescopic flue assembly for rear or side flue outlet in Pack
B is supplied as a separate order.
Unpack and check the contents.
A
E
B
Pack A Contents
ABoiler
B Hardware Pack Box
C
C Wall Mounting Plate
D These Installation/Users Instructions
E Wall Mounting Template
F
D
Boiler Guarantee & Registration Pack
F
Boiler Guarantee
HARDWARE PACK CONTENTS
Gas Valve Pack
1. Pipe - Gas Inlet
2. Washer - Gas (blue)
3. Gas Cock
Gas Valve Pack
DHW Pack
1. 1/2" Top Hat Washer (x2)
2. Cap Female
3. Plug Male and Clip
4. Nut G1/2 16 Brass (Flat)
5. Washer 18.5 x 11 x 11.8 (x2)
6. Pipe DHW Outlet
7. Pipe DHW Inlet
8. Valve DHW Inlet
Accessory Pack
1. Screw (x2)
2. Wallplug (x2)
3. Turret Clamp Screw (spare)
Flow Valve Pack
1. Pipe CH Flow
2. Washer CH
3. Valve Flow
2
3
Filling Loop Pack
1. 3/8" Top Hat Washer
2. Valve Filling Loop
3. Pipe Filling Loop
4. Washer Fibre 3/8”
Return Valve Pack
1. Pipe CH Return
2. Washer CH
3. Valve Return
DHW Pack
1
3
1
2
8
7
1
5
5
4
Filling Loop
4
6
3
Accessory Pack
1
2
1
3
2
Return Valve Pack
3
1
Flow Valve Pack
3
1
2
2
continued . . . . .
18
Installation and Servicing
SECTION 2 - INSTALLATION
INSTALLATION
2.3 UNPACKING CONT’D
Note. This flue system incorporates a removable flue outlet nose that utilises a push fit location system. This enables the
installation of deflector, high level or balcony outlet flue kits without the removal of the whole ‘B’ pack terminal. The appliance
must not be operated without the desired outlet nose correctly fitted in place.
Note. Location dimples must be aligned with terminal mounting frame.
Pack B Contents Telescopic
A
Telescopic Flue Terminal
B
Flue Turret
C
Rubber Terminal Wall Seal
DScrew
E
Sealing Tape
F
Wall Seal (White)
B
F
A
C
E
D
Pack B Contents Non-Telescopic
A
Flue Terminal
B
Flue Turret
C
Rubber Terminal Wall Seal
D
Cutting Aid
E
Wall Seal (White)
B
D
E
A
C
2.4 FRONT PANEL REMOVAL
1. Loosen the 2 screws retaining the front panel.
2. Pull the two clips downwards to disengage.
3. Pull the front panel forward and upwards to remove.
2
1
Installation and Servicing
19
2.5 WALL MOUNTING TEMPLATE
Extended centre line
155
(200)
The wall mounting template is located on the internal protective
packaging. The template shows the position of the fixing and rear
flue centre holes for a standard installation
“A” - See Diagram in
Section 1.16
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 fitting a side flue, extend the flue centreline onto the side by
155mm on a standard wall fix 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 flue duct. Marking both the centre
and the circumference of the flue duct.
4. Remove the template plate from the wall.
2.6 PREPARING THE WALL
IMPORTANT.
Ensure that, during the cutting operation, masonry falling
outside of the building does not cause damage or personal
injury.
Rear flue only
5" diameter hole
1. Cut the flue hole (preferably with a 5” core boring tool),
ensuring that the hole is square to the wall.
Both wall faces immediately around the cut hole should be
flat.
Side flue only
5" diameter hole
X
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.
Section
through wall
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.
Note. Check all of the hole
positions before drilling.
3G9495
INSTALLATION
SECTION 2 - INSTALLATION
2.7 FITTING THE WALL MOUNTING PLATE
2.8 MOUNTING THE BOILER
Screw the wall mounting plate to the wall using 2 wall plugs
(previously fitted) with the 2 screws provided.
1. Ensure the plastic plugs are removed from both the CH
and DHW connections before mounting the boiler.
Choose one of the 2 sets of slots in left and right bank.
Ensure that at least one of the screws is fitted into a top slot
and the mounting bracket is level.
Example of fixing
Note. Boiler may contain residual water.
2. Lift the boiler onto the wall mounting plate (refer to the
Introduction section for safe handling advice), locating it
over the two tabs.
esp9496
20
Installation and Servicing
SECTION 2 - INSTALLATION
2.9 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 flue
incorporating a terminal and rubber wall seals.
Horizontal Flue Terminal (600mm long) ‘B’ Pack - contains: Flue
turret, non telescopic single piece flue incorporating a terminal and
rubber wall seals.
Horizontal Flue Terminal (1000mm long) ‘B’ Pack - Flue turret,
telescopic flue incorporating a terminal, rubber wall seals and
instructions.
Note. If ‘B’ packs are used on their own (either 1 piece or telescopic), then
they MUST be fitted horizontally as the flue inside is designed to slope 1.5
degrees.
D Pack Flue Extension 100mm DIA 1000mm long
D Pack Flue Extension 100mm DIA 500mm long
D Pack Flue Extension 100mm Dia 2000mm long
Roof Flue Kit with Vertical Connector
recommended that a support bracket is fitted 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 - & Concentric Flue Screw Retaining
Kit (Optional Kit of mechanical fixing of flue joints)
Only use water as a lubricant during assembly.
The ‘B’ pack terminal is classed as part of the maximum flue
length.
These flue system incorporates a removable flue outlet nose that
utilises a push fit location system. This enables the installation
of deflector, high level or balcony flue kits without the removal of
the whole ‘B’ pack terminal. The appliance must not be operated
without the desired outlet nose correctly fitted 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 fitted in accordance to
the installation instructions provided with them.
When extension ‘D’ Packs are used the flue 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
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 Deflector Kit
High Level Flue Outlet Kit
Balcony Flue Outlet Kit
Soffit Kit
The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from
any maximum flue length
The maximum permissible concentric flue length when using a standard (500mm) kit is 4.5 metres
The maximum permissible concentric flue length when using this kit is dependant on the length
of the balcony flue outlet run which combined with the concentric run must not exceed the
maximum flue length requirement of the appliance it is to be fitted to
This kit enables fitment of an external flue below soffits.
24 kW Appliances
30 kW Appliances
35 kW Appliances
Total Maximum: 9 metres - minus any flue kit options or bends
Total Maximum: 8 metres - minus any flue kit options or bends
Total Maximum: 6 metres - minus any flue kit options or bends
Total Maximum Permissible Vertical Flue Length combining both Roof Terminal and ‘D’ Packs
24, 30 & 35kW Appliances
Total Maximum: 7.5 Metres - minus any bends
Powered Vertical Flue
24, 30 & 35kW Appliances
Total Maximum: 5 Metres - Concentric Flue and 17m flue pipe only. For additional details
refer to the powered Vertical Instructions
90º Elbow Kit 60/100 - (Equivalent flue length resistance = 1M)
45º Elbow Kit 60/100 - (Equivalent flue 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
‘B’ Pack Flue Type 60/100
Horizontal Flue Terminal
(600mm long) B Pack
Telescopic Flue B Pack
Horizontal Flue Terminal
(1000mm long) B Pack
Horizontal Flue Terminal
(1000mm long) B Pack cut 75mm
Std Metric Brick 102.5mm wide
Minimum Permissible Wall Thickness
Maximum Permissible Wall Thickness
Rear Flue Rear Flue + Stand-Off Side Flue Rear Flue Rear Flue + Stand-Off Side Flue
126*
102.5
102.5
501
456
456
231
546
186
501
186
501
429
761
384
716
384
716
471
426
426
686
641
641
* If wall thickness is <126 and >102.5, contact Ideal Boilers.
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 flue only.
Installation and Servicing
21
FLUE OUTLET
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)
SECTION 2 - INSTALLATION
....... DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED, CONT’D
100mm
Edge of turret
to outside face of wall plus
44mm = flue length
A
REAR
Fit
to wall
inc. Stand
off Frame
WALL
REAR
Fit
to wall
Edge of turret
to outside face of wall plus
44mm = flue length
A
SIDE
Fit
to wall
WALL
Note. Maximum permissible
flue length is measured from
centre line of appliance flue
outlet to outside wall face.
Edge of turret
to outside face of wall plus
44mm = flue length
A
WALL
FIGURE 1
Minimum clearance 5mm
NOTES
Centre of turret to edge of turret = 100mm
Turret has a flue 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
Flue length measured from outer terminal lip
to end of outer flue
A + 44mm
FIGURE 2
Shows the flue required when measured from outside edge of turret to the outside face of the wall (to obtain cut length add 44mm)
B Pack (Standard)
Plus 1 (1m D pack)
Plus 2 (1m D pack)
Plus 3 (1m D pack)
Plus 4 (1m D pack)
Plus 5 (1m D pack)
Plus 6 (1m D pack)
Plus 7 (1m D pack)
Plus 8 (1m D pack)
Plus 9 (1m D pack)
181
1131
2081
3031
3981
4931
5881
6831
7781
8731
556
1506
2456
3406
4356
5306
6256
7206
8186
9000
286
1236
2186
3136
4086
5036
5986
6936
7886
8836
484
1434
2384
3334
4284
5234
6184
7134
8084
9000
601
1551
2501
3451
4401
5351
6301
7251
8201
9000
816
1766
2716
3666
4616
5566
6516
7466
8416
9000
526
1476
2426
3376
4326
5276
6226
7176
8126
9000
741
1691
2641
3591
4541
5491
6441
7391
8341
9000
Max output 35 kW
Max output 30 kW
Max output 24 kW
FLUE OUTLET
Minimum & Maximum finished flue lengths obtainable (dimension ‘A’ +44mm)
Horizontal Flue Terminal Telescopic Flue B Pack
Horizontal Flue
Horizontal Flue Terminal
(600mm long) B Pack
Terminal (1000mm long)
(1000mm long) B Pack
B Pack (Telescopic)
(Telescopic) Cut 75mm
Minimum
Maximum
Minimum
Maximum
Minimum
Maximum
Minimum
Maximum
Note; Telescopic flue B Pack or attached “D” pack extensions do not need to be cut between minimum and maximum values
shown above (except where specified). Horizontal Flue Terminal (600mm long) B Pack flue 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.
22
Installation and Servicing
SECTION 2 - INSTALLATION
2.10 CUTTING & SETTING THE FLUE LENGTH
TELESCOPIC FLUES
TELESCOPIC FLUE B PACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT
BE CUT
HORIZONTAL FLUE TERMINAL (1000MM LONG) B PACK (TELESCOPIC) MUST ONLY BE CUT IF REQUIRED FLUE
LENGTHS ARE BETWEEN 602 & 652MM. THIS WILL REQUIRE 75MM TO BE CUT OFF THE TERMINAL END OF THE
1000MM TELESCOPIC FLUE.
ALL OTHER LENGTHS OBTAINED USING “D” PACK EXTENSIONS IN FLUE LENGTH TABLE 1, COLUMN “HORIZONTAL
FLUE TERMINAL (1000MM LONG) B PACK CUT 75MM” (TELESCOPIC) SHOULD HAVE THE 75MM CUT OFF THE “D”
PACK EXTENSION AND NOT TELESCOPIC FLUE
CUT 75MM OFF HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK (TELESCOPIC)
1. Measure cut flue length (A+44mm). (If required telescopic length is not between
658 and 708 then proceed to “Setting Telescopic Flue B Pack”).
2. Remove telescopic end piece from the flue body and set aside.
3. Mark the circumference 75mm from the open end of the outer flue.
4. Cut along the 75mm mark cutting only the outer flue ensuring the cut is square.
5. Dress the cut end to make sure all burr is removed and the cut edge is in its
original shape.
6. Measure 20mm from the newly cut edge of the outer flue, place a mark at the top of the flue approximately 20mm wide &
write “STOP” on the terminal side of the line.
7. Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure it’s cut
square.
8. Remove all burrs and place a chamfer on the outer edge to aid assembly.
9. Re-assemble telescopic section.
SETTING TELESCOPIC FLUE B PACK
1. Measure the required flue length (A+44mm).
FLUE OUTLET
2. Measure from the outer terminal lip to end of outer flue. Pull apart flue until
desired length is achieved. ENSURE THE STOP MARK IS NOT VISIBLE,
IF IT IS, THE FLUE IS TOO SHORT AND SHOULD NOT BE USED.
3. Check that both flue seams are at the top and the outlet terminal is
uppermost.
4. Drill a 3.5mm hole through one of the 2 outer side holes in the outer flue
section into the inserted outer flue (as shown). Take care not to pierce the
inner plastic flue. Fit screw provided.
5. Seal the joint on the outer air duct with the tape provided.
6. Fit internal and external wall seals (see installing flue).
CUTTING HORIZONTAL FLUE TERMINAL (600MM LONG) B PACK
1. Measure the required cut flue length (A+44mm). If inside the dimensions
shown in Figure 2 (page 22) “1 Piece 600mm” proceed.
2. Measure from the outer terminal lip to end of outer flue. Mark the
required cut length (A+44) around the circumference of the outer flue and
cut following the mark to ensure it is cut square.
3. Dress the cut end to make sure all burrs are removed and the cut edge is
in its original shape.
4. Mark the inner tube 10mm longer than the outer tube around its
circumference and cut following the mark to ensure it is cut square.
5. Remove all burrs and place a light chamfer on the outer edge to aid
assembly.
Installation and Servicing
23
SECTION 2 - INSTALLATION
2.11 INSTALLING THE FLUE
FITTING FLUE THROUGH THE WALL
1. Measure wall thickness and add 14mm.
2. Measure from the outer terminal lip towards the end of outer flue, place a
small location mark at the dimension acquired at point 1.
3. Add a further 14mm to the dimension, obtained at item 1 (point 1) and
place an additional small location mark.
4. Fit external black wall seal ensuring the inside of the outer lip is in contact
with the terminal lip you have been measuring from (see fig 1 below)
5. Fit the internal wall seal approximately 65mm before the outer of
the 2 location marks.
6. For an internal fit place flue terminal in the centre of the 5” drilled
hole in the wall. Apply pressure and lightly move the flue left to
right or up and down. This will cause the outer flange to fold in
and allow the flue to pass through the wall.
7. Push through a further 65mm or until the inner flange is pressed
against the inner wall. This will allow the outer flange to return to
its original shape.
8. Pull back the flue until the first of the 2 location marks is level with
the internal face of the wall.
Note. If the 2 location marks are not visible then the flue is not
pulled back far enough to obtain the correct seal. If the 1st location mark has passed the face of the wall the flue has been
pulled too far back and the outer wall seal will have been dislodged from its mounting and will need to be refitted.
9. When 1st mark is in line with the wall, whilst holding the flue firmly, push the white wall sealing flange to the wall until the 2nd
of the two marks is just visible. If the last location mark is clearly past the white inner wall seal then the outer wall seal will
have been dislodged from its mounting and will need to be re-fitted.
10.Ensure the seam and the outlet terminal are at the top and fitted as shown.
Note. If less than 50% of the length of the flue is internal the flue should be fitted from outside.
Terminal
MUST be
fitted as
shown
Wall Seal Lip
Fig 1
FLUE OUTLET
Terminal Lip
24
Rubber
Terminal
Wall Seal
Location
mark 1
Location
mark 2
Ensure lip of wall seal is positioned
over step on plastic nose of flue terminal
(note, seal is cut away for clarity)
FITTING THE TURRET - Ensure the condense trap/siphon is filled with water
1. Ensure the rubber seal is fitted correctly on the appliance manifold and that all flue seals are undamaged.
2. Hold the flue firmly and push the turret on until it has travelled 30mm on to the flue pipe and is fully engaged. Make sure the
flue has not rotated or moved forward during fitting and the flue seam is uppermost.
3. Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold.
4. Fully engage the clamp location section into the manifold location holes. Rotate down on to turret flange.
5. Secure clamp to appliance using securing screw.
6. Ensure all sample points are accessible and all sample plugs and caps are fitted.
Retaining
screw
D
Clamp Lugs
A
B
Flue Outlet
A - Duct Assembly
B - Flue Turret
C - Turret Clamp
D - Seal
Sample points
Flue Outlet
C
Installation and Servicing
SECTION 2 - INSTALLATION
2.12 FITTING THE OPTIONAL ROOF FLUE KIT (FLAT OR PITCHED)
Note.
A flat or pitched roof flashing plate (not supplied) is required before proceeding
with the installation of this kit.
This kit is suitable for both flat and pitched roof terminations, using a concentric
flue to run vertically from the top of the boiler and terminating above roof level.
Connection to the top of the boiler is made using the supplied vertical
connector.
WEATHER PROOFING
Where the flue passes through the roof line an adequate seal must be made.
This is achieved by using either:
- Flat roof weather collar
or
- Universal weather collar.
ACCESSORIES
Flue Duct Extension Kits are available for flue lengths extending beyond 1m.
These packs contain 1m extension ducts and may be cut to the desired length.
If the offset vertical option is used an Elbow Kit is required.
FLUE OUTLET
Please visit www.idealboilers.com to access the Flue and Accessories Guide
for this boiler.
Installation and Servicing
25
SECTION 2 - INSTALLATION
2.13 FLUE TERMINAL POSITION
The terminal should be positioned so that products of
combustion can safely disperse at all times.
Pluming may occur at the termination so, where possible,
terminal positions where this could cause a nuisance
should be avoided.
300mm
Minimum dimensions are shown below
min
690mm
Fixed
m
300mm
min
rf8394-1
0m
30
in
m
rf8393-1
625mm
Fixed
A
A
B
07
98
26
A
If chimney penetrates dotted area such that A is less
than 300mm, B shall not be less than 300mm.
RF
FLUE OUTLET
Flat roof - with structure
A = 600mm
B = 2000mm
The flue terminal shall not penetrate the shaded area of the roof
Pitched roof - with velux window
or opening
Where two or more vertical fanned draught chimney configurations terminate in close
proximity at the same height, they shall be separated by at least 300mm. Where any one
vertical outlet is more than 300mm above the other, then they shall be separated by at least
1500mm.
Where any vertical fanned draught chimney configuration outlet is within 2000mm measured
horizontally of an opening window, then it shall be at least 300mm above the opening.
Note.
The equivalent flue length
resistance of the elbow kits are:
90o elbow kit = 1m
45o elbow kit = 0.6m
Installation and Servicing
SECTION 2 - INSTALLATION
2.14 ASSEMBLING THE ROOF FLUE KIT
Determine the correct height that the flue should terminate above
the roof. If after calculating or measuring the overall flue height
from the top of the boiler, it is necessary to cut both pipes of
assembly A, then ensure they are cut equally leaving the inner
flue tube longer than the outer air tube as supplied.
MAX LENGTH:
7.5m
o
1. Position the roof flashing plate (supplied separately) over the
hole cut in the roof and insert flue terminal from the roof end.
max 41
min 16
o
Ensure the cut pipe ends are free from any burrs.
BOILER
nm8739
1
2. Fit the vertical connector (supplied in kit) in accordance with the
instructions provided with the vertical connector kit.
Flue Terminal
ASSEMBLY A
3. Secure the vertical connector by applying downward pressure
on the connector.
4. Position the clamp on the top face of the flue manifold and push
it horizontally backwards. Locate both clamp lugs into the flue
manifold and secure to the flue manifold with the M5 retaining
screw.
Pitched roof tile
weather collar
Note. Ensure turret sample points are servicable and all caps and
plugs are fitted. Fill the condense trap/siphon with water.
nm8740
5
4
Extension
Duct
FLUE OUTLET
Flat roof tile
weather collar
5. Push extension duct (if required (supplied separately)) into
vertical connector.
Vertical
connector
3G9557b
2
6
'X'
6. If the last extension duct requires cutting, measure ‘X’, the distance
(outer ducts), between the duct and the terminal and add 100 mm to this
dimension. This gives the length of the last extension duct.
Note. Check the position of the inner flue duct relative to the outer duct on
the assembled extension duct(s) and ensure the terminal flue duct is cut
longer than the air duct to ensure engagement in the final flue duct seal.
7. Finally ensure the roof flashing plate is correctly sealed to the roof.
Installation and Servicing
27
INSTALLATION
SECTION 2 - INSTALLATION
2.15 CONDENSATE DRAIN
Condensate Pump
Where gravity discharge to an internal termination is not physically
possible or where very long internal pipe runs would be required
to reach a suitable discharge point, a condensate pump of a
specification recommended by the boiler or pump manufacturer
should be used terminating into a suitable internal foul water
discharge point such as an internal soil and vent stack or internal
kitchen or bathroom waste pipe etc. (fig 3).
137
149
This appliance is fitted with a siphonic 75mm condensate trap
system that requires filling before operating the appliance for the
1st time or after maintenance.
In order to minimise the risk of freezing during prolonged very cold
spells, one of the following methods of terminating condensate
drainage pipe should be adopted.
Internal Drain Connections
Wherever possible, the condensate drainage pipe should be routed
to drain by gravity to a suitable internal foul water discharge point
such as an internal soil and vent stack or kitchen or bathroom
waste pipe etc. See Figs 1 and 2.
Figure 1 - Connection of Condensate Drainage Pipe to
Internal Soil & Vent Stack
-
-
-
For connections to an external soil/vent stack see Fig 4.
Insulation measures as described should be used.
When a rainwater downpipe is used, an air break must be
installed between the condensate drainage pipe and the
downpipe to avoid reverse flow of rainwater into the boiler
should the downpipe become flooded or frozen, see Fig 5.
Where the condensate drain pipe terminates over an open
foul drain or gully, the pipe should terminate below the grating
level, but above water level, to minimise “wind chill” at the open
end. The use of a drain cover (as used to prevent blockage by
leaves) may offer further prevention from wind chill. See Fig 6.
Where the condensate drain pipe terminates in a purpose
designed soakaway (see BS 6798) any above ground
condensate drain pipe sections should be run and insulated as
described above. See Fig 7.
Unheated Internal Areas
Internal condensate drain pipes run in unheated areas, e.g. lofts
basements and garages, should be treated as external pipe.
Ensure the customer is aware of the effects created by a frozen
condensate and is shown where this information can be found in
the user manual.
Figure 2 - Connection of a Condensate Drainage Pipe
Downstream of a Sink, Basin, Bath or Shower Water Trap to
Internal Soil Vent Stack
Minimum
connection
height up to 3
storeys
Sink/basin/
bath or
shower
Min Ø 19mm
Internal pipe
75
≥ 100
≥ 450
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
-
≥ 100
Min Ø 19mm
Internal pipe
The external pipe run should be kept to a minimum using the most
direct and “most vertical” route possible to the discharge point, with
no horizontal sections in which condensate might collect.
Boiler
with 75mm
sealed
condensate
trap
Soil & vent stack
Boiler
with 75mm
sealed
condensate
trap
75
FLUE OUTLET
All condensate pipework should conform to the following:
a. Where a new or replacement boiler is being installed, access to
an internal ‘gravity discharge’ termination should be one of the
main factors considered in determining boiler location.
b. Plastic with push fit or solvent connections.
c. Internal plastic pipe work a minimum of 19mm ID (typically
22mm OD).
d. External plastic pipe must be a minimum of 30mm ID (typically
32 OD) before it passes through the sleeved wall.
e. All horizontal pipe runs must fall a minimum of 45mm per metre
away from the Boiler.
f. External & unheated pipework should be kept to a minimum and
insulated with Class “O” waterproof pipe insulation.
g. All installations must be carried out in accordance to the
relevant connection methods as shown in the “Condensate
installation diagrams” & BS6798.
h. Pipework must be installed so that it does not allow spillage into
the dwelling in the event of a blockage (through freezing)
i. All internal burrs should be removed from the pipe work and any
fittings.
External Drain Connections
The use of an externally run condensate drainage pipe should
only be considered after exhausting all internal termination options
as described previously. An external system must terminate at a
suitable foul water discharge point or purpose designed soakaway.
If an external system is chosen then the following measures must
be adopted:
Internal soil & vent stack
Condensate
Drain
47
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
continued . . . . .
28
Installation and Servicing
SECTION 2 - INSTALLATION
Boiler
with 75mm
sealed
condensate
trap
Min Ø 30mm
Internal pipe
Water/
weather proof
insulation
Min Ø 19mm
Internal pipe
Min Ø 30mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
combined foul/
rain water drain
External air
break
Air gap
Terminated
and cut at 45º
43mm 90º male/
female bend
68mm Ø PVCU
Strap on fitting
Visible air break
at plug hole
Min Ø 19mm
Internal pipe
Sink, basin, bath or
shower with integral
overflow and 75mm trap
Water/
weather proof
insulation
Minimum 30mm
internal pipe
45º pipe
termination
FLUE OUTLET
Boiler
with 75mm
sealed
condensate
trap
Minimum
connection
height up to 3
storeys
Figure 6 - Connection of Condensate Drainage Pipe
Upstream of a Sink, Basin, Bath or Shower Waste Trap to
External Drain, Gulley or Rainwater Hopper
75
Figure 5 - Connection of a Condensate Drainage Pipe to an
External Rainwater Downpipe (only combined foul/rainwater
drain)
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
≥ 100
Condensate pump
(Install in accordance with manufacturer’s instructions)
≥ 450
Min Ø 19mm
Internal pipe
≥ 25 Below grate
75
Min Ø 19mm
Internal pipe
Water/weather
proof insulation
75
Visible air break
Boiler
with 75mm
sealed
condensate
trap
Figure 4 - Connection of condensate Drainage Pipe to
External Soil & Vent Stack
Soil & vent stack
Figure 3 - Connection of a Condensate Pump Typical
Method (see manufacturer’s detailed instructions)
INSTALLATION
.......CONDENSATE DRAIN - CONT’D
Figure 7 - Connection of a Condensate Drainage Pipe to an
External Purpose Made Soakaway.
Boiler
with 75mm
sealed
condensate
trap
Max 3m external
pipework
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
≥ 300
≥ 25
Min Ø 19mm
Internal pipe
Water/Weather
proof insulation
75
Min Ø 30mm
Internal pipe
≥ 500
Limestone
chippings
2 rows of three Ø12mm holes
25mm centres, 50mm from
the bottom of the tube, facing
away from the house
Installation and Servicing
29
2.16 CONNECTIONS & FILLING
NOTES.
Ensure all boss blanking plugs are removed before connecting hardware. Each
valve must be fitted to the correct boss as shown in the picture.
Ensure each union is fitted with fibre seals provided.
Do not subject any of the isolating valves to heat as the seals may be damaged.
WATER CONNECTIONS CH
1. Connect the CH flow service valve (black handle) and
copper tail provided in the hardware pack to the threaded
boss connection provided at the lower rear of the boiler.
2. Connect the CH rtn. valve (black handle) and copper tail.
WATER CONNECTIONS DHW
1. Fit the DHW inlet service valve (blue handle) and copper
tail to the threaded boss connection ensuring the seal
provided is correctly located.
Note. The domestic hot water flow rate is
automatically regulated to a maximum:
24 = 9.9 l/m
(2.2 gpm)
30 = 12.4
l/m
(2.8 gpm)
35 = 14.5
l/m
(3.2 gpm)
SAFETY VALVE DRAIN
The safety valve connection, located at the bottom righthand side of the boiler, comprises a 15mm diameter stub
pipe.
The Installer to provide a compression joint on the end
of the stub pipe. This assists with pipe removal when
servicing.
The discharge pipe should be positioned so that the
discharge of water or steam cannot create a hazard to
the occupants of the premises or damage the electrical
components and wiring.
2. Fit the DHW outlet pipe tail to DHW outlet connection,
ensuring the seal provided is correctly located.
3. Fit the filling loop provided between the DHW inlet valve
and the CH return valve.
3G9705
INSTALLATION
SECTION 2 - INSTALLATION
GAS CONNECTION
IMPORTANT.
The gas service cock is sealed with a nonmetallic blue fibre washer, which must not be overheated when
making capillary connections. Refer to Section 1.16 for details
of the position of the gas connection.
For additional gas supply info refer to “Gas Supply” on page 12.
CH Flow
DHW
Outlet
Gas
Supply
Safety Valve
Drain Connection
15mm elbow
or fittings
(not supplied)
DHW
Inlet
Pressure Relief Valve
Drain Pipe
CH
Return
Filling
Loop
30
Installation and Servicing
.......CONNECTIONS & FILLING CONT
FILLING
IMPORTANT - when filling:
When filling there may be a slight water leak from the air vent therefore electrical connections should be protected.
Filling
Top Up
1. Ensure filling loop is connected and all washers in place.
1. Ensure filling loop is connected and all washers in place.
2. Ensure dust cap on auto air vent is slackened off. Refer to
Section 3.24.
2. Ensure dust cap on auto air vent is slackened off. Refer to
Section 3.24.
3. Check the following isolation handles on water connections
are in the horizontal filling position (blue handle on DHW
inlet A and black handle on CH return C ).
3. Turn the DHW Inlet handle (blue A ) to the horizontal
position.
Note. The CH flow isolation valve handle MUST be in the
vertical position to enable filling.
4. Slowly turn the filling loop handle (blue B ) to the
horizontal open position until the pressure gauge reads
between 1 to 1.5 bar.
4. Slowly turn the filling loop handle (blue B ) to the
horizontal open position until the pressure gauge reads
between 1 to 1.5 bar.
5. Once the pressure gauge dial reads between 1-1.5 bar
turn the handle (blue B ) on the filling loop back to the
closed (vertical) position.
5. Once the pressure gauge dial reads between 1 to1.5 bar
turn the filling loop handle (blue B ) back to the closed
(vertical) position.
6. Turn the DHW Inlet handle (blue A ) to the open (vertical)
position.
6. Turn the CH Return handle (black C ) and the DHW Inlet
handle (blue A ) to the open (vertical) position.
7. Disconnect the filling loop from the DHW Inlet valve and fit
the grey cap to the open end.
8. Fit the Plug to the free end of the filling loop.
7. Disconnect the filling loop from the DHW Inlet valve and fit
the grey cap to the open end.
8. Fit the Plug to the free end of the filling loop.
Note. Open all DHW taps to ensure water is flowing freely.
Once satisfied close all taps.
Note. Open all DHW taps to ensure water is flowing freely.
Once satisfied close all taps.
Filling Positions shown
Top Up Positions shown
Cap
Filling
Loop
Cap
Filling
Loop
Plug
A
A
DHW Inlet
(Blue)
DHW Inlet
(Blue)
B
B
C
Filling Loop
(Blue)
CH Return
(Black)
Installation and Servicing
Plug
C
Filling Loop
(Blue)
CH Return
(Black)
31
INSTALLATION
SECTION 2 - INSTALLATION
INSTALLATION
SECTION 2 - INSTALLATION
2.17 ELECTRICAL CONNECTIONS
WARNING. This appliance MUST be earthed.
A mains supply of 230Vac ~ 50 Hz is required.
The fuse rating should be 3A. All external controls and wiring
must be suitable for mains voltage.
Wiring external to the boiler MUST be in accordance with the
current I.E.E. (BS.7671) Wiring Regulations and any local
regulations.
Wiring should be 3 core PVC insulated cable, not less than
0.75mm2 (24 x 0.2mm), and to BS 6500 Table 16. For IE
reference should be made to the current ETCI rules for
electrical installations.
Connection must be made in a way that allows complete
isolation of the electrical supply such as a double pole switch
having a 3mm contact separation in both poles. The means of
isolation must be accessible to the user after installation.
2.18 INSTALLER WIRING
The Logic boiler comes pre-fitted with 1.8m of mains cable. This
must be connected to a permanent live supply and NOT switched
by thermostats/programmers. If the supply cord is damaged, it
must be replaced by the manufacturer, service agent or similarly
qualified persons in order to avoid hazard.
Accessing the installer wiring
1. Isolate the mains supply from the boiler.
2. Remove the front panel. Refer to section 3.2.
3. Swing down the control box into the service position,
unclip and swing back the installer wiring cover and latch
into the retaining clips. Refer to Section 3.8.
INSTALLER CONNECTIONS (LHS)
32
All of the connections can now be readily accessed, the plugs
can be removed to aid wiring.
Note the cable strain relief system and grommets. Once any
wiring is completed, to secure the boiler, reverse the order
above.
Note The link wire on the 230V installer room stat/timer
connection gives a demand in conjunction with the timer option
plug inside the timer option cover (located on the front of the
new control box).
INSTALLER CONNECTIONS (RHS)
Installation and Servicing
SECTION 2 - INSTALLATION
External Controls – Extra Low Voltage
Wiring a 230V 50Hz Room Thermostat,
Diagram A (with optional timer, Diagram
B)
If parts of the pipework run outside the
Wiring OpenTherm Room Control
house or if the boiler will be left off for DIAGRAM
more
or other OpenTherm Master Device,
DIAGRAM A:
B:
thanora day or so then a frost thermostat
Diagram D.
Programmable Room Stat
Room Stat with External Timer
should
Room Stat with Internal
Timer be wired into the system.
1. Remove the timer link
plug inside
This is usually done at the programmer, in
the timer option cover, located on
Optional
Optional
Room
Stat or
which
case the programmer
selector switches
the front of the control box
Frost controls
Frost
Programmable
are set to OFF and all the other
Room Stat
Timer
2. Unclip the timer link socket
Stat from the
Room
Stat be left in the runningStat
MUST
position.
aperture on the rear of the control box,
The frost thermostat should be sited in a
locate the plug on the same harness
cold place but where it can sense heat
branch and connect these together.
from the system.
3. Using the rubber bung located
Wiring a system frost thermostat, see
adjacent to these connections,
insert
Frost
Room
digarams A, B and C. Wire theFrost
frostRoom
Stat
Stat/ L N
Stat
Stat/ L N
it into the open aperture.
(Optional) Timer
(Optional) Timer
thermostat across the two connections
as shown.
4. Locate the OpenTherm connection on
the right hand side of the boiler installer
Note. If the boiler is installed in a garage it
connections area and connect the 2
may be necessary to fit a pipe thermostat,
core cable from the OpenTherm device.
preferably on the return pipework.
2. Connect the external cable from
the room stat/timer across these
two connections, if a general live
connection is used for the room stat
or timer then connect this to the
fused spur, on the load side (see
Diagram C)
3. If the room thermostat has
compensation and requires a neutral
connection, make this connection to
the fused spur, on the load side.
DIAGRAM
A:
DIAGRAM
A:
DIAGRAM
B:
DIAGRAM
B:
Programmable
Stat or
Programmable
Room StatRoom
or
Stat with
Internal Timer
Room StatRoom
with Internal
Timer
Frost
Stat
Frost Protection
External Controls – 230V 50Hz
1. Remove the link wire from the room
stat/timer plug.
Optional
INSTALLATION
2.19 EXTERNAL WIRING
Optional Room Stat or
Room Stat or
Frost Programmable
Programmable
Stat
Room Stat Room Stat
DIAGRAM C:
Stat withTimer
External Timer
Room StatRoom
with External
Use of General Live for Room Stat
Optional
Optional
Frost
Frost
Stat
Room Stat
Optional
Frost
Stat
Stat
Stat Room Stat Room
Timer
Timer
DIAGRAM D:
OpenTherm Device
DO NOT CONNECT 230V TO THESE
TERMINALS OR THE BOILER ELECTRONICS
WILL BE DAMAGED
OpenTherm Device
E.G. Honeywell OT
Bridge R8810
Mains In
Frost
Stat
(Optional)
Room Frost Room
Stat/ Stat
L NStat/
(Optional) Timer
Timer
L N
Frost
Stat
(Optional)
Room Frost Room
Stat
Stat/ L NStat/
(Optional) Timer
Timer
L N
Frost
Stat
(Optional)
Room
Stat/
Timer
2.20 REPLACING PRE-FITTED MAINS CABLE
DIAGRAM
C:
DIAGRAM
C:
Use of
General
Live Stat
for Room Stat
Use of General
Live
for Room
Optional
Frost
Stat
If it is necessary to use an alternative mains cable to the one pre-fitted then use
Room Stat
Optional
Room Stat
the
following
guide.
Frost
L N
Open
Therm
Outside
Sensor
Strain Relief
6
Stat
Replacement
wiring should comply with notes in Section 2.18 and be caried out
by a qualified person to avoid a hazard.
1. Isolate the mains
supply to the boiler.
Mains In
Mains In
2. Remove the front panel. Refer to Section 3.2.
Frost
Room Frost
Swing
theRoom
control box down into the service position, unclip and swing back the
3.
Stat
Stat
Stat/ L NStat/ L N
Timer
Timer
installer
wiring
cover to latch into the retaining clips. Refer to Section 3.8.
(Optional)
(Optional)
4. Unplug the mains connector and release the cable from strain relief.
5. Unscrew the L N & E connections & remove wires from connector.
6. Remove the mains cable by pulling back through the grommet .
7. Route the replacement through the grommet and re-fit in reverse order.
8. Close the installer wiring cover ensuring that it is located correctly and that the
cable is retained into the strain relief as shown.
9. Swing the control box back up into the operating position and re-fit the front
panel ensuring a good seal is made.
NOTE. When making the mains electrical connections to the boiler it is important
that the wires are prepared in such a way that the earth conductor is longer than
the current carrying conductors, such that if the cord anchorage should slip, the
current carrying conductors become taut before the earthing conductor.
Installation and Servicing
4
33
bk
bk
bk
gy
r
g
b
br
g/y
o
p
v
y
r
br
CH SWL
FL
F SWL
3
4
CH L
1
2
L
N
PE
3
2
1
7
6
5
4
3
2
1
w
br
r
bk
r
g/y
b
3
MAINS LIVE
r
MAINS NEUTRAL
br b
1
AUXILIARY LIVE
X1
2
5
DHW LIVE
CH LIVE
3 2 1
r
r
b
g/y
2
3
PUMP LIVE
g/y
Chassis
Earth
g/y bk
1
IONISATION
PE
IGNITION
ELECTRODE
g/y bk
SPARK
GENERATOR
b
bk w br
4
IGNITION LIVE
6
X2
1
2
3
1
2
3
3 2 1
2 3 4
1
1
bk
2
2
PUMP
FAN
DETECTION
ELECTRODE
2
1
p
b
DIVERTOR
VALVE
1 2 3 4 5 6
r
r
p bk
p bk y
y
b
r bk
bk or
1 2
FLOW
THERM
1 2
bk
DHW FLOW
TURBINE
3 2 1
WATER
PRESSURE
SWITCH
RETURN
THERM
r
bk
p
4
3
2
1
3
3
bk bk
gy v
r
2
2
v
1
bk
1
2
3
4
5
3
v
2
1
TIMER LINK
SERVICE
CONNECTOR
bk g
r y
X3
3 2 1
GAS VALVE NC
GAS VALVE +
y bk
X4
6 5 4 3 2 1
NO. 2 B2 24V
NO. 5 A2 24V
NO. 6 B1
NO. 4 B3
NO. 3 A3
NO. 1 A1
GAS
VALVE
bk
b
X9
5 4 3 2 1
X8
5 4 3 2 1
X7
8 7 6 5 4 3 2 1
X5
6 5 4 3 2 1
FAN FEEDBACK
FAN PWM
FAN GND
PUMP FEEDBACK
PUMP PWM
PUMP GND
PELV
X6
6 5 4 3 2 1
TURBINE SIGNAL
TURBINE GND
TURBINE 5V
WPS SIGNAL
WPS GND
WPS 5V
230V 50Hz Mains
FLUE +
FLUE RETURN +
RETURN FLOW +
FLOW DHW +
DHW -
KEY
black
grey
red
green
blue
brown
green/yellow
orange
pink
violet
yellow
g/y
b
OWC +
OWC OPENTHERM +
OPENTHERM OPENTHERM 5V
34
CHIP COM BUS 24V
CHIP COM BUS GND
CHIP COM BUS 5V
CHIP COM BUS RX
CHIP COM BUS TX
INSTALLATION
SECTION 2 - INSTALLATION
2.21 WIRING DIAGRAM
Installation and Servicing
2.22 COMMISSIONING AND TESTING
A. Electrical Installation
B. Gas Installation
1. Checks to ensure electrical safety should be carried out by
a competent person.
1. The whole of the gas installation, including the meter,
should be inspected and tested for tightness and purged in
accordance with the recommendations of BS.6891.
In IE refer to IS.813.
2. ALWAYS carry out the preliminary electrical system
checks, i.e. earth continuity, polarity, resistance to earth
and short circuit, using a suitable test meter.
2. Purge air from the gas installation by the approved methods
only.
WARNING. Whilst effecting the required gas tightness test and purging air from the gas installation,
open all windows and doors, extinguish naked lights and DO NOT SMOKE.
GENERAL
Please Note: The combustion for this appliance has
been checked, adjusted and preset at the factory for
operation on the gas type defined on the appliance
data plate. DO NOT adjust the air/gas ratio valve.
Having checked:
- That the boiler has been installed in accordance
with these instructions.
- The integrity of the flue system and the flue seals,
as described in the Flue Installation section.
Proceed to put the boiler into operation as follows:
Gas
Supply
CHECK THE OPERATIONAL (WORKING) GAS
INLET PRESSURE
Set up the boiler to operate at maximum rate by
opening hot tap to maximum flow.
With the boiler operating in the maximum rate
condition check that the operational (working) gas
pressure at the inlet gas pressure test point complies
with the requirements - refer to “Gas Supply” on page
12.
Ensure that this inlet pressure can be obtained with all
other gas appliances in the property working.
Gas Pressure
Test Point
As part of the commissioning process, the combustion of this appliance must be checked
and the Benchmark Checklist completed. A flow chart to assist is provided on page 67.
ATTENTION !
IT IS A CONDITION OF THE MANUFACTURER’S WARRANTY THAT THE
BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED
AND LEFT WITH THE APPLIANCE
Installation and Servicing
35
INSTALLATION
SECTION 2 - INSTALLATION
INSTALLATION
SECTION 2 - INSTALLATION
2.23 INITIAL LIGHTING
Legend
A. Domestic Hot Water Temperature Knob
B. Central Heating Temperature Knob
C. Mode Knob
D. Boiler Status Display
E. Burner ‘on’ Indicator
F. Central Heating Economy Setting
G. CH Flow Isolating Valve
H. Gas Inlet Pressure Test Point
I. Gas Service Cock
J. DHW Inlet Valve
K. CH Return Isolating Valve
L. DHW Outlet
M. Filling Loop Valve
N. Pressure Gauge
P. Restart Button
Q. Installer Function Button
e
ºC
MIN
MAX
MIN
BOILER
OFF
MAX
MODE
RESTART
N
A
D
Q
CH Flow
Note.
It is important the burner is not operated before the system is fully
vented of air. If it is necessary to operate the appliance pump to
assist venting of the air this must be done with the gas service cock
turned off.
E
B F
C
DHW
Outlet
G
1. Check that the system has been filled and that the boiler is not
airlocked. Ensure the automatic air vent cap is open.
P
Gas
Supply
DHW
Inlet
J
L
CH
Return
K
I
H
2. Refit the boiler front panel. Refer to Section 3.2.
3. Check that the drain cock is closed and that the CH and DHW
isolating valves (G,K & J) are OPEN.
4. Check that the electrical supply is OFF.
5. Check that the boiler mode knob (C) is OFF.
6. Check that the gas service cock (I) is OPEN.
Filling
Loop
M
For additional gas supply information refer to “Gas Supply”
on page 12.
7. Slacken the screw in the inlet pressure test point (H) and connect 13.Turn off the DHW tap.
a gas pressure gauge via a flexible tube.
14.Remove gas pressure guage, tighten inlet pressure test
point and check for gas tightness.
8. Switch the electricity supply ON and check all external controls are
calling for heat.
CENTRAL HEATING
9. Set the CH temp control (B) to max and turn the mode knob (C) to
’. The boiler control should now go through its ignition sequence
‘
until the burner is established.
10.If the boiler does not light then after 5 attempts the boiler will lock
out and display fault code L 2.
Restart the boiler (Refer to Section 2.25). The boiler will repeat its
ignition sequence. If restart occurs 5 times within 15 minutes then
LC will be shown.
When the burner is established the ‘ ’ will be shown on the display
with the ‘ ’ indicating central heating operation and the current flow
temperature shown in the 2 digit display.
DOMESTIC HOT WATER
11.With the boiler firing, set the DHW Temp Knob (A) to maximum
and fully open a DHW tap.
The boiler should continue to run and the display should change
from showing ‘ ’ to ‘ ’
12.Ensure that with the boiler operating the dynamic gas pressure is
able to obtain maximum output. Refer to Table 2.
IMPORTANT
The gas input to the burner is regulated by the gas valve
according to the air flow produced by the fan. It is NOT useradjustable. Any interference to sealed settings on the gas valve
will adversely affect operation and render our warranty void.
36
THE DISPLAY
The user control has one display to inform the user about
the status of the boiler. The LCD Display shows the status
of the flame. If no flame is detected the flame symbol
will not be visible. When the flame is detected the flame
symbol will be visible permanently.
Below is a list with display function in normal operation.
0 0 Standby, no demand for heat present.
Boiler is active for central heating.
Boiler is active for domestic hot water.
Boiler is in lockout for a specific error. Display will
show a number after the “ ” to indicate which error is
detected.
F Boiler has a fault for a specific error. Display will
show a number after the “
detected.
” to indicate which error is
Note: Boiler frost protection - boiler operates if the
ambient temperature is below 5ºC until it reaches 19ºC.
Note. The boiler incorporates a fan overrun cycle which
MUST NOT be prematurely interrupted by isolation of the
mains electricity supply.
Installation and Servicing
2.24 GENERAL CHECKS
Make the following checks for correct operation in:
WATER CIRCULATION SYSTEM
1. Fully open all DHW taps in turn and ensure that water flows
freely from them.
The display should show
1. With the system COLD, check that the initial pressure is
correct to the system design requirements.
‘ ’ then
3. With the system still hot, turn off the gas, water and
electricity supplies to the boiler and drain down to complete
the flushing process.
‘ ’ ‘ ’ when the burner lights
2. Close all taps except the furthest one from the boiler and check
that the boiler is firing at maximum rate.
Note: A flushing solution should be used during the flushing
procedure. Flushing solutions: Fernox Superfloc,
Sentinel X300 (new systems) or X400 (existing
systems). Refer to Section 1.19.
This is factory set to give a DHW temperature rise of
approximately 35oC at the flow rate stated on page 10 under
“operation”.
4. Refill and vent the system, add inhibitor (refer to section
1.19), clear all air locks and again check for water
soundness.
3. Reduce the DHW draw-off rate to about 3 l/min (0.7gpm) and
check that the boiler modulates to deliver DHW at approximately
65oC.
5. Reset the system initial pressure to the design
requirement.
4. Close the DHW tap and check that the main burner extinguishes.
The pump should overrun for 60 seconds.
6. Balance the system. Refer to Section 1.18.
When the pump stops the display sequence should read:
7. Check the condensate drain for leaks and check that it is
discharging correctly.
Note. On systems in excess of 2 bar inlet pressure a water
pressure governor may be required to prevent water noise.
CENTRAL HEATING (CH)
& DOMESTIC HOT WATER (DHW) MODE.
8. Finally, set the controls to the User’s requirements.
Note: The pump will operate briefly as a self-check once every
24 hours in the absence of any system demand.
WATER TEMPERATURES
Temperatures can be selected using the CH and DHW thermostats.
1. Ensure that the CH external controls are calling for heat.
The display should show:
‘ ’‘ ’
2. Fully open a DHW tap and check that hot water is delivered.
The display should show
‘ ’ ‘ ’
3. Gas Rate
Check the boiler gas rate when the boiler is at full DHW
output.
Check at the gas meter, with no other appliance in use.
Refer to Tables 2 & 3 for gas rates.
For pre-pressurised systems, this should be 1.0 bar.
2. With the system HOT, examine all water connections
for soundness. The system pressure will increase with
temperature rise but should not exceed 2.5 bar.
Knob Setting
CH Flow Temp
DHW Outlet Temp
o
o
Max
80
65
Min
30
40
C
C
Due to system variations and seasonal temperature
fluctuations DHW flow rates/temperature rise will vary, requiring
adjustment at the draw off tap : the lower the rate the higher the
temperature, and vice versa.
4. Close the DHW tap.
5. Set the central heating external controls to OFF. The burner
should go off and the pump continue to run for two minutes.
The display should read:
6. Check the correct operation of the timer (if fitted) and all
other system controls. Operate each control separately and
check that the main burner responds. Installation and Servicing
37
INSTALLATION
SECTION 2 - INSTALLATION
INSTALLATION
SECTION 2 - INSTALLATION
2.25 RESTART PROCEDURE
Legend
A. Domestic Hot Water Temperature Knob
B. Central Heating Temperature Knob
C. Mode Knob
D. Boiler status Display
E. Burner ‘on’ Indicator
F. Restart Button
G. Pressure Gauge
H. Installer Function Button
To restart the boiler, press the RESTART button (F).
e
ºC
MIN
MAX
MIN
MAX
MODE
RESTART
G
A
D
H
F
BOILER
OFF
E
B
C
2.26 ACCESSING THE INSTALLER MODE
To access Installer Mode press the “RESTART” and “FUNCTION”
buttons together for more than 5s.
1. The last 3 faults will be shown
See Frame 4.1 for Fault Code descriptions
2. “SL” will be shown
To run the burner at minimum rate press “RESTART”, otherwise
press the “FUNCTION” button.
5. “dU” will be shown
To move the diverter valve to mid-position for replacement press
“RESTART”, otherwise press the “FUNCTION” button.
3. “SH” will be shown
To run the burner at maximum rate press “RESTART”, otherwise
press the “FUNCTION” button.
6. “P1” will be shown
To set the minimum CH pump speed to 100% press “RESTART”,
otherwise press the “FUNCTION” button.
4. “VF” will be shown
To activate the venting function press “RESTART”, otherwise press
the “FUNCTION” button.
7. “P7” will be shown
To set the minimum CH pump speed to 70% (default) press
“RESTART”, otherwise press the “FUNCTION” button to Exit.
The venting function runs for 5 minutes before automatically
returning to normal operation
The diverter valve moves between CH and DHW every 30s
The Pump alternates between being on for 50s and then off for 10s
2.27 HANDING OVER
After completing the installation and commissioning of the system the installer should hand over to the householder by
the following actions:
1. Hand the User Instructions to the householder and
explain his/her responsibilities under the relevant national
regulations.
2. Explain and demonstrate the lighting and shutting down
procedures.
3. The operation of the boiler and the use and adjustment of all
system controls should be fully explained to the householder,
to ensure the greatest possible fuel economy consistent with
the household requirements of both heating and hot water
consumption.
Advise the User of the precautions necessary to prevent
damage to the system and to the building, in the event of the
system remaining inoperative during frosty conditions.
4. Explain the function and the use of the boiler heating and
domestic hot water controls.
Explain that due to system variations and seasonal
temperature fluctuations DHW flow rates/temperature
rise will vary, requiring adjustment at the draw off tap. It
is therefore necessary to draw the user’s attention to the
section in the Users Instructions titled “Control of Water
Temperature” and the following statement:
“Additionally, the temperature can be controlled by the
user via the draw-off tap: the lower the rate the higher
the temperature, and vice versa”.
6. Explain and demonstrate the function of timers and
temperature controls, radiator valves etc., for the economic
use of the system.
7. If a timer is fitted draw attention to the timer Users
Instructions and hand them to the householder.
8. Loss of system water pressure
Explain that the dial on the control panel front indicates
the central heating system pressure and that if the normal
COLD pressure of the system is seen to decrease over a
period of time then a water leak is indicated. Explain the repressurising procedure and if unable to re-pressurise or if the
pressure continues to drop a registered local heating installer
should be consulted. Refer to Section 2.16.
9. Explain boiler restart procedure. Refer to Section 2.26.
10.After installation and commissioning please complete
the
Commissioning Checklist before
handover to the customer. For IE, its is necessary to
complete a “Declaration of Conformity” to indicate compliance
to I.S. 813:2002.
IMPORTANT
11.A comprehensive service should be carried out ANNUALLY.
Stress the importance of regular servicing by a Gas Safe
Registered Engineer. In IE servicing work must be carried out
5. Explain the function of the boiler fault mode.
by a Registered Gas Installer (RGII).
Emphasise that if a fault is indicated refer to “Fault Codes” in
12.Inform the householder of the guarantee/registration found
the User Guide.
within the envelope pack and the requirement to register it to
receive the full benefit of the warranty.
38
Installation and Servicing
SECTION 3 - SERVICING
3.1 SERVICING SCHEDULE
For the very latest copy of literature for specification & maintenance practices, visit our website www.idealboilers.com, where you
will be able to download the relevant information.
WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity
supply to the appliance before servicing.
Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927.
To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and
serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out
at least annually.
It is the law that any service work must be carried out by a Gas Safe Registered Engineer. In IE service work must be carried out
by a Registered Gas Installer (RGII).
1. Light the boiler and carry out a pre-service check, noting any
operational faults.
2. Check the flue terminal (and terminal guard if fitted) is
undamaged and clear of any obstruction.
3. Check all water and gas joints for signs of leakage. Remake
any suspect joints ensuring a gas tightness check is carried
out if applicable and the water system is correctly refilled,
vented and re-pressurised.
CLEANING PROCEDURE
Note. In order to carry out either servicing or replacement of
components the boiler front panel must be removed.
Refer to Section 3.2.
1. Clean the main burner. Refer to Section 3.4.
2. Clean the heat exchanger & condensate trap/siphon. Refer to
Section 3.6.
3. Check the main injector for blockage or damage. Refer to
Section 3.3.
4. Check that the flue terminal is unobstructed and that the flue
system is sealed correctly.
ALSO IF THE DHW FLOW RATE IS IN QUESTION :5. Check the DHW filter for blockage. Refer to Section 3.25.
The cleaning procedures are covered more fully in Sections 3.33.7 and MUST be carried out in sequence.
IMPORTANT.
6. After completing the servicing or exchange of components
always test for gas tightness.
7. When work is complete the front panel MUST be correctly
refitted, ensuring that a good seal is made.
GENERAL
Please Note: During Servicing, and after any
maintenance or change of part of the combustion
circuit, the following must be checked:
- The integrity of the flue system and the flue seals.
- The integrity of the boiler combustion circuit and
the relevant seals.
- The operational (working) gas inlet pressure at
maximum rate.
- The gas rate.
- The combustion performance.
SERVICING
INSPECTION
COMPETENCE TO CARRY OUT THE CHECK
OF COMBUSTION PERFORMANCE
Please Note:
BS 6798:2009 Specification for
installation and maintenance of gas-fired boilers of
rated input not exceeding 70kW net advises that:
- The person carrying out a combustion
measurement should have been assessed as
competent in the use of a flue gas analyser and the
interpretation of the results.
- The flue gas analyser used should be one meeting
the requirements of BS7927 or BS-EN50379-3
and be calibrated in accordance with the analyser
manufacturer’s requirements, and
- Competence can be demonstrated by satisfactory
completion of the CPA1 ACS assessment, which
covers the use of electronic portable combustion
gas analysers in accordance with BS7967, Parts 1
to 4.
Do NOT OPERATE the boiler if the front panel is
not fitted.
8. If, for any reason, the condensate trap/siphon has been
removed ensure the trap is refilled with water before
reassembling.
9. Check the gas consumption.
Flue Sampling Point
Air Sample
Point
10.Check combustion by connecting the flue gas analyser to the
flue gas sampling point as shown in the diagram and measure
CO & CO2.
If the CO/CO2 ratio is greater than 0.004 AND the integrity of
the complete flue system and combustion circuit seals have
been verified and the inlet gas pressure (and gas rate) have
been verified, then contact Ideal.
Ensure all caps and seals
are re-fitted after use
11.Complete the service section in the Benchmark
Commissioning Checklist.
Installation and Servicing
39
SECTION 3 - SERVICING
3.2 BOILER FRONT PANEL REMOVAL / REPLACEMENT
REMOVAL
REPLACEMENT
1. Loosen the two screws retaining the front panel.
3. Hook the panel onto the top retaining clips.
2. Pull the two clips down to disengage and pull panel forward
and upward and remove.
4. Push the panel until the 2 bottom spring clips engage
ensuring the 4 control knobs line up with the holes in the
front panel.
5. Re-tighten the two retaining screws.
3
2
1
view from top of boiler
SERVICING
view from bottom of boiler
3.3 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING
1. Disconnect the electrical leads from the
fan.
1
3
2. Remove the clip from the gas control
valve outlet and ease the pipe upwards.
Rotate and then ease down to remove.
3. Remove the extended nut on the fan
mounting bracket.
4. Lift off fan and venturi assembly.
5. Undo the two M4 screws and release the
nozzle assembly.
6. Inspect the injector for blockage or
damage.
5
7. Inspect fan outlet sealing gasket and
replace if necessary.
Injector
2
40
Installation and Servicing
SECTION 3 - SERVICING
3.4 BURNER REMOVAL AND CLEANING
1. Ensure the sump is fully drained
3
2. Undo the two screws and remove the sump cover retaining the lower
flue manifold.
2
2
3. Lift the manifold to clear the bottom sealing gasket and remove
manifold.
4. Remove the 2 burner front fixing screws and loosen the 2 rear
extended nuts by at least ten turns.
5. Lift off the burner from the combustion chamber. To facilitate the
removal angle the burner as shown.
4
IMPORTANT
The burner head is a ceramic plaque construction. Care must be
taken to ensure that the burner is not placed down upon
its face as this may cause damage to the ceramic.
6. Brush off any deposits that may be on the ceramic with a
SOFT brush.
7. Inspect the sealing gasket around the burner for any
signs of damage. Replace as necessary.
SERVICING
5
4
3.5 CLEANING THE CONDENSATE TRAP/SIPHON
1. Pull off the rubber pipe at the sump drain.
4. Clean siphon with water.
2. Disconnect the condensate drain pipe.
5. Re-assemble in reverse order.
3. Turn the siphon clockwise to disengage and lift to
remove.
B When re-assembling ensure the trap is full of water.
Note. Keep siphon upright when removing
1
Filling Loop
CH
Flow
Installation and Servicing
DHW Condensate Gas DHW
Outlet
Drain
Inlet
CH
Return
CH Circuit
Drain
41
SECTION 3 - SERVICING
3.6 CLEANING THE HEAT EXCHANGER
1
Note: Ensure the condensate trap/siphon
is fully drained before cleaning. Refer to
Section 3.18.
Ignition Electrode
Flame Detection
1. Remove ignition and flame detection
electrodes. Refer to Section 3.13 & 3.14.
2. It is advisable to replace the sump cover
prior to the water flush process.
3. Thoroughly flush the heat exchanger
by pouring water into the top of the
combustion chamber ensuring the full top
area is covered.
4. Remove the sump cover and clean loose
deposits from the sump.
5. Inspect the ignition and detection
electrodes. Ensure that they are clean
and in good condition - replace if
necessary.
3
SERVICING
6. Re-fit the ignition and flame detection
electrodes, ensuring that the earth tab is
fitted to the ignition electrode.
7. Check that the ignition and detection gaps
are correct. Refer to Sections 3.13 & 3.14.
3.7REASSEMBLY
Reassemble the boiler in the following order:
1. Ensure that the condensate trap/siphon is full of water.
6. Refit the sump cover.
2. Refit the burner ensuring the sealing gasket is correctly
positioned and free from damage (tighten the 4 fixing screws
in the sequence shown below).
7. Swing the control box back into its working position and
secure.
IMPORTANT. Ensure that the boiler front panel is
correctly fitted and that a good seal is made.
3. Refit the fan / venturi assembly ensuring the retaining tabs
are correctly positioned and the sealing gasket is correctly
positioned and free from damage. Refit the gas outlet pipe
and clip.
8. Refit the boiler front panel.
4. Reconnect the fan electrical leads.
10.Reconnect the electrical supply.
9. Turn on the gas supply at the gas service cock.
5. Remove the sump cover and refit the lower flue manifold as
shown.
4
2
5
1
42
3
Installation and Servicing
SECTION 3 - SERVICING
3.8 REPLACEMENT OF COMPONENTS
GENERAL
IMPORTANT.
When work is complete, the front panel must be correctly
refitted - ensuring that a good seal is made.
When replacing ANY component
1. Isolate the electricity supply.
2. Turn off the gas supply.
3. Remove the boiler front panel. Refer to Section 3.2.
4. Swing the control box down into its servicing position.
Notes.
1. In order to assist fault finding, the control panel has
an LCD diagnostic display. The key to boiler fault
conditions is shown in Section 4.
2. In order to replace components in Sections 3.22-3.30 it
is necessary to drain the boiler. Refer to Section 3.21.
After replacing ANY component check operation of the boiler,
including gas soundness, gas rate and combustion test.
THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED
3.9 FAN REPLACEMENT
2. Disconnect the electrical leads from
the fan.
8
Retaining Tabs
2
SERVICING
1. Refer to Section 3.8.
3. Remove the clip from the gas control
valve outlet.
4. Remove the extended nut retaining
the fan mounting bracket.
5. Lift and remove the fan and venturi
assembly.
6. Remove the screw and twist venturi
anti-clockwise to remove venturi
assembly, noting the orientation of
the venturi in relation to the fan body.
4
7. Transfer the venturi assembly to
the new fan, replacing the ‘o’ ring if
evidence of damage or deterioration
is visible.
6
8. Fit the new fan / venturi assembly
ensuring the retaining tabs are
correctly positioned and the fan
outlet sealing gasket is correctly
positioned and free from damage.
Refit the extended nut.
9. Reassemble the boiler in reverse
order, taking care not to overtighten
the screw on the fan mounting
bracket and ensure all gas ‘o’ rings
are in place
10.Check that the boiler operates in
both DHW and CH Modes.
Installation and Servicing
3
43
SECTION 3 - SERVICING
3.10 BURNER INJECTOR REPLACEMENT
2
1. Refer to Section 3.8.
2. Disconnect the electrical leads from the fan.
3. Remove the clip from the gas valve to
venturi pipe and ease the pipe upwards,
rotate and ease down to remove.
4
4. Loosen the screw retaining the fan
mounting bracket.
5. Lift and remove the fan and venturi
assembly.
6. Remove the 2 injector housing screws.
6
7. Withdraw the injector housing.
Injector
8. Fit the new injector housing complete with
injector.
9. Reassemble in reverse order, ensuring
that the new gas seal supplied is located
correctly in the injector housing.
SERVICING
10.Check that the boiler operates in both DHW
& CH modes.
3
3.11 BURNER REPLACEMENT
1. See Section 3.8.
2. Refer to Section 3.4.
3. Undo the two screws and remove the sump cover.
4
3
3
4. Lift the manifold to clear the bottom sealing gasket and remove
manifold.
5. Remove the 2 front fixing screws and loosen the 2 rear
extended nuts.
6. Lift off the burner from the combustion chamber. To facilitate
the removal angle the burner as shown.
7. Fit the new burner, replacing any damaged or deteriorating
sealing gasket.
8. Reassemble in reverse order.
9. Check that the boiler operates in both DHW & CH modes.
5
6
5
44
Installation and Servicing
SECTION 3 - SERVICING
3.12 RETURN THERMISTOR REPLACEMENT
1. Refer to Section 3.8.
2. Unclip the return thermistor from the return pipe and withdraw it from the
boiler.
3. Disconnect the electrical lead from the thermistor.
4. Reconnect the electrical lead to the new thermistor and reassemble in
reverse order, ensuring that the thermistor is securely fitted to the pipe on the
thermistor locator tab as shown.
5. Check that the boiler operates in both DHW & CH Mode.
4
Thermistor Locator Tab
(with thermistor fitted)
SERVICING
2
3.13 IGNITION ELECTRODE REPLACEMENT
1. Refer to Section 3.8.
2. Remove the burner. Refer to Section
3.11.
3. Unplug the ignition lead from the
electrode.
Ignition Electrode
4. Remove the earth lead from the ignition
electrode.
5. Remove the 2 screws holding the
ignition electrode to the combustion
chamber.
6. Remove the electrode.
7. Fit the new ignition electrode, using
the new gasket supplied. Check
dimensions as shown.
8. Reassemble in reverse order.
9. Check the operation of the boiler. Refer
to Section 2.23 & 2.24.
Spark Gap
3.5mm
Installation and Servicing
dge
ht e
aig
Str
m
3m
45
SECTION 3 - SERVICING
3.14 FLAME DETECTION ELECTRODE REPLACEMENT
1. Refer to Section 3.8.
2. Remove the burner. Refer to
Section 3.4.
Flame Detection Electrode
3. Unplug the flame detection lead
from the electrode.
4. Remove the 2 screws retaining
the detection electrode.
5. Remove the electrode.
6. Fit the new flame detection
electrode, using the new gasket
supplied.
7. Reassemble in reverse order.
ge
ed
ht
g
i
a
Str
SERVICING
8. Check that the boiler operates in
both DHW & CH modes.
m
.5m
12
3.15 SPARK GENERATOR REPLACEMENT
3.16 GAS CONTROL VALVE REPLACEMENT
1. Refer to Section 3.8
2. Disconnect the leads from the spark generator.
3. Gently push down the generator to release the top clip
from the gas valve mounting bracket.
4. Lift the spark generator up and out of the bottom
retaining moulding.
5. Fit the new spark generator and re-assemble in reverse
order ensuring that the the earth lead is replaced.
6. Check that the boiler operates in both DHW & CH
modes.
1.
2.
3.
4.
5.
Refer to Section 3.8.
Unplug the electrical lead connection from the gas control valve.
Remove the outlet gas valve clip and slide the pipe upwards.
Undo the gas inlet pipe union at the inlet to the gas valve.
Undo the single screw fixing the gas valve to the mounting
bracket and withdraw the valve forwards.
6. Fit the new gas control valve ensuring that the ‘o’ ring and
sealing washer are in place and reconnect gas and electrical
connections.
7. Check that the boiler operates in both DHW & CH modes.
3
Spark Generator
2
4
46
5
Installation and Servicing
SECTION 3 - SERVICING
3.17 DIVERTER VALVE ACTUATOR REPLACEMENT
Refer to Section 3.8.
To remove the motor:
1. Remove the condensate trap/siphon. Refer to
Section 3.5.
2. Place a flat bladed screwdriver in the actuator
slot provided and ease out the actuator.
3
3. Before replacing the diverter valve actuator
proceed as follows:
a. Ensure that the switched live to the boiler
is off and that all DHW taps are shut.
b. Press and hold the “RESTART” and
“FUNCTION” buttons together for more
than 5s, the last 3 faults will then be
shown in sequence before “SL” is shown
c. Press the “FUNCTION” button, “SH” will
be shown
d. Press the “FUNCTION” button, “UF” will
be shown
e. Press the “FUNCTION” button, “DU” will
be shown
f.
4. Fit the new motor ensuring the arm is correctly
engaged in the metal fork and re-assemble in
reverse order ensuring the condensate trap/
siphon is refilled with water.
5. Check the operation of the boiler.
SERVICING
Press the “FUNCTION” button and the
diverter valve will move to the mid-position
6
Note. All spares will be delivered in mid-position
therefore ignore point 3 and proceed to point 4.
3.18 CONDENSATE TRAP/SIPHON REPLACEMENT
1. Refer to Section 3.8.
2. Pull off the rubber pipe at the sump drain.
3. Disconnect the condensate drain pipe.
4. Turn the siphon clockwise to disengage and lift
to remove.
Note. Keep siphon upright when removing.
5. Clean siphon with water or replaced if
damaged.
6. Re-assemble in reverse order.
7. When re-assembling ensure the trap is full of
water.
3
8. Check that the boiler operates in both DHW
and CH modes.
2
Siphon
Installation and Servicing
47
SECTION 3 - SERVICING
3.19 PCB REPLACEMENT
Note. Fit the earth strap provided with the PCB to your wrist and
secure to a suitable earth on the boiler chassis.
1. Refer to Section 3.8.
3
2. Ensure the control knobs are in the 12 o clock position.
3. Carefully release the six retaining clips and remove control
box cover.
4. Unplug all lead connections to the PCB, also where
applicable, push the small plastic clip with an electrical
screwdriver to facilitate plug removal.
5. Spring out the four side retaining clips and pull the PCB
upwards to clear the 4 corner retaining posts.
6. Take the new PCB.
7. Re-connect all plug connections.
5
SERVICING
8. Reassemble in reverse order.
9. a. Turn power on, display shows uP.
Rotate all three dials fully anticlockwise.
b.Press RESTART, display shows oF
c. Turn power off
d. Turn power on, display shows F9
e. Using central heating knob, rotate
clockwise or anticlockwise to show
“C” for Combi, then press RESTART
button.
f. Using central heating knob, rotate
clockwise or anticlockwise to show
“n” for Natural Gas, then press
restart button.
g. Using central heating knob rotate
clockwise or anticlockwise to show boiler size, select
correct 24, 30 or 35, then press RESTART button.
h. Display shows “C”, “n”, Boiler size, internal number.
j. Press restart. New PCB is now programmed.
4
Plastic clip
4
IMPORTANT.IT IS CRITICAL FOR SAFE
OPERATION THAT THE CORRECT BOILER SIZE
AND FUEL TYPE IS ENTERED INTO THE BOILER.
10.Check that the boiler operates in both DHW and CH modes.
3.20 DHW FLOW TURBINE SENSOR REPLACEMENT
5
4
3
1. Refer to Section 3.8.
5. Use the clip to ease the turbine sensor from its housing.
2. Drain the DHW system. Refer to Section 3.21.
6. Re-assemble in reverse order.
3. Pull off the electrical connection.
7. Check that the boiler operates in both DHW & CH modes.
4. Using a suitable tool, lift and remove the retaining clip.
48
Installation and Servicing
SECTION 3 - SERVICING
3.21 DRAINING THE BOILER
Filling Loop
CENTRAL HEATING CIRCUIT
1. Refer to Section 3.8.
2. Close all the CH water isolating valves on the boiler inlet.
3. To drain the primary heat exchanger circuit: Open the drain
valve and attach a length of hose to the CH drain point.
4. After replacing any component on the boiler, remove the
hose, close the drain valve and open all system isolating
valves (re-pressurise as appropriate by re-connecting the
filling loop, refer to Section 2.16) before proceeding to check
operation of the boiler.
5. Disconnect filling loop. Refer to Section 2.16.
6. Check that the boiler operates in both DHW & CH modes.
CH
Flow
DOMESTIC HOT WATER CIRCUIT
DHW Condensate Gas DHW
Outlet
Drain
Inlet
CH
Return
CH Circuit
Drain
1. Refer to Section 3.8.
2. Close all the DHW water isolating valves on the boiler inlet.
3. To drain the domestic hot water circuit: As there is no direct drain for the domestic hot water circuit, depending on the location
of the boiler, opening the lowest hot water tap may drain this circuit. However it must be noted that some residual water will be
experienced during replacement of components.
4. After replacing any component on the boiler, close tap, close the drain valve and open all system isolating valves (re-pressurise
as appropriate by re-connecting the filling loop, refer to Section 2.16) before proceeding to check operation of the boiler.
5. Disconnect filling loop. Refer to Section 2.16.
SERVICING
6. Check that the boiler operates in both DHW & CH modes.
3.22 PRESSURE GAUGE REPLACEMENT
1. Refer to Section 3.8.
2. Drain the heating system. Refer to Section
3.21.
3. Remove the boiler front (See Section 3.8),
lower the control panel and remove the
control box cover.
4. Ensuring there is no pressure in the system
unclip the C clip from the flow manifold port
and remove the capillary connection together
with ‘o’ ring.
4
5. Releasing the two retaining clips on the
pressure gauge ease the pressure gauge
through the front of the control panel.
6. Fit the new pressure gauge from the front of
the control panel ensuring correct orientation.
Locate push fit connection into port ensuring
‘o’ ring in place and secure with the C clip.
7. Refill the boiler. Refer to Section 2.16.
8. Check that the boiler operates in both DHW &
CH modes.
5
Installation and Servicing
49
SECTION 3 - SERVICING
3.23 SAFETY RELIEF VALVE REPLACEMENT
1. Refer to Section 3.8.
3
4
2. Drain the boiler. Refer to Section 3.21.
3. Remove the clip on return thermistor. Refer to Section 3.12.
4. Pull out and remove the clip (positioned behind the safety
valve) retaining the safety valve.
5. Undo the safety valve pipe compression fitting positioned
outside the boiler casing.
6. Lift out the safety valve/pipe assembly.
7. Remove the safety valve pipe and transfer to the new safety
valve.
8. Reassemble in reverse order ensuring the retaining clip is
correctly fitted, the pipe compression fitting retightened and
return thermistor is re-clipped.
9. Refill the boiler. Check that the boiler operates in both DHW
& CH modes.
SERVICING
3.24 PUMP AUTOMATIC AIR VENT REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Dust Cap
5
Refer to Section 3.8.
Drain the boiler. Refer to Section 3.21.
Remove the expansion vessel. Refer to Section 3.32.
Firstly, increase access area by disconnecting the 22mm pipe connection at
top of pump manifold and bottom of heat exchanger and remove pipe. Refer
to Section 3.26.
The automatic air vent head is retained in the pump body with a bayonet
connection. The air vent head and float assembly is removed by turning the
head anti-clockwise (viewed from above) and pulling upwards.
Reassemble in reverse order. Ensure the air vent head ‘o’ ring seal is fitted.
Ensure the air vent cap is loose.
Refill the boiler. Refer to Section 2.16. Check for leaks around the new air vent
joint.
Check that the boiler operates in both DHW & CH modes.
3.25 DHW FILTER & DHW FLOW REGULATOR CLEANING/REPLACEMENT
1. Refer to Section 3.8.
4
2. Drain the DHW system. Refer to Section
3.21.
3. Turn the housing anti clockwise and pull
forward to remove the cartridge.
4. Using a pair of pliers, pull out the plastic
filter/flow regulator.
5. Clean or replace filter as necessary.
6. Reassemble in reverse order.
7. Refill the boiler.
3
8. Check that the boiler operates in both
DHW & CH modes.
50
Installation and Servicing
SECTION 3 - SERVICING
3.26 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT
To remove the valve body assembly:
16. Twist and remove the DHW manifold.
1. Refer to Section 3.8.
17. Remove the two diverter valve body fixing screws and
withdraw the diverter valve body assembly.
2. Drain the boiler. Refer to Section 3.21.
3. Remove the condensate trap/siphon. Refer to Section 3.18.
4. Remove the electrical plug. Refer to Section 3.17.
5. Place a flat bladed screwdriver in the diverter
valve motor body slot provided and ease out the
motor. Refer to Section 3.17.
18. Fit the new diverter valve body assembly and replace the
two fixing screws.
19. Refit the DHW manifold, fit the assembly back to the boiler
and reassemble in reverse order.
20. Refill the boiler. Check that the boiler operates in both DHW
& CH modes.
6. Remove the return thermistor electrical connection. Refer to
Section 3.12.
7. Remove the pump electrical connections. Refer to Section
3.28 no. 3.
18
12
17
8. Remove DHW Turbine electrical connection. Refer to
Section 3.20 no. 3.
11
9. Remove the DHW plate heat exchanger (note orientation).
Refer to Section 3.27.
10. Undo the safety valve pipe compression fitting. See No.5
Section 3.23.
11.Loosen the nut above pump and rotate the pipe.
12.If required remove expansion vessel connection hose.
Refer to Section 3.32.
14
13. Remove the DHW inlet and CH return connection situated
beneath the boiler.
14. Remove the four torx head screws fixing the return
manifold to the boiler sheet steel base.
13
15. Lift the manifold assembly and remove from boiler.
3.27 DHW PLATE HEAT EXCH. REPLACEMENT
1.
2.
3.
4.
5.
Refer to Section 3.8.
Drain the boiler. Refer to Section 3.21.
Remove condensate trap/siphon. Refer to Section 3.18.
Remove the diverter valve actuator. Refer to Section 3.17.
Remove the 2 allen screws securing the plate heat exchanger
to the composite housings.
6. Manoeuvre the plate heat exchanger out of the top LH or
centre of the controls area. Be aware of any water spillage.
7. Fit the new plate heat exchanger, using the new o-rings
supplied.
Note. Ensure that the depressions are on the bottom prior to
fitting.
8. Reassemble in reverse order.
9. Refill the boiler. Refer to Section 2.16.
10.Check that the boiler operates in both DHW & CH modes.
5
Installation and Servicing
3.28 PUMP HEAD REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Refer to Section 3.8.
Drain the boiler. Refer to Section 3.21.
Disconnect the two electrical leads from the pump.
Remove the 4 allen screws retaining the pump head.
Remove the pump head.
Fit the new pump head.
Reassemble in reverse order.
Refill the boiler. Refer to Section 2.16.
Check that the boiler operates in both DHW & CH
modes.
3
4
51
SERVICING
16
SECTION 3 - SERVICING
3.29 CH WATER PRESSURE SWITCH REPLACEMENT
1. Refer to Section 3.8.
2. Drain the boiler. Refer to Section 3.21.
3. Pull off the two electrical connections.
4. Using a suitable tool, pull out the metal retaining
clip.
5. Carefully withdraw the pressure switch.
6. Fit the new pressure switch and re-assemble in
reverse order.
7. Refill the boiler. Refer to Section 2.16.
4
8. Check that the boiler operates in both DHW & CH
modes.
5
SERVICING
3
3.30 FLOW THERMISTOR REPLACEMENT
1. Refer to Sections 3.8.
2. Drain down the boiler. Refer to Sections 3.21.
3. Unplug the electrical lead.
4. Unscrew the thermistor (to facilitate removal a
13mm socket spanner should be used).
5. Fit the new thermistor using the sealing
washer provided.
3
6. Reassemble in the reverse order.
7. Refill the boiler. Refer to Section 2.16.
4
8. Check that the boiler operates in both DHW &
CH modes.
52
Installation and Servicing
SECTION 3 - SERVICING
3.31 HEAT ENGINE REPLACEMENT
Refer also to Section 2.1 - ‘Boiler Exploded View’
IMPORTANT
Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag.
1. Refer to Section 3.8.
3.18, no. 2.
2. Drain the boiler. Refer to Section 3.21.
14.Remove the two heat exchanger fixing screws.
3. Remove the fan / venturi assembly and place on one
side. Refer to Section 3.3.
15.Remove the Heat exchanger, slide out of location bracket.
4. Remove the burner and place on one side. Refer to Section
3.4.
5. Remove the ignition and detection electrodes. Refer to
Section 3.13 & 3.14.
6. Remove the spark generator. Refer to Section 3.15.
7. Remove the gas valve. Refer to Section 3.16.
8. Remove the expansion vessel. Refer to Section 3.32.
9. Remove the return thermistor. Refer to Sections 3.12.
10.Remove the 2 M5 screws retaining the gas valve
mounting bracket and transfer bracket to the new heat
exchanger.
16. If replacement sump required: Rotate heat exchanger
assembly 180º. Place new sump onto heat exchanger,
ensuring correct orientation and seal is in place. Then gently
apply pressure to the base of the sump at each tab fixing
point and engage tabs onto the heat exchanger.
17.Reassemble in reverse order, ensuring the heat exchanger
is located correctly in the LHS retaining bracket. Replace
any new ‘o’ rings supplied with new heat exchanger and
replace gaskets or seals if any sign of damage is evident.
When replacing the spring clips located on the return
pipe connection, ensure clip is oriented to correctly match
connecting pipe diameters.
18.Ensure the trap/siphon is filled with water. Refer to Section 3.18.
11.Undo the pump union nut and remove pipe.
19.Refill the boiler and check for leaks. Refer to Section 2.16.
12.Remove the two retaining pipe clips and remove pipes.
20.Check that the boiler operates in both DHW & CH modes.
Shown as 180º position
9
14
16
12
9
10
11
12
Installation and Servicing
53
SERVICING
13.Remove the condensate rubber pipe. Refer to Section
SECTION 3 - SERVICING
3.32 EXPANSION VESSEL RECHARGING & REPLACEMENT
RECHARGING
Recharge
Point
1. Refer to Section 3.8.
2. Remove the charge point cover.
3. Recharge the tank pressure to 0.75 bar.
4. Re-assemble in reverse order.
8
5. Check that the boiler operates in both DHW &
CH modes.
REPLACEMENT
6. Refer to Section 3.8.
7. Drain the boiler CH circuit. Refer to Section 3.21.
8. Remove the retaining clip on the vessel water
connection pipe and remove the pipe.
9. Support the expansion vessel and unscrew the
2 screws from the securing bracket, located
on the top of the boiler, and remove. (Note the
position of the bracket on the vessel)
9
10.Remove the expansion vessel.
SERVICING
11.Fit the new expansion vessel.
12.Reassemble in reverse order ensuring the seal
is in place.
13.Refill the boiler and check for leaks. Refer to
Section 2.18.
14.Check tht the boiler operates in both DHW &
CH modes.
54
Installation and Servicing
SECTION 4 - FAULT FINDING
‘L1’
GO TO SECTION 4.2 FLOW TEMPERATURE OVERHEAT LOCKOUT
‘L2’
GO TO SECTION 4.3 IGNITION LOCKOUT
‘LC’
5 RESETS WITHIN 15 MINS TURN POWER OFF AND ON
‘L6’
GO TO SECTION 4.4 FALSE FLAME LOCKOUT
‘F1’
GO TO SECTION 4.5 LOW WATER PRESSURE
‘F2 or Fn or Ln’
GO TO SECTION 4.6 FLAME LOSS
‘F3’
GO TO SECTION 4.7 FAN FAULT
‘L4 or F4’
GO TO SECTION 4.8 FLOW THERMISTOR FAULT
‘L5 or F5’
GO TO SECTION 4.9
RETURN THERMISTOR FAULT
‘F6’
GO TO SECTION 4.10
OUTSIDE SENSOR FAULT
‘F7’
LOW MAINS VOLTAGE CONTACT ELECTRICITY PROVIDER
‘F9 or L9 or F8 or L8’
‘FU’
‘dU’
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
4.1 FAULT FINDING CHART MAIN MENU
PCB UNCONFIGURED OR FAULTY
SEE SECTION 3.19
IF FAULT PERSISTS REPLACE PCB
DIFF GREATER THAN 50°C
CHECK ISOLATION VALVES ARE OPEN
CHECK PUMP
CHECK RAD VALVES OPEN
CHECK SYSTEM BLOCKAGES
DIVERTER VALVE IN MID-POSITION FOR SERVICE
ROTATE KNOBS FULLY CLOCKWISE
TURN POWER OFF AND ON
RESTART BOILER
NO CH BUT HW OK
GO TO SECTION 4.11
NO HW BUT CH OK
GO TO SECTION 4.12
NO DISPLAY
GO TO SECTION 4.13
RESTART PROCEDURE: to restart boiler press the restart button.
Installation and Servicing
55
SECTION 4 - FAULT FINDING
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
4.2 ‘L1’ - FLOW TEMPERATURE OVERHEAT LOCKOUT
Is the Boiler and CH System filled with water and all
isolation and radiator valves open?
NO
Fill and vent the system and open all
isolation valves, then restart boiler
YES
Check that the Pump is rotating freely. Is
the Differential now below 20°C?
YES
Is the Flow/Return Differential across the Boiler in
excess of 30°C?
NO
NO
Check the Return Thermistors
(Refer to Section 3.12)
Replace the Pump,
then restart boiler
Check resistance using a suitable multimeter
connected across the thermistor’s terminal pins
At 25 oC expect
9,700 -10,300
Ohms
At 60 C expect
2,400- 2,600
Ohms
At 85 oC expect
1,000- 1,100
Ohms
o
YES
OK, now
restart boiler
RESTART PROCEDURE: to restart boiler press the restart
button.
4.3 ‘L2’ - IGNITION LOCKOUT
If the boiler is restarted does the
boiler ignite for a short time and
then extinguish?
NO
Is the Gas Pressure available at
the Boiler Inlet (>18 mbar)?
NO
Check gas supply and
rectify fault
YES
YES
Is 24Vdc supply available at the
Gas Valve?
Check the detection electrode
and associated harness for:
continuity, visual condition and
position (Refer to Section 3.14).
Check if the condensate pipe is
blocked.
Check flue is installed correctly.
Replace as necessary.
YES
Unplug gas valve.
Is resistance between outside pins
between 4k Ω (± 2)?
NO
NO
Check wiring connection
from gas valve to PCB for
continuity. If the wiring is
OK then replace the PCB
Replace Gas Valve
YES
Check spark generator and
associated harness for: continuity
and visual condition. (Refer
to Section 3.15) Are these
functioning correctly?
Check siphon and condensate
drain pipework for blockage and
rectify if necessary. Boiler now
working OK?
NO
NO
Replace Spark
Generator and harness
as necessary
YES
YES
Check ignition electrode and
associated harness for: continuity,
visual condition and position.
(Refer to Section 3.13) Are these
functioning correctly?
NO
Replace Ignition
Electrode and
associated harness as
necessary
Replace Gas Valve
RESTART PROCEDURE: to restart boiler press the restart button.
56
Installation and Servicing
SECTION 4 - FAULT FINDING
Restart the boiler, does Boiler Work OK?
YES
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
4.4 ‘L6’ - FALSE FLAME LOCKOUT
Check routing and integrity of internal boiler wiring is OK. Check
condition of Flame Sense Electrode and replace if deteriorated.
NO
Separate the flame detection electrode in-line connector. Is there
continuity between the terminal pins connected to the electrode?
YES
Replace Flame Detection Electrode
NO
Check routing and integrity of internal boiler wiring
RESTART PROCEDURE - To restart boiler, press and release RH push button.
4.5 ‘F1’ - LOW WATER PRESSURE
Are the Boiler and CH System filled with water and all isolation and
radiator valves open (check pressure gauge is between 1 to 1.5 bar)?
YES
NO
Fill and vent the system and open all
isolation valves
NO
Re-fit connections
YES
Replace water pressure sensor
Are connections on water pressure sensor secure?
4.6 ‘F2 OR FN OR LN’ - FLAME LOSS
Does the boiler ignite for a short
time and then extinguish?
NO
NO
NO
Is 24Vdc supply available at the
Gas Valve while the flame is on?
NO
YES
YES
Check the detection electrode and
associated harness for: continuity,
visual condition and position
(Refer to Section 3.14). Check if
condensate pipe is blocked. Check
if flue is blocked.
Replace as necessary.
Re-fit correctly or replace
Check spark generator and
associated harness for: continuity
and visual condition. (Refer
to Section 3.15) Are these
functioning correctly?
NO
Check wiring from gas
valve to PCB for continuity.
If the wiring is OK then
replace the PCB
Replace Spark Generator
and Harness as necessary.
YES
Check ignition electrode and
associated harness for: continuity,
visual condition and position.
(Refer to Section 3.13) Are these
functioning correctly?
NO
Replace Ignition
Electrode and
associated harness as
necessary
YES
Check siphon and condensate
drain pipe work for blockage and
rectify if necessary. Boiler now
working OK?
Installation and Servicing
Check gas supply and
rectify fault
YES
YES
Is the top flue manifold seal present
and correctly fitted. ?
Is the Gas Pressure available at
the Boiler Inlet (18 mbar)?
NO
Replace Gas Valve
57
SECTION 4 - FAULT FINDING
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
4.7 ‘F3’ - FAN FAULT
Does the wiring from the Fan to the PCB have
secure connections at both ends and has not
deteriorated? Does the wiring have continuity?
NO
Rectify Wiring &
connections
NO
Replace PCB
YES
Is there 230Vac at the Blue and Brown connections
to the 3 way connection on the Fan?
YES
Replace Fan
4.8 ‘F4 OR L4’ - FLOW THERMISTOR FAULT
NO
Is the wiring securely connected to the Flow Thermistor
(located in the top of the Heat Exchanger?)
Securely connect the wiring to the Water
Flow Thermistor
YES
Disconnect the wiring from the Flow Thermistor
Check the resistance using a suitable multimeter connected
across the Thermistor’s terminal pins.
At 25 oC expect
9,700 -10,300
Ohms
At 60 oC expect
2,400- 2,600
Ohms
At 85 oC expect
1,000- 1,100
Ohms
NO
Fit a new Thermistor
Is the Thermistor value correct?
NO
YES
Is the wiring securely connected to the low voltage 6 way
connector at the front left hand side of the PCB?
YES
Securely connect the wiring to the PCB
Replace PCB
4.9 ‘F5 OR L5’ - RETURN THERMISTOR FAULT
Remove the Return Thermistor from the CH Return
Pipe and disconnect the wires.
Check the resistance using a suitable multimeter
connected across the thermistor’s terminal pins.
At 25 oC expect
9,700 -10,300
Ohms
At 60 oC expect
2,400- 2,600
Ohms
At 85 C expect
1,000- 1,100
Ohms
o
NO
Fit a new Thermistor
Is the Thermistor value correct?
YES
Is there continuity between the PCB and the Thermistor?
NO
Check and replace wiring as necessary
YES
Replace PCB
58
Installation and Servicing
SECTION 4 - FAULT FINDING
NO
Is the wiring securely connected at both the boiler and
Outside Sensor?
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
4.10 ‘F6’ - OUTSIDE SENSOR FAULT
Securely connect the wiring at both the
boiler and Outside Sensor
YES
Disconnect the wires to the outside sensor.
Check the resistance using a suitable multimeter
connected across the Outside Sensor’s terminal pins.
At 0 C
expect
31,000 -35,000
Ohms
At 15 oC expect
15,000 -16,500
Ohms
At 30 C expect
7,700- 8,500
Ohms
o
o
NO
Fit a new Outside Sensor
Is the Outside Sensor value correct?
Securely connect the wiring at the
Terminal Block and the PCB
NO
YES
Is the wiring securely connected between the
incoming terminal block boiler connection of the
Outside Sensor and the PCB?
YES
Replace PCB
4.11 NO CH OPERATION BUT HW WORKS OK
Is the mode knob in the Winter position?
YES
Are the Timer and the Room Thermostat switched on?
YES
Are the Radiator Valves Open?
YES
Is there 230Vac at (A)?
NO
Move the mode knob to the Winter position
NO
Switch the Timer and Room Thermostat On
NO
Open the Radiator Valves
There is no Voltage from the Timer/Room Stat. This
is not boiler fault. Ensure Voltage is supplied to
boiler by rectifying external wiring.
NO
YES
Replace the Diverter Valve Motor
A
Installation and Servicing
59
SECTION 4 - FAULT FINDING
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
4.12 NO HW BUT CH ON
Does the display shows a “Tap symbol” when
a tap is on?
NO
Is hot and cold pipework crossed?
NO
YES
Are the flow rates correct as per Section 1.2.
NO
YES
Is the wiring between the PCB and the diverter NO
valve motor connected?
YES
Check diverter head fully engaged and clip
secured onto waterset.
NO
YES
Is diverter stuck in the CH position?
NO
Adjust flow rates to achieve 35ºC
temp rise and check filter fitted in
turbine is not blocked with debris.
Is the wiring connected
between PCB and DHW
sensor?
NO
YES
Reconnect wiring or
replace wiring harness if
no continuity.
Remove the turbine, and
check for debris in the
turbine & filter. Replace
turbine if necessary. Is
DHW OK?
Re-engage diverter
head and secure clip to
waterset
NO
Replace turbine sensor
Replace PCB
YES
Re-connect wiring
Check and re-fit diverter valve actuator head.
Is Boiler DHW OK?
NO
Change diverter valve motor
4.13 NO DISPLAY
Is there 230Vac to the boiler at L and N?
NO
Supply power to the boiler
NO
Connect the wiring from the terminal block to the
PCB securely.
YES
Is the wiring from the terminal block to the PCB
connected securely?
YES
Replace the PCB?
L
60
N
Installation and Servicing
SECTION 5 - SPARE PARTS
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. Failure to do so
could affect safety or performance of this appliance.
Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www.idealparts.com
Our Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665.
When calling, and to ensure we can provide you with the most accurate parts information, please ensure you have the following to
hand;
-
Boiler Model
-
Appliance GC Number
-
Boiler Serial Number
Installation and Servicing
61
SECTION 6 - BENCHMARK & COMMISSIONING
62
Installation and Servicing
SECTION 6 - BENCHMARK & COMMISSIONING
Benchmark Commissioning and
Servicing Section
It is a requirement that the boiler is installed and commissioned to the
manufacturer’s instructions and the data fields on the commissioning checklist
completed in full.
To instigate the boiler guarantee the boiler needs to be registered with the
manufacturer within one month of the installation.
To maintain the boiler guarantee it is essential that the boiler is serviced annually
by a Gas Safe registered engineer who has been trained on the boiler installed.
The service details should be recorded on the Benchmark Service Interval
Record and left with the householder.
www.centralheating.co.uk
© Heating and Hotwater Industry Council (HHIC)
Installation and Servicing
63
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
CONTROLS
Programmable room thermostat
Optimum start control
Combination Boiler
Fitted
Fitted
Fitted
Automatic bypass to system
Fitted
Boiler interlock
ALL SYSTEMS
Yes
Yes
CENTRAL HEATING MODE
OR
mbar
OR
mbar
Central heating return temperature
COMBINATION BOILERS ONLY
Yes
Yes
DOMESTIC HOT WATER MODE
OR
mbar OR
mbar
Cold water inlet temperature
Yes
Temperature
CONDENSING BOILERS ONLY
Yes
ALL INSTALLATIONS
AND
²
Ratio
AND
²
Ratio
Yes
Yes
Yes
Yes
* All installations in England and Wales must be
to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance
will then be issued to the customer.
www.centralheating.co.uk
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
SERVICE 01
SERVICE 02
AND
(Where Possible)
AND
AND
²%
²%
(Where Possible)
Signature
Signature
SERVICE 03
SERVICE 04
AND
(Where Possible)
AND
AND
²%
²%
(Where Possible)
Signature
Signature
SERVICE 05
SERVICE 06
AND
(Where Possible)
AND
(Where Possible)
Signature
SERVICE 07
SERVICE 08
AND
AND
(Where Possible)
Signature
SERVICE 09
SERVICE 10
AND
Signature
AND
AND
AND
²%
²%
Signature
(Where Possible)
AND
AND
²%
²%
Signature
(Where Possible)
AND
²%
²%
AND
AND
(Where Possible)
AND
²%
²%
²%
²%
²%
²%
²%
²%
²%
²%
Signature
* All installations in England and Wales must be
to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance
will then be issued to the customer.
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO
CHECK ON COMMISSIONING A CONDENSING BOILER
Important Preliminary Information on Checks
The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING.
If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG)
separate guidance is provided with the conversion kit supplied and this must be followed.
PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK
The installation instructions must have been followed, gas type verified and gas supply pressure / gas rate checked as
required prior to commissioning.
As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN
THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are
correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance
has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids).
The ECGA should be of the correct type, as specified by BS 7967.
Prior to its use, the ECGA should have been maintained and calibrated as specified by the manufacturer. The installer
must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer’s instructions.
KEY:
CO = carbon monoxide
CO2 = carbon dioxide
O2 = oxygen
Combustion Ratio = The CO reading measured in ppm divided by the CO2 reading first converted to ppm
ppm = parts per million
GS(I&U)R = Gas Safety (Installation and Use) Regulations
*Setting to Minimum Rate:
1. Hold “RESTART” and “FUNCTION” buttons together for more than 5s
2. Last 3 faults will be shown
3. SL shown, press “RESTART”
4. Burner will run for 10 minutes at minimum rate
66
Installation and Servicing
Start
Set Boiler to Maximum Gas Rate
In accordance with boiler instructions,
set boiler to operate at maximum rate
(full load condition). Allow sufficient
time for combustion to stabilise.
Note. Do not insert analyser probe
during this period to avoid possible
flooding of sensor.
Carry Out Flue Integrity Check Using Analyser
Insert analyser probe into air inlet test point (where available) and allow
readings to stabilise.
Note. Where no air inlet test point is provided then a flue integrity check with
the analyser is not possible. The installer should verify that flue integrity has
been visually checked in accordance with the “Prior to CO level and
combustion ratio check” (see opposite page) before proceeding to the
“check CO level and combustion ratio at maximum rate” stage below.
Verify Flue Integrity
Analyser readings indicate that combustion products and inlet air
must be mixing. Further investigation of the flue is therefore required.
Check that flue components are assembled, fixed and supported as
per instructions. Check that flue and flue terminal are not obstructed.
Is
O2 more than or
equal to 20.6% OR CO2
less than or equal to
0.2%?
No
Yes
Is
O2 more than or
equal to 20.6% OR CO2
less than or equal to
0.2%?
Check CO level and Combustion Ratio
at Maximum Gas Rate
Yes
With boiler still set at maximum gas rate,
insert analyser probe into flue gas
sampling point. Allow readings to stabilise
before recording.
No
Turn off appliance and call Ideal Technical Helpline for advice
The appliance must not be commissioned until problems are identified
and resolved. If commissioning cannot be fully completed, the appliance
must be disconnected from the gas supply in accordance with GSIUR.
No
Yes
Check that no seals, e.g. Those on flue extensions, have
been displaced during installation. Rectify if necessary.
Is
CO level less
than 350ppm AND CO/CO2
ratio less than
0.0040?
Is
CO level less
than 350ppm AND CO/CO2
ratio less than
0.0040?
Set Boiler to Minimum Gas Rate
(*see opposite page)
In accordance with boiler instructions, set boiler to
operate at minimum rate (to minimum load condition).
Allow sufficient time for combustion to stabilise.
Yes
Check CO and Combustion Ratio at Minimum Gas Rate
With boiler set at minimum rate, insert analyser probe into flue
gas sampling point. Allow readings to stabilise before recording.
No
Turn off Appliance and Call Ideal Technical Helpline
The appliance must not be commissioned until problems
are identified and resolved. If commissioning cannot be
fully completed, the appliance must be disconnected from
the gas supply in accordance with GS(I&U)R. NOTE:
Check and record CO level and combustion ratio at both
maximum AND minimum rate before contacting Ideal.
No
Is
CO level less
than 350ppm AND CO/CO2
ratio less than
0.0040?
Yes
Boiler is Operating Satisfactorily
No further actions required.
Ensure test points are capped, boiler case is correctly replaced and all
other commissioning procedures are completed. Complete Benchmark
Checklist, recording CO and combustion ratio readings as required.
Installation and Servicing
67
Technical Training
The Ideal Technical Training Centre offers a series of first
class training courses for domestic, commercial and industrial
heating installers, engineers and system specifiers.
For details of courses please ring:................ 01482 498 432
Manufactured under an ISO 9001
registered quality management system
The code of practice for the installation,
commissioning & servicing of central heating systems
FM 59915
Ideal Boilers Ltd., P.O. Box 103, National Ave, Kingston upon Hull, HU5
4JN. Telephone: 01482 492 251 Fax: 01482 448 858.
Registration No. London 322 137.
Ideal Boilers Ltd. pursues a policy of continuing improvement in
the design and performance of its products. The right is therefore
reserved to vary specification without notice.
Installer Support Helpline: 01482 498 663
Customer Helpline: 01482 498 660
www.idealboilers.com
8.
FAULT CODES
DISPLAY CODE ON BOILER
DESCRIPTION
ACTION
F1
Low Water Pressure
Check system water pressure is between 1 & 1.5bar on the system pressure gauge. To
re-pressurise the system see Section 3. If the boiler still fails to operate then please contact
Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the
warranty period. In IE contact a Registered Gas Installer (RGII).
F2
Flame Loss
1.Check other gas appliances in the house are working to confirm a supply is present in
the property.
F3
Fan Fault
Restart the appliance - if the boiler fails to operate then please contact Ideal (if under
warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty
period. In IE contact a Registered Gas Installer (RGII).
F4
L4
Flow Thermistor
Restart the appliance - if the boiler fails to operate then please contact Ideal (if under
warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty
period. In IE contact a Registered Gas Installer (RGII).
F5
L5
Return Thermistor
Restart the appliance - if the boiler fails to operate then please contact Ideal (if under
warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty
period. In IE contact a Registered Gas Installer (RGII).
F6
Outside Sensor Failure
Restart the appliance - if the boiler fails to operate then please contact Ideal (if under
warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty
period. In IE contact a Registered Gas Installer (RGII).
F7
Low Mains Voltage
Contact a qualified electrician or your electricity provider.
F9
Unconfigured PCB
Unconfigured PCB. Please contact Ideal (if under warranty) or alternatively a Gas Safe
Registered Engineer if outside of the warranty period. In IE contact a Registered Gas
Installer (RGII).
L1
Flow Temperature Overheat
or No Water Flow
Check system water pressure is between 1 & 1.5bar on the system pressure gauge.
To re-pressurise the system see Section 3. If the boiler fails to operate then please contact
Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the
warranty period. In IE contact a Registered Gas Installer (RGII).
L2
Ignition Lockout
1.Check condensate Pipe for blockages (refer to Section 4)
2.If other appliances do not work or there are no other appliances, check the gas supply
is on at the meter and/or pre payment meter has credit. If the boiler fails to operate then
please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer
if outside of the warranty period. In IE contact a Registered Gas Installer (RGII).
L9
2.Check other gas appliances in the house are working to confirm a supply is present in
the property.
3.If other appliances do not work or there are no other appliances, check the gas supply
is on at the meter and/or pre payment meter has credit. If the boiler fails to operate then
please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer
if outside of the warranty period. In IE contact a Registered Gas Installer (RGII).
L6
False Flame Lockout
Restart the appliance - if the boiler fails to operate then please contact Ideal (if under
warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty
period. In IE contact a Registered Gas Installer (RGII).
LC
5 Boiler Resets in 15 minutes
1.Turn electrical supply to boiler off and on.
FU
Flow/Return Differential >
50°C
If the boiler fails to operate then please contact Ideal (if under warranty) or alternatively
a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a
Registered Gas Installer (RGII).
Diverter Valve in mid-position
for service
Rotate all knobs fully clockwise, turn boiler power off and on then press restart
U
2.If the boiler fails to operate please contact Ideal (if under warranty) or alternatively
a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a
Registered Gas Installer (RGII).
Ideal Consumer Helpline
Tel: 01482 498660
www.idealboilers.com
Ideal Boilers pursues a policy of continuing improvement in the design and performance
of its products. The right is therefore reserved to vary specification without notice.
Ideal, P.O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN.
Tel. 01482 492251 Fax. 01482 448858. Registration No. London 322 137.
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