IDEAL C24 Logic Max Combi2 Instruction manual

INSTALLATION

& SERVICING

LOGIC MAX COMBI

2

C24 C30 C35

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 Heating.

For the very latest copy of literature for specification and maintenance practices visit our website idealheating.com where you can download the relevant information in PDF format.

July 2022

UIN 228290 A05

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 NOx (Gross)

Annual Energy Consumption

Sound Power Level, Indoors

Domestic Hot Water

Domestic Hot Water

Water heating energy efficiency (Eco) Tapping Profile L

Daily fuel consumption 24hr (GCV) Actual measured

Annual electricity consumption

Annual fuel consumption

ERP DATA

SYMBOL n/a n/a n/a n/a n/a n/a

P4

P1 elmax elmin

PSB ƞ4 ƞ1

Pstby

Pign

%

% kW kW

NOx, pond Hs mg/kWh

QHE

LWA

GJ dB

Qelec ƞWH

Qfuel

AEC

AFC kWh

% kWh kWh

GJ kW kW kW kW kW

UNITS n/a n/a n/a n/a n/a n/a

90

98.6

0.05

0

28

75

50

0.136

82

14.7

29

11

24.3

8

0.044

0.013

0.002

24 kW yes no no no no yes

90

98.6

0.05

0

30

75

46

0.137

79

15.14

29

11

24.3

8

0.028

0.026

0.002


90

98.6

0.05

0

25

75

46

0.133

81

14.83

28

11

MODEL


24.3

8

0.028

0.009

0.003

2

WEEE DIRECTIVE 2012/19/EU

Waste Electrical and Electronic Equipment Directive

• At the end of the product life, dispose of the packaging

and product in a corresponding recycle centre.

• Do not dispose of the unit with the usual domestic refuse.

• Do not burn the product.

• Remove the batteries.

• Dispose of the batteries according to the local statutory

requirements and not with the usual domestic refuse.

The code of practice for the installation, commissioning & servicing of central heating systems

Installation and Servicing

PRODUCT FICHE

LOGIC MAX COMBI 2 C BOILER

Ideal Heating ERP DATA

SYMBOL

Condensing boiler

Seasonal space heating efficiency class

Rated heat output

Seasonal space heating energy efficiency

Annual energy consumption

Sound power level, indoors

Water heating energy efficiency class ƞ s

Q

HE

L

WA

Seasonal Space Heating Energy Efficiency of the Boiler

UNITS kW

%

GJ dB

Temperature control (from fiche of temperature control)

Class I Class II Class III Class IV

1% 2% 1.5% 2%

Class V

3%

Class VI

4%

Class VII

3.5%

24 kW

50

Class VIII

5%

MODEL

30 kW

Yes

A

24

94*

75

46

A

35 kW

46

94%

*% A

% B

Solar Contribution (from fiche of solar device)

Collector Size

(in m 2 )

Tank Volume

(in m 3 )

Collector

Efficiency

(in %)

Tank rating

A* = 0.95

A = 0.91

B = 0.86

C = 0.83

D-G = 0.81

= (‘ III ’x + ‘ IV ’ x ) x 0.9 x ( / 100 x ) =

%

C

%

Seasonal Space Heating Energy Efficiency of Package TOTAL: A+B+C=

Seasonal Space Heating Energy Efficiency Class of Package

< 30%

F

≥ 30%

E

≥ 34%

D

≥ 36%

C

≥ 75%

B

≥ 82%

A

≥ 90%

A+

≥ 98%

A++

≥ 125%

A+++

≥ 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

NOTES FOR THE INSTALLER

For any technical queries please ring the Ideal installer helpline : 01482 498663

BOILER RESTART PROCEDURE -

Press the RESTART button. The boiler will repeat the ignition sequence if a heat demand is present.

DEFINITIONS

WARNING:

Risk of injury or death

CAUTION:

Risk of damage to objects

IMPORTANT:

Important information

Table of Acronyms

CH - Central Heating

DHW - Domestic Hot Water

TRV - Thermostatic Radiator Valve

PRV - Pressure Relief Valve

IE - Ireland

ETCI - Electro-Technical Council of Ireland

BS - British Standard

WRAS - Water Regulations Advisory Scheme

SAP - Standard Assessment Procedure

IEE - Institution of Electrical Engineers

UKCA - UK Conformity Assessed

RHS - Right Hand Side

LHS - Left Hand Side

PCB - Printed Circuit Board

4

Ideal Heating reserve the right to vary specification without notice


CONTENTS

Section 1 - General ..................................................................................... 6

1.1 Introduction ................................................................................... 8

1.2 Operation ...................................................................................... 8

1.3 Safe Handling ............................................................................... 8

1.4 Optional Accessories .................................................................... 8

1.5 Safety............................................................................................ 9

1.6 Safe Handling of Substances ....................................................... 9

1.7 Location of Boiler ......................................................................... 9

1.8 Air Supply ................................................................................... 10

1.9 Gas Supply ................................................................................. 10

1.10 Water Circulation System ........................................................... 10

1.11 Boiler Controls ............................................................................ 10

1.12 Electrical Supply ......................................................................... 10

1.13 Condensate Drain ....................................................................... 10

1.14 Boiler Dimensions, Services & Clearances .................................11

1.15 System Requirements - Central Heating .................................... 12

1.16 System Requirements - DHW ..................................................... 13

1.17 System Balancing ....................................................................... 13

1.18 Water Treatment ......................................................................... 13

Section 2 - Installation .............................................................................. 14

2.1 Boiler Assembly - Exploded View ............................................... 14

2.2 Unpacking ................................................................................... 15

2.3 Wall Mounting Template.............................................................. 16

2.4 Preparing the Wall ...................................................................... 16

2.5 Fitting the Wall Mounting Plate ................................................... 16

2.6 Mounting the Boiler ..................................................................... 16

2.7 Flues and Locations.................................................................... 17

2.8 Flues and Locations - Continued ................................................ 18

2.9 Horizontal Flue Positions ........................................................... 19

2.10 Vertical Flue Positions ............................................................... 19

2.11 Flue System Dimensions ........................................................... 20

2.12 Fitting the Turret.......................................................................... 20

2.13 Cutting the Flue .......................................................................... 21

2.14 Assembling the Vertical Flue ...................................................... 22

2.15 Condensate Drain ....................................................................... 23

2.16 Condensate Drain - Cont. ........................................................... 24

2.17 Connections & Filling .................................................................. 25

2.18 Connections & Filling Cont. ........................................................ 26

2.19 Electrical Connections ................................................................ 27

2.20 Installer Wiring ............................................................................ 27

2.21 External Wiring ........................................................................... 28

2.22 Wiring Diagram ........................................................................... 29

2.23 Replacing Pre-Fitted Mains Cable .............................................. 30

2.24 Commissioning and Testing ........................................................ 30

2.25 Initial Lighting .............................................................................. 31

2.26 User Interface Commissioning .................................................... 32

2.27 Changing Boiler Operating Mode .............................................. 32

2.28 Preheat Function ....................................................................... 32

2.29 Intelligent Preheat Function ....................................................... 32

2.30 Menu Operation .......................................................................... 33

2.31 Setting Maximum and Minimum Rates ....................................... 33

2.32 General Checks .......................................................................... 34

2.33 Restart Procedure ....................................................................... 35

2.34 Handing Over.............................................................................. 35

Section 3 - Servicing ................................................................................. 36

3.1 Servicing Schedule ..................................................................... 36

3.2 Removal / Replacement of Components .................................... 37

3.3

3.4

3.5

3.6

Draining the Boiler ...................................................................... 37

Boiler Front Panel Removal / Replacement ................................ 38

Flue Manifold Removal/Replacement ......................................... 38

Fan and Venturi Assembly Removal and Cleaning ..................... 39

3.7

3.8

Burner Removal and Cleaning .................................................... 40

Cleaning the Heat Exchanger ..................................................... 40

3.9 Ignition / Detection Electrode Replacement / Inspection ............ 41

3.10 Cleaning the Condensate Trap ................................................... 41

3.11 Burner Injector Replacement ...................................................... 42

3.12 DHW Filter & DHW Flow Regulator Cleaning/Replacement ....... 42

3.13 External System Filter Cleaning Guide ....................................... 42

3.14 Burner Replacement ................................................................... 43

3.15 Return Thermistor Replacement ................................................. 43

3.16 Spark Generator Replacement ................................................... 43

3.17 Gas Control Valve Replacement ................................................. 44

3.18 Diverter Valve Actuator Replacement ......................................... 44

3.19 Condensate Trap Replacement / Cleaning ................................. 44

3.20 Primary PCB Replacement ......................................................... 45

3.21 DHW Flow Turbine Sensor Replacement ................................... 46

3.22 Pressure Gauge Replacement ................................................... 46

3.23 PRV Replacement ...................................................................... 47

3.24 Pump Automatic Air Vent Replacement ..................................... 47

3.25 Replacement of DHW Thermistor ............................................... 48

3.26 DHW Plate Heat Exchanger Replacement ................................. 48

3.27 Diverter Valve Body Assembly Replacement .............................. 49

3.28 Pump Head Replacement ........................................................... 50

3.29 CH Water Pressure Switch Replacement ................................... 50

3.30 Flow Thermistor Replacement .................................................... 51

3.31 Heat Engine Replacement .......................................................... 52

3.32 Expansion Vessel Recharging & Replacement .......................... 53

Section 4 - Fault Finding ........................................................................... 54

4.1

4.2

4.3

4.4

Main Menu, Fault Help ................................................................ 54

Overheat Lockout ....................................................................... 54

Ignition Lockout........................................................................... 55

Flame On Before Gas Valve On ................................................. 55

4.5

4.6

4.7

4.8

Low Water Pressure ................................................................... 55

Flame Loss ................................................................................. 56

Fan Fault..................................................................................... 56

Flow Thermistor Fault ................................................................ 57

4.9 Return Thermistor Fault ............................................................. 57

4.10 Outside Sensor Fault .................................................................. 58

4.11 No CH Operation but DHW works OK ........................................ 58

4.12 No DHW but CH Works OK ........................................................ 59

4.13 No Display .................................................................................. 60

4.14 DHW Thermistor Fault ................................................................ 60

Section 5 - Spare Parts ............................................................................ 61

Section 6 - Benchmark to Commissioning ................................................ 62


Section 1 - General

Table 1 General Data

Gas Supply

Gas Supply Connection

Injector Size

Inlet Connection

Outlet Connection

Flow Connection

Return Connection

Flue Terminal Diameter

Average Flue Temp-Mass Flow Rate

CO2 Content (± 0.7) mm

Cold Water

Cold Hot Water

Central Heating

Central Heating mm

DHW

Max. DHW

Min. CH bar (psi) bar (psi) [kPa] bar (psi) [kPa]

Maximum Working Pressure (Sealed Systems)

Maximum Domestic Hot Water Inlet Pressure

Minimum Domestic Hot Water Inlet Pressure*

Minimum DHW Inlet Pressure to Operate at 0.6 bar System Pressure

Electrical Supply

Power Consumption

Fuse Rating

Water Content

Packaged Weight

Lift Weight

Boiler Casing Size

W

Central Heating litre (gal)

Domestic Hot Water litre (gal) kg kg

Height mm

Width mm

Depth mm

24 kW

4.15

30 kW

2H - G20 - 20 mbar

15 mm copper compression

4.65


35 kW

4.9

63ºC - 11g/s

9.2%

8.5%




100

68ºC - 13g/s

9.3%

8.5%

2.5 (36.3)

73ºC - 15g/s

9.7%

8.8%

0.8(11.6)[80]

34.8

28.5

10.0 (145) [1000]

1.3(18.9) [130] 1.3(18.9)**[130]

All Model Sizes 0.5 bar

94

230 V ~ 50 Hz

93 110

External : 3 A Internal : T4A HRC L250 V

1.2 (0.26)

1.0 (0.22)

35

28.6

700

395

278

35

28.6

6

*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

Boiler Input: Max

Boiler ‘Q’ Net CV

Gross CV

Gas Consumption kW kW

24.3

27 m 3 /h 2.512

(ft 3 /h) (89)

Boiler Output :

Non Condensing

70ºC Mean Water Temp.

kW 24.2

Condensing

40ºC Mean Water Temp.

kW 25.6

Seasonal Efficiency* SEDBUK 2005

Seasonal Efficiency* SEDBUK 2009/2012

NOx Classification

Min

24 kW 30 kW 35 kW

4.9

6.1

7.1

5.4

0.5

(17.8)

6.7

0.627

(22)

7.9

0.734

(25.9)

4.8

5.1

6.1

6.4

7.1

7.5

91.10% 91.10% 91.10%

89.60% 89.60% 89.60%

CLASS 6

Note. Gas consumption is calculated using a calorific value of

38.7 MJ/m 3 (1038 Btu/ft 3 ) gross or 34.9 MJ/m 3 (935 Btu/ft 3 ) nett

To obtain the gas consumption at a different calorific value: a. For l/s - divide the gross heat input (kW) by the gross C.V. of the gas (MJ/m 3 ) b. For Btu/h - multiply the gross heat input (kW) by 26.8

c. For ft 3 /h - divide the gross heat input (Btu/h) by the gross C.V. of the gas (Btu/ft 3 ) d. For m 3 /h - multiply l/s by 3.6

Table 3 Performance Data - Domestic Hot Water

Maximum DHW Input:

Boiler ‘Q’ Net CV

Gross CV

Gas Consumption

Maximum DHW Output

DHW Flow Rate

At 35ºC Temp. Rise

DHW Specific Rate kW kW m 3 /h ft 3 /h kW l/min gpm l/min gpm

24 kW 30 kW 35 kW

24.3

30.4

35.4

27 33.7

39.3

2.512

89

24.2

3.135

111

30.3

3.657

129

35.3

9.9

2.2

11.5

2.5

12.4

2.8

14.5

3.2

14.5

3.2

16.9

3.7

* 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, has been certified by a notified body.

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.

I

2H

= An appliance designed for use on 2nd family gas, Group H only.

II

2H/3P

= An appliance designed for use on 2nd or 3rd family gases,

Group H or P.


LOGIC MAX COMBI

2

C

Natural Gas Only

BOILER SIZE kW

24

30

35

G.C. Applicance No

(Benchmark No.)

47-349-99

47-387-01

47-387-02

Destination Country: GB

Section 1 - General

For UK, 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

B

oiler ........................................................................

Page

Make and model ...................................................... Above

Appliance serial no. on data badge ................Front Cover

SEDBUK No. % ................................................................6

Controls

Time and temperature control to heating ........................28

Heating zone valves .......................................................13

TRVs ...............................................................................10

Auto bypass ....................................................................13

Boiler interlock ................................................................10

For all boilers

Flushing to BS.7593 .......................................................13

Inhibitor ...........................................................................13

Central heating mode

Heat input ................................................. to be calculated

B

oiler ........................................................................

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 .................................................................13

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 ..................................................... 23-24

For all boilers: Complete, sign & hand over to customer

NOTE TO THE INSTALLER: COMPLETE THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE INSTRUCTIONS WITH APPLIANCE

For assistance call

Technical Helpline

01482 498663


8

Section 1 - General

1.1 INTRODUCTION

The Logic Max Combi 2 C range of boilers are wall mounted, condensing, combination gas boilers.

Features:

• High efficiency

• Full sequence

• Automatic spark ignition

• Low water content

• Fanned flue

The boiler is supplied fully assembled with a DHW plate heat exchanger, diverter valve, circulating pump, pressure gauge,

PRV and CH expansion vessel.

Variable CH and DHW temperature controls are fitted on the user control and the boiler features a DHW preheat facility.

The boiler includes as standard:

-

-

-

Automatic bypass

Boiler frost protection

Daily pump and diverter valve exercise.

The boiler casing is of white painted mild steel 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.

A PRV grommet is fitted to the boiler which requires the correct fitting and securing of a clip (supplied) to ensure safe discharge of the PRV should this occur.

The Ideal System filter is supplied with this boiler. Installation instructions for this are located within the system filter box.

Be sure to follow Ideal System filter installation and maintenance guide for correct method of installation. Failure to install the system filter correctly will affect boiler warranty.

Data Plate

The boiler model and serial number are shown on the data label which can be located on the bottom of the boiler casing, shown in - Water & Gas Connection Diagram.

Refer to Section

1.14

When there is a demand for CH, the heating system is supplied at the selected temperature of between 30 o C and

80 o C, 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:

24 kW 9.9 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 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.

1.3 SAFE HANDLING

This boiler may require 2 or more operatives to move it to its installation site, remove it from its packaging base and during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling.

Caution should be exercised during these operations.

Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered:

• Grip the boiler at the base.

• Be physically capable.

• Use personal protective equipment as appropriate, e.g. gloves, safety footwear.

During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or the weight is light.

• Keep back straight.

• Avoid twisting at the waist.

• Avoid upper body/top heavy bending.

• Always grip with the palm of the hand.

• Use designated hand holds.

• Keep load as close to the body as possible.

• Always use assistance if required.

1.2 OPERATION

With no demand for CH, the boiler fires only when DHW is drawn off, or periodically for a few seconds without any DHW draw-off, in order to maintain the DHW plate heat exchanger in a heated condition. This only occurs if the “PREHEAT” button is pressed and the display reads “PREHEAT ON or

PREHEAT TIMED”.

1.4 OPTIONAL ACCESSORIES

Please visit idealheating.com to access the optional accessories for this boiler.

SCAN for link


Section 1 - General

1.5 SAFETY

Current Gas Safety (installation and use) regulations or rules in force:

The appliance is suitable only for installation in the UK and should be installed in accordance with the rules in force.

In the UK, installations 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.

1.6 SAFE HANDLING OF SUBSTANCES

No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture.

1.7 LOCATION OF BOILER

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 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.

The Boiler has been tested and certified to:

BSEN 15502-1, BSEN 15502-2, BSEN 15502-2-1,

BSEN 60335-1, BSEN 60335-2-102, BSEN 55014-1 and

BSEN 55014-2 for use with Natural Gas & Propane.

Detailed recommendations are contained in the following

British Standard Codes of Practice:

BS5440:1

BS5440:2

Flues (for gas appliances of rated input not exceeding 70 kW).

Ventilation (for gas appliances of rated input not exceeding 70 kW).

BSEN12828 Heating Systems in buildings: Design for water based heating systems.

BSEN12831 Heating Systems in buildings: Method for calculation of the design heat load.

BSEN14336 Heating Systems in buildings: Installation and commissioning of water based heating

systems.

BS5546

BS6798

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.

BS6891 Installation and maintenance of low pressure gas installation pipework.

BS 7593:2019 Code of practice for the preparation, commissioning and maintenance of domestic central heating and cooling water systems.

WARNING:

Rear access to the boiler is not permitted.

CAUTION:

Do not fit the boiler outside.

Timber Framed Buildings

Boilers installed in a timber-framed building must comply with

IGE/UP7 +A 2008.

Bathroom Installations

CAUTION: This appliance is IP20 rated, do not clean with jets of water.

You may install the boiler in any internal space. The installation must comply with the current IEE (BS 7671) Wiring Regulations and the electrical regulations applicable in Scotland.

If the appliance is to be installed in a room containing a bath or shower then the appliance must be installed beyond Zone 2, as detailed in BS7671.

600 m m

2

2*

1 1

600 mm

2

600 mm

2

1

600 mm

2

Health & Safety Document No.635.

The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be taken, in any way, as overriding statutory obligations.

IMPORTANT:

This appliance is UKCA/CE certificated for safety and performance. Do not connect external control devices directly to this appliance unless recommended in this manual or by Ideal Heating in writing. If in doubt, please enquire.

Unapproved control devices could invalidate the warranty of this appliance and infringe the Gas Safety Regulations.

A

A

Bathroom Installations

[0] Zone 0

[1] Zone 1

[2] Zone 2

[2*] Without the end wall, zone 2 must extend 600 mm from the bath

[A] 600 mm radius from the bath or shower

A

0010017086-002


10

Section 1 - General

Compartment Installations

A boiler installed in a compartment does not require ventilation.

However, A boiler installed in a compartment must provide adequate clearances for servicing. The compartment should also be fitted with a suitable label in accordance with current standards.

Refer to Section

1.14

Installation pipes must be fitted in accordance with BS6891.

The complete installation MUST be tested for gas tightness and purged as described, for the majority of installations the appropriate standard is IGEM/UP/1B [23], but alternatively

IGEM/UP/1 [21] or IGEM/UP/1A [22], as appropriate, can be utilized.

1.8 AIR SUPPLY

It is not necessary to have an air vent in the room or internal space where the boiler is installed.

1.10 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

BS6798 and, in addition, for smallbore and microbore systems,

BS5449.

Water treatment is covered later in these instructions.

Refer to Section

1.18

1.9 GAS SUPPLY

Consult the local gas supplier to establish an adequate supply of gas. Do not use existing service pipes without consulting the local gas supplier.

The gas supply must be governed with a meter.

A gas meter can only be connected by the local gas supplier or by a Gas Safe Registered Engineer.

An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the required gas supply rate.

It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS6891.

Whilst the principle of the 1:1 gas valve ensures the Logic range is able to deliver it is full output at inlet pressures as low as 14 mb, other gas appliances in the property may not be as tolerant. When operating pressures are found to be below the minimum meter outlet of 19 mb 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 BS6400-1 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

1.4

1.2

1

0.4

0.2

0.8

0.6

0

0 5 10 15 20 25 30 35 40

Heat Input to Boiler (kW)

IMPORTANT:

Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve.

1.11 BOILER CONTROLS

Install CH controls to ensure that the boiler has no demand when there is no requirement from the system.

Heating systems with TRVs in individual rooms must include a thermostat to control the temperature in rooms without TRVs.

At least 10% of the minimum boiler heat output should be achieved using a room thermostat. A bypass circuit with an automatic bypass valve must be fitted to systems with TRVs or two-port valves on all the radiators to ensure water flow.

1.12 ELECTRICAL SUPPLY

WARNING: This appliance must be earthed

Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS7671) Wiring Regulations and any local regulations which apply.

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.

1.13 CONDENSATE DRAIN

The condensate drain provided must be connected to the drainage point on site. All condensate drainage pipework and fittings must be made of plastic.

IMPORTANT:

The condensate drain pipework should be installed in accordance with BS6798.

The drain outlet on the boiler is sized for standard 21.5 mm overflow pipe. It is a universal fitting to allow use of different brands of pipework.

Refer to Section

2.15


Section 1 - General

1.14 BOILER DIMENSIONS, SERVICES & CLEARANCES

The boiler connections are made on the boiler connection tails.

The following minimum clearances must be maintained for operation and servicing.

Additional space will be required for installation, depending upon site conditions.

Refer to Section

2.17

Side and Rear Flue a. Provided that the flue hole is cut accurately, e.g. with a core drill, the flue can be installed from inside the building where wall thicknesses do not exceed 600 mm.

2.5 mm 2.5 mm from case

395 mm

278 mm

Flue terminal

200 mm

98 mm

152mm

700 mm

100 mm*

Water and Gas Connections Underside View

PRV

Grommet

Cond.

Drain

43.5

43.5

32 33 21 36 61

32

43.5

CH

Flow

21 36 DHW

Outlet

61 Gas

Inlet

75

Inlet

75

75

94 CH 94

Return

94

Data

Plate

PRV

Grommet

Cond.

Drain

Measurements in mm

Front Clearance

The minimum front clearance when built in to a cupboard is

5 mm from the cupboard door but 450 mm overall clearance is still required, with the cupboard door open, to allow for servicing.

*

Bottom Clearance

Bottom clearance after installation can be reduced to 15 mm.

This must be obtained with an easily removable panel to provide the 100 mm clearance required for servicing.

For easy access to the pressure gauge a bottom clearance of 15 mm is required for a partial open door.

CH

Flow

PRV Grommet

Refer to Section

2.17

DHW

Outlet

Gas DHW

Inlet

CH

Return

CH Circuit

Drain

IMPORTANT:

Please ensure there is sufficient clearance either side and below the boiler, particularly from door hinges and the base of a cupboard, to allow the door to be opened to allow the pressure gauge to be checked.

Also ensure there is sufficient access to the system filter for draining, cleaning and dosing. For guidance please see Ideal

System Filter Installation Manual.


12

Section 1 - General

1.15 SYSTEM REQUIREMENTS - CENTRAL HEATING

Table 4 Vessel Sizing 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.

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 national and local regulations.

2.

Design the system for flow temperatures up to 80 o C.

3. The system components must be suitable for an operating pressure of 3 bar and a maximum temperature of 110°C.

The following components are incorporated within the appliance: a.

Circulating pump.

b.

PRV, 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.

PRV setting bar 3.0

Vessel charge pressure bar 0.5 to 0.75

System pre-charge pressure bar None 1.0

System volume

(litres)

25

50

75

100

125

150

175

190

200

250

300

For other system volumes multiply by the factor across

Expansion vessel volume (litres)

1.6 1.8

3.1 3.7

4.7 5.5

6.3 7.4

7.8 9.2

9.4 11.0

10.9 12.9

11.9 14.0

12.5 14.7

15.6 18.4

18.8 22.1

0.063 0.074

4.

Makeup Water.

One of the following provisions must be made for replacing system water loss: a.

Manually filled vessel

The vessel must:

• Have a visible water level

• Be mounted at least 150 mm above the system’s

highest point

• Connect through a non-return valve to the system

• Be at least 150 mm below the makeup vessel on the

return side of the radiators b.

System prepressurisation.

The efficiency of the expansion vessel will be reduced in a pressurised system; a larger vessel or smaller system volume may be necessary. If the vessel’s capacity is not sufficient, an additional vessel must be installed on the return to the boiler.

If the system is not pressurised, the cold water capacity must not exceed 143 litres.

Guidance on vessel sizing is given in Table 4.

5. Filling

The system may be filled by the following method:

Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling.

a.

Thoroughly flush out the whole system with cold water.

b. Fill and vent the system until the pressure gauge registers 1 bar and examine for leaks.

Refer to Section

2.17

c.

Check that a 15 mm diameter pipe is correctly located and secured (using the clip supplied)

d. Check the operation of the PRV by raising the water pressure until the valve lifts. This should occur within

0.3 bar of the preset lift pressure.

e.

Check no escape of water occurs except at the discharge point

f.

Release water from the system until the minimum system design pressure is reached;

1.0 bar if the system is to be pre-pressurised.

Water Flow Rate and Pressure Loss

Max CH Output

Water Flow Rate kW 24.2

l/min 17.3

(gal/min) (3.8)

Temperature Differential

Head available for System

With Ideal System Filter

Fitted & Valves o C 20 m.w.g. 3.4

(ft.w.g.) (11.1) m.w.g

(ft.w.g)

3.1

10.2


Section 1 - General

1.16 SYSTEM REQUIREMENTS - DHW


1.

The DHW service must be in accordance with BS.5546 &

BS6700.

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. The boiler will require the flow rate to be set to obtain a temperature rise of 35 o tap furthest from the boiler.

C at the

Refer to Section

1.2

3.

The boilers are suitable for connection to most types of washing machine and dishwasher appliances.

4.

If the shower/mixer valve does not incorporate non-return valves the following must be followed: a.

The cold inlet to the boiler is fitted with an approved

anti-vacuum or syphon non-return valve.

b.

Hot and cold water supplies to the shower are of

equal pressure.

5. Hard Water Areas

Where the water hardness exceeds 200 mg/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.

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.

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.

1.17 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.

Note.

Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass.

Balancing

1.

Set the programmer to ON.

2.

Close the manual or thermostatic valves on all radiators, leaving the twin lockshield valves (on the radiators referred to above) in the OPEN position.

Refer to Section

1.11

3.

Turn up the room thermostat and adjust the lockshield valve to give an uninterrupted flow through the radiator.

These valves should now be left as set.

4. Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators, to give around 20 o C temperature drop at each radiator.

5.

Adjust the room thermostat and programmer to

NORMAL settings.

Note. Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass.

1.18 WATER TREATMENT

CAUTION: Do not fill the heating system with softened water. Softened water could enhance corrosion.

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 Heating invalid.

The Ideal System Filter will aid against the build up of iron oxide debris, however the below water treatment is also recommended by Ideal Heating.

Ideal Heating recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in

Central Heating Systems.

If water treatment is used, Ideal Heating recommend only the use of SCALEMASTER SM-1 PRO, 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.


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. BS7593:2019 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.

For further information contact:

Fernox www.fernox.com Tel: +44 (0) 3301 007750

Sentinel Performance Solutions www.sentinelprotects.com Tel: +44 (0) 1928 704330

Scalemaster Water Treatment Products www.scalemaster.co.uk Tel: +44 (0) 1785 811636

Calmag Ltd . www.calmag Ltd.com Tel: +44 (0) 1535 210320

Adey www.adey.com Tel: +44 (0) 1242 546700

13

Section 2 - Installation

2.1 BOILER ASSEMBLY - EXPLODED VIEW

104 CH Return Valve

105 CH Flow Valve

106 DHW Inlet & Outlet

107 Filling Loop Pipe

108 Pump Head

110 Auto Air Vent

111 Diverter Valve Motor

112 Diverter Valve Body & Paddle

113 Pressure Relief Valve

114 Pipe - PRV Outlet

115 Pipe - Flow

116 Pipe - Return

117 Pipe - Expansion Vessel

118 Expansion Vessel

119 Return Group Manifold

120 Flow Group Manifold

121 Plate Heat Exchanger

124 Flow Regulator

127 Flow Sensor/Turbine

131 Water Pressure Switch

135 Pressure Gauge

203 Gas Cock

205 Gas Valve

206 Pipe - Gas Injector

211 Injector Assy

214 Venturi

215 Fan

217 Burner

218 Gasket - Burner

219 Sump Clean Out Cover

223 Flue Manifold

224 Flue Manifold Top

227 Clamp Retaining Flue Turret

228 Hose Condensate Internal

229 Condensate Trap

231 Condensate Outlet Connection

239 Condensate Drain Tube

302 PCB

306 Ignition/Detection Electrode

308 Ignitor Unit

309 Thermistor

313 Ignition Lead

324 Control Box Lid

325 Control Box Front

326 Blank Insert

401 Heat Engine

503 Wall Mounting Bracket

504 Front Panel

505 Fascia

506 Bracket - Spark Generator

507 Bracket - Expansion Vessel

Note that item numbers are linked to the spares list

504

224

227

505

503

14

326

223

135

1

2

3

0 4 bar

324

215

325

217

218

306 313

214

211

206

302

205

308

401

105

506

228

219

309

115 116

229

106

239 120

203

106

131 127

124

507

113

107

104 108

118

114

231

110 111

112

121

309

119

117


2.2 UNPACKING

The boiler is supplied fully assembled in Pack A.


Unpack and check the contents

Pack A Contents

1.

Boiler

2.

Hardware Pack Box

3.

Wall Mounting Plate

4.

These Installation/Users Instructions

5.

Boiler Warranty

6.

Wall Mounting Template

7.

PRV Pipe

8.

Ideal System Filter

4

2

3

5

1 6

7

Hardware Pack

Box Contents

9. 1x HP Box Dividers - 289 x 111 x 57.5 mm

10. 1x Plug Male and Clip

11.

1x Pipe DHW Outlet

12.

1x Pipe Filling Loop

13.

1x Valve DHW Inlet

14.

2x Pipe CH Flow/Return

15.

1x Valve Filling Loop

16.

1x Valve CH G 3 /

4

x 22 mm Filling Loop

17.

1x Cap Female

18.

1x Valve CH G 3 /

4

x 22 mm

19. 1x Pipe DHW Inlet

20.

1x Nut G 1 /

2 x 16 Brass (Flat)

21.

1x Gas Cock

22.

1x PRV Clip

Accessory Bag Contents

23.

9x Washers*

24.

2x Wall Plugs

25.

2x Screws

26.

1x Flue Clamp Screw

23

9

18

22

14

21`

15 12 10

20

8

17

19

13

11

16

IMPORTANT

This clip needs to be fitted to ensure correct operation of the boiler.

Refer to Section

2.17

24 25

26

*Refer to Valve Washer Template inside box lid.



2.3 WALL MOUNTING TEMPLATE

IMPORTANT: Ensure the wall where the boiler will be is flat.

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.

1. Secure the template into the required position. Ensure it is square by hanging a plumbline.

2. If fitting a side flue, extend the flue centreline onto the side by 155 mm on a standard wall fix or 200 mm 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.

2.4 PREPARING THE WALL

WARNING: Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury.

1. Check all of the hole positions before drilling.

2. Cut the flue hole with a 127 mm core boring tool, ensure the hole is square to the wall.

3. Drill the 2 mounting holes with a 7.5 mm / 8 mm masonry drill and insert the plastic plugs provided.

4. Locate 2 No.14 x 50 mm 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.

X

Section through wall

Extended centre line

155

(200)

“A”

Refer to Section

2.8

Rear flue only

127 mm diameter hole

Side flue only

127 mm diameter hole

2.5 FITTING THE WALL MOUNTING PLATE

1. Screw the wall mounting plate to the wall using 2 wall plugs fitted previously with the 2 screws provided.

2. 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

2.6 MOUNTING THE BOILER

1. Lift the boiler onto the wall mounting plate and locate it over the 2 tabs.

16

esp9496


Section 2 - Flue Installation

2.7 FLUES AND LOCATIONS

This installation & servicing manual must be read in conjunction with flue kit and fitting guide.

Telescopic horizontal flue

0.5 or 0.7 m

Horizontal flue

0.6 or 0.8 m

Flue extension

0.5 m, 1 m or 2 m

Flue deflector

Vertical flue terminal and connector

Ideal part no.

0.5 m 208169

0.7 m 208174

Flue elbow 90°

Ideal part no.

0.6 m 208171

0.8 m 217442

Flue elbow 45°

Ideal part no.

0.5 m 211037

1 m 203129

2 m 211038

Weather collar pitched roof

Ideal part no.

208176

Weather collar flat roof

Ideal part no.

211039

Ideal part no.

203130

Balcony flue kit

Ideal part no.

203131

Ideal part no.

152258

Ideal part no.

152259

Soffit kit

Raised horizontal flue kit

Ideal part no. 208177

WARNING:

• It is critical that products of combustion cannot re-enter the building

• The flue terminal must always have a free passage of air.

CAUTION:

• White sections of the flue must not be visible outside .

• Install a flue terminal guard where the flue terminal is less than 2 metres above a platform where persons can walk or come into contact with the terminal.

• Water is the only permitted lubricant for flue assembly.

Ideal part no. 211302 Ideal part no. 208290

Rubber

Terminal

Wall Seal

Terminal

MUST be fitted as shown



2.8 FLUES AND LOCATIONS - CONTINUED

L

B

1 m

2 m

3 m

4 m

18

B = Top Clearance

Top Clearance is measure from the top of the turret to the top of the hole where the flue terminates.

L = Effective flue length.

The effective length of the flue is measured from the edge of the turret to the flue terminal lip.

IMPORTANT INFORMATION

Install the flue in accordance to BS 5440:1 2008

Position the terminal, so the products of combustion do not cause a nuisance.

The terminal outlet duct must not be closer than 25 mm to combustible material.

The flue is secured in the wall using either sand and cement or heatproof silicone.

The flue must be supported by a bracket every metre of flue length and at every change of direction. Concealed flues must have inspection hatches no more than 1.5 metres from joints.

Where possible inspection hatches should be located at change of directions. Where this is not possible then bends must be viewable from both sides.

Inspection hatches must be at least 300 mm 2 .

Horizontal

24 kW

Maximum Effective Flue Length

9.0 metres

30 kW

35 kW

Vertical

24/30/35 kW equivalence. The following table is an example.

Part

45 o elbow

90 o elbow

8.0 metres

6.0 metres

7.5 metres

Elbows increase resistance and have an effective flue length x

2

2

Resistance

1.2 metres

2.0 metres

Effective flue length 3.2 metres

Flue systems that require extension kits must be installed with a 1.5° decline from the flue terminal back to the boiler.

A 1.5° decline can be achieved by designing the flue with a

26 mm rise per meter length of flue.

Table 5 - Flue Terminal Position

Flue Terminal Positions Min. Spacing*

1.

Directly below, above or alongside an opening.

2. Below guttering, drain pipes or soil pipes.

300 mm

75 mm

25 mm*

3.

Below eaves. 200 mm

25 mm*

4. Below balconies or a car port roof. 200 mm

25 mm*

5.

From vertical drain pipes or soil pipes.

6.

From an internal or external corner or a boundary alongside the terminal.

7.

Above adjacent ground, roof or balcony level.

8.

From a surface or a boundary facing the terminal.

9.

From a terminal facing a terminal.

10.

From an opening in a car port into dwelling.

150 mm

25 mm*

300 mm

25 mm*

300 mm

600 mm

1200 mm

1200 mm

11.

12.

13.

14.

15.

16.

Vertically from a terminal on the same wall.

Horizontally from a terminal wall.

Horizontally from an adjacent window

Facing an opening into an adjacent building

At an angle to the boundary

Parallel to a boundary

17. Below ground level – open light well

90°

45°

1500 mm

300 mm

600 mm

2000 mm

300 mm

600 mm

300 mm a) Below ground b) Above floor level c) From side

<1,000 mm

300 mm

300 mm d) From facing surface 600 mm

*Only one reduction down to 25mm is allowed per installation.



2.9 HORIZONTAL FLUE POSITIONS

8 Facing the boundary

1

3

2

4

5

7

3 2

3

Boundary

8

16

Parallel to the boundary

1

2

16 6

Boundary

300

1

4

1

1

10

5

15

3

600

7

300 c.

a. < 1000

300

600 d.

300 b.

17

15 At an angle to the boundary

1

600

2

13

6

6

All measurements : mm

11

12

9

3

14 Opening in adjacent building

2

1

14

Refer to Table 5

2.10 VERTICAL FLUE POSITIONS

Height Difference ‘A’

Less than 300

Greater than 300

B = 300

B = 1500

690

Fixed

Separation

Distance

‘B’

300

2000

600 600

600

Boundary

2000

600

200

300

Boundary

All measurements : mm

Refer to Table 5


20

30


2.11 FLUE SYSTEM DIMENSIONS

Flue Design

IMPORTANT:

1. Flue lengths may vary, always measure flue lengths before cutting.

2. Effective flue length and actual flue length are different measurements.

3. Effective flue length is made up of the flue length equivalence and the flue sections between the turret, elbows and terminal.

4. Actual flue length is the amount of flue needed to achieve the effective flue length, this includes insertions.

2.12 FITTING THE TURRET

1. Ensure the condensate trap in filled with water

2. Ensure the rubber seal is not damaged and fitted correctly on the appliance manifold.

3. Firmly hold the flue and push the turret on until it has travelled 30 mm ensuring the flue has not rotated or moved forward.

4. Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold.

5. Fully engage the clamp location section into the manifold location hole and rotate down onto the flange.

6. Use the securing screws to secure the clamp to the appliance.

7. Ensure all sample points are accessible and all sample plugs and caps are fitted.

30

Turret insertion (mm) Elbow insertion (mm)

D

Flue Outlet

A - Duct Assembly

B - Flue Turret

C - Turret Clamp

D - Seal

Flue Outlet

B

A

C

Retaining screw

Sample points Clamp Lugs

Part

1 m flue length

1 m flue length

0.6 m flue terminal

Total

Actual

Length

1 m

1 m

0.6 m

2.6 m

Insertion Effective

Length

30 mm 970 mm

30 mm

30 mm

90 mm

970 mm

570 mm

2510 mm

100mm

Edge of turret to outside face of wall plus

44mm = flue length

A


Flue length measured from outer terminal lip to end of outer flue

10 mm A + 44 mm

10 mm

Mark Cut Length = “A” + 44 mm from terminal lip

A + 44 mm

10 mm

Adjust to Length =

“A” + 44 mm from terminal lip

Drill Hole

Mark 2 Flush with the inner wall seal

Mark 1 Flush with inter wall

Adhere sealing tape

125 mm Cored drilled hole


2.13 CUTTING THE FLUE


CUTTING HORIZONTAL FLUE TERMINAL

(non-telescopic)

1. Measure the required cut flue length (A + 44 mm)

2. Measure from the outer terminal lip to the end of outer tube. Mark the required cut length (A + 44 mm) around the circumference of the outer tube and cut following the mark to ensure it is cut square.

10 mm to end of outer flue

A + 44 mm

3. Mark and cut the inner tube 10 mm longer than the outer tube ensure the cut is square.

+14 mm

+14 mm

Mark 2

Wall Thickness

Mark 1

4. Remove all burrs on the inner and outer tube and place a light chamfer on the inner tube to aid with assembly.

10 mm


A + 44 mm



7. Place the terminal end of the flue into the 127 mm core drilled centrally and slowly apply slight pressure and move the flue up or down or side to side. This will cause the external wall seal to fold in and allow the flue to pass through the wall.

Correctly sealed wall seal

8. When the inner wall seal is flush against the wall pull back the flue until Mark 1 is flush with the inner wall surface.

SETTING TELESCOPIC FLUE

9. Hold the flue steady and push the inner wall seal towards the wall until Mark 2 is just visible.


FITTING THE FLUE THROUGH THE WALL

(External Installation)

A + 44 mm

1. Follow steps 1 - 5 from above.

2. Pull flue apart until the desired length is achieved ensuring the stop mark is not visible.

3. Ensure both flue seams are at the top and the flue outlet terminal is uppermost.

4. Drill a 3.5 mm hole through the small and large outer tube using the pilot hole on the large outer tube.

5. Secure large and small outer tube using the screws provided.

Mark 2 Mark 1

6. Seal the joint on the out tube with the tape provided.

7. Fit the internal and external wall seals.


10 mm

Adjust to Length =


2. Push the flue through the 127 mm core drilled hole from the outside

3. Return inside the property and fit the inner wall seal to the flue.

4. Pull the flue internally until Mark 1 is flush with the inner wall surface.

5. Holding the flue in this position push the inner wall seal towards the wall until Mark 2 is just visible.

If Mark 1 is not flush with the inner wall surface and can be seen prior to the wall surface, then the external wall seal will have been dislodged and will require to be re-fitted. If this situation occurs, then please start the process from the beginning.

On completion the flue will be correctly installed as below.

+14 mm Wall Thickness

Drill Hole Adhere sealing tape

Mark 2 Flush with the inner wall seal


10 mm A + 44 mm

10 mm


A + 44 mm

+14 mm

+14 mm

Mark 2

Wall Thickness

Mark 1

FITTING THE FLUE THROUGH THE WALL

(Internal Installation)

1. Measure the thickness of the wall.

2. To this measurement add 14 mm.

3. Make a mark on the flue shown as mark 1 (top right).

4. Make another mark on the flue a further 14 mm in shown as Mark 2 above right.

5. Fit the external wall seal (black) to the flue terminal ensuring it is fitted on the terminal outer lip seal.


6. Fit the inner wall seal approximately 65 mm prior to Mark 2.

Mark 2


Mark 1



IMPORTANT: Ensure no White flue is visible between the flue terminal and the wall.


A video showing how to correctly measure and fit a flue can be found by scanning the QR Code.


SCAN for Flue Fitting

Video’s

For the full range of

FLUE AND ACCESSORIES please visit idealheating.com/flues

SCAN for Flues and

Accessories Guide

22

2.14 ASSEMBLING THE VERTICAL FLUE

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.

Ensure the cut pipe ends are free from any burrs.

1. Position the roof flashing plate (supplied separately) over the hole cut in the roof and insert flue terminal from the roof end.

2. Fit the vertical connector (supplied in kit) in accordance with the instructions provided.

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.

1

Flue Terminal

MAX LENGTH:

7.5m

BOILER

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.

weather collar flat roof weather collar pitched roof

'X'

6

5

Extension

Duct

5. Push extension duct (if required (supplied separately)) into vertical connector.

Note. Ensure turret sample points are servicable and all caps and plugs are fitted. Fill the condense trap/siphon with water.

6. If the last extension duct requires cutting, measure ‘X’, the distance between the duct (outer) and the terminal, and add 100 mm to this dimension. This gives the length of the last extension duct.

4

Vertical connector

2


2.15 CONDENSATE DRAIN


38

Condensate

Drain

129.5

44

This appliance is fitted with a siphonic 75 mm condensate trap system that requires filling before operating the appliance for the 1st time or after maintenance.

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 19 mm ID

(typically 22 mm OD).

d. External plastic pipe must be a minimum of 30 mm

ID (typically 32 mm OD) before it passes through the sleeved wall.

e. All horizontal pipe runs must fall a minimum of 52 mm per metre away from the Boiler.

f. External & unheated pipework should be kept to a minimum and insulated with Class “O” waterproof pipe insulation through freezing or otherwise.

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.

In order to minimise the risk of freezing, terminate the condensate drainage pipe using one of the following methods:

Internal Drain Connections

Route the condensate pipe by gravity to an internal, foul water discharge point.

Refer to Fig.

1 & 2

Condensate Pump

When it is not practical to terminate the condensate pipe to an internal foul water discharge point using gravity, use a suitable pump recommended by the boiler or pump manufacturer.

Refer to Fig.

3

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:

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.

- For connections to an external soil/vent stack.Insulation measures as described should be used.

Refer to Fig.

4

- 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.

Refer to Fig.

5

- 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.

Refer to Fig.

6

- 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.

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.

Note. Please check current HHIC condensate discharge guidance available via the Gas Safe Registered Technical

Bulletins List. Not irish continued . . . . .



2.16 CONDENSATE DRAIN - CONT.

Figure 1 - Connection of Condensate Drainage Pipe to

Internal Soil & Vent Stack

Boiler with 75 mm sealed condensate trap

Min Ø 19 mm

Internal pipe

Figure 2 - Connection of a Condensate Drainage Pipe

Downstream of a Sink, Basin, Bath or Shower Water Trap to

Internal Soil Vent Stack


Min Ø 19 mm

Internal pipe

Minimum connection height up to 3 storeys

Sink/basin/ bath or shower

Figure 3 - Connection of a Condensate Pump Typical

Method (see manufacturer’s detailed instructions)

Visible air break


Min Ø 19 mm

Internal pipe

Condensate pump

(Install in accordance with manufacturers instructions)

Figure 4 - Connection of Condensate Drainage Pipe to

External Soil & Vent Stack


Min Ø 19 mm

Internal pipe

Water/weather proof insulation

Min Ø 30 mm

Internal pipe

Minimum connection height up to 3 storeys

24

Figure 5 - Connection of a Condensate Drainage Pipe to an

External Rainwater Downpipe (only combined foul/rainwater drain)


Min Ø 19 mm

Internal pipe

Min Ø 30 mm

Internal pipe

Terminated and cut at 45º

43 mm 90º male/ female bend

Water/ weather proof insulation Combined foul/ rain water drain

External air break

Air gap

68 mm Ø PVCU

Strap on fitting

Figure 6 - Connection of a Condensate Drainage Pipe to an

External Purpose Made Soakaway.


Min Ø 19 mm

Internal pipe

Min Ø 30 mm

Internal pipe

Water/Weather proof insulation

Max 3 m external pipework

Terminated and cut at 45º

Limestone chippings

≥ 500

2 rows of three Ø12 mm holes

25 mm centres, 50 mm from the bottom of the tube, facing away from the house



2.17 CONNECTIONS & FILLING

CAUTION: Heating the isolation valves may damage the fibre seals

Fit each union with the fibre seals provided.

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 return valve (black handle) and copper tail.

IMPORTANT Install the Ideal system filter according to system filter installation and maintenance guide. Failure to install the system filter correctly will affect boiler warranty.

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.

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.

GAS CONNECTION

CAUTION: The gas service cock is sealed with a non-metallic blue fibre washer, which must not be overheated when making capillary connections.

PRV DRAIN

The PRV connection, located at the bottom left-hand side of the boiler, comprises an open ended grommet.

IMPORTANT

The grommet is designed for 15 mm Ø copper pipe.

If possible, preassemble and solder the pipework before

Installing.

If this is not possible the soldering must be more than

100 mm away from the grommet. Make sure the grommet is not damaged by the heat.

Install the condensate pipe as follows:

1. Make sure that the 15 mm Ø copper pipe is cut perpendicular to the pipe.

2. Make sure that the pipe is not damaged, and clean and free from burs.

3. Using pliers put the clip over the grommet. Continue to hold the clip open.

SCAN for video

Note.

Do not release the clip until step 5 (see below).

4. Push the copper pipe into the grommet (minimum of

15 mm). Make sure that the pipe is parallel with the grommet.

5. Below the stop mark on the grommet open the pliers to release the clip.

6. Make sure that the clip and pipe are attached correctly.

7. Make sure that the PRV discharge pipe is correctly attached. Make sure that the angle of the pipe run is sufficient to remove discharged water.

For details of the position of the gas connection:

Refer to Section

1.14

Refer to Gas Supply

1.9

WARNING:

Make sure that the water or steam (from the boiler) is discharged safely. Hot water or steam is dangerous and can cause serious injury, and damage to electrical systems.

Clip

Stop point

15 mm

CH Flow

DHW

Outlet

Gas

Supply

DHW

Inlet

CH

Return

A purpose made PRV drain pipe is provided with the boiler to allow safe discharge through a wall to the outside of the building. This is particularly relevant to ‘high rise’ installations but can be used for all installations.

Filling

Loop

The domestic hot water flow rate is automatically regulated to a maximum: kW

24

30

35

L/m

9.9

12.4

14.5

gpm

2.2

2.8

3.2

PRV

Drain Connection

15 mm Fitting

(not supplied) PRV

Drain Pipe (supplied)


26


2.18 CONNECTIONS & FILLING CONT.

FILLING

WARNING: Protect electrical connections from water

1. Connect the filling loop, ensuring the washers are in place.

2. Loosen the auto air vent dust cap.

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 and black handle on CH return C ).

4. Position the CH flow isolation valve handle in the vertical position to enable filling.

5. Slowly turn the filling loop handle (green B ) to the horizontal open position until the pressure gauge reads between 1 to 1.5 bar.

6. Turn the filling loop handle (green closed (vertical) position.

B ) back to the

7. Turn the CH Return handle (black C ) and the DHW

Inlet handle (blue ) to the open (vertical) position.

8. Disconnect the filling loop from the DHW Inlet valve and fit the grey cap to the open end.

9. Fit the Plug to the free end of the filling loop.

Top Up

1. Connect the filling loop, ensuring the washers are in place.

2. Loosen the auto air vent dust cap.

Refer to Section

3.24

3. Turn the DHW Inlet handle (blue ) to the horizontal position.

4. Slowly turn the filling loop handle (green B ) to the horizontal open position until the pressure gauge reads between 1 to 1.5 bar.

5. Turn the handle (green B ) on the filling loop back to the closed (vertical) position.

6. Turn the DHW Inlet handle (blue ) 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.

SCAN for video

Filling

Loop

Filling System Positions shown

Plug

Cap

B

A

DHW Inlet

(Blue)

Filling

Loop

Top Up Pressure Positions shown

Plug

Cap

B

A DHW Inlet

(Blue)

Filling Loop

(Green)

C

CH Return

(Black)

Filling Loop

(Green)

C

CH Return

(Black)



2.19 ELECTRICAL CONNECTIONS

WARNING: This appliance must be earthed

A mains supply of 230 V ~ 50 Hz is required.

3 A fuse required. All external controls and wiring must be suitable for mains voltage.

Wiring external to the boiler must follow current I.E.E

(BS7671) wiring regulations and local regulations.

Wiring should be 3 core PVC insulated cable, not less than

0.75 mm 2 (24 x 0.2 mm), and to BS6500 Table 16.

Connection must be made in a way that allows complete isolation of the electrical supply. The means of isolation must be accessible to the user after installation.

2.20 INSTALLER WIRING

WARNING: Ensure the supply cord is not damaged

The boiler must be connected to a permanent live power supply.

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.

4. Carefully pierce the grommet, release the cable clamp via the screws and pull wiring through.

5. Connect external wiring to the appropriate connections securely and then refit the cable clamp.

Once any wiring is completed, to secure the boiler, reverse the order above.

The link wire on the 230 V installer room stat/timer connection gives a demand in conjunction with the timer option plug inside the timer option cover. This is located on the front of the control box.

Installer Connections (LHS) Installer Connections (RHS)


FROST STAT

OPTIONAL

ROOM

STAT/

MAINS IN

TIMER L N

IN

SL2

L

IN

SL1

L

MAINS IN

L N

FROST STAT

OPTIONAL

STAT/ MAINS IN

TIMER L N

IN

SL2

L

IN

SL1

L

MAINS IN

L N

OPEN THERM./

WEATHER COMP.

B

27

28


2.21 EXTERNAL WIRING

External Controls – 230 V 50 Hz

Wiring a 230 V Programmable Room Stat (Diagrams A & C) or 230 V Timer & Room Stat (Diagram B).

1. Remove the link wire from the room stat/timer connection.

2. Connect the external cable from the room stat/timer across this connection. 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.

Frost Protection

If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system.

This is usually done at the programmer, in which case the programmer selector switches are set to OFF and all the other controls MUST be left in the running position.

The frost thermostat should be sited in a cold place, but where it can sense heat from the system.

Wiring a system frost thermostat, see diagrams E. Wire the frost thermostat across the two connections as shown.

If the boiler is installed in a garage it may be necessary to fit a pipe thermostat, preferably on the return pipework.

Optional External Controls – Extra Low Voltage

Wiring OpenTherm Programmable Room Stat (Diagram D).

1. Remove the timer link plug inside the timer option cover, located on the front of the control box.

2. Unclip the timer link socket from the aperture on the rear of the control box, locate the plug on the same harness branch and connect these together.

3. Using the rubber bung located adjacent to these connections, insert it into the open aperture.

4. Connect the external cable from the OpenTherm

Programmable Room Stat on the RHS of the boiler installer connections, labelled OpenTherm.

Diagram A: 230 V

Programmable Room Stat

Programmable

Room Stat

Diagram B: 230 V

Timer & Room Stat

Room

Stat Timer

Diagram C: 230 V


Use of Live from Isolator

Room

Stat

Mains In

Diagram D: OpenTherm


OpenTherm

Programmable

Room Stat

Diagram E: 230 V

Op � onal Frost Stat

Op � onal

Frost Stat

Room

Stat/

Timer

L N Room

Stat/

Timer

L N Room

Stat/

Timer

L N Open

Therm

Outside

Sensor

Frost

Stat


2.22 WIRING DIAGRAM


Flame Sensor r o w v r r er re h r r

2 3 4 h

1 2 3

3 2 1

1 2 3



2.23 REPLACING PRE-FITTED MAINS CABLE

If it is necessary to use an alternative mains cable to the one pre-fitted then use the following guide.

Replacement wiring should comply with notes and be carried out by a qualified person.

Refer to Section

2.21

1. Isolate the mains supply to the boiler.

2. Remove the front panel.

3. Swing the control box down into the service position, unclip and swing back the installer wiring cover to latch into the retaining clips.

4. Unscrew the L N & E connections & remove wires from connector.

5. Remove the mains cable by pulling back through the grommet.

6. Route the replacement through the grommet and re-fit.

7. Close the installer wiring cover ensuring that it is located correctly and that the cable is retained into the strain relief as shown.

Strain

Relief

5

8. Swing the control box back up into the operating position and re-fit the front panel ensuring a good seal is made.

The earth connection should be longer than the current carrying connections. If the cord anchorage slips, the current carrying wires become taut before the earth.

30

2.24 COMMISSIONING AND TESTING

A. Electrical Installation

WARNING: Electrical safety checks should be carried out by a qualified person.

Complete preliminary electrical system checks.

General

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.

Check the following:

1. The boiler has been installed in accordance with these instructions.

2. 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:

1. Check the operational gas inlet pressure.

2. Set up the boiler to operate at maximum rate by opening hot tap to maximum flow.

3. With the boiler operating in the maximum rate condition, check that the operational gas pressure at the inlet gas pressure test point complies with the requirements.

4. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working.

Refer to Gas Supply page 10

B. Gas Installation

WARNING: Open windows, doors and extinguish flames before starting the next steps. Do not smoke.

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.

2. Purge air from the gas installation by the approved methods only.

Gas

Supply

Gas Pressure

Test Point

IMPORTANT: A condition of the manufacturer’s warranty is that Benchmark commissioning process is

completed. The flow chart is provided on

page 67.



2.25 INITIAL LIGHTING

Legend

A. Domestic Hot Water

Temperature Knob

B. Central Heating

Temperature Knob

C. Hot Keys

D. Boiler Status Display

E. Burner On indicator

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

1 bar

Min

A

2 bar

2

1

0 bar

4

3

E D

On at 60°C

Target 60°C

Ready

Radiator Target 60°C

Room Thermostat or

Timer Off

On

Preheat Menu Mode

C

CAUTION: Do not operate the appliance before it has been fully vented of air. If it is necessary to operate the pump, do so with the gas service cock turned off.

The boiler incorporates a fan overrun cycle which must not be interrupted by isolation of electricity supply.

1. Check that the system has been filled and that the boiler is not airlocked.

2. Ensure the automatic air vent cap is open.

3. Refit the boiler front panel.

Refer to Section

3.2

4. Check that the drain cock is closed and that the CH and

DHW isolating valves (G,K & J) are OPEN.

5. Press the Mode button until a cross is shown going through both tap and radiator icons (boiler off).

6. Switch the electrical supply OFF.

7. Check that the gas service cock (I) is OPEN.

8. Slacken the screw in the inlet pressure test point (H) and connect a gas pressure gauge via a flexible tube.

9. Switch the electricity supply ON and check all external controls are calling for heat.

CH Flow

DHW

Outlet

Gas

Supply

J

DHW

Inlet

CH

Return

G L

I

H

Max

Filling

Loop

M

K

B

Pressure Gauge

N

1

2

3

0 bar

4

On at 60°C

Target 60°C Radiator

Target 60°C

Preheat

On

Menu

Mode

1

2

3

0 bar

4

CENTRAL HEATING

10. Press the Mode Button (C) until there is no longer a cross through the Radiator icon. Turn the Central Heating

Temperature Knob clockwise until a target of 80°C is shown. The boiler control will now go through its ignition sequence until the burner is established.

11. If the boiler does not light then after 5 attempts the boiler will lock out and display “Ignition Lockout”. Press the

Restart Button. The boiler will repeat its ignition sequence.

If Restart occurs 5 times within 15 minutes then “Too Many

Restarts” will be shown.

When the burner is established the flame symbol (E) will be shown on the display and the current flow temperature will be shown in the large digits underneath the radiator symbol.

DOMESTIC HOT WATER

12. With the boiler firing, rotate the DHW Temp Knob (A) clockwise until a target of 65°C is shown and fully open a DHW tap. The boiler should continue to run and the current DHW temperature will be shown in the large digits underneath the tap symbol.

13. 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 user-adjustable. Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void.

Refer to Gas Supply page 10

14. Turn off the DHW tap.

15. Remove gas pressure gauge, tighten inlet pressure test point and check for gas tightness.



2.26 USER INTERFACE COMMISSIONING

When the boiler is powered up for the first time, you will have the options to set the contact details for boiler servicing and to vent the system.

Vent the system?

Set your contact details for boiler service?

(defaults to Ideal Heating contact information otherwise)

No Yes No Yes

2.27 CHANGING BOILER OPERATING MODE

The boiler mode is displayed by default, to change the mode, simply press mode and select the desired mode.

Off

To Switch On

Press Mode Button & then On

Off

To Switch On


Off

Mode

Summer

Mode

Winter

Mode

Off On On

Off Off On

Menu Mode

32

2.28 PREHEAT FUNCTION

Preheating will occur when the flow Temperature drops

15°C below the DHW target.

It will run until the flow temperature reaches 5°C below the

DHW target or until 3 minutes has passed.

The preheat function will only run for a maximum of once in 30 minutes.

2.29 INTELLIGENT PREHEAT FUNCTION

If Preheat is switched to Timed then preheating will only occur when required, rather than all the time. The boiler learns the usage patten for DHW over a week and then times the DHW preheat to only operate during the usage periods from the previous week.

This improves the speed of response for DHW whilst also reducing the use of gas.

Ready

Target 60°C

Ready


Room Thermostat or

Timer Off

On

Preheat Menu

Press

Mode

Ready

Target 60°C

Ready


Room Thermostat or

Timer Off

Timed

Preheat Menu

Press

Mode



2.30 MENU OPERATION

The menu option contains a list of attributes that show the operating state of the boiler. The installer should scroll down the menu and press enter to select the desired option.

Menu

Exit

Service Contact Name

Service Phone Number

Change Service Time

Down Enter

Press

Note. For Diverter Valve Mid Position, press down until mid position highlighted.

2.31 SETTING MAXIMUM AND MINIMUM RATES

Maximum DHW and Minimum Rate can be accessed through the menu option.

Maximum DHW Rate

Target Fan Speed: 6800rpm

Actual Fan Speed: 6800rpm

Time remaining: 10 mins

Exit

Press

The boiler will run at Maximum DHW Rate for

10mins as long as there is sufficient cooling load

Minimum Rate

Target Fan Speed: 1400rpm

Actual Fan Speed: 1400rpm

Time remaining: 10 mins

Exit

Press

The boiler will run at Minimum Rate for 10mins

If the return temperature is under 40°C then the fan will run for 30s at maximum rate before ramping down over 60s to minimum rate.

If the return temperature is above 40°C then the fan will ramp down over 60s to minimum rate.


34

On at 65°C

Boiler Target 65°C

Ready

Radiator Target

60°C

Room Thermostat or

Timer Off


2.32 GENERAL CHECKS

Make the following checks for correct operation in:

1.

Fully open all DHW taps in turn and ensure that water flows freely from them.

The display should show:

Ready

Target 60°C

Ready

Radiator Target

60°C

Room Thermostat or

Timer Off

Off

Preheat Menu Mode

5. 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.

Menu Mode

2. Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate. This is factory set to give a DHW temperature rise of approximately

35 o C at the flow rate stated on page 10 under “operation”.

3. Reduce the DHW draw-off rate to about 3 l/min (0.7 gpm) and check that the boiler modulates to deliver DHW at approximately

65 o C.

4. Close the DHW tap and check that the main burner extinguishes. The pump should overrun for 60 seconds.

When the pump stops the display should show:

Ready

Target 60°C

Ready

To Switch On


On

Preheat Menu Mode

Note. On systems in excess of 2 bar inlet pressure a water pressure governor may be required to prevent water noise.

CH & DHW MODES

1. Ensure that the CH external controls are calling for heat.

2. Fully open a DHW tap and check that hot water is delivered.


On at 65°C

Target 65°C

Ready


Hot Water Priority

WATER CIRCULATION SYSTEM

1. With the system cold, check that the initial pressure is correct to the system design requirements.

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.

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.

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

1.18

4. Refill and vent the system, add inhibitor, clear all air locks and again check for water soundness.

5.

Reset the system initial pressure to the design requirement.

6.

Balance the system.

Refer to Section

1.17

7. Check the condensate drain for leaks and check that it is discharging correctly.

8.

Finally, set the controls to the User’s requirements.

The pump will operate briefly as a self-check once every 24 hours in the absence of any system demand.

Off

Preheat Menu Mode

Gas Rate

1. Check the boiler gas rate when the boiler is at full DHW output.

2. Check at the gas meter, with no other appliance in use.

Refer to Tables 2 & 3 for gas rates.

3. Close the DHW tap.

4. Set the central heating external controls to OFF. The burner should go off and the pump continue to run for two minutes.


WATER TEMPERATURES

Temperatures can be selected using the CH and DHW thermostats.

Temperature Knob

Setting

Max

Min

CH Flow Temp DHW Outlet o C

80

30 o C

65

40

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.


2.33 RESTART PROCEDURE


To restart the boiler, press the Restart button.

Ignition Lockout

1 Check other gas appliances work.

2 Restart boiler.

3 If fault persists, contact installer.

Ignition Lockout


2 Restart boiler.


Restart

Press

Menu

Restart Button

2.34 HANDING OVER

After commissioning the system, hand it over to the householder by the following actions:

1. Hand the Instructions to the householder and explain their responsibilities under the relevant national regulations.

2. Explain and demonstrate the lighting and shutting down procedures.

3. Explain how to operate the boiler and system controls.

4. Ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption.

5. Explain the precautions necessary to prevent damage to the system and to the building, in the event of the system remaining inoperative during frosty conditions.

6. Explain the function and the use of the boiler heating and domestic hot water controls.

7. 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” .

8. Explain the function of the boiler fault mode.

9. Explain and demonstrate the function of timers and temperature controls, radiator valves etc., for the economic use of the system.

10. If a timer is fitted draw attention to the timer Users

Instructions and hand them to the householder.

11. Explain that the gauge behind the drop down door, 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 re-pressurising 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

2.17

12. Explain boiler restart procedure.

Refer to Section

2.33

13. After installation and commissioning please complete the Commissioning Checklist before handover to the customer.

Refer to

Page 62

IMPORTANT

14. A comprehensive service should be carried out annually.

Stress the importance of regular servicing by a Gas Safe

Registered Engineer.

15. Inform the householder of the boiler warranty and the requirement to register it to receive the full benefit.

1

2

3

0 bar

4


36

Section 3 - Servicing

3.1 SERVICING SCHEDULE

WARNING: Servicing can only be carried out by Gas Safe Registered Engineers

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

BS EN 50379-3:2012.

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.

For the latest copy of literature, visit our website idealheating.com.

PRELIMINARY INSPECTION

1. Light the boiler and carry out a pre-service check, refer to the fault finding chart.

2. Check the flue terminal (and terminal guard if fitted) for damage and obstruction.

3. Check combustion by connecting the flue gas analyser to the flue gas sampling point as shown in the diagram and measure CO and CO

2

at maximum rate. Set the boiler to

Maximum and Minimum heat inputs.

Refer to Section

2.31

If the CO / CO

2

ratio is greater than 0.004 please proceed to “Cleaning Procedure”.

If the CO / CO

2

ratio is less than 0.004 please proceed to

“Check Procedure”.

CHECK PROCEDURE

1. 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.

2. Proceed to “IMPORTANT”.

CLEANING PROCEDURE

1. Remove the casing.

2. Visually check the appliance for signs of leakage.

3. Remove the flue manifold.

4. Remove the fan.

5. Remove the burner.

6. Refit the sump outlet cover.

7. Clean the heat exchanger by pouring warm water across the whole heat engine to flush deposits taking care to avoid pouring water over the electrode.

8. Check the electrode for damage and clean using an abrasive cloth. Check and adjust the spark gap. Replace the electrode if damaged.

9. Clean out the sump outlet to ensure any debris is removed.

10. Remove and clean the condensate trap and re- prime the trap before re-installing.

11. Check the DHW filter for blockage.

12. Re-assemble the components in reverse order.

13. Clean the Ideal system filter. Refer to the system filter installation and maintenance guide for the correct method of servicing.

14. Carry out post service checks on the combustion circuit.

See General below.

15. Check the system water quality in accordance with

BS7593:2019.

16. Complete the service record in the Benchmark section.

IMPORTANT

1. If, for any reason, the condensate trap has been removed, ensure the trap is refilled with water before re-assembling.

2. After completing the servicing or exchange of components, always ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve.

3. When work is complete the front panel MUST be correctly refitted, ensuring that a good seal is made.

4. Clean the Ideal system filter, refer to system filter installation and maintenance guide for correct method of servicing.

5. Complete the service section in the Benchmark

Commissioning Checklist.

GENERAL

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.

Do not operate the boiler if the front panel is not fitted .

Flue

Sampling

Point

Air Sample

Point

Ensure all caps and seals are re-fitted after use



3.2 REMOVAL / REPLACEMENT OF COMPONENTS

WARNING: Do not operate the boiler without a front panel fitted

When replacing any component.

1. Isolate the electricity supply.

2. Turn off the gas supply.

3. Remove the boiler front panel.

Refer to Section

3.4

4. Swing the control box down into its servicing position.

After removing / replacing any component.

5. Ensure all gas valve connections are gas tight with a gas

soundness check up to the gas control valve.

6. Ensure all water connections are tight.

7. Test the appliance for correct and safe operation.

Refer to Section

3.1 (General)

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 3.12, 3.15 and 3.21-3.32, it is necessary to drain the boiler.

Refer to Section

3.3

3.3 DRAINING THE BOILER

Refer to Section

3.2

CENTRAL HEATING CIRCUIT

1. Close all the CH water isolating valves on both the flow and return.

2. To drain the primary heat exchanger circuit: Open the drain valve and attach a length of hose to the CH drain point.

43.5

3. After replacing any component on the boiler, remove the hose, close the drain valve and open all system isolating valves.

32 33 36 94

4. Repressurise by reconnecting the filling loop, check for leaks before proceeding to check operation of the boiler.

5. Disconnect filling loop.

Refer to Section

2.17

DOMESTIC HOT WATER CIRCUIT

1. Close all the DHW water isolating valves on the boiler inlet.

2. 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 released during replacement of components.

.

3. After replacing any component on the boiler, open isolating valve.

PRV

Grommet

CH

Flow

DHW

Outlet

Gas

DHW

Inlet

CH

Return Circuit

Drain


37

38


3.4 BOILER FRONT PANEL REMOVAL / REPLACEMENT

REMOVAL

1. Loosen the two screws retaining the front panel.

2. Pull the two clips down to disengage and pull panel forward and upward and remove.

REPLACEMENT

4. Hook the panel onto the top retaining clips.

5. Push the panel until the 2 bottom spring clips engage ensuring the 2 knobs and 4 buttons line up with the holes in the front panel.

6. Re-tighten the two retaining screws.

2

1

3

View from bottom of boiler

3.5 FLUE MANIFOLD REMOVAL/REPLACEMENT

1. Remove the two sump cover retaining screws.

2. Remove the sump cover.

3. Lift the manifold upwards to clear the sump.

4. Move the manifold to the left and pull down to remove.

View from top of boiler



3.6 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING

1. Disconnect the electrical leads from the fan.

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.

7. Clean the outside of the injector and use a small flue brush to clean the injector hole. Do not use anything abrasive such as a file.

8.

Remove the screw and twist venturi anti-clockwise to remove venturi assembly, noting the orientation of the venturi in relation to the fan body.

9. Inspect fan outlet sealing gasket and replace if necessary.

10. Ensure the venturi is free from dust/debris.

11. Check the ‘O’-rings are fitted correctly to the gas outlet pipe replacing if any damage is witnessed.

1

3

8

Injector

Nozzle

5

2


39


3.7 BURNER REMOVAL AND CLEANING

Refer to Section

3.6

1. Remove the 2 burner front fixing screws and the

2 rear extended nuts.

2. Lift and pull forward the burner from the combustion chamber by holding the burner with two finger in the air inlet duct and your thumb on the top of the burner.

3. Tilt the burner towards yourself so that it raises to the vertical position.

4. Pull the burner out from the left hand side of the boiler once it is in the vertical position.

SCAN for video

1 1

Place thumb here

Insert two fingers 5. Carefully brush the ceramic burner with a soft non metallic bristle brush.

1 Lift the burner approximately 5 to 10 mm from the heat engine and then pull forward by the same amount.

3.8 CLEANING THE HEAT EXCHANGER

1. Replace the sump cover prior to the water flush process.

2. Thoroughly flush the heat exchanger by pouring water into the top of the combustion chamber ensuring the full surface of the heat exchanger is cleaned. Avoid pouring water over the electrode.

3. Remove the sump cover and clean loose deposits from the sump.

4. Inspect the ignition/detection electrode. Ensure that it is clean and in good condition - replace if necessary.

5. Check that the ignition gap is correct.

Refer to Section

3.9

2

40

Combined Ignition Detection Electrode



3.9 IGNITION / DETECTION ELECTRODE REPLACEMENT / INSPECTION

Refer to Section

3.2

Ignition /Detection

Electrode

Straight edge

1. Remove the fan.

Refer to Section

3.6

2. Remove the flue manifold.

3. Remove the burner.

Refer to Section

3.14

4. When servicing the boiler inspect the condition of the electrode and check the dimensions shown. If there is damage to the electrode continue to follow steps below for replacment.

5. Unplug the ignition lead from the electrode.

6. Remove the earth lead from the electrode.

7. Remove the 2 screws holding the electrode to the combustion chamber.

Spark Gap

3.5 mm 8. Remove the electrode.

9. Fit the new electrode, using the new gasket supplied. Check dimensions as shown.

Refer to Section

2.32 & 2.33

3 mm

3.10 CLEANING THE CONDENSATE TRAP

CAUTION: Keep trap upright when removing

1. Pull off the rubber pipe at the sump drain.

2. Turn the trap clockwise to disengage and lift to remove.

3. Clean and fill trap with water.

1

Condensate

Drain

SCAN for video

PRV

Grommet


Gas

CH

Circuit

Drain

41


3.11 BURNER INJECTOR REPLACEMENT

Refer to Section

3.6

3.12 DHW FILTER & DHW FLOW REGULATOR CLEANING/REPLACEMENT

Refer to Section

3.2

1. Isolate the DHW system.

Refer to Section

3.3

2. Turn the housing anti clockwise and pull forward to remove the cartridge. Be prepared for some water release.

3. Using a pair of pliers, pull out the plastic filter/flow regulator.

4. Clean or replace filter as necessary.

2

42

3.13 EXTERNAL SYSTEM FILTER CLEANING GUIDE

1. Switch off the boiler (isolate electrical supply).

2. Close the inlet/outlet valves. Remove magnet and vent.

3. Remove drain valve cap, open drain valve and vent.

4. Open inlet valve slowly and flush out filter until water runs clear.

5. Close the inlet valve. Close the drain valve.

6. Reinsert the magnet and replace the drain valve cap.

7. Open inlet/outlet valves, refill system and vent.

8. Restart the boiler.

3

Vent

2

2

5

1

Close

1

Close

CAUTION: Ensure that the magnet pocket is kept dry.

1

Close

IMPORTANT: Repressurise the system after cleaning the filter, as loss of pressure will occur.

2

Close

3

3

Vent

6

2

2

Open

1

1

4

7

2

Vent

1

Open

1

Open

1

Open


3.14 BURNER REPLACEMENT


Refer to Section

3.2 & 3.7

3.15 RETURN THERMISTOR REPLACEMENT

1. Isolate and drain down the boiler.

2. Remove the clip from the pump housing and remove the thermistor.

3. Disconnect the electrical lead from the thermistor.

4. Reconnect the electrical lead to the new thermistor and reassemble, ensuring that the thermistor is fully engaged and the clip is correctly located.

SCAN for video

2

Refer to Section

3.2

2

3.16 SPARK GENERATOR REPLACEMENT

1. Disconnect the leads from the spark generator.

2. Gently push up the generator to release the bottom clip from the gas valve mounting bracket.

3. Lift the spark generator up and out of the bottom retaining location point.

Refer to Section

3.2

4. Fit the new spark generator and reassemble, ensuring that the the earth lead is replaced.


43


3.17 GAS CONTROL VALVE REPLACEMENT

Refer to Section

3.2

1. Disconnect and remove the condensate trap and rubber connector.

Refer to Section

3.19

2. Unplug the electrical lead connection from the gas control valve.

3. Remove the outlet gas valve clip and slide the pipe upwards.

4. Undo the gas inlet pipe union at the inlet to the gas valve.

5. Undo the two screws fixing the gas valve to the chassis base and lift the gas valve upwards.

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. Refit the trap.

8. Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve.

3

5

3.18 DIVERTER VALVE ACTUATOR REPLACEMENT

Refer to Section

3.2

To remove the motor:

1. Remove the condensate trap.

Refer to Section

3.10

2. Press Down on the hot keys until the diverter valve mid position is highlighted. Ensure that the diverter valve is in mid position.

Refer to Section

2.30

3. Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator.

4. Disconnect the electrical plug from the motor.

5. Fit the new motor ensuring the arm is correctly engaged in the metal fork and reassemble ensuring the condensate trap is refilled with water. Reconnect the electrical plug to the motor.

44

Note. All spares will be delivered in mid-position.

3.19 CONDENSATE TRAP REPLACEMENT / CLEANING

Refer to Section

3.2



3.20 PRIMARY PCB REPLACEMENT

Press Select to confirm & the following screen is shown:

WARNING: It is critical that the correct boiler size and fuel type is entered in to the boiler.

CAUTION: Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis.

Program this model?

1/6

Combi 24 kW

Natural Gas

Back Yes

Refer to Section

3.2

1. Carefully release the four retaining clips and remove control box cover.

2. Unplug all lead connections to the PCB.

3. Spring out the four side retaining clips and pull the PCB upwards to clear the corner retaining posts.

4. Fit the new PCB.

5. Re-connect all plug connections.

6. Reassemble.

7. Turn power on, display shows:

Installer

Initialise spare PCB?

Yes

Press Yes and the following screen is shown:

Select Boiler Brand

Option 1 of 5

Logic Max

Press Next until [Logic Max] is shown. Press Select.

Select Boiler Brand

Option 1 of 4

Combi

Back Next Select

Press Next until correct Boiler type is shown:

Combi, Heat, System UK or System IE

Press Select to confirm & the following screen is shown:

Select Boiler Model

Option 1 of 6

Combi

24 kW

Natural Gas

Back Next Select

Press Next until correct Boiler model shown

1/6, Combi 24 kW, Natural Gas

2/6, Combi 24 kW, Propane

3/6, Combi 30 kW, Natural Gas

4/6, Combi, 30 kW, Propane

5/6, Combi, 35 kW, Natural Gas

6/6, Combi, 35 kW, Propane

Press Yes to finish

FROST STAT

OPTIONAL

STAT/ MAINS IN

TIMER L N

IN

SL2

L

IN

SL1

L

MAINS IN

L N

1

3

1


45


3.21 DHW FLOW TURBINE SENSOR REPLACEMENT

Refer to Section

3.2

1. Drain the DHW system.

Refer to Section

3.3

2. Pull off the electrical connection.

Refer to Section

3.21

3. Using a suitable tool, lift and remove the retaining clip.

4. Use the clip to ease the turbine sensor from its housing.

5. Reassemble with new sensor.

4

2

3

46

3.22 PRESSURE GAUGE REPLACEMENT

Refer to Section

3.2

1. Drain the boiler.

Refer to Section

3.3

2. Remove the boiler front (see section 3.4), lower the control panel and remove the control box cover.

3. Ensuring there is no pressure in the system unclip the

C clip from the flow pipe port and remove the capillary connection together with ‘O’ ring.

4. Releasing the two retaining clips on the pressure gauge ease the pressure gauge through the front of the control panel.

5. Fit the new pressure gauge from the front of the lower control panel ensuring correct orientation. Locate push fit connection into flow pipe ensuring ‘O’ ring in place and secure with the ‘C’ clip.

6. Refill the boiler.

Refer to Section

2.17

3

5



3.23 PRV REPLACEMENT

Refer to Section

3.2


Refer to Section

3.3

2. Remove the trap and rubber pipe.

3. Pull out and remove the clip retaining the PRV.

4. Lift out the PRV/pipe assembly.

5. Remove the pipe and transfer to the new PRV.

6. Reassemble ensuring the retaining clip is correctly fitted.

SCAN for video

7. Check the operation of the PRV by raising the water pressure until the valve lifts. This should occur within 0.3 bar of the preset lift pressure.

8. Check no escape of water occurs except at the discharge point

Refer to Section

2.17

9. Release water from the system until the minimum system design pressure is reached;

1.0 bar if the system is to be pre-pressurised.

3

3

3.24 PUMP AUTOMATIC AIR VENT REPLACEMENT

Refer to Section

3.2


Refer to Section

3.3

2. Remove the expansion vessel.

Refer to Section

3.32

3. Firstly, increase access area by disconnecting the

22 mm pipe connection at top of pump manifold and bottom of heat exchanger and remove pipe.

4. 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.

5. Reassemble. Ensure the air vent head ‘O’ ring seal is fitted.

6. Ensure the air vent cap is loose.

7. Refill the boiler. Check for leaks around the new air vent joint.

Refer to Section

2.17

Dust Cap


47


3.25 REPLACEMENT OF DHW THERMISTOR

Refer to Section

3.2

4. Fit the replacement thermistor and reassemble.

5. Re-establish the DHW supply, turn on a hotwater tap checking for leaks.

1. Isolate the DHW system.

2. Remove the retaining clip and extract the thermistor.

Be prepared for some water release.

3. Disconnect the wiring harness.

DHW

Thermistor position

2

48

3.26 DHW PLATE HEAT EXCHANGER REPLACEMENT


Refer to Section

3.3

2. Remove condensate trap.

Refer to Section

3.10

3. Remove the 2 hex screws securing the plate heat exchanger to the composite housings.

4. Manoeuvre the plate heat exchanger out of the top LH or centre of the controls area. Be aware of any water spillage.

Refer to Section

3.2

5. Fit the new plate heat exchanger, using the new

‘O’-rings supplied.

Ensure that the depressions are on the bottom prior to fitting.

6. Reassemble.


Refer to Section

2.17

8. Check that the boiler operates in both DHW & CH modes.

3

SCAN for video



3.27 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT

Refer to Section

3.2

T o remove the valve body assembly:


Refer to Section

3.3

2. Remove the condensate trap.

Refer to Section

3.10

3. Remove the electrical plug from the divertor valve.

4. Place a flat bladed screwdriver in the diverter valve motor

body slot provided and ease out the motor.

Refer to Section

3.18

5. Remove the return thermistor electrical connection.

Refer to Section

3.15

6. Remove the pump electrical connections.

Refer to Section

3.28

7. Remove DHW Turbine electrical connection.

Refer to Section

3.3

8. Remove the DHW plate heat exchanger (note orientation).

Refer to Section

3.26

9. Loosen the nut above pump and rotate the pipe.

10. If required remove expansion vessel connection hose.

Refer to Section

3.32

11. Remove the DHW inlet and CH return connection situated beneath the boiler.

12. Remove the four torx head screws fixing the return manifold to the boiler sheet steel base.

13. Lift the manifold assembly and remove from boiler.

14. Twist and remove the DHW manifold.

15. Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly.

16. Fit the new diverter valve body assembly and replace the two fixing screws.

17. Refit the DHW manifold, fit the assembly back to the boiler and reassemble.

18. Refill the boiler and check for leaks. Check that the boiler operates in both DHW & CH modes.

11

16 17

10


13 15 12

49

50


3.28 PUMP HEAD REPLACEMENT

Refer to Section

3.2


Refer to Section

3.3

2. Disconnect the two electrical leads from the pump.

3. Remove the 4 hex screws retaining the pump head.

4. Remove the pump head.

Be aware of water spillage.

5. Fit the new pump head.

6. Reassemble.


Refer to Section

2.17

3

3

3.29 CH WATER PRESSURE SWITCH REPLACEMENT

Refer to Section

3.2


Refer to Section

3.3

2. Pull off the two electrical connections.

3. Using a suitable tool, pull out the metal retaining clip.

4. Carefully withdraw the pressure switch.

5. Fit the new pressure switch and reassemble. Ensure the

‘O’ ring is fitted and replace clip.


Refer to Section

2.17

3

4

2

2



3.30 FLOW THERMISTOR REPLACEMENT

1. Drain down the boiler.

Refer to Section

3.3

5. Reassemble.


Refer to Section

2.17

2. Unplug the electrical lead.

3. Remove the clip from the flow pipe and remove the thermistor.

4. Fit the new thermistor, ensure ‘O’ ring is fitted and replace clip.

Refer to Section

3.2

7. Check that the boiler operates in both DHW & CH modes.

3

2

Shown rotated 90º


51

52


3.31 HEAT ENGINE REPLACEMENT

Refer to Section

2.1

CAUTION: Protect the gas and electrical controls with a waterproof sheet.

Refer to Section

3.2

1. Drain the boiler (CH Circuit Drain).

Refer to Section

3.3

2. Undo the two screws and remove the sump cover retaining the lower flue manifold.

3. Lift the manifold to clear the bottom sealing gasket and remove manifold.

4. Remove the fan / venturi assembly and place on one side.

Refer to Section

3.6

5. Remove the burner and place on one side.

Refer to Section

3.7

6. Remove the ignition/detection electrode.

Refer to Section

3.9

7. Remove the spark generator.

Refer to Section

3.16

8. Remove the gas valve.

Refer to Section

3.17


Refer to Section

3.32

10. Remove the 2 M5 screws retaining the spark generator, mounting bracket and transfer bracket to the new heat exchanger.

11. Undo the pump union nut, remove clip and remove pipe from expansion vessel.

12. Remove the two retaining pipe clips and remove pipes.

13. Remove the condensate rubber pipe.

Refer to Section

3.19 No.2

14. Remove the two heat exchanger fixing screws.

15. Remove the heat exchanger, slide out of location bracket.

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.

4

6

2

7

10

12

12

18

17. Reassemble, 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 diametres.

18. Ensure the trap is filled with water.

Refer to Section

3.19

19. Refill the boiler and check for leaks.

Refer to Section

2.15

20. Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve.

8

9

14

14

11

11

13

1



3.32 EXPANSION VESSEL RECHARGING & REPLACEMENT

Refer to Section

3.2

RECHARGING

1. Remove the charge point cap.

2. Recharge the tank pressure to 0.75 bar.

3. Reassemble.

7

REPLACEMENT

4. Drain the boiler CH circuit.

Refer to Section

3.3

5. Remove the retaining clip on the vessel water connection pipe and remove the pipe.

6. 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.


8. Fit the new expansion vessel.

9. Reassemble ensuring the ‘O’ ring seal is in place and refit the retaining clip.

10. Refill the boiler and check for leaks.

Refer to Section

2.18

Recharge

Point

6


53

Section 4 - Fault Finding

4.1 MAIN MENU, FAULT HELP

Fault finding help can be accessed through the menu.

Fault finding help lists all the common faults with the necessary checks. More detailed fault checks and actions are described in the following pages.

Menu

Exit

Change Service Time

Fault History

Fault Help

Vent System

Sensor Readings

Down Up Enter

Press

Fault Help

[Ideal] Technical Help Line:

[01482 498663]

[Spares: 01482 498665]

Exit Next

Fault Help

Exit

Low Water Pressure

Ignition Lockout

Overheat Lockout

Down Up

Press

Enter

Press

Fault Help

Only carry out the following tests if you are gas safe qualified

Exit Next

Press

54

4.2 OVERHEAT LOCKOUT

Is the Boiler and CH System filled with water and all isolation, system filter and radiator valves open?

YES

Is the Flow/Return Differential across the Boiler in excess of 30°C?

NO

Check the Flow and Return Thermistors

Refer to Section

3.15

& 3.30

Check resistance using a suitable multimeter connected across the thermistor’s terminal pins

Temperature Resistance kΩ

25 o C

60 o C

85 o C

9.7 – 10.3

2.4 – 2.6

1.0 – 1.1

NO

YES

Fill and vent the system and open all isolation valves, then restart boiler

Check that the Pump is rotating freely.

Is the Differential now below 20°C?

NO YES

Replace the Pump, then restart boiler

OK, now restart boiler



4.3 IGNITION LOCKOUT

If the boiler is restarted does the boiler ignite for a short time and then extinguish?

YES

Check the detection electrode and associated harness for: continuity, visual condition and position

Refer to Section

3.9

Check if the condensate pipe is blocked

Replace as necessary

Check trap and condensate drain pipe work for blockage and rectify if necessary. Boiler now working

OK?

NO

Replace Gas Valve

NO

YES

Is the Gas Pressure available at the Boiler Inlet (>18 mbar)?

YES

Is approx 24 Vdc supply available at the Gas Valve?

YES

Unplug gas valve. Is resistance between outside pins between

4 k Ω (± 2)?

YES

Check spark generator and associated harness for: continuity and visual condition

Refer to Section

3.16

Are these functioning correctly?

YES

Check ignition electrode and associated harness for: continuity, visual condition and position

Refer to Section

3.9

NO

NO

NO

NO

NO


Check gas supply and rectify fault

Check wiring connection from gas valve to

PCB for continuity. If the wiring is OK then replace the PCB

Replace Gas Valve

Replace Spark

Generator and harness as necessary

Replace Ignition

Electrode and associated harness as necessary

4.4 FLAME ON BEFORE GAS VALVE ON

Restart the boiler, does Boiler Work OK?

NO

YES

Check routing and integrity of internal boiler wiring is OK

Check condition of Electrode and replace if deteriorated

Replace Electrode

4.5 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

Are connections on water pressure switch secure?

NO

NO

YES


Fill and vent the system and open all isolation valves

Re-fit connections

Replace water pressure switch

continued.......

55

56


4.6 FLAME LOSS

Does the boiler ignite for a short time and then extinguish?

YES

Check the Ignition/ detection electrode and associated harness for: continuity, visual condition and position

Refer to Section

3.9

Check if condensate pipe is blocked. Check if flue is blocked.

Replace as necessary

NO Is the Gas Pressure available at the Boiler Inlet (>18 mbar)?

YES

Is 24V DC supply available at the

Gas Valve while the flame is on?

NO

NO

YES

Check spark generator and associated harness for: continuity and visual condition

Refer to Section

3.16


YES

Check ignition electrode and associated harness for: continuity, visual condition and position

Refer to Section

3.9


YES

NO

NO

Check trap and condensate drain pipe work for blockage and rectify if necessary. Boiler now working

OK?

NO

Check gas supply and rectify fault

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

Replace Ignition

Electrode and associated harness as necessary

Replace Gas Valve

4.7 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?

YES

Is there 230 VAC at the Blue and Brown connections to the 3 way connection on the Fan?

NO

Rectify Wiring & connections

NO

YES

Replace PCB

Replace Fan



4.8 FLOW THERMISTOR FAULT

NO

Is the wiring securely connected to the Flow Thermistor located in the Flow Pipe lower LHS of Boiler?

YES

Disconnect the wiring from the Flow Thermistor

Check the resistance using a suitable multimeter connected across the Thermistor’s terminal pins


25 o C

60 o C

85 o C

9.7 – 10.3

2.4 – 2.6

1.0 – 1.1

Is the Thermistor value correct?

YES

Is the wiring securely connected to the 8 way connector X7?

NO

NO

YES

Securely connect the wiring to the Flow

Thermistor

Fit a new Thermistor

Securely connect the wiring to the PCB

Replace PCB

4.9 RETURN THERMISTOR FAULT

Pump Housing

Check the resistance using a suitable multimeter connected across the thermistor’s terminal pins


25 o C

60 o C

85 o C

9.7 – 10.3

2.4 – 2.6

1.0 – 1.1

Is the Thermistor value correct?

YES

Is there continuity between the PCB and the Thermistor?

NO

NO

YES

Replace PCB

Fit a new Thermistor

Check and replace wiring as necessary

Installation and Servicing continued.......

57


4.10 OUTSIDE SENSOR FAULT

Is the wiring securely connected at both the boiler and

Outside Sensor?

NO 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


0 o C

15 o C

30 o C

31.0 – 35.0

15.0 – 16.5

7.7 – 8.5

Is the Outside Sensor value correct?

YES

Is the wiring securely connected between the incoming terminal block boiler connection of the

Outside Sensor and the PCB?

YES

Replace PCB

NO

NO

Fit a new Outside Sensor

Securely connect the wiring at the

Terminal Block and the PCB

58

4.11 NO CH OPERATION BUT DHW WORKS OK

YES

Is “Off” shown underneath the rad on the display?

Press Mode button (B) until “Off” not shown

NO

Are CH Timer and Room Thermostat switched on?

YES

Are the Radiator Valves Open?

YES

NO

NO

Is there 230 V AC (SL1)?

YES

If an OpenTherm Room Stat is not connected, is there a link wire across the OpenTherm connections

(B)?

YES

Replace the Divertor Valve

NO

NO

Switch CH Timer and Room Thermostat On

Open the Radiator Valves

No voltage from Timer/Room Stat

This is not a boiler fault

Ensure voltage is supplied to boiler by rectifying external wiring

Connect a link wire across the OpenTherm connections

OPEN THERM./

WEATHER COMP.

B



4.12 NO DHW BUT CH WORKS OK

Does tap symbol change from blue to orange when a tap is turned on?

NO

Are hot & cold pipe work crossed?

NO

YES

Correct pipe work

YES

Is wiring connected between PCB

& DHW turbine?

NO Re-connect wiring

YES

Remove turbine & check for debris in turbine & filter. Replace turbine if necessary

NO Replace DHW turbine

Are the flow rates correct?

Refer to Section

1.2

NO

Adjust flow rates to achieve 35°C temp rise and check filter fitted in turbine is not blocked with debris

YES

Is the wiring between the PCB and the diverter valve motor connected?

NO

YES

Reconnect wiring or replace wiring harness if no continuity

Is diverter head fully engaged and clip secured onto water set?

YES

NO

NO

Is diverter valve stuck in CH position?

YES

Re-engage diverter head and secure clip to water set

Replace PCB

Check and re-fit diverter valve actuator head.

Is boiler DHW OK?

NO

Change diverter valve motor

FROST STAT

OPTIONAL

ROOM

STAT/ MAINS IN

TIMER L N

IN

SL2

L

IN

SL1

L

OPEN THERM./

WEATHER COMP.

MAINS IN

L N

B

Installation and Servicing continued.......

59

60


4.13 NO DISPLAY

Is there 230 V AC to the boiler at L and N?

YES

Is the wiring from the terminal block to the PCB connected securely?

YES

Replace the PCB

NO

NO

Supply power to the boiler

Connect the wiring from the terminal block to the

PCB securely

L

N

4.14 DHW THERMISTOR FAULT

Disconnect the DHW thermistor electrical connection

Check the resistance using a suitable multi-meter connected across the thermistor’s terminal pins


25 o C 9.7 – 10.3

60 o C 2.4 – 2.6

Is the thermistor value correct?

YES

Is there continuity between the PCB and the

Thermistor?

YES

Replace the PCB

NO

NO

Fit a new thermistor

Check and replace wiring as necessary


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 Heating.

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 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

LINK to spares


Section 6 - Benchmark to Commissioning

62 Installation and Servicing


Benchmark Commissioning &

Warranty Validation Service Record

It is a requirement that the boiler is installed and commissioned to the manufacturers’ instructions and the data fields on the commissioning checklist completed in full.

To instigate the boiler warranty the boiler needs to be registered with the manufacturer within one month of the installation. The warranty rests with the end-user (consumer), and they should be made aware it is ultimately their responsibility to register with the manufacturer, within the allotted time period.

It is essential that the boiler is serviced in line with the manufacturers’ recommendations, at least annually. This must be carried out by a competent Gas

Safe registered engineer. The service details should be recorded on the Benchmark

Service and Interim Boiler Work Record and left with the householder. Failure to comply with the manufacturers’ servicing instructions and requirements will invalidate the warranty.

www.hhic.co.uk

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.

Failure to install and commission according to the manufacturers’ instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.

* All installations in England and Wales must be notified to Local Authority Building Control (LABC) either directly or through a

Competent Persons Scheme. A Building Regulations Compliance Certificate will then be issued to the customer.

© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk


64


GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD

Address:

Boiler make and model:

Boiler serial number:

Commissioned by (PRINT NAME):

Company name:

Company email:

Gas Safe registration number:

Telephone number:

Company address:

Commissioning date:

Heating and hot water system complies with the appropriate Building Regulations? Yes

Optional: Building Regulations Notification Number (if applicable):

Time, temperature control and boiler interlock provided for central heating and hot water

Boiler Plus requirements (tick the appropriate box(s))

Yes

Boiler Plus option chosen for combination boiler in ENGLAND

Weather compensation

Load compensation

Smart thermostat with automisation and optimisation

Flue Gas Heat Recovery

Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination boiler

Zone valves

Thermostatic radiator valves

Automatic bypass to system

Underfloor heating pre-existing pre-existing pre-existing pre-existing

Fitted

Fitted

Fitted

Fitted

Water quality

The system has been flushed, cleaned and a suitable inhibitor applied upon final fill, in accordance with BS7593 and boiler manufacturers’ instructions

What system cleaner was used?

What inhibitor was used?

Primary water system filter pre-existing

CENTRAL HEATING MODE measure and record (as appropriate)

Gas rate (for combination boilers complete DHW mode gas rate)

Brand:

Brand:

Fitted m 3/ hr or

Product:

Product:

Not required

Not required

Not required

Not required

Yes

Not required ft 3 /hr

Central heating output left at factory settings?

If no, what is the maximum central heating output selected?

Dynamic gas inlet pressure

Central heating flow temperature

Central heating return temperature

System correctly balanced/rebalanced?

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)?

Water scale reducer/softener

What type of scale reducer/softener has been fitted?

Water meter fitted?

If yes- DHW expansion vessel

Pressure reducing valve

DOMESTIC HOT WATER MODE Measure and record pre-existing pre-existing pre-existing

Brand:

Gas rate

Dynamic gas inlet pressure at maximum rate

Cold water inlet temperature

Hot water has been checked at all outlets

CONDENSATE DISPOSAL m 3/ hr

Yes

The condensate drain has been installed in accordance with the manufacturers’ instructions and/or BS5546/BS6798

Point of termination Internal

Method of disposal

ALL INSTALLATIONS

Gravity

Yes

Yes

Fitted

Yes

Fitted

Fitted

Product: or

No

Yes

No

Not required

No

Not required

Not required ft 3 /hr mbar

°C

Temperature °C

External (only where internal termination impractical)

Pumped kW mbar

°C

°C

Yes

Record the following

At max rate:

At min rate (where possible)

CO ppm CO

2

% CO/CO

2

Ratio

CO ppm CO

2

% CO/CO

2

Ratio

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’ instructions, and readings are correct?

Yes

The operation of the boiler and system controls have been demonstrated to and understood by the customer

The manufacturers’ literature, including Benchmark Checklist and Service Record, has been explained and left with the customer

Yes

Yes

Commissioning Engineer’s signature

Customer’s signature

(To confirm satisfactory demonstration and receipt of manufacturers’ literature)






SERVICE & INTERIM BOILER WORK RECORD

It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed.

Service provider

When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the manufacturers’ specified spare parts.

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Date:

Engineer name:

Telephone N o :

Company name:

Gas Safe registration N o :

Max rate CO ppm CO

Min rate CO ppm CO

² %

² %

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’ instructions, and readings are correct?”

CO/CO

²

CO/CO

² yes

Gas rate: m 3 /h OR

Were parts fitted?

delete as appropriate Yes

Parts fitted:

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

Comments: ft 3 /h

No yes n/a


Date:

Engineer name:

Telephone N o :

Company name:

Gas Safe registration N o :

Max rate CO ppm CO

Min rate CO ppm CO

² %

² %


CO/CO

²

CO/CO

² yes

Gas rate: m 3 /h OR

Were parts fitted?

delete as appropriate Yes

Parts fitted:


Comments: ft 3 /h

No yes n/a

Signature:

*A System inhibitor efficacy test is required on every annual service in accordance with the manufacturers’ instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

Signature:



Date:

Engineer name:

Telephone N o :

Company name:

Gas Safe registration N

Max rate CO ppm CO

² %

Min rate CO ppm CO

² %

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’ instructions, and readings are correct?” o :

CO/CO

CO/CO

²

² yes

Gas rate: m 3 /h OR

Were parts fitted?

delete as appropriate

Yes

Parts fitted: ft 3 /h

No


Comments: yes n/a


Date:

Engineer name:

Telephone N o :

Company name:

Gas Safe registration N

Max rate CO ppm CO

² %

Min rate CO ppm CO

² %

Where possible, has a flue integrity check been undertaken in accordance with manufacturers’ instructions, and readings are correct?” o :

CO/CO

CO/CO

²

² yes

Gas rate: m 3 /h OR

Were parts fitted?


Yes

Parts fitted:


Comments: ft 3 /h

No yes n/a

Signature:


Signature:



Date:

Engineer name:

Telephone N o :

Company name:

Gas Safe registration N o

Max rate CO ppm CO

² %

Min rate CO ppm CO

² %


:

CO/CO

CO/CO

²

² yes

Gas rate: m 3 /h OR

Were parts fitted?


Yes

Parts fitted:


Comments: ft 3 /h

No yes n/a


Date:

Engineer name:

Telephone N o :

Company name:

Gas Safe registration N o

Max rate CO ppm CO

² %

Min rate CO ppm CO

² %


:

CO/CO

CO/CO

²

² yes

Gas rate: m 3 /h OR

Were parts fitted?


Yes

Parts fitted:


Comments: ft 3 /h

No yes n/a

Signature: Signature:







66


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 EN 50379-3:2012.

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

CO

2

= carbon dioxide

O

2

= oxygen

Combustion Ratio = The CO reading measured in ppm divided by the CO

2

reading first converted to ppm ppm = parts per million

GS(I&U)R = Gas Safety (Installation and Use) Regulations


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.

Refer to Section

2.31 on page 33

Note . Do not insert analyser probe during this period to avoid possible flooding of sensor.

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

O 2 more than or equal to 20.6% or CO 2 less than or equal to 0.2%?

Yes

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.

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/CO

2 ratio less than 0.0040?

Yes

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 max. and min. rate before contacting Ideal.

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.

No

Is

O 2 more than or equal to 20.6% OR CO 2 less than or equal to 0.2%?

Yes

Check CO level and Combustion Ratio at Maximum Gas

Rate.

With boiler still set at maximum gas rate, insert analyser probe into flue gas sampling point. Allow readings to stabilise before recording.

No

Is

CO level less than 350ppm AND CO/CO 2 ratio less than 0.0040?

Yes

Set Boiler to Minimum Gas Rate.

In accordance with boiler instructions, set boiler to operate at minimum rate (to minimum load condition). Allow sufficient time for combustion to stabilise.

Refer to Section

2.31 on page 33

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

Is

CO level less than 350ppm AND CO/CO 2 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.


At Ideal Heating we take our environmental impact seriously, therefore when installing any Ideal Heating product please make sure to dispose of any previous appliance in an environmentally conscious manner. Households can contact their local authority to find out how.

See https://www.gov.uk/managing-your-waste-an-overview for guidance on how to efficiently recycle your business waste.

Technical Training

Our Expert Academy offer a range of training options designed and delivered by our experts in heating.

For details please contact: expert-academy.co.uk

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.

Ideal is a trademark of Ideal Boilers.

Registered Office

Ideal Boilers Ltd., National Avenue, Hull, East Yorkshire, HU5 4JB

Tel 01482 492251 Fax 01482 448858

Registration No. London 322 137

EU Authorised Representative:

Atlantic SFDT

44 Boulevard des Etats-Unis, 85 000 La Roche-Sur-Yon, France

+33 (0)2 51 44 34 34

Ideal Technical Helpline: 01482 498663

Ideal Consumer Helpline: 01482 498660

Ideal Parts: 01482 498665 idealheating.com

USER GUIDE

LOGIC MAX COMBI

2

C24 C30 C35




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 Heating.

For the very latest copy of literature for specification and maintenance practices visit our website idealheating.com where you can download the relevant information in PDF format.

July 2022

UIN 228290 A05

WEEE DIRECTIVE 2012/19/EU

Waste Electrical and Electronic Equipment Directive

• At the end of the product life, dispose of the packaging

and product in a corresponding recycle centre.

• Do not dispose of the unit with the usual domestic refuse.

• Do not burn the product.

• Remove the batteries.

• Dispose of the batteries according to the local statutory

requirements and not with the usual domestic refuse.

2

All Gas Safe Register installers carry a Gas Safe Register ID card, and have a registration number. Both should be recorded in the

Benchmark Commissioning Checklist. You can check your installer by calling Gas Safe Register direct on 0800 4085500.

Ideal Heating is a member of the Benchmark scheme and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

THE BENCHMARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE

User Guide

CONTENTS

1.2. Boiler Operation .......................................................................4-5

1.3 System Water Pressure ..............................................................6

1.4 Points for the boiler user .............................................................6

1.5 Frozen Condensate Drain ...........................................................7

1.6 General Information.....................................................................7

1.7 Troubleshooting ...........................................................................8

1.8 Display Functions - Normal Operation Mode ..............................9

1.9 Display Functions - Fault messages .........................................10

1.1 INTRODUCTION

The Logic MAX Combi 2 is a combination boiler providing both central heating and instantaneous domestic hot water.

Featuring full sequence automatic ignition and fan assisted combustion.

Due to the high efficiency of the boiler, condensate is produced from the flue gases and this is drained to a suitable disposal point through a plastic waste pipe at the base of the boiler. A condensate ‘plume’ will also be visible at the flue terminal.

Safety

Current Gas Safety (Installation & Use) Regulations or rules in force.

It is the law that this appliance installation and any work carried out on the appliance is carried out by a Gas Safe Registered engineer in accordance with the above Regulations.

It is essential that the instructions in this booklet are strictly followed, for safe and economical operation of the boiler.

Electricity Supply

This appliance must be earthed.

Supply: 230 V ~ 50 Hz. The fusing should be 3 A.

Important Notes

• This appliance must not be operated without the casing correctly fitted and forming an adequate seal.

• If the boiler is installed in a compartment then the compartment MUST NOT be used for storage purposes.

• If it is known or suspected that a fault exists on the boiler then it MUST NOT BE USED until the fault has been corrected by a Gas Safe Registered Engineer.

• Under NO circumstances should any of the sealed components on this appliance be used incorrectly or tampered with.

• T

his appliance can be used by children 8 years and above.

A

lso persons with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, provided they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved. Children shall not play with the appliance.

C

leaning and user maintenance shall not be made by children without supervision.

User Guide 3

4

1.2 BOILER OPERATION

E D

On at 60°C

Target 60°C

Ready


Room Thermostat or

Timer Off

On

Preheat Menu Mode

A C F B

Legend

A. Domestic Hot Water

Temperature Knob

B. Central Heating Temperature Knob

C. Hot Keys

D. Boiler Status Display

E. Burner On Indicator

F. Mode Button

TO START THE BOILER

Start the boiler as follows:

1.

Ensure that all hot water taps are turned off.

2.

Switch on electricity to the boiler and check that all external controls, e.g. programmer and room thermostat, are on.

3.

Press the Mode Button until Ready or On is shown underneath both the Tap and Radiator symbols.

4. Turn the Domestic Hot water temperature knob (A) clockwise until a 65°C target temperature is shown. Turn the Central Heating temperature Knob (B) clockwise until an 80°C target temperature is shown.

The boiler will commence ignition sequence, supplying heat to the central heating, if required.

Note. In normal operation the boiler status display (D) will display messages.

Refer to Section

1.8

Boiler frost protection - boiler will fire if temperature is below

5ºC.

During normal operation the burner on symbol (E) will remain illuminated when the burner is lit.

If the boiler fails to light after five attempts the following fault messages will be displayed:

Ignition Lockout


2 Restart boiler.


Restart Menu

To restart the boiler, press ‘Restart’. The boiler will repeat the ignition sequence. If the boiler still fails to light consult a

Registered Gas Installer.

OPERATION MODES

Winter Conditions - (Central Heating and Domestic Hot Water required)

Press the Mode Button until either Ready or On is shown under both the Tap and Radiator symbols [ ].

The boiler will fire and supply heat to the radiators.

The domestic hot water preheat will operate with the preheat button set to ‘Preheat On’ .

Summer Conditions - (Domestic Hot Water only required)

Press the Mode button until Ready or On is shown under the

Tap symbol [ ] and Off is shown under the Radiator symbol

[ ].

OR

Set the central heating demand on the external controls to

OFF.

0 bar

4

3

The domestic hot water preheat will operate with the preheat button set to ‘ Hot Water On ’.

Boiler Off

Set the mode button (C) to ‘ BOILER OFF ’. The boiler mains power supply must be left on to enable frost protection (see

Frost Protection).

PREHEAT - DOMESTIC HOT WATER

The domestic hot water heat exchanger within the boiler can be kept preheated to provide faster delivery of hot water at the tap. This is achieved by pressing the preheat button to

‘Preheat On’ or ‘Preheat Timed’ .

The boiler will operate periodically for a few seconds to maintain the domestic hot water heat exchanger in a preheated condition. The average time period between operation is 90 minutes. This may vary considerably due to the surrounding ambient temperature of the boiler. The boiler will operate whenever there is a demand for domestic hot water.

If standard hot water delivery is satisfactory set the preheat to

‘ Preheat Off ’.

If Preheat is switched to Timed then preheating will only occur when required rather than all the time. The boiler learns the usage patten for DHW over week and then times the the DHW preheat to only operate during the usage periods from the previous week.

This improves the speed of response for DHW whilst also reducing the use of gas.

CONTROL OF WATER TEMPERATURE


The domestic hot water temperature is limited by the boiler controls to a maximum temperature of 65 º C, adjustable via the domestic hot water temperature knob (A). At low DHW draw off rates the maximum temperature may exceed 65ºC.

Approximate temperatures for domestic hot water:

Knob Setting

Minimum

Maximum

Hot Water Temperature (approx.)

40ºC

65ºC

Due to system variations and seasonal temperature fluctuations, domestic hot water flow rates/temperature rise will vary, requiring adjustment at the tap : the lower the flow rate the higher the temperature, and vice versa.

User Guide

CENTRAL HEATING

The boiler controls the central heating radiator temperature to a maximum of 80 o C, adjustable via the central heating temperature knob (B).

Approximate temperatures for central heating:

Knob Setting

Minimum

Maximum

Central Heating Radiator Temperature (approx.)

30ºC

80ºC

For economy setting [ ] refer to Efficient Heating System

Operation.

EFFICIENT HEATING SYSTEM OPERATION

The boiler is a high efficiency, condensing appliance which will automatically adjust its output to match the demand for heat.

Therefore gas consumption is reduced as the heat demand is reduced.

The boiler condenses water from the flue gases when operating most efficiently. To operate your boiler efficiently

(using less gas) turn the central heating knob (B) until the leaf symbol is shown [ ]. In winter periods it may be necessary to turn the knob clockwise towards a higher temperature e.g.

80, to meet your heating requirements. This will depend on the house and radiators used.

Reducing the room thermostat setting by 1ºC can reduce gas consumption by up to 10%.

WEATHER COMPENSATION

When the Weather Compensation option is fitted to the system then the central heating temperature knob (B) becomes a method of controlling room temperature. Turn the knob clockwise to increase room temperature and anti-clockwise to decrease room temperature. Once the desired setting has been achieved, leave the knob in this position and the system will automatically achieve the desired room temperature for all outside weather conditions.

BOILER FROST PROTECTION

The boiler is fitted with frost protection that operates in all modes, provided the power supply to the boiler is always turned on. If the water in the boiler falls below 5ºC, the frost protection will activate and run the boiler to avoid freezing.

The process does not guarantee that all other parts of the system will be protected.

If a system frost thermostat has been installed, the boiler must be set in winter mode, [ ], for the system frost protection to run.

If no system frost protection is provided and frost is likely during a short absence from home it is recommended to leave the system heating controls or built in programmer (if fitted) switched on and running at a reduced temperature setting. For longer periods, the entire system should be drained.

BOILER RESTART

To restart the boiler, when directed in the listed fault messages press the “Restart” button. The boiler will repeat its ignition sequence. If the boiler still fails to start consult a Gas Safe

Registered Engineer.

MAINS POWER OFF

To remove all power to the boiler the mains power switch must be turned off.

User Guide 5

1.3 SYSTEM WATER PRESSURE

The system pressure gauge which can be viewed by lowering the drop down door, indicates the central heating system pressure. If the pressure is seen to fall below the original installation pressure of 1-2 bar over a period of time and continue to fall then a water leak may be indicated.

In this event re-pressurise the system as shown below. If unable to do so or if the pressure continues to drop a Gas Safe Registered Engineer should be contacted.

THE BOILER WILL NOT OPERATE IF THE PRESSURE HAS REDUCED TO LESS THAN

0.3 BAR UNDER THIS CONDITION.

1 bar

Min

To Top up the system :-

1. Ensure both & handles (blue & green) are in closed position (as shown below)

2. Remove the plug and cap and retain.

3. Connect the filling loop to the Domestic Hot Water (DHW) inlet and tighten. Also ensure that the other end of filling loop is hand tight.

4. Turn the Domestic Hot Water (DHW) Inlet blue handle to the horizontal position.

5. Ensuring no leaks are seen, gradually turn the filling loop handle (green) B to the horizontal position.

2 bar

2

1

0 bar

4

3

Max

6. Wait for the pressure gauge to reach 1 to 1.5 bar.

7. Once pressure is reached turn valves & closed position.

B back to the

8. Disconnect the filling loop, replace cap and plug. There can be some water spillage at this point.

SCAN for video

Filling Positions shown

Filling

Loop

Plug

DHW Inlet

Valve

Filling

Loop

Top Up Positions shown

Cap DHW Inlet

Valve

Cap

B

Plug

B

A

(Blue)

A

(Blue)

6

Filling Loop

Handle

(Green)

C

(Black)

CH Return

Filling Loop

Handle

(Green)

C

CH Return

(Black)

1.4 POINTS FOR THE BOILER USER

In line with our current warranty policy we would ask that you check through the following guide to identify any problems external to the boiler prior to requesting a service engineers visit. Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit, or for any pre-arranged visit where access is not gained by the engineer.

FOR ANY QUERIES PLEASE RING THE IDEAL CONSUMER HELPLINE : 01482 498660

BOILER RESTART PROCEDURE - To restart boiler press the restart button

User Guide

1.5 FROZEN CONDENSATE DRAIN

This appliance is fitted with a siphonic condensate trap system that reduces the risk of the appliance condensate from freezing. However should the condensate pipe to this appliance freeze, please follow these instructions: a. If you do not feel competent to carry out the defrosting instructions below please call your local Gas Safe

Registered installer for assistance.

b. If you do feel competent to carry out the following instructions please do so with care when handling hot utensils. DO NOT attempt to thaw pipework above ground level.

If this appliance develops a blockage in its condensate pipe, its condensate will build up to a point where it will make a gurgling noise prior to locking out displaying “Ignition Lockout” on the display. If the appliance is restarted it will make a gurgling noise prior to it locking out displaying “Ignition Lockout” on the display.

To unblock a frozen condensate pipe;

1. Follow the routing of the plastic pipe from its exit point on the appliance, through its route to its termination point.

Locate the frozen blockage. It is likely that the pipe is frozen at the most exposed point external to the building or where there is some obstruction to flow. This could be at the open end of the pipe, at a bend or elbow, or where there is a dip in the pipe in which condensate can collect.

The location of the blockage should be identified as closely as possible before taking further action.

1.6 GENERAL INFORMATION

BOILER PUMP

The boiler pump will operate briefly as a self-check once every

24 hours, regardless of system demand.

MINIMUM CLEARANCES

Clearance of 165 mm above, 100 mm below, 2.5 mm at the sides and 450 mm at the front of the boiler casing must be allowed for servicing.

BOTTOM CLEARANCE

Bottom clearance after installation can be reduced to 5 mm.

This must be obtained with an easily removable panel, to enable the system pressure gauge to be visible and to provide the 100 mm clearance required for servicing.

SERVICE REQUEST FUNCTION

When the boiler has been installed for more than 1 year the following message will appear on screen:

Service Due

2. Apply a hot water bottle, microwaveable heat pack or a warm damp cloth to the frozen blockage area. Several applications may have to be made before it fully defrosts.

Warm water can also be poured onto the pipe from a watering can or similar. DO NOT use boiling water.

3. Caution when using warm water as this may freeze and cause other localised hazards.

4. Once the blockage is removed and the condensate can flow freely, restart the appliance. (Refer to “To Start the boiler”)

5. If the appliance fails to ignite, call your Gas Safe Registered engineer.

Preventative Solutions

During cold weather, set the central heating temperature knob

(B) to “ MAX ”, (Remember to return to original setting once cold spell is over).

Place the heating on continuous and turn the room thermostat down to 15ºC overnight or when unoccupied. (Return to normal after cold spell).

SCAN for video

ESCAPE OF GAS

Should a gas leak or fault be suspected contact the

National Gas Emergency Service without delay.

Telephone 0800 111 999 .

Ensure that;

- All naked flames are extinguished.

- Do not operate electrical switches.

- Open all windows and doors.

CLEANING

For normal cleaning simply dust with a dry cloth. To remove stubborn marks and stains, wipe with a damp cloth and finish off with a dry cloth. DO NOT use abrasive cleaning materials.

MAINTENANCE

The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually by a Gas Safe Registered Engineer.

[ Telephone Number ]

Restart Menu Mode

Press “Restart” to clear this message.

User Guide 7

8

1.7 TROUBLESHOOTING

NO HOT WATER

Check the mains power is turned on and that the tap symbol is either blue or orange

Is water coming out of the hot water tap when turned on?

YES

NO

See boiler “Display Functions” section. If “Boiler off” is displayed then contact Ideal Customer

Services Helpline if your appliance is under warranty or a

Gas Safe Registered Engineer, if out of warranty

NO CENTRAL HEATING

Check the mains power is turned on and that the radiator symbol is either blue or orange

Check the programmer (internal or external to the boiler) is in an “ON” position and the room thermostat is turned up

Does the boiler operate and provide central heating?

YES

Check the time settings on the programmer are as you require and adjust if necessary

NO

NO HOT WATER OR CENTRAL

HEATING

Check the mains power is turned on and that the tap and radiator symbols are either blue or orange

Does the boiler have a display showing on the front control panel?

YES

See boiler “Display Functions” section

Contact a Gas Safe Registered

Engineer

NO


Engineer


Engineer

User Guide

1.8 DISPLAY FUNCTIONS - NORMAL OPERATION MODE

Off Mode

Normal Operation Screens

Winter Mode, DHW Demand

How to adjust Boiler

Temperatures

CH Knob Rotated

(without outside sensor connected)

Off

To Switch On


Off

To Switch On


Menu Mode

Summer Mode, No Heat Demand

Ready

Target 60°C

On

Preheat

Off

To Switch On


Menu Mode

Summer Mode, DHW Demand

On at 60°C

Target 60°C

Ready


Room Thermostat or

Timer Off

On

Preheat Menu Mode

Winter Mode, DHW & CH Demands

On at 60°C

Target 60°C

Ready


Hot Water Priority

Off

Preheat Menu Mode

Winter Mode, CH Demand

Ready

Target 60°C

On at 60°C


Set by Room Stat

On

Preheat Menu Mode

Winter Mode, Pre-heat Demand

Radiator Target

60°C

Back Menu

DHW Knob Rotated

Target

60°C

Back Menu

CH Knob Rotated

(outside sensor connected)

On at 60°C

Target 60°C

On

Preheat

Off

To Switch On


Menu Mode

Winter Mode, No Heat Demand

On

Back

Room Temperature Target

20°C

Menu

Ready

Target 60°C

Off

Preheat

Ready

Radiator Target

60°C

Room Thermostat or

Timer Off

Menu Mode

Preheat Active

Switch Off at 60°C

Ready


Room Thermostat or

Timer Off

On

Preheat Menu Mode

Boiler Frost Protection Service Required

Service Due

Boiler Frost Protection Active

Phone 01482 498660

Switch Off Temperature 19°C

Menu Mode Restart Menu Mode

The display scrolls through a maximum of 3 messages under any operational condition, as shown above

Note. The temperatures shown below are for illustration purposes only. The measured temperatures will be shown on the boiler.

User Guide 9

10

1.9 DISPLAY FUNCTIONS - FAULT MESSAGES

Overheat Lockout

1 With boiler off & system cold, fill system to 1.0 bar.

2 Bleed radiators, refill system to 1.0 bar.

3 Check radiator valves & boiler valves are

open.

4 Restart boiler.

5 If fault persists contact installer.

Restart Menu

Outside Sensor Fault

Contact Installer

Menu

Ignition Lockout


2 Restart boiler.


Return Thermistor Fault

Contact Installer

Restart Menu Restart Menu

Flame Loss

Contact Installer

Fan Fault

Contact Installer

Menu

Too Many Restarts

Contact Installer

Menu

Flame On Before Gas On

Contact Installer

Menu

PCB Fault

Contact Installer

Menu

Low Mains Voltage

Contact electricity provider

Restart Menu

Flow Thermistor Fault

Contact Installer

Restart Menu

Menu

Low Water Pressure

1 With boiler off & system cold,

fill system to 1.0 bar.



Menu

Room Thermostat Fault

Check room thermostat batteries

Menu

Spare PCB Not Set

Contact Installer

Menu

No Water Flow





Menu

Pump Rotor Blocked

Contact Installer

Menu

Pump Dry Run





Menu

Pump Fault

Contact Installer

Menu

User Guide

DHW Thermistor Fault

Contact Installer

Restart Menu

Gas Valve Fault

Contact electricity provider

Restart Menu

Blocked Flue/Condensate

1 Check if condensate pipe

blocked/frozen

2 Check if flue blocked

3 If fault persists, contact installer

Restart Menu

User Guide 11

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.

or in IE a Registered Gas Installer (RGII).

, or in IE a Registered Gas Installer (RGII).

At Ideal Heating we take our environmental impact seriously, therefore when installing any Ideal Heating product please make sure to dispose of any previous appliance in an environmentally conscious manner. Households can contact their local authority to find out how.

See https://www.gov.uk/managing-your-waste-an-overview for guidance on how to efficiently recycle your business waste.

Technical Training

Our Expert Academy offer a range of training options designed and delivered by our experts in heating.

For details please contact: expert-academy.co.uk

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.

Ideal is a trademark of Ideal Boilers.

Registered Office

Ideal Boilers Ltd., National Avenue, Hull, East Yorkshire, HU5 4JB

Tel 01482 492251 Fax 01482 448858

Registration No. London 322 137

EU Authorised Representative:

Atlantic SFDT

44 Boulevard des Etats-Unis, 85 000 La Roche-Sur-Yon, France

+33 (0)2 51 44 34 34




IDEAL C24 Logic Max Combi2 Instruction manual

INSTALLATION

& SERVICING

LOGIC MAX COMBI

C24 C30 C35

ERP DATA

2

Installation and Servicing

PRODUCT FICHE

Installation and Servicing 3

NOTES FOR THE INSTALLER

For any technical queries please ring the Ideal installer helpline : 01482 498663

BOILER RESTART PROCEDURE -

Press the RESTART button. The boiler will repeat the ignition sequence if a heat demand is present.

DEFINITIONS

Risk of injury or death

Risk of damage to objects

IMPORTANT:

Table of Acronyms

4

Installation and Servicing

CONTENTS

Installation and Servicing 5

Section 1 - General

6

Installation and Servicing

LOGIC MAX COMBI

C

Natural Gas Only

Section 1 - General

Before installing this boiler, read the Code of Practice sheet at the rear of this book.

BENCHMARK COMMISSIONING CHECKLIST DETAILS

B

B

Installation and Servicing 7

8

Section 1 - General

1.1 INTRODUCTION

1.3 SAFE HANDLING

1.2 OPERATION

1.4 OPTIONAL ACCESSORIES

Installation and Servicing

Section 1 - General

1.5 SAFETY

1.6 SAFE HANDLING OF SUBSTANCES

1.7 LOCATION OF BOILER

Do not fit the boiler outside.

IMPORTANT:

Installation and Servicing 9

10

Section 1 - General

1.8 AIR SUPPLY

1.10 WATER CIRCULATION SYSTEM

IMPORTANT:

1.9 GAS SUPPLY

IMPORTANT:

1.11 BOILER CONTROLS

1.12 ELECTRICAL SUPPLY

1.13 CONDENSATE DRAIN

IMPORTANT:

Installation and Servicing

Section 1 - General

1.14 BOILER DIMENSIONS, SERVICES & CLEARANCES

IMPORTANT:

Installation and Servicing 11

12

Section 1 - General

1.15 SYSTEM REQUIREMENTS - CENTRAL HEATING

Installation and Servicing

Section 1 - General

1.16 SYSTEM REQUIREMENTS - DHW

Domestic Hot Water

1.17 SYSTEM BALANCING

Balancing

1.18 WATER TREATMENT

Central Heating

IMPORTANT

Installation and Servicing

13

Section 2 - Installation