INSTALLATION AND SERVICING LOGIC COMBI ESP1 24 30 35 For Users Guide see reverse of book When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. For the very latest copy of literature for specification and maintenance practices visit our website www.idealboilers.com where you can download the relevant information in PDF format. June 2016 UIN 215120 A01 ERP DATA MODEL Condensing Boiler Low Temperature Boiler B1 Boiler Cogeneration Space Heater Equipped with a Supplementary Heater Combination Heater Nominal Heat Output for Space Heating Full Load Part Load Auxiliary Electricity Consumption Full Load Part Load Standby Seasonal Space Heating Energy Efficiency Full Load Part Load Standby Loss Ignition Emissions Annual Energy Consumption Sound Power Level, Indoors Domestic Hot Water SYMBOL n/a n/a n/a n/a n/a n/a UNITS n/a n/a n/a n/a n/a n/a 24 yes no no no no yes 30 yes no no no no yes 35 yes no no no no yes P4 P1 kW kW 24.2 7.8 24.2 7.8 24.2 7.8 elmax elmin PSB kW kW kW 0.029 0.012 0.005 0.032 0.013 0.005 0.042 0.013 0.005 ƞ4 ƞ1 Pstby Pign % % kW kW 90 98.6 0.05 0 90 98.6 0.05 0 90 98.6 0.05 0 NOx QHE LWA mg/kWh GJ dB 31.5 74.1 48 27.8 74.1 46 33.1 74.1 44 Qelec ƞWH kWh % kWh kWh GJ 0.075 84.1 7.11 16.30 5.32 0.075 84.1 7.10 16.30 5.32 0.074 84.40 7.01 16.10 5.31 Qfuel AEC AFC 2 Installation and Servicing PRODUCT FICHE LOGIC ESP1 COMBINATION BOILER Ideal Boilers ERP DATA SYMBOL Condensing boiler Seasonal Space heating efficiency class Rated heat output Seasonal space heating energy efficiency UNITS 30 GJ dB QHE LWA 35 Yes A 24 94* kW % ƞs Annual energy consumption Sound power level, indoors Water heating energy efficiency class MODEL 24 74.1 46 A 48 Seasonal Space Heating Energy Efficiency of the Boiler 44 *% A Temperature control (from fiche of temperature control) % Class I Class II Class III Class IV Class V Class VI Class VII Class VIII 1% 2% 1.5% 2% 3% 4% 3.5% 5% B Solar Contribution (from fiche of solar device) Tank Volume (in m3) Collector Size (in m2) = (‘III ’x + ‘IV ’ x Collector Efficiency (in %) ) x 0.9 x ( Tank rating A* = 0.95 A = 0.91 B = 0.86 C = 0.83 D-G = 0.81 / 100 x % = % TOTAL: A+B+C= Seasonal Space Heating Energy Efficiency of Package C Seasonal Space Heating Energy Efficiency Class of Package G < 30% F E ≥ 30% ≥ 34% D ≥ 36% C ≥ 75% B ≥ 82% A ≥ 90% A+ A++ A+++ ≥ 98% ≥ 125% ≥ 150% The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installed in a building, as the efficiency is influenced by further factors such as heat loss in the products in relation to the building size and its characteristics Installation and Servicing 3 4 Installation and Servicing NOTES FOR THE INSTALLER FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL INSTALLER HELPLINE : 01482 498704 NOTE. BOILER RESTART PROCEDURE To restart the boiler press the RESTART button. The boiler will repeat the ignition sequence if a heat demand is present. DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level........................... A01 (JUNE 2016) Ideal Boilers reserve the right to vary specification without notice Installation and Servicing 5 6 Installation and Servicing CONTENTS 1GENERAL................................................................... 10 3SERVICING................................................................ 39 1.1Introduction................................................................. 10 3.1 Servicing Schedule..................................................... 39 1.2Operation.................................................................... 10 3.2 Boiler Front Panel Removal / Replacement................ 40 1.3 Safe Handling.............................................................. 10 3.3 Fan And Venturi Assembly Removal And Cleaning..... 40 1.4 Optional Extra Kits...................................................... 11 3.4 Burner Removal & Cleaning........................................ 41 1.5Safety.......................................................................... 11 3.5 Cleaning the Condensate Trap/Siphon....................... 41 1.6 Safe Handling Of Substances..................................... 11 3.6 Cleaning the Heat Exchanger..................................... 42 1.7 Location of Boiler ....................................................... 11 3.7Reassembly................................................................ 42 1.8 Gas Supply.................................................................. 12 3.8 Replacement Of Components..................................... 43 1.9 Flue Installation........................................................... 12 3.9 Fan Replacement........................................................ 43 1.10Terminal....................................................................... 13 1.11 Air Supply.................................................................... 13 3.10 Burner Injector Replacement...................................... 44 3.11 Burner Replacement................................................... 44 1.12 Water Circulation System............................................ 13 3.12 Return Thermistor Renewal........................................ 45 1.13 Boiler Control Interlocks.............................................. 13 3.13 Ignition Electrode Replacement.................................. 45 1.14 Electrical Supply.......................................................... 13 3.14 Flame Detection Electrode Replacement.................... 46 1.15 Condensate Drain....................................................... 13 3.15 Spark Generator Replacement................................... 46 1.16 Boiler Dimensions, Services & Clearances................. 14 3.16 Gas Control Valve Replacement................................. 46 1.17 System Requirements................................................. 16 3.17 Diverter Valve Actuator Replacement......................... 47 1.18 System Balancing....................................................... 16 3.18 Condensate Trap/Siphon Replacement...................... 47 1.19 Water Treatment......................................................... 16 3.19 PCB Replacement....................................................... 48 2INSTALLATION.......................................................... 17 2.1 Boiler Assembly - Exploded View................................ 17 2.2Unpacking................................................................... 18 2.3 Unpacking Cont’d........................................................ 19 2.4 Front Panel Removal.................................................. 19 2.5 Wall Mounting Template.............................................. 20 2.6 Preparing The Wall...................................................... 20 2.7 Fitting The Wall Mounting Plate..................................... 20 2.8 Mounting The Boiler.................................................... 20 2.9 Determining The Flue Length & Flue Packs Req’d .... 21 2.10 Cutting & Setting The Flue Length.............................. 23 2.11 Installing The Flue....................................................... 24 2.12 Fitting The Optional Roof Flue Kit............................... 25 3.20 DHW Flow Turbine Sensor Replacement................... 48 3.21 Draining The Boiler..................................................... 49 3.22 Pressure Gauge Renewal........................................... 49 3.23 Safety Relief Valve Renewal....................................... 50 3.24 Pump Automatic Air Vent Replacement...................... 50 3.25 DHW Filter & Flow Reg Cleaning/Replacement.......... 50 3.26 Diverter Valve Body Assembly Replacement.............. 51 3.27 DHW Plate Heat Exch. Replacement.......................... 51 3.28 Pump Head Replacement........................................... 51 3.29 CH Water Pressure Switch Replacement................... 52 3.30 Flow Thermistor Replacement.................................... 52 3.31 Heat Engine Renewal................................................. 53 3.32 Expansion Vessel Recharging & Replacement........... 54 2.13 Flue Terminal Position................................................. 26 4 FAULT FINDING......................................................... 55 2.14 Assembling The Roof Flue Kit..................................... 27 4.1 Fault Finding Chart Main Menu................................... 55 2.15 Condensate Drain....................................................... 28 4.2 ‘L1’ - Flow Temp Overheat Lockout............................. 56 2.16 Connections & Filling.................................................. 30 4.3 ‘L2’ - Ignition Lockout.................................................. 56 2.17 Electrical Connections................................................. 32 4.4 ‘L6’ - False Flame Lockout ......................................... 57 2.18 Installer Wiring............................................................ 32 4.5 ‘F1’ - Low Water Pressure........................................... 57 2.19 External Wiring............................................................ 33 4.6 ‘F2 Or Fn Or Ln’ - Flame Loss.................................... 57 2.20 Replacing Pre-Fitted Mains Cable.............................. 33 4.7 ‘F3’ - Fan Fault............................................................ 58 2.21 Wiring Diagram........................................................... 34 4.8 ‘F4 Or L4’ - Flow Thermistor Fault............................... 58 ‘F5 Or L5’ - Return Thermistor Fault........................... 58 2.22 Commissioning And Testing........................................ 35 4.9 2.23 Initial Lighting.............................................................. 36 4.10 ‘F6’ - Outside Sensor Fault......................................... 59 2.24 General Checks.......................................................... 37 4.11 2.25 Restart Procedure....................................................... 38 4.12 No HW But CH On...................................................... 60 2.26 Accessing The Installer Mode..................................... 38 4.13 No Display................................................................... 60 2.27 Handing Over.............................................................. 38 Installation and Servicing No CH Operation but HW Works OK.......................... 59 5 SPARE PARTS........................................................... 61 6 BENCHMARK & COMMISSIONING.......................... 62 7 SECTION 1 - GENERAL Table 1 - General Data 2430 35 Gas supply 2H - G20 - 20mbar Gas Supply Connection 15mm copper compression Injector Size mm 4.15 4.65 4.9 Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter mm 100 Average Flue Temp-Mass Flow Rate (DHW) 63ºC - 11g/s 68ºC - 13g/s 73ºC - 15g/s Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.5 (36.3) Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) (kPa) 10.0 (145) (1000) 2 Minimum Domestic Hot Water Inlet Pressure* bar (lb/in ) (kPa) 0.8 (11.6) (80) 1.3 (18.9) (130) 1.3 (18.9)** (130) Minimum DHW Inlet Pressure to operate at 0.6bar system pressure All Model sizes 0.5 bar Electrical Supply 230 V ~ 50 Hz Power Consumption W 94 101 114 Fuse RatingExternal : 3A Internal : T4A HRC L250 V Water content Central Heating litre (gal) 1.2 (0.26) Domestic Hot Water litre (gal) Packaged Weight kg Maximum Installation Weight Boiler Casing Size Height Width Depth 0.5 (0.11) 33.7 kg 28.9 mm mm mm 33.8 33.9 29 700 395 278 29.1 *Required for maximum flow rate. Boiler operates down to 2 l/min DHW delivery ** In areas of low water pressure the DHW restrictor can be removed Table 2 - Performance Data - Central Heating Table 3 - Performance Data - Domestic Hot Water Boiler Input : Max. Min. 243035 Boiler Input ‘Q’ Nett CV kW 24.3 4.9 6.1 7.1 Gross CV kW 27.05.46.77.9 Maximum DHW Input : 24 30 35 Nett CV kW 24.3 30.4 35.4 Gross CV kW 27.0 33.7 39.3 Gas Consumption m /h2.512 3.135 3.657 (ft3/h)(89) (111) (129) Maximum DHW Output 30.3 35.3 Non Condensing kW 184.108.40.206.1 70oC Mean Water temp. DHW Flow Rate l/min 9.9 12.4 14.5 Condensing kW 220.127.116.11.5 at 35°C temp. rise. (gpm) (2.2) (2.8) (3.2) 40oC Mean Water temp. DHW Specific Rate l/min 11.5 Seasonal efficiency* SEDBUK 2005 91.1% 91.1% 91.1% (gpm) (2.5) Seasonal efficiency* SEDBUK 2009 89.6% 89.6% 89.6% Gas Consumption m3/h 2.5120.5000.6270.734 (ft3/h)(89)(17.8)(22)(25.9) Boiler Output : 3 kW 24.2 14.5 16.9 (3.2) (3.7) NOx Classification CLASS 5 * The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by a notified body. Note. Gas consumption is calculated using a calorific value of 38.7 MJ/m3 (1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett To obtain the gas consumption at a different calorific value: Key to symbols GB = United Kingdom c. For ft3/h - divide the gross heat input (Btu/h) by the gross C.V. of the gas (Btu/ft3) (Countries of destination) PMS=Maximum operating pressure of water C13 C33 C53 = A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal, which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which, in this case, are concentric. The fan is up stream of the combustion chamber. a. For l/s - divide the gross heat input (kW) by the gross C.V. of the gas (MJ/m3) b. For Btu/h - multiply the gross heat input (kW) by 26.8 IE = Ireland I2H =An appliance designed for use on 2nd Family gas, Group H only. d. For m3/h - multiply l/s by 3.6 8 Installation and Servicing SECTION 1 - GENERAL LOGIC COMBI ESP1 Natural Gas only Boiler size G.C. Appliance No. (Benchmark No.) 24 30 35 Destination Country: PI No. 47-349-2186CR16 47-349-2286CR16 47-349-2386CR16 GB, IE For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the manufacturer’s instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist. Before installing this boiler, read the Code of Practice sheet at the rear of this book. BENCHMARK COMMISSIONING CHECKLIST DETAILS Boiler Page Make and model.......................................................... 9 Appliance serial no. on data badge ........... Front Cover SEDBUK No. %........................................................... 8 Controls Time and temperature control to heating.................. 32 Time and temperature control to hot water .............. 32 Heating zone valves................................................. n/a TRV’s........................................................................ 13 Auto bypass.............................................................. 13 Boiler interlock........................................................... 13 For ..................................................................... all boilers Flushing to BS.7593.................................................. 16 Inhibitor..................................................................... 16 Central heating mode Heat input....................................................to be calculated Page Burner operating pressure....................................... n/a Central heating flow temp.............measure and record Central heating return temp..........measure and record For combination boilers only Scale reducer............................................................ 16 Hot water mode Heat input.............................................to be calculated Max. operating burner pressure............................... n/a Max. operating water pressure......... measure & record Cold water inlet temp....................... measure & record Hot water outlet temp....................... measure & record Water flow rate at max. setting......... measure & record For condensing boilers only Condensate drain.................................................28-29 For all boilers: complete, sign & hand over to customer For assistance see Technical Helpline on the back page NOTE TO THE INSTALLER: COMPLETE THE BENCHMARK COMMISSIONING CHECKLIST AND LEAVE THESE INSTRUCTIONS WITH APPLIANCE Installation and Servicing 9 SECTION 1 - GENERAL 1.1INTRODUCTION 1.2OPERATION The Logic Combi ESP1 range of boilers are wall mounted, full sequence, automatic spark ignition, low water content, fanned flue, high efficiency, condensing, combination gas boilers. With no demand for CH, the boiler fires only when DHW is drawn off, When there is a demand for CH, the heating system is supplied at the selected temperature of between 45oC and 80oC, until DHW is drawn off. The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW draw-off of Note. Due to the high efficiency of the boiler a plume of water vapour will form at the terminal during operation. Central heating (CH) output is fully modulating with a range of: 24 4.8 to 24.2kW 30 6.1 to 24.2kW 35 7.1 to 24.2kW Instantaneous domestic hot water (DHW) output is also fully modulating with a maximum of : 2424.2kW 3030.3kW 3535.3kW 24 9.9 l/min at 35ºC temperature rise. 30 12.4 l/min at 35ºC temperature rise. 35 14.5 l/min at 35ºC temperature rise. The DHW draw off rate specified above is the nominal that the boiler flow regulator will give. Due to system variations and seasonal temperature fluctuations DHW flow rates/temperature rise will vary, requiring adjustment at the draw off tap. At low DHW draw-off rates the maximum temperature may exceed 65ºC. The boiler is supplied fully assembled with DHW plate heat exchanger, diverter valve, circulating pump, pressure gauge, safety valve and CH expansion vessel. The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating, and performance of key components to aid commissioning and fault finding. Variable CH and DHW temperature controls are fitted on the user control.. 1.3 SAFE HANDLING The boiler includes as standard: - Automatic bypass - Boiler frost protection - Daily pump and diverter valve exercise. The boiler casing is of white painted mild steel with a white polymer front panel. The boiler temperature controls are visibly located in the control panel on the front of the boiler. The heat exchanger is manufactured from cast aluminium. The boiler is suitable for connection to fully pumped, sealed heating systems ONLY. Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework. Pipework from the boiler is routed downwards. Data Plate The boiler model and serial number can be located on the bottom of the boiler casing, shown in Section 1.16 - Water & Gas Connection Diagram. 10 This boiler may require 2 or more operatives to move it to its installation site, remove it from its packaging base and during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling. Caution should be exercised during these operations. Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered: • Grip the boiler at the base. • Be physically capable. • Use personal protective equipment as appropriate, e.g. gloves, safety footwear. During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/ or the weight is light. • • • • • • • Keep back straight. Avoid twisting at the waist. Avoid upper body/top heavy bending. Always grip with the palm of the hand. Use designated hand holds. Keep load as close to the body as possible. Always use assistance if required. Installation and Servicing SECTION 1 - GENERAL 1.4 OPTIONAL EXTRA KITS 1.6 SAFE HANDLING OF SUBSTANCES Please visit www.idealboilers.com to access the Flue and Accessories Guide for this boiler. No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture. 1.5SAFETY 1.7 LOCATION OF BOILER Current Gas Safety (installation and use) regulations or rules in force: The boiler must be installed on a flat and vertical internal wall, capable of adequately supporting the weight of the boiler and any ancillary equipment. The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force. In GB, the installation must be carried out by a Gas Safe Registered Engineer. It must be carried out in accordance with the relevant requirements of the: • Gas Safety (Installation and Use) Regulations • Appropriate Building Regulations, either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland). • Water Fittings Regulations or Water byelaws in Scotland. • Current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice. In IE, the installation must be carried out by a Registered Gas Installer (RGII) and installed in accordance with the current edition of I.S.813 “Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation. Detailed recommendations are contained in the following British Standard Codes of Practice: BS.5440:1 Flues (for gas appliances of rated input not exceeding 70 kW). BS.5440:2 Ventilation (for gas appliances of rated input not exceeding 70 kW). The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary, unless required by the local authority. For electrical safety reasons there must be no access available from the back of the boiler. The boiler must not be fitted outside. Timber Framed Buildings If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineering document IGE/UP/7:2006 Edition 2. Bathroom Installations This appliance is rated IP20. The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current IEE (BS.7671) Wiring Regulations and the electrical provisions of the building regulations applicable in Scotland, with respect to the installation of the boiler in a room or internal space containing a bath or shower. For IE reference should be made to the current ETCI rules for electrical installations and I.S. 813:2002. If the appliance is to be installed in a room containing a bath or shower then, providing water jets are not going to be used for cleaning purposes (as in communal baths/showers), the appliance must be installed beyond Zone 2, as detailed in BS.7671. Ceiling BSEN. 12828 Heating Systems in buildings: Design for water based heating systems. BSEN 12831 BSEN 14336 BS.5546 BS.6798 Heating Systems in buildings: Method for calculation of the design heat load. Heating Systems in buildings: Installation and commissioning of water based heating systems. Installation of gas hot water supplies for domestic purposes (2nd Family Gases) Installation of gas fired hot water boilers of rated input not exceeding 70 kW. BS.6891Low pressure installation pipes. Health & Safety Document No. 635. Recessed window Zone 2 2.25m Zone 1 0.6m Zone 0 3G8913a The Electricity at Work Regulations, 1989. Compartment Installations The manufacturer’s notes must NOT be taken, in any way, as overriding statutory obligations. A compartment used to enclose the boiler should be designed and constructed specially for this purpose. An existing cupboard or compartment may be used, provided that it is modified for the purpose. In both cases, details of essential features of cupboard / compartment design, including airing cupboard installation, are to conform to the following: • BS.6798 (No cupboard ventilation is required - see ‘Air Supply’ for details). • The position selected for installation MUST allow adequate space for servicing in front of the boiler, This can be by means of an opening door • For the minimum clearances required for safety and subsequent service, see the wall mounting template and Section 1.16. In addition, sufficient space may be required to allow lifting access to the wall mounting plate. IMPORTANT. These appliances are CE certificated for safety and performance. It is, therefore, important that no external control devices, e.g. flue dampers, economisers etc., are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Ideal Boilers in writing. If in doubt please enquire. Any direct connection of a control device not approved by Ideal Boilers could invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety Regulations and the above regulations. Installation and Servicing 11 SECTION 1 - GENERAL 1.8 GAS SUPPLY The local gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas. An existing service pipe must NOT be used without prior consultation with the local gas supplier. The boiler MUST be installed on a gas supply with a governed meter only. A gas meter can only be connected by the local gas supplier or by a Gas Safe Registered Engineer. In IE by a Registered Gas Installer (RGII). An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the rate of gas supply required. 2. It is important that the position of the terminal allows the free passage of air across it at all times. 3. Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 4. 4. Where the lowest part of the terminal is fitted less than 2m above a balcony, above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard. Terminal guards are available from boiler suppliers. (Ask for TFC flue guard model no. K6 - round, plastic coated). In case of difficulty contact: TFC Group. Tel. + 44 (0) 01732 351 680 Tower House, Vale Rise Fax. + 44 (0) 01732 354 445 Tonbridge. Kent TN9 1TB www.tfc-group.co.uk It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS.6891. Whilst the principle of the 1:1 gas valve ensures the Logic range is able to deliver it is full 5. output at inlet pressures as low as 14mb, other gas appliances in the property may not be as tolerant. When operating pressures 6. are found to be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation. Allowing for the acceptable pressure loss of 1mb across the installation pipework, it can be assumed that a minimum permitted operating pressure of 18mb will be delivered to the inlet of the appliance. (Reference BS.6400-1 Clause 6.2 Pressure Absorption). The external gas cock could further reduce the operating pressure when measured at its test point. The pressure drop is relative to the heat input to the boiler (kW), refer to graph below. Gas Cock Pressure Drop Pressure drop (mbar ) 2 1.5 1 0.5 0 20 30 40 50 Heat Input to Boiler (kW) IMPORTANT. Installation pipes must be fitted in accordance with BS.6891. In IE refer to IS.813:2002. The complete installation MUST be tested for gas tightness and purged as described in the above code. 1.9 FLUE INSTALLATION Pluming will occur at the terminal so terminal positions where this could cause a nuisance should be avoided. The flue must be installed in accordance with the recommendations of BS.5440-1. In IE refer to I.S. 813. The following notes are intended for general guidance: 1. The boiler MUST be installed so that the terminal is exposed to external air. 12 The air inlet/products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm to combustible material. Detailed recommendations on the protection of combustible material are given in BS.5440-1. IMPORTANT. It is essential to ensure, in practice, that products of combustion discharging from the terminal cannot re-enter the building or buildings through any openings into the building such as ventilators, windows, doors, or other sources of natural air infiltration, such as forced ventilation openings etc. If products of combustion re-entry is identified or suspected this should be immediately investigated and corrected following the guidance provided in the current Gas Industry Unsafe Situation Procedure. Flue Terminal Positions 2.5 10 The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of any building. Table 4 - Balanced Flue Terminal Position 3 0 Ensure that the guard is fitted centrally. Min. Spacing* 1. Directly below, above or alongside an open window, air vent or other ventilation opening. 300mm 2. Below guttering, drain pipes or soil pipes. BS5440-1 25mm* 75mm 3. Below eaves. BS5440-1 25mm* 200mm 4. Below balconies or a car port roof. BS5440-1 25mm* 200mm 5. From vertical drain pipes or soil pipes. BS5440-1 25mm* 150mm 6. From an internal or external corner or to a boundary alongside the terminal. BS5440-1 25mm* 300mm 7. Above adjacent ground, roof or balcony level. 300mm 8. From a surface or a boundary facing the terminal. 600mm 9. From a terminal facing a terminal. 1,200mm 10. From an opening in a car port (e.g. door or window) into dwelling. 1,200mm 11. Vertically from a terminal on the same wall. 1,500mm 12. Horizontally from a terminal on the wall. 300mm Vertical Terminals 13. Above the roof pitch with roof slope of all angles. Above flat roof. 300mm 300mm 14. From a single wall face. From corner walls. 300mm 300mm 15. Below velux window 2000mm 16. Above or side of velux window 600mm * Only one reduction down to 25mm is allowable per installation otherwise BS5440-1 dimensions must be followed. Installation and Servicing SECTION 1 - GENERAL 1.10TERMINAL The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Section 2.9. 1.11 AIR SUPPLY It is NOT necessary to have a purpose-provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation; therefore the requirements of BS.6798, Clause 12, and BS. 5440:2 may be disregarded. 1.12 WATER CIRCULATION SYSTEM IMPORTANT. A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping. The central heating system should be in accordance with BS.6798 and, in addition, for smallbore and microbore systems, BS.5449. WATER TREATMENT - Refer to Section 1.19. 1.13 BOILER CONTROL INTERLOCKS Central heating system controls should be installed to ensure that the boiler has no demand when there is no requirement from the system, in compliance with Building Regulations. Heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve. When thermostatic radiator valves are used, the space heating temperature control over a living / dining area or hallway having a heating requirement of at least 10% of the minimum boiler heat output should be achieved using a room thermostat, whilst other rooms are individually controlled by thermostatic radiator valves. However, if the system employs thermostatic radiator valves on all radiators, or two port valves, then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position. 1.14 ELECTRICAL SUPPLY WARNING. This appliance must be earthed. Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations which apply. For IE reference should be made to the current ETCI rules for electrical installations. The mains supply to the boiler and system wiring centre shall be through one common fused double pole isolator and for new heating systems, and where practical replacement installations, the isolator shall be situated adjacent to the appliance. 1.15 CONDENSATE DRAIN (Refer to Section 2.15) A condensate drain is provided on the boiler. This drain must be connected to a drainage point on site. All pipework and fittings in the condensate drainage system MUST be made of plastic - no other materials may be used. IMPORTANT. Any external runs must be in accordance with BS.6798. The drain outlet on the boiler is sized for standard 21.5mm overflow pipe. It is a universal fitting to allow use of different brands of pipework. Installation and Servicing 13 SECTION 1 - GENERAL 1.16 BOILER DIMENSIONS, SERVICES & CLEARANCES The boiler connections are made on the boiler connection tails. Refer to Section 2.16. drill, the flue can be installed from inside the building where wall thicknesses do not exceed 600mm. Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside. The following minimum clearances must be maintained for operation and servicing. Additional space will be required for installation, depending upon site conditions. Side and Rear Flue a. Provided that the flue hole is cut accurately, e.g. with a core 2.5 from case 2.5 Installation from inside ONLY b. If a core boring tool is to be used inside the building the space in which the boiler is to be installed must be at least wide enough to accommodate the tool. 395 WALL Side flue dim. A 700 Underside View - Dimensions to Wall Filling Loop PRV 56.4 37.5 CH RETURN 75 DHW INLET GAS INLET 28.5 28.5 60.6 DHW OUTLET 65 COND. DRAIN 43.5 CH FLOW DATA PLATE Centre line of boiler CH Flow DHW Outlet Gas DHW Inlet WALL CH Return CH Circuit Drain Front clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required, with the cupboard door open, to allow for servicing. * Bottom clearance 14 Bottom clearance after installation can be reduced to 5mm. This must be obtained with an easily removable panel to provide the 100mm clearance required for servicing. Installation and Servicing SECTION 1 - GENERAL 1.17 SYSTEM REQUIREMENTS - Central Heating Notes Safety valve settingbar a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority. Vessel charge pressure b. Antifreeze fluid, corrosion and scale inhibitor fluids suitable for use with boilers having aluminium heat exchangers may be used in the central heating system. General 1. The installation must comply with all relevant national and local regulations. 2. The installation should be designed to work with flow temperatures of up to 84 oC. bar 0.5 to 0.75 System pre-charge pressurebar System volume (litres) 3.0 None 1.0 Expansion vessel volume (litres) 25 1.61.8 50 3.13.7 75 4.75.5 100 6.37.4 125 7.89.2 150 9.411.0 175 10.912.9 190 11.914.0 200 12.514.7 250 15.618.4 300 18.822.1 For other system volumes multiply by the factor across 0.0630.074 3. All components of the system must be suitable for a working pressure of 3 bar and a maximum design temperature of 110 oC. Extra care should be taken in making all connections so that the risk of leakage is minimised. The following components are incorporated within the appliance: Water Flow Rate and Pressure Loss a. Circulating pump. Max CH Output b. Safety valve, with a non-adjustable preset lift pressure of 3 bar. c. Pressure gauge, covering a range of 0 to 4 bar. d. An 8-litre expansion vessel, with an initial charge pressure of 0.75 bar. Water flow rate Temperature Differential Head available for system kW 24.2 l/min 17.3 (gal/min)(3.8) o C20 m.w.g. 3.4 (ft.w.g.)(11.1) 4. ‘Make-up’ Water. Provision must be made for replacing water loss from the system, either : a. From a manually filled ‘make-up’ vessel with a readily visible 5.Filling water level. The vessel should be mounted at least 150mm above the highest point of the system and be connected The system may be filled by the following method: through a non-return valve to the system, fitted at least Where the mains pressure is excessive a pressure 150mm below the ‘make-up’ vessel on the return side of reducing valve must be used to facilitate filling. the radiators. or a. Thoroughly flush out the whole system with cold b. Where access to a ‘make-up’ vessel would be difficult, by water. pre-pressurisation of the system. b. Fill and vent the system until the pressure gauge The maximum cold water capacity of the system should registers 1bar and examine for leaks. Refer to not exceed 143 litres, if not pressurized. However, if Section 2.16 for filling detail. the system is to be pressurized, the efficiency of the expansion vessel will be reduced and a larger vessel c. Check the operation of the safety valve by raising the (or smaller system volume) may be necessary. If the water pressure until the valve lifts. This should occur capacity of the vessel is not considered sufficient for this, within 0.3bar of the preset lift pressure. or for any other reason, an additional vessel MUST be d. Release water from the system until the installed on the return to the boiler. minimum system design pressure is reached; Guidance on vessel sizing is given in table above. 1.0 bar if the system is to be pre-pressurised. continued . . . . . . Installation and Servicing 15 SECTION 1 - GENERAL ........ SYSTEM REQUIREMENTS - CONT Domestic Hot Water 1.18 SYSTEM BALANCING The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of the minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available. See note regarding thermostatic radiator valves on page 13. 1. The DHW service must be in accordance with BS.5546 & BS.6700. 2. Refer to Table 1 for minimum and maximum working pressures. In areas of low mains water pressures the domestic hot water regulator may be removed from the DHW flow turbine cartridge. Refer to Section 3.20. The boiler will require the flow rate to be set to obtain a temperature rise of 35oC at the tap furthest from the boiler. Note. Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass. 3. The boilers are suitable for connection to most types of washing machine and dishwasher appliances. BALANCING 4. When connecting to suitable showers, ensure that: a. The cold inlet to the boiler is fitted with an approved antivacuum or syphon non-return valve. 1. Set the programmer to ON. Close the manual or thermostatic valves on all radiators, leaving the twin lockshield valves (on the radiators referred to above) in the OPEN position. Turn up the room thermostat and adjust the lockshield valve to give an uninterrupted flow through the radiator. IMPORTANT. Provision must be made to accommodate the expansion of DHW contained within the appliance. If the DHW inlet contains a back flow prevention device or non-return valve, e.g. a water meter, then a mini expansion vessel should be fitted between the device and the boiler in the cold inlet pipe. These valves should now be left as set. Cold water, rising main and pipework in exposed areas need to be suitably lagged to prevent freezing. Note. DHW Expansion Vessel kit available from Ideal. 3. Adjust the room thermostat and programmer to NORMAL settings. b. Hot and cold water supplies to the shower are of equal pressure. 5. Hard Water Areas Where the water hardness exceeds 200mg/litre (200 ppm), it is recommended that a proprietary scale reducing device is fitted into the boiler cold supply within the requirements of the local water company. 2. Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators, to give around 20oC temperature drop at each radiator. 1.19 WATER TREATMENT CENTRAL HEATING The Logic range of boilers have an ALUMINIUM alloy heat exchanger. IMPORTANT. The application of any other treatment to this product may render the guarantee of Ideal Boilers Invalid. Ideal Boilers recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems. If water treatment is used Ideal Boilers recommend only the use of SCALEMASTER GOLD 100, FERNOX, MBI, ADEY MC1, SENTINEL X100 or CALMAG CM100 inhibitors and associated water treatment products, which must be used in accordance with the manufacturers’ instructions. DOMESTIC HOT WATER 1. It is most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers’ instructions. 2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. BS 7593 details the steps necessary to clean a domestic heating system. 3. In hard water areas, treatment to prevent lime scale may be necessary - however the use of artificially softened water is NOT permitted. 4. Under no circumstances should the boiler be fired before the system has been thoroughly flushed. 16 In hard water areas where mains water can exceed 200ppm Total Hardness (as defined by BS 7593 Table 2) a scale reducing device should be fitted into the boiler cold supply within the requirements of the local water company. The use of artificially softened water, however, is not permitted. Ideal Boilers recommend the use of Fernox Quantomat, Sentinel Combiguard,Calmag CalPhos I scale reducing devices or Scalemaster In-line Scale Inhibitor branded Ideal, which must be used in accordance with the manufacturers’ instructions. Notes. For further information contact: Fernox Cookson Electronics Forsyth Road, Sheerwater, Woking, Surrey GU21 5RZ +44 (0) 8706 015000 Sentinel Performance Solutions The Heath Business & Technical Park Runcorn, Cheshire WA7 4QX Tel: 0800 389 4670 Scalemaster Water Treatment Products Emerald Way, Stone, Staffordshire ST15 0SR Tel: +44 (0) 1785 811636 Calmag Ltd. Unit 3-6, Crown Works, Bradford Road, Sandbeds, Keighley, West Yorkshire BD20 5LN Tel: +44 (0) 1535 210320 Adey Professional Heating Solutions Gloucester Road, Cheltenham GL51 8NR Tel: +44 (0) 1242 546700 Installation and Servicing SECTION 2 - INSTALLATION 104 105 106 107 108 110 111 112 113 114 115 116 117 118 119 120 121 124 127 131 135 203 204 205 206 211 214 215 CH Return Valve CH Flow Valve DHW Inlet & Outlet Filling Loop Pipe Pump Head Auto Air Vent Diverter Valve Motor Diverter Valve Body & Paddle Pressure Relief Valve Pipe - PRV Outlet Pipe - Flow Pipe - Return Pipe - Expansion Vessel Expansion Vessel Note that item numbers are linked to the spares list 217 218 219 223 224 227 228 229 231 302 304 306 307 308 Return Group Manifold Flow Group Manifold Plate Heat Exchanger Flow Regulator Flow Sensor/Turbine Water Pressure Switch Pressure Gauge Gas Cock Pipe - Gas Inlet Gas Valve Pipe - Gas Injector Injector Assy Venturi Fan Burner Gasket - Burner Sump Clean Out Cover Flue Manifold Flue Manifold Top Clamp Retaining Flue Turret Hose Condensate Internal Siphon Trap Condensate Outlet Connection Primary PCB Control Thermistor (Return) Electrode Ignition Electrode Detection Ignitor Unit 504 Thermistor Flow Ignition Lead Detection Lead Control Box Lid Control Box Front Blank Insert Heat Engine Wall Mounting Bracket Front Panel Fascia Bracket - Gas Valve Bracket - Expansion Vessel 227 224 505 215 503 214 217 206 218 205 309 313 320 324 325 326 401 503 504 505 506 507 INSTALLATION 2.1 BOILER ASSEMBLY - Exploded View 118 313 211 306 320 507 309 401 307 204 506 308 223 231 115 228 116 111 110 121 135 219 105 324 304 229 106 203 106 120 112 131 104 113 127 107 124 326 325 Installation and Servicing 302 119 114 117 108 17 INSTALLATION SECTION 2 - INSTALLATION 2.2UNPACKING The boiler is supplied fully assembled in Pack A. A telescopic or non-telescopic flue assembly for rear or side flue outlet in Pack B is supplied as a separate order. Unpack and check the contents. A E B Pack A Contents ABoiler B Hardware Pack Box C C Wall Mounting Plate D These Installation/Users Instructions E Wall Mounting Template F D Boiler Guarantee & Registration Pack F Boiler Guarantee HARDWARE PACK CONTENTS Gas Valve Pack 1. Pipe - Gas Inlet 2. Washer - Gas (blue) 3. Gas Cock Gas Valve Pack DHW Pack 1. 1/2" Top Hat Washer (x2) 2. Cap Female 3. Plug Male and Clip 4. Nut G1/2 16 Brass (Flat) 5. Washer 18.5 x 11 x 11.8 (x2) 6. Pipe DHW Outlet 7. Pipe DHW Inlet 8. Valve DHW Inlet Accessory Pack 1. Screw (x2) 2. Wallplug (x2) 3. Turret Clamp Screw (spare) Flow Valve Pack 1. Pipe CH Flow 2. Washer CH 3. Valve Flow 2 3 Filling Loop Pack 1. 3/8" Top Hat Washer 2. Valve Filling Loop 3. Pipe Filling Loop 4. Washer Fibre 3/8” Return Valve Pack 1. Pipe CH Return 2. Washer CH 3. Valve Return DHW Pack 1 3 1 2 8 7 1 5 5 4 Filling Loop 4 6 3 Accessory Pack 1 2 1 3 2 Return Valve Pack 3 1 Flow Valve Pack 3 1 2 2 continued . . . . . 18 Installation and Servicing SECTION 2 - INSTALLATION INSTALLATION 2.3 UNPACKING CONT’D Note. This flue system incorporates a removable flue outlet nose that utilises a push fit location system. This enables the installation of deflector, high level or balcony outlet flue kits without the removal of the whole ‘B’ pack terminal. The appliance must not be operated without the desired outlet nose correctly fitted in place. Note. Location dimples must be aligned with terminal mounting frame. Pack B Contents Telescopic A Telescopic Flue Terminal B Flue Turret C Rubber Terminal Wall Seal DScrew E Sealing Tape F Wall Seal (White) B F A C E D Pack B Contents Non-Telescopic A Flue Terminal B Flue Turret C Rubber Terminal Wall Seal D Cutting Aid E Wall Seal (White) B D E A C 2.4 FRONT PANEL REMOVAL 1. Loosen the 2 screws retaining the front panel. 2. Pull the two clips downwards to disengage. 3. Pull the front panel forward and upwards to remove. 2 1 Installation and Servicing 19 2.5 WALL MOUNTING TEMPLATE Extended centre line 155 (200) The wall mounting template is located on the internal protective packaging. The template shows the position of the fixing and rear flue centre holes for a standard installation “A” - See Diagram in Section 1.16 Care MUST be taken to ensure the correct holes are drilled. 1. Tape template into the required position, ensuring its squareness by hanging a plumbline as shown. 2. If fitting a side flue, extend the flue centreline onto the side by 155mm on a standard wall fix or 200mm if using a stand-off bracket. 3. Mark the following on to the wall: a The selected group of wall mounting screw holes. b.The centre position of the flue duct. Marking both the centre and the circumference of the flue duct. 4. Remove the template plate from the wall. 2.6 PREPARING THE WALL IMPORTANT. Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury. Rear flue only 5" diameter hole 1. Cut the flue hole (preferably with a 5” core boring tool), ensuring that the hole is square to the wall. Both wall faces immediately around the cut hole should be flat. Side flue only 5" diameter hole X 2. Drill 2 mounting holes (marked from template) with a 7.5mm / 8mm masonry drill and insert the plastic plugs, provided, for the wall mounting plate. Section through wall 3. Locate 2 No.14 x 50mm screws in the wall mounting plate (one at each side, in any of the 3 holes provided at each side) and screw home. Ensure mounting bracket is level. Note. Check all of the hole positions before drilling. 3G9495 INSTALLATION SECTION 2 - INSTALLATION 2.7 FITTING THE WALL MOUNTING PLATE 2.8 MOUNTING THE BOILER Screw the wall mounting plate to the wall using 2 wall plugs (previously fitted) with the 2 screws provided. 1. Ensure the plastic plugs are removed from both the CH and DHW connections before mounting the boiler. Choose one of the 2 sets of slots in left and right bank. Ensure that at least one of the screws is fitted into a top slot and the mounting bracket is level. Example of fixing Note. Boiler may contain residual water. 2. Lift the boiler onto the wall mounting plate (refer to the Introduction section for safe handling advice), locating it over the two tabs. esp9496 20 Installation and Servicing SECTION 2 - INSTALLATION 2.9 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT. The boiler must be installed in a vertical position in accordance to the installation instructions. FLUE KITS Telescopic Flue‘B’ Pack - contains: Flue turret, telescopic flue incorporating a terminal and rubber wall seals. Horizontal Flue Terminal (600mm long) ‘B’ Pack - contains: Flue turret, non telescopic single piece flue incorporating a terminal and rubber wall seals. Horizontal Flue Terminal (1000mm long) ‘B’ Pack - Flue turret, telescopic flue incorporating a terminal, rubber wall seals and instructions. Note. If ‘B’ packs are used on their own (either 1 piece or telescopic), then they MUST be fitted horizontally as the flue inside is designed to slope 1.5 degrees. D Pack Flue Extension 100mm DIA 1000mm long D Pack Flue Extension 100mm DIA 500mm long D Pack Flue Extension 100mm Dia 2000mm long Roof Flue Kit with Vertical Connector recommended that a support bracket is fitted on every 1 metre of pipe work used and the bracket is located as close to the collar as possible. The bracketing must ensure a 1.5 degree fall back to the appliance. Optional Flue Finishing Kit - & Concentric Flue Screw Retaining Kit (Optional Kit of mechanical fixing of flue joints) Only use water as a lubricant during assembly. The ‘B’ pack terminal is classed as part of the maximum flue length. These flue system incorporates a removable flue outlet nose that utilises a push fit location system. This enables the installation of deflector, high level or balcony flue kits without the removal of the whole ‘B’ pack terminal. The appliance must not be operated without the desired outlet nose correctly fitted in place, ensuring the side location dimples are in line with the mounting face allowing the correct sealing of the components. It is IMPORTANT that all attachments are fitted in accordance to the installation instructions provided with them. When extension ‘D’ Packs are used the flue duct must incline 1.5 degrees away from the appliance, to allow the condensate to drain back to the boiler and out of the condensate drain. It is The TURRET supplied in the ‘B’ Pack has an upper combustion sample point with a screw cap seal and a lower air sample point with an air stopper seal. Ensure all caps & seals are in place. Additional Termination Kits available for use with these ‘B’ packs. Flue Deflector Kit High Level Flue Outlet Kit Balcony Flue Outlet Kit Soffit Kit The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from any maximum flue length The maximum permissible concentric flue length when using a standard (500mm) kit is 4.5 metres The maximum permissible concentric flue length when using this kit is dependant on the length of the balcony flue outlet run which combined with the concentric run must not exceed the maximum flue length requirement of the appliance it is to be fitted to This kit enables fitment of an external flue below soffits. 24 kW Appliances 30 kW Appliances 35 kW Appliances Total Maximum: 9 metres - minus any flue kit options or bends Total Maximum: 8 metres - minus any flue kit options or bends Total Maximum: 6 metres - minus any flue kit options or bends Total Maximum Permissible Vertical Flue Length combining both Roof Terminal and ‘D’ Packs 24, 30 & 35kW Appliances Total Maximum: 7.5 Metres - minus any bends Powered Vertical Flue 24, 30 & 35kW Appliances Total Maximum: 5 Metres - Concentric Flue and 17m flue pipe only. For additional details refer to the powered Vertical Instructions 90º Elbow Kit 60/100 - (Equivalent flue length resistance = 1M) 45º Elbow Kit 60/100 - (Equivalent flue length resistance = 0.6M) Minimum Horizontal Flue Lengths (Centre line of turret to outside of wall terminal) Telescopic Flue ‘B’ Pack = 400mm Horizontal Flue terminal (600mm long) ‘B’ Pack = 285mm Wall Thickness ‘B’ Pack Flue Type 60/100 Horizontal Flue Terminal (600mm long) B Pack Telescopic Flue B Pack Horizontal Flue Terminal (1000mm long) B Pack Horizontal Flue Terminal (1000mm long) B Pack cut 75mm Std Metric Brick 102.5mm wide Minimum Permissible Wall Thickness Maximum Permissible Wall Thickness Rear Flue Rear Flue + Stand-Off Side Flue Rear Flue Rear Flue + Stand-Off Side Flue 126* 102.5 102.5 501 456 456 231 546 186 501 186 501 429 761 384 716 384 716 471 426 426 686 641 641 * If wall thickness is <126 and >102.5, contact Ideal Boilers. For Flue lengths between 658 & 708 use a Horizontal Flue Terminal (1000mm long) B Pack, cut 75mm off the end of the terminal section of the telescopic flue only. Installation and Servicing 21 FLUE OUTLET Total Maximum Permissible Horizontal Concentric Flue Length combining both ‘B’ Packs and ‘D’ Packs (Measured from centreline of the turret to the outside of the wall terminal) SECTION 2 - INSTALLATION ....... DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED, CONT’D 100mm Edge of turret to outside face of wall plus 44mm = flue length A REAR Fit to wall inc. Stand off Frame WALL REAR Fit to wall Edge of turret to outside face of wall plus 44mm = flue length A SIDE Fit to wall WALL Note. Maximum permissible flue length is measured from centre line of appliance flue outlet to outside wall face. Edge of turret to outside face of wall plus 44mm = flue length A WALL FIGURE 1 Minimum clearance 5mm NOTES Centre of turret to edge of turret = 100mm Turret has a flue insertion of 30mm The compressed outer wall seal has protruding wall to seal mounting lip - 14mm From centreline of turret to wall. Rear mount 155mm, side (including clearance) 200mm Flue length measured from outer terminal lip to end of outer flue A + 44mm FIGURE 2 Shows the flue required when measured from outside edge of turret to the outside face of the wall (to obtain cut length add 44mm) B Pack (Standard) Plus 1 (1m D pack) Plus 2 (1m D pack) Plus 3 (1m D pack) Plus 4 (1m D pack) Plus 5 (1m D pack) Plus 6 (1m D pack) Plus 7 (1m D pack) Plus 8 (1m D pack) Plus 9 (1m D pack) 181 1131 2081 3031 3981 4931 5881 6831 7781 8731 556 1506 2456 3406 4356 5306 6256 7206 8186 9000 286 1236 2186 3136 4086 5036 5986 6936 7886 8836 484 1434 2384 3334 4284 5234 6184 7134 8084 9000 601 1551 2501 3451 4401 5351 6301 7251 8201 9000 816 1766 2716 3666 4616 5566 6516 7466 8416 9000 526 1476 2426 3376 4326 5276 6226 7176 8126 9000 741 1691 2641 3591 4541 5491 6441 7391 8341 9000 Max output 35 kW Max output 30 kW Max output 24 kW FLUE OUTLET Minimum & Maximum finished flue lengths obtainable (dimension ‘A’ +44mm) Horizontal Flue Terminal Telescopic Flue B Pack Horizontal Flue Horizontal Flue Terminal (600mm long) B Pack Terminal (1000mm long) (1000mm long) B Pack B Pack (Telescopic) (Telescopic) Cut 75mm Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum Note; Telescopic flue B Pack or attached “D” pack extensions do not need to be cut between minimum and maximum values shown above (except where specified). Horizontal Flue Terminal (600mm long) B Pack flue will require cutting on values below maximum values shown in the table above. If using the 2000mm D Pack , the maximum usable length per extension is 1950mm If using the 500mm D Pack, the maximum usable length per extension is 450mm. 22 Installation and Servicing SECTION 2 - INSTALLATION 2.10 CUTTING & SETTING THE FLUE LENGTH TELESCOPIC FLUES TELESCOPIC FLUE B PACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT HORIZONTAL FLUE TERMINAL (1000MM LONG) B PACK (TELESCOPIC) MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 & 652MM. THIS WILL REQUIRE 75MM TO BE CUT OFF THE TERMINAL END OF THE 1000MM TELESCOPIC FLUE. ALL OTHER LENGTHS OBTAINED USING “D” PACK EXTENSIONS IN FLUE LENGTH TABLE 1, COLUMN “HORIZONTAL FLUE TERMINAL (1000MM LONG) B PACK CUT 75MM” (TELESCOPIC) SHOULD HAVE THE 75MM CUT OFF THE “D” PACK EXTENSION AND NOT TELESCOPIC FLUE CUT 75MM OFF HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK (TELESCOPIC) 1. Measure cut flue length (A+44mm). (If required telescopic length is not between 658 and 708 then proceed to “Setting Telescopic Flue B Pack”). 2. Remove telescopic end piece from the flue body and set aside. 3. Mark the circumference 75mm from the open end of the outer flue. 4. Cut along the 75mm mark cutting only the outer flue ensuring the cut is square. 5. Dress the cut end to make sure all burr is removed and the cut edge is in its original shape. 6. Measure 20mm from the newly cut edge of the outer flue, place a mark at the top of the flue approximately 20mm wide & write “STOP” on the terminal side of the line. 7. Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure it’s cut square. 8. Remove all burrs and place a chamfer on the outer edge to aid assembly. 9. Re-assemble telescopic section. SETTING TELESCOPIC FLUE B PACK 1. Measure the required flue length (A+44mm). FLUE OUTLET 2. Measure from the outer terminal lip to end of outer flue. Pull apart flue until desired length is achieved. ENSURE THE STOP MARK IS NOT VISIBLE, IF IT IS, THE FLUE IS TOO SHORT AND SHOULD NOT BE USED. 3. Check that both flue seams are at the top and the outlet terminal is uppermost. 4. Drill a 3.5mm hole through one of the 2 outer side holes in the outer flue section into the inserted outer flue (as shown). Take care not to pierce the inner plastic flue. Fit screw provided. 5. Seal the joint on the outer air duct with the tape provided. 6. Fit internal and external wall seals (see installing flue). CUTTING HORIZONTAL FLUE TERMINAL (600MM LONG) B PACK 1. Measure the required cut flue length (A+44mm). If inside the dimensions shown in Figure 2 (page 22) “1 Piece 600mm” proceed. 2. Measure from the outer terminal lip to end of outer flue. Mark the required cut length (A+44) around the circumference of the outer flue and cut following the mark to ensure it is cut square. 3. Dress the cut end to make sure all burrs are removed and the cut edge is in its original shape. 4. Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure it is cut square. 5. Remove all burrs and place a light chamfer on the outer edge to aid assembly. Installation and Servicing 23 SECTION 2 - INSTALLATION 2.11 INSTALLING THE FLUE FITTING FLUE THROUGH THE WALL 1. Measure wall thickness and add 14mm. 2. Measure from the outer terminal lip towards the end of outer flue, place a small location mark at the dimension acquired at point 1. 3. Add a further 14mm to the dimension, obtained at item 1 (point 1) and place an additional small location mark. 4. Fit external black wall seal ensuring the inside of the outer lip is in contact with the terminal lip you have been measuring from (see fig 1 below) 5. Fit the internal wall seal approximately 65mm before the outer of the 2 location marks. 6. For an internal fit place flue terminal in the centre of the 5” drilled hole in the wall. Apply pressure and lightly move the flue left to right or up and down. This will cause the outer flange to fold in and allow the flue to pass through the wall. 7. Push through a further 65mm or until the inner flange is pressed against the inner wall. This will allow the outer flange to return to its original shape. 8. Pull back the flue until the first of the 2 location marks is level with the internal face of the wall. Note. If the 2 location marks are not visible then the flue is not pulled back far enough to obtain the correct seal. If the 1st location mark has passed the face of the wall the flue has been pulled too far back and the outer wall seal will have been dislodged from its mounting and will need to be refitted. 9. When 1st mark is in line with the wall, whilst holding the flue firmly, push the white wall sealing flange to the wall until the 2nd of the two marks is just visible. If the last location mark is clearly past the white inner wall seal then the outer wall seal will have been dislodged from its mounting and will need to be re-fitted. 10.Ensure the seam and the outlet terminal are at the top and fitted as shown. Note. If less than 50% of the length of the flue is internal the flue should be fitted from outside. Terminal MUST be fitted as shown Wall Seal Lip Fig 1 FLUE OUTLET Terminal Lip 24 Rubber Terminal Wall Seal Location mark 1 Location mark 2 Ensure lip of wall seal is positioned over step on plastic nose of flue terminal (note, seal is cut away for clarity) FITTING THE TURRET - Ensure the condense trap/siphon is filled with water 1. Ensure the rubber seal is fitted correctly on the appliance manifold and that all flue seals are undamaged. 2. Hold the flue firmly and push the turret on until it has travelled 30mm on to the flue pipe and is fully engaged. Make sure the flue has not rotated or moved forward during fitting and the flue seam is uppermost. 3. Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold. 4. Fully engage the clamp location section into the manifold location holes. Rotate down on to turret flange. 5. Secure clamp to appliance using securing screw. 6. Ensure all sample points are accessible and all sample plugs and caps are fitted. Retaining screw D Clamp Lugs A B Flue Outlet A - Duct Assembly B - Flue Turret C - Turret Clamp D - Seal Sample points Flue Outlet C Installation and Servicing SECTION 2 - INSTALLATION 2.12 FITTING THE OPTIONAL ROOF FLUE KIT (FLAT OR PITCHED) Note. A flat or pitched roof flashing plate (not supplied) is required before proceeding with the installation of this kit. This kit is suitable for both flat and pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level. Connection to the top of the boiler is made using the supplied vertical connector. WEATHER PROOFING Where the flue passes through the roof line an adequate seal must be made. This is achieved by using either: - Flat roof weather collar or - Universal weather collar. ACCESSORIES Flue Duct Extension Kits are available for flue lengths extending beyond 1m. These packs contain 1m extension ducts and may be cut to the desired length. If the offset vertical option is used an Elbow Kit is required. FLUE OUTLET Please visit www.idealboilers.com to access the Flue and Accessories Guide for this boiler. Installation and Servicing 25 SECTION 2 - INSTALLATION 2.13 FLUE TERMINAL POSITION The terminal should be positioned so that products of combustion can safely disperse at all times. Pluming may occur at the termination so, where possible, terminal positions where this could cause a nuisance should be avoided. 300mm Minimum dimensions are shown below min 690mm Fixed m 300mm min rf8394-1 0m 30 in m rf8393-1 625mm Fixed A A B 07 98 26 A If chimney penetrates dotted area such that A is less than 300mm, B shall not be less than 300mm. RF FLUE OUTLET Flat roof - with structure A = 600mm B = 2000mm The flue terminal shall not penetrate the shaded area of the roof Pitched roof - with velux window or opening Where two or more vertical fanned draught chimney configurations terminate in close proximity at the same height, they shall be separated by at least 300mm. Where any one vertical outlet is more than 300mm above the other, then they shall be separated by at least 1500mm. Where any vertical fanned draught chimney configuration outlet is within 2000mm measured horizontally of an opening window, then it shall be at least 300mm above the opening. Note. The equivalent flue length resistance of the elbow kits are: 90o elbow kit = 1m 45o elbow kit = 0.6m Installation and Servicing SECTION 2 - INSTALLATION 2.14 ASSEMBLING THE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied. MAX LENGTH: 7.5m o 1. Position the roof flashing plate (supplied separately) over the hole cut in the roof and insert flue terminal from the roof end. max 41 min 16 o Ensure the cut pipe ends are free from any burrs. BOILER nm8739 1 2. Fit the vertical connector (supplied in kit) in accordance with the instructions provided with the vertical connector kit. Flue Terminal ASSEMBLY A 3. Secure the vertical connector by applying downward pressure on the connector. 4. Position the clamp on the top face of the flue manifold and push it horizontally backwards. Locate both clamp lugs into the flue manifold and secure to the flue manifold with the M5 retaining screw. Pitched roof tile weather collar Note. Ensure turret sample points are servicable and all caps and plugs are fitted. Fill the condense trap/siphon with water. nm8740 5 4 Extension Duct FLUE OUTLET Flat roof tile weather collar 5. Push extension duct (if required (supplied separately)) into vertical connector. Vertical connector 3G9557b 2 6 'X' 6. If the last extension duct requires cutting, measure ‘X’, the distance (outer ducts), between the duct and the terminal and add 100 mm to this dimension. This gives the length of the last extension duct. Note. Check the position of the inner flue duct relative to the outer duct on the assembled extension duct(s) and ensure the terminal flue duct is cut longer than the air duct to ensure engagement in the final flue duct seal. 7. Finally ensure the roof flashing plate is correctly sealed to the roof. Installation and Servicing 27 INSTALLATION SECTION 2 - INSTALLATION 2.15 CONDENSATE DRAIN Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc. (fig 3). 137 149 This appliance is fitted with a siphonic 75mm condensate trap system that requires filling before operating the appliance for the 1st time or after maintenance. In order to minimise the risk of freezing during prolonged very cold spells, one of the following methods of terminating condensate drainage pipe should be adopted. Internal Drain Connections Wherever possible, the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc. See Figs 1 and 2. Figure 1 - Connection of Condensate Drainage Pipe to Internal Soil & Vent Stack - - - For connections to an external soil/vent stack see Fig 4. Insulation measures as described should be used. When a rainwater downpipe is used, an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse flow of rainwater into the boiler should the downpipe become flooded or frozen, see Fig 5. Where the condensate drain pipe terminates over an open foul drain or gully, the pipe should terminate below the grating level, but above water level, to minimise “wind chill” at the open end. The use of a drain cover (as used to prevent blockage by leaves) may offer further prevention from wind chill. See Fig 6. Where the condensate drain pipe terminates in a purpose designed soakaway (see BS 6798) any above ground condensate drain pipe sections should be run and insulated as described above. See Fig 7. Unheated Internal Areas Internal condensate drain pipes run in unheated areas, e.g. lofts basements and garages, should be treated as external pipe. Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual. Figure 2 - Connection of a Condensate Drainage Pipe Downstream of a Sink, Basin, Bath or Shower Water Trap to Internal Soil Vent Stack Minimum connection height up to 3 storeys Sink/basin/ bath or shower Min Ø 19mm Internal pipe 75 ≥ 100 ≥ 450 Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break - ≥ 100 Min Ø 19mm Internal pipe The external pipe run should be kept to a minimum using the most direct and “most vertical” route possible to the discharge point, with no horizontal sections in which condensate might collect. Boiler with 75mm sealed condensate trap Soil & vent stack Boiler with 75mm sealed condensate trap 75 FLUE OUTLET All condensate pipework should conform to the following: a. Where a new or replacement boiler is being installed, access to an internal ‘gravity discharge’ termination should be one of the main factors considered in determining boiler location. b. Plastic with push fit or solvent connections. c. Internal plastic pipe work a minimum of 19mm ID (typically 22mm OD). d. External plastic pipe must be a minimum of 30mm ID (typically 32 OD) before it passes through the sleeved wall. e. All horizontal pipe runs must fall a minimum of 45mm per metre away from the Boiler. f. External & unheated pipework should be kept to a minimum and insulated with Class “O” waterproof pipe insulation. g. All installations must be carried out in accordance to the relevant connection methods as shown in the “Condensate installation diagrams” & BS6798. h. Pipework must be installed so that it does not allow spillage into the dwelling in the event of a blockage (through freezing) i. All internal burrs should be removed from the pipe work and any fittings. External Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously. An external system must terminate at a suitable foul water discharge point or purpose designed soakaway. If an external system is chosen then the following measures must be adopted: Internal soil & vent stack Condensate Drain 47 Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break continued . . . . . 28 Installation and Servicing SECTION 2 - INSTALLATION Boiler with 75mm sealed condensate trap Min Ø 30mm Internal pipe Water/ weather proof insulation Min Ø 19mm Internal pipe Min Ø 30mm Internal pipe Boiler with 75mm sealed condensate trap combined foul/ rain water drain External air break Air gap Terminated and cut at 45º 43mm 90º male/ female bend 68mm Ø PVCU Strap on fitting Visible air break at plug hole Min Ø 19mm Internal pipe Sink, basin, bath or shower with integral overflow and 75mm trap Water/ weather proof insulation Minimum 30mm internal pipe 45º pipe termination FLUE OUTLET Boiler with 75mm sealed condensate trap Minimum connection height up to 3 storeys Figure 6 - Connection of Condensate Drainage Pipe Upstream of a Sink, Basin, Bath or Shower Waste Trap to External Drain, Gulley or Rainwater Hopper 75 Figure 5 - Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe (only combined foul/rainwater drain) Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break ≥ 100 Condensate pump (Install in accordance with manufacturer’s instructions) ≥ 450 Min Ø 19mm Internal pipe ≥ 25 Below grate 75 Min Ø 19mm Internal pipe Water/weather proof insulation 75 Visible air break Boiler with 75mm sealed condensate trap Figure 4 - Connection of condensate Drainage Pipe to External Soil & Vent Stack Soil & vent stack Figure 3 - Connection of a Condensate Pump Typical Method (see manufacturer’s detailed instructions) INSTALLATION .......CONDENSATE DRAIN - CONT’D Figure 7 - Connection of a Condensate Drainage Pipe to an External Purpose Made Soakaway. Boiler with 75mm sealed condensate trap Max 3m external pipework Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break ≥ 300 ≥ 25 Min Ø 19mm Internal pipe Water/Weather proof insulation 75 Min Ø 30mm Internal pipe ≥ 500 Limestone chippings 2 rows of three Ø12mm holes 25mm centres, 50mm from the bottom of the tube, facing away from the house Installation and Servicing 29 2.16 CONNECTIONS & FILLING NOTES. Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown in the picture. Ensure each union is fitted with fibre seals provided. Do not subject any of the isolating valves to heat as the seals may be damaged. WATER CONNECTIONS CH 1. Connect the CH flow service valve (black handle) and copper tail provided in the hardware pack to the threaded boss connection provided at the lower rear of the boiler. 2. Connect the CH rtn. valve (black handle) and copper tail. WATER CONNECTIONS DHW 1. Fit the DHW inlet service valve (blue handle) and copper tail to the threaded boss connection ensuring the seal provided is correctly located. Note. The domestic hot water flow rate is automatically regulated to a maximum: 24 = 9.9 l/m (2.2 gpm) 30 = 12.4 l/m (2.8 gpm) 35 = 14.5 l/m (3.2 gpm) SAFETY VALVE DRAIN The safety valve connection, located at the bottom righthand side of the boiler, comprises a 15mm diameter stub pipe. The Installer to provide a compression joint on the end of the stub pipe. This assists with pipe removal when servicing. The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring. 2. Fit the DHW outlet pipe tail to DHW outlet connection, ensuring the seal provided is correctly located. 3. Fit the filling loop provided between the DHW inlet valve and the CH return valve. 3G9705 INSTALLATION SECTION 2 - INSTALLATION GAS CONNECTION IMPORTANT. The gas service cock is sealed with a nonmetallic blue fibre washer, which must not be overheated when making capillary connections. Refer to Section 1.16 for details of the position of the gas connection. For additional gas supply info refer to “Gas Supply” on page 12. CH Flow DHW Outlet Gas Supply Safety Valve Drain Connection 15mm elbow or fittings (not supplied) DHW Inlet Pressure Relief Valve Drain Pipe CH Return Filling Loop 30 Installation and Servicing .......CONNECTIONS & FILLING CONT FILLING IMPORTANT - when filling: When filling there may be a slight water leak from the air vent therefore electrical connections should be protected. Filling Top Up 1. Ensure filling loop is connected and all washers in place. 1. Ensure filling loop is connected and all washers in place. 2. Ensure dust cap on auto air vent is slackened off. Refer to Section 3.24. 2. Ensure dust cap on auto air vent is slackened off. Refer to Section 3.24. 3. Check the following isolation handles on water connections are in the horizontal filling position (blue handle on DHW inlet A and black handle on CH return C ). 3. Turn the DHW Inlet handle (blue A ) to the horizontal position. Note. The CH flow isolation valve handle MUST be in the vertical position to enable filling. 4. Slowly turn the filling loop handle (blue B ) to the horizontal open position until the pressure gauge reads between 1 to 1.5 bar. 4. Slowly turn the filling loop handle (blue B ) to the horizontal open position until the pressure gauge reads between 1 to 1.5 bar. 5. Once the pressure gauge dial reads between 1-1.5 bar turn the handle (blue B ) on the filling loop back to the closed (vertical) position. 5. Once the pressure gauge dial reads between 1 to1.5 bar turn the filling loop handle (blue B ) back to the closed (vertical) position. 6. Turn the DHW Inlet handle (blue A ) to the open (vertical) position. 6. Turn the CH Return handle (black C ) and the DHW Inlet handle (blue A ) to the open (vertical) position. 7. Disconnect the filling loop from the DHW Inlet valve and fit the grey cap to the open end. 8. Fit the Plug to the free end of the filling loop. 7. Disconnect the filling loop from the DHW Inlet valve and fit the grey cap to the open end. 8. Fit the Plug to the free end of the filling loop. Note. Open all DHW taps to ensure water is flowing freely. Once satisfied close all taps. Note. Open all DHW taps to ensure water is flowing freely. Once satisfied close all taps. Filling Positions shown Top Up Positions shown Cap Filling Loop Cap Filling Loop Plug A A DHW Inlet (Blue) DHW Inlet (Blue) B B C Filling Loop (Blue) CH Return (Black) Installation and Servicing Plug C Filling Loop (Blue) CH Return (Black) 31 INSTALLATION SECTION 2 - INSTALLATION INSTALLATION SECTION 2 - INSTALLATION 2.17 ELECTRICAL CONNECTIONS WARNING. This appliance MUST be earthed. A mains supply of 230Vac ~ 50 Hz is required. The fuse rating should be 3A. All external controls and wiring must be suitable for mains voltage. Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations. Wiring should be 3 core PVC insulated cable, not less than 0.75mm2 (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for electrical installations. Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm contact separation in both poles. The means of isolation must be accessible to the user after installation. 2.18 INSTALLER WIRING The Logic boiler comes pre-fitted with 1.8m of mains cable. This must be connected to a permanent live supply and NOT switched by thermostats/programmers. If the supply cord is damaged, it must be replaced by the manufacturer, service agent or similarly qualified persons in order to avoid hazard. Accessing the installer wiring 1. Isolate the mains supply from the boiler. 2. Remove the front panel. Refer to section 3.2. 3. Swing down the control box into the service position, unclip and swing back the installer wiring cover and latch into the retaining clips. Refer to Section 3.8. INSTALLER CONNECTIONS (LHS) 32 All of the connections can now be readily accessed, the plugs can be removed to aid wiring. Note the cable strain relief system and grommets. Once any wiring is completed, to secure the boiler, reverse the order above. Note The link wire on the 230V installer room stat/timer connection gives a demand in conjunction with the timer option plug inside the timer option cover (located on the front of the new control box). INSTALLER CONNECTIONS (RHS) Installation and Servicing SECTION 2 - INSTALLATION External Controls – Extra Low Voltage Wiring a 230V 50Hz Room Thermostat, Diagram A (with optional timer, Diagram B) If parts of the pipework run outside the Wiring OpenTherm Room Control house or if the boiler will be left off for DIAGRAM more or other OpenTherm Master Device, DIAGRAM A: B: thanora day or so then a frost thermostat Diagram D. Programmable Room Stat Room Stat with External Timer should Room Stat with Internal Timer be wired into the system. 1. Remove the timer link plug inside This is usually done at the programmer, in the timer option cover, located on Optional Optional Room Stat or which case the programmer selector switches the front of the control box Frost controls Frost Programmable are set to OFF and all the other Room Stat Timer 2. Unclip the timer link socket Stat from the Room Stat be left in the runningStat MUST position. aperture on the rear of the control box, The frost thermostat should be sited in a locate the plug on the same harness cold place but where it can sense heat branch and connect these together. from the system. 3. Using the rubber bung located Wiring a system frost thermostat, see adjacent to these connections, insert Frost Room digarams A, B and C. Wire theFrost frostRoom Stat Stat/ L N Stat Stat/ L N it into the open aperture. (Optional) Timer (Optional) Timer thermostat across the two connections as shown. 4. Locate the OpenTherm connection on the right hand side of the boiler installer Note. If the boiler is installed in a garage it connections area and connect the 2 may be necessary to fit a pipe thermostat, core cable from the OpenTherm device. preferably on the return pipework. 2. Connect the external cable from the room stat/timer across these two connections, if a general live connection is used for the room stat or timer then connect this to the fused spur, on the load side (see Diagram C) 3. If the room thermostat has compensation and requires a neutral connection, make this connection to the fused spur, on the load side. DIAGRAM A: DIAGRAM A: DIAGRAM B: DIAGRAM B: Programmable Stat or Programmable Room StatRoom or Stat with Internal Timer Room StatRoom with Internal Timer Frost Stat Frost Protection External Controls – 230V 50Hz 1. Remove the link wire from the room stat/timer plug. Optional INSTALLATION 2.19 EXTERNAL WIRING Optional Room Stat or Room Stat or Frost Programmable Programmable Stat Room Stat Room Stat DIAGRAM C: Stat withTimer External Timer Room StatRoom with External Use of General Live for Room Stat Optional Optional Frost Frost Stat Room Stat Optional Frost Stat Stat Stat Room Stat Room Timer Timer DIAGRAM D: OpenTherm Device DO NOT CONNECT 230V TO THESE TERMINALS OR THE BOILER ELECTRONICS WILL BE DAMAGED OpenTherm Device E.G. Honeywell OT Bridge R8810 Mains In Frost Stat (Optional) Room Frost Room Stat/ Stat L NStat/ (Optional) Timer Timer L N Frost Stat (Optional) Room Frost Room Stat Stat/ L NStat/ (Optional) Timer Timer L N Frost Stat (Optional) Room Stat/ Timer 2.20 REPLACING PRE-FITTED MAINS CABLE DIAGRAM C: DIAGRAM C: Use of General Live Stat for Room Stat Use of General Live for Room Optional Frost Stat If it is necessary to use an alternative mains cable to the one pre-fitted then use Room Stat Optional Room Stat the following guide. Frost L N Open Therm Outside Sensor Strain Relief 6 Stat Replacement wiring should comply with notes in Section 2.18 and be caried out by a qualified person to avoid a hazard. 1. Isolate the mains supply to the boiler. Mains In Mains In 2. Remove the front panel. Refer to Section 3.2. Frost Room Frost Swing theRoom control box down into the service position, unclip and swing back the 3. Stat Stat Stat/ L NStat/ L N Timer Timer installer wiring cover to latch into the retaining clips. Refer to Section 3.8. (Optional) (Optional) 4. Unplug the mains connector and release the cable from strain relief. 5. Unscrew the L N & E connections & remove wires from connector. 6. Remove the mains cable by pulling back through the grommet . 7. Route the replacement through the grommet and re-fit in reverse order. 8. Close the installer wiring cover ensuring that it is located correctly and that the cable is retained into the strain relief as shown. 9. Swing the control box back up into the operating position and re-fit the front panel ensuring a good seal is made. NOTE. When making the mains electrical connections to the boiler it is important that the wires are prepared in such a way that the earth conductor is longer than the current carrying conductors, such that if the cord anchorage should slip, the current carrying conductors become taut before the earthing conductor. Installation and Servicing 4 33 bk bk bk gy r g b br g/y o p v y r br CH SWL FL F SWL 3 4 CH L 1 2 L N PE 3 2 1 7 6 5 4 3 2 1 w br r bk r g/y b 3 MAINS LIVE r MAINS NEUTRAL br b 1 AUXILIARY LIVE X1 2 5 DHW LIVE CH LIVE 3 2 1 r r b g/y 2 3 PUMP LIVE g/y Chassis Earth g/y bk 1 IONISATION PE IGNITION ELECTRODE g/y bk SPARK GENERATOR b bk w br 4 IGNITION LIVE 6 X2 1 2 3 1 2 3 3 2 1 2 3 4 1 1 bk 2 2 PUMP FAN DETECTION ELECTRODE 2 1 p b DIVERTOR VALVE 1 2 3 4 5 6 r r p bk p bk y y b r bk bk or 1 2 FLOW THERM 1 2 bk DHW FLOW TURBINE 3 2 1 WATER PRESSURE SWITCH RETURN THERM r bk p 4 3 2 1 3 3 bk bk gy v r 2 2 v 1 bk 1 2 3 4 5 3 v 2 1 TIMER LINK SERVICE CONNECTOR bk g r y X3 3 2 1 GAS VALVE NC GAS VALVE + y bk X4 6 5 4 3 2 1 NO. 2 B2 24V NO. 5 A2 24V NO. 6 B1 NO. 4 B3 NO. 3 A3 NO. 1 A1 GAS VALVE bk b X9 5 4 3 2 1 X8 5 4 3 2 1 X7 8 7 6 5 4 3 2 1 X5 6 5 4 3 2 1 FAN FEEDBACK FAN PWM FAN GND PUMP FEEDBACK PUMP PWM PUMP GND PELV X6 6 5 4 3 2 1 TURBINE SIGNAL TURBINE GND TURBINE 5V WPS SIGNAL WPS GND WPS 5V 230V 50Hz Mains FLUE + FLUE RETURN + RETURN FLOW + FLOW DHW + DHW - KEY black grey red green blue brown green/yellow orange pink violet yellow g/y b OWC + OWC OPENTHERM + OPENTHERM OPENTHERM 5V 34 CHIP COM BUS 24V CHIP COM BUS GND CHIP COM BUS 5V CHIP COM BUS RX CHIP COM BUS TX INSTALLATION SECTION 2 - INSTALLATION 2.21 WIRING DIAGRAM Installation and Servicing 2.22 COMMISSIONING AND TESTING A. Electrical Installation B. Gas Installation 1. Checks to ensure electrical safety should be carried out by a competent person. 1. The whole of the gas installation, including the meter, should be inspected and tested for tightness and purged in accordance with the recommendations of BS.6891. In IE refer to IS.813. 2. ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit, using a suitable test meter. 2. Purge air from the gas installation by the approved methods only. WARNING. Whilst effecting the required gas tightness test and purging air from the gas installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE. GENERAL Please Note: The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type defined on the appliance data plate. DO NOT adjust the air/gas ratio valve. Having checked: - That the boiler has been installed in accordance with these instructions. - The integrity of the flue system and the flue seals, as described in the Flue Installation section. Proceed to put the boiler into operation as follows: Gas Supply CHECK THE OPERATIONAL (WORKING) GAS INLET PRESSURE Set up the boiler to operate at maximum rate by opening hot tap to maximum flow. With the boiler operating in the maximum rate condition check that the operational (working) gas pressure at the inlet gas pressure test point complies with the requirements - refer to “Gas Supply” on page 12. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working. Gas Pressure Test Point As part of the commissioning process, the combustion of this appliance must be checked and the Benchmark Checklist completed. A flow chart to assist is provided on page 67. ATTENTION ! IT IS A CONDITION OF THE MANUFACTURER’S WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE Installation and Servicing 35 INSTALLATION SECTION 2 - INSTALLATION INSTALLATION SECTION 2 - INSTALLATION 2.23 INITIAL LIGHTING Legend A. Domestic Hot Water Temperature Knob B. Central Heating Temperature Knob C. Mode Knob D. Boiler Status Display E. Burner ‘on’ Indicator F. Central Heating Economy Setting G. CH Flow Isolating Valve H. Gas Inlet Pressure Test Point I. Gas Service Cock J. DHW Inlet Valve K. CH Return Isolating Valve L. DHW Outlet M. Filling Loop Valve N. Pressure Gauge P. Restart Button Q. Installer Function Button e ºC MIN MAX MIN BOILER OFF MAX MODE RESTART N A D Q CH Flow Note. It is important the burner is not operated before the system is fully vented of air. If it is necessary to operate the appliance pump to assist venting of the air this must be done with the gas service cock turned off. E B F C DHW Outlet G 1. Check that the system has been filled and that the boiler is not airlocked. Ensure the automatic air vent cap is open. P Gas Supply DHW Inlet J L CH Return K I H 2. Refit the boiler front panel. Refer to Section 3.2. 3. Check that the drain cock is closed and that the CH and DHW isolating valves (G,K & J) are OPEN. 4. Check that the electrical supply is OFF. 5. Check that the boiler mode knob (C) is OFF. 6. Check that the gas service cock (I) is OPEN. Filling Loop M For additional gas supply information refer to “Gas Supply” on page 12. 7. Slacken the screw in the inlet pressure test point (H) and connect 13.Turn off the DHW tap. a gas pressure gauge via a flexible tube. 14.Remove gas pressure guage, tighten inlet pressure test point and check for gas tightness. 8. Switch the electricity supply ON and check all external controls are calling for heat. CENTRAL HEATING 9. Set the CH temp control (B) to max and turn the mode knob (C) to ’. The boiler control should now go through its ignition sequence ‘ until the burner is established. 10.If the boiler does not light then after 5 attempts the boiler will lock out and display fault code L 2. Restart the boiler (Refer to Section 2.25). The boiler will repeat its ignition sequence. If restart occurs 5 times within 15 minutes then LC will be shown. When the burner is established the ‘ ’ will be shown on the display with the ‘ ’ indicating central heating operation and the current flow temperature shown in the 2 digit display. DOMESTIC HOT WATER 11.With the boiler firing, set the DHW Temp Knob (A) to maximum and fully open a DHW tap. The boiler should continue to run and the display should change from showing ‘ ’ to ‘ ’ 12.Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output. Refer to Table 2. IMPORTANT The gas input to the burner is regulated by the gas valve according to the air flow produced by the fan. It is NOT useradjustable. Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void. 36 THE DISPLAY The user control has one display to inform the user about the status of the boiler. The LCD Display shows the status of the flame. If no flame is detected the flame symbol will not be visible. When the flame is detected the flame symbol will be visible permanently. Below is a list with display function in normal operation. 0 0 Standby, no demand for heat present. Boiler is active for central heating. Boiler is active for domestic hot water. Boiler is in lockout for a specific error. Display will show a number after the “ ” to indicate which error is detected. F Boiler has a fault for a specific error. Display will show a number after the “ detected. ” to indicate which error is Note: Boiler frost protection - boiler operates if the ambient temperature is below 5ºC until it reaches 19ºC. Note. The boiler incorporates a fan overrun cycle which MUST NOT be prematurely interrupted by isolation of the mains electricity supply. Installation and Servicing 2.24 GENERAL CHECKS Make the following checks for correct operation in: WATER CIRCULATION SYSTEM 1. Fully open all DHW taps in turn and ensure that water flows freely from them. The display should show 1. With the system COLD, check that the initial pressure is correct to the system design requirements. ‘ ’ then 3. With the system still hot, turn off the gas, water and electricity supplies to the boiler and drain down to complete the flushing process. ‘ ’ ‘ ’ when the burner lights 2. Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate. Note: A flushing solution should be used during the flushing procedure. Flushing solutions: Fernox Superfloc, Sentinel X300 (new systems) or X400 (existing systems). Refer to Section 1.19. This is factory set to give a DHW temperature rise of approximately 35oC at the flow rate stated on page 10 under “operation”. 4. Refill and vent the system, add inhibitor (refer to section 1.19), clear all air locks and again check for water soundness. 3. Reduce the DHW draw-off rate to about 3 l/min (0.7gpm) and check that the boiler modulates to deliver DHW at approximately 65oC. 5. Reset the system initial pressure to the design requirement. 4. Close the DHW tap and check that the main burner extinguishes. The pump should overrun for 60 seconds. 6. Balance the system. Refer to Section 1.18. When the pump stops the display sequence should read: 7. Check the condensate drain for leaks and check that it is discharging correctly. Note. On systems in excess of 2 bar inlet pressure a water pressure governor may be required to prevent water noise. CENTRAL HEATING (CH) & DOMESTIC HOT WATER (DHW) MODE. 8. Finally, set the controls to the User’s requirements. Note: The pump will operate briefly as a self-check once every 24 hours in the absence of any system demand. WATER TEMPERATURES Temperatures can be selected using the CH and DHW thermostats. 1. Ensure that the CH external controls are calling for heat. The display should show: ‘ ’‘ ’ 2. Fully open a DHW tap and check that hot water is delivered. The display should show ‘ ’ ‘ ’ 3. Gas Rate Check the boiler gas rate when the boiler is at full DHW output. Check at the gas meter, with no other appliance in use. Refer to Tables 2 & 3 for gas rates. For pre-pressurised systems, this should be 1.0 bar. 2. With the system HOT, examine all water connections for soundness. The system pressure will increase with temperature rise but should not exceed 2.5 bar. Knob Setting CH Flow Temp DHW Outlet Temp o o Max 80 65 Min 30 40 C C Due to system variations and seasonal temperature fluctuations DHW flow rates/temperature rise will vary, requiring adjustment at the draw off tap : the lower the rate the higher the temperature, and vice versa. 4. Close the DHW tap. 5. Set the central heating external controls to OFF. The burner should go off and the pump continue to run for two minutes. The display should read: 6. Check the correct operation of the timer (if fitted) and all other system controls. Operate each control separately and check that the main burner responds. Installation and Servicing 37 INSTALLATION SECTION 2 - INSTALLATION INSTALLATION SECTION 2 - INSTALLATION 2.25 RESTART PROCEDURE Legend A. Domestic Hot Water Temperature Knob B. Central Heating Temperature Knob C. Mode Knob D. Boiler status Display E. Burner ‘on’ Indicator F. Restart Button G. Pressure Gauge H. Installer Function Button To restart the boiler, press the RESTART button (F). e ºC MIN MAX MIN MAX MODE RESTART G A D H F BOILER OFF E B C 2.26 ACCESSING THE INSTALLER MODE To access Installer Mode press the “RESTART” and “FUNCTION” buttons together for more than 5s. 1. The last 3 faults will be shown See Frame 4.1 for Fault Code descriptions 2. “SL” will be shown To run the burner at minimum rate press “RESTART”, otherwise press the “FUNCTION” button. 5. “dU” will be shown To move the diverter valve to mid-position for replacement press “RESTART”, otherwise press the “FUNCTION” button. 3. “SH” will be shown To run the burner at maximum rate press “RESTART”, otherwise press the “FUNCTION” button. 6. “P1” will be shown To set the minimum CH pump speed to 100% press “RESTART”, otherwise press the “FUNCTION” button. 4. “VF” will be shown To activate the venting function press “RESTART”, otherwise press the “FUNCTION” button. 7. “P7” will be shown To set the minimum CH pump speed to 70% (default) press “RESTART”, otherwise press the “FUNCTION” button to Exit. The venting function runs for 5 minutes before automatically returning to normal operation The diverter valve moves between CH and DHW every 30s The Pump alternates between being on for 50s and then off for 10s 2.27 HANDING OVER After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions: 1. Hand the User Instructions to the householder and explain his/her responsibilities under the relevant national regulations. 2. Explain and demonstrate the lighting and shutting down procedures. 3. The operation of the boiler and the use and adjustment of all system controls should be fully explained to the householder, to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption. Advise the User of the precautions necessary to prevent damage to the system and to the building, in the event of the system remaining inoperative during frosty conditions. 4. Explain the function and the use of the boiler heating and domestic hot water controls. Explain that due to system variations and seasonal temperature fluctuations DHW flow rates/temperature rise will vary, requiring adjustment at the draw off tap. It is therefore necessary to draw the user’s attention to the section in the Users Instructions titled “Control of Water Temperature” and the following statement: “Additionally, the temperature can be controlled by the user via the draw-off tap: the lower the rate the higher the temperature, and vice versa”. 6. Explain and demonstrate the function of timers and temperature controls, radiator valves etc., for the economic use of the system. 7. If a timer is fitted draw attention to the timer Users Instructions and hand them to the householder. 8. Loss of system water pressure Explain that the dial on the control panel front indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated. Explain the repressurising procedure and if unable to re-pressurise or if the pressure continues to drop a registered local heating installer should be consulted. Refer to Section 2.16. 9. Explain boiler restart procedure. Refer to Section 2.26. 10.After installation and commissioning please complete the Commissioning Checklist before handover to the customer. For IE, its is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 813:2002. IMPORTANT 11.A comprehensive service should be carried out ANNUALLY. Stress the importance of regular servicing by a Gas Safe Registered Engineer. In IE servicing work must be carried out 5. Explain the function of the boiler fault mode. by a Registered Gas Installer (RGII). Emphasise that if a fault is indicated refer to “Fault Codes” in 12.Inform the householder of the guarantee/registration found the User Guide. within the envelope pack and the requirement to register it to receive the full benefit of the warranty. 38 Installation and Servicing SECTION 3 - SERVICING 3.1 SERVICING SCHEDULE For the very latest copy of literature for specification & maintenance practices, visit our website www.idealboilers.com, where you will be able to download the relevant information. WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing. Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927. To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually. It is the law that any service work must be carried out by a Gas Safe Registered Engineer. In IE service work must be carried out by a Registered Gas Installer (RGII). 1. Light the boiler and carry out a pre-service check, noting any operational faults. 2. Check the flue terminal (and terminal guard if fitted) is undamaged and clear of any obstruction. 3. Check all water and gas joints for signs of leakage. Remake any suspect joints ensuring a gas tightness check is carried out if applicable and the water system is correctly refilled, vented and re-pressurised. CLEANING PROCEDURE Note. In order to carry out either servicing or replacement of components the boiler front panel must be removed. Refer to Section 3.2. 1. Clean the main burner. Refer to Section 3.4. 2. Clean the heat exchanger & condensate trap/siphon. Refer to Section 3.6. 3. Check the main injector for blockage or damage. Refer to Section 3.3. 4. Check that the flue terminal is unobstructed and that the flue system is sealed correctly. ALSO IF THE DHW FLOW RATE IS IN QUESTION :5. Check the DHW filter for blockage. Refer to Section 3.25. The cleaning procedures are covered more fully in Sections 3.33.7 and MUST be carried out in sequence. IMPORTANT. 6. After completing the servicing or exchange of components always test for gas tightness. 7. When work is complete the front panel MUST be correctly refitted, ensuring that a good seal is made. GENERAL Please Note: During Servicing, and after any maintenance or change of part of the combustion circuit, the following must be checked: - The integrity of the flue system and the flue seals. - The integrity of the boiler combustion circuit and the relevant seals. - The operational (working) gas inlet pressure at maximum rate. - The gas rate. - The combustion performance. SERVICING INSPECTION COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE Please Note: BS 6798:2009 Specification for installation and maintenance of gas-fired boilers of rated input not exceeding 70kW net advises that: - The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results. - The flue gas analyser used should be one meeting the requirements of BS7927 or BS-EN50379-3 and be calibrated in accordance with the analyser manufacturer’s requirements, and - Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment, which covers the use of electronic portable combustion gas analysers in accordance with BS7967, Parts 1 to 4. Do NOT OPERATE the boiler if the front panel is not fitted. 8. If, for any reason, the condensate trap/siphon has been removed ensure the trap is refilled with water before reassembling. 9. Check the gas consumption. Flue Sampling Point Air Sample Point 10.Check combustion by connecting the flue gas analyser to the flue gas sampling point as shown in the diagram and measure CO & CO2. If the CO/CO2 ratio is greater than 0.004 AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure (and gas rate) have been verified, then contact Ideal. Ensure all caps and seals are re-fitted after use 11.Complete the service section in the Benchmark Commissioning Checklist. Installation and Servicing 39 SECTION 3 - SERVICING 3.2 BOILER FRONT PANEL REMOVAL / REPLACEMENT REMOVAL REPLACEMENT 1. Loosen the two screws retaining the front panel. 3. Hook the panel onto the top retaining clips. 2. Pull the two clips down to disengage and pull panel forward and upward and remove. 4. Push the panel until the 2 bottom spring clips engage ensuring the 4 control knobs line up with the holes in the front panel. 5. Re-tighten the two retaining screws. 3 2 1 view from top of boiler SERVICING view from bottom of boiler 3.3 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING 1. Disconnect the electrical leads from the fan. 1 3 2. Remove the clip from the gas control valve outlet and ease the pipe upwards. Rotate and then ease down to remove. 3. Remove the extended nut on the fan mounting bracket. 4. Lift off fan and venturi assembly. 5. Undo the two M4 screws and release the nozzle assembly. 6. Inspect the injector for blockage or damage. 5 7. Inspect fan outlet sealing gasket and replace if necessary. Injector 2 40 Installation and Servicing SECTION 3 - SERVICING 3.4 BURNER REMOVAL AND CLEANING 1. Ensure the sump is fully drained 3 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 2 2 3. Lift the manifold to clear the bottom sealing gasket and remove manifold. 4. Remove the 2 burner front fixing screws and loosen the 2 rear extended nuts by at least ten turns. 5. Lift off the burner from the combustion chamber. To facilitate the removal angle the burner as shown. 4 IMPORTANT The burner head is a ceramic plaque construction. Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic. 6. Brush off any deposits that may be on the ceramic with a SOFT brush. 7. Inspect the sealing gasket around the burner for any signs of damage. Replace as necessary. SERVICING 5 4 3.5 CLEANING THE CONDENSATE TRAP/SIPHON 1. Pull off the rubber pipe at the sump drain. 4. Clean siphon with water. 2. Disconnect the condensate drain pipe. 5. Re-assemble in reverse order. 3. Turn the siphon clockwise to disengage and lift to remove. B When re-assembling ensure the trap is full of water. Note. Keep siphon upright when removing 1 Filling Loop CH Flow Installation and Servicing DHW Condensate Gas DHW Outlet Drain Inlet CH Return CH Circuit Drain 41 SECTION 3 - SERVICING 3.6 CLEANING THE HEAT EXCHANGER 1 Note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Section 3.18. Ignition Electrode Flame Detection 1. Remove ignition and flame detection electrodes. Refer to Section 3.13 & 3.14. 2. It is advisable to replace the sump cover prior to the water flush process. 3. Thoroughly flush the heat exchanger by pouring water into the top of the combustion chamber ensuring the full top area is covered. 4. Remove the sump cover and clean loose deposits from the sump. 5. Inspect the ignition and detection electrodes. Ensure that they are clean and in good condition - replace if necessary. 3 SERVICING 6. Re-fit the ignition and flame detection electrodes, ensuring that the earth tab is fitted to the ignition electrode. 7. Check that the ignition and detection gaps are correct. Refer to Sections 3.13 & 3.14. 3.7REASSEMBLY Reassemble the boiler in the following order: 1. Ensure that the condensate trap/siphon is full of water. 6. Refit the sump cover. 2. Refit the burner ensuring the sealing gasket is correctly positioned and free from damage (tighten the 4 fixing screws in the sequence shown below). 7. Swing the control box back into its working position and secure. IMPORTANT. Ensure that the boiler front panel is correctly fitted and that a good seal is made. 3. Refit the fan / venturi assembly ensuring the retaining tabs are correctly positioned and the sealing gasket is correctly positioned and free from damage. Refit the gas outlet pipe and clip. 8. Refit the boiler front panel. 4. Reconnect the fan electrical leads. 10.Reconnect the electrical supply. 9. Turn on the gas supply at the gas service cock. 5. Remove the sump cover and refit the lower flue manifold as shown. 4 2 5 1 42 3 Installation and Servicing SECTION 3 - SERVICING 3.8 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When work is complete, the front panel must be correctly refitted - ensuring that a good seal is made. When replacing ANY component 1. Isolate the electricity supply. 2. Turn off the gas supply. 3. Remove the boiler front panel. Refer to Section 3.2. 4. Swing the control box down into its servicing position. Notes. 1. In order to assist fault finding, the control panel has an LCD diagnostic display. The key to boiler fault conditions is shown in Section 4. 2. In order to replace components in Sections 3.22-3.30 it is necessary to drain the boiler. Refer to Section 3.21. After replacing ANY component check operation of the boiler, including gas soundness, gas rate and combustion test. THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 3.9 FAN REPLACEMENT 2. Disconnect the electrical leads from the fan. 8 Retaining Tabs 2 SERVICING 1. Refer to Section 3.8. 3. Remove the clip from the gas control valve outlet. 4. Remove the extended nut retaining the fan mounting bracket. 5. Lift and remove the fan and venturi assembly. 6. Remove the screw and twist venturi anti-clockwise to remove venturi assembly, noting the orientation of the venturi in relation to the fan body. 4 7. Transfer the venturi assembly to the new fan, replacing the ‘o’ ring if evidence of damage or deterioration is visible. 6 8. Fit the new fan / venturi assembly ensuring the retaining tabs are correctly positioned and the fan outlet sealing gasket is correctly positioned and free from damage. Refit the extended nut. 9. Reassemble the boiler in reverse order, taking care not to overtighten the screw on the fan mounting bracket and ensure all gas ‘o’ rings are in place 10.Check that the boiler operates in both DHW and CH Modes. Installation and Servicing 3 43 SECTION 3 - SERVICING 3.10 BURNER INJECTOR REPLACEMENT 2 1. Refer to Section 3.8. 2. Disconnect the electrical leads from the fan. 3. Remove the clip from the gas valve to venturi pipe and ease the pipe upwards, rotate and ease down to remove. 4 4. Loosen the screw retaining the fan mounting bracket. 5. Lift and remove the fan and venturi assembly. 6. Remove the 2 injector housing screws. 6 7. Withdraw the injector housing. Injector 8. Fit the new injector housing complete with injector. 9. Reassemble in reverse order, ensuring that the new gas seal supplied is located correctly in the injector housing. SERVICING 10.Check that the boiler operates in both DHW & CH modes. 3 3.11 BURNER REPLACEMENT 1. See Section 3.8. 2. Refer to Section 3.4. 3. Undo the two screws and remove the sump cover. 4 3 3 4. Lift the manifold to clear the bottom sealing gasket and remove manifold. 5. Remove the 2 front fixing screws and loosen the 2 rear extended nuts. 6. Lift off the burner from the combustion chamber. To facilitate the removal angle the burner as shown. 7. Fit the new burner, replacing any damaged or deteriorating sealing gasket. 8. Reassemble in reverse order. 9. Check that the boiler operates in both DHW & CH modes. 5 6 5 44 Installation and Servicing SECTION 3 - SERVICING 3.12 RETURN THERMISTOR REPLACEMENT 1. Refer to Section 3.8. 2. Unclip the return thermistor from the return pipe and withdraw it from the boiler. 3. Disconnect the electrical lead from the thermistor. 4. Reconnect the electrical lead to the new thermistor and reassemble in reverse order, ensuring that the thermistor is securely fitted to the pipe on the thermistor locator tab as shown. 5. Check that the boiler operates in both DHW & CH Mode. 4 Thermistor Locator Tab (with thermistor fitted) SERVICING 2 3.13 IGNITION ELECTRODE REPLACEMENT 1. Refer to Section 3.8. 2. Remove the burner. Refer to Section 3.11. 3. Unplug the ignition lead from the electrode. Ignition Electrode 4. Remove the earth lead from the ignition electrode. 5. Remove the 2 screws holding the ignition electrode to the combustion chamber. 6. Remove the electrode. 7. Fit the new ignition electrode, using the new gasket supplied. Check dimensions as shown. 8. Reassemble in reverse order. 9. Check the operation of the boiler. Refer to Section 2.23 & 2.24. Spark Gap 3.5mm Installation and Servicing dge ht e aig Str m 3m 45 SECTION 3 - SERVICING 3.14 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Section 3.8. 2. Remove the burner. Refer to Section 3.4. Flame Detection Electrode 3. Unplug the flame detection lead from the electrode. 4. Remove the 2 screws retaining the detection electrode. 5. Remove the electrode. 6. Fit the new flame detection electrode, using the new gasket supplied. 7. Reassemble in reverse order. ge ed ht g i a Str SERVICING 8. Check that the boiler operates in both DHW & CH modes. m .5m 12 3.15 SPARK GENERATOR REPLACEMENT 3.16 GAS CONTROL VALVE REPLACEMENT 1. Refer to Section 3.8 2. Disconnect the leads from the spark generator. 3. Gently push down the generator to release the top clip from the gas valve mounting bracket. 4. Lift the spark generator up and out of the bottom retaining moulding. 5. Fit the new spark generator and re-assemble in reverse order ensuring that the the earth lead is replaced. 6. Check that the boiler operates in both DHW & CH modes. 1. 2. 3. 4. 5. Refer to Section 3.8. Unplug the electrical lead connection from the gas control valve. Remove the outlet gas valve clip and slide the pipe upwards. Undo the gas inlet pipe union at the inlet to the gas valve. Undo the single screw fixing the gas valve to the mounting bracket and withdraw the valve forwards. 6. Fit the new gas control valve ensuring that the ‘o’ ring and sealing washer are in place and reconnect gas and electrical connections. 7. Check that the boiler operates in both DHW & CH modes. 3 Spark Generator 2 4 46 5 Installation and Servicing SECTION 3 - SERVICING 3.17 DIVERTER VALVE ACTUATOR REPLACEMENT Refer to Section 3.8. To remove the motor: 1. Remove the condensate trap/siphon. Refer to Section 3.5. 2. Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator. 3 3. Before replacing the diverter valve actuator proceed as follows: a. Ensure that the switched live to the boiler is off and that all DHW taps are shut. b. Press and hold the “RESTART” and “FUNCTION” buttons together for more than 5s, the last 3 faults will then be shown in sequence before “SL” is shown c. Press the “FUNCTION” button, “SH” will be shown d. Press the “FUNCTION” button, “UF” will be shown e. Press the “FUNCTION” button, “DU” will be shown f. 4. Fit the new motor ensuring the arm is correctly engaged in the metal fork and re-assemble in reverse order ensuring the condensate trap/ siphon is refilled with water. 5. Check the operation of the boiler. SERVICING Press the “FUNCTION” button and the diverter valve will move to the mid-position 6 Note. All spares will be delivered in mid-position therefore ignore point 3 and proceed to point 4. 3.18 CONDENSATE TRAP/SIPHON REPLACEMENT 1. Refer to Section 3.8. 2. Pull off the rubber pipe at the sump drain. 3. Disconnect the condensate drain pipe. 4. Turn the siphon clockwise to disengage and lift to remove. Note. Keep siphon upright when removing. 5. Clean siphon with water or replaced if damaged. 6. Re-assemble in reverse order. 7. When re-assembling ensure the trap is full of water. 3 8. Check that the boiler operates in both DHW and CH modes. 2 Siphon Installation and Servicing 47 SECTION 3 - SERVICING 3.19 PCB REPLACEMENT Note. Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis. 1. Refer to Section 3.8. 3 2. Ensure the control knobs are in the 12 o clock position. 3. Carefully release the six retaining clips and remove control box cover. 4. Unplug all lead connections to the PCB, also where applicable, push the small plastic clip with an electrical screwdriver to facilitate plug removal. 5. Spring out the four side retaining clips and pull the PCB upwards to clear the 4 corner retaining posts. 6. Take the new PCB. 7. Re-connect all plug connections. 5 SERVICING 8. Reassemble in reverse order. 9. a. Turn power on, display shows uP. Rotate all three dials fully anticlockwise. b.Press RESTART, display shows oF c. Turn power off d. Turn power on, display shows F9 e. Using central heating knob, rotate clockwise or anticlockwise to show “C” for Combi, then press RESTART button. f. Using central heating knob, rotate clockwise or anticlockwise to show “n” for Natural Gas, then press restart button. g. Using central heating knob rotate clockwise or anticlockwise to show boiler size, select correct 24, 30 or 35, then press RESTART button. h. Display shows “C”, “n”, Boiler size, internal number. j. Press restart. New PCB is now programmed. 4 Plastic clip 4 IMPORTANT.IT IS CRITICAL FOR SAFE OPERATION THAT THE CORRECT BOILER SIZE AND FUEL TYPE IS ENTERED INTO THE BOILER. 10.Check that the boiler operates in both DHW and CH modes. 3.20 DHW FLOW TURBINE SENSOR REPLACEMENT 5 4 3 1. Refer to Section 3.8. 5. Use the clip to ease the turbine sensor from its housing. 2. Drain the DHW system. Refer to Section 3.21. 6. Re-assemble in reverse order. 3. Pull off the electrical connection. 7. Check that the boiler operates in both DHW & CH modes. 4. Using a suitable tool, lift and remove the retaining clip. 48 Installation and Servicing SECTION 3 - SERVICING 3.21 DRAINING THE BOILER Filling Loop CENTRAL HEATING CIRCUIT 1. Refer to Section 3.8. 2. Close all the CH water isolating valves on the boiler inlet. 3. To drain the primary heat exchanger circuit: Open the drain valve and attach a length of hose to the CH drain point. 4. After replacing any component on the boiler, remove the hose, close the drain valve and open all system isolating valves (re-pressurise as appropriate by re-connecting the filling loop, refer to Section 2.16) before proceeding to check operation of the boiler. 5. Disconnect filling loop. Refer to Section 2.16. 6. Check that the boiler operates in both DHW & CH modes. CH Flow DOMESTIC HOT WATER CIRCUIT DHW Condensate Gas DHW Outlet Drain Inlet CH Return CH Circuit Drain 1. Refer to Section 3.8. 2. Close all the DHW water isolating valves on the boiler inlet. 3. To drain the domestic hot water circuit: As there is no direct drain for the domestic hot water circuit, depending on the location of the boiler, opening the lowest hot water tap may drain this circuit. However it must be noted that some residual water will be experienced during replacement of components. 4. After replacing any component on the boiler, close tap, close the drain valve and open all system isolating valves (re-pressurise as appropriate by re-connecting the filling loop, refer to Section 2.16) before proceeding to check operation of the boiler. 5. Disconnect filling loop. Refer to Section 2.16. SERVICING 6. Check that the boiler operates in both DHW & CH modes. 3.22 PRESSURE GAUGE REPLACEMENT 1. Refer to Section 3.8. 2. Drain the heating system. Refer to Section 3.21. 3. Remove the boiler front (See Section 3.8), lower the control panel and remove the control box cover. 4. Ensuring there is no pressure in the system unclip the C clip from the flow manifold port and remove the capillary connection together with ‘o’ ring. 4 5. Releasing the two retaining clips on the pressure gauge ease the pressure gauge through the front of the control panel. 6. Fit the new pressure gauge from the front of the control panel ensuring correct orientation. Locate push fit connection into port ensuring ‘o’ ring in place and secure with the C clip. 7. Refill the boiler. Refer to Section 2.16. 8. Check that the boiler operates in both DHW & CH modes. 5 Installation and Servicing 49 SECTION 3 - SERVICING 3.23 SAFETY RELIEF VALVE REPLACEMENT 1. Refer to Section 3.8. 3 4 2. Drain the boiler. Refer to Section 3.21. 3. Remove the clip on return thermistor. Refer to Section 3.12. 4. Pull out and remove the clip (positioned behind the safety valve) retaining the safety valve. 5. Undo the safety valve pipe compression fitting positioned outside the boiler casing. 6. Lift out the safety valve/pipe assembly. 7. Remove the safety valve pipe and transfer to the new safety valve. 8. Reassemble in reverse order ensuring the retaining clip is correctly fitted, the pipe compression fitting retightened and return thermistor is re-clipped. 9. Refill the boiler. Check that the boiler operates in both DHW & CH modes. SERVICING 3.24 PUMP AUTOMATIC AIR VENT REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. Dust Cap 5 Refer to Section 3.8. Drain the boiler. Refer to Section 3.21. Remove the expansion vessel. Refer to Section 3.32. Firstly, increase access area by disconnecting the 22mm pipe connection at top of pump manifold and bottom of heat exchanger and remove pipe. Refer to Section 3.26. The automatic air vent head is retained in the pump body with a bayonet connection. The air vent head and float assembly is removed by turning the head anti-clockwise (viewed from above) and pulling upwards. Reassemble in reverse order. Ensure the air vent head ‘o’ ring seal is fitted. Ensure the air vent cap is loose. Refill the boiler. Refer to Section 2.16. Check for leaks around the new air vent joint. Check that the boiler operates in both DHW & CH modes. 3.25 DHW FILTER & DHW FLOW REGULATOR CLEANING/REPLACEMENT 1. Refer to Section 3.8. 4 2. Drain the DHW system. Refer to Section 3.21. 3. Turn the housing anti clockwise and pull forward to remove the cartridge. 4. Using a pair of pliers, pull out the plastic filter/flow regulator. 5. Clean or replace filter as necessary. 6. Reassemble in reverse order. 7. Refill the boiler. 3 8. Check that the boiler operates in both DHW & CH modes. 50 Installation and Servicing SECTION 3 - SERVICING 3.26 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT To remove the valve body assembly: 16. Twist and remove the DHW manifold. 1. Refer to Section 3.8. 17. Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly. 2. Drain the boiler. Refer to Section 3.21. 3. Remove the condensate trap/siphon. Refer to Section 3.18. 4. Remove the electrical plug. Refer to Section 3.17. 5. Place a flat bladed screwdriver in the diverter valve motor body slot provided and ease out the motor. Refer to Section 3.17. 18. Fit the new diverter valve body assembly and replace the two fixing screws. 19. Refit the DHW manifold, fit the assembly back to the boiler and reassemble in reverse order. 20. Refill the boiler. Check that the boiler operates in both DHW & CH modes. 6. Remove the return thermistor electrical connection. Refer to Section 3.12. 7. Remove the pump electrical connections. Refer to Section 3.28 no. 3. 18 12 17 8. Remove DHW Turbine electrical connection. Refer to Section 3.20 no. 3. 11 9. Remove the DHW plate heat exchanger (note orientation). Refer to Section 3.27. 10. Undo the safety valve pipe compression fitting. See No.5 Section 3.23. 11.Loosen the nut above pump and rotate the pipe. 12.If required remove expansion vessel connection hose. Refer to Section 3.32. 14 13. Remove the DHW inlet and CH return connection situated beneath the boiler. 14. Remove the four torx head screws fixing the return manifold to the boiler sheet steel base. 13 15. Lift the manifold assembly and remove from boiler. 3.27 DHW PLATE HEAT EXCH. REPLACEMENT 1. 2. 3. 4. 5. Refer to Section 3.8. Drain the boiler. Refer to Section 3.21. Remove condensate trap/siphon. Refer to Section 3.18. Remove the diverter valve actuator. Refer to Section 3.17. Remove the 2 allen screws securing the plate heat exchanger to the composite housings. 6. Manoeuvre the plate heat exchanger out of the top LH or centre of the controls area. Be aware of any water spillage. 7. Fit the new plate heat exchanger, using the new o-rings supplied. Note. Ensure that the depressions are on the bottom prior to fitting. 8. Reassemble in reverse order. 9. Refill the boiler. Refer to Section 2.16. 10.Check that the boiler operates in both DHW & CH modes. 5 Installation and Servicing 3.28 PUMP HEAD REPLACEMENT 1. 2. 3. 4. 5. 6. 7. 8. 9. Refer to Section 3.8. Drain the boiler. Refer to Section 3.21. Disconnect the two electrical leads from the pump. Remove the 4 allen screws retaining the pump head. Remove the pump head. Fit the new pump head. Reassemble in reverse order. Refill the boiler. Refer to Section 2.16. Check that the boiler operates in both DHW & CH modes. 3 4 51 SERVICING 16 SECTION 3 - SERVICING 3.29 CH WATER PRESSURE SWITCH REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.21. 3. Pull off the two electrical connections. 4. Using a suitable tool, pull out the metal retaining clip. 5. Carefully withdraw the pressure switch. 6. Fit the new pressure switch and re-assemble in reverse order. 7. Refill the boiler. Refer to Section 2.16. 4 8. Check that the boiler operates in both DHW & CH modes. 5 SERVICING 3 3.30 FLOW THERMISTOR REPLACEMENT 1. Refer to Sections 3.8. 2. Drain down the boiler. Refer to Sections 3.21. 3. Unplug the electrical lead. 4. Unscrew the thermistor (to facilitate removal a 13mm socket spanner should be used). 5. Fit the new thermistor using the sealing washer provided. 3 6. Reassemble in the reverse order. 7. Refill the boiler. Refer to Section 2.16. 4 8. Check that the boiler operates in both DHW & CH modes. 52 Installation and Servicing SECTION 3 - SERVICING 3.31 HEAT ENGINE REPLACEMENT Refer also to Section 2.1 - ‘Boiler Exploded View’ IMPORTANT Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. 1. Refer to Section 3.8. 3.18, no. 2. 2. Drain the boiler. Refer to Section 3.21. 14.Remove the two heat exchanger fixing screws. 3. Remove the fan / venturi assembly and place on one side. Refer to Section 3.3. 15.Remove the Heat exchanger, slide out of location bracket. 4. Remove the burner and place on one side. Refer to Section 3.4. 5. Remove the ignition and detection electrodes. Refer to Section 3.13 & 3.14. 6. Remove the spark generator. Refer to Section 3.15. 7. Remove the gas valve. Refer to Section 3.16. 8. Remove the expansion vessel. Refer to Section 3.32. 9. Remove the return thermistor. Refer to Sections 3.12. 10.Remove the 2 M5 screws retaining the gas valve mounting bracket and transfer bracket to the new heat exchanger. 16. If replacement sump required: Rotate heat exchanger assembly 180º. Place new sump onto heat exchanger, ensuring correct orientation and seal is in place. Then gently apply pressure to the base of the sump at each tab fixing point and engage tabs onto the heat exchanger. 17.Reassemble in reverse order, ensuring the heat exchanger is located correctly in the LHS retaining bracket. Replace any new ‘o’ rings supplied with new heat exchanger and replace gaskets or seals if any sign of damage is evident. When replacing the spring clips located on the return pipe connection, ensure clip is oriented to correctly match connecting pipe diameters. 18.Ensure the trap/siphon is filled with water. Refer to Section 3.18. 11.Undo the pump union nut and remove pipe. 19.Refill the boiler and check for leaks. Refer to Section 2.16. 12.Remove the two retaining pipe clips and remove pipes. 20.Check that the boiler operates in both DHW & CH modes. Shown as 180º position 9 14 16 12 9 10 11 12 Installation and Servicing 53 SERVICING 13.Remove the condensate rubber pipe. Refer to Section SECTION 3 - SERVICING 3.32 EXPANSION VESSEL RECHARGING & REPLACEMENT RECHARGING Recharge Point 1. Refer to Section 3.8. 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order. 8 5. Check that the boiler operates in both DHW & CH modes. REPLACEMENT 6. Refer to Section 3.8. 7. Drain the boiler CH circuit. Refer to Section 3.21. 8. Remove the retaining clip on the vessel water connection pipe and remove the pipe. 9. Support the expansion vessel and unscrew the 2 screws from the securing bracket, located on the top of the boiler, and remove. (Note the position of the bracket on the vessel) 9 10.Remove the expansion vessel. SERVICING 11.Fit the new expansion vessel. 12.Reassemble in reverse order ensuring the seal is in place. 13.Refill the boiler and check for leaks. Refer to Section 2.18. 14.Check tht the boiler operates in both DHW & CH modes. 54 Installation and Servicing SECTION 4 - FAULT FINDING ‘L1’ GO TO SECTION 4.2 FLOW TEMPERATURE OVERHEAT LOCKOUT ‘L2’ GO TO SECTION 4.3 IGNITION LOCKOUT ‘LC’ 5 RESETS WITHIN 15 MINS TURN POWER OFF AND ON ‘L6’ GO TO SECTION 4.4 FALSE FLAME LOCKOUT ‘F1’ GO TO SECTION 4.5 LOW WATER PRESSURE ‘F2 or Fn or Ln’ GO TO SECTION 4.6 FLAME LOSS ‘F3’ GO TO SECTION 4.7 FAN FAULT ‘L4 or F4’ GO TO SECTION 4.8 FLOW THERMISTOR FAULT ‘L5 or F5’ GO TO SECTION 4.9 RETURN THERMISTOR FAULT ‘F6’ GO TO SECTION 4.10 OUTSIDE SENSOR FAULT ‘F7’ LOW MAINS VOLTAGE CONTACT ELECTRICITY PROVIDER ‘F9 or L9 or F8 or L8’ ‘FU’ ‘dU’ FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 4.1 FAULT FINDING CHART MAIN MENU PCB UNCONFIGURED OR FAULTY SEE SECTION 3.19 IF FAULT PERSISTS REPLACE PCB DIFF GREATER THAN 50°C CHECK ISOLATION VALVES ARE OPEN CHECK PUMP CHECK RAD VALVES OPEN CHECK SYSTEM BLOCKAGES DIVERTER VALVE IN MID-POSITION FOR SERVICE ROTATE KNOBS FULLY CLOCKWISE TURN POWER OFF AND ON RESTART BOILER NO CH BUT HW OK GO TO SECTION 4.11 NO HW BUT CH OK GO TO SECTION 4.12 NO DISPLAY GO TO SECTION 4.13 RESTART PROCEDURE: to restart boiler press the restart button. Installation and Servicing 55 SECTION 4 - FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 4.2 ‘L1’ - FLOW TEMPERATURE OVERHEAT LOCKOUT Is the Boiler and CH System filled with water and all isolation and radiator valves open? NO Fill and vent the system and open all isolation valves, then restart boiler YES Check that the Pump is rotating freely. Is the Differential now below 20°C? YES Is the Flow/Return Differential across the Boiler in excess of 30°C? NO NO Check the Return Thermistors (Refer to Section 3.12) Replace the Pump, then restart boiler Check resistance using a suitable multimeter connected across the thermistor’s terminal pins At 25 oC expect 9,700 -10,300 Ohms At 60 C expect 2,400- 2,600 Ohms At 85 oC expect 1,000- 1,100 Ohms o YES OK, now restart boiler RESTART PROCEDURE: to restart boiler press the restart button. 4.3 ‘L2’ - IGNITION LOCKOUT If the boiler is restarted does the boiler ignite for a short time and then extinguish? NO Is the Gas Pressure available at the Boiler Inlet (>18 mbar)? NO Check gas supply and rectify fault YES YES Is 24Vdc supply available at the Gas Valve? Check the detection electrode and associated harness for: continuity, visual condition and position (Refer to Section 3.14). Check if the condensate pipe is blocked. Check flue is installed correctly. Replace as necessary. YES Unplug gas valve. Is resistance between outside pins between 4k Ω (± 2)? NO NO Check wiring connection from gas valve to PCB for continuity. If the wiring is OK then replace the PCB Replace Gas Valve YES Check spark generator and associated harness for: continuity and visual condition. (Refer to Section 3.15) Are these functioning correctly? Check siphon and condensate drain pipework for blockage and rectify if necessary. Boiler now working OK? NO NO Replace Spark Generator and harness as necessary YES YES Check ignition electrode and associated harness for: continuity, visual condition and position. (Refer to Section 3.13) Are these functioning correctly? NO Replace Ignition Electrode and associated harness as necessary Replace Gas Valve RESTART PROCEDURE: to restart boiler press the restart button. 56 Installation and Servicing SECTION 4 - FAULT FINDING Restart the boiler, does Boiler Work OK? YES FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 4.4 ‘L6’ - FALSE FLAME LOCKOUT Check routing and integrity of internal boiler wiring is OK. Check condition of Flame Sense Electrode and replace if deteriorated. NO Separate the flame detection electrode in-line connector. Is there continuity between the terminal pins connected to the electrode? YES Replace Flame Detection Electrode NO Check routing and integrity of internal boiler wiring RESTART PROCEDURE - To restart boiler, press and release RH push button. 4.5 ‘F1’ - LOW WATER PRESSURE Are the Boiler and CH System filled with water and all isolation and radiator valves open (check pressure gauge is between 1 to 1.5 bar)? YES NO Fill and vent the system and open all isolation valves NO Re-fit connections YES Replace water pressure sensor Are connections on water pressure sensor secure? 4.6 ‘F2 OR FN OR LN’ - FLAME LOSS Does the boiler ignite for a short time and then extinguish? NO NO NO Is 24Vdc supply available at the Gas Valve while the flame is on? NO YES YES Check the detection electrode and associated harness for: continuity, visual condition and position (Refer to Section 3.14). Check if condensate pipe is blocked. Check if flue is blocked. Replace as necessary. Re-fit correctly or replace Check spark generator and associated harness for: continuity and visual condition. (Refer to Section 3.15) Are these functioning correctly? NO Check wiring from gas valve to PCB for continuity. If the wiring is OK then replace the PCB Replace Spark Generator and Harness as necessary. YES Check ignition electrode and associated harness for: continuity, visual condition and position. (Refer to Section 3.13) Are these functioning correctly? NO Replace Ignition Electrode and associated harness as necessary YES Check siphon and condensate drain pipe work for blockage and rectify if necessary. Boiler now working OK? Installation and Servicing Check gas supply and rectify fault YES YES Is the top flue manifold seal present and correctly fitted. ? Is the Gas Pressure available at the Boiler Inlet (18 mbar)? NO Replace Gas Valve 57 SECTION 4 - FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 4.7 ‘F3’ - FAN FAULT Does the wiring from the Fan to the PCB have secure connections at both ends and has not deteriorated? Does the wiring have continuity? NO Rectify Wiring & connections NO Replace PCB YES Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan? YES Replace Fan 4.8 ‘F4 OR L4’ - FLOW THERMISTOR FAULT NO Is the wiring securely connected to the Flow Thermistor (located in the top of the Heat Exchanger?) Securely connect the wiring to the Water Flow Thermistor YES Disconnect the wiring from the Flow Thermistor Check the resistance using a suitable multimeter connected across the Thermistor’s terminal pins. At 25 oC expect 9,700 -10,300 Ohms At 60 oC expect 2,400- 2,600 Ohms At 85 oC expect 1,000- 1,100 Ohms NO Fit a new Thermistor Is the Thermistor value correct? NO YES Is the wiring securely connected to the low voltage 6 way connector at the front left hand side of the PCB? YES Securely connect the wiring to the PCB Replace PCB 4.9 ‘F5 OR L5’ - RETURN THERMISTOR FAULT Remove the Return Thermistor from the CH Return Pipe and disconnect the wires. Check the resistance using a suitable multimeter connected across the thermistor’s terminal pins. At 25 oC expect 9,700 -10,300 Ohms At 60 oC expect 2,400- 2,600 Ohms At 85 C expect 1,000- 1,100 Ohms o NO Fit a new Thermistor Is the Thermistor value correct? YES Is there continuity between the PCB and the Thermistor? NO Check and replace wiring as necessary YES Replace PCB 58 Installation and Servicing SECTION 4 - FAULT FINDING NO Is the wiring securely connected at both the boiler and Outside Sensor? FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 4.10 ‘F6’ - OUTSIDE SENSOR FAULT Securely connect the wiring at both the boiler and Outside Sensor YES Disconnect the wires to the outside sensor. Check the resistance using a suitable multimeter connected across the Outside Sensor’s terminal pins. At 0 C expect 31,000 -35,000 Ohms At 15 oC expect 15,000 -16,500 Ohms At 30 C expect 7,700- 8,500 Ohms o o NO Fit a new Outside Sensor Is the Outside Sensor value correct? Securely connect the wiring at the Terminal Block and the PCB NO YES Is the wiring securely connected between the incoming terminal block boiler connection of the Outside Sensor and the PCB? YES Replace PCB 4.11 NO CH OPERATION BUT HW WORKS OK Is the mode knob in the Winter position? YES Are the Timer and the Room Thermostat switched on? YES Are the Radiator Valves Open? YES Is there 230Vac at (A)? NO Move the mode knob to the Winter position NO Switch the Timer and Room Thermostat On NO Open the Radiator Valves There is no Voltage from the Timer/Room Stat. This is not boiler fault. Ensure Voltage is supplied to boiler by rectifying external wiring. NO YES Replace the Diverter Valve Motor A Installation and Servicing 59 SECTION 4 - FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 4.12 NO HW BUT CH ON Does the display shows a “Tap symbol” when a tap is on? NO Is hot and cold pipework crossed? NO YES Are the flow rates correct as per Section 1.2. NO YES Is the wiring between the PCB and the diverter NO valve motor connected? YES Check diverter head fully engaged and clip secured onto waterset. NO YES Is diverter stuck in the CH position? NO Adjust flow rates to achieve 35ºC temp rise and check filter fitted in turbine is not blocked with debris. Is the wiring connected between PCB and DHW sensor? NO YES Reconnect wiring or replace wiring harness if no continuity. Remove the turbine, and check for debris in the turbine & filter. Replace turbine if necessary. Is DHW OK? Re-engage diverter head and secure clip to waterset NO Replace turbine sensor Replace PCB YES Re-connect wiring Check and re-fit diverter valve actuator head. Is Boiler DHW OK? NO Change diverter valve motor 4.13 NO DISPLAY Is there 230Vac to the boiler at L and N? NO Supply power to the boiler NO Connect the wiring from the terminal block to the PCB securely. YES Is the wiring from the terminal block to the PCB connected securely? YES Replace the PCB? L 60 N Installation and Servicing SECTION 5 - SPARE PARTS When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. Failure to do so could affect safety or performance of this appliance. Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www.idealparts.com Our Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665. When calling, and to ensure we can provide you with the most accurate parts information, please ensure you have the following to hand; - Boiler Model - Appliance GC Number - Boiler Serial Number Installation and Servicing 61 SECTION 6 - BENCHMARK & COMMISSIONING 62 Installation and Servicing SECTION 6 - BENCHMARK & COMMISSIONING Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturer’s instructions and the data fields on the commissioning checklist completed in full. To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation. To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed. The service details should be recorded on the Benchmark Service Interval Record and left with the householder. www.centralheating.co.uk © Heating and Hotwater Industry Council (HHIC) Installation and Servicing 63 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Programmable room thermostat Optimum start control Combination Boiler Fitted Fitted Fitted Automatic bypass to system Fitted Boiler interlock ALL SYSTEMS Yes Yes CENTRAL HEATING MODE OR mbar OR mbar Central heating return temperature COMBINATION BOILERS ONLY Yes Yes DOMESTIC HOT WATER MODE OR mbar OR mbar Cold water inlet temperature Yes Temperature CONDENSING BOILERS ONLY Yes ALL INSTALLATIONS AND ² Ratio AND ² Ratio Yes Yes Yes Yes * All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer. www.centralheating.co.uk SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 AND (Where Possible) AND AND ²% ²% (Where Possible) Signature Signature SERVICE 03 SERVICE 04 AND (Where Possible) AND AND ²% ²% (Where Possible) Signature Signature SERVICE 05 SERVICE 06 AND (Where Possible) AND (Where Possible) Signature SERVICE 07 SERVICE 08 AND AND (Where Possible) Signature SERVICE 09 SERVICE 10 AND Signature AND AND AND ²% ²% Signature (Where Possible) AND AND ²% ²% Signature (Where Possible) AND ²% ²% AND AND (Where Possible) AND ²% ²% ²% ²% ²% ²% ²% ²% ²% ²% Signature * All installations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer. © Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING. If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) separate guidance is provided with the conversion kit supplied and this must be followed. PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK The installation instructions must have been followed, gas type verified and gas supply pressure / gas rate checked as required prior to commissioning. As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids). The ECGA should be of the correct type, as specified by BS 7967. Prior to its use, the ECGA should have been maintained and calibrated as specified by the manufacturer. The installer must have the relevant competence for use of the analyser. Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer’s instructions. KEY: CO = carbon monoxide CO2 = carbon dioxide O2 = oxygen Combustion Ratio = The CO reading measured in ppm divided by the CO2 reading first converted to ppm ppm = parts per million GS(I&U)R = Gas Safety (Installation and Use) Regulations *Setting to Minimum Rate: 1. Hold “RESTART” and “FUNCTION” buttons together for more than 5s 2. Last 3 faults will be shown 3. SL shown, press “RESTART” 4. Burner will run for 10 minutes at minimum rate 66 Installation and Servicing Start Set Boiler to Maximum Gas Rate In accordance with boiler instructions, set boiler to operate at maximum rate (full load condition). Allow sufficient time for combustion to stabilise. Note. Do not insert analyser probe during this period to avoid possible flooding of sensor. Carry Out Flue Integrity Check Using Analyser Insert analyser probe into air inlet test point (where available) and allow readings to stabilise. Note. Where no air inlet test point is provided then a flue integrity check with the analyser is not possible. The installer should verify that flue integrity has been visually checked in accordance with the “Prior to CO level and combustion ratio check” (see opposite page) before proceeding to the “check CO level and combustion ratio at maximum rate” stage below. Verify Flue Integrity Analyser readings indicate that combustion products and inlet air must be mixing. Further investigation of the flue is therefore required. Check that flue components are assembled, fixed and supported as per instructions. Check that flue and flue terminal are not obstructed. Is O2 more than or equal to 20.6% OR CO2 less than or equal to 0.2%? No Yes Is O2 more than or equal to 20.6% OR CO2 less than or equal to 0.2%? Check CO level and Combustion Ratio at Maximum Gas Rate Yes With boiler still set at maximum gas rate, insert analyser probe into flue gas sampling point. Allow readings to stabilise before recording. No Turn off appliance and call Ideal Technical Helpline for advice The appliance must not be commissioned until problems are identified and resolved. If commissioning cannot be fully completed, the appliance must be disconnected from the gas supply in accordance with GSIUR. No Yes Check that no seals, e.g. Those on flue extensions, have been displaced during installation. Rectify if necessary. Is CO level less than 350ppm AND CO/CO2 ratio less than 0.0040? Is CO level less than 350ppm AND CO/CO2 ratio less than 0.0040? Set Boiler to Minimum Gas Rate (*see opposite page) In accordance with boiler instructions, set boiler to operate at minimum rate (to minimum load condition). Allow sufficient time for combustion to stabilise. Yes Check CO and Combustion Ratio at Minimum Gas Rate With boiler set at minimum rate, insert analyser probe into flue gas sampling point. Allow readings to stabilise before recording. No Turn off Appliance and Call Ideal Technical Helpline The appliance must not be commissioned until problems are identified and resolved. If commissioning cannot be fully completed, the appliance must be disconnected from the gas supply in accordance with GS(I&U)R. NOTE: Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ideal. No Is CO level less than 350ppm AND CO/CO2 ratio less than 0.0040? Yes Boiler is Operating Satisfactorily No further actions required. Ensure test points are capped, boiler case is correctly replaced and all other commissioning procedures are completed. Complete Benchmark Checklist, recording CO and combustion ratio readings as required. Installation and Servicing 67 Technical Training The Ideal Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers. For details of courses please ring:................ 01482 498 432 Manufactured under an ISO 9001 registered quality management system The code of practice for the installation, commissioning & servicing of central heating systems FM 59915 Ideal Boilers Ltd., P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Ideal Boilers Ltd. pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice. Installer Support Helpline: 01482 498 663 Customer Helpline: 01482 498 660 www.idealboilers.com 8. FAULT CODES DISPLAY CODE ON BOILER DESCRIPTION ACTION F1 Low Water Pressure Check system water pressure is between 1 & 1.5bar on the system pressure gauge. To re-pressurise the system see Section 3. If the boiler still fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). F2 Flame Loss 1.Check other gas appliances in the house are working to confirm a supply is present in the property. F3 Fan Fault Restart the appliance - if the boiler fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). F4 L4 Flow Thermistor Restart the appliance - if the boiler fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). F5 L5 Return Thermistor Restart the appliance - if the boiler fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). F6 Outside Sensor Failure Restart the appliance - if the boiler fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). F7 Low Mains Voltage Contact a qualified electrician or your electricity provider. F9 Unconfigured PCB Unconfigured PCB. Please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). L1 Flow Temperature Overheat or No Water Flow Check system water pressure is between 1 & 1.5bar on the system pressure gauge. To re-pressurise the system see Section 3. If the boiler fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). L2 Ignition Lockout 1.Check condensate Pipe for blockages (refer to Section 4) 2.If other appliances do not work or there are no other appliances, check the gas supply is on at the meter and/or pre payment meter has credit. If the boiler fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). L9 2.Check other gas appliances in the house are working to confirm a supply is present in the property. 3.If other appliances do not work or there are no other appliances, check the gas supply is on at the meter and/or pre payment meter has credit. If the boiler fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). L6 False Flame Lockout Restart the appliance - if the boiler fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). LC 5 Boiler Resets in 15 minutes 1.Turn electrical supply to boiler off and on. FU Flow/Return Differential > 50°C If the boiler fails to operate then please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). Diverter Valve in mid-position for service Rotate all knobs fully clockwise, turn boiler power off and on then press restart U 2.If the boiler fails to operate please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Registered Gas Installer (RGII). Ideal Consumer Helpline Tel: 01482 498660 www.idealboilers.com Ideal Boilers pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice. Ideal, P.O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN. Tel. 01482 492251 Fax. 01482 448858. Registration No. London 322 137.