Instruction Manual for ideal HEATING models including: C24 Logic Combi2 C Boiler, C24, Logic Combi2 C Boiler, Combi2 C Boiler, Boiler
INSTALLATION & SERVICING
LOGIC COMBI2 C24 C30 C35
When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Heating. For the very latest copy of literature for specification and maintenance practices visit our website idealheating.com where you can download the relevant information in PDF format. February 2023 UIN 236183 A01
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 6HDVRQDO6SDFH+HDWLQJ(QHUJ\(FLHQF\ Full Load Part Load Standby Loss Ignition
ERP DATA
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
P4
kW
P1
kW
elmax
kW
elmin
kW
PSB
kW
%
%
Pstby
kW
Pign
kW
24 yes no no no no yes
24.3 8
0.046 0.013 0.002
90 98.7 0.05
0
MODEL 30 yes no no no no yes
24.3 8
0.027 0.01 0.003
90 98.7 0.05
0
35 yes no no no no yes
24.3 8
0.026 0.012 0.002
90 98.7 0.05
0
Emissions
NOx (Gross)
Annual Energy Consumption
Sound Power Level, Indoors
Domestic Hot Water
Domestic Hot Water
:DWHUKHDWLQJHQHUJ\HFLHQF\(FR 7DSSLQJ3UR¿OH/
Daily fuel consumption 24hr (GCV) Actual measured Annual electricity consumption Annual fuel consumption
NOx, pond Hs mg/kWh
28
QHE
GJ
75
LWA
dB
50
Qelec :+ Qfuel AEC AFC
kWh %
kWh kWh GJ
0.157 81
14.76 34 11
25 75 46
0.157 81
14.631 34 11
30 75 46
0.158 79
15.14 34 11
WEEE DIRECTIVE 2012/19/EU Waste Electrical and Electronic Equipment Directive
· At the end of the product life, dispose of the packaging and product in a corresponding recycle centre.
· Do not dispose of the unit with the usual domestic refuse. · Do not burn the product. · Remove the batteries. · Dispose of the batteries according to the local statutory
requirements and not with the usual domestic refuse.
The code of practice for the installation, commissioning & servicing of central heating systems
2
Installation and Servicing
PRODUCT FICHE
LOGIC COMBI2 C BOILER Ideal Heating ERP DATA
SYMBOL
UNITS
MODEL
24
30
35
Condensing boiler
Yes
6HDVRQDOVSDFHKHDWLQJHFLHQF\FODVV
A
Rated heat output
kW
24
6HDVRQDOVSDFHKHDWLQJHQHUJ\HFLHQF\
V
%
94*
Annual energy consumption
QHE
GJ
75
Sound power level, indoors :DWHUKHDWLQJHQHUJ\HFLHQF\FODVV
LWA
dB
50
46
46
A
6HDVRQDO6SDFH+HDWLQJ(QHUJ\(FLHQF\RIWKH%RLOHU
94% *% A
7HPSHUDWXUHFRQWUROIURP¿FKHRIWHPSHUDWXUHFRQWURO
Class I 1%
Class II 2%
Class III 1.5%
Class IV 2%
Class V 3%
Class VI 4%
Class VII 3.5%
Class VIII 5%
% B
6RODU&RQWULEXWLRQIURP¿FKHRIVRODUGHYLFH
&ROOHFWRU6L]H (in m2)
Tank Volume (in m3)
Collector (FLHQF\
(in %)
Tank rating A* = 0.95 A = 0.91 B = 0.86 C = 0.83 D-G = 0.81
= (`III 'x
+ `IV ' x
) x 0.9 x (
/ 100 x
) =
%
C
6HDVRQDO6SDFH+HDWLQJ(QHUJ\(FLHQF\RI3DFNDJHTOTAL: A+B+C=
%
6HDVRQDO6SDFH+HDWLQJ(QHUJ\(FLHQF\&ODVVRI3DFNDJH
G < 30%
F
E
D
C
B
A
A+
A++
A+++
7KHHQHUJ\HFLHQF\RIWKHSDFNDJHRISURGXFWVSURYLGHGIRULQWKLVGRFXPHQWPD\QRWFRUUHVSRQGWRLWVDFWXDOHQHUJ\HFLHQF\RQFH LQVWDOOHGLQDEXLOGLQJDVWKHHFLHQF\LVLQÀXHQFHGE\IXUWKHUIDFWRUVVXFKDVKHDWORVVLQWKHSURGXFWVLQUHODWLRQWRWKHEXLOGLQJVL]HDQGLWV
characteristics.
Installation and Servicing
3
NOTES FOR THE INSTALLER
For any technical queries please ring the Ideal installer helpline : 01482 498663
BOILER RESTART PROCEDURE 3UHVVWKH5(67$57EXWWRQ7KHERLOHUZLOOUHSHDWWKHLJQLWLRQVHTXHQFHLIDKHDWGHPDQGLVSUHVHQW
DEFINITIONS
WARNING: Risk of injury or death CAUTION: Risk of damage to objects IMPORTANT: Important information
Table of Acronyms
CH - Central Heating DHW - Domestic Hot Water TRV - Thermostatic Radiator Valve PRV - Pressure Relief Valve IE - Ireland ETCI - Electro-Technical Council of Ireland BS - British Standard WRAS - Water Regulations Advisory Scheme
SAP - Standard Assessment Procedure IEE - Institution of Electrical Engineers UKCA - UK Conformity Assessed RHS - Right Hand Side LHS - Left Hand Side PCB - Printed Circuit Board
4
Installation and Servicing
CONTENTS
Section 1 - General.................................................................................6 1.1 Introduction ...............................................................................8 1.2 Operation ..................................................................................8 1.3 Safe Handling ...........................................................................8 1.4 Optional Accessories ................................................................8 1.5 Safety........................................................................................9 1.6 Safe Handling of Substances ...................................................9 1.7 Location of Boiler .....................................................................9 1.8 Air Supply ...............................................................................10 1.9 Gas Supply .............................................................................10 1.10 Water Circulation System .......................................................10 1.11 Boiler Controls ........................................................................10 1.12 Electrical Supply .....................................................................10 1.13 Condensate Drain...................................................................10 1.14 Boiler Dimensions, Services & Clearances ............................11 1.15 System Requirements - Central Heating ................................12 1.16 System Requirements - DHW.................................................13 1.18 Water Treatment .....................................................................13 1.17 System Balancing ...................................................................13
Section 2 - Installation ..........................................................................14 2.1 Boiler Assembly - Exploded View ...........................................14 2.2 Unpacking...............................................................................15 2.3 Wall Mounting Template..........................................................16 2.4 Preparing the Wall ..................................................................16 2.5 Fitting the Wall Mounting Plate ...............................................16 2.6 Mounting the Boiler.................................................................16 2.7 Flues and Locations................................................................17 2.8 Flues and Locations - Cont.....................................................18 2.9 Horizontal Flue Positions .......................................................19 2.10 Vertical Flue Positions ...........................................................19 2.11 Flue System Dimensions .......................................................20 2.12 Fitting the Turret......................................................................20 2.13 Cutting the Flue ......................................................................21 2.14 Assembling the Vertical Flue ..................................................22 2.15 Condensate Drain...................................................................23 2.16 Condensate Drain - Cont'd .....................................................24 2.17 Connections & Filling ..............................................................25 2.18 Connections & Filling Continued.............................................26 2.19 Electrical Connections ............................................................27 2.20 Installer Wiring ........................................................................27 2.21 External Wiring .......................................................................28 2.22 Wiring Diagram .......................................................................29 2.23 Replacing Pre-Fitted Mains Cable ..........................................30 2.24 Commissioning and Testing....................................................30 2.25 Initial Lighting..........................................................................31 2.26 The Display.............................................................................32 2.27 General Checks ......................................................................32 2.28 General Checks - Water Circulation .......................................33 2.29 Restart Procedure...................................................................33 2.30 Accessing the Installer Mode..................................................34 2.31 Handing Over..........................................................................34
Section 3 - Servicing.............................................................................35 3.1 Servicing Schedule .................................................................35 3.2 Removal / Replacement of Components ................................36 3.3 Draining the Boiler ..................................................................36 3.4 Boiler Front Panel Removal / Replacement............................37 3.5 Flue Manifold Removal/Replacement.....................................37 3.6 Fan and Venturi Assembly Removal and Cleaning.................38 3.7 Burner Removal and Cleaning................................................39 3.8 Cleaning the Heat Exchanger.................................................39 3.9 Ignition / Detection Electrode Replacement / Inspection ........40 3.10 Cleaning the Condensate Trap ...............................................40 3.11 DHW Filter & DHW Flow Regulator Cleaning/Replacement...41 3.12 Burner Injector Replacement ..................................................41 3.13 Burner Replacement...............................................................41 3.14 Return Thermistor Replacement............................................42 3.15 Spark Generator Replacement ...............................................42 3.16 Gas Control Valve Replacement.............................................43 3.17 Diverter Valve Actuator Replacement .....................................43 3.19 Condensate Trap Replacement / Cleaning.............................44 3.18 Primary PCB Replacement.....................................................44 3.20 DHW Flow Turbine Sensor Replacement ...............................45 3.21 Pressure Gauge Replacement ...............................................45 3.22 PRV Replacement ..................................................................46 3.23 Pump Automatic Air Vent Replacement ..................................46 3.24 Replacement of DHW Thermistor...........................................47 3.25 DHW Plate Heat Exchanger Replacement .............................47 3.26 Diverter Valve Body Assembly Replacement..........................48 3.27 Pump Head Replacement.......................................................49 3.28 CH Water Pressure Switch Replacement ...............................49 3.29 Flow Thermistor Replacement................................................50 3.30 Heat Engine Replacement......................................................51 3.31 Expansion Vessel Recharging & Replacement ......................52
Section 4 - Fault Finding.......................................................................53 4.1 Fault Finding Main Menu ........................................................53 4.2 `L 01' - Overheat Lockout........................................................54 4.3 `L 02' - Ignition Lockout ...........................................................54 4.4 `L 06' - Flame On Before Gas Valve On..................................55 4.5 `F 01' - Low Water Pressure ...................................................55 4.6 `F 02 - Flame Loss .................................................................55 4.7 `F 03' - Fan Fault.....................................................................56 4.8 F 04 or L 04' - Flow Thermistor Fault .....................................56 4.9 `F 05 or L 05' - Return Thermistor Fault .................................57 4.10 `F 06' - Outside Sensor Fault ..................................................57 4.11 No CH Operation but DHW Works OK ...................................58 4.12 No DHW but CH Works OK ....................................................59 4.13 No Display ..............................................................................60 4.14 `F0U' Flow/Return Differential Greater than 50°C ..................60 4.15 F 0C' DHW Thermistor Fault...................................................60
Section 5 - Spare Parts ........................................................................61
Section 6 - Benchmark to Commissioning............................................62
Installation and Servicing
5
Table 1 General Data
Section 1 - General
24
30
35
Gas Supply
2H - G20 - 20 mbar
Gas Supply Connection
15 mm copper compression
,QMHFWRU6L]H
mm
4.15
4.65
4.9
Inlet Connection
Cold Water
15 mm copper compression
Outlet Connection
Cold Hot Water
15 mm copper compression
Flow Connection
Central Heating
22 mm copper compression
Return Connection
Central Heating
22 mm copper compression
Flue Terminal Diameter
mm
100
Average Flue Temp-Mass Flow Rate
DHW
63ºC - 11g/s 68ºC - 13g/s 73ºC - 15g/s
CO2 Content (± 0.7)
Max. DHW
9.2%
9.3%
9.7%
Min. CH
8.5%
8.5%
8.8%
Maximum Working Pressure (Sealed Systems)
bar (psi)
2.5 (36.3)
Maximum Domestic Hot Water Inlet Pressure
bar (psi) [kPa]
10.0 (145) [1000]
Minimum Domestic Hot Water Inlet Pressure*
bar (psi) [kPa]
0.8(11.6)(80) 1.3(18.9) (130) 1.3(18.9)**(130)
Minimum DHW Inlet Pressure to Operate at 0.6 bar System Pressure
$OO0RGHO6L]HVEDU
Electrical Supply
9a+]
Power Consumption
W
96
91
110
Fuse Rating
([WHUQDO$,QWHUQDO7$+5&/9
Water Content
Central Heating litre (gal)
1.2 (0.26)
Domestic Hot Water litre (gal)
1.0 (0.22)
Packaged Weight
kg
32.8
33
33
Lift Weight
kg
28.5
28.6
28.6
%RLOHU&DVLQJ6L]H
Height mm
700
Width mm
395
Depth mm
278
5HTXLUHGIRUPD[LPXPÀRZUDWH%RLOHURSHUDWHVGRZQWR/PLQ'+:GHOLYHU\ ** 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
24
30
35
Net CV
kW 24.3 4.9
6.1
7.1
Gross CV kW
27
5.4
6.7
7.9
Gas Consumption
m3/h 2.512 0.5 0.627 0.734
%RLOHU2XWSXW
(ft3/h) (89) (17.8) (22) (25.9)
Non Condensing 70ºC Mean Water Temp.
kW
24.2
4.8
6.1
7.1
Condensing 40ºC Mean Water Temp.
kW
25.6
5.1
6.4
7.5
6HDVRQDO(FLHQF\
6('%8. 91.10% 91.10% 91.10%
6HDVRQDO(FLHQF\
6('%8. 89.60% 89.60% 89.60%
12[&ODVVL¿FDWLRQ
CLASS 6
Maximum DHW Input:
24
30
35
Nett CV
kW 24.3 30.4
35.4
Gross CV Gas Consumption
kW m3/h ft3/h
27 2.512
89
33.7 3.135 111
39.3 3.657 129
Maximum DHW Output kW 24.2 30.3
35.3
DHW Flow Rate At 35ºC Temp. Rise '+:6SHFL¿F5DWH
l/min 9.9 12.4
14.5
gpm 2.2
2.8
3.2
l/min 11.5 14.5
16.9
gpm 2.5
3.2
3.7
* The value is used in the UK Government's Standard Assessment
Procedure (SAP) for energy rating of dwellings. The test data from ZKLFKLWKDVEHHQFDOFXODWHGKDVEHHQFHUWL¿HGE\DQRWL¿HGERG\.
1RWH*DVFRQVXPSWLRQLVFDOFXODWHGXVLQJDFDORUL¿FYDOXHRI MJ/m3 (1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett
7RREWDLQWKHJDVFRQVXPSWLRQDWDGLHUHQWFDORUL¿FYDOXH
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 c. For ft3/h - divide the gross heat input (Btu/h) by the gross C.V. of
the gas (Btu/ft3) d. For m3/h - multiply l/s by 3.6
C13 C33 C53 = A room sealed appliance designed for connection via GXFWVWRDKRUL]RQWDORUYHUWLFDOWHUPLQDOZKLFKDGPLWV fresh air to the burner and discharges the products of FRPEXVWLRQ WR WKH RXWVLGH WKURXJK RUL¿FHV ZKLFK LQ this case, are concentric. The fan is up stream of the combustion chamber.
I2H = An appliance designed for use on 2nd family gas, Group H only.
II2H/3P = An appliance designed for use on 2nd or 3rd family gases, Group H or P.
6
Installation and Servicing
LOGIC COMBI2 C
Natural Gas Only
BOILER SIZE
24 30 35
G.C. Applicance No (Benchmark No.) 47-349-93 47-349-94 47-349-95
Destination Country: GB
Section 1 - General
)RU8.WRFRPSO\ZLWK%XLOGLQJ5HJXODWLRQV3DUW/3DUWLQ6FRWODQG WKHERLOHUVKRXOGEH¿WWHGLQDFFRUGDQFHZLWKWKH PDQXIDFWXUHU¶VLQVWUXFWLRQV6HOIFHUWL¿FDWLRQWKDWWKHERLOHUKDVEHHQLQVWDOOHGWRFRPSO\ZLWK%XLOGLQJ5HJXODWLRQVFDQEH 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 ................. 29
Time and temperature control to hot water ............. 29
+HDWLQJ]RQHYDOYHV................................................ n/a
TRV's........................................................................ 12 Auto bypass .................................................................... 12
Boiler interlock.......................................................... 12
For all boilers
Flushing to BS.7593................................................. 15 Inhibitor ........................................................................... 15 Central heating mode
Heat input...................................................to be calculated
Page Burner operating pressure ...................................... n/a &HQWUDOKHDWLQJÀRZWHPS ...........measure and record Central heating return temp. ........measure and record For combination boilers only Scale reducer ........................................................... 15 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 :DWHUÀRZUDWHDWPD[VHWWLQJ........ measure & record )RUFRQGHQVLQJERLOHUVRQO\ Condensate drain................................................25-26 For all boilers: Complete, sign & hand over to customer
NOTE TO THE INSTALLER: COMPLETE THE BENCHMARK COMMISSIONING CHECKLIST AND LEAVE THESE INSTRUCTIONS WITH APPLIANCE
Installation and Servicing
For assistance call Technical Helpline 01482 498663
7
Section 1 - General
1.1 INTRODUCTION
The Logic Combi2 range of boilers are wall mounted, condensing, combination gas boilers.
)HDWXUHV
+LJKHFLHQF\ · Full sequence · Automatic spark ignition · Low water content )DQQHGÀXH
The boiler is supplied fully assembled with DHW plate heat exchanger, diverter valve, circulating pump, pressure gauge, PRV and CH expansion vessel.
9DULDEOH&+DQG'+:WHPSHUDWXUHFRQWUROVDUH¿WWHGRQWKH user control and the boiler features a DHW preheat facility.
7KHERLOHULQFOXGHVDVVWDQGDUG
-
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 1.13 - Water & Gas Connection Diagram.
Refer to Section
1.2 OPERATION
:LWKQRGHPDQGIRU&+WKHERLOHU¿UHVRQO\ZKHQ'+:LV GUDZQRRUSHULRGLFDOO\IRUDIHZVHFRQGVZLWKRXWDQ\'+: GUDZRLQRUGHUWRPDLQWDLQWKH'+:SODWHKHDWH[FKDQJHULQ a heated condition.
When there is a demand for CH, the heating system is supplied at the selected temperature of between 30oC and 80o&XQWLO'+:LVGUDZQR7KHIXOORXWSXWIURPWKHERLOHULV then directed via the diverter valve to the plate heat exchanger WRVXSSO\DQRPLQDO'+:GUDZRRI
24 kW 9.9 l/min at 35ºC temperature rise. 30 kW 12.4 l/min at 35ºC temperature rise. 35 kW 14.5 l/min at 35ºC temperature rise.
7KH'+:GUDZRUDWHVSHFL¿HGDERYHLVWKHQRPLQDOWKDW WKHERLOHUÀRZUHJXODWRUZLOOJLYH'XHWRV\VWHPYDULDWLRQV DQGVHDVRQDOWHPSHUDWXUHÀXFWXDWLRQV'+:ÀRZUDWHV WHPSHUDWXUHULVHZLOOYDU\UHTXLULQJDGMXVWPHQWDWWKHGUDZR tap.
$WORZ'+:GUDZRUDWHVWKHPD[LPXPWHPSHUDWXUHPD\ exceed 65ºC.
The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating, and performance of key components to aid commissioning DQGIDXOW¿QGLQJ
1.3 SAFE HANDLING
This boiler may require 2 or more operatives to move it to its installation site, remove it from its packaging base and during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions VKRXOGEHFRQVLGHUHG
· Grip the boiler at the base. · Be physically capable. · Use personal protective equipment as appropriate, e.g.
gloves, safety footwear.
During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or the weight is light.
· Keep back straight. · Avoid twisting at the waist. · Avoid upper body/top heavy bending. · Always grip with the palm of the hand. · Use designated hand holds. · Keep load as close to the body as possible. · Always use assistance if required.
1.4 OPTIONAL ACCESSORIES
Please visit idealheating.com to access the optional accessories for this boiler.
SCAN for link
8
Installation and Servicing
Section 1 - General
1.5 SAFETY
1.6 SAFE HANDLING OF SUBSTANCES
&XUUHQW*DV6DIHW\LQVWDOODWLRQDQGXVH UHJXODWLRQVRU rules in force:
The appliance is suitable only for installation in GB 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 WKHUHOHYDQWUHTXLUHPHQWVRIWKH
· 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. :KHUHQRVSHFL¿FLQVWUXFWLRQVDUHJLYHQUHIHUHQFHVKRXOGEH made to the relevant British Standard Code of Practice.
7KH%RLOHUKDVEHHQWHVWHGDQGFHUWL¿HGWR
BSEN 15502-1, BSEN 15502-2, BSEN 15502-2-1, BSEN 60335-1, BSEN 60335-2-102, BSEN 55014-1 and BSEN 55014-2 for use with Natural Gas & Propane.
Detailed recommendations are contained in the following %ULWLVK6WDQGDUG&RGHVRI3UDFWLFH
BS5440:1
Flues (for gas appliances of rated input not exceeding 70 kW).
BS5440:2
Ventilation (for gas appliances of rated input not exceeding 70 kW).
BSEN12828 BSEN12831 BSEN14336
+HDWLQJ6\VWHPVLQEXLOGLQJV'HVLJQIRUZDWHU based heating systems.
+HDWLQJ6\VWHPVLQEXLOGLQJV0HWKRGIRU calculation of the design heat load.
+HDWLQJ6\VWHPVLQEXLOGLQJV,QVWDOODWLRQ and commissioning of water based heating systems.
BS5546 BS6798
Installation of gas hot water supplies for domestic purposes (2nd Family Gases)
,QVWDOODWLRQRIJDV¿UHGKRWZDWHUERLOHUVRI rated input not exceeding 70 kW.
BS6891
Installation and maintenance of low pressure gas installation pipework.
BS 7593:2019 Code of practice for the preparation, commissioning and maintenance of domestic central heating and cooling water systems.
No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture.
1.7 LOCATION OF BOILER
7KHERLOHUPXVWEHLQVWDOOHGRQDÀDWDQGYHUWLFDOLQWHUQDOZDOO capable of adequately supporting the weight of the boiler and any ancillary equipment. 7KHERLOHUPD\EH¿WWHGRQDFRPEXVWLEOHZDOODQGLQVXODWLRQ between the wall and the boiler is not necessary, unless required by the local authority.
WARNING: Rear access to the boiler is not permitted.
CAUTION: 'RQRW¿WWKHERLOHURXWVLGH
7LPEHU)UDPHG%XLOGLQJV Boilers installed in a timber-framed building must comply with IGE/UP7 +A 2008.
%DWKURRP,QVWDOODWLRQV
CAUTION: This appliance is IP20 rated, do not clean with jets of water.
You may install the boiler in any internal space. The installation must comply with the current IEE (BS 7671) Wiring Regulations and the electrical regulations applicable in Scotland.
If the appliance is to be installed in a room containing a bath or shower then the appliance must be installed beyond Zone 2, as detailed in BS7671.
600 mm
600 mm
11
2 2*
2
2250 mm
+HDOWK 6DIHW\'RFXPHQW1R 7KH(OHFWULFLW\DW:RUN5HJXODWLRQV
The manufacturer's notes must NOT be taken, in any way, as overriding statutory obligations.
IMPORTANT: 7KLVDSSOLDQFHLV8.&$&(FHUWL¿FDWHGIRU safety and performance. Do not connect external control devices directly to this appliance unless recommended in this manual or by ,GHDO+HDWLQJ in writing. If in doubt, please enquire.
Unapproved control devices could invalidate the warranty of this appliance and infringe the Gas Safety Regulations.
A
%DWKURRP,QVWDOODWLRQV [0] Zone 0 [1] Zone 1 [2] Zone 2 >
@:LWKRXWWKHHQGZDOO]RQHPXVWH[WHQGPPIURPWKHEDWK [A] 600 mm radius from the bath or shower
Installation and Servicing
9
Section 1 - General
Compartment Installations
A boiler installed in a compartment does not require ventilation. However, A boiler installed in a compartment must provide adequate clearances for servicing. The compartment should DOVREH¿WWHGZLWKDVXLWDEOHODEHOLQDFFRUGDQFHZLWKFXUUHQW standards.
Refer to Section
1.8 AIR SUPPLY
t is not necessary to have an air vent in the room or internal space where the boiler is installed.
1.9 GAS SUPPLY
Consult the local gas supplier to establish an adequate supply of gas. Do not use existing service pipes without consulting the local gas supplier.
The gas supply must be governed with a meter.
A gas meter can only be connected by the local gas supplier or by a Gas Safe Registered Engineer.
An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the required gas supply rate. ,WLVWKHUHVSRQVLELOLW\RIWKH*DV,QVWDOOHUWRVL]HWKHJDV installation pipework in accordance with BS6891. :KLOVWWKHSULQFLSOHRIWKHJDVYDOYHHQVXUHVWKH/RJLF range is able to deliver it is full output at inlet pressures as low as 14 mb, other gas appliances in the property may not be as tolerant. When operating pressures are found to be below the minimum meter outlet of 19 mb these should be checked to ensure this is adequate for correct and safe operation.
Allowing for the acceptable pressure loss of 1mb across the installation pipework, it can be assumed that a minimum permitted operating pressure of 18mb will be delivered to the inlet of the appliance.
(Reference BS6400-1 Clause 6.2 Pressure Absorption).
The external gas cock could further reduce the operating pressure when measured at its test point. The pressure drop is relative to the heat input to the boiler (kW), refer to graph below.
Pressure Drop (mbar)
Gas Cock Pressure Drop 1.4
1.2
1
0.8
0.6
0.4
0.2
0
0
5
10
15
20
25
30
35
40
Heat Input to Boiler (kW)
IMPORTANT: Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve. ,QVWDOODWLRQSLSHVPXVWEH¿WWHGLQDFFRUGDQFHZLWK%6
The complete installation MUST be tested for gas tightness and purged as described, for the majority of installations the appropriate standard is IGEM/UP/1B [23], but alternatively IGEM/UP/1 [21] or IGEM/UP/1A [22], as appropriate, can be XWLOL]HG
1.10 WATER CIRCULATION SYSTEM
IMPORTANT: A minimum length of 1 metre of copper SLSH0867EH¿WWHGWRERWKÀRZDQGUHWXUQFRQQHFWLRQVIURP the boiler before connection to any plastic piping. The central heating system should be in accordance with BS6798 and, in addition, for smallbore and microbore systems, %6(1$
Water treatment is covered later in these instructions.
Refer to Section
1.11 BOILER CONTROLS
Install CH controls to ensure the boiler has no demand when there is no requirement from the system. Heating systems with TRVs in individual rooms must include a thermostat to control the temperature in rooms without TRVs. At least 10% of the minimum boiler heat output should be achieved using a room thermostat. A bypass circuit with an DXWRPDWLFE\SDVVYDOYHPXVWEH¿WWHGWRV\VWHPVZLWK759VRU WZRSRUWYDOYHVRQDOOWKHUDGLDWRUVWRHQVXUHZDWHUÀRZ
1.12 ELECTRICAL SUPPLY
WARNING: This appliance must be earthed
Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS7671) Wiring Regulations and any local regulations which apply. The mains supply to the boiler and system wiring centre shall be through one common fused double pole isolator and for new heating systems, and where practical replacement installations, the isolator shall be situated adjacent to the appliance.
1.13 CONDENSATE DRAIN
The condensate drain provided must be connected to the drainage point on site. All condensate drainage pipework and ¿WWLQJVPXVWEHPDGHRISODVWLF
IMPORTANT: The condensate drain pipework should be installed in accordance with BS6798. 7KHGUDLQRXWOHWRQWKHERLOHULVVL]HGIRUVWDQGDUGPP RYHUÀRZSLSH,WLVDXQLYHUVDO¿WWLQJWRDOORZXVHRIGLHUHQW brands of pipework.
Refer to Section
10
Installation and Servicing
Section 1 - General
1.14 BOILER DIMENSIONS, SERVICES & CLEARANCES
Refer to Section
The boiler connections are made on the boiler connection tails.
7KHIROORZLQJPLQLPXPFOHDUDQFHVPXVWEHPDLQWDLQHG IRURSHUDWLRQDQGVHUYLFLQJ
Additional space will be required for installation, depending upon site conditions.
6LGHDQG5HDU)OXH D 3URYLGHGWKDWWKHÀXHKROHLVFXWDFFXUDWHO\HJZLWKDFRUH
GULOOWKHÀXHFDQEHLQVWDOOHGIURPLQVLGHWKHEXLOGLQJZKHUH
wall thicknesses do not exceed 600 mm.
2.5 200
2.5
from case
395
278
98 152
Flue terminal
700
100* Water and Gas Connections
Measurements in mm Underside View - Dimension to Wall
43.5
65
21 36
61
75
56.5
37.5
CH Flow
DHW
Gas
DHW
Outlet
Inlet
Inlet
CH Return
PRV
Data Plate
Cond. Drain
PRV Measurements in mm
Front Clearance The minimum front clearance when built in to a cupboard is 5 mm from the cupboard door but 450 mm overall clearance is still required, with the cupboard door open, to allow for servicing.
* Bottom Clearance
Bottom clearance after installation can be reduced to 5 mm. This must be obtained with an easily removable panel to provide the 100 mm clearance required for servicing.
CH Flow
DHW Cond. Gas Outlet Drain
DHW Inlet
CH Return
CH Circuit Drain
IMPORTANT:3OHDVHHQVXUHWKHUHLVVXFLHQW clearance either side and below the boiler, particularly from door hinges and the base of a cupboard.
Installation and Servicing
11
Section 1 - General
1.15 SYSTEM REQUIREMENTS - CENTRAL HEATING
D 7KHPHWKRGRI¿OOLQJUH¿OOLQJWRSSLQJXSRU ÀXVKLQJVHDOHGSULPDU\KRWZDWHUFLUFXLWVIURPWKH mains via a temporary hose connection is only allowed if acceptable to the local water authority.
E $QWLIUHH]HÀXLGFRUURVLRQDQGVFDOHLQKLELWRUÀXLGV suitable for use with boilers having aluminium heat exchangers may be used in the central heating system.
General
The installation must comply with national and local regulations.
'HVLJQWKHV\VWHPIRUÀRZWHPSHUDWXUHVXSWRoC.
The system components must be suitable for an operating pressure of 3 bar and a maximum temperature of 110°C.
The following components are incorporated within the DSSOLDQFH
D Circulating pump.
E PRV, with a non-adjustable preset lift pressure of 3 bar.
F Pressure gauge, covering a range of 0 to 4 bar.
G An 8 litre expansion vessel, with an initial charge pressure of 0.75 bar.
0DNHXS:DWHUOne of the following provisions must be PDGHIRUUHSODFLQJV\VWHPZDWHUORVV
D 0DQXDOO\¿OOHGYHVVHO 7KHYHVVHOPXVW
Have a visible water level
Be mounted at least 150 mm above the system's highest point
Connect through a non-return valve to the system
Be at least 150 mm below the makeup vessel on the return side of the radiators
E System prepressurisation. 7KHHFLHQF\RIWKHH[SDQVLRQYHVVHOZLOOEH
UHGXFHGLQDSUHVVXULVHGV\VWHPDODUJHUYHVVHO or smaller system volume may be necessary. If WKHYHVVHO¶VFDSDFLW\LVQRWVXFLHQWDQDGGLWLRQDO vessel must be installed on the return to the boiler.
If the system is not pressurised, the cold water capacity must not exceed 143 litres.
*XLGDQFHRQYHVVHOVL]LQJLVJLYHQLQWDEOHDERYH
:DWHU)ORZ5DWHDQG3UHVVXUH/RVV
Max CH Output
kW
Water Flow Rate
l/min
7HPSHUDWXUH'LHUHQWLDO
(gal/min) oC
Head available for System
m.w.g. (ft.w.g.)
24.2 17.3 (3.8) 20 3.4 (11.1)
Table 4 Vessel Sizing
PRV setting
bar
9HVVHOFKDUJHSUHVVXUH
bar
6\VWHPSUHFKDUJHSUHVVXUH bar
6\VWHPYROXPH
OLWUHV
25 50 75 100 125 150 175 190 200 250 300 )RURWKHUV\VWHPYROXPHV PXOWLSO\E\WKHIDFWRUDFURVV
3.0
0.5 to 0.75
None
1.0
([SDQVLRQYHVVHO YROXPHOLWUHV
1.6
1.8
3.1
3.7
4.7
5.5
6.3
7.4
7.8
9.2
9.4
11.0
10.9
12.9
11.9
14.0
12.5
14.7
15.6
18.4
18.8
22.1
0.063
0.074
)LOOLQJ
7KHV\VWHPPD\EH¿OOHGE\WKHIROORZLQJPHWKRG
Where the mains pressure is excessive a pressure UHGXFLQJYDOYHPXVWEHXVHGWRIDFLOLWDWH¿OOLQJ D 7KRURXJKO\ÀXVKRXWWKHZKROHV\VWHPZLWKFROGZDWHU E Fill and vent the system until the pressure gauge
registers 1 bar and examine for leaks.
Refer to Section
F Check the operation of the PRV by raising the water pressure until the valve lifts. This should occur within 0.3 bar of the preset lift pressure.
G Check no escape of water occurs except at the discharge point
H Release water from the system until the PLQLPXPV\VWHPGHVLJQSUHVVXUHLVUHDFKHG 1.0 bar if the system is to be pre-pressurised.
DOMESTIC HOT WATER
The DHW service must be in accordance with BS5546 & BS6700.
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 ÀRZWXUELQHFDUWULGJH7KHERLOHUZLOOUHTXLUHWKHÀRZUDWHWREH set to obtain a temperature rise of 35oC at the tap furthest from the boiler.
Refer to Section
The boilers are suitable for connection to most types of washing machine and dishwasher appliances.
12
Installation and Servicing
Section 1 - General
1.16 SYSTEM REQUIREMENTS - DHW
If the shower/mixer valve does not incorporate nonUHWXUQYDOYHVWKHIROORZLQJPXVWEHIROORZHG D7KHFROGLQOHWWRWKHERLOHULV¿WWHGZLWKDQDSSURYHG anti-vacuum or syphon non-return valve. E Hot and cold water supplies to the shower are of equal pressure.
+DUG:DWHU$UHDVWhere the water hardness exceeds 200 mg/ litre (200 ppm), it is recommended that a SURSULHWDU\VFDOHUHGXFLQJGHYLFHLV¿WWHGLQWRWKHERLOHU cold supply within the requirements of the local water company.
IMPORTANT Provision must be made to accommodate the expansion of DHW contained within the DSSOLDQFH,IWKH'+:LQOHWFRQWDLQVDEDFNÀRZSUHYHQWLRQ device or non-return valve, e.g. a water meter, then a mini H[SDQVLRQYHVVHOVKRXOGEH¿WWHGEHWZHHQWKHGHYLFHDQG the boiler in the cold inlet pipe. Cold water, rising main and pipework in exposed areas QHHGWREHVXLWDEO\ODJJHGWRSUHYHQWIUHH]LQJ
Note DHW Expansion Vessel kit available from Ideal.
1.17 SYSTEM BALANCING
The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of the minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available. See note regarding thermostatic radiator valves on page 10.
1RWH6\VWHPVLQFRUSRUDWLQJ]RQHYDOYHVZKLFKFRXOG FRPSOHWHO\FXWRWKHÀRZWKURXJKWKHV\VWHPPXVWDOVR include a bypass.
Balancing 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 YDOYHWRJLYHDQXQLQWHUUXSWHGÀRZWKURXJKWKHUDGLDWRU These valves should now be left as set. 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. Adjust the room thermostat and programmer to NORMAL settings.
1.18 WATER TREATMENT
Central Heating
The Logic range of boilers have an ALUMINIUM alloy heat exchanger. IMPORTANT 7KHDSSOLFDWLRQRIDQ\RWKHUWUHDWPHQWWR WKLVSURGXFWPD\UHQGHUWKHJXDUDQWHHRI,GHDO+HDWLQJ LQYDOLG
,GHDO+HDWLQJrecommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems. If water treatment is used ,GHDO+HDWLQJrecommend only the use of SCALEMASTER SM-1 PRO, FERNOX, MBI, ADEY MC1, SENTINEL X100 or CALMAG CM100 inhibitors and associated water treatment products, which must be used in accordance with the manufacturers' instructions.
This boiler can be used with a water softener. However, the KHDWLQJV\VWHPVKRXOGQRWEH¿OOHGZLWKVRIWHQHGZDWHUDV any softening chemicals could enhance corrosion of certain materials in the heating system, including aluminium and VWHHO7KHKHDWLQJV\VWHPVKRXOGDOZD\VEH¿OOHGIURPWKH bypass on the water softener installation. It is most important that the correct concentration of the
water treatment products is maintained in accordance with the manufacturers' instructions. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough FOHDQVLQJ%6GHWDLOVWKHVWHSVQHFHVVDU\WR clean a domestic heating system.
In hard water areas, treatment to prevent lime scale may be necessary.
8QGHUQRFLUFXPVWDQFHVVKRXOGWKHERLOHUEH¿UHG EHIRUHWKHV\VWHPKDVEHHQWKRURXJKO\ÀXVKHG
'RPHVWLF+RWZDWHU
In hard water areas where mains water can exceed SSP7RWDO+DUGQHVVDVGH¿QHGE\%67DEOH D VFDOHUHGXFLQJGHYLFHVKRXOGEH¿WWHGLQWRWKHERLOHUFROG supply within the requirements of the local water company. The mains cold water feed can come from a water softener as the materials used in the domestic hot water circuit are fully resistant to any chemicals in softened water. ,GHDO+HDWLQJ 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. )RUIXUWKHULQIRUPDWLRQFRQWDFW )HUQR[ZZZIHUQR[FRP7HO
Sentinel Performance Solutions ZZZVHQWLQHOSURWHFWVFRP7HO
Scalemaster Water Treatment Products ZZZVFDOHPDVWHUFRXN7HO
Calmag Ltd. - www.calmag Ltd.com. 7HO $GH\ZZZDGH\FRP7HO +44 (0) 1242 546700
Installation and Servicing
13
INSTALLATION
Section 2 - Installation
2.1 BOILER ASSEMBLY - EXPLODED VIEW
104 CH Return Valve 105 CH Flow Valve 106 DHW Inlet & Outlet 107 Filling Loop Pipe 108 Pump Head 110 Auto Air Vent 111 Diverter Valve Motor 112 Diverter Valve Body & Paddle 113 Pressure Relief Valve 114 Pipe - PRV Outlet 115 Pipe - Flow 116 Pipe - Return 117 Pipe - Expansion Vessel 118 Expansion Vessel
119 Return Group Manifold 120 Flow Group Manifold 121 Plate Heat Exchanger 124 Flow Regulator 127 Flow Sensor/Turbine 131 Water Pressure Switch 135 Pressure Gauge 203 Gas Cock 205 Gas Valve 206 Pipe - Gas Injector 211 Injector Assy 214 Venturi 215 Fan 217 Burner
218 Gasket - Burner 219 Sump Clean Out Cover 223 Flue Manifold 224 Flue Manifold Top 227 Clamp Retaining Flue Turret 228 Hose Condensate Internal 229 Condensate Trap 231 Condensate Outlet Connection 239 Condensate Drain Tube 302 PCB 306 Ignition/Detection Electrode 308 Ignitor Unit 309 Thermistor 313 Ignition Lead
324 Control Box Lid 325 Control Box Front 326 Blank Insert 401 Heat Engine 503 Wall Mounting Bracket 504 Front Panel 505 Fascia 506 Bracket - Spark Generator 507 Bracket - Expansion Vessel
Note that item numbers are linked to the spares list
504 505
227
224 503
223
324 135
2
1
3
04 bar
326
14
215
217
218
306 214
313 507
211 401
506 308
206 205
228 116
219 309
115
325 302
229
239
120
106
203 131
105
106 127 124
107
104
108
231
118 114
121
110
111
112
309 113
119 117
Installation and Servicing
INSTALLATION
Section 2 - Installation
2.2 UNPACKING
The boiler is supplied fully assembled in Pack A.
3DFN$&RQWHQWV Boiler Hardware Pack Box Wall Mounting Plate These Installation/Users Instructions Boiler Warranty Wall Mounting Template
8QSDFNDQGFKHFNWKHFRQWHQWV 2
3
4
6
1
5
+DUGZDUH3DFN
Box Contents
1x HP Box Dividers - 289 x 111 x 57.5 mm
12
1x Plug Male and Clip
1x Pipe DHW Outlet
1x Pipe Filling Loop
16
1x Valve DHW Inlet
2x Pipe CH Flow/Return
7
1x Valve Filling Loop
1x Valve CH G3/4 x 22 mm Filling Loop
1x Cap Female
1x Valve CH G3/4 x 22 mm
1x Pipe DHW Inlet
1x Nut G1/216 Brass (Flat)
1x Gas Cock
Accessory Bag Contents
9x 2x 2x 1x
Washers* Wall Plugs Screws Flue Clamp Screw
20
13 10 8
19 18
15 17 11 9
14
21 22 23
*Refer to Valve Washer Template inside box lid.
Installation and Servicing
15
INSTALLATION
Section 2 - Installation
2.3 WALL MOUNTING TEMPLATE
The wall mounting template is located on the internal protective packaging. The template shows the position RIWKH¿[LQJDQGUHDUÀXHFHQWUHKROHVIRUDVWDQGDUG installation
Care MUST be taken to ensure the correct holes are drilled. Secure the template into the required position. Ensure it
is square by hanging a plumbline. ,I¿WWLQJDVLGHÀXHH[WHQGWKHÀXHFHQWUHOLQHRQWRWKH
VLGHE\PPRQDVWDQGDUGZDOO¿[RUPPLI XVLQJDVWDQGREUDFNHW 0DUNWKHIROORZLQJRQWRWKHZDOO
a The selected group of wall mounting screw holes. E 7KHFHQWUHSRVLWLRQRIWKHÀXHGXFW0DUNLQJERWKWKH
FHQWUHDQGWKHFLUFXPIHUHQFHRIWKHÀXHGXFW Remove the template plate from the wall.
Extended centre line
155
"A"
(200)
Refer to Section
2.4 PREPARING THE WALL
WARNING: Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury.
Check all of the hole positions before drilling. &XWWKHÀXHKROHZLWKDPPFRUHERULQJWRROHQVXUH
the hole is square to the wall. Drill the 2 mounting holes with a 7.5 mm / 8 mm masonry
drill and insert the plastic plugs provided. Locate 2 No.14 x 50 mm screws in the wall mounting plate
(one at each side, in any of the 3 holes provided at each side) and screw home. Ensure mounting bracket is level.
X
Section through wall
Rear flue only
Side flue only
127 mm diameter hole 127 mm diameter hole
2.5 FITTING THE WALL MOUNTING PLATE
1. Screw the wall mounting plate to the wall using 2 wall SOXJV¿WWHGSUHYLRXVO\ZLWKWKHVFUHZVSURYLGHG
2. Choose one of the 2 sets of slots in left and right bank. (QVXUHWKDWDWOHDVWRQHRIWKHVFUHZVLV¿WWHGLQWRDWRS slot and the mounting bracket is level.
Example of fixing
2.6 MOUNTING THE BOILER
1. Lift the boiler onto the wall mounting plate and locate it over the 2 tabs.
esp9496
16
Installation and Servicing
Section 2 - Installation
2.7 FLUES AND LOCATIONS
7KLVLQVWDOODWLRQ VHUYLFLQJPDQXDOPXVWEHUHDGLQFRQMXQFWLRQZLWKÀXHNLWDQG¿WWLQJJXLGH
Telescopic horizontal flue 0.5 or 0.7 m
Horizontal flue 0.6 or 0.8 m
Flue extension 0.5 m, 1 m or 2 m
Flue deflector
Vertical flue terminal and connector
Ideal part no. 0.5 m 208169 0.7 m 208174
Flue elbow 90°
Ideal part no. 0.6 m 208171 0.8 m 217442
Flue elbow 45°
Ideal part no. 0.5 m 211037
1 m 203129 2 m 211038
Weather collar pitched roof
Ideal part no. 208176
Weather collar flat roof
Ideal part no. 211039
Ideal part no. 203130
Balcony flue kit
Ideal part no. 203131
Ideal part no. 152258
Ideal part no. 152259
Soffit kit
Raised horizontal flue kit
Ideal part no. 208177
Ideal part no. 211302
Ideal part no. 208290
WARNING:
· It is critical that products of combustion cannot re-enter the building
· 7KHÀXHWHUPLQDOPXVWDOZD\VKDYHDIUHHSDVVDJHRI air.
CAUTION:
:KLWHVHFWLRQVRIWKHÀXHPXVWQRWEHYLVDEOHRXWVLGH. ,QVWDOODÀXHWHUPLQDOJXDUGZKHUHWKHÀXHWHUPLQDOLVOHVV
than 2 metres above a platform where persons can walk or come into contact with the terminal. :DWHULVWKHRQO\SHUPLWWHGOXEULFDQWIRUÀXHDVVHPEO\
Terminal MUST be fitted as shown
Rubber Terminal Wall Seal
Installation and Servicing
17
FLUE OUTLET
Section 2 - Installation 2.8 FLUES AND LOCATIONS - CONTINUED
L
B
26 mm 52 mm 78 mm 104 mm
1 m 2m
3m 4m
B = Top Clearance Top Clearance is measure from the top of the turret to the top RIWKHKROHZKHUHWKHÀXHWHUPLQDWHV
/ (HFWLYHÀXHOHQJWK
7KHHHFWLYHOHQJWKRIWKHÀXHLVPHDVXUHGIURPWKHHGJHRI WKHWXUUHWWRWKHÀXHWHUPLQDOOLS
Flue systems that require extension kits must be installed ZLWKDGHFOLQHIURPWKHÀXHWHUPLQDOEDFNWRWKHERLOHU $GHFOLQHFDQEHDFKLHYHGE\GHVLJQLQJWKHÀXHZLWKD PPULVHSHUPHWHUOHQJWKRIÀXH
IMPORTANT INFORMATION ,QVWDOOWKHÀXHLQDFFRUGDQFHWR%6 Position the terminal, so the products of combustion do not cause a nuisance.
The terminal outlet duct must not be closer than 25 mm to combustible material.
7KHÀXHLVVHFXUHGLQWKHZDOOXVLQJHLWKHUVDQGDQGFHPHQW or heatproof silicone.
7KHÀXHPXVWEHVXSSRUWHGE\DEUDFNHWHYHU\PHWUHRIÀXH OHQJWKDQGDWHYHU\FKDQJHRIGLUHFWLRQ&RQFHDOHGÀXHV must have inspection hatches no more than 1.5 metres from joints.
Where possible inspection hatches should be located at change of directions. Where this is not possible then bends must be viewable from both sides.
Inspection hatches must be at least 300 mm2.
Horizontal
0D[LPXP(HFWLYH)OXH/HQJWK
24 kW
9.0 metres
30 kW
8.0 metres
35 kW
6.0 metres
Vertical
24/30/35 kW
7.5 metres
(OERZVLQFUHDVHUHVLVWDQFHDQGKDYHDQHHFWLYHÀXH
length equivalence. The following table is an example.
Part
Resistance
45o elbow
0.6 metres
90o elbow
1.0 metres
Table 5 - Flue Terminal Position
Flue Terminal Positions
0LQ6SDFLQJ
Directly below, above or alongside an opening. 300 mm
Below guttering, drain pipes or soil pipes.
75 mm
25 mm*
Below eaves.
200 mm
25 mm*
Below balconies or a car port roof.
200 mm
25 mm*
From vertical drain pipes or soil pipes.
150 mm
25 mm*
From an internal or external corner or a
300 mm
boundary alongside the terminal.
25 mm*
7. Above adjacent ground, roof or balcony level.
300 mm
From a surface or a boundary facing the terminal. 600 mm
From a terminal facing a terminal.
1200 mm
From an opening in a car port into dwelling.
1200 mm
Vertically from a terminal on the same wall.
1500 mm
+RUL]RQWDOO\IURPDWHUPLQDOZDOO
PP
+RUL]RQWDOO\IURPDQDGMDFHQWZLQGRZ
PP
Facing an opening into an adjacent building
2000 mm
At an angle to the boundary
90°
300 mm
45°
600 mm
Parallel to a boundary
300 mm
Below ground level open light well
a) Below ground <1,000 mm
E $ERYHÀRRUOHYHO c) From side
PP 300 mm
d) From facing surface
600 mm
2QO\RQHUHGXFWLRQGRZQWRPPLVDOORZHGSHULQVWDOODWLRQ
18
Installation and Servicing
FLUE OUTLET
Section 2 - Installation 2.9 HORIZONTAL FLUE POSITIONS
8 Facing the boundary
1
600 300 300 600
2000
2 3
5 4
1
3
2
14 Opening in adjacent
7
32
building
Boundary
1 13
16 6 8
4
1
12
1
10
5
6
11
300 15
Boundary
600
7
a. < 1000
300 c.
300
600 d.
6 14
9
300 b.
16 Parallel to the boundary 1
3 2
17 15 At an angle to the
boundary 1
2 3
All measurements : mm
Refer to Table 5
2.10 VERTICAL FLUE POSITIONS
Height Difference `A'
Less than 300
B = 300
Greater than 300
B = 1500
690 Fixed
Separation Distance
`B'
Height Difference
`A'
600
600
600
2000 300
Boundary
Boundary
All measurements : mm
2000
600 2000
625
fixed
300
Refer to Table 5
Installation and Servicing
19
FLUE OUTLET
Section 2 - Installation
2.11 FLUE SYSTEM DIMENSIONS
Flue Design
IMPORTANT:
)OXHOHQJWKVPD\YDU\DOZD\VPHDVXUHÀXHOHQJWKV before cutting.
(HFWLYHÀXHOHQJWKDQGDFWXDOÀXHOHQJWKDUHGLHUHQW measurements.
(HFWLYHÀXHOHQJWKLVPDGHXSRIWKHÀXHOHQJWK HTXLYDOHQFHDQGWKHÀXHVHFWLRQVEHWZHHQWKHWXUUHW elbows and terminal.
$FWXDOÀXHOHQJWKLVWKHDPRXQWRIÀXHQHHGHGWRDFKLHYH WKHHHFWLYHÀXHOHQJWKWKLVLQFOXGHVLQVHUWLRQV
30
30
2.12 FITTING THE TURRET
(QVXUHWKHFRQGHQVDWHWUDSLQ¿OOHGZLWKZDWHU
(QVXUHWKHUXEEHUVHDOLVQRWGDPDJHGDQG¿WWHG correctly on the appliance manifold.
)LUPO\KROGWKHÀXHDQGSXVKWKHWXUUHWRQXQWLOLWKDV WUDYHOOHGPPHQVXULQJWKHÀXHKDVQRWURWDWHGRU moved forward.
4. Push the turret into the manifold ensuring the upper SODVWLFOLSLVÀXVKZLWKWKHWRSRIWKHPDQLIROG
5. Fully engage the clamp location section into the manifold ORFDWLRQKROHDQGURWDWHGRZQRQWRWKHÀDQJH
6. Use the securing screws to secure the clamp to the appliance.
7. Ensure all sample points are accessible and all sample SOXJVDQGFDSVDUH¿WWHG
Turret insertion (mm)
Elbow insertion (mm)
D
Flue Outlet
A - Duct Assembly B - Flue Turret C - Turret Clamp D - Seal
A B
Flue Outlet C
Retaining screw
Sample points
Clamp Lugs
FLUE OUTLET WALL
Part PÀXHOHQJWK
Actual Insertion /HQJWK
1000 mm 30 mm
90° elbow PÀXHOHQJWK 90° elbow
1000 mm
n/a 30 mm
n/a
PÀXHWHUPLQDO 600 mm 30 mm
Total
(HFWLYH /HQJWK 970 mm 1000 mm 970 mm 1000 mm
570 mm
4.510 mm
100mm
Edge of turret to outside face of wall plus
44mm = flue length
A
20
Installation and Servicing
Section 2 - Installation
2.13 CUTTING THE FLUE
CUTTING HORIZONTAL FLUE TERMINAL QRQWHOHVFRSLF 0HDVXUHWKHUHTXLUHGFXWÀXHOHQJWK$PP 2. Measure from the outer terminal lip to the end of outer
tube. Mark the required cut length (A + 44 mm) around the circumference of the outer tube and cut following the mark to ensure it is cut square. 3. Mark and cut the inner tube 10 mm longer than the outer tube ensure the cut is square. 4. Remove all burrs on the inner and outer tube and place a light chamfer on the inner tube to aid with assembly.
10 mm Mark Cut Length = "A" + 44 mm from terminal lip
A + 44 mm
SETTING TELESCOPIC FLUE 1. Measure the required length (A + 44 mm) 3XOOÀXHDSDUWXQWLOWKHGHVLUHGOHQJWKLVDFKLHYHG
ensuring the stop mark is not visible. (QVXUHERWKÀXHVHDPVDUHDWWKHWRSDQGWKHÀXHRXWOHW
terminal is uppermost. 4. Drill a 3.5 mm hole through the small and large outer
tube using the pilot hole on the large outer tube. 5. Secure large and small outer tube using the screws
provided. 6. Seal the joint on the out tube with the tape provided. 7. Fit the internal and external wall seals.
10 mm Adjust to Length = "A" + 44 mm from terminal lip
+14 mm +14 mm
Wall Thickness
Mark 2
Mark 1
3ODFHWKHWHUPLQDOHQGRIWKHÀXHLQWRWKHPPFRUH drilled centrally and slowly apply slight pressure and PRYHWKHÀXHXSRUGRZQRUVLGHWRVLGH7KLVZLOOFDXVH WKHH[WHUQDOZDOOVHDOWRIROGLQDQGDOORZWKHÀXHWRSDVV through the wall.
:KHQWKHLQQHUZDOOVHDOLVÀXVKDJDLQVWWKHZDOOSXOO EDFNWKHÀXHXQWLO0DUNLVÀXVKZLWKWKHLQQHUZDOO surface.
+ROGWKHÀXHVWHDG\DQGSXVKWKHLQQHUZDOOVHDO towards the wall until Mark 2 is just visible.
FITTING THE FLUE THROUGH THE WALL ([WHUQDO,QVWDOODWLRQ
1. Follow steps 1 - 5 from above.
3XVKWKHÀXHWKURXJKWKHPPFRUHGULOOHGKROHIURP the outside
5HWXUQLQVLGHWKHSURSHUW\DQG¿WWKHLQQHUZDOOVHDOWR WKHÀXH
3XOOWKHÀXHLQWHUQDOO\XQWLO0DUNLVÀXVKZLWKWKHLQQHU wall surface.
+ROGLQJWKHÀXHLQWKLVSRVLWLRQSXVKWKHLQQHUZDOOVHDO towards the wall until Mark 2 is just visible.
,I0DUNLVQRWÀXVKZLWKWKHLQQHUZDOOVXUIDFHDQGFDQEH seen prior to the wall surface, then the external wall seal ZLOOKDYHEHHQGLVORGJHGDQGZLOOUHTXLUHWREHUH¿WWHG,I this situation occurs, then please start the process from the beginning. 2QFRPSOHWLRQWKHÀXHZLOOEHFRUUHFWO\LQVWDOOHGDVEHORZ
FLUE OUTLET
Drill Hole
Adhere sealing tape
Mark 2 Flush with the inner wall seal
FITTING THE FLUE THROUGH THE WALL ,QWHUQDO,QVWDOODWLRQ
1. Measure the thickness of the wall.
2. To this measurement add 14 mm. 0DNHDPDUNRQWKHÀXHVKRZQDVPDUNEHORZ 0DNHDQRWKHUPDUNRQWKHÀXHDIXUWKHUPPLQVKRZQ
as Mark 2 above right. )LWWKHH[WHUQDOZDOOVHDOEODFN WRWKHÀXHWHUPLQDO
HQVXULQJLWLV¿WWHGRQWKHWHUPLQDORXWHUOLSVHDO
6. Fit the inner wall seal approximately 65 mm prior to Mark 2.
Mark 1 Flush with inter wall
125 mm Cored drilled hole
Correctly sealed wall seal
IMPORTANT: (QVXUHQR:KLWHÀXHLVYLVLEOHEHWZHHQ WKHÀXHWHUPLQDODQGWKHZDOO
Installation and Servicing
21
Section 2 - Installation
$YLGHRVKRZLQJKRZWRFRUUHFWO\ PHDVXUHDQG¿WDÀXHFDQEH IRXQGE\YLHZLQJWKH45&RGH
SCAN
for Flue Fitting Video's
For the full range of
FLUE AND ACCESSORIES
please visit idealheating.com/ ÀXHV
SCAN
for Flues and Accessories Guide
min 25o max 45o
2.14 ASSEMBLING THE VERTICAL FLUE
'HWHUPLQHWKHFRUUHFWKHLJKWWKDWWKHÀXHVKRXOGWHUPLQDWHDERYHWKH URRI,IDIWHUFDOFXODWLQJRUPHDVXULQJWKHRYHUDOOÀXHKHLJKWIURPWKHWRS of the boiler, it is necessary to cut both pipes of assembly A, then ensure WKH\DUHFXWHTXDOO\OHDYLQJWKHLQQHUÀXHWXEHORQJHUWKDQWKHRXWHUDLU tube as supplied.
Ensure the cut pipe ends are free from any burrs.
3RVLWLRQWKHURRIÀDVKLQJSODWHVXSSOLHGVHSDUDWHO\ RYHUWKHKROH FXWLQWKHURRIDQGLQVHUWÀXHWHUPLQDOIURPWKHURRIHQG
Fit the vertical connector (supplied in kit) in accordance with the instructions provided.
Secure the vertical connector by applying downward pressure on the connector.
3RVLWLRQWKHFODPSRQWKHWRSIDFHRIWKHÀXHPDQLIROGDQGSXVK LWKRUL]RQWDOO\EDFNZDUGV/RFDWHERWKFODPSOXJVLQWRWKHÀXH PDQLIROGDQGVHFXUHWRWKHÀXHPDQLIROGZLWKWKH0UHWDLQLQJVFUHZ
MAX LENGTH: 7.5m
BOILER
nm8739
1
Flue Terminal
1RWH&KHFNWKHSRVLWLRQRIWKHLQQHUÀXHGXFW relative to the outer duct on the assembled H[WHQVLRQGXFWV DQGHQVXUHWKHWHUPLQDOÀXH duct is cut longer than the air duct to ensure HQJDJHPHQWLQWKH¿QDOÀXHGXFWVHDO
)LQDOO\HQVXUHWKHURRIÀDVKLQJSODWHLV correctly sealed to the roof.
weather collar flat roof
weather collar pitched roof
5
6
'X'
Push extension duct (if required (supplied separately)) into vertical
4
connector.
1RWHEnsure turret sample points are servicable and all caps and plugs DUH¿WWHG)LOOWKHFRQGHQVHWUDSVLSKRQZLWKZDWHU
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.
22
Extension Duct
Vertical connector
2
Installation and Servicing
FLUE OUTLET
Section 2 - Installation
2.15 CONDENSATE DRAIN
Condensate
38
Drain
129.5
44
7KLVDSSOLDQFHLV¿WWHGZLWKDVLSKRQLFPPFRQGHQVDWH WUDSV\VWHPWKDWUHTXLUHV¿OOLQJEHIRUHRSHUDWLQJWKH appliance for the 1st time or after maintenance.
$OOFRQGHQVDWHSLSHZRUNVKRXOGFRQIRUPWRWKHIROORZLQJ
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.
E 3ODVWLFZLWKSXVK¿WRUVROYHQWFRQQHFWLRQV
c. Internal plastic pipe work a minimum of 19 mm ID (typically 22 mm OD).
d. External plastic pipe must be a minimum of 30 mm ID (typically 32 mm OD) before it passes through the sleeved wall.
H $OOKRUL]RQWDOSLSHUXQVPXVWIDOODPLQLPXPRIPP per metre away from the Boiler.
f. External & unheated pipework should be kept to a minimum and insulated with Class "O" waterproof pipe LQVXODWLRQWKURXJKIUHH]LQJRURWKHUZLVH
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 WKURXJKIUHH]LQJ
i. All internal burrs should be removed from the pipe work DQGDQ\¿WWLQJV
,QRUGHUWRPLQLPLVHWKHULVNRIIUHH]LQJWHUPLQDWHWKH
condensate drainage pipe using one of the following PHWKRGV
Internal Drain Connections Route the condensate pipe by gravity to an internal, foul water discharge point.
Refer to Fig.
&RQGHQVDWH3XPS When it is not practical to terminate the condensate pipe to an internal foul water discharge point using gravity, use a suitable pump recommended by the boiler or pump manufacturer.
Refer to Fig. 3
External Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously. An external system must terminate at a suitable foul water discharge point or purpose designed soakaway. If an external system LVFKRVHQWKHQWKHIROORZLQJPHDVXUHVPXVWEHDGRSWHG
The external pipe run should be kept to a minimum using the most direct and "most vertical" route possible to the GLVFKDUJHSRLQWZLWKQRKRUL]RQWDOVHFWLRQVLQZKLFK condensate might collect.
- For connections to an external soil/vent stack.Insulation measures as described should be used.
Refer to Fig. 4
- When a rainwater downpipe is used, an air break must be installed between the condensate drainage pipe and WKHGRZQSLSHWRDYRLGUHYHUVHÀRZRIUDLQZDWHULQWRWKH ERLOHUVKRXOGWKHGRZQSLSHEHFRPHÀRRGHGRUIUR]HQ
Refer to Fig. 5
- Where the condensate drain pipe terminates in a purpose designed soakaway (see BS 6798) any above ground condensate drain pipe sections should be run and insulated as described above.
Refer to Fig. 6
- Where the condensate drain pipe terminates over an open foul drain or gully, the pipe should terminate below the grating level, but above water level, to minimise "wind chill" at the open end. The use of a drain cover DVXVHGWRSUHYHQWEORFNDJHE\OHDYHV PD\RHU further prevention from wind chill.
8QKHDWHG,QWHUQDO$UHDV Internal condensate drain pipes run in unheated areas, e.g. lofts basements and garages, should be treated as external pipe. (QVXUHWKHFXVWRPHULVDZDUHRIWKHHHFWVFUHDWHGE\D IUR]HQFRQGHQVDWHDQGLVVKRZQZKHUHWKLVLQIRUPDWLRQFDQ be found in the user manual. 1RWHPlease check current HHIC condensate discharge guidance available via the Gas Safe Registered Technical Bulletins List.
FLUE OUTLET
Installation and Servicing
continued . . . . .
23
Section 2 - Installation
2.16 CONDENSATE DRAIN - CONT'D
Figure 1 - Connection of Condensate Drainage Pipe to Internal Soil & Vent Stack
Boiler with 75 mm
sealed condensate
trap
Min Ø 19 mm Internal pipe
Figure 2 - Connection of a Condensate Drainage Pipe Downstream of a Sink, Basin, Bath or Shower Water Trap to Internal Soil Vent Stack
Boiler with 75 mm
sealed condensate
trap
Min Ø 19 mm Internal pipe
Internal soil & vent stack
PP
Soil & vent stack
PP
Minimum connection height up to 3 storeys
Sink/basin/ bath or shower
Figure 3 - Connection of a Condensate Pump Typical Method (see manufacturer's detailed instructions)
Boiler with 75 mm
sealed condensate
trap
Min Ø 19 mm Internal pipe
Visible air break
Condensate pump (Install in accordance with manufacturers instructions)
75 mm Soil & vent stack PP
Figure 4 - Connection of Condensate Drainage Pipe to External Soil & Vent Stack
Boiler ZLWKPP
sealed condensate
trap
Min Ø 19 mm Internal pipe
Water/weather proof insulation
0LQPP Internal pipe
Minimum connection height up to 3 storeys
Figure 5 - Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe (only combined foul/rainwater drain)
Boiler with 75 mm
sealed condensate
trap
Min Ø 19 mm Internal pipe
Min Ø 30 mm Internal pipe
Water/ weather proof insulation
Combined foul/ rain water drain
Terminated and cut at 45º
External air break
Air gap
43 mm 90º male/ female bend
68 mm Ø PVCU Strap on fitting
24
Figure 6 - Connection of a Condensate Drainage Pipe to an External Purpose Made Soakaway.
Boiler with 75 mm
sealed condensate
trap
Min Ø 19 mm Internal pipe
Min Ø 30 mm Internal pipe
Water/Weather proof insulation
Max 3 m external pipework
Terminated and cut at 45º
Limestone chippings
URZVRIWKUHHPPKROHV PPFHQWUHVPPIURP WKHERWWRPRIWKHWXEHIDFLQJ
away from the house
Installation and Servicing
FLUE OUTLET
INSTALLATION
Section 2 - Installation
2.17 CONNECTIONS & FILLING
CAUTION: Heating the isolation valves may damage the ¿EUHVHDOV )LWHDFKXQLRQZLWKWKH¿EUHVHDOVSURYLGHG
PRV DRAIN
The PRV connection, located at the bottom right-hand side of the boiler.
WATER CONNECTIONS CH &RQQHFWWKH&+ÀRZVHUYLFHYDOYHEODFNKDQGOH DQG
copper tail provided in the hardware pack to the threaded boss connection provided at the lower rear of the boiler. Connect the CH return. valve (black handle) and copper tail.
WATER CONNECTIONS DHW Fit the DHW inlet service valve (blue handle) and copper
tail to the threaded boss connection ensuring the seal provided is correctly located. Fit the DHW outlet pipe tail to DHW outlet connection, ensuring the seal provided is correctly located. )LWWKH¿OOLQJORRSSURYLGHGEHWZHHQWKH'+:LQOHWYDOYH and the CH return valve.
7KHGRPHVWLFKRWZDWHUÀRZUDWHLVDXWRPDWLFDOO\ UHJXODWHGWRDPD[LPXP
N:
L/m
gpm
24
9.9
2.2
30
12.4
2.8
35
14.5
3.2
WARNING:Make sure that the water or steam (from the boiler) is discharged safely. Hot water or steam is dangerous and can cause serious injury, and damage to electrical systems.
GAS CONNECTION CAUTION: The gas service cock is sealed with a nonPHWDOOLFEOXH¿EUHZDVKHUZKLFKPXVWQRWEHRYHUKHDWHG when making capillary connections.
)RUGHWDLOVRIWKHSRVLWLRQRIWKHJDVFRQQHFWLRQ
Refer to Section
Refer to Gas Supply
CH Flow
DHW Outlet
Gas Supply
DHW Inlet
CH Return
Filling Loop
Installation and Servicing
25
INSTALLATION
Section 2 - Installation
2.18 CONNECTIONS & FILLING CONTINUED
FILLING WARNING: Protect electrical connections from water
1. &RQQHFWWKH¿OOLQJORRSHQVXULQJWKHZDVKHUVDUHLQ place.
2. Loosen the auto air vent dust cap.
Refer to Section
3. Check the following isolation handles on water FRQQHFWLRQVDUHLQWKHKRUL]RQWDO¿OOLQJSRVLWLRQEOXH handle on DHW inlet and black handle on CH return C ).
4. 3RVLWLRQWKH&+ÀRZLVRODWLRQYDOYHKDQGOHLQWKHYHUWLFDO SRVLWLRQWRHQDEOH¿OOLQJ
5. 6ORZO\WXUQWKH¿OOLQJORRSKDQGOHJUHHQ B ) to the KRUL]RQWDORSHQSRVLWLRQXQWLOWKHSUHVVXUHJDXJHUHDGV between 1 to 1.5 bar.
6. 7XUQWKH¿OOLQJORRSKDQGOHJUHHQ B ) back to the closed (vertical) position.
7. Turn the CH Return handle (black C ) and the DHW Inlet handle (blue ) to the open (vertical) position.
8. 'LVFRQQHFWWKH¿OOLQJORRSIURPWKH'+:,QOHWYDOYHDQG ¿WWKHJUH\FDSWRWKHRSHQHQG
9. )LWWKH3OXJWRWKHIUHHHQGRIWKH¿OOLQJORRS
Top Up 1. &RQQHFWWKH¿OOLQJORRSHQVXULQJWKHZDVKHUVDUHLQ
place. 2. Loosen the auto air vent dust cap.
Refer to Section
3. Turn the DHW Inlet handle (blue WRWKHKRUL]RQWDO position.
4. 6ORZO\WXUQWKH¿OOLQJORRSKDQGOHJUHHQ B ) to the KRUL]RQWDORSHQSRVLWLRQXQWLOWKHSUHVVXUHJDXJHUHDGV between 1 to 1.5 bar.
5. Turn the handle (green B RQWKH¿OOLQJORRSEDFNWRWKH closed (vertical) position.
6. Turn the DHW Inlet handle (blue ) to the open (vertical) position.
7. 'LVFRQQHFWWKH¿OOLQJORRSIURPWKH'+:,QOHWYDOYHDQG ¿WWKHJUH\FDSWRWKHRSHQHQG
8. )LWWKH3OXJWRWKHIUHHHQGRIWKH¿OOLQJORRS
SCAN for video
)LOOLQJ6\VWHP3RVLWLRQVVKRZQ
Filling Loop
Cap Plug
7RS8S3UHVVXUH3RVLWLRQVVKRZQ
Filling Loop
Cap Plug
A
DHW Inlet %OXH
B
B
A
DHW Inlet %OXH
Filling Loop *UHHQ
26
C
CH Return %ODFN
Filling Loop *UHHQ
C
CH Return %ODFN
Installation and Servicing
INSTALLATION
Section 2 - Installation
2.19 ELECTRICAL CONNECTIONS
WARNING: This appliance must be earthed
$PDLQVVXSSO\RI9a+]LVUHTXLUHG 3 A fuse required. All external controls and wiring must be suitable for mains voltage. Wiring external to the boiler must follow current I.E.E (BS7671) wiring regulations and local regulations.
Wiring should be 3 core PVC insulated cable, not less than 0.75 mm2[PP DQGWR%6(1 Table 16.
Connection must be made in a way that allows complete isolation of the electrical supply. The means of isolation must be accessible to the user after installation.
2.20 INSTALLER WIRING
WARNING: Ensure the supply cord is not damaged
The boiler must be connected to a permanent live power supply. $FFHVVLQJWKHLQVWDOOHUZLULQJ 1. Isolate the mains supply from the boiler. 2. Remove the front panel.
Refer to Section
3. Swing down the control box into the service position, unclip and swing back the installer wiring cover and latch into the retaining clips.
4. Carefully pierce the grommet, release the cable clamp via the screws and pull wiring through.
5. Connect external wiring to the appropriate connections VHFXUHO\DQGWKHQUH¿WWKHFDEOHFODPS
Once any wiring is completed, to secure the boiler, reverse the order above.
The link wire on the 230 V installer room stat/timer connection gives a demand in conjunction with the timer option plug inside the timer option cover. This is located on the front of the control box.
,QVWDOOHU&RQQHFWLRQV/+6
,QVWDOOHU&RQQHFWLRQV5+6
COMBI
COMBI
FROST STAT OPTIONAL
ROOM STAT/ MAINS IN TIMER L N
FROST STAT OPTIONAL
ROOM STAT/ MAINS IN TIMER L N
Installation and Servicing
OPEN THERM./ WEATHER COMP.
27
INSTALLATION
Section 2 - Installation
2.21 EXTERNAL WIRING
External Controls 230 V 50 Hz
Frost Protection
Wiring a 230V Programmable Room Stat (Diagrams A & C) or 230V Timer & Room Stat (Diagram B).
1. Remove the link wire from the room stat/timer connection.
2. Connect the external cable from the room stat/timer across this connection. If a general live connection is used for the room stat or timer then connect this to the fused spur, on the load side (see Diagram C).
3. If the room thermostat has compensation and requires a neutral connection, make this connection to the fused spur, on the load side.
2SWLRQDO([WHUQDO&RQWUROV±([WUD/RZ9ROWDJH
If parts of the pipework run outside the house or if the ERLOHUZLOOEHOHIWRIRUPRUHWKDQDGD\RUVRWKHQDIURVW thermostat should be wired into the system.
This is usually done at the programmer, in which case the programmer selector switches are set to OFF and all the other controls MUST be left in the running position.
The frost thermostat should be sited in a cold place, but where it can sense heat from the system.
Wiring a system frost thermostat, see diagrams E. Wire the frost thermostat across the two connections as shown.
,IWKHERLOHULVLQVWDOOHGLQDJDUDJHLWPD\EHQHFHVVDU\WR¿W a pipe thermostat, preferably on the return pipework.
Wiring OpenTherm Programmable Room Stat (Diagram D).
1. Remove the timer link plug inside the timer option cover, located on the front of the control box.
2. Unclip the timer link socket from the aperture on the rear of the control box, locate the plug on the same harness branch and connect these together.
3. Using the rubber bung located adjacent to these connections, insert it into the open aperture.
4. Connect the external cable from the OpenTherm Programmable Room Stat on the RHS of the boiler installer connections, labelled OpenTherm.
Diagram A: 230 V Programmable Room Stat
Diagram B: 230 V Timer & Room Stat
Programmable Room Stat
Room Stat
Timer
Diagram C: 230 V Programmable Room Stat Use of Live from Isolator
Room Stat
Mains In
Diagram D: OpenTherm Programmable Room Stat
OpenTherm Programmable
Room Stat
Diagram E: 230 V Oponal Frost Stat
Oponal Frost Stat
Room Stat/ Timer
LN
Room Stat/ Timer
LN
Room Stat/ Timer
LN
Open Outside Therm Sensor
Frost Stat
28
Installation and Servicing
29
Installation and Servicing
Key EN%ODFN J\ *UH\ U 5HG J JUHHQ E EOXH EU EURZQ J\ JUHHQ\HOORZ R RUDQJH S SLQN Y YLROHW \ \HOORZ Z ZKLWH
Primary PCB
w o gy
v
X10 1 2 3 45
Mains In N
L
Room Stat /Timer OpZnal Frost Stat
3 21 6 5 4 3 21
X1
X2
g/y
br bk br bk
b
w
g/y
r
r b
3 21 6 5 4 3 216 5 4 3 216 5 4 321 8 765 4 3 21 5 4 321 5 43 21
X3
X4
X5
X6
X7
X8
X9
bk bp
y
p y p y b r bk
b
bk bk bk or
bk bk p b bk bk
r
bk gy v
Flow Thmr
rby
bk
Chassis Connector 5 1
62 73 84
bk r 12345
Water Pressure Switch
5 4 3 2 1 g/y
g/y
21
Diverter Valve
321
Return DHW Thermistor Thmr
1234 5678
vv bk
Aperture Connector
gy
Spark Generator
bk
Electrode b
r
Gas Valve
Chassis Earth
1
2
2
3
3
4
Fan
DHW Flow Turbine
r
1
3
2
2
b
3
1
Pump
vow
Open Therm
Weather Compensaon
INSTALLATION
2.22 WIRING DIAGRAM
Section 2 - Installation
INSTALLATION
Section 2 - Installation
2.23 REPLACING PRE-FITTED MAINS CABLE
If it is necessary to use an alternative mains cable to the one SUH¿WWHGWKHQXVHWKHIROORZLQJJXLGH
Replacement wiring should comply with notes and be carried RXWE\DTXDOL¿HGSHUVRQ
Refer to Section
Isolate the mains supply to the boiler. Remove the front panel. Swing the control box down into the service position,
unclip and swing back the installer wiring cover to latch into the retaining clips. Unscrew the L N & E connections & remove wires from connector. Remove the mains cable by pulling back through the grommet. 5RXWHWKHUHSODFHPHQWWKURXJKWKHJURPPHWDQGUH¿W Close the installer wiring cover ensuring that it is located correctly and that the cable is retained into the strain relief as shown.
Strain 6 Relief
Swing the control box back up into the operating position DQGUH¿WWKHIURQWSDQHOHQVXULQJDJRRGVHDOLVPDGH
The earth connection should be longer than the current carrying connections. If the cord anchorage slips, the current carrying wires become taut before the earth.
2.24 COMMISSIONING AND TESTING
$ (OHFWULFDO,QVWDOODWLRQ
WARNING: Electrical safety checks should be FDUULHGRXWE\DTXDOL¿HGSHUVRQ
Complete preliminary electrical system checks.
General The combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas W\SHGH¿QHGRQWKHDSSOLDQFHGDWDSODWH
Do not adjust the air / gas ratio valve. &KHFNWKHIROORZLQJ 1. The boiler has been installed in accordance with these
instructions.
7KHLQWHJULW\RIWKHÀXHV\VWHPDQGWKHÀXHVHDOVDV described in the Flue Installation Section.
3URFHHGWRSXWWKHERLOHULQWRRSHUDWLRQDVIROORZV
1. Check the operational gas inlet pressure.
2. Set up the boiler to operate at maximum rate by opening KRWWDSWRPD[LPXPÀRZ
3. With the boiler operating in the maximum rate condition check that the operational gas pressure at the inlet gas pressure test point complies with the requirements.
4. Ensure that this inlet pressure can be obtained with all other gas appliances in the property working.
Refer to Gas Supply page 10
% *DV,QVWDOODWLRQ WARNING: Open windows, doors and extinguish ÀDPHVEHIRUHVWDUWLQJWKHQH[WVWHSV'RQRWVPRNH
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.
Purge air from the gas installation by the approved methods only.
Gas Supply
Gas Pressure Test Point
IMPORTANT: A condition of the manufacturer's warranty is that Benchmark commissioning process is FRPSOHWHG7KHÀRZFKDUWLVSURYLGHGRQpage 67.
30
Installation and Servicing
INSTALLATION
Section 2 - Installation
2.25 INITIAL LIGHTING
/HJHQG A. Domestic Hot Water
Temperature Knob B. Central Heating
Temperature Knob C. Mode Button D. Boiler Status Display E. Burner On indicator F. Restart Button 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
2
1
3
0
4
bar
N
A
ED
CF
B
CAUTION: Do not operate the appliance before it has been fully vented of air. If it is necessary to operate the pump, do so with the gas service cock WXUQHGR
The boiler incorporates a fan overrun cycle which must not be interrupted by isolation of electricity supply.
&KHFNWKDWWKHV\VWHPKDVEHHQ¿OOHGDQGWKDWWKHERLOHU is not airlocked.
5H¿WWKHERLOHUIURQWSDQHO
Refer to Section
Check that the drain cock is closed and that the CH and DHW isolating valves (G,K & J) are OPEN.
Press the Mode button until a cross is shown going through ERWKWDSDQGUDGLDWRULFRQVERLOHUR
Switch the electrical supply OFF Check that the gas service cock (I) is OPEN. Slacken the screw in the inlet pressure test point (H) and
FRQQHFWDJDVSUHVVXUHJDXJHYLDDÀH[LEOHWXEH Switch the electricity supply ON and check all external
controls are calling for heat.
CH Flow
G
DHW Outlet
Gas Supply
L
I H
DHW Inlet
J
CH Return
Filling Loop
K M
CENTRAL HEATING
Press the Mode Button (C) until there is no longer a cross through the Radiator icon. Turn the Central Heating Temperature Knob clockwise until a target of 80°C is shown. The boiler control will now go through its ignition sequence until the burner is established.
If the boiler does not light then after 5 attempts the boiler will lock out and display fault code L2. Press the Restart Button (F). The boiler will repeat its ignition sequence. If Restart occurs 5 times within 15 minutes then L 0C will be shown.
:KHQWKHEXUQHULVHVWDEOLVKHGWKHÀDPHV\PERO( ZLOOEH VKRZQRQWKHGLVSOD\DQGWKHFXUUHQWÀRZWHPSHUDWXUHZLOO be shown in the large digits underneath the radiator symbol.
DOMESTIC HOT WATER
:LWKWKHERLOHU¿ULQJURWDWHWKH'+:7HPS.QRE$ clockwise until a target of 65°C is shown and fully open a DHW tap. The boiler should continue to run and the current DHW temperature will be shown in the large digits underneath the tap symbol.
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 DFFRUGLQJWRWKHDLUÀRZSURGXFHGE\WKHIDQ,WLVQRWXVHU adjustable. Any interference to sealed settings on the gas YDOYHZLOODGYHUVHO\DHFWRSHUDWLRQDQGUHQGHURXUZDUUDQW\ void.
Refer to Gas Supply page 10
7XUQRWKH'+:WDS
Remove gas pressure gauge, tighten inlet pressure test point and check for gas tightness.
Installation and Servicing
31
INSTALLATION
Section 2 - Installation
2.26 THE DISPLAY
The user control has one display to inform the user about the status of the boiler. The display shows the status of the ÀDPH,IQRÀDPHLVGHWHFWHGWKHQÀDPHV\PEROZLOOQRWEH YLVLEOH:KHQWKHÀDPHLVGHWHFWHGWKHÀDPHV\PEROZLOO be visible permanently. Below is a list with display function.
%RLOHU20RGH Press the Mode button once to enable DHW or twice to enable CH.
&+2 Press the Mode button until the cross disappears to enable CH.
:LQWHU0RGHQRKHDWGHPDQG
%RLOHULVDFWLYHIRU&HQWUDO Heating
%RLOHULVDFWLYHIRU'RPHVWLF Hot Water
2.27 GENERAL CHECKS
0DNHWKHIROORZLQJFKHFNVIRUFRUUHFWRSHUDWLRQLQ 1 Fully open all DHW taps in turn and ensure that water
ÀRZVIUHHO\IURPWKHP The display should show
then
Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate. This is factory set to give a DHW temperature rise of DSSUR[LPDWHO\ & DW WKH ÀRZ UDWH VWDWHG RQ SDJH under `operation'.
5HGXFHWKH'+:GUDZRUDWHWRDERXWOPLQJSP and check that the boiler modulates to deliver DHW at approximately 65°C.
Close the DHW tap and check that the main burner extinguishes. The pump should overrun for 60 seconds. When the pump VWRSVWKHGLVSOD\VKRXOGVKRZZ
1RWH On systems in excess of 2 bar inlet pressure a water pressure governor may be required to prevent water noise.
&(175$/+($7,1*&+ '20(67,&+27:$7(5 '+: 02'( Ensure that the CH external controls
are calling for heat. 7KHGLVSOD\VKRXOGVKRZ
PH
PREHEAT ON
FP L 01 F 01
%RLOHULVKHDWLQJXSWKH 3ODWH+HDW([FKDQJHU
%RLOHULVDFWLYHIRUERLOHU frost protection: operates if the ambient temperature is below 5°C until it reaches 19°C.
%RLOHULVLQ/RFNRXWIRUD VSHFL¿FHUURUDisplay will show a number after the "L" to indicate which error is detected
%RLOHUKDVDIDXOWIRUD VSHFL¿FHUURUDisplay will show a number after the "F" to indicate which error is detected.
32
Fully open a DHW tap and check that hot water is delivered. The display should show
*DV5DWH 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.
Close the DHW tap. Set the central heating
external controls to OFF. The EXUQHUVKRXOGJRRDQGWKH pump continue to run for two minutes. 7KHGLVSOD\VKRXOGVKRZ &KHFNWKHFRUUHFWRSHUDWLRQRIWKHWLPHULI¿WWHG DQGDOO other system controls. Operate each control separately and check that the main burner responds.
Installation and Servicing
INSTALLATION
Section 2 - Installation
2.28 GENERAL CHECKS - WATER CIRCULATION
WATER CIRCULATION SYSTEM With the system COLD, check that the initial pressure is
correct to the system design requirements.
For pre-pressurised systems, this should be 1.0 bar. 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. :LWKWKHV\VWHPVWLOOKRWWXUQRWKHJDVZDWHUDQG electricity supplies to the boiler and drain down to FRPSOHWHWKHÀXVKLQJSURFHVV 1RWH $ÀXVKLQJVROXWLRQVKRXOGEHXVHGGXULQJWKHÀXVKLQJ SURFHGXUH)OXVKLQJVROXWLRQV)HUQR[6XSHUÀRF6HQWLQHO X300 (new systems) or X400 (existing systems).
Refer to Section
5H¿OODQGYHQWWKHV\VWHPDGGLQKLELWRU5HIHUWRVHFWLRQ 1.17), clear all air locks and again check for water soundness.
Reset the system initial pressure to the design requirement.
Balance the system.
Refer to Section
Check the condensate drain for leaks and check that it is discharging correctly.
Finally, set the controls to the User's requirements. Note 7KHSXPSZLOORSHUDWHEULHÀ\DVDVHOIFKHFNRQFH every 24 hours in the absence of any system demand.
WATER TEMPERATURES
Temperatures can be selected using the CH and DHW thermostats.
7HPSHUDWXUH.QRE Setting Max
Min
&+)ORZ7HPS oC 80
30
'+:2XWOHW oC 65
40
Due to system variations and seasonal temperature ÀXFWXDWLRQV'+:ÀRZUDWHVWHPSHUDWXUHULVHZLOOYDU\ UHTXLULQJDGMXVWPHQWDWWKHGUDZRWDSWKHORZHUWKHUDWH
the higher the temperature, and vice versa.
2.29 RESTART PROCEDURE
LeJHQG
A. Domestic Hot Water Temperature Knob
B. Central Heating Temperature Knob
C. Mode Button D. Boiler Status Display E. Burner On indicator F. Restart Button
2
1
3
0
4
bar
A
ED
C
F
B
If an L code is shown on the display then the boiler can be restarted by pressing the Restart button (F).
Installation and Servicing
33
INSTALLATION
Section 2 - Installation
2.30 ACCESSING THE INSTALLER MODE
To access Installer Mode, press the "MODE" and "RESTART" buttons together for more than 5s.
1. The last 3 faults will be shown. See Frame 4.1 for Fault Code descriptions. 2. "PH" will be shown.
To change the preheat setting press Restart, press Mode, then press Restart again, otherwise press Mode.
7LPHG3UHKHDW)XQFWLRQ
If Preheat is switched On, then preheating will occur at the same times that hot water demands occurred on the previous day.
E.g. If you have a shower at 6am on a Monday, then the boiler will automatically preheat the water for your shower for 6am on a Tuesday.
Consequently the function becomes active 24 hours after it is switched on. This function is designed to maximise comfort, whilst minimising energy consumption. 3. "SH" will be shown.
To run the burner at maximum rate press "RESTART", otherwise press "MODE". 4. "SL" will be shown.
To run the burner at minimum rate press "RESTART", otherwise press "MODE". Note that if the return temperature is less than 40°C then the burner will run at maximum rate
for 30s before ramping down to minimum rate over 60s and then running at minimum rate for 10 minutes. If the return temperature is more than 40°C the burner will immediately ramp down to minimum rate over 60s and then run at minimum rate for 10 minutes. 5. "UF" will be shown.
To activate the Venting function press "RESTART", otherwise press "MODE". The Venting function runs for 5 minutes before automatically returning to normal operation. The diverter valve moves between CH and DHW every 30s. The SXPSDOWHUQDWHVEHWZHHQEHLQJRQIRUVDQGWKHQRIRU 10s. 6. "dU" will be shown.
To move the diverter valve to mid-position for replacement press "RESTART", otherwise press "MODE". 7. "P1" will be shown.
To set the minimum CH pump speed to 100% press "RESTART", otherwise press "MODE". 8. "P7" will be shown.
To set the minimum CH pump speed to 70% press "RESTART", otherwise press "MODE". 9. "SE" will be shown.
For service timer function refer to separate instructions. Press "MODE" to exit.
2.31 HANDING OVER
$IWHUFRPSOHWLQJWKHLQVWDOODWLRQDQGFRPPLVVLRQLQJRIWKHV\VWHPWKHLQVWDOOHUVKRXOGKDQGRYHUWRWKHKRXVHKROGHUE\ WKHIROORZLQJDFWLRQV
Hand the Instructions to the householder and explain his/her responsibilities under the relevant national regulations.
Explain and demonstrate the lighting and shutting down procedures.
The operation of the boiler and the use and adjustment of all system controls should be fully explained to the householder, to ensure the greatest possible fuel economy consistent with the householder requirements of both heating and hot water consumption. Advise the user of the precautions necessary to prevent damage to the system and to the building. In the event of the system remaining inoperative during frosty conditions.
Explain the function and the use of the boiler heating and domestic hot water controls. Explain that due to system YDULDWLRQVDQGVHDVRQDOWHPSHUDWXUHÀXFWXDWLRQV'+: ÀRZUDWHVWHPSHUDWXUHULVHZLOOYDU\UHTXLULQJDGMXVWPHQW DWWKHGUDZRWDS,WLVWKHUHIRUHQHFHVVDU\WRGUDZWKH user's attention to the section in the Users Instructions titled "Control of Water Temperature" and the following statement.
³$GGLWLRQDOO\WKHWHPSHUDWXUHVFDQEHFRQWUROOHGE\ WKHXVHUYLDWKHGUDZRWDSWKHORZHUWKHUDWHWKH KLJKHUWKHWHPSHUDWXUHDQGYLFHYHUVD´
Explain the function of the boiler fault mode. Emphasise that if a fault is indicated refer to "Fault Codes" in the User Guide.
Explain and demonstrate the function of timers and temperature controls, radiator valves etc. for the economic use of the system.
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 re-pressurising procedure and if unable to re-pressurise or if the pressure continues to drop a registered local heating installer should be consulted.
Refer to Section
Explain boiler restart procedure.
Refer to Section
After installation and commissioning please complete the Commissioning Checklist before handover to the customer.
Refer to Page 62
IMPORTANT A comprehensive service should be carried out annually.
Stress the importance of regular servicing by a Gas Safe Registered Engineer. Inform the householder of the guarantee/registration found within the envelope pack and then requirement to UHJLVWHULWWRUHFHLYHWKHIXOOEHQH¿WRIWKHZDUUDQW\
34
Installation and Servicing
SERVICING
Section 3 - Servicing 3.1 SERVICING SCHEDULE
WARNING: Servicing can only be carried out by Gas Safe Registered Engineers Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing &RPEXVWLRQWHVWLQJPXVWEHFDUULHGRXWE\DFRPSHWHQWSHUVRQXVLQJDFRPEXVWLRQDQDO\VHUFRQIRUPLQJWR %6(1
7RHQVXUHWKHFRQWLQXHGVDIHDQGHFLHQWRSHUDWLRQRIWKHDSSOLDQFHLWLVUHFRPPHQGHGWKDWLWLVFKHFNHGDWUHJXODULQWHUYDOV and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually.
For the latest copy of literature, visit our website idealheating.com.
PRELIMINARY INSPECTION
1. Light the boiler and carry out a pre-service check, refer to WKHIDXOW¿QGLQJFKDUW
&KHFNWKHÀXHWHUPLQDODQGWHUPLQDOJXDUGLI¿WWHG IRU damage and obstruction.
&KHFNFRPEXVWLRQE\FRQQHFWLQJWKHÀXHJDVDQDO\VHUWR WKHÀXHJDVVDPSOLQJSRLQWDVVKRZQLQWKHGLDJUDPDQG measure CO and CO2 at maximum rate. Set the boiler to Maximum and Minimum heat inputs.
Refer to Section
If the CO / CO2 ratio is greater than 0.004 please proceed to "Cleaning Procedure". If the CO / CO2 ratio is less than 0.004 please proceed to "Check Procedure".
CHECK PROCEDURE
1. Check all water and gas joints for signs of leakage. Remake any suspect joints ensuring a gas tightness check is carried out if applicable and the water system is FRUUHFWO\UH¿OOHGYHQWHGDQGUHSUHVVXULVHG
2. Proceed to "IMPORTANT".
IMPORTANT 1. If, for any reason, the condensate trap has been removed,
HQVXUHWKHWUDSLVUH¿OOHGZLWKZDWHUEHIRUHUHDVVHPEOLQJ 2. After completing the servicing or exchange of components
always ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve. 3. When work is complete the front panel MUST be correctly UH¿WWHGHQVXULQJWKDWDJRRGVHDOLVPDGH &OHDQWKHV\VWHP¿OWHULI¿WWHG 5. Complete the service section in the Benchmark Commissioning Checklist.
GENERAL
During Servicing, and after any maintenance or change of SDUWRIWKHFRPEXVWLRQFLUFXLWWKHIROORZLQJPXVWEHFKHFNHG - 7KHLQWHJULW\RIWKHÀXHV\VWHPDQGWKHÀXHVHDOV - 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.
CLEANING PROCEDURE 1. Remove the casing. 2. Visually check the appliance for signs of leakage. 5HPRYHWKHÀXHPDQLIROG 4. Remove the fan. 5. Remove the burner. 5H¿WWKHVXPSRXWOHWFRYHU 7. Clean the heat exchanger by pouring warm water across
WKHZKROHKHDWHQJLQHWRÀXVKGHSRVLWVWDNLQJFDUHWR avoid pouring water over the electrode. 8. Check the electrode for damage and clean using an abrasive cloth. Check and adjust the spark gap. Replace the electrode if damaged. 9. Clean out the sump outlet to ensure any debris is removed. 10. Remove and clean the condensate trap and re- prime the trap before re-installing. &KHFNWKH'+:¿OWHUIRUEORFNDJH 12. Re-assemble the components in reverse order. &OHDQWKHV\VWHP¿OWHULI¿WWHG 14. Carry out post service checks on the combustion circuit. See General below. 15. Check the system water quality in accordance with %6 16. Complete the service record in the Benchmark section.
'RQRWRSHUDWHWKHERLOHULIWKHIURQWSDQHOLVQRW¿WWHG
Flue Sampling
Point Air Sample
Point
(QVXUHDOOFDSVDQGVHDOVDUHUH¿WWHGDIWHUXVH
Installation and Servicing
35
SERVICING
Section 3 - Servicing
3.2 REMOVAL / REPLACEMENT OF COMPONENTS
WARNING: Do not operate the boiler without a IURQWSDQHO¿WWHG
:KHQUHSODFLQJDQ\FRPSRQHQW
1. Isolate the electricity supply. 7XUQRWKHJDVVXSSO\ 3. Remove the boiler front panel.
Refer to Section
4. Swing the control box down into its servicing position.
$IWHUUHPRYLQJUHSODFLQJDQ\FRPSRQHQW
5. Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve.
6. Ensure all water connections are tight. 7. Test the appliance for correct and safe operation.
Refer to Section (General)
1RWHV ,QRUGHUWRDVVLVWIDXOW¿QGLQJWKHFRQWUROSDQHOKDVDQ
LCD diagnostic display. The key to boiler fault conditions is shown in Section 4.
2. In order to replace components in Sections , and -, it is necessary to drain the boiler.
3.3 DRAINING THE BOILER
Refer to Section
CENTRAL HEATING CIRCUIT &ORVHDOOWKH&+ZDWHULVRODWLQJYDOYHVRQERWKWKHÀRZ
and return. 7RGUDLQWKHSULPDU\KHDWH[FKDQJHUFLUFXLW2SHQWKH
drain valve and attach a length of hose to the CH drain point. 3. After replacing any component on the boiler, remove the hose, close the drain valve and open all system isolating valves. 5HSUHVVXULVHE\UHFRQQHFWLQJWKH¿OOLQJORRSFKHFNIRU leaks before proceeding to check operation of the boiler. 'LVFRQQHFW¿OOLQJORRS
DOMESTIC HOT WATER CIRCUIT 1. Close all the DHW water isolating valves on the boiler
inlet. 7RGUDLQWKHGRPHVWLFKRWZDWHUFLUFXLW$VWKHUHLVQR
direct drain for the domestic hot water circuit, depending on the location of the boiler, opening the lowest hot water tap may drain this circuit. However it must be noted that some residual water will be released during replacement of components. 3. After replacing any component on the boiler, open isolating valve.
PRV
CH
DHW
Gas
DHW
Flow
Outlet
Inlet
CH Return
CH Circuit Drain
36
Installation and Servicing
SERVICING
Section 3 - Servicing
3.4 BOILER FRONT PANEL REMOVAL / REPLACEMENT
REMOVAL
1. Loosen the two screws retaining the front panel.
2. Pull the two clips down to disengage and pull panel forward and upward and remove.
REPLACEMENT
3. Hook the panel onto the top retaining clips.
4. Push the panel until the 2 bottom spring clips engage ensuring the 2 knobs and 2 buttons line up with the holes in the front panel.
5. Re-tighten the two retaining screws.
2 3
1
View from bottom of boiler
View from top of boiler
3.5 FLUE MANIFOLD REMOVAL/REPLACEMENT
1. Remove the two sump cover retaining screws. 2. Remove the sump cover. 3. Lift the manifold upwards to clear the sump. 4. Move the manifold to the left and pull down to remove.
Installation and Servicing
37
SERVICING
Section 3 - Servicing
3.6 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING
1. Disconnect the electrical leads from the fan.
2. Remove the clip from the gas control valve outlet and ease the pipe upwards. Rotate and then ease down to remove.
3. Remove the extended nut on the fan mounting bracket.
/LIWRIDQDQGYHQWXULDVVHPEO\
8QGRWKHWZR0VFUHZVDQGUHOHDVHWKHQR]]OH assembly.
6. Inspect the injector for blockage or damage.
&OHDQWKHRXWVLGHRIWKHLQMHFWRUDQGXVHDVPDOOÀXH brush to clean the injector hole. Do not use anything DEUDVLYHVXFKDVD¿OH
8. Remove the screw and twist venturi anti-clockwise to remove venturi assembly, noting the orientation of the venturi in relation to the fan body.
9. Inspect fan outlet sealing gasket and replace if necessary. 10. Ensure the venturi is free from dust/debris. &KHFNWKHµ2¶ULQJVDUH¿WWHGFRUUHFWO\WRWKHJDVRXWOHW
pipe replacing if any damage is witnessed.
1
3
8
Injector
1R]]OH 5
2 38
Installation and Servicing
SERVICING
Section 3 - Servicing
3.7 BURNER REMOVAL AND CLEANING
Refer to Section
5HPRYHWKHEXUQHUIURQW¿[LQJVFUHZVDQGWKH 2 rear extended nuts.
2. Lift and pull forward the burner from the combustion FKDPEHUE\KROGLQJWKHEXUQHUZLWKWZR¿QJHULQWKHDLU inlet duct and your thumb on the top of the burner.
3. Tilt the burner towards yourself so that it raises to the vertical position.
4. Pull the burner out from the left hand side of the boiler once it is in the vertical position.
SCAN for video
1
1
Place thumb here ,QVHUWWZR¿QJHUV
5. Carefully brush the ceramic burner with a soft non metallic bristle brush.
1
Lift the burner approximately 5 to 10 mm
from the heat engine and then pull forward
by the same amount.
3.8 CLEANING THE HEAT EXCHANGER
5HSODFHWKHVXPSFRYHUSULRUWRWKHZDWHUÀXVKSURFHVV
7KRURXJKO\ÀXVKWKHKHDWH[FKDQJHUE\SRXULQJZDWHU into the top of the combustion chamber ensuring the full surface of the heat exchanger is cleaned. Avoid pouring water over the electrode.
3. Remove the sump cover and clean loose deposits from the sump.
4. Inspect the ignition/detection electrode. Ensure that it is clean and in good condition - replace if necessary.
5. Check that the ignition gap is correct.
Refer to Section
2
Combined Ignition Detection Electrode
Installation and Servicing
39
SERVICING
Section 3 - Servicing
3.9 IGNITION / DETECTION ELECTRODE REPLACEMENT / INSPECTION
Refer to Section
1. Remove the fan.
Refer to Section
5HPRYHWKHÀXHPDQLIROG
3. Remove the burner.
Refer to Section
4. When servicing the boiler inspect the condition of the electrode and check the dimensions shown. If there is damage to the electrode continue to follow steps below for replacment.
5. Unplug the ignition lead from the electrode.
6. Remove the earth lead from the electrode.
7. Remove the 2 screws holding the electrode to the combustion chamber.
8. Remove the electrode.
9. Fit the new electrode, using the new gasket supplied. Check dimensions as shown.
Spark Gap 3.5 mm
Refer to Section
Ignition /Detection Electrode
Straight edge
3 mm
3.10 CLEANING THE CONDENSATE TRAP
CAUTION: Keep trap upright when removing
3XOORWKHUXEEHUSLSHDWWKHVXPS drain.
2. Turn the trap clockwise to disengage and lift to remove.
&OHDQDQG¿OOWUDSZLWKZDWHU
Condensate Drain
Filling Loop
1
SCAN for video
PRV
CH
DHW
Gas
DHW
Flow
Outlet
Inlet
CH Return
CH Circuit Drain
40
Installation and Servicing
Section 3 - Servicing
3.11 DHW FILTER & DHW FLOW REGULATOR CLEANING/REPLACEMENT
Refer to Section
1. Isolate the DHW system.
Refer to Section
2. Turn the housing anti clockwise and pull forward to remove the cartridge. Be prepared for some water release.
8VLQJDSDLURISOLHUVSXOORXWWKHSODVWLF¿OWHUÀRZ regulator.
&OHDQRUUHSODFH¿OWHUDVQHFHVVDU\
5. Reassemble.
6. Reestablish the Cold mains supply to the boiler.
3
SERVICING
3.12 BURNER INJECTOR REPLACEMENT
3.13 BURNER REPLACEMENT
Refer to Section
Installation and Servicing
Refer to Section
SCAN for video
41
SERVICING
Section 3 - Servicing
3.14 RETURN THERMISTOR REPLACEMENT
Refer to Section
1. Isolate and drain down the boiler. 2. Remove the clip from the pump housing and remove
the thermistor. 2
3. Disconnect the electrical lead from the thermistor. 4. Reconnect the electrical lead to the new thermistor
and reassemble, ensuring that the thermistor is fully engaged and the clip is correctly located.
3.15 SPARK GENERATOR REPLACEMENT
Refer to Section
1. Disconnect the leads from the spark generator.
2. Gently push down the generator to release the top clip from the gas valve mounting bracket.
3. Lift the spark generator up and out of the bottom retaining location point.
4. Fit the new spark generator and re-assemble ensuring that the the earth lead is replaced.
42
Installation and Servicing
SERVICING
Section 3 - Servicing
3.16 GAS CONTROL VALVE REPLACEMENT
Refer to Section
1. Disconnect and remove the trap and rubber connector.
Refer to Section
2. Unplug the electrical lead connection from the gas control valve.
3. Remove the outlet gas valve clip and slide the pipe upwards.
4. Undo the gas inlet pipe union at the inlet to the gas valve. 8QGRWKHWZRVFUHZV¿[LQJWKHJDVYDOYHWRWKHFKDVVLV
base and lift the gas valve upwards. 6. Fit the new gas control valve ensuring that the `o' ring
and sealing washer are in place and reconnect gas and electrical connections. 5H¿WWKHWUDSDQG¿OO 8. Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve.
3 5
3.17 DIVERTER VALVE ACTUATOR REPLACEMENT
Refer to Section
7RUHPRYHWKHPRWRU 1. Remove the condensate trap.
Refer to Section
2. Press Down on the hot keys until the diverter valve mid position is highlighted. Ensure that the diverter valve is in mid position.
3ODFHDÀDWEODGHGVFUHZGULYHULQWKHDFWXDWRUVORW provided and ease out the actuator.
4. Disconnect the electrical plug from the motor.
5. Fit the new motor ensuring the arm is correctly engaged in the metal fork and reassemble ensuring the FRQGHQVDWHWUDSLVUH¿OOHGZLWKZDWHU
6. Reconnect the electrical plug to the motor.
Installation and Servicing
1RWHAll spares will be delivered in mid-position. 43
SERVICING
COMBI
Section 3 - Servicing 3.19 CONDENSATE TRAP REPLACEMENT / CLEANING
3.18 PRIMARY PCB REPLACEMENT
1 WARNING: ,WLVFULWLFDOWKDWWKHFRUUHFWERLOHUVL]H and fuel type is entered in to the boiler.
CAUTION: Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis.
Refer to Section
1. Remove and keep the screw.
2. Carefully release the four retaining clips and remove control box cover.
FROST STAT OPTIONAL
ROOM STAT/ MAINS IN TIMER L N
3. Unplug all lead connections to the PCB.
4. Spring out the four side retaining clips and pull the PCB
2
upwards to clear the corner retaining posts.
5. Fit the new PCB.
6. Re-connect all plug connections.
7. Reassemble.
8. Switch mains power on, wait for "uP" to be shown.
9. Simultaneously press Mode & Restart buttons so that "oF" is shown.
10. 6ZLWFKPDLQVSRZHURDQGZDLWIRUV
11. Switch mains power on, wait for "F9 SU" to be shown
12. Rotate the CH Temperature Knob until "F9 C" is shown.
13. Press Restart.
14. Rotate the CH Temperature Knob until "F9 n" is shown.
15. Press Restart.
16. Rotate the Temperature Knob until the appropriate boiler output is shown (24 kW, 30 kW or 35 kW). Press Restart.
17. The boiler type (C), gas type (n), output (24/30/35) and parameter set number will be shown in rotation.
,IWKLVLV2.SUHVV5HVWDUWWRFRPSOHWHWKHFRQ¿JXUDWLRQ RWKHUZLVHVZLWFKPDLQVSRZHURWRVWDUWDJDLQ 4
Refer to Section
2
44
Installation and Servicing
Section 3 - Servicing
3.20 DHW FLOW TURBINE SENSOR REPLACEMENT
Refer to Section
1. Drain the DHW system.
Refer to Section
3XOORWKHHOHFWULFDOFRQQHFWLRQ
3. Using a suitable tool, lift and remove the retaining clip. 4. Use the clip to ease the turbine sensor from its housing. 5. Reassemble.
3
4
SERVICING
3.21 PRESSURE GAUGE REPLACEMENT
Refer to Section
1. Drain the heating system.
Refer to Section
2. Remove the boiler front (see section 2.3), lower the control panel and remove the control box cover.
3. Ensuring there is no pressure in the system unclip the &FOLSIURPWKHÀRZSLSHSRUWDQGUHPRYHWKHFDSLOODU\ connection together with `O' ring.
4. Releasing the two retaining clips on the pressure gauge ease the pressure gauge through the front of the control panel.
5. Fit the new pressure gauge from the front of the lower FRQWUROSDQHOHQVXULQJFRUUHFWRULHQWDWLRQ/RFDWHSXVK¿W FRQQHFWLRQLQWRÀRZSLSHHQVXULQJµ2¶ULQJLQSODFHDQG secure with the C clip.
5H¿OOWKHERLOHU
Refer to Section
3 5
Installation and Servicing
45
SERVICING
Section 3 - Servicing
3.22 PRV REPLACEMENT
Refer to Section
1. Drain the boiler.
Refer to Section
2. Remove the trap and rubber pipe. 3. Pull out and remove the clip retaining the PRV. 4. Lift out the PRV/pipe assembly. 5. Remove the pipe and transfer to the new PRV. 5HDVVHPEOHHQVXULQJWKHUHWDLQLQJFOLSLVFRUUHFWO\¿WWHG
7. Check the operation of the PRV by raising the water pressure until the valve lifts. This should occur within 0.3 bar of the preset lift pressure.
SCAN for video
8. Check no escape of water occurs except at the discharge point
Refer to Section
9. Release water from the system until the minimum V\VWHPGHVLJQSUHVVXUHLVUHDFKHGEDULIWKH
system is to be pre-pressurised.
3
3.23 PUMP AUTOMATIC AIR VENT REPLACEMENT
Refer to Section
1. Drain the boiler.
Refer to Section
2. Remove the expansion vessel.
Refer to Section
3. Firstly, increase access area by disconnecting the 22 mm pipe connection at top of pump manifold and bottom of heat exchanger and remove pipe.
4. The automatic air vent head is retained in the pump body ZLWKDED\RQHWFRQQHFWLRQ7KHDLUYHQWKHDGDQGÀRDW assembly is removed by turning the head anti-clockwise (viewed from above) and pulling upwards.
5. Reassemble. Ensure the air vent head `o' ring seal is ¿WWHG
6. Ensure the air vent cap is loose. 5H¿OOWKHERLOHU&KHFNIRUOHDNVDURXQGWKHQHZDLUYHQW
joint.
Refer to Section
Air Vent Cap
46
Installation and Servicing
Section 3 - Servicing
3.24 REPLACEMENT OF DHW THERMISTOR
Refer to Section
1. Isolate the DHW system 2. Remove the retaining clip and extract the thermistor.
Be prepared for some water release. 3. Disconnect the wiring harness.
4. Fit the replacement thermistor and reassemble.
5. Reestablish the DHW supply, turn on a hotwater tap checking for leaks
DHW Thermistor position
2
SERVICING
3.25 DHW PLATE HEAT EXCHANGER REPLACEMENT
Refer to Section
1. Drain the boiler.
Refer to Section
2. Remove condensate trap.
Refer to Section
3. Remove the 2 hex screws securing the plate heat exchanger to the composite housings.
4. Manoeuvre the plate heat exchanger out of the top LH or centre of the controls area. Be aware of any water spillage.
5. Fit the new plate heat exchanger, using the new o-rings supplied.
1RWH Ensure that the depressions are on the bottom SULRUWR¿WWLQJ
5H¿OOWKHERLOHU
Refer to Section
3
Installation and Servicing
SCAN for video
47
SERVICING
Section 3 - Servicing
3.26 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT
Refer to Section
TRUHPRYHWKHYDOYHERG\DVVHPEO\ 1. Drain the boiler.
Refer to Section
2. Remove the condensate trap.
Refer to Section
3. Remove the electrical plug from the divertor valve. 3ODFHDÀDWEODGHGVFUHZGULYHULQWKHGLYHUWHUYDOYH motor body slot provided and ease out the motor.
Refer to Section
5. Remove the return thermistor electrical connection.
Refer to Section
6. Remove the pump electrical connections. Refer to Section No. 2.
7. Remove DHW Turbine electrical connection. Refer to Section No. 2.
8. Remove the DHW plate heat exchanger (note orientation).
Refer to Section
16
9. Loosen the nut above pump and rotate the pipe. 10. If required remove expansion vessel connection hose.
Refer to Section
11. If required remove connection to PRV discharge pipe. 12. Remove the DHW inlet and CH return connection
situated beneath the boiler. 13. 5HPRYHWKHIRXUWRU[KHDGVFUHZV¿[LQJWKHUHWXUQ
manifold to the boiler sheet steel base. 14. Lift the manifold assembly and remove from boiler. 15. Twist and remove the DHW manifold. 16. 5HPRYHWKHWZRGLYHUWHUYDOYHERG\¿[LQJVFUHZVDQG
withdraw the diverter valve body assembly. 17. Fit the new diverter valve body assembly and replace
WKHWZR¿[LQJVFUHZV 18. 5H¿WWKH'+:PDQLIROG¿WWKHDVVHPEO\EDFNWRWKH
boiler and reassemble. 19. 5H¿OOWKHERLOHUDQGFKHFNIRUOHDNV&KHFNWKDWWKH
boiler operates in both DHW & CH modes.
17
3 9
17
11 12
48
Installation and Servicing
SERVICING
Section 3 - Servicing
3.27 PUMP HEAD REPLACEMENT
3
Refer to Section
1. Drain the boiler.
Refer to Section
2. Disconnect the two electrical leads from the pump. 3. Remove the 4 hex screws retaining the pump head. 4. Remove the pump head.
Be aware of water spillage. 5. Fit the new pump head. 5H¿OOWKHERLOHU
Refer to Section
3
3.28 CH WATER PRESSURE SWITCH REPLACEMENT
Refer to Section
1. Drain the boiler.
Refer to Section
3XOORWKHWZRHOHFWULFDOFRQQHFWLRQV
3. Using a suitable tool, pull out the metal retaining clip.
4. Carefully withdraw the pressure switch.
5. Fit the new pressure switch and reassemble. Ensuring WKDWWKHµ2¶ULQJLV¿WWHGUHSODFHFOLS
5H¿OOWKHERLOHU
Refer to Section
3
2 2
Installation and Servicing
49
SERVICING
Section 3 - Servicing
3.29 FLOW THERMISTOR REPLACEMENT
Refer to Section
1. Drain down the boiler.
Refer to Section
2. Unplug the electrical lead. 5HPRYHWKHFOLSIURPWKHÀRZSLSHDQGUHPRYHWKH
thermistor. )LWWKHQHZWKHUPLVWRUHQVXUHµ2¶ULQJLV¿WWHGDQG
replace clip.
5. Reassemble.
5H¿OOWKHERLOHU
Refer to Section
Shown rotated 90º
3 2
50
Installation and Servicing
SERVICING
Section 3 - Servicing
3.30 HEAT ENGINE REPLACEMENT
Refer to Section
CAUTION: Protect the gas and electrical controls with a waterproof sheet.
Refer to Section
1. Drain the boiler (CH Circuit Drain).
Refer to Section
2. Undo the two screws and remove the sump cover UHWDLQLQJWKHORZHUÀXHPDQLIROG
3. Lift the manifold to clear the bottom sealing gasket and remove manifold.
4. Remove the fan / venturi assembly and place on one side.
Refer to Section
5. Remove the burner and place on one side.
Refer to Section
6. Remove the ignition/detection electrode.
Refer to Section
7. Remove the spark generator.
Refer to Section
8. Remove the gas valve.
Refer to Section
9. Remove the expansion vessel.
Refer to Section
10. Remove the 2 M5 screws retaining the spark generator, mounting bracket and transfer bracket to the new heat exchanger.
11. Undo the pump union nut, remove clip and remove pipe from expansion vessel.
12. Remove the two retaining pipe clips and remove pipes. 13. Remove the condensate rubber pipe.
Refer to Section 1R
5HPRYHWKHWZRKHDWH[FKDQJHU¿[LQJVFUHZV 15. Remove the heat exchanger, slide out of location
bracket. ,IUHSODFHPHQWVXPSUHTXLUHG5RWDWHKHDWH[FKDQJHU
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 DWHDFKWDE¿[LQJSRLQWDQGHQJDJHWDEVRQWRWKHKHDW exchanger.
17. Reassemble, ensuring the heat exchanger is located correctly in the LHS retaining bracket. Replace any new `O' rings supplied with new heat exchanger and replace gaskets or seals if any sign of damage is evident. When replacing the spring clips located on the return pipe connection, ensure clip is oriented to correctly match connecting pipe diametres.
18. (QVXUHWKHWUDSLV¿OOHGZLWKZDWHU
Refer to Section
5H¿OOWKHERLOHUDQGFKHFNIRUOHDNV
Refer to Section
20. Ensure all gas valve connections are gas tight with a gas soundness check up to the gas control valve.
4
5
9
6 14
7
10
14
12
11
11
12
13
18
1
8
Installation and Servicing
51
SERVICING
Section 3 - Servicing
3.31 EXPANSION VESSEL RECHARGING & REPLACEMENT
Refer to Section
RECHARGING
1. Remove the charge point cover.
7
2. Recharge the tank pressure to 0.75 bar.
3. Reassemble.
4. Check that the boiler operates in both DHW & CH modes.
REPLACEMENT
5. Drain the boiler CH circuit.
Refer to Section
6. Remove the retaining clip on the vessel water connection pipe and remove the pipe.
7. Support the expansion vessel and unscrew the 2 screws from the securing bracket, located on the top of the boiler, and remove.
Note the position of the bracket on the vessel.
8. Remove the expansion vessel.
9. Fit the new expansion vessel.
10. Reassemble in reverse order ensuring the clip and the seal is in place.
5H¿OOWKHERLOHUDQGFKHFNIRUOHDNV
Refer to Section
12. Check that the boiler operates in both DHW & CH modes.
Recharge Point
1
6
52
Installation and Servicing
FAULT FINDING
Section 4 - Fault Finding
4.1 FAULT FINDING MAIN MENU
`L 01' `L 02' `L 0C' `L 06' `F 01' `F 02' `F 03' `L 04' or `F 04' `L 05' or `F 05' `F 06' `F 07' `F 09' `F 0C' `F 0U' `L 0d' `F 0t' `F 10' `F 12' `F 13' or `F 15' or `F 17' `F 14' `F 16' `dU' No CH, but HW OK No HW, but CH OK No Display
Go to Section 4.2: Flow Temperature Overheat Lockout Go to Section 4.3: Ignition Lockout
5 Restarts within 15 minutes: Turnpower off & on Go to Section 4.4: False Flame Lockout Go to Section 4.5: Low Water Pressure Go to Section 4.6: Flame Loss Go to Section 4.7: Fan Fault Go to Section 4.8: Flow Thermistor Fault
Go to Section 4.9: Return Thermistor Fault Go to Section 4.10: Outside Sensor Fault Low Mains Voltage: Contact Electricity Provider
PCB Fault: Replace PCB DHW Thermistor Fault: Go to Section 4.15 Go to Section 4.14: Flow/Return Differential greater than 50°C Go to Section 4.3: Ignition Lockout: Blocked Flue/Condensate Room Thermostat Fault: Check Room Stat & connections Spark Generator Fault: Check wiring, if OK replace spark generator
Pump Rotor Blocked: Clear blockage Pump Fault: Check pump wiring, if OK replace pump
High Mains Voltage: Contact electricity provider Gas Valve Fault: Check gas valve wiring, if OK replace gas valve
Diverter Valve in midp-osition for service, press Restart to end Go to Section 4.11 Go to Section 4.12 Go to Section 4.13
Installation and Servicing
53
Section 4 - Fault Finding
4.2 `L 01' - OVERHEAT LOCKOUT
,VWKH%RLOHUDQG&+6\VWHP¿OOHGZLWKZDWHUDQGDOO LVRODWLRQV\VWHP¿OWHUDQGUDGLDWRUYDOYHVRSHQ"
YES ,VWKH)ORZ5HWXUQ'LHUHQWLDODFURVVWKH%RLOHULQ H[FHVVRI&"
NO Check the Flow and Return Thermistors
Refer to Section
Check resistance using a suitable multimeter connected across the thermistor's terminal pins
Temperature 25 oC 60 oC 85 oC
5HVLVWDQFHN 9.7 10.3 2.4 2.6 1.0 1.1
NO
Fill and vent the system and open all
isolation valves, then restart boiler
YES
Check that the Pump is rotating freely. ,VWKH'LHUHQWLDOQRZEHORZ&"
NO
YES
Replace the Pump, then restart boiler
OK, now restart boiler
FAULT FINDING
4.3 `L 02' - IGNITION LOCKOUT
If the boiler is restarted does the boiler ignite for a short time and WKHQH[WLQJXLVK"
YES
Check the electrode and DVVRFLDWHGKDUQHVVIRU continuity, visual condition and position.
Refer to Section
Check if the condensate pipe is blocked. Replace as necessary
NO
Is the Gas Pressure available at
NO
WKH%RLOHU,QOHW!PEDU "
YES
Is approx 24 V DC supply available NO DWWKH*DV9DOYH"
YES
Unplug gas valve. Is resistance
between outside pins between
NO
4k : "
YES
Check spark generator and DVVRFLDWHGKDUQHVVIRUFRQWLQXLW\
NO
and visual condition.
Refer to Section
$UHWKHVHIXQFWLRQLQJFRUUHFWO\"
YES
Check trap and condensate drain
YES Check electrode and associated
NO
pipe work for blockage and rectify
KDUQHVVIRUFRQWLQXLW\YLVXDO
if necessary. Boiler now working 2."
NO
condition and position.
Refer to Section
Replace Gas Valve
$UHWKHVHIXQFWLRQLQJFRUUHFWO\"
Check gas supply and rectify fault
Check wiring connection from gas valve to PCB for continuity. If the wiring is OK then replace the PCB
Replace Gas Valve
Replace Spark Generator and harness as necessary
Replace electrode and associated harness as necessary
54
Installation and Servicing
Section 4 - Fault Finding
4.4 `L 06' - FLAME ON BEFORE GAS VALVE ON
5HVWDUWWKHERLOHUGRHV%RLOHU:RUN2." NO
YES
Check routing and integrity of internal boiler wiring is OK. Check condition of Electrode and replace if deteriorated.
Replace Electrode
4.5 `F 01' - LOW WATER PRESSURE
$UHWKH%RLOHUDQG&+6\VWHP¿OOHGZLWKZDWHUDQGDOOLVRODWLRQDQG
NO
UDGLDWRUYDOYHVRSHQFKHFNSUHVVXUHJDXJHLVEHWZHHQWREDU "
YES $UHFRQQHFWLRQVRQZDWHUSUHVVXUHVZLWFKVHFXUH"
NO YES
Fill and vent the system and open all isolation valves
5H¿WFRQQHFWLRQV
Replace water pressure switch
FAULT FINDING
4.6 `F 02 - FLAME LOSS
Does the boiler ignite for a short
NO
WLPHDQGWKHQH[WLQJXLVK"
YES
Check the electrode and DVVRFLDWHGKDUQHVVIRUFRQWLQXLW\ visual condition and position
Refer to Section
Check if condensate pipe is EORFNHG&KHFNLIÀXHLVEORFNHG Replace as necessary
Is the Gas Pressure available at
NO
WKH%RLOHU,QOHW!PEDU "
YES
Is 24Vdc supply available at the *DV9DOYHZKLOHWKHÀDPHLVRQ"
NO
YES
Check spark generator and associated KDUQHVVIRUFRQWLQXLW\DQGYLVXDO
NO
condition.
Refer to Section
$UHWKHVHIXQFWLRQLQJFRUUHFWO\"
YES
Check electrode and associated harness IRUFRQWLQXLW\YLVXDOFRQGLWLRQDQG
NO
position.
Refer to Section
$UHWKHVHIXQFWLRQLQJFRUUHFWO\"
YES
Check gas supply and rectify fault
Check wiring from gas valve to PCB for continuity. If the wiring is OK then replace the PCB
Replace Spark Generator and Harness as necessary.
Replace electrode and associated harness as necessary
Check trap and condensate drain
NO
pipe work for blockage and rectify
if necessary. Boiler now working
2."
Replace Gas Valve
Installation and Servicing
55
Section 4 - Fault Finding
4.7 `F 03' - FAN FAULT
Does the wiring from the Fan to the PCB have secure connections at both ends and has not GHWHULRUDWHG"'RHVWKHZLULQJKDYHFRQWLQXLW\"
YES
Is there 230 VAC at the Blue and Brown connections WRWKHZD\FRQQHFWLRQRQWKH)DQ"
NO
Rectify Wiring &
connections
NO YES
Replace PCB Replace Fan
FAULT FINDING
4.8 F 04 OR L 04' - FLOW THERMISTOR FAULT
Is the wiring securely connected to the Flow Thermistor Located in the Flow Pipe lower LHS of Boiler
YES
Disconnect the wiring from the Flow Thermistor
Check the resistance using a suitable multimeter connected across the Thermistor's terminal pins.
Temperature 25 oC 60 oC 85 oC
5HVLVWDQFHN 9.7 10.3 2.4 2.6 1.0 1.1
,VWKH7KHUPLVWRUYDOXHFRUUHFW"
YES
Is the wiring securely connected to the low voltage 6 way FRQQHFWRUDWWKHIURQWOHIWKDQGVLGHRIWKH3&%"
NO NO
NO YES
Securely connect the wiring to the Flow Thermistor
Fit a new Thermistor
Securely connect the wiring to the PCB Replace PCB
56
Installation and Servicing
FAULT FINDING
Section 4 - Fault Finding 4.9 `F 05 OR L 05' - RETURN THERMISTOR FAULT
Pump Housing
Check the resistance using a suitable multimeter
connected across the thermistor's terminal pins.
NO
Temperature 25 oC 60 oC 85 oC
5HVLVWDQFHN 9.7 10.3 2.4 2.6 1.0 1.1
,VWKH7KHUPLVWRUYDOXHFRUUHFW"
YES
,VWKHUHFRQWLQXLW\EHWZHHQWKH3&%DQGWKH7KHUPLVWRU"
NO
YES Replace PCB
Fit a new Thermistor Check and replace wiring as necessary
4.10 `F 06' - OUTSIDE SENSOR FAULT
NO Is the wiring securely connected at both the boiler and 2XWVLGH6HQVRU"
YES
Disconnect the wires to the outside sensor.
Check the resistance using a suitable multimeter
connected across the Outside Sensor's terminal pins.
NO
Temperature 5HVLVWDQFHN
0 oC
31.0 35.0
15 oC
15.0 16.5
30 oC
7.7 8.5
,VWKH2XWVLGH6HQVRUYDOXHFRUUHFW"
YES
Is the wiring securely connected between the
NO
incoming terminal block boiler connection of the
2XWVLGH6HQVRUDQGWKH3&%"
YES
Replace PCB
Securely connect the wiring at both the boiler and Outside Sensor
Fit a new Outside Sensor
Securely connect the wiring at the Terminal Block and the PCB
Installation and Servicing
57
Section 4 - Fault Finding
4.11 NO CH OPERATION BUT DHW WORKS OK
,V³2´VKRZQXQGHUQHDWKWKHUDGLDWRURQWKHGLVSOD\"
YES
NO
NO $UH&+7LPHUDQG5RRP7KHUPRVWDWVZLWFKHGRQ"
YES NO
$UHWKH5DGLDWRU9DOYHV2SHQ"
YES
,VWKHUH9DFDW5RRP6WDW7LPHU "
NO
YES
If an OpenTherm Room Stat is not connected,
NO
is there a link wire across the OpenTherm
FRQQHFWLRQV"
YES
Replace the Divertor Valve
3UHVV0RGHEXWWRQXQWLO³2´QRWVKRZQ
Refer to Section
Switch CH Timer and Room Thermostat On
Open the Radiator Valves
No voltage from Timer/Room Stat. This is not a boiler fault. Ensure voltage is supplied to boiler by rectifying external wiring.
Connect a link wire across the OpenTherm connections.
FAULT FINDING
COMBI
FROST STAT OPTIONAL
ROOM STAT/ MAINS IN
TIMER L N
L
N
58
Installation and Servicing
Section 4 - Fault Finding
4.12 NO DHW BUT CH WORKS OK
When a tap is turned on does 00 change to DWHPSHUDWXUH"
NO $UHKRW FROGSLSHZRUNFURVVHG" YES Correct pipe work NO
YES
Is wiring connected between PCB NO Re-connect wiring '+:WXUELQH"
YES
Remove turbine & check for
NO
GHEULVLQWXUELQH ¿OWHU5HSODFH
turbine if necessary.
Replace DHW turbine
$UHWKHÀRZUDWHVFRUUHFW"
Refer to Section
YES
NO $GMXVWÀRZUDWHVWRDFKLHYH& WHPSULVHDQGFKHFN¿OWHU¿WWHGLQ
turbine is not blocked with debris
Is the wiring between the PCB and the diverter NO YDOYHPRWRUFRQQHFWHG"
YES
Reconnect wiring or replace wiring harness if no continuity
Is diverter head fully engaged and clip secured NO RQWRZDWHUVHW"
YES
Re-engage diverter head and secure clip to water set
,VGLYHUWHUYDOYHVWXFNLQ&+SRVLWLRQ" YES
NO Replace PCB
&KHFNDQGUH¿WGLYHUWHUYDOYHDFWXDWRUKHDG,V ERLOHU'+:2."
NO
Change diverter valve motor
FAULT FINDING
A
B
Installation and Servicing
59
Section 4 - Fault Finding
4.13 NO DISPLAY
,VWKHUH9DFWRWKHERLOHUDW/DQG1" YES
Is the wiring from the terminal block to the PCB FRQQHFWHGVHFXUHO\"
YES
5HSODFHWKH3&%"
NO
Supply power to the boiler
NO
Connect the wiring from the terminal block to the
PCB securely.
FAULT FINDING
4.14 `F0U' FLOW/RETURN DIFFERENTIAL GREATER THAN 50°C
$UHLVRODWLRQYDOYHVRSHQ" YES
,VSXPSRSHUDWLQJ"
NO
Open isolation valves
NO
Check pump wiring, if Ok replace pump
YES $UHUDGLDWRUYDOYHVRSHQ"
NO
Open radiators valves
YES Check for system blockages
4.15 F 0C' DHW THERMISTOR FAULT
Disconnect the DHW thermistor electrical connection. NO
Check the resistance using a suitable multi-meter connected across the thermistor's terminal pins.
Temperature 25 oC 60 oC
5HVLVWDQFHN 9.7 10.3 2.4 2.6
,VWKHWKHUPLVWRUYDOXHFRUUHFW" YES
Is there continuity between the PCB and the
NO
7KHUPLVWRU"
YES
5HSODFHWKH3&%"
Fit a new thermistor Check and replace wiring as necessary.
60
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 DQGSHUIRUPDQFHVSHFL¿FDWLRQWKDWZHUHTXLUH'RQRWXVHUHFRQGLWLRQHGRUFRS\SDUWVWKDWKDYHQRWEHHQFOHDUO\ authorised by Ideal. )DLOXUHWRGRVRFRXOGDHFWVDIHW\RUSHUIRUPDQFHRIWKLVDSSOLDQFH
Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on LGHDOSDUWVFRP
LINK to spares
2XU3DUWVWHDPDUHDOVRDYDLODEOHWRKHOSZLWK\RXU,GHDO6SDUH3DUWVHQTXLULHVRQ When calling, and to ensure we can provide you with the most accurate parts information, please ensure you have WKHIROORZLQJWRKDQG - Boiler Model - Appliance GC Number - Boiler Serial Number
Installation and Servicing
61
Section 6 - Benchmark to Commissioning
62
Installation and Servicing
Section 6 - Benchmark to Commissioning
Benchmark Commissioning & Warranty Validation Service Record
It is a requirement that the boiler is installed and commissioned to the manufacturers' LQVWUXFWLRQVDQGWKHGDWD¿HOGVRQWKHFRPPLVVLRQLQJFKHFNOLVWFRPSOHWHGLQIXOO 7RLQVWLJDWHWKHERLOHUZDUUDQW\WKHERLOHUQHHGVWREHUHJLVWHUHGZLWKWKH PDQXIDFWXUHUZLWKLQRQHPRQWKRIWKHLQVWDOODWLRQ7KHZDUUDQW\UHVWVZLWKWKH HQGXVHUFRQVXPHU DQGWKH\VKRXOGEHPDGHDZDUHLWLVXOWLPDWHO\WKHLU UHVSRQVLELOLW\WRUHJLVWHUZLWKWKHPDQXIDFWXUHUZLWKLQWKHDOORWWHGWLPHSHULRG ,WLVHVVHQWLDOWKDWWKHERLOHULVVHUYLFHGLQOLQHZLWKWKHPDQXIDFWXUHUV¶ UHFRPPHQGDWLRQVDWOHDVWDQQXDOO\7KLVPXVWEHFDUULHGRXWE\DFRPSHWHQW*DV 6DIHUHJLVWHUHGHQJLQHHU7KHVHUYLFHGHWDLOVVKRXOGEHUHFRUGHGRQWKH%HQFKPDUN 6HUYLFHDQG,QWHULP%RLOHU:RUN5HFRUGDQGOHIWZLWKWKHKRXVHKROGHU)DLOXUHWR FRPSO\ZLWKWKHPDQXIDFWXUHUV¶VHUYLFLQJLQVWUXFWLRQVDQGUHTXLUHPHQWVZLOOLQYDOLGDWH WKHZDUUDQW\
www.hhic.co.uk
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. )DLOXUHWRLQVWDOODQGFRPPLVVLRQDFFRUGLQJWRWKHPDQXIDFWXUHUV¶LQVWUXFWLRQVDQGFRPSOHWHWKLV%HQFKPDUN&RPPLVVLRQLQJ&KHFNOLVWZLOOLQYDOLGDWHWKH ZDUUDQW\7KLVGRHVQRWDIIHFWWKHFXVWRPHU¶VVWDWXWRU\ULJKWV
$OOLQVWDOODWLRQVLQ(QJODQGDQG:DOHVPXVWEHQRWL¿HGWR/RFDO$XWKRULW\%XLOGLQJ&RQWURO/$%& HLWKHUGLUHFWO\RUWKURXJKD &RPSHWHQW3HUVRQV6FKHPH$%XLOGLQJ5HJXODWLRQV&RPSOLDQFH&HUWL¿FDWHZLOOWKHQEHLVVXHGWRWKHFXVWRPHU
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
Installation and Servicing
63
Section 6 - Benchmark to Commissioning
GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD
Address:
%RLOHUPDNHDQGPRGHO
%RLOHUVHULDOQXPEHU
&RPPLVVLRQHGE\35,171$0(
*DV6DIHUHJLVWUDWLRQQXPEHU
&RPSDQ\QDPH
7HOHSKRQHQXPEHU
&RPSDQ\HPDLO
&RPSDQ\DGGUHVV
&RPPLVVLRQLQJGDWH
+HDWLQJDQGKRWZDWHUV\VWHPFRPSOLHVZLWKWKHDSSURSULDWH%XLOGLQJ5HJXODWLRQV"<HV
2SWLRQDO%XLOGLQJ5HJXODWLRQV1RWL¿FDWLRQ1XPEHULIDSSOLFDEOH
7LPHWHPSHUDWXUHFRQWURODQGERLOHULQWHUORFNSURYLGHGIRUFHQWUDOKHDWLQJDQGKRWZDWHU
<HV
%RLOHU3OXVUHTXLUHPHQWVWLFNWKHDSSURSULDWHER[V
%RLOHU3OXVRSWLRQFKRVHQIRUFRPELQDWLRQERLOHULQ(1*/$1'
:HDWKHUFRPSHQVDWLRQ /RDGFRPSHQVDWLRQ
6PDUWWKHUPRVWDWZLWKDXWRPLVDWLRQDQGRSWLPLVDWLRQ )OXH*DV+HDW5HFRYHU\
7LPHDQGWHPSHUDWXUHFRQWUROWRKRWZDWHU
&\OLQGHUWKHUPRVWDWDQGSURJUDPPHUWLPHU
&RPELQDWLRQERLOHU
Zone valves
SUHH[LVWLQJ
)LWWHG
Thermostatic radiator valves
SUHH[LVWLQJ
)LWWHG
$XWRPDWLFE\SDVVWRV\VWHP
SUHH[LVWLQJ
)LWWHG
8QGHUÀRRUKHDWLQJ
SUHH[LVWLQJ
)LWWHG
:DWHUTXDOLW\
7KHV\VWHPKDVEHHQÀXVKHGFOHDQHGDQGDVXLWDEOHLQKLELWRUDSSOLHGXSRQ¿QDO¿OOLQDFFRUGDQFHZLWK%6DQGERLOHUPDQXIDFWXUHUV¶LQVWUXFWLRQV
1RWUHTXLUHG 1RWUHTXLUHG 1RWUHTXLUHG 1RWUHTXLUHG
<HV
:KDWV\VWHPFOHDQHUZDVXVHG"
:KDWLQKLELWRUZDVXVHG"
3ULPDU\ZDWHUV\VWHP¿OWHU
SUHH[LVWLQJ
&(175$/+($7,1*02'(PHDVXUHDQGUHFRUGDVDSSURSULDWH
%UDQG %UDQG
)LWWHG
3URGXFW 3URGXFW
1RWUHTXLUHG
*DVUDWHIRUFRPELQDWLRQERLOHUVFRPSOHWH'+:PRGHJDVUDWH
mhr
or
ftKU
&HQWUDOKHDWLQJRXWSXWOHIWDWIDFWRU\VHWWLQJV"
<HV
1R
,IQRZKDWLVWKHPD[LPXPFHQWUDOKHDWLQJRXWSXWVHOHFWHG"
N:
'\QDPLFJDVLQOHWSUHVVXUH
mbar
&HQWUDOKHDWLQJÀRZWHPSHUDWXUH
&
&HQWUDOKHDWLQJUHWXUQWHPSHUDWXUH
&
6\VWHPFRUUHFWO\EDODQFHGUHEDODQFHG"
<HV
&20%,1$7,21%2,/(5621/<
,VWKHLQVWDOODWLRQLQDKDUGZDWHUDUHDDERYHSSP "
<HV
1R
:DWHUVFDOHUHGXFHUVRIWHQHU
SUHH[LVWLQJ
)LWWHG
1RWUHTXLUHG
:KDWW\SHRIVFDOHUHGXFHUVRIWHQHUKDVEHHQ¿WWHG"
%UDQG
3URGXFW
:DWHUPHWHU¿WWHG"
<HV
1R
,I\HV'+:H[SDQVLRQYHVVHO
SUHH[LVWLQJ
)LWWHG
1RWUHTXLUHG
3UHVVXUHUHGXFLQJYDOYH
SUHH[LVWLQJ
)LWWHG
1RWUHTXLUHG
'20(67,&+27:$7(502'(0HDVXUHDQGUHFRUG
*DVUDWH
mhr
or
ftKU
'\QDPLFJDVLQOHWSUHVVXUHDWPD[LPXPUDWH
mbar
&ROGZDWHULQOHWWHPSHUDWXUH
&
+RWZDWHUKDVEHHQFKHFNHGDWDOORXWOHWV
<HV
7HPSHUDWXUH&
&21'(16$7(',6326$/
7KHFRQGHQVDWHGUDLQKDVEHHQLQVWDOOHGLQDFFRUGDQFHZLWKWKHPDQXIDFWXUHUV¶LQVWUXFWLRQVDQGRU%6%6
<HV
3RLQWRIWHUPLQDWLRQ
Internal
([WHUQDORQO\ZKHUHLQWHUQDOWHUPLQDWLRQLPSUDFWLFDO
0HWKRGRIGLVSRVDO
*UDYLW\
3XPSHG
$//,167$//$7,216
5HFRUGWKHIROORZLQJ
$WPD[UDWH $WPLQUDWHZKHUHSRVVLEOH
&2SSP &2SSP
&2 % &2 %
&2&2 5DWLR &2&2 5DWLR
:KHUHSRVVLEOHKDVDÀXHLQWHJULW\FKHFNEHHQXQGHUWDNHQLQDFFRUGDQFHZLWKPDQXIDFWXUHUV¶LQVWUXFWLRQVDQGUHDGLQJVDUHFRUUHFW"
<HV
7KHRSHUDWLRQRIWKHERLOHUDQGV\VWHPFRQWUROVKDYHEHHQGHPRQVWUDWHGWRDQGXQGHUVWRRGE\WKHFXVWRPHU
<HV
7KHPDQXIDFWXUHUV¶OLWHUDWXUHLQFOXGLQJ%HQFKPDUN&KHFNOLVWDQG6HUYLFH5HFRUGKDVEHHQH[SODLQHGDQGOHIWZLWKWKHFXVWRPHU
<HV
&RPPLVVLRQLQJ(QJLQHHU¶VVLJQDWXUH
&XVWRPHU¶VVLJQDWXUH 7RFRQ¿UPVDWLVIDFWRU\GHPRQVWUDWLRQDQGUHFHLSWRIPDQXIDFWXUHUV¶OLWHUDWXUH
$OOLQVWDOODWLRQVLQ(QJODQGDQG:DOHVPXVWEHQRWL¿HGWR/RFDO$XWKRULW\%XLOGLQJ&RQWURO/$%& HLWKHUGLUHFWO\RUWKURXJKD &RPSHWHQW3HUVRQV6FKHPH$%XLOGLQJ5HJXODWLRQV&RPSOLDQFH&HUWL¿FDWHZLOOWKHQEHLVVXHGWRWKHFXVWRPHU
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
64
Installation and Servicing
Section 6 - Benchmark to Commissioning
6(59,&( ,17(5,0%2,/(5:25.5(&25'
,WLVUHFRPPHQGHGWKDW\RXUERLOHUDQGKHDWLQJV\VWHPDUHUHJXODUO\VHUYLFHGDQGPDLQWDLQHGLQOLQHZLWKPDQXIDFWXUHUV¶LQVWUXFWLRQVDQGWKDWWKHDSSURSULDWHVHUYLFH LQWHULPZRUNUHFRUGLVFRPSOHWHG
Service provider :KHQFRPSOHWLQJDVHUYLFHUHFRUGDVEHORZ SOHDVHHQVXUH\RXKDYHFDUULHGRXWWKHVHUYLFHDVGHVFULEHGLQWKHPDQXIDFWXUHUV¶LQVWUXFWLRQV$OZD\VXVHWKH PDQXIDFWXUHUV¶VSHFL¿HGVSDUHSDUWV
SERVICE/INTERIM WORK ON BOILER GHOHWHDVDSSURSULDWH 'DWH
SERVICE/INTERIM WORK ON BOILER GHOHWHDVDSSURSULDWH 'DWH
(QJLQHHUQDPH
&RPSDQ\QDPH
7HOHSKRQH1o:
*DV6DIHUHJLVWUDWLRQ1o:
0D[UDWH &2SSP &2² 0LQUDWH &2SSP &2²
% &2&2² % &2&2²
:KHUHSRVVLEOHKDVDÀXHLQWHJULW\FKHFNEHHQ
XQGHUWDNHQLQDFFRUGDQFHZLWKPDQXIDFWXUHUV¶
\HV
LQVWUXFWLRQVDQGUHDGLQJVDUHFRUUHFW"´
(QJLQHHUQDPH
&RPSDQ\QDPH
7HOHSKRQH1o:
*DV6DIHUHJLVWUDWLRQ1o:
0D[UDWH &2SSP &2² 0LQUDWH &2SSP &2²
% &2&2² % &2&2²
:KHUHSRVVLEOHKDVDÀXHLQWHJULW\FKHFNEHHQ
XQGHUWDNHQLQDFFRUGDQFHZLWKPDQXIDFWXUHUV¶
\HV
LQVWUXFWLRQVDQGUHDGLQJVDUHFRUUHFW"´
*DVUDWH
mK
25
ftK
:HUHSDUWV¿WWHG"GHOHWHDVDSSURSULDWH <HV
1R
3DUWV¿WWHG
*DVUDWH
mK
25
ftK
:HUHSDUWV¿WWHG"GHOHWHDVDSSURSULDWH <HV
1R
3DUWV¿WWHG
6\VWHPLQKLELWRUFRQFHQWUDWLRQKDVEHHQFKHFNHGDQG
6\VWHPLQKLELWRUFRQFHQWUDWLRQKDVEHHQFKHFNHGDQG
DSSURSULDWHDFWLRQWDNHQLQDFFRUGDQFHZLWK%6
\HV
QD
DSSURSULDWHDFWLRQWDNHQLQDFFRUGDQFHZLWK%6
\HV
QD
DQGERLOHUPDQXIDFWXUHUV¶LQVWUXFWLRQV
DQGERLOHUPDQXIDFWXUHUV¶LQVWUXFWLRQV
&RPPHQWV
&RPPHQWV
Signature:
Signature:
$6\VWHPLQKLELWRUHI¿FDF\WHVWLVUHTXLUHGRQHYHU\DQQXDOVHUYLFHLQDFFRUGDQFHZLWKWKHPDQXIDFWXUHUV¶ LQVWUXFWLRQVDQG%6,WLVRQO\DFFHSWDEOHWRQRWKDYHXQGHUWDNHQWKLVLIWKHVHUYLFHHQJLQHHUV
DWWHQGDQFHYLVLWZDVLQEHWZHHQDQQXDOVHUYLFHVWRDWWHQGDQRQZDWHUIDFLQJFRPSRQHQW
$6\VWHPLQKLELWRUHI¿FDF\WHVWLVUHTXLUHGRQHYHU\DQQXDOVHUYLFHLQDFFRUGDQFHZLWKWKHPDQXIDFWXUHUV¶ LQVWUXFWLRQVDQG%6,WLVRQO\DFFHSWDEOHWRQRWKDYHXQGHUWDNHQWKLVLIWKHVHUYLFHHQJLQHHUV
DWWHQGDQFHYLVLWZDVLQEHWZHHQDQQXDOVHUYLFHVWRDWWHQGDQRQZDWHUIDFLQJFRPSRQHQW
SERVICE/INTERIM WORK ON BOILER GHOHWHDVDSSURSULDWH 'DWH
SERVICE/INTERIM WORK ON BOILER GHOHWHDVDSSURSULDWH 'DWH
(QJLQHHUQDPH
&RPSDQ\QDPH
7HOHSKRQH1o:
*DV6DIHUHJLVWUDWLRQ1o:
0D[UDWH &2SSP &2² 0LQUDWH &2SSP &2²
% &2&2² % &2&2²
:KHUHSRVVLEOHKDVDÀXHLQWHJULW\FKHFNEHHQ
XQGHUWDNHQLQDFFRUGDQFHZLWKPDQXIDFWXUHUV¶
\HV
LQVWUXFWLRQVDQGUHDGLQJVDUHFRUUHFW"´
(QJLQHHUQDPH
&RPSDQ\QDPH
7HOHSKRQH1o:
*DV6DIHUHJLVWUDWLRQ1o:
0D[UDWH &2SSP &2² 0LQUDWH &2SSP &2²
% &2&2² % &2&2²
:KHUHSRVVLEOHKDVDÀXHLQWHJULW\FKHFNEHHQ
XQGHUWDNHQLQDFFRUGDQFHZLWKPDQXIDFWXUHUV¶
\HV
LQVWUXFWLRQVDQGUHDGLQJVDUHFRUUHFW"´
*DVUDWH
mK
25
ftK
:HUHSDUWV¿WWHG"GHOHWHDVDSSURSULDWH <HV
1R
3DUWV¿WWHG
*DVUDWH
mK
25
ftK
:HUHSDUWV¿WWHG"GHOHWHDVDSSURSULDWH <HV
1R
3DUWV¿WWHG
6\VWHPLQKLELWRUFRQFHQWUDWLRQKDVEHHQFKHFNHGDQG
6\VWHPLQKLELWRUFRQFHQWUDWLRQKDVEHHQFKHFNHGDQG
DSSURSULDWHDFWLRQWDNHQLQDFFRUGDQFHZLWK%6
\HV
QD
DSSURSULDWHDFWLRQWDNHQLQDFFRUGDQFHZLWK%6
\HV
QD
DQGERLOHUPDQXIDFWXUHUV¶LQVWUXFWLRQV
DQGERLOHUPDQXIDFWXUHUV¶LQVWUXFWLRQV
&RPPHQWV
&RPPHQWV
Signature:
Signature:
$6\VWHPLQKLELWRUHI¿FDF\WHVWLVUHTXLUHGRQHYHU\DQQXDOVHUYLFHLQDFFRUGDQFHZLWKWKHPDQXIDFWXUHUV¶
$6\VWHPLQKLELWRUHI¿FDF\WHVWLVUHTXLUHGRQHYHU\DQQXDOVHUYLFHLQDFFRUGDQFHZLWKWKHPDQXIDFWXUHUV¶
LQVWUXFWLRQVDQG%6,WLVRQO\DFFHSWDEOHWRQRWKDYHXQGHUWDNHQWKLVLIWKHVHUYLFHHQJLQHHUV
LQVWUXFWLRQVDQG%6,WLVRQO\DFFHSWDEOHWRQRWKDYHXQGHUWDNHQWKLVLIWKHVHUYLFHHQJLQHHUV
DWWHQGDQFHYLVLWZDVLQEHWZHHQDQQXDOVHUYLFHVWRDWWHQGDQRQZDWHUIDFLQJFRPSRQHQW
DWWHQGDQFHYLVLWZDVLQEHWZHHQDQQXDOVHUYLFHVWRDWWHQGDQRQZDWHUIDFLQJFRPSRQHQW
SERVICE/INTERIM WORK ON BOILER GHOHWHDVDSSURSULDWH 'DWH
(QJLQHHUQDPH
&RPSDQ\QDPH
7HOHSKRQH1o:
*DV6DIHUHJLVWUDWLRQ1o:
0D[UDWH &2SSP &2² 0LQUDWH &2SSP &2²
% &2&2² % &2&2²
:KHUHSRVVLEOHKDVDÀXHLQWHJULW\FKHFNEHHQ
XQGHUWDNHQLQDFFRUGDQFHZLWKPDQXIDFWXUHUV¶
\HV
LQVWUXFWLRQVDQGUHDGLQJVDUHFRUUHFW"´
SERVICE/INTERIM WORK ON BOILER GHOHWHDVDSSURSULDWH 'DWH
(QJLQHHUQDPH
&RPSDQ\QDPH
7HOHSKRQH1o:
*DV6DIHUHJLVWUDWLRQ1o:
0D[UDWH &2SSP &2² 0LQUDWH &2SSP &2²
% &2&2² % &2&2²
:KHUHSRVVLEOHKDVDÀXHLQWHJULW\FKHFNEHHQ
XQGHUWDNHQLQDFFRUGDQFHZLWKPDQXIDFWXUHUV¶
\HV
LQVWUXFWLRQVDQGUHDGLQJVDUHFRUUHFW"´
*DVUDWH
mK
25
ftK
:HUHSDUWV¿WWHG"GHOHWHDVDSSURSULDWH <HV
1R
3DUWV¿WWHG
*DVUDWH
mK
25
ftK
:HUHSDUWV¿WWHG"GHOHWHDVDSSURSULDWH <HV
1R
3DUWV¿WWHG
6\VWHPLQKLELWRUFRQFHQWUDWLRQKDVEHHQFKHFNHGDQG
6\VWHPLQKLELWRUFRQFHQWUDWLRQKDVEHHQFKHFNHGDQG
DSSURSULDWHDFWLRQWDNHQLQDFFRUGDQFHZLWK%6
\HV
QD
DSSURSULDWHDFWLRQWDNHQLQDFFRUGDQFHZLWK%6
\HV
QD
DQGERLOHUPDQXIDFWXUHUV¶LQVWUXFWLRQV
DQGERLOHUPDQXIDFWXUHUV¶LQVWUXFWLRQV
&RPPHQWV
&RPPHQWV
Signature:
Signature:
$6\VWHPLQKLELWRUHI¿FDF\WHVWLVUHTXLUHGRQHYHU\DQQXDOVHUYLFHLQDFFRUGDQFHZLWKWKHPDQXIDFWXUHUV¶ LQVWUXFWLRQVDQG%6,WLVRQO\DFFHSWDEOHWRQRWKDYHXQGHUWDNHQWKLVLIWKHVHUYLFHHQJLQHHUV
DWWHQGDQFHYLVLWZDVLQEHWZHHQDQQXDOVHUYLFHVWRDWWHQGDQRQZDWHUIDFLQJFRPSRQHQW
$6\VWHPLQKLELWRUHI¿FDF\WHVWLVUHTXLUHGRQHYHU\DQQXDOVHUYLFHLQDFFRUGDQFHZLWKWKHPDQXIDFWXUHUV¶ LQVWUXFWLRQVDQG%6,WLVRQO\DFFHSWDEOHWRQRWKDYHXQGHUWDNHQWKLVLIWKHVHUYLFHHQJLQHHUV
DWWHQGDQFHYLVLWZDVLQEHWZHHQDQQXDOVHUYLFHVWRDWWHQGDQRQZDWHUIDFLQJFRPSRQHQW
$OOLQVWDOODWLRQVLQ(QJODQGDQG:DOHVPXVWEHQRWL¿HGWR/RFDO$XWKRULW\%XLOGLQJ&RQWURO/$%& HLWKHUGLUHFWO\RUWKURXJKD &RPSHWHQW3HUVRQV6FKHPH$%XLOGLQJ5HJXODWLRQV&RPSOLDQFH&HUWL¿FDWHZLOOWKHQEHLVVXHGWRWKHFXVWRPHU
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
Installation and Servicing
65
Section 6 - Benchmark to Commissioning
FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER
Important Preliminary Information on Checks
The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING. If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) separate guidance is provided with the conversion kit supplied and this must be followed.
PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK The installation instructions must have been followed, gas type verified and gas supply pressure / gas rate checked as required prior to commissioning. As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids). The ECGA should be of the correct type, as specified by BS EN 50379-3:2012. Prior to its use, the ECGA should have been maintained and calibrated as specified by the manufacturer. The installer must have the relevant competence for use of the analyser. Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer's instructions.
KEY: CO = carbon monoxide 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
IMPORTANT: Ensure boiler is in normal operation with a heat demand before setting Maximum / Minimum rate function.
Setting to Maximum Rate: 1. Hold "MODE" & "RESTART" buttons together for more than 5s 2. Last 3 faults will be shown 3. SH shown, press "RESTART" button 4. Burner will run for 10 minutes at maximum rate 5. Press "RESTART" to exit Maximum Rate mode
Setting to Minimum Rate: 1. Hold "MODE" & "RESTART" buttons together for more than 5s 2. Last 3 faults will be shown 3. SH shown, press "MODE" button 4. SL shown, press "RESTART" 5. If the return temperature is under 40°C then the fan will run for 30s at maximum rate before ramping down over
60s to minimum rate. 6. Burner will run for 10 minutes at minimum rate 7. Press "RESTART" to exit Minimum Rate mode
66
Installation and Servicing
Section 6 - Benchmark to Commissioning
Start
Set Boiler to Maximum Gas Rate.
In accordance with boiler instructions, set boiler to operate at maximum rate (full load
condition). Allow sufficient time for combustion to stabilise.
Refer to Page 66
Note. Do not insert analyser probe during this period to avoid possible flooding of sensor.
Verify Flue Integrity.
Analyser readings indicate that combustion products and inlet air must be mixing. Further investigation of the flue is
therefore required.
Check that flue components are assembled, fixed and supported as per instructions. Check that flue and flue
terminal are not obstructed.
Is
O more than or
equal to 20.6% or CO less
Yes
than or equal to 0.2%?
No
Turn off appliance and call Ideal Technical Helpline for advice.
The appliance must not be commissioned until problems are identified and resolved. If commissioning cannot be fully completed, the appliance must be disconnected from the gas supply in accordance with GSIUR.
Check that no seals, e.g. Those on flue extensions, have been displaced during installation. Rectify if necessary.
Is
CO level less than 350ppm and CO/CO2
Yes
ratio less than 0.0040?
No
Turn off Appliance and Call Ideal Technical Helpline. The appliance must not be commissioned until problems are identified and resolved. If commissioning cannot be fully completed, the appliance must be disconnected from
the gas supply in accordance with GS(I&U)R. Note. Check and record CO level and combustion ratio at
both max. and min. rate before contacting Ideal.
Installation and Servicing
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.
Is
O more than or
No
equal to 20.6% OR COless
than or equal to 0.2%?
Yes
Check CO level and Combustion Ratio at Maximum Gas Rate.
With boiler still set at maximum gas rate, insert analyser probe into flue gas sampling point. Allow readings to stabilise before recording.
Is
CO level less
No
than 350ppm AND CO/CO
ratio less than 0.0040?
Yes
Set Boiler to Minimum Gas Rate.
In accordance with boiler instructions, set boiler to operate at minimum rate (to
minimum load condition). Allow sufficient time for combustion to stabilise.
Refer to Page 66
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.
Is
CO level less
No
than 350ppm AND CO/CO
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.
67
Notes
68
Installation and Servicing
Notes
Installation and Servicing
69
At Ideal Heating we take our environmental impact seriously, therefore when installing any Ideal Heating product please make sure to dispose of any previous appliance in an environmentally conscious manner. Households can contact their local authority to find out how. See https://www.gov.uk/managing-your-waste-an-overview for guidance on how to efficiently recycle your business waste.
Technical Training Our Expert Academy offer a range of training options designed and delivered by our experts in heating. For details please contact: expert-academy.co.uk
Ideal Boilers Ltd., pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.
Ideal is a trademark of Ideal Boilers. Registered Office
Ideal Boilers Ltd., National Avenue, Hull, East Yorkshire, HU5 4JB Tel 01482 492251 Fax 01482 448858 Registration No. London 322 137
EU Authorised Representative: Atlantic SFDT
44 Boulevard des Etats-Unis, 85 000 La Roche-Sur-Yon, France +33 (0)2 51 44 34 34
Ideal Technical Helpline: 01482 498663 Ideal Consumer Helpline: 01482 498660
Ideal Parts: 01482 498665 idealheating.com
Acrobat Distiller 23.0 (Windows)