Ideal Boilers BOXER C 24 Installation And Servicing Manual Download Page 23

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BOXER

combination boiler -

Installation and Servicing

INSTALLATION

32 FUNCTIONAL FLOW WIRING DIAGRAM

WARNING.

Whilst effecting the required gas soundness test and purging air from the gas installation,

open all windows and doors, extinguish naked lights and

DO NOT SMOKE.

A. Electrical Installation
1.

Checks to ensure electrical safety should be carried out by

a competent person.

ALWAYS carry out the preliminary electrical system checks,

i.e. earth continuity, polarity, resistance to earth and short

circuit, using a suitable test meter.

B. Gas Installation
1.

The whole of the gas installation, including the meter,

should be inspected and tested for soundness and purged

in accordance with the recommendations of BS. 6891.

Purge air from the gas installation by approved methods

only.

Retighten the union and test for gas soundness.

33 COMMISSIONING AND TESTING

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Summary of Contents for BOXER C 24

Page 1: ...you can be assured conform to the safety and performance specification we require Do not use reconditioned or copy parts that have not been clearly authorised by the manufacturer installation and servicing C24 C28 Combination boiler Your installation and servicing guide ...

Page 2: ...ross C V of the gas Btu ft3 Key to symbols I E Ireland GB United Kingdom Countries of destination PMS Maximum operating pressure of water C12 C32 C52 A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which in this case are concentric The fan is...

Page 3: ...s 21 to 23 BOXER Natural Gas only G C Appliance No 47 348 22 BOXER C 24 G C Appliance No 47 348 23 BOXER C 28 PI No 0049AU2867 BOXER C 24 0049AU2949 BOXER C 28 Destination Countries GB IE NOTE TO THE INSTALLER LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER ALSO COMPLETE THE BENCHMARK LOG BOOK AND GIVE THIS TO THE CUSTOMER BENCHMARK LOG BOOK DETAILS Boiler Page Make and model 3 Appliance Serial...

Page 4: ...MUST include drain cocks in appropriate places Pipework from the boiler is routed downwards as standard but may be routed upwards behind the boiler using the stand off frame supplied in a separate kit OPERATION With no demand for CH the boiler fires only when DHW is drawn off When there is a demand for CH the heating system is supplied at the selected temperature of between 45 o C and 82 o C until...

Page 5: ...essary unless required by the local authority For electrical safety reasons there must be no access available from the back of the boiler The boiler must not be fitted outside Timber Framed Buildings If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineering document IGE UP 7 1998 Where installation will be in an unusual locati...

Page 6: ...e ONLY b If a core boring tool is to be used inside the building the space in which the boiler is to be installed must be at least wide enough to accommodate the tool Front clearance The minimum front clearance when built in to a cupboard is 5 mm 1 4 from the cupboard door but 480 mm 18 7 8 overall clearance is still required with the cupboard door open to allow for servicing Bottom clearance Bott...

Page 7: ...utside air 4 In siting the air vents care must be taken to avoid the freezing of pipework GAS SUPPLY The local gas supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must NOT be used without prior consultation with the local gas supplier The boiler MUST be installed on a gas supply with a gove...

Page 8: ...ations which apply The point of connection to the mains should be readily accessible and adjacent to the boiler 3 SYSTEM REQUIREMENTS Central Heating Safety valve setting bar 3 0 Vessel charge pressure bar 0 75 to 1 System pre charge pressure bar 1 0 System volume Expansion vessel litres volume litres 25 1 8 50 3 7 75 5 5 100 7 4 125 9 2 150 11 0 175 11 9 190 14 0 200 14 7 250 18 4 300 22 1 For ot...

Page 9: ...nection from a draw off tap supplied from a service pipe under mains pressure Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling i Thoroughly flush out the whole system with cold water ii Fill and vent the system until the pressure gauge registers 1 5 bar and examine for leaks iii Check the operation of the safety valve by raising the water pressure ...

Page 10: ...1 424 5351 Tandem House Marlowe Way Croydon Surrey CRO 4XS Tel 0870 5601 5000 Sentinel Division Notes 1 It is most important that the correct concentration of the water treatment product is maintained in accordance with the manufacturers instructions 2 If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing BS 7593 1992 details the steps nece...

Page 11: ...11 BOXER combination boiler Installation and Servicing INSTALLATION 8 BOILER ASSEMBLY Exploded View INSTALLATION ...

Page 12: ...0 5 21 7 7 2 2 1 D 7 7 2 0 28 17 1 3 7 6 5 3 2 6 7 2 16 E 7 326 7 2 1 2 7 8 8 7 2 0 5 1 2 1 7 17 5 2 7 2 6 6 7 5 80 5 1 5 029 7 0 3 7 520 7 2 2 32 176 2 9 7 1 8 175 1 2 5 21 7 5 2 66 6 7 1 25 217 25 5 6 6 2 1 25 7 2 8 2 2 5 25 217 17 5 1 2 7 0 3 7 2 1 1 0 2 817 3 1 1 21 7 6 5 1 7 1 2 5 1 6 6 6 2 1 1 7 2 7 3 7 03 7 17 2 6 7 326 7 21 0 5 21 7 17 5 2 7 8 2 6 6 7 5 8 0 5 1 86 1 7 2 3 7 21 67 1 2 7 25 ...

Page 13: ...e side the removed casing to avoid damage 12 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED Notes 1 The flue duct MUST be inclined at 1 5 degrees to the horizontal to not allow the rain come into the boiler 2 If the boiler is to be installed with upward piping routed behind the boiler then the optional stand off kit should be used Care must be taken when cutting the ducts and marking wall to ...

Page 14: ...nd off kit the fixing holes with center to center distance of 392 mm 15 7 16 c The position of the flue duct hole Note Mark the centre of the hole as well as the circumference 4 Remove the template from the wall 14 WALL MOUNTING TEMPLATE 13 FLUE ASSEMBLY Exploded View 1 An optional flue duct extension kit is required for wall thicknesses greater than Side 580 mm 23 5 8 Rear 620 mm 24 3 8 w o stand...

Page 15: ...is will allow for the fitted stand off kit 1 Measure and note wall thickness X Refer to Frame 12 2 Add 90 mm 3 9 16 to dimension X and measuring from the groove cut the outer tube only 3 To ensure the tube is cut square mark the flue all the way round 4 Cut the inner tube to a length 20 mm 3 4 longer to aid engagement 17 CUTTING THE FLUE SIDE Wall thicknesses of 114 to 580 mm Note If using the ext...

Page 16: ... is in place 6 Connect a pipe to the safety drain outlet using a pressure fitting 15 mm O dia Service connections may be made now before mounting the boiler If required refer to Frames 24 to 27 or b Use stand off kit To allow pipework to be taken upwards 1 Assemble the 4 plastic plugs and the screws on the stand off frame as indicated 2 Fit the stand off frame on the wall 3 Hang the boiler onto th...

Page 17: ...he stand off option is used secure the support bracket using the spacer bracket and long wood screw Note When no extension duct is used the flue restrictor supplied in hardware pack A must be fitted Flue restrictor 20 FLUE EXTENSION DUCTS For flue lengths greater than 720 mm Pack D Flue extension duct kit contents 1 A maximum of 3 extension ducts one suitably cut plus the standard flue duct may be...

Page 18: ...he flue all the way round 7 Cut to length at the right size the external duct and cut the internal one 20 mm longer 8 De burr the metal edges 22 FITTING THE KIT General Notes 1 Fitting the Piping Frame top entry pipework is an option as well as mounting from the bottom or through the wall If pipes are run vertically within the boiler back space provided by optional stand off frame positions they m...

Page 19: ...ONNECTIONS continued DHW CONNECTIONS Note The flow regulator and the filter are mounted internal of the boiler It should be inspected to ensure no blockage is evident See frame 65 Isolating valve shown in the open position 22 mm copper pipe 22 mm copper pipe Isolating valve shown in the open position C H FLOW C H RETURN 15 mm copper pipe D H W OUTLET D C W INLET Isolating valve shown in the open p...

Page 20: ...heck for water soundness IMPORTANT when filling a The cap on the automatic air vent refer to Frame 64 MUST be loose at all times When filling there may be a slight water leak from the vent therefore electrical connections should be protected b Bleed any air from the pump and ensure that it is free to rotate i Remove the vent plug ii Using a screwdriver rotate the shaft several times iii Replace th...

Page 21: ...ost protection electronic system When the temperature detected by the CH sensor is below 5 C the boiler is put into operation till the CH sensor detects a temperature off 15 C The frost protection electronic system is operating only if the electrical supply and gas are On Room Thermostat The room thermostat is placed onto the 24 Vdc circuit Do not connect any external supply to the room thermostat...

Page 22: ...P1 P2 FS1 Programmer connection Y Y 2YHUKHDW WKHUPRVWDW EN EU E EN RU E EU Z J J J EN J E EU J EU E JU U Z Z RU Z J Z Z Z Z EU Z EU U U E EU J EU E 0DLQV VXSSO 9 3XPS ODPH GHWHFWLRQ HOHFWURGH 0DLQV VZLWFK DQ LU SUHVVXUH VZLWFK 5HVHW EXWWRQ 3URJUDPPHU VHQVRU VHQVRU ORZ VZLWFK RZ VZLWFK 5 6 7 17 5 2 21 EN U 5 4 4 3 3 2 2 2 1 1 1 5 4 3 2 1 5 4 3 2 1 5 4 3 2 1 6 1 2 3 4 1 2 GND1 GND2 GND3 GND4 GND5 A9...

Page 23: ... test meter B Gas Installation 1 The whole of the gas installation including the meter should be inspected and tested for soundness and purged in accordance with the recommendations of BS 6891 2 Purge air from the gas installation by approved methods only 3 Retighten the union and test for gas soundness 33 COMMISSIONING AND TESTING EU E EU Y E Y EN RU Z E EU EU Z Z EU EU Z E Z EU E Z JU U 0DLQV VX...

Page 24: ...ap 5 6 7 17 5 2 21 J Boiler On Off switch L Inlet pressure test point M Burner pressure test point N CH flow O DHW outlet P Gas inlet Q DHW inlet R CH return S Pressure gauge Control panel The user panel is equipped with two regulation knobs and the CH knob has a double function In the minimum position turn all LHS the boiler works only in DHW mode summer position between first line and maximum po...

Page 25: ...ressure cannot be achieved by the above method further adjustment can be made using the MIN GAS potentiometer on the PCB refer to Frame 61 25 Check the new setting pressure Switch the boiler OFF then ON to check the pressure Maximum pressure 26 Set the DHW control knob to maximum and fully open a DHW tap to ensure adequate DHW flow refer to Table 2 27 Operate the boiler in this mode for 5 minutes ...

Page 26: ...ds the burner should relight to supply central heating if there is a request for it Make the following checks for correct operation in DOMESTIC HOT WATER DHW MODE 1 With no call for CH or DHW the boiler is in stand by mode Only the mains led is On 2 Fully open all DHW taps in turn and ensure that water flows freely from them The flame led is On 3 Close all taps except the furthest one from the boi...

Page 27: ...hot water controls 5 Explain the function of the boiler fault mode Emphasise that if a fault is indicated the boiler should be turned off and a registered local heating installer consulted 6 Explain and demonstrate the function of time and temperature controls radiator valves etc for the economic use of the system WATER TEMPERATURES The design water output temperatures are as follows Central Heati...

Page 28: ... then no further action need be taken If not proceed to Step 3 but see note above 3 Switch OFF the electrical supply 4 Remove the casing refer to frame 41 5 Remove the expansion vessel and vertical protection shield refer to frame 43 6 Clean the main burner refer to frame 46 7 Clean the heat exchanger refer to frame 47 8 Check the main injector for blockage or damage refer to frame 52 9 Check that...

Page 29: ...he plastic fascia board B remove and place on one side 3 Release the four fixing clamps on the upper and lower positions 2 2 C 4 Lift and remove casing D 5 Place the removed casing to one side to avoid damage A B C C D 42 CONTROL HOUSING ACCESS 1 Remove the casing see Frame 41 2 Remove the 3 screws keeping the control housing in place 3 Pull down and swing the housing 3 2 2 2 D SERVICING ...

Page 30: ...he expansion vessel from the protection shield and hang it on the frame bottom 4 Remove the two clips retaining the vertical protection shield and remove it only for 24 kW 5 Disconnect the wiring from the ignition transformer remove the 3 screws securing the air guide to the main chassis and remove the air guide only for 28 kW Note Take care not to disturb the expansion vessel flexible pipe 3 3 2 ...

Page 31: ...ll system isolating valves before proceeding to check operation of the boiler 5 drain point 5 45 FAN ASSEMBLY REMOVAL AND CLEANING 1 Remove the casing refer Frame 41 2 Disconnect the electrical leads from the fan 3 Undo the retaining screw on the fan mounting bracket 4 Slide the fan forward and down and disengage from the fan outlet connector 5 Clean with a soft brush Note Take care not to damage ...

Page 32: ...R REMOVAL AND CLEANING 1 Undo and remove the 2 clips assembling the combustion chamber 2 Remove the combustion chamber 3 Disconnect the leads from ignition and ionisation electrodes including the earth lead 4 Unscrew the nut off the gas burner pipe then remove the 4 screws securing the burner 5 Remove the burner from the combustion chamber 6 Inspect the sealing gasket of the burner connection for ...

Page 33: ...its using a soft brush 6 Re assemble in reverse order 3 49 REPLACEMENT OF COMPONENTS GENERAL When replacing ANY component 1 Isolate the electricity supply 2 Turn off the gas supply 3 Remove the casing refer to Frame 41 4 If it is necessary to drain the boiler refer to Frame 44 After replacing ANY component check operation of the boiler including gas soundness gas rate and combustion test IMPORTANT...

Page 34: ...20 12394 9888 30 7947 6433 40 5242 4300 50 3548 2945 60 2459 2063 70 1740 1475 80 1256 1075 90 923 797 100 690 600 TABLE OF RESISTANCE VALUES AS A FUNCTION OF THE TEMPERATURE OF THE SENSORS 51 FAN REPLACEMENT 1 Refer to Frame 49 2 Remove the boiler casing Refer to Frame 41 3 Disconnect the electrical leads from the fan 4 Undo the retaining screw s on the fan mounting bracket 5 Slide the fan forwar...

Page 35: ...e combustion chamber 8 Unscrew the injectors 9 Fit the new injectors complete with copper gaskets 10 Re assemble in reverse order Note Check that all of the injectors have been replaced and security tightened 7 8 9 6 6 52 VENTURI REPLACEMENT 1 Refer to Frame 49 2 Remove the fan assembly Refer to Frame 45 3 Remove the boiler casing Refer to Frame 41 4 Disconnect the two silicon pipes from the ventu...

Page 36: ... screws securing the burner 7 Remove the burner from the combustion chamber 8 Fit the new burner and re assemble in reverse order using a new gasket 6 6 6 7 55 OVERHEAT THERMOSTAT REPLACEMENT 1 Refer to Frame 49 2 Remove the casing Refer to Frame 41 3 Remove the electrical leads of the overheat thermostat 4 Remove the combustion chamber Refer to Frame 47 5 Unclip the overheat thermostat from the h...

Page 37: ...e order PP 4 4 4 6 6 6 6 57 HEAT EXCHANGER REPLACEMENT 1 Refer to Frame 49 2 Remove the casing Refer to Frame 41 3 Remove the expansion vessel and shield air guide Refer to Frame 43 4 Unscrew 3 screws and remove front panel of the collector hood 5 Remove the heat exchanger baffle by pulling forwards 6 Remove the combustion chamber Refer Frame 47 7 Drain the CH and DHW circuit Refer to frame 44 8 D...

Page 38: ...TOR REPLACEMENT 1 Refer to Frame 49 2 Remove the casing Refer to Frame 41 3 Remove the expansion vessel and shield air guide Refer to Frame 43 4 Isolate and drain the DHW and CH circuits Refer to Frame 44 5 Unscrew the two DHW pipe nuts 6 Unscrew the two screws fixing the thermostatic actuator and pull it upwards 7 Fit the new actuator and re assemble in reverse order using new seals if necessary ...

Page 39: ...inimum pressure adjuster Refer to Frame 35 11 Check the operation of the boiler and adjust the maximum and minimum pressures as necessary Refer to Frame 35 4 5 6 8 7 61 PCB REPLACEMENT 1 Refer to Frame 49 2 Remove the casing Refer to Frame 41 3 Swing the control housing down into the servicing position Refer to Frame 42 4 Remove the two knobs To remove also the two shafts it is necessary to squeez...

Page 40: ...r 62 MAINS SWITCH REPLACEMENT 63 PRESSURE GAUGE REPLACEMENT 1 Refer to Frame 49 2 Remove the casing Refer to Frame 41 3 Remove the expansion vessel and shield air guide Refer to Frame 43 4 Drain the boiler Refer to Frame 44 5 Unclip the temperature sensor 6 Unscrew the pressure gauge nut 3 4 8 6 7 Swing the control housing into the service position 8 Pull out the pressure gauge pipe and temperatur...

Page 41: ... to Frame 43 3 Drain the boiler Refer to Frame 44 4 For BOXER C 24 Unscrew the air vent from the CH return assembly and remove it For BOXER C 28 Pull out the air vent clip from the CH return assembly and pull up the air vent head 5 Fit the new air vent and re assemble in reverse order 6 Refill the boiler Refer to Frames 4 and 28 IMPORTANT Ensure that the vent cap is loose A 6 Unscrews the safety r...

Page 42: ...en screws securing the pump head 7 Remove the pump head 8 Fit the new pump head 9 Re assemble in reverse order 10 Refill the boiler Refer to Frames 4 and 28 5 6 67 AIR PRESSURE SWITCH REPLACEMENT 1 Refer to Frame 49 2 Remove the casing Refer to Frame 41 3 Disconnect the electrical lead from the air pressure switch 4 Disconnect the two silicon pipes from the air pressure switch 5 Unscrew the two sc...

Page 43: ...e boiler Refer to Frames 4 and 28 5 4 69 EXPANSION VESSEL REPLACEMENT 1 Refer to Frame 49 2 Remove the casing Refer to Frame 41 3 Drain the boiler Refer to Frame 44 4 Undo the union nut on the vessel water flexible connection pipe 5 Remove the expansion vessel Refer to Frame 43 6 Fit the new expansion vessel using the new sealing washer provided 7 Re assemble in reverse order 8 Refill the boiler R...

Page 44: ... 7 Fit the new flow switch and re assemble in 5 6 6 71 IGNITION TRANSFORMER REPLACEMENT 1 Refer to Frame 49 2 Remove the casing Refer to Frame 41 3 Remove the expansion vessel and shield Refer to Frame 43 4 Disconnect the electrical leads from the ignition transformer 5 Remove the screws securing the ignition transformer heat shield and remove the assembly 6 Unscrew the screw fixing the ignition t...

Page 45: ...ROLS ARE CALLING FOR HEAT NO ARE THE SELECTOR SWITCH PROGRAMMER AND ROOM STAT ALL CALLING FOR HEAT NO REPAIR OR REPLACE FAULTY WIRING OR THERMISTOR YES TOP UP THE SYSTEM PRESSURE VIA THE FILLING DEVICE TO AT LEAST 1 bar YES YES ENSURE THE ROOM THERMOSTAT AND PROGRAMMER ARE CALLING FOR HEAT AND THE SELECTOR SWITCH IS SET TO HEATING ENSURE ALL SERVICES ARE ON AND NO DHW TAPSARE OPEN BEFORE REPLACING...

Page 46: ...N HARNESS DOES THE PUMP RUN DOES THE FAN RUN IS THERE 230 VacAT THE PUMP CONNECTION FREE THE SPINDLE USING A SCREWDRIVER OR REPLACE THE PUMP IS THE FLAME FAILURE LED ILLUMINATED REMOVE THE PUMP NUT DOES THE IMPELLOR SPIN FREELY IS THERE 230 VacAT THE PCB CONNECTOR A1 ACROSS PINS 1 AND 2 IS THERE 230 VacAT THE FAN CONNECTIONS IS THE CONTINUITY OF THE AIR PRESSURE SWITCH CONNECTING LEAD OK IS THERE ...

Page 47: ...SARY DOES THE IGNITER OPERATE TICKING SOUND REPAIR OR REPLACE FAULTY WIRING RECTIFY WIRING FAULT REPLACE FAULTY PCB DOES THE BURNER LIGHT ENSURE THE ELECTRODE LEAD IS CONNECTED UNDAMAGED AND NOT SHORTED TO EARTH ENSURE THE ELECTRODE IS UNDAMAGED AND THE SPARK GAP IS CORRECT ARE THE FAN VENTURI AND FLUE CLEAR OF OBSTRUCTIONS AND THE SENSIING PIPES UNDAMAGED AND CORRECTLY CONNECTED IS THERE 132 VacA...

Page 48: ... REPLACE FAULTY WIRING OR THERMISTOR REPLACE FAULTY PCB ENSURE THERE IS SUFFICIENTWATER PRESSURE AND THE SUPPLY PIPE ISADEQUATE CLEAN INLET FILTER AND FLOWSWITCH REPLACE FAULTY FLOWSWITCH IF NECESSARY REPAIR OR REPLACE FAULTY WIRING CHECKTHE 3 WAYVALVE THERMOSTATIC ELEMENT IS THE SPINDLE FULLY RETRACTED IS THE SYSTEM FULLY VENTED WITH ALL ISOLATORVALVESFULLY OPEN AND THE SYSTEM PRESSURE IS 1bar DI...

Page 49: ...RESSURE STABLE REPLACE FAULTY GAS VALVE FAULTY THERMISTOR THIS HAS NOW BEEN REPLACED IS THE DHW TEMPERATURE SATISFACTORY REPLACE FAULTY THERMOSTATIC ELEMENT IN 3 WAY VALVE RECTIFY EXTERNAL SYSTEM FAULT DOES THE BURNER EXTINGUISH WHEN THE DHW TAP IS CLOSED REPLACE FAULTY PCB REPLACE FAULTY FLOWSWITCH THE BOILER IS OPERATING REPLACE THE DHW THERMISTOR IS THE WATER TEMPERATURE NOWSTABLE NO NO NO NO Y...

Page 50: ...nsformer 1 172410 8 Pump Head 24 kW 1 172411 Pump Head 28 kW 1 172412 9 Pressure gauge 1 172413 10 Control panel 1 172416 11 Fascia 1 172415 12 Automatic air vent 24 kW 1 172417 Automatic air vent 28 kW 1 172418 16 Pressure relief valve 1 172419 17 DHW flow switch 1 172420 20 CH sensor 1 172421 21 Diverter valve 1 172422 26 Overheat thermostat 1 172423 27 Low water switch 1 172424 28 DHW sensor 1 ...

Page 51: ...51 BOXER combination boiler Installation and Servicing SHORT LIST OF PARTS 87 SHORT PARTS LIST 1 3 5 6 7 8 9 12 12a 10 11 16 20 28 43 17 27 26 21 48 40 39 33 31 30 29 ...

Page 52: ...ucts The right is therefore reserved to vary specification without notice The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 The code of practice for the installation commissioning servicing of central heating systems BO...

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Ideal Boilers BOXER C 24, Installation And Servicing Manual

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