Ideal Boilers Classic m3050 Installation And Servicing Download

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classic m -

Installation & Servicing

SHORT LIST OF PARTS

Ecl 1600

70 CONTROLS ASSEMBLY

33.

Controls assy complete with screws.

34.

Controls hinge bracket.

35.

User controls (without item 38).

36.

PCB (primary controls).

38.

User controls housing kit.

54.

Jumper link.

Summary of Contents for Classic m3050

Page 1: ......

Page 2: ... in 100 4 Table 2 Performance Data Table 1 Boiler Data The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body CAUTION To avoid the possibility of injury during the installation servicing or cleaning of this appliance care should be taken when handling edges of s...

Page 3: ... 391 50 m5080 G C Appliance No 41 391 51 PI No 0063BL9812 Destination Countries UK 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 No on Data Badge 12 Controls as applicable Forall boilers Flushing to BS 7593 11 Inhibitor 11 Gas inl...

Page 4: ...uilding where wall thicknesses do not exceed 600mm 24 Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside Installation from inside ONLY b If a core boring tool is to be used inside the building the space in which the boiler is to be installed must be at least wide enough to accommodate the tool Ecl 1573 Re...

Page 5: ... and any relevant requirements of the local authority Detailed recommendations are contained in the following British Standard Codes of Practice BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW BS 5449 Forced circulation hot water systems BS 5546 Installation of gas hot water supplies for domestic purp...

Page 6: ...nal is fitted within 850mm 34 of a plastic or painted gutter or 450mm 18 of painted eaves then an aluminium shield at least 750mm 30 long should be fitted centrally to the underside of the gutter or painted surface 6 The air inlet products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm 1 to combustible material Detailed recommendations on the protection of combustible mate...

Page 7: ...ermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS 5449 For further information refer to the Good Practice Guide 143 publication of the Energy Efficiency Office available from the Building Research Establishment Garston Watford WD2 7...

Page 8: ... and programmer to NORMAL settings The system should be vented directly off the boiler flow pipe as close to the boiler as possible The cold feed entry should be inverted and MUST be positioned between the pump and the vent and not more than 150mm 6 away from the vent connection Note Combined feed and vent pipes may also be fitted There should be a minimum height 450mm 18 of open vent above the ci...

Page 9: ...nto the feed expansion cistern to a minimum c Provision for connection of a discharge pipe The valve or discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or cause damage to electrical components and wiring 3 Pressure Gauge A pressure gauge covering at least the range 0 4 bar 0 60 lb in2 must be fitted to the system T...

Page 10: ...nected to a point close to the inlet side of the pump the connecting pipe being not less than 15 mm 1 2 nominal size and not incorporating valves of any sort b The vessel capacity must be adequate to accept the expansion of the system water when heated to 110 C 230 F c The charge pressure must not be less than the static water head above the vessel The pressure attained in the system when heated t...

Page 11: ...boiler has a cast iron heat exchanger IMPORTANT The application of any other treatment to this product may render the guarantee of Caradon Plumbing invalid If water treatment is used Caradon Plumbing Ltd recommend only the use of FERNOX or SENTINEL water treatment products which must be used in accordance with the manufacturers instructions For further information contact Sentinel Division Betz De...

Page 12: ...ri assy 16 Fan assy 17 Gas pipe assy 19 Gas valve assy 20 Fan bracket assy 21 Orifice plate 23 Control thermistor 24 Overheat thermostat 25 Igniton electrode 26 Flame sensing electrode 35 User control LEGEND 1 Front casing panel 2 Case sealing panel 4 Bottom cover panel 5 Flue sensing nipple 6 Flue baffle 5080 only 7 Flue hood 8 Flue connection 9 Flue hood clip 36 PCB primary controls 42 Sightglas...

Page 13: ...ols and hardware pack 4 Remove instructions and read thoroughly before unpacking user s controls and hardware pack and retain in safe place 5 Lift off the cardboard carton 6 Dispose of packaging 12 PACKAGING REMOVAL Ecl 1608 Ecl 1460 Flue terminal Flue turret assembly E c l 1 5 7 6 Hardware Pack z 50mm x No 10 wood screws 3 off z Wall plugs TP2B 3 off z Turret clamp z M5 x 10 pozi Hex screw z Main...

Page 14: ...ks dim X 160 flue dim L 195 required Up to 480 mm Up to 480 mm none Up to 1430 mm Up to 1430 mm Pack D 1 off Up to 2380 mm Up to 2380 mm Pack D 2 off Up to 3000 mm Up to 3000 mm Pack D 3 off Note If the boiler is to be installed with downward routing of pipes then the optional stand off kit can be used Care must taken when cutting the ducts and marking the wall to suit this condition 13 FRONT PANE...

Page 15: ...the following a The wall mounting plate screw positions choose one from each group and lower fixing screw position b 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 16 WALL MOUNTING TEMPLATE Rear flue arrangement shown 15 FLUE ASSEMBLY Exploded View LEGEND 1 Duct assembly 2 Flue Turret 3 Turret gasket 4 M5 x 10 po...

Page 16: ...sing the stand 0ff kit then locate the stand off channel and screw home 19 CUTTING THE FLUE SIDE Wall thicknesses of 114 to 300mm Note If using the extension ducts go to Frame 20 1 Measure and note wall thickness X Refer Frame 14 2 Add 115mm 4 1 2 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 ...

Page 17: ...s together 5 Repeat steps 1 4 if a second flue extension is required 6 Measure and mark the flue length required onto the flue measuring from the groove near the terminal 7 To ensure a square cut mark the flue all the way round 8 Cut to length using the cardboard support aid 9 Remove the cardboard off cut and deburr the metal edges 22 FITTING THE KIT 20 FLUE EXTENSION DUCTS For flue lengths greate...

Page 18: ...repared hole in the wall 2 Locate the flue turret on the top of the boiler ensuring that the turret gasket is in place 3 Locate the flue into the turret 4 Secure the flue turret on top of the boiler by inserting the open ends of the turret clamp under the 2 studs and fixing it in the middle with the single M5 x 10mm pozi hex screw provided 5 Flues over 1 metre long Fix the flue support bracket to ...

Page 19: ... Extend a gas supply pipe NOT LESS THAN 15mm O D to the boiler and connect to the gas service cock via the union Ensure that the gas supply pipe does not foul the boiler casing 27 ELECTRICAL CONNECTIONS WARNING This appliance MUST be earthed A mains supply of 230 V 50 Hz is required The fuse rating should be 3 A Wiring external to the boiler MUST be in accordance with the current I E E BS 7671 Wir...

Page 20: ...ive full details Diagram A shows an application to boilers fitted with a room thermostat only Diagrams B and C show applications to boilers fitted with alternative time controls Earths are not shown for clarity but must never be omitted L3 L2 L1 N Room stat N if required Optional Frost stat Ecl 1543 A Mains in System controls L3 L2 L1 N Room stat N if required Optional Frost stat Ecl 1544 B Mains ...

Page 21: ...erheat thermostat Control thermistor Gas valve User control and display ON OFF Switch Service connection MAINS SUPPLY 230V 50Hz Permanent black link Fan y y Chassis earth y g Ecl 1848 Control PCB Fused at 3 15ATL 30 PICTORIAL WIRING LEGEND b blue bk black br brown r red w white or orange y yellow pk pink y g yellow green INSTALLATION ...

Page 22: ...ctrical Installation 1 Checks to ensure electrical safety should be carried out by a competent person 2 ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable test meter 32 COMMISSIONING AND TESTING bk br bk External switch e g room stat programmer b or or v v b y g DC Gas valve Overheat thermostat L N PCB b r ...

Page 23: ...ult codes L F will be displayed Press the reset button the boiler will then repeat its ignition sequence When the burner is established the GREEN burner ON neon will be permanently illuminated 11 Ensure that with the boiler operating the dynamic gas pressure is 20 mb IMPORTANT The gas input to the burner is regulated by the gas valve according to the air flow produced by the fan It is NOT user adj...

Page 24: ...peration 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 household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during fro...

Page 25: ...requency of servicing will depend upon the installation condition and usage but should be carried out at least annually It is the law that any service work must be carried out by a registered CORGI installer 1 Light the boiler and carry out a pre service check noting any operational faults 2 Check the gas consumption 3 Connect a suitable gas analyser to the sampling point on top of the boiler or i...

Page 26: ...OVAL AND CLEANING 1 Undo and remove the 6 screws securing the burner the 3 screws at the rear are extended to ease access 2 Remove the burner from the combustion chamber IMPORTANT The burner head is a ceramic plaque construction Care should be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic 3 Brush off any deposits that may be on the ceramic...

Page 27: ...80 only ensuring baffles are fully located in the heat exchanger 2 Refit the flue spigot to the flue turret 3 Refit the collector hood to the heat exchanger Ensure the sealing gasket around the flue outlet on the collector hood is in place Renew any damaged or deteriorating gaskets 4 Slide the flue spigot downwards and secure the 2 spring clips Ensure the clips are located correctly over the inter...

Page 28: ... the control thermistor 3 Pull the control thermistor and spring clip off the flow pipe 4 Replace thermistor and reconnect leads ensuring that the spring clip is securely holding the thermistor to the flow pipe 5 Re assemble the boiler in reverse order 6 Check the operation of the boiler Note Removal of the collector hood and flue spigot will facilitate better access WARNING Beware these component...

Page 29: ... the fan 3 Undo the gas pipe union connection to the injector housing 4 Undo the single retaining screw on the fan mounting bracket 5 Remove the fan 6 Unscrew the 3 retaining screws and remove the venturi assembly noting the orientation of the venturi in relation to the fan body 7 Transfer the venturi assembly to the new fan replacing the gasket if evidence of damage or deterioration is visible 8 ...

Page 30: ...ve the electrode taking care not to dislodge the grommet from the casing 6 Fit the new ignition electrode using the new gasket supplied and check dimensions on shown 7 Reassemble in reverse order 8 Check operation of the boiler Refer to Frame 36 4 Unbolt the sensing electrode earth lead from the earth point beneath the boiler 5 Remove the electrode complete with grommet 6 Fit the new sensing elect...

Page 31: ...ews from the underside of the appliance Unhook and remove the front panel 3 Remove the bottom panel 2 screws 4 Allow the RHS of the bottom panel to lower slightly 5 Remove the gas valve electrical connections and the silicon sensing pipe 6 Withdraw the LHS of the bottom panel from the retaining clips 7 Undo the union nut between the gas valve and the gas inlet cock 8 Undo the union nut on the outl...

Page 32: ...ckets to the new control box 10 Reassemble in reverse order ensuring that the control box is located correctly in the housing before reconnecting the electrical wiring 11 Check operation of the boiler Refer to Frame 36 1 Refer to Frame 36 2 Remove the boiler bottom panel refer to Frame 37 3 Unscrew the 2 control box screws and allow the control box to lower 4 Push out the mains switch from the rea...

Page 33: ...HERMOSTAT REPLACEMENT 1 Refer to Frame 36 2 Pull off the electrical leads from the thermostat body 3 Pull the thermostat and clip from the pipe 4 Fit the new thermostat ensuring that the clip is securely holding the thermostat to the flow pipe 5 Re assemble in reverse order 6 Check operation of the boiler Refer to Frame 36 Note Removal of the collector hood and flue spigot will facilitate better a...

Page 34: ...loves supplied with the spare part 6 Damp down the combustion chamber area containing the insulation boards 7 Remove the split pin and washer from the LHS of the combustion chamber 8 Remove the insulation boards The replacement boards are supplied in a plastic bag This bag should be retained and the discarded boards should now be placed into it 9 Sweep any dampened particles and place in the plast...

Page 35: ...e control thermistor and over heat thermostat from the flow pipe 9 Drain the boiler using the heat exchanger drain point Ecl 1645 9 1 0 1 1 10 Remove the 2 M5 x 10 screws from the bottom of the inter panel 11 Slide the heat engine and inter panel assembly downwards to disengage and remove from the casing 12 Reassemble in reverse order replacing gaskets or seals if any sign of damage or deteriorati...

Page 36: ...l is correctly seated compressing the seal to make an airtight joint 6 Check operation of boiler Refer Frame 36 Ecl 1648 1 Ecl 1649 2 Ecl 1650 Seals 58 COLLECTOR HOOD REMOVAL Refer to Frame 36 1 Remove the 2 spring clips securing the collector hood to the heat exchanger 2 Slide the flue spigot upwards into the flue turret to allow the collector hood to slide forwards 3 Remove the collector hood 4 ...

Page 37: ... ALTERNATING L F GO TO FRAME 60 ALTERNATING L E GO TO FRAME 61 ALTERNATING L A GO TO FRAME 62 ALTERNATING L 8 GO TO FRAME 63 ALTERNATING H 1 GO TO FRAME 64 ALTERNATING H F GO TO FRAME 65 ALTERNATING H n GO TO FRAME 66 ALTERNATING H E GO TO FRAME 61 In order to assist fault finding the boiler has an LCD display The key to the display codes is as follows ...

Page 38: ...ition electrode and associated harness for continuity visual condition position Are these functioning correctly Check gas valve wiring for continuity YES Check the detection electrode and associated harness for continuity visual condition position Replace if necessary If the boiler reset button is pressed does the boiler ignite for a short time then extinguish Is 200 v DC supply available at the g...

Page 39: ...nect thermistor wires Are the thermistor values correct Replace the thermistor NO NO YES Replace PCB Check and replace wiring as necessary 65 H F FLAME DETECTION SHORT CIRCUIT Replace detection electrode Is there continuity between the detection electrode terminal at the PCB and earth Check the detection electrode for continuity and visual condition Replace if necessary NO YES 66 H n PHASE REVERSA...

Page 40: ...on 1 170 906 14 E69 270 Injector and housing 1 170 908 16 E69 271 Fan assembly 1 170 909 19 E67 497 Gas control valve Honeywell VK115V 1 170 913 23 E67 501 Control thermistor 1 170917 24 E67 502 Overheat thermostat 1 170918 25 E67 503 Ignition electrode and gasket 1 170 919 26 E67 504 Flame sensing electrode and gasket 1 170 920 35 E67 517 Users controls 1 170 929 36 E67 518 PCB primary controls i...

Page 41: ...41 classic m Installation Servicing SHORT LIST OF PARTS 11 12 14 16 23 24 25 6 26 35 37 36 39 42 45 52 53 Ecl1700 19 67 SHORT LIST OF PARTS ...

Page 42: ...tion Servicing SHORT LIST OF PARTS 68 CASE ASSEMBLY 69 BURNER ASSEMBLY 1 Front casing panel with screws 2 Sealing panel with screws 4 Bottom panel with screws 11 Burner assembly with screws and gasket Ecl 1601 1 4 2 Ecl1702 ...

Page 43: ...ng SHORT LIST OF PARTS Ecl 1600 34 35 38 36 54 39 70 CONTROLS ASSEMBLY 33 Controls assy complete with screws 34 Controls hinge bracket 35 User controls without item 38 36 PCB primary controls 38 User controls housing kit 54 Jumper link ...

Page 44: ...g of central heating systems CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001 1994 Quality System accepted by BSI Caradon Plumbing Ltd P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 Technical Training The Caradon Plumbing Limited Technical Training Centre offers a series of first class training courses for domestic ...

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