background image

10

 

Installation and Servicing

SECTION 1 - GENERAL

1.1 INTRODUCTION

The

 Inde Combi 

range of boilers are wall mounted, full 

sequence, automatic spark ignition, low water content, fanned 

flue, high efficiency, condensing, combination gas boilers.

Note. 

Due to the high efficiency of the boiler a plume of water 

vapour will form at the terminal during operation.

Central heating (CH) output is fully modulating with a range of:
24 

4.8 to 24.2kW

30 

6.1 to 24.2kW

35 

7.1 to 24.2kW

Instantaneous domestic hot water (DHW) output is also fully 

modulating with a maximum of :
24 24.2kW
30 30.3kW
35 35.3kW
The boiler is supplied fully assembled with DHW plate heat 

exchanger, diverter valve, circulating pump, pressure gauge, 

safety valve and CH expansion vessel.

Variable CH and DHW temperature controls are fitted on the user 

control and the boiler features a DHW preheat facility.
The boiler includes as standard:

Automatic bypass

Boiler frost protection

Daily pump and diverter valve exercise

Mechanical 24hr timer

The boiler casing is of white painted mild steel with a white 

polymer front panel.
The boiler temperature controls are visible located in the control 

panel on the front of the boiler.
The heat exchanger is manufactured from cast aluminium.
The boiler is suitable for connection to fully pumped, sealed 

heating systems ONLY.  Adequate arrangements for completely 

draining the system by provision of drain cocks MUST be 

provided in the installation pipework.
Pipework from the boiler is routed downwards.

Data Plate

The boiler model and serial number can be located on the bottom of 

the boiler casing, shown in Section 1.16 - Water & Gas Connection 

Diagram.

1.2 OPERATION

With no demand for CH, the boiler fires only when DHW is drawn 

off, or periodically for a few seconds without any DHW draw-off, 

in order to maintain the DHW plate heat exchanger in a heated 

condition.  This only occurs if pre-heat knob is in the ‘ON’ period.
When there is a demand for CH, the heating system is supplied at 

the selected temperature of between 30

o

C and 80

o

C, until DHW 

is drawn off.  The full output from the boiler is then directed via 

the diverter valve to the plate heat exchanger to supply a nominal 

DHW draw-off of 
24 

9.9 l/min at 35 

o

C temperature rise.

30 

12.4 l/min at 35 

o

C temperature rise.

35 

14.5 l/min at 35 

o

C temperature rise.

The DHW draw off rate specified above is the nominal that the 

boiler flow regulator will give.  Due to system variations and 

seasonal temperature fluctuations DHW flow rates/temperature 

rise will vary, requiring adjustment at the draw off tap.
At low DHW draw off rates, the maximum temperature may 

exceed 65ºC.
The boiler features a comprehensive diagnostic system which 

gives detailed information on the boiler status when operating, and 

performance of key components to aid commissioning and fault finding.

1.3  SAFE HANDLING

This boiler may require 2 or more operatives to move it to its 

installation site, remove it from its packaging base and during 

movement into its installation location.  Manoeuvring the boiler 

may include the use of a sack truck and involve lifting, pushing 

and pulling.  
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques 

when performing these tasks and the following precautions should 

be considered:
•  Grip the boiler at the base.

•  Be physically capable.

•  Use personal protective equipment as appropriate, e.g. 

gloves, safety footwear.

During all manoeuvres and handling actions, every attempt 

should be made to ensure the following unless unavoidable  and/

or the weight is light.
•  Keep back straight.

•  Avoid twisting at the waist.

•  Avoid upper body/top heavy bending.

•  Always grip with the palm of the hand.

•  Use designated hand holds.

•  Keep load as close to the body as possible.
•  Always use assistance if required.

1.4  OPTIONAL EXTRA KITS

Please visit www.idealboilers.com to access the Flue and 

Accessories Guide for this boiler.

Summary of Contents for INDEPENDENT+ COMBI 24

Page 1: ...Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers For the very latest copy of literature for specification and maintenance practices visit our website www...

Page 2: ...P1 kW 8 0 8 0 8 0 Auxiliary Electricity Consumption Full Load elmax kW 0 042 0 032 0 029 Part Load elmin kW 0 012 0 013 0 013 Standby PSB kW 0 005 0 005 0 005 Seasonal Space Heating Energy Efficiency...

Page 3: ...I Class VII Class VIII 1 2 1 5 2 3 4 3 5 5 PRODUCT FICHE The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installe...

Page 4: ...4 Installation and Servicing...

Page 5: ...19 Ideal Boilers reserve the right to vary specification without notice FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL INSTALLER HELPLINE 01482 498704 NOTE BOILER RESTART PROCEDURE To restart the bo...

Page 6: ...6 Installation and Servicing...

Page 7: ...nd Venturi Assembly Removal and Cleaning 40 3 4 Burner Removal And Cleaning 41 3 5 Cleaning The Condensate Trap Siphon 41 3 6 Cleaning The Heat Exchanger 42 3 7 Reassembly 42 3 8 Replacement Of Compon...

Page 8: ...y 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 Key to symbols GB United Kingdom IE Ireland Countries of destination PMS Maximum...

Page 9: ...ure record Cold water inlet temp measure record Hot water outlet temp measure record Water flow rate at max setting measure record For condensing boilers only Condensate drain 28 For all boilers compl...

Page 10: ...ition This only occurs if pre heat knob is in the ON period When there is a demand for CH the heating system is supplied at the selected temperature of between 30o C and 80o C until DHW is drawn off T...

Page 11: ...vice not approved by Ideal Boilers could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations 1 6 SAFE HANDLING OF...

Page 12: ...cing from the terminal to obstructions and ventilation openings are specified in Table 4 4 Where the lowest part of the terminal is fitted less than 2m 6 6 above a balcony above ground or above a flat...

Page 13: ...diator valves are used the space heating temperature control over a living dining area or hallway having a heating requirement of at least 10 of the minimum boiler heat output should be achieved using...

Page 14: ...a core drill the flue can be installed from inside the building 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...

Page 15: ...ling topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority b Antifreeze fluid corrosion and...

Page 16: ...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 2006 details the steps necessary to clean...

Page 17: ...sket Burner 219 Sump Clean Out Cover 223 Flue Manifold 224 Flue Manifold Top 227 Clamp Retaining Flue Turret 228 Hose Condensate Internal 229 Siphon Trap 231 Condensate Outlet Connection 302 PCB 304 C...

Page 18: ...1 12 2 2 UNPACKING The boiler is supplied fully assembled in Pack A A telescopic or non telescopic flue assembly for rear or side flue outlet in Pack B is suppled as a separate order Unpack and check...

Page 19: ...B Pack B Contents Non Telescopic A Flue Terminal B Flue Turret C Rubber Terminal Wall Seal D Cutting Aid Note This flue system incorporates a removable flue outlet nose that utilises a push fit locat...

Page 20: ...t during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Cut the flue hole preferably with a 5 core boring tool ensuring that the hole is squar...

Page 21: ...ion Kits available for use with these B packs Flue Deflector Kit The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from any maximum flue length High Level Flue Ou...

Page 22: ...inimum Maximum Minimum Maximum Minimum Maximum B Pack Standard 181 556 286 484 601 816 526 741 Plus 1 1m D pack 1121 1506 1236 1434 1551 1766 1476 1691 Plus 2 1m D pack 2071 2456 2186 2384 2501 2716 2...

Page 23: ...he outlet terminal is upper most 4 Drill a 3 5mm hole through one of the 2 outer side holes in the outer flue section into the inserted outer flue as shown Take care not to pierce the inner plastic fl...

Page 24: ...been dislodged from its mounting and will need to be refitted 7 Ensure the seam and the outlet terminal are at the top and fitted as shown Note If less than 50 of the length of the flue is internal t...

Page 25: ...ade using the supplied vertical connector WEATHER PROOFING Where the flue passes through the roof line an adequate seal must be made This is achieved by using either Flat roof weather collar or Univer...

Page 26: ...enetrate the shaded area of the roof Note The equivalent flue length resistance of the elbow kits are 90o elbow kit 1m 45o elbow kit 0 6m If chimney penetrates dotted area such that A is less than 300...

Page 27: ...n the instructions provided with the vertical connector kit 3 Secure the vertical connector by applying downward pressure on the connector 4 Position the clamp on the top face of the flue manifold and...

Page 28: ...harge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc fig 3 External Drain Connections The use of an externally run condensate drainage pipe should only be...

Page 29: ...pipe Water Weather proof insulation Max 3m external pipework Limestone chippings 500 300 25 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house Minimum...

Page 30: ...hand side of the boiler comprises a 15mm diameter stub pipe The Installer to provide a compression joint on the end of the stub pipe This assists with pipe removal when servicing The discharge pipe sh...

Page 31: ...ny local regulations 2 18 INSTALLER WIRING A mains cable must be connected to a permanent live supply and NOT switched by thermostats programmers To do so follow the instructions below Accessing the i...

Page 32: ...DAMAGED Outside Sensor Open Therm OpenTherm Device E G Honeywell OT Bridge R8810 External Controls 230V 50Hz Wiring a 230V 50Hz Room Thermostat Diagram A with optional timer Diagram B 1 Remove the lin...

Page 33: ...P GND X9 X8 OWC OWC OPENTHERM OPENTHERM OPENTHERM 5V CHIP COM BUS TX CHIP COM BUS 24V CHIP COM BUS GND CHIP COM BUS 5V CHIP COM BUS RX MAINS LIVE MAINS NEUTRAL AUXILIARY LIVE IONISATION 2 2 FLOW DHW D...

Page 34: ...W Outlet Gas Supply CH Return DHW Inlet Gas Pressure Test Point WARNING Whilst effecting the required gas tightness test and purging air from the gas installation open all windows and doors extinguish...

Page 35: ...that the gas service cock I is OPEN 7 Slacken the screw in the inlet pressure test point H and connect a gas pressure gauge via a flexible tube 8 Switch the electricity supply ON and check mechanical...

Page 36: ...show then when the burner lights 2 Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate This is factory set to give a DHW temperature rise of appr...

Page 37: ...between being on for 50s and then off for 10s 5 dU will be shown To move the diverter valve to mid position for replacement press RESTART otherwise press PREHEAT 6 P1 will be shown To set the minimum...

Page 38: ...r the relevant national regulations 2 Explain and demonstrate the lighting and shutting down procedures 3 The operation of the boiler and the use and adjustment of all system controls should be fully...

Page 39: ...demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS7967 Parts 1 to 4 Note In order to carry o...

Page 40: ...ring the 4 control knobs line up with the holes in the front panel 5 Re tighten the two retaining screws view from bottom of boiler view from top of boiler 3 1 2 1 Disconnect the electrical leads from...

Page 41: ...nstruction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic 6 Brush off any deposits that may be on the ceramic with a SOFT brush 7...

Page 42: ...nition and detection gaps are correct Refer to Sections 3 13 3 14 1 Ignition Electrode Flame Detection Reassemble the boiler in the following order 1 Ensure that the condensate trap siphon is full of...

Page 43: ...boiler Refer to Section 3 22 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 3 9 FAN REPLACEMENT 1 Refer to Section 3 8 2 Disconnect the electrical leads from the fan 3 Remove the clip...

Page 44: ...rse order ensuring that the new gas seal supplied is located correctly in the injector housing 10 Check that the boiler operates in both DHW CH modes 4 3 3 3 11 BURNER REPLACEMENT 5 5 6 1 See Section...

Page 45: ...8 Reassemble in reverse order 9 Check the operation of the boiler Refer to Section 2 22 2 23 3 12 RETURN THERMISTOR REPLACEMENT 1 Refer to Section 3 8 2 Unclip the return thermistor from the return p...

Page 46: ...rode 4 Remove the 2 screws retaining the detection electrode 5 Remove the electrode 6 Fit the new flame detection electrode using the new gasket supplied 7 Reassemble in reverse order 8 Check that the...

Page 47: ...acing the diverter valve actuator proceed as follows a Ensure that the switched live to the boiler is off and that all DHW taps are shut and that pre heat is switched off b Press and hold the PREHEAT...

Page 48: ...the four side retaining clips and pull the PCB upwards to clear the corner retaining posts 7 Take the new PCB 8 Re connect all plug connections 9 Reassemble in reverse order 10 a Turn power on displa...

Page 49: ...o 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...

Page 50: ...to port ensuring o ring in place and secure with the C clip 7 Refill the boiler Refer to Section 2 16 8 Check that the boiler operates in both DHW CH modes 3 23 PRESSURE GAUGE REPLACEMENT 4 5 1 Refer...

Page 51: ...ap siphon Refer to Section 3 18 4 Remove the electrical plug Refer to Section 3 17 5 Place a flat bladed screwdriver in the diverter valve motor body slot provided and ease out the motor Refer to Sect...

Page 52: ...9 Refill the boiler Refer to Section 2 16 10 Check that the boiler operates in both DHW CH modes 1 Refer to Section 3 8 2 Drain the boiler Refer to Section 3 22 3 Disconnect the two electrical leads f...

Page 53: ...ovided 6 Reassemble in the reverse order 7 Refill the boiler Refer to Section 2 16 8 Check that the boiler operates in both DHW CH modes 3 31 FLOW THERMISTOR REPLACEMENT 4 3 1 Refer to Section 3 8 2 D...

Page 54: ...to correctly match connecting pipe diameters 18 Ensure the trap siphon is filled with water Refer to Section 3 18 19 Refill the boiler and check for leaks Refer to Section 2 16 20 Ensure all gas valv...

Page 55: ...rcuit Refer to Section 3 22 8 Remove the retaining clip on the vessel water connection pipe and remove the pipe 9 Support the expansion vessel and unscrew the 2 screws from the securing bracket locate...

Page 56: ...GO TO SECTION 4 9 RETURN THERMISTOR FAULT GO TO SECTION 4 10 OUTSIDE SENSOR FAULT LOW MAINS VOLTAGE CONTACT ELECTRICITY PROVIDER PCB UNCONFIGURED OR FAULTY SEE SECTION 3 19 IF FAULT PERSISTS REPLACE...

Page 57: ...rectify fault NO YES Is 24Vdc supply available at the Gas Valve YES Check spark generator and associated harness for continuity and visual condition Refer to Section 3 15 Are these functioning correct...

Page 58: ...these functioning correctly YES Check siphon and condensate drain pipe work for blockage and rectify if necessary Boiler now working OK Check wiring from gas valve to PCB for continuity If the wiring...

Page 59: ...1 000 1 100 Ohms Is the Thermistor value correct YES Is the wiring securely connected to the low voltage 6 way connector at the front left hand side of the PCB YES Replace PCB Fit a new Thermistor NO...

Page 60: ...and the PCB Replace PCB Fit a new Outside Sensor NO Securely connect the wiring at the Terminal Block and the PCB Is the wiring securely connected at both the boiler and Outside Sensor YES NO Securel...

Page 61: ...d the diverter valve motor connected YES YES Check diverter head fully engaged and clip secured onto waterset YES Is diverter stuck in the CH position YES Check and re fit diverter valve actuator head...

Page 62: ...ils of approved Ideal Parts Distributors are available on www idealparts com Our Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665 When calling and to ensure...

Page 63: ...63 Installation and Servicing...

Page 64: ......

Page 65: ...ta fields on the commissioning checklist completed in full To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation To maintain th...

Page 66: ...priate Building Regulations and then handed to the customer to keep for future reference GAS BOILER SYSTEM COMMISSIONING CHECKLIST CONTROLS Programmable room thermostat Optimum start control Combinati...

Page 67: ...larly and that the appropriate Service Interval Record is completed Service Provider SERVICE RECORD SERVICE 01 AND Where Possible AND Signature SERVICE 02 AND Where Possible AND Signature SERVICE 03 A...

Page 68: ...ical Bulletin TB 008 where chimney flues are in voids The ECGA should be of the correct type as specified by BS 7967 Prior to its use the ECGA should have been maintained and calibrated as specified b...

Page 69: ...bled fixed and supported as per instructions Check that flue and flue terminal are not obstructed Check that no seals e g Those on flue extensions have been displaced during installation Rectify if ne...

Page 70: ...70 NOTES Installation and Servicing...

Page 71: ...71 NOTES Installation and Servicing...

Page 72: ...he code of practice for the installation commissioning servicing of central heating systems Ideal Boilers Ltd PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 01482 492251 Fax 01482 448858 Re...

Reviews: