Ideal Boilers responce 80 Installation And Servicing Manual Download

Page: 57 / 64

Response 80 / 100 / 120

- Installation

SHORT LIST OF PARTS

BURNER ASSEMBLY - Exploded View

28. Pressure sensing pipe.

29. Sensing pipe clamp plate

54. Fan / burner mounting 'O' ring.

55. Fan 'O' ring.

56. Pressure pipe 'O' ring.

57. Gas manifold gasket.

58. Gas valve gasket.

68. Gas cock

1/2

74. Injector pipe 'O' ring.

75. Gas elbow 'O' ring.

LEGEND

Burner.

Burner injector.

Gas valve.

Flame sensing electrode.

Ignition electrode.

19. Fan assembly.

Summary of Contents for responce 80

Page 1: ......

Page 2: ...as water and electrical connections before the boiler is fitted and it fits inside a cupboard Its compact size up to half that of other combis makes the Response ideal for any kitchen It can be instal...

Page 3: ...e temp mass flow rate 235 o C 11 8 g s 235 o C 14 7 g s 235 o C 14 7 g s Max DHW water inlet pressure bar lb in2 10 0 145 0 10 0 145 0 10 0 145 0 Min DHW water inlet pressure bar lb in2 1 0 14 1 2 17...

Page 4: ...mperature of 60 o C The boiler casing is of white painted mild steel with a drop down controls access door The boiler temperature control is located behind the controls access door The heat exchanger...

Page 5: ...er is then directed by the automatic switching off of the circulation pump to heat the inner coils and supply a maximum draw off of Response 80 9 6 l min 2 1 gpm at 35 0 rise Response 100 12 0 l min 2...

Page 6: ...ng the space in which the boiler is to be installed must be at least wide enough to accommodate the tool Boiler connections are made on the mounting frame Refer to Frame GENERAL Front clearance The mi...

Page 7: ...d by a CORGI registered installer in accordance with the above regulations Failure to install appliances correctly could lead to prosecution It is in your own interest and that of safety to ensure the...

Page 8: ...e passage of air across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 6 4 Where the lowest part of the terminal is fitt...

Page 9: ...stallation should be designed to work with flow temperatures of up to 90 C 4 Working Pressure All components of the system must be suitable for a working pressure of 3 bar 45 lb in2 and temperature of...

Page 10: ...pressurise the system to the desired charge pressure see table below CH Return Ecl 6053 Hose unions Mains water supply Temporary hose disconnect after filling Additional stop valve Double check valve...

Page 11: ...e l sec 0 382 0 508 gal min 5 04 6 7 Temperature o C 11 11 differential o F 20 20 Head available for m w g 2 75 2 5 system pump pos 3 ft w g 9 0 8 0 Water Flow Rate and Pressure Loss 9 Draining the sy...

Page 12: ...ressure sensing pip 30 EMC filter 32 CH Return pipe assy 33 Pump pipe assy 34 CH Lower flow pipe assy 35 CH Upper flow pipe assy 36 DHW Upper cold pipe assy 37 DHW Upper hot pipe assy 38 DHW Lower col...

Page 13: ...r side flue outlet in Pack B Unpack and check the contents Pack A Contents The boiler These Installation Servicing Instructions The User s Instructions Wall mounting template Wall mounting frame 1 pai...

Page 14: ...t may be necessary to shorten the standard flue before adding extension duct s in order to prevent interference between flue duct connections and the boiler flue elbow 4000mm maximum for the 100 and 1...

Page 15: ...t be fitted close to a corner 11 REAR FLUE ASSEMBLY Exploded View 12 WALL MOUNTING TEMPLATE Rear Flue IMPORTANT For direct mounting wall mounting frame on wall choose one black dot in each group If us...

Page 16: ...nto the wall plugs and leave 10mm proud Hang the frame onto the screws and tighten up or b Use stand off channels To allow pipework to be taken upwards Insert wall plugs Put the screws into the wall p...

Page 17: ...5 Remove the cardboard support and any burrs For flue lengths greater than 600mm 23 5 8 refer to Frames 30 to 32 Flue Extension Ducts 16 FITTING THE FLUE IMPORTANT To facilitate turret fixing or remo...

Page 18: ...the cable clamps Refer to Frame 39 2 WARNING ENSURE that the plastic plugs are removed from both the DHW and CH pipes before mounting N B Some spillage of water may occur from the pipework when mounti...

Page 19: ...gh neatly or c When the wall face is rough and the rubber seal on its own would be ineffective 1 Position the terminal wall plate over the terminal 2 Drill 4 fixing holes with a 7mm 1 4 masonry drill...

Page 20: ...Refer to Frame 10 1 Tape template into the selected position 2 Ensure squareness by hanging a plumbline as shown 3 Mark onto the wall the following a The 6 wall mounting plate screw positions choose o...

Page 21: ...nal is to be sited within 25 40mm of a corner or vertical pipe refer to Table 3 then the hole MUST be accurately cut and the rubber weather seal trimmed around the groove provided The terminal wall pl...

Page 22: ...rame with the 6mm screws provided Hang channels and frame onto the screws and tighten up Note If the clearances above and below the boiler are less than the length of the pipes it will be necessary to...

Page 23: ...ket using the spacer bracket and long wood screw INSTALLATION SIDE FLUE OUTLET 1 The boiler may be prewired to the loose electrical connector and secured with the cable clamps Refer to Frame 39 2 WARN...

Page 24: ...gh neatly or c When the wall face is rough and the rubber seal on its own would be ineffective 1 Position the terminal wall plate over the terminal 2 Drill 4 fixing holes with a 7mm 1 4 masonry drill...

Page 25: ...board support aid from the flue and place safely to one side 2 Fit the inner flue extension duct onto the inner flue duct 3 Fit the outer flue extension duct onto the outer air duct 4 Drill one 3 2mm...

Page 26: ...E TO THE TURRET 1 Insert the flue into the prepared hole Refer to Frame 26 for details 2 Mate the flue to the turret Refer to Frame 28 for details Note To facilitate turret fixing or removal do NOT ma...

Page 27: ...Extend a gas supply pipe of not less than 22mm O D copper or 3 4 BSP iron to the boiler A working gas pressure of 20mbar 8 w g must be available at the boiler inlet with the boiler firing at full DHW...

Page 28: ...ecure the connector to the panel with the screw Incoming mains wiring detail INSTALLATION INSTALLATION WARNING This appliance MUST be efficiently earthed A mains supply of 230 V 50 Hz is required The...

Page 29: ...v v 41 FUNCTIONAL FLOW WIRING DIAGRAM INSTALLATION INSTALLATION LEGEND b blue bk black br brown gy grey or orange pk pink r red v violet w white y yellow y g yellow green LEGEND b blue bk black br br...

Page 30: ...y the boiler and system controls The means of isolation must be accessible to the user after installation Internal Programmer The Ideal Programmer Kit is supplied with its own instructions Associated...

Page 31: ...sure see Frame 36 is at least 20 mbar when the boiler is firing 13 Set the boiler on off switch C to OFF 14 Remove the pressure gauge and tube Replace the sealing screw in the pressure test point Ensu...

Page 32: ...kshield valves be set a half turn open and the bypass a half turn to one turn open a minimum of one turn open is recommended when TRVs are used Make minor adjustments to each radiator to achieve the s...

Page 33: ...tabs from the slots 1 Turn off the gas supply at the gas service cock and disconnect the electricity supply 2 Remove the screw and lift off the boiler front panel SERVICING SERVICING To ensure the co...

Page 34: ...or renew as necessary Refer to Frame 65 for replacement Note Always take care when handling the fan in order to preserve the balance of the impeller 50 BURNER REMOVAL AND CLEANING 6 Check the spark a...

Page 35: ...he boiler models Frame 45 Gas rate Note that the pressure is set by the gas valve according to fan speed which in turn is controlled by reference to boiler temperature and mode CH HW thus the burner p...

Page 36: ...ystem to foul the valve 6 Disconnect the plug in lead from the temperature sensor and unscrew the sensor to release it 7 Screw in the new sensor using thread sealant reconnect and re assemble in rever...

Page 37: ...to Frame 48 2 Remove the PCB cover 3 Undo the securing screw and lift off the spark generator cover if fitted 4 Disconnect the electrical leads from the spark generator 5 Withdraw the spark generator...

Page 38: ...nger taking care not to damage the electrodes 6 Remove the spark and detection electrodes Refer to Frame 58 7 Remove the 3 securing screws and withdraw the burner from the mounting flange 8 Fit the ne...

Page 39: ...5 Remove the 2 securing screws from the pressure gauge sub panel 6 Gently ease the pressure switch housing out of the pressure switch sensing hose 7 Unplug the electrical leads from the gas valve 8 U...

Page 40: ...e controls panel 4 Close the isolating valves on the CH flow return at the base of the boiler then release CH system pressure by opening one of the CH drain cocks on the isolating valves It is not adv...

Page 41: ...are when handling the fan in order to preserve the balance of the impeller 6 Fit the new fan ensuring that a All seals are correctly refitted b The sensing pipe is correctly refitted c The fan is full...

Page 42: ...e made non interchangeable If in doubt refer to Frame 40 Pictorial Wiring 8 Reassemble in reverse order 9 Test both DHW and CH modes of operation 1 Disconnect the electrical supply to the boiler 2 Rem...

Page 43: ...re on the same side as the inlet pipe If necessary use an Allen key to remove the motor and reposition it 10 Transfer the short inlet pipe to the inlet side of the replacement pump using a new sealing...

Page 44: ...er together with the screw securing the turret to the flue pipe Remove the turret 7 Remove the fan venturi and sensing pipe Refer to Frame 49 8 Unscrew and remove the HW expansion vessel 9 Undo the 2...

Page 45: ...the control panel 6 Compress the clips on the sides of the programmer and withdraw it from the retaining bracket 7 Fit the new programmer and re assemble in reverse order 8 Check the operation of the...

Page 46: ...pen the isolating valve and bleed air out at the tap s 11 Reconnect the electrical supply and open a HW tap to test operation of the boiler SERVICING 74 WATER FLOW SWITCH REPLACEMENT SERVICING 75 INLE...

Page 47: ...r 8 Replace with a new valve and restore the pipework in reverse order using new sealing washer 9 Open cocks fit filling loop fill vent and pressurise to 1 bar or as required 10 Restore the electrical...

Page 48: ...anel and remove the panel to gain access to the expansion vessel connector Where RH clearance is NOT available Remove the fan refer Frame 49 and gas valve refer Frame 62 to gain access to the expansio...

Page 49: ...e is not detected the spark stops the gas valve closes the fan continues to run for a post purge The gas valve reopens and the spark restarts PCB 41 will attempt 4 ignitions If all 4 attempts fail the...

Page 50: ...ections OK YES Is the CH light on PCB 40 flashing Check the lead to the pump Replace cap Switch off and change pump YES Is the HW light lit on PCB 40 If the boiler has been unused with mains off the p...

Page 51: ...s the switch close Reconnect the flow switch Unplug the lead from the HW sensor and transfer temporarily to a replacement sensor Will the boiler operate Fit new HW sensor which has failed low resistan...

Page 52: ...Replace fuse Examine fan harness checking especially for short circuits between wires or terminals If no fault found power up board without fan harness connected Does fuse F1 blow YES NO YES EXIT YES...

Page 53: ...cock fully open NO NO Is the gas supply pressure adequate at the appliance inlet during an ignition trial period i e when LED 2 on PCB 41 goes off NO YES Contact the gas supplier Is the supply pressur...

Page 54: ...ectrodes or leads externally to the burner YES YES NO Rectify poor connections or replace the spark generator or electrodes Remove the fan and burner assembly and reconnect spark leads to the electrod...

Page 55: ...mm of the burner at closest point Rectify any fault Does the boiler now run YES Is this a new installation Has any electrical work been done to the boiler or the house wiring YES Check the polarity of...

Page 56: ...valve free from foreign matter correctly set and in the closed position NO YES Replace safety valve and refill repressurise Fire the boiler up on CH Observe pressure gauge as system reaches temperatu...

Page 57: ...pe 29 Sensing pipe clamp plate 54 Fan burner mounting O ring 55 Fan O ring 56 Pressure pipe O ring 57 Gas manifold gasket 58 Gas valve gasket 68 Gas cock 1 2 74 Injector pipe O ring 75 Gas elbow O rin...

Page 58: ...Response 80 100 120 Installation SHORT LIST OF PARTS 88 CONTROLS AREA Exploded View Legend 7 PCB 41 8 PCB 40 9 Fan speed control board 10 Spark generator assembly 30 EMC filter 67 Transformer assembl...

Page 59: ...1 143 Response 80 1 075212 E01 797 Response 100 120 1 075213 4 Flame sensing electrode Buccleuch c w 1 off sensing electrode gasket 1 off M4 x 10 lg pozi pan hd screw 1 off M4 shakeproof washer 1 1520...

Page 60: ...ly c w 6 off M4 x 10 lg pozi hex hd screws 1 075192 43 E00 081 Boiler RH side panel assembly c w 6 off M4 x 10 lg pozi hex hd screws 1 075193 44 E00 082 Tank cover panel assembly c w 3 off M4 x 10 lg...

Page 61: ...61 Response 80 100 120 Installation 89 SHORT PARTS LIST 90 BOILER CASING ASSEMBLY SHORT LIST OF PARTS Res 5972...

Page 62: ...62 Response 80 100 120 Installation NOTES...

Page 63: ...63 Response 80 100 120 Installation NOTES...

Page 64: ...ved 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...

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