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22

INSTALLATION

combination boiler - 

Installation and Servicing

3 1 PICTORIAL WIRING DIAGRAM

LEGEND

b

-

blue.

bk

-

black.

br

-

brown.

r

-

red.

w

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white.

y/g

-

yellow/green.

gr

-

green.

or

-

orange.

v

-

violet.

gy

-

grey.

A9

L1 N

A1

TA

A2

A3

FUSE1

A6

A5

A8

J1

J5

G

P

L

B

L

O

C

C

O

(F

LA

M

E

 F

A

IL

U

R

E

)

P

R

E

S

E

N

Z

A

 F

IA

M

M

A

(B

U

R

N

E

R

 O

N

)

F

U

N

Z

. R

IS

C

A

LD

A

M

.

(C

H

 M

O

D

E

)

L

IN

E

A

(P

O

W

E

R

 O

N

)

M

E

T

P1

P2

FS1

Programmer connection

v

v

Overheat thermostat

bk

br

b

bk

or

b

br

w

y/g

y/g

y/g

bk

y/g

b

br

y/g

br

b

gr

r

w

w

or

w

gy

w

w

w

w

br

w

br

r

r

b

br

y/g

br

b

Mains supply
230 V - 50 Hz

Pump

Flame 
detection
electrode

Mains
switch

Fan

Air pressure 
switch

Reset

button

Programmer

CH sensor

DHW  sensor

Flow switch

Low switch

A4

RESET

ENTER

OFF

ON

1

2

3

4

5

6

7

17.26

bk r

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

G

N

D

1

G

N

D

2

G

N

D

3

G

N

D

4

G

N

D

5

A9

3

2

1

r

Ignition
transformer

Ignition
electrodes

Y2

Gas 
valve

or

b

br

132 Vac

47 Vdc

Connection ID for
Gas Valve lead

r

INSTALLATION

Summary of Contents for Europa 24

Page 1: ...installation servicing 24 28 Your installation servicing guide ...

Page 2: ...oss 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: ...ms 21 to 23 Natural Gas only G C Appliance No 47 348 20 europa 24 G C Appliance No 47 348 21 europa 28 PINo 0049AU2867 europa 24 0049AU2949 europa 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 T O THE CUSTOMER BENCHMARK LOG BOOK DETAILS Boiler Page Make and model 3 Appliance Serial No on Da...

Page 4: ... 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 DHW is drawn off The full ...

Page 5: ...iler is not necessary 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...

Page 6: ...ore 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 Bottom clearance af...

Page 7: ...ide 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 governe...

Page 8: ...t 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 other system volumes multiply by the factor across 0 074 WATER CIRCULATION SYSTEM The boilers are ...

Page 9: ... 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 until t...

Page 10: ...andem 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 necessary to cle...

Page 11: ...tion boiler Installation and Servicing 8 BOILER ASSEMBLY Exploded View 1 7 6 5 2 46 3 4 10 41 40 39 38 37 36 34 33 32 31 49 30 29 28 24 9 8 14 16 38 22 13 17 21 25 19 20 26 27 97 47 11 48 23 35 42 42 43 44 45 96 INSTALLATION ...

Page 12: ...LOW 4 TAPE TEMPLATE B INTO SELECTED POSITION 5 MARK ON THE CENTRE OF THE FLUE HOLE AS WELL AS THE CIRCUMFERENCE 6 IF USING THE OPTIONAL STAND OFF KIT FOR UPWARD PIPING MARK ON THE HOLE CENTRE AND CIRCUMFERENCE OF THE DASHED CIRCLE 7 PROCEED TO POINT 4 ABOVE TEMPLATE INSTRUCTIONS INSTRUCTIONS FOR RH LH SIDE EXIT FLUE Formounting Stand offkit WITHOUT MIN INSTALLED CLEARANCE FOR ACCESS TO LOWER CONTR...

Page 13: ...side the removed casing to avoid damage 1 2 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 s...

Page 14: ...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 1 4 WALL MOUNTING TEMPLATE 1 3 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 off kit 570 mm 22 3 8 with sta...

Page 15: ...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 1 7 CUTTING THE FLUE SIDE Wall thicknesses of 114 to 580 mm Note If using the extension ...

Page 16: ...bre seal is in place 7 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 2 3 2 1 a b c d e b a c d e 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 o...

Page 17: ...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 2 0 FLUE EXTENSION DUCTS For flue lengths greater than 720 mm Pack DFlue extension duct kit contents 1 A maximum of 3 extension ducts one suitably cut plus the standard flue duct may be us...

Page 18: ...l 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 2 2 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 must avoid...

Page 19: ...NNECTIONS continued DHWCONNECTIONS 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 pos...

Page 20: ... 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 the vent plug Note Some slight water leakage will occur c A manual air vent is fitted...

Page 21: ...t 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 t...

Page 22: ...verheat thermostat bk br b bk or b br w y g y g y g bk y g b br y g br b gr r w w or w gy w w w w br w br r r b br y g br b Mains supply 230 V 50 Hz Pump Flame detection electrode Mains switch Fan Air pressure switch Reset button Programmer CH sensor DHW sensor Flow switch Low switch A4 RESET ENTER OFF ON 1 2 3 4 5 6 7 17 26 bk r 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 G ...

Page 23: ... 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 3 3 COMMISSIONINGAND TESTING br b br v b v bk or w b br br w w br br w b w br b w gr r Mains supply 230 V 50 Hz y g br b y g y ...

Page 24: ... Off switch A Ca p RESET ENTER OFF O N 1 2 3 4 5 6 7 17 26 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 T Manual air vent 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 positio...

Page 25: ...Test for gas soundness around ALL boiler gas components using leak detection fluid 22 When the burner has ignited check the minimum burner pressure refer to Table 2 23 If necessary correct the pressure by turning the adjusting screw D anticlockwise to INCREASE the pressure or clockwise to DECREASE the pressure 24 If the minimum burner pressure cannot be achieved by the above method further adjustm...

Page 26: ...s 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 W ATER 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: ...t 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 Heating...

Page 28: ...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 the f...

Page 29: ...tic 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 4 2 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 S E R V I C I N G ...

Page 30: ...pansion 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 2 4 3...

Page 31: ...pen all system isolating valves before proceeding to check operation of the boiler 5 drain point 5 4 5 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 d...

Page 32: ...OVAL 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 any s...

Page 33: ...ng a soft brush 6 Re assemble in reverse order 3 4 9 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 When ...

Page 34: ...5659 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 5 1 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 ...

Page 35: ...stion 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 5 2 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 venturi pip...

Page 36: ... 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 5 5 OVERHEA T 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 heat e...

Page 37: ...de 3 4 mm ignition electrodes 4 4 4 6 6 6 6 5 7 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 R...

Page 38: ...EPLACEMENT 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 5 5 6...

Page 39: ...djuster 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 6 1 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 squeeze the shaft ends...

Page 40: ...INS SWITCH REPLACEMENT 6 3 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 temperature sens...

Page 41: ...Frame 43 3 Drain the boiler Refer to Frame 44 4 For europa 24 Unscrew the air vent from the CH return assembly and remove it For europa 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 relief ...

Page 42: ...ws 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 6 7 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 screws a...

Page 43: ...er Refer to Frames 4 and 28 5 4 6 9 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 Refer ...

Page 44: ... the new flow switch and re assemble in 5 6 6 7 1 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 transf...

Page 45: ...MINATED ENSUREALLTHECONTROLSARE CALLINGFORHEAT NO ARETHESELECTORSWITCH PROGRAMMER ANDROOMSTATALLCALLINGFORHEAT NO REPAIRORREPLACEFAULTY WIRINGORTHERMISTOR YES TOPUPTHESYSTEMPRESSUREVIA THEFILLINGDEVICETOATLEAST1bar YES YES ENSURETHEROOMTHERMOSTATAND PROGRAMMERARECALLINGFORHEATAND THESELECTORSWITCHISSETTOHEATING ENSUREALLSERVICESAREONANDNODHW TAPSAREOPEN BEFOREREPLACINGTHE PROGRAMMER CHECK THE ONAN...

Page 46: ...Y FAN HARNESS DOESTHEPUMPRUN DOES THE FAN RUN IS THERE 230 Vac AT THE PUMPCONNECTION FREE THE SPINDLE USING ASCREWDRIVEROR REPLACETHEPUMP ISTHEFLAMEFAILURELED ILLUMINATED REMOVE THE PUMP NUT DOES THE IMPELLOR SPIN FREELY IS THERE 230 Vac AT THE PCBCONNECTORA1 ACROSSPINS1AND2 IS THERE 230 Vac AT THE FAN CONNECTIONS ISTHECONTINUITYOFTHE AIRPRESSURESWITCH CONNECTINGLEADOK IS THERE 230 Vac AT THE PCBF...

Page 47: ...NECESSARY DOES THE IGNITER OPERATE TICKINGSOUND REPAIRORREPLACE FAULTY WIRING RECTIFY WIRING FAULT REPLACEFAULTYPCB DOES THE BURNER LIGHT ENSURE THE ELECTRODE LEADISCONNECTED UNDAMAGEDANDNOT SHORTEDTOEARTH ENSURE THE ELECTRODE IS UNDAMAGED AND THE SPARKGAPISCORRECT ARETHEFANVENTURI AND FLUE CLEAR OF OBSTRUCTIONS AND THE SENSIINGPIPES UNDAMAGED AND CORRECTLY CONNECTED ISTHERE132VacATPINS1 AND2AND47...

Page 48: ...PAIRORREPLACE FAULTYWIRINGOR THERMISTOR REPLACEFAULTYPCB ENSURETHEREIS SUFFICIENT WATER PRESSURE AND THE SUPPLYPIPEISADEQUATE CLEANINLETFILTERAND FLOWSWITCH REPLACE FAULTYFLOWSWITCHIF NECESSARY REPAIRORREPLACE FAULTY WIRING CHECKTHE3WAYVALVE THERMOSTATIC ELEMENT ISTHESPINDLEFULLY RETRACTED ISTHESYSTEMFULLY VENTEDWITHALL ISOLATORVALVESFULLY OPEN AND THE SYSTEM PRESSUREIS 1bar DISCONNECT PLUG A6 IS ...

Page 49: ...PRESSURESTABLE REPLACEFAULTYGAS VALVE FAULTY THERMISTOR THIS HAS NOW BEEN REPLACED ISTHEDHWTEMPERATURE SATISFACTORY REPLACE FAULTY THERMOSTATIC ELEMENTIN3WAY VALVE RECTIFYEXTERNAL SYSTEM FAULT DOESTHEBURNER EXTINGUISH WHEN THE DHW TAPISCLOSED REPLACEFAULTYPCB REPLACE FAULTY FLOWSWITCH THEBOILERISOPERATING REPLACETHEDHW THERMISTOR IS THE WATER TEMPERATURE NOW STABLE NO NO NO NO YES YES YES YES CHEC...

Page 50: ...mer 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 172414 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 17242...

Page 51: ...51 SHORT LIST OF PARTS combination boiler Installation and Servicing 8 7 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: ...nce of its products 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 hea...

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