IDEAL INSTINCT 40 User Manual Download

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Installation & Servicing

INSTALLATION

4 BOILER ASSEMBLY -

Exploded View

INST

ALLA

TION

308

502

309

304

306

105

302

305

208

232

230

231

310

301

501

80kW Model shown

KEY

105 Auto Air Vent

208 Burner Fixings Kit

230 Fan

231 Gas Valve Kit

232 Venturi 30kW Kit

301 Dry Fire Thermistor Kit

302 Lead Ignition Kit

304 Ignitor Unit

305 Electrode Detection Kit

306 Ignition Electrode Kit

308 Fascia Plastic

309 HMI Board

310 Primary PCB

501 Jacket Assembly Kit

502 Door Assembly Kit

Summary of Contents for INSTINCT 40

Page 1: ...ured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of literature fo...

Page 2: ...e Heating Full Load P4 kW 40 40 60 60 Part Load P1 kW 13 13 19 5 19 5 Auxiliary Electricity Consumption Full Load elmax kW 0 135 0 135 0 092 0 092 Part Load elmin kW 0 03 0 03 0 026 0 026 Standby PSB...

Page 3: ...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 installed...

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

Page 5: ...5 Installation Servicing...

Page 6: ...15 16 20 20 24 30 Btu hr 27300 27300 40950 51200 54600 68250 68250 81900 102350 Boiler Output condensing Mean 40 C Max kW 42 0 41 2 63 5 62 1 84 4 82 6 103 9 124 7 158 0 Btu hr 143300 140600 216650 21...

Page 7: ...tination PMS Maximum operating pressure of water C13 C33 A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal which admits fresh air to the burner and dischar...

Page 8: ...ed in accordance with the current edition of I S 813 Domestic Gas Installations or I S 820 Non Domestic Gas Installations as appropriate the current Building Regulations and reference should be made t...

Page 9: ...are available for concentric flue configuration These packs contain additional 1 metre ducts and may be cut to the desired length Flue duct extension kits are available for open flue configurations Th...

Page 10: ...NT The application of any other treatment to this product may render the guarantee of Ideal Boilers INVALID Ideal Boilers recommend Water Treatment in accordance with Guidance Notes on Water Treatment...

Page 11: ...clearances for vertical flue 200mm for horizontal flue 350mm 415mm for 100 150 for open flue 350mm 100 150 Concentric Flue Connector Models 100kW 120kW 150kW Minimum boiler top clearances for vertica...

Page 12: ...g features a A non adjustable preset lift pressure not exceeding 4 bar 60 lbf in2 b A manual testing device c Provision for connection of a discharge pipe The valve or discharge pipe should be positio...

Page 13: ...301 501 80kW Model shown KEY 105 Auto Air Vent 208 Burner Fixings Kit 230 Fan 231 Gas Valve Kit 232 Venturi 30kW Kit 301 Dry Fire Thermistor Kit 302 Lead Ignition Kit 304 Ignitor Unit 305 Electrode D...

Page 14: ...all mounting template from the front of the boiler Remove the packing piece from the top of the boiler Check the contents against the list in Frame 6 Unpacking Note some items are contained within the...

Page 15: ...or personal injury 1 Cut the flue hole ensuring that the hole is square to the wall Both wall faces immediately around the cut hole should be flat 2 Drill 4 boiler top fixing holes with a 12mm 1 2 mas...

Page 16: ...side air or to a room internal space If to a room internal space it must itself be adequately ventilated as above The temperature within the boiler room shall not exceed 25 C within 100mm of the floor...

Page 17: ...allowed for that flue option Note Horizontal terminal resistance includes 1 x 90o elbow Worked examples are shown on page 21 and 22 Alternatively the resistances of flue components are given on page 2...

Page 18: ...2 Finishing plates x2 Bracket RF 2499 Note See Frame 18 for elbow equivalent lengths FLUE OUTLET Vertical concentric flue application maximum lengths and pressure differentials Model 40 40P 60 60P 80...

Page 19: ...ow concentric 152618 152619 n a n a 3 90o elbow n a n a 158773 158774 4 45o elbow pair n a n a 158775 158776 5 Flat Weather Collar 152611 152612 158780 158780 6 Pitched Weather Collar 152609 152610 15...

Page 20: ...0 8 65 3 5 100 3 3 172 4 3 Horizontal wall kit 80 125 90 45 7 86 6 2 135 4 8 Horizontal wall kit 100 150 90 30 7 6 70 8 65 3 5 100 3 3 Pipes Elbows 45 bend 80 125 7 5 1 1 13 5 1 1 22 1 1 45 bend 100 1...

Page 21: ...25 Vertical Flue Kit 80 125 135 4 8 2 x 1m extension flue 2 x 21 7 2 x 1 2 x 45 elbow 2 x 22 2 x 1 1 Total Flue Resistance 222 9 Horizontal Flue for 40kW Model Resistance Pa Resistance m Flue Size 80...

Page 22: ...4 The total maximum flue resistance for a 120kW Model is 288 Pa or 17 6m 100 150 Therefore this installation is acceptable Example 4 FLUE OUTLET Horizontal Flue for 120kW Model Resistance Pa Resistan...

Page 23: ...it is important that the inner duct is maintained at 20mm longer than the outer duct to allow correct connection of the ducts Care should be taken to support the inner duct when cutting the flue Note...

Page 24: ...in the car port into the building Vertically from a terminal on the same wall Horizontally from a terminal on the same wall 300 mm 300 mm 300 mm 75 mm 200 mm 200 mm 150 mm 300 mm 300 mm 600 mm 1200 mm...

Page 25: ...er than the boiler capacity an ideal solution is to use multiple boiler arrangements The ideal way to control a multiple boiler installation is with our modulating sequencer See below a typical instal...

Page 26: ...in Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must termina...

Page 27: ...Minimum connection height up to 3 storeys Soil vent stack 450 Boiler with 75mm sealed condensate trap Min 19mm Internal pipe Min 30mm Internal pipe Water weather proof insulation 75 Boilers without 75...

Page 28: ...system see Frame 49 INSTALLATION Flow Return 31 GAS CONNECTION Refer to Frame 1 for details of the position of the gas connection A MINIMUM working gas pressure of 17 5 mbar 7 w g must be available at...

Page 29: ...ting sequencer kit a bms outside temperature sensor DHW demand can be controlled by 230V programmer and or cylinder thermostat tank sensor kit The electrical supply and their inputs onto the boiler ca...

Page 30: ...s as appropriate e g Grundfos 40 60 UPS is satisfactory If the current draw is more than this eg a Grundfos 40 120 UPS then an external relay should be operated by the CH Pump or DHW Pump connections...

Page 31: ...ow Thermistor Return Thermistor Flame Sensor Electrode Spark Electrode Spark Generator PCB Gas Valve Water Pressure Switch Diagnostic Connection Chassis Earth w bk bk bk bk br b b b b b b r or r bk bk...

Page 32: ...n similar to the following will be displayed line 5 may vary depending on setup Line 5 indicates Switched Live or OpenTherm or 0 10V depending on which controls are connected to the boiler Hot Water D...

Page 33: ...es See Frame 42 for adjusting the system frost protection temperature setpoint Cylinder Frost Protect Burner Power 100 Outside Temp 10 C Frost Setpoint 5 C Hot Water Temp 4 C Cylinder Frost Protection...

Page 34: ...ti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Ideal Evomax 80kW Normal Operation Set Flow Temp Set DHW Temp Press SELECT and a screen similar...

Page 35: ...l vary as the boiler operates Press SELECT to exit this option Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation VIEWING THE FAU...

Page 36: ...put 0 10V Off 0 10V Capacity 0 10V Temperature Press and to change to the required setting and then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and...

Page 37: ...Setback DHW Pump Valve Set Booster Press SELECT and the following screen will be displayed Set Night Setback On Off Press and to change to required setting and then press ENTER to store Rotate the KNO...

Page 38: ...ystem Frost Protection Function is only operational if an Outside Sensor has been connected The CH pump is switched on if the Outside Temp is less than the System Frost Protection Temp The CH pump is...

Page 39: ...the DHW Thermistor input Rotate the KNOB clockwise until the following screen is displayed Rotate the KNOB clockwise until the following screen is displayed Installer Mode O S Room Temp DHW Sensor Fa...

Page 40: ...alve Press and to change to the required setting and then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation 44 U...

Page 41: ...link from position 9 to position 10 in the installer terminal block should be removed and a wire added from position 10 to the DHW Call input on the boiler Note that a hydraulic bypass is required to...

Page 42: ...Plan Valve Pump INSTALLATION 48 BOILER CONTROL OF PUMP AND DIVERTER VALVE Pump CH Pump Timer L N CH On HW On Boiler DHW Pump Fused Spur L N E C S R S Note 1 The boiler can use an Outside Sensor which...

Page 43: ...210 10236 EXTERNAL CONTROLS VIA OPENTHERM EXTERNAL CONTROLS VIA 0 10V INPUT EXTERNAL CONTROLS VIA SWITCHED LIVE Note that the boiler requires a 4 minute pump overrun period The boiler warranty will be...

Page 44: ...AND TESTING A ELECTRICAL 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...

Page 45: ...ler is set for winter operation see user interface basic operating instructions 7 The boiler will commence the ignition sequence If after 5 attempts the boiler has failed to light then it will lock ou...

Page 46: ...t 53 GENERAL CHECKS 54 HANDING OVER IMPORTANT Point out to the owner that the boiler must have regular maintenance and cleaning at least annually in order to ensure reliable and efficient operation Re...

Page 47: ...es 59 and 60 5 Inspect the heat exchanger through the burner opening If there are signs of aluminium oxide build up spray water down the flueways Refer to Frame 60 6 Remove the sump cover and scrape o...

Page 48: ...bow fixing screws and remove elbow by pulling downwards 7 Disconnect the electrical connections from the gas valve s 8 Disconnect the electrical connections from the fan 9 Undo the gas valve union nut...

Page 49: ...Remove the front panel Refer to frame 57 3 Remove the fan and gas assembly Refer to frame 58 4 Remove the burner Refer to frame 59 5 Remove the ignition and detection electrodes Refer to frame 66 67...

Page 50: ...nly or mixing chamber to fan 150 only 7 Transfer venturi and gas valve assembly to the new fan 8 Reassemble in reverse order replacing all gaskets 9 Check the operation of the boiler Refer to frame 55...

Page 51: ...8 Remove the 4 screws retaining the inlet flange to gas valve transfer to new valve 100 120 only 9 Fit new gas valve to venturi using the new seal provided ensure gas injector is fitted correctly 10 R...

Page 52: ...he front panel Refer to frame 57 3 Pull off the spark lead and earth connection 4 Remove the two retaining cap head screws 5 Pull out the electrode and pull off the old gasket 6 Replace with new elect...

Page 53: ...oiler 4 Disconnect the electrical connections from the switch 5 Unscrew the water pressure switch 6 Refit new switch 7 Connect electrical connections 8 Refill the system ensuring all the air escapes v...

Page 54: ...operation of the boiler Refer to Frame 55 4 72 USER INTERFACE BOARD 1 Refer to Frame 55 2 Remove the upper front panel put the control panel into the service position Refer to Frame 57 3 Fit the eart...

Page 55: ...derThermistor Fault Ext Interlock Off External Interlock Operated Reset Interlock Go to Frame 85 Ext Interlock Off Ignition Lockout Check Gas to Boiler Check Condensate Pipe Refer to Instructions Rese...

Page 56: ...ck gas supply and rectify fault no yes Is the following voltage available at the Gas Valve approximately 215Vdc for 40 60 80 and 150kW approximately 240Vac for 100 and 120kW See note Check wiring from...

Page 57: ...Pipe is blocked Check if the Flue is blocked Replace as necessary yes If the boiler is Reset does the boiler Ignite for a short time and then Extinguish no Check Gas Supply and rectify fault no Is the...

Page 58: ...a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 At 60 C expect 2 400 2 600 At 85 C expect 1 000 1 100 Is the thermistor value correct yes Check and re...

Page 59: ...pect 19 000 21 000 At 20 C expect 12 000 13 000 Is the thermistor value correct yes Ensure the wiring has continuity and is securely connected no Does the Outside Sensor wiring between the boiler term...

Page 60: ...Is the wiring securely connected at both the boiler and cylinder thermistor yes 85 EXTERNAL INTERLOCK OFF Is an External Interlock connected to the boiler yes Has the External Interlock operated no Do...

Page 61: ...connected to the boiler note that the Ideal Prog Room Stat is an OpenTherm device Does the wiring from the boiler to the OpenTherm device have continuity yes no Rectify wiring from boiler to OpenTher...

Page 62: ...a Power Closed Diverter Valve no no Set boiler correctly See page 45 yes Is there 230Vac at D Check wiring from PCB to D no yes yes Does wiring to external DHW Pump have continuity and is to the corr...

Page 63: ...PCB connected securely yes yes Connect the cable from the main PCB to the user interface PCB securely no Is the cable from the main PCB to the user interface PCB connected securely yes yes Replace cab...

Page 64: ...inter Mode see Frame 36 no Is the boiler set to Winter Mode yes yes Ensure between 2V and 10V is correctly connected to these terminals from the external device no Is a voltage of between 2V and 10V b...

Page 65: ...l Failure to do so could affect safety or performance of this appliance Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www idealparts com Our...

Page 66: ...tinuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice The Ideal Boilers Technical Training Centre offers a series of fi...

Page 67: ...n be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of liter...

Page 68: ...or storage purposes Do not store objects around or on the boiler and keep access clear at all times Do not obstruct ventilation ducts grilles or openings in the boiler room room space or compartment t...

Page 69: ...ndicates whether Switched Live or OpenTherm is controlling the boiler Line 3 indicates the current operating State Pre Purge or Ignition or Burner On or Pump Overrun Burner Power and Flow Temperature...

Page 70: ...ill vary depending the maximum output of the boiler Ideal Evomax 80kW Normal Operation Set Flow Temp Set DHW Temp Press SELECT and a screen similar to the following will be displayed The kW output num...

Page 71: ...condensate will build up to a point where it will make a gurgling noise prior to locking out displaying Ignition Lockout on the display If the appliance is reset it will make a gurgling noise prior to...

Page 72: ...01482 492 251 Fax 01482 448 858 Registered in England no 322137 Ideal Boilers Limited pursues a policy of continuing improvement in the design and performance of its products The right is therefore r...

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