IDEAL MINI C24 Installation And Servicing Download

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INSTALLATION

Mini

--- Installation & Servicing

22 PICTORIAL WIRING

Mini C24, Mini C28, Mini C32

LD1

LD2

LD3

LD4

SB1

X11

Ignition

electrodes

Flame detection

electrode

External controls

terminal block

Electric supply

terminal block

Three way

diverter valve

Pump

Fan

Primary circuit

flow switch

Air pressure

switch

D.h.w. flow

switch

C.h. temperature

probe NTC

Modulating

gas valve

Safety

thermostat

D.h.w. temperature

probe NTC

bn = brown

bu = blue

bk = black

wh = white

rd = red

gy = grey

gn = green

ye = yellow

vt = violet

og = orange

gnye = green/yellow

bn bu bk

bu bk gn

gy
gy

Wiring diagram for boiler equiped with electronic control p.c.b. type: Bertelli & Partners DIMS11---SA03/16740

COM

Time switch

Electronic control P.C.B.

LD1

LD2

LD3

K1 K3 K4

LD4

SB1

1 2 3 4

7 8 9

10 11 12

13 14

17 18

28 29 30 31 32 33 34 35 36 37 38

Electronic

control p.c.b.

Pin position ref. numbering

INST

ALLA

TION

Summary of Contents for MINI C24

Page 1: ...authorised by Ideal Boilers installation and Your Ideal installation and servicing guide servicing For users guide see reverse of book For the very latest copy of literature for specification purpose...

Page 2: ...2 Mini Installation Servicing...

Page 3: ...NDMENTS Relevant Installation changes implemented in this book from book reference 17962 1062 4 2007 F Further guidance added to Important Notes section of User Guide Ideal Stelrad Group reserve the r...

Page 4: ...1 010 128 4 0 400 0 444 56 5 0 176 Seasonal efficiency SEDBUK Band D 78 2 Band D 78 3 Band D 78 3 NOx classification Class 3 Class 2 Class 3 The value is used in the UK Government s Standard Assessme...

Page 5: ...y completing and signing the Benchmark Commissioning Checklist BENCHMARK COMMISSIONING CHECKLIST DETAILS Boiler Page Make and model 5 Appliance serial no on data badge 13 SEDBUK No 4 Controls Time and...

Page 6: ...tion can be reduced to 20mm However 200mm must be available for servicing Front clearance The minimum front clearance when built into a cupboard is 50mm 2 from the cupboard door However 450mm 17 3 4 o...

Page 7: ...n and Use Regulations or rules in force The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation must be carrie...

Page 8: ...lation MUST be tested for gas soundness and purged as described in the above code The boiler is adjusted at the factory for use with the relevant supply gas A working gas pressure equal to that stated...

Page 9: ...uld be in accordance with BS 5546 and BS 6700 Copper tubing to BS 2871 1 is recommended for water carrying pipework and MUST be used for pipework carrying potable water Any soldered joints on potable...

Page 10: ...tap supplied from a service pipe under mains pressure Where the mains pressure is excessive a pressure reducing valve shall be used to facilitate filling When installing the filling connection provid...

Page 11: ...e 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 BS5449 Su...

Page 12: ...diverter valve 6 Main circuit drainage cock 7 Central heating flow cock 8 By pass valve 9 Central heating CH return cock 10 3 bar pressure relief valve 11 Gas cock 12 Expansion vessel 13 Gas valve in...

Page 13: ...12 Main circuit drainage cock 13 Auto air vent 14 Pump 15 Electronic control pcb 16 3 bar pressure relief valve 17 Return manifold 18 DHW flow switch 19 Right hand panel 20 Boiler front panel 21 Appl...

Page 14: ...ke pipe 100 mm 4 J Flue pipe 60 mm 2 3 8 with terminal grille assembly K Band L Turret air pipe gasket M Flue pipe gaskets 2 off N Boiler turret gasket O Flue turret P Self tapping screws 4 8x13 4 off...

Page 15: ...Mini S24 Mini C28 Mini S28 Table 8 for model Mini C32 For the correct use of the restrictors with vertical roof kit 80 125 mm refer to Table 9 for models Mini C24 Mini S24 Mini C28 Mini S28 Table 10 f...

Page 16: ...e flue duct air duct connection to the end of the flue outlet grille air inlet duct For each additional 45 M F and 90 M F flue bend used the maximum permissible length of flue system must be reduced b...

Page 17: ...ounting plate screw position b Extend the centre line as shown Mark the flue duct centre from the corner see diagram and template Note mark the centre of the hole as well as the circumference 4 Remove...

Page 18: ...emove the front and side panels refer to frame 21 and strip off the protective coating The panels may be placed to one side and re fitted when the installation is complete Fit the horizontal flue syst...

Page 19: ...3 15 AF Mini C24 Mini C28 Mini C32 only For external controls wiring see frame 26 Note the switch contacts of any external programmer room or frost thermostat must be volt free Connecting a switched l...

Page 20: ...black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow bu bn gnye bu bn bk bn bu bn bu bk bu bn gnye bn bu bk bu bn bk bu bn bu bk gnye bu bk gnye bk bk gy gy gy gy bn...

Page 21: ...white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow bu bn gnye bu bn bk bn bu bu bn gnye bn bu bk bu bn bu bk gnye bu bk gnye bk bk gy gy gy gy bn bu bk bk bk bk bk ye gy X8...

Page 22: ...ch DHW flow switch Pump DHW temp rd bk bk bu CH temp 38 37 31 30 bu bu rd 10 9 bu bn Three way 6 8 bk bu 7 div valve bn wh 33 34 28 29 Gas Valve gy 36 35 ye modulation coil 23 25 13 14 gy gy bu bk bu...

Page 23: ...ntrol pcb Fan Air pressure switch CH flow switch Pump bk bk CH temp 31 30 bu bu 10 9 bu bn 28 29 Gas Valve gy 36 35 ye modulation coil 23 25 13 14 gy gy bu bk bu Safety thermostat Gas Valve on off ope...

Page 24: ...r switches set to OFF all the controls MUST be left in the running position The frost thermostat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown w...

Page 25: ...ted on the following picture and connect a gas pressure gauge via a flexible tube Be sure to select the correct pressure test point Refer to Tables for pressures 6 Check that the gas service cock is O...

Page 26: ...lating operator 11 Start the boiler and check again the maximum gas pressure setting 12 Turn the boiler off and disconnect the gauge and close the gas valve outlet pressure test point E Important afte...

Page 27: ...ne the current setting by keeping the reset button D pressed for more than 5 seconds The lamps A will flash a number of times corresponding to the setting 4 To change the setting turn the knob B to a...

Page 28: ...cked at the gas meter with no other appliance in use If this check is not possible ensure that the burner pressure is 11 7 4 7 mbar in w g for all models 4 Water circulation system Note Fernox Superfl...

Page 29: ...rformed The factory setting is Natural gas 17 Calibrate the gas valve according to the instructions given in this manual 18 Set the correct gas pressure for central heating output required 19 Stick th...

Page 30: ...operation 4 Run the boiler and check the percentage of CO and CO2 in the flue gasses at the sampling point indicated in the following drawing Air intake sampling point Exhaust gas sampling point Note...

Page 31: ...vice cock and disconnect the electricity supply 2 Remove the screws A and lift off the boiler front panel A A 3 Loosen the screws B 4 Bring the base of the panels away from the boiler and lift them fr...

Page 32: ...Mini C24 Mini C28 Mini S24 Mini S28 4 mm 5 32 Ignition Detection Male Female 10 mm Burner blades 3 8 10 mm 3 8 Mini C32 9 Check that the spark and detection electrodes leads are in good condition and...

Page 33: ...B A B 4 Disconnect the pipe which connects the venturi device to the air pressure switch 5 Unscrew the screws C and remove the clamp D C D F If the right clearance is at least 50 cm 20 6 Unscrew the 3...

Page 34: ...ly 2 Remove outer and inner casing refer to frame 36 3 Open the combustion chamber and disconnect the electrodes leads 4 Remove the burner Refer to frame 37 5 Undo the screws that hold the electrodes...

Page 35: ...on of the boiler Gas manifold Injectors Burner 46 OVERHEAT THERMOSTAT REPLACEMENT 1 Remove outer and inner casing refer to frame 36 For models Mini C28 Mini S28 and Mini C32 remove the screw A and the...

Page 36: ...the DHW circuit at the bottom of the boiler 4 Empty the DHW circuit Replacement 5 Disconnect the leads from the probe to be replaced and unscrew it 6 Screw in the new probe using a new gasket reconnec...

Page 37: ...ame 21 6 Squeeze the tabs D to release the temperature pressure gauge E and remove it 7 Re assemble in reverse order C B E D A 51 EXPANSION VESSEL REPLACEMENT If the CH expansion vessel is faulty ther...

Page 38: ...ew the 3 screws E and remove the fan E E F 7 Re assemble in reverse order If the right clearance is less than 50 cm 20 6 Remove the combustion chamber lid see frame 37 7 Remove the 3 screws F and remo...

Page 39: ...ection not used 55 PUMP REPLACEMENT COMPLETE 1 Disconnect the electrical supply 2 Remove the front and right hand side casing panels refer to frame 36 3 Release system pressure by opening the main cir...

Page 40: ...t When re assembling the electronic control ignition p c b 11 Fit the p c b into the control panel by first inserting the front lower edge under the control knob shafts Lower the rear edge and ensure...

Page 41: ...ll flash a number of times corresponding to the setting as on next figure A B 1 flash for combi models 4 flashes for system boilers 22 To change the setting turn the knob B to the position shown on th...

Page 42: ...ssure by opening the main circuit drainage cock Do not release CH pressure using the pressure relief valve It may cause debris within the system to foul the valve 5 Remove the CH circuit flow switch s...

Page 43: ...odel is factory fitted with a 10 litre min flow limiter The Mini C28 model is factory fitted with a 12 litre min flow limiter The Mini C32 model is factory fitted with a 14 litre min flow limiter Tabl...

Page 44: ...ul the valve 5 Remove the combustion chamber panel A by unscrewing the screws B For models Mini C28 Mini S28 and Mini C32 only remove the screw C and the plate D 6 Remove the clips E and the safety th...

Page 45: ...actuator see frame 63 7 Completely unscrew the two Allen key screws A which hold the exchanger to the brass groups A 8 Move the exchanger towards the rear of the boiler and extract it 9 Re assemble in...

Page 46: ...view 13 Refer to the following exploded view to remove the internal parts of the three way diverter valve 14 Re assemble in reverse order 65 PROGRAMMER REPLACEMENT Mini C only if fitted 1 Disconnect t...

Page 47: ...temperature probe NTC Faulty d h w temperature probe NTC Mini C only Faulty primary circuit no water or absence of flow Faulty air pressure switch Lack of burner ignition no ignition signal from the...

Page 48: ...d programmer are calling for heat Also that all services are on and the selector switch is set to heating Are only the two green leds on front fascia flashing together or alternately Is there at least...

Page 49: ...B When a DHW tap is opened and the DHW temperature is set to maximum does the water become hot Is the boiler mode setting correct Refer to frame 56 Follow the instruction Boiler mode setting Refer to...

Page 50: ...Is it between 12 k and 1 5 k Check resistance of CH temperature probe Is it between 12 k and 1 5 k Are LED2 and LED 3 flashing Replace faulty thermistor Are LED2 flashing and LED 3 on Replace faulty...

Page 51: ...rown and Blue at gas valve harness connector on PCB Is fuse continuity O K on PCB Is there a burner pressure during ignition period Replace faulty PCB Replace fuses Are the ignition leads disconnected...

Page 52: ...e polarity of the mains correct Replace faulty detection lead assy Rectify electrode position or replace faulty electrode Does the burner remain alight more than 10 seconds Connect lead correctly Is t...

Page 53: ...or replace faulty wiring Is there continuity of the Air Pressure Switch harness Is there continuity between NC and C at the Air Pressure Switch Replace faulty Air Pressure Switch Replace faulty PCB Re...

Page 54: ...t Is there 17 mbar gas pressure at the gas inlet Is there max burner pressure when the boiler first lights Is the maximum water flow correct 10 0 L min 24 kW model 12 0 L min 28 kW model 14 0 L min 32...

Page 55: ...3 715 Main heat exchanger O rings mod Mini C28 Mini S28 Mini C32 1 173240 5 E90 627 Gas valve gaskets 1 172611 6 H03 699 Fan mod Mini C24 Mini S24 1 173253 H03 700 Fan mod Mini C28 Mini S28 1 173254 7...

Page 56: ...e 1 170977 27 169 141 1 2 flat gasket 3 075514 28 169 033 3 4 flat gasket 4 075415 29 Side case panel 2 174508 30 H17 563 Control panel door 1 173637 31 Front case panel 1 174510 1 2 5 4 6 3 8 16 12 9...

Page 57: ...rson s SELF CERTIFICATION SCHEME BUILDING CONTROL Contact your relevant Local Authority Building Control LABC who will arrange an inspection or contact a government approved inspector LABC will record...

Page 58: ...BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED GAS RATE BURNER OPERATING PRESSURE IF APPLICABLE CENTRAL HEATING FLOW TEMPERATURE CENTRAL HEATING RETURN TEMPERATURE m3 h...

Page 59: ...ARD SERIAL No COMMENTS SIGNATURE DATE SERVICE 3 ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE DATE SERVICE 4 ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No CO...

Page 60: ...fiers For details of courses please ring 01482 498 432 Ideal boilers P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 Ideal...

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