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IDEAL MINI C28, Installation And Servicing, Page: 1 / 60

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IDEAL MINI C28 Installation And Servicing Download Page 1

installation and

servicing

mini

Your Ideal installation and servicing guide

C24/C28/C32

S24/S28

When replacing any part of this appliance, use only spare parts that you can be

assured conform to safety and performance specification that we require. Do not use

reconditioned or copy parts that have not been clearly authorised by Ideal Boilers

Summary of Contents for MINI C28

Page 1: ... guide C24 C28 C32 S24 S28 When replacing any part of this appliance use only spare parts that you can be assured conform to safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers ...

Page 2: ... 361 0 373 47 4 0 151 1 035 131 7 0 400 0 456 58 0 0 176 Seasonal efficiency SEDBUK Band D 78 2 Band D 78 3 Band D 79 4 The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body Table 3 Performance Data Domestic Hot Water Mini C24 Mini C28 Mini C32 Maximum Burner p...

Page 3: ...nd signing the Benchmark log book Benchmark Log Book Details Boiler Page Make and model 3 Appliance serial no on data badge 11 SEDBUK No 2 Controls Time and temperature control to heating 23 24 Time and temperature control to hot water 24 Heating zone valves 23 TRV s 9 Auto bypass 9 Boiler interlock 9 For all boilers Flushing to BS 7593 7 Inhibitor 7 Central heating mode Heat input to be calculate...

Page 4: ...lation 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 overall clearance is still required with the cupboard door open to allow for servicing Side and Rear Flue a Provided that the flue hole is cut accurately e g with a core drill the flue can be install...

Page 5: ...ng may be hotter than this for a short period of time GAS SAFETY Current Gas Safety Installation 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 carried out by a CORGI Registered Installer It must be carried out in accordance with the relevant requirements...

Page 6: ...ropane gas boilers MUST be installed with pipes cylinders and pressure regulators fitted in accordance with BS 5482 1 Bulk tank installations MUST comply with the Home Office code of practice for storage of liquefied petroleum gas at fixed installations The complete installation MUST be tested for gas soundness and purged as described in the above code The boiler is adjusted at the factory for use...

Page 7: ...ater carrying pipework and MUST be used for pipework carrying potable water Any soldered joints on potable water pipework MUST NOT be made with solder containing lead Ancillary pipework not forming part of the useful heating surface should be lagged to prevent heat loss and any possible freezing particularly where pipes run through roof spaces or ventilated underfloor spaces Draining taps should b...

Page 8: ...ssive a pressure reducing valve shall be used to facilitate filling When installing the filling connection provided with the boiler an additional WRAS approved valve must be fitted to the mains water supply upstream of the double check valve to fully comply the Water Regulations CH return Hose unions Mains Water Supply Temporary hose disconnect after filling Stop valve Additional stop valve Double...

Page 9: ...dividual 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 Such an arrangement will provide for a more efficient control of the environment and will also avoid the continuous running of the circulation pump during programmed heating ON periods saving electrical energy It is therefore strong...

Page 10: ...erter 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 inlet pressure tap 14 Modulating gas valve 15 Burner pressure tap 16 Flame detection electrode 17 Ignition electrodes 18 Burner 19 Combustion chamber 20 Primary heat exchanger 21 Fan 22 Air pressure switch ...

Page 11: ...nage cock 12 Auto air vent 13 Pump 14 Ignition pcb 15 3 bar pressure relief valve 16 Return manifold 17 DHW flow switch 18 Right hand panel 19 Boiler front panel 20 Appliance data badge inside 21 Left hand panel 22 CH circuit pressure gauge 23 Model identification instructions 24 Control panel door 25 Main control pcb 26 CH flow switch 27 3 way diverter valve 28 Heat exchanger flow pipe 29 DHW hea...

Page 12: ... 4 J Flue pipe ø 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 Q Self tapping screw 4 2x13 2 off R Wall finishing gaskets 2 off J I K L M N O P R Q Optional extras if ordered are available in separate boxes F Electronic programmer kit F Extension duct kit pack D ø 60 100 F ...

Page 13: ...ini S24 Mini C28 Mini S28 Table 10 for model Mini C32 Table 7 Models Mini C24 Mini S24 Mini C28 Mini S28 Pipe length ø 60 100 Restrictor Between 0 3 11 8 and 1 m 39 ø 44 mm More than 1 m 39 up to 2 m 78 5 ø 47 mm More than 2 m 78 5 up to 4 m 157 no restrictor Table 8 Model Mini C32 Pipe length ø 60 100 Restrictor Between 0 3 11 8 and 1 m 39 ø 47 mm More than 1 m 39 up to 2 7 m 8 10 no restrictor T...

Page 14: ...pe flue kits For calculation of total flue length the distance MUST be measured from the centreline of the flue duct air duct connection to the end of the flue outlet grille air inlet duct For each additional 45 and 90 flue bend used the maximum permissible length of flue system must be reduced by 0 5m or 1m respectively Lengths of allowable equivalent flue outlet and air inlet ducts are indicated...

Page 15: ...ounting plate screw position b Extended the centre line as shown Mark the flue ductcentre from the corner see diagram and template Note mark the centre of the hole as well as the circumference 4 Remove the template from the wall Extended centre Spirit level 15 DRILLING THE WALL Rear flue shown IMPORTANT Ensure that during the cutting operation masonry falling outside the building does not cause da...

Page 16: ...Remove 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 system referring to the instructions contained with the kit Make good the internal wall surface using the seal provided 18 CONNECTIONS Fit the service valves washers and tail pipes as shown Central Heati...

Page 17: ...be 3 A 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 live feed to external controls terminal block may be dangerous and will result in serious damage to the boiler For Mini S24 Mini S28 refer to frame 27 21 ELECTRICAL CONNECTIONS Incoming mains wiring det...

Page 18: ...e gnye gnye bu gnye gy rd bu wh rd bu rd bu bn bu bn bn bu bn bu bk bn bu 3 1 2 rd bu bn bn gnye gnye gnye gnye gnye gnye gnye gnye gnye bu bn bn bu rd rd wh bu rd bu rd rd gy bn bu bu bu bn bu gy rd gnye ye wh gnye vt og bn bu bk rd bk wh gn NC COM NO og ye bk wh vt bu bn bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow 16 17 18 19 20 31 3...

Page 19: ... gy rd bu wh rd bu rd bu bn bu bn bn bu bn bu bk bn bu 3 1 2 rd bu bn bn gnye gnye gnye gnye gnye gnye gnye gnye gnye bu bn bn bu rd rd wh bu rd bu rd rd gy bn bu bu bu bn bu gy rd gnye ye wh gnye vt og bn bu bk rd bk wh gn NC COM NO og ye bk wh vt bu bn bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow 16 17 18 19 20 31 30 29 28 27 26 25 24...

Page 20: ... bu bn bn bu bn bu rd bu bn bn gnye gnye gnye gnye gnye gnye gnye gnye gnye bu bn rd bu rd rd gy bn bu bu bu bn bu gy rd gnye ye wh gnye vt og bn bu bk NC COM NO og ye bk wh vt bu bn bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow 16 17 18 19 20 31 30 29 28 27 26 25 24 23 22 21 101 104 105 102 103 111 112 109 113 116 114 115 122 121 120 11...

Page 21: ...gnye gnye gnye gnye gnye gnye gnye gnye gnye bu bn rd bu rd rd gy bn bu bu bu bn bu gy rd gnye ye wh gnye vt og bn bu bk NC COM NO og ye bk wh vt bu bn bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow 16 17 18 19 20 31 30 29 28 27 26 25 24 23 22 21 bn gnye bu Electronic control p c b Full sequence ignition device Pin position ref numbering ...

Page 22: ...u bk vt og bu bk bu bn Safety thermostat Gas Valve on off operators 113 114 115 111 112 wh ye rd 17 P C B 1 P C B 2 25 FUNCTIONAL FLOW DIAGRAM Mini S24 Mini S28 4 L N Programmer Room thermostat Main control pcb Ignition pcb Fan Air pressure switch CH flow switch Pump Ignition electrodes Detection electrode bn rd bk bn CH temp probe 3 28 29 bk bu 8 9 bu bn bn brown bu blue bk black wh white rd red ...

Page 23: ...normally be left at least 24 hours without frost damage However if parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system To maintain frost protection with the programmer selector switches set to OFF all the controls MUST be left in the running position The frost thermostat should be sited in a...

Page 24: ...l lamp F Programmer optional G System pressure and temperature gauge A B C D E F Central Heating flow Domestic hot water outlet Gas inlet Domestic cold water inlet Central Heating return Mini C24 Mini C28 Mini C32 Mini S24 Mini S28 G Mini C shown IMPORTANT Before lighting the boiler you should note especially that 1 Check that all the drain cocks are closed and any valves in the flow and return ar...

Page 25: ... and close the pressure test point D 4 Open the burner pressure test point E and connect the gauge 5 Remove the protection cap from the mechanical pressure adjustment components B and C 6 Start the boiler at its maximum power Operate the boiler in DHW mode or ensure that the boiler is not range rated if the test is carried out in CH mode Maximum valve setting 7 If necessary rotate the maximum gas ...

Page 26: ...e is obtained at the tap This corresponds to a flow rate of about 10 0 2 2 l min gpm Mini C24 11 6 2 6 l min gpm Mini C28 13 1 2 9 l min gpm Mini C32 d Turn off the DHW tap 2 Central heating all models Operate each control separately and check that the main burner or circulating pump as the case may be responds 3 Gas rate Check the boiler gas rate when the boiler is at full output The gas rate wil...

Page 27: ...o the Lighting Instruction label affixed to the inside of the lower front door 3 Explain and demonstrate the lighting and shutting down procedures 4 The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption 5 ...

Page 28: ...the figures given in Table 3 for HW 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 If your meter reads CO in parts per million the figure must be divided by 10 000 to convert it to a percentage 5 If the ratio of CO CO2 is less than 004 and the gas...

Page 29: ...rvice 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 freeing them from the top hooks B B Mini C shown 5 Remove the screws C and remove the boiler inner casing C C SERVICING ...

Page 30: ... 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 renew as necessary 38 BURNER PRESSURE CHECK After any servicing reference should be made to Table 2 and Table 3 or the data plate which quote details of the burner pressures If the burner pressures a...

Page 31: ...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 screws E and remove the fan and skip to step 9 E E F If the right clearance is less than 50 cm 20 6 Remove the combustion chamber panel see frame 36 7 Remove the 3 screws F and remove the flue hood w...

Page 32: ...ply 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 and remove 6 For models Mini C24 Mini C28 Mini S24 Mini S28 fit new electrodes as necessary following the sequence illustrated Ignition 1st Ignition 2nd Detection 3rd 7 Check the spark gap 4 mm 5 32 ...

Page 33: ...ion 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 plate B A B 2 Disconnect the wiring C 3 Remove the spring D which holds the overheat thermostat on the pipe of the primary heat exchanger and remove it C D 4 Re assemble in reverse order 5 Apply an ...

Page 34: ...6 Screw in the new sensor using a new gasket reconnect and re assemble in reverse order CH thermistor DHW thermistor Drainage cock 48 GAS VALVE ON OFF OPERATOR COILS REPLACEMENT Check 1 Disconnect the electrical supply 2 Remove the front casing panel 3 Disconnect the connector A and check the electrical resistance of the coils referring to the following diagram Lower on off operator approx 920 W U...

Page 35: ...rame 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 there are 2 options A If it has a punctured diaphragm but is otherwise leak free than it can be left in place and a new vessel added to the return side of the system external to the boiler provided it is...

Page 36: ...rew 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 remove the flue hood with the fan 8 Unscrew the 3 screws E and remove the fan 9 Re assemble in reverse order To correctly connect the venturi device to the air pressure switch refer to the following illu...

Page 37: ...ction H connection 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 circuit drainage cock Do not release CH pressure using the pressure relief valve It may cause debris within the system to foul the valve 4 Disconnect the connector A 5 Remove the fork B and m...

Page 38: ...ition of the jumpers when the main control p c b is fitted on a Mini S24 or Mini S28 boiler The numbers refer to the marking printed on the circuit board 1 2 3 4 5 6 7 8 9 1 1 2 3 4 5 6 7 8 9 2 Important When re assembling the electronic control p c b 10 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 that no...

Page 39: ... correct wiring connectors on the switch N O do not use C Looking through the switch box B it is possible to verify the position of the spindle C C Boiler OFF Pump operating 59 CH FLOW SWITCH MEMBRANE REPLACEMENT 1 Disconnect the electrical supply 2 Remove front casing panel refer to frame 36 3 Close off the isolating cocks of the CH circuit at the bottom of the boiler 4 Release system pressure by...

Page 40: ... the boiler Warning ensure that all the electric parts and wiring are dry and do not touch other electric parts during the following operations 3 Hold the flow switch sensor and bring the ring in contact with the sensor as illustrated in the following drawing 4 Observe if the lamp fitted in the sensor body is lit If not reverse the ring and repeat the previous operation 5 Fit the ring on the spind...

Page 41: ... 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 thermostat F It is not necessary to disconnect it from the wiring B A C D E F 7 Remove the fork G lift the pipe H and rotate it right then move it downwards freeing it from the heat exchanger connection 8 Remove the diverter valve actuator see frame 64...

Page 42: ... unscrew the two connections A and remove the pipe B A B 8 Completely unscrew the two Allen key screws C which hold the exchanger to the brass groups C 9 Move the exchanger towards the rear of the boiler and extract it 10 Re assemble in the reverse order Attention When reassembling the exchanger be sure to put the off center location securing pin indicated towards the left side of the boiler 64 DI...

Page 43: ...in the system to foul the valve 5 Release the pressure of the DHW circuit by opening a hot tap 6 Remove the diverter valve actuator see frame 64 7 Remove the fork D and remove the primary circuit flow switch E 8 Disconnect the thermistor F 9 Unscrew the connector G disconnect the CH flow and DHW outlet isolator valves D E G F 10 Remove the DHW heat exchanger see frame 63 11 Remove the fork H and m...

Page 44: ... wiring diagram in frame 22 for the correct wiring connection 6 Replace the panels and check the operation of the new programmer 67 CH DRAIN COCK REPLACEMENT 1 Disconnect the electrical supply 2 Remove front and right hand casing panels refer to frame 36 3 Close off the isolating cocks of the CH circuit at the bottom of the boiler 4 Release system pressure by opening the main circuit drainage cock...

Page 45: ...SERVICING Mini Installation Servicing 45 SERVICING ...

Page 46: ...lamps are then activated To reset the main control p c b to the normal operation it is necessary to turn the knob to the position or switch off the boiler for a short while at the fused spur isolation switch ON OFF 1 2 3 4 ON OFF 1 2 3 4 ON OFF 1 2 3 4 The following table gives a summary of the relationship between each of the possible lamp combinations and their meaning Normally operating boiler ...

Page 47: ... burner pressure 11 7 mbar with boiler and system cool Is the gas inlet pressure 17mbar Rectify gas supply fault Is there 16V dc at Grey and Black connections on modulator coil Adjust max stop on Gas Valve to achieve 11 7 mbar 10 5 mbar for Mini C32 Is modulator harness continuity O K Repair or replace faulty wiring Replace faulty PCB 1 Does the heating flow pipe become warm quickly Is there a DHW...

Page 48: ...lace faulty wiring Replace faulty PCB 1 Replace the sensor Is red LED illuminated Repair or replace faulty DHW detector valve Faulty sensor now replaced Is there 230V ac between Blue and Black at the 3 way valve connection Is the continuity of the 3 way valve harness O K Repair or replace faulty wiring Replace faulty PCB 1 Replace faulty motor assembly Replace faulty valve body assembly Continued ...

Page 49: ...arness O K Repair or replace faulty wiring Replace faulty PCB 1 Continued from page 47 of fault finding Is the green LED on front fascia flashing 4 times per second Access the 4 dip switches on p c b 1 Move the 1 dip switch off then on This activates p c b service mode Refer to fault code frame 68 Is LED 1 flashing with LED 2 on When the pump runs does the spindle of the water flow detector extend...

Page 50: ...perated Check continuity Is there continuity of over heat thermostat wiring at PCB connection Repair or replace damaged wiring Replace faulty gas valve Allow boiler to cool and press re set Is there ignition at the burner Is a spark visible at the burner during ignition Are the ignition leads disconnected or damaged and sparking to earth Are the ignition leads correctly connected to PCB 2 Rectify ...

Page 51: ...ectify wiring fault Is the burner pressure within 1 2 and 11 7 mbar 1 5 and 10 5 for Mini C32 with the boiler running Continued from page 50 of fault finding Refer back to page 47 of fault finding to continue Is the position of the detection electrode correct and electrode undamaged Refer to frame 43 Adjust burner pressure Refer to frame 29 yes no no no no no yes yes yes yes yes Is the resistance ...

Page 52: ...ons between PCB 1 and PCB 2 are O K Replace faulty PCB 2 Replace faulty PCB 1 Repair or replace wiring Replace faulty fan Are the sensing pipes undamaged and connected Replace sensing pipes Is the flue clear and venturi O K Clear flue Repair or replace Replace faulty Air Pressure Switch Is the Air Pressure Switch harness continuity O K Repair or replace faulty wiring Is the burner on Replace fault...

Page 53: ...pply fault Is the maximum water flow Check the DHW inlet filter Remove debris and clean or replace filter Rectify water supply fault Is the continuity of the modulator harness O K Repair or replace faulty wiring Replace Faulty PCB Replace faulty gas valve Boiler Operating Correctly Continued from page 48 Adjust the max setting on the gas valve Refer to frame 29 Check that 11 7 mbar 10 5 mbar for M...

Page 54: ...er O rings mod Mini C24 Mini S24 1 173238 Main heat exchanger O rings mod Mini C28 Mini S28 1 173240 Main heat exchanger O rings mod Mini C32 1 173140 5 Gas valve gaskets 1 172611 6 Fan mod Mini C24 Mini S24 1 173253 Fan mod Mini C28 Mini S28 1 173254 7 Fan mod Mini C32 1 173139 8 E83 013 Safety valve 1 172494 9 E83 154 Electronic regulation p c b 1 172561 10 E83 142 Full sequence ignition device ...

Page 55: ...00 26 E83 117 Automatic air purger valve 1 172525 27 E83 173 Window glass rubber frame 1 170977 28 169 141 1 2 flat gasket 3 075514 29 169 033 3 4 flat gasket 4 075415 30 E83 171 Side case panel 2 172577 31 Control panel door 1 172552 32 Front case panel 1 172578 1 2 5 4 6 3 8 16 13 9 10 14 19 20 23 25 17 15 11 24 12 18 31 30 32 30 21 22 26 27 28 29 ...

Page 56: ...es please ring 01482 498 432 September 2003 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 Caradon Ideal Limited pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice the code of practice for the installa...

Page 57: ... S24 S28 When replacing any part of this appliance use only spare parts that you can be assured conform to safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers ...

Page 58: ...orage purposes F Under no circumstances should any of the sealed components on this appliance be used incorrectly or tampered with F If it is known or suspected that a fault exist on the boiler then it MUST NOT BE USED until the fault has been corrected by a CORGI registered installer or in IE a competent person MINIMUM CLEARANCES Clearances of 200 mm 7 7 8 above and below 25 mm 1 at left 50 mm 2 ...

Page 59: ...g gas savings TO SHUT DOWN THE BOILER For short periods To turn the boiler off set the function selector C to the O position The appliance On lamp A will flash every 4 seconds For long periods When you do not expect to use the boiler for a long period 1 Switch the the electricity supply off 2 Shut off the gas supply cock and the valves for the water circuits fitted under the boiler 3 If necessary ...

Page 60: ...on and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency September 2003 Caradon Ideal Limited pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice Ideal Boilers P O Box 103 National Ave Kingst...

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