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15

INSTALLATION

Project Heat - 

Installation and Servicing

  

325

324

219

303

506

308

307

306

106

512

505

504

215

225

227

233

226

224              

503

214

205

204

206

211

217

223

218

103

104

313

105

401

302

229

231

301

304

228

203

314

BCC*

Note 

that item numbers are linked to the spares list

103  

HEAT EXCHANGER DRAIN 

104 

  FLOW SENSOR

105  

PIPE - FLOW

106  

PIPE - RETURN

203  

GAS COCK 

204  

PIPE - GAS INLET

205  

GAS VALVE 

206  

PIPE - GAS INJECTOR

211  

INJECTOR ASSEMBLy 

214  

VENTURI

215  

FAN 

217  

BURNER 

218  

GASKET - BURNER

219  

SUMP CLEAN OUT COVER

10   BOILER assEMBLy - Exploded View

223

 

  FLUE MANIFOLD

224  

FLUE MANIFOLD TOP

225  

FLUE MANIFOLD - TOP SEALING CAP

226

 

  FLUE MANIFOLD - REAR SEALING CAP

227  

CLAMP RETAINING FLUE TURRET

228  

HOSE CONDENSATE INTERNAL

229  

SIPHON TRAP

231  

CONDENSATE OUTLET CONNECTION

233  

FLUE SENSING NIPPLE 

301  

CONTROLS BOX FIXINGS HINGE & SPRING 

302  

PRIMARy PCB* 

303  

CUI BOARD 

304  

CONTROL THERMISTOR (RETURN)

306  

ELECTRODE IGNITION

307  

ELECTRODE DETECTION

308  

IGNITOR UNIT

313  

IGNITION LEAD

314  

CONTROL BOX LENS

324  

CONTROLS BOX LID 

325  

CONTROL BOX FRONT 

401  

HEAT ENGINE 

503  

WALL MOUNTING BRACKET  

504  

FRONT PANEL  

 

505  

FASCIA  

 

 

506  

BRACKET - GAS VALVE

512 

  INFILL FRONT PANEL    

IN

s

T

a

LL

a

TION

* Note that production boiler PCBs are factory pre-set to 

operate for boiler range and output, but when ordering 

Primary PCB as a spare, an additional Boiler Chip Card 

(BCC) MUST also be purchased for your specific boiler 

range and output.

Summary of Contents for Project Heat 15

Page 1: ...nform 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 for speci...

Page 2: ...2 Project Heat Installation and Servicing...

Page 3: ...boiler turn mode knob to reset position and immediately turn knob back to required setting The boiler will repeat the ignition sequence if a heat demand is present Notes for the installer Page 6 Stan...

Page 4: ...h divide the gross heat input Btu h by the gross C V of the gas Btu ft3 c For m3 h multiply l s by 3 6 Key to symbols GB United Kingdom IE Ireland Countries of destination PMS Maximum operating pressu...

Page 5: ...entral heating mode Heat input to be calculated For assistance see Technical Helpline on the back page Page Burner operating pressure n a Central heating flow temp measure and record Central heating r...

Page 6: ...mation on the boiler status when operating and performance of key components to aid commissioning and fault finding Safe Handling This boiler may require 2 or more operatives to move it to its install...

Page 7: ...e Any direct connection of a control device not approved by Ideal Stelrad Group could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations a...

Page 8: ...one reduction down to 25mm is allowable per installation otherwise BS5440 1 2008 dimensions must be followed Flue Terminal Positions Min Spacing 1 Directly below above or alongside an opening window a...

Page 9: ...d if this requirement is not complied with Condensate drain Refer to Frames 32 33 A condensate drain is provided on the boiler This drain must be connected to a drainage point on site All pipework and...

Page 10: ...om inside the building where Front clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required with the cupboard door...

Page 11: ...tial temperature of 25o C across the boiler is not exceeded 4 Adjust room and cylinder thermostats and programmer to NORMAL settings The system should be vented directly off the boiler flow pipe as cl...

Page 12: ...rge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or cause damage to electrical components and wiring 3 Pressure Gauge A pre...

Page 13: ...e inlet side of the pump the connecting pipe being not less than 15 mm 1 2 nominal size and not incorporating valves of any sort b The vessel capacity must be adequate to accept the expansion of the s...

Page 14: ...eat range of boilers have an aluminium alloy heat exchanger Important The application of any other treatment to this product may render the guarantee of Ideal Stelrad Group Invalid Ideal Stelrad Group...

Page 15: ...FOLD TOP SEALING CAP 226 FLUE MANIFOLD REAR SEALING CAP 227 CLAMP RETAINING FLUE TURRET 228 HOSE CONDENSATE INTERNAL 229 SIPHON TRAP 231 CONDENSATE OUTLET CONNECTION 233 FLUE SENSING NIPPLE 301 CONTRO...

Page 16: ...k and check the contents Pack A Contents A Boiler B Hardware Pack Box C Wall Mounting Plate D These Installation Users Instructions E Wall Mounting Template located on internal protective packaging F...

Page 17: ...Flue turret C Wall Seal white D Wall Seal black E Cutting Aid A B C E D Pack B Contents Rear Flue Outlet Kit 55 80 A Plastic Connector B Flue Terminal C Rubber terminal wall seal D 2 x Self Tapping S...

Page 18: ...stallation Care MUST be taken to ensure the correct holes are drilled 1 Tape template into the required position ensuring its squareness by hanging a plumbline as shown 2 If fitting a side flue extend...

Page 19: ...ole B pack terminal The appliance must not be operated without the desired outlet nose correctly fitted in place ensuring the side location dimples are in line with the mounting face allowing the corr...

Page 20: ...ret to outside face of wall plus 44mm flue length SIDE Fit towall A WALL Minimum clearance 5mm 20 DETERMINING THE FLUE LENGTH and flue packs required cont d Shows the flue required when measured from...

Page 21: ...et terminal is upper most 4 Drill a 3 5mm hole through one of the 2 outer side holes in the outer flue section into the inserted outer flue as shown Take care not to pierce the inner plastic flue Fit...

Page 22: ...its mounting and will need to be refitted 9 When 1st mark is in line with the wall whilst holding the flue firmly push the white wall sealing flange to the wall until the 2nd of the two marks is just...

Page 23: ...e terminal as shown below in Figure 1 FIGURE 1 FIGURE 2 Once the flue is installed it is important that the rubber terminal wall seal is pressed against the outside wall to create an adequate seal bet...

Page 24: ...ween the plastic connector and the terminal air duct with the tape provided 6 Push the terminal assembly through the prepared hole in the wall until the rubber seal clears the outside wall Rest the as...

Page 25: ...wall as this movement engages the rear flue air and flue seal 3 Screw the boiler bottom retaining bracket to the wall with the screw provided 4 Remove the top flue blanking disk refer to Frame 26 Fill...

Page 26: ...ust be made This is achieved by using either Flat roof weather collar or Universal weather collar Accessories Flue Duct Extension Kits are available for flue lengths extending beyond 1m These packs co...

Page 27: ...positions where this could cause a nuisance should be avoided Minimum dimensions are shown below rf8392 Terminal Position Minimum Dimension Directly below an opening air brick windows etc 300 mm Belo...

Page 28: ...rminal Pitched roof tile weather collar Flat roof tile weather collar 1 3G9557b X 6 3 Secure the vertical connector by applying downward pressure on the connector 4 Position the clamp on the top face...

Page 29: ...ernal Drain 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 mus...

Page 30: ...mum 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 75mm s...

Page 31: ...electrical connections Wiring should be 3 core PVC insulated cable not less than 0 75mm2 24 x 0 2mm and to BS 6500 Table 16 For IE reference should be made to the current ETCI rules for electrical in...

Page 32: ...the servicing position 5 Route incoming cable through a grommet in the bottom panel note that the grommets are blind and will require puncturing and secure using the clamp and screws provided in the...

Page 33: ...mains supply to the boiler 2 Remove the front panel Refer to Frame 12 3 Swing the control box down into the service position 4 Loosen the pump wire cable clamp 5 Route pump cable through the cable cl...

Page 34: ...1 2 3 4 5 6 7 8 9 10 11 205862 10075b Fan Return Thermistor Control Thermistor Flame Sensor Electrode Spark Electrode Spark Generator PCB Gas Valve Chassis Earth Service Connector Fused at 4AT Pump M...

Page 35: ...has been checked adjusted and preset at the factory for operation on the gas type defined on the appliance data plate Do not adjust the air gas ratio valve Having checked That the boiler has been ins...

Page 36: ...Check that the electrical supply is OFF 4 Check that the boiler mode control knob B is off 5 Check that the gas service cock F is OPEN 6 Slacken the screw in the inlet pressure test point E and connec...

Page 37: ...re control B Mode Control Knob C Boiler Status D Burner on indicator A B C D 44 HANDING OVER 6 Explain and demonstrate the function of time and temperature controls radiator valves etc for the economi...

Page 38: ...re covered more fully in Frames 51 55 and must be carried out in sequence Important 6 After completing the servicing or exchange of components always test for gas tightness 7 When work is complete the...

Page 39: ...ntrol knobs line up with the holes in the front panel 5 Re tighten the two retaining screws 47 fan and venturi assembly removal and cleaning 1 Disconnect the electrical leads from the fan 2 Undo the g...

Page 40: ...urner as shown Important The burner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic 6 Brush...

Page 41: ...ection gaps are correct Refer to Frames 57 58 1 Ignition Electrode Flame Detection Reassemble the boiler in the following order 1 Ensure that the condensate trap siphon is full of water 2 Refit the bu...

Page 42: ...BOILER MUST NOT BE OPERATED without THE FRONT PANEL FITTED 53 fan replacement 1 Refer to Frame 52 2 Disconnect the electrical leads from the fan 3 Undo the gas pipe union connection to the injector h...

Page 43: ...new gas seal supplied is located correctly in the injector housing 10 Check operation of the boiler Refer to Frames 41 42 2 4 3 6 55 burner REPLACEMENT 5 5 6 1 See Frame 48 2 Refer to Frame 52 3 Undo...

Page 44: ...der 9 Check the operation of the boiler Refer to Frames 41 42 56 control return thermistor reNEWAL 1 Refer to Frame 52 2 Disconnect the electrical leads from the thermistors 3 Unclip the flow thermist...

Page 45: ...rth leads are correctly replaced 5 Check operation of the boiler Refer to Frames 41 42 Flame Detection Electrode Spark Generator 12 5mm Straight edge 1 Refer to Frame 52 2 Remove the burner Refer to F...

Page 46: ...orwards 6 Fit the new gas control valve ensuring the two sealing washers are in place and reconnect gas and electrical connections 7 Check operation of the boiler Refer to Frames 41 42 2 4 5 3 1 Refer...

Page 47: ...ttach the appropriate Boiler Chip Card BCC to it this should correspond to the output of the boiler 15kW or 24kW Note Ensure the correct orientation of BCC by placing TOP side up as shown 8 Re connect...

Page 48: ...n reverse order 6 Check operation of the boiler Refer to Frames 41 42 63 User control PCB replacement 3 Potentiometer spindle Control Knobs to be in vertical position PCB 4 3G9954 64 Water Flow switch...

Page 49: ...m the heat exchanger return pipe elbow 11 Remove the screw retaining the flow pipe bracket and remove the bracket from its rear retention slot 12 Pull the flow pipe to the right to disengage from the...

Page 50: ...TURN THERMISTOR FAULT GO TO FRAME 75 OUTSIDE SENSOR FAULT LOW MAINS VOLTAGE CONTACT ELECTRICITY PROVIDER PCB FAULT REPLACE PCB BCC NOT FITTED RESET BOILER No CH NO dhw GO TO FRAME 79 GO TO FRAME 80 If...

Page 51: ...ioning correctly NO Check siphon and condensate drain pipe work for blockage and rectify if necessary Boiler now working OK Check wiring connection from gas valve to PCB for continuity If the wiring i...

Page 52: ...will vary depending on the type of meter used to measure the value In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve 72 aLTERNATING F AND 3 F...

Page 53: ...e correct way yes no Reverse pump Check that the system pipework is correct 77 aLTERNATING F AND d No Water Flow Are the boiler and CH system filled with water and all isolation and radiator valves op...

Page 54: ...ion yes no Move the mode knob to the ON position Are the Timer and the Cylinder Thermostat switched on yes no Switch the Timer and Cylinder Thermostat On Is there 230Vac at A yes NO There is no Voltag...

Page 55: ...by Ideal 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...

Page 56: ...56 SPARE parts Project Heat Installation and Servicing...

Page 57: ...data fields on the commissioning checklist completed in full To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation To maintain...

Page 58: ...priate Building Regulations and then handed to the customer to keep for future reference GAS BOILER SYSTEM COMMISSIONING CHECKLIST CONTROLS Programmable room thermostat Optimum start control Combinati...

Page 59: ...larly and that the appropriate Service Interval Record is completed Service Provider SERVICE RECORD SERVICE 01 AND Where Possible AND Signature SERVICE 02 AND Where Possible AND Signature SERVICE 03 A...

Page 60: ...llowed e g Gas Safe Register Technical Bulletin TB 008 where chimney flues are in voids The ECGA should be of the correct type as specified by BS 7967 Prior to its use the ECGA should have been mainta...

Page 61: ...e assembled fixed and supported as per instructions Check that flue and flue terminal are not obstructed Check that no seals e g Those on flue extensions have been displaced during installation Rectif...

Page 62: ...The Ideal 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 pl...

Page 63: ...ce use only spare parts that you can 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 Idea...

Page 64: ...ied out by a Registered Gas Installer RGII and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to t...

Page 65: ...temperature Once the desired setting has been achieved leave the knob in this position and the system will automatically achieve the desired room temperature for all outside weather conditions To Shu...

Page 66: ...in the pipe in which condensate can collect The location of the blockage should be identified as closely as possible before taking further action 2 Apply a hot water bottle microwaveable heat pack or...

Page 67: ...r to requesting a service engineers visit Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit or for any pre arranged visit where access...

Page 68: ...d In IE contact a Registered Gas Installer RGII Flame Loss See Action Fault Code L 2 Fan Fault Reset the appliance if the boiler fails to operate then please contact Ideal if under warranty or alterna...

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