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39

Installation and Servicing

 

SECTION 3 - SERVICING

 

39

3.1  SERVICING SCHEDULE

F

or the very latest copy of literature for specification & maintenance practices, visit our website www.idealboilers.com, where you 

will be able to download the relevant information.

WARNING.

  Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity 

supply to the appliance before servicing.
Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927.

To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and 

serviced as necessary.  The frequency of servicing will depend upon the installation condition and usage but should be carried out 

at least annually.  
It is the law that any service work must be carried out by a Gas Safe Registered Engineer. In IE service work must be carried out 

by a Registered Gas Installer (RGII).

GENERAL

Please Note

: During routine servicing, and after any 

maintenance or change of part of the combustion 

circuit, the following must be checked:

-  The integrity of the flue system and the flue seals,

-  The integrity of the boiler combustion circuit and 

the relevant seals

-  The operational (working) gas inlet pressure at 

maximum rate.

-  The gas rate
-  The combustion performance.

COMPETENCE TO CARRY OUT THE CHECK 

OF COMBUSTION PERFORMANCE

Please Note

BS 6798:2009 Specification for 

installation and maintenance of gas-fired boilers of 

rated input not exceeding 70kW net advises that:
-  The person carrying out a combustion 

measurement should have been assessed as 

competent in the use of a flue gas analyser and the 

interpretation of the results.

-  The flue gas analyser used should be one meeting 

the requirements of BS7927 or BS-EN50379-3 

and be calibrated in accordance with the analyser 

manufacturers requirements, and

-  Competence can be demonstrated by satisfactory 

completion of the CPA1 ACS assessment, which 

covers the use of electronic portable combustion 

gas analysers in accordance with BS7967, Parts 1 

to 4.

Flue Sampling Point

Air Sample

Point

Ensure all caps and seals

are re-fitted after use

Note

.  In order to carry out either servicing or replacement of components 

the boiler front panel must be removed.  Refer to Section 3.2.

PRELIMINARY INSPECTION

1.

  Light the boiler and carry out a pre-service check, noting any 

operational faults (refer to appropriate fault finding chart as 

necessary).

2.

   Check the flue terminal (and terminal guard if fitted) is undamaged 

and clear of any obstruction.

3.

   Check combustion by connecting the flue gas analyser to the flue 

gas sampling point as shown in the diagram and measure CO and 

CO

2

 at maximum rate. To set the boiler to Maximum and Minimum 

heat inputs see page 66. Repeat at minimum rate.

  If the CO / CO

2

 ratio is greater than 0.004 please proceed to 

“Cleaning Procedure”.

  If the CO / CO

2

 ratio is less than 0.004 please proceed to “Check 

Procedure”.

CHECK PROCEDURE

1. 

Check all water and gas joints for signs of leakage.  Remake any 

suspect joints ensuring a gas tightness check is carried out if 

applicable and the water system is correctly refilled, vented and re-

pressurised.

2.

  Proceed to “IMPORTANT”.

CLEANING PROCEDURE

1.

  Clean the main burner. Refer to Section 3.4.

2.

  Clean the heat exchanger & condensate trap/siphon. Refer to 

Section 3.5 & 3.6.

3.

  Check the main injector for blockage or damage. Refer to  Section 3.3.

ALSO IF THE DHW FLOW RATE IS IN QUESTION:

4. 

Check the DHW filter for blockage. 

5. 

The cleaning procedures are covered more fully in Sections 3.3 - 

3.7 and MUST be carried out in sequence.

6. 

Proceed to “IMPORTANT”.

Do not operate the boiler if the front panel is not fitted.

IMPORTANT

1. 

If, for any reason, the condensate trap/siphon has been removed, 

ensure the trap is refilled with water before re-assembling.

2. 

After completing the servicing or exchange of components always 

ensure all gas valve connections are gas tight with a gas soundness 

check up to the gas control valve.

3. 

When work is complete the front panel MUST be correctly refitted, 

ensuring that a good seal is made.

4. 

Complete the service section in the Benchmark Commissioning 

Checklist.

SER

VICING

Содержание i-mini C24

Страница 1: ...t 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 Ideal For the very latest copy...

Страница 2: ...W 24 3 24 3 Part Load P1 kW 8 0 8 0 Auxiliary Electricity Consumption Full Load elmax kW 0 042 0 032 Part Load elmin kW 0 012 0 013 Standby PSB kW 0 005 0 005 Seasonal Space Heating Energy Efficiency...

Страница 3: ...I 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 in a bui...

Страница 4: ...4 Installation and Servicing...

Страница 5: ...19 Ideal Boilers reserve the right to vary specification without notice FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL INSTALLER HELPLINE 08708 498057 NOTE BOILER RESTART PROCEDURE To restart the bo...

Страница 6: ...6 Installation and Servicing...

Страница 7: ...ement 40 3 3 Fan And Venturi Assembly Removal And Cleaning 40 3 4 Burner Removal And Cleaning 41 3 5 Cleaning The Condensate Trap Siphon 41 3 6 Cleaning The Heat Exchanger 42 3 7 Reassembly 42 3 8 Rep...

Страница 8: ...h divide the gross heat input Btu h by the gross C V of the gas Btu ft3 d For m3 h multiply l s by 3 6 Key to symbols GB United Kingdom IE Ireland Countries of destination PMS Maximum operating press...

Страница 9: ...reducer 16 Hot water mode Heat input to be calculated Max operating burner pressure n a Max operating water pressure measure record Cold water inlet temp measure record Hot water outlet temp measure...

Страница 10: ...in at 35 o C temperature rise The DHW draw off rate specified above is the nominal that the boiler flow regulator will give Due to system variations and seasonal temperature fluctuations DHW flow rate...

Страница 11: ...device not approved by Ideal Boilers could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations 1 6 SAFE HANDLING...

Страница 12: ...tion otherwise BS5440 1 2008 dimensions must be followed Flue Terminal Positions Min Spacing 1 Directly below above or alongside an opening window air vent or other ventilation opening 300mm 12 2 Belo...

Страница 13: ...radiator valves are used the space heating temperature control over a living dining area or hallway having a heating requirement of at least 10 of the minimum boiler heat output should be achieved us...

Страница 14: ...ill the flue can be installed from inside the building where wall thicknesses do not exceed 600mm Where the space into which the boiler is going to be installed is less than the length of flue require...

Страница 15: ...r capacity of the system should not exceed 143 litres if not pressurized However if the system is to be pressurized the efficiency of the expansion vessel will be reduced and a larger vessel or smalle...

Страница 16: ...al water company The use of artificially softened water however is not permitted Ideal Boilers recommend the use of Fernox Quantomat Sentinel Combiguard and Calmag CalPhos I scale reducing devices whi...

Страница 17: ...Assy 214 Venturi 215 Fan 217 Burner 218 Gasket Burner 219 Sump Clean Out Cover 223 Flue Manifold 224 Flue Manifold Top 227 Clamp Retaining Flue Turret 228 Hose Condensate Internal 229 Siphon Trap 231...

Страница 18: ...11 8 9 2 6 5 1 12 2 2 UNPACKING The boiler is supplied fully assembled in Pack A A telescopic or non telescopic flue assembly for rear or side flue outlet in Pack B is suppled as a separate order Unpa...

Страница 19: ...let nose that utilises a push fit location system This enables the installation of deflector high level or balcony outlet flue kits without the removal of the whole B pack terminal The appliance must...

Страница 20: ...NT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Cut the flue hole preferably with a 5 core boring tool ensuring that the...

Страница 21: ...aps seals are in place Additional Termination Kits available for use with these B packs Flue Deflector Kit The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from...

Страница 22: ...ue Terminal 1000mm long B Pack Telescopic Cut 75mm Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum B Pack Standard 181 556 286 484 601 816 526 741 Plus 1 1m D pack 1121 1506 1236 1434...

Страница 23: ...he outlet 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 fl...

Страница 24: ...been dislodged from its mounting and will need to be refitted 7 Ensure the seam and the outlet terminal are at the top and fitted as shown Note If less than 50 of the length of the flue is internal t...

Страница 25: ...the boiler is made using the supplied vertical connector WEATHER PROOFING Where the flue passes through the roof line an adequate seal must be made This is achieved by using either Flat roof weather c...

Страница 26: ...tructions provided with the vertical connector kit 3 Secure the vertical connector by applying downward pressure on the connector 4 Position the clamp on the top face of the flue manifold and push it...

Страница 27: ...enetrate the shaded area of the roof Note The equivalent flue length resistance of the elbow kits are 90o elbow kit 1m 45o elbow kit 0 6m If chimney penetrates dotted area such that A is less than 300...

Страница 28: ...nal soil and vent stack or internal kitchen or bathroom waste pipe etc fig 3 External Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting...

Страница 29: ...pipe Water Weather proof insulation Max 3m external pipework Limestone chippings 500 300 25 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house Minimum...

Страница 30: ...the bottom right hand side of the boiler comprises a 15mm diameter stub pipe The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of...

Страница 31: ...ny local regulations 2 18 INSTALLER WIRING A mains cable must be connected to a permanent live supply and NOT switched by thermostats programmers To do so follow the instructions below Accessing the i...

Страница 32: ...DAMAGED Outside Sensor Open Therm OpenTherm Device E G Honeywell OT Bridge R8810 External Controls 230V 50Hz Wiring a 230V 50Hz Room Thermostat Diagram A with optional timer Diagram B 1 Remove the lin...

Страница 33: ...2 PUMP LIVE DHW LIVE X3 PUMP GND X9 X8 OWC OWC OPENTHERM OPENTHERM OPENTHERM 5V CHIP COM BUS TX CHIP COM BUS 24V CHIP COM BUS GND CHIP COM BUS 5V CHIP COM BUS RX MAINS LIVE MAINS NEUTRAL AUXILIARY LIV...

Страница 34: ...tion 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 installed in accordance with these instructions The integrity of...

Страница 35: ...est point H and connect a gas pressure gauge via a flexible tube 8 Switch the electricity supply ON and check all external controls are calling for heat Note The boiler incorporates a fan overrun cycl...

Страница 36: ...show then when the burner lights 2 Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate This is factory set to give a DHW temperature rise of appr...

Страница 37: ...PREHEAT 4 VF will be shown To activate the venting function press RESTART otherwise press PREHEAT The venting function runs for 5 minutes before automatically returning to normal operation The diverte...

Страница 38: ...d the requirement to register it to receive the full benefit of the warranty 1 Hand the User Instructions to the householder and explain his her responsibilities under the relevant national regulation...

Страница 39: ...use of electronic portable combustion gas analysers in accordance with BS7967 Parts 1 to 4 Flue Sampling Point Air Sample Point Ensure all caps and seals are re fitted after use Note In order to carry...

Страница 40: ...e two M4 screws and release the nozzle assembly 6 Inspect the injector for blockage or damage 7 Inspect fan outlet sealing gasket and replace if necessary REMOVAL 1 Loosen the two screws retaining the...

Страница 41: ...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 off any deposits that ma...

Страница 42: ...nition and detection gaps are correct Refer to Sections 3 13 3 14 1 Ignition Electrode Flame Detection Reassemble the boiler in the following order 1 Ensure that the condensate trap siphon is full of...

Страница 43: ...boiler Refer to Section 3 21 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 3 9 FAN REPLACEMENT 1 Refer to Section 3 8 2 Disconnect the electrical leads from the fan 3 Remove the clip...

Страница 44: ...rse order ensuring that the new gas seal supplied is located correctly in the injector housing 10 Check that the boiler operates in both DHW CH modes 4 3 3 3 11 BURNER REPLACEMENT 5 5 6 1 See Section...

Страница 45: ...8 Reassemble in reverse order 9 Check the operation of the boiler Refer to Section 2 23 2 24 3 12 RETURN THERMISTOR REPLACEMENT 1 Refer to Section 3 8 2 Unclip the return thermistor from the return p...

Страница 46: ...rode 4 Remove the 2 screws retaining the detection electrode 5 Remove the electrode 6 Fit the new flame detection electrode using the new gasket supplied 7 Reassemble in reverse order 8 Check that the...

Страница 47: ...ewdriver in the actuator slot provided and ease out the actuator 3 Before replacing the diverter valve actuator proceed as follows a Ensure that the switched live to the boiler is off and that all DHW...

Страница 48: ...ut the four side retaining clips and pull the PCB upwards to clear the corner retaining posts 7 Take the new PCB 8 Re connect all plug connections 9 Reassemble in reverse order 10 a Turn power on disp...

Страница 49: ...ngth of hose to the CH drain point 4 After replacing any component on the boiler remove the hose close the drain valve and open all system isolating valves re pressurise as appropriate before proceedi...

Страница 50: ...ction 3 32 4 Firstly increase access area by disconnecting the 22mm pipe connection at top of pump manifold and bottom of heat exchanger and remove pipe Refer to Section 3 26 5 The automatic air vent...

Страница 51: ...y 1 Refer to Section 3 8 2 Drain the boiler Refer to Section 3 21 3 Remove the condensate trap siphon Refer to Section 3 18 4 Remove the electrical plug Refer to Section 3 17 5 Place a flat bladed scr...

Страница 52: ...oiler Refer to Section 2 16 8 Check that the boiler operates in both DHW CH modes 3 30 FLOW THERMISTOR REPLACEMENT 4 3 3 29 CH WATER PRESSURE SWITCH REPLACEMENT 1 Refer to Section 3 8 2 Drain the boil...

Страница 53: ...rectly match connecting pipe diameters 18 Ensure the trap siphon is filled with water Refer to Section 3 18 19 Refill the boiler and check for leaks Refer to Section 2 16 20 Ensure all gas valve conne...

Страница 54: ...uit Refer to Section 3 21 8 Remove the retaining clip on the vessel water connection pipe and remove the pipe 9 Support the expansion vessel and unscrew the 2 screws from the securing bracket located...

Страница 55: ...GO TO SECTION 4 9 RETURN THERMISTOR FAULT GO TO SECTION 4 10 OUTSIDE SENSOR FAULT LOW MAINS VOLTAGE CONTACT ELECTRICITY PROVIDER PCB UNCONFIGURED OR FAULTY SEE SECTION 3 19 IF FAULT PERSISTS REPLACE...

Страница 56: ...rectify fault NO YES Is 24Vdc supply available at the Gas Valve YES Check spark generator and associated harness for continuity and visual condition Refer to Section 3 15 Are these functioning correct...

Страница 57: ...these functioning correctly YES Check siphon and condensate drain pipe work for blockage and rectify if necessary Boiler now working OK Check wiring from gas valve to PCB for continuity If the wiring...

Страница 58: ...1 000 1 100 Ohms Is the Thermistor value correct YES Is the wiring securely connected to the low voltage 6 way connector at the front left hand side of the PCB YES Replace PCB Fit a new Thermistor NO...

Страница 59: ...and the PCB Replace PCB Fit a new Outside Sensor NO Securely connect the wiring at the Terminal Block and the PCB Is the wiring securely connected at both the boiler and Outside Sensor YES NO Securel...

Страница 60: ...d the diverter valve motor connected YES YES Check diverter head fully engaged and clip secured onto waterset YES Is diverter stuck in the CH position YES Check and re fit diverter valve actuator head...

Страница 61: ...ils of approved Ideal Parts Distributors are available on www idealparts com Our Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665 When calling and to ensure...

Страница 62: ...62 Installation and Servicing SECTION 5 SPARE PARTS...

Страница 63: ...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 the b...

Страница 64: ...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...

Страница 65: ...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...

Страница 66: ...ical 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 maintained and calibrated as specified b...

Страница 67: ...bled 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 Rectify if ne...

Страница 68: ...68 NOTES Installation and Servicing...

Страница 69: ...69 NOTES Installation and Servicing...

Страница 70: ...70 NOTES Installation and Servicing...

Страница 71: ...71 NOTES Installation and Servicing...

Страница 72: ...The code of practice for the installation commissioning servicing of central heating systems Ideal Installer Technical Helpline 0870 849 8057...

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