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Installation and Servicing

SECTION 2 - INSTALLATION

2.1 BOILER ASSEMBLY - E

xploded

iew

Note

that item numbers are linked to the spares list

104

CH Return Valve

105

CH Flow Valve

106

DHW Inlet & Outlet

107

Filling Loop

108

Pump Head

110

Air Vent Pump

111

Divertor Valve Head

112

Divertor Valve Cartridge

113

Pressure Relief Valve

114

Pipe - PRV Outlet

115

Pipe - Flow

116

Pipe - Return

117

Pipe - Expansion Vessel

118

Expansion Vessel

119

Return Group Manifold

120

Flow Group Manifold

121

Plate Heat Exchanger

127

Flow Turbine

131

Water Pressure Switch

135

Pressure Gauge

203

Gas Cock

204

Pipe - Gas Inlet

205

Gas Valve

206

Pipe - Gas Injector

211

Injector Assy

214

Venturi

215

Fan

217

Burner

218

Gasket - Burner

221

Sump Clean Out Cover

223

Flue Manifold

224

Recuperator Assy

226

Air Duct Assy

228

Recuperator Inlet Pipe

229

Recuperator Outlet Pipe

231

Guide Bracket

232

Clamp Retaining Flue Turret

233

Hose Condensate Internal

234

Siphon Trap

236

Condensate Outlet Connection

238

Flue Sensing Nipple

302

PCB

304

Control Thermistor (Return)

306

Electrode Ignition

307

Electrode Detection

308

Ignitor Unit

309

Thermistor Flow

313

Ignition Lead

320

Detection Lead

324

Control Box Lid

325

Control Box Front

326

Blank Insert

401

Heat Engine

503

Wall Mounting Bracket

504

Front Panel

505

Fascia

506

Bracket - Gas Valve

507

Bracket - Expansion Vessel

512

Casing Door

514

Front Panel Door

516

Module Casing

516

232

512

224

118

228

229

507

226

238

503

114

117

108

221

204

205

206

211

506

308

214

218

320

401

313

302

325

326

231

223

217

309

307

306

304

233

236

116

104

106

203

106

135

105

121

111

112

504

505

514

215

324

234

107

110

113

119

131

120

127

115

INST

ALLA

TION

Содержание LOGIC CODE COMBI ESP1 26

Страница 1: ...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 literature...

Страница 2: ...P1 kW 7 9 7 9 7 9 Auxiliary Electricity Consumption Full Load elmax kW 0 086 0 093 0 093 Part Load elmin kW 0 062 0 045 0 05 Standby PSB kW 0 003 0 003 0 003 Seasonal Space Heating Energy Efficiency...

Страница 3: ...Class IV Class V Class VI Class VII Class VIII 1 2 1 5 2 3 4 3 5 5 The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency onc...

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

Страница 5: ...16 Ideal Boilers reserve the right to vary specification without notice FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL INSTALLER HELPLINE 01482 498704 NOTE BOILER RESTART PROCEDURE To restart the bo...

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

Страница 7: ...l Replacement 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...

Страница 8: ...22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter mm 100 Average Flue Temp Mass Flow Rate DHW 30 C 11g s 32 C 13g s 35 C 15g s Average Flue Temp...

Страница 9: ...oilers only Scale 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 out...

Страница 10: ...of the boiler casing as shown in Section 1 16 Water Gas Connection Diagram 1 2 OPERATION With no demand for CH the boiler fires only when DHW is drawn off When there is a demand for CH the heating sy...

Страница 11: ...y Ideal Boilers in writing If in doubt please enquire Any direct connection of a control device not approved by Ideal Boilers could invalidate the certification and the normal appliance warranty It co...

Страница 12: ...inal to obstructions and ventilation openings are specified in Table 4 4 Where the lowest part of the terminal is fitted less than 2m above a balcony above ground or above a flat roof to which people...

Страница 13: ...tic 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...

Страница 14: ...to 5mm This must be obtained with an easily removable panel to provide the 100mm clearance required for servicing Front clearance The minimum front clearance when built in to a cupboard is 5mm from th...

Страница 15: ...s or for any other reason an additional vessel MUST be installed on the return to the boiler Guidance on vessel sizing is given in the above table Notes a The method of filling refilling topping up or...

Страница 16: ...Hot Water 1 The DHW service must be in accordance with BS5546 BS6700 2 Refer to Table 1 for minimum and maximum working pressures In areas of low mains water pressures the domestic hot water regulato...

Страница 17: ...r 223 Flue Manifold 224 Recuperator Assy 226 Air Duct Assy 228 Recuperator Inlet Pipe 229 Recuperator Outlet Pipe 231 Guide Bracket 232 Clamp Retaining Flue Turret 233 Hose Condensate Internal 234 Sip...

Страница 18: ...K CONTENTS Gas Valve Pack 1 Pipe Gas Inlet 2 Washer Gas blue 3 Gas Cock Filling Loop Pack 1 3 8 Top Hat Washer 2 Valve Filling Loop 3 Pipe Filling Loop 4 Washer Fibre 3 8 Return Valve Pack 1 Pipe CH R...

Страница 19: ...l D Screw E Sealing Tape F Wall Seal white D C A E F B Pack B Contents Non Telescopic A Flue terminal B Flue turret C Rubber terminal wall seal D Cutting Aid E Wall Seal white UNPACKING CONT D A D B C...

Страница 20: ...ll faces immediately around the cut hole should be flat 2 Drill 2 mounting holes marked from template with a 7 5mm 8mm masonry drill and insert the plastic plugs provided for the wall mounting plate 3...

Страница 21: ...nt with an air stopper seal Ensure all caps seals are in place Additional Termination Kits are available for use with these B packs Flue Deflector Kit The resistance is the equivalent of 1 metre of fl...

Страница 22: ...al 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 1551 1766...

Страница 23: ...let 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...

Страница 24: ...l 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 visible If the last...

Страница 25: ...the 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 collar or Universal weather collar...

Страница 26: ...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 27: ...al 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 horizontally backwards Locate both...

Страница 28: ...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...

Страница 29: ...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 seal...

Страница 30: ...must not be overheated when making capillary connections Refer to Section 1 16 for details of the position of the gas connection For additional gas supply info refer to Section 1 8 Gas Supply SAFETY V...

Страница 31: ...valve and fit the grey cap to the open end 8 Fit the Plug to the free end of the filling loop Note open all DHW taps to ensure water is flowing freely once satisfied close all taps Top Up 1 Ensure fil...

Страница 32: ...oiler comes pre fitted with 1 8m of mains cable This must be connected to a permanent live supply and NOT switched by thermostats programmers If the supply cord is damaged it must be replaced by the m...

Страница 33: ...the control box 2 Unclip the timer link socket from the aperture on the rear of the control box locate the plug on the same harness branch and connect these together 3 Using the rubber bung located ad...

Страница 34: ...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 LIVE IONI...

Страница 35: ...justed 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 installed in accordance...

Страница 36: ...of air If it is necessary to operate the appliance pump to assist venting of the air this must be done with the gas service cock turned off 2 Refit the boiler front panel Refer to Section 3 2 3 Check...

Страница 37: ...lay should 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 r...

Страница 38: ...procedure 10 After installation and commissioning please complete the Commissioning Checklist before handover to the customer For IE its is necessary to complete a Declaration of Conformity to indica...

Страница 39: ...to Section 3 25 The cleaning procedures are covered more fully in Sections 3 3 to 3 7 and MUST be carried out in sequence IMPORTANT 6 After completing the servicing or exchange of components always te...

Страница 40: ...ed nut on the fan mounting bracket 4 Lift off fan and venturi assembly 5 Inspect the injector for blockage or damage 6 Inspect fan outlet sealing gasket and replace if necessary 1 2 3 5 Injector 1 FRO...

Страница 41: ...le withdrawing the burner 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 ceram...

Страница 42: ...Check that the ignition 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 s...

Страница 43: ...EMENT 1 Refer to Secton 3 8 2 Disconnect the electrical leads from the fan 3 Remove the clip from the gas control valve outlet 4 Remove the extended nut retaining the fan mounting bracket 5 Lift and r...

Страница 44: ...located correctly in the injector housing 10 Check operation of the boiler 2 4 3 11 BURNER REPLACEMENT 1 See Section 3 8 2 Refer to Section 3 4 3 Remove the fan Refer to Section 3 9 4 Undo the two scr...

Страница 45: ...s as shown 8 Reassemble in reverse order 9 Check the operation of the boiler Refer to Sectons 2 22 2 23 3 12 RETURN THERMISTOR RENEWAL 1 Refer to Section 3 8 2 Unclip the return thermistor from the re...

Страница 46: ...detection lead from the electrode 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 r...

Страница 47: ...e 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 taps are shut and that pre heat is switched o...

Страница 48: ...r to facilitate plug removal 5 Spring out the four side retaining clips and pull the PCB upwards to clear the 4 corner retaining posts 6 Take the new PCB 7 Re connect all plug connections 8 Reassemble...

Страница 49: ...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 by re connecting the filling...

Страница 50: ...area by disconnecting the 22mm pipe connection at top of pump chamber and bottom of heat exchanger and remove pipe 5 The automatic air vent head is retained in the pump body with a bayonet connection...

Страница 51: ...ng screws and withdraw the diverter valve body assembly 18 Fit the new diverter valve body assemble and replace the two fixing screws 19 Refit the DHW manifold fit the assembly back to the boiler and...

Страница 52: ...the new pressure switch and re assemble in reverse order 7 Refill the boiler 8 Check operation of the boiler Refer to Sections 2 22 2 23 3 4 5 1 Refer to Section 3 8 2 Drain down the boiler Refer to...

Страница 53: ...and remove pipe 12 Remove the two retaining spring clips and remove pipes 13 Remove the condensate rubber pipe Refer to Section 3 18 no 2 14 Remove the two heat exchanger fixing screws 15 Remove the...

Страница 54: ...rain the boiler CH circuit Refer to Section 3 21 8 Remove the retaining clip on the vessel water connection pipe 9 Support the expansion vessel and unscrew the 2 screws from the securing clamp located...

Страница 55: ...downwards 10 Remove the C clips from the recuperator pipes and disconnect 11 Fit the new recuperator assembly replacing all flue seals and O rings with those provided Ensure both flue seals are corre...

Страница 56: ...ION 4 8 FLOW THERMISTOR FAULT 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...

Страница 57: ...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 58: ...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 59: ...t 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 N...

Страница 60: ...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 61: ...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 62: ...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 c...

Страница 63: ...63 Installation and Servicing...

Страница 64: ......

Страница 65: ...ommissioning 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 boiler guarantee...

Страница 66: ...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 67: ...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 68: ...tem to confirm that all components are correctly assembled fixed and supported Check that maximum flue lengths have not been exceeded and all guidance has been followed e g Gas Safe Register Technical...

Страница 69: ...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 70: ...vary specification without notice The Ideal Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system sp...

Страница 71: ...require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of literature for specification and maintenance practices visit our website www...

Страница 72: ...the current ETCI rules for electrical installation It is essential that the instructions in this booklet are strictly followed for safe and economical operation of the boiler ELECTRICITY SUPPLY This...

Страница 73: ...er fails to light after five attempts the fault code will be displayed refer to Fault Code page OPERATION MODES Winter Conditions Central Heating and Domestic Hot Water required Set the mode knob C to...

Страница 74: ...ob towards the MAX position to meet heating requirements This will depend on the house and radiators used Reducing the room thermostat setting by 1 C can reduce gas consumption by up to 10 WEATHER COM...

Страница 75: ...made before it fully defrosts Warm water can also be poured onto the pipe from a watering can or similar DO NOT use boiling water 3 Caution when using warm water as this may freeze and cause other loc...

Страница 76: ...he time settings on the programmer are as you require and adjust if necessary Check the programmer internal or external to the boiler is in an ON position and the room thermostat is turned up NO HOT W...

Страница 77: ...e boiler The boiler is operating in central heating mode The boiler is operating in domestic hot water mode The boiler is operating in frost protection 7 NORMAL OPERATION DISPLAY CODES The boiler mode...

Страница 78: ...other gas appliances in the house are working to confirm a supply is present in the property 2 If other appliances do not work or there are no other appliances check the gas supply is on at the meter...

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