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31

INSTALLATION

Project Heat - 

Installation and Servicing

 

34 CONNECTIONs

NOTEs. 

Ensure all pipe blanking plugs are removed before connecting.

Note.  The gas isolation handle is 

shown in the open position.

WaTER CONNECTIONs

The boiler flow and return pipes are supplied fitted to the boiler 

and ready for top connection.

note

. For heating loads in excess of 17.6kW (60,000 Btu/h) 

use 28mm x 22mm connectors to connect the boiler flow and 

return pipes to 28mm.
Top Connection

Connect the system pipework to the boiler flow and return 

pipes.

gas CONNECTION

IMpORTaNT. 

The gas service cock is sealed with a non-

metallic blue fibre washer, which must not be overheated when 

making capillary connections. Refer to Frame 1 for details of 

the position of the gas connection.
For additional gas supply information refer to “Gas Supply” 

on page 8.

35  ELECTRICaL CONNECTIONs

Wiring should be 3 core PVC insulated cable, not less than 

0.75mm

2

 (24 x 0.2mm), and to BS 6500 Table 16. For IE 

reference should be made to the current ETCI rules for 

electrical installations.

The mains supply to the boiler and system wiring centre shall 

be through one common fused double pole isolator.  For 

heating systems, and where practicable replacement boiler 

installations, the isolator shall be situated adjacent to the 

appliance.

noTe.  The appliance musT be Wired WiTh a 

permanenT live supply.  The sysTem pump 

musT be Wired To The boiler (see Frame 41).  

The boiler WarranTy Will be invalid iF This 

requiremenT is noT complied WiTh.

Warning

. This appliance MUST be earthed.

A mains supply of 230Vac ~ 50 Hz is required. 

The fuse rating should be 3A.  All external controls and wiring 

must be suitable for mains voltage.  

Wiring external to the boiler MUST be in accordance with the 

current I.E.E. (BS.7671) Wiring Regulations and any local 

regulations.

Yellow

Handle

205862-10073

Gas Supply

Flow

Return

IN

s

T

a

LL

a

TION

Содержание Project Heat 15

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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