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Serial Code Prefix ABO & onwards

1. E ER i Q 5 a 7 143 5 65 2855285 60 6 i zH O Q 6 fea 1 a O LL gt A 3829 m 1 95 95 si 5 Cy s 6 m m 5 mu FE ee ee _ Front clearance ine E a The minimum front clearance when Min Top Clearance mm A SIDE Flue type 167 193 219 245 271 297 323 349 375 401 built in to a cupboard is 5mm from Distance from Horizontal mm required to achieve 1 5deg fall to the appliance the cupboard door but 450mm overall 26 52 78 104 130 156 182 208 234 mm 7 clearance is still required with the all cupboard door open to allovv for 7 4 15 degree servicing Top Clearance A 1 0 t Bottom clearance 20 l Mi 30 Bottom clearance after installation 4 0 can be reduced to 5mm 5 0 60 Max 35kW This must be obtained with an 7 0 easily removable panel to enable 8 0 Max 30kW 305 the consumer to view the system m 9 0 Max 24kVV b pressure gauge and to provide Distance in metres from edge of turret to side vvall Dimension H the 100mm clearance required for 1 Dimension must remain inside the Maximum flue length requirement for the designated output of the applaince been installed servicing 2 For flue lengths requiring pack extentions the flue must incline by 26mm pe
2. FITTING THE TURRET Ensure the condense trapisiphon is filled vvith vvater 1 Ensure the rubber seal is fitted correctly on the appliance manifold and that all flue seals are undamaged 2 Hold the flue firmly and push the turret on until it has travelled 30mm on to the flue pipe and is fully engaged Make sure the flue has not rotated or moved forward during fitting and the flue seam is upper most Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold 3 4 Fully engage the clamp location section into the manifold location holes Rotate down on to turret flange 5 Secure clamp to appliance using securing screw 6 Ensure all sample points are accessible and all sample plugs and caps are fitted Retaining Clamp Lugs screw Duct Assembly Flue Turret Turret Clamp Seal l s R J 0 J a il Flue Outlet 20 Independent Combi Installation and Servicing INSTALLATION 17 FITTING THE OPTIONAL ROOF FLUE KIT Flat or Pitched Note A flat or pitched roof flashing plate not supplied is required before proceeding with the installation of this kit This kit is suitable for both flat and pitched roof terminations using a concentric flue to run vertically from the top of the boiler and terminating above roof level 5 I Shield Connection to the top of the boiler R is made using the supplied vertical Ti ea connector the gutter
3. Additional stop valve Temporary hose disconnect after filling Double check valve assembly note direction of flow Independent Combi Installation and Servicing Safety valve setting bar Vessel charge pressure bar 0 5 to 0 75 System pre charge pressure bar System volume litres 25 50 75 100 125 150 175 190 200 250 300 For other system volumes multipiy by the factor across Expansion vessel volume litres VVater Flovv Rate and Pressure Loss Max CH Output kVV 24 2 Btu h 82 600 17 3 3 8 C 20 F 36 NTT 2 DOMESTIC HOT 1 The domestic hot water service must be in accordance with BS 5546 and BS 6700 Refer to Table 1 for minimum and maximum vvorking pressures In areas of low mains water pressures the domestic hot water regulator may be removed from the DHW flow turbine cartridge Refer to Frame 69 The boiler will require the flow rate to be set to obtain a temperature rise of 35 C at the tap furthest from the boiler l min gal min Water flow rate Temperature Differential s The boilers are suitable for connection to most types of washing machine and dishwasher appliances 4 When connecting to suitable showers ensure that a The cold inlet to the boiler is fitted with an approved anti vacuum or syphon non return valve b Hot and cold water supplies to the shower are of equal pressure 5 Hard Water Areas Where the water hardness ex
4. 95 15 MO A JO b 6 5 4 SIUM A 4 yuld d p r 1 UMOJG JQ yoejq yq niq q AIM uIq n L Independent Combi Installation and Servicing 28 INSTALLATION 28 COMMISSIONING AND TEST NG A Electrical Installation B Gas Installation 1 Checks to ensure electrical safety should be carried out by a 1 The whole of the gas installation including the meter competent person should be inspected and tested for tightness and purged in accordance with the recommendations of BS 6891 2 ALWAYS carry out the preliminary electrical system checks i e In IE refer to 1S 813 2002 earth continuity polarity resistance to earth and short circuit using a suitable test meter 2 Purge air from the gas installation by the approved 3 After wiring the boiler all grommets in the bottom panel MUST be in place to ensure that the boiler case sealing is maintained WARNING Whilst effecting the required gas tightness test and purging air from the gas installation open all windows and doors extinguish naked lights and DO NOT SMOKE GENERAL Please Note The combustion for this appliance 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 h
5. 10 a Turn power on Ribbon b Displays 8 blue light on off first digit input Cable second digit input 1st letter appliance type Connection i e 2 4 4 c c Move knob to required setting standby summer winter Note fno BCC fitted on non programmed board C2 will be displayed The correct BCC for this appliance will need to be fitted 11 Check operation of the boiler Refer to Frames 29 amp 30 42 Independent Combi Installation and Servicing SERVICING 52 USER CONTROL PCB REPLACEMENT Note Fit the earth strap provided with the PCB to your wrist and a suitable earth on the boiler chassis 1 Refer to Frame 40 2 Remove the main PCB refer to Frame 56 3 Unclip the PCB and lift to clear the mounting posts 4 Fit the new PCB ensuring the 4 potentiometer spindles line up with the control knobs which must be in a vertical position Reassemble in reverse order 6 Check operation of the boiler Refer to Frames 29 amp 30 Potentiometer spindle 53 REPLACING THE MECHANICAL TIMER Refer to Frame 40 Remove the boiler front panel Refer to Frame 34 Pull out the plate with timer attached Disconnect 5 way connector Remove programmer and fit new programmer Re fit 5 way connector Push fit mechanical timer into housing SNe aS Se YS Replace the front panel ensuring a good seal is made 9 Check operation of the boiler Refer to Fr
6. 5 Before replacing the diverter valve actuator proceed as follows a Re connect the inline connector block b Ensure that the switched live to the boiler is off and that all DHW taps are shut and that pre heat is switched off c Hold the mode knob in the restart position for more than 10 secs d The display will alternate between d and U and the actuator will move into the mid position e The divertor valve will initially drive all the way out this may cause the spindle to become detached from the body If this occurs simply screw back into the body so the cycle can continue driving fully in before going to mid position f Replace the actuator into the boiler 6 Fit the new motor ensuring the arm is correctly engaged in the metal fork and re assemble in reverse order ensuring the condensate trap siphon is refilled with water 7 Check the operation of the boiler Refer to Frames 29 amp 30 Note All spares will be delivered in mid position therefore ignore point 5 and proceed to point 6 after re connecting the inline connector Independent Combi Installation and Servicing 41 SERVICING SERVICING oN SERVICING 50 CONDENSATE TRAP SIPHON REPLACEMENT Refer to Frame 40 Pull off the rubber pipe at the sump drain Disconnect the condensate drain pipe Turn the siphon clockwise to disengage and lift to remove Note Keep siphon upright when removing Clean
7. Remove condensate trap siphon Refer to Frame 50 Remove the diverter valve actuator Refer to Frame 49 Remove the 2 allen screws securing the plate heat exchanger to the composite housings Manoeuvre the plate heat exchanger out of the top LH or centre of the controls area Be aware of any water spillage Fit the new plate heat exchanger using the new o rings supplied Note Ensure that the depressions are on the bottom prior to fitting Reassemble in reverse order 9 Refill the boiler Refer to Frame 23 10 Check operation of the boiler Refer to Frame 29 amp 30 62 PUMP HEAD REPLACEMENT Refer to Frame 40 Drain the boiler Refer to Frame 55 Disconnect the electrical lead from the pump Remove the 4 Allen screws retaining the pump head ov Remove the pump head EL Fit the nevv pump head m Reassemble in reverse order ce Refill the boiler Refer to Frame 23 Check operation of the boiler Refer to Frames 29 amp 30 22S eo 19 46 Independent Combi Installation and Servicing SERVICING 63 CH WATER PRESSURE SWITCH REPLACEMENT Refer to Frame 40 Drain the boiler Refer to frame 55 Pull off the two electrical connections Using a suitable tool pull out the metal retaining clip Carefully withdraw the pressure switch Fit the new pressure switch and re assemble in reverse order Refill the boiler Check operation of the boiler Refer to Frames 29 amp 3
8. Explain the function and the use of the boiler heating and domestic hot water controls Explain that due to system variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap It is therefore necessary to draw the users attention to the section in the Users Instructions titled Control of Water Temperature and the following statement Additionally the temperature can be controlled by the user via the draw off tap the lower the rate the higher the temperature and vice versa Explain the function of the boiler fault mode Emphasise that if a fault is indicated refer to Fault Codes in the User Guide Explain and demonstrate the function of time and temperature controls radiator valves etc for the economic use of the system 10 After installation and commissioning please complete K THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS the Commissioning Checklist before handover to the customer For IE its is necessary to complete a Declaration of Conformity to indicate compliance to 1 5 813 2002 IMPORTANT 11 A comprehensive service should be carried out ANNUALLY Stress the importance of regular servicing by a Gas Safe Registered Engineer n IE servicing vvork must be carried out by a Registered Gas Installer RGII 12 Inform the householder of the guar
9. See boiler Operation Modes and Fault Codes section Contact a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII Independent Combi User s 8 NORMAL OPERATION DISPLAY CODES DISPLAY CODE ON BOILER DESCRIPTION burner The boiler is in standby operation awaiting either a central heating call or hot water demand burner The boiler has a call for central heating but the appliance has reached the desired temperature set on the boiler burner The boller has a call for hot vvater but the appliance has reached the desired temperature set on the boiler 2 burner The boller is operating in central heating The boiler is operating in domestic hot water burner The boiler is operating in domestic hot water preheat burner The boiler is operating in frost protection FOR ANY QUERIES PLEASE RING THE IDEAL CONSUMER HELPLINE 01482 498660 NOTE BOILER RESTART PROCEDURE To restart boiler turn mode to restart position and immediately turn knob back to required setting 1 ril continued Independent Combi User s 7 9 FAULT CODES DISPLAY CODE ON BOILER DESCRIPTION ACTION burner burner BCC Activation Fault Restart the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty burner burner BCC Fault period In IE contact a
10. The domestic hot vvater preheat vvill operate vvith the preheat knob A set to preheat on Summer Conditions Domestic Hot Water only required Set the mode knob D to K summer Set the central heating demand on the external controls to OFF The domestic hot vvater preheat vvill operate vvith the preheat knob A set to preheat on Boiler Off Set the mode knob D to boiler off The boiler mains power supply must be left on to enable frost protection see Frost Protection Independent Combi User s Boiler Base PREHEAT DOMESTIC HOT WATER The domestic hot water heat exchanger within the boiler can be kept preheated to provide faster delivery of hot water at the tap This is achieved by turning the preheat on off knob A to preheat on The boiler will operate periodically for a few seconds to maintain the domestic hot water heat exchanger in a preheated condition The average time period between operation is 90 minutes This may vary considerably due to the surrounding ambient temperature of the boiler The boiler will operate whenever there is a demand for domestic hot water If standard hot water delivery is satisfactory turn the knob A to preheat off CONTROL OF WATER TEMPERATURE Domestic Hot Water The domestic hot water temperature is limited by the boiler controls to a maximum temperature of 64 C adjustable via the domestic hot water temperature knob B
11. 38 ndependent Combi Installation and Servicing SERVICING 44 RETURN THERMISTOR RENEWAL Refer to Frame 40 Unclip the return thermistor from the return pipe and withdraw it from the boiler 3 Disconnect the electrical lead from the thermistor 4 Reconnect the electrical lead to the new thermistor and reassemble in reverse order ensuring that the thermistor is securely fitted to the pipe on thermistor locator tab as shown Check the operation of the boiler Refer to Frames 29 amp 30 Thermistor Locator Tab with thermistor fitted 45 IGNITION ELECTRODE REPLACEMENT Refer to Frame 40 Remove the burner Refer to Frame 43 Unplug the ignition lead from the electrode Ignition Electrode Remove the earth lead from the ignition electrode Remove the 2 screws holding the ignition electrode to the combustion chamber 6 Remove the electrode 7 Fit the new ignition electrode using the new gasket supplied Check dimensions as shown Reassemble in reverse order 9 Check the operation of the boiler Refer to Frames 29 amp 30 Spark Gap Yi 3 5mm 1 Independent Combi Installation and Servicing 39 SERVICING SERVICING SERVICING 46 FLAME DETECTION ELECTRODE REPLACEMENT Refer to Frame 40 Remove the burner Refer to Frame 43 3 Unplug the flame detection lead from the electrode Remove the 2 screws retaining the detection electrode 5
12. Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No CO At min rate Where Possible CO At max rate Record At max rate Record At min rate Where Possible Comments Comments Signature Allinstallations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer Heating and Hotwater Industry Council HHIC Signature THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk FLOVVCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory set and must not be adjusted DURING COMMISSIONING If the boiler requires conversion to operate with a different gas family e g conversion from natural gas to LPG sepa rate guidance is provided with the conversion kit supplied and this must be followed PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK The installation instructions must have been followed gas type verified and gas supply pressure gas rate checked as required prior to commissioning As part of the installation process ESPECIAL
13. INSTALLATION AND SERVICING INDEPENDENT COMBI C24 C50 CS5 For Users Guide see reverse of book O m For details of document amendments refer to page 3 When replacing any part on this appliance 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 Ideal For the very latest copy of literature for specification and maintenance practices visit our website www idealboilers com where you can download the relevant information in PDF format August 2014 UIN 210922 1 L ndependent Combi Installation and Servicing NOTES FOR THE INSTALLER FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL INSTALLER HELPLINE 01482 498704 NOTE BOILER RESTART PROCEDURE To restart boiler turn mode knob to restart position and immediately turn knob back to required setting The boiler will repeat the ignition sequence if a heat demand is present DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level A01 August 14 Ideal Stelrad Group reserve the right to vary specification vvithout notice ndependent Combi Installation and Servicing GENERAL Table 1 General Data 63 C 11g 8 73 C 15g s Maximum Domestic Hot Inlet bar kPa 10 0 a Minimum Domestic Hot Water Inlet
14. 5 Check the DHW filter for blockage Refer to Frame 64 and be calibrated in accordance with the analyser The cleaning procedures are covered more fully in Frames 35 to 39 manufacturers requirements and and MUST be carried out in sequence Competence can be demonstrated by satisfactory IMPORTANT completion of the CPA1 ACS assessment which covers the use of electronic portable combustion 6 After completing the servicing or exchange of components always 7 9 gas analysers in accordance vvith BS7967 Parts 1 test for gas tightness to 4 7 When work is complete the front panel MUST be correctly refitted ensuring that a good seal is made Do NOT OPERATE the boiler if the front panel is not fitted 8 If for any reason the condensate trap siphon has been removed ensure the trap is refilled with water before Flue Sampling Point e reassembling 9 Check the gas consumption 57 Pea ww 10 Check combustion by connecting the flue gas analyser to the flue XS gas sampling point as shown in the diagram and measure CO amp CO If the CO CO ratio is greater than 0 004 AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure and gas rate have been verified then contact Ideal Ensure all caps and seals are re fitted after use 11 Complete the service section in the Benchmark Commissioning Checklist Independent Combi Installation a
15. 813 2002 The following notes are intended for general guidance 1 The boiler MUST be installed so that the terminal is exposed to external air 2 t is important that the position of the terminal allows the free passage of air across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 4 4 VVhere the lovvest part of the terminal is fitted less than 2m 6 6 above a balcony above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard Terminal guards are available from boiler suppliers Ask for TFC flue guard model no K6 round plastic coated In case of difficulty contact TFC Group Tower House Vale Rise Tonbridge Kent TN9 1TB Ensure that the guard is fitted centrally Tel 44 0 01732 351 680 Fax 44 0 01732 354 445 www tfc group co uk 5 The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of any building 6 The air inlet products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm 1 to combustible material Detailed recommendations on the protection of combustible material are given in BS 5440 1 2008 IMPORTANT It is essential to ensure in practice that products of combustion discharging from the terminal cannot re enter the building or buildings through any openings into the build
16. When the burner is established the BLUE Burner On neon F will be illuminated the LED display E will show status DOMESTIC HOT WATER 11 With the boiler firing set the DHW Temp knob B to maximum and fully open a DHW tap The boiler should continue to run and the LED display E should show status 2 12 Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output Refer to Table 2 IMPORTANT The gas input to the burner is regulated by the gas valve according to the air flow produced by the fan It is NOT user adjustable Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void For additional gas supply info refer to Gas Supply on page 8 13 Turn off the DHW tap 30 Handle Slacken the screw in the inlet pressure test point J and connect a gas Yellow f m Handle m Handle MECHANICAL TIMER Outer dial Align current time to arrovv THE DISPLAY The user control has one neon and one display to inform the user about the status The display vvill shovv the status of the boiler The neon will show the status of the flame If no flame is detected the neon is off When the flame is detected the neon will be lit permanently Below is a list with display function in normal operation C Standby no demand for heat present c Boiler is active for central heating d Boiler is active for d
17. than with the appliance we reserve the right to levy a charge for the visit or for any pre arranged visit where access is not gained by the engineer TROUBLESHOOTING NO HOT WATER Check the mains power is turned on and ensure mode knob D is in the Summer or winter position s water coming out of the hot water tap when turned on YES See boiler Fault Codes section If 0 is displayed then contact Ideal Customer Services Helpline if your appliance is under warranty or a Gas Safe Registered Engineer in IE a Registered Gas Installer RGII if out of warranty Contact a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII NO CENTRAL HEATING Check the mains power is turned on and ensure mode knob D is in the winter position Check the programmer internal or external to the boiler is in an ON position and the room thermostat is turned up Does the boiler operate and provide central heating YES Check the time settings on the programmer are as you require and adjust if necessary See boiler Operation Modes and Fault Codes section If 0 is displayed then contact a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII NO HOT WATER OR CENTRAL HEATING Check the mains power is turned on and ensure mode knob D is in the winter position Does the boiler have a display showing on the front control panel
18. 000 1 100 Ohms the Thermistor NO YES Check and replace Replace PCB wiring as necessary Is the Thermistor value correct 77 ALTERNATING F AND 6 OUTSIDE SENSOR FAULT m NO Securely connect the vviring at both the s the wiring securely connected at both the boiler and boilerand Outside Sensor Outside Sensor Disconnect the wires to the outside sensor Check the resistance using a suitable multimeter connected across the Outside Sensor s terminal pins Fit a new Outside Sensor AtO C expect 31 000 35 000 Ohms At15 C expect 15 000 16 500 Ohms At 30 C expect 7 700 8 500 Ohms Is the Outside Sensor value correct Securely connect the wiring at the Terminal Block and the PCB Is the wiring securely connected between the incoming terminal block boiler connection of the Outside Sensor and the PCB VES Replace PCB 78 ALTERNATING F AND 7 LOW MAINS VOLTAGE Contact electricity provider O Z Q Z IL z O Z Q IL 9 q O Q IL q O Q IL E IL O Q Lu ndependent Combi Installation and Servicing 53 FAULT FINDING 79 ALTERNATING F AND 9 PCB FAULT Replace PCB Ensure that the BCC boiler chip card small plastic part is fitted to the PCB otherwise replace PCB 80 ALTERNATING AND 4 FLOW THERMISTOR FAULT Is the wiring securely connected to the Flow Thermistor Securely connect the wiring to
19. 2 3 4 Re assemble in reverse order 5 Check operation of the boiler Refer to Frames 29 amp 30 REPLACEMENT Refer to Frame 40 Drain the boiler CH circuit Refer to Frame 55 Remove the retaining clip on the vessel water connection pipe Support the expansion vessel and unscrew the 2 screws from the securing clamp located on the top of the boiler and remove Note the position of the bracket on the vessel 10 Remove the expansion vessel 11 Fit the new expansion vessel 12 Reassemble in reverse order ensuring the seal is in place 13 Refill the boiler 14 Check operation of the boiler Refer to Frames 29 amp 30 68 BOILER SEALING PANEL SEAL REPLACEMENT Refer to Frame 40 Remove the old seal from the casing and thoroughly clean the casing surfaces Fit the new seal ensuring the bottom joint provides an air tight seal Reassemble in reverse order 6 Check operation of the boiler Refer to Frames 29 amp 30 Note Ensure that the boiler front panel is correctly sealed compressing the seal to make an airtight joint Independent Combi Installation and Servicing 49 SERVICING FAULT FINDING 69 ALTERNATING L AND 1 FLOW TEMPERATURE OVERHEAT LOCKOUT Is the Boiler and CH System filled with water and all isolation and radiator valves open Is the Flow Return Differential across the Boiler in excess of 30 C Check the Return Thermistor Refer to Fr
20. Auto Air Vent Divertor Valve Motor Divertor Valve Body amp Paddle Pressure Relief Valve Pipe PRV Outlet Pipe Flow Pipe Return Pipe Expansion Vessel Expansion Vessel Return Group Manifold Flow Group Manifold 121 124 127 131 135 203 204 205 206 211 214 215 217 218 219 504 Plate Heat Exchanger Flow Regulator Flow Sensor Turbine Water Pressure Switch Pressure Gauge Gas Cock Pipe Gas Inlet Gas Valve Pipe Gas Injector Injector Assy Venturi Fan Burner Gasket Burner Sump Clean Out Cover Independent Combi Installation and Servicing 223 224 227 228 229 231 301 302 303 304 306 307 308 309 313 Note that item numbers are linked to the spares list Flue Manifold Flue Manifold Top Clamp Retaining Flue Turret Hose Condensate Internal Siphon Trap Condensate Outlet Connection Ctrl Box Fixings Hings amp Spring Primary PCB CUI Board Control Thermistor Return Electrode Ignition Electrode Detection Ignitor Unit Thermistor Flow Ignition Lead 314 320 324 325 326 401 503 504 505 506 507 512 Control Box Lens Detection Lead Control Box Lid Control Box Front Programmer Insert Heat Engine Wall Mounting Bracket Front Panel Fascia Bracket Gas Valve Bracket Expansion Vessel Front Panel Door Note that production boiler PCBs are factory pre set to operate for boiler range and output When ordering Primary PCB as a Spare
21. Boiler interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions What system cleaner was used What inhibitor was used Quantity litres Has a primary water system filter been installed CENTRAL HEATING MODE measure and record Gas rate m OR ft hr Burner operating pressure if applicable OR Gas inlet pressure mbar Central heating flow temperature Central heating return temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate m OR ft hr Burner operating pressure at maximum rate OR Gas inlet pressure at maximum rate mbar Cold water inlet temperature C Hot water has been checked at all outlets Temperature Water flow rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 ALL INSTALLATIONS At max rate CO ppm CO COz At min rate where possible CO ppm CO COz Record the follovving The heating and hot vvater system complies vvith the appropriate Building Regulations The boiler and associated products have been installe
22. Insulation measures as described should be used When a rainwater downpipe is used an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse flow of rainwater into the boiler should the downpipe become flooded or frozen see Fig 5 Where the condensate drain pipe terminates over an open foul drain or gully the pipe should terminate below the grating level but above water level to minimise wind chill at the open end The use of a drain cover as used to prevent blockage by leaves may offer further prevention from wind chill See Fig 6 Where the condensate drain pipe terminates in a purpose designed soak away see BS 6798 any above ground condensate drain pipe sections should be run and insulated as described above See Fig 7 Unheated Internal Areas Internal condensate drain pipes run in unheated areas e g lofts basements and garages should be treated as external pipe Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual Figure 2 Connection of a Condensate Drainage Pipe Downstream of a Sink Basin Bath or Shower Water Trap to Internal Soil Vent Stack Boiler with 75mm sealed condensate Min 19mm Internal pipe Sink basin bath or shovver x O 5 o V o Boilers without 75mm sealed condensate trap mu
23. Operating Satisfactorily No further actions required Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed Complete Benchmark Checklist recording CO and combustion ratio readings as required For additional fault finding advice please visit Ideal s website www idealboilers com Technical Training The Ideal Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers DCNCHITIGS H m ten COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Manufactured under an ISO 9001 The code of practice for the installation i registered quality management system commissioning amp servicing of central heating systems FM 59915 Ideal Boilers Ltd P O Box 103 National Ave Kingston upon Hull HUS 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 Ideal Stelrad Group 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 Stelrad Group Ideal Technical Helpline 01482 498 663 www idealboilers com USERS INDEPENDENT COMBI C24 50 CS5 For Installation Guide see reverse of book When replacing any part on this appliance u
24. Refer to Frame 67 Firstly increase access area by disconnecting the 22mm pipe connection at top of pump chamber and bottom of heat exchanger and remove pipe Refer to Frame 57 The automatic air vent head is retained in the pump body with a bayonet connection The air vent head and float assembly is removed by turning the head anti clockwise viewed from above and pulling upwards Reassembly is the reverse of the above Ensure the air vent head o ring seal is in place when refitting and the new o ring is fitted to the return pipe top connection Ensure the air vent cap is loose Refill the boiler Check for leaks around the new air vent joint Check the operation of the boiler Refer to Frames 29 amp 30 59 DHW FLOW TURBINE CARTRIDGE REPLACEMENT Refer to Frame 40 Drain the DHW system Refer to Frame 55 3 Turn the housing anti clockwise and pull forward to remove the cartridge Using a pair of pliers pull out the plastic filter flow regulator Clean or replace filter as necessary Reassemble in reverse order Refill the boiler Check operation of the boiler Refer to Frames 29 amp 30 Independent Combi Installation and Servicing 45 SERVICING SERVICING SERVICING 60 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT To remove the valve body assembly 18 Fit the new diverter valve body assemble and replace the Refer to Frame 40 two fixing screws Drain the boiler
25. Registered Gas Installer RGII burner burner Low Water Pressure Check system water pressure is between 1 amp 1 5bar on the system pressure gauge G To re pressurise the system see Section 3 If the boiler still fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Flame Loss 1 Check 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 and or pre payment meter has credit If the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Fan Fault Restart the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Flow Thermistor Restart the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Return Thermistor Restart the a
26. When work is complete the front panel must be correctly refitted ensuring that a good seal is made When replacing ANY component Isolate the electricity supply Remove the boiler front panel Refer to Frame 34 Notes Release the retaining clip and swing the control box down 1 In order to assist fault finding the control panel has an into its servicing position LED diagnostic display n order to replace components in Frames 56 67 it is necessary to drain the boiler Refer to Frame 55 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED SERVICING 41 FAN REPLACEMENT Retaining Tabs Refer to Frame 40 2 Disconnect the electrical leads from the fan Remove the clip from the gas control valve outlet Remove the extended nut retaining the fan mounting bracket Lift and remove the fan and venturi assembly 6 Remove the screw and twist venturi anti clockwise to remove venturi assembly noting the orientation of the venturi in relation to the fan body Transfer the venturi assembly to the new fan replacing the o ring if evidence of damage or deterioration is visible Fit the new fan venturi assembly ensuring the retaining tabs are correctly positioned and the fan outlet sealing gasket is correctly positioned and free from damage Refit the extended nut Reassemble the boiler in reverse order taking care not to overtighten the screw on the fan mounting bracket C
27. an additional Boiler Chip Card BCC MUST also be purchased for your specific boiler range and output a Check boller serial letter code on data plate to obtain correct BCC 13 INSTALLATION INSTALLATION 6 INSTALLATION 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 Unpack and check the contents Pack A Contents A moo 7 14 Boiler Hardware Bag Wall Mounting Plate These Installation Users Instructions Wall Mounting Template located on internal protective packaging GOMBI Boiler Guarantee amp Registration Pack HARDWARE PACK CONTENTS Gas Valve Pack Gas Cock Valve DHW Valve Return Valve Flow Pipe DHW Inlet Nut G 1 2 Washer Gas Washer DHW Washer CH 10 Screw 11 Wall Plug 12 Turret Clamp Screw spare CON O QG FP W NB gt Fixings Pack Independent Combi Installation and Servicing INSTALLATION 7 UNPACKING CONT D Note This flue system incorporates a removable flue outlet nose that utilises a push fit location system This enables the installation of deflector high level
28. bathroom waste pipe etc See Figs 1 and 2 Figure 1 Connection of Condensate Drainage Pipe to Internal Soil amp Vent Stack Boiler with 75mm sealed condensate Min 19mm a Internal pipe Soil amp vent stack Minimum connection height up to 3 storeys Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break 24 Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal 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 all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose designed soak away If an external system is chosen then the following measures must be adopted The external pipe run should be kept to a minimum using the most direct and most vertical route possible to the discharge point with no horizontal sections in which condensate might collect For connections to an external soil vent stack see Fig 4
29. buildings Design for water based heating systems BSEN 12831 2003 Heating Systems in buildings Method for calculation of the design heat load BSEN 14336 2004 Heating Systems in buildings Installation and commissioning of water based heating systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW BS 6891 Low pressure installation pipes Health amp Safety Document No 635 The Electricity at Work Regulations 1989 The manufacturer s notes must NOT be taken in any way as overriding statutory obligations IMPORTANT These appliances are CE certificated for safety and performance It is therefore important that no external control devices e g flue dampers economisers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Ideal Stelrad Group in writing If in doubt please enquire 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 and the above regulations SAFE HANDLING OF SUBSTANCES No asbestos mercury or CFCs are included in any part of the boiler or its manufacture Independent Combi Installation and Servicing LOCATION OF BOILER The bo
30. burner from the combustion chamber To facilitate the removal angle the burner 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 Brush off any deposits that may be on the ceramic with a SOFT brush Inspect the sealing gasket around the burner for any signs of damage Replace as necessary 37 CLEANING THE CONDENSATE TRAP SIPHON Pull off the rubber pipe at the sump drain 4 Clean siphon with water Disconnect the condensate drain pipe 5 Re assemble in reverse order Turn the siphon clockwise to disengage and lift to B When re assembling ensure the trap is full of water remove Note Keep siphon upright when removing Independent Combi Installation and Servicing 35 SERVICING SERVICING SERVICING 38 CLEANING THE HEAT EXCHANGER Note Ensure the condensate trap siphon is fully drained before cleaning Refer to Frame 50 Remove ignition and flame detection electrodes Refer to Frames 45 amp 46 It is advisable to replace the sump cover prior to the water flush process Thoroughly flush the heat exchanger by pouring water into the top of the combustion chamber ensuring the full top area is covered Remove the sump cover and clean loose deposits from the sump Inspect the ignition and detection electrodes Ensure that they are clean and in go
31. h Instantaneous domestic hot water DHW output is also fully modulating with a maximum of C24 24 2kVV 82 600 Btu h C30 30 3kVV 103 300 Btu h C35 35 3kVV 120 500 Btu h The boiler is supplied fully assembled with DHW plate heat exchanger diverter valve circulating pump pressure gauge safety valve and CH expansion vessel Variable CH and DHW temperature controls are fitted on the user control and the boiler features a DHW preheat facility The boiler includes as standard Automatic bypass Boiler frost protection Daily pump and diverter valve exercise Mechanical 24hr timer The boiler casing is of white painted mild steel The boiler temperature controls are visible located in the control panel on the front of the boiler The heat exchanger is manufactured from cast aluminium The boiler is suitable for connection to fully pumped sealed heating systems ONLY Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework Pipework from the boiler is routed downwards Data Plate The boiler model and serial number can be located on the bottom of the boiler casing shown in Frame 1 Water amp Gas Connection Diagram OPERATION With no demand for CH the boiler fires only wnen DHW is drawn off or periodically for a few seconds without any DHW draw off in order to maintain the DHW plate heat exchanger in a heated condition This onl
32. lack of experience and knowledge provided they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards involved Children shall not play with the appliance Cleaning and user maintenance shall not be made by children without supervision All Gas Safe Register installers carry a Gas Safe Register ID card and have a registration number Both should be recorded in the Benchmark Commissioning Checklist You can check your installer by calling Gas Safe Register direct on 0800 4085500 Ideal Stelrad Group is a member of the Benchmark scheme and fully supports the aims of the programme Benchmark has been introduced to improve the standards of installation and 7 commissioning of central heating systems in the UK and to encourage the regular servicing of all J enc mar central heating systems to ensure safety and efficiency THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS THE BENCHMARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE 2 Independent Combi User s 2 BOILER OPERATION Legend Domestic Hot Water Preheat On Off Knob Domestic Hot Water Temperature Knob Central Heating Temperature Knob Mode Knob Boiler Status Burner on Indicator Pressure Gauge Central Heating Economy Setting A B C D G P TO START THE BOILER If a programmer is fitted refer to separ
33. siphon with water or replaced if damaged Re assemble in reverse order When re assembling ensure the trap is full of water Check operation of the boiler Refer to Frames 29 amp 30 51 MAIN PCB REPLACEMENT Note that production boiler PCB s 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 Note Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis Refer to Frame 40 Note the control knob positions Remove the 2 screws retaining the control box cover Carefully lift the 4 retaining clips and remove control box cover 5 Unplug all lead connections to the PCB including the ribbon cable to facilitate ribbon cable removal ease side clips apart and pull upwards also where applicable push the small plastic clip with an electrical screwdriver to facilitate plug removal 6 Spring out the two side retaining clips and pull the PCB upwards to clear the 4 corner retaining posts 7 Take the new Primary PCB and attach the appropriate Boiler Chip Card BCC to it this should correspond to the output of the boiler 24kW 30kW or 35kW Note Ensure the correct orientation of BCC by placing TOP side up as shown 8 Re connect all plug connections 9 Reassemble in reverse order
34. soffits Total Maximum Permissible Horizontal Concentric Flue Length combining both B Packs and D Packs Measured from centreline of the turret to the outside of the wall terminal 24 kW appliances Total Maximum 9 metres minus any flue kit options or bends 8 metres minus any flue kit options or bends 35 kW Appliances Total Maximum 6 metres minus any flue kit options or bends Total Maximum Permissible Vertical Flue Length combining both Roof Terminal and D Packs 24 30 amp 35kW Appliances Total Maximum 7 5 Metres minus any bends Std Metric Brick 102 5mm wide B Pack Flue Type Minimum permissible Wall Thickness Maximum permissible Wall Thickness 1 Flue Rear Flue Std Off Side Flue Rear Flue Std Off Side Flue recommended that a support bracket is fitted on every 1 metre of pipe work used and the bracket is located as close to the collar as possible The bracketing must ensure a 1 5 degree fall back to the appliance Optional Flue Finishing Kit UIN 155988 amp Concentric Flue Screw Retaining Kit Optional Kit of mechanical fixing of flue joints Only use water as a lubricant during assembly The B pack terminal is classed as part of the maximum flue length These flue systems incorporates a removable flue outlet nose that utilises a push fit location system This enables the installation of deflector high level or balcony flue kits without the remova
35. standard 21 5mm 3 4 overflow pipe It is a universal fitting to allow use of different brands of pipework Independent Combi Installation and Servicing GENERAL 1 BOILER DIMENSIONS SERVICES amp CLEARANCES all dimensions in mm The boiler connections are made on the boiler bulkhead fittings Refer to Frame 23 wall thicknesses do not exceed 600mm 24 Where the The following minimum clearances must be maintained for space into which the boiler is going to be installed is less operation and servicing than the length of flue required the flue must be fitted from Additional space will be required for installation depending upon the outside site conditions Installation from inside ONLY Side and Rear Flue b Ifa core boring tool is to be used inside the building the a Provided that the flue hole is cut accurately e g with a core space in which the boiler is to be installed must be at least drill the flue can be installed from inside the building where wide enough to accommodate the tool CLEARANCES 25 BOILER DIMENSIONS 25 m from case 278 1 155 Flue terminal 700 a Q SONOS N 2 Inset Water Connections and Gas Connection Underside View Dimensions Wall mani a 9 2 m a boler I 7
36. the Flow located in the top of the Heat Exchanger Thermistor Disconnect the wiring from the Flow Thermistor Check the resistance using a suitable multimeter connected l l across the Thermistor s terminal pins Fit a new Thermistor At25 C expect 9 700 10 300 Ohms At60 C expect 2 400 2 600 Ohms At85 C expect 1 000 1 100 Ohms Is the Thermistor value correct Securely connect the wiring to the PCB YES Is the wiring securely connected to the low voltage 6 way connector at the front left hand side of the PCB Replace PCB 81 ALTERNATING c AND 2 BCC FAULT BOILER CHIP CARD Is the correct BCC for the boiler securely inserted into the Securely insert the correct BCC for the boiler slot at the front left of the PCB into the PCB and after switching power on and identified by the label on the BCC c being shown restart boiler Note Ensure the correct orientation of BCC by placing TOP side up Replace the BCC with a new BCC that is correct for the boiler After switching power on and cO being shown YES press restart Is c2 still shown a Replace PCB RESTART PROCEDURE To restart boiler turn mode knob to restart position and immediately turn knob back to required setting O Z Q Lu z O Z Q Lu lt O Z Q lt O Q Lu z q O Q J 54 Independent Combi Installation and Servicing FAULT FINDING 8
37. the Weather Compensation option is fitted to the system then the central heating temperature knob C becomes a method of controlling room temperature Turn the knob clockwise to increase room temperature and anti clockwise to decrease room 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 BOILER FROST PROTECTION The boiler is fitted with frost protection that operates in all modes provided the power supply to the boiler is always turned on If the water in the boiler falls below 5 C the frost protection will activate and run the boiler to avoid freezing The process does not guarantee that all other parts of the system will be protected If a system frost thermostat has been installed the boiler must be set in winter mode m for the system frost protection to run If no system frost protection is provided and frost is likely during a short absence from home it is recommended to leave the system heating controls or built in programmer if fitted switched on and run at a reduced temperature setting For longer periods the entire system should be drained BOILER RESTART To restart the boiler when directed in the listed fault codes see section 9 turn the mode knob D to restart position and IMMEDIATELY turn knob back to required setting The boiler will repeat its i
38. these functioning correctly Check ignition electrode and associated harness for continuity visual condition and position Refer to Frame 45 Are these functioning correctly Check gas supply and rectify fault Check wiring connection from gas valve to PCB for continuity If the wiring is OK then replace the PCB Replace Gas Valve Replace Spark Generator and harness as necessary Replace Ignition Electrode and associated harness as necessary Note due to the wave form of the rectified voltage the reading 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 RESTART PROCEDURE To restart boiler turn mode knob to restart position and immediately turn knob back to required setting 50 Independent Combi Installation and Servicing FAULT FINDING 71 ALTERNATING L AND 5 5 RESTARTS WITHIN 15 MINS Turn power off and on 72 ALTERNATING L AND 6 FALSE FLAME LOCKOUT l l Check routing and integrity of internal boiler Restart the boiler does Boiler Work OK wiring is OK Check condition of Flame Sense Electrode and replace if deteriorated Separate the flame detection electrode in line connector Is there continuity between the terminals Replace Flame Detection Electrode pins connected to the electrode Check routing and integrity of internal boiler wirin
39. 0 64 DHW FILTER amp DHW FLOW REGULATOR CLEANING REPLACEMENT Refer to Frame 40 Isolate the DHW supply and drain down Refer to Frame 55 Turn the housing anti clockwise and pull forward to remove the cartridge Be aware of water spillage Using a pair of pliers pull out the plastic filter flow regulator Clean or replace filter as necessary Reassemble in reverse order Re instate the DHW supply and check for leaks Check operation of the boiler Refer to Frames 29 amp 30 65 FLOW THERMISTOR REPLACEMENT Refer to Frame 40 Drain down the boiler Refer to Frame 55 Unplug the electrical lead Unscrew the thermistor to facilitate removal a 13mm socket spanner should be used Fit the new thermistor using the sealing washer provided 6 Reassemble in the reverse order Refill the boiler 8 Check the operation of the boiler Refer to Frames 29 amp 30 Independent Combi Installation and Servicing 47 SERVICING SERVICING SERVICING 66 HEAT ENGINE RENEWAL Refer also to Frame 5 Boiler Exploded View IMPORTANT Before starting the removal procedure protect the gas and electrical controls with a waterproof sheet or plastic bag 1 Refer to Frame 40 2 Drain the boiler Refer to Frame 55 3 Remove the fan venturi assembly and place on one side M 10 11 48 Refer to Frame 41 Remove the burner and place on one side Refer to Fr
40. 13a A compartment used to enclose the boiler should be designed and constructed specially for this purpose An existing cupboard or compartment may be used provided that it is modified for the purpose In both cases details of essential features of Cupboard compartment design including airing cupboard installation are to conform to the following e BS 6798 No cupboard ventilation is required see Air Supply for details e The position selected for installation MUST allow adequate space for servicing in front of the boiler e For the minimum clearances required for safety and subsequent service see the wall mounting template and Frame 1 In addition sufficient space may be required to allow lifting access to the wall mounting plate GENERAL GAS SUPPLY The local gas supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must NOT be used without prior consultation with the local gas supplier The boiler MUST be installed on a gas supply with a governed meter only A gas meter can only be connected by the local gas supplier or by a Gas Safe Registered Engineer In IE by a Registered Gas Installer RGII An existing meter should be checked preferably by the gas supplier to ensure that the meter is adequate to deal with the rate of gas supply required It is the responsibility of the Gas Installer to
41. 2 ALTERNATING c AND 0 LOW MAINS VOLTAGE Restart Boiler RESTART PROCEDURE To restart boiler turn mode knob to restart position and immediately turn knob back to required setting 83 NOCH OPERATION BUT HW WORKS OK NO Is the mode knob in the Winter position Move the mode knob to the Winter position FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING YES Are the Timer and the Room Thermostat switched NO l on Switch the Timer and Room Thermostat On YES NO Are the Radiator Valves Open Open the Radiator Valves YES NO There is no Voltage from the Timer Room Stat This Is there 230Vac at A is not boiler fault Ensure Voltage is supplied to boiler by rectifying external wiring YES Replace the Divertor Valve Independent Combi Installation and Servicing 55 FAULT FINDING 84 NO HW BUT CH ON Does the display show d when a tap is on Is hot and cold pipework crossed NO R Are the flovv rates correct as per Frame 2 Adjust flow rates to achieve 35 temp rise and check filter fitted in s the wiring connected YES turbine is not blocked with debris between PCB and DHW sensor Is the wiring between the PCB and the diverter valve motor connected Reconnect wiring or replace wiring harness if Remove the turbine and YES no continuity check for debris in the turbine amp filter Replace turbine if necessary Is Check diverter head fully engaged an
42. Approximate temperatures for domestic hot water Knob Setting Hot Water Temperature approx 40 C 104 F 54 C TATP Due to system variations and seasonal temperature fluctuations domestic hot water flow rates temperature rise will vary requiring adjustment at the tap the lower the flow rate the higher the temperature and vice versa Central Heating The boiler controls the central heating radiator temperature to a maximum of 80 C adjustable via the central heating temperature knob C Approximate temperatures for central heating Knob Setting Central Heating Radiator Temperature approx 45 C 113 F BOC 176 For economy setting refer to Efficient Heating System Operation EFFICIENT HEATING SYSTEM OPERATION The boiler is a high efficiency condensing appliance which will automatically adjust its output to match the demand for heat Therefore gas consumption is reduced as the heat demand is reduced The boiler condenses water from the flue gases when operating most efficiently To operate your boiler efficiently using less gas turn the central heating temperature knob C to the position or lower In winter periods it may be necessary to turn the knob 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 COMPENSATION When
43. ERNAL 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 1 Remove the front panel Refer to Frame 34 Swing the control box down into the service position Refer to frame 40 2 3 Route cable through the cable clamp and grommet and tighten to provide cord anchorage 4 Connect the live neutral and earth wires to the terminal strip When making the mains electrical connections to the boiler it is important that the wires are prepared in such a way that the earth conductor is longer than the current carrying conductors such that if the cord anchorage should slip the current carrying conductors become taut before the earthing conductor Swing the control box back up into the operating position and re fit the front panel ensuring a good seal is made The Independent Combi boiler comes pre fitted with a link wire between the room thermostat Timer connections on the terminal strip This creates a permanent call for heat and must be removed when adding a room thermostat ROOM THERMOSTAT WIRING 1 Remove link wire between Room stat timer terminals 2 Connect room stat as shown in wiring diagram opposite 3 If room stat has a neutral connection connect this to terminal N load in the fused spur FROST THERMOSTAT WIRING Optional If parts of the system are vulnerable to freezing or the programmer is likely to be lef
44. Flue Terminal on the connector ASSEMBLY A 4 Position the clamp on the top face of the flue manifold and push it horizontally backwards Locate both clamp lugs into the flue manifold and secure to the flue manifold with the M5 retaining screw 5 Push fit extension duct if required supplied separately into vertical connector Pitched roof tile Note Ensure turret sample points are servicable and all caps and Flat roof tile weather collar plugs are fitted Fill the condense trap siphon with water weather collar 7 7 N N N N N N d mee Extension Duct Vertical connector 3G9557b 6 Ifthe last extension duct requires cutting measure X the distance outer ducts between the duct and the terminal and add 100 mm to this O dimension This gives the length of the last extension duct X Note Check the position of the inner flue duct relative to the outer duct on longer than the air duct to ensure engagement in the final flue duct seal m R J 0 J m il m the assembled extension duct s and ensure the terminal flue duct is cut 7 Finally ensure the roof flashing plate is correctly sealed to the roof Independent Combi Installation and Servicing 23 INSTALLATION INSTALLATION 21 CONDENSATE DRAIN This appliance is fitted with a siphonic 75mm condensate trap system that requires filling before operating the appliance for the 1st time or after mai
45. G CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer name Telephone number Address Boiler make and model Boiler serial number Commissioned by PRINT NAME Gas Safe register number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS tick the appropriate boxes Room thermostat and programmer timer Programmable room thermostat Time and temperature control to heating l Load weather compensation Optimum start control Time and temperature control to hot water Cylinder thermostat and programmer timer Combination Boiler Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted Not required Automatic bypass to system i Not required
46. LE 1 COLUMN HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK CUT 75MM TELESCOPIC SHOULD HAVE THE 75MM CUT OFF THE D PACK EXTENSION AND NOT TELESCOPIC FLUE CUT 75MM OFF HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK TELESCOPIC 1 Measure cut flue length A 44mm If required telescopic length is not between 658 and 708 then proceed to Setting Telescopic Flue B Pack Remove telescopic end piece from the flue body and set aside Mark the circumference 75mm from the open end of the outer flue Cut along the 75mm mark cutting only the outer flue ensuring the cut is square 5 Dress the cut end to make sure all burr is removed and the cut edge is in its original shape 6 Measure 20mm from the newly cut edge of the outer flue place a mark at the top of the flue approximately 20mm wide amp write stop the terminal side of the line 7 Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure its cut square 8 Remove all burrs and place a chamfer on the outer edge to aid assembly 9 Re assemble telescopic section SETTING TELESCOPIC FLUE B PACK 1 Measure the required flue length A 44mm 2 Measure from the outer terminal lip to end of outer flue Pull apart flue until desired length is achieved ENSURE THE STOP MARK IS NOT VISIBLE IF IT IS THE FLUE IS TOO SHORT AND SHOULD NOT BE USED 3 Check that both flue seams are at the top and the outlet termi
47. LY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER visually check the integrity of the whole flue system 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 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 by the manufacturer The installer must have the relevant competence for use of the analyser Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer s instructions KEY CO carbon monoxide CO carbon dioxide O2 oxygen Combustion Ratio The CO reading measured in ppm divided by the CO2 reading first converted to ppm ppm parts per million GS ISU R Gas Safety Installation and Use Regulations Setting to Minimum Rate Turn the CH temperature control knob into the 10 O clock position Create a CH demand by ensuring that the system controls are requesting heat and the boiler Mode Knob is in the Winter Position Within an overall time of 3 seconds turn the CH temperature control knob fully clockwise back to 10 O clock and then fully clockwise again S will be shown on the display and the boiler output will be reduced to minimum The boiler will remain at minimum r
48. Pressure bar Ib in kPa 0 8 11 6 80 1 3 18 9 130 11 3 18 9 130 Electrical Supply 230 V 50 Hz Power Consumption W 146 152 Fuse Rating External 3A T4H HRC L250 V SLE in m in Boiler Casing Size Height mm in 700 a Width in 395 15 5 Depth i 278 11 Required for maximum flow rate Boiler operates down to 2 l min DHW delivery In areas of low water pressure the DHW restrictor can be removed 22 44 Table 3 Performance Data Domestic Hot Water Nett CV kW 24 3 30 4 35 4 Nett CV kW kal 3 49 61 Btu h 82 900 16 600 20 700 Btu h 82 900 103 600 120 900 Gross CV kw 27 0 54 67 Gross kWj 270 33 7 39 3 Btu h 92 000 18 400 23 000 26 Btu h 92 000 115 000 134 200 Gas Consumption m3 hl 2 512 0 500 0 627 Gas Consumption m3 h 2 912 3 135 3 657 ff7 h 89 17 8 22 ft h 89 111 129 Boiler Output Maximum 24 2 30 3 35 3 Non Condensing i i DHW Output 82 103 300 1 120 500 70 C Mean Water temp Btu h DHW Flow Rate Imin 12 4 14 5 Condensing at 35 C temp rise gpm 2 8 3 2 40 C Mean Water temp Btu h i DHW Specific Rat I mi 11 5 14 5 16 9 Seasonal efficiency SEDBUK 20051 1 91 91 1 a n a5 Seasonal efficiency SEDBUK 2009 89 89 88 9 NOx Classification CLASS 5 The value is used in the UK Governments Standard Assessment Procedure SAP for energy ratin
49. Refer to frame 55 19 Refit the DHW manifold fit the assembly back to the boiler and reassemble in reverse order 19 Refill the boiler Check operation of the boiler Refer to Frames 29 amp 30 Remove the condensate trap siphon Refer to Frame 50 Remove the electrical plug Refer to Frame 49 point 3 Place a flat bladed screwdriver in the diverter valve motor body slot provided and ease out the motor Refer to Frame 49 Remove the return thermistor electrical connection Refer to Frame 44 Remove the pump electrical connection Refer to Frame 62 no 3 Remove DHW Turbine electrical connection Refer to Frame 54 no 3 Remove the DHW plate heat exchanger note orientation Refer to Frame 61 Undo the safety valve pipe compression fitting See No 5 Frame 67 Loosen the nut above pump and rotate the pipe m wh g 7 4 If required remove expansion vessel connection hose Refer to Frame 67 Remove the DHW inlet and CH return connection situated beneath the boiler J 4 m Z 4 A Remove the three torx head screvvs fixing the return manifold to the boiler sheet steel base Lift the manifold assembly and remove from boiler Twist and remove the DHW manifold Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly 61 DHW PLATE HEAT EXCHANGER REPLACEMENT Refer to Frame 40 Drain the boiler Refer to Frame 55
50. Remove the electrode Fit the new flame detection electrode using the new gasket supplied 7 Reassemble in reverse order 8 Check the operation of the boiler Refer to Frames 29 amp 30 47 SPARK GENERATOR REPLACEMENT Refer to Frame 40 2 Disconnect the leads from the spark generator Remove the single M5 Screw securing the spark generator to the gas valve mounting bracket Fit the new spark generator and re assemble in reverse order ensuring the two earth leads are correctly replaced Check operation of the boiler Refer to Frames 29 amp 30 Spark Generator 40 Independent Combi Installation and Servicing SERVICING 48 GAS CONTROL VALVE REPLACEMENT Refer to Frame 40 Unplug the electrical lead connection from the gas control valve and disconnect the earth wire Disconnect the earth wire Remove the outlet gas valve clip and slide the pipe upwards Undo the gas inlet pipe union at the inlet to the gas valve Undo the single screw fixing the gas valve to the mounting bracket and withdraw the valve forwards Check operation of the boiler Refer to Frames 29 amp 30 ik R j m ri m GAIA 4 Re 49 DIVERTER VALVE ACTUATOR REPLACEMENT To remove the motor 2 Remove the condensate trap siphon Refer to Frame 40 3 Disconnect the inline connector block 4 Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator
51. TIMER Outer dial 221 247 d ill Align current time to arrovv MANSA PERIOD SETTING UP The outer dial should be set to the current time Rotate the dial slowly in a clockwise direction until the correct hour is aligned with the arrow printed on the dial Note that the outer dial is printed with the 24hr clock e g 8 00am 8 on the dial 8 00pm 20 on the dial Do not attempt to rotate the dial in an anti clockwise direction PROGRAMMING SWITCHING TIMES Set tappets to outer edge for ON periods and set tappets to inner edge for OFF periods The example shown has been set with 2 on periods ON at 9 00am OFF at 1 00pm 13 hours ON at 6 00pm 18 hours OFF at 10 00pm 22 hours Manual Switch Operation To set the timer for timed operation move the switch to the TIMED position To set the timer to be continuously on move the switch to the MANUAL ON position To set the timer to be continuously off move the switch to the MANUAL OFF position Note If boiler does not light when in timed on or manual on position increase temperature on room stat 7 POINTS FOR THE BOILER USER Note n line with our current warranty policy we would ask that you check through the following guide to identify any problems external to the boiler prior to requesting a service engineers visit Should the problem be found to be other
52. WATER TREATMENT CENTRAL HEATING The Independent Combi 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 recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems If water treatment is used Ideal Stelrad Group recommend only the use of Scalemaster Gold 100 FERNOX MB 1 ADEY MC1 SENTINEL X100 or CALMAG CM100 inhibitors and associated water treatment products which must be used in accordance with the manufacturers instructions Notes 1 t is most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturer s instructions 2 If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing BS 7593 2006 details the steps necessary to clean a domestic heating system 3 n hard water areas treatment to prevent lime scale may be necessary however the use of artificially softened water is NOT permitted 4 Under no circumstances should the boiler be fired before the system has been thoroughly flushed 12 2 Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators to give around 20 C temperature drop at each radiator 3 Adjust the room th
53. able to help with your Ideal Spare Parts enquiries on 01482 498665 When calling and to ensure we can provide you with the most accurate parts information please ensure you have the following to hand Boiler Model Appliance GC Number Boiler Serial Number Independent Combi Installation and Servicing 57 Code OT Practice For the installation commissioning and servicing of domestic heating and hot water products Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations Installers are required to carry out work in accordance with the following THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The use of the word installer is not limited to installation itself and covers those carrying out installation commissioning and or servicing of heating and hot water products or the use of supporting products such as water treatment or test equipment Customer includes householders landlords and tenants Heating and Hotwater Industry Council HHIC S tandards of Work Be competent and qualified to undertake the work req
54. ail to DHW outlet connection ensuring the seal provided is correctly located 3 If connecting the boiler to heating loads in excess of 60 000 Btu h connecting flow and return heating systems pipework must be sized in 28mm diameter at the point of pipe connection to the boiler tails Use 22mm x 28mm pipe adaptors as appropriate 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 SAFETY VALVE DRAIN The safety valve connection located at the bottom right hand side of the boiler comprises a 15mm diameter stub pipe The Installer to provide a compression joint on the end of the stub pipe This assists with pipe removal when servicing The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring CH Flow ressure Relief Valve Drain Connection 15mm elbow or fittings not supplied Pressure Relief Valve Drain Pipe 26 FILLING IMPORTANT when filling A Ensure the dust cap on air vent located at the rear of the pump chamber is slightly unscrewed B When filling there may be a slight water leak from the air vent therefore electrical
55. ame 43 Remove the ignition and detection electrodes and divertor actuator head Refer to Frames 45 46 and 49 Remove the spark generator Refer to Frame 47 Remove the gas valve Refer to Frame 48 Remove the expansion vessel Refer to Frame 67 Remove the flow thermistor Refer to Frame 65 Remove the 2 M5 screws retaining the gas valve mounting bracket and transfer bracket to the new heat exchanger Undo the inlet pipe union nut and remove the retaining spring clip and remove pipe 12 13 14 15 16 17 18 19 Undo the flow pipe union nut and remove pipe Remove the condensate rubber pipe Refer to Frame 50 no 2 Remove the two heat exchanger fixing screws Remove the Heat exchanger slide out of location bracket If replacement sump required Rotate heat exchanger assembly 180 Place new sump onto heat exchanger ensuring correct orientation and seal is in place Then gently apply pressure to the base of the sump at each tab fixing point and engage tabs onto the heat exchanger Ensure the trap siphon is filled with water Refer to Frames 50 amp 55 Refill the boiler Check operation of the boiler Refer to Frames 29 amp 30 Shown as 180 position Independent Combi Installation and Servicing SERVICING 67 EXPANSION VESSEL RECHARGING amp REPLACEMENT RECHARGING Recharge 1 Refer to Frame 40 Point Remove the charge point cover Recharge the tank pressure to 0 75 bar
56. ame 44 Check resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 expect 9 700 10 300 Ohms At 60 expect 2 400 2 600 Ohms Fill and vent the system and open all isolation valves then restart boiler Check that the Pump is rotating freely Is the Differential now below 20 C Replace the Pump then restart boiler OK now restart boiler RESTART PROCEDURE To restart boiler turn mode knob to restart position and immediately turn knob back to required setting At 85 expect 1 000 1 100 Ohms 70 ALTERNATING L AND 2 IGNITION LOCKOUT If the boiler is restart does the boiler ignite for a short time and then extinguish Check the detection electrode and associated harness for continuity visual condition and position Refer to Frame 46 Check if the condensate pipe is blocked Check flue is installed correctly Replace as necessary Check siphon and condensate drain pipe work for blockage and rectify if necessary Boiler now working OK Replace Gas Valve FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING Is the Gas Pressure available at the Boiler Inlet gt 18 mbar Is 215Vdc supply available at the Gas Valve See note Unplug gas valve Is resistance between outside pins 4KQ 2 YES Check spark generator and associated harness for continuity and visual condition Refer to Frame 47 Are
57. ames 29 amp 30 Note To program refer to user guide at rear of this book 3G9985 Mechanical Programmer Independent Combi Installation and Servicing 43 SERVICING SERVICING SERVICING 54 DHW FLOW TURBINE SENSOR REPLACEMENT Refer to Frame 40 Drain the DHW system Refer to Frame 55 Pull off the electrical connection Using a suitable tool lift and remove the retaining clip Use the clip to ease the turbine sensor from its housing 6 Re assemble in reverse order 7 Check operation of the boiler Refer to Frame 29 amp 30 55 DRAINING THE BOILER CENTRAL HEATING CIRCUIT Refer to Frame 40 Close all the CH water isolating valves on the boiler inlet To drain the primary heat exchanger circuit Open the drain valve and attach a length of hose to the CH drain point 1 li After replacing any component on the boiler remove the hose close the drain valve and open all system isolating valves re pressurise as appropriate Check operation of the boiler Refer to Frames 29 8 30 OT Circuit Drain CH DOMESTIC HOT WATER CIRCUIT Return Refer to Frame 40 Close the DHW water isolating valve on the boiler inlet To drain the domestic hot water circuit As there is no direct drain for the domestic hot water circuit depending on the location of the boiler opening the lowest hot water tap may drain this circuit However it must be noted that some residual w
58. and the display sequence should read i Uu VVhen the pump stops the display sequence should read 7 Uu Note On systems in excess of 2 bar inlet pressure a vvater pressure governor may be required to prevent water noise CENTRAL HEATING CH amp DOMESTIC HOT WATER DHW MODE 1 Ensure that the CH external controls are calling for heat The display should read c 2 Fully open a DHW tap and check that hot water is delivered The display should read ale d 3 Gas Rate Check the boiler gas rate when the boiler is at full DHW output Check at the gas meter with no other appliance in use Refer to Tables 2 amp 3 for gas rates 4 Close the DHW tap 5 Set the central heating external controls to OFF The burner should go off and the pump continue to run for two minutes The display should read m 6 Check the correct operation of the timer and all other system controls Operate each control separately and check that the main burner responds Independent Combi Installation and Servicing LATION WATER CIRCULATION SYSTEM 1 With the system COLD check that the initial pressure is correct to the system design requirements For pre pressurised systems this should be 1 0 bar 2 With the system HOT examine all water connections for soundness The system pressure will increase with temperature rise but should not exceed 2 5 bar 3 With the system still hot turn off the gas water a
59. antee registration found within the envelope pack and the requirement to register it to receive the full benefit of the warranty Independent Combi Installation and Servicing SERVICING 33 SERVICING SCHEDULE For the very latest copy of literature for specification amp maintenance practices visit our website www idealboilers com where you will be able to download the relevant information N B Technical Bulletins are also available on www idealboilers com 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 RGIl INSPECTION GENERAL 1 Light the boiler and carry out a pre service check noting any Please Note During routine servicing and after any operational faults maintenance or change of part of the combustion 2 Check the flue terminal and terminal guard if fitted is undamaged circui
60. as been installed in accordance with these instructions The integrity of the flue system and the flue seals as described in the Flue Installation section Proceed to put the boiler into operation as follows CHECK THE OPERATIONAL WORKING GAS INLET PRESSURE Set up the boiler to operate at maximum rate by opening hot tap to maximum flow With the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point complies with the requirements refer to Gas Supply on page 8 Gas Supply Ensure that this inlet pressure can be obtained with all other gas appliances in the property working Gas Pressure Test Point As part of the commissioning process the combustion of this appliance must be checked and the Benchmark Checklist completed A flow chart to assist is provided on page 63 ATTENTION IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE Independent Combi Installation and Servicing 29 INSTALLATION INSTALLATION INSTALLATION 29 INITIAL LIGHTING Legend Domestic Hot Water Preheat On Off Knob Domestic Hot Water Temperature Knob Central Heating Temperature Knob Mode Knob Boiler Status A B C D F Burner on Indicator G CH Flow Isolating Valve H System Pressure Gauge J Gas Inlet Pressure Test Point K Ga
61. ate for 5 minutes before reverting to normal operation Set Boiler to Maximum Gas Rate Carry Out Flue integrity Check Using Analyser Insert analyser probe into air inlet test point where available and allow In accordance with boiler instructions set boiler to operate at maximum rate readings to stabilise full load condition Allow sufficient time for combustion to stabilise Note Where no air inlet test point is provided then a flue integrity check with the analyser is not possible The installer should verify that flue integrity has Note Do not insert analyser probe been visually checked in accordance with the Prior to CO level and during this period to avoid possible combustion ratio check see opposite page before proceeding to the flooding of sensor check CO level and combustion ratio at maximum rate stage below Verify Flue Integrity Analyser readings indicate that combustion products and inlet air O2 more than or must be mixing Further investigation of the flue is therefore required equal to 20 6 OR COz Check that flue components are assembled fixed and supported as ess than or equal to per instructions Check that flue and flue terminal are not obstructed Check CO level and Combustion Ratio at Maximum Gas Rate Oz more than or equal to 20 6 OR COz With boiler still set at maximum gas rate less than or equal to insert analyser probe into flue gas sampling point Allow readings to stabili
62. ate instructions for the programmer before continuing Start the boiler as follows 1 Check that the electricity supply to boiler is off 2 Set the mode knob D to off 3 Set the Domestic Hot Water temperature knob B and Central Heating temperature knob C to max 4 Set the preheat knob A to preheat on Ensure that all hot water taps are turned off 6 Switch on electricity to the boiler and check that all external controls e g programmer and room thermostat are on 7 Set the mode knob D to winter The boiler will commence ignition sequence first supplying heat to preheat the domestic hot water and then to the central heating if required Note n normal operation the boiler status display E will show codes 0 Standby no demand for heat Central Heating being supplied ci Domestic hot water being supplied P Domestic hot water preheat F Boiler frost protection boiler will fire if temperature is below 5 C During normal operation the burner on indicator F will remain illuminated when the burner is lit Note If the boiler fails to light after five attempts the fault code L c will be displayed refer to Fault Code page OPERATION MODES Winter Conditions Central Heating and Domestic Hot Water required Set the mode knob m winter The boiler will fire and supply heat to the radiators but will give priority to domestic hot vvater on demand
63. ater will be experienced during replacement of components After replacing any component on the boiler close tap close the drain valve and open all system isolating valves re pressurise as appropriate Check operation of the boiler Refer to Frames 29 amp 30 56 PRESSURE GAUGE RENEWAL Refer to Frame 40 Drain the heating system Refer to Frame 55 Unscrew the pressure gauge and discard Fit new pressure gauge using suitable jointing compound Refill the boiler Check operation of the boiler Refer to Frames 29 amp 30 44 Independent Combi Installation and Servicing SERVICING 57 SAFETY RELIEF VALVE RENEWAL 1 Refer to Frame 40 Drain the boiler Refer to Frame 55 Remove the clip on return thermistor Refer to Frame 44 Pull out and remove the clip positioned behind the safety valve retaining the safety valve Undo the safety valve pipe compression fitting positioned outside the boiler casing Lift out the safety valve pipe assembly Remove the safety valve pipe and transfer to the new safety valve Reassemble in reverse order ensuring the retaining clip is correctly fitted the pipe compression fitting retightened and return thermistor is re clipped Refill the boiler Check operation of the boiler Refer to Frames 29 amp 30 58 PUMP AUTOMATIC AIR VENT REPLACEMENT Refer to Frame 40 Drain the boiler Refer to frame 55 Remove the expansion vessel
64. ation Safe Handling Servicing Short List of Parts Thermostatic Radiator Valves Water and Systems Water Connections Water Treatment Wiring Diagram For GB to comply with Building Regulations Part L1 Part 6 in Scotland the boiler should be fitted in accordance with the manufacturer s instructions Self certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist Before installing this boiler read the Code of Practice sheet at the rear of this book BENCHMARK COMMISSIONING CHECKLIST DETAILS Boiler Make and model 5 Burner operating pressure n a Appliance serial no on data badge Front Cover Central heating flow temp measure and record SEDBUK 4 Central heating return temp measure and record Controls For combination boilers only Time and temperature control to heating 27 Scale 12 Time and temperature control to hot water 27 Hot vvater mode Heating zone valves n a aa oabaldda to be calculated lib r eee 9 Max operating burner pressure n a AUtO DY 10 r al ikrar nin 9 Max operating vvater pres
65. ceeds 200mg litre 200ppm it is recommended that a proprietary scale reducing device is fitted into the boiler cold supply within the requirements of the local water company IMPORTANT Provision MUST be made to accomodate the expan sion of DHW contained within the appliance If the DHW inlet contains a back flow prevention device or non return valve e g a water meter then a mini expansion vessel should be fitted between the device and the boiler in the cold inlet pipe Cold water rising main amp pipework in exposed areas need to be suitably lagged to prevent freezing DHW Expansion Vessel Kit available from Ideal 11 GENERAL 3 SYSTEM BALANCING The boiler does not normally need a bypass but at least some radiators on the heating circuit of load of at least 10 of the minimum boiler output must be provided with twin lockshield valves so that this minimum heating load is always available See note regarding thermostatic radiator valves on page 9 Note Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass BALANCING 1 Set the programmer to ON Close the manual or thermostatic valves on all radiators leaving the twin lockshield valves on the radiators referred to above in the OPEN position Turn up the room thermostat and adjust the lockshield valve to give an uninterrupted flow through the radiator These valves should now be left as set 4
66. connections should be protected CH 1 Ensure that the CH isolating handles are open Dust Cap 2 Fill and vent the system Refer to Frame 2 for setting pressure DHW 1 Fully open all DHW taps and ensure that water flows freely from the 2 Close all taps Note The DHW flow rate is automatically regulated to a max 24 9 9 2 2 gpm 30 12 4 2 8 gpm 35 14 5 3 2 gpm Note that all isolation handles are shown in the open postion DHW Outlet DHW Inlet CH Return Gas Pressure Safety Test Point Drain Valve Black Handle Independent Combi Installation and Servicing INSTALLATION 24 ELECTRICAL CONNECTIONS V ARNING This appliance MUST be earthed VViring should be 3 core PVC insulated cable not less than A mains supply of 230Vac 50 Hz is required 0 75mm 24 x 0 2mm and to BS 6500 Table 16 For IE reference should be made to the current ETCI rules for electrical The fuse rating should be 3A All external controls and wiring installations must be suitable for mains voltage Wiring external to the boiler MUST be in accordance with the current 1 E E BS 7671 Wiring Regulations and any local regulations Connection must be made in a vvay that allovvs complete isolation of the electrical supply such as a double pole switch having a 3mm 1 8 contact separation in both poles The means of isolation must be accessible to the user after installation 25 INT
67. d and commissioned in accordance vvith the manufacturer s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature Allinstallations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a CNCHIIGS Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer eel THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe registe
68. d clip Re engage diverter DHW OK secured onto waterset head and secure clip to YES wateset NO Is diverter stuck in the CH position Replace PCB YE Check and replace diverter valve actuator head Is Boiler DHW OK NO Change diverter valve assembly Replace turbine sensor Re connect wiring 85 NO DISPLAY Is there 230Vac to the boiler at L and N NO Supply power to the boiler YES Is the wiring from the terminal block to the Main PCB Connect the wiring from the terminal block to the connected securely Main PCB securely Is the ribbon cable from the main PCB to the User Connect the ribbon from the main PCB to the User Interface PCB connected securely Interface PCB securely Replace the Is ribbon cable damaged User Interface PCB Replace ribbon cable O Z Q O Z Q Lu z O Z Q O Q Lu z O Q Lu J 56 ndependent Combi Installation and Servicing SPARE PARTS When replacing any part on this appliance 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 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 com Our Parts team are also avail
69. densate drain It is 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 any maximum flue length High Level Flue Outlet Kit The maximum permissible concentric flue length when using a standard 500mm kit is 4 5 metres Balcony Flue Outlet Kit 30 kW Appliances Total Maximum 90 Elbow Kit 60 100 Equivalent flue length resistance 1M 45 Elbow Kit 60 100 Equivalent flue length resistance 0 6M Minimum Horizontal Flue Lengths Centre line of turret to outside of wall terminal Telescopic Flue B Pack 400mm Horizontal Flue terminal 600mm long B Pack 285mm Wall Thickness Horizontal Flue Terminal 600mm long B Pack Telescopic Flue B Pack Horizontal Flue Terminal 1000mm long B Pack Horizontal Flue Terminal 1000mm long B Pack cut 75mm For Flue lengths between 658 amp 708 use a Horizontal Flue Terminal 1000mm long B Pack cut 75mm off the end of the terminal section of the telescopic flue only Independent Combi Installation and Servicing The maximum permissible concentric flue length when using this kit is dependant on the length of the balcony flue outlet run which combined with the concentric run must not exceed the maximum flue length requirement of the appliance it is to be fitted to Soffit Kit This kit enables fitment of an external flue below
70. elux window 2000mm 79 16 Above or side of velux window 600mm 24 Only one reduction down to 25mm is allowable per installation otherwise BS5440 1 2008 dimensions must be followed Independent Combi Installation and Servicing GENERAL AIR SUPPLY It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed due to the low surface temperatures of the boiler casing during operation therefore the requirements of BS 6798 Clause 12 and BS 5440 2 may be disregarded WATER CIRCULATION SYSTEM IMPORTANT A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping The central heating system should be in accordance with BS 6798 and in addition for smallbore and microbore systems BS 5449 WATER TREATMENT see Frame 4 BOILER CONTROL INTERLOCKS Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating in compliance with Building Regulations Heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve When thermostatic radiator valve
71. er fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII 5 Boiler Resets in 15 minutes 1 Turn electrical supply to boiler off and on 2 If the boiler fails to operate please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII False Flame Lockout Restart the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII 8 Independent Combi User s
72. ermostat and programmer to NORMAL settings DOMESTIC HOT WATER In hard water areas where mains water can exceed 200ppm Total Hardness as defined by BS 7593 2006 Table 2 a scale reducing device together with Scalemaster in line scale inhibitor branded Ideal should be fitted into the boiler cold supply within the requirements of the local water company The use of artificially softened water however is not permitted Ideal Stelrad Group recommend the use of Fernox Quantomat Sentinel Combiguard and Calmag CalPhos scale reducing devices which must be used in accordance with the manufacturers instructions For further information contact Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ 44 0 8706 015000 Sentinel Performance Solutions The Heath Business amp Technical Park Runcorn Cheshire WA7 4QX Tel 0800 389 4670 Scalemaster Water Treatment Products Emerald Way Stone Staffordshire ST15 OSR Tel 44 0 1785 811636 Calmag Ltd Unit 3 6 Crown Works Bradford Road Sandbeds Keighley West Yorkshire BD20 5LN Tel 44 0 1535 210320 Adey Professional Heating Solutions Gloucester Road Cheltenham GL51 8NR Tel 44 0 1242 546700 Independent Combi Installation and Servicing 5 104 105 106 108 110 111 112 113 114 115 116 117 118 119 120 INSTALLATION BOILER ASSEMBLY Exploded View CH Return Valve CH Flow Valve DHW Inlet amp Outlet Pump Head
73. g RESTART PROCEDURE To restart boiler turn mode knob to restart position and immediately turn knob back to required setting 73 ALTERNATING F AND 1 LOW WATER PRESSURE Are the Boiler and CH System filled with water and Fill and vent the system and open all all isolation and radiator valves open check pressure isolation valves gauge is between 1 to 1 5 bar Re fit connections YES Are connections on water pressure sensor secure Replace water pressure sensor FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING Independent Combi Installation and Servicing 51 FAULT FINDING 74 ALTERNATING F AND 2 FLAME LOSS Does the boiler ignite for a short Is the Gas Pressure available at Check gas supply and time and then extinguish the Boiler Inlet 18 mbar rectify fault Check the detection electrode and associated harness for continuity Is 215Vdc supply available at the NO Check wiring from gas _ visual condition and position Refer Gas Valve while the flame is on 1 b valve to PCB for continuity to Frame 46 Check if condensate See note If the wiring is OK then pipe is blocked Check if flue is replace the PCB blocked Replace as necessary Check spark generator and associated harness for continuity Replace Spark Generator and visual condition Refer to and Harness as necessary Check ignition electrode and _ Frame 47 Are these functioning as
74. g of dwellings The test data from which it has been calculated have been certified by a notified body Note Gas consumption is calculated using a Key to symbols calorific value of 38 7 1038 Btu ft gross GB United Kingdom IE Ireland Countries of destination or 34 9 MJ m 935 Btu ft nett PMS Maximum operating pressure of water To obtain the gas consumption at a different calorific value C A room sealed appliance designed for connection ducts a horizontal or vertical terminal vvhich admits fresh air to the burner a For l s divide the gross heat 7 and discharges the products of combustion to the outside through kW by the gross C V of the gas orifices which in this case are concentric The fan is up stream of b For f h divide the gross heat input Btu h the combustion chamber by the gross C V of the gas Btu ft c For m h multiply I s by 3 6 An appliance designed for use on 2nd Family gas Group H only 4 Independent Combi Installation and Servicing GENERAL CONTENTS Air Supply Benchmark Commissioning Checklist Independent Combi Natural Gas only Boiler size Boiler Clearances Benchmark No Boiler Exploded Diagram 86 CL 08 Condensate Drain 86 CL 08 Electrical Connections 47 348 87 86 CL 08 Electrical Supply Fault Finding Destination Country Flue Fitting Flue Installation Gas Safety Regulations Gas Supply Install
75. gnition sequence If the boiler still fails to start consult a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII MAINS POWER OFF To remove all power to the boiler the mains power switch must be turned off 3 SYSTEM WATER PRESSURE The system pressure gauge G see page 3 indicates the central heating system pressure If the pressure is seen to fall below the original installation pressure of 1 2 bar over a period of time and continue to fall then a water leak may be indicated In this event re pressurise the system If unable to do so or if the pressure continues to drop a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII should be consulted THE BOILER WILL NOT OPERATE IF THE PRESSURE HAS REDUCED TO LESS THAN 0 3 BAR UNDER THIS CONDITION 4 CONDENSATE DRAIN This appliance is fitted with a siphonic condensate trap system that reduces the risk of the appliance condensate from freezing However should the condensate pipe to this appliance freeze please follow these instructions a f you do not feel competent to carry out the defrosting instructions below please call your local Gas Safe Registered installer for assistance b If you do feel competent to carry out the following instructions please do so with care when handling hot utensils Do not attempt to thaw pipework above ground level If this appliance develops a blockage in its condensate pipe its condensate will b
76. heck the operation of the boiler Refer to Frames 29 amp 30 Independent Combi Installation and Servicing 3 SERVICING 42 BURNER INJECTOR REPLACEMENT Refer to Frame 40 2 Disconnect the electrical leads from the fan Remove the clip from the gas valve to venturi pipe and ease the pipe upwards rotate and ease down to remove Loosen the screw retaining the fan mounting bracket Lift and remove the fan and venturi assembly Remove the 2 injector housing screws Withdraw the injector housing Fit the new injector housing complete with 4 injector Reassemble in reverse order ensuring that the F A new gas seal supplied is located correctly in the injector housing 10 Check operation of the boiler Refer to Frames 29 amp 30 Injector SERVICING 43 BURNER REPLACEMENT See Frame 39 Refer to Frame 40 Undo the two screws and remove the sump cover Lift the manifold to clear the bottom sealing gasket and remove manifold Remove the 2 front fixing screws and loosen the 2 rear extended nuts Lift off the burner from the combustion chamber To facilitate the removal angle the burner as shown Fit the new burner replacing any damaged or deteriorating sealing gasket Reassemble in reverse order Refer to Frame 42 Check the operation of the boiler Refer to Frames 29 amp 30 M n aN sl r wt r R aa x xr il eee
77. iler must be installed on a flat and vertical internal wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by the local authority For electrical safety reasons there must be no access available from the back of the boiler The boiler must not be fitted outside Timber Framed Buildings If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineering document IGE UP 7 2006 Edition 2 Bathroom Installations This appliance is rated IP20 The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current IEE BS 7671 Wiring Regulations and the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower For IE reference should be made to the current ETCI rules for electrical installations and l S 813 2002 If the appliance is to be installed in a room containing a bath or shower then providing water jets are not going to be used for cleaning purposes as in communal baths showers the appliance must be installed beyond Zone 2 as detailed in BS 7671 Compartment Installations Ceiling Recessed window Zone 2 3G89
78. ing such as ventilators windows doors or other sources of natural air infiltration such as forced ventilation openings etc If products of combustion re entry is identified or suspected this should be immediately investigated and corrected following the guidance provided in the current Gas Industry Unsafe Situation Procedure The terminal assembly can be adapted to accommodate various wall thicknesses Refer to Frame 1 Table 4 Balanced Flue Terminal Position Flue Terminal Positions Min Spacing 1 Directly below above or alongside an opening window air vent or other ventilation opening 300mm 12 25mm 1 75mm 3 25mm 17 200mm 8 25mm 1 200mm 8 25mm 1 150mm 6 2 Below guttering drain pipes or soil pipes BS5440 1 2008 3 Below eaves BS5440 1 2008 4 Below balconies or a car port roof BS5440 1 2008 5 From vertical drain pipes or soil pipes BS5440 1 2008 500mm 26 1200mm 487 e g door or vvindovv into dvvelling 1 200mm 48 i 500mm 607 300mm 127 Vertical Terminals 13 Above the roof pitch with roof slope of all angles Above flat roof 7 Above adjacent ground roof or balcony level 300mm 12 6 From an internal or external corner or to a 25mm 1 boundary along side the terminal BS5440 1 2008 300mm 12 300mm 12 300mm 12 14 From a single vvall face 300mm 12 From corner walls 300mm 12 15 Below v
79. it e Timer Deletion Kit Independent Combi Installation and Servicing GENERAL 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 Gas Safe Registered Engineer It must be carried out in accordance with the relevant requirements of the e Gas Safety Installation and Use Regulations e The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland e The Water Fittings Regulations or Water byelaws in Scotland e The Current 1 E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a Registered Gas Installer RGII and installed in accordance with the current edition of 1 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW BSEN 12828 2003 Heating Systems in
80. l of the whole 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 correct sealing of the components It is IMPORTANT that all attachments are fitted in accordance to the installation instructions provided with them The TURRET supplied in the B Pack has an upper combustion sample point with a screw cap seal and a lower air sample point with an air stopper seal Ensure all caps amp seals are in place 456 m R J 0 J m il 17 INSTALLATION 14 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED CONT D F U RE 1 Edge of turret Edge of turret Edge of turret to outside face of wall plus to outside face of vvall plus to outside face of vvall plus 44mm flue length 44mm flue length 44mm flue length Note Maximum permissible flue length is measured from centre line of appliance flue outlet to outside wall face to wall to wall to wall inc Stand off Frame Minimum clearance 5mm Flue length measured from outer terminal lip to end of outer flue INCHES A 44mm Centre of turret to edge of turret 100mm Turret has a flue insertion of 30mm The compressed outer wall seal has protruding wall to seal mounting lip 14mm From centreline of turret to wall Rear mount 155mm side including clearance 200mm FIGURE 2 Shows the flue re
81. mall location mark at the dimension acquired at point 1 iH 3 Fit external black wall seal ensuring the inside of the outer lip is in contact with the terminal lip you have been measuring from see fig 1 Point 4 4 Foran internal fit place flue terminal in the centre of the 5 drilled hole in the wall Apply pressure and lightly move the flue left to right or up and down This will cause the outer flange to fold in and allow the flue to pass through the wall 5 Push through a further 65mm This will allow the outer flange to return to its original shape 6 Pull back the flue until the location mark point 1 is level with the internal face of the wall Correctly sealed wall Note If the location mark is not visible then the flue is not pulled back far R enough to obtain the correct seal If the location mark has passed the face of the wall the flue has been pulled to far back and the outer wall seal will have 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 the flue should be fitted from outside _7 MUST be A fitted as Terminal Lip mil shovvn Fig 1 Rubber Terminal Wall Seal over step on plastic nose of flue terminal note seal is cut away for clarity il Ensure lip of vvall seal is positioned
82. n Off Knob B Domestic Hot Water Temperature Knob E Boiler Status F Burner on Indicator C Central Heating Temperature Knob D Mode Knob 32 HANDING OVER P Central Heating Economy Setting After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions 1 Hand the User Instructions to the householder and 7 Draw attention to the timer Users Instructions and hand them explain his her responsibilities under the relevant national to the householder regulations 8 Loss of system water pressure Explain that the dial underneath the boller indicates the procedures central heating system pressure and that if the normal 3 The operation of the boiler and the use and adjustment of all COLD pressure of the system is seen to decrease over a system controls should be fully explained to the householder period of time then a water leak is indicated Explain the re to ensure the greatest possible fuel economy consistent vvith pressurising procedure and if unable to re pressurise or if the the household requirements of both heating and hot vvater pressure continues to drop a registered local heating installer consumption should be consulted Advise the User of the precautions necessary to prevent 9 Explain Boller restart procedure 32 damage to the system and to the building in the event of the system remaining inoperative during frosty conditions
83. nal is upper most h A 44mm from terminal lp Drill Hole Adhere sealing tape 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 screw provided 5 Seal the joint on the outer air duct with the tape provided 6 Fit external wall seal see installing flue CUTTING HORIZONTAL FLUE TERMINAL 600MM LONG B PACK 1 Measure the required cut flue length A 44mm If inside the dimensions shown in Figure 2 1 Piece 600mm proceed 2 Measure from the outer terminal lip to end of outer flue Mark the required cut length A 44 around the circumference of the outer flue and cut following the mark to ensure its cut square 10mm 3 Dress the cut end to make sure all burr s are removed and the cut edge Mark Cut Length A 44mm from terminal lip is in its original shape 4 Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure its cut square m R J 0 l J m il 5 Remove all burrs and place a light chamfer on the outer edge to aid assembly Independent Combi Installation and Servicing INSTALLATION 16 INSTALLING THE FLUE FITTING FLUE THROUGH THE VVALL 1 VVall Thickness 1 Measure wall thickness and add 14mm 2 Measure from the outer terminal lip towards the end of outer flue place a s
84. nd electricity supplies to the boiler and drain down to complete the flushing process INSTALLATION Note A flushing solution should be used during the flushing procedure Flushing solutions Fernox Superfloc Sentinel X300 new systems or X400 existing systems Refer to Frame 4 4 Refill and vent the system add inhibitor see Frame 4 clear all air locks and again check for water soundness 5 Restart the system initial pressure to the design requirement 6 Balance the system Refer to Frame 3 7 Check the condensate drain for leaks and check that it is discharging correctly 8 Finally set the controls to the User s requirements Note The pump will operate briefly as a self check once every 24 hours in the absence of any system demand WATER TEMPERATURES Temperatures can be selected using the CH and DHW thermostats Knob Setting CH Flow Temp DHW Outlet Temp F F rir es aa Due to system variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap the lower the rate the higher the temperature and vice versa 31 INSTALLATION 31 RESTART PROCEDURE To restart boiler turn the mode control knob D to restart position and immediately turn knob back to required setting The boiler will repeat the ignition sequence if a heat demand is present INSTALLATION A Domestic Hot Water Preheat O
85. nd Servicing 33 SERVICING SERVICING SERVICING 34 BOILER FRONT PANEL REMOVAL REPLACEMENT REMOVAL 1 Loosen the two screws retaining the front panel 2 Pull the two spring clips down to disengage and pull panel forward and upward and remove REPLACEMENT Hook the panel onto the top retaining clips Push the panel until the 2 bottom spring clips engage ensuring the 4 control knobs line up with the holes in the front panel Re tighten the two retaining screws view from bottom of boiler view from top of boiler 35 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING Disconnect the electrical leads from the fan Remove the clip from the gas control valve outlet and ease the pipe upwards rotate and then ease down to remove Remove the extended nut on the fan mounting bracket Lift off fan and venturi assembly 5 Undo the two M4 screws and release the nozzle assembly Inspect the injector for blockage or damage 7 Inspect fan outlet sealing gasket and replace if necessary Injector 34 Independent Combi Installation and Servicing SERVICING 36 BURNER REMOVAL AND CLEANING Ensure the sump is fully drained Undo the two screws and remove the sump cover retaining the lower flue manifold Lift the manifold to clear the bottom sealing gasket and remove manifold Remove the 2 burner front fixing screws and loosen the 2 rear extended nuts by at least ten turns Lift off the
86. nfirm satisfactory demonstration and receipt of manufacturer s instructions Advise the customer that regular product servicing is needed in line with manufacturers recommendations to ensure that safety and efficiency is maintained Respond promptly to calls from a customer following completion of work providing advice and assistance by phone and if necessary visiting the customer Rectify any installation problems at no cost to the customer during the installer s guarantee period www centralheating co uk Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the 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 the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed The service details should be recorded on the Benchmark Service Interval Record and left with the householder 2enchmar COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk Heating and Hotwater Industry Council HHIC Independent Combi Installation and Servicing 59 GAS BOILER SYSTEM COMMISSIONIN
87. nt Stack Boiler Water weather with 75mm proof insulation sealed condensate trap Min 30mm Internal pipe Min 19mm Internal Soil 8 vent stack Minimum connection height up to 3 Boilers without 75mm sealed storeys condensate trap must be fitted with a 75mm trap and visible air break Figure 6 Connection of Condensate Drainage Pipe Upstream of a Sink Basin Bath or Shower Waste Trap to External Drain Gulley or Ranwater Hopper Boiler with 75mm sealed condensate Visible air break trap at plug hole Min 19mm Internal pee Sink basin bath or shower with integral overflow and 75mm trap Minimum 30mm internal pipe termination 25 INSTALLATION INSTALLATION INSTALLATION 23 CONNECTIONS amp FILLING NOTES Ensure all boss blanking plugs are removed before connecting hardware Each valve must be fitted to the correct boss as shown in the picture Ensure each union is fitted with fibre seals provided Do not subject any of the isolating valves to heat as the seals may be damaged WATER CONNECTIONS CH 1 Connect the CH flow service valve provided in the hardware pack to the threaded boss connection provided at the lower rear of the boiler 2 Connect the CH return valve black handle WATER CONNECTIONS DHW 1 Fit the DHW inlet service valve blue handle to the threaded boss connection ensuring the seal provided is correctly located 2 Fit the DHW outlet pipe t
88. ntenance All condensate pipework should conform to the following a Where a new or replacement boiler is being installed access to an internal gravity discharge termination should be one of the main factors considered in determining boiler location b Plastic with push fit or solvent connections Internal plastic pipe work a minimum of 19mm ID typically 22mm OD d External plastic pipe must be a minimum of 30mm ID typically 32 OD before it passes through the sleeved wall e All horizontal pipe runs must fall a minimum of 45mm per metre away from the Boiler f External amp unheated pipe work should be kept to a minimum and insulated with Class O waterproof pipe insulation g All installations must be carried out in accordance to the relevant connection methods as shown in the Condensate installation diagrams amp BS6798 2009 h Pipe work must be installed so that it does not allow spillage into the dwelling in the event of a blockage through freezing i All internal burrs should be removed from the pipe work and any fittings In order to minimise the risk of freezing during prolonged very cold spells one of the following methods of terminating condensate drainage pipe should be adopted internal Drain Connections Wherever possible the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or
89. o original setting once cold spell is over Place the heating on continuous and turn the room thermostat down to 15 C overnight or when unoccupied Return to normal after cold spell Independent Combi User s 5 GENERAL INFORMATION BOILER PUMP The boiler pump will operate briefly as a self check once every 24 hours regardless of system demand MINIMUM CLEARANCES Clearance of 165mm 6 1 7 above 100mm 4 below 2 5mm 91 5 at the sides and 450mm 17 4 at the front of the boiler casing must be allowed for servicing Bottom Clearance Bottom clearance after installation can be reduced to 5mm This must be obtained with an easily removable panel to enable the system pressure gauge to be visible and to provide the 100mm clearance required for servicing ESCAPE OF GAS Should a gas leak or fault be suspected contact the National Gas Emergency Service without delay Telephone 0800 111 999 Ensure that All naked flames are extinguished Do not operate electrical switches Open all windows and doors CLEANING For normal cleaning simply dust with a dry cloth To remove stubborn marks and stains wipe with a damp cloth and finish off with a dry cloth DO NOT use abrasive cleaning materials MAINTENANCE The appliance should be serviced at least once a year by a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII Independent Combi User s 6 MECHANICAL 24 HOUR
90. od condition replace if necessary Re fit the ignition and flame detection electrodes ensuring that the earth tab is fitted to the ignition electrode Check that the ignition and detection gaps are correct Refer to Frames 45 amp 46 39 REASSEMBLY Reassemble the boiler in the following order Ensure that the condensate trap siphon is full of water Refit the burner ensuring the sealing gasket is correctly positioned and free from damage tighten the 4 fixing screws in the sequence shown below Refit the fan venturi assembly ensuring the retaining tabs are correctly positioned and the sealing gasket is correctly positioned and free from damage Refit the gas outlet pipe and clip 4 Reconnect the fan electrical leads 5 Remove the sump cover and refit the lower flue manifold as 36 shown Ignition Electrode Flame Detection Refit the sump cover Swing the control box back into its working position and secure IMPORTANT Ensure that the boiler front panel is correctly fitted and that a good seal is made 8 Refit the boiler front panel 9 Tum on the gas supply at the gas service cock 10 Reconnect the electrical supply Independent Combi Installation and Servicing SERVICING 40 REPLACEMENT OF COMPONENTS GENERAL After replacing ANY component check operation of the boiler including gas soundness gas rate and combustion test IMPORTANT Turn off the gas supply
91. omestic hot water P Boiler is heating up the plate heat exchanger F Boiler is active for boiler frost protection Boiler is in lockout for a specific error Display will be blinking alternating with a number or letter to show which error is detected r F Boiler has a fault for a specific error Display will be blinking alternating with a number or letter to show which error is detected Note Boiler frost protection boiler fires if temperature is below 5 degrees C Note The boiler incorporates a fan overrun cycle which MUST NOT be prematurely interrupted by isolation of the mains electricity supply Independent Combi Installation and Servicing INSTAL 30 GENERAL CHECKS Make the follovving checks for correct operation in DOMESTIC HOT WATER DHVV MODE 1 Fully open all DHW taps in turn and ensure that water flows freely from them The display should read d X neon flashing then d 2 neon steady 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 approximately 35 C at the flow rate stated on page 6 under operation 3 Reduce the DHW draw off rate to about 3 I min 0 7gpm and check that the boiler modulates to deliver DHW at approximately 64 C 4 Close the DHW tap and check that the main burner extinguishes The pump should overrun for 60 seconds
92. or balcony outlet flue kits without the removal of the whole B pack terminal The appliance must not be operated without the desired outlet nose correctly fitted in place Note Location dimples must be aligned with terminal mounting frame Pack B Contents Non Telescopic A Flue Terminal B Flue Turret C Rubber Terminal Wall Seal D Cutting Aid Pack B Contents Telescopic A Telescopic Flue Terminal B Flue Turret C Rubber Terminal Wall Seal D Screw E Sealing Tape 8 FRONT PANEL REMOVAL 1 Loosen the 2 screws retaining the front panel 2 Pull the two spring clips downwards to disengage 3 Pull the front panel forward and upwards to remove Independent Combi Installation and Servicing 15 INSTALLATION INSTALLATION 9 VVALL MOUNTING TEMPLATE Extended centre line 155 S 0 The vvall mounting template is located on the internal protective N A See Diagram in packaging The template shows the position of the fixing and rear Far JFrame 1 flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled 2 1 Tape template into the required position ensuring its squareness by hanging a plumbline as shovvn SU If fitting a side flue extend the flue centreline onto the side by 155mm on a standard wall fix or 200mm if using a stand off bracket Mark the following on to the wall a The selected grou
93. ould be mounted at least 150mm above the highest point of the system and be connected through a non return valve to the system fitted at least 150mm below the make up vessel on the return side of the radiators or b Where access to a make up vessel would be difficult by pre pressurisation of the system The maximum cold water 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 smaller system volume may be necessary If the capacity of the vessel is not considered sufficient for this or for any other reason an additional vessel MUST be installed on the return to the boiler Guidance on vessel sizing is given in Frame 2 Filling The system may be filled by the following method Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling a Thoroughly flush out the whole system with cold water b Fill and vent the system until the pressure gauge registers 1bar and examine for leaks c Check the operation of the safety valve by raising the water pressure until the valve lifts This should occur within 0 3bar of the preset lift pressure d Release water from the system until the minimum system design pressure is reached 1 0 bar if the system is to be pre pressurised Mains water supply Hose unions N q CH Return
94. p of wall mounting screw holes b The centre position of the flue duct Marking both the centre and the circumference of the flue duct INSTALLATION Remove the template plate from the wall 10 PREPARING THE WALL IMPORTANT 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 flue only 7 flue only ensuring that the hole is square to the wall diameter hole 5 diameter hole Both wall faces immediately around the cut hole should be flat X Drill 2 mounting holes marked from template with a 7 5mm 8mm masonry drill and insert the plastic plugs provided Section for the wall mounting plate through wall Locate 2 No 14 x 50mm screws in the wall mounting plate one at each side in any of the 3 holes provided at each side and screw home Ensure mounting bracket is level Note Check all of the hole positions before drilling 11 FITTING THE WALL MOUNTING PLATE 12 MOUNTING THE BOILER Screw the wall mounting plate to the wall using 2 wall plugs 1 Ensure the plastic plugs are removed from both the CH previously fitted with the 2 screws provided and DHW connections before mounting the boiler Choose one of the 2 sets of slots in left and right bank Note boiler may contain residual water Ensuring that at least one of the screws is fitted into a to
95. p slot and the mounting bracket is level Lift the boiler onto the wall mounting plate refer to the Introduction section for safe handling advice locating it over the two tabs Example of fixing 3G9948 Independent Combi Installation and Servicing INSTALLATION 13 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT The boiler must be installed in a vertical position in accordance to the installation instructions FLUE KITS Telescopic Flue B Pack contains Flue turret telescopic flue incorporating a terminal and rubber wall seal Horizontal Flue Terminal 600mm long B Pack contains Flue turret non telescopic single piece flue incorporating a terminal and rubber wall seal Horizontal Flue Terminal 1000mm long B Pack Flue turret telescopic flue incorporating a terminal rubber wall seal and instructions Note If B packs are used on their own either 1 piece or telescopic then they can be fitted horizontally as the flue inside is designed to slope 1 5 degrees Flue Kit 203129 D Pack Flue Extension 100mm DIA 1000mm long Flue Kit 211037 D Pack Flue Extension 100mm DIA 500mm long Flue Kit 211038 D Pack Flue Extension 100mm Dia 2000mm long Flue Kit 211039 Roof Flue Kit with Vertical Connector When extension D Packs are used the flue duct must incline 1 5 degrees away from the appliance to allow the condensate to drain back to the boiler and out of the con
96. ppliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII Outside Sensor Failure Restart the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII EMEK Eu Lovv Mains Voltage Contact a qualified electrician or your electricity provider burner burner Unconfigured PCB Unconfigured PCB Please contact ldeal if under vvarranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Flow Temperature Overheat Check system water pressure is between 1 amp 1 5bar on the system pressure gauge G or No Water Flow To re pressurise the system see Section 3 If the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Flame Loss 1 Check other gas appliances in the house are working to confirm a supply is present in the property 2 f other appliances do not work or there are no other appliances check the gas supply is on at the meter and or pre payment meter has credit If the boil
97. quired when measured from outside edge of turret to the outside face of the wall to obtain cut length add 44mm Minimum amp Maximum finished flue lengths obtainable dimension A 44mm Horizontal Flue Horizontal Flue Terminal 600mm long B Pack Terminal 1000mm long 1000mm long B Pack B Pack Telescopic Telescopic Cut 75mm output 35 output 30 kVV Max output 24 kVV Note Telescopic flue B Pack or attached D pack extensions do not need to be cut betvveen minimum and maximum values shown above except where specified Horizontal Flue Terminal 600mm long B Pack flue will require cutting on values below maximum values shown in the table above If using the 2000mm D Pack the maximum usable length per extension is 1950mm If using the 500mm D Pack the maximum usable length per extension is 450mm l R J 0 J a il 18 ndependent Combi Installation and Servicing INSTALLATION 15 CUTTING amp SETTING THE FLUE LENGTH TELESCOPIC FLUES TELESCOPIC FLUE B PACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK TELESCOPIC MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 amp 652MM THIS WILL REQUIRE 75MM TO BE CUT OFF THE TERMINAL END OF THE 1000MM TELESCOPIC FLUE ALL OTHER LENGTHS OBTAINED USING D PACK EXTENSIONS IN FLUE LENGTH TAB
98. r 1 Metre of flue length No flue length greater that the maximum flue length shown above should be exceeded 10 Independent Combi Installation and Servicing 2 GENERAL SYSTEM REQUIREMENTS Central Heating Notes a b The method of filling refilling topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority Antifreeze fluid corrosion and scale inhibitor fluids suitable for use with boilers having aluminium heat exchangers may be used in the central heating system General 1 The installation must comply with all relevant national and local regulations The installation should be designed to work with flow temperatures of up to 86 C All components of the system must be suitable for a working pressure of 3 bar and temperature of 110 C Extra care should be taken in making all connections so that the risk of leakage is minimised The following components are incorporated within the appliance a Circulating pump b Safety valve with a non adjustable preset lift pressure of 3 bar c Pressure gauge covering a range of 0 to 4 bar d An 8 litre expansion vessel with an initial charge pressure of 0 75 bar Make up Water Provision must be made for replacing water loss from the system either a From a manually filled make up vessel with a readily visible water level The vessel sh
99. r No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Engineer name Comments Engineer name 033 Company name Telephone No SERV CE 04 ve Company name Telephone No Gas safe register No At max rate Record At min rate VVhere Possible Gas safe register No At max rate Record At min rate VVhere Possible Comments Comments Signature SERVICE 05 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate AND 1 CO 96 Record At min rate VVhere Possible AND CO 96 At max rate Record At min rate VVhere Possible Comments Comments Signature SERVICE 07 Signature SERVICE 08 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No CO At min rate Where Possible CO At max rate Record At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 09 Signature SERVICE 10 Engineer name
100. s Service Cock L DHW Inlet Valve M CH Return Isolating Valve N DHW Outlet P Central Heating Economy Setting 3G9928 1 Check that the system has been filled to the required pressure and that the boiler is not airlocked Ensure the automatic air vent cap is open Note It is important the burner is not operated before the system is fully vented 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 Frame 34 3 Check that the drain cock is closed and that the CH and DHW isolating valves M L and G are OPEN Check that the electrical supply is OFF Check that the boiler mode knob D is off Check that the gas service cock K is OPEN 17705 pressure gauge via a flexible tube 8 Switch the electricity supply ON and check mechanical timer is in Manual On position CENTRAL HEATING 9 Setthe CH temp control C to max and turn the mode knob D to m The boiler control should now go through its ignition sequence until the burner is established 10 If the boiler does not light code L g willbe displayed After 5 attempts the boiler will lock out and display fault code L constantly Restart the boiler Refer to Frame 31 The boiler will repeat its ignition sequence If restart occurs 5 times within 15 minutes then L 5 will be shown If power is removed this will be restarted
101. s 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 using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves However if the system employs thermostatic radiator valves on all radiators or two port valves then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position ELECTRICAL SUPPLY WARNING This appliance must be earthed Wiring external to the appliance MUST be in accordance with the current 1 E E BS 7671 Wiring Regulations and any local regulations which apply 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 and for new heating systems and where practical replacement boiler installations the isolator shall be situated adjacent to the appliance CONDENSATE DRAIN Refer to Frames 21 22 amp 37 A condensate drain is provided on the boiler This drain must be connected to a drainage point on site All pipework and fittings in the condensate drainage system MUST be made of plastic no other materials may be used IMPORTANT Any external runs must be in accordance with BS 6798 The drain outlet on the boiler is sized for
102. se before recording Turn off appliance and call Ideal Technical Helpline for advice The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with GSIUR CO level less han 350ppm AND ratio less than 0 0040 Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary Set Boiler to Minimum Gas Rate see opposite page In accordance with boiler instructions set boiler to operate at minimum rate to minimum load condition Allow sufficient time for combustion to stabilise CO level less than 350ppm AND ratio less than 0 0040 Check CO and Combustion Ratio at Minimum Gas Rate With boiler set at minimum rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Turn off Appliance and Call Ideal Technical Helpline The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with GS I amp U R NOTE Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ideal CO level less han 350ppm AND CO CO ratio less than 0 0040 Yes Boiler is
103. se 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 Ideal For the very latest copy of literature for specification and maintenance practices visit our website www idealboilers com where you can download the relevant information in PDF format For alternative languages in our User Guides please visit our website www idealboilers com 1 INTRODUCTION The Independent is a combination boiler providing both central heating and instantaneous domestic hot water Featuring full sequence automatic ignition and fan assisted combustion Due to the high efficiency of the boiler condensate is produced from the flue gases and this is drained to a suitable disposal point through a plastic waste pipe at the base of the boiler A condensate plume Important Notes nee l will also be visible at the flue terminal Boiler Operation Controls Diagram To Start the Boiler Operation Modes SAFETY Current Gas Safety Installation amp Use Regulations or rules in force In your own interest and that of safety it is the law that this Control of Water Temperature boiler must be installed by a Gas Safe Registered Engineer in Efficient Heating System Operation accordance with the above regulations Weather Compensation In IE the installation must be carried out by a Registered Gas Installer Boiler Frost Pro
104. shield 1 VVEATHER PROOFING VVhere the flue passes through the roof line an adequate seal must be made Soffit Flue Kit Option 500 max 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 contain 1m extension ducts and may be cut to the desired length If the offset vertical option is used an elbow Kit is required For a full accessories list refer to page 6 Optional Extras and Frame 25 Flue Arrangement 18 ROOF FLUE KIT CONTENTS OPTIONS j Flue Terminal Flue Seal Collar Flat Roof Vertical connector 90 elbow UIN 211039 UIN 152259 UIN 208175 UIN 203130 Vertical Connector B Flue Seal Collar Tile Roof 45 elbow UIN 152258 UIN 203131 Roof Flue Extension Duct UIN 211037 500mm UIN 203129 1000mm UIN 211038 2000mm Soffit Flue Kit UIN 211067 ndependent Combi Installation and Servicing 21 FLUE OUTLET INSTALLATION 19 FLUE TERMINAL POSITION The terminal should be positioned so that products of combustion can safely disperse at all times Pluming may occur at the termination so where possible terminal positions where this could cause a nuisance should be avoided Minimum dimen
105. sions are shown below Aluminium shield Pitched Roof with structure Flat roof with structure Flat Roof Weather Collar Universal Weather Collar B 2000mm The flue terminal shall not penetrate the shaded area of the roof Terminal Position Directly below an opening air brick windows etc 300 mm Note 300 mm The equivalent flue length resistance of 900 mm the elbow kits are Below velux windows 2000mm 90 elbow kit 1m Above or side of velux windows 600mm 45 elbow kit 0 6m l s R J 0 J a il 22 ndependent Combi Installation and Servicing INSTALLATION 20 ASSEMBLING THE ROOF FLUE KIT Determine the correct height that the flue should terminate above A the roof If after calculating or measuring the overall flue height from the top of the boiler it is necessary to cut both pipes of assembiy A then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied Ensure the cut pipe ends are free from any burrs 1 Position the roof flashing plate supplied separately over the hole cut in the roof and insert flue terminal from the roof end max 41 MAX LENGTH 7 5m BOILER nm8739 2 Fit the vertical connector supplied in kit in accordance vvith the in the instructions provided vvith the vertical connector kit 3 Secure the vertical connector by applying downward pressure
106. size the gas gas installation pipework in accordance with BS6891 2005 Whilst the principle of the 1 1 gas valve ensures the Independent Combi range is able to deliver it s full output at inlet pressures as low as 14mb other gas appliances in the property may not be as tolerant When operating pressures are found to be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation Allowing for the acceptable pressure loss of 1mb across the installation pipework it can be assumed that a minimum permitted operating pressure of 18mb will be delivered to the inlet of the appliance Reference BS 6400 1 Clause 6 2 Pressure Absorption The external gas cock could further reduce the operating pressure when measured at its test point The pressure drop is relative to the heat input to the boiler kW refer to graph below Gas Cock Pressure Drop ma 2 o o 5 o 5 N o Le 20 30 Heat Input to Boiler kW IMPORTANT Installation pipes must be fitted in accordance with BS 6891 In IE refer to 15 813 2002 The complete installation MUST be tested for gas tightness and purged as described in the above code FLUE INSTALLATION Pluming will occur at the terminal so terminal positions where this could cause a nuisance should be avoided The flue must be installed in accordance with the recommendations of BS 5440 1 2008 In IE refer to I S
107. sociated harness for continuity correctly visual condition and position Refer to Frame 45 Are these PIS HONIG 2 Replace Ignition Electrode and associated harness as necessary Check siphon and condensate drain pipe NO work for blockage and rectify if necessary 4 Replace Gas Valve Boiler now working OK Note due to the wave form of the rectified voltage the reading 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 75 ALTERNATING F AND 3 FAN FAULT Does the wiring from the Fan to the PCB have secure connections at both ends and has not Rectify Wiring amp deteriorated Does the wiring have continuity connections Replace PCB Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan Replace Fan FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 52 Independent Combi Installation and Servicing FAULT FINDING 76 ALTERNATING F AND 5 RETURN THERMISTOR FAULT Remove the Return Thermistor from the CH Return Pipe and disconnect the wires Fit a new Thermistor Check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 expect 9 700 10 300 Ohms At 60 expect 2 400 2 600 Ohms Is there continuity between the PCB and At85 C expect 1
108. st be fitted with a 75mm trap and visible air break continued Independent Combi Installation and Servicing INSTALLATION 22 CONDENSATE DRAIN CONT D Figure 3 Connection of a Condensate Pump Typical Method see manufacturers detailed instructions Boiler with 75mm sealed condensate trap Min 19mm Internal pipe Visible air break Condensate pump Install in accordance with manufacturers instructions Figure 5 Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe only combined foul rainwater drain Boiler with 75mm sealed condensate trap Min 19mm Internal pipe weather proof insulation combined foul rain water drain Min 30mm Internal pipe External air break Air gap Terminated and cut at 45 43mm 90 male female bend 68mm PVCU Strap on fitting Figure 7 Connection of a Condensate Drainage Pipe to an External Purpose Made Soak Away Boiler with 75mm sealed condensate trap Min 30mm Water Weather Internal pipe roof insulation Min 19mm Internal pipe Limestone chippings Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house Independent Combi Installation and Servicing Figure 4 Connection of condensate Drainage Pipe to External Soil amp Ve
109. sure measure amp record 9 Cold water inlet temp measure amp record For all boilers Hot water outlet temp measure amp record Flushing t 557900 12 Water flow rate at max setting measure amp record E elie EAE 12 For condensing boilers only Central heating mode Condensate drain 24 Heat NPU sisas to be calculated For all boilers complete sign amp hand over to customer For assistance see Technical Helpline on the back page NOTE TO THE INSTALLER COMPLETE 7 THE BENCHMARK COMMISSIONING 7 Ay CHECKLIST AND LEAVE THESE e 4 4 INSTRUCTIONS WITH APPLIANCE THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Independent Combi Installation and Servicing 5 GENERAL INTRODUCTION The Independent Combi range of boilers are wall mounted full sequence automatic spark ignition low water content fanned flue high efficiency condensing combination gas boilers Note Due to the high efficiency of the boiler a plume of water vapour will form at the terminal during operation Central heating CH output is fully modulating with a range of C24 4 8 to 24 2kW 16 500 to 82 600 Btu h C30 6 1 to 24 2kW 20 700 to 82 600 Btu h C35 7 1 to 24 2kW 24 100 to 82 600 Btu
110. t the following must be checked and clear of any obstruction The integrity of the flue system and the flue seals 3 Check all water and gas joints for signs of leakage Remake any The integrity of the boiler combustion circuit and suspect joints ensuring a gas tightness check is carried out if the relevant seals applicable and the water system is correctly refilled vented and operational working gas inlet pressure at re pressurised maximum rate CLEANING PROCEDURE The gas rate Note In order to carry out either servicing or replacement of The combustion performance components the boiler front panel must be removed Refer to Frame 34 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 1 Clean the main burner Refer to frame 36 2 Clean the heat exchanger amp condensate trap siphon Refer to Frames 37 amp 38 3 Check the main injector for blockage or damage Refer to Frame The person carrying out a combustion measurement should have been assessed as 4 Check that the flue terminal is unobstructed and that the flue system competent in the use of a flue gas analyser and the is sealed correctly interpretation of the results ALSO IF THE DHW FLOW RATE IS IN QUESTION The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3
111. t off during cold vveather a frost stat should be fitted in coniunction vvith a pipe thermostat 1 Position the frost thermostat in a suitable position i e area vulnerable to FROST freezing OL STAT O OPTIONAL 2 Connect frost stat across terminals marked frost stat as shown in wiring diagram opposite 26 EXTERNAL ELECTRICAL CONTROLS Use of General Live for Room Stat Wiring External to the Boiler The fuse rating should be 3A Optional Wiring external to the boiler MUST be in accordance with the current 1 E E Frost Stat BS 7671 Wiring Regulations and any local regulations Frost Protection 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 L N Frost Stat The frost thermostat should be sited in a cold place but where it can sense heat from the system 3G9990 Note fthe boiler is installed in a garage it may be necessary to fit a pipe l thermostat preferably on the return pipework Earths are not shown for clarity but must never be omitted Independent Combi Installation and Servicing 27 INSTALLATION INSTALLATION 1835 ule 1501 27 WIRING DIAGRAM NOILY TIVWLSNI A BA JOHA 4 1 81 yq 194 UOHAS
112. tection RGII and installed in accordance with the current edition of 1 S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical Mains Power Off installation Preheat Domestic Hot Water Boiler Restart System Water Pressure It is essential that the instructions in this booklet are strictly Condensate Drain followed for safe and economical operation of the boiler General Information ELECTRICITY SUPPLY Boiler Pump This appliance must be earthed Minimum Clearances Supply 230 V 50 Hz The fusing should be 3A Escape of Gas Cleaning IMPORTANT NOTES Maintenance e This appliance must not be operated without the casing Mechanical 24 Hour Timer correctly fitted and forming an adequate seal Points for the Boiler User e If the boiler is installed in a compartment then the compartment Troubleshooting MUST NOT be used for storage purposes Normal Operation Display Codes e f itis Known or suspected that a fault exists on the boiler then Fault Codes it MUST NOT BE USED until the fault has been corrected by a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII e Under NO circumstances should any of the sealed components on this appliance be used incorrectly or tampered with e This appliance can be used by children 8 years and above Also persons vvith reduced physical sensory or mental capabilities or
113. tions should be considered e Grip the boiler at the base e Be physically capable e Use personal protective equipment as appropriate e g gloves safety footwear During all manoeuvres and handling actions every attempt should be made to ensure the following unless unavoidable and or the weight is light e Keep back straight e Avoid twisting at the waist e Avoid upper body top heavy bending e Always grip with the palm of the hand e Use designated hand holds e Keep load as close to the body as possible e Always use assistance if required OPTIONAL EXTRA KITS e Horizontal Flue Terminal 600mm long e Horizontal Flue Terminal 1000mm long e Telescopic B Pack e Flue Extension Ducts 1000mm long e Flue Extension Ducts 2000mm long e Flue Extension Ducts 500mm long 24 up to 9m 30 up to 8m 35 up to 6m e Flue Finishing Kit e 90 Elbow Kit maximum per installation 24 upto 6 elbows 30 upto 6 elbows 35 upto 4 elbows e 45 Elbow Kit maximum per installation 24 upto 6 elbows 30 upto 6 elbows 35 upto 4 elbows e Roof Flue Kit to a maximum of 7 5m High Level Flue Outlet Kit e Flue Deflector Kit e Adjustable Flue Support Bracket e Raised Horizontal Flue Kit e Concentric Flue Screw Retaining Kit e Weather Collar e Soffit Flue Kit e Pre Piping Frame Kit e Stand Off Kit e Condensate Pump Kit DHW Expansion Vessel Kit e Weather Compensation Kit e RF Mechanical Programmable Room Thermostat K
114. uild up to a point where it will make a gurgling noise prior to locking out an L2 fault code If the appliance is restarted it will make a gurgling noise prior to it locking out on a failed ignition L2 code To unblock a frozen condensate pipe 1 Follow the routing of the plastic pipe from its exit point on the appliance through its route to its termination point Locate the frozen blockage It is likely that the pipe is frozen at the most exposed point external to the building or where there is some obstruction to flow This could be at the open end of the pipe at a bend or elbow or where there is a dip 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 a warm damp cloth to the frozen blockage area Several applications may have to be 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 localised hazards 4 Once the blockage is removed and the condensate can flow freely restart the appliance Refer to To Light the boiler 5 If the appliance fails to ignite call your Gas Safe Registered engineer Preventative solutions During cold weather set the central heating temperature knob C to maximum Must return t
115. uired Install commission service and use products in accordance with the manufacturer s instructions provided Ensure that where there is responsibility for design work the installation is correctly sized and fit for purpose Meet the requirements of the appropriate Building Regulations Where this involves notifiable work be a member of a Competent Persons Scheme or confirm that the customer has notified Local Authority Building Control LABC prior to work commencing Complete all relevant sections of the Benchmark Checklist Service Record when carrying out commissioning or servicing of a product or system Ensure that the product or system is left in a safe condition and whenever possible in good working order Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing work Refer to the manufacturer s helpline where assistance is needed Report product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Hand over the manufacturer s instructions including the Benchmark Checklist to the customer on completion of an installation Obtain the customer s signature on the Benchmark Checklist to co
116. y occurs if pre heat knob is in the ON period When there is a demand for CH the heating system is supplied at the selected temperature of between 45 C and 80 C until DHW is drawn off The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW draw off of C24 9 9 l min at 35 C temperature rise C30 12 4 l min at 35 C temperature rise C35 14 5 l min at 35 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 rates temperature rise will vary requiring adjustment at the draw off tap At low DHW draw off rate the maximum temperature is limited to 64 C by the modulating gas control The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating and performance of key components to aid commissioning and fault finding 6 SAFE HANDLING This boiler may require 2 or more operatives to move it to its installation site remove it from its packaging base and during movement into its installation location Manoeuvring the boiler may include the use of a sack truck and involve lifting pushing and pulling Caution should be exercised during these operations Operatives should be knowledgeable in handling techniques when performing these tasks and the following precau

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