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combination boilers INSTALLATION & SERVICING

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1. n a AUO DyUDISSuaidestititiuxtuied eic ANE DEI E KL eTa 9 Max operating water pressure measure amp record sie Wigi iqe r GRE 9 Cold water inlet temp measure amp record For all boilers Hot water outlet temp measure amp record Flushing to B5 7999 ieiunio rete evt mtEer 12 Water flow rate at max setting measure amp record Aone rol ec 12 For condensing boilers only Central heating mode Condensate CAIN eee esenuc e icitc ian a ganan pem subc San ier un aside 24 Heat no UPPER ET 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 ul UT INSTRUCTIONS WITH APPLIANCE THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS i combi Installation and Servicing 5 GENERAL INTRODUCTION The i 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 24 4 8 to 24 2kW 16 500 to 82 600 Btu h 30 6 1 to 24 2kW
2. i combi Installation and Servicing INSTALLATION DIVERTOR VALVE PADDLE BYPASS CARTRIDGE GAS COCK PIPE GAS INLET GAS VALVE PIPE GAS INJECTOR INJECTOR ASSEMBLY VENTURI FAN BURNER GASKET BURNER SUMP CLEAN OUT COVER FLUE MANIFOLD FLUE MANIFOLD TOP CLAMP RETAINING FLUE TURRET HOSE CONDENSATE INTERNAL SIPHON TRAP CONDENSATE OUTLET CONNECTION PRIMARY PCB CUI BOARD ELECTRODE IGNITION 307 308 309 313 314 324 325 326 401 503 504 506 507 510 Note that item numbers are linked to the spares list ELECTRODE DETECTION IGNITER UNIT FLOW THERMISTOR IGNITION LEAD CONTROL BOX LENS CONTROLS BOX LID CONTROL BOX FRONT MECHANICAL TIMER HEAT ENGINE WALL MOUNTING BRACKET FRONT PANEL BRACKET GAS VALVE BRACKET EXPANSION VESSEL ACCESS FLAP 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 R d FL 71 a 5 js 19 INSTALLATION INSTALLATION 6 14 UNPACKING INSTALLATION 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 IMPORTANT To unpa
3. EAE UP E ee SS ee EM oe i combi Installation and Servicing 21 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 dimensions are shown below mex gt tap Cu gt Vs ap w i eee e L E t ete EIE cm Jo t e uL UT w A aom ee t EEr 2 Tot te t gt n2 Ld le ae RNC L P c tC ut om LI 3 A i m S ield v mE PSI 73 731154 ya 4t a t Ves maaa fey Pitched Roof with structure In p Flat roof with structure ta bie C y se ata Flat Roof EL 690mm 7 p Em an Fixed 7 wo LT Eamus d JIE o e Universal Weather I B 2000mm Ir Slat 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 SO in 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 45 elbow kit 0 6m li I J Q ll J a L 22 i combi Installation and Servicing INSTALLATION 20 ASSEMBLING THE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof If after calculating or measuring
4. Telephone No Gas safe register No Gas safe register No AND AND CO CO At max rate Record At min rate Where Possible At max rate Record At min rate Where 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 At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 09 Signature SERVICE 10 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible 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 penchmar THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING A
5. YES Are the Timer and the Room Thermostat switched NO l 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 i combi Installation and Servicing DO FAULT FINDING 83 NO HW BUT CH ON Does the display show d when a tap is on Is hot and cold pipework crossed NO Are the flow rates correct as per Frame 2 Adjust flow rates to achieve 35 temp rise and check filter fitted in YES turbine is not blocked with debris Is the wiring between the PCB and the diverter m Reconnect wiring or valve actuator connected iv replace wiring harness if YES no continuity Is the wiring connected between PCB and DHW sensor Check diverter head fully engaged onto NO Re engage diverter waterset body E head YES Remove the turbine and check for debris in the O turbine Replace turbine Is diverter stuck in the CH position M Replace PCB if necessary Is DHW OK YES Check and replace diverter valve actuator head Replace turbine sensor Is Boiler DHW OK NO Change diverter valve assembly 84 NO DISPLAY s 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 th
6. 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 PRESSURE GAUGE RENEWAL 44 Refer to Frame 40 Drain the heating system Refer to Frame 53 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 After replacing any component on the boiler close tap close the drain valve and open all system isolating valves re i combi Installation and Servicing SERVICING 56 SAFETY RELIEF VALVE RENEWAL 1 Refer to Frame 40 2 Drain the boiler Refer to Frame 53 Remove the return thermistor Refer to frame 64 4 Pull out and remove the clip positioned behind the safety valve retaining the safety valve 5 Undo the safety valve pipe compression fitting positioned outside the boiler casing 6 Lift out the safety valve pipe assembly 7 Remove the safety valve pipe and transfer to the new safety valve 8 Reassemble in reverse order ensuring the retaining clip is correctly fitted and the pipe compression fitting retightened 9 Refill the boiler Check operation of the boiler Refer to Frames 29 amp 30 57 PUMP AUTOMATIC AIR VENT REPLACEMENT Refer to Frame 40 Drain the boiler Refer to Frame 53 Remove the return thermistor Refer to Dust Cap
7. li J 0 i J L i combi Installation and Servicing INSTALLATION 14 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED CONT D F G U RE 1 Edge of turret Edge of turret Edge of turret to outside face of wall plus to outside face of wall plus to outside face of wall 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 NCU 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 required 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 Max output 35 k Max output 30 kW Max output 24 kW Note Telescopic flue B Pack or attached D pack extensions do not need to be cut betwe
8. 20 700 to 82 600 Btu h 35 7 1 to 24 2kW 24 100 to 82 600 Btu h Instantaneous domestic hot water DHW output is also fully modulating with a maximum of 24 242kW 82 600 Btu h 30 30 3kW 103 300 Btu h 35 35 3kW 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 OPERATION With no demand for CH the boiler fires only when DHW is drawn off or periodically for a few seconds without any DHW draw off in order to maintain the DHW calorifier in a heated condition This only occurs if pre heat on When there is a demand for CH the heating system is supplied at the select
9. 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 i 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 valves are used the space heating temperatur
10. 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 Fitted Not required 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 OR Burner operating pressure if applicable OR Gas inlet pressure 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 reduc
11. 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 trap Min 19mm LL Internal pipe Sink basin bath or x O oO 77 c o gt od Oo o C c i o c Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break continued i combi Installation and Servicing INSTALLATION 22 CONDENSATE DRAIN CONT D Figure 3 Connection of a Condensate Pump Typical Method see manufacturers detailed instructions Visible air break Boiler with 75mm 7 sealed condensate trap Min 19mm Internal pipe 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 weather proof Min 19mm insulation Internal pipe Min 30mm Internal pipe Terminated and cut at 45 43mm 90 male female bend combined foul rain water drain External air break Air gap 68mm PVCU Strap on fitting Figure 7 Connection of
12. 4 14 5 at 35 C temp rise gpm o 2 8 3 2 The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating 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 MJ m 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 Ci C C A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal which admits fresh air to the burner a For l s divide the gross heat rd and discharges the products of combustion to the outside through kW by the gross C V of the gas MJ rr orifices which in this case are concentric The fan is up stream of b For fti h divide the gross heat input Btu h the combustion chamber by the gross C V of the gas Btu ft l An appliance designed for use on 2nd Family gas Group H only c For m h multiply I s by 3 6 4 i combi Installation and Servicing GENERAL i combi CONTENTS Natural Gas only Air Supply Boiler size Benchmark Commissioning Checklist Benchmark No Boiler Clearances 86CM68 Boiler Exploded Diagram 86CM68 Condensate Drain 86CM68 Electrical Connections Electrical Supply Destination Country GB IE Fault
13. CH temp control C to max and turn the mode control knob A to The boiler control should now go through its ignition sequence until the burner is established 10 If the boiler does not light code L will be displayed After 5 attempts the boiler will lock out and display fault code L constantly Reset the boiler Refer to Frame 31 The boiler will repeat its ignition sequence If reset occurs 5 times within 15 minutes then L 5 will be shown If power is removed this will be reset When the burner is established the BLUE Burner On neon E will be illuminated the LED display D will show status DOMESTIC HOT WATER 11 With the boiler firing set the DHW Temp Control knob B to maximum and fully open a DHW tap The boiler should continue to run and the LED display D should show status g 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 14 To turn on the DHW pre heat facility turn the DHW knob B fully clockwise and then back to the desired setting a decimal point F will appear in the boiler status window
14. Duct Assembly Flue Turret Turret Clamp Seal li I J Q ll J a L Flue Outlet 20 i 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 Connection to the top of the boiler is made using a separately supplied vertical connector WEATHER PROOFING Where the flue passes through the roof line an adequate seal must be made This is achieved by using either Flat roof weather 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 D b 2 SI 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 nm8736 18 ROOF FLUE KIT CONTENTS OPTIONS Flue Terminal Flue Seal Collar Flat Roof Vertical connector 90 elbow j UIN 203132 UIN 152259 UIN 208175 UIN 203130 45 elbow UIN 203131 Flue Seal Collar Tile Roof auct UIN 152258 support Roof Flue Extension Duct UIN 203129
15. Electricity Supply Note n normal operation the boiler status display D will This appliance must be earthed show codes Supply 230 V 50 Hz The fusing should be 3A Li Standby no demand for heat Important Notes CH being supplied L This appliance must not be operated without the casing correctly rl fitted and forming an adequate seal ORN DelhgsHpplled e lf the boiler is installed in a compartment then the compartment F DHW preheat indi A PAP l Lr Boiler frost protection boiler will fire if temperature is lf itis known or suspected that a fault exists on the boiler then below 5 degrees C it MUST NOT BE USED until the fault has been corrected by a Gas Safe Registered Engineer or in IE a Registered Gas Installer During normal operation the burner on indicator E will remain RGII illuminated when the burner is lit e Under NO circumstances should any of the sealed components on this appliance be used incorrectly or tampered with Note If the boiler fails to light after five attempts the fault code l l l L will be displayed This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or RESET PROCEDURE lack of experience and knowledge unless they have been given supervision or instructions concerning use of the appliance by a person responsible for their safety To reset boiler turn the mode control knob A to reset position and i
16. Finding Flue Fitting Flue Installation Gas Safety Regulations Gas Supply Installation Safe Handling Servicing Spare Parts Info 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 ccccccccsseeceeeeceeeeseeesseeeseeeesseeess 5 Burner operating pressure seeeeeseses n a Appliance serial no on data badge Front Cover Central heating flow temp measure and record SEDBUIS NO cae esac ese eset nsee sean cs so iar 4 Central heating return temp measure and record Controls For combination boilers only Time and temperature control to heating 2f Scale reducer NR m 12 Time and temperature control to hot water 2f Hot water mode Heating zone valves eeeeeeeereeeee n a Heat go 8 PRONUM QM to be calculated Dic cc geen aseceee 9 Max operating burner pressure
17. In IE contact a Registered Gas Installer RGII burner burner Ignition Lockout burner burner Fan Fault Reset the appliance if the boiler fails to operate then please contact Ideal Boilers if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII Flow Thermistor Reset the appliance if the boiler fails to operate then please contact Ideal Boilers 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 burner burner Return Thermistor Reset the appliance if the boiler fails to operate then please contact Z r Ideal Boilers if under warranty or alternatively a Gas Safe Registered l 3 Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII 6 i combi User s
18. Release water from the system until the inn UIS eNom Or Taw minimum system design pressure is reached 1 0 bar if the system is to be pre pressurised continued i combi Installation and Servicing 11 GENERAL CONTINUED DOMESTIC HOT WATER 1 The domestic hot water service must be in accordance with BS 5546 and BS 6700 Refer to Table 1 for minimum and maximum working 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 67 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 The boilers are suitable for connection to most types of washing machine and dishwasher appliances 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 3 SYSTEM BALANCING b Hot and cold water supplies to the shower are of equal pressure 5 Hard Water Areas Where the water hardness exceeds 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 expansion 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 v
19. 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 Hand the User Instructions to the householder and T 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 xo nd RAS AE Orden UT CIS MN Explain that the dial underneath the boiler indicates the procedures central heating system pressure and that if the normal 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 with pressurising procedure and if unable to re pressurise or if the the household requirements of both heating and hot water pressure continues to drop a registered local heating installer consumption should be consulted Advise the User of the precautions necessary to prevent 9 Explain Boiler res
20. a Condensate Drainage Pipe to an External Purpose Made Soak Away Boiler with 75mm sealed condensate trap Min 30mm Water Weather Internal pipe proof insulation Min 19mm Internal aer Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break 2 rows of three 212mm holes 25mm centres 50mm from the bottom of the tube facing away from the house i combi Installation and Servicing Limestone chippings Figure 4 Connection of condensate Drainage Pipe to External Soil amp Vent Stack Boiler Water weather with 75mm proof insulation sealed condensate trap Min 30mm Internal pipe Min 19mm Internal a Soil amp 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 Water i weather proof Min 19mm i Internal pipe P d insulation Sink basin bath or Minimum 30mm shower with integral internal pip z overflow and 75mm trap L 45 pipe termination 2 25 Below grate 25 INSTALLATION INSTALLATION INSTALLATION 23 CONNECTIONS amp FILLING NOTES Ensure all boss blanking plugs are removed befor
21. indicating pre heat ON 15 To turn off the pre heat facility turn the DHW knob B fully clockwise and then back to the desired setting the decimal point F will disappear in the boiler status window indicating pre heat OFF 30 STATUS BURIYER Safety Drain Valve aS Se d E DB eV c Es Q 2 N gt Sn a 7 uwm Esc o E or ag vid ju i THE DISPLAY The user control has one neon and one display to inform the user about the status The display will show 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 8 Standby no demand for heat present Boiler is active for central heating Boiler is active for domestic hot water Boiler is heating up the plate heat exchanger 1 70 Q 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 ia 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 interrupte
22. order 8 Check the operation of the boiler Refer to Frames 29 amp 30 i combi Installation and Servicing 39 SERVICING SERVICING SERVICING 46 SPARK GENERATOR REPLACEMENT Refer to Frame 40 2 Disconnect the leads from the spark generator Remove the M5 screws securing the spark generator to the boiler chassis 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 47 GAS CONTROL VALVE REPLACEMENT Refer to Frame 40 Unplug the electrical lead connection from the gas control valve and disconnect the earth wire Undo the union nut on the outlet of the gas control valve Undo the gas inlet pipe union at the inlet to the gas control valve Loosen the back nut retaining the valve to the bracket and withdraw the valve forwards Fit the new gas control valve ensuring the two sealing washers are in place and reconnect gas and electrical connections Check operation of the boiler Refer to Frames 29 amp 30 40 i combi Installation and Servicing SERVICING 48 DIVERTER VALVE ACTUATOR REPLACEMENT To remove the motor 1 Refer to frame 40 2 Remove the condensate trap siphon Refer to Frame 49 Diverter Valve Motor 3 Remove the wiring connector by inserting a terminal screwdriver to release the latch then withdraw the connecto
23. pump head d T TEE Fit the new pump head Reassemble in reverse order Refill the boiler fe e d eS EP dw M MCN D OS ER MER Demi ae 61 CH WATER PRESSURE SWITCH REPLACEMENT Refer to Frame 40 Drain the boiler Refer to frame 53 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 7 Refill the boiler 8 Check operation of the boiler Refer to Frames 29 amp 30 Refer to Frame 40 Drain the boiler Refer to frame 53 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 i combi Installation and Servicing Check operation of the boiler Refer to Frames 29 amp 30 NE 47 SERVICING SERVICING SERVICING 63 FLOW THERMISTOR REPLACEMENT Refer to Frame 40 Drain down the boiler Refer to Frame 53 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 Reassemble in the reverse order Refill the boiler Check the operation of the boiler R
24. segment Bring the timeswitch into the correct condition by manually turning the programme ring clockwise through a 24 hour cycle M SS VM l EZNE RR e v D Turn the programme ring clockwise until the correct time of day on the ring lines up with the time indicator ON segment 1 KER Mi s 2 au al uT Note The segment dial can be turned when the time controller is operating In case of power failure re adjust the time controller to the correct time of day turning the dial in a 24hr Programme Ring clockwise direction Timer control segments 1 Segment 15 mins Push towards programme ring OFF Push away from programme ring ON Permanent Override By rotating the central switch so that the symbol 1 lines up with the time indicator Y the unit will be permanently ON With the symbol C lining up with the time indicator Y the unit acts as a timeswitch With the symbol 0 lining up with the time indicator Y the unit will be permanently OFF i combi User s 5 POINTS FOR THE BOILER USER Note n line with our current warranty policy we would ask that you check through the Troubleshooting guide to identify any problems external to the boiler prior to requesting a service engineers visit Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit or for any pre arranged visit where access is not gained by the engineer TROUBLE
25. 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 Check the operation of the boiler Refer to Frames 29 amp 30 as 20 T g e v bv hU 38 i combi Installation and Servicing SERVICING 44 IGNITION ELECTRODE REPLACEMENT Refer to Frame 40 Remove the burner Refer to Frame 43 Unplug the ignition lead from the electrode Remove the earth lead from the ignition Ignition Electrode electrode Remove the 2 screws holding the ignition electrode to the combustion chamber 6 Remove the electrode T Fitthe new ignition electrode using the new gasket supplied Check dimensions as shown 8 Reassemble in reverse order 9 Check the operation of the boiler Refer to Frames 29 amp 30 Spark Gap LAN 3 5mm t1 45 FLAME DETECTION ELECTRODE REPLACEMENT 1 Refer to Frame 40 2 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 Remove the electrode Fitthe new flame detection electrode using the new gasket supplied T Reassemble in reverse
26. 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 No measurement of the combustion is necessary DO NOT adjust the air gas ratio valve Having checked That the boiler has 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 Gas Supply 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 Ensure that this inlet pressure can be obtained with all other Gas Pressure gas appliances in the property Test Point working 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 MANU
27. 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 Ceiling Recessed window Zone 2 3G8913a Compartment Installations 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 itis modified for the purpose In both cases details of essential features of c
28. valve to the system Water flow rate l min 17 3 fitted at least 150mm below the make up vessel on the gal min 3 8 return side of the radiators or Temperature Differential eC 20 b Where access to a make up vessel would be difficult by F 36 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 5 Filling Head available for m w g 3 4 system ft w g 11 1 The system may be filled by the following method Mains water supply Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling Hose unions 1 EN CH Return 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 Additional c Check the operation of the safety valve by raising the N SIOpWANg water pressure until the valve lifts This should occur Temporary hose within 0 3bar of the preset lift pressure disconnect after filling Double check valve assembly d
29. view the system pressure gauge and The i combi is a combination boiler providing both central heating and to provide the 100mm clearance required for servicing instantaneous domestic hot water To light the boiler Refer to Frame 1 Safety Current Gas Safety Installation amp Use 1 CHECK THAT THE ELECTRICITY SUPPLY TO BOILER IS Regulations or rules in force OFF In your own interest and that of safety it is the law that this boiler 2 Set the mode knob control A to Off must be installed by a Gas Safe Registered Engineer in accordance 3 Set the Domestic Hot Water temperature control B and with the above regulations In IE the installation must be carried out by a Registered Gas Installer RGII and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Central Heating temperature control C to max 4 Ensure that all hot water taps are turned off 5 Switch ON electricity to the boiler and check that all controls e g timer and room thermostat are ON refer to mechanical timer instructions Page 4 It is essential that the instructions in this booklet are strictly followed 9 Setthe mode knob control to winter f Iii for safe and economical operation of the boiler If there is a central heating demand the boiler will commence the ignition sequence
30. 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 Boilers in writing If in doubt please enquire Any direct connection of a control device not approved by Ideal Boilers could invalidate the certification and the normal appliance warranty It 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 i combi Installation and Servicing LOCATION OF BOILER The boiler 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
31. 0 4 63 C 11g s_ 68C 139 s 73 C 15g s Maximum worl Pressure Sealed Systems bar wi 2 9 gt Minimum Domestic Hot Water Inlet Pressure bar Um Fuse Rating External 3A Internal T4H HRC L250 V Water content Central Heating litre gal 5 a 0 26 Domestic Hot Water litre gal 0 11 347 76 5 Maximum Installation Weight kg Ib 30 85 68 30 95 68 2 31 05 68 4 i Boiler Casing Size Height mm in 700 27 5 Width m in 395 15 5 Depth mm in 285 11 2 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 19D UPON Vata Cental F Table 3 Performance Data Domestic Hot Water ps Maximum DHW Input 24 30 35 Boiler Input Q Nett CV kW in 3 4 9 6 1 Nette dd Btu h Btu h 82 900 103 600 120 900 Gross CV kW ZR 54 67 Gross CV KW 270 33 7 39 3 Gas Consumption m h 2 512 0 500 0 627 Gas Consumption m h 2 512 9 135 3 657 Boiler Input Boiler Output i 24 2 30 3 35 9 Non Condensing 4 8 6 1 82 T 103 300 120 500 70 C Mean Water temp Btu h 82 600 16 500 20 700 Condensing 5 1 6 4 40 C Mean Water temp Btu h 87 400 17 500 21 800 DHW Specific Rate min 11 5 145 16 9 Seasonal efficiency SEDBUK 2005 9196 91 1 gpm 2 5 3 2 3 7 Seasonal efficiency SEDBUK 2009 89 89 88 9 NOx Classification CLASS 5 l min 12
32. 124 130 135 combination boilers INSTALLATION amp SERVICING INSTRUCTIONS For User Guide see reverse of book ORE C UIN 207496 AO3 January 2014 THESE INSTRUCTIONS TO BE RETAINED BY USER i combi Installation and Servicing NOTES FOR THE INSTALLER FOR ANY TECHNICAL QUERIES PLEASE RING THE i COMBI INSTALLER TECHNICAL HELPLINE 01482 498663 NOTE BOILER RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting The boiler will repeat the ignition sequence if a heat demand is present DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level A02 Jan 13 to A03 Jan 14 Page 12 Water Treatment Addition of Adey Professional Heating Solutions Page 29 Item 3 added to Electrical Installation otatement added ref to commissioning process of combustion Page 59 New Page Added Benchmark Commissiong amp Servicing Section Page 60 amp 61 New updated Commissioning Checklist amp Service Record Sheets Page 62 amp 63 New pages added Flowchart for CO Level and Combustion Ratio Check on Commissioning a Condensing Boiler USER GUIDE Page 3 Addition of Weather Compensation paragraph Ideal Boilers reserve the right to vary specification without notice i combi Installation and Servicing 3 GENERAL Table 1 General Data icombi 88 Flue Terminal Diameter mm in 10
33. 90 Note f the boiler is installed in a garage it may be necessary to fit a pipe thermostat preferably on the return pipework Earths are not shown for clarity but must never be omitted i combi Installation and Servicing 2 INSTALLATION INSTALLATION ye1S ddng SOJ4 ule Hl DJ q q 27 WIRING DIAGRAM NOIIwN I IN LSINI SAIC JOPA JojeJouoc x 1eds q HL Lal a Hlad Joy9UUOD SOIAIOS is uouws NEN umo MO J Jaye T 3 d JO q nier elele eel ss eje visio x l1 JOJOIA A oDueJo JO Aai H uooJ6 Mo a 6 A OWUM M MOJA yuid d p l J UMOJG Jq y9ejq yq eniqg q A3M euiquJn MO 4 J9JeAM i combi Installation and Servicing 28 INSTALLATION 28 COMMISSIONING AND TESTING 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 should be inspected and tested for tightness and purged in competent person 2 ALWAYS carry out the preliminary electrical system checks accordance with the recommendations of BS 6891 In IE refer to 1S 813 2002 i e earth continuity polarity resistance to earth and short circuit using a suitable test meter 3 After wiring the boiler all grommets in the bottom panel 2 Purge air from the gas installation by the approved methods only MUST be in place
34. 98 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 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 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 T
35. DHW connections i 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 D Pack contains 1 metre length of flue pipe Functional length 950mm 1 support bracket and instructions 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 condensate drain It is 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 m
36. EL X100 inhibitors and associated water treatment products which must be used in accordance with the manufacturers instructions Notes 1 Itis most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers instructions 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 In hard water areas treatment to prevent lime scale may be necessary however the use of artificially softened water is NOT permitted Under no circumstances should the boiler be fired before the system has been thoroughly flushed 12 These valves should now be left as set 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 thermostat 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 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 Boilers recommend the use of Fernox Quantomat Sentinel Combiguard and Calmag CalPh
37. ER CONTROLS BURNER Legend Mode Control Knob DHW Preheat Control Knob CH Control Knob Boiler Status Burner on Indication Pre Heat on off Indication Programmer Pressure Gauge Condensate Drain A B C D E F G H J i combi User s 3 Loss of system water pressure The gauge H 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 then a water leak may be indicated In this event re pressurise the boiler 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 INDICATED BY F1 LOW WATER PRESSURE THE BOILER WILL NOT OPERATE IF THE PRESSURE HAS REDUCED TO LESS THAN 0 3 BAR UNDER THIS CONDITION 3G9933 PRESSURE GAUGE 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 If y
38. FACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE i combi Installation and Servicing 29 INSTALLATION INSTALLATION INSTALLATION 29 INITIAL LIGHTING Legend Mode Control Knob DHW Preheat Control CH Control Boiler Status Burner on Indication Pre Heat on off Indication CH Flow Isolating Valve Pressure Gauge Gas Inlet Pressure Test Point Gas Service Cock DHW Inlet valve CH Return Isolating Valve DHW Outlet Z Sr Wt cpm oou gt 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 upper and lower front panels 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 control knob A is off Check that the gas service cock K is OPEN Slacken the screw in the inlet pressure test point J and connect a gas pressure gauge via a flexible tube 8 Switch electricity supply ON amp check mechanical timer is in Permanently On position NOs CENTRAL HEATING 9 Set the
39. Fan FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 52 i combi Installation and Servicing FAULT FINDING 75 ALTERNATING F AND 4 FLOW THERMISTOR FAULT Check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 Ohms At 60 C expect 2 400 2 600 Ohms At85 C expect 1 000 1 100 Ohms Fit a new Thermistor Is there continuity between the PCB and Is the Thermistor value correct the Thermistor Check and replace Replace PCB wiring as necessary 76 ALTERNATING F AND 5 RETURN THERMISTOR FAULT Check the resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 Ohms At 60 C expect 2 400 2 600 Ohms At85 C expect 1 000 1 100 Ohms Fit a new Thermistor Is there continuity between the PCB and Is the Thermistor value correct the Thermistor NO YES Check and replace Replace PCB wiring as necessary 0 Z A Z LL J d LL Q Z a LL 3 d LL 0 Z A Z LL d LL 0 Z A LL d LL 0 Z A LL d LL i combi Installation and Servicing 59 FAULT FINDING 77 ALTERNATING F AND 7 LOW MAINS VOLTAGE Contact electricity provider 78 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 79 AL
40. Frame 64 Using a suitable screwdriver positioned between the air vent dust cap and the plastic protrusion turn the air vent carefully anti clockwise to disengage and lift to remove VANDI IM Fit the new air vent and ensure dust cap is open n Re assemble in reverse order ensuring the return thermistor is replaced 5 t bh 4 Refill the boiler Check operation of the boiler Refer to Frames 29 amp 30 i combi Installation and Servicing 45 SERVICING SERVICING SERVICING 58 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT To remove the valve body assembly 1 Refer to Frame 40 Drain the boiler Refer to frame 53 Remove the condensate trap siphon Refer to Frame 49 Remove the electrical plug Refer to Frame 48 ae oS I9 Place a flat bladed screwdriver in the diverter valve motor body slot provided and ease out the motor Refer to Frame 48 6 Remove the return thermistor electrical connection Refer to Frame 64 7 Remove the pump electrical connection Refer to Frame 60 no 3 8 Remove DHW Turbine electrical connection Refer to Frame 54 no 3 9 Remove the DHW plate heat exchanger note orientation Refer to Frame 59 10 Undo the safety valve pipe compression fitting See No 5 Frame 56 11 Remove the compression fitting above the pump and rotate the pipe 12 If required remove expansion vessel connection hose Refer to Frame 66 no 8 13 Remove the DHW i
41. It is a universal fitting to allow use of different brands of pipework i combi Installation and Servicing 1 GENERAL 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 If a 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 BOILER DIMENSIONS 10 285 terminal Frontclearance W The minimum front clearance when built in to a cupboard is 5mm 435 65 285985 606 75 564 375 Yr from the cupboard door but 450mm overall clearance is still required with the cupboard door open to
42. ND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk 62 FLOWCHART 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 ESPECIALLY 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 manufa
43. O level less Allow sufficient time for combustion to stabilise than 350ppm AND CO CO2 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 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 i combi Installation and Servicing 63 Ideal Boilers provides after sales assistance and Technical advice for i combi boilers Ideal Technical Helpline 01482 498663 Ideal Boilers P O Box 103 National Avenue Kingston Upon Hull HU5 4JN penchmar THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS We reserve the right to chan
44. ODE ON BOILER DESCRIPTION burner The boiler is in standby mode awaiting either a central heating call or hot water demand Li purher The boiler has a call for central heating but the appliance has reached the desired E temperature set on the boiler The boiler has a call for hot water but the appliance has reached the desired temperature set on the boiler Li burner The boiler is operating in central heating mode burner The boiler is operating in hot water mode f burner The boiler is operating in pre heat mode burner The boiler is operating in frost mode continued i combi User s T FAULT CODES DISPLAY CODE ON BOILER DESCRIPTION ACTION burner burner Outside Sensor Failure Reset the appliance if the boiler fails to operate then please contact Ideal Boilers if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII PETER BUTWET Low Mains Voltage Contact a qualified electrician or your electricity provider Unconfigured PCB Unconfigured PCB Please contact Ideal Boilers if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII BUTTER Same 5 Boiler Resets in 15 minutes 1 Turn power off and on at the fused spur 2 f the boiler fails to operate please contact Ideal Boilers if under warranty or alternatively a Gas Safe R
45. SHOOTING NO HOT WATER Check the mains switch fused Check the mains switch fused spur is turned on and ensure spur is turned on and ensure Check the fused spur is turned switch mode control knob A is switch mode control knob A is on and ensure switch mode in the summer or winter position in the winter position control knob A is in the winter position NO HOT WATER OR CENTRAL HEATING NO CENTRAL HEATING Check the timer is in an ON Is water coming out of the hot NO position and the room thermostat Does the boiler have a display water tap when turned on is turned up showing on the front control panel YES Does the boiler operate and provide central heating See boiler Fault Codes section If 0 is displayed then contact Ideal Boilers if your appliance is under warranty or a Gas Safe Registered Engineer Check the time settings on the in IE a Registered Gas Installer programmer are as you require Contact a Gas Safe Registered RGII if out of warranty and adjust if necessary Engineer or in IE a Registered Gas Installer RGII See boiler Operation Modes and Fault Codes section See boiler Operation Modes and Fault Codes section If 0 is displayed then contact a Gas Safe Registered Engineer or in IE a Contact a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII Registered Gas Installer RGII 6 i combi User s OPERATION MODES DISPLAY C
46. TERNATING C AND 0 BCC ACTIVATION FAULT Reset the boiler RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting 80 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 c0 being shown reset 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 reset Is c2 still shown m Replace PCB RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting O Z A LL 1 d LL Z A LL z d LL O Z a LL d LL 0 Z A LL z d LL O Z a LL d Iu 54 i combi Installation and Servicing FAULT FINDING 81 ALTERNATING F AND 7 LOW MAINS VOLTAGE Reset Boiler RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting 82 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
47. Vac 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 Heian must be suitable for mains voltage l l l l Connection must be made in a way that allows 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 Wiring external to the boiler MUST be in accordance with the current I E E BS 7671 Wiring Regulations and any local regulations 25 INTERNAL 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 Swing the lower front panel down Refer to Frame 39 Route cable through the grommet and cable clamp and tighten to provide cord anchorage 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 retain with the screws previously removed The boiler comes pre fitted
48. aled 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 1 Fully open all DHW taps and ensure that water flows freely from the The safety valve connection located at the bottom right hand Note side of the boiler comprises a 15mm diameter stub pipe The DHW flow rate is automatically regulated to a max 24 9 9 I m 2 2 N B Use a compression fitting when connecting to the safety 30 124 a 2 pe valve drain pipe to facilitate replacement of the safety valve if ARE 145 Vm 3 2 gpm required l 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 DHW Outlet Gas Supply Pressure Relief Valve Drain Connection 15mm elbow or fittings not supplied Pressure Relief Valve Gas Pressure Drain Pipe Test Point 26 Note that all isolation handles are shown in the open postion DHW Inlet CH Return Safety Drain Handle Valve Black Handle i combi Installation and Servicing INSTALLATION 24 ELECTRICAL CONNECTIONS WARNING This appliance MUST be earthed Wiring should be 3 core PVC insulated cable not less than A mains supply of 230
49. allow for servicing Bottom clearance Bottom clearance after installation can be reduced to 5mm This must be obtained with an easily removable panel to CH FLOW 4 GAS INLET DHW INLET 4 PRY enable the consumer to view the system pressure gauge and to provide the 100mm clearance required for servicing COND DRAIN CH RETURN 4 DHW OUTLET Min Top Clearance A 165mm Rear flue type Min Top Clearance A SIDE Fluetype 197 193 219 245 271 297 323 349 375 401 Distance from Horizontal mm required to achieve 1 5deg fall to the appliance 26 52 78 104 130 156 182 208 234 mm 1 1 5 degree Top Clearance a a 6 0 Max 35kW 7 0 8 0 Max 30kW 305 9 0 Max 24kW Distance in metres from edge of turret to side wall Dimension H 1 Dimension H must remain inside the Maximum flue length requirement for the designated output of the applaince been installed 2 For flue lengths requiring D pack extentions the flue must incline by 26mm per 1 Metre of flue length No flue length greater that the maximum flue length shown above should be exceeded i combi Installation and Servicing GENERAL 2 SYSTEM REQUIREMENTS Central Heating Notes a 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 Saf
50. 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 i J Q i J L 5 Remove all burrs and place a light chamfer on the outer edge to aid assembly i combi Installation and Servicing INSTALLATION 16 INSTALLING THE FLUE FITTING FLUE THROUGH THE WALL 14m Wall Thickness Measure wall thickness and add 14mm 2 Measure from the outer terminal lip towards the end of outer flue place a small location mark at the dimension acquired at point 1 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 N Note If the location mark is not visible then the flue is not pulled back far e
51. at the gas meter with no other appliance in use Refer to Tables 2 amp 3 for gas rates Close the DHW tap The burner should go off and the pump continue to run i combi Installation and Servicing 5 Set the central heating external controls to OFF The burner should go off and the pump continue to run for four minutes The display should read m Uu Check the correct operation of the timer and all other system controls Operate each control separately and check that the main burner responds 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 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 With the system still hot turn off the gas water and electricity supplies to the boiler and drain down to complete the flushing process 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 5 clear all air locks and again check for water soundness 5 Reset the system initial pressure to the design requirement 6 Balance the system Refer to Frame 3 T Check the condensate drain for leaks and check that i
52. ck the boiler 1 Remove outer sleeve 2 Remove top end support 3 Stand up the boiler with aid of base tray 4 Remove base tray ensuring bottom end support is still in place Pack A Contents A Boiler B Hardware Bag C Wall Mounting Plate D These Installation Users Instructions E Wall Mounting Template located on internal protective packaging F Turret Clamp G Boiler Guarantee amp Registration Pack HARDWARE PACK CONTENTS Gas Valve Pack Gas Cock Valve DHW Valve Return OONDAARWN gt 11 12 Turret Clamp Screw Washer DHW Washer CH 10 Screw Valve Flow Pipe DHW Outlet Nut G 1 2 Washer Gas Wall Plug E e TT i 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 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 Term
53. ckwise and when the display shows turn the knob fully anti clockwise IMMEDIATELY Finally move the knob into the required position Standby Summer or Winter 11 Check operation of the boiler Refer to Frames 29 amp 30 ANISS j 7y 1 E S444 4 7274 a whos n rte FE Ths pr bea gt me p s Sie 4 f 22 C ur aw i combi Installation and Servicing SERVICING 51 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 50 3 Unclip the PCB and lift to clear the mounting posts 4 Fit the new PCB ensuring the 3 potentiometer spindles line up with the control knobs which must be in a vertical position 5 Reassemble in reverse order 6 Check operation of the boiler Refer to Frames 29 amp 30 PCB iiti Potentiometer spindle Control Knobs to be in vertical position p A x OFF A aise E STATUS BURNER RESET MIN PRE MIN MAX PREHEAT MODE Da m 52 REPLACING THE MECHANICAL TIMER Refer to Frame 40 owing the boiler lower front panel into the service position Refer to Frame 34 Remove the 4 fixing screws Disconnect the 4 push on connectors Remove programmer Re fit 4 push on connectors to new programmer Fit programmer and retain with 4 screws previously removed Replace the lower
54. cturer s instructions KEY CO carbon monoxide CO carbon dioxide O2 oxygen Combustion Ratio The CO reading measured in ppm divided by the CO reading first converted to ppm ppm parts per million GS I amp UJR 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 9 Will be shown on the display and the boiler output will be reduced to minimum The boiler will remain at minimum rate for 5 minutes before reverting to normal operation i combi Installation and Servicing 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 readings to stabilise set boiler to operate at maximum rate full load condition Allow sufficient Note Where no air inlet test point is provided then a flue integrity check with time for combustion to stabilise 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 duri
55. customer 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 register 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 Company name SERVICE 03 00m Telephone No Company name SERVICE 04 Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 05 Engineer name Engineer name Company name Company name Telephone No
56. cy of servicing will depend upon the installation condition and usage but should be carried out at least annually It is the law that any service work must be carried out by a Gas Safe Registered Engineer In IE service work must be carried out by a Registered Gas Installer RGII INSPECTION 1 Light the boiler and carry out a pre service check noting any operational faults 2 Check the flue terminal and terminal guard if fitted is undamaged and clear of any obstruction 3 Check all water and gas joints for signs of leakage Remake any suspect joints ensuring a gas tightness check is carried out if applicable and the water system is correctly refilled vented and re pressurised CLEANING PROCEDURE Note In order to carry out either servicing or replacement of components the boiler upper and lower front panels must be removed Refer to Frame 34 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 95 4 Check that the flue terminal is unobstructed and that the flue system is sealed correctly ALSO IF THE DHW FLOW RATE IS IN QUESTION 5 Check the DHW filter for blockage Refer to Frame 62 The cleaning procedures are covered more fully in Frames 34 39 and MUST be carried out in sequence IMPORTANT 6 After completing the servicing or exchange of components always t
57. d by isolation of the mains electricity supply i combi Installation and Servicing INSTALLATION 30 GENERAL CHECKS Make the following checks for correct operation in DOMESTIC HOT WATER DHW MODE 1 Fully open all DHW taps in turn and ensure that water flows freely from them The display should read d then d when the burner lights Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate N We This is factory set to give a DHW temperature rise of approximately 35 C at the flow rate stated on page 6 under operation Reduce the DHW draw off rate to about 3 l min 0 7gpm and check that the boiler modulates to deliver DHW at approximately 64 C Close the DHW tap and check that the main burner extinguishes The pump should overrun for 60 seconds and the display sequence should read m Uu When the pump stops the display sequence should read m Uu Note On systems in excess of 2 bar inlet pressure a water 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 after first satisfying DHW preheat if necessary Dp X Fully open a DHW tap and check that hot water is delivered The display should read d X le IN Gas Rate Check the boiler gas rate when the boiler is at full DHW output Check
58. d 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 1 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 6 From an internal or external corner or to a 25mm 1 boundary along side the terminal BS5440 1 2008 300mm 12 7 Above adjacent ground roof or balcony level 300mm 12 8 From a surface or a boundary facing the terminal 600mm 24 9 From a terminal facing a terminal 1 200mm 48 10 From an opening in a car port e g door or window into dwelling 1 200mm 48 11 Vertically from a terminal on the same wall 1 500mm 60 12 Horizontally from a terminal on the wall 300mm 12 Vertical Terminals 13 Above the roof pitch with roof slope of all angles Above flat roof 300mm 12 300mm 12 14 From a single wall face 300mm 12 From corner walls 300mm 12 15 Below velux window 2000mm 79 16
59. e 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 FILLING 1 Connect the CH flow service valve provided in the IMPORTANT when filling hardware pack to the threaded boss connection provided at the lower rear of the boiler A Ensure the dust cap on air vent located at the rear of the pump 2 Connect the CH return valve black handle 3 If connecting the boiler to heating loads in excess of B 60 000 Btu h 17 5kW connecting flow and return heating systems pipework must be sized in 28mm diameter at the point of pipe connection to the chamber is slightly unscrewed When filling there may be a slight water leak from the air vent therefore electrical connections should be l i protected boiler tails Use 22mm x 28mm pipe adaptors as CH appropriate i Dust C 1 Ensure that the CH isolating Epa WATER CONNECTIONS DHW handles are open 1 Fit the DHW inlet service valve blue handle to the 2 Fill and vent the system Refer to threaded boss connection ensuring the seal provided is Frame 2 for setting pressure correctly located DHW 2 Fit the DHW outlet pipe tail to DHW outlet connection ensuring the seal provided is correctly located 2 Close all taps GAS CONNECTION IMPORTANT The gas service cock is se
60. e control over a living dining area or hallway having a heating requirement of at least 1096 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 I 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 standard 21 5mm 3 4 overflow pipe
61. e 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 0 Z A LL lt LL Z A LL d LL 0 Z A LL d LL 0 Z A LL z d LL O Z a LL d LL 56 i 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 Boilers Failure to do so could affect safety or performance of this appliance Our Parts team are also available to help with your 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 i combi Installation and Servicing 57 Code Of 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
62. echanical 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 removal 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 Itis 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 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 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 requir
63. eck wiring connection from gas valve to PCB for continuity If the wiring is Is 215Vdc supply available at the Gas Valve See note Check the detection electrode OK then replace the PCB and associated harness for Unplug gas valve Is resistance NO Check if the condensate pipe is between outside pins 4KQ 2 39 Replace Gas Valve blocked continuity visual condition and position Refer to Frame 45 Check flue is installed correctly YES Replace as necessary Check spark generator and associated harness for continuity Replace Spark and visual condition Refer to Generator and harness Frame 46 Are these functioning as necessary correctly Replace Ignition Electrode and associated harness as necessary Check siphon and condensate Check ignition electrode and drain pipe work for blockage and associated harness for continuity rectify if necessary Boiler now visual condition and position working OK Refer to Frame 44 Are these functioning correctly Replace Gas Valve 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 FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required se
64. ed 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 24 9 9 I min at 35 C temperature rise 30 12 4 l min at 35 C temperature rise 35 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 precautions should be considered Grip the boiler at the base Be physically capable Use personal protective equipment as approp
65. 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 10mm 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 terminal is upper most Adjust to Length A 44mm from terminal lip Drill Hole Adhere sealing tape 4 Drilla 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
66. efer to Frames 29 amp 30 64 RETURN THERMISTOR REPLACEMENT DANILA MIIN Refer to Frame 40 Drain the boiler Refer to Frame 53 Unplug the electrical connection Using a suitable tool pull out the retaining clip Carefully pull the thermistor upwards to remove Fit the new thermistor and re assemble in reverse order Refill the boiler Check the operation of the boiler Refer to Frames 29 amp 30 a a E SPS 65 HEAT ENGINE RENEWAL Refer also to Frame 5 Boiler Exploded View IMPORTANT Before starting the removal procedure protect the Refer to Frame 40 gas and electrical controls with a waterproof sheet or plastic bag Drain the boiler Refer to Frame 53 Remove the fan venturi assembly and place on one side Refer to Frame 41 Remove bumerandplacsonone cide alert Frame d 17 Ensure the trap siphon is filled with water Refer to Frame 49 Remove the ignition and detection electrodes Refer to sea UNe end Frames 44 amp 45 19 Check operation of the boiler Refer to Frames 29 amp 30 Remove the spark generator Refer to Frame 46 ftm a Remove the gas valve Refer to Frame 47 Remove the expansion vessel Refer to Frame 66 Remove the flow thermistor Refer to Frame 63 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 swing the pipe and pull down to remove from heat exc
67. egistered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner False Flame Lockout Reset the appliance if the boiler fails to operate then please contact Ideal Boilers 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 BCC Activation Fault Reset the appliance if the boiler fails to operate then please contact Ideal Boilers 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 BCC Fault burner Low Water Pressure Check system pressure is between 1 amp 1 5bar on the pressure gauge If the boiler fails to operate then please contact Ideal Boilers 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 Temperature Overheat 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 Boilers if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period
68. ement of the appliance it is to be fitted to 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 30 kW Appliances Total Maximum 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 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 Std Metric Brick 102 5mm wide B Pack Flue Type Minimum permissible Wall Thickness Maximum permissible Wall Thickness Rear Flue Rear Flue Std Off Side Flue Rear Flue Rear Flue Std Off Side Flue 600mm long B Pack 1000mm long B Pack 1000mm long B Pack cut 75mm 6 4 716 716 ie 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 56 384 641 5 38 4
69. en 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 i ul J Q i J L 18 i 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 TABLE 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 ooo qe 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
70. er 14 Check operation of the boiler Refer to Frames 29 amp 30 67 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 self adhesive seal ensuring all joints provide an air tight seal 5 Reassemble in reverse order 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 i combi Installation and Servicing Recharge Point 49 SERVICING FAULT FINDING 68 ALTERNATING L AND 1 FLOW TEMPERATURE OVERHEAT LOCKOUT Is the Boiler and CH System filled with water and all Fill and vent the system and open all isolation and radiator valves open isolation valves then reset boiler Is the Flow Return Differential across the Boiler in Check that the Pump is rotating freely Is excess of 30 C the Differential now below 20 C Check the Flow and Return Thermistors Refer to Replace the Pump pd Po Frame od T6 then reset boiler TOU RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting 69 ALTERNATING L AND 2 IGNITION LOCKOUT If the boiler is reset does the boiler Is the Gas Pressure available at Check gas supply and ignite for a short time and then the Boiler Inlet 218 mbar rectify fault extinguish Ch
71. er been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate OR Burner operating pressure at maximum rate OR Gas inlet pressure at maximum rate Cold water inlet temperature 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 CO2 At min rate where possible CO ppm CO CO2 Record the following The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in accordance with 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 enchmoern Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the
72. essel should be fitted between the device and the boiler in the cold inlet pipe Cold water rising main and pipework on exposed areas need to be suitably lagged to prevent freezing Note DHW Expansion Vessel Kit availabe from Ideal Boilers 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 4 WATER TREATMENT CENTRAL HEATING The range of boilers have an ALUMINIUM alloy heat exchanger IMPORTANT The application of any other treatment to this product may render the guarantee of i combi Invalid Ideal Boilers recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems If water treatment is used Ideal Boilers recommend only the use of Scalemaster Gold 100 FERNOX MB 1 ADEY MC1 or SENTIN
73. est for gas tightness 7 When work is complete the front panels MUST be correctly refitted ensuring that a good seal is made Do NOT OPERATE the boiler if the upper 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 reassembling 9 Check the gas consumption 10 Check combustion by connecting the flue gas analyser to the flue 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 Boilers 11 Complete the service section in the Benchmark Commissioning Checklist i combi Installation and Servicing GENERAL Please Note During routine servicing and after any maintenance or change of part of the combustion circuit the following must be checked The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals The operational working gas inlet pressure at maximum rate The gas rate The combustion performance COMPETENCE TO CARRY OUT THE CHECK OF COMBUSTION PERFORMANCE Please Note BS 6798 2009 Specification for installation and maintenance of gas fired boilers of rated input not exceeding 70kW net advises that The perso
74. et procedure 10 After installation and commissioning please complete THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC th e HEATING AND HOT WATER SYSTEMS Commissioning Checklist before handover to the customer For IE its is necessary to complete a Declaration of Conformity to indicate compliance to I S 813 2002 IMPORTANT 11 A comprehensive service should be carried out ANNUALLY Stress the importance of regular servicing by a Gas Safe Registered Engineer In IE servicing work must be carried out by a Registered Gas Installer RGII 12 Inform the householder of the guarantee registration found within the envelope pack and the requirement to register it to receive the full benefit of the warranty i 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 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 frequen
75. ety valve setting bar b Antifreeze fluid corrosion and scale inhibitor fluids suitable for Vessel charge pressure bar 0 5 to 0 75 use with boilers having aluminium heat exchangers may be used System pre charge pressure bar in the central heating system System volume Expansion vessel General litres volume litres 1 The installation must comply with all relevant national and local 25 regulations 50 2 The installation should be designed to work with flow 75 temperatures of up to 86 C 100 3 All components of the system must be suitable for a working 125 pressure of 3 bar and temperature of 110 C Extra care should 150 be taken in making all connections so that the risk of leakage 175 is minimised 190 The following components are incorporated within the 200 appliance 250 a Circulating pump 300 b Safety valve with a non adjustable preset lift pressure of For other system volumes 3 bar multiply by the factor across 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 4 Make up Water Provision must be made for replacing water loss from the system either Water Flow Rate and Pressure Loss a From a manually filled make up vessel with a readily Max CH Output kW 242 visible water level The vessel should be mounted at Btu h 82 600 least 150mm above the highest point of the system and be connected through a non return
76. facturers 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 enchmar 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 i combi Installation and Servicing 59 GAS BOILER SYSTEM COMMISSIONING 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
77. front panel Check operation of the boiler Refer to Frames 29 amp 30 Note To program refer to user guide at rear of this book i combi Installation and Servicing 43 SERVICING SERVICING SERVICING 53 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 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 amp 30 DOMESTIC HOT WATER CIRCUIT 54 DHW FLOW TURBINE SENSOR REPLACEMENT Refer to Frame 40 Close the DHW water isolating valve on the boiler inlet Circuit Drain CH Return 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 water will be experienced during replacement of components pressurise as appropriate Check operation of the boiler Refer to Frames 29 amp 30 Refer to Frame 40 Drain the DHW system Refer to Frame 53 Pull off the electrical connection 4 Using a suitable tool lift and remove the retaining clip
78. ge the specifications without prior notice Consumers statutory rights are not affected 124 130 135 combination boilers USER GUIDE For Installation Guide see reverse of book DNE ANI G EN I BIE THESE INSTRUCTIONS TO BE RETAINED BY USER gt m M UM CENE ee a a ee ee ee VEM ee EM ee ee i FOR ANY QUERIES PLEASE RING THE i i COMBI CONSUMER HELPLINE 01482 498660 NOTE BOILER RESET PROCEDURE To reset boiler turn mode control knob to reset position and immediately turn knob back to required setting l G m e e e e ees uX XX XX XX uA X EO ees ees SS RS GRO RR RS RS es RS S RS S S eee SN S eee m mm Introduction Minimum Clearances The i combi is a wall mounted room sealed condensing combination Clearances of 165mm 6 1 2 above 100mm 4 below boiler featuring full sequence automatic spark ignition and fan 2 5mm 1 8 at the sides and 450mm 17 3 4 at the front of assisted combustion the boiler casing must be allowed for servicing Due to the high efficiency of the boiler condensate is produced from Bottom clearance the flue gases and this is drained to a suitable disposal point through Bottom clearance after installation can be reduced to 5mm a plastic waste pipe at the base of the boiler A condensate plume This must be obtained with an easily removable panel to will also be visible at the flue terminal enable the consumer to
79. hanger Pull out the flow pipe spring clip pull the pipe down to remove from heat exchanger Remove the condensate rubber pipe from the sump Remove the two heat exchanger fixing screws To remove the Heat exchanger slide out of location bracket Reassemble in reverse order ensuring the heat exchanger LH retaining bracket is correctly positioned Replace any new o rings supplied with new heat exchanger and replacing gaskets or seals if any sign of damage is evident When replacing the spring clips located on the return pipe connection ensure clip is oriented to correctly match connecting pipe diameters 48 i combi Installation and Servicing SERVICING 66 EXPANSION VESSEL RECHARGING amp REPLACEMENT RECHARGING 1 Refer to Frame 40 Remove the charge point cover Recharge the tank pressure to 0 75 bar 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 53 Unscrew the union nut 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 taking care not to damage the adjacent wiring harness 11 Fit the new expansion vessel 12 Reassemble in reverse order 13 Refill the boil
80. he 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 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
81. inal Wall Seal D D Cutting Aid A C Pack B Contents Telescopic A Telescopic Flue Terminal B Flue Turret C Rubber Terminal Wall Seal D Screw Sealing Tape C l FRONT PANEL REMOVAL Lift the lower front panel access panel 3 Remove the two upper front panel fixing screws lift the panel and remove Unscrew the two fixing screws close the access panel to retain the screws and hinge the lower front panel down into the service position i combi Installation and Servicing 15 INSTALLATION INSTALLATION 9 WALL MOUNTING TEMPLATE The wall mounting template is located on the internal protective packaging The template shows the position of the fixing and rear flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled 1 Tape template into the required position ensuring its squareness by hanging a plumbline as shown 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 group 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 i
82. ing Remove the extended nut on the fan mounting bracket 4 Lift off fan and venturi assembly 5 Inspect the injector for blockage or damage 6 Inspect fan outlet sealing gasket and replace if necessary Injector 34 i combi Installation and Servicing SERVICING 36 BURNER REMOVAL AND CLEANING 1 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 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 Note Ensure condensate trap is fully drained before removal 1 Pull off the rubber pipe at the siphon 2 Disconnect the condensate drain pipe 3 4 5 Turn the siphon clockwise to disengage and lift to remove Flush out all deposits with clean water Reassemble in reverse order Note When reassembling ensure the
83. 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 neon of Work Be competent and qualified to undertake the work required 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 Hegulations 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 p
84. lue duct relative to the outer duct on longer than the air duct to ensure engagement in the final flue duct seal li J Q li J L G 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 i combi Installation and Servicing 23 INSTALLATION INSTALLATION 21 CONDENSATE DRAIN Condensate Condensate Drain 9498 This appliance is fitted with a siphonic 75mm condensate trap system that requires filling before operating the appliance for the 1st time or after maintenance 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 BS67
85. mmediately turn knob back to required setting The boiler will repeat the ignition sequence If the boiler still fails to light e Children should be supervised to ensure that they do not play with consult a Gas Safe Registered Engineer or in IE a Registered the appliance Gas Installer RGII In cases of repeated or continuous shutdown a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII should be called to investigate and rectify the condition causing this and carry out an operational test Only the manufacturers original parts should be used for replacement 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 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 commissioning of fy central heating systems in the UK and to encourage the regular servicing of all central heating J enc mar systems to ensure safety and efficiency THE BENCHMARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 2 i combi User s Operation Weather Compensation Winter conditions i e CH and DHW required When
86. n carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements and Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS7967 Parts 1 to 4 Air Sampl Point Ensure all caps and seals are re fitted after use 33 SERVICING SERVICING SERVICING 34 BOILER UPPER amp LOWER FRONT PANEL REMOVAL REPLACEMENT REMOVAL REPLACEMENT Lift the lower front panel access panel 4 Unscrew the two fixing screws close the access panel to 9 retain the two screws and hinge the lower front panel down into the service position Remove the two upper front panel fixing screws lift the panel and remove Hook the upper panel onto the top retaining clips Retain the upper panel with the two fixing screws previously removed ensuring a good seal is made Swing the lower front panel up and retain with the two Screws Close the lower front panel access panel aan rr 35 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING Disconnect the electrical leads from the fan Undo the gas pipe union connection to the injector hous
87. nd 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 I 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 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
88. ng 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 must be mixing Further investigation of the flue is therefore required Check that flue components are assembled fixed and supported as per instructions Check that flue and flue terminal are not obstructed O2 more than or equal to 20 6 OR CO2 ess than or equal to Check CO level and Combustion Ratio Oz more than or at Maximum Gas Rate equal to 20 6 OR CO With boiler still set at maximum gas rate less than or equal to insert analyser probe into flue gas sampling point Allow readings to stabilise 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 CO CO2 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 C
89. njury 1 Cut the flue hole preferably with a 5 core boring tool ensuring that the hole is square to the wall Both wall faces immediately around the cut hole should be flat Drill 2 mounting holes marked from template with a 7 5mm 8mm masonry drill and insert the plastic plugs provided for the wall mounting plate 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 11 FITTING THE WALL MOUNTING PLATE Screw the wall mounting plate to the wall using 2 wall plugs previously fitted with the 2 screws provided Choose one of the 2 sets of slots in left and right bank Ensuring that at least one of the screws is fitted into a top slot and the mounting bracket is level Example of fixing 3G9948 ZO Extended centre line 155 200 A See Diagram in Frame 1 B c M Rear flue only Side flue only 5 diameter hole 5 diameter hole P Section through wall Note Check all of the hole positions before drilling 12 MOUNTING THE BOILER NOTE ENSURE BOTTOM END SUPPORT IS LEFT IN PLACE Lift the boiler onto the wall mounting plate refer to the Introduction section for safe handling advice locating it over the two tabs Remove the bottom end support packaging Ensure the plastic plugs are removed from both the CH and
90. nlet and CH return connection situated beneath the boiler 14 Remove the three torx head screws fixing the return manifold to the boiler sheet steel base 15 Lift the manifold assembly and remove from boiler 16 Twist and remove the DHW manifold 17 Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly 18 Fit the new diverter valve body assemble and replace the two fixing screws 19 Refit the DHW manifold fit the assembly back to the boiler and reassemble in reverse order 19 Refill the boiler Check operation of the boiler Refer to Frames 29 amp 30 59 DHW PLATE HEAT EXCHANGER REPLACEMENT Refer to Frame 40 Drain the boiler Refer to frame 53 Remove the condensate siphon Refer to Frame 49 Remove the two plate heat exchanger fixing screws Slide the plate heat exchanger to the left and push the plate back to disengage Remove the plate heat exchanger 7 Fit the new plate heat exchanger using the new O rings provided and re assemble in reverse order 8 Refill the boiler 9 Check operation of the boiler Refer to Frames 29 amp 30 46 i combi Installation and Servicing SERVICING 60 PUMP HEAD REPLACEMENT Refer to Frame 40 Drain the boiler Refer to Frame 53 Disconnect the electrical lead from the pump Remove the 4 Allen screws retaining the pump head Onun AGAN Type UP015 60 CESA03 P N 96878772 Remove the
91. nough 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 Mark 1 Flush with inter wall 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 Jess than 50 of the length of the flue is internal the flue should be fitted from outside Correctly sealed wall 5 Cored drilled 93 hole Wall Seal Lip Fig 1 shown te Terminal Lip Terminal Ensure lip of wall seal is positioned over step on plastic nose of flue terminal note seal is cut away for clarity FITTING THE TURRET 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
92. ntinuity Is 215Vdc supply available at the Check wiring from gas visual condition and position Refer Gas Valve while the flame is on valve to PCB for continuity to Frame 45 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 NO associated harness for continuity Replace Spark Generator and visual condition Refer to and Harness as necessary Check ignition electrode and Frame 46 Are these functioning associated harness for continuity correctly visual condition and position Refer to Frame 44 Are these dh A NEHOMA COREENI Replace Ignition Electrode and associated harness as necessary Check siphon and condensate drain pipe NO work for blockage and rectify if necessary 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 74 ALTERNATING F AND 3 FAN FAULT Does the wiring from the Fan to the PCB have l 7 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
93. ontrols to 64 C system should be drained maximum at low draw off rate adjustable via the DHW temperature control B If the system includes a frost thermostat then during cold weather the boiler should be turned OFF at the time switch if Due to system variations and seasonal temperature fluctuations fitted ONLY The mains supply should be left switched ON with DHW flow rates temperature rise will vary requiring adjustment at the boiler thermostat left in the normal running position the draw off tap the lower the rate the higher the temperature and vice versa Boiler Overheat Protection The boiler controls will shut down the boiler in the event of Approx flow temperatures for the boiler thermostat settings are i i l overheating Should this occur a fault code will be displayed Knob Setting Flow Temperature Betertodactteham 40 C 104 F 64 C 147 F Flame Failure Should this occur a fault code F will be displayed Refer to fault chart Central Heating The boiler controls the central heating radiator temperature to a maximum of 80 C adjustable via the CH temperature control C The boiler is a high efficiency combination boiler which is most efficient when operating in condensing mode The boiler will operate in this mode if the CH temperature control C is set to the e position economy mode This control should be set l to maximum for very cold periods continued 1 BOIL
94. operty 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 3as Cock Pressure Drop a 2 E 2 2 T 2 3 un un v a 00 50 100 150 200 25 0 30 0 heat input to boiler KW 359 0 400 45 0 IMPORTANT Installation pipes must be fitted in accordance with BS 6891 In IE refer to 1S 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 l S 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 lt is important that the position of the terminal allows the free passage of ai
95. os 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 i combi Installation and Servicing 5 104 105 106 108 110 111 112 113 114 115 116 117 118 119 120 121 124 127 128 131 135 BOILER ASSEMBLY Exploded View CH RETURN VALVE CH FLOW VALVE DHW INLET amp OUTLET PUMP HEAD AIR VENT PUMP DIVERTOR VALVE MOTOR DIVERTOR VALVE BODY PRESSURE RELIEF VALVE PIPE PRV OUTLET PIPE FLOW PIPE RETURN PIPE EXPANSION VESSEL EXPANSION VESSEL RETURN GROUP KIT FLOW GROUP KIT PLATE HEAT EXCHANGER FLOW REGULATOR CARTRIDGE FLOW SENSOR TURBINE RETURN THERMISTOR WATER PRESSURE SWITCH PRESSURE GAUGE LX A N CAN 138 137 203 204 205 206 211 214 215 217 218 219 223 224 227 228 229 231 302 303 306
96. ou 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 build up to a point where it will make a gurgling noise prior to locking out an L2 fault code If the appliance is reset 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 wa
97. ower flue manifold as shown D 36 Ignition Electrode Earth Wire Flame Detection Refit the sump cover Refit the boiler upper and lower front panels IMPORTANT Ensure that the boiler upper front panel is correctly fitted and that a good seal is made 8 Turn on the gas supply at the gas service cock 9 Reconnect the electrical supply i combi Installation and Servicing SERVICING 40 REPLACEMENT OF COMPONENTS GENERAL When replacing ANY component Isolate the electricity supply Turn off the gas supply Remove the lower front panel fixing screws swing the panel After replacing ANY component check operation of the boiler including gas soundness gas rate and combustion test IMPORTANT When work is complete the front panels must be correctly refitted ensuring that a good seal is made into the servicing position and remove the upper front panel Notes Refer to Frame 34 1 In order to assist fault finding the control panel has an LED diagnostic display 2 In order to replace components in Frames 54 67 it is necessary to drain the boiler Refer to Frame 53 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 41 FAN REPLACEMENT T Refer to Frame 40 2 Disconnect the electrical leads from the fan Undo the gas pipe union connection to the injector housing Remove the extended nut retaining the fan mounting bracket Lift and remove the fan and vent
98. p is full of water Check operation of the boiler Refer to Frames 29 amp 30 i combi Installation and Servicing SERVICING SERVICING SERVICING 50 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 1 Refer to Frame 40 2 Note the control knob positions 3 Remove the 2 screws retaining the control box cover 4 Carefully lift the cover at the front amp pull forward to remove 5 Unplug all lead connections to the PCB including the ribbon cable 6 Spring out the two side retaining clips and pull the PCB upwards to clear the 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 Plastic Clip Ribbon Cable Connection 42 9 Reassemble in reverse order 10 Turn power back on to the boiler after a few moments the display will start alternating between c and 0 Turn the reset knob fully clo
99. r 4 Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator 5 Before replacing the diverter valve actuator proceed as follows a Ensure that the switched live to the boiler is off and that all DHW taps are shut and that pre heat is switched off b Hold the mode knob in the reset position for more than 10 secs a ito C The display will alternate between d and U and the actuator will move into the mid position d The divertor valve will initially drive all the way out this may cause the spindle to screwdriver slot 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 e 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 A spares will be deliverd in mid position therefore ignore point 5 and proceed to point 6 49 CONDENSATE TRAP SIPHON REPLACEMENT 1 Refer to Frame 40 Note Ensure condensate trap is fully drained before removal Pull off the rubber pipe at the SIPHON Disconnect the condensate drain pipe Turn the siphon clockwise to disengage and lift to remove 5 Reassemble in reverse order 6 When reassembling ensure the tra
100. r across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 4 4 Where the lowest 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 building 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 correcte
101. riate 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 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 Horizontal Flue Terminal 1000mm long e Horizontal Flue Terminal 600mm long e Flue Extension Ducts 1000mm long 24 up to 9m 30 up to 8m 35 up to 6m 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 Telescopic B Pack Raised Horizontal Flue Outlet Kit High Level Flue Outlet Kit e Flue Deflector Kit e Balcony Flue Kit Roof Flue Kit to a maximum of 7 5m e Concentric Flue Screw Retaining Kit Weather Collar Adjustable Flue Support Bracket e Flue Finishing Kit e Stand Off Kit e Weather Compensation Kit e Valve Cover Kit e Condensate Pump Kit e DHW Expansion Vessel Kit e RF Mechanical Programmable Room Thermostat Kit i 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 a
102. roduct 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 Heport 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 confirm 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 Hespond promptly to calls from a customer following completion of work providing advice and assistance by phone and if necessary visiting the customer Hectify 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 manu
103. t is discharging correctly 8 Note The pump will operate briefly as a self check once every 24 hours in the absence of any system demand Finally set the controls to the User s requirements WATER TEMPERATURES Temperatures can be selected using the CH and DHW thermostats Knob Setting CH Flow Temp DHW Outlet Temp C F C F sore seem BUD 45006 31 INSTALLATION INSTALLATION 31 RESET PROCEDURE To reset the boiler turn the mode control A to the reset position and immediately turn the knob back to the required setting The boiler will repeat the ignition sequence if a heat demand is present STATUS BURMER INSTALLATION Legend A Mode Control Knob B DHW Control C CH Control D Boiler Status E Burner on Indication F Pre Heat on off Indication 32 HANDING OVER After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions damage to the system and to the building in the event of the system remaining inoperative during frosty conditions 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
104. ter as this may freeze and cause other localised hazards 4 Once the blockage is removed and the condensate can flow freely reset 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 boiler stat to maximum Must return to original setting once cold spell is over Place the heating on continuous and turn the room stat down to 15 C overnight or when unoccupied Return to normal after cold spell Escape of gas Should a gas leak or fault be suspected contact the National Gas Emergency Service without delay Telephone 0800 111 999 Do NOT search for gas leaks with a naked flame 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 i combi User s MECHANICAL 24 HOUR TIMER PROGRAMMING THE TIMER 1 Decide what times you would like the timeswitch to switch ON and OFF Push segments towards the programme ring for an OFF iE period and push away from ring for an ON period The minimum switching interval is 15 minutes and this can be increased in 15 minute steps Permanently OFF Time amp Control Indicator OFF
105. the Weather Compensation option is fitted to the system Ensure the mode knob control A is set to winter III then the CH Temperature Control 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 Summer conditions i e DHW only required the knob in this position and the system will automatically achieve Set the mode knob control to Summer 9 the desired room temperature for all outside weather conditions The boiler will fire and supply heat to the radiators but will give priority to DHW on demand Set the CH external controls to OFF Note The pump will operate briefly as a self check once every 24 To shut down the boiler hours regardless of system demand Sat the mode knob control to OFF Pre heat is enabled if the pre heat indicator F is lit To switch pre heat on or off move the DHW Pre heat control knob B fully clockwise and then return it to the required DHW temperature To relight the boiler Repeat the procedure detailed in To light the boiler setting Frost protection Control of water temperature If no system frost protection is provided and frost is likely during Domestic Hot Water a short absence from home leave the heating controls if fitted at a reduced temperature setting For longer periods the entire The DHW temperature is limited by the boiler c
106. the overall flue height from the top of the boiler it is necessary to cut both pipes of assembly 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 separately in accordance with the instructions provided with the vertical connector kit Flue Terminal 3 Secure the vertical connector by applying downward pressure 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 clamp with the M5 retaining screw 5 Push fit extension duct if required supplied separately into Pitched roof tile vertical connector Flat roof tile weather cola a one Note Ensure turret sample points are servicable and all caps and plugs are fitted Extension nm8740 Duct Vertical connector 3G9557b 6 If the 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 XC Note Check the position of the inner f
107. trap is full of water i combi Installation and Servicing nt ID l T 35 SERVICING SERVICING SERVICING 38 CLEANING THE HEAT EXCHANGER Note Ensure the condensate trap siphon is fully drained before cleaning Refer to Frame 53 Remove ignition and flame detection electrodes Refer to Frames 44 amp 45 Itis 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 good condition replace if necessary Re fit the ignition and flame detection electrodes Ensure that earth wire is connected to the electrode Check that the ignition and detection gaps are correct Refer to Frames 44 amp 45 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 A B C D 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 Reconnect the fan electrical leads 5 Remove the sump cover and refit the l
108. tting 50 i combi Installation and Servicing FAULT FINDING 70 ALTERNATING L AND 5 5 RESETS WITHIN 15 MINS Turn power off and on 71 ALTERNATING L AND 6 FALSE FLAME LOCKOUT l Check routing and integrity of internal boiler Reset 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 wiring RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting FINDING FAULT FINDING FAULT FINDING FAULT FINDING 72 ALTERNATING F AND 1 LOW WATER PRESSURE AULT 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 Are connections on water pressure switch secure Re fit connections Replace water pressure switch i combi Installation and Servicing 51 FAULT FINDING 73 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 co
109. upboard 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 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 size the gas Installer to size the gas installation pipework in accordance with BS6891 2005 Whilst the principle of the 1 1 gas valve ensures the boiler range is able to deliver it s full output at inlet pressures as low as 14mb other gas appliances in the pr
110. uri assembly 6 Remove the screw and twist venturi anti 10 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 Check the operation of the boiler Refer to Frames 29 amp 30 i combi Installation and Servicing Retaining Tabs 3 SERVICING SERVICING SERVICING 42 BURNER INJECTOR REPLACEMENT Refer to Frame 40 Disconnect the electrical leads from the fan Undo the gas pipe union connection to the injector housing 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 injector Reassemble in reverse order ensuring that the new gas seal supplied is located correctly in the injector housing 10 Check operation of the boiler Refer to Frames 29 amp 30 43 BURNER REPLACEMENT See Frame 40 Refer to Frame 41 Undo the two screws and remove
111. 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 Optional 2 Connect room stat as shown in wiring diagram opposite Frost Stat 3 If room stat has a neutral connection connect this to terminal N load in the fused spur FROST THERMOSTAT WIRING OON a If parts of the system are vulnerable to freezing or the programmer is likely to O oPTionat be left off during cold weather a frost stat should be fitted in conjunction with a OCO pipe thermostat 1 Position the frost thermostat in a suitable position i e area vulnerable to freezing 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 Room The fuse rating should be 3A Stat Optional Wiring external to the boiler MUST be in accordance with the current 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 The frost thermostat should be sited in a cold place but where it can sense heat from the system 99

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