Ideal Boilers LOGIC Code Combi 26, Installation And Servicing

Page 1: ...rm to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of literature for specification and maintenance practices visit our website www idealheating com where you can download the relevant information in PDF format For users guide see reverse of book December 2010 UIN 206279 A01 ...

Page 2: ...2 Ideal Logic Code Combi Installation and Servicing ...

Page 3: ...al Stelrad Group reserve the right to vary specification without notice For any technical queries plese ring the ideal installer technical helpline 01482 445570 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 Notes for the installer ...

Page 4: ...Average Flue Temp Mass Flow Rate CH 63ºC 11g s 68ºC 13g s 73ºC 13g s Maximum Working Pressure Sealed Systems bar lb in2 2 5 36 3 Maximum Domestic Hot Water Inlet Pressure bar lb in2 10 0 145 Minimum Domestic Hot Water Inlet Pressure bar lb in2 1 0 14 5 1 3 18 9 1 6 23 2 Electrical Supply 230 V 50 Hz Power Consumption W 146 152 177 Fuse Rating External 3A Internal T4H HRC L250 V Water content CH li...

Page 5: ...nhibitor 12 Central heating mode Heat input to be calculated For assistance see Technical Helpline on the back page Page Burner operating pressure n a Central heating flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reducer 12 Hot water mode Heat input to be calculated Max operating burner pressure n a Max operating water pressure measu...

Page 6: ...downwards operation With no demand for CH the boiler fires only when DHW is drawn off When there is a demand for CH the heating system is supplied at the selected temperature of between 45o C and 80o 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 26 10 7 l min at 35 o C temperature ris...

Page 7: ...rence 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 I S 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 th...

Page 8: ...ce 1 The boiler MUST be installed so that the terminal is exposed to external air 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 unless required by the local authori...

Page 9: ...dual 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 temperature control over a living dining area or hallway having a heating requirement of at least 10 of the minimum boiler heat output should be achieved using a room thermostat whilst other room...

Page 10: ... to view the system pressure gauge and to provide the 100mm clearance required for servicing Front clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required with the cupboard door open to allow for servicing Rear Flue Only Minimum top clearance required is 145mm 395 278 76 830 Side flue dim A 2 5 from case 206279 1...

Page 11: ...er reason an additional vessel must be installed on the return to the boiler Guidance on vessel sizing is given in Frame 2 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 b Antifreeze fluid corrosion and scale inhibitor fluids suitable for use w...

Page 12: ...uld the boiler be fired before the system has been thoroughly flushed For further information contact Fernox Manufacturing Co Ltd Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ 44 0 1799 521133 Sentinel Performance Solutions The Heath Business Technical Park Runcorn Cheshire WA7 4QX Tel 0800 389 4670 Scalemaster Water Treatment Products Emerald Way Stone Staffordshire ST15 0SR ...

Page 13: ... 232 Clamp Retaining Flue Turret 233 Hose Condensate Internal 234 Siphon Trap 235 Siphon Trap Cap Seal 236 Condensate Outlet Connection 238 Flue Sensing Nipple 301 Ctrol Box Fixings Hings Spring 302 Primary PCB 303 CUI Board 304 Control Thermistor Flow Return 306 Electrode Ignition 307 Electrode Detection 308 Ignitor Unit 309 Thermistor No Flow 313 Ignition Lead 314 Control Box Lens 324 Control Bo...

Page 14: ...ng Loop Pack 1 3 8 Top Hat Washer x2 2 Plastic Chain x2 3 3 8 Blanking Cap x1 4 Valve Dbl Check Filling Loop x1 5 3 8 Fibre Washer x2 6 3 8 Blanking Cap Extended x1 7 Valve Filling Loop x1 8 Filling Loop with 3 8 Nuts x1 Return Valve Pack 1 Pipe CH Return 2 Washer CH 3 Valve Return DHW Pack 1 Pipe DHW Outlet 2 Valve Return DHW 3 Washer DHW x2 4 Pipe DHW Inlet 5 Nut 1 2 Accessory Pack 1 Screw x2 2 ...

Page 15: ... the front panel 2 Pull the two spring clips downwards to disengage 3 Pull the front panel forward and upwards to remove Pack B Contents Telescopic Available as Option Kit A Telescopic flue terminal B Flue turret C Rubber terminal wall seal D Screw E Sealing Tape isfu8751d D C B A E 1 2 Pack B Contents Non Telescopic A Flue terminal B Flue turret C Rubber terminal wall seal D Cutting Aid 8 unpacki...

Page 16: ... depth 45mm 10 DETERMINING THE FLUE LENGTH and flue packs required Note Maximum Flue lengths 26 9m horizontal flue 33 8M Horizontal flue 38 6m horizontal flue 26 33 38 7 5M ROOF FLUE 26 33 38 5m PRIMARY AND 17M SECONDARY IS A TYPICAL MAX FLUE LENGTH For alternative details refer to Powered Vertical Instructions 90o Elbow Kit 60 100 Equivalent flue length resistance 1m 45o elbow Kit 60 100 Equivale...

Page 17: ...l Flue Rear flue dim X 155 Side flue dim L 197 Extra packs required Boiler Size Up to 640 mm Up to 640 mm none 26 33 38 Up to 1590 mm Up to 1590 mm Pack D 1 off 26 33 38 Up to 2540 mm Up to 2540 mm Pack D 2 off 26 33 38 Up to 3490 mm Up to 3490 mm Pack D 3 off 26 33 38 Up to 4440 mm Up to 4440 mm Pack D 4 off 26 33 38 Up to 5390 mm Up to 5390 mm Pack D 5 off 26 33 38 Up to 6340 mm Up to 6340 mm Pa...

Page 18: ...g outside of the building does not cause damage or personal injury 1 Cut the flue hole preferably with a 5 core boring tool ensuring that the hole is square to the wall Both wall faces immediately around the cut hole should be flat 2 Drill 2 holes with a 7 5mm 8mm masonry drill and insert the plastic plugs provided for the wall mounting plate 3 Locate 2 No 14 x 50mm screws in the wall mounting pla...

Page 19: ...using the extension ducts go to Frame 18 b If the stand off Frame is used it is essential to add 45mm to X the measured wall thickness when marking the flue this will allow for the fitted Frame 1 Measure and note wall thickness X Refer to Frame 10 2 Add 90mm to dimension X and measuring from the ring cut the outer tube only 3 To ensure the tube is cut square mark the flue all the way around 4 Cut ...

Page 20: ...Frame 10 3 Add 115mm to dimension L and set telescopic flue length as indicated in drawing 4 Using a 3 5mm drill bit drill one hole in outer air duct taking care not to pierce plastic inner flue 5 Fix to length using self tappers provided 6 Seal outer air duct using the tape provided nm8945 L 115 Drill hole Adhere sealing tape Measurement to be taken from this point NON TELESCOPIC FLUE Wall thickn...

Page 21: ...n flue If the telescopic flue terminal is used it is not always necessary to cut an extension pack 1 Measure the total flue length L from the centre of the boiler outlet to the outside wall 2 Subtract 65mm from this dimension 3 Subtract 950mm for each D pack to be used 4 If the remainder Y is 300mm 500mm this can be taken up by the adjustment in the telescopic flue 5 If the remainder Y is 500mm 95...

Page 22: ... its length The boiler includes as standard a 75mm condensate trap The condensate trap also includes a siphon to reduce the possibility of freezing in the drain outlet If external condensate pipe run is greater than 3m then pipe should be 32mm nominal diameter Consideration should be given to insulating external condensate pipe runs 203 47 149 Condensate Drain 22 Mounting the Boiler 1 Ensure the p...

Page 23: ... and vent stack Make connection to SVP using a solvent welded saddle BOILER External wall Ground Level Open end of pipe direct into gulley below grating but above water level DRAIN cla7775 4 Termination to soak away 5 termination to drain gully BOILER External wall Ground Level Termination to Soak away cla7774 minimum 500mm BOILER esp8882 BOILER cla7771a DRAIN Ground Level Open end of pipe direct ...

Page 24: ...h and pull back to seal against outside wall face 4 Ensure rubber flue seal is present fully engaged into plastic top flue manifold then locate the flue turret into the flue manifold and secure by applying downward pressure 5 Engage the clamp in its slide mechanism and push it horizontally backwards 6 Fit the previously removed screw fixing Note Flues over 1 metre long It is recommended that a sup...

Page 25: ... achieved by using either Flat roof weather collar or Universal weather collar Accessories Flue Duct Extension Kits are available for flue lengths extending beyond 1m These packs contain 1m extension ducts and may be cut to the desired length If the offset vertical option is used an elbow Kit is required For a full accessories list refer to page 7 Optional Extras and Frame 29 Assembling the Roof F...

Page 26: ...rminal positions where this could cause a nuisance should be avoided Minimum dimensions are shown below rf8392 Note The equivalent flue length resistance of the elbow kits are 90o elbow kit 1m 45o elbow kit 0 6m Terminal Position Minimum Dimension Directly below an opening air brick windows etc 300 mm Below plastic painted gutters 300 mm Painted surface 300 mm Below eaves or balcony 500 mm Below v...

Page 27: ...rtical connector supplied separately in accordance with the in the instructions provided with the vertical connector kit 3 Secure the vertical connector by applying downward pressure on the connector 4 Engage the clamp in its slide mechanism and push it horizontally backwards Fit the the previously removed screw fixing 5 Push fit extension duct if required supplied separately into vertical connect...

Page 28: ...h union is fitted with fibre seals provided Do not subject any of the isolating valves to heat as the seals may be damaged Note that all isolation handles are shown in the open postion WATER CONNECTIONS CH 1 Connect the CH flow service valve black handle and copper tail provided in the hardware pack to the threaded boss connection provided at the lower rear of the boiler 2 Connect the CH rtn valve...

Page 29: ...rammable Room Thermostat 7 day kit Combined 7 day timer and room thermostat with wireless communication to receiver unit which fits into control box of the boiler Features English language installation help messages Also OpenTherm Control for gas consumption saving Room thermostat no timer Wiring 1 Remove link wire between Room stat timer terminals 2 Connect room stat across terminals as shown in ...

Page 30: ...AL ROOM STAT TIMER Room Stat or Prog Room Stat Optional Frost Stat DIAGRAM A Internal Timer or Programmable Room Stat 3G9561 N L N FROST STAT OPTIONAL ROOM STAT TIMER Room Stat Optional Frost Stat DIAGRAM B External Timer 34 rEPLACING PRE FITTED MAINS CABLE If it is necessary to use an alternative mains cable to the one pre fitted then use the following guide Replacement wiring should comply with ...

Page 31: ...hermistor Flow Thermistor Return Thermistor Flame Sensor Electrode Spark Electrode Spark Generator PCB Gas Valve Divertor Valve Pump Chassis Earth Internal Timer Low Voltage Connection Internal Timer High Voltage Connection Service Connector Fused at 4AT blue black brown red pink yellow white yellow green grey orange violet b bk br r p y w y g g or v KEY r bk r bk b y bk p y bk bk bk bk b br br br...

Page 32: ... 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 wor...

Page 33: ...n cock is closed and that the CH and DHW isolating valves L M and G are OPEN 4 Check that the electrical supply is OFF 5 Check that the boiler mode control knob D is off 6 Check that the gas service cock K is OPEN 7 Slacken the screw in the inlet pressure test point J and connect a gas pressure gauge via a flexible tube 8 Switch the electricity supply ON and check all external controls are calling...

Page 34: ...on steady when the burner lights 3 Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate This is factory set to give a DHW temperature rise of approximately 35o C at the flow rate stated on page 6 under operation 4 Reduce the DHW draw off rate to about 3 l min 0 7gpm and check that the boiler modulates to deliver DHW at approximately 64o C 5 Clo...

Page 35: ...plained to the householder to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions 4 Explain the function and the use of the boiler heating and domestic ho...

Page 36: ...e DHW filter for blockage Refer to Frame 72 The cleaning procedures are covered more fully in Frames 44 48 and must be carried out in sequence Important 6 After completing the servicing or exchange of components always test for gas tightness 7 When work is complete the front panel MUST be correctly refitted ensuring that a good seal is made Do not operate the boiler if the front panel is not fitte...

Page 37: ... retaining screws TOP POD DOOR REMOVAL 1 Loosen the two screws securing the pod door 2 Remove the pod door lifting upwards pulling forward Top Pod Door REPLACEMENT 3 Hook the top pod door onto the top retaining clips 4 Re tighten the two retaining screws 44 fan and venturi assembly removal and cleaning 1 Disconnect the electrical leads from the fan 2 Undo the gas pipe union connection to the injec...

Page 38: ...thdrawing the burner Important The burner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic 6 Brush off any deposits that may be on the ceramic with a SOFT brush 7 Inspect the sealing gasket around the burner for any signs of damage Replace as necessary 1 Remove the cleaning plug taking care w...

Page 39: ...ode 7 Check that the ignition and detection gaps are correct Refer to Frames 54 55 1 Ignition Electrode Flame Detection Reassemble the boiler in the following order 1 Ensure that the condensate trap siphon is full of water 2 Refit the burner ensuring the sealing gasket is correctly positioned and free from damage tighten the 4 fixing screws in the sequence shown below 3 Refit the fan venturi assem...

Page 40: ... Refer to Frame 63 THE BOILER MUST NOT BE OPERATED without THE FRONT PANEL FITTED 50 fan replacement 1 Refer to Frame 49 2 Disconnect the electrical leads from the fan 3 Undo the gas pipe union connection to the injector housing 4 Remove the extended nut retaining the fan mounting bracket 5 Lift and remove the fan and venturi assembly 6 Remove the screw and twist venturi anti clockwise to remove v...

Page 41: ...y in the injector housing 10 Check operation of the boiler Refer to Frames 38 39 2 4 3 6 52 burner REPLACEMENT 1 See Frame 45 2 Refer to Frame 49 3 Remove the fan Refer to Frame 50 4 Undo the two screws and remove the sump cover 5 Lift the manifold to clear the bottom sealing gasket and remove manifold 6 Remove the 2 front fixing screws and remove the 2 rear extended nuts 7 Lift off the burner fro...

Page 42: ...ion of the boiler Refer to Frames 38 39 53 control thermistor return thermistor reNEWAL 1 Refer to Frame 49 2 Unclip the control thermistor from the flow pipe and withdraw it from the boiler 3 Unclip the return thermistor from the return pipe and withdraw it from the boiler 4 Disconnect the electrical leads from the thermistors 5 Reconnect the electrical leads to the new thermistors and reassemble...

Page 43: ...er ensuring the two earth leads are correctly replaced 5 Check operation of the boiler Refer to Frames 38 39 Flame Detection Electrode Spark Generator 12 5mm Straight edge 1 Refer to Frame 49 2 Remove the burner Refer to Frame 52 3 Unplug the flame detection lead from the electrode 4 Remove the 2 screws retaining the detection electrode 5 Remove the electrode 6 Fit the new flame detection electrod...

Page 44: ...alve to the bracket and withdraw the valve forwards 6 Fit the new gas control valve ensuring the two sealing washers are in place and reconnect gas and electrical connections 7 Check operation of the boiler Refer to Frames 38 39 58 diverter valve actuator replacement 1 Refer to Frame 49 2 Remove the electrical plug 3 Using a suitable tool pull out the retaining clip and lift the diverter head from...

Page 45: ... also where applicable push the small plastic clip with an electrical screwdriver to facilitate plug removal 6 Spring out the two side retaining clips and pull the PCB upwards to clear the 4 corner retaining posts 7 Take the new Primary PCB and attach the appropriate Boiler Chip Card BCC to it this should correspond to the output of the boiler 24kW 30kW or 35kW Note Ensure the correct orientation ...

Page 46: ...knobs which must be in a vertical position 5 Reassemble in reverse order 6 Check operation of the boiler Refer to Frames 38 39 61 User control PCB replacement 3 62 DHW FLOW TURBINE Sensor REPLACEMENT 1 Refer to Frame 49 2 Remove condensate trap siphon Refer to Frame 59 3 Lift off the flow turbine sensor plastic retaining clip 4 Unplug the electrical connection and transfer to new turbine sensor 5 ...

Page 47: ... 1 Refer to Frame 50 2 Close all the DHW water isolating valves on the boiler inlet 3 To drain the DHW circuit As there is no direct drain for the DHW 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 4 After replacing any component on the boi...

Page 48: ... air vent head o ring seal is in place when refitting and the new o ring is fitted to the return pipe top connection 7 Ensure the air vent cap is loose 8 Refill the boiler Refer to Frame 30 Check for leaks around the new air vent joint 9 Check the operation of the boiler Refer to Frames 38 39 5 Dust Cap 4 67 DHW FLOW TURBINE CARTRIDGE REPLACEMENT 1 Refer to Frame 49 2 Drain the DHW circuit Refer t...

Page 49: ...sm ensuring the correct fit of the pin 10 Reassemble in reverse order 11 Refill the boiler Refer to Frame 30 12 Check operation of the boiler Refer to Frames 38 39 FRONT CARTRIDGE REAR CARTRIDGE 3 4 9 8 1 Refer to Frame 49 2 Drain the boiler Refer to Frame 63 3 Remove condensate trap siphon Refer to Frame 59 4 Remove the diverter valve actuator Refer to Frame 58 5 Remove the 2 allen screws securin...

Page 50: ...flow regulator housing 6 Remove the filter 7 Clean or replace filter as necessary 8 Reassemble in reverse order 9 Refill the boiler Refer to Frame 30 10 Check Operation of the boiler Refer to Frames 38 39 6 DHW Flow Regulator 1 Refer to Frame 49 2 Isolate the mains cold water supply to the boiler 3 Drain the boiler DHW circuit Refer to Frame 63 4 Remove the DHW flow turbine cartridge Refer to Fram...

Page 51: ...ame 59 no 2 17 Remove the two heat exchanger fixing screws 18 Remove the Heat exchanger slide to the right out of location bracket 19 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 17 13 15 11 When replacing the spring clips ...

Page 52: ...er to Frame 52 7 Disconnect the flue sampling tube 8 Undo the 4 screws retaining the recuperator assembly to the underside on the boiler top panel 9 Remove the recuperator from the flue connection by pulling downwards 10 Remove the C clips from the recuperator pipes and disconnect 11 Fit the new recuperator assembly replacing all flue seals and O rings with those provided Ensure both flue seals ar...

Page 53: ...OR FAULT GO TO FRAME 88 OUTSIDE SENSOR FAULT LOW MAINS VOLTAGE CONTACT ELECTRICITY PROVIDER PCB FAULT REPLACE PCB AND RESET GO TO FRAME 89 NO WATER FLOW THERMISTOR FAULT RESET BOILER No CH but HW OK No HW but CH OK No Display GO TO FRAME 91 GO TO FRAME 92 GO TO FRAME 93 If PCB replaced as a spare ensure that the BCC boiler chip card small plastic part is fitted to the PCB otherwise replace PCB ALT...

Page 54: ... Is 215Vdc supply available at the Gas Valve See note yes Is 230 VAC at spark generator Check spark generator and associated harness for continuity and visual condition Refer to Frame 56 Are these functioning correctly yes Check ignition electrode and associated harness for continuity visual condition and position Refer to Frame 54 Are these functioning correctly NO Check siphon and condensate dra...

Page 55: ... s terminal pins At 25 o C expect 9 700 10 300 Ohms At 60 o C expect 2 400 2 600 Ohms At 85 o C expect 1 000 1 100 Ohms Does the boiler now work OK 82 aLTERNATING L AND 6 False Flame Lockout Reset the boiler does Boiler Work OK NO Check routing and integrity of internal boiler wiring is OK Check condition of Flame Sense Electrode and replace if deteriorated Separate the flame detection electrode i...

Page 56: ...ing from gas valve to PCB for continuity If the wiring is OK then replace the PCB no Replace Spark Generator and Harness as necessary no Replace Ignition Electrode and associated harness as necessary no 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 indi...

Page 57: ...lock boiler connection of the Outside Sensor and the PCB Replace PCB Fit a new Outside Sensor and reset after powering up no Securely connect the wiring at the Terminal Block and the PCB and now reset Is the wiring securely connected at both the boiler and Outside Sensor Note Boiler must be reset to recognise the sensor after the removal yes no Securely connect the wiring at both the boiler and Ou...

Page 58: ... with a new BCC that is correct for the boiler After switching power on and c0 being shown press reset Is c2 still shown Replace PCB YES 91 nO ch oPERATION BUT hw WORKS ok Is the mode knob in the Winter position yes no Move the mode knob to the Winter position Are the Timer and the Room Thermostat switched on yes no Switch the Timer and Room Thermostat On Are the Radiator Valves Open yes no Open t...

Page 59: ...sor yes Are the flow rates correct as per Frame 2 Is the wiring between the PCB and the diverter valve motor connectedand is continuity OK yes yes Check diverter head fully engaged and clip secured onto waterset yes yes Is diverter stuck in the CH position Is the 230VAC present at the brown wire of actuator yes Check and replace diverter valve motor head Is Boiler DHW OK NO Change diverter Valve c...

Page 60: ...9 127 H78 133 Flow Sensor Hall Effect 1 175590 128 H86 071 DHW Flow Turbine 26 1 176137 H86 072 DHW Flow Turbine 33 1 176138 H86 073 DHW Flow Turbine 38 1 176139 131 H78 139 Water Pressure Sensor 1 175596 135 H78 145 Pressure Gauge 1 175679 205 H78 149 Gas Valve kit 1 175562 211 H78 156 Injector Housing 26 1 175610 H78 157 Injector Housing 33 1 175611 H78 158 Injector Housing 38 1 175612 215 H78 1...

Page 61: ......

Page 62: ...chmark Commissioning Checklist will invalidate the warranty This does not affect he customer s statutory rights If yes and if required by the manufacturer has a water scale reducer been fitted If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted Telephone Number ...

Page 63: ... Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number ...

Page 64: ...hnical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 Manufactured under an ISO 9001 registered quality management system The code of practice for the installation commissioning servicing of central heating systems Ideal Installer Technical Hel...