Ideal Boilers LOGIC COMBI ESP1 24, Installation & Servicing

Page 1: ...Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers For the very latest copy of literature for specification and maintenance practices visit our website www...

Page 2: ...P1 kW 8 0 8 0 8 0 Auxiliary Electricity Consumption Full Load elmax kW 0 042 0 032 0 029 Part Load elmin kW 0 012 0 013 0 013 Standby PSB kW 0 005 0 005 0 005 Seasonal Space Heating Energy Efficiency...

Page 3: ...I Class VII Class VIII 1 2 1 5 2 3 4 3 5 5 PRODUCT FICHE The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installe...

Page 4: ...4 Installation and Servicing...

Page 5: ...19 Ideal Boilers reserve the right to vary specification without notice FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL INSTALLER HELPLINE 01482 498704 NOTE BOILER RESTART PROCEDURE To restart the bo...

Page 6: ...6 Installation and Servicing...

Page 7: ...Panel Removal Replacement 40 3 3 Fan And Venturi Assembly Removal And Cleaning 40 3 4 Burner Removal Cleaning 41 3 5 Cleaning the Condensate Trap Siphon 41 3 6 Cleaning the Heat Exchanger 42 3 7 Reass...

Page 8: ...ut Non Condensing kW 24 2 4 8 6 1 7 1 70o C Mean Water temp Condensing kW 25 6 5 1 6 4 7 5 40o C Mean Water temp Seasonal efficiency SEDBUK 2005 91 1 91 1 91 1 Seasonal efficiency SEDBUK 2009 89 6 89...

Page 9: ...re record Cold water inlet temp measure record Hot water outlet temp measure record Water flow rate at max setting measure record For condensing boilers only Condensate drain 28 29 For all boilers com...

Page 10: ...ere is a demand for CH the heating system is supplied at the selected temperature of between 30o C and 80o C until DHW is drawn off The full output from the boiler is then directed via the diverter va...

Page 11: ...nection 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 regulatio...

Page 12: ...full output at inlet pressures as low as 14mb other gas appliances in the property may not be as tolerant When operating pressures are found to be below the minimum meter outlet of 19mb these should b...

Page 13: ...hermostatic 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...

Page 14: ...hat the flue hole is cut accurately e g with a core drill the flue can be installed from inside the building where wall thicknesses do not exceed 600mm Where the space into which the boiler is going t...

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

Page 16: ...t Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ 44 0 8706 015000 Sentinel Performance Solutions The Heath Business Technical Park Runcorn Cheshire WA7 4QX Tel 0800 389 4670...

Page 17: ...06 Pipe Gas Injector 211 Injector Assy 214 Venturi 215 Fan 217 Burner 218 Gasket Burner 219 Sump Clean Out Cover 223 Flue Manifold 224 Flue Manifold Top 227 Clamp Retaining Flue Turret 228 Hose Conden...

Page 18: ...S Gas Valve Pack 1 Pipe Gas Inlet 2 Washer Gas blue 3 Gas Cock Filling Loop Pack 1 3 8 Top Hat Washer 2 Valve Filling Loop 3 Pipe Filling Loop 4 Washer Fibre 3 8 Return Valve Pack 1 Pipe CH Return 2 W...

Page 19: ...B 1 2 Pack B Contents Non Telescopic A Flue Terminal B Flue Turret C Rubber Terminal Wall Seal D Cutting Aid E Wall Seal White 2 3 UNPACKING CONT D A D B C E Note This flue system incorporates a remo...

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

Page 21: ...t with an air stopper seal Ensure all caps 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 pi...

Page 22: ...al 1000mm long B Pack Telescopic Cut 75mm Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum B Pack Standard 181 556 286 484 601 816 526 741 Plus 1 1m D pack 1131 1506 1236 1434 1551 1766...

Page 23: ...terminal is uppermost 4 Drill a 3 5mm hole through one of the 2 outer side holes in the outer flue section into the inserted outer flue as shown Take care not to pierce the inner plastic flue Fit scre...

Page 24: ...l need to be refitted 9 When 1st mark is in line with the wall whilst holding the flue firmly push the white wall sealing flange to the wall until the 2nd of the two marks is just visible If the last...

Page 25: ...ade using the 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 Univer...

Page 26: ...enetrate the shaded area of the roof Note The equivalent flue length resistance of the elbow kits are 90o elbow kit 1m 45o elbow kit 0 6m If chimney penetrates dotted area such that A is less than 300...

Page 27: ...he instructions provided with the vertical connector kit 3 Secure the vertical connector by applying downward pressure on the connector 4 Position the clamp on the top face of the flue manifold and pu...

Page 28: ...ischarge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc fig 3 External Drain Connections The use of an externally run condensate drainage pipe should only...

Page 29: ...ternal pipe Water Weather proof insulation Max 3m external pipework Limestone chippings 500 300 25 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house M...

Page 30: ...ed 2 Fit the DHW outlet pipe tail to DHW outlet connection ensuring the seal provided is correctly located 3 Fit the filling loop provided between the DHW inlet valve and the CH return valve GAS CONNE...

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

Page 32: ...iler reverse the order above Note 1 The link wire on the 230V installer room stat timer connection gives a demand in conjunction with the OpenTherm link wire located on the right hand side of the cont...

Page 33: ...tat L N Optional Timer Optional Timer DIAGRAM C Use of General Live for Room Stat Optional Room Stat Frost Stat Mains In Frost Room Stat Stat L N Optional Timer DIAGRAM A DIAGRAM B Room Stat with Exte...

Page 34: ...D X9 X8 OWC OWC OPENTHERM OPENTHERM OPENTHERM 5V CHIP COM BUS TX CHIP COM BUS 24V CHIP COM BUS GND CHIP COM BUS 5V CHIP COM BUS RX MAINS LIVE MAINS NEUTRAL AUXILIARY LIVE IONISATION 2 2 FLOW DHW DHW X...

Page 35: ...s only 2 22 COMMISSIONING AND TESTING 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 d...

Page 36: ...mp control B to max and turn the mode knob C to The boiler control should now go through its ignition sequence until the burner is established 10 If the boiler does not light then after 5 attempts the...

Page 37: ...show then when the burner lights 2 Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate This is factory set to give a DHW temperature rise of appr...

Page 38: ...mestic 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...

Page 39: ...monstrated 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 Note In order to carry out...

Page 40: ...the front panel 5 Re tighten the two retaining screws 3 3 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING 1 Disconnect the electrical leads from the fan 2 Remove the clip from the gas control valve out...

Page 41: ...ion 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 Inspec...

Page 42: ...nition and detection gaps are correct Refer to Sections 3 13 3 14 1 Ignition Electrode Flame Detection Reassemble the boiler in the following order 1 Ensure that the condensate trap siphon is full of...

Page 43: ...boiler Refer to Section 3 21 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 3 9 FAN REPLACEMENT 1 Refer to Section 3 8 2 Disconnect the electrical leads from the fan 3 Remove the clip...

Page 44: ...rse order ensuring that the new gas seal supplied is located correctly in the injector housing 10 Check that the boiler operates in both DHW CH modes 4 3 3 3 11 BURNER REPLACEMENT 5 5 6 1 See Section...

Page 45: ...8 Reassemble in reverse order 9 Check the operation of the boiler Refer to Section 2 23 2 24 3 12 RETURN THERMISTOR REPLACEMENT 1 Refer to Section 3 8 2 Unclip the return thermistor from the return p...

Page 46: ...rode 4 Remove the 2 screws retaining the detection electrode 5 Remove the electrode 6 Fit the new flame detection electrode using the new gasket supplied 7 Reassemble in reverse order 8 Check that the...

Page 47: ...r slot provided and ease out the actuator 3 Before replacing the diverter valve actuator proceed as follows a Ensure that the switched live to the boiler is off and that all DHW taps are shut b Press...

Page 48: ...Spring out the four side retaining clips and pull the PCB upwards to clear the corner retaining posts 7 Take the new PCB 8 Re connect all plug connections 9 Reassemble in reverse order 10 a Turn power...

Page 49: ...3 To drain the primary heat exchanger circuit Open the drain valve and attach a length of hose to the CH drain point 4 After replacing any component on the boiler remove the hose close the drain valv...

Page 50: ...ction 3 32 4 Firstly increase access area by disconnecting the 22mm pipe connection at top of pump manifold and bottom of heat exchanger and remove pipe Refer to Section 3 26 5 The automatic air vent...

Page 51: ...y 1 Refer to Section 3 8 2 Drain the boiler Refer to Section 3 21 3 Remove the condensate trap siphon Refer to Section 3 18 4 Remove the electrical plug Refer to Section 3 17 5 Place a flat bladed scr...

Page 52: ...oiler Refer to Section 2 16 8 Check that the boiler operates in both DHW CH modes 3 30 FLOW THERMISTOR REPLACEMENT 4 3 3 29 CH WATER PRESSURE SWITCH REPLACEMENT 1 Refer to Section 3 8 2 Drain the boil...

Page 53: ...to correctly match connecting pipe diameters 18 Ensure the trap siphon is filled with water Refer to Section 3 18 19 Refill the boiler and check for leaks Refer to Section 2 16 20 Ensure all gas valv...

Page 54: ...rcuit Refer to Section 3 21 8 Remove the retaining clip on the vessel water connection pipe and remove the pipe 9 Support the expansion vessel and unscrew the 2 screws from the securing bracket locate...

Page 55: ...GO TO SECTION 4 9 RETURN THERMISTOR FAULT GO TO SECTION 4 10 OUTSIDE SENSOR FAULT LOW MAINS VOLTAGE CONTACT ELECTRICITY PROVIDER PCB UNCONFIGURED OR FAULTY SEE SECTION 3 19 IF FAULT PERSISTS REPLACE...

Page 56: ...rectify fault NO YES Is 24Vdc supply available at the Gas Valve YES Check spark generator and associated harness for continuity and visual condition Refer to Section 3 15 Are these functioning correct...

Page 57: ...these functioning correctly YES Check siphon and condensate drain pipe work for blockage and rectify if necessary Boiler now working OK Check wiring from gas valve to PCB for continuity If the wiring...

Page 58: ...1 000 1 100 Ohms Is the Thermistor value correct YES Is the wiring securely connected to the low voltage 6 way connector at the front left hand side of the PCB YES Replace PCB Fit a new Thermistor NO...

Page 59: ...and the PCB Replace PCB Fit a new Outside Sensor NO Securely connect the wiring at the Terminal Block and the PCB Is the wiring securely connected at both the boiler and Outside Sensor YES NO Securel...

Page 60: ...d the diverter valve motor connected YES YES Check diverter head fully engaged and clip secured onto waterset YES Is diverter stuck in the CH position YES Check and re fit diverter valve actuator head...

Page 61: ...ils of approved Ideal Parts Distributors are available on www idealparts com Our Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665 When calling and to ensure...

Page 62: ...62 Installation and Servicing SECTION 6 BENCHMARK COMMISSIONING...

Page 63: ...ons 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...

Page 64: ...priate Building Regulations and then handed to the customer to keep for future reference GAS BOILER SYSTEM COMMISSIONING CHECKLIST CONTROLS Programmable room thermostat Optimum start control Combinati...

Page 65: ...larly and that the appropriate Service Interval Record is completed Service Provider SERVICE RECORD SERVICE 01 AND Where Possible AND Signature SERVICE 02 AND Where Possible AND Signature SERVICE 03 A...

Page 66: ...letin 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 ma...

Page 67: ...bled fixed and supported as per instructions Check that flue and flue terminal are not obstructed Check that no seals e g Those on flue extensions have been displaced during installation Rectify if ne...

Page 68: ...68 NOTES Installation and Servicing...

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Page 72: ...he code of practice for the installation commissioning servicing of central heating systems Ideal Boilers Ltd PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 01482 492251 Fax 01482 448858 Re...