Ideal Heating LOGIC MAX SYSTEM2 S15, Installation & Servicing

Page 1: ...o not use reconditioned or copy parts that have not been clearly authorised by Ideal Heating For the very latest copy of literature for specification and maintenance practices visit our website idealheating com where you can download the relevant information in PDF format October 2022 UIN 228291 A06 INSTALLATION SERVICING LOGIC MAX SYSTEM2 S15 S18 S24 S30 ...

Page 2: ...yes yes Low Temperature Boiler n a n a no no no no B1 Boiler n a n a no no no no Cogeneration Space Heater n a n a no no no no Equipped with a Supplementary Heater n a n a no no no no Combination Heater n a n a no no no no Nominal Heat Output for Space Heating Full Load P4 kW 15 1 18 1 24 3 30 3 Part Load P1 kW 4 9 5 9 8 0 9 9 Auxiliary Electricity Consumption Full Load elmax kW 0 020 0 025 0 044 ...

Page 3: ...in the products in relation to the building size and its characteristics Collector Size in m2 Tank Volume in m3 Collector Efficiency in Tank rating A 0 95 A 0 91 B 0 86 C 0 83 D G 0 81 Solar Contribution from fiche of solar device Seasonal Space Heating Energy Efficiency of Package TOTAL A B C Seasonal Space Heating Energy Efficiency Class of Package III x IV x x 0 9 x 100 x G G F E D C B A A A A ...

Page 4: ...e if a heat demand is present NOTES FOR THE INSTALLER WARNING Risk of injury or death CAUTION Risk of damage to objects Table of Acronyms CH Central Heating DHW Domestic Hot Water TRV Thermostatic Radiator Valve PRV Pressure Relief Valve IE Ireland ETCI Electro Technical Council of Ireland BS British Standard WRAS Water Regulations Advisory Scheme SAP Standards Assessment Procedure IEE Institution...

Page 5: ...eration 32 2 29 Maximum and Minimum Rates 32 2 30 General Checks 33 2 31 Restart Procedure 34 2 32 Handing Over 34 Section 3 Servicing 35 3 1 Servicing Schedule 35 3 2 Removal Replacement of Components 36 3 3 Draining the Boiler 36 3 4 Boiler Front Panel Removal Replacement 37 3 5 Flue Manifold Removal Replacement 37 3 6 Fan and Venturi Assembly Removal and Cleaning 38 3 7 Burner Removal and Clean...

Page 6: ...ection via ducts to a horizontal or vertical terminal which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which in this case are concentric The fan is up stream of the combustion chamber I2H An appliance designed for use on 2nd family gas Group H only II2H 3P An appliance designed for use on 2nd or 3rd family gases Group H or P The value i...

Page 7: ... 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 23 24 For all boilers Complete sign hand over to customer For UK 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...

Page 8: ...0o C and 80o C 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 1 3 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 Manoe...

Page 9: ...oubt please enquire Unapproved control devices could invalidate the warranty of this appliance and infringe the Gas Safety Regulations 1 6 SAFE HANDLING OF SUBSTANCES No asbestos mercury or CFCs are included in any part of the boiler or its manufacture 1 7 LOCATION OF BOILER The boiler must be installed on a flat and vertical internal wall capable of adequately supporting the weight of the boiler ...

Page 10: ...densate drain pipework should be installed in accordance with BS6798 The drain outlet on the boiler is sized for standard 21 5 mm overflow pipe It is a universal fitting to allow use of different brands of pipework Refer to Section 2 15 1 8 AIR SUPPLY It is not necessary to have an air vent in the room or internal space where the boiler is installed 1 9 GAS SUPPLY Consult the local gas supplier to...

Page 11: ... Drain 98 200 152 CH Circuit Drain PRV Grommet Front Clearance The minimum front clearance when built in to a cupboard is 5 mm from the cupboard door but 450 mm overall clearance is still required with the cupboard door open to allow for servicing Bottom Clearance Bottom clearance after installation can be reduced to 15 mm This must be obtained with an easily removable panel to provide the 100 mm ...

Page 12: ...he system is not pressurised the cold water capacity must not exceed 143 litres Guidance on vessel sizing is given in table above 1 15 SYSTEM REQUIREMENTS CENTRAL HEATING PRV setting bar 3 0 Vessel charge pressure bar 0 5 to 0 75 System pre charge pressure bar None 1 0 System volume Expansion vessel litres volume litres 25 1 6 1 8 50 3 1 3 7 75 4 7 5 5 100 6 3 7 4 125 7 8 9 2 150 9 4 11 0 175 10 9...

Page 13: ...r Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems If water treatment is used Ideal Heating recommend only the use of SCALEMASTER SM 1 PRO FERNOX MBI ADEY MC1 SENTINEL X100 or CALMAG CM100 inhibitors and associated water treatment products which must be used in accordance with the manufacturers instructions This boiler can be used with a water...

Page 14: ...turi 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 Condensate Internal 229 Condensate Trap 231 Condensate Outlet Connection 239 Condensate Drain Tube 302 PCB 306 Ignition Detection Electrode 308 Ignitor Unit 309 Thermistor 313 Ignition Lead 324 Control Box Lid 325 Control Box Front 326 Blank Insert 401...

Page 15: ...l Mounting Template 6 Boiler Warranty 7 PRV Drain Pipe 8 Ideal System Filter Unpack and check the contents Hardware Pack Box Contents 9 1x HP Box 180 x 111 x 57 5 mm 10 2x Pipe CH Flow Return 11 1x Gas Cock 12 2x Valve CH G3 4 x 22 mm 13 1x Pipe Gas Inlet 14 1x PRV Clip Accessory Bag Contents 15 3x Washers 16 2x Wall Plugs 17 2x Screws 18 1x Flue Clamp Screw 17 18 16 1 2 3 4 6 5 Refer to Valve Was...

Page 16: ...g 2 Cut the flue hole with a 127 mm core boring tool ensure the hole is square to the wall 3 Drill the 2 mounting holes with a 7 5 mm 8 mm masonry drill and insert the plastic plugs provided 4 Locate 2 No 14 x 50 mm 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 2 5 FITTING THE WALL MOUNTING PLATE 2 6 M...

Page 17: ...ector Weather collar Ideal part no 152258 Ideal part no 0 5 m 211037 1 m 203129 2 m 211038 Balcony flue kit Ideal part no 208177 Soffit kit Ideal part no 211302 Raised horizontal flue kit Ideal part no 208290 pitched roof 0 6 m 208171 0 8 m 217442 Ideal part no WARNING It is critical that products of combustion cannot re enter the building The flue terminal must always have a free passage of air C...

Page 18: ...m 12 Horizontally from a terminal wall 300 mm 13 Horizontally from an adjacent window 600 mm 14 Facing an opening into an adjacent building 2000 mm 15 At an angle to the boundary 90 300 mm 45 600 mm 16 Parallel to a boundary 300 mm 17 Below ground level open light well a Below ground 1 000 mm b Above floor level 300 mm c From side 300 mm d From facing surface 600 mm Only one reduction down to 25mm...

Page 19: ...a 1000 3 2 1 600 3 4 5 1 2 2000 Opening in adjacent building 14 3 1 2 300 At an angle to the boundary 15 2 Parallel to the boundary 16 Facing the boundary 8 6 0 0 1 300 3 All measurements mm Boundary Boundary 600 Height Difference A Less than 300 B 300 Greater than 300 B 1500 300 625 fixed 2000 600 2000 690 Fixed Separation Distance B Height Difference A 300 600 600 2000 All measurements mm Refer ...

Page 20: ...sure the rubber seal is not damaged and fitted correctly on the appliance manifold 3 Firmly hold the flue and push the turret on until it has travelled 30 mm ensuring the flue has not rotated or moved forward 4 Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold 5 Fully engage the clamp location section into the manifold location hole and rotate d...

Page 21: ...l pull back the flue until Mark 1 is flush with the inner wall surface 9 Hold the flue steady and push the inner wall seal towards the wall until Mark 2 is just visible FITTING THE FLUE THROUGH THE WALL External Installation 1 Follow steps 1 5 from above 2 Push the flue through the 127 mm core drilled hole from the outside 3 Return inside the property and fit the inner wall seal to the flue 4 Pull...

Page 22: ... the instructions provided 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 push it horizontally backwards Locate both clamp lugs into the flue manifold and secure to the flue manifold with the M5 retaining screw nm8739 min 25 o max 45 o MAX LENGTH 7 5m BOILER Flue Terminal weather collar pitched roof weath...

Page 23: ...a suitable pump recommended by the boiler or pump manufacturer Refer to Fig 3 External Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose designed soakaway If an external system is chosen then ...

Page 24: ... Terminated and cut at 45º 43 mm 90º male female bend Water weather proof insulation 68 mm Ø PVCU Strap on fitting Boiler with 75 mm sealed condensate trap Boiler with 75 mm sealed condensate trap Min Ø 19 mm Internal pipe Min Ø 30 mm Internal pipe Water Weather proof insulation Max 3 m external pipework Limestone chippings 500 300 25 2 rows of three Ø12 mm holes 25 mm centres 50 mm from the botto...

Page 25: ...the bottom left hand side of the boiler comprises an open ended grommet IMPORTANT The grommet is designed for 15 mm Ø copper pipe If possible preassemble and solder the pipework before Installing If this is not possible the soldering must be more than 100 mm away from the grommet Make sure the grommet is not damaged by the heat Install the condensate pipe as follows 1 Make sure that the 15 mm Ø co...

Page 26: ...nclip and swing back the installer wiring cover and latch into the retaining clips All of the connections can now be readily accessed the plugs can be removed to aid wiring 5 Connect the switched live to the terminal block as shown Note The cable strain relief system and grommets Once any wiring is completed to secure the boiler reverse the order above FROST THERMOSTAT WIRING If parts of the syste...

Page 27: ...grommet and re fit 7 Close the installer wiring cover ensuring that it is located correctly and that the cable is retained into the strain relief as shown 6 8 Swing the control box back up into the operating position and re fit the front panel ensuring a good seal is made The earth connection should be longer than the current carrying connections If the cord anchorage slips the current carrying wi...

Page 28: ...de Spark Generator 1 2 3 Fan 2 3 4 Pump 1 2 3 3 2 1 2 Gas Valve 1 X7 X1 X2 X3 X5 X6 X8 X9 X10 g y br b r bk r w br g y bk b g y g y bk b r r b Chassis Earth bk b p y bk p y bk or bk bk r bk p gy bk v bk y b r bk v bk o gy v 1 2 3 5 4 v o v w w WPS Signal WPS Gnd 1 2 3 4 5 6 g y Switched Live 1 Out In Switched Live 2 Out In gy Key bk Black gy Grey r Red g green b blue br brown g y green yellow o or...

Page 29: ... with the requirements Refer to Gas Supply page 10 Ensure that this inlet pressure can be obtained with all other gas appliances in the property working 2 24 COMMISSIONING AND TESTING Service Required Restart Menu Mode Service Due Phone 01482 498660 SERVICE REQUIRED function When the boiler has run for more than 1 year the following screen will appear To cancel this message press RESTART IMPORTANT...

Page 30: ...estart Button The boiler will repeat its ignition sequence If Restart occurs 5 times within 15 minutes then Too Many Restarts will be shown When the burner is established the flame symbol D will be shown on the display and the current flow temperature will be shown in the large digits underneath the radiator symbol 11 Ensure that with the boiler operating the dynamic gas pressure is able to obtain...

Page 31: ...LER OPERATING MODE The boiler mode is displayed by default to change the mode simply press mode and select the desired mode WITHOUT OUTSIDE SENSOR CONNECTED To Switch On Press Mode Button Menu Mode Off How to change operating mode from Boiler Off to Boiler On On Mode No Heat Demand Target 60 C Menu Mode Ready Timer Off or Room Thermostat Cylinder Thermostat Off Press To Switch On Press Mode Button...

Page 32: ...ns as long as there is sufficient cooling load Target Fan Speed 1400rpm Actual Fan Speed 1400rpm Time remaining 10 mins Exit Minimum Rate Press The boiler will run at Minimum Rate for 10mins If the return temperature is under 40 C then the fan will run for 30s at maximum rate before ramping down over 60s to minimum rate If the return temperature is above 40 C then the fan will ramp down over 60s t...

Page 33: ...xternal controls are calling for heat and the DHW external controls are not The display should show 2 Gas Rate Check the boiler gas rate when the boiler is at maximum output Check at the gas meter with no other appliance in use Refer to Table 2 3 Set the central heating external controls to OFF The burner should go off The display should show 4 Check the correct operation of the timer if fitted an...

Page 34: ...tem controls 4 Ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption 5 Explain the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions 6 Explain the function and the use of the boiler heating and domestic hot water controls 7 Expla...

Page 35: ... Check the system water quality in accordance with BS7593 2019 15 Complete the service record in the Benchmark section Do not operate the boiler if the front panel is not fitted PRELIMINARY INSPECTION 1 Light the boiler and carry out a pre service check refer to the fault finding chart 2 Check the flue terminal and terminal guard if fitted for damage and obstruction 3 Check combustion by connectin...

Page 36: ...r to assist fault finding the control panel has an LCD diagnostic display The key to boiler fault conditions is shown in Section 4 2 In order to replace components in Sections 3 12 3 14 and 3 3 3 25 it is necessary to drain the boiler Refer to Section 3 3 3 3 DRAINING THE BOILER CENTRAL HEATING CIRCUIT 1 Close all the CH water isolating valves on both the flow and return 2 To drain the primary hea...

Page 37: ...panel onto the top retaining clips 4 Push the panel until the 2 bottom spring clips engage ensuring the 1 knob and 4 buttons line up with the holes in the front panel 5 Re tighten the two retaining screws View from bottom of boiler View from top of boiler 1 2 3 1 Remove the two sump cover retaining screws 2 Remove the sump cover 3 Lift the manifold upwards to clear the sump 4 Move the manifold to ...

Page 38: ...crews and release the nozzle assembly 6 Inspect the injector for blockage or damage 7 Clean the outside of the injector and use a small flue brush to clean the injector hole Do not use anything abrasive such as a file 8 Remove the screw and twist venturi anti clockwise to remove venturi assembly noting the orientation of the venturi in relation to the fan body Injector Nozzle 9 Inspect fan outlet ...

Page 39: ...he left hand side of the boiler once it is in the vertical position 5 Carefully brush the ceramic burner with a soft non metallic bristle brush 1 1 Place thumb here Insert two fingers 1 SCAN for video 3 8 CLEANING THE HEAT EXCHANGER 1 Replace the sump cover prior to the water flush process 2 Thoroughly flush the heat exchanger by pouring water into the top of the combustion chamber ensuring the fu...

Page 40: ...ition lead from the electrode 6 Remove the earth lead from the electrode 7 Remove the 2 screws holding the electrode to the combustion chamber 8 Remove the electrode 9 Fit the new electrode using the new gasket supplied Check dimensions as shown Refer to Section 2 30 2 31 Ignition Detection Electrode Spark Gap 3 5 mm Refer to Section 3 2 3 10 CLEANING THE CONDENSATE TRAP CH Flow Gas CH Return Cond...

Page 41: ...he drain valve cap 7 Open inlet outlet valves refill system and vent 8 Restart the boiler IMPORTANT Repressurise the system after cleaning the filter as loss of pressure will occur CAUTION Ensure that the magnet pocket is kept dry Refer to Section 3 6 3 12 BURNER INJECTOR REPLACEMENT SCAN for video 3 13 BURNER REPLACEMENT Refer to Section 3 2 3 7 2 3 14 RETURN THERMISTOR REPLACEMENT 1 Isolate and ...

Page 42: ...ve the trap and rubber connector 2 Unplug the electrical lead connection from the gas control valve 3 Remove the outlet gas valve clip and slide the pipe upwards 4 Undo the gas inlet pipe union at the inlet to the gas valve 5 Undo the two screw fixing the gas valve to the chassis base and lift the gas valve upwards 6 Fit the new gas control valve ensuring that the O ring and sealing washer are in ...

Page 43: ...m until the minimum system design pressure is reached 1 0 bar if the system is to be pre pressurised 3 Refer to Section 2 17 3 18 PRESSURE GAUGE REPLACEMENT 1 Drain the boiler 2 Remove the boiler front see section 3 2 lower the control panel and remove the control box cover 3 Ensuring there is no pressure in the system unclip the C clip from the flow pipe port and remove the capillary connection t...

Page 44: ...s Select Select Boiler Name Option 1 of 4 System2 UK Press Next until System UK is shown then press Select Select Boiler Model Option 1 of 6 System UK 15kW Natural Gas Back Next Select Press Next until correct Boiler model shown 1 6 System 15 NG 2 6 System 18 NG 3 6 System 18 Propane 4 6 System 24 NG 5 6 System 30 NG 6 6 System 30 Propane Press Select to confirm the following screen is shown Progr...

Page 45: ...upwards 5 Reassemble Ensure the air vent head o ring seal is fitted 6 Ensure the air vent cap is loose 7 Refill the boiler Check for leaks around the new air vent joint Air Vent Cap Refer to Section 3 25 Refer to Section 2 17 Refer to Section 3 3 Refer to Section 3 2 3 21 PUMP AUTOMATIC AIR VENT REPLACEMENT Refer to Section 3 2 Refer to Section 3 3 Refer to Section 2 17 3 2 1 Drain the boiler 2 Di...

Page 46: ... is fitted and replace clip 6 Refill the boiler 7 Check that the boiler operates Refer to Section 2 30 2 32 4 2 Refer to Section 3 2 Refer to Section 3 3 Refer to Section 2 17 3 Shown rotated 90º 1 Drain down the boiler 2 Unplug the electrical lead 3 Remove the clip from the flow pipe and remove the thermistor 4 Fit the new thermistor ensure O ring is fitted and replace clip 3 24 FLOW THERMISTOR R...

Page 47: ...CH circuit 6 Remove the retaining clip on the vessel water connection pipe and remove the pipe 7 Support the expansion vessel and unscrew the 2 screws from the securing bracket located on the top of the boiler and remove Note the position of the bracket on the vessel 8 Remove the expansion vessel 9 Fit the new expansion vessel 10 Reassemble ensuring the O ring seal is in place and refit the retain...

Page 48: ...at exchanger fixing screws 15 Remove the Heat exchanger slide out of location bracket 16 If replacement sump required Rotate heat exchanger assembly 180º Place new sump onto heat exchanger ensuring correct orientation and seal is in place Then gently apply pressure to the base of the sump at each tab fixing point and engage tabs onto the heat exchanger 17 Reassemble ensuring the heat exchanger is ...

Page 49: ...checks More detailed fault checks and actions are described in the following pages 4 1 MAIN MENU FAULT HELP Refer to Section 3 14 3 23 4 2 OVERHEAT LOCKOUT Is the Boiler and CH System filled with water and all isolation system filter and radiator valves open YES Fill and vent the system and open all isolation valves then restart boiler Is the Flow Return Differential across the Boiler in excess of...

Page 50: ...nd rectify if necessary Boiler now working OK Check wiring connection 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 Electrode and associated harness as necessary NO Replace Gas Valve NO Unplug gas valve Is resistance between outside pins between 4k Ω 2 YES Replace Gas Valve NO YES Refer to Section 3 9 Re...

Page 51: ...tly YES Check trap 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 is OK then replace the PCB NO Replace Spark Generator and Harness as necessary NO Replace Electrode and associated harness as necessary NO Replace Gas Valve NO Refer to Section 3 9 Refer to Section 3 9 4 7 FAN FAULT Does the w...

Page 52: ...eck and replace wiring as necessary NO Disconnect the wiring from the Flow Thermistor Check the resistance using a suitable multimeter connected across the Thermistor s terminal pins Temperature Resistance kΩ 25 o C 9 7 10 3 60 o C 2 4 2 6 85 o C 1 0 1 1 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 YE...

Page 53: ...ected at both the boiler and Outside Sensor YES NO Securely connect the wiring at both the boiler and Outside Sensor NO 4 11 NO CH OPERATION Is Off shown underneath the rad on the display NO YES Press Mode button B until Off not shown Are CH Timer and Room Thermostat switched on YES NO Switch CH Timer and Room Thermostat On Are the Radiator Valves Open YES NO Open the Radiator Valves Is there 230V...

Page 54: ...Press mode button until OFF is not shown under the Tap symbol Is there 230 V at SL2 IN NO Check system controls and wiring Is an Outside Sensor connected YES YES Check wiring from terminal strip to PCB Ensure that 230 V is not connected to SL1 IN YES 4 13 NO DISPLAY Is there 230Vac to the boiler at L and N YES NO Supply power to the boiler Is the wiring from the terminal block to the PCB connected...

Page 55: ...eal Failure to do so could affect safety or performance of this appliance Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on idealparts com Our Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665 When calling and to ensure we can provide you with the most accurate parts information please ensure you have ...

Page 56: ...56 Installation and Servicing Section 6 Benchmark Commissioning ...

Page 57: ...uld be made aware it is ultimately their responsibility to register with the manufacturer within the allotted time period It is essential that the boiler is serviced in line with the manufacturers recommendations at least annually This must be carried out by a competent Gas Safe registered engineer The service details should be recorded on the Benchmark Service and Interim Boiler Work Record and l...

Page 58: ...ate Gas rate for combination boilers complete DHW mode gas rate m3 hr or ft3 hr Central heating output left at factory settings Yes No If no what is the maximum central heating output selected kW Dynamic gas inlet pressure mbar Central heating flow temperature C Central heating return temperature C System correctly balanced rebalanced Yes COMBINATION BOILERS ONLY Is the installation in a hard wate...

Page 59: ...y test is required on every annual service in accordance with the manufacturers instructions and BS 7593 It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non water facing component SERVICE INTERIM WORK ON BOILER delete as appropriate Date Engineer name Company name Telephone No Gas Safe registration No Max rate C...

Page 60: ...UE 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...

Page 61: ...s 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 necessary 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 disconn...

Page 62: ...deal Technical Helpline 01482 498663 Ideal Consumer Helpline 01482 498660 Ideal Parts 01482 498665 idealheating com Ideal Boilers Ltd pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice At Ideal Heating we take our environmental impact seriously therefore when installing any Ideal Heating prod...