IDEAL 41-392-98, Installation And Servicing

Page 1: ...y authorised by Ideal Boilers installation and Your Ideal installation and servicing guide servicing For users guide see reverse of book For the very latest copy of literature for specification purposes please visit our website www idealboilers com where you will be able to download the relevant information in pdf format 17962 1062 4 4307 64A4 GB 1796210624 S24 S28 For details of document amendmen...

Page 2: ...2 Mini Installation Servicing ...

Page 3: ...ENDMENTS Relevant Installation changes implemented in this book from book reference 17962 1062 4 2007 F Further guidance added to Important Notes section of User Guide Ideal Stelrad Group reserve the right to vary specification without notice ...

Page 4: ...1 1 010 128 4 0 400 0 444 56 5 0 176 Seasonal efficiency SEDBUK Band D 78 2 Band D 78 3 Band D 78 3 NOx classification Class 3 Class 2 Class 3 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 Table 3 Performance Data Domestic Hot Water Mini C24 Mini C28 Mi...

Page 5: ...by completing and signing the Benchmark Commissioning Checklist BENCHMARK COMMISSIONING CHECKLIST DETAILS Boiler Page Make and model 5 Appliance serial no on data badge 13 SEDBUK No 4 Controls Time and temperature control to heating 24 25 Time and temperature control to hot water 24 25 Heating zone valves 24 TRV s 11 Auto bypass 11 Boiler interlock 11 For all boilers Flushing to BS 7593 9 Inhibito...

Page 6: ...ation can be reduced to 20mm However 200mm must be available for servicing Front clearance The minimum front clearance when built into a cupboard is 50mm 2 from the cupboard door However 450mm 17 3 4 overall clearance is still required with the cupboard door open to allow for servicing Side and Rear Flue a Provided that the flue hole is cut accurately e g with a core drill the flue can be installe...

Page 7: ...on and Use Regulations or rules in force The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation must be carried out by a CORGI Registered Installer It must be carried out in accordance with the relevant requirements of the F Gas Safety Installation and Use Regulations F The appropriate Building Regulations e...

Page 8: ...llation MUST be tested for gas soundness and purged as described in the above code The boiler is adjusted at the factory for use with the relevant supply gas A working gas pressure equal to that stated in Table 1 MUST be available at the boiler inlet Where applicable the appliance can be converted for G20 Natural Gas or G31 Propane Gas by using the appropriate conversion kit IMPORTANT Installation...

Page 9: ...ould be in accordance with BS 5546 and BS 6700 Copper tubing to BS 2871 1 is recommended for water carrying pipework and MUST be used for pipework carrying potable water Any soldered joints on potable water pipework MUST NOT be made with solder containing lead Ancillary pipework not forming part of the useful heating surface should be lagged to prevent heat loss and any possible freezing particula...

Page 10: ...f tap supplied from a service pipe under mains pressure Where the mains pressure is excessive a pressure reducing valve shall be used to facilitate filling When installing the filling connection provided with the boiler an additional WRAS approved valve must be fitted to the mains water supply upstream of the double check valve to fully comply the Water Regulations CH return Hose unions Mains Wate...

Page 11: ...ve 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 as stated in BS5449 Such an arrangement will provide for a more efficient control of the environment and will also avoid the continuous running of the circulation pump during programmed heating ON periods saving electrica...

Page 12: ...y diverter valve 6 Main circuit drainage cock 7 Central heating flow cock 8 By pass valve 9 Central heating CH return cock 10 3 bar pressure relief valve 11 Gas cock 12 Expansion vessel 13 Gas valve inlet pressure tap 14 Modulating gas valve 15 Burner pressure tap 16 Flame detection electrode 17 Ignition electrodes 18 Burner 19 Combustion chamber 20 Primary heat exchanger 21 Fan 22 Air pressure sw...

Page 13: ...e 12 Main circuit drainage cock 13 Auto air vent 14 Pump 15 Electronic control pcb 16 3 bar pressure relief valve 17 Return manifold 18 DHW flow switch 19 Right hand panel 20 Boiler front panel 21 Appliance data badge inside 22 Left hand panel 23 CH circuit pressure gauge 24 Model identification instructions 25 Control panel door 26 CH flow switch 27 3 way diverter valve 28 Heat exchanger flow pip...

Page 14: ... 4 J Flue pipe ø 60 mm 2 3 8 with terminal grille assembly K Band L Turret air pipe gasket M Flue pipe gaskets 2 off N Boiler turret gasket O Flue turret P Self tapping screws 4 8x13 4 off Q Self tapping screw 4 2x13 2 off R Wall finishing gaskets 2 off J I K L M N O P R Q Optional extras if ordered are available in separate boxes F Electronic programmer kit F Extension duct kit pack D ø 60 100 F ...

Page 15: ...S24 Mini C28 Mini S28 Table 8 for model Mini C32 For the correct use of the restrictors with vertical roof kit ø 80 125 mm refer to Table 9 for models Mini C24 Mini S24 Mini C28 Mini S28 Table 10 for model Mini C32 Table 7 Models Mini C24 Mini S24 Mini C28 Mini S28 Pipe length ø 60 100 Restrictor Between 0 5 19 5 and 1 m 39 ø 44 mm More than 1 m 39 up to 2 m 78 5 ø 47 mm More than 2 m 78 5 up to 4...

Page 16: ... flue duct air duct connection to the end of the flue outlet grille air inlet duct For each additional 45 M F and 90 M F flue bend used the maximum permissible length of flue system must be reduced by 0 9m or 1 65m respectively For each additional 90 F F Flue bend used the maximum permissible length of flue system must be reduced by 2 75m Lengths of allowable equivalent flue outlet and air inlet d...

Page 17: ...mounting plate screw position b Extend the centre line as shown Mark the flue duct centre from the corner see diagram and template Note mark the centre of the hole as well as the circumference 4 Remove the template from the wall Extended centre Spirit level 15 DRILLING THE WALL Rear flue shown IMPORTANT Ensure that during the cutting operation masonry falling outside the building does not cause da...

Page 18: ...Remove the front and side panels refer to frame 21 and strip off the protective coating The panels may be placed to one side and re fitted when the installation is complete Fit the horizontal flue system referring to the instructions contained with the kit Make good the internal wall surface using the seal provided 18 CONNECTIONS Fit the service valves washers and tail pipes as shown Central Heati...

Page 19: ... 3 15 AF Mini C24 Mini C28 Mini C32 only For external controls wiring see frame 26 Note the switch contacts of any external programmer room or frost thermostat must be volt free Connecting a switched live feed to external controls terminal block may be dangerous and will result in serious damage to the boiler For Mini S24 Mini S28 refer to frame 27 21 ELECTRICAL CONNECTIONS Incoming mains wiring d...

Page 20: ...k black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow bu bn gnye bu bn bk bn bu bn bu bk bu bn gnye bn bu bk bu bn bk bu bn bu bk gnye bu bk gnye bk bk gy gy gy gy bn bu bk rd rd bk bk bk bk ye gy bu bu rd bu wh X8 ye rd rd gy wh bu rd bu bu bk bn bu bu Wiring diagram for boiler equiped with electronic control p c b type Bertelli Partners DIMS11 SA03 16740 NC COM...

Page 21: ...h white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow bu bn gnye bu bn bk bn bu bu bn gnye bn bu bk bu bn bu bk gnye bu bk gnye bk bk gy gy gy gy bn bu bk bk bk bk bk ye gy X8 ye gy bu bu bk bn bu bu Wiring diagram for boiler equiped with electronic control p c b type Bertelli Partners DIMS11 SA03 16740 NC COM NO Electronic control P C B LD1 LD2 LD3 F1 F2 K1 K3 K4 LD4 P4 ...

Page 22: ...tch DHW flow switch Pump DHW temp rd bk bk bu CH temp 38 37 31 30 bu bu rd 10 9 bu bn Three way 6 8 bk bu 7 div valve bn wh 33 34 28 29 Gas Valve gy 36 35 ye modulation coil 23 25 13 14 gy gy bu bk bu Safety thermostat Gas Valve on off operators 11 12 27 bk rd 32 Ignition electrodes Detection electrode 15 16 39 probe NTC probe NTC 26 bk 2 1 bu bn INSTALLATION ...

Page 23: ...ontrol pcb Fan Air pressure switch CH flow switch Pump bk bk CH temp 31 30 bu bu 10 9 bu bn 28 29 Gas Valve gy 36 35 ye modulation coil 23 25 13 14 gy gy bu bk bu Safety thermostat Gas Valve on off operators 11 12 27 bk Ignition electrodes Detection electrode 15 16 39 probe NTC 26 bk 2 1 bu bn INSTALLATION ...

Page 24: ...or switches set to OFF all the controls MUST be left in the running position The frost thermostat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown with minimal disturbance to other wiring External Programmers On the combi boilers this should be of the single channel type as this boiler does not incorporate a pre heat facility for the instantaneo...

Page 25: ...ated on the following picture and connect a gas pressure gauge via a flexible tube Be sure to select the correct pressure test point Refer to Tables for pressures 6 Check that the gas service cock is ON 7 Switch the electricity supply ON and check that all external controls are calling for heat 8 Set the main switch C to ON Following a pre purge period the gas control solenoid valve should open an...

Page 26: ...ulating operator 11 Start the boiler and check again the maximum gas pressure setting 12 Turn the boiler off and disconnect the gauge and close the gas valve outlet pressure test point E Important after the gas pressure checks and any adjustment operations all of the test points must be sealed and replace the adjustment protection cap Ignition rate adjustment 1 Turn on the boiler 2 Check that the ...

Page 27: ...ine the current setting by keeping the reset button D pressed for more than 5 seconds The lamps A will flash a number of times corresponding to the setting 4 To change the setting turn the knob B to a position corresponding to the desired delay By turning the control B the lock out signal lamp E blinks quickly 2 per second indicating that the setting has changed and must be memorized 1 4 2 3 5 6 7...

Page 28: ...ecked at the gas meter with no other appliance in use If this check is not possible ensure that the burner pressure is 11 7 4 7 mbar in w g for all models 4 Water circulation system Note Fernox Superfloc flushing solution should be used during the flushing procedure a With the system HOT examine all water connections for soundness b With the system still HOT turn off the gas water and electricity ...

Page 29: ...erformed The factory setting is Natural gas 17 Calibrate the gas valve according to the instructions given in this manual 18 Set the correct gas pressure for central heating output required 19 Stick the self adhesive label included with the conversion kit indicating the type of gas and the gas pressures to which the appliance has been set over the existing label on the bottom of the control panel ...

Page 30: ... operation 4 Run the boiler and check the percentage of CO and CO2 in the flue gasses at the sampling point indicated in the following drawing Air intake sampling point Exhaust gas sampling point Note If your meter reads CO in parts per million the figure must be divided by 10 000 to convert it to a percentage 5 If the ratio of CO CO2 is less than 004 and the gas rates measured in steps 3 and 4 ar...

Page 31: ...rvice cock and disconnect the electricity supply 2 Remove the screws A and lift off the boiler front panel A A 3 Loosen the screws B 4 Bring the base of the panels away from the boiler and lift them freeing them from the top hooks B B Mini C shown 5 Remove the screws C and remove the boiler inner casing C C SERVICING ...

Page 32: ... Mini C24 Mini C28 Mini S24 Mini S28 4 mm 5 32 Ignition Detection Male Female 10 mm Burner blades 3 8 10 mm 3 8 Mini C32 9 Check that the spark and detection electrodes leads are in good condition and renew as necessary 38 BURNER PRESSURE CHECK After any servicing reference should be made to Table 2 and Table 3 or the data plate which quote details of the burner pressures If the burner pressures a...

Page 33: ... B A B 4 Disconnect the pipe which connects the venturi device to the air pressure switch 5 Unscrew the screws C and remove the clamp D C D F If the right clearance is at least 50 cm 20 6 Unscrew the 3 screws E and remove the fan and skip to step 9 E E F If the right clearance is less than 50 cm 20 6 Remove the combustion chamber panel see frame 36 7 Remove the 3 screws F and remove the flue hood ...

Page 34: ...ply 2 Remove outer and inner casing refer to frame 36 3 Open the combustion chamber and disconnect the electrodes leads 4 Remove the burner Refer to frame 37 5 Undo the screws that hold the electrodes and remove 6 For models Mini C24 Mini C28 Mini S24 Mini S28 fit new electrodes as necessary following the sequence illustrated Ignition 1st Ignition 2nd Detection 3rd 7 Check the spark gap 4 mm 5 32 ...

Page 35: ...ion of the boiler Gas manifold Injectors Burner 46 OVERHEAT THERMOSTAT REPLACEMENT 1 Remove outer and inner casing refer to frame 36 For models Mini C28 Mini S28 and Mini C32 remove the screw A and the plate B A B 2 Disconnect the wiring C 3 Remove the spring D which holds the overheat thermostat on the pipe of the primary heat exchanger and remove it C D 4 Re assemble in reverse order 5 Apply an ...

Page 36: ...he DHW circuit at the bottom of the boiler 4 Empty the DHW circuit Replacement 5 Disconnect the leads from the probe to be replaced and unscrew it 6 Screw in the new probe using a new gasket reconnect and re assemble in reverse order DHW temperature probe Drainage cock 48 GAS VALVE ON OFF OPERATOR COILS REPLACEMENT Check 1 Disconnect the electrical supply 2 Remove the front casing panel 3 Disconne...

Page 37: ...rame 21 6 Squeeze the tabs D to release the temperature pressure gauge E and remove it 7 Re assemble in reverse order C B E D A 51 EXPANSION VESSEL REPLACEMENT If the CH expansion vessel is faulty there are 2 options A If it has a punctured diaphragm but is otherwise leak free than it can be left in place and a new vessel added to the return side of the system external to the boiler provided it is...

Page 38: ...rew the 3 screws E and remove the fan E E F 7 Re assemble in reverse order If the right clearance is less than 50 cm 20 6 Remove the combustion chamber lid see frame 37 7 Remove the 3 screws F and remove the flue hood with the fan 8 Unscrew the 3 screws E and remove the fan 9 Re assemble in reverse order To correctly connect the venturi device to the air pressure switch refer to the following illu...

Page 39: ...nection not used 55 PUMP REPLACEMENT COMPLETE 1 Disconnect the electrical supply 2 Remove the front and right hand side casing panels refer to frame 36 3 Release system pressure by opening the main circuit drainage cock Do not release CH pressure using the pressure relief valve It may cause debris within the system to foul the valve 4 Disconnect the connector A 5 Unscrew the locknut B and move the...

Page 40: ...nt When re assembling the electronic control ignition p c b 11 Fit the p c b into the control panel by first inserting the front lower edge under the control knob shafts Lower the rear edge and ensure that no wiring is trapped beneath 12 Insert the spindles in the control panel knobs until the notch C reaches the potentiometer edge It is not necessary to force them in the knob 13 While tightening ...

Page 41: ...ill flash a number of times corresponding to the setting as on next figure A B 1 flash for combi models 4 flashes for system boilers 22 To change the setting turn the knob B to the position shown on the previous figure By turning the knob B the lock out signal lamp E blinks quickly twice per second indicating that the setting as changed and must be memorised 23 To memorize the setting keep pressed...

Page 42: ...essure by opening the main circuit drainage cock Do not release CH pressure using the pressure relief valve It may cause debris within the system to foul the valve 5 Remove the CH circuit flow switch see frame 57 6 Unscrew the four screws A open the hydraulic operator and remove the membrane B 7 Re assemble in reverse order When assembling the membrane ensure to place the concave side of the membr...

Page 43: ...model is factory fitted with a 10 litre min flow limiter The Mini C28 model is factory fitted with a 12 litre min flow limiter The Mini C32 model is factory fitted with a 14 litre min flow limiter Table 11 Nominal flow rate litres min Colour 10 Yellow 12 Brown 14 Pink To install the threaded ring with the flow limiter 1 Disconnect the electrical supply 2 Remove the front panel of the case and empt...

Page 44: ...oul the valve 5 Remove the combustion chamber panel A by unscrewing the screws B For models Mini C28 Mini S28 and Mini C32 only remove the screw C and the plate D 6 Remove the clips E and the safety thermostat F It is not necessary to disconnect it from the wiring A B E D F C 7 Unscrew the locknut G lift the pipe H and rotate it right then move it downwards freeing it from the heat exchanger conne...

Page 45: ... actuator see frame 63 7 Completely unscrew the two Allen key screws A which hold the exchanger to the brass groups A 8 Move the exchanger towards the rear of the boiler and extract it 9 Re assemble in the reverse order Attention When reassembling the exchanger be sure to put the off center location securing pin indicated towards the left side of the boiler 63 DIVERTER VALVE ACTUATOR REPLACEMENT M...

Page 46: ... view 13 Refer to the following exploded view to remove the internal parts of the three way diverter valve 14 Re assemble in reverse order 65 PROGRAMMER REPLACEMENT Mini C only if fitted 1 Disconnect the electrical supply 2 Gain access to the main control p c b steps 1 to NO TAG of frame 56 3 Disconnect the wiring at the programmer 4 Squeeze the hooks that hold the programmer on the control panel ...

Page 47: ...h temperature probe NTC Faulty d h w temperature probe NTC Mini C only Faulty primary circuit no water or absence of flow Faulty air pressure switch Lack of burner ignition no ignition signal from the full seqence ignition device Overheat thermostat lock out Lack of power supply or fauly electronic control p c b Faulty Electronic control ignition p c b Lamp OFF Lamp ON Flashing lamp alone or simul...

Page 48: ...nd programmer are calling for heat Also that all services are on and the selector switch is set to heating Are only the two green leds on front fascia flashing together or alternately Is there at least one of the led flashing Is there 230V between Live and Earth at the mains connection in the control box Rectify external wiring fault Is there continuity across the fuses on the PCB Replace faulty f...

Page 49: ...CB When a DHW tap is opened and the DHW temperature is set to maximum does the water become hot Is the boiler mode setting correct Refer to frame 56 Follow the instruction Boiler mode setting Refer to frame 56 Is the red LED illuminated on DHW flow sensor Is there 5V dc between Red and Blue on connecting harness Is the harness continuity O K Repair or replace faulty wiring Repair faulty PCB Repair...

Page 50: ...Is it between 12 kΩ and 1 5 kΩ Check resistance of CH temperature probe Is it between 12 kΩ and 1 5 kΩ Are LED2 and LED 3 flashing Replace faulty thermistor Are LED2 flashing and LED 3 on Replace faulty thermistor Repair or replace faulty wiring Repair or replace faulty wiring Remove the pump nut Does the pump rotate freely when turned Replace faulty pump Re pressurise system and vent Is the heati...

Page 51: ...Brown and Blue at gas valve harness connector on PCB Is fuse continuity O K on PCB Is there a burner pressure during ignition period Replace faulty PCB Replace fuses Are the ignition leads disconnected or damaged and sparking to earth Is a spark visible at the burner during ignition Is there ignition at the burner Adjust ignition burner pressure Replace faulty electrode assy Make connection Rectif...

Page 52: ...he polarity of the mains correct Replace faulty detection lead assy Rectify electrode position or replace faulty electrode Does the burner remain alight more than 10 seconds Connect lead correctly Is the lead connected Is the burner pressure within min and max value with the boiler running Rectify wiring fault yes see Table 2 at page 4 for the correct value Replace faulty PCB yes Is the burner lig...

Page 53: ... or replace faulty wiring Is there continuity of the Air Pressure Switch harness Is there continuity between NC and C at the Air Pressure Switch Replace faulty Air Pressure Switch Replace faulty PCB Repair or replace faulty flame detection signal connection harness Refer to frame 43 yes yes yes no no no no no yes yes Are the sensing pipes undamaged and connected Is there continuity across C and NO...

Page 54: ...lt Is there 17 mbar gas pressure at the gas inlet Is there max burner pressure when the boiler first lights Is the maximum water flow correct 10 0 L min 24 kW model 12 0 L min 28 kW model 14 0 L min 32 kW model Rectify water supply fault Check the DHW inlet filter Remove debris and clean or replace filter With the DHW hot does the burner pressure modulate if the DHW temperature setting is reduced ...

Page 55: ...03 715 Main heat exchanger O rings mod Mini C28 Mini S28 Mini C32 1 173240 5 E90 627 Gas valve gaskets 1 172611 6 H03 699 Fan mod Mini C24 Mini S24 1 173253 H03 700 Fan mod Mini C28 Mini S28 1 173254 7 H08 608 Fan mod Mini C32 1 173139 8 E83 013 Safety valve 1 172494 9 Electronic regulation p c b 1 174500 10 E00 684 Primary circuit flow switch 1 075419 11 H32 551 DHW flow switch mod Mini C24 Mini ...

Page 56: ...me 1 170977 27 169 141 1 2 flat gasket 3 075514 28 169 033 3 4 flat gasket 4 075415 29 Side case panel 2 174508 30 H17 563 Control panel door 1 173637 31 Front case panel 1 174510 1 2 5 4 6 3 8 16 12 9 13 19 20 23 25 17 14 10 24 11 18 30 29 31 29 21 22 15 26 27 28 P5 ...

Page 57: ...erson s SELF CERTIFICATION SCHEME BUILDING CONTROL Contact your relevant Local Authority Building Control LABC who will arrange an inspection or contact a government approved inspector LABC will record the data and will issue a certificate of compliance Scheme members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com within 10 days You must ensure that the notification number issu...

Page 58: ...E BOILER MANUFACTURER S INSTRUCTIONS THE SYSTEM CLEANER USED THE INHIBITOR USED GAS RATE BURNER OPERATING PRESSURE IF APPLICABLE CENTRAL HEATING FLOW TEMPERATURE CENTRAL HEATING RETURN TEMPERATURE m3 hr ft hr N A mbar C C HAS A WATER SCALE REDUCER BEEN FITTED WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED YES NO GAS RATE MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE COLD WATER INLET TEMPERATURE HOT ...

Page 59: ...CARD SERIAL No COMMENTS SIGNATURE DATE SERVICE 3 ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE DATE SERVICE 4 ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE DATE SERVICE 5 ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE DATE SERVICE 6 ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATUR...

Page 60: ...ifiers For details of courses please ring 01482 498 432 Ideal boilers P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice the code of practice for th...