IDEAL Classic LX RS 230, Installation And Service Manual

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Page 2: ...2 Classic LX RS Installation CAUTION To avoid the possibility of injury during the installation servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components ...

Page 3: ...MINIMUM mbar in w g 4 0 1 6 8 7 3 5 9 7 3 9 12 0 4 8 pressure HOT MID mbar in w g 8 5 3 4 12 0 4 8 12 1 4 9 14 0 5 6 MAXIMUM mbar in w g 14 5 5 8 15 0 6 0 15 0 6 0 16 5 6 6 Seasonal Efficiency SEDBUK 70 8 73 2 72 3 72 3 Boiler Size RS 230 RS 240 RS 250 RS 260 Gas supply connection Rc 1 2 1 2 1 2 BSP Female Flow connection 22mm copper Return connection 22mm copper Maximum static water head m ft 30 ...

Page 4: ...symbols IE Ireland GB United Kingdom Countries of destination PMS Maximum operating pressure of water C12 A room sealed appliance designed for connection via ducts to a horizontal 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 I2H An appliance designed for use on 2nd Family gas Group H only B...

Page 5: ...rated input not exceeding 60 kW BS 5449 Forced circulation hot water systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 5440 Part 1 Flues for gas appliances of rated input not exceeding 60 kW BS 5440 Part 2 Ventilation for gas appliances of rated input not exceeding 60 kW BS 7593 Treatment of water in Domestic Hot Water Central Heating Systems Health S...

Page 6: ...ends of the gravity flow and return pipes and fit a 22 mm to 28 mm copper connection at the boiler gravity flow and return connections in order to run the gravity circuits in 28 mm pipe Front clearance 450mm 17 3 4 from the front of the boiler casing Minimum front clearance when built in to cupboard is 75mm 3 The following minimum clearances must be maintained for operation and servicing Additiona...

Page 7: ...e 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 A gas meter can only be connected by the local gas supplier or by a local regional contractor An existing meter should be checked preferably by ...

Page 8: ...om thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS 5449 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 boiler heat output should be achieved using a room thermostat whilst other rooms are individually controlled...

Page 9: ...hermostat 12 Igniter button 13 Programmer optional 14 Interpanel 15 Thermostat pocket 16 Overheat thermostat if fitted 17 Main burner 18 Combustion chamber 19 Boiler drain point 20 Boiler thermostat 21 Heat exchanger 22 Flue baffles INSTALLATION INSTALLATION LEGEND 1 Collector hood 2 Boiler flue duct 3 Gravity flow pipe 4 Pumped return pipe 5 Gravity return pipe 6 Pumped flow pipe ...

Page 10: ...te painted 5 UNPACKING continued Standard Model 1 Unpack the boiler 2 Remove the casing as follows and place to one side to avoid damage a Release the controls pod fixing screws a 3 full turns only Remove the pod by pulling it forward to disengage from the keyhole slots b Undo the 3 screws b retaining the casing to the back panel c Remove the casing in the direction of the arrows 3 Remove the boil...

Page 11: ...rements to avoid cavitation Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Caradon Plumbing Limited Note A cold water feed must be available back to the boiler when all automatic valves are in the closed position refer to BS 6798 and when close coupled the feed must not be in a vertical leg System return Connections ...

Page 12: ... cover plate screw holes 7mm 9 32 and insert the plastic plugs 4 Remove the template from the wall IMPORTANT The wall must be of suitable load bearing capacity 1 Cut the appropriate hole in the wall for insertion of the terminal assembly Note The terminal must not come into contact with a combustible material such as that used in the non standard construction of timber framework and plasterboard e...

Page 13: ...e boiler back panel onto the angled tabs on the top of the wall mounting plate DO NOT USE THE BURNER ASSEMBLY FOR LIFTING 2 Adjust the flue to its horizontal position by tilting the boiler forward at the bottom then turning the jacking screw Release and check alignment with a spirit level Secure the jacking screw with a No 10 x 50 mm wood screw 3 Fit the top cover plate in position above the boile...

Page 14: ...remaining sachet of sealant provided 7 Fasten the terminal grille to the flue and air ducts using the 2 securing screws 6 provided 5 Terminal grille 6 Terminal grille securing screws Legend 1 Boiler air duct 2 Boiler flue duct 3 Terminal air duct 4 Terminal flue duct INSTALLATION 13 FITTING THE FLUE ASSEMBLY Typical minimum overlap 50mm 2 INSTALLATION FLUE TERMINAL ASSEMBLY 3 Remove the terminal a...

Page 15: ... separation in both poles or a plug and socket serving only the boiler and system controls The means of isolation must be accessible to the user after installation Note If the optional Programmer Kit is to be fitted refer to the instructions provided with the kit ignore this frame and go to Frame 18 The wiring diagrams illustrated in Frames 20 23 cover the systems most likely to be fitted to this ...

Page 16: ...storage heater and can normally be left at least 24 hrs without frost damage However 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 stat should be wired into the system This is usually done at the programmer in which case the programme selector switches are set to Off and all other controls MUST be left in the running positio...

Page 17: ... point E and connect a gas pressure gauge via a flexible tube 4 Turn the gas control knob clockwise until resistance is felt and then release WAIT FOR 3 MINUTES 5 Push in and retain fully depressed the gas control knob A Press and release the piezo unit button D repeatedly until the pilot is seen to light through the sightglass B 6 Hold the gas control knob depressed for 15 seconds after the pilot...

Page 18: ...sing bottom panel Standard Model Draw attention to the lighting instruction label affixed to the controls pod door 3 Explain and demonstrate the lighting and shutting down procedures 4 The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the Householder to ensure the greatest possible fuel economy consistent with household requirements of both ...

Page 19: ...eplacement of components the boiler casing must be removed Frame 30 Deluxe model LX Standard model 31 BURNER AND AIR BOX REMOVAL 1 Remove the screw retaining the burner support bracket to the combustion chamber 2 Remove the M5 pozi screw situated at the left hand bottom rear of the burner and pull the burner downwards in order to disengage the retention tab Remove burner to a safe place for inspec...

Page 20: ...Push the sliding catch in and lower the glass fascia to the closed position Standard Model Close the controls pod door 34 RE ASSEMBLY 33 CLEANING THE BURNER AND PILOT ASSEMBLY Refer to Frame 31 for illustration of the procedure below 1 Brush off any deposits that may have fallen onto the burner head ensuring the flame ports are unobstructed and remove any debris that may have collected Note Brushe...

Page 21: ...he piezo unit Refit the new unit and re assemble in reverse order 6 Refit the control box assembly 7 Replace the boiler casing 8 Check the operation of the new piezo unit SERVICING When replacing any component 1 Isolate the electricity supply 2 Turn off the gas supply at the boiler refer to the illustration below Note The gas cock is shown in the CLOSED position 3 Remove the boiler casing refer to...

Page 22: ...ion of the control thermostat 41 CONTROL THERMOSTAT REPLACEMENT 1 Refer to Frame 36 2 Unclip the thermostat capillary from the clips situated on the back panel 3 Remove the thermostat phial from the pocket in the heat exchanger 4 Pull off the thermostat knob 6 Remove the 2 screws securing the thermostat 7 Pull off the 2 electrical connections from the thermostat head and the thermostat earth lead ...

Page 23: ...shield is refitted 7 Replace the boiler casing 8 Check the operation of the thermocouple SERVICING 42 OVERHEAT THERMOSTAT REPLACEMENT 1 Refer to Frame 36 2 Slacken the screw at the thermostat pocket and withdraw the phial from the pocket 3 Unclip the capillary from the back panel 4 Remove the control box fixing screw and pull the control box forward and downward to disengage 5 Remove the thermosta...

Page 24: ...ge the keyhole fixings Pull the assembly downwards to clear the water pipes from the back panel 11 Remove the 4 rubber grommets from the top of the back panel to facilitate the fitting of the new heat exchanger 12 Fit the new heat exchanger assembly complete with its 4 pipe connections and hang the 4 keyhole slots over the screws Retighten the 4 screws 13 Replace the 4 rubber grommets in order to ...

Page 25: ...ler casing 7 Set the programmer to the desired programme and check the operation of the boiler 1 Refer to Frame 36 2 Remove the old seal from the casing surround 3 Thoroughly clean the casing surfaces and fit the adhesive seals 4 Replace the boiler casing Detail of programmer SERVICING 49 CASING SEAL REPLACEMENT Note The standard model is illustrated here Use the same procedure for the casing seal...

Page 26: ...d require resetting Does the pilot now stay alight YES NO Clean the contacts and reconnect securely Replace the overheat thermostat NO NO Replace the gas valve NO Have you confirmed that the system controls are Calling for Heat Note After any faults have been corrected return all thermostatic and other controls to the previously noted settings NO Check the boiler thermostat Does the main burner li...

Page 27: ...llary 1 113 193 27 308 012 Thermostat knob1 013 909 30 308 523 Boiler casing assembly white stove enamel with sightglass and foil insulation Standard model only 1 079 932 31 308 524 Controls casing door white plastic with Lighting Instructions Standard model only 1 079 937 34 308 329 Boiler sealing pack 1 079 594 39 308 507 Overheat thermostat RANCO LM 7 P 5054 sealed systems only 1 100 787 40 Boi...

Page 28: ...GEND Numbers up to 44 relate to the B G spares list 28 Thermostat pocket 32 Wall mounting plate 33 Back panel 35 Balanced flue terminal 37 Programmer optional 39 Overheat thermostat if fitted 100 Boiler flue duct 101 Rubber sealing grommets 102 Interpanel 103 Boiler drain point 54 BOILER ASSEMBLY Exploded view 21 Gas service cock 106 Sealing gasket 13 Burner manifold 14 Air box pilot burner assy 1...

Page 29: ...29 Classic LX RS Installation SHORT LIST OF PARTS 57 BOILER CASING ASSEMBLY 56 SHORT PARTS Standard Model Deluxe Model ...

Page 30: ...e 01482 492 251 Fax 01482 448 858 Registration No London 322 137 Registered Office National Avenue Kingston upon Hull HU5 4JN A subsidiary of Caradon p l c Technical Training The Caradon Plumbing Limited Technical 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 ri...

Page 31: ...l be giving away a free boiler for the five best ideas every year to be selected by our Technical Director Please complete this form using extra sheets if required and post it or fax it to us on 01482 498699 Boiler details Model Size e g Classic RS 230 Mexico CF 3 60 etc Details on control panel door Date of Installation Installer details Name Address Post Code Telephone Please include STD code Ho...

Page 32: ...lease arrange for me to join an Ideal factory tour Range guides required The Ideal Guide a specifier s and installer s introduction to the Ideal domestic boiler range The Ideal Householders Guide to assist the installer when presenting to his her customers Technical manuals required The Ideal C class combi boiler The Ideal Classic wall hung boiler The Ideal Classic System wall hung boiler The Idea...