background image

12

 

Installation and Servicing

SECTION 1 - GENERAL

1.8  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.
The boiler MUST be installed on a gas supply with a governed 

meter only.
A gas meter can only be connected by the local gas supplier or 

by a Gas Safe Registered Engineer. In IE by a Registered Gas 

Installer (RGII).
An existing meter should be checked, preferably by the gas 

supplier, to ensure that the meter is adequate to deal with the rate 

of gas supply required. 

It is the responsibility of the Gas Installer to size the gas Installer to 

size the gas installation pipework in accordance with BS6891:2005.  

Whilst the principle of the 1:1 gas valve ensures the Independent 

Combi range is able to deliver it’s 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 be checked to ensure 

this is adequate for correct and safe operation.
Allowing for the acceptable pressure loss of 1mb across the 

installation pipework, it can be assumed that a minimum permitted 

operating pressure of 18mb will be delivered to the inlet of 

the appliance.  (Reference BS 6400-1 Clause 6.2 Pressure 

Absorption).
The external gas cock could further reduce the operating pressure 

when measured at its test point.  The pressure drop is relative to 

the heat input to the boiler (kW), refer to graph below.

0

0.5

1

1.5

2

2.5

3

0

10

20

30

40

50

Pre

ss

ure

 d

ro

 (mb

ar 

)

Heat Input to Boiler (kW)

Gas Cock Pressure Drop 

IMPORTANT.

Ensure all gas valve connections are gas tight with a gas 

soundness check up to the gas control valve.

Installation pipes must be fitted in accordance with BS.6891. In IE 

refer to IS.813:2002. 
The complete installation MUST be tested for gas tightness and 

purged as described in the above code.

1.9  FLUE INSTALLATION

Pluming will occur at the terminal so terminal positions where this 

could cause a nuisance should be avoided.

The flue must be installed in accordance with the 

recommendations of BS. 5440-1: 2008.  

In IE refer to I.S. 813:2002.
The following notes are intended for general guidance:

1.

  The boiler MUST be installed so that the terminal is exposed 

to external air.

2.

  It is important that the position of the terminal allows the free 

passage of air across it at all times.

3.

  Minimum acceptable spacing from the terminal to obstructions 

and ventilation openings are specified in Table 4.

4.

  Where the lowest part of the terminal is fitted less than 2m 

(6’6”) above a balcony, above ground or above a flat roof 

to which people have access then the terminal MUST be 

protected by a purpose designed guard.  

  Terminal guards are available from boiler suppliers. (Ask for 

TFC flue guard model no. K6 - round, plastic coated). In case 

of difficulty contact:

  TFC Group 

Tel. + 44 (0) 01732 351 680 

Tower House, Vale Rise 

Fax. + 44 (0) 01732 354 445 

Tonbridge. Kent TN9 1TB 

www.tfc-group.co.uk

  Ensure that the guard is fitted centrally.

5.

  The flue assembly shall be so placed or shielded as to prevent 

ignition or damage to any part of any building.

6.

  The air inlet/products outlet duct and the terminal of the boiler 

MUST NOT be closer than 25mm (1”) to combustible material. 

Detailed recommendations on the protection of combustible 

material are given in BS. 5440-1:2008.

IMPORTANT

. It is essential to ensure, in practice, that products 

of combustion discharging from the terminal cannot re-enter the 

building or buildings through any openings into the building such 

as ventilators, windows, doors, or other sources of natural air 

infiltration, such as forced ventilation openings etc.
If products of combustion re-entry is identified or suspected this 

should be immediately investigated and corrected following the 

guidance provided in the current Gas Industry Unsafe Situation 

Procedure.

 

The terminal assembly can be adapted to accommodate various 

wall thicknesses. Refer to Section 2.9.

* Only one reduction down to 25mm is allowable per installation 

  otherwise BS5440-1 2008 dimensions must be followed.

Flue Terminal Positions 

Min. Spacing*

1.

  Directly below, above or alongside an opening

 

window, air vent or other ventilation opening. 

 

300mm

2. 

Below guttering, drain pipes or soil pipes. 

 

25mm*

  

BS5440-1 2008

 

75mm

3.

  Below eaves. 

 

25mm*

  

BS5440-1 2008

 

200mm

4. 

Below balconies or a car port roof. 

 

25mm*

  

BS5440-1 2008 

200mm

5.

  From vertical drain pipes or soil pipes. 

 

25mm*

  

BS5440-1 2008 

150mm

6.

  From an internal or external corner or to a  

 

25mm*

 

boundary along side the terminal. 

BS5440-1 2008 

300mm

7.

 

Above adjacent ground, roof or balcony level. 

 

300mm

8.

  From a surface or a boundary facing the terminal.   

600mm

9.

  From a terminal facing a terminal. 

 

1,200mm

10.

 From an opening in a car port 

 

(e.g. door or window) into dwelling. 

 

1,200mm

11.

  Vertically from a terminal on the same wall. 

 

1,500mm

12. 

Horizontally from a terminal on the wall. 

 

300mm

 

Vertical Terminals

13.

 Above the roof pitch with roof slope of all angles.   

300mm

 

Above flat roof. 

 

300mm

14.

 From a single wall face. 

 

300mm

 

From corner walls. 

 

300mm

15. 

Below velux window 

 

2000mm

16. 

Above or side of velux window 

 

600mm

Table 4 - Balanced Flue Terminal Position 

 

Summary of Contents for INDEPENDENT COMBI 24

Page 1: ...u can be assured conform to the safety and performance speci cation that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of li...

Page 2: ...Part Load 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 E...

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: ...01482 498704 NOTE BOILER RESTART PROCEDURE To restart the boiler press the RESTART button The boiler will repeat the ignition sequence if a heat demand is present NOTES FOR THE INSTALLER Relevant Inst...

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

Page 7: ...nd Venturi Assembly Removal and Cleaning 40 3 4 Burner Removal And Cleaning 41 3 5 Cleaning The Condensate Trap Siphon 41 3 6 Cleaning The Heat Exchanger 42 3 7 Reassembly 42 3 8 Replacement Of Compon...

Page 8: ...y 26 8 c For ft3 h divide the gross heat input Btu h by the gross C V of the gas Btu ft3 d For m3 h multiply l s by 3 6 Key to symbols GB United Kingdom IE Ireland Countries of destination PMS Maximum...

Page 9: ...ld 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 For all boilers complete sign hand...

Page 10: ...ition This only occurs if pre heat knob is in the ON period When there 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 T...

Page 11: ...vice 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 regulations 1 6 SAFE HANDLING OF...

Page 12: ...cing from the terminal to obstructions and ventilation openings are specified in Table 4 4 Where the lowest part of the terminal is fitted less than 2m 6 6 above a balcony above ground or above a flat...

Page 13: ...diator 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...

Page 14: ...a core drill the flue can be installed from inside the building where wall thicknesses do not exceed 600mm 24 Where the space into which the boiler is going to be installed is less than the length of...

Page 15: ...ling 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...

Page 16: ...with the manufacturers instructions 2 If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing BS 7593 2006 details the steps necessary to clean...

Page 17: ...sket Burner 219 Sump Clean Out Cover 223 Flue Manifold 224 Flue Manifold Top 227 Clamp Retaining Flue Turret 228 Hose Condensate Internal 229 Siphon Trap 231 Condensate Outlet Connection 302 PCB 304 C...

Page 18: ...1 12 2 2 UNPACKING The boiler is supplied fully assembled in Pack A A telescopic or non telescopic flue assembly for rear or side flue outlet in Pack B is suppled as a separate order Unpack and check...

Page 19: ...B Pack B Contents Non Telescopic A Flue Terminal B Flue Turret C Rubber Terminal Wall Seal D Cutting Aid Note This flue system incorporates a removable flue outlet nose that utilises a push fit locat...

Page 20: ...t during the cutting operation masonry falling 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 squar...

Page 21: ...ion Kits available for use with these B packs Flue Deflector Kit The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from any maximum flue length High Level Flue Ou...

Page 22: ...inimum Maximum Minimum Maximum Minimum Maximum B Pack Standard 181 556 286 484 601 816 526 741 Plus 1 1m D pack 1121 1506 1236 1434 1551 1766 1476 1691 Plus 2 1m D pack 2071 2456 2186 2384 2501 2716 2...

Page 23: ...he outlet terminal is upper most 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 fl...

Page 24: ...been dislodged from its mounting and will need to be refitted 7 Ensure the seam and the outlet terminal are at the top and fitted as shown Note If less than 50 of the length of the flue is internal t...

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: ...n the 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...

Page 28: ...ernal 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 mus...

Page 29: ...connection height up to 3 storeys Soil vent stack 450 Boiler with 75mm sealed condensate trap Min 19mm Internal pipe Min 30mm Internal pipe Water weather proof insulation 75 Boilers without 75mm seal...

Page 30: ...hand side of the boiler comprises a 15mm diameter stub pipe The Installer to provide a compression joint on the end of the stub pipe This assists with pipe removal when servicing The discharge pipe sh...

Page 31: ...NOT switched by thermostats programmers To do so follow the instructions below Accessing the installer wiring 1 Isolate the mains supply from the boiler 2 Remove the front panel Refer to section 3 2...

Page 32: ...am B 1 Remove the link wire from the room stat timer plug 2 Connect the external cable from the room stat timer across these two connections if a general live connection is used for the room stat or t...

Page 33: ...VE X3 PUMP GND 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 F...

Page 34: ...W Outlet Gas Supply CH Return DHW Inlet Gas Pressure Test Point WARNING Whilst effecting the required gas tightness test and purging air from the gas installation open all windows and doors extinguish...

Page 35: ...that the gas service cock I is OPEN 7 Slacken the screw in the inlet pressure test point H and connect a gas pressure gauge via a flexible tube 8 Switch the electricity supply ON and check mechanical...

Page 36: ...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 37: ...ation The diverter valve moves between CH and DHW every 30s The Pump alternates between being on for 50s and then off for 10s 5 dU will be shown To move the diverter valve to mid position for replacem...

Page 38: ...r the relevant national regulations 2 Explain and demonstrate the lighting and shutting down procedures 3 The operation of the boiler and the use and adjustment of all system controls should be fully...

Page 39: ...dance with the analyser manufacturers requirements and Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas a...

Page 40: ...ring the 4 control knobs 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 3 1 2 1 Disconnect the electrical leads from...

Page 41: ...nstruction 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...

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: ...E 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 from the gas control valve outlet 4 Remove the ext...

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 22 2 23 3 12 RETURN THERMISTOR REPLACEMENT 1 Refer to Section 3 8 2 Unclip the return thermistor from the return p...

Page 46: ...3 4 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 electrode using the new gasket sup...

Page 47: ...acing 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 and that pre heat is switched off b Press and hold the PREHEAT...

Page 48: ...splay shows F9 e Using central heating knob rotate clockwise or anticlockwise to show C for Combi then press RESTART button f Using central heating knob rotate clockwise or anticlockwise to show n for...

Page 49: ...o direct drain for the domestic hot water 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...

Page 50: ...to port ensuring o ring in place and secure with the C clip 7 Refill the boiler Refer to Section 2 16 8 Check that the boiler operates in both DHW CH modes 3 23 PRESSURE GAUGE REPLACEMENT 4 5 1 Refer...

Page 51: ...ap siphon Refer to Section 3 18 4 Remove the electrical plug Refer to Section 3 17 5 Place a flat bladed screwdriver in the diverter valve motor body slot provided and ease out the motor Refer to Sect...

Page 52: ...9 Refill the boiler Refer to Section 2 16 10 Check that the boiler operates in both DHW CH modes 1 Refer to Section 3 8 2 Drain the boiler Refer to Section 3 22 3 Disconnect the two electrical leads f...

Page 53: ...ovided 6 Reassemble in the reverse order 7 Refill the boiler Refer to Section 2 16 8 Check that the boiler operates in both DHW CH modes 3 31 FLOW THERMISTOR REPLACEMENT 4 3 1 Refer to Section 3 8 2 D...

Page 54: ...n the return pipe connection ensure clip is oriented 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 fo...

Page 55: ...rcuit Refer to Section 3 22 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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 63: ...63 Installation and Servicing...

Page 64: ......

Page 65: ...ta 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 To maintain th...

Page 66: ...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 67: ...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 68: ...ue 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 Tec...

Page 69: ...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 70: ...70 Installation and Servicing...

Page 71: ...71 Installation and Servicing...

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...

Reviews: