Ideal Boilers mini HE C24, Installation And Servicing

Page 1: ...arts that have not been clearly authorised by Ideal Boilers For details of document amendments refer to page 3 Your Ideal installation and servicing guide 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 1138 1 0406 64A4 ...

Page 2: ...2 mini HE Installation Servicing ...

Page 3: ...ENTS Relevant Installation changes implemented in this book from Mod Level 4905 to 0406 F Pages 33 and 37 Amendment to the illustration of the air pressure switch connection Caradon Ideal Limited reserve the right to vary specification without notice ...

Page 4: ...1 SEDBUK Band B 87 7 Band B 86 9 Band B 87 5 Band B 87 0 NOx classification Class 2 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 HE C24 mini HE C28 Maximum Burner pressure Hot G20 G31 mbar in w g 10 8 4 ...

Page 5: ...e Benchmark Commissioning Checklist BENCHMARK COMMISSIONING CHECKLIST DETAILS Boiler Page Make and model 5 Appliance serial no on data badge 14 SEDBUK No 4 Controls Time and temperature control to heating 26 Time and temperature control to hot water 26 Heating zone valves 26 TRV s 12 Auto bypass 12 Boiler interlock 12 For all boilers Flushing to BS 7593 9 Inhibitor 9 Central heating mode Heat inpu...

Page 6: ... 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 installed fro...

Page 7: ...twisting at the waist F Avoid upper body top heavy bending F Always grip with the palm of the hand F Use designated hand holds F Keep load as dose to the body as possible F Always use assistance if required DHW OPERATION With no call for CH the boiler fires only when DHW is drawn off When there is a call for CH the heating system is supplied at the selected temperature until DHW is drawn off The o...

Page 8: ...o allow lifting access to the wall mounting plate GAS SUPPLY The local gas supplier should be consulted at the installation 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 Natural gas boilers must be installed on a gas supply with a governed meter A gas meter can only be conne...

Page 9: ...ated within the combi boiler and only requires connection to the mains water supply Additional Pumps The boiler is supplied with an integral circulating pump If the boiler is to be used in conjunction with any additional circulating pumps please contact the Technical Helpline for advice on application IMPORTANT A minimum length of 1m of copper pipe MUST be fitted to both flow and return connection...

Page 10: ...he installation must comply with the requirements of BS 6798 and BS 5449 2 Flow Temperature The installation should be designed to work with flow temperatures of up to 90 C 3 Working Pressure All components of the system must be suitable for a working pressure of 3 bar 45 lb in2 and temperature of 110 C Extra care should be taken in making all connections so that the risk of leakage is minimised T...

Page 11: ... system volume must not exceed 96 litres when pressurised to 0 5 bar cold 88 litres when pressurised to 0 7 bar cold 81 litres when pressurised to 1 0 bar cold If the pressure exceeds 2 65 bar when the boiler is up to temperature with all radiators in use then an additional expansion vessel MUST be installed on the return pipework For expansion volumes see Table 5 Guidance on vessel sizing is give...

Page 12: ...449 For further information refer to Good Practise Guide 143 a publication of the energy efficiency office available from the building research establishment Garston Watford WD2 7JR tel 44 0 1923 664258 The boiler is fitted with an automatic internal bypass No further system bypass is required Typical installation D A TRV B Room T stat Balancing valve TRV TRV 6 DOMESTIC HOT WATER REQUIREMENTS 1 Th...

Page 13: ...l 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 switch 23 Venturi device 24 Flue outlet pipe 25 Air intake pipe 26 Automatic air vent 27 Overheat th...

Page 14: ...n pipe 11 Auto air vent 12 Main circuit drainage cock 13 Pump 14 DHW flow switch 15 DHW Thermistor 16 Ignition pcb 17 Right hand panel 18 Boiler front panel 19 Appliance data badge inside 20 Left hand panel 21 CH circuit pressure gauge 22 Model identification instructions 23 Control panel door 24 Main control pcb 25 CH Thermistor 26 CH flow switch 27 Heat exchanger flow pipe 28 Return manifold 29 ...

Page 15: ...Turret air pipe gasket J Flue pipe gasket K Boiler turret gasket L Flue turret M Self tapping screws 4 8x13 4 off N Wall finishing gasket internal plastic O Wall finishing gasket external rubber G H I J K L M N O Optional extras if ordered are available in separate boxes F Electronic programmer kits 24 hrs 7 day F Extension duct kit pack D ø 60 100 F Flue support kits ø 80 100 125 F Vertical outle...

Page 16: ...each additional 45 and 90 flue bend used the maximum permissible length of flue system must be reduced by 1 m or 1 5 m respectively Cutting lengths of flue and air ducts Measure the wall thickness and when using a side outlet the gap between the inner wall and the boiler side casing Use the following chart to calculate the cutting length of air duct Mark the air duct making reference on the groove...

Page 17: ... 165 mm Side Outlet RH Wall thickness Gap 67 mm Side Outlet LH Wall thickness Gap 213 mm 12 REAR FLUE ASSEMBLY Legend 1 Wall finishing gasket external rubber 2 Self tapping screw 4 2x13 3 Flue turret 4 Boiler turret gasket 5 Flue pipe gasket 6 Turret air pipe gasket 7 Centring spring 8 Air flue pipe with terminal grille assembly 9 Wall finishing gasket internal plastic 1 8 9 7 6 5 4 3 2 13 WALL MO...

Page 18: ... flue shown IMPORTANT Ensure that during the cutting operation masonry falling outside 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 square to the wall 2 Drill the fixing holes with an 8mm 5 16 masonry drill Fit suitable wall plugs not provided Note If the teminal is to be sited within 25 40 mm of a corner o...

Page 19: ...nly poured into the flue outiet and does not spill into the boiler casing Fit the flue system referring to the instructions contained with the kit Make good the internal wall surface using the seal provided A 18 CONNECTIONS Fit the service valves washers and tail pipes as shown Central Heating flow Domestic hot water outlet Gas inlet Domestic cold water inlet Central Heating return Connect to the ...

Page 20: ... part of its length All pipework and fittings in the condensate drain system must be made of plastic No other materials may be used To avoid condensate being trapped the drainpipe should be run with a fall of at least 2 5 45 mm m away from the boiler the number of bends and joints should be kept at minimum the drainpipe should be adequately fixed to pevent pipe sagging 21 ELECTRICAL CONNECTIONS Wa...

Page 21: ...ntrol panel When completely pulled out the panel can rotate 45 downwards to facilitate the operations on the internal parts 5 Loosen the screws D and remove the service panel D 1 2 L N 3 Mains Power supply terminal block External controls terminal block Volt free contacts Thermostat link Remove when wiring external thermostats Refer to frame 25 Note Ensure that the lengths of the current conductor...

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Page 23: ...rd bu bn bu bn bn bu bn bu bk bn bu 3 1 2 bu bn bn gnye gnye gnye gnye gnye gnye gnye gnye gnye bu bn bn bu rd rd wh bu rd bu rd rd gy bn bu bu bu bn bu gy rd gnye gnye vt og bn bu rd bk wh gn NC COM NO bu bn bk bu bn bu bn bn brown bu blue bk black wh white rd red gy grey gn green ye yellow vt violet og orange gnye green yellow 16 17 18 19 20 31 30 29 28 27 26 25 24 23 22 21 optional 101 104 105 ...

Page 24: ... 20 28 29 bk bu bk 8 9 bu bn Three way 5 7 bk bn 6 div valve bu wh 16 17 30 31 26 27 bk bk 120 122 rd rd 11 12 13 14 15 bn bu bk bn bu bn bu bk bn bu 101 102 103 104 105 Gas Valve bk 22 23 gy modulation coil 108 106 107 110 109 bu bk bn bu bu bk bu bn Safety thermostat Gas Valve on off operators 113 114 115 111 112 bu bn rd 17 P C B 1 P C B 2 bn Flue thermostat bn Ignition electrodes Detection ele...

Page 25: ...eater and can normally be left at least 24 hours 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 thermostat should be wired into the system To maintain frost protection with the programmer selector switches set to OFF all the controls MUST be left in the running position The frost thermostat should...

Page 26: ...e and connect a gas pressure gauge via a flexible tube Be sure to select the correct pressure test point Refer to Tables for pressures 7 Check that the gas service cock is ON 8 Switch the electricity supply ON and check that all external controls are calling for heat 9 Set the main switch C to ON Following a pre purge period the gas control solenoid valve should open and the spark commence continu...

Page 27: ...ckwise the pressure increases Minimum valve setting 8 Disconnect one of the two connectors A 9 If necessary rotate the minimum gas pressure adjustment B using a pozidrive screwdriver until you obtain the required pressure as indicated on Table 1 at page 4 burner pressure By rotating clockwise the pressure increases 10 Turn the boiler off and re connect the wire to the modulating operator 11 Start ...

Page 28: ...re of approximately 35 C rise is obtained at the tap This corresponds to a flow rate of about litres min gpm models 10 1 2 2 mini HE C24 11 7 2 6 mini HE C28 d Turn off the DHW tap 2 Central heating all models Operate each control separately and check that the main burner or circulating pump as the case may be responds 3 Gas rate G20 Check the boiler gas rate when the boiler is at full output The ...

Page 29: ...ttention to the Lighting Instruction label affixed to the inside of the lower front 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 heating and hot water cons...

Page 30: ...W 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 Sampling points Exhaust gas Sampling points Air intake 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...

Page 31: ...he gas service cock and disconnect the electricity supply 2 Remove the screws A and lift off the boiler front panel 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 5 Remove the screws C and remove the boiler inner casing C C SERVICING ...

Page 32: ...ervicing 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 are incorrect ensure the inlet pressure with the appliance running is correct refer Table 1 If the burner pressures require adjustment refer to frame 27 To adjust pressures If the appliance still does not operate correctly refer to the appropriate fault fin...

Page 33: ...he screw C and remove the fan holder bracket D A B C D 6 Remove the fan by sliding it towards left see the arrow 7 Check that the impeller runs freely Clean with a soft brush or renew as necessary Refer to frame 51 for replacement Note Always take care when handling the fan in order to preserve the balance of the impeller 8 Check the venturi E for cleaness E 9 Re assemble in reverse order To corre...

Page 34: ... combustion chamber and disconnect the electrodes leads 4 Remove the burner Refer to frame 35 5 Undo the screws that hold the electrodes and remove 6 Fit new electrodes as necessary following the sequence illustrated Ignition 1st Ignition 2nd Detection 3rd 7 Check the spark gap 4 mm 5 32 Ignition Detection Male Female 10 mm Burner blade 3 8 8 Re assemble in reverse order 9 Check the ignition and o...

Page 35: ...emove the flue thermostat 6 Assemble the flue thermostat carrying out the removal operations in reverse sequence B A C 46 THERMISTOR REPLACEMENT 1 Disconnect the electrical supply 2 Remove the front and right hand side casing panels refer to frame 34 Removal of CH thermistor 3 To remove the CH thermistor close off the isolating cocks of the CH circuit at the bottom of the boiler 4 Release system p...

Page 36: ... casing panel refer to frame 34 3 Disconnect the connectors A and B 4 Disconnect the earth wiring from the gas valve 5 Unscrew the connectors C and remove the pipe D 6 Unscrew the inlet connector 7 Unscrew the screws E and remove the valve 8 Fit the new gas valve in reverse order ensuring new gaskets are fitted and check for gas soundness 9 Check the operation of the boiler B C D E A 49 WATER TEMP...

Page 37: ...drainage cock Do not release CH pressure using the pressure relief valve It may cause debris within the system to foul the valve 5 Completely unscrew the connection A the locknut B and remove the expansion vessel from the top of the boiler A B 6 Re assemble in reverse order 51 FAN REPLACEMENT 1 Disconnect the electrical supply 2 Remove outer and inner casing 3 Disconnect the connectors A and the e...

Page 38: ...connection H connection not used 54 PUMP REPLACEMENT COMPLETE 1 Disconnect the electrical supply 2 Remove the front and right hand side casing panels refer to frame 34 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 Loosen the connect...

Page 39: ...rol p c b is fitted The numbers refer to the marking printed on the circuit board 1 2 3 4 5 6 7 8 9 Important When re assembling the electronic control p c b 10 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 11 Insert the spindles in the control panel knobs until the notch D...

Page 40: ...he correct wiring connectors on the switch N O do not use C Looking through the switch box B it is possible to verify the position of the spindle C C Boiler OFF Pump operating 58 CH FLOW SWITCH MEMBRANE REPLACEMENT 1 Disconnect the electrical supply 2 Remove front casing panel refer to frame 34 3 Close off the isolating cocks of the CH circuit at the bottom of the boiler 4 Release system pressure ...

Page 41: ...ains electricity supply to the boiler Warning ensure that all the electric parts and wiring are dry and do not touch other electric parts during the following operations 3 Hold the flow switch sensor and bring the ring in contact with the sensor as illustrated in the following drawing 4 Observe if the lamp fitted in the sensor body is lit If not reverse the ring and repeat the previous operation 5...

Page 42: ...rse order Fit the clip H with the arrow pointing upwards as illustrated in the drawing Do not force the connection F when tighting it D L B A E B C F H I M J K G 62 RECUPERATOR REPLACEMENT 1 Disconnect the electrical supply 2 Remove outer and inner casing as explained in frame 34 3 Close off the isolating cocks of the CH circuit at the bottom of the boiler 4 Release system pressure by opening the ...

Page 43: ...SERVICING mini HE Installation Servicing 43 After reassembling ensure that the fan exchanger and exchanger elbow gaskets are correctly mounted and ensure a good sealing A B C D F H I J K G L E SERVICING ...

Page 44: ...e actuator see frame 64 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 64 DIVERTER VALVE ACTUATOR REPLACEMENT ...

Page 45: ...ew the connector G disconnect the CH flow and DHW outlet isolator valves D E G F F 10 Remove the DHW heat exchanger see frame 63 11 Remove the fork H and move away the pipe I 12 Unscrew the screw J and remove the diverter flow group H I J rear 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 66 PROGRAMMER REPL...

Page 46: ... the pressure relief valve It may cause debris within the system to foul the valve 5 Remove the CH drain cock A from the return body 6 Re assemble in reverse order A 68 CONDENSATE TRAP REPLACEMENT 1 Disconnect the electrical supply 2 Remove front and right hand casing panels refer to frame 34 3 Disconnect the trap from the draining pipe 4 Using pliers remove the spring A moving it up wards 5 Remov...

Page 47: ...ture probe The following table gives a summary of the relationship between each of the possible lamp combinations and their meaning Normally operating boiler CH operation DHW operation Frost protect operation DHW operation Excessive temperature on primary circuit Faulty CH temperature probe NTC Faulty DHW temperature probe NTC Faulty primary circuit no water or absence of flow Lack of burner ignit...

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Page 49: ... 16 max Repair or replace faulty wiring Is the continuity of the modulator harness O K Repair faulty gas valve Repair faulty PCB 1 When a DHW tap is opened and the DHW temperature is set to maximum does the water become hot Is the p c b jumper in position 8 Refer to frame 55 Connect jumper in position 8 Is the red LED illuminated on DHW flow sensor Is there 5V dc between Red and Blue on connecting...

Page 50: ...o no no no no yes yes yes yes yes yes yes yes Check resistance of DHW thermistor Is it between 12 kW and 1 5 kW Check resistance of CH thermistor Is it between 12 kW and 1 5 kW Are LED2 and LED 3 flashing Replace faulty thermistor Are LED2 flashing 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...

Page 51: ...Is there 230V at Black and Blue at gas valve harness connector on PCB 2 Repair or replace faulty wiring Is there 230V at pin 11 Brown on PCB connecting harness at PCB 1 Is there continuity of overheat thermostat wiring at PCB connection Has the main overheat thermostat operated Check continuity Is fuse continuity O K on PCB 2 Is there a burner pressure during ignition period Replace faulty PCB 2 R...

Page 52: ...e assembly 5W from tip to connector no Is the polarity of the mains correct Replace faulty detection lead assy Rectify electrode position or replace faulty electrode Does the burner remain alight Connect lead correctly Is the lead connected Replace faulty PCB 2 Is the burner pressure within min and max value with the boiler running Rectify wiring fault no yes Is the condense freely discharged thro...

Page 53: ...cted Replace faulty PCB 1 Is LED 1 flashing and LED 2 and LED 3 on Switch to on position Is there 230V at pin 101 PCB 2 Repair 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 fan Replace faulty Air Pressure Switch Is there continuity across C and NO on the Air Pressure Switch Repair or re...

Page 54: ...at 10 0 L min 24 kW model 11 6 L min 28 kW model Rectify gas supply fault 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 Rectify water supply fault Check the DHW inlet filter Remove debris and clean or replace filter With the DHW hot does the burner pressure mod...

Page 55: ...3984 6 E90 627 Gas valve gaskets 1 172611 7 169 127 Air pressure switch mod mini HE C24 1 173236 H08 605 Air pressure switch mod mini HE C28 1 173136 8 E83 013 Safety valve 1 172494 9 Electronic regulation p c b 1 174017 10 E83 142 Full sequence ignition device 1 172548 11 E00 684 Primary circuit flow switch 1 075419 12 E83 082 DHW flow switch mod mini HE C24 1 172503 13 E00 688 Main flow switch m...

Page 56: ...56 mini HE Installation Servicing 32 Control panel door 1 173988 33 Front case panel 1 173989 1 4 6 2 5 7 8 17 13 9 10 14 29 30 23 25 18 15 11 24 12 20 32 31 33 31 21 22 16 26 27 28 19 3 ...

Page 57: ...Person 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 iss...

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: ...fiers 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 Caradon Ideal Limited 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 t...