IDEAL Logic SYSTEM 15 Installation And Servicing

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User manual (6 pages)

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Installation and servicing (72 pages)

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Page 1 Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. For the very latest copy of literature for specification and maintenance practices visit our website www.idealboilers.com where you can download the relevant information in PDF format.
Page 2 Ideal Logic System - Installation and Servicing...
Page 3 Relevant Installation changes implemented in this book from Mod Level ..a06 (Feb 14) to a07 (May 14) Cover pages Re-brand outer covers page 11 Paragraph 4b updated Ideal Stelrad Group reserve the right to vary specification without notice Ideal Logic System - Installation and Servicing...
Page 4 C.V. of the gas (Btu/ft = An appliance designed for use on 2nd Family gas, Group H only. c. For m /h - multiply l/s by 3.6. Ideal Logic System - Installation and Servicing...
Page 5: Table Of Contents
For all boilers: complete, sign & hand over to customer For assistance see Technical Helpline on the back page NOTE TO ThE INsTaLLER: COMpLETE ThE BENChMaRK COMMIssIONINg ChECKLIsT aND LEaVE ThEsE INsTRUCTIONs WITh appLIaNCE Ideal Logic System - Installation and Servicing...
Page 6: Safe Handling
• PRV Wall Outlet Kit considered: • Pressure Gauge Extension Kit • Grip the boiler at the base. • Be physically capable. • Use personal protective equipment as appropriate, e.g. gloves, safety footwear. Ideal Logic System - Installation and Servicing...
Page 7: Location Of Boiler
Installation and Servicing Instructions or as otherwise recommended by Ideal stelrad group in writing. If in doubt In both cases, details of essential features of cupboard / please enquire.
Page 8: Flue Installation
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. Ideal Logic System - Installation and Servicing...
Page 9: Air Supply
Any external runs must be in accordance with BS 6798. The drain outlet on the boiler is sized for standard 21.5mm (3/4”) overflow pipe. It is a universal fitting to allow use of different brands of pipework. Ideal Logic System - Installation and Servicing...
Page 10 Bottom clearance after installation can be reduced to 5mm. Gas Inlet This must be obtained with an easily removable panel, to enable the consumer to view the system pressure gauge, and to provide the 100mm clearance required for servicing. Ideal Logic System - Installation and Servicing...
Page 11: Pump
This should occur within 0.3 bar Ecl 6053 of the preset lift pressure. iv. Release water from the system until the minimum system design pressure is reached; 1.0 bar if the system is to be pre- pressurised. Ideal Logic System - Installation and Servicing...
Page 12: Water Treatment
Sentinel Performance Solutions Treatment in Central Heating Systems. The Heath Business & Technical Park Runcorn Cheshire WA7 4QX If water treatment is used Ideal stelrad group recommend Tel: 0800 389 4670 only the use of Scalemaster Gold 100, FERNOX, MB-1, www.sentinel-solutions.net...
Page 13 Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specific boiler range and output. Ideal Logic System - Installation and Servicing...
Page 14 Accessory Pack Return Valve Pack Flow Valve Pack 1. Screw (x2) 2. Wallplug (x2) 3. Turret Clamp Screw (x1) Flow Valve Pack 1. Pipe CH Flow 2. Washer CH 3. Valve Flow (with gauge) Ideal Logic System - Installation and Servicing...
Page 15: Front Panel Removal
Wall Seal (white) FRONT paNEL REMOVaL 1. Loosen the 2 screws retaining the front panel. 2. Pull the two spring clips downwards to disengage. 3. Pull the front panel forward and upwards to remove. Ideal Logic System - Installation and Servicing...
Page 16: Safe Handling
Ensuring that at least one of the screws is fitted into a top 2. Lift the boiler onto the wall mounting plate (refer to the slot. Introduction section for safe handling advice), locating it over the two tabs. Example of fixing 3G9948 Ideal Logic System - Installation and Servicing...
Page 17 Horizontal Flue Terminal (1000mm long) B Pack cut 75mm For Flue lengths between 658 & 708 use a horizontal Flue Terminal (1000mm long) B pack, cut 75mm off the end of the terminal section of the telescopic flue only. Ideal Logic System - Installation and Servicing...
Page 18 Note; Telescopic flue B Pack or attached “D” pack extensions do not need to be cut between minimum and maximum values shown above (except where specified). Horizontal Flue Terminal (600mm long) B Pack flue will require cutting on values below maximum values shown in the table above. Ideal Logic System - Installation and Servicing...
Page 19 4. Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure its cut square. 5. Remove all burrs and place a light chamfer on the outer edge to aid assembly. Ideal Logic System - Installation and Servicing...
Page 20 6. Ensure all sample points are accessible and all sample plugs and caps are fitted. Retaining Clamp Lugs Sample points screw Flue Outlet A - Duct Assembly B - Flue Turret C - Turret Clamp D - Seal Flue Outlet Ideal Logic System - Installation and Servicing...
Page 21 Vertical connector elbow UIN 203132 UIN 152259 UIN 208175 UIN 203130 elbow UIN 203131 Flue Flue Seal Collar - Tile Roof duct UIN 152258 support Roof Flue Extension Duct UIN 203129 Flue duct support Ideal Logic System - Installation and Servicing...
Page 22: Flue Terminal Position
The equivalent flue length resistance Below eaves or balcony 500 mm of the elbow kits are: Below velux windows 2000mm elbow kit = 1m Above or side of velux windows 600mm elbow kit = 0.6m Ideal Logic System - Installation and Servicing...
Page 23 7. Finally ensure the roof flashing plate is correctly sealed to the roof. Ideal Logic System - Installation and Servicing...
Page 24 Boilers without 75mm sealed condensate trap must be fitted with condensate trap must be fitted with a 75mm trap and visible air break a 75mm trap and visible air break continued ..Ideal Logic System - Installation and Servicing...
Page 25 75mm trap and visible air break ≥ 500 2 rows of three Ø12mm holes 25mm centres, 50mm from the bottom of the tube, facing away from the house Ideal Logic System - Installation and Servicing...
Page 26: Electrical Connections
Wiring external to the boiler MUST be in accordance with the having a 3mm (1/8”) contact separation in both poles. The current I.E.E. (BS.7671) Wiring Regulations and any local means of isolation must be accessible to the user after regulations. installation. Ideal Logic System - Installation and Servicing...
Page 27: Internal Wiring
VALVE SPUR BOILER CH ON TIMER HW ON HW OFF 3G10022 LOgiC SYSTEM BOiLEr WiTH S PLan SYSTEM S PLAN VALVE S PLAN FUSED VALVE SPUR BOILER CH ON TIMER HW ON 3G10023 Ideal Logic System - Installation and Servicing...
Page 28: External Electrical Controls
The frost thermostat should be sited in a cold place but where it can sense heat from the system. Note. If the boiler is installed in a garage it may be necessary to fit a pipe thermostat, preferably on the return pipework. Ideal Logic System - Installation and Servicing...
Page 29: Wiring Diagram
INSTALLATION 28 WIRINg DIagRaM Ideal Logic System - Installation and Servicing...
Page 30: Ideal Logic System - Installation And Servicing
Benchmark Checklist completed. A flow chart to assist is provided on page 59. aTTENTION ! IT Is a CONDITION OF ThE MaNUFaCTURERs WaRRaNTy ThaT ThE BENChMaRK COMMIssIONINg ChECKLIsT Is FULLy COMpLETED aND LEFT WITh ThE appLIaNCE Ideal Logic System - Installation and Servicing...
Page 31: Initial Lighting
11. Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output. Refer to Table 2. Note. The boiler incorporates a fan overrun cycle which MUST NOT be prematurely interrupted by isolation of the mains electricity supply. Ideal Logic System - Installation and Servicing...
Page 32: Handing Over
7. If a timer is fitted draw attention to the timer Users Instructions the envelope pack and the requirement to register it to receive and hand them to the householder. the full benefit of the warranty. Ideal Logic System - Installation and Servicing...
Page 33: Servicing Schedule
(and gas rate) have been verified, then contact Ideal. 11. Complete the service section in the Benchmark Commissioning Checklist.
Page 34 3. Remove the extended nut on the fan mounting bracket. 4. Lift off fan and venturi assembly. 5. Inspect the injector for blockage or damage. 6. Inspect fan outlet sealing gasket and replace if necessary. Injector Ideal Logic System - Installation and Servicing...
Page 35: Burner Removal And Cleaning
1. Pull off the rubber pipe noting the position and flush out any deposits with clean water. 2. Replace the cleaning plug and refill the siphon with water. 3. Replace the rubber pipe connector with the twin wall seal fitted to the condensate siphon. Ideal Logic System - Installation and Servicing...
Page 36: Cleaning The Heat Exchanger
4. Reconnect the fan electrical leads. 11. Check the operation of the boiler. refer to Frames 30 & 5. Remove the sump cover and refit the lower flue manifold as shown. 6. Refit the sump cover. Ideal Logic System - Installation and Servicing...
Page 37: Replacement Of Components
Refit the extended nut. 9. Reassemble the boiler in reverse order, taking care not to overtighten the screw on the fan mounting bracket. 10. Check the operation of the boiler. Refer to Frames 30 & 31. Ideal Logic System - Installation and Servicing...
Page 38 7. Fit the new burner, replacing any damaged or deteriorating sealing gasket. 8. Reassemble in reverse order. Refer to Frame 40. 9. Check the operation of the boiler. Refer to Frames 30 & 31. Ideal Logic System - Installation and Servicing...
Page 39 Check dimensions as shown. 8. Reassemble in reverse order. 9. Check the operation of the boiler. Refer to Frames 30 & 31. a i g S t r Spark Gap 3.5mm Ideal Logic System - Installation and Servicing...
Page 40 4. Fit the new spark generator and re- Spark Generator assemble in reverse order ensuring the two earth leads are correctly replaced. 5. Check operation of the boiler. Refer to Frames 30 & 31. Ideal Logic System - Installation and Servicing...
Page 41 4. Turn the siphon clockwise to disengage and lift to remove. 5. Reassemble in reverse order. 6. When reassembling ensure the trap is full of water. 7. Check operation of the boiler. Refer to Frames 30 & 31. Siphon Ideal Logic System - Installation and Servicing...
Page 42 “Boiler Type Card Fault - Contact Installer” Plastic The correct BCC for this appliance will need to Clip be fitted. 11. Check operation of the boiler. Refer to Frames 30 & 31. Ribbon Cable Connection Ideal Logic System - Installation and Servicing...
Page 43: Draining The Boiler
(re-pressurise as appropriate) before proceeding to check operation of the boiler. 5. Check operation of the boiler. Refer to Frames Circuit 30 & 31. Drain Flow Retrun Ideal Logic System - Installation and Servicing...
Page 44 7. Ensure the air vent cap is loose. 8. Refill the boiler. Refer to Frame 23. Check for leaks around the new air vent joint. 9. Check the operation of the boiler. Refer to Frames 30 & 31. Ideal Logic System - Installation and Servicing...
Page 45: Pump Head
5. Fit the new thermistor using the sealing washer provided. 6. Reassemble in the reverse order. 7. Refill the boiler. Refer to Frame 23. 8. Check the operation of the boiler. Refer to Frames 30 & 31. Ideal Logic System - Installation and Servicing...
Page 46: Expansion Vessel
19. Check operation of the boiler. Refer to Frames 30 & 31. 11. Undo the inlet pipe union nut and remove the retaining spring clip and remove pipe. Ideal Logic System - Installation and Servicing...
Page 47 5. Reassemble in reverse order. 6. Check operation of the boiler. Refer to Frames 30 & 31. Note. Ensure that the boiler front panel is correctly sealed, compressing the seal to make an airtight joint. Ideal Logic System - Installation and Servicing...
Page 48 **If PCB replaced as a spare ensure that the BCC (boiler chip card - small plastic part) is fitted to the PCB otherwise replace PCB. REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Ideal Logic System - Installation and Servicing...
Page 49 In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve. REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Ideal Logic System - Installation and Servicing...
Page 50: Pressure Gauge
Rectify Wiring & connections both ends and has not deteriorated? Does the wiring have continuity? Replace PCB Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan? Replace Fan Ideal Logic System - Installation and Servicing...
Page 51 After switching power on and ‘c0’ being shown, Replace PCB press reset. Is ‘c2’ still shown? REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. Ideal Logic System - Installation and Servicing...
Page 52 Move the mode knob to the ON position Is boiler mode knob in the ON position? Check system controls and wiring Is there 230V at (A) Refer to Frame 79? Check wiring from terminal strip to PCB. Ideal Logic System - Installation and Servicing...
Page 53: Spare Parts
When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. Failure to do so could affect safety or performance of this appliance.
Page 54: Short List Of Parts
Short liSt of partS Ideal Logic System - Installation and Servicing...
Page 55 Gas Safe registered engineer who has been trained on the boiler installed. The service details should be recorded on the Benchmark Service Interval Record and left with the householder. www.centralheating.co.uk © Heating and Hotwater Industry Council (HHIC) Ideal Logic System - Installation and Servicing...
Page 56: Gas Boiler System Commissioning Checklist
GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Programmable room thermostat Optimum start control...
Page 57: Service Record
SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % (Where Possible) (Where Possible) Signature Signature SERVICE 03 SERVICE 04...
Page 58 4. “S” will be shown on the display and the boiler output will be reduced to minimum. 5. The boiler will remain at minimum rate for 5 minutes before reverting to normal operation. Ideal Logic System - Installation and Servicing...
Page 59 0.2%? sampling point. Allow readings to stabilise before recording. Turn off appliance and call Ideal Technical Helpline for advice The appliance must not be commissioned until problems are identified CO level less and resolved. If commissioning cannot be fully completed, the appliance than 350ppm AND CO/CO must be disconnected from the gas supply in accordance with GSIUR.
Page 60 & servicing of central heating systems FM 59915 Ideal Boilers Ltd., 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.
Page 61 Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. For the very latest copy of literature for specification and maintenance practices visit our...
Page 62: Minimum Clearances
Benchmark Commissioning Checklist. You can check your installer by calling Gas Safe Register direct on 0800 4085500. Ideal stelrad group is a member of the Benchmark scheme and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.
Page 63: Frost Protection
REDUCED to LEss tHAn 0.3 BAR UnDER tHIs ConDItIon. BOiLEr COnTrOLS Legend a. CH Temperature Control D. Burner ‘on’ Indicator g. Economy Mode B. Mode Control E. Pressure Gauge C. Boiler Status F. Condensate Drain Ideal Logic System - User’s...
Page 64 During cold weather, set the boiler stat to maximum, (Must return to original setting once cold spell is over) Place the heating on continuous and turn the room stat down to 15ºC overnight or when unoccupied. (Return to normal after cold spell). Ideal Logic System - User’s...
Page 65: Troubleshooting
“Fault Codes” section. If “0” is displayed then contact a Gas is displayed then contact a Gas Safe Registered Engineer or in Safe Registered Engineer or in IE a Registered Gas Installer IE a Registered Gas Installer (RGII) (RGII) Ideal Logic System - User’s...
Page 66 The boiler has a call for central heating / hot water but the appliance has reached the desired temperature set on the boiler. The boiler is operating for central heating / hot water. The boiler is operating in frost mode. continued ..Ideal Logic System - User’s...
Page 67: Fault Codes
5 Boiler Resets in 15 minutes 1. Turn power off and on at the fused spur. 2. If the boiler fails to operate please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period.
Page 68 Ideal stelrad group pursues a policy of continuing improvement in the design and performance Ideal Consumer Helpline of its products. The right is therefore reserved to vary specification without notice. Tel: 01482 498660 Ideal, P.O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN.

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