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IDEAL F80 Installation And Servicing

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installation and
servicing
Your Ideal installation and servicing guide
See reverse for
Models F80, F120, F160
& F200, F240, F280
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 Boilers.
August 2009 UIN 202441 A06
xtra
users guide
xtra

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Summary of Contents for IDEAL F80

  • Page 1 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 Boilers. August 2009 UIN 202441 A06...

  • Page 2: Hydraulic Resistance

    For ft/h divide the gross heat input (Btu/h) by the gross C.V. Any direct connection of a control device not approved by Ideal of the gas (Btu/ft Stelrad Group could invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety HEALTH &...

  • Page 3: Table Of Contents

    GENERAL xtra CONTENTS Natural Gas only PI No. 0063 BR 3123 Boiler Assembly - exploded view........10 Destination Countries: GB, Boiler Clearances............. 8 Boiler Dimensions............7 Commissioning and Testing.......... 31 Electrical Connections........... 13 Electrical Supply............... 6 Fault Finding.

  • Page 4: Gas Supply

    GENERAL INTRODUCTION IGE/UP/1 Soundness testing and purging of industrial and commercial gas installations. boilers are fully automatically controlled, floor xtra IGE/UP/2 Gas installation pipework, boosters and standing, fanned, super efficient condensing appliances. compressors on industrial and commercial The comprehensive boiler controls built into the appliance premises.

  • Page 5: Water Circulation

    The boiler must NOT be used for direct hot water supply. The hot flue resistance is 100Pa (0.4" w.g.) for F80 and F120, and 150Pa water storage cylinder MUST be of the indirect type.

  • Page 6: Electrical Supply

    Guidance Notes on Water Treatment in Central Heating Systems. Ideal Stelrad Group recommend the use of Fernox Copal or MB1 or GE Betz Sentinel X100 inhibitors and associated water treatment products, which must be used in accordance with the manufacturers' instructions.

  • Page 7: Boiler Dimensions

    All dimensions shown in mm SIDE VIEW FRONT VIEW Flue Centre Line 1150 R2" Flow Connection Flue R1" Gas Connection PLAN VIEW REAR VIEW Electrical Conduit Electrical Conduit R2" Return Connection Inlet O110 F80-F160 1024 F200-F280 1048 1165 1327 im8252 Installation & Servicing xtra...

  • Page 8: Boiler Clearances

    GENERAL BOILER CLEARANCES The minimum dimensions as indicated must be respected Right Side: to ensure good access around the boiler. 150mm Recommended minimum clearances are as follows. Front: Rear: 600mm; except, access doors may be closer, but not 700mm or adequate space from the rear of the jacket to less than 200mm and 600mm must still be available make the flue connections and access to the flue sample for service across the width of the boiler.
  • Page 9 Feed see notes position or raise the cistern above the minimum requirement specified by Ideal Stelrad Group. The isolation valves should be fitted as close to the pump as possible. System The information provided is based on the following assumptions:...

  • Page 10: Boiler Assembly - Exploded View

    INSTALLATION BOILER ASSEMBLY - Exploded View (F280 shown) im8267 Data plate Legend 1. Control fascia panel 11. Venturi 27. Burner manifold 2. Burner switch 12. Control Module 33. Air pressure switch 3. Pressure gauge 14. Alarm / boiler run relays board 37.

  • Page 11: Locating/Levelling The Boiler

    INSTALLATION PACKAGING REMOVAL / REMOVAL FROM PALLET / LOCATING & LEVELLING The boiler is delivered assembled and protected by a cardboard sleeve and fittings and fixed on a wooden base. This allows the boiler to be handled by a forklift. The packaged boiler will pass through a 800mm wide opening and unpacked boiler through a 700mm wide opening.

  • Page 12: Water Connections

    INSTALLATION CONDENSATE DRAIN The condensate drain must be connected to the condensate bulk head connector on the back of the boiler and then connected to a drainage point, preferably within the building. The pipe size from the condensate connector on the lower rear panel is 21.5mm.

  • Page 13: Electrical Connections

    (24 x 0.2 mm) and to BS. 6500, Table 16. The fuse earth conductor is longer than the current carrying conductors, rating should be 5A for F80-F120 and 7A for F160-F280. such that if the cord anchorage should slip the current carrying Wiring external to the boiler MUST be in accordance with the conductors become taut before the earthing conductor.
  • Page 14 INSTALLATION 15 INSTALLER CONNECTIONS 230V AC permanent mains supply Optional connections for programmable room stat. 230V AC and modulating sequencer kits output for CH system pump. max 1 amp 24 Volt connection Optional connections for outside temperature Optional 230V AC sensor kit output for DHW pump or divertor valve.
  • Page 15 INSTALLATION 16 CH CONTROL CONNECTIONS Input terminals are available for connecting a variety of system 3. Programmable Room Thermostat Kit. controls for central heating demand. The programmable room thermostat kit incorporates a Heating demand can be controlled by: room temperature sensor and a programmer capable of controlling the heat output from the boiler to satisfy 1.

  • Page 16: Wiring Diagrams

    INSTALLATION 18 PICTORIAL WIRING DIAGRAM Installation & Servicing xtra...
  • Page 17 D H W modifications are required. 230 VAC Permanent Alternatives: The Ideal mains supply If either pump requires more than 1 amp supply current, connection programmable room must be made via a relay thermostat, outside sensor and tank sensor kit...
  • Page 18 Parameter 46 = 23 If a live output is required for positioning of the valve to satisfy DHW demand. Alternatives: The Ideal programmable room thermostat, outside sensor and tank sensor kit provides enhanced user comfort. Full instructions provided with kits.
  • Page 19 INSTALLATION 22 EXAMPLES OF HEATING SYSTEMS Heating system with DHW production (storage tank Output = Boiler Output) and mixing header. 3 way diverting valve Heating System Flow Pump Storage Heating circuit tank output boiler output Return im8196 Filter Primary Mixing System Header Pump...
  • Page 20 INSTALLATION 23 BASIC CONTROLS DISPLAY MASTER MODULE CONTROL PANEL A. Burner switch B. Pressure gauge C. Display D. Reset button RESET E. Mode button xtra F . Step button G . Store button H. + button (to increase MODE STEP STORE values) - button (to decrease...
  • Page 21 INSTALLATION 24 STANDARD CONTROLS ACCESS Modes of Operation The standby, parameter and information modes are accessible without the service code. Standby Mode S t b y The standby mode will be shown after start up or reset of the boiler control module. If no buttons are pressed for 20 minutes the display will automatically be set to standby mode.
  • Page 22 INSTALLATION 25 STANDARD CONTROLS ACCESS CONT'D Info Mode I N F O Info mode is entered from standby mode by pressing the 'mode' button twice. Press Display P A R A I N F O Press the step button until the desired information is displayed. The dot after the 1st digit will be flashing indicating the boiler is in 'info' mode.
  • Page 23 INSTALLATION 26 STANDARD CONTROLS ACCESS CONT'D Info mode cont'd..Press Display Description b. 0. 0 C. 8 2 Heat Exchanger Temperature T7 ( 0. 1 Rate of increase in Temperature T7 ( C/s) E. 0. 1 Ionisation Current or (micro amps) F.
  • Page 24 INSTALLATION 27 STANDARD CONTROLS ACCESS CONT'D Info mode cont'd..Press Display Description Burner Run Hours, DHW N. 0 0 100 thousands/10 thousands Burner Run Hours, DHW thousands/hundreds Burner Run Hours, DHW tens/units Service Mode L 6 0 H 8 0 It is possible for servicing purposes to run the boiler on maximum or minimum loads.
  • Page 25 INSTALLATION 28 ADVANCED CONTROLS ACCESS There is little requirement for advanced controls access as factory preset values are satisfactory for most parameters. If parameter changes are required with the optional kits then further instructions are provided with them. This mode must only be entered by a competent engineer. This level of access MUST NOT be entered by the user. Code Mode C O D E By entering the service code the following additional features are accessible:...
  • Page 26 INSTALLATION 29 ADVANCED CONTROLS ACCESS CONT'D Lower Upper Factory Press Display Description Limit Limit Setting P A R A DHW Temperature ( C) T3 1. 6 0 Instant water heater Storage tank DHW System 00 = Off 01 = On 2.
  • Page 27 INSTALLATION 30 ADVANCED CONTROLS ACCESS CONT'D Lower Upper Factory Press Display Description Limit Limit Setting Booster time (minutes) note 00 = Off CH flow parallel shift For use with outside temperature sensor Tplus ( Temperature added to DHW temperature set point (parameter 1) when storage tank used.
  • Page 28 INSTALLATION 31 ADVANCED CONTROLS ACCESS CONT'D Lower Upper Factory Press Display Description Limit Limit Setting Forced low time (x 9 seconds) Do not Do not adjust adjust TIME - Temp. differential between flow temp & set point at which slow start ends. Slow start TIME - Modulation rate in slow start X 400rpm/min CH post pump time (minutes)
  • Page 29 INSTALLATION 32 ADVANCED CONTROLS ACCESS CONT'D Lower Upper Factory Press Display Description Limit Limit Setting CH type x0=Room thermostat x1=Outside temperature x2=N/A x3=N/A x4=0-10V: capacity (using BMS 0-10V kit) x5=0-10V: temperature (using BMS 0-10V kit) x6=+/- control x7=NTC6 on AM4 + RT: capacity x8=0-10V on AM4 + RT: temperature 0x=N/A - First digit factory set to '0'.
  • Page 30 INSTALLATION 34 FAN MODE (with code) Press Display Description F A N Fan speed 4 8 0 0 Actual fan speed e.g. 5500rpm 35 COMMUNICATION MODE (with code) Press Display Description In this mode the communication between the boiler control module, optional control interface C O N N kit, and optional programmable room thermostat or modulating sequencer is shown.

  • Page 31: Commissioning And Testing

    INSTALLATION 38 COMMISSIONING AND TESTING A. ELECTRICAL INSTALLATION B. GAS INSTALLATION 1. The whole of the gas installation, including the meter, 1. Checks to ensure electrical safety should be carried out should be inspected and tested for soundness and by a competent person. then purged in accordance with the recommendations 2.

  • Page 32: Servicing

    SERVICING 41 HANDING OVER ROUTINE OPERATION Full instructions covering routine lighting and operation of the IMPORTANT. boiler are given on the Lighting and Operation Instruction Point out to the owner that the boiler must have regular Label located on the inside of the lower front door. maintenance and cleaning, at least annually, in order to ensure Draw the attention of the boiler owner or his representative to reliable and efficient operation.

  • Page 33: Servicing Schedule

    5. Remove and inspect the fan/venturi assembly. Refer to Ideal Stelrad Group does not accept any liability resulting from Frame 46. the use of unauthorised parts or the repair and servicing of 6.
  • Page 34 SERVICING 45 CASING REMOVAL AND ACCESS Front Panels 2. Loosen 3 screws on one side of the inner front panel and undo the 3 screws from the other side. 1. Pull the front panel forwards at the top, lift off the The panel will now slide to one side for removal.
  • Page 35 F80-F120 employ push fit). 5. Whilst providing temporary support for the gas valve remove the 4 screws securing the gas valve (F160- F280) or gas valve outlet elbow (F80-F120) to the venturi. 6. Remove sensing pipe from venturi (F160-F280 only).
  • Page 36 SERVICING 48 REMOVAL / CLEANING OF BURNER 1. Refer to Frame 42. 2. Refer to Frame 47 for removal of burner manifold. 3. Remove the gasket from the 4 studs. 4. Draw the burner out of the heat exchanger. 5. The burner can be cleaned on the inside surface using a soft brush and/or vacuum.
  • Page 37 SERVICING 50 REMOVAL OF SUMP COVER 1. Refer to Frame 42. 2. Remove the jacket front and inner front panels. (Refer to Frame 45). 3. Remove the 6 nuts and withdraw the sump cover plate taking care to retain the gasket. 4.

  • Page 38: Gas Valve Replacement

    6. Re-assemble in reverse order. Connect the sensing tube from the T-piece to P1 and the sensing tube from the gas valve outlet elbow (F80-F120) or venturi gas valve connections (F160-F280) to P2. 7. Refer to Frame 42 for final safety checks.
  • Page 39 SERVICING 54 IGNITION/DETECTION ELECTRODE TESTING/REPLACEMENT 1. Refer to Frame 42. 2. Remove the jacket front and inner front panels. Refer to Frame 45. 3. It is possible to measure the ionisation current with a voltmeter set at 0-10VDC. (0-10VDC = 0-10 micro amps ionisation current).
  • Page 40 SERVICING 56 WATER PRESSURE SWITCH REPLACEMENT 1. Refer to Frame 42. 2. Remove the jacket front, control fascia, top and right side panels. (Refer to Frame 45). 3. Isolate water circuit and drain boiler. 4. Pull off the electrical connections (no polarity) from the pressure switch.
  • Page 41 SERVICING 59 BOILER CONTROL MODULE REPLACEMENT 1. Refer to Frame 42. 2. Remove the front and inner front panels. (Refer to Frame 45). 3. Disconnect the electrical connections from the module. 4. Remove the 4 screws securing the control module to the main control panel.

  • Page 42: Fault Finding

    FAULT FINDING Detailed instructions on the replacement of faulty components Before attempting any electrical fault finding ALWAYS carry out are contained in the 'Servicing' section of these Installation & the preliminary electrical system checks as detailed in the Servicing Instructions. Instructions for the British Gas Multimeter or other similar commercially available meter.
  • Page 43 FAULT FINDING Boiler Control Module Error Codes Continued Code Description Action Incorrect tacho signal from fan Check wiring to fan. If wiring OK replace fan. Flow/return temperature differential too high Check no air in system or boiler Check adequate flow of water through boiler Flow thermistor short circuit Check wiring Disconnect terminals from thermistor &...
  • Page 44 FAULT FINDING Boiler Control Module Blocking Codes Code Description Action Air Pressure Switch did not close Check flue for blockage Check/clean burner Check Air Pressure Switch sensing pipes condition Check fan speed Check air Pressure Switch & replace if necessary Flow temperature too high Check no air in system or boiler Check adequate flow of water through boiler...

  • Page 45: Short List Of 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 boilers.
  • Page 46 SHORT LIST OF PARTS SHORT LIST 51 & 52 im8253b Installation & Servicing xtra...
  • Page 47 NOTES Installation & Servicing xtra...
  • Page 48 Technical Training The Ideal Boilers 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 ring: ..01482 498 432 Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN.

This manual is also suitable for:

F160F120F280F200F240

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