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IDEAL Isar M30100 Installation And Servicing Manual

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Summary of Contents for IDEAL Isar M30100

  • Page 2 GENERAL Table 1 - General Data Gas supply 2H - G20 - 20mbar Gas Supply Connection 22mm copper Injector size Stereomatic 5.6mm dia. Inlet Connection Domestic Hot Water 15mm copper Outlet Connection Domestic Hot Water 15mm copper Flow Connection Central Heating 22mm copper Return Connection Central Heating...
  • Page 3 GENERAL isar CONTENTS page no. Natural Gas only Air Supply ..............7 G.C. Appliance No. 47-348-15 Boiler Clearances ............6 PI No.0063BL9811 Boiler Exploded Diagram ........10, 11 Destination Countries: UK, IE Condensate Drain ............8 Electrical Connections ..........22 Electrical Supply ............
  • Page 4 GENERAL INTRODUCTION BOILER WATER CIRCUIT DIAGRAMS The isar m30100 combi boiler is a fully automatically controlled, wall mounted, low water content, fanned flue Central Heating Circuit combination condensing gas boiler. Expansion vessel Note. Due to the high efficiency of the boiler a plume of water vapour will form at the terminal during operation.
  • Page 5 Installation and Servicing Instructions or as otherwise recommended by Caradon Ideal Limited in writing. If in doubt please enquire. Any direct connection of a control device not approved by Caradon Ideal Limited could invalidate the certification and the normal appliance warranty.
  • Page 6 GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in) The boiler connections are made on the boiler piping frame. Centre Refer to Frame 17. line of The following minimum clearances must be maintained for boiler operation and servicing. Additional space will be required for installation, depending upon site conditions.
  • Page 7 GENERAL GAS SUPPLY 2. It is important that the position of the terminal allows the free passage of air across it at all times. The local gas supplier should be consulted, at the installation 3. Minimum acceptable spacing from the terminal to planning stage, in order to establish the availability of an obstructions and ventilation openings are specified in adequate supply of gas.
  • Page 8 GENERAL THERMOSTATIC RADIATOR VALVES (TRV) ELECTRICAL SUPPLY Caradon Ideal Limited recommend that heating systems Wiring external to the appliance MUST be in accordance with utilising full thermostatic radiator valve control of temperature in the current I.E.E. (BS.7671) Wiring Regulations and any local individual rooms should also be fitted with a room thermostat regulations which apply.
  • Page 9 GENERAL SYSTEM REQUIREMENTS - CH (continued) and HOT WATER General 5. Filling. The system may be filled by one of the following methods: 1. The installation must comply with all relevant national and local regulations. Through a temporary hose connection from a 'draw-off' tap, supplied from a service pipe under mains 2.
  • Page 10 The isar boiler has an ALUMINIUM alloy heat exchanger IMPORTANT. The application of any other treatment to this product may render the guarantee of Caradon Ideal Limited invalid. If water treatment is used Caradon Ideal Limited recommend only the use of...
  • Page 11 INSTALLATION BOILER ASSEMBLY - Exploded View Data badge isar combination condensing - Installation and Servicing...
  • Page 12 INSTALLATION UNPACKING Pack A Contents Also contained in Pack A: The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to Hardware Pack (listed below). 460mm, rear or side flue outlet, in Pack B. These Installation &...
  • Page 13 INSTALLATION 10 BOTTOM PANEL AND FRONT PANEL REMOVAL 1. Undo the 4 retaining screws. Front panel 2. Allow the RHS of the bottom panel to lower slightly. 3. Withdraw the LHS of the bottom panel from the retaining clips. 4. Lift front panel and remove. 5.
  • Page 14 INSTALLATION 12 FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than : Side 300mm (11 "). Rear 345mm (13 "). LEGEND 1. Duct assembly. 2. Flue Turret. 3. Turret seal. 4.
  • Page 15 INSTALLATION 14 PREPARING THE WALL WARNING. Ensure that, 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 square to the wall. Both wall faces immediately around the cut hole should be flat.
  • Page 16 INSTALLATION 17 FITTING THE PIPING FRAME (Rear Flue outlet shown) Note. The CH Flow isolating valve(A), pressure gauge, is supplied separately in the hardware pack. Fit to the piping frame BEFORE mounting the boiler. Fit the wall mounting frame either: Directly to the wall Insert wall plugs.
  • Page 17 INSTALLATION 18 MOUNTING THE BOILER 1. Ensure that the plastic plugs are removed from both the DHW and CH pipes before mounting. N.B. Some spillage of water may occur from the pipework when mounting the boiler to the frame. 2. Lift the boiler onto the wall mounting frame, locating it over the tabs at the top of the frame.
  • Page 18 INSTALLATION 20 TERMINAL WALL PLATE (optional) 2. Drill 4 fixing holes with a 7mm (1/4") masonry drill. This plate is supplied in the Flue Finishing Kit (together with 3. Insert the 4 plastic plugs provided. one inner and one outer flue seal) it allows neat concealment and full compression of the outer seal (if fitted).
  • Page 19 INSTALLATION 24 SERVICE CONNECTIONS General Notes 1. Fitting the Piping Frame, top entry pipework is an option, as 2. Horizontal connecting pipes, where used, must be run well as mounting from the bottom or through the wall. outside the limits of the boiler casing. If pipes are run vertically within the boiler back space provided by optional stand-off frame positions they must avoid any obstructions imposed by the channels and by a...
  • Page 20 INSTALLATION WATER CONNECTIONS - continued DHW CONNECTIONS Cross bar 'O' Ring Retaining Outlet screw connector Regulator / Filter Piping frame 15mm copper pipe Note. The DHW inlet isolating valve incorporates a flow regulator / filter. D.H.W. Outlet Isolating valve It should be inspected to ensure no (shown in the blockage is evident.
  • Page 21 INSTALLATION 29 CONDENSATE DRAIN Refer also to the British Gas document: 'Guidance Notes for In order to defer the onset of freezing of the condensate drain the Installation of Domestic Gas Condensing Boilers' (1989). when the pipe is run externally the pipe should be run as far as possible within the building.
  • Page 22 INSTALLATION 31 ELECTRICAL CONNECTIONS WARNING. This appliance MUST be earthed. Wiring should be 3 core PVC insulated cable, not less than 0.75 mm (24 x 0.2mm), and to BS 6500 Table 16. A mains supply of 230 V ~ 50 Hz is required. Connection must be made in a way that allows complete The fuse rating should be 3A.
  • Page 23 INSTALLATION 33 EXTERNAL ELECTRICAL CONTROLS Wiring External to the Boiler The fuse rating should be 3A. L2 L1 Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local Room ’stat regulations. Room Thermostat If the thermostat has a neutral connection, use it (it provides for more energy efficient operation by reducing switching...
  • Page 24 INSTALLATION 34 PICTORIAL WIRING DIAGRAM LEGEND - blue. - white. bk - black. y/g - yellow/green. br - brown. gy - grey. - red. or - orange. - yellow. - violet Flue Overheat thermistor thermostat Control thermistor Return thermistor Diverter valve Mains supply Gas valve...
  • Page 25 INSTALLATION 35 FUNCTIONAL FLOW WIRING DIAGRAM Mains Switch Filter PCB No. External switch e.g. room'stat, programmer Flame detection electrode Overheat thermostat DC Gas valve Flue thermistor electrode DHW thermistor CH return thermistor CH control thermistor Pump Diverter valve Ecl 1993 LEGEND - red y/g - yellow/green...
  • Page 26 INSTALLATION 37 INITIAL LIGHTING Flue Casting Control panel in servicing position LEGEND A. Automatic air vent. B. Inlet pressure test point K. Mains On neon C. CH return isolating L. Boiler On/Off valve Clamp switch D. DHW inlet isolating M. DHW thermostat valve knob Control panel in working position...
  • Page 27 INSTALLATION 38 INITIAL LIGHTING - continued 17. Set the boiler ON/OFF switch (L) to OFF. 14. DOMESTIC HOT WATER 18. Swing the control panel into servicing position. Refer to Frame 47. With the boiler firing, set the DHW thermostat knob (M) to maximum and fully open a DHW tap.
  • Page 28 Emphasise that if a fault is indicated, the boiler should be benefits of the Ideal Care Scheme details of which are turned off and a registered local heating installer consulted. outlined in the householder pack supplied with this boiler.
  • Page 29 SERVICING 42 SERVICING SCHEDULE 7. Check the main injector for blockage or damage. To ensure the continued safe and efficient operation of the 8. Wherever possible remove and clean the condensate trap appliance it is recommended that it is checked at regular (refer to Frame 50) and check the drain for blockage.
  • Page 30 SERVICING 43 SAMPLING POINT 44 BOILER FRONT PANEL REMOVAL 1. Remove the 2 securing screws. 2. Pull the panel forward at the bottom and lift to disengage it from the top lugs. Sample point Front panel 45 BOILER BOTTOM PANEL REMOVAL 46 BOILER SEALING PANEL REMOVAL 1.
  • Page 31 SERVICING 47 THE CONTROL PANEL IN THE SERVICING POSITION 1. Swing the control panel down into the servicing position Remove the 2 securing screws and withdraw the user control. Unplug the low voltage electrical lead from the back of the user control. Unplug the spark lead from the bottom of the control box.
  • Page 32 SERVICING 48 FAN, GAS INJECTOR AND VENTURI ASSEMBLY REMOVAL AND CLEANING 1. Disconnect the electrical leads from the fan. 2. Undo the gas pipe union connection to the injector housing. 3. Undo the single retaining screw on the fan Fan and venturi mounting bracket.
  • Page 33 SERVICING 50 CLEANING THE CONDENSATE 'S' TRAP 1. Swing the control panel down into the servicing position. Refer to Frame 47. Screw Condensate trap 2. Disconnect the condensate drain pipe. 3. Remove the securing screw and elongated bolt, pull the trap down and forwards to remove.
  • Page 34 SERVICING 53 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When work is complete, if the sealing panel has been When replacing ANY component removed, it must be correctly refitted - ensuring that a good seal is made. 1. Isolate the electricity supply. Notes.
  • Page 35 SERVICING 56 BURNER INJECTOR REPLACEMENT Retaining 1. Refer to Frame 53. screw 2. Remove the boiler sealing panel. Refer to Frame 46. Injector 3. Disconnect the electrical leads from the fan. 4. Undo the gas pipe union connection to the injector housing.
  • Page 36 SERVICING 59 CONTROL THERMISTOR, RETURN THERMISTOR AND OVERHEAT THERMOSTAT REPLACEMENT 1. Refer to Frame 53. 4. Re-connect the electrical leads and re-assemble in reverse order ensuring that the spring clip is securely on the pipe. 2. Unclip the thermistor / thermostat from the flow / return pipe and withdraw it from the controls compartment.
  • Page 37 10. Remove the insulation boards. The replacement boards Caradon Ideal Limited recommend that, for your own comfort are supplied in a plastic bag. This bag should be retained and safety and to comply with good working practice, the and the discarded boards should now be placed into it.
  • Page 38 SERVICING 63 GAS CONTROL VALVE REPLACEMENT 1. Refer to Frame 53. 7. Undo the union nut (B) on the RHS of the gas control valve. 2. Remove the casing bottom panel. Refer to Frame 45. 8. Slacken the screw securing the valve mounting bracket and withdraw the valve, complete with bracket and inlet pipe.
  • Page 39 SERVICING 65 CONDENSATE 'S' TRAP REPLACEMENT 1. Refer to Frame 53. 2. Remove the casing bottom panel. Refer to Frame 45. 3. Swing the control panel down into the servicing position. Refer to Frame 47. 4. Disconnect the condensate drain pipe. Screw Condensate trap 5.
  • Page 40 SERVICING 67 CONTROL BOX REPLACEMENT 1. Refer to Frame 53. 7. Re-assemble in reverse order, ensuring that the control box is located correctly in the housing before reconnecting 2. Swing the control panel down into the servicing position. the electrical wiring. Refer to Frame 47.
  • Page 41 SERVICING 69 USER CONTROL REPLACEMENT Note. Only the display unit is replaced. 1. Refer to Frame 53. 2. Loosen the securing screw on the underside of the user control. 3. Pull the display unit forward to remove. 4. Push the new display unit into position. 5.
  • Page 42 SERVICING 71 SAFETY RELIEF VALVE REPLACEMENT 1. Refer to Frame 53. 6. Withdraw the securing pin. 7. Remove the safety valve. 2. Remove the casing bottom panel. Refer to Frame 45. 8. Fit the new safety valve and refit the securing pin. 3.
  • Page 43 SERVICING 73 DRAINING THE BOILER 1. Refer to frame 53. 2. Remove the boiler bottom panel. Refer to Frame 45. 3. Close all the water isolating valves on the piping frame. 4. Attach a length of hose to the drain point and open the drain valve.
  • Page 44 SERVICING 75 DHW PLATE HEAT EXCHANGER REPLACEMENT 1. Refer to Frame 53. 2. Remove the boiler bottom panel. Refer to Frame 45. D.H.W. Plate heat exchanger 3. Drain the boiler. Refer to Frame 73. 4. Remove the 4 screws securing the rear support plate and withdraw the plate - Refer to Frame 66.
  • Page 45 SERVICING 77 HEAT ENGINE REPLACEMENT 15. Remove the flue. Refer also to Frame 7 - 'Boiler exploded view'. 16. Remove the edge clip securing the flue sensor wiring. IMPORTANT 17. Remove the blind grommet to gain access to the return pipe securing bracket.
  • Page 46 SERVICING 78 EXPANSION VESSEL REPLACEMENT 1. Refer to Frame 53. 2. Drain the boiler. Refer to Frame 73. 3. Undo all the gas and water connection unions on the boiler side of the valves. 4. Remove the turret screw and remove the turret clamp. 5.
  • Page 47 FAULT FINDING 80 FAULT FINDING CHART MAIN MENU In order to assist fault finding, the boiler has an LED diagnostic display. The key to the display codes is as follows: GO TO FRAME 81 ALTERNATING 'L' 'F' ALTERNATING 'L' 'E' GO TO FRAME 82 GO TO FRAME 83 ALTERNATING 'L' 'A'...
  • Page 48 FAULT FINDING 81 L..F..(FLAME DETECTION) If the boiler reset button is Is 17mbar gas pressure Check gas supply pressed does the boiler ignite for available at the boiler inlet ? and rectify fault a short time then extinguish? Check gas valve Is 200V DC supply Check the detection electrode and wiring for...
  • Page 49 FAULT FINDING 83 L..A......(OVER HEAT SENSOR) Can the overheat condition be reset by pressing Replace overheat thermostat the boiler reset button when the system is cold ? Is the boiler and CH system filled with Fill and vent the system and open all water and all isolation valves open ? isolation valves Does the pump setting give a differential...
  • Page 50 FAULT FINDING 86 H..2..(RETURN TEMPERATURE SENSOR) Remove the boiler return thermistor from the CH return pipe. Check resistance. The sensors can be checked by measuring their resistance, using a suitable multimeter connected across the sensors' terminal pins At 25 expect 9,700-10,300 Ohms At 60...
  • Page 51 FAULT FINDING 88 H..4..(FLUE SENSOR) Is the system filled and vented and all Can the fault condition be reset by switching off isolation valves open ? the mains supply to the boiler ? Fill and vent the Check wiring for continuity from the system and open all PCB to the flue thermistor isolating valves...
  • Page 52 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 53 SHORT LIST OF PARTS 91 SHORT PARTS LIST 2096 isar combination condensing - Installation and Servicing...
  • Page 54 SHORT LIST OF PARTS 92 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom panel with screws. 93 BURNER ASSEMBLY 11. Burner assembly with screws and gasket. Ecl 1598 isar combination condensing - Installation and Servicing...
  • Page 55 NOTES isar combination condensing - Installation and Servicing...
  • Page 56 & servicing of central heating systems Manufactured under a BS EN ISO 9001: 1994 Quality System accepted by BSI 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.
  • Page 57 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. ENGINEERED FOR PEACE OF MIND...
  • Page 58 (Natural Gas Only) G.C. Appliance No. 47-348-15 Destination Countries: GB, IE Introduction Important Notes The isar is a wall mounted, room sealed, condensing This appliance must not be operated without the casing combination boiler, featuring full sequence automatic spark correctly fitted and forming an adequate seal.
  • Page 59 5. Set the mains ON/OFF switch to ON. The boiler will fire periodically for a few seconds to maintain the DHW calorifier in a preheated condition and whenever there is a The mains on neon (B) will illuminate and the boiler will demand for DHW.
  • Page 60 Telephone: 01482 492 251 Fax: performance of its products. The 01482 448 858. Registration No. right is therefore reserved to vary London 322 137. specification without notice. March 2001 UIN 156411 A01 Ideal Consumer Helpline Tel: 01482 498 660 www.idealboilers.com...