IDEAL INDEPENDENT COMBI 24 Installation And Servicing
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IDEAL INDEPENDENT COMBI 24 Installation And Servicing

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INSTALLATION AND
SERVICING
INDEPENDENT COMBI
24 30 35
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.
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.
February 2018
UIN 215344 A06

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Summary of Contents for IDEAL INDEPENDENT COMBI 24

  • 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.
  • Page 2 ERP DATA MODEL SYMBOL UNITS Condensing Boiler Low Temperature Boiler B1 Boiler Cogeneration Space Heater Equipped with a Supplementary Heater Combination Heater Nominal Heat Output for Space Heating Full Load 24.3 24.3 24.3 Part Load Auxiliary Electricity Consumption Full Load 0.042 0.032 0.029...
  • Page 3 PRODUCT FICHE INDEPENDENT COMBINATION BOILER Ideal Boilers ERP DATA SYMBOL UNITS MODEL Condensing boiler Seasonal Space heating efficiency class Rated heat output ƞ Seasonal space heating energy efficiency Annual energy consumption Sound power level, indoors Water heating energy efficiency class...
  • Page 4 Installation and Servicing...
  • Page 5 Relevant Installation changes implemented in this book from Mod Level ..A05 (Sep 17) to A06 (Feb 18) Page 31 & 32 - 2.18 Installer Wiring & 2.19 External Wiring Information added regarding OpenTherm option kits. Ideal Boilers reserve the right to vary specification without notice Installation and Servicing...
  • Page 6 Installation and Servicing...

  • Page 7: Table Of Contents

    CONTENTS GENERAL ............... 8 SERVICING ..............39 Introduction ..............10 Servicing Schedule ............39 Operation ...............10 Boiler Front Panel Removal / Replacement ....40 Safe Handling ..............10 Fan and Venturi Assembly Removal and Cleaning ..40 Optional Extra Kits ............10 Burner Removal And Cleaning ........41 Safety ................11 Cleaning The Condensate Trap/Siphon ......41 Safe Handling Of Substances ........11...

  • Page 8: General

    SECTION 1 - GENERAL Table 1 - General Data Gas supply 2H - G20 - 20mbar Gas Supply Connection 15mm copper compression Injector Size (mm) 4.15 4.65 Inlet Connection Domestic Hot Water 15mm copper tail Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection Central Heating...
  • Page 9 SECTION 1 - GENERAL INDEPENDENT COMBI Natural Gas only Boiler size G.C. Appliance No. PI No. (Benchmark No.) 47-349-24 86CR16 47-349-25 86CR16 47-349-26 86CR16 Destination Country: GB, IE For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the manufacturer’s instructions.

  • Page 10: Introduction

    SECTION 1 - GENERAL 1.1 INTRODUCTION 1.2 OPERATION The Independent Combi range of boilers are wall mounted, full With no demand for CH, the boiler fires only when DHW is drawn sequence, automatic spark ignition, low water content, fanned off, or periodically for a few seconds without any DHW draw-off, flue, high efficiency, condensing, combination gas boilers.

  • Page 11: Safety

    In both cases, details of essential features of cupboard / compartment design, including airing cupboard installation, are to Any direct connection of a control device not approved by Ideal conform to the following: Boilers could invalidate the certification and the normal appliance warranty.

  • Page 12: Gas Supply

    SECTION 1 - GENERAL 1.8 GAS SUPPLY 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 The local gas supplier should be consulted, at the installation to which people have access then the terminal MUST be planning stage, in order to establish the availability of an adequate protected by a purpose designed guard.

  • Page 13: Terminal

    SECTION 1 - GENERAL 1.10 TERMINAL The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Section 2.9. 1.11 AIR SUPPLY It is NOT necessary to have a purpose-provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation;...

  • Page 14: Boiler Dimensions, Services & Clearances

    SECTION 1 - GENERAL 1.16 BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm The boiler connections are made on the boiler bulkhead fittings. Refer to Section 2.16. wall thicknesses do not exceed 600mm (24”). Where the The following minimum clearances must be maintained for space into which the boiler is going to be installed is less operation and servicing.

  • Page 15: System Requirements

    Additional Cold water, rising main & pipework in exposed areas need to be stop valve suitably lagged to prevent freezing. Temporary hose DHW Expansion Vessel Kit available from Ideal. (disconnect after filling) Double check valve assembly note direction of flow...

  • Page 16: System Balancing

    Total Hardness (as defined by BS 7593:2006 Table 2) a scale reducing device together with Scalemaster in-line scale IMPORTANT. inhibitor branded Ideal should be fitted into the boiler cold The application of any other treatment to this product may supply within the requirements of the local water company.

  • Page 17: Installation

    SECTION 2 - INSTALLATION 2.1 BOILER ASSEMBLY - Exploded View CH Return Valve Flow Group Manifold Gasket - Burner Ignition Lead CH Flow Valve Plate Heat Exchanger Sump Clean Out Cover Control Box Lens DHW Inlet & Outlet Flow Regulator Flue Manifold Detection Lead Pump Head...

  • Page 18: Unpacking

    SECTION 2 - INSTALLATION 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 the contents. Pack A Contents Boiler Hardware Bag...

  • Page 19: Unpacking Cont'd

    SECTION 2 - INSTALLATION 2.3 UNPACKING CONT’D Note. This flue system incorporates a removable flue outlet nose that utilises a push fit location system. This enables the installation of deflector, high level or balcony outlet flue kits without the removal of the whole ‘B’ pack terminal. The appliance must not be operated without the desired outlet nose correctly fitted in place.

  • Page 20: Wall Mounting Template

    SECTION 2 - INSTALLATION 2.5 WALL MOUNTING TEMPLATE Extended centre line 1 5 5 (2 0 0 ) The wall mounting template is located on the internal protective “A” - See Diagram in Section 1.16 packaging. The template shows the position of the fixing and rear flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled.

  • Page 21: Determining The Flue Length And Flue Packs Req'd

    (1000mm long) B Pack cut 75mm * If wall thickness is <126 and >102.5, contact Ideal Boilers. 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.
  • Page 22 SECTION 2 - INSTALLATION ..DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED, CONT’D FIGURE 1 Edge of turret Edge of turret Edge of turret to outside face of wall plus to outside face of wall plus to outside face of wall plus 44mm = ue length 44mm = ue length 44mm = ue length...

  • Page 23: Cutting & Setting The Flue Length

    SECTION 2 - INSTALLATION 2.10 CUTTING & SETTING THE FLUE LENGTH TELESCOPIC FLUES TELESCOPIC FLUE B PACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT HORIZONTAL FLUE TERMINAL (1000MM LONG) B PACK (TELESCOPIC) MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 &...

  • Page 24: Installing The Flue

    SECTION 2 - INSTALLATION 2.11 INSTALLING THE FLUE FITTING FLUE THROUGH THE WALL 1. Measure wall thickness and add 14mm. 2. Measure from the outer terminal lip towards the end of outer flue, place a small location mark at the dimension acquired at point 1. 3.

  • Page 25: Fitting The Optional Roof Flue Kit (Flat Or Pitched)

    SECTION 2 - INSTALLATION 2.12 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched) Note. A flat or pitched roof flashing plate (not supplied) is required before proceeding with the installation of this kit. This kit is suitable for both flat and pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level.

  • Page 26: Flue Terminal Position

    SECTION 2 - INSTALLATION 2.13 FLUE TERMINAL POSITION The terminal should be positioned so that products of combustion can safely disperse at all times. Pluming may occur at the termination so, where possible, terminal positions where this could cause a nuisance should be avoided.

  • Page 27: Assembling The Roof Flue Kit

    SECTION 2 - INSTALLATION 2.14 ASSEMBLING THE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied.

  • Page 28: Condensate Drain

    SECTION 2 - INSTALLATION 2.15 CONDENSATE DRAIN Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer Condensate should be used terminating into a suitable internal foul water...
  • Page 29 SECTION 2 - INSTALLATION CONDENSATE DRAIN - CONT’D..Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to Method (see manufacturers detailed instructions) External Soil & Vent Stack Boiler Water/weather Visible air break with 75mm proof insulation Boiler...

  • Page 30: Connections & Filling

    SECTION 2 - INSTALLATION 2.16 CONNECTIONS & FILLING NOTES. Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown in the picture. Ensure each union is fitted with fibre seals provided. Do not subject any of the isolating valves to heat as the seals may be damaged.

  • Page 31: Electrical Connections

    SECTION 2 - INSTALLATION 2.17 ELECTRICAL CONNECTIONS Wiring should be 3 core PVC insulated cable, not less than WARNING. This appliance MUST be earthed. 0.75mm (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for A mains supply of 230Vac ~ 50 Hz is required.

  • Page 32: External Wiring

    SECTION 2 - INSTALLATION 2.19 EXTERNAL WIRING External Controls – 230V 50Hz Optional External Controls – Extra Low Frost Protection Voltage Wiring a 230V 50Hz Room Thermostat, If parts of the pipework run outside the Diagram A (with optional timer, Diagram B) Wiring OpenTherm Room Control or other house or if the boiler will be left off for more OpenTherm Master Device, Diagram D.

  • Page 33: Wiring Diagram

    SECTION 2 - INSTALLATION 2.20 WIRING DIAGRAM Installation and Servicing...

  • Page 34: Commissioning And Testing

    SECTION 2 - INSTALLATION 2.21 COMMISSIONING AND TESTING A. Electrical Installation B. Gas Installation 1. Checks to ensure electrical safety should be carried out by a 1. The whole of the gas installation, including the meter, competent person. should be inspected and tested for tightness and purged in accordance with the recommendations of BS.

  • Page 35: Initial Lighting

    SECTION 2 - INSTALLATION 2.22 INITIAL LIGHTING BOILER Legend A. Domestic Hot Water Temperature Knob ºC B. Central Heating Temperature Knob HOT WATER PREHEAT C. Mode Knob D. Boiler Status Display MODE PREHEAT RESTART E. Burner ‘on’ Indicator Central Heating Economy Setting G.

  • Page 36: General Checks

    SECTION 2 - INSTALLATION 2.23 GENERAL CHECKS Make the following checks for correct operation in: WATER CIRCULATION SYSTEM 1. With the system COLD, check that the initial pressure is 1. Fully open all DHW taps in turn and ensure that water flows correct to the system design requirements.

  • Page 37: Restart Procedure

    SECTION 2 - INSTALLATION 2.24 RESTART PROCEDURE To restart the boiler, press the RESTART button (G). BOILER ºC HOT WATER PREHEAT MODE PREHEAT RESTART Legend A. Domestic Hot Water Temperature Knob B. Central Heating Temperature Knob C. Mode Knob D. Boiler Status Display E.

  • Page 38: Handing Over

    SECTION 2 - INSTALLATION 2.26 HANDING OVER After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions: 1. Hand the User Instructions to the householder and 7. Draw attention to the timer Users Instructions and hand them explain his/her responsibilities under the relevant national to the householder.

  • Page 39: Servicing

    SECTION 3 - SERVICING 3.1 SERVICING SCHEDULE For the very latest copy of literature for specification & maintenance practices, visit our website www.idealboilers.com, where you will be able to download the relevant information. WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing.

  • Page 40: Boiler Front Panel Removal / Replacement

    SECTION 3 - SERVICING 3.2 BOILER FRONT PANEL REMOVAL / REPLACEMENT REMOVAL REPLACEMENT 1. Loosen the two screws retaining the front panel. 3. Hook the panel onto the top retaining clips. 2. Pull the two clips down to disengage and pull panel forward 4.

  • Page 41: Burner Removal And Cleaning

    SECTION 3 - SERVICING 3.4 BURNER REMOVAL AND CLEANING 1. Ensure the sump is fully drained 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 3. Lift the manifold to clear the bottom sealing gasket and remove manifold.

  • Page 42: Cleaning The Heat Exchanger

    SECTION 3 - SERVICING 3.6 CLEANING THE HEAT EXCHANGER Note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Section 3.18. 1. Remove ignition and flame detection electrodes. Refer to Section 3.13 & 3.14. 2.

  • Page 43: Replacement Of Components

    SECTION 3 - SERVICING 3.8 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When work is complete, the front panel must be correctly When replacing ANY component refitted - ensuring that a good seal is made. 1. Isolate the electricity supply. Notes. 1. In order to assist fault finding, the control panel has 2.

  • Page 44: Burner Injector Replacement

    SECTION 3 - SERVICING 3.10 BURNER INJECTOR REPLACEMENT 1. Refer to Section 3.8. 2. Disconnect the electrical leads from the fan. 3. Remove the clip from the gas valve to venturi pipe and ease the pipe upwards, rotate and ease down to remove. 4.

  • Page 45: Return Thermistor Replacement

    SECTION 3 - SERVICING 3.12 RETURN THERMISTOR REPLACEMENT 1. Refer to Section 3.8. 2. Unclip the return thermistor from the return pipe and withdraw it from the boiler. 3. Disconnect the electrical lead from the thermistor. 4. Reconnect the electrical lead to the new thermistor and reassemble in reverse order, ensuring that the thermistor is securely fitted to the pipe on the thermistor locator tab as shown.

  • Page 46: Flame Detection Electrode Replacement

    SECTION 3 - SERVICING 3.14 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Section 3.8. Flame Detection Electrode 2. Remove the burner. Refer to Section 3.4. 3. Unplug the flame detection lead from the electrode. 4. Remove the 2 screws retaining the detection electrode.

  • Page 47: Diverter Valve Actuator Replacement

    SECTION 3 - SERVICING 3.17 DIVERTER VALVE ACTUATOR REPLACEMENT Refer to Section 3.8. To remove the motor: 1. Remove the condensate trap/siphon. Refer to Section 3.5. 2. Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator. 3.

  • Page 48: Pcb Replacement

    SECTION 3 - SERVICING 3.19 PCB REPLACEMENT Note. Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis. 1. Refer to Section 3.8. 2. Ensure the control knobs are in the 12 o clock position. 3.

  • Page 49: Replacing The Mechanical Timer

    SECTION 3 - SERVICING 3.21 REPLACING THE MECHANICAL TIMER 1. Refer to Section 3.8. 2. Remove the boiler front panel. Refer to Section 3.2. 3. Ease out the blanking plate using screwdriver slot situated at the bottom centre of the plate and discard. 4.

  • Page 50: Pressure Gauge Replacement

    SECTION 3 - SERVICING 3.23 PRESSURE GAUGE REPLACEMENT 1. Refer to Section 3.8. 2. Drain the heating system. Refer to Section 3.22. 3. Remove the boiler front (See Section 3.2), lower the control panel and remove the control box cover. 4.

  • Page 51: Pump Automatic Air Vent Replacement

    SECTION 3 - SERVICING 3.25 PUMP AUTOMATIC AIR VENT REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.22. 3. Remove the expansion vessel. Refer to Section 3.33. 4. Firstly, increase access area by disconnecting the 22mm pipe connection Dust Cap at top of pump chamber and bottom of heat exchanger and remove pipe Refer to Section 3.26.

  • Page 52: Dhw Plate Heat Exchanger Replacement

    SECTION 3 - SERVICING 3.27 DHW PLATE HEAT EXCHANGER REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.22. 3. Remove condensate trap/siphon. Refer to Section 3.18. 4. Remove the diverter valve actuator. Refer to Section 3.17. 5.

  • Page 53: Dhw Filter & Dhw Flow Reg Cleaning / Replacement

    SECTION 3 - SERVICING 3.30 DHW FILTER & DHW FLOW REGULATOR CLEANING / REPLACEMENT 1. Refer to Section 3.8. 2. Drain the DHW system. Refer to Section 3.22. 3. Turn the housing anti clockwise and pull forward to remove the cartridge. 4.

  • Page 54: Heat Engine Replacement

    SECTION 3 - SERVICING 3.32 HEAT ENGINE REPLACEMENT Refer also to Section 2.1 - ‘Boiler Exploded View’ IMPORTANT Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. 1. Refer to Section 3.8. 14.

  • Page 55: Expansion Vessel Recharging & Replacement

    SECTION 3 - SERVICING 3.33 EXPANSION VESSEL RECHARGING & REPLACEMENT RECHARGING Recharge Point 1. Refer to Section 3.8. 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order. 5. Check that the boiler operates in both DHW & CH modes.

  • Page 56: Fault Finding

    SECTION 4 - FAULT FINDING 4.1 FAULT FINDING CHART MAIN MENU GO TO SECTION 4.2 - ‘L1’ FLOW TEMPERATURE OVERHEAT LOCKOUT GO TO SECTION 4.3 - ‘L2’ IGNITION LOCKOUT 5 RESETS WITHIN 15 MINS - ‘LC’ TURN POWER OFF AND ON GO TO SECTION 4.4 - ‘L6’...

  • Page 57: L1' - Flow Temperature Overheat Lockout

    SECTION 4 - FAULT FINDING 4.2 ‘L1’ - FLOW TEMPERATURE OVERHEAT LOCKOUT Is the Boiler and CH System filled with water and all Fill and vent the system and open all isolation and radiator valves open? isolation valves, then restart boiler Is the Flow/Return Differential across the Boiler in Check that the Pump is rotating freely.

  • Page 58: L6' - False Flame Lockout

    SECTION 4 - FAULT FINDING 4.4 ‘L6’ - FALSE FLAME LOCKOUT Check routing and integrity of internal boiler wiring is OK. Check Restart the boiler, does Boiler Work OK? condition of Flame Sense Electrode and replace if deteriorated. Replace Flame Detection Electrode Separate the flame detection electrode in-line connector.

  • Page 59: F3' - Fan Fault

    SECTION 4 - FAULT FINDING 4.7 ‘F3’ - FAN FAULT Does the wiring from the Fan to the PCB have Rectify Wiring & secure connections at both ends and has not connections 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...

  • Page 60: F6' - Outside Sensor Fault

    SECTION 4 - FAULT FINDING 4.10 ‘F6’ - OUTSIDE SENSOR FAULT Securely connect the wiring at both the Is the wiring securely connected at both the boiler and boiler and Outside Sensor Outside Sensor? Disconnect the wires to the outside sensor. Check the resistance using a suitable multimeter connected across the Outside Sensor’s terminal pins.

  • Page 61: No Hw But Ch On

    SECTION 4 - FAULT FINDING 4.12 NO HW BUT CH ON Does the display shows a “Tap symbol” when Is hot and cold pipework crossed? a tap is on? Adjust flow rates to achieve 35ºC Are the flow rates correct as per Section 1.2. Is the wiring connected temp rise and check filter fitted in between PCB and DHW...

  • Page 62: 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 63 Installation and Servicing...
  • Page 65 NOTES Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the data 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.
  • Page 66 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 67 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 68 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING. If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) sepa- rate guidance is provided with the conversion kit supplied and this must be followed.
  • Page 69 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 70 Installation and Servicing...
  • Page 71 Installation and Servicing...
  • Page 72 & servicing of central heating systems registered quality management system Technical Training The Ideal 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 498432 Ideal Boilers Ltd.

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