IDEAL C24 Installation And Servicing
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IDEAL C24 Installation And Servicing

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See also: User Manual , Installation Manual
INSTALLATION
AND SERVICING
INDEPENDENT
C24 C30 C35
For Users Guide see reverse of book
For details of document amendments, refer to page 3
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.
May 2014
UIN 205367 A08

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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 Independent - Installation and Servicing...
  • Page 3 DOCUMENT aMENDMENTs Relevant Installation changes implemented in this book from Mod Level ..a07 (Feb 14) to a08 (May 14) Cover pages Re-brand outer covers Ideal Stelrad Group reserve the right to vary specification without notice Independent - Installation and Servicing...
  • Page 4 general Table 1 - general Data Independent 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 22mm copper compression...

  • Page 5: Table Of Contents

    general CONTENTs Independent Natural gas only air supply ..............9 Boiler size g.C. appliance No. pI No. Benchmark Commissioning Checklist ..... 60 (Benchmark No.) Boiler Clearances ............10 Boiler Exploded Diagram ........... 13 47-348-68 86 CL 08 Condensate Drain .......... 9,24,25,42 47-348-69 86 CL 08 Electrical Connections ..........

  • Page 6: Safe Handling

    general saFE haNDLINg INTRODUCTION This boiler may require 2 or more operatives to move it to its The Independent range of boilers are wall mounted, full installation site, remove it from its packaging base and during sequence, automatic spark ignition, low water content, fanned movement into its installation location.

  • Page 7: Gas Safety Regulations

    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

    general 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 9: Electrical Supply

    general 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 10 general BOILER DIMENsIONs, sERVICEs & CLEaRaNCEs all dimensions in mm The boiler connections are made on the boiler bulkhead fittings. Refer to Frame 23. 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 11: Domestic Hot Water

    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 12: Water Treatment

    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 13 INSTALLATION BOILER assEMBLy - Exploded View Note that item numbers are linked to the spares list CH RETURN VALVE PIPE - GAS INLET IGNITER UNIT CH FLOW VALVE GAS VALVE THERMISTOR FLOW DHW INLET & OUTLET PIPE - GAS INJECTOR IGNITION LEAD PUMP HEAD INJECTOR ASSEMBLY...
  • Page 14 INSTALLATION 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 Wall Mounting Plate...

  • Page 15: Front Panel Removal

    INSTALLATION 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 16: Mounting The Boiler

    INSTALLATION 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 Frame 1 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 17 INSTALLATION 13 DETERMININg ThE FLUE LENgTh aND FLUE paCKs REqUIRED IMPORTANT. The boiler must be installed in a vertical position in accordance to the installation instructions. FLUE KITs Telescopic Flue‘B’ pack - contains: Flue turret, telescopic flue incorporating a terminal and rubber wall seal. horizontal Flue Terminal (600mm long) ‘B’...
  • Page 18 INSTALLATION 14 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 19: Cutting & Setting The Flue Length

    INSTALLATION 15 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 20: Installing The Flue

    INSTALLATION 16 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 21: Fitting The Optional Roof Flue Kit (Flat Or Pitched)

    INSTALLATION 17 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 22: Flue Terminal Position

    INSTALLATION 19 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. Minimum dimensions are shown below 300mm 625mm...

  • Page 23: Assembling The Roof Flue Kit

    INSTALLATION 20 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 24: Condensate Drain

    INSTALLATION 21 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 should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc.
  • Page 25 INSTALLATION 22 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 sealed...

  • Page 26: Water Connections

    INSTALLATION 23 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. WaTER CONNECTIONs Ch FILLINg 1.

  • Page 27: Electrical Connections

    INSTALLATION 24 ELECTRICaL CONNECTIONs Warning. This appliance MUST be earthed. Wiring should be 3 core PVC insulated cable, not less than 0.75mm (24 x 0.2mm), and to BS 6500 Table 16. For IE A mains supply of 230Vac ~ 50 Hz is required. reference should be made to the current ETCI rules for electrical The fuse rating should be 3A.

  • Page 28: Wiring Diagram

    INSTALLATION 27 WIRINg DIagRaM Independent - Installation and Servicing...

  • Page 29: Commissioning And Testing

    INSTALLATION 28 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 30: Initial Lighting

    INSTALLATION 29 INITIaL LIghTINg Legend a. Pre-heat On/off B. DHW temperature control C. CH temperature control D. Off/Summer/Winter/Reset Control E. Boiler Status F. Burner ‘on’ indicator g. CH Flow Isolating Valve h. Pressure Gauge J. Gas Inlet Pressure Test Point K.
  • Page 31 INSTALLATION 30 gENERaL ChECKs Make the following checks for correct operation in: DOMEsTIC hOT WaTER (DhW) MODE WaTER CIRCULaTION sysTEM 1. Fully open all DHW taps in turn and ensure that water flows 1. With the system COLD, check that the initial pressure is freely from them.

  • Page 32: Handing Over

    INSTALLATION 31 REsET pROCEDURE To reset boiler, turn the mode control knob (D) to reset position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence if a heat demand is present. Legend a. Pre-heat On/off D.

  • Page 33: Servicing Schedule

    (and gas rate) have been Ensure all caps and seals verified, then contact Ideal. are re-fitted after use 11. Complete the service section in the Benchmark Commissioning Checklist.

  • Page 34: Fan And Venturi Assembly Removal And Cleaning

    SERVICING 34 BOILER FRONT paNEL REMOVaL / REpLaCEMENT REMOVaL 1. Loosen the two screws retaining the front panel. 2. Pull the two spring clips down to disengage and pull panel forward and upward and remove. REpLaCEMENT 3. Hook the panel onto the top retaining clips. 4.

  • Page 35: Burner Removal And Cleaning

    SERVICING 36 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 36: Cleaning The Heat Exchanger

    SERVICING 38 CLEaNINg ThE hEaT ExChaNgER note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Frame 50. 1. Remove ignition and flame detection electrodes. Refer to Frames 45 & 46. 2. It is advisable to replace the sump cover prior to the water flush process.

  • Page 37: Replacement Of Components

    SERVICING 40 REpLaCEMENT OF COMpONENTs gENERaL After replacing ANY component check operation of the boiler, including gas soundness, gas rate and combustion When replacing aNy component test. 1. Isolate the electricity supply. IMpORTaNT. When work is complete, the front panel must be correctly 2.

  • Page 38: Burner Injector Replacement

    SERVICING 42 BURNER INJECTOR REpLaCEMENT 1. Refer to Frame 40. 2. Disconnect the electrical leads from the fan. 3. Undo the gas pipe union connection to the injector housing. 4. Loosen the screw retaining the fan mounting bracket. 5. Lift and remove the fan and venturi assembly. 6.

  • Page 39: Ignition Electrode Replacement

    SERVICING 44 RETURN ThERMIsTOR RENEWaL 1. Refer to Frame 40. 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 40: Flame Detection Electrode Replacement

    SERVICING 46 FLaME DETECTION ELECTRODE REpLaCEMENT 1. Refer to Frame 40. 2. Remove the burner. Refer to Frame 43. 3. Unplug the flame detection lead from the electrode. Flame Detection Electrode 4. Remove the 2 screws retaining the detection electrode. 5.

  • Page 41: Gas Control Valve Replacement

    SERVICING 48 gas CONTROL VaLVE REpLaCEMENT 1. Refer to Frame 40. 2. Unplug the electrical lead connection from the gas control valve and disconnect the earth wire. 3. Undo the union nut on the outlet of the gas control valve. 4.
  • Page 42 SERVICING 50 CONDENsaTE TRap/sIphON REpLaCEMENT 1. Refer to Frame 40. Note: Ensure condensate trap is fully drained before removal. 2. Pull off the rubber pipe at the sump drain. 3. Disconnect the condensate drain pipe. 4. Turn the siphon clockwise to disengage and lift to Siphon remove.

  • Page 43: User Control Pcb Replacement

    SERVICING 52 UsER CONTROL pCB REpLaCEMENT Note. Fit the earth strap provided with the PCB to your wrist and a suitable earth on the boiler chassis. 1. Refer to Frame 40. 2. Remove the main PCB, refer to Frame 51. 3.

  • Page 44: Draining The Boiler

    SERVICING 54 DhW FLOW TURBINE sENsOR REpLaCEMENT 1. Refer to Frame 40. 2. Remove condensate trap/siphon. Refer to Frame 50. 3. Lift off the flow turbine sensor plastic retaining clip. 4. Unplug the electrical connection and transfer to new turbine sensor. 5.

  • Page 45: Pump Automatic Air Vent Replacement

    SERVICING 57 saFETy RELIEF VaLVE RENEWaL 1. Refer to Frame 40. 2. Drain the boiler. Refer to Frame 55. 3. Remove condensate trap/siphon. Refer to Frame 50. 4. Remove expansion vessel. Refer to Frame 67. 5. Disconnect electrical connection from return thermistor. 6.

  • Page 46: Diverter Valve Internal Cartridge Replacement

    SERVICING 60 DIVERTER VaLVE INTERNaL CaRTRIDgE REpLaCEMENT FRONT CaRTRIDgE REpLaCEMENT REaR CaRTRIDgE REpLaCEMENT 1. Refer to Frame 40. 1. Refer to Frame 40. 2. Drain the boiler. Refer to Frame 55. 2. Drain the boiler. Refer to Frame 55. 3. Remove the diverter valve head. Refer 3.

  • Page 47: Pump

    SERVICING 62 pUMp hEaD REpLaCEMENT 1. Refer to Frame 40. 2. Drain the boiler. Refer to Frame 55. 3. Disconnect the electrical lead from the pump. 4. Remove the 4 Allen screws retaining the pump head. 5. Remove the pump head. 6.

  • Page 48: Heat Engine Renewal

    SERVICING 65 NO FLOW ThERMIsTOR REpLaCEMENT 1. Refer to Frame 40. 2. Drain down the boiler. Refer to Frame 55. 3. Unplug the electrical lead. 4. Unscrew the thermistor (to facilitate removal a 13mm socket spanner should be used). 5. Fit the new thermistor using the sealing washer provided.

  • Page 49: Expansion Vessel Recharging & Replacement

    SERVICING 67 ExpaNsION VEssEL REChaRgINg & REpLaCEMENT REChaRgINg Recharge 1. Refer to Frame 40. Point 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order 5. Check operation of the boiler. Refer to Frames 29 &...
  • Page 50 SERVICING 69 aLTERNaTINg ‘L’ aND ‘1’ - 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 reset boiler Check that the Pump is rotating freely.

  • Page 51: Fault Finding

    Fault Finding 71 aLTERNaTINg ‘L’ aND ‘5’ - 5 REsETs WIThIN 15 MINs Turn power off and on 72 aLTERNaTINg ‘L’ aND ‘6’ - FaLsE FLaME LOCKOUT Check routing and integrity of internal boiler Reset the boiler, does Boiler Work OK? wiring is OK.
  • Page 52 Fault Finding 74 aLTERNaTINg ‘F’ aND ‘2’ - FLaME LOss Does the boiler ignite for a short Is the Gas Pressure available at Check gas supply and time and then extinguish? the Boiler Inlet (18 mbar)? rectify fault Check the detection electrode and Check wiring from gas associated harness for: continuity, Is 215Vdc supply available at the...
  • Page 53 Fault Finding 76 aLTERNaTINg ‘F’ aND ‘5’ - RETURN ThERMIsTOR FaULT Remove the Return Thermistor from the CH Return Fit a new Thermistor Pipe and disconnect the wires. Check the resistance using a suitable multimeter connected across the thermistor’s terminal pins. At 25 expect 9,700 - 10,300...
  • Page 54 Fault Finding 79 aLTERNaTINg ‘F’ aND ‘9’ - pCB FaULT Replace PCB - Ensure that the BCC (boiler chip card - small plastic part) is fitted to the PCB otherwise replace PCB. 80 aLTERNaTINg ‘F’ aND ‘4’ - FLOW ThERMIsTOR FaULT Securely connect the wiring to the Flow Is the wiring securely connected to the Flow Thermistor Thermistor...
  • Page 55 Fault Finding 82 aLTERNaTINg ‘c’ aND ‘0’ - LOW MaINs VOLTagE Reset Boiler REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. 83 NO Ch OpERaTION BUT hW WORKs OK Move the mode knob to the Winter position Is the mode knob in the Winter position? Are the Timer and the Room Thermostat switched...
  • Page 56 Fault Finding 84 NO hW BUT Ch ON Is the red neon Is hot and cold Does the display show “d” when a tap is on? illuminated on the turbine pipework crossed? sensor? Adjust flow rates to achieve 35º Are the flow rates correct as per Frame 2. Replace PCB temp rise and check filter fitted in turbine is not blocked with debris.

  • Page 57: 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 59 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 60: 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 61: 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 62 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 63 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 64 & 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.

This manual is also suitable for:

Independent c30Independent c35Independent c24

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