IDEAL Independent C24 Installation And Servicing
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IDEAL Independent C24 Installation And Servicing

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See also: User 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.idealheating.com where you can download the relevant information in PDF format.
November 2010
UIN 205367 A03
Packaged boiler contents have been
checked by operator number...........

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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.idealheating.com where you can download the relevant information in PDF format.
  • Page 2 Independent - Installation and Servicing...

  • Page 3: Flue Installation

    Page deleted refer to Boiler Assembly Frame Installer Notification Guidelines Page deleted page 60 - 61 Commissioning Checklist Forms updated Boiler guarantee Page deleted. Now found in Guarantee /Registration Pack 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 air supply ..............9 Natural gas only Benchmark Commissioning Checklist ..... 60 Boiler size g.C. appliance No. pI No. Boiler Clearances ............10 (Benchmark No.) Boiler Exploded Diagram ........... 13 47-348-68 86 CL 08 Condensate Drain .......... 9,21,22,43 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 In both cases, details of essential features of cupboard / recommended by Ideal stelrad group in writing. If in doubt compartment design, including airing cupboard installation, are to please enquire.

  • Page 8: Flue Installation

    gENERaL The local gas supplier should be consulted, at the installation 3. Minimum acceptable spacing from the terminal to obstructions planning stage, in order to establish the availability of an adequate and ventilation openings are specified in supply of gas. An existing service pipe must NOT be used without Table 4.

  • Page 9: Air Supply

    gENERaL The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Frame 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 10 gENERaL BOILER DIMENsIONs, sERVICEs & CLEaRaNCEs all dimensions in mm The boiler connections are made on the boiler bulkhead fittings. Refer to Frame 28. 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

    Check the operation of the safety valve by raising the water pressure until the valve lifts. This should occur within 0.3bar of the preset lift pressure. DHW Expansion Vessel Kit available from Ideal. d. Release water from the system until the minimum system design pressure is reached;...

  • 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 ELECTRODE IGNITION CH FLOW VALVE GAS VALVE ELECTRODE DETECTION DHW INLET & OUTLET PIPE - GAS INJECTOR IGNITER UNIT PUMP HEAD INJECTOR ASSEMBLY...
  • Page 14 INsTaLLaTION UNpaCKINg The boiler is supplied fully assembled in one Pack A, together with a non-telescopic flue assembly for lengths up to 595mm, rear or side flue outlet, in Pack B. Unpack and check the contents. pack a Contents Boiler Hardware Bag Wall Mounting Plate These Installation/Users Instructions...
  • Page 15 INsTaLLaTION 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. DETERMININg ThE FLUE LENgTh aND FLUE paCKs REqUIRED IMpORTaNT.
  • Page 16 INsTaLLaTION 9 DETERMININg ThE FLUE LENgTh aND FLUE paCKs REqUIRED CONT’D Notes. NON - TELEsCOpIC FLUE 1. It is recommended that a support bracket Total Flue length dimension Flue is fitted for every 1 metre of extension pipe (measuring from CL of turret to outside wall) used and a bracket should be used at every joint, to ensure pipes are held at the correct Rear flue...

  • Page 17: Wall Mounting Template

    INsTaLLaTION 11 WaLL MOUNTINg TEMpLaTE The wall mounting template is located on the internal protective Extended centre line packaging. Note. V - See Diagram Below The template shows the positions of the fixing holes and the rear flue hole centre for standard installation. Care MUST be taken to ensure the correct holes are drilled.
  • Page 18 INsTaLLaTION 13 TERMINaL WaLL sEaL assEMBLy / pOsITIONINg Prior to fitting the flue, the rubber terminal wall seal provided Once the flue is installed it is IMPORTANT that the rubber in the flue pack MUST be fitted to the flue terminal as shown terminal wall seal is pressed against the outside wall to create below in Figure 1.
  • Page 19 INsTaLLaTION 15 sETTINg ThE FLUE - sIDE Wall thicknesses of 148 to 378mm non TelesCopiC Flue - Wall thickness of 115mm to 440mm Notes. If using the extension ducts go to Frame 16. 1. Measure and note side flue length L. Refer to Frame 8. 2.
  • Page 20 INsTaLLaTION 17 FLUE ExTENsION DUCTs - continued Use a maximum of 9m extended flue ONLY (C24) Use a maximum of 8m extended flue ONLY (C30) Use a maximum of 6m extended flue ONLY (C35) general arrangement Flue length 1. A maximum number of extension ducts are possible for each boiler output with one suitably cut.

  • Page 21: Mounting The Boiler

    INsTaLLaTION 19 FITTINg ThE WaLL MOUNTINg pLaTE 20 MOUNTINg ThE BOILER Screw the wall mounting plate to the wall using 2 wall plugs 1. Ensure the plastic plugs are removed from both the CH (previously fitted) with the 2 screws provided. and DHW connections before mounting the boiler.
  • Page 22 INsTaLLaTION 22 CONDENsaTE pIpE TERMINaTION CONFIgURaTIONs notes: all exTernal pipe runs MusT be in aCCorDanCe WiTh bs 6798 1. INTERNaL TO sINK WasTE UpsTREaM OF sINK WasTE TRap BOILER Open end of pipe direct into gulley below grating but above water level cla7771a Ground Level DRAIN...

  • Page 23: Connecting The Flue To The Boiler

    INsTaLLaTION 23 CONNECTINg ThE FLUE TO ThE BOILER Notes. noTe. siDe Flue • Before fitting the flue turret fill the condensate trap within the boiler by Select the orientation pouring a cupful of water into the flue before inserting turret into outlet (shown below).

  • Page 24: Fitting The Optional Roof Flue Kit (Flat Or Pitched)

    INsTaLLaTION 24 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 25: Flue Terminal Position

    INsTaLLaTION 26 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 26: Assembling The Roof Flue Kit

    INsTaLLaTION 27 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 27: Connections & Filling

    INsTaLLaTION 28 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 28: Electrical Connections

    INsTaLLaTION 29 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 29 INsTaLLaTION 32 WIRINg DIagRaM Independent - Installation and Servicing...

  • Page 30: Commissioning And Testing

    INsTaLLaTION 33 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 31: Initial Lighting

    INsTaLLaTION 34 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 32 INsTaLLaTION 35 gENERaL ChECKs continue to run. Make the following checks for correct operation in: DOMEsTIC hOT WaTER (DhW) MODE 1. With no call for CH or DHW the boiler should fire for a short period to preheat the DHW plate heat exchanger if the pre- heat control knob is in the ‘ON’...

  • Page 33: Handing Over

    INsTaLLaTION 36 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. Legend a. Pre-heat On/off D. Off/Summer/Winter/Reset Control B. DHW temperature control E.

  • Page 34: Servicing Schedule

    0.004 AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas pressure (and gas rate) have been verified, then contact Ideal. Flue Sampling Point 11. Complete the service section in the Benchmark Commissioning Checklist.

  • Page 35: Fan And Venturi Assembly Removal And Cleaning

    sERVICINg 39 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 36: Burner Removal And Cleaning

    sERVICINg 41 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 37: Cleaning The Heat Exchanger

    sERVICINg 43 CLEaNINg ThE hEaT ExChaNgER note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Frame 55. 1. Remove ignition and flame detection electrodes. Refer to Frames 50 & 51. 2. It is advisable to replace the sump cover prior to the water flush process.

  • Page 38: Replacement Of Components

    sERVICINg 45 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. 2. Turn off the gas supply. When work is complete, the front panel must be correctly refitted - ensuring that a good seal is made.

  • Page 39: Burner Injector Replacement

    sERVICINg 47 BURNER INJECTOR REpLaCEMENT 1. Refer to Frame 45. 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 40: Ignition Electrode Replacement

    sERVICINg 49 CONTROL ThERMIsTOR & RETURN ThERMIsTOR RENEWaL 1. Refer to Frame 45. 2. Unclip the control thermistor from the flow pipe and withdraw it from the boiler. 3. Unclip the return thermistor from the return pipe and withdraw it from the boiler.

  • Page 41: Flame Detection Electrode Replacement

    sERVICINg 51 FLaME DETECTION ELECTRODE REpLaCEMENT 1. Refer to Frame 45. 2. Remove the burner. Refer to Frame 48. 3. Unplug the flame detection lead from the electrode. Flame Detection Electrode 4. Remove the 2 screws retaining the detection electrode. 5.

  • Page 42: Gas Control Valve Replacement

    sERVICINg 53 gas CONTROL VaLVE REpLaCEMENT 1. Refer to Frame 45. 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 43 sERVICINg 55 CONDENsaTE TRap/sIphON REpLaCEMENT 1. Refer to Frame 45. 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. Remove the cleaning plug 5.

  • Page 44: User Control Pcb Replacement

    sERVICINg 57 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 47. 2. Remove the main PCB, refer to Frame 56. 3.

  • Page 45: Draining The Boiler

    sERVICINg 59 DhW FLOW TURBINE sENsOR REpLaCEMENT 1. Refer to Frame 45. 2. Remove condensate trap/siphon. Refer to Frame 55. 3. Lift off the flow turbine sensor plastic retaining clip. 4. Unplug the electrical connection and transfer to new turbine sensor. 5.

  • Page 46: Pump Automatic Air Vent Replacement

    sERVICINg 62 saFETy RELIEF VaLVE RENEWaL 1. Refer to Frame 45. 2. Drain the boiler. Refer to Frame 60. 3. Remove condensate trap/siphon. Refer to Frame 55. 4. Remove expansion vessel. Refer to Frame 72. 5. Disconnect electrical connection from return thermistor. 6.

  • Page 47: Diverter Valve Internal Cartridge Replacement

    sERVICINg 65 DIVERTER VaLVE INTERNaL CaRTRIDgE REpLaCEMENT FRONT CaRTRIDgE REpLaCEMENT REaR CaRTRIDgE REpLaCEMENT 1. Refer to Frame 45. 1. Refer to Frame 45. 2. Drain the boiler. Refer to Frame 60. 2. Drain the boiler. Refer to Frame 60. 3. Remove the diverter valve head. Refer 3.

  • Page 48: Pump Head Replacement

    sERVICINg 67 pUMp hEaD REpLaCEMENT 1. Refer to Frame 45. 2. Drain the boiler. Refer to Frame 60. 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 49: Heat Engine Renewal

    sERVICINg 70 NO FLOW ThERMIsTOR REpLaCEMENT 1. Refer to Frame 45. 2. Drain down the boiler. Refer to Frame 60. 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 50: Expansion Vessel Recharging & Replacement

    sERVICINg 72 ExpaNsION VEssEL REChaRgINg & REpLaCEMENT REChaRgINg 1. Refer to Frame 45. Recharge 2. Remove the charge point cover. Point 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order 5. Check operation of the boiler. Refer to Frames 34 &...

  • Page 51: Fault Finding

    FaULT FINDINg 74 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 Is the Flow/Return Differential across the Boiler in Check that the Pump is rotating freely.
  • Page 52 FaULT FINDINg 76 aLTERNaTINg ‘L’ aND ‘3’ - NO WaTER FLOW 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, reset the boiler. Check pump connection and check Reset the boiler.
  • Page 53 FaULT FINDINg 79 aLTERNaTINg ‘F’ aND ‘1’ - LOW WaTER pREssURE Are the Boiler and CH System filled with water and Fill and vent the system and open all all isolation and radiator valves open (check pressure isolation valves gauge is between 1 to 1.5 bar)? Are connections on water pressure sensor secure? Re-fit connections Replace water pressure sensor...
  • Page 54 FaULT FINDINg 82 aLTERNaTINg ‘F’ aND ‘4’ - FLOW ThERMIsTOR FaULT Remove the Flow Thermistor from the CH Flow Pipe Fit a new Thermistor 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 55 FaULT FINDINg 85 aLTERNaTINg ‘F’ aND ‘7’ - LOW MaINs VOLTagE Contact electricity provider 86 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. 87 aLTERNaTINg ‘F’...
  • Page 56 FaULT FINDINg 89 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. 90 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 57 FaULT FINDINg 91 NO hW BUT Ch ON YES Is hot and cold Is the red neon 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.
  • Page 58 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 59: Short List Of Parts

    shORT LIsT OF paRTs Independent - Installation and Servicing...
  • Page 60 Failure to install and commission according to the manufacturer’s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect he customer’s statutory rights. Gas Safe Register Number Telephone Number If yes, and if required by the manufacturer, has a water scale reducer been fitted? If the condensate pipe terminates externally has the pipe diameter been increased and weatherproof insulation fitted?
  • Page 61 Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number Gas Safe Register Number...
  • Page 62 & 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 c35

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