Benchmark i-mini 30 Installation And Servicing
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Benchmark i-mini 30 Installation And Servicing

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INSTALLATION

AND SERVICING

24, 30
For users guide see reverse of book
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 2015
UIN 212128 A01

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  • Page 1: And Servicing

    INSTALLATION AND SERVICING May 2015 UIN 212128 A01 24, 30 For users guide see reverse of book 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 24.2 24.2 Part Load Auxiliary electricity Consumption Full Load 0.029 0.031 Part Load 0.012...
  • Page 3 PRodUCt fiCHe i-Mini 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 74.9 Sound power level, indoors Water heating energy efficiency class Seasonal Space Heating Energy Efficiency of the Boiler Temperature control (from fiche of temperature control) Class I...
  • Page 4 i-mini - Installation and Servicing...
  • Page 5 noteS foR tHe inStAlleR foR Any teCHniCAl qUeRieS PleASe RinG tHe ideAl inStAlleR HelPline : 08708 498057 note. boileR ReStARt PRoCedURe - To restart boiler, turn mode knob to restart position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence if a heat demand is present. doCUMent AMendMentS Relevant Installation changes implemented in this book from Mod Level .........
  • Page 6 general table 1 - General data i-mini 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 7: Table Of Contents

    Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist. Before installing this boiler, read the Code of Practice sheet at the rear of this book.

  • Page 8: Safe Handling

    general SAfe HAndlinG intRodUCtion This boiler may require 2 or more operatives to move it to its The i-mini range of boilers are wall mounted, full sequence, installation site, remove it from its packaging base and during automatic spark ignition, low water content, fanned flue, high movement into its installation location.

  • Page 9: Gas Safety Regulations

    general SAfety loCAtion of boileR Current Gas Safety (installation and use) regulations or rules The boiler must be installed on a flat and vertical internal wall, in force: capable of adequately supporting the weight of the boiler and any ancillary equipment. The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force.

  • Page 10: Flue Installation

    general GAS SUPPly 3. Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 4. The local gas supplier should be consulted, at the installation 4. Where the lowest part of the terminal is fitted less than 2m planning stage, in order to establish the availability of an adequate (6’6”) above a balcony, above ground or above a flat roof supply of gas.

  • Page 11: Air 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 12 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 13: Pump

    general SySteM ReqUiReMentS - Central Heating notes Safety valve setting a. The method of filling, refilling, topping up or flushing sealed Vessel charge pressure 0.5 to 0.75 primary hot water circuits from the mains via a temporary hose System pre-charge pressure bar None connection is only allowed if acceptable to the local water authority.

  • Page 14: Inhibitor

    Ideal Boilers, recommend the use of Fernox Quantomat, Sentinel Ideal Boilers, recommend Water Treatment in accordance Combiguard and Calmag CalPhos I scale reducing devices, which with the Benchmark Guidance Notes on Water Treatment in must be used in accordance with the manufacturers’ instructions. Central Heating Systems.
  • Page 15 INSTALLATION boileR ASSeMbly - exploded View CH Return Valve Plate Heat Exchanger Flue Manifold Control Box Lens CH Flow Valve Flow Regulator Flue Manifold Top Detection Lead DHW Inlet & Outlet Flow Sensor/Turbine Clamp Retaining Flue Turret Control Box Lid Pump Head Water Pressure Switch Hose Condensate Internal...
  • Page 16 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 17 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 18: 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 packaging. The template shows the position of the fixing and rear Frame 1 flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled.
  • Page 19 INSTALLATION 13 deteRMininG tHe flUe lenGtH And flUe PACKS ReqUiRed IMPORTANT. The boiler must be installed in a vertical position recommended that a support bracket is fitted on every 1 metre of in accordance to the installation instructions. pipe work used and the bracket is located as close to the collar as possible.

  • Page 20: Installation And Servicing

    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 21 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 22 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 23 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 24 INSTALLATION 19 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 25: Flue Terminal Position

    INSTALLATION 20 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. 3 0 0 m m Minimum dimensions are shown below m i n...

  • Page 26: 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 Condensate should be used terminating into a suitable internal foul water Drain...
  • Page 27 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 28: 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 29: 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 30: Wiring Diagram

    INSTALLATION 27 WiRinG diAGRAM i-mini - Installation and Servicing...

  • Page 31: Commissioning And Testing

    3G9927 As part of the commissioning process, the combustion of this appliance must be checked and the Benchmark Checklist completed. A flow chart to assist is provided on page 65. Attention ! it iS A Condition of tHe MAnUfACtUReRS WARRAnty tHAt tHe...

  • Page 32: Initial Lighting

    INSTALLATION 29 initiAl liGHtinG Legend A. Domestic Hot Water Preheat On/Off Knob B. Domestic Hot Water Temperature Knob C. Central Heating Temperature Knob D. Mode Knob E. Boiler Status Burner ‘on’ Indicator G. CH Flow Isolating Valve H. System Pressure Gauge Gas Inlet Pressure Test Point K.
  • Page 33 INSTALLATION 30 GeneRAl CHeCKS Make the following checks for correct operation in: WAteR CiRCUlAtion SySteM 1. With the system COLD, check that the initial pressure is DOMESTIC HOT WATER (DHW) MODE correct to the system design requirements. 1. Fully open all DHW taps in turn and ensure that water flows For pre-pressurised systems, this should be 1.0 bar.

  • Page 34: Handing Over

    inStAllAtion 31 ReStARt PRoCedURe To restart boiler, turn the mode control knob (D) to restart position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence if a heat demand is present. Legend A. Domestic Hot Water Preheat On/Off d.

  • Page 35: Servicing Schedule

    (and gas rate) have been Ensure all caps and seals verified, then contact Ideal Boilers. are re-fitted after use 11. Complete the service section in the Benchmark Commissioning Checklist. i-mini - i-mini - Installation and Servicing...
  • Page 36 SERVICING 34 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 spring clips down to disengage and pull panel 4.

  • Page 37: 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 38: 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 39: 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. 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 40 SERVICING 42 bURneR injeCtoR RePlACeMent 1. Refer to Frame 40. 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 41 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 42 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 43 SERVICING 48 GAS CONTROL VALVE REPLACEMENT 1. Refer to Frame 40. 2. Unplug the electrical lead connection from the gas control valve. 3. Disconnect the earth wire. 4. Remove the outlet gas valve clip and slide the pipe upwards 5. Undo the gas inlet pipe union at the inlet to the gas valve.
  • Page 44 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 remove.
  • Page 45 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 46: Draining The Boiler

    SERVICING 54 dRAininG tHe boileR CH Circuit Inlet Return Flow Outlet Drain CentRAl HeAtinG CiRCUit 1. Refer to Frame 40. 2. Close all the CH water isolating valves on the boiler inlet. 3. To drain the primary heat exchanger circuit: Open the drain valve and attach a length of hose to the CH drain point. 4.
  • Page 47 SERVICING 56 SAFETY RELIEF VALVE RENEWAL 1. Refer to Frame 40. 2. Drain the boiler. Refer to Frame 54. 3. Remove the clip on return thermistor. Refer to frame 44. 4. Pull out and remove the clip (positioned behind the safety valve) retaining the safety valve.
  • Page 48 SERVICING 62 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT To remove the valve body assembly: 17. Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly. 1. Refer to Frame 40. 18. Fit the new diverter valve body assemble and replace the 2.
  • Page 49 SERVICING 62 CH WAteR PReSSURe SenSoR RePlACeMent 1. Refer to Frame 40. 2. Drain the boiler. Refer to frame 54. 3. Pull off the two electrical connections. 4. Using a suitable tool, pull out the metal retaining clip. 5. Carefully withdraw the pressure switch. 6.
  • Page 50 SERVICING 65 HeAt enGine ReneWAl Refer also to Frame 5 - ‘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 Frame 40. 13. Remove the condensate rubber pipe. Refer to Frame 50, no. 2. 2.
  • Page 51 SERVICING 66 ExPANSION VESSEL RECHARGING & REPLACEMENT Recharge Point ReCHARGinG 1. Refer to Frame 40. 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 52: Fault Finding

    Fault Finding 68 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 restart boiler Is the Flow/Return Differential across the Boiler in excess of 30°C? Check that the Pump is rotating freely.
  • Page 53 Fault Finding 70 ALTERNATING ‘L’ AND ‘5’ - 5 RESTARTS WITHIN 15 MINS Turn power off and on 71 ALTERNATING ‘L’ AND ‘6’ - FALSE FLAME LOCKOuT Check routing and integrity of internal boiler Restart the boiler, does Boiler Work OK? wiring is OK.
  • Page 54 Fault Finding 73 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 55 Fault Finding 75 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 56 Fault Finding 78 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. 79 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 57 Fault Finding 81 AlteRnAtinG ‘c’ AND ‘0’ - LOW MAINS VOLTAGE Restart Boiler ReStARt PRoCedURe - To restart boiler, turn mode knob to restart position and immediately turn knob back to required setting. 82 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 58 Fault Finding 83 no HW bUt CH on Does the display show “d” when a tap is on? Is hot and cold pipework crossed? Adjust flow rates to achieve 35º Are the flow rates correct as per Frame 2. Is the wiring connected temp rise and check filter fitted in between PCB and DHW turbine is not blocked with debris.

  • Page 59: Spare Parts Info

    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 60: Spare Parts

    SPARE PARtS i-mini - Installation and Servicing...
  • Page 61 To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed. The service details should be recorded on the Benchmark Service Interval Record and left with the householder.

  • Page 62: Boiler Interlock

    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 63: 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 64 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 65 Boiler is Operating Satisfactorily No further actions required. Ensure test points are capped, boiler case is correctly replaced and all other commissioning procedures are completed. Complete Benchmark Checklist, recording CO and combustion ratio readings as required. i-mini - Installation and Servicing...
  • Page 66 Notes i-mini - Installation and Servicing...
  • Page 67 Notes i-mini - Installation and Servicing...
  • Page 68 The code of practice for the installation, commissioning & servicing of central heating systems Ideal Installer/Technical Helpline: 0870 849 8057...

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