IDEAL INSTINCT 40 User Manual
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IDEAL INSTINCT 40 User Manual

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INSTALLATION
AND SERVICING
40 60 80 100 120 150
40P 60P 80P
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.idealcommercialboilers.com where you can download the relevant information in PDF format.
March 2016
UIN 214128 A01

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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.idealcommercialboilers.com where you can download the relevant information in PDF format.
  • 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 Part Load 19.5 19.5 Auxiliary Electricity Consumption Full Load 0.135 0.135 0.092 0.092...
  • Page 3 PRODUCT FICHE INSTINCT HEAT 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 123.9 122.6 185.8 181.9 Sound power level, indoors Seasonal Space Heating Energy Efficiency of the Boiler...
  • Page 4 Installation & Servicing...
  • Page 5 Installation & Servicing...

  • Page 6: Performance Data

    For m /h multiply l/s by 3.6. Any direct connection of a control device not approved by Ideal Boilers could invalidate the certification and the normal appliance Propane gas consumption is calculated using a calorific value of warranty. It could also infringe the Gas Safety Regulations and 95.7 MJ/m...

  • Page 7: Table Of Contents

    GENERAL CONTENTS INSTINCT HEAT Boiler Assembly - Exploded view........13 40, 60, 80, 100, 120, & 150 Boiler Clearances............11 40P, 60P & 80P Commissioning and Testing...........44 Electrical Connections............29 Natural Gas & LPG PI No. 86 CL 166 Electrical Supply..............10 Destination Countries: GB, IE Fault Finding.

  • Page 8: Introduction

    IGE/UP/1 Soundness testing and purging of industrial and conversion kit supplied by Ideal. commercial gas installation. Natural gas variants of the boiler are Cat I and cannot be converted...

  • Page 9: Flue Installation

    Clean Air Act. adequately supporting the weight of the boiler and any ancillary IMPORTANT equipment or on a boiler frame supplied in kit form by Ideal It is the responsibility of the installer to ensure, in practice, that Boilers.

  • Page 10: Electrical Supply

    Ideal Boilers recommend Water Treatment in accordance with Guidance Notes on Water Treatment in Central Heating Systems. If water treatment is used Ideal Boilers recommend only the use of SCALEMASTER GOLD 100, FERNOX, MBI, ADEY MC1, inhibitors and associated water...

  • Page 11: Boiler Clearances

    GENERAL BOILER CLEARANCES AND CONNECTIONS The following minimum clearances must be maintained for operation and servicing. Front of boiler - 450mm Sides of boiler - 25mm Above boiler - dependent upon the flue system see drawings Below boiler - 300mm Clearance between multiple boiler installations - 25mm 80/125 Concentric Flue Connector 100/150 Concentric Flue Connector...
  • Page 12 MUST comply with the pump manufacturer’s minimum Feed requirements, to avoid cavitation. Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Ideal Boilers. System System flow to The isolation valves should be fitted as close to the pump as...

  • Page 13: Boiler Assembly - Exploded View

    INSTALLATION BOILER ASSEMBLY - Exploded View 80kW Model shown Auto Air Vent Dry Fire Thermistor Kit Fascia Plastic Burner Fixings Kit Lead Ignition Kit HMI Board Ignitor Unit Primary PCB Gas Valve Kit Electrode Detection Kit Jacket Assembly Kit Venturi 30kW Kit Ignition Electrode Kit Door Assembly Kit Installation &...
  • Page 14 INSTALLATION PACKAGING REMOVAL • Check the contents against the list in Frame 6 ‘Unpacking’. • The boiler should be laying on its back with the straps Note: some items are contained within the top packing removed. piece. • Carefully read the installation instructions before proceeding. •...
  • Page 15 INSTALLATION WALL MOUNTING TEMPLATE Note: Horizontal flue runs must be inclined at 1.5-3 to the horizontal to allow Note. The template shows the positions for the condensate to drain back to the boiler. top fixing holes. Care must be taken to ensure the correct holes are drilled.

  • Page 16: Ventilation

    INSTALLATION MOUNTING THE BOILER • Due care should be taken when lifting the boilers, with respect to their weights, see Table 2 on Page 6. Also refer to Safe Handling on Page 8. 1. Lift the boiler onto the wall mounting plate as shown.

  • Page 17: Flue Kits

    Multiple boilers may be installed with a common flue header not available for 150kW Models. (not supplied by Ideal). The flue system should be designed For vertical flue: this is the distance from the top of the boiler and supplied by a specialist flue company. BS 6644 and case to the aperture in the weather collar.
  • Page 18 INSTALLATION 14 VERTICAL ROOF FLUE KIT Vertical concentric flue application ~ maximum lengths and pressure differentials Model 40/40P 60/60P 80/80P Max flue length (m) 14.3 17.6 Max flue press diff (Pa) Flue Size 80 / 125 100 / 150 Vertical flue kit No 158654 158656 Contents...
  • Page 19 INSTALLATION 17 FLUE KIT ACCESSORIES Accessory Part No. 80/125 100/150 elbow (concentric) 152616 152617 elbow (concentric) 152618 152619 elbow 158773 158774 elbow (pair) 158775 158776 Flat Weather Collar 152611 152612 158780 158780 Pitched Weather Collar 152609 152610 158779 158779 1m Extension (concentric) 152400 152401 1m Extension (pair)
  • Page 20 INSTALLATION 18 FLUE RESISTANCES CONCENTRIC FLUE SYSTEMS For concentric flue systems with elbows fitted, use the table to correct the maximum flue extension capability. Alternatively use the table to design the flue system, deducting the individual resistance of components from the maximum pressure drop allowed in the flue for that boiler.
  • Page 21 INSTALLATION 19 EXAMPLES OF CALCULATING FLUE RESISTANCES/LENGTHS - EXAMPLE 1 Example 1 Horizontal Flue for 40kW Model Resistance (Pa) Resistance (m) Flue Size 80/125 80/125 Horizontal Wall Flue Kit 80/125 2 x 1m extension flue 2 x (4.8) 2 x (1) 1 x 90º...
  • Page 22 INSTALLATION 21 EXAMPLES OF CALCULATING FLUE RESISTANCES/LENGTHS - EXAMPLE 3 Example 3 Open Flue for Evomax 40 Resistance (m) Flue Size 5 x 1m extension 5 x 1 2 x 45º elbow 2 x 0.6 Total Flue Resistance The maximum flue extension for an Evomax 40 on open flue is 70m. Therefore this installation is acceptable.
  • Page 23 INSTALLATION 23 ASSEMBLING THE FLUE Flue terminals or extension ducts may be cut to shorter lengths Care must be taken when assembling flues, not to damage if required. When cutting a duct ensure it is square by marking the seals. the length all the way around and only cut back the plain end.
  • Page 24 INSTALLATION 24 FLUE TERMINATION POSITION Due to the high efficiency of these boilers pluming will occur. For this reason vertical termination is recommended, and in any case, terminal positions which could cause problems should where possible be avoided. Particular care should be taken in the case of large multiple boiler installations, and complying with the requirements of the Clean Air Act.

  • Page 25: Option Kits

    Frame & Header Option Kits. 26 SEQUENCER CONTROL OF MULTIPLE BOILERS In installations where the heat load is greater than the boiler capacity an ideal solution is to use multiple boiler arrangements. Legend 1. Non-return valve 7.
  • Page 26 INSTALLATION 27 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 27 INSTALLATION 28 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 29 BOILER WATER CONNECTIONS The boiler flow and return pipes are terminated with a 1 ” BSP male taper connection located at the bottom of the appliance. Note. This appliance is NOT suitable for use with a direct hot water cylinder. Plastic plugs fitted into the open ends of the flow and return pipes must be removed before connecting the system pipework.

  • Page 29: Electrical Connections

    INSTALLATION 32 ELECTRICAL CONNECTIONS Warning. This appliance MUST be efficiently earthed. switch, having a 3mm (1/8”) contact separation in both poles, or a plug and unswitched socket serving only the boiler and A mains supply of 230V 50Hz is required. The supply wiring system controls.

  • Page 30: Installer Connections

    INSTALLATION 34 INSTALLER CONNECTIONS Installation & Servicing...
  • Page 31 INSTALLATION 35 INTERNAL WIRING Installation & Servicing...

  • Page 32: User Interface

    INSTALLATION 36 BASIC CONTROLS DISPLAY USER INTERFACE Ideal Mains On When the mains to the boiler is switched on a screen similar to the following will be displayed The designation at the end of the bottom line indicates whether the boiler is suitable for Natural Gas...
  • Page 33 INSTALLATION 37 BASIC CONTROLS DISPLAY CONTINUED..Central Heating Mode Central Heating Central Heating If there is an ongoing Central Heating Demand screens similar to CH Switched Live On Burner Power 100% the following will be displayed Burner On Outside Temp’ 10°C Line 2 indicates whether Switched Live or OpenTherm is controlling Flow Setpoint...
  • Page 34 Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending the Ideal Evomax 80kW maximum output of the boiler Ideal Evomax 80kW Normal Operation Set Flow Temp’...
  • Page 35 The kW output number in the 1st line will vary depending the maximum The kW output number in the 1st line will vary depending the output of the boiler maximum output of the boiler Ideal Evomax 80kW Ideal Evomax 80kW Normal Operation Set Flow Temp’...
  • Page 36 INSTALLATION 40 USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS SETTING TO 0-10V Press SELECT and then hold + and - down together for more than 5s, the following screen will be displayed Installer Mode Normal Operation Set Flow Temp’ Set DHW Temp’ Rotate the KNOB clockwise until the following screen is displayed Installer Mode Show Hours Run...
  • Page 37 INSTALLATION 41 USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS CONTINUED..ENABLING NIGHT SETBACK Note- Booster Function is only operational if Outside Sensor has Note- Night Setback is only operational if Outside Sensor has been connected been connected When Night Setback is enabled the boiler will run at the normal flow temp. If Booster function is enabled and CH Demand is ongoing for more during CH Demand and reduced temperature when for no demand than 10 minutes then the Flow Temp.
  • Page 38 INSTALLATION 42 USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS Note: if this menu option is not displayed then the “2nd sL DHW/CH” menu CHANGING THE MINIMUM FLOW TEMPERATURE SETPOINT option has been set for CH. CH Priority can be set from the “2nd sL DHW/ Boiler default setting is that minimum flow temperature setpoint is 30°C CH”...
  • Page 39 Thermostat providing a 230V input to the DHW Switched Live This feature helps make the boiler fully compatible with the CH/DHW Instead a DHW Thermistor, available as a kit from Ideal, can be system. The default Soft Start time is 5s...
  • Page 40 INSTALLATION 44 USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS CONTINUED..REVERTING TO FACTORY SETTINGS DISABLING THE ANTI-LEGIONELLA FUNCTION Press SELECT, hold + and - together for more than 5s, the Note that the Anti-Legionella Temperature Function is only following screen will be displayed operational if a Domestic Hot Water Thermistor has been connected.
  • Page 41 Note that a hydraulic bypass is required to allow pump overrun. Note that the boiler can use an Outside Sensor, which is available from ideal Note that a Frost Stat can be as a Weather Compensation Kit. In connected into CH call.
  • Page 42 Ideal as a Weather Compensation Kit. Note 3. The boiler can use a Tank Sensor rather than a Cylinder Thermostat, which is available from Ideal as a kit. Note 4. A Frost Thermostat can be connected into CH Call...
  • Page 43 INSTALLATION 49 EXTERNAL CONTROLS VIA SWITCHED LIVE, 0-10V INPUT OR OPENTHERM Note that the boiler requires a 4 minute pump overrun If the CH Pump connection is used and the electrical current period. draw is 1.3A inductive or less then the pump can be connected directly into the CH Pump connection (a Grundfos 40/50 UPS is The boiler warranty will be invalid if this is not provided.

  • Page 44: Commissioning And Testing

    Programamble Room thermostat is available from Ideal as a kit. Note 2. The Tank Temperature Sensor is available from ideal as a kit. Note 3. The boiler must be configured to control a Power Open diverter Valve (See page 34)

  • Page 45: Initial Lighting

    INSTALLATION 52 INITIAL LIGHTING 6. Switch the electricity supply ON and check that all 1. Check that the system has been filled and the boiler is not air locked - the external controls are calling for heat. Check air in the boiler could damage the heat exchanger. For this reason the boiler is set for winter operation - see user interface airvent located in the left top side must never be shut off.

  • Page 46: Handing Over

    INSTALLATION 53 GENERAL CHECKS Make the following checks for correct operation. c. Refill and vent the system, clear all air locks and again check for water soundness. 1. The correct operation of ANY secondary system controls should be proved. Operate each control separately and d.

  • Page 47: Servicing

    Press SELECT and the following screen witll be displayed. The kW output number in the 1st line will vary depending on the Ideal Boilers does not accept any liability resulting from maximum output of the boiler. the use of unauthorised parts or the repair and servicing...
  • Page 48 SERVICING 58 REMOVAL OF FAN AND GAS VALVE ASSEMBLY 1. Refer to Frame 55. 7. Disconnect the electrical connections from the gas valve/s. 2. Remove the upper front panel, Refer to Frame 57. 8. Disconnect the electrical connections from the fan. 3.

  • Page 49: Burner Removal

    SERVICING 59 BURNER REMOVAL 1. Refer to Frame 55. 2. Remove the front panel (Refer to frame 57) 3. Remove the fan and gas valve assembly (Refer to frame 58) 4. Remove the six/eight extended nuts securing the burner to release the burner body.
  • Page 50 SERVICING 63 FAN REPLACEMENT 6. Remove the screws retaining the fan plate (80 only) or 1. Refer to Frame 55. mixing chamber to fan (150 only). 2. Remove the upper front panel (Refer to frame 57). 7. Transfer venturi and gas valve assembly to the new fan. 3.

  • Page 51: Gas Valve Replacement

    SERVICING 64 GAS VALVE REPLACEMENT 1. Refer to Frame 55. 7. Remove the venturi from the mixture chamber before removing the gas valve (as in (4) - 150 only). 2. Remove the upper front panel (Refer to frame 57). 8. Remove the 4 screws retaining the inlet flange to gas valve & 3.
  • Page 52 SERVICING 65 VENTURI REPLACEMENT 1. Refer to Frame 55. 2. Remove the front panel (Refer to frame 57) 3. Remove the fan and gas assembly (Refer to frame 58) 4. Remove venturi from fan / mixture chamber and gas valve (Refer to frame 63/64) 5.
  • Page 53 SERVICING 68 AUTOMATIC AIR VENT REMOVAL 1. Refer to Frame 55. 2. Remove the front panel. Refer to Frame 67. 3. Unscrew the air vent (A) from the self sealing fitting (B) on the top left of the flow pipe. 4.
  • Page 54 SERVICING 71 MAIN PCB REPLACEMENT 1. Refer to Frame 55. 4. Pull off all of the main PCB connectors. 2. Remove the upper front panel & put the control panel 5. Remove the four plastic nuts retaining the main PCB. into the service position.

  • Page 55: Fault Finding

    FAULT FINDING 73 FAULT FINDING CHART - MAIN MENU Overheat Lockout Return Thmr Fault Fill System to 1 Bar Check Return Go to Frame 81 Go to Frame 74 Vent System Thermistor Wiring Return Thermistor Fault Overheat Lockout Check Pump Spins Free Check Return Thmr Reset Boiler (10K @ 25°C,2K at 66°C)
  • Page 56 FAULT FINDING 74 OVERHEAT LOCKOUT Has PCB just been replaced? Reset Boiler Fill and vent the system and open all Are the boiler and CH/DHW system isolation valves, then reset the boiler. filled with water and are all isolation valves and radiator valves open? Check the flow and return Is the flow/return differential across thermistors (refer to Frame 80 &...
  • Page 57 FAULT FINDING 76 FALSE FLAME LOCKOUT / ERROR 20 Check routing and integrity of internal boiler Reset the boiler, does boiler work OK? wiring is OK. Check condition of Flame Sense Electrode and replace if deteriorated. Disconnect the electrical connection to the Flame Replace Flame Detection Electrode Sense Electrode.
  • Page 58 FAULT FINDING 79 FAN FAULT Rectify wiring & connections Does the wiring from the Fan to the PCB have secure connections at both ends and has not deteriorated? Does the wiring have continuity? Replace main PCB Is there 230Vac at the blue and brown connections to the 3 way connection on the Fan? Replace Fan 80 FLOW THERMISTOR FAULT...
  • Page 59 FAULT FINDING 82 OUTSIDE SENSOR FAULT Is the wiring securely connected at both the boiler and Securely connect the wiring at both Outside Sensor? the boiler and Outside sensor Disconnect the wires to the Outside Sensor. Check the Fit a new outside sensor resistance using a suitable multimeter connected across the thermistor’s terminal pins.
  • Page 60 FAULT FINDING 84 CYLINDER THERMISTOR FAULT Change menu setting for DHW Sensor Is a DHW Thermistor connected to the boiler? to “Switched Live” (See Frame 36) Is the wiring securely connected at both the boiler and Securely connect the wiring at both cylinder thermistor? the boiler and cylinder thermistor Fit a new cylinder thermistor...
  • Page 61 Open the Radiator Valves Is an OpenTherm device connected to the boiler (note Does the wiring from the boiler to the that the Ideal Prog Room Stat is an OpenTherm device)? OpenTherm device have continuity? There is no voltage from the Timer/ Room Stat.
  • Page 62 Frame 38 for setting DHW Temp.) Is an OpenTherm device connected to the Does the wiring from the boiler to the boiler (note that the ideal programmable Room OpenTherm device have continuity? Stat is an OpenTherm device)? There is no voltage from the Rectify wiring Timer/Cylinder Stat.
  • Page 63 FAULT FINDING 89 NO DISPLAY Supply power to the boiler Is there 230Vac to the boiler at (E)? Connect the wiring from the terminal block Is the wiring from the boiler terminal block to the main to the main PCB securely PCB connected securely? Connect the cable from the main PCB to Is the cable from the main PCB to the user interface PCB...
  • Page 64 FAULT FINDING 90 0-10V INTERFACE Set the boiler to accept a 0-10V input (see Is the boiler set to accept a 0-10V Input? Frame 37) Set the boiler to Winter Mode (see Frame Is the boiler set to Winter Mode? Ensure between 2V and 10V is correctly Is a voltage of between 2V and 10V being supplied to connected to these terminals from the...

  • Page 65: 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 66 Technical Training The Ideal Boilers 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 498 432 Ideal is a trademark of Ideal Boilers.
  • Page 67 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...

  • Page 68: Important Notes

    Important Notes INSTINCT HEAT • This appliance must not be operated without the casing correctly fitted and forming an adequate seal. 40, 60, 80, 100, 120, & 150 40P, 60P & 80P • If the boiler is installed in a compartment then the compartment MUST NOT be used for storage purposes.
  • Page 69 BOILER CONTROLS / DISPLAY Standby Mode Standby Mode If the boiler has been switched to Standby Mode the following screen will be displayed For Central Heating No Boiler operation will take place with this setting. See Frame 38 to change to Summer or Winter select Winter Mode setting For Hot Water...
  • Page 70 Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending the Ideal Evomax 80kW maximum output of the boiler Ideal Evomax 80kW Normal Operation Set Flow Temp’...

  • Page 71: Frost Protection

    To shut Down the Boiler 2. Apply a hot water bottle, microwaveable heat pack or a warm damp cloth to the frozen blockage area. Several applications 1. For short periods may have to be made before it fully defrosts. Warm water Set the external controls to OFF.
  • Page 72 Ideal Boilers Limited pursues a policy of continuing improvement in the design and performance of its Ideal Consumer Helpline products. The right is therefore reserved to vary specification without notice. Tel: 01482 498376 Ideal is a trademark of Ideal Boilers. Registered Office;...

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