IDEAL C35 Installation And Servicing

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Installation and servicing (72 pages)

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Installation

INSTALLATION

AND SERVICING

Independent + Combi

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.

website www.idealheating.com where you can download the relevant information in PDF format.

February 2014

UIN 207607 A04

Packaged boiler contents have been

checked by operator number...........

Table of Contents

Summary of Contents for IDEAL C35

Page 1 Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
Page 2 Independent + Combi - Installation and Servicing...
Page 3 Relevant Installation changes implemented in this book from Mod Level ..a03 (Jan 14) to a04 (Feb 14) page 29 “General” paragraph updated. Ideal Stelrad Group reserve the right to vary specification without notice Independent + Combi - Installation and Servicing...
Page 4 gENERaL Table 1 - general Data Independent + Combi 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 5 gENERaL CONTENTs Independent + Combi 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 47-348-85 86 CL 08 Condensate Drain .......... 9,24,25,42 47-348-86 86 CL 08 Electrical Connections ..........
Page 6 gENERaL saFE haNDLINg INTRODUCTION This boiler may require 2 or more operatives to move it to its The Independent + Combi range of boilers are wall mounted, installation site, remove it from its packaging base and during full sequence, automatic spark ignition, low water content, fanned flue, high efficiency, condensing, combination gas boilers.
Page 7 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 gENERaL 4. Where the lowest part of the terminal is fitted less than 2m gas sUppL y (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 gENERaL aIR sUppL y 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 all dimensions in mm BOILER DIMENsIONs, sERVICEs & CLEaRaNCEs 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 than the length of flue required the flue must be fitted from operation and servicing.
Page 11 Cold water, rising main & pipework in exposed areas need to be (disconnect after filling) Double check valve suitably lagged to prevent freezing. assembly note direction of flow DHW Expansion Vessel Kit available from Ideal. Independent + Combi - Installation and Servicing...
Page 12 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 assEMBL y - Exploded View Note that item numbers are linked to the spares list CH RETURN VALVE PRESSURE GAUGE CONTROL THERMISTOR (RETURN) CH FLOW VALVE GAS COCK ELECTRODE IGNITION DHW INLET & OUTLET PIPE - GAS INLET ELECTRODE DETECTION PUMP HEAD GAS VALVE...
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 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 INsTaLLaTION WaLL MOUNTINg TEMpLa TE 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 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 Edge of turret Edge of turret Edge of turret FIgURE 1 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 INsTaLLaTION 15 CUTTINg & sETTINg ThE FLUE LENgTh TELEsCOpIC FLUEs TELEsCOpIC FLUE B p aCK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT hORIzONT aL FLUE TERMINaL (1000MM LONg) B p aCK (TELEsCOpIC) MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 &...
Page 20 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 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 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 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 INsTaLLaTION 21 CONDENsa TE 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 CONDENsa TE 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 with 75mm Visible air break proof insulation Boiler sealed...
Page 26 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 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 INsTaLLaTION 27 WIRINg DIagRaM Independent + Combi - Installation and Servicing...
Page 29 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 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: WaTER CIRCULaTION sysTEM DOMEsTIC hOT W aTER (DhW) MODE 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 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 (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 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 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 sERVICINg 38 CLEaNINg ThE hEa T 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 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 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 sERVICINg 44 RETURN ThERMIsTOR RENEW aL 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 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 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 CONDENsa TE TRap/sIphON REpLaCEMENT 1. Refer to Frame 40. 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. Note. Keep siphon upright Siphon when removing 5.
Page 43 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 56. 3.
Page 44 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 sERVICINg 57 saFETy RELIEF V aLVE RENEW aL 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 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 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 sERVICINg 65 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 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 FaULT FINDINg 69 aLTERNa TINg ‘L’ aND ‘1’ - FLOW TEMpERa TURE OVERhEa T 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 71 aLTERNa TINg ‘L’ aND ‘5’ - 5 REsETs WIThIN 15 MINs Turn power off and on 72 aLTERNa TINg ‘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 aLTERNa TINg ‘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 aLTERNa TINg ‘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 aLTERNa TINg ‘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 aLTERNa TINg ‘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 aLTERNa TINg ‘ c’ aND ‘0’ - LOW MaINs VOLT agE Reset Boiler REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. 83 NO Ch OpERa TION 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 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 57 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 58 Independent + Combi - Installation and Servicing...
Page 59 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 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 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.
Page 65 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 66 Benchmark Commissioning Checklist. You can check your installer by calling Gas Safe Register direct on 0800 4085500. Ideal stelrad group is a member of the Benchmark scheme and fully supports the aims of the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.
Page 67 Central heating operation Winter conditions - i.e. Ch and DhW required. The boiler controls the central heating radiator temperature to a maximum of 80 C, adjustable via the CH temperature control (C). Ensure the mode knob control (D) is set to winter ( The Independent + Combi is a high efficiency combination boiler The boiler will fire and supply heat to the radiators but will give which is most efficient when operating in condensing mode.
Page 68 Loss of system water pressure Condensate Drain The gauge (G) indicates the central heating system pressure. If This appliance is fitted with a siphonic condensate trap the pressure is seen to fall below the original installation pressure system that reduces the risk of the appliance condensate of 1-2 bar over a period of time then a water leak may be from freezing.
Page 69 MEChaNICaL 24 hOUR TIMER sETTINg Up Outer dial The outer dial should be set to the current time. Rotate the dial slowly in a clockwise direction, until the correct Manual OFF hour is aligned with the arrow printed on the dial. PERIOD Note that the outer dial is printed with the 24hr clock e.g.
Page 70 See boiler “Operation Modes” section. If ‘0’ is displayed then and “Fault Codes” section contact Ideal Customer Services Helpline if your appliance is under warranty or a Gas Safe Check the time settings on the Registered Engineer, in IE a...
Page 71 OpERa TION MODEs DEsCRIpTION DIspLay CODE ON BOILER The boiler is in standby mode awaiting either a central heating call or hot water demand. The boiler has a call for central heating but the appliance has reached the desired temperature set on the boiler. The boiler has a call for hot water but the appliance has reached the desired temperature set on the boiler.
Page 72 5 Boiler Resets in 15 minutes 1. Turn power off and on at the fused spur. 2. If the boiler fails to operate please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period.

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IDEAL C35 Installation And Servicing

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