Ideal Boilers icos system m3080 Installation And Servicing
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Ideal Boilers icos system m3080 Installation And Servicing

Ideal Boilers icos system m3080 Installation And Servicing

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Summary of Contents for Ideal Boilers icos system m3080

  • Page 2 GENERAL Table 1 - General Data Gas supply 2H-G20-20mbar Gas Supply Connection 22mm copper Injector size Stereomatic 5.6mm dia. Flow Connection Central Heating 22mm copper Return Connection Central Heating 22mm copper Flue Terminal Diameter mm (in) 100 (4) Maximum Working Pressure (Sealed Systems) bar (lb/in 2.65 (38.5) Electrical Supply / Power consumption...

  • Page 3: Table Of Contents

    GENERAL icos system CONTENTS Natural Gas only Air Supply ............... 7 G.C. Appliance No. 41-391-52 Boiler Clearances ............6 PI No.0063BM9802 Boiler Exploded Diagram ........10, 11 Destination Countries: UK, IE Condensate Drain ............8 Electrical Connections ..........22 Electrical Supply ............8 Extension Ducts - Fitting ..........

  • Page 4: Boiler Water Circuit Diagram

    OPERATION INTRODUCTION When there is a demand for heat, the heating system is The icos system m3080 boiler is a fully automatically supplied at the selected temperature of between 42 C and controlled wall mounted, low water content, fanned flue condensing gas boiler.

  • Page 5: Air Supply

    GENERAL SAFETY LOCATION OF BOILER AND FLUE OUTLET The boiler must be installed on a flat and vertical wall, capable Current Gas Safety (installation and use) regulations or rules in force. of adequately supporting the weight of the boiler and any ancillary equipment.
  • Page 6 GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in) The boiler connections are made on the boiler piping frame. Centre Refer to Frame 17. line of boiler The following minimum clearances must be maintained for operation and servicing. Additional space will be required for installation, depending upon site conditions.

  • Page 7: Gas Supply

    GENERAL GAS SUPPLY exposed to external air. 2. It is important that the position of the terminal allows the The local gas supplier should be consulted, at the installation free passage of air across it at all times. planning stage, in order to establish the availability of an 3.

  • Page 8: Condensate Drain

    GENERAL a bypass between the boiler flow and return is fitted, to ensure The hydraulic resistance of the boilers, at MAXIMUM OUTPUT, with adequate flow when all TRVs are closed - however this is NOT an 11 C (20 F) temperature differential, is shown in Graph 1. recommended as a large proportion of TRVs can restrict water circulation and inhibit the condensing mode of condensing Graph 1 - Water flow rate and pressure loss...
  • Page 9 GENERAL SYSTEM REQUIREMENTS (continued) General 1. The installation must comply with all relevant national and 5. Filling. The system may be filled by the following method: local regulations. Through a temporary hose connection from a 'draw-off' tap, 2. The installation should be designed to work with flow supplied from a service pipe under mains pressure.

  • Page 10: Water Treatment

    GENERAL SYSTEM BALANCING BALANCING 1. Set the programmer to ON. The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% Close the manual or thermostatic valves on all of the minimum boiler output must be provided with twin radiators, leaving the twin lockshield valves (on the radiators referred to above) in the OPEN position.
  • Page 11 INSTALLATION BOILER ASSEMBLY - Exploded View icos system condensing - Installation and Servicing...
  • Page 12 INSTALLATION UNPACKING Pack A Contents Also contained in Pack A: The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to Hardware Pack (listed below). 460mm, rear or side flue outlet, in Pack B. These Installation &...
  • Page 13 INSTALLATION 10 BOTTOM PANEL AND FRONT PANEL REMOVAL 1. Undo the 4 retaining screws. 2. Allow the RHS of the bottom panel to lower slightly. Front panel 3. Withdraw the LHS of the bottom panel from the retaining clips. 4. Lift front panel and remove. 5.
  • Page 14 INSTALLATION 12 FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than : Side 300mm (11 "). Rear 345mm (13 "). LEGEND 1. Duct assembly. 2. Flue Turret. 3. Turret seal. 4.
  • Page 15 INSTALLATION 14 PREPARING THE WALL WARNING. Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury. 1. Cut the flue hole (preferably with a 5" core boring tool), ensuring that the hole is square to the wall. Both wall faces immediately around the cut hole should Rear flue only Side flue only...
  • Page 16 INSTALLATION 17 FITTING THE PIPING FRAME (Rear Flue outlet shown) Note. The flow isolating valve (A), c/w pressure gauge, is supplied separately in the hardware pack. Fit to the piping frame BEFORE mounting the boiler. Fit the wall mounting frame either: a.

  • Page 17: Mounting The Boiler

    INSTALLATION 18 MOUNTING THE BOILER 1. Ensure that the plastic plugs are removed from both the pipes before mounting. N.B.Some spillage of water may occur from the pipework when mounting the boiler to the frame. 2. Lift the boiler onto the wall mounting frame, locating it over the tabs at the top of the frame.
  • Page 18 INSTALLATION 20 TERMINAL WALL PLATE (optional) 2. Drill 4 fixing holes with a 7mm (1/4") masonry drill. This plate is supplied in the Flue Finishing Kit (together with 3. Insert the 4 plastic plugs provided. one inner and one outer flue seal) it allows neat concealment and full compression of the outer seal (if fitted).

  • Page 19: Service Connections

    INSTALLATION 24 SERVICE CONNECTIONS General Notes 1. Fitting the Piping Frame, top entry pipework is an option, 2. Horizontal connecting pipes, where used, must be run as well as mounting from the bottom or through the wall. outside the limits of the boiler casing. If pipes are run vertically within the boiler back space provided by optional stand-off frame positions they must avoid any obstructions imposed by the channels and by a...

  • Page 20: Gas Connection

    INSTALLATION 26 GAS CONNECTION 1. Extend a gas supply pipe of not less than 15mm O.D. copper to the boiler. A working gas pressure of 20mbar (8" w.g) should be Rubber washer available at the boiler inlet, with the boiler firing at full output.
  • Page 21 INSTALLATION 29 FILLING 1. Swing the control panel down into the servicing position - Refer to Frame 45. 2. Remove the boiler sealing panel - Refer to Frame 44. Automatic air vent 3. Ensure that the isolating valves are open. 4.

  • Page 22: Electrical Connections

    INSTALLATION 30 ELECTRICAL CONNECTIONS WARNING. This appliance MUST be earthed. Wiring should be 3 core PVC insulated cable, not less than 0.75 mm (24 x 0.2mm), and to BS 6500 A mains supply of 230 V ~ 50 Hz is required. Table 16.

  • Page 23: External Controls

    INSTALLATION 32 EXTERNAL CONTROLS Wiring External to the Boiler The fuse rating should be 3A. L2 L1 Wiring external to the boiler MUST be in accordance with the Room ’stat current I.E.E. (BS.7671) Wiring Regulations and any local regulations. Room Thermostat If the thermostat has a neutral connection, use it (it provides if required Mains in...
  • Page 24 INSTALLATION 33 PICTORIAL WIRING DIAGRAM LEGEND - white. - blue. y/g - yellow/green. bk - black. gy - grey. br - brown. or - orange. - red. - violet. pk - pink. - yellow. Flue thermistor Overheat thermostat Control Gas valve thermistor MAINS SUPPLY...

  • Page 25: Flow Wiring Diagram

    INSTALLATION 34 FUNCTIONAL FLOW WIRING DIAGRAM Mains Switch Filter External switch e.g. room'stat, programmer PCB No. Flame detection electrode Overheat thermostat DC Gas valve Flue thermistor electrode CH return thermistor (not fitted) Control thermistor Pump Ecl 1991 LEGEND - yellow - blue - white bk - black...

  • Page 26: Initial Lighting

    INSTALLATION 36 INITIAL LIGHTING Control panel in servicing position LEGEND A. Automatic air vent. Clamp B. Inlet pressure test point. C. Return isolating valve. D. Gas service cock. Control panel in working position E. Flow isolating valve. F . Pressure gauge. G.
  • Page 27 INSTALLATION 37 INITIAL LIGHTING - continued 12. Set the boiler thermostat knob to maximum and set the 15. Set the boiler ON/OFF switch (J) to OFF. boiler ON - OFF switch to ON. The RED mains ON neon 16. Swing the control panel into the servicing position. Refer to (H) should now be illuminated.

  • Page 28: Handing Over

    INSTALLATION 39 HANDING OVER After completing the installation and commissioning of the 6. Explain and demonstrate the function of time and system the installer should hand over to the householder by temperature controls, radiator valves etc., for the economic the following actions: use of the system.

  • Page 29: Gas Supply

    SERVICING Note. This must be done with the heat engine and deposits 40 SERVICING SCHEDULE in a dry condition - refer to Frame 49. To ensure the continued safe and efficient operation of the 7. Check the main injector for blockage or damage. appliance it is recommended that it is checked at regular 8.
  • Page 30 SERVICING 43 BOILER BOTTOM PANEL REMOVAL 44 BOILER SEALING PANEL REMOVAL 1. Turn off the gas supply at the gas service cock and 1. Remove the 2 securing screws. disconnect the electricity supply. 2. Pull the right hand side of the panel down, slide it to the 2.
  • Page 31 SERVICING 46 FAN, GAS INJECTOR AND VENTURI ASSEMBLY REMOVAL AND CLEANING 1. Disconnect the electrical leads from the fan. 2. Undo the gas pipe union connection to the injector housing. 3. Undo the single retaining screw on the fan mounting bracket.

  • Page 32: Cleaning The Heat Exchanger

    SERVICING 48 CLEANING THE CONDENSATE 'S' TRAP 1. Swing the control panel down into the servicing position - Screw Condensate trap Refer to Frame 45. 2. Disconnect the condensate drain pipe. 3. Remove the securing screw and elongated bolt, pull the trap down and forwards to remove.

  • Page 33: Replacement Of Components

    SERVICING REPLACEMENT OF COMPONENTS GENERAL When replacing any component : IMPORTANT. 1. Isolate the electricity supply. When work is complete, if the sealing panel has been 2. Turn off the gas supply. removed, it must be correctly refitted - ensuring that a good seal is made.
  • Page 34 SERVICING 54 BURNER INJECTOR REPLACEMENT Retaining 1. Refer to Frame 51. screw 2. Remove the boiler sealing panel - Refer to Frame 44. Injector 3. Disconnect the electrical leads from the fan. 4. Undo the gas pipe union connection to the injector housing.
  • Page 35 SERVICING 57 CONTROL THERMISTOR AND OVERHEAT THERMOSTAT REPLACEMENT 1. Refer to Frame 51. 4. Re-connect the electrical leads and re-assemble in 2. Unclip the thermistor / thermostat from the flow pipe and reverse order ensuring that the spring clip is securely on withdraw it from the controls compartment.

  • Page 36: Combustion Chamber

    SERVICING 60 COMBUSTION CHAMBER INSULATION REPLACEMENT The insulation boards used in the combustion chamber of 9. Remove the split pin and washer from the RHS of the this product are made of high temperature glass fibres with a combustion chamber. binder of organic and inorganic materials.
  • Page 37 SERVICING 61 GAS CONTROL VALVE REPLACEMENT 1. Refer to Frame 51. 7. Undo the union nut (B) on the RHS of the gas control valve. 2. Remove the casing bottom panel. Refer to Frame 43. 8. Slacken the screw securing the valve mounting bracket and withdraw the valve, complete with bracket and inlet 3.
  • Page 38 SERVICING 63 CONTROL BOX REPLACEMENT 1. Refer to Frame 51. 2. Swing the control panel down into the servicing position. Refer to Frame 45. 3. Unplug the user control electrical lead and low voltage lead from the control box and remove the control. Refer to diagram A.
  • Page 39 SERVICING 65 USER CONTROL REPLACEMENT Note. Only the display unit is replaced. 1. Refer to Frame 51. 2. Loosen the securing screw on the underside of the user control. 3. Pull the display unit forward to remove. 4. Push the new display unit into position. 5.
  • Page 40 SERVICING 67 SAFETY RELIEF VALVE REPLACEMENT 1. Refer to Frame 51. housing. 6. Withdraw the securing pin. 2. Remove the casing bottom panel. Refer to Frame 43. 7. Remove the safety valve. 3. Drain the boiler. Refer to Frame 69. 4.

  • Page 41: Draining The Boiler

    SERVICING 69 DRAINING THE BOILER 1. Refer to Frame 51. 2. Remove the boiler bottom panel. Refer to Frame 43. 3. Close all the water isolating valves on the piping frame. 4. Attach a length of hose to the drain point and open the drain valve.
  • Page 42 SERVICING 71 HEAT ENGINE REPLACEMENT 15. Remove the flue. Refer also to Frame 7 - 'Boiler exploded view'. 16. Remove the edge clip securing the flue sensor wiring. IMPORTANT 17. Remove the blind grommet to gain access to the return Before starting the removal procedure, protect the gas and pipe securing bracket.
  • Page 43 SERVICING 72 EXPANSION VESSEL REPLACEMENT 1. Refer to Frame 51. 2. Drain the boiler - Refer to Frame 69. 3. Undo all the gas and water connection unions on the boiler side of the valves. 4. Remove the turret screw and remove the turret clamp. 5.

  • Page 44: Fault Finding

    FAULT FINDING 74 FAULT FINDING CHART MAIN MENU In order to assist fault finding, the boiler has an LED diagnostic display. The key to the display codes is as follows: ALTERNATING 'L' 'F' GO TO FRAME 75 GO TO FRAME 76 ALTERNATING 'L' 'E' ALTERNATING 'L' 'A' GO TO FRAME 77...
  • Page 45 FAULT FINDING 75 L..F..(FLAME DETECTION) If the boiler reset button is Check gas Is 17mbar gas pressure pressed does the boiler ignite supply and rectify available at the boiler inlet ? for a short time then extinguish? fault Check gas valve Check the detection electrode and Is 200 V DC supply wiring for...
  • Page 46 FAULT FINDING 77 L..A......(OVER HEAT SENSOR) Can the overheat condition be reset by pressing Replace overheat thermostat the boiler reset button when the system is cold ? Is the boiler and CH system filled with Fill and vent the system and open all water and all isolation valves open ? isolation valves Does the pump setting give a differential...
  • Page 47 FAULT FINDING 80 H..4..(FLUE SENSOR) Is the system filled and vented and all Can the fault condition be reset by switching off isolation valves open ? the mains supply to the boiler ? Fill and vent the Check wiring for continuity from the system and open all PCB to the flue thermistor isolating valves...

  • Page 48: Short List Of 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 Boilers.
  • Page 49 SHORT LIST OF PARTS 83 SHORT PARTS LIST Ecl 2106 icos system condensing - Installation and Servicing...
  • Page 50 LIST OF PARTS 84 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom panel with screws. 85 BURNER ASSEMBLY 11. Burner assembly with screws and gasket. Ecl 1598 icos system condensing - Installation and Servicing...
  • Page 51 NOTES icos system condensing - Installation and Servicing...
  • Page 52 & servicing of central heating systems Manufactured under a BS EN ISO 9001: 1994 Quality System accepted by BSI Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137.

  • Page 54: Important Notes

    (Natural Gas Only) G.C. Appliance No. 41-391-52 Destination Countries: GB, IE Introduction Important Notes The icos system is a wall mounted, room sealed, condensing This appliance must not be operated without the casing boiler, featuring full sequence automatic spark ignition and fan correctly fitted and forming an adequate seal.

  • Page 55: Boiler Controls

    To light the boiler. Refer to Frame 1 Control of water temperature If a programmer is fitted refer to separate instructions for the The boiler controls the central heating radiator temperature to a programmer before continuing. maximum of 82 C, adjustable via the thermostat knob (F). 1.

  • Page 56: Frost Protection

    Frost protection DO NOT FIRE THE BOILER IF THE PRESSURE HAS REDUCED TO ZERO FROM THE ORIGINAL SETTING. If no frost protection is provided and frost is likely during a short absence from home, leave the heating controls (if fitted) at a Condensate Drain reduced temperature setting.

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