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IDEAL Mini C24 Installation And Servicing

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installation and
servicing
mini
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
Model
Serial No.
C24,C28,C32
S24,S28
For users guide see reverse of book
When replacing any part of this appliance, use only spare parts that you can be assured
conform to safety and performance specification that we require. Do not use
reconditioned or copy parts that have not been clearly authorised by Ideal Boilers
17962.1062.4
4307 64A4 GB
*1796210624*
For the very latest copy of literature for specification purposes please visit our website
www.idealboilers.com where you will be able to download the relevant information in pdf format.

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Summary of Contents for IDEAL Mini C24

  • Page 1 When replacing any part of this appliance, use only spare parts that you can be assured conform to safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers 17962.1062.4...
  • Page 2 Mini --- Installation & Servicing...
  • Page 3 DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from book reference....17962.1062.4 2007 F Further guidance added to Important Notes section of User Guide Ideal Stelrad Group reserve the right to vary specification without notice Mini Installation & Servicing...
  • Page 4 GENERAL Table 1 --- Boiler Data Mini C24 Mini C28 Mini C32 Mini S24 Mini S28 Gas supply type & connection G20 20mbar, G31 37mbar, 22 mm copper 2H3P Inlet / Outlet connection --- Domestic Hot Water 15 mm copper Flow &...
  • Page 5 GENERAL Mini CONTENTS Boiler size G.C. appliance No. PI No. Air supply (Benchmark No.) Benchmark Commissioning Checklist Mini C24 47 ---348 ---18 0694BM3420 Boiler clearances Mini C28 47 ---348 ---19 0694BM3420 Mini C32 47 ---348 ---25A 0694BM3420 Boiler exploded view...
  • Page 6 GENERAL BOILER WATER CONNECTION Pipe size O.D. mm CH flow Wall mounting CH return plate Gas inlet DHW cold inlet * DHW hot outlet * 20 (3/4”) * Pipe connections not used on system boilers 255 (10”) 85 (3 5/16”) BOILER CLEARANCES (17 3/4”) overall clearance is still required, with the cupboard door open, to allow for servicing.
  • Page 7 INTRODUCTION GAS SAFETY Current Gas Safety (Installation and Use) Mini C24, Mini C28 and Mini C32 are wall mounted, low water content, balanced flue combination gas boilers. Regulations or rules in force Mini S24 and Mini S28 are wall mounted, low water content, The appliance is suitable only for installation in GB and IE and balanced flue system gas boilers.
  • Page 8 GENERAL The boiler may be fitted on a combustible wall and insulation IMPORTANT Installation pipes MUST be fitted in accordance between the wall and the boiler is not necessary, unless with BS. 6891. In IE refer to I.S. 813.2002. required by the local authority. Pipework from the meter to the boiler MUST be of an adequate size, i.e.
  • Page 9 Kent TN9 1TB Tel. +44 (0) 1732 359 888 Fax No. +44 (0) Treatment in Central Heating Systems. 1732 354 455 www.tfc---group.co.uk Ideal Stelrad Group recommend the use of Fernox, GE Betz IMPORTANT It is absolutely ESSENTIAL to ensure, in Sentinel or Salamander water treatment products, which must practice, that products of combustion discharging from the be used in accordance with the manufacturers instructions.
  • Page 10 (see Table 5). temperatures of up to 90 ˚C. 3 Working Pressure Table 5 Mini C24, Mini S24, Mini C28, Mini S28 All components of the system must be suitable for a working System charge pressure pressure of 3 bar (45 lb/in ) and temperature of 110 ˚C.
  • Page 11 2 For the minimum and maximum working pressures of the b. Hot and cold supplies are of equal pressure. Mini C24, Mini C28 and Mini C32 domestic hot water circuit refer to Table 1, page 4. 6 Hard water areas 3 The cold water supply pipe should be flushed before In areas where the water is ’hard’...
  • Page 12 BOILER WATER CIRCUIT DIAGRAM 1 Domestic hot water (DHW) heat exchanger 2 Domestic hot water (DHW) flow switch Mini C24 --- Mini C28 --- Mini C32 3 Domestic hot water (DHW) outlet pipe 4 Domestic cold water inlet cock 5 Three ---way diverter valve...
  • Page 13 34 Burner 11 DHW temperature probe 23 CH circuit pressure gauge 35 Air pressure switch 12 Main circuit drainage cock 24 Model identification & instructions 36 Expansion vessel * Mini C24, Mini C28 and Mini C32 only Mini Installation & Servicing...
  • Page 14 F Pre ---piping frame F 1/2” DHW cold inlet isolating valve --- 1 off. * F Natural gas to LPG conversion kit * Mini C24, Mini C28 and Mini C32 only F LPG to natural gas conversion kit PACKAGING To unpack the boiler refer to the instructions on carton end flap.
  • Page 15 INSTALLATION FITTING THE FLUE SYSTEM Table 9 --- Models Mini C24, Mini S24, Mini C28, Mini S28 Pipe length (ø 80/125) Restrictor The maximum total equivalent lengths are given in Table 7 and Table 8 for co---axial pipes ø 60 ---100 mm, Between 0,5 (19.5“) and 1,5 m (59“)
  • Page 16 INSTALLATION FITTING THE FLUE SYSTEM (cont.) For each additional 45˚ M&F and 90˚ M&F flue bend used, the maximum permissible length of flue system must be Co---axial Flue kits. reduced by 0,9m or 1,65m respectively. Horizontal. For each additional 90˚ F&F Flue bend used, the maximum For calculation of total flue length, the distance MUST be permissible length of flue system must be reduced by 2,75m.
  • Page 17 INSTALLATION WALL MOUNTING TEMPLATE (rear flue) IMPORTANT Detailed installation steps are given directly on the wall mounting template 1 Tape the template into the selected position. 2 Ensure squareness by hanging a plumbline. 3 Mark onto the wall the following: a.
  • Page 18 Gas inlet Domestic cold water inlet * Central Heating return * Mini C24, Mini C28 and Mini C32 only Connect to the tail pipes by proprietory fittings. The pipework may be directed down or through the rear wall as required.
  • Page 19 Mains wiring should be 3 core PVC insulated flexible cord NOT LESS than 0.75 mm (24 x 0.2mm) and to BS. 6500, Mini C24, Mini C28 Mini C32 only Table 16. (0.5mm flex is not acceptable --- for mechanical, For external controls wiring see frame 26.
  • Page 20 INSTALLATION PICTORIAL WIRING Mini C24, Mini C28, Mini C32 Wiring diagram for boiler equiped with electronic control p.c.b. type: Bertelli & Partners DIMS11 ---SA03/16740 Electric supply External controls Three way Pump Ignition Primary circuit Air pressure Flame detection terminal block...
  • Page 21 INSTALLATION PICTORIAL WIRING Mini S24, Mini S28 Wiring diagram for boiler equiped with electronic control p.c.b. type: Bertelli & Partners DIMS11 ---SA03/16740 Electric supply External controls Pump Ignition Primary circuit Air pressure Flame detection terminal block terminal block electrodes flow switch switch electrode Electronic control P .C.B.
  • Page 22 INSTALLATION FUNCTIONAL FLOW DIAGRAM Mini C24, Mini C28, Mini C32 CH flow DHW flow switch switch Gas Valve Gas Valve (on--- off operators) (modulation coil) Three way div. valve Electronic DHW temp. probe NTC Air pressure switch control pcb CH temp.
  • Page 23 INSTALLATION FUNCTIONAL FLOW DIAGRAM Mini S24, Mini S28 CH flow switch Gas Valve Gas Valve (on--- off operators) (modulation coil) Electronic Air pressure switch control pcb CH temp. probe NTC Safety thermostat Pump Ignition electrodes Detection electrode Mini Installation & Servicing...
  • Page 24 Power supply terminal block Optional Programmer Kit External controls For the models Mini C24, Mini C28 and Mini C32 (combi) an terminal block optional digital programmer kit is available with its relevant instructions. Note: the switch contacts of any external programmer, External programmer room or frost thermostat must be volt free.
  • Page 25 Mini S24 Mini S28 Legend Central Heating flow A Appiance operation lamps Domestic hot B Domestic hot water temperature control Mini C24, water outlet Gas inlet Mini C28, Mini C32 Domestic cold B Service knob Mini S24, Mini S28 water inlet...
  • Page 26 “heat demand”. 5 Run the boiler in c.h. mode (for combi boilers: do not open any d.h.w. tap) Mini C24 Mini C28 Mini C32 Mini S24 Mini S28 1 Remove the front panel of the case.
  • Page 27 11 Turn the boiler off and on positioning the main switch C as 13 Press the reset button D repeatedly (4 times) until the indicated in the next figure. lamps A give the follow indication: Mini C24 Where: Lamp ON Mini C28...
  • Page 28 Make the following checks for correct operation: 4 Water circulation system 1 Hot water (Mini C24, Mini C28 and Mini C32 models). Note. Fernox Superfloc flushing solution should be used a. Fully open all DHW taps in turn and ensure that water flows during the flushing procedure.
  • Page 29 8 Turn the boiler OFF positioning the main switch C as in figure below. Natural gas 125 mA L.P .G. 165 mA Mini C24 Mini C28 13 To change the setting turn the knob B to a position Mini C32 corresponding to the gas used as shown in the figure above.
  • Page 30 SERVICING SERVICING SCHEDULE Note. If your meter reads CO in parts per million the figure must be divided by 10,000 to convert it to a percentage. To ensure the continued safe and efficient operation of the 5 If the ratio of CO/CO is less than ,004 and the gas rates appliance it is recommended that it is checked at regular measured in steps 3 and 4 are close to nominal then no...
  • Page 31 SERVICING REMOVAL OF OUTER AND INNER 5 Remove the screws C and remove the boiler inner casing. CASING 1 Turn off the gas supply at the gas service cock and disconnect the electricity supply. 2 Remove the screws A and lift off the boiler front panel. 3 Loosen the screws B.
  • Page 32 Burner blade Ignition Male Detection Female Mini C24, Mini C28, Mini S24, Mini S28 Burner blades 4 Disconnect the electrodes leads. 4 mm (5/32”) 5 Undo the four screws C placed at the right and left sides of the burner and extract it.
  • Page 33 SERVICING RE ---ASSEMBLY 6 Refit the inner case cover. IMPORTANT. Ensure the boiler sealing panel is correctly fitted and that a good seal is made. Re ---assemble the boiler in the following order: 3 Refit the burner. 7 Refit the boiler side and front panels. 4 Reconnect the electrodes to the electronic pcb.
  • Page 34 4 Remove the burner. Refer to frame 37. 5 Undo the screws that hold the electrodes and remove. Detection 6 For models Mini C24, Mini C28, Mini S24, Mini S28, fit new electrodes as necessary following the sequence illustrated. 10 mm (3/8”)
  • Page 35 SERVICING BURNER INJECTORS Injectors REPLACEMENT Burner 1 Remove the burner. Refer to frame 37. 2 Unscrew the injectors from the gas manifold. 3 Check that the new injectors are of the correct size and fit it using new gaskets. Gas manifold 4 Re ---assemble in reverse order.
  • Page 36 SERVICING TEMPERATURE PROBE Removal of DHW temperature probe (Combi boilers) REPLACEMENT 3 To remove the DHW temperature probe close off the isolating cock of the DHW circuit at the bottom of the 1 Disconnect the electrical supply. boiler. 2 Remove the front and right hand side casing panels (refer to frame 36).
  • Page 37 SERVICING GAS VALVE REPLACEMENT 1 Turn off the gas supply at the gas service cock and disconnect the electricity supply. 2 Remove the front casing panel (refer to frame 36). 3 Disconnect the connectors A and B. 4 Disconnect the earth wiring from the gas valve. 5 Unscrew the connectors C and remove the pipe D 6 Unscrew the inlet connector.
  • Page 38 SERVICING FAN REPLACEMENT If the right clearance is at least 50 cm (20”)..6 Unscrew the 3 screws E and remove the fan. 1 Disconnect the electrical supply. 2 Remove outer and inner casing. 3 Disconnect the connectors A and the earth connection B. 7 Re ---assemble in reverse order.
  • Page 39 SERVICING AIR PRESSURE SWITCH REPLACEMENT Two different types of air pressure switch may be used in the boiler. Refer tho the following drawings in accordance with the type of air pressure switch used. 1 Disconnect the electrical supply. 2 Remove outer and inner casing as explained in frame 36. 3 Disconnect the pressure sensing pipe from the air pressure switch.
  • Page 40 Attention After installing the electronic control/ignition p.c.b.: Combi boilers (Mini C24, Mini C28, Mini C32) 14 Make sure the CH ( ) and DHW ( ) temperature adjustment knobs can move freely for the complete range.
  • Page 41 18 Position the control knob C as in the figure below and disconnect the C.h. temperature probe. It is now possible to check the current setting by pressing Mini C24 reset button D for more than 5 seconds. The three lamps A Mini C28...
  • Page 42 SERVICING CH FLOW SWITCH REPLACEMENT 5 Re ---assemble in reverse order. Refer to the following illustration for the correct wiring 1 Disconnect the electrical supply. connectors on the switch 2 Remove the front casing panel. 3 Remove the fork A. N.O.
  • Page 43 SERVICING DHW FILTER AND FLOW LIMITER Flow limiter REPLACEMENT The Mini C24 model is factory fitted with a 10 litre/min. flow Mini C only limiter. 1 Disconnect the electrical supply. The Mini C28 model is factory fitted with a 12 litre/min. flow 2 Remove the front panel of the case and empty the DHW limiter.
  • Page 44 SERVICING PRIMARY HEAT EXCHANGER 7 Unscrew the locknut G, lift the pipe H and rotate it right then move it downwards freeing it from the heat REPLACEMENT exchanger connection. 1 Disconnect the electrical supply. 8 Completely unscrew the connection I 2 Remove outer and inner casing as explained in frame 36.
  • Page 45 SERVICING DHW HEAT EXCHANGER 8 Move the exchanger towards the rear of the boiler and extract it. REPLACEMENT 9 Re ---assemble in the reverse order. Mini C only Attention. When reassembling the exchanger be sure to 1 Disconnect the electrical supply. put the off center location/securing pin indicated towards 2 Remove outer casing (refer to frame 36).
  • Page 46 SERVICING DIVERTER VALVE INTERNAL PARTS REPLACEMENT Mini C only 1 Disconnect the electrical supply. 2 Remove front and left hand casing panels (refer to frame 36). 3 Close the isolating cocks of the CH circuit and DHW supply at the bottom of the boiler. 4 Release system pressure by opening the main circuit drainage cock.
  • Page 47 FAULT FINDING ELECTRONIC CONTROL/IGNITION The following table gives a summary of the relationship between each of the possible lamp combinations and their P .C.B. OPTICAL INFORMATION meaning. The electronic control/ignition p.c.b. is provided with three Normally operating boiler lamps (L.E.D. indicators) A, that give optical information during the normal operation of the boiler or for service and fault fiinding purpose.
  • Page 48 FAULT FINDING FAULT FINDING With a fast pulse showing on LED 1 the boiler will continue to operate with a reduced performance in some fault conditions. WARNING Before commencing fault finding please check the following: Care must be taken when conducting fault finding tests to Are all wiring connections OK ? guard against the risk of electric shock.
  • Page 49 FAULT FINDING Continued from page 48 of fault finding Is there between 0V dc Is the continuity of the Repair or replace With the boiler and and 16V dc at the modulator harness faulty wiring heating circuit warm connections on the O.K? does the burner modulating coil?
  • Page 50 FAULT FINDING Continued from page 48 of fault finding. Is there at least one of the LEDs flashing? Continued on page Are LED2 and LED 3 Are LED2 flashing Is LED 1 flashing with flashing? and LED 3 on? 51 of fault finding LED 2 on ? Replace faulty Replace faulty...
  • Page 51 FAULT FINDING Are LED 1 and LED 3 Continued on flashing with LED 2 Continued from page 50 page 53 of on, plus lockout LED of fault finding fault finding on the fascia on? Is there > 17 mbar at Rectify gas supply the gas valve inlet? fault.
  • Page 52 FAULT FINDING Continued from page 51 of fault finding Adjust the burner minimum Can the minimum burner Is the burner light on? pressure refer to frame 29 pressure be achieved ? (Pressure values are given in Table 2 on page 4) Replace faulty PCB Is the position of the Rectify electrode...
  • Page 53 FAULT FINDING Continued from page 51 of fault finding Is LED 1 on and Is LED 1, LED 2 Replace faulty Is LED 1 and LED 2 LED 2 and LED 3 and LED 3 on? flashing and LED 3 flashing? Is there continuity of Has the main...
  • Page 54 FAULT FINDING Continued from page 49 Is there > 17 mbar Rectify gas supply Is there max burner Is there a temperature rise gas pressure at the fault. pressure* when the of 35 ˚C across the DHW gas inlet? circuit at: boiler first lights? 10.0 L/min 24 kW model 11.6 L/min 28 kW model...
  • Page 55 172581 H32---550 Magnetic flow switch and filter (mod. Mini C24, Mini C28, Mini C32) 174461 E83---127 Ignition electrode --- left (mod. Mini C24, Mini S24, Mini C28, Mini S28) 172533 Ignition electrode --- left (mod. Mini C32) H05---186 173502 E83---126 Ignition electrode --- right (mod.
  • Page 56 E69---243 Window (glass + rubber frame) 170977 169---141 1/2” flat gasket 075514 169---033 3/4” flat gasket 075415 Side case panel 174508 H17---563 Control panel door 173637 Front case panel 174510 Mini --- Installation & Servicing...
  • Page 57 INSTALLER NOTIFICATION GUIDELINES IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE In addition a change to Building Regulations (England and Wales) requires the installer to notify when installing a heating appliance, as from 1st April 2005. Install and commission this appliance to manufacturers’...
  • Page 58 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME &...
  • Page 59 SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
  • Page 60 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: ..

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