Ideal Heating i305 Installation & Servicing
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Ideal Heating i305 Installation & Servicing

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H E A T I N G
INSTALLATION
& SERVICING
POD HEAT INTERFACE UNIT
INDIRECT POD i305, i405, i505, i605, i705
DIRECT POD D30, D40, D50, D60
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 Heating.
For the very latest copy of literature for specification and maintenance practices visit our website idealheating.com
where you can download the relevant information in PDF format.
July 2021
UIN 224649 A03

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Summary of Contents for Ideal Heating i305

  • Page 1 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 Heating.
  • Page 2 Installation and Servicing...
  • Page 3 Relevant Installation changes implemented in this book from Mod Level ..A02 (May 21) to A03 (July 21) Updated images & additional Section 3.17 - Domestic Hot Water Thermistor Ideal Heating reserve the right to vary specification without notice Installation and Servicing...
  • Page 4 Installation and Servicing...

  • Page 5: Table Of Contents

    CONTENTS GENERAL ................. 8 SERVICING ..............29 Introduction ................ 8 Servicing Schedule ............29 Operation ................8 Key Components - Indirect ..........30 Safe Handling ..............9 Key Components - Direct ..........31 Optional Extra Kits ............. 9 HIU Front Panel Removal / Replacement ....... 32 Safety ................
  • Page 6 SECTION 1 - GENERAL Table 1 - General Data Indirect Direct Models i305 i405 i505 i605 i705 Domestic Hot Inlet Connection 22mm copper Water Domestic Hot Outlet Connection 22mm copper Water Flow Connection Central Heating 22mm copper Return Connection Central Heating...
  • Page 7 SECTION 1 - GENERAL Table 2 - Performance Data Indirect Direct Models i305 i405 i505 i605 i705 Primary Supply Temperature @ 50kPa 70°C Primary Flow Rate 0.188 0.265 0.314 0.310 0.319 0.188 0.265 0.314 0.310 Primary Return Temperature °C 30.3 31.7...

  • Page 8: General

    Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the INDIRECT RANGE installation pipework. • Ideal POD i305 = 30kW DHW output with 5kW indirect CH • Pipework from the HIU can be routed upwards or output performance downwards.

  • Page 9: Safe Handling

    SECTION 1 - GENERAL 1.3 SAFE HANDLING CIBSE CP1 (2020) Heat Network code of practice. This HIU may require 2 or more operatives to move it to its BS EN. 12828 Heating Systems in buildings: Design for water- installation site, remove it from its packaging base and during based heating systems.

  • Page 10: Primary Heat Supply Connection

    SECTION 1 - GENERAL 1.9 WATER CIRCULATION SYSTEM Ceiling IMPORTANT. A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the HIU before connection Recessed to any plastic piping. window Zone 2 2.25m The central heating system should be in accordance with BS 7593 Code of practice for the preparation, commissioning...

  • Page 11: Hiu Dimensions, Services & Clearances

    SECTION 1 - GENERAL 1.12 HIU DIMENSIONS, SERVICES & CLEARANCES HIU Dimensions, Services & Clearances Front Clearance The HIU connections are made on to the HIU first fix kit valve The minimum front clearance when built into a cupboard is connection tails.

  • Page 12: System Requirements

    SECTION 1 - GENERAL 1.13 SYSTEM REQUIREMENTS Notes Domestic Hot Water a. The method of filling, refilling, topping up or flushing sealed 1. The DHW service must be in accordance with BS 6700. secondary circuits from the mains via a temporary hose 2.

  • Page 13: System Balancing - Central Heating

    The application of any other treatment to this product may render the guarantee of Ideal Heating invalid. The use of Ideal Heating recommend the use of Fernox Quantomat, Sentinel the optional Ideal Filter will aid against the build up of iron...

  • Page 14: Installation

    505 Casing Screw Kit 104 Mini Expansion Vessel 132 Primary Flow Pipe CH 2 203 Clip on Thermistor for 18mm Pipe 506 Ideal Heating Badge 105 Primary Return Manifold 133 Primary Return Pipe 204 Cable Entry Kit 507 Door 106 Pressure Test Points...

  • Page 15: Unpacking

    SECTION 2 - INSTALLATION 2.2 UNPACKING The POD HIU is supplied in 2 parts, the First Fix Kit and the main appliance. For further details on the First Fix Kit, refer to the instructions enclosed in the kit To unpackage the appliance: Remove the straps from the outside of the packaging.

  • Page 16: Mounting The Heat Interface Unit

    SECTION 2 - INSTALLATION 2.3 MOUNTING THE HEAT INTERFACE UNIT Ensure the plastic plugs are removed from both the Lift the HIU onto the wall mounting plate (refer to the Primary and DHW connections before mounting the HIU. Introduction section for safe handling advice), locating it over the two tabs.

  • Page 17: System Filling

    SECTION 2 - INSTALLATION PRESSURE RELIEF VALVE (INDIRECT ONLY) The safety valve connection, located at the bottom right-hand side of the HIU, comprises a 15mm diameter stub pipe. The installer must provide a suitable joint on the end of the stub pipe. This assists with pipe removal when servicing.
  • Page 18 SECTION 2 - INSTALLATION Filling Primary Circuit (Direct) Remove front cover (section 3.4) and the insulation (section 3.12) to gain access to the Primary and CH Air Vents. Ensure isolation valves C, D, E and F are in closed position (handle horizontal).

  • Page 19: Electrical Connections

    SECTION 2 - INSTALLATION 2.6 ELECTRICAL CONNECTIONS WARNING. This appliance MUST be earthed. For IE reference should be made to the current ETCI rules for All electrical work within the unit should be carried out by a electrical installations. competent person and be compliant with BS 7671. Connection must be made in such a way that allows complete A mains supply of 230Vac ~ 50Hz is required.

  • Page 20: Installer Wiring

    SECTION 2 - INSTALLATION 2.7 INSTALLER WIRING The image below shows the HIU electrical connections. Accessing the installer wiring Isolate the mains supply from the HIU. The HIU must be connected to a permanent live supply via the Open the drop-down cover and remove the front access ‘L’...

  • Page 21: Wiring Diagram

    SECTION 2 - INSTALLATION 2.9 WIRING DIAGRAM MAINS LIVE MAINS NEUTRAL AUXILIARY LIVE CH LIVE Cylinder Thermostat CH Return Thermistor+ CH Return Thermistor- CH Flow Thermistor+ CH Flow Thermistor- DHW Thermistor+ DHW Thermistor- Primary Return Thermistor+ Primary Return Thermistor- Pump Feedback Pump PWM Out Pump GND Turbine Signal...

  • Page 22: External Wiring

    SECTION 2 - INSTALLATION 2.10 EXTERNAL WIRING Electrical Installation 1. Checks to ensure electrical safety should be carried out by a competent person. 2. ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit, using a suitable test meter.

  • Page 23: Display Functions

    SECTION 2 - INSTALLATION 2.12 DISPLAY FUNCTIONS 2.12.1 MENU NAVIGATION The user control has a Symbolic LCD which provides information to the user about the status of the HIU. The temperatures shown as follows are for illustration purposes only. The actual set point or measured temperatures will be shown on the HIU. Notes: HIU frost protection –...

  • Page 24: Normal Operation

    SECTION 2 - INSTALLATION DISPLAY FUNCTIONS - CONT’D 2.12.2 NORMAL OPERATION In normal operation with DHW and CH enabled and Preheat disabled the display will show: HOT WATER PREHEAT ºC With a DHW demand the display will show the tap symbol and the DHW delivery temperature: HOT WATER PREHEAT ºC...

  • Page 25: Set Ch Temperature 45°C - 25°C

    SECTION 2 - INSTALLATION DISPLAY FUNCTIONS - CONT’D 2.12.3 SET CH TEMPERATURE 45°C - 25°C The maximum flow temperature is defaulted to 45°C, this can be adjusted and limited, up to a maximum of 85°C by following the procedure below: Turn off the power to the HIU, turn the power back on, then press and hold the reset and the menu buttons together for 5 seconds until 'uP' is shown: Press the reset button within five minutes.

  • Page 26: Service Modes

    SECTION 2 - INSTALLATION DISPLAY FUNCTIONS - CONT’D 2.12.4 SERVICE MODES Navigate the Standard menu as displayed on page 26 - +/- using the ‘Menu’ button until the ‘Preheat Enable’ screen is displayed. HOT WATER HOT WATER Then press + and – buttons together for 3 seconds to PREHEAT PREHEAT enter service mode.
  • Page 27 SECTION 2 - INSTALLATION SERVICE MODES - CONT’D If +/- buttons are pressed the Central Heating will run at maximum rate for up to 30 minutes Press the Menu button again to progress to the ‘Slab Setting’ service mode: If +/- buttons are pressed the CH Slab setting function will be activated. This function will increase the CH flow temperature from 15°...

  • Page 28: Reset Procedure

    SECTION 2 - INSTALLATION 2.13 RESET PROCEDURE To Reset the HIU, press the RESET button (A). Legend A. Reset Button B. - Function Button C. + Function Button D. Menu Button E. HIU Status Display F. CH System Pressure Gauge (Indirect Only) G.

  • Page 29: Servicing

    SECTION 3 - SERVICING SERVICING 3.1 SERVICING SCHEDULE For the very latest copy of literature for specification & maintenance practices, visit our website idealheating.com, where you will be able to download the relevant information. To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary.

  • Page 30: Key Components - Indirect

    SECTION 3 - SERVICING 3.2 KEY COMPONENTS - INDIRECT PHEX Assembly DHW Manifold Primary Return 15. Air Vent CH 23. Thermistor DHW Assembly PHEX Assembly CH 16. PRV 24. Mini Expansion vessel Manifold DHW Flow Expansion Vessel 17. Auto Air Vent 25.

  • Page 31: Key Components - Direct

    SECTION 3 - SERVICING 3.3 KEY COMPONENTS - DIRECT Note: Greyed out parts Waterset CH 13. Air Vent DCW 22. Pressure Test Point listed on this key are not Manifold Primary Flow 14. Air Vent Primary 23. Thermistor DHW applicable to the Direct HIU Assembly model.

  • Page 32: Hiu Front Panel Removal / Replacement

    SECTION 3 - SERVICING 3.4 HIU FRONT PANEL REMOVAL / REPLACEMENT REMOVAL Pull open the door panel. Remove the two screws retaining the front panel on the bottom edge – retain screws. Pull front panel forward from the bottom and lift away to disengage from top retention.

  • Page 33: Primary Strainer Removal, Cleaning & Replacement

    SECTION 3 - SERVICING 3.6 PRIMARY STRAINER REMOVAL, CLEANING & REPLACEMENT 1. Isolate and drain primary circuit – refer to Section 3.5. 2. Refer to Section 3.4 for front panel removal. 3. Completely unscrew the strainer cap and retract strainer carrier from body.

  • Page 34: Expansion Vessel Recharging

    SECTION 3 - SERVICING 3.8 CH EXPANSION VESSEL RECHARGING & REPLACEMENT (INDIRECT ONLY) RECHARGING 1. Refer to Section 3.4 for front panel removal. 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order. 5.

  • Page 35: Circulation Pump Head Replacement

    SECTION 3 - SERVICING 3.10 CH CIRCULATION PUMP HEAD REPLACEMENT 1. Refer to Section 3.4 for front panel removal. 2. Isolate and Drain the HIU. Refer to Section 3.5. 3. Disconnect the plug of the low voltage harness from the pump by placing a small flat bladed screw driver into the slot in the clip.

  • Page 36: Replacement

    SECTION 3 - SERVICING 3.12 INTERNAL INSULATION FRONT SECTION REMOVAL & REPLACEMENT 1. Refer to Section 3.4 for front panel removal. 2. Remove harness from the insulation channel and lower down. 3. Remove front insulation section by pulling forward and away. 4.

  • Page 37: Dhw Plate Heat Exchanger Removal & Replacement

    SECTION 3 - SERVICING 3.13 DHW PLATE HEAT EXCHANGER REMOVAL & REPLACEMENT 1. Isolate and drain the HIU. Refer to Section 3.5. Note: Failure to correctly locate the poisition of the elbows will prevent the retention clips from being fitted. 2.

  • Page 38: Plate Heat Exchanger Removal & Replacement

    SECTION 3 - SERVICING 3.14 CH PLATE HEAT EXCHANGER REMOVAL & REPLACEMENT 1. Isolate and drain the HIU. Refer to Section 3.5. Note: Failure to correctly locate the poisition of the elbows will prevent the retention clips from being fitted. 2.

  • Page 39: Water Pressure Switch Removal & Replacement

    SECTION 3 - SERVICING 3.15 CH WATER PRESSURE SWITCH REMOVAL & REPLACEMENT 1. Isolate and drain the HIU. Refer to Section 3.5. 2. Remove the front panel. Refer to Section 3.4. 3. Pull off the two electrical connections. 4. Using a suitable tool, pull out the metal retaining clip.

  • Page 40: Domestic Hot Water Thermistor

    SECTION 3 - SERVICING 3.17 DOMESTIC HOT WATER THERMISTOR 1. Isolate and drain down the HIU. Refer to Section 3.5. 2. Remove the front panel. Refer to Section 3.4. 3. Remove front insulation section. Refer to Section 3.12. 4. Unplug the electrical lead from the thermistor.

  • Page 41: Pressure Relief Valve

    SECTION 3 - SERVICING 3.19 CH PRESSURE RELIEF VALVE 1. Isolate and drain down the HIU's CH circuit Refer to Section 3.5. 2. Pull out and remove the clip (positioned at the rear of the water set) retaining the Pressure Relief Valve (PRV). 3.

  • Page 42: Pcb Removal & Replacement

    SECTION 3 - SERVICING 3.20 PCB REMOVAL & REPLACEMENT Note: Fit the earth strap to your wrist and secure to a suitable earth on the HIU chassis. 1. Ensure the HIU is disconnected from the Mains power supply and if the credit control valve is fitted ensure this is also powered down to prevent exposure to mains electricity.

  • Page 43: Dhw Flow Regulator

    SECTION 3 - SERVICING 3.21 DHW FLOW REGULATOR 1. Isolate and drain down the HIU. Refer to Section 3.5. 2. Remove the front panel. Refer to Section 3.4. 3. Remove insulation front section. Refer to Section 3.12. 4. Disconnect the connector on the flow turbine harness. 5.

  • Page 44: Dhw Picv

    SECTION 3 - SERVICING 3.23 DHW PICV 1. Isolate the mains electrical supply. 2. Remove the front panel. Refer to Section 3.4. 3. Remove insulation front section to expose plate heat exchanger(s). Refer to Section 3.12. 4. Isolate and drain the HIU. Refer to Section 3.5. 5.

  • Page 45: Heat Meter Installation

    SECTION 3 - SERVICING 3.25 HEAT METER INSTALLATION Note: This unit is designed to be fitted with the Ideal HIU Heat 10. Lift the right-hand side of the control panel out of its hinge Meter only. mounting and feed the 4 wires (3 if wireless MBUS) under the lower part of the panel below the hinge point.
  • Page 46 SECTION 3 - SERVICING 14. Lower the control panel and gather up the excess wires and cable tie them inside the front return lip of the right-hand side panel. 15. Connect the MBUS to the additional MBUS communication device if fitted. Secure the excess metering cable to the plastic retention clips behind the heat meter body, using cable ties if required.
  • Page 47 THIS PAGE HAS BEEN LEFT INTENTIONALLY BLANK...

  • Page 48: Fault Finding

    SECTION 4 - FAULT FINDING FAULT FINDING 4.1 DISPLAY FAULTS Display Fault Action Check system water pressure is between 1 and 1.5 bar on the system pressure gauge. If system pressure is low top up the CH circuit as per the steps in Section 2.5.
  • Page 49 SECTION 4 - FAULT FINDING Display Fault Action Remove harness to primary return thermistor and using a multi-meter measure the resistance of the thermistor – This should be around 10kΩ in Primary Thermistor ambient conditions. If thermistor is functioning correctly reconnect harness Fault to flow thermistor and reset unit.

  • Page 50: Additional Fault Finding

    SECTION 4 - FAULT FINDING 4.2 ADDITIONAL FAULT FINDING No CH operation but DHW OK Is CH enabled Enable CH on the user via the user interface? interface as Please refer to described in Section 2.1 Section 2.1 Are the timer Switch and room the timer...

  • Page 51: Fault Codes - Numeric

    SECTION 4 - FAULT FINDING 4.3 FAULT CODES - NUMERIC Code Fault Display Type/Action CH Flow Thermistor Open Circuit CH Valve to mid-position CH Flow Thermistor Short Circuit CH Valve to mid-position CH Return Thermistor Open Circuit Pump Modulation lost CH Return Thermistor Short Circuit Pump Modulation lost CH Primary Return Thermistor Open/Short...

  • Page 52: Spare Parts

    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 53: Commissioning

    COMMISSIONING HEAT INTERFACE UNIT COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstra�ng compliance with the appropriate Building Regula�ons and then handed to the customer to keep for future reference. Failure to install and commission according to the manufacturer's instruc�ons and complete this Commissioning Checklist will invalidate the warranty.
  • Page 54 It is recommended that your HIU and hea�ng system is serviced regularly and that the appropriate Service Interval Record is completed. Notes for the Service Provider. Before comple�ng the appropriate Service Record below, please ensure that you have carried out the service as described in the manufacturer's instruc�ons.
  • Page 55 It is recommended that your HIU and hea�ng system is serviced regularly and that the appropriate Service Interval Record is completed. Notes for the Service Provider. Before comple�ng the appropriate Service Record below, please ensure that you have carried out the service as described in the manufacturer's instruc�ons.
  • Page 56 At Ideal Heating we take our environmental impact seriously, therefore when installing any Ideal Heating product please make sure to dispose of any previous appliance in an environmentally conscious manner. Households can contact their local authority to find out how.

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