Ideal Heating i-mini C24 Installation And Servicing
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Ideal Heating i-mini C24 Installation And Servicing

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INSTALLATION
AND SERVICING
C24, C30
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.idealboilers.com where you can download the relevant information in PDF format.
April 2019
UIN 222352

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  • Page 1 INSTALLATION AND SERVICING April 2019 UIN 222352 C24, C30 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.
  • 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 24.3 24.3 Part Load Auxiliary Electricity Consumption Full Load 0.042 0.032 Part Load 0.012...
  • Page 3 PRODUCT FICHE I-MINI C 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 Sound power level, indoors Water heating energy efficiency class Seasonal Space Heating Energy Efficiency of the Boiler Temperature control (from fiche of temperature control) Class I...
  • Page 4 Installation and Servicing...
  • Page 5 NOTES FOR THE INSTALLER FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL INSTALLER HELPLINE : 08708 498057 NOTE. BOILER RESTART PROCEDURE - To restart the boiler, press the “RESTART” button. The boiler will repeat the ignition sequence if a heat demand is present.
  • Page 6 Installation and Servicing...

  • Page 7: Table Of Contents

    CONTENTS GENERAL ..............10 SERVICING ............... 39 Introduction ..............10 Servicing Schedule ............ 39 Operation ..............10 Boiler Front Panel Removal / Replacement ....40 Safe Handling ............. 10 Fan And Venturi Assembly Removal And Cleaning ..40 Optional Extra Kits ............. 10 Burner Removal And Cleaning ........

  • Page 8: General

    SECTION 1 - GENERAL Table 1 - General Data 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 9 SECTION 1 - GENERAL i-mini C Natural Gas only Boiler size G.C. Appliance No. (Benchmark No.) 47-349-30 47-349-31 Destination Country: GB, IE For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the manufacturer’s instructions.

  • Page 10: Introduction

    SECTION 1 - GENERAL fault finding. 1.1 INTRODUCTION The i-mini C range of boilers are wall mounted, full sequence, 1.3 SAFE HANDLING automatic spark ignition, low water content, fanned flue, high efficiency, condensing, combination gas boilers. This boiler may require 2 or more operatives to move it to its installation site, remove it from its packaging base and during Note.

  • Page 11: Safety

    SECTION 1 - GENERAL 1.5 SAFETY 1.7 LOCATION OF BOILER Current Gas Safety (installation and use) regulations or rules The boiler must be installed on a flat and vertical internal wall, in force: capable of adequately supporting the weight of the boiler and any ancillary equipment.

  • Page 12: Gas Supply

    SECTION 1 - GENERAL 1.8 GAS SUPPLY 3. Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 4. The local gas supplier should be consulted, at the installation 4. Where the lowest part of the terminal is fitted less than 2m planning stage, in order to establish the availability of an adequate (6’6”) above a balcony, above ground or above a flat roof supply of gas.

  • Page 13: Terminal

    SECTION 1 - GENERAL 1.10 TERMINAL 1.15 CONDENSATE DRAIN The terminal assembly can be adapted to accommodate various Refer to Section 2.15 wall thicknesses. Refer to Section 2.9. A condensate drain is provided on the boiler. This drain must be 1.11 AIR SUPPLY connected to a drainage point on site.

  • Page 14: Boiler Dimensions, Services & Clearances

    SECTION 1 - GENERAL 1.16 BOILER DIMENSIONS, SERVICES & CLEARANCES The boiler connections are made on the boiler bulkhead fittings. Refer to Section 2.16. wall thicknesses do not exceed 600mm. Where the space The following minimum clearances must be maintained for into which the boiler is going to be installed is less than operation and servicing.

  • Page 15: System Requirements

    SECTION 1 - GENERAL 1.17 SYSTEM REQUIREMENTS CENTRAL HEATING Safety valve setting Notes Vessel charge pressure 0.5 to 0.75 a. The method of filling, refilling, topping up or flushing sealed System pre-charge pressure bar None primary hot water circuits from the mains via a temporary hose System volume Expansion vessel connection is only allowed if acceptable to the local water...

  • Page 16: System Balancing

    SECTION 1 - GENERAL ..SYSTEM REQUIREMENTS - CONT’D DOMESTIC HOT WATER 1. The domestic hot water service must be in accordance with BS 5. Hard Water Areas 5546 and BS 6700. Where the water hardness exceeds 200mg/litre, it is recommended that a proprietary scale reducing device is fitted 2.

  • Page 17: Installation

    SECTION 2 - INSTALLATION 2.1 BOILER ASSEMBLY - Exploded View CH Return Valve Flow Group Manifold Gasket - Burner Ignition Lead CH Flow Valve Plate Heat Exchanger Sump Clean Out Cover Detection Lead DHW Inlet & Outlet Flow Regulator Flue Manifold Control Box Lid Pump Head Flow Sensor/Turbine...

  • Page 18: Unpacking

    SECTION 2 - INSTALLATION 2.2 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...

  • Page 19: Unpacking Cont'd

    SECTION 2 - INSTALLATION 2.3 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 20: Wall Mounting Template

    SECTION 2 - INSTALLATION 2.5 WALL MOUNTING TEMPLATE Extended centre line 1 5 5 (2 0 0 ) The wall mounting template is located on the internal protective A** - See Diagram in Section 1.16 packaging. The template shows the position of the fixing and rear flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled.

  • Page 21: Determining The Flue Length/Flue Packs Req'd

    SECTION 2 - INSTALLATION 2.9 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT. The boiler must be installed in a vertical position Optional Flue Finishing Kit - Concentric Flue Screw in accordance to the installation instructions. Retaining Kit (Optional Kit of mechanical fixing of flue joints) Only use water as a lubricant during assembly.
  • Page 22 SECTION 2 - INSTALLATION ..DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED, CONT’D FIGURE 1 Edge of turret Edge of turret Edge of turret 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 23: Cutting & Setting The Flue Length

    SECTION 2 - INSTALLATION 2.10 CUTTING & SETTING THE FLUE LENGTH TELESCOPIC FLUES TELESCOPIC FLUE B PACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT HORIZONTAL FLUE TERMINAL (1000MM LONG) B PACK (TELESCOPIC) MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 &...

  • Page 24: Installing The Flue

    SECTION 2 - INSTALLATION 2.11 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 25: Fitting The Optional Roof Flue Kit (Flat Or Pitched)

    SECTION 2 - INSTALLATION 2.12 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 26: Assembling The Roof Flue Kit

    SECTION 2 - INSTALLATION 2.13 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 27: Flue Terminal Position

    SECTION 2 - INSTALLATION 2.14 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.

  • Page 28: Condensate Drain

    SECTION 2 - INSTALLATION 2.15 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 Condensate should be used terminating into a suitable internal foul water...
  • Page 29 SECTION 2 - INSTALLATION ..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...

  • Page 30: Connections & Filling

    SECTION 2 - INSTALLATION 2.16 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.

  • Page 31: Electrical Connections

    SECTION 2 - INSTALLATION 2.17 ELECTRICAL CONNECTIONS Wiring should be 3 core PVC insulated cable, not less than WARNING. This appliance MUST be earthed. 0.75mm (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for A mains supply of 230Vac ~ 50 Hz is required.

  • Page 32: External Wiring

    SECTION 2 - INSTALLATION 2.19 EXTERNAL WIRING External Controls – 230V 50Hz Optional External Controls – Extra Low Frost Protection Voltage Wiring a 230V 50Hz Room Thermostat, If parts of the pipework run outside the Diagram A (with optional timer, Diagram B) Wiring OpenTherm Room Control or other house or if the boiler will be left off for more OpenTherm Master Device, Diagram D.

  • Page 33: Wiring Diagram

    SECTION 2 - INSTALLATION 2.20 WIRING DIAGRAM Installation and Servicing...

  • Page 34: Commissioning And Testing

    SECTION 2 - INSTALLATION 2.21 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 2.

  • Page 35: Initial Lighting

    SECTION 2 - INSTALLATION 2.22 INITIAL LIGHTING BOILER Legend A. Domestic Hot Water Temperature Knob ºC B. Central Heating Temperature Knob HOT WATER PREHEAT C. Mode Knob D. Boiler Status Display MODE PREHEAT RESTART E. Burner ‘on’ Indicator Central Heating Economy Setting G.

  • Page 36: General Checks

    SECTION 2 - INSTALLATION 2.23 GENERAL CHECKS Make the following checks for correct operation in: WATER CIRCULATION SYSTEM 1. With the system COLD, check that the initial pressure is 1. Fully open all DHW taps in turn and ensure that water flows correct to the system design requirements.

  • Page 37: Restart Procedure

    SECTION 2 - INSTALLATION 2.24 RESTART PROCEDURE Legend A. Domestic Hot Water Temperature Knob B. Central Heating Temperature Knob C. Mode Knob D. Boiler status Display E. Burner ‘on’ Indicator F. Restart Button G. Preheat On/Off Button H. Pressure Gauge To restart the boiler, press the RESTART button (F).

  • Page 38: Handing Over

    SECTION 2 - INSTALLATION 2.26 HANDING OVER After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions: 1. Hand the User Instructions to the householder and 6. Explain and demonstrate the function of timers and explain his/her responsibilities under the relevant national temperature controls, radiator valves etc., for the economic regulations.

  • Page 39: Servicing

    SECTION 3 - SERVICING 3.1 SERVICING SCHEDULE For the very latest copy of literature for specification & maintenance practices, visit our website www.idealboilers.com, where you will be able to download the relevant information. WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing.

  • Page 40: Boiler Front Panel Removal / Replacement

    SECTION 3 - SERVICING 3.2 BOILER FRONT PANEL REMOVAL / REPLACEMENT REMOVAL REPLACEMENT 1. Loosen the two screws retaining the front panel. 3. Hook the panel onto the top retaining clips. 2. Pull the two clips down to disengage and pull panel forward 4.

  • Page 41: Burner Removal And Cleaning

    SECTION 3 - SERVICING 3.4 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 42: Cleaning The Heat Exchanger

    SECTION 3 - SERVICING 3.6 CLEANING THE HEAT EXCHANGER Note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Section 3.18. 1. Remove ignition and flame detection electrodes. Refer to Section 3.13 & 3.14. 2.

  • Page 43: Replacement Of Components

    SECTION 3 - SERVICING 3.8 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. Ensure all gas valve connections are gas tight with a gas When replacing ANY component soundness check up to the gas control valve. 1. Isolate the electricity supply. When work is complete, the front panel must be correctly refitted - ensuring that a good seal is made.

  • Page 44: Burner Injector Replacement

    SECTION 3 - SERVICING 3.10 BURNER INJECTOR REPLACEMENT 1. Refer to Section 3.8. 2. Disconnect the electrical leads from the fan. 3. Remove the clip from the gas valve to venturi pipe and ease the pipe upwards, rotate and ease down to remove. 4.

  • Page 45: Return Thermistor Replacement

    SECTION 3 - SERVICING 3.12 RETURN THERMISTOR REPLACEMENT 1. Refer to Section 3.8. 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 46: Flame Detection Electrode Replacement

    SECTION 3 - SERVICING 3.14 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Section 3.8. Flame Detection Electrode 2. Remove the burner. Refer to Section 3.4. 3. Unplug the flame detection lead from the electrode. 4. Remove the 2 screws retaining the detection electrode.

  • Page 47: Diverter Valve Actuator Replacement

    SECTION 3 - SERVICING 3.17 DIVERTER VALVE ACTUATOR REPLACEMENT Refer to Section 3.8. To remove the motor: 1. Remove the condensate trap/siphon. Refer to Section 3.5. 2. Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator. 3.

  • Page 48: Pcb Replacement

    SECTION 3 - SERVICING 3.19 PCB REPLACEMENT Note. Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis. 1. Refer to Section 3.8. 2. Ensure the control knobs are in the 12 o clock position. 3.

  • Page 49: Draining The Boiler

    SECTION 3 - SERVICING 3.21 DRAINING THE BOILER CENTRAL HEATING CIRCUIT 1. Refer to Section 3.8. 2. Close all the CH water isolating valves on the boiler inlet. 3. To drain the primary heat exchanger circuit: Open the drain valve and attach a length of hose to the CH drain point. 4.

  • Page 50: Safety Relief Valve Replacement

    SECTION 3 - SERVICING 3.23 SAFETY RELIEF VALVE REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.21. 3. Remove the clip on return thermistor. Refer to Section 3.12. 4. Pull out and remove the clip (positioned behind the safety valve) retaining the safety valve.

  • Page 51: Diverter Valve Body Assembly Replacement

    SECTION 3 - SERVICING 3.26 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT To remove the valve body assembly: 17. Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly. 1. Refer to Section 3.8. 18. Fit the new diverter valve body assembly and replace the 2.

  • Page 52: Ch Water Pressure Switch Replacement

    SECTION 3 - SERVICING 3.29 CH WATER PRESSURE SWITCH REPLACEMENT 1. Refer to Section 3.8. 2. Drain the boiler. Refer to Section 3.21. 3. Pull off the two electrical connections. 4. Using a suitable tool, pull out the metal retaining clip.

  • Page 53: Heat Engine Replacement

    SECTION 3 - SERVICING 3.31 HEAT ENGINE REPLACEMENT Refer also to Section 2.1 - ‘Boiler Exploded View’ IMPORTANT Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. 1. Refer to Section 3.8. 14.

  • Page 54: Expansion Vessel Recharging & Replacement

    SECTION 3 - SERVICING 3.32 EXPANSION VESSEL RECHARGING & REPLACEMENT RECHARGING Recharge 1. Refer to Section 3.8. Point 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order. 5. Check that the boiler operates in both DHW & CH modes.

  • Page 55: Fault Finding

    SECTION 4 - FAULT FINDING 4.1 FAULT FINDING CHART MAIN MENU GO TO SECTION 4.2 - ‘L1’ FLOW TEMPERATURE OVERHEAT LOCKOUT GO TO SECTION 4.3 - ‘L2’ IGNITION LOCKOUT 5 RESETS WITHIN 15 MINS - ‘LC’ TURN POWER OFF AND ON GO TO SECTION 4.4 - ‘L6’...

  • Page 56: L1' - Flow Temperature Overheat Lockout

    SECTION 4 - FAULT FINDING 4.2 ‘L1’ - FLOW TEMPERATURE OVERHEAT 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 restart boiler Is the Flow/Return Differential across the Boiler in Check that the Pump is rotating freely.

  • Page 57: L6' - False Flame Lockout

    SECTION 4 - FAULT FINDING 4.4 ‘L6’ - FALSE FLAME LOCKOUT Check routing and integrity of internal boiler wiring is OK. Check Restart the boiler, does Boiler Work OK? condition of Flame Sense Electrode and replace if deteriorated. Replace Flame Detection Electrode Separate the flame detection electrode in-line connector.

  • Page 58: F3' - Fan Fault

    SECTION 4 - FAULT FINDING 4.7 ‘F3’ - FAN FAULT Does the wiring from the Fan to the PCB have Rectify Wiring & secure connections at both ends and has not connections deteriorated? Does the wiring have continuity? Replace PCB Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan? Replace Fan...

  • Page 59: F6' - Outside Sensor Fault

    SECTION 4 - FAULT FINDING 4.10 ‘F6’ - OUTSIDE SENSOR FAULT Securely connect the wiring at both the Is the wiring securely connected at both the boiler and boiler and Outside Sensor Outside Sensor? Disconnect the wires to the outside sensor. Check the resistance using a suitable multimeter connected across the Outside Sensor’s terminal pins.

  • Page 60: No Hw But Ch On

    SECTION 4 - FAULT FINDING 4.12 NO HW BUT CH ON Does the display shows a “Tap symbol” when Is hot and cold pipework crossed? a tap is on? Adjust flow rates to achieve 35ºC Are the flow rates correct as per Section 1.2. Is the wiring connected temp rise and check filter fitted in between PCB and DHW...

  • Page 61: Spare Parts

    SECTION 5 - 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 62: Benchmark & Commissioning

    SECTION 5 - SPARE PARTS Installation and Servicing...
  • Page 63 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 64 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 65 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 66 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 67 Start Set Boiler to Maximum Gas Rate Carry Out Flue Integrity Check Using Analyser In accordance with boiler instructions, Insert analyser probe into air inlet test point (where available) and allow set boiler to operate at maximum rate readings to stabilise. (full load condition).
  • Page 68 NOTES Installation and Servicing...
  • Page 69 NOTES Installation and Servicing...
  • Page 70 NOTES Installation and Servicing...
  • Page 71 NOTES Installation and Servicing...
  • Page 72 The code of practice for the installation, commissioning & servicing of central heating systems Ideal Installer/Technical Helpline: 0870 849 8057...

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