Ideal Boilers mini HE C24 Installation And Servicing
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Ideal Boilers mini HE C24 Installation And Servicing

Ideal Boilers mini HE C24 Installation And Servicing

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installation and
servicing
mini HE
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
C24,C28
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
17962.1138.1
0406 64A4 GB
*1796211381*
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 Boilers mini HE 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 17962.1138.1...
  • Page 2 mini HE --- Installation & Servicing...
  • Page 3 DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level.....4905 to 0406 F Pages 33 and 37 Amendment to the illustration of the air pressure switch connection Caradon Ideal Limited reserve the right to vary specification without notice mini HE --- Installation &...
  • Page 4 GENERAL Table 1 --- Boiler Data mini HE C24 mini HE C28 Gas supply type & connection G20 20mbar, G31 37mbar, 22 mm copper 2H3P Inlet / Outlet connection --- Domestic Hot Water 15 mm copper Flow & return connection --- Central Heating...
  • Page 5 HE CONTENTS Boiler size G.C. appliance No. PI No. Air supply (Benchmark No.) Benchmark Commissioning Checklist mini HE C24 47 ---348 ---38 0694BP0384 Boiler clearances mini HE C28 47 ---348 ---39 0694BP0384 Boiler exploded view Destination countries: GB, IE...

  • Page 6: Boiler Clearances

    GENERAL BOILER WATER CONNECTION Pipe size O.D. mm CH flow CH return Gas inlet Wall DHW cold inlet mounting Plate DHW hot outlet Condensate drain connection area BOILER CLEARANCES Side and Rear Flue All dimensions in mm (in.) a. Provided that the flue hole is cut accurately, e.g. with a core drill, the flue can be installed from inside the building where The following minimum clearances must be maintained for wall thickness does not exceed 600 mm (24”).

  • Page 7: Gas Safety

    INTRODUCTION F Avoid upper body/top heavy bending. F Always grip with the palm of the hand. mini HE C24 and mini HE C28 are wall mounted, low water F Use designated hand holds. content, balanced flue, condensing combination gas boilers.

  • Page 8: Gas Supply

    GENERAL GAS SUPPLY these Installation and Servicing Instructions or as otherwise recommended by Caradon Ideal Ltd. in writing. If in doubt The local gas supplier should be consulted, at the installation please enquire. stage, in order to establish the availability of an adequate Any direct connection of a control device not approved by supply of gas.

  • Page 9: Water Circulation System

    GENERAL WATER CIRCULATION SYSTEM 7 Above adjacent ground, roof or 300 mm (12”) balcony level The boilers are designed for connection to pressurised, fully pumped, sealed water central heating systems ONLY. The 8 From a surface or a boundary 600 mm (24”) domestic hot water (DHW) calorifier is incorporated within the facing the terminal.

  • Page 10: Electrical Supply

    GENERAL Domestic Hot Water Fernox Calmag Ltd. Cookson Electronics Unit 4---6 Crown Works In hard water areas where mains water can exceed 200ppm Forsyth Road Bradford Road Total Hardness (as defined by BS 7593:1993 Table 2) a scale Sheerwater Sandbeds reducing device should be fitted into the boiler cold supply Woking Keighley...
  • Page 11 GENERAL 5 Size of expansion vessel Table 5 For the system water expansion to be contained by the 6 litre System charge pressure expansion vessel the cold system volume must not exceed: (bar) 96 litres when pressurised to 0.5 bar (cold) Safety valve setting 88 litres when pressurised to 0.7 bar (cold) Vessel pre ---charge pressure...

  • Page 12: Domestic Hot Water

    2 For the minimum and maximum working pressures of the b. Hot and cold supplies are of equal pressure. mini HE C24 and mini HE C28 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 13: Boiler Water Circuit Diagram

    GENERAL BOILER WATER CIRCUIT DIAGRAM 7 Central heating flow cock 8 By ---pass valve 9 Central heating (CH) return cock 10 3 bar pressure relief valve 11 Gas cock 12 Expansion vessel 13 Gas valve inlet pressure tap 14 Modulating gas valve 15 Burner pressure tap 16 Flame detection electrode 17 Ignition electrodes...

  • Page 14: Boiler Assembly

    INSTALLATION BOILER ASSEMBLY --- Exploded View 1 Air pressure switch 14 DHW flow switch 28 Return manifold 2 Recuperator 15 DHW Thermistor 29 3 way diverter valve 3 Condensate trap 16 Ignition pcb 30 DHW heat exchanger 17 Right hand panel 31 Bypass pipe 4 Overheat thermostat 18 Boiler front panel...
  • Page 15 INSTALLATION UNPACKING H Centring spring Turret---air pipe gasket The boiler is supplied fully assembled in one pack A, together Flue pipe gasket with a standard flue assembly for lengths up to 960 mm (37” 3/4), rear or side flue outlet, in pack B. K Boiler ---turret gasket Flue turret Unpack and check the contents.

  • Page 16: Fitting The Flue System

    INSTALLATION FITTING THE FLUE SYSTEM Horizontal Concentric Air duct The minimum and maximum equivalent length for co---axial pipes ø 60 ---100 and ø 80 ---125 mm are given in Rear Outlet Wall thickness + 125 mm Table 6. Rear outlet+Stand ---off Wall thickness + 160 mm The minimum and maximum equivalent length for ø...

  • Page 17: Wall Mounting Template

    INSTALLATION Cutting lengths of flue and air ducts Twin Pipe Measure the wall thickness and, when using a side outlet, the Air duct gap between the inner wall and the boiler side casing. Use Rear Outlet Wall thickness + 130 mm the following chart to calculate the cutting lengths of both flue and air ducts.
  • Page 18 INSTALLATION WALL MOUNTING TEMPLATE Extended centre (side flue) IMPORTANT Detailed installation steps are given directly on the wall mounting template Spirit level 1 Tape the template into the selected position. 2 Ensure squareness by hanging a plumbine. 3 Mark onto the wall the following: a.

  • Page 19: Mounting The Boiler

    INSTALLATION MOUNTING THE BOILER Lift the boiler onto the wall mounting plate locating the bar at the rear of the back panel assembly into the bracket. As added protection, the boiler should be lifted with the lower polystyrene packaging in place. Lower the boiler into position.

  • Page 20: Condensate Drain

    INSTALLATION CONDENSATE DRAIN through freezing) of external drainage pipework does not give rise to spillage within the dwelling. Refer also to the British Gas document: “Guidance Notes If a part of the drainpipe runs externally this part should be for the installation of Domestic Gas Condensing Boilers” kept as short as possible and protected to reduce the risk of (1989).
  • Page 21 INSTALLATION ELECTRICAL CONNECTIONS 4 Remove the side panels or move the lower part of the side panels and pull the control panel. Incoming mains wiring detail To gain access to the power supply and external controls terminal blocks: 1 Remove the screws A and the front panel of the case. When completely pulled out, the panel can rotate 45°...
  • Page 22 INSTALLATION PICTORIAL WIRING mini HE C24, mini HE C28 Wiring diagram for boiler equiped with full sequence ignition device type: Bertelli & Partners FM30 External controls Electric supply Air pressure Ignition Flame detection terminal block terminal block switch electrodes electrode...
  • Page 23 INSTALLATION Wiring diagram for boiler equiped with full sequence ignition device type: Honeywell FPLD External controls Electric supply Air pressure Ignition Flame detection terminal block terminal block switch electrodes electrode Flue Safety thermostat thermostat gnye gnye Condensate trap Electronic control p.c.b. P .C.B.

  • Page 24: Functional Flow Diagram

    INSTALLATION FUNCTIONAL FLOW DIAGRAM mini HE C24, mini HE C28, Ignition Detection P .C.B. #1 P .C.B. #2 electrodes electrode Pump Condensate trap CH temp. probe Main Ignition pcb Air pressure switch DHW temp. probe control pcb Three way div. valve...

  • Page 25: External Electrical Controls

    INSTALLATION EXTERNAL ELECTRICAL CONTROLS switches set to OFF, all the controls MUST be left in the running position. Wiring external to the boiler MUST be in accordance with the The frost thermostat should be sited in a cold place but where current I.E.E.

  • Page 26: Initial Lighting

    INSTALLATION INITIAL LIGHTING Central Heating flow Domestic hot water outlet Gas inlet Domestic cold water inlet Central Heating return Legend A Appiance On lamp B Domestic hot water temperature control C Main switch and radiator temperature control D Boiler reset button E Lock ---out signal lamp F Programmer (optional) G System pressure and temperature gauge...
  • Page 27 INSTALLATION TO ADJUST PRESSURES (burner pressure). By rotating clockwise the pressure increases. Nomenclature of the parts on the gas valve 10 Turn the boiler off and re ---connect the wire to the modulating operator. A Modulation operator’s electric connectors 11 Start the boiler and check again the maximum gas B Minimum gas pressure adjustment pressure setting.

  • Page 28: Commissioning And Testing

    DO NOT SMOKE. GENERAL CHECKS 10.8 (4.3) mbar (in. w.g.) for the model mini HE C24 and 10.0 (4.0) mbar (in. w.g.) for the model mini HE C28. Make the following checks for correct operation: mbar (in.

  • Page 29: Gas Conversion

    INSTALLATION GAS CONVERSION 6 Adjust the burner pressures according to the indications given in frame 27. 1 Disconnect the electrical supply. 7 Stick the self ---adhesive label (included with the 2 Replace the burner injectors as explained in frame 43. conversion kit, indicating the type of gas, and the gas 3 Re ---assemble the burner, the front panel of the pressures to which the appliance has been set) over the...

  • Page 30: Servicing Schedule

    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 Removal And Cleaning

    SERVICING BURNER REMOVAL AND CLEANING 6 Undo the four screws F placed at the right and left sides of the burner and extract it. 1 Disconnect the electrical supply. 2 Remove outer and inner casing (refer to frame 34). 3 Undo the screws A and remove the fan holder bracket B and the combustion chamber panel C.
  • Page 33 SERVICING FAN AND VENTURI REMOVAL AND 7 Check that the impeller runs freely. Clean with a soft brush or renew as necessary. Refer to frame 51 for replacement. CLEANING Note: Always take care when handling the fan, in order to 1 Disconnect the electrical supply.

  • Page 34: Replacement Of Components

    SERVICING REPLACEMENT OF COMPONENTS GENERAL THE BOILER MUST NOT BE OPERATED IF THE INNER CASE COVER IS NOT FITTED. When replacing any component: If the CH and/or the DHW circuits have been emptied: 1 Isolate the electricity supply at the switched spur. N.B.

  • Page 35: Overheat Thermostat

    SERVICING OVERHEAT THERMOSTAT 3 Disconnect the wiring C . REPLACEMENT 4 Remove the spring D which holds the overheat thermostat on the pipe of the primary heat exchanger and remove it. 1 Remove outer and inner casing (refer to frame 34). 2 Remove the screws A and the plate B.
  • Page 36 SERVICING GAS VALVE ON---OFF OPERATOR Replacement COILS REPLACEMENT 5 Remove the screw B, withdraw the coils unit C. 6 Replace it and re ---assemble in reverse order. Check 1 Disconnect the electrical supply. 2 Remove the front casing panel. 3 Disconnect the connector A and check the electrical resistance of the coils referring to the following diagram Upper on---off operator approx.

  • Page 37: Fan Replacement

    SERVICING EXPANSION VESSEL REPLACEMENT valve. It may cause debris within the system to foul the valve. If the CH expansion vessel is faulty, there are 2 options: 5 Completely unscrew the connection A, the locknut B and remove the expansion vessel from the top of the boiler. A If it has a punctured diaphragm, but is otherwise leak free, than it can be left in place and a new vessel added to the return side of the system, external to the boiler, provided it...

  • Page 38: Air Pressure Switch

    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 34. 3 Disconnect the pressure sensing pipe from the air pressure switch.
  • Page 39 SERVICING MAIN CONTROL PCB 7 Unscrew the four screws that hold the main control p.c.b. on to the control panel. REPLACEMENT 8 Remove it by lifting its rear edge and freeing it from any of 1 Disconnect the electrical supply. the wiring.
  • Page 40 SERVICING IGNITION PCB REPLACEMENT 1 Gain access to the parts located inside the control panel as explained in the the frame 55. 2 Remove all the wiring connected to the ignition p.c.b. To disconnect the connectors indicated, delicately flex the hook present on one side of each socket.
  • Page 41 Flow limiter reverse order. Spring seat Flow limiter D --- body The mini HE C24 model is factory fitted with a 10 litre/min. flow limiter. C --- filter Spring The mini HE C28 model is factory fitted with a 12 litre/min.
  • Page 42 SERVICING PRIMARY HEAT EXCHANGER Fit the clip H with the arrow pointing upwards as illustrated in the drawing. REPLACEMENT Do not force the connection F when tighting it. 1 Disconnect the electrical supply. 2 Remove outer and inner casing as explained in frame 34. 3 Close off the isolating cocks of the CH circuit at the bottom of the boiler.
  • Page 43 SERVICING After reassembling ensure that the fan ---exchanger and exchanger ---elbow gaskets are correctly mounted and ensure a good sealing. mini HE --- Installation & Servicing...

  • Page 44: Dhw Heat Exchanger

    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. 1 Disconnect the electrical supply. Attention. When reassembling the exchanger be sure to 2 Remove outer casing (refer to frame 34). put the off center location/securing pin indicated towards 3 Close the isolating cocks of the CH circuit and DHW the left side of the boiler.
  • Page 45 SERVICING DIVERTER VALVE INTERNAL PARTS REPLACEMENT 1 Disconnect the electrical supply. 2 Remove front and left hand casing panels (refer to frame 34). 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 46 SERVICING CH DRAIN COCK REPLACEMENT 1 Disconnect the electrical supply 2 Remove front and right hand casing panels (refer to frame 34). 3 Close off the isolating cocks of the CH circuit at the bottom of the boiler. 4 Release system pressure by opening the main circuit drainage cock.

  • Page 47: Fault Finding

    FAULT FINDING MAIN CONTROL P .C.B. The following table gives a summary of the relationship between each of the possible lamp combinations and their OPTICAL INFORMATION meaning. The main control p.c.b. is provided with three lamps (L.E.D. indicators) A that give optical information during the normal operation of the boiler or for service and fault fiinding Normally operating boiler purpose.
  • Page 48 )$8/7 ),1',1* :LWK D IDVW SXOVH VKRZLQJ RQ /('  WKH ERLOHU ZLOO FRQWLQXH WR )$8/7 ),1',1* RSHUDWH ZLWK D UHGXFHG SHUIRUPDQFH LQ VRPH IDXOW FRQGLWLRQV :$51,1* &DUH PXVW EH WDNHQ ZKHQ FRQGXFWLQJ IDXOW ILQGLQJ WHVWV WR %HIRUH FRPPHQFLQJ IDXOW ILQGLQJ SOHDVH FKHFN WKH IROORZLQJ JXDUG DJDLQVW WKH ULVN RI HOHFWULF VKRFN  9DF LV WKH QRPLQDO 8.
  • Page 49 FAULT FINDING Continued from page 48 of fault finding Is the continuity of the Repair or replace With the boiler and modulator harness faulty wiring heating circuit warm Is there between 0V dc O.K? does the burner and 16V dc at the Grey pressure reduce if the and Black connections heating temperature...
  • Page 50 FAULT FINDING Continued from page 48 of fault finding. Is the green LED on front fascia flashing 4 times per second? Continued on page Are LED2 and LED 3 Are LED2 flashing Access the 4 dip flashing? LED 3 on? 51 of fault finding switches on p.c.b.
  • 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 LED 4 on the of fault finding fault finding facia 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 Is the position of the detection electrode Rectify electrode Does the burner correct, and electrode position or replace remain alight? undamaged? Refer to faulty electrode. frame 41. Is the lead Connect lead Is the resistance of the connected ? correctly...
  • Page 53 FAULT FINDING Continued from Is LED 1 on and LED Is LED 1 flashing and page 51 of fault 2 flashing? LED 2 and LED 3 on? finding Is dip---switch # 3 in Is dip---switch # 3 in Replace faulty PCB #1 Replace faulty PCB #1 the off position? the off position?
  • Page 54 FAULT FINDING Continued from page 49 Is there > 17 mbar Rectify gas supply Is there a temperature rise Is there max burner gas pressure at the fault. pressure* when the of 35 ° C across the DHW gas inlet? boiler first lights? circuit at: 10.0 L/min 24 kW model...
  • Page 55 Boiler 173---148 Burner (mod. mini HE C24) 075427 173---149 Burner (mod. mini HE C28) 075535 Main heat exchanger + ’O’ rings (mod. mini HE C24) 173991 Main heat exchanger + ’O’ rings (mod. mini HE C28) 173992 Recuperator 173993 169---069 Injectors for natural gas (mod.
  • Page 56 Control panel door 173988 Front case panel 173989 mini HE --- Installation & Servicing...
  • Page 57 INSTALLER In addition a change to Building Regulations (England and Wales) requires the installer to notify NOTIFICATION when installing a heating appliance, as from 1st April 2005. GUIDELINES IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE 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

    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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Mini he c28

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