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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  • Page 2: Sedbuk No

    GENERAL Table 1 - General Data Gas supply 2H-G20-20mbar Gas Supply Connection Rc1/2 (1/2" BSP Female) Injector size Stereomatic 5.6mm dia. Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter mm (in) 100 (4) Maximum Working Pressure (Sealed Systems) bar (lb/in...

  • Page 3: Table Of Contents

    GENERAL icos system m3080 CONTENTS Natural Gas only Air Supply ............... 7 Boiler Clearances ............6 G.C. Appliance No. 41 391 52 Boiler Interlocks ............8 Boiler Exploded Diagram ........10 & 11 PI No. 0063BM9802 Condensate Drain ..........8 & 21...

  • Page 4: Icos System M3080

    Pipework from the boiler is routed downwards as standard, but INTRODUCTION may be routed upwards behind the boiler using the stand-off The icos system m3080 is a cast aluminium wall mounted, frame (supplied in a separate kit). full sequence, automatic spark ignition, low water content, fanned flue, high efficiency, condensing system gas boiler.

  • Page 5: Gas Safety Regulations

    GENERAL OPTIONAL EXTRA KITS Any direct connection of a control device not approved by Caradon Ideal Limited could invalidate the certification and the ! Flue Extension Ducts (1000mm long, up to 6m ) . normal appliance warranty. It could also infringe the Gas Safety ! Flue Finishing Kit Regulations and the above regulations.

  • Page 6: Boiler Clearances

    GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in) The boiler connections are made on the boiler piping frame. where wall thicknesses do not exceed 600mm (24"). Refer to Frames 20 & 21. Where the space into which the boiler is going to be installed is less than the length of flue required the flue The following minimum clearances must be maintained for must be fitted from the outside.

  • Page 7: Air Supply

    GENERAL 3. Minimum acceptable spacing from the terminal to GAS SUPPLY obstructions and ventilation openings are specified in The local gas supplier should be consulted, at the installation Table 3. planning stage, in order to establish the availability of an 4.

  • Page 8: Trv's

    GENERAL a bypass between the boiler flow and return is fitted, to ensure The hydraulic resistance of the boilers, at MAXIMUM OUTPUT, adequate flow when all TRVs are closed. with an 11 C (20 F) temperature differential, is shown in Graph 1.
  • 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 local regulations. method: 2. The installation should be designed to work with flow Through a temporary hose connection from a 'draw-off' temperatures of up to 82 tap, supplied from a service pipe under mains pressure.

  • Page 10: For All Boilers Flushing To Bs.7593

    GENERAL SYSTEM BALANCING Turn up the room thermostat and adjust these lockshield valves to give boiler flow and return temperatures not more The boiler does not normally need a bypass but at least some than 20 C apart. radiators on the heating circuit, of load at least 10% of the minimum boiler output, must be provided with twin lockshield These valves should now be left as set.

  • Page 11: Appliance Serial No. On Data Badge

    INSTALLATION BOILER ASSEMBLY - Exploded View "" " & $" & " " #& ,=J= >=@CA icos system - Installation and Servicing...
  • Page 12 INSTALLATION UNPACKING Pack A Contents ! Hardware Pack & fittings. The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to ! These Installation & Servicing Instructions. 650mm, rear or side flue outlet, in Pack B. ! The User's Instructions.
  • Page 13 INSTALLATION 10 PACKAGING REMOVAL 1. Ensure the boiler is stood correctly, as marked on the carton. 2. Remove the strapping. 3. Fold back the top flaps to gain access to: Wall mounting plate. Instructions. Hardware pack & fittings. User control. Pre-piping frame 4.
  • Page 14 INSTALLATION 12 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT.The boiler MUST be installed in a vertical position Dimension X - Wall thickness. Dimension L - Wall thickness plus boiler spacing . Dimension S - Stand-off frame depth = 33mm. FLUE KITS Pack B - supplied as standard Pack D - optional extension kit for side flue or rear flue outlet.

  • Page 15: Flue Fitting

    INSTALLATION 13 FLUE ASSEMBLY - Exploded View An optional flue duct extension kit is required for wall thicknesses greater than : Side 455mm (18"). Rear 490mm (19 "). LEGEND 1. Duct assembly. 2. Flue Turret. 3. Turret gasket. 4. M5 x 10 pozi screw. 5.

  • Page 16: Preparing The Wall

    INSTALLATION 15 PREPARING THE WALL IMPORTANT. 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. Rear flue only Side flue only Both wall faces immediately around the cut hole...

  • Page 17: Extension Ducts - Fitting

    INSTALLATION 18 FLUE EXTENSION DUCTS - For flue lengths greater than 650mm Pack D Flue extension duct kit contents. Flue support cutting aid Extension duct & clamp (shown folded up) 1.0m (39") long Wall plugs - 4 off Flue duct support Ecl 1244 No.
  • Page 18 INSTALLATION 21 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: Wall plug a.

  • Page 19: Mounting The Boiler

    INSTALLATION 22 MOUNTING THE BOILER IMPORTANT. Before mounting the boiler on the wall fit the 'S' trap hose moulding/nut. 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.

  • Page 20: Water Connections

    INSTALLATION WATER CONNECTIONS Notes. 1. For heating loads in excess of 60,000 Btu/h use 28mm x 22mm connectors to connect the boiler flow and return pipes to 28mm system pipework. 2. Do not subject any of the isolating valves to heat as the seals may be damaged.

  • Page 21: For Condensing Boilers Only Condensate Drain

    INSTALLATION 25 GAS CONNECTION Rubber seal IMPORTANT.The gas service cock contains a non- metallic seal so must not be overheated when making capillary connections. Gas cock (shown in the Refer to Frame 2 for details of the position of the gas open position) connection.
  • Page 22 INSTALLATION 28 FILLING 1. Remove the boiler front and sealing panels. Refer to Frames 40 & 41. 2. Swing the control box down into the servicing position - Automatic air vent Refer to Frame 42. 3. Ensure that the isolating valves are open. 4.

  • Page 23: 29 Electrical Connections

    INSTALLATION 29 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 Table 16. A mains supply of 230 V ~ 50 Hz is required. For IE reference should be made to the current ETCI rules for electrical installations.

  • Page 24: Time And Temperature Control To Heating

    INSTALLATION 31 EXTERNAL ELECTRICAL CONTROLS Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and L2 L1 any local regulations. For IE reference should be made to the current ETCI rules for electrical installations. Room 'stat The fuse rating should be 3A.
  • Page 25 INSTALLATION 32 PICTORIAL WIRING DIAGRAM LEGEND - red b - blue v - violet bk - black w - white br - brown y - yellow gy - grey y/g - yellow/green or - orange pk - pink icos system - Installation and Servicing...

  • Page 26: Flow Wiring Diagram

    INSTALLATION 33 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 Return control thermistor (not fitted) Flow control thermistor Pump Ecl 2534 LEGEND b - blue - red bk - black v - violet...

  • Page 27: Initial Lighting

    INSTALLATION 35 INITIAL LIGHTING LEGEND A. Boiler On/Off switch. B. Thermostat knob. C. Mains On neon. D. Burner On Neon E. Reset button. F . Injector pressure test point. G. Inlet pressure test point. H. Gas service cock. J. Casing pressure test point. K.
  • Page 28 INSTALLATION 36 INITIAL LIGHTING - continued IMPORTANT. The gas input to the burner is regulated by the gas 13. Set the boiler thermostat knob (B) to position 6 and valve according to the air flow produced by the fan. It switch the boiler on/off switch (A) to ON.

  • Page 29: Handing Over

    INSTALLATION 38 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 7. If any programmer is fitted then draw attention to the explain his/her responsibilities under the relevant Programmer Users Instructions and hand them to the national regulations.

  • Page 30: Servicing

    SERVICING 39 SERVICING SCHEDULE 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. Wherever possible remove and clean the condensate 'S' intervals and serviced as necessary.
  • Page 31 SERVICING BOILER SEALING PANEL / BOTTOM PANEL REMOVAL 1. To remove the sealing panel remove the 4 screws. 2. Remove the panel. Flue gas 3. To remove the bottom panel remove the 2 sampling screws. point 4. Pull the right hand side of the panel down. Slide it to the right and withdraw.

  • Page 32: Burner Removal And Cleaning

    SERVICING 43 FAN 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 screw on the fan mounting bracket. 4. Lift off fan and venturi assembly. 5.

  • Page 33: Cleaning The Heat Exchanger

    SERVICING 45 CLEANING THE CONDENSATE 'S' TRAP 1. Swing the control box down into the servicing Condensate trap position. Refer to Frame 42. 2. Disconnect the condensate drain pipe. 3. Remove the screw and elongated bolt, pull the trap down and forward to remove. 4.

  • Page 34: Replacement Of Components

    SERVICING 48 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When replacing ANY component : When work is complete, the sealing panel, if removed, must 1. Isolate the electricity supply. be correctly refitted - ensuring that a good seal is made. 2. Turn off the gas supply. Notes.

  • Page 35: Burner Injector Replacement

    SERVICING 51 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 48. 2. Remove the boiler front and sealing panels. Refer to Frames Injector 40 & 41. 3. Disconnect the electrical leads from the fan. 4. Undo the gas pipe union connection to the injector housing. 5.

  • Page 36: Ignition Electrode Replacement

    SERVICING 54 IGNITION ELECTRODE REPLACEMENT 4. Unplug the ignition electrode lead from the control box. 1. Refer to Frame 48. 5. Remove the screw holding the ignition electrode to the 2. Remove the boiler front and sealing panels. Refer to combustion chamber.

  • Page 37: Combustion Chamber Insulation Replacement

    SERVICING 56 COMBUSTION CHAMBER INSULATION REPLACEMENT The insulation boards used in the combustion chamber of this 7. Remove the detection earth probe. product are made of high temperature glass fibres with a 8. Damp down the combustion chamber area containing the binder of organic and inorganic materials.

  • Page 38: Gas Control Valve Replacement

    SERVICING 57 GAS CONTROL VALVE REPLACEMENT 3. Swing the control box down into the 1. Refer to Frame 48. servicing position. Refer to Frame 42. 2. Remove the boiler front and bottom panels. Refer to Frames 40 & 4. Unplug the electrical lead from the gas control valve and disconnect the earth wire.

  • Page 39: Control Box Replacement

    SERVICING 59 CONTROL BOX REPLACEMENT 9. Reassemble in reverse order, ensuring that the control box is located correctly in the housing before reconnecting the 1. Refer to Frame 48. electrical wiring. 2. Remove the boiler front and bottom panels. Refer to 10.
  • Page 40 SERVICING 61 USER CONTROL REPLACEMENT Note. Only the display unit is replaced. 1. Refer to Frame 48. 2. Loosen the 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 41 SERVICING 63 SAFETY RELIEF VALVE REPLACEMENT 1. Refer to Frame 48. 6. Withdraw the securing pin. 2. Remove the boiler front and bottom panels. Refer to 7. Remove the safety valve. Frame 40 & 41. 8. Fit the new safety valve and refit the securing pin. 3.

  • Page 42: Pump

    SERVICING 65 DRAINING THE BOILER 1. Refer to Frame 48. 2. Remove the boiler front and bottom panels. Refer to Frame 40 & 41. 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 43: Heat Exchanger Replacement

    SERVICING 67 HEAT EXCHANGER REPLACEMENT 16. Remove the flue casting. Refer also to Frames 7 & 8 - 'Boiler exploded view'. 17. Remove the edge clip securing the flue thermistor wiring. IMPORTANT 18. Remove the blind grommet to gain access to the return Before starting the removal procedure, protect the gas and pipe securing bracket.

  • Page 44: Boiler Sealing Panel Seal Replacement

    SERVICING 68 EXPANSION VESSEL REPLACEMENT 1. Refer to Frame 48 . 2. Drain the boiler. Refer to Frame 65. 3. Unscrew all the gas and water connection unions on the boiler side of the valves. 4. Remove the screw from the turret clamp and remove the turret.

  • Page 45: Fault Finding

    FAULT FINDING 70 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: GO TO FRAME 71 ALTERNATING 'L' 'F' ALTERNATING 'L' 'E' GO TO FRAME 72 GO TO FRAME 73 ALTERNATING 'L' 'A'...
  • Page 46 FAULT FINDING 71 L..F..(FLAME DETECTION ERROR) If the boiler reset button is Check gas supply Is gas pressure available at pressed does the boiler ignite for and rectify fault the boiler inlet ? a short time then extinguish? Check gas valve Is 200 V DC supply Check the detection electrode and wiring for...
  • Page 47 FAULT FINDING 73 L..A..(OVERHEAT ERROR) 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 48 FAULT FINDING 76 H..4..(FLUE THERMISTOR) 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 49: Short List Of Parts

    SHORT LIST OF PARTS The following are parts commonly required due to damage or When ordering spares please quote: expendability. Their failure or absence is likely to affect safety 1. Boiler model or performance of this appliance. 2. Appliance G.C. No. The list is extracted from the British Gas List of Parts, which 3.
  • Page 50 SHORT LIST OF PARTS 79 SHORT LIST " " "# $" Ecl 2538 icos system - Installation and Servicing...
  • Page 51 LIST OF PARTS 80 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom panel with screws. 81 CONTROLS ASSEMBLY Controls assy with screws. Controls hinge bracket. User controls (without item 38). PCB (primary controls). User controls housing Mains switch.
  • 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.

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