Ideal Boilers responce 80 Installation And Servicing Manual
  1. Manuals
  2. Brands
  3. Ideal Boilers Manuals
  4. Boiler
  5. responce 80
  6. Installation and servicing manual
Ideal Boilers responce 80 Installation And Servicing Manual

Ideal Boilers responce 80 Installation And Servicing Manual

Wall mounted, gas fired, fanned flue combination boiler
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the responce 80 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Ideal Boilers responce 80

Summary of Contents for Ideal Boilers responce 80

  • Page 2 Response: The combi boiler The Ideal Response is a wall mounted, fanned flue combination boiler which serves a home's central heating system and delivers hot water on demand. It has been designed to be 'friendly' to the user, installer and service engineer. Response: The fit anywhere combi Simple fanned 'go anywhere' flue The Response's flue turret simply rotates through 360°...

  • Page 3: Performance Data

    PERFORMANCE DATA IMPORTANT. This manual is applicable only to Response boilers with a data plate prefix of RF or above Table 1 - General Data Gas supply type & connection 2H-G20-20mbar, 22mm copper Inlet connection Domestic Hot Water 15mm copper Outlet connection Domestic Hot Water 15mm copper...

  • Page 4: Table Of Contents

    Response 80 (Natural gas) G.C. Appliance No..47 348 02 B.G. Certified - P.I. No..87 AS 93 Response 100 (Natural gas) G.C. Appliance No..47 348 04 B.G. Certified - P.I. No..87 AT 20 Response 120 (Natural gas) G.C.
  • Page 5 GENERAL draw-off of : OPERATION Response 80 9.6 l/min (2.1 gpm) at 35 rise With no call for CH the boiler fires only when DHW is drawn off. Response 100 12.0 l/min (2.6 gpm) at 35 rise When there is a call for CH, the heating system is supplied at the Response 120 14.4 l/min (3.1 gpm)
  • Page 6 GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in.) Boiler connections are made on the mounting frame. Refer to Frame The following minimum clearances must be maintained for operation and servicing. Additional space will be required for installation, depending upon site conditions.

  • Page 7: Air Supply

    GENERAL Timber Framed Buildings SAFETY If the boiler is to be fitted in a timber framed building it should be Current Gas Safety (Installation and Use) Regulations fitted in accordance with the Institute of Gas Engineering or rules in force. document IGE/UP/7:1998.

  • Page 8: Gas Supply

    GENERAL GAS SUPPLY FLUE INSTALLATION The local gas supplier should be consulted, at the installation The flue must be installed in accordance with the planning stage, in order to establish the availability of an adequate recommendations of BS. 5440: Part 1. supply of gas.

  • Page 9: Electrical Supply

    GENERAL THERMOSTATIC RADIATOR VALVES (TRV) Ensure that the mains water supply pressure is adequate to provide the required DHW flow rate. Refer to Table 1 on page 3. Caradon Plumbing Limited recommend that heating systems utilising full thermostatic radiator valve control of temperature The central heating system should be installed and in individual rooms should also be fitted with a room commissioned in accordance with BS.
  • Page 10 GENERAL SEALED SYSTEM REQUIREMENTS - Central Heating - continued 5. Filling the system Mains water supply Fill the system through a temporary hose connection from a draw-off tap supplied from a service pipe under mains pressure. Where the mains pressure is excessive a pressure reducing valve shall be used to facilitate filling.
  • Page 11 GENERAL SEALED SYSTEM REQUIREMENTS - Central Heating - continued 7. Thermostatic radiator valves. Caradon Plumbing Limited support the recommendations made by leading manufacturers of domestic heating controls that heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve.
  • Page 12 INSTALLATION BOILER ASSEMBLY - Exploded View LEGEND Gas injection pipe. 25. DHW Flow switch. 39. DHW Lower hot pipe 11. Boiler overheat t'stat. Pressure gauge sub assy. assy. 26. Automatic air vent. 12. Water pressure switch. Flue outlet elbow 40. Boiler front panel. 27.
  • Page 13 INSTALLATION UNPACKING The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to 600mm, rear or side flue outlet, in Pack B. Unpack and check the contents. Hardware Pack Pack A Contents M6 x 16 Pp.
  • Page 14 INSTALLATION 10 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED Calculate the total length of flue by the following: USE A MAXIMUM OF 3 EXTENSION DUCTS ONLY FOR THE 80 AND A MAXIMUM OF 4 Rear flue length = Dim. W + 79mm (3 ") EXTENSION DUCTS FOR THE 100 AND 120.
  • Page 15 INSTALLATION REAR FLUE ASSEMBLY - Exploded View LEGEND 1. Terminal. 2. Weather seal. 3. Duct assembly. 4. Sealing ring. 5. Clamping ring. 6. No.8 x 8 self tapping screw. 7. Flue turret. 8. M5 x 10 pozi Hex screw. 9. Turret clamp. 12 WALL MOUNTING TEMPLATE (Rear Flue) IMPORTANT.
  • Page 16 INSTALLATION 14 FITTING THE WALL MOUNTING FRAME Fit the wall mounting frame either: a. Directly to the wall ! ! ! ! ! Insert wall plugs. ! ! ! ! ! Put the screws into the wall plugs and leave 10mm proud ! ! ! ! ! Hang the frame onto the screws and tighten up.
  • Page 17 INSTALLATION 15 CUTTING THE FLUE - Wall thicknesses up to 600mm (23 ") 1. The flue cut length is calculated as detailed in Frame 10. 2. Measure from the groove and mark the tube. 3. To ensure the tube is cut square, mark the flue all the way round using (e.g).

  • Page 18: Mounting The Boiler

    INSTALLATION 17 MOUNTING THE BOILER 1. The boiler may be prewired to the loose electrical connector and secured with the cable clamps. Refer to Frame 39. 2. WARNING. ENSURE that the plastic plugs are removed from both the DHW and CH pipes before mounting.
  • Page 19 INSTALLATION 19 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the rubber seal. It should be used, where practicable:: a. When the wall is more than 24" thick (to support the flue weight and prevent movement). b.
  • Page 20 INSTALLATION 20 SIDE FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than: 504mm (19 ") - LHS flue 380mm (15") - RHS flue Refer to Frame 10. 2. When cutting the ducts always use the cardboard LEGEND support cutting aid...
  • Page 21 INSTALLATION 22 DRILLING THE WALL (Side Flue) IMPORTANT. Ensure that, during the cutting operation, masonry falling outside 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.
  • Page 22 INSTALLATION 24 FITTING THE WALL MOUNTING FRAME - continued Use stand-off channels (To allow pipework to be taken upwards). ! ! ! ! ! Insert the wall plugs. ! ! ! ! ! Put the screws into the wall plugs and leave 10mm proud.
  • Page 23 INSTALLATION 27 MOUNTING THE BOILER 1. The boiler may be prewired to the loose electrical connector and secured with the cable clamps. Refer to Frame 39. 2. WARNING. Ensure that the plastic plugs are removed from both the DHW and CH pipes before mounting.
  • Page 24 INSTALLATION 29 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the rubber seal. It should be used (where practicable): a. When the wall is more than 24" thick (to support the flue weight and prevent movement). b.
  • Page 25 INSTALLATION 30 FLUE EXTENSION DUCT PACK D CONTENTS Use a maximum of 3 extension ducts only for the 80 and a maximum of 4 extension ducts for the 100 and 120. 31 ASSEMBLING THE EXTENDED FLUE 1. Remove the cardboard support aid from the flue and place safely to one side.

  • Page 26: Service Connections

    INSTALLATION 32 CUTTING THE FLUE TO LENGTH 1. Check the flue length measurement made in Frame 10. 2. Use this dimension to mark the flue length, starting from the groove, as illustrated. 3. To ensure a square cut, mark the flue all the way round, using, e.g.

  • Page 27: Water Connections

    INSTALLATION 35 WATER CONNECTIONS For central heating loads greater than 60 000 BTU's the Refer to General Note, Frame 34, for guidance. flow and return circuits should be increase to 28mm pipe diameter immediately upon leaving the boiler with the Note.

  • Page 28: Electrical Connections

    INSTALLATION 38 ELECTRICAL CONNECTIONS Wiring external to the boiler MUST be in accordance with WARNING. This appliance MUST be efficiently earthed the current I.E.E. (BS7671) Wiring Regulations and any local regulations. A mains supply of 230 V ~ 50 Hz is required. Connection must be made in a way that allows complete The fuse rating should be 3 A.
  • Page 29 INSTALLATION 40 PICTORIAL WIRING LEGEND br - brown pk - pink w - white b - blue gy - grey - red y - yellow bk - black or - orange v - violet y/g - yellow/green 41 FUNCTIONAL FLOW WIRING DIAGRAM PCB 40 LEGEND b - blue...

  • Page 30: Commissioning And Testing

    INSTALLATION Earths are not shown for clarity but must never be omitted. 42 EXTERNAL ELECTRICAL CONTROLS Wiring External to the Boiler WARNING . This appliance must be efficiently earthed. A mains supply of 230 V ~ 50 Hz is required. The fuse rating should be 3A.

  • Page 31: Initial Lighting

    INSTALLATION 44 INITIAL LIGHTING The illustration is shown with the control door removed. The illustration is shown with the control & front panel removed. LEGEND E Burner pressure test point. A 'Mains on' neon. J Gas service cock. F Signal pressure test point (Lo). B 'Burner on' neon.

  • Page 32: Handing Over

    INSTALLATION 45 GENERAL CHECKS Response 80 43.1 to 47.7 litres per minute 1.52 to 1.68 cu/ft per minute Make the following checks for correct operation: Response 100 51.9 to 57.4 litres per minute 1. Hot water 1.8 to 2.0 cu/ft per minute Fully open all DHW taps in turn and ensure that water Response 120 64.8 to 71.6...

  • Page 33: Servicing Schedule

    SERVICING 47 SERVICING SCHEDULE must be divided by 10,000 to convert it to a percentage. To ensure the continued safe and efficient operation of the If the ratio of CO/CO is less than 0.004 and the gas appliance it is recommended that it is checked at regular rates measured in steps 3 and 4 are close to nominal intervals and serviced as necessary.

  • Page 34: Burner Removal And Cleaning

    SERVICING 49 FAN REMOVAL AND CLEANING 1. Disconnect the pressure sensing pipe as follows: Undo the single top fixing screw on the fan inlet venturi and slacken the other 2 location screws. Undo the 2 screws securing the sensing pipe to the manifold block. Slide the fan inlet venturi upward to disengage and remove the venturi and sensing pipe assembly.

  • Page 35: Cleaning The Heat Exchanger

    SERVICING 51 CLEANING THE HEAT EXCHANGER 1. Place a plastic sheet or similar beneath the boiler and remove all visible loose deposits from the heat exchanger fins, using a suitable brush. 2. Take care to clean debris from the ledge inside the combustion chamber.
  • Page 36 SERVICING 55 CH AND HW TEMPERATURE SENSOR REPLACEMENT (Spares for both are identical) 1. Disconnect the electrical supply. 2. Remove the boiler front and sealing panels. Refer to Frame 48. 3. Remove the fan (refer to Frame 49) : the CH and HW thermistors are now exposed.
  • Page 37 SERVICING 57 OVERHEAT THERMOSTAT REPLACEMENT 1. Disconnect the electrical supply to the boiler. Remove the electrical connector (secured by one screw) from the boiler base. 2. Remove the controls panel. Swing the panel upside down and fix with the long screws. Remove the bottom panel. 3.
  • Page 38 SERVICING 60 BURNER REPLACEMENT 1. Remove front and sealing panels. Refer to Frame 48. 2. Remove the fan assembly. Refer to Frame 49. 3. Disconnect the 2 ignition leads and one detection lead from the electrodes. 4. Undo the 3 fixing screws securing the burner assembly. 5.
  • Page 39 SERVICING 62 GAS CONTROL VALVE AND SOLENOID REPLACEMENT To replace the gas valve COMPLETE Refer to Frame 54. 1. Remove the front and sealing panels. Refer to Frame 2. Remove the casing bottom panel. 3. Remove the control panel. Disconnect the electrical leads (noting their position for refitting) and place panel safely to one side.
  • Page 40 SERVICING 63 GAS CONTROL VALVE REPLACEMENT - continued 10. Supporting the valve, undo the 4 retaining screws and withdraw the gas valve, leaving the plate with the 3 studs in place. 11. Transfer the gas cock union and elbow assembly to the new gas valve, reusing the four M5 x 10 screws, together with the new 'O' ring seal provided.
  • Page 41 SERVICING 65 FAN UNIT REPLACEMENT 1. Remove the front and sealing panels. Refer to Frame 48. 2. a. Undo the single fixing screw on the fan inlet venturi and slacken the other 2 location screws. Undo the 2 screws securing the sensing pipe to the manifold block.
  • Page 42 SERVICING 66 PRINTED CIRCUIT BOARD REPLACEMENT The Response uses: PCB 41 PCB 41 - Ignition sequence PCB 40 - Logic sequence Fan speed control 1. Isolate the electrical supply. Refer to Frame 54. 2. Remove the front panel. 3. Remove the PCB cover 4.

  • Page 43: Electrical Connections

    SERVICING 68 PUMP REPLACEMENT 5. Drain down (refer to Frame 68) by opening the CH drain cock. Do not release system pressure using the Note. The Grundfos 15/60 pump is available in several pressure relief valve as it may cause debris within the versions, according to the position of the electrical connector system to foul the valve.
  • Page 44 SERVICING 70 HEAT EXCHANGER REPLACEMENT - continued 4. Remove the bottom panel. 5. Attach drain pipes to the 2 boiler drain points. Open the CH drain by turning the grey knobs and the HW drain by slackening the drain point. Note the marking on the bottom of the valves.

  • Page 45: Water Pressure Switch

    SERVICING 71 BOILER SEALING PANEL SEAL 72 WATER PRESSURE SWITCH 1. Disconnect the electricity supply. Refer to Frame 54. 1. Refer to Frame 48. 2. Close the CH flow and return isolating valves at the bottom of 2. Remove the screws and disengage panel. the boiler.
  • Page 46 SERVICING 74 WATER FLOW SWITCH REPLACEMENT 1. Isolate the electrical supply. Refer to Frame 54. 2. Remove the boiler bottom panel . 3. Remove the controls panel. If a programmer is fitted it is necessary to disconnect the programmer harness at the terminal block.
  • Page 47 SERVICING 76 MAINS TRANSFORMER REPLACEMENT 1. Isolate the electrical supply to the boiler. Refer to Frame 54. 2. Remove the boiler front panel. Refer to Frame 48. 3. Release the screws securing the PCB cover and remove the cover. 4. Disconnect the transformer electrical leads at the in-line connector 5.
  • Page 48 SERVICING 78 CH EXPANSION VESSEL REPLACEMENT If the CH expansion vessel is faulty, there are 3 options: A. If it has a punctured diaphragm, but is otherwise leak free, then it can be left in place and a new vessel added to the system, external to the boiler, provided it is of adequate capacity and pre-charge pressure.

  • Page 49: Fault Finding

    FAULT FINDING 79 FAULT FINDING MAIN MENU WARNING. No part of the boiler should be touched without first isolating the mains supply. START THE BOILER FROM COLD Note. Switching the boiler on/off switch 'off' when a frost thermostat is wired directly from the mains may leave a live feed to the boiler.
  • Page 50 FAULT FINDING 80 HW but no CH WARNING . When panels are removed for service, live parts are exposed so caution should be exercised when fault-finding. Note 1 . At the end of a call for heat by the room thermostat / time control, a 2 minute pump overrun period occurs. During this time the boiler will not restart for CH even if the controls are calling for heat.
  • Page 51 FAULT FINDING 81 CH but no HW WARNING. When panels are removed for service, live parts are exposed so caution should be exercised when fault-finding. Is the HW light on PCB 40 flashing ? Unplug the lead from the sensor and connect it temporarily to a replacement sensor, if available.
  • Page 52 FAULT FINDING 82 Fan not running WARNING . When panels are removed for service, live parts are exposed so caution should be exercised when fault-finding. Is the system pressure gauge indicating Go to Frame 86 water pressure below 0.5 bar ? Make sure the boiler mains switch is ON Is there mains voltage to the boiler ? and the heating switch is on, if required.
  • Page 53 FAULT FINDING 83 Power to PCB 41 but burner pressure incorrect or zero Notes. 1. The burner pressure is not user-adjustable: it is regulated by the gas valve, according to the air flow generated by the fan and, on cold ignition, should be slightly higher than the value quoted on the Data Plate.
  • Page 54 FAULT FINDING 84 Spark generation and ignition WARNING. When panels are removed for service, live parts are exposed so caution should be exercised when fault-finding. Note. Do not attempt to measure the voltage between the spark generator output (spark) leads ! Fan and gas supply OK.
  • Page 55 FAULT FINDING 85 Flame detection and mixture WARNING . When panels are removed for service, live parts are exposed so caution should be exercised when fault-finding. Boiler does not light, or lights briefly at the correct burner pressure then goes off, leaving LED 2 on PCB 41 lit Is this a new installation ? Check that the gas injector is unobstructed.
  • Page 56 FAULT FINDING 86 Low system pressure indicated on pressure gauge. Check that the wiring to the low water Check the pressure on the gauge on the boiler pressure switch terminals 1, 2 and 3 control panel. corresponds with that shown in the wiring diagrams.
  • Page 57 SHORT LIST OF PARTS 87 BURNER ASSEMBLY - Exploded View LEGEND Burner. 28. Pressure sensing pipe. Burner injector. 57. Gas manifold gasket. 29. Sensing pipe clamp plate Gas valve. 58. Gas valve gasket. 54. Fan / burner mounting 'O' ring. Flame sensing electrode.
  • Page 58 SHORT LIST OF PARTS 88 CONTROLS AREA - Exploded View Legend Fan speed control board PCB 41. EMC filter. Spark generator assembly. PCB 40. Transformer assembly. Response 80 / 100 / 120 - Installation...

  • Page 59: Short List Of Parts

    SHORT LIST OF PARTS The following are parts commonly required as replacements, due to When ordering spares please quote: damage or expendability. Their failure or absence is likely to affect the safety and/or performance of this appliance. 1. Boiler model (see Data Plate) 2.
  • Page 60 SHORT LIST OF PARTS Key No. G.C. Part No. Description Qty. Product No. E00-060 DHW expansion vessel (Zilmet ref. Zi 160 S/D 1/4"), c/w: 1 off " fibre washer. 075179 E00-061 CH expansion vessel - 8 litre (Zilmet ref. Zi 304080), c/w: 1 off "...
  • Page 61 SHORT LIST OF PARTS 90 BOILER CASING ASSEMBLY 89 SHORT PARTS LIST Res 5972 Response 80 / 100 / 120 - Installation...
  • Page 62 NOTES Response 80 / 100 / 120 - Installation...
  • Page 63 NOTES Response 80 / 100 / 120 - Installation...

  • Page 64: Servicing

    CERTIFIED PRODUCT 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.

This manual is also suitable for:

Responce 100Responce 120

Table of Contents