Ideal Boilers icos m3080 Installation And Servicing
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Ideal Boilers icos m3080 Installation And Servicing

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Your Ideal installation and servicing guide
m3080
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 Boilers.
ENGINEERED FOR PEACE OF MIND

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Summary of Contents for Ideal Boilers icos m3080

  • 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 ENGINEERED FOR PEACE OF MIND use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.

  • Page 2: Sedbuk No

    GENERAL Table 1 - Boiler Data Boiler Size 3080 Gas supply type and connection 2H-G20-20 mbar Rc " BSP Female) Injector size Stereomatic 5.6mm dia. Flow connection 22mm copper Return connection 22mm copper Flue terminal diameter mm (in.) 100 (4) Maximum static water head m (ft.) 30.5 (100)

  • Page 3: Table Of Contents

    GENERAL icos m3080 CONTENTS Air Supply ............... 7 Natural Gas only Boiler Clearances ............4 G.C. Appliance No. 41 391 49 Boiler Exploded Diagram ..........12 Boiler Interlocks ............7 PI No. 0063BM3094 Electrical Connections ..........20 Electrical Supply ............7 Destination Country: GB, IE Electrical Systems Diagrams ........

  • Page 4: Boiler Clearances

    GENERAL Return BOILER WATER CONNECTIONS Flow The boiler flow and return pipes are supplied fitted to the boiler ready for top connection Notes. a. For the heating loads in excess of 60,000 Btu/h, 28mm (1") flow and return pipes should be used to and from the boiler. b.

  • Page 5: Gas Safety Regulations

    Gas Safety (Installation and Use) Regulations INTRODUCTION • The appropriate Building Regulations either The Building The icos m3080 is a fully automatically controlled, wall Regulations, The Building Regulations (Scotland), Building mounted, low water content, balanced flue, fanned, condensing Regulations (northern Ireland).

  • Page 6: Flue Installation Requirements

    GENERAL IMPORTANT. LOCATION OF BOILER Installation pipes MUST be fitted in accordance with BS. 6891. The boiler must be installed on a flat and vertical wall, capable In IE refer to I.S.813:2002. Pipework from the meter to the of adequately supporting the weight of the boiler and any boiler MUST be of an adequate size, i.e.

  • Page 7: Trv's

    GENERAL 6. The air inlet/products outlet duct and the terminal of the Single feed, indirect cylinders are not recommended and MUST boiler MUST NOT be closer than 25mm (1") to combustible NOT be used on sealed systems. material. Detailed recommendations on the protection of combustible material are given in BS.5440-1:2000.

  • Page 8: Pump

    GENERAL OPEN VENT SYSTEM REQUIREMENTS The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150mm (6") away from the vent connection.
  • Page 9 GENERAL LOW HEAD AND LARGE SYSTEMS WITH EXTENSIVE PIPE RUNS - OPEN VENT This arrangement is useful for large systems where radiators at the extremities are difficult to vent. This can lead to pumping over with conventional feed and vent arrangements.
  • Page 10 GENERAL SEALED SYSTEM REQUIREMENTS - continued 4. Expansion Vessel The static head available from the cistern should be adequate to provide the desired initial system design A diaphragm type expansion vessel must be pressure. The cold feed pipe from the cistern should connected to a point close to the inlet side of the include a non-return valve and a stop valve with an pump, the connecting pipe being not less than 15 mm...

  • Page 11: For All Boilers Flushing To Bs.7593

    GENERAL SEALED SYSTEM REQUIREMENTS - continued Safety valve setting 3.0 bar 2.5 bar 2.0 bar Vessel charge and initial system pressure Total water content of system Expansion vessel volume litres litres 11.8 10.0 11.7 10.0 17.7 15.0 10.9 15.6 13.4 23.7 11.3 20.0...

  • Page 12: Appliance Serial No. On Data Badge

    INSTALLATION 10 BOILER ASSEMBLY - Exploded view Data badge 22. Flue thermistor. 23. Control thermistor. 24. Overheat thermostat. LEGEND 25. Ignition electrode. 14. Injector & housing Front casing panel. Flue manifold. 26. Flame detection electrode. 15. Venturi assy. Sealing panel Flue fixing 32.

  • Page 13: Controls

    INSTALLATION 11 UNPACKING Pack A Contents ! Hardware Pack (listed below). The boiler is supplied fully assembled in one Pack A, ! These Installation & Servicing Instructions. together with a standard flue assembly for lengths up to 650mm, rear or side flue outlet, in Pack B. ! The User's Instructions.

  • Page 14: Flue Fitting

    INSTALLATION 13 FRONT PANEL AND BOTTOM PANEL REMOVAL 1. Remove the 2 retaining screws. 2. Lift front panel and remove. 3. To remove the bottom panel remove the 2 screws. 4. Pull the RH side of the panel down. Slide it to the right and withdraw.

  • Page 15: Wall Mounting Template

    INSTALLATION 15 FLUE ASSEMBLY - Exploded View An optional flue duct extension kit is required for wall thicknesses greater than : Side 455mm (18") Rear 490mm "). LEGEND 1. Duct assembly. 2. Flue turret. 3. Turret gasket. 4. M5 x 10 pozi screw. 5.

  • Page 16: Preparing The Wall

    INSTALLATION 17 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.

  • Page 17: Extension Ducts - Fitting

    INSTALLATION 20 FLUE EXTENSION DUCTS - For flue lengths greater than 480mm 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: Mounting The Boiler

    INSTALLATION 23 MOUNTING THE BOILER 1. Lift the boiler onto the wall mounting plate, as shown. 2. Check the boiler alignment using a spirit level and adjust as necessary with the jacking screw. 3. Align the hole in the jacking plate with the pre- drilled hole in the wall and fix in position with the No.10 x 2"...

  • Page 19: For Condensing Boilers Only Condensate Drain

    Refer to Frame 2 for details of the position of the gas connection. casing. The principle of the 1:1 gas valve ensures that the icos m3080 Refer to Frame 34 for details of the pressure test point is able to deliver its full output at inlet pressures well below position.

  • Page 20: Electrical Connections

    INSTALLATION 28 ELECTRICAL CONNECTIONS WARNING. Wiring should be 3 core PVC insulated cable NOT LESS This appliance MUST be earthed. 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 21: Electrical Systems Diagrams

    INSTALLATION 30 PICTORIAL WIRING DIAGRAM LEGEND blue black brown grey orange pink violet white yellow/green 31 FUNCTIONAL FLOW WIRING DIAGRAM Mains Switch Filter PCB No. External switch e.g. room'stat, programmer Overheat Flame detection electrode thermostat DC Gas valve Flue thermistor Ignition electrode Control thermistor Ecl 6086...

  • Page 22: Time And Temperature Control To Heating

    INSTALLATION 32 EXTERNAL ELECTRICAL CONTROLS L2 L1 Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Room 'stat Wiring Regulations and any local regulations. For IE reference should be made to the current ETCI rules for electrical installations. The fuse should be 3A.

  • Page 23: 34 Initial Lighting

    N.B. The principle of the 1:1 gas valve ensures that the E Reset button. L Flue thermistor. icos m3080 is able to deliver its full output at inlet pressures well below those required by BS. 6891. F Injector pressure test point.

  • Page 24: Handing Over

    INSTALLATION 35 GENERAL CHECKS Make the following checks for correct operation: 3. Water Circulation System 1. Central Heating The correct operation of ANY programmer and all Note. Fernox Superfloc, Sentinel X300 (new systems) or other system controls should be proved. Operate X400 (existing systems) flushing solutions should be used each control separately and check that the main during the flushing procedure.

  • Page 25: Servicing

    SERVICING 37 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 intervals 8. Wherever possible, remove and clean the condensate ‘S’ and serviced as necessary.

  • Page 26: Burner Removal And Cleaning

    SERVICING 40 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 the fan and venturi assembly. 5.

  • Page 27: Cleaning The Heat Exchanger

    SERVICING 42 CLEANING THE CONDENSATE 'S' TRAP 1. Undo the plastic union nut on the condensate ‘S’ trap outlet. 2. Remove the 2 screws. 3. Pull the trap down and forward to remove. 4. Flush out any deposits with clean water. Ecl 1554 43 CLEANING THE HEAT EXCHANGER 1.

  • Page 28: Replacement Of Components

    SERVICING 45 REPLACEMENT OF COMPONENTS GENERAL When replacing ANY component: IMPORTANT When work is complete, the sealing panel must be 1. Isolate the electricity supply. correctly fitted, ensuring that a good seal is made. 2. Turn off the gas supply. Note.

  • Page 29: Fan Replacement

    SERVICING 47 FAN REPLACEMENT Orifice plate 1. Refer to Frame 45. Gasket 2. Remove the boiler front and sealing panels. Refer to Frames 38 & 39. 3. Disconnect the electrical leads from the fan. 4. Unscrew the gas pipe union connection to the injector housing.

  • Page 30: Ignition Electrode Replacement

    SERVICING 49 IGNITION ELECTRODE REPLACEMENT 1. Refer to Frame 45. 2. Remove the boiler front and sealing panels. Refer to Frames 38 & 39 3. Lower the control box, as shown in Frame 53. 4. Unplug the ignition electrode lead from the control box. 5.

  • Page 31: Burner Injector Replacement

    SERVICING 51 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 45. 2. Remove the boiler front and sealing panels. Refer to Frames 38 & 39. 3. Remove the fan / venturi assembly. Copper washer 4. Remove the 2 injector housing screws. 6.

  • Page 32: Control Box Replacement

    SERVICING 53 CONTROL BOX REPLACEMENT 1. Refer to Frame 45. 2. Remove the front panel. 3. Remove the bottom panel. 4. Remove the 2 control box screws. 5. Carefully unplug all the electrical wiring from the control box. 6. With the control box lowered, pull the assembly forward to remove from the housing.

  • Page 33: Overheat Thermostat Replacement

    SERVICING 55 OVERHEAT THERMOSTAT REPLACEMENT 1. Refer to Frame 45. 2. Remove the boiler front and sealing panels. Refer to Frames 38 & 39. 3. Pull off the electrical leads from the thermostat body. 4. Pull the thermostat and clip from the pipe.

  • Page 34: Combustion Chamber Insulation Replacement

    SERVICING 57 COMBUSTION CHAMBER INSULATION REPLACEMENT The insulation boards used in the combustion chamber of this 7. Damp down the combustion chamber area containing the product are made of high temperature glass fibres with a binder insulation boards. of organic and inorganic materials. 8.

  • Page 35: Heat Exchanger Replacement

    SERVICING 58 HEAT EXCHANGER REPLACEMENT 13. Pull the CH return pipe up and out of the heat Refer also to Frame 10, 'Boiler exploded view'. exchanger. 1. Refer to Frame 45. 14. Remove the flue casing. 2. Remove front, bottom and sealing panels. Refer to 15.

  • Page 36: Boiler Sealing Panel Seal Replacement

    SERVICING 59 BOILER SEALING PANEL SEAL REPLACEMENT 1. Refer Frame 45. 2. Remove the front panel. Refer to Frame 38. 3. Remove the boiler sealing panel. Refer to Frame 39. 4. Remove the old seal from the casing and thoroughly clean the casing surfaces. 5.

  • Page 37: Fault Finding

    FAULT FINDING 61 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 62 ALTERNATING 'L' 'F' ALTERNATING 'L' 'E' GO TO FRAME 63 GO TO FRAME 64 ALTERNATING 'L' 'A'...

  • Page 38: Fault Finding

    FAULT FINDING 62 L..F..(FLAME ERROR) If the boiler reset button is Is gas pressure available at Check gas supply pressed does the boiler ignite for the boiler inlet ? and rectify fault a short time then extinguish? Check gas valve Is 200V DC supply available Check the detection electrode and wiring for...
  • Page 39 FAULT FINDING 64 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 40 FAULT FINDING 67 H..F..(FLAME DETECTION - SHORT CIRCUIT ERROR) Remove flame detection electrode terminal from PCB. Replace PCB. Is there continuity between the 2 terminal pins ? Replace flame detection electrode 68 H..4..(FLUE THERMISTOR ERROR) Is the system filled and vented and all Can the fault condition be reset by switching isolation valves open ? off the mains supply to the boiler ?

  • Page 41: Short List Of 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 Boilers Limited.

  • Page 42: Short List

    SHORT LIST OF PARTS 70 SHORT LIST Ecl 2423 71 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom casing panel with screws. icos - Installation & Servicing...
  • Page 43 LIST OF PARTS 72 CONTROLS ASSEMBLY Controls assy with screws. Controls hinge bracket. User controls (without item 38). PCB (primary controls). User control housing Mains switch. Jumper link. Ecl 1600 73 BURNER ASSEMBLY 11. Burner assembly with screws and gasket. Ecl 1598 icos - Installation &...
  • Page 44 & 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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