Ideal Boilers Classic m3050 Installation And Servicing
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Ideal Boilers Classic m3050 Installation And Servicing

Ideal Boilers Classic m3050 Installation And Servicing

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Summary of Contents for Ideal Boilers Classic m3050

  • Page 2: Burner Operating Pressure

    GENERAL Table 1 - Boiler Data Boiler Size m30-50 m50-80 Gas supply type and connection 2H-G20-20mbar Rc " BSP Female) Injector size Stereomatic 5.4mm dia. Flow connection 22mm copper Return connection 22mm copper Maximum static water head m (ft.) 30.5 (100) Minimum static water head m (ft.) 0.45 (1.5)

  • Page 3: Table Of Contents

    GENERAL classic m CONTENTS Natural Gas only Air Supply ..............6 m3050 ......G.C. Appliance No. 41 391 50 m5080 ......G.C. Appliance No. 41 391 51 Boiler Clearances ............4 Boiler Exploded Diagram ........... 12 PI No. 0063BL9812 Destination Countries: UK, IE Electrical Connections ..........

  • Page 4: Boiler Clearances

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

  • Page 5: Gas Safety Regulations

    GENERAL INTRODUCTION BS. 5440:2 Ventilation (for gas appliances of rated input not exceeding 70 kW). The classic m boiler is a fully automatically controlled, wall BS. 5449 Forced circulation hot water systems. mounted, low water content, fan flued, non condensing gas boiler.

  • Page 6: Gas Inlet Working Pressure

    GENERAL Compartment Installations Table 3 - Balanced flue terminal position A compartment used to enclose the boiler should be designed Terminal Position Minimum Spacing and constructed specially for this purpose. An existing cupboard or compartment may be used, provided 1. Directly below or alongside an that it is modified for the purpose.

  • Page 7: Electrical Supply

    GENERAL THERMOSTATIC RADIATOR VALVES (TRV) The hot water cylinder and ancillary pipework, not forming part of the useful heating surface, should be lagged to prevent heat Caradon Plumbing Ltd. recommend that heating systems loss and any possible freezing - particularly where pipes run utilising full thermostatic radiator valve control of temperature in through roof spaces and ventilated underfloor spaces.

  • 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 Ecl 1606 lead to pumping over with conventional feed and vent arrangements.
  • Page 10 GENERAL SEALED SYSTEM REQUIREMENTS - continued 4. Expansion Vessel A diaphragm type expansion vessel must be include a non-return valve and a stop valve with an connected to a point close to the inlet side of the automatic air vent connected between them, the stop pump, the connecting pipe being not less than 15 valve being located between the system and the mm (...

  • Page 11: 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 LEGEND 10. Flue hood seal. 19. Gas valve assy. 36. PCB - primary controls. Front casing panel. 11. Burner assy. 20. Fan bracket assy. 42. Sightglass. Case sealing panel. 12. C/Cham Insulation. 21. Orifice plate. 44.
  • Page 13 INSTALLATION 11 UNPACKING Pack A Contents Also contained in Pack A: Hardware Pack (listed below). The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to These Installation & Servicing Instructions. 460mm, rear or side flue outlet, in Pack B.
  • Page 14 INSTALLATION 13 FRONT PANEL AND BOTTOM PANEL REMOVAL 1. Remove the 2 retaining screws. 2. Lift front panel and remove. 3. Remove the 2 bottom panel screws. 4. Allow the RHS of the bottom panel to lower slightly. 5. Withdraw the LHS of the bottom panel from the retaining clips.

  • Page 15: Flue Fitting

    INSTALLATION 15 FLUE ASSEMBLY - Exploded View 1. An optional flue duct extension kit is required for wall thicknesses greater than : Side 300mm (11 "). Rear 345mm (13 "). LEGEND 1. Duct assembly. 2. Flue Turret. 3. Turret gasket. 4.

  • 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. Both wall faces immediately around the cut hole should be flat.

  • 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: Gas Connection

    INSTALLATION 25 BOILER WATER CONNECTIONS Return The boiler flow and return pipes are supplied fitted to the boiler and ready for top connection. Flow Note. For heating loads in excess of 60 000 Btu/hr use 28mm connectors. TOP CONNECTION Connect the system pipework to the boiler flow and return pipes. 26 GAS CONNECTION IMPORTANT.

  • Page 20: Wiring Diagrams

    INSTALLATION 28 INTERNAL WIRING A pictorial wiring diagram is shown in Frame 29 . 1. Route the mains cable into the bottom Rear centre of the boiler. 2. Wire the live and neutral and earth wires into the plug. Note. Ensure that the lengths of the current carrying conductors are shorter than the earth conductor so that if the cable slips in its anchorage the current carrying conductors become taut before the earth conductor.
  • Page 21 INSTALLATION 30 PICTORIAL WIRING Overheat thermostat Control Gas valve thermistor Chassis earth y/g MAINS SUPPLY 230V 50Hz Permanent black link Service connection Fused at 3.15ATL Control PCB ON / User control and display Switch LEGEND - red - yellow - blue - white pk - pink bk - black...

  • Page 22: Flow Wiring Diagram

    INSTALLATION 31 FUNCTIONAL FLOW WIRING DIAGRAM Mains Switch External switch.e.g. room'stat, programmer Flame detection electrode Overheat thermostat DC Gas valve electrode Control thermistor Ecl 1849 LEGEND y/g - yellow/green - red - blue - violet gy - grey - yellow bk - black pk - pink or - orange...

  • Page 23: Initial Lighting

    INSTALLATION 33 INITIAL LIGHTING Note. Boiler is shown with the front panel and sealing panel removed. LEGEND A On/Off switch. B Thermostat knob. H Casing pressure test point. J Overheat thermostat. C 'Mains On' neon. K Flow thermistor. D 'Burner On' neon. E Reset button.

  • Page 24: Handing Over

    INSTALLATION 34 GENERAL CHECKS Make the following checks for correct operation b. With the system still HOT, turn off the gas, water and electricity supplies to the boiler and drain down to complete the flushing process. 1. Central Heating The correct operation of ANY programmer and all other Refill and vent the system, add inhibitor (see Frame system controls should be proved.

  • Page 25: Servicing

    SERVICING 36 SERVICING SCHEDULE 7. Check that the flue terminal is unobstructed and that the flue To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals system is sealed correctly. and serviced as necessary.

  • Page 26: Burner Removal And Cleaning

    SERVICING 39 FAN AND VENTURI ASSEMBLY REMOVAL 1. Disconnect the electrical leads from the fan. 2. Undo the gas pipe union connection to the injector housing. 3. Undo the single retaining screw on the fan mounting bracket. 4. Lift off fan and venturi assembly. 5.

  • Page 27: Cleaning The Heat Exchanger

    SERVICING 41 CLEANING THE HEAT EXCHANGER 1. Remove ignition and sensing electrodes (Frames 47 &48). 2. Remove the 2 spring clips securing the collector hood to the heat exchanger. 3. Slide the flue spigot upwards into the flue turret to allow the collector hood to slide forwards and remove the collector hood.

  • Page 28: Replacement Of Components

    SERVICING 43 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT When replacing ANY component: When work is complete, the sealing panel must be correctly fitted, ensuring that a good seal is made. 1. Isolate the electricity supply. 2. Turn off the gas supply. Note.

  • Page 29: Fan Replacement

    SERVICING 45 FAN REPLACEMENT 1. Refer to Frame 36. 2. Disconnect the electrical leads from the fan. 3. Undo the gas pipe union connection to the injector housing. 4. Undo the single retaining screw on the fan mounting bracket. 5. Remove the fan 6.

  • Page 30: Ignition Electrode Replacement

    SERVICING 47 IGNITION ELECTRODE REPLACEMENT 1. Refer to Frame 36. 2. Lower the control box, as shown in Frame 52. 3. Unplug the spark electrode lead from the control box. 4. Undo the single retaining screw holding the spark electrode to the combustion chamber.

  • Page 31: Burner Injector Replacement

    SERVICING 49 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 36. 2. Remove the fan / venturi assembly, as shown in Frame 45. 3. Unscrew the 2 injector housing retaining screws. 4. Withdraw the injector housing. 5. Fit the new injector housing. 6.

  • Page 32: Control Box Replacement

    SERVICING 51 CONTROL BOX REPLACEMENT Refer to Frame 36. 1. Remove the 2 retaining screws. 2. Lift front panel and remove. 3. Remove the 2 bottom panel screws. 4. Allow the RHS of the bottom panel to lower slightly. 5. Withdraw the LHS of the bottom panel from the retaining clips.

  • Page 33: Overheat Thermostat Replacement

    SERVICING 53 SIGHT GLASS REPLACEMENT 1. Refer to Frame 36. 2. Unscrew the 2 sight glass retaining screws. 3. Remove the sightglass, gasket and bracket. 4. Fit new sight glass, using the new bracket and gasket supplied. Sightglass 5. Reassemble in reverse order. 6.

  • Page 34: Combustion Chamber Insulation Replacement

    SERVICING 55 COMBUSTION CHAMBER INSULATION REPLACEMENT The insulation boards used in the combustion chamber of this 8. Remove the insulation boards. The replacement product are made of high temperature glass fibres with a boards are supplied in a plastic bag. This bag should binder of organic and inorganic materials.
  • Page 35 SERVICING 57 HEAT ENGINE REPLACEMENT Refer to Frame ‘Exploded view’ 1. Refer to Frame 36. 10. Remove the 2 M5 x 10 screws from the bottom of the inter panel. 2. Remove the control box (refer to Frame 51) and place to one side.

  • Page 36: Boiler Sealing Panel Seal Replacement

    SERVICING 57 BOILER SEALING PANEL SEAL REPLACEMENT Refer Frame 36. 1. Remove the 2 retaining screws from the underside of the appliance. Unhook and remove the front panel. 2. Undo the 4 screws to remove the panel. 3. Remove the old seal from the casing and thoroughly clean the casing surfaces.

  • Page 37: Fault Finding

    FAULT FINDING 59 FAULT FINDING CHART MAIN MENU In order to assist fault finding, the boiler has an LCD display. The key to the display codes is as follows: ALTERNATING 'L' 'F' GO TO FRAME 60 GO TO FRAME 61 ALTERNATING 'L' 'E' ALTERNATING 'L' 'A' GO TO FRAME 62...
  • Page 38 FAULT FINDING 60 L..F..(FLAME ERROR) If the boiler reset button is Is 17mbar gas pressure Check gas supply pressed does the boiler ignite for available at the boiler inlet ? and rectify fault a short time then extinguish? Check gas valve Is 200 v DC supply Check the detection electrode and wiring for...
  • Page 39 FAULT FINDING 63 L..8..(FAN) Replace fan Is 14V DC present Is nominal 330 V DC present across yellow and pink across red and blue at the fan at the fan connector? connector as reset button is Replace PCB pressed? Check wiring harness for continuity.

  • Page 40: Short List Of Parts

    When replacing a 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.
  • Page 41 SHORT LIST OF PARTS 67 SHORT LIST OF PARTS Ecl1700 classic m - Installation & Servicing...
  • Page 42 SHORT LIST OF PARTS 68 CASE ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom panel with screws. 69 BURNER ASSEMBLY 11. Burner assembly with screws and gasket. classic m - Installation & Servicing...
  • Page 43 SHORT LIST OF PARTS 70 CONTROLS ASSEMBLY 33. Controls assy complete with screws. 34. Controls hinge bracket. 35. User controls (without item 38). 36. PCB (primary controls). 38. User controls housing kit. 54. Jumper link. Ecl 1600 classic m - Installation &...
  • Page 44 Technical Training The Caradon Plumbing Limited Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers. 01482 498432 For details of courses please ring: CERTIFIED PRODUCT The code of practice for the installation, Manufactured under a BS EN ISO 9001: commissioning &...

This manual is also suitable for:

Classic m5080

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