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Benchmark Procombi Exclusive 24 Installation & Servicing Instructions Manual

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Procombi
Installation & Servicing Instructions
THESE INSTRUCTIONS TO BE RETAINED BY USER
UIN 212131 A01
May 2015
24, 30 & 35
For User Guide see reverse of book
Pro
Pro
30
off
max
reset
min
preheat
mode
Exclusive
status
burner
e
min
max
preheat
Exclusive
G.C. Number
Procombi Exclusive 24 No. 47 348 79
Procombi Exclusive 30 No. 47 348 80
Procombi Exclusive 35 No. 47 348 81

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  • Page 1 Exclusive G.C. Number Procombi Exclusive 24 No. 47 348 79 Procombi Exclusive 30 No. 47 348 80 Procombi Exclusive 35 No. 47 348 81 THESE INSTRUCTIONS TO BE RETAINED BY USER UIN 212131 A01 May 2015...
  • Page 2 ERP DATA MODEL SYMBOL UNITS Condensing Boiler Low Temperature Boiler B1 Boiler Cogeneration Space Heater Equipped with a Supplementary Heater Combination Heater Nominal Heat Output for Space Heating Full Load 24.2 24.2 24.2 Part Load Auxiliary Electricity Consumption Full Load 0.029 0.031 0.042...
  • Page 3 PRODUCT FICHE PROCOMBI EXCLUSIVE COMBINATION BOILER Ideal Boilers ERP DATA SYMBOL UNITS MODEL Condensing boiler Seasonal Space heating efficiency class Rated heat output ƞ Seasonal space heating energy efficiency Annual energy consumption 74.9 Sound power level, indoors Water heating energy efficiency class Seasonal Space Heating Energy Efficiency of the Boiler Temperature control (from fiche of temperature control) Class I...
  • Page 4 Procombi Exclusive - Installation and Servicing...
  • Page 5 NOTES FOR THE INSTALLER FOR ANY TECHNICAL QUERIES PLEASE RING THE PROCOMBI INSTALLER/TECHNICAL HELPLINE : 01482 498700 NOTE. BOILER RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence, if a heat demand is present. DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level .........
  • Page 6 GENERAL Table 1 - General Data Procombi Exclusive Series II Gas supply 2H - G20 - 20mbar Gas Supply Connection 15mm copper compression Injector Size (mm) 4.15 4.65 Inlet Connection Domestic Hot Water 15mm copper tail Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection Central Heating...

  • Page 7: Table Of Contents

    Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist. Before installing this boiler, read the Code of Practice sheet at the rear of this book.
  • Page 8 GENERAL SAFE HANDLING INTRODUCTION The Procombi Exclusive range of boilers are wall mounted, full This boiler may require 2 or more operatives to move it to its installation site, remove it from its packaging base and during sequence, automatic spark ignition, low water content, fanned flue, high efficiency, condensing, combination gas boilers.
  • Page 9 GENERAL SAFETY LOCATION OF BOILER Current Gas Safety (installation and use) regulations or rules The boiler must be installed on a flat and vertical internal wall, in force: capable of adequately supporting the weight of the boiler and any ancillary equipment. The appliance is suitable only for installation in GB and IE and The boiler may be fitted on a combustible wall and insulation should be installed in accordance with the rules in force.

  • Page 10: Flue Installation

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

  • Page 11: Air Supply

    GENERAL AIR SUPPLY It is NOT necessary to have a purpose-provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation;...
  • Page 12 GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm The boiler connections are made on the boiler bulkhead fittings. Refer to Frame 22. wall thicknesses do not exceed 600mm (24”). Where the The following minimum clearances must be maintained for space into which the boiler is going to be installed is less operation and servicing.

  • Page 13: Pump

    GENERAL SYSTEM REQUIREMENTS - Central Heating Notes a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water Safety valve setting authority.

  • Page 14: Domestic Hot Water

    Calmag CalPhos I scale reducing devices, which must be used in Procombi recommend Water Treatment in accordance accordance with the manufacturers’ instructions. with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems. For further information contact: If water treatment is used Procombi recommend only...
  • Page 15 INSTALLATION BOILER ASSEMBLY - Exploded View Note that item numbers are linked to the spares list CH RETURN VALVE WATER PRESSURE SWITCH CUI BOARD CH FLOW VALVE PRESSURE GAUGE ELECTRODE IGNITION DHW INLET & OUTLET GAS COCK ELECTRODE DETECTION PUMP HEAD PIPE - GAS INLET IGNITER UNIT AIR VENT PUMP...
  • Page 16 INSTALLATION UNPACKING The boiler is supplied fully assembled in Pack A. A telescopic or non-telescopic flue assembly for rear or side flue outlet in Pack B is suppled as a separate order. Unpack and check the contents. iMPOr TanT. To unpack the boiler: 1.

  • Page 17: Front Panel Removal

    INSTALLATION UNPACKING CONT’D Note. This flue system incorporates a removable flue outlet nose that utilises a push fit location system. This enables the installation of deflector, high level or balcony outlet flue kits without the removal of the whole ‘B’ pack terminal. The appliance must not be operated without the desired outlet nose correctly fitted in place.

  • Page 18: Safe Handling

    INSTALLATION WALL MOUNTING TEMPLATE Extended centre line 1 5 5 (2 0 0 ) The wall mounting template is located on the internal protective “A” - See Diagram in packaging. The template shows the position of the fixing and rear Frame 1 flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled.
  • Page 19 INSTALLATION 12 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED recommended that a support bracket is fitted on every 1 metre of IMPORTANT. The boiler must be installed in a vertical position in pipe work used and the bracket is located as close to the collar as accordance to the installation instructions.
  • Page 20 INSTALLATION 13 DETERMINING THE FLUE LENGTH AND FLUE PACKS REqUIRED, CONT’D Edge of turret Edge of turret Edge of turret FIGURE 1 to outside face of wall plus to outside face of wall plus to outside face of wall plus 44mm = ue length 44mm = ue length 44mm = ue length...
  • Page 21 INSTALLATION 14 CUTTING & SETTING THE FLUE LENGTH TELESCOPIC FLUES TELESCOPIC FLUE B PACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT HORIzONTAL FLUE TERMINAL (1000MM LONG) B PACK (TELESCOPIC) MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 &...
  • Page 22 INSTALLATION 15 INSTALLING THE FLUE FITTING FLUE THROUGH THE WALL 1. Measure wall thickness and add 14mm. 2. Measure from the outer terminal lip towards the end of outer flue, place a small location mark at the dimension acquired at point 1. 3.
  • Page 23 INSTALLATION 16 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched) Note. A flat or pitched roof flashing plate (not supplied) is required before proceeding with the installation of this kit. This kit is suitable for both flat and pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level.
  • Page 24 INSTALLATION 18 FLUE TERMINAL POSITION The terminal should be positioned so that products of combustion can safely disperse at all times. Pluming may occur at the termination so, where possible, terminal positions where this could cause a nuisance should be avoided. 3 0 0 m m Minimum dimensions are shown below m i n...
  • Page 25 INSTALLATION 19 ASSEMBLING THE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied.
  • Page 26 INSTALLATION 20 CONDENSATE DRAIN Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer Condensate should be used terminating into a suitable internal foul water Drain...
  • Page 27 INSTALLATION 21 CONDENSATE DRAIN - CONT’D..Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to Method (see manufacturers detailed instructions) External Soil & Vent Stack Boiler Water/weather with 75mm Visible air break proof insulation Boiler sealed...

  • Page 28: Water Connections

    INSTALLATION 22 CONNECTIONS & FILLING NOTES. Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown in the picture. Ensure each union is fitted with fibre seals provided. Do not subject any of the isolating valves to heat as the seals may be damaged. WATER CONNECTIONS CH FILLING 1.

  • Page 29: Wiring Diagram

    INSTALLATION 23 ELECTRICAL CONNECTIONS Warning. This appliance MUST be earthed. Wiring should be 3 core PVC insulated cable, not less than A mains supply of 230Vac ~ 50 Hz is required. 0.75mm (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for electrical The fuse rating should be 3A.

  • Page 30: Procombi Exclusive - Installation And Servicing

    INSTALLATION 26 WIRING DIAGRAM Procombi Exclusive - Installation and Servicing...

  • Page 31: Commissioning And Testing

    3G9927 As part of the commissioning process, the combustion of this appliance must be checked and the Benchmark Checklist completed. A flow chart to assist is provided on page 65. ATTENTION ! IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE...
  • Page 32 INSTALLATION 28 INITIAL LIGHTING Legend A. Mode Control Knob status burner B. DHW/Preheat Control C. CH Control D. Boiler Status reset preheat preheat mode E. Burner ‘on’ Indication F. Pre Heat on/off Indication G. CH Flow Isolating Valve H. Pressure Gauge J.
  • Page 33 INSTALLATION 29 GENERAL CHECKS Make the following checks for correct operation in: WATER CIRCULATION SYSTEM DOMESTIC HOT WATER (DHW) MODE 1. With the system COLD, check that the initial pressure is correct to the system design requirements. 1. Fully open all DHW taps in turn and ensure that water flows freely from them.

  • Page 34: Handing Over

    INSTALLATION 30 RESET PROCEDURE To reset the boiler, turn the mode control (A) to the reset position and immediately turn the knob back to the required setting. The boiler will repeat the ignition sequence if a heat demand is present. status burner reset...
  • Page 35 (and gas rate) have been verified, then contact Procombi. 11. Complete the service section in the Benchmark Commissioning Checklist. Procombi Exclusive - Installation and Servicing...
  • Page 36 SERVICING 33 BOILER UPPER & LOWER FRONT PANEL REMOVAL / REPLACEMENT REMOVAL REPLACEMENT 1. Lift the lower front panel access panel. 4. Hook the upper panel onto the top retaining clips. 2. Unscrew the two fixing screws, close the access panel to 5.

  • Page 37: Burner Removal And Cleaning

    SERVICING 35 BURNER REMOVAL AND CLEANING 1. Ensure the sump is fully drained 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 3. Lift the manifold to clear the bottom sealing gasket and remove manifold.

  • Page 38: Cleaning The Heat Exchanger

    SERVICING 37 CLEANING THE HEAT EXCHANGER note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Frame 48. 1. Remove ignition and flame detection electrodes. Refer to Frames 43 & 44. 2. It is advisable to replace the sump cover prior to the water flush process.
  • Page 39 SERVICING 39 REPLACEMENT OF COMPONENTS GENERAL After replacing ANY component check operation of the When replacing ANY component boiler, including gas soundness, gas rate and combustion test. 1. Isolate the electricity supply. IMPORTANT. 2. Turn off the gas supply. When work is complete, the front panels must be correctly refitted - ensuring that a good seal is made.
  • Page 40 SERVICING 41 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 39. 2. Disconnect the electrical leads from the fan. 3. Remove the clip from the gas valve to venturi pipe and ease the pipe upwards, rotate and ease down to remove. 4.
  • Page 41 SERVICING 43 IGNITION ELECTRODE REPLACEMENT 1. Refer to Frame 39. 2. Remove the burner. Refer to Frame 42. 3. Unplug the ignition lead from the electrode. Ignition Electrode 4. Remove the earth lead from the ignition electrode. 5. Remove the 2 screws holding the ignition electrode to the combustion chamber.
  • Page 42 SERVICING 45 SPARK GENERATOR REPLACEMENT 1. Refer to Frame 39. 2. Disconnect the leads from the spark generator 3. Remove the single M5 Screw securing the spark generator to the gas valve mounting bracket. 4. Lift the spark generator up and out of the bottom retaining moulding.
  • Page 43 SERVICING 47 DIVERTER VALVE ACTUATOR REPLACEMENT To remove the motor: 1. Refer to Frame 39. 2. Remove the condensate trap/siphon. Refer to Frame 48. 3. Disconnect the inline connector block. 4. Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator.
  • Page 44 SERVICING 49 MAIN PCB REPLACEMENT * Note. that production boiler PCB’s are factory pre-set to operate for boiler range and output, but when ordering Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specific boiler range and output.
  • Page 45 SERVICING 50 USER CONTROL PCB REPLACEMENT Note. Fit the earth strap provided with the PCB to your wrist and a suitable earth on the boiler chassis. 1. Refer to Frame 39. 2. Remove the main PCB, refer to Frame 49. 3.

  • Page 46: Draining The Boiler

    SERVICING 52 DRAINING THE BOILER CENTRAL HEATING CIRCUIT 1. Refer to Frame 39. 2. Close all the CH water isolating valves on the boiler inlet. 3. To drain the primary heat exchanger circuit: Open the drain valve and attach a length of hose to the CH drain point. 4.
  • Page 47 SERVICING 55 SAFETY RELIEF VALVE RENEWAL 1. Refer to Frame 39. 2. Drain the boiler. Refer to Frame 52. 3. Remove the return thermistor. Refer to frame 63. 4. Pull out and remove the clip (positioned behind the safety valve) retaining the safety valve.
  • Page 48 SERVICING 57 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT To remove the valve body assembly: 16. Twist and remove the DHW manifold. 17. Remove the two diverter valve body fixing screws and 1. Refer to Frame 39. withdraw the diverter valve body assembly. 2.

  • Page 49: Pump Head

    SERVICING 59 PUMP HEAD REPLACEMENT 1. Refer to Frame 39. 2. Drain the boiler. Refer to Frame 52. 3. Disconnect the two electrical leads from the pump. 4. Remove the 4 Allen screws retaining the pump head. 5. Remove the pump head. 6.
  • Page 50 SERVICING 61 DHW FILTER & DHW FLOW REGULATOR CLEANING/REPLACEMENT 1. Refer to Frame 39. 2. Drain the boiler. Refer to frame 52. 3. Turn the housing anti clockwise and pull forward to remove the cartridge. 4. Using a pair of pliers, pull out the plastic filter/flow regulator.

  • Page 51: Expansion Vessel

    SERVICING 64 HEAT ENGINE RENEWAL Refer also to Frame 5 - ‘Boiler Exploded View’ IMPORTANT - Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. 1. Refer to Frame 39. 13. Remove the condensate rubber pipe from the sump. 14.
  • Page 52 SERVICING 65 ExPANSION VESSEL RECHARGING & REPLACEMENT RECHARGING 1. Refer to Frame 39. Recharge Point 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order 5. Check operation of the boiler. Refer to Frames 28 &...

  • Page 53: Return Thermistor

    FAULT FINDING 67 ALTERNATING ‘L’ AND ‘1’ - FLOW TEMPERATURE OVERHEAT LOCKOUT Is the Boiler and CH System filled with water and all Fill and vent the system and open all isolation and radiator valves open? isolation valves, then reset boiler Is the Flow/Return Differential across the Boiler in Check that the Pump is rotating freely.

  • Page 54: Water Pressure Switch

    FAULT FINDING 69 ALTERNATING ‘L’ AND ‘5’ - 5 RESETS WITHIN 15 MINS Turn power off and on 70 ALTERNATING ‘L’ AND ‘6’ - FALSE FLAME LOCKOUT Check routing and integrity of internal boiler Reset the boiler, does Boiler Work OK? wiring is OK.

  • Page 55: Gas Valve

    FAULT FINDING 72 ALTERNATING ‘F’ AND ‘2’ - FLAME LOSS Does the boiler ignite for a short Is the Gas Pressure available at Check gas supply and time and then extinguish? the Boiler Inlet (18 mbar)? rectify fault Check the detection electrode and Check wiring from gas associated harness for: continuity, Is 215Vdc supply available at the...
  • Page 56 FAULT FINDING 74 ALTERNATING ‘F’ AND ‘4’ - FLOW THERMISTOR FAULT Check the resistance using a suitable multimeter Fit a new Thermistor connected across the thermistor’s terminal pins. At 25 expect 9,700 - 10,300 Ohms At 60 expect 2,400 - 2,600 Ohms At 85 expect...

  • Page 57: Fault Finding

    FAULT FINDING 76 ALTERNATING ‘F’ AND ‘7’ - LOW MAINS VOLTAGE Contact electricity provider 77 ALTERNATING ‘F’ AND ‘9’ - PCB FAULT Replace PCB - Ensure that the BCC (boiler chip card - small plastic part) is fitted to the PCB otherwise replace PCB. 78 ALTERNATING ‘C’...
  • Page 58 FAULT FINDING 80 ALTERNATING ‘F’ AND ‘7’ - LOW MAINS VOLTAGE Reset Boiler RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. 81 NO CH OPERATION BUT HW WORKS OK Move the mode knob to the Winter position Is the mode knob in the Winter position? Are the Timer and the Room Thermostat switched...
  • Page 59 FAULT FINDING 82 NO HW BUT CH ON Is hot and cold pipework crossed? Does the display show “d” when a tap is on? Adjust flow rates to achieve 35º Are the flow rates correct as per Frame 2. temp rise and check filter fitted in turbine is not blocked with debris.

  • Page 60: Spare Parts

    SPARE 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 Procombi. Failure to do so could affect safety or performance of this appliance.
  • Page 61 Procombi Exclusive - Installation and Servicing...
  • Page 63 To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed. The service details should be recorded on the Benchmark Service Interval Record and left with the householder.
  • Page 64 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Programmable room thermostat Optimum start control...

  • Page 65: Service Record

    SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % (Where Possible) (Where Possible) Signature Signature SERVICE 03 SERVICE 04...
  • Page 66 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING. If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) sepa- rate guidance is provided with the conversion kit supplied and this must be followed.
  • Page 67 Boiler is Operating Satisfactorily No further actions required. Ensure test points are capped, boiler case is correctly replaced and all other commissioning procedures are completed. Complete Benchmark Checklist, recording CO and combustion ratio readings as required. Procombi Exclusive - Installation and Servicing...
  • Page 68 Ideal Boilers provides after-sales assistance and Technical advice for Procombi Exclusive boilers Procombi Helpline: 01482 498700 Ideal Boilers P.O. Box 103, National Avenue, Kingston Upon Hull, HU5 4JN We reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected.

This manual is also suitable for:

Procombi exclusive 30Procombi exclusive 35

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