2 isar - - combi boilers, system boilers, thermostats...

2 isar - Installation and Servicing

GENERAL

Gas supply 2H - G20 - 20mbar

Gas Supply Connection Rc 1/2 (1/2” BSP female)

Injector Size Stereomatic 5.6mm dia.

Inlet Connection Domestic Hot Water 15mm copper compression

Outlet Connection Domestic Hot Water 15mm copper compression

Flow Connection Central Heating 22mm copper compression

Return Connection Central Heating 22mm copper compression

Flue Terminal Diameter mm (in) 100 (4)

Average Flue Temp/Mass Flow Rate (DHW) 74oC / 20.3 g/s

Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.65 (38.5)

Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) 10.0 (145)

Minimum Domestic Hot Water Inlet Pressure bar (lb/in2) 0.5 (7)

Electrical Supply / Power Consumption 230 V ~ 50 Hz. / 148 W

Fuse Rating External : 3A Internal : T3.15A L250 V

Water content Central Heating litre (gal) 2.0 (0.44)

Domestic Hot Water 0.5 (0.11)

Packaged Weight kg (lb) 50 (110)

Maximum Installation Weight kg (lb) 43 ( 95)

Boiler Casing Size Height mm (in) 687 (27)

Width mm (in) 390 (15 3/8)

Depth mm (in) 278 (11)

Table 1 - General Data

Note. Gas consumption is calculated using acalorific value of 38.7 MJ/m3 (1038 Btu/ft3) grossor 34.9 MJ/m3 (935 Btu/ft3) nett

To obtain the gas consumption at a differentcalorific value:

a. For l/s - divide the gross heat input (kW) bythe gross C.V. of the gas (MJ/m3)

b. For ft3/h - divide the gross heat input (Btu/h)by the gross C.V. of the gas (Btu/ft3)

Key to symbols

GB = United Kingdom IE = Ireland (Countries of destination)

PMS = Maximum operating pressure of water

C13 C33 C53 = A room sealed appliance designed for connection via ducts to ahorizontal or vertical terminal, which admits fresh air to the burnerand discharges the products of combustion to the outside throughorifices which, in this case, are concentric. The fan is up streamof the combustion chamber.

I2H = An appliance designed for use on 2nd Family gas, Group H only.

* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from whichit has been calculated have been certified by a notified body.

CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning ofthis appliance care should be taken when handling edges of sheet steel components

Table 2 - Performance Data - Central Heating

Maximum DHW Input :

Nett CV kW 30.2

(Btu/h) (103 000)

Gross CV kW 33.5

(Btu/h) (114 400)

Gas Consumption l/s 0.87

(ft3/h) (110)

Maximum DHW Output kW 29.3

(Btu/h) (100 000)

DHW Flow Rate at 35°C temp. rise. l/min 12.0

(gpm) 2.6

DHW Specific Rate l/min 13.9

(gpm) 3.1

Table 3 - Performance Data - Domestic Hot Water

Boiler Input : Max. Min.

Boiler Input ‘Q’ Nett CV kW 24.4 9.1

(Btu/h) (83 300) (31 000)

Gross CV kW 27.1 10.1

(Btu/h) (92 500) (34 400)

Gas Consumption l/s 0.70 0.26

(ft3/h) (89.1) (33.2)

Boiler Output :

Non Condensing kW 23.4 8.8

70oC Mean Water temp. (Btu/h) (80 000) (30 000)

Condensing kW 25.1 9.6

40oC Mean Water temp. (Btu/h) (85 700) (32 800)

Seasonal efficiency* (SEDBUK) Band A [90.1]%

NOx Classification Class 4

3isar - Installation and Servicing

GENERAL

CONTENTSAir Supply ....................................................................... 7

Boiler Clearances ......................................................... 6

Boiler Exploded Diagram ............................................ 11

Boiler Interlocks ............................................................ 8

Condensate Drain ................................................... 8, 22

Electrical Connections ............................................... 23

Electrical Supply ........................................................... 8

Extension Ducts - Fitting ............................................. 17

Fault Finding ........................................................... 48-52

Flow Wiring Diagram .................................................. 26

Flue Fitting .................................................................... 16

Flue Installation ............................................................. 7

Gas Safety Regulations ................................................ 5

Gas Supply ..................................................................... 7

Installation ............................................................. 11- 29

Mandatory Requirements ..........................................5-8

Pump .......................................................................... 45

Servicing ................................................................ 30-47

Short List of Parts ....................................................... 53

Thermostatic Radiator valves ..................................... 8

Water and Systems ...................................................... 7

Water Connections ............................................... 20-21

Water Treatment ......................................................... 10

Wiring Diagrams ................................................... 23-26

isar m30100Natural Gas only

G.C. Appliance No. 47 348 15

PI No. 0063 BL 9811

Destination Country: GB, IE

NOTE TO THE INSTALLER: LEAVE THESEINSTRUCTIONS ADJACENT TO THE GAS METER.ALSO COMPLETE THE BENCHMARK LOG BOOK

AND GIVE THIS TO THE CUSTOMER.

BENCHMARK LOG BOOK DETAILSBoiler Page

Make and model .......................................................3Appliance serial no. on data badge ....................... 11SEDBUK No. % .........................................................2

ControlsTime and temperature control to heating ............. 24Time and temperature control to hot water .......... 24Heating zone valves ..............................................n/aTRV's .........................................................................8Auto bypass ..............................................................8Boiler interlock ..........................................................8

For all boilersFlushing to BS.7593 .............................................. 10Inhibitor .................................................................. 10

Central heating modeHeat input ................................................ to be calculated

For assistance see Technical Helpline on the back page

PageBurner operating pressure ...... measure and recordCentral heating flow temp. ...... measure and recordCentral heating return temp. ... measure and record

For combination boilers onlyScale reducer ......................................................... 10

Hot water modeHeat input .......................................... to be calculatedMax. operating burner pressure ..... measure & recordMax. operating water pressure .... measure & recordCold water inlet temp ................... measure & recordHot water outlet temp. .................. measure & recordWater flow rate at max. setting ..... measure & record

For condensing boilers onlyCondensate drain .................................................. 22

For all boilers: complete, sign & hand over to customer

For GB, to comply with Building Regulations Part L1 (Part J in Scotland) the boiler should be fitted in accordance with themanufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can bedemonstrated by completing and signing the Benchmark log book.


GENERAL

1 BOILER WATER CIRCUIT DIAGRAMSINTRODUCTIONThe isar m30100 is a wall mounted, full sequence, automaticspark ignition, low water content, fanned flue, high efficiency,condensing, combination gas boiler.

Note. Due to the high efficiency of the boiler a plume of watervapour will form at the terminal during operation.

Central heating (CH) output is fully modulating with a range of8.8 to 23.4kW (30,000 to 80,000 Btu/h)

Instantaneous domestic hot water (DHW) output is also fullymodulating with a maximum of 29.3kW (100,000 Btu/h)

The boiler is supplied fully assembled with DHW plate heatexchanger, diverter valve, circulating pump, pressure gauge,safety valve and CH expansion vessel.

Variable CH and DHW temperature controls are fitted on theuser control and the boiler features a DHW preheat facility.

The boiler casing is of white painted mild steel with the usercontrols capable of being mounted remotely from the boiler if theoption is required.

The boiler temperature controls are visible at the bottom RHS ofthe front panel.

The heat exchanger is of cast aluminium.

The boiler is suitable for connection to fully pumped, sealedwater systems ONLY. Adequate arrangements for completelydraining the system by provision of drain cocks MUST beprovided in the installation pipework.

Pipework from the boiler is routed downwards as standard, butmay be routed upwards behind the boiler using the stand-offframe (supplied in a separate kit).

OPERATIONWith no demand for CH, the boiler fires only when DHW isdrawn off, or periodically for a few seconds without any DHWdraw-off, in order to maintain the DHW calorifier in a heatedcondition.

When there is a demand for CH, the heating system is suppliedat the selected temperature of between 30 oC and 82oC, untilDHW is drawn off. The full output from the boiler is thendirected via the diverter valve to the plate heat exchanger tosupply a maximum DHW draw-off of 12 l/min at 35 oCtemperature rise.

At low DHW draw-off rate the maximum temperature is limited to65 oC by the modulating gas control.

Refer also to Frame 1 - 'Boiler Water Circuit Diagrams'

The boiler features a comprehensive diagnostic system whichgives detailed information on the boiler status when operating,and performance of key components to aid commissioning andfault finding.

Central Heating Circuit

Expansion

vessel

Automatic

air vent

Gas valve

Plate heat

exchanger

Pump

Safety

relief valve

Condensate

'S' trap

Diverter

valve

Water

pressure

gauge

Sump

Fan

Burner

CH

Flo

w

Ga

sC

on

de

nsa

te d

rain

Dis

ch

arg

e p

ipe

CH

Re

turn

Domestic Hot Water Circuit

Expansion

vessel

Automatic

air vent

Heat

exchanger

Gas valve

Pump

Safety

relief valve

Condensate

'S' trap

Diverter

valve

Water

pressure

gauge

Sump

Fan

Burner

DH

W H

ot o

ut

Ga

sC

on

de

nsa

te d

rain

Dis

ch

arg

e p

ipe

Ecl 2

38

8

DH

W C

old

in

Plate heat

exchanger

Heat

exchanger


GENERAL

SAFETYCurrent Gas Safety (installation and use) regulations or rulesin force:

The appliance is suitable only for installation in GB and IE andshould be installed in accordance with the rules in force.

In GB, the installation must be carried out by a CORGIRegistered Installer. It must be carried out in accordance withthe relevant requirements of the:• Gas Safety (Installation and Use) Regulations• The appropriate Building Regulations either The Building

Regulations, The Building Regulations (Scotland), BuildingRegulations (northern Ireland).

• The Water Fittings Regulations or Water byelaws inScotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should bemade to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a CompetentPerson and installed in accordance with the current edition ofI.S.813 "Domestic Gas Installations", the current BuildingRegulations and reference should be made to the current ETCIrules for electrical installation.

Detailed recommendations are contained in the following BritishStandard Codes of Practice:

BS. 5440:1 Flues (for gas appliances of rated input notexceeding 70 kW).

BS. 5440:2 Ventilation (for gas appliances of rated input notexceeding 70 kW).

BS. 5449 Forced circulation hot water systems.

BS. 5546 Installation of gas hot water supplies for domesticpurposes (2nd Family Gases)

BS. 6798 Installation of gas fired hot water boilers of ratedinput not exceeding 70 kW.

BS. 6891 Low pressure installation pipes.

Health & Safety Document No. 635.

The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be taken, in any way, asoverriding statutory obligations.

IMPORTANT. These appliances are CE certificated for safetyand performance. It is, therefore, important that no externalcontrol devices, e.g. flue dampers, economisers etc., are

directly connected to these appliances unless covered by theseInstallation and Servicing Instructions or as otherwiserecommended by Caradon Ideal Limited in writing. If in doubtplease enquire.

Any direct connection of a control device not approved byCaradon Ideal Limited could invalidate the certification and thenormal appliance warranty. It could also infringe the Gas SafetyRegulations and the above regulations.

SAFE HANDLING OF SUBSTANCESCare should be taken when handling the boiler insulationpanels, which can cause irritation to the skin. No asbestos,mercury or CFCs are included in any part of the boiler or itsmanufacture.

LOCATION OF BOILERThe boiler must be installed on a flat and vertical wall, capableof adequately supporting the weight of the boiler and anyancillary equipment.

The boiler may be fitted on a combustible wall and insulationbetween the wall and the boiler is not necessary, unlessrequired by the local authority.

For electrical safety reasons there must be no access availablefrom the back of the boiler.

The boiler must not be fitted outside.

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it shouldbe fitted in accordance with the Institute of Gas Engineeringdocument IGE/UP/7:1998.

Bathroom Installations

This appliance is rated IP20.

The boiler may be installed in any room or internal space,although particular attention is drawn to the requirements of thecurrent IEE (BS.7671) Wiring Regulations and, in Scotland, theelectrical provisions of the building regulations applicable inScotland, with respect to the installation of the boiler in a roomor internal space containing a bath or shower. For Irelandreference should be made to the current ETCI rules forelectrical installations and I.S.813:2002.

If the appliance is to be installed in a room containing a bath orshower then, providing water jets are not going to be used forcleaning purposes (as in communal baths/showers), theappliance can be installed in Zone 3, as detailed in BS.7671.

Compartment Installations

A compartment used to enclose the boiler should be designedand constructed specially for this purpose.

An existing cupboard or compartment may be used, providedthat it is modified for the purpose.

In both cases, details of essential features of cupboard /compartment design, including airing cupboard installation,are to conform to the following:

! BS 6798 (No cupboard ventilation is required - see ‘AirSupply’ for details).

! The position selected for installation MUST allow adequatespace for servicing in front of the boiler.

! For the minimum clearances required for safety andsubsequent service, see the wall mounting template andFrame 2. In addition, sufficient space may be required toallow lifting access to the wall mounting plate.

OPTIONAL EXTRA KITS! Flue Extension Ducts. (1000mm long up to 6m).

! Flue Finishing Kit.

! 90o Elbow Kit (maximum 4 elbows per installation).

! 45o Elbow Kit (maximum 4 elbows per installation).

! Roof Flue Kit (to a maximum of 8m).

! Powered Vertical Flue Kit (to a maximum primary fluelength of 8m + a maximum secondary flue length of 6m)

! Twin Fluing Kit (up to a maximum of 46m combined totalflue and airducts)

! Remote User Controls Kit

! Boiler Stand-off Kit

! Siphon Kit

! Valve Cover Kit


GENERAL

Ecl

606

4

CH FlowDHW Outlet

Condensate Drain

Gas Control CH Return

Centreline of boiler

6343 49 49 57 66

DHW Inlet

390 (15 3/8")

Flueterminal

278 (11")5 (1/4")

100 (4")*

400 (15 3/4")

5 (1/4")

165(6 1/2")

Inset: Water Connections and Gas Connection

See inset

CLEARANCES BOILER DIMENSIONS

687(27")

2 BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in)

The boiler connections are made on the boiler piping frame.Refer to Frames 24-26.

The following minimum clearances must be maintained foroperation and servicing.

Additional space will be required for installation, dependingupon site conditions.

Side and Rear Fluea Provided that the flue hole is cut accurately, e.g. with a core

drill, the flue can be installed from inside the building where

Front clearanceThe minimum front clearance when built in to a cupboard is5mm (1/4") from the cupboard door but 450mm (17 3/4")overall clearance is still required, with the cupboard door open,to allow for servicing.

* Bottom clearanceBottom clearance after installation can be reduced to 5mm.However, 100mm must be available for servicing.

wall thicknesses do not exceed 600mm (24"). Where thespace into which the boiler is going to be installed is lessthan the length of flue required the flue must be fitted fromthe outside.

Installation from inside ONLYb. If a core boring tool is to be used inside the building the

space in which the boiler is to be installed must be at leastwide enough to accommodate the tool.

REAR FLUE ONLYMIN. Top clearance required = 145 mm (5 3/4")

SIDE FLUE ONLY

Horizontal length of flue Top clearancefrom centre line of boiler required (MIN.)

to outside wall Dim. A

0.5 m 160 mm (6 5/16")

1.0 m 170 mm (6 11/16)

1.5 m 185 mm (7 1/4")

2.0 m 200 mm ( 7 7/8")

2.5 m 210 mm (8 1/4")

3.0 m 225 mm (8 7/8")

3.5 m 265 mm (9 1/4")

3.5 m 250 mm (10 5/8")

4.5 m 260 mm (10 1/4")

5.0 m 275 mm (10 13/16")

5.5 m 290 mm (11 3/8")

6.0 m 300 mm (11 13/16")


GENERAL

The following notes are intended for general guidance:

1. The boiler MUST be installed so that the terminal is exposedto external air.

2. It is important that the position of the terminal allows the freepassage of air across it at all times.

3. Minimum acceptable spacing from the terminal to obstructionsand ventilation openings are specified inTable 4.

4. Where the lowest part of the terminal is fitted less than 2m(6'6") above a balcony, above ground or above a flat roof towhich people have access then the terminal MUST beprotected by a purpose designed guard.

Terminal guards are available from boiler suppliers. (Ask forTFC flue guard model no. K6 - round, plastic coated). In caseof difficulty contact:

Grasslin (UK) Ltd., Tower House, Vale Rise, Tonbridge,Kent TN9 1TB.Tel: +44 (0) 1732 359 888. Fax: +44 (0) 1732 354 445www.tfc-group.co.uk

Ensure that the guard is fitted centrally.

5. The flue assembly shall be so placed or shielded as toprevent ignition or damage to any part of any building.

6. The air inlet/products outlet duct and the terminal of the boilerMUST NOT be closer than 25mm (1") to combustible material.Detailed recommendations on the protection of combustiblematerial are given in BS. 5440-1:2000. In IE refer toI.S.813:2002.

IMPORTANT. It is absolutely essential to ensure, in practice,that products of combustion discharging from the terminalcannot re-enter the building or any other adjacent buildingthrough ventilators, windows, doors, other sources of natural airinfiltration, or forced ventilation / air conditioning.

If this should occur the appliance MUST be turned OFF, labelledas 'unsafe' until corrective action can be taken.

TERMINALThe terminal assembly can be adapted to accommodate variouswall thicknesses. Refer to Frame 12 .

AIR SUPPLYIt is NOT necessary to have a purpose-provided air vent in theroom or internal space in which the boiler is installed. Neither isit necessary to ventilate a cupboard or compartment in which theboiler is installed, due to the low surface temperatures of theboiler casing during operation; therefore the requirements of BS6798, Clause 12, and BS 5440:2 may be disregarded. In IE therequirements of I.S.813:2002 may be disregarded.

WATER CIRCULATION SYSTEM

IMPORTANT.A minimum length of 1 metre of copper pipe MUST be fitted toboth flow and return connections from the boiler beforeconnection to any plastic piping.

The central heating system should be in accordance withBS.6798 and, in addition, for smallbore and microboresystems, BS.5449.

WATER TREATMENT - see Frame 6

GAS SUPPLYThe local gas supplier should be consulted, at the installationplanning stage, in order to establish the availability of anadequate supply of gas. An existing service pipe must NOT beused without prior consultation with the local gas supplier.

The boiler MUST be installed on a gas supply with a governedmeter only.

A gas meter can only be connected by the local gas supplier ora CORGI registered engineer. In IE by a Competent Person.

An existing meter should be checked, preferably by the gassupplier, to ensure that the meter is adequate to deal with therate of gas supply required.

N.B. The principle of the 1:1 gas valve ensures that the isarm30100 is able to deliver its full output at inlet pressureswell below those required by BS. 6891.

IMPORTANT.Installation pipes MUST be fitted in accordance with BS. 6891.In IE refer to I.S.813:2002. Pipework from the meter to theboiler MUST be of an adequate size, i.e. no longer than 20mand not less than 15mm O.D.

The complete installation MUST be tested for gas soundnessand purged as described in the above code.

FLUE INSTALLATIONPluming will occur at the terminal so terminal positions wherethis could cause a nuisance should be avoided.

The flue must be installed in accordance with therecommendations of BS. 5440-1: 2000. In IE refer toI.S.813:2002.

Table 4 - Balanced flue terminal position

Terminal Position Minimum Spacing

1. Directly below or alongside anopening window, air brick or otherventilation opening 300 mm (12")

2. Below guttering, drain pipes or soilpipes 75 mm ( 3")

3. Below eaves 200 mm ( 8")

4. Below balconies or a car port roof 200 mm ( 8")

5. From vertical drain pipes or soil pipes 150 mm ( 6")

6. From an internal or external corner orto a boundary alongside the terminal 300 mm ( 12")

7. Above adjacent ground, roof orbalcony level 300 mm (12")

8. From a surface or a boundaryfacing the terminal 600 mm (24")

9. From a terminal facing a terminal 1200 mm (48")

10. From an opening in a car port(e.g. door or window) into dwelling 1200 mm (48")

11. Vertically from a terminal on thesame wall 1500 mm (60")

12. Horizontally from a terminal on the wall 300 mm (12")


GENERAL

Notes

a. The method of filling, refilling, topping up or flushingsealed primary hot water circuits from the mains via atemporary hose connection is only allowed if acceptableto the local water authority.

b. Antifreeze fluid, corrosion and scale inhibitor fluidssuitable for use with boilers having aluminium heatexchangers may be used in the central heating system.

Advice should be sought from a local water treatmentcompany.

BOILER CONTROL INTERLOCKSCaradon Ideal Limited recommend that heating systemsutilising full thermostatic radiator valve control of temperaturein individual rooms should also be fitted with a roomthermostat controlling the temperature in a space served byradiators not fitted with such a valve as stated in BS. 5449.

When thermostatic radiator valves are used, the spaceheating temperature control over a living area having aheating requirement of at least 0.9kW (3000Btu/h) of theboiler heat output should be achieved using a roomthermostat whilst other rooms are individually controlled bythermostatic radiator valves. A higher proportion of TRVs maybe used, provided that a bypass between the boiler flow andreturn is fitted, to ensure adequate flow when all TRVs areclosed.

For further information refer to the 'Good Practice Guide 143',a publication of the Energy Efficiency Office, available fromthe Building Research Establishment, Garston, Watford WD27JR. Tel: +44 (0) 1923 664258.

ELECTRICAL SUPPLYWARNING. The appliance MUST be efficiently earthed.

Wiring external to the appliance MUST be in accordance withthe current I.E.E. (BS.7671) Wiring Regulations and any localregualtions which apply. For Ireland reference should be madeto the current ETCI rules for electrical installations.

The point of connection to the mains should be readilyaccessible and adjacent to the boiler.

CONDENSATE DRAIN Refer to Frames 28 & 47.

A condensate drain is provided on the boiler. This drain must beconnected to a drainage point on site. All pipework and fittings inthe condensate drainage system MUST be made of plastic - noother materials may be used.

IMPORTANT.Any external runs must be insulated

The drain outlet on the boiler is standard 21.5mm (3/4”) overflowpipe.

3 SYSTEM REQUIREMENTS - Central Heating

Safety valve setting bar 3.0

Vessel charge pressure bar 0.5 to 0.75

System pre-charge pressure bar None 1.0

System volume Expansion vessel(litres) volume (litres)

25 1.6 1.8

50 3.1 3.7

75 4.7 5.5

100 6.3 7.4

125 7.8 9.2

150 9.4 11.0

175 10.9 12.9

190 11.9 14.0

200 12.5 14.7

250 15.6 18.4

300 18.8 22.1

For other system volumesmultiply by the factor across 0.063 0.074


GENERAL

4 SYSTEM REQUIREMENTS - CH (continued) and Hot Water

General

1. The installation must comply with all relevant national andlocal regulations.

2. The installation should be designed to work with flowtemperatures of up to 82

oC.

3. All components of the system must be suitable for a workingpressure of 3 bar and temperature of 110

oC. Extra care should

be taken in making all connections so that the risk of leakageis minimised.

The following components are incorporated within theappliance:

a. Circulating pump.

b. Safety valve, with a non-adjustable preset lift pressure of3 bar.

c. Pressure gauge, covering a range of 0 to 6 bar.

d. An 8-litre expansion vessel, with an initial charge pressureof 0.75 bar.

4. 'Make-up' Water. Provision must be made for replacing waterloss from the system, either :

a. From a manually filled 'make-up' vessel with a readilyvisible water level. The vessel should be mounted atleast 150mm above the highest point of the system andbe connected through a non-return valve to the system,fitted at least 150mm below the 'make-up' vessel on thereturn side of the radiators.

or

b. Where access to a 'make-up' vessel would be difficult,by pre-pressurisation of the system.

The maximum cold water capacity of the system shouldnot exceed 143 litres, if not pressurized. However, ifthe system is to be pressurized, the efficiency of theexpansion vessel will be reduced and a larger vessel(or smaller system volume) may be necessary. If thecapacity of the vessel is not considered sufficient forthis, or for any other reason, an additional vesselMUST be installed on the return to the boiler.

Guidance on vessel sizing is given in Frame 3.

5. Filling. The system may be filled by the following method:

a. 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 pressurereducing valve must be used to facilitate fil l ing.When installing the filling device it must be connected asshown below, to fully comply with the water regulations.This may involve the fitting of an additional WRASapproved isolator valve to the mains supply.

i. Thoroughly flush out the whole system withcold water.

ii. Fill and vent the system until the pressuregauge registers 1.5 bar and examine for leaks.

iii. Check the operation of the safety valve byraising the water pressure until the valve lifts.This should occur within 0.3 bar of the preset liftpressure.

iv. Release water from the system until theminimum system design pressure is reached;1.0 bar if the system is to be pre-pressurised.

Water Flow Rate and Pressure Loss

Max CH Output kW 23.4

(Btu/h) (80 000)

Water flow rate l/sec 0.37

(gal/min) 4.8

Temperature Differential oC 15

(oF) (27)

Head available for m.w.g. 2.3

system pump. (ft.w.g.) 7.5

DOMESTIC HOT WATER1. The domestic hot water service must be in accordance

with BS 5546 and BS 6700.

2. Refer to Table 1 for minimum and maximum workingpressures.

3. The boilers are suitable for connection to most types ofwashing machine and dishwasher appliances.

4. When connecting to suitable showers, ensure that:

a. The cold inlet to the boiler is fitted with an approvedanti-vacuum or syphon non-return valve.

b. Hot and cold water supplies to the shower are of equalpressure.

5. Hard Water AreasWhere the water hardness exceeds 200mg/litre, it isrecommended that a proprietary scale reducing device isfitted into the boiler cold supply within the requirements ofthe local water company.

IMPORTANTProvision MUST be made to accommodate the expansion ofDHW contained within the appliance, if a non-return valve isfitted to the DHW inlet.

CH Return

Ecl 6053

Hose unions

Mains

water supply

Temporary hose

(disconnect after filling)

Additional

stop valve

Double check valve

assembly

(note direction of flow)

10

INSTALLATION

isar - Installation and Servicing

The boiler does not normally need a bypass but at least someradiators on the heating circuit, of load of at least 10% of theminimum boiler output, must be provided with twin lockshieldvalves so that this minimum heating load is always available.See note regarding thermostatic radiator valves on page 8.

Note.Systems incorporating zone valves which couldcompletely cut off the flow through the system must alsoinclude a bypass.BALANCING1. Set the programmer to ON.

Close the manual or thermostatic valves on all radiators,

5 SYSTEM BALANCINGleaving the twin lockshield valves (on the radiatorsreferred to above) in the OPEN position.Turn up the room thermostat and adjust theselockshield valves to give boiler flow and returntemperatures not more than 20 oC apart.These valves should now be left as set.

2. Open all manual or thermostatic radiator valves andadjust the lockshield valves on the remaining radiators,to give around 15 oC temperature drop at each radiator.

3. Adjust the room thermostat and programmer toNORMAL settings.

6 WATER TREATMENT

Central Heating

These boilers incorporate an ALUMINIUM heat exchanger.IMPORTANT. The application of any other treatment to this product may render the guarantee of Caradon Ideal LimitedINVALID.Caradon Ideal Limited recommend Water Treatment in accordance with the Benchmark Guidance Notes on WaterTreatment in Central Heating Systems.

Caradon Ideal Limited recommend the use of Fernox Copal or MB1, GE Betz Sentinel X100 or Salamander CorrosionGuard inhibitors and associated water treatment products, which must be used in accordance with the manufacturersinstructions.

Notes.1. It is most important that the correct concentration of the water treatment products is maintained in accordance with the

manufacturers' instructions.

2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing.BS7593:1992 details the steps necessary to clean a domestic heating system.

3. In hard water areas, treatment to prevent limescale may be necessary - however the use of artificially softened water isNOT permitted.

4. Under no circumstances should the boiler be fired before the system has been thoroughly flushed.

Domestic Hot Water

In hard water areas where main water can exceed 200ppm Total Hardness (as defined by BS 7593:1993 Table 2) a scalereducing device should be fitted into the water boiler cold supply within the requirements of the local water company. Theuse of artificially softened water, however, is NOT permitted.

Caradon Ideal Limited recommend the use of Fernox Quantomat, GE Betz Sentinel Combiguard and Calmag CalPhos Iscale reducing devices, which must be used in accordance with the manufacturers instructions.

For further information contact:

Fernox Manufacturing Co. Ltd, Cookson Electronics, Forsyth Road, Sheerwater, Woking, Surrey. GU21 5RZ. Tel. +44 (0) 1799 521133orG E Betz Ltd, Sentinel Division, Foundry Lane, Widnes, Cheshire, WA8 8UD. Tel. +44 (0) 151 424 5351orSalamander Engineering Ltd, Unit 24, Reddicap Trading Estate, Sutton Coldfield, West Midlands B75 7BU. Tel. +44 (0) 121 378 0952orCalmag Ltd, Unit 4, Crown Works, Bradford Road, Sandbeds, Keighley, West Yorkshire, BD20 5LN. Tel. +44 (0) 1535 210 320

14. Injector and housing.15. Venturi assembly.16. Fan assembly.17. Automatic air vent.18. Gas service cock.19. Gas control valve.20. Fan bracket.21. Orifice plate.22. Flue thermistor23. Control therm. (flow/return)24. Overheat thermostat.25. Ignition electrode.

1. Front casing panel.2. Boiler sealing panel.3. Sump cover.4. Bottom casing panel.5. Flue sensing nipple.6. Return pipe.8. Flue manifold.9. Flue manifold fixing.10. Interpanel.11. Burner.12. Comb. chamber ins.13. Heat exchanger.

7 BOILER ASSEMBLY - Exploded View Legend

26. Flame detection electrode.32. Condensate 'S' trap.35. User control.36. Primary controls (PCB).39. Mains switch.44. Piping frame.51. Mains connector.53. Turret gasket.57. CH stub pipe.59. Flow restrictor.60. DHW inlet/outlet pipe.61. Pressure relief valve.

62. Expansion vessel.63. Expansion vessel pipe.64. Pressure gauge.65. DHW thermistor.66. Diverter valve head.67. Diverter valve.68. Diverter valve manifold.69. Pump.70. Pump manifold.71. DHW plate heat exchanger.75. Control box clamp.

11

INSTALLATION


8 BOILER ASSEMBLY - Exploded View

8

5 4453

14

13

15

62

5918

64

4

2

63

1

69

75

3536

66

70

32

23

67

23

68

2471

17

26

25

3

1957

60 6

11

12

39 Ecl

606

5

2116

61

5760

51 65

10

9

20

22

Data badge

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INSTALLATION


9 UNPACKINGThe boiler is supplied fully assembled in one Pack A,together with a standard flue assembly for lengths up to650mm, rear or side flue outlet, in Pack B.

Unpack and check the contents.

Hardware Pack & Fittings

! 50mm x No.14 wood screws - 4 off.

! Wall plugs (TP2B ) - 4 off.

! Water treatment warning label.

! Turret clamp.

! M5 x 10 pozi Hex screw.

! ‘S’ Trap hose.

Pack A Contents

! Hardware Pack and fittings.

! These Installation & Servicing Instructions.

! The User's Instructions.

! The user Control (display unit).

! Benchmark log book.

! 2 year guarantee form.

Pack B Contents

Flue turret.

Flue terminal.

Flue support cutting aid.

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4

Flue terminalFlue turret

! Safety drain pipe nut and olive.

! CH Flow isolating valve c/w pressure gauge.

! 22mm fibre washers - 3 off.

! 15mm fibre washers - 3 off.

! Mains connector.

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INSTALLATION


1. Ensure the boiler is stood upright on a sound flat surface.

2. Carefully remove the strapping.

3. Fold back the top flaps to gain access to:

! Wall mounting plate.

! Instructions.

! Hardware pack & fittings.

! User control.

4. Remove the instructions and read thoroughly beforeunpacking the product.

5. When ready for installation lift off the cardboard carton.

10 PACKAGING REMOVAL

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6

11 BOTTOM PANEL AND FRONT PANEL REMOVAL

1. Remove the 2 screws from the underside ofthe boiler.

2. Pull the panel forward at the bottom and liftto disengage it from the top lugs.

3. Remove the screws from the underside ofthe boiler.

4. Pull the RHS of the panel down, slide it tothe right and withdraw.

Ecl 2425

Bottom panel

Front panel

Retaining clip

1

3

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INSTALLATION


Ecl6066

160mm160 + S = 193mm

FLUE KITS

Pack B - supplied as standard

Pack D - optional extension kit for side flue or rear flue outlet.

Refer to 'Flue Extension Ducts'

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

12 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED

Notes.

1. The flue duct MUST be inclined at 1.5 degreesto the horizontal to allow condensate to drainback into the boiler and out through thecondensate drain.

2. If the boiler is to be installed with upward pipingrouted behind the boiler then the optionalstand-off kit should be used. Care must betaken when cutting the ducts and marking thewall to suit this condition.

Total Flue length dimension Flue

Rear flue Side flue Extra packsdim. X+160 dim. L+195 required

Up to 650 mm Up to 650 mm none

Up to 1600 mm Up to 1600 mm Pack D - 1 off






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4 5

Note.The template shows the positions of the fixing holes andthe flue hole centres for standard installation and for usingthe stand-off kit. Care MUST be taken to ensue the correctholes are drilled.

1. Separate the templates.

2. Tape template A into the selected position.

3. Ensure squareness by hanging a plumbline as shown. Iffitting a side flue extend the flue centre line onto the sidewall and tape template B into the selected position.

4. Mark onto the wall the following:

a The piping frame screw positions (choose one fromeach group).

b. The position of the flue duct hole (see diagram belowand template).

Note. Mark the centre of the hole as well as the circumference

5. Remove the template from the wall.

14 WALL MOUNTING TEMPLATE

13 FLUE ASSEMBLY - Exploded View

An optional flue duct extension kit is required forwall thicknesses greater than :

Side 455mm (18").

Rear 490mm (19 1/4").

Rear flue arrangement shown

Ecl 2360

V

AA BBB

Extended centre line

305

See Note

Note. If wall thickness is greater than 305mm then dimension H must be

reduced by the same amount and the offset may be adjusted accordingly.

18 31 44 57 70 83 96 109 122 135 148

See wall mounting template

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9

0.51.0

1.52.0

2.53.0

3 .5

4.04.5

5.05.5

V

Distance in metres from side of the boiler to the side wall

LEGEND

1. Duct assembly.

2. Flue turret.

3. Turret gasket.

4. M5 x 10 pozi screw.

5. Turret clamp.

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INSTALLATION


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15 PREPARING THE WALL

IMPORTANT.

Ensure that, during the cutting operation, masonryfalling outside of the building does not cause damageor personal injury.

1. Cut the flue hole (preferably with a 5" core boringtool), ensuring that the hole is square to the wall.Both wall faces immediately around the cut holeshould be flat.

2. Drill 4 holes with a 7mm (1/4") masonry drill andinsert the plastic plugs, provided, for the pipingframe.

3. Locate 4 No.10 x 2" screws in the piping frame(one at each side, in any of the 3 holes providedat each side) and screw home.

16 CUTTING THE FLUE - REAR Wall thicknesses of 114 to 490mm

Notes.

a. If using the extension ducts go to Frame 18.

b. If the stand-off frame is used it is essential add 33mm to'X' the measured wall thickness when marking the flue(this will allow for the fitted frame).

1. Measure and note wall thickness X. Refer to Frame 12.

2. Add 90mm (3 1/2") to dimension X and, measuring fromthe ring, cut the outer tube only.

3. To ensure the tube is cut square, mark the flue all the wayround.

4. Cut the inner tube to a length 20mm (3/4") longer to aidengagement, using the cardboard support.

17 CUTTING THE FLUE - SIDE Wall thicknesses of 114 to 455mm

Note. If using the extension ducts go to Frame 18.

1. Measure and note side flue length L. Refer toFrame 12.

2. Add 125mm (5") to dimension L and, measuringfrom the ring, cut the outer tube only.

3. To ensure the tube is cut square, mark the flue allthe way around.

4. Cut the inner tube to a length 20mm (3/4") longer toaid engagement, using the cardboard support.

2011

X

Sectionthrough wall

Note. Check all of the holepositions before drilling.

Side flue only5" diameter hole

Rear flue only5" diameter hole

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INSTALLATION


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1. A maximum of 6 extension ducts (one suitablycut) plus the standard flue duct may be usedtogether.

2. Flue extensions of greater length than 1m (39")should be supported with the bracket provided,suitably adjusted. Refer to Frames 18 and 23.

19 FLUE EXTENSION DUCTS - continued

1. Remove the cardboard support aid from the flue and placesafely to one side.

2. Fit the inner flue extension duct onto the inner flue duct.

3. Fit the outer flue extension duct onto the outer air duct.

4. Using the clamp provided clamp the flue lengths together.

5. Repeat steps 1-4 if a second flue extension is required.

6. Measure and mark the flue length required onto the flue,measuring from the ring near the terminal.

7. To ensure a square cut, mark the flue all the way round.

8. Cut to length using the cardboard support aid.

9. Remove the cardboard and deburr the metal edges.

20 FITTING THE KIT

18 FLUE EXTENSION DUCTS - For flue lengths greater than 650mm

Pack D Flue extension duct kit contents

Note. Side flue shown

General arrangement

Flue duct support

Flue support cutting aid(shown folded up)

Wall plugs - 4 off

Extension duct & clamp1.0m (39") long

No. 10 x2" wood screw - 4 offEcl 1244

Ecl 6085

Boiler

Standard flue

Terminal grille

Flue length

Extension flue

Use a maximum of 6m extended flue ONLY

Measure from

this RING

2

3

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INSTALLATION


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21 FITTING THE PIPING FRAME (Rear Flue outlet shown)

Note. The CH Flow isolating valve (A), c/w pressure gauge, issupplied separately in the Hardware Pack. Fit to thepiping frame BEFORE mounting the boiler.

Fit the wall mounting frame either:

a. Directly to the wall

!!!!! Insert wall plugs.

!!!!! Put the screws into the wall plugs and leave 10mmproud

!!!!! Hang the frame onto the screws (take care to use thesame hole position from each group as previouslychosen with the wall template) and tighten up.

!!!!! Locate the support bracket on the piping frame.

or

b. Use the stand-off frame (To allow pipework to be taken upwards).

!!!!! Insert wall plugs.

!!!!! Put the screws into the wall plugs and leave10mm proud.

!!!!! Hang the stand-off frame onto the screws andtighten up.

!!!!! Fasten the piping frame to the stand-off framewith the 6mm screws provided.

!!!!! Locate the support bracket on the piping frame.

Note.If the clearances above and below the boiler are lessthan the length of the pipes it will be necessary toposition the pipes behind the wall mounting plateBEFORE the plate is screwed to the wall.

Note.

Service connections may be made now,before mounting the boiler, if required.Refer to Frames 24-26.

A

Wallplug

Screw(10mm proud)

Pipingframe

Supportbracket

Fourpositions

Ecl

239

4

Ecl

239

3

Pipingframe

A

Wallplug

Screw(10mm proud)

Fourpositions

Fourpositions

Stand offframe

6mm Screw

Support bracket

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INSTALLATION


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Gasket

22 MOUNTING THE BOILERIMPORTANT.

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 CH andDHW pipes before mounting. N.B. Some spillage of water mayoccur from the pipework when mounting the boiler to the frame.

2. Lift the boiler onto the wall mounting frame, locating it over the tabs atthe top of the frame.

3. Lower the boiler into position, engaging it onto the support bracket.Note. Ensure the condensate drain pipe is correctly positioned beforecontinuing.

4. Using the fibre washers supplied in the hardware pack, engage andthen tighten the 4 water unions.

5. Engage and tighten the gas union, ensuring that the rubber seal is inplace. DO NOT overtighten.

6. Connect a pipe to the safety drain outlet using the nut and olivesupplied in the boiler hardware pack.

7. Plug the user control (display unit, pack A) into the control box. Referto Frame 65.

8. Screw the user control into position.

23 CONNECTING THE FLUE TO THE BOILER

Note. Before fitting the flue turret fill the condensate trap within the boiler by pouring a cupful of water into the flue outlet A.Take care to ensure that the water is only poured into the flue outlet, and does not spill into the boiler casing.

1. Insert the flue assembly through the prepared hole inthe wall.

2. Locate the flue turret on the top of the boiler,ensuring that the turret gasket is in place.Check that the flue seal ‘A’ locatedin the top of the flue manifoldis secure and giving aneffective seal.

3. Locate the flue into theturret.

4. Secure the flue turret ontop of the boiler byinserting the open ends ofthe turret clamp under the2 studs and fixing it in themiddle with the single M5 x10mm pozi-hex screwprovided.

5. Flues over 1 metre long.

Fix the flue support bracket tothe wall, using the 4 wall plugsand wood screws.

NB. The space bracket will utilise onefixing hole only whilst used in conjunctionwith the stand-off option.

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24 WATER CONNECTIONS - CH

Notes.

1. For heating loads in excess of 60,000 Btu/h use 28mm x 22mmconnectors to connect the boiler flow and return pipes to 28mmsystem pipework.

2. Do not subject any of the isolating valves to heat as the seals maybe damaged.

C.H. FLOW

C.H. RETURN

Ecl2396

22mm copper pipe

Isolating valve

(shown in the

open position)

Piping frame

Drain

point

22mm copper pipe

Isolating valve

(shown in the

open position)

Pressure gauge

Condensate drain pipe located here.

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INSTALLATION


ecl6

068

Pipingframe

Rubber seal

Gas cock(shown in theopen position)

GAS IN

D.H.W. Inlet

D.H.W. Outlet

2023

15mm copper pipe

15mm copper pipe

Regulator / Filter

'O' Ring

Piping frame

Isolating valve(shown in theopen position)

Outletconnector

Retainingscrew

Cross bar

The safety valve is located at the bottom RHS of the boiler.

The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants ofthe premises or damage the electrical components and wiring.

27 SAFETY VALVE DRAIN

IMPORTANT. The gas service cock contains a non-metallic seal so must not be overheated when makingcapillary connections.

Refer to Frame 2 for details of the position of the gasconnection.

The principle of the 1:1 gas valve ensures that theisar m30100 is able to deliver its full output at inletpressures well below those required by BS. 6891.

A boiler gas supply pipe length of 20m and not lessthan 15mm O.D. can be connected to the boiler viathe gas service cock union.

Ensure that the gas supply pipe does not foul theboiler casing.

Refer to Frame 36 or 'Servicing' for details of thepressure test point position.

26 GAS CONNECTION

25 WATER CONNECTIONS - DHW

Note. The DHW inletisolating valve incorporatesa flow regulator / filter. It shouldbe inspected to ensure no blockageis evident.

1. To remove, turn off the valve, undo theretaining screw and pull out the filterby grasping the crossbar with pliers.

2. Reassemble in reverse order,inserting in the direction of the arrow.

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INSTALLATION


2025

Condensatedrain

Front view

155mm

Side view

Diverter valve(shown in theCH position)

Forward positionindicates DHW

Automaticair vent

Cap

Ventplug

2026

Pump

Rotate theshaft to free

a. b. c.

28 CONDENSATE DRAIN

Refer also to the British Gas document: 'Guidance Notes forthe Installation of Domestic Gas Condensing Boilers' (1989).

The condensate drain (provided in the h/ware pack) must beconnected from the boiler ‘S’ trap to a drainage point,preferably within the building.

Ensure that the condensate trap is full of water beforecommissioning the boiler . Refer to Frame 23.

The routing of the drain must be made to allow a minimumfall of 1 in 20 away from the boiler, throughout its length.

The drainage pipework must be arranged so that obstruction(e.g. through freezing) of external drainage pipe does not giverise to spillage within the dwelling.

IMPORTANT.If excessive external pipework cannot be avoided anadditional siphon kit and insulation are recommended toprevent possible freezing.

All pipework and fittings in the condensate drain systemmust be made of plastic. No other materials may be used.

The drain outlet on the boiler is standard 21.5mm overflowpipe. This size must not be reduced in any part of its length.

29 FILLING

Central Heating

1. Remove the boiler front and sealing panels. Refer toFrames 42 & 43.

2. Swing the control box down into the servicing position.Refer to Frame 44.

3. Ensure that the CH isolating valves are open.

4. Fill and vent the system. Check for water soundness.

IMPORTANT - when filling:

a. Remove the diverter valve actuator (refer toFrame 60) and depress the spindle several timesduring filling. Replace diverter valve actuator.

b. The cap on the automatic air vent MUST be looseat all times. Refer to Frame 68.

When filling, there may be a slight water leak from the venttherefore electrical connections should be protected.

c. Bleed any air from the pump and ensure that it is free torotate.

i. Remove the vent plug

ii. Using a screwdriver, rotate the shaft several times

iii. Replace the vent plug.

Note. Some slight water leakage will occur.

Note. The domestic hot water flow rate is automaticallyregulated to a maximum of 12 l/min (2.6 gpm).

Domestic Hot Water1. Fully open all DHW taps and ensure that water flows

freely from them.

2. Close all taps.

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INSTALLATION


30 ELECTRICAL CONNECTIONS

Wiring should be 3 core PVC insulated cable, not lessthan 0.75 mm2 (24 x 0.2mm), and to BS 6500 Table 16.For IE reference should be made to the current ETCIrules for electrical installations.

Connection must be made in a way that allowscomplete isolation of the electrical supply such as adouble pole switch having a 3mm (1/8") contactseparation in both poles, or a plug and socket, servingonly the boiler and system controls. The means ofisolation must be accessible to the user afterinstallation.

WARNING. This appliance MUST be earthed.

A mains supply of 230 V ~ 50 Hz is required.

The fuse rating should be 3A. All external controls and wiringmust be suitable for mains voltage.

Wiring external to the boiler MUST be in accordance with thecurrent I.E.E. (BS.7671) Wiring Regulations and any localregulations.

1. Route the mains cable into the bottom rear centre ofthe boiler.

2. Wire the permanent live supply into the 5-way

remote plug terminals, L3, N & .

IMPORTANT.A permanent live is ESSENTIAL in order for theadvanced diagnostic controls to function correctly.

31 INTERNAL WIRING

3. Wire any switched live supply into L2 or connect L1 and L2via external control switching as shown in Frame 32. Ineither case remove the wire link fitted to L1 to L2.

4. Secure the mains lead with the cable clamp.

5. Connect the mains lead connector. Ensure it is fullylocated.

L3

N

L2

L1

Mains Connector

(supplied in hardware pack)

Socket

(fixed to boiler)

Remove link when connecting external programmer.

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7

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A pictorial wiring diagram is shown in Frame 33.

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.

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INSTALLATION


32 EXTERNAL ELECTRICAL CONTROLS

Wiring External to the Boiler

The fuse rating should be 3A.

Wiring external to the boiler MUST be in accordance with thecurrent I.E.E. (BS.7671) Wiring Regulations and any localregulations. For IE reference should be made to the currentETCI rules for electrical installations.

Room Thermostat

If the thermostat has a neutral connection, use it (it providesfor more energy efficient operation by reducing switchingtemperature differentials).

Frost Protection

If parts of the pipework run outside the house or if the boilerwill be left off for more than a day or so then a frost thermostatshould be wired into the system.

This is usually done at the programmer, in which case theprogrammer selector switches are set to OFF and all the othercontrols MUST be left in the running position.

The frost thermostat should be sited in a cold place but whereit can sense heat from the system.

Note. If the boiler is installed in a garage it may be necessaryto fit a pipe thermostat, preferably on the return pipework.

Wiring should be as shown, with minimal disturbance to otherwiring of the programmer.

Designation of the terminals will vary but the programmer andthermostat manufacturers' leaflets will give full details.

Diagram A

shows an application to boilers fitted with a room thermostatonly.

Diagrams B & C

show applications to boilers fitted with alternative timecontrols.

Earths are not shown for clarity but must never beomitted.

L3 L2 L1N

Room 'stat

N if required

Optional

Frost 'stat

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06

9

A

Mains in

System

controls

L3 L2 L1N

Room 'stat

N if required

Optional

frost 'stat

Ecl 6

07

0

B

Mains in

System controls

L3 L2 L1N

Room 'stat

N if required

Optional

frost 'stat

Ecl 6

07

1

C

Mains in

System

controls

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INSTALLATION


bk

br

brbk

br

v

br

b

bk

pk

pk

b

pk pk

pk

vvv

v

pkr

r

y

r

r

b

r

r

r

r

or

or

or

or

b

br

b

bb

pk

pk

gy

y y

bk

bk

y/g

y/g

y/g

y/g

y/ g

b

bk

Fluethermistor Overheat

thermostat

Controlthermistor(flow)

Gas valve

PUMP

Controlthermistor(return)

DHWThermistor

User controland display

ON /OFFSwitch

Serviceconnection

Mainssupply230V 50Hz

Permanentblack link

Fan

bk

y

Chassisearth y/g

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9

Fused at 3.15ATL

r

r

b

b

br

Diverter valve

Filter

Control PCBPHC 033

33 PICTORIAL WIRING DIAGRAM

LEGEND

b - bluebk - blackbr - browngy - greyor - orange

pk - pinkr - redv - violetw - whitey - yellowy/g - yellow/green

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INSTALLATION


34 FUNCTIONAL FLOW WIRING DIAGRAM

WARNING. Whilst effecting the required gas soundness test and purging air from the gas installation,open all windows and doors, extinguish naked lights and DO NOT SMOKE.

A. Electrical Installation

1. Checks to ensure electrical safety should be carried out bya competent person.

2. ALWAYS carry out the preliminary electrical system checks,i.e. earth continuity, polarity, resistance to earth and shortcircuit, using a suitable test meter.

B. Gas Installation

1. The whole of the gas installation, including the meter,should be inspected and tested for soundness and purgedin accordance with the recommendations of BS. 6891.In IE refer to I.S.813:2002.

2. Purge air from the gas installation by the approvedmethods only.

35 COMMISSIONING AND TESTING

321

bk

oror

Divertervalve

gyv

r

v v v v

Pump

pk

bry/g

b

y/g

DC gas valve

brbr

Mains switch

DCFan

rbky

pkb

Flame detection electrode

y/gr

r

Flue thermistoryy

pkpk

bb

rr

DHW thermistor

CH control thermistor flow

CH control thermistor return

electrode

Ecl 6072

br

y/g

y/g

br

bk

N

L

E

bbFilter

External switch e.g. room 'stat, programmer

PCB No.�

PHC 033

Overheat

thermostat

LEGENDb - bluebk - blackbr - browngy - grey

or - orangepk - pinkr - redv - violet

w - whitey - yellowy/g - yellow/green

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INSTALLATION


36 INITIAL LIGHTING

1. Check that the system has been filled and that the boiler isnot airlocked. Ensure the automatic air vent cap (N) is open.

Note.It is important the burner is not operated before the system isfully vented of air. If it is necessary to operate the appliancepump to assist venting of the air this must be done with thegas service cock turned off.

2. Refit the boiler sealing panel. Refer to Frame 43.

3. Check that all the drain cocks are closed and that the CHand DHW isolating valves (T, W and S) are OPEN.

4. Check that the electrical supply is OFF.

5. Check that the boiler on/off switch (A) is off.

6. Carefully align the user control and push gently into place.Secure with the single screw located underneath.

7. Check that the gas service cock (H) is OPEN.

8. Slacken the screw in the inlet pressure test point (G) andconnect a gas pressure gauge via a flexible tube.

9. Swing the control box to the working position and securewith the clamp.

10. Reconnect the ignition lead to the control box.

11. Connect the low voltage electrical lead from the user controlto the control box (refer to Frame 44) and screw the controlinto position.

12. Switch the electricity supply ON and check all external controlsare calling for heat.

13. CENTRAL HEATINGSet the boiler thermostat knob (B) to position 6 and switchthe boiler on/off switch (A) to ON. The RED mains-on neon(C) should now be illuminated. The boiler control should

The displayThe user control has one neon and one display to inform theuser about the status. The display will show the status of theboiler. The neon will show the status of the flame. If no flame isdetected the neon is blinking. When the flame is detected theneon will be lit permanently.

Below is a list with display function in normal operation.

Standby, no demand for heat present.

Boiler is active for central heating.

Boiler is active for domestic hot water.

Boiler is heating up the plate heat exchanger.

Boiler is in lockout for a specific error. Display will beblinking, alternating with a number or letter to show whicherror is detected.

Boiler is in lockout for a specific error. Display will beblinking,0 alternating with a number or letter to show whicherror is detected.

LEGEND

A. Boiler On/Off switch.

B. CH thermostat knob.

C. Mains On neon.

D. Burner On neon.

E. Reset button.

F. Injector pressure testpoint.

G. Inlet pressure test point.

H. Gas service cock.

J. Casing pressure test point.

K. Overheat thermostat.

L. Flue thermistor.

M. Control thermistor (flow).

N. Automatic air vent.

P. Control box (Servicingposition).

R. Pressure gauge.

S. CH Flow isolating valve.

T. CH Return isolating valve.

U. DHW outlet.

Y. DHW thermostat knob.

now go through its ignition sequence until the burner isestablished.

14. If the boiler does not light after 3 attempts the fault code will be displayed, Press the reset button (E) and the

boiler will repeat its ignition sequence.

When the burner is established the GREEN 'Burner On'neon (D) will be illuminated, the LED display will showstatus c.

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INSTALLATION


38 GENERAL CHECKS

CENTRAL HEATING (CH) & DOMESTIC HOT WATER (DHW)MODE.

1. Ensure that the CH external controls are calling for heat.

The display should read:

after first satisfying DHW preheat if necessary. ( )

2. Fully open a DHW tap and check that hot water isdelivered.


3. Gas RateCheck the boiler gas rate when the boiler is at full DHWoutput.

Check at the gas meter, with no other appliance in use.Refer to Table 3 for gas rates.

4. Close the DHW tap. The burner should go off and thepump continue to run.


flashing

then

flashing

After 15 seconds the burner should relight, to supply centralheating.


37 INITIAL LIGHTING - continued

15. DOMESTIC HOT WATER

With the boiler firing, set the DHW thermostat knob (Y) tomaximum and fully open a DHW tap.

The boiler should continue to run and the LED display shouldshow status .

16. Ensure that with the boiler operating the dynamic gas pressure isable to obtain maximum output. Refer to Table 2.N.B. The principle of the 1:1 gas valve ensures that the isarm30100 is able to deliver its full output at inlet pressures wellbelow those required by BS. 6891.

IMPORTANTThe gas input to the burner is regulated by the gas valveaccording to the air flow produced by the fan. It is NOT user-adjustable. Any interference to sealed settings on the gas valvewill adversely affect operation and render our warranty void.

17. Turn off the DHW tap.

18. Set the boiler on/off switch (A) to OFF.

19. Swing the control box into the servicing position.Refer to Frame 44.

20. Remove the pressure gauge and tube. Tighten thesealing screw in the pressure test point. Ensure agas tight seal is made.

21. Swing the control box back into its workingposition and secure. Reconnect the ignition lead.

22. Refit the user control.

23. Refit the boiler front and bottom panels.

24. Switch the boiler on again.

DOMESTIC HOT WATER (DHW) MODE1. With no call for CH or DHW the boiler should fire for a short

period to preheat the DHW plate heat exchanger.The display should read

returning to

when the burner switches off.

Notes.a. If no DHW is drawn off, the boiler will fire periodically

for a short time, to maintain the plate heat exchangertemperature.

b. The DHW preheat operates 24 hours a day .

2. Fully open all DHW taps in turn and ensure that water flowsfreely from them.


flashing then

when the burner lights.

3. Close all taps except the furthest one from the boiler and checkthat the boiler is firing at maximum rate.

This is factory set to give a DHW temperature rise ofapproximately 35oC at the flow rate: 12.0 l/min (2.6 gpm)

4. Reduce the DHW draw-off rate to about 3 l/min (0.7 gpm)and check that the boiler modulates to deliver DHW atapproximately 65oC.

5. Close the DHW tap and check that the main burnerextinguishes. The pump should overrun for a few secondsand the display sequence should read:

When the pump stops the display sequence should read:

Note. On systems in excess of 2 bar inlet pressure a waterpressure governor may be required to prevent water noise.

Make the following checks for correct operation in:

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INSTALLATION


40 HANDING OVER

7. If any programmer is fitted draw attention to the ProgrammerUsers Instructions and hand them to the householder.

8. Loss of system water pressure

Explain that the dial underneath the boiler indicates thecentral heating system pressure and that if the normal COLDpressure of the system is seen to decrease over a period oftime then a water leak is indicated. In this event a CORGIregistered installer should be consulted. In IE consult aCompetent Person.

WARNING.Do not fire the boiler if the pressure has reduced to zero fromthe original setting.

9. After installation, commissioning and customer hand-over

please complete the appliance log book andleave this with the customer. For IE, it is necessary tocomplete a “Declaration of Conformity” to indicatecompliance to I.S.813:2002.

10. Stress the importance of regular servicing by a CORGIregistered installer and that a comprehensive service shouldbe carried out AT LEAST ONCE A YEAR. In IE servicing workmust be carried out by a Competent Person.

11. As the installer you may wish to undertake the servicecontract yourself or alternatively offer to the customer thebenefits of the Ideal Care Scheme, details of which areoutlined in the householder pack supplied with this boiler.

1. Hand the User Instructions to the householder andexplain his/her responsibilities under the relevantnational regulations.

2. Explain and demonstrate the lighting and shuttingdown procedures.

3. The operation of the boiler and the use and adjustmentof all system controls should be fully explained to thehouseholder, to ensure the greatest possible fueleconomy consistent with the household requirements ofboth heating and hot water consumption.

Advise the User of the precautions necessary to preventdamage to the system and to the building, in the eventof the system remaining inoperative during frostyconditions.

4. Explain the function and the use of the boiler heatingand domestic hot water controls.

5. Explain the function of the boiler fault mode.

Emphasise that if a fault is indicated, the boiler shouldbe turned off and a CORGI registered installerconsulted. In IE contact a Competent Person.

6. Explain and demonstrate the function of time andtemperature controls, radiator valves etc., for theeconomic use of the system.

WATER TEMPERATURESTemperatures can be selected via the CH and DHWthermostats.

39 GENERAL CHECKS - continued

CH & DHW CONT.

5. Set the central heating external controls to OFF. Theburner should go off and the pump continue to run fora few seconds.


returning to

when the pump stops.

6. Check the correct operation of the programmer (iffitted) and all other system controls. Operate eachcontrol separately and check that the main burnerresponds.

WATER CIRCULATION SYSTEM1. With the system COLD, check that the initial pressure is

correct to the system design requirements.

For pre-pressurised systems, this should be 1.0 bar.

2. With the system HOT, examine all water connections forsoundness. The system pressure will increase withtemperature rise but should not exceed 2.5 bar.

3. With the system still hot, turn off the gas, water andelectricity supplies to the boiler and drain down tocomplete the flushing process.

Note. A flushing solution should be used during the flushingprocedure. Flushing solutions: Fernox Superfloc,Sentinel X300 (new systems) or X400 (existingsystems). Refer to Frame 6.

4. Refill and vent the system, add inhibitor (see Frame 6),clear all air locks and again check for water soundness.Affix the water treatment warning label, supplied in thehardware pack, in a prominent position on the system, toprevent the use of incorrect water treatment additives.

5. Reset the system initial pressure to the designrequirement.

6. Balance the system. Refer to Frame 5.

7. Check the condensate drain for leaks and check that it isdischarging correctly.

8. Finally, set the controls to the User's requirements.

Note. The pump will operate briefly as a self-check onceevery 24 hours in the absence of any system demand.

Knob Setting CH Flow DHW OutletTemp Temp

oC (oF) oC (oF)

Max 82 (180) 65 (150)

Min 30 (86) 42 (110)

After completing the installation and commissioning of the system theinstaller should hand over to the householder by the following actions:

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41 SERVICING SCHEDULE

To ensure the continued safe and efficient operation of theappliance it is recommended that it is checked at regularintervals and serviced as necessary. The frequency ofservicing will depend upon the installation condition andusage but should be carried out at least annually.

It is the law that any service work must be carried out by aCORGI registered installer. In IE service work must becarried out by a Competent Person.

Note. Some aluminium oxide build-up on the heatexchanger fins is usual with this type of condensingboiler. Though removal is recommended annually,the heat exchanger MUST be inspected and cleanedafter a MAXIMUM of 2 years operation.

1. Light the boiler and carry out a pre-service check, notingany operational faults.

2. Check the gas consumption.

3. Connect a suitable gas analyser to the sampling point onthe top of the boiler (refer to Frame 43) or into the flueterminal if access is possible (optional test).For correct boiler operation, the CO/CO2 content of theflue gas should not be greater than 0.004 ratio.If this is the case, and the gas input is at least 90% of thenominal, then no further action need be taken. If not,proceed to Step 5 but see note above.

4. Clean the main burner.

5. Clean the heat exchanger.

6. Check the condition of the combustion chamberinsulation. Any cracked/damaged pieces should bereplaced.

7. Check the main injector for blockage or damage.

8. Wherever possible remove and clean the condensate ‘S’trap (refer to Frame 47) and check the drain for blockage.

9. Check that the flue terminal is unobstructed and that theflue system is sealed correctly.

10. Check the DHW filter for blockage. Refer to Frame 25.

The servicing procedures are covered more fully in Frames42-49and MUST be carried out in sequence.

Note. In order to carry out either servicing or replacement ofcomponents the boiler front panel and sealing panelmust be removed. Refer to Frames 42 and 43.

WARNING. Always turn OFF the gas supply at the gasservice cock, and switch OFF and disconnect theelectricity supply to the appliance before servicing.

IMPORTANT.

11. After completing the servicing or exchange of componentsalways test for gas soundness and carry out functionalchecks in 3 and 4 above.

12. When work is complete the sealing panel MUST becorrectly refitted, ensuring that a good seal is made.

Do NOT OPERATE the boiler if the sealingpanel is not fitted.

13. If, for any reason, the condensate ‘S’ trap has beenremoved ensure the trap is refilled with water beforereassembly.

14. Complete the service section in the Benchmark log book.

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43 BOILER SEALING PANEL / BOTTOM PANEL REMOVAL

42 BOILER FRONT PANEL REMOVAL

1. Remove the 2 screws from theunderside of the boiler.

2. Pull the panel forward at the bottom andlift to disengage it from the top lugs.

Ecl

244

2

1

1. To remove the sealing panel removethe 4 screws.

2. Remove the panel.

3. To remove the bottom panel removethe 2 screws.

4. Pull the right hand side of the paneldown. Slide it to the right andwithdraw.

Ecl

244

3

3

1

Flue gas

sampling point

Ecl 2443

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SERVICING


44 THE CONTROL BOX IN THE SERVICING POSITION

1. Remove the 2 screws and withdraw the usercontrol.

2. Unplug the low voltage electrical lead from theback of the user control.

3. Unplug the igntion lead from the bottom of thecontrol box.

4. Turn the clamp, swing the control box down andpull slightly forward.

Control box

User control

Ecl

239

8

1

32

Swing control panel down and forward into service position

Clamp4

Ecl2399

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SERVICING


23

14

Ecl 6073

45 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING

46 BURNER REMOVAL AND CLEANING

1. Remove the 6 screws securing theburner (the 3 screws at the rear areextended to ease access).

2. Lift off the burner from the combustionchamber.

IMPORTANTThe burner head is a ceramic plaqueconstruction. Care must be taken toensure that the burner is not placeddown upon its face as this may causedamage to the ceramic.

3. Brush off any deposits that may be onthe ceramic with a SOFT brush.

4. Inspect the sealing gasket around theburner and combustion chamberinsulation for any signs of damage.Replace as necessary.

Note.

Take care not to disturb the detection earthprobe at the rear of the combustionchamber.

1. Disconnect the electrical leads from thefan.

2. Undo the gas pipe union connection to theinjector housing.

3. Undo the screw on the fan mountingbracket.

4. Lift off fan and venturi assembly.

5. Inspect the injector for blockage ordamage.

Ecl 6074

1

2

4

Detection

earth

probe

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SERVICING


Ecl

607

5

2

Sump cover

3

Detection earth

probe

Heat exchanger

Condensate trap

Condensate drain pipe

Elongated bolt.

Ecl

2444

2

3

48 CLEANING THE HEAT EXCHANGER

Reassemble the boiler in the following order:

1. Refit the condensate ‘S’ trap, ensuring that it is full of water.

2. Refit the sump cover.

3. Refit the electrodes. (Check dimensions; Frames 56 & 57).

4. Refit the burner.

5. Refit the fan / venturi assembly.

6. Reconnect the fan electrical lead.

1. Remove ignition and flame detection electrodes. Referto Frames 56 & 57.

2. Remove the 3 screws retaining the sump cover andremove.

3. Using a suitable tool as supplied in the standard BritishGas Flue brush kit, clean between the heat exchangerfins from the top of the heat exchanger.

4. Access to the base of the heat exchanger is nowpossible. Brush clean any deposits from the base of theheat exchanger and remove any loose deposits from thesump.

5. Inspect the ignition and detection electrodes. Ensurethat they are clean and in good condition - replace ifnecessary.

6. Check that the ignition and detection gaps are correct.Refer to Frames 56 & 57.

7. Check the condition of the combustion chamberinsulation. Any cracked/damaged pieces should bereplaced.

Note. Take care not to disturb the detection earth probe atthe rear of the combustion chamber.

7. Refit the boiler sealing panel.

IMPORTANT.Ensure that the boiler sealing panel is correctly fitted andthat a good seal is made.

8. Swing the control box back into its working position andsecure.

9. Refit the display unit.

10. Refit the boiler front and bottom panels.

11. Turn on the gas supply at the gas service cock.

12. Reconnect the electrical supply.

49 REASSEMBLY

1. Swing the control box down into theservicing position. Refer to Frame 44.

2. Disconnect the condensate drain pipe.

3. Remove the screw and elongated bolt,pull the trap down and forward toremove.

4. Flush out any deposits with cleanwater.

47 CLEANING THE CONDENSATE 'S' TRAP

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GasketOrifice plate

Ecl 2373

5

3

7

4

50 REPLACEMENT OF COMPONENTS

GENERAL

When replacing ANY component

1. Isolate the electricity supply.

2. Turn off the gas supply.

3. Remove the boiler front panel. Refer to Frame 42.

After replacing ANY component check operation of the boiler,including gas soundness, gas rate and combustion test.

1. Refer to Frame 50.


3. Unplug the electrical lead.

4. Disconnect the flue sampling tube from the thermistorhousing.

5. Remove the aluminium nipple securing the thermistorto the flue manifold.

6. Withdraw the thermistor.

7. Fit the new flue thermistor, using the gasket supplied.

8. Reassemble in reverse order.

9. Check the operation of the boiler. Refer to Frame 50.

51 FLUE THERMISTOR REPLACEMENT

52 FAN REPLACEMENT


2. Remove the boiler front and sealing panels. Refer to Frames42 & 43.

3. Disconnect the electrical leads from the fan.

4. Undo the gas pipe union connection to the injector housing.

5. Remove the screw retaining the fan mounting bracket.

6. Remove the fan and venturi assembly.

7. Unscrew the 3 screws and remove the venturiassembly, noting the orientation of the venturi inrelation to the fan body.

8. Transfer the venturi assembly to the new fan,replacing the gasket if evidence of damage ordeterioration is visible.

9. Fit the new fan / venturi assembly.

10. Reassemble the boiler in reverse order, taking care notto overtighten the screw on the fan mounting bracket.


Fluesamplingtube

nippleThermistor

Ecl

209

7

IMPORTANT.When work is complete, the sealing panel, if removed, mustbe correctly refitted - ensuring that a good seal is made.

Notes.1. In order to assist fault finding, the control panel has an

LED diagnostic display. The key to boiler fault conditionsis shown in Frame 76.

2. In order to replace components in Frames 66-74 it isnecessary to drain the boiler. Refer to Frame 69.

THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED

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54 BURNER REPLACEMENT1. Refer to Frame 50.

2. Remove the boiler front and sealing panels. Refer to Frames42 & 43.

3. Remove the fan assembly. Refer to Frame 52.

4. Remove the 6 screws securing the burner (the 3 screws at therear are extended to ease access).

5. Lift off the burner from the combustion chamber.

6. Fit the new burner, replacing any damaged or deterioratingsealing gasket.



Note. Take care not to disturb the detection earth probe at therear of the combustion chamber.

53 BURNER INJECTOR REPLACEMENT



3. Disconnect the electrical leads from the fan.

4. Undo the gas pipe union connection to the injector housing.

5. Remove the screw retaining the fan mounting bracket.

6. Remove the fan and venturi assembly

7. Remove the 2 injector housing screws.

8. Withdraw the injector housing.

9. Fit the new injector housing complete with injector.

10. Reassemble in reverse order, ensuring that the new gasseal supplied is located correctly in the injector housing.

11. Check operation of the boiler. Refer to Frame 50. Mounting bracket

7

Ecl 2400

5

Injector

Fan

Gas pipe union

Overheat thermostat

Control thermistor

Flowpipe

Return thermistor

Return pipe

2037

55 CONTROL THERMISTOR, RETURN THERMISTOR & OVERHEAT ‘STAT REPLACEMENT


2. Remove the boiler front and sealing panels.Refer to Frames 42 & 43.

3. Unclip the thermistor / thermostat from the flow / return pipe andwithdraw it from the controls compartment.

4. Disconnect the electrical leads from thethermistor / thermostat.

5. Reconnect the electrical leads andreassemble in reverse order, ensuring that thespring clip is securely on the pipe.

6. Check the operation of the boiler. Refer toFrame 50.

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5

Ecl 6

07

6

Straight edge

25mm + 2

- 2

Ecl 6078

Ecl 2375

5

56 IGNITION ELECTRODE REPLACEMENT

57 FLAME DETECTION ELECTRODE REPLACEMENT



3. Unplug the ignition electrode lead from the control box.





4. Unplug the flame detection electrode lead from thecontrol box.

5. Remove the screw holding the ignition electrode to thecombustion chamber.

6. Remove the earth lead from the ignition electrode.

7. Remove the electrode, taking care not to dislodge thegrommet from the casing.

8. Fit the new ignition electrode, using the new gasketsupplied. Check dimensions as shown.



5. Remove the screw holding the flame detection electrode tothe combustion chamber.

6. Unbolt the sensing electrode earth lead from the earth pointbeneath the boiler.

7. Remove the electrode, complete with grommet.

8. Fit the new flame electrode, using the new gasket supplied.Check dimensions as shown.



Straight edge

11mm+ 0- 4

Spark gap 3mm

+2

-0

Ecl 6077

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58 COMBUSTION CHAMBER INSULATION REPLACEMENT

The insulation boards used in the combustion chamber of thisproduct are made of high temperature glass fibres with abinder of organic and inorganic materials.

Caradon Ideal Limited recommend that, for your own comfortand safety and to comply with good working practice, theprocedure described below is followed:



3. Remove the fan / venturi assembly. Refer to Frame 45.

4. Remove the burner. Refer to Frame 46.

5. Remove the screw holding the ignition electrode andwithdraw it from the combustion chamber

6. Remove the screw holding the flame detection electrodeand withdraw it from the combustion chamber.

Prior to removal of the board the following protectiveequipment should be worn:

! Face mask supplied with the spare part.

! Gloves supplied with the spare part.

7. Remove the detection earth probe.

8. Damp down the combustion chamber area containing theinsulation boards.

9. Remove the split pin and washer from the RHS of thecombustion chamber.

10. Remove the insulation boards. The replacement boardsare supplied in a plastic bag. This bag should be retainedand the discarded boards should now be placed into it.

11. Sweep any dampened particles and place in the plasticbag.

12. Fit new insulation boards.

Note.The boards are designed to be interlocking and should befitted as shown.

13. Fit the new split pin and washer in the RHS of the chamber.

14. Remove the gloves and face mask and place them in theplastic bag.

15. Wash your hands and any areas of skin which may havecome into contact with any of the particles from theinsulation board.

Note. Seal the plastic bag and dispose of it and its contentsinto a commercial tip.


17. Check operation of the boiler. Refer to Frame 50.

Rear

Front

Combustionchamber

LH Side

RH Side

Ecl 2403

6

7

5

Fit insulation in the following order:

1. Front.

2. Left Hand Side.

3. Rear.

4. Right Hand Side.

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59 GAS CONTROL VALVE REPLACEMENT


2. Remove the casing front & bottom panel.Refer to Frames 42 & 43.


4. Unplug the electrical lead from the gas control valve anddisconnect the earth wire.

5. Remove the sensing tube from the gas control valve.

6. Undo the gas inlet pipe union at the gasservice cock.

7. Undo the union nut on the outlet of the gascontrol valve.

8. Slacken the screw securing the valvemounting bracket and withdraw the valve,complete with bracket and inlet pipe.

9. Transfer the mounting bracket and gas inlet pipe to thenew gas control valve.

10. Fit the new gas control valve, ensuring that any sealsshowing damage or deterioration are replaced.Reassemble in reverse order.

11. Ensure the sensing tube is correctly replaced and notkinked or blocked in any way.


60 DIVERTER VALVE ACTUATOR REPLACEMENT



3. Squeeze the tab and unplug the electrical leadfrom the valve actuator.

4. Rotate the actuator anticlockwise and pullforward to remove.

5. Fit the new actuator and reassemble in reverseorder.


8 Mounting bracket

ECL6079

4

6

7

1120

40

Electricallead

Tab

Divertervalve actuator

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61 CONDENSATE 'S' TRAP REPLACEMENT



3. Swing the control box down into the servicingposition. Refer to Frame 44.

4. Disconnect the condensate drain pipe.

5. Remove the securing screw and elongated bolt,pull the trap down and forward to remove.

6. Transfer the drain pipe to the new trap andreassemble in reverse order.

7. When reassembling ensure the trap is full of water.


Condensate 'S' trap

Ecl

608

0

Condensate drain

4

Elongated bolt

5

62 DHW THERMISTOR REPLACEMENT



3. Remove the 4 screws securing the support plate andwithdraw the plate.

Note. The M4 screws fit the casing and the self-tappingscrews fit the plastic pump and valve housings.

4. Withdraw the securing pin.

5. Disconnect the electrical lead.

6. Ease out the sensor and discard.

7. Fit the new sensor, ensuring silicone grease is appliedto the 'O' ring.

8. Refit the securing pin.

9. Reassemble in reverse order, ensuring correct locationof screws in support plate, and that tabs on the pumpand valve housings engage in slots.


Support plate

Discharge pipe

M4 screw

2055

M4 screw

Self tapperscrew

Sensor

Electrical lead

Securing pin

2042

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SERVICING


ScrewsC.

B .

A.

Hinge armsControl box mounting bracket

Electrical lead Control box

Control box

Controlbox

Ecl

204

3

Low voltage lead

Clamp

3

Ecl 2445

Displayunit

User control



3. Remove the 2 screws and allow the user control to lower.

4. Push out the mains switch from the rear, as shown.

5. Fit the new switch, ensuring that the electrical leads are

64 MAINS SWITCH REPLACEMENT

63 CONTROL BOX REPLACEMENT1. Refer to Frame 50.



4. Unplug the user control electrical lead and low voltagelead from the control box and remove the control. Referto diagram A.

5. Return the control box to the working position andsecure with the clamp. Unscrew the mounting bracketscrews to remove the bracket. Refer to diagram B.

6. Release the clamp and carefully remove the controlbox from the hinge arms. Refer to diagram C.

7. Unplug all the electrical wiring from the control box andremove.

8. Transfer mounting bracket and hinge arms to the newcontrol box.

9. Reassemble in reverse order, ensuring that the control boxis located correctly in the housing before reconnecting theelectrical wiring.


Electricallead

Mains switch

Display unit

Key

Keyway

2030

replaced on the correct terminals (refer to Frame 34) andthe key on the switch is correctly aligned with the slot in theplastic moulding.



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SERVICING


2

Display

unit

Ecl2044

Note. Only the display unit is replaced.


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.



65 USER CONTROL REPLACEMENT

66 PRESSURE GAUGE REPLACEMENT


2. Drain the boiler. Refer to Frame 69.

3. Unscrew the pressure gauge and discard.

4. Fit the new pressure gauge, using a suitable jointingcompound.

5. Refill the boiler. Refer to Frame 29.


2041

Pressure gauge

Flow isolation valve(shown in the open position)

DisplayunitUser control

Ecl2404

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SERVICING


67 SAFETY RELIEF VALVE REPLACEMENT


2. Remove the casing front andbottom panels. Refer toFrames 42 & 43.


4. Remove the discharge pipe.

5. Remove the 4 screws retaining the rear support plate andwithdraw the plate.

Note. The M4 screws fit the casing and the self -tappingscrews fit the plastic pump and valve housings, asshown.

6. Withdraw the securing pin.

68 AUTOMATIC AIR VENT REPLACEMENT




4. Unscrew the air vent from the extension pipe on theboiler boss.

5. Fit the new air vent, complete with 'O' ring provided,and reassemble in reverse order.

Note. In the event that the extension pipe is removed atthe same time as the air vent, remove it from theair vent and refit it into the heat exchanger beforefitting the new air vent, ensuring that its ‘O’ ringseal is in place.

IMPORTANT.Ensure that the vent cap (A) is loose.



7. Remove the safety valve.

8. Fit the new safety valve and refit the securing pin.

9. Reassemble in reverse order, ensuring correct locationof screws in the support plate and that tabs on thepump and valve housings engage in slots.

10. Reconnect the discharge pipe.



Support plateM4 screw

2012

M4 screw

Self tapperscrew

Discharge pipe

Safety relief valve

Securing pin20

39

Ecl

209

8

Air vent

Vent cap (A)

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69 DRAINING THE BOILER

1. Refer to frame 50.

2. Remove the boiler bottom panel. Refer to Frame 43.

3. Close all the water isolating valves on the pipingframe.

4. Attach a length of hose to the drain point and openthe drain valve.

5. After replacing any component on the boiler,close the drain valve, remove the hose and openall system isolating valves before proceeding tocheck operation of the boiler.

6. Check operation of the boiler. Refer to Frame 50

70 DIVERTER VALVE MECHANISM REPLACEMENT




4. Remove the 4 screws retaining the rearsupport plate and withdraw the plate. Refer toFrame 67.

Note. The M4 screws fit the casing and the self-tapping screws fit the plastic pump andvalve housings.

5. Remove the valve actuator head. Refer toFrame 60.

6. Remove the 4 Allen screws and remove thevalve mechanism.

7. Fit the new valve mechanism and gasket,ensuring correct fit over the location pin.

8. Reassemble in reverse order, ensuring correctlocation of screws in the support plate and thattabs on the pump and valve housings engage inslots.


10. Check operation of the boiler. Refer toFrame 50.

isolating valve(shown closed)

Isolating valves

Drain point

Drain valve

2099

TO OPEN

ecl 6081

Valve mechanism

Locating

pin hole

Gasket

6

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SERVICING


18mm.

Diverter valve housing side

Divertervalve

housingside

Pump housing side

Pumphousing

side

24mm.

DHW plate heat exchanger

DHW Plate heat exchanger

Note. The DHW plate heat exchanger will only fit one way

Ecl

240

66

Pump head

Electricallead

Ecl

204

7

6

72 PUMP HEAD REPLACEMENT




4. Swing the control box down into theservicing position. Refer to Frame 44.

5. Disconnect the electrical lead from thepump.

6. Remove the 4 Allen screws retaining thepump head.

7. Remove the pump head.

8. Fit the new pump head.


10. Refill the boiler. Refer to Frame 29


71 DHW PLATE HEAT EXCHANGER REPLACEMENT




4. Remove the 4 screws securing the rearsupport plate and withdraw the plate. Referto Frame 67.

Note. The M4 screws fit the casing and theself-tapping screws fit the plastic pumpand valve housings.

5. Remove the 2 Torx screws securing theplate heat exchanger from the valve andpump housings.

6. Raise the RH side of the heat exchanger,lower the LH side through the bottom of theboiler and remove.

7. Fit the new heat exchanger, using the newgaskets supplied.

8. Reassemble in reverse order ,ensuringcorrect location of screws in the supportplate and that tabs on the pump and valvehousings engage in slots.



SE

RV

ICIN

G

46

SERVICING


Edge clip

12 13

14

23

10

Spring clip

Return pipe

securing bracket17

25

11Interpanel

15

Overheat

thermostat

Control

thermistor

Flow pipe

1821

Flow pipe

securing bracket

19

26

27

Ecl6082

Refer also to Frame 8 - 'Boiler Exploded View'.

IMPORTANT

Before starting the removal procedure, protect the gas andelectrical controls with a waterproof sheet or plastic bag.


2. Remove the boiler front, bottom and sealing panels.Refer to Frames 42 & 43.


4. Remove the control box and place on one side. Refer toFrame 63.

5. Remove the fan / venturi assembly and place on oneside. Refer to Frame 45.

6. Remove the burner and place on one side. Refer to Frame46.

7. Remove the ignition and detection electrodes. Refer toFrames 56 and 57.

8. Release the flue from the turret. Refer to Frame 23.

9. Remove the turret from the boiler. Refer to Frame 23.

10. Remove the automatic air vent, complete with the adapter.

11. Remove the M5 nut retaining the flue casting spring clipand remove the spring clip.

12. Remove the M5 x 10 screw retaining the flue casting.

13. Release the silicone tubing from the sampling point.

14. Release the electrical connection to the flue thermistor.

15. Undo the 2 M5 x 10 flue spring clip retaining bracketscrews and remove the bracket.

16. Remove the flue casting.

73 HEAT ENGINE REPLACEMENT17. Remove the edge clip securing the flue thermistor wiring.

18. Remove the blind grommet to gain access to the returnpipe securing bracket.

19. Unscrew the M5 screw and remove the return pipe securingbracket by sliding forwards.

20. Remove the overheat thermostat and the controlthermistor. Refer to Frame 55.

21. Remove the securing pin to release the flow pipe.

22. Remove the condensate ‘S’ trap. Refer to Frame 61.

23. Remove the 2 M5 screws securing the interpanel to theback panel.

24. Slide the heat exchanger and interpanel assembly upwardto disengage and remove from the casing, complete withthe flow pipe.

25. Remove the 2 M6 countersunk screws, remove theinterpanel and transfer to the new heat exchanger.

26. Remove the M5 screw and remove the flow pipe securingbracket.

27. Remove the flow pipe and transfer to the new heatexchanger.

28. Reassemble in reverse order, replacing gaskets or seals ifany sign of damage or deterioration is evident.

Note. The heat exchanger is supplied with new combustionchamber insulation boards. These should be fitted(refer to Frame 58 before the burner and fan / venturiassembly and before the ignition and detectionelectrodes are replaced).


30. Check operation of the boiler. Refer to Frame 50.SE

RV

ICIN

G

47

SERVICING


Seals

Ecl2448

2

75 BOILER SEALING PANEL SEAL REPLACEMENT


2. Remove the boiler front and sealingpanels. Refer to Frames 42 & 43 .

3. Remove the old seal from the casingand thoroughly clean the casingsurfaces.

4. Fit the new adhesive seals, note thatthey are supplied to the correct lengthfor the relevant sides.



Note. Ensure that the boiler sealingpanel is correctly sealed,compressing the seal to make anairtight joint.

74 EXPANSION VESSEL REPLACEMENT



3. Unscrew all the gas and water connection unions on theboiler side of the valves.

4. Remove the screw from the turret clamp and remove.

5. Remove the turret.

6. Lift the complete boiler from the wall mounting frameand place on a flat surface, face down, to expose theexpansion vessel.

7. Unscrew the union nut on the vessel water connectionpipe.

8. Unscrew the 2 screws from the securing clamp andremove.

9. Remove the expansion vessel.

10. Fit the new expansion vessel.




Note.

If preferred, and for convenience, a new expansion vesselmay be installed elsewhere in the heating system, providingit ensures equivalent system protection.

7

8

Ecl6083�

Expansion vessel

Securing clamp

Rear view of the boiler

SE

RV

ICIN

G

48

FAULT FINDINGF

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G


76 FAULT FINDING CHART MAIN MENU

ALTERNATING 'L' 'F' GO TO FRAME 77

ALTERNATING 'L' 'E' GO TO FRAME 78

ALTERNATING 'L' 'A' GO TO FRAME 79

ALTERNATING 'L' '8' GO TO FRAME 80

ALTERNATING 'H' '1' GO TO FRAME 81




ALTERNATING 'H' 'F' GO TO FRAME 85

In order to assist fault finding the boiler has an LED diagnostic display. The key to the display codes is as follows:

ALTERNATING 'H' 'n' GO TO FRAME 86

ALTERNATING 'H' 'E' GO TO FRAME 78

49

FAULT FINDING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING


77 L.....F..... (FLAME DETECTION ERROR)

Check the ignition electrode and associated harnessfor: continuity, visual condition, position

(Refer to Frame 56).

Are these functioning correctly ?

Check gas valvewiring forcontinuity

YES

Check the detection electrode andassociated harness for:

continuity, visual condition, position(Refer to Frame 57).

Replace as necessary.

If the boiler reset button ispressed does the boiler ignite for

a short time then extinguish?

Is 200V DC supply availableat the gas valve ?

(see Note)

NO

YESYES

Is gas pressure available atthe boiler inlet ?

Replace PCB

Check gas supplyand rectify fault

Replace ignition electrode and associatedharness as necessary

NO

Replace gas valve

YES

NO

NO

78 L.....E..... or H.....E..... (PCB ERROR)

Internal fault within the PCB Replace PCB

Note. Due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used tomeasure the value (some may measure the possible peak voltage of 339V). In general terms a reading greaterthan 150V indicates that the correct voltage is supplied to the gas valve.

50

FAULT FINDINGF

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G


Does the pump setting give a differentialacross the boiler in excess of 25 oC ?

Can the overheat condition be reset by pressingthe boiler reset button when the system is cold ?

Replace the system pumpSet CH control knob to maximum.If the overheat trips again measure the flow temp:

Over 90 oC Check control thermistor(Refer to Frame 81)

Under 90 oC Replace overheat 'stat

YES

YES

Check that the pump is rotating freely.

Is differential now below 25 oC ?

NO

NO

79 L.....A..... (OVERHEAT ERROR)

Fill and vent the system and open allisolation valves

YES

Is the boiler and CH system filled withwater and all isolation valves open ?

OK

NO YES

NOReplace overheat thermostat

80 L....8..... (FAN ERROR)

Is nominal 330 V DC present acrossred and blue at the fan connector as

reset button is pressed?

Replace fanYES

NO

Replace harness

81 H.....1..... (CONTROL THERMISTOR [FLOW] ERROR)

YES

Is there continuity between thePCB and the thermistor ?

Check resistance using a suitable multimeterconnected across the thermistor’s terminal pins

At 25 oC expect 9,700 - 10,300 Ohms



Remove the boiler control thermistor from theCH flow pipe and disconnect thermistor wires.

Are the thermistor values correct ? Replace the thermistorNO

NO

YES Replace PCB

Check and replace wiring as necessary

Replace PCB

YES Is 14V DC present acrossyellow and pink at the fan

connector?

Check wiring harness for continuity.Is there continuity? NO

YESNO

51

FAULT FINDING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING

FA

UL

T F

IND

ING


82 H.....2..... (CONTROL THERMISTOR [RETURN] ERROR)

YES


Remove the boiler return thermistor from theCH return pipe.


NO

YESReplace PCB


83 H.....3..... (DHW THERMISTOR ERROR)

YES


Remove the boiler DHW thermistor from the plateheat exchanger and disconnect thermistor wires.


NO

YESReplace PCB










52

FAULT FINDINGF

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G F

AU

LT

FIN

DIN

G


84 H......4..... (FLUE THERMISTOR ERROR)

Check wiring for continuity from thePCB to the flue thermistor

Can the fault condition be reset by switching offthe mains supply to the boiler ?

Is the system filled and vented and allisolation valves open ?

NO

YES

Are thermistor values correct ?

Replace PCB Replace thermistor

Fill and vent thesystem and open all

isolating valves

YES

Are thermistor values correct ?

Inspect heatexchanger for

blockage or damagein the flueways.

Clean or replace asnecessary

Replace thermistor

NO

86 H......n..... (PHASE REVERSAL ERROR)

Check wiring to the boiler forreversed live and neutral

YES NO

YES NO

85 H......F..... (FLAME DETECTION ERROR)

Replace flame detection electrode

Is there continuity between the 2 terminal pins ?NO

YES

Remove flame detection electrode terminal from PCB

Replace PCB









53

SHORT LIST OF PARTS


When ordering spares please quote:

1. Boiler model

2. Appliance G.C. No.

3. Description.

4. Quantity.

5. Product number.

The following are parts commonly required due to damage orexpendability. Their failure or absence is likely to affect safety orperformance of this appliance.

The list is extracted from the British Gas List of Parts, whichcontains all available spare parts.

The full list is held by British Gas Services, Caradon Ideal Limiteddistributors and merchants.

Key No. G.C. Part No. Description Qty. Product Number

1 E69-280 Front casing panel 1 170 994

4 E69-384 Bottom casing panel 1 171 027

11 E67-489 Burner 1 170 905

12 E85-096 Combustion chamber insulation 1 172 626

14 E67-492 Injector and housing 1 170 908

16 E85-097 Fan assembly 1 172 625

17 E69-286 Automatic air vent 1 170 988

19 E69-288 Gas control valve 1 170 913

22 E67-500 Flue thermistor 1 170 916

23 E67-501 Control thermistor (flow/return) 2 170 917

24 E67-502 Overheat thermostat 1 170 918

25 E69-291 Ignition electrode and gasket 1 170 985

26 E67-504 Flame detection electrode and gasket 1 170 920

32 E67-511 Condensate 'S' trap 1 170 926

35 E69-394 User control (display unit) 1 170 993

36 E85-103 PCB primary controls (includes plastic housing) 1 172 490

37 E67-519 Fuse PCB (3.15A L250V) 1 170 931

39 E67-521 Mains switch 1 170 933

45 E67-527 Gasket kit (servicing) 1 170 938

52 E68-376 Seal kit (sealing panel) 1 171 014

53 E68-380 Turret gasket 1 171 022

61 E69-338 Pressure relief valve 1 170 992

62 E69-339 Expansion vessel 1 170 989

64 E69-341 Pressure gauge 1 170 991

65 E69-403 DHW thermistor 1 170 996

66 E69-404 Diverter valve motor head 1 170 997

67 E69-405 Diverter valve body 1 170 998

69 E69-342 Pump 1 170 990

71 E69-408 Plate heat exchanger 1 170 995

When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performancespecification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.

54

SHORT LIST OF PARTS


87 SHORT LIST

Ecl 2408

45 52

53

19

25

22

1411

16

17

23

24

62

32

71

65

69

64

61

67

66

35

39

37

26

12

36

55

LIST OF PARTS


Ecl 1598

88 BOILER CASING ASSEMBLY

1. Front casing panel with screws.

2. Sealing panel with screws.

4. Bottom panel with screws.

Ecl

210

1

1

4

2

89 CONTROLS ASSEMBLY

33. Controls assy with screws.

34. Controls hinge bracket.

35. User controls (without item 38).

36. PCB (primary controls).

38. User controls housing

39. Mains switch.

54. Jumper link (not shown)

90 BURNER ASSEMBLY

11. Burner assembly with screws and gasket.

Ecl 2552

36

34

39

38 35

July 2003 156 412 A08

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.

Technical Training

Caradon Ideal Limited pursues a policy of continuingimprovement in the design and performance of its products. Theright is therefore reserved to vary specification without notice.

The Ideal Boilers Technical Training Centre offers a seriesof first class training courses for domestic, commercial andindustrial heating installers, engineers and systemspecifiers.For details of courses please ring: ............. 01482 498 432

CERTIFIED PRODUCTManufactured under a BS EN ISO 9001:1994 Quality System accepted by BSI

The code of practice for the installation,commissioning & servicing of central heating systems

Ideal Installer/Technical Helpline: 01482 498 663www.idealboilers.com

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