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iNSTALLATioN AND SERViciNg

1. WATER FLOW LOCKOUT Is the Boiler and CH System filled with water and all isolation and radiator valves open If the PCB has been replaced check a BCC has been fitted then reset the boiler Is the Flow Return Differential across the Boiler in excess of 30 C Check the Control No Water Flow and Return Thermistors Refer to Frame 46 amp 60 Replace the Pump then reset boiler Fill and vent the system and open all isolation valves then reset boiler Check that the Pump is rotating freely Is the Differential now below 20 C OK now reset boiler RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting 66 ALTERNATING L AND 2 IGNITION LOCKOUT NO If the boiler is reset does the boiler ignite for a short time and then extinguish YES Check the detection electrode and associated harness for continuity visual condition and position Refer to Frame 48 Check if the condensate pipe is blocked Check flue is installed correctly Replace as necessary YES YES associated harness for and visual condition Refer to Frame 49 Are these functioning correctly YES Check siphon and condensate drain pipe work for blockage and rectify if necessary Boiler now working OK Replace Gas Valve associated harness for Is the Gas Pressure available at the Boiler Inlet gt 18 mbar Is 215Vdc supply available at the
2. 150mm 6 8 From a surface or a boundary facing the terminal 600mm 24 9 From a terminal facing a terminal 1 200mm 48 10 From an opening in a car port e g door or window into dwelling 1 200mm 48 7 Above adjacent ground roof or balcony level 300mm 12 6 From an internal or external corner or to a 25mm 1 boundary along side the terminal BS5440 1 2008 300mm 12 11 Vertically from a terminal on the same wall 1 500mm 60 12 Horizontally from a terminal on the wall 300mm 12 Vertical Terminals 13 Above the roof pitch with roof slope of all angles 300mm 12 Above flat roof 300mm 12 14 From a single wall face 300mm 12 From corner walls 300mm 12 15 Below velux window 2000mm 79 16 Above or side of velux window 600mm 24 Only one reduction down to 25mm is allowable per installation otherwise BS5440 1 2008 dimensions must be followed Ideal Logic System Installation and Servicing GENERAL TERMINAL The terminal assembly can be adapted to accommodate various wall thicknesses Refer to Frame 8 AIR SUPPLY It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed due to the low surface temperatures of the boiler casing during operation therefore the requirements
3. EP a i G m 35 SERVICING SERVICING SERVICING 40 CLEANING THE HEAT EXCHANGER Note Ensure the condensate trap siphon is fully drained before cleaning Refer to Frame 51 Remove ignition and flame detection electrodes Refer to Frames 47 amp 48 lis advisable to replace the sump cover prior to the water flush process Thoroughly flush the heat exchanger by pouring water into the top of the combustion chamber ensuring the full top area is covered Remove the sump cover and clean loose deposits from the sump Inspect the ignition and detection electrodes Ensure that they are clean and in good condition replace if necessary Re fit the ignition and flame detection electrodes ensuring that both earth tabs are fitted to ignition electrode Check that the ignition and detection gaps are correct Refer to Frames 47 amp 48 41 REASSEMBLY Reassemble the boiler in the following order Ensure that the condensate trap siphon is full of water Refit the burner ensuring the sealing gasket is correctly positioned and free from damage tighten the 4 fixing screws in the sequence shown below Refit the fan venturi assembly ensuring the retaining tabs are correctly positioned and the sealing gasket is correctly positioned and free from damage Reconnect the fan electrical leads 5 Remove the sump cover and refit the lower flue manifold as 36
4. Is the wiring from the terminal block to the Main PCB Connect the wiring from the terminal block to the connected securely Main PCB securely Is the ribbon cable from the main PCB to the User Connect the ribbon from the main PCB to the User Interface PCB connected securely Interface PCB securely y YES NO Replace the Is ribbon cable damaged User Interface j YES PCB Replace ribbon cable 77 NO HW YES YES YES Is there 230V at A Refer to Frame 75 YES Check wiring from terminal strip to PCB 52 Ideal Logic System Installation and Servicing O Z A Z LL lt LL O Z a LL H lt LL O A LL x LL O A LL lt LL O a LL H x LL SPARE PARTS When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Failure to do so could affect safety or performance of this appliance Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www idealparts com Our Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665 When calling and to ensure we can provide you with the most accurate parts information please ensure you have the following to hand Boiler Model Appliance GC Number Boiler Ser
5. LP TE TTA FT LH m 90 Max 15 18 amp 24kW Distance in metres from edge of turret to side wall Dimension H 1 Dimension H must remain inside the Maximum flue length requirement for the designated kW capacity of the appliance been installed 2 For flue lengths requiring D pack extentions the flue must incline hy 26mm per 1 Metre of flue length Mo flue length greater that the maximum flue length shown above should be exceeded 10 Ideal Logic System Installation and Servicing GENERAL 2 Notes a The method of filling refilling topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority b Antifreeze fluid corrosion and scale inhibitor fluids suitable for use with boilers having aluminium heat exchangers may be used in the central heating system General 1 The installation must comply with all relevant national and local regulations 2 The installation should be designed to work with flow temperatures of up to 86 C 3 All components of the system must be suitable for a working pressure of 3 bar and temperature of 110 C Extra care should be taken in making all connections so that the risk of leakage is minimised The following components are incorporated within the appliance a b Circulating pump Safety valve with a non adjustable preset lift pressure of 3 bar Pressure gauge cove
6. Company name Telephone No SERVICE 04 e Company name Telephone No Gas safe register No At max rate Record At min rate Where Possible Gas safe register No At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 05 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate AND CO Record At min rate Where Possible AND CO At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 07 Signature SERVICE 08 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate CO Record At min rate Where Possible CO At max rate Record At min rate Where Possible Comments Comments Signature SERVICE 09 Signature SERVICE 10 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate CO Record At min rate Where Possible CO At max rate Record At min rate Whe
7. Condensate installation diagrams amp BS6798 2009 h Pipe work must be installed so that it does not allow spillage into the dwelling in the event of a blockage through freezing i All internal burrs should be removed from the pipe work and any fittings In order to minimise the risk of freezing during prolonged very cold spells one of the following methods of terminating condensate drainage pipe should be adopted internal Drain Connections Wherever possible the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc See Figs 1 and 2 Figure 1 Connection of Condensate Drainage Pipe to Internal Soil amp Vent Stack Boiler with 75mm sealed condensate Min 19mm Internal pipe Soil amp vent stack Minimum connection height up to 3 storeys Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break 24 Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom wast
8. 23 CONNECTIONS amp FILLING NOTES Ensure all boss blanking plugs are removed before connecting hardware Each valve must be fitted to the correct boss as shown in the picture Ensure each union is fitted with fibre seals provided Do not subject any of the isolating valves to heat as the seals may be damaged WATER CONNECTIONS CH 1 Connect the CH flow service valve provided in the hardware pack to the threaded boss connection provided at the lower rear of the boiler 2 Connect the CH return valve 3 For boiler outputs of 18 24 amp 30 If connecting the boiler to heating loads in excess of 60 000 Btu h connecting flow and return heating systems pipework must be sized in 28mm diameter at the point of pipe connection to the boiler tails Use 22mm x 28mm pipe adaptors as appropriate GAS CONNECTION IMPORTANT The gas service cock is sealed with a non metallic blue fibre washer which must not be overheated when making capillary connections Refer to Frame 1 for details of the position of the gas connection For additional gas supply information refer to Gas Supply on page 8 SAFETY VALVE DRAIN The safety valve connection located at the bottom right hand side of the boiler comprises a 15mm diameter stub pipe The Installer to provide a comprssion joint on the end of the stub pipe This assists with pipe removal when servicing FILLING IMPORTANT when filling A Ensure that the CH isolating
9. BOILER CHIP CARD Is the correct BCC for the boiler securely inserted into the slot at the front left of the PCB identified by the label on the BCC Replace the BCC with a new BCC that is correct for the boiler After switching power on and cO being shown press reset Is c2 still shown Securely insert the correct BCC for the boiler into the PCB and after switching power on and CO being shown reset boiler Note Ensure the correct orientation of BCC by placing TOP side up YES Replace PCB RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting Ideal Logic System Installation and Servicing 51 O Z A LL 5 lt LL O Z A LL J lt LL O Z A L lt L O Z a L B lt L O Z A L B lt LL FAULT FINDING 75 NO CH OPERATION Is the mode knob in the ON position YES Are the Timer and the Room Thermostat or cylinder thermostat switched on YES Are the Radiator Valves Open YES Is there 230Vac at A NO YES Check wiring from There is no Voltage from the terminal strip to Timer Room Stat This is not PCB boiler fault Ensure Voltage is supplied to boiler by rectifying y external wiring en chh oke OW lt Ow OB OP OL QO See WE Z Z 76 NO DISPLAY Is there 230Vac to the boiler at L and N see Frame 75 Supply power to the boiler YES
10. Ensure the dust cap on air vent located at the rear of the pump chamber is slightly unscrewed When filling there may be a slight water leak from the air vent therefore electrical connections should be Dust Cap protected handles are open Fill and vent the system Refer to Frame 2 for filling and setting pressure procedure Check for water soundness The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring Safety Valve Drain Connection 15mm elbow or fittings not supplied Safety Valve Drain Pipe CH Flow 205552 10119 26 Note that all isolation handles are shown in the open position Handle Supply Handle CH Return Ideal Logic System Installation and Servicing INSTALLATION 24 ELECTRICAL CONNECTIONS WARNING This appliance MUST be earthed A mains supply of 230Vac 50 Hz is required The fuse rating should be 3A All external controls and wiring must be suitable for mains voltage Wiring external to the boiler MUST be in accordance with the current I E E BS 7671 Wiring Regulations and any local regulations 25 INTERNAL WIRING Wiring should be 3 core PVC insulated cable not less than 0 75mm 24 x 0 2mm and to BS 6500 Table 16 For IE reference should be made to the current ETCI rules for electrical installations Connecti
11. shown Refit the sump cover Ignition Electrode Flame Detection Refit the boiler front panel IMPORTANT Ensure that the boiler front panel is correctly fitted and that a good seal is made Swing the control box back into its working position and secure 9 Turn on the gas supply at the gas service cock 10 Reconnect the electrical supply 11 Check the operation of the boiler refer to Frame 31 amp 32 Ideal Logic System Installation and Servicing SERVICING 42 REPLACEMENT OF COMPONENTS GENERAL After replacing ANY component check operation of the boiler including gas soundness gas rate and combustion test IMPORTANT Turn off the gas supply When work is complete the front panel must be correctly refitted ensuring that a good seal is made When replacing ANY component Isolate the electricity supply Remove the boiler front panel Refer to 36 Notes Release the retaining clip and swing the control box down 1 In order to assist fault finding the control panel has into its servicing position an LED diagnostic display The key to boiler fault conditions is shown in Frame 64 In order to replace components in Frames 55 62 it is necessary to drain the boiler Refer to Frame 54 THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED 43 FAN REPLACEMENT Retaining Tabs Refer to Frame 42 2 Disconnect the electrical leads from the fan Undo the gas pipe
12. 14mm From centreline of turret to wall Rear mount 155mm side including clearance 200mm FIGURE 2 Shows the flue required when measured from outside edge of turret to the outside face of the wall to obtain cut length add 44mm Minimum amp Maximum finished flue lengths obtainable dimension A 44mm Horizontal Flue Terminal Telescopic Flue B Pack Horizontal Flue Horizontal Flue Terminal 600mm long B Pack Terminal 1000mm long 1000mm long B Pack B Pack Telescopic Telescopic Cut 75mm Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum B Pack Standard Plus 1 1m D pack Plus 2 1m D pack Plus 3 1m D pack Plus 4 1m D pack Plus 5 1m D pack Plus 6 1m D pack Plus 7 1m D pack Plus 8 1m D pack Plus 9 1m D pack 8186 8084 8201 8416 8126 8341 8721 9000 8836 9000 9000 9000 9000 9000 Max output 15 18 amp 24 kW Note Telescopic flue B Pack or attached D pack extensions do not need to be cut between minimum and maximum values shown above except where specified Horizontal Flue Terminal 600mm long B Pack flue will require cutting on values below maximum values shown in the table above l J 0 lI J L 18 Ideal Logic System Installation and Servicing INSTALLATION 15 CUTTING amp SETTING THE FLUE LENGTH TELESCOPIC FLUES TELESCOPIC FLUE B PACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN IT
13. Remove the 2 screws holding the ignition electrode to the combustion chamber 6 Remove the electrode 7 Fit the new ignition electrode using the new gasket supplied Check dimensions as shown 8 Reassemble in reverse order 9 Check the operation of the boiler Refer to Frames 31 amp 32 Spark Gap u 3 5mm 1 Ideal Logic System Installation and Servicing 39 SERVICING SERVICING SERVICING 48 FLAME DETECTION ELECTRODE REPLACEMENT 1 Refer to Frame 42 2 Remove the burner Refer to Frame 45 3 Unplug the flame detection lead from the electrode Remove the 2 screws retaining the detection electrode 5 Remove the electrode 6 Fit the new flame detection electrode using the new gasket supplied 7 Reassemble in reverse order 8 Check the operation of the boiler Refer to Frames 31 amp 32 49 SPARK GENERATOR REPLACEMENT Refer to Frame 42 2 Disconnect the leads from the spark generator Remove the M5 screws securing the spark generator to the boiler chassis Fit the new spark generator and re assemble in reverse order ensuring the two earth leads are correctly replaced Check operation of the boiler Refer to Frames 31 amp 32 Spark Generator 40 Flame Detection Electrode Ideal Logic System Installation and Servicing SERVICING 50 GAS CONTROL VALVE REPLACEMENT Refer to Frame 42 Unplug the electrical lead connection from th
14. THE CHECK OF Note In order to carry out either servicing or replacement of components the boiler front panel must be removed Refer to Frame 36 1 Clean the main burner Refer to Frame 38 COMBUSTION PERFORMANCE Please Note maintenance of gas fired boilers of rated input not exceeding BS 6798 2009 Specification for installation and 7TOkW net advises that 2 Clean the heat exchanger amp condensate trap siphon Refer to Frames 39 amp 40 3 Check the main injector for blockage or damage Refer to Frame 37 4 Check that the flue terminal is unobstructed and that the flue system is sealed correctly The cleaning procedures are covered more fully in Frames 37 40 and MUST be carried out in sequence IMPORTANT 6 After completing the servicing or exchange of components always test for gas tightness 7 When work is complete the front panel MUST be correctly refitted ensuring that a good seal is made Do NOT OPERATE the boiler if the front panel is not fitted 8 If for any reason the condensate trap siphon has been removed ensure the trap is refilled with water before reassembling 9 Check the gas consumption 10 Check combustion by connecting the flue gas analayser to the flue gas sampling point as shown in the diagram and measure CO amp CO If the CO CO ratio is greater than 0 004 AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas
15. before handover to the remaining inoperative during frosty conditions customer For IE its is necessary to complete a Declaration of Explain the function and the use of the boiler heating controls Conformity to indicate compliance to l S 813 2002 IMPORTANT 11 Acomprehensive service should be carried out ANNUALLY Stress the importance of regular servicing by a Gas Safe Registered Engineer In IE servicing work must be carried out by a Registered Gas Installer RGII 12 Inform the householder of the guarantee registration found within the envelope pack and the requirement to register it to receive the full benefit of the warranty Explain the function of the boiler fault mode Emphasise that if a fault is indicated refer to Fault Codes in the User Guide Explain and demonstrate the function of time and temperature controls radiator valves etc for economic use of the system If a timer is fitted draw attention to the timer Users Instructions and hand them to the householder 32 Ideal Logic System Installation and Servicing SERVICING 35 SERVICING SCHEDULE For the very latest copy of literature for specification amp maintenance practices visit our website www idealboilers com where you will be able to download the relevant information N B Technical Bulletins are also available on www idealboilers com WARNING Always turn OFF the gas supply at the gas service cock and switch OFF and disconnect the electri
16. boiler Refer to Frames 31 amp 32 ENS A Qu 56 SAFETY RELIEF VALVE RENEWAL Refer to Frame 42 Drain the boiler Refer to Frame 54 Remove the condensate trap siphon Refer to Frame 51 Remove expansion vessel Refer to Frame 62 Disconnect the electrical connection from the return thermistor Disconnect the 22mm pipe connection at the rear of the pump outlet Pull off the clip retaining the pipe to the heat exchanger swing the pipe to clear the pump and remove pipe Undo the safety valve union connection Withdraw the clip securing the safety valve Lift safety valve from boiler Fit the new safety valve and reassemble in reverse order ensuring the new o ring is fitted to the top of the return pipe Refill boiler Refer to Frame 23 Check operation of boiler Refer to Frames 31 amp 32 57 PUMP AUTOMATIC AIR VENT REPLACEMENT Refer to Frame 42 Drain the boiler Refer to Frame 54 Remove the expansion vessel Refer to Frame 62 Firstly increase access area by disconnecting the 22mm pipe connection at top of pump chamber and bottom of heat exchanger and remove pipe Refer to Frame 56 no s 5 6 amp 7 The automatic air vent head is retained in the pump body with a bayonet connection The air vent head and float assembly is removed by turning the head anti clockwise viewed from above and pulling upwards Reassembly is the
17. bracket 3 Mark the following on to the wall a The selected group of wall mounting screw holes b The centre position of the flue duct Marking both the centre and the circumference of the flue duct 200 es A See Diagram in a ___ YFrame1 _ Remove the template plate from the wall 10 PREPARING THE WALL IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal ee I min Rear flue only Side flue only 1 Cut the flue hole preferably with a 5 core boring tool Pn diamalerpol Si aiareterhol ensuring that the hole is square to the wall Both wall faces immediately around the cut hole should be flat X 2 Drill 2 mounting holes marked from template with a 7 5mm Section 8mm masonry drill and insert the plastic plugs provided through wall for the wall mounting plate 3 Locate 2 No 14 x 50mm screws in the wall mounting plate Note Check all of the hole one at each side in any of the 3 holes provided at each positions before drilling side and screw home Ensure mounting bracket is level 11 FITTING THE WALL MOUNTING PLATE 12 MOUNTING THE BOILER Screw the wall mounting plate to the wall using 2 wall 1 Ensure the plastic plug is removed from the CH plugs previously fitted with the 2 screws provided connections be
18. in the inlet pressure test point G and connect a gas pressure gauge via a flexible tube 7 eo 8 Switch the electricity supply ON and check all external controls are Calling for heat CENTRAL HEATING 9 Setthe CH temp control A to max and turn the mode control knob B to ON The boiler control should now go through its ignition sequence until the burner is established 10 If the boiler does not light after 5 attempts the boiler will lock out and display fault code L constantly Reset the boiler Refer to Frame 33 The boiler will repeat its ignition sequence If reset occurs 5 times within 15 minutes then L 5 will be shown If power is removed this will be reset When the burner is established the BLUE Burner On neon D will be illuminated the LED display C will show status C 11 Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output Refer to Table 2 Ideal Logic System Installation and Servicing J CH Return IMPORTANT The gas input to the burner is regulated by the gas valve according to the air flow produced by the fan It is NOT user adjustable Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void For additional gas supply information refer to Gas Supply on page 8 THE DISPLAY The user control has one neon and one display to inform the user about the status The display will show
19. installed CENTRAL HEATING MODE measure and record Gas rate OR ft hr Burner operating pressure if applicable OR Gas inlet pressure mbar Central heating flow temperature C Central heating return temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate OR ft hr Burner operating pressure at maximum rate OR Gas inlet pressure at maximum rate mbar Cold water inlet temperature C Hot water has been checked at all outlets Temperature Water flow rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 Yes ALL INSTALLATIONS At max rate CO ppm CO CO At min rate where possible CO ppm CO CO Record the following The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Y es The manufacturer s literature including Benchmark Checklist and Service Record ha
20. or measuring the overall flue height from the top of the boiler it is necessary to cut both pipes of assembly A then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied Ensure the cut pipe ends are free from any burrs 1 Position the roof flashing plate Supplied separately over the hole cut in the roof and insert flue terminal from the roof end max 41 MAX LENGTH 7 5m BOILER nm8739 2 Fit the vertical connector supplied separately in accordance with the in the instructions provided with the vertical connector kit Flue Terminal ASSEMBLY A 3 Secure the vertical connector by applying downward pressure on the connector 4 Position the clamp on the top face of the flue manifold and push it horizontally backwards Locate both clamp lugs into the flue manifold and secure to the flue manifold with the M5 retaining screw Pitched roof tile 5 Push fit extension duct if required supplied separately into Flat roof tile weather collar vertical connector 7 weather collar _ Se F I Note Ensure turret sample points are servicable and all caps and C plugs are fitted nm8740 Extension Duct Vertical connector 3G9557b 6 If the last extension duct requires cutting measure X the distance outer ducts between the duct and the terminal and add 100 mm to this x dimension This gives the length of the last extension du
21. point where available and allow set boiler to operate at maximum rate readings to stabilise full load condition Allow sufficient Note Where no air inlet test point is provided then a flue integrity check with time for combustion to stabilise the analyser is not possible The installer should verify that flue integrity has Note Do not insert analyser probe been visually checked in accordance with the Prior to CO level and during this period to avoid possible combustion ratio check see opposite page before proceeding to the flooding of sensor check CO level and combustion ratio at maximum rate stage below Verify Flue Integrity Analyser readings indicate that combustion products and inlet air must be mixing Further investigation of the flue is therefore required Check that flue components are assembled fixed and supported as per instructions Check that flue and flue terminal are not obstructed O2 more than or equal to 20 6 OR CO2 ess than or equal to Check CO level and Combustion Ratio O2 more than or at Maximum Gas Rate equal to 20 6 OR CO2 With boiler still set at maximum gas rate less than or equal tg insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Turn off appliance and call Ideal Technical Helpline for advice The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the ap
22. pressure and gas rate have been verified then contact Ideal 11 Complete the service section in the Benchmark Commissioning Checklist Ideal Logic System Installation and Servicing The person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser manufacturers requirements and Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS7967 Parts 1 to 4 Air Sample Ensure all caps and seals are re fitted after use 33 SERVICING SERVICING SERVICING 36 BOILER FRONT PANEL REMOVAL REPLACEMENT REMOVAL 1 Loosen the two screws retaining the front panel 2 Pull the two spring clips down to disengage and pull panel forward and upward and remove REPLACEMENT Hook the panel onto the top retaining clips Push the panel until the 2 bottom spring clips engage ensuring the 4 control knobs line up with the holes in the front panel Re tighten the two retaining screws view from bottom of boiler view from top of boiler 37 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING Disconnect the electrical leads from the fan Undo the gas pipe
23. provided with the PCB to your wrist and a suitable earth on the boiler chassis 1 Refer to Frame 42 2 Remove the main PCB refer to Frame 52 3 Unclip the PCB and lift to clear the mounting posts 4 Fitthe new PCB ensuring the 4 potentiometer spindles line up with the control knobs which must be in a vertical position 5 Reassemble in reverse order 6 Check operation of the boiler Refer to Frames 31 amp 32 Potentiometer spindle 3G9954 54 DRAINING THE BOILER CENTRAL HEATING CIRCUIT EEEE Refer to Frame 42 se rL ry Close all the CH water isolating valves on the G 2 boiler inlet To drain the primary heat exchanger circuit Open the drain valve and attach a length of hose to the CH drain point E 7 After replacing any component on the boiler remove the hose close the drain valve and open all system isolating valves re pressurise as appropriate before proceeding to check operation of the boiler Check operation of the boiler Refer to Frames 31 amp 32 OQ Circuit Drain Ideal Logic System Installation and Servicing 43 SERVICING SERVICING SERVICING 55 PRESSURE GAUGE RENEWAL Refer to Frame 42 Drain the heating system Refer to inte O is mal Frame 54 O Unscrew the pressure gauge and discard cm Fit new pressure gauge using suitable jointing compound Refill the boiler Refer to Frame 23 Check operation of the
24. use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of literature for specification and maintenance practices visit our website www idealboilers com where you can download the relevant information in PDF format K Q lt IrmI A s u _ wi i rs H sss men FOR ANY QUERIES PLEASE RING THE IDEAL CONSUMER HELPLINE 01482 498660 NOTE BOILER RESET PROCEDURE I To reset boiler turn mode control knob to reset position and immediately turn knob back to required setting L m e e e e J eee ees ees es ees eee ees ees ee eee eee ee ee eee ee ee ee 1 Introduction Minimum Clearances The Logic System is a wall mounted room sealed condensing Clearances of 165mm 6 1 2 above 100mm 4 below system boiler featuring full sequence automatic spark ignition and fan 2 5mm 1 8 at the sides and 450mm 17 3 4 at the front of assisted combustion the boiler casing must be allowed for servicing Due to the high efficiency of the boiler condensate is produced from Bottom clearance the flue gases and this is drained to a suitable disposal point through Bottom clearance after installation can be reduced to 5mm a plastic waste pipe at the base of the boiler A condensate plume This must be obtained with an easily removable panel to will also be visible at the flue terminal enable the consumer to view the system pressure gauge and Safety to provide the 100mm
25. 1 131 135 203 204 INSTALLATION BOILER ASSEMBLY Exploded View Note that item numbers are linked to the spares list CH RETURN VALVE CH FLOW VALVE PUMP HEAD PUMP AUTO AIR VENT PRESSURE RELIEF VALVE PIPE PRV OUTLET PIPE FLOW PIPE RETURN PIPE EXPANSION VESSEL EXPANSION VESSEL FLOW GROUP MANIFOLD BY PASS KIT WATER PRESSURE TRANSDUCER PRESSURE GAUGE SAFETY VALVE DRAIN PIPE GAS COCK PIPE GAS INLET 205 206 211 214 215 217 218 219 223 224 227 228 229 231 301 GAS VALVE PIPE GAS INJECTOR INJECTOR ASSEMBLY VENTURI FAN BURNER GASKET BURNER SUMP CLEAN OUT COVER FLUE MANIFOLD FLUE MANIFOLD TOP CLAMP RETAINING FLUE TURRET HOSE CONDENSATE INTERNAL SIPHON TRAP CONDENSATE OUTLET CONNECTION CONTROLS BOX FIXINGS HINGE amp SPRING PRIMARY PCB CUI BOARD Ideal Logic System Installation and Servicing 304 306 308 309 314 324 401 503 505 506 507 CONTROL THERMISTOR RETURN ELECTRODE IGNITION ELECTRODE DETECTION IGNITER UNIT THERMISTOR CONTROL NO FLOW IGNITION LEAD CONTROL BOX LENS CONTROLS BOX LID CONTROL BOX FRONT HEAT ENGINE WALL MOUNTING BRACKET FRONT PANEL FASCIA BRACKET GAS VALVE BRACKET EXPANSION VESSEL Note that production boiler PCBs are factory pre set to operate for boiler range and output but when ordering Primary PCB as a spare an additional Boiler Chip Card BCC MUST also be purchased for your specifi
26. 2 location marks are not visible then the flue is not nole pulled back far enough to obtain the correct seal If the 1st location mark has passed the face of the wall the flue has been pulled to far back and the outer wall seal will have been dislodged from its mounting and will need to be refitted 9 When 1st mark is in line with the wall whilst holding the flue firmly push the white wall sealing flange to the wall until the 2nd of the two marks is just visible If the last location mark is clearly passed the white inner wall seal then the outer wall seal will have been dislodged from its mounting and will need to be re fitted 10 Ensure the seam and the outlet terminal are at the top and fitted as shown Note If less than 50 of the length of the flue is internal the flue should be fitted from outside Wall Seal Lip Terminal Fig 1 _ MUST be fitted as La Terminal Lip shown Rubber Location Location Terminal mark 2 mark 1 N Wall Seal Z Ensure lip of wall seal is positioned lr over step on plastic nose of flue terminal note seal is cut away for clarity FITTING THE TURRET Ensure the rubber seal is fitted correctly on the appliance manifold and that all flue seals are undamaged Hold the flue firmly and push the turret on until it has travelled 30mm on to the flue pipe and is fully engaged Make sure the flue has not rotated or moved forward during fitting and the
27. 4 8 to 15kW 16 500 to 51 300 Btu h 18 4 8 to 18kW 16 500 to 61 600 Btu h 24 4 8 to 24 2kW 16 500 to 82 600 Btu h 30 6 1 to 30 3kW 20 700 to 103 300 Btu h The boiler is supplied fully assembled with circulating pump pressure gauge safety valve and CH expansion vessel A variable CH temperature control is fitted on the user control The boiler includes as standard Boiler frost protection Daily pump exercise Note The appliance must be wired with a permanent live supply or the boiler frost protection will not operate The boiler warranty will be invalid if this requirement is not complied with The boiler casing is of white painted mild steel The boiler temperature control is visibly located in the control panel on the front of the boiler The heat exchanger is manufactured from cast aluminium The boiler is suitable for connection to fully pumped sealed heating systems ONLY Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework Pipework from the boiler is routed downwards OPERATION When there is a demand for CH the heating system is supplied at the selected temperature of between 30 C and 80 C The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating and performance of key components to aid commissioning and fault finding SAFE HANDLING This boiler ma
28. 42 Remove the 2 screws retaining the control box cover Carefully lift the 4 retaining clips and remove control box cover Unplug all lead connections to the PCB including the ribbon cable to facilitate ribbon cable removal ease side clips apart and pull upwards also where applicable push the small plastic clip with an electrical screwdriver to facilitate plug removal Spring out the two side retaining clips and pull the PCB upwards to clear the 4 corner retaining posts Take the new Primary PCB and attach the appropriate Boiler Chip Card BCC to it this should correspond to the output of the boiler 15kW 18kW 24kW or 30kW Note Ensure the correct orientation of BCC by placing TOP side up as shown Re connect all plug connections Reassemble in reverse order a Turn power on b Displays 8 blue light on off first digit input second digit input 1st letter appliance type i e 2 4 s c Move knob to required setting standby summer winter Note fno BCC fitted on non programmed board items a amp b will be displayed then Boiler Type Card Fault Contact Installer The correct BCC for this appliance will need to be fitted Check operation of the boiler Refer to Frames 31 amp 32 Plastic f Clip Ideal Logic System Installation and Servicing SERVICING 53 USER CONTROL PCB REPLACEMENT Note Fit the earth strap
29. 7671 Wiring Regulations and the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower For IE reference should be made to the current ETCI rules for electrical installations and l S 813 2002 If the appliance is to be installed in a room containing a bath or shower then providing water jets are not going to be used for cleaning purposes as in communal baths showers the appliance must be installed beyond Zone 2 as detailed in BS 7671 Ceiling Recessed window Zone 2 3G8913a Compartment Installations A compartment used to enclose the boiler should be designed and constructed specially for this purpose An existing cupboard or compartment may be used provided that 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 e BS 6798 No cupboard ventilation is required see Air Supply for details The position selected for installation MUST allow adequate space for servicing in front of the boiler For the minimum clearances required for safety and subsequent service see the wall mounting template and Frame 1 In addition sufficient space may be required to allow lifting access to the wall mounting plate GENERAL 4 Where the lowest part of the terminal
30. ALTERNATING F and 2 FLAME LOSS GO TO FRAME 70 ALTERNATING F and 3 FAN FAULT GO TO FRAME 71 ALTERNATING F and 4 CONTROL NO FLOW THERMISTOR FAULT GO TO FRAME 72 ALTERNATING F and 5 RETURN THERMISTOR FAULT GO TO FRAME 73 ALTERNATING F and 6 OUTSIDE SENSOR FAULT LOW MAINS VOLTAGE ALTERNATING F and 7 CONTACT ELECTRICITY PROVIDER PCB FAULT ALTERNATING F and 9 REPLACE PCB GO TO FRAME 74 ALTERNATING c and 2 BCC FAULT BOILER CHIP CARD ALTERNATING c and 0 RESET BOILER NO CH GO TO FRAME 75 GO TO FRAME 77 NO DISPLAY GO TO FRAME 76 Note that production boiler PCBs are factory pre set to operate for boiler range and output but when ordering Primary PCB as a spare an additional Boiler Chip Card BCC MUST also be purchased for your specific boiler range and output O Z A Z L lt LL O Z A LL s lt LL O A L x LL O A LL x LL O a LL H x LL If PCB replaced as a spare ensure that the BCC boiler chip card small plastic part is fitted to the PCB otherwise replace PCB RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting 48 Ideal Logic System Installation and Servicing FAULT FINDI NG 65 ALTERNATING L AND 1 FLOW TEMPERATURE OVERHEAT LOCKOUT OR NO
31. Additional space will be required for installation depending upon the outside site conditions Installation from inside ONLY Side and Rear Flue b Ifa core boring tool is to be used inside the building the space in which the boiler is to be installed must be at least a Provided that the flue hole is cut accurately e g with a core i wide enough to accommodate the tool drill the flue can be installed from inside the building where CLEARANCES BOILER DIMENSIONS 278 lt 2 5 lt gt Flue terminal em See inset Front clearance The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm overall clearance is still required with the cupboard door open to allow for servicing Bottom clearance Gas Inlet Bottom clearance after installation can be reduced to 5mm Condensate Drain CH Rem This must be obtained with an easily removable panel to enable Lo Y the consumer to view the system pressure gauge and to provide the 100mm clearance required for servicing DT E 522 E l J Min Top Clearance A 165mm Rear flue type Min Top Clearance 167 193 219 245 aTh 29M 323 B49 375 009 mm ASIDE Flue type Distance from Horizontal rim required to achieve 1 5deq fall ta the appliance 26 5A 7a 104 130 156 152 206 233 mm E a nm 1 5 degree Clearance 7 0 5 0 Max 30kW 305
32. Gas Valve See note Unplug gas valve Is resistance between outside pins 4KQ 2 Check spark generator and Check ignition electrode and visual condition and position Refer to Frame 47 Are these functioning correctly Check gas supply and rectify fault NO Check wiring connection y from gas valve to PCB for continuity If the wiring is OK then replace the PCB aoe Replace Gas Valve ae Replace Spark Generator and harness continuity as necessary Replace Ignition Electrode and associated harness as necessary continuity Note due to the wave form of the rectified voltage the reading will vary depending on the type of meter used to measure the value In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting Ideal Logic System Installation and Servicing 49 FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING 67 ALTERNATING L AND 6 FALSE FLAME LOCKOUT Check routing and integrity of internal boiler Reset the boiler does Boiler Work OK wiring is OK Check condition of Flame Sense Electrode and replace if deteriorated Separate the flame detection electrode in line Replace Flame Detection Electrode connector Is there continuity between the termi
33. IC FLUE B PACK 1 Measure the required flue length A 44mm 10mm 2 Measure from the outer terminal lip to end of outer flue Pull apart flue until Adjust to Length A 44mm from terminal lip desired length is achieved ENSURE THE STOP MARK IS NOT VISIBLE F l IF IT IS THE FLUE IS TOO SHORT AND SHOULD NOT BE USED 3 Check that both flue seams are at the top and the outlet terminal is upper most Drill Hole 4 Drilla 3 5mm hole through one of the 2 outer side holes in the outer flue Adhere sealing tape section into the inserted outer flue as shown Take care not to pierce the inner plastic flue Fit screw provided 5 Seal the joint on the outer air duct with the tape provided 6 Fit internal and external wall seals see installing flue CUTTING HORIZONTAL FLUE TERMINAL 600MM LONG B PACK 1 Measure the required cut flue length A 44mm If inside the dimensions shown in Figure 2 1 Piece 600mm proceed 2 Measure from the outer terminal lip to end of outer flue Mark the required cut length A 44 around the circumference of the outer flue and cut following the mark to ensure its cut square 10mm 3 Dress the cut end to make sure all burr s are removed and the cut edge Mark Cut Length A 44mm from terminal lip is in its original shape 4 Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure its cut square li d E J 0 l
34. INSTALLATION AND SERVICING LOGIC SYS EM 15 18 24 SO For Users Guide see reverse of book Q il e For details of document amendments refer to page 3 THE QUEEN S AWARDS FOR ENTERPRISE INNOVATION 2013 When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of literature for specification and maintenance practices visit our website www idealboilers com where you can download the relevant information in PDF format May 2014 E UIN 206025 A06 L Ideal Logic System Installation and Servicing NOTES FOR THE INSTALLER m FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL INSTALLER HELPLINE 01482 498704 NOTE BOILER RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting The boiler will repeat the ignition sequence if a heat demand is present DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level A05 Jan 14 to A06 May 14 Cover Pages Re brand outer covers Page 11 Paragraph 4b updated Ideal Stelrad Group reserve the right to vary specification without notice Ideal Logic System Installation and Servicing 3 GENERAL Table 1 General Data 22mm copper compr
35. Installer RGII burner burner Control No Flow Thermistor Reset the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Return Thermistor Reset the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGIl Ideal Logic System User s T I Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance Ideal Consumer Helpline of its products The right is therefore reserved to vary specification without notice Tel 01 482 49 5660 Ideal P O Box 103 National Ave Kingston Upon Hull HU5 4JN www idealboilers com Tel 01482 492251 Fax 01482 448858 Registration No London 322 137
36. Roof Flue Kit to a maximum of 7 5m e Powered Vertical Flue Kit 5m primary and 17m secondary is a typical maximum length For alternative details refer to Powered Vertical Instructions e Flue Finishing Kit High Level Flue Outlet Kit e Flue Deflector Kit e Adjustable Flue Support Bracket e Balcony Flue Kit e Raised Horizontal Flue Outlet Kit Concentric Flue Screw Retaining Kit e Weather Collar Universal e Weather Collar Flat Roof e Stand Off Kit e Stand Off Kit inc pipes e Pre Piping Frame Kit e Condensate Pump Kit Weather Compensation Kit e Security Bracket Kit PRY Wall Outlet Kit e Pressure Gauge Extension Kit Ideal Logic System Installation and Servicing GENERAL SAFETY Current Gas Safety installation and use regulations or rules in force The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation must be carried out by a Gas Safe Registered Engineer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation and Use Regulations e The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations Northern Ireland e The Water Fittings Regulations or Water byelaws in Scotland The Current l E E Wiring Regulations Where no specific instructions are given reference should be
37. S SPECIFIED RANGE AND MUST NOT BE CUT HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK TELESCOPIC MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 amp 652MM THIS WILL REQUIRE 75MM TO BE CUT OFF THE TERMINAL END OF THE 1000MM TELESCOPIC FLUE ALL OTHER LENGTHS OBTAINED USING D PACK EXTENSIONS IN FLUE LENGTH TABLE 1 COLUMN HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK CUT 75MM TELESCOPIC SHOULD HAVE THE 75MM CUT OFF THE D PACK EXTENSION AND NOT TELESCOPIC FLUE CUT 75MM OFF HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK TELESCOPIC 1 Measure cut flue length A 44mm If required telescopic length is not between 658 and 708 then proceed to Setting Telescopic Flue B Pack Remove telescopic end piece from the flue body and set aside Mark the circumference 75mm from the open end of the outer flue Cut along the 75mm mark cutting only the outer flue ensuring the cut is square oc ee oe I Dress the cut end to make sure all burr is removed and the cut edge is in its original shape 6 Measure 20mm from the newly cut edge of the outer flue place a mark at the top of the flue approximately 20mm wide amp write stop the terminal side of the line 7 Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure its cut square 8 Remove all burrs and place a chamfer on the outer edge to aid assembly 9 Re assemble telescopic section SETTING TELESCOP
38. TERNAL WIRING CONT D LOGIC SYSTEM BOILER WITH S PLAN SYSTEM I L O nll BOILER sL ta CEEEEIC ON ON ON OFF ON TL INSTALLATION wont HW ON 3610023 27 REPLACING PRE FITTED MAINS CABLE If it is necessary to use an alternative mains cable to the one pre fitted then use the following guide Replacement wiring should comply with notes in Frame 24 Isolate the mains supply to the boiler Remove the front panel Refer to Frame 36 Swing the control box down into the service position Refer to frame 42 4 Remove the live neutral and earth wires from the terminal block Loosen the cable clamp and withdraw the mains cable 6 Route replacement cable back through the cable clamp and grommet and re tighten to provide cord anchorage Connect the live neutral and earth wires to the terminal strip When making the mains electrical connections to the boiler it is important that the wires are prepared in such a way that the earth conductor is longer than the current carrying conductors such that if the cord anchorage should slip the current carrying conductors become taut before the earthing conductor Swing the control box back up into the operating position and re fit the front panel ensuring a good seal is made 28 EXTERNAL ELECTRICAL CONTROLS Wiring External to the Boiler The fuse rating should be 3A Wiring external to the boiler MUST be in accordance with the current E E BS 7671 Wi
39. Thickness Std Metric Brick 102 5mm wide B Pack Flue Type 60 100 Minimum permissible Wall Thickness Maximum permissible Wall Thickness VC Rear Flue Rear Flue Std Off Side Flue Rear Flue Rear Flue Std Off Side Flue Horizontal Flue Terminal 116 102 5 102 5 501 456 456 600mm long B Pack Telescopic Flue B Pak __ 231 16 f 1 4o po o f 3 Horizontal Flue Terminal 546 501 501 716 716 1000mm long B Pack T e Te Horizontal Flue Terminal 1000mm long B Pack cut 75mm For Flue lengths between 658 amp 708 use a Horizontal Flue Terminal 1000mm long B Pack cut 75mm off the end of the terminal section of the telescopic flue only li J 0 ll B L Ideal Logic System Installation and Servicing INSTALLATION 14 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED CONT D F G U RE 1 Edge of turret Edge of turret Edge of turret to outside face of wall plus to outside face of wall plus to outside face of wall plus 44mm flue length 44mm flue length 44mm flue length Note Maximum permissible flue length is measured from centre line of appliance flue outlet to outside wall face to wall inc Stand off Frame Minimum clearance 5mm Flue length measured from outer terminal lip to end of outer flue NOTES A 44mm Centre of turret to edge of turret 100mm Turret has a flue insertion of 30mm The compressed outer wall seal has protruding wall to seal mounting lip
40. ain back to the boiler and out of the condensate drain It is recommended that a support bracket is fitted on every 1 metre of pipe work used and the bracket is located as close to the collar as possible The bracketing must ensure a 1 5 degree fall back to the appliance Optional Flue Finishing Kit UIN 155988 amp Concentric Flue Screw Retaining Kit Optional Kit of mechanical fixing of flue joints Only use water as a lubricant during assembly The B pack terminal is classed as part of the maximum flue length These flue systems incorporates a removable flue outlet nose that utilises a push fit location system This enables the installation of deflector high level or balcony flue kits without the removal of the whole B pack terminal The appliance must not be operated without the desired outlet nose correctly fitted in place ensuring the side location dimples are in line with the mounting face allowing the correct sealing of the components Itis IMPORTANT that all attachments are fitted in accordance to the installation instructions provided with them The TURRET supplied in the B Pack has an upper combustion sample point with a screw cap seal and a lower air sample point with an air stopper seal Ensure all caps amp seals are in place Additional Termination Kits available for use with these B packs Flue Deflector Kit The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from any m
41. aximum flue length High Level Flue Outlet Kit The maximum permissible concentric flue length when using a standard 500mm kit is 4 5 metres Balcony Flue Outlet Kit The maximum permissible concentric flue length when using this kit is dependant on the length of the balcony flue outlet run which combined with the concentric run must not exceed the maximum flue length requirement of the appliance it is to be fitted to Total Maximum Permissible Horizontal Concentric Flue Length combining both B Packs and D Packs Measured from centreline of the turret to the outside of the wall terminal 15 18 amp 24 kW appliances Total Maximum 9 metres minus any flue kit options or bends 30 kW Appliances Total Maximum 8 metres minus any flue kit options or bends Total Maximum Permissible Vertical Flue Length combining both Roof Terminal and D Packs 15 18 24 amp 30kW Appliances Total Maximum 7 5 Metres minus any bends Powered Vertical Flue 15 18 24 amp 30kW Appliances Total Maximum 5 Metres Concentric Flue and 17m flue pipe only For additional details refer to the powered Vertical Instructions 90 Elbow Kit 60 100 Equivalent flue length resistance 1M 45 Elbow Kit 60 100 Equivalent flue length resistance 0 6M Minimum Horizontal Flue Lengths Centre line of turret to outside of wall terminal Telescopic Flue B Pack 400mm Horizontal Flue terminal 600mm long B Pack 285mm Wall
42. azards 4 Once the blockage is removed and the condensate can flow freely reset the appliance Refer to To Light the boiler 5 If the appliance fails to ignite call your Gas Safe Registered engineer Preventative solutions During cold weather set the boiler stat to maximum Must return to original setting once cold spell is over Place the heating on continuous and turn the room stat down to 15 C overnight or when unoccupied Return to normal after cold spell Escape of gas Should a gas leak or fault be suspected contact the National Gas Emergency Service without delay Telephone 0800 111 999 Do NOT search for gas leaks with a naked flame Cleaning For normal cleaning simply dust with a dry cloth To remove stubborn marks and stains wipe with a damp cloth and finish off with a dry cloth DO NOT use abrasive cleaning materials Maintenance The appliance should be serviced at least once a year by a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII Ideal Logic System User s POINTS FOR THE BOILER USER Note In line with our current warranty policy we would ask that you check through the following guide to identify any problems external to the boiler prior to requesting a service engineers visit Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit or for any pre arranged visit where access is not gained by the eng
43. c boiler range and output 118 136 114 17 206025 10142 13 INSTALLATION INSTALLATION INSTALLATION 6 UNPACKING The boiler is supplied fully assembled in Pack A A telescopic or non telescopic flue assembly for rear or side flue outlet in Pack B is suppled as a separate order Unpack and check the contents Pack A Contents A Boiler B Hardware Pack Box C Wall Mounting Plate D These Installation Users Instructions E Wall Mounting Template located on internal protective packaging Turret Clamp Safety Valve Drain Pipe Boiler Guarantee amp Registration Pack G T HARDWARE PACK CONTENTS Gas Valve Pack 1 Pipe Gas Inlet 2 Washer Gas blue Gas Valve Pack Accessory Pack 3 Gas Cock Return Valve Pack 1 G 1 Pipe CH Return y 1 T 2 Washer CH 3 Valve Return Accessory Pack 1 Screw x2 Return Valve Pack Flow Valve Pack 2 Wallplug x2 3 Turret Clamp Screw x1 s i x Flow Valve Pack a a 1 Pipe CH Flow 2 Washer CH 2 Oo 3 Valve Flow with gauge 14 Ideal Logic System Installation and Servicing INSTALLATION f UNPACKING CONT D Note This flue system incorporates a removable
44. ce has been followed e g Gas Safe Register Technical Bulletin TB 008 where chimney flues are in voids The ECGA should be of the correct type as specified by BS 7967 Prior to its use the ECGA should have been maintained and calibrated as specified by the manufacturer The installer must have the relevant competence for use of the analyser Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer s instructions KEY CO carbon monoxide CO carbon dioxide O2 oxygen Combustion Ratio The CO reading measured in ppm divided by the CO2 reading first converted to ppm ppm parts per million GS I amp U R Gas Safety Installation and Use Regulations Setting to Minimum Rate Turn the CH temperature control knob into the 10 O clock position Create a heat demand by ensuring that the system controls are requesting heat and the boiler Mode Knob is in the On Position Within an overall time of 3 seconds turn the CH temperature control knob fully clockwise back to 10 O clock and then fully clockwise again 4 S will be shown on the display and the boiler output will be reduced to minimum 5 The boiler will remain at minimum rate for 5 minutes before reverting to normal operation Ideal Logic System Installation and Servicing Set Boiler to Maximum Gas Rate Carry Out Flue Integrity Check Using Analyser In accordance with boiler instructions Insert analyser probe into air inlet test
45. city supply to the appliance before servicing Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927 To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually It is the law that any service work must be carried out by a Gas Safe Registered Engineer In IE service work must be carried out by a Registered Gas Installer RGII INSPECTION 1 Light the boiler and carry out a pre service check noting any operational faults 2 Check the flue terminal and terminal guard if fitted is undamaged and clear of any obstruction 3 Check all water and gas joints for signs of leakage i Remake any suspect joints ensuring a gas tightness check is carried out if applicable and the water system is correctly refilled vented and re pressurised CLEANING PROCEDURE GENERAL Please Note During routine servicing and after any maintenance or change of part of the combustion circuit the following must be checked The integrity of the flue system and the flue seals The integrity of the boiler combustion circuit and the relevant seals The operational working gas inlet pressure at maximum rate The gas rate The combustion performance COMPETENCE TO CARRY OUT
46. clearance required for servicing Current Gas Safety Installation amp Use Regulations or rules in force To light the boiler Refer to Frame 1 In your own interest and that of safety it is the law that this boiler If a programmer is fitted refer to separate instructions for the must be installed by a Gas Safe Registered Engineer in accordance programmer before continuing with the above regulations 1 CHECK THAT THE ELECTRICITY SUPPLY TO BOILER IS In IE the installation must be carried out by a Registered Gas Installer OFF RGII and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical Set the mode control knob B to Off 3 Set the Central Heating temperature control A to max 4 Switch ON electricity to the boiler and check that all installation external controls e g programmer and room thermostat It is essential that the instructions in this booklet are strictly followed are ON a for safe and economical operation of the boiler P Saliba pode contol icp ian Electricity Supply The boiler will commence the ignition sequence supplying heat to the central heating if required Note n normal operation the boiler status display C will show codes bd This appliance must be earthed Supply 230 V 50 Hz The fusing should be 3A Important Notes This appl
47. ct lI lt l E B 0 li J L ae SB Note Check the position of the inner flue duct relative to the outer duct on X the assembled extension duct s and ensure the terminal flue duct is cut longer than the air duct to ensure engagement in the final flue duct seal 7 Finally ensure the roof flashing plate is correctly sealed to the roof Ideal Logic System Installation and Servicing 23 INSTALLATION INSTALLATION 21 CONDENSATE DRAIN Condensate Drain This appliance is fitted with a siphonic 75mm condensate trap system that requires filling before operating the appliance for the 1st time or after maintenance All condensate pipework should conform to the following a Where a new or replacement boiler is being installed access to an internal gravity discharge termination should be one of the main factors considered in determining boiler location b Plastic with push fit or solvent connections c Internal plastic pipe work a minimum of 19mm ID typically 22mm OD d External plastic pipe must be a minimum of 30mm ID typically 32 OD before it passes through the sleeved wall e All horizontal pipe runs must fall a minimum of 45mm per metre away from the Boiler f External amp unheated pipe work should be kept to a minimum and insulated with Class O waterproof pipe insulation g All installations must be carried out in accordance to the relevant connection methods as shown in the
48. ct Fit a new Thermistor Is there continuity between the PCB and Thermistor Replace PCB Check and replace wiring as necessary 72 ALTERNATING F AND 5 RETURN THERMISTOR FAULT Remove the Return Thermistor from the CH Return Pipe and disconnect the wires Check the resistance using a suitable multimeter connected across the thermistors terminal pins At 25 C expect 9 700 10 300 Ohms At 60 C expect 2 400 2 600 Ohms At 85 C expect 1 000 1 100 Ohms Is the Thermistor value correct Fit a new Thermistor Is there continuity between the PCB and Thermistor Replace PCB Check and replace wiring as necessary 73 ALTERNATING F AND 6 OUTSIDE SENSOR FAULT Is the wiring securely connected at both the boiler and Outside Sensor Disconnect the wires to the outside sensor Check the resistance using a suitable multimeter connected across the Outside Sensors terminal pins Ohms Ohms Ohms AtO C expect At15 C expect At 30 C expect 31 000 35 000 15 000 16 500 7 700 8 500 Is the Outside Sensor value correct NO Securely connect the wiring at both the boiler and Outside Sensor NO gt Fit a new Outside Sensor Is the wiring securely connected between the incoming terminal block boiler connection of the Outside Sensor and the PCB YES NO Replace PCB Securely connect the wiring at the Terminal Block and the PCB 74 ALTERNATING c AND 2 BCC FAULT
49. cuit of load of at least 10 of the minimum boiler output must be provided with twin lockshield valves so that this minimum heating load is always available See note regarding thermostatic radiator valves on page 9 Note Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass BALANCING 1 4 Set the programmer to ON Close the manual or thermostatic valves on all radiators leaving the twin lockshield valves on the radiators referred to above in the OPEN position Turn up the room thermostat and adjust the lockshield valve to give an uninterrupted flow through the radiator These valves should now be left as set WATER TREATMENT CENTRAL HEATING The Logic System range of boilers have an ALUMINIUM alloy heat exchanger IMPORTANT The application of any other treatment to this product may render the guarantee of Ideal Stelrad Group Invalid Ideal Stelrad Group recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems If water treatment is used Ideal Stelrad Group recommend only the use of Scalemaster Gold 100 FERNOX MBI ADEY MC1 or SENTINEL X100 inhibitors and associated water treatment products which must be used in accordance with the manufacturers instructions Notes 1 12 It is most important that the correct concentration of the water treatment products is maintaine
50. customer following completion of work providing advice and assistance by phone and if necessary visiting the customer Rectify any installation problems at no cost to the customer during the installer s guarantee period www centralheating co uk Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the data fields on the commissioning checklist completed in full To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed The service details should be recorded on the Benchmark Service Interval Record and left with the householder 2enchmar COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk Heating and Hotwater Industry Council HHIC Ideal Logic System Installation and Servicing 55 GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to in
51. d in accordance with the manufacturers instructions If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing BS 7593 2006 details the steps necessary to clean a domestic heating system In hard water areas treatment to prevent lime scale may be necessary however the use of artificially softened water is NOT permitted Under no circumstances should the boiler be fired before the system has been thoroughly flushed Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators to give around 20 C temperature drop at each radiator Adjust the room thermostat and programmer to NORMAL settings For further information contact Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ 44 0 0870 601 5000 Sentinel Performance Solutions The Heath Business amp Technical Park Runcorn Cheshire WA7 4QX Tel 0800 389 4670 www sentinel solutions net Scalemaster Water Treatment Products Emerald Way Stone Staffordshire ST15 OSR Tel 44 0 1785 811636 Calmag Ltd Unit 3 6 Crown Works Bradford Road Sandbeds Keighley West Yorkshire BD20 5LN Tel 44 0 1535 210 320 Adey Professional Heating Solutions Gloucester Road Cheltenham GL51 8NR Tel 44 0 1242 546700 Ideal Logic System Installation and Servicing 5 104 105 110 113 114 115 116 117 118 120 12
52. e gas control valve and disconnect the earth wire Undo the union nut on the outlet of the gas control valve Undo the gas inlet pipe union at the inlet to the gas control valve Loosen the back nut retaining the valve to the bracket and withdraw the valve forwards Fit the new gas control valve ensuring the two sealing washers are in place and reconnect gas and electrical connections Check operation of the boiler Refer to Frames 31 amp 32 51 CONDENSATE TRAP SIPHON REPLACEMENT 1 Refer to Frame 42 Note Ensure condensate trap is fully drained before removal Pull off the rubber pipe at the sump drain Disconnect the condensate drain pipe Turn the siphon clockwise to disengage and lift to remove Reassemble in reverse order When reassembling ensure the trap is full of water Check operation of the boiler Refer to Frames 31 amp 32 Ideal Logic System Installation and Servicing 41 SERVICING SERVICING 52 MAIN PCB REPLACEMENT SERVICING Note that production boiler PCBs are factory pre set to operate for boiler range and output but when ordering Primary PCB as a spare an additional Boiler Chip Card BCC MUST also be purchased for your specific boiler range and output Note Fit the earth strap provided with the PCB to your wrist and secure to a suitable earth on the boiler chassis 1 Refer to Frame 42 2 Note the control knob positions 10 11
53. e pipe etc fig 3 External Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose designed soak away If an external system is chosen then the following measures must be adopted The external pipe run should be kept to a minimum using the most direct and most vertical route possible to the discharge point with no horizontal sections in which condensate might collect For connections to an external soil vent stack see Fig 4 Insulation measures as described should be used When a rainwater downpipe is used an air break must be installed between the condensate drainage pipe and the downpipe to avoid reverse flow of rainwater into the boiler should the downpipe become flooded or frozen see Fig 5 Where the condensate drain pipe terminates over an open foul drain or gully the pipe should terminate below the grating level but above water level to minimise wind chill at the open end The use of a drain cover as used to prevent blockage by leaves may offer further prevention from wind chill See Fig 6 Where the condensate drain pipe terminates in a purpose designed soak away see BS 6798 any above ground condensate drain pipe sections should be run and insulated as described above See Fig 7 Unheated Internal A
54. e property working Gas Pressure Test Point As part of the commissioning process the combustion of this appliance must be checked and the Benchmark Checklist completed A flow chart to assist is provided on page 59 ATTENTION IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE 30 Ideal Logic System Installation and Servicing INSTALLATION 31 INITIAL LIGHTING Legend CH temperature control Mode Control Knob Boiler Status Burner on indicator CH Flow Isolating Valve Pressure Gauge Gas Inlet Pressure Test Point Gas Service Cock CH Return Isolating Valve Drain Valve ACrToanmmoonpy 10121 Note Valves shown are in the open position 1 Check that the system has been filled and that the boiler is not airlocked Ensure the automatic air vent cap is open Refer to Frame 28 Note It is important the burner is not operated before the system is fully vented of air If it is necessary to operate the appliance pump to assist venting of the air this must be done with the gas service cock turned off 2 Refit the boiler front panel Refer to Frame 36 3 Check that the drain valve K is closed and that the CH isolating valve E and J are OPEN Check that the electrical supply is OFF Check that the boiler mode control knob B is off Check that the gas service cock H is OPEN Slacken the screw
55. ed Wiring external to the appliance MUST be in accordance with the current I E E BS 7671 Wiring Regulations and any local regulations which apply For IE reference should be made to the current ETCI rules for electrical installations The mains supply to the boiler and system wiring centre shall be through one common fused double pole isolator For new heating systems and where practicable replacement boiler installations the isolator shall be situated adjacent to the appliance CONDENSATE DRAIN Refer to Frames 21 22 amp 39 A condensate drain is provided on the boiler This drain must be connected to a drainage point on site All pipework and fittings in the condensate drainage system MUST be made of plastic no other materials may be used IMPORTANT Any external runs must be in accordance with BS 6798 The drain outlet on the boiler is sized for standard 21 5mm 3 4 overflow pipe It is a universal fitting to allow use of different brands of pipework Ideal Logic System Installation and Servicing GENERAL 1 BOILER DIMENSIONS SERVICES amp CLEARANCES all dimensions in mm The boiler connections are made on the boiler connection tails Refer to Frame 23 wall thicknesses do not exceed 600mm 24 Where the The following minimum clearances must be maintained for space into which the boiler is going to be installed is less operation and servicing than the length of flue required the flue must be fitted from
56. ely turn knob back to required setting The boiler will repeat the ignition sequence if a heat demand is present Legend A CH temperature control B Mode Control Knob C Boiler Status D Burner on indicator 34 HANDING OVER After completing installation and commissioning of the system the installer should hand over to the householder by the following actions Hand the User Instructions to the householder and explain his 8 Loss of system water pressure her responsibilities under the relevant national regulations Explain that the dial underneath the boiler indicates the central Explain and demonstrate lighting and shut down procedures heating system pressure and that if the normal COLD pressure The operation of the boiler and the use and adjustment of all of the system is seen to decrease over a period of time then a system controls should be fully explained to the householder water leak is indicated Explain the re pressurising procedure to ensure the greatest possible fuel economy consistent with and if unable to re pressurise or if the pressure continues to drop the household requirements of both heating and hot water a registered local heating installer should be consulted consumption 9 Explain Boiler reset procedure Advise the User of the precautions necessary to prevent damage After installation and commissioning please complete the to the system and the building in the event of the system Benchmark Commissioning Checklist
57. er Refer to Frame 54 Unplug the electrical lead Unscrew the thermistor to facilitate removal a 13mm socket spanner should be used Fit the new thermistor using the sealing washer provided Reassemble in the reverse order 7 Refill the boiler Refer to Frame 23 8 Check the operation of the boiler Refer to Frames 31 amp 32 Ideal Logic System Installation and Servicing X GRUN DFOS Y Type UPO15 60 CESA0G Pkasara 230V Peony SOHz 2 5pf O GFS IAF BU ci 0 39 90 Vo SDP LowEnegy A sa amp 3 45 SERVICING SERVICING SERVICING 61 HEAT ENGINE RENEWAL Refer also to Frame 5 Boiler Exploded View IMPORTANT Before starting the removal procedure protect the gas and electrical controls with a waterproof sheet or plastic bag 1 Refer to Frame 42 12 Undo the flow pipe union nut and remove pipe 2 Drain the boiler Refer to Frame 54 13 Remove the condensate rubber pipe Refer to Frame 51 no 3 Remove the fan venturi assembly and place on one side 2 Refer to Frame 43 14 Remove the two heat exchanger fixing screws 4 Remove the burner and place on one side Referto Frame 15 Remove the Heat exchanger 45 16 Reassemble in reverse order ensuring the heat exchanger 5 Remove the ignition and detection electrodes Refer to LH retaining bracket is correctly positioned Replace any Frames 47 amp 48 new o rings supplied with new heat exchanger and replaci
58. ession Flue Terminal Diameter mm in Maximum Working Pressure Sealed Systems bar Ib in Power Consumption W 126 131 146 152 Fuse Rating External 3A Internal T4H HRC L250 V Water content litre gal 1 2 0 20 Packaged Weight kg Ib 34 5 76 34 5 76 34 5 76 34 5 76 Maximum Installation Weight kg Ib 28 61 7 28 61 7 28 61 7 28 61 7 Boiler Casing Size mm in 700 27 5 mm in 395 15 5 m in 278 11 m In Table 2 Performance Data Central Heating 4 l l 520 T MAX 30 X IN Q Nett CV kW 9 15 1 4 9 18 1 4 9 24 3 6 1 30 4 Btu h 16 600 51 520 16 600 61 800 16 600 82 900 20 700 103 600 Gross CV kW 54 16 6 5 4 20 1 5 4 27 0 6 7 33 7 Btu h 18 400 56 800 18 400 68 600 18 400 92 000 23 000 115 000 9 22 Gas Consumption m h 0 500 1 537 0 500 1 872 0 500 2 512 0 622 3 130 ft h 17 8 54 7 17 8 66 1 17 8 8 111 Boiler Output Non Condensing kW 4 8 15 0 18 0 i 24 2 l 30 3 70 C Mean Water temp Btu h 16 500 51 300 61 600 82 600 103 300 Condensing kW 5 1 15 9 19 1 l 25 6 31 0 40 C Mean Water temp Btu h 17 500 54 250 65 100 87 400 105 800 Seasonal efficiency SEDBUK 2005 91 1 Seasonal efficiency SEDBUK 2009 89 3 89 2 89 5 NOx Classification CLASS 5 The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwell
59. fficiency condensing boiler which is most efficient when operating in condensing mode The boiler will operate in this mode if the CH temperature control A is set to the e position economy mode This control should be set to maximum for very cold periods Weather Compensation When the Weather Compensation option is fitted to the system then the CH Temperature Control A becomes a method of controlling room temperature Turn the knob clockwise to increase room temperature and anti clockwise to decrease room temperature Once the desired setting has been achieved leave the knob in this position and the system will automatically achieve the desired room temperature for all outside weather conditions To Shut Down the Boiler Set the mode control knob to OFF To Relight the Boiler Repeat the procedure detailed in To light the boiler 1 BOILER CONTROLS Legend A CH Temperature Control B Mode Control C Boiler Status Ideal Logic System User s D Burner on Indicator E Pressure Gauge F Condensate Drain Frost Protection If no system frost protection is provided and frost is likely during a short absence from home leave the heating controls if fitted at a reduced temperature setting For longer periods the entire system should be drained If the system includes a frost thermostat then during cold weather the boiler should be turned OFF at the time switch if fitted ONLY The mains supply sh
60. flue outlet nose that utilises a push fit location system This enables the installation of deflector high level or balcony outlet flue kits without the removal of the whole B pack terminal The appliance must not be operated without the desired outlet nose correctly fitted in place Note Location dimples must be aligned with terminal mounting frame Pack B Contents Non Telescopic A Flue terminal D B Flue turret C Rubber terminal wall seal i E C D Cutting Aid E Wall Seal white A Pack B Contents Telescopic Telescopic flue terminal Flue turret Rubber terminal wall seal F C Screw Sealing Tape Wall Seal white m oO W gt 8 FRONT PANEL REMOVAL 1 Loosen the 2 screws retaining the front panel 2 Pull the two spring clips downwards to disengage 3 Pull the front panel forward and upwards to remove Ideal Logic System Installation and Servicing 15 INSTALLATION INSTALLATION 9 WALL MOUNTING TEMPLATE The wall mounting template is located on the internal protective packaging The template shows the position of the fixing and rear flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled 1 Tape template into the required position ensuring its squareness by hanging a plumbline as shown 2 If fitting a side flue extend the flue centreline onto the side by 155mm on a standard wall fix or 200mm if using a stand off
61. flue seam is upper most Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold Fully engage the clamp location section into the manifold location holes Rotate down on to turret flange Secure clamp to appliance using securing screw Ensure all sample points are accessible and all sample plugs and caps are fitted Retaining Clamp Lugs screw Duct Assembly Flue Turret Turret Clamp Seal Flue Outlet Ideal Logic System Installation and Servicing INSTALLATION 17 FITTING THE OPTIONAL ROOF FLUE KIT Flat or Pitched Note A flat or pitched roof flashing plate not supplied is required before proceeding with the installation of this kit This kit is suitable for both flat and pitched roof terminations using a concentric flue to run vertically from the top of the boiler and terminating above roof level Connection to the top of the boiler is made using a separately supplied vertical connector WEATHER PROOFING Where the flue passes through the roof line an adequate seal must be made This is achieved by using either Flat roof weather collar or Universal weather collar ACCESSORIES Flue Duct Extension Kits are available for flue lengths extending beyond 1m These packs contain 1m extension ducts and may be cut to the desired length If the offset vertical option is used an elbow Kit is required For a full accessories list refer to page 6 Opti
62. fore mounting the boiler Choose one of the 2 sets of slots in left and right bank Lift the boiler onto the wall mounting plate refer to the Ensuring that at least one of the screws is fitted into a top Introduction section for safe handling advice locating it slot over the two tabs Example of fixing 3G9948 ZO 16 Ideal Logic System Installation and Servicing FLUE OUTLET INSTALLATION 13 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT The boiler must be installed in a vertical position in accordance to the installation instructions FLUE KITS Telescopic Flue B Pack contains Flue turret telescopic flue incorporating a terminal and rubber wall seals Horizontal Flue Terminal 600mm long B Pack contains Flue turret non telescopic single piece flue incorporating a terminal and rubber wall seals Horizontal Flue Terminal 1000mm long B Pack Flue turret telescopic flue incorporating a terminal rubber wall seals and instructions Note If B packs are used on their own either 1 piece or telescopic then they can be fitted horizontally as the flue inside is designed to slope 1 5 degrees D Pack contains 1 metre length of flue pipe Functional length 950mm 1 support bracket and instructions When extension D Packs are used the flue duct must incline 1 5 degrees away from the appliance to allow the condensate to dr
63. g for central heating hot water am 9 burner The boiler is operating in frost mode continued 6 Ideal Logic System User s FAULT CODES aa usa s aaa sas burner burner Boiler Chip Card BCC Please contact Ideal if under warranty or alternatively a Gas Safe Not Fitted Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Outside Sensor Failure Reset the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII uen Barnes Low Mains Voltage Contact a qualified electrician or your electricity provider burner burner PCB Fault PCB Fault Please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII 5 Boiler Resets in 15 minutes 1 Turn power off and on at the fused spur 2 If the boiler fails to operate please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner False Flame Lockout Reset the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if ou
64. hat they do not play with the appliance In cases of repeated or continuous shutdown a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII should be called to investigate and rectify the condition causing this and carry out an operational test Only the manufacturers original parts should be used for replacement All Gas Safe Register installers carry a Gas Safe Register ID card and have a registration number Both should be recorded in the Benchmark Commissioning Checklist You can check your installer by calling Gas Safe Register direct on 0800 4085500 Ideal Stelrad Group is a member of the Benchmark scheme and fully supports the aims of the programme Benchmark has been introduced to improve the standards of installation and A commissioning of central heating systems in the UK and to encourage the regular servicing of all enc mar central heating systems to ensure safety and efficiency THE BENCHMARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 2 Ideal Logic System User s Operation Note The pump will operate briefly as a self check once every 24 hours regardless of system demand Control of Water Temperature The boiler controls the central heating radiator temperature to a maximum of 80 C adjustable via the CH temperature control A The Logic System is a high e
65. i Thoroughly flush out the whole system with cold water li Fill and vent the system until the pressure gauge registers 1 5 bar and examine for leaks iii Check the operation of the safety valve by raising the water pressure until the valve lifts This should occur within 0 3 bar of the preset lift pressure Release water from the system until the minimum system design pressure is reached 1 0 bar if the system is to be pre pressurised Ideal Logic System Installation and Servicing SYSTEM REQUIREMENTS Central Heating Safety valve setting bar 0 5 to 0 75 Expansion vessel volume litres Vessel charge pressure System pre charge pressure bar System volume litres 25 50 75 100 125 150 175 190 200 250 300 For other system volumes multiply by the factor across Max CH uutput kW 15 18 24 2 30 3 Btu h 51 300 61 600 82 600 103 300 Water flowrate I min 10 7 13 17 2 2125 gal min 2 4 2 8 3 8 4 7 20 20 20 20 36 36 36 36 5 45 3 3 1 9 16 2 14 7 10 8 6 2 Temp differential C F Head available m w g for system ft w g Mains water supply Hose unions N CH Return Additional stop valve Temporary hose disconnect after filling Double check valve assembly Ecl 6053 note direction of flow 11 3 GENERAL SYSTEM BALANCING The boiler does not normally need a bypass but at least some radiators on the heating cir
66. ial Number Ideal Logic System Installation and Servicing 53 Code Of Practice For the installation commissioning and servicing of domestic heating and hot water products Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations Installers are required to carry out work in accordance with the following THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The use of the word installer is not limited to installation itself and covers those carrying out installation commissioning and or servicing of heating and hot water products or the use of supporting products such as water treatment or test equipment Customer includes householders landlords and tenants Heating and Hotwater Industry Council HHIC seca of Work Be competent and qualified to undertake the work required Install commission service and use products in accordance with the manufacturer s instructions provided Ensure that where there is responsibility for design work the installation is correctly sized and fit for purpose Meet the requirements of the appropr
67. iance must not be operated without the casing correctly Standby no demand for heat fitted and forming an adequate seal c Heat being supplied e f the boiler is installed in a compartment then the compartment r Boiler frost protection boiler will fire if temperature is MUST NOT be used for storage purposes below 5 degrees C fitis known or suspected that a fault exists on the boiler then it MUST NOT BE USED until the fault has been corrected by a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGIl Note If the boiler fails to light after five attempts the fault code Under NO circumstances should any of the sealed components on will be displayed this appliance be used incorrectly or tampered with This appliance is not intended for use by persons including RESET iia children with reduced physical sensory or mental capabilities or To reset boiler turn the mode control knob B to reset position lack of experience and knowledge unless they have been given and immediately turn knob back to ON The boiler will repeat supervision or instructions concerning use of the appliance by a the ignition sequence If the boiler still fails to light consult person responsible for their safety a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII During normal operation the burner on indicator D will remain illuminated when the burner is lit Children should be supervised to ensure t
68. iate Building Regulations Where this involves notifiable work be a member of a Competent Persons Scheme or confirm that the customer has notified Local Authority Building Control _LABC prior to work commencing Complete all relevant sections of the Benchmark Checklist Service Record when carrying out commissioning or servicing of a product or system Ensure that the product or system is left in a safe condition and whenever possible in good working order Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing work Refer to the manufacturer s helpline where assistance is needed Report product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Hand over the manufacturer s instructions including the Benchmark Checklist to the customer on completion of an installation Obtain the customer s signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of manufacturer s instructions Advise the customer that regular product servicing is needed in line with manufacturers recommendations to ensure that safety and efficiency is maintained Respond promptly to calls from a
69. ineer TROUBLESHOOTING NO HOT WATER Check the mains switch fused Check the mains switch fused spur is turned on and ensure spur is turned on and ensure NO CENTRAL HEATING mode control knob B is in the ON position Check the programmer is in an ON position and the room thermostat is turned up mode control knob B is in the ON position Check the programmer is in an ON position and the cylinder thermostat is turned up Does the boiler operate and provide hot water YES Does the boiler operate and provide central heating YES Check the time settings on the Check the time settings on the programmer are as you require programmer are as you require and adjust if necessary and adjust if necessary See boiler Operation Modes See boiler Operation Modes and Fault Codes section If 0 and Fault Codes section If 0 is displayed then contact a Gas is displayed then contact a Gas Safe Registered Engineer or in Safe Registered Engineer or in IE a Registered Gas Installer IE a Registered Gas Installer RGII RGII Ideal Logic System User s OPERATION MODES DISPLAY CODE ON BOILER DESCRIPTION burner The boiler is in standby mode awaiting either a central heating call or hot water demand burner The boiler has a call for central heating hot water but the appliance has reached the desired temperature set on the boiler burner The boiler is operatin
70. ings The test data from which it has been calculated have been certified by a notified body Note Gas consumption is calculated using a Key to symbols calorific value of 38 7 MJ m 1038 Btu ft gross GB United Kingdom IE Ireland Countries of destination or 34 9 MJ m 935 Btu ft nett l PMS Maximum operating pressure of water To obtain the gas consumption at a different calorific value C C C A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal which admits fresh air to the burner a For l s divide the gross heat aP and discharges the products of combustion to the outside through kW by the gross C V of the gas MJ m orifices which in this case are concentric The fan is up stream of b For f h divide the gross heat input Btu h the combustion chamber by the gross C V of the gas Btu ff I I An appliance designed for use on 2nd Family gas Group H only c For m h multiply I s by 3 6 4 Ideal Logic System Installation and Servicing GENERAL IDEAL LOGIC SYSTEM CONTENTS Air Supply Natural Gas onl y Benchmark Commissioning Checklist Boiler size G C Appliance No Boiler Clearances Benchmark No Boiler Exploded Diagram 86 CL 08 Condensate Drain 86 CL 08 Commissioning amp Testing 86 CL 08 PlecHical Connections Electrical Supply 41 750 32 86 CL 08 Fault Finding Flue Fitting Flue Installation Gas Safety Regulations Ga
71. is fitted less than 2m GAS SUPPLY The local gas supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must NOT be used without prior consultation with the local gas supplier The boiler MUST be installed on a gas supply with a governed meter only A gas meter can only be connected by the local gas supplier or by a Gas Safe Registered Engineer In IE by a Registered Gas Installer RGII An existing meter should be checked preferably by the gas supplier to ensure that the meter is adequate to deal with the rate of gas supply required It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS6891 2005 Whilst the principle of the 1 1 gas valve ensures the Logic range is able to deliver it s full output at inlet pressures as low as 14mb other gas appliances in the property may not be as tolerant When operating pressures are found to be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation Allowing for the acceptable pressure loss of 1mb across the installation pipework it can be assumed that a minimum permitted operating pressure of 18mb will be delivered to the inlet of the appliance Reference BS 6400 1 Clause 6 2 Pressure Absorption The external gas cock could further reduce the operating pressure when mea
72. l J a L 5 Remove all burrs and place a light chamfer on the outer edge to aid assembly Ideal Logic System Installation and Servicing lI I J 0 ll J s L 20 INSTALLATION 16 INSTALLING THE FLUE FITTING FLUE THROUGH THE WALL 14mm lt 1 Measure wall thickness and add 14mm 14m Wall Thickness 2 Measure from the outer terminal lip towards the end of outer flue place a small location mark at the dimension acquired at point 1 3 Add a further 14mm to the dimension obtain at item 1 point 1 and place an additional small location mark 4 Fit external black wall seal ensuring the inside of the outer lip is in contact Mark 2 Point 1 with the terminal lip you have been measuring from see fig 1 5 Fit the internal wall seal approximately 65mm before the outer of the 2 location marks i i Mark 2 Flush with 6 For an internal fit place flue terminal in the centre of the 5 drilled he I Dnprags lassa hole in the wall Apply pressure and lightly move the flue left to right or up and down This will cause the outer flange to fold in and allow the flue to pass through the wall 7 Push through a further 65mm or until the inner flange is press against the inner wall This will allow the outer flange to return to its original shape k 8 Pull back the flue until the first of the 2 location marks is level with wiku kaspa ku the internal face of the wall K K 5 Cored drilled l Note If the
73. l increase with temperature rise but should not exceed 2 5 bar Check at the gas meter with no other 3 With the system still hot turn off the gas water and electricity supplies to the appliance in use Refer to Table 2 for gas boiler and drain down to complete the flushing process rate Note A flushing solution should be used during the flushing procedure Set the central heating external controls Flushing solutions Fernox Superfloc Sentinel X300 new systems or to OFF The burner should go off and the X400 existing systems Refer to Frame 4 pump continue to run for 4 minutes Refill and vent the system add inhibitor see Frame 4 clear all air locks and The display should read again check for water soundness Check the correct operation of the timer Reset the system initial pressure to the design requirement and all other system controls Operate Balance the system Refer to Frame 3 each control separately and check that the Check the condensate drain for leaks and check that it is discharging correctly main burner responds Finally set the controls to the User s requirements Note The pump will operate briefly as a self check once every 24 hours in the absence of any system demand WATER TEMPERATURES Knob Setting CH Flow Temp C F Temperatures can be selected using the CH temperature control A O 30 86 33 RESET PROCEDURE To reset boiler turn the mode control knob B to reset position and immediat
74. made to the relevant British Standard Code of Practice In IE the installation must be carried out by a Registered Gas Installer RGII and installed in accordance with the current edition of S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW BSEN 12828 2003 Heating Systems in buildings Design for water based heating systems BSEN 12831 2003 Heating Systems in buildings Method for calculation of the design heat load Heating Systems in buildings Installation and commissioning of water based heating BSEN 14336 2004 systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW BS 6891 Low pressure installation pipes Health amp Safety Document No 635 The Electricity at Work Regulations 1989 The manufacturer s notes must NOT be taken in any way as overriding statutory obligations IMPORTANT These appliances are CE certificated for safety and performance It is therefore important that no external control devices e g flue dampers econo
75. male female bend 68mm PVCU Strap on fitting Figure 7 Connection of a Condensate Drainage Pipe to an External Purpose Made Soak Away Boiler with 75mm sealed condensate trap Min 30mm Water Weather Internal pipe roof insulation Min 19mm Internal pee Limestone chippings Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house Ideal Logic System Installation and Servicing Figure 4 Connection of condensate Drainage Pipe to External Soil amp Vent Stack Boiler Water weather with 75mm proof insulation sealed condensate trap Min 30mm Internal pipe Min 19mm Internal se Soil amp vent stack t 1 aa Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break Minimum connection height up to 3 storeys Figure 6 Connection of Condensate Drainage Pipe Upstream of a Sink Basin Bath or Shower Waste Trap to External Drain Gulley or Ranwater Hopper Boiler with 75mm sealed condensate Visible air break trap at plug hole Min 19mm Internal spe Sink basin bath or shower with integral overflow and 75mm trap Minimum 30mm internal pipe Water weather proof insulation termination 2 25 Below grate 25 INSTALLATION INSTALLATION INSTALLATION
76. misers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Ideal Stelrad Group in writing If in doubt please enquire Any direct connection of a control device not approved by Ideal Stelrad Group could invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations SAFE HANDLING OF SUBSTANCES No asbestos mercury or CFCs are included in any part of the boiler or its manufacture Ideal Logic System Installation and Servicing LOCATION OF BOILER The boiler must be installed on a flat and vertical internal wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by the local authority For electrical safety reasons there must be no access available from 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 should be fitted in accordance with the Institute of Gas Engineering document IGE UP 7 2006 Edition 2 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 the current IEE BS
77. n IE refer to IS 813 2002 i e earth continuity polarity resistance to earth and short circuit using a suitable test meter 1 Checks to ensure electrical safety should be carried out by a competent person 2 Purge air from the gas installation by the approved methods only 3 After wiring the boiler all grommets in the bottom panel MUST be in place to ensure that the boiler case sealing is maintained WARNING Whilst effecting the required gas tightness test and purging air from the gas installation open all windows and doors extinguish naked lights and DO NOT SMOKE GENERAL Please Note The combustion for this appliance has been checked adjusted and preset at the factory for operation on the gas type defined on the appliance data plate DO NOT adjust the air gas ratio valve Having checked That the boiler has been installed in accordance with these instructions The integrity of the flue system and the flue seals as described in the Flue Installation section Proceed to put the boiler into operation as follows CHECK THE OPERATIONAL WORKING GAS INLET PRESSURE Set up the boiler to operate at maximum rate With the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point complies with the requirements refer to Gas Supply on page 8 Ensure that this inlet pressure can be obtained with all other gas appliances in th
78. nals pins connected to the electrode Check routing and integrity of internal boiler wiring RESET PROCEDURE To reset boiler turn mode knob to reset position and immediately turn knob back to required setting 68 ALTERNATING F AND 1 LOW WATER PRESSURE Is the Boiler and CH System filled with water and all Fill and vent the system and open all isolation valves isolation and radiator valves open check pressure gauge is between 1 to 1 5 bar Re fit connections Are connections on water pressure sensor secure Replace water pressure sensor 69 ALTERNATING F AND 2 FLAME LOSS Does the boiler ignite for a short Is the Gas Pressure available at NO Check gas supply and time and then extinguish the Boiler Inlet 18 mbar IT rectify fault Is 215Vdc supply available at the Gas NO Check wiring from gas Valve while the flame is on See note X p valve to PCB for continuity If the wiring is OK then Check the detection electrode and I replace the PCB j a YES associated harness for continuity visual condition and position Refer Check Spark generator and associated to Frame 48 Check if condensate harness for continuity and visual Replace Spark Generator pipe is blocked Check if flue is condition Refer to Frame 49 Are these and Harness as necessary blocked functioning correctly Replace as necessary Check ignition electrode and associated Replace Ignition harness for continuity visual c
79. ner pressure n a PUNO DY OSS u u u xs 2 9 Max operating water pressure measure amp record Boiler interlock 9 Cold water inlet temp measure amp record FOT oee a all boilers Hot water outlet temp measure amp record Flushing to BS 7 593 serrare oirn aat 12 Water flow rate at max setting measure amp record a a o us O E E ss 12 For condensing boilers only Central heating mode Condensate drain 24 25 Heat WD UN arerin uuu u u to be calculated For all boilers complete sign amp hand over to customer For assistance see Technical Helpline on the back page NOTE TO THE INSTALLER COMPLETE THE BENCHMARK COMMISSIONING 7 Ay CHECKLIST AND LEAVE THESE e y LLA INSTRUCTIONS WITH APPLIANCE THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Ideal Logic System Installation and Servicing 5 GENERAL INTRODUCTION The Logic System range of boilers are wall mounted full sequence automatic spark ignition low water content fanned flue high efficiency condensing system gas boilers Note Due to the high efficiency of the boiler a plume of water vapour will form at the terminal during operation Central heating CH output is fully modulating with a range of 15
80. ng Remove the spark generator Refer to Frame 49 gaskets or seals if any sign of damage is evident When replacing the spring clips located on both the flow and return pipe connections ensure clip is oriented to correctly match Remove the expansion vessel Refer to Frame 62 connecting pipe diameters Remove the control no flow thermistor Refer to Frame 60 17 Ensure the trap siphon is filled with water Refer to Frame 51 10 Remove the 2 M5 screws retaining the gas valve mounting 18 Refill the boiler Refer to Frame 23 bracket and transfer bracket to the new heat exchanger 11 Undo the inlet pipe union nut and remove the retaining spring clip and remove pipe Remove the gas valve Refer to Frame 50 m oe gt 19 Check operation of the boiler Refer to Frames 31 amp 32 12 fr GRUNDFOS Py CE A 46 Ideal Logic System Installation and Servicing SERVICING 62 EXPANSION VESSEL RECHARGING amp REPLACEMENT RECHARGING 1 Remove the charge point cover 2 Recharge the tank pressure to 0 75 bar 3 4 Re assemble in reverse order Check operation of the boiler Refer to Frames 31 amp 32 REPLACEMENT 9 Refer to Frame 42 Drain the boiler CH circuit Refer to Frame 54 Unscrew the union nut on the vessel water connection pipe Support the expansion vessel and unscrew the 2 screws from the securing clamp located on the top of the boiler and remove Note the positi
81. of BS 6798 Clause 12 and BS 5440 2 may be disregarded WATER CIRCULATION SYSTEM IMPORTANT A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping The central heating system should be in accordance with BS 6798 and in addition for smallbore and microbore systems BS 5449 WATER TREATMENT see Frame 4 BOILER CONTROL INTERLOCKS Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating in compliance with Building Regulations Heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve When thermostatic radiator valves are used the space heating temperature control over a living dining area or hallway having a heating requirement of at least 10 of the minimum boiler heat output should be achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves However if the system employs thermostatic radiator valves on all radiators or two port valves then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position ELECTRICAL SUPPLY WARNING This appliance must be earth
82. oiler Refer to Frames 31 amp 32 45 BURNER REPLACEMENT See Frame 38 Refer to Frame 42 Undo the two screws and remove the sump cover Lift the manifold to clear the bottom sealing gasket and remove manifold Remove the 2 front fixing screws and loosen the 2 rear extended nuts Lift off the burner from the combustion chamber To facilitate the removal angle the burner as shown Fit the new burner replacing any damaged or deteriorating sealing gasket Reassemble in reverse order Refer to Frame 41 Check the operation of the boiler Refer to Frames 31 amp 32 n w oat M a lt a 7 x lt en A TE 7 ts 38 Ideal Logic System Installation and Servicing SERVICING 46 RETURN THERMISTOR RENEWAL Refer to Frame 42 Unclip the return thermistor from the return pipe and withdraw it from the boiler 3 Disconnect the electrical leads from the thermistor 4 Reconnect the electrical lead to the new thermistor and reassemble in reverse order ensuring that the thermistor is securely fitted to the pipe on the thermistor locator tab as shown Check the operation of the boiler Refer to Frames 31 amp 32 Thermistor Locator Tab with thermistor fitted 47 IGNITION ELECTRODE REPLACEMENT Refer to Frame 42 Remove the burner Refer to Frame 45 Unplug the ignition lead from the electrode Ignition Electrode Remove the earth lead from the ignition electrode
83. on must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm 1 8 contact separation in both poles The means of isolation must be accessible to the user after installation The Logic System boiler comes pre fitted with 1 8m of mains cable This must be connected to a permanent live supply and NOT switched by thermostats programmers For installers wishing to change this cable refer to Frame 27 The terminal block cover carries two spare fuses for the main PCB Connecting the Switched Live to the Boiler Consult the Y Plan and S Plan diagrams below Isolate the mains supply to the boiler Remove the front panel Refer to Frame 7 Swing the control box down into the servicing position ao oY screws provided in the hardware pack 6 Connect the switched live to the terminal block as shown FROST THERMOSTAT WIRING If parts of the system are vulnerable to freezing or the programmer is likely to be left off during cold weather a frost stat should be fitted in conjunction with a pipe thermostat Ideal Logic System Installation and Servicing Route incoming cable through a grommet in the bottom panel note that the grommets are blind and will require puncturing and secure using the clamp and Spare PCB fuses BOILER opi CL 3610022 See overleaf for S Plan System ALLA E INS INSTALLATION 26 IN
84. on of the bracket on the vessel Remove the expansion vessel 10 Fit the new expansion vessel 11 Reassemble in reverse order 12 Refill the boiler Refer to Frame 23 13 Check operation of the boiler Refer to Frames 31 amp 32 63 BOILER SEALING PANEL SEAL REPLACEMENT Refer to Frame 42 Remove the old seal from the casing and thoroughly clean the casing surfaces Fit the new seal ensuring the bottom joint provides an air tight seal Reassemble in reverse order 6 Check operation of the boiler Refer to Frames 31 amp 32 Note Ensure that the boiler front panel is correctly sealed compressing the seal to make an airtight joint Ideal Logic System Installation and Servicing Recharge 47 SERVICING FAULT FINDING 64 FAULT FINDING CHART MAIN MENU In order to assist fault finding the boiler has a 7 segment display The key to the display codes is as follows GO TO FRAME 65 ALTERNATING L and 1 FLOW TEMPERATURE OVERHEAT LOCKOUT or NO WATER FLOW LOCKOUT GO TO FRAME 66 ALTERNATING L and 2 IGNITION LOCKOUT 5 RESETS WITHIN 15 MINS ALTERNATING L and 5 TURN POWER OFF AND ON GO TO FRAME 67 ALTERNATING L and 6 FALSE FLAME LOCKOUT BCC BOILER CHIP CARD NOT FITTED ALTERNATING F and 0 SEE FRAME 52 GO TO FRAME 68 ALTERNATING F and 1 LOW WATER PRESSURE GO TO FRAME 69
85. onal Extras 18 ROOF FLUE KIT CONTENTS OPTIONS Flue Terminal Flue Seal Collar Flat Roof Vertical connector 90 elbow UIN 203132 UIN 152259 UIN 208175 UIN 203130 45 elbow UIN 203131 Flue Seal Collar Tile Roof duct UIN 152258 support Roof Flue Extension Duct UIN 203129 l Ideal Logic System Installation and Servicing 21 INSTALLATION INSTALLATION 19 FLUE TERMINAL POSITION The terminal should be positioned so that products of combustion can safely disperse at all times Pluming may occur at the termination so where possible terminal positions where this could cause a nuisance should be avoided Minimum dimensions are shown below Aluminium shield Pitched Roof with structure Flat roof with structure B 2000mm i The flue terminal shall not penetrate the shaded area of the roof Terminal Position Directly below an opening air brick windows etc 300 mm 300 Note 300 mm The equivalent flue length resistance of the 500 mm elbow kits are Below velux windows 2000mm 90 elbow kit 1m Above or side of velux windows 600mm 45 elbow kit 0 6m lI E J 0 ll J L 22 Ideal Logic System Installation and Servicing INSTALLATION 20 ASSEMBLING THE ROOF FLUE KIT Determine the correct height that the flue should terminate above A the roof If after calculating
86. ondition Electrode and and position Refer to Frame 47 Are associated harness as Note due to the wave form of these functioning correctly necessary the rectified voltage the reading will vary depending on the type of meter used to measure the value In general terms a readina areater Check siphon and condensate drain pipe NO ae FEO In ss asha ee Gayani work for blockage and rectify if necessary Replace Gas Valve Boiler now working OK voltage is supplied to the gas valve 70 ALTERNATING F AND 3 FAN FAULT Does the wiring from the Fan to the PCB have secure connections at NO Rectify Wiring amp connections both ends and has not deteriorated Does the wiring have continuity NO y TES Replace PCB Is there 230Vac at the Blue and Brown connections to the 3 way connection on the Fan YES Replace Fan 50 Ideal Logic System Installation and Servicing O Z a Z LL lt LL O Z a LL s lt LL O A LL x LL O A LL x L O a LL H x LL FAULT FINDING 71 ALTERNATING F AND 4 CONTROL NO FLOW THERMISTOR FAULT Remove the Control No Flow Thermistor from the Heat Exchanger and disconnect the wires Check the resistance using a suitable multimeter connected across the thermistors terminal pins At 25 C expect 9 700 10 300 Ohms At60 C expect 2 400 2 600 Ohms At 85 C expect 1 000 1 100 Ohms Is the Thermistor value corre
87. ould be left switched ON with the boiler thermostat left in the normal running position Boiler Overheat Protection The boiler controls will shut down the boiler in the event of overheating Should this occur a fault code L will be displayed Refer to fault chart Flame Failure Should this occur a fault code L will be displayed Refer to fault chart Loss of System Water Pressure The gauge E indicates the central heating system pressure If the pressure is seen to fall below the original installation pressure of 1 2 bar over a period of time then a water leak may be indicated In this event conduct the re pressurising procedure as follows Re pressurise via the filling loop to 1 bar if unsure contact your installer turn off the tap on the filling loop and turn switch B to the reset position and then back on again to reset the boiler If unable to do so or if the pressure continues to drop after filling a Gas Safe Registered Engineer or in IE a Registered Gas Installer RGII should be consulted NOTE THE BOILER WILL NOT OPERATE IF PRESSURE HAS REDUCED TO LESS THAN 0 3 BAR UNDER THIS CONDITION G Economy Mode Condensate Drain This appliance is fitted with a siphonic condensate trap system that reduces the risk of the appliance condensate from freezing However should the condensate pipe to this appliance freeze please follow these instructions a If you do not feel competent to carry out the defrosting instr
88. pliance must be disconnected from the gas supply in accordance with GSIUR CO level less han 350ppm AND CO CO2 ratio less than 0 0040 Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary Set Boiler to Minimum Gas Rate see opposite page In accordance with boiler instructions set boiler to operate at minimum rate to minimum load condition CO level less Allow sufficient time for combustion to stabilise than 350ppm AND CO COz2 ratio less than 0 0040 Check CO and Combustion Ratio at Minimum Gas Rate With boiler set at minimum rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Turn off Appliance and Call Ideal Technical Helpline The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with GS I amp U R NOTE Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ideal CO level less han 350ppm AND CO CO ratio less than 0 0040 Yes Boiler is Operating Satisfactorily No further actions required Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed Complete Benchmark Checklist recording CO and combus
89. re Possible Comments Comments Signature Allinstallations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer Heating and Hotwater Industry Council HHIC Signature THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk 58 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory set and must not be adjusted DURING COMMISSIONING If the boiler requires conversion to operate with a different gas family e g conversion from natural gas to LPG sepa rate guidance is provided with the conversion kit supplied and this must be followed PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK The installation instructions must have been followed gas type verified and gas supply pressure gas rate checked as required prior to commissioning As part of the installation process ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that maximum flue lengths have not been exceeded and all guidan
90. reas Internal condensate drain pipes run in unheated areas e g lofts basements and garages should be treated as external pipe Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual Figure 2 Connection of a Condensate Drainage Pipe Downstream of a Sink Basin Bath or Shower Water Trap to Internal Soil Vent Stack Boiler with 75mm sealed condensate Min 19mm a Internal pipe Sink basin bath or shower x O oO 7 o gt o O 72 a pa Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break continued Ideal Logic System Installation and Servicing INSTALLATION 22 CONDENSATE DRAIN CONT D Figure 3 Connection of a Condensate Pump Typical Method see manufacturers detailed instructions Visible air break Boiler with 75mm ra sealed condensate trap Min 19mm Internal pipe Condensate pump Install in accordance with manufacturers instructions Figure 5 Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe only combined foul rainwater drain Boiler with 75mm sealed condensate trap weather proof Min 19mm I i insulation Internal pipe combined foul rain water drain Min 30mm Internal pipe External air break Air gap Terminated and cut at 45 43mm 90
91. reverse of the above Ensure the air vent head o ring seal is in place when refitting and the new o ring is fitted to the return pipe top connection Ensure the air vent cap is loose Refill the boiler Refer to Frame 23 Check for leaks around the new air vent joint Check the operation of the boiler Refer to Frames 31 amp 32 44 Ideal Logic System Installation and Servicing SERVICING 58 PUMP HEAD REPLACEMENT Refer to Frame 42 Drain the boiler Refer to Frame 54 Disconnect the electrical lead from the pump Remove the 4 Allen screws retaining the pump head Remove the pump head Fit the new pump head Reassemble in reverse order Refill the boiler Refer to Frame 23 Check operation of the boiler Refer to Frames 31 amp 32 59 CH WATER PRESSURE SENSOR REPLACEMENT Refer to Frame 42 Drain the boiler Refer to Frame 54 3 Remove condensate trap siphon Refer to Frame 51 Using a suitable tool pull out the retaining clip Pull the pressure sensor upwards to remove Unplug the electrical connection and transfer to the new pressure sensor Push the new pressure sensor onto the rear pump housing and fit retaining clip 8 Reassemble in reverse order 9 Refill the boiler Refer to Frame 23 Check Operation of the boiler Refer to Frames 31 amp 32 60 CONTROL NO FLOW THERMISTOR REPLACEMENT Refer to Frame 42 Drain down the boil
92. ring Regulations and any local regulations Frost Protection If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system The frost thermostat should be sited in a cold place but where it can sense heat from the system Note f the boiler is installed in a garage it may be necessary to fit a pipe thermostat preferably on the return pipework 28 Ideal Logic System Installation and Servicing INSTALLATION NOILY TIVWLSNI 90S66 S20902 29 WIRING DIAGRAM yeg sisseuo B A 49 Jo esJauay BI yieds j 1o jo uuoo S 1O SIL U L I MO 4 ON q O1JUOD ues Josues a nss iq Jaye poxno l3 Josuas wailed qi uue j Zs amp J J yq 1q q d yA 49 eee l U c ccc IA ee a ae JO WL Le fe e fetel elelee eelle x ax x x T x J JOJA A Bugeljo JO Aai B u iB Aoj B yM M NO J yuid d pol J UMOIg JQ yoe lq xq eniq q AJM 29 Ideal Logic System Installation and Servicing INSTALLATION INSTALLATION 30 COMMISSIONING AND TESTING A Electrical Installation B Gas Installation 1 The whole of the gas installation including the meter should be inspected and tested for tightness and purged in accordance with the recommendations of BS 6891 2 ALWAYS carry out the preliminary electrical system checks I
93. ring a range of 0 to 4 bar An 8 litre expansion vessel with an initial charge pressure of 0 75 bar Make up Water Provision must be made for replacing water loss from the system either a From a manually filled make up vessel with a readily visible water level The vessel should be mounted at least 150mm above the highest point of the system and be connected through a non return valve to the system fitted at least 150mm below the make up vessel on the return side of the radiators or Where access to a make up vessel would be difficult by pre pressurisation of the system The maximum cold water capacity of the system should not exceed 143 litres This is the maximum system volume for the boiler expansion vessel If the capacity of the vessel is not considered sufficient for this or for any other reason an additional vessel MUST be installed on the return to the boiler Guidance on vessel sizing is given in table opposite 5 Filling The system may be filled by the following method Through a temporary hose connection from a draw off tap supplied from a service pipe under mains pressure Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling When installing the filling device it must be connected as below to fully comply with the water regulations This may involve the fitting of an additional WRAS approved isolator valve to the mains supply
94. s Supply Initial Lighting Installation Safe Handling Servicing Spare Parts Info Thermostatic Radiator Valves Water and Systems Water Connections Water Treatment Wiring Diagram For GB to comply with Building Regulations Part L1 Part 6 in Scotland the boiler should be fitted in accordance with the manufacturer s instructions Self certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist Before installing this boiler read the Code of Practice sheet at the rear of this book BENCHMARK COMMISSIONING CHECKLIST DETAILS Boiler Make and mode el 5 Burner operating pressure n a Appliance serial no on data badge Front Cover Central heating flow temp measure and record se 1 NO ene ee gt u uuu us A Central heating return temp measure and record Controls For combination boilers only Time and temperature control to heating 27 Scale reducer 12 Time and temperature control to hot water N A Hot water mode Heating zone valves 27 Heat NPU u ULU uuu usss sassa to be calculated 2 uzanan asnan anus 9 Max operating bur
95. s been explained and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature Allinstallations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a enchmar Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Engineer name Comments Engineer name SERVICE 03 1 e
96. stall and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights Customer name Telephone number Address Boiler make and model Boiler serial number Commissioned by PRINT NAME Gas Safe register number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS tick the appropriate boxes Room thermostat and programmer timer Programmable room thermostat Time and temperature control to heating f Load weather compensation Optimum start control Time and temperature control to hot water Cylinder thermostat and programmer timer Combination Boiler Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted Not required Automatic bypass to system Not required Boiler interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions What system cleaner was used What inhibitor was used Quantity litres Has a primary water system filter been
97. sured at its test point The pressure drop is relative to the heat input to the boiler kW refer to graph below Gas Cock Pressure Drop s 2 2 p o M 5 i 2 2 10 0 150 200 28 0 30 0 heat input to boiler KW 35 0 400 45 0 IMPORTANT Installation pipes must be fitted in accordance with BS 6891 In IE refer to 1S 813 2002 The complete installation MUST be tested for gas tightness and purged as described in the above code FLUE INSTALLATION Pluming will occur at the terminal so terminal positions where this could cause a nuisance should be avoided The flue must be installed in accordance with the recommendations of BS 5440 1 2008 In IE refer to I S 813 2002 The following notes are intended for general guidance 1 The boiler MUST be installed so that the terminal is exposed to external air 2 Itis important that the position of the terminal allows the free passage of air across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 4 6 6 above a balcony above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard Terminal guards are available from boiler suppliers Ask for TFC flue guard model no K6 round plastic coated In case of difficulty contact TFC Group Ltd Tower House Vale Rise Tonbridge Kent TN9 1TB Ensure that the g
98. the status of the boiler The neon will show the status of the flame If no flame is detected the neon is off When the flame is detected the neon will be lit permanently Below is a list with display function in normal operation g Standby no demand for heat present Boiler is active for central heating or hot water m Boiler is active for boiler frost protection pe Boiler is in lockout for a specific error Display will be blinking alternating with a number or letter to show which error is detected Boiler has a fault for a specific error Display will be blinking alternating with a number or letter to show which error is detected Note Boiler frost protection boiler fires if temperature is below 5 degrees C Note The boiler incorporates a fan overrun cycle which MUST NOT be prematurely interrupted by isolation of the mains electricity supply 31 INSTALLATION INSTALLATION INSTALLATION 32 GENERAL CHECKS Make the following checks for correct operation CENTRAL HEATING CH MODE WATER CIRCULATION SYSTEM 1 Ensure that the CH external controls are 4 With the system COLD check that the initial pressure is correct to the calling for heat system design requirements The display should read c 3 For pre pressurised systems this should be 1 0 bar Check the boiler gas rate when the boiler is 2 With the system HOT examine all water connections for soundness The system at full output pressure wil
99. tion ratio readings as required Ideal Logic System Installation and Servicing 59 For additional fault finding advice please visit Ideal s website wwwi idealboilers com Technical Training The Ideal Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers j enchmar 01482 498 432 COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The code of practice for the installation Manufactured under an ISO 9001 commissioning amp servicing of central heating systems registered quality management system FM 59915 Ideal Boilers Ltd P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice Ideal Stelrad Group Ideal Installer Helpline 01482 498 663 www idealboilers com USER GUIDE LOGIC SYS EM 15 18 24 SO For Installation Guide see reverse of book THE QUEEN S AWARDS FOR ENTERPRISE INNOVATION 2013 When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not
100. tside of the warranty period In IE contact a Registered Gas Installer RGIl burner burner BCC Activation Fault Reset the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner BCC Fault burner burner burner Low Water Pressure Check system pressure is between 1 amp 1 5bar on the pressure gauge If the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Flow Temperature Overheat Flame Loss 1 Check other gas appliances in the house are working to confirm a supply is present in the property 2 If other appliances do not work or there are no other appliances check the gas supply is on at the meter and or pre payment meter burner burner has credit If the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas Installer RGII burner burner Fan Fault Reset the appliance if the boiler fails to operate then please contact Ideal if under warranty or alternatively a Gas Safe Registered Engineer if outside of the warranty period In IE contact a Registered Gas
101. uard is fitted centrally Tel 44 0 01732 351 680 Fax 44 0 01732 354 445 www tfc group co uk 5 The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of any building 6 The air inlet products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm 1 to combustible material Detailed recommendations on the protection of combustible material are given in BS 5440 1 2008 IMPORTANT It is essential to ensure in practice that products of combustion discharging from the terminal cannot re enter the building or buildings through any openings into the building such as ventilators windows doors or other sources of natural air infiltration such as forced ventilation openings etc If products of combustion re entry is identified or suspected this should be immediately investigated and corrected following the guidance provided in the current Gas Industry Unsafe Situation Procedure Table 4 Balanced Flue Terminal Position Flue Terminal Positions Min Spacing 1 Directly below above or alongside an opening window air vent or other ventilation opening 300mm 12 2 Below guttering drain pipes or soil pipes 25mm 1 BS5440 1 2008 75mm 3 25mm 1 BS5440 1 2008 200mm 8 4 Below balconies or a car port roof 25mm 1 BS5440 1 2008 200mm 8 5 From vertical drain pipes or soil pipes BS5440 1 2008 3 Below eaves 25mm 1
102. uctions below please call your local Gas Safe Registered installer for assistance b If you do feel competent to carry out the following instructions please do so with care when handling hot utensils Do not attempt to thaw pipework above ground level If this appliance develops a blockage in its condensate pipe its condensate will build up to a point where it will make a gurgling noise prior to locking out an L2 fault code If the appliance is reset it will make a gurgling noise prior to it locking out on a failed ignition L2 code To unblock a frozen condensate pipe 1 Follow the routing of the plastic pipe from its exit point on the appliance through its route to its termination point Locate the frozen blockage It is likely that the pipe is frozen at the most exposed point external to the building or where there is some obstruction to flow This could be at the open end of the pipe at a bend or elbow or where there is a dip in the pipe in which condensate can collect The location of the blockage should be identified as closely as possible before taking further action 2 Apply a hot water bottle microwaveable heat pack or a warm damp cloth to the frozen blockage area Several applications may have to be made before it fully defrosts Warm water can also be poured onto the pipe from a watering can or similar DO NOT use boiling water 3 Caution when using warm water as this may freeze and cause other localised h
103. union connection to the injector housing Remove the extended nut on the fan mounting bracket Lift off fan and venturi assembly 5 Inspect the injector for blockage or damage Inspect fan outlet sealing gasket and replace if necessary Injector 34 Ideal Logic System Installation and Servicing SERVICING 38 BURNER REMOVAL AND CLEANING Ensure the sump is fully drained Undo the two screws and remove the sump cover retaining the lower flue manifold Lift the manifold to clear the bottom sealing gasket and remove manifold Remove the 2 burner front fixing screws and loosen the 2 rear extended nuts by at least ten turns Lift off the burner from the combustion chamber To facilitate the removal angle the burner as shown IMPORTANT The burner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic Brush off any deposits that may be on the ceramic with a SOFT brush Inspect the sealing gasket around the burner for any signs of damage Replace as necessary 39 CLEANING THE CONDENSATE TRAP SIPHON Pull off the rubber pipe noting the position and flush out any deposits with clean water 2 Replace the cleaning plug and refill the siphon with water Replace the rubber pipe connector with the twin wall seal fitted to the condensate siphon Ideal Logic System Installation and Servicing
104. union connection to the injector housing Remove the extended nut retaining the fan mounting bracket Lift and remove the fan and venturi assembly 6 Remove the screw and twist venturi anti clockwise to remove venturi assembly noting the orientation of the venturi in relation to the fan body Transfer the venturi assembly to the new fan replacing the o ring if evidence of damage or deterioration is visible Fit the new fan venturi assembly ensuring the retaining tabs are correctly positioned and the fan outlet sealing gasket is correctly positioned and free from damage Refit the extended nut Reassemble the boiler in reverse order taking care not to overtighten the screw on the fan mounting bracket Check the operation of the boiler Refer to Frames 31 amp 32 Ideal Logic System Installation and Servicing 3 SERVICING SERVICING SERVICING 44 BURNER INJECTOR REPLACEMENT Refer to Frame 42 Disconnect the electrical leads from the fan 3 Undo the gas pipe union connection to the injector housing Loosen the screw retaining the fan mounting bracket Lift and remove the fan and venturi assembly Remove the 2 injector housing screws Withdraw the injector housing Fit the new injector housing complete with injector Reassemble in reverse order ensuring that the new gas seal supplied is located correctly in the injector housing 10 Check operation of the b
105. y require 2 or more operatives to move it to its installation site remove it from its packaging base and during movement into its installation location Manoeuvring the boiler may include the use of a sack truck and involve lifting pushing and pulling Caution should be exercised during these operations Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered Grip the boiler at the base Be physically capable Use personal protective equipment as appropriate e g gloves safety footwear During all manoeuvres and handling actions every attempt should be made to ensure the following unless unavoidable and or the weight is light e Keep back straight e Avoid twisting at the waist Avoid upper body top heavy bending Always grip with the palm of the hand Use designated hand holds e Keep load as close to the body as possible Always use assistance if required OPTIONAL EXTRA KITS e Horizontal Flue Terminal 600mm long e Horizontal Flue Terminal 1000mm long Horizontal Flue Telescopic Flue Extension Ducts 1000mm long 15 up to 9m 18 up to 9m 24 up to 9m 30 up to 8m 90 Elbow Kit maximum per installation 15 up to 6 elbows 18 up to 6 elbows 24 up to 6 elbows 30 up to 6 elbows e 45 Elbow Kit maximum per installation 15 up to 6 elbows 18 up to 6 elbows 24 up to 6 elbows 30 up to 6 elbows e

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