Ideal Boilers Logic System 15 Installation And Servicing
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Ideal Boilers Logic System 15 Installation And Servicing

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INSTALLATION
AND SERVICING
LOGIC System
15, 18, 24, 30
For users guide see reverse of book
For details of document amendments, refer to page 3
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.
January 2014
UIN 205552 A05
November 2009
UIN 204626 A03

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  • Page 1 INSTALLATION AND SERVICING LOGIC System 15, 18, 24, 30 For users guide see reverse of book For details of document amendments, refer to page 3 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.
  • Page 2 Ideal Logic System - Installation and Servicing...
  • Page 3 NOTEs FOR ThE INsTaLLER 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 ..a04 (Jul 13) to a05 (Jan 14) page 30...
  • Page 4 general Table 1 - general Data Ideal Logic system Gas supply 2H - G20 - 20mbar Gas Supply Connection 15mm copper compression Injector Size (mm) 4.15 4.15 4.15 4.65 Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter mm (in)
  • Page 5 general CONTENTs IDEAL LOGIC SYSTEM air supply ..............9 Natural gas only Benchmark Commissioning Checklist ..... 56 Boiler size g.C. appliance No. pI No. Boiler Clearances ............10 (Benchmark No.) Boiler Exploded Diagram ........... 13 Condensate Drain ..........24,25 41-750-24 86 CL 08 Commissioning &...

  • Page 6: Safe Handling

    general INTRODUCTION The Logic system range of boilers are wall mounted, full During all manoeuvres and handling actions, every attempt should sequence, automatic spark ignition, low water content, fanned be made to ensure the following unless unavoidable and/or the flue, high efficiency, condensing, system gas boilers. weight is light.

  • Page 7: Location Of Boiler

    general saFETy LOCaTION OF BOILER Current gas safety (installation and use) regulations or rules The boiler must be installed on a flat and vertical internal wall, in force: capable of adequately supporting the weight of the boiler and any ancillary equipment. The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force.

  • Page 8: Gas Supply

    general gas sUppLy 4. Where the lowest part of the terminal is fitted less than 2m (6’6”) above a balcony, above ground or above a flat roof The local gas supplier should be consulted, at the installation to which people have access then the terminal MUST be planning stage, in order to establish the availability of an adequate protected by a purpose designed guard.

  • Page 9: Air Supply

    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;...
  • Page 10 general BOILER DIMENsIONs, sERVICEs & 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.
  • Page 11 general sysTEM REqUIREMENTs - Central heating Notes a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection safety valve setting is only allowed if acceptable to the local water authority. Vessel charge pressure 0.5 to 0.75 b.

  • Page 12: Water Treatment

    general sysTEM BaLaNCINg The boiler does not normally need a bypass but at least some radiators on the heating circuit, 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.
  • Page 13 INSTALLATION BOILER assEMBLy - Exploded View Note that item numbers are linked to the spares list CH RETURN VALVE PIPE - GAS INJECTOR ELECTRODE IGNITION CH FLOW VALVE INJECTOR ASSEMBLY ELECTRODE DETECTION PUMP HEAD VENTURI IGNITER UNIT PUMP AUTO AIR VENT THERMISTOR CONTROL/NO FLOW PRESSURE RELIEF VALVE BURNER...
  • Page 14 INSTALLATION UNpaCKINg The boiler is supplied fully assembled in Pack A. A telescopic or non-telescopic flue assembly for rear or side flue outlet in Pack B is suppled as a separate order. Unpack and check the contents. pack a Contents Boiler Hardware Pack Box Wall Mounting Plate...
  • Page 15 INSTALLATION UNpaCKINg..CONT’D Note. This flue system incorporates a removable flue outlet nose that utilises a push fit location system. This enables the installation of deflector, high level or balcony outlet flue kits without the removal of the whole ‘B’ pack terminal. The appliance must not be operated without the desired outlet nose correctly fitted in place.

  • Page 16: Mounting The Boiler

    INSTALLATION WaLL MOUNTINg TEMpLaTE Extended centre line 1 5 5 The wall mounting template is located on the internal protective (2 0 0 ) V - See Diagram packaging. The template shows the position of the fixing and rear in frame 1 flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled.
  • Page 17 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’...

  • Page 18: Installation And Servicing

    INSTALLATION 14 DETERMININg ThE FLUE LENgTh aND FLUE paCKs REqUIRED, CONT’D FIgURE 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 = ue length 44mm = ue length 44mm = ue length...

  • Page 19: Cutting & Setting The Flue Length

    INSTALLATION 15 CUTTINg & sETTINg ThE FLUE LENgTh TELEsCOpIC FLUEs TELEsCOpIC FLUE B paCK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT hORIzONTaL FLUE TERMINaL (1000MM LONg) B paCK (TELEsCOpIC) MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 &...

  • Page 20: Installing The Flue

    INSTALLATION 16 INsTaLLINg ThE FLUE FITTINg FLUE ThROUgh ThE WaLL 1. Measure wall thickness and add 14mm. 2. Measure from the outer terminal lip towards the end of outer flue, place a small location mark at the dimension acquired at point 1. 3.

  • Page 21: Fitting The Optional Roof Flue Kit (Flat Or Pitched)

    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.

  • Page 22: Flue Terminal Position

    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 300mm 625mm...

  • Page 23: Assembling The Roof Flue Kit

    INSTALLATION 20 assEMBLINg ThE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied.

  • Page 24: Class

    INSTALLATION 21 CONDENsaTE DRaIN Condensate pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer 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 waste pipe etc.
  • Page 25 INSTALLATION 22 CONDENsaTE DRaIN - CONT’D..Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to Method (see manufacturers detailed instructions) External Soil & Vent Stack Boiler Water/weather Visible air break with 75mm proof insulation Boiler sealed...

  • Page 26: Electrical Connections

    INSTALLATION 23 CONNECTIONs & FILLINg NOTEs. Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown in the picture. Ensure each union is fitted with fibre seals provided. Do not subject any of the isolating valves to heat as the seals may be damaged.

  • Page 27: Internal Wiring

    INSTALLATION 25 INTERNaL WIRINg 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 31. Connecting the Switched Live to the Boiler 1.

  • Page 28: External Electrical Controls

    INSTALLATION 26 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. 1. Isolate the mains supply to the boiler. 2.
  • Page 29 INSTALLATION 28 WIRINg DIagRaM Ideal Logic System - Installation and Servicing...

  • Page 30: Commissioning And Testing

    INSTALLATION 29 COMMIssIONINg aND TEsTINg B. gas Installation a. Electrical Installation 1. The whole of the gas installation, including the meter, 1. Checks to ensure electrical safety should be carried out by a should be inspected and tested for tightness and purged in competent person.

  • Page 31: Initial Lighting

    INSTALLATION 30 INITIaL LIghTINg Legend a. CH temperature control B. Mode Control Knob C. Boiler Status D. Burner ‘on’ indicator E. CH Flow Isolating Valve F. Pressure Gauge g. Gas Inlet Pressure Test Point h. Gas Service Cock J. CH Return Isolating Valve K.

  • Page 32: Handing Over

    INSTALLATION 31 gENERaL ChECKs Make the following checks for correct operation: CENTRaL hEaTINg (Ch) MODE WaTER CIRCULaTION sysTEM 1. Ensure that the CH external controls are 1. With the system COLD, check that the initial pressure is correct to the calling for heat.

  • Page 33: Servicing Schedule

    SERVICING 34 sERVICINg sChEDULE For the very latest copy of literature for specification & 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 electricity supply to the appliance before servicing.

  • Page 34: Fan And Venturi Assembly Removal And Cleaning

    SERVICING 35 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 3. Hook the panel onto the top retaining clips. 4.

  • Page 35: Burner Removal And Cleaning

    SERVICING 37 BURNER REMOVaL aND CLEaNINg 1. Ensure the sump is fully drained 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 3. Lift the manifold to clear the bottom sealing gasket and remove manifold.

  • Page 36: Cleaning The Heat Exchanger

    SERVICING 39 CLEaNINg ThE hEaT ExChaNgER note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Frame 50. 1. Remove ignition and flame detection electrodes. Refer to Frames 46 & 47. 2. It is advisable to replace the sump cover prior to the water flush process.

  • Page 37: Replacement Of Components

    SERVICING 41 REpLaCEMENT OF COMpONENTs gENERaL After replacing ANY component check operation of the boiler, including gas soundness, gas rate and combustion When replacing aNy component test. 1. Isolate the electricity supply. IMpORTaNT. 2. Turn off the gas supply. When work is complete, the front panel must be correctly refitted - ensuring that a good seal is made.

  • Page 38: Burner Injector Replacement

    SERVICING 43 BURNER INJECTOR REpLaCEMENT 1. Refer to Frame 41. 2. Disconnect the electrical leads from the fan. 3. Undo the gas pipe union connection to the injector housing. 4. Loosen the screw retaining the fan mounting bracket. 5. Lift and remove the fan and venturi assembly. 6.

  • Page 39: Ignition Electrode Replacement

    SERVICING 45 RETURN ThERMIsTOR RENEWaL 1. Refer to Frame 41. 2. 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.

  • Page 40: Flame Detection Electrode Replacement

    SERVICING 47 FLaME DETECTION ELECTRODE REpLaCEMENT 1. Refer to Frame 41. 2. Remove the burner. Refer to Frame 44. 3. Unplug the flame detection lead from the Flame Detection Electrode electrode. 4. Remove the 2 screws retaining the detection electrode. 5.

  • Page 41: Gas Control Valve Replacement

    SERVICING 49 gas CONTROL VaLVE REpLaCEMENT 1. Refer to Frame 41. 2. Unplug the electrical lead connection from the gas control valve and disconnect the earth wire. 3. Undo the union nut on the outlet of the gas control valve. 4.
  • Page 42 SERVICING 51 MaIN pCB REpLaCEMENT 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.

  • Page 43: Draining The Boiler

    SERVICING 52 UsER CONTROL pCB REpLaCEMENT Note. Fit the earth strap provided with the PCB to your wrist and a suitable earth on the boiler chassis. 1. Refer to Frame 41. 2. Remove the main PCB, refer to Frame 51. 3.

  • Page 44: Pump Automatic Air Vent Replacement

    SERVICING 54 pREssURE gaUgE RENEWaL 1. Refer to Frame 41. 2. Drain the heating system. Refer to Frame 53. 3. Unscrew the pressure gauge and discard. 4. Fit new pressure gauge, using suitable jointing compound. 5. Refill the boiler. Refer to Frame 23. 6.

  • Page 45: Pump Head Replacement

    SERVICING 57 pUMp hEaD REpLaCEMENT 1. Refer to Frame 41. 2. Drain the boiler. Refer to Frame 53. 3. Disconnect the electrical lead from the pump. 4. Remove the 4 Allen screws retaining the pump head. 5. Remove the pump head. 6.

  • Page 46: Heat Engine Renewal

    SERVICING 60 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 41. 12. Undo the flow pipe union nut and remove pipe. 2.

  • Page 47: Expansion Vessel Recharging & Replacement

    SERVICING 61 ExpaNsION VEssEL REChaRgINg & REpLaCEMENT REChaRgINg 1. Remove the charge point cover. Recharge 2. Recharge the tank pressure to 0.75 bar. Point 3. Re-assemble in reverse order 4. Check operation of the boiler. Refer to Frames 30 & 31. REpLaCEMENT 5.

  • Page 48: Fault Finding

    Fault Finding 63 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 64 - aLTERNaTINg ‘L’ and ‘1’ FLOW TEMpERaTURE OVERhEaT LOCKOUT or NO WaTER FLOW LOCKOUT gO TO FRaME 65 - aLTERNaTINg ‘L’...
  • Page 49 Fault Finding 64 aLTERNaTINg ‘L’ aND ‘1’ - FLOW TEMpERaTURE OVERhEaT LOCKOUT OR NO WaTER FLOW LOCKOUT Is the Boiler and CH System filled with water and all Fill and vent the system and open all isolation and radiator valves open? isolation valves, then reset boiler If the PCB has been replaced check a BCC has been fitted then reset the boiler.
  • Page 50 Fault Finding 66 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.
  • Page 51 Fault Finding 70 aLTERNaTINg ‘F’ aND ‘4’ - CONTROL / NO FLOW ThERMIsTOR FaULT Fit a new Thermistor 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. Is there continuity between the PCB and Thermistor? At 25 expect...
  • Page 52 Fault Finding 74 NO Ch OpERaTION Move the mode knob to the ON position Is the mode knob in the ON position? Switch the Timer, Room Stat and Cylinder Stat On Are the Timer and the Room Thermostat or cylinder thermostat switched on? Open the Radiator Valves Are the Radiator Valves Open?

  • Page 53: Spare Parts

    SPARE PARtS When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. Failure to do so could affect safety or performance of this appliance.

  • Page 54: Short List Of Parts

    Short liSt of partS Ideal Logic System - Installation and Servicing...
  • Page 55 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.

  • Page 56: Boiler Interlock

    GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. CONTROLS Programmable room thermostat Optimum start control...
  • Page 57 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider SERVICE 01 SERVICE 02 ² % ² % ² % ² % (Where Possible) (Where Possible) Signature Signature SERVICE 03 SERVICE 04...
  • Page 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.
  • Page 59 Start 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 point (where available) and allow set boiler to operate at maximum rate readings to stabilise. (full load condition).
  • Page 60 & servicing of central heating systems 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.

  • Page 61: Users Guide

    USERS GUIDE LOGIC System 15, 18, 24, 30 For installation guide see reverse of book 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.

  • Page 62: Benchmark Commissioning Checklist

    FOR aNy qUERIEs pLEasE RINg ThE IDEaL CONsUMER hELpLINE : 01482 498660 NOTE. BOILER REsET pROCEDURE - To reset boiler, turn mode control knob to reset position and immediately turn knob back to required setting. Minimum Clearances Introduction Clearances of 165mm (6 ”) above, 100mm (4”) below, The Logic system is a wall mounted, room sealed, condensing 2.5mm (1/8”) at the sides and 450mm (17 3/4”) at the front of...

  • Page 63: Frost Protection

    Frost Protection operation If no system frost protection is provided and frost is likely during a note. The pump will operate briefly as a self-check once every 24 short absence from home, leave the heating controls (if fitted) at a hours, regardless of system demand.

  • Page 64: Condensate Drain

    Condensate Drain Escape of Gas Should a gas leak or fault be suspected contact the This appliance is fitted with a siphonic condensate trap National Gas Emergency Service without delay. Telephone system that reduces the risk of the appliance condensate 0800 111 999 from freezing.

  • Page 65: Troubleshooting

    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 engineer.
  • Page 66 OpERaTION MODEs DEsCRIpTION DIspLay CODE ON BOILER The boiler is in standby mode awaiting either a central heating call or hot water demand. The boiler has a call for central heating / hot water but the appliance has reached the desired temperature set on the boiler.

  • Page 67: Gas Supply

    FaULT CODEs DEsCRIpTION aCTION DIspLay CODE ON BOILER Boiler Chip Card (BCC) Please contact Ideal (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period. In IE contact a Not Fitted Registered Gas Installer (RGII). 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...
  • Page 68 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: 01482 498660 Ideal, P.O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN. www.idealboilers.com Tel.

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