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Procombi
Installation & Servicing Instructions
THESE INSTRUCTIONS TO BE RETAINED BY USER
UIN 211289 A01
September 2014
24, 30 & 35
For User Guide see reverse of book
Pro
Pro
off
max
reset
min
preheat
mode
Exclusive
30
status
burner
e
min
max
preheat
Exclusive
G.C. Number
Procombi Exclusive 24 No. 47 348 79
Procombi Exclusive 30 No. 47 348 80
Procombi Exclusive 35 No. 47 348 81
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Summary of Contents for Ideal Boilers Procombi Exclusive 24
- Page 1 Exclusive G.C. Number Procombi Exclusive 24 No. 47 348 79 Procombi Exclusive 30 No. 47 348 80 Procombi Exclusive 35 No. 47 348 81 THESE INSTRUCTIONS TO BE RETAINED BY USER UIN 211289 A01 September 2014...
- Page 2 Procombi Exclusive - Installation and Servicing...
- Page 3 NOTEs FOR ThE INsTaLLER FOR aNy TEChNICaL qUERIEs pLEasE RINg ThE pROCOMbI INsTaLLER/TEChNICaL hELpLINE : 01482 498700 NOTE. bOILER REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. The boiler will repeat the ignition sequence, if a heat demand is present. DOCUMENT aMENDMENTs Relevant Installation changes implemented in this book from Mod Level ........a01 (Sep 14) Procombi reserve the right to vary specification without notice...
- Page 4 general Table 1 - general Data procombi Exclusive Series II Gas supply 2H - G20 - 20mbar Gas Supply Connection 15mm copper compression Injector Size (mm) 4.15 4.65 Inlet Connection Domestic Hot Water 15mm copper tail Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection Central Heating...
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Page 5: Table Of Contents
general CONTENTs Procombi Exclusive Series II air supply ..............9 Natural gas only benchmark Commissioning Checklist ..... 60 boiler size g.C. appliance No. pI No. boiler Clearances ............10 (benchmark No.) boiler Exploded Diagram ........... 13 47-348-79 86CM68 Condensate Drain .......... 9,24,25,41 47-348-80 86CM68 Electrical Connections .......... -
Page 6: Safe Handling
general saFE haNDLINg INTRODUCTION This boiler may require 2 or more operatives to move it to its The procombi Exclusive range of boilers are wall mounted, full installation site, remove it from its packaging base and during sequence, automatic spark ignition, low water content, fanned movement into its installation location. -
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: Flue Installation
general gas sUppLy 3. Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in The local gas supplier should be consulted, at the installation Table 4. planning stage, in order to establish the availability of an adequate 4. -
Page 9: Air Supply
general aIR sUppLy It is NOT necessary to have a purpose-provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation;... - Page 10 general bOILER DIMENsIONs, sERVICEs & CLEaRaNCEs all dimensions in mm The boiler connections are made on the boiler bulkhead fittings. Refer to Frame 22. wall thicknesses do not exceed 600mm (24”). Where the The following minimum clearances must be maintained for space into which the boiler is going to be installed is less operation and servicing.
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Page 11: Pump
general sysTEM REqUIREMENTs - Central heating Notes a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water safety valve setting authority. -
Page 12: Domestic Hot Water
general ....CONTINUED DOMEsTIC hOT WaTER b. Hot and cold water supplies to the shower are of equal pressure. 1. The domestic hot water service must be in accordance with 5. hard Water areas - Where the water hardness exceeds BS 5546 and BS 6700. 200mg/litre (200ppm), it is recommended that a proprietary 2. - Page 13 INSTALLATION bOILER assEMbLy - Exploded View Note that item numbers are linked to the spares list CH RETURN VALVE BYPASS CARTRIDGE ELECTRODE DETECTION CH FLOW VALVE DIVERTOR VALVE PADDLE IGNITER UNIT DHW INLET & OUTLET GAS COCK FLOW THERMISTOR PUMP HEAD PIPE - GAS INLET IGNITION LEAD AIR VENT PUMP...
- 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. iMPOrTanT. To unpack the boiler: 1.
- 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.
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Page 16: Safe Handling
INSTALLATION WaLL MOUNTINg TEMpLaTE Extended centre line 1 5 5 (2 0 0 ) The wall mounting template is located on the internal protective “A” - See Diagram in packaging. The template shows the position of the fixing and rear Frame 1 flue centre holes for a standard installation Care MUST be taken to ensure the correct holes are drilled. - Page 17 INSTALLATION 12 DETERMININg ThE FLUE LENgTh aND FLUE paCKs REqUIRED IMpORTaNT. The boiler must be installed in a vertical position in recommended that a support bracket is fitted on every 1 metre of accordance to the installation instructions. pipe work used and the bracket is located as close to the collar as possible.
- Page 18 INSTALLATION 13 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...
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Page 19: Cutting & Setting The Flue Length
INSTALLATION 14 CUTTINg & sETTINg ThE FLUE LENgTh TELEsCOpIC FLUEs TELEsCOpIC FLUE b paCK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT BE CUT hORIzONTaL FLUE TERMINaL (1000MM LONg) b paCK (TELEsCOpIC) MUST ONLY BE CUT IF REQUIRED FLUE LENGTHS ARE BETWEEN 602 &... -
Page 20: Installing The Flue
INSTALLATION 15 INsTaLLINg ThE FLUE FITTINg FLUE ThROUgh ThE WaLL 1. Measure wall thickness and add 14mm. 2. Measure from the outer terminal lip towards the end of outer flue, place a small location mark at the dimension acquired at point 1. 3. -
Page 21: Fitting The Optional Roof Flue Kit (Flat Or Pitched)
INSTALLATION 16 FITTINg ThE OpTIONaL ROOF FLUE KIT (Flat or pitched) Note. A flat or pitched roof flashing plate (not supplied) is required before proceeding with the installation of this kit. Soffit Flue Kit Option 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 Shield... -
Page 22: Flue Terminal Position
INSTALLATION 18 FLUE TERMINaL pOsITION The terminal should be positioned so that products of combustion can safely disperse at all times. pluming may occur at the termination so, where possible, terminal positions where this could cause a nuisance should be avoided. Minimum dimensions are shown below 300mm 625mm... -
Page 23: Assembling The Roof Flue Kit
INSTALLATION 19 assEMbLINg ThE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied. - Page 24 INSTALLATION 20 CONDENsaTE DRaIN Condensate pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a Condensate specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water Drain discharge point such as an internal soil and vent stack or internal...
- Page 25 INSTALLATION 21 CONDENsaTE DRaIN - CONT’D..Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to Method (see manufacturers detailed instructions) External Soil & Vent Stack Boiler Water/weather Visible air break with 75mm proof insulation Boiler sealed...
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Page 26: Water Connections
INSTALLATION 22 CONNECTIONs & FILLINg NOTEs. Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown in the picture. Ensure each union is fitted with fibre seals provided. Do not subject any of the isolating valves to heat as the seals may be damaged. WaTER CONNECTIONs Ch FILLINg 1. -
Page 27: Wiring Diagram
INSTALLATION 23 ELECTRICaL CONNECTIONs Warning. This appliance MUST be earthed. 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 A mains supply of 230Vac ~ 50 Hz is required. reference should be made to the current ETCI rules for electrical The fuse rating should be 3A. -
Page 28: Procombi Exclusive - Installation And Servicing
INSTALLATION 26 WIRINg DIagRaM Procombi Exclusive - Installation and Servicing... -
Page 29: Commissioning And Testing
INSTALLATION 27 COMMIssIONINg aND TEsTINg a. Electrical Installation b. gas Installation 1. Checks to ensure electrical safety should be carried out by a 1. The whole of the gas installation, including the meter, competent person. should be inspected and tested for tightness and purged in accordance with the recommendations of BS. -
Page 30: Initial Lighting
INSTALLATION 28 INITIaL LIghTINg Legend A. Mode Control Knob status burner B. DHW/Preheat Control C. CH Control D. Boiler Status reset preheat preheat mode E. Burner ‘on’ Indication F. Pre Heat on/off Indication G. CH Flow Isolating Valve H. Pressure Gauge J. - Page 31 INSTALLATION 29 gENERaL ChECKs Make the following checks for correct operation in: WaTER CIRCULaTION sysTEM 1. With the system COLD, check that the initial pressure DOMEsTIC hOT WaTER (DhW) MODE is correct to the system design requirements. 1. Fully open all DHW taps in turn and ensure that water flows freely from them.
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Page 32: Handing Over
INSTALLATION 30 REsET pROCEDURE To reset the boiler, turn the mode control (A) to the reset position and immediately turn the knob back to the required setting. The boiler will repeat the ignition sequence if a heat demand is present. status burner reset... -
Page 33: Servicing Schedule
SERVICING 32 sERVICINg sChEDULE For the very latest copy of literature for specification & maintenance practices, visit our website www.pro-heat.co.uk where you will be able to download the relevant information. 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 33 bOILER UppER & LOWER FRONT paNEL REMOVaL / REpLaCEMENT REMOVaL REpLaCEMENT 1. Lift the lower front panel access panel. 4. Hook the upper panel onto the top retaining clips. 2. Unscrew the two fixing screws, close the access panel to 5. -
Page 35: Burner Removal And Cleaning
SERVICING 35 bURNER REMOVaL aND CLEaNINg 1. Ensure the sump is fully drained 2. Undo the two screws and remove the sump cover retaining the lower flue manifold. 3. Lift the manifold to clear the bottom sealing gasket and remove manifold. -
Page 36: Cleaning The Heat Exchanger
SERVICING 37 CLEaNINg ThE hEaT ExChaNgER note: Ensure the condensate trap/siphon is fully drained before cleaning. Refer to Ignition Electrode Flame Detection Frame 48. 1. Remove ignition and flame detection electrodes. Refer to Frames 43 & 44. 2. It is advisable to replace the sump cover prior to the water flush process. -
Page 37: Replacement Of Components
SERVICING 39 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 panels must be correctly refitted - ensuring that a good seal is made. -
Page 38: Burner Injector Replacement
SERVICING 41 bURNER INjECTOR REpLaCEMENT 1. Refer to Frame 39. 2. Disconnect the electrical leads from the fan. 3. Remove the clip from the gas valve to venturi pipe and ease the pipe upwards, rotate and ease down to remove. 4. -
Page 39: Ignition Electrode Replacement
SERVICING 43 IgNITION ELECTRODE REpLaCEMENT 1. Refer to Frame 39. 2. Remove the burner. Refer to Frame 42. 3. Unplug the ignition lead from the electrode. Ignition Electrode 4. Remove the earth lead from the ignition electrode. 5. Remove the 2 screws holding the ignition electrode to the combustion chamber. -
Page 40: Spark Generator Replacement
SERVICING 45 spaRK gENERaTOR REpLaCEMENT 1. Refer to Frame 39. 2. Disconnect the leads from the spark generator 3. Remove the single M5 Screw securing the spark generator to the gas valve mounting bracket. 4. Lift the spark generator up and out of the bottom retaining moulding. -
Page 41: Diverter Valve Actuator Replacement
SERVICING 47 DIVERTER VaLVE aCTUaTOR REpLaCEMENT To remove the motor: 1. Refer to Frame 39. 2. Remove the condensate trap/siphon. Refer to Frame 48. 3. Disconnect the inline connector block. 4. Place a flat bladed screwdriver in the actuator slot provided and ease out the actuator. - Page 42 SERVICING 49 MaIN pCb REpLaCEMENT * Note. that production boiler PCB’s are factory pre-set to operate for boiler range and output, but when ordering Primary PCB as a spare, an additional Boiler Chip Card (BCC) MUST also be purchased for your specific boiler range and output.
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Page 43: User Control Pcb Replacement
SERVICING 50 UsER CONTROL pCb REpLaCEMENT Note. Fit the earth strap provided with the PCB to your wrist and a suitable earth on the boiler chassis. 1. Refer to Frame 39. 2. Remove the main PCB, refer to Frame 49. 3. -
Page 44: Draining The Boiler
SERVICING 52 DRaININg ThE bOILER CENTRaL hEaTINg CIRCUIT 1. Refer to Frame 39. 2. Close all the CH water isolating valves on the boiler inlet. 3. To drain the primary heat exchanger circuit: Open the drain valve and attach a length of hose to the CH drain point. 4. -
Page 45: Pump Automatic Air Vent Replacement
SERVICING 55 saFETy RELIEF VaLVE RENEWaL 1. Refer to Frame 39. 2. Drain the boiler. Refer to Frame 52. 3. Remove the return thermistor. Refer to frame 63. 4. Pull out and remove the clip (positioned behind the safety valve) retaining the safety valve. -
Page 46: Pump Head
SERVICING 57 DIVERTER VaLVE bODy assEMbLy REpLaCEMENT To remove the valve body assembly: 16. Twist and remove the DHW manifold. 1. Refer to Frame 39. 17. Remove the two diverter valve body fixing screws and withdraw the diverter valve body assembly. 2. -
Page 47: Water Pressure Switch
SERVICING 60 Ch WaTER pREssURE sWITCh REpLaCEMENT 1. Refer to Frame 39. 2. Drain the boiler. Refer to frame 3. Pull off the two electrical connections. 4. Using a suitable tool, pull out the metal retaining clip. 5. Carefully withdraw the pressure switch. -
Page 48: Heat Engine Renewal
SERVICING 63 RETURN ThERMIsTOR REpLaCEMENT 1. Refer to Frame 39. 2. Drain the boiler. Refer to frame 58. 3. Unplug the electrical connection. 4. Using a suitable tool, pull out the retaining clip. 5. Carefully pull the thermistor upwards to remove. 6. -
Page 49: Expansion Vessel Recharging & Replacement
SERVICING 65 ExpaNsION VEssEL REChaRgINg & REpLaCEMENT REChaRgINg 1. Refer to Frame 39. Recharge Point 2. Remove the charge point cover. 3. Recharge the tank pressure to 0.75 bar. 4. Re-assemble in reverse order 5. Check operation of the boiler. Refer to Frames 28 &... -
Page 50: Fault Finding
Fault Finding 67 aLTERNaTINg ‘L’ aND ‘1’ - FLOW TEMpERaTURE OVERhEaT LOCKOUT Is the Boiler and CH System filled with water and all Fill and vent the system and open all isolation and radiator valves open? isolation valves, then reset boiler Is the Flow/Return Differential across the Boiler in Check that the Pump is rotating freely. - Page 51 Fault Finding 69 aLTERNaTINg ‘L’ aND ‘5’ - 5 REsETs WIThIN 15 MINs Turn power off and on 70 aLTERNaTINg ‘L’ aND ‘6’ - FaLsE FLaME LOCKOUT Check routing and integrity of internal boiler Reset the boiler, does Boiler Work OK? wiring is OK.
- Page 52 Fault Finding 72 aLTERNaTINg ‘F’ aND ‘2’ - FLaME LOss Does the boiler ignite for a short Is the Gas Pressure available at Check gas supply and time and then extinguish? the Boiler Inlet (18 mbar)? rectify fault Check the detection electrode and Check wiring from gas associated harness for: continuity, Is 215Vdc supply available at the...
- Page 53 Fault Finding 74 aLTERNaTINg ‘F’ aND ‘4’ - FLOW ThERMIsTOR FaULT Check the resistance using a suitable multimeter Fit a new Thermistor connected across the thermistor’s terminal pins. At 25 expect 9,700 - 10,300 Ohms At 60 expect 2,400 - 2,600 Ohms At 85 expect...
- Page 54 Fault Finding 76 aLTERNaTINg ‘F’ aND ‘7’ - LOW MaINs VOLTagE Contact electricity provider 77 aLTERNaTINg ‘F’ aND ‘9’ - pCb FaULT Replace PCB - Ensure that the BCC (boiler chip card - small plastic part) is fitted to the PCB otherwise replace PCB. 78 aLTERNaTINg ‘C’...
- Page 55 Fault Finding 80 aLTERNaTINg ‘F’ aND ‘7’ - LOW MaINs VOLTagE Reset Boiler REsET pROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting. 81 NO Ch OpERaTION bUT hW WORKs OK Move the mode knob to the Winter position Is the mode knob in the Winter position? Are the Timer and the Room Thermostat switched...
- Page 56 Fault Finding 82 NO hW bUT Ch ON Is hot and cold pipework crossed? Does the display show “d” when a tap is on? Adjust flow rates to achieve 35º Are the flow rates correct as per Frame 2. temp rise and check filter fitted in turbine is not blocked with debris.
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Page 57: Spare Parts
SPARE PARtS When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Procombi. Failure to do so could affect safety or performance of this appliance. - Page 58 SPARE PARtS Procombi Exclusive - Installation and Servicing...
- Page 59 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 60 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 61 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 62 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 63 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 64 Ideal Boilers provides after-sales assistance and Technical advice for Procombi Exclusive boilers procombi helpline: 01482 498700 Ideal boilers p.O. box 103, National avenue, Kingston Upon hull, hU5 4jN We reserve the right to change the specifications without prior notice. Consumers’ statutory rights are not affected.
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Page 65: User Guide
Procombi Exclusive 24, 30 & 35 User Guide For Installation Guide see reverse of book status burner reset preheat preheat mode Exclusive THESE INSTRUCTIONS TO BE RETAINED BY USER... -
Page 66: Introduction
INTRODUCTION CONTENTs The procombi Exclusive is a combination boiler providing both central heating and instantaneous domestic hot water. Featuring 1. Introduction .............. 2 full sequence automatic ignition and fan assisted combustion. Safety ................. 2 Due to the high efficiency of the boiler, condensate is produced from the flue gases and this is drained to a suitable disposal point through Electricity Supply ............ -
Page 67: Boiler Operation
bOILER OpERaTION Legend status burner A. Mode Knob B. Domestic Hot Water / Preheat Knob reset preheat preheat C. Central Heating Temperature Knob mode D. Boiler Status E. Burner ‘on’ Indicator F. Domestic Hot Water Preheat on / off indicator G. -
Page 68: Efficient Heating System Operation
3. sysTEM WaTER pREssURE EFFICIENT hEaTINg sysTEM OpERaTION The boiler is a high efficiency, condensing appliance which will The system pressure gauge (H - see automatically adjust its output to match the demand for heat. page 3) indicates the central heating Therefore gas consumption is reduced as the heat demand is system pressure. -
Page 69: General Information
gENERaL INFORMaTION MEChaNICaL 24 hOUR TIMER bOILER pUMp The boiler pump will operate briefly as a self-check once every 24 Align current hours, regardless of system demand. time to arrow MINIMUM CLEaRaNCEs Timed Manual ON Clearance of 165mm (6 ”) above, 100mm (4”) below, 2.5mm Time &... -
Page 70: Points For The Boiler User
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 71: Normal Operation Display Codes
NORMaL OpERaTION DIspLay CODEs 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 but the appliance has reached the desired temperature set on the boiler. -
Page 72: Fault Codes
FaULT CODEs DEsCRIpTION aCTION DIspLay CODE ON bOILER BCC Activation Fault Reset the appliance - if the boiler fails to operate then please contact Procombi (if under warranty) or alternatively a Gas Safe Registered Engineer if outside of the warranty period.
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