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installation and
servicing
C24 & C28
Combination boiler
Your installation and servicing guide
When replacing any part on this appliance, use only spare parts that you can be assured conform
to the safety and performance specification we require. Do not use reconditioned or copy parts
that have not been clearly authorised by the manufacturer.
Supplied By www.heating spares.co Tel. 0161 620 6677
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Table of Contents
Related Manuals for Ideal Boilers Boxer C24
Summary of Contents for Ideal Boilers Boxer C24
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Page 1: Combination Boiler
installation and servicing C24 & C28 Combination boiler Your installation and servicing guide When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification we require. Do not use reconditioned or copy parts that have not been clearly authorised by the manufacturer. - Page 2 GENERAL Table 1 - General Data BOXER C 24 BOXER C 28 Table 2 - Performance Data - Central Heating and Domestic Hot Water (D.H.W.) BOXER C 24 BOXER C 28 Max. Min. Max. Min. ∆ Note. For 3rd Family gases, supply and burner pressure are given in the instructions sheet supplied with the Conversion kit. Note.
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Page 3: Table Of Contents
GENERAL BOXER CONTENTS page no. Natural Gas only G.C. Appliance No. 47-348-22 (BOXER C 24) Air Supply G.C. Appliance No. 47-348-23 (BOXER C 28) Boiler Clearances PI No. 0049AU2867 (BOXER C 24) 0049AU2949 (BOXER C 28) Boiler Exploded Diagram 10, 11 Destination Countries: Electrical Connections Electrical Supply... - Page 4 GENERAL INTRODUCTION BOILER WATER CIRCUIT DIAGRAMS The BOXER combi boiler Central Heating Circuit Air Pressure Switch Note. Heat Due to the high efficiency of the boiler a plume of water vapour exchanger Pressure may form at the terminal during operation. switch Flame sensing Ignition...
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Page 5: Gas Safety Regulations
GENERAL OPTIONAL EXTRA KITS l Flue Extension Duct 1 m SAFE HANDLING OF SUBSTANCES Flue extension ducts 250 mm lengthPack D1 l 90 Elbow l 45 Elbow l Roof Flue Kit l Inclined roof tile LOCATION OF BOILER AND FLUE OUTLET l Flat roof tile l Vertical flue connection l Boiler Stand-off Kit... -
Page 6: Boiler Clearances
GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in) 8r‡r…ÃyvrÂsÃi‚vyr… (3/4”) Side and Rear Flue (2 3/4”) (3 5/32”) (3 5/8”) (2 3/4”) ‡ ‡ ‚ … ‡ y … y ‚ ‡ ‡ ˆ ‡ ˆ... -
Page 7: Air Supply
GENERAL GAS SUPPLY IMPORTANT. IMPORTANT FLUE INSTALLATION TERMINAL AIR SUPPLY Table 3 - Balanced flue terminal position Terminal Position Minimum Spacing Table 4 Boxer Air from room/internal space Air direct from outside cm (in ) cm (in ) C 24 265 (41) 133 (21) C 28... -
Page 8: Electrical Supply
GENERAL WATER CIRCULATION SYSTEM WATER TREATMENT - See frame 6 THERMOSTATIC RADIATOR VALVES (TRV) IMPORTANT ELECTRICAL SUPPLY SYSTEM REQUIREMENTS - Central Heating Safety valve setting Notes Vessel charge pressure a. The method of filling, refilling, topping up or flushing System pre-charge pressure sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable System volume... -
Page 9: Mandatory Requirements 5 To
GENERAL SYSTEM REQUIREMENTS - CH (continued) and HOT WATER General 5. Filling. iii. BOXER C 24 BOXER C 28 4. 'Make-up' Water. Hhv† h‡r…ƈƒƒy’ 8CÃSr‡ˆ… C‚†r Èv‚† 9‚ˆiyr Ãpurpx ‰hy‰r Ãh††r€iy’ T‡‚ ƒÃ‰hy‰r 6qqv‡v‚hyà BOXER C 24 v†‚yh‡v‚ BOXER C 28 ‰hy‰r U r €ƒ‚…h…’Ãu‚†r DOMESTIC HOT WATER... -
Page 10: Boiler Exploded Diagram
INSTALLATION SYSTEM BALANCING Note. BALANCING WATER TREATMENT The BOXER boiler has a COPPER heat exchanger IMPORTANT. The application of any other treatment to this product may render the guarantee invalid. FERNOX MB1 or SENTINEL X100 is recommended Notes MUST BOILER ASSEMBLY - Exploded View Legend BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. - Page 11 INSTALLATION BOILER ASSEMBLY - Exploded View BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 12 INSTALLATION UNPACKING Pack A Contents Unpack and check the contents. P AAT@UÃA P S Ã"À ÃAGV @ P AAT@UÃA P S Ã!$à € ÃAG V @ P AAT@UÃA P S Ã!À ÃAGV @ P AAT@UÃA P S à $à € ÃAG V @ Hardware Pack ! &...
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Page 13: Side Outlet
INSTALLATION 11 CASING REMOVAL 12 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT. 185 + S = 235 mm 185 mm Note. FLUE KITS For flue options refer Pack B to page 5. Pack D Refer to 'Flue Extension Ducts' Total Flue length dimension Flue Rear flue... -
Page 14: Wall Mounting Template
INSTALLATION 13 FLUE ASSEMBLY - Exploded View Side Rear LEGEND Rear flue arrangement shown 14 WALL MOUNTING TEMPLATE Notes. a. If rear flue is used, only part (A) off template is necessary. b. If side flue is used, also part (B) off template is necessary; then follow the instructions given on it. -
Page 15: Preparing The Wall
INSTALLATION 15 PREPARING THE WALL WARNING. Side flue Rear flue only 5’’ only 5’’ diameter diameter hole hole Section through wall Note: Check all of the hole Note. If the terminal is to be sited within 25-40 mm of a corner or vertical positions before drilling. -
Page 16: Mounting The Boiler
INSTALLATION 18 MOUNTING THE BOILER Note. All the isolating valves are supplied separately in the Note. hardware pack. If the clearances above and below the boiler are less than the length of the pipes it will be necessary to position the pipes behind the wall mounting plate Directly to the wall BEFORE the plate is screwed to the wall. -
Page 17: Extension Ducts - Fitting
INSTALLATION 19 CONNECTING THE FLUE TO THE BOILER 5. Flues over 0.72 metre long. Note. When no extension duct is used, the flue restrictor supplied in hardware pack “A”, must be fitted. 20 FLUE EXTENSION DUCTS - For flue lengths greater than 720 mm Pack D Flue extension duct kit contents. - Page 18 INSTALLATION 22 FITTING THE KIT V X U H 0 H D *5229( !À€ 23 SERVICE CONNECTIONS General Notes BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
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Page 19: Water Connections
INSTALLATION WATER CONNECTIONS CH CONNECTIONS Refer to General Note, Frame 23, for guidance. Note. Do not subject any of the isolating valves to heat as the seals may be damaged. C.H. FLOW C.H. RETURN WATER CONNECTIONS - continued DHW CONNECTIONS D.C.W. - Page 20 INSTALLATION 26 GAS CONNECTION GAS IN 27 SAFETY VALVE DRAIN 28 FILLING Central Heating IMPORTANT - when filling: iii. Note Some slight water leakage will occur. Domestic Hot Water Note. BOXER C 28 BOXER C 24 BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel.
- Page 21 INSTALLATION 29 ELECTRICAL CONNECTIONS WARNING 30 EXTERNAL ELECTRICAL CONTROLS Wiring External to the Boiler A9 - Plug TA - Plug Frost Protection Room ‘stat Time controls Room Thermostat Programmer Do not connect any external supply to the room thermostat: this will permanently damage the PCB (see A).
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Page 22: Electrical Connections
INSTALLATION 31 PICTORIAL WIRING DIAGRAM LEGEND ’t ’t Dtv‡v‚ ’t Hhv†Ã†ˆƒƒy’ Bh†Ã ryrp‡…‚qr† !"ÃWÃÃ$ÃC“ ‰hy‰r ’t 132 Vac 47 Vdc Connection ID for i… Gas Valve lead Qˆ€ƒ … … Ayh€rà Hhv† qr‡rp‡v‚ ‚… †v‡pu i… ryrp‡…‚qr Dtv‡v‚ i… ‡…h†s‚…€r… i…... -
Page 23: Flow Wiring Diagram
INSTALLATION 32 FUNCTIONAL FLOW WIRING DIAGRAM Bh†Ã ‰hy‰r ’t Hhv†Ã†ˆƒƒy’ !"ÃWÃÃ$ÃC“ S‚‚€·†‡h‡ i… ’t ix ix i… ‚… Dtv‡v‚ P‰r…urh‡Ã‡ur…€‚†‡h‡ ‡…h†s‚…€r… i… ‰ ’t ‰ i… Qˆ€ƒ ’t G‚Æv‡pu i… i… ’t 8CÆr†‚… ’t Ay‚Æv‡pu i… ... - Page 24 INSTALLATION 34 INITIAL LIGHTING LEGEND Control panel 5(6( 7 2) ) (17( 5 10. CENTRAL HEATING BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 25 INSTALLATION 35 INITIAL LIGHTING - continued 12. DOMESTIC HOT WATER 17. CHECKING BURNER PRESSURE Minimum pressure LEGEND Maximum pressure BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 26 INSTALLATION 36 GENERAL CHECKS Make the following checks for correct operation in: Make the following checks for correct operation in: DOMESTIC HOT WATER (DHW) MODE CENTRAL HEATING (CH) & DOMESTIC HOT WATER (DHW) MODE. BOXER C 28 BOXER C 24 3.
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Page 27: Installation 10 To
INSTALLATION 37 GENERAL CHECKS - continued WATER CIRCULATION SYSTEM Note A flushing solution should be used during the flushing procedure. Flushing solutions, Fernox Superfloc, Sentinel X300 (new systems) or X400 (existing systems). Refer to Frame 6. WATER TEMPERATURES Central Heating prominent position Domestic Hot Water Knob Setting... -
Page 28: Servicing Schedule
SERVICING 39 SERVICING SCHEDULE WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity It is the law that any service work must be carried out by a supply to the appliance before servicing. registered CORGI installer. - Page 29 SERVICING 41 BOILER CASING REMOVAL 42 CONTROL HOUSING ACCESS BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 30 SERVICING 43 EXPANSION VESSEL AND VERTICAL PROTECTION SHIELD REMOVAL Note. Take care not to disturb the expansion vessel flexible pipe. (BOXER C 24) (BOXER C 28) BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 31 SERVICING 44 DRAINING THE BOILER 6. After replacing any component on the boiler, close the drain valve and open all system isolating valves before proceeding drain to check operation of the boiler. point 45 FAN ASSEMBLY REMOVAL AND CLEANING Note. Take care not to damage the fan impellor (BOXER C 24) (BOXER C 28)
- Page 32 SERVICING 46 VENTURI REMOVAL AND CLEANING 47 BURNER REMOVAL AND CLEANING (BOXER C 24) (BOXER C 28) Note. Check the ignition and detection probes are in the correct position and re-connected. BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 33 SERVICING 48 CLEANING THE HEAT EXCHANGER 49 REPLACEMENT OF COMPONENTS GENERAL When replacing ANY component IMPORTANT. THE BOILER MUST NOT BE LEFT IN AN OPERATIONAL CONDITION IF THE SEALING CASING IS NOT FITTED BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel.
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Page 34: Fan Replacement
SERVICING 50 C.H. AND D.H.W. SENSOR REPLACEMENT TABLE OF RESISTANCE VALUES AS A FUNCTION OF THE TEMPERATURE OF THE SENSORS T°C 33242 25633 19947 15659 12394 9888 7947 6433 5242 4300 3548 2945 2459 2063 1740 1475 1256 1075 Relation between the temperature (°C) and nominal resistance (Ohm) of the CH and DHW sensors. - Page 35 SERVICING 52 VENTURI REPLACEMENT 53 BURNER INJECTOR REPLACEMENT 8 - 9 Note. Check that all of the injectors have been replaced and security tightened. BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 36 SERVICING 54 BURNER REPLACEMENT 55 OVERHEAT THERMOSTAT REPLACEMENT BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 37 SERVICING 56 IGNITION/FLAME DETECTION ELECTRODES REPLACEMENT #ÃÃ$À€ 57 HEAT EXCHANGER REPLACEMENT BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 38 SERVICING 58 DIVERTER VALVE ACTUATOR REPLACEMENT 59 COMBUSTION CHAMBER INSULATION REPLACEMENT Prior to removal of the board the following protective equipment should be worn: • Face mask • Gloves BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
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Page 39: Pump
SERVICING 60 GAS CONTROL VALVE REPLACEMENT 61 PCB REPLACEMENT BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677... - Page 40 SERVICING 62 MAINS SWITCH REPLACEMENT 63 PRESSURE GAUGE REPLACEMENT BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 41 SERVICING 64 SAFETY RELIEF VALVE REPLACEMENT 65 AUTOMATIC AIR VENT REPLACEMENT BOXER C 24 BOXER C 28 BOXER C 24 IMPORTANT. BOXER C 28 BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 42 SERVICING 66 PUMP HEAD REPLACEMENT 67 AIR PRESSURE SWITCH REPLACEMENT BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 43 SERVICING 68 LOW WATER SWITCH REPLACEMENT 69 EXPANSION VESSEL REPLACEMENT Note. If preferred, and for convenience, a new expansion vessel may be installed on the return pipework elsewhere in the heating system providing it ensures equivalent system protection. BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel.
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Page 44: Servicing 28 To
SERVICING 70 DHW FLOW SWITCH REPLACEMENT 71 IGNITION TRANSFORMER REPLACEMENT BOXER C 24 BOXER C 28 BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677... -
Page 45: Fault Finding
FAULT FINDING 72 FAULT FINDING ENSURE THE ROOM THERMOSTAT AND PROGRAMMER ARE CALLING FOR HEAT AND THE SELECTOR SWITCH IS SET TO HEATING. ENSURE ALL SERVICES ARE ON AND NO DHW TAPS ARE OPEN IS THERE 230 Vac AT THE BOTTOM IS THE POWER LED RECTIFY EXTERNAL FAULT CONNECTIONS OF THE OFF/ON SWITCH... - Page 46 FAULT FINDING WITH THE SYSTEM PRESSURE >1 bar IS THERE CONTINUITY BETWEEN NO AND C REPLACE FAULTY WATER PRESSURE CONTACTS ON THE WATER PRESSURE SWITCH SWITCH IS THERE CONTINUITY BETWEEN THE REPAIR OR REPLACE FAULTY PRESSURE SWITCH CONNECTOR AND THE WIRING PCB CONNECTOR REPLACE FAULTY PCB...
- Page 47 FAULT FINDING WITH THE FAN RUNNING ARE THE FAN VENTURI IS THERE CONTINUITY AND FLUE CLEAR OF RECTIFY OR DOES THE GAS VALVE OPEN BETWEEN NO & C OBSTRUCTIONS AND THE REPLACE AS CONTACTS ON THE AIR SENSIING PIPES NECESSARY PRESSURE SWITCH UNDAMAGED AND CORRECTLY CONNECTED...
- Page 48 FAULT FINDING IS THERE >17mbar INLET IS THE BURNER PRESSURE RECTIFY GAS SUPPLY PRESSURE AT THE GAS CORRECT (DATA TABLE 2) FAULT VAL VE ADJUST THE BURNER PRESSURE IS THE SYSTEM FULLY ENSURE ALL VALVES VENTED WITH ALL DO THE RADIATORS GET HOT ARE OPEN WITH THE ISOLATOR VALVES FULLY SYSTEM VENTED AND...
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Page 49: Fault Finding 45 To
FAULT FINDING ENSURE THE WATER IS THE WATER FLOW IS THE DHW WATER TEMPERA- PRESSURE IS CONSTANT AT APPROX TURE STABLE CONSTANT AND THE 10 l/min SUPPLY IS STABLE REPLACE THE DHW IS THE VOLTAGE Vdc AT THERMISTOR.IS THE REPLACE FAULTY PCB PLUG A2 BETWEEN PINS 3 WATER TEMPERATURE AND 4 STABLE... -
Page 50: Short List Of Parts
SHORT LIST OF PARTS BOXER C 24 BOXER C 28 BOXER C 24 BOXER C 28 Caradon Ideal Limited Key No. G.C. Part No. Description Qty. Product Number BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677... - Page 51 SHORT LIST OF PARTS 87 SHORT PARTS LIST 20 - 28 BOXER combination boiler - Installation and Servicing Supplied By www.heating spares.co Tel. 0161 620 6677...
- Page 52 Technical Training The code of practice for the installation, commissioning & servicing of central heating systems Ideal Boilers Caradon Ideal Limited BOXER Installer/Technical Helpline: 01482 498 663 Supplied By www.heating spares.co Tel. 0161 620 6677...
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