Bongioanni IDEA/36 T, IDEA/54 T, IDEA/18 T, IDEA/27 T, IDEA/18 I Installation And Servicing Instructions

IDEA

IDEA

INSTALLATION AND SERVICING

INSTRUCTIONS

tipo P

may we thank you for having chosen a BONGIOANNI product.
This manual has been prepared with the aim to acquaint you with the boiler
you have purchased.
Please take time to read it because the instructions and suggestions on the
installation, use and maintenance of your boiler will enable you to obtain the
best results from our high quality product for a very long time.

Bongioanni spa

Dear customer,

IDEA boilers are manufactured to the highest standard of quality, performance and safety in
accordance with EC standards and requirements.
They comply with Gas Safety Regulations and carry the CE mark.

IDEA boilers are classified as type B

11BS

and are designed for use on gas category II

2H3+

.

The Manufacturer will not assume any responsibility for the non observance of any relevant
statutory installation requirements, regulations and codes of practice, or any recommenda­tions and instructions included in this manual.

The installation of IDEA boilers must be in accordance with relevant statutory requirements,
the Gas Safety (Installation and Use) Regulations 1994, Health & Safety at Work Act,
Building Ragulations, I.E.E. Regulations, Construction (Design & Management) Regulations
1994, Local Authority Bylaws, Local Gas Undertaking Regulations, Local & National Water
Byelaws, Fire Authority Regulations and Insurance Company requirements.

The following codes of practice are also applicable:

BS6880 Codes of practice for low temperature hot water heating systems of

output greater than 45 kW. Parts 1, 2 & 3: 1988.

CP342 Code of practice for centralised hot water supply, part 2 Buildings other

than individual dwellings.

BS6644 1991 specifications for gas fired hot water boilers of rated inputs between

60 kW and 2 MW.

IGE/UP/2 Gas installation pipework, boosters and compressors on industrial and

commercial premises.

CIBSE Guide Reference sections B7, B11 and B13.

BS5440 Installation of flues and ventilation for gas appliances of rated input not

exceeding 60 kW.

British Gas IM/11 Flues for commercial and industrial gas fired boilers and air heaters.

CONFORMITY STATEMENT

INSTALLATION REQUIREMENTS

GUIDE TO CONTENTS

1 Description

1.1 General remarks

1.2 Boiler models

1.3 Dimensional drawings

1.4 Technical data

1.5 Boiler components and ancillaries

1.5.1 Gas valves used

1.5.2 IDEA boilers with electric ignition
IDEA boilers with electronic ignition

1.6 Exploded drawings and parts list

1.6.1 Exploded view of boiler block unaccessoried version

1.6.2

Parts list IDEA unaccessoried version

1.6.3 Exploded view of boiler block accessoried version

1.6.4

Parts list IDEA accessoried version

1.6.5

Control panel

2 Installation and operating instructions

2.1 Boiler room

2.2 Gas connection

2.3 Water connection

2.4 Flue connection

2.5 Electrical supply and connection

2.5.1 IDEA boilers with electric ignition

2.5.2 IDEA boilers with electronic ignition

2.6 Casing assembly

2.7 First lighting and boiler control

2.7.1 IDEA boilers with electric ignition

2.7.2 IDEA boilers with electronic ignition

2.7.3 Changing gas type

2.7.4 Checking the flue thermostat

3 Boiler operating and maintenance

Guidance for the user

3.1 Commissioning the boiler

3.1.1 IDEA boilers with electric ignition

3.1.2 IDEA boilers with electronic ignition

3.2 Switching the boiler off

3.3 Warning

3.4 Cleaning the boiler

3.5 Flue safety thermostat

DESCRIPTION

IDEA boilers consists of a range of 6 atmospheric gas fired cast iron sectional boilers offering
high efficiency and low emissions.

Each heat exchanger comprises:

- one front left section

- a variable number of intermediate sections

- one front right section
all connected to each other by means of bi-conical nipples (St 37-2 DIN 1626).
Each boiler is fitted with a stainless steel multi-bar atmospheric gas burner, for operation with
natural gas or LPG.
IDEA boilers are available in the following model configuration:

- T = with electric ignition and pilot-thermocouple system for the flame monitoring

- I = with electronic ignition and ionisation flame detection.

1

1.1 GENERAL REMARKS

1.2 BOILER MODELS

IDEA BOILERS (ELECTRONIC IGNITION - IONIZED)

with pump

Nominal heat output and vessel

Model No. of sections Btu/h kW Ref. No. Ref. No.

IDEA/18 I 3 61,400 18 1810023 1810223
IDEA/27 I 4 92,200 27 1810024 1810224
IDEA/36 I 5 122,900 36 1810035 1810235
IDEA/45 I 6 153,600 45 1810026 -
IDEA/54 I 7 184,300 54 1810027 -
IDEA/63 I 8 215,000 63 1810028 -

IDEA BOILERS (ELECTRIC IGNITION)

with pump

Nominal heat output and vessel

Model No.of sections Btu/h kW Ref. No. Ref. No.

IDEA/18 T 3 61,400 18 1810003 1810203
IDEA/27 T 4 92,200 27 1810004 1810204
IDEA/36 T 5 122,900 36 1810015 1810215
IDEA/45 T 6 153,600 45 1810006 -
IDEA/54 T 7 184,300 54 1810007 -
IDEA/63 T 8 215,000 63 1810008 -

1

1.3 DIMENSIONAL DRAWINGS

IDEA LXBCMPHaHcHr

18 PV 450 80 290 160 125 600 455 395 280
27 PV 600 90 400 200 195 600 455 395 280

18 450 80 290 160 145 600 530 - 370
27 450 90 250 200 65 600 530 - 370
36 600 75 360 240 135 600 530 - 370
45 600 75 320 280 55 600 530 - 370
54 800 120 480 320 175 640 530 - 370
63 800 120 440 360 95 640 530 - 370

IDEA PV IDEA
a FLOW CONNECTION (installation 3/4” 1”
r RETURN CONNECTION (installation) 3/4” 1”
g GAS CONNECTION 3/4” 3/4”
c FILL COCK CONNECTION 1/2” -

X

a

B

P

L

C

M

g

r

480

Hc

Ha

Hr

c

2

TECHNICAL DATA

1.4

IDEA (P = with Polidoro burner) 18 PV 27 PV 36 PV 18 27 36 45 54 63
No. of sections 3 4 5345678
Nominal heat input kW 19.9 29.8 34.8 19.9 29.8 39.7 49.7 59.6 69.5

Btu/h 67,900 101,700 135,500 67,900 101,700 135,500 169,600 203,400 237,200

Nominal heat output kW 18 27 31,5 18 27 36 45 54 63

Btu/h 61,400 92,200 122,900 61,400 92,200 122,900 153,600 184,300 215,000
No. of burner injectors 23 4234567
Pilot injectors Ø (T-model only)

Natural Gas G 20 (2 holes) mm 0.29 0.29 0.29 0.29 0.29 0.29 0.29 0.29 0.29
LPG G30/G 31 (1 hole) mm 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24 0.24

Burner injectors Ø
Natural Gas G 20 mm 2.70 2.70 2.60 2.70 2.70 2.60 2.60 2.60 2.60
LPG G30/G 31 mm 1.55 1.55 1.45 1.55 1.55 1.55 1.55 1.55 1.55

Inlet pressure
Natural Gas G20 mbar 20 20 20 20 20 20 20 20 20
LPG G30/G31 mbar 30/37 30/37 30/37 30/37 30/37 30/37 30/37 30/37 30/37

Burner pressure
Natural Gas G20 mbar 11,6 11,6 10,1 11,6 11,6 13,2 13,2 13,2 13,2
LPG G30/G31 mbar 28/35 28/35 28/35 28/35 28/35 28/35 28/35 28/35 28/35

Gas rate
(continuous operation)
( 15°C ; 1013 mbar)Nat. Gas G20 m3/h 2.11 3.15 3.69 2.11 3.15 4.20 5.26 6.31 7.36

LPG G30 kg/h 1.57 2.35 2.75 1.57 2.35 3.13 3.92 4.71 5.49

G31 kg/h 1.54 2.31 2.71 1.54 2.31 3.08 3.86 4.63 5.39
Flue outlet Ø mm 110 130 150 110 130 150 150 180 180
Negative pressure required

at flue outlet Pa 1 1 1111111
Electrical supply
T - model W 100 100 100 6 6 6 6 6 6

I - model W 110 110 110 16 16 16 16 16 16
Water content l 11 14 17 11 14 17 20 23 26
Max operating temperature °C 90 90 90 90 90 90 90 90 90
Max hydraulic

pressure bar 3 3 3333333
Capacity of

expansion vessel l 10 10 10 - - - - - -
Flue gas mass flow

g/s 13 18 26 13 18 226 28 41 43

Flue gas temperature

°C 130 136 115 130 136 125 146 126 135

Weight kg 115 137 156 107 126 145 167 191 211

230 V~ - 50 Hz

3

10

1000 2000 3000 4000 5000 6000 7000 8000 9000

90

170

250

330

410

18

27

36

45

54

63

mbar

IDEA

IDEA

IDEA

IDEA

IDEA

IDEA

Q

l/h

VELOCITA' 3

IDEA 18 - 27 - 36 - PV

WATERSIDE PRESSURE DROP

(not accessoried model)

DISCHARGE HEAD (PV models)

Q

l/h

1500

1000

2000 2500 3000 3500

0

1

2

3

4

H (m)

GAS TYPE NATURAL GAS LPG

IDEA 18 I SIT NOVA 822 SIT NOVA 822
IDEA 27 I SIT NOVA 822 SIT NOVA 822
IDEA 36 I SIT NOVA 822 SIT NOVA 822
IDEA 45 I SIT NOVA 822 SIT NOVA 822
IDEA 54 I SIT NOVA 822 SIT NOVA 822
IDEA 63 I SIT NOVA 822 SIT NOVA 822

GAS TYPE NATURAL GAS LPG

IDEA 18 T SIT NOVA 820 SIT NOVA 820
IDEA 27 T SIT NOVA 820 SIT NOVA 820
IDEA 36 T SIT NOVA 820 SIT NOVA 820
IDEA 45 T SIT NOVA 820 SIT NOVA 820
IDEA 54 T SIT NOVA 820 SIT NOVA 820
IDEA 63 T SIT NOVA 820 SIT NOVA 820

GAS VALVES

IDEA BOILERS IDEA BOILERS
ELECTRIC IGNITION ELECTRONIC IGNITION

COMPONENTS:

- on/off switch

- automatic combination gas control valve

- stainless steel multi-bar atmospheric gas burner
complete with venturi

- low consumption pilot burner

- ceramic ignition electrode

- thermocouple with interrupter adapter

- electric igniter

- boiler control thermostat

- safety high limite thermostat with thermocouple
serial contacts

- flue thermostat with indication lamp for chim­ney obstruction

- boiler thermometer

- external flue hood

- stove enamelled casing

COMPONENTS:

- on/off switch

- automatic combination gas control valve

- stainless steel multi-bar atmospheric gas burner
complete with venturi

- electronic flame controller

- ceramic ignition and ionisation electrodes

- boiler lockout/reset button

- boiler control thermostat

- safety high limit thermostat

- flue thermostat with indication lamp for chim­ney obstruction

- boiler thermometer

- external flue hood

- stove enamelled casing

1.5.1

1.5 BOILER COMPONENTS AND ANCILLARIES

1.5.2

IDEA BOILERS - ELECTRIC IGNITION

IDEA BOILERS - ELECTRONIC IGNITION/IONIZED

4

1.6.1

EXPLODED VIEW OF BOILER BLOCK (unaccesoried version)

EXPLODED DRAWINGS AND PARTS LIST

1.6

5

IDEA

N. DESCRIPTION 18 27 36

45 54 63
1 Flue hood 1846053 1846084 1846055 1846056 1846057 1846058
2 Ceramic rope ø 8 8567000
3 Front right side section 1830000
4 Intermediate section 1830500
5 Front left side section 1830900
6 Thermostat pocket 1764200

10 Rubber square gasket 1866000
11 Pipe 1852202
16 Pipe 1852100
19 Cock with cap and chain 8591201
20 Bottom rear cover plate 1845283 1845284 1845285 1845286 1845287 1845288
21 Insulating rear cover K 45 1866513 1866514 1866515 1866516 1866517 1866518
22 Base tray 1845003 1845004 1845005 1845006 1845007 1845008
23 Plate DB 1200 1892603 1892604 1892605 1892606 1892607 1892608
24 Insulating front cover K 45 1866503 1866504 1866505 1866506 1866507 1866508
25 Gas burner assembly 1855103 1855104 1855105 1855106 1855107 1855108
26 Peep-hole with sight-glass 1855060
27 Polidoro pilot burner ( T-models ) 0160300
27 Ignition electrode ( T-models ) 0161600
27 Thermocouple ( T-models ) 0160500
27 Electrode fixing bracket ( I-models ) 1848009
27 Ignition electrode ( I-models ) 1861500
27 Ionisation electrode ( I-models ) 1861501
28 Rubber gasket 0166301
29 Sit 820 gas valve ( T-models ) 0156100
29 Sit 822 gas valve ( I-models ) 1856010
30 Flange pipe 1852300
31 Gas sealing rubber gasket 1866001
32 Gasket 8566000
33 Blind plug 8589802
34 Pipe 1851800
35 Front apron 1845203 1845204 1845205 1845206 1845207 1845208
36 Tie rods 8584002 8584003 8584004 8584005 8584006 8584007
37 Black tissue felt AT 20 1880100
38 Bi-conical nipple 8589500

1.6.2 PARTS LIST IDEA UNACCESORIED VERSION

6

1.6.3

EXPLODED VIEW OF BOILER BLOCK (accesoried version)

7

IDEA

N. DESCRIPTION 18 PV 27 PV 36 PV

1 Flue hood 1846053 1846084 1846055
2 Ceramic rope ø 8 8567000
3 Front right side section 1830000
4 Intermediate section 1830500
5 Front left side section 1830900
6 Thermostat pocket 1764200
7 Expansion vessel 0162500
8 Manometer 8561901

9 Automatic air vent valve 1362101
10 Rubber square gasket 1866000
11 Pipe 1851600
12 Ball cock 3/4 MM mini 1391300
13 Pipe 1851900
14 Pipe 1851700
15 Safety valve 3 bar 8562100
16 Pipe 1851500
17 Blind plug 8589604
18 Circulating pump 0159306
19 Cock with cap and chain 8591201
20 Bottom rear cover plate 1845283 1845284 1845285
21 Insulating rear cover K 45 1866513 1866514 1866515
22 Base tray 1845003 1845004 1845005
23 Plate DB 1200 1892603 1892604 1892605
24 Insulating front cover K 45 1866503 1866504 1866505
25 Gas burner assembly 1855103 1855104 1855105
26 Peep-hole with sight-glass 1855060
27 Polidoro pilot burner ( T-models ) 0160300
27 Ignition electrode ( T-models ) 0161600
27 Thermocouple ( T-models ) 0160500
27 Electrode fixing brackets ( I-models ) 1848009
27 Ignition electrode ( I-models ) 1861500
27 Ionisation electrode ( I-models ) 1861501
28 Rubber gasket 0166301
29 Sit 820 gas valve ( T-models ) 0156100
29 Sit 822 gas valve ( I-models ) 1856010
30 Flange pipe 1852300
31 Gas sealing rubber gasket 1866001
32 Gasket 8566000
33 Blind plug 8589802
34 Pipe 1851800
35 Front apron 1845203 1845204 1845205
36 Tie rods 8584002 8584003 8584004
37 Black tissue felt AT 20 1880100
38 Bi-conical nipple 8589500

1.6.4 PARTS LIST IDEA ACCESORIED VERSION

8

1.6.5 CONTROL PANEL

N. DESCRIPTION FUNCTION

1 RED LAMP “LOCKOUT” (I-model only) TO INDICATE LOCKOUT OF IONISATION CONTROL
2 RED LAMP “BOILER VOLTAGE” TO INDICATE 220V BOILER VOLTAGE
3 GREEN LAMP “PUMP OPERATING”(PV-models) TO INDICATE OPERATION OF CIRCULATING PUMP
4 RED LAMP “CHIMNEY OBSTRUCTED” TO INDICATE OBSTRUCTION OR INADEQUACY OF

THE CHIMNEY

5 BOILER THERMOMETER TO CHECK THE BOILER WATER TEMPERATURE
6 BOILER THERMOSTAT TO REGULATE THE BOILER WATER TEMPERATURE
7 ON/OFF SWITCH TO SWITCH THE BOILER ON/OFF
8 KNOCKOUT FOR OPTIONAL CLIMATIC CONTROLLER
9 FLUE THERMOSTAT RESET BUTTON TO RESET THE FLUE THERMOSTAT
10 SAFETY THERMOSTAT RESET BUTTON TO RESET THE SAFETY THERMOSTAT
11 CONTROL RESET RED BUTTON (I-models only) TO RESET THE IONISATION FLAME CONTROL

REF. NO. DESCRIPTION ***

1849100 COMPLETE CONTROL PANEL (boilers

from 3 to 7 sections) x -

1849102 COMPLETE CONTROL PANEL (boilers

from 3 to 7 sections) - x

1849108 COMPLETE CONTROL PANEL (boilers with

8 sections) x -

1849118 COMPLETE CONTROL PANEL (boilers with

8 sections) - x

1872202 PANEL FRONT PLASTIC COVER x x
1872200 PANEL REAR PLASTIC COVER x x
8584747 HINGE 4 x 40 FOR COVER x x
0172701 WIRED CONNECTION for SIT NOVA VALVE x x
0672501 CONNECTION MM 540 - x
1861500 ELECTRODE FOR IGNITER - x
1861501 ELECTRODE IONIZATION CONTROL - x
0161600 ELECTRODE FOR IGNITER x -
1872512 P.C.B.TYPE A FOR “MICRO” CONTROLLER x x

REF. NO. DESCRIPTION ***

8587518 IGNITER x -
1871700 THERMOSTAT DIAL x x
1872207 PLASTIC CABLE CLAMP x x
1872550 HONEYWELL FLAME CONTROLLER - x
8562706 LIMIT THERMOSTAT 110°C 220 V - x
8562701 LIMIT THERMOSTAT 110°C mmV x -
8562799 BOILER THERMOSTAT x x
8562858 THERMOMETER x x
8572525 CONTROL FLAME RESET - x
8572539 RED LENS ø 6 x x
8572540 GREEN LENS ø 6 x x
8572541 RED LAMP x x
8572542 GREEN LAMP x x
8572543 BLACK BIPOLAR SWITCH x x
8562713 FLUE THERMOSTAT (boilers from 3 to 7 sections) x x
8562703 FLUE THERMOSTAT (boilers with 8 sections) x x

8592360 MICRO SWITCH WITH IGNITION CABLES x-

* T-MODELS ** I-MODELS

COMPONENTS OF THE CONTROL PANEL

9

°c

1234 5 6 7 8

10

11

2

1

9

The gas connection should comply with relevant requirements of Gas Safety (Installation and
Use) Regulations.
Gas supply pipework should be fitted in accordance with CP.331/3 taking into account the size
of the boiler (see technical data § 1.4).

INSTALLATION AND OPERATING INSTRUCTIONS

The boiler should be connected to the chimney with rigid flue pipes and fittings, construc­ted and dimensioned according th the Local Regulations in force.
The flue thermostat is pre-set and its sensor is positioned so as to operate in accordance
with set Standards.
It is therefore absolutely forbidden to either modify or reposition the thermostat bulb or
electrical connections, or replace it with a non-original part..

2

BOILER INSTALLATION2.1

The location chosen for the boiler must allow for the provision of a satisfactory flue and provi­de an adequate space for servicing and air circulation around the boiler, in accordance with
requirements of Local Regulations, particularly in order to avoid any possible risk for the user
or malfunctioning of the boiler.

The connection of the boiler to the water system should comply with all appropriate regula­tions. In th case of installations in known hard water areas (hardness greater than 20 French
degrees) appropriate treatment of the system fill water is strongly recommended.
If there is a need to treat the water with an anti-freeze agent, then carefully follow the recom­mendations of the anti-freeze supplier/manufacturer, especially when mixing water with the
antifreeze.
The IDEA accessoried boilers are fitted with a 3-speed circulating pump.
Listed below are graphs showing waterside pressure drop and discharge head.

GAS CONNECTION2.2

WATER CONNECTION2.3

FLUE CONNECTION2.4

10

1000 2000 3000 4000 5000 6000 7000 8000 9000

90

170

250

330

410

18

27

36

45

54

63

mbar

IDEA

IDEA

IDEA

IDEA

IDEA

IDEA

Q
l/h

SPEED 3

IDEA 18 - 27 - 36 - PV

WATERSIDE PRESSURE DROP

(unaccessoried models)

DISCHARGE HEAD

(PV models)

Q

l/h

1500

1000

2000 2500 3000 3500

0

1

2

3

4

H (m)

10

ELECTRICAL SUPPLY AND CONNECTION2.5

IDEA BOILERS WITH ELECTRIC IGNITION2.5.1

The electrical installation and connection must be in accordance with the latest Local
Authority Regulations.
To simplify installation and servicing operations, all our gas boilers are fitted with a
P.C.B. TYPE A.
Connect the boiler to the electrical supply (see technical data § 1.4) ensuring that polarity
is correct (PH = phase into pole 1 - N = neutral into pole 2) and that it is earthed properly
The room thermostat should be connected between terminals No.7 and No.8 after remo­ving the yellow-red cable bridge between them.
The time clock should be connected between terminals No.5 and No.6 after removing the
yellow-red cable bridge between them.

The terminal boards marked from No.53 to No.60 should be used to implement the
climatic controller “Micro”. Instructions for connection are detailed on the booklet

blu blu blu

ACC

C1

nero

nero

LR

22

PH

IG

Fus

TF

20

23

14

marrone giallo marrone

giallo

15

3

5 6

OR

7

A1

25

D1

12

13

4

11

18

21

17

E1

marroneblu

blu

nero

nero

nero nero

LPT LF

F4

marrone

K4

Q1

TA

8

25

9

16

10

TAI

B1 25

TR

VG

L

1

N

2

OR

~

60

59

56 55

58

24

57

71

N

giallo

marrone

PR

LEGEND :

❏❏

Terminal

➁➁

Connection on P.C.B.
ACC Electric igniter
FUS Fuse
IG Main switch
LF Flue saftey thermostat indicator lamp
LPT Voltage indicator lamp
LR Heating function indicator lamp (model

PV only)
~ OR Supply for time clock
OR Connections for time clock
PR Circulating pump (model PV only)
TAI Pump overrun relay
TA Connections for room thermostat
TF Flue thermostat
TR Boiler control thermostat
VG Gas valve

CONNECTION OF CIRCULATING PUMP (unaccessoried
models).

It can be made between terminals 11 and 13.
(should the boiler fitted with a water storage calorifier, then
follow the instructions delivered with the same).

CONNECTION OF THE PUMP OVERRUN RELAY
(OPTIONAL)

Ensure that pump has been connected between terminals 11 and

13.
After having removed the cable bridge between terminals 9
and 12, the three faston male terminals of overreun relay
should be connected as follows:

C(C) to terminal 12
NC(1) to terminal 10
NO(2) to terminal 9

WARNING

The pump overrun relay TAI should have the possibility to be
setted at a temperature HIGHER than that of the boiler con­trol thermostat TR.

11

54

53

The connections between control panel and ionisation panel are already made by Bongioanni, as

shown below.

C1

neronero

LR

22

PH

IG

Fus

TF

20

23

14

marrone giallo marrone

giallo

15

3

5 6

OR

7

A1

25

D1

12

13

4

11

18 21

17

E1

marroneblu

blu

nero

nero

nero nero

LPT LF

F4

marrone

K4

Q1

TA

8

25

9

16

10

TAI

B1 25

TR

L

1

N

2

FILTRO ANTIDISTURBO

66

60

59

56 55

58

24

57

71

N

centralina ionizzazione

giallo

giallo

FILTRO ANTIDISTURBO

OR

~

PR

IDEA BOILERS WITH ELECTRONIC IGNITION2.5.1

1615

1413121110987654321

3

1

2

TS

SBPR

IONIZZAZIONE

TERRA

ACCENSIONE

22

V.1

V.2

SB

BLU

NERO

ARANCIO

NERO

BIANCO

BLU

ROSSO

GIALLO

67
68
69
70

62

61

65
64
63

MARRONE

MARRONE

BLU

BLU

71

12

The legend and instructions for the connection of the circulating pump are on the previous page

54

53

25

1

2

3

ignition

EMC - FILTER

EMC - FILTER

IONISATION

EARTH

IGNITION

22

- Turn the control knob to
pilot position.

- Press it fully. As soon as
gas flows from pilot burner,
the ignition electrode will
spark.

- Check that spark is approx
5 mm. long.

- When pilot burner lights,
wait approx. 20 seconds
before releasing the knob.
The pilot burner should

stay alight. If not, repeat the operation. Ensure that thermocouple voltage (measu-

red as near as possible to the valve) is 5 mV at least.

- Turn the knob to burner position.

- Remove the gas test point screw downstream. Move the water column manometer
to the pressure test point downstream the burner. Refit the inlet test screw.

- Turn the boiler thermostat dial to the required temperature. When burner is fully
ignited, set the burner gas pressure to the pressure shown in the techincal data table

1.4 according to the gas type used.

- Seal the adjustment screw.

- If burner does not ignite, than check that the correct electrical supply is being
fed to the gas valve.

- If there is voltage, then check that gas rate is sufficient before replacing gas
valve.

- If there is no voltage, check function of main switch, flue safety thermostat,
time clock, room thermostat, boiler control thermostat.

- Switch the burner off using the main switch. Wait 30 seconds at least. Re-light the
burner and check the slow ignition (approx. value: 8 mbar.).

CASING ASSEMBLY2.6

IDEA boilers are supplied complete with assembled casing.
Electrical and water connections can be made very easily without the need to desmantle any
part of the casing.
It is sufficient to open the front door to have complete access to the control panel.

FIRST LIGHTING AND BOILER CONTROL

Ensure that system and boiler are filled with water and both have been perfectly vented.
Ensure that boiler has been supplied to operate with the appropriate type of gas, otherwise
see § 2.7.3 (Changing gas type).
Shut the gas cock, remove the inlet pressure point screw on the gas valve and connect a
water column manometer. Open the gas cock and check that the inlet gas pressure value is
20 mbar or slightly higher. (Warning: if pressure value is not stable or greater than 37 mbar
it will be necessary to fit a pressure reducing valv e to the gas inlet. Apply to a qualified Gas
Service Engineer). Turn the boiler main switch on position Iafter checking that there is vol­tage on net (voltage indicator lamp should be on before turning main switch).

2.7

IDEA BOILERS WITH ELECTRIC IGNITION

2.7.1

CONTROL
KNOB

PRESSURE
ADJUSTING SCREW

PILOT PRESSURE
ADJUSTING SCREW

TEST POINT SCREW
DOWNSTREAM

INLET TEST POINT
SCREW

13

IDEA boilers are supplied for use on Natural Gas. Should they be used with LPG, just ask for gas tran­sformation kit to be sent for changing from Natural Gas to LPG.

BOILER MODEL KIT REF. NO. No./ ø INJECTORS ø pilot injectors

Idea 18 1885123 2/1,55 0,24
Idea 27 1885124 3/1,55 0,24
Idea 36 1885135 4/1,55 0,24
Idea 45 1885126 5/1,55 0,24
Idea 54 1885127 6/1,55 0,24
Idea 63 1885128 7/1,55 0,24

Changing from Natural Gas to LPG:

- Exchange the injectors of main burner.

- Fully tighten the pressure regulator screw and replace the pressure regulator cap by the one (without
hole) supplied with the kit.

- Check the burner pressure upstream the gas valve and set the pressure regulator according to values
quoted on Technical Data Table 1.4.

- Check that burner pressure value downstream the gas valve corresponds to what reported on
Technical Data Table 1.4. Seal the pressure regulating screw.

Changing from LPG to Natural Gas:

- Exchange the injectors of main burner.

- Set the burner pressure according to values quoted on Technical Data Table1.4.

- Replace the pressure regulator cap by the one supplied with the kit.

- Seal the pressure regulating screw.

IDEA BOILERS WITH ELECTRONIC IGNITION

- Turn the boiler thermostat dial to the required temperature. As soon as gas flows

from the main burner, the ignition electrode will spark.
If not, check that the correct voltage is being supplied to the gas control valve.

- If there is voltage, then replace the gas control.

- If there is no voltage, then check the function of main switch, flue safety ther­mostat, time clock, room thermostat, boiler control thermostat.

- Ensure that electrode spark is 5 mm. long and that it shoot out between ignition
plug and gas outlet slots on the burner.

If there is spark but main burner does not ignite, ensure that:

- gas installation has been completely vented;

- voltage arrives to gas valve.
If the burner lights but the ignition spark keeps operating and after a few seconds

the ionisation control trips, ensure that:

- on control panel phase is connected to pole 1 and neutral to pole 2;

- ionisation plug is not broken or incorrectly positioned or damaged because of
humidity;

- installation has been correctly earthed and that the earth cable conneceted to
the burner is adequately secured.

- Turn off the boiler main switch. Remove the test point screw downstream the bur­ner. Move the water column manometer to the pressure test point downstream the
boiler. Refit the inlet test screw. When burner is fully ignited, set the burner gas
pressure to the pressure shown in the technical data table 1.4 according to the gas
type used. Seal the adjustment screw.

- Switch the burner off using the main switch. Wait 30 seconds at least. Re-light the
burner and check the slow ignition (approx. value: 8 mbar.).

CHANGING GAS SUPPLY TYPE

2.7.2

2.7.3

14

BOILER OPERATING AND MAINTENANCE Guidance for the User

The only operation that the end user can carry out on the boiler are as follows:

- check the presence of water in the boiler and installation (once a week at least)

- Reset of circulating pump, when fitted, after a period of inactivity of more than 15 days.
[Switch off the boiler , unscrew the pump scre w (it is normal that a small quantity of water
overflows) and release the disk wheel by means of a screw driver].

- Reset of limit thermostat when pilot burner does not stay alight after ignition (IDEA boi­lers with electric ignition).

- Reset of limit thermostat and of boiler lockout button, when boiler is tripped (IDEA boi­lers with electronic ignition).

- In case of doubts, or should the boiler go to lockout for more than three times, then apply
to a Qualified Gas Service Engineer.

3

CHECKING THE FLUE THERMOSTAT2.7.4

It is strongly recommended that the efficient and safe operation of the flue thermostat is
checked as follows:

- temporarily obstruct the flue above the darught diverter with an insulating material
capable of enduring temperature of approx. 300°C

- open all the windows of boiler room to ensure air circulation before lighting the boi­ler

- the burner should stop within 2 minutes and the signal lamp indicating chimney
should light (if not, flue thermostat should be replaced)

- turn off the main switch, turn off gas supply at the gas service cock

- refit the flue duct

- remove the temporary flue obstruction

- wait until the thermostat phial has cooled (approx. 10 minutes after intervention)

- reset the flue thermostat

- re-light the boiler.

SHOULD THE FLUE THERMOSTAT SIGNAL LAMP LIGHT AT ANY TIME
DURING NORMAL OPERATION, CHECK THE CHIMNEY DRAUGHT.

SWITCHING THE BOILER ON

- Open gas cock

- turn main switch ON

- Adjust boiler thermostat dial to the minimal temperature.

3.1

15

To clean the boiler it is suitable to apply to a Qualified Gas Service Engineer, proceeding
as follows:

- disconnect and remove the burner, cleaning it thoroughly with the help of a vaccum
cleaner and dusting brush.

- Dismantle the flue hood for cleaning

- Clean the fins/flue passes of the heat exchanger using flue brush.

- Clean the chimney/check for obstruction.

To clean the boiler casing use a damp dusting cloth.

WARNING: Always turn off the electrical supply before starting

Do not use detergents or solvents. To remove particularly resistant stains, use alcohol.
Re-check thermostat settings and reconnect the electrical supply.

- Turn the control knob to pilot position.

- Press it fully. As soon as gas flows from
pilot burner, the ignition electrode will
spark.

- When pilot burner lights, wait approx. 20
seconds before releasing the knob. The
pilot burner should stay alight. If not,
repeat the operation.

- Turn the knob to burner position.

- Turn the boiler thermostat dial to the
required temperature.

- Should any problem occurr during boiler

ignition, even though all operations have been madecorrectly, then apply to a qua­lified Gas Service Engineer.

IDEA BOILERS WITH ELECTRIC IGNITION

3.1.1

CONTROL
KNOB

PRESSURE
ADJUSTING SCREW

PILOT PRESSURE
ADJUSTING SCREW

TEST POINT SCREW
DOWNSTREAM

INLET TEST POINT
SCREW

IDEA BOILERS WITH ELECTRONIC IGNITION

- Turn the boiler thermostat dial to the required temperature. As soon as gas flows
from pilot burner, the ignition electrode will spark.

- After approx. 10 seconds the igniter will stop sparking and main burner will remain
alight.

- Should any problem occurr during boiler ignition, even though all operations have
been made correctly, then apply to a qualified Gas Service Engineer.

3.1.2

CLEANING THE BOILER3.4

Servicing and cleaning must be carried out each year by a Qualified Gas Service Engineer
on a regular basis, to ensure boiler efficiency and long life.

SWITCHING THE BOILER OFF

- Turn main switch OFF

- Turn OFF gas supply.
WARNING: If the boiler is located in a place where temperature can drop under 0°C, it is

strongly recommended to put antifreeze into the installation.

WARNING

3.2

3.3

16

EDIZIONE 5/97

FLUE SAFETY THERMOSTAT3.5

RE-STARTING THE BOILER

The activation of the flue safety thermostat is indicated by a red signal lamp on the control
facia corresponding to the symbol “chimney obstructed”.

To re-start the boiler proceed as follows:

- turn off power supply

- remove the casing front panel to reach the flue thermostat reset button

- remove (unscrew) the plastic cover on the reset button

- push down the red reset button

- refit the plastic cover and re-assemble the casing front panel

- turn on power supply.

WARNING: should the flue safety thermostat trip more than three times, it is abso­lutely vital to call for a Qualified Service Engineer to check for the possible cause of
failure. Should the chimney draught be inadequate, then corrective action must be
taken.

PROHIBITION: the flue safety thermostat has been pre-setted and its sensor positioned

in such a way that the device will trip in accordance with the Regulations in force.
Therefore it is absolutely forbidden to change either the phial position or electrical con­nection. It is also forbidden to replace the flue safety thermostat with another of non-origi­nal supply.

17

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