ideal Isar M3050 User guide

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GENERAL

Table 1 - Boiler Data

Boiler Size m30-50 m50-80

Gas supply type and connection 2H-G20-20mbar Rc

Injector size Stereomatic 5.4mm dia.

Flow connection 22mm copper

Return connection 22mm copper

Maximum static water head m (ft.) 30.5 (100)

Minimum static water head m (ft.) 0.45 (1.5)

Electrical supply 230 V ~ 50 Hz

Boiler power consumption 38W

Fuse rating External: 3A Internal: F3.15A TL 250V

Water content litre (gal.) 3.65 (0.8)

Dry Weight kg (lb.) 43 (95 )

Boiler size Height mm (in.) 580 (23)

Width mm (in.) 390 (15)

Depth mm (in.) 278 (11)

Flue terminal diameter mm (in.) 100 (4)

Table 2 - Performance Data

1/2 (1/2" BSP Female)

Boiler Size m30-50 m50-80

Input Min Max Min Max

Boiler input 'Q' = Nett kW 9.7 16.2 15.8 26.2

CV Btu/h 33 100 55 300 54 000 89 500

Boiler input 'Q' = Gross kW 10.7 18.0 17.5 29.1

CV Btu/h 36 700 61 400 59 900 99 400 Gas consumption l/s (cu.ft/h) 0.27 (35.4) 0.46 (59.1) 0.45 (57.7) 0.75 (95.7)

Boiler output 'P' = 70 °C Mean water kW 8.8 14.7 14.7 23.4

temperature Btu/h 30 000 50 000 50 000 80 000

Seasonal efficiency (SEDBUK) * Band D [ 78.8 ]% Band D [ 78.6 ]%

Nox classification class 4

* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated have been certified by a notified body.

Note.

Gas consumption is calculated using a calorific value of 38.7 MJ/m3 (1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett. To obtain the gas consumption at a different calorific value:-

a. For l/s - divide the gross heat input (kW) by the gross C.V.

of the gas (MJ/m3)

b. For ft

/h - divide the gross heat input (Btu/h) by the gross

C.V. of the gas (Btu/ft3)

Key to symbols GB = United Kingdom IE = Ireland

PMS = Maximum operating pressure of water

C13C33C53 = A room sealed appliance designed for connection

via ducts to a horizontal terminal which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which, in this case, are concentric. The fan is up stream of the combustion chamber.

= An appliance designed for use on 2nd Family gas,

Group H only.

(Countries of destination)

CAUTION.

this appliance, care should be taken when handling edges of sheet steel components.

To avoid the possibility of injury during the installation, servicing or cleaning of

classic m - Installation & Servicing

GENERAL

classic m

Natural Gas only

m3050 ........................ G.C. Appliance No. 41 391 50

m5080 ........................ G.C. Appliance No. 41 391 51

PI No. 0063BL9812

Destination Countries: UK, IE

CONTENTS

Air Supply ...................................................................... 6

Boiler Clearances ......................................................... 4

Boiler Exploded Diagram........................................... 12

Electrical Connections............................................... 19

Electrical Supply ........................................................... 7

Extension Ducts - Fitting ........................................... 17

Fault Finding ............................................................... 37

Flow Wiring Diagram .................................................. 22

Flue Fitting .................................................................. 15

Flue Installation ............................................................ 6

Gas Safety Regulations ............................................... 5

BENCHMARK LOG BOOK DETAILS

Boiler Page

Make and model ........................................................ 3

Appliance Serial No. on Data Badge ...................... 12

Controls ............................................... as applicable

Forall boilers

Flushing to BS.7593 ................................................ 11

Inhibitor .................................................................... 11

Gas inlet working pressure ....................................... 6

Burner operating pressure ........................................ 2

Heat input .......................................... to be calculated

Temperature differential .............measure and record

For combination boilers only ................. Not applicable

For domestic hot water mode ................ Not applicable

For condensing boilers ........................... Not applicable

For all boilers: complete, sign & hand over to customer

For assistance see Technical Helpline number on the back page

Gas Supply .................................................................... 6

Installation ................................................................... 12

Mandatory Requirements ............................................ 5

Pump ............................................................................ 8

Servicing ...................................................................... 25

Short List of Parts ...................................................... 40

Terminal ......................................................................... 6

Thermostatic Radiator valves ..................................... 7

Water and Systems....................................................8-9

Water Connections ..................................................... 19

Water Treatment.......................................................... 11

Wiring Diagrams ......................................................... 20

NOTE TO THE INSTALLER:

LEAVE THESE

INSTRUCTIONS ADJACENT TO THE GAS METER.

ALSO COMPLETE THE BENCHMARK LOG BOOK

AND GIVE THIS TO THE CUSTOMER.

classic m - Installation & Servicing

GENERAL

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Return

Flow

BOILER WATER CONNECTIONS

The boiler flow and return pipes are supplied fitted to the boiler ready for top connection

Notes.

a. For the heating loads in excess of 60, 000 Btu/hr boilers,

28mm (1") flow and return pipes should be used to and from the boiler.

b. This appliance is NOT suitable for use with a direct hot

water cylinder.

BOILER CLEARANCES all dimensions in mm (in.)

The following minimum clearances must be maintained for operation and servicing.

Additional space will be required for installation, depending upon site conditions.

Side and Rear Flue a Provided that the flue hole is cut accurately, e.g. with a core

drill, the flue can be installed from inside the building where wall thicknesses do not exceed 600mm (24"). Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside.

Installation from inside ONLY b. If a core boring tool is to be used inside

the building the space in which the boiler is to be installed must be at least wide enough to accommodate the tool.

5 (1/4")

165 (6 1/2")

50 (2")

Ecl 1574

400 (15 3/4")

Front clearance

The minimum front clearance when built in to a cupboard is 5mm (1/4") from the cupboard door but 450mm (17 3/4") overall clearance is still required, with the cupboard door open, to allow for servicing.

100 (4")

Jacking screw

Gas

30 mm (1

1/8

390 (15 3/8")

50 (2")

278 (11")

50 (2")

Flue terminal

582 (23")

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111mm

Gas

3/8

* Bottom clearance

Bottom clearance after installation can be reduced to 5mm. However, 100mm must be available for servicing.

classic m - Installation & Servicing

GENERAL

INTRODUCTION

The classic m boiler is a fully automatically controlled, wall

mounted, low water content, fan flued, non condensing gas boiler. It has full modulating central heating outputs of 8.8 kW (30,000 Btu/h) to 14.7 kW (50,000 Btu/h) and 14.7Kw (50 000 Btu/h) to 23.4Kw (80 000 Btu/h)

The boiler casing is of white painted mild steel with user controls capable of being mounted remotely from the boiler, if the option is required.

The heat exchanger is cast iron.

Note. These boilers cannot be used on systems which include gravity circulation.

The boilers are suitable for connection to fully pumped, open vented or sealed water systems. Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework.

OPERATION

When there is a demand for heat, the heating system is supplied selected temperature of between 65oC and 82oC.

The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating and performance of key components to aid commissioning and fault finding.

BS. 5440:2 Ventilation (for gas appliances of rated input not

exceeding 70 kW).

BS. 5449 Forced circulation hot water systems.

BS. 5546 Installation of gas hot water supplies for domestic

purposes (2nd Family Gases).

BS. 6798 Installation of gas fired hot water boilers of rated

input not exceeding 60 kW.

BS. 6891 Low pressure installation pipes.

Health & Safety Document No. 635

The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be taken, in any way, as overriding statutory obligations.

IMPORTANT. These appliances are CE certificated for safety and performance. It is, therefore, important that no external control devices, e.g. flue dampers, economisers etc., are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Caradon Plumbing Limited in writing. If in doubt please enquire.

Any direct connection of a control device not approved by Caradon Plumbing Ltd. could invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety Regulations and the above regulations.

OPTIONAL EXTRA KITS

z D Pack Flue Extension Ducts (1000mm long)

z Flue Finishing Kit

Elbow Kit (Maximum 2 per installation)

z 90

Elbow Kit (Maximum 2 per installation)

z 45

z Roof flue Kit

z Powered Vertical Flue Kit

z Remote User Controls Kit

z Boiler Stand-off Kit

SAFETY

Current Gas Safety (Installation and Use) Regulations or rules in force.

It is law that all gas appliances are installed and serviced by a CORGI registered installer in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with.

The installation of the boiler MUST also be in accordance with the latest I.E.E (BS 7671) Wiring Regulations, local building regulations, bye-laws of the local water authority, the building regulations and the Building Standards (Scotland) and any relevant requirements of the local authority.

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation panels, which can cause irritation to the skin. No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture.

LOCATION OF BOILER

The boiler must be installed on a flat and vertical wall, capable of adequately supporting the weight of the boiler and any ancillary equipment.

The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary, unless required by the local authority.

For electrical safety reasons there must be no access from the back of the boiler.

The boiler must not be fitted outside.

Detailed recommendations are contained in the following British Standard Codes of Practice:

BS. 5440:1 Flues (for gas appliances of rated input not

exceeding 70 kW).

classic m - Installation & Servicing

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the British Gas publication 'Guide for Gas Installations in Timber Frame Housing', reference IGE/UP/ 7:1998.

GENERAL

Compartment Installations

A compartment used to enclose the boiler should be designed and constructed specially for this purpose. An existing cupboard or compartment may be used, provided that it is modified for the purpose.

In both cases details of essential features of cupboard / compartment design, including airing cupboard installation, are to conform to the following:

z BS. 6798. (No cupboard ventilation is required - see “Air

Supply” for details).

z The position selected for installation MUST allow adequate

space for servicing in front of the boiler.

z For the minimum clearances required for safety and

subsequent service, see the wall mounting template and Frame 2. In addition, sufficient space may be required to allow lifting access to the wall mounting plate.

GAS SUPPLY

The local gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas. An existing service pipe must NOT be used without prior consultation with the local gas supplier. The boiler must installed on a gas supply with a governed meter only.

A gas meter can only be connected by the local gas supplier or by a registered CORGI engineer.

An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the rate of gas supply required. A working gas pressure of 20 mbar should be available at the boiler inlet.

IMPORTANT.

Installation pipes MUST be fitted in accordance with BS. 6891. Pipework from the meter to the boiler MUST be of an adequate size, i.e. not less than 15mm O.D.

The complete installation MUST be tested for gas soundness and purged as described in the above code.

Table 3 - Balanced flue terminal position

Terminal Position

1. Directly below or alongside an

opening window, air vent or other 300 mm (12") ventilation opening

2. Below guttering, drain pipes or soil pipes 75 mm ( 3")

3. Below eaves 200 mm ( 8")

4. Below balconies or a car port roof 200 mm ( 8")

5. From vertical drain pipes or soil pipes 75 mm ( 3")

6. From internal or external corners 300mm (12")

7. Above adjacent ground, roof or

balcony level 300 mm (12")

8. From a surface facing the terminal 600 mm (24")

9. From a terminal facing a terminal 1200 mm (48")

10. From an opening in a car port

(e.g. door or window) into dwelling 1200 mm (48")

11. Vertically from a terminal on the same wall 1500 mm (60")

12. Horizontally from a terminal on the wall 300 mm (12")

boiler MUST NOT be closer than 25mm (1") to combustible material. Detailed recommendations on the protection of combustible material are given in BS. 5440: 2000.

Minimum Spacing

IMPORTANT. It is absolutely ESSENTIAL to ensure, in

practice, that products of combustion discharging from the terminal cannot re-enter the building or any other adjacent building through ventilators, windows, doors, other sources of natural air infiltration, or forced ventilation / air conditioning.

If this should occur the appliance MUST be turned OFF, labelled as 'unsafe' until corrective action taken.

TERMINAL

The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Frame 11 - Unpacking.

FLUE INSTALLATION

The flue must be installed in accordance with the recommendations of BS. 5440: Part 1.

The following notes are intended for general guidance.

1. The boiler MUST be installed so that the terminal is exposed to external air.

2. It is important that the position of the terminal allows the free passage of air across it at all times.

3. Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 3.

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 to which people have access, then the terminal MUST be protected by a purpose designed guard.

Ensure that the guard is fitted centrally.

5. Where the terminal is fitted within 850mm (34") of a plastic or painted gutter or 450mm (18") of painted eaves then an aluminium shield at least 750mm (30") long should be fitted centrally to the underside of the gutter or painted surface.

6. The air inlet/products outlet duct and the terminal of the

AIR SUPPLY

It is NOT necessary to have a purpose-provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation; therefore the requirements of BS 6798, Clause 12, and BS 5440:2 may be disregarded.

WATER CIRCULATION SYSTEM

For the types of system and correct piping procedure see Frames 1, and 3 to 8.

The central heating system should be in accordance with BS. 6798 and, in addition, for smallbore and microbore systems, BS. 5449.

WATER TREATMENT - see Frame 9

The hot water storage cylinder MUST be of the indirect type and should preferably be manufactured of copper.

Single feed, indirect cylinders are not recommended and MUST NOT be used on sealed systems.

The appliances are NOT suitable for gravity central heating nor are they suitable for the provision of gravity domestic hot water.

classic m - Installation & Servicing

GENERAL

The hot water cylinder and ancillary pipework, not forming part of the useful heating surface, should be lagged to prevent heat loss and any possible freezing - particularly where pipes run through roof spaces and ventilated underfloor spaces.

The boiler must be vented.

The hydraulic resistance of the boilers, at MAXIMUM OUTPUT, with an 11 oC (20 oF) temperature differential, is shown in Graph 1.

Graph 1 - Water flow rate and pressure loss

1.0

0.5

THERMOSTATIC RADIATOR VALVES (TRV)

Caradon Plumbing Ltd. recommend that heating systems

utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS. 5449.

For further information refer to the 'Good Practice Guide 143', publication of the Energy Efficiency Office, available from the Building Research Establishment, Garston, Watford WD2 7JR. Tel: 01923 664 258

ELECTRICAL SUPPLY

Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations which apply.

The point of connection to the mains should be readily accessible and adjacent to the boiler.

Pressure Drop Across Boiler

(metres water)

8.8 11.7 14.7 17.6 20.5 23.4 Boiler Output (kW)

Ecl 1603

classic m - Installation & Servicing

GENERAL

OPEN VENT SYSTEM REQUIREMENTS

The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150mm (6") away from the vent connection.

Note. Combined feed and vent pipes may also be fitted.

There should be a minimum height, 450mm (18"), of open vent above the cistern water level. If this is not possible refer to Frame 5. The vertical distance between the highest point of the system and the feed/expansion cistern water level MUST not be less than 450 mm (18"). The pump must be fitted on the flow side of the boiler.

A suitable pump is a domestic circulator capable of providing a maximum

C (20oF) temperature differential across the boiler with the whole of the

11 heating circuit open (e.g. Grundfos UPS 15/50, 15/60 or equivalent). With the minimum flow circuit allowed by the controls the differential must not exceed 25 oC.

The vertical distance between the pump and feed/expansion cistern MUST comply with the pump manufacturer's minimum requirements, to avoid cavitation. Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Caradon Plumbing Ltd. The isolation valves should be fitted as close to the pump as possible.

Ecl 1604

SCHEMATIC PIPEWORK AND SYSTEM BALANCING

The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load 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 footnote re. thermostatic radiator valves).

Balancing

1. Set the programmer to ON for both

CH and HW. Turn the cylinder thermostat down. Close the manual or thermostatic valves on all radiators, leaving the twin lockshield valves (on the radiators referred to above) in the open position. Turn up the room thermostat and adjust these lockshield valves to give boiler flow and return temperatures not more than 20 apart. These valves should now be left as set.

2. Open all manual or thermostatic radiator valves and adjust the lockshield valves on remaining radiators to give around 11 temperature drop at each radiator.

3. Turn up the cylinder thermostat and adjust the cylinder balancing valve so that the cylinder achieves a maximum flow consistent with adequate flow to the radiators. Check that with only the domestic hot water loop in circuit a differential temperature of 20 across the boiler is not exceeded.

4. Adjust room and cylinder thermostats and programmer to NORMAL settings.

Ecl 1605

Note.

Systems incorporating zone valves which could completely shut off the flow through the system, must be wired such that the boiler will not fire or continue to fire when this occurs.

classic m - Installation & Servicing

GENERAL

LOW HEAD AND LARGE SYSTEMS WITH EXTENSIVE PIPE RUNS - OPEN VENT

This arrangement is useful for large systems where radiators at the extremities are difficult to vent. This can lead to pumping over with conventional feed and vent arrangements.

The following conditions MUST be observed:

1. The top of the automatic air vent must be below the cold water level.

2. The static water level (cold) must be at least 200mm above the top of the horizontal flow pipe, fitted as shown. The vent connection MUST NOT be made immediately off the top of the boiler as venting is made less efficient.

3. The maximum practical length of 22mm cold feed pipe should be used in order to reduce the effective volume of hot system water expanding into the feed/ expansion cistern to a minimum.

Note. The pump manufacturers' minimum requirements must be complied with.

Ecl 1606

All dimensions in mm (in.).

NB. Imperial dimensions are approximate

SEALED SYSTEM REQUIREMENTS

Note. The method of filling, refilling, topping up or flushing

sealed primary hot water circuit from the mains via a temporary hose connection is only allowed if acceptable to the local water authority.

1. General

a. The installation must

comply with the requirements of BS. 6798 and BS. 5449.

b. The installation

should be designed to work with flow temperatures of up to 82° C.

c. All components of the

system, including the heat exchanger of the indirect cylinder, must be suitable for a working pressure of 3 bar (45lb/in ) and temperature of 110°C. Care should be taken in making all connections so that the risk of leakage is minimised.

2. Safety Valve

A spring loaded safety valve complying with the relevant requirements of BS. 6759 must be fitted in the flow pipe as close to the boiler as possible and with no intervening valve or restriction. The valve should have the following features:

a. A non-adjustable preset lift pressure not exceeding

3bar (45lb/in

b. A manual testing device.

c. Provision for connection of a discharge pipe.

3. Pressure Gauge

A pressure gauge covering at least the range 0-4 bar (0-60 lb/in be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel.

The valve or discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or cause damage to electrical components and wiring.

) must be fitted to the system. The gauge should

classic m - Installation & Servicing

SEALED SYSTEM REQUIREMENTS - continued

4. Expansion Vessel

a. A diaphragm type expansion vessel must be

connected to a point close to the inlet side of the pump, the connecting pipe being not less than 15

1/2" nominal) size and not incorporating valves

mm ( of any sort.

b. The vessel capacity must be adequate to accept the

expansion of the system water when heated to 110° C (230° F).

c. The charge pressure must not be less than the static

water head above the vessel. The pressure attained in the system when heated to 110° C (230° F) should be at least 0.35 bar (5 Ib/in

) less than the lift pressure of the safety valve. For guidance on vessel sizing refer to the table in Frame 8.

For further details refer to BS. 5449, BS. 7074:1 and the British Gas Corporation publication 'Material and Installation Specifications for Domestic Central Heating and Hot Water'.

5. Cylinder

The cylinder must be either of the indirect coil type or a direct cylinder fitted with an immersion calorifier which is suitable for operating on a gauge pressure of 0.35 bar

(5 Ib/in

) in excess of the safety valve setting. Single feed

indirect cylinders are not suitable for sealed systems.

6. Make-up Water

Provision must be made for replacing water loss from the system, either:

a. From a manually filled make-up vessel with a readily

visible water level. The vessel should be mounted at least 150 mm (6") above the highest point of the system, and be connected through a non-return valve to the system, fitted at least 300 mm (12") below the make-up vessel on the return side of the domestic hot water cylinder or radiators.

b. Where access to a make-up vessel would be difficult

by pre-pressurisation of the system. Refer to 'Filling', below.

7. Mains Connection

There must be no direct connection to the mains water supply or to the water storage tank supplying domestic water, even through a non-return valve, without the approval of the local water authority.

8. Filling

The system may be filled by one of the following

methods:

a. Through a cistern, used for no other purposes, via a

ball valve permanently connected directly to a service pipe and/or a cold water distributing pipe. The static head available from the cistern should be adequate to provide the desired initial system design pressure. The cold feed pipe from the cistern should

GENERAL

include a non-return valve and a stop valve with an automatic air vent connected between them, the stop valve being located between the system and the automatic air vent. The stop valve may remain open during normal operation of the system if automatic water make-up is required.

b. Through a self-contained unit comprising a cistern,

pressure booster pump (if required) and, if necessary, an automatic pressure reducing valve and flow restrictor. The cistern should be supplied through a temporary connection from a service pipe or cold water distributing pipe. This unit may remain permanently connected to the heating system to provide limited automatic water make-up. Where the temporary connection is supplied from a service pipe or distributing pipe which also supplies other draw-off points at a lower level then a double check valve shall be installed upstream of the draw-off point.

c. Through a temporary hose connection from a draw-off

tap supplied from a service pipe under mains pressure. Where the mains pressure is excessive a pressure reducing valve shall be used to facilitate filling.

The following fittings shall form a permanent part of the system and shall be fitted in the order stated:

A stop valve complying with the requirements of BS. 1010, Part 2 (the hose from the draw-off tap shall be connected to this fitting). A test cock. A double check valve of an approved type.

• Thoroughly flush out the whole of the system with cold water, without the pump in position.

• With the pump fitted, fill and vent the system until the pressure gauge registers 1.5 bar (21.5lb/in

Examine for leaks.

• Check the operation of the safety valve by manually raising the water pressure until the valve lifts. This should occur within ± 0.3 bar (± 4.3lb/in

) of the pre-

set lift pressure.

• Release water from the system until the initial system design pressure is reached.

• Light the boiler and heat the system to the maximum working temperature. Examine for leaks.

• Turn off the boiler and drain the system while still hot.

• Refill and vent the system.

• Adjust the initial pressure to the required value.

Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be less than that given by the table on the following page, multiplied by a factor of 0.8 (for flow temperatures of less than 83 °C).

classic m - Installation & Servicing

GENERAL

SEALED SYSTEM REQUIREMENTS - continued

Safety valve setting 3.0 bar 2.5 bar 2.0 bar

Vessel charge and initial 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0 system pressure bar bar bar bar bar bar bar bar

Total water content of system Expansion vessel volume litres

25 litres 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0

50 4.2 5.4 7.8 4.7 6.7 11.8 5.6 10.0

75 6.3 8.2 11.7 7.0 10.0 17.7 8.4 15.0

100 8.3 10.9 15.6 9.4 13.4 23.7 11.3 20.0

125 10.4 13.6 19.5 11.7 16.7 29.6 14.1 25.0

150 12.5 16.3 23.4 14.1 20.1 35.5 16.9 30.0

175 14.6 19.1 27.3 16.4 23.4 41.4 19.7 35.0

200 16.7 21.8 31.2 18.8 26.8 47.4 22.6 40.0

225 18.7 24.5 35.1 21.1 30.1 53.3 25.4 45.0

250 20.8 27.2 39.0 23.5 33.5 59.2 28.2 50.0

275 22.9 30.0 42.9 25.8 36.8 65.1 31.0 55.0

300 25.0 32.7 46.8 28.2 40.2 71.1 33.9 60.0

Multiplying factors for other system volumes 0.0833 0.109 0.156 0.094 0.134 0.237 0.113 0.20

WATER TREATMENT

The classic m boiler has a cast iron heat exchanger

IMPORTANT.

The application of any other treatment to this product may render the guarantee of Caradon Plumbing invalid.

If water treatment is used Caradon Plumbing Ltd. recommend only the use of FERNOX or SENTINEL water treatment products, which must be used in accordance with the manufacturers' instructions. For further information contact:

Fernox Manufacturing Co. Ltd.

Tandem House

Marlowe Way

Croydon

Surrey CRO 4XS

Tel: 0870 5601 5000

Notes.

1. It is most important that the correct concentration of the

water treatment product is maintained in accordance with the manufacturers' instructions.

2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. BS. 7593:1992 details the steps necessary to clean a domestic central heating system.

3. In hard water areas, treatment to prevent lime scale may be necessary - however, the use of artificially softened water is NOT permitted.

4. Under no circumstances should the boiler be fired before the system has been thoroughly flushed.

Sentinel Division

Betz Dearborn Ltd.

Widnes

Cheshire

WA8 8UD

Tel: 0151 424 5351

classic m - Installation & Servicing

BOILER ASSEMBLY - Exploded view

INSTALLATION

LEGEND

1. Front casing panel.

2. Case sealing panel.

4. Bottom cover panel.

5. Flue sensing nipple.

6. Flue baffle (5080 only).

7. Flue hood.

8. Flue connection.

9. Flue hood clip.

10. Flue hood seal.

11. Burner assy.

12. C/Cham Insulation.

13. Heat engine.

14. Injector & housing.

15. Venturi assy.

16. Fan assy.

17. Gas pipe assy.

19. Gas valve assy.

20. Fan bracket assy.

21. Orifice plate.

23. Control thermistor.

24. Overheat thermostat.

25. Igniton electrode.

26. Flame sensing electrode.

35. User control.

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36. PCB - primary controls.

42. Sightglass.

44. Wall mtg. plate.

51. Mains connector.

53. Turret gasket .

classic m - Installation & Servicing

INSTALLATION

UNPACKING

The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to 460mm, rear or side flue outlet, in Pack B.

Optional extras if ordered are supplied in separate boxes.

Unpack and check the contents.

Pack A Contents

Also contained in Pack A:

z Hardware Pack (listed below).

z These Installation & Servicing Instructions.

z The User's Instructions.

z The User's control.

z Benchmark log book.

Hardware Pack

z 50mm x No.10 wood screws -

3 off.

z Wall plugs (TP2B ) - 3 off.

z Turret clamp.

z M5 x 10 pozi Hex screw.

z Mains connector.

INSTALLATION

Pack B Contents

z Flue turret.

z Flue terminal.

z Flue support cutting aid.

PACKAGING REMOVAL

1. Ensure the boiler is stood correctly as marked on the

carton.

2. Remove the strapping.

3. Fold back the top flaps to gain access to the wall

mounting plate, instructions, user controls and hardware pack.

Ecl 1608

Flue turret assembly

Ecl 1460

Flue terminal

4. Remove instructions and read thoroughly before unpacking, user’s controls and hardware pack and retain in safe place.

5. Lift off the cardboard carton.

6. Dispose of packaging.

classic m - Installation & Servicing

Ecl 1576

INSTALLATION

FRONT PANEL AND BOTTOM PANEL REMOVAL

1. Remove the 2 retaining screws.

2. Lift front panel and remove.

3. Remove the 2 bottom panel screws.

4. Allow the RHS of the bottom panel to lower slightly.

5. Withdraw the LHS of the bottom panel from the retaining

clips.

6. Place bottom and front panel to one side to avoid damage.

Ecl 157

INSTALLATION

DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED

IMPORTANT.

The boiler MUST be installed in a vertical position

Dimension X - Wall thickness.

Dimension L - Wall thickness plus

boiler spacing.

Dimension S - Stand-off frame depth = 33mm

FLUE KITS

Pack B - supplied as standard

Pack D - optional extension kit for side flue

or rear flue outlet.

Refer to 'Flue Extension Ducts'

160 + S = 193mm

160mm

Total Flue length dimension Flue

Rear flue Side flue Extra packs

dim. X+160 flue dim. L+195 required

Up to 480 mm Up to 480 mm none

Up to 1430 mm Up to 1430 mm Pack D - 1 off

Up to 2380 mm Up to 2380 mm Pack D - 2 off

Up to 3000 mm Up to 3000 mm Pack D - 3 off

Note.

If the boiler is to be installed with downward routing of pipes then the optional stand-off kit can be used. Care must taken when cutting the ducts and marking the wall to suit this condition.

Ecl 1578

classic m - Installation & Servicing

INSTALLATION

Ecl 1579

FLUE ASSEMBLY - Exploded View

1. An optional flue duct extension kit is required for wall

thicknesses greater than :

Side 300mm (11

Rear 345mm (13

LEGEND

1. Duct assembly.

2. Flue Turret.

3. Turret gasket.

4. M5 x 10 pozi screw.

5. Turret clamp.

Rear flue arrangement shown

3/4").

1/2").

WALL MOUNTING TEMPLATE

1. Separate the templates.

2. Tape template A into the selected position.

3. Ensure squareness by hanging a plumbline as shown. If

fitting a side flue extend the flue centre line onto the side wall, tape template B into selected position.

4. Mark onto the wall the following:

a. The wall mounting plate screw positions (choose one

from each group) and lower fixing screw position.

b. The position of the flue duct hole.

Note.

Mark the centre of the hole as well as the circumference

4. Remove the template from the wall.

classic m - Installation & Servicing

Ecl1675

FLUE OUTLET

PREPARING THE WALL

IMPORTANT. Ensure that, during the cutting

operation, masonry falling outside of the building does not cause damage or personal injury.

1. Cut the flue hole (preferably with a 5" core boring tool), ensuring that the hole is square to the wall. Both wall faces immediately around the cut hole should be flat.

2. Drill 3 holes with a 7mm ( insert the plastic plugs provided, for the wall mounting plate and the jacking screw plate.

Note.

If using the stand-off kit then drill 4 holes (choosing one from each group but not the jacking screw).

3. Locate two No.10 x 2" screws in the wall mounting plate (one at each side, in any of the 3 holes provided at each side) and screw home.

Note.

If using the stand-0ff kit then locate the stand-off channel and screw home.

1/4") masonry drill and

INSTALLATION

CUTTING THE FLUE - REAR Wall thicknesses of 114 to 345mm

Note. If using the extension ducts go to Frame 20.

If the stand-off frame is used it is essential to add 33mm to dimension X.

1. Measure and note wall thickness X. Refer Frame 14.

2. Add 75mm (3 ") to dimension X and, measuring from

the groove, cut the outer tube only.

3. To ensure the tube is cut square, mark the flue all the way round.

4. Cut the inner tube to a length 20mm (3/4") longer to aid engagement. Use the cardboard support.

CUTTING THE FLUE - SIDE Wall thicknesses of 114 to 300mm

Note. If using the extension ducts go to Frame 20.

1. Measure and note wall thickness X. Refer Frame 14.

2. Add 115mm (4 1/2 ") to dimension X and, measuring

from the groove, cut the outer tube only.

3. To ensure the tube is cut square, mark the flue all the way round.

4. Cut the inner tube to a length 20mm (3/4") longer to aid engagement. Use the cardboard support.

Ecl 1461

FLUE OUTLET

classic m - Installation & Servicing

INSTALLATION

FLUE EXTENSION DUCTS - For flue lengths greater than 480mm

Pack D Flue extension duct kit contents.

Extension duct & clamp

1.0m (39") long

Flue support cutting aid (shown folded up)

Wall plugs - 4 off

Ecl 1244

FLUE EXTENSION DUCTS - continued

Use a maximum of 3m extended flue ONLY

Flue duct support

General arrangement

1. A maximum of 3 extension ducts (one suitably

cut) plus the standard flue duct may be used together.

2. Flue extensions of greater length than 1m (39") should be supported with the bracket provided, suitably adjusted. Refer to Frame 24.

Note. Side flue shown

No. 10 x2" wood screw - 4 off

Flue length

Extension flue

Standard flue

Boiler

Ecl 1591

Terminal grille

FITTING THE KIT

1. Remove the cardboard support aid from the flue and

place safely to one side.

2. Fit the inner flue extension duct onto the inner flue duct.

3. Fit the outer flue extension duct onto the outer air duct.

4. Using the clamp provided clamp the flue lengths together.

5. Repeat steps 1-4 if a second flue extension is required.

6. Measure and mark the flue length required onto the flue,

measuring from the groove near the terminal.

7. To ensure a square cut, mark the flue all the way round.

8. Cut to length using the cardboard support aid.

9. Remove the cardboard off-cut and deburr the metal

edges.

classic m - Installation & Servicing

GROOVE

Ecl 1532

FLUE OUTLET

MOUNTING THE BOILER

1. Lift the boiler onto the wall mounting plate, as

shown.

2. Check the boiler alignment using a spirit level and adjust as necessary with the jacking screw.

3. Align the hole in the jacking plate with the predrilled hole in the wall and fix in position with the No.10 x 2" screw provided.

INSTALLATION

CONNECTING THE FLUE TO THE BOILER

1. Insert the flue assembly through the prepared hole in the

wall.

2. Locate the flue turret on the top of the boiler, ensuring that the turret gasket is in place.

3. Locate the flue into the turret.

4. Secure the flue turret on top of the boiler by inserting the

open ends of the turret clamp under the 2 studs and fixing it in the middle with the single M5 x 10mm pozihex screw provided.

5. Flues over 1 metre long.

Fix the flue support bracket to the wall, using the wall plug and wood screw. For standard installations use the short wood screw.

If the stand-off option is used, secure the support bracket using the spacer bracket and long wood screw.

gasket

Ecl 1592

classic m - Installation & Servicing

INSTALLATION

BOILER WATER CONNECTIONS

The boiler flow and return pipes are supplied fitted to the boiler and ready for top connection.

Note. For heating loads in excess of 60 000 Btu/hr use 28mm connectors.

TOP CONNECTION

Connect the system pipework to the boiler flow and return pipes.

Return

Flow

INSTALLATION

Ecl 1573

GAS CONNECTION

IMPORTANT. The gas service cock contains a non-metallic

seal so must not be overheated when making capillary connections.

Refer to Frame 2 for details of the position of the gas connection.

A working gas pressure of 20 mbar (8" w.g.) should be

ELECTRICAL CONNECTIONS

available at the boiler inlet with the boiler firing. Refer to Frame 33 or 'Servicing' for details of the pressure test point position.

Extend a gas supply pipe NOT LESS THAN 15mm O.D. to the boiler and connect to the gas service cock via the union. Ensure that the gas supply pipe does not foul the boiler casing.

WARNING. This appliance MUST be earthed.

A mains supply of 230 V ~ 50 Hz is required.

The fuse rating should be 3 A.

Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations.

classic m - Installation & Servicing

All external controls and wiring MUST be suitable for mains voltage.

Wiring should be 3 core PVC insulated cable NOT LESS than 0.75 mm

Connection must be made in a way that allows complete isolation of the electrical supply - such as a double pole switch having a 3mm ( poles, or a plug and socket serving only the boiler and system controls. The means of isolation must be accessible to the user after installation.

(24 x 0.2mm) and to BS. 6500, Table 16.

1/8") contact separation in both

INSTALLATION

INTERNAL WIRING

A pictorial wiring diagram is shown in Frame 29 .

1. Route the mains cable into the bottom Rear centre of the boiler.

2. Wire the live and neutral and earth wires into the plug.

Note. Ensure that the lengths of the current carrying conductors

are shorter than the earth conductor so that if the cable slips in its anchorage the current carrying conductors become taut before the earth conductor.

3. Secure the mains lead with the cable clamp.

4. Reconnect the mains lead plug. Ensure it is fully located.

Note. Wire any switched live supply into L2.

INSTALLATION

Ecl 1542

Incoming mains

wiring detail

Remove link when connecting external programmer.

EXTERNAL ELECTRICAL CONTROLS

Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations.

The fuse should be 3A.

Room Thermostat

If the thermostat has a neutral connection use it. (It provides for more energy efficient operation by reducing switching temperature differentials.)

If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system. This is usually done at the programmer, in which case the programmer selector switches are set to OFF and all other controls MUST be left in the running position.

The frost thermostat should be sited in a cold place but where it can sense heat from the system.

Note. If the boiler is installed in a garage it may be necessary to fit a pipe thermostat, preferably on the return pipework.

Designation of the terminals will vary but the programmer and thermostat manufacturers' leaflets will give full details.

Diagram A shows an application to boilers fitted with a room thermostat only

L2 L1

Mains Plug

(supplied in hardware pack)

Optional Frost ’stat

Mains in

Socket

(fixed to boiler)

Mains in

L3 L2 L1

Optional Frost ’stat

System controls

L3 L2 L1N

Ecl1257

Room ’stat

if required

Room ’stat

if required

System controls

Ecl 1543

Ecl 1544

Diagrams B and C show applications to boilers fitted with alternative time controls.

Earths are not shown for clarity but must never be omitted.

Mains in

Room ’stat

Ecl 1545

if required

Optional Frost ’stat

classic m - Installation & Servicing

PICTORIAL WIRING

Fan

INSTALLATION

Overheat thermostat

Permanent black link

Control thermistor

MAINS SUPPLY 230V 50Hz

Fused at

3.15ATL

Control PCB

Gas valve

Chassis earth y/g

y/g

or or

Service connection

INSTALLATION

LEGEND b - blue bk - black br - brown

r - red w - white or - orange

classic m - Installation & Servicing

User control and display

pkr pk

Ecl 1848

y/g

ON / OFF Switch

y - yellow pk - pink y/g - yellow/green

FUNCTIONAL FLOW WIRING DIAGRAM

INSTALLATION

Mains Switch

DC Fan

electrode

Ecl 1849

3 2

Flame detection electrode

Control thermistor

bk y pk

y/g

r r

PCB

or or

External switch.e.g. room'stat, programmer

Overheat thermostat

DC Gas valve

y/g

LEGEND

b - blue

bk - black

br - brown

COMMISSIONING AND TESTING

A. Electrical Installation

1. Checks to ensure electrical safety should be carried out by a

competent person.

2. ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit, using a suitable test meter.

r - red

y - yellow

w - white

WARNING. Whilst effecting the required gas soundness test and purging air from the gas

installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.

y/g - yellow/green

gy - grey

v - violet

pk - pink

or - orange

B. Gas Installation

1. The whole of the gas installation, including the meter, should

be inspected and tested for soundness and purged in accordance with the recommendations of BS. 6891.

2. Purge air from the gas installation by the approved methods only.

classic m - Installation & Servicing

INSTALLATION

INITIAL LIGHTING

LEGEND

A On/Off switch. B Thermostat knob. C 'Mains On' neon. D 'Burner On' neon. E Reset button. F Inlet pressure test point. G Gas service cock.

1. Check that the system has been filled and that the boiler is

not air locked.

H Casing pressure test point. J Overheat thermostat. K Flow thermistor.

Note. Boiler is shown with the front panel and sealing panel removed.

2. Check that all drain cocks are closed and any valves in the flow and return are open.

3. Check the electrical supply is off.

4. Refit the boiler sealing panel

5. Check the gas service is ON and the On/Off switch is OFF.

6. Carefully align the user control and gently push into place

and secure with the single screw located underneath.

7. Remove the screw in the inlet pressure test point and connect a gas pressure gauge via a flexible tube .

8. Switch the electricity supply ON and check all external controls are calling for heat.

9. Set the boiler thermostat knob to maximum position and switch the boiler ON - OFF switch to ON the RED mains ON neon should now be illuminated. The boiler control should now go through its ignition sequence until the burner is established.

10. If the boiler does not light after 3 attempts the fault codes 'L' 'F' will be displayed. Press the reset button; the boiler will then repeat its ignition sequence. When the burner is established the GREEN burner ON neon will be permanently illuminated

11. Ensure that with the boiler operating the dynamic gas pressure is 20 mb.

IMPORTANT. The gas input to the burner is regulated by the gas valve according to the air flow produced by the fan. It is NOT user-adjustable. Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void.

Ecl 1619

Ecl 1280

LED Display

12. Switch OFF the ON-OFF switch.

13. Remove the pressure gauge and tube. Replace the

sealing screw in pressure test point. Ensure a gas tight seal is made.

14. Refit the boiler front panel and bottom panel .

THE DISPLAY

The user controls has one neon and one display to inform the user about the status. The display will show the status of the boiler. The neon will show the status of the flame. If no flame is detected the neon is blinking. When the flame is detected the neon will be lit permanently.

Below is a list with display function in normal operation.

'o' Standby, no demand for heat present.

'c' Boiler is active for central heating.

'H' Boiler is blocking for a specific error, display will be

blinking alternating with a number and letter to show what kind error is detected.

'L' Boiler is in lockout for a specific error, the display will

be blinking alternating with a number and letter to show what kind of error is detected.

INSTALLATION

classic m - Installation & Servicing

GENERAL CHECKS

INSTALLATION

Make the following checks for correct operation

1. Central Heating

The correct operation of ANY programmer and all other system controls should be proved. Operate each control separately and check that the main burner or circulating pump, as the case may be, responds.

2. Gas rate

Operate the boiler for 10 minutes. Check the boiler gas rate, ensuring the boiler is at full output whilst measurements are recorded (see Table 2).

3. Water circulation system

INSTALLATION

Note. Flushing solutions should be used during the flushing

procedure - refer to Frame 9.

a. With the system HOT examine all water connections for

soundness.

Knob Setting Flow Temperature

°C °F

Min 65 150

Max 82 180

b. With the system still HOT, turn off the gas, water

and electricity supplies to the boiler and drain down to complete the flushing process.

c. Refill and vent the system, add inhibitor (see Frame

9), clear all air locks and again check for water soundness.

d. Balance the system (see Frame 4).

4. Finally set the controls to the User’s requirements.

• The temperatures quoted alongside are approximate, and

vary between installations.

HANDING OVER

After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions:

1. Hand the User's Instructions to the householder and

explain his or her responsibilities under Relevant National Regulations.

2. Explain and demonstrate the lighting and shutting down procedures.

3. The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption. Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions.

4. Explain the function and the use of the boiler controls and external controls.

5. Explain the function of the boiler fault mode. Explain that if a fault is indicated the boiler should be turned off and a local heating installer consulted.

7. If any programmer is fitted then draw attention to the Programmer User's Instructions and hand them to the householder.

8. After installation, commissioning, and customer

hand-over please complete the appliance log book and leave this with the customer.

9. IMPORTANT

A comprehensive service should be carried out ANNUALLY.

Stress the importance of regular servicing by a CORGI registered installer. As the installer you may wish to undertake the service contract yourself or, alternatively, offer to the customer the benefits of the Ideal Care Scheme, details of which are outlined in the Householder Pack supplied with this boiler.

6. Explain and demonstrate the function of time and temperature controls, radiator valves, etc., for the economic use of the system.

classic m - Installation & Servicing

Ecl 1596

Flue gas sampling point

SERVICING SCHEDULE

SERVICING

To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually. It is the law that any service work must be

carried out by a registered CORGI installer.

1. Light the boiler and carry out a pre-service check, noting any operational faults.

2. Check the gas consumption.

3. Connect a suitable gas analyser to the sampling point on

top of the boiler or into the flue terminal, if access if possible. Refer to Frame38

For correct boiler operation the CO/CO gas should not be greater than 0.004 ratio. If this is the case, and the gas input is at least 90% of the nominal, once compliance with the note above is ensured, then no further action need be taken. If not, proceed to step 4 .

4. Clean the main burner.

5. Clean the heat exchanger.

6. Check the main injector for blockage or damage.

content of the flue

7. Check that the flue terminal is unobstructed and that the flue system is sealed correctly.

The servicing procedures are covered more fully in Frames 37 to 42 and MUST be carried out in sequence.

Note. In order to carry out either servicing or replacement of components the boiler front panel, bottom panel and sealing panel must be removed. Refer to Frames 37 and 38.

WARNING.

service cock, and switch off and disconnect the electricity supply to the appliance before servicing.

IMPORTANT.

8. After completing the servicing or exchange of components

always test for gas soundness and carry out functional checks as in 2 and 3 above.

9. When work is complete the sealing panel MUST be correctly refitted, ensuring that a good seal is made.

10. Complete the service section in the Benchmark log book.

DO NOT OPERATE THE BOILER IF THE SEALING PANEL IS NOT FITTED.

Always turn off the gas supply at the gas

BOILER FRONT PANEL REMOVAL

1. Remove the 2 securing screws from the underside of

the appliance.

2. Pull the panel forward at the bottom and lift to disengage it from the top lugs.

Ecl 1595

BOILER SEALING/ BOTTOM PANEL REMOVAL

1. To remove the sealing panel remove the 4 retaining

screws.

2. Remove the panel.

3. To remove the bottom panel remove the 2 screws.

4. Pull the RHS of the panel down and slide it to the right

to withdraw.

SERVICING

classic m - Installation & Servicing

FAN AND VENTURI ASSEMBLY REMOVAL

1. Disconnect the electrical leads from the fan.

2. Undo the gas pipe union connection to the injector

housing.

3. Undo the single retaining screw on the fan mounting bracket.

4. Lift off fan and venturi assembly.

5. Inspect the injector for blockage or damage.

SERVICING

Ecl 1629

BURNER REMOVAL AND CLEANING

1. Undo and remove the 6 screws securing the burner. (the 3

screws at the rear are extended to ease access.)

2. Remove the burner from the combustion chamber.

IMPORTANT

The burner head is a ceramic plaque construction.

Care should be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic.

SERVICING

3. Brush off any deposits that may be on the ceramic with a

SOFT brush.

4. Inspect the sealing gasket around the burner for any signs of damage. Replace if necessary.

Ecl1630

classic m - Installation & Servicing

CLEANING THE HEAT EXCHANGER

1. Remove ignition and sensing

electrodes (Frames 47 &48).

2. Remove the 2 spring clips securing the collector hood to the heat exchanger.

3. Slide the flue spigot upwards into the flue turret to allow the collector hood to slide forwards and remove the collector hood.

4. Slide the flue spigot downwards and remove from the flue turret.

5. Remove the 6 flue baffles (m5080 only).

6. Using a suitable tool as supplied in the standard B.G. flue brush kit clean between the heat exchanger fins from the bottom of the heat exchanger.

SERVICING

RE-ASSEMBLY

Reassemble the boiler in the following order.

1. Refit the baffles (m5080 only) ensuring baffles are fully

located in the heat exchanger.

Ecl 1631

SERVICING

7. Refit the fan / venturi assembly.

2. Refit the flue spigot to the flue turret.

3. Refit the collector hood to the heat exchanger. Ensure the

sealing gasket around the flue outlet on the collector hood is in place. Renew any damaged or deteriorating gaskets.

4. Slide the flue spigot downwards and secure the 2 spring clips. Ensure the clips are located correctly over the inter panel.

5. Refit the electrodes (check dimensions, see Frame 47 &

48).

6. Refit the burner, renewing any damaged or deteriorating sealing gaskets.

classic m - Installation & Servicing

8. Reconnect the fan electrical lead.

9. Refit the boiler front and bottom panel.

IMPORTANT.

Ensure the boiler sealing panel is correctly fitted and that a good seal is made.

10. Refit the boiler casing.

11. Turn on the gas supply at the gas service cock.

12. Reconnect the electrical supply.

REPLACEMENT OF COMPONENTS

GENERAL

When replacing ANY component:

1. Isolate the electricity supply.

2. Turn off the gas supply.

3. Remove the boiler front panel and sealing panel

(Frames 37 & 38).

4. After replacing any components check the operation

of the boiler including gas soundness, gas rates and combustion test.

SERVICING

IMPORTANT

When work is complete, the sealing panel must be correctly fitted, ensuring that a good seal is made.

Note.

In order to assist fault finding, the control panel has an LCD display. The key to boiler fault conditions is shown in Frame 59.

THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED

CONTROL THERMISTOR REPLACEMENT

1. Refer to Frame 36.

2. Pull the electrical leads off the control

thermistor.

3. Pull the control thermistor and spring clip off the flow pipe.

4. Replace thermistor and reconnect

SERVICING

leads, ensuring that the spring clip is securely holding the thermistor to the flow pipe.

5. Re-assemble the boiler in reverse order.

6. Check the operation of the boiler.

Note.

Removal of the collector hood and flue spigot will facilitate better access.

WARNING.

Beware these components may be hot if the boiler has recently been run.

Ecl 1636

classic m - Installation & Servicing

FAN REPLACEMENT

1. Refer to Frame 36.

2. Disconnect the electrical leads from the fan.

3. Undo the gas pipe union connection to the

injector housing.

4. Undo the single retaining screw on the fan mounting bracket.

5. Remove the fan

6. Unscrew the 3 retaining screws and remove

the venturi assembly, noting the orientation of the venturi in relation to the fan body.

7. Transfer the venturi assembly to the new fan, replacing the gasket if evidence of damage or deterioration is visible.

8. Fit the new fan / venturi assembly .

9. Re-assemble the boiler in reverse order taking

care not to over tighten the single retaining screw on the fan mounting bracket.

10. Check the operation of the boiler. Refer to Frame 36.

SERVICING

BURNER REPLACEMENT

1. Refer to Frame 36.

2. Remove fan assy. Refer paragraphs

2 & 3, Frame 45.

3. Undo and remove the 6 screws securing the burner (the 3 screws at the rear are extended to ease access.)

4. Remove the burner.

5. Fit the new burner.

6. Re-assemble the boiler in reverse

order.

7. Check operation of the boiler. Refer to Frame 36.

Ecl 1632

SERVICING

Ecl 1633

classic m - Installation & Servicing

SERVICING

Straight edge

25mm

+ 2

- 2

Ecl 1699

IGNITION ELECTRODE REPLACEMENT

1. Refer to Frame 36.

2. Lower the control box, as shown in Frame 52.

3. Unplug the spark electrode lead from the control box.

4. Undo the single retaining screw holding the spark electrode

to the combustion chamber.

5. Remove the electrode, taking care not to dislodge the grommet from the casing.

6. Fit the new ignition electrode, using the new gasket supplied and check dimensions on shown.

Spark gap 3mm

-0

11mm

+ 0

- 4

Ecl 15555

Straight edge

SENSING ELECTRODE REPLACEMENT

1. Refer to Frame 36.

SERVICING

2. Lower the control box, as shown in Frame 52.

3. Unplug the sensing electrode lead from the control

box.

Ecl 1634

Ecl 1697

7. Reassemble in reverse order.

8. Check operation of the boiler. Refer to Frame 36.

Ecl1558

4. Unbolt the sensing electrode earth lead from the earth point beneath the boiler.

5. Remove the electrode, complete with grommet.

6. Fit the new sensing electrode, using the new gasket supplied.

7. Reassemble in reverse order.

8. Check operation of the boiler. Refer to Frame 36.

Ecl 1634

classic m - Installation & Servicing

BURNER INJECTOR REPLACEMENT

SERVICING

1. Refer to Frame 36.

2. Remove the fan / venturi assembly,

as shown in Frame 45.

3. Unscrew the 2 injector housing retaining screws.

4. Withdraw the injector housing.

5. Fit the new injector housing.

6. Reassemble in reverse order,

ensuring that the new gas seal supplied is located correctly in the injector housing.

7. Check operation of the boiler. Refer to Frame 36.

Ecl 1637

GAS CONTROL VALVE REPLACEMENT

1. Refer to Frame 36.

2. Remove the 2 retaining screws from the underside of the

appliance. Unhook and remove the front panel.

3. Remove the bottom panel 2 screws.

4. Allow the RHS of the bottom panel to lower slightly.

5. Remove the gas valve electrical connections and the silicon

sensing pipe.

6. Withdraw the LHS of the bottom panel from the retaining clips.

7. Undo the union nut between the gas valve and the gas inlet

cock.

8. Undo the union nut on the outlet side of the gas valve.

9. Undo the gas valve bracket retaining nut and slide the gas valve forward, and remove.

10. Fit new valve, reassemble in reverse order, ensuring that any seals showing damage or deterioration are replaced.

11. Check operation of the boiler. Refer to Frame 36.

SERVICING

classic m - Installation & Servicing

Ecl 1638

CONTROL BOX REPLACEMENT

Refer to Frame 36.

1. Remove the 2 retaining screws.

2. Lift front panel and remove.

3. Remove the 2 bottom panel screws.

4. Allow the RHS of the bottom panel to lower slightly.

5. Withdraw the LHS of the bottom panel from the

retaining clips.

6. Unscrew the 2 control box retaining screws.

7. Unplug all the electrical wiring from the control box.

8. With the control box lowered, pull the assembly

forward to remove from the housing.

9. Transfer the mounting brackets to the new control box.

10. Reassemble in reverse order, ensuring that the control box is located correctly in the housing before reconnecting the electrical wiring.

11. Check operation of the boiler. Refer to Frame 36.

SERVICING

Ecl 1639

Ecl 1566

Mounting brackets

Control box

MAINS SWITCH REPLACEMENT

1. Refer to Frame 36.

SERVICING

2. Remove the boiler bottom panel (refer to Frame 37).

3. Unscrew the 2 control box screws and allow the control box

to lower.

4. Push out the mains switch from the rear, as shown.

Ecl 1565

5. Refit the new switch ensuring the electrical leads are reconnected correctly. Ensure that the key on the switch is correctly aligned with the slot in the plastic moulding.

6. Reassemble in reverse order.

7. Check operation of the boiler. Refer to Frame 36.

Ecl 1562

classic m - Installation & Servicing

SIGHT GLASS REPLACEMENT

1. Refer to Frame 36.

2. Unscrew the 2 sight glass retaining screws.

3. Remove the sightglass, gasket and

bracket.

4. Fit new sight glass, using the new bracket and gasket supplied.

5. Reassemble in reverse order.

6. Check operation of the boiler. Refer to

Frame 36.

SERVICING

Sightglass

Gasket

OVERHEAT THERMOSTAT REPLACEMENT

1. Refer to Frame 36.

2. Pull off the electrical leads from the

thermostat body.

3. Pull the thermostat and clip from the pipe.

4. Fit the new thermostat, ensuring that the clip is securely holding the thermostat to the flow pipe.

5. Re-assemble in reverse order.

6. Check operation of the boiler. Refer to

Frame 36.

Note.

Removal of the collector hood and flue spigot will facilitate better access.

WARNING.

Beware these components may be hot if the boiler has recently been run.

Bracket

Ecl 1642

SERVICING

classic m - Installation & Servicing

Ecl 1643

SERVICING

COMBUSTION CHAMBER INSULATION REPLACEMENT

The insulation boards used in the combustion chamber of this product are made of high temperature glass fibres with a binder of organic and inorganic materials.

Caradon Plumbing Limited recommend that, for your own comfort and safety and to comply with good working practise, the procedure described below is followed:

1. Refer to Frame 36.

2. Remove the fan / venturi assembly, as shown in Frame 39.

3. Remove the burner as shown in Frame 40.

4. Undo the retaining screw from the ignition electrode and

withdraw it from the combustion chamber

5. Undo the retaining screw from the detection electrode and withdraw it from the combustion chamber.

Prior to removal of the board the following protective equipment should be worn:

• Face mask supplied with the spare part

• Gloves supplied with the spare part

6. Damp down the combustion chamber area containing the insulation boards.

7. Remove the split pin and washer from the LHS of the combustion chamber.

8. Remove the insulation boards. The replacement boards are supplied in a plastic bag. This bag should be retained and the discarded boards should now be placed into it.

9. Sweep any dampened particles and place in the plastic bag.

10. Fit new insulation boards.

Note. The boards are designed to be interlocking and

should be fitted as shown.

11. Fit the new split pin and washer in the LHS of the combustion chamber.

12. Remove the gloves and face mask and place them in the plastic bag.

13. Wash your hands and any areas of skin which may have come into contact with any of the particles from the insulation board.

Note. Seal the plastic bag and dispose of it and its contents into a commercial tip.

14. Reassemble in reverse order.

15. Check operation of the boiler. Refer to Frame 36.

SERVICING

Ecl 1644

LH Side

Rear

Front

Fit in the following order; Front, RHS, Rear LHS.

RH Side

classic m - Installation & Servicing

SERVICING

HEAT ENGINE REPLACEMENT

Refer to Frame ‘Exploded view’

1. Refer to Frame 36.

2. Remove the control box (refer to Frame 51) and place to

one side.

3. Remove the fan assembly (refer to Frame 45 ) and place to one side.

4. Remove the burner (refer to Frame 46) and place to one side.

5. Remove the ignition and sensing electrodes (refer to Frames 47 & 48).

6. Remove the collector assembly (refer to Frame 58).

7. Remove the flue baffles (classic m5080 only).

8. Remove the control thermistor and over heat thermostat

from the flow pipe.

9. Drain the boiler using the heat exchanger drain point.

10. Remove the 2 M5 x 10 screws from the bottom of the

inter panel.

11. Slide the heat engine and inter panel assembly downwards to disengage and remove from the casing.

12. Reassemble in reverse order, replacing gaskets or seals if any sign of damage or deterioration is evident.

Note.

The heat engine is supplied with new combustion chamber insulation boards. These should be fitted (refer to Frame 55) before the burner, fan assemblies and before the ignition/sensing electrodes are replaced.

13. Check the operation of the boiler. Refer to Frame 36.

SERVICING

classic m - Installation & Servicing

Ecl 1645

SERVICING

BOILER SEALING PANEL SEAL REPLACEMENT

Refer Frame 36.

1. Remove the 2 retaining screws from the underside of the appliance. Unhook and remove the front panel.

2. Undo the 4 screws to remove the panel.

3. Remove the old seal from the casing and thoroughly clean the casing

surfaces.

4. Fit the new adhesive seals, note that they are supplied to the correct length for the relevant sides.

5. Reassemble in reverse order.

Note.

Ensure that the boiler sealing panel is correctly seated, compressing the seal to make an airtight joint.

6. Check operation of boiler. Refer Frame 36.

Ecl 1648

SERVICING

Refer to Frame 36.

1. Remove the 2 spring clips securing

2. Slide the flue spigot upwards into

3. Remove the collector hood.

4. Reassemble in reverse order

5. Slide the flue spigot down from the

6. Fit the spring retaining clips.

7. Check operation of the boiler.

8. Refer to Frame 36.

COLLECTOR HOOD REMOVAL

the collector hood to the heat exchanger.

the flue turret to allow the collector hood to slide forwards.

ensuring the location tabs in the collector hood gasket fit into the inter panel locations.

flue turret and locate on the collector hood.

Ecl 1649

Seals

Ecl 1650

classic m - Installation & Servicing

FAULT FINDING

FAULT FINDING CHART MAIN MENU

In order to assist fault finding, the boiler has an LCD display. The key to the display codes is as follows:

ALTERNATING 'L' 'F'

ALTERNATING 'L' 'E'

ALTERNATING 'L' 'A'

ALTERNATING 'L' '8'

ALTERNATING 'H' '1'

ALTERNATING 'H' 'F'

GO TO FRAME 60

GO TO FRAME 61

GO TO FRAME 62

GO TO FRAME 63

GO TO FRAME 64

GO TO FRAME 65

ALTERNATING 'H' 'n'

ALTERNATING 'H' 'E'

GO TO FRAME 66

GO TO FRAME 61

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

classic m - Installation & Servicing

L.....F.......(FLAME ERROR)

FAULT FINDING

If the boiler reset button is

pressed does the boiler ignite for

a short time then extinguish?

YES

Check the detection electrode and

associated harness for:

continuity, visual condition, position

Replace if necessary.

Note.

Due the wave form of this rectified voltage, the reading will vary depending on the type of meter used to measure the valve, (some may measure the possible peak voltage of 339 V). In general terms a reading greater than 150 V indicates that the correct voltage is supplied to the gas valve.

Check the ignition electrode and associated harness

for: continuity, visual condition, position

Replace ignition electrode and associated

harness as necessary

Is 17mbar gas pressure

available at the boiler inlet ?

YES

Is 200 v DC supply

available at the gas valve ?

YES

Are these functioning correctly ?

Check gas supply

and rectify fault

Check gas valve

YES

Replace gas valve

wiring for

continuity

Replace PCB

L.....E......or H.....E. (BOARD ERROR)

Code indicates internal fault

within the PCB

L.......A.........................(OVER HEAT)

Can the overheat condition be reset by pressing

the boiler reset button when the system is cold ?

YES

Is the boiler and CH system filled with

water and all isolation valves open ?

YES

Does the pump setting give a differential

across the boiler in excess of 25 oC

YES

Replace PCB

Replace overheat thermostat

Fill and vent the system and open all

isolation valves

Increase the pump setting.

Is differential now below 25

C ?

YES

If the overheat trips again measure the flow temp:

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Set CH control knob to maximum.

Over 90

Under 90

C Check control thermistor

(Refer to Frame 64) .

C Replace overheat 'stat

Replace the system pump

classic m - Installation & Servicing

FAULT FINDING

L....8..... (FAN)

Is nominal 330 V DC present

across red and blue at the fan

connector as reset button is

pressed?

H.....1..... (FLOW TEMPERATURE)

Remove the boiler control thermistor from the

CH flow pipe and disconnect thermistor wires

Check resistance. The sensors can be checked

by measuring their resistance, using a suitable

multimeter connected across the sensors'

C expect 9,700-10,300 Ohms

At 25

At 60 0 C expect 2,400-2,600 Ohms

C expect 1,000-1,100 Ohms

At 85

Check wiring harness for continuity.

terminal pins

YES

Is there continuity?

Is 14V DC present

across yellow and pink

at the fan connector?

YES

Replace fan

Replace PCB

Replace harness

Are the thermistor values correct ?

YES

Is there continuity between the

PCB and the thermistor ?

H......F........ (FLAME DETECTION - SHORT CIRCUIT)

Is there continuity between the detection

electrode terminal at the PCB and earth ?

YES

Replace detection electrode

YES

Replace the thermistor

Replace PCB

Check and replace wiring as necessary

Check the detection electrode for

continuity and visual condition.

Replace if necessary.

H......n........ (PHASE REVERSAL)

classic m - Installation & Servicing

Check wiring to the boiler for

reversed live and neutral

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SHORT LIST OF PARTS

The following are parts commonly required due to damage or expendability. Their failure or absence is likely to affect safety or performance of this appliance.

The list is extracted from the British Gas List of Parts, which contains all available spare parts.

The full lists is held by British Gas Services, British Gas distributors and merchants.

When replacing a 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 Boilers.

Key No. GC Part No. Description Qty. Product No.

1 E67-471 Front casing panel 1 170 897

4 E69-260 Bottom cover panel m3050 1 171 117

E69-261 Bottom cover panel m5080 1 171 118

6 E69-262 Baffle kit m5080 1 171 133

11 E67-489 Burner 1 170 905

When ordering spares please quote:

1. Boiler Model

2. Appliance G.C. Number

3. Description

4. Quantity

5. Product Number

12 E67-490 Combustion chamber insulation 1 170 906

14 E69-270 Injector and housing 1 170 908

16 E69-271 Fan assembly 1 170 909

19 E67-497 Gas control valve - Honeywell VK115V 1 170 913

23 E67-501 Control thermistor 1 170917

24 E67-502 Overheat thermostat 1 170918

25 E67-503 Ignition electrode and gasket 1 170 919

26 E67-504 Flame sensing electrode and gasket 1 170 920

35 E67-517 Users controls 1 170 929

36 E67-518 PCB primary controls (include plastic housing) 1 170 930

37 E67-519 Fuse PCB (3.15A L250V) 1 170 931

39 E67-521 Main switch 1 170 933

42 E67-524 Sightglass assembly kit 1 170 949

45 E67-527 Gasket kit 1 170 398

52 E68-376 Sealing kit 1 171 014

53 E68-380 Turret gasket 1 171 022

classic m - Installation & Servicing

SHORT LIST OF PARTS

classic m - Installation & Servicing

Ecl1700

CASE ASSEMBLY

1. Front casing panel with screws.

2. Sealing panel with screws.

4. Bottom panel with screws.

SHORT LIST OF PARTS

Ecl 1601

BURNER ASSEMBLY

11. Burner assembly with screws and gasket.

Ecl1702

classic m - Installation & Servicing

CONTROLS ASSEMBLY

33. Controls assy complete with screws.

34. Controls hinge bracket.

35. User controls (without item 38).

36. PCB (primary controls).

38. User controls housing kit.

54. Jumper link.

SHORT LIST OF PARTS

Ecl 1600

classic m - Installation & Servicing

Technical Training

The Caradon Plumbing Limited Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers. For details of courses please ring:

01482 498432

The code of practice for the installation,

commissioning & servicing of central heating systems

Caradon Plumbing Ltd.

Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137.

Caradon Plumbing Ltd.

improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.

P.O. Box 103, National Ave.,

pursues a policy of continuing

CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001: 1994 Quality System accepted by BSI

June 2001 156124 A01

Ideal Care Helpline

www.idealboilers.com

Tel: 01482 498 663

ideal Isar M3050 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual