INSTALLATION

& SERVICING
IDEAL CLASSIC
24 30 35

When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance
specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
For the very latest copy of literature for specification and maintenance practices visit our website www.idealboilers.com
where you can download the relevant information in PDF format.

July 2018
UIN 212135 A06
ERP DATA
MODEL
SYMBOL UNITS 24 30 35
Condensing Boiler n/a n/a yes yes yes
Low Temperature Boiler n/a n/a no no no
B1 Boiler n/a n/a no no no
Cogeneration Space Heater n/a n/a no no no
Equipped with a Supplementary Heater n/a n/a no no no
Combination Heater n/a n/a yes yes yes
Nominal Heat Output for Space Heating
Full Load P4 kW 24.2 24.3 24.2
Part Load P1 kW 7.8 7.8 7.8
Auxiliary Electricity Consumption
Full Load elmax kW 0.042 0.032 0.029
Part Load elmin kW 0.012 0.013 0.013
Standby PSB kW 0.005 0.005 0.005
Seasonal Space Heating Energy Efficiency
Full Load ƞ4 % 89.8 90.0 89.8
Part Load ƞ1 % 96.9 96.9 96.9
Standby Loss Pstby kW 0.050 0.050 0.050
Ignition Pign kW 0 0 0

Emissions NOx mg/kWh 26 26 31

Annual Energy Consumption QHE GJ 76 76 76
Sound Power Level, Indoors LWA dB 45 46 44
Domestic Hot Water
Qelec kWh 0.076 0.075 0.074
ƞWH % 78 78 78
Qfuel kWh 7.800 7.700 7.700
AEC kWh 16 16 16
AFC GJ 6 6 6

2 IDEAL CLASSIC - Installation and Servicing


PRODUCT FICHE

IDEAL CLASSIC COMBINATION BOILER

Ideal Boilers
ERP DATA
SYMBOL UNITS MODEL
24 30 35
Condensing boiler Yes
Seasonal Space heating efficiency class A
Rated heat output kW 24
Seasonal space heating energy efficiency ƞs % 92*
Annual energy consumption QHE GJ 76
Sound power level, indoors LWA dB 45 46 44
Water heating energy efficiency class A

Seasonal Space Heating Energy Efficiency of the Boiler *%

A
Temperature control (from fiche of temperature control) %
Class I Class II Class III Class IV Class V Class VI Class VII Class VIII
1% 2% 1.5% 2% 3% 4% 3.5% 5% B

Solar Contribution (from fiche of solar device)

Collector Size Tank Volume Collector Tank rating

(in m2) (in m3) Efficiency A* = 0.95
(in %) A = 0.91
B = 0.86
C = 0.83
D-G = 0.81

%
= (‘III ’x + ‘IV ’ x ) x 0.9 x ( / 100 x = C

%
Seasonal Space Heating Energy Efficiency of Package TOTAL: A+B+C=

Seasonal Space Heating Energy Efficiency Class of Package

G F E D C B A A+ A++ A+++

< 30% ≥ 30% ≥ 34% ≥ 36% ≥ 75% ≥ 82% ≥ 90% ≥ 98% ≥ 125% ≥ 150%

The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installed in a


building, as the efficiency is influenced by further factors such as heat loss in the products in relation to the building size and its characteristics

IDEAL CLASSIC - Installation and Servicing 3

4 IDEAL CLASSIC - Installation and Servicing
 NOTES FOR THE INSTALLER
FOR ANY TECHNICAL QUERIES PLEASE RING THE
IDEAL INSTALLER/TECHNICAL HELPLINE : 01482 498704
NOTE. BOILER RESET PROCEDURE -
To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.
The boiler will repeat the ignition sequence, if a heat demand is present.

DOCUMENT AMENDMENTS
Relevant Installation changes implemented in this book from Mod Level........ A05 (Feb 18) To A06 (July 18)

Page 6
Change to NOX Classification

Page 7
Removal of PI No.

Section 4
Update to Water Treatment information

Sections 32, 39, 46 & 64

Important additional Gas information

Ideal Boilers reserve the right to vary specification without notice

IDEAL CLASSIC - Installation and Servicing 5

 GENERAL
Table 1 - General Data
IDEAL CLASSIC 24 30 35
Gas supply 2H - G20 - 20mbar
Gas Supply Connection 15mm copper compression
Injector Size mm 4.15 4.65 4.9
Inlet Connection Domestic Hot Water 15mm copper tail
Outlet Connection Domestic Hot Water 15mm copper compression
Flow Connection Central Heating 22mm copper compression
Return Connection Central Heating 22mm copper compression
Flue Terminal Diameter mm 100
Average Flue Temp-Mass Flow Rate (DHW) 63oC - 11g/s 68oC - 13g/s 73oC - 15g/s
Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.5 (36.3)
Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) (kPa) 10.0 (145) (1000)
Minimum Domestic Hot Water Inlet Pressure* bar (lb/in2) (kPa) 0.8 (11.6) (80) 1.3 (18.9)** (130) 1.3 (18.9)** (130)
Electrical Supply 230 V ~ 50 Hz.
Power Consumption W 146 152 177
Fuse Rating External : 3A Internal : T4H HRC L250 V
Water content Central Heating litre 1.2
Domestic Hot Water litre 0.5
Packaged Weight kg 34.6 34.7 34.8
Maximum Installation Weight kg 30.85 30.95 31.05
Boiler Casing Size Height mm 700
Width mm 395
Depth mm 285

*Required for maximum flow rate. Boiler operates down to 2 l/min DHW delivery
** In areas of low water pressure the DHW restrictor can be removed

Table 2 - Performance Data - Central Heating Table 3 - Performance Data - Domestic Hot Water
Boiler Input : Max. Min. Maximum DHW Input : 24 30 35
24 30 35
Nett CV kW 24.3 30.4 35.4
Boiler Input ‘Q’ Nett CV kW 24.3 4.9 6.1 7.1


Gross CV kW
27.0 5.4 6.7 7.9 Gross CV kW 27.0 33.7 39.3

Gas Consumption m3/h 2.512 0.500 0.627 0.734 Gas Consumption m3/h 2.512 3.135 3.657
(ft3/h) (89) (17.8) (22) (25.9) (ft3/h) (89) (111) (129)
Boiler Output : Maximum kW 24.2 30.3 35.3

Non Condensing kW
24.2 4.8 6.1 7.1
DHW Output
70oC Mean Water temp.
DHW Flow Rate l/min 9.9 12.4 14.5

Condensing kW
25.6 5.1 6.4 7.5 at 35°C temp. rise. (gpm) (2.2) (2.8) (3.2)
40oC Mean Water temp.
DHW Specific Rate l/min 11.5 14.5 16.9
Seasonal efficiency* SEDBUK 2005 91% 91.1% 91% (gpm) (2.5) (3.2) (3.7)
Seasonal efficiency* SEDBUK 2009 89% 89% 89%
NOx Classification CLASS 6

* 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 Key to symbols
calorific value of 38.7 MJ/m3 (1038 Btu/ft3) gross GB = United Kingdom IE = Ireland (Countries of destination)
or 34.9 MJ/m3 (935 Btu/ft3) nett
PMS = Maximum operating pressure of water
To obtain the gas consumption at a different
C13 C33 C53 = A room sealed appliance designed for connection via ducts to a
calorific value:
horizontal or vertical terminal, which admits fresh air to the burner
a. For l/s - divide the gross heat input (kW) by and discharges the products of combustion to the outside through
the gross C.V. of the gas (MJ/m3) orifices which, in this case, are concentric. The fan is up stream of
b. For ft3/h - divide the gross heat input (Btu/h) the combustion chamber.
by the gross C.V. of the gas (Btu/ft3) I2H = An appliance designed for use on 2nd Family gas, Group H only.
c. For m3/h - multiply l/s by 3.6.

6 IDEAL CLASSIC - Installation and Servicing

 GENERAL

IDEAL CLASSIC CONTENTS

Natural Gas only
Air Supply ......................................................................11
Boiler size G.C. Appliance No. Benchmark Commissioning Checklist ...................... 62
(Benchmark No.)
Boiler Clearances ........................................................ 12
24 47-349-07 Boiler Exploded Diagram ............................................ 15
30 47-349-08 Condensate Drain ..........................................11,26,27,43
35 47-349-55 Electrical Connections ................................................ 29
Electrical Supply ..........................................................11
Destination Country: GB, IE Fault Finding ........................................................... 52-58
Flue Fitting .............................................................. 19-25
Flue Installation ........................................................... 10
Gas Safety Regulations ................................................ 9
Gas Supply ................................................................... 10
Installation ............................................................... 15-34
Pump  ............................................................................ 48
Safe Handling ................................................................. 8
Servicing ................................................................. 35-51
Spare Parts info ........................................................... 59
Thermostatic Radiator Valves .....................................11
Water and Systems ...........................................11,13,14
Water Connections ...................................................... 28
Water Treatment ......................................................... 14
Wiring Diagram ............................................................ 30

For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the
manufacturer’s instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Commissioning Checklist.
Before installing this boiler, read the Code of Practice sheet at the rear of this book.

BENCHMARK COMMISSIONING CHECKLIST DETAILS

Boiler Page Page
Make and model.......................................................... 7 Burner operating pressure....................................... n/a
Appliance serial no. on data badge ........... Front Cover Central heating flow temp.............measure and record
SEDBUK No. %........................................................... 6 Central heating return temp..........measure and record
Controls For combination boilers only
Time and temperature control to heating.................. 29 Scale reducer............................................................ 14
Time and temperature control to hot water .............. 29 Hot water mode
Heating zone valves................................................. n/a Heat input.............................................to be calculated
TRV’s........................................................................ 11 Max. operating burner pressure............................... n/a
Auto bypass.............................................................. 11 Max. operating water pressure......... measure & record
Boiler interlock........................................................... 11 Cold water inlet temp....................... measure & record
For all boilers Hot water outlet temp....................... measure & record
Flushing to BS.7593.................................................. 14 Water flow rate at max. setting......... measure & record
Inhibitor..................................................................... 14 For condensing boilers only
Central heating mode Condensate drain...................................................... 26
Heat input....................................................to be calculated For all boilers: complete, sign & hand over to customer
For assistance see Technical Helpline on the back page

NOTE TO THE INSTALLER: COMPLETE

THE BENCHMARK COMMISSIONING
CHECKLIST AND LEAVE THESE
INSTRUCTIONS WITH APPLIANCE

IDEAL CLASSIC - Installation and Servicing 7

 GENERAL

INTRODUCTION SAFE HANDLING

The Ideal Classic range of boilers are wall mounted, full This boiler may require 2 or more operatives to move it to its
sequence, automatic spark ignition, low water content, fanned installation site, remove it from its packaging base and during
flue, high efficiency, condensing, combination gas boilers. movement into its installation location. Manoeuvring the boiler
Note. Due to the high efficiency of the boiler a plume of water may include the use of a sack truck and involve lifting, pushing and
vapour will form at the terminal during operation. pulling.
Central heating (CH) output is fully modulating with a range of: Caution should be exercised during these operations.
24 4.8 to 24.2kW Operatives should be knowledgeable in handling techniques when
30 6.1 to 24.2kW performing these tasks and the following precautions should be
35 7.1 to 24.2 kW considered:
Instantaneous domestic hot water (DHW) output is also fully
• Grip the boiler at the base.
modulating with a maximum of :
• Be physically capable.
24 24.2kW • Use personal protective equipment as appropriate, e.g. gloves,
30 30.3kW safety footwear.
35 35.3kW
During all manoeuvres and handling actions, every attempt should
The boiler is supplied fully assembled with DHW plate heat be made to ensure the following unless unavoidable and/or the
exchanger, diverter valve, circulating pump, pressure gauge, weight is light.
safety valve and CH expansion vessel.
• Keep back straight.
Variable CH and DHW temperature controls are fitted on the user • Avoid twisting at the waist.
control and the boiler features a DHW preheat facility.
• Avoid upper body/top heavy bending.
The boiler includes as standard: • Always grip with the palm of the hand.
- Automatic bypass • Use designated hand holds.
- Boiler frost protection • Keep load as close to the body as possible.
- Daily pump and diverter valve exercise • Always use assistance if required.
- Mechanical 24hr timer
The boiler casing is of white painted mild steel. OPTIONAL EXTRA KITS
The boiler temperature controls are visible located in the control
• Horizontal Flue Terminal - (1000mm long)
panel on the front of the boiler.
• Horizontal Flue Terminal - (600mm long)
The heat exchanger is manufactured from cast aluminium.
• Horizontal Flue Terminal - (600mm long) Weather Protection
The boiler is suitable for connection to fully pumped, sealed • Flue Extension Ducts (1000mm long)
heating systems ONLY. Adequate arrangements for completely • Flue Extension Ducts (2000mm long)
draining the system by provision of drain cocks MUST be provided • Flue Extension Ducts (500mm long)
in the installation pipework. 24-up to 9m
Pipework from the boiler is routed downwards. 30-up to 8m
Data Plate 35-up to 6m
• 90o Elbow Kit (maximum per installation)
The boiler model and serial number can be located on the bottom of the
24-up to 6 elbows
boiler casing, shown in Frame 1 - Water & Gas Connection Diagram.
30-up to 6 elbows
35-up to 4 elbows
OPERATION • 45o Elbow Kit (maximum per installation)
24-up to 6 elbows
With no demand for CH, the boiler fires only when DHW is drawn
30-up to 6 elbows
off, or periodically for a few seconds without any DHW draw-off, in
30-up to 4 elbows
order to maintain the DHW calorifier in a heated condition. This
only occurs if pre-heat on. • Telescopic B Pack
• Raised Horizontal Flue Outlet Kit
When there is a demand for CH, the heating system is supplied at
the selected temperature of between 45oC and 80oC, until DHW • High Level Flue Outlet Kit
is drawn off. The full output from the boiler is then directed via • Flue Deflector Kit
the diverter valve to the plate heat exchanger to supply a nominal • Balcony Flue Kit
DHW draw-off of • Soffit Flue Kit
24 9.9 l/min at 35 oC temperature rise. • Roof Flue Kit (to a maximum of 7.5m)
30 12.4 l/min at 35 oC temperature rise • Concentric Flue Screw Retaining Kit
35 14.5 l/min at 35ºC temperature rise • Weather Collar
The DHW draw off rate specified above is the nominal that the • Adjustable Flue Support Bracket
boiler flow regulator will give. Due to system variations and • Flue Finishing Kit
seasonal temperature fluctuations DHW flow rates/temperature • Stand-Off Kit
rise will vary, requiring adjustment at the draw off tap.
• Weather Compensation Kit
At low DHW draw-off rate the maximum temperature is limited to • Valve Cover Kit
64 oC by the modulating gas control.
• Condensate Pump Kit
The boiler features a comprehensive diagnostic system which
• DHW Expansion Vessel Kit
gives detailed information on the boiler status when operating,
• RF Mechanical Programmable Room Thermostat Kit
and performance of key components to aid commissioning and
fault finding.

8 IDEAL CLASSIC - Installation and Servicing

 GENERAL

SAFETY LOCATION OF BOILER

Current Gas Safety (installation and use) regulations or rules The boiler must be installed on a flat and vertical internal wall,
in force: capable of adequately supporting the weight of the boiler and any
ancillary equipment.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force. The boiler may be fitted on a combustible wall and insulation
In GB, the installation must be carried out by a Gas Safe between the wall and the boiler is not necessary, unless required
Registered Engineer. It must be carried out in accordance with by the local authority.
the relevant requirements of the: For electrical safety reasons there must be no access available
• Gas Safety (Installation and Use) Regulations from the back of the boiler.
• The appropriate Building Regulations either The Building The boiler must not be fitted outside.
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland). Timber Framed Buildings
• The Water Fittings Regulations or Water byelaws in Scotland. If the boiler is to be fitted in a timber framed building it should be
• The Current I.E.E. Wiring Regulations. fitted in accordance with the Institute of Gas Engineering document
IGE/UP/7:2006 - Edition 2.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice. Bathroom Installations
In IE, the installation must be carried out by a Registered Gas This appliance is rated IP20.
Installer (RGII) and installed in accordance with the current edition
of I.S.813 “Domestic Gas Installations”, the current Building The boiler may be installed in any room or internal space, although
Regulations and reference should be made to the current ETCI particular attention is drawn to the requirements of the current
rules for electrical installation. IEE (BS.7671) Wiring Regulations and the electrical provisions
of the building regulations applicable in Scotland, with respect to
Detailed recommendations are contained in the following British the installation of the boiler in a room or internal space containing
Standard Codes of Practice: a bath or shower. For IE reference should be made to the current
BS. 5440:1 Flues (for gas appliances of rated input not ETCI rules for electrical installations and I.S. 813:2002.
exceeding 70 kW). If the appliance is to be installed in a room containing a bath or
BS. 5440:2 Ventilation (for gas appliances of rated input not shower then, providing water jets are not going to be used for
exceeding 70 kW). cleaning purposes (as in communal baths/showers), the appliance
BSEN. 12828:2003 Heating Systems in buildings: Design for must be installed beyond Zone 2, as detailed in BS.7671.
water based heating systems.
BSEN 12831:2003 Heating Systems in buildings: Method for Ceiling
calculation of the design heat load.
BSEN 14336:2004 Heating Systems in buildings: Installation
and commissioning of water based heating
systems. Recessed
BS. 5546 Installation of gas hot water supplies for domestic window
purposes (2nd Family Gases) 2.25m Zone 2

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

input not exceeding 70 kW.
0.6m
Zone 1
BS. 6891 Low pressure installation pipes.
Health & Safety Document No. 635.
The Electricity at Work Regulations, 1989. Zone 0
The manufacturer’s notes must NOT be taken, in any way, as 3G8913a

overriding statutory obligations.

Compartment Installations
IMPORTANT. These appliances are CE certificated for safety
and performance. It is, therefore, important that no external A compartment used to enclose the boiler should be designed and
control devices, e.g. flue dampers, economisers etc., are constructed specially for this purpose.
directly connected to these appliances unless covered by
An existing cupboard or compartment may be used, provided that
these Installation and Servicing Instructions or as otherwise
it is modified for the purpose.
recommended by Ideal Boilers in writing. If in doubt please
enquire. Braces for compartments must be easily removable for service access.
Any direct connection of a control device not approved by Ideal In both cases, details of essential features of cupboard /
Boilers could invalidate the certification and the normal appliance compartment design, including airing cupboard installation, are to
warranty. It could also infringe the Gas Safety Regulations and conform to the following:
the above regulations.
• BS 6798 (No cupboard ventilation is required - see ‘Air Supply’
for details).
SAFE HANDLING OF SUBSTANCES • The position selected for installation MUST allow adequate
No asbestos, mercury or CFCs are included in any part of the space for servicing in front of the boiler.
boiler or its manufacture. • For the minimum clearances required for safety and
subsequent service, see the wall mounting template and
Frame 1. In addition, sufficient space may be required to
allow lifting access to the wall mounting plate.
IDEAL CLASSIC - Installation and Servicing 9
 GENERAL

GAS SUPPLY 3. Minimum acceptable spacing from the terminal to obstructions

and ventilation openings are specified in
The local gas supplier should be consulted, at the installation
Table 4.
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without 4. Where the lowest part of the terminal is fitted less than 2m
prior consultation with the local gas supplier. above a balcony, above ground or above a flat roof to which
people have access then the terminal MUST be protected by a
The boiler MUST be installed on a gas supply with a governed purpose designed guard.
meter only.
Terminal guards are available from boiler suppliers. (Ask for
A gas meter can only be connected by the local gas supplier or TFC flue guard model no. K6 - round, plastic coated). In case
by a Gas Safe Registered Engineer. In IE by a Registered Gas of difficulty contact:
Installer (RGII). TFC Group Tel. + 44 (0) 01732 351 680
An existing meter should be checked, preferably by the gas Tower House, Vale Rise Fax. + 44 (0) 01732 354 445
supplier, to ensure that the meter is adequate to deal with the rate Tonbridge. Kent TN9 1TB www.tfc-group.co.uk
of gas supply required. Ensure that the guard is fitted centrally.
It is the responsibility of the Gas Installer to size the gas 5. The flue assembly shall be so placed or shielded as to prevent
installation pipework in accordance with BS6891:2005. Whilst ignition or damage to any part of any building.
the principle of the 1:1 gas valve ensures the boiler range is
6. The air inlet/products outlet duct and the terminal of the boiler
able to deliver it’s full output at inlet pressures as low as 14mb,
MUST NOT be closer than 25mm to combustible material.
other gas appliances in the property may not be as tolerant.
Detailed recommendations on the protection of combustible
When operating pressures are found to be below the minimum
material are given in BS. 5440-1:2008.
meter outlet of 19mb these should be checked to ensure this is
adequate for correct and safe operation. IMPORTANT. It is essential to ensure, in practice, that products
of combustion discharging from the terminal cannot re-enter the
Allowing for the acceptable pressure loss of 1mb across the building or buildings through any openings into the building such
installation pipework, it can be assumed that a minimum permitted as ventilators, windows, doors, or other sources of natural air
operating pressure of 18mb will be delivered to the inlet of the infiltration, such as forced ventilation openings etc.
appliance. (Reference BS 6400-1 Clause 6.2 Pressure Absorption).
If products of combustion re-entry is identified or suspected this
The external gas cock could further reduce the operating pressure should be immediately investigated and corrected following the
when measured at its test point. The pressure drop is relative to guidance provided in the current Gas Industry Unsafe Situation
the heat input to the boiler (kW), refer to graph below. Procedure.
The terminal assembly can be adapted to accommodate various
Gas Cock Pressure Drop wall thicknesses. Refer to Frame 1.
3

2.5 Table 4 - Balanced Flue Terminal Position

Pressure drop (mbar )

2 Flue Terminal Positions Min. Spacing*

1.5 1. Directly below, above or alongside an opening
window, air vent or other ventilation opening. 300mm
1
2. Below guttering, drain pipes or soil pipes. 25mm*
0.5 BS5440-1 2008 75mm
0 3. Below eaves. 25mm*
0 10 20 30 40 50 BS5440-1 2008 200mm
Heat Input to Boiler (kW) 4. Below balconies or a car port roof. 25mm*
BS5440-1 2008 200mm
5. From vertical drain pipes or soil pipes. 25mm*
IMPORTANT. BS5440-1 2008 150mm
Ensure all gas valve connections are gas tight with a gas 6. From an internal or external corner or to a 25mm*
soundness check up to the gas control valve. boundary along side the terminal. BS5440-1 2008 300mm
Installation pipes must be fitted in accordance with BS.6891. In IE 7. Above adjacent ground, roof or balcony level. 300mm
refer to IS.813:2002. 8. From a surface or a boundary facing the terminal. 600mm
The complete installation MUST be tested for gas tightness and 9. From a terminal facing a terminal. 1,200mm
purged as described in the above code. 10. From an opening in a car port
(e.g. door or window) into dwelling. 1,200mm
FLUE INSTALLATION 11. Vertically from a terminal on the same wall. 1,500mm
Pluming will occur at the terminal so terminal positions where this 12. Horizontally from a terminal on the wall. 300mm
could cause a nuisance should be avoided.
Vertical Terminals
The flue must be installed in accordance with the 13. Above the roof pitch with roof slope of all angles. 300mm
recommendations of BS. 5440-1: 2008. Above flat roof. 300mm
In IE refer to I.S. 813:2002. 14. From a single wall face. 300mm
The following notes are intended for general guidance: From corner walls. 300mm
15. Below velux window 2000mm
1. The boiler MUST be installed so that the terminal is exposed
to external air. 16. Above or side of velux window 600mm

2. It is important that the position of the terminal allows the free * Only one reduction down to 25mm is allowable per installation
passage of air across it at all times. otherwise BS5440-1 2008 dimensions must be followed.

10 IDEAL CLASSIC - Installation and Servicing

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

WATER CIRCULATION SYSTEM

IMPORTANT.
A minimum length of 1 metre of copper pipe MUST be fitted
to both flow and return connections from the boiler before
connection to any plastic piping.
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 4

BOILER CONTROL INTERLOCKS

Central heating systems controls should be installed to ensure
the boiler is switched off when there is no demand for heating, in
compliance with Building Regulations.
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.
When thermostatic radiator valves are used, the space heating
temperature control over a living / dining area or hallway having
a heating requirement of at least 10% of the minimum boiler heat
output should be achieved using a room thermostat, whilst other
rooms are individually controlled by thermostatic radiator valves.
However, if the system employs thermostatic radiator valves on all
radiators, or two port valves, then a bypass circuit must be fitted
with an automatic bypass valve to ensure a flow of water should
all valves be in the closed position.

ELECTRICAL SUPPLY
WARNING.
This appliance must be earthed.
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. For IE reference should be made to the
current ETCI rules for electrical installations.
The mains supply to the boiler and system wiring centre shall
be through one common fused double pole isolator and for
new heating systems, and where practical replacement boiler
installations, the isolator shall be situated adjacent to the
appliance.

CONDENSATE DRAIN
Refer to Frames 20, 21 & 36
A condensate drain is provided on the boiler. This drain must be
connected to a drainage point on site. All pipework and fittings in
the condensate drainage system MUST be made of plastic - no
other materials may be used.
IMPORTANT.
Any external runs must be in accordance with BS 6798.
The drain outlet on the boiler is sized for standard 21.5mm
overflow pipe. It is a universal fitting to allow use of different
brands of pipework.

IDEAL CLASSIC - Installation and Servicing 11

 GENERAL
1 BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm
The boiler connections are made on the boiler bulkhead fittings.
Refer to Frame 22.
wall thicknesses do not exceed 600mm. Where the space
The following minimum clearances must be maintained for into which the boiler is going to be installed is less than
operation and servicing. the length of flue required the flue must be fitted from the
Additional space will be required for installation, depending upon outside.
site conditions. Installation from inside ONLY
Side and Rear Flue b. If a core boring tool is to be used inside the building the
a. Provided that the flue hole is cut accurately, e.g. with a core space in which the boiler is to be installed must be at least
drill, the flue can be installed from inside the building where wide enough to accommodate the tool.

2.5 285
2.5 from case 395
155
Side flue
dim. A

700

Underside View - Dimensions to Wall

DATA PLATE

43.5 65 28.5 28.5 60.6 75 56.4 37.5

DHW OUTLET

GAS INLET

DHW INLET
CH FLOW

COND. DRAIN

CH RETURN

PRV

103 99 99 99 103

WALL

Front clearance
The minimum front clearance when built in to a
cupboard is 5mm from the cupboard door but
450mm overall clearance is still required, with
the cupboard door open, to allow for servicing.

* Bottom clearance
Bottom clearance after installation can be
reduced to 5mm.
This must be obtained with an easily
removable panel, to enable the consumer
to view the system pressure gauge, and to
provide the 100mm clearance required for
servicing.

12 IDEAL CLASSIC - Installation and Servicing

 GENERAL
2 SYSTEM REQUIREMENTS - Central Heating
Notes
a. The method of filling, refilling, topping up or flushing sealed
primary hot water circuits from the mains via a temporary hose
connection is only allowed if acceptable to the local water
authority. Safety valve setting bar 3.0
b. Antifreeze fluid, corrosion and scale inhibitor fluids suitable for Vessel charge pressure bar 0.5 to 0.75
use with boilers having aluminium heat exchangers may be used
System pre-charge pressure bar None 1.0
in the central heating system.
System volume Expansion vessel
General (litres) volume (litres)
1. The installation must comply with all relevant national and local
25 1.6 1.8
regulations.
50 3.1 3.7
2. The installation should be designed to work with flow 75 4.7 5.5
temperatures of up to 86 oC. 100 6.3 7.4
3. All components of the system must be suitable for a working 125 7.8 9.2
pressure of 3 bar and temperature of 110 oC. Extra care should 150 9.4 11.0
be taken in making all connections so that the risk of leakage 175 10.9 12.9
is minimised. 190 11.9 14.0
The following components are incorporated within the 200 12.5 14.7
appliance: 250 15.6 18.4
a. Circulating pump. 300 18.8 22.1
b. Safety valve, with a non-adjustable preset lift pressure of
For other system volumes
3 bar.
multiply by the factor across 0.063 0.074
c. Pressure gauge, covering a range of 0 to 4 bar.
d. An 8-litre expansion vessel, with an initial charge pressure
of 0.75 bar.
4. ‘Make-up’ Water. Provision must be made for replacing water
loss from the system, either : Water Flow Rate and Pressure Loss
a. From a manually filled ‘make-up’ vessel with a readily Max CH Output kW 24.2
visible water level. The vessel should be mounted at
least 150mm above the highest point of the system and
be connected through a non-return valve to the system, Water flow rate l/min 17.3
fitted at least 150mm below the ‘make-up’ vessel on the
return side of the radiators. or
Temperature Differential o
C 20
b. Where access to a ‘make-up’ vessel would be difficult, by
pre-pressurisation of the system.
The maximum cold water capacity of the system should Head available for m.w.g. 3.4
not exceed 143 litres, if not pressurized. However, if system
the system is to be pressurized, the efficiency of the
expansion vessel will be reduced and a larger vessel
(or smaller system volume) may be necessary. If the
capacity of the vessel is not considered sufficient for
this, or for any other reason, an additional vessel MUST
be installed on the return to the boiler.
Guidance on vessel sizing is given in Frame 2.
5. Filling
The system may be filled by the following method: Mains
water supply
Where the mains pressure is excessive a pressure reducing
valve must be used to facilitate filling.
CH Return Hose unions
a. Thoroughly flush out the whole system with cold water.
b. Fill and vent the system until the pressure gauge
registers 1bar and examine for leaks.
Additional
stop valve
c. Check the operation of the safety valve by raising the
water pressure until the valve lifts. This should occur Temporary hose
within 0.3bar of the preset lift pressure. (disconnect after filling) Double check valve
assembly
(note direction of flow)
d. Release water from the system until the 6053

minimum system design pressure is reached;

1.0 bar if the system is to be pre-pressurised.
continued . . . . .

IDEAL CLASSIC - Installation and Servicing 13

 GENERAL

2 ...............CONTINUED
DOMESTIC HOT WATER b. Hot and cold water supplies to the shower are of equal
pressure.
1. The domestic hot water service must be in accordance with
BS 5546 and BS 6700. 5. Hard Water Areas - Where the water hardness exceeds
200mg/litre (200ppm), it is recommended that a proprietary
2. Refer to Table 1 for minimum and maximum working scale reducing device is fitted into the boiler cold supply
pressures. In areas of low mains water pressures the within the requirements of the local water company.
domestic hot water regulator may be removed from the
DHW flow turbine cartridge. Refer to Frame 67. The boiler IMPORTANT
will require the flow rate to be set to obtain a temperature Provision MUST be made to accomodate the expansion of DHW
rise of 35oC at the tap furthest from the boiler. contained within the appliance. If the DHW inlet contains a back
flow prevention device or non-return valve, e.g. a water meter,
3. The boilers are suitable for connection to most types of
then a mini expansion vessel should be fitted between the device
washing machine and dishwasher appliances.
and the boiler in the cold inlet pipe.
4. If the shower/mixer valve does not incorporate non-return Cold water, rising main and pipework on exposed areas need to
valves the following must be followed: be suitably lagged to prevent freezing.
a. The cold inlet to the boiler is fitted with an approved
Note. DHW Expansion Vessel Kit availabe from Ideal Boilers.
anti-vacuum or syphon non-return valve.

3 SYSTEM BALANCING
The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of the
minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available. See
note regarding thermostatic radiator valves on page 11.
Note. Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass.
BALANCING
1. Set the programmer to ON. These valves should now be left as set.
Close the manual or thermostatic valves on all radiators, 2. Open all manual or thermostatic radiator valves and
leaving the twin lockshield valves (on the radiators referred to adjust the lockshield valves on the remaining radiators, to
above) in the OPEN position. give around 20oC temperature drop at each radiator.
Turn up the room thermostat and adjust the lockshield valve 3. Adjust the room thermostat and programmer to
to give an uninterrupted flow through the radiator. NORMAL settings.

4 WATER TREATMENT
DOMESTIC HOT WATER
CENTRAL HEATING In hard water areas where mains water can exceed 200ppm Total Hardness
The range of boilers have an ALUMINIUM alloy heat (as defined by BS 7593:2006 Table 2) a scale reducing device together with
exchanger. Scalemaster in-line scale inhibitor should be fitted into the boiler cold supply
IMPORTANT. within the requirements of the local water company. The use of artificially
softened water, however, is not permitted.
The application of any other treatment to this product
may render the guarantee of Ideal Boilers Invalid. Ideal Boilers recommend the use of Fernox Quantomat, Sentinel
Ideal Boilers recommend Water Treatment in accordance Combiguard and Calmag CalPhos I scale reducing devices, which must be
with the Benchmark Guidance Notes on Water Treatment in used in accordance with the manufacturers’ instructions.
Central Heating Systems.
If water treatment is used Ideal Boilers recommend only the For further information contact:
use of SCALEMASTER SM-1 PRO, FERNOX-MB-1, ADEY Fernox Cookson Electronics
MC1, SENTINEL-X100 or CALMAG CM100 inhibitors and Forsyth Road, Sheerwater, Woking, Surrey GU21 5RZ
associated water treatment products, which must be used in +44 (0) 8706 015000
accordance with the manufacturers’ instructions. Sentinel Performance Solutions
Notes. The Heath Business & Technical Park, Runcorn, Cheshire WA7 4QX
1. It is most important that the correct concentration of the Tel: 0800 389 4670
water treatment products is maintained in accordance Scalemaster Water Treatment Products
with the manufacturers’ instructions. Emerald Way, Stone, Staffordshire ST15 0SR
2. If the boiler is installed in an existing system any Tel: +44 (0) 1785 811636
unsuitable additives MUST be removed by thorough Calmag Ltd.
cleansing. BS 7593:2006 details the steps necessary to Unit 3-6, Crown Works, Bradford Road,
clean a domestic heating system. Sandbeds, Keighley, West Yorkshire BD20 5LN
3. In hard water areas, treatment to prevent lime scale may Tel: +44 (0) 1535 210320
be necessary - however the use of artificially softened
Adey Professional Heating Solutions
water is NOT permitted.
Gloucester Road, Cheltenham GL51 8NR
4. Under no circumstances should the boiler be fired Tel: +44 (0) 1242 546700
before the system has been thoroughly flushed.

14 IDEAL CLASSIC - Installation and Servicing

 INSTALLATION

5 BOILER ASSEMBLY - Exploded View Note that item numbers are linked to the spares list

INSTALLATION
104 CH RETURN VALVE 131 WATER PRESSURE SWITCH 303 CUI BOARD
105 CH FLOW VALVE 135 PRESSURE GAUGE 306 ELECTRODE IGNITION
106 DHW INLET & OUTLET 203 GAS COCK 307 ELECTRODE DETECTION
108 PUMP HEAD 204 PIPE - GAS INLET 308 IGNITER UNIT
110 AIR VENT PUMP 205 GAS VALVE 309 FLOW THERMISTOR
111 DIVERTOR VALVE MOTOR 206 PIPE - GAS INJECTOR 313 IGNITION LEAD
112 DIVERTOR VALVE BODY 211 INJECTOR ASSEMBLY 314 CONTROL BOX LENS
113 PRESSURE RELIEF VALVE 214 VENTURI 324 CONTROLS BOX LID
114 PIPE - PRV OUTLET 215 FAN 325 CONTROL BOX FRONT
115 PIPE - FLOW 217 BURNER 326 MECHANICAL TIMER
116 PIPE - RETURN 218 GASKET - BURNER 401 HEAT ENGINE
117 PIPE - EXPANSION VESSEL 219 SUMP CLEAN OUT COVER 503 WALL MOUNTING BRACKET
118 EXPANSION VESSEL 223 FLUE MANIFOLD 504 FRONT PANEL
119 RETURN GROUP KIT 224 FLUE MANIFOLD TOP 506 BRACKET - GAS VALVE
120 FLOW GROUP KIT 227 CLAMP RETAINING FLUE TURRET 507 BRACKET - EXPANSION VESSEL
121 PLATE HEAT EXCHANGER 228 HOSE CONDENSATE INTERNAL 510 ACCESS FLAP
124 FLOW REGULATOR CARTRIDGE 229 SIPHON TRAP
127 FLOW SENSOR/TURBINE 231 CONDENSATE OUTLET CONNECTION
128 RETURN THERMISTOR 302 PRIMARY PCB* * Note. that production boiler PCB’s are
factory pre-set to operate for boiler range and
output, but when ordering Primary PCB as a
spare, an additional Boiler Chip Card (BCC)
MUST also be purchased for your specific
boiler range and output.

504

227
503

224

313 217 118

215

309
218
214
507
306
128
211 110
116 115 111
206 307 121
223

308 401
506 120 112 113

205 131
204 117
127 114
105
228 124 119
135
510 229
219 108
231
106
203 106
104
324
302
314 303
326
325

IDEAL CLASSIC - Installation and Servicing 15

 INSTALLATION
6 UNPACKING
INSTALLATION

The boiler is supplied fully assembled in Pack A. A telescopic or non-telescopic flue assembly for rear or side flue outlet in
Pack B is suppled as a separate order.

Unpack and check the contents.

IMPORTANT. To unpack the boiler:

1. Remove outer sleeve
2. Remove top end support
3. Stand up the boiler with aid of base tray
4. Remove base tray ensuring bottom end
support is still in place.

A
E
Pack A Contents
A Boiler B
B Hardware Bag
C Wall Mounting Plate
D These Installation/Users Instructions
E Wall Mounting Template
(located on internal protective packaging) C
F Boiler Guarantee & Registration Pack

G Boiler Guarantee

HARDWARE PACK CONTENTS

Gas Valve Pack

1
1. Gas Cock 3
2. Valve - DHW 2
3. Valve - Return
4. Valve - Flow
5. Pipe - DHW Outlet
6. Nut - G 1/2" 4
7. Washer - Gas 5 Fixings Pack
8. Washer - DHW
10 7
9. Washer - CH
10. Screw 12
8
11. Wall Plug
12. Turret Clamp Screw (spare) 6 11 9

16 IDEAL CLASSIC - Installation and Servicing

 INSTALLATION
6 UNPACKING CONT’D

Note. This flue system incorporates a removable flue outlet nose that utilises a push fit location system. This enables the
installation of deflector, high level or balcony outlet flue kits without the removal of the whole ‘B’ pack terminal. The appliance
must not be operated without the desired outlet nose correctly fitted in place.
Note. Location dimples must be aligned with terminal mounting frame.

Pack B Contents Non-Telescopic

A Flue Terminal D
B Flue Turret
C Rubber Terminal Wall Seal
D Cutting Aid A C
B

Pack B Contents Telescopic

A Telescopic Flue Terminal
B Flue Turret
C Rubber Terminal Wall Seal
D Screw
E Sealing Tape C
B A

FLUE OUTLET
D

7 FRONT PANEL REMOVAL

1. Lift the lower front panel access panel. 3. Remove the two upper front panel fixing screws, lift the panel
and remove.
2. Unscrew the two fixing screws, close the access panel to
retain the screws and hinge the lower front panel down into
the service position.

2 3
1

IDEAL CLASSIC - Installation and Servicing 17

 INSTALLATION
8 WALL MOUNTING TEMPLATE
INSTALLATION

Extended centre line

155
(200)
The wall mounting template is located on the internal protective “A” - See Diagram in
packaging. The template shows the position of the fixing and rear Frame 1
flue centre holes for a standard installation
Care MUST be taken to ensure the correct holes are drilled.
1. Tape template into the required position, ensuring its squareness
by hanging a plumbline as shown.
2. If fitting a side flue, extend the flue centreline onto the side by
155mm on a standard wall fix or 200mm if using a stand-off
bracket.
3. Mark the following on to the wall:
a The selected group of wall mounting screw holes.
b. The centre position of the flue duct. Marking both the centre
and the circumference of the flue duct.
4. Remove the template plate from the wall.
88
3G99

9 PREPARING THE WALL

IMPORTANT.
Ensure that, during the cutting operation, masonry falling
outside of the building does not cause damage or personal
injury.
Rear flue only Side flue only
1. Cut the flue hole (preferably with a 5” core boring tool), 5" diameter hole 5" diameter hole
ensuring that the hole is square to the wall.
Both wall faces immediately around the cut hole should be
flat. X
2. Drill 2 mounting holes (marked from template) with a 7.5mm Section
/ 8mm masonry drill and insert the plastic plugs, provided, through wall
for the wall mounting plate.
3. Locate 2 No.14 x 50mm screws in the wall mounting plate Note. Check all of the hole
(one at each side, in any of the 3 holes provided at each positions before drilling.

3G9495
side) and screw home. Ensure mounting bracket is level.

10 FITTING THE WALL MOUNTING PLATE 11 MOUNTING THE BOILER

Screw the wall mounting plate to the wall using 2 wall plugs NOTE. ENSURE BOTTOM END SUPPORT IS LEFT IN PLACE
(previously fitted) with the 2 screws provided.
Choose one of the 2 sets of slots in left and right bank. 1. Lift the boiler onto
Ensuring that at least one of the screws is fitted into a top slot the wall mounting
and the mounting bracket is level. plate (refer to the
Introduction section
for safe handling
Example of fixing advice), locating it
over the two tabs.
2. Remove the
bottom end support
packaging.
3. Ensure the plastic
plugs are removed
from both the CH and
DHW connections.

3G9948

9982b

18 IDEAL CLASSIC - Installation and Servicing

 INSTALLATION
12 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED

IMPORTANT. The boiler must be installed in a vertical position in recommended that a support bracket is fitted on every 1 metre of
accordance to the installation instructions. pipe work used and the bracket is located as close to the collar as
FLUE KITS possible. The bracketing must ensure a 1.5 degree fall back to the
appliance.
Telescopic Flue‘B’ Pack - contains: Flue turret, telescopic flue
incorporating a terminal and rubber wall seals. Optional Flue Finishing Kit - UIN 155988 & Concentric Flue
Screw Retaining Kit (Optional Kit of mechanical fixing of flue joints)
Horizontal Flue Terminal (600mm long) ‘B’ Pack - contains: Flue
turret, non telescopic single piece flue incorporating a terminal and Only use water as a lubricant during assembly.
rubber wall seals. The ‘B’ pack terminal is classed as part of the maximum flue
Horizontal Flue Terminal (1000mm long) ‘B’ Pack - Flue turret, length.
telescopic flue incorporating a terminal, rubber wall seals and These flue systems incorporates a removable flue outlet nose that
instructions. utilises a push fit location system. This enables the installation
Note. If ‘B’ packs are used on their own (either 1 piece or telescopic), then of deflector, high level or balcony flue kits without the removal of
they can be fitted horizontally as the flue inside is designed to slope 1.5 the whole ‘B’ pack terminal. The appliance must not be operated
degrees. without the desired outlet nose correctly fitted in place, ensuring
the side location dimples are in line with the mounting face allowing
Flue Kit 203129 - D Pack Flue Extension 100mm DIA 1000mm long the correct sealing of the components.
Flue Kit 211037 - D Pack Flue Extension 100mm DIA 500mm long
It is IMPORTANT that all attachments are fitted in accordance to
Flue Kit 211038 - D Pack Flue Extension 100mm Dia 2000mm long the installation instructions provided with them.
Flue Kit 211039 - Roof Flue Kit with Vertical Connector
The TURRET supplied in the ‘B’ Pack has an upper combustion
When extension ‘D’ Packs are used the flue duct must incline sample point with a screw cap seal and a lower air sample point
1.5 degrees away from the appliance, to allow the condensate with an air stopper seal. Ensure all caps & seals are in place.
to drain back to the boiler and out of the condensate drain. It is

Additional Termination Kits available for use with these ‘B’ packs.
Flue Deflector Kit The resistance is the equivalent of 1 metre of flue pipe and therefore must be deducted from
any maximum flue length
High Level Flue Outlet Kit The maximum permissible concentric flue length when using a standard (500mm) kit is 4.5 metres
Balcony Flue Outlet Kit The maximum permissible concentric flue length when using this kit is dependant on the length
of the balcony flue outlet run which combined with the concentric run must not exceed the
maximum flue length requirement of the appliance it is to be fitted to
Soffit Kit This kit enables fitment of an external flue below soffits.

Total Maximum Permissible Horizontal Concentric Flue Length combining both ‘B’ Packs and ‘D’ Packs
(Measured from centreline of the turret to the outside of the wall terminal)
24 kW appliances Total Maximum: 9 metres - minus any flue kit options or bends

FLUE OUTLET
30 kW Appliances Total Maximum: 8 metres - minus any flue kit options or bends
35 kW Appliances Total Maximum: 6 metres - minus any flue kit options or bends

Total Maximum Permissible Vertical Flue Length combining both Roof Terminal and ‘D’ Packs
24, 30 & 35 kW Appliances Total Maximum: 7.5 Metres - minus any bends

90º Elbow Kit 60/100 - (Equivalent flue length resistance = 1M)

45º Elbow Kit 60/100 - (Equivalent flue length resistance = 0.6M)
Minimum Horizontal Flue Lengths (Centre line of turret to outside of wall terminal)
Telescopic Flue ‘B’ Pack = 400mm
Horizontal Flue terminal (600mm long) ‘B’ Pack = 285mm

Wall Thickness Std Metric Brick 102.5mm wide

‘B’ Pack Flue Type 60/100 Minimum permissible Wall Thickness Maximum permissible Wall Thickness
Rear Flue Rear Flue + Std-Off Side Flue Rear Flue Rear Flue + Std-Off Side Flue
Horizontal Flue Terminal 116 102.5 102.5 501 456 456
(600mm long) B Pack
Telescopic Flue B Pack 231 186 186 429 384 384
Horizontal Flue Terminal 546 501 501 761 716 716
(1000mm long) B Pack
Horizontal Flue Terminal 471 426 426 686 641 641
(1000mm long) B Pack cut 75mm
For Flue lengths between 658 & 708 use a Horizontal Flue Terminal (1000mm long) B Pack, cut 75mm off the end of the terminal
section of the telescopic flue only.

IDEAL CLASSIC - Installation and Servicing 19

 INSTALLATION

13 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED, CONT’D

FIGURE 1 Edge of turret

to outside face of wall plus
Edge of turret
to outside face of wall plus
Edge of turret
to outside face of wall plus
44mm = flue length 44mm = flue length 44mm = flue length
100mm A A A
Note. Maximum permissible
flue length is measured from
centre line of appliance flue
outlet to outside wall face.
REAR REAR SIDE
Fit Fit Fit
to wall to wall to wall
inc. Stand

WALL

WALL

WALL
off Frame

Minimum clearance 5mm

Flue length measured from outer terminal lip

to end of outer flue
NOTES A + 44mm
Centre of turret to edge of turret = 100mm
Turret has a flue insertion of 30mm
The compressed outer wall seal has protruding wall to seal mounting lip - 14mm
From centreline of turret to wall. Rear mount 155mm, side (including clearance) 200mm

FIGURE 2
Shows the flue required when measured from outside edge of turret to the outside face of the wall (to obtain cut length add 44mm)

Minimum & Maximum finished flue lengths obtainable (dimension ‘A’ +44mm)
Horizontal Flue Terminal Telescopic Flue B Pack Horizontal Flue Horizontal Flue Terminal
(600mm long) B Pack Terminal (1000mm long) (1000mm long) B Pack
B Pack (Telescopic) (Telescopic) Cut 75mm
Minimum Maximum Minimum Maximum Minimum Maximum Minimum Maximum
B Pack (Standard) 171 556 286 484 601 816 526 741
FLUE OUTLET

Max output 35 kW
Plus 1 (1m D pack) 1121 1506 1236 1434 1551 1766 1476 1691
Plus 2 (1m D pack) 2071 2456 2186 2384 2501 2716 2426 2641

Max output 30 kW
Plus 3 (1m D pack) 3021 3406 3136 3334 3451 3666 3376 3591
Plus 4 (1m D pack) 3971 4356 4086 4284 4401 4616 4326 4541

Max output 24 kW
Plus 5 (1m D pack) 4921 5306 5036 5234 5351 5566 5276 5491
Plus 6 (1m D pack) 5871 6256 5986 6184 6301 6516 6226 6441
Plus 7 (1m D pack) 6821 7206 6936 7134 7251 7466 7176 7391
Plus 8 (1m D pack) 7771 8186 7886 8084 8201 8416 8126 8341
Plus 9 (1m D pack) 8721 9000 8836 9000 9000 9000 9000 9000

Note; Telescopic flue B Pack or attached “D” pack extensions do not need to be cut between minimum and maximum values
shown above (except where specified). Horizontal Flue Terminal (600mm long) B Pack flue will require cutting on values
below maximum values shown in the table above.
If using the 2000mm D Pack , the maximum usable length per extension is 1950mm
If using the 500mm D Pack, the maximum usable length per extension is 450mm.

20 IDEAL CLASSIC - Installation and Servicing

 INSTALLATION

14 CUTTING & SETTING THE FLUE LENGTH

TELESCOPIC FLUES
TELESCOPIC FLUE B PACK SHOULD ONLY BE ADJUSTED FOR USE WITHIN ITS SPECIFIED RANGE AND MUST NOT
BE CUT
HORIZONTAL FLUE TERMINAL (1000MM LONG) B PACK (TELESCOPIC) MUST ONLY BE CUT IF REQUIRED FLUE
LENGTHS ARE BETWEEN 602 & 652MM. THIS WILL REQUIRE 75MM TO BE CUT OFF THE TERMINAL END OF THE
1000MM TELESCOPIC FLUE.
ALL OTHER LENGTHS OBTAINED USING “D” PACK EXTENSIONS IN FLUE LENGTH TABLE 1, COLUMN “HORIZONTAL
FLUE TERMINAL (1000MM LONG) B PACK CUT 75MM” (TELESCOPIC) SHOULD HAVE THE 75MM CUT OFF THE “D”
PACK EXTENSION AND NOT TELESCOPIC FLUE

CUT 75MM OFF HORIZONTAL FLUE TERMINAL 1000MM LONG B PACK (TELESCOPIC)
1. Measure cut flue length (A+44mm). (If required telescopic length is not between
658 and 708 then proceed to “Setting Telescopic Flue B Pack”).
2. Remove telescopic end piece from the flue body and set aside.
3. Mark the circumference 75mm from the open end of the outer flue.
4. Cut along the 75mm mark cutting only the outer flue ensuring the cut is square.
5. Dress the cut end to make sure all burr is removed and the cut edge is in its
original shape.
6. Measure 20mm from the newly cut edge of the outer flue, place a mark at the top of the flue approximately 20mm wide &
write stop the terminal side of the line.
7. Mark the inner tube 10mm longer than the outer tube around its circumference and cut following the mark to ensure its cut
square
8. Remove all burrs and place a chamfer on the outer edge to aid assembly.
9. Re-assemble telescopic section.

SETTING TELESCOPIC FLUE B PACK

1. Measure the required flue length (A+44mm).
2. Measure from the outer terminal lip to end of outer flue. Pull apart flue until

FLUE OUTLET
desired length is achieved. ENSURE THE STOP MARK IS NOT VISIBLE,
IF IT IS, THE FLUE IS TOO SHORT AND SHOULD NOT BE USED.
3. Check that both flue seams are at the top and the outlet terminal is upper
most.
4. Drill a 3.5mm hole through one of the 2 outer side holes in the outer flue
section into the inserted outer flue (as shown). Take care not to pierce the
inner plastic flue. Fit screw provided.
5. Seal the joint on the outer air duct with the tape provided.
6. Fit external wall seal (see installing flue).

CUTTING HORIZONTAL FLUE TERMINAL (600MM LONG) B PACK

1. Measure the required cut flue length (A+44mm). If inside the dimensions
shown in Figure 2 “1 Piece 600mm” proceed.
2. Measure from the outer terminal lip to end of outer flue. Mark the
required cut length (A+44) around the circumference of the outer flue and
cut following the mark to ensure its cut square.
3. Dress the cut end to make sure all burr’s are removed and the cut edge
is in its original shape.
4. Mark the inner tube 10mm longer than the outer tube around its
circumference and cut following the mark to ensure its cut square.
5. Remove all burrs and place a light chamfer on the outer edge to aid
assembly.

IDEAL CLASSIC - Installation and Servicing 21

 INSTALLATION

15 INSTALLING THE FLUE

FITTING FLUE THROUGH THE WALL
1. Measure wall thickness and add 14mm.
2. Measure from the outer terminal lip towards the end of outer flue, place a
small location mark at the dimension acquired at point 1.
3. Fit external black wall seal ensuring the inside of the outer lip is in contact
with the terminal lip you have been measuring from (see fig 1)
4. For an internal fit, place flue terminal in the centre of the 5” drilled hole
in the wall. Apply pressure and lightly move the flue left to right or up
and down. This will cause the outer flange to fold in and allow the flue to
pass through the wall.
5. Push through a further 65mm. This will allow the outer flange to return
to its original shape.
6. Pull back the flue until the location mark point 1 is level with the internal
face of the wall.
Note. If the location mark is not visible then the flue is not pulled back
far enough to obtain the correct seal. If the location mark has passed
the face of the wall the flue has been pulled to far back and the outer
wall seal will have been dislodged from its mounting and will need to be
refitted.
7. Ensure the seam and the outlet terminal are at the top and fitted as shown.
Note. If less than 50% of the length of the flue is internal the flue should be
fitted from outside.

Wall Seal Lip Terminal

Fig 1 MUST be
fitted as
Terminal Lip shown

Rubber
Terminal
Wall Seal

Ensure lip of wall seal is positioned

over step on plastic nose of flue terminal
(note, seal is cut away for clarity)
FLUE OUTLET

FITTING THE TURRET - Ensure the condense trap/siphon is filled with water
1. Ensure the rubber seal is fitted correctly on the appliance manifold and that all flue seals are undamaged.
2. Hold the flue firmly and push the turret on until it has travelled 30mm on to the flue pipe and is fully engaged. Make sure the
flue has not rotated or moved forward during fitting and the flue seam is upper most.
3. Push the turret into the manifold ensuring the upper plastic lip is flush with the top of the manifold.
4. Fully engage the clamp location section into the manifold location holes. Rotate down on to turret flange.
5. Secure clamp to appliance using securing screw.
6. Ensure all sample points are accessible and all sample plugs and caps are fitted.

Retaining Sample points Clamp Lugs

screw

D
A

B
Flue Outlet

A - Duct Assembly
B - Flue Turret
C - Turret Clamp
D - Seal
Flue Outlet
C

22 IDEAL CLASSIC - Installation and Servicing

 INSTALLATION

16 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched)

Note.
A flat or pitched roof flashing plate (not supplied) is required before proceeding
with the installation of this kit.

This kit is suitable for both flat and pitched roof terminations, using a concentric
flue to run vertically from the top of the boiler and terminating above roof level.
Connection to the top of the boiler is made
using a separately supplied vertical connector.

WEATHER PROOFING
Where the flue passes through the roof line
an adequate seal must be made. This is
achieved by using either:
- Flat roof weather collar
or
- Universal weather collar.

ACCESSORIES
Flue Duct Extension Kits are available for flue
lengths extending beyond 1m. These packs
contain 1m extension ducts and may be cut to
the desired length.
If the offset vertical option is used an elbow Kit
is required.
Soffit Flue Kit supplied as an optional extra.
For a full accessories list refer to page 8,
Optional Extras.

17 ROOF FLUE KIT CONTENTS / OPTIONS

FLUE OUTLET
Flue Terminal Flue Seal Collar - Flat Roof Vertical connector 90o elbow
UIN 211039 UIN 152259 UIN 208175 UIN 203130

Vertical
Connector

Flue Seal Collar - Tile Roof 45o elbow

UIN 152258 UIN 203131

Flue
duct
support
Roof Flue Extension Duct
UIN 211037 (500mm)
Soffit Flue Kit
UIN 203129 (1000mm)
UIN 211302 UIN 211038 (2000mm)

Flue
duct
support

IDEAL CLASSIC - Installation and Servicing 23

 INSTALLATION

18 FLUE TERMINAL POSITION

The terminal should be positioned so that products of
combustion can safely disperse at all times.
Pluming may occur at the termination so, where possible,
terminal positions where this could cause a nuisance
should be avoided. 300mm
Minimum dimensions are shown below min

m 690mm
0m
30 Fixed
300mm in
m
min

rf8394-1
625mm
Fixed
rf8393-1

Flat roof - with structure

If chimney penetrates dotted area such that A is less

than 300mm, B shall not be less than 300mm.
FLUE OUTLET

A A
A

B
RF
98
07

A = 600mm
B = 2000mm
The flue terminal shall not penetrate the shaded area of the roof
Pitched roof - with velux window
or opening

Where two or more vertical fanned draught chimney configurations terminate in close
Note.
proximity at the same height, they shall be separated by at least 300mm. Where any
one vertical outlet is more than 300mm above the other, then they shall be separated The equivalent flue length
by at least 1500mm. resistance of the elbow kits are:
90o elbow kit = 1m
Where any vertical fanned draught chimney configuration outlet is within 2000mm
measured horizontally of an opening window, then it shall be at least 300mm above 45o elbow kit = 0.6m
the opening.

24 IDEAL CLASSIC - Installation and Servicing

 INSTALLATION

19 ASSEMBLING THE ROOF FLUE KIT

Determine the correct height that the flue should terminate above
the roof. If after calculating or measuring the overall flue height
from the top of the boiler, it is necessary to cut both pipes of
assembly A, then ensure they are cut equally leaving the inner
flue tube longer than the outer air tube as supplied.
Ensure the cut pipe ends are free from any burrs.

o
min 25

o
max 45
1. Position the roof flashing plate (supplied separately) over the
hole cut in the roof and insert flue terminal from the roof end.
MAX LENGTH:
7.5m

nm8739
BOILER

2. Fit the vertical connector (supplied in kit) in accordance with the

instructions provided with the vertical connector kit.
Flue Terminal 3. Secure the vertical connector by applying downward pressure
ASSEMBLY A
on the connector.

4. Position the clamp on the top face of the flue manifold and push
it horizontally backwards. Locate both clamp lugs into the flue
manifold and secure to the flue manifold clamp with the M5
retaining screw.
5. “Push” fit extension duct (if required (supplied separately)) into
Pitched roof tile vertical connector.
Flat roof tile weather collar
weather collar Note. Ensure turret sample points are servicable and all caps and
plugs are fitted. Fill the condensate trap siphon with water.

nm8740
Extension

FLUE OUTLET
5 Duct

Vertical
4 connector

2
3G9557b

6. If the last extension duct requires cutting, measure ‘X’, the distance (outer ducts),
between the duct and the terminal and add 100 mm to this dimension. This
gives the length of the last extension duct.
6
'X' Note. Check the position of the inner flue duct relative to the outer duct on the
assembled extension duct(s) and ensure the terminal flue duct is cut longer than
the air duct to ensure engagement in the final flue duct seal.

7. Finally ensure the roof flashing plate is correctly sealed to the roof.

IDEAL CLASSIC - Installation and Servicing 25

 INSTALLATION
20 CONDENSATE DRAIN
INSTALLATION

Condensate Pump
Where gravity discharge to an internal termination is not physically
possible or where very long internal pipe runs would be required
to reach a suitable discharge point, a condensate pump of a
Condensate specification recommended by the boiler or pump manufacturer
47 should be used terminating into a suitable internal foul water
Drain
discharge point such as an internal soil and vent stack or internal
kitchen or bathroom waste pipe etc. (fig 3).
137 156 External Drain Connections
The use of an externally run condensate drainage pipe should
only be considered after exhausting all internal termination options
This appliance is fitted with a siphonic 75mm condensate trap as described previously. An external system must terminate at a
system that requires filling before operating the appliance for the suitable foul water discharge point or purpose designed soak away.
1st time or after maintenance. If an external system is chosen then the following measures must
be adopted:
All condensate pipework should conform to the following:
a. Where a new or replacement boiler is being installed, access to The external pipe run should be kept to a minimum using the most
an internal ‘gravity discharge’ termination should be one of the direct and “most vertical” route possible to the discharge point, with
main factors considered in determining boiler location. no horizontal sections in which condensate might collect.
b. Plastic with push fit or solvent connections. - For connections to an external soil/vent stack see Fig 4.
c. Internal plastic pipe work a minimum of 19mm ID (typically Insulation measures as described should be used.
22mm OD) - When a rainwater downpipe is used, an air break must be
d. External plastic pipe must be a minimum of 30mm ID (typically installed between the condensate drainage pipe and the
32 OD) before it passes through the sleeved wall. downpipe to avoid reverse flow of rainwater into the boiler
e. All horizontal pipe runs, must fall a minimum of 45mm per metre should the downpipe become flooded or frozen, see Fig 5.
away from the Boiler. - Where the condensate drain pipe terminates over an open
f. External & unheated pipe work should be kept to a minimum foul drain or gully, the pipe should terminate below the grating
and insulated with Class “O” waterproof pipe insulation. level, but above water level, to minimise “wind chill” at the open
g. All installations must be carried out in accordance to the end. The use of a drain cover (as used to prevent blockage by
relevant connection methods as shown in the “Condensate leaves) may offer further prevention from wind chill. See Fig 6.
installation diagrams” & BS6798:2009 - Where the condensate drain pipe terminates in a purpose
h. Pipe work must be installed so that it does not allow spillage designed soak away (see BS 6798) any above ground
into the dwelling in the event of a blockage (through freezing) condensate drain pipe sections should be run and insulated as
i. All internal burrs should be removed from the pipe work and any described above. See Fig 7
fittings. Unheated Internal Areas
In order to minimise the risk of freezing during prolonged very cold Internal condensate drain pipes run in unheated areas, e.g. lofts
spells, one of the following methods of terminating condensate basements and garages, should be treated as external pipe.
drainage pipe should be adopted. Ensure the customer is aware of the effects created by a frozen
Internal Drain Connections condensate and is shown where this information can be found in
the user manual.
Wherever possible, the condensate drainage pipe should be routed
to drain by gravity to a suitable internal foul water discharge point
such as an internal soil and vent stack or kitchen or bathroom
waste pipe etc. See Figs 1 and 2.

Figure 2 - Connection of a Condensate Drainage Pipe

Figure 1 - Connection of Condensate Drainage Pipe to
Downstream of a Sink, Basin, Bath or Shower Water Trap to
Internal Soil & Vent Stack
Internal Soil Vent Stack

Boiler Boiler
with 75mm with 75mm
sealed sealed
condensate
Soil & vent stack

condensate
trap trap
Min Ø 19mm
Internal soil & vent stack

Internal pipe Min Ø 19mm

Internal pipe
≥ 100
75

≥ 100

Sink/basin/
75

Minimum
bath or
connection shower
≥ 450

height up to 3
storeys

Boilers without 75mm sealed Boilers without 75mm sealed

condensate trap must be fitted with condensate trap must be fitted with
a 75mm trap and visible air break a 75mm trap and visible air break

continued . . . . .

26 IDEAL CLASSIC - Installation and Servicing

 INSTALLATION
21 CONDENSATE DRAIN - CONT’D.......

INSTALLATION
Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to
Method (see manufacturers detailed instructions) External Soil & Vent Stack

Boiler Water/weather
Visible air break with 75mm proof insulation
Boiler sealed
with 75mm condensate
sealed trap

Soil & vent stack

condensate Min Ø 30mm
trap Internal pipe
Min Ø 19mm
75

Internal pipe

75
Min Ø 19mm
Internal pipe Minimum

≥ 450
connection
height up to 3
Condensate pump
Boilers without 75mm sealed storeys
(Install in accordance with manufacturers instructions)
condensate trap must be fitted with
a 75mm trap and visible air break

Figure 5 - Connection of a Condensate Drainage Pipe to an Figure 6 - Connection of Condensate Drainage Pipe
External Rainwater Downpipe (only combined foul/rainwater Upstream of a Sink, Basin, Bath or Shower Waste Trap to
drain) External Drain, Gulley or Ranwater Hopper

Boiler Boiler
with 75mm with 75mm
sealed sealed
≥ 100

condensate
condensate Visible air break
trap
Water/ trap at plug hole
weather proof Water/
Min Ø 19mm combined foul/
insulation weather proof
Internal pipe rain water drain Min Ø 19mm
insulation
Internal pipe
Min Ø 30mm External air
Internal pipe break Sink, basin, bath or

≥ 25 Below grate
Minimum 30mm
75

shower with integral internal pipe

Air gap
overflow and 75mm trap
Terminated
and cut at 45º

43mm 90º male/ 68mm Ø PVCU 45º pipe

female bend Strap on fitting termination

Figure 7 - Connection of a Condensate Drainage Pipe to an

External Purpose Made Soak Away.

Boiler
with 75mm
sealed
condensate
trap
Min Ø 30mm Water/Weather
Internal pipe proof insulation
Min Ø 19mm
Internal pipe Max 3m external
75

pipework
≥ 25
≥ 300

Boilers without 75mm sealed Limestone

condensate trap must be fitted with chippings
a 75mm trap and visible air break ≥ 500

2 rows of three Ø12mm holes

25mm centres, 50mm from
the bottom of the tube, facing
away from the house

IDEAL CLASSIC - Installation and Servicing 27

 INSTALLATION
22 CONNECTIONS & FILLING
INSTALLATION

NOTES.
Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown
in the picture.
Ensure each union is fitted with fibre seals provided.

Do not subject any of the isolating valves to heat as the seals may be damaged.

WATER CONNECTIONS CH FILLING

1. Connect the CH flow service valve provided in the
IMPORTANT - when filling:
hardware pack to the threaded boss connection
provided at the lower rear of the boiler. A. Ensure the dust cap on air vent
located at the rear of the pump
2. Connect the CH return valve (black handle).
chamber is slightly unscrewed.
3. If connecting the boiler to heating loads in excess of
B. When filling, there may be a slight
60,000 Btu/h (17.5kW), connecting flow and return
water leak from the air vent therefore
heating systems pipework must be sized in 28mm
electrical connections should be
diameter at the point of pipe connection to the
protected.
boiler tails. Use 22mm x 28mm pipe adaptors as
appropriate. CH -
1. Ensure that the CH isolating Dust Cap
WATER CONNECTIONS DHW handles are open.
1. Fit the DHW inlet service valve (blue handle) to the
2. Fill and vent the system. Refer to
threaded boss connection ensuring the seal provided is
Frame 2 for setting pressure.
correctly located.
DHW -
2. Fit the DHW outlet pipe tail to DHW outlet connection, 1. Fully open all DHW taps and ensure
ensuring the seal provided is correctly located. that water flows freely from the.
2. Close all taps.
GAS CONNECTION
IMPORTANT. The gas service cock is sealed with a non-
metallic blue fibre washer, which must not be overheated when
making capillary connections. Refer to Frame 1 for details of the
position of the gas connection.
For additional gas supply information refer to “Gas Supply” on
page 10.

SAFETY VALVE DRAIN

The safety valve connection, located at the bottom right-hand
Note.
side of the boiler, comprises a 15mm diameter stub pipe.
The DHW flow rate is automatically regulated to a max:
N.B. Use a compression fitting when connecting to the safety 24 = 9.9 l/m (2.2 gpm)
valve drain pipe to facilitate replacement of the safety valve if 30 = 12.4 l/m (2.8 gpm)
required. 35 = 14.5 l/m (3.2 gpm)
The discharge pipe should be positioned so that the discharge
of water or steam cannot create a hazard to the occupants of
the premises or damage the electrical components and wiring.

CH Flow
Note that all isolation
DHW Outlet
handles are shown in the
Gas Supply open postion.

DHW Inlet
CH Return

Black
Handle Yellow
Pressure Relief Valve
Drain Connection
Handle

15mm elbow
or fittings Gas Pressure Safety
Pressure Relief Valve Blue
(not supplied) Drain Pipe Test Point Drain
Handle Valve
Black
Handle

28 IDEAL CLASSIC - Installation and Servicing

 INSTALLATION

23 ELECTRICAL CONNECTIONS

INSTALLATION
WARNING. This appliance MUST be earthed. Wiring should be 3 core PVC insulated cable, not less than
A mains supply of 230Vac ~ 50 Hz is required. 0.75mm2 (24 x 0.2mm), and to BS 6500 Table 16. For IE
reference should be made to the current ETCI rules for electrical
The fuse rating should be 3A. All external controls and wiring
installations.
must be suitable for mains voltage.
Connection must be made in a way that allows complete isolation
Wiring external to the boiler MUST be in accordance with the
of the electrical supply such as a double pole switch having
current I.E.E. (BS.7671) Wiring Regulations and any local
a 3mm (1/8”) contact separation in both poles. The means of
regulations.
isolation must be accessible to the user after installation.

24 INTERNAL WIRING 2
A mains cable must be connected to a permanent live supply and NOT switched by
thermostats/programmers. To do so follow the instructions below:
1. Swing the lower front panel down. Refer to Frame 33.
2. Route cable through the grommet and cable clamp and tighten to provide cord anchorage.
3. Connect the live, neutral and earth wires to the terminal strip. When making the mains
electrical connections to the boiler it is important that the wires are prepared in such a
way that the earth conductor is longer than the current carrying conductors, such that if
the cord anchorage should slip, the current carrying conductors become taut before the
earthing conductor.
4. Swing the control box back up into the operating position and retain with the screws
previously removed.
The boiler comes pre-fitted with a link wire between the room thermostat/Timer

connections on the terminal strip. This creates a permanent call for heat
and must be removed when adding a room thermostat.
ROOM THERMOSTAT - WIRING
1. Remove link wire between Room stat/timer terminals. Optional
2. Connect room stat as shown in wiring diagram opposite. Frost Stat

3. If room stat has a neutral connection, connect this to terminal N (load) in

the fused spur.
FROST THERMOSTAT - WIRING FROST
STAT
If parts of the system are vulnerable to freezing or the programmer is likely to (OPTIONAL)
be left off during cold weather, a frost stat should be fitted in conjunction with a L N
pipe thermostat. Room
N Stat
1. Position the frost thermostat in a suitable position, i.e. area vulnerable to
freezing.
2. Connect frost stat across terminals marked frost stat as shown in wiring ROOM
diagram opposite. STAT/
TIMER
9989

25 EXTERNAL ELECTRICAL CONTROLS

Use of General Live for Room Stat
Wiring External to the Boiler Room
The fuse rating should be 3A. Stat
Optional
Wiring external to the boiler MUST be in accordance with the current I.E.E. Frost Stat
(BS.7671) Wiring Regulations and any local regulations.
Frost Protection Mains In
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.
Frost Stat L N Room Stat
The frost thermostat should be sited in a cold place but where it can sense heat
from the system.
9990
Note. If the boiler is installed in a garage it may be necessary to fit a pipe
thermostat, preferably on the return pipework. Earths are not shown for clarity but must
never be omitted.

IDEAL CLASSIC - Installation and Servicing 29

 INSTALLATION

30
KEY
b - blue
bk - black
br - brown
r - red PCB
p - pink
y - yellow
w - white
y/g - yellow/green
g - grey
or - orange
v - violet
26 WIRING DIAGRAM

X8 X6 X5 X7 X13 X3 X2 X1C X1B X1A

11 10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1 4 3 2 1 5 4 3 2 1 3 2 1 9 8 7 6 5 4 3 2 1 5 4 3 2 1 6 5 4 3 2 1

y/g
b

br

bk y/g
y bk
b
bk p
bk bk bk bk y/g
p bk b
r or r br
b r
b r

bk
INSTALLATION

y/g Spark
Generator Earth Room Main Frost
bk b br bk
bk y/g Stat Supply Stat
b p y bk b b br b bk
Flame b br r bk
Water Water Flow Return y/g
Sensor y/g
Flow pressure Thermistor Thermistor 1 2 3 4
Electrode
Turbine Switch Fan
bk
Pump

Spark TIMER
Service Electrode Gas Divertor
Connector Valve Valve p bk
y

IDEAL CLASSIC - Installation and Servicing

 INSTALLATION
27 COMMISSIONING AND TESTING

INSTALLATION
A. Electrical Installation B. Gas Installation
1. Checks to ensure electrical safety should be carried out by a 1. The whole of the gas installation, including the meter,
competent person. should be inspected and tested for tightness and purged in
accordance with the recommendations of BS. 6891.
2. ALWAYS carry out the preliminary electrical system checks,
In IE refer to IS.813:2002.
i.e. earth continuity, polarity, resistance to earth and short
circuit, using a suitable test meter. 2. Purge air from the gas installation by the approved methods
only.
3. After wiring the boiler, all grommets in the bottom panel
MUST be in place to ensure that the boiler case sealing is
maintained.

WARNING. Whilst effecting the required gas tightness test and purging air from the gas installation,
open all windows and doors, extinguish naked lights and DO NOT SMOKE.

GENERAL
Please Note: The combustion for this appliance has
been checked, adjusted and preset at the factory for
operation on the gas type defined on the appliance
data plate. DO NOT adjust the air/gas ratio valve.
Having checked:
- That the boiler has been installed in accordance
with these instructions.
- The integrity of the flue system and the flue seals,
as described in the Flue Installation section.
Proceed to put the boiler into operation as follows:
CHECK THE OPERATIONAL (WORKING) GAS
INLET PRESSURE
CH Flow
Set up the boiler to operate at maximum rate by
DHW flow.
opening hot tap to maximum Outlet
With the boiler operating in
the maximum rate condition Gas Supply
check that the operational
(working) gas pressure at DHW Inlet
the inlet gas pressure test
CH Return
point complies with the
requirements - refer to “Gas
Black
Supply” on page 10.
Handle Yellow
Ensure that this inlet pressure
Handle
can be obtained with all other
gas appliances in the property
working. Gas Pressure Safety
Test Point Blue Drain
Handle Valve
Black
Handle
3G9927

As part of the commissioning process, the combustion of this appliance must be checked
and the Benchmark Checklist completed. A flow chart to assist is provided on page 65.

ATTENTION !
IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE
BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED
AND LEFT WITH THE APPLIANCE

IDEAL CLASSIC - Installation and Servicing 31

 INSTALLATION
28 INITIAL LIGHTING 30
INSTALLATION

E
Legend
A. Mode Control Knob off e
status burner

max
B. DHW/Preheat Control
C. CH Control
D. Boiler Status mode
reset min preheat min max preheat

E. Burner ‘on’ Indication

F. Pre Heat on/off Indication A B C D F
G. CH Flow Isolating Valve G N 20 19 18 1

H. Pressure Gauge 21 7
16

22
I 0

15
23
J. Gas Inlet Pressure Test Point

14 13 12 1
24
H
Classic

1
K. Gas Service Cock

2
3

1
10
L
4

L. DHW Inlet valve

5 9
6 8

M
7

M. CH Return Isolating Valve

Black
N. DHW Outlet Handle Yellow
Handle
1. Check that the system has been filled to the required pressure and that
the boiler is not airlocked. Ensure the automatic air vent cap is open. Safety
K Blue
3G9928
J Drain
Note. Handle Black Valve
It is important the burner is not operated before the system is fully Handle
vented of air. If it is necessary to operate the appliance pump to assist
venting of the air this must be done with the gas service cock turned off. MECHANICAL TIMER
2. Refit the boiler upper and lower front panels. Refer to Frame 33. Timer Control Permanently ON

3. Check that the drain cock is closed and that the CH and DHW isolating Permanently OFF
valves (M, L and G) are OPEN.
4. Check that the electrical supply is OFF. 20 19 18 1
21 7
16
5. Check that the boiler mode control knob (A) is off.

22

15
23
6. Check that the gas service cock (K) is OPEN.

1 4 13 1 2 1
24
7. Slacken the screw in the inlet pressure test point (J) and connect a

1
gas pressure gauge via a flexible tube.

2
8. Switch electricity supply ON & check mechanical timer is in “Permanently

1
10
4
On” position. 5 9
6 7 8

CENTRAL HEATING
9. Set the CH temp control (C) to max and turn the mode control knob (A) to
. The boiler control should now go through its ignition sequence until THE DISPLAY
the burner is established. The user control has one neon and one display to
10. If the boiler does not light code will be displayed. After 5 attempts inform the user about the status. The display will
the boiler will lock out and display fault code constantly. Reset the show the status of the boiler. The neon will show
boiler (Refer to Frame 30). The boiler will repeat its ignition sequence. If the status of the flame. If no flame is detected the
reset occurs 5 times within 15 minutes then will be shown. If power is neon is off. When the flame is detected the neon
removed this will be reset. will be lit permanently.
When the burner is established the BLUE ‘Burner On’ neon (E) will be Below is a list with display function in normal
illuminated, the LED display (D) will show status . operation.
DOMESTIC HOT WATER Standby, no demand for heat present.
11. With the boiler firing, set the DHW Temp Control knob (B) to maximum Boiler is active for central heating.
and fully open a DHW tap.
Boiler is active for domestic hot water.
The boiler should continue to run and the LED display (D) should show
status Boiler is heating up the plate heat exchanger.
12. Ensure that with the boiler operating the dynamic gas pressure is able to Boiler is active for boiler frost protection.
obtain maximum output. Refer to Table 2.
Boiler is in lockout for a specific error. Display
IMPORTANT - The gas input to the burner is regulated by the gas valve will be blinking, alternating with a number or
according to the air flow produced by the fan. It is NOT user-adjustable. letter to show which error is detected.
Any interference to sealed settings on the gas valve will adversely
Boiler has a fault for a specific error. Display
affect operation and render our warranty void.
will be blinking, alternating with a number or
For additional gas supply info refer to “Gas Supply” on page 10. letter to show which error is detected.
13. Turn off the DHW tap.
Note: Boiler frost protection - boiler fires if
14. To turn on the DHW pre heat facility, turn the DHW knob (B) fully temperature is below 5 degrees C.
clockwise and then back to the desired setting, a decimal point (F) will
appear in the boiler status window indicating pre heat ‘ON’.
15. To turn off the pre heat facility, turn the DHW knob (B) fully clockwise and Note. The boiler incorporates a fan overrun cycle
then back to the desired setting, the decimal point (F) will disappear in the which MUST NOT be prematurely interrupted by
boiler status window indicating pre heat ‘OFF’. isolation of the mains electricity supply.

32 IDEAL CLASSIC - Installation and Servicing

 INSTALLATION

29 GENERAL CHECKS

INSTALLATION
Make the following checks for correct operation in: WATER CIRCULATION SYSTEM
DOMESTIC HOT WATER (DHW) MODE 1. With the system COLD, check that the initial pressure
1. Fully open all DHW taps in turn and ensure that water flows is correct to the system design requirements.
freely from them. For pre-pressurised systems, this should be 1.0 bar.
The display should read: 2. With the system HOT, examine all water connections
for soundness. The system pressure will increase with
temperature rise but should not exceed 2.5 bar.
then:
when the burner lights. 3. With the system still hot, turn off the gas, water and
electricity supplies to the boiler and drain down to
2. Close all taps except the furthest one from the boiler and check
complete the flushing process.
that the boiler is firing at maximum rate.
Note: A flushing solution should be used during the
This is factory set to give a DHW temperature rise of flushing procedure. Flushing solutions: Fernox
approximately 35oC at the flow rate stated on page 8 under Superfloc, Sentinel X300 (new systems) or X400
“operation”. (existing systems). Refer to Frame 4.
3. Reduce the DHW draw-off rate to about 3 l/min (0.7gpm) and 4. Refill and vent the system, add inhibitor (see Frame
check that the boiler modulates to deliver DHW at approximately 4), clear all air locks and again check for water
64oC. soundness.
4. Close the DHW tap and check that the main burner extinguishes. 5. Reset the system initial pressure to the design
The pump should overrun for 60 seconds and the display requirement.
sequence should read: 6. Balance the system. Refer to Frame 3.
7. Check the condensate drain for leaks and check that it
When the pump stops the display sequence should read: is discharging correctly.
8. Finally, set the controls to the User’s requirements.
Note. On systems in excess of 2 bar inlet pressure a water Note: The pump will operate briefly as a self-check
pressure governor may be required to prevent water noise. once every 24 hours in the absence of any system
demand.
CENTRAL HEATING (CH)
& DOMESTIC HOT WATER (DHW) MODE.

1. Ensure that the CH external controls are calling for heat.

The display should read:

2. Fully open a DHW tap and check that hot water is delivered.
The display should read:


3. Gas Rate WATER TEMPERATURES
Check the boiler gas rate when the boiler is at full DHW Temperatures can be selected using the CH and DHW thermostats.
output.
Knob Setting CH Flow Temp DHW Outlet Temp
Check at the gas meter, with no other appliance in use. o
C (oF) o
C (oF)
Refer to Tables 2 & 3 for gas rates.
Max 80 (176) 64 (147)
4. Close the DHW tap. Min 45 (113) 40 (104)

5. Set the central heating external controls to OFF. The burner Due to system variations and seasonal temperature
should go off and the pump continue to run for four minutes fluctuations DHW flow rates/temperature rise will vary, requiring
The display should read: adjustment at the draw off tap : the lower the rate the higher the
temperature, and vice versa.

6. Check the correct operation of the timer and all other system
controls. Operate each control separately and check that the
main burner responds.

IDEAL CLASSIC - Installation and Servicing 33

 INSTALLATION
30 RESET PROCEDURE
INSTALLATION

To reset the boiler, turn the mode control (A) to the reset position and immediately turn the knob back to the required setting.
The boiler will repeat the ignition sequence if a heat demand is present.
30
E

off status burner

e
max

reset min preheat min max preheat

mode

A B C D F
20 19 18 1
21 7
16

22
I 0

15
23

14 13 12 1
24
Classic

1
2
Legend

1
10
4
5 9
6 7 8

A. Mode Control Knob D. Boiler Status

B. DHW Control E. Burner ‘on’ Indication
C. CH Control F. Pre Heat on/off Indication

31 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 Instructions to the householder and 7. Draw attention to the timer Users Instructions and hand them
explain his/her responsibilities under the relevant national to the householder.
regulations.
8. Loss of system water pressure
2. Explain and demonstrate the lighting and shutting down
Explain that the dial underneath the boiler indicates the
procedures.
central heating system pressure and that if the normal
3. The operation of the boiler and the use and adjustment of all COLD pressure of the system is seen to decrease over a
system controls should be fully explained to the householder, period of time then a water leak is indicated. Explain the re-
to ensure the greatest possible fuel economy consistent with pressurising procedure and if unable to re-pressurise or if the
the household requirements of both heating and hot water pressure continues to drop a registered local heating installer
consumption. should be consulted.
Advise the User of the precautions necessary to prevent 9. Explain Boiler reset procedure.
damage to the system and to the building, in the event of the
10. After installation and commissioning please complete
system remaining inoperative during frosty conditions.
4. Explain the function and the use of the boiler heating and
domestic hot water controls. the Commissioning Checklist before
Explain that due to system variations and seasonal handover to the customer. For IE, its is necessary to
temperature fluctuations DHW flow rates/temperature complete a “Declaration of Conformity” to indicate compliance
rise will vary, requiring adjustment at the draw off tap. It to I.S. 813:2002.
is therefore necessary to draw the users attention to the IMPORTANT
section in the Users Instructions titled “Control of Water
Temperature” and the following statement: 11. A comprehensive service should be carried out ANNUALLY.

“Additionally, the temperature can be controlled by the Stress the importance of regular servicing by a Gas Safe
user via the draw-off tap: the lower the rate the higher Registered Engineer. In IE servicing work must be carried out
the temperature, and vice versa”. by a Registered Gas Installer (RGII).

5. Explain the function of the boiler fault mode. 12. Inform the householder of the guarantee/registration found
within the envelope pack and the requirement to register it to
Emphasise that if a fault is indicated refer to “Fault Codes” in
receive the full benefit of the warranty.
the User Guide.
6. Explain and demonstrate the function of time and
temperature controls, radiator valves etc., for the economic
use of the system.

34 IDEAL CLASSIC - Installation and Servicing

 SERVICING
32 SERVICING SCHEDULE
For the very latest copy of literature for specification & maintenance practices, visit our website www.idealboilers.com where you
will be able to download the relevant information.
WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity
supply to the appliance before servicing.
Combustion testing must be carried out by a competent person using a combustion analyser conforming to BS7927.
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 Gas Safe Registered Engineer. In IE service work must be carried out
by a Registered Gas Installer (RGII).

INSPECTION GENERAL
1. Light the boiler and carry out a pre-service check, noting any Please Note: During routine servicing, and after any
operational faults. maintenance or change of part of the combustion
2. Check the flue terminal (and terminal guard if fitted) is undamaged circuit, the following must be checked:
and clear of any obstruction. - The integrity of the flue system and the flue seals,
3. Check all water and gas joints for signs of leakage. Remake any - The integrity of the boiler combustion circuit and
suspect joints ensuring a gas tightness check is carried out if the relevant seals
applicable and the water system is correctly refilled, vented and - The operational (working) gas inlet pressure at
re-pressurised. maximum rate.
CLEANING PROCEDURE - The gas rate
Note. In order to carry out either servicing or replacement of - The combustion performance.
components the boiler upper and lower front panels must be
removed. Refer to Frame 33. COMPETENCE TO CARRY OUT THE CHECK

SERVICING
1. Clean the main burner. Refer to frame 35. OF COMBUSTION PERFORMANCE
Please Note: BS 6798:2009 Specification for
2. Clean the heat exchanger & condensate trap/siphon. Refer to
installation and maintenance of gas-fired boilers of
Frames 36 & 37.
rated input not exceeding 70kW net advises that:
3. Check the main injector for blockage or damage. Refer to Frame
- The person carrying out a combustion
41.
measurement should have been assessed as
4. Check that the flue terminal is unobstructed and that the flue system competent in the use of a flue gas analyser and the
is sealed correctly. interpretation of the results.
ALSO IF THE DHW FLOW RATE IS IN QUESTION :- - The flue gas analyser used should be one meeting
the requirements of BS7927 or BS-EN50379-3
5. Check the DHW filter for blockage. Refer to Frame 61. and be calibrated in accordance with the analyser
The cleaning procedures are covered more fully in Frames 34-38 and manufacturers requirements, and
MUST be carried out in sequence. - Competence can be demonstrated by satisfactory
IMPORTANT. completion of the CPA1 ACS assessment, which
6. After completing the servicing or exchange of components always covers the use of electronic portable combustion
ensure all gas valve connections are gas tight with a gas soundness gas analysers in accordance with BS7967, Parts 1
check up to the gas control valve. to 4.

7. When work is complete the front panels MUST be correctly refitted,

ensuring that a good seal is made.

Do NOT OPERATE the boiler if the upper front panel is

not fitted. Flue Sampling Point
8. If, for any reason, the condensate trap/siphon has been removed Air Sample
ensure the trap is refilled with water before Point
reassembling.
9. Check the gas consumption.
10. Check combustion by connecting the flue gas analyser to the flue
gas sampling point as shown in the diagram and measure CO &
CO2.
Ensure all caps and seals
If the CO/CO2 ratio is greater than 0.004 AND the integrity of the are re-fitted after use
complete flue system and combustion circuit seals have been
verified and the inlet gas pressure (and gas rate) have been
verified, then contact Ideal Boilers.
11. Complete the service section in the Benchmark Commissioning
Checklist.

IDEAL CLASSIC - Installation and Servicing 35

 SERVICING
33 BOILER UPPER & LOWER FRONT PANEL REMOVAL / REPLACEMENT

REMOVAL REPLACEMENT
1. Lift the lower front panel access panel. 4. Hook the upper panel onto the top retaining clips.
2. Unscrew the two fixing screws, close the access panel to 5. Retain the upper panel with the two fixing screws previously
retain the two screws and hinge the lower front panel down removed ensuring a good seal is made.
into the service position.
6. Swing the lower front panel up and retain with the two
3. Remove the two upper front panel fixing screws, lift the screws.
panel and remove.
7. Close the lower front panel access panel.

2&6 3&5

1&7
SERVICING

34 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING

1. Disconnect the electrical leads from the fan. 1

3
2. Remove the clip from the gas control valve
outlet and ease the pipe upwards rotate and
then ease down to remove.
3. Remove the extended nut on the fan
mounting bracket.
4. Lift off fan and venturi assembly.
5. Inspect the injector for blockage or damage.
6. Inspect fan outlet sealing gasket and 5
replace if necessary.

Injector

36 IDEAL CLASSIC - Installation and Servicing

 SERVICING
35 BURNER REMOVAL AND CLEANING

1. Ensure the sump is fully drained 3

2. Undo the two screws and remove the sump cover retaining the lower 2 2
flue manifold.
3. Lift the manifold to clear the bottom sealing gasket and remove
manifold.
4. Remove the 2 burner front fixing screws and loosen the 2 rear
extended nuts by at least ten turns.
5. Lift off the burner from the combustion chamber. To facilitate the
removal angle the burner as shown.
IMPORTANT
The burner head is a ceramic plaque construction. Care must be taken
to ensure that the burner is not placed down upon its face as this
may cause damage to the ceramic.
6. Brush off any deposits that may be on the ceramic with a SOFT brush. 4
7. Inspect the sealing gasket around the burner for any signs of
damage. Replace as necessary.

SERVICING
4

36 CLEANING THE CONDENSATE TRAP/SIPHON

Note: Ensure condensate trap is fully drained before removal.
1. Pull off the rubber pipe at the siphon.
2. Disconnect the condensate drain pipe.
3. Turn the siphon clockwise to disengage and lift to remove.
4. Flush out all deposits with clean water.
5. Reassemble in reverse order
Note. When reassembling ensure the trap is full of water

IDEAL CLASSIC - Installation and Servicing 37

 SERVICING
37 CLEANING THE HEAT EXCHANGER

1
Note: Ensure the condensate trap/siphon
is fully drained before cleaning. Refer to Ignition Electrode Flame Detection
Frame 48.
1. Remove ignition and flame detection
electrodes. Refer to Frames 43 & 44.
2. It is advisable to replace the sump cover
prior to the water flush process.
3. Thoroughly flush the heat exchanger
by pouring water into the top of the
combustion chamber ensuring the full top
area is covered.
4. Remove the sump cover and clean loose
deposits from the sump.
Earth Wire
5. Inspect the ignition and detection 3
electrodes. Ensure that they are clean
and in good condition - replace if
necessary.
6. Re-fit the ignition and flame detection
SERVICING

electrodes. Ensure that earth wire is

connected to the electrode
7. Check that the ignition and detection gaps
are correct. Refer to Frames 43 & 44.

38 REASSEMBLY
Reassemble the boiler in the following order:
1. Ensure that the condensate trap/siphon is full of water. 6. Refit the sump cover.
2. Refit the burner ensuring the sealing gasket is correctly 7. Refit the boiler upper and lower front panels.
positioned and free from damage (tighten the 4 fixing screws
in the sequence A,B,C,D, shown below). IMPORTANT. Ensure that the boiler upper front panel is
correctly fitted and that a good seal is made.
3. Refit the fan / venturi assembly ensuring the retaining tabs
are correctly positioned and the sealing gasket is correctly 8. Turn on the gas supply at the gas service cock.
positioned and free from damage. 9. Reconnect the electrical supply.
4. Reconnect the fan electrical leads.
5. Remove the sump cover and refit the lower flue manifold as
shown.

D
B

A
C

38 IDEAL CLASSIC - Installation and Servicing

 SERVICING
39 REPLACEMENT OF COMPONENTS

GENERAL IMPORTANT.
When replacing ANY component Ensure all gas valve connections are gas tight with a gas
soundness check up to the gas control valve.
1. Isolate the electricity supply.
When work is complete, the front panels must be correctly
2. Turn off the gas supply. refitted - ensuring that a good seal is made.
3. Remove the lower front panel fixing screws, swing the panel Notes.
into the servicing position and remove the upper front panel. 1. In order to assist fault finding, the control panel has an
Refer to Frame 33. LED diagnostic display.
2. In order to replace components in Frames 53-65 it is
After replacing ANY component check operation of the boiler, necessary to drain the boiler. Refer to Frame 52.
including gas soundness, gas rate and combustion test.

THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED

SERVICING
40 FAN REPLACEMENT

1. Refer to Frame 39.

8 Retaining Tabs
2. Disconnect the electrical leads from the fan.
2
3. Remove the clip from the gas control valve
outlet.
4. Remove the extended nut retaining the fan
mounting bracket.
5. Lift and remove the fan and venturi assembly.
6. Remove the screw and twist venturi anti- 4
clockwise to remove 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 ‘o’ ring if evidence of damage or
deterioration is visible.
8. Fit the new fan / venturi assembly ensuring the 6
retaining tabs are correctly positioned and the
fan outlet sealing gasket is correctly positioned
and free from damage. Refit the extended nut.
9. Reassemble the boiler in reverse order, taking
care not to overtighten the screw on the fan
mounting bracket and ensure all gas ‘o’ rings
are in place
10. Check the operation of the boiler. Refer to 3
Frames 28 & 29.

IDEAL CLASSIC - Installation and Servicing 39

 SERVICING
41 BURNER INJECTOR REPLACEMENT
2
4
1. Refer to Frame 39.
2. Disconnect the electrical leads from the
fan.
3. Remove the clip from the gas valve to
venturi pipe and ease the pipe upwards,
rotate and ease down to remove.
4. Loosen the screw retaining the fan
mounting bracket.
5. Lift and remove the fan and venturi 6
assembly.
6. Remove the 2 injector housing screws.
7. Withdraw the injector housing.
8. Fit the new injector housing complete
with injector.
9. Reassemble in reverse order, ensuring
that the new gas seal supplied is located
correctly in the injector housing.
SERVICING

3
10. Check operation of the boiler. Refer to
Frames 28 & 29.

42 BURNER REPLACEMENT
1. See Frame 39.
4
2. Remove Fan. Refer to Frame 40.
3. Undo the two screws and remove the sump cover. 3 3
4. Lift the manifold to clear the bottom sealing gasket and remove
manifold.
5. Remove the 2 front fixing screws and loosen the 2 rear
extended nuts.
6. Lift off the burner from the combustion chamber. To facilitate
the removal angle the burner as shown.
7. Fit the new burner, replacing any damaged or deteriorating
sealing gasket.
8. Reassemble in reverse order.
5
9. Check the operation of the boiler. Refer to Frames 28 & 29.

40 IDEAL CLASSIC - Installation and Servicing

 SERVICING

43 IGNITION ELECTRODE REPLACEMENT

1. Refer to Frame 39.
2. Remove the burner. Refer to Frame 42.
3. Unplug the ignition lead from the electrode.
4. Remove the earth lead from the ignition Ignition Electrode
electrode.
5. Remove the 2 screws holding the ignition
electrode to the combustion chamber.
6. Remove the electrode.
7. Fit the new ignition electrode, using the new
gasket supplied. Check dimensions as shown.
8. Reassemble in reverse order.
9. Check the operation of the boiler. Refer to
Frames 28 & 29.

ge
t ed
Spark Gap h
aig
3.5mm Str

m
3m

SERVICING
44 FLAME DETECTION ELECTRODE REPLACEMENT
1. Refer to Frame 39.
2. Remove the burner. Refer to Frame 42.
3. Unplug the flame detection lead from the
electrode. Flame Detection Electrode
4. Remove the 2 screws retaining the detection
electrode.
5. Remove the electrode.
6. Fit the new flame detection electrode, using the
new gasket supplied.
7. Reassemble in reverse order.
8. Check the operation of the boiler. Refer to
Frames 28 & 29.

ge
t ed
h
aig
Str

m m
1 2.5

IDEAL CLASSIC - Installation and Servicing 41

 SERVICING

45 SPARK GENERATOR REPLACEMENT

1. Refer to Frame 39.

2. Disconnect the leads from the spark
generator.
3. Pull the spark generator to unclip
from the mounting bracket. Spark Generator 3
4. Fit the new spark generator and re-
assemble in reverse order ensuring
that the the earth lead is replaced.
5. Check operation of the boiler. Refer
to Frames 28 & 29.
SERVICING

46 GAS CONTROL VALVE REPLACEMENT

1. Refer to Frame 39.
2. Unplug the electrical lead connection
from the gas control valve and
disconnect the earth wire.
3. Remove the outlet gas valve clip and 2
slide the pipe upwards.
4. Undo the gas inlet pipe union at the
inlet to the gas control valve.
5. Undo the single screw fixing the gas 5
valve to the mounting bracket and
withdraw the valve forwards. To gain
access, temporarily move the seal.
6. Fit the new gas control valve, ensuring
that the ‘o’ ring and sealing washer
are in place. Replace screw and re-
connect gas and electrical connections.
Ensure sealing washer is fully
located.
7. Ensure all gas valve connections are
gas tight with a gas soundness check
up to the gas control valve.
8. Check operation of the boiler. Refer to
Frames 28 & 29.

42 IDEAL CLASSIC - Installation and Servicing

 SERVICING

47 DIVERTER VALVE ACTUATOR REPLACEMENT

To remove the motor:

1. Refer to Frame 39.
2. Remove the condensate trap/siphon. Refer to
Frame 48.
3. Disconnect the inline connector block.
4. Place a flat bladed screwdriver in the actuator slot
provided and ease out the actuator.
5. Before replacing the diverter valve actuator 3
proceed as follows:
a. Re-connect the inline connector
block.
b. Ensure that the switched live to the boiler is
off and that all DHW taps are shut and that
pre-heat is switched off.
c. Hold the mode knob in the reset position for
more than 10 secs.
d. The display will alternate between “d” and
“U” and the actuator will move into the mid-

SERVICING
position.
e. The divertor valve will initially drive all the
way out, this may cause the spindle to
become detached from the body. If this
occurs simply screw back into the body so
the cycle can continue driving fully in before
going to mid-position.
f. Replace the actuator into the boiler.
6
6. Fit the new motor ensuring the arm is correctly
engaged in the metal fork and re-assemble in
reverse order ensuring the condensate trap/
siphon is refilled with water.
7. Check the operation of the boiler. Refer to Frames
28 & 29.
Note. All spares will be delivered in mid-position
therefore ignore point 5 and proceed to point 6 after
re-connecting the inline connector.

48 CONDENSATE TRAP/SIPHON REPLACEMENT

3

1. Refer to Frame 39.

Note: Ensure condensate trap is fully drained 2
before removal.
2. Pull off the rubber pipe at the SIPHON.
3. Disconnect the condensate drain pipe.
4. Turn the siphon clockwise to disengage and
lift to remove.
5. Reassemble in reverse order.
6. When reassembling ensure the trap is full of
water.
7. Check operation of the boiler. Refer to
Frames 28 & 29.

IDEAL CLASSIC - Installation and Servicing 43

 SERVICING

49 MAIN PCB REPLACEMENT

* Note. that production boiler PCB’s are

factory pre-set to operate for boiler range and
output, but when ordering Primary PCB as a
spare, an additional Boiler Chip Card (BCC)
MUST also be purchased for your specific
boiler range and output.

Note. Fit the earth strap provided with the

PCB to your wrist and secure to a suitable
earth on the boiler chassis.

1. Refer to Frame 39.

2. Note the control knob positions.
3. Remove the 2 screws retaining the control
box cover.
4. Carefully lift the cover at the front & pull
forward to remove. 3
5. Unplug all lead connections to the PCB
including the ribbon cable.
6. Spring out the two side retaining clips and pull the PCB 10. a. Turn power on
SERVICING

upwards to clear the retaining posts. b. Displays “8” blue light on/off, “first digit input”, “second
7. Take the new Primary PCB and attach the appropriate digit input”, “1st letter appliance type”, i.e. “2”, “4”, “c”
Boiler Chip Card (BCC) to it (this should correspond to c. Move knob to required setting (standby, summer,
the output of the boiler: 24kW, 30kW or 35kW). winter)
Note. Ensure the correct orientation of BCC by placing Note. If no BCC fitted on non programmed board “C2” will
“TOP” side up. be displayed. The correct BCC for this appliance will need
to be fitted.
8. Re-connect all plug connections.
11. Check operation of the boiler. Refer to Frames 28 & 29.
9. Reassemble in reverse order.

Plastic
Clip 5 5
6

Ribbon Cable Connection

44 IDEAL CLASSIC - Installation and Servicing

 SERVICING
50 USER CONTROL PCB REPLACEMENT
Note. Fit the earth strap provided with the PCB to your
wrist and a suitable earth on the boiler chassis.
1. Refer to Frame 39.
2. Remove the main PCB, refer to Frame 49.
3. Unclip the PCB and lift to clear the mounting posts.
4. Fit the new PCB ensuring the 3 potentiometer
spindles line up with the control knobs which must
be in a vertical position.
5. Reassemble in reverse order.
6. Check operation of the boiler. Refer to Frames 28 &
29.

PCB

SERVICING
Potentiometer spindle

Control Knobs (to be in vertical position)

30

off status burner

e
max

reset min preheat min max preheat

mode

20 19 18 1
21 7
16
22

I 0
15
23

14 13 12 1
24

51 REPLACING THE MECHANICAL TIMER Classic

1
2
3

1
10

4
5 9
6 7 8

4
1. Refer to Frame 39.
2. Swing the boiler lower front panel into the service
position. Refer to Frame 33.
3. Remove the 4 fixing screws.
4. Disconnect the 4 push on connectors.
5. Remove programmer.
6. Re-fit 4 push on connectors to new programmer.
7. Fit programmer and retain with 4 screws previously
removed. 3
8. Replace the lower front panel.
9. Check operation of the boiler. Refer to Frames 28 &
29.
Note. To program refer to user guide at rear of this
book.

IDEAL CLASSIC - Installation and Servicing 45

 SERVICING
52 DRAINING THE BOILER

CENTRAL HEATING CIRCUIT

1. Refer to Frame 39.
2. Close all the CH water isolating valves on the boiler inlet.
3. To drain the primary heat exchanger circuit: Open the drain
valve and attach a length of hose to the CH drain point.
4. After replacing any component on the boiler, remove the hose,
close the drain valve and open all system isolating valves (re-
pressurise as appropriate).
5. Check operation of the boiler. Refer to Frames 28 & 29.

9960
CH
Gas DHW Circuit
DOMESTIC HOT WATER CIRCUIT CH DHW Inlet Drain
Flow CH
1. Refer to Frame 39. Outlet
Return
2. Close the DHW water isolating valve on the boiler inlet.
3. To drain the domestic hot water circuit: As there is no direct drain for the domestic hot water circuit, depending on the
location of the boiler, opening the lowest hot water tap may drain this circuit. However it must be noted that some residual
water will be experienced during replacement of components.
SERVICING

4. After replacing any component on the boiler, close tap, close the drain valve and open all system isolating valves (re-
pressurise as appropriate)
5. Check operation of the boiler. Refer to Frames 28 & 29.

53 DHW FLOW TURBINE SENSOR REPLACEMENT

1. Refer to Frame 39.

2. Drain the DHW system. Refer to
Frame 52.
3. Pull off the electrical connection. 5

4. Using a suitable tool, lift and

remove the retaining clip.
5. Use the clip to ease the turbine
sensor from its housing. 4
6. Re-assemble in reverse order.
7. Check operation of the boiler. 3
Refer to Frame 28 & 29.

54 PRESSURE GAUGE RENEWAL

1. Refer to Frame 39.

2. Drain the heating system. Refer to Frame 52.
3. Unscrew the pressure gauge and discard.
4. Fit new pressure gauge, using suitable jointing
compound.
5. Refill the boiler.
6. Check operation of the boiler. Refer to Frames
28 & 29.

46 IDEAL CLASSIC - Installation and Servicing

 SERVICING
55 SAFETY RELIEF VALVE RENEWAL

1. Refer to Frame 39.

2. Drain the boiler. Refer to Frame 52.
3. Remove the return thermistor. Refer to
frame 63.
4. Pull out and remove the clip (positioned
behind the safety valve) retaining the
safety valve.
5. Undo the safety valve pipe compression
fitting positioned outside the boiler
casing.
6. Lift out the safety valve/pipe assembly.
7. Remove the safety valve pipe and
transfer to the new safety valve.
8. Reassemble in reverse order ensuring
the retaining clip is correctly fitted and 7 4
the pipe compression fitting retightened.
9. Refill the boiler. Check operation of the

SERVICING
boiler. Refer to Frames 28 & 29.

56 PUMP AUTOMATIC AIR VENT REPLACEMENT

4 3

1. Refer to Frame 39.

2. Drain the boiler. Refer to Frame 52.
3. Remove the return thermistor. Refer to Dust Cap
Frame 63.
4. Using a suitable screwdriver positioned
between the air vent dust cap and the plastic
protrusion, turn the air vent carefully anti
clockwise to disengage and lift to remove.
5. Fit the new air vent and ensure dust cap is
open
6. Re-assemble in reverse order ensuring the
return thermistor is replaced.
7. Refill the boiler. Check operation of the
boiler. Refer to Frames 28 & 29.

IDEAL CLASSIC - Installation and Servicing 47

 SERVICING
57 DIVERTER VALVE BODY ASSEMBLY REPLACEMENT
To remove the valve body assembly: 16. Twist and remove the DHW manifold.
1. Refer to Frame 39. 17. Remove the two diverter valve body fixing screws and
2. Drain the boiler. Refer to frame 52. withdraw the diverter valve body assembly.
3. Remove the condensate trap/siphon. Refer to Frame 48. 18. Fit the new diverter valve body assemble and replace the
two fixing screws.
4. Remove the electrical plug. Refer to Frame 47.
19. Refit the DHW manifold, fit the assembly back to the boiler
5. Place a flat bladed screwdriver in the diverter valve motor
and reassemble in reverse order.
body slot provided and ease out the motor Refer to Frame
47. 20. Refill the boiler. Check operation of the boiler. Refer to
Frames 28 & 29.
6. Remove the return thermistor electrical connection. Refer to
Frame 63.
7. Remove the pump electrical connection. Refer to Frame 59 no. 3.
8. Remove DHW Turbine electrical connection. Refer to
Frame 53 no. 3. 18
12
9. Remove the DHW plate heat exchanger (note orientation). 11
17
Refer to Frame 58.
10. Undo the safety valve pipe compression fitting. See No.5
Frame 55.
11. Remove the compression fitting above the pump and rotate
the pipe.
SERVICING

12. If required remove expansion vessel connection hose.

Refer to Frame 65, no. 8. 14

13. Remove the DHW inlet and CH return connection situated

beneath the boiler.
16
14. Remove the three torx head screws fixing the return
manifold to the boiler sheet steel base.
13
15. Lift the manifold assembly and remove from boiler.

58 DHW PLATE HEAT EXCHANGER REPLACEMENT 4

1. Refer to Frame 39.
2. Drain the boiler. Refer to frame 52.
3. Remove the condensate siphon. Refer to Frame 48.
4. Remove the two plate heat exchanger fixing screws.
5. Slide the plate heat exchanger to the left and push the plate
back to disengage.
6. Remove the plate heat exchanger.
7. Fit the new plate heat exchanger using the new ‘O’ rings
provided and re-assemble in reverse order.
Note. Ensure dimples and “bottom” are lower most.
8. Refill the boiler.
9. Check operation of the boiler. Refer to Frames 28 & 29.

59 PUMP HEAD REPLACEMENT

1. Refer to Frame 39. 3
2. Drain the boiler. Refer to Frame 52.
3. Disconnect the two electrical leads from the pump.
4. Remove the 4 Allen screws retaining the pump head.
5. Remove the pump head. 4
6. Fit the new pump head.
7. Reassemble in reverse order.
8. Refill the boiler.
9. Check operation of the boiler. Refer to Frames 28 & 29.

48 IDEAL CLASSIC - Installation and Servicing

 SERVICING
60 CH WATER PRESSURE SWITCH REPLACEMENT
1. Refer to Frame 39.
2. Drain the boiler. Refer to frame
52. 4
5
3. Pull off the two electrical
connections.
4. Using a suitable tool, pull out the
metal retaining clip.
5. Carefully withdraw the pressure
switch.
6. Fit the new pressure switch and
re-assemble in reverse order.
7. Refill the boiler.
8. Check operation of the boiler.
Refer to Frames 28 & 29.
3

61 DHW FILTER & DHW FLOW REGULATOR CLEANING/REPLACEMENT

1. Refer to Frame 39.

SERVICING
2. Drain the boiler. Refer to frame 52.
3. Turn the housing anti clockwise and pull
forward to remove the cartridge.
3
4. Using a pair of pliers, pull out the plastic
filter/flow regulator.
5. Clean or replace filter as necessary.
6. Reassemble in reverse order.
7. Refill the boiler.
4
8. Check operation of the boiler. Refer to
Frames 28 & 29.

62 FLOW THERMISTOR REPLACEMENT

1. Refer to Frame 39. 3
4
2. Drain down the boiler. Refer to Frame 52.
3. Unplug the electrical lead.
4. Unscrew the thermistor (to facilitate removal a 13mm
socket spanner should be used).
5. Fit the new thermistor using the sealing washer provided.
6. Reassemble in the reverse order.
7. Refill the boiler.
8. Check the operation of the boiler. Refer to Frames 28 & 29.

IDEAL CLASSIC - Installation and Servicing 49

 SERVICING
63 RETURN THERMISTOR REPLACEMENT
1. Refer to Frame 39.
3
2. Drain the boiler. Refer to frame 52.
3. Unplug the electrical connection.
4. Using a suitable tool, pull out the retaining clip.
5. Carefully pull the thermistor upwards to remove.
6. Fit the new thermistor and re-assemble in reverse order.
7. Refill the boiler. 4
8. Check the operation of the boiler. Refer to Frames 28 & 29.

64 HEAT ENGINE RENEWAL Refer also to Frame 5 - ‘Boiler Exploded View’

IMPORTANT - Before starting the removal procedure, protect the
gas and electrical controls with a waterproof sheet or plastic bag.

1. Refer to Frame 39. 14. Remove the two heat exchanger fixing screws.
2. Drain the boiler. Refer to Frame 52. 15. To remove the Heat exchanger slide out of location bracket.
SERVICING

3. Remove the fan / venturi assembly and place on one side. 16. If replacement sump required: Rotate heat exchanger
Refer to Frame 40. assembly 180º. Place new sump onto heat exchanger,
4. Remove burner and place on one side. Refer to Frame 42. ensuring correct orientation and seal is in place. Then
gently apply pressure to the base of the sump at each tab
5. Remove the ignition and detection electrodes. Refer to
fixing point and engage tabs onto the heat exchanger.
Frames 43 & 44.
17. Reassemble in reverse order, ensuring the heat exchanger LH
6. Remove the spark generator. Refer to Frame 45.
retaining bracket is correctly positioned. Replace any new ‘o’
7. Remove the gas valve. Refer to Frame 46. rings supplied with new heat exchanger and replacing gaskets
8. Remove the expansion vessel. Refer to Frame 65. or seals if any sign of damage is evident. When replacing the
9. Remove the flow thermistor. Refer to Frame 62. spring clips located on the return pipe connection, ensure clip
is oriented to correctly match connecting pipe diameters.
10. Remove the 2 M5 screws retaining the gas valve mounting
bracket and transfer bracket to the new heat exchanger. 18. Ensure the trap/siphon is filled with water. Refer to Frame
48.
11. Undo the inlet pipe union nut, swing the pipe and pull down
to remove from heat exchanger. 19. Refill the boiler.
12. Pull out the flow pipe spring clip, pull the pipe down to 20. Ensure all gas valve connections are gas tight with a gas
remove from heat exchanger. soundness check up to the gas control valve.
13. Remove the condensate rubber pipe from the sump. 21. Check operation of the boiler. Refer to Frames 28 & 29.

14

10

Shown as 180º position

13 11

12

16

50 IDEAL CLASSIC - Installation and Servicing

 SERVICING
65 EXPANSION VESSEL RECHARGING & REPLACEMENT
RECHARGING
1. Refer to Frame 39. Recharge
2. Remove the charge point cover. Point
3. Recharge the tank pressure to 0.75 bar.
4. Re-assemble in reverse order
5. Check operation of the boiler. Refer to Frames 28 8
& 29.
REPLACEMENT
6. Refer to Frame 39.
7. Drain the boiler CH circuit. Refer to Frame 52.
8. Remove the retaining clip on the vessel connection
pipe.
9. Support the expansion vessel and unscrew the 2
screws from the securing clamp, located on the top
of the boiler, and remove. (Note the position of the
bracket on the vessel) 9
10. Remove the expansion vessel taking care not to
damage the adjacent wiring harness.
11. Fit the new expansion vessel.
12. Reassemble in reverse order ensuring the ‘o’ ring
seal is in place.
13. Refill the boiler.

SERVICING
14. Check operation of the boiler. Refer to Frames 28
& 29.

66 BOILER SEALING PANEL SEAL REPLACEMENT

1. Refer to Frame 39.

2. Remove the old seal from the casing and
thoroughly clean the casing surfaces.
3. Fit the new self adhesive seal ensuring all
joints provide an air tight seal.
5. Reassemble in reverse order.
6. Check operation of the boiler. Refer to
Frames 28 & 29.
Note. Ensure that the boiler front panel is
correctly sealed, compressing the seal
to make an airtight joint.

IDEAL CLASSIC - Installation and Servicing 51

 FAULT FINDING
67 ALTERNATING ‘L’ AND ‘1’ - FLOW TEMPERATURE OVERHEAT LOCKOUT
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Is the Boiler and CH System filled with water and all NO Fill and vent the system and open all
isolation and radiator valves open? isolation valves, then reset boiler

YES

Is the Flow/Return Differential across the Boiler in YES Check that the Pump is rotating freely. Is
excess of 30°C? the Differential now below 20°C?

NO NO YES

Check the Flow and Return Thermistors (Refer to OK, now

Replace the Pump,
Frame 74 & 75) reset boiler
then reset boiler

RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.

68 ALTERNATING ‘L’ AND ‘2’ - IGNITION LOCKOUT

If the boiler is reset does the boiler NO Is the Gas Pressure available at NO Check gas supply and
ignite for a short time and then the Boiler Inlet (>18 mbar)? rectify fault
extinguish?
YES

YES Check wiring connection

Is 215Vdc supply available at the NO
from gas valve to PCB for
Gas Valve? (* See note)
continuity. If the wiring is
Check the detection electrode OK then replace the PCB
YES
and associated harness for:
continuity, visual condition and
position (Refer to Frame 44). Unplug gas valve. Is resistance NO
Check if the condensate pipe is between outside pins 4KΩ (±2)? Replace Gas Valve
blocked.
Check flue is installed correctly. YES
Replace as necessary
Check spark generator and NO
associated harness for: continuity Replace Spark
and visual condition. (Refer to Generator and harness
Frame 45) Are these functioning as necessary
correctly?

YES

Replace Ignition
Check siphon and condensate Check ignition electrode and NO
YES Electrode and
drain pipe work for blockage and associated harness for: continuity,
associated harness as
rectify if necessary. Boiler now visual condition and position.
necessary
working OK? (Refer to Frame 43) Are these
functioning correctly?
NO

Replace Gas Valve

* Note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the
value. In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve.

RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.

52 IDEAL CLASSIC - Installation and Servicing

 FAULT FINDING

69 ALTERNATING ‘L’ AND ‘5’ - 5 RESETS WITHIN 15 MINS

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
Turn power off and on

70 ALTERNATING ‘L’ AND ‘6’ - FALSE FLAME LOCKOUT

YES Check routing and integrity of internal boiler

Reset the boiler, does Boiler Work OK? wiring is OK. Check condition of Flame Sense
Electrode and replace if deteriorated.
NO

Separate the flame detection electrode in-line YES

connector. Is there continuity between the terminals Replace Flame Detection Electrode
pins connected to the electrode?

NO

Check routing and integrity of internal boiler wiring.

RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.

71 ALTERNATING ‘F’ AND ‘1’ - LOW WATER PRESSURE

Are the Boiler and CH System filled with water and NO Fill and vent the system and open all
all isolation and radiator valves open (check pressure isolation valves
gauge is between 1 to 1.5 bar)?

YES
NO
Are connections on water pressure switch secure? Re-fit connections

YES

Replace water pressure switch

IDEAL CLASSIC - Installation and Servicing 53

 FAULT FINDING
72 ALTERNATING ‘F’ AND ‘2’ - FLAME LOSS
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Does the boiler ignite for a short NO Is the Gas Pressure available at NO Check gas supply and
time and then extinguish? the Boiler Inlet (18 mbar)? rectify fault

YES YES

Check the detection electrode and

associated harness for: continuity, Is 215Vdc supply available at the Check wiring from gas
NO
visual condition and position (Refer Gas Valve while the flame is on? valve to PCB for continuity.
to Frame 44). Check if condensate (* See note) If the wiring is OK then
pipe is blocked. Check if flue is replace the PCB
blocked. YES
Replace as necessary
Check spark generator and NO
associated harness for: continuity Replace Spark Generator
and visual condition. (Refer to and Harness as necessary.
Check ignition electrode and YES
Frame 45) Are these functioning
associated harness for: continuity, correctly?
visual condition and position.
(Refer to Frame 43) Are these
functioning correctly? NO Replace Ignition Electrode and
associated harness as necessary
YES

Check siphon and condensate drain pipe NO

work for blockage and rectify if necessary. Replace Gas Valve
Boiler now working OK?

* Note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the
value. In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve.

73 ALTERNATING ‘F’ AND ‘3’ - FAN FAULT

Does the wiring from the Fan to the PCB have

NO Rectify Wiring &
secure connections at both ends and has not
deteriorated? Does the wiring have continuity? connections

YES
NO
Replace PCB
Is there 230Vac at the Blue and Brown connections
to the 3 way connection on the Fan? YES
Replace Fan

54 IDEAL CLASSIC - Installation and Servicing

 FAULT FINDING

74 ALTERNATING ‘F’ AND ‘4’ - FLOW THERMISTOR FAULT

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
Check the resistance using a suitable multimeter NO
connected across the thermistor’s terminal pins. Fit a new Thermistor
At 25 oC expect 9,700 - 10,300 Ohms
At 60 C expect
o
2,400 - 2,600 Ohms
At 85 oC expect 1,000 - 1,100 Ohms
YES Is there continuity between the PCB and
Is the Thermistor value correct? the Thermistor?

NO YES

Check and replace Replace PCB

wiring as necessary

75 ALTERNATING ‘F’ AND ‘5’ - RETURN THERMISTOR FAULT

Check the resistance using a suitable multimeter NO

connected across the thermistor’s terminal pins. Fit a new Thermistor
At 25 oC expect 9,700 - 10,300 Ohms
At 60 oC expect 2,400 - 2,600 Ohms
At 85 oC expect 1,000 - 1,100 Ohms
YES Is there continuity between the PCB and
Is the Thermistor value correct? the Thermistor?

NO YES

Check and replace Replace PCB

wiring as necessary

IDEAL CLASSIC - Installation and Servicing 55

 FAULT FINDING

76 ALTERNATING ‘F’ AND ‘7’ - LOW MAINS VOLTAGE

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Contact electricity provider

77 ALTERNATING ‘F’ AND ‘9’ - PCB FAULT

Replace PCB -
Ensure that the BCC (boiler chip card - small plastic part) is
fitted to the PCB otherwise replace PCB.

78 ALTERNATING ‘C’ AND ‘0’ - BCC ACTIVATION FAULT

Reset the boiler

RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.

79 ALTERNATING ‘c’ AND ‘2’ - BCC FAULT (BOILER CHIP CARD)

Is the correct BCC for the boiler securely inserted into the NO Securely insert the correct BCC for the boiler
slot at the front left of the PCB? into the PCB and after switching power on and
(identified by the label on the BCC) ‘c0’ being shown, reset boiler.
Note. Ensure the correct orientation of BCC by
YES
placing “TOP” side up.
Replace the BCC with a new BCC (that is correct for the
boiler). After switching power on and ‘c0’ being shown, YES
press reset. Is ‘c2’ still shown? Replace PCB

RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.

56 IDEAL CLASSIC - Installation and Servicing

 FAULT FINDING

80 ALTERNATING ‘F’ AND ‘7’ - LOW MAINS VOLTAGE

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
Reset Boiler

RESET PROCEDURE - To reset boiler, turn mode knob to reset position and immediately turn knob back to required setting.

81 NO CH OPERATION BUT HW WORKS OK

NO
Is the mode knob in the Winter position? Move the mode knob to the Winter position

YES

Are the Timer and the Room Thermostat switched NO

on? Switch the Timer and Room Thermostat On

YES

NO
Are the Radiator Valves Open? Open the Radiator Valves

YES

NO There is no Voltage from the Timer/Room Stat. This

Is there 230Vac at (A)? is not boiler fault. Ensure Voltage is supplied to
boiler by rectifying external wiring.
YES

Replace the Divertor Valve

IDEAL CLASSIC - Installation and Servicing 57

 FAULT FINDING

82 NO HW BUT CH ON
NO
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Does the display show “d” when a tap is on? Is hot and cold pipework crossed?

YES

NO
Are the flow rates correct as per Frame 2. Adjust flow rates to achieve 35º
temp rise and check filter fitted in
YES turbine is not blocked with debris.

Is the wiring between the PCB and the diverter NO

Reconnect wiring or
valve actuator connected? NO
replace wiring harness if
YES no continuity. Is the wiring connected NO
between PCB and DHW
sensor?
Check diverter head fully engaged onto NO Re-engage diverter
waterset body YES
head.
Remove the turbine, and
YES
check for debris in the
NO turbine. Replace turbine
Is diverter stuck in the CH position Replace PCB if necessary. Is DHW
OK?
YES
NO
Check and replace diverter valve actuator head. Replace turbine sensor
Is Boiler DHW OK?

NO

Change diverter valve assembly.

Re-connect wiring

83 NO DISPLAY

Is there 230Vac to the boiler at L and N? NO Supply power to the boiler

YES

Is the wiring from the terminal block to the Main PCB NO Connect the wiring from the terminal block to the
connected securely? Main PCB securely.

YES

Is the ribbon cable from the main PCB to the User NO Connect the ribbon from the main PCB to the User
Interface PCB connected securely? Interface PCB securely

YES

NO Replace the
Is ribbon cable damaged? User Interface
PCB
YES

Replace ribbon cable

L N

58 IDEAL CLASSIC - Installation and Servicing

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

Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www.idealparts.com

Our Parts team are also available to help with your Spare Parts enquiries on 01482 498665.
When calling, and to ensure we can provide you with the most accurate parts information, please ensure you have the following to
hand;
- Boiler Model
- Appliance GC Number
- Boiler Serial Number

IMPORTANT NOTE.
Propane Boilers - After installation of a conversion kit, and when ordering future spares be sure to quote the serial letter code AAV -
which indicates a Propane boiler - and the boilers original serial letter code from the original data plate.

IDEAL CLASSIC - Installation and Servicing 59

 SPARE PARTS

60 IDEAL CLASSIC - Installation and Servicing

 Benchmark Commissioning and
Servicing Section
It is a requirement that the boiler is installed and commissioned to the
manufacturers instructions and the data fields on the commissioning checklist
completed in full.

To instigate the boiler guarantee the boiler needs to be registered with the
manufacturer within one month of the installation.

To maintain the boiler guarantee it is essential that the boiler is serviced annually
by a Gas Safe registered engineer who has been trained on the boiler installed.
The service details should be recorded on the Benchmark Service Interval
Record and left with the householder.

www.centralheating.co.uk

© Heating and Hotwater Industry Council (HHIC)

IDEAL CLASSIC - Installation and Servicing 61

GAS BOILER SYSTEM COMMISSIONING CHECKLIST

This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.

CONTROLS
Programmable room thermostat
Optimum start control
Combination Boiler
Fitted
Fitted
Fitted
Automatic bypass to system Fitted
Boiler interlock

ALL SYSTEMS
Yes

Yes

CENTRAL HEATING MODE

OR
mbar OR mbar

Central heating return temperature

COMBINATION BOILERS ONLY

Yes
Yes

DOMESTIC HOT WATER MODE

OR
mbar OR mbar
Cold water inlet temperature
Yes Temperature

CONDENSING BOILERS ONLY

Yes

ALL INSTALLATIONS
AND ² Ratio
AND ² Ratio
Yes
Yes
Yes
Yes

* Allinstallations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer.

www.centralheating.co.uk
SERVICE RECORD

It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.

Service Provider

SERVICE 01 SERVICE 02

AND ²% AND ²%
(Where Possible) AND ²% (Where Possible) AND ²%

Signature Signature

SERVICE 03 SERVICE 04

AND ²% AND ²%
(Where Possible) AND ²% (Where Possible) AND ²%

Signature Signature

SERVICE 05 SERVICE 06

AND ²% AND ²%
(Where Possible) AND ²% (Where Possible) AND ²%

Signature Signature

SERVICE 07 SERVICE 08

AND ²% AND ²%
(Where Possible) AND ²% (Where Possible) AND ²%

Signature Signature

SERVICE 09 SERVICE 10

AND ²% AND ²%
(Where Possible) AND ²% (Where Possible) AND ²%

Signature Signature

* Allinstallations in England and Wales must be to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance will then be issued to the customer.

© Heating and Hotwater Industry Council (HHIC) www.centralheating.co.uk

 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO
CHECK ON COMMISSIONING A CONDENSING BOILER

Important Preliminary Information on Checks

The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING.
If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) sepa-
rate guidance is provided with the conversion kit supplied and this must be followed.

PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK

The installation instructions must have been followed, gas type verified and gas supply pressure / gas rate checked as
required prior to commissioning.
As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN
THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are
correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance
has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids).
The ECGA should be of the correct type, as specified by BS 7967.
Prior to its use, the ECGA should have been maintained and calibrated as specified by the manufacturer. The installer
must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer’s instructions.

KEY:
CO = carbon monoxide
CO2 = carbon dioxide
O2 = oxygen
Combustion Ratio = The CO reading measured in ppm divided by the CO2 reading first converted to ppm
ppm = parts per million
GS(I&U)R = Gas Safety (Installation and Use) Regulations

*Setting to Minimum Rate:

1. Turn the CH temperature control knob into the 10 O’clock position.
2. Create a CH demand by ensuring that the system controls are requesting heat and the boiler Mode
Knob is in the Winter Position.
3. Within an overall time of 3 seconds, turn the CH temperature control knob fully clockwise, back to
10 O’clock and then fully clockwise again.
4. “S” will be shown on the display and the boiler output will be reduced to minimum
5. The boiler will remain at minimum rate for 5 minutes before reverting to normal operation

64 IDEAL CLASSIC - Installation and Servicing

 Start

Set Boiler to Maximum Gas Rate Carry Out Flue Integrity Check Using Analyser
In accordance with boiler instructions, Insert analyser probe into air inlet test point (where available) and allow
set boiler to operate at maximum rate readings to stabilise.
(full load condition). Allow sufficient Note. Where no air inlet test point is provided then a flue integrity check with
time for combustion to stabilise. the analyser is not possible. The installer should verify that flue integrity has
Note. Do not insert analyser probe been visually checked in accordance with the “Prior to CO level and
during this period to avoid possible combustion ratio check” (see opposite page) before proceeding to the
flooding of sensor. “check CO level and combustion ratio at maximum rate” stage below.

Verify Flue Integrity Is

Analyser readings indicate that combustion products and inlet air O2 more than or
No equal to 20.6% OR CO2
must be mixing. Further investigation of the flue is therefore required.
Check that flue components are assembled, fixed and supported as less than or equal to
per instructions. Check that flue and flue terminal are not obstructed. 0.2%?

Yes

Is Check CO level and Combustion Ratio

O2 more than or at Maximum Gas Rate
equal to 20.6% OR CO2 Yes
With boiler still set at maximum gas rate,
less than or equal to insert analyser probe into flue gas
0.2%? sampling point. Allow readings to stabilise
No before recording.

Turn off appliance and call Ideal Technical Helpline for advice
The appliance must not be commissioned until problems are identified Is
and resolved. If commissioning cannot be fully completed, the appliance CO level less
No than 350ppm AND CO/CO2
must be disconnected from the gas supply in accordance with GSIUR.
ratio less than
0.0040?

Check that no seals, e.g. Those on flue extensions, have Yes

been displaced during installation. Rectify if necessary.
Set Boiler to Minimum Gas Rate
(*see opposite page)
In accordance with boiler instructions, set boiler to
Is operate at minimum rate (to minimum load condition).
CO level less Yes Allow sufficient time for combustion to stabilise.
than 350ppm AND CO/CO2
ratio less than
0.0040?
Check CO and Combustion Ratio at Minimum Gas Rate
No With boiler set at minimum rate, insert analyser probe into flue
gas sampling point. Allow readings to stabilise before recording.

Turn off Appliance and Call Ideal Technical Helpline

The appliance must not be commissioned until problems Is
are identified and resolved. If commissioning cannot be CO level less
No than 350ppm AND CO/CO2
fully completed, the appliance must be disconnected from
the gas supply in accordance with GS(I&U)R. NOTE: ratio less than
Check and record CO level and combustion ratio at both 0.0040?
maximum AND minimum rate before contacting Ideal.
Yes

Boiler is Operating Satisfactorily

No further actions required.
Ensure test points are capped, boiler case is correctly replaced and all
other commissioning procedures are completed. Complete Benchmark
Checklist, recording CO and combustion ratio readings as required.

IDEAL CLASSIC - Installation and Servicing 65

 NOTES

66 IDEAL CLASSIC - Installation and Servicing

 NOTES

IDEAL CLASSIC - Installation and Servicing 67

 NOTES

68 IDEAL CLASSIC - Installation and Servicing

 NOTES

IDEAL CLASSIC - Installation and Servicing 69

 NOTES

70 IDEAL CLASSIC - Installation and Servicing

 NOTES

IDEAL CLASSIC - Installation and Servicing 71

 FM 59915
The code of practice for the installation, Manufactured under an ISO 9001
commissioning & servicing of central heating systems registered quality management system

Technical Training
The Ideal 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

Ideal Boilers Ltd. pursues a policy of continuing improvement in the design and performance of its products.
The right is therefore reserved to vary specification without notice.

Ideal Boilers Ltd., PO Box 103, National Avenue, Kingston Upon Hull, HU5 4JN
Tel 01482 492251 Fax 01482 448858
Registration No. London 322 137

Ideal Technical Helpline: 01482 498663

Ideal Consumer Helpline: 01482 498660
www.idealboilers.com