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IDEAL INDUSTRIES HE12 Boiler User Manual

1. 775 to 1680 B Pack 1 off D Pack 1 off see Frame 10 Standard flue 1680 to 2585 B Pack 1 off D Pack 2 off see Frame 10 Terminal grille 2585 to 3000 B Pack 1 off D Pack 3 off see Frame 10 Boiler Il n 0 Il gt J L Il 0 Flue extensions of greater length than 1m 39 should be supported with the bracket provided suitable adjusted Refer to Frame 28 cla7675 30 FITTING THE KIT Fit the inner flue extension duct onto the inner flue duct Fit the outer flue extension duct onto the outer air duct Repeat steps 1 and 2 if a second flue extension is required Measure and mark the flue length required onto the flue measuring from the ring near the terminal Refer to Frames 10 and 283 for the detail of flue length calculation Ensure the support clip is in position to facilitate cutting E Measure from To ensure a square cut mark the flue all the way this RING around areas De burr the cut edges 22 classic HE Installation amp Servicing INSTALLATION 31 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
2. Drill 3 holes 3 2mm 1 8 dia through the outer flue x duct and boiler sealing ring Do NOT drill the inner flue duct cla7662 Insert the self tapping screws provided in order to fix the boiler sealing ring in position classic HE Installation amp Servicing Air pressure switch amp CO CO sensing pipes Electrical connections 8 Stick the self adhesive foam strip provided in the boiler hardware pack onto the flue immediately behind the boiler sealing ring 17 REAR FLUE OUTLET INSTALLATION 16 FITTING THE FLUE ASSEMBLY AND OPTIONAL FLUE FINISHING KIT if required A Without Optional Flue finishing Kit B With Optional Flue finishing Kit 1 Insert the flue assembly through the hole 1 Fit the black outer wall seal over B 2 Ensure the notch is at the top This will terminal and ensure the retaining rim is aid the location of the studs into the boiler located in the terminal depression back panel 2 Fit flue pipe assembly through the hole previously cut in wall 3 Fit wall mounting plate Frame 17 mount ss the boiler Frame 18 and connect the flue to the boiler frame 19 4 Fit outer wall sealing plate over outer wall seal and retain with the 4 screws and wall plugs provided cla7663 17 WALL MOUNTING PLATE e bracket 1 If downward routing of pipes is required then the downward routing wall bracket supplied in the downward piping kit should be
3. Tape the template into the selected position Ensure squareness by hanging a plumb line as shown Extend the flue centre line onto the side wall and measure in 120mm for standard installation or 156mm when using downward routing pipe kit Mark onto the wall the following a The 2 wall mounting plate screw positions choose one from each group b The fixing hole for the jacking screw c The position of the flue duct hole Note Mark the centre of the hole as well as the circumference Remove template from the wall 22 PREPARING THE WALL IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Cut the flue hole preferably with a 125mm 5 core boring tool ensuring that the hole is square to the wall If the hole has been accurately cut with a drill then making good the inner wall face is not essential as a seal is provided an optional extra outer wall seal is required if necessary However both wall faces immediately around the cut hole should be flat make good if necessary For less accurate holes make good to approximately 125mm 5 diameter at the 2 wall faces Drill 3 holes 2 for the wall mounting plate and 1 for the jacking screw with an 8mm 5 16 masonry drill classic HE Installation amp Servicing LEGEND Terminal External weather seal optional Internal weather seal optional
4. Switchmaster Midi is similar in operation but the wiring differs slightly see the manufacturer s literature LEGEND blue black brown grey orange pink red violet white yellow yellow green classic HE Installation amp Servicing On Off Switch LEGEND thermostat b blue bk black Fan br brown tt gy grey fa or arange Thermostat f Ignition pk pink sensor detection N lectrod r red electro DA v violet qr Y w white y yellow ylg yellow green 44 MID POSITION VALVE Pumped only Room Thermostat Terminals cla7677 Overheat Thermostat m Cylinder Mid Position Thermostat valve details Terminals HONEYWELL Y PLAN V4073H 1039 TLX 2259 0r2284 PEGLER Unishare DT 1701 etc LANDIS amp GYR LGM SK3 LT2701 A C L 679 H 340 30 UO RTE RTM RTC DRAYTON Flowshare 2 SOPAC Centra Share ZV20 EB MID DANFOSS DMV 3M SWITCHMASTER Terminal strip suitably Boiler supply connector r Typical Programme CH May be Clas1 4 selected independently 29 INSTALLATION INSTALLATION INSTALLATION 45 TWO SPRING CLOSED VALVE Pumped only Notes 1 Some earth wires are omitted for TLX 2259 clarity Ensure proper earth continuity 0r2284 when wiring 2 Numbering of terminals on RT
5. 8 Remove all loose deposits from the heat exchanger particularly between the fins using a suitable brush 9 Check that the fan impellor runs freely Remove any debris from the impellor with a soft brush 10 Re assemble in reverse order Check that a The pilot burner injector is not blocked or damaged Refer to Frame 67 for removal details b The pilot burner is clean and unobstructed c The ignition detection electrode is clean and undamaged d The ignition detection lead is in good condition e The spark gap is correct refer to Frame 67 Clean or renew as necessary Note The pilot shield is located around the pilot assembly bracket and is located by the electrode retaining nut 5 Clean the sump of any debris 6 Clean between the recuperator fins with a suitable strip of steel 7T Re assemble in reverse order ensuring rubber grommets are replaced classic HE Installation amp Servicing SERVICING 58 CLEANING THE SIPHON 1 Pull the heat shield forward to remove from clips 2 Unscrew the siphon union connection 4 l 3 Remove the rubber sump connection pipe and the amp 4 blockage sensing pipe wo 4 Remove the two siphon 3 retaining screws and remove siphon 5 Thoroughly clean the siphon 6 Recharge the siphon with water 7 Re assemble in reverse order Ensuring the rubber sump 59 REASSEMBLY Reassemble the boiler in the following order 1 Refit the flu
6. If any programmer is fitted draw attention to the Programmer User s Instructions and hand them to the Householder After installation and commissioning please complete the b enchmark Commissioning Checklist before handover to the customer For IE it is necessary to complete a Declaration of Conformity to indicate compliance to l S 813 2002 registered installer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR In IE servicing work must be carried out by a Competent Person classic HE Installation amp Servicing SERVICING 52 SERVICING SCHEDULE 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 CORGI registered installer In IE service work must be carried out by a Competent Person As the installer you may wish to undertake the service contract yourself or alternatively offer to the customer the benefits of the Ideal Care Scheme details of which are outlined in the household pack supplied with this boiler 1 Light the boiler and carry out a pre service check noting any operational faults Operate the boiler for at least 20 minutes Check the gas consumption 2 Connect a suitable gas analyser to
7. Fully pumped CH and indirect DHW e Pumped heating only e Pumped indirect DHW only SAFE HANDLING This boiler may require 2 operatives to move it to its installation site remove it from its packaging base and during movement into its installation location Manoeuvring the boiler may include the use of a sack truck and involve lifting pushing and pulling Caution should be exercised during these operations Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered Grip the boiler Refer to Frame 18 Split the boiler down to reduce the weight e g remove casing and hardware pack Refer to Frame 9 Be physically capable Use PPE as appropriate e g gloves safety footwear During all manoeuvres and handling actions every attempt should be made to ensure the following unless unavoidable and or the weight is light Keep back straight Avoid twisting at the waist Avoid upper body top heavy bending Always grip with the palm of the hand Use designated hand holds Keep load as close to the body as possible Always use assistance if required OPTIONAL EXTRA KITS FLUING Flue Extension Ducts 1000mm long up to 3m 90 Elbow Kit 60 100 dia maximum no per installation up to 2 elbows 45 Elbow Kit 60 100 dia maximum no per installation up to 2 elbows Side Outlet Kit Vertical Connector Kit Fl
8. GENERAL 6 SEALED SYSTEM REQUIREMENTS continued 7 Mains Connection There must be no direct connection to the mains water supply or to the water storage tank supplying domestic water even through a non return valve without the approval of the local water authority Filling The system may be filled by one of the following methods a Through a cistern used for no other purposes via a ball valve permanently connected directly to a service pipe and or a cold water distributing pipe The static head available from the cistern should be adequate to provide the desired initial system design pressure The cold feed pipe from the cistern should include a non return valve and a stop valve with an automatic air vent connected between them the stop valve being located between the system and the automatic air vent The stop valve may remain open during normal operation of the system if automatic water make up is required b Through a self contained unit comprising a cistern pressure booster pump if required and if necessary an automatic pressure reducing valve and flow restrictor The cistern should be supplied through a temporary connection from a service pipe or cold water distributing pipe This unit may remain permanently connected to the heating System to provide limited automatic water make up Where the temporary connection is supplied from a service pipe or distributing pipe which also supplies other draw off
9. 1 Ensure the flue seal collar B is located onto the flue MIN LENGTH assembly A for all models 1m Position the roof flashing plate D supplied separately over Y the hole cut in the roof and insert flue assembly A from the roof end Remove the casing top blanking plate and gasket and refit to the boiler rear flue hole Fit the boiler vertical conversion kit to be found in the vertical connector kit Refer to Frame 26 No s 2 to 7 Push fit the vertical connector E supplied separately into the boiler flue connection and retain with the four securing screws provided Push fit extension duct F if required supplied separately and the roof flue kit assembly A into the vertical connector E If the last extension duct requires cutting measure 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 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 Slide down and position the flue seal collar B over the roof plate D and secure it with the 3 screws C to the flue assembly A Finally ensure the roof flashing plate D is correctly sealed to the roof mxhe7688
10. 2 Open the controls access door by hinging downwards 3 Ensure that the gas inlet cock D is OPEN 4 Press the overheat reset button E located as shown in Frame 1 5 Ensure that the mains on off switch C is in the OFF position 6 Switch ON the electricity supply to the boiler Check that all external controls e g room thermostat etc are ON 7 Turn the boiler thermostat knob B to position 6 and the mains on off switch C to ON After about 15 seconds the boiler will light automatically this can be viewed through the sight glass A Set the boiler thermostat to the desired position 8 Close the controls access door In winter conditions i e central heating and domestic hot water the thermostat should be set at position 5 or 6 For summer conditions i e domestic hot water only the thermostat should be set at position 3 These settings however are offered for general guidance only and other settings may be found preferable dependent upon the type of system installed or as recommended by the installer CAUTION To avoid the possibility of injury during the installation servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components classic HE Users CONTROL OF WATER TEMPERATURE 1 Adjust the boiler thermostat B to give the required temperature of central heating 2 The boiler thermostat automatically switches the main burner OFF and ON to maint
11. A 19 Swing the control box back into its working position and secure 20 Refit the controls pod to the boiler casing and tighten the 2 front fixing screws 21 Close the pod door 2 casing retaining Screws Control box securing Screws cla7679 controls support fixing screws Controls door 50 GENERAL CHECKS Make the following checks for correct operation 1 Set the boiler thermostat knob to position 6 and operate the mains on off switch Check that the main burner lights and extinguishes in response 2 The correct operation of ANY programmer and all other system controls should be proved Operate each control separately and check that the main burner or circulating pump as the case may be responds 3 Check that the casing is sealed correctly and compressing the sealing strip all around the casing 4 Water Circulating System a With the system HOT examine all water connections for soundness b With the system still hot turn off the gas water and electricity supplies to the boiler and drain down in order to complete the flushing process c Refill and vent the system clear all air locks and again check for water soundness d Balance the system 51 HANDING OVER After completing the installation and commissioning of the 6 system the installer should hand over to the householder by the following actions 1 Hand the User s Instructions to the Househol
12. Change pressure switch classic HE Installation amp Servicing SHORT LIST OF PARTS The following are parts commonly required due to damage or expendability When ordering spares please quote Their failure or absence is likely to affect safety or performance of this appliance The list is extracted from the British Gas List of Parts which contains all 1 Boiler Model available spare parts 2 Appliance G C Number The full list is held by British Gas Ideal Stelrad Group distributors and E Br merchants 5 Product Number 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 GC Part No Description L Product No E83 619 Sightglass Assembly Kit 171 414 E72 529 Main Burner Kit HE9 HE12 171 012 HE15 HE18 174 063 E85 308 Main Injector Kit HE9 171 424 E83 624 HE12 171 425 E83 625 HE15 171 426 E83 626 HE18 171 427 E80 493 Pilot Burner Injector Kit 171 435 E87 018 Pilot Burner Head c w Injector Kit 171 439 Gas Valve Kit 174 172 E83 635 Ignition Electrode Kit 171 442 Controls Box Kit c w PCB 174 171 H20 882 PCB25E 173 799 Air Pressure Switch Kit 174 064 Controls Casing Kit 174 071 Flue Protection Thermostat Kit 174 072 Fan Assembly Kit 174 065 174 066 174 067 174 068 Front Panel Assembly Kit 174 069 Control Door Kit 173 586 Casing Seal
13. Flue assembly Side outlet kit Optional Extended centre line X Section through wall SIDE FLUE OUTLET 5 diameter flue hole 19 INSTALLATION 23 CUTTING THE FLUE For flue lengths 270 to 775mm ONLY Measure and note the side flue length Y refer to Frame 10 Add 143mm 5 s to dimension Y and measuring from the ring cut both outer and inner tube Ensure support clip is in position to facilitate cutting To ensure the tube is cut square mark the flue all the way around Cut to length and remove any burrs Measure from this RING For flue lengths greater than 775mm refer to Frames 28 29 and 30 Flue extension ducts 24 FITTING THE FLUE ASSEMBLY Insert the flue assembly through the hole 1 2 Ensure the flue terminal is in the correct position cla7704 j Il a gt 0 Il gt L Il i 0 25 WALL MOUNTING PLATE 1 If downward routing of pipes is required then the downward routing wall bracket supplied in the downward piping kit should be fitted to the wall now Fix the mounting plate to the wall with the No 14 x 50mm wood screws or to the downward piping bracket with the M6 x 12 Hex hd screws provided 3 Check with a spirit level that the plate is horizontal e Downward piping cla7667 bracket Wall mounting bracket 20 classic HE Installation amp Servicing INSTALLATION 26 MOUN
14. 3 4 9 12 7 5 1 Seasonal efficiency SEDBUK Band B 87 21 87 2 86 8 86 8 NOx classification Class 3 Class 2 Class 1 Class 1 The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body Note Gas consumption is calculated using a calorific value of 38 7 MJ m 1038 Btu f gross or 34 9 MJ m 935 Btu ft nett To obtain the gas consumption at a different calorific value a FORL S divide the gross heat input kW by the gross C V of the gas MJ m b FOR FTH divide the gross heat input Btu h by the gross C V of the gas Btu ft3 Key to symbols GB United Kingdom PMS Maximum operating pressure of water IE Ireland Countries of destination C C A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which in this case are concentric The fan is down stream of the combustion chamber An appliance designed for use on 2nd Family gas Group H only 2H CAUTION To avoid the possibility of injury during the installation servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components classic HE Installation amp Servicing GENERAL c
15. FLUE OUTLET classic HE Installation amp Servicing 25 INSTALLATION INSTALLATION 36 GAS CONNECTION 37 WATER CONNECTIONS Refer to Gas Supply page 8 1 Remove the plastic plugs from the flow and Refer to Frame 2 for gas inlet service dimensions return pipes A minimum pressure of 20 mbar MUST be available at the boiler inlet Make all water connections and check for with the boiler operating The main gas cock is on the left hand side of water soundness the gas control valve as shown To facilitate connection the gas cock may be removed from the gas control valve 38 CONDENSATE DRAIN Refer also to the British Gas document Guidance Notes for the Installation of Domestic Gas Condensing Boilers 1989 Front View The boiler comes with a built in condensate siphon trap The boiler condensate drain must be connected to a drainage point preferably within the building This condensate drainage should be run in standard 21 5mm overflow pipe Connection to the boiler is made by fitting the siphon nut and sealing washer to the threaded siphon outlet Ensure that the condensate siphon is full of water before commissioning the boiler Refer to Frames 19 and 27 The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler throughout its length The drainage pipework must be arranged so that obstruction e g through freezing of external drainage pipes does not give rise to spilla
16. Refer to Frame 49 Flow wiring diagram ond Flue protection 42 EXTERNAL CONTROLS External wiring must be in accordance with the current I E E BS 7671 Wiring Regulations For Ireland reference should be made to the current ETCI rules for electrical installations The wiring diagrams illustrated in Frames 43 46 cover the Systems most likely to be fitted to this appliance For wiring external controls to the classic HE boiler reference should be made to the system wiring diagrams supplied by the relevant manufacturer in conjunction with the wiring diagrams shown in Frames 43 46 Difficulty in wiring should not arise providing the following directions are observed 1 Controls that switch the system on or off e g a time switch must be wired in series in the live mains lead to the boiler 2 Controls that override an on off control e g frost thermostat 28 Route the mains cable into the box from the RHS of the thermostat LEGEND Air pressure b blue pk pink switch bk black r red Limit br brown v violet thermostat gy grey wo white ALL EARTHS must be connected or orange yig yellowgreen Not all earths are shown for clarity boiler Connect the live neutral and earth wires into the terminal strip as shown Secure the mains lead with the cable clamp On completion of all wiring connections relocate the control box and secure cla7738 Earth y g O O Live br OO L Neutral
17. Servicing 3 Table 1 General Data Boiler Size GENERAL HE12 Gas supply connection Rc 1 2 1 2 1 2 BSP Female Flow connection 22mm copper Return connection 22mm copper Maximum static water head m ft 30 5 100 Minimum static water head m ft 0 45 1 5 Electrical supply 230V 50 Hz Boiler power consumption 100W Fuse rating External 3A Internal F1A to BS 4265 Water content litre gal 3 0 0 67 3 95 0 87 Packaged Weight kg Ib 45 99 50 110 Maximum installation weight kg Ib 40 88 45 99 Boiler size mm in 700 27 5 mm in 380 15 0 mm in 280 11 25 Flue duct diameter mm in 100 4 0 Flue duct length max m ft Table 2 Performance Data Boiler Size HE9 3 9 8 HE12 HE15 HE18 Input Q Nett CV kW Btu h Gross CV kW Btu h 9 4 32 100 10 5 35 800 12 6 43 000 14 0 47 800 15 7 53 600 17 4 59 400 18 9 64 500 20 9 71 300 Gas Consumption l s cu ft h 0 27 34 3 0 36 45 8 0 45 57 2 0 54 68 7 Output P 70 C Mean Water temp kW Btu h 40 C Mean Water temp kW Btu h 9 0 30 700 9 8 33 400 12 0 40 900 13 1 44 700 15 0 51 200 16 2 55 300 18 0 61 400 19 4 66 200 Burner Setting Pressure Hot mbar in w g 12 0 4 8 10 4 4 2 12
18. The maximum practical length of 15mm cold feed pipe should be used in order to reduce the effective volume of system water expanding into the feed expansion cistern to a minimum Note The pump manufacturers minimum cla7840 Minimum Requirements NNNNNNNMNNNNNNNNNMNNNNNNNNNNNNNNNNNNNNN Feed expansion cistern 450 179 45 Surge Min 200 arrester 8 Min 75 3 Min 3 4 NE Y Flow c Open vent To pump 150 Highest le 6 point of flow or cla7839 retum Max Max practical length requirements must be complied with All dimensions in mm in N B Imperial dimensions are approximate 10 classic HE Installation amp Servicing GENERAL 5 SEALED SYSTEM REQUIREMENTS Make up vessel max capacity 3I Hose union bib tap Air vent Non return Y valve Water supply Drain cock Safety valve best Pressure gauge 1 Automatic air vent HEATING CIRCUIT Hosepipe P b disconnect after filling Y Hose unions N a ba Additional stop valve Temporary hose disconnect after filling BOILER A Expansion vessel Double check valve Hose connector assembly note direction of flow Note 4 Expansion Vessel 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 a A
19. and Screws Kit 174 070 E83 682 Overheat Thermostat LM7 Kit 171 950 E97 310 Limit Thermostat Kit 173 353 classic HE Installation amp Servicing 43 SHORT LIST OF PARTS 78 SHORT PARTS LIST classic HE Installation amp Servicing 44 INSTALLER NOTIFICATION GUIDELINES IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE In addition a change to Building Regulations England and Wales requires the installer to notify when installing a heating appliance as from 1st April 2005 Install and commission this appliance to manufacturers instructions Complete the Benchmark Checklist Competent Person s Choose SELF CERTIFICATION SCHEME Buildings Regulations ee notification route If you notify via CORGI Scheme Contact your relevant CORGI will then notify the Local Authority relevant Local Authority Building Building Control LABC who Control LABC scheme will arrange an inspection on members behalf or contact a government approved inspector Scheme members only Call CORGI on 0870 88 88 777 LABC will record the data or log onto and will issue a www corgi notify com certificate of compliance within 10 days You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS compliance to the property FULLY CO
20. be lagged to prevent heat loss and any possible freezing particularly where pipes run through roof spaces and ventilated under floor spaces Boilers not fitted to a sealed system must be vented IMPORTANT A minimum length of 1m of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping This applies to ALL types of installation Draining taps MUST be located in accessible positions which permit the draining of the whole system including the boiler classic HE Installation amp Servicing and hot water storage vessel They should be at least 1 2 BSP nominal size and be in accordance with BS 2879 The boiler is fitted with a special drain plug which is provided to drain the BOILER ONLY in the event of the system drain plug being unable to do so The hydraulic resistance of the boilers at MAXIMUM OUTPUT with an 11 C 20 F temperature differential are shown in Table 5 Maximum boiler operating temperature should be 82 C 180 F Table 5 Water flow rate and pressure loss Boiler Size HE 9 12 15 18 Boiler kW 9 0 12 15 18 Output Btu h x 1000 30 7 40 9 50 2 60 4 Water Flow I min 11 7 15 6 19 5 23 4 Rate gal h 155 206 258 309 Pressure mbar 54 0 93 5 98 4 142 5 Loss in wg 21 6 37 4 39 3 57 WATER TREATMENT These boilers incorporate a cast iron heat exchanger and an aluminium heat exchanger IMPORTANT The application of
21. boiler except that for bathroom installations the point of connection to the mains MUST be situated outside of the bathroom Note Where a room sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower See Frame 41 for details CONDENSATE DRAIN Refer to Frames 38 39 and 40 A condensate drain siphon 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 insulated The drain outlet on the boiler is standard 21 5mm 3 4 overflow pipe 3 OPEN VENT SYSTEM REQUIREMENTS FULLY PUMPED Feed expansion 450 173 4 The system should be vented directly off the boiler flow pipe as close to the cistern Mimimum boiler as possible The cold feed entry should be inverted and MUST be Water positioned between the pump and the vent and not more than 150mm 6 cold away from the vent connection There should be a minimum height 450mm 173 4 of open vent above cistern water level If this is impossible refer below The vertical distance between the highest point of the system and the feed level 450 173 4 Mimimum 22mm Open vent expansion cistern
22. fitted to the wall now 2 Fix the mounting plate to the wall with the No 14 x 50mm wood screws or to the downward piping bracket with the M6 x 12 Hex hd screws provided 3 Check with a spirit level that the plate is horizontal Wall mounting bracket cla8181 18 MOUNTING THE BOILER Note The boiler may require two men to lift it onto the wall mounting plate For downward routing of pipes the M5 spacer supplied in the downward piping kit should now be fitted to the back of the boiler 1 Lift the boiler onto the wall mounting plate hooks as shown 2 Remove the bottom packaging protection Jacking screw 3 Check the boiler alignment using a spirit level and adjust as 3 necessary with the jacking screw 4 Line up the hole in the jacking screw with the hole in the wall previously drilled and secure with the No 14 x 50mm wood M5 Spacer Screw 19 CONNECTING THE FLUE TO THE BOILER 1 Locate the 3 sealing ring studs in the holes in the back panel p Note The sealing ring studs will locate in the back panel one way only This will ensure that the terminal grille is correctly aligned 2 Secure the flue to the boiler using the three M5 nuts provided 3 Before fitting the flue turret fill the siphon trap within the boiler by pouring a cupful of water into the recuperator outlet 0 Take care to ensure that the water is only poured into the recuperator outlet and does not spill into th
23. hot water systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 7593 Treatment of water in domestic hot water central heating systems BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW Health amp Safety Document No 635 The Electricity at Work Regulations 1989 Manufacturer s notes must NOT be taken in any way as overriding statutory obligations IMPORTANT These appliances are certificated by the British Standards Institution for safety and performance It is therefore important that no external control devices e g flue dampers economisers etc are directly connected to these appliances unless covered by these Installation and Servicing instructions or otherwise recommended by Ideal Stelrad Group in writing If in doubt please enquire Any direct reconnection of a control device not approved by Ideal Stelrad Group could invalidate the BSI Certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations SAFE HANDLING OF SUBSTANCES Care should be taken when handling the boiler insulation panels which can cause irritation to the skin No asbestos mercury or CFCs are included in any part of this boiler LOCATION OF BOILER The boiler must be installed on a flat and vertical wall capable of adequately supporting the
24. structure Minimum dimensions are shown below Terminal Position Directly below an opening Flat roof with structure air brick windows etc 300 mm Below plastic painted gutters Painted surface 300 mm Below eaves or balcony 500 mm 34 FLUE ARRANGEMENT Part No Description HE9 HE12 HE15 HE18 Flat roof n a Maximum Flue Length m 4 4 4 4 CAN CICMENENENEN T 201 180 Flue ext 60 100 201 189 Terminal Vertical Roof 60 100 Universal 158 431 Weather Collar Pitched Roof weather collar 158 432 Weather Collar Flat Roof 201 182 90 Elbow Kit 60 100 201 183 45 Elbow Kit 60 100 201 867 Vertical Connector Kit BOILER Note The equivalent flue length resistance of the 90 elbow kit 60 100 is 1 0m and the 45 elbow kit 60 100 is 0 75m mxhe7687 FLUE OUTLET 24 classic HE Installation amp Servicing INSTALLATION 35 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 Refer to No MAX LENGTH 7 below for all models 4m Ensure the cut pipe ends are free from any burrs
25. water level MUST not be less than 450mm 173 4 150 6 The pump MUST be fitted on the flow side of the boiler A suitable pump is a domestic circulator capable of providing an 11 C 20 F Max System temperature differential e g Grundfos UPS 15 50 or equivalent The vertical flow to distance between the pump and feed expansion cistern MUST comply with Connections pump the pump manufacturers minimum requirements to avoid cavitation Should to boiler Inverted cold these conditions not apply either lower the pump position or raise the cistern feed entry above the minimum requirement specified by Ideal Stelrad Group Note A cold water feed must be available back to the boiler when all automatic valves are in the closed position refer to BS 6798 and when close coupled the feed must not be in a vertical leg 4 LOW HEAD INSTALLATIONS The classic HE range of boilers can be installed in low head situations by fitting a surge arrester in the expansion pipe as shown The following conditions MUST be observed 1 The surge arrester must be at least 42mm in diameter x 150mm long thus ensuring MINIMUM air gap and a MINIMUM depth of water below the static water level cold of 75mm The static water level cold must be at least 200mm above the top of the horizontal flow pipe fitted as shown The vent connection MUST NOT be made immediately off Return the top of the boiler as venting is made less efficient
26. 2 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 3 DATE SERVICE 4 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 5 DATE SERVICE 6 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 7 DATE SERVICE 8 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE SERVICE 9 DATE SERVICE 10 DATE ENGINEER NAME ENGINEER NAME COMPANY NAME COMPANY NAME TEL No TEL No CORGI ID CARD SERIAL No CORGI ID CARD SERIAL No COMMENTS COMMENTS SIGNATURE SIGNATURE LE EDEN ben chmark The code of practice for the installation commissioning amp servicing of central heating systems Ideal Boilers P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance
27. BOILER CONTROL INTERLOCKS Ideal Stelrad Group recommend that heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS 5449 continued 9 GENERAL Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating or hot water 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 1096 of the 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 without end switches 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 The appliance MUST be efficiently 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 Ireland reference should be made to the current ETCI rules for electrical installations The point of connection to the mains should be readily accessible and adjacent to the
28. E thermostats is specific to the RTM RTC manufacturer 3 This is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster valve has grey and orange auxiliary switch leads but the grey wire must be connected to the live supply LEGEND gy grey b blue ylg yellow green bk black or orange br brown v violet r red pk pink y yellow w white Boiler supply connector 46 FROST PROTECTION L A M Double pole Typical frost stat e g programmer SOPAC TA547 04 To system controls Central heating systems fitted wholly inside the house do not normally require frost protection as the house acts as a storage heater and can normally be left at least 24 hrs without frost damage However if parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system This is usually done at the programmer in which case the programme selector switches are set to OFF and all other controls MUST be left in the running position The frost thermostat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown with minimal disturbance to other wiring of the programmer 30 Room TE Aux Cylinder Thermostat Une es ni switch Thermostat Terminals wires Terminals HONEYWELL S PLAN i 3 2 V4043H 1056 ud or PEGLER sys
29. ER SCALE REDUCER BEEN FITTED YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE amp RECORD GAS RATE m3 hr ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE NA mbar COLD WATER INLET TEMPERATURE C HOT WATER OUTLET TEMPERATURE C WATER FLOW RATE Its min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS IF REQUIRED BY THE MANUFACTURER HAVE YOU RECORDED A CO CO2 RATIO READING N A YES CO CO2 RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER COMMISSIONING ENG S NAME PRINT CORGI ID No SIGN DATE SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below Service Provider Before completing the appropriate Service Interval Record below please ensure you have carried out the service as described in the boiler manufacturer s instructions Always use the manufacturer s specified spare part when replacing all controls SERVICE 1 DATE SERVICE
30. ICING SERVICING 55 CLEANING THE FAN ASSEMBLY THE FLUEWAYS 1 Remove the air pressure switch and CO CO sensing pipes 2 Disconnect the electrical connections 3 Remove the 2 fan fixing screws and remove the fan by pulling forward 56 CLEANING THE BURNER AND PILOT ASSEMBLY 1 Brush off any deposits that may have fallen on to the burner head ensuring the flame ports are unobstructed and remove any debris that may have collected Note Brushes with metallic bristles must not be used 2 Remove the main burner injector and ensure there is no blockage or damage Clean or renew as necessary 3 Refit the injector using an approved jointing compound sparingly 4 Inspect the pilot burner and ignition detection electrode Ensure that they are clean and in good condition 57 CLEANING THE RECUPERATOR 1 Remove the 2 rubber grommets to gain screwdriver access to remove the side tie rods retaining the combustion chamber and remove the tie rods Also remove the two front tie rods 2 Remove the combustion chamber 3 Remove the sump rubber hose connection 4 Unclip the two side sump retention clips and remove the sump 34 4 Pull off the two electrical connections to the flue protection thermostat 7 5 Slacken the two M5 nuts on the front tie rods releasing the tie rods from the combustion chamber 6 Unhook the rear collector hood tags and remove collector hood 7 Remove the flue baffles
31. LLATION B GAS INSTALLATION 1 The whole of the gas installation including the meter MUST be inspected and tested for soundness and purged in 2 ALWAYS carry out preliminary electrical system accordance with the recommendations of BS 6891 checks i e earth continuity polarity resistance to In IE refer to 1 5 813 2002 earth and short circuit using a suitable test meter 2 Purging air from the gas installation may be expedited by loosening the union on the gas service cock on the boiler and purging until gas is detected 3 Retighten the union and check for gas soundness 1 Checks to ensure electrical safety should be carried out by a competent person WARNING Whilst effecting the required gas soundness test and purging air from the gas installation open all windows and doors extinguish naked lights and DO NOT SMOKE 48 INITIAL LIGHTING LEGEND E Main burner pressure adjuster A Sightglass F Burner pressure test point B Gas service cock H Boiler mains on off switch C Inlet pressure test point J Overheat thermostat reset D Thermostat knob button 99 Set the boiler thermostat knob D to position 6 and the boiler Mains On Off switch H to ON The fan will start After the fan has run for a few seconds the pilot solenoid valve should open and the intermittent spark commence continuing until the pilot is established The main burner will then cross light smoothly If this sequence does not occur refer to the Fault Fi
32. MPLETED AND LEFT WITH THE APPLIANCE CORGI will record the data and will send a certificate of classic HE Installation amp Servicing 45 BENCHMARKNo Benchmar J GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No NOTIFICATION No CONTROLS To comply with the Building Regulations each section must have a tick in one or other of the boxes TIME amp TEMPERATURE CONTROL TO HEATING ROOM T STAT amp PROGRAMMER TIMER PROGRAMMABLE ROOMSTAT TIME amp TEMPERATURE CONTROL TO HOT WATER CYLINDER T STAT amp PROGRAMMER TIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER S INSTRUCTIONS T THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE MEASURE amp RECORD GAS RATE m3 hr ft3 hr BURNER OPERATING PRESSURE IF APPLICABLE N A mbar CENTRAL HEATING FLOW TEMPERATURE C CENTRAL HEATING RETURN TEMPERATURE C FOR COMBINATION BOILERS ONLY HAS A WAT
33. OT be used for storage purposes e The ventilation provided for the boiler during installation MUST NOT be blocked and a check should be made periodically that the ventilation areas are free from any obstruction e Ifitis known or suspected that a fault exists on the boiler then it MUST NOT be used until the fault has been corrected by a CORGI registered installer or in IE a competent person Under NO circumstances should any of the sealed components on this appliance be used incorrectly or tampered with This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety e Children should be supervised to ensure that they do not play with the appliance MINIMUM CLEARANCES A clearance of 450mm 17 3 4 MUST be available at the front of the boiler for servicing The minimum clearances given below MUST be complied with in order to maintain the safe running of the boiler Above the boiler 100 mm 4 At each side of the boiler 5 mm 1 4 Underneath the boiler 100 mm 4 In front of the boiler 5 mm 1 4 TO LIGHT THE BOILER REFER TO FRAME 1 If a programmer is fitted refer to separate instructions for the programmer before continuing 1 CHECK THAT THE ELECTRICITY SUPPLY TO THE BOILER IS OFF
34. Pack 1 off D Pack 3 off Jacking screw for B Pack Product No 201 816 Side flue only boiler alignment D Pack Product No 201 180 Side Outlet Kit Product No 201 866 Note A roof flue kit is available as an optional extra for Measured from centre line of boiler to outside of wall vertical flue installation supplied with separate Note The flue duct MUST be inclined at 1 5 degrees to the fitting instructions Refer to Frames 31 to 35 horizontal to allow condensate to drain back into the boiler and out through the condensate drain Only necessary if using one or more D extension duct packs classic HE Installation amp Servicing 15 INSTALLATION INSTALLATION 11 FLUE ASSEMBLY Exploded View 1 An optional flue duct extension kit is required for wall thicknesses greater than 775mm 30 1 2 side flue Refer to Frame 10 LEGEND Terminal Weather seal optional extra Flue assembly Boiler sealing ring Flue extension pipe O ring 12 WALL MOUNTING TEMPLATE Note The template shows the positions of the fixing holes and the rear flue outlet hole centre for standard installation Care MUST be taken to ensure the correct holes are drilled 1 Tape template into the selected position Ensure squareness by hanging a plumbline as shown 2 If fitting a side flue refer to Frame 21 Mark onto the wall the following The wall mounting plate screw p
35. TING THE BOILER Note The boiler may require two men to lift it onto the wall mounting plate For downward routing of pipes the M5 spacer supplied in the downward piping kit should now be fitted to the back of the boiler 1 The boiler is supplied for rear outlet installation Remove the blanking plate from the top outlet and retain Remove the fan electrical connections the air pressure switch sensing pipe the CO CO sensing pipe and the 2 fan fixing screws and remove the fan Refer to frame 15 Remove the top section of the recuperator Refer to Frame 15 Remove the rubber fan seal and fit this to the new recuperator top outlet casting Fit the blanking plate and gasket to the rear flue hole with the 3 M5 nuts provided Fit the recuperator top outlet casting c w rubber fan seal and retain with the two M5 Screws previously removed Remove the plastic sealing plug and fit the top outlet connecting casting and gasket retaining with the 2 M4 screws and 1 M5 screw provided Refit the fan into the rubber seal and secure with the 2 fixing Screws replace the fan electrical connections air pressure switch sensing pipe and CO CO sensing pipe Lift the boiler onto the wall mounting bracket Remove the bottom packaging protection Jacking screw 10 Check the boiler alignment to the wall using a spirit level and adjust as necessary with the jacking Screw M5 Spacer Line up the hole in the jacking screw w
36. ain the selected temperature Approximate flow temperatures for the boiler thermostat settings are Knob Setting Flow Temperature C F 1 54 130 2 60 140 3 66 150 4 71 160 5 77 170 6 82 180 TO SHUT DOWN THE BOILER 1 Forshort periods Turn the boiler on off switch C to OFF When heating is again required restore the switch to ON 2 Forlonger periods Turn the boiler ON OFF switch C to OFF Switch the electricity supply to OFF TO RELIGHT THE BOILER Repeat the procedure 1 8 detailed in To light the boiler FROST PROTECTION If no frost protection is provided and frost is likely during a short absence from home leave the heating controls at a reduced temperature setting For longer periods the entire system should be drained including the domestic water supply If the system includes a frost thermostat then during cold weather the boiler should be turned OFF at the time switch es ONLY The mains supply should be left switched ON with the boiler thermostat left in the normal running position 1 BOILER CONTROLS View inside boiler controls area CL1036 2 LEGEND BOILER OVERHEAT THERMOSTAT The boiler is fitted with a safety cutout thermostat This will shut down the boiler in the event of overheating Should this occur allow the boiler to cool press the reset button E then relight as detailed in steps 1 8 in To light the boiler I
37. allation amp Servicing connection pipe and blockage sensing pipe are correctly replaced 4 Refit the air box assembly and burner Ensure that the burner 7 Check the sightglass in the boiler casing Clean or renew as 8 Check for gas soundness Check the gas service cock and 9 Refit the boiler casing refer to Frame 49 Note that it is not 2 Unfasten the 2 nuts and washers holding the sightglass assembly to 3 When fixing the new assembly ensure that the parts are in the correct 4 Retighten the 2 nuts to ensure an airtight seal Do NOT overtighten front fixing is refitted 5 Refit the combustion chamber replacing the rope seal if necessary ensuring the two rubber sealing grommets are replaced 6 Reconnect the gas supply and the electrical wiring Refer to Frames 36 amp 41 necessary Refer to Frame 62 pressure test point necessary to disturb the controls casing pod 10 Close the controls pod door MAIN BURNER After any servicing reference should be made to Table 2 which quotes details of the rated output with the related burner setting pressure and the heat input Any required adjustments should be made by using the pressure adjustment screw Refer to initial Lighting Frame 48 Note n order to assist fault finding the control box printed circuit board is fitted with 2 indicator lights which represent the following boiler conditions Neon I3 Mains electricity ON Neon SG1 Flashes to indi
38. any debris from inside the base of the casing 9 Check that the flue terminal is unobstructed and that the flue system is sealed correctly 10 If the appliance has been installed in a compartment check that the ventilation areas are clear The servicing procedures are covered more fully in Frames 54 to 60 and must be carried out in sequence WARNING Disconnect the electrical supply and turn off gas supply IMPORTANT After completing the servicing or exchange of components always test for gas soundness and carry out functional checks as appropriate Refer to Frame 48 item 18 for gas adjustment sealing When work is complete the casing MUST be correctly refitted ensuring that a good seal is made The boiler must NOT be operated if the casing is not fitted 11 Complete the service section of the Benchmark Commissioning Checklist 2 casing retaining Screws Controls door 4 Remove the 4 screws retaining the air box pilot assembly to the vertical manifold and carefully remove the assembly 5 On re fitting the air box assembly remove the old gasket from the manifold and ensure the new gasket is located correctly Check that the joint is made gas tight Ideal Boilers recommend the air box fixing screws be replaced with a torque of 4 0Nm in the number order shown on the diagram below and be repeated to ensure even clamping Air box assembly B b urner ta location 33 SERVICING SERV
39. any other treatment to this product may render the guarantee of Ideal Stelrad Group INVALID Ideal Stelrad Group recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems Ideal Stelrad Group recommend the use of Fernox GE Betz Sentinel or Salamander water treatment products which must be used on accordance with the manufacturers instructions For further information contact Fernox Manufacturing Co Ltd Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ Tel 44 0 1799 521133 or Sentinel Performance Solutions The Heath Business amp Technical Park Runcorn Cheshire WAT 4QX Tel 0800 389 4670 www sentinel solutions net or Salamander Engineering Ltd Unit 24 Reddicap Trading Estate Sutton Coldfield West Midlands B75 7BU Tel 44 0 121 378 0952 Notes 1 It is most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers instructions 2 If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing BS7593 1992 details the steps necessary to clean a domestic heating system 3 In hard water areas treatment to prevent limescale may be necessary however the use of artificially softened water is NOT permitted 4 Under no circumstances should the boiler be fired before the system has been thoroughly flushed
40. are specified in Table 4 and are related to maximum rated heat input Table 4 High and low vent areas Boiler Air from room internal Air direct from space cm in outside cm in HE9 102 16 51 8 HE12 135 21 68 11 HE15 170 26 83 13 HE18 198 31 102 16 3 Both air vents MUST communicate with the same room or internal space or MUST be on the same wall to outside air 4 In siting the air vents care must be taken to avoid the freezing of pipework Water circulation system WATER CIRCULATION SYSTEM The boiler must NOT be used for direct hot water supply For the types of system and correct piping procedure refer to Introduction and Frame 1 The central heating system should be in accordance with BS 6798 and in addition for Smallbore and Microbore systems BS 5449 The domestic hot water system if applicable should be in accordance with the relevant recommendations of BS 5546 Copper tubing to BS 2871 1 is recommended for water carrying pipework The hot water storage cylinder MUST be of the indirect type and should preferably be manufactured of copper Single feed indirect cylinders are not recommended and MUST NOT be used on sealed systems The appliances are NOT suitable for gravity central heating nor are they suitable for the provision of gravity domestic hot water The hot water cylinder and ancillary pipework not forming part of the useful heating surface should
41. ate is produced from the flue gases and this is drained to a suitable disposal point through the plastic waste pipe at the right lower rear of the boiler A condensate plume will also often be visible at the flue terminal SAFETY Current Gas Safety Installation amp Use Regulations or rules in force In your own interest and that of safety it is the law that this boiler must be installed by a CORGI registered installer In IE the installation must be carried out by a competent person and installed in accordance with the current edition of I S 813 domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation It is essential that the instructions in this booklet are strictly followed for safe and economical operation of the boiler ELECTRICITY SUPPLY This appliance must be efficiently earthed Supply 230 V 50 Hz The fusing should be 3A Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm 1 8 contact separation in both poles or a plug and socket serving only the boiler and system controls The means of isolation must be accessible to the user after installation IMPORTANT NOTES This appliance must not be operated without the casing correctly fitted and forming an adequate seal e If the boiler is installed in a compartment then the compartment MUST N
42. b mI Col N Terminal strip Controls support Mains cable Terminal strip Cable clamp Screw Mains connection plate RS O heat thermostat Ty Thermostat sensor L brbr Connect to b N cla7856 Combined spark amp sensing electrode AS On Off switch A must be wired into the mains lead in parallel with the control s to be overridden Refer to Frame 46 3 If a proprietary system is used follow the instructions supplied by the manufacturer 4 System designs featuring controls or wiring arrangements which allow the boiler to fire when there is no pump circulation taking place should not be fitted Advice on required modifications to the wiring may be obtained from the component manufacturers Notes 1 Connection between a frost thermostat and the time control should be made without disturbing other wiring 2 A frost thermostat should be sited in a cool place in the house but where it can sense heat from the system classic HE Installation amp Servicing INSTALLATION 43 PICTORIAL WIRING Limit Flue protection 1 b br gy or bk pk Printed circuit board Thermostat control knob Notes Some earth wires are omitted for clarity Ensure proper earth continuity when wiring Numbering of terminals on thermostats is specific to the manufacturer This is a fully controlled system set the boiler thermostat to maximum
43. building 6 The air inlet products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm 1 to combustible material Detailed recommendations on the protection of combustible material are given in BS 5440 1 2000 In IE refer to I S 813 2002 IMPORTANT It is absolutely ESSENTIAL to ensure in practice that products of combustion discharging from the terminal cannot re enter the building or any other adjacent building through ventilators windows doors other sources of natural air infiltration or forced ventilation air conditioning If this should occur the appliance MUST be turned OFF labelled unsafe and corrective action taken Table 3 Balanced Flue Terminal Position Flue Terminal Positions Min Spacing Directly below or alongside an opening window air vent or other ventilation opening 300mm 12 25mm 1 75mm 3 25mm 1 200mm 8 25mm 1 200mm 8 25mm 1 150mm 6 25mm 1 300mm 12 300mm 12 600mm 24 1 200mm 48 Below guttering drain pipes or soil pipes BS5440 1 2000 Below eaves BS5440 1 2000 Below balconies or a car port roof BS5440 1 2000 From vertical drain pipes or soil pipes BS5440 1 2000 From an internal or external corner or to a boundary along side the terminal BS5440 1 2000 7 Above adjacent ground roof or balcony level From a surface or a boundary facing the terminal From a terminal facing a termina
44. cate ignition operation stops after detection The boiler MUST NOT be operated if the casing is not fitted da7151 Gasket Glass Gasket 35 SERVICING SERVICING SERVICING 63 OVERHEAT THERMOSTAT REPLACEMENT 1 Refer to Frame 61 4 Pull off the electrical connections at the thermostat Remove the backnut retaining the thermostat to the casing Withdraw the thermostat phial from the heat exchanger pocket and 3 Swing the control box down into the servicing position unclip from the casing 2 Remove the control box fixing screws 5 Fit the new thermostat and reassemble in reverse order 6 Check the operation of the boiler cla7742 Backnut 64 THERMOSTAT CONTROL THERMISTOR SENSOR LEAD amp ON OFF SWITCH REPLACEMENT Refer also to Frame 61 A Remove the control box fixing screws B Swing the control box down into the servicing position Thermostat control 1 Pull the knob off the shaft 2 Remove the backnut securing the thermostat control to the control box 3 Pull off the Molex connector from the printed circuit board 4 Replace and reassemble in reverse order Thermistor sensor lead 5 Pull the sensor lead connector off the printed circuit board and cut the cable strap securing the thermistor harness to the bottom panel of the control box if fitted and remove the strap 6 Remove the sensor from the heat exchanger pocket a
45. classic Your Ideal installation and servicing guide See reverse for classic users guide HES HE12 HE15 HE18 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 7 4 BOILERS use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers J e The High Efficiency Pioneers January 2008 UIN 201 850 A06 For the very latest copy of literature for specification purposes please visit our website www idealboilers com where you will be able to download the relevant information in pdf format classic HE Installation amp Servicing DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level A05 Oct 06 to A06 Jan 08 Various Pages Company Name Change Page 26 amp 27 Frames 39 amp 40 Condensate Pipe Termination Configurations BS6798 recommends that a second trap and an air break are required where the siphon trap within the boiler is less than 75mm for configuration 2 and 3 Page 27 Frame 40 Condensate Pipe Termination Configurations Statement added with ref to termination into a down pipe Page 33 Frame 54 Burner and Air Box Removal Item No 5 added Users Guide Page 2 Important Notes 2 new bullet points added Ideal Stelrad Group reserve the right to vary specification without notice classic HE Installation amp
46. der and explain his or her responsibilities under the current Gas T Safety Installation and Use Regulations or rules in force 2 Draw attention to the Lighting Instruction label affixed to the controls pod door 8 3 Explain and demonstrate the lighting and shutting down procedures 4 The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the Householder to ensure the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent 10 damage to the system and to the building in the event of the system remaining inoperative during frosty conditions 5 Explain the function and the use of the boiler thermostat and external controls 32 Stress the importance of regular servicing by a CORGI Knob Setting Flow Temperature C F WARNING The boiler MUST NOT be operated with the casing removed 5 Finally set the controls to the user s requirements The temperatures quoted above are approximate and vary between installations Explain the function of the boiler overheat thermostat and emphasise that if cutout persists the boiler should be turned off and a registered CORGI installer consulted In IE contact a Competent Person Explain and demonstrate the function of time and temperature controls radiator valves etc for the economic use of the system
47. diaphragm type expansion vessel must be connected at a point close to the inlet side of the pump the connecting pipe being not less than 15mm 1 2 nominal size and not incorporating valves of any sort The vessel capacity must be adequate to accept the expansion of the system water when heated to 110 C 230 F The charge pressure must not be less than the static water head above the vessel The pressure attained in the system when heated to 110 C 230 F should be at least 0 35 bar 5lb in less than the lift pressure of the safety valve 1 General The installation must comply with the requirements of BS 6798 and BS 5449 The installation should be designed to work with flow temperatures of up to 82 C All components of the system including the heat exchanger of the indirect cylinder must be suitable for a working pressure of 3 bar 45 Ib in and temperature of 110 C Care should be taken in making all connections so that the risk of leakage is minimised For guidance on vessel sizing refer to the table in Frame 6 For further details refer to BS 5449 For IE refer to the current edition of I S 813 Safety Valve Cylinder The cylinder must be either of the indirect coil type or a direct cylinder fitted with an immersion calorifier which is suitable for operating on a gauge pressure of 0 35 bar 5Ib in in excess of the safety valve setting Single feed indirect cylinders are not suitable for sealed sy
48. e flue in Pack B User s Instructions F 1 year guarantee form Note For side flue applications the optional extra C Hardware Pack listed below side outlet kit is required Unpack and check the contents 14 Hardware Pack 1 Contents gt Pack B Contents INSTALLATION A D B E V LF e Cd 2 e WALL MOUNT ING 9 d TEMPLATE E xi EO meme i TEM a J Pipe Flue extension 1 off E Washer M4 Form C 3 off Screw M4 x 8 PP Taptite 3 off Nut Siphon 1 off F No 14x2 slotted woodscrew 3 off J Nut M5 hex 3 off Washer siphon sealing 1 off G Wallplug 3 off K Screw No 8 x 8 PP S tap 3 off O ring 1 off H Sealing ring 1 off L Polyurethane foam seal 1 off B cla7673 Terminal grille assy 1 off ix7408 classic HE Installation amp Servicing INSTALLATION 9 PACKAGING AND CASING REMOVAL 1 Cut straps and remove outer carton a Casing retaining screws 2 Remove packing from top of boiler Note the wall mounting plate is packed on this packing Front l 3 Leave bottom packing in place ront pane 4 Slightly open plastic controls door to gain access to the front panel fixing screws 5 Remove the front casing as follows and place to one side to avoid damage a Undo the 2 front casing retaining screws a retaining the casing to the back
49. e baffles 2 Inspect the collector hood rope gasket and replace if necessary ensuring that the self adhesive rope is fitted centrally on to the lip of the collector hood fan assembly The boiler efficiency will be adversely affected if incorrectly fitted Refit the collector hood and retain with the 2 front and side tie rods Tighten the nuts and screw Ensure that the sealing gasket is compressed 3 Refit the fan fan electrical connections the thermostat electrical connections the red pressure sensing pipe the blue CO CO sensing pipe and the two fan fixing screws 60 GAS PRESSURE ADJUSTMENT PILOT The pilot is factory set to maximum and no further adjustment is possible If after removing and checking the injector as detailed in Frame 67 and ensuring that there is an inlet pressure of 20 mbar available the pilot does not light then contact Ideal Stelrad Group Relight in accordance with Initial Lighting Frame 48 REPLACEMENT OF PARTS 61 GENERAL When replacing any component 1 Isolate the electricity supply 2 Turn OFF the gas supply 3 Remove the boiler front panel Refer to Frame 53 IMPORTANT When work is complete the casing must be correctly refitted ensuring that a good seal is made 62 SIGHTGLASS REPLACEMENT 1 Refer to Frame 61 the casing front panel order The frame must have the return edge at the bottom 5 Replace the boiler front panel Refer to Frame 49 classic HE Inst
50. e boiler casing 4 Re engage the recuperator top section flue connecting ring into the cla7665 o plastic flue pipe and retain the top section with the two screws previously removed ensure the top section to main recuperator body 2 sealing gasket is correctly positioned in its retaining groove ET Tp 5 Refit the fan fan electrical connections the red pressure sensing pipe and the blue CO CO sensing pipe Refit the 2 fan fixing screws REAR FLUE OUTLET 18 classic HE Installation amp Servicing INSTALLATION 20 FLUE ASSEMBLY Exploded view For wall thickness 270mm to 775mm The optional side outlet kit is required for all side flue applications An optional flue duct extension kit is required for lengths distance from the outside wall to the relevant side of the boiler casing greater than 775mm 30 1 2 Refer to Frame 10 21 WALL MOUNTING TEMPLATE Note The template shows the positions for the fixing holes and the flue hole centres for standard installation If the flow and return pipes are to be routed down behind the boiler the downward routing pipe bracket supplied with the Downward Piping Kit must be used This bracket is secured to the wall and it is essential to use only those holes as shown on the wall mounting template Care MUST be taken to ensure the correct holes are drilled
51. e electrode and pilot shield retaining both with the electrode nut Check the spark gap 3 Remove the electrode retaining nut and remove the pilot paik gap hiel lect RRIPISSH SIS CIBUS 7 Reassemble in reverse order 4 Unscrew the central pilot fixing screw and lift the pilot clear of the pilot injector The pilot injector may now be unscrewed if required 8 Check the operation of the boiler 9 The pilot is factory set to maximum and no further adjustment is possible Ensure there is an inlet pressure of 20 mbar available Also check burner ignition and cross lighting 5 Replace the pilot burner injector if necessary and retain with the M4 screw previously removed Ensure the copper sealing washer is replaced when refitting the pilot injector classic HE Installation amp Servicing 37 SERVICING SERVICING 38 mo om 5 M 68 IGNITION ELECTRODE AND LEAD REPLACEMENT Refer to Frame 61 Remove the burner and air box assembly Refer to Frame 54 Remove the electrode retaining nut Remove the pilot shield Remove the ignition electrode and integral lead Refit the new electrode and lead in reverse order Ensure that the pilot shield is replaced 7 Check the spark gap Refer to Frame 67 8 Reassemble in reverse order 9 Check the operation of the boiler 69 MAIN BURNER AND MAIN BURNER INJECTOR REPLACEMENT Refer to Frame 61 Remove the screw retaining the front burner support
52. ecklist all central heating systems to ensure safety and efficiency You can check your installer by calling CORGI direct on 01256 372300 Ideal Stelrad Group is a member of the Benchmark initiative and fully supports the aims of the programme Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of CZ LLL THE BENCHMARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE classic HE Users POINTS FOR THE BOILER USER Note n line with our current warranty policy we would ask that you check through the following guide to identify any problems external to the boiler prior to requesting a service engineers visit Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit or for any pre arranged visit where access is not gained by the engineer TROUBLESHOOTING TYPICAL NON PRODUCT FAULTS Boiler is not working for central heating or hot water Boiler goes through the ignition sequence but will not fire for central heating or hot water Boiler is operating satisfactorily for domestic hot water but will not operate for central heating Boiler is operating satisfactorily for central heating but will not operate for domestic hot water Boiler will not fire the pilot light is lit but the igniter continues to spark and the main burner does not i
53. ed by a factor of 0 8 for flow temperatures of less than 88 C Table 6 Safety valve setting 2 5 bar Vessel charge and initial system pressure 0 5 1 0 bar bar Total water content of system litres Expansion vessel volume litres 25 50 75 100 125 150 175 200 225 250 275 300 2 3 3 3 4 7 6 7 7 0 10 0 9 4 13 4 11 7 16 7 14 1 20 1 16 4 23 4 18 8 26 8 21 1 30 1 33 5 36 8 40 2 Multiplying factors for other system volumes 0 134 12 classic HE Installation amp Servicing 30 35 cla7926 LEGEND 9 Sightglass 12 Main Burner 17 Gas Valve 19 Control Box classic HE Installation amp Servicing 23 24 26 27 INSTALLATION 7 BOILER ASSEMBLY Exploded view L SN i S SULA up e ex a PCB25E 30 Air pressure switch 35 Controls Casing 37 Flue Protection Thermostat 22 i Fan Front Panel Controls Door p Condensate siphon trap 13 INSTALLATION INSTALLATION 8 UNPACKING The boiler is supplied fully assembled in Pack A Pack A Contents together with a standard flue assembly for lengths from 75mm 3 up to 705mm 27 3 4 rear flue and A The complete boiler D Wall mounting template from 270mm 10 5 8 up to 775mm 30 1 2 side B Installation amp Servicing E Wall mounting plat
54. efer to l S 813 2002 Pipework from the meter to the boiler MUST be of an adequate size The complete installation MUST be tested for gas soundness and purged as described in the above code FLUE INSTALLATION Pluming may occur at the terminal so terminal positions which would cause a nuisance should be avoided The flue must be installed in accordance with the recommendations of BS 5440 1 2000 In IE refer to I S 813 2002 The following notes are intended for general guidance 1 The boiler MUST be installed so that the terminal is exposed to external air 2 It is important that the position of the terminal allows the free passage of air across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 3 4 Where the lowest part of the terminal is fitted less than 2m 6 6 above a balcony above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard Terminals guards are available from boiler suppliers ask for TFC Flue Guard Model No K6 round plastic coated In case of difficulty seek advice from Grasslin UK Ltd Tower House Vale Rise Tonbridge Kent TN9 1TB Tel 44 0 1732 359 888 Fax 44 0 1732 354 445 www tfc group co uk Ensure that the guard is fitted centrally 5 The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of any
55. f the cutout condition still persists turn off the boiler and consult a CORGI registered installer or in IE a competent person CONDENSATE DRAIN The condensate drain F must not be modified or blocked Blockage of the condensate drain caused by debris or freezing can cause automatic shutdown of the boiler If freezing is suspected and the pipe run is accessible an attempt may be made to free the obstruction by pouring hot water over the exposed pipe and clearing any blockage from the end of the pipe If this fails to remedy the problem the assistance of a CORGI registered installer or in Ireland a competent person should be sought ESCAPE OF GAS Should a gas leak be suspected contact your local gas supplier without delay Do NOT search for gas leaks with a naked flame CLEANING For normal cleaning simply dust with a dry cloth To remove stubborn marks and stains wipe with a damp cloth and finish off with a dry cloth Do NOT use abrasive cleaning materials MAINTENANCE The appliance should be serviced at least once a year by a CORGI registered installer or in IE a competent person Controls Sightglass Thermostat knob Mains on off switch Gas service cock shown in the OPEN position Overheat thermostat reset button Condensate Drain All CORGI registered installers carry a CORGI ID card and have a registration number Both should be recorded in the Benchmark Commissioning Ch
56. ge within the dwelling 70mm 2 3 4 Condensate siphon drain 38mm 1 1 2 Side View cla7644 IMPORTANT If excessive external pipework cannot be avoided a condensate removal pump available as an option and insulation are recommended to prevent possible freezing All pipework and fittings in the condensate drain system must be made of plastic No other materials may be used The drain outlet on the boiler is standard 21 5mm overflow pipe This size must not be reduced in any part of its length 39 CONDENSATE PIPE TERMINATION CONFIGURATIONS Note ALL EXTERNAL PIPE RUNS MUST BE INSULATED OR UPSIZED TO 32MM MAXIMUM LENGTH 3M EXTERNAL 1 INTERNAL TO SINK WASTE UPSTREAM OF SINK WASTE Sink constitutes TRAP BOILER air break cla7771 75mm trap Open end of pipe direct into gulley below grating but above water level Ground Level 2 INTERNAL TO SINK WASTE DOWNSTREAM OF SINK WASTE TRAP PREFERRED METHOD Air Break Open end of pipe direct into gulley below grating but above water level cla9252 75m m trap Ground Level continued 26 classic HE Installation amp Servicing INSTALLATION 40 CONDENSATE PIPE TERMINATION CONFIGURATIONS continued 3 INTERNAL CONNECTION TO SOILAND VENT STACK Termination into a down pipe can take place providing it can be confirmed that the down pipe is part of a combined waste and rain BOILER water system Make connection to SVP usi
57. gnite Boiler cycling on and off the fan and burner come on for short periods but the pump can be heard Solution Check on off switch C is in the on position Press overheat thermostat E the boiler should then relight If the fault recurs turn off the boiler and contact the installer Check condensate pipe is not blocked or frozen If blocked clear blockage if not possible to check contact your installer Check gas supply try at another gas appliance e g cooker fire If no gas supply then not a boiler fault contact your gas supplier If an external programmer is fitted check that the central heating channel is at an on period Check that the room thermostat is set at the required temperature Test the room thermostat by turning this fully up if this does not respond contact your installer If an external programmer is fitted check that the domestic hot water channel is at an on period Check that the domestic hot water cylinder thermostat is set at the required temperature Test the cylinder thermostat by turning this fully up if this does not respond contact your installer This is a symptom of crossed polarity i e the live and neutral supply to the boiler are crossed over This is not a boiler fault contact your installer to correct the wiring There is an air lock in the boiler or system pipework and the interrupter thermostat is shutting down the boiler Vent air from the radiator
58. ich the boiler is to be installed must be at least wide enough to accommodate the tool Pelmet O Cupboard cla7635 Front View Side View 380 Pumped a 15 flow pipe Pumped return 296 pipe 115 8 Flue Gas terminal connection Condensate drain point connection L Y Ow 470 2 3 4 280 11 64 2 1 2 classic HE Installation amp Servicing GENERAL Bathrooms This range of appliances is rated IP 1XB The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current E E BS 7671 Wiring Regulations and in Scotland the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower For Ireland reference should be made to the current ETCI rules for electrical installations and 1 5 813 2002 If the appliance is to be installed in a room containing a bath or shower then providing waterjets are not going to be used for cleaning purposes such as communal baths showers the appliance can be installed in Zone 3 as detailed in BS 7671 Where installation will be in an unusual location special procedures may be necessary and BS 6798 gives detailed guidance on this aspect Compartment Installations A compartment used to enclose the boi
59. icing Page Burner operating pressure measure and record Central heating flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reducer Hot water mode Heat input Max operating burner pressure Max operating water pressure Cold water inlet temp Hot water outlet temp n a Water flow rate at max setting For condensing boilers only Condensate drain For all boilers complete sign amp hand over to customer For assistance see Technical Helpline on the back page benchmark GENERAL INTRODUCTION The classic HE 9 12 15 and 18 are a range of automatically fully controlled wall mounted balanced flue fanned high efficiency condensing gas boilers The primary heat exchanger is cast iron The secondary heat exchanger is aluminium The boiler casing is of white enamelled mild steel The boiler casing has a removable controls pod containing a drop down door The boiler thermostat is located behind the drop down door Note These boilers cannot be used on systems which include gravity circulation See Frame 1 for details of the correct boiler tappings to use The boilers are supplied with a standard flue kit suitable for rear outlet from 114 mm 4 1 2 to 705 mm 30 1 2 Side outlet applications require the optional extra side outlet kit The boilers are suitable for connection to the following open vented or sealed systems
60. is made using a separately supplied vertical connector kit 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 For a full accessories list refer to page 6 Optional Extras and Frame 34 Flue Arrangement 32 ROOF FLUE KIT CONTENTS OPTIONS Flue assembly with terminal Flue seal collar 3 5x13 screw Pitched roof tile flat roof tile weather collar Vertical connector 60 100 boiler vertical conversion kit Roof flue extension duct kit 60 100 90 elbow kit 60 100 45 elbow kit 60 100 mxhe7681 Note tems D E F Gand H are not supplied with the roof flue kit classic HE Installation amp Servicing ex7534 23 ad M UU goes BL INSTALLATION 33 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 Pitched Roof e With
61. it out of the holder and disengage the fuse Refer to Frame 78 for fuse location 74 COMBUSTION CHAMBER INSULATION REPLACEMENT 1 Refer to Frame 61 2 Remove the burner and air box assembly Refer to Tie rods Frame 54 3 Remove the 4 tie rods Note remove rubber grommets to gain access to side tie rod screwdriver slots Remove the combustion chamber Remove the 2 side panel retaining brackets Remove the side insulation panels Remove the front and rear insulation panels Fit the new front and rear insulation panels Fit the new side panels and retain with the brackets and screws previously removed S E 10 Reassemble in reverse order Combustion chamber o ec oO Ov classic HE Installation amp Servicing 39 SERVICING SERVICING 1 2 3 4 40 11 SERVICING 75 HEAT EXCHANGER REPLACEMENT Note Refer to Frame 7 Boiler assembly Exploded view for illustration of the procedure detailed below Refer to Frame 61 Remove the burner air box assembly Refer to Frame 54 Drain the system Disconnect the water connections If compression fittings are used then cut the pipes both above and below the fittings in order to allow the heat exchanger assembly to be removed Remove the heat exchanger drain plug and drain the residual water into a suitable receptacle Remove the fan collector hood assembly refer to Frame 55 Pull off the electrical connections fro
62. ith the hole in the wall previously drilled and secure with the cla ore No 14x50mm wood screw Electrical connections 27 CONNECTING THE FLUE TO THE BOILER Note Before fitting the flue turret fill the condensate trap or siphon trap within the boiler by pouring a cupful of water into the flue outlet A Take care to ensure that the water is only poured into the flue outlet and does not spill into the boiler casing 1 Insert the flue assembly through the prepared hole in the wall 2 Fitthe flat self adhesive gasket supplied to the flange of the turret carefully aligning the fixing holes Locate the flue turret on the top of the boiler CHECK THAT THE FLUE SEAL LOCATED IN THE TOP OF THE FLUE MANIFOLD IS SECURE ANDGIVING AN EFFECTIVE SEAL 3 Locate the flue into the turret and push to ensure full engagement 4 Secure the flue turret on top of the boiler with the 4 screws provided 5 Flues over 1 metre long Fix the flue support bracket to the wall using the 2 wall plugs and wood screws classic HE Installation amp Servicing Air pressure switch amp CO CO2 sensing pipes Gasket 21 SIDE FLUE OUTLET INSTALLATION 28 FLUE EXTENSION DUCTS For flue lengths greater than 705mm rear flue or 775mm side flue e Washers 2 off Wall plugs 2 off mxhe7656 Flue duct support 29 FLUE EXTENSION DUCTS continued Flue length Accessories Product No RorL Upto 775 B Pack 1 off see Frame 10
63. l From an opening in a car port e g door or window into dwelling Vertically from a terminal on the same wall Horizontally from a terminal on the wall 1 200mm 48 1 500mm 60 300mm 12 Vertical Terminals Above the roof pitch with roof slope of all angles Above flat roof 300mm 12 300mm 12 600mm 24 1000mm 40 From a single wall face From corner walls Twin Flue Applications Centre distance between air inlet and flue outlet ducts 120mm 5 Only one reduction down to 25mm is allowable per installation otherwise BS5440 1 2000 dimensions must be followed classic HE Installation amp Servicing GENERAL TERMINAL The terminal assembly can be adapted to accommodate various wall thicknesses Refer to Frame 10 AIR SUPPLY Detailed recommendations for air supply are given in BS 5440 2 In IE refer to I S 813 2002 The following notes are for general guidance 1 It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed 2 If the boiler is to be installed in a cupboard or compartment permanent air vents are required for cooling purposes in the cupboard compartment at both high and low levels The air vents must either communicate with room internal space or be direct to outside air The minimum effective areas of the permanent air vents required in the cupboard compartment
64. lassic HE Natural Gas only Boiler size 87 BQ 10 87 BQ 10 87 BQ 10 87 BQ 10 CONTENTS Air Supply3 mve eI eS 9 Benchmark Commissioning Checklist Boiler Clearances Boiler Exploded View Electrical Connections Electrical Regulations Extension Ducts Fitting External Controls FaultFinding Flue Installation Rear installation Side installation Gas Safety Gas Supply Initial Eighting Eee 31 32 Installation Safe Handling Servicing Short List of Parts Spares Replacement System Electrical Diagrams TermminabGuards a aa cee ee cee ee ee Lo 8 Water and Systems Water Treatment For GB to comply with Building Regulations Part L1 Part J 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 BENCHMARK COMMISSIONING CHECKLIST Boiler Make and model Appliance serial no on data badge SEDBUK No Controls Time and temperature control to heating 29 30 Time and temperature control to hot water 29 30 Auto bypass Boiler interlock For all boilers Flushing to BS 7593 Inhibitor Central heating mode Heat input NOTE TO THE INSTALLER COMPLETE THE BENCHMARK COMMISSIONING CHECKLIST AND LEAVE THESE INSTRUCTIONS WITH APPLIANCE classic HE Installation amp Serv
65. ler MUST be designed and constructed specially for this purpose An existing cupboard or compartment may be used provided it is modified for the purpose In both cases details of essential features of cupboards compartment design including airing cupboard installation are to conform to the following BS 6798 The position selected for installation MUST allow adequate space for servicing in front of the boiler and for air circulation around the boiler Refer to Air Supply For the minimum clearances required for safety and subsequent service refer to the wall mounting diagram Frame 2 In addition sufficient space may be required to allow lifting access to the wall mounting plate GAS SUPPLY The local gas supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must NOT be used without prior consultation with the local gas supplier The boiler is to be installed only on a gas supply with a governed meter A gas meter can only be connected by the local gas supplier or by a local regional contractor An existing meter should be checked preferably by the gas supplier to ensure that the meter is adequate to deal with the rate of gas supply required A MINIMUM pressure of 20 mbar MUST be available at the boiler inlet with the boiler operating Installation pipes MUST be fitted in accordance with BS 6891 In IE r
66. m the overheat thermostat and pull off the white rubber tube from the siphon blockage sensing pipe a Rear Flue Outlet Remove the two screws retaining the recuperator top section Pull the recuperator top section to release the flue pipe connection b Side Flue Outlet Remove the 3 screws retaining the top outlet connection casting and remove casting Refer to Frame 26 No 6 7 Remove the combustion chamber by unscrewing the 4 tie rods 8 Remove the thermostat sensors from the pockets on the heat exchanger by removing the M3 screws and plates Remove the condensate sump Refer to Frame 57 Slacken 3 turns only the 2 bottom heat exchanger interpanel retaining screws and remove the top 2 heat exchanger interpanel retaining screws Lift the heat exchanger interpanel assembly upward and forward to disengage key hole fixings Pull the assembly downwards to clear the water pipes from the back panel Note Take care with any residual water held in the heat exchanger recuperator 76 CASING FRONT SEAL REPLACEMENT 1 Refer to Frame 61 Remove the old seal from the casing front and thoroughly clean the casing surface Fit the new self adhesive seal Replace the boiler casing front Reverse of casing panel 12 Remove the 2 rubber sealing grommets from the top of the back panel to facilitate fitting the new assembly 13 Fit the new heat exchanger assembly complete with water pipes and hang it on the bottom ke
67. nd unclip from the casing 7 Remove the strain relief bush from the back panel base 8 Remove the sensor lead through the grommet in the control box 9 Replace and reassemble in reverse order ensuring the new cable strap is fitted and securing the thermistor harness On off switch 10 Disconnect the electrical connectors from the rear of the switch 11 Press in the 2 side retaining clips and remove the Switch 12 Reassemble in reverse order Cla 2655 36 classic HE Installation amp Servicing SERVICING 65 LIMIT THERMOSTAT REPLACEMENT ketum pipe Bonds y 1 Refer to Frame 61 2 Remove the limit thermostat assembly from the boiler flow pipe 3 Disconnect the electrical connectors 4 Clip new thermostat onto flow pipe 5 Reassemble in reverse order NOTE UNDER NO CIRCUMSTANCES REFIT THE LIMIT THERMOSTAT ONTO THE RETURN PIPE 66 FLUE PROTECTION THERMOSTAT REPLACEMENT 1 Refer to Frame 61 2 Pull off the two electrical connections 3 Remove the two nuts retaining the flue protection thermostat 4 Replace the thermostat and re assemble in reverse order 67 PILOT BURNER REPLACEMENT N Spark gap 7 3 to 5 mm Pilot shield X Electrode e Pilot burner Electrode retaining O N nu D screw Ld Pilot er 25mm 1 PE burner ZA 1 Refer to Frame 61 va Electrode 2 Remove the burner and air box assembly Refer to Frame 4 i 6 Replace th
68. nding section 9 Test for gas soundness around ALL boiler gas components using leak detection fluid 10 Operate the boiler for 10 minutes to stabilise the burner temperature TO LIGHT THE BOILER 11 The boiler is pre set at the factory to its nominal rating If the burner pressure measured is incorrect it may be reset using the following procedure Refer to Table 2 page 4 a Set the mains On Off switch H to OFF 1 Check that all the drain cocks are closed and any valves in the flow and return are open 2 Check that the gas service cock B is OPEN and the boiler mains On Off switch H is OFF b Switch the electricity supply OFF 3 Fitting the Boiler Casing See diagram A Frame 49 c Swing the control box down into the servicing position R the main b djust E Hook the top edge of the boiler front casing into the channel de RAMOS M DN c es Sr PERE on the top of the boiler assembly Swing the bottom of the e Turn the adjusting screw clockwise to INCREASE the casing down and secure with the 2 captive screws pressure or anticlockwise to DECREASE the pressure The casing must seat correctly and compress the sealin strip to si an airtight joint y P 9 f Swing the control box back into its working position Visually check the side seals but if side clearances are g Switch the electricity supply ON limited then check that the top and bottom edges of the h Set the mains On Off switch H to ON and check the casi
69. ng a solvent welded saddle Air Break v cla9253 m 4 TERMINATION TO SOAK AWAY External E wall GEHE EE BOILER ERER Termination to Soak away cla7774 Ground Level 5 TERMINATION TO DRAIN GULLEY External wall Open end of pipe direct into gulley below grating but above water level BOILER cla7775 Ground Level classic HE Installation amp Servicing 27 INSTALLATION INSTALLATION INSTALLATION 41 ELECTRICAL CONNECTIONS 3 WARNING The appliance must be efficiently earthed 4 A mains supply of 230 V 50 Hz is required All external controls and wiring must be suitable for mains 5 voltage Wiring should be in 3 core PVC insulated amp sheathed 6 cable not less than 0 75mm 24 x 0 2mm to BS 6500 Table 16 Wiring Regulations and local regulations For IE reference should be made to the current ETCI rules for electrical installations Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm 1 8 contact separation in both poles or a plug and socket serving only the boiler and system controls The means of isolation must be accessible to the user after installation 1 Remove controls pod by slackening front fixing screws and pull pod forward may find it easier to remove the controls pod door 2 Remove the control box securing screws Swing the box down into the servicing position
70. ng are correctly located new setting pressure To gain access to the gas valve 12 If necessary repeat steps 11a to h until the required a Remove the controls support casing Release the pressure is achieved Record this value in the Benchmark controls support front fixing screws 3 turns only Remove Commissioning Checklist the pod by pulling it forward to disengage from the 13 Set the main On Off H switch to OFF keyhole slots 14 Switch the electricity supply OFF b Remove the control box securing screws and swing it 15 Swing the control box down into the servicing position down into the servicing position See diagram B Frame 49 16 Refit the main burner pressure adjuster cover 4 Slacken the screw in the burner pressure test point F and 47 Remove the pressure gauge and tube Retighten the connect a gas pressure gauge via a flexible tube sealing screw in the pressure test point Ensure a gas 5 Swing the control box back into its working position tight seal is made 6 Press the overheat thermostat reset button J 18 After the gas pressure checks and any adjustment operations the adjustment screw cover must be sealed 7 itch the electricit ly ON heck that all ext I i dra dle with a suitable paint to highlight unauthorised adjustment controls are calling for heat continued classic HE Installation amp Servicing 31 INSTALLATION INSTALLATION INSTALLATION 49 INITIAL LIGHTING continued
71. not crossed over Is there a supply on terminals of main gas valve Does the NO spark now cease when gas is lit YES Is there a supply voltage at pilot gas valve Is the main burner injector clear YES Replace main gas solenoid valve YES NO Check for condensate blockage Reset the overheat stat Set control stat to maximum Allow the boiler to reach temperature if the overheat stat trips again measure flow temperature If above 90 C replace control stat If below 90 C replace overheat stat Replace the overheat thermostat Replace the sensor Replace fuse BUT before attempting to start boiler check for short between live and neutral also between live and earth on all items plugged into PCB Check all connections to PCB If no error found replace PCB Check connections and leads to pressure switch If no fault found change pressure switch Check PCB by substitution Change limit thermostat Reset flue protection thermostat Change flue protection thermostat Check gap at ignition electrode Check electrode and lead are undamaged and not close to earthed metalwork b N Y Y ES O NO ES NO ES NO YES Check all connections to PCB If no fault found change PCB Check pressure switch sensing pipes for blockages bad connections and reversed connection Check S trap for blockage Is pressure difference at switch greater than 0 9 mbar
72. of its products The right is therefore reserved to vary specification without notice Technical Training The Ideal Boilers 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 498 432 CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001 2000 Quality System accepted by BSI Ideal The High Efficiency Pioneers Ideal Stelrad Group Ideal Installer Technical Helpline 01482 498 663 www idealboilers com classic Your Ideal users guide See reverse for Classic installation amp servicing instructions HES HE12 HE15 HE18 When replacing any part on this appliance use only spare parts that you can be 7 4 i BOILERS i assured conform to the safety and performance specification that we require D t J e o no use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers The High Efficiency Pioneers classic HE Natural Gas Only Destination Countries GB IE HE9 G C Appliance No 41 415 58 HE12 G C Appliance No 41 415 59 HE15 G C Appliance No 41 421 45 HE18 G C Appliance No 41 421 46 INTRODUCTION The classic HE is a wall mounted room sealed high efficiency condensing boiler featuring full sequence automatic spark ignition and fan assisted combustion Due to the very high efficiency condens
73. ositions choose one from each group Note Mark the centre of the flue hole as well as the circumference The position of the flue duct hole The jacking screw fixing hole Remove the template from the wall 13 PREPARING THE WALL IMPORTANT Ensure that during the cutting operation aid masonry falling outside of the building does not cause ae nog te c damage or personal injury g 1 Cut the flue hole preferably with a 125mm 5 core boring tool ensuring that the hole is square to the wall If the hole has been quite accurately cut with a drill then making good the wall faces is not essential as seals are provided at both ends of the flue However both wall faces immediately around the cut hole should be flat make good if necessary For less accurate holes make good to approximately 125mm 5 diameter at the two wall faces through wall Drill 3 holes two for the wall mounting plate and one for the jacking screw with an 8mm 5 16 masonry drill Insert the plastic pl ided RR E E Note Check all of the hole positions BEFORE drilling j Il a B 0 Il gt J L t Il M 16 classic HE Installation amp Servicing INSTALLATION 14 CUTTING THE FLUE wall thicknesses of 75 to 705mm Note f the downward piping kit bracket is to be used it is essential that 30mm is added to the measured wall thickness when marking the flue Measure and note the
74. panel b Lift the bottom of the front of the boiler casing up slightly then unhook from the top cla7630 6 Remove the hardware pack from the inside of the boiler Remove the boiler from its packaging base But do not Packaging base remove bottom packaging The boiler may now be stood upright on its controls support protection frame to ease Controls pod casing handling and installation 8 Unpack the boiler terminal box pack B and if applicable the extension flue box es pack D 10 DETERMINING THE FLUE LENGTH FLUE KITS Itis MOST IMPORTANT that the boiler is installed Pack B supplied as standard in a vertical position Pack D optional extension kit for side flue or vertical flue outlet Refer to Frame 28 Side Outlet Kit For side outlet applications Refer to Frame 20 2T BEARELUE 1 A maximum of 3 extension ducts plus the standard flue duct INSTALLATION may be used together 2 Flue extensions of greater than 1m 39 should be supported with the bracket provided 90 Elbow kit equivalent flue length resistance 1 5m 45 Elbow kit equivalent flue length resistance 1 0m Flue length for rear gt 190mm 190mm Flue length mm Accessories From 75 up to 705 Rear flue or B Pack 1 off From 270 up to 775 Side flue 775 to 1680 B Pack 1 off D Pack 1 off SIDE FLUE INSTALLATION CLA7636 1680 to 2585 B Pack 1 off D Pack 2 off 2585 to 3000 B
75. points at a lower level then a double check valve shall be installed upstream of the draw off point c Through a temporary hose connection from a draw off tap supplied from a service pipe under mains pressure Where the mains pressure is excessive a pressure reducing valve shall be used to facilitate filling The following fittings shall form a permanent part of the System and shall be fitted in the order stated A stop valve complying with the requirements of BS 1010 Part 2 the hose from the draw off tap shall be connected to this fitting A test cock A double check valve of an approved type Thoroughly flush out the whole of the system with cold water without the pump in position With the pump fitted fill and vent the system until the pressure gauge registers 1 5 bar 21 5lb in Examine for leaks Check the operation of the safety valve by manually raising the water pressure until the valve lifts This should occur within 0 3 bar 4 3lb in of the pre set lift pressure Release water from the system until the initial system design pressure is reached Light the boiler and heat the system to the maximum working temperature Examine for leaks Turn off the boiler and drain the system while still hot Refill and vent the system Sizing procedure for expansion vessels The volume of the expansion vessel litres fitted to a sealed system shall not be less than that given by Table 6 multipli
76. s and ensure all thermostatic radiator valves are in the open position If unable to free the air lock contact your installer Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance Ideal Consumer Helpline of its products The right is therefore reserved to vary specification without notice Tel 01482 498660 www idealboilers com i Id al The High Efficiency Pioneers Ideal Boilers P O Box 103 National Ave Kingston Upon Hull HU5 4JN Tel 01482 492251 Fax 01482 448858 Registration No London 322 137
77. stems A spring loaded safety valve complying with the relevant requirements of BS 6759 must be fitted in the flow pipe as close to the boiler as possible and with no intervening valve or restriction The valve should have the following features a A non adjustable pre set lift pressure not exceeding 3 bar 45 Ib in b A manual testing device Make up Water Provision must be made for replacing water loss from the system either c Provision for connection of a discharge pipe The valve or discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to a From a manually fitted make up vessel with a readily visible water level The vessel should be mounted at least 150mm 6 above the highest point of the the occupants of the premises or cause damage to electrical components and wiring Pressure Gauge A pressure gauge covering at least the range 0 4 bar 0 60 Ib in must be fitted to the system The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel classic HE Installation amp Servicing system and be connected through a non return valve to the system fitted at least 300mm 12 below the make up vessel on the return side of the domestic hot water cylinder or radiators Where access to a make up vessel would be difficult by pre pressurisation of the system Refer to Filling 11
78. strap to the combustion chamber Remove the M5 pozi screw situated at the left hand bottom rear of the burner Pull the burner downward to disengage the retention tab and remove the burner At this stage the main burner injector can be removed checked cleaned or replaced as required Ensure that a new copper sealing washer is used Fit the new burner ensuring that the retention tab is correctly located in the air box slot and reassemble in reverse order Check the burner for cross lighting and flame stability 70 GAS CONTROL VALVE REPLACEMENT 1 Refer to Frame 61 Remove the burner and air box assembly Refer to 8 Remove the 4 screws retaining the manifold to the gas Frame 54 Remove the control box fixing screws Swing the control box down into the servicing position 4 Disconnect the gas control valve electrical leads 5 Undo the gas cock union 6 Whilst supporting the gas control valve remove the 2 screws retaining the manifold to the back panel SERVICING Pilot shield Electrode NC retaining VA nut Burner tab Air box assembly IRTAB location i Burner fixing C Screw see note 3 Main burner injector 7 Remove the gas control manifold assembly control valve and fit the manifold to the new valve Ensure that the new control is fitted the correct way round an arrow engraved on back indicates the direction of flow 9 Transfer the gas cock union to the ne
79. tem 4 3 14 SZ 13010 1926 or LANDIS amp GYR 2 SK2 LL4453 etc ud or A C L ub 679 H 308 D cr 1 2 4 DRAYTON gy 3 1 N ZV22 or ZV28 or SOPAC dee zv20 2EBete bk DANFOSS NE DMV 2 Y or 1 SWITCHMASTER see Auto Zone VM4 note 4 o Terminal strip Er suitably 5 L enclosed E E o a 0 D o Ooc on pattie _ gt ool 030 E L 0 FO 6 B Change over Typical shown satisfied programmer using change over contacts To system controls Designation of the terminals will vary but the programmer and thermostat manufacturer s leaflets will give full details If a boiler is installed in a garage it may be necessary to fit a pipe thermostat Diagram A shows a double pole frost thermostat which should suffice for all systems which do not use the OFF terminals of the programmer Diagram B shows a change over frost stat which will cover most systems which do use CH OFF If however on such a system the HW pipework is in an isolated part of the house a second frost stat may be used to protect it If in doubt ask your installer for advice classic HE Installation amp Servicing INSTALLATION 47 COMMISSIONING AND TESTING The Benchmark Log Section of this book or equivalent self certification should be completed and signed to demonstrate compliance with Building Regulations A ELECTRICAL INSTA
80. the sampling point on the top RHS of the back panel For correct boiler operation the CO CO content of the flue gas should not be greater than 0 004 ratio If this is the case and the gas input is at least 9096 of the nominal then no further action need be taken If not proceed to paragraph 3 3 Clean the main burner Refer to Frame 56 4 Clean the heat exchanger Refer to Frame 55 53 BOILER FRONT PANEL REMOVAL 1 Open the controls pod door and release the 2 captive screws at the bottom of the casing then unhook the casing front panel from the back panel and remove Retain the front panel in a safe place 2 Isolate the gas supply at the service cock fitted to the boiler 54 BURNER AND AIR BOX REMOVAL 1 Remove the screw retaining the front burner support strap to the combustion chamber Remove the M5 pozi situated at the LH bottom rear of the burner and pull the burner downwards to disengage the retention tab Remove the burner to a safe place for inspection and cleaning 2 Remove the 2 control box fixing screws Swing the box downwards to disengage 3 Pull the HT lead connection off the printed circuit board and pull the lead upwards through the bottom panel grommet classic HE Installation amp Servicing 5 Clean the main and pilot injectors Refer to Frame 56 6 Clean the recuperator Refer to Frame 57 7 Remove and clean the siphon Refer to Frame 58 and then check the drain for blockage 8 Remove
81. ty of C NC terminals START Is the mains on neon I3 illuminated S NO Is there a live supply on EITHER terminal of overheat stat YES Can the overheat stat be reset when the System is cold Is there a live supply on BOTH terminals of overheat stat Check that the boiler thermostat is set at maximum and the mains on off switch is ON Is the fan turning Remove the sensor NTC from the PCB Is the fan turning YES NO NO Is there a supply on the fan m connector at PCB Molex Has the fuse blown on PCB to marked FAN NO YES Is there a live supply on the violet lead to pressure switch Is there a supply at the fan YES YES NO Change Rectify bad Is there a live supply on the red fan connection lead to the pressure switch YES UE Is there a live supply on Is the ignition electrode sparking BOTH terminals of limit stat YES NO YES Is there a live supply on BOTH um terminals of the flue protection stat Does the pilot light NO YES Is there a regular spark from tube SG1 on the PCB Is there a gas Does the spark NO stop after the pilot is lit NO YES supply to the boiler Is the boiler casing YES correctly fitted Check the polarity of the mains supply Check the continuity of the ignition lead from connector to electrode Is the pilot injector blocked Does main burner cross light from pilot Ensure pilot and main gas valve leads are
82. ue Finishing Kit Roof Flue Kit High Level Flue Outlet Kit Flue Deflector Kit OTHER OPTIONAL KITS Downward Piping Kit Condensate Pump Kit 6 CURRENT GAS SAFETY INSTALLATION AND USE REGULATIONS OR RULES IN FORCE The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation must be carried out by a CORGI Registered Installer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation and Use Regulations The appropriate Building Regulations either The Building Regulations The Building Standards Scotland Building Regulations Northern Ireland The Water Fittings Regulations or Water byelaws in Scotland e The Current I E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a Competent Person and installed in accordance with the current edition of 1 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice BS 6891 Low pressure installation pipes BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW BS 5449 Forced circulation
83. w gas control valve using an approved jointing compound 10 Reassemble in reverse order 11 Check the operation of the boiler 12 Refer to Frame 48 item 18 for gas adjustment sealing classic HE Installation amp Servicing SERVICING 71 FAN REPLACEMENT PII prESSUrE Switch ee Electrical CO CO sensing pipes canneliaiis 1 Refer to Frame 61 2 Remove the two fan electrical connections the red pressure sensing pipe the blue CO CO sensing pipe and the two fan fixing screws 3 Pull the fan forward remove and retain 4 Fit the new fan and reassemble in reverse order ensuring the fan leads 2 sensing tubes and the two fan fixing screws are reconnected Fixing 5 Check the operation of the boiler screws Refer to Frame 61 el Remove the APS fixing screw Remove the 2 sensing tubes from the APS Remove the 3 electrical connections from the APS Fit the new APS and reassemble in reverse order oa fF ON BS Check the operation of the boiler 73 PRINTED CIRCUIT BOARD PCB REPLACEMENT 1 Refer to Frame 61 5 Disengage the PCB from the mounting posts and withdraw 2 Remove the control box fixing screws and swing the from the control box control box down into the servicing position 6 Fit the new PCB and reassemble in reverse order 3 Disconnect the detection lead from the PCB 7 Check the operation of the boiler 4 Unplug all the Molex connectors from the PCB Fuse To change the fuse prise
84. wall thickness X Refer to Frame 10 Mark the wall thickness onto the flue To ensure the tube is cut square mark the flue all the way around Position the inner flue spring to support the inner flue during the cutting process Cut to length X refer to Frame 10 Remove any burrs and remove the inner flue support ring Measure from this RING 15 FITTING THE FLUE CONNECTING RING AND THE BOILER SEALING RING TO THE FLUE Remove the two fan electrical connections the red pressure sensing pipe the blue CO CO sensing pipe and the two fan fixing screws 2 Pull the fan forward remove and retain 3 Remove the two fixing screws retaining the removable top section of the aluminium recuperator and carefully lift the recuperator top section from the main body Fixing screws 4 Fit the O ring to the flue extension ring and fit the flue extension ring to be found in the boiler hardware pack to the rear of the recuperator top section using the three M4 x 10 taptite screws and form C washers also to be found in the boiler hardware pack 5 f using the flue finishing kit push the black outer wall seal over the outer flue duct Refer to Frame 16 prior to fitting the flue ring Fit the boiler sealing ring inside the terminal B pack outer flue duct Ensure the boiler sealing ring is fully engaged Ensure the notch aligns with the label on the outer flue duct This ensures correct alignment of the flue terminal
85. weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by the local authority The boiler must not be fitted outside Timber Framed Buildings If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineering document IGE UP 7 1998 continued on page 8 classic HE Installation amp Servicing GENERAL 1 BOILER WATER CONNECTIONS Pumped 1 SNS Pumped return flow This appliance in NOT suitable for use in a direct hot water system or for gravity circulation 2 BOILER CLEARANCES The following minimum clearances must Front clearance 450mm 17 3 4 from the front of the boiler casing be maintained for operation and servicing Minimum front clearance when built behind a concealed panel is 5mm 4 Additional space will be required for provided that the top and bottom of the casing is not enclosed and the side installation depending upon site clearance is 40mm 2 at both sides conditions See also Table 4 Side and Rear Flue sab RIINA 5 1 4 a Provided that the flue hole is cut H p Siearance __ accurately e g with a core drill the flue can be installed from inside the building Installation from inside ONLY If a core boring tool is to be used inside the building the space in wh
86. y hole slots and screws Refit the top 2 screws and tighten 4 Screws 14 Replace the 2 rubber sealing grommets 15 Reassemble in reverse order 16 Remake all water connections ensuring that the compression fittings if used are correctly refitted 17 Fully test all functions including water and gas soundness classic HE Installation amp Servicing 77 SIPHON REPLACEMENT 1 Refer to Frame 61 2 Remove the burner Refer to Frame 54 3 Pull the heat shield forward to remove from clips 4 Pull off the rubber sump connecting pipe and the blockage sensing pipe 5 Unscrew the siphon union connection 6 Remove the two siphon retaining Screws and remove siphon 7T Re fit the new siphon and gasket and reassemble in reverse order ensuring the rubber sump connecting pipe and blockage sensing pipe are correctly replaced 8 Ensure the siphon is charged with water and the heat shield is replaced classic HE Installation amp Servicing SERVICING 41 SERVICING Z a Z n 1 lt L e a Z n r lt L a e n r q n NO Replace Check all connections to PCB gas valve If no fault found replace PCB 2 FAULT FINDING Check mains supply and fuses Check programmer and system thermostats are all ON Check that boiler plug and socket are OK and fully connected YES If condensate pump kit fitted check continui

IDEAL INDUSTRIES HE12 Boiler User Manual

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