Ideal Boilers HE15 Installation And Servicing Download Page 25

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INSTALLATION

icos system -

Installation and Servicing

29 WATER CONNECTIONS

Notes.

For heating loads in excess of 60,000 Btu/h use 28mm x 22mm
connectors to connect the boiler flow and return pipes to 28mm
system pipework.

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

nm84

22mm copper pipe

Isolating valve

(

shown in the

open position

)

Piping frame

Drain
point

Condensate drain
pipe located here

22mm copper pipe

Isolating valve

(

shown in the

open position

)

Pressure gauge

FLOW

RETURN

Compression
gas coc

The safety valve is located at the bottom RHS of the boiler.

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

28 SAFETY VALVE DRAIN

INST

ALLA

TION

200214-11.pmd

17/11/2006, 09:35

Summary of Contents for HE15

Page 1: ... specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers For users guide see reverse of book 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 For details of document amendments refer to page 3 HE...

Page 2: ...2 icos system Installation and Servicing ...

Page 3: ...rame 15 Preparing the Wall Item no 3 Screw description changed to 14 x 2 Page 20 Frame 21 Fitting the Piping Frame and Valves New pictorial image of compression gas cock Page 23 Frame 25 Mounting the Boiler Item no 6 Fibre washer is now blue not green Page 24 Frame 27 Gas Connection Fibre washer is now blue not green New pictorial image of compression gas cock Page 25 Frame 29 Water Connections Ne...

Page 4: ...Ireland Countries of destination PMS Maximum operating pressure of water C13 C33 C53 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 up stream of the combustion chamber I2H An appliance designed fo...

Page 5: ...ated For assistance see Technical Helpline on the back page Page Burner operating pressure n a Central heating flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reducer n a Hot water mode Heat input n a Max operating burner pressure n a Max operating water pressure n a Cold water inlet temp n a Hot water outlet temp n a Water flow rate a...

Page 6: ...stem is supplied at the selected temperature of between 30o C and 82o C Expansion vessel Automatic air vent Heat exchanger Gas valve Pump Safety relief valve Condensate S trap Water pressure gauge Sump Fan Burner Flow Gas Condensate drain Discharge pipe Ecl 2789 Return Refer also to Frame 1 Boiler Water Circuit Diagram The boiler features a comprehensive diagnostic system which gives detailed info...

Page 7: ...s or as otherwise recommended by Caradon Ideal Limited in writing If in doubt please enquire Any direct connection of a control device not approved by Caradon Ideal Limited could invalidate the 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 insulati...

Page 8: ... the plastic fascia should be removed See Frame 38 Bottom clearance After installation can be reduced to 5mm in an adequately ventilated enclosed cupboard However 100mm must be available for servicing REARFLUEONLY MIN Top clearance required 145 mm 5 3 4 where wall thicknesses do not exceed 600mm 24 Where the space into which the boiler is going to be installed is less than the length of flue requi...

Page 9: ...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 ...

Page 10: ... bypass between the boiler flow and return is fitted to ensure adequate flow when all TRVs are closed For further information refer to the Good Practice Guide 143 a publication of the Energy Efficiency Office available from the Building Research Establishment Garston Watford WD2 7JR Tel 44 0 1923 664258 ELECTRICAL SUPPLY WARNING The appliance MUST be efficiently earthed Wiring external to the appl...

Page 11: ...ce pipe under mains pressure Where the mains pressure is excessive a pressure reducing valve must be used to facilitate filling When installing the filling device it must be connected as below to fully comply with the water regulations This may involve the fitting of an additional WRAS approved isolator valve to the mains supply i Thoroughly flush out the whole system with cold water ii Fill and v...

Page 12: ...ustion chamber insulation 13 Heat exchanger 14 Injector housing 15 Venturi assembly 16 Fan assembly 7 BOILER ASSEMBLY Exploded View Legend 51 Mains connector 53 Turret gasket kit 57 CH return stub 58 CH flow stub 61 Pressure relief valve 62 Expansion vessel 63 Expansion vessel pipe assy 64 Pressure gauge 69 Pump 70 Pumpmanifold 75 Control box clamp 94 Ignition lead 103 Dry fire thermistor Fernox M...

Page 13: ...13 INSTALLATION icos system Installation and Servicing 8 BOILER ASSEMBLY Exploded View nm8038 103 40 94 INSTALLATION ...

Page 14: ...turret Flue terminal Flue support cutting aid Ecl 2354 Flue terminal Flue turret nm8023 B C E A D F Hardware Pack Contents A Isolation valve c w pressure gauge 1 off B Isolation valve c w drain 1 off C Compression gas cock 1 off D Valve securing clip 22mm 2 off E Valve securing clip 15mm 1 off F Pre piping frame support bracket 1 off G S trap hose 1 off H 15mm olive 1 off I Pressure relief valve n...

Page 15: ...the instructions and read thoroughly before unpacking the product 5 When ready for installation lift off the cardboard carton 10 PACKAGING REMOVAL 11 BOTTOM PANEL REMOVAL 1 Remove the screws from the underside of the boiler 2 Pull the RHS of the panel down slide it to the right and withdraw 3 Remove the screws from bottom of the front panel 4 Lift panel up and off top pegs Boiler Hardware pack box...

Page 16: ...Wall thickness plus boiler spacing Dimension S Stand off frame depth 33mm 12 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED Notes 1 The flue duct MUST be inclined at 1 5 degrees to the horizontal to allow condensate to drain back into the boiler and out through the condensate drain 2 If the boiler is to be installed with upward piping routed behind the boiler then the optional stand off kit s...

Page 17: ...o the side wall Tape template B into the selected position 4 Mark onto the wall the following a The piping frame screw positions choose one from each group b The position of the flue duct hole see diagram below and template Note Mark the centre of the hole as well as the circumference 5 Remove the template from the wall 14 WALL MOUNTING TEMPLATE 13 FLUE ASSEMBLY Exploded View An optional flue duct...

Page 18: ... CUTTING THE FLUE REAR Wall thicknesses of 114 to 490mm Notes a If using the extension ducts go to Frame 18 b If the stand off frame is used it is essential add 33mm to X the measured wall thickness when marking the flue this will allow for the fitted frame 1 Measure and note wall thickness X Refer to Frame 12 2 Add 90mm 3 1 2 to dimension X and measuring from the ring cut the outer tube only 3 To...

Page 19: ...e clamp provided clamp the flue lengths together 5 Repeat steps 1 4 if a second flue extension is required 6 Measure and mark the flue length required onto the flue measuring from the ring near the terminal 7 To ensure a square cut mark the flue all the way around 8 Cut to length using the cardboard support aid 9 Remove the cardboard and deburr the metal edges 20 FITTING THE KIT 18 FLUE EXTENSION ...

Page 20: ...me Wall plug Screw 10mm proud Support bracket nm8444 TOFITTHEPRE PIPINGFRAMEUSINGTHESTAND OFFFRAME OPTION KIT To allow pipework to be taken upwards Put the screws into the wall plugs and leave 10mm proud Hang the stand off frame onto the screws and tighten up Fasten the piping frame to the stand off frame with the 6mm screws provided Locate the support bracket on the piping frame Note If the clear...

Page 21: ...ANT If excessive external pipework cannot be avoided an additional siphon kit and insulation are recommended in order 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 5 mm overflow pipe This size must not be reduced in any part of its length BOILER cla7771 75mm ...

Page 22: ...RNAL CONNECTION TO SOILAND VENT STACK Make connection to SVP using a solvent welded saddle BOILER External wall Ground Level Termination to Soak away cla7774 minimum 500mm BOILER External wall Ground Level Open end of pipe direct into gulley below grating but above water level DRAIN cla7775 4 TERMINATION TO SOAKAWAY 5 TERMINATION TO DRAIN GULLEY ...

Page 23: ...e boiler to the frame 3 Lift the boiler onto the wall mounting frame locating it over the tabs at the top of the frame 4 Lower the boiler into position engaging it onto the support bracket Note Ensure the condensate drain pipe is correctly positioned through the hole in the pre piping frame before continuing 5 Using the fibre washers supplied in the hardware pack box engage and then tighten the 2 ...

Page 24: ...cing for details of the pressure test point position nm7898 2 1 3 26 CONNECTING THE FLUE TO THE BOILER 1 Locate the flue into the turret 2 Insert the flue assembly through the prepared hole in the wall 3 Locate the flue turret on the top of the boiler ensuring that the turret gasket is in place Check that the flue A seal located in the top of the flue manifold is secure and giving an effective sea...

Page 25: ...461 22mm copper pipe Isolating valve shown in the open position Piping frame Drain point Condensate drain pipe located here 22mm copper pipe Isolating valve shown in the open position Pressure gauge FLOW RETURN Compression gas cock The safety valve is located at the bottom RHS of the boiler The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to th...

Page 26: ...ng valves are open 4 Fill and vent the system Check for water soundness IMPORTANT when filling a When filling there may be a slight water leak from the vent therefore electrical connections should be protected b Bleed any air from the pump and ensure that it is free to rotate i Remove the vent plug ii Using a screwdriver rotate the shaft several times iii Replace the vent plug Note Some slight wat...

Page 27: ...ductor 32 INTERNAL WIRING Wiring should be 3 core PVC insulated cable not less than 0 75 mm2 24 x 0 2mm and to BS 6500 Table 16 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 soc...

Page 28: ... which case the programmer selector switches are set to OFF and all the 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 If the boiler is installed in a garage it may be necessary to fit a pipe thermostat preferably on the return pipework Designation of the terminals will vary but the programmer and...

Page 29: ...N icos system Installation and Servicing Dry fire thermistor nm8042 34 PICTORIAL WIRING DIAGRAM LEGEND b blue bk black br brown gy grey or orange pk pink r red v violet w white y yellow y g yellow green INSTALLATION ...

Page 30: ...e preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable test meter B Gas Installation 1 The whole of the gas installation including the meter should be inspected and tested for soundness and purged in accordance with the recommendations of BS 6891 In IE refer to I S 813 2002 2 Purge air from the gas installation by the approved me...

Page 31: ...ne display to inform the user about the status The display will show the status of the boiler The neon will show the status of the flame If no flame is detected the neon is blinking When the flame is detected the neon will be lit permanently Below is a list with the display function in normal operation Standby no demand for heat present Boiler is active for central heating Boiler is in lockout for...

Page 32: ...hecks for correct operation 1 Ensure that the external controls are calling for heat After ignition the display should read white neon on 2 Gas Rate Check the boiler gas rate when the boiler is at full output checked at the gas meter with no other appliance in use Refer to Table 2 for gas rates 3 Set the external controls to OFF The burner should go off and the pump continue to run for a few secon...

Page 33: ...benefits of the Ideal Care Scheme details of which are outlined in the householder pack supplied with this boiler 1 Hand the User Instructions to the householder and explain his her responsibilities under the relevant national regulations 2 Explain and demonstrate the lighting and shutting down procedures 3 The operation of the boiler and the use and adjustment of all system controls should be ful...

Page 34: ...hould be replaced 7 Check the main injector for blockage or damage 8 Wherever possible remove and clean the condensate S trap refer to Frame 47 and check the drain for blockage 9 Check that the flue terminal is unobstructed and that the flue system is sealed correctly The servicing procedures are covered more fully in Frames 42 to 49 and MUST be carried out in sequence Note In order to carry out e...

Page 35: ...draw the user control 2 Unplug the low voltage electrical lead from the back of the user control 3 Turn the clamp swing the control box down and pull slightly forward 1 To remove the sealing panel remove the 4 screws 2 Remove the panel 3 To remove the bottom panel remove the 2 screws 4 Pull the right hand side of the panel down Slide it to the right and withdraw SERVICING ...

Page 36: ...urner the 3 screws at the rear are extended to ease access 2 Lift off the burner from the combustion chamber IMPORTANT The burner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic 3 Brush off any deposits that may be on the ceramic with a SOFT brush 4 Inspect the sealing gasket around the burn...

Page 37: ...ew and elongated bolt pull the trap down and forward to remove 4 Flush out any deposits with clean water 47 CLEANING THE CONDENSATE S TRAP 1 Remove ignition and flame detection electrodes Refer to Frames 56 57 2 Remove the 3 screws retaining the sump cover and remove 3 Using a suitable tool as supplied in the standard British Gas Flue brush kit clean between the heat exchanger fins from the top of...

Page 38: ...nnection to the injector housing 5 Remove the screw retaining the fan mounting bracket 6 Remove the fan and venturi assembly Refer to Frame 45 7 Unscrew the 3 screws and remove the venturi assembly noting the orientation of the venturi in relation to the fan body 8 Transfer the venturi assembly to the new fan replacing the gasket if evidence of damage or deterioration is visible 9 Fit the new fan ...

Page 39: ...50 2 Remove the boiler front and sealing panels Refer to Frames 42 43 3 Unclip the thermistor thermostat from the flow pipe and withdraw it from the controls compartment 4 Disconnect the electrical leads from the thermistor thermostat 5 Reconnect the electrical leads and reassemble in reverse order ensuring the spring clip is securely on the pipe 6 Check the operation of the boiler Refer to Frame ...

Page 40: ...tion chamber 5 Remove the remaining screw holding the ignition electrode to the combustion chamber 6 Remove the electrode 7 Fit the new ignition electrode using the new gasket supplied Check dimensions as shown 8 Reassemble in reverse order and check that no damage to the combustion chamber insulation has occurred during the electrode replacement 9 Check the operation of the boiler Refer to Frame ...

Page 41: ...erse order 11 Ensure the sensing tube is correctly replaced and not kinked or blocked in any way 12 Check operation of the boiler Refer to Frame 50 60 CONDENSATE S TRAP REPLACEMENT 1 Refer to Frame 50 2 Remove the boiler front and bottom panels Refer to Frames 42 43 3 Swing the control box down into the servicing position Refer to Frame 44 4 Disconnect the condensate drain pipe 5 Remove the screw ...

Page 42: ... the spare part z Gloves supplied with the spare part 8 Damp down the combustion chamber area containing the insulation boards 9 Remove the split pin and washer from the RHS of the combustion chamber 10 Remove the insulation boards The replacement boards are supplied in a plastic bag This bag should be retained and the discarded boards should now be placed into it 11 Sweep any dampened particles a...

Page 43: ...cal wiring from the control box and remove 8 Transfer mounting bracket and hinge screws to the new control box 1 Refer to Frame 50 2 Remove boiler front and bottom panels Refer to Frames 42 43 3 Remove the 2 screws and allow the user control to lower 4 Push out the mains switch from the rear as shown 63 MAINS SWITCH REPLACEMENT Display unit User control Ecl 2380 3 5 Fit the new switch ensuring tha...

Page 44: ...iler Refer to Frame 50 64 USER CONTROL REPLACEMENT 65 PRESSURE GAUGE REPLACEMENT 1 Refer to Frame 50 2 Drain the boiler Refer to Frame 68 3 Unscrew the pressure gauge and discard 4 Fit the new pressure gauge using a suitable jointing compound 5 Refill the boiler Refer to Frame 30 6 Check operation of the boiler Refer to Frame 50 2041 Pressure gauge Flow isolation valve shown in the open position E...

Page 45: ...crew Self tapper screws Discharge pipe Safety relief valve Securing pin Ecl 2091 1 Refer to Frame 50 2 Remove the boiler front and sealing panels Refer to frames 42 and 43 3 Drain the boiler Refer to frame 68 4 Remove the turret from the boiler Refer to frame 26 5 Release the silicon tubing from the sample point 6 Release the electrical connections from the dry fire thermistor 7 Release the electr...

Page 46: ...e boiler Refer to Frame 30 11 Check operation of the boiler Refer to Frame 50 68 DRAINING THE BOILER 1 Refer to Frame 50 2 Remove the boiler front and bottom panels Refer to Frame 42 43 3 Close all the water isolating valves on the piping frame 4 Attach a length of hose to the drain point and open the drain valve 5 After replacing any component on the boiler close the drain valve remove the hose a...

Page 47: ...racket 15 Remove the M5 x 10 screw retaining the flue casting 16 Remove the flue casting 70 HEAT EXCHANGER REPLACEMENT 17 Remove the automatic air vent Refer to Frame 67 18 Remove the edge clip securing the dry fire thermistor wiring 19 Remove the blind grommet to gain access to the return pipe securing bracket 20 Remove the M5 screw and remove the return pipe securing bracket by sliding forwards ...

Page 48: ...r to Frame 50 2 Drain the boiler Refer to Frame 68 3 Unscrew all the gas and water connection unions on the boiler side of the valves 4 Remove the screw from the turret clamp and remove the turret 5 Lift the complete boiler from the wall mounting frame and place on a flat surface face down to expose the expansion vessel 6 Unscrew the union nut on the vessel water connection pipe 7 Unscrew the 2 sc...

Page 49: ...RAME 75 ALTERNATING L A GO TO FRAME 76 ALTERNATING L 8 GO TO FRAME 77 ALTERNATING H 1 GO TO FRAME 78 ALTERNATING H 4 GO TO FRAME 79 ALTERNATING H F GO TO FRAME 80 In order to assist fault finding the boiler has an LED diagnostic display The key to the display codes is as follows ALTERNATING H n GO TO FRAME 81 ALTERNATING H E GO TO FRAME 75 ALTERNATING H9 GO TO FRAME 79 ALTERNATING L9 GO TO FRAME 7...

Page 50: ...nd associated harness as necessary NO Replace gas valve YES NO NO 75 L E or H E BOARD ERROR Note Due to the wave form of the rectified voltage the reading will vary depending on the type of meter used to measure the value some may measure the possible peak voltage of 339V In general terms a reading greater than 150V indicate that the correct voltage is supplied to the gas valve As an alternative t...

Page 51: ...ed with water and all isolation valves open OK NO YES NO Replace overheat thermostat 77 L 8 FAN ERROR Is nominal 330 V DC present across red and blue at the fan connector as reset button is pressed Replace fan YES NO Replace harness 78 H 1 CONTROL THERMISTOR ERROR YES Is there continuity between the PCB and the thermistor Remove the boiler control thermistor from either the CH flow return pipe and...

Page 52: ...s correct Inspect heat exchanger for blockage or damage in the flueways Clean or replace as necessary Replace thermistor NO YES NO 81 H n PHASE REVERSAL ERROR Check wiring to the boiler for reversed live and neutral 80 H F FLAME DETECTION ERROR Replace flame detection electrode Is there continuity between the 2 terminal pins NO YES Remove flame detection electrode terminal from PCB Replace PCB Che...

Page 53: ...l 1 173 509 4 E69 384 Bottom casing panel 1 171 027 11 E67 489 Burner 1 170 905 12 Combustion chamber insulation 1 173 520 14 E67 492 Injector and housing 1 170 908 16 E85 097 Fan assembly 1 172 625 17 E69 286 Automatic air vent 1 170 988 19 E69 288 Gas control valve 1 171 035 23 E67 501 Control thermistor 1 170 917 24 E67 502 Overheat thermostat 1 170 918 25 Ignition electrode kit 1 173 528 26 Fl...

Page 54: ...54 SHORT LIST OF PARTS icos system Installation and Servicing 82 SHORT LIST 35 45 40 94 52 16 19 39 37 25 12 11 23 26 69 95 64 61 62 17 14 32 24 36 nm8046 103 ...

Page 55: ...crews 2 Sealing panel with screws 4 Bottom panel with screws 84 CONTROLS ASSEMBLY 33 Controls assy with screws 34 Controls hinge bracket 35 User controls without item 38 36 PCB primary controls 38 User controls housing 39 Mains switch 54 Jumper link not shown 85 BURNER ASSEMBLY 11 Burner assembly with screws and gasket ...

Page 56: ...56 NOTES icos system Installation and Servicing ...

Page 57: ...nt Local Authority Building Control LABC who will arrange an inspection or contact a government approved inspector LABC will record the data and will issue a certificate of compliance If you notify via CORGI Scheme CORGI will then notify the relevant Local Authority Building Control LABC scheme on members behalf Scheme members only Call CORGI on 0870 88 88 777 or log onto www corgi notify com with...

Page 58: ...WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR THE DOMESTIC HOT WATER MODE MEASURE RECORD GAS RATE ft3 hr MAXIMUM BURNER OPERATING PRESSURE IF APPLICABLE mbar COLD WATER INLET TEMPERATURE o C HOT WATER OUTLET TEMPERATURE o C WATER FLOW RATE lts min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS YES FOR AL...

Page 59: ...CARD SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID CARD SERIAL No COMMENTS SIGNATUR...

Page 60: ...pecification without notice 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 The code of practice for the installation commissio...

Page 61: ...HE15 HE24 ...

Page 62: ...al parts should be used for replacement Minimum Clearances Clearances of 165mm 6 1 2 above 100mm 4 below 5mm 1 4 at the sides and 450mm 17 3 4 at the front of the boiler casing must be allowed for servicing The minimum front and bottom clearance allowed when built into a cupboard is 5mm To light the boiler Refer to Frame 1 If a programmer is fitted refer to separate instructions for the programmer...

Page 63: ... F will be displayed Press the reset button and the boiler will relight If the fault recurs turn off the boiler and consult a CORGI registered installer or in IE a competent person Loss of system water pressure The gauge H indicates the central heating system pressure If the pressure is seen to fall below the original installation pressure of 1 2 bar over a period of time then a water leak may be ...

Page 64: ...tic hot water are set at the required temperature To test operation of either thermostat turn fully up If no response contact your installer Boiler is not working for central heating or hot water and the display shows L A L A L A L A L A flashing Press reset button D for 2 seconds the boiler should then re light If fault recurs this indicates an overheat condition The boiler should be turned off a...

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