Ideal Boilers HE24 Installation And Servicing Instructions Download Page 13 | Manualshive

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INSTALLATION

isar + programmer -

Installation and Servicing

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202851-1new.pmd

17/11/2006, 07:40

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Summary of Contents for HE24

Page 1: ...ety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers HE24 HE30 HE35 For details of document amendments refer to page 3 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 Octo...

Page 2: ...2 isar programmer Installation and Servicing ...

Page 3: ...grammer Installation and Servicing DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level A01 Oct 06 Caradon Ideal Limited reserve the right to vary specification without notice ...

Page 4: ...nited Kingdom IE 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 appl...

Page 5: ...er 28 Heating zone valves n a TRV s 10 Auto bypass 10 Boiler interlock 10 For all boilers Flushing to BS 7593 12 Inhibitor 12 Central heating mode Heat input to be calculated 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 ...

Page 6: ... min at 35 o C temperature rise The DHW draw off rate specified above is the nominal that the boiler flow regulator will give Due to system variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap At low DHW draw off rate the maximum temperature is limited to 65 o C by the modulating gas control Refer also to Frame 1 Boiler...

Page 7: ... the boiler or its manufacture LOCATION OF BOILER The boiler must be installed on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by the local authority For electrical safety reasons there must be no access ava...

Page 8: ...aced or shielded as to prevent ignition or damage to any part of any 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 IMPORTANT It is absolutely essential to ensure in practice that products of combustion discharging from ...

Page 9: ...standard depth wall unit In order for it to do so the plastic fascia should be removed See Frame 39 Bottom clearance Bottom clearance after installation can be reduced to 5mm However 100mm must be available for servicing Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside Installation from inside ONLY b If...

Page 10: ...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 10 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 p...

Page 11: ...ppliances 4 When connecting to suitable showers ensure that a The cold inlet to the boiler is fitted with an approved anti vacuum or syphon non return valve b Hot and cold water supplies to the shower are of equal pressure CH Return Ecl 6053 Hose unions Mains water supply Temporary hose disconnect after filling Additional stop valve Double check valve assembly note direction of flow The boiler doe...

Page 12: ...rnox Qantomat GE Betz Sentinel Combiguard and Calmag CalPhos I scale reducing devices which must be used in accordance with the manufacturers instructions 19 Gas control valve 20 Fan bracket 21 Orifice plate 23 Control thermistor flow return 24 Overheat thermostat 25 Ignition electrode 26 Flame detection electrode 32 Kit Trap and seal 35 User control 36 Primary controls PCB 39 Mains switch 44 Pipi...

Page 13: ...SEMBLY Exploded View 8 5 44 53 14 13 15 62 59 18 64 4 75 35 36 66 67 23 23 68 24 71 17 26 25 3 19 57 60 6 11 12 40 103 39 32 21 16 69 70 61 57 60 51 65 10 9 20 2 63 1 nm8423 Data badge 94 WILO pump shown tim e P R O G R A M M E R pr og pr og se le ct se le ct INSTALLATION ...

Page 14: ...nal Flue turret nm8424 B C E A D F time P R O G R A M M E R prog prog select select nm8452 A B C D E F G H I J K L R M N O P Q Hardware Pack Contents A Isolation valve c w pressure gauge 1 off B Isolation valve c w drain 1 off C Bulkhead connector 1 off D Restrictor valve 1 off E Compression gas cock 1 off F Valve securing clip 22mm 2 off G Valve securing clip 15mm 3 off H Pre piping frame support...

Page 15: ...nd read thoroughly before unpacking the product 5 When ready for installation lift off the cardboard carton 10 PACKAGING REMOVAL 11 BOTTOM AND FRONT 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 Pre pip...

Page 16: ...utting the ducts and marking the wall to suit this condition Note MAXIMUM FLUE LENGTHS HE24 AND 30 6M HORIZONTAL FLUE HE35 3M HORIZONTAL FLUE HE24 AND 30 8M ROOF FLUE HE35 5M ROOF FLUE HE 24 AND 30 14M TOTAL POWERED VERTICAL FLUE HE 35 8M TOTAL POWERED VERTICAL FLUE HE24 AND HE30 20M TOTAL AIR PLUS FLUE DUCT 60 60 TWIN FLUE KIT HE24 HE30 AND HE35 46M TOTAL AIR PLUS FLUE DUCT 80 80 TWIN FLUE KIT 90...

Page 17: ...o the side wall and 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 ...

Page 18: ...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 ensure the tube is cut square mark the flue all the way around 4 Cut the inner tube to a length 20mm 3 4 longer to aid engagement using the ...

Page 19: ... 4 Using the clamp provided clamp the flue lengths together 5 Repeat steps 1 4 if a second flue extension is required 6 Measure and mark the flue length required onto the flue measuring from the 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...

Page 20: ...ll 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 clearances...

Page 21: ... IMPORTANT If excessive external pipework cannot be avoided an additional siphon kit 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 BOILER cla7771 75mm tra...

Page 22: ...TION 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 INSTALLATION ...

Page 23: ...e 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 4 water unions 6 Engage and tight...

Page 24: ...er 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 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 seal A located in t...

Page 25: ...ge is able to deliver it s full output at inlet pressures down to 14mb However if dynamic pressures below 20mb are experienced ensure this is adequate for ALL other gas appliances in the property A boiler gas supply pipe length of 20m and not less than 15mm O D can be connected to the boiler via the gas service cock union Ensure that the gas supply pipe does not foul the boiler casing Refer to Fra...

Page 26: ...refer to Frame 62 and depress the spindle several times during filling Replace diverter valve actuator b When filling there may be a slight water leak from the air vent therefore electrical connections should be protected c Bleed any air from the pump and ensure that it is free to rotate For Wilo Pump To ensure the pump is free to rotate i Remove the vent plug ii Using a screwdriver rotate the sha...

Page 27: ...BS 7671 Wiring Regulations and any local regulations 1 Route the mains cable into the bottom rear centre of the boiler 2 Wire the permanent live supply into the 5 way remote plug terminals L3 N IMPORTANT A permanent live is ESSENTIAL in order for the advanced diagnostic controls to function correctly 33 INTERNAL WIRING 3 Wire the normal room thermostat switched live supply into L2 or connect L1 an...

Page 28: ...fferentials Frost Protection 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 The frost thermostat should be sited in a cold place but where it can sense heat from the system L3 L2 L1 N Room stat N if required nm8428 A Mains in System controls System Controls L N nm8429 Diagram A shows...

Page 29: ...on and Servicing nm8413 Dry fire thermistor Diverter Valve Permanent black link br b bk y g y g 35 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: ...ompetent person 2 ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable test meter 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 IS 813 2002 2 Purge air from the...

Page 31: ...ntrols are calling for heat 13 CENTRALHEATING Switch the boiler on off switch A to ON The boiler control should now go through its ignition sequence until the burner is established LEGEND A Boiler On Off switch B LED display C Select reset button D Injector pressure test point E Inlet pressure test point F Gas service cock G Casing pressure test point H Overheat thermostat J Control thermistor flo...

Page 32: ...d DHW off periods 2 Fully open all DHW taps in turn and ensure that water flows freely from them The LCD display symbols will be then when the burner lights Make the following checks for correct operation in 3 Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate This is factory set to give a DHW temperature rise of approximately 35o C at the fl...

Page 33: ...ystem controls Operate each control separately and check that the main burner responds WATER CIRCULATION SYSTEM 1 With the system COLD check that the initial pressure is correct to the system design requirements For pre pressurised systems this should be 1 0 bar 2 With the system HOT examine all water connections for soundness The system pressure will increase with temperature rise but should not ...

Page 34: ... the Programmer Users Instructions and hand them to the householder 8 Loss of system water pressure Explain that the dial underneath the boiler indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated Explain the re pressurising procedure and if unable to repressurise or if the pressure...

Page 35: ...anel forward at the bottom and lift to disengage it from the top lugs tim e P R O G R A M M E R pro g pro g sele ct sele ct nm8431 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 tim e P R O G R A M M E R pro g pro g sele ct sele ct nm8432 SERVICING ...

Page 36: ...RVICING POSITION 1 Remove the 2 screws and withdraw 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 nm8433 time P R O G R A M M E R prog prog select select nm7540 SERVICING ...

Page 37: ...pon 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 burner and combustion chamber insulation for any signs of damage Replace as necessary Note Take care not to disturb the ionisation probes at the front and rear of the combustion chamber 1 Disconnect the electrical leads from the fan 2 Un...

Page 38: ...s Ensure that they are clean and in good condition replace if necessary 6 Check the condition of the combustion chamber insulation Any cracked or damaged pieces must be replaced Note Take care not to disturb the ionisation probes at the front and rear of the combustion chamber 7 Check that the ignition and detection gaps are correct Refer to Frames 58 59 7 Refit the boiler sealing panel IMPORTANT ...

Page 39: ...om the fan 4 Undo the gas pipe union connection to the injector housing 5 Remove the screw retaining the fan mounting bracket 6 Remove the fan and venturi assembly Refer to Frame 47 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 dete...

Page 40: ...g 5 Remove the screw retaining the fan mounting bracket 6 Remove the fan and venturi assembly 7 Remove the 2 injector housing screws 8 Withdraw the injector housing 9 Fit the new injector housing complete with injector 10 Reassemble in reverse order ensuring that the new gas seal supplied is located correctly in the injector housing 11 Check operation of the boiler Refer to Frame 52 Mounting brack...

Page 41: ...k 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 52 5 Remove the electrode 6 Fit the new flame detection electrode using the new gasket supplied Check dimensions as shown 7 Reassemble in reverse order and check that no damage to the combu...

Page 42: ...with bracket and inlet pipe 9 Transfer the mounting bracket and gas inlet pipe to the new gas control valve 10 Fit the new gas control valve ensuring that any seals showing damage or deterioration are replaced Reassemble in reverse 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 52 62 DIVERTER VALVE ACTUATO...

Page 43: ...th 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...

Page 44: ...r to Frames 52 72 for draining the appliance 2 Remove the casing front bottom panel Refer to Frames 44 45 3 Remove the 4 screws securing the support plate and withdraw the plate Note The M4 screws fit the casing and the self tapping screws fit the plastic pump and valve housings 4 Withdraw the securing pin 5 Disconnect the electrical lead 6 Ease out the sensor and discard 7 Fit the new sensor ensu...

Page 45: ...Unplug the user control electrical lead and low voltage lead from the control box and remove the control Refer to diagram A 5 Return the control box to the working position and secure with the clamp Unscrew the mounting bracket screws to remove the bracket Refer to diagram B 6 Release the clamp and carefully remove the control box from the hinge arms Refer to diagram C 7 Unplug all the electrical ...

Page 46: ...display unit forward to remove 4 Push the new display unit into position 5 Reassemble in reverse order 6 Check operation of the boiler Refer to Frame 52 68 USER CONTROL REPLACEMENT 69 PRESSURE GAUGE REPLACEMENT 1 Refer to Frame 52 2 Drain the boiler Refer to Frame 72 3 Unscrew the pressure gauge and discard 4 Fit the new pressure gauge using a suitable jointing compound 5 Refill the boiler Refer t...

Page 47: ...nut retaining the flue casting spring clip and remove the spring clip 9 Undo the 2 M5 x 10 flue spring clip retaining bracket screws and remove the bracket 10 Remove the M5 x 10 screw retaining the flue casting 11 Remove the flue casting 12 Remove the screw and rear bracket Pull the air vent and plug assembly from the heat exchanger and replace with the parts supplied in the air vent kit 13 Re ass...

Page 48: ...roceeding to check operation of the boiler 7 Check operation of the boiler Refer to Frame 52 73 DIVERTER VALVE MECHANISM REPLACEMENT 1 Refer to Frame 52 2 Remove the casing front bottom panel Refer to Frames 44 45 3 Drain the boiler Refer to Frame 72 4 Remove the 4 screws retaining the rear support plate and withdraw the plate Refer to Frame 70 Note The M4 screws fit the casing and the self tappin...

Page 49: ...e casing front bottom panel Refer to Frames 44 45 3 Drain the boiler Refer to Frame 72 4 Remove the 4 screws securing the rear support plate and withdraw the plate Refer to Frame 70 Note The M4 screws fit the casing and the self tapping screws fit the plastic pump and valve housings 5 Remove the 2 Torx screws allen screws on the CP waterset securing the plate heat exchanger from the valve and pump...

Page 50: ... casting 76 HEAT ENGINE REPLACEMENT 17 Remove the automatic air vent Refer to Frame 71 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 21 Remove the overheat thermostat and the control thermistor Refer to Frame 57 22 R...

Page 51: ...N VESSEL REPLACEMENT 1 Refer to Frame 52 2 Drain the boiler Refer to Frame 72 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 5 Remove the turret 6 Lift the complete boiler from the wall mounting frame and place on a flat surface face down to expose the expansion vessel 7 Unscrew the union nut on the vessel wate...

Page 52: ... L F GO TO FRAME 80 L E GO TO FRAME 81 L A GO TO FRAME 82 L 8 GO TO FRAME 83 H 1 GO TO FRAME 84 H 2 GO TO FRAME 85 H 3 GO TO FRAME 86 H 4 GO TO FRAME 87 H F GO TO FRAME 88 In order to assist fault finding the boiler has an LED diagnostic display The key to the display codes is as follows H n GO TO FRAME 89 H E GO TO FRAME 81 H 9 GO TO FRAME 87 L 9 GO TO FRAME 87 ...

Page 53: ...ectrode and associated harness as necessary NO Replace gas valve YES NO NO 81 L E or H E PCB 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 indicates that the correct voltage is supplied to the gas valve As an alter...

Page 54: ...stem filled with water and all isolation valves open OK NO YES NO Replace overheat thermostat 83 L 8 FAN ERROR Is nominal 330 V DC present across red and blue at the fan connector as boiler select reset button is pressed Replace fan YES NO Replace harness 84 H 1 CONTROL THERMISTOR FLOW ERROR YES Is there continuity between the PCB and the thermistor Check resistance using a suitable multimeter con...

Page 55: ...ontinuity between the PCB and the thermistor Remove the boiler DHW thermistor from the plate heat exchanger and disconnect thermistor wires Are the thermistor values correct Replace the thermistor NO NO YES Replace PCB Check and replace wiring as necessary Check resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 o C expect 9 700 10 300 Ohms At 60 o C expec...

Page 56: ...er for blockage or damage in the flueways Clean or replace as necessary Replace thermistor NO 89 H n PHASE REVERSAL ERROR Check wiring to the boiler for reversed live and neutral YES NO YES NO 88 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 Check resistance using a s...

Page 57: ...Kit Trap and Seal 1 174 244 35 itime user control programmer 1 174 487 36 V9PCBprimaryctrls includesplastichousing HE24 30 35 1 174 486 37 E67 519 Fuse PCB 3 15A L250V 1 170 931 39 Mains switch c w harness 1 173 537 40 Spark generator assy 1 173 538 45 E67 527 Gasket kit servicing 1 170 938 52 E68 376 Seal kit sealing panel 1 171 014 53 E68 380 Turret gasket 1 171 022 61 E69 338 Pressure relief va...

Page 58: ...58 SHORT LIST OF PARTS isar programmer Installation and Servicing 90 SHORT LIST nm8440 103 t i m e P R O G R A M M E R p r o g p r o g s e l e c t s e l e c t ...

Page 59: ...4 Bottom panel with screws 92 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 93 BURNER ASSEMBLY 11 Burner assembly with screws and gasket nm8441 36 34 39 38 35 time P R O G R A M M E R prog prog select select ...

Page 60: ...60 NOTES isar programmer Installation and Servicing ...

Page 61: ...vant 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 wi...

Page 62: ...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 63: ...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 64: ...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...

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