Ideal Boilers HE30 Installation And Servicing Manual Download Page 18

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icos

Installation & Servicing

INSTALLATION

FLUE OUTLET

17 PREPARING THE WALL

IMPORTANT.

Ensure that, during the

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

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

Drill 3 holes with a 7mm (

1/4

masonry drill and insert the plastic
plugs provided, for the wall mounting
plate.

Note.

If using Stand Off kit option, refer to
instructions in kit.

19 CUTTING THE FLUE - SIDE

Wall thicknesses of 114mm to 535mm

18 CUTTING THE FLUE - REAR

Wall thicknesses of 114mm to 638mm

Note.

If using the extension ducts go to Frame 20.

Measure and note side flue length L. Refer to Frame 14.

Add 155mm (6

") to dimension L and, measuring from

the ring, cut the outer tube only.

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

Cut the inner tube to a length 20mm (

3/4

") longer to aid

engagement.

Notes.
a.

If using the extension ducts go to Frame 20.

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

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

Add 67mm (2

") to dimension X and, measuring from

the ring, cut the outer tube only.

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

Cut the inner tube to a length 20mm (

3/4

") longer to aid

engagement.

ecl8166

Note.

Check all of the hole

positions before drilling

Rear flue only

5" diameter hole

Section
through wall

Side flue only
5" diameter hole

cla7841

202414-6.pmd

19/02/2008, 13:07

Summary of Contents for HE30

Page 1: ...onform 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 HE30 HE36 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 See reverse for icos users guide January 20...

Page 2: ...2 icos Installation Servicing ...

Page 3: ...Frames 24 25 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 30 Frame 41 Initial Lighting Display code P added to The Display paragraph Page 45 Frame 70 L F Board Error Addition of new flow chart Page 46 Frame 72 L A Overheat Error Note added Page 4...

Page 4: ...gross or 34 9 MJ m3 935 Btu ft3 nett To obtain the gas consumption at a different calorific value a For l s divide the gross heat input kW by the gross C V of the gas MJ m3 b For ft 3 h divide the gross heat input Btu h by the gross C V of the gas Btu ft3 Key to symbols GB United Kingdom IE Ireland Countries of destination PMS Maximum operating pressure of water C13 C33 A room sealed appliance des...

Page 5: ...g 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 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 out...

Page 6: ...ill the flue can be installed from inside the building where wall thicknesses do not exceed 600mm 24 Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside Installation from inside ONLY b If a core boring tool is to be used inside the building the space in which the boiler is to be installed must be at least ...

Page 7: ...tor Kit z Flue Extension Ducts D Pack 1000mm long up to 3m z Flue Finishing Kit z High Level Flue Outlet Kit z Roof Flue Kit to a maximum of 5m z Twin Flue Kit z Vertical Outlet Kit SAFETY 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 installa...

Page 8: ...OT be used without prior consultation with the local gas supplier The boiler MUST be installed on a gas supply with a governed meter only A gas meter can only be connected by the local gas supplier or by a CORGI registered engineer In IE by a Competent Person 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 ...

Page 9: ... UK Ltd Tel 44 0 01732 359 888 Tower House Vale Rise Fax 44 0 01732 354 445 Tonbridge Kent TN9 1TB www tfc group com 5 The flue assembly shall be so placed 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 co...

Page 10: ...ential temperature of 20 o C across the boiler is not exceeded 4 Adjust room and cylinder thermostats and programmer to NORMAL settings The system should be vented directly off the boiler flow pipe as close to the boiler as possible The cold feed entry should be inverted and MUST be positioned between the pump and the vent and not more than 150mm 6 away from the vent connection Note Combined feed ...

Page 11: ... valve or discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or cause damage to electrical components and wiring 3 Pressure Gauge A pressure gauge covering at least the range 0 4 bar 0 60 lb in2 must be fitted to the system The gauge should be easily seen from the filling point and should preferably be connected at th...

Page 12: ...sion vessel must be connected to a point close to the inlet side of the pump the connecting pipe being not less than 15 mm 1 2 nominal size and not incorporating valves of any sort b The vessel capacity must be adequate to accept the expansion of the system water when heated to 110o C 230o F c The charge pressure must not be less than the static water head above the vessel The pressure attained in...

Page 13: ...nd water treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating systems Ideal Stelrad Group recommend the use of FERNOX COPAL or MB1 GE Betz Sentinel X100 OR Salamander Corrosion Guard inhibitors and associated water treatment which must be used in accordance with the manufacturers instructions For further information contact Notes 1 It is most important th...

Page 14: ...nel RH LH 6 Bottom panel 14 Burner assembly 17 Injector housing 19 Fan assembly 22 Gas valve assembly 25 Dry Fire Thermostat 26 Control Thermistor 27 Overheat Thermostat 28 Ignition electrode 29 Flame detection electrode 34 Condensate S trap LEGEND 37 User Control 38 PCB primary control 41 Main switch c w harness 42 Spark generator 46 Burner gasket 54 Burner earth pin ionisation probe INSTALLATION...

Page 15: ...ting template C Wall mounting plate D 1 year guarantee form E These Installation Servicing User s Instructions F Water Treatment Warning Label G Hardware pack H Flue Turret Pack B Contents Flue terminal 1 Ensure the boiler is stood correctly as marked on the carton 2 Cut and remove the strapping 3 Fold back the top flaps to gain access to the wall mounting plate literature and wall mounting templa...

Page 16: ...0O ELBOW KIT 60 100 EQUIVALENT FLUE LENGTH RESISTANCE 1 5M 45O ELBOW KIT 60 100 EQUIVALENT FLUE LENGTH RESISTANCE 1 0M MINIMUM FLUE LENGTH FOR REAR OUTLET AND SINGLE BRICK WALL 251MM 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 Only necessary if using one or more D extension duct packs...

Page 17: ...e line onto the side wall as shown 3 Mark onto the wall the following a The 3 wall mounting plate screw positions see instructions on wall mounting template 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 4 Remove the template from the wall 16 WALL MOUNTING TEMPLATE 15 FLUE ASSEMBLY Exploded View LEGEND 1 Duct assemb...

Page 18: ...f using the extension ducts go to Frame 20 1 Measure and note side flue length L Refer to Frame 14 2 Add 155mm 61 8 to dimension L 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 Notes a If using the extension ducts go to Frame 20 b If the stand off frame is us...

Page 19: ... duct 3 Using the clamp provided clamp the flue lengths together 4 Repeat steps 1 4 if a second flue extension is required 22 FITTING THE KIT 20 FLUE EXTENSION DUCTS For flue lengths greater than 775mm Pack D Flue extension duct kit contents Note Side flue shown Use a maximum of 3m extended flue ONLY General arrangement Flue duct support Wall plugs 2 off Extension duct 1 0m 39 long Support fixing ...

Page 20: ...boiler is standard 21 5mm overflow pipe This size must not be reduced in any part of its length A plastic cap is fitted to the end of the condensate drain adapter this must be removed before connection is made nm8114 Front View Side View 300mm approx Condensate drain Refer also to the British Gas document Guidance Notes for the Installation of Domestic Gas Condensing Boilers 1989 BOILER cla7771 75...

Page 21: ...viding it can be confirmed that the down pipe is part of a combined waste and rain water system 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 G...

Page 22: ...EFFECTIVESEAL 3 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 wall plug and screws 26 MOUNTING THE BOILER Note Refer to Safe Handling Page 7 1 Lift the boiler onto the wall mounting plate as shown 2 Check the boiler alignment using a spirit level and adjust as necessary with the jacking screw nm81...

Page 23: ...l 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 7 Optional Extras 29 ROOF FLUE...

Page 24: ...0 mm min nm8243 Flat Roof 600mm 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 Minimum dimensions are shown below mxhe7686 mxhe7687 31 FLUE ARRANGEMENT Note The equivalent flue length resistance of the 90o elbow kit 60 100 ...

Page 25: ...uring screws provided Lubricate flue seal using lubricant supplied in hardware pack 4 Push fit extension duct F if required supplied separately and the roof flue kit assembly A into the vertical connector E Lubricate seals using lubricant supplied in hardware pack 5 If the last extension duct requires cutting measure the distance outer ducts between the duct and the terminal and add 100 mm to this...

Page 26: ...cted to the boiler via the gas service cock union Ensure that the gas supply pipe does not foul the boiler casing Refer to Frame 41 for details of the pressure test point position 35 ELECTRICAL CONNECTIONS WARNING This appliance MUST be earthed A mains supply of 230 V 50 Hz is required All external controls and wiring MUST be suitable for mains voltage The fuse rating should be 3 A Wiring external...

Page 27: ...n correctly 3 Wire the switched live supply into L2 or connect L1 and L2 via external control switching as shown in Frame 37 In either case remove the wire link fitted L1 to L2 4 Secure the mains lead with the cable clamp 5 Connect the mains lead connector Ensure it is fully located Note Ensure that the lengths of the current carrying conductors are shorter than the earth conductor so that if the ...

Page 28: ... y g 38 FUNCTIONAL FLOW WIRING DIAGRAM 37 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 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 Overheat thermostat 1 2 br r r bk y pk b Mains Switch Flame detection electrode DC Fan Ignition electrode Control therm...

Page 29: ...The fuse should be 3A Room Thermostat If the thermostat has a neutral connection use it It provides for more energy efficient operation by reducing switching temperature differentials 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 This is usually done at the programm...

Page 30: ...er operating the dynamic gas pressure is able to obtain maximum output Refer to Table 2 N B The principle of the 1 1 gas valve ensures that the icos HE range 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 IMPORTANT The gas input to the burner is regulate...

Page 31: ... Explain and demonstrate the lighting and shutting down procedures 3 The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent damage to the system and t...

Page 32: ...ll depend upon the installation condition and usage but should be carried out annually It is the law that any service work must be carried out by a CORGI registered installer In IE service work must be carried out by a competent person 1 Light the boiler and carry out a pre service check noting any operational faults 2 Check the gas consumption 3 Connect a suitable gas analyser to the sampling poi...

Page 33: ... 6 screws securing the burner the centre screw at the rear is 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 sea...

Page 34: ...move 4 Using a suitable tool clean the exposed heat exchanger fins through the sump cover Also vacuum any debris from the top of the heat exchanger 5 Access to the base of the heat exchanger is now possible Brush clean any deposits from the base of the heat exchanger and remove any loose deposits from the sump 6 Inspect the ignition and detection electrodes Ensure that they are clean and in good c...

Page 35: ...y fitted ensuring that a good seal is made Note In order to assist fault finding the control panel has an LED diagnostic display The key to boiler fault conditions is shown in Frame 69 52 REPLACEMENT OF COMPONENTS 1 Refer to Frame 52 2 Remove the boiler front panels and inner sealing panel Refer to Frames 45 and 46 3 Pull the electrical leads off the control thermistor and remove earth connection ...

Page 36: ...nturi assembly to the new fan replacing the gasket if evidence of damage or deterioration is visible 9 Fit the new fan venturi assembly 10 Reassemble the boiler in reverse order taking care not to overtighten the screw on the fan mounting bracket 11 Check the operation of the boiler Refer to Frame 52 1 Refer to Frame 52 2 Remove the boiler front and sealing panels Refer to Frames 45 46 3 Remove th...

Page 37: ... reverse order 9 Check operation of the boiler Refer to Frame 52 56 IGNITION ELECTRODE REPLACEMENT 1 Refer to Frame 52 2 Remove the boiler front panels and inner sealing panel Refer to Frames 45 and 46 3 Unplug the ignition lead from the electrode 4 Remove the burner Refer to Frame 48 5 Remove the earth lead from the ignition electrode 6 Remove the remaining screw holding the ignition electrode to...

Page 38: ...ion from the gas control valve 5 Undo the union nut between the gas valve and the gas inlet cock 6 Undo the union nut on the outlet side of the gas control valve 7 Undo the gas valve bracket screw slide the gas valve forward and remove 8 Remove the valve fixing bracket 9 Transfer the mounting bracket and gas inlet pipe to the new gas control valve 10 Fit new gas control valve ensuring that any sea...

Page 39: ...ve the bottom panel 4 Remove the 2 control box screws 5 Carefully unplug all the electrical wiring from the control box 6 With the control box lowered pull the assembly forward to remove from the housing 7 Remove the user control from the assembly 8 Transfer the mounting brackets to the new control box 9 Reassemble in reverse order ensuring that the control box is located correctly in the housing ...

Page 40: ...al connection 6 Unscrew and withdraw the thermistor 7 Fit the new thermistor using the gasket supplied 8 Reassemble in reverse order 9 Check operation of the boiler Refer to Frame 52 1 Refer to Frame 52 2 Remove the boiler front panels and inner sealing panel 3 Pull off the 2 electrical leads from the thermostat body 4 Remove the 2 screws retaining the O H thermostat 5 Fit the new thermostat and r...

Page 41: ...anifold bracket screws located on the top panel of the boiler and the LH side of the flue manifold bracket inside the boiler Slide out the flue manifold bracket then slide out the plastic flue manifold assembly from the keyhole slots on the back panel and remove from the joint at the back of the sump 5 Remove the fan assembly and place to one side Refer to Frame 54 6 Remove the ignition and detect...

Page 42: ...ng pipe to prevent damage when removing heat exchanger 22 Slide the heat exchanger and sump assembly complete with the CH return pipe upwards to disengage the sump spigot from the chassis and remove from the casing 23 Fit the new heat exchanger re assembling in reverse order replacing the gaskets or seals if any sign of damage or deterioration is evident To ensure a positive flue seal is confirmed...

Page 43: ...erse order Note Ensure that the boiler sealing panel is correctly seated compressing the seal to make an airtight joint 7 Check operation of boiler Refer to Frame 52 1 Refer to Frame 52 2 Remove the boiler front panel Refer to Frame 45 3 Undo the plastic union nut on the condensate S trap outlet and disconnect the flexible hose 4 Remove the screw retaining the S trap bracket and remove the bracket...

Page 44: ...FRAME 71 ALTERNATING L A GO TO FRAME 72 ALTERNATING L 8 GO TO FRAME 73 ALTERNATING H 1 GO TO FRAME 74 ALTERNATING H F GO TO FRAME 75 ALTERNATING H 4 GO TO FRAME 76 ALTERNATING H n GO TO FRAME 77 ALTERNATING H E GO TO FRAME 71 In order to assist fault finding the boiler has an LED diagnostic display The key to the display codes is as follows ALTERNATING H9 GO TO FRAME 76 ALTERNATING L9 GO TO FRAME ...

Page 45: ...s 200V DC supply available at the gas valve NO YES YES Is gas pressure available at the boiler inlet Replace PCB Check gas supply and rectify fault Replace ignition electrode and associated harness as necessary NO Replace gas valve YES NO NO 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 possibl...

Page 46: ...OK YES OK Check all earths for continuity Is continuity OK Correct Connection HE ONLY Check earth wire is connected to detection lead Is this correct Correct wiring or replace detection lead LEONLY Check Continuity of OH thermostat Is this correct Correct wiring or replace thermostat Check for an excess voltage between neutral and earth Is the value below 50V Check earth connection to the boiler I...

Page 47: ...er connected across the thermistors terminal pins At 25 o C expect 9 700 10 300 Ohms At 60 o C expect 2 400 2 600 Ohms At 85 o C expect 1 000 1 100 Ohms Remove the boiler flow thermistor from the CH flow pipe and disconnect thermistor wires Are the thermistor values correct Replace the thermistor NO NO YES Replace PCB Check and replace wiring as necessary Replace PCB YES Is 14V DC present across y...

Page 48: ...n all isolating valves YES Check resistance using a suitable multimeter connected across the flue thermistor terminal pins At 25 o C expect 9 700 10 300 Ohms At 60 o C expect 2 400 2 600 Ohms At 85 o C expect 1 000 1 100 Ohms Are thermistor values correct Inspect heat exchanger for blockage or damage in the flueways Clean or replace as necessary Replace thermistor NO 77 H n PHASE REVERSAL ERROR YE...

Page 49: ...ing Front Painted 1 174 302 2 H42 808 Kit Panel Case Sealing 1 174 303 4 H42 809 Kit Panel Side RH LH Painted 1 174 304 6 H42 810 Kit Bottom Panel Painted 1 174 305 14 H29 002 Kit Burner 1 174 080 17 E67 492 Kit Injector Housing 1 170 908 19 H07 771 Kit Fan FIME PX 130 0082 1 173 525 22 H42 817 Kit Gas Valve 1 174 306 25 H29 018 Kit Thermistor Dry Fire 1 174 087 26 H29 019 Kit Thermistor Boiler Co...

Page 50: ...50 icos Installation Servicing SHORT LIST OF PARTS 78 SHORT LIST nm8120 37 42 45 38 39 41 14 19 22 25 29 34 36 28 26 27 17 46 54 68 69 1 6 2 4 ...

Page 51: ...51 icos Installation Servicing NOTES ...

Page 52: ...52 icos Installation Servicing NOTES ...

Page 53: ...cal 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 within 10...

Page 54: ...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 55: ...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 56: ...ecification 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 commission...

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