IDEAL classic HE15P Installation And Servicing Manual Download Page 38 | Manualshive

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38

classic HE P

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Installation & Servicing

SERVICING

70 GAS CONTROL VALVE REPLACEMENT

1.

Refer to Frame 61.

2.

Remove the burner and air box assembly. Refer to
Frame 54.

3.

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.

7.

Remove the gas control / manifold assembly.

8.

Remove the 4 screws retaining the manifold to the gas
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 new 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 14 for gas sealing.

1.

Refer to Frame 61.

2.

Remove the burner and air box assembly. Refer to Frame 54.

3.

Remove the electrode retaining nut.

4.

Remove the pilot shield.

5.

Remove the ignition electrode and integral lead.

6.

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.

68 IGNITION ELECTRODE AND LEAD REPLACEMENT

1.

Refer to Frame 61.

2.

Remove the screw retaining the front
burner support strap to the combustion
chamber.

3.

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.

4.

At this stage the main burner injector can
be removed, checked, cleaned or
replaced as required.

5.

Fit the new burner, ensuring that the
retention tab is correctly located in the air
box slot and reassemble in reverse order.

6.

Check the burner for cross-lighting and
flame stability.

69 MAIN BURNER AND MAIN BURNER INJECTOR REPLACEMENT

SER

VICING

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20/02/2008, 13:57

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Summary of Contents for classic HE15P

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 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 HE15P HE18P For details of document amendments refer to page 3 January...

Page 2: ...2 classic HE P Installation Servicing ...

Page 3: ...tions 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 Users Guide Page 2 Important Notes 2 new bullet points added DOCUMENT AMENDMENTS Ideal Stelrad Group reserve the right to vary...

Page 4: ...t Btu h by the gross C V of the gas Btu ft3 Table 1 General Data Table 2 Performance Data Key to symbols GB United Kingdom IE Ireland Countries of destination PMS Maximum operating pressure of water C12 C32 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 thro...

Page 5: ...ssistance see Technical Helpline on the back page 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 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 r...

Page 6: ...ump Kit CURRENT GAS SAFETY INSTALLATIONAND 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 ap...

Page 7: ...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 wide enough to accommodate the tool Front clearance 450mm 17 3 4 from the front of the boiler casing Minimum front clearance when built behind a concealed panel is 5mm 1 4 provided that the top and bottom of the casing is not enclosed and the side clearance is 40mm 2 at both ...

Page 8: ...al 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 ...

Page 9: ... 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 ...

Page 10: ...evel cold of 75mm 2 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 the top of the boiler as venting is made less efficient 3 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 cis...

Page 11: ...e 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 the same point as the expansion vessel 4 Expansion Vessel a A 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...

Page 12: ... 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 cister...

Page 13: ...ed view LEGEND 24 30 27 35 9 12 19 37 26 23 17 Condensate siphon trap Data Plate cla7926 9 Sightglass 12 Main Burner 17 Gas Valve 19 Control Box 23 PCB25E 24 Air pressure switch 26 Controls Casing 27 Flue Protection Thermostat 30 Fan 35 Front Panel 37 Controls Door INSTALLATION ...

Page 14: ...y 1 off 8 UNPACKING Pack A Contents A The complete boiler B Installation Servicing User s Instructions C Hardware Pack listed below Hardware Pack 1 Contents A Pipe Flue extension 1 off B Nut Siphon 1 off C Washer siphon sealing 1 off D O ring 1 off cla7643 C E D A B F D Wall mounting template E Wall mounting plate F 1 year guarantee form E Washer M4 Form C 3 off F No 14x2 slotted woodscrew 3 off G...

Page 15: ...extension ducts plus the standard flue duct may be used together 2 Flue extensions of greater than 1m 39 should be supported with the bracket provided 90o Elbow kit equivalent flue length resistance 1 5m 45o Elbow kit equivalent flue length resistance 1 0m 10 DETERMINING THE FLUE LENGTH Note A roof flue kit is available as an optional extra for vertical flue installation supplied with separate fit...

Page 16: ...The wall mounting plate screw positions choose one from each group Note Mark the centre of the flue hole as well as the circumference b The position of the flue duct hole c The jacking screw fixing hole 4 Remove the template from 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 preferabl...

Page 17: ...r 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 6 Drill 3 holes 3 2mm 1 8 dia through the outer flue duct and boiler sealing ring Do NOT drill t...

Page 18: ...ove the bottom packaging protection 3 Check the boiler alignment using a spirit level and adjust as 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 screw 19 CONNECTING THE FLUE TO THE BOILER A Without Optional Flue finishing Kit 1 Insert the flue assembly through the hole 2 Ensure the notch ...

Page 19: ...and 1 for the jacking screw with an 8mm 5 16 masonry drill 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 esse...

Page 20: ...sure the tube is cut square mark the flue all the way around 4 Cut to length and remove any burrs 24 FITTING THE FLUE ASSEMBLY 1 Insert the flue assembly through the hole 2 Ensure the flue terminal is in the correct position 23 CUTTING THE FLUE For flue lengths 270 to 775mm ONLY 1 If downward routing of pipes is required then the downward routing wall bracket supplied in the downward piping kit sh...

Page 21: ...re switch sensing pipe and CO CO2 sensing pipe 8 Lift the boiler onto the wall mounting bracket 9 Remove the bottom packaging protection 10 Check the boiler alignment to the wall using a spirit level and adjust as necessary with the jacking screw 11 Line up the hole in the jacking screw with the hole in the wall previously drilled and secure with the No 14x50mm wood screw 26 MOUNTING THE BOILER 27...

Page 22: ...ark the flue all the way around 6 De burr the cut edges 29 FLUE EXTENSION DUCTS continued 28 FLUE EXTENSION DUCTS For flue lengths greater than 705mm rear flue or 775mm side flue Flue duct support Wall plugs 2 off Washers 2 off Extension duct clamp 1 0m 39 long Support fixing screws 2 off Clamp screws 2 off mxhe7656 cla7675 R or L Flue length Accessories Product No R or L Up to 775 B Pack 1 off se...

Page 23: ... 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 Arrangem...

Page 24: ...531 610 mm min ex7532 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 Terminal Position Minimum Dimension Directly below an opening air brick windows etc 300 mm Below plastic painted gutter...

Page 25: ...2 to 7 5 Push fit the vertical connector E supplied separately into the boiler flue connection and retain with the four securing screws provided 6 Push fit extension duct F if required supplied separately and the roof flue kit assembly A into the vertical connector E 7 If the last extension duct requires cutting measure the distance outer ducts between the duct and the terminal and add 100 mm to t...

Page 26: ...nd 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 spillage within the dwelling IMPORTANT If excessive external pipework cannot be avoided a condensate removal pump available as an option and insulati...

Page 27: ... providing 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 TERMINATIONTODRAIN...

Page 28: ...ump 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 LEGEND b blue bk black br brow...

Page 29: ...anufacturer 3 This is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see the manufacturer s literature 43 PICTORIAL WIRING 44 MID POSITION VALVE Pumped only 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 o...

Page 30: ... 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 disturban...

Page 31: ...e limited then check that the top and bottom edges of the casing are correctly located Note If the Sealed System Unit is fitted remove the unit casing in order to inspect the top casing seal To gain access to the gas valve a Remove the controls support casing Release the controls support front fixing screws 3 turns only Remove the pod by pulling it forward to disengage from the keyhole slots b Rem...

Page 32: ...ervicing by a CORGI 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 After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions 51 HANDING OVER 50 GENERAL CHECKS Make the following checks for correct operati...

Page 33: ...assembly 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 1 Open the...

Page 34: ... 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 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 t...

Page 35: ...rubber sump connection pipe and the blockage sensing pipe 4 Remove the two siphon 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 connection pipe and blockage sensing pipe are correctly replaced Reassemble the boiler in the following order 1 Refit the flue baffles 2 Inspect the collector hood ...

Page 36: ...etaining the thermostat to the casing Withdraw the thermostat phial from the heat exchanger pocket and unclip from the casing 5 Fit the new thermostat and reassemble in reverse order 6 Check the operation of the boiler cla7994 6 Remove the sensor from the heat exchanger pocket and unclip from the casing 7 Remove the strain relief bush from the back panel base 8 Remove the sensor lead through the g...

Page 37: ...ut Check the spark gap 7 Reassemble in reverse order 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 37 mbar available Also check burner ignition and cross lighting 1 Refer to Frame 61 2 Remove the limit thermostat assembly from the boiler flow pipe 3 Disconnect the electrical connectors 4 Clip new...

Page 38: ...r to Frame 48 item 14 for gas sealing 1 Refer to Frame 61 2 Remove the burner and air box assembly Refer to Frame 54 3 Remove the electrode retaining nut 4 Remove the pilot shield 5 Remove the ignition electrode and integral lead 6 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...

Page 39: ...vicing position 3 Disconnect the detection lead from the PCB 4 Unplug all the Molex connectors from the PCB 74 COMBUSTION CHAMBER INSULATION REPLACEMENT 1 Refer to Frame 61 2 Remove the burner and air box assembly Refer to Frame 54 3 Remove the 4 tie rods Note remove rubber grommets to gain access to side tie rod screwdriver slots 4 Remove the combustion chamber 5 Remove the 2 side panel retaining...

Page 40: ...5 Remove the fan collector hood assembly refer to Frame 55 Pull off the electrical connections from the overheat thermostat and pull off the white rubber tube from the siphon blockage sensing pipe 6 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 ...

Page 41: ...ber sump connecting pipe and the blockage sensing pipe 5 Unscrew the siphon union connection 6 Remove the two siphon retaining screws and remove siphon 7 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 4 6 5 3 SERVICING...

Page 42: ...ply on the fan connector at PCB Molex marked FAN YES YES NO NO Check the polarity of the mains supply Check the continuity of the ignition lead from connector to electrode Does the spark now cease when gas is lit Ensure pilot and main gas valve leads are not crossed over Is there a supply voltage at pilot gas valve Is there a live supply on the red lead to the pressure switch NO Is there a regular...

Page 43: ...069 37 Control Door Kit 1 173 586 39 Casing Seal and Screws Kit 1 174 070 45 E83 682 Overheat Thermostat LM7 Kit 1 171 950 59 E97 310 Limit Thermostat Kit 1 173 353 The following are parts commonly required due to damage or expendability 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 a...

Page 44: ...44 classic HE P Installation Servicing SHORT LIST OF PARTS 78 SHORT PARTS LIST 12 30 35 19 9 24 17 18 23 FUSE 37 39 26 27 15 14 13 13 A 45 59 cla7850 ...

Page 45: ...t 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 withi...

Page 46: ...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 47: ...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 48: ...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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