Evo HE H12 Installation & Servicing Instructions Manual Download

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Advanced High Efficiency Boilers

Installation & Servicing Instructions

See reverse for

evo HE

Users Guide

Manufactured exclusively for Wolseley Centers Ltd. by Ideal Boilers

For details of document amendments, refer to page 3

H12, H16, H19, H22

(V3 Flue System)

Wall mounted, balanced flue, fanned gas boiler

October 2007 UIN 203323 A02

203323-2.pmd

21/09/2007, 11:26

Summary of Contents for H12

Page 1: ...ctions See reverse for evo HE Users Guide Manufactured exclusively for Wolseley Centers Ltd by Ideal Boilers For details of document amendments refer to page 3 H12 H16 H19 H22 V3 Flue System Wall mounted balanced flue fanned gas boiler October 2007 UIN 203323 A02 ...

Page 2: ...2 evo HE H Installation Servicing ...

Page 3: ...tion of telescopic reference and update to table Page 17 Frame 15 Flue Assembly Exploded View Change of dimensions for wall thicknesses Page 18 Frame 18 Setting The Flue Rear All frame updated Page 18 Frame 19 Setting The Flue Side All frame updated Page 19 Frame 20 Flue Extension Ducts Dimension changes Page 19 Frame 22 Fitting the Kit Dimension Changes Page 21 Frame 25 Condensate Pipe Terminatio...

Page 4: ...erature Btu h 43 300 57 400 68 300 79 500 35 900 32 800 Seasonal efficiency SEDBUK Band A 90 1 90 4 90 3 90 2 NOx classification Class 5 The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body CAUTION To avoid the possibility of injury during the installation ser...

Page 5: ...d 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 at m...

Page 6: ... 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 wide enough to accommodate the tool Front clearance The minimum front clearance when built in to a cupboard is 5mm 1 4 from the cupboard door but 450mm 17 3 4 overall...

Page 7: ...Roof Flue Kit to a maximum of 7 5m z Powered Vertical Flue Kit 5m primary and 17m secondary is a typical maximum length For alternative maximum lengths refer to Powered Vertical Instructions z High Level Flue Outlet Kits z Flue Deflector Kit z Weather Collar z Twin Fluing Kits to a maximum of 60m combined total of flue and air ducts z Horizontal Flue Terminal 600mm long z Remote User Control Kit z...

Page 8: ...ferably by the gas supplier to ensure that the meter is adequate to deal with the rate of gas supply required N B The principle of the 1 1 gas valve ensures that the evo HE H 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 Installation pip...

Page 9: ...acent to the boiler CONDENSATE DRAIN Refer to Frames 23 44 A condensate drain is provided on the boiler This drain must be connected to a drainage point All pipework and fittings in the condensate drainage system MUST be made of plastic no other materials may be used IMPORTANT Any external runs must be insulated The drain outlet on the boiler is standard 21 5mm 3 4 overflow pipe TERMINAL The termi...

Page 10: ...it a differential 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 Com...

Page 11: ...he 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 ...

Page 12: ...ansion 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 ...

Page 13: ...mmend water treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating systems Wolseley Centers Ltd 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 importan...

Page 14: ...e assy 20 Fan bracket assy 21 Orifice plate 22 Flue thermistor LEGEND 1 Front casing panel 2 Sealing panel 3 Sump cover plate 4 Bottom casing panel 5 Flue sensing nipple 6 Return pipe 7 Flow pipe 10 BOILER ASSEMBLY Exploded view 23 Control thermistor 24 Overheat thermostat 25 Ignition electrode 26 Flame detection electrode 32 S trap 33 Control assy 40 Spark generator 44 Wall mounting plate 53 Turr...

Page 15: ...ns F Water Treatment Warning Label G Hardware pack 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 template 4 Remove the instructions and read thoroughly before unpacking the product 5 When ready for installation lift off the outer sleeve 6 Remove the top p...

Page 16: ...ef Graph within Kit Instructions 80 80 TWIN FLUE KIT 60M TOTAL AIR PLUS FLUE DUCT Ref Graph within Kit Instructions MINIMUM HORIZONTAL FLUE LENGTHS TELESCOPIC TERMINAL 370MM Centre Line of turret to outside of wall terminal ONE PIECE TERMINAL 285MM 195mm 195mm Wall Thickness X Side flue length L Notes 1 When extension D packs are used the flue duct MUST be inclined at 1 5 degrees to the horizontal...

Page 17: ... 4 Mark onto the wall the following a The 2 wall mounting plate screw positions choose one from each group and the jacking screw position If using the stand off kit mark on 4 screw positions choosing 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 16 WALL MOUNTI...

Page 18: ...me 18 b For shorter flue requirements use non telescopic B Pack 1 Measure and note wall thickness X Refer to Frame 14 2 Measure distance from side of boiler to inside of wall and add to wall thickness X L Refer to Frame 14 3 Add 115mm to dimension L and set telescopic flue length as indicated in drawing 4 Using a 3 5mm drill bit drill two holes in outer air duct taking care not to pierce plastic i...

Page 19: ...wn folded up Wall plugs 4 off Extension duct clamp 1 0m 39 long No 10 x2 wood screw 4 off nm8732 20 FITTING THE KIT Because of the flexibility of the telescopic flue terminal it is not always necessary to cut an extension pack 1 Measure the total flue length from the centre of the boiler outlet to the outside wall 2 Subtract 70mm from this dimension 3 Subtract 950mm for each D pack to be used 4 If...

Page 20: ...als 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 A plastic cap is fitted to the end of the condensate drain adaptor This must be removed before connection is made nm8734 Front View Side View 155mm Condensate drain Refer also to the British Gas document Guidance Notes for the Installation of Domestic Gas Condensi...

Page 21: ...le 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 Termination into a down pipe can take place providing it can be confirmed that the down pipe is part of a combined waste and rain water syst...

Page 22: ...anifold is secure and giving an effective seal 4 Secure the flue turret on top of the boiler by inserting the open ends of the turret clamp under the 2 studs and fixing it in the middle with the single M5 x 10mm pozi hex screw provided 5 Flues over 1 metre long Fix the flue support bracket to the wall using the wall plug and wood screw For standard installations use the short wood screw If the sta...

Page 23: ...a concentric flue to run vertically from the top of the boiler and terminating above roof level Connection to the top of the boiler is made using both a separately supplied vertical connector and a 80 125 adaptor WEATHERPROOFING Where the flue passes through the roof line an adequate seal must be made This is achieved by using either Flat roof weather collar or Universal weather collar ACCESSORIES...

Page 24: ...ned 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 gutters 300 mm Painted surface 300 mm Below eaves or balco...

Page 25: ...25 evo HE H Installation Servicing INSTALLATION FLUE OUTLET rf8737 rf8738 31 FLUE ARRANGEMENT Note The equivalent flue length resistance of the elbow kits are 90o elbow kit 1m 45o elbow kit 0 6m ...

Page 26: ...of tile weather collar 1 nm8741 2 Extension Duct Vertical connector Turret clamp 3 nm8743 X 4 2 Push fit the vertical connector supplied seperately into the boiler flue connection and retain with the turret clamp and securing screw supplied with the boiler ENSURING THE GASKETSINTHEBOILERFLUEOUTLETARECORRECTLY FITTED 3 Push fit extension duct if required supplied separately into vertical connector ...

Page 27: ...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 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...

Page 28: ... diagnostic controls to function correctly 3 Wire the switched live supply into L2 or connect L1 and L2 via external control switching as shown in Frame 32 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 ...

Page 29: ...lay br b 38 FUNCTIONAL FLOW WIRING DIAGRAM Overheat thermostat 1 2 br r r bk y pk b Mains Switch Flame detection electrode DC Fan Ignition electrode CH return thermistor not fitted Control thermistor DC Gas valve b v bk or or N L Control PCB User PCB y g r r y b y b nm 7201 br y g br bk E b Flue thermistor Spark generator External switch e g room stat programmer 37 PICTORIAL WIRING DIAGRAM LEGEND ...

Page 30: ...ns 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 progr...

Page 31: ...re that with the boiler 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 evo HE H 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 ...

Page 32: ...plain his or her responsibilities under current Gas Safety Installation and Use Regulations or rules in force 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 fully explained to the householder to ensure the greatest possible fuel economy consistent with household requirements of both heati...

Page 33: ...nsumption 12 Connect a suitable gas analyser to the sampling point on the top of the boiler refer to Frame 45 or into the flue terminal if access is possible optional test For correct boiler operation the CO CO2 content of the flue gas should not be greater than 0 004 ratio 13 Complete the service section in the Benchmark Commissioning Checklist To ensure the continued safe and efficient operation...

Page 34: ...ner 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 burner...

Page 35: ...the gas service cock 10 Reconnect the electrical supply 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 the heat exchanger 4 Access to the base of the heat exchanger is now possible Brus...

Page 36: ...panels Refer to Frames 45 46 3 Pull the electrical leads off the control thermistor 4 Pull the control thermistor and spring clip off the IMPORTANT When work is complete the sealing panel must be correctly 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 REPLACEM...

Page 37: ...idence 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 the fan assembly Refer to Frame 54 4 Remove the 6 screws s...

Page 38: ...rode 5 Remove the remaining screw holding the ignition electrode to the combustion chamber 6 Remove the electrode 5 Remove the flame detection electrode 6 Fit the new flame detection electrode using the new gasket supplied Check dimension as shown 7 Reassemble in reverse order and check that no damage to the combustion chamber insulation has occurred during the electrode replacement 8 Check operat...

Page 39: ...be 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 Transfer the mounting bracket and gas inlet pipe to the new gas control valve 9 Fit new gas control valve ensuring that any seals showing damage or deterioration a...

Page 40: ... 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 be...

Page 41: ...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 and sealing panels Refer to Frames 45 46 3 Pull off the electrical leads from the thermostat body 4 Pull the thermostat and clip from the pipe 5 Fit the new thermostat ensuring that the clip is securely holding the thermostat to the flow pipe 6 Reassembl...

Page 42: ...e 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 and ...

Page 43: ... the flue thermistor 13 Unscrew the M5 x 10 screw retaining the top manifold flue casing 14 Remove the top half of the flue manifold from the appliance 15 Undo the 4 M5 x 10 screws scuring the bottom flue manifold casting 16 Pull the CH return pipe CH flow pipe and the bottom flue manifold together up and out of the heat exchanger 17 Remove the condensate S trap Refer to Frame 49 18 Unscrew the 2 ...

Page 44: ...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 68 CONDENSATE S TRAP REPLACEMENT 1 Refer to Frame 52 2 Remove the boiler front panel Refer to Frame 45 3 Remove the boiler bottom panel Refer to Frame 46 4 Undo the plastic union nut on the condensate S trap outlet 5 Remove the 2 screws 6 ...

Page 45: ...O 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 FRAM...

Page 46: ...associated harness as necessary NO Replace gas valve YES NO NO 71 L E or H E BOARD ERROR Internal fault within the PCB Replace PCB 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 suppl...

Page 47: ...S Is there continuity between the PCB and the thermistor Check resistance using a suitable multimeter 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 ...

Page 48: ...Ohms At 85 o C expect 1 000 1 100 Ohms Are thermistor values correct Replace PCB Replace thermistor Fill and vent the system and open 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...

Page 49: ...y 1 172 625 19 E67 497 Gas control valve 1 170 913 22 E67 500 Flue thermistor 1 170 916 23 E67 501 Control thermistor 2 170 917 24 E67 502 Overheat thermostat 1 170 918 25 Ignition electrode kit 1 173 528 26 Flame detection electrode and gasket 1 173 529 32 E67 511 Condensate S trap 1 170 926 34 E65 515 Controls hinge bracket kit 1 170 928 35 User controls 1 173 160 36 PCB primary controls kit V9 ...

Page 50: ...vo HE H Installation Servicing SHORT LIST OF PARTS nm8077 78 SHORT LIST 79 BOILER CASING ASSEMBLY nm 7300 4 2 1 1 Front casing panel with screws 2 Sealing panel with screws 4 Bottom casing panel with screws ...

Page 51: ...Y Ecl 1598 11 Burner assembly with screws and gasket LIST OF PARTS 80 CONTROLS ASSEMBLY 33 Controls assy with screws 34 Controls hinge bracket 35 User controls without item 38 36 PCB primary controls 38 User control housing 39 Mains switch 54 Jumper link ...

Page 52: ...52 evo HE H Installation Servicing NOTES ...

Page 53: ...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 within ...

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: ...Wolseley Installer Technical Helpline 0870 8498057 The code of practice for the installation commissioning servicing of central heating systems ...

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