ideal esprit installation and servicing HE24, HE30, HE35

installation and
servicing
PAKAGED BOILER CONTENTS
HAVE BEEN CHECKED BY OPERATOR No........
ideal esprit
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
HE24, HE30, HE35
For users guide see reverse of book
When replacing any part on this appliance, use only spare parts that you can be
assured conform 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.
September 2008 UIN 203642 A06
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.
2
Esprit - Installation and Servicing
DOCUMENT AMENDMENTS
Relevant Installation changes implemented in this book from Mod Level ............... A05 (Mar 08) A06 (Sep 08)
Page 6, - Optional Extra Kits
• Additional text to include Adjustable Support Bracket
Page 10, Frame 2 - Boiler Dimensions, Services & Clearances
• Pictorial change to illustrate wall mounting template
Page 17, Frame 10 - Flue Lengths
• Additional text in notes to include information on support bracket and lubricant
Page 20, Frame 17 - Flue Extension Ducts
• Additional text to include information on lubricant
Page 22, Frame 22 - Condensate Pipe Termination Configurations
• Pictorial change to drawing 2
Page 23, Frame 23 - Condensate Pipe Termination Configurations
• Pictorial change to note 3
Page 25, Frame 26 - Roof Flue Kit Contents/Options
• Diagram change to include Flue Duct Support
Page 29 & 30, Frame 31 - Water and Gas Connections
• Pictorial changes
Page 31, Frame 34 - Electrical Connections - Installer Wiring
• Pictorial changes to Diagram A and B
Page 33, Frame 36 - Pictorial Wiring Diagram
• Colour changes made to Diverter Valve
Page 39, Frame 44 - Servicing Schedule
• Additional text added to note 4 with reference to Ionisation probes as a serviceable item
Page 47, Frame 63 - Combustion Chamber Insulation Replacement
• Additional text added to note 6 with reference to Ionisation probes as a serviceable item
Ideal Stelrad Group reserve the right to vary specification without notice
Esprit - Installation and Servicing
3
GENERAL
Table 1 - General Data
Esprit
Gas supply
Gas Supply Connection
Injector Size
Inlet Connection
Domestic Hot Water
Outlet Connection
Domestic Hot Water
Flow Connection
Central Heating
Return Connection
Central Heating
Flue Terminal Diameter
mm (in)
Average Flue Temp-Mass Flow Rate
(DHW)
Maximum Working Pressure (Sealed Systems)
bar (lb/in2)
Maximum Domestic Hot Water Inlet Pressure*
bar (lb/in2)
Minimum Domestic Hot Water Inlet Pressure
bar (lb/in2)
Electrical Supply
Power Consumption
Fuse Rating
Water content
Central Heating
litre (gal)
Domestic Hot Water
Packaged Weight
kg (lb)
Maximum Installation Weight
kg (lb)
Boiler Casing Size
Height
mm (in)
Width
mm (in)
Depth
mm (in)
HE24
HE30
HE35
2H - G20 - 20mbar
Rc 1/2 (1/2” BSP female)
Stereomatic 5.6mm dia.
5.7mm dia
15mm copper compression
15mm copper compression
22mm copper compression
22mm copper compression
100 (4)
o
74 C - 12 g/s
82 oC-14g/s
66 oC-10g/s
2.5 (36.3)
10.0 (145)
1.0
1.3
1.7**
230 V ~ 50 Hz.
140 W
175 W
177 W
External : 3A Internal : T3.15A L250 V
2.0 (0.44)
0.5 (0.11)
54.5 (120)
54.8 (121)
55.1 (122)
46.8 (103)
47.1 (104)
47.4 (105)
750 (29 1/2)
450 (17 3/4)
330 (13)
*Required for maximum flow rate. Boiler operates down to 0.2 bar.
**Note: in areas of low water pressure the DHW restrictor can be removed (Refer to Frame 4).
Table 2 - Performance Data - Central Heating
Boiler Input :
Boiler Input ‘Q’
Nett CV
kW
(Btu/h)
Gross CV
kW
(Btu/h)
Gas Consumption
l/s
(ft3/h)
Table 3 - Performance Data - Domestic Hot Water
Max.
Min.
24.4
9.1
Maximum DHW Input :
Nett CV
(83 300)
(31 000)
27.1
10.1
(92 500)
(34 400)
0.70
0.26
(89.0)
(33.1)
kW
23.8
8.8
70oC Mean Water temp.
Condensing
kW
40oC Mean Water temp.
Seasonal efficiency*
(Btu/h)
(81 200)
(30 000)
(Btu/h)
(SEDBUK)
Maximum
DHW Output
9.6
(32 800)
NOx Classification
HE35
24.3
30.2
36.0
27.0
33.5
39.9
(Btu/h) (92 100) (114 400) (136 200)
l/s
(ft3/h)
(86 700)
Band A [90.0]%
kW
Gas Consumption
25.4
HE30
(Btu/h) (82 900) (103 000) (122 800)
Gross CV
Boiler Output :
Non Condensing
kW
HE24
0.7
0.87
1.03
(89.0)
(110)
(131)
kW
23.4
29.3
35.2
(Btu/h) (80 000) (100 000) (120 000)
DHW Flow Rate
at 35°C temp. rise.
l/min
(gpm)
9.6
(2.1)
12.0
2.6
14.4
(3.2)
DHW Specific Rate
l/min
(gpm)
11.2
(2.5)
14.0
(3.1)
16.8
(3.7)
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.
Note. Gas consumption is calculated using a
calorific value of 38.7 MJ/m3 (1038 Btu/ft3) 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)
3
b. For ft /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 C53 = A room sealed appliance designed for connection via ducts to a
horizontal or vertical terminal, which admits fresh air to the burner
and discharges the products of combustion to the outside through
orifices which, in this case, are concentric. The fan is up stream
of the combustion chamber.
I2H
= An appliance designed for use on 2nd Family gas, Group H only.
CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of
this appliance care should be taken when handling edges of sheet steel components
4
Esprit - Installation and Servicing
GENERAL
CONTENTS
Esprit
Air Supply ....................................................................... 8
Natural Gas only
Boiler size
G.C. Appliance No.
(Benchmark No.)
PI No.
47 348 46
47 348 47
47 348 48
87 BS 051
87 BS 051
87 BS 051
HE24
HE30
HE35
Destination Country:
Benchmark Commissioning Checklist ..................... 70
Boiler Clearances ....................................................... 10
Boiler Exploded Diagram ............................................ 15
Condensate Drain ............................................. 11,22,23
Electrical Connections ............................................... 30
Extension Ducts - Fitting ............................................. 20
Fault Finding ........................................................... 60-64
GB, IE
Flow Wiring Diagram .................................................. 33
Flue Fitting .................................................................... 18
Flue Installation ............................................................. 8
Gas Safety Regulations ................................................ 7
Gas Supply ..................................................................... 8
Installation ............................................................. 13-38
Mandatory Requirements ........................................ 7-11
Safe Handling ................................................................ 7
Servicing ................................................................ 39-58
Short List of Parts ....................................................... 65
Thermostatic Radiator Valves ................................... 11
Water and Systems ........................................... 8,11-13
Water Connections ..................................................... 29
Water Treatment ......................................................... 13
Esp8896(1)
Wiring Diagrams ................................................... 33-34
For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the
manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Commissioning Checklist.
BENCHMARK COMMISSIONING CHECKLIST DETAILS
Boiler
Page
Make and model ....................................................... 5
Appliance serial no. on data badge ...................... 14
SEDBUK No. % ......................................................... 4
Controls
Time and temperature control to heating ............. 31
Time and temperature control to hot water .......... 31
Heating zone valves .............................................. n/a
TRV's ....................................................................... 11
Auto bypass ............................................................ 11
Boiler interlock ........................................................ 11
For all boilers
Flushing to BS.7593 .............................................. 13
Inhibitor .................................................................. 13
Central heating mode
Heat input ................................................ to be calculated
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 .......................................... to be calculated
Max. operating burner pressure .............................. n/a
Max. operating water pressure ........... measure & record
Cold water inlet temp ..................... measure & record
Hot water outlet temp. .................... measure & record
Water flow rate at max. setting ............ measure & record
For condensing boilers only
Condensate drain .................................................. 22
For all boilers: complete, sign & hand over to customer
For assistance see Technical Helpline on the back page
NOTE TO THE INSTALLER: COMPLETE
THE BENCHMARK COMMISSIONING
CHECKLIST AND LEAVE THESE
INSTRUCTIONS WITH APPLIANCE
Esprit - Installation and Servicing
5
GENERAL
INTRODUCTION
SAFE HANDLING
The Esprit range of boilers are wall mounted, full sequence,
automatic spark ignition, low water content, fanned flue, high
efficiency, condensing, combination gas boilers.
This boiler may require 2 or more operatives to move it to its
installation site, remove it from its packaging base and during
movement into its installation location. Manoeuvring the boiler
may include the use of a sack truck and involve lifting, pushing
and pulling.
Note. Due to the high efficiency of the boiler a plume of water
vapour will form at the terminal during operation.
Central heating (CH) output is fully modulating with a range of
8.8 to 23.4kW (30,000 to 80,000 Btu/h)
Instantaneous domestic hot water (DHW) output is also fully
modulating with a maximum of :
HE24 23.4kW (80,000 Btu/h)
HE30 29.3kW (100,000 Btu/h)
HE35 35.2kW (120,000 Btu/h)
The boiler is supplied fully assembled with DHW plate heat
exchanger, diverter valve, circulating pump, pressure gauge,
safety valve and CH expansion vessel.
Variable CH and DHW temperature controls are fitted on the
user control and the boiler features a DHW preheat facility and
a preheat ON/OFF switch.
The boiler temperature controls are accessible behind the
casing lower door.
The heat exchanger is of cast aluminium.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques
when performing these tasks and the following precautions
should be considered:
•
Grip the boiler at the base.
•
Be physically capable.
•
Use PPE as appropriate, e.g. gloves, safety footwear.
During all manoeuvres and handling actions, every attempt
should be made to ensure the following unless unavoidable
and/or the weight is light.
•
Keep back straight.
•
Avoid twisting at the waist.
•
Avoid upper body/top heavy bending.
•
Always grip with the palm of the hand.
•
Use designated hand holds.
•
Keep load as close to the body as possible.
The boiler is suitable for connection to fully pumped, sealed
water systems ONLY. Adequate arrangements for completely
draining the system by provision of drain cocks MUST be
provided in the installation pipework.
•
Always use assistance if required.
Pipework from the boiler is routed downwards as standard, but
may be routed upwards behind the boiler using the stand-off
frame (supplied in a separate kit).
z Flue Extension Ducts. (1000mm long).
HE24-upto 6m
HE30-upto 6m
HE35-upto 3m
The boiler includes a filling loop, an automatic by-pass and a
75mm condensate trap with integral siphon. Boiler frost
protection is included as standard.
OPERATION
With no demand for CH, the boiler fires only when DHW is
drawn off, or periodically for a few seconds without any DHW
draw-off, in order to maintain the DHW calorifier in a heated
condition. (This facility can be turned off if required).
When there is a demand for CH, the heating system is
supplied at the selected temperature of between 30 oC and
82oC, until DHW is drawn off. The full output from the boiler is
then directed via the diverter valve to the plate heat exchanger to
supply a nominal DHW draw-off of
HE24 9.6 l/min at 35 oC temperature rise.
HE30 12 l/min at 35 oC temperature rise.
HE35 14.4 l/min at 35 oC 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 oC by the modulating gas control.
Refer also to Frame 1 - 'Boiler Water Circuit Diagrams'
The boiler features a comprehensive diagnostic system which
gives detailed information on the boiler status when operating,
and performance of key components to aid commissioning and
fault finding.
6
OPTIONAL EXTRA KITS
z Flue Finishing Kit.
o
z 90 Elbow Kit (maximum per installation).
HE24-upto 4 elbows
HE30-upto 4 elbows
HE35-upto 2 elbows
o
z 45 Elbow Kit (maximum per installation).
HE24-upto 4 elbows
HE30-upto 4 elbows
HE35-upto 2 elbows
z 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 details refer to
Powered Vertical Instructions).
z
z
z
z
z
z
z
z
z
z
z
z
z
High Level Flue Outlet Kits
Flue Deflector Kit
Weather Collars
Twin Fluing Kits 80mm diameter (up to a maximum of 60m
combined total flue and airducts)
Twin Fluing Kits 60mm diameter (up to a maximum of 18m
combined total flue and airducts)
Horizontal Flue Terminal 600mm long
Adjustable Flue Support Bracket
Boiler Stand-off Kit
Condensate Pump Kit
Programmer Kit - Mechanical 24 hour
Programmer Kit - Electronic 7 day
RF Thermostat/Programmer Kit - Mechanical 24 hour
RF Thermostat/Programmer Kit - electronic 7 day
Esprit - Installation and Servicing
GENERAL
SAFETY
LOCATION OF BOILER
Current Gas Safety (installation and use) regulations or rules
in force:
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 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 appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (northern Ireland).
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 available
from the back of the boiler.
The boiler must not be fitted outside.
Timber Framed Buildings
•
The Water Fittings Regulations or Water byelaws in
Scotland.
If the boiler is to be fitted in a timber framed building it should
be fitted in accordance with the Institute of Gas Engineering
document IGE/UP/7:1998.
•
The Current I.E.E. Wiring Regulations.
Bathroom Installations
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a Competent
Person and installed in accordance with the current edition of
I.S.813 "Domestic Gas Installations", the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
Detailed recommendations are contained in the following British
Standard Codes of Practice:
BS. 5440:1
Flues (for gas appliances of rated input not
exceeding 70 kW).
BS. 5440:2
Ventilation (for gas appliances of rated input not
exceeding 70 kW).
BS. 5449
Forced circulation hot water systems.
BS. 5546
Installation of gas hot water supplies for
domestic purposes (2nd Family Gases)
BS. 6798
Installation of gas fired hot water boilers of rated
input not exceeding 70 kW.
BS. 6891
Low pressure installation pipes.
Health & Safety Document No. 635.
This appliance is rated IP20.
The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of the
current IEE (BS.7671) Wiring Regulations and, in Scotland, the
electrical provisions of the building regulations applicable in
Scotland, with respect to the installation of the boiler in a room
or internal space containing a bath or shower. For IE reference
should be made to the current ETCI rules for electrical
installations and I.S. 813:2002.
If the appliance is to be installed in a room containing a bath or
shower then, providing water jets are not going to be used for
cleaning purposes (as in communal baths/showers), the
appliance can be installed in Zone 3, as detailed in BS.7671.
Ceiling
0.75m
2.25m
Unzoned
Zone 3
2.4m
0.6m
Zone 1
0.6m
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
IMPORTANT. These appliances are CE certificated for safety
and performance. It is, therefore, important that no external
control devices, e.g. flue dampers, economisers etc., are
directly connected to these appliances unless covered by these
Installation and Servicing Instructions or as otherwise
recommended by Ideal Stelrad Group in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by Ideal
Stelrad Group could invalidate the certification and the normal
appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.
SAFE HANDLING OF SUBSTANCES
Care should be taken when handling the boiler insulation
panels, which can cause irritation to the skin. No asbestos,
mercury or CFCs are included in any part of the boiler or its
manufacture.
Esprit - Installation and Servicing
Zone 2
Zone 0
esp8913
Compartment Installations
A compartment used to enclose the boiler should be designed
and constructed specially for this purpose.
An existing cupboard or compartment may be used, provided
that it is modified for the purpose.
In both cases, details of essential features of cupboard /
compartment design, including airing cupboard installation,
are to conform to the following:
z BS 6798 (No cupboard ventilation is required - see ‘Air
Supply’ for details).
z The position selected for installation MUST allow adequate
space for servicing in front of the boiler.
z For the minimum clearances required for safety and
subsequent service, see Frame 2. In addition, sufficient
space may be required to allow lifting access to the wall
mounting plate.
7
GENERAL
GAS SUPPLY
Table 4 - Balanced Flue Terminal Position
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an
adequate supply of gas. An existing service pipe must NOT be
used without prior consultation with the local gas supplier.
Flue Terminal Positions
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 required.
N.B. The principle of the 1:1 gas valve ensures that the Esprit
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.
Min. Spacing*
1. Directly below, above or alongside an opening
window, air vent or other ventilation opening.
300mm (12")
2. Below guttering, drain pipes or soil pipes.
BS5440-1 2000
25mm ( 1")*
75mm (3")
3. Below eaves.
BS5440-1 2000
25mm (1")*
200mm (8")
4. Below balconies or a car port roof.
BS5440-1 2000
25mm (1")*
200mm (8")
5. From vertical drain pipes or soil pipes.
BS5440-1 2000
25mm (1")*
150mm (6")
6. From an internal or external corner or to a
boundary along side the terminal.
BS5440-1 2000
25mm (1")*
300mm (12")
7. Above adjacent ground, roof or balcony level.
300mm (12")
8. From a surface or a boundary facing the terminal.
600mm (24")
9. From a terminal facing a terminal.
1,200mm (48")
10. From an opening in a car port
(e.g. door or window) into dwelling.
1,200mm (48")
11. Vertically from a terminal on the same wall.
1,500mm (60")
Installation pipes must be fitted in accordance with BS.6891. In
IE refer to IS.813:2002. Pipework from the meter to the boiler
MUST be of an adequate size, i.e. no longer than 20m and not
less than 15mm O.D.
12. Horizontally from a terminal on the wall.
13. Above the roof pitch with roof slope of all angles.
Above flat roof.
300mm (12")
300mm (12")
The complete installation MUST be tested for gas soundness
and purged as described in the above code.
14. From a single wall face.
From corner walls.
300mm (12")
300mm (12")
FLUE INSTALLATION
Pluming will occur at the terminal so terminal positions where
this could 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 across it at all times.
3. Minimum acceptable spacing from the terminal to
obstructions and ventilation openings are specified in
Table 4.
4. Where the lowest part of the terminal is fitted less than 2m
(6'6") above a balcony, above ground or above a flat roof to
which people have access then the terminal MUST be
protected by a purpose designed guard.
Terminal guards are available from boiler suppliers. (Ask for
TFC flue guard model no. K6 - round, plastic coated). In case
of difficulty contact:
Grasslin (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.co.uk
Ensure that the guard is fitted centrally.
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
combustible material are given in BS. 5440-1:2000.
8
300mm (12")
Vertical Terminals
* Only one reduction down to 25mm is allowable per installation
otherwise BS5440-1 2000 dimensions must be followed.
IMPORTANT. It is absolutely essential to ensure, in practice,
that products of combustion discharging from the terminal
cannot re-enter the building or any other adjacent building
through ventilators, windows, doors, other sources of natural
air infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF,
labelled as 'unsafe' until corrective action can be taken.
TERMINAL
The terminal assembly can be adapted to accommodate
various wall thicknesses. Refer to Frame 10 .
AIR SUPPLY
It is NOT necessary to have a purpose-provided air vent in the
room or internal space in which the boiler is installed. Neither
is it necessary to ventilate a cupboard or compartment in which
the boiler is installed, due to the low surface temperatures of
the boiler casing during operation; therefore the requirements
of BS 6798, Clause 12, and BS 5440:2 may be disregarded.
WATER CIRCULATION SYSTEM
IMPORTANT.
A minimum length of 1 metre of copper pipe MUST be fitted to
both flow and return connections from the boiler before
connection to any plastic piping.
The central heating system should be in accordance with
BS.6798 and, in addition, for smallbore and microbore
systems, BS.5449.
WATER TREATMENT - see Frame 6
Esprit - Installation and Servicing
GENERAL
1
BOILER WATER CIRCUIT DIAGRAMS
CENTRAL HEATING CIRCUIT
Expansion
Vessel
Burner
Automatic
Air Vent
Fan
Heat
Exchanger
Sump
Pressure
Relief Valve
Divertor
Valve
Gas Valve
Water Pressure
Gauge
DOMESTIC HOT WATER CIRCUIT
CH Return
PRV
Gas
Plate Heat
Exchanger
CH Flow
Condensate Drain
Condensate
Siphon
Pump
Expansion
Vessel
Burner
Automatic
Air Vent
Fan
Heat
Exchanger
Sump
Pressure
Relief Valve
Divertor
Valve
Gas Valve
Water Pressure
Gauge
Condensate
Siphon
Esprit - Installation and Servicing
PRV
DHW In
Gas
Plate Heat
Exchanger
DHW Out
Condensate Drain
ESP8829
Pump
9
GENERAL
2
all dimensions in mm
BOILER DIMENSIONS, SERVICES & CLEARANCES
Side and Rear Flue
Provided that the flue hole is cut accurately, e.g. with a core drill,
the flue can be installed from inside the building where wall
thicknesses do not exceed 600mm. 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.
The boiler connections are made on the boiler. Refer to
Frames 30.
The following minimum clearances must be maintained for
operation and servicing.
Additional space will be required for installation, depending
upon site conditions.
CLEARANCES
5
BOILER DIMENSIONS
5
450
330
160
64mm
Wall
Mounting
Plate
750
200*
460
Front clearance - The minimum front clearance when built in to a cupboard is 5mm from the cupboard door but 450mm
overall clearance is still required, with the cupboard door open, to allow for servicing.
* Bottom clearance - Bottom clearance after installation can be reduced to 5mm. However, 200mm must be available for
servicing.
SIDE FLUE ONLY
Horizontal length of flue
from centre line of boiler
to outside wall
HE24 HE30
HE35
esp8820
CH Return
DHW In
Gas
DHW Out
CH Flow
Condensate
Drain
PRV
WATER AND GAS CONNECTIONS
53
49
129
65
46
70
65
31
44
Top clearance
required (MIN.)
Dim. A
0.5 m
0.5 m
0.5 m
160 mm
1.0 m
1.0 m
1.0 m
170 mm
1.5 m
1.5 m
1.5 m
185 mm
2.0 m
2.0 m
2.0 m
200 mm
2.5 m
2.5 m
2.5 m
210 mm
3.0 m
3.0 m
3.0 m
225 mm
3.5 m
3.5 m
N/A
250 mm
4.0 m
4.0 m
N/A
260 mm
4.5 m
4.5 m
N/A
265 mm
5.0 m
5.0 m
N/A
275 mm
5.5 m
5.5 m
N/A
290 mm
6.0 m
6.0 m
N/A
300 mm
REAR FLUE ONLY
MIN. Top clearance required = 160 mm
10
Esprit - Installation and Servicing
GENERAL
BOILER CONTROL INTERLOCKS
Ideal Stelrad Group recommend that heating systems
utilising full thermostatic radiator valve control of temperature
in individual rooms should also be fitted with a room
thermostat controlling the temperature in a space served by
radiators not fitted with such a valve as stated in BS. 5449.
Central heating system controls should be installed to
ensure the boiler is switched off when there is no demand
for heating or hot 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 port
valves without end switches, then a bypass circuit is
incorporated within the boiler to ensure a flow of water
should all valves be in the closed position.
3
ELECTRICAL SUPPLY
WARNING.
This appliance must be earthed.
Wiring external to the appliance MUST be in accordance with
the current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply. For IE reference should be made to
the current ETCI rules for electrical installations.
The point of connection to the mains should be readily
accessible and adjacent to the boiler.
N.B. THE FAN VOLTAGE IS 325VDC
CONDENSATE DRAIN Refer to Frames 21 & 49.
A condensate drain is provided on the boiler. This drain must
be connected to a drainage point on site. 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.
SYSTEM REQUIREMENTS - Central Heating
Notes
a. The method of filling, refilling, topping up or flushing
sealed primary hot water circuits from the mains via a
temporary hose connection is only allowed if acceptable
to the local water authority.
Safety valve setting
bar
3.0
Vessel charge pressure
bar
0.5 to 0.75
System pre-charge pressure bar
System volume
(litres)
b. Antifreeze fluid, corrosion and scale inhibitor fluids
suitable for use with boilers having aluminium heat
exchangers may be used in the central heating system.
None
1.0
Expansion vessel
volume (litres)
25
1.6
1.8
50
3.1
3.7
75
4.7
5.5
General
100
6.3
7.4
1. The installation must comply with all relevant national and
local regulations.
125
7.8
9.2
150
9.4
11.0
175
10.9
12.9
190
11.9
14.0
200
12.5
14.7
250
15.6
18.4
300
18.8
22.1
0.063
0.074
Advice should be sought from a local water treatment
company.
2. The installation should be designed to work with flow
o
temperatures of up to 82 C.
3. All components of the system must be suitable for a working
o
pressure of 3 bar and temperature of 110 C. Extra care should
be taken in making all connections so that the risk of leakage
is minimised.
The following components are incorporated within the
appliance:
a.
Circulating pump.
For other system volumes
multiply by the factor across
b. Safety valve, with a non-adjustable preset lift pressure of
3 bar.
c.
Pressure gauge, covering a range of 0 to 6 bar.
d. An 8-litre expansion vessel, with an initial charge pressure
of 1.0 bar.
4. 'Make-up' Water. Provision must be made for replacing
water loss from the system, either :
a.
From a manually filled 'make-up' vessel with a readily
visible water level. The vessel should be mounted at
least 150mm above the highest point of the system and
be connected through a non-return valve to the system,
fitted at least 150mm below the 'make-up' vessel on the
return side of the radiators.
Esprit - Installation and Servicing
or
b.
Where access to a 'make-up' vessel would be difficult,
by pre-pressurisation of the system.
The maximum cold water capacity of the system
should not exceed 143 litres, if not pressurized.
However, if the system is to be pressurized, the
efficiency of the expansion vessel will be reduced and
a larger vessel (or smaller system volume) may be
necessary. If the capacity of the vessel is not
considered sufficient for this, or for any other reason,
an additional vessel MUST be installed on the return
to the boiler.
Guidance on vessel sizing is given in Frame 3.
11
GENERAL
SYSTEM REQUIREMENTS - CH (continued) and Hot Water
4
5. Filling
Where the mains pressure is excessive a pressure reducing
valve must be used to facilitate filling.
a. Thoroughly flush out the whole system with
cold water.
b. Fill and vent the system until the pressure
gauge registers 1.5 bar and examine for leaks.
Water Flow Rate and Pressure Loss
Max CH Output
kW
(Btu/h)
Water flow rate
l/sec
(gal/min)
c. Check the operation of the safety valve by
raising the water pressure until the valve lifts.
This should occur within 0.3 bar of the preset lift pressure.
Temperature Differential
d. Release water from the system until the
minimum system design pressure is reached;
1.0 bar if the system is to be pre-pressurised.
Head available for
o
C
o
system pump.
23.8
(81 200)
0.38
4.8
15
( F)
(27)
m.w.g.
2.3
(ft.w.g.)
7.5
DOMESTIC HOT WATER
1. The domestic hot water service must be in accordance
with BS 5546 and BS 6700.
2. Refer to Table 1 for minimum and maximum working
pressures.
In areas of low mains water pressures the domestic hot
water restrictor may be removed from the inlet valve. The
boiler will require the flow rate to be set to obtain a
o
temperature rise of 35 C at the tap furthest from the boiler.
3. The boilers are suitable for connection to most types of
washing machine and dishwasher appliances.
5. Hard Water Areas
Where the water hardness exceeds 200mg/litre, it is
recommended that a proprietary scale reducing device is
fitted into the boiler cold supply within the requirements of
the local water company.
IMPORTANT
Provision MUST be made to accommodate the expansion of
DHW contained within the appliance, if a non-return valve is
fitted to the DHW inlet.
4. When connecting to suitable showers, ensure that:
5
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.
SYSTEM BALANCING
The boiler is fitted with an automatic bypass.
BALANCING
1. Set the programmer to ON.
Close the manual or thermostatic valves on all radiators,
leaving the twin lockshield valves (on the radiators referred
to above) in the OPEN position.
Turn up the room thermostat and adjust these lockshield
valves to give boiler flow and return temperatures not more
than 20oC apart.
2. Open all manual or thermostatic radiator valves and
adjust the lockshield valves on the remaining radiators,
to give around 15 oC temperature drop at each radiator.
3. Adjust the room thermostat and programmer to NORMAL
settings.
See note regarding thermostatic radiator valves on page 11.
These valves should now be left as set.
12
Esprit - Installation and Servicing
6
INSTALLATION
INSTALLATION
WATER TREATMENT
CENTRAL HEATING
The Esprit range of boilers have an ALUMINIUM alloy
heat exchanger.
IMPORTANT.
The application of any other treatment to this product
may render the guarantee of Ideal Stelrad Group.
Ideal Stelrad Group recommend Water Treatment in
accordance with the Benchmark Guidance Notes on
Water Treatment in Central Heating Systems.
If water treatment is used Ideal Stelrad Group recommend
only the use of FERNOX-COPAL or MB1, GE BETZ SENTINEL X100
or Salamander Corrosion Guard inhibitors and associated
water treatment products, which must be used in accordance
with the manufacturers' instructions.
Notes.
1. It is most important that the correct concentration of the
water treatment products is maintained in accordance with
the manufacturers' instructions.
2. If the boiler is installed in an existing system any unsuitable
additives MUST be removed by thorough cleansing. BS
7593:1992 details the steps necessary to clean a domestic
heating system.
3. In hard water areas, treatment to prevent lime scale may be
necessary - however the use of artificially softened water is
NOT permitted.
4. Under no circumstances should the boiler be fired before
the system has been thoroughly flushed.
DOMESTIC HOT WATER
In hard water areas where main water can exceed 200ppm
Total Hardness (as defined by BS 7593:1993 Table 2) a
scale reducing device should be fitted into the boiler cold
supply within the requirements of the local water company.
The use of artificially softened water, however, is not
permitted.
Ideal Stelrad Group recommend the use of Fernox
Qantomat, GE Betz Sentinel Combiguard and Calmag
CalPhos I scale reducing devices, which must be used in
accordance with the manufacturers' instructions.
For further information contact:
Fernox Manufacturing Co. Ltd
Cookson Electronics
Forsyth Road
Sheerwater
Woking
Surrey GU21 5RZ
+44 (0) 1799 521133
Sentinel Performance Solutions
The Heath Business & Technical Park
Runcorn
Cheshire WA7 4QX
Tel: 0800 389 4670
www.sentinel-solutions.net
Salamander Engineering Ltd
Unit 24 Reddicap Trading Estate
Sutton Coldfield
West Midlands B75 7BU
Tel: +44 (0) 121 3780952
Calmag Ltd.
Unit 4-6, Crown Works
Bradford Road
Sandbeds, Keighley
West Yorkshire BD20 5LN
Tel: +44 (0) 1535 210 320
Esprit - Installation and Servicing
13
INSTALLATION
INSTALLATION
7
14
BOILER ASSEMBLY - Exploded View Legend
1.
Front Casing Panel
31. Spark Generator
2.
Front Casing Door
32. Ignition Lead
3.
Sump Cover Plate
33. Connection Pipes
4.
Flue Sensing Nipple
34. Flow Regulator
5.
Return Pipe
35. Pressure Relief Valve
6.
Flue Manifold
36. Expansion Vessel
7.
Interpanel
37. Expansion Vessel Pipe
8.
Burner
38. Pressure Gauge
9.
Combustion Chamber Insulation
39. DHW Thermistor
10. Heat Engine
40. Diverter Valve Head
11. Injector & Housing
41. Diverter Valve Cartridge
12. Venturi
42. Flow Group Manifold
13. Fan
43. Pump
14. Automatic Air Vent (Heat Exchanger)
44. Return Group Manifold
15. Gas Service Cock
45. Plate Heat Exchanger
16. Gas Valve
46. Dry Fire Thermistor
17. Gas Injector Pipe
47. Water Pressure Switch
18. Fan Bracket
48. Reed Switch
19. Orifice Plate
49. Reed Switch Cartridge & Filter
20. Control Thermistor (Flow/Return)
50. Air Vent (Pump)
21. Overheat Thermostat
51. Filling Loop
22. Ignition Electrode
52. Return Valve
23. Flame Sensing Electrode
53. Flow Valve
24. Condensate Trap/Siphon
54. DHW Valve
25. User Control PCB
64. Control Box Sub Assy
26. PCB Primary Controls
65. Control Box Lid
27. Mains Switch
71. Control Box Hinge
28. Pre-Heat & Winter/Summer Switch
78. Turret Clamp
29. Wall Mounting Bracket
86. Burner Earth Pin
30. Turret Gasket
91. Flow Pipe
Esprit - Installation and Servicing
INSTALLATION
8
BOILER ASSEMBLY - Exploded View
19
12
13
78
30
11
30
4
6
18
29
14
31
8
17
46
86
36
9
23
22
10
3
7
91
65
24
64
16
71
32
26
38
40
45
5
1
25
27
28
48
41
37
44
47
35
39
42
49
50
51
43
2
21
20
33
53
54
15
52
34
Esprit - Installation and Servicing
Esp9176
15
INSTALLATION
INSTALLATION
9
UNPACKING
The boiler is supplied fully assembled in one Pack A, together with a telescopic flue
assembly for lengths up to 595mm, rear or side flue outlet, in Pack B.
Unpack and check the contents.
Pack A Contents
A
Boiler
B
Hardware Pack Box
(positioned at bottom of boiler)
C
Wall Mounting Bracket
(positioned at bottom of boiler)
D
Installation/Users
Instructions
E
Wall Mounting Template
F
2 Year Guarantee
C
A
E
B
F
D
esp8821
HARDWARE PACK CONTENTS
Accessory Pack
1. Screws x 3
2. Wall Plugs x3
3. 1/2" Fibre washer (spare) x 1
4. 1/2" Gas washer (blue) (spare) x 1
5. 3/4" Fibre washer (spare) x 1
Accessory Pack
Gas Pack
Return Valve Pack
1
3
1
3
4
1
Gas Pack
1. Gas Cock x 1
2. 1/2" Gas washer (blue) x 1
3. Gas Inlet Bend 15mm x 1
Return Valve Pack
1. Return Valve Assembly c/w drain
2. Outlet bend 22mm
3. Fibre Washer
5
2
2
3
2
DHW Pack
Flow Valve Pack
Filling Loop Pack
4
Flow Valve Pack
1. Outlet bend 22mm x 1
2. 22mm CH valve,
nut & olive x 1
3. 3/4" Fibre washer x 1
1
2
2
1
5
1
2
3
DHW Pack
1. Pipe DHW outlet x 1
2. 15mm valve c/w nut & olive
& flow regulator x 1
3. Inlet bend 15mm x 1
4. Nut G1/2 x 2
5. 1/2" Fibre washer x 3
3
esp9262
Filling Loop Pack
1. Isolating valve c/w double non return valve x 1
2. Flexible Hose x 1
PACK B CONTENTS
A
B
A
C
Telescopic flue terminal
B
Flue turret
C
Screws
D
Sealing tape
D
nm8751
16
Esprit - Installation and Servicing
INSTALLATION
INSTALLATION
10 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED
IMPORTANT.
The boiler MUST be installed in a vertical position
Pack B - supplied as standard
Dimension X - Wall thickness.
Dimension L
FLUE KITS
Pack D - optional extension kit for side flue or
rear flue outlet.
- Wall thickness plus boiler spacing.
Dimension S - Optional Stand-off frame depth = 33mm
Finishing Kit - Supplied as an optional extra.
Refer to 'Flue Extension Ducts'
REAR FLUE
Note. MAXIMUM FLUE LENGTHS:
HE24 & 30
- 6M (HORIZONTAL FLUE)
HE35
- 3M (HORIZONTAL FLUE)
169 + S = 202mm
(with optional
stand-off frame)
HE24, 30 & 35
- 7.5M (ROOF FLUE)
HE 24, 30 & 35
- 5M PRIMARY AND 17M SECONDARY IS A
TYPICAL MAX. FLUE LENGTH. (For alternative details refer to
Powered Vertical Instructions)
169 mm
90O ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 1M)
HE24, HE30 & HE35
- 18M TOTAL (AIR PLUS FLUE DUCT-60/60 TWIN FLUE KIT)
HE24, HE30 & HE35
- 60M TOTAL (AIR PLUS FLUE DUCT - 80/80 TWIN FLUE KIT)
esp8815
45O ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 0.6M)
NOTE. If the option of a loft terminal grille is used with the 80/80 twin flue, then a minimum
of 300mm radial clearance around the grill must be maintained at ALL times.
MINIMUM HORIZONTAL FLUE LENGTHS
(Centre Line of turret to outside of wall terminal)
- TELESCOPIC TERMINAL = 370MM
- ONE PIECE TERMINAL = 285MM
Wall thickness X
Notes.
1. It is recommended that a support bracket is fitted for every
1 meter of extension pipe used and a bracket should be
used at every joint, to ensure pipes are held at the correct
angle.
If a slip joint coupling is to be used then a bracket should
be used to secure the collar.
4. If the boiler is to be installed with upward piping routed
behind the boiler then the optional stand-off kit should be
used. Care must be taken when cutting the ducts and
marking the wall to suit this condition.
5. Only use water as a lubricant during assembly. Do not use
mineral based oils.
2. When extension ‘D’ packs are used 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.
3. If the telescopic ‘B’ pack, or horizontal flue terminal (600
long) only are used, they may be mounted horizontally.
The 1.5 degrees is taken care of by the inclination of the
flue within the air pipe.
Total Flue length dimension
SIDE FLUE
Wall thickness X
225mm 225mm
Flue
(measuring from CL of turret to outside wall)
Rear flue
dim. X+169
Side flue
dim. L+225
Extra packs
required
Boiler
Size
Up to 595 mm
Up to 595 mm
none
HE24,30 & 35
Up to 1545 mm
Up to 1545 mm
Pack D - 1 off
HE24,30 & 35
Up to 2495 mm
Up to 2495 mm
Pack D - 2 off
HE24,30 & 35
Up to 3445 mm
Up to 3445 mm
Pack D - 3 off
HE24, 30 & 35*
Up to 4395 mm
Up to 4395 mm
Pack D - 4 off
HE24 & 30
Up to 5345 mm
Up to 5345 mm
Pack D - 5 off
HE24 & 30
Up to 6000 mm
Up to 6000 mm
Pack D - 6 off
HE24 & 30
Side flue length L
*Esprit HE35 is capable of 3m flue only
Esprit - Installation and Servicing
17
11 FLUE ASSEMBLY - Exploded View
An optional flue duct extension kit is required for
wall thicknesses greater than :
Side
365mm (14 3/8")
Rear
426mm (15 3/4").
LEGEND
1. Duct assembly.
1
2. Flue turret.
3. Turret gasket.
4. M5 x 10 pozi screw.
esp8822
5. Turret clamp.
Rear flue arrangement shown
12 WALL MOUNTING TEMPLATE
Note.
The template shows the positions of the fixing holes and the
rear flue outlet hole centre for standard installation. Care
MUST be taken to ensure the correct holes are drilled.
Extended
2 centre
line
1
169mm
1. Tape template into the selected position. Ensure
squareness by hanging a plumbline as shown.
2. If fitting a side flue extend the flue centre line onto the side
wall and measure in 169mm for standard installation.
203707A01
Note. If using stand-off kit distance increases to 206mm.
4
891
esp
3. Mark onto the wall the following:
nm8761
INSTALLATION
INSTALLATION
a The wall mounting plate screw
positions (choose one from each
group).
b. The position of the flue duct hole
(see diagram).
Note. Mark the centre of the hole as well
as the circumference
4. Remove the template from the wall.
18
Esprit - Installation and Servicing
INSTALLATION
13 PREPARING 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 (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.
Side flue only
5" diameter hole
X
Section
through wall
Note. Check all of the hole
positions before drilling.
esp8816
2. Drill 3 holes with an 8mm masonry drill and
insert the plastic plugs, provided, for the wall
mounting plate.
Rear flue only
5" diameter hole
14 SETTING THE FLUE - REAR Wall thicknesses of 200 to 426mm
Notes.
a. If using the extension ducts go to Frame 16.
b. If the stand-off frame is used it is essential add 33mm to
'X' the measured wall thickness when marking the flue
(this will allow for the fitted frame).
Adhere sealing tape
Drill hole
c. For wall thickness less than 200mm use none telescopic
b pack.
X + 85
OUTLET
1. Measure and note wall thickness X. Refer to Frame 10.
2. Add 85mm (4") to dimension X and set telescopic flue
length as indicated in drawing.
3. Using a 3.5mm drill bit, drill two holes in outer air duct
taking care not to pierce plastic inner flue.
4. Fix to length using self tappers provided.
Measurement to be
taken from this point
esp8938
5. Seal out air duct using the tape provided.
15 SETTING THE FLUE - SIDE
Wall thicknesses of 140 to 365mm
Note.
a. If using the extension ducts go to Frame 16.
Adhere sealing tape
Drill hole
1. Measure and note wall thickness X. Refer to Frame 10.
FLUE
b. For shorter flue requirements use non telescopic
b pack.
L + 145
2. Measure distance from side of boiler to inside of wall
and add to wall thickness X = L. Refer to Frame 10.
3. Add 156mm to dimension L, hand set telescopic flue
length as indicated in drawing.
Measurement to be
taken from this point
4. Using a 3.5mm drill bit, drill two holes in outer air duct
taking care not to pierce plastic inner flue.
5. Fix to length using self tappers provided.
esp8939
6. Seal outer air duct using the tape provided.
Esprit - Installation and Servicing
19
INSTALLATION
16 FLUE EXTENSION DUCTS - For total flue lengths greater than 595mm
Pack D Flue extension duct kit contents
Flue support cutting aid
(shown folded up)
Extension duct & clamp
1.0m (39") long
Wall plugs - 4 off
nm8732
Flue duct support
No. 10 x2" wood screw - 4 off
17 FLUE EXTENSION DUCTS - continued
Flue length
Use a maximum of 6m extended flue ONLY (HE24 & 30)
Use a maximum of 3m extended flue ONLY (HE35)
Extension flue
General arrangement
1. A maximum of 6 extension ducts for the HE24/
HE30 and a maximum of 3 extension ducts for
the HE35 (one suitably cut) plus the standard
flue duct may be used together.
Standard flue
FLUE OUTLET
2. Flue extensions of greater length than 1m (39")
should be supported with the bracket provided,
suitably adjusted. Refer to Frames 16 and 24.
Terminal grille
Boiler
Note.
3. Only use water as a lubricant during assembly.
Do not use mineral based oils.
Side flue shown
nm8762
18 FITTING THE KIT
6. If the remainder Y is less than 300mm, shorten the
previous ‘D’ pack to 400mm and adjust the telescopic
terminal.
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.
7. Measure and mark the length on the flue, to ensure a
square cut mark the flue all the way around and cut to
length.
2. Subtract 70mm from this dimension.
3. Subtract 950mm for each ‘D’ pack to be used.
4. If the remainder Y is 300mm 525mm this can be taken up
by the adjustment in the
telescopic flue.
L
70
950
Y
525
300
5. If the remainder Y is 525mm 950mm it will be necessary to
cut a ‘D’ pack to 400mm.
esp8940
20
Esprit - Installation and Servicing
INSTALLATION
19 FITTING THE WALL MOUNTING PLATE
Screw the wall mounting plate to the
wall using 3 wall plugs (previously
fitted) with the 3 screws provided.
Choose one of the 3 sets of slots in left,
right and centre bank. Ensuring that at
least one of the screws is fitted into a
top slot.
Example of fixing
esp8817
OUTLET
20 MOUNTING THE BOILER
1. Ensure the plastic plugs are removed
from both the CH and DHW connections
before mounting the boiler.
FLUE
2. Lift the boiler onto the wall mounting plate
(refer to the Introduction section for safe
handling advice), locating it over the top
angled return.
esp8828
Esprit - Installation and Servicing
21
INSTALLATION
INSTALLATION
21 CONDENSATE DRAIN
Refer also to the British Gas document: 'Guidance Notes
for the Installation of Domestic Gas Condensing Boilers'
(1989).
Ensure that the siphon is full of water before
commissioning the boiler . Refer to Frame 24.
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
pipe does not give rise to spillage within the dwelling.
IMPORTANT.
All pipework and fittings in the condensate drain system
must be made of plastic. No other materials may be
used. The maximum length of external plastic pipework
is 3m and must be insulated.
The drain outlet on the boiler is standard 21.5mm
overflow pipe and is suitable for either push fit or solvent
weld applications. This size must not be reduced in any
part of its length.
53
49
The boiler includes as standard, a 75mm condensate
trap. The condensate trap also includes a siphon to
reduce the possibility of freezing in the drain outlet.
Condensate
Drain
129
22 CONDENSATE PIPE TERMINATION CONFIGURATIONS
Note. ALL EXTERNAL PIPE RUNS MUST BE INSULATED
MAXIMUM EXTERNAL PIPE LENGTH IS 3 METRES
1. INTERNAL TO SINK WASTE
UPSTREAM OF SINK WASTE
TRAP
Sink constitutes
air break
BOILER
Open end of pipe
direct into gulley
below grating but
above water level
esp8880
Ground Level
DRAIN
2. INTERNAL TO SINK WASTE
DOWNSTREAM OF SINK
WASTE TRAP (PREFERRED
METHOD)
BOILER
Sink
Open end of pipe
direct into gulley
below grating but
above water level
esp8881
Ground Level
DRAIN
continued . . . .
22
Esprit - Installation and Servicing
INSTALLATION
INSTALLATION
23 CONDENSATE PIPE TERMINATION CONFIGURATIONS . . . continued
3. INTERNAL CONNECTION TO SOIL AND VENT STACK
* Make connection to SVP using a solvent welded saddle
BOILER
esp8882
4. TERMINATION TO SOAK AWAY
External
wall
Termination
to Soak away
BOILER
cla7774
minimum
500mm
Ground Level
5. TERMINATION TO DRAIN / GULLEY
External
wall
Open end of pipe
direct into gulley
below grating but
above water level
BOILER
cla7775
Ground Level
DRAIN
Esprit - Installation and Servicing
23
INSTALLATION
INSTALLATION
24 CONNECTING THE FLUE TO THE BOILER
Note.
Before fitting the flue turret fill the condensate trap within the
boiler 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. Push through and pull back to seal against outside
wall face.
3. Locate the flue turret on the top of the boiler, ensuring that
the turret gasket is in place. Also ensure the turret is
located concentric with the flue aperture on the boiler top
panel. Check that the flue seal located in the top of the flue
manifold 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 4 wall
plugs and wood screws.
NB. The space bracket will utilise one fixing hole only
whilst used in conjunction with the stand-off option.
2
3
1
esp8824
24
Esprit - Installation and Servicing
INSTALLATION
25 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched)
Note.
A flat or pitched roof flashing plate (not supplied) is required before
proceeding with the installation of this kit.
This kit is suitable for both flat and pitched roof terminations, using a
concentric flue to run vertically from the top of the boiler and terminating
above roof level.
WEATHER PROOFING
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
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 Frames
26 and 28, Flue Arrangement.
26 ROOF FLUE KIT CONTENTS / OPTIONS
Flue Terminal
UIN 203132
Flue Seal Collar - Flat Roof
UIN 152259
Vertical connector
UIN 204180
90o elbow
UIN 203130
45o elbow
UIN 203131
Flue
duct
support
Flue Seal Collar - Tile Roof
UIN 152258
esp9177
Roof Flue Extension Duct
UIN 203129
Esprit - Installation and Servicing
25
FLUE
OUTLET
nm8736
INSTALLATION
27 FLUE TERMINAL POSITION
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.
rf8392
Minimum dimensions are shown below
m
m
0
30
300mm
in
m
min
rf8393-1
625mm
Fixed
300mm
FLUE OUTLET
min
Flat roof - with structure
rf8394-1
690mm
Fixed
26
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 balcony
500 mm
Esprit - Installation and Servicing
INSTALLATION
28 FLUE ARRANGEMENT
Note.
The equivalent flue length resistance of the elbow kits are:
90o elbow kit = 1m
rf8737
FLUE
rf8738
OUTLET
45o elbow kit = 0.6m
Esprit - Installation and Servicing
27
INSTALLATION
29 ASSEMBLING THE ROOF FLUE KIT
Determine the correct height that the flue should terminate
above the roof. If after calculating or measuring the overall flue
height from the top of the boiler, it is necessary to cut both
pipes, then ensure they are cut equally leaving the inner flue
tube longer than the outer air tube as supplied.
1. Position the roof flashing plate (supplied separately) over the
hole cut in the roof and insert flue terminal from the roof end.
MAX LENGTH:
7.5m
o
max 41
min 16
o
Ensure the cut pipe ends are free from any burrs.
BOILER
esp8887
1
Flue Terminal
2. Push fit the vertical connector (supplied separately) into the
boiler flue connection and retain with the turret clamp and
securing screw (supplied with the boiler). ENSURING THE
GASKETS IN THE BOILER FLUE OUTLET ARE CORRECTLY
FITTED.
Pitched roof tile
weather collar
Flat roof tile
weather collar
3. "Push" fit extension duct (if required (supplied separately)) into
vertical connector.
3
Extension
Duct
FLUE OUTLET
nm8740
Turret
clamp
2
Vertical
connector
nm8743
esp8850
4
'X'
4. If the last extension duct requires cutting, measure ‘X’, the distance
(outer ducts), between the duct and the terminal and add 100 mm to
this dimension. This gives the length of the last extension duct.
Note. Check the position of the inner flue duct relative to the outer duct
on the assembled extension duct(s) and ensure the terminal flue duct
is cut longer than the air duct to ensure engagement in the final flue
duct seal.
5. Finally ensure the roof flashing plate is correctly sealed to the roof.
28
Esprit - Installation and Servicing
30
PRESSURE RELIEF VALVE (PRV) OUTLET - (SAFETY VALVE DRAIN)
The PRV outlet is located at the rear RHS of the boiler service connection area.
Connection of additional pipewok to the PRV outlet should be made prior to connection of CH, DHW and gas connections
for ease of access.
The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants
of the premises or damage the electrical components and wiring.
31
WATER AND GAS CONNECTIONS
Included in the hardware pack provided with the boiler are all the necessary isolation valves, seals and pipework to connect
the CH, DHW and gas connections (refer to Frame 9). Components are also provided for an integral filling loop. Each
connection is individually bagged with the correct seals and pipework, and should only be opened when required.
1. Pre-assemble the filling loop between the CH return
and DHW inlet isolation valves as shown in the photo.
2. Attach this assembly to the bottom of the boiler using
the sealing washers provided. The copper tail pipes
may now be connected to the valve outlets.
3. Connect the gas service cock using the washer
provided. The copper tail pipe may now be fitted.
4. Connect the DHW outlet connection
5. Connect the CH flow isolation valve using the washer
provided. The copper tail pipe may now be fitted.
WATER CONNECTIONS - CH
GAS CONNECTION
Notes.
IMPORTANT.
The gas service cock is sealed with a nonmetallic blue fibre washer so must not be overheated when
making capillary connections.
For heating loads in excess of 60,000 Btu/h use 28mm x
22mm connectors to connect the boiler flow and return pipes
to 28mm system pipework.
Refer to Frame 2 for details of the position of the gas connection.
N.B. The principle of the 1:1 gas valve ensures that the
Esprit HE range is able to deliver its 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.
Do not subject any of the isolating valves to heat as the seals
may be damaged.
WATER CONNECTIONS - DHW
Note. The DHW inlet isolating valve incorporates a flow
regulator and a CH filling loop connection.
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.
CH Flow
Connection
Gas
Connection
DHW Outlet
Connection
DHW Inlet
Connection
CH Return
Connection
CH Filling
Loop
Inlet Pressure
Test Point
esp8826
Esprit - Installation and Servicing
Filling Loop Valve
(shown in closed postion)
Flow
Regulator
Filling Loop Valve
(shown in closed postion)
29
INSTALLATION
INSTALLATION
32
FILLING
Central Heating
IMPORTANT - when filling:
1. Remove the front panel. Refer to
Frame 45.
A. Ensure dust cap on auto air vent is
opened up one full turn.
2. Ensure that the CH isolating
valves are open.
B. When filling, there may be a slight
water leak from the air vent therefore
electrical connections should be
protected.
3. Fill and vent the system using the
filling loop, fitted between the DHW
inlet valve and the CH return valve.
Refer to Frame 31 and Frame 4 for
setting pressure.
Check for water soundness.
A
Domestic Hot Water
Note. The domestic hot water flow rate is
automatically regulated to a maximum:
HE24 = 9.6
l/m
(2.1 gpm)
HE30 = 12.0
l/m
(2.6 gpm)
HE35 = 14.4
l/m
(3.2 gpm)
1. Fully open all DHW taps and ensure
that water flows freely from them.
2. Close all taps.
33 ELECTRICAL CONNECTIONS
WARNING. This appliance MUST be earthed.
A mains supply of 230 V ~ 50 Hz is required.
The fuse rating should be 3A. All external controls and wiring
must be suitable for mains voltage.
Wiring external to the boiler MUST be in accordance with the
current I.E.E. (BS.7671) Wiring Regulations and any local
regulations.
For IE reference should be made to the current ETCI rules for
electrical installations.
Wiring should be 3 core PVC insulated cable, not less than
0.75 mm2 (24 x 0.2mm) and no greater than 1.25mm2, and
to BS 6500 Table 16.
Connection must be made in a way that allows complete
isolation of the electrical supply such as a double pole
switch having a 3mm (1/8") contact separation in both
poles, or an unswitched plug and socket, serving only the
boiler and system controls. The means of isolation must
be accessible to the user after installation.
34 ELECTRICAL CONNECTIONS - INSTALLER WIRING
The Esprit boiler comes pre-fitted with 1m of mains cable.
This must be connected to a permanent live supply and NOT
switched by thermostats/programmers. For installers
wishing to change this cable refer to Frame 35.
5. Route incoming cables through cable glands provided,
after removing air sealing plugs.
The Esprit boiler comes pre-fitted with a link wire between R1
and R2 on the terminal strip. This creates a permanent call
for heat and must be removed when adding a room
thermostat/programmer.
To add thermostat/programmer:
1. Isolate the mains supply to the boiler.
2. Remove the front panel. Refer to Frame 45.
3. Swing the control box down into the servicing position.
Refer to Frame 46.
6. Connect wires to terminal block, see instructions
opposite.
4. Remove the terminal block cover to access the terminals
for electrical connections.
7. Re-fit terminal block cover, nibbling out the plastic as
required from the cable entry to secure the cables.
8. Tighten cable gland to provide cable anchorage.
9. Swing the control box back up into the operating condition
and re-fit the front panel ensuring a good seal is made.
4
Pre fitted link wire
Pre fitted
mains cable
R3
R2
R1
F2
F1
LEGEND
L
Live
N
Neutral
F1
Frost Thermostat Switched Live
F2
Frost Thermostat Live Feed
R1
Room Thermostat Switched Live
R2
Room Thermostat Live Feed
R3
Room Thermostat Switched Live
N
esp8854
L
INSTALLATION
INSTALLATION
esp9189
(When using optional internal programmer kits)
30
Esprit - Installation and Servicing
34 CONT’D ..........ELECTRICAL CONNECTIONS - INSTALLER WIRING
Ideal Boilers offer 4 kits as follows:
(see individual kits for installation instructions)
PROGRAMMER KIT MECHANICAL 24 HOUR- 24 hour mechanical programmer fits into the control box of the boiler. This can be
fitted in conjunction with a room thermostat.
PROGRAMMER KIT ELECTRONIC 7 DAY - 7 day electronic programmer fits into the control box of the boiler. This can be fitted in
conjunction with a room thermostat.
RF THERMOSTAT/PROGRAMMER KIT MECHANICAL 24 HOUR - Combined 24 hour mechanical programmer and room
thermostat with wireless communication to receiver unit which fits into control box of the boiler.
RF THERMOSTAT/PROGRAMMER KIT ELECTRONIC 7 DAY - Combined 7 day programmer and room thermostat with wireless
communication to receiver unit which fits into control box of the boiler.
ROOM THERMOSTAT (NO PROGRAMMER)
Optional
Frost Stat
DIAGRAM A - NO PROGRAMMER
1. Remove link wire between R1 and R2.
2. Connect room thermostat across terminals R1 and
R2 as shown in diagram A
3. If room thermostat has a neutral connection,
connect this to terminal N (load) in the fused spur.
L
ROOM THERMOSTAT + PROGRAMMER
N
1. Remove link wire between R1 & R2.
F1
2. Connect room thermostat and programmer in
series as shown in diagram B.
F2
3. If room thermostat has a neutral connection,
connect this to terminal N (load) in the fused spur.
R1
N
Room
Stat
R2
R3
If parts of the system are vulnerable to freezing or the
programmer is likely to be left off during cold weather, a
frost thermostat should be fitted.
R3 connection is used with
integral programmer kit
esp9396
FROST THERMOSTAT
1. Position the frost thermostat in a suitable position,
i.e. area vulnerable to freezing.
2. Connect frost thermostat across terminals
F1 and F2 as shown in diagrams A and B.
DIAGRAM B - EXTERNAL PROGRAMMER
Optional
Frost Stat
L
N
F1
F2
R1
N
Room
Stat
R2
R3
esp9397
External
Programmer
Esprit - Installation and Servicing
31
INSTALLATION
INSTALLATION
INSTALLATION
INSTALLATION
35 REPLACING PRE-FITTED MAINS CABLE
If it is necessary to use an alternative mains cable to the one
pre-fitted then use the following guide.
9. Route replacement cable back through the cable gland
and re-tighten to provide cord anchorage.
Replacement wiring should comply with notes in Frame 33.
10. Connect the earth wire to the earth post by trapping the
stripped end between the cupped and flat washer. Secure
with nut provided.
1. Isolate the mains supply to the boiler.
2. Remove the front panel. Refer to Frame 45.
11. Connect the live and neutral wires to the terminal strip.
3. Swing the control box down into the service position.
Refer to Frame 46.
4. Remove the terminal block cover to access the terminals
for electrical connections.
5. Remove the mains cover to access the earth post.
6. Remove the live and neutral wires from the terminal block.
7. Remove the top nut from the earth post and remove the
earth connection ring terminal from the post.
8. Slacken the cable gland and withdraw the mains cable.
When making the mains electrical connections to the
boiler it is important that the wires are prepared in such a
way that the earth conductor is longer than the current
carrying conductors, such that if the cord anchorage
should slip, the current carrying conductors become taut
before the earthing conductor.
12. Re-fit the mains and terminal block covers ensuring
cables are located in the cable entry position.
13. Swing the control box back up into the operating position
and re-fit the front panel ensuring a good seal is made.
Earth Post
esp8931
5
4
32
Esprit - Installation and Servicing
36 PICTORIAL WIRING DIAGRAM
LEGEND
b - blue
bk - black
br - brown
gy
or
pk
r
-
grey
orange
pink
red
v w y y/g -
INSTALLATION
INSTALLATION
violet
white
yellow
yellow/green
Dry fire
thermistor
Water pressure
switch
y/g
Prog. connection
(Optional)
Mains r
Supply
y/g
bk
br
R3
R2
R1
F2
F1
N
L
Supply earth
stud
(Ctrls. assy)
b
w
b
Diverter
Valve
1
2
bk
br
3
summer/
winter
switch
EMI
screen
esp9267
ON/OFF
switch
DHW preheat
switch
Esprit - Installation and Servicing
DHW flow
switch
33
INSTALLATION
INSTALLATION
37 FUNCTIONAL FLOW WIRING DIAGRAM
br
L
Summer/winter
switch
bk
bk
R1
External
Switch
e.g.
room’stat
R2
Prog.
(optional)
r
bk
b
R3
br
b
N
E
Water
pressure
switch
Dry fire
thermistor
DHW Preheat
Switch
b
b
DHW Thermistor
b
b
b
b
b b
gy
v
r
DHW Flow Switch
bk
br
b
Diverter
Val ve
esp8889
LEGEND
b - blue
bk - black
br - brown
gy - grey
or
pk
r
v
-
orange
pink
red
violet
w - white
y - yellow
y/g - yellow/green
38 COMMISSIONING AND TESTING
B. Gas Installation
A. Electrical Installation
1. Checks to ensure electrical safety should be carried out by
a competent 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.
1. The whole of the gas installation, including the meter,
should be inspected and tested for tightness and purged
in accordance with the recommendations of BS. 6891.
In IE refer to IS.813:2002.
2. Purge air from the gas installation by the approved
methods only.
WARNING. Whilst effecting the required gas soundness test and purging air from the gas installation,
open all windows and doors, extinguish naked lights and DO NOT SMOKE.
34
Esprit - Installation and Servicing
39 INITIAL LIGHTING
X
Z
U
W
V
LEGEND
M. Gas Service Cock
B. Winter/Summer Switch
N. CH Flow Isolating Valve
C. Preheat On/Off Switch
P. CH Return Isolating Valve
D. CH Temperature Control
R. DHW Inlet Isolating Valve
T
N
S
M
L
R
E. DHW Temperature Control S. DHW Outlet
F. Burner Light
T. Overheat Thermostat
G. Display
U. Control thermistor (flow)
H. Reset Button
V. Return Thermistor
J. Pressure Gauge
W. Auto Air Vent (Heat exch.)
H
G
F
reset
min
max
min
max
E
K. Programmer Kit (Optional) X. Spark Generator
L. Inlet Pressure Test Point
P
Z. Auto Air Vent (Pump)
J
D
preheat on
winter
off
summer
C
boiler on
off
B
A
K
esp9265
A. Boiler On/Off switch
1. Check that the system has been filled and that the boiler is
not airlocked. Ensure the automatic air vent caps (W & Z) are
open.
Note.
It is important the burner is not operated before the system is
fully vented of air. If it is necessary to operate the appliance
pump to assist venting of the air this must be done with the
gas service cock turned off.
2. Swing the control box to the working position .
3. Refit the boiler front panel. Refer to Frame 45.
THE DISPLAY
The user control has one light and one display to inform the
user about the status. The display will show the status of the
boiler. The light will show the status of the flame. If no flame is
detected the light is blinking. When the flame is detected the
light will be lit permanently.
Below is a list with display function in normal operation.
4. Check that all the drain cocks are closed and that the CH
and DHW isolating valves (N, P and R) are OPEN.
Standby, no demand for heat present.
5. Check that the electrical supply is OFF.
Boiler is active for central heating.
6. Check that the boiler on/off switch (A) is off, the winter/summer
switch (B) is in the winter position and the preheat switch (C)
is on.
Boiler is active for domestic hot water.
7. Check that the gas service cock (M) is OPEN.
Boiler is in lockout for a specific error. Display will be
blinking, alternating with a number or letter to show which
error is detected.
8. Slacken the screw in the inlet pressure test point (L) and
connect a gas pressure gauge via a flexible tube.
9. Switch the electricity supply ON and check all external controls
are calling for heat.
10. CENTRAL HEATING
Set the CH temperature control (D) to maximum and switch
the boiler on/off switch (A) to ON. The boiler control should
now go through its ignition sequence until the burner is
established.
11. If the boiler does not light after 3 attempts the fault code
will be displayed, Press the reset button (H) and the boiler
will repeat its ignition sequence.
When the burner is established the WHITE 'Burner On' light
(F) will be illuminated, the display will show status c.
Esprit - Installation and Servicing
Boiler is heating up the plate heat exchanger.
Boiler is in lockout for a specific error. Display will be
blinking, alternating with a number or letter to show which
error is detected.
Note.
If the boiler displays fault code ‘LE’ on installation, check the
pressure gauge (J). The required minimum system pressure
cold is 1.0 bar. See Frame 32 if system need filling.
continued . . . .
35
INSTALLATION
INSTALLATION
INSTALLATION
INSTALLATION
40 INITIAL LIGHTING - continued
12. DOMESTIC HOT WATER
With the boiler firing, set the DHW temperature control
(E) to maximum and fully open a DHW tap.
The boiler should continue to run and the LED display
should show status .
13. Ensure 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
Esprit 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 regulated by the gas valve
according to the air flow produced by the fan. It is NOT
user-adjustable. Any interference to sealed settings on
the gas valve will adversely affect operation and render
our warranty void.
14. Turn off the DHW tap.
15. Set the boiler on/off switch (A) to OFF.
16. Remove the pressure gauge and tube. Tighten the
sealing screw in the pressure test point. Ensure a gas
tight seal is made.
41 GENERAL CHECKS
Make the following checks for correct operation in:
DOMESTIC HOT WATER (DHW) MODE
1. With no call for CH or DHW the boiler should fire for a
short period to preheat the DHW plate heat exchanger.
The display should read
returning to
when the burner switches off.
Notes.
a. If no DHW is drawn off, the boiler will fire periodically
for a short time, to maintain the plate heat exchanger
temperature.
b.
The DHW preheat operates 24 hours a day with the
preheat switch in the ‘ON’ position. Preheat can be
disabled with the switch in the ‘OFF’ position.
2. Fully open all DHW taps in turn and ensure that water
flows freely from them.
The display should read:
flashing then
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 35oC at the flow rate stated on page 6 under
“operation”.
4. Reduce the DHW draw-off rate to about 3 l/min (0.7gpm)
and check that the boiler modulates to deliver DHW at
approximately 65oC.
5. Close the DHW tap and check that the main burner
extinguishes. The pump should overrun for a few seconds
and the display sequence should read:
When the pump stops the display sequence should
read:
Note. On systems in excess of 2 bar inlet pressure a water
pressure governor may be required to prevent water noise.
when the burner lights.
36
Esprit - Installation and Servicing
INSTALLATION
CENTRAL HEATING (CH) & DOMESTIC HOT WATER (DHW)
MODE.
WATER CIRCULATION SYSTEM
1. With the system COLD, check that the initial pressure is
correct to the system design requirements.
1. Ensure that the CH external controls are calling for heat.
The display should read:
after first satisfying DHW preheat if necessary. (
2. Fully open a DHW tap and check that hot water is
delivered.
The display should read:
3. Gas Rate
Check the boiler gas rate when the boiler is at full DHW
output.
Check at the gas meter, with no other appliance in use.
Refer to Table 3 for gas rates.
4. Close the DHW tap. The burner should go off and the
pump continue to run.
The display should read:
flashing
INSTALLATION
42 GENERAL CHECKS - continued
)
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 exceed 2.5 bar.
3. With the system still hot, turn off the gas, water and
electricity supplies to the boiler and drain down to
complete the flushing process.
Note. A flushing solution should be used during the flushing
procedure. Flushing solutions: Fernox Superfloc,
Sentinel X300 (new systems) or X400 (existing
systems). Refer to Frame 6.
4. Refill and vent the system, add inhibitor (see Frame 6),
clear all air locks and again check for water soundness.
Affix the water treatment warning label, supplied in the
hardware pack, in a prominent position on the system, to
prevent the use of incorrect water treatment additives.
5. Reset the system initial pressure to the design
requirement.
6. Balance the system. Refer to Frame 5.
7. Check the condensate drain for leaks and check that it is
discharging correctly.
then
8. Finally, set the controls to the User's requirements.
flashing
After 15 seconds the burner should relight, to supply
central heating.
The display should read:
Note. The pump will operate briefly as a self-check once
every 24 hours in the absence of any system demand.
CH & DHW CONT.
5. Set the central heating external controls to OFF. The
burner should go off and the pump continue to run for a
few seconds.
The display should read:
returning to
when the pump stops.
6. Check the correct operation of the programmer (if fitted)
and all other system controls. Operate each control
separately and check that the main burner responds.
WATER TEMPERATURES
Temperatures can be selected via the CH and DHW
temperature controls.
Knob Setting
CH Flow
Temp
o
C (oF)
DHW Outlet
Temp
o
C (oF)
Max
82 (180)
65 (150)
Min
30 (86)
42 (110)
Esprit - Installation and Servicing
37
INSTALLATION
INSTALLATION
43 HANDING OVER
After completing the installation and commissioning of the system the installer should hand over to the householder
by the following actions:
1. Hand the User Instructions to the householder and
explain his/her responsibilities under the relevant
national regulations.
6. Explain and demonstrate the function of time and
temperature controls, radiator valves etc., for the economic
use of the system.
2. Explain and demonstrate the lighting and shutting
down procedures.
7. If a programmer is fitted draw attention to the Programmer
Users Instructions and hand them to the householder.
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 the household requirements
of both heating and hot water consumption.
8. Loss of system water pressure
Advise the User of the precautions necessary to prevent
damage to the system and to the building, in the event
of the system remaining inoperative during frosty
conditions.
Explain that the dial behind the controls panel 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 repressurising procedure and if unable to re-pressurise or if
the pressure continues to drop a registered local heating
installer should be consulted.
WARNING.
4. Explain the function and the use of the boiler heating
and domestic hot water controls.
Explain that due to system variations and seasonal
temperature fluctuations DHW flow rates/temperature
rise will vary, requiring adjustment at the draw off tap. It
is therefore necessary to draw the users attention to the
section in the Users Instructions titled “Control of Water
Temperature” and the following statement:
“Additionally, the temperature can be controlled by
the user via the draw-off tap: the lower the rate the
higher the temperature, and vice versa”.
5. Explain the function of the boiler fault mode.
Emphasise that if a fault is indicated, the boiler should
be turned off and a CORGI registered local heating
installer consulted. In IE contact a competent person.
38
Do not fire the boiler if the pressure has reduced to zero
from the original setting.
9. After installation and commissioning please complete
the
Commissioning Checklist before handover
to the customer.
For IE, its is necessary to complete a “Declaration of
Conformity” to indicate compliance to I.S. 813:2002.
10. IMPORTANT
A comprehensive service should be carried out ANNUALLY.
Stress the importance of regular servicing by a CORGI
registered installer. In IE servicing work must be carried out
by a competent person.
11. As the installer you may wish to undertake the service
contract yourself or alternatively offer to the customer the
benefits of the Ideal Care Scheme, details of which are
outlined in the householder pack supplied with this boiler.
Esprit - Installation and Servicing
SERVICING
44 SERVICING SCHEDULE
WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity
supply to the appliance before servicing.
The servicing procedures are covered more fully in Frames
46-51 and MUST be carried out in sequence.
To ensure the continued safe and efficient operation of the
appliance it is recommended that it is checked at regular
intervals and serviced as necessary. The frequency of
servicing will depend upon the installation condition and
usage but should be carried out at least annually.
Note. In order to carry out either servicing or replacement of
components the boiler front panel must be removed. Refer to
Frame 45.
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.
6. Check that the flue terminal is unobstructed and that the
flue system is sealed correctly.
7. Check the DHW filter for blockage. Refer to Frame 75.
Do NOT OPERATE the boiler if the front panel is not fitted.
10. If, for any reason, the condensate trap/siphon has been
removed ensure it is refilled with water before
reassembling.
11. Check the gas consumption.
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.
45 BOILER FRONT PANEL REMOVAL
Flue
sampling
point
1. Loosen the 2 screws securing the front
panel (located under the boiler).
2. Pull the tabs on the retaining clips to
release the bottom of the front panel.
3. Pull the panel forward at the bottom and
lift to disengage the top lugs.
2
1
esp8852(1)
Esprit - Installation and Servicing
39
SERVICING
3. Clean the heat exchanger and the condensate trap/siphon.
5. Check the main injector for blockage or damage.
8. After completing the servicing or exchange of components
always test for gas tightness.
9. When work is complete the boiler front panel MUST be
correctly refitted, ensuring that a good seal is made.
2. Clean the main burner.
4. Check the condition of the combustion chamber
insulation. Any cracked, damaged or displaced pieces
should be replaced. Ionisation probes are a servicable
component and require inspecting annually. Replace if
distorted.
IMPORTANT.
SERVICING
46 THE CONTROL BOX IN THE SERVICING POSITION
1. Pull the panel forward at the top to disengage the
two clips.
2. Carefully swing the control down into its
servicing position.
SERVICING
esp8854
47 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING
4
1. Disconnect the electrical leads from the
fan.
1
2. Undo the gas pipe union connection to the
injector housing.
2
3
3. Undo the screw on the fan mounting
bracket.
4. Lift off fan and venturi assembly.
5. Inspect the injector for blockage or
damage.
Ecl 6073
48 BURNER REMOVAL AND CLEANING
1
1. Remove the 6 screws securing the burner (the 3 screws at the
rear are extended to ease access).
2
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.
4
3. Brush off any deposits that may be on the ceramic with a SOFT
brush.
Ionisation
Probes
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.
40
nm
740
0
Esprit - Installation and Servicing
SERVICING
49 CLEANING THE CONDENSATE TRAP/SIPHON
1. Remove the cleaning plug and allow any residual
condensate / debris to drain.
1
2. If necessary pull off the top tube and flush out any
debris.
3. Replace the tube and cleaning plug.
SERVICING
2
50 CLEANING THE HEAT EXCHANGER
1. Remove ignition and flame detection electrodes.
Refer to Frames 58 & 59.
3
2. Remove the 3 screws retaining the sump cover and
remove.
Ionisation
probes
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.
5. Inspect the ignition and detection electrodes. Ensure
that they are clean and in good condition - replace if
necessary.
Sump cover
nm7401
4. 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. 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.
2
Heat exchanger
51 REASSEMBLY
Reassemble the boiler in the following order:
1. Refit the sump cover.
2. Refit the electrodes. (Check dimensions; Frames 58 & 59).
3. Refit the burner.
6. Swing the control box back into its working position and
secure.
7. Re-fit the boiler front panel.
IMPORTANT.
4. Refit the fan / venturi assembly.
8. Ensure that the boiler front panel is correctly fitted by
engaging the securing clips and that a good seal is made.
5. Reconnect the fan electrical leads.
9. Turn on the gas supply at the gas service cock.
10. Reconnect the electrical supply.
Esprit - Installation and Servicing
41
SERVICING
52 REPLACEMENT OF COMPONENTS
GENERAL
IMPORTANT.
When work is complete, the front panel, if removed, must be
correctly refitted - ensuring that a good seal is made.
When replacing ANY component
1. Isolate the electricity supply.
Notes.
1. In order to assist fault finding, the control panel has an
LED diagnostic display. The key to boiler fault conditions
is shown in Frame 84.
2. Turn off the gas supply.
3. Remove the boiler front panel. Refer to Frame 45.
After replacing ANY component check operation of the boiler,
including gas tightness, gas rate and combustion test.
2. In order to replace some components it is necessary to
drain the boiler. Refer to Frame 72.
THE BOILER MUST NOT BE OPERATED WITHOUT THE FRONT PANEL FITTED
53 DRY FIRE THERMISTOR REPLACEMENT
SERVICING
1. Refer to Frame 52.
2. Drain down the boiler. Refer to Frame 72.
3. Unplug the electrical lead.
4. Unscrew the thermistor.
5. Fit the new thermistor using the sealing washer
provided.
6. Reassemble in the reverse order.
7. Check the operation of the boiler. Refer to Frame 52 .
nm8766
54 FAN REPLACEMENT
1. Refer to Frame 52.
2. Disconnect the electrical leads from the fan.
3. Undo the gas pipe union connection to the injector housing.
Orifice plate
Gasket
4. Remove the screw retaining the fan mounting bracket.
5. Remove the fan and venturi assembly. Refer to Frame 47.
6. Unscrew the 3 screws and remove the venturi
assembly, noting the orientation of the venturi in
relation to the fan body.
6
2
3
4
7. Transfer the venturi assembly to the new fan,
replacing the gasket if evidence of damage or
deterioration is visible.
8. Fit the new fan / venturi assembly.
9. Reassemble the boiler in reverse order, taking care
not to overtighten the screw on the fan mounting
bracket.
esp8861
10. Check the operation of the boiler. Refer to Frame 52.
42
Esprit - Installation and Servicing
SERVICING
55 BURNER INJECTOR REPLACEMENT
1. Refer to Frame 52.
2. Disconnect the electrical leads from the fan.
3. Undo the gas pipe union connection to the injector
housing.
6
4. Remove the screw retaining the fan mounting
bracket.
5. Remove the fan and venturi assembly
Injector
6. Remove the 2 injector housing screws.
7. Withdraw the injector housing.
Fan
8. Fit the new injector housing complete with injector.
9. Reassemble in reverse order, ensuring that the new
gas seal supplied is located correctly in the injector
housing.
10. Check operation of the boiler. Refer to Frame 52.
SERVICING
Gas pipe union
4
Mounting bracket
esp8862
56 BURNER REPLACEMENT
1. Refer to Frame 52.
2. Remove the fan assembly. Refer to Frame 47.
3. Remove the 6 screws securing the burner (the 3
screws at the rear are extended to ease
access).
3
4. Lift off the burner from the combustion chamber.
4
5. Fit the new burner, replacing any damaged or
deteriorating sealing gasket.
6. Reassemble in reverse order.
5
7. Check the operation of the boiler. Refer to Frame
52.
Note.
Take care not to disturb the ionisation
probes at the front and rear of the
combustion chamber.
Ionisation
Probes
esp
886
3
Esprit - Installation and Servicing
43
SERVICING
57 CONTROL THERMISTOR, RETURN THERMISTOR & OVERHEAT ‘STAT REPLACEMENT
(Note. Refer to Frame 39 for locations)
1. Refer to Frame 52.
2. Unclip the thermistor / thermostat from the flow / return
pipe and withdraw it from the controls compartment.
3. Disconnect the electrical leads from the thermistor /
thermostat.
4. Reconnect the electrical leads to the replacement part
and reassemble in reverse order, ensuring that the
spring clip is securely on the pipe.
5. Check the operation of the boiler. Refer to Frame 52.
Overheat Thermostat
Return Thermistor
SERVICING
Control Thermistor
58 IGNITION ELECTRODE REPLACEMENT
1. Refer to Frame 52.
2. Unplug the ignition lead from the
electrode.
3. Remove the earth lead from the ignition
electrode.
4. Remove the remaining screw holding the
ignition electrode to the combustion
chamber.
3
esp
886
5
4
5. Remove the electrode.
6. Fit the new ignition electrode, using the
new gasket supplied. Check dimensions
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 the operation of the boiler. Refer to
Frame 52.
44
Esprit - Installation and Servicing
SERVICING
59 FLAME DETECTION ELECTRODE REPLACEMENT
1. Refer to Frame 52.
2. Unplug the flame detection lead from the electrode.
5. Fit the new flame detection electrode, using the new
gasket supplied. Check dimensions as shown.
6. Reassemble in reverse order, and check that no damage
to the combustion chamber insulation has occurred
during the electrode replacement.
3. Remove the 2 screws holding the flame detection
electrode to the combustion chamber.
4. Remove the electrode.
7. Check the operation of the boiler. Refer to Frame 52.
esp
886
SERVICING
4
3
60 SPARK GENERATOR REPLACEMENT
1. Refer to Frame 52.
2. Disconnect the leads from the spark
generator and bracket.
3. Remove the M5 screw securing the spark
generator bracket to the flue casting.
4. Remove the 2 M4 screws securing the
spark generator to the bracket.
5. Fit the new spark generator and reassemble in reverse order.
6. Check operation of the boiler. Refer to
Frame 52.
3
2
4
2
2
esp8802
Esprit - Installation and Servicing
45
SERVICING
61 GAS CONTROL VALVE REPLACEMENT
1. Refer to Frame 52.
2. Swing the control box down into the servicing position.
Refer to Frame 46.
3. Unplug the electrical lead connection from the gas
control valve and disconnect the earth wire.
5
4. Undo the gas inlet pipe union at the gas service cock.
5. Undo the union nut on the outlet of the gas control valve.
6. Remove the back nut retaining the valve to the bottom
panel and withdraw the valve upwards.
7. Fit the new gas control valve.
8. Check operation of the boiler. Refer to Frame 52.
SERVICING
6
4
3
62 DIVERTER VALVE ACTUATOR REPLACEMENT
1. Refer to Frame 52.
4
3
2. Swing the control box down into the
servicing position. Refer to Frame 46.
3. Remove the electrical connection.
4. Using a suitable tool pull out the retaining
clip and lift the diverter head from the
brass body.
5. Fit new actuator head and reassemble in
reverse order.
6. Check operation of the boiler. Refer to
Frame 52.
46
Esprit - Installation and Servicing
SERVICING
63 COMBUSTION CHAMBER INSULATION REPLACEMENT
Ideal Stelrad Group recommend that, for your own comfort
and safety and to comply with good working practice, the
procedure described below is followed:
8. Remove the split pin and washer from the RHS of the
combustion chamber.
9. 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.
1. Refer to Frame 52.
10. Sweep any dampened particles and place in the plastic
bag.
2. Remove the fan / venturi assembly. Refer to Frame 47.
11. Fit new insulation boards.
3. Remove the burner. Refer to Frame 48.
4. Remove the ignition electrode. Refer to Frame 58.
Note.
The boards are designed to be interlocking and should be
fitted as shown.
5. Remove the flame detection electrode. Refer to Frame
59.
12. Fit the new split pin and washer in the RHS of the
chamber.
6. Remove the front and rear ionisation probes. Ionisation
probes are a servicable component and require
inspecting annually. Replace if distorted.
13. Remove the gloves and face mask and place them in the
plastic bag.
Prior to removal of the board the following protective
equipment should be worn:
14. Wash your hands and any areas of skin which may have
come into contact with any of the particles from the
insulation board.
Note. Seal the plastic bag and dispose of it and its contents
into a commercial tip.
z Face mask supplied with the spare part.
z Gloves supplied with the spare part.
7. Damp down the combustion chamber area containing
the insulation boards.
15. Reassemble in reverse order, remembering to re-fit the
ionisation probes first.
16. Check operation of the boiler. Refer to Frame 52.
Fit insulation in the following order:
1.
Rear.
2.
Left Hand Side.
3.
Front.
4.
Right Hand Side.
8
LH Side
Front
Rear
6
RH Side
Combustion
chamber
5
4
esp8866
Esprit - Installation and Servicing
47
SERVICING
The insulation boards used in the combustion chamber of
this product are made of high temperature glass fibres with
a binder of organic and inorganic materials.
SERVICING
64 CONDENSATE TRAP/SIPHON REPLACEMENT
1. Refer to Frame 52.
2. Swing the control box down into the servicing position.
Refer to Frame 46.
3. Pull off the rubber top pipe.
5. Remove the backnut retaining the siphon to the bottom
panel.
6. Fit the new siphon in reverse order ensuring the siphon
is full of water.
7. Check operation of the boiler. Refer to Frame 52.
4. Undo the siphon plastic union connection.
5
3
SERVICING
4
65 DHW THERMISTOR REPLACEMENT
1. Refer to Frames 52 & 72 for draining the appliance.
2. Swing the control box into the servicing position. Refer
to Frame 46.
3. Drain the DHW circuit. Refer to Frame 72.
5. Disconnect the in line electrical connection and
withdraw the thermistor.
6. Reassemble in reverse order.
7. Check operation of the boiler. Refer to Frame 52.
4. Unscrew the knurled retaining nut.
4
48
5
Esprit - Installation and Servicing
SERVICING
66 PRIMARY PCB REPLACEMENT
1. Refer to Frame 52.
2. Swing the control box down into the servicing position.
Refer to Frame 46.
3. Remove the two screws retaining the control box lid.
4. Unclip the controls box lid and remove.
5. Remove all of the terminal connections to the primary
PCB.
4
6. Unclip the two plastic posts retaining the primary PCB and
remove.
7. Fit the new primary PCB.
8. Reassemble in reverse order.
SERVICING
9. Check the operation of the boiler. Refer to Frame 52.
5
esp8853
6
3
67 MAINS, PREHEAT AND SUMMER SWITCH REPLACEMENT
1. Refer to Frame 52.
2. Swing the control box down into the servicing
position. Refer to Frame 46.
4
3. Remove the two screws retaining the control box lid.
4. Unclip the controls box lid and remove.
5. Push the switch/switches to be replaced out from the
rear.
3
6. Disconnect electrical leads from switches.
7. Fit new switch, ensuring that the electrical leads are
replaced on the correct terminals (refer to Frames 36
and 37) and the key on the switch is correctly aligned
with the slot in the plastic moulding.
8. Reassemble in reverse order.
9. Check operation of boiler. Refer to Frame 52.
esp8849
6
5
Esprit - Installation and Servicing
49
SERVICING
68 USER CONTROL PCB
Note. Anti static precautions must be observed
when handling the user control PCB.
1. Refer to Frame 52.
2. Swing the control box into the servicing
position. Refer to Frame 46.
3. Remove the 2 screws retaining the control box
lid.
4. Remove the Controls box lid by unclipping the
plastic clips.
4
5. Unclip and remove the primary PCB. Refer to
Frame 67.
6. Remove the plate interface shield.
7. Attach the earth strap supplied to wrist and
clip on to main boiler chassis.
6
5
SERVICING
8. Remove the electrical connection from the
back of the user control PCB.
9. Remove the three screws retaining the user
control PCB and replace.
10. Re assemble the boiler in reverse order.
11. Check the operation of the boiler. Refer to
Frame 52.
9
esp8855
3
69 PRESSURE GAUGE REPLACEMENT
1. Refer to Frame 52.
2. Drain the boiler. Refer to Frame 72.
6
3. Swing the control box into the servicing position. Refer to
Frame 46.
4. Unscrew the pressure gauge connection.
5
5. Remove the 2 screws retaining the controls box lid.
6. Remove the controls box lid by unclipping the plastic clips.
7. Unclip the pressure gauge head from the plastic control
box surround.
8. Fit the new pressure gauge.
9. Re-assemble the boiler in reverse order.
10. Check the operation of the boiler. Refer to Frame 52.
7
esp8867
4
50
Esprit - Installation and Servicing
SERVICING
70 SAFETY RELIEF VALVE REPLACEMENT
1. Refer to Frame 52.
3
4
2. Drain the boiler CH circuit. Refer to Frame
72.
3. Unscrew the nut securing the pipe to the
pump outlet.
4. Disconnect the electrical connections.
5. Withdraw the pump clip.
6. Remove screw securing pump through
bottom panel.
7. Pull pump forward to disengage from
manifold and remove.
5
8. Unscrew the discharge pipe union nut.
9. Unscrew the safety valve retaining screw.
10. Pull the safety valve upwards to remove.
11. Fit the new safety valve and tighten the
securing screw.
12. Reassemble in reverse order.
SERVICING
10
13. Refill the boiler. Refer to Frame 32.
8
14. Check operation of the boiler. Refer to
Frame 52.
6
9
71 AUTOMATIC AIR VENT REPLACEMENT
Fan
6
1. Refer to Frame 52.
2. Drain the boiler. Refer to frame 72.
3. Remove the turret from the boiler. Refer to
frame 24.
Air vent
4. Release the silicon tubing from the sample
point.
5. Release the electrical connections from the
spark generator.
6. Remove the M5 x 10 screw retaining the top
flue manifold casting.
Plug
7. Remove the top flue manifold casting.
8. Remove the fan from the boiler. Refer to
Frame 47.
9. Remove the burner from the heat exchanger.
Refer to Frame 48.
10. Unscrew the air vent from its heat exchanger
mount and replace.
11. Re assemble the boiler in reverse order.
Esprit - Installation and Servicing
5
esp8936
12. Refill the boiler. Refer to frame 32. Check for
leaks around the new air vent joint.
13. Check the operation of the boiler. Refer to frame 52.
51
SERVICING
72 DRAINING THE BOILER
1. Refer to frame 52
2. Close all the water isolating (CH and DHW) valves
on the boiler inlet.
3. To drain the central heating circuit:
a.
Attach a length of hose to the drain point and
open the drain valve.
4. To drain the domestic hot water circuit. As there
is no direct drain for the domestic hot water circuit,
depending on the location of the boiler, opening
the lowest hot water tap may drain this circuit.
However it must be noted that some residual
water will be experienced during replacement of
components.
CH Flow
isolation
valve
DHW inlet
isolation
valve
SERVICING
5. After replacing any component on the boiler,
close the drain valve, remove the hose and open
all system isolating valves (re-pressurise as
appropriate with filling loop provided) before
proceeding to check operation of the boiler.
CH Return
isolation
valve
Drain
valve
6. Check operation of the boiler. Refer to Frame 52.
esp9266
Drain
point
73 DIVERTER VALVE INTERNAL PARTS REPLACEMENT
1. Refer to Frame 52.
2. Swing the control box down into the servicing position. Refer
to Frame 46.
3. Drain the boiler. Refer to Frame 72.
4. Remove the diverter valve actuator head. Refer to Frame 62.
9. Remove the two union connections to the CH flow and
the DHW flow at the underside of the boiler.
10. Lift the divertor brass housing and remove.
11. Unscrew the top and bottom connections to access the
internal parts.
12. Fit the new valve mechanisms ensuring the correct fit of
the pin.
5. Remove the water pressure switch. Refer to Frame 77.
6. Remove flow pipe union nut.
13. Reassemble in reverse order.
7. Unscrew the pressure gauge connection.
14. Refill the boiler. Refer to Frame 32.
8. Remove the allen screw retaining the divertor brass
housing.
15. Check operation of the boiler. Refer to
Frame 52.
4
11
12
8
6
10
7
12
5
11
52
Esprit - Installation and Servicing
SERVICING
74 DHW FLOW SWITCH REPLACEMENT
1. Refer to frame 52.
2. Swing the control box down into the servicing
position. Refer to Frame 46.
3. Unplug the electrical connection.
4. Carefully pull the switch upwards to
disengage.
5. Fit the new switch and replace the electrical
plug connection.
6. Re-assemble in reverse order
4
7. Check operation of the boiler. Refer to
Frame 52.
SERVICING
5
3
75 DHW FILTER REPLACEMENT
1. Refer to frame 52.
2. Swing the control box down into the
servicing position. Refer to Frame 46.
3. Drain the boiler. Refer to Frame 72.
4. Remove the DHW flow switch. Refer to
Frame 74.
6
5
5. Unscrew the DHW filter housing from the
main brass body.
6. Remove and fit new filter.
7. Re-assemble in reverse order.
8. Refill the boiler. Refer to Frame 32.
9. Check operation of the boiler. Refer to
Frame 52.
Esprit - Installation and Servicing
53
SERVICING
76 FLOW LIMITER REPLACEMENT
1. Refer to frame 52.
2. Isolate the mains cold water supply to the boiler.
3. Drain the boiler DHW circuit. Refer to Frame 72.
4. Unscrew the three union connections at the DHW
isolating valve and remove the valve.
5. Remove the circlip retaining the flow limiter.
6. Using a suitable tool, pull the flow limiter from the
valve body.
7. Fit the new flow limiter and reassemble in
reverse order.
8. Refill the boiler. Refer to Frame 32.
SERVICING
9. Check operation of the boiler. Refer to Frame 52.
6
4
5
77 WATER PRESSURE SWITCH REPLACEMENT
1. Refer to frame 52.
2. Swing the control box down into the servicing
position. Refer to Frame 46.
3. Drain the boiler CH circuit. Refer to Frame 72.
4. Pull off the two electrical connections from the
switch.
5. Pull off the earth connection.
6. Unscrew the water pressure switch.
7. Re-assemble in reverse order.
8. Refill the boiler. Refer to Frame 32.
9. Check operation of the boiler. Refer to Frame 52.
4
6
5
54
Esprit - Installation and Servicing
SERVICING
78 DHW PLATE HEAT EXCHANGER REPLACEMENT
1. Refer to Frame 52.
2. Swing the control box down into the
servicing position. Refer to Frame 46.
3. Drain the boiler. Refer to Frame 72.
4. Remove divertor valve actuator. Refer to
Frame 62.
6
7
6
5. Remove gas valve. Refer to Frame 61.
6. Remove the 2 allen screws securing the
plate heat exchanger to the brass
housings.
4
7. Manoeuvre the plate heat exchanger out of
the boiler.
8. Fit the new plate heat exchanger, using the
new o-rings supplied.
9. Reassemble in reverse order.
SERVICING
10. Refill the boiler. Refer to Frame 32.
11. Check operation of the boiler. Refer to
Frame 52.
79 PUMP HEAD REPLACEMENT
1. Refer to Frame 52.
2. Drain the boiler CH circuit. Refer to Frame 72.
3. Swing the control box down into the servicing
position. Refer to Frame 46.
4
5
4. Disconnect the electrical lead from the pump.
5. Remove the 4 Allen screws retaining the pump
head.
6. Remove the pump head.
7. Fit the new pump head.
8. Reassemble in reverse order.
9. Refill the boiler. Refer to Frame 32.
10. Check operation of the boiler. Refer to Frame 52.
Esprit - Installation and Servicing
55
SERVICING
80 HEAT ENGINE REPLACEMENT
14. Remove the automatic air vent. Refer to Frame 71.
Refer also to Frame 8 - 'Boiler Exploded View'.
IMPORTANT
15. Undo the M5 x 12 screws securing the bottom flue
manifold casting and remove.
Before starting the removal procedure, protect the gas and
electrical controls with a waterproof sheet or plastic bag.
16. Remove the M5 screw and remove the return pipe
securing bracket by sliding forwards.
1. Refer to Frame 52.
2. Drain the boiler. Refer to Frame 72.
17. Remove the overheat thermostat and the control
thermistor. Refer to Frame 57.
3. Swing the control box down into the servicing position.
Refer to Frame 46.
18. Unscrew the brass union connection to release the flow
pipe.
4. Remove the fan / venturi assembly and place on one
side. Refer to Frame 47.
19. Remove the condensate trap/ siphon. Refer to Frame 64.
20. Loosen the 2 bottom M5 screws securing the inter panel to
the back panel and remove the 2 upper M5 screws.
5. Remove the burner and place on one side. Refer to
Frame 56.
21. Slide the heat exchanger and inter panel assembly
upward to disengage and remove from the casing,
complete with the flow pipe.
6. Remove the ignition and detection electrodes. Refer to
Frames 58 & 59.
22. Remove the 2 M6 countersunk screws, remove the inter
panel and transfer to the new heat exchanger.
7. Remove the spark generator. Refer to Frame 60.
8. Release the flue from the turret. Refer to Frame 24.
23. Remove the M5 screw and remove the flow pipe securing
bracket.
10. Release the silicone tubing from the sampling point.
24. Remove the flow pipe and transfer to the new heat
exchanger.
11. Release the electrical connection to the dry fire
thermistor.
12. Remove the M5 x 10 screw retaining the top flue manifold
casting.
13. Remove the top casting of the flue manifold from the
appliance.
25. Reassemble in reverse order, replacing gaskets or seals
if any sign of damage or deterioration is evident.
Note. The heat exchanger is supplied with new combustion
chamber insulation boards. These should be fitted (refer
to Frame 63 before the burner and fan / venturi
assembly and before the ignition and detection
electrodes are replaced).
26. Refill the boiler. Refer to Frame 32.
27. Check operation of the boiler. Refer to Frame 52.
20
12
10
14
11
18
15
15
16
22
23
56
esp8869
SERVICING
9. Remove the turret from the boiler. Refer to Frame 24.
Esprit - Installation and Servicing
SERVICING
81 EXPANSION VESSEL CHARGING
IF REQUIRED THE EXPANSION VESSEL PRESSURE CAN BE RECHARGED BY
USING THE CONNECTION ACCESSIBLE THROUGH THE BACK PANEL.
The initial charge of the expansion vessel should be 1.0 bar before filling the system.
Esprit - Installation and Servicing
SERVICING
Expansion Vessel
Charging Point
57
SERVICING
82 EXPANSION VESSEL REPLACEMENT - SIDE FLUE APPLICATION
SIDE FLUE APPLICATION AND 450MM ACCESS
AVAILABLE ABOVE THE BOILER
SERVICING
1. Refer to Frame 52.
2. Swing the control panel down into the servicing
position. Refer to Frame 46.
3. Drain the boiler. Refer to Frame 72.
4. Remove the two screws retaining the expansion
vessel bracket at top rear of the boiler.
5. Unscrew the union nut on the vessel water
connection pipe.
6. Unscrew the extension nut holding the expansion
vessel in place
7. Lift and remove the expansion vessel.
8. Fit the new expansion vessel.
9. Re-assemble in reverse order
10. Refill the boiler. Refer to Frame 32.
11. Check operation of the boiler. Refer to Frame 52.
5
6
83 EXPANSION VESSEL REPLACEMENT - REAR FLUE APPLICATION
REAR FLUE APPLICATION OR 450MM
ACCESS ABOVE THE BOILER NOT AVAILABLE
9
10
1. Refer to Frame 52.
2. Swing the control panel down into the servicing
position. Refer to Frame 46.
3. Drain the boiler. Refer to Frame 72.
4. Unscrew all of the gas and water connection
unions on the boiler side of the valves (including
the condensate connection and the pressure
relief valve pipe).
5. Remove the screw from the turret clamp and
remove the clamp.
6. Remove the turret.
7. Lift the complete boiler from the wall mounting
bracket and place on a flat surface.
8. Remove the bracket retaining the expansion
vessel at the top rear of the boiler.
9. Unscrew the union nut on the vessel water
connection pipe.
10. Unscrew the extension nut holding the expansion
vessel in place.
11. Remove the expansion vessel.
12. Fit the new expansion vessel.
13. Reassemble in reverse order
14. Refill the boiler. Refer to Frame 32.
15. Check operation of the boiler. Refer to Frame 52.
58
Esprit - Installation and Servicing
FAULT FINDING
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
84 FAULT FINDING CHART MAIN MENU
In order to assist fault finding the boiler has an LED diagnostic display. The key to the display codes is as follows:
ALTERNATING 'L' 'F'
GO TO FRAME 85
ALTERNATING 'L' 'E'
GO TO FRAME 86 OR 88
ALTERNATING 'L' 'A'
GO TO FRAME 87 OR 88
ALTERNATING 'L' '8'
GO TO FRAME 89
ALTERNATING 'H' '1'
GO TO FRAME 90
ALTERNATING 'H' '2'
GO TO FRAME 91
ALTERNATING 'H' '3'
GO TO FRAME 92
ALTERNATING 'H' '4'
GO TO FRAME 93
ALTERNATING 'H' 'F'
GO TO FRAME 94
ALTERNATING 'H' 'n'
GO TO FRAME 95
ALTERNATING 'H' 'E'
GO TO FRAME 86
ALTERNATING 'H9'
GO TO FRAME 93
ALTERNATING 'L9'
GO TO FRAME 93
Esprit - Installation and Servicing
59
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
FAULT FINDING
85 L.....F.....(FLAME DETECTION ERROR)
NO
If the boiler reset button is
pressed does the boiler ignite for
a short time then extinguish?
NO
Is gas pressure available at
the boiler inlet ?
Check gas supply
and rectify fault
YES
YES
Is 200V DC supply available
at the gas valve ?
(see Note)
Check the detection electrode and
associated harness for:
continuity, visual condition, position
(Refer to Frame 59).
Check gas valve
wiring for
continuity
NO
YES
Replace as necessary.
Check spark generator and associated
harness for continuity and visual condition.
(Refer to Frame 60).
YES
NO
Replace spark
generator
Are these functioning correctly ?
Check the ignition
electrode and associated
harness for:
continuity,
visual condition, position
(Refer to Frame 58).
Are these functioning
correctly ?
Replace PCB
YES
Replace gas valve
NO
Replace ignition electrode and
associated harness as necessary
Check syphon and condensate drain
pipework for blockage
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 alternative to a meter, a mains
voltage checking device may be used. E.g. an electrical screwdriver or mains tester.
86 L.....E.....
or
H.....E.....
Check for excess voltage between neutral
and earth. Is the value below 50V?
(PCB ERROR)
NO
Check earth connection to the boiler. If value is still in
excess of 50V consult a Qualified Electrician to check the
household electrical supply and circuitry
YES
LE ONLY: Check continuity of OH
thermostat. Is this correct?
Correct wiring or replace thermostat
NO
YES
HE ONLY: Check earth wire is connected to
detection lead. Is this correct?
NO
Correct wiring or replace detection lead
YES
Check all earths for continuity
Correct connections
NO
YES
Internal fault within the PCB
Press and hold reset button for 2
seconds. Does boiler operate
correctly?
YES
OK
NO
Turn boiler off and wait for 5
seconds. Turn boiler on.
Does boiler operate correctly?
YES
OK
NO
Replace PCB
60
Esprit - Installation and Servicing
87 L.....A.....
(OVERHEAT ERROR)
NO
Can the overheat condition be reset by pressing
the boiler reset button when the system is cold ?
Replace overheat thermostat
YES
NO
Is the boiler and CH system filled with
water and all isolation valves open ?
Fill and vent the system and open all
isolation valves
YES (also refer to Frame 88)
YES
Does the pump setting give a differential
o
across the boiler in excess of 25 C ?
Check that the pump is rotating freely.
o
Is differential now below 25 C ?
NO
NO
Set CH control knob to maximum.
If the overheat trips again measure the flow temp:
YES
Replace the system pump
OK
o
Over 90 C Check control thermistor
(Refer to Frame 90)
Note. With V9 Primary Control PCB, overheat LA/HA or H9/L9 when
reset will display 3 horizontal lines and will not attempt to refire until
the temperature in the heat exchanger drops below 50oC.
o
Under 90 C Replace overheat 'stat
88 L.....E..... OR L.....A.....
(WATER PRESSURE SWITCH)
Note.
LE occurs when boiler is cold.
LA occurs when boiler is hot.
YES
Can the overheat condition be reset by pressing
the boiler reset button when the system is cold ?
OK
NO
Is the boiler and CH system filled with water
with a minimum pressure of 1.0 bar (cold)
and all isolation valves open?
NO
Fill and vent the system and open all
isolation valves
YES (also refer to Frame 86)
Is 230V available across the water pressure
switch electrical leads
NO
Replace PCB
YES
Replace water pressure switch
Note. With V9 Primary Control PCB, overheat LA/HA or H9/L9 when
reset will display 3 horizontal lines and will not attempt to refire until
the temperature in the heat exchanger drops below 50oC.
89 L....8..... (FAN ERROR)
Is nominal 330 V DC present across
red and blue at the fan connector as
reset button is pressed?
YES
YES
Is 14V DC present across
yellow and pink at the fan
connector?
Replace fan
NO
YES
NO
Check wiring harness for continuity.
Is there continuity?
Esprit - Installation and Servicing
NO
Replace PCB
Replace harness
61
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
FAULT FINDING
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
FAULT FINDING
90 H.....1.....
(CONTROL THERMISTOR [FLOW] ERROR)
Remove the boiler control thermistor from the CH
flow pipe and disconnect thermistor wires.
Check resistance using a suitable multimeter
connected across the thermistor’s terminal pins
o
expect
9,700 - 10,300
Ohms
o
expect
2,400 - 2,600
Ohms
o
expect
1,000 - 1,100
Ohms
At 25 C
At 60 C
At 85 C
Are the thermistor values correct ?
YES
NO
YES
Is there continuity between the PCB and the thermistor ?
NO
Replace the thermistor
Replace PCB
Check and replace wiring as necessary
91 H.....2..... (CONTROL THERMISTOR [RETURN] ERROR)
Remove the boiler return thermistor from the CH return pipe.
Check resistance using a suitable multimeter
connected across the thermistor’s terminal pins
o
expect
9,700 - 10,300
Ohms
o
expect
2,400 - 2,600
Ohms
o
expect
1,000 - 1,100
Ohms
At 25 C
At 60 C
At 85 C
Are the thermistor values correct ?
YES
YES
Is there continuity between the PCB and the thermistor ?
92 H.....3.....
NO
NO
Replace the thermistor
Replace PCB
Check and replace wiring as necessary
(DHW THERMISTOR ERROR)
Remove the boiler DHW thermistor from the plate
heat exchanger and disconnect thermistor wires.
Check resistance using a suitable multimeter
connected across the thermistor’s terminal pins
o
expect
9,700 - 10,300
Ohms
o
expect
2,400 - 2,600
Ohms
o
expect
1,000 - 1,100
Ohms
At 25 C
At 60 C
At 85 C
Are the thermistor values correct ?
YES
Is there continuity between the PCB and the thermistor ?
62
NO
YES
NO
Replace the thermistor
Replace PCB
Check and replace wiring as necessary
Esprit - Installation and Servicing
FAULT FINDING
H9/L9
(HEAT EXCHANGER OVERHEAT)
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
93 H.....4.... (DRY FIRE THERMISTOR ERROR)
Is the system filled and vented and
all isolation valves open ?
Can the fault condition be reset by switching off
the mains supply to the boiler ?
Is the pump operating correctly?
Ensure flow through system.
NO
YES
NO
Fill and vent the
system and open all
isolating valves
Check wiring for continuity from the
PCB to the dry fire thermistor
Check resistance using a suitable multimeter
connected across the dry fire thermistor’s
terminal pins
Check resistance using a suitable multimeter
connected across the thermistor’s terminal pins
o
At 25 C expect
9,700 - 10,300
Ohms
o
2,400 - 2,600
Ohms
o
1,000 - 1,100
Ohms
At 60 C expect
At 85 C expect
o
expect
9,700 - 10,300
Ohms
o
expect
2,400 - 2,600
Ohms
o
expect
1,000 - 1,100
Ohms
At 25 C
At 60 C
At 85 C
Are thermistor values correct ?
YES
NO
Are thermistor values correct ?
YES
Replace PCB
Inspect heat
exchanger for
blockage or damage
in the flueways.
Clean or replace as
necessary
NO
Replace thermistor
Replace thermistor
Note. With V9 Primary Control PCB, overheat LA/HA
or H9/L9 when reset will display 3 horizontal lines and
will not attempt to refire until the temperature in the
heat exchanger drops below 50oC.
94 H......F.....
(FLAME DETECTION ERROR)
Remove flame detection electrode terminal from PCB
Is there continuity between the 2 terminal pins ?
NO
Replace PCB
YES
Replace flame detection electrode
95 H......n.....
(PHASE REVERSAL ERROR)
Check wiring to the boiler for
reversed live and neutral
Esprit - Installation and Servicing
63
SHORT LIST OF PARTS
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 available spare parts.
The full list is held by British Gas Services, Ideal Stelrad Group
distributors and merchants.
When ordering spares please quote:
1. Boiler model
2. Appliance G.C. No.
3. Description.
4. Quantity.
5. Product number.
When replacing any part on this appliance use only spare parts that you can be assured conform 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.
Key No.
1.
2.
8.
9.
11.
11.
13.
13.
14.
16.
20.
21.
22.
23.
24.
25.
26.
27.
28.
30.
31.
32.
35.
36.
38.
39.
40.
41.
43.
45.
45.
45.
46.
47.
48.
49.
50.
51.
59.
69.
86.
87.
90.
64
G.C. Part No.
H58074
H58075
E67489
H07660
E67492
H07770
E85097
H07771
H15912
H58082
H58084
H58086
H07664
H07665
H58088
H58091
H49852
H58092
H58098
H58101
H07731
H07790
H58130
H58131
H46712
E69403
H58165
H58198
H58199
H58201
H58202
H58203
H29018
H58208
H58211
H58220
H58225
H58227
H58254
H58273
E78200
H58310
E67519
Description
Front Casing Panel
Front Casing Door
Burner
Combustion Chamber Insulation
Injector & Housing
Injector & Housing
Fan
Fan
Automatic Air Vent Kit (Heat Exchanger)
Gas Valve
Control Thermistor (Flow / Return)
Overheat Thermostat
Ignition Electrode
Flame sensing electrode
Kit – Trap and Seal
User Control PCB
PCB Primary Controls
Mains Switch
Pre-Heat & Winter/Summer Switch
Turret Gasket
Spark Generator
Ignition Lead
Pressure Relief Valve Kit
Expansion Vessel
Pressure Gauge
DHW Thermistor
Diverter Valve Head
Diverter Valve Cartridge
Pump
Plate Heat Exchanger
Plate Heat Exchanger
Plate Heat Exchanger
Dry Fire Thermistor
Water Pressure Switch
Reed Switch
REED Switch Cartridge & Filter
Air Vent (Pump)
Filling Loop
Detection Lead
Control Box Clip Kit
Burner Earth Pin
Heat Engine Gasket Kit
Fuse - PCB Kit
Product Number
24, 30
35
24, 30
35
24
30
35
174782
174783
170905
173520
170908
173520
172625
173525
172668
174789
174790
174791
173528
173529
174793
174795
174486
174796
174797
174806
173538
173510
174811
174812
173892
170996
174813
174814
174817
174820
174821
174822
174087
174755
174819
174844
174894
174825
174787
174826
171845
174877
170931
Esprit - Installation and Servicing
SHORT LIST OF PARTS
96 SHORT LIST
8
11
1
13
16
14
2
9
21
20
22
25
24
23
26
30
31
27 & 28
32
35
38
36
39
40
50
41
43
45
47
46
51
59
69
48
86
87
49
90
esp9182
Esprit - Installation and Servicing
65
SHORT LIST OF PARTS
97 CONTROLS ASSEMBLY
67
65
66
25
69
26
68
25. User Control PCB
26. PCB Primary Control
64
70
27. Mains Switch
28. Pre-heat and Winter/Summer Switch
27
38. Pressure Gauge
65. Control Box Lid
38
28
Esp8894
66. Mains Cover
67. Controls Cover
68. Potentiometer Knob
69. Control Box Clip
70. Programmer Insert
98 BURNER ASSEMBLY
8. Burner assembly with screws and gasket.
Ecl 1598
66
Esprit - Installation and Servicing
NOTES
Esprit - Installation and Servicing
67
NOTES
68
Esprit - Installation and Servicing
INSTALLER NOTIFICATION GUIDELINES
IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE
In addition a change to Building Regulations (England and Wales) requires the installer to notify
when installing a heating appliance, as from 1st April 2005.
Install and commission
this appliance to
manufacturers' instructions
Complete the
Benchmark Checklist
Competent Person's
SELF CERTIFICATION SCHEME
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 days
You must ensure that the
notification number
issued by CORGI is written
onto the Benchmark Checklist
Choose
Buildings Regulations
notification route
BUILDING CONTROL
Contact your relevant
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
IT IS A CONDITION OF THE
MANUFACTURERS WARRANTY
CORGI will record the data and
will send a certificate of
compliance to the property
THAT THE BENCHMARK
COMMISSIONING CHECKLIST IS
FULLY COMPLETED AND LEFT
WITH THE APPLIANCE
Technical Training
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
Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull,
HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858.
Registration No. London 322 137.
Ideal Stelrad Group pursues a policy of continuing
improvement in the design and performance of its products. The
right is therefore reserved to vary specification without notice.
Ideal Installer/Technical Helpline: 01482 498 673
www.idealboilers.com