Mexico Installation Guide
INSTALLATION
AND SERVICING
MEXICO
he15 he18 he24 he30 he36
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.
For the very latest copy of literature for specification and maintenance practices visit our
website www.idealboilers.com where you can download the relevant information in PDF format.
June 2015
UIN 201787 A12
ERP DATA
MODEL
Symbol
n/a
Units
n/a
15
yes
18
yes
24
yes
30
yes
36
yes
Low Temperature Boiler
n/a
n/a
no
no
no
no
no
B1 Boiler
n/a
n/a
no
no
no
no
no
Cogeneration Space Heater
n/a
n/a
no
no
no
no
no
Equipped with a Supplementary Heater
n/a
n/a
no
no
no
no
no
Combination Heater
n/a
n/a
no
no
no
no
no
P4
P1
kW
kW
15
4.9
18
5.9
24
7.8
30
9.7
36
11.7
elmax
elmin
PSB
kW
kW
kW
0.038
0.024
0.01
0.038
0.024
0.01
0.038
0.024
0.01
0.042
0.028
0.01
0.042
0.028
0.01
ƞ4
ƞ1
Pstby
Pign
%
%
kW
kW
88.5
99
0.055
0
88.2
98.5
0.055
0
87.9
97.1
0.055
0
88.4
97.2
0.055
0
89
97.3
0.055
0
NOx
QHE
LWA
mg/kWh
GJ
dB
16
46.0
40
13
56.0
41
19
75.0
42
20
94.0
45
25
113.0
45
Condensing Boiler
Nominal Heat Output for Space Heating
Full Load
Part Load
Auxiliary Electricity Consumption
Full Load
Part Load
Standby
Seasonal Space Heating Energy Efficiency
Full Load
Part Load
Standby Loss
Ignition
Emissions
Annual Energy Consumption
Sound Power Level, Indoors
2
mexico HE - Installation & Servicing

product fiche
mexico he heat boiler
Ideal Boilers
ErP Data Symbol
Condensing boiler
Seasonal Space heating efficiency class
Rated heat output
Seasonal space heating energy efficiency
Units
ƞson
Annual energy consumption
Sound power level, indoors
QHE
LWA
15
18
model
24
30
36
30
92*
36
92*
94.0
45
113.0
45
kW
%
15
93*
18
93*
Yes
A
24
92*
GJ
dB
46.0
40
56.0
41
75.0
42
Seasonal Space Heating Energy Efficiency of the Boiler
*%
A
Temperature control (from fiche of temperature control)
%
Class I
Class II
Class III
Class IV
Class V
Class VI
Class VII
Class VIII
1%
2%
1.5%
2%
3%
4%
3.5%
5%
B
Solar Contribution (from fiche of solar device)
Tank Volume
(in m3)
Collector Size
(in m2)
= (‘III ’x
+ ‘IV ’ x
Collector
Efficiency
(in %)
) x 0.9 x (
Tank rating
A* = 0.95
A = 0.91
B = 0.86
C = 0.83
D-G = 0.81
/ 100 x
%
=
%
TOTAL: A+B+C=
Seasonal Space Heating Energy Efficiency of Package
C
Seasonal Space Heating Energy Efficiency Class of Package
G

< 30%
F
E
≥ 30%
≥ 34%
D
≥ 36%
C
≥ 75%
B
≥ 82%
A
≥ 90%
A+
A++
A+++
≥ 98%
≥ 125%
≥ 150%
The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficiency once installed in a
building, as the efficiency is influenced by further factors such as heat loss in the products in relation to the building size and its characteristics
mexico HE - Installation & Servicing
3
4
mexico HE - Installation & Servicing
Notes for the installer
For any technical queries pleAse ring the ideal
installer/technical helpline : 01482 498663
DOCUMENT amendments
Relevant Installation changes implemented in this book from Mod Level.......A11 (May 14) to A12 (June 15)
Page 2 - ERP Table
New table inserted
Page 3 - Product Fiche
New page inserted
Ideal Boilers reserve the right to vary specification without notice
mexico HE - Installation & Servicing
5
GENERAL
Table 1 - General Data
Boiler Size
HE15HE18HE24 HE30HE36
Gas Supply Connection
Rc 1/2
in. BSP
Flow and Return Connections
maximum Static Water Head
m (ft.)
MINIMUM Static Water Head
m (ft.)
Rc 1/2
22mm copper 22mm copper
30.5 (100)
30.5 (100)
Rc 1/2
Rc 1/2
Rc 1/2
22mm copper
22mm copper
22mm copper
30.5 (100)
30.5 (100)
30.5 (100)
0.45 (1.5)
0.45 (1.5)
0.45 (1.5)
0.45 (1.5)
0.45 (1.5)
Electrical Supply
230V - 50Hz
230V - 50Hz
230V - 50Hz
230V - 50Hz
230V - 50Hz
Power Consumption
38W
38W
38W
42W
42W
Fuse RatingExternal : 3A internal T3.15A L250V
Water Content
2.0 (0.44)
2.0 (0.44)
2.0 (0.44)
4.7 (1.0)
4.7 (1.0)
Packaged Weight
litre (gal.)
kg. (lb.)
55.4 (122.4)
55.4 (122.4)
55.4 (122.4)
69 (152)
69 (152)
Maximum Inst Weight
kg. (lb.)
52 (114.6)
52 (114.6)
52 (114.6)
68 (150)
68 (150)
Boiler Size
Height
mm (in.)
850 (33.5)
850 (33.5)
850 (33.5)
850 (33.5)
850 (33.5)
Width
mm (in.)
450 (17.7)
450 (17.7)
450 (17.7)
450 (17.7)
450 (17.7)
Depth
mm (in.)
530 (20.9)
530 (20.9)
530 (20.9)
530 (20.9)
530 (20.9)
Gas Type
I2H-G20
I2H-G20
I2H-G20
I2H-G20
I2H-G20
Gas Supply Pressure
20mb
20mb
20mb
20mb
20mb
100 (4)
100 (4)
100 (4)
100 (4)
100 (4)
6
6
6
3
3
Flue duct diameter
mm (in.)
Flue horizontal duct length (max)
m
Table 2 - Performance Data
Boiler Size
HE15HE18HE24HE30HE36HE15-24
HE30-36
max maxmaxmaxmax min min
Input ‘Q’ Nett CV
Gross CV
kW (Btu/h)
kW (Btu/h)
Gas Consumption l/s (cu.ft/h)
15.1 (51,500) 18.7 (63,800) 24.4 (83,300) 30.7 (104,700) 37.5 (128,000)
9.1 (31,000)
10.6 (36,200)
16.8 (57,200) 20.7 (70,800) 27.1 (92,500) 34.0 (116,000) 41.6 (142,000) 10.1 (34,400)
11.8 (40,300)
0.43 (54.7)
Output ‘P’ 70 c Mean Water temp. kW (Btu/h) 14.6 (50,000)
40oc Mean Water temp. kW (Btu/h) 15.5 (53,000)
o
Seasonal efficiency (SEDBUK) *
Band A
[90.4]%
0.53 (68.0)
0.70 (89.7)
0.26 (33.3)
0.30 (38.4)
18.2 (62,300) 23.4 (80,000) 30.1 (102,700) 37.0 (126,200)
8.8 (30,000)
10.6 (36,200)
19.2 (65,700) 25.1 (85,700) 32.8 (111,800) 39.8 (135,800)
9.6 (32,800)
11.4 (38,900)
-
-
[90.3]%
[90.2]%
NOx classification
*
0.88 (111.9)
[90.4]%
1.07 (136.0)
[90.7]%
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.
Key to symbols
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:-
GB = United KingdomIE = Ireland (Countries of destination)
PMS=Maximum operating pressure of water
C13 c33
=
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.
a. For l/s- divide the gross heat input (kW) by the gross
C.V. of the gas (MJ/m3)
b. For ft3/h - divide the gross heat input (Btu/h) by the
gross C.V. of the gas (Btu/ft3)
c. For m /h - multiply l/s by 3.6
3
=
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.
6
mexico HE - Installation & Servicing
mexico HE
General
Contents
Natural Gas only
Boiler size
HE15
HE18
HE24
HE30
HE36
G.C. Appliance No.
(Benchmark No.)
41-429-39
41-429-65
41-429-98
41-429-99
41-415-20
PI No.
0063 BQ 3906
0063 BQ 3906
0063 BQ 3906
0063 BQ 3906
0063 BQ 3906
Destination Countries: GB, IE
Air Supply ......................................................................11
Benchmark Commissioning Checklist ...................... 54
Boiler Clearances .......................................................... 8
Boiler Exploded Diagram ............................................ 16
Electrical Connections ................................................ 29
Electrical Supply ..........................................................11
Electrical Systems Diagrams ..................................... 31
Extension Ducts - Fitting ............................................ 24
Fault Finding ........................................................... 47-50
Flow Wiring Diagram ................................................... 30
Flue Fitting .............................................................. 21-28
Flue Installation Requirements .................................. 10
Gas Safety Regulations ................................................ 9
Gas Supply ................................................................... 10
Initial Lighting .............................................................. 32
Installation ............................................................... 16-33
Mandatory Requirements ............................................. 9
Safe Handling ................................................................. 9
Servicing ................................................................. 34-46
Short List of Parts ....................................................... 51
Terminal Guards .......................................................... 10
Thermostatic Radiator valves .................................... 11
Water and Systems ............................................... 12-15
Water Connections ................................................... 8,19
Water Treatment ......................................................... 15
Wiring Diagrams ..................................................... 29-31
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.
Before installing this boiler, read the Code of Practice sheet at the rear of this book.
Benchmark Commissioning Checklist Details
Boiler
Page
Make and model.......................................................... 7
Appliance serial no. on data badge .......................... 16
SEDBUK No. %........................................................... 6
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.................................................. 15
Inhibitor..................................................................... 15
Central heating mode
Heat input....................................................to be calculated
Page
Burner operating pressure............measure and record
Central heating flow temp.............measure and record
Central heating return temp..........measure and record
For combination boilers only
Scale reducer........................................................... n/a
Hot water mode
Heat input................................................................. n/a
Max. operating burner pressure............................... n/a
Max. operating water pressure................................. n/a
Cold water inlet temp............................................... n/a
Hot water outlet temp............................................... n/a
Water flow rate at max. setting................................. n/a
For condensing boilers only
Condensate drain...................................................... 19
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
mexico HE - Installation & Servicing
7
GENERAL
1BOILER SERVICE CONNECTIONS
450 (173/4)
530 (21)
225 (87/8)
1. This appliance is NOT suitable for use
in a direct hot water system.
2. If the boiler is to be used on a sealed
system an Overheat Thermostat is
fitted as standard.
850
(331/2)
232 (91/8)
288 (115/16)
348 (1311/16)
2
Flow
Return
Gas
Flow
Return
Gas
Flammable materials must not be placed in close proximity to the appliance.
Materials giving off flammable vapours must not be stored in the same room as
the appliance.
Floor mounting
1. The floor must be flat, level and of suitable load
bearing capacity.
2. The back of the boiler may be fitted up to the wall.
Boiler
In addition a MINIMUM clearance of 450 mm (17 /4”)
must be available at the front of the boiler, for
servicing.
FlueOverall Space Dim.
Model Length Depth Height Width
HE15
6m
HE18
6m 530 870460
HE24
6m
530 870460
HE30
3m
530 870460
HE36
3m
530 870460
The minimum overall dimensions of the space in
which the boiler is to operate and to facilitate servicing
are as shown
3
mxhe7564
530 870460
Top clearance
Boiler clearances
Additional space may be required for installation,
depending upon site conditions.
449 (171/16)
467 (183/8)
All dimensions
in mm (in.)
floor mounting and BOILER CLEARANCES
690
(271/4)
20
(3/4)
5
(1/4)
5
(1/4)
mxhe7565
Minimum front clearance when built behind a
concealing panel is 5mm (1/4”).
All dimensions in mm (in.)
INTRODUCTION
The mexico HE range of boilers are fully automatically controlled,
floor standing, low water content, balanced flue, fanned,
condensing gas boilers. They have full modulating central heating
outputs of :
HE15 8.8 kW (30,000 Btu/h) to 14.6 kW (50,000 Btu/h).
HE18 8.8 kW (30,000 Btu/h) to 18.2 kW (62,300 Btu/h).
HE24 8.8 kW (30,000 Btu/h) to 23.4 kW (80,000 Btu/h).
HE30 10.6 kW (36,200 Btu/h) to 30.1 kW (102,700 Btu/h).
HE36 10.6 kW (36,200 Btu/h) to 37.0 kW (126,200 Btu/h).
Due to the very high efficiency of the boiler a plume of water
vapour will form at the flue terminal during operation depending on
external conditions.
8
The boiler casing is of white painted mild steel with the user
controls capable of being mounted remotely from the boiler, if the
option is required.
The heat exchanger is of cast aluminium.
Artificially softened water must NOT be used.
A pre-piping frame is provided to allow system and gas
connection to be made prior to boiler installation.
Note.
These boilers cannot be used on systems which include gravity
circulation.
The boilers are suitable for connection to fully pumped, open
vented or sealed water systems. Adequate arrangements for
completely draining the system by provision of drain cocks MUST
be provided in the installation pipework.
mexico HE - Installation & Servicing
General
Safety
Operation
When there is a demand for heat, the heating system is supplied
at the selected temperature of between 30oC and 82oC.
Current Gas Safety (Installation and Use) Regulations or
rules in force.
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.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
Safe Handling
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.
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.
• Always use assistance if required.
• Gas Safety (Installation and Use) Regulations
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (northern Ireland).
• The Water Fittings Regulations or Water bye-laws in Scotland.
• The Current I.E.E. Wiring Regulations.
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 Registered Gas
Installer 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.
BSEN. 12828:2003 Heating Systems in buildings: Design for
water based heating systems.
Optional extra kits
FLUING:
Flue Extension Ducts.
HE15, 18 & 24 -up to 6m
HE30, & 36 - up to 3m
In GB, the installation must be carried out by a Gas Safe
Registered Engineer. It must be carried out in accordance with
the relevant requirements of the:
(1000mm long)
 90o Elbow Kit (60/100 dia maximum no. per installation)
HE15, 18 & 24 -up to 4 elbows
HE30, & 36 - up to 2 elbows
BSEN 12831:2003 Heating Systems in buildings: Method for
calculation of the design heat load.
BSEN 14336:2004
BS. 5546
Heating Systems in buildings: Installation
and commissioning of water based heating
systems.
Installation of gas hot water supplies for domestic
purposes (2nd Family Gases).
 45o Elbow Kit (60/100 dia maximum no. per installation)
HE15, 18 & 24 -up to 4 elbows
HE30, & 36 - up to 2 elbows
BS. 6798Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
 Concentric Flue Screw Retaining Kit
Health & Safety Document No. 635
 Roof Flue Kit (60/100)
HE15, 18 & 24 -up to a maximum of 8m
HE30, & 36 -up to a maximum of 5m
 Pitched Roof Tile (for roof flue kit)
 Flat Roof Tile (for roof flue kit)
 Vertical Flue Adaptor
 Vertical Outlet Flue Kit with Elbow (60/100)
HE15, 18 & 24 - to a maximum length of 6m
HE30, & 36 - to a maximum length of 3m
Flue Finishing Kit
High Level Flue Outlet Kit
Flue Deflector Kit
OTHER OPTIONAL KITS:
Remote User Control Kit
Condensate Pump Kit
Concealment Panel Kit
RS Boiler Terminal Wall Plate Kit
 Adjustable Flue Support Bracket
mexico HE - Installation & Servicing
BS. 6891
Low pressure installation pipes.
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 Boilers in writing. If in doubt please
enquire.
Any direct connection of a control device not approved by Ideal
Boilers may 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.
9
GENERAL
Location of boiler
The boiler must be installed on a flat and level floor, capable of
adequately supporting the weight of the boiler and any ancillary
equipment.
The boiler may be fitted on a combustible floor. Insulation is not
necessary, unless required by the local authority.
For electrical safety reasons there must be no access from the
back of the boiler.
The boiler must not be fitted outside.
Timber Framed Buildings
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/7:2006.
Bathroom Installations
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 Gas Safe Registered Engineer. In IE by a Registered Gas
Installer (RGII).
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.
This appliance is rated IP20.
It is the responsibility of the Gas Installer to size the gas installation
pipework in accordance with BS6891:2005. Whilst the principle
of the 1:1 gas valve ensures the Mexico HE range is able to
deliver it’s full output at inlet pressures as low as 14mb, other gas
appliances in the property may not be as tolerant. When operating
pressures are found to be below the minimum meter outlet of 19mb
these should be checked to ensure this is adequate for correct and
safe operation.
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 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.
The external gas cock could further reduce the operating pressure
when measured at its test point. The pressure drop is relative to
the heat input to the boiler (kW), refer to graph below.
Allowing for the acceptable pressure loss of 1mb across the
installation pipework, it can be assumed that a minimum permitted
operating pressure of 18mb will be delivered to the inlet of
the appliance. (Reference BS 6400-1 Clause 6.2 Pressure
Absorption).
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
must be installed beyond Zone 2, as detailed in BS.7671.
Ceiling
Recessed
window
Zone 2
2.25m
Zone 1
0.6m
Zone 0
3G8913a
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:
BS. 6798. (No cupboard ventilation is required - see “Air
Supply” for details).
The position selected for installation MUST allow adequate
space for servicing in front of the boiler.
For the minimum clearances required for safety and
subsequent service see Frame 2.
This position MUST also permit the provision of a satisfactory
flue termination.
Boiler may be fitted under a worktop/surface. Boiler can
be fitted behind a kitchen cupboard door without need for
ventilation.
GAS SUPPLY
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.
10
Important.
Installation pipes MUST be fitted in accordance with BS. 6891.
In IE refer to I.S.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.
The complete installation MUST be tested for gas tightness and
purged as described in the above code.
Flue installation
Pluming will occur at the terminal so terminal positions which would
cause a nuisance should be avoided.
The flue must be installed in accordance with the recommendations
of BS.5440-1:2008. 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 3.
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. Ensure that the guard
is fitted centrally.
Terminal guards are available from boiler suppliers. Ask for TFC
Flue Guard Model No. K6 (round plastic-coated). In case of
difficulty contact:
mexico HE - Installation & Servicing
General
TFC Group Ltd.
Tower House, Vale Rise
Tonbridge. kent TN9 1TB
Tel. + 44 (0) 01732 351 680
Fax. +44(0) 01732 354 445
www.tfc-group.co.uk
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.5440-1:2008. In IE refer
to I.S.813:2002.
IMPORTANT. It is essential to ensure, in practice, that products
of combustion discharging from the terminal cannot re-enter the
building or buildings through any openings into the building such
as ventilators, windows, doors, or other sources of natural air
infiltration, such as forced ventilation openings etc.
If products of combustion re-entry is identified or suspected this should
be immediately investigated and corrected following the guidance
provided in the current Gas Industry Unsafe Situation Procedure.
Table 3 - Balanced Flue Terminal Position
Flue Terminal Positions
Min. Spacing*
1. Directly below or alongside an opening
window, air vent or other ventilation opening.
300mm (12”)
2. Below guttering, drain pipes or soil pipes.
BS5440-1 2008
25mm ( 1”)*
75mm (3”)
3. Below eaves.
BS5440-1 2008
25mm (1”)*
200mm (8”)
4. Below balconies or a car port roof.
BS5440-1 2008
25mm (1”)*
200mm (8”)
5. From vertical drain pipes or soil pipes.
BS5440-1 2008
25mm (1”)*
150mm (6”)
6. From an internal or external corner or to a boundary along side the terminal. BS5440-1 2008
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”)
12. Horizontally from a terminal on the wall.
300mm (12”)
Vertical Terminals
13. Above the roof pitch with roof slope of all angles.
Above flat roof.
300mm (12”)
300mm (12”)
14. From a single wall face. 600mm (24”)
From corner walls. 1000mm (40”)
15. Below Velux Window 2000mm (79”)
16. Above or side of velux window
600mm (24”)
* Only one reduction down to 25mm is allowable per installation
otherwise BS5440-1 2008 dimensions must be followed.
Terminal
The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frame 19.
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. In IE the
requirements of I.S.813:2002 may be disregarded.
mexico HE - Installation & Servicing
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.
For boiler outputs greater than 60,000 btu/h (17.6 kW) the flow
and return pipework should be connected in 28mm pipe.
For the types of system and correct piping procedure see Frames
1, and 3 to 8.
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 9
The hot water storage cylinder MUST be of the indirect type and
should preferably be manufactured of copper.
Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat loss
and any possible freezing - particularly where pipes run through
roof spaces and ventilated underfloor spaces.
The boiler must be vented.
The hydraulic resistance of the boilers, at MAXIMUM OUTPUT, is
shown in Graph 1.
Graph 1 - Water flow rate and pressure loss
Resistance (metres water)
2.50
HE15, 18 & 24
HE30 & 36
2.00
1.50
1.00
0.50
0.00
10
15
20
25
Flow Rate (l/min)
30
35
Boiler Control Interlocks
Ideal Boilers 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 systems 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 must be fitted with an automatic bypass valve to ensure a
flow of water should all valves be in the closed position.
11
GENERAL
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 Ireland 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 325V DC.
3
Condensate drain - Refer to Frames 13, 15 and 18
A condensate drain is provided on the boiler. This drain must be
connected to a drainage point. All pipework and fittings in the
condensate drainage system MUST be made of plastic - no other
materials may be used.
Important.
Installation must be in accordance with BS 6798.
The drain outlet on the boiler is sized for standard 21.5mm (3/4”)
overflow pipe. It is a universal fitting to allow use of different
brands of pipework.
OPEN VENT SYSTEM REQUIREMENTS
The system should be vented directly off the boiler flow pipe, as close to
the boiler as possible. The cold feed entry should be inverted and MUST be
positioned between the pump and the vent, and not more than 150mm (6”)
away from the vent connection.
Note. Combined feed and vent pipes may also be fitted.
There should be a minimum height 450mm (18”) of open vent above the
cistern water level. If this is not possible refer to Frame 5. The vertical distance
between the highest point of the system and the feed/expansion cistern water
level MUST not be less than 450 mm (18”). The pump must be fitted on the
flow side of the boiler.
A suitable pump is a domestic circulator capable of providing a maximum 11oC
(20oF) temperature differential across the boiler with the whole of the heating
circuit open (e.g. Grundfos UPS 15/50, 15/60 or equivalent). With the minimum
flow circuit allowed by the controls the differential must not exceed 25 oC. (18oC
for the HE15)
Return & flow
connections
load 30 - 60 = 22 mm
load 70 - 80 = 28 mm
cla7647
The vertical distance between the pump and feed/expansion cistern MUST
comply with the pump manufacturer’s minimum requirements, to avoid
cavitation. Should these conditions not apply either lower the pump position or
raise the cistern above the minimum requirement specified by Ideal Boilers.
The isolation valves should be fitted as close to the pump as possible.
4schematic pipework and system balancing
The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load at least 10% of the
minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available (see
footnote re. thermostatic radiator valves).
Balancing
1. Set the programmer to ON for both CH and HW. Turn the cylinder
thermostat down. 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 20 oC apart. These valves should now
be left as set.
2. Open all manual or thermostatic radiator valves and adjust the
lockshield valves on remaining radiators to give around 11oC
temperature drop at each radiator.
3. Turn up the cylinder thermostat and adjust the cylinder balancing
valve so that the cylinder achieves a maximum flow consistent with
adequate flow to the radiators. Check that with only the domestic hot
water loop in circuit a differential temperature of 20 oC across the
boiler is not exceeded.
4. Adjust room and cylinder thermostats and programmer to NORMAL
settings.
12
cla7648
mexico HE - Installation & Servicing
General
5
LOW HEAD and large systems with extensive pipe runs - open vent
This arrangement is useful for large systems where
radiators at the extremities are difficult to vent. This can
lead to pumping over with conventional feed and vent
arrangements.
cla7649
The following conditions MUST be observed:
1. The top of the automatic air vent must be below the
cold water level.
2. The static water level (cold) must be at least 200mm
above the top of the horizontal flow pipe, fitted as
shown. The vent connection MUST NOT be made
immediately off the top of the boiler as venting is
made less efficient.
3. The maximum practical length of 22mm cold feed
pipe should be used in order to reduce the effective
volume of hot system water expanding into the feed/
expansion cistern to a minimum.
Flow
Return
All dimensions in mm (in.).
nb. Imperial dimensions are approximate
Note. The pump manufacturers’ minimum requirements must be complied with.
6
sealed system requirements
Notes.
a. The method of filling, refilling, topping up or flushing
sealed primary hot water circuit from the mains
via a temporary hose connection is only allowed
if acceptable to the local water
authority.
Non-return
valve
Automatic
air vent
b. When installing the filling device,
it must be connected as shown
to fully comply with the water
regulations. This may involve
the fitting of an additional WRAS
approval isolator valve to the mains
supply.
Hosepipe
(disconnect
after filling)
cla7650
Hose unions
Additional
stop valve
Temporary hose
(disconnect
after filling)
1.General
Hose
Double check valve
connector
assembly
(note direction of flow)
a. The installation must comply with the
requirements of BS. 6798 and BS. 5449.
b. The installation should be designed to work with
flow temperatures of up to 82 oC.
a. A non-adjustable preset lift pressure not exceeding 3bar
(45lb/in2).
c.
b. A manual testing device.
c. Provision for connection of a discharge pipe.
The valve or discharge pipe should be positioned so
that the discharge of water or steam cannot create
a hazard to the occupants of the premises or cause
damage to electrical components and wiring.
All components of the system, including the heat
exchanger of the indirect cylinder, must be suitable
for a working pressure of 3 bar (45lb/in2) and
temperature of 110oC. Care should be taken in
making all connections so that the risk of leakage
is minimised.
2. Safety Valve
A spring loaded safety valve complying with the
relevant requirements of BS. 6759 must be fitted in the
flow pipe as close to the boiler as possible and with no
intervening valve or restriction. The valve should have
the following features:
mexico HE - Installation & Servicing
3. Pressure Gauge
A pressure gauge covering at least the range 0-4 bar
(0-60 lb/in2) must be fitted to the system. The gauge
should be easily seen from the filling point and should
preferably be connected at the same point as the
expansion vessel.
13
GENERAL
7
sealed system requirements - continued
4. Expansion Vessel
a. A diaphragm type expansion vessel must be
connected to a point close to the inlet side of the
pump, the connecting pipe being not less than 15 mm
(1/2” nominal) size and not incorporating valves of any
sort.
b. The vessel capacity must be adequate to accept the
expansion of the system water when heated to 110oC
(230oF).
include a non-return valve and a stop valve with an
automatic air vent connected between them, the stop
valve being located between the system and the
automatic air vent. The stop valve may remain open
during normal operation of the system if automatic
water make-up is required.
b. Through a self-contained unit comprising a cistern,
pressure booster pump (if required) and, if necessary,
an automatic pressure reducing valve and flow
restrictor. The cistern should be supplied through a
temporary connection from a service pipe or cold water
distributing pipe.
This unit may remain permanently connected to the
heating system to provide limited automatic water
make-up. Where the temporary connection is supplied
from a service pipe or distributing pipe which also
supplies other draw-off points at a lower level then a
double check valve shall be installed upstream of the
draw-off point.
c. Through a temporary hose connection from a draw-off
tap supplied from a service pipe under mains pressure.
Where the mains pressure is excessive a pressure
reducing valve shall be used to facilitate filling.
c. The charge pressure must not be less than the static
water head above the vessel. The pressure attained in
the system when heated to 110o C (230o F) should be
at least 0.35 bar (5 Ib/in2) less than the lift pressure of
the safety valve.
For guidance on vessel sizing refer to the table in
Frame 8.
For further details refer to BS. 5449, BS. 7074:1 and
the British Gas Corporation publication ‘Material
and Installation Specifications for Domestic Central
Heating and Hot Water’. For IE refer to the current
edition of I.S.813.
5. Cylinder
The cylinder must be either of the indirect coil type or a
direct cylinder fitted with an immersion calorifier which is
suitable for operating on a gauge pressure of 0.35 bar
(5 Ib/in2) in excess of the safety valve setting. Single feed
indirect cylinders are not suitable for sealed systems.
The following fittings shall form a permanent part of the
system and shall be fitted in the order stated:
A stop valve complying with the requirements of
BS. 1010, Part 2 (the hose from the draw-off tap shall
be connected to this fitting).
A test cock.
A double check valve of an approved type.
6. 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 150 mm (6”) above the highest point of the
system, and be connected through a non-return valve
to the system, fitted at least 300 mm (12”) below the
make-up vessel on the return side of the domestic hot
water cylinder or radiators.
or
b.
Where access to a make-up vessel would be difficult
by pre-pressurisation of the system. Refer to ‘Filling’,
below.
7. Mains Connection
There must be no direct connection to the mains water
supply or to the water storage tank supplying domestic
water, even through a non-return valve, without the
approval of the local water authority.
8.Filling
The system may be filled by one of the following methods:
a. Through a cistern, used for no other purposes, via a
ball valve permanently connected directly to a service
pipe and/or a cold water distributing pipe.
The static head available from the cistern should be
adequate to provide the desired initial system design
pressure. The cold feed pipe from the cistern should
• Thoroughly flush out the whole of the system with cold
water, without the pump in position.
• With the pump fitted, fill and vent the system until the
pressure gauge registers 1.5 bar (21.5lb/in2). Examine
for leaks.
• Check the operation of the safety valve by manually
raising the water pressure until the valve lifts. This
should occur within ± 0.3 bar (± 4.3lb/in2.) of the preset
lift pressure.
• Release water from the system until the initial system
design pressure is reached.
• Light the boiler and heat the system to the maximum
working temperature. Examine for leaks.
• Turn off the boiler and drain the system while still hot.
• Refill and vent the system.
• Adjust the initial pressure to the required value.
Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be less
than that given by the table on the following page, multiplied by a factor of 0.8 (for flow temperatures of less than 83o C).
14
mexico HE - Installation & Servicing
General
8sealed system requirements - continued
Safety valve setting
3.0 bar
2.5 bar
2.0 bar
Vessel charge and initial 0.5 1.0 1.50.5 1.01.50.5
1.0
system pressure
bar bar barbar barbarbar
bar
Total water content of system
litres
Expansion vessel volume litres
25
2.1 2.7 3.92.3 3.35.92.8
5.0
50
4.2 5.4 7.8 4.7 6.711.85.6
10.0
75
6.3
8.2
11.7 7.0 10.0 17.7 8.415.0
100
8.3
10.9
15.6 9.4
125
10.4 13.6 19.511.7 16.729.614.1
25.0
13.4 23.7 11.320.0
150
12.5 16.3 23.414.1 20.135.516.9
30.0
175
14.6 19.1 27.316.4 23.441.419.7
35.0
200
16.7 21.8 31.218.8 26.847.422.6
40.0
225
18.7 24.5 35.121.1 30.153.325.4
45.0
250
20.8 27.2 39.023.5 33.559.228.2
50.0
275
22.9 30.0 42.925.8 36.865.131.0
55.0
300
25.0 32.7 46.828.2 40.271.133.9
60.0
Multiplying factors for
other system volumes 0.08330.109 0.1560.094 0.1340.2370.1130.20
9
WATER TREATMENT
The mexico HE boiler range have an aluminium alloy
heat exchanger
Important. The application of any other treatment
to this product may render the guarantee of Ideal
Boilers invalid.
Ideal Boilers recommend water treatment in accordance
with the Benchmark Guidance Notes on Water Treatment in
Central Heating systems.
If water treatment is used Ideal Boilers recommend only
the use of Scalemaster Gold 100, Fernox, MB-1, Adey MC1
or Sentinel-X100 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
7593:2006 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.
mexico HE - Installation & Servicing
For further information contact:
Fernox Cookson Electronics
Forsyth Road
Sheerwater
Woking
Surrey GU21 5RZ
+44 (0) 870 601 5000
Sentinel Performance Solutions
The Heath Business & Technical Park
Runcorn
Cheshire WA7 4QX
Tel: 0800 389 4670
www.sentinel-solutions.net
Scalemaster Water Treatment Products
Emerald Way
Stone
Staffordshire ST15 0SR
Tel: +44 (0) 1785 811636
Calmag Ltd.
Unit 3-6, Crown Works
Bradford Road
Sandbeds, Keighley
West Yorkshire BD20 5LN
Tel: +44 (0) 1535 210 320
Adey Professional Heating Solutions
Gloucester Road,
Cheltenham GL51 8NR
Tel: +44 (0) 1242 546700
15
INSTALLATION
Installation
10BOILER ASSEMBLY - Exploded view
3
mexico HE24 shown
38
41 37
4
5
19
17
28
29
14
2
25
7
22
Dataplate
9
1
34
20
10
43
27
26
6
mxhe7922
36
mexico HE36
heat exchanger
14
28
54
29
25
27
26
7
9
LEGEND
16
1 Front casing panel
14 Burner assembly
29 Flame detection electrode
2 Sealing panel
17 Injector & housing
34 Condensate ‘S’ trap
3 Top casing panel
19 Fan assembly
36 Condensate ‘S’ trap hose
4 LH casing side panel
20 Gas pipe assembly
37 User controls
5 RH casing side panel
22 Gas valve assembly
38 PCB primary control
6 Lower front panel
25 Dry fire thermistor
41 Main switch c/w harness
7 Sump cover plate
26 Control thermistor
43 Pre-piping frame
9 Return pipe
27 Overheat thermostat
54 Burner earth pin (ionisation probe)
10 Flow pipe
28 Ignition electrode
mexico HE - Installation & Servicing
11UNPACKING
A
The boiler is supplied fully assembled in Pack A.
A non-telescopic flue assembly for rear or side flue
outlet in Pack B is suppled as a separate order.
D
B
C
Unpack and check the contents.
Pack A Contents
E
The boiler
These Installation & Servicing/User Instructions
Floor standing template
1 year guarantee form
Hardware Pack Box
Hardware Pack Box Contents (E)
A Pre-piping frame
B Flue turret
C Screws - 4 off
DGasket
E Flue connector
F Screws - 5 off
G Condensate Pipe Bracket
H Flue turret lubricant
I Sealing washers - 3 off
(1 x 1/2” gas and 2 x 22mm water connection)
mxhe7570
A
B
C
D
E
A
B
I
H
C
D
E
G
F
F
mex9220
Pack B Contents
Flue terminal
mxhe7658
12 Packaging removal
1. Fold back the top flaps and remove outer
sleeve.
2. The Installation & Servicing/Users
Instructions can be found on top of the
boiler.
3. Remove wood screw at bottom rear of
boiler, retaining the hardware pack box
and remove box.
4. When the boiler is to be fitted to the pre
piping Frame (refer to Frame 21) remove
the top and inner sleeve and the boiler
from its wooden base.
The inner sleeve can be used to protect
the floor when fitting the boiler to the
pre-piping frame.
1
3
mxhe7812
4
mexico HE - Installation & Servicing
13 Fitting and connecting the pre-piping
Frame/Condensate Pipe Support Bracket
1. Determine the position required for the boiler and tape template
into place.
20mm
Note.
Clamp
The template gives positions for both wall
or flush with 600mm deep kitchen
units and the positional options
Condensate
pipe support
of the condensate pipe bracket
bracket
dependant upon boiler size. To
Pre-piping
Frame
facilitate upward routing of
pipework behind boiler,
position the template
40mm (minimum) away
from the back wall.
2. Using the floor
template, mark
the pre-piping
frame fixing holes,
the boiler fixing holes, the
condensate pipe support bracket fixing
holes and the flue hole (refer to Frame 14).
3. Drill the 4 holes in the floor and screw the prepiping frame in place.
4. Drill the 2 holes in the floor and screw the condensate pipe support bracket
in place. If the condensate pipe is to be fitted through the rear wall then fit a
short piece of plastic pipe to the bracket and mark the wall for drilling. Refer
to Frame 15 for condensate drain detail. When complete retain condensate
pipe with bracket clamp and fixing screws, protruding 20mm as shown.
5. The gas, water flow and water return can now be connected.
Note. Measure and cut out flue hole using template (Refer to Frame 14).
mxhe7983
17
INSTALLATION
Installation
14 Flue Hole template
Important. Ensure that, during the cutting
operation, masonry falling outside of the building
does not cause damage or personal injury.
127mm (5") dia.
flue hole
Note.
The template shows the position of the flue hole
centres lines. (Flue options can be flush to wall
or in line with 600mm deep kitchen units)
1. Extend flue centre line vertically, (for rear, left
or right as appropriate), up to 690mm (centre
line of flue).
2.Mark onto the wall the position of the flue
duct hole.
CL for boiler pushed
back to wall
690mm
(27 1/4")
3. Cut the flue hole preferably with a 125mm
(5”) coreboring tool, ensuring that the hole is
square to the wall.
4. Remove the template from the floor.
86
e79
mxh
Note. If only the terminal pack
‘B’ is used (up to 775mm) no flue
incline is required.
15 gas connection
Gas CONNECTION
The boiler gas connection is built into the pre-piping
frame.
IMPORTANT. the gas service cock is sealed with a nonmetallic fibre washer seal so must not be overheated
when making capillary connections.
Refer to Fame 1 for details of the position of the gas
connection.
Ensure that the gas supply pipe does not foul the boiler
casing.
Refer to Frame 40 for details of the pressure test point
position.
16 Boiler Water Connections
mxhe7593
If flow and return pipes are required to run behind the boiler, this can be
facilitated by fitting the boiler in line with the front of 600mm deep kitchen
units thus creating a 70mm space behind the boiler.
18
Return
Note.
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.
Flow
The boiler flow and return connections are built into the pre-piping frame.
Gas
INSTALLATION
Installation
mexico HE - Installation & Servicing
17condensate drain
This appliance is fitted with a siphonic 75mm condensate trap
system that requires filling before operating the appliance for the
1st time or after maintenance.
All condensate pipework should conform to the following:
a. Where a new or replacement boiler is being installed, access to
an internal ‘gravity discharge’ termination should be one of the
main factors considered in determining boiler location.
b. Plastic with push fit or solvent connections.
c. Internal plastic pipe work a minimum of 19mm ID (typically
22mm OD)
d. External plastic pipe must be a minimum of 30mm ID (typically
32 OD) before it passes through the sleeved wall.
e. All horizontal pipe runs, must fall a minimum of 45mm per metre
away from the Boiler.
f. External & unheated pipe work should be kept to a minimum
and insulated with Class “O” waterproof pipe insulation.
g. All installations must be carried out in accordance to the
relevant connection methods as shown in the “Condensate
installation diagrams” & BS6798:2009
h. Pipe work must be installed so that it does not allow spillage
into the dwelling in the event of a blockage (through freezing)
i. All internal burrs should be removed from the pipe work and any
fittings.
In order to minimise the risk of freezing during prolonged very cold
spells, one of the following methods of terminating condensate
drainage pipe should be adopted.
Internal Drain Connections
Wherever possible, the condensate drainage pipe should be routed
to drain by gravity to a suitable internal foul water discharge point
such as an internal soil and vent stack or kitchen or bathroom
waste pipe etc. See Figs 1 and 2.
External Drain Connections
The use of an externally run condensate drainage pipe should
only be considered after exhausting all internal termination options
as described previously. An external system must terminate at a
suitable foul water discharge point or purpose designed soak away.
If an external system is chosen then the following measures must
be adopted:
The external pipe run should be kept to a minimum using the most
direct and “most vertical” route possible to the discharge point, with
no horizontal sections in which condensate might collect.
-
-
-
-
For connections to an external soil/vent stack see Fig 4.
Insulation measures as described should be used.
When a rainwater downpipe is used, an air break must be
installed between the condensate drainage pipe and the
downpipe to avoid reverse flow of rainwater into the boiler
should the downpipe become flooded or frozen, see Fig 5.
Where the condensate drain pipe terminates over an open
foul drain or gully, the pipe should terminate below the grating
level, but above water level, to minimise “wind chill” at the open
end. The use of a drain cover (as used to prevent blockage by
leaves) may offer further prevention from wind chill. See Fig 6.
Where the condensate drain pipe terminates in a purpose
designed soak away (see BS 6798) any above ground
condensate drain pipe sections should be run and insulated as
described above. See Fig 7
Unheated Internal Areas
Internal condensate drain pipes run in unheated areas, e.g. lofts
basements and garages, should be treated as external pipe.
Ensure the customer is aware of the effects created by a frozen
condensate and is shown where this information can be found in
the user manual.
Condensate Pump
Where gravity discharge to an internal termination is not physically
possible or where very long internal pipe runs would be required
to reach a suitable discharge point, a condensate pump of a
specification recommended by the boiler or pump manufacturer
should be used terminating into a suitable internal foul water
discharge point such as an internal soil and vent stack or internal
kitchen or bathroom waste pipe etc. (fig 3).
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
Minimum
connection
height up to 3
storeys
Min Ø 19mm
Internal pipe
75
Sink/basin/
bath or
shower
≥ 100
≥ 100
≥ 450
75
Min Ø 19mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
Soil & vent stack
Boiler
with 75mm
sealed
condensate
trap
Figure 2 - Connection of a Condensate Drainage Pipe
Downstream of a Sink, Basin, Bath or Shower Water Trap to
Internal Soil Vent Stack
Internal soil & vent stack
Figure 1 - Connection of Condensate Drainage Pipe to
Internal Soil & Vent Stack
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
continued . . . . .
mexico HE - Installation & Servicing
19
INSTALLATION
Installation
18 Condensate drain - Cont’d.......
Boiler
with 75mm
sealed
condensate
trap
Min Ø 30mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
Water/
weather proof
insulation
Min Ø 19mm
Internal pipe
Min Ø 30mm
Internal pipe
Boiler
with 75mm
sealed
condensate
trap
combined foul/
rain water drain
External air
break
Air gap
Terminated
and cut at 45º
43mm 90º male/
female bend
68mm Ø PVCU
Strap on fitting
Minimum
connection
height up to 3
storeys
Figure 6 - Connection of Condensate Drainage Pipe
Upstream of a Sink, Basin, Bath or Shower Waste Trap to
External Drain, Gulley or Ranwater Hopper
Visible air break
at plug hole
Min Ø 19mm
Internal pipe
Sink, basin, bath or
shower with integral
overflow and 75mm trap
75
Figure 5 - Connection of a Condensate Drainage Pipe to an
External Rainwater Downpipe (only combined foul/rainwater
drain)
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
≥ 100
Condensate pump
(Install in accordance with manufacturers instructions)
≥ 450
Min Ø 19mm
Internal pipe
Water/
weather proof
insulation
Minimum 30mm
internal pipe
45º pipe
termination
≥ 25 Below grate
75
Min Ø 19mm
Internal pipe
Water/weather
proof insulation
75
Visible air break
Boiler
with 75mm
sealed
condensate
trap
Figure 4 - Connection of condensate Drainage Pipe to
External Soil & Vent Stack
Soil & vent stack
Figure 3 - Connection of a Condensate Pump Typical
Method (see manufacturers detailed instructions)
Figure 7 - Connection of a Condensate Drainage Pipe to an
External Purpose Made Soak Away.
Boiler
with 75mm
sealed
condensate
trap
Min Ø 30mm
Internal pipe
Water/Weather
proof insulation
Max 3m external
pipework
Boilers without 75mm sealed
condensate trap must be fitted with
a 75mm trap and visible air break
≥ 300
≥ 25
Min Ø 19mm
Internal pipe
75
INSTALLATION
Installation
≥ 500
Limestone
chippings
2 rows of three Ø12mm holes
25mm centres, 50mm from
the bottom of the tube, facing
away from the house
20
mexico HE - Installation & Servicing
Installation
Important. The boiler must be installed in a vertical position
Dimension X - Wall thickness.
Dimension L - Wall thickness plus boiler spacing.
Flue kits
Pack B - supplied as standard.
Finishing Kit - supplied as an optional extra.
Screw Kit - optional kit for mecahnical fixing of flue joints.
Pack D - optional extension kit for side flue or rear flue outlet.
Total Flue length dimension
Rear flue
dim. X+75
Up to
Up to
Up to
Up to
Up to
Up to
Up to
Side flue
dim. L+225
775 mm
1680 mm
2585 mm
3490 mm
4395 mm
5300 mm
6000 mm
Up to
Up to
Up to
Up to
Up to
Up to
Up to
775 mm
1680 mm
2585 mm
3490 mm
4395 mm
5300 mm
6000 mm
INSTALLATION
19 DETERMINING THE FLUE LENGTH and flue packs required
Flue
Extra packs
required
none
Pack D - 1 off
Pack D - 2 off
Pack D - 3 off
Pack D - 4 off
Pack D - 5 off
Pack D - 6 off
Note. The flue duct MUST be inclined at 1.5 degrees
to the horizontal to allow condensate to drain back into
the boiler and out through the condensate drain. (Only
necessary if using one or more ‘D’ extension duct packs)
Refer to ‘Flue Extension Ducts’.
Note. Maximum Flue lengths:
HE15, 18 and 24- 6m (horizontal flue)
HE30 and 36 - 3m (horizontal flue)
HE15, 18 and 24- 8m (vertical flue)
HE 30 and 36 - 5m (vertical flue)
90o Elbow Kit (Equivalent flue length resistance = 1.5m)
45o elbow Kit (Equivalent flue length resistance = 1.0m)
Notes.
225mm 225mm
75 mm
1. It is recommended that a
support bracket is fitted for
every 1 metre of extension
pipe used and a bracket
should be used at every joint,
to ensure pipes are held at
the correct angle.
Side flue
length L
Rear flue
length X
If a slip joint coupling is to be
used then a bracket should
be used to secure the collar.
mxhe7595
Boiler pushed
back to the wall
2. Only use water as lubricant
during assembly.
20FLUE ASSEMBLY - Exploded View
An optional flue duct extension kit is required for
wall thicknesses greater than :
Side545mm (211/2”)
7
Rear705mm (273/4”)
2
3
4
1
6
LEGEND
1. Duct assembly
Flue Outlet
5
2. Flue turret
3. Turret fixing screws
5. Flue connector screws
6. Turret gasket
7. Foam sealing tape
mxhe7597
4. Flue connector
mexico HE - Installation & Servicing
Rear flue arrangement shown
21
Installation
21 MOUNTING THE BOILER Onto the Pre-piping Frame
135mm
FLUE OUTLET
6d
Sealing Gasket
Top panel
4
3
5
8
9
2
4
Return
mxhe7610
Flow
5
Inlet pipe end cut at 45o
60mm (HE15, HE18, HE24)
190mm (HE30, HE36)
Flexible hose
from 'S' trap
Outlet pipe 6c
6a
8
4
Gas
Note. Use the boiler packaging sleeve to protect the
floor.
1. Remove the two screws retaining the lower front panel and remove the
panel
2. Remove the two screws retaining the upper front panel.
3. Lift the upper front panel and remove. If the optional extra concealment
panel kit is to be fitted to either left or right hand side panel, it must NOW
be fitted (refer to separate instructions provided with kit).
4. At this stage fit the flue assembly and turret (see Frame 28 or 33)
and in the case of rear flue fit the optional flue finishing kit, refer
to Frame 27, if required. Remove the top panel to facilitate turret
fitting.
5. Fit the sealing washers to the water and gas connections.
6.If the condensate pump is to be used, it must now be fitted (If not to be
fitted go to No. 7)
a. Fit the condensate pump fixing slots over the two screw heads. The
screws position the pump but cannot be tightened.
b. Prepare to route the condensate pump cable, the mains cable and
the remote user controls wiring (if required) up the rear of the
boiler and through the grommet to be found at the top left of the
boiler.
c. Using the rubber connecting joint, provide a plastic outlet pipe from 1
the pump outlet connection, to a suitable drain point connection
taking care to route the pipework such that it will not foul the boiler
when fitted. Refer to Frame 18.
d.Make up the inlet plastic pipe connection to the following drawing and fit
6d
to the ‘S’ trap flexible hose connection.
7. Remove the four screws retaining the boiler to the wooden packaging
10
6d
Inlet pipe
from ‘S’ trap
Rubber
connecting
joint
10.Connect the condensate pump inlet ensuring the pipe is
base and using the packaging sleeve to protect the floor,
pushed to bottom of the pump housing. If no pump is fitted
slide the boiler onto the pre-piping frame ensuring the
connect the S trap flexible hose to the previously installed
mains cable and the condensate pump cable (if fitted) is
condensate drain pipe. Refer to Frame 13.
routed through the grommet at the top left of the boiler.
11.Wire the mains connection, the condensate pump connection
8. Screw the boiler frame to the floor through the 2 slots in
(if fitted) and the remote user control (if fitted). Refer to Frame
the front of the boiler runners.
35.
9. Connect the gas and water union connections ensuring the
sealing washers are in place.
22
mexico HE - Installation & Servicing
Installation
22cutting the flue - REAR Wall thicknesses of 114 to 705mm
Note.
If using the extension ducts go to Frame 24, 25 and 26.
1. Measure and note wall thickness X. Refer to Frame 19.
2. Add 5mm (1/4”) to dimension X and, measuring from the ring, cut
both outer and inner tube. Ensure support spring clip is in position
to facilitate cutting.
cla7841
3. To ensure the tube is cut square, mark the flue all the way around.
4. De-burr the cut edges.
23cutting the flue LH OR TO RH side - Wall thickness of 114 to 545mm
Note. If using the extension ducts go to Frame 24, 25 and 26.
1. Measure and note side flue length L. Refer to Frame 19.
2. Add 60mm (23/8”) to dimension L and measuring from the ring, cut
both outer and inner tube. Ensure support spring clip is in position to
facilitate cutting.
cla7841
3. To ensure the tube is cut square, mark the flue all the way around.
4. De-burr the cut edges.
24Flue Extension Ducts - for flue lengths greater than 775mm
Pack D Flue extension duct kit contents
Extension duct & clamp
1.0m (39") long
Washers - 2 off
mxhe7656
Note.
FLUE OUTLET
Wall plugs - 2 off
Only use water as
a lubricant during
assembly.
Flue duct support
Clamp screws - 2 off
Support fixing screws - 2 off
25Flue extension ducts - continued
Use a maximum of 6m extended flue ONLY (HE15, HE18, HE24)
Use a maximum of 3m extended flue ONLY (HE30, HE36)
General arrangement
1.A maximum of 6 extension ducts for the HE15,
HE18 and HE24 and a maximum of 3 extension
ducts for the HE30 and HE36 (one suitably
cut) plus the standard flue duct may be used
together.
2. Flue extensions of greater length than 1m (39”)
should be supported with the bracket provided,
suitably adjusted. Refer to Frame 24.
mexico HE - Installation & Servicing
Note.
Side flue shown
mxhe7599
23
Installation
26Fitting the kit
1. Fit the inner flue extension duct onto the inner
flue duct.
2. Fit the outer flue extension duct onto the
outer air duct.
3. Repeat steps 1 and 2 if a second flue
extension is required.
4.Measure and mark the flue length
required onto the flue, measuring
from the ring near the terminal.
(Refer to Frames 19 and 23 for
detail of length measurement)
1
2
Measure from
this
RING
mxhe7843
5. To ensure a square cut, mark the
flue all the way around.
6. De-burr the cut edges.
27Fitting the Optional Flue Finishing Kit and Optional RS Sealing Plate
Flue Finishing Kit
RS Sealing Plate
1. Fit black outer wall seal over terminal and ensure the retaining rim is
located in the terminal depression.
If the mexico HE is replacing a room sealed
appliance, an optional extra terminal wall sealing
plate is available to make good the rectangular
flue hole.
2. Fit flue pipe assembly through the hole previously cut in wall.
3. Fit white inner wall seal to pipe assembly (side flue).
4. Fit outer wall sealing plate over outer wall seal and retain with the 4
screws and wall plugs provided.
Contents:
Contents:
Wall Seal plate - 1 off
Screws No. 10x2” Woodscrew - 4 off
Wallplugs - 4 off
Wall Seal White - 1 off
Wall Seal Black - 1 off
Wall Sealing Plate - 1 off
Screws No. 10x2” - 4 off
1
24
35
0m
m
3
4
40
0m
CL
o
fb
69
0m
m
mxhe7984
FLUE OUTLET
Wallplugs - 4 off
m
oile
r
mxhe7985
mexico HE - Installation & Servicing
Installation
28connecting the flue to THE BOILER
1. Measure 68mm from the cut end of the flue assembly and mark a line on the
flue.
2. Fit the flue connector over the end of the flue and align the end of the connector
with the marked line.
3. Ensure the ‘V’ cutout on the flue connector is aligned with the top of the turret
(use label as a guide).
4.Mark the 3 fixing screw holes and drill the three holes with a 3.2 (1/8”) dia drill.
Do not drill through the inner flue pipe.
5. Retain the connector with the 3 screws provided.
6. Adhere the 70mm wide x 20mm deep foam strip (found in the
hardware pack box) to the flue assembly tube to provide an
inner seal to the hole cut in the wall.
7. Insert the flue assembly through the prepared hole in the
wall.
4
8. Remove the top outlet blanking plate or boiler top panel
to facilitate turret fitting. To ensure a positive flue seal is
confirmed it may be necessary to remove the worktop or
adjacent cupboard to view the joint.
10
A
1
6
5
Flue Outlet
9
Top outlet
blanking plate
Sealing Gasket
mxhe7710
Fix the flue support bracket to
the wall, using the wall plug
and wood screw.
2
68mm
12.Flues over 1 metre long.
B
9
10.Smear lubricant (to be found in hardware pack)
over both inner flue duct seal and outer air duct
seal and locate the flue onto the turret ensuring
the 2 bayonet fixings on the flue connector
(B) engage to the lugs on the turret (A).
11.Replace the top outlet blanking plate.
7
FLUE OUTLET
9. Fit the sealing gasket and push the flue turret into the
top of the boiler flue sealing ring and retain with the 4
screws provided.
Label
3
mexico HE - Installation & Servicing
25
Installation
29Fitting 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.
Connection to the top of the boiler is made using a
separately supplied vertical connector
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 9,
Optional Extras.
mxhe7652
FLUE OUTLET
30 Roof Flue Kit Contents / options
Note. Items D, E, F, G and H are not supplied with
the roof flue kit.
A. Flue assembly with terminal
B. Flue seal collar
H
C. 3.5x13 screw
G
F
D. Pitched roof tile/flat roof tile
weather collar
E. Vertical connector (60/100)
comes with gasket and fixing
screws
F. Roof flue extension duct kit
(60/100)
G.90o elbow kit (60/100)
E
A
D
H.45o elbow kit (60/100)
26
C
B
mxhe7778
mexico HE - Installation & Servicing
Installation
31Flue 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.
Minimum dimensions are shown below
m
0m
30
in
m
300mm
min
300mm
min
625mm
Fixed
rf8394-1
rf8393-1
690mm
Fixed
Flat roof - with structure
A
A
A
07
98
RF
B
A = 600mm
B = 2000mm
If chimney penetrates dotted area such that A is less
than 300mm, B shall not be less than 300mm.
The flue terminal shall not penetrate the shaded area of the roof
Pitched roof - with velux window or opening
Where two or more vertical fanned draught chimney configurations terminate in close proximity
at the same height, they shall be separated by at least 300mm. Where any one vertical outlet is
more than 300mm above the other, then they shall be separated by at least 1500mm.
Note.
Where any vertical fanned draught chimney configuration outlet is within 2000mm measured
horizontally of an opening window, then it shall be at least 300mm above the opening.
90o elbow kit = 1m
FLUE OUTLET
The equivalent flue length
resistance of the elbow kits are:
45o elbow kit = 0.6m
32Flue Arrangement
Part No. Description60/100 Quantity
Maximum Flue Length (m)
8
8
8
5
5
7
7
7
6
6
201 189 Terminal Vertical Roof 60/100
1
1
1
1
1
152 258 Weather Collar Pitched Roof
1
1
1
1
1
152 259 Weather Collar Flat Roof
1
1
1
1
1
201 182 90o Elbow Kit (60/100)
4
4
4
2
2
201 183 45o Elbow Kit (60/100)
4
4
4
2
2
201 869 Vertical Connector
1
1
1
1
1
Note.
The equivalent flue length resistance of the 90o elbow kit
(60/100) is 1m and the 45o elbow kit (60/100) is 0.75m.
mexico HE - Installation & Servicing
mxhe7687
n/a
201 180 Flue ext. 60/100
HE15HE18 HE24 HE30 HE36
mxhe7686
27
Installation
33 Assembling the Roof Flue Kit
1. Ensure the flue seal collar B is located onto the flue assembly
A.
o
MAX LENGTH:
HE15 - 8m
HE18 - 8m
HE 24 - 8m
HE 30 - 5m
HE 36 - 5m
o
max 41
Ensure the cut pipe ends are free from any burrs.
1
min 16
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 of
assembly A, then ensure they are cut equally leaving the inner
flue tube longer than the outer air tube as supplied. (Refer to No.
5 below)
A
B
7469
2. Position the roof flashing plate D (supplied separately) over
the hole cut in the roof and insert flue assembly A from the
roof end.
4. “Push” fit extension duct F (if required, supplied
se par at ely ) and th e ro o f fl u e k i t a s s e mb l y
into the vertical connector E. Using the lubricant
found in the hardware pack to facilitate fitting.
A
E
mxhe7653
3. Remove the casing top outlet blanking plate (2 screws) or
boiler top panel to facilitate fitting the vertical connector.
Fit the sealing gasket and push fit the vertical connector E
(supplied separately) into the boiler flue connection and retain
with the four securing screws provided.
2
5. If the last extension duct requires cutting, measure
the distance (outer ducts) between the duct and the
terminal and add 100 mm to this dimension. This
Ø 100
gives the length of the last extension duct.
Ø
mxhe7654
7470
7. Finally ensure the roof flashing plate D is
correctly sealed to the roof.
28
A
D
6. Slide down and position the flue seal collar B
over the roof plate D and secure it with the 3
screws C to the flue assembly A.
F
60
D
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.
4
6
E
5
mxhe7688
FLUE OUTLET
A
3
A
A
C
C
B
B
D
ix7474
mexico HE - Installation & Servicing
Installation
Warning. This appliance MUST be earthed.
A mains supply of 230 V ~ 50 Hz is required.
All external controls and wiring MUST be suitable for mains
voltage.
The fuse rating should be 3 A.
Wiring external to the boiler MUST be in accordance with the
current I.E.E. (BS.7671) Wiring Regulations and any local
regulations.
Installation
34electrical connections
Wiring should be 3 core PVC insulated cable NOT LESS than
0.75 mm2 (24 x 0.2mm) and to BS. 6500, Table 16.
For IE reference should be made to the current ETCI rules for
electrical installations.
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 a
plug and socket serving only the boiler and system controls.
The means of isolation must be accessible to the user after
installation.
35 internal wiring
A pictorial wiring diagram is shown in Frame 40.
1. Route the mains cable via the rear of the boiler through the
grommit at the left hand side.
Mains Connector
(supplied in hardware pack)
2. Wire the permanent live supply into the 5-way remote plug
terminals, L3, N & .
L3
2
N
5
important.
A permanent live is essential in order for the advanced
diagnostic controls to function correctly.
L2
L1
Ensure that the lengths of the live and neutral wires are shorter
than the earth wires so that if the cable slips in its anchorage
the current carrying wire become taut before the earth wire.
isfu9867
Socket
(fixed to boiler)
Remove link when connecting external programmer/roomstat
3. Wire any switched live supply into L2 or connect L1 and L2
via external control switching as shown in Frame 39. In either
case remove the wire link fitted to L1 to L2.
KEY
L3 - Permanent Live
L2 - Switched live input
L1 - Live Feed output
4. Secure the mains lead with the cable clamp.
5. Connect the mains lead connector. Ensure it is fully located
into the socket.
If a condensate pump is to be fitted:
1. Route the cable via the rear of the boiler through the
grommit at the left hand side.
Condensate Pump Plug
(fixed to boiler)
2. Remove the condensate pump plug from mating connector.
Mating Connector
(fixed to boiler)
L1
L2
3. Remove wire link between L1 and L2.
L1
L2
4. Wire in condensate pump as shown below.
5. Secure cable sheath in cable clamps.
2
3
Ensure that the lengths of the live and neutral wires are shorter
than the earth wires so that if the cable slips in its anchorage
the current carrying wire become taut before the earth wire.
N
N
L3
L3
4
KEY
L3 - Brown
N - Blue
- Green/Yellow
L2 - Black
L1 - Grey
mexico HE - Installation & Servicing
5
Condensate Pump Plug
(fixed to boiler)
L1
L2
N
L3
29
36pictorial wiring diagram
LEGEND
b-blue
bk - black
br-brown
gy-grey
or-orange
pk - pink
r-red
v -violet
w -white
y-yellow
y/g-yellow/green
pk
y
bk
b
r
Fan
Dry fire
thermistor
Overheat
thermostat
or
or
r
y y
Gas valve
Flow
control
thermistor
r
Mains supply
230V 50Hz
Condensate
pump connector
bk
br
y/g
y/g
b
b
Chassis
earth
y/g
bk
INSTALLATION
Installation
Spark generator
y/g
bk
y/g
br
bk
b
b
Ferrite
bk
bk
b
br
or
Service
connection
or
Fused at
3.15ATL
User
control
and
display
v
ON /OFF
Switch
y
bk
b
Control PCB
r
r
pk
y/g
br
y
y
r
r
37functional flow wiring diagram
LEGEND
b-blue
bk - black
br-brown
gy-grey
or-orange
pk - pink
r-red
v -violet
w -white
y-yellow
y/g-yellow/green
br
r
br
2
1
Control PCB
pk
r
Cond.
Pump
Alarm
L
br
r
r
External
switch
or
or
b
Flame detection
electrode
y/g
y/g
E
Overheat
thermostat
br
b
DC Gas valve
Spark generator
y
Ignition electrode
Control thermistor
bk
y
Dry fire
thermistor
30
bk
bk
y
r
DC
Fan
N
b
Mains Switch
r
r
User PCB
b
v
mxhe7604
mexico HE - Installation & Servicing
38 External electrical controls
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.
The fuse should be 3A.
Room Thermostat
mxhe9221
If the thermostat has a neutral connection use it.
(It provides for more energy efficient operation by
reducing switching temperature differentials.)
Frost Protection
mxhe9222
If parts of the pipework run outside the house or if
the boiler will be left off for more than a day or so
then a frost thermostat should be wired into the
system. This is usually done at the programmer, in
which case the programmer selector switches are
set to OFF and all other controls MUST be left in the
running position.
The frost thermostat should be sited in a cold place
but where it can sense heat from the system.
If the boiler is installed in a garage it may be
necessary to fit a pipe thermostat, preferably on the
return pipework.
Important. Ensure that the frost thermostat is wired
so that the system pump and/or external diverter
valve is energised, as appropriate.
Designation of the terminals will vary but the
programmer and thermostat manufacturers’ leaflets
will give full details.
mxhe9223
Diagram A shows an application to boilers fitted
with a room thermostat only.
Diagrams B and C show applications to boilers
fitted with alternative time controls.
Earths are not shown for clarity but must never be omitted.
39commissioning and testing
A. Electrical Installation
B. Gas Installation
1. Checks to ensure electrical safety should be carried out by a
competent person.
1. The whole of the gas installation, including the meter,
should be inspected and tested for soundness and purged
in accordance with the recommendations of BS. 6891.
In IE refer to I.S. 813:2002.
2. Purge air from the gas installation by the approved methods
only.
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.
WARNING.
Whilst effecting the required gas tightness test and purging air from the gas
installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.
mexico HE - Installation & Servicing
31
INSTALLATION
Installation
INSTALLATION
Installation
40INITIAL LIGHTING
PLEASE NOTE: The combustion for this appliance has
been checked, adjusted and preset at the factory for
operation on the gas type defined on the appliance data
plate. Do not adjust the air/gas ratio valve.
having checked:
• That the boiler has been installed in accordance with
these instructions.
With the boiler operating in the maximum rate condition check that
the operational (working) gas pressure at the inlet gas pressure test
point (G) complies with the requirements of “Gas Supply” on page 10.
Ensure that this inlet pressure can be obtained with all other gas
appliances in the property working.
10. CHECK the operationAL (working) gas inlet pressure
• The integrity of the flue system and the flue seals.
N.B. The principle of the 1:1 gas valve ensures that the mexico
HE range is able to deliver their 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.
• The integrity of the boiler combustion circuit and the
relevant seals.
1. Check that the system has been filled and that the
boiler is not air locked.
Note. It is important the burner is not operated before
the system is fully vented of air. If it is necessary to
operate the system pump to assist venting of the air
this must be done with the gas service cock turned off.
2. Check that all drain cocks are closed and any valves
in the flow and return are open.
3. Check the electrical supply is off.
4. Check the gas service cock is open.
5. Check that the boiler on/off switch (A) is OFF
6. Slacken the screw in the inlet pressure test point (G)
and connect a gas pressure gauge via a flexible tube.
7. Switch the electricity supply ON and check all external
controls are calling for heat.
8. Set the boiler thermostat knob (B) 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.
9. If the boiler does not light after 3 attempts the fault
codes L’ ‘F’ will be displayed. Press the reset button
(C); the boiler will then repeat its ignition sequence.
When the burner is established the WHITE burner ON
neon (D) will be permanently illuminated.
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 useradjustable. Any interference to sealed settings on the gas
valve will adversely affect operation and render our warranty
void.
11.Switch off the boiler on/off switch.
12.Remove the pressure gauge and tube. Tighten the sealing screw in
pressure test point. Ensure a gas tight seal is made.
13.Refit the boiler front panel.
The display
The user control has one neon and one display to inform the user
about the status: the display will show the status of the boiler and the
neon will show the status of the flame. If no flame is detected the neon
is blinking. When the flame is detected the neon will be lit permanently.
Below is a list with display function in normal operation.
Standby. No demand for heat present.
Boiler is active for central heating or domestic hot water.
Boiler is in lockout for a specific error. The display will be blinking,
alternating with a number or letter to show which error is detected.
Boiler is in lockout for a specific error. The display will be blinking,
alternating with a number or letter to show which error is detected.
Boiler frost protection. Boiler will fire when temperature is less than
3 degrees.
A
E
C B
D
Flue
sampling
point
Flue
sampling
point
A E
C B
D
Spark
generator
LEGEND
A On/Off switch
Auto Air
vent
B CH Thermostat knob
C Reset button
Flow thermistor
D Burner On Neon
E Display
OH thermostat
F Injector pressure test point
Dry fire
thermistor
G Inlet pressure test point
H Gas service cock
GAS VALVE
G
F
OH
thermostat
Flow
thermistor
H
mexico HE15, HE18 & HE24
32
mxhe7619
H
mexico HE30 & HE36
mexico HE - Installation & Servicing
41 GENERAL CHECKS
Make the following checks for correct operation:
1. Central Heating
The correct operation of ANY programmer and all other
system controls should be proved. Operate each control
separately and check that the main burner or circulating
pump, as the case may be, responds.
Ensure the external controls are calling for heat. After
ignition the display should read:
2. Gas Rate
Operate the boiler for 10 minutes. Check the boiler gas
rate (see Table 2), ensuring the boiler is at full output whilst
measurements are recorded.
3. Water Circulation System
Knob Setting
Flow Temperature
o
o
C
F
Min
30
86
Max
82
180
Note.Fernox Superfloc, Sentinel X300 (new systems) / X400
(existing systems) or Salamander products flushing
solutions should be used during the flushing procedure.
Refer to Frame 9.
a. With the system HOT examine all water connections for
soundness.
b. With the system still HOT, turn off the gas, water and
electricity supplies to the boiler and drain down to complete
the flushing process.
c. Refill and vent the system, add inhibitor (see Frame 9),
clear all air locks and again check for water soundness.
Adhere 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.
d. Balance the system. Refer to Frame 4.
4. Check the condensate drain for leaks and check that it is
discharging correctly
5. Finally set the controls to the user’s requirements.
•
The temperatures quoted alongside are approximate, and
vary between installations.
42handing 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 Installation / User’s Instructions to the
householder and explain his or her responsibilities under
current Gas Safety (Installation and Use) Regulations or
rules in force.
2. Explain and demonstrate the lighting and shutting down
procedures.
6. Explain and demonstrate the function of time and temperature
controls, radiator valves, etc., for the economic use of the system.
7.If any programmer is fitted then draw attention to the Programmer
User’s Instructions and hand them to the householder.
8. After installation and commissioning please complete the
3. The operation of the boiler and the use and adjustment
of ALL system controls should be fully explained to
Commissioning Checklist before handover to
the householder to ensure the greatest possible fuel
the customer. For IE, its is necessary to complete a “Declaration
economy consistent with household requirements of both
of Conformity” to indicate compliance to I.S. 813:2002.
heating and hot water consumption.
Advise the User of the precautions necessary to prevent 9. Important
damage to the system and to the building in the event of Stress the importance of regular servicing by a Gas Safe
the system remaining inoperative during frosty conditions.
Registered Engineer and that a comprehensive service should be
carried out AT LEAST ONCE A YEAR. In IE servicing work must
4. Explain the function and the use of the boiler heating
be carried out by a Registered Gas Installer.
controls.
5. Explain the function of the boiler fault mode.
Emphasise that if a fault is indicated the boiler should
be turned off and a Gas Safe Registered Engineer
consulted. In IE contact a Registered Gas Installer.
10.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 household
pack supplied with this boiler.
As part of the commissioning process, the combustion of this appliance must be checked
and the Benchmark Checklist completed. A flow chart to assist is provided on page 57.
ATTENTION !
IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE
BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED
AND LEFT WITH THE APPLIANCE
mexico HE - Installation & Servicing
33
INSTALLATION
Installation
Servicing
43servicing SCHEDULE
For the very latest copy of literature for specification & maintenance practices, visit our website www.idealboilers.com, where you
will be able to download the relevant information. N.B. Technical Bulletins are also available on www.idealboilers.com.
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
annually. It is the law that any service work must be carried out by a Gas Safe Registered Engineer. In IE service work must be
carried out by a Registered Gas Installer.
PLEASE NOTE: During routine servicing and after any
maintenance or change of part of the combustion circuit, the
following must be checked:
• The integrity of the flue system and the flue seals.
• The integrity of the boiler combustion circuit and the relevant seals.
• The operational (working) gas inlet pressure at maximum
rate. Refer to Frame 40.
• The gas rate. Refer to Frame 41.
• The combustion performance. Refer to step 3.
1. Light the boiler and carry out a pre-service check, noting any
operational faults.
2. Check the gas consumption.
3. Connect a suitable gas analyser to the sampling point on top
of the boiler or into the flue terminal, if access is possible.
Refer to Frame 46.
For correct boiler operation the CO/CO2 ratio of the flue gas
should not be greater than 0.004 ratio. If the combustion
reading is greater than the acceptable value AND the
integrity of the complete flue system and combustion circuit
seals have been verified and the inlet gas press (and gas
rate) have been verified, then contact Ideal.
Competence to carry out the check of Combustion
Performance
PLEASE NOTE. BS6798: 2009 Specification for Installation and
maintenance of Gas Fired boiler of rated input not exceeding 70
kW net advises that:
• The person carrying out a combustion measurement should
have been assessed as competent in the use of a flue gas
analyser and the interpretation of the results;
• The flue gas analyser used should be one meeting the
requirements of BS7927 or BS-EN50379-3 and be calibrated
in accordance with the analyser manufacturers’ requirements.
• Competence can be demonstrated by satisfactory
completion of the CPA1 ACS assessment, which covers
the use of electronic portable combustion gas analysers in
accordance with BS 7967, parts 1 to 4.
5. Clean the heat exchanger and ‘S’ trap.
6. Check the condition of the combustion chamber insulation.
Any cracked or damaged pieces should be replaced (HE15,
HE18 and HE24 only).
Ionisation probes are a servicable component and require
inspecting annually and replacing if distorted.
7. Check the main injector for blockage or damage.
8. Wherever possible, remove and clean the condensate ‘S’ trap
(refer to Frame 48) and check the drain for blockage.
9. Check that the flue terminal is unobstructed and that the flue
system is sealed correctly.
10.If fitted, clean the condensate pump.
The servicing procedures are covered more fully in Frames
46 to 50 and must be carried out in sequence.
Note. In order to carry out either servicing or replacement of
components the boiler front panels, and sealing panel must be
removed. Refer to Frames 44 and 45.
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.
IMPORTANT.
11.After completing the servicing or exchange of components
always test for gas tightness and carry out functional checks
as in paragraphs 2 and 3.
12.When work is complete the sealing panel MUST be correctly
refitted, ensuring that a good seal is made.
DO NOT OPERATE THE BOILER IF THE sealing panel
IS NOT FITTED.
13.Complete the service section of the Benchmark Commissioning
Checklist.
CO/CO2
sampling
point
44 boiler front panel removal
1. Remove the two screws retaining the lower
front panel and remove the panel.
3
2. Remove the two screws retaining the upper
front panel.
3. Lift the upper front panel and remove.
2
mxhe7613
SERVICING
4. Clean the main burner.
1
34
mexico HE - Installation & Servicing
Servicing
46FAN AND VENTURI ASSEMBLY
removal and cleaning
45Boiler sealing panel
removal
1. To remove the sealing panel remove the 4 screws.
1. Undo the gas pipe union connection to the injector
housing.
2. Remove the panel.
2. Undo the screw on the fan mounting bracket.
3. Lift off the fan and venturi assembly.
4. Disconnect the electrical leads from the fan.
5. Inspect the injector for blockage or damage.
4
3
1
servicing
mxhe7614
2
mxhe7747
47Burner removal and cleaning
1. Remove the 6 fixings securing the burner
(the 3 screws at the rear are extended to
ease access).
2. Lift off the burner from the combustion
chamber.
1
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.
2
4
3. Brush off any deposits that may be on the
ceramic with a soft brush.
4. Inspect the sealing gasket around
the burner and combustion chamber
insulation for any signs of damage.
Replace as necessary.
Ionisation
Probes
Note.
Take care not to disturb the ionisation probes
at the front and rear of the combustion
chamber.
nm
740
0
mexico HE 24 shown
mexico HE - Installation & Servicing
35
Servicing
48cleaning the Condensate ‘S’ trap & Condensate Pump (if fitted)
If condensate pump fitted refer to separate instructions for
cleaning procedure.
1. If a condensate pump is fitted, it must be removed and
pulled forward to gain access to the condensate ‘S’
trap. Refer to Frame 69.
Note. Care must be taken with residual water when
removing the outlet pipe.
4
2. Remove the plastic union sealing nut on the bottom of
the condensate ‘S’ trap.
3. Remove and clean from the cartridge and ball any
residual deposits.
4. Inspect the opaque ‘S’ trap for further signs of dirt and
clean as necessary.
2
5. Replace the cartridge and ball and replace the plastic
sealing nut.
6. Replace the condensate pump.
49cleaning the heat exchanger
3
Ionisation
probes
2. Remove the 3 screws retaining the sump cover and remove.
3. Using a suitable tool clean the exposed heat exchanger fins
through the sump cover. Also vacuum any debris from the top
of the heat exchanger.
4. Remove any loose deposits from the sump.
5. Inspect the ignition and detection electrodes. Ensure that they
are clean and in good condition - replace if necessary.
6. Check the condition of the combustion chamber insulation
(HE15, 18 and 24 only). Any cracked or damaged pieces
must be replaced.
Sump cover
mxhe7684
servicing
1. Remove ignition and flame detection electrodes. Refer to
Frames 55 and 56.
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 55 and 56.
2
Heat exchanger
3
mexico HE24 shown
50reassembly
Reassemble the boiler in the following order.
1. Refit the sump cover plate.
6. Refit the boiler sealing panel.
Important.
Ensure the boiler sealing panel is correctly fitted and
that a good seal is made.
2. Refit the electrodes (check dimensions Frames
55 and 56).
7. Refit the boiler front panels.
3. Refit the burner.
8. Turn on the gas supply at the gas service cock.
4. Refit the fan / venturi assembly.
9. Reconnect the electrical supply.
5. Reconnect the fan electrical leads.
36
mexico HE - Installation & Servicing
Servicing
51replacement of components
General
When replacing ANY component:
IMPORTANT
When work is complete, the sealing panel must be
correctly fitted, ensuring that a good seal is made.
1. Isolate the electricity supply.
2. Turn off the gas supply.
Note.
3. Remove the boiler front panels and inner sealing panel.
Refer to Frames 44 and 45.
After replacing ANY component check operation of the boiler
including gas tightness, gas rate and combustion test.
In order to assist fault finding, the control panel has an
LED diagnostic display. The key to boiler fault conditions
is shown in Frame 70.
servicing
The boiler must not be operated without the sealing panel fitted
52 Flow thermistor replacement
mexico HE15, HE18 & HE24
1. Refer to Frame 51.
2. Remove the boiler front panels and inner sealing
panel. Refer to Frames 44 and 45.
Note. Only the boiler front panels need removing
on the HE15, 18 and 24 models)
3. Pull the electrical leads off the flow thermistor and
remove earth connection.
4. Remove the two screws retaining the flow
thermistor.
5. Replace flow thermistor retaining with the fixing
screws previously removed and reconnect leads.
3
6. Reassemble the boiler in reverse order.
7. Check the operation of the boiler. Refer to Frame
51.
4
mexico HE30 & HE36
4
3
mexico HE - Installation & Servicing
37
Servicing
53 fan replacement
1. Refer to Frame 51.
2. Remove the boiler front panels and inner
sealing panel. Refer to Frames 44 and 45.
3. Unscrew the gas pipe union connection to
the injector housing.
Orifice plate
Gasket
4. Unscrew and remove the screw retaining
the fan mounting bracket.
6
5. Remove the fan and venturi assembly.
7
6. Disconnect the electrical leads from the
fan.
7. Remove the 3 screws and remove the
venturi assembly, noting the orientation of
the venturi in relation to the fan body.
3
4
8. Transfer the venturi assembly to the new
fan, replacing the gasket if evidence of
damage or deterioration is visible.
9. Fit the new fan / venturi assembly.
servicing
10.Reassemble the boiler in reverse order,
taking care not to over tighten the screw
on the fan mounting bracket.
11.Check the operation of the boiler. Refer to
Frame 51.
mxhe7748
54 burner replacement
1. Refer to Frame 51.
2. Remove the boiler front panels and inner
sealing panel. Refer to Frames 44 and 45.
4
3. Remove the fan assembly. Refer to Frame 53
(no’s 3 to 6.)
5
4. Remove the 6 fixings securing the burner (the
3 screws at the rear are extended to ease
access).
6
5. Lift off the burner from the combustion
chamber.
6. Fit the new burner, replacing any damaged or
deteriorating sealing gasket.
ionisation
probes
7. Reassemble in reverse order.
8. Check the operation of the boiler. Refer to
Frame 51.
Note. Take care not to disturb the burner
ionisation probes at the front and rear of
the combustion chamber. (burner earth
pins are at the front only on the HE30 and
HE36)
38
nm
740
2
HE24 shown
mexico HE - Installation & Servicing
Servicing
55 ignition electrode replacement
1. Refer to Frame 51.
2. Remove the boiler front panels and inner sealing panel.
Refer to Frames 44 and 45.
8mm +- 1 (HE15, HE18, HE24)
15mm +- 1 (HE30, HE36)
3. Unplug the ignition lead from the electrode.
4. Remove the burner. Refer to Frame 54.
5. Remove the earth lead from the ignition electrode.
6. Remove the remaining screw holding the ignition
electrode to the combustion chamber.
7. Remove the electrode.
8. Fit the new ignition electrode, using the new gasket
supplied. Check dimensions as shown.
9. Reassemble in reverse order and check that no damage
to the combustion chamber insulation has occurred
during the electrode replacement. (HE15, HE18 and
HE24 only)
mxhe7693
5
10.Check operation of the boiler. Refer to Frame 51.
servicing
6
5
mxhe7785
6
mexico HE24 shown
mexico HE30 and HE36 shown
56Flame Detection electrode replacement
1. Refer to Frame 51.
2. Remove the boiler front panels and inner sealing panel. Refer to
Frames 44 and 45.
22mm +- 1 (HE15, HE18, HE24)
16mm +- 1 (HE30, HE36)
3. Unplug the flame detection lead from the electrode.
4. Remove the burner. Refer to Frame 54.
5. Remove the 2 screws holding the flame detection electrode to the
combustion chamber.
6. Remove the flame detection electrode.
7. Fit the new flame detection electrode, using the new gasket supplied.
Check dimension as shown.
8. Reassemble in reverse order and check that no damage to the
combustion chamber insulation has occurred during the electrode
replacement. (HE15, HE18 and HE24 only).
9. Check operation of the boiler. Refer to Frame 51.
mxhe7695
5
mexico HE24 shown
mxhe7714
5
mexico HE - Installation & Servicing
mexico HE30 and HE36 shown
39
Servicing
57 Spark generator replacement
1. Refer to Frame 51.
4
4
2. Remove the boiler front panels
and inner sealing panel. Refer to
Frames 44 and 45.
3. Disconnect the leads from the
spark generator and bracket.
4. Remove the 2 M4 screws securing
the spark generator to the bracket.
5. Fit the new spark generator and
re-assemble in reverse order.
6. Check operation of the boiler.
Refer to Frame 51.
mexico HE30 and HE36
3
mexico HE15, HE18 and HE24
3
58 burner injector replacement
4
1. Refer to Frame 51.
2. Remove the boiler front panels and inner sealing panel.
Refer to Frames 44 and 45.
Copper washer
4. Remove the 2 injector housing screws.
6. Withdraw the injector housing.
7. Fit the new injector housing, complete with injector.
8. Reassemble in reverse order, ensuring that the new gas
seal supplied is located correctly in the injector housing.
9. Check operation of the boiler. Refer to Frame 51.
Rubber moulded seal
mxhe7750
59gas control valve replacement
1. Refer to Frame 51.
2. Remove the boiler front panels and inner sealing
panel. Refer to Frames 44 and 45.
3. Unplug the electrical lead from the gas control valve
and disconnect the earth wire.
8
4. Undo the sensing tube connection at the gas control
valve.
5. Undo the union nut at the gas valve pre-piping frame
connection.
6. Undo the union nut on the outlet side of the gas
control valve and remove valve.
7
7. Undo the 4 gas valve bracket screws, bracket and gas
inlet pipe and remove.
8. Remove the valve bracket fixing screw.
4
9. Transfer the mounting bracket and gas inlet pipe to
the new gas control valve.
10.Fit new gas control valve, ensuring that any seals
showing damage or deterioration are replaced.
mxhe7791
servicing
3. Remove the fan / venturi assembly. Refer to Frame 53.
3
6
5
11.Reassemble in reverse order.
12.Ensure the sensing tubing is correctly replaced.
13.Check operation of the boiler. Refer to Frame 51.
40
mexico HE - Installation & Servicing
Servicing
60control box replacement
3
1. Refer to Frame 51.
2. Remove the boiler upper front panel. Refer to Frame 44.
3. Remove the 2 control box mounting bracket screws.
4. Pull the control box forward. Carefully unplug all the electrical
wiring from the control box.
5. To remove the user control from the assembly pull the control
forward to disconnect the plug.
6. Transfer the mounting brackets to the new control box.
7. Reassemble in reverse order.
8. Check operation of the boiler. Refer to Frame 51.
6
Mounting brackets
N.B. To change the user control only.
9. Loosen the screw on the underside of the user
control.
10
10.Pull the display unit forward to remove.
11.Push the new display unit into position.
mxhe7699
12.Reassemble in reverse order.
Control box
9
servicing
13.Check the operation of the boiler. Refer to
Frame 51.
5
61 Wiring Harness Replacement
A pictorial wiring diagram is shown in Frame 36.
1. Refer to frame 51
2. Remove the boiler upper front panel. Refer to frame 44
3. Remove the sealing panel. Refer to frame 45
4. Disconnect the wiring harness from the Fan, Controls Box, Flow
Thermistor, Spark Generator, Gas Valve, Overheat Thermistor, Dry
Fire Thermistor, and Earth post.
5. Remove the condensate pump terminal strip securing screw to
gain access to the back of the terminal strips.
6. With an Allan key remove the ‘rivscrew’ from the back of the
brackets to release the terminal block.
6
7. Reassemble the new harness to the brackets in reverse order.
62mains switch replacement
1. Refer to Frame 51.
2. Remove the boiler upper front panel. Refer to Frame 44.
3. Remove the screws retaining the user control. Refer to
Frame 60, No. 3.
4. Push out the mains switch from the rear, as shown.
5. Refit the new switch, ensuring that the electrical leads are
replaced on the correct terminals and the key on the switch is
correctly aligned with the slot in the plastic moulding.
6. Reassemble in reverse order.
7. Check operation of the boiler. Refer to Frame 51.
Red
Brown
Electrical
connections
5
4
mexico HE - Installation & Servicing
41
Servicing
63overheat thermostat replacement
mexico HE15, HE18 & HE24
1. Refer to Frame 51.
2. Remove the boiler front panels and inner sealing panel
(HE30 and HE36 only). Refer to Frames 44 and 45.
3. Pull off the 2 electrical leads from the thermostat body.
4. Remove the 2 screws retaining the O/H thermostat.
5. Fit the new thermostat, and reconnect leads
6. Reassemble in reverse order.
7. Check operation of the boiler. Refer to Frame 51.
3
mexico HE30 & HE36
4
servicing
4
3
64 Dry Fire thermistor replacement
1. Refer to Frame 51.
2. Remove the boiler front panels and inner sealing panel.
Refer to Frames 44 and 45.
mexico HE30 & HE36
3. Drain down the system.
4. Pull off the electrical connection.
5. Unscrew and withdraw the thermistor.
6. Fit the new thermistor, using the gasket supplied.
7. Reassemble in reverse order.
8. Check operation of the boiler. Refer to Frame 51.
mexico HE15, HE18 & HE24
4
5
4
5
42
mexico HE - Installation & Servicing
Servicing
65combustion chamber insulation replacement (HE15, HE18 and HE24 only)
Insulation now supplied as one piece which is flexible and easy to shape and install
Ideal Boilers recommends that, for your own comfort and safety and to
comply with good working practice, the procedure described below is
followed:
11. Sweep any dampened particles and place in the plastic bag.
1. Refer to 'Replacement of Components' Frame.
2. Remove the boiler front and sealing panels. Refer to 'Boiler Front
Panel Removal' and 'Boiler Sealing Panel Removal' Frame.
(a) Locate and align the insulation with the electrode holes and
position the insulation into the combustion chamber.
(b) Push the flexible material into the corners of the combustion
chamber ensuring it is flat and flush against the combustion
chamber wall.
(c) Interlock the insulation piece along the back wall of the
combustion chamber.
(d) Again push the flexible material into the corners of the
combustion chamber ensuring it is flat and flush against the
combustion chamber wall.
(e) Secure the insulation by replacing the ionisation probes with
those supplied in the kit. Note that ionisation probes are a
serviceable component and require inspecting annually.
4. Remove the burner. Refer to 'Burner removal and cleaning' Frame.
5. Remove the ignition electrode. Refer to 'Ignition Electrode
replacement' Frame.
6. Remove the flame detection electrode. Refer to 'Flame Detection
electrode replacement' Frame.
7. Remove the front and rear ionisation probes and discard.
Prior to removal of the board the following protective equipment should
be worn:
- Face mask supplied with the spare part.
- Gloves supplied with the spare part.
8. Damp down the combustion chamber area containing the
insulation boards.
9. Remove the split pin and washer from the RHS of the combustion
chamber and discard.
10. Remove the insulation boards. The replacement one piece
insulation board is supplied in a plastic bag. This bag should be
retained and the discarded boards should now be placed into it.
Old Style Insulation
10
Note. The insulation is designed to be interlocking and should be fitted
as shown.
13. Remove the gloves and face mask and place them in the plastic
bag.
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.
15. Reassemble in reverse order.
16. Check operation of the boiler. Refer to 'General Checks' Frames.
New Style Insulation
LH Side
Ionisation
Probes
9
Rear
Front
7
Combustion
chamber
Insulation
RH Side
Combustion
chamber
6
5
esp9466
mexico HE - Installation & Servicing
43
servicing
3. Remove the fan / venturi assembly. Refer to 'Fan and Venturi
Assembly removal and cleaning' Frame.
12. Fit new insulation board -
Servicing
66heat exchanger replacement
Refer also to Frame 10, ‘Boiler exploded view’.
13
1. Refer to Frame 51.
2. Remove boiler front panels and inner sealing panel refer
frames 44 & 45.
3. Remove the outer wall sealing plate (if fitted) and turn the
terminal anticlockwise to unlock the turret bayonet fixing
and pull the terminal to disconnect the boiler turret from
the flue assembly.
4. Fully drain the system
5. Disconnect the gas, water flow & water return union
connections at the pre-piping frame
6. Disconnect the condensate connection at the ‘S’ trap and
the condensate pump (if fitted)
7. Protect the floor area front of the boiler, remove the
screws fixing the boiler to the pre-piping frame and pull
the boiler forward to clear any kitchen unit obstructions
taking care with the electrical wiring.
14
8. Remove the fan & venturi assembly (refer to frame 46)
9. Remove burner (refer to frame 47)
servicing
10.Remove ignition electrode (frame 55) & detection
electrode (frame 56)
11.HE30 & HE36 models only – Remove the spark
generator (frame 57) and remove the electrical
connections from the flow thermistor (frame 52 and the
overheat thermostat (frame 63)
12.Remove the dry fire thermostat (frame 64)
13.HE15, 18 & 24 only – Remove the rubber plug to gain
screwdriver access to the fixing screw retaining the heat
exchanger bottom right copper pipe bracket and remove
the screw.
15
14.HE30 &36 only – Unscrew the copper pipe connection at
the top left of the heat exchanger and remove the pipe by
pulling upwards through the rubber grommet.
15.Remove the 4 screws retaining the flue turret and remove
the turret.
16.Remove the 4 screws retaining the flue support bracket.
17.Remove the 19 screws retaining the rear air box and
remove the box.
18.HE15, 18 & 24 only- Pull the flue elbow bracket slightly
sideways to release the elbow and pull the plastic flue
elbow assembly from its joint.
19.HE30 &36 only- Pull the plastic pipe from its joint.
16
17
18
19
continued . . . .
44
mexico HE - Installation & Servicing
Servicing
67heat exchanger replacement . . .continued
20.HE15, 18 & 24 only- Unscrew the 5mm
hex. Hd. Screw retaining the copper pipe
retention plate and remove plate.
20
21.HE30 & 36 only - Unscrew the return
connection union.
21
22
22.Remove the 5 screws retaining the sump.
23.Remove the ‘S’ trap bracket fixing screw and remove the
‘S’ trap.
servicing
24.Lift the heat exchanger to clear the bottom panel, pull
forward and remove.
25.Fit the new heat exchanger, reassembling in reverse
order, replacing gaskets or seals if any sign of damage
or deterioration is evident. To ensure a positive flue seal
is confirmed it may be necessary to remove the worktop
or adjacent cupboard to view the joint.
26.Check the operation of the boiler. Refer to frame 51.
23
22
68 inner sealing panel seal replacement
1. Refer Frame 51.
2. Remove the boiler front panels and refer to
Frame 44.
3. Remove the inner sealing panel. Refer to
Frame 45.
4. Remove the old seal from the panel and
thoroughly clean the panel surfaces.
5. Fit the new adhesive seals - note that they
are supplied to the correct length for the
relevant sides.
Note.
Ensure that the boiler sealing panel is correctly
seated, compressing the seal to make an airtight
joint.
7. Check operation of boiler. Refer to
Frame 51.
mexico HE - Installation & Servicing
mxhe7614
6. Reassemble in reverse order.
45
Servicing
69 Condensate ‘S’ trap replacement & condensate Pump (if Fitted)
1. Refer to Frame 51.
2. Remove the boiler front panels. Refer to Frame 44.
3. Condense pump removal (if fitted):
a. Disconnect the outlet pipe rubber connecting joint
taking care to capture any liquid held in the pipe.
b. Lift the inlet pipe to clear the pump.
Outlet pipe
3b
Inlet pipe
from ‘S’ trap
c.
Remove the pump wiring cover.
d. Remove the 5 wires from the terminal strip.
3a
e.
Lift the condensate pump from the two screw
fixings.
f.Pull the pump forward and remove the wiring
through the top grommet.
3e
servicing
3c
5
4
4. Undo the plastic union nut on the condensate ‘S’ trap
outlet and disconnect the flexible hose.
5. Remove the screw retaining the ‘S’ trap bracket and
remove the bracket.
6. Loosen the top nut on the ‘S’ trap then pull the trap down
and forward to remove.
7. Reassemble in reverse order, ensuring the condensate
pump is correctly replaced.
8. Check operation of the boiler. Refer to Frame 51.
6
46
mexico HE - Installation & Servicing
Fault finding
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
70 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:
IF BOILER FAILS TO RUN WHEN
DEMAND IS PRESENT
GO TO FRAME 71
ALTERNATING ‘L’ ‘F’
GO TO FRAME 72
ALTERNATING ‘L’ ‘E’ OR ‘HE’
GO TO FRAME 73
ALTERNATING ‘L’ ‘A’
GO TO FRAME 74
ALTERNATING ‘L’ ‘8’
GO TO FRAME 75
ALTERNATING ‘H’ ‘1’
GO TO FRAME 76
ALTERNATING ‘H’ ‘F’
GO TO FRAME 77
ALTERNATING ‘H’ ‘4’ or ‘H9’ or ‘L9’
GO TO FRAME 78
ALTERNATING ‘H’ ‘n’
GO TO FRAME 79
71 Condensate Pump Failure
Is switched live present on the L2
terminal?
NO
Check external controls wiring and
function.
yes
Power down the boiler and check for
continuity between the common (C)
and normally closed (NC) wires on the
condensate pump. Is there continuity?
NO
Check condensate pump reservoir is
empty and check overflow float switch is
moving freely.
NO
Check wiring continuity from L2 through
to the PCB J1 black wire.
yes
Re-apply power to the boiler. Is switched live
present on the common (C) terminal of the
condensate pump connector?
yes
Follow normal boiler fault finding procedure.
mexico HE - Installation & Servicing
47
Fault finding
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
72 L.....F.......
(Flame error)
If the boiler reset button is
pressed does the boiler ignite for
a short time then extinguish?
NO
NO
Is gas pressure available at
the boiler inlet ?
Check gas supply
and rectify fault
YES
yes
NO
Is 200V DC supply available
at the gas valve ?
Check the detection electrode and
associated harness for:
continuity, visual condition, position
(Refer to Frame 56).
Check gas valve
wiring for continuity
YES
Replace PCB
Replace as necessary.
Check spark generator and associated
harness for continuity and visual condition.
Refer to Frame 57. Are these functioning
correctly?
NO
Replace
spark generator
YES
Check the ignition electrode and associated harness for:
continuity, visual condition, position
(Refer to Frame 55)
NO
Replace ignition electrode and associated
harness as necessary
Are these functioning correctly ?
NO
Check syphon and
condensate drain
pipework for blockage
Replace gas
valve
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 multimeter a mains checking device may be used. E.g. an electrical screwdriver or a mains tester.
73L.....E......orH.....E......
Check for an excess voltage
between neutral and earth.
Is the value below 50V?
(board 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
NO
Correct wiring or replace
thermostat
NO
Correct wiring or replace
detection lead
YES
LE ONLY:
Check Continuity of OH thermostat.
Is this correct?
YES
HE ONLY: Check earth wire is
connected to detection lead.
Is this correct?
Turn boiler off and wait for 5
seconds.Turn boiler on.
Does boiler operate correctly?
YES
YES
Check all earths for continuity.
Is continuity OK?
NO
Correct Connection
YES
Internal fault within the PCB
48
NO
Press and hold reset
button for 2 seconds.
Does boiler operate
correctly?
OK
NO
Replace
PCB
NO
YES
OK
mexico HE - Installation & Servicing
Fault finding
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
NO
Does the pump setting give a differential across
the boiler in excess of 25 oC ?
YES
Over 90 oC Check control thermistor
(Refer to Frame 52) .
Increase the pump setting.
Is differential now below 25 oC ?
yes
NO
Replace the system pump
75 L....8.....
Set CH control knob to maximum.
If the overheat trips again measure the flow temp:
OK
Under 90 oC Replace overheat ‘stat
Note. With V9 Primary Control PCB, overheat LA/HA or H9/L9 when
reset will display 3 horizontal lines and will not attempt to re-fire until
the temperature in the heat exchanger drops below 50oC.
(fan error)
YES
Is nominal 330 V DC present across
red and blue at the fan connector as
reset button is pressed?
Is 14V DC present
across yellow and pink
at the fan connector?
YES
Replace fan
NO
NO
YES
Check wiring harness for continuity. Is there continuity?
76 H.....1.....
NO
Replace PCB
Replace harness
(flow thermistor error)
Remove the boiler flow thermistor from the CH flow
pipe and disconnect thermistor wires.
Check resistance, using a suitable multimeter
connected across the thermistors terminal pins
At 25 oC expect 9,700 -10,300
Ohms
At 60 oC expect 2,400- 2,600
Ohms
At 85 C
Ohms
o
expect
1,000 - 1,100
Are the thermistor values correct ?
yes
Is there continuity between the
PCB and the thermistor ?
mexico HE - Installation & Servicing
NO
yes
NO
Replace the thermistor
Replace PCB
Check and replace wiring as necessary
49
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
74l.......A........ (overheat error)
Fault finding
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
77 H......F........
(flame detection - short circuit error)
Remove flame detection electrode terminal from PCB.
NO
Replace PCB.
Is there continuity between the 2 terminal pins ?
YES
Replace flame detection electrode
78
H.....4...... (DRY FIRE thermistor error)
H9/L9 (Flue gas Overheat)
Can the fault condition be reset by switching off
the mains supply to the boiler ?
Is the system filled and vented and all isolation
valves open ?
Is the pump operating correctly? Ensure flow
through system.
NO
yes
Check wiring for continuity from the PCB
to the dry fire thermistor
Fill and vent the
system and open all
isolating valves
Check resistance, using a suitable multimeter
connected across the flue thermistor terminal pins.
Check resistance, using a suitable multimeter
connected across the dry fire thermistor terminal
pins.
At 25 oC expect 9,700 -10,300
Ohms
At 60 C expect 2,400- 2,600
Ohms
At 85 oC expect 1,000 - 1,100
Ohms
o
NO
At 25 oC expect 9,700 -10,300
Ohms
At 60 Cexpect 2,400- 2,600
Ohms
At 85 oC expect
Ohms
o
1,000 - 1,100
Are thermistor values correct ?
yes
Are dry fire thermistor values correct ?
yes
Replace PCB
Inspect heat
exchanger for
blockage or damage
in the flueways.
Clean or replace as
necessary
NO
Replace dry fire
thermistor
NO
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 re-fire until the temperature in the heat
exchanger drops below 50oC.
79H......n........
(phase reversal error)
Check wiring to the boiler for
reversed live and neutral
50
mexico HE - Installation & Servicing
SPARE parts
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. Failure to do so
could affect safety or performance of this appliance.
Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www.idealparts.com
Our Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665.
When calling, and to ensure we can provide you with the most accurate parts information, please ensure you have the following to
hand;
-
Boiler Model
-
Appliance GC Number
-
Boiler Serial Number
mexico HE - Installation & Servicing
51
Benchmark Commissioning and
Servicing Section
It is a requirement that the boiler is installed and commissioned to the
manufacturers instructions and the data fields on the commissioning checklist
completed in full.
To instigate the boiler guarantee the boiler needs to be registered with the
manufacturer within one month of the installation.
To maintain the boiler guarantee it is essential that the boiler is serviced annually
by a Gas Safe registered engineer who has been trained on the boiler installed.
The service details should be recorded on the Benchmark Service Interval
Record and left with the householder.
www.centralheating.co.uk
© Heating and Hotwater Industry Council (HHIC)
GAS BOILER SYSTEM COMMISSIONING CHECKLIST
This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating
compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference.
CONTROLS
Programmable room thermostat
Optimum start control
Combination Boiler
Fitted
Fitted
Fitted
Automatic bypass to system
Fitted
Boiler interlock
ALL SYSTEMS
Yes
Yes
CENTRAL HEATING MODE
OR
mbar
OR
mbar
Central heating return temperature
COMBINATION BOILERS ONLY
Yes
Yes
DOMESTIC HOT WATER MODE
OR
mbar OR
mbar
Cold water inlet temperature
Yes
Temperature
CONDENSING BOILERS ONLY
Yes
ALL INSTALLATIONS
AND
²
Ratio
AND
²
Ratio
Yes
Yes
Yes
Yes
* Allinstallations in England and Wales must be
to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance
will then be issued to the customer.
www.centralheating.co.uk
SERVICE RECORD
It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed.
Service Provider
SERVICE 01
SERVICE 02
AND
(Where Possible)
AND
AND
²%
²%
(Where Possible)
Signature
Signature
SERVICE 03
SERVICE 04
AND
(Where Possible)
AND
AND
²%
²%
(Where Possible)
Signature
Signature
SERVICE 05
SERVICE 06
AND
(Where Possible)
AND
(Where Possible)
Signature
SERVICE 07
SERVICE 08
AND
AND
(Where Possible)
Signature
SERVICE 09
SERVICE 10
AND
Signature
AND
AND
AND
²%
²%
Signature
(Where Possible)
AND
AND
²%
²%
Signature
(Where Possible)
AND
²%
²%
AND
AND
(Where Possible)
AND
²%
²%
²%
²%
²%
²%
²%
²%
²%
²%
Signature
* Allinstallations in England and Wales must be
to Local Authority Building Control (LABC) either directly or through a
Competent Persons Scheme. A Building Regulations Compliance
will then be issued to the customer.
© Heating and Hotwater Industry Council (HHIC)
www.centralheating.co.uk
FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO
CHECK ON COMMISSIONING A CONDENSING BOILER
Important Preliminary Information on Checks
The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING.
If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG) separate guidance is provided with the conversion kit supplied and this must be followed.
PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK
The installation instructions must have been followed, gas type verified and gas supply pressure / gas rate checked as
required prior to commissioning.
As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN
THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are
correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance
has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids).
The ECGA should be of the correct type, as specified by BS 7967.
Prior to its use, the ECGA should have been maintained and calibrated as specified by the manufacturer. The installer
must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer’s instructions.
KEY:
CO = carbon monoxide
CO2 = carbon dioxide
O2 = oxygen
Combustion Ratio = The CO reading measured in ppm divided by the CO2 reading first converted to ppm
ppm = parts per million
GS(I&U)R = Gas Safety (Installation and Use) Regulations
*Minimum Rate Setting:
Please note; this boiler cannot be set to operate continuously at minimum rate.
For further advice, contact Ideal Customer Services Department.
56
mexico HE - Installation & Servicing
Start
Set Boiler to Maximum Gas Rate
In accordance with boiler instructions,
set boiler to operate at maximum rate
(full load condition). Allow sufficient
time for combustion to stabilise.
Note. Do not insert analyser probe
during this period to avoid possible
flooding of sensor.
Carry Out Flue Integrity Check Using Analyser
Insert analyser probe into air inlet test point (where available) and allow
readings to stabilise.
Note. Where no air inlet test point is provided then a flue integrity check with
the analyser is not possible. The installer should verify that flue integrity has
been visually checked in accordance with the “Prior to CO level and
combustion ratio check” (see opposite page) before proceeding to the
“check CO level and combustion ratio at maximum rate” stage below.
Verify Flue Integrity
Analyser readings indicate that combustion products and inlet air
must be mixing. Further investigation of the flue is therefore required.
Check that flue components are assembled, fixed and supported as
per instructions. Check that flue and flue terminal are not obstructed.
Is
O2 more than or
equal to 20.6% OR CO2
less than or equal to
0.2%?
No
Yes
Is
O2 more than or
equal to 20.6% OR CO2
less than or equal to
0.2%?
Check CO level and Combustion Ratio
at Maximum Gas Rate
Yes
With boiler still set at maximum gas rate,
insert analyser probe into flue gas
sampling point. Allow readings to stabilise
before recording.
No
Turn off appliance and call Ideal Technical Helpline for advice
The appliance must not be commissioned until problems are identified
and resolved. If commissioning cannot be fully completed, the appliance
must be disconnected from the gas supply in accordance with GSIUR.
No
Yes
Check that no seals, e.g. Those on flue extensions, have
been displaced during installation. Rectify if necessary.
Is
CO level less
than 350ppm AND CO/CO2
ratio less than
0.0040?
Is
CO level less
than 350ppm AND CO/CO2
ratio less than
0.0040?
Set Boiler to Minimum Gas Rate
(*see opposite page)
In accordance with boiler instructions, set boiler to
operate at minimum rate (to minimum load condition).
Allow sufficient time for combustion to stabilise.
Yes
Check CO and Combustion Ratio at Minimum Gas Rate
With boiler set at minimum rate, insert analyser probe into flue
gas sampling point. Allow readings to stabilise before recording.
No
Turn off Appliance and Call Ideal Technical Helpline
The appliance must not be commissioned until problems
are identified and resolved. If commissioning cannot be
fully completed, the appliance must be disconnected from
the gas supply in accordance with GS(I&U)R. NOTE:
Check and record CO level and combustion ratio at both
maximum AND minimum rate before contacting Ideal.
No
Is
CO level less
than 350ppm AND CO/CO2
ratio less than
0.0040?
Yes
Boiler is Operating Satisfactorily
No further actions required.
Ensure test points are capped, boiler case is correctly replaced and all
other commissioning procedures are completed. Complete Benchmark
Checklist, recording CO and combustion ratio readings as required.
mexico HE - Installation & Servicing
57
Notes
58
mexico HE - Installation & Servicing
Notes
mexico HE - Installation & Servicing
59
For additional fault finding advice please visit our website
www.idealboilers.com
Technical Training
The Ideal 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
Manufactured under an ISO 9001
registered quality management system
The code of practice for the installation,
commissioning & servicing of central heating systems
FM 59915
Ideal Boilers Ltd., 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 Boilers Ltd., 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 498 663
www.idealboilers.com
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