Ideal Icos 30kw - 36kw V3 manual
installation and
servicing
icos
Your Ideal installation and servicing guide
See reverse for icos users guide
For details of document amendments, refer to page 3
HE30, HE36
When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require. Do not
use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
January 2008
UIN 202414 A06
For the very latest copy of literature for specification purposes please visit our website
www.idealboilers.com where you will be able to download the relevant information in pdf format.
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DOCUMENT AMENDMENTS
Relevant Installation changes implemented in this book from Mod Level ............ A05 (Oct 06) to A06 (Jan 08)
•
Various Changes
Company Name Change.
•
Page 9, Electrical Supply
Note for fan voltage.
•
Page 21, Frame 25 - Condensate Pipe Termination Configurations
Statement added with ref. to termination into a down pipe.
•
Page 20 & 21, Frames 24 & 25 - Condensate Pipe Termination Configurations
BS6798 recommends that a second trap and an air break are required where the siphon trap within the boiler is less than
75mm for configuration 2 and 3.
•
Page 30, Frame 41 - Initial Lighting
Display code “P” added to “The Display” paragraph.
•
Page 45, Frame 70 - L... F... (Board Error)
Addition of new flow chart.
•
Page 46, Frame 72 - L... A... (Overheat Error)
Note added.
•
Page 47, Frame 76 - H9/L9 Flue Gas Overheat
Note added.
•
Page 48 - Short List of Parts
Part number change to PCB Primary Control.
•
Users Guide, Page 2 - Important Notes
2 new bullet points added.
•
Users Guide, Page 2 - Operation
Addition of display code “P”.
Ideal Stelrad Group reserve the right to vary specification without notice
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GENERAL
Table 1 - Boiler Data
Boiler Size
HE30, HE36
2H-G20-20 mbar Rc1/2 (1/2" BSP Female)
Gas supply type and connection
Injector size
Stereomatic 5.6mm dia.
Flow connection
28mm copper
Return connection
28mm copper
Flue terminal diameter
mm (in.)
100 (4)
Maximum static water head
m (ft.)
30.5 (100)
Minimum static water head
m (ft.)
0.45 (1.5)
Electrical supply
230 V ~ 50 Hz
Boiler power consumption
42W
Fuse rating
External: 3A Internal: T3.15A L250 V
IP rating
IP20
Water content
litre (gal.)
4.7 (1.0)
Packaged weight
kg (lb.)
56.2 (124)
Maximum installation weight
kg (lb.)
52.6 (116)
Boiler size
Height mm (in.)
645 (25 1/2")
Width mm (in.)
450 (17 3/4")
Depth mm (in.)
410 (16")
Table 2 - Performance Data
Boiler Size
Boiler input 'Q' =
HE 36 Max
HE 30-36 Min
Nett CV
kW
Btu/h
30.7
104,700
37.5
128,000
10.6
36,200
Gross CV
kW
Btu/h
34.0
116,000
41.6
142,000
11.8
40,300
0.88 (111.9)
1.07 (136.0)
0.30 (38.4)
Gas consumption
Boiler output 'P' =
HE 30 Max
l/s (cu.ft/h)
o
70 C Mean water
temperature
kW
Btu/h
30.1
102,700
37.0
126,200
10.4
35,500
40 oC Mean water
temperature
kW
Btu/h
32.8
111,800
39.8
135,800
11.4
38,900
Band A
[90.7]%
[90.7]%
-
95.9
96.7
-
Seasonal efficiency (SEDBUK) *
Seasonal boiler efficiency (Building Regs L2)
NOx classification
*
Class 5
The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings.
The test data from which it has been calculated have been certified by a notified body.
Note.
Key to symbols
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 Kingdom
a. For l/s - divide the gross heat input (kW) by the gross
C.V. of the gas (MJ/m3)
3
b. For ft /h - divide the gross heat input (Btu/h) by the
gross C.V. of the gas (Btu/ft3)
IE = 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.
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.
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GENERAL
icos
CONTENTS
Air Supply ....................................................................... 9
Natural Gas only
Boiler size
HE30
HE36
Benchmark Commissioning Checklist ..................... 54
G.C. Appliance No.
(Benchmark No.)
PI No.
41-399-10
41-399-16
87 BQ 79
87 BQ 79
Destination Countries:
Boiler Clearances ......................................................... 6
Boiler Exploded Diagram ............................................ 14
GB, IE
Electrical Connections ............................................... 26
Electrical Supply ........................................................... 9
Electrical Wiring Diagrams ........................................ 28
Extension Ducts - Fitting ............................................. 19
Fault Finding ................................................................. 44
Flow Wiring Diagram .................................................. 28
Flue Fitting .................................................................... 18
Flue Installation Requirements .................................... 8
Gas Safety Regulations ................................................ 8
Gas Supply ..................................................................... 8
Initial Lighting .............................................................. 30
Installation ................................................................... 14
Mandatory Requirements ............................................. 7
Safe Handling ................................................................ 7
Servicing ...................................................................... 32
Short List of Parts ....................................................... 50
Terminal Guards ............................................................ 8
Thermostatic Radiator valves .................................... 9
Water and Systems .................................................... 10
Water Connections ....................................................... 6
Water Treatment ......................................................... 13
For GB, to comply with Building Regulations Part L1 (Part J in Scotland) the boiler should be fitted in accordance with the
manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Commissioning Checklist.
BENCHMARK COMMISSIONING CHECKLIST DETAILS
Boiler
Page
Make and model ....................................................... 5
Appliance serial no. on data badge ...................... 14
SEDBUK No. % ......................................................... 4
Controls
Time and temperature control to heating ............. 29
Time and temperature control to hot water .......... 29
Heating zone valves .............................................. n/a
TRV's ......................................................................... 9
Auto bypass .............................................................. 9
Boiler interlock .......................................................... 9
For all boilers
Flushing to BS.7593 .............................................. 13
Inhibitor .................................................................. 13
Central heating mode
Heat input ................................................ to be calculated
Page
Burner operating pressure .................................... n/a
Central heating flow temp. ...... measure and record
Central heating return temp. ... measure and record
For combination boilers only
Scale reducer ......................................................... n/a
Hot water mode
Heat input ............................................................... 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 .................................................. 20
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
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GENERAL
1
BOILER WATER CONNECTIONS
The boiler flow and return pipes (28mm) are supplied fitted to the boiler ready for
top connection.
The flow and return pipes should be continued in 28mm while the system load is
above 60,000 Btu (17.6 kW). Below which they may be reduced to 22mm.
Notes.
a. This appliance is NOT suitable for use with a direct hot water cylinder.
b. If the boiler is to be used on a sealed system an overheat thermostat is fitted
as standard
2
BOILER CLEARANCES
SIDE FLUE ONLY
Horizontal length of flue
from centre line of boiler
to outside wall
The following minimum clearances must be maintained for
operation and servicing.
Additional space will be required for installation, depending upon
site conditions.
Side and Rear Flue
a
Provided that the flue hole is cut accurately, e.g. with a core drill,
the flue can be installed from inside the building where wall
thicknesses do not exceed 600mm (24"). Where the space into
which the boiler is going to be installed is less than the length of
flue required the flue must be fitted from the outside.
Top clearance
required (MIN.)
Dim. A
0.5 m
165 mm (6 1/2")
1.0 m
170 mm (6 11/16)
1.5 m
185 mm (7 1/4")
2.0 m
200 mm ( 7 7/8")
2.5 m
210 mm (8 1/4")
3.0 m
225 mm (8 7/8")
Installation from inside ONLY
b. If a core boring tool is to be used inside the building the space in
which the boiler is to be installed must be at least wide enough
to accommodate the tool.
REAR FLUE ONLY
MIN. Top clearance required = 145 mm
all dimensions in mm
137
15 from case
410
450
400
56
115
A
50
55
nm8112
nm8113
645
150
59
300 (approx)
218
480
52
*
Front clearance
The minimum front clearance when built in to a cupboard
is 5mm from the cupboard door but 450mm overall
clearance is still required, with the cupboard door open, to
allow for servicing.
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Bottom clearance
after installation can be reduced to 5mm. However,
150mm must be available for servicing.
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GENERAL
INTRODUCTION
The icos range of boilers are a fully automatically controlled,
wall mounted, low water content, balanced flue, fanned,
condensing gas boiler. It has full modulating central heating
outputs of :
HE30 10.4 kW (35,600 Btu/h) to 30.1 kW (102,700 Btu/h).
HE36 10.4 kW (35,600 Btu/h) to 37 kW (126,200 Btu/h).
Due to the high efficiency of the boiler a plume of water vapour
will form at the flue terminal during operation depending on
external conditions.
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.
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.
OPERATION
When there is a demand for heat, the heating system is
o
supplied at the selected temperature of between 30 C and
o
82 C.
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.
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.
OPTIONAL EXTRA KITS
z
z
z
z
Condensate Pump Kit
Remote User Control Kit
Siphon Kit
Stand Off Kit
Fluing Kits:
z 45o Elbow Kit (maximum 2 elbows per installation)
z
z
z
z
z
z
z
z
90o Elbow Kit (maximum 2 elbows per installation)
Flue Deflector Kit
Flue Extension Ducts - D Pack (1000mm long up to 3m)
Flue Finishing Kit
High Level Flue Outlet Kit
Roof Flue Kit (to a maximum of 5m)
Twin Flue Kit
Vertical Outlet Kit
SAFETY
Current Gas Safety (Installation and Use) Regulations or
rules in force.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI
Registered Installer. It must be carried out in accordance with
the relevant requirements of the:
• Gas Safety (Installation and Use) Regulations
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (northern Ireland).
• The Water Fittings Regulations or Water byelaws 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 Competent
Person and installed in accordance with the current edition of
I.S.813 "Domestic Gas Installations", the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
Detailed recommendations are contained in the following British
Standard Codes of Practice:
BS. 5440:1
Flues (for gas appliances of rated input not
exceeding 70 kW).
BS. 5440:2
Ventilation (for gas appliances of rated input not
exceeding 70 kW).
BS. 5449
Forced circulation hot water systems.
BS. 5546
Installation of gas hot water supplies for
domestic purposes (2nd Family Gases).
BS. 6798
Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS. 6891
Low pressure installation pipes.
Health & Safety Document No. 635
The Electricity at Work Regulations, 1989.
The manufacturer’s notes must NOT be taken, in any way, as
overriding statutory obligations.
IMPORTANT. These appliances are CE certificated for safety
and performance. It is, therefore, important that no external
control devices, e.g. flue dampers, economisers etc., are
directly connected to these appliances unless covered by these
Installation and Servicing Instructions or as otherwise
recommended by Ideal Stelrad Group in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by Ideal
Stelrad Group 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.
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GENERAL
LOCATION OF BOILER
The boiler must be installed on a flat and vertical wall, capable
of adequately supporting the weight of the boiler and any
ancillary equipment.
The boiler may be fitted on a combustible wall and insulation
between the wall and the boiler is not necessary, unless
required by the local authority.
For electrical safety reasons there must be no access 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/7:1998.
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the
rate of gas supply required.
N.B. The principle of the 1:1 gas valve ensures that the icos
HE range is able to deliver it’s full output at inlet pressures
down to 14mb. However if dynamic pressures below 20mb are
experienced ensure this is adequate for ALL other gas
appliances in the property.
IMPORTANT.
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 soundness
and purged as described in the above code.
Bathroom Installations
This appliance is rated IP20.
The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of the
current IEE (BS.7671) Wiring Regulations and, in Scotland, the
electrical provisions of the building regulations applicable in
Scotland, with respect to the installation of the boiler in a room
or internal space containing a bath or shower. For Ireland
reference should be made to the current ETCI rules for electrical
installations and I.S.813:2002.
If the appliance is to be installed in a room containing a bath or
shower then, providing water jets are not going to be used for
cleaning purposes (as in communal baths/showers), the
appliance can be installed in Zone 3, as detailed in BS.7671.
Compartment Installations
A compartment used to enclose the boiler should be designed
and constructed specially for this purpose.
An existing cupboard or compartment may be used, provided
that it is modified for the purpose.
In both cases details of essential features of cupboard /
compartment design, including airing cupboard installation, are
to conform to the following:
z BS. 6798. (No cupboard ventilation is required - see “Air
Supply” for details).
z The position selected for installation MUST allow adequate
space for servicing in front of the boiler.
z For the minimum clearances required for safety and
subsequent service see the wall mounting template and
Frame 2. In addition, sufficient space may be required to
allow lifting access to the wall mounting plate.
z If the appliance is using a B23 twin flue pipe system then
compartment ventilation is required. Refer to Installation
Instructions for the 80/80 twin flue system.
Boiler House Installations
When installed in a separate boiler house and using the air
inlet with the twin pipe flue system, ventilation must be in
accordance with BS5440:2.
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.5440-1:2000. In IE refer to I.S.813:2002.
The following notes are intended for general guidance.
1. The boiler MUST be installed so that the terminal is
exposed to external air.
2. It is important that the position of the terminal allows the
free passage of air across it at all times.
3. Minimum acceptable spacing from the terminal to obstructions
and ventilation openings are specified in Table 3.
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 2000
25mm ( 1")*
75mm (3")
3. Below eaves.
BS5440-1 2000
25mm (1")*
200mm (8")
4. Below balconies or a car port roof.
BS5440-1 2000
25mm (1")*
200mm (8")
5. From vertical drain pipes or soil pipes.
BS5440-1 2000
25mm (1")*
150mm (6")
6. From an internal or external corner or to a
boundary along side the terminal.
BS5440-1 2000
25mm (1")*
300mm (12")
7. Above adjacent ground, roof or balcony level.
300mm (12")
8. From a surface or a boundary facing the terminal.
600mm (24")
9. From a terminal facing a terminal.
1,200mm (48")
10. From an opening in a car port
(e.g. door or window) into dwelling.
1,200mm (48")
11. Vertically from a terminal on the same wall.
1,500mm (60")
12. Horizontally from a terminal on the wall.
300mm (12")
Vertical Terminals
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.
The boiler MUST be installed on a gas supply with a governed
meter only.
A gas meter can only be connected by the local gas supplier or
by a CORGI registered engineer. In IE by a Competent Person.
300mm (12")
300mm (12")
14. From a single wall face - Flat Roof
From a single wall face - Pitched Roof
From corner walls.
600mm (24")
1000mm (40")
1000mm (40")
Twin Flue Applications
15. Centre distance between air inlet and flue
outlet ducts.
120mm (5")
* Only one reduction down to 25mm is allowable per installation
otherwise BS5440-1 2000 dimensions must be followed.
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13. Above the roof pitch with roof slope of all angles.
Above flat roof.
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GENERAL
Ensure that the guard is fitted centrally.
Terminal guards are available from boiler suppliers. Ask for
TFC Flue Guard Model No. K3 (round plastic-coated). In
case of difficulty contact:
Grasslin (UK) Ltd.
Tower House, Vale Rise
Tonbridge. Kent TN9 1TB
Tel. +44(0) 01732 359 888
Fax. +44(0) 01732 354 445
www.tfc-group.com
5. The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of any building.
6. The air inlet/products outlet duct and the terminal of the
boiler MUST NOT be closer than 25mm (1") to combustible
material. Detailed recommendations on the protection of
combustible material are given in BS.5440-1:2000. In IE
refer to I.S.813:2002.
The boiler must be vented.
The hydraulic resistance of the boilers, at MAXIMUM OUTPUT,
o
o
with an 11 C (20 F) temperature differential, is shown in
Graph 1.
Graph 1 - Water flow rate and pressure loss
0.7
Resistance (metres water)
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.
0.6
0.5
0.4
0.3
0.2
0.1
0
5
IMPORTANT.
It is absolutely ESSENTIAL to ensure, in practice, that products
of combustion discharging from the terminal cannot re-enter the
building or any other adjacent building through ventilators,
windows, doors, other sources of natural air infiltration, or
forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF, labelled
as 'unsafe' until corrective action can be taken.
TERMINAL
The terminal assembly can be adapted to accommodate
various wall thicknesses. Refer to Frame 14.
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.
Only for boiler house installation must BS5440:2 be adhered to.
10
15
20
25
Flow rate (l/m)
Ideal Stelrad Group recommend that heating systems utilising
full thermostatic radiator valve control of temperature in
individual rooms should also be fitted with a room thermostat
controlling the temperature in a space served by radiators not
fitted with such a valve as stated in BS. 5449.
Central heating 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.
ELECTRICAL SUPPLY
IMPORTANT.
WARNING.
This appliance must be earthed.
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.
35
BOILER CONTROL INTERLOCKS
WATER CIRCULATION SYSTEM
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.
30
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.
Note. The Fan voltage is 325V DC.
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.
CONDENSATE DRAIN - Refer to Frames 23, 24, 25 & 49
A condensate drain is provided on the boiler. This drain must
be connected to a drainage point. All pipework and fittings in
the condensate drainage system MUST be made of plastic - no
other materials may be used.
IMPORTANT.
Any external runs must be insulated.
The drain outlet on the boiler is standard 21.5mm (3/4”) overflow
pipe.
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GENERAL
3
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
o
o
maximum 11 C (20 F) 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
o
differential must not exceed 25 C.
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 Stelrad Group. The isolation valves should be fitted
as close to the pump as possible.
4
SCHEMATIC 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 in condensing mode, 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
o
20 C 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
o
11 C 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
o
differential temperature of 20 C across
the boiler is not exceeded.
4. Adjust room and cylinder thermostats
and programmer to NORMAL settings.
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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.
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.
Note. The pump manufacturers' minimum requirements must be complied with.
6
All dimensions in mm (in.).
NB. Imperial dimensions are approximate
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
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.
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.
c.
Hosepipe
(disconnect
after filling)
Hose unions
Additional
stop valve
ecl6060
1. General
a.
Automatic
air vent
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.
Temporary hose
(disconnect
after filling)
a.
Double check valve
assembly
(note direction of flow)
A non-adjustable preset lift pressure not exceeding
3bar (45lb/in2).
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.
3. Pressure Gauge
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:
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.
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Hose connector
11
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GENERAL
SEALED SYSTEM REQUIREMENTS - continued
7
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).
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.
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.
pressure. The cold feed pipe from the cistern should
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.
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.
• 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.
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
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).
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GENERAL
8
SEALED SYSTEM REQUIREMENTS - continued
Safety valve setting
3.0 bar
Vessel charge and initial
system pressure
0.5
bar
2.5 bar
1.0
bar
1.5
bar
Total water content of system
litres
0.5
bar
1.0
bar
2.0 bar
1.5
bar
0.5
bar
1.0
bar
Expansion vessel volume litres
25
2.1
2.7
3.9
2.3
3.3
5.9
2.8
5.0
50
4.2
5.4
7.8
4.7
6.7
11.8
5.6
10.0
75
6.3
8.2
11.7
7.0
10.0
17.7
8.4
15.0
100
8.3
10.9
15.6
9.4
13.4
23.7
11.3
20.0
125
10.4
13.6
19.5
11.7
16.7
29.6
14.1
25.0
150
12.5
16.3
23.4
14.1
20.1
35.5
16.9
30.0
175
14.6
19.1
27.3
16.4
23.4
41.4
19.7
35.0
200
16.7
21.8
31.2
18.8
26.8
47.4
22.6
40.0
225
18.7
24.5
35.1
21.1
30.1
53.3
25.4
45.0
250
20.8
27.2
39.0
23.5
33.5
59.2
28.2
50.0
275
22.9
30.0
42.9
25.8
36.8
65.1
31.0
55.0
300
25.0
32.7
46.8
28.2
40.2
71.1
33.9
60.0
Multiplying factors for
other system volumes
0.0833
0.109
0.156
0.094
0.134
0.237
0.113
0.20
9
WATER TREATMENT
The icos boiler range have an ALUMINIUM alloy heat exchanger
IMPORTANT. The application of any other treatment to this product may render the guarantee of Ideal
Stelrad Group invalid.
Ideal Stelrad Group recommend water treatment in accordance with the Benchmark Guidance Notes on Water
Treatment in Central Heating systems.
Ideal Stelrad Group recommend the use of FERNOX-COPAL or MB1,GE Betz Sentinel X100 OR Salamander Corrosion
Guard inhibitors and associated water treatment, which must be used in accordance with the manufacturers' instructions.
For further information contact:
Fernox Manufacturing Co. Ltd
Cookson Electronics
Forsyth Road
Sheerwater
Woking
Surrey
GU21 5RZ
Tel: +44 (0) 1799 521133
Sentinel Performance Solutions
The Heath Business & Technical Park
Runcorn
Cheshire
WA7 4QX
Tel: 0800 389 4670
www.sentinel-solutions.net
Salamander Engineering Ltd
Unit 24
Reddicap Trading Estate
Sutton Coldfield
West Midlands
B75 7BU
Tel: +44 (0) 121 3780952
Notes
1. It is most important that the correct concentration of the water
treatment product 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.
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.
BS. 7593:1992 details the steps necessary to clean a
domestic central heating system.
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INSTALLATION
INSTALLATION
10 BOILER ASSEMBLY - Exploded view
42
4
17
19
28
4
29
54
14
25
46
Data
Badge
nm8200
27
26
34
22
2
6
1
38
41
37
LEGEND
1
Front panel
22 Gas valve assembly
37 User Control
2
Front sealing panel
25 Dry Fire Thermostat
38 PCB primary control
4
Side panel RH/LH
26 Control Thermistor
41 Main switch c/w harness
6
Bottom panel
27 Overheat Thermostat
42 Spark generator
14 Burner assembly
28 Ignition electrode
46 Burner gasket
17 Injector & housing
29 Flame detection electrode
54 Burner earth pin (ionisation probe)
19 Fan assembly
34 Condensate ‘S’ trap
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11
INSTALLATION
INSTALLATION
UNPACKING
The boiler is supplied fully assembled in one Pack A,
together with a standard flue assembly for lengths up to
650mm, rear or side flue outlet, in Pack B.
A
Unpack and check the contents.
B
C
D
Pack A Contents
E
A The boiler
B Wall mounting template
F
C Wall mounting plate
D 1 year guarantee form
H
E These Installation & Servicing/
User’s Instructions
G
F Water Treatment Warning Label
G Hardware pack
H Flue Turret
nm8114
Hardware Pack
A
B
A 50mm x No.14 wood screws - 3 off
C
B Wall plugs (TP2B ) - 3 off
C Mains connector - 1 off
D Lubricant - 1 off
E Turret Sealing Gasket - 1 off
F Turret Fixing Screws - 4 off
D
F
E
G
H
G Condensate Tube - 1 off
H No. 8 x 10 boiler fixing screw - 1 off
nm9226
Pack B Contents
Flue terminal
mxhe7658
12 PACKAGING REMOVAL
1. Ensure the boiler is stood correctly, as marked on the
carton.
3
6
2. Cut and remove the strapping.
5
3. Fold back the top flaps to gain access to the wall
mounting plate, literature and wall mounting
template.
4. Remove the instructions and read thoroughly before
unpacking the product.
7
6. When ready for installation lift off the outer sleeve.
7. Remove the top protection packing.
nm8231
5. Remove the hardware pack and keep in a safe
place.
8. Remove the two packaging ends.
8
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INSTALLATION
INSTALLATION
13 FRONT AND BOTTOM PANEL REMOVAL
1. To remove the front panel remove the 4 screws from the
bottom panel.
2. Lift the panel up and off the top pegs.
3
3. To remove the bottom panel remove the 4 screws and
withdraw.
1
14 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED
IMPORTANT. The boiler MUST be installed in a vertical position
Dimension X - Wall thickness.
Dimension L - Wall thickness plus boiler spacing.
FLUE KITS
137
Pack B - supplied as standard
For additional fluing options refer to OPTIONAL EXTRA KITS on page 7.
MAXIMUM FLUE LENGTHS:
nm8115
HORIZONTAL FLUE
- 3M
ROOF FLUE KIT
- 5M
90O ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 1.5M)
45O ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 1.0M)
MINIMUM FLUE LENGTH:
FOR REAR OUTLET AND SINGLE BRICK WALL
- 251MM
225
Total Flue length dimension
Rear flue
dim. X+137
Up to
Side flue
dim. L+225
Rear flue length X
225
Flue
Extra packs
required
775 mm
Up to
775 mm
none
Up to 1680 mm
Up to
1680 mm
Pack D - 1 off
Up to 2585 mm
Up to
2585 mm
Pack D - 2 off
Up to 3000 mm
Up to
3000 mm
Pack D - 3 off
Side flue length L
Jacking screws
Notes.
1. The flue duct MUST be inclined at 1.5 degrees to the horizontal to allow condensate to drain back into the boiler and out
through the condensate drain. (Only necessary if using one or more ‘D’ extension duct packs).
2. If the boiler is to be installed with downward piping routed behind the boiler then the optional stand-off kit should be used.
Care must be taken when cutting the ducts and marking the wall to suit this condition.
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INSTALLATION
15 FLUE ASSEMBLY - Exploded View
An optional flue duct extension kit is required for
wall thicknesses greater than :
Side
535mm (21")
Rear
638mm(251/8").
2
LEGEND
1. Duct assembly.
2. Flue turret.
3. Turret gasket.
nm8165
Rear flue arrangement shown
16 WALL MOUNTING TEMPLATE
Extended centre line
Note.
The template shows the positions of the fixing holes and
the flue hole centres for standard installation. If using
stand off kit option, refer to instructions in kit. Care MUST
be taken to ensure the correct holes are drilled.
V
1. Tape template into the selected position.
2. Ensure squareness by hanging a plumbline as shown. If
fitting a side flue extend the flue centre line onto the side
wall as shown.
137m
m
a
The 3 wall mounting plate screw positions (see
instructions on wall mounting template).
b.
The position of the flue duct hole (see diagram below,
and template).
FLUE OUTLET
3. Mark onto the wall the following:
Note. Mark the centre of the hole as well as the
circumference
4. Remove the template from the wall.
nm8116
nm8257
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INSTALLATION
17 PREPARING THE WALL
IMPORTANT. Ensure that, during the
cutting operation, masonry falling outside
of the building does not cause damage or
personal injury.
Rear flue only
5" diameter hole
1. Cut the flue hole (preferably with a 5"
core boring tool), ensuring that the
hole is square to the wall.
Both wall faces immediately around
the cut hole should be flat.
2. Drill 3 holes with a 7mm (1/4")
masonry drill and insert the plastic
plugs provided, for the wall mounting
plate.
Side flue only
5" diameter hole
Section
through wall
Note.
If using Stand Off kit option, refer to
instructions in kit.
Note. Check all of the hole
positions before drilling
ecl8166
18 CUTTING THE FLUE - REAR Wall thicknesses of 114mm to 638mm
Notes.
a. If using the extension ducts go to Frame 20.
1. Measure and note wall thickness X. Refer to Frame 14.
2. Add 67mm (25/8") to dimension X and, measuring from
the ring, cut the outer tube only.
cla7841
3. To ensure the tube is cut square, mark the flue all the
way around.
4. Cut the inner tube to a length 20mm (3/4") longer to aid
engagement.
19 CUTTING THE FLUE - SIDE
Wall thicknesses of 114mm to 535mm
Note. If using the extension ducts go to Frame 20.
1. Measure and note side flue length L. Refer to Frame 14.
2. Add 155mm (61/8") to dimension L and, measuring from
the ring, cut the outer tube only.
3. To ensure the tube is cut square, mark the flue all the
way around.
4. Cut the inner tube to a length 20mm (3/4") longer to aid
engagement.
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18
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cla7841
FLUE OUTLET
b. If the stand-off frame is used it is essential to add
33mm to dimension X.
18
19/02/2008, 13:07
INSTALLATION
20 FLUE EXTENSION DUCTS - For flue lengths greater than 775mm
Pack D Flue extension duct kit contents.
Extension duct
1.0m (39") long
Washers - 2 off
Wall plugs - 2 off
Support fixing screws - 2 off
Flue duct support
nm8242
Clamp screws - 2 off
21 FLUE EXTENSION DUCTS - continued
Flue length
Use a maximum of 3m extended flue ONLY
Extension flue
General arrangement
1. A maximum of 3 extension ducts (one suitably
cut) plus the standard flue duct may be used
together.
Note. Side flue shown
Terminal grille
Boiler
Ecl 6085
FLUE OUTLET
2. Flue extensions of greater length than 1m (39")
should be supported with the bracket provided,
suitably adjusted.
Standard flue
22 FITTING 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.
5. Measure and mark the flue length required onto the flue,
measuring from the ring near the terminal.
3. Using the clamp provided, clamp the flue lengths together.
6. To ensure a square cut, mark the flue all the way around.
4. Repeat steps 1-4 if a second flue extension is required.
7. Cut to length, and deburr the metal edges.
1
2
Measure from
this
RING
mxhe7843
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INSTALLATION
INSTALLATION
23 CONDENSATE DRAIN
Refer also to the British Gas document: 'Guidance Notes for
the Installation of Domestic Gas Condensing Boilers' (1989).
The condensate drain provided on the boiler must be
connected to a drainage point, preferably within the
building.
The routing of the drain must be made to allow a
minimum fall of 1 in 20 away from the boiler,
throughout its length.
The drainage pipework must be arranged so that
obstruction (e.g. through freezing) of external
drainage pipe does not give rise to spillage within
the dwelling.
Front View
IMPORTANT. If excessive external pipework cannot
be avoided an additional siphon kit and insulation
are recommended, in order to prevent possible
freezing.
Side View
All pipework and fittings in the condensate drain
system must be made of plastic. No other materials
may be used.
nm8114
The drain outlet on the boiler is standard 21.5mm
overflow pipe. This size must not be reduced in any
part of its length.
300mm
(approx)
A plastic cap is fitted to the end of the condensate
drain adapter this must be removed before
connection is made.
Condensate
drain
24 CONDENSATE PIPE TERMINATION CONFIGURATIONS
Note. ALL EXTERNAL PIPE RUNS MUST BE INSULATED OR UPSIZED TO 32MM - MAXIMUM LENGTH 3M EXTERIOR
1. INTERNAL TO SINK WASTE
UPSTREAM OF SINK WASTE
TRAP
Sink constitutes
air break
BOILER
Open end of pipe
direct into gulley
below grating but
above water level
75mm trap
cla7771
Ground Level
DRAIN
2. INTERNAL TO SINK WASTE
DOWNSTREAM OF SINK
WASTE TRAP (PREFERRED
METHOD)
BOILER
Sink
Air Break
cla9252
Open end of pipe
direct into gulley
below grating but
above water level
75mm trap
Ground Level
DRAIN
continued . . . .
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INSTALLATION
INSTALLATION
25 CONDENSATE PIPE TERMINATION CONFIGURATIONS . . . continued
3. INTERNAL CONNECTION TO SOIL AND VENT STACK
Termination into a down pipe can take place providing it can be confirmed
that the down pipe is part of a combined waste and rain water system.
* Make connection to SVP using a solvent welded saddle.
BOILER
Air Break
cla9253
4. TERMINATION TO SOAK AWAY
External
wall
Termination
to Soak away
BOILER
cla7774
minimum
500mm
Ground Level
5. TERMINATION TO DRAIN / GULLEY
External
wall
Open end of pipe
direct into gulley
below grating but
above water level
BOILER
cla7775
Ground Level
DRAIN
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INSTALLATION
INSTALLATION
26 MOUNTING THE BOILER
Note. Refer to Safe Handling (Page 7).
1. Lift the boiler onto the wall mounting plate, as shown.
2. Check the boiler alignment using a spirit level and
adjust as necessary with the jacking screw.
3. Fix boiler to wall mounting plate using self
tapping screw (supplied in hardware pack).
4. Connect condensate hose to the S-trap. Ensure
correct end is used.
1
3
nm8258
4
nm8403
27 CONNECTING THE FLUE TO THE BOILER
1. Fit the turret seal (supplied in the hardware
pack) to turret, locate the flue into the turret
and push to ensure full engagement. Use
lubricant from hardware pack to lubricate
seals when engaging.
2. CHECK THAT THE FLUE SEAL LOCATED IN
THE TOP OF THE FLUE MANIFOLD IS
SECURE AND GIVING AN EFFECTIVE SEAL.
1
3. Secure the flue turret on top of the boiler with
the 4 screws provided.
5. Flues over 1 metre long.
Fix the flue support bracket to the wall, using
the wall plug and screws.
2
nm8167
3
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INSTALLATION
28 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched)
Note.
A flat or pitched roof flashing plate (not supplied) is
required before proceeding with the installation of
this kit.
This kit is suitable for both flat and pitched roof
terminations, using a concentric flue to run vertically
from the top of the boiler and terminating above roof
level.
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 7,
Optional Extras.
mxhe7652
29 ROOF FLUE KIT CONTENTS / OPTIONS
FLUE OUTLET
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
G
F
H
C. 3.5x13 screw
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
H. 45o elbow kit (60/100)
D
C
B
mxhe7778
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INSTALLATION
30 FLUE TERMINAL POSITION
The terminal should be positioned so that products of
combustion can safely disperse at all times.
Pluming may occur at the termination so, where
possible, terminal positions where this could cause
a nuisance should be avoided.
Minimum dimensions are shown below
*
nm8243
610 mm
min.
ex7531
610 mm
min.
Terminal Position
Minimum Dimension
Directly below an opening,
air brick, windows, etc.
300 mm
Below plastic / painted gutters
300 mm
Painted surface
300 mm
Below eaves or balcony
500 mm
31 FLUE ARRANGEMENT
Part No. Description
60/100 Quantity
HE30
HE36
n/a
Maximum Flue Length (m)
5
5
201 180
Flue ext. 60/100
6
6
201 189
Terminal Vertical Roof 60/100
1
1
158 431
Weather Collar Pitched Roof
1
1
158 432
Weather Collar Flat Roof
1
1
201 182
90 Elbow Kit (60/100)
2
2
201 183
45 Elbow Kit (60/100)
2
2
201 869
Vertical Connector
1
1
o
o
mxhe7686
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.
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FLUE OUTLET
*Flat Roof 600mm
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INSTALLATION
32 ASSEMBLING THE ROOF FLUE KIT
Determine the correct height that the flue should terminate
above the roof. If after calculating or measuring the overall flue
height from the top of the boiler, it is necessary to cut both
pipes of assembly A, then ensure they are cut equally leaving
the inner flue tube 20mm longer than the outer air tube as
supplied. (Refer to No. 5 below)
Ensure the cut pipe ends are free from any burrs.
1. Ensure the flue seal collar B is located onto the flue
assembly A.
max 41
MAX LENGTH:
HE 30 - 5m
HE 36 - 5m
o
min 16
o
1
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.
nm8168
3. 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. Lubricate flue
seal using lubricant (supplied in hardware pack).
2
4. "Push" fit extension duct F (if required, supplied separately)
and the roof flue kit assembly A into the vertical connector E.
Lubricate seals using lubricant (supplied in hardware pack).
A
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
gives the length of the last extension duct.
E
3
A
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 20mm longer than the air duct to
ensure engagement in the final flue duct seal.
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.
D
7470
F
FLUE OUTLET
7. Finally ensure the roof flashing plate D is
correctly sealed to the roof.
6
4
nm8170
E
A
A
C
C
5
nm8256
B
D
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B
ix7474
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INSTALLATION
INSTALLATION
33 GAS CONNECTION
IMPORTANT. The gas service cock is sealed with a non-metallic
fibre washer seal so must not be overheated when making
capillary connections.
Refer to Frame 2 for details of the position of the gas connection.
N.B. The principle of the 1:1 gas valve ensures that the icos
HE range is able to deliver it’s full output at inlet pressures
down to 14mb. However if dynamic pressures below 20mb
are experienced ensure this is adequate for ALL other gas
appliances in the property.
A boiler gas supply pipe length of 20m and not less than
15mm O.D. can be connected to the boiler via the gas
service cock union.
Ensure that the gas supply pipe does not foul the boiler
casing.
Refer to Frame 41 for details of the pressure test point
position.
34 BOILER WATER CONNECTIONS
The boiler flow and return pipes are supplied fitted to the
boiler and ready for top connection to 28mm pipes.
TOP CONNECTION
nm8111
Connect the system pipework to the boiler flow and return
pipes.
35 ELECTRICAL CONNECTIONS
WARNING. This appliance MUST be earthed.
Wiring should be 3 core PVC insulated cable NOT LESS
than 0.75 mm2 (24 x 0.2mm) and to BS. 6500, Table 16.
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.
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.
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For IE reference should be made to the current ETCI rules
for electrical installations.
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INSTALLATION
INSTALLATION
36 INTERNAL WIRING
A pictorial wiring diagram is shown in Frame 37.
1. Route the mains cable into the bottom LHS rear of the casing.
If using the stand-off kit then route through the grommet.
2. Wire a permanent live supply into the 5-way remote plug
terminals L3, N and .
IMPORTANT. A permanent live is ESSENTIAL in order for
the advanced diagnostic controls to function correctly.
3. Wire the switched live supply into L2 or connect L1 and L2
via external control switching, as shown in Frame 37. In
either case, remove the wire link fitted L1 to L2.
4. Secure the mains lead with the cable clamp.
5. Connect the mains lead connector. Ensure it is fully located.
Note.
Ensure that the lengths of the current carrying conductors are
shorter than the earth conductor so that if the cable slips in its
anchorage the current carrying conductors become taut
before the earth conductor.
Ecl 1542
Incoming mains wiring detail
L3
N
Ecl2367
L2
L1
Remove link when connecting external programmer.
Mains Connector
Socket
(supplied in hardware pack)
(fixed to boiler)
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37 PICTORIAL WIRING DIAGRAM
pk
y
bk
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
b
r
y/g
Dry fire
thermistor
Fan
y/g
or
or
Overheat
thermostat
y y
Gas valve
r
Control
thermistor
r
Chassis
earth y/g
b
y/g
bk
INSTALLATION
INSTALLATION
MAINS
SUPPLY
230V 50Hz
y/g
Spark generator
bk
Filter
bk
y/g
y/g
y/g
y/g
br
b
Ferrite
bk
br
User
control
and
display
b
b
or
Fused at
3.15ATL
Service
connection
ON /OFF
Switch
or
y
bk
b
Control PCB
r
nm8143
r
pk
y
y
y/g
r
br
r
38 FUNCTIONAL FLOW WIRING DIAGRAM
Mains Switch
b
y/g
Control PCB
LEGEND
b - blue
bk - black
br - brown
gy - grey
or - orange
pk - pink
r - red
Ignition electrode
v - violet
w - white
y - yellow
y/g - yellow/green
Control thermistor
E
y/g
External switch e.g.
room'stat, programmer
or
Overheat
or
thermostat
pk
b
Flame detection
electrode
y/g
DC Gas valve
br
b
Spark generator
y
bk
y
Dry fire
thermistor
b
User PCB
r
nm8144
r
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L
bk
bk
y
r
DC
Fan
N
br
br
r
br
2
1
b
Filter
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INSTALLATION
INSTALLATION
39 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
If the thermostat has a neutral connection use it.
(It provides for more energy efficient operation by
reducing switching temperature differentials.)
Frost Protection
If parts of the pipework run outside the house or if
the boiler will be left off for more than a day or so
then a frost thermostat should be wired into the
system. This is usually done at the 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.
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.
40 COMMISSIONING 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 soundness test and purging air from the gas
installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.
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INSTALLATION
INSTALLATION
41 INITIAL LIGHTING
Note. Boiler is shown with the front panel and sealing panel removed.
LEGEND
A On/Off switch.
G Gas service cock.
B Thermostat knob.
H Overheat thermostat.
C 'Burner On' neon.
J
D Reset button.
K Spark generator.
E Injector pressure test point.
L Dry Fire Thermostat.
Control thermistor.
F Inlet pressure test point.
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.
K
L
H
J
4. Ensure the boiler sealing panel is fitted.
5. Check the gas service cock is open.
7. Slacken the screw in the inlet pressure test point (G)
and connect a gas pressure gauge via a flexible tube.
8. Switch the electricity supply ON and check all external
controls are calling for heat.
9. Set the boiler thermostat knob (B) to position 6 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.
10. If the boiler does not light after 3 attempts the fault
codes L' 'F' will be displayed. Press the reset button (D);
the boiler will then repeat its ignition sequence. When
the burner is established the WHITE burner ON neon
(C) will be permanently illuminated
11. Ensure that with the boiler operating the dynamic gas
pressure is able to obtain maximum output. Refer to
Table 2.
N.B. The principle of the 1:1 gas valve ensures that the
icos HE range is able to deliver it’s full output at inlet
pressures down to 14mb. However if dynamic
pressures below 20mb are experienced ensure this is
adequate for ALL other gas appliances in the property.
IMPORTANT.
The gas input to the burner is regulated by the gas
valve according to the air flow produced by the fan. It
is NOT user-adjustable. Any interference to sealed
settings on the gas valve will adversely affect
operation and render our warranty void.
12. Switch OFF the boiler on/off switch.
13. Remove the pressure gauge and tube. Tighten the
sealing screw in pressure test point. Ensure a gas tight
seal is made.
14. Refit the boiler front panel and bottom panel.
G
F
A
E
C D
B
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.
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.
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nm8122
6. Check that the boiler on/off switch (A) is OFF
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42 GENERAL CHECKS
Make the following checks for correct operation:
Note. Fernox Superfloc, Sentinel X300 (new systems) or
X400 (existing systems) flushing solutions should be
used during the flushing procedure. Refer to Frame 9.
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
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.
43 HANDING OVER
After completing the installation and commissioning of the system the
installer should hand over to the householder by the following actions:
1. Hand the 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.
3. The operation of the boiler and the use and adjustment of
ALL system controls should be fully explained to the
householder to ensure the greatest possible fuel
economy consistent with household requirements of both
heating and hot water consumption.
Advise the User of the precautions necessary to prevent
damage to the system and to the building in the event of
the system remaining inoperative during frosty conditions.
4. Explain the function and the use of the boiler heating
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 CORGI registered installer consulted. In
IE contact a competent person.
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
Commissioning Checklist before
the
handover to the customer.
For IE, its is necessary to complete a “Declaration of
Conformity” to indicate compliance to I.S. 813:2002.
9. IMPORTANT
Stress the importance of regular servicing by a CORGI
registered installer and that a comprehensive service
should be carried out AT LEAST ONCE A YEAR. In IE
servicing work must be carried out by a competent
person.
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.
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INSTALLATION
INSTALLATION
SERVICING
44 SERVICING SCHEDULE
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 CORGI registered installer. In IE service work must be
carried out by a competent person.
1. Light the boiler and carry out a pre-service check, noting
any operational faults.
2. Check the gas consumption.
3. Connect a suitable gas analyser to the sampling 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 this is the
case, and the gas input is at least 90% of the nominal,
once compliance with the note above is ensured, then no
further action need be taken. If not, proceed to step 4 .
4. Clean the main burner.
The servicing procedures are covered more fully in Frames
44-68 and MUST be carried out in sequence.
Note. In order to carry out either servicing or replacement of
components the boiler front panel, bottom panel and sealing panel
must be removed. Refer to Frames 45 and 46.
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.
9. After completing the servicing or exchange of components
always test for gas soundness and carry out functional checks
as in paragraphs 2 and 3.
10. 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.
5. Clean the heat exchanger and ‘S’ trap.
6. Check the main injector for blockage or damage.
SERVICING
8. Check that the flue terminal is unobstructed and that the
flue system is sealed correctly.
11. Complete the service section in the Benchmark
Commissioning Checklist.
7. Wherever possible, remove and clean the condensate ‘S’
trap (refer to Frame 49) and check the drain for blockage.
45 BOILER FRONT PANEL REMOVAL
1. Remove the 2 screws from the underside of the
appliance.
1. To remove the sealing panel remove the 4 screws.
2. Remove the panel.
3. To remove the bottom panel remove the 4 screws.
nm8171
2. Pull the front panel forward at the bottom and lift to
disengage it from the top lugs.
46 BOILER SEALING PANEL/
BOTTOM PANEL REMOVAL
3
nm8145
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SERVICING
47 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING
1. Disconnect the electrical leads from
the fan.
2. Undo the gas pipe union connection to
the injector housing.
3. Undo the screw on the fan mounting
bracket.
4
1
4. Lift off the fan and venturi assembly.
5. Inspect the injector for blockage or
damage.
2
3
SERVICING
Ecl 6073
48 BURNER REMOVAL AND CLEANING
1. Remove the 6 screws securing the
burner (the centre screw at the rear is
extended to ease access).
2. Lift off the burner from the combustion
chamber.
IMPORTANT
The burner head is a ceramic plaque
construction. Care must be taken to
ensure that the burner is not placed
down upon its face as this may cause
damage to the ceramic.
3. Brush off any deposits that may be on
the ceramic with a SOFT brush.
4. Inspect the sealing gasket around the
burner for any signs of damage.
Replace as necessary.
nm8124
Note.
Take care not to disturb the ionisation
probes at the front and rear of the
combustion chamber.
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SERVICING
49 CLEANING THE CONDENSATE 'S' TRAP
If condensate pump fitted refer to
separate instructions for cleaning
procedure.
Note. Care must be taken with residual water
when removing the outlet pipe.
3
1. Remove the plastic union sealing nut on the
bottom of the condensate ‘S’ trap.
2. Remove and clean from the cartridge and
ball any residual deposits.
1
3. Inspect the opaque ‘S’ trap for further signs
of dirt and clean as necessary.
4. Replace the cartridge and ball and replace
the plastic sealing nut.
50 CLEANING THE HEAT EXCHANGER
SERVICING
1. Remove ignition electrode. Refer to
Frame 56.
2
1
2. Remove flame detection electrode.
Refer to Frame 57.
3. Remove the 3 screws retaining the
sump cover and remove.
4. Using a suitable tool clean the exposed
heat exchanger fins through the sump
cover. Also vacuum any debris from the
top of the heat exchanger.
5. Access to the base of the heat
exchanger is now possible. Brush clean
any deposits from the base of the heat
exchanger and remove any loose
deposits from the sump.
6. Inspect the ignition and detection
electrodes. Ensure that they are clean
and in good condition - replace if
necessary.
Sump cover
nm8125
7. Check that the ignition and detection
gaps are correct. Refer to Frames 56 &
3
Heat exchanger
51 REASSEMBLY
Reassemble the boiler in the following order.
1. Refit the condensate ‘S’ trap, ensuring that it is full of water.
2. Refit the sump cover plate.
IMPORTANT.
Ensure the boiler sealing panel is correctly fitted and
that a good seal is made.
3. Refit the electrodes (check dimensions Frames 56 & 57).
8. Refit the boiler front and bottom panels.
4. Refit the burner.
9. Turn on the gas supply at the gas service cock.
5. Refit the fan / venturi assembly.
10. Reconnect the electrical supply.
6. Reconnect the fan electrical leads.
7. Refit the boiler sealing panel.
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SERVICING
52 REPLACEMENT OF COMPONENTS
GENERAL
When replacing ANY component:
1. Isolate the electricity supply.
IMPORTANT
When work is complete, the sealing panel must be
correctly fitted, ensuring that a good seal is made.
2. Turn off the gas supply.
3. Remove the boiler front panel. Refer to Frame 45.
After replacing ANY component check operation of the boiler
including gas soundness, gas rate and combustion test.
Note.
In order to assist fault finding, the control panel has an
LED diagnostic display. The key to boiler fault
conditions is shown in Frame 69.
SERVICING
THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED
53 CONTROL THERMISTOR REPLACEMENT
1. Refer to Frame 52.
2. Remove the boiler front panels and
inner sealing panel. Refer to Frames
45 and 46.
3. Pull the electrical leads off the control
thermistor and remove earth
connection.
4. Remove the two screws retaining the
control thermistor.
5. Replace control thermistor retaining
with the fixing screws previously
removed and reconnect leads.
6. Reassemble the boiler in reverse
order.
7. Check the operation of the boiler. Refer
to Frame 52.
4
3
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SERVICING
54 FAN REPLACEMENT
1. Refer to Frame 52.
2. Remove the boiler front and sealing
panels. Refer to Frames 45 & 46.
Orifice plate
Gasket
3. Disconnect the electrical leads from
the fan.
7
3
4. Unscrew the gas pipe union
connection to the injector housing.
5. Unscrew and remove the screw
retaining the fan mounting bracket.
4
5
6. Remove the fan and venturi assembly.
7. Remove the 3 screws and remove the
venturi assembly, noting the
orientation of the venturi in relation to
the fan body.
8. Transfer the venturi assembly to the
new fan, replacing the gasket if
evidence of damage or deterioration
is visible.
SERVICING
9. Fit the new fan / venturi assembly.
10. Reassemble the boiler in reverse
order, taking care not to overtighten
the screw on the fan mounting
bracket.
Ecl 2336
11. Check the operation of the boiler.
Refer to Frame 52.
55 BURNER REPLACEMENT
1. Refer to Frame 52.
2. Remove the boiler front and sealing
panels. Refer to Frames 45 & 46.
4
3. Remove the fan assembly. Refer to
Frame 54.
5
4. Remove the 6 screws securing the
burner (the centre screw at the rear is
extended to ease access).
5. Lift off the burner from the combustion
chamber.
6. Fit the new burner, replacing any
damaged or deteriorating sealing
gasket.
8. Check the operation of the boiler. Refer
to Frame 52.
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nm8126
7. Reassemble in reverse order.
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SERVICING
56 IGNITION ELECTRODE REPLACEMENT
1. Refer to Frame 52.
2. Remove the boiler front panels and inner
sealing panel. Refer to Frames 45 and 46.
15mm +- 1 (HE30, HE36)
3. Unplug the ignition lead from the electrode.
Stra
ight
4. Remove the burner. Refer to Frame 48.
5. Remove the earth lead from the ignition
electrode.
Edg
e
1
nm8118
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.
5
9. Reassemble in reverse order.
10. Check operation of the boiler. Refer to
Frame 52.
SERVICING
6
57 FLAME DETECTION ELECTRODE REPLACEMENT
1. Refer to Frame 52.
2. Remove the boiler front panels and
inner sealing panel. Refer to
Frames 45 and 46.
16mm +- 1 (HE30, HE36)
Stra
ight
3. Unplug the flame detection lead
from the electrode.
Edg
e
5. Remove the 2 screws holding the
flame detection electrode to the
combustion chamber.
1
nm8148
4. Remove the burner. Refer to
Frame 48.
6. Remove the flame detection
electrode.
7. Fit the new flame detection
electrode, using the new gasket
supplied. Check dimension as
shown.
5
8. Reassemble in reverse order.
9. Check operation of the boiler. Refer
to Frame 52.
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SERVICING
58 SPARK GENERATOR REPLACEMENT
2
3
1. Refer to Frame 52.
2. Disconnect the leads from the spark
generator and bracket.
3. Remove the M4 screw securing the
spark generator bracket to the casing
side panel.
4
4. Remove the 2 M4 screws securing the
spark generator to the bracket.
5. Fit the new spark generator and reassemble in reverse order.
6. Check operation of the boiler. Refer to
Frame 52.
59 BURNER INJECTOR REPLACEMENT
4
1. Refer to Frame 52.
Copper washer
SERVICING
2. Remove the boiler front and sealing panels. Refer to
Frames 45 & 46.
3. Remove the fan / venturi assembly. Refer to Frame 47.
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 52.
Rubber moulded seal
Ecl 2340
60 GAS CONTROL VALVE REPLACEMENT
1. Refer to Frame 52.
11. Reassemble in reverse order.
2. Remove the boiler front, bottom and sealing
panels. Refer to Frames 45 & 46.
12. Ensure the sensing tubing is correctly replaced.
13. Check operation of the boiler. Refer to Frame 52.
3. Unplug the electrical lead from the gas control
valve and disconnect the earth wire.
4. Undo the sensing tube connection from the gas
control valve.
8
5. Undo the union nut between the gas valve and
the gas inlet cock.
6. Undo the union nut on the outlet side of the gas
control valve.
7. Undo the gas valve bracket screw, slide the gas
valve forward and remove.
7
8. Remove the valve fixing bracket.
9. Transfer the mounting bracket and gas inlet pipe
to the new gas control valve.
10. Fit new gas control valve, ensuring that any seals
showing damage or deterioration are replaced.
5
nm8244
3
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4
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SERVICING
61 CONTROL BOX REPLACEMENT
1. Refer to Frame 52.
2. Remove the front panel.
3. Remove the bottom panel.
3
4. Remove the 2 control box screws.
5. Carefully unplug all the electrical wiring from the control box.
6. With the control box lowered, pull the assembly forward to
remove from the housing.
2
7. Remove the user control from the assembly.
8. Transfer the mounting brackets to the new control box.
9. Reassemble in reverse order, ensuring that the control box is
located correctly in the housing before reconnecting the
electrical wiring.
10. Check operation of the boiler. Refer to Frame 52.
N.B. To change the user control only.
4
11. Loosen the screw on the underside of the user control.
Ecl 2438
12. Pull the display unit forward to remove.
13. Push the new display unit into position.
SERVICING
14. Reassemble in reverse order.
15. Check the operation of the boiler. Refer to Frame 52.
Mounting brackets
11
Control box
Ecl 2419
62 MAINS SWITCH REPLACEMENT
1. Refer to Frame 52.
2. Remove the boiler front and bottom panel.
Refer to Frames 45 & 46.
3. Remove the 2 control box screws and lower
the control box.
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 (refer to Frame 38) 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 52.
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SERVICING
63 OVERHEAT THERMOSTAT REPLACEMENT
1. Refer to Frame 52.
2. Remove the boiler front panels and inner sealing
panel.
3. Pull off the 2 electrical leads from the thermostat
body.
4. Remove the 2 screws retaining the O/H thermostat.
5. Fit the new thermostat, and reconnect leads
6. Reassemble in reverse order.
7. Check operation of the boiler. Refer to Frame 52.
4
SERVICING
3
64 DRY FIRE THERMISTOR REPLACEMENT
1. Refer to Frame 52.
2. Remove the boiler front panels
and inner sealing panel. Refer to
Frames 45 and 46.
5
6
3. Drain down the system.
4. Drain down the heat exchanger
from the drain cock.
5. Pull off the electrical connection.
6. Unscrew and withdraw the
thermistor.
7. Fit the new thermistor, using the
gasket supplied.
8. Reassemble in reverse order.
4
9. Check operation of the boiler.
Refer to Frame 52.
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SERVICING
65 HEAT EXCHANGER REPLACEMENT
Note. If the installation allows the boiler to be removed from
the wall, the replacement will be more easily conducted if this
is done. This will necessitate disconnection of all services to
the boiler. If this is possible, remove the boiler after step 10.
Refer also to Frame 10, 'Boiler Assembly - Exploded View'.
1. Refer to Frame 52.
2. Remove front, bottom and sealing panels. Refer to
Frames 45 & 46 and remove painted side panels.
3. Remove the control box and place to one side. Refer to
Frame 61.
15. Remove the pipe cover plate off the boiler top panel.
16. Pull the flow pipe off the heat exchanger and remove from
the casing.
17. Remove the two screws retaining the flue manifold
bracket, (screws located on the top panel of the boiler
and the LH side of the flue manifold bracket inside the
boiler). Slide out the flue manifold bracket, then slide out
the plastic flue manifold assembly from the keyhole slots
on the back panel, and remove from the joint at the back
of the sump.
4. Attach a length of hose to the drain nipple on the bottom of
the heat exchanger and drain down the boiler.
15
17
SERVICING
4
5. Remove the fan assembly and place to one side. Refer to
Frame 54.
6. Remove the ignition and detection electrodes. Refer to
Frames 56 & 57.
7. Remove the spark generator. Refer to Frame 58.
8. Remove the burner and place to one side. Refer to Frame
55.
17
9. Release the flue from the turret.
10. Remove the turret from the boiler. Refer to Frame 15.
11. Release the silicon tubing from the sample point.
12. Release the electrical connections to the dry fire thermistor.
Refer to Frame 64.
13. Release the electrical connections to the control thermistor
and overheat thermostat. Refer to Frames 53 and 63.
14. Remove the retaining clip off the flow pipe connection and
cut or disconnect flow and return pipework from the system.
14
continued .................................
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SERVICING
66 HEAT EXCHANGER REPLACEMENT
continued .................................
18. Undo the 5 retaining screws from the boiler bottom
panel.
18
19. Remove the ‘S’ trap fixing bracket screw and
disconnect the ‘S’ trap. Refer to Frame 68.
SERVICING
19
20. Undo the 2 fixing screws from the mounting brackets on the top left and top right of the heat exchanger.
20
20
21. Remove gas valve sensing pipe (to prevent damage
when removing heat exchanger).
22. Slide the heat exchanger and sump assembly complete
with the CH return pipe upwards to disengage the sump
spigot from the chassis and remove from the casing.
21
23. Fit the new heat exchanger, re-assembling in reverse
order, replacing the gaskets or seals if any sign of
damage or deterioration is evident. To ensure a positive
flue seal is confirmed it may be necessary to remove
the worktop or adjacent cupboard to view the joint.
24. Check the operation of the boiler. Refer to Frame 52.
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SERVICING
67 BOILER SEALING PANEL SEAL REPLACEMENT
1. Refer Frame 52.
2. Remove the front panel. Refer to Frame 45.
3. Remove the boiler sealing panel. Refer to Frame 46.
4. Remove the old seal from the casing and thoroughly
clean the casing surfaces.
5. Fit the new adhesive seals - note that they are
supplied to the correct length for the relevant sides.
Seals
6. Reassemble in reverse order.
Note.
Ensure that the boiler sealing panel is correctly
seated, compressing the seal to make an airtight
joint.
7. Check operation of boiler.
Refer to
Frame 52.
3
SERVICING
nm8201
68 CONDENSATE ‘S’ TRAP REPLACEMENT
1. Refer to Frame 52.
2. Remove the boiler front panel. Refer to Frame 45.
3. Undo the plastic union nut on the condensate 'S' trap
outlet and disconnect the flexible hose.
5. Loosen the top nut on the ‘S’ trap then pull the trap
down and forward to remove.
6. Reassemble in reverse order.
7. Check operation of the boiler. Refer to Frame 52.
4. Remove the screw retaining the ‘S’ trap bracket and
remove the bracket.
3
4
5
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FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
FAULT FINDING
69 FAULT FINDING CHART MAIN MENU
In order to assist fault finding the boiler has an LED diagnostic display. The key to the display codes is as follows:
ALTERNATING 'L' 'F'
GO TO FRAME 70
ALTERNATING 'L' 'E'
GO TO FRAME 71
ALTERNATING 'L' 'A'
GO TO FRAME 72
ALTERNATING 'L' '8'
GO TO FRAME 73
ALTERNATING 'H' '1'
GO TO FRAME 74
ALTERNATING 'H' 'F'
GO TO FRAME 75
ALTERNATING 'H' '4'
GO TO FRAME 76
ALTERNATING 'H' 'n'
GO TO FRAME 77
ALTERNATING 'H' 'E'
GO TO FRAME 71
ALTERNATING 'H9'
GO TO FRAME 76
ALTERNATING 'L9'
GO TO FRAME 76
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FAULT FINDING
NO
NO
Is gas pressure available
at the boiler inlet ?
If the boiler reset button is
pressed does the boiler ignite
for a short time then extinguish?
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
70 L.....F....... (FLAME ERROR)
Check gas supply
and rectify fault
YES
YES
Check the detection electrode and
associated harness for:
Check gas valve
wiring for continuity
YES
continuity, visual condition, position
(Refer to Frame 57).
Replace as necessary.
NO
Is 200V DC supply
available at the gas valve ?
Replace PCB
Check spark generator and associated harness
for continuity and visual condition. Refer to
Frame 58. Are these functioning correctly?
NO
Replace
spark generator
YES
Check the ignition electrode and associated harness
for:
continuity, visual condition, position
(Refer to Frame 56).
Are these functioning correctly ?
Check syphon
and condensate
drain pipework
for blockage
NO
Replace ignition electrode and associated
harness as necessary
YES
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.
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FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
FAULT FINDING
71 L.....E......
or
H.....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
YES
LE ONLY:
Check Continuity of OH thermostat.
Is this correct?
NO
Correct wiring or replace
thermostat
NO
Correct wiring or replace
detection lead
YES
HE ONLY: Check earth wire is
connected to detection lead.
Is this correct?
YES
Check all earths for continuity.
Is continuity OK?
NO
Correct Connection
YES
Internal fault within the PCB
NO
Press and hold reset button for 2
seconds. Does boiler operate
correctly?
YES
OK
NO
Turn boiler off and wait for 5
seconds.Turn boiler on.
Does boiler operate correctly?
YES
OK
NO
Replace PCB
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FAULT FINDING
(OVERHEAT ERROR)
NO
Can the overheat condition be reset by pressing
the boiler reset button when the system is cold ?
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
72 L.......A........
Replace overheat thermostat
YES
Is the boiler and CH system filled with
water and all isolation valves open ?
NO
Fill and vent the system and open all
isolation valves
NO
Set CH control knob to maximum.
If the overheat trips again measure the flow
temp:
YES
Does the pump setting give a differential
o
across the boiler in excess of 25 C ?
o
YES
Over 90 C Check control thermistor
(Refer to Frame 70) .
o
Increase the pump setting.
Under 90 C Replace overheat 'stat
o
Is differential now below 25 C ?
YES
NO
Replace the system pump
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.
OK
73 L....8..... (FAN ERROR)
Is nominal 330 V DC present across
red and blue at the fan connector as
reset button is pressed?
YES
Is 14V DC present
across yellow and pink
at the fan connector?
Replace fan
NO
NO
YES
Check wiring harness for continuity. Is there continuity?
74 H.....1.....
YES
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
o
expect
9,700 - 10,300
Ohms
o
expect
2,400 -
2,600
Ohms
o
expect
1,000 -
1,100
Ohms
At 25 C
At 60 C
At 85 C
Are the thermistor values correct ?
YES
Is there continuity between the
PCB and the thermistor ?
NO
YES
NO
Replace the thermistor
Replace PCB
Check and replace wiring as necessary
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FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
FAULT FINDING
75 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
76 H.....4...... (DRY FIRE THERMISTOR ERROR) H9/L9 (FLUE GAS OVERHEAT)
Is the system filled and vented and all
isolation valves open ?
Can the fault condition be reset by
switching off the mains supply to the boiler
?
Is the pump operating correctly? Ensure
flow through system.
NO
YES
NO
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.
o
expect
9,700 - 10,300
Ohms
o
expect
2,400 -
2,600
Ohms
o
expect
1,000 -
1,100
Ohms
At 25 C
At 60 C
At 85 C
o
9,700 - 10,300
Ohms
o
2,400 -
2,600
Ohms
o
1,000 -
1,100
Ohms
At 25 C expect
Check resistance, using a suitable multimeter
connected across the thermistor terminal pins.
At 60 C expect
At 85 C expect
Are thermistor values correct ?
YES
Are thermistor values correct ?
YES
Inspect heat
exchanger for
blockage or damage
in the flueways.
Clean or replace as
necessary
NO
Replace PCB
NO
Replace thermistor
Replace thermistor
Note. With V9 Primary Control PCB, overheat LA/HA or
H9/L9 when reset will display 3 horizontal lines and will
not attempt to re-fire until the temperature in the heat
exchanger drops below 50oC.
77 H......n........
(PHASE REVERSAL ERROR)
Check wiring to the boiler for
reversed live and neutral
Foot Note: POLARITY CHECKS
Use a multimeter (set to measure 230 V AC or more), connecting the black lead to a reliable Earth point (not Neutral for this
particular test).
You should find 230 V on terminal L and zero (or a small reading) on terminal N.
N.B. Some meters may trip residual current devices during this test.
icos - Installation & Servicing
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LIST OF PARTS
The following are parts commonly required due to damage or
expendability. Their failure or absence is likely to affect safety or
performance of this appliance.
When ordering spares please quote:
1. Boiler Model
2. Appliance G.C. Number
The list is extracted from the British Gas List of Parts, which
contains all available spare parts.
3. Description
4. Quantity
The full list is held by British Gas Services, Ideal Stelrad Group
distributors and merchants.
5. Product Number
When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance
specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers Limited.
Key No.
GC Part No.
Description
Qty.
1
H42-807
Kit - Casing Front (Painted)
1
174 302
2
H42-808
Kit - Panel Case (Sealing)
1
174 303
4
H42-809
Kit - Panel - Side - RH/LH (Painted)
1
174 304
6
H42-810
Kit - Bottom Panel (Painted)
1
174 305
14
H29-002
Kit - Burner
1
174 080
17
E67-492
Kit - Injector & Housing
1
170 908
19
H07-771
Kit - Fan (FIME PX 130/0082)
1
173 525
22
H42-817
Kit - Gas Valve
1
174 306
25
H29-018
Kit - Thermistor - Dry Fire
1
174 087
26
H29-019
Kit - Thermistor - Boiler Control
1
174 088
27
H29-020
Kit - Thermostat - Overheat
1
174 089
28
H07-664
Kit - Electrode - Ignition
1
173 528
29
H07-665
Kit - Electrode - Flame Detection
1
173 529
34
H29-029
Kit - ‘S’ Trap
1
174 090
36
H29-031
Hose - ‘S’ Trap
1
174 091
37
H29-032
Kit - User Control
1
174 152
38
H29-034
Kit - PCB - Primary Control V9
1
174 486
39
E67-519
Kit - Fuse - 3.15A - PCB
1
170 931
41
H07-777
Mains Switch c/w Harness
1
173 537
42
H42-861
Kit - Spark Generator
1
174 307
45
H29-047
Kit - Gaskets - Servicing
1
174 096
46
H29-050
Gasket - Burner
1
174 093
54
H29-062
Kit - Earth Pin - Burner
1
174 086
68
H07-790
Lead - Ignition
1
173 510
69
H42-870
Kit - Lead - Detection
1
174 330
icos - Installation & Servicing
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Product No.
49
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SHORT LIST OF PARTS
78 SHORT LIST
14
17
46
4
22
2
1
6
19
25
28
27
26
29
39
34
36
42
38
41
37
45
69
54
68
nm8120
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NOTES
icos - Installation & Servicing
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51
19/02/2008, 13:08
NOTES
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INSTALLER NOTIFICATION GUIDELINES
IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE
In addition a change to Building Regulations (England and Wales) requires the installer to notify
when installing a heating appliance, as from 1st April 2005.
Install and commission
this appliance to
manufacturers' instructions
Complete the
Benchmark Checklist
Competent Person's
SELF CERTIFICATION SCHEME
If you notify via CORGI Scheme,
CORGI will then notify the
relevant Local Authority Building
Control (LABC) scheme
on members behalf
Scheme members only:
Call CORGI on 0870 88 88 777
or log onto:
www.corgi-notify.com
within 10 days
You must ensure that the
notification number
issued by CORGI is written
onto the Benchmark Checklist
Choose
Buildings Regulations
notification route
BUILDING CONTROL
Contact your relevant
Local Authority
Building Control (LABC) who
will arrange an inspection
or contact a government
approved inspector
LABC will record the data
and will issue a
certificate of compliance
IT IS A CONDITION OF THE
MANUFACTURERS WARRANTY
CORGI will record the data and
will send a certificate of
compliance to the property
THAT THE BENCHMARK
COMMISSIONING CHECKLIST IS
FULLY COMPLETED AND LEFT
WITH THE APPLIANCE
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19/02/2008, 13:08
BENCHMARK No.
GAS BOILER COMMISSIONING CHECKLIST
COLLECTIVE MARK
BOILER SERIAL No.
NOTIFICATION No.
CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes
TIME & TEMPERATURE CONTROL TO HEATING
ROOM T/STAT & PROGRAMMER/TIMER
PROGRAMMABLE ROOMSTAT
CYLINDER T/STAT & PROGRAMMER/TIMER
COMBI BOILER
FITTED
NOT REQUIRED
HOT WATER ZONE VALVES
FITTED
NOT REQUIRED
THERMOSTATIC RADIATOR VALVES
FITTED
AUTOMATIC BYPASS TO SYSTEM
FITTED
TIME & TEMPERATURE CONTROL TO HOT WATER
HEATING ZONE VALVES
NOT REQUIRED
FOR ALL BOILERS CONFIRM THE FOLLOWING
THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURERÕS INSTRUCTIONS?
THE SYSTEM CLEANER USED
THE INHIBITOR USED
FOR THE CENTRAL HEATING MODE, MEASURE & RECORD
GAS RATE
m3/hr
BURNER OPERATING PRESSURE (IF APPLICABLE)
N/A
ft3/hr
mbar
o
CENTRAL HEATING FLOW TEMPERATURE
C
o
CENTRAL HEATING RETURN TEMPERATURE
C
FOR COMBINATION BOILERS ONLY
HAS A WATER SCALE REDUCER BEEN FITTED?
YES
NO
WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?
FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD
GAS RATE
m3/hr
N/A
MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE)
ft3/hr
mbar
o
COLD WATER INLET TEMPERATURE
C
o
HOT WATER OUTLET TEMPERATURE
C
WATER FLOW RATE
lts/min
FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING
THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH
THE MANUFACTURER'S INSTRUCTIONS?
YES
FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING
THE HEATING AND HOT WATER SYSTEM COMPLIES
WITH CURRENT BUILDING REGULATIONS
THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED
IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS
IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2 RATIO READING?
N/A
THE OPERATION OF THE APPLIANCE AND SYSTEM
CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER
THE MANUFACTURER'S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER
COMMISSIONING ENG'S NAME PRINT
SIGN
202414-6.pmd
54
CORGI ID No.
DATE
19/02/2008, 13:08
YES
CO/CO2 RATIO
SERVICE INTERVAL RECORD
It is recommended that your heating system is serviced regularly
and that you complete the appropriate Service Interval Record Below.
Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service
as described in the boiler manufacturer's instructions. Always use the manufacturer's specified spare part when replacing all controls
SERVICE 1 DATE
SERVICE 2 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 3 DATE
SERVICE 4 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 5 DATE
SERVICE 6 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 7 DATE
SERVICE 8 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
SERVICE 9 DATE
SERVICE 10 DATE
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
ENGINEER NAME
COMPANY NAME
TEL No.
CORGI ID CARD SERIAL No.
COMMENTS
SIGNATURE
SIGNATURE
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use
Technical Training
The Ideal Boilers Technical Training Centre offers a series
of first class training courses for domestic, commercial and
industrial heating installers, engineers and system
specifiers.
For details of courses please ring: ............. 01482 498 432
The code of practice for the installation,
commissioning & servicing of central heating systems
icos
Your Ideal us
See reverse
CERTIFIED PRODUCT
Manufactured under a BS EN ISO 9001:
2000 Quality System accepted by BSI
Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull,
HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858.
Registration No. London 322 137.
Ideal Stelrad Group pursues a policy of continuing
improvement in the design and performance of its products. The
right is therefore reserved to vary specification without notice.
HE30,
Ideal Installer/Technical Helpline: 01482 498 663
www.idealboilers.com
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When replacing any part on
assured conform to the safety
use reconditioned or copy pa
users guide
icos
Your Ideal users guide
See reverse for icos installation & servicing instructions
HE30, HE36
When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require. Do not
use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
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icos HE30, HE36
(Natural Gas Only)
Destination Countries: GB, IE
Introduction
HE30
HE36
•
This appliance is not intended for use by persons
(including children) with reduced physical, sensory or
mental capabilities, or lack of experience and knowledge,
unless they have been given supervision or instruction
concerning use of the appliance by a person responsible
for their safety.
•
Children should be supervised to ensure that they do not
play with the appliance.
The icos is a wall mounted, room sealed, super efficient
condensing boiler featuring full sequence automatic spark
ignition and fan assisted combustion.
Due to the very high efficiency, condensate is produced from
the flue gases and this is drained to a suitable disposal point
through the plastic waste pipe at the right lower rear of the
boiler. A condensate 'plume' will also often be visible at the
flue terminal.
Safety
Current Gas Safety (Installation & Use)
Regulations or rules in force.
In your own interest, and that of safety, it is the law that this
boiler must be installed by a CORGI registered installer.
In IE the installation must be carried out by a competent
person and installed in accordance with the current edition of
I.S. 813 “domestic Gas Installations”, the current Building
Regulations and reference should be made to the current
ETCI rules for electrical installation.
It is essential that the instructions in this booklet are strictly
followed, for safe and economical operation of the boiler.
Electricity Supply
The appliance must be earthed.
Supply 230 V - 50 Hz.
The fusing should be 3A.
This appliance is intended to be connected to the supply via a
double-pole switch, having a 3mm contact separation in both
poles, serving only the boiler and system controls. Alternatively,
a 3-pin UNSWITCHED socket may be used.
G.C. Appliance No. 41-399-10
G.C. Appliance No. 41-399-16
In cases of repeated or continuous shutdown a CORGI
registered installer or in IE a competent person should be called
to investigate and rectify the condition causing this and carry out
an operational test after each intervention on the device. Only the
manufacturers original parts should be used for replacement.
Minimum Clearances
Clearances of 165mm (6 1/2") above, 150mm (6") below,
15mm (5/8") at the sides and 450mm (17 3/4") at the front of the
boiler casing must be allowed for servicing.
The minimum front and bottom clearance allowed when built
into a cupboard is 5mm.
To light the boiler (Refer to Frame 1)
1. CHECK THAT THE ELECTRICITY SUPPLY TO THE BOILER
IS OFF.
2. Set the mains on/off switch (A) to off and the CH thermostat
knob (C) to maximum.
3. Switch on the electricity supply to the boiler and check that all
external controls, e.g. programmer, room thermostat, etc are
on.
4. Set the mains on/off switch to ON.
The boiler will commence the ignition sequence, supplying heat
to the system when required.
Important Notes
Operation
•
This appliance must not be operated without
the casing correctly fitted and forming an adequate seal.
•
If the boiler is installed in a compartment then the compartment
MUST NOT be used for storage purposes.
In normal operation the control unit display (F) will show the
codes:
•
If the boiler is installed with a loft air grille and roof flue, the loft
must not be used as a living space and care must be taken to
ensure that the loft air grille is not blocked.
O - Standby (no demand for heat)
•
If the appliance is fitted with a twin flue system using a loft air
grille and both the boiler and grille are installed within a
cupboard or compartment, then permanent air vents are
required and care must be taken to ensure that the air vents
are not blocked.
•
Under NO circumstances should any of the sealed components
on this appliance be used incorrectly or tampered with.
•
If it is known or suspected that a fault exists on the boiler
then it MUST NOT BE USED until the fault has been
corrected by a CORGI registered installer or in IE a
competent person.
C - CH or DHW being supplied
P - Boiler frost protection (boiler will fire when temperature is
less than 3oC)
During ignition the LED (E) will flash.
During normal running the LED will remain illuminated.
Note. If the boiler fails to light after 3 attempts the fault code 'L' 'F'
will be displayed.
Press and hold the reset button for 2 seconds then release.
The boiler will repeat the ignition sequence. If the boiler fails to
light consult a CORGI registered installer or in IE a competent
person.
All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded
in the Benchmark Commissioning Checklist. You can check your installer by calling CORGI direct on 01256 372300.
Ideal Stelrad Group is a member of the Benchmark initiative and fully supports the aims of
the programme. Benchmark has been introduced to improve the standards of installation and
commissioning of central heating systems in the UK and to encourage the regular servicing of
all central heating systems to ensure safety and efficiency.
THE BENCHMARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE
icos - Users
2
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Control of water temperature
Boiler Overheat Thermostat
The boiler controls the central heating radiator temperature to a
maximum of 820C, adjustable via the CH thermostat knob (C).
This thermostat will shut down the boiler in the event of
overheating. Should this occur a fault code 'L' 'A' will be
displayed. Press the reset button (D) and the boiler will relight.
If the fault recurs turn off the boiler and consult a CORGI
registered installer or in IE a competent person.
Approx CH flow temperatures for the boiler thermostat settings
are:
Knob Setting
Flow Temperature
o
o
C
F
Minimum
30
86
Maximum
82
180
Flame failure
Should this occur a fault code L-F will be displayed. Press the
reset button and the boiler will relight. If the fault recurs, turn off
the boiler and consult a CORGI registered installer or in IE a
competent person.
Condensate Drain
To shut down the boiler
The condensate drain must not be modified or blocked.
1. For short periods
Blockage of the condensate drain, caused by debris or freezing,
can cause automatic shutdown of the boiler.
Set the mains on/off switch (A) to OFF.
2. For longer periods
Set the mains on/off switch (A) to OFF. Switch the electricity
supply to OFF. For longer periods the entire system should be
drained, including the domestic hot water supply.
If freezing is suspected and the pipe run is accessible an attempt
may be made to free the obstruction by pouring hot water over the
exposed pipe and clearing any blockage from the end of the pipe.
If this fails to remedy the problem the assistance of a CORGI
registered installer or in IE a competent person should be sought.
Escape of gas
To relight the boiler
Should a gas leak or fault be suspected contact your local gas
supplier without delay.
Repeat the procedure detailed in 'To light the boiler'.
Do NOT search for gas leaks with a naked flame.
Frost Protection
If no frost protection is provided and frost is likely during a short
absence from home leave the heating controls (if fitted) at a
reduced temperature setting.
Cleaning
For longer periods the entire system should be drained.
To remove stubborn marks and stains use a damp cloth and mild
detergent.
If the system includes a frost thermostat then, during cold
weather, the boiler should be turned OFF at the time switch (if
fitted) ONLY. The mains supply should be left switched ON, with
the boiler thermostat left in the normal running position.
For normal cleaning simply dust with a dry cloth.
DO NOT use abrasive cleaning materials.
Maintenance
The appliance should be serviced at least once a year by a CORGI
registered installer or in IE a competent person.
1
BOILER CONTROLS
Legend
E
Boiler on/off switch
B
Thermostat knob
C
Reset button
D
LED
E
Display
F
Condensate drain
D
nm8173
A
C
F
A
B
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.
icos - Users
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POINTS FOR THE BOILER USER
Note. In line with our current warranty policy we would ask that you check through the following guide to identify any
problems external to the boiler prior to requesting a service engineers visit. Should the problem be found to be other than
with the appliance we reserve the right to levy a charge for the visit, or for any pre-arranged visit where access is not gained
by the engineer.
TROUBLESHOOTING - TYPICAL NON PRODUCT FAULTS
Problem
Solution
Boiler is not working for
central heating or hot water.
•
Check there is power to the boiler – switch (A) in the ON position and ‘0 ’ displayed on the
controls.
•
If ‘0 ’ not displayed then not a boiler fault – contact your installer/service company.
•
Check external programmer is set to an ‘ON’ period and the relevant function selected i.e.
central heating or domestic hot water. Test by overriding the programmer by setting to
‘continuous.
•
Check room thermostat for central heating or the cylinder thermostat for domestic hot water,
are set at the required temperature. To test operation of either thermostat turn fully up. If no
response contact your installer.
Boiler is not working for
•
central heating or hot water
•
but attempts to fire by going
through 3 ignition attempts.
Display shows ‘L : F ’ (flashing). •
Press reset button (D) for 2 seconds to repeat ignition sequence.
Boiler is not working for
central heating or hot water
and the display shows ‘L:A ’
(flashing).
•
Press reset button (D) for 2 seconds, the boiler should then re-light. If fault recurs this
indicates an overheat condition. The boiler should be turned off and your installer contacted.
•
Check if ALL radiators have thermostatic radiator valves fitted. If they have contact your
installer.
Boiler is not working for
central heating or hot water
and the display shows ‘H:A ’
(flashing).
•
Check if ALL radiators have thermostatic radiator valves fitted. If they have contact your
installer.
Check gas supply (try another appliance – cooker/fire etc.) – If no gas supply then not a boiler
fault – contact gas supplier.
Check condensate pipe is not blocked or frozen. If blocked, clear blockage – if not possible to
check contact your installer.
Ideal Consumer Helpline
Tel: 01482 498660
www.idealboilers.com
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Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance
of its products. The right is therefore reserved to vary specification without notice.
Ideal Boilers, P.O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN. Tel.
01482 492251 Fax. 01482 448858. Registration No. London 322 137.
19/02/2008, 13:08
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