IDEAL icos HE12 Installation And Servicing
  1. Manuals
  2. Brands
  3. IDEAL Manuals
  4. Boiler
  5. HE12
  6. Installation and servicing

IDEAL icos HE12 Installation And Servicing

Hide thumbs Also See for icos HE12:
Table of Contents

Advertisement

Quick Links

See also: Installation and Servicing Manual , User Manual
back
installation and
servicing
Packaged Boiler Contents have
been Checked by Operator Number.......
icos
(V3 Flue System)
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
HE12, HE15, HE18, HE24
For users guide see reverse of book
When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require. Do not
use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
September 2009
UIN 203318 A05
For the very latest copy of literature for specification & maintenance
practices visit our website www.idealboilers.com where you will
be able to download the relevant information in pdf format.

Advertisement

Table of Contents
loading

Related Manuals for IDEAL icos HE12

Summary of Contents for IDEAL icos HE12

  • Page 1 When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers. September 2009 UIN 203318 A05 For the very latest copy of literature for specification &...
  • Page 2 back icos - Installation & Servicing...
  • Page 3 Page 49 - Short Parts List • New updated parts list Page 52 - Code of Practice • New Code of Practice Guidelines added. Ideal Stelrad Group reserve the right to vary specification without notice icos - Installation & Servicing...

  • Page 4: Boiler Size

    back GENERAL Table 1 - Boiler Data Boiler Size HE 12, HE 15, HE 18, HE 24 Gas supply type and connection 2H-G20-20 mbar Rc " BSP Female Injector size Stereomatic 5.6mm dia. (HE 12 5.8mm dia). Flow connection 22mm copper Return connection 22mm copper Flue terminal diameter...

  • Page 5: Table Of Contents

    back GENERAL icos CONTENTS Air Supply ............... 9 Natural Gas only Benchmark Commissioning Checklist ..... 58 Boiler Clearances ............6 Boiler size G.C. Appliance No. PI No. Boiler Exploded Diagram ..........14 Benchmark No. Electrical Connections ..........29 HE12 41 397 95 87 BP 34 Electrical Supply ............

  • Page 6: Boiler Clearances

    back GENERAL BOILER WATER CONNECTIONS The boiler flow and return pipes are supplied fitted to the boiler ready for top connection Notes. a. For the heating loads in excess of 60,000 Btu/h, 28mm (1") flow and return pipes should be used to and from the boiler. b.

  • Page 7: Gas Safety Regulations

    Ideal Stelrad Group in writing. If in doubt please enquire. • Flue Extension Ducts (1000mm long up to 6m) Any direct connection of a control device not approved by Ideal • Flue Finishing Kit Stelrad Group may invalidate the certification and the normal •...

  • Page 8: Flue Installation Requirements

    back GENERAL the principle of the 1:1 gas valve ensures the icos HE range is SAFE HANDLING OF SUBSTANCES able to deliver it’s full output at inlet pressures as low as 14mb, Care should be taken when handling the boiler insulation other gas appliances in the property may not be as tolerant.

  • Page 9: Trv's

    BOILER CONTROL INTERLOCKS material. Detailed recommendations on the protection of combustible material are given in BS.5440-1:2000. In IE Ideal Stelrad Group recommend that heating systems utilising refer to I.S.813:2002. full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat...

  • Page 10: Controls

    Return & flow connections specified by Ideal Stelrad Group. The isolation valves should be fitted load 30 - 60 = 22 mm as close to the pump as possible. load 70 - 80 = 28 mm...
  • Page 11 back GENERAL 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.
  • Page 12 back GENERAL SEALED SYSTEM REQUIREMENTS - continued 4. Expansion Vessel A diaphragm type expansion vessel must be pressure. The cold feed pipe from the cistern should connected to a point close to the inlet side of the include a non-return valve and a stop valve with an pump, the connecting pipe being not less than 15 mm automatic air vent connected between them, the stop "...

  • Page 13: For All Boilers Flushing To Bs.7593

    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.

  • Page 14: Boiler Exploded Diagram

    back INSTALLATION 10 BOILER ASSEMBLY - Exploded view 23. Control thermistor. 24. Overheat thermostat. 25. Ignition electrode. LEGEND 15. Venturi assy. 26. Flame detection electrode. Front casing panel. Flue manifold. 32. 'S' trap 16. Fan assy. Sealing panel 10. Interpanel. 17.
  • Page 15 back INSTALLATION 11 UNPACKING The boiler is supplied fully assembled in one Pack A, together with a telescopic flue assembly for lengths up to 595mm, rear or side flue outlet, in Pack B. Unpack and check the contents. Pack A Contents The boiler Wall mounting template on cardboard...
  • Page 16 back INSTALLATION 12 PACKAGING REMOVAL 1. Ensure the boiler is stood correctly, as marked on the carton. 2. Cut and remove the strapping. 3. Fold back the top flaps to gain access to the wall mounting plate, literature and wall mounting card template.

  • Page 17: Flue Fitting

    back INSTALLATION 14 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT. The boiler MUST be installed in a vertical position. Dimension X - Wall thickness. FLUE KITS Dimension L - Wall thickness plus boiler spacing. Pack B - supplied as standard. Dimension S - Stand-off frame depth = 33mm.
  • Page 18 back INSTALLATION 15 FLUE ASSEMBLY - Exploded View An optional flue duct extension kit is required for wall thicknesses greater than : Side 395mm Rear 435mm LEGEND 1. Duct assembly. 2. Flue turret. 3. Turret gasket. 4. M5 x 10 pozi screw. 5.
  • Page 19 back 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. 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.
  • Page 20 back INSTALLATION 19A SETTING THE FLUE - REAR Wall thicknesses of 210 to 435mm Notes. a. If using the extension ducts go to Frame 18. b. If the stand-off frame is used it is essential to add 33mm to dimension X. c.

  • Page 21: Extension Ducts - Fitting

    back INSTALLATION 20 FLUE EXTENSION DUCTS - For total flue lengths greater than 595mm Pack D Flue extension duct kit contents. Flue support cutting aid Extension duct & clamp (shown folded up) 1.0m (39") long Wall plugs - 4 off Flue duct support nm8732 No.

  • Page 22: For Condensing Boilers Only Condensate Drain

    back INSTALLATION 23 CONDENSATE DRAIN The condensate drain provided on the boiler must be connected to a drainage point, preferably within the building. Ensure that the condensate trap is full of water before commissioning the boiler. Refer to Frame 27. The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler, throughout its length.
  • Page 23 back 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...

  • Page 24: Mounting The Boiler

    back INSTALLATION 26 MOUNTING THE BOILER 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. Align the hole in the jacking plate with the pre- drilled hole in the wall and fix in position with the No.10 x 2"...
  • Page 25 back 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.

  • Page 26: Flue Terminal Position

    back 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 300mm 625mm...
  • Page 27 back INSTALLATION 31 FLUE ARRANGEMENT Note. The equivalent flue length resistance of the elbow kits are: elbow kit = 1m elbow kit = 0.6m icos - Installation & Servicing...
  • Page 28 back 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 longer than the outer air tube as supplied.

  • Page 29: Gas Connection

    back INSTALLATION 33 GAS CONNECTION IMPORTANT. The gas service cock is sealed with a non-metallic A boiler gas supply pipe length of 20m and not less than fibre washer seal so must not be overheated when making 15mm O.D. can be connected to the boiler via the gas capillary connections.

  • Page 30: Internal Wiring

    back INSTALLATION 36 INTERNAL WIRING A pictorial wiring diagram is shown in Frame 37. The mains lead connector is pre-fitted. This must be removed to allow wiring. 1. Route the mains cable into the bottom LHS rear of the casing. If using the stand-off kit then route through the grommet.

  • Page 31: Electrical Systems Diagrams

    back INSTALLATION 37 PICTORIAL WIRING DIAGRAM LEGEND b - blue bk - black Flue br - brown thermistor gy - grey or - orange Overheat pk - pink thermostat - red Gas valve v - violet Flow control w - white thermistor Chassis y - yellow...

  • Page 32: Time And Temperature Control To Heating

    back 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.

  • Page 33: 41 Initial Lighting

    back INSTALLATION 41 INITIAL LIGHTING 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 appliance pump to assist venting of the air this must be done with the gas service cock turned off.

  • Page 34: Handing Over

    In IE contact a Registered Gas Installer (RGII). the benefits of the Ideal Care Scheme, details of which are outlined in the household pack supplied with this 6. Explain and demonstrate the function of time and boiler.

  • Page 35: Servicing

    back SERVICING 44 SERVICING SCHEDULE For the very latest copy of literature for specification and maintenance practices visit our website www.idealboilers.com, where you will be able to download relevant information. N.B. Technical Bulletins are also available on our website. 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.

  • Page 36: Burner Removal And Cleaning

    back 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. Lift off the fan and venturi assembly. 5.

  • Page 37: Cleaning The Heat Exchanger

    back SERVICING 49 CLEANING THE CONDENSATE 'S' TRAP 1. Undo the plastic union nut on the condensate ‘S’ trap outlet. 2. Remove the 2 screws. 3. Pull the trap down and forward to remove. 4. Flush out any deposits with clean water.

  • Page 38: Replacement Of Components

    back SERVICING 52 REPLACEMENT OF COMPONENTS GENERAL When replacing ANY component: IMPORTANT When work is complete, the sealing panel must be 1. Isolate the electricity supply. correctly fitted, ensuring that a good seal is made. 2. Turn off the gas supply. Note.
  • Page 39 back SERVICING 54 FAN REPLACEMENT Orifice plate 1. Refer to Frame 52. Gasket 2. Remove the boiler front and sealing panels. Refer to Frames 45 & 46. 3. Disconnect the electrical leads from the fan. 4. Unscrew the gas pipe union connection to the injector housing.
  • Page 40 back SERVICING 56 IGNITION ELECTRODE REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 45 & 46. 3. Unplug the ignition lead from the electrode. 4. Remove the earth lead from the ignition electrode. 5.
  • Page 41 back SERVICING 58 SPARK GENERATOR REPLACEMENT 1. Refer to Frame 57. 2. Disconnect the leads from the spark generator. 3. Remove the M4 screws securing the spark generator to the boiler chassis. 4. Fit the new spark generator and re-assemble in reverse order.
  • Page 42 back SERVICING 61 CONTROL BOX REPLACEMENT 1. Refer to Frame 52. 2. Remove the front panel. 3. Remove the bottom panel. 4. Remove the 2 control box screws. 5. Carefully unplug all the electrical wiring from the control box. 6. With the control box lowered, pull the assembly forward to remove from the housing.
  • Page 43 back SERVICING 63 OVERHEAT THERMOSTAT REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 45 & 46. 3. Pull off the electrical leads from the thermostat body. 4. Pull the thermostat and clip from the pipe.

  • Page 44: Combustion Chamber

    SERVICING 68 COMBUSTION CHAMBER INSULATION REPLACEMENT 11. Fit new insulation piece - Ideal Stelrad Group recommends that, for your own comfort and safety and to comply with good working practice, the (a) Locate and align the insulation with the electrode...
  • Page 45 back SERVICING 66 HEAT EXCHANGER REPLACEMENT 17. Remove the condensate 'S' trap. Refer to Frame 49. Refer also to Frame 10, 'Boiler exploded view'. 18. Unscrew the 2 M5 x 10 screws from the inter panel. 1. Refer to Frame 52. 19.
  • Page 46 back 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.

  • Page 47: Fault Finding

    back 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 GO TO FRAME 71 ALTERNATING 'L' 'E' ALTERNATING 'L' 'A' GO TO FRAME 72...
  • Page 48 back FAULT FINDING 70 L..F..(FLAME ERROR) If the boiler reset button is Is gas pressure available at Check gas supply pressed does the boiler ignite for the boiler inlet ? and rectify fault a short time then extinguish? Check the detection electrode and associated harness for: Check gas valve Is 200V DC supply available...
  • Page 49 back FAULT FINDING 72 L..A..(OVERHEAT ERROR) Can the overheat condition be reset by pressing Replace overheat thermostat the boiler reset button when the system is cold ? Is the boiler and CH system filled with Fill and vent the system and open all water and all isolation valves open ? isolation valves Does the pump setting give a differential...
  • Page 50 back FAULT FINDING 75 H..F..(FLAME DETECTION - SHORT CIRCUIT ERROR) Remove flame detection electrode terminal from PCB. Replace PCB. Is there continuity between the 2 terminal pins ? Replace flame detection electrode 76 H..4..(FLUE THERMISTOR ERROR) H9/L9 (HEAT EXCHANGER OVERHEAT) Is the system filled and vented and all isolation valves open, including TRV's &...

  • Page 51: Short List Of Parts

    When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers Limited.

  • Page 52: Short List

    back SHORT LIST OF PARTS 78 SHORT LIST nm8077d 79 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom casing panel with screws. icos - Installation & Servicing...

  • Page 53: Burner Assembly

    back LIST OF PARTS 80 CONTROLS ASSEMBLY Controls assy with screws. Controls hinge bracket. User controls (without item 38). PCB (primary controls). User control housing Mains switch. Jumper link. 81 BURNER ASSEMBLY 11. Burner assembly with screws and gasket. Ecl 1598 icos - Installation &...
  • Page 54 back NOTES icos - Installation & Servicing...
  • Page 55 back NOTES icos - Installation & Servicing...
  • Page 56 back...

  • Page 57: Installer Notification Guidelines

    back INSTALLER NOTIFICATION GUIDELINES 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 Choose SELF CERTIFICATION SCHEME BUILDING CONTROL...

  • Page 58: Benchmark Commissioning Checklist

    back Gas Safe Register ID Number...
  • Page 59 back Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number Gas Safe Register ID Number...
  • Page 60 & servicing of central heating systems 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.

This manual is also suitable for:

Icos he15Icos he24He18

Table of Contents