IDEAL HE24 Installation And Servicing
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IDEAL HE24 Installation And Servicing

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  • Page 2 GENERAL Table 1 - General Data isar HE24 HE30 HE35 Gas supply 2H - G20 - 20mbar Gas Supply Connection Rc 1/2 (1/2” BSP female) Injector Size Stereomatic 5.6mm dia. Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection...

  • Page 3: Table Of Contents

    Air Supply ............... 7 Natural Gas only Boiler Clearances ............6 Boiler size G.C. Appliance No. PI No. Boiler Exploded Diagram ..........11 HE24 47 348 31 0063 BO 3317 Condensate Drain ........... 8, 22 HE30 47 348 30 0063 BO 3317 Electrical Connections ..........
  • Page 4 DHW is drawn off. The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a maximum DHW draw-off of HE24 9.6 l/min at 35 C temperature rise. HE30 12 l/min at 35 C temperature rise.

  • Page 5: Location Of Boiler

    HE24-upto 8m Installation and Servicing Instructions or as otherwise HE30-upto 8m recommended by Caradon Ideal Limited in writing. If in doubt HE35-upto 5m please enquire. ! Powered Vertical Flue Kit (to a maximum primary flue...

  • Page 6: Flue Installation

    GENERAL Compartment Installations The complete installation MUST be tested for gas soundness and purged as described in the above code. A compartment used to enclose the boiler should be designed and constructed specially for this purpose. FLUE INSTALLATION An existing cupboard or compartment may be used, provided Pluming will occur at the terminal so terminal positions where that it is modified for the purpose.
  • Page 7 600mm (24"). SIDE FLUE ONLY Horizontal length of flue Top clearance from centre line of boiler required (MIN.) to outside wall Dim. A HE24 HE30 HE35 0.5 m 0.5 m 0.5 m 160 mm (6 ") 5/16 1.0 m...

  • Page 8: Inhibitor

    GENERAL THERMOSTATIC RADIATOR VALVES (TRV) ELECTRICAL SUPPLY WARNING. Caradon Ideal Limited recommend that heating systems utilising full thermostatic radiator valve control of temperature This appliance must be earthed. in individual rooms should also be fitted with a room Wiring external to the appliance MUST be in accordance with the current I.E.E.

  • Page 9: Domestic Hot Water

    GENERAL SYSTEM REQUIREMENTS - CH (continued) and Hot Water an additional vessel MUST be installed on the return to the boiler. Water Flow Rate and Pressure Loss Guidance on vessel sizing is given in Frame 3. Max CH Output 23.4 5.

  • Page 10: Water Treatment

    Water Treatment in Central Heating Systems. For further information contact: Fernox Manufacturing Co. Ltd Cookson Electronics If water treatment is used Caradon Ideal Limited recommend Forsyth Road only the use of FERNOX-COPAL or MB1, GE BETZ SENTINEL X100 Sheerwater...
  • Page 11 INSTALLATION BOILER ASSEMBLY - Exploded View isar - Installation and Servicing...
  • Page 12 INSTALLATION UNPACKING Pack A Contents The boiler is supplied fully assembled in one Pack A, Hardware Pack and fittings. together with a standard flue assembly for lengths up to These Installation & Servicing Instructions. 650mm, rear or side flue outlet, in Pack B. The User's Instructions.
  • Page 13 INSTALLATION 10 PACKAGING REMOVAL 1. Ensure the boiler is stood upright on a sound flat surface. 2. Carefully remove the strapping. 3. Fold back the top flaps to gain access to: Wall mounting plate. Instructions. Hardware pack & fittings. User control. 4.
  • Page 14 Up to 650 mm Up to 650 mm none HE24,30 & 35 Up to 1600 mm Up to 1600 mm Pack D - 1 off HE24,30 & 35 Up to 2550 mm Up to 2550 mm Pack D - 2 off HE24,30 &...
  • Page 15 INSTALLATION 13 FLUE ASSEMBLY - Exploded View An optional flue duct extension kit is required for wall thicknesses greater than : Side 455mm (18"). Rear 490mm (19 "). LEGEND 1. Duct assembly. 2. Flue turret. 3. Turret gasket. 4. M5 x 10 pozi screw. 5.
  • Page 16 INSTALLATION 15 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 Side flue only 1. Cut the flue hole (preferably with a 5" core boring 5"...
  • Page 17 Ecl 1244 No. 10 x2" wood screw - 4 off 19 FLUE EXTENSION DUCTS - continued Use a maximum of 6m extended flue ONLY (HE24 & 30) Use a maximum of 3m extended flue ONLY (HE35) General arrangement 1. A maximum of 6 extension ducts for the HE24/...
  • Page 18 INSTALLATION 21 FITTING THE PIPING FRAME (Rear Flue outlet shown) Note. The CH Flow isolating valve (A), c/w pressure gauge, is supplied separately in the Hardware Pack. Fit to the piping frame BEFORE mounting the boiler. Wall plug Fit the wall mounting frame either: Four positions Directly to the wall...

  • Page 19: Condensate Drain

    INSTALLATION 22 CONDENSATE DRAIN Refer also to the British Gas document: 'Guidance Notes for the Installation of Domestic Gas Condensing Boilers' (1989). The condensate drain (provided in the h/ware pack) must be connected from the boiler ‘S’ trap to a drainage point, preferably within the building.

  • Page 20: Connecting The Flue To The Boiler

    INSTALLATION 24 CONNECTING THE FLUE TO THE BOILER Note. Before fitting the flue turret fill the condensate trap within the boiler by pouring a cupful of water into the flue outlet A. Take care to ensure that the water is only poured into the flue outlet, and does not spill into the boiler casing. 1.

  • Page 21: Gas Connection

    INSTALLATION 26 WATER CONNECTIONS - DHW Cross bar 'O' Ring Retaining Outlet screw connector Regulator / Filter Note. The DHW inlet Piping frame 15mm copper pipe isolating valve incorporates a flow regulator / filter. It should be inspected to ensure no blockage is evident.

  • Page 22: Electrical Connections

    Note. The domestic hot water flow rate is automatically regulated to a maximum: HE24 = 9.6 l/m (2.1 gpm) HE30 = 12.0 l/m (2.6 gpm) HE35 = 14.4 l/m (3.2 gpm) isar - Installation and Servicing...

  • Page 23: Electrical Supply

    INSTALLATION 30 ELECTRICAL CONNECTIONS Wiring should be 3 core PVC insulated cable, not less than WARNING . This appliance MUST be earthed. 0.75 mm (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for A mains supply of 230 V ~ 50 Hz is required.

  • Page 24: External Electrical Controls

    INSTALLATION 32 EXTERNAL ELECTRICAL CONTROLS Wiring External to the Boiler The fuse rating should be 3A. Wiring external to the boiler MUST be in accordance with the L2 L1 current I.E.E. (BS.7671) Wiring Regulations and any local regulations. Room 'stat Room Thermostat If the thermostat has a neutral connection, use it (it provides for more energy efficient operation by reducing switching...
  • Page 25 INSTALLATION 33 PICTORIAL WIRING DIAGRAM LEGEND b - blue - red bk - black v - violet br - brown w - white gy - grey y - yellow or - orange y/g - yellow/green pk - pink isar - Installation and Servicing...

  • Page 26: Flow Wiring Diagram

    INSTALLATION 34 FUNCTIONAL FLOW WIRING DIAGRAM LEGEND b - blue or - orange bk - black pk - pink w - white br - brown - red y - yellow gy - grey v - violet y/g - yellow/green 35 COMMISSIONING AND TESTING B.

  • Page 27: Initial Lighting

    INSTALLATION 36 INITIAL LIGHTING LEGEND A. Boiler On/Off switch. B. CH thermostat knob. N. Automatic air vent. D. Burner On neon. P . Control box (Servicing position). E. Reset button. R. Pressure gauge. F . Injector pressure test point. S. CH Flow isolating valve. G.
  • Page 28 INSTALLATION 37 INITIAL LIGHTING - continued 17. Turn off the DHW tap. 15. DOMESTIC HOT WATER 18. Set the boiler on/off switch (A) to OFF. With the boiler firing, set the DHW thermostat knob (Y) to 19. Swing the control box into the servicing position. Refer to maximum and fully open a DHW tap.
  • Page 29 INSTALLATION 39 GENERAL CHECKS - continued WATER CIRCULATION SYSTEM CENTRAL HEATING (CH) & DOMESTIC HOT WATER (DHW) MODE. 1. With the system COLD, check that the initial pressure is correct to the system design requirements. 1. Ensure that the CH external controls are calling for heat. For pre-pressurised systems, this should be 1.0 bar.

  • Page 30: Gas Supply

    11. As the installer you may wish to undertake the service economic use of the system. contract yourself or alternatively offer to the customer the benefits of the Ideal Care Scheme, details of which are outlined in the householder pack supplied with this boiler. 41 SERVICING SCHEDULE To ensure the continued safe and efficient operation of the replaced.
  • Page 31 SERVICING 42 BOILER FRONT PANEL REMOVAL 1. Remove the 2 screws from the underside of the boiler. 2. Pull the panel forward at the bottom and lift to disengage it from the top lugs. 43 BOILER SEALING PANEL / BOTTOM PANEL REMOVAL 1.
  • Page 32 SERVICING 44 THE CONTROL BOX IN THE SERVICING POSITION 1. Remove the 2 screws and withdraw the user control. 2. Unplug the low voltage electrical lead from the back of the user control. 3. Turn the clamp, swing the control box down and pull slightly forward.

  • Page 33: Burner Removal And Cleaning

    SERVICING 45 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 fan and venturi assembly. 5.

  • Page 34: Cleaning The Heat Exchanger

    SERVICING 47 CLEANING THE CONDENSATE 'S' TRAP 1. Swing the control box down into the servicing position. Refer to Frame 44. 2. Disconnect the condensate drain pipe. 3. Remove the screw and elongated bolt, pull the trap down and forward to remove.

  • Page 35: Replacement Of Components

    SERVICING 50 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When work is complete, the sealing panel, if removed, must When replacing ANY component be correctly refitted - ensuring that a good seal is made. 1. Isolate the electricity supply. Notes. 1. In order to assist fault finding, the control panel has an 2.
  • Page 36 SERVICING 53 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 50. 2. Remove the boiler front and sealing panels. Refer to Injector Frames 42 & 43. 3. Disconnect the electrical leads from the fan. 4. Undo the gas pipe union connection to the injector housing. 5.
  • Page 37 SERVICING 56 IGNITION ELECTRODE REPLACEMENT 1. Refer to Frame 50. 6. Remove the electrode. 2. Remove the boiler front and sealing panels. Refer to 7. Fit the new ignition electrode, using the new gasket Frames 42 & 43. supplied. Check dimensions as shown. 3.
  • Page 38 SERVICING 58 SPARK GENERATOR REPLACEMENT 1. Refer to Frame 50. 2. Disconnect the leads from the spark generator and bracket. 3. Remove the M5 screw securing the spark generator bracket to the flue casting. 4. Remove the 2 M4 screws securing the spark generator to the bracket.
  • Page 39 9. Remove the split pin and washer from the RHS of the combustion chamber. Caradon Ideal Limited recommend that, for your own comfort and safety and to comply with good working practice, the 10. Remove the insulation boards. The replacement boards procedure described below is followed: are supplied in a plastic bag.

  • Page 40: Pump

    SERVICING 62 CONDENSATE 'S' TRAP REPLACEMENT 1. Refer to Frame 50. 2. Remove the casing front & bottom panel. Refer to Frames 42 & 43. 3. Swing the control box down into the servicing position. Refer to Frame 44. 4. Disconnect the condensate drain pipe. 5.
  • Page 41 SERVICING 64 CONTROL BOX REPLACEMENT 8. Transfer mounting bracket and hinge arms to the new control box. 1. Refer to Frame 50. 9. Reassemble in reverse order, ensuring that the control box 2. Remove the casing front & bottom panel. is located correctly in the housing before reconnecting the Refer to Frames 42 &...
  • Page 42 SERVICING 66 USER CONTROL REPLACEMENT Note. Only the display unit is replaced. 1. Refer to Frame 50. 2. Loosen the screw on the underside of the user control. 3. Pull the display unit forward to remove. 4. Push the new display unit into position. 5.
  • Page 43 SERVICING 68 SAFETY RELIEF VALVE REPLACEMENT 7. Remove the safety valve. 1. Refer to Frame 50. 8. Fit the new safety valve and refit the securing pin. 2. Remove the casing front and bottom panels. Refer to 9. Reassemble in reverse order, ensuring correct Frames 42 &...

  • Page 44: Draining The Boiler

    SERVICING 70 DRAINING THE BOILER 1. Refer to frame 50. 2. Remove the boiler bottom panel. Refer to Frame 43. 3. Close all the water isolating valves on the piping frame. 4. Attach a length of hose to the drain point and open the drain valve.
  • Page 45 SERVICING 72 DHW PLATE HEAT EXCHANGER REPLACEMENT 1. Refer to Frame 50. 2. Remove the casing front & bottom panel. Refer to Frames 42 & 43. 3. Drain the boiler. Refer to Frame 70. 4. Remove the 4 screws securing the rear support plate and withdraw the plate.
  • Page 46 SERVICING 74 HEAT ENGINE REPLACEMENT 17. Remove the automatic air vent, complete with the adapter. Refer also to Frame 8 - 'Boiler Exploded View'. Refer to Frame 69. IMPORTANT 18. Remove the edge clip securing the flue thermistor wiring. Before starting the removal procedure, protect the gas and 19.
  • Page 47 SERVICING 75 EXPANSION VESSEL REPLACEMENT 1. Refer to Frame 50. 2. Drain the boiler. Refer to Frame 70. 3. Unscrew all the gas and water connection unions on the boiler side of the valves. 4. Remove the screw from the turret clamp and remove. Expansion vessel 5.
  • Page 48 FAULT FINDING 77 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 78 ALTERNATING 'L' 'E' GO TO FRAME 79 ALTERNATING 'L' 'A' GO TO FRAME 80...

  • Page 49: Fault Finding

    FAULT FINDING 78 L..F..(FLAME DETECTION 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? Is 200V DC supply available Check gas valve Check the detection electrode and at the gas valve ?
  • Page 50 FAULT FINDING 80 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 51 FAULT FINDING 83 H..2..(CONTROL THERMISTOR [RETURN] ERROR) Remove the boiler return thermistor from the CH return pipe. Check resistance using a suitable multimeter connected across the thermistor’s terminal pins At 25 C expect 9,700 - 10,300 Ohms At 60 C expect 2,400 - 2,600 Ohms...
  • Page 52 FAULT FINDING 85 H..4..(FLUE THERMISTOR ERROR) Is the system filled and vented and all Can the fault condition be reset by switching off isolation valves open ? the mains supply to the boiler ? Fill and vent the Check wiring for continuity from the system and open all PCB to the flue thermistor isolating valves...

  • Page 53: 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.
  • Page 54 SHORT LIST OF PARTS 88 SHORT LIST isar - Installation and Servicing...
  • Page 55 LIST OF PARTS 89 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom panel with screws. 90 CONTROLS ASSEMBLY Controls assy with screws. Controls hinge bracket. User controls (without item 38). PCB (primary controls). User controls housing Mains switch.
  • Page 56 & 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.

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