Ideal Boilers Ideal Esprit HE24 Installation And Servicing Manual
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Ideal Boilers Ideal Esprit HE24 Installation And Servicing Manual

Ideal Boilers Ideal Esprit HE24 Installation And Servicing Manual

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installation and
servicing
ideal esprit
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
HE24, HE30, HE35
For users guide see reverse of book
When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require. Do not
use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
January 2008 UIN 203642 A04
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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Summary of Contents for Ideal Boilers Ideal Esprit HE24

  • 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. January 2008 UIN 203642 A04 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.
  • Page 2 Esprit - Installation and Servicing...
  • Page 3 DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level ....A03 (Oct 07) A04 (Jan 08) Page 15, Frame 8 - Boiler Assembly - Exploded View • Pictorial change to show new water pressure switch. Page 25, Frame 26 - Roof Flue Kit Contents/Options •...
  • Page 4 GENERAL Table 1 - General Data Esprit HE24 HE30 HE35 Gas supply 2H - G20 - 20mbar Gas Supply Connection Rc 1/2 (1/2” BSP female) Injector Size Stereomatic 5.6mm dia. 5.7mm dia Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection Domestic Hot Water 15mm copper compression...
  • Page 5 GENERAL Esprit CONTENTS Air Supply ............... 8 Natural Gas only Benchmark Commissioning Checklist ..... 70 Boiler size G.C. Appliance No. PI No. Boiler Clearances ............10 (Benchmark No.) Boiler Exploded Diagram ..........15 HE24 47 348 46 87 BS 051 Condensate Drain ..........

  • Page 6: Safe Handling

    GENERAL SAFE HANDLING INTRODUCTION The Esprit range of boilers are wall mounted, full sequence, This boiler may require 2 or more operatives to move it to its automatic spark ignition, low water content, fanned flue, high installation site, remove it from its packaging base and during efficiency, condensing, combination gas boilers.
  • Page 7 GENERAL SAFETY LOCATION OF BOILER Current Gas Safety (installation and use) regulations or rules The boiler must be installed on a flat and vertical wall, capable in force: of adequately supporting the weight of the boiler and any ancillary equipment. The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force.

  • Page 8: Gas Supply

    GENERAL GAS SUPPLY Table 4 - Balanced Flue Terminal Position Flue Terminal Positions Min. Spacing* The local gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an 1. Directly below, above or alongside an opening adequate supply of gas.
  • Page 9 GENERAL BOILER WATER CIRCUIT DIAGRAMS CENTRAL HEATING CIRCUIT Expansion Vessel Burner Automatic Air Vent Heat Exchanger Sump Pressure Divertor Relief Valve Valve Gas Valve Water Pressure Gauge Pump DOMESTIC HOT WATER CIRCUIT Condensate Plate Heat Siphon Exchanger Expansion Vessel Burner Automatic Air Vent Heat...
  • Page 10 GENERAL all dimensions in mm BOILER DIMENSIONS, SERVICES & CLEARANCES The boiler connections are made on the boiler. Refer to Side and Rear Flue Frames 30. 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 The following minimum clearances must be maintained for thicknesses do not exceed 600mm.

  • Page 11: Electrical Supply

    GENERAL BOILER CONTROL INTERLOCKS ELECTRICAL SUPPLY WARNING. Ideal Stelrad Group recommend that heating systems This appliance must be earthed. utilising full thermostatic radiator valve control of temperature Wiring external to the appliance MUST be in accordance with in individual rooms should also be fitted with a room the current I.E.E.

  • Page 12: Domestic Hot Water

    GENERAL SYSTEM REQUIREMENTS - CH (continued) and Hot Water 5. Filling Where the mains pressure is excessive a pressure reducing Water Flow Rate and Pressure Loss valve must be used to facilitate filling. Max CH Output 23.8 a. Thoroughly flush out the whole system with (Btu/h) (81 200) cold water.

  • Page 13: Water Treatment

    INSTALLATION WATER TREATMENT CENTRAL HEATING DOMESTIC HOT WATER The Esprit range of boilers have an ALUMINIUM alloy In hard water areas where main water can exceed 200ppm heat exchanger. Total Hardness (as defined by BS 7593:1993 Table 2) a IMPORTANT. scale reducing device should be fitted into the boiler cold The application of any other treatment to this product supply within the requirements of the local water company.
  • Page 14 INSTALLATION BOILER ASSEMBLY - Exploded View Legend Front Casing Panel 31. Spark Generator Front Casing Door 32. Ignition Lead Sump Cover Plate 33. Connection Pipes Flue Sensing Nipple 34. Flow Regulator Return Pipe 35. Pressure Relief Valve Flue Manifold 36. Expansion Vessel Interpanel 37.
  • Page 15 INSTALLATION BOILER ASSEMBLY - Exploded View Esp9176 Esprit - Installation and Servicing...
  • Page 16 INSTALLATION 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 Boiler Hardware Pack Box (positioned at bottom of boiler) Wall Mounting Bracket...
  • Page 17 INSTALLATION 10 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED FLUE KITS IMPORTANT. The boiler MUST be installed in a vertical position Pack B - supplied as standard Dimension X - Wall thickness. Pack D - optional extension kit for side flue or Dimension L - Wall thickness plus boiler spacing.
  • Page 18 INSTALLATION 11 FLUE ASSEMBLY - Exploded View An optional flue duct extension kit is required for wall thicknesses greater than : Side 365mm (14 ") Rear 426mm (15 "). LEGEND 1. Duct assembly. 2. Flue turret. 3. Turret gasket. 4. M5 x 10 pozi screw. esp8822 5.
  • Page 19 INSTALLATION 13 PREPARING THE WALL IMPORTANT. Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury. 1. Cut the flue hole (preferably with a 5" core boring Rear flue only Side flue only tool), ensuring that the hole is square to the wall.
  • Page 20 INSTALLATION 16 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 21: Mounting The Boiler

    INSTALLATION 19 FITTING THE WALL MOUNTING PLATE Screw the wall mounting plate to the wall using 3 wall plugs (previously fitted) with the 3 screws provided. Choose one of the 3 sets of slots in left, right and centre bank. Ensuring that at Example of fixing least one of the screws is fitted into a top slot.

  • Page 22: Condensate Drain

    INSTALLATION 21 CONDENSATE DRAIN Refer also to the British Gas document: 'Guidance Notes for the Installation of Domestic Gas Condensing Boilers' (1989). Ensure that the siphon is full of water before commissioning the boiler . Refer to Frame 24. The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler, throughout its length.
  • Page 23 INSTALLATION 23 CONDENSATE PIPE TERMINATION CONFIGURATIONS . . . continued 3. INTERNAL CONNECTION TO SOIL AND VENT STACK * Make connection to SVP using a solvent welded saddle BOILER esp8882 4. TERMINATION TO SOAK AWAY External wall Termination BOILER to Soak away cla7774 Ground Level minimum...
  • Page 24 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.
  • Page 25 INSTALLATION 25 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched) Note. A flat or pitched roof flashing plate (not supplied) is required before proceeding with the installation of this kit. This kit is suitable for both flat and pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level.

  • Page 26: Flue Terminal Position

    INSTALLATION 27 FLUE TERMINAL POSITION The terminal should be positioned so that products of combustion can safely disperse at all times. Pluming may occur at the termination so, where possible, terminal positions where this could cause a nuisance should be avoided. Minimum dimensions are shown below 300mm 625mm...
  • Page 27 INSTALLATION 28 FLUE ARRANGEMENT Note. The equivalent flue length resistance of the elbow kits are: elbow kit = 1m elbow kit = 0.6m Esprit - Installation and Servicing...
  • Page 28 INSTALLATION 29 ASSEMBLING THE ROOF FLUE KIT Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied.
  • Page 29 INSTALLATION PRESSURE RELIEF VALVE (PRV) OUTLET - (SAFETY VALVE DRAIN) The PRV outlet is located at the rear RHS of the boiler service connection area. Connection of additional pipewok to the PRV outlet should be made prior to connection of CH, DHW and gas connections for ease of access.

  • Page 30: Electrical Connections

    INSTALLATION FILLING Central Heating IMPORTANT - when filling: 1. Remove the front panel. Refer to A. Ensure dust cap on auto air vent is Frame 45. opened up one full turn. 2. Ensure that the CH isolating B. When filling, there may be a slight valves are open.
  • Page 31 INSTALLATION 34 CONT’D ..ELECTRICAL CONNECTIONS - INSTALLER WIRING Ideal Boilers offer 4 kits as follows: (see individual kits for installation instructions) PROGRAMMER KIT MECHANICAL 24 HOUR- 24 hour mechanical programmer fits into the control box of the boiler. This can be fitted in conjunction with a room thermostat.
  • Page 32 INSTALLATION 35 REPLACING PRE-FITTED MAINS CABLE If it is necessary to use an alternative mains cable to the one 9. Route replacement cable back through the cable gland pre-fitted then use the following guide. and re-tighten to provide cord anchorage. Replacement wiring should comply with notes in Frame 33.
  • Page 33 INSTALLATION 36 PICTORIAL WIRING DIAGRAM LEGEND gy - grey v - violet b - blue or - orange w - white bk - black pk - pink y - yellow - red br - brown y/g - yellow/green Water pressure Dry fire switch thermistor...

  • Page 34: Commissioning And Testing

    INSTALLATION 37 FUNCTIONAL FLOW WIRING DIAGRAM Summer/winter External switch Switch e.g. room’stat Prog. (optional) Water pressure switch Dry fire thermistor DHW Preheat Switch DHW Thermistor Diverter DHW Flow Switch Val ve esp8889 LEGEND b - blue or - orange bk - black pk - pink w - white br - brown...

  • Page 35: Initial Lighting

    INSTALLATION 39 INITIAL LIGHTING LEGEND A. Boiler On/Off switch M. Gas Service Cock B. Winter/Summer Switch N. CH Flow Isolating Valve C. Preheat On/Off Switch P. CH Return Isolating Valve D. CH Temperature Control R. DHW Inlet Isolating Valve E. DHW Temperature Control S.
  • Page 36 INSTALLATION 40 INITIAL LIGHTING - continued 12. DOMESTIC HOT WATER IMPORTANT The gas input to the burner is regulated by the gas valve With the boiler firing, set the DHW temperature control according to the air flow produced by the fan. It is NOT (E) to maximum and fully open a DHW tap.
  • Page 37 INSTALLATION 42 GENERAL CHECKS - continued CENTRAL HEATING (CH) & DOMESTIC HOT WATER (DHW) WATER CIRCULATION SYSTEM 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 38: Handing Over

    INSTALLATION 43 HANDING OVER After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions: 1. Hand the User Instructions to the householder and 6. Explain and demonstrate the function of time and explain his/her responsibilities under the relevant temperature controls, radiator valves etc., for the economic national regulations.

  • Page 39: Servicing Schedule

    SERVICING 44 SERVICING SCHEDULE WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing. To ensure the continued safe and efficient operation of the Note. In order to carry out either servicing or replacement of appliance it is recommended that it is checked at regular components the boiler front panel must be removed.

  • Page 40: Burner Removal And Cleaning

    SERVICING 46 THE CONTROL BOX IN THE SERVICING POSITION 1. Pull the panel forward at the top to disengage the two clips. 2. Carefully swing the control down into its servicing position. esp8854 47 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING 1.

  • Page 41: Cleaning The Heat Exchanger

    SERVICING 49 CLEANING THE CONDENSATE TRAP/SIPHON 1. Remove the cleaning plug and allow any residual 2. If necessary pull off the top tube and flush out any condensate / debris to drain. debris. 3. Replace the tube and cleaning plug. 50 CLEANING THE HEAT EXCHANGER 1.

  • Page 42: Replacement Of Components

    SERVICING 52 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When work is complete, the front panel, if removed, must be When replacing ANY component correctly refitted - ensuring that a good seal is made. 1. Isolate the electricity supply. Notes. 2. Turn off the gas supply. 1.
  • Page 43 SERVICING 55 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 52. 2. Disconnect the electrical leads from the fan. 3. Undo the gas pipe union connection to the injector housing. 4. Remove the screw retaining the fan mounting bracket. 5. Remove the fan and venturi assembly Injector 6.
  • Page 44 SERVICING 57 CONTROL THERMISTOR, RETURN THERMISTOR & OVERHEAT ‘STAT REPLACEMENT (Note. Refer to Frame 39 for locations) 1. Refer to Frame 52. 4. Reconnect the electrical leads to the replacement part and reassemble in reverse order, ensuring that the 2. Unclip the thermistor / thermostat from the flow / return spring clip is securely on the pipe.
  • Page 45 SERVICING 59 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Frame 52. 5. Fit the new flame detection electrode, using the new gasket supplied. Check dimensions as shown. 2. Unplug the flame detection lead from the electrode. 6. Reassemble in reverse order, and check that no damage 3.
  • Page 46 SERVICING 61 GAS CONTROL VALVE REPLACEMENT 1. Refer to Frame 52. 2. Swing the control box down into the servicing position. Refer to Frame 46. 3. Unplug the electrical lead connection from the gas control valve and disconnect the earth wire. 4.
  • Page 47 SERVICING 63 COMBUSTION CHAMBER INSULATION REPLACEMENT The insulation boards used in the combustion chamber of 9. Remove the insulation boards. The replacement boards this product are made of high temperature glass fibres with a are supplied in a plastic bag. This bag should be retained binder of organic and inorganic materials.
  • Page 48 SERVICING 64 CONDENSATE TRAP/SIPHON REPLACEMENT 1. Refer to Frame 52. 5. Remove the backnut retaining the siphon to the bottom panel. 2. Swing the control box down into the servicing position. Refer to Frame 46. 6. Fit the new siphon in reverse order ensuring the siphon is full of water.
  • Page 49 SERVICING 66 PRIMARY PCB REPLACEMENT 1. Refer to Frame 52. 2. Swing the control box down into the servicing position. Refer to Frame 46. 3. Remove the two screws retaining the control box lid. 4. Unclip the controls box lid and remove. 5.
  • Page 50 SERVICING 68 USER CONTROL PCB Note. Anti static precautions must be observed when handling the user control PCB. 1. Refer to Frame 52. 2. Swing the control box into the servicing position. Refer to Frame 46. 3. Remove the 2 screws retaining the control box lid.
  • Page 51 SERVICING 70 SAFETY RELIEF VALVE REPLACEMENT 1. Refer to Frame 52. 2. Drain the boiler CH circuit. Refer to Frame 3. Unscrew the nut securing the pipe to the pump outlet. 4. Disconnect the electrical connections. 5. Withdraw the pump clip. 6.

  • Page 52: Draining The Boiler

    SERVICING 72 DRAINING THE BOILER 1. Refer to frame 52 2. Close all the water isolating (CH and DHW) valves on the boiler inlet. 3. To drain the central heating circuit: CH Flow Isolation Attach a length of hose to the drain point and open the valve drain valve.
  • Page 53 SERVICING 74 DHW FLOW SWITCH REPLACEMENT 1. Refer to frame 52. 2. Swing the control box down into the servicing position. Refer to Frame 46. 3. Unplug the electrical connection. 4. Carefully pull the switch upwards to disengage. 5. Fit the new switch and replace the electrical plug connection.
  • Page 54 SERVICING 76 FLOW LIMITER REPLACEMENT 1. Refer to frame 52. 2. Isolate the mains cold water supply to the boiler. 3. Drain the boiler DHW circuit. Refer to Frame 72. 4. Unscrew the three union connections at the DHW isolating valve and remove the valve.
  • Page 55 SERVICING 78 DHW PLATE HEAT EXCHANGER REPLACEMENT 1. Refer to Frame 52. 2. Swing the control box down into the servicing position. Refer to Frame 46. 3. Drain the boiler. Refer to Frame 72. 4. Remove divertor valve actuator. Refer to Frame 62.
  • Page 56 SERVICING 80 HEAT ENGINE REPLACEMENT 14. Remove the automatic air vent. Refer to Frame 71. Refer also to Frame 8 - 'Boiler Exploded View'. 15. Undo the M5 x 12 screws securing the bottom flue IMPORTANT manifold casting and remove. Before starting the removal procedure, protect the gas and 16.
  • Page 57 SERVICING 81 EXPANSION VESSEL CHARGING IF REQUIRED THE EXPANSION VESSEL PRESSURE CAN BE RECHARGED BY USING THE CONNECTION ACCESSIBLE THROUGH THE BACK PANEL. The initial charge of the expansion vessel should be 1.0 bar before filling the system. Expansion Vessel Charging Point Esprit - Installation and Servicing...
  • Page 58 SERVICING 82 EXPANSION VESSEL REPLACEMENT - SIDE FLUE APPLICATION SIDE FLUE APPLICATION AND 450MM ACCESS AVAILABLE ABOVE THE BOILER 1. Refer to Frame 52. 2. Swing the control panel down into the servicing position. Refer to Frame 46. 3. Drain the boiler. Refer to Frame 72. 4.
  • Page 59 Esprit - Installation and Servicing...

  • Page 60: Fault Finding

    FAULT FINDING 84 FAULT FINDING CHART MAIN MENU In order to assist fault finding the boiler has an LED diagnostic display. The key to the display codes is as follows: ALTERNATING 'L' 'F' GO TO FRAME 85 ALTERNATING 'L' 'E' GO TO FRAME 86 OR 88 ALTERNATING 'L' 'A' GO TO FRAME 87 OR 88...
  • Page 61 FAULT FINDING 85 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 62: Water Pressure Switch

    FAULT FINDING 87 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 YES (also refer to Frame 88)
  • Page 63 FAULT FINDING 90 H..1..(CONTROL THERMISTOR [FLOW] ERROR) Remove the boiler control thermistor from the CH flow pipe and disconnect thermistor wires. Check resistance using a suitable multimeter connected across the thermistor’s terminal pins At 25 expect 9,700 - 10,300 Ohms At 60 expect...
  • Page 64 FAULT FINDING H9/L9 (HEAT EXCHANGER OVERHEAT) 93 H..4..(DRY FIRE THERMISTOR ERROR) Is the system filled and vented and all isolation valves open ? Can the fault condition be reset by switching off Is the pump operating correctly? the mains supply to the boiler ? Ensure flow through system.

  • Page 65: 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 66: Short List

    SHORT LIST OF PARTS 96 SHORT LIST 27 & 28 esp9182 Esprit - Installation and Servicing...

  • Page 67: Burner Assembly

    SHORT LIST OF PARTS 97 CONTROLS ASSEMBLY 25. User Control PCB 26. PCB Primary Control 27. Mains Switch 28. Pre-heat and Winter/Summer Switch 38. Pressure Gauge 65. Control Box Lid Esp8894 66. Mains Cover 67. Controls Cover 68. Potentiometer Knob 69.
  • Page 68 NOTES Esprit - Installation and Servicing...

  • Page 69: Installer Notification Guidelines

    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...
  • Page 70 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K 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 &...

  • Page 71: Service Interval Record

    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.
  • Page 72 & 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.
  • Page 73 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 74: Electricity Supply

    Esprit HE24, HE30, HE35 HE24 G.C. Appliance No. 47-348-46 HE30 G.C. Appliance No. 47-348-47 (Natural Gas Only) HE35 G.C. Appliance No. 47-348-48 Destination Countries: GB, IE I n t r o d u c t i o n Children should be supervised to ensure that they do not play with the appliance.
  • Page 75 Frost protection Summer conditions - i.e. DHW only required. If no system frost protection is provided and frost is likely during a short Ensure the Winter/Summer switch (J) is set to summer. absence from home, leave the heating controls (if fitted) at a reduced Set the CH external controls to OFF.
  • Page 76 The right is therefore reserved to vary specification without notice. Tel: 01482 498660 Ideal Boilers, P.O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN. Tel. www.idealboilers.com 01482 492251 Fax. 01482 448858. Registration No. London 322 137.

This manual is also suitable for:

Ideal esprit he30Ideal esprit he35

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