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IDEAL icos system HE15 Installation And Servicing

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See also: Installation and Servicing Manual , User Manual
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installation and
servicing
PACKAGED BOILER CONTENTS
HAVE BEEN CHECKED BY OPERATOR No........
icos system
(V3 Flue System)
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
HE15, 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.
October 2009 UIN 203320 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.

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Summary of Contents for IDEAL icos system HE15

  • 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. October 2009 UIN 203320 A05 For the very latest copy of literature for specification &...
  • Page 2 back icos system - Installation and Servicing...
  • Page 3 DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level .....A04 (Oct 08) to A05 (Oct 09) Ideal Stelrad Group reserve the right to vary specification without notice icos system - Installation and Servicing...
  • Page 4 back GENERAL Table 1 - General Data Boiler Size HE15 HE24 Gas supply 2H-G20-20mbar Gas Supply Connection Rc1/2 (1/2" BSP Female) Injector size Stereomatic 5.6mm dia. Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter mm (in) 100 (4)

  • Page 5: Table Of Contents

    GENERAL icos system HE15 & HE24 CONTENTS Air Supply ............... 9 Natural Gas only Benchmark Commissioning Checklist ..... 66 Boiler Clearances ............8 Boiler size G.C. Appliance No. PI No. Boiler Interlocks ............10 (Benchmark No.) Boiler Exploded Diagram ........12, 13...

  • Page 6: Controls

    back GENERAL INTRODUCTION The icos system HE range is a cast aluminium wall mounted, The boiler features a comprehensive diagnostic system which full sequence, automatic spark ignition, low water content, gives detailed information on the boiler status when operating, and performance of key components to aid commissioning fanned flue, high efficiency, condensing system gas boiler.

  • Page 7: Controls

    Elbow Kit (Maximum 4 elbows / installation) please enquire. • Concentric Flue Screw Retaining Kit Any direct connection of a control device not approved by Ideal • Powered Vertical Flue Kit 5m primary and 17m secondary Stelrad Group could invalidate the certification and the normal is a typical maximum length.
  • Page 8 back GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in) The boiler connections are made on the boiler piping frame. where wall thicknesses do not exceed 600mm (24"). Refer to Frames 34 & 32. Where the space into which the boiler is going to be installed is less than the length of flue required the flue The following minimum clearances must be maintained for must be fitted from the outside.

  • Page 9: Gas Supply

    back GENERAL GAS SUPPLY Table 3 - 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 10: Inhibitor

    WATER CIRCULATION SYSTEM BOILER CONTROL INTERLOCKS IMPORTANT. Ideal Stelrad Group recommend that heating systems utilising full thermostatic radiator valve control of temperature in A minimum length of 1metre of copper pipe MUST be fitted to individual rooms should also be fitted with a room thermostat...
  • Page 11 back GENERAL SYSTEM REQUIREMENTS - continued The maximum cold water capacity of the system should General not exceed 143 litres, if not pressurized. However, if the 1. The installation must comply with all relevant national and system is to be pressurized, the efficiency of the local regulations.

  • Page 12: Controls

    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 or GE Betz Sentinel X100 inhibitors and associated water treatment products, which must be used in accordance with the manufacturers instructions.
  • Page 13 back INSTALLATION BOILER ASSEMBLY - Exploded View icos system - Installation and Servicing...
  • Page 14 back 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 Pre-piping Frame...
  • Page 15 back INSTALLATION 10 PACKAGING REMOVAL 1. Ensure the boiler is on a sound flat surface. 2. Carefully remove the strapping. 3. Fold back the top flaps to gain access to: Instructions 1 year guarantee Pre-piping frame Wall mounting template/ Wall mounting template. protective packaging (located under pre-piping frame on protective packaging).
  • Page 16 back INSTALLATION 12 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT.The boiler MUST be installed in a vertical position FLUE KITS Dimension X - Wall thickness. Pack B - supplied as standard. Dimension L - Wall thickness plus boiler spacing. Finishing Kit - supplied as an optional extra.
  • Page 17 back INSTALLATION 12A DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED, CONT'D Notes. 1. It is recommended that a support bracket is fitted for every 1 meter of extension pipe used and a bracket Total Flue length dimension Flue should be used at every joint, to ensure pipes are held at (measuring from CL of turret to outside wall) the correct angle.
  • Page 18 back INSTALLATION 14 WALL MOUNTING TEMPLATE The wall mounting template is located on the internal protective packaging. Extended centre line Note. The template shows the positions of the fixing holes and V - See Diagram Below the rear flue hole centre for standard installation. Care MUST be taken to ensure the correct holes are drilled.
  • Page 19 back INSTALLATION 16 TERMINAL WALL SEAL ASSEMBLY / POSITIONING Prior to fitting the flue, the rubber terminal wall seal provided Once the flue is installed it is IMPORTANT that the rubber in the flue pack MUST be fitted to the flue terminal as shown terminal wall seal is pressed against the outside wall to below in Figure 1.
  • Page 20 back INSTALLATION 18 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 back INSTALLATION 21 FITTING THE PIPING FRAME AND VALVES (Rear Flue outlet shown) Note. Isolating valves are supplied separately in the hardware pack box. Fit to the piping frame BEFORE mounting the boiler. TO FIT THE PRE-PIPING FRAME DIRECTLY TO THE WALL TO FIT THE PRE-PIPING FRAME USING THE STAND-OFF FRAME •...

  • Page 22: Condensate Drain

    back INSTALLATION 22 CONDENSATE DRAIN Before mounting the boiler on the wall, 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. Ensure that the condensate trap is full of water before commissioning the boiler.
  • Page 23 back INSTALLATION 24 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 25 MOUNTING THE BOILER IMPORTANT. 5. Using the fibre washers supplied in the hardware pack box, engage and then tighten the 4 water unions. 1. Before mounting the boiler on the wall place it on its left 6. Engage and tighten the gas union, ensuring that the blue hand side, fit the 'S' trap hose moulding/nut and fold the fibre washer is in place.
  • Page 25 back INSTALLATION 27 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 29 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 30 FLUE ARRANGEMENT Note. The equivalent flue length resistance of the elbow kits are: elbow kit = 1m elbow kit = 0.6m icos system - Installation and Servicing...
  • Page 28 back INSTALLATION 31 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 32 GAS CONNECTION IMPORTANT. The gas service cock is sealed with a non-metallic blue fibre washer so must not be overheated when making capillary connections. Refer to Frame 2 for details of the position of the gas connection. A boiler gas supply pipe length of 20m and not less than 15mm O.D.

  • Page 30: Electrical Connections

    back INSTALLATION WATER CONNECTIONS Isolating valve (shown in the open position) Condensate drain pipe located here Pressure gauge Piping frame 22mm copper pipe Isolating valve Compression (shown in the gas cock open position) Drain point FLOW Notes. 1. For heating loads in excess of 60,000 Btu/h use 28mm x 22mm connectors to connect the 22mm copper pipe boiler flow and return pipes to 28mm system...

  • Page 31: Electrical Supply

    back INSTALLATION 36 ELECTRICAL CONNECTIONS Wiring should be 3 core PVC insulated cable, not less WARNING. This appliance MUST be earthed. than 0.75 mm (24 x 0.2mm), and to BS 6500 Table 16. A mains supply of 230 V ~ 50 Hz is required. For IE reference should be made to the current ETCI The fuse rating should be 3A.

  • Page 32: External Electrical Controls

    back INSTALLATION 38 EXTERNAL ELECTRICAL CONTROLS Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations. For IE reference should be made L2 L1 to the current ETCI rules for electrical installations. Room 'stat The fuse rating should be 3A.
  • Page 33 back INSTALLATION 39 PICTORIAL WIRING DIAGRAM LEGEND - red b - blue v - violet bk - black w - white br - brown y - yellow gy - grey y/g - yellow/green or - orange Dry fire pk - pink thermistor icos system - Installation and Servicing...

  • Page 34: Flow Wiring Diagram

    back INSTALLATION 40 FUNCTIONAL FLOW WIRING DIAGRAM Dry fire thermistor y r bk v nm8043b LEGEND b - blue - red bk - black v - violet br - brown w - white gy - grey y - yellow or - orange y/g - yellow/green pk - pink 41 COMMISSIONING AND TESTING...

  • Page 35: Initial Lighting

    back INSTALLATION 42 INITIAL LIGHTING LEGEND A. Boiler On/Off switch. B. Thermostat knob. D. Burner On Neon E. Reset button. F . Injector pressure test point. G . Inlet pressure test point. H. Gas service cock. J. Casing pressure test point. K.

  • Page 36: Gas Supply

    back INSTALLATION 43 INITIAL LIGHTING - continued For additional gas supply information refer to "Gas Supply" on page 9. 13. Set the boiler thermostat knob (B) to position 6 and switch the boiler on/off switch (A) to ON. The boiler IMPORTANT.

  • Page 37: Handing Over

    Programmer Users Instructions and hand them to the contract yourself or alternatively offer to the customer the householder. benefits of the Ideal Care Scheme, details of which are outlined in the householder pack supplied with this boiler. icos system -...

  • Page 38: Servicing Schedule

    back SERVICING 46 SERVICING SCHEDULE For the very latest copy of literature for specification & maintenance practices, visit our website www.idealboilers.com, where you will be able to download the relevant information. N.B. Technical Bulletins are also available on www.idealboilers.com. 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 39 back SERVICING BOILER SEALING PANEL / BOTTOM PANEL REMOVAL 1. To remove the sealing panel remove the 4 screws. 2. Remove the panel. 3. To remove the bottom panel remove the 2 screws. 4. Pull the right hand side of the panel down. Slide it to the right and withdraw.

  • Page 40: Burner Removal And Cleaning

    back SERVICING 50 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 41: Cleaning The Heat Exchanger

    back SERVICING 52 CLEANING THE CONDENSATE 'S' TRAP 1. Swing the control box down into the servicing position. Refer to Frame 49. 2. Disconnect the condensate drain pipe. 3. Remove the screw and elongated bolt, pull the trap down and forward to remove. 4.

  • Page 42: Replacement Of Components

    back SERVICING 55 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When replacing ANY component : When work is complete, the sealing panel, if removed, must 1. Isolate the electricity supply. be correctly refitted - ensuring that a good seal is made. 2. Turn off the gas supply. Notes.
  • Page 43 back SERVICING 58 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 55. 2. Remove the boiler front and sealing panels. Refer to Injector Frames 47 & 48. 3. Disconnect the electrical leads from the fan. 4. Undo the gas pipe union connection to the injector housing. 5.
  • Page 44 back SERVICING 61 IGNITION ELECTRODE REPLACEMENT 5. Remove the remaining screw holding the ignition 1. Refer to Frame 55. electrode to the combustion chamber. 2. Remove the boiler front and sealing panels. Refer to 6. Remove the electrode. Frames 47 & 48. 7.
  • Page 45 back SERVICING 63 SPARK GENERATOR REPLACEMENT 1. Refer to Frame 55. 2. Disconnect the lead from the spark generator and bracket. 3. Remove the 2 M4 screws securing the spark generator to the chassis. 4. Fit the new spark generator and re-assemble in reverse order.
  • Page 46 SERVICING 66 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 47 back SERVICING 67 CONTROL BOX REPLACEMENT 9. Reassemble in reverse order, ensuring that the control box is located correctly in the housing before reconnecting 1. Refer to Frame 55. the electrical wiring. 2. Remove the boiler front and bottom panels. Refer to 10.
  • Page 48 back SERVICING 69 USER CONTROL REPLACEMENT Note. Only the display unit is replaced. 1. Refer to Frame 55. 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 49 back SERVICING 71 SAFETY RELIEF VALVE REPLACEMENT 6. Withdraw the securing pin. 1. Refer to Frame 55. 2. Remove the boiler front and bottom panels. Refer to 7. Remove the safety valve. Frame 47 & 48. 8. Fit the new safety valve and refit the securing pin. 3.

  • Page 50: Draining The Boiler

    back SERVICING 73 DRAINING THE BOILER 1. Refer to Frame 55. 2. Remove the boiler front and bottom panels. Refer to Frame 47 & 48. 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 51 back SERVICING 75 HEAT EXCHANGER REPLACEMENT 17. Remove the edge clip securing the dry fire thermistor Refer also to Frame 8 - 'Boiler Exploded View'. wiring. IMPORTANT 18. Remove the blind grommet to gain access to the return pipe securing bracket. Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag.
  • Page 52 back SERVICING 76 EXPANSION VESSEL REPLACEMENT 1. Refer to Frame 55. 2. Drain the boiler. Refer to Frame 73. 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 the turret.
  • Page 53 back FAULT FINDING 78 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: GO TO FRAME 79 ALTERNATING 'L' 'F' GO TO FRAME 80 ALTERNATING 'L' 'E' ALTERNATING 'L' 'A' GO TO FRAME 81...

  • Page 54: Fault Finding

    back FAULT FINDING 79 L..F..(FLAME DETECTION ERROR) If the boiler reset button is Check gas supply Is gas pressure available at pressed does the boiler ignite for and rectify fault the boiler inlet ? a short time then extinguish? Check gas valve Is 200 V DC supply Check the detection electrode and...
  • Page 55 back FAULT FINDING 80 L..E..H..E..(PCB ERROR) Check earth connection to the boiler. If it is Check for an excess voltage between still in excess of 50 V consult a qualified neutral and earth. electrician to check the household Is the value below 50V? electrical supply and circuitry.
  • Page 56 back FAULT FINDING 81 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 57 back FAULT FINDING H9/L9 (HEAT EXCHANGER OVERHEAT) 84 H..4..(DRY FIRE THERMISTOR ERROR) Can the fault condition be reset by switching off Is the system filled and vented and all isolation the mains supply to the boiler ? valves open, including TRV's & Bypass? Check the pump is operating correctly in Heating &...

  • Page 58: 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 Stelrad Group.
  • Page 59 back SHORT LIST OF PARTS 87 SHORT LIST nm8046b icos system - Installation and Servicing...

  • Page 60: Burner Assembly

    back LIST OF PARTS 88 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom panel with screws. 89 CONTROLS ASSEMBLY Controls assy with screws. Controls hinge bracket. User controls (without item 38). PCB (primary controls). User controls housing Mains switch.
  • Page 61 back NOTES icos system - Installation and Servicing...
  • Page 62 back NOTES icos system - Installation and Servicing...
  • Page 63 back NOTES icos system - Installation and Servicing...
  • Page 64 back...

  • Page 65: 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 66 back Gas Safe Register ID Number...
  • Page 67 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 68 Manufactured under an ISO 9001 registered quality management system FM 59915 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.

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Icos system he24

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