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IDEAL istor HE260 Installation And Servicing

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PACKAGED BOILER CONTENTS
HAVE BEEN CHECKED BY OPERATOR No........
istor
(V3 Flue System)
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
HE260, HE325
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 2010
UIN 203325 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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  • 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 2010...
  • Page 2 istor system store - Installation and Servicing...
  • Page 3 Relevant Installation changes implemented in this book from Mod Level ..... A03 to A04 (Jan 2010) Pipework layout changes to tank module & various other changes throughout book. Ideal Stelrad Group reserve the right to vary specification without notice istor system store -...
  • Page 4 GENERAL Table 1 - General Data Boiler size istor HE260 istor HE325 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 22mm copper Outlet Connection...
  • Page 5 GENERAL istor CONTENTS Air Supply ..............10 Natural Gas only Benchmark Commissioning Checklist ..... 74 Boiler size G.C. Appliance No. PI No. Boiler Clearances ............8 (Benchmark No.) Boiler Exploded Diagram ......... 15,16,17 HE260 41-394-13 87 BP 34 Condensate Drain ..........10,22,23 HE325 41-394-14 87 BP 34...

  • Page 6: Safe Handling

    GENERAL INTRODUCTION 1 BOILER WATER CIRCUIT DIAGRAMS The istor HE260 & HE325 boilers are a fully automatically controlled, CENTRAL HEATING CIRCUIT condensing, system store, fanned flue, gas boiler. Note. Due to the high efficiency of the boiler a plume of water vapour will form at the terminal during operation.
  • Page 7 Elbow Kit (max 4 elbows/ installation) please enquire. • Concentric Flue Screw Retaining Kit Any direct connection of a control device not approved by Ideal • Remote User controls (for remote monitoring of Stelrad Group could invalidate the certification and the normal programmer) appliance warranty.
  • Page 8 GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in) The boiler connections are made on the boiler piping frame. Refer to Frame 23. Installation from inside ONLY b. If a core boring tool is to be used inside the building The following minimum clearances must be maintained for the space in which the boiler is to be installed must operation and servicing.

  • Page 9: Gas Supply

    GENERAL GAS SUPPLY Table 4 - Balanced Flue Terminal Position The local gas supplier should be consulted, at the installation Flue Terminal Positions Min. Spacing* planning stage, in order to establish the availability of an 1. Directly below or alongside an opening adequate supply of gas.

  • Page 10: Electrical Supply

    WATER TREATMENT - see Frame 9 THERMOSTATIC RADIATOR VALVES (TRV) 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.
  • Page 11 GENERAL FLUING OPTIONS Roof flue kit (to a maximum of 7.5m) 100mm Concentric flue (to maximum flue length of 6m) Powered Vertical Flue Kit (typical installation maximum 5m primary with 17m secondary) For detailed maximums refer to Powered Vertical Kit Instructions. ist9827 istor system store condensing - Installation and Servicing...
  • Page 12 GENERAL SYSTEM REQUIREMENTS - Central Heating Notes a. The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority. Safety valve setting b.
  • Page 13 (D2) to be connected. If Guidance or BBA Info sheet No.33 advice should be sought unvented hot water storage systems are installed from either your local Building Control Officer or Ideal Stelrad Group. where discharges from safety devices may not be apparent i.e.
  • Page 14 GENERAL SYSTEM REQUIREMENTS - Domestic Hot Water (continued) the installation of an electronically operated device to The discharge pipe MUST NOT be blocked or used for warn when discharge takes place. any other purpose. Note. The tundish must not be removed. The discharge will consist of scalding water and steam.

  • Page 15: Water Treatment

    Technical Park, Runcorn, Sheerwater Woking The application of any other treatment to this Cheshire, WA7 4QX Surrey GU21 5RZ product may render the guarantee of Ideal Stelrad Tel. 0800 389 4670 +44 (0) 1799 521133 Group invalid. www.sentinel-solutions.net Ideal Stelrad Group recommend Water Treatment in Salamander Engineering Ltd Calmag Ltd.
  • Page 16 INSTALLATION 10 BOILER MODULE ASSEMBLY - Exploded View Data badge istor system store - Installation and Servicing...
  • Page 17 INSTALLATION 11 TANK MODULE ASSEMBLY - Exploded View ist9832 istor system store - Installation and Servicing...
  • Page 18 INSTALLATION 12 BOILER PACKAGING AND REMOVAL The boiler is supplied in two separate cartons. The tank 1. Ensure the tank module is stood correctly as marked on module carton includes the pre-piping frame, the hardware the carton. pack, the literature pack and cardboard template. 2.
  • Page 19 INSTALLATION 13 FITTING THE PRE-PIPING FRAME 1. Using the cardboard template mark the position of the appliance and the fixing holes for the pre-piping frame. 2. Fasten the pre-piping frame to the floor. Using suitable fixing screws and plugs dependant on the floor material, fasten the pre-piping frame to the floor.

  • Page 20: Gas Connection

    INSTALLATION 15 CH WATER CONNECTIONS Central Heating connections Refer to the Note in Frame 13 for guidance. IMPORTANT Do not subject any of the isolating valves to heat as the seals may be damaged. 16 GAS CONNECTION Fibre washer IMPORTANT. The gas service cock is sealed with a non-metallic fibre washer so must not be overheated when making capillary...
  • Page 21 INSTALLATION 17 SAFETY VALVE DRAIN (DHW) The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring. IMPORTANT. The discharge pipe arrangement must comply with G3 Building Regulations.

  • Page 22: Condensate Drain

    INSTALLATION 19 CONDENSATE DRAIN The condensate drain connection point position is shown in If external condensate pipe run is greater than 3m then pipe the diagram below. A 700mm long flexible hose is supplied must be 32mm nominal diamater. Consideration should be strapped to the cylinder module frame and an adaptor is given to insulating external condensate pipe runs.
  • Page 23 INSTALLATION 21 CONTINUED... 3. INTERNAL CONNECTION TO SOIL AND VENT STACK BOILER 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 Air Break cla9253 External...
  • Page 24 INSTALLATION TANK CONNECTION TO THE PIPING FRAME General Before moving the appliance onto the piping frame provision must be made for the condensate drain which may be easier before the boiler is moved into position. Refer to Frame 19. 1. Lift tank section over the piping frame and engage the rear of the base onto the runner of the piping frame.

  • Page 25: Flue System

    INSTALLATION 25 BOILER UNIT CONNECTION General The gas pipe is supplied strapped to the cylinder module frame. It is suggested that all pipes are connected to the pre-piping frame before boiler connections are made. It is also suggested that the CH safety valve drain is connected before the CH flow pipe is fitted.
  • Page 26 INSTALLATION 27 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED For the 100mm concentric flue system Dimension X - Wall thickness. Total Flue length dimension Flue (measuring from CL of turret to outside wall) Dimension L - Wall thickness plus boiler spacing. Rear flue LH Side flue RH Side flue...
  • Page 27 INSTALLATION 28 FLUE ASSEMBLY - Exploded View Rear flue arrangement shown 1. An optional flue duct extension kit is required for flue lengths greater than : RH Side 595mm LH Side 595mm Rear 595mm LEGEND 1. Duct assembly. 2. Flue Turret. 3.
  • Page 28 INSTALLATION 30 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 29 INSTALLATION 32 CONNECTING THE FLUE TO THE BOILER Note. a. BEFORE fitting the flue turret, fill the condensate trap within the boiler by pouring a cupful of water into the flue outlet A. b. Take care to ensure that the water is only poured into the flue outlet, and does not spill into the boiler casing.
  • Page 30 INSTALLATION 33 FLUE EXTENSION DUCTS - For 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 31 INSTALLATION 36 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 32: Flue Terminal Position

    INSTALLATION 38 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 33 INSTALLATION 39 FLUE ARRANGEMENT Note. The equivalent flue length resistance of the elbow kits are: elbow kit = 1m elbow kit = 0.6m istor system store - Installation and Servicing...
  • Page 34 INSTALLATION 40 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 35 INSTALLATION 41 FILLING Central Heating When filling, there may be a slight water leak from the vent Refer to system requirements Frame 5. therefore electrical connections should be protected. 1. Remove the boiler sealing panel. Refer to Frame 56. c. Open manual air vent above the diverter valve and bleed any air from the diverter valve.

  • Page 36: Electrical Connections

    INSTALLATION 42 ELECTRICAL CONNECTIONS Immersion heater Note. WARNING. This appliance MUST be earthed. An immersion heater is supplied fitted to the cylinder and is Boiler water connection intended for use as a back up heat source of DHW. Wiring of A mains supply of 230 V ~ 50 Hz is required.

  • Page 37: External Electrical Controls

    INSTALLATION 44 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 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.
  • Page 38 INSTALLATION 45 PICTORIAL WIRING DIAGRAM LEGEND - blue. bk - black. br - brown. - red. Overheat - yellow. thermostat - white. Dry fire y/g - yellow/ thermistor green. Return Flow gy - grey. Diverter valve thermistor thermistor or - orange. - violet Gas valve PUMP...

  • Page 39: Commissioning And Testing

    INSTALLATION 46 FUNCTIONAL FLOW WIRING DIAGRAM Mains Switch External switch e.g. PCB No. room'stat. Fost stat Flame detection electrode Overheat thermostat RAC Gas valve Spark generator electrode Dry fire thermistor DHW thermistor CH return thermistor Pump v v v v CH control thermistor Diverter valve...

  • Page 40: Initial Lighting

    INSTALLATION 48 INITIAL LIGHTING LEGEND Tube A. Air vent. B. Inlet pressure test point. C. CH return isolating valve. D. Mains water inlet isolating valve. E. Gas service cock. F . DHW outlet. G . CH flow isolating valve. H. Pressure gauge. L.
  • Page 41 INSTALLATION 49 GENERAL CHECKS Make the following checks for correct operation in: WATER CIRCULATION SYSTEM DOMESTIC HOT WATER (DHW) MODE 1. With no call for CH or DHW the boiler should fire for a 1. With the system COLD, check that the initial pressure is short period to preheat the storage tank.

  • Page 42: Handing Over

    7. A programmer is fitted so draw attention to the Users benefits of the Ideal Care Scheme details of which are Instructions and hand them to the householder. outlined in the householder pack supplied with this boiler.

  • Page 43: Servicing Schedule

    SERVICING 51 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 44 SERVICING 52 SAMPLING POINT 53 BOILER FRONT PANEL REMOVAL 1. Remove the 2 securing screws. 2. Pull the top panel forward at the top and lift to disengage it from the locating pins. 3. Pull the bottom panel forward off the locating pins.
  • Page 45 SERVICING 54 CONTROLS FACIA PANEL REMOVAL Refer to Frame 51. 1. Ensure the power supply is turned off. 2. Disconnect the 14 way in-line molex connector. 3. Remove the 2 M5 screws securing the panel. 4. Lift off the panel from its locating slots. 5.
  • Page 46 SERVICING 56 BOILER SEALING PANEL REMOVAL 1. Turn off the gas supply at the gas service cock and disconnect the electricity supply. 2. Slacken the backnut securing the DHW vessel to its support bracket and remove carefully to one side. It is unnecessary to disconnect the hose at this stage.

  • Page 47: Burner Removal And Cleaning

    SERVICING 58 BURNER REMOVAL AND CLEANING 1. Remove the 6 screws securing the burner (the 3 screws at the rear are extended to ease access). 2. Lift off the burner from the combustion chamber. IMPORTANT The burner head is a ceramic plaque construction.

  • Page 48: Cleaning The Heat Exchanger

    SERVICING 60 CLEANING THE DHW FILTERS The DHW inlet filter is fitted within the Pressure Reducing Valve, which is fitted externally to the appliance on the DHW inlet pipe. 1. Close the cold water stop cock to the property or isolate the 3.

  • Page 49: Replacement Of Components

    SERVICING 63 REPLACEMENT OF COMPONENTS GENERAL After replacing ANY component check operation of the boiler including gas tightness, gas rate and combustion test. When replacing ANY component in the boiler module. IMPORTANT. 1. Isolate the electricity supply from both the boiler and the When work is complete, if the sealing panel has been immersion heater.
  • Page 50 SERVICING 66 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 53 & 54. 2. Remove the boiler sealing panel. Refer to Frame 56. 3. Disconnect the electrical leads from the fan. 4. Undo the gas pipe union connection to the injector housing. 5.
  • Page 51 SERVICING 68 CONTROL THERMISTOR, RETURN THERMISTOR AND OVERHEAT THERMOSTAT REPLACEMENT 1. Refer to Frame 53 & 54. 2. Unclip the thermistor / thermostat from the flow / return pipe and withdraw it from the controls compartment. 3. Disconnect the electrical leads from the thermistor / thermostat.
  • Page 52 SERVICING 71 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 53 SERVICING 72 GAS CONTROL VALVE REPLACEMENT 1. Refer to Frame 53 & 54. 4. Remove the sensing tube from the gas control valve. Note. 5. Undo the gas inlet pipe union. Ensure surrounding water system pipework is cooled to a 6.
  • Page 54 SERVICING 74 CONDENSATE 'S' TRAP REPLACEMENT 1. Refer to Frame 53 & 54. Note. Ensure surrounding water system pipework is cooled to a point where it cannot represent a burn hazard. 2. Slacken the backnut on the DHW expansion vessel and remove to one side as shown.
  • Page 55 SERVICING 76 CONTROL BOX REPLACEMENT 1. Refer to Frame 53 & 54 . 2. Slacken the backnut on the DHW expansion vessel and remove to one side as shown. 3. Remove the fixing screw locating the control box bracket. 4. Unplug all the electrical wiring from the control box and remove.
  • Page 56 SERVICING 79 DISPLAY UNIT REPLACEMENT Note. Only the display unit is replaced. 1. Refer to Frame 53 & 54. 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.
  • Page 57 SERVICING 81 SAFETY RELIEF VALVE REPLACEMENT 1. Remove the casing bottom panel. Refer to Frame 53. 2. Drain the boiler. Refer to Frame 3. Remove the discharge pipe. 4. Remove the valve and pressure gauge. 5. Transfer the pressure gauge to the new relief valve.
  • Page 58 SERVICING 83 TEMPERATURE & PRESSURE RELIEF VALVE REPLACEMENT 1. Refer to Frame 53 & 54. 2. Remove the DHW expansion vessel. Refer to Frame 56. 3. Drain the cylinder. Refer to Frame 86. 4. Remove the control box fixing screws and slide the box to enable the valve to be removed through the cutout in the boiler module base plate.

  • Page 59: Draining The Boiler

    SERVICING 85 DRAINING THE BOILER 1. Refer to frame 53. CH Isolating valves 2. Close all the water isolating valves on the piping frame. isolating valve 3. Attach a length of hose to the (shown closed) drain point and open the drain TO OPEN valve.
  • Page 60 SERVICING 87 DIVERTER VALVE MECHANISM REPLACEMENT 1. Refer to Frame 53 & 54. 2. Drain the boiler. Refer to Frame 85. 3. Undo the 3 union nuts securing the valve body and remove valve. 4. Replace the valve using new fibre washers on the union nuts.
  • Page 61 SERVICING 89 CH EXPANSION VESSEL REPLACEMENT 1. Refer to Frame 53 & 54. 2. Drain the boiler. Refer to Frame 85. 3. Undo the union nut on the vessel water connection pipe. 4. Remove the screw and remove the securing clamp.
  • Page 62 SERVICING 91 BOILER SEALING PANEL SEAL REPLACEMENT 1. Refer to Frames 53 & 54. 2. Remove the old seal from the casing and thoroughly clean the casing surfaces. 3. Fit the new adhesive seals, note that they are supplied to the correct length for the relevant sides.
  • Page 63 SERVICING 93 HEAT ENGINE REPLACEMENT 15. Using a suitable tool undo the push fit connections from Refer also to Frame 10 - 'Boiler exploded view'. the flow and return pipes of the boiler removing the To replace the heat exchanger it is necessary to separate the pump assembly and the diverter valve assembly.
  • Page 64 SERVICING 94 HEAT ENGINE REPLACEMENT - continued 31. Undo the M5 screw and remove the flow pipe securing bracket. 32. Remove the flow pipe and transfer to the new heat engine. 33. Reassemble in reverse order, replacing gaskets or seals if any sign of damage or deterioration is evident.

  • Page 65: Fault Finding

    FAULT FINDING 96 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: 'L' 'F' GO TO FRAME 97 'L' 'E' GO TO FRAME 98 'L' 'A' GO TO FRAME 99 'L' '8'...
  • Page 66 FAULT FINDING 97 L..F..(FLAME DETECTION) If the boiler reset button is Check gas supply Is 17mbar gas pressure pressed does the boiler ignite and rectify fault available at the boiler inlet ? for a short time then extinguish? Check gas valve Is 200V DC supply Check the detection electrode and wiring for...
  • Page 67 FAULT FINDING 99 L..A......(OVER HEAT SENSOR) 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 68 FAULT FINDING 102 H..2..(RETURN TEMPERATURE SENSOR) Check resistance. The sensors can be checked by Remove the boiler return measuring their resistance, using a suitable multimeter thermistor from the CH connected across the sensors' terminal pins return pipe. At 25 expect 9,700-10,300 Ohms...
  • Page 69 FAULT FINDING 104 H..4..(DRY FIRE THERMISTOR) H9/L9 (HEAT EXCHANGER OVERHEAT) 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 ? Is the pump operating correctly? Ensure flow through system.

  • Page 70: 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 71 SHORT LIST OF PARTS 107 SHORT PARTS LIST ist9881 istor system store - Installation and Servicing...
  • Page 72 SHORT LIST OF PARTS 108 BOILER CASING ASSEMBLY 1. Sealing panel with screws. 109 BURNER ASSEMBLY 7. Burner assembly with screws and gasket. Ecl 1598 istor system store - Installation and Servicing...
  • Page 73 istor system store - Installation and Servicing...

  • Page 75: Installer Notification Guidelines

    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 76 Gas Safe Register ID Number...
  • Page 77 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 78 istor system store - Installation and Servicing...
  • Page 79 istor system store - Installation and Servicing...
  • Page 80 & servicing of central heating systems Manufactured under a BS EN ISO 9001: 1994 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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