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Ideal Boilers HE12 Installation And Servicing
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Ideal Boilers HE12 Installation And Servicing

Ideal Boilers HE12 Installation And Servicing

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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 2005
UIN 200 212 A10
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.
ENGINEERED FOR PEACE OF MIND

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Summary of Contents for Ideal Boilers 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. ENGINEERED FOR PEACE OF MIND...
  • Page 2 icos - Installation & Servicing...
  • Page 3 DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level ..A09 (May 05) to A10 (Sept 05) • Page 15, Frame 11 - Unpacking Mains Connector added to hardware pack contents. • Page 25, Frame 32 - Pictorial Wiring Diagram Update to wiring diagram.
  • Page 4 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 Boiler Clearances ............6 Boiler size G.C. Appliance No. PI No. Boiler Exploded Diagram ..........14 Benchmark No. Electrical Connections ..........23 HE12 41 397 95 0063 BO 3315 Electrical Supply ............9 HE15 41 397 83 0063 BO 3315 Electrical Systems Diagrams ........
  • Page 6 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 ! Remote User Control Kit outputs of : ! Boiler Stand-off Kit HE12 9.3 kW (32,000 Btu/h) to 12.0 kW (41,000 Btu/h). ! Siphon Kit HE15 8.8 kW (30,000 Btu/h) to 14.7 kW (50,000 Btu/h). HE18 8.8 kW (30,000 Btu/h) to 17.6 kW (60,000 Btu/h).
  • Page 8 GENERAL IMPORTANT. LOCATION OF BOILER Installation pipes MUST be fitted in accordance with BS. 6891. The boiler must be installed on a flat and vertical wall, capable In IE refer to I.S.813:2002. Pipework from the meter to the boiler of adequately supporting the weight of the boiler and any MUST be of an adequate size, i.e.
  • Page 9 GENERAL 6. The air inlet/products outlet duct and the terminal of the Single feed, indirect cylinders are not recommended and MUST boiler MUST NOT be closer than 25mm (1") to combustible NOT be used on sealed systems. material. Detailed recommendations on the protection of combustible material are given in BS.5440-1:2000.
  • Page 10 GENERAL OPEN VENT SYSTEM REQUIREMENTS The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150mm (6") away from the vent connection.
  • Page 11 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 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 GENERAL SEALED SYSTEM REQUIREMENTS - continued Safety valve setting 3.0 bar 2.5 bar 2.0 bar Vessel charge and initial system pressure Total water content of system Expansion vessel volume litres litres 11.8 10.0 11.7 10.0 17.7 15.0 10.9 15.6 13.4 23.7 11.3 20.0...
  • Page 14 INSTALLATION 10 BOILER ASSEMBLY - Exploded view 22. Flue thermistor. 23. Control thermistor. 24. Overheat thermostat. 25. Ignition electrode. LEGEND 14. Injector & housing 26. Flame detection electrode. Front casing panel. Flue manifold. 15. Venturi assy. 32. 'S' trap Sealing panel Flue fixing 16.
  • Page 15 INSTALLATION 11 UNPACKING The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to 650mm, rear or side flue outlet, in Pack B. Unpack and check the contents. Pack A Contents The boiler Wall mounting template Wall mounting plate...
  • Page 16 INSTALLATION 13 FRONT AND BOTTOM PANEL REMOVAL 1. To remove the front panel remove the 2 screws from the bottom panel. 2. Lift the panel up and off the top pegs. 3. To remove the bottom panel remove the 2 screws. 4.
  • Page 17 INSTALLATION 15 FLUE ASSEMBLY - Exploded View An optional flue duct extension kit is required for wall thicknesses greater than : Side 455mm (18") Rear 490mm "). LEGEND 1. Duct assembly. 2. Flue turret. 3. Turret gasket. 4. M5 x 10 pozi screw. 5.
  • Page 18 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.
  • Page 19 INSTALLATION 20 FLUE EXTENSION DUCTS - For flue lengths greater than 480mm 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 Ecl 1244 No.
  • Page 20 INSTALLATION 23 CONDENSATE DRAIN Refer also to the British Gas document: 'Guidance Notes for The condensate drain provided on the boiler must be the Installation of Domestic Gas Condensing Boilers' (1989). connected to a drainage point, preferably within the building. Ensure that the condensate trap is full of water before commissioning the boiler.
  • Page 21 INSTALLATION 25 CONDENSATE PIPE TERMINATION CONFIGURATIONS . . . continued 3. INTERNAL CONNECTION TO SOIL AND VENT STACK * Make connection to SVP using a solvent welded saddle BOILER cla7773 4. TERMINATION TO SOAK AWAY External wall Termination BOILER to Soak away cla7774 Ground Level minimum...
  • Page 22 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 23 INSTALLATION 28 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 24 INSTALLATION 31 INTERNAL WIRING A pictorial wiring diagram is shown in Frame 32. 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. 2.
  • Page 25 INSTALLATION 32 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 26 INSTALLATION 34 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. Room Thermostat If the thermostat has a neutral connection use it.
  • Page 27 INSTALLATION 36 INITIAL LIGHTING Note. Boiler is shown with the front panel 1. Check that the system has been filled and that the and sealing panel boiler is not air locked. removed. Note. It is important the burner is not operated before the system is fully vented of air.
  • Page 28 INSTALLATION 36a INITIAL LIGHTING - continued THE DISPLAY The user control has one neon and one display to inform the Boiler is active for central heating. user about the status: the display will show the status of the boiler and the neon will show the status of the flame. If no Boiler is in lockout for a specific error.
  • Page 29 SERVICING 39 SERVICING SCHEDULE 8. Wherever possible, remove and clean the condensate ‘S’ To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals trap (refer to Frame 44) and check the drain for blockage. and serviced as necessary.
  • Page 30 SERVICING 42 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 31 SERVICING 44 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. 45 CLEANING THE HEAT EXCHANGER 1.
  • Page 32 SERVICING 47 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 33 SERVICING 49 FAN REPLACEMENT Orifice plate 1. Refer to Frame 47. Gasket 2. Remove the boiler front and sealing panels. Refer to Frames 40 & 41. 3. Disconnect the electrical leads from the fan. 4. Unscrew the gas pipe union connection to the injector housing.
  • Page 34 SERVICING 51 IGNITION ELECTRODE REPLACEMENT 1. Refer to Frame 47. 2. Remove the boiler front and sealing panels. Refer to Frames 40 & 41. 3. Unplug the ignition lead from the electrode. 4. Remove the earth lead from the ignition electrode. 5.
  • Page 35 SERVICING 53 SPARK GENERATOR REPLACEMENT 1. Refer to Frame 47. 2. Disconnect the leads from the spark generator and bracket. 3. Remove the M4 screw securing the spark generator bracket to the flue casting. 4. Remove the 2 M4 screws securing the spark generator to the bracket.
  • Page 36 SERVICING 56 CONTROL BOX REPLACEMENT 1. Refer to Frame 47. 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 37 SERVICING 58 OVERHEAT THERMOSTAT REPLACEMENT 1. Refer to Frame 47. 2. Remove the boiler front and sealing panels. Refer to Frames 40 & 41. 3. Pull off the electrical leads from the thermostat body. 4. Pull the thermostat and clip from the pipe.
  • Page 38 SERVICING 60 COMBUSTION CHAMBER INSULATION REPLACEMENT 8. Damp down the combustion chamber area containing the The insulation boards used in the combustion chamber of insulation boards. this product are made of high temperature glass fibres with a binder of organic and inorganic materials. 9.
  • Page 39 SERVICING 61 HEAT EXCHANGER REPLACEMENT 15. Pull the CH return pipe up and out of the heat Refer also to Frame 10, 'Boiler exploded view'. exchanger. 1. Refer to Frame 47. 16. Unscrew the M5 x 10 screw retaining the flue casting. 2.
  • Page 40 SERVICING 62 BOILER SEALING PANEL SEAL REPLACEMENT 1. Refer Frame 47. 2. Remove the front panel. Refer to Frame 40. 3. Remove the boiler sealing panel. Refer to Frame 41. 4. Remove the old seal from the casing and thoroughly clean the casing surfaces. 5.
  • Page 41 FAULT FINDING 64 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 65 ALTERNATING 'L' 'F' ALTERNATING 'L' 'E' GO TO FRAME 66 GO TO FRAME 67 ALTERNATING 'L' 'A'...
  • Page 42 FAULT FINDING 65 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 gas valve Is 200V DC supply available Check the detection electrode and wiring for...
  • Page 43 FAULT FINDING 67 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 44 FAULT FINDING 70 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 H9/L9 (FLUE GAS OVERHEAT) 71 H..4..(FLUE THERMISTOR ERROR) Is the system filled and vented and all Can the fault condition be reset by switching isolation valves open ?
  • Page 45 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 46 SHORT LIST OF PARTS 73 SHORT LIST nm8077 74 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom casing panel with screws. icos - Installation & Servicing...
  • Page 47 LIST OF PARTS 75 CONTROLS ASSEMBLY Controls assy with screws. Controls hinge bracket. User controls (without item 38). PCB (primary controls). User control housing Mains switch. Jumper link. 76 BURNER ASSEMBLY 11. Burner assembly with screws and gasket. Ecl 1598 icos - Installation &...
  • Page 48 NOTES icos - Installation & Servicing...
  • Page 49 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 50 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 51 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 52 & 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 53 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 HE12, HE15, HE18, HE24 HE12 G.C. Appliance No. 41-397-95 HE15 G.C. Appliance No. 41-397-83 (Natural Gas Only) HE18 G.C. Appliance No. 41-397-84 Destination Countries: GB, IE HE24 G.C. Appliance No. 41-397-85 Introduction ! Under NO circumstances should any of the sealed components on this appliance be used incorrectly or tampered with.
  • Page 55 Control of water temperature Boiler Overheat Thermostat The boiler controls the central heating radiator temperature to a This thermostat will shut down the boiler in the event of maximum of 82 C, adjustable via the CH thermostat knob (C). overheating. Should this occur a fault code 'L' 'A' will be displayed.
  • Page 56 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.

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