IDEAL INDUSTRIES HE12 manual

i ns ta l l ati o n a n d se r v icing icos (V3 Flue System) Y ou r I d eal i ns tal la tion an d s e r v ici n g guide For details of document amendments, refer to page 3 When replacing any part on this appliance, use only spare par ts that you can be assured conform to the safety and perf or mance specification that we require . Do not use recond[...]

2 icos - Installation & Servicing[...]

3 icos - Installation & Servicing DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level ......................... A03 to A04 (Apr 08) Ideal Stelrad Group reserve the right to vary specification without notice • Page 15, Frame 1 1 - Unpacking Change to boiler contents, wall mounting template now mounted on i[...]

4 icos - Installation & Servicing GENERAL Boiler Size HE 12 Max HE 15 Max HE 18 Max HE 24 Max HE 12 Min HE 15-24 Min Boiler input 'Q' = Nett CV k W 12.2 15.1 18.7 24.4 9.8 9.1 Btu/ h 41 600 51 500 63 800 83 300 33 400 31 000 Gross CV k W 13.5 16.8 20.7 27.1 10.9 10.1 Btu/ h 46 000 57 200 70 800 92 500 37 200 34 400 Gas consumption l/s[...]

5 icos - Installation & Servicing GENERAL CONTENTS Air Supply ....................................................................... 9 Benchmark Commissioning Checklist ..................... 54 Boiler Clearances ......................................................... 6 Boiler Exploded Diagram ............................................ 14 E[...]

6 icos - Installation & Servicing GENERAL nm8729 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. This appliance is NOT suitable for use with a direct hot water cyl[...]

7 icos - Installation & Servicing GENERAL INTRODUCTION The icos range of boilers are a fully automatically controlled, wall mounted, low water content, balanced flue, fanned, condensing gas boiler . It has full modulating central heating outputs of : HE12 9.3 kW (32,000 Btu/h) to 12.0 kW (41,000 Btu/h). HE15 8.8 kW (30,000 Btu/h) to 14.6 kW (50[...]

8 icos - Installation & Servicing GENERAL SAFE HANDLING OF SUBST ANCES Care should be taken when handling the boiler insulation panels, which can cause irritation to the skin. No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture. LOCA TION OF BOILER The boiler must be installed on a flat and vertical wall, capa[...]

9 icos - Installation & Servicing GENERAL Single feed, indirect cylinders are not recommended and MUST NOT be used on sealed systems. The appliances are NOT suitable for gravity central heating nor are they suitable for the provision of gravity domestic hot water . The hot water cylinder and ancillary pipework, not forming part of the useful he[...]

10 icos - Installation & Servicing GENERAL 3 OPEN VENT SYSTEM REQUIREMENTS 4 SCHEMA TIC PIPEWORK AND SYSTEM BALANCING The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load at least 10% of the minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is [...]

11 icos - Installation & Servicing GENERAL Non-return valve Automatic air vent Hose unions Additional stop valve Hose connector Hosepipe (disconnect after filling) Double check valve assembly ( note direction of flow) T emporary hose (disconnect after filling) ecl6060 Note. The pump manufacturers' minimum requirements must be complied with[...]

12 icos - Installation & Servicing GENERAL 7 SEALED SYSTEM REQUIREMENTS - continued pressure. The cold feed pipe from the cistern should include a non-return valve and a stop valve with an automatic air vent connected between them, the stop valve being located between the system and the automatic air vent. The stop valve may remain open during [...]

13 icos - Installation & Servicing GENERAL Safety valve setting 3.0 bar 2.5 bar 2.0 bar V essel charge and initial 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0 system pressure bar bar bar bar bar bar bar bar T ot al water content of system Exp ansion vessel volume litres litres 25 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0 50 4.2 5.4 7.8 4.7 6.7 1 1.8 5.6 10.0 75 6.3 [...]

14 icos - Installation & Servicing INST ALLA TION nm8744 40 94 8. Flue manifold. 10. Interpanel. 11 . Burner assy . 12. Combustion chamber Insulation. 13. Heat exchanger 14. Injector & housing 15. V enturi assy . 16. Fan assy . 17. Gas pipe assy . 19. Gas control valve assy . 20. Fan bracket assy . 21. Orifice plate. 22. Flue thermistor . L[...]

15 icos - Installation & Servicing INST ALLA TION G C A B E F D nm7890 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. 11 UNP ACKING Hardware Pack A 50mm x No.14 wood screws - 3 off B Wall plugs (TP2B ) - 3[...]

16 icos - Installation & Servicing INST ALLA TION W all Thickness X 160 mm 160 + S = 193mm nm8943 13 FRONT AND BOTT OM P ANEL REMOV AL IMPORT ANT . The boiler MUST be inst alled in a vertical position. Dimension X - Wall thickness. Dimension L - Wall thickness plus boiler spacing. Dimension S - S tand-of f frame depth = 33mm. 1. T o remove the [...]

17 icos - Installation & Servicing INST ALLA TION FLUE OUTLET 1 nm8752 16 W ALL MOUNTING TEMPLA TE 15 FLUE ASSEMBL Y - Exploded V iew LEGEND 1. Duct assembly . 2. Flue turret. 3. T urret gasket. 4. M5 x 10 pozi screw . 5. T urret clamp. An optional flue duct extension kit is required for wall thicknesses greater than : Side 395mm Rear 435mm nm9[...]

18 icos - Installation & Servicing INST ALLA TION FLUE OUTLET 17 PREP ARING THE W ALL IMPORT ANT . 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. Both wal[...]

19 icos - Installation & Servicing INST ALLA TION FLUE OUTLET 1. A maximum of 6 extension ducts (one suitably cut) plus the standard flue duct may be used together . 2. Flue extensions of greater length than 1m (39") should be supported with the bracket provided, suitably adjusted. Refer to Frame 20 & 26. 21 FLUE EXTENSION DUCTS - cont[...]

20 icos - Installation & Servicing INST ALLA TION 23 CONDENSA TE DRAIN The condensate drain provided on the boiler must be connected to a drainage point, preferably within the building. Ensure that the condensate trap is full of water before commissioning the boiler . Refer to Frame 27. The routing of the drain must be made to allow a minimum f[...]

21 icos - Installation & Servicing INST ALLA TION 25 CONDENSA TE PIPE TERMINA TION CONFIGURA TIONS . . . continued cla9253 BOILER Air Break 3. INTERNAL CONNECTION T O SOIL AND VENT ST ACK * Make connection to SVP using a solvent welded saddle BOILER External wall Ground Level T ermination to Soak away cla7774 minimum 500mm BOILER External wall [...]

22 icos - Installation & Servicing INST ALLA TION nm8755 2 1 3 27 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 flue outlet A. Make sure the plastic cap is removed from the end of the condensate drain adapter. T ake care to ensure that the wate[...]

23 icos - Installation & Servicing INST ALLA TION FLUE OUTLET Flue duct suppor t V ertical connector UIN 203135 90 o elbow UIN 203130 45 o elbow UIN 203131 Roof Flue Extension Duct UIN 203129 nm8735 Flue T erminal UIN 203132 Flue Seal Collar - Flat Roof UIN 152259 Flue Seal Collar - Tile Roof UIN 152258 29 ROOF FLUE KIT CONTENTS / OPTIONS 28 FI[...]

24 icos - Installation & Servicing INST ALLA TION FLUE OUTLET rf8394-1 690mm Fixed 300mm min 30 FLUE TERMINAL POSITION rf8393-1 300mm min 300mm min 625mm Fixed Flat roof - with structure 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, ter[...]

25 icos - Installation & Servicing INST ALLA TION FLUE OUTLET rf8737 rf8738 31 FLUE ARRANGEMENT Note. The equivalent flue length resistance of the elbow kits are: 90 o elbow kit = 1m 45 o elbow kit = 0.6m[...]

26 icos - Installation & Servicing INST ALLA TION FLUE OUTLET 32 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[...]

27 icos - Installation & Servicing INST ALLA TION 33 GAS CONNECTION IMPORT ANT . The gas service cock is sealed with a non-metallic fibre washer seal so must not be overheated when making capillary connections. Refer to Frame 2 for details of the position of the gas connection. N.B. The principle of the 1:1 gas valve ensures that the icos HE ra[...]

28 icos - Installation & Servicing INST ALLA TION 36 INTERNAL WIRING Incoming mains wiring detail A pictorial wiring diagram is shown in Frame 37. 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-of f kit then route through the gromm[...]

29 icos - Installation & Servicing INST ALLA TION Spark generator nm 8076 bk b br bk b bk r b v b r br b r r b r r r or or or or b pk pk y y y/g y/g Ferrite y/g y/g y/g y/g y/g y/g bk bk Flue thermistor Overheat thermostat Flow control thermistor Gas valve ON /OFF Switch Service connection MAINS SUPPLY 230V 50Hz Permanent black link Fan y y Cha[...]

30 icos - Installation & Servicing INST ALLA TION B. GAS INST ALLA TION 1. The whole of the gas installation, including the meter , should be inspected and tested for soundness and purged in accordance with the recommendations of BS. 6891. In IE refer to I.S. 813:2002. 2. Purge air from the gas installation by the approved methods only . W ARNI[...]

31 icos - Installation & Servicing INST ALLA TION nm8780 41 INITIAL LIGHTING LEGEND A 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 Overheat thermostat. L Flue thermistor . M Flow thermistor . Z S pa[...]

32 icos - Installation & Servicing INST ALLA TION 42 GENERAL CHECKS Make the following checks for correct operation: 1. Central Heating The correct operation of ANY programmer and all other system controls should be proved. Operate each control separately and check that the main burner or circulating pump, as the case may be, responds. Ensure t[...]

33 icos - Installation & Servicing SERVICING 44 SERVICING SCHEDULE 45 BOILER FRONT P ANEL REMOV AL 46 BOILER SEALING P ANEL/ BOTTOM P ANEL REMOV AL 1. Remove the 2 screws from the underside of the appliance. 2. Pull the front panel forward at the bottom and lif t to disengage it from the top lugs. 1. T o remove the sealing panel remove the 4 sc[...]

34 icos - Installation & Servicing SERVICING 2 3 1 4 E c l 6073 47 F AN AND VENTURI ASSEMBL Y REMOV AL 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 of f the fan and venturi assembly . 5. Inspect the injector for[...]

35 icos - Installation & Servicing SERVICING 50 CLEANING THE HEA T EXCHANGER 49 CLEANING THE CONDENSA TE '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 . 51 REASSEMBL Y Reassemble the boiler in[...]

36 icos - Installation & Servicing SERVICING GENERAL When replacing ANY component: 1. Isolate the electricity supply . 2. T urn off the gas supply . 3. Remove the boiler front panel. Refer to Frame 40. After replacing ANY component check operation of the boiler including gas soundness, gas rate and combustion test. THE BOILER MUST NOT BE OPERA [...]

37 icos - Installation & Servicing SERVICING Gasket Orifice plate E c l 2336 5 3 7 4 55 BURNER REPLACEMENT 54 F AN REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 45 & 46. 3. Disconnect the electrical leads from the fan. 4. Unscrew the gas pipe union connection to the injector housing. 5. Uns[...]

38 icos - Installation & Servicing SERVICING 57 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front, bottom & sealing panels. Refer to Frames 45 & 46. 3. Unplug the flame detection lead from the electrode. 4. Remove the 2 screws holding the flame detection electrode to the combustion chamber . 56 IGNIT[...]

39 icos - Installation & Servicing SERVICING E c l 23 4 0 Copper washer 4 Rubber mou l ded sea l 59 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 45 & 46. 3. Remove the fan / venturi assembly . Refer to Frame 54. 4. Remove the 2 injector housing screws. 6. Withdraw the injec[...]

40 icos - Installation & Servicing SERVICING 62 MAINS SWITCH REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and bottom panel. Refer to Frames 45 & 46. 3. Remove the 2 control box screws and lower the control box. 4. Push out the mains switch from the rear , as shown. 5. Refit the new switch, ensuring that the electrical leads [...]

41 icos - Installation & Servicing SERVICING 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 45 & 46. 3. Pull off the silicon tube from the thermistor housing. 4. Remove the aluminium nipple securing the thermistor to the flue manifold. 5. Withdraw the thermistor . 6. Unplug the inline electrical connect[...]

42 icos - Installation & Servicing SERVICING 65 COMBUSTION CHAMBER INSULA TION REPLACEMENT 1 Rear Front Combustion chamber LH Side RH Side nm8748 7 6 5 The insulation boards used in the combustion chamber of this product are made of high temperature glass fibres with a binder of organic and inorganic materials. Ideal S telrad Group recommend th[...]

43 icos - Installation & Servicing SERVICING 66 HEA T EXCHANGER REPLACEMENT Refer also to Frame 10, 'Boiler exploded view'. 1. Refer to Frame 52. 2. Remove front, bottom and sealing panels. Refer to Frames 45 & 46. 3. Remove the control box and place to one side. Refer to Frame 61. 4. Attach a length of hose to the drain nipple on[...]

44 icos - Installation & Servicing SERVICING 67 BOILER SEALING P ANEL SEAL REPLACEMENT 1. Refer Frame 52. 2. Remove the front panel. Refer to Frame 45. 3. Remove the boiler sealing panel. Refer to Frame 46. 4. Remove the old seal from the casing and thoroughly clean the casing surfaces. 5. Fit the new adhesive seals - note that they are supplie[...]

45 icos - Installation & Servicing FAUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING 69 F AUL T FINDING CHART MAIN MENU AL TERNA TING 'L' 'F' GO TO FRAME 70 AL TERNA TING 'L' 'E' GO TO FRAME 71 AL TERNA TING 'L' 'A' GO TO FRAME 72 AL TERNA T[...]

46 icos - Installation & Servicing FAUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING 70 L.....F ....... (FLAME ERROR) Check the ignition electrode and associated harness for: continuity , visual condition , position (Refer to Frame 56). Are these functioning correctly ? Check gas valve wiring for con[...]

47 icos - Installation & Servicing FAUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING Does the pump setting give a differential across the boiler in excess of 25 o C ? Can the overheat condition be reset by pressing the boiler reset button when the system is cold ? YES YES NO 72 L.......A........ (OVE[...]

48 icos - Installation & Servicing FAUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING 75 H......F ........ (FLAME DETECTION - SHORT CIRCUIT ERROR) Replace flame detection electrode Is there continuity between the 2 terminal pins ? Replace PCB. NO YES 76 H.....4...... (FL UE T HE RM I STOR ERROR) Check[...]

49 icos - Installation & Servicing SHORT LIST OF P ARTS The following are parts commonly required due to damage or expendability . Their failure or absence is likely to affect safety or performance of this appliance. The list is extracted from the British Gas List of Parts, which contains all available spare p arts. The full list is held by Bri[...]

50 icos - Installation & Servicing SHORT LIST OF P ARTS nm8077 78 SHORT LIST 79 BOILER CASING ASSEMBL Y 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom casing panel with screws.[...]

51 icos - Installation & Servicing 81 BURNER ASSEMBL Y E c l 1598 11 . Burner assembly with screws and gasket. LIST OF P ARTS 80 CONTROLS ASSEMBL Y 33. Controls assy with screws. 34. Controls hinge bracket. 35. User controls (without item 38). 36. PCB (primary controls). 38. User control housing 39. Mains switch. 54. Jumper link.[...]

52 icos - Installation & Servicing NOTES[...]

53 icos - Installation & Servicing INST ALLER NOTIFICA TION GUIDELINES IT IS A REQUIREMENT OF CORGI MEMBERSHIP T O REGISTER EVERY GAS APPLIANCE In addition a change to Building Regulations (England and W ales) requires the installer to notify when installing a heating appliance, as from 1st April 2005. Competent Person's SELF CERTIFICA TIO[...]

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Ideal Boilers , P .O. Box 103, National A ve, Kingston upon Hull, HU5 4JN. T elephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. T echnical T raining Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its product s. The right is therefore reserved to vary specification without no[...]

users guide icos Y our I de al users g u i d e When replacing any part on this appliance, use only spare par ts that you can be assured conform to the safety and perf or mance specification that we require . Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers . HE12, HE15, HE18, HE24 For installation g u i [...]

2 icos - Users Introduction The icos is a wall mounted, room sealed, super efficient condensing boiler featuring full sequence automatic spark ignition and fan assisted combustion. Due to the very high efficiency , condensate is produced from the flue gases and this is drained to a suitable disposal point through the plastic waste pipe at the right[...]

3 icos - Users Control of water temperature The boiler controls the central heating radiator temperature to a maximum of 82 0 C, adjustable via the CH thermostat knob (C). Approx CH flow temperatures for the boiler thermostat settings are: Knob Setting Flow T emperature o C o F Minimum 30 86 Maximum 82 180 T o shut down the boiler 1. For short peri[...]

Ideal Boilers , P .O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN. T el. 01482 492251 Fax. 01482 448858. Registration No. London 322 137. Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice. Ideal Consumer Helpline T[...]