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IDEAL INDUSTRIES HE15 manual

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Table of contents for the manual

  • Page 1

    i ns ta l l ati o n a n d se r v icing classic Y ou r I d eal i ns tal la tion an d s e r v ici n g guide See reverse for classic users guide 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[...]

  • Page 2

    2 classic HE - Installation & Servicing 201850-6.pmd 21/02/2008, 12:57 2[...]

  • Page 3

    classic HE - Installation & Servicing 3 DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level ............ A 05 (Oct 06) to A06 (Jan 08) • V arious Pages Company Name Change. • Page 26 & 27, Frames 39 & 40 - Condensate Pipe T ermination Configurations BS6798 recommends that a second trap and an ai[...]

  • Page 4

    4 classic HE - Installation & Servicing GENERAL CAUTION. T o avoid the possibility of injury during the inst allation, servicing or cleaning of this appliance, care should be taken when handling edges of sheet steel components Boiler Size HE 9 HE12 HE15 HE18 Gas supply connection (in. BSP) Rc 1/2 (1/2) 1/2" (BSP Female) Flow connection 22m[...]

  • Page 5

    classic HE - Installation & Servicing 5 GENERAL CONTENTS Air Supply . ..................................................................... 9 Benchmark Commissioning Checklist ..................... 46 Boiler Clearances ......................................................... 7 Boiler Exploded View ..............................................[...]

  • Page 6

    6 classic HE - Installation & Servicing GENERAL INTRODUCTION The classic HE 9, 12, 15 and 18 are a range of automatically fully controlled, wall mounted, balanced flue, fanned, high efficiency , condensing gas boilers. The primary heat exchanger is cast iron. The secondary heat exchanger is aluminium. The boiler casing is of white enamelled mil[...]

  • Page 7

    classic HE - Installation & Servicing 7 GENERAL This appliance in NOT suitable for use in a direct hot water system or for gravity circulation. 1 BOILER W A TER CONNECTIONS The following minimum clearances must be maintained for operation and servicing. Additional space will be required for installation, depending upon site conditions. Side and[...]

  • Page 8

    8 classic HE - Installation & Servicing GENERAL Bathrooms This range of appliances is rated IP 1XB. The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. (BS.7671) Wiring Regulations and, in Scotland, the electrical provisions of the building regulations appli[...]

  • Page 9

    classic HE - Installation & Servicing 9 GENERAL Boiler Size HE 9 1 2 1 5 1 8 Boiler k W 9. 0 1 2 1 5 1 8 Output Btu/h x 1000 30.7 40.9 50.2 60.4 Water Flow l/min 1 1.7 15.6 19.5 23.4 Rate gal/h 15 5 20 6 25 8 30 9 Pressure mbar 54.0 93.5 98.4 142.5 Loss i n w g 21.6 37.4 39.3 5 7 T able 5 - W ater flow rate and pressure loss TERMINAL The termin[...]

  • Page 10

    10 classic HE - Installation & Servicing GENERAL Minimum Requirements Note. The pump manufacturers minimum requirements must be complied with. System return Connections to boiler Inverted cold feed entry System flow to pump 150 (6") Max 15mm Cold feed 450 (17 3 / 4 ") Mimimum 450 (17 3 / 4 ") Mimimum 22mm Open vent Feed / expansi[...]

  • Page 11

    classic HE - Installation & Servicing 11 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 5 SEALED SYSTEM REQUIREMENTS Note. The method of filling, refilling, to[...]

  • Page 12

    12 classic HE - Installation & Servicing GENERAL 6 SEALED SYSTEM REQUIREMENTS - continued Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be less than that given by T able 6, multiplied by a factor of 0.8 (for flow temperatures of less than 88 o C). Safety valve setting 3.0[...]

  • Page 13

    classic HE - Installation & Servicing 13 INST ALLA TION 7 BOILER ASSEMBL Y - Exploded view LEGEND 24 30 27 35 9 12 19 37 26 23 17 Condensate siphon trap Data Plate cla7926 9. Sightglass 12. Main Burner 17. Gas V alve 19. Control Box 23. PCB25E 24. Air pressure switch 26. Controls Casing 27. Flue Protection Thermostat 30. Fan 35. Front Panel 37.[...]

  • Page 14

    14 classic HE - Installation & Servicing INST ALLA TION The boiler is supplied fully assembled in Pack A , together with a standard flue assembly for lengths from 75mm (3") up to 705mm (27 3/4 ") rear flue and from 270mm (10 5/8") up to 775mm (30 1/2 ") side flue in Pack B. Note. For side flue applications the optional extra[...]

  • Page 15

    classic HE - Installation & Servicing 15 INST ALLA TION 1. Cut straps and remove outer carton. 2. Remove packing from top of boiler (Note the wall mounting plate is packed on this packing) 3. Leave bottom packing in place. 4. Slightly open plastic controls door to gain access to the front panel fixing screws. 5. Remove the front casing as follo[...]

  • Page 16

    16 classic HE - Installation & Servicing INST ALLA TION REAR FLUE OUTLET 1 2 3 4 5 6 Note. Check all of the hole positions BEFORE drilling 11 FLUE ASSEMBL Y - Exploded V iew LEGEND 1. T erminal 2. Weather seal (optional extra) 3. Flue assembly 4. Boiler sealing ring 5. Flue extension pipe 6. 'O' ring 1. An optional flue duct extension[...]

  • Page 17

    classic HE - Installation & Servicing 17 INST ALLA TION REAR FLUE OUTLET 14 CUTTING THE FLUE - wall thicknesses of 75 to 705mm 1. Measure and note the wall thickness X (Refer to Frame 10). 2. Mark the wall thickness onto the flue. 3. T o ensure the tube is cut square, mark the flue all the way around. 4. Position the inner flue spring to suppor[...]

  • Page 18

    18 classic HE - Installation & Servicing INST ALLA TION REAR FLUE OUTLET 1. Locate the 3 sealing ring studs in the holes in the back panel. Note. The sealing ring studs will locate in the back panel one way only . This will ensure that the terminal grille is correctly aligned. 2. Secure the flue to the boiler using the three M5 nuts provided. 3[...]

  • Page 19

    classic HE - Installation & Servicing 19 INST ALLA TION SIDE FLUE OUTLET cla7712 1 2 4 3 5 The optional side outlet kit is required for all side flue applications. An optional flue duct extension kit is required for lengths (distance from the outside wall to the relevant side of the boiler casing) greater than 775mm (30 1/2"). Refer to Fra[...]

  • Page 20

    20 classic HE - Installation & Servicing INST ALLA TION SIDE FLUE OUTLET cla7667 Downward piping bracket Wall mounting bracket 25 W ALL MOUNTING PLA TE For flue lengths greater than 775mm refer to Frames 28, 29 and 30 - Flue extension ducts. 1. Measure and note the side flue length "Y" (refer to Frame 10). 2. Add 143mm (5 5 / 8 "[...]

  • Page 21

    classic HE - Installation & Servicing 21 INST ALLA TION SIDE FLUE OUTLET cla7672 8 Jacking screw 10 9 Note. The boiler may require two men to lift it onto the wall mounting plate. For downward routing of pipes the M5 spacer (supplied in the downward piping kit) should now be fitted to the back of the boiler. 1. The boiler is supplied for rear o[...]

  • Page 22

    22 classic HE - Installation & Servicing INST ALLA TION SIDE FLUE OUTLET 30 FITTING THE KIT 1. Fit the inner flue extension duct onto the inner flue duct. 2. Fit the outer flue extension duct onto the outer air duct. 3. Repeat steps 1 and 2 if a second flue extension is required. 4. Measure and mark the flue length required onto the flue, measu[...]

  • Page 23

    classic HE - Installation & Servicing 23 INST ALLA TION FLUE OUTLET 31 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 v[...]

  • Page 24

    24 classic HE - Installation & Servicing INST ALLA TION FLUE OUTLET Part No. D e scription HE 9 HE12 HE15 HE18 n/a Maximum Flue Length (m) 4 4 4 4 201 180 Flue ext. 60/100 3 3 3 3 201 189 T erminal V ertical Roof 60/100 1 1 1 1 158 431 Weather Collar Pitched Roof 1 1 1 1 158 432 Weather Collar Flat Roof 1 1 1 1 201 182 90 o Elbow Kit (60/100) 2[...]

  • Page 25

    classic HE - Installation & Servicing 25 INST ALLA TION FLUE OUTLET 35 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 l[...]

  • Page 26

    26 classic HE - Installation & Servicing INST ALLA TION 37 W A TER CONNECTIONS 1. Remove the plastic plugs from the flow and return pipes. 2. Make all water connections and check for water soundness. 36 GAS CONNECTION Refer to 'Gas Supply ', page 8. Refer to Frame 2 for gas inlet service dimensions. A minimum pressure of 20 mbar MUST [...]

  • Page 27

    classic HE - Installation & Servicing 27 INST ALLA TION 40 CONDENSA TE PIPE TERMINA TION CONFIGURA TIONS . . . continued cla9253 BOILER Air Break 3 . INTERNAL CONNECTION T O SOIL AND VENT ST ACK T ermination 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[...]

  • Page 28

    28 classic HE - Installation & Servicing INST ALLA TION cla7738 Limit thermostat O/heat thermostat Thermostat sensor L br br L On/Off switch ALL EARTHS must be connected (Not all earths are shown for clarity) Air pressure switch Flue protection thermostat cla7856 Combined spark & sensing electrode Potentiometer L NTC NC N C NO P .C.B. 25 GV[...]

  • Page 29

    classic HE - Installation & Servicing 29 INST ALLA TION Flue protection thermostat Thermostat sensor Limit thermostat cla7677 Notes. 1. Some earth wires are omitted for clarity . Ensure proper earth continuity when wiring. 2. Numbering of terminals on thermostats is specific to the manufacturer. 3. This is a fully controlled system - set the bo[...]

  • Page 30

    30 classic HE - Installation & Servicing INST ALLA TION Notes. 1. Some earth wires are omitted for clarity . Ensure proper earth continuity when wiring. 2. Numbering of terminals on thermostats is specific to the manufacturer. 3. This is a fully controlled system - set the boiler thermostat to maximum. 4. Switchmaster valve has grey and orange [...]

  • Page 31

    classic HE - Installation & Servicing 31 INST ALLA TION 47 COMMISSIONING AND TESTING A. ELECTRICAL INST ALLA TION 1. Checks to ensure electrical safety should be carried out by a competent person. 2. AL W A YS carry out preliminary electrical system checks, i.e. earth continuity , polarity , resistance to earth and short circuit using a suitabl[...]

  • Page 32

    32 classic HE - Installation & Servicing INST ALLA TION 49 INITIAL LIGHTING - continued 1. Hand the User's Instructions to the Householder and explain his or her responsibilities under the current Gas Safety (Installation and Use) Regulations or rules in force. 2. Draw attention to the Lighting Instruction label affixed to the controls pod[...]

  • Page 33

    classic HE - Installation & Servicing 33 SERVICING cla7851 2 casing retaining screws T o ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary . The frequency of servicing will depend upon the installation condition and usage, but should be carried [...]

  • Page 34

    34 classic HE - Installation & Servicing SERVICING 1. Remove the air pressure switch and CO/CO 2 sensing pipes. 2. Disconnect the electrical connections. 3. Remove the 2 fan fixing screws and remove the fan by pulling forward. 55 CLEANING THE F AN ASSEMBL Y / THE FLUEW A YS 56 CLEANING THE BURNER AND PILOT ASSEMBL Y 1. Brush off any deposits th[...]

  • Page 35

    classic HE - Installation & Servicing 35 SERVICING MAIN BURNER After any servicing, reference should be made to T able 2 which quotes details of the rated output with the related burner setting pressure and the heat input. Any required adjustments should be made by using the pressure adjustment screw . Refer to 'initial Lighting', Fra[...]

  • Page 36

    36 classic HE - Installation & Servicing SERVICING cla7742 64 THERMOST A T CONTROL, THERMISTOR SENSOR LEAD & ON/OFF SWITCH REPLACEMENT Refer also to Frame 61. A. Remove the control box fixing screws B. Swing the control box down into the servicing position. Thermostat control 1. Pull the knob off the shaft. 2. Remove the backnut securing th[...]

  • Page 37

    classic HE - Installation & Servicing 37 SERVICING 67 PILOT BURNER REPLACEMENT 1. Refer to Frame 61. 2. Remove the burner and air box assembly . Refer to Frame 54. 3. Remove the electrode retaining nut and remove the pilot shield and electrode. 4. Unscrew the central pilot fixing screw and lift the pilot clear of the pilot injector . The pilot [...]

  • Page 38

    38 classic HE - Installation & Servicing SERVICING 70 GAS CONTROL V AL VE REPLACEMENT 1. Refer to Frame 61. 2. Remove the burner and air box assembly . Refer to Frame 54. 3. Remove the control box fixing screws. Swing the control box down into the servicing position. 4. Disconnect the gas control valve electrical leads. 5. Undo the gas cock uni[...]

  • Page 39

    classic HE - Installation & Servicing 39 SERVICING 1. Refer to Frame 61. 2. Remove the two fan electrical connections, the red pressure sensing pipe, the blue CO/CO 2 sensing pipe and the two fan fixing screws. 3. Pull the fan forward, remove and retain. 4. Fit the new fan and reassemble in reverse order , ensuring the fan leads, 2 sensing tube[...]

  • Page 40

    40 classic HE - Installation & Servicing SERVICING 76 CASING FRONT SEAL REPLACEMENT 12. Remove the 2 rubber sealing grommets from the top of the back panel to facilit ate fitting the new assembly . 13. Fit the new heat exchanger assembly , complete with water pipes, and hang it on the bottom key hole slots and screws. Refit the top 2 screws and[...]

  • Page 41

    classic HE - Installation & Servicing 41 SERVICING 77 SIPHON REPLACEMENT 1. Refer to Frame 61. 2. Remove the burner . Refer to Frame 54. 3. Pull the heat shield forward to remove from clips. 4. Pull off the rubber sump connecting pipe and the blockage sensing pipe. 5. Unscrew the siphon union connection. 6. Remove the two siphon retaining screw[...]

  • Page 42

    42 classic HE - Installation & Servicing FAUL T FINDING FA UL T FINDING F A UL T FINDING F A UL T FINDING Check all connections to PCB. If no fault found, replace PCB Reset the overheat 'stat. Set control 'stat to maximum. Allow the boiler to reach temperature - if the overheat 'stat trips again, measure flow temperature. If abov[...]

  • Page 43

    classic HE - Installation & Servicing 43 SHORT LIST OF P ARTS Key No. G C Part No. Description Q t y . Product No. 9 E83-619 Si gh t glass Assembly Kit 1 171 414 1 2 E72-529 Main Burner Kit HE9, HE12 1 171 012 HE15, HE18 1 174 063 1 3 E85-308 Main Injector Kit H E9 1 171 424 E83-624 HE12 1 171 425 E83-625 HE15 1 171 426 E83-626 HE18 1 171 427 1[...]

  • Page 44

    44 classic HE - Installation & Servicing SHORT LIST OF P ARTS 78 SHORT P ARTS LIST 12 30 35 19 9 24 17 18 23 FUSE 37 39 26 27 15 14 13 13 A 45 59 cla7850 201850-6.pmd 21/02/2008, 12:58 44[...]

  • Page 45

    classic HE - Installation & Servicing 45 INST ALLER NOTIFICA TION GUIDELINES IT IS A REQUIREMENT OF CORGI MEMBERSHIP T O REGISTER EVER Y 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 CERTIF[...]

  • Page 46

    CONTROLS T o comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME & TEMPERA TURE CONTROL T O HEA TING ROOM T/ST A T & PROGRAMMER/TIMER PROGRAMMABLE ROOMST A T TIME & TEMPERA TURE CONTROL T O HOT WA TER CYLINDER T/ST A T & PROGRAMMER/TIMER COMBI BOILER HEA TING ZONE V AL VES FITTED NOT[...]

  • Page 47

    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 48

    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 products. The right is therefore reserved to vary specification without not[...]

  • Page 49

    users guide classic Y our I de al users g u i d e See reverse for classic installation & servicing instructions 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 b[...]

  • Page 50

    classic HE - Users 2 INTRODUCTION The classic HE is a wall mounted, room sealed, high efficiency 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 [...]

  • Page 51

    classic HE - Users 3 All CORGI registered installers carry a CORGI ID card, and have a registration number . Both should be recorded in the Benchmark Commissioning Checklist. Y ou can check your installer by calling CORGI direct on 01256 372300. THE BENCHMARK SERVICE INTERV AL RECORD MUST BE COMPLETED AFTER EACH SERVICE Ideal Stelrad Group is a mem[...]

  • Page 52

    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[...]