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INSTALLATION AND SERVICING

1. 3 degrees AE CB Flue AE CB Flue W sampling r nA sampling al point i x point si Z Spark 5 LEGEND generator On Off switch Auto Air t B CH Thermostat knob Ri LL sl Da C Resetbutton 3 oo Flow thermist D Burner On Neon do os LI E Displa il FILI OH thermostat e IGO HJV ho F Injector pressure test point Dry fire ioe G Inlet pressure test point nl H H Ni thermistor o LU fe lu H Gasservice cock AE Gdl 9 eo ag GAS G F eH lle OH Rel hi Lo N ia thermostat smi 3 tai Ra i oo i Q P So SS Flow agi d thermistor cane a H mxhe7619 H J mexico HE15 HE18 amp HE24 mexico HE30 amp HE36 30 mexico HE Installation amp Servicing INSTALLATION 41 GENERAL CHECKS Make the following checks for correct operation Note Fernox Superfloc Sentinel X300 new systems X400 existing systems or Salamander products flushing 1 Central Heating solutions should be used during the flushing procedure The correct operation of ANY programmer and all other Refer to Frame 9 system controls should be proved Operate each control a With the system HOT examine all water connections for separately and check that the main burner or circulating soundness pump as the case may be responds b With the system still HOT turn off the
2. control valve and remove valve Undo the 4 gas valve bracket screws bracket and gas inlet pipe and remove Remove the valve bracket fixing screw Transfer the mounting bracket and gas inlet pipe to the new gas control valve Fit new gas control valve ensuring that any seals showing damage or deterioration are replaced 11 Reassemble in reverse order 12 Ensure the sensing tubing is correctly replaced 13 Check operation of the boiler Refer to Frame 51 mxhe7791 38 mexico HE Installation amp Servicing SERVICING 60 CONTROL BOX REPLACEMENT Refer to Frame 51 Remove the boiler upper front panel Refer to Frame 44 Remove the 2 control box mounting bracket screws Pull the control box forward Carefully unplug all the electrical wiring from the control box Toremove the user control from the assembly pull the control forward to disconnect the plug 6 Transfer the mounting brackets to the new control box 7 Reassemble in reverse order 8 Check operation of the boiler Refer to Frame 51 N B To change the user control only 9 10 11 12 13 Loosen the screw on the underside of the user control Pull the display unit forward to remove Push the new display unit into position Reassemble in reverse
3. ALTERNATING L A GO TO FRAME 74 ALTERNATING L 8 GO TO FRAME 75 ALTERNATING H 1 GO TO FRAME 76 ALTERNATING H F GO TO FRAME 77 ALTERNATING 4 or H9 or L9 GO TO FRAME 78 ALTERNATING n GO TO FRAME 79 71 CONDENSATE PUMP FAILURE Is switched live present on the L2 Check external controls wiring and terminal function YES Power down the boiler and check for continuity between the common C Check condensate pump reservoir is and normally closed NC wires on the empty and check overflow float switch is condensate pump Is there continuity moving freely YES Re apply power to the boiler Is switched live present on the common C terminal of the Check wiring continuity from L2 through condensate pump connector to the PCB J1 black wire YES Follow normal boiler fault finding procedure 2 A 2 2 A 2 5 Z Q J 2 Z Q lt 2 lt mexico HE Installation amp Servicing 45 FAULT FINDING FLAME ERROR If the boiler reset button is pressed does the boiler ignite for a short time then extinguish I VES YES Check the detection electrode and Is 200V DC supp
4. mexico HE Installation amp Servicing SERVICING 67 HEAT EXCHANGER REPLACEMENT continued 20 HE15 18 amp 24 only Unscrew the 5mm hex Hd Screw retaining the copper pipe retention plate and remove plate HE30 amp 36 only Unscrew the return connection union Remove the 5 screws retaining the sump Remove the S trap bracket fixing screw and remove the S trap Lift the heat exchanger to clear the bottom panel pull forward and remove Fit the new heat exchanger reassembling in reverse order replacing gaskets or seals if any sign of damage or deterioration is evident To ensure a positive flue seal is confirmed it may be necessary to remove the worktop or adjacent cupboard to view the joint 26 Check the operation of the boiler Refer to frame 51 68 INNER SEALING PANEL SEAL REPLACEMENT Refer Frame 51 Remove the boiler front panels and refer to Frame 44 Remove the inner sealing panel Refer to Frame 45 Remove the old seal from the panel and thoroughly clean the panel surfaces Fit the new adhesive seals note that they are supplied to the correct length for the relevant sides 6 Reassemble in reverse order Note Ensure that the boiler sealing panel is correctly seated compressing the seal to make an airtight joint mxhe7614 7 Check operation of boiler Refer to Frame 51 mexico HE Installation amp Servicing
5. MUST be available at the front of the boiler for servicing Minimum front clearance when built behind a concealing panel is 5mm 1 INTRODUCTION The mexico HE range of boilers are fully automatically controlled floor standing low water content balanced flue fanned condensing gas boilers They have full modulating central heating outputs of HE15 8 8 kW 30 000 Btu h to 14 6 kW 50 000 Btu h HE18 8 8 kW 30 000 Btu h to 18 2 kW 62 300 Btu h HE24 8 8 kW 30 000 Btu h to 23 4 kW 80 000 Btu h HE30 10 6 kW 36 200 Btu h to 30 1 kW 102 700 Btu h HE36 10 6 kW 36 200 Btu h to 37 0 kW 126 200 Btu h Due to the very high efficiency of the boiler a plume of water vapour will form at the flue terminal during operation depending on external conditions 7S 449 17 467 18 All dimensions in mm in mxhe7564 Overall Space Dim Depth Height Width 530 870 460 530 870 460 530 870 460 530 870 460 530 870 460 Boiler Model HE15 6m HE18 6m HE24 6m HE30 3m HE36 3m Top clearance 7 mxhe7565 All dimensions in mm in Front view Side view The boiler casing is of white painted mild steel with the user controls capable of being mounted remotely from the boiler if the option is required
6. Fit the sealing gasket and push the flue turret into the top of the boiler flue sealing ring and retain with the 4 screws provided Smear lubricant to be found in hardware pack over both inner flue duct seal and outer air duct seal and locate the flue onto the turret ensuring the 2 bayonet fixings on the flue connector B engage to the lugs on the turret A Replace the top outlet blanking plate Flue Outlet Top outlet Flues over 1 metre long blanking plate Fix the flue support bracket to the wall using the wall plug Sealing Gasket and wood screw mxhe7710 FLUE OUTLET mexico HE Installation amp Servicing 23 INSTALLATION 29 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 Connection to the top of the boiler is made using a separately supplied vertical connector WEATHER PROOFING Where the flue passes through the roof line an adequate seal must be made This is achieved by using either Flat roof weather collar or Universal weather collar ACCESSORIES Flue Duct Extension Kits are available for flue lengths extending beyond 1m These packs contain 1m extension ducts and may be cut to the desired
7. INSTALLATION AND SERVICING MEXICO HE15 HE18 HE24 HE30 HE36 For details of document amendments refer to page 3 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 For the very latest copy of literature for specification and maintenance practices visit our website www idealboilers com where you can download the relevant information in PDF format February 2014 UIN 201787 A10 E L mexico HE Installation amp Servicing a a a a ee a a a a a a a a ee _ ii NOTES FOR THE INSTALLER I 1 FOR ANY TECHNICAL QUERIES PLEASE RING THE IDEAL I INSTALLER TECHNICAL HELPLINE 01482 498663 I L ee ee ee es es es DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level A09 Mar 13 to A10 Feb 14 Page 7 8 9 Update to standards Page 13 Water Treatment Addition of Adey Page 31 Addition of statement ref to Benchamark Commissioning Checklist Page 51 New Page Added Benchmark Commissiong amp Servicing Section Page 52 amp 53 New updated Commiss
8. mexico HE Installation amp Servicing 47 2 2 lt a J lt a lt lt lt TI 78 FAULT FINDING a PR SA FLAME DETECTION SHORT CIRCUIT ERROR Remove flame detection electrode terminal from PCB Is there continuity between the 2 terminal Replace PCB pins Replace flame detection electrode DRY FIRE THERMISTOR ERROR H9 L9 FLUE GAS OVERHEAT Can the fault condition be reset by switching off the mains supply to the boiler Is the system filled and vented and all isolation valves open 165 Is the pump operating correctly Ensure flow through system Check wiring for continuity from the PCB to the dry fire thermistor YES NO Fill and vent the system and open all isolating valves Check resistance using a suitable multimeter connected across the dry fire thermistor terminal pins At25 C expect 9 700 10 300 Ohms At60 C expect 2 400 2 600 Ohms At85 C expect 1 000 1 100 Ohms Check resistance using a suitable multimeter connected across the flue thermistor terminal pins At25 C expect 9 700 10 300 Ohms At60 C expect 2 400 2 600 Ohms At85 C expect 1 000 1 100 Ohms 48 Are thermistor values correct Are dry fire thermistor values
9. Customer name Telephone number Address Boiler make and model Boiler serial number Commissioned by PRINT NAME Gas Safe register number Company name Telephone number Company address Commissioning date To be completed by the customer on receipt of a Building Regulations Compliance Certificate Building Regulations Notification Number if applicable CONTROLS tick the appropriate boxes Room thermostat and programmer timer Programmable room thermostat Time and temperature control to heating Load weather compensation Optimum start control Time and temperature control to hot water Cylinder thermostat and programmer timer Combination Boiler Heating zone valves Fitted Not required Hot water zone valves Fitted Not required Thermostatic radiator valves Fitted Not required Automatic bypass to system Fitted Not required Boiler interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions What system cleaner was used What inhibitor was used Quantity Has a primary water system filter been installed CENTRAL HEATING MODE measure and record Gas rate OR Burner operating pressure if applicable OR Gas inlet pressure Central heating flow temperature
10. y 9 br 37 FUNCTIONAL FLOW WIRING DIAGRAM LEGEND Mains Switch b blue N L bk black 2 r br brown 1 Control PCB gy grey Cond External or orange Alarm pk pink r red a Overheat v violet thermostat w white y yellow DC Gas valve y g yellow green Op QO Ignition electrode v Dry fire thermistor Control thermistor r User PCB mxhe7604 28 mexico HE Installation amp Servicing INSTALLATION Wiring external to the boiler MUST be in accordance with the current 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 It provides for more energy efficient operation by reducing switching temperature differentials Frost Protection If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system This is usually done at the programmer in which case the programmer selector switches are set to OFF and all other controls MUST be left in the running position The frost thermostat should be sited in a cold place but where it can sense heat from the system If the boiler is installed in a garage it may be necessary to fit a pipe ther
11. IE Flow Wiring Diagram Flue Fitting Flue Installation Requirements Gas Safety Regulations Gas Supply Initial Lighting Installation Mandatory Requirements Safe Handling Servicing Short List of Parts Terminal Guards Thermostatic Radiator valves Water and Systems Water Connections Water Treatment Wiring Diagrams For GB to comply with Building Regulations Part L1 Part 6 in Scotland the boiler should be fitted in accordance with the manufacturer s instructions Self certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist Before installing this boiler read the Code of Practice sheet at the rear of this book BENCHMARK COMMISSIONING CHECKLIST DETAILS Boiler Make and model Appliance serial no on data badge SEDBUK No Controls Time and temperature control to heating Time and temperature control to hot water Heating zone valves Auto bypass Boiler interlock Flushing to BS 7593 Inhibitor Central heating mode Heat input NOTE TO THE INSTALLER COMPLETE THE BENCHMARK COMMISSIONING CHECKLIST AND LEAVE THESE INSTRUCTIONS WITH APPLIANCE mexico HE Installation amp Servicing Page Burner operating pressure measure and record Central heating flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reducer Hot w
12. 29 Flame detection electrode 34 Condensate S trap 36 Condensate S trap hose 37 User controls 38 PCB primary control 41 Main switch c w harness 43 Pre piping frame 54 Burner earth pin ionisation probe mexico HE Installation amp Servicing INSTALLATION 11 UNPACKING The boiler is supplied fully assembled in Pack A Anon telescopic flue assembly for rear or side flue outlet in Pack B is suppled as a separate order TA t 4 Unpack and check the contents Pack A Contents The boiler These Installation amp Servicing User Instructions Floor standing template 1 year guarantee form Hardware Pack Box mxhe7570 INSTALLATION mugwD gt Hardware Pack Box Contents E A B Pre piping frame Flue turret Screws 4 off Gasket Flue connector Screws 5 off Condensate Pipe Bracket G o Flue turret lubricant xa Sealing washers 3 off kc 1 x 1 gas and 2 x 22mm water connection s TIOTNMDIO Pack B Contents Flue terminal 12 PACKAGING REMOVAL 13 FITTING AND CONNECTING THE PRE PIPING 1 Fold back the top flaps and remove outer FRAME CONDENSATE PIPE SUPPORT BRACKET sleeve 1 Determine the position required for the boiler and tape template 2 The Installation amp Servicing Users into place Instructions can be found on top of the Note boiler The template gives positions for both wall Remove
13. At max rate Record At min rate Where Possible Comments Comments SERVICE 05 Signature SERVICE 06 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments SERVICE 07 Signature SERVICE 08 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments SERVICE 09 Signature SERVICE 10 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible Comments Comments Allinstallations in England and Wales must be notified to Local Authority Building Control LABC either directly or through a Competent Persons Scheme A Building Regulations Compliance Certificat
14. Current Gas Safety Installation and Use Regulations or rules in force The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force In GB the installation must be carried out by a Gas Safe Registered Engineer It must be carried out in accordance with the relevant requirements of the e Gas Safety Installation and Use Regulations e The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations northern Ireland The Water Fittings Regulations or Water bye laws in Scotland e The Current I E E Wiring Regulations Where no specific instructions are given reference should be made to the relevant British Standard Code of Practice In IE the installation must be carried out by a Registered Gas Installer and installed in accordance with the current edition of 1 5 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice BS 5440 1 Flues for gas appliances of rated input not exceeding 70 kW BS 5440 2 Ventilation for gas appliances of rated input not exceeding 70 kW BS 5449 Forced circulation hot water systems BSEN 12828 2003 Heating Systems in buildings Design for water based heating systems
15. The heat exchanger is of cast aluminium Artificially softened water must NOT be used A pre piping frame is provided to allow system and gas connection to be made prior to boiler installation Note These boilers cannot be used on systems which include gravity circulation The boilers are suitable for connection to fully pumped open vented or sealed water systems Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework mexico HE Installation amp Servicing GENERAL OPERATION When there is a demand for heat the heating system is supplied at the selected temperature of between 30 C and 82 C The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating and performance of key components to aid commissioning and fault finding SAFE HANDLING This boiler may require 2 or more operatives to move it to its installation site remove it from its packaging base and during movement into its installation location Manoeuvring the boiler may include the use of a sack truck and involve lifting pushing and pulling Caution should be exercised during these operations Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered e Grip the boiler at the base e physically capable e Use PPE as appropriate e g
16. Using the rubber connecting joint provide a plastic outlet pipe from gt mxhe7610 the pump outlet connection to a suitable drain point connection taking care to route the pipework such that it will not foul the boiler when fitted Refer to Frame 18 Make up the inlet plastic pipe connection to the following drawing and fit to the S trap flexible hose connection Remove the four screws retaining the boiler to the wooden packaging 0 Return Inlet pipe end cut at 45 _ 60mm HE15 HE18 HE24 190mm HE30 HE36 Flexible hose from S trap 4 2141 Rubber connecting joint base and using the packaging sleeve to protect the floor 10 Connect the condensate pump inlet ensuring the pipe is slide the boiler onto the pre piping frame ensuring the pushed to bottom of the pump housing If no pump is fitted mains cable and the condensate pump cable if fitted is connect the S trap flexible hose to the previously installed routed through the grommet at the top left of the boiler condensate drain pipe Refer to Frame 13 Screw the boiler frame to the floor through the 2 slots in 11 Wire the mains connection the condensate pump connection the front of the boiler runners if fitted and the remote user control if fitted Refer to Frame Connect the gas and water union connections ensuring the 35 sealing washers are in place FLUE OUTLET 20 mexico HE Inst
17. compartment used to enclose the boiler should be designed and constructed specially for this purpose An existing cupboard or compartment may be used provided that it is modified for the purpose In both cases details of essential features of cupboard compartment design including airing cupboard installation are to conform to the following BS 6798 No cupboard ventilation is required see Air Supply for details The position selected for installation MUST allow adequate space for servicing in front of the boiler For the minimum clearances required for safety and subsequent service see Frame 2 This position MUST also permit the provision of a satisfactory flue termination Boiler may be fitted under a worktop surface Boiler can be fitted behind a kitchen cupboard door without need for ventilation GAS SUPPLY The local gas supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must NOT be used without prior consultation with the local gas supplier 8 The boiler MUST be installed on a gas supply with a governed meter only A gas meter can only be connected by the local gas supplier by a Gas Safe Registered Engineer In IE by a Registered Gas Installer RGII An existing meter should be checked preferably by the gas supplier to ensure that the meter is adequate to deal with the rate
18. gloves safety footwear During all manoeuvres and handling actions every attempt should be made to ensure the following unless unavoidable and or the weight is light e Keep back straight e Avoid twisting at the waist e Avoid upper body top heavy bending e Always grip with the palm of the hand e Use designated hand holds e Keep load as close to the body as possible e Always use assistance if required OPTIONAL EXTRA KITS FLUING Flue Extension Ducts HE15 18 amp 24 up to 6m HE30 amp 36 up to 3m 90 Elbow Kit 60 100 dia maximum no per installation HE15 18 amp 24 up to 4 elbows HE30 amp 36 up to 2 elbows 45 Elbow Kit 60 100 dia maximum no per installation HE15 18 amp 24 up to 4 elbows HE30 amp 36 up to 2 elbows Concentric Flue Screw Retaining Kit Roof Flue Kit 60 100 HE15 18 amp 24 up to a maximum of 8m HE30 amp 36 up to a maximum of 5m Pitched Roof Tile for roof flue kit Flat Roof Tile for roof flue kit Vertical Flue Adaptor Vertical Outlet Flue Kit with Elbow 60 100 HE15 18 amp 24 to a maximum length of HE30 amp 36 to a maximum length of 3m Flue Finishing Kit High Level Flue Outlet Kit Flue Deflector Kit 1000mm long OTHER OPTIONAL KITS Remote User Control Kit Condensate Pump Kit Concealment Panel Kit RS Boiler Terminal Wall Plate Kit Adjustable Flue Support Bracket mexico HE Installation amp Servicing SAFETY
19. of gas supply required It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS6891 2005 Whilst the principle of the 1 1 gas valve ensures the Mexico HE range is able to deliver it s full output at inlet pressures as low as 14mb other gas appliances in the property may not be as tolerant When operating pressures are found to be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation Allowing for the acceptable pressure loss of 1mb across the installation pipework it can be assumed that a minimum permitted operating pressure of 18mb will be delivered to the inlet of the appliance Reference BS 6400 1 Clause 6 2 Pressure Absorption The external gas cock could further reduce the operating pressure when measured at its test point The pressure drop is relative to the heat input to the boiler kW refer to graph below Gas Cock Pressure Drop 3 25 2 8 15 2 8 05 Dt T T T T 00 50 100 150 200 250 300 350 400 450 heat input to boiler kW IMPORTANT Installation pipes MUST be fitted in accordance with BS 6891 In IE refer to 1 5 813 2002 Pipework from the meter to the boiler MUST be of an adequate size i e no longer than 20m and not less than 15mm O D The complete installation MUST be tested for gas tightness and purged as described in the above code FL
20. 20 9 530 20 9 Gas Type I2H G20 I2H G20 I2H G20 I2H G20 12H G20 Gas Supply Pressure 20mb 20mb 20mb 20mb 20mb Flue duct diameter 100 4 100 4 100 4 100 4 100 4 Flue horizontal duct length max Table 2 Performance Data Nett CV Gross CV kW Btu h kW Btu h 15 1 51 500 16 8 57 200 6 18 7 63 800 20 7 70 800 6 24 4 83 300 27 1 92 500 6 30 7 104 700 37 5 128 000 34 0 116 000 41 6 142 000 3 9 1 31 000 10 1 34 400 3 10 6 36 200 11 8 40 300 Gas Consumption l s cu ft h 0 43 54 7 0 53 68 0 0 70 89 7 0 88 111 9 1 07 136 0 0 26 33 3 0 30 38 4 Output P 70 c Mean Water temp kW Btu h 40 c Mean Water temp kW Btu h 14 6 50 000 15 5 53 000 18 2 62 300 19 2 65 700 23 4 80 000 25 1 85 700 30 1 102 700 37 0 126 200 32 8 111 800 39 8 135 800 8 8 30 000 9 6 32 800 10 6 36 200 11 4 38 900 Seasonal efficiency SEDBUk BandA 90 4 90 3 90 21 90 41 90 7 NOx classification Class 5 i The value is used in the UK Government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by a notified body Note Gas consumption is calculated using a calorific value o
21. 43 SERVICING SERVICING 1 SERVICING 69 CONDENSATE S TRAP REPLACEMENT amp CONDENSATE PUMP IF FITTED Refer to Frame 51 2 Remove the boiler front panels Refer to Frame 44 3 Condense pump removal if fitted Outlet pipe 44 Disconnect the outlet pipe rubber connecting joint taking care to capture any liquid held in the pipe Inlet pipe from S trap Lift the inlet pipe to clear the pump Remove the pump wiring cover Remove the 5 wires from the terminal strip Lift the condensate pump from the two screw fixings Pull the pump forward and remove the wiring through the top grommet Undo the plastic union nut on the condensate S trap outlet and disconnect the flexible hose Remove the screw retaining the S trap bracket and remove the bracket Loosen the top nut on the S trap then pull the trap down and forward to remove Reassemble in reverse order ensuring the condensate pump is correctly replaced Check operation of the boiler Refer to Frame 51 mexico HE Installation amp Servicing FAULT FINDING 70 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 IF BOILER FAILS TO RUN WHEN DEMAND IS PRESENT ili GO TO FRAME 71 ALTERNATING L F GO TO FRAME 72 ALTERNATING L E OR HE GO TO FRAME 73
22. Central heating return temperature COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm If yes and if required by the manufacturer has a water scale reducer been fitted What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas rate OR Burner operating pressure at maximum rate OR Gas inlet pressure at maximum rate Cold water inlet temperature Hot water has been checked at all outlets Yes Temperature Water flow rate CONDENSING BOILERS ONLY The condensate drain has been installed in accordance with the manufacturer s instructions and or BS5546 BS6798 ALL INSTALLATIONS At max rate co ppm CO CO At min rate where possible CO CO Record the following The heating and hot water system complies with the appropriate Building Regulations The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions The operation of the boiler and system controls have been demonstrated to and understood by the customer The manufacturer s literature including Benchmark Checklist and Service Record has been explained and left with the customer Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature Allinstallations
23. Heating Systems in buildings Method for calculation of the design heat load Heating Systems in buildings Installation and commissioning of water based heating BSEN 12831 2003 BSEN 14336 2004 systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 60 kW BS 6891 Low pressure installation pipes Health amp Safety Document No 635 The Electricity at Work Regulations 1989 The manufacturer s notes must NOT be taken in any way as overriding statutory obligations IMPORTANT These appliances are CE certificated for safety and performance It is therefore important that no external control devices e g flue dampers economisers etc are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Ideal Boilers in writing If in doubt please enquire Any direct connection of a control device not approved by Ideal Boilers may invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations SAFE HANDLING OF SUBSTANCES 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 7 GENERAL LOCATION OF BOILER The
24. Regulations or 7 If any programmer is fitted then draw attention to the Programmer rules in force User s Instructions and hand them to the householder 2 Explain and demonstrate the lighting and shutting down procedures 8 After installation and commissioning please complete the 1 benchmari 3 The operation of the boiler and the use and adjustment EHI of ALL system controls should be fully explained to HEATING AND HOT WATER SYSTEMS e the householder to ensure the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent 9 IMPORTANT damage to the system and to the building in the event of the system remaining inoperative during frosty conditions Commissioning Checklist before handover to the customer For IE its is necessary to complete a Declaration of Conformity to indicate compliance to 1 5 813 2002 Stress the importance of regular servicing by a Gas Safe Registered Engineer and that a comprehensive service should be 4 Explain the function and the use of the boiler heating carried out AT LEAST ONCE A YEAR In IE servicing work must controls be carried out by a Registered Gas Installer 5 Explain the function of the boiler fault mode 10 As the installer you may wish to undertake the service contract Emphasise that if a fault is indicated the boiler should yourself or alternatively offer to the
25. With boiler set at minimum rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording mexico HE Installation amp Servicing Turn off Appliance and Call Ideal Technical Helpline The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with GS I amp U R NOTE Check and record CO level and combustion ratio at both maximum AND minimum rate before contacting Ideal CO level less han 350ppm AND CO CO ratio less than 0 0040 Boiler is Operating Satisfactorily No further actions required Ensure test points are capped boiler case is correctly replaced and all other commissioning procedures are completed Complete Benchmark Checklist recording CO and combustion ratio readings as required 55 For additional fault finding advice please visit our website www idealboilers com Technical Training The Ideal Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers 2 enchmari 01482 498 432 COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The code of practice for the installation Manufactured under an ISO 90
26. any loose deposits from the sump 5 Inspect the ignition and detection electrodes Ensure that they are clean and in good condition replace if necessary Check the condition of the combustion chamber insulation HE15 18 and 24 only Any cracked or damaged pieces must be replaced mxhe7684 Note care not to disturb the ionisation probes at the front and rear of the combustion chamber 7 Check that the ignition and detection gaps are correct Refer to Frames 55 and 56 mexico HE24 shown 50 REASSEMBLY Reassemble the boiler in the following order 6 Refit the boiler sealing panel IMPORTANT Ensure the boiler sealing panel is correctly fitted and Refit the electrodes check dimensions Frames that a good seal is made Refit the sump cover plate 55 and 56 7 Refit the boiler front panels Refit the burner 8 Turn on the gas supply at the gas service cock Refit the fan venturi assembly 9 Reconnect the electrical supply Reconnect the fan electrical leads 34 mexico HE Installation amp Servicing SERVICING 51 REPLACEMENT OF COMPONENTS GENERAL When replacing ANY component 1 Isolate the electricity supply 2 Turn off the gas supply 3 Remove the boiler front panels and inner sealing panel Refer to Frames 44 and 45 After replacing ANY component check operation of the boiler including gas tightness gas rate and combustion test IMPORTANT When
27. be adjusted accordingly 15 GAS CONNECTION GAS CONNECTION Refer to Fame 1 for details of the position of the gas The boiler gas connection is built into the pre piping connection frame Ensure that the gas supply pipe does not foul the boiler IMPORTANT the gas service cock is sealed with a non Casing metallic fibre washer seal so must not be overheated Refer to Frame 40 for details of the pressure test point when making capillary connections position 16 BOILER WATER CONNECTIONS The boiler flow and return connections are built into the pre piping frame Note For heating loads in excess of 60 000 Btu h use 28mm x 22mm connectors to connect the boiler flow and return pipes to 28mm mxhe If flow and return pipes are required to run behind the boiler this can be facilitated by fitting the boiler in line with the front of 600mm deep kitchen units thus creating a 70mm space behind the boiler 16 mexico HE Installation amp Servicing INSTALLATION 17 CONDENSATE DRAIN This appliance is fitted with a siphonic 75mm condensate trap system that requires filling before operating the appliance for the 1st time or after maintenance All condensate pipework should conform to the following a Where new or replacement boiler is being installed access to an internal gravity discharge termination should be one of the main factors considered in determining boiler location b Plastic with push fit o
28. ceramic with a SOFT brush Inspect the sealing gasket around the burner and combustion chamber insulation for any signs of damage Replace as necessary Note Take care not to disturb the ionisation probes at the front and rear of the combustion chamber mexico HE Installation amp Servicing lonisation Probes mexico HE 24 shown 33 SERVICING SERVICING SERVICING 48 CLEANING THE CONDENSATE S TRAP amp CONDENSATE PUMP IF FITTED If condensate pump fitted refer to separate instructions for cleaning procedure 1 If a condensate pump is fitted it must be removed and pulled forward to gain access to the condensate S trap Refer to Frame 69 Note Care must be taken with residual water when removing the outlet pipe Remove the plastic union sealing nut on the bottom of the condensate S trap Remove and clean from the cartridge and ball any residual deposits Inspect the opaque S trap for further signs of dirt and clean as necessary Replace the cartridge and ball and replace the plastic sealing nut Replace the condensate pump 49 CLEANING THE HEAT EXCHANGER Remove ignition and flame detection electrodes Refer to Frames 55 and 56 Remove the 3 screws retaining the sump cover and remove lonisation Using a suitable tool clean the exposed heat exchanger fins through the sump cover Also vacuum any debris from the top of the heat exchanger Remove
29. correct a NO Inspect heat Replace Replace dry fire thermistor Replace thermistor exchanger for blockage or damage in the flueways Clean or replace as necessary Note With V9 Primary Control PCB overheat LA HA or H9 L9 when reset will display 3 horizontal lines and will not attempt to re fire until the temperature in the heat exchanger drops below 50 C PHASE REVERSAL ERROR Check wiring to the boiler for reversed live and neutral mexico HE Installation amp Servicing SPARE 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 Failure to do so could affect safety or performance of this appliance Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www idealparts com Our Parts team are also available to help with your Ideal Spare Parts enquiries on 01482 498665 When calling and to ensure we can provide you with the most accurate parts information please ensure you have the following to hand Boiler Model Appliance GC Number Boiler Serial Number mexico HE Installation amp Servicing 49 Code Of Practice For the installation commissioning and servicing of domestic heating an
30. customer the benefits of the be turned off and a Gas Safe Registered Engineer Ideal Care Scheme details of which are outlined in the household consulted In IE contact a Registered Gas Installer pack supplied with this boiler As part of the commissioning process the combustion of this appliance must be checked and the Benchmark Checklist completed A flow chart to assist is provided on page 55 ATTENTION IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE mexico HE Installation amp Servicing 31 INSTALLATION SERVICING SERVICING 43 SERVICING SCHEDULE For the very latest copy of literature for specification amp 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 To 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 out annually It is the law that any service work must be carried out by a GAS Safe Registered Engineer In IE service work must be carried out by a Registered Gas Installer PLEASE NOTE During routine servicing and after any maintenance or change of part of the combustion circuit
31. in England and Wales must be notified to Local Authority Building Control LABC either directly or through a A Competent Persons Scheme A Building Regulations Compliance Certificate will then be issued to the customer COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS Heating and Hotwater Industry Council HHIC www centralheating co uk SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed Service Provider Before completing the appropriate Service Record below please ensure you have carried out the service as described in the manufacturer s instructions Always use the manufacturer s specified spare part when replacing controls SERVICE 01 SERVICE 02 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible At max rate Record At min rate Where Possible SERVICE 03 Signature SERVICE 04 Engineer name Engineer name Company name Company name Telephone No Telephone No Gas safe register No Gas safe register No At max rate Record At min rate Where Possible
32. length If the offset vertical option is used an elbow Kit is required For a full accessories list refer to page 7 Optional Extras 30 ROOF FLUE KIT CONTENTS OPTIONS NOTE ITEMS D E F G AND H ARE NOT SUPPLIED WITH THE ROOF FLUE KIT Flue assembly with terminal mxhe7652 3 5x13 screw Pitched roof tile flat roof tile weather collar E Vertical connector 60 100 comes with gasket and fixing screws A B Flue seal collar Roof flue extension duct kit 60 100 90 elbow kit 60 100 45 elbow kit 60 100 mxhe7778 24 mexico HE Installation amp Servicing INSTALLATION 31 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 Pitched Roof Li with structure Aluminium shield Flat roof with structure B 2000mm Directly below an opening The flue terminal shall not penetrate the shaded area of the roof air brick windows etc 300 mm 300 mm Below eaves or balcony Note The equivalent flue length resistance of the elbow kits are Above or side of velux windows 9
33. must be made in a way that allows complete The fuse rating should be 3 A isolation of the electrical supply such as a double pole switch having a 3mm 1 8 contact separation in both poles or a Wiring external to the boiler MUST be in accordance with the plug and socket serving only the boiler and system controls current E E BS 7671 Wiring Regulations and any local The means of isolation must be accessible to the user after regulations installation 35 INTERNAL WIRING A pictorial wiring diagram is shown in Frame 40 1 Route the mains cable via the rear of the boiler through the grommit at the left hand side Mains Connector Socket supplied in hardware pack fixed to boiler Wire the permanent live supply into the 5 way remote plug DO terminals L3 N amp gt DO IMPORTANT DO A permanent live is ESSENTIAL in order for the advanced ri diagnostic controls to function correctly OO Ensure that the lengths of the live and neutral wires are shorter than the earth wires so that if the cable slips in its anchorage Remove link when connecting external programmer roomstat the current carrying wire become taut before the earth wire Wire any switched live supply into L2 or connect L1 and L2 via external control switching as shown in Frame 39 In either KEY case remove the wire link fitted to L1 to L2 L3 Permanent Live Secure the mains lead with the cable clamp L2 Switched
34. refilling topping up or flushing sealed primary hot water circuit from the mains via a temporary hose connection is only allowed if acceptable to the local water authority Drain cock Safety valve cla7649 Feed expansion Top of air vent to be below water level cistern Automatic air vent N Air separator Boiler ber 1 Max practical length Flow All dimensions in mm in NB Imperial dimensions are approximate Make up vessel max capacity 31 Hose union bib tap Air vent Non return valve Pressure gauge Automatic When installing the filling device it must be connected as shown to fully comply with the water regulations This may involve lt air vent HEATING CIRCUIT Hosepipe ali disconnect the fitting of an additional WRAS approval isolator valve to the mains BOILER supply y A General a The installation must comply with the requirements of BS 6798 and BS 5449 The installation should be designed to work with flow temperatures of up to 82 C All components of the system including the heat exchanger of the indirect cylinder must be suitable for a working pressure of 3 bar 45lb in and temperature of 110 C Care should be taken in making all connections so that the risk of leakage is minimised Safety Valve A spring loaded safety valve complying with the relevant requirements of BS 6759 must b
35. reverse flow of rainwater into the boiler should the downpipe become flooded or frozen see Fig 5 Where the condensate drain pipe terminates over an open foul drain or gully the pipe should terminate below the grating level but above water level to minimise wind chill at the open end The use of a drain cover as used to prevent blockage by leaves may offer further prevention from wind chill See Fig 6 Where the condensate drain pipe terminates in a purpose designed soak away see BS 6798 any above ground condensate drain pipe sections should be run and insulated as described above See Fig 7 Unheated Internal Areas Internal condensate drain pipes run in unheated areas e g lofts basements and garages should be treated as external pipe Ensure the customer is aware of the effects created by a frozen condensate and is shown where this information can be found in the user manual Figure 2 Connection of a Condensate Drainage Pipe Downstream of a Sink Basin Bath or Shower Water Trap to Internal Soil Vent Stack Boiler with 75mm sealed condensate trap Min 19mm 7 Internal pipe Sink basin bath or shower Internal soil amp vent stack Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break continued 17 INSTALLATION INSTALLATION INSTALLATION 18 CONDENSATE DRAIN CONT D 18 Figure 3 Connection of a Condensa
36. the following must be checked e The integrity of the flue system and the flue seals e integrity of the boiler combustion circuit and the relevant seals e operational working gas inlet pressure at maximum rate Refer to Frame 40 e The gas rate Refer to Frame 41 The combustion performance Refer to step 3 1 Light the boiler and carry out a pre service check noting any operational faults 2 Check the gas consumption 3 Connect a suitable gas analyser to the sampling point on top of the boiler or into the flue terminal if access is possible Refer to Frame 46 For correct boiler operation the CO CO2 ratio of the flue gas should not be greater than 0 004 ratio If the combustion reading is greater than the acceptable value AND the integrity of the complete flue system and combustion circuit seals have been verified and the inlet gas press and gas rate have been verified then contact Ideal Competence to carry out the check of Combustion Performance PLEASE NOTE BS6798 2009 Specification for Installation and maintenance of Gas Fired boiler of rated input not exceeding 70 kW net advises that e person carrying out a combustion measurement should have been assessed as competent in the use of a flue gas analyser and the interpretation of the results e The flue gas analyser used should be one meeting the requirements of BS7927 or BS EN50379 3 and be calibrated in accordance with the analyser
37. the pipe is frozen at the most exposed point external to the building or where there is some obstruction to flow This could be at the open end of the pipe at a bend or elbow or where there is a dip in the pipe in which condensate can collect The location of the blockage should be identified as closely as possible before taking further action 2 Apply a hot water bottle microwaveable heat pack or a warm damp cloth to the frozen blockage area Several applications may have to be made before it fully defrosts Warm water can also be poured onto the pipe from a watering can or similar DO NOT use boiling water 3 Caution when using warm water as this may freeze and cause other localised hazards 4 Once the blockage is removed and the condensate can flow freely reset the appliance Refer to To Light the boiler 5 If the appliance fails to ignite call your Gas Safe Registered engineer Preventative solutions During cold weather set the boiler stat to maximum Must return to original setting once cold spell is over Place the heating on continuous and turn the room stat down to 15 C overnight or when unoccupied Return to normal after cold spell 1 BOILER CONTROLS Legend A Boiler on off switch B CH thermostat knob Cc Reset button D LED E Display i CAUTION To avoid the possibility of injury during the installation servicing or cleaning of this appliance car
38. thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS 5449 Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating or hot water When thermostatic radiator valves are used the space heating temperature control over a living dining area or hallway having a heating requirement of at least 10 of the boiler heat output should be achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves However if the system employs thermostatic radiator valves on all radiators or two port valves without end switches then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position GENERAL ELECTRICAL SUPPLY CONDENSATE DRAIN Refer to Frames 13 15 and 18 WARNING A condensate drain is provided on the boiler This drain must be This appliance must be earthed connected to a drainage point All pipework and fittings in the Wiring external to the appliance MUST be in accordance with condensate drainage system MUST be made of plastic no other the current I E E BS 7671 Wiring Regulations and any local materials may be used regulations which apply For Ireland reference should be made to the current ETCI rules for electrical installations IMPORTANT The point of connection to the mains should be
39. wood screw at bottom rear of or flush with 600mm deep kitchen boiler retaining the hardware pack box units and the positional options Condensat and remove box of the condensate pipe bracket pipe support When the boiler is to be fitted to the pre dependant upon boiler size To brack Pre piping piping Frame refer to Frame 21 remove facilitate upward routing of pipework behind boiler the top and inner sleeve and the boiler from its wooden base The inner sleeve can be used to protect the floor when fitting the boiler to the position the template 40mm minimum away from the back wall 2 Using the floor template mark the pre piping frame fixing holes the boiler fixing holes the condensate pipe support bracket fixing holes and the flue hole refer to Frame 14 3 Drill the 4 holes in the floor and screw the pre piping frame in place 4 Drill the 2 holes in the floor and screw the condensate pipe support bracket in place If the condensate pipe is to be fitted through the rear wall then fit a short piece of plastic pipe to the bracket and mark the wall for drilling Refer to Frame 15 for condensate drain detail When complete retain condensate pipe with bracket clamp and fixing screws protruding 20mm as shown 5 The gas water flow and water return can now be connected Note Measure and cut out flue hole using template Refer to Frame 14 pre piping frame mxhe7812 mexico HE Installat
40. work is complete the sealing panel must be correctly fitted ensuring that a good seal is made Note In order to assist fault finding the control panel has an LED diagnostic display The key to boiler fault conditions is shown in Frame 70 THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED 52 FLOW THERMISTOR REPLACEMENT Refer to Frame 51 Remove the boiler front panels and inner sealing panel Refer to Frames 44 and 45 Note Only the boiler front panels need removing on the HE15 18 and 24 models Pull the electrical leads off the flow thermistor and remove earth connection Remove the two screws retaining the flow thermistor Replace flow thermistor retaining with the fixing screws previously removed and reconnect leads Reassemble the boiler in reverse order Check the operation of the boiler Refer to Frame 51 mexico HE30 amp HE36 mexico HE Installation amp Servicing mexico HE15 HE18 amp HE24 35 SERVICING SERVICING 53 FAN REPLACEMENT Refer to Frame 51 Remove the boiler front panels and inner sealing panel Refer to Frames 44 and 45 Unscrew the gas pipe union connection to the injector housing Unscrew and remove the screw retaining the fan mounting bracket Remove the fan and venturi assembly Disconnect the electrical leads from the fan Remove the 3 screws and remove the venturi assembly noting the orientatio
41. 0 elbow kit 1m 45 elbow kit 0 6m 32 FLUE ARRANGEMENT Part No Description 60 100 Quantity n a Maximum Flue Length 8 8 8 5 5 vaste 201 180 Flue ext 7 7 7 6 e BOILER Note BOILER The equivalent flue length resistance of the 90 elbow kit 60 100 is 1m and the 45 elbow kit 60 100 is 0 75m mxhe7686 mxhe7687 OUTLET mexico HE Installation amp Servicing 25 INSTALLATION 33 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 Refer to No 5 below MAX LENGTH HE15 8m Ensure the cut pipe ends are free from any burrs HE18 8m HE 24 8m 1 Ensure the flue seal collar B is located onto the flue assembly HE 30 5m A HE 36 5m Position the roof flashing plate D supplied separately over the hole cut the roof and insert flue assembly A from the roof end Remove the casing top outlet blanking plate 2 screws or boiler top panel to facilitate fitting the vertical connector Fit the sealing gasket and push fit the vertical connector E supplied separately into the boiler
42. 01 commissioning amp servicing of central heating systems registered quality management system FM 59915 Ideal 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 Boilers 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 Stelrad Group Ideal Installer Technical Helpline 01482 498 663 www idealboilers com USERS GUIDE MEXICO HE15 HE18 HE24 HE30 HE36 For installation 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 mexico HE15 HE18 HE24 HE30 HE36 Natural Gas Only Destination Countries GB IE HE15 G C Appliance No 41 429 39 HE18 G C Appliance No 41 429 65 HE24 G C Appliance No 41 429 98 HE30 G C Appliance No 41 429 99 HE36 G C Appliance No 41 415 20 Introduction The mexico HE is a floor standing room sealed condensing boiler featuring full sequence automatic spark ignition and fan assisted combustion Due to the very high efficiency of the boiler condensate is produced from the flue gases and this is drained toa suitable disposal point through the plast
43. 0mm Internal pipe Min 19mm Internal pipe Minimum connection height up to 3 storeys rg pre __ Soil amp vent stack Boilers without 75mm sealed condensate trap must be fitted with 75mm trap and visible air break Figure 6 Connection of Condensate Drainage Pipe Upstream of a Sink Basin Bath or Shower Waste Trap to External Drain Gulley or Ranwater Hopper Boiler with 75mm sealed condensate trap Visible air break O at plug hole Water AN J weather proof insulation LU Min 19mm Internal pipe Sink basin bath or si Minimum 30mm shower with integral internal pipe TL overflow and 75mm trap L 45 pipe termination mexico HE Installation amp Servicing 2 25 Below grate INSTALLATION 19 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT The boiler MUST be installed in a vertical position Total Flue length dimension Fue Dimension apes thickness Rear flue Side flue Extra packs Dimension L Wall thickness plus boiler spacing required dim X 75 dim L 225 FLUE KITS Upto 775 Up to 775 Up to 1680 mm Up to 1680 Pack D 1 off Pack B supplied as standard Upto 2585 mm Upto 2585 mm Pack D 2 off Finishing Kit supplied as an optional extra Up to 3490 mm Upto 3490 mm Pack D 3 off 8 n Up to 4395 mm Upto 4395 P
44. 24 Remove the boiler front panels and inner sealing panel HE30 and HE36 only Refer to Frames 44 and 45 Pull off the 2 electrical leads from the thermostat body Remove the 2 screws retaining the O H thermostat Fit the new thermostat and reconnect leads Reassemble in reverse order Check operation of the boiler Refer to Frame 51 mexico HE30 amp HE36 64 DRY FIRE THERMISTOR REPLACEMENT 1 Refer to Frame 51 mexico HE30 amp HE36 Remove the boiler front panels and inner sealing panel vr Refer to Frames 44 and 45 Drain down the system Pull off the electrical connection Unscrew and withdraw the thermistor Fit the new thermistor using the gasket supplied Reassemble in reverse order Check operation of the boiler Refer to Frame 51 mexico HE15 HE18 amp HE24 40 mexico HE Installation amp Servicing SERVICING 65 COMBUSTION CHAMBER INSULATION REPLACEMENT HE15 HE18 and HE24 only INSULATION NOW SUPPLIED AS ONE PIECE WHICH IS FLEXIBLE AND EASY TO SHAPE AND INSTALL Ideal Boilers recommends that for your own comfort and safety and to comply with good working practice the procedure described below is followed Refer to Replacement of Components Frame Remove the boiler front and sealing panels Refer to Boiler Front Panel Removal and Boiler Sealing Panel Removal Frame Remove the fan venturi assembly Refer to Fan and Venturi Assembly removal and c
45. ARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE mexico HE Users Control of water temperature The boiler controls the central heating radiator temperature to a maximum of 82 C adjustable via the CH thermostat knob B Approx CH flow temperatures for the boiler thermostat settings are Knob Setting Flow Temperature Minimum 30 86 Maximum 82 180 To shut down the boiler 1 For short periods Set the mains on off switch A to OFF 2 For longer periods Set the mains on off switch A to OFF Switch the electricity supply to OFF For longer periods the entire system should be drained including the domestic hot water supply To relight the boiler Repeat the procedure detailed in To light the boiler Frost Protection If no frost protection is provided and frost is likely during a short absence from home leave the heating controls if fitted at a reduced temperature setting For longer periods the entire system should be drained If the system includes a frost thermostat then during cold weather the boiler should be turned OFF at the time switch if fitted ONLY The mains supply should be left switched ON with the boiler thermostat left in the normal running position Boiler Overheat Thermostat This thermostat will shut down the boiler in the event of overheating Should this occur a fault code t A will be displayed Press the reset button and t
46. NG SERVICING SERVICING 57 SPARK GENERATOR REPLACEMENT Refer to Frame 51 Remove the boiler front panels and inner sealing panel Refer to Frames 44 and 45 Disconnect the leads from the spark generator and bracket Remove the 2 M4 screws securing the spark generator to the bracket Fit the new spark generator and re assemble in reverse order Check operation of the boiler Refer to Frame 51 mexico HE15 HE18 and HE24 58 BURNER INJECTOR REPLACEMENT 1 Refer to Frame 51 Remove the boiler front panels and inner sealing panel Refer to Frames 44 and 45 Remove the fan venturi assembly Refer to Frame 53 Remove the 2 injector housing screws Withdraw the injector housing Fit the new injector housing complete with injector Reassemble in reverse order ensuring that the new gas seal supplied is located correctly in the injector housing Check operation of the boiler Refer to Frame 51 Rubber moulded seal 59 GAS CONTROL VALVE REPLACEMENT Refer to Frame 51 Remove the boiler front panels and inner sealing panel Refer to Frames 44 and 45 Unplug the electrical lead from the gas control valve and disconnect the earth wire Undo the sensing tube connection at the gas control valve Undo the union nut at the gas valve pre piping frame connection Undo the union nut on the outlet side of the gas
47. UE INSTALLATION Pluming will occur at the terminal so terminal positions which would cause a nuisance should be avoided The flue must be installed in accordance with the recommendations of BS 5440 1 2008 In IE refer to 1 5 813 2002 The following notes are intended for general guidance 1 The boiler MUST be installed so that the terminal is exposed to external air 2 Itis important that the position of the terminal allows the free passage of air across it at all times 3 Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 3 4 Where the lowest part of the terminal is fitted less than 2m 6 6 above a balcony above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard Ensure that the guard is fitted centrally Terminal guards are available from boiler suppliers Ask for TFC Flue Guard Model No K6 round plastic coated In case of difficulty contact mexico HE Installation amp Servicing GENERAL TFC Group Ltd Tower House Vale Rise Tonbridge kent TN9 1TB Tel 44 0 01732 351 680 Fax 44 0 01732 354 445 www tfc group co uk 5 The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of any building 6 The air inlet products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm 1 to combustible material Detailed r
48. ack D 4 off Screw Kit optional kit for mecahnical fixing of flue joints Upto 5300 Upto 5300mm Pack D 5 off Pack D optional extension kit for side flue or rear flue outlet to 6000 mm Upto 6000 mm Pack D 6 off Note The flue duct MUST be inclined at 1 5 degrees to the horizontal to allow condensate to drain back into the boiler and out through the condensate drain Only Note MAXIMUM FLUE LENGTHS necessary if using one or more D extension duct packs HE15 18 AND 24 6M HORIZONTAL FLUE HE30 AND 36 HORIZONTAL FLUE HE15 18 AND 24 8M VERTICAL FLUE HE 30 AND 36 5M VERTICAL FLUE 90 ELBOW KIT EQUIVALENT FLUE LENGTH RESISTANCE 1 5M 45 ELBOW KIT EQUIVALENT FLUE LENGTH RESISTANCE 1 0M Refer to Flue Extension Ducts 225mm 225mm 75mm Boiler pushed Notes oe back to the wall 1 Itis recommended that support bracket is fitted for every 1 metre of extension pipe used and a bracket should be used at every joint to ensure pipes are held at the correct angle Side flue length L Rear flue ia length X If a slip joint coupling is to be used then a bracket should be used to secure the collar mxhe7595 Side view 2 Only use water as lubricant during assembly 20 FLUE ASSEMBLY Exploded View An optional flue duct extension kit is required for wall thicknesses greater than Side 545mm 21 Rear 705
49. ain measure the flow temp YES Over 90 Check control thermistor _ Y Refer to Frame 52 Increase the pump setting Is differential now below 25 C Under 90 C Replace overheat stat NO YES Note With V9 Primary Control PCB overheat LA HA or H9 L9 when Replace the system pump OK reset will display 3 horizontal lines and will not attempt to re fire until the temperature in the heat exchanger drops below 50 C T9 Lab FAN ERROR YES Is 14V DC present across yellow and pink Replace fan at the fan connector Is nominal 330 V DC present across red and blue at the fan connector as gt reset button is pressed NO YES Check wiring harness for continuity Is there continuity Replace PCB Replace harness FLOW THERMISTOR ERROR Remove the boiler flow thermistor from the CH flow pipe and disconnect thermistor wires Check resistance using a suitable multimeter connected across the thermistors terminal pins At25 C expect 9 700 10 300 Ohms At60 C expect 2 400 2 600 Ohms At85 C expect 1 000 1 100 Ohms Are the thermistor values correct Replace the thermistor Replace PCB FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING Is there continuity between the PCB and the thermistor Check and replace wiring as necessary
50. allation amp Servicing INSTALLATION 22 CUTTING THE FLUE REAR wall thicknesses of 114 to 705mm Note If using the extension ducts go to Frame 24 25 and 26 1 Measure and note wall thickness X Refer to Frame 19 2 Add 5mm 1 4 to dimension X and measuring from the ring cut both outer and inner tube Ensure support spring clip is in position to facilitate cutting 3 To ensure the tube is cut square mark the flue all the way around Measure from this De burr the cut edges RING 23 CUTTING THE FLUE LH OR TO RH SIDE Wall thickness of 114 to 545mm Note f using the extension ducts go to Frame 24 25 and 26 Measure and note side flue length L Refer to Frame 19 Add 60mm 2 to dimension L and measuring from the ring cut both outer and inner tube Ensure support spring clip is in position to facilitate cutting ensure the tube is cut square mark the flue all the way around Measure from De burr the cut edges this RING 24 FLUE EXTENSION DUCTS for flue lengths greater than 775mm Pack D Flue extension duct kit contents Washers 2 off Wall plugs 2 off pog Note Only use water as a lubricant during assembly mxhe7656 Flue duct support Clamp screws 2 off Support fixing screws 2 off 25 FLUE EXTENSION DUCTS continued Pe Use a maximum of 6m extended flue ONLY HE15 HE18 HE24 Evanston fue Use a maximum of 3m extended flue ONLY HE30 HE36 General arr
51. an 60 000 btu h 17 6 kW the flow and return pipework should be connected in 28mm pipe For the types of system and correct piping procedure see Frames 1 3 to 8 The central heating system should be in accordance with BS 6798 and in addition for smallbore and microbore systems BS 5449 WATER TREATMENT see Frame 9 The hot water storage cylinder MUST be of the indirect type and should preferably be manufactured of copper 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 heating surface should be lagged to prevent heat loss and any possible freezing particularly where pipes run through roof spaces and ventilated underfloor spaces The boiler must be vented The hydraulic resistance of the boilers at MAXIMUM OUTPUT is shown in Graph 1 Graph 1 Water flow rate and pressure loss 2 50 _ HE15 18 amp 24 sso HESO amp 36 2 00 1 50 1 00 0 50 0 00 Resistance metres water 10 15 20 25 30 35 Flow Rate l min BOILER CONTROL INTERLOCKS Ideal Boilers recommend that heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room
52. angement 1 A maximum of 6 extension ducts for the HE15 Standard flue HE18 and HE24 and a maximum of 3 extension ducts for the HE30 and HE36 one suitably Terminal grille cut plus the standard flue duct may be used together Flue extensions of greater length than 1m 39 should be supported with the bracket provided suitably adjusted Refer to Frame 24 E mxhe7599 Side flue shown O ee oe mexico HE Installation amp Servicing 21 FLUE OUTLET INSTALLATION 26 FITTING THE KIT Fit the inner flue extension duct onto the inner wo flue duct Fit the outer flue extension duct onto the outer air duct Repeat steps 1 and 2 if a second flue extension is required Measure and mark the flue length required onto the flue measuring from the ring near the terminal Refer to Frames 19 and 23 for detail of length measurement To ensure a square cut mark the flue all the way around De burr the cut edges Measure from this RING mxhe7843 27 FITTING THE OPTIONAL FLUE FINISHING KIT AND OPTIONAL RS SEALING PLATE Flue Finishing Kit Fit black outer wall seal over terminal and ensure the retaining rim is located in the terminal depression Fit flue pipe assembly through the hole previously cut in wall Fit white inner wall seal to pipe assembly side flue Fit outer wall sealing plate over outer wall seal and retain with the 4 screws and wall plugs provided Cont
53. anufacturer The installer must have the relevant competence for use of the analyser Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer s instructions KEY CO carbon monoxide CO carbon dioxide O2 oxygen Combustion Ratio The CO reading measured in ppm divided by the reading first converted to ppm ppm parts per million GS I amp U R Gas Safety Installation and Use Regulations Minimum Rate Setting Please note this boiler cannot be set to operate continuously at minimum rate For further advice contact Ideal Customer Services Department mexico HE Installation amp Servicing Set Boiler to Maximum Gas Rate In accordance with boiler instructions set boiler to operate at maximum rate full load condition Allow sufficient time for combustion to stabilise Note Do not insert analyser probe during this period to avoid possible flooding of sensor Carry Out Flue Integrity Check Using Analyser Insert analyser probe into air inlet test point where available and allow readings to stabilise Note Where no air inlet test point is provided then a flue integrity check with the analyser is not possible The installer should verify that flue integrity has been visually checked in accordance with the Prior to CO level and combustion ratio check see opposite page before proceeding to the check CO level and combustion ratio at
54. ater supply or to the water storage tank supplying domestic water even through a non return valve without the approval of the local water authority Filling The system may be filled by one of the following methods a Througha cistern used for no other purposes via a ball valve permanently connected directly to a service pipe and or a cold water distributing pipe The static head available from the cistern should be adequate to provide the desired initial system design 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 normal operation of the system if automatic water make up is required Through a self contained unit comprising a cistern pressure booster pump if required and if necessary an automatic pressure reducing valve and flow restrictor The cistern should be supplied through a temporary connection from a service pipe or cold water distributing pipe This unit may remain permanently connected to the heating system to provide limited automatic water make up Where the temporary connection is supplied from a service pipe or distributing pipe which also supplies other draw off points at a lower level then a double check valve shall be installed upstream of the draw off point Through a temporary hose connecti
55. ater mode Heat input Max operating burner pressure Max operating water pressure Cold water inlet temp Hot water outlet temp n a Water flow rate at max setting For condensing boilers only Condensate drain For all boilers complete sign amp hand over to customer For assistance see Technical Helpline on the back page benchmari COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS GENERAL 1 BOILER SERVICE CONNECTIONS le 450 17 Flue 225 8 1 This appliance is NOT suitable for use in a direct hot water system lf the boiler is to be used a sealed system an Overheat Thermostat is fitted as standard 232 9 288 115 5 348 13 2 FLOOR MOUNTING AND BOILER CLEARANCES Flammable materials must not be placed in close proximity to the appliance Materials giving off flammable vapours must not be stored in the same room as the appliance Floor mounting 1 The floor must be flat level and of suitable load bearing capacity 2 The back of the boiler may be fitted up to the wall Boiler clearances The minimum overall dimensions of the space in which the boiler is to operate and to facilitate servicing are as shown Additional space may be required for installation depending upon site conditions In addition a MINIMUM clearance of 450 mm 17
56. ature of 20 C across the boiler is not exceeded Adjust room and cylinder thermostats and programmer to NORMAL settings 10 V Air vent A 450 18 Minimum 450 18 Minimum 150 6 Max System flow to L pump Inverted cold feed entry Return amp flow connections load 30 60 22 mm load 70 80 28 mm 22mm Open vent Alternative Cylinder balancing valve cla7648 Elbow then BOILER Return mexico HE Installation amp Servicing GENERAL 5 This arrangement is useful for large systems where LOW HEAD AND LARGE SYSTEMS WITH EXTENSIVE PIPE RUNS OPEN VENT Ceiling radiators at the extremities are difficult to vent This can lead to pumping over with conventional feed and vent arrangements The following conditions MUST be observed 1 The top of the automatic air vent must be below the cold water level The static water level cold must be at least 200mm above the top of the horizontal flow pipe fitted as shown The vent connection MUST NOT be made immediately off the top of the boiler as venting is made less efficient The maximum practical length of 22mm cold feed pipe should be used in order to reduce the effective volume of hot system water expanding into the feed expansion cistern to a minimum Note The pump manufacturers minimum requirements must be complied with 6 SEALED SYSTEM REQUIREMENTS Notes a The method of filling
57. boiler must be installed on a flat and level floor capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible floor Insulation is not necessary unless required by the local authority For electrical safety reasons there must be no access from the back of the boiler The boiler must not be fitted outside Timber Framed Buildings If the boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineering document IGE UP 7 2006 Bathroom Installations This appliance is rated IP20 The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current IEE BS 7671 Wiring Regulations and the electrical provisions of the building regulations applicable in Scotland with respect to the installation of the boiler in a room or internal space containing a bath or shower For IE reference should be made to the current ETCI rules for electrical installations and 1 5 813 2002 If the appliance is to be installed in a room containing a bath or shower then providing water jets are not going to be used for cleaning purposes as in communal baths showers the appliance must be installed beyond Zone 2 as detailed in BS 7671 Ceiling Recessed A window Zone 2 368913 Compartment Installations
58. co HE Installation amp Servicing GENERAL 8 SEALED SYSTEM REQUIREMENTS continued Safety valve setting Vessel charge and initial 0 5 Total water content of system litres 25 50 75 100 125 150 175 200 225 250 275 300 Multiplying factors for other system volumes 9 WATER TREATMENT The mexico HE boiler range have an ALUMINIUM alloy heat exchanger IMPORTANT The application of any other treatment to this product may render the guarantee of Ideal Stelrad Group invalid Ideal Stelrad Group recommend water treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating systems If water treatment is used Ideal Stelrad Group recommend only the use of Scalemaster Gold 100 FERNOX MB 1 ADEY MC1 or SENTINEL X100 inhibitors and associated water treatment products which must be used in accordance with the manufacturers instructions Notes 1 Itis most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers instructions Ifthe boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing BS 7593 2006 details the steps necessary to clean a domestic heating system In hard water areas treatment to prevent lime scale may be necessary however the use of artificially softened water is NOT permitted Under no circumstances should the boiler be fired bef
59. d hot water products Benchmark places responsibilities on both manufacturers and installers The purpose is to ensure that customers are provided with the correct equipment for their needs that it is installed commissioned and serviced in accordance with the manufacturer s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations Installers are required to carry out work in accordance with the following THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS The use of the word installer is not limited to installation itself and covers those carrying out installation commissioning and or servicing of heating and hot water products or the use of supporting products such as water treatment or test equipment Customer includes householders landlords and tenants Heating and Hotwater Industry Council HHIC oa of Work Be competent and qualified to undertake the work required Install commission service and use products in accordance with the manufacturer s instructions provided Ensure that where there is responsibility for design work the installation is correctly sized and fit for purpose Meet the requirements of the appropriate Building Regulations Where this involves notifiable work be a member of a Competent Persons Scheme or confirm that the customer has notified Local Auth
60. ditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Ideal Boilers The isolation valves should be fitted as close to the pump as possible Feed expansion cistern Water level cold Connections to boiler System return 4 SCHEMATIC 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 always available see footnote re thermostatic radiator valves Balancing 1 Set the programmer to ON for both and HW Turn the cylinder thermostat down Close the manual or thermostatic valves on all radiators leaving the twin lockshield valves on the radiators referred to above in the open position Turn up the room thermostat and adjust these lockshield valves to give boiler flow and return temperatures not more than 20 C apart These valves should now be left as set Open all manual or thermostatic radiator valves and adjust the lockshield valves on remaining radiators to give around 11 C temperature drop at each radiator Turn up the cylinder thermostat and adjust the cylinder balancing valve so that the cylinder achieves a maximum flow consistent with adequate flow to the radiators Check that with only the domestic hot water loop in circuit a differential temper
61. e fitted in the flow pipe as close to the boiler as possible and with no intervening valve or restriction The valve should have the following features mexico HE Installation amp Servicing gt Hose unions Lf after filling Double check valve assembly note direction of flow Pump Additional stop valve Expansion vessel Temporary hose disconnect after filling Hose connector Anon adjustable preset lift pressure not exceeding 3bar 45lb in A manual testing device Provision for connection of a discharge pipe The valve or discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or cause damage to electrical components and wiring Pressure Gauge A pressure gauge covering at least the range 0 4 bar 0 60 Ib in must be fitted to the system The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel 11 7 4 5 GENERAL SEALED SYSTEM REQUIREMENTS continued Expansion Vessel a Adiaphragm type expansion vessel must be connected to a point close to the inlet side of the pump the connecting pipe being not less than 15 mm 1 2 nominal size and not incorporating valves of any sort The vessel capacity must be adequate to accept the expansion of the system water when heated to 110 C 230 F The charge pressur
62. e must not be less than the static water head above the vessel The pressure attained in the system when heated to 110 C 230 F should be at least 0 35 bar 5 Ib in less than the lift pressure of the safety valve For guidance on vessel sizing refer to the table in Frame 8 For further details refer to BS 5449 BS 7074 1 and the British Gas Corporation publication Material and Installation Specifications for Domestic Central Heating and Hot Water For IE refer to the current edition of 1 5 813 Cylinder The cylinder must be either of the indirect coil type or a direct cylinder fitted with an immersion calorifier which is suitable for operating on a gauge pressure of 0 35 bar 5 Ib in in excess of the safety valve setting Single feed indirect cylinders are not suitable for sealed systems Make up Water Provision must be made for replacing water loss from the system either a From a manually filled make up vessel with a readily visible water level The vessel should be mounted at least 150 mm 6 above the highest point of the system and be connected through a non return valve to the system fitted at least 300 mm 12 below the make up vessel on the return side of the domestic hot water cylinder or radiators or Where access to a make up vessel would be difficult by pre pressurisation of the system Refer to Filling below Mains Connection There must be no direct connection to the mains w
63. e should be taken when handling edges of sheet steel components mexico HE Users Escape of gas Maintenance Should a gas leak or fault be suspected contact your local gas The appliance should be serviced at least once a year by a Gas supplier without delay SAfe Registered Engineer or in IE a Registered Gas Installer Do NOT search for gas leaks with a naked flame Cleaning For normal cleaning simply dust with a dry cloth To remove stubborn marks and stains use a damp cloth and mild detergent DO NOT use abrasive cleaning materials POINTS FOR THE BOILER USER Note n line with our current warranty policy we would ask that you check through the following guide to identify any problems external to the boiler prior to requesting a service engineers visit Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit or for any pre arranged visit where access is not gained by the engineer TROUBLESHOOTING TYPICAL NON PRODUCT FAULTS Boiler is not working for Check there is power to the boiler switch A the ON position and 9 displayed on the central heating or hot water controls If 9 not displayed then not a boiler fault contact your installer service company Check external programmer is set to an ON period and the relevant function selected i e central heating or domestic hot water Test by overriding the programmer by setting to cont
64. e will then be issued to the customer Heating and Hotwater Industry Council HHIC Signature THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk 54 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A CONDENSING BOILER Important Preliminary Information on Checks The air gas ratio valve is factory set and must not be adjusted DURING COMMISSIONING If the boiler requires conversion to operate with a different gas family e g conversion from natural gas to LPG sepa rate guidance is provided with the conversion kit supplied and this must be followed PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK The installation instructions must have been followed gas type verified and gas supply pressure gas rate checked as required prior to commissioning As part of the installation process ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that maximum flue lengths have not been exceeded and all guidance has been followed e g Gas Safe Register Technical Bulletin TB 008 where chimney flues are in voids The ECGA should be of the correct type as specified by BS 7967 Prior to its use the ECGA should have been maintained and calibrated as specified by the m
65. ecommendations on the protection of combustible material are given in BS 5440 1 2008 In IE refer to 1 5 813 2002 IMPORTANT It is essential to ensure in practice that products of combustion discharging from the terminal cannot re enter the building or buildings through any openings into the building such as ventilators windows doors or other sources of natural air infiltration such as forced ventilation openings etc If products of combustion re entry is identified or suspected this should be immediately investigated and corrected following the guidance provided in the current Gas Industry Unsafe Situation Procedure Table 3 Balanced Flue Terminal Position Flue Terminal Positions Min Spacing Directly below or alongside an opening window air vent or other ventilation opening Below guttering drain pipes or soil pipes BS5440 1 2008 300mm 12 25mm 1 75mm 3 25mm 1 200mm 8 25mm 1 200mm 8 25mm 1 150mm 6 25mm 1 300mm 12 300mm 12 600mm 247 1 200mm 48 Below eaves BS5440 1 2008 Below balconies or a car port roof BS5440 1 2008 From vertical drain pipes or soil pipes BS5440 1 2008 From an internal or external corner or to a boundary along side the terminal BS5440 1 2008 7 Above adjacent ground roof or balcony level From a surface or a boundary facing the terminal From a terminal facing a terminal From an opening in a car
66. ems at no cost to the customer during the installer s guarantee period www centralheating co uk Benchmark Commissioning and Servicing Section It is a requirement that the boiler is installed and commissioned to the manufacturers instructions and the data fields on the commissioning checklist completed in full To instigate the boiler guarantee the boiler needs to be registered with the manufacturer within one month of the installation To maintain the boiler guarantee it is essential that the boiler is serviced annually by a Gas Safe registered engineer who has been trained on the boiler installed The service details should be recorded on the Benchmark Service Interval Record and left with the householder DCNCHITIO COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS www centralheating co uk Heating and Hotwater Industry Council HHIC GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference Failure to install and commission according to the manufacturer s instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty This does not affect the customer s statutory rights
67. ents Wall Seal White 1 off Wall Seal Black 1 off Wall Sealing Plate 1 off Screws No 10x2 4 off Wallplugs 4 off 22 RS Sealing Plate If the mexico HE is replacing a room sealed appliance an optional extra terminal wall sealing plate is available to make good the rectangular flue hole Contents Wall Seal plate 1 off Screws No 10x2 Woodscrew 4 off Wallplugs 4 off mxhe7985 mexico HE Installation amp Servicing INSTALLATION 28 CONNECTING THE FLUE TO THE BOILER Measure 68mm from the cut end of the flue assembly and mark a line on the flue Fit the flue connector over the end of the flue and align the end of the connector with the marked line Ensure the V cutout on the flue connector is aligned with the top of the turret use label as a guide Mark the 3 fixing screw holes and drill the three holes with a 3 2 dia drill Do not drill through the inner flue pipe Retain the connector with the 3 screws provided Adhere the 70mm wide x 20mm deep foam strip found in the hardware pack box to the flue assembly tube to provide an inner seal to the hole cut in the wall Insert the flue assembly through the prepared hole in the wall Remove the top outlet blanking plate or boiler top panel to facilitate turret fitting To ensure a positive flue seal is confirmed it may be necessary to remove the worktop or adjacent cupboard to view the joint
68. f 38 7 MJ m 1038 Btu ft gross or 34 9 MJ m 935 nett To obtain the gas consumption at a different calorific value a For l s divide the gross heat input kW by the gross C V of the gas b For ft h divide the gross heat input Btu h by the gross C V of the gas Btu ft For m h multiply l s 3 6 CAUTION Key to symbols GB United Kingdom PMS Maximum operating pressure of water Cai 2H IE Ireland Countries of destination A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which in this case are concentric The fan is up stream of the combustion chamber An appliance designed for use on 2nd Family gas Group H only To avoid the possibility of injury during the installation servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components mexico HE Installation amp Servicing GENERAL CONTENTS Air Supply Benchmark Commissioning Checklist Boiler Clearances Boiler Exploded Diagram Electrical Connections Electrical Supply Electrical Systems Diagrams Extension Ducts Fitting Fault Finding mexico HE Natural Gas only Benchmark No 0065 3906 0063 3906 0063 3908 1 E 41 415 20 0063 BQ 3906 Destination Countries
69. flue connection and retain with the four securing screws provided mxhe7653 Push fit extension duct F if required supplied separately and the roof flue kit assembly A into the vertical connector E Using the lubricant found in the hardware pack to facilitate fitting If the last extension duct requires cutting measure the distance outer ducts between the duct and the terminal and add 100 mm to this dimension This gives the length of the last extension duct Note Check the position of the inner flue duct relative to the outer duct on the assembled extension duct s and ensure the terminal flue duct is cut longer than the air duct to ensure engagement in the final flue duct seal Slide down and position the flue seal collar B over the roof plate D and secure it with the 3 screws C to the flue assembly A mxhe7654 Finally ensure the roof flashing plate D is correctly sealed to the roof FLUE OUTLET mxhe7688 ix7474 26 mexico HE Installation amp Servicing INSTALLATION 34 ELECTRICAL CONNECTIONS WARNING This appliance MUST be earthed Wiring should be 3 core PVC insulated cable NOT LESS than 0 75 mm 24 x 0 2mm and to BS 6500 Table 16 mains supply of 230 V 50 Hz is required For IE reference should be made to the current ETCI rules for All external controls and wiring MUST be suitable for mains electrical installations voltage Connection
70. gas water and Ensure the external controls are calling for heat After electricity supplies to the boiler and drain down to complete ignition the display should read the flushing process c 35 white neon on c Refill and vent the system add inhibitor see Frame 9 2 Gas Rate clear all air locks and again check for water soundness Operate the boiler for 10 minutes Check the boiler gas Adhere the water treatment warning label supplied in the rate see Table 2 ensuring the boiler is at full output whilst hardware pack in a prominent position on the system to measurements are recorded prevent the use of incorrect water treatment additives d Balance the system Refer to Frame 4 3 Water Circulation System 4 Check the condensate drain for leaks and check that it is discharging correctly Knob Setting Flow Temperature 5 Finally set the controls to the user s requirements C F Min 30 86 The temperatures quoted alongside are approximate and Max 82 180 vary between installations 42 HANDING OVER After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions 1 Hand the Installation User s Instructions to the 6 Explain and demonstrate the function of time and temperature householder and explain his or her responsibilities under controls radiator valves etc for the economic use of the system current Gas Safety Installation and Use
71. he boiler will relight If the fault recurs turn off the boiler and consult a Gas Safe Registered Engineer or in IE a Registered Gas Installer Flame failure Should this occur a fault code L F will be displayed Press the reset button and the boiler will relight If the fault recurs turn off the boiler and consult a Gas Safe Registered Engineer or in IE a Registered Gas Installer Condensate Drain This appliance is fitted with a siphonic condensate trap system that reduces the risk of the appliance condensate from freezing However should the condensate pipe to this appliance freeze please follow these instructions a If you do not feel competent to carry out the defrosting instructions below please call your local Gas Safe Registered installer for assistance b If you do feel competent to carry out the following instructions please do so with care when handling hot utensils Do not attempt to thaw pipework above ground level If this appliance develops a blockage in its condensate pipe the condensate will build up to a point where it will make a gurgling noise prior to locking out an L2 fault code If the appliance is reset it will make a gurgling noise prior to it locking out on a failed ignition L2 code To unblock a frozen condensate pipe 1 Follow the routing of the plastic pipe from its exit point on the appliance through its route to its termination point Locate the frozen blockage It is likely that
72. ic waste pipe at the right lower rear of the boiler A condensate plume will also often be visible at the flue terminal Safety Current Gas Safety Installation amp Use Regulations or rules in force In your own interest and that of safety it is the law that this boiler must be installed by a Gas Safe Registered Engineer In IE the installation must be carried out by a Registered Gas Installer and installed in accordance with the current edition of 1 S 813 domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation It is essential that the instructions in this booklet are strictly followed for safe and economical operation of the boiler Electricity Supply The appliance must be earthed Supply 230 V 50 Hz The fusing should be This appliance is intended to be connected to the supply via a double pole switch having a 3mm contact separation in both poles serving only the boiler and system controls Alternatively a 3 pin UNSWITCHED socket may be used Important Notes e This appliance must not be operated without the casing correctly fitted and forming an adequate seal Ifthe boiler is installed in a compartment then the compartment MUST NOT be used for storage purposes e Under NO circumstances should any of the sealed components on this appliance be used incorrectly or tampered with e If it is known or su
73. ilst effecting the required gas tightness test and purging air from the gas installation open all windows and doors extinguish naked lights and DO NOT SMOKE 2 Purge air from the gas installation by the approved methods 29 INSTALLATION INSTALLATION INSTALLATION 40 INITIAL LIGHTING PLEASE NOTE The combustion for this appliance has 10 CHECK THE OPERATIONAL WORKING GAS INLET PRESSURE been checked adjusted and preset at the factory for operation on the gas type defined on the appliance data plate Do not adjust the air gas ratio valve having checked With the boiler operating in the maximum rate condition check that the operational working gas pressure at the inlet gas pressure test point G complies with the requirements of Gas Supply on page 8 That the boiler has been installed in accordance with Ensure that this inlet pressure can be obtained with all other gas these instructions appliances in the property working e The integrity of the flue system and the flue seals N B The principle of the 1 1 gas valve ensures that the mexico HE range is able to deliver their full output at inlet pressures down to 14mb However if dynamic pressures below 20mb are experienced ensure this is adequate for ALL other gas appliances in the property e integrity of the boiler combustion circuit and the relevant seals 1 Check that the system has been filled and that the boiler is not air locked IMPORTANT N
74. inuous Check room thermostat for central heating or the cylinder thermostat for domestic hot water are set at the required temperature To test operation of either thermostat turn fully up If no response contact your installer Boiler is not working for Press reset button C for 2 seconds to repeat ignition sequence central heating or hot water but attempts to fire by going through 3 ignition attempts Display shows L F flashing Check condensate pipe is not blocked or frozen If blocked clear blockage if not possible to check contact your installer Check gas supply try another appliance cooker fire etc If no gas supply then not a boiler fault contact gas supplier Boiler is not working for Press reset button C for 2 seconds the boiler should then re light If fault recurs this indicates central heating or hot water an overheat condition The boiler should be turned off and your installer contacted aa SONS Check if ALL radiators have thermostatic radiator valves fitted If they have contact your installer Boiler is not working for Check if ALL radiators have thermostatic radiator valves fitted If they have contact your installer central heating or hot water and the display shows H A flashing Ideal Boilers 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 P O Box 103 Natio
75. ion amp Servicing 15 INSTALLATION INSTALLATION 14 FLUE HOLE TEMPLATE 127mm 5 dia IMPORTANT Ensure that during the cutting flue hole operation masonry falling outside of the building does not cause damage or personal injury Note 3 Li Q The template shows the position of the flue hole centres lines Flue options can be flush to wall or in line with 600mm deep kitchen units for boiler pushed 1 Extend flue centre line vertically for rear left back to wall or right as appropriate up to 690mm centre line of flue 690mm 27 1 4 2 Mark onto the wall the position of the flue duct hole 3 Cut the flue hole preferably with a 125mm 5 coreboring tool ensuring that the hole is square to the wall 4 Remove the template from the floor See wall mounting template Flue duct hole offset V mm 18 31 44 57 70 83 96 109 122 135 148 05 Note f only the terminal pack 3 1 0 EE B is used to 775mm no flue 15 201 i incline is required 3 0 SA E F tvi 3 51 I 1 ic ront view 40 dii 4 50 cu ei 55 11395 H Distance in metres from side of the boiler to the side wall See Note Note f wall thickness is greater than 305mm then dimension H must be reduced by the same amount and the offset may
76. ioning Checklist amp Service Record Sheets Page 54 amp 55 New pages added Flowchart for CO Level and Combustion Ratio Check on Commissioning a Condensing Boiler Ideal Boilers reserve the right to vary specification without notice mexico HE Installation amp Servicing 3 Table 1 General Data Boiler Size GENERAL Gas Supply Connection Flow and Return Connections 22mm copper 22mm copper 22mm copper 22mm copper 22mm copper MAXIMUM Static Water Head 30 5 100 30 5 100 30 5 100 30 5 100 30 5 100 MINIMUM Static Water Head 0 45 1 5 0 45 1 5 0 45 1 5 0 45 1 5 0 45 1 5 Electrical Supply 230V 50Hz 230V 50Hz 230V 50Hz 230V 50Hz 230V 50Hz Power Consumption 38W 38W 38W 42W 42W Fuse Rating External 3A internal T3 15A L250V Water Content litre gal 2 0 0 44 2 0 0 44 2 0 0 44 4 7 1 0 4 7 1 0 Packaged Weight kg Ib 55 4 122 4 55 4 122 4 55 4 122 4 69 152 69 152 Maximum Inst Weight kg Ib 52 114 6 52 114 6 52 114 6 68 150 68 150 Boiler Size Height mm in 850 33 5 850 33 5 850 33 5 850 33 5 850 33 5 Width mm in 450 17 7 450 17 7 Depth mm in 450 17 7 530 20 9 450 17 7 530 20 9 450 17 7 530 20 9 530
77. leaning Frame Remove the burner Refer to Burner removal and cleaning Frame Remove the ignition electrode Refer to Ignition Electrode replacement Frame Remove the flame detection electrode Refer to Flame Detection electrode replacement Frame 7 Remove the front and rear ionisation probes and discard Prior to removal of the board the following protective equipment should be worn Face mask supplied with the spare part Gloves supplied with the spare part Damp down the combustion chamber area containing the insulation boards Remove the split pin and washer from the RHS of the combustion chamber and discard Remove the insulation boards The replacement one piece insulation board is supplied in a plastic bag This bag should be retained and the discarded boards should now be placed into it Old Style Insulation Combustion chamber mexico HE Installation amp Servicing 11 Sweep any dampened particles and place in the plastic bag 12 Fit new insulation board a Locate and align the insulation with the electrode holes and position the insulation into the combustion chamber b Push the flexible material into the corners of the combustion chamber ensuring it is flat and flush against the combustion chamber wall c Interlock the insulation piece along the back wall of the combustion chamber d Again push the flexible material into the corners of the combustion chambe
78. live input Connect the mains lead connector Ensure it is fully located L1 Live Feed output into the socket If a condensate pump is to be fitted 1 Route the cable via the rear of the boiler through the grommit at the left hand side Condensate Pump Plug Mating Connector fixed to boiler fixed to boiler Remove the condensate pump plug from mating connector Remove wire link between L1 and L2 Wire in condensate pump as shown below Secure cable sheath in cable clamps Ensure that the lengths of the live and neutral wires are shorter than the earth wires so that if the cable slips in its anchorage the current carrying wire become taut before the earth wire Condensate Pump Plug fixed to boiler KEY L3 Brown N Blue Green Yellow L2 Black L1 Grey mexico HE Installation amp Servicing 27 INSTALLATION INSTALLATION INSTALLATION 36 PICTORIAL WIRING DIAGRAM LEGEND b blue bk black br brown gy grey or orange pk pink r red v violet white Flow yellow TITLE cotta ylg yellow green Chassis earth y g Mains supply 230V 50Hz Condensate pan pump connector pk Spark generator User control and display Service connection Fused at 3 15ATL Control PCB pei
79. ly available Check gas valve associated harness for at the gas valve wiring for continuity Is gas pressure available at Check gas supply the boiler inlet and rectify fault continuity visual condition position Refer to Frame 56 YES Replace as necessary Replace PCB Check spark generator and associated harness for continuity and visual condition NO ioni Replace Refer to Frame 57 Are these functioning p correctly gt spark generator YES Check the ignition electrode and associated harness for NO Replace ignition electrode and associated continuity visual condition position harness as necessary Refer to Frame 55 Are these functioning correctly NO Check syphon and Replace gas condensate drain valve pipework for blockage Note Due to the wave form of the rectified voltage the reading will vary depending on the type of meter used to measure the value some may measure the possible peak voltage of 339V In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve As an alternative to a multimeter a mains checking device may be used E g an electrical screwdriver or a mains tester BOARD ERROR Check for an excess voltage Check earth connection to the boiler If value is still in between neutral and earth excess of 50V consult a
80. manufacturers requirements e Competence can be demonstrated by satisfactory completion of the CPA1 ACS assessment which covers the use of electronic portable combustion gas analysers in accordance with BS 7967 parts 1 to 4 44 BOILER FRONT PANEL REMOVAL 1 Remove the two screws retaining the lower front panel and remove the panel 2 Remove the two screws retaining the upper front panel 3 Lift the upper front panel and remove 32 4 Clean the main burner Clean the heat exchanger and S trap 6 Check the condition of the combustion chamber insulation Any cracked or damaged pieces should be replaced HE15 HE18 and HE24 only lonisation probes are a servicable component and require inspecting annually and replacing if distorted 7 Check the main injector for blockage or damage 8 Wherever possible remove and clean the condensate S trap refer to Frame 48 and check the drain for blockage 9 Check that the flue terminal is unobstructed and that the flue system is sealed correctly 10 If fitted clean the condensate pump The servicing procedures are covered more fully in Frames 46 to 50 and MUST be carried out in sequence Note n order to carry out either servicing or replacement of components the boiler front panels and sealing panel must be removed Refer to Frames 44 and 45 WARNING Always turn off the gas supply at the gas service cock and switch off and disconnect the electricity s
81. maximum rate stage below Verify Flue Integrity equal to 20 6 OR CO2 ess than or equal to Analyser readings indicate that combustion products and inlet air must be mixing Further investigation of the flue is therefore required Check that flue components are assembled fixed and supported as per instructions Check that flue and flue terminal are not obstructed Check CO level and Combustion Ratio at Maximum Gas Rate Yes gt With boiler still set at maximum gas rate insert analyser probe into flue gas sampling point Allow readings to stabilise before recording Turn off appliance and call Ideal Technical Helpline for advice The appliance must not be commissioned until problems are identified and resolved If commissioning cannot be fully completed the appliance must be disconnected from the gas supply in accordance with GSIUR CO level less an 350ppm AND CO COz ratio less than 0 0040 ratio less than 0 0040 Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary Set Boiler to Minimum Gas Rate see opposite page In accordance with boiler instructions set boiler to operate at minimum rate to minimum load condition Allow sufficient time for combustion to stabilise Check CO and Combustion Ratio at Minimum Gas Rate
82. mm 27 LEGEND Duct assembly Flue turret Turret fixing screws Flue connector Flue connector screws Turret gasket Foam sealing tape mxhe7597 Si Gor NS Rear flue arrangement shown mexico HE Installation amp Servicing 19 INSTALLATION INSTALLATION 21 MOUNTING THE BOILER ONTO THE PRE PIPING FRAME NOTE USE THE BOILER PACKAGING SLEEVE TO PROTECT THE FLOOR Remove the two screws retaining the lower front panel and remove the panel Top panel Remove the two screws retaining the upper front panel Lift the upper front panel and remove If the optional extra concealment panel kit is to be fitted to either left or right hand side panel it must NOW be fitted refer to separate instructions provided with kit At this stage fit the flue assembly and turret see Frame 28 or 33 and in the case of rear flue fit the optional flue finishing kit refer to Frame 27 if required Remove the top panel to facilitate turret fitting Fit the sealing washers to the water and gas connections If the condensate pump is to be used it must now be fitted If not to be fitted go to No 7 Fit the condensate pump fixing slots over the two screw heads The screws position the pump but cannot be tightened Prepare to route the condensate pump cable the mains cable and the remote user controls wiring if required up the rear of the boiler and through the grommet to be found at the top left of the boiler
83. mostat preferably on the return pipework Important Ensure that the frost thermostat is wired so that the system pump and or external diverter valve is energised as appropriate Designation of the terminals will vary but the programmer and thermostat manufacturers leaflets will give full details Diagram A shows an application to boilers fitted with a room thermostat only Diagrams B and C show applications to boilers fitted with alternative time controls 39 COMMISSIONING AND TESTING A ELECTRICAL INSTALLATION competent person using a Suitable test meter mexico HE Installation amp Servicing 38 EXTERNAL ELECTRICAL CONTROLS 1 Checks to ensure electrical safety should be carried out by a 2 ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit if required System a ey controls Optional Frost stat System controls e N Mains in AS if required I I Optional frost stat System controls SEE N Mains in if required Optional frost stat Earths are not shown for clarity but MUST NEVER BE OMITTED B GAS INSTALLATION mxhe9221 mxhe9222 mxhe9223 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 1 5 813 2002 only WARNING Wh
84. n of the venturi in relation to the fan body Transfer the venturi assembly to the new fan replacing the gasket if evidence of damage or deterioration is visible Fit the new fan venturi assembly Reassemble the boiler in reverse order taking care not to over tighten the screw on the fan mounting bracket Check the operation of the boiler Refer to Frame 51 54 BURNER REPLACEMENT Refer to Frame 51 Remove the boiler front panels and inner sealing panel Refer to Frames 44 and 45 Remove the fan assembly Refer to Frame 53 no s 3 to 6 Remove the 6 fixings securing the burner the 3 screws at the rear are extended to ease access Lift off the burner from the combustion chamber Fit the new burner replacing any damaged or deteriorating sealing gasket Reassemble in reverse order Check the operation of the boiler Refer to Note 36 Frame 51 Take care not to disturb the burner ionisation probes at the front and rear of the combustion chamber burner earth pins are at the front only on the HE30 and HE36 SERVICING Orifice plate Gasket mxhe7748 ionisation probes HE24 shown mexico HE Installation amp Servicing SERVICING 55 IGNITION ELECTRODE REPLACEMENT Refer to Frame 51 Remove the boiler front panels and inner sealing panel Refer to Frames 44 and 45 8mm 1 HE15 HE18 HE24 Unplug the ignition lead from the elec
85. nal Ave Kingston Upon Hull HU5 4JN Ideal Consumer Helpline Tel 01482 498660 www idealboilers com Tel 01482 492251 Fax 01482 448858 Registration No London 322 137
86. nd the condensate pump if fitted 7 Protect the floor area front of the boiler remove the screws fixing the boiler to the pre piping frame and pull the boiler forward to clear any kitchen unit obstructions taking care with the electrical wiring 8 Remove the fan amp venturi assembly refer to frame 46 9 Remove burner refer to frame 47 10 Remove ignition electrode frame 55 amp detection electrode frame 56 11 HE30 amp HE36 models only Remove the spark generator frame 57 and remove the electrical connections from the flow thermistor frame 52 and the overheat thermostat frame 63 12 Remove the dry fire thermostat frame 64 13 HE15 18 amp 24 only Remove the rubber plug to gain screwdriver access to the fixing screw retaining the heat exchanger bottom right copper pipe bracket and remove the screw 14 HE30 amp 36 only Unscrew the copper pipe connection at the top left of the heat exchanger and remove the pipe by pulling upwards through the rubber grommet 15 Remove the 4 screws retaining the flue turret and remove the turret 16 Remove the 4 screws retaining the flue support bracket 17 Remove the 19 screws retaining the rear air box and remove the box 18 HE15 18 amp 24 only Pull the flue elbow bracket slightly sideways to release the elbow and pull the plastic flue elbow assembly from its joint 19 HE30 amp 36 only Pull the plastic pipe from its joint 42 continued
87. on from a draw off tap supplied from a service pipe under mains pressure Where the mains pressure is excessive a pressure reducing valve shall be used to facilitate filling The following fittings shall form a permanent part of the system and shall be fitted in the order stated A stop valve complying with the requirements of BS 1010 Part 2 the hose from the draw off tap shall be connected to this fitting A test cock A double check valve of an approved type e Thoroughly flush out the whole of the system with cold water without the pump in position With the pump fitted fill and vent the system until the pressure gauge registers 1 5 bar 21 5lb in Examine for leaks Check the operation of the safety valve by manually raising the water pressure until the valve lifts This should occur within 0 3 bar 4 3lb in of the preset lift pressure Release water from the system until the initial system design pressure is reached Light the boiler and heat the system to the maximum working temperature Examine for leaks Turn off the boiler and drain the system while still hot Refill and vent the system Adjust the initial pressure to the required value 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 the table on the following page multiplied by a factor of 0 8 for flow temperatures of less than 83 C 12 mexi
88. order Check the operation of the boiler Refer to Control box Frame 51 61 WIRING HARNESS REPLACEMENT A pictorial wiring diagram is shown in Frame 36 1 Refer to frame 51 2 Remove the boiler upper front panel Refer to frame 44 3 4 Disconnect the wiring harness from the Fan Controls Box Flow Remove the sealing panel Refer to frame 45 Thermistor Spark Generator Gas Valve Overheat Thermistor Dry Fire Thermistor and Earth post Remove the condensate pump terminal strip securing screw to gain access to the back of the terminal strips With an Allan key remove the rivscrew from the back of the brackets to release the terminal block Reassemble the new harness to the brackets in reverse order 62 MAINS SWITCH REPLACEMENT Refer to Frame 51 Remove the boiler upper front panel Refer to Frame 44 Remove the screws retaining the user control Refer to Frame 60 No 3 Push out the mains switch from the rear as shown Refit the new switch ensuring that the electrical leads are replaced on the correct terminals and the key on the switch is correctly aligned with the slot in the plastic moulding Reassemble in reverse order Check operation of the boiler Refer to Frame 51 mexico HE Installation amp Servicing Electrical connections 39 SERVICING SERVICING SERVICING 63 OVERHEAT THERMOSTAT REPLACEMENT Refer to Frame 51 mexico HE15 HE18 amp HE
89. ore the system has been thoroughly flushed mexico HE Installation amp Servicing O 0 5 1 0 1 5 1 0 1 5 system pressure bar bar bar 0 5 bar bar bar bar Expansion vessel volume litres For further information contact Fernox Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ 44 0 870 601 5000 Sentinel Performance Solutions The Heath Business amp Technical Park Runcorn Cheshire WA7 4QX Tel 0800 389 4670 www sentinel solutions net Scalemaster Water Treatment Products Emerald Way Stone Staffordshire ST15 OSR Tel 44 0 1785 811636 Calmag Ltd Unit 3 6 Crown Works Bradford Road Sandbeds Keighley West Yorkshire BD20 5LN Tel 44 0 1535 210 320 Adey Professional Heating Solutions Gloucester Road Cheltenham GL51 8NR Tel 44 0 1242 546700 13 INSTALLATION LEGEND 1 2 3 4 5 6 7 9 1 14 Front casing panel Sealing panel Top casing panel LH casing side panel RH casing side panel Lower front panel Sump cover plate Return pipe 0 Flow pipe mxhe7922 INSTALLATION 10 BOILER ASSEMBLY Exploded view mexico HE24 shown Datapla te mexico HE36 heat exchanger 14 Burner assembly 17 Injector amp housing 19 Fan assembly 20 Gas pipe assembly 22 Gas valve assembly 25 Dry fire thermistor 26 Control thermistor 27 Overheat thermostat 28 Ignition electrode 34 43
90. ority Building Control LABC prior to work commencing Complete all relevant sections of the Benchmark Checklist Service Record when carrying out commissioning or servicing of a product or system Ensure that the product or system is left in a safe condition and whenever possible in good working order Highlight to the customer any remedial or improvement work identified during the course of commissioning or servicing work Refer to the manufacturer s helpline where assistance is needed Report product faults and concerns to the manufacturer in a timely manner Customer Service Show the customer any identity card that is relevant to the work being carried out prior to commencement or on request Give a full and clear explanation demonstration of the product or system and its operation to the customer Hand over the manufacturer s instructions including the Benchmark Checklist to the customer on completion of an installation Obtain the customer s signature on the Benchmark Checklist to confirm satisfactory demonstration and receipt of manufacturer s instructions Advise the customer that regular product servicing is needed in line with manufacturers recommendations to ensure that safety and efficiency is maintained Respond promptly to calls from a customer following completion of work providing advice and assistance by phone and if necessary visiting the customer Rectify any installation probl
91. ote t is important the burner is not operated before The gas input to the burner is regulated by the gas valve the system is fully vented of air If it is necessary to according to the air flow produced by the fan It is NOT user operate the system pump to assist venting of the air adjustable Any interference to sealed settings on the gas this must be done with the gas service cock turned off valve will adversely affect operation and render our warranty 2 Check that all drain cocks are closed and any valves vold in the flow and return are open 11 Switch OFF the boiler on off switch 3 Check the electrical supply is off 12 Remove the pressure gauge and tube Tighten the sealing screw in 4 Check the gas service cock is open pressure test point Ensure a gas tight seal is made 5 Check that the boiler on off switch A is OFF 13 Refit the boiler front panel 6 Slacken the screw in the inlet pressure test point G THE DISPLAY and connect a gas pressure gauge via a flexible tube 7 Switch the electricity supply ON and check all external The user control has one neon and one display to inform the 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 flame is detected the neon is blinking When the flame is detected the neon will be lit permanently controls are calling for heat 8 Set the boiler thermostat knob B to maximum and switch the boiler on off switch A
92. port e g door or window into dwelling Vertically from a terminal on the same wall Horizontally from a terminal on the wall Vertical Terminals 1 200mm 48 1 500mm 60 300mm 12 Above the roof pitch with roof slope of all angles Above flat roof 300mm 127 300mm 12 600mm 24 1000mm 40 2000mm 79 600mm 24 From a single wall face From corner walls Below Velux Window Above or side of velux window Only one reduction down to 25mm is allowable per installation otherwise BS5440 1 2008 dimensions must be followed TERMINAL The terminal assembly can be adapted to accommodate various wall thicknesses Refer to Frame 19 AIR SUPPLY It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed due to the low surface temperatures of the boiler casing during operation therefore the requirements of BS 6798 Clause 12 and BS 5440 2 may be disregarded In IE the requirements of 1 5 813 2002 may be disregarded mexico HE Installation amp Servicing WATER CIRCULATION SYSTEM IMPORTANT A minimum length of 1 metre of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping For boiler outputs greater th
93. qualified electrician to check Is the value below 50V the household electrical supply and circuitry VES LE ONLY Check Continuity of OH thermostat Is this correct ves HE ONLY Check earth wire is Turn boiler off and wait for 5 connected to detection lead Correct wiring or replace seconds Turn boiler on Is this correct detection lead Does boiler operate correctly Correct wiring or replace thermostat yes YES NO Check all earths for continuity Correct Connection Replace Is continuity OK PCB YES Press and hold reset Internal fault within the PCB button for 2 seconds Does boiler operate correctly YES 2 O 2 J lt lt a lt lt lt 46 mexico Installation amp Servicing FAULT FINDING OVERHEAT ERROR Can the overheat condition be reset by pressing the boiler reset button when the system is cold YES Is the boiler and CH system filled with Fill and vent the system and open all water and all isolation valves open isolation valves YES Does the pump setting give a differential across the boiler in excess of 25 C Replace overheat thermostat Set CH control knob to maximum If the overheat trips ag
94. r ensuring it is flat and flush against the combustion chamber wall e Secure the insulation by replacing the ionisation probes with those supplied in the kit Note that ionisation probes are a serviceable component and require inspecting annually Note The insulation is designed to be interlocking and should be fitted as shown 13 Remove the gloves and face mask and place them in the plastic bag 14 Wash your hands and any areas of skin which may have come into contact with any of the particles from the insulation board Note Seal the plastic bag and dispose of it and its contents into a commercial tip 15 Reassemble in reverse order 16 Check operation of the boiler Refer to General Checks Frames New Style Insulation lonisation Probes Insulation Combustion _ chamber esp9466 41 SERVICING SERVICING SERVICING 66 HEAT EXCHANGER REPLACEMENT Refer also to Frame 10 Boiler exploded view 1 Refer to Frame 51 2 Remove boiler front panels and inner sealing panel refer frames 44 amp 45 3 Remove the outer wall sealing plate if fitted and turn the terminal anticlockwise to unlock the turret bayonet fixing and pull the terminal to disconnect the boiler turret from the flue assembly 4 Fully drain the system 5 Disconnect the gas water flow amp water return union connections at the pre piping frame 6 Disconnect the condensate connection at the S trap a
95. r solvent connections c Internal plastic pipe work a minimum of 19mm ID typically 22mm OD d External plastic pipe must be a minimum of 30mm ID typically 32 OD before it passes through the sleeved wall e All horizontal pipe runs must fall a minimum of 45mm per metre away from the Boiler f External amp unheated pipe work should be kept to a minimum and insulated with Class O waterproof pipe insulation g All installations must be carried out in accordance to the relevant connection methods as shown in the Condensate installation diagrams amp BS6798 2009 h Pipe work must be installed so that it does not allow spillage into the dwelling in the event of a blockage through freezing i All internal burrs should be removed from the pipe work and any fittings In order to minimise the risk of freezing during prolonged very cold spells one of the following methods of terminating condensate drainage pipe should be adopted Internal Drain Connections Wherever possible the condensate drainage pipe should be routed to drain by gravity to a suitable internal foul water discharge point such as an internal soil and vent stack or kitchen or bathroom waste pipe etc See Figs 1 and 2 Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point a condensate pump of a specification recommended by
96. readily accessible Installation must be in accordance with BS 6798 and adjacent to the boiler The drain outlet on the boiler is sized for standard 21 5mm 3 4 N B THE FAN VOLTAGE IS 325V DC overflow pipe It is a universal fitting to allow use of different brands of pipework 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 Note Combined feed and vent pipes may also be fitted There should be a minimum height 450mm 18 of open vent above the cistern water level If this is not possible refer to Frame 5 The vertical distance between the highest point of the system and the feed expansion cistern water level MUST not be less than 450 mm 18 The pump must be fitted on the flow side of the boiler A suitable pump is a domestic circulator capable of providing a maximum 11 C 20 F temperature differential across the boiler with the whole of the heating circuit open e g Grundfos UPS 15 50 15 60 or equivalent With the minimum flow circuit allowed by the controls the differential must not exceed 25 C 18 C for the HE15 The vertical distance between the pump and feed expansion cistern MUST comply with the pump manufacturer s minimum requirements to avoid cavitation Should these con
97. spected that a fault exists on the boiler then it MUST NOT BE USED until the fault has been corrected by a Gas SAfe Registered Engineer or in IE a Registered Gas Installer e This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety e Children should be supervised to ensure that they do not play with the appliance In cases of repeated or continuous shutdown a Gas Safe Registered Engineer or in IE a Registered Gas Installer should be called to investigate and rectify the condition causing this and carry out an operational test after each intervention on the device Only the manufacturers original parts should be used for replacement Minimum Clearances Clearances of 20mm 3 4 above 5mm 1 4 at the sides and 450mm 17 3 4 at the front of the boiler casing must be allowed for servicing The minimum front clearance allowed when built into a cupboard is 5mm To light the boiler Refer to Frame 1 1 CHECK THAT THE ELECTRICITY SUPPLY TO THE BOILER IS OFF 2 Set the mains on off switch A to off and the CH thermostat knob B to maximum 3 Switch on the electricity supply to the boiler and check that all external controls e g programmer room stat etc are on 4 Set the mains on off
98. switch to ON The boiler will commence the ignition sequence supplying heat to the system when required Operation In normal operation the control unit display E will show the codes O Standby no demand for heat C CH or DHW being supplied P Boiler frost protection boiler will fire when temperature is less than 3 C During ignition the LED D will flash During normal running the LED will remain illuminated Note f the boiler fails to light after 3 attempts the fault code L F will be displayed Press and hold the reset button C for 2 seconds then release The boiler will repeat the ignition sequence If the boiler fails to light consult a Gas Safe Registered Engineer or in IE a Registered Gas Installer All Gas Safe Registered Engineers carry a Gas Safe Register ID card and have a registration number Both should be recorded in the Benchmark Commissioning Checklist You can check your installer by calling Gas Safe Register direct on 0800 4085500 Ideal Boilers is a member of the Benchmark scheme and fully supports the aims of the programme Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency benchmari THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS THE BENCHM
99. te Pump Typical Method see manufacturers detailed instructions Visible air break Boiler with 75mm _ sealed condensate k o N Min 9 19mm Internal pipe Condensate pump Install in accordance with manufacturers instructions Figure 5 Connection of a Condensate Drainage Pipe to an External Rainwater Downpipe only combined foul rainwater drain Boiler with 75mm sealed condensate trap Water weather proof insulation Min 19mm Internal pipe combined foul rain water drain External air break Min 30mm Internal pipe Air gap Terminated and cut at 45 43mm 90 male female bend 68mm PVCU Strap on fitting Figure 7 Connection of a Condensate Drainage Pipe to an External Purpose Made Soak Away Boiler with 75mm sealed condensate Min 30mm Internal pipe Water Weather proof insulation Min 19mm Internal pipe Max 3m external pipework w NI N A Limestone chippings Boilers without 75mm sealed condensate trap must be fitted with a75mm trap and visible air break 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house Figure 4 Connection of condensate Drainage Pipe to External Soil amp Vent Stack Boiler Water weather with 75mm proof insulation sealed condensate Min 3
100. the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc fig 3 Figure 1 Connection of Condensate Drainage Pipe to Internal Soil amp Vent Stack Boiler with 75mm sealed condensate Min 19mm Internal pipe 4 x D pan gt o N CY cD Minimum connection height up to 3 storeys gt Boilers without 75mm sealed condensate trap must be fitted with a 75mm trap and visible air break mexico HE Installation amp Servicing External Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose designed soak away If an external system is chosen then the following measures must be adopted The external pipe run should be kept to a minimum using the most direct and most vertical route possible to the discharge point with no horizontal sections in which condensate might collect For connections to an external soil vent stack see Fig 4 Insulation measures as described should be used When a rainwater downpipe is used an air break must be installed between the condensate drainage pipe and the downpipe to avoid
101. to ON The boiler control should now go through its ignition sequence Below is a list with display function in normal operation until the burner is established 9 Ifthe boiler does not light after 3 attempts the fault codes L F will be displayed Press the reset button C the boiler will then repeat its ignition sequence Boiler is in lockout for a specific error The display will be blinking When the burner is established the WHITE burner ON alternating with a number or letter to show which error is detected neon D will be permanently illuminated Standby No demand for heat present Boiler is active for central heating or domestic hot water cmc c Boiler is in lockout for a specific error The display will be blinking alternating with a number or letter to show which error is detected P Boiler frost protection Boiler will fire when temperature is less than
102. trode Spark gap 3 5mm 15mm 1 HE30 HE36 Remove the burner Refer to Frame 54 Remove the earth lead from the ignition electrode Remove the remaining screw holding the ignition electrode to the combustion chamber 7 Remove the electrode 8 Fit the new ignition electrode using the new gasket supplied Check dimensions as shown Reassemble in reverse order and check that no damage to the combustion chamber insulation has occurred during the electrode replacement HE15 HE18 and HE24 only 10 Check operation of the boiler Refer to Frame 51 mxhe7785 mexico HE24 shown mexico HE30 and HE36 shown 56 FLAME DETECTION ELECTRODE REPLACEMENT Refer to Frame 51 22mm 1 HE15 HE18 HE24 Remove the boiler front panels and inner sealing panel Refer to 16mm 1 HE30 HE36 Frames 44 and 45 Unplug the flame detection lead from the electrode Remove the burner Refer to Frame 54 Remove the 2 screws holding the flame detection electrode to the combustion chamber Remove the flame detection electrode Fit the new flame detection electrode using the new gasket supplied Check dimension as shown Reassemble in reverse order and check that no damage to the combustion chamber insulation has occurred during the electrode replacement HE15 HE18 and HE24 only Check operation of the boiler Refer to Frame 51 mxhe77 14 mexico HE Installation amp Servicing 37 SERVICI
103. upply to the appliance before servicing IMPORTANT 11 After completing the servicing or exchange of components always test for gas tightness and carry out functional checks as in paragraphs 2 and 3 12 When work is complete the sealing panel MUST be correctly refitted ensuring that a good seal is made DO NOT OPERATE THE BOILER IF THE SEALING PANEL IS NOT FITTED 13 Complete the service section of the Benchmark Commissioning Checklist o CO CO sampling point mxhe7613 mexico HE Installation amp Servicing 45 BOILER SEALING PANEL REMOVAL 1 To remove the sealing panel remove the 4 screws 2 Remove the panel _mihe7614 SERVICING 46 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING Undo the gas pipe union connection to the injector housing Undo the screw on the fan mounting bracket Lift off the fan and venturi assembly Disconnect the electrical leads from the fan Inspect the injector for blockage or damage tO mxhe7747 47 BURNER REMOVAL AND CLEANING Remove the 6 fixings securing the burner the 3 screws at the rear are extended to ease access Lift off the burner from the combustion chamber IMPORTANT The burner head is a ceramic plaque construction Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic Brush off any deposits that may be on the

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