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installation and servicing

1. SERVICE 6 Date Energy Efficiency Checklist completed Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number CORGI ID Number CORGI ID Number Comments Comments Signature Signature SERVICE 7 Date Energy Efficiency Checklist completed SERVICE 8 Date Energy Efficiency Checklist completed Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number CORGI ID Number Comments CORGI ID Number Comments Signature Signature SERVICE 9 Date Energy Efficiency Checklist completed SERVICE 10 Date Energy Efficiency Checklist completed Engineer Name Engineer Name Company Name Company Name Telephone Number Telephone Number CORGI ID Number CORGI ID Number Comments Comments Signature Signature 9 back Technical Training The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers enc For details of courses please ring 01482 498 432 COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVI
2. Measurement to be taken from this point nm8945 isar Installation and Servicing 9 back Pack D Flue extension duct kit contents Extension duct amp clamp 1 0m 39 long nm8732 Flue duct support 19 FLUE EXTENSION DUCTS continued Use a maximum of 6m extended flue ONLY HE24 amp 30 Use a maximum of 3m extended flue ONLY HE35 General arrangement 1 A maximum of 6 extension ducts for the HE24 HE30 and a maximum of 3 extension ducts for the HE35 one suitably 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 Frames 18 and 26 20 FITTING THE KIT Because of the flexibility of the telescopic flue terminal it is not always necessary to cut an extension pack 1 Measure the total flue length from the centre of the boiler outlet to the outside wall 2 Subtract 70mm from this dimension 3 Subtract 950mm for each D pack to be used if the remainder Y is less than 300mm shorten the Measure and mark the length on the flue to ensure a INSTALLATION 18 FLUE EXTENSION DUCTS For total flue lengths greater than 595mm Flue support cutting aid shown folded up Wall plugs 4 off No 10 x2 wood screw 4 off Flue length Extension flue Standard flue Terminal grille Boiler g Note Side flue shown nm8762 previous D
3. Remove the 2 Torx screws allen screws on the CP waterset securing the plate heat exchanger from the valve and pump housings Raise the RH side of the heat exchanger lower the LH side through the bottom of the boiler and remove nm 2842 Fit the new heat exchanger using the new gaskets supplied Reassemble in reverse order ensuring correct location of screws in the support plate and that tabs the pump and valve Diverter valve Pump housing housings engage in slots housing side side Refill the boiler Refer to Frame 36 DHW Plate heat exchanger Check operation of the boiler Refer to Frame 57 80 PUMP HEAD REPLACEMENT Wilo and CP Refer to Frame 57 Remove the casing front amp bottom panel Electrical Refer to Frames 49 amp 50 lead Drain the boiler Refer to Frame 77 Swing the control box down into the servicing position Refer to Frame 51 Disconnect the electrical lead from the pump Remove the 4 Allen screws retaining the pump head Remove the pump head Fit the new pump head Reassemble in reverse order Refill the boiler Refer to Frame 36 Check operation of the boiler Refer to Frame 57 Pump head Wilo pump shown isar Installation and Servicing 53 SERVICING 9 back SERVICING 81 HEAT ENGINE REPLACEMENT Refer also to Frame 8 Boiler Exploded View IMPORTANT Before starting the removal procedure protect the gas and ele
4. The drainage pipework must be arranged so that obstruction e g through freezing of external drainage pipe does not give rise to spillage within the dwelling IMPORTANT If excessive external pipework cannot be avoided an additional siphon kit and insulation are recommended to prevent possible freezing All pipework and fittings in the condensate drain system must be made of plastic No other materials may be used Condensate ea 155mm drain The drain outlet on the boiler is standard 21 5mm overflow pipe This size must not be reduced in any part of its length 23 CONDENSATE PIPE TERMINATION CONFIGURATIONS Note ALL EXTERNAL PIPE RUNS MUST BE INSULATED 1 INTERNAL TO SINK WASTE UPSTREAM OF SINK WASTE 3 Sink constitutes BOILER air break Open end of pipe direct into gulley below grating but above water level 7771 75mm trap Ground Level 2 INTERNAL TO SINK WASTE DOWNSTREAM OF SINK WASTE TRAP PREFERRED BOILER METHOD Open end of pipe direct into gulley below grating but above water level If drain termination is to soil stack a 75mm trap will be required cla7772 75mm trap Ground Level continued isar Installation and Servicing 21 INSTALLATION INSTALLATION 24 CONDENSATE PIPE TERMINATION CONFIGURATIONS continued 3 INTERNAL CONNECTION TO SOIL AND VENT STACK Termination into a down pipe can take place providing it can be confirmed th
5. 9 back 46 GENERAL CHECKS continued CENTRAL HEATING CH amp DOMESTIC HOT WATER DHW MODE Ensure that the CH external controls are calling for heat The display should read after first satisfying DHW preheat if necessary E 5 N Fully open a DHW tap and check that hot water is delivered The display should read M d X Gas Rate Check the boiler gas rate when the boiler is at full DHW output Check at the gas meter with no other appliance in use Refer to Table 3 for gas rates Close the DHW tap The burner should go off and the pump continue to run The display should read d X then flashing i c flashing After 15 seconds the burner should relight to supply central heating The display should read CH amp DHW CONT 5 Set the central heating external controls to OFF The burner should go off and the pump continue to run for a few seconds The display should read returning to n when the pump stops Check the correct operation of the programmer if fitted and all other system controls Operate each control separately and check that the main burner responds WATER TEMPERATURES Temperatures can be selected via the CH and DHW thermostats CH Flow Temp ec F DHW Outlet Temp Knob Setting 82 180 65 150 30 86 42 110 isar Installation and Servicing INSTALLATION WATER CIRCULATION SYSTEM 1
6. Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression GENERAL Flue Terminal Diameter mm in 100 4 Average Flue Temp Mass Flow Rate DHW 66 C 10g s 74 C 12 g s 82 C 14g s Maximum Working Pressure Sealed Systems bar Ib in 2 5 36 3 Maximum Domestic Hot Water Inlet Pressure bar Ib in 10 0 145 Minimum Domestic Hot Water Inlet Pressure bar Ib in 0 5 7 Electrical Supply 230 V 50 Hz Power Consumption 148W 148W 152W Fuse Rating External Internal T3 15A L250 V Water content Central Heating litre gal 2 0 0 44 Domestic Hot Water 0 5 0 11 Packaged Weight kg Ib 52 115 52 115 53 117 Maximum Installation Weight 42 5 94 43 95 43 5 96 Boiler Casing Size Height i 687 27 Width i 390 15 3 8 Depth i 278 11 Table 2 Performance Data Central Heating Table 3 Performance Data Domestic Hot Water Boiler Input Max in Maximum DHW Input HE24 HE30 HE35 Boiler Input Q NettCV kW 24 4 9 1 NettCV 243 30 2 36 0 Btu h 83 300 31 000 Btu h 82 900 103 000 122 800 Gross CV kW 27 1 10 1 Gross CV kW 27 0 33 5 39 9 Btu h 92 500 34 400 Btu h 92 100 114 400 136 200 Gas Consumption l s 0 70 0 26 Gas Consumption 5 07 0 87 1 03 f h 890 33 1 f h 89 0 110 131 kw 234 29 3 35 2
7. Refer to Frame 57 Remove the boiler front and sealing panels Refer to Frames 49 amp 50 Disconnect the electrical leads from the fan Undo the gas pipe union connection to the injector housing Remove the screw retaining the fan mounting bracket Remove the fan and venturi assembly 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 11 Check operation of the boiler Refer to Frame 57 Refer to Frame 57 61 BURNER REPLACEMENT 1 2 Remove the boiler front and sealing panels Refer to Frames 49 amp 50 Remove the fan assembly Refer to Frame 59 Remove the 6 screws 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 Frame 57 Note Take care not to disturb the ionisation probes at the front and rear of the combustion chamber SERVICING Mounting bracket Ecl 2400 lonisation Probes 62 CONTROL THERMISTOR RETURN THERMISTOR amp OVERHEAT STAT REPLACEMENT Refer to Frame 57 Remove the boiler front and sealing panels Refer to Fram
8. With the system COLD check that the initial pressure is correct to the system design requirements For pre pressurised systems this should be 1 0 bar With the system HOT examine all water connections for soundness The system pressure will increase with temperature rise but should not exceed 2 5 bar With the system still hot turn off the gas water and electricity supplies to the boiler and drain down to complete the flushing process Note A flushing solution should be used during the flushing procedure Flushing solutions Fernox Superfloc Sentinel X300 new systems or X400 existing systems Refer to Frame 6 Refill and vent the system add inhibitor see Frame 6 clear all air locks and again check for water soundness Affix the water treatment warning label supplied in the hardware pack in a prominent position on the system to prevent the use of incorrect water treatment additives Reset the system initial pressure to the design requirement 6 Balance the system Refer to Frame 5 7 Check the condensate drain for leaks and check that it is discharging correctly 8 Finally set the controls to the User s requirements Note The pump will operate briefly as a self check once every 24 hours in the absence of any system demand 37 INSTALLATION 9 back SERVICING 47 HANDING OVER After completing the installation and commissioning of the system the installer should hand over to the ho
9. remove it from its packaging base and during movement into its installation During all manoeuvres and handling actions every location Manoeuvring the boiler may include the use of a sack truck and attempt should be made to ensure the following involve lifting pushing and pulling unless unavoidable and or the weight is light Keep back straight Avoid twisting at the waist Avoid upper body top heavy bending Always grip with the palm of the hand Use designated hand holds Keep load as close to the body as possible Always use assistance if required 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 Grip the boiler at the base Be physically capable Use PPE as appropriate e g gloves safety footwear 6 isar Installation and Servicing 9 back GENERAL OPTIONAL EXTRA KITS BS 6798 Installation of gas fired hot water boilers of rated input not exceeding 70 kW Flue Extension Ducts 1000mm long BS 6891 Low pressure installation pipes HE24 upto 6m HE30 upto HE35 upto 3m Flue Finishing Kit 90 Elbow Kit maximum per installation HE24 upto 4 elbows HE30 upto 4 elbows HE35 upto 2 elbows 45 Elbow Kit maximum per installation HE24 upto 4 elbows HE30 upto 4 elbows HE35 upto 2 elbows Roof Flue Kit to a maximum of 7 5
10. 2 lt 2 a 2 2 2 lt 2 a 2 H 2 lt 2 a 2 H 2 lt FAULT FINDING 84 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 56 ALTERNATING 1 GO TO FRAME 85 ALTERNATING L E GO TO FRAME 86 ALTERNATING L A GO TO FRAME 87 ALTERNATING L 8 GO TO FRAME 88 ALTERNATING 1 GO TO FRAME 89 ALTERNATING H 2 GO TO FRAME 90 ALTERNATING 3 GO TO FRAME 91 ALTERNATING H 4 GO TO FRAME 92 ALTERNATING GO TO FRAME 93 ALTERNATING H n GO TO FRAME 94 ALTERNATING H E ALTERNATING H9 GO TO FRAME 86 GO TO FRAME 92 ALTERNATING L9 GO TO FRAME 92 isar Installation and Servicing 9 back FAULT FINDING 85 L F FLAME DETECTION ERROR If the boiler reset button is pressed does the boiler ignite for a short time then extinguish Is gas pressure available at Check gas supply the boiler inlet and rectify fault Is 200V DC supply available Check gas valve at the gas valve wiring for see Note continuity Check the detectio
11. 400 2 000 Ohms At 85 C expect 1 000 1 100 Ohms Are thermistor values correct Are thermistor values correct YES No s No Replace PCB Replace thermistor Inspect heat exchanger Replace thermistor 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 refire until the temperature in the heat exchanger drops below 50 C 9 I E FLAME DETECTION ERROR Remove flame detection electrode terminal from PCB Y Is there continuity between the 2 terminal pins Replace PCB YES Y Replace flame detection electrode PHASE REVERSAL ERROR Check wiring to the boiler for reversed live and neutral s 2 H 2 lt L 2 a 2 L 2 lt 2 a 2 2 2 lt 2 s 2 2 lt 2 a 2 H 2 lt 60 isar Installation and Servicing 9 back SHORT LIST OF PARTS The following are parts commonly required due to damage or When ordering spares please quote expendability Their failure or absence is likely to affect safety or performance of this appliance Boiler model Appliance G C No The list is extracted from the British Gas List of Parts which contains all avai
12. C apart These valves should now be left as set Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators to give around 15 C temperature drop at each radiator Adjust the room thermostat and programmer to NORMAL settings 11 9 back 6 WATER TREATMENT CENTRAL HEATING The isar range of boilers have an ALUMINIUM alloy heat exchanger IMPORTANT The application of any other treatment to this product may render the guarantee of Ideal Stelrad Group 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 FERNOX COPAL or MB1 GE BETZ SENTINEL X100 or Salamander Corrosion Guard 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 If the boiler is installed an existing system any unsuitable additives MUST be removed by thorough cleansing BS 7593 1992 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 circumst
13. D A Boiler Hardware Pack Box Pre piping Frame These Installation Users Instructions Wall Mounting Template located on internal protective packaging 1 Year Guarantee I B Hardware Pack Contents Isolation valve c w pressure gauge 1 off Isolation valve c w drain 1 off Bulkhead connector 1 off Restrictor valve 1 off Compression gas cock 1 off Valve securing clip 22mm 2 off Pack B Contents A B C D 14 Telescopic flue terminal Flue turret Screws Sealing tape Valve securing clip 15mm 3 off Pre piping frame support bracket 1 off S trap hose 1 off 15mm olive 1 off Pressure relief valve nut 1 off No 14x2in woodscrew 4 off nm8452 Wallplug 4 off Fibre washer 19 ID x 26 OD 3 off 12mm sealing washer 3 off Gas line sealing washer 1 off Hole plug white 6 off Mains connector 1 off nm8751 isar Installation and Servicing 10 PACKAGING REMOVAL Ensure the boiler is on a sound flat surface Carefully remove the strapping Fold back the top flaps to gain access to Instructions 1 year guarantee Pre piping frame Wall mounting template located under pre piping frame on protective packaging Remove the instructions and read thoroughly before unpacking the product When ready for installation lift of
14. 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 BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases isar Installation and Servicing 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 Stelrad Group in writing If in doubt please enquire Any direct connection of a control device not approved by Ideal Stelrad Group could 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 manufactu
15. Non Condensing kw 23 4 8 8 DHW Output Btu h 80 000 100 000 120 000 70 C Mean Water temp Btu h 80 000 30 000 Condensing kW 25 1 9 6 DHW Flow Rate l min 40 C Mean Water temp Btu h 85 700 32 800 at 35 C temp rise gpm Seasonal efficiency SEDBUK Band A 90 1 DHW Specific Rate l min NOx Classification Class 5 gpm 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 Boiler Output Note Gas consumption is calculated using a Key to symbols calorific value of 38 7 MJ m 1038 Btu ft gross GB United Kingdom IE Ireland Countries of destination or 34 9 MJ m 935 Btu f nett i PMS Maximum operating pressure of water To obtain the gas consumption at a different calorfic Velim C C C A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal which admits fresh air to the burner a For l s divide the gross heat input kW by and discharges the products of combustion to the outside through the gross C V of the gas MJ m orifices which in this case are concentric The fan is up stream b For ft h divide the gross heat input Btu h of the combustion chamber by the gross C V of the gas Btu ft I appliance designed for use on 2nd Family gas Group
16. Remove the burner from the heat exchanger Refer to Frame 53 12 Unscrew the air vent from its heat exchanger mount and replace 13 Re assemble the boiler in reverse order 14 Refill the boiler Refer to frame 36 Check for leaks around the new air vent joint 15 Check the operation of the boiler Refer to frame 57 isar Installation and Servicing ST SERVICING SERVICING 77 DRAINING THE BOILER Refer to frame 57 Remove the boiler bottom panel Refer to Frame 50 Close all the water isolating CH and DHW valves on the piping frame To drain the central heating circuit attach a length of hose to the drain point and open the drain valve However it must be noted that some residual water may be experienced during the replacement of components As there is no direct drain for the domestic hot water circuit depending on the location of the boiler opening the lowest hot water tap may drain this circuit However it must be noted that some residual water will be experienced during replacement of components After replacing any component on the boiler close the drain valve remove the hose and open all system isolating valves re pressurise as appropriate before proceeding to check operation of the boiler Check operation of the boiler Refer to Frame 57 SERVICING Compression gas cock ce Isolating valves CA g TO OPEN Drain valve Drain point 78 DIVERTER VA
17. S T U W Y 2 Control thermistor flow 1 Check that the system has been filled and that the boiler is not airlocked Ensure the automatic air vent cap N is open Note It is important the burner is not operated before the system is fully vented of air If it is necessary to operate the appliance pump to assist venting of the air this must be done with the gas service cock turned off 2 Refit the boiler sealing panel Refer to Frame 50 3 Check that all the drain cocks are closed and that the CH and DHW isolating valves T W and S are OPEN 4 Check that the electrical supply is OFF 5 Check that the boiler on off switch A is off 6 Carefully align the user control and push gently into place Secure with the single screw located underneath 7 Check that the gas service cock H is OPEN 8 Slacken the screw in the inlet pressure test point G and connect a gas pressure gauge via a flexible tube Swing the control box to the working position and secure with the clamp 10 Connect the low voltage electrical lead from the user control to the control box refer to Frame 51 11 Screw the control into position 12 Switch the electricity supply ON and check all external controls are calling for heat 13 CENTRALHEATING Set the boiler thermostat knob B to position 6 and switch the boiler on off switch A to ON The boiler control should now go through its ignition sequence until the burner is
18. and Gas Connection Centre line of boiler SIDE FLUE ONLY Top clearance required MIN Dim A Horizontal length of flue from centre line of boiler to outside wall HE24 HE30 HE35 6 5 16 CH Flow DHW Outlet 6 11 16 DHW Inlet Condensate Drain 7 1 4 Gas Control CH Return 7 7 8 8 1 4 8 7 8 Front clearance 9 7 8 The minimum front clearance when built in to a cupboard is 5mm 10 1 4 1 4 from the cupboard door but 450mm 17 3 4 overall 10 7 16 clearance is still required with the cupboard door open to allow for servicing 10 13 16 N B The boiler will not fit into a standard depth wall unit In order for 11 3 8 it to do so the plastic fascia should be removed See Frame 44 Bottom clearance Bottom clearance after installation can be reduced to 5mm However 100mm must be available for servicing isar Installation and Servicing 11 13 16 REAR FLUE ONLY MIN Top clearance required 145 mm 5 3 4 9 back GENERAL BOILER CONTROL INTERLOCKS Ideal Stelrad Group recommend that heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS 5449 Central heating systems controls should be instal
19. at the front and rear of the combustion chamber isar Installation and Servicing lonisation Probes 41 SERVICING SERVICING Swing the control box down into the servicing position Refer to Frame 51 Disconnect the condensate drain pipe Remove the screw and elongated bolt pull the trap down and forward to remove Flush out any deposits with clean water 55 CLEANING THE HEAT EXCHANGER Remove ignition and flame detection electrodes Refer to Frames 63 amp 64 Remove the 3 screws retaining the sump cover and remove Using a suitable tool as supplied in the standard British Gas Flue brush kit clean between the heat exchanger fins from the top of the heat exchanger Access to the base of the heat exchanger is now possible Brush clean any deposits from the base of the heat exchanger and remove any loose deposits from the sump Sump cover 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 Any cracked or damaged pieces must be replaced Note Take care not to disturb the ionisation probes at the T front and rear of the combustion chamber Check that the ignition and detection gaps are correct Refer to Frames 63 amp 64 56 REASSEMBLY Reassemble the boiler in the following order 42 Refit the condensate S trap ensu
20. 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 Aluminium shield Pitched Roof with structure Flat roof with structure Terminal Position Directly below an opening air brick windows etc 300 mm Below plastic painted gutters Painted surface 300 mm Below eaves or balcony 500 mm ad MM UD E ee SD EE isar Installation and Servicing 25 9 back INSTALLATION 30 FLUE ARRANGEMENT Note The equivalent flue length resistance of the elbow kits are 90 elbow kit 1m 45 elbow kit 0 6m Universal weather collar Flat roof weather collar BOILER E J 0 J J LL 26 isar Installation and Servicing 9 back INSTALLATION 31 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 Ensure the cut pipe ends are free from any burrs 1 Position the roof flashing plate supplied separately o
21. commission this equipment to the manufacturer s instructions may invalidate the warranty but does not affect statutory rights Customer Name Telephone Number Address Boiler Make and Model Boiler SerialNumber Commissioned by print name CORGI ID Number Company Name Telephone Number Company Address Commissioning Date To be completed by the customer on receipt of a Building Regulations Compliance Certicate Building Regulations Notification Number if applicable CONTROLS Tick the appropriate boxes Time and Temperature Control to Heating Room Thermostat and Programmable Load Weather m Optimum Star Programmer Timer Room Thermostat Compensation Contro Time and Temperature Control to Hot Water Cylinder Thermostat and Programmer Timer Lj Combination Boiler al 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 le Boiler Interlock Provided ALL SYSTEMS The system has been flushed and cleaned in accordance with BS7593 and boiler manufacturer s instructions Yes What system cleaner was used What inhibitor was used Quantity litres CENTRAL HEATING MODE Measure and Record Gas Rate m hr OR ft hr Burner Operating Pressure if applicable e mbar OR Gas In
22. established isar Installation and Servicing INSTALLATION CH Return isolating valve Control box in working position LED display E B 14 If the boiler does not light after 3 attempts the fault code i will be displayed Press the reset button E and the boiler will repeat its ignition sequence When the burner is established the WHITE Burner On neon D will be illuminated the LED display will show status c The display 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 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 Below is a list with display function in normal operation 7 Standby no demand for heat present Boiler is active for central heating Boiler is active for domestic hot water Boiler is heating up the plate heat exchanger Boiler is in lockout for a specific error Display will be blinking alternating with a number or letter to show which error is detected Boiler is in lockout for a specific error Display will be blinking O alternating with a number or letter to show which error is detected 35 INSTALLATION 9 back INSTALLATION 44 INITIAL LIGHTING continued 15 DOMESTIC HOT WATER With the boiler
23. firing set the DHW thermostat knob Y to maximum and fully open a DHW tap The boiler should continue to run and the LED display should show status g Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output Refer to Table 2 N B The principle of the 1 1 gas valve ensures that the isar HE range is able to deliver it s 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 IMPORTANT The gas input to the burner is regulated by the gas valve according to the air flow produced by the fan It is NOT user adjustable Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void 45 GENERAL CHECKS Make the following checks for correct operation in DOMESTIC HOT WATER DHW MODE 1 With no call for CH or DHW the boiler should fire for a short period to preheat the DHW plate heat exchanger The display should read toX returning to B when the burner switches off Notes a If no DHW is drawn off the boiler will fire periodically for a short time to maintain the plate heat exchanger temperature b The DHW preheat operates 24 hours a day Fully open all DHW taps in turn and ensure that water flows freely from them The display should read d c flashing then d when the burner lights IN 36 INSTALL
24. is fitted centrally Tel 44 0 01732 359 888 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 recommendations on the protection of combustible material are given in BS 5440 1 2000 IMPORTANT It is absolutely essential to ensure in practice that products of combustion discharging from the terminal cannot re enter the building or any other adjacent building through ventilators windows doors other sources of natural air infiltration or forced ventilation air conditioning If this should occur the appliance MUST be turned OFF labelled as unsafe until corrective action can be taken TERMINAL The terminal assembly can be adapted to accommodate various wall thicknesses Refer to Frame 12 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 WATER CIRCULATION SYSTEM IMPORTANT A minimum length of 1 metre of copper pipe MUST be fitted to bot
25. the pipes behind the wall mounting plate BEFORE the plate is screwed to the wall Wall lu PS Wall plug Screw 10mm proud Screw 10mm proud Piping frame Piping Support frame bracket Support bracket e euo 1 Remove valves and clips from Valve securing Valve securing the hardware pack box clip 22mm clip 15mm A 2 Assemble valves to the frame bs and secure in place with clips m provided Make sure to fit valves in correct order shown Bulkhead Isolation valve connector c w pressure gauge Compression gas cock Restrictor valve Isolation valve c w drain 2 E 3 0 J E LL Note Service connections may be made now before mounting the boiler if required Refer to Frames 32 34 20 isar Installation and Servicing back 22 CONDENSATE DRAIN INSTALLATION Refer also to the British Gas document Guidance Notes for the Installation of Domestic Gas Condensing Boilers 1989 Before mounting the boiler on the wall the condensate drain provided in the h ware pack must be connected from the boiler S trap to a drainage point preferably within the building Ensure that the condensate trap is full of water before commissioning the boiler Refer to Frame 26 The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler throughout Front View Side View its length
26. thickness X Refer to Frame 12 as indicated in drawing Using a 3 5mm drill bit drill two holes in outer air duct taking care not to pierce plastic inner flue Fix to length using self tappers provided Seal outer air duct using the tape provided 17 SETTING THE FLUE SIDE Notes If using the extension ducts go to Frame 18 For shorter flue requirements use non telescopic B Pack Measure and note wall thickness X Refer to Frame 12 Measure distance from side of boiler to inside of wall and add to wall thickness X L Refer to Frame 12 Add 115mm to dimension L and set telescopic flue length as indicated in drawing Using a 3 5mm drill bit drill two holes in outer air duct taking care not to pierce plastic inner flue Fix to length using self tappers provided Seal outer air duct using the tape provided FLUE OUTLET Add 75mm to dimension X and set telescopic flue length INSTALLATION Rear flue only 5 diameter hole Side flue only 5 diameter hole Section through wall NO XO Note Check all of the hole positions before drilling ae Wall thicknesses of 210 to 435mm Adhere sealing tape Drill hole N XE m Measurement to be taken from this point Wall thicknesses of 170 to 395mm Pa Adhere sealing tape Drill hole d R L 115
27. to BS 7593 Inhibitor Central heating mode Heat input NOTE TO THE INSTALLER COMPLETE THE BENCHMARK COMMISSIONING CHECKLIST AND LEAVE THESE INSTRUCTIONS WITH APPLIANCE isar Installation and Servicing Burner operating pressure Central heating flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reducer Hot water mode Heat input Max operating burner pressure Max operating water pressure Cold water inlet temp Hot water outlet temp measure amp record Water flow rate at max setting measure amp record For condensing boilers only Condensate drain Forallboilers complete sign amp hand over to customer For assistance see Technical Helpline on the back page COLLECTIVE MARK THE MARK OF QUALITY FOR THE INSTALLATION COMMISSIONING AND SERVICING OF DOMESTIC HEATING AND HOT WATER SYSTEMS 9 back GENERAL INTRODUCTION 1 BOILER WATER The isar range of boilers are wall mounted full sequence automatic spark CIRCUIT DIAGRAMS ignition low water content fanned flue high efficiency condensing combination gas boilers 15 Note Due to the high efficiency of the boiler a plume of water vapour will form IA 2 Expansion at the terminal during operation vessel Central heating CH output is fully modulating with a range of 8 8 to 23 4kW 30 000 to 80 000 Btu h Instantaneous d
28. 0mm 12 Horizontally from a terminal on the wall Vertical Terminals Above the roof pitch with roof slope of all angles Above flat roof 300mm 12 300mm 12 300mm 12 300mm 12 From a single wall face From corner walls Only one reduction down to 25mm is allowable per installation otherwise BS5440 1 2000 dimensions must be followed FLUE INSTALLATION Pluming will occur at the terminal so terminal positions where this could cause a nuisance should be avoided The flue must be installed in accordance with the recommendations of BS 5440 1 2000 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 It is 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 4 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 Terminal guards are available from boiler suppliers Ask for TFC flue guard model no K6 round plastic coated In case of difficulty contact Grasslin UK Ltd Tower House Vale Rise Tonbridge Kent TN9 1TB Ensure that the guard
29. ATION 17 Turn off the DHW tap 18 Set the boiler on off switch A to OFF 19 Swing the control box into the servicing position Refer to Frame 51 20 Remove the pressure gauge and tube Tighten the sealing screw in the pressure test point Ensure a gas tight seal is made 21 Swing the control box back into its working position and secure Reconnect the ignition lead 22 Refit the user control 23 Fit the boiler front and bottom panels 24 THEFASCIA a To remove the plastic fascia prise off the retaining star washers using a pair of pliers and place to one side b Fill the remaining fixing holes with the white push in caps provided 25 Switch the boiler on again Star fixings Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate This is factory set to give a DHW temperature rise of approximately 35 C at the flow rate stated on page 6 under operation Reduce the DHW draw off rate to about l min 0 7gpm and check that the boiler modulates to deliver DHW at approximately 65 C 5 Close the DHW tap and check that the main burner extinguishes The pump should overrun for a few seconds and the display sequence should read d When the pump stops the display sequence should read n u Note On systems in excess of 2 bar inlet pressure a water pressure governor may be required to prevent water noise isar Installation and Servicing
30. CING OF DOMESTIC HEATING AND HOT WATER SYSTEMS BSI amp The code of practice for the installation Manufactured under an ISO 9001 commissioning amp servicing of central heating systems registered quality management system FM 59915 Ideal Boilers P O Box 103 National Ave Kingston upon Hull BOILERS HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 J e Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its products The The High Efficiency right is therefore reserved to vary specification without notice Ideal Stelrad Group Ideal Installer Technical Helpline 01482 498 665 www idealboilers com
31. Explain and demonstrate the function of time and 48 SERVICING SCHEDULE SERVICING temperature controls radiator valves etc for the economic use of the system If a programmer is fitted draw attention to the Programmer Users Instructions and hand them to the householder Loss of system water pressure Explain that the dial underneath the boiler indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated Explain the re pressurising procedure and if unable to repressurise or if the pressure continues to drop a registered local heating installer should be consulted WARNING Do not fire the boiler if the pressure has reduced to zero from the original setting After installation and commissioning please complete the 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 10 IMPORTANT A comprehensive service should be carried out ANNUALLY Stress the importance of regular servicing by a CORGI registered installer In IE servicing work must be carried out by a competent person As the installer you may wish to undertake the service contract yourself or alternatively offer to the customer the benefits of the Ideal Care Scheme details of which are outlined in the householder pack supplied with thi
32. FLUE KIT HE24 HE30 amp HE35 60M TOTAL AIR PLUS FLUE DUCT 80 80 TWIN FLUE KIT MINIMUM HORIZONTAL FLUE LENGTHS TELESCOPIC TERMINAL 370MM Centre Line of turret to outside of wall terminal ONE PIECE TERMINAL 285MM Wall Thickness X Notes 1 When extension D packs are used 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 2 If the telescopic B pack or horizontal flue terminal 600 long SIDE FLUE only are used they may be mounted horizontally The 1 5 degrees is taken care of by the inclination of the flue within the air pipe Wall Thickness X 3 If the boiler is to be installed with upward piping routed 195mm behind the boiler then the optional stand off kit should be used Care must be taken when cutting the ducts and aii g marking the wall to suit this condition Total Flue length dimension measuring from CL of turret to outside wall Rear flue Side flue Extra packs Boiler dim X 160 dim L 195 required Size a Up to 595 mm Up to 595 mm none HE24 30 amp 35 Side flue length L Up to 1545 mm Up to 1545 mm Pack D 1 off HE24 30 amp 35 Up to 2495 mm Up to 2495 mm Pack D 2 off HE24 30 amp 35 Up to 3445 mm Up to 3445 mm Pack D 3 off HE24 30 amp 35 Up to 4395 mm Up to 4395 mm Pack D 4 off HE24 amp 30 Up to 5345 mm Up to 5345 mm Pack D 5 off HE24 am
33. Fan assembly Automatic air vent Gas service cock 19 20 21 23 24 25 26 32 35 36 39 40 44 51 53 5T Gas control valve Fan bracket Orifice plate Control thermistor flow return Overheat thermostat Ignition electrode Flame detection electrode Kit Trap and seal User control Primary controls PCB Mains switch Spark generator Piping frame Mains connector Turret gasket kit CH stub pipe Flow restrictor DHW inlet outlet pipe Pressure relief valve Expansion vessel Expansion vessel pipe Pressure gauge DHW thermistor Diverter valve head Diverter valve Diverter valve manifold Pump Wilo pump shown Pump manifold DHW plate heat exchanger Control box clamp Ignition lead Dry fire thermistor Note Two waterset assemblies are used on this appliance WILO and CP These units are not interchangeable 12 isar Installation and Servicing INSTALLATION 9 back TIVLSNI gt gt 9 Q x ui a m o o 4 4 m 8 Data badge 13 isar Installation and Servicing 9 back INSTALLATION 9 UNPACKING INSTALLATION The boiler is supplied fully assembled in one Pack A together with a telescopic flue assembly for lengths up to 595mm rear or side flue outlet in Pack B Unpack and check the contents Pack A Contents A B C
34. H only CAUTION To avoid the possibility of injury during the installation servicing or cleaning of this appliance should be taken when handling edges of sheet steel components 4 isar Installation and Servicing 9 back isar Natural Gas only Boiler size Benchmark No 87 BP 34 87 BP 34 47 348 29 87 BP 34 Destination Country GENERAL CONTENTS Air Supply Benchmark Commissioning Checklist Boiler Clearances Boiler Exploded Diagram Condensate Drain Electrical Connections Electrical Supply Extension Ducts Fitting Fault Finding Flow Wiring Diagram FlueFitting Flue Installation Gas Safety Regulations Gas Supply Installation Mandatory Requirements Safe Handling Servicing Short List of Parts 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 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 Auto bypass Boiler interlock For all boilers Flushing
35. HE CONTROL BOX IN THE SERVICING POSITION SERVICING Remove the 2 screws and withdraw the user control Unplug the low voltage electrical lead from the Turn the clamp swing the control box down and 40 back of the user control pull slightly forward Control box Ecl 2818 Swing control panel down and forward into service position isar Installation and Servicing SERVICING 52 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING Disconnect the electrical leads from the fan Undo the gas pipe union connection to the injector housing Undo the screw on the fan mounting bracket Lift off fan and venturi assembly Inspect the injector for blockage or damage Ecl 6073 53 BURNER REMOVAL AND CLEANING Remove the 6 screws 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 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
36. LVE MECHANISM REPLACEMENT Refer to Frame 57 Remove the casing front amp bottom panel Refer to Frames 49 amp 50 Drain the boiler Refer to Frame 77 Remove the 4 screws retaining the rear support plate and withdraw the plate Refer to Frame 75 Note The M4 screws fit the casing and the self tapping screws fit the plastic pump and valve housings Remove the valve actuator head Refer to Frame 67 Remove the 4 Allen screws and remove the valve mechanism Fit the new valve mechanism and gasket ensuring correct fit over the location pin Reassemble in reverse order ensuring correct location of screws in the support plate and that tabs on the pump and valve housings engage in slots Refill the boiler Refer to Frame 36 Check operation of the boiler Refer to Frame 57 52 Valve mechanism Locating pin hole lt gt Sy Allen isar Installation and Servicing isolating valve shown closed SERVICING 79 DHW PLATE HEAT EXCHANGER REPLACEMENT WILO AND CP Refer to Frame 57 Remove the casing front amp bottom panel DHW plate heat exchanger Refer to Frames 49 amp 50 3 Drain the boiler Refer to Frame 77 4 Remove the 4 screws securing the rear support plate and withdraw the plate Refer to Frame 75 Diverter Z Note The M4 screws fit the casing and the valve self tapping screws fit the plastic pump housing and valve housings
37. T FINDING FAULT FINDING FAULT FINDING FAULT FINDING OVERHEAT ERROR FAULT FINDING Can the overheat condition be reset by pressing the boiler reset button when the system is cold Replace overheat thermostat YES Is the boiler and CH system filled with water and all isolation valves open Fill and vent the system and open all isolation valves YES Does the pump setting give a differential across the boiler in excess of 25 C Check that the pump is rotating freely Is differential now below 25 C No YES Set CH control knob to maximum If the overheat trips again measure the flow temp Over 90 C Check control thermistor Refer to Frame 89 Under 90 Replace overheat stat Replace the system pump OK Note With V9 Primary Control PCB overheat LA HA or H9 L9 when reset will display 3 horizontal lines and will not attempt to refire until the temperature in the heat exchanger drops below 50 C 88 L 8 FAN ERROR Is nominal 330 V DC present across red and blue at the fan connector as Replace fan Is 14V DC present across yellow and pink at the fan connector reset button is pressed 58 NO Replace PCB NO gt Check wiring harness for continuity Is there continuity Replace harness dn
38. TANT 9 After completing the servicing or exchange of components always test for gas soundness 10 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 11 If for any reason the condensate S trap has been removed ensure the trap is refilled with water before reassembling 12 Check the gas consumption 13 Connect a suitable gas analyser to the sampling point on the top of the boiler refer to Frame 45 or into the flue terminal if access is possible optional test For correct boiler operation the CO CO content of the flue gas should not be greater than 0 004 ratio 14 Complete the service section in the Benchmark Commissioning Checklist isar Installation and Servicing SERVICING 49 BOILER FRONT PANEL REMOVAL Remove the 2 screws from the underside of the boiler Pull the panel forward at the bottom and lift to disengage it from the top lugs 50 BOILER SEALING PANEL BOTTOM PANEL REMOVAL To remove the sealing panel remove the 4 screws Remove the panel To remove the bottom panel remove the 2 screws Pull the right hand side of the panel down Slide it to the right and withdraw isar Installation and Servicing oo N N E Flue gas sampling point 39 SERVICING 9 back SERVICING 51 T
39. ances should the boiler be fired before the system has been thoroughly flushed INSTALLATION DOMESTIC HOT WATER In hard water areas where main water can exceed 200ppm Total Hardness as defined by BS 7593 1993 Table 2 a scale reducing device should be fitted into the boiler cold supply within the requirements of the local water company The use of artificially softened water however is not permitted Ideal Stelrad Group recommend the use of Fernox Qantomat GE Betz Sentinel Combiguard and Calmag CalPhos scale reducing devices which must be used in accordance with the manufacturers instructions For further information contact Fernox Manufacturing Co Ltd Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ 44 0 1799 521133 Sentinel Performance Solutions The Heath Business amp Technical Park Runcorn Cheshire WA7 4QX Tel 0800 389 4670 www sentinel solutions net Salamander Engineering Ltd Unit 24 Reddicap Trading Estate Sutton Coldfield West Midlands B75 7BU Tel 44 0 121 3780952 Calmag Ltd Unit 4 6 Crown Works Bradford Road Sandbeds Keighley West Yorkshire BD20 5LN Tel 44 0 1535 210 320 BOILER ASSEMBLY Exploded View Legend Front casing panel Boiler sealing panel Sump cover Bottom casing panel Flue sensing nipple Return pipe Flue manifold Interpanel Burner Combustion chamber insulation Heat exchanger Injector and housing Venturi assembly
40. assembly Refer to Frame 52 Remove the burner Refer to Frame 53 Remove the ignition electrode Refer to Frame 63 Remove the flame detection electrode Refer to Frame 64 Remove the front and rear ionisation probes 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 Fit insulation in the following order 1 Rear 2 Left Hand Side 3 Front 4 Right Hand Side Combustion chamber isar Installation and Servicing 8 Damp down the combustion chamber area containing the insulation boards 9 Remove the split pin and washer from the RHS of the combustion chamber 10 Remove the insulation boards The replacement boards are supplied in a plastic bag This bag should be retained and the discarded boards should now be placed into it 11 Sweep any dampened particles and place in the plastic bag 12 Fit new insulation boards Note The boards are designed to be interlocking and should be fitted as shown 13 Fit the new split and washer in RHS of the chamber 14 Remove the gloves and face mask and place them in the plastic bag 15 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 16 Reassemble in reve
41. at the down pipe is part of a combined waste and rain water system Make connection to SVP using a solvent welded saddle BOILER INSTALLATION cla7773 4 TERMINATION TO SOAK AWAY Externa wal BOILER Termination to Soak away cla7774 Ground Level minimum 500mm 5 TERMINATION TO DRAIN GULLEY Open end of pipe BOILER direct into gulley 31 below grating but above water level cla7775 Ground Level 22 isar Installation and Servicing e back 25 MOUNTING THE BOILER IMPORTANT 1 Before mounting the boiler on the wall place it on its left hand side fit the S trap hose moulding nut and fold the hose to facilitate fitting into pre piping frame 2 Ensure that the plastic plugs are removed from both the CH and DHW pipes before mounting Some spillage of water may occur from the pipework when mounting the boiler to the frame 3 Lift the boiler onto the wall mounting frame locating it over the tabs at the top of the frame 4 Lower the boiler into position engaging it onto the support bracket Note Ensure the condensate drain pipe is correctly positioned through the hole in the pre piping frame before continuing INSTALLATION Using the fibre washers supplied in the hardware pack box engage and then tighten the 4 water unions Engage and tighten the gas union ensuring that the blue fibre washer is in place DO NOT overtighten Connect a pipe to the safe
42. at 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 both a separately supplied vertical connector and a 80 125 adaptor 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 length If the offset vertical option is used an elbow Kit is required For a full accessories list refer to page 7 Optional Extras and Frame 31 Flue Arrangement nm8736 28 ROOF FLUE KIT CONTENTS OPTIONS I Flue Seal Collar Flat Roof 90 elbow UIN 203132 UIN 152259 UIN 203130 45 elbow UIN 203131 duct UIN 152258 support Roof Flue Extension Duct UIN 203129 E 3 0 J _ LL 1 1 l 1 1 1 1 I 1 1 1 1 Flue Flue Seal Collar Tile Roof 1 1 1 1 1 1 1 1 1 24 isar Installation and Servicing 9 back 29 FLUE TERMINAL POSITION INSTALLATION The terminal should
43. complete with bracket and inlet pipe Transfer the mounting bracket and gas inlet pipe to the new gas control valve Fit the new gas control valve ensuring that any seals showing damage or deterioration are replaced Reassemble in reverse order Ensure the sensing tube is correctly replaced and not kinked or blocked in any way Check operation of the boiler Refer to Frame 57 67 DIVERTER VALVE ACTUATOR REPLACEMENT 46 Refer to Frame 57 Remove the casing front amp bottom panel Refer to Frames 49 amp 50 Squeeze the tab and unplug the electrical lead from the valve actuator Rotate the actuator anticlockwise and pull forward to remove Fit new actuator and reassemble in reverse order Check operation of the boiler Refer to Frame 57 Mounting bracket ECL 6079 Diverter valve actuator Tab Electrical isar Installation and Servicing 9 back SERVICING 68 COMBUSTION CHAMBER INSULATION REPLACEMENT The insulation boards used in the combustion chamber of this product are made of high temperature glass fibres with a binder of organic and inorganic materials Ideal Stelrad Group recommend that for your own comfort and safety and to comply with good working practice the procedure described below is followed 1 Refer to Frame 57 2 Remove the boiler front and sealing panels Refer to Frames 49 amp 50 Remove the fan venturi
44. ctrical controls with a waterproof sheet or plastic bag 1 Refer to Frame 57 2 Remove the boiler front bottom and sealing panels Refer to Frames 49 amp 50 3 Drain the boiler Refer to Frame 77 4 Remove the control box and place on one side Refer to Frame 71 Remove the fan venturi assembly and place on one side Refer to Frame 52 Remove the burner and place on one side Refer to Frame 53 Remove the ignition and detection electrodes Refer to Frames 63 amp 64 Remove the spark generator Refer to Frame 65 Release the flue from the turret Refer to Frame 26 Remove the turret from the boiler Refer to Frame 26 Release the silicone tubing from the sampling point Release the electrical connection to the dry fire thermistor Remove the M5 x 10 screw retaining the top flue manifold casting 14 Remove the top casting of the flue manifold from the appliance 15 Remove the automatic air vent Refer to Frame 76 16 Undo the 4 M x 10 screws securing the bottom flue manifold casting and remove Overheat thermostat Control thermistor 54 SERVICING 17 Remove the edge clip securing the dry fire thermistor wiring 18 Remove the blind grommet to gain access to the return pipe securing bracket 19 Remove the M5 screw and remove the return pipe securing bracket by sliding forwards 20 Remove the overheat thermostat and the control thermistor Refer
45. e CP Expansion vessel E69 341 Pressure gauge E69 403 DHW thermistor Wilo DHW thermistor CP Diverter valve motor head Wilo CP Diverter valve body Wilo CP E69 342 Pump Wilo Pump Head CP E69 408 Plate heat exchanger Ignition lead Detection lead Dry Fire Thermistor 2 IX l lA l3 l3 l3 l3 l3 l3 l3 l3 l l3 l3 Be l3 NI n ol Refer to boiler serial letter code on data plate to identify correct spare isar Installation and Servicing 61 9 back 95 SHORT LIST SHORT LIST OF PARTS 62 isar Installation and Servicing 9 back LIST OF PARTS 96 BOILER CASING ASSEMBLY 1 Front casing panel with screws 2 Sealing panel with screws 4 Bottom panel with screws 97 CONTROLS ASSEMBLY 33 Controls assy with screws 34 Controls hinge bracket 35 User controls without item 38 36 PCB primary controls 38 User controls housing 39 Mains switch 54 Jumper link not shown Ecl 2552 98 BURNER ASSEMBLY 11 Burner assembly with screws and gasket Ecl 1598 isar Installation and Servicing 63 9 back NOTES 64 isar Installation and Servicing 9 back INSTALLER NOTIFICATION GUIDELINES IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE In addition a change to Building Regulations England and Wales re
46. e new sensor ensuring silicone grease is applied to the O ring Self tapper Screw N Tey SES M4 screw Discharge pipe 48 isar Installation and Servicing 71 CONTROL BOX REPLACEMENT Refer to Frame 57 Remove the casing front amp bottom panel Refer to Frames 49 amp 50 Swing the control box down into the servicing position Refer to Frame 51 Unplug the user control electrical lead and low voltage lead from the control box and remove the control Refer to diagram A Return the control box to the working position and secure with the clamp Unscrew the mounting bracket Screws to remove the bracket Refer to diagram B Release the clamp and carefully remove the control box from the hinge arms Refer to diagram C Unplug all the electrical wiring from the control box and remove Control Hinge arms 72 MAINS SWITCH REPLACEMENT Refer to Frame 57 Remove the casing front amp bottom panel Refer to Frames 49 amp 50 3 Remove the 2 screws and allow the user control to lower 4 Push out the mains switch from the rear as shown 5 Fit the new switch ensuring that the electrical leads are Ecl 2445 Display unit User control isar Installation and Servicing SERVICING Transfer mounting bracket and hinge arms to the new control box Reassemble in reverse order ensuring that the control box is located correctly in the housing before reco
47. e 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 7 9 back GENERAL For the minimum clearances required for safety and subsequent service see the wall mounting template and Frame 2 In addition sufficient space may be required to allow lifting access to the wall mounting plate 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 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 or by a CORGI registered engineer In IE by a competent person An existing meter should be checked preferably by the gas supplier to ensure that the meter is adequate to deal with the rate of gas supply required N B The principle of the 1 1 gas valve ensures that the isar HE range is able to delive
48. er 10 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 150mm above the highest point of the system and be connected through a non return valve to the system fitted at least 150mm below the make up vessel on the return side of the radiators Expansion vessel volume litres 1 6 1 8 3 1 3 7 4 7 5 5 6 3 7 4 7 8 9 2 9 4 11 0 10 9 12 9 11 9 14 0 12 5 14 7 15 6 18 4 18 8 22 1 System volume litres 25 50 75 100 125 150 175 190 200 250 300 0 063 0 074 or Where access to a make up vessel would be difficult by pre pressurisation of the system The maximum cold water capacity of the system should not exceed 143 litres if not pressurized However if the system is to be pressurized the efficiency of the expansion vessel will be reduced and a larger vessel or smaller system volume may be necessary If the capacity of the vessel is not considered sufficient for this or for any other reason isar Installation and Servicing 9 back 4 an additional vessel MUST be installed on the return to the boiler Guidance on vessel sizing is given in Frame 3 5 Filling The system may be filled by the following method a Through a temporary hose connection from a draw off tap supplied from a service pipe under mains pressure Where the mains pressure is excessive a pressure reducing
49. er than the earth conductor so that if the cable slips in its anchorage the current carrying conductors become taut before the earth conductor Ecl 1542 isar Installation and Servicing 31 INSTALLATION 9 back INSTALLATION 39 EXTERNAL ELECTRICAL CONTROLS Wiring External to the Boiler The fuse rating should be 3A Wiring external to the boiler MUST be in accordance with the current I E E BS 7671 Wiring Regulations and any local regulations 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 the 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 Note f the boiler is installed in a garage it may be necessary to fit a pipe thermostat preferably on the return pipework Wiring should be as shown with minimal disturbance to other wiring of the programmer Designation of the terminals will vary but the programmer and thermostat manufacturers leaflets will give full details Diagram A Shows an applicat
50. es 49 amp 50 Unclip the thermistor thermostat from the flow return pipe and withdraw it from the controls compartment Overheat thermostat 4 Disconnect the electrical leads from the thermistor thermostat Reconnect the electrical leads and reassemble in reverse order ensuring that the spring clip is securely on the pipe Check the operation of the boiler Refer to Frame 57 Return pipe Control thermistor 44 Return thermistor isar Installation and Servicing 9 back SERVICING 63 IGNITION ELECTRODE REPLACEMENT Refer to Frame 57 Remove the electrode Remove the boiler front and sealing panels Refer to Fit the new ignition electrode using the new gasket Frames 49 amp 50 supplied Check dimensions as shown Unplug the ignition lead from the electrode Reassemble in reverse order and check that no damage 4 Remove the earth lead from the ignition electrode to the combustion chamber insulation has occurred Remove the remaining screw holding the ignition during ihe electrode replacement electrode to the combustion chamber Check the operation of the boiler Refer to Frame 57 Spark gap 3 5mm 1 64 FLAME DETECTION ELECTRODE REPLACEMENT 1 Refer to Frame 57 6 Fit the new flame detection electrode using the new gasket Remove the boiler front and sealing panels Refer to supplied Check dimensions as shown Frames 49 am
51. experienced ensure this is adequate for ALL other gas appliances in the property A boiler gas supply pipe length of 20m and not less than 15mm O D can be connected to the boiler via the gas service cock union Ensure that the gas supply pipe does not foul the boiler casing Refer to Frame 43 or Servicing for details of the pressure test point position Blue fibre washer Compression gas cock shown in the open position 35 SAFETY VALVE DRAIN The safety valve is located at the bottom RHS of the boiler The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring isar Installation and Servicing 29 INSTALLATION e INSTALLAT Central Heating Remove the sealing panel Refer to Frames 49 amp 50 a Swing the control box down into the servicing position Refer to Frame 51 Ensure that the CH isolating valves are open Fill and vent the system Check for water soundness INSTALLATION IMPORTANT when filling Remove the diverter valve actuator refer to Frame 67 and depress the spindle several times during filling Replace diverter valve actuator When filling there may be a slight water leak from the air vent therefore electrical connections should be protected Bleed any air from the pump and ensure that it is free to For Wilo Pump To ensure the pump i
52. ey v w white red y yellow violet ylg yellow green 42 COMMISSIONING AND TESTING Electrical Installation Checks to ensure electrical safety should be carried out by a competent person ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable test meter INSTALLATION bk External switch e g room stat programmer or il Overheat thermostat PCB No PHC 033 DC Gas valve no Diverter Valve Gas Installation 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 1S 813 2002 Purge air from the gas installation by the approved methods only WARNING Whilst effecting the required gas soundness test and purging air from the gas installation open all windows and doors extinguish naked lights and DO NOT SMOKE 34 isar Installation and Servicing 9 back 43 INITIAL LIGHTING Boiler On Off switch CH thermostat knob Burner On neon Automatic air vent Control box Servicing Reset button position Injector pressure test Pressure gauge point CH Flow isolating valve Inlet pressure test point DHW outlet DHW inlet DHW thermostat knob Spark generator Gas service cock Casing pressure test point Overheat thermostat R
53. f the cardboard carton INSTALLATION Wall mounting template protective packaging Hardware pack box Boiler 11 BOTTOM AND FRONT PANEL REMOVAL 1 Remove the screws from the underside of the boiler Pull the RHS of the panel down slide it to the right and withdraw Remove the screws from bottom of the front panel Lift panel up and off top pegs isar Installation and Servicing Pre piping nm9242 15 INSTALLATION 9 back INSTALLATION 12 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED IMPORTANT The boiler MUST be installed in a vertical position Dimension X Wall thickness Dimension L Wall thickness plus boiler spacing Dimension S Stand off frame depth 33mm FLUE KITS Pack B supplied as standard Pack D optional extension kit for side flue or rear flue outlet Finishing Kit Supplied as an optional extra REAR FLUE INSTALLATION Refer to Flue Extension Ducts pad 160 6 m Note MAXIMUM FLUE LENGTHS HE24 amp 30 6M HORIZONTAL FLUE HE35 3M HORIZONTAL FLUE HE24 30 amp 35 7 5M ROOF FLUE HE 24 30 amp 35 5M PRIMARY AND 17M SECONDARY IS A TYPICAL MAX FLUE LENGTH For alternative details refer to Powered Vertical Instructions 90 ELBOW KIT 60 100 EQUIVALENT FLUE LENGTH RESISTANCE 1M 45 ELBOW KIT 60 100 EQUIVALENT FLUE LENGTH RESISTANCE 0 6M HE24 HE30 amp HE35 18M TOTAL AIR PLUS FLUE DUCT 60 60 TWIN
54. for a few seconds without any DHW draw off in order to maintain the DHW calorifier in a heated condition Sumner When there is a demand for CH the heating system is supplied at the Automatic selected temperature of between 30 C and 82 C until DHW is drawn off Lj air vent The full output from the boiler is then directed via the diverter valve to the J plate heat exchanger to supply a nominal DHW draw off of Heat HE24 9 6 l min at 35 C temperature rise exchanger HE30 12 l min at 35 C temperature rise Gas valve HE35 14 4 l min at 35 C temperature rise ee ate nea The DHW draw off rate specified above is the nominal that the boiler flow exchanger regulator will give Due to system variations and seasonal temperature S trap Pump fluctuations DHW flow rates temperature rise will vary requiring adjustment Diverter 2 at the draw off tap valve Safety relief valve At low DHW draw off rate the maximum temperature is limited to 65 C by the modulating gas control pressure gauge q Refer also to Frame 1 Boiler Water Circuit Diagrams 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 DHW Hot out DHW Cold in Ej af Condensate drain Discharge pipe SAFE HANDLING This boiler may require 2 or more operatives to move it to its installation site
55. h flow and return connections from the boiler before connection to any plastic piping 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 6 isar Installation and Servicing 9 back GENERAL 2 The boiler connections are made on the boiler piping frame Refer to Frames 32 34 The following minimum clearances must be maintained for operation and servicing Additional space will be required for installation depending upon site conditions Side and Rear Flue a Provided that the flue hole is cut accurately e g with a core drill the flue can be installed from inside the building where wall thicknesses do not exceed 600mm 24 CLEARANCES b 4 5 1 4 e BOILER DIMENSIONS SERVICES amp CLEARANCES 390 15 3 8 all dimensions in mm in Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside Installation from inside ONLY If a core boring tool is to be used inside the building the space in which the boiler is to be installed must be at least wide enough to accommodate the tool BOILER DIMENSIONS 278 11 8 lt 5 1 4 from case 165 6 1 2 Flue terminal 400 15 3 4 Inset Water Connections
56. he current ETCI rules for electrical installations The fuse rating should be 3A All external controls and wiring must be suitable for mains voltage Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole Wiring external to the boiler MUST be in accordance with the switch having a 3mm 1 8 contact separation in both current I E E BS 7671 Wiring Regulations and any local poles or a plug and socket serving only the boiler and regulations System controls The means of isolation must be accessible to the user after installation 38 INTERNAL WIRING A pictorial wiring diagram is shown in Frame 40 1 Route the mains cable into the bottom rear centre of Wire any switched live supply into L2 or connect L1 and L2 the boiler via external control switching as shown in Frame 39 In either case remove the wire link fitted to L1 to L2 Wire the permanent live supply into the 5 way Secure the mains lead with the cable clamp remote plug terminals L3 N amp IMPORTANT 5 Connect the mains lead connector Ensure it is fully A permanent live is ESSENTIAL in order for the advanced diagnostic controls to function correctly Remove link when connecting external programmer Mains Connector Socket supplied in hardware pack fixed to boiler Note Ensure that the lengths of the current carrying conductors are short
57. inal pins At 25 9 700 10 300 Ohms At 60 C expect 2 400 2 600 Ohms At 85 C expect 1 000 1 100 Ohms Are the thermistor values correct Replace the thermistor YES Is there continuity between the PCB and the thermistor Replace PCB Check and replace wiring as necessary a 2 3 2 lt 2 a r 2 lt LL a 2 lt 2 a 2 2 2 a 2 LL 2 2 lt isar Installation and Servicing 59 9 back 68 FAULT FINDING 92 H 4 DRY FIRE THERMISTOR ERROR H9 L9 HEAT EXCHANGER OVERHEAT Is the system filled and vented and all isolation valves open Is the pump operating correctly Ensure flow through system NO Can the fault condition be reset by switching off the mains supply to the boiler YES NO Check wiring for continuity from the PCB to the dry fire thermistor Fill and vent the system and open all isolating valves Check resistance using a suitable multimeter connected across the dry fire thermistor s terminal pins Check resistance using a suitable multimeter connected across the thermistor s terminal pins At25 C expect 9 700 10 300 Ohms At 60 C expect 2 400 2 600 Ohms At 85 C expect 1 000 1 100 Ohms At 25 C expect 9 700 10 300 Ohms At60 C expect 2
58. ined and left with the customer Yes Commissioning Engineer s Signature Customer s Signature To confirm satisfactory demonstration and receipt of manufacturer s literature All installations 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 Certificate will then be issued to the customer s enchmari 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 1 Date Energy Efficiency Checklist completed Yes No SERVICE 2 Date Energy Efficiency Checklist completed Yes No L Engineer Name Engineer Name Company Name Telephone Number Company Name Telephone Number CORGI ID Number CORGI ID Number Comments Comments Signature SERVICE 3 Date Energy Efficiency Checklist completed vol Signature SERVICE 4 Date Energy Efficiency Checklist completed Engineer Name Engineer Name Company Name Company Name Telephone Number CORGI ID Number Telephone Number CORGI ID Number Comments Comments Signature Signature SERVICE 5 Date Energy Efficiency Checklist completed
59. ion to boilers fitted with a room thermostat only Diagrams amp C show applications to boilers fitted with alternative time controls Earths are not shown for clarity but must never be omitted 32 INSTALLATION if required System controls Optional Frost stat System controls Mains in Optional frost stat System controls Mains in Optional frost stat isar Installation and Servicing Ecl 6069 N o Ecl 6071 9 back INSTALLATION 40 PICTORIAL WIRING DIAGRAM LEGEND b blue red bk black violet r v br brown w white gy grey y yellow or orange ylg yellow green pk pink Dry fire thermistor eR or Overheat re thermostat Control thermistor r a Control or return thermistor flow Permanent Supply black link 50Hz Chassis earth y g Tis bk br Diverter Service connection Fused at 3 15ATL Control PCB 033 DHW Thermistor User control Switch and display isar Installation and Servicing 33 INSTALLATION 9 back INSTALLATION 41 FUNCTIONAL FLOW WIRING DIAGRAM Mains Switch ZA 2 1 electrode Dry fire thermistor DHW thermistor Es CH control thermistor return B CH control thermistor flow LE nm8949 LEGEND b blue or orange bk black pk pink br brown r gy gr
60. isar V3 Flue System Your Ideal installation and servicing guide HE24 HE30 HE35 For users guide see reverse of book When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers February 2008 UIN 203319 A03 For the very latest copy of literature for specification purposes please visit our website www idealboilers com where you will be able to download the relevant information in pdf format 5 Ide l The High Efficiency Pioneers isar Installation and Servicing 9 DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level A02 to A03 March 08 e Page 14 Frame 9 Unpacking Change to Pack A contents with regard to Wall Mounting Template Page 15 Frame 10 Packing Removal Wall Mounting Template change Page 17 Frame 14 Wall Mounting Template Change to procedure for mounting boiler onto a wall Ideal Stelrad Group reserve the right to vary specification without notice isar Installation and Servicing 3 9 back Table 1 General Data isar HE24 HE30 HE35 Gas supply 2H G20 20mbar Gas Supply Connection Rc 1 2 1 2 BSP female Injector Size Stereomatic 5 6mm dia 5 7mm dia Inlet Connection Domestic Hot Water 15mm copper compression
61. lable spare parts Description Quantity The full list is held by British Gas Services Ideal Stelrad Group distributors and merchants o BOO No Product number When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers Front casing panel 173 509 E69 384 Bottom casing panel 171 027 E67 489 Burner 170 905 Combustion chamber insulation 173 520 E67 492 Injector and housing HE24 30 170 908 HE35 173 522 E85 097 Fan assembly HE24 30 172 625 HE35 173 525 170 988 171 035 170 917 170 918 173 528 173 529 170 984 174 244 173 533 174 486 170 931 173 537 173 538 170 938 171 014 171 022 170 992 173 977 173 066 170 991 170 996 173 974 173 628 173 624 170 990 173 963 173 544 170 995 173 545 173 510 173 512 173 617 E69 286 Automatic air vent E69 288 Gas control valve E67 501 Control thermistor flow return E67 502 Overheat thermostat Ignition electrode kit Flame detection electrode kit HE24 30 HE35 H40 140 Kit Trap and Seal User control display unit PCB primary controls kit V9 HE24 30 35 E67 519 Fuse PCB 3 15A L250V Mains switch c w harness Spark generator assy E67 527 Gasket kit servicing E68 376 Seal kit sealing panel E68 380 Turret gasket E69 338 Pressure relief valve Wilo Pressure relief valv
62. led 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 1096 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 ELECTRICAL SUPPLY WARNING This appliance must be earthed Wiring external to the appliance MUST be in accordance with the current E E BS 7671 Wiring Regulations and any local regulations which apply For IE reference should be made to the current ETCI rules for electrical installations The point of connection to the mains should be readily accessible and adjacent to the boiler Note The fan voltage is 325V DC for the 35kW boiler CONDENSATE DRAIN Refer to Frames 22 amp 54 A condensate drain is provided on the boiler This drain must be connected to a drainage point on site All pipework and fittings in the condensate drainage system MUST be made of plastic no other materials may be used IMPORTANT Any external runs must be insulated The drain outlet on the boi
63. ler Refer to Frame 77 including gas soundness gas rate and combustion test THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED 58 DRY FIRE THERMISTOR REPLACEMENT Refer to Frame 57 Remove the boiler front and sealing panels Refer to Frames 49 amp 50 Drain down the boiler Refer to Frame 77 Unplug the electrical lead Unscrew the thermistor Fit the new thermistor using the sealing washer provided Reassemble in the reverse order Check the operation of the boiler nm8766 59 FAN REPLACEMENT Refer to Frame 57 Remove the boiler front and sealing panels Refer to Frames 49 amp 50 Orifice plate Disconnect the electrical leads from the fan Undo the gas pipe union connection to the injector housing Remove the screw retaining the fan mounting bracket Remove the fan and venturi assembly Refer to Frame 52 Unscrew the 3 screws and remove the venturi assembly noting the orientation 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 overtighten the screw on the fan mounting bracket 11 Check the operation of the boiler Refer to Frame 57 isar Installation and Servicing 43 SERVICING SERVICING 60 BURNER INJECTOR REPLACEMENT
64. ler is standard 21 5mm 3 4 overflow pipe 3 SYSTEM REQUIREMENTS Central Heating Notes a Antifreeze fluid corrosion and scale inhibitor fluids suitable The method of filling refilling topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local Safety valve setting bar 3 0 water authority Vessel charge pressure bar 0 5 to 0 75 System pre charge pressure bar None 1 0 for use with boilers having aluminium heat exchangers may be used in the central heating system Advice should be sought from a local water treatment company General The installation must comply with all relevant national and local regulations The installation should be designed to work with flow temperatures of up to 82 C All components of the system must be suitable for a working pressure of 3 bar and temperature of 110 Extra care should be taken in making all connections so that the risk of leakage is minimised The following components are incorporated within the appliance a Circulating pump For other system volumes multiply by the factor across b Safety valve with a non adjustable preset lift pressure of 3 bar Pressure gauge covering a range of 0 to 6 bar An 8 litre expansion vessel with an initial charge pressure of 0 75 bar Make up Water Provision must be made for replacing wat
65. let Pressure mbar Central Heating Flow Temperature Central Heating Return Temperature C COMBINATION BOILERS ONLY Is the installation in a hard water area above 200ppm Yes No If yes has a water scale reducer been fitted Yes No What type of scale reducer has been fitted DOMESTIC HOT WATER MODE Measure and Record Gas Rate m3 hr OR ft hr Burner Operating Pressure at maximum rate mbar OR _ Gas Inlet Pressure at maxiumum rate mbar 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 Yes ALL INSTALLATIONS If required by the manufacturer record the following CO OR CO ppm CO CO Ratio The heating and hot water system complies with the appropriate Building Regulations Yes The boiler and associated products have been installed and commissioned in accordance with the manufacturer s instructions Yes The operation of the boiler and system controls have been demonstrated to and understood by the customer Yes The manufacturer s literature including Benchmark Checklist and Service Record has been expla
66. m Powered Vertical Flue Kit 5m primary and 17m secondary is a typical maximum length For alternative details refer to Powered Vertical Instructions High Level Flue Outlet Kits Flue Deflector Kit Weather Collar Twin Fluing Kits up to a maximum of 60m combined total flue and airducts Horizontal Flue Terminal 600mm long Remote User Controls Kit Boiler Stand off Kit Siphon Kit Valve Cover Kit Contensate Pump Kit SAFETY 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 CORGI Registered Installer It must be carried out in accordance with the relevant requirements of the Gas Safety Installation and Use Regulations The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Regulations northern Ireland The Water Fittings Regulations or Water byelaws in Scotland 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 Competent Person 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
67. n electrode and associated harness for continuity visual condition position Refer to Frame 64 Replace as necessary YES Replace PCB Check spark generator and associated harness for continuity and visual condition Refer to Frame 65 Are these functioning correctly Replace spark generator Check the ignition electrode and associated harness for continuity visual condition position Refer to Frame 63 Are these functioning correctly Check syphon and condensate YES drain pipework for blockage Replace ignition electrode and associated Replace gas valve harness as necessary 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 meter a mains voltage checking device may be used E g an electrical screwdriver or mains tester PCB ERROR Press and hold reset button for 2 seconds Does boiler operate correctly IL Turn boiler off and wait for 5 seconds Turn boiler on Does boiler operate correctly Replace PCB isar Installation and Servicing 57 Internal fault within the PCB FAULT FINDING FAUL
68. nnecting the electrical wiring 10 Check operation of the boiler Refer to Frame 57 A Electrical lead Control box Low voltage lead B Control box mounting bracket replaced on the correct terminals refer to Frame 36 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 57 nm 2872 Display unit Mains switch Electrical lead 49 SERVICING 9 back SERVICING SERVICING 73 USER CONTROL REPLACEMENT Note Only the display unit is replaced Refer to Frame 57 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 order Check operation of the boiler Refer to Frame 57 User control 74 PRESSURE GAUGE REPLACEMENT Refer to Frame 57 Drain the boiler Refer to Frame 77 Unscrew the pressure gauge and discard Fit the new pressure gauge using a suitable jointing compound Refill the boiler Refer to Frame 36 6 Check operation of the boiler Refer to Frame 57 50 Display unit Flow isolation valve shown in the open position isar Installation and Servicing SERVICING 75 SAFETY RELIEF VALVE REPLACEMENT 7 Remove the safety valve Refer to Frame 57 8 Fit the new safety valve and refit the
69. o connect the boiler open position flow and return pipes to 28mm system pipework Do not subject any of the isolating valves to heat as the seals may be damaged Pressure gauge 7 ee wy SY id T ZS Piping frame 22mm copper pipe 0 denda ili Isolating valve gas coc shown in the open position C H FLOW 22 C H RETURN INSTALLATIO 33 WATER CONNECTIONS DHW Cross bar Retaining Outlet screw connector Note The DHW inlet 92 ili Piping frame isolating valve incorporates Tom capper pips a flow regulator filter It should be inspected to ensure no blockage is evident D H W Outlet 1 To remove turn off the valve undo the Isolating valve retaining screw and pull out the filter shown in the by grasping the crossbar with pliers Compression open position Reassemble in reverse order gas cock 15mm copper pipe inserting in the direction of the arrow 28 isar Installation and Servicing 9 back INSTALLATION 34 GAS CONNECTION IMPORTANT The gas service cock is sealed with a non metallic blue fibre washer so must not be overheated when making capillary connections Refer to Frame 2 for details of the position of the gas connection N B The principle of the 1 1 gas valve ensures that the isar HE range is able to deliver it s full output at inlet pressures down to 14mb However if dynamic pressures below 20mb are
70. omestic hot water DHW output is also fully modulating with Bumer a maximum of Automatic HE24 24 4kW 80 000 Btu h air vent HE30 29 3kW 100 000 Btu h LL HE35 35 2kW 120 000 Btu h Heat The boiler is supplied fully assembled with DHW plate heat exchanger exchanger diverter valve circulating pump pressure gauge safety valve and CH expansion vessel Gas valve Variable CH and DHW temperature controls are fitted on the user control and heat the boiler features a DHW preheat facility S trap exenanger The boiler casing is of white painted mild steel with the user controls Dvete Pump capable of being mounted remotely from the boiler if the option is required valve HL Safety The boiler temperature controls are visible at the bottom RHS of the front relief valve panel pressure The heat exchanger is of cast aluminium gauge The boiler is suitable for connection to fully pumped sealed water systems ONLY Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework Pipework from the boiler is routed downwards as standard but may be routed upwards behind the boiler using the stand off frame supplied in a separate kit OPERATION Expansion Discharg pipe o D o c o Domestic Hot Water Circuit vessel With no demand for CH the boiler fires only when DHW is drawn off or periodically
71. p 30 Up to 6000 mm Up to 6000 mm Pack D 6 off HE24 amp 30 isar HE35 is capable of 3m flue only 16 isar Installation and Servicing 9 back INSTALLATION 13 FLUE ASSEMBLY Exploded View An optional flue duct extension kit is required for wall thicknesses greater than Side 395mm Rear 435mm LEGEND Duct assembly Flue turret Turret gasket The flue terminal MUST be fitted with the TOP uppermost to allow the Turret clamp correct fit and use of the plume management system M5 x 10 pozi screw Rear flue arrangement shown nm8760 14 WALL MOUNTING TEMPLATE The wall mounting template is located on the internal s Extended centre protective packaging Note The template shows the positions of the fixing holes and the rear flue hole centre for standard installation Care MUST be taken to ensure the correct holes are drilled Tape template into the selected position Ensure squareness by hanging a plumbline as shown If fitting a side flue extend the flue centre line onto the side wall and measure in 155mm for standard installation ONIINQOR TIVA Note f using stand off kit distance increases to 188mm Mark onto the wall the following a The wall mounting plate screw positions choose one from each group b The position of the flue duct hole see diagram below Note Mark the centre of the hole as well as the ci
72. p 50 Reassemble in reverse order and check that no damage to the combustion chamber insulation has occurred during the Unplug the flame detection lead from the electrode electrode replacement Remove the 2 screws holding the flame detection electrode to the combustion chamber Check the operation of the boiler Refer to Frame 57 Remove the electrode 65 SPARK GENERATOR REPLACEMENT Refer to Frame 57 Disconnect the leads from the spark generator and bracket Remove the M5 screw securing the spark generator bracket to the flue casting 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 57 nm8802 isar Installation and Servicing 45 SERVICING 9 back SERVICING SERVICING 66 GAS CONTROL VALVE REPLACEMENT Refer to Frame 57 Remove the casing front amp bottom panel Refer to Frames 49 amp 50 Swing the control box down into the servicing position Refer to Frame 51 Unplug the electrical lead from the gas control valve and disconnect the earth wire Remove the sensing tube from the gas control valve Undo the gas inlet pipe union at the gas service cock Undo the union nut on the outlet of the gas control valve Slacken the screw securing the valve mounting bracket and withdraw the valve
73. pack to 400mm and adjust the telescopic terminal square cut mark the flue all the way around and cut to length If the remainder Y is 300mm lt 525mm this can be taken up 70 lt gt lt by the adjustment in the telescopic flue If the remainder Y is 525mm 950mm it will be necessary to cut a D pack to 400mm esp8940 isar Installation and Servicing FLUE OUTLET 19 9 back INSTALLATION 21 FITTING THE PIPING FRAME AND VALVES Rear Flue outlet shown Note solating valves are supplied separately in the hardware pack box Fit to the piping frame BEFORE mounting the boiler TO FIT THE PRE PIPING FRAME DIRECTLY TO THE WALL TOFIT THE PRE PIPING FRAME USING THE STAND OFF FRAME Insert wall plugs OPTION KIT To allow pipework to be taken upwards Put the screws into the wall plugs and leave 10mm proud Put the screws into the wall plugs and leave 10mm proud Hang the frame onto the screws take care to use the Hang the stand off frame onto the screws and tighten up same hole position from each group as previously chosen Fasten the piping frame to the stand off frame with the with the wall template and tighten up 6mm screws provided Locate the support bracket on the piping frame Locate the support bracket on the piping frame Note If the clearances above and below the boiler are less than the length of the pipes it will be necessary to position
74. quires the installer to notify when installing a heating appliance as from 1st April 2005 Install and commission this appliance to manufacturers instructions Complete the Benchmark Checklist Competent Person s Choose SELF CERTIFICATION SCHEME Buildings Regulations BUILDING CONTROL notification route If you notify via CORGI Scheme Contact your relevant CORGI will then notify the Local Authority relevant Local Authority Building Building Control LABC who Control LABC scheme will arrange an inspection on members behalf or contact a government approved inspector Scheme members only Call CORGI on 0870 88 88 777 LABC will record the data or log onto and will issue a www corgi notify com certificate of compliance within 10 days You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS compliance to the property FULLY COMPLETED AND LEFT WITH THE APPLIANCE CORGI will record the data and will send a certificate of isar Installation and Servicing 65 9 back 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
75. r it s 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 IMPORTANT Installation pipes must be fitted in accordance with BS 6891 In IE refer to 1S 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 soundness and purged as described in the above code Table 4 Balanced Flue Terminal Position Flue Terminal Positions Min Spacing Directly below above or alongside an opening window air vent or other ventilation opening 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 24 1 200mm 48 Below guttering drain pipes or soil pipes BS5440 1 2000 Below eaves BS5440 1 2000 Below balconies or a car port roof BS5440 1 2000 From vertical drain pipes or soil pipes BS5440 1 2000 From an internal or external corner or to a boundary along side the terminal BS5440 1 2000 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 port e g door or window into dwelling Vertically from a terminal on the same wall 1 200mm 48 1 500mm 60 30
76. rcumference Remove the template from the wall Flue duct hole ESI 31 44 57 70 83 109 122 135 m Y 4 5 A E i 50 A E 1 5 5 rr 305 n v 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 be adjusted accordingly M o FLUE OUTLET isar Installation and Servicing 17 9 back 15 PREPARING THE WALL IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury Cut the flue hole preferably with a 5 core boring tool ensuring that the hole is square to the wall Both wall faces immediately around the cut hole should be flat Drill 4 holes with a 7 5mm 8mm masonry drill and insert the plastic plugs provided for the piping frame Locate 4 No 14 x 50mm screws in the piping frame one at each side in any of the 3 holes provided at each side and screw home 16 SETTING THE FLUE REAR Notes If using the extension ducts go to Frame 18 If the stand off frame is used it is essential to add 33mm to dimension X For shorter flue requirements less than 210mm use non telescopic B Pack Measure and note wall
77. re LOCATION OF BOILER The boiler must be installed on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible wall and insulation between the wall and the boiler is not necessary unless required by the local authority For electrical safety reasons there must be no access available 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 1998 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 in Scotland 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 can be installed in Zone 3 as detailed in BS 7671 Compartment Installations A compartment used to enclos
78. ring that it is full of water Refit the sump cover Refit the electrodes Check dimensions Frames 63 amp 64 Refit the burner Refit the fan venturi assembly Reconnect the fan electrical lead SERVICING 54 CLEANING THE CONDENSATE S TRAP Condensate trap ongated bolt Condensate drain pipe lonisation Heat exchanger 7 Refit the boiler sealing panel IMPORTANT Ensure that the boiler sealing panel is correctly fitted and that a good seal is made Swing the control box back into its working position and secure 9 Refit the display unit 10 Refit the boiler front and bottom panels 11 Turn on the gas supply at the gas service cock 12 Reconnect the electrical supply isar Installation and Servicing 9 back _ _ SERVICING 57 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT When work is complete the sealing panel if removed must Whenreplacing ANY component be correctly refitted ensuring that a good seal is made 1 Isolate the electricity supply Notes 2 Turn off the gas supply 1 In order to assist fault finding the control panel has an LED diagnostic display The key to boiler fault conditions 3 Remove the boiler front panel Refer to Frame 49 isshown in Erama 84 In order to replace components in Frames 74 82 it is After replacing ANY component check operation of the boiler necessary to drain the boi
79. rse order remembering to re fit the ionisation probes first 17 Check operation of the boiler Refer to Frame 57 47 SERVICING 9 back SERVICING SERVICING Refer to Frame 57 Remove the casing front amp bottom panel Refer to Frames 49 amp 50 Swing the control box down into the servicing position Refer to Frame 51 Disconnect the condensate drain pipe Remove the securing screw and elongated bolt pull the trap down and forward to remove Transfer the drain pipe to the new trap and reassemble in reverse order When reassembling ensure the trap is full of water Check operation of the boiler Refer to Frame 57 Elongated bolt Condensate drain pipe 70 DHW THERMISTOR REPLACEMENT Refer to Frames 57 amp 77 for draining the appliance 8 Refit the securing pin 9 Reassemble in reverse order ensuring correct location Remove the casing front amp bottom panel of screws in support plate and that tabs on the pump Refer to Frames 49 amp 50 and valve housings engage in slots Remove the 4 screws securing the support plate and 10 Check operation of the boiler Refer to Frame 57 withdraw the plate Note The M4 screws fit the casing and the self tapping screws fit the plastic pump and valve housings 4 Withdraw the securing pin Disconnect the electrical lead Ease out the sensor and discard Fit th
80. s CONTROL THERMISTOR FLOW ERROR Remove the boiler control thermistor from the CH flow pipe and disconnect thermistor wires 60 expect 2 400 2 600 At85 C expect 1 000 1 100 Check resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 Ohms Ohms Ohms Are the thermistor values correct Replace the thermistor YES Is there continuity between the PCB and the thermistor Replace PCB Check and replace wiring as necessary isar Installation and Servicing 9 back FAULT FINDING 9U H 2 CONTROL THERMISTOR RETURN ERROR Remove the boiler return thermistor from the CH return pipe Check resistance using a suitable multimeter connected across the thermistor s terminal pins At 25 expect 9 700 10 300 Ohms At 60 expect 2 400 2 600 Ohms At 85 C expect 1 000 1 100 Ohms Are the thermistor values correct Replace the thermistor YES Is there continuity between the PCB and the thermistor Replace PCB Check and replace wiring as necessary DHW THERMISTOR ERROR Remove the boiler DHW thermistor from the plate heat exchanger and disconnect thermistor wires Check resistance using a suitable multimeter connected across the thermistor s term
81. s always available See note regarding thermostatic radiator valves on page 10 Note Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass BALANCING 1 Set the programmer to ON Close the manual or thermostatic valves on all radiators leaving the twin lockshield valves on the radiators referred to above in the OPEN position isar Installation and Servicing GENERAL SYSTEM REQUIREMENTS CH continued and Hot Water Water Flow Rate and Pressure Loss Max CH Output kW Btu h 23 4 80 000 0 37 4 8 15 27 2 3 7 5 Water flow rate gal min C CF m w g ft w g Temperature Differential Head available for system pump Mains water supply Hose unions x CH Return Additional stop valve Temporary hose disconnect after filling Double check valve assembly Ecl 6053 note direction of flow Hard Water Areas Where the water hardness exceeds 200mg litre it is recommended that a proprietary scale reducing device is fitted into the boiler cold supply within the requirements of the local water company IMPORTANT Provision MUST be made to accommodate the expansion of DHW contained within the appliance if a non return valve is fitted to the DHW inlet Turn up the room thermostat and adjust these lockshield valves to give boiler flow and return temperatures not more than 20
82. s boiler WARNING Always turn OFF the gas supply at the gas service cock and switch OFF and disconnect the electricity supply to the appliance before servicing 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 at least annually It is the law that any service work must be carried out by a CORGI registered installer In IE service work must be carried out by a competent person 1 Light the boiler and carry out a pre service check noting any operational faults 2 Clean the main burner Clean the heat exchanger amp S trap Check the condition of the combustion chamber insulation Any cracked damaged or displaced pieces should be replaced Check the main injector for blockage or damage Wherever possible remove and clean the condensate S trap refer to Frame 54 and check the drain for blockage Check that the flue terminal is unobstructed and that the flue system is sealed correctly Check the DHW filter for blockage Refer to Frame 33 The servicing procedures are covered more fully in Frames 49 56 and MUST be carried out in sequence 38 Note n order to carry out either servicing or replacement of components the boiler front panel and sealing panel must be removed Refer to Frames 49 and 50 IMPOR
83. s free to rotate i Remove the vent plug ii Using a screwdriver rotate the shaft several times b a Automatic air vent Diverter valve shown in the CH position Forward position indicates DHW For CP Pump To ensure the pump is free to rotate i Unscrew the central cap ii Gently pull the cap out to engage with the shaft iii Rotate the cap and spindle Note Some slight water leakage will occur a b Automatic air vent Diverter valve shown in the CH position Forward position indicates DHW Domestic Hot Water 1 Fully open all DHW taps and ensure that water flows freely from them 2 Close all taps 30 rotate iii Replace the vent plug Note Some slight water leakage will occur nm 2930 Pump Rotate the shaft to free Vent plug To vent the pump Repeat steps i and ii Move the fitting from side to side to allow air to vent Ensure the cap is fully retightened Central Cap The domestic hot water flow rate is automatically regulated to a maximum 24 9 6 I m 2 1 gpm HE30 12 0 I m 2 6 gpm HE35 14 4 I m 3 2 gpm isar Installation and Servicing 9 back 37 ELECTRICAL CONNECTIONS INSTALLATION 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 For IE A mains supply of 230 V 50 Hz is required reference should be made to t
84. securing pin Remove the casing front and bottom panels Refer to Frames 49 amp 50 9 Reassemble in reverse order ensuring correct location of screws in the support plate and that tabs Drain the boiler Refer to Frame 77 on the pump and valve housings engage in slots 4 Remove the discharge pipe 10 Reconnect the discharge pipe 5 Remove the 4 screws retaining the rear support plate and 11 Refill the boiler Refer to Frame 36 withdraw the plate 12 Check operation of the boiler Refer to Frame 57 Note The M4 screws fit the casing and the self tapping screws fit the plastic pump and valve housings as shown 6 Withdraw the securing pin Self tapper Screw SES _ EN 9 M4 screw Support plate Lt ar Discharge pipe eet 76 AUTOMATIC AIR VENT REPLACEMENT Refer to Frame 57 Spark Generator Remove the boiler front and sealing panels Refer to frames 49 amp 50 Drain the boiler Refer to frame 77 Remove the turret from the boiler Refer to gt frame 26 R Air vent Release the silicon tubing from the sample point Release the electrical connections from the dry fire thermistor Release the electrical connections from the spark generator Remove the M5 x 10 screw retaining the top flue manifold casting Remove the casting Remove the fan from the boiler Refer to Frame 52 nm8767
85. t the complete boiler from the wall mounting frame and place on a flat surface face down to expose the expansion vessel Unscrew the union nut on the vessel water connection pipe Unscrew the 2 screws from the securing clamp and Securing clamp remove Remove the expansion vessel 10 Fit the new expansion vessel 11 Reassemble in reverse order 12 Refill the boiler Refer to Frame 36 13 Check operation of the boiler Refer to Frame 57 Note If preferred and for convenience a new expansion vessel may be installed elsewhere in the heating system providing it ensures equivalent system protection Ecl 6083 Rear view of the boiler 83 BOILER SEALING PANEL SEAL REPLACEMENT Refer to Frame 57 Remove the boiler front and sealing panels Refer to Frames 49 amp 50 Remove the old seal from the casing and thoroughly clean the casing surfaces Fit the new adhesive seals note that they are supplied to the correct length for the relevant sides 5 Reassemble in reverse order 6 Check operation of the boiler Refer to Frame 57 Note Ensure that the boiler sealing panel is correctly sealed compressing the seal to make an airtight joint nm 2764 isar Installation and Servicing 55 SERVICING 9 back a 2 H 2 lt 2 a 2 L
86. to Frame 62 21 Remove the securing pin to release the flow pipe 22 Remove the condensate S trap Refer to Frame 69 23 Remove the 2 M5 screws securing the interpanel to the back panel 24 Slide the heat exchanger and interpanel assembly upward to disengage and remove from the casing complete with the flow pipe 25 Remove the 2 M6 countersunk screws remove the interpanel and transfer to the new heat exchanger 26 Remove the M5 screw and remove the flow pipe securing bracket 27 Remove the flow pipe and transfer to the new heat exchanger 28 Reassemble in reverse order replacing gaskets or seals if any sign of damage or deterioration is evident Note The heat exchanger is supplied with new combustion chamber insulation boards These should be fitted refer to Frame 68 before the burner and fan venturi assembly and before the ignition and detection electrodes are replaced 29 Refill the boiler Refer to Frame 36 30 Check operation of the boiler Refer to Frame 57 Return pipe securing bracket Flow pipe securing bracket isar Installation and Servicing 9 back SERVICING 82 EXPANSION VESSEL REPLACEMENT 1 Refer to Frame 57 2 Drain the boiler Refer to Frame 77 3 Unscrew all the gas and water connection unions on the boiler side of the valves Remove the screw from the turret clamp and remove Expansion vessel 5 Remove the turret Lif
87. ty drain outlet using the nut and olive supplied in the boiler hardware pack box nm8024 INSTALLATION 26 CONNECTING THE FLUE TO THE BOILER Note Before fitting the flue turret fill the condensate trap within the boiler by pouring a cupful of water into the flue outlet A Take care to ensure that the water is only poured into the flue outlet and does not spill into the boiler casing Locate the flue into the turret Insert the flue assembly through the prepared hole in the wall Push through and pull back to seal against outside wall face Locate the flue turret on the top of the boiler ensuring that the turret gasket is in place Also ensure the turret is located concentric with the flue aperture on the boiler top panel Check that the flue seal A located in the top of the flue manifold is secure and giving an effective seal Secure the flue turret on top of the boiler by inserting the open ends of the turret clamp under the 2 studs and fixing it in the middle with the single M5 x 10mm pozi hex screw provided Flues over 1 metre long Fix the flue support bracket to the wall using the 4 wall plugs and wood screws NB The space bracket will utilise one fixing hole only whilst used in conjunction with the stand off option nm8764 23 isar Installation and Servicing 9 back INSTALLATION 27 FITTING THE OPTIONAL ROOF FLUE KIT Flat or Pitched Note A fl
88. useholder by the following actions 1 Hand the User Instructions to the householder and explain his her responsibilities under the relevant national regulations Explain and demonstrate the lighting and shutting down procedures The operation of the boiler and the use and adjustment of all system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions Explain the function and the use of the boiler heating and domestic hot water controls 9 Explain that due to system variations and seasonal temperature fluctuations DHW flow rates temperature rise will vary requiring adjustment at the draw off tap It is therefore necessary to draw the users attention to the section in the Users Instructions titled Control of Water Temperature and the following statement Additionally the temperature can be controlled by the user via the draw off tap the lower the rate the higher the temperature and vice versa Explain the function of the boiler fault mode Emphasise that if a fault is indicated the boiler should be turned off and a CORGI registered local heating installer consulted In IE contact a competent person 6
89. valve must be used to facilitate filling When installing the filling device it must be connected as shown below to fully comply with the water regulations This may involve the fitting of an additional WRAS approved isolator valve to the mains supply i Thoroughly flush out the whole system with cold water ii Fill and vent the system until the pressure gauge registers 1 5 bar and examine for leaks iii Check the operation of the safety valve by raising the water pressure until the valve lifts This should occur within 0 3 bar of the preset lift pressure iv Release water from the system until the minimum system design pressure is reached 1 0 bar if the system is to be pre pressurised DOMESTIC HOT WATER 1 5 The boiler does not normally need a bypass but at least some The domestic hot water service must be in accordance with BS 5546 and BS 6700 Refer to Table 1 for minimum and maximum working pressures The boilers are suitable for connection to most types of washing machine and dishwasher appliances When connecting to suitable showers ensure that a The cold inlet to the boiler is fitted with an approved anti vacuum or syphon non return valve b Hot and cold water supplies to the shower are of equal pressure SYSTEM BALANCING radiators on the heating circuit of load of at least 10 of the minimum boiler output must be provided with twin lockshield valves so that this minimum heating load i
90. ver the hole cut in the roof and insert flue terminal from the roof end MAX LENGTH 7 5m BOILER lt Flue Terminal 2 Push fit the vertical connector supplied seperately into the boiler flue connection and retain with the turret clamp and securing screw supplied with the boiler ENSURING THE GASKETS IN THE BOILER FLUE OUTLET ARE CORRECTLY FITTED Push fit extension duct if required supplied separately into vertical connector Pitched roof tile Flat roof tile weather collar weather collar x ES Extension d li Duct nm8740 Turret clamp Vertical connector nm8741 If the last extension duct requires cutting measure X 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 FLUE OUTLET Finally ensure the roof flashing plate is correctly sealed to the roof isar Installation and Servicing 27 9 back INSTALLATION Z 32 WATER CONNECTIONS CH Notes 1 For heating loads in excess of 60 000 Btu h use 28mm x 22mm Isolating valve shown the Condensate drain pipe located here connectors t

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