Excel HE C24, HE C28, HE C32 User Manual

Download

installation and servicing

excel

Your Ideal installation and servicing guide

See reverse for

excel

users guide

When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.

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.

HE C24, C28, C32

For details of document amendments, refer to page 3

November 2007 UIN 201279 A06

the nation’s favourite for

PLUMBING & HEATING SUPPLIES

SECURE PAYMENTS

shop online with confidence

FREE SHIPPING

on all orders over £100 to mainland UK

FINANCE AVAILABLE

spread the cost with low interest rates

PRICE MATCH

always get the best deals available

Boilers Radiators Heating controls



Cylinders Fires Renewable energy

Bathroom suites Kitchen sinks & taps Showers Wet rooms Towel warmers Bathroom furniture & much more

HUGE REDUCTIONS

we have

ON THOUSANDS OF ITEMS

0844 800 3460

CALL US ON

visit our website

plumbnation.co.uk

excel HE - Installation and Servicing

3excel HE - Installation and Servicing

DOCUMENT AMENDMENTS

Relevant Installation changes implemented in this book from Mod Level ........... A05 (Oct 06) to A06 (Nov 07)

• Page 4, Table 1 - General Data

New Maximum working pressure figures.

• Page 7, Optional Extra Kits

Addition of High Level Flue Outlet Kit.

• Page 40, Frame 63 - PCB Replacement

Note added re: antistatic precautions.

• Page 42, Frame 66 - Air Pressure Switch Replacement

New photograph added showing correct orientation of air pressure switch.

• Users Guide - Page 2, Important Notes

Additon of two new bullets into important notes.

Ideal Stelrad Group reserve the right to vary specification without notice

excel HE - Installation and Servicing

GENERAL

CAUTION.

To avoid the possibility of injury during the installation, servicing or cleaning of

this appliance care should be taken when handling edges of sheet steel components

Note. Gas consumption is calculated using a

calorific value of 38.7 MJ/m3 (1038 Btu/ft3) gross or

34.9 MJ/m3 (935 Btu/ft3) nett To obtain the gas consumption at a different calorific value: a. For l/s - divide the gross heat input (kW) by the

gross C.V. of the gas (MJ/m3)

b. For ft3/h - divide the gross heat input (Btu/h) by

the gross C.V. of the gas (Btu/ft

)

Key to symbols GB = United Kingdom IE = Ireland (Countries of destination) PMS = Maximum operating pressure of water C

12 C32 C52

= A room sealed appliance designed for connection via ducts to a horizontal

or vertical terminal, which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which, in this case, are concentric. The fan is up stream of the combustion chamber.

I2H= An appliance designed for use on 2nd Family gas, Group H only.

Table 1 - General Data

excel HE C24 excel HE C28 excel HE C32

Max Min Max Min Max Min

Burner pressure (hot) G20 mbar 13.4 5.0 10.5 3.9 12.9 3.8

(in.w.g.) (5.3) (2.0) (4.2) (1.6) (5.2) (1.5)

Input based on nett CV kW 24.4 15.2 29.0 18.4 33.4 19.0

(btu/h) (83,300) (51,900) (98,900) (62,800) (114,000) (64,800)

Input based on gross CV kW 27.1 16.9 32.2 20.4 37.1 21.1

(btu/h) (92,400) (57,600) (109,900) (69,600) (126,600) (72,000) Output: Non condensing kW 23.4 14.2 28.0 17.6 32.0 17.9 70oC Mean Water temp. (btu/h) (80,000) (48,500) (95,500) (60,000) (109,000) (61,000) Condensing kW 25.1 15.3 29.8 18.3 34.3 18.9 40oC Mean Water temp. (btu/h) (85,600) (52,200) (101,700) (62,400) (117,000) (65,000) Gas consumption (Hot) G20 l/s 0.700 0.40 0.83 0.53 0.96 0.54

(ft3/h) 89.0 50.4 105.9 67 122 69.4 Seasonal efficiency * (SEDBUK) Band B [ 86.4 ]% Band B [ 86.4 ]% Band B [ 86.3 ]%

*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.

Table 2 - Performance Data - Central Heating

HE C24 Max HE C24 Min HE C28 Max HE C28 Min HE C32 Max HE C32 Min

Max. Burner pressure (hot) G20 mbar (in.w.g.) 13.4 (5.3) 2.2 (0.9) 10.5 (4.2) 1.5 (0.6) 12.9 (5.2) 1.6 (0.6) Input based on nett CV kW (btu/h) 24.4 (83,300) 29.0 (98,900) 33.4 (114,000) Input based on gross CV kW (btu/h) 27.1 (92,400) 32.2 (109,900) 37.1 (126,600) Output kW (btu/h) 23.4 (80,000) 28.0 (95,500) 32.0 (109,000) Gas consumption (Hot) G20 l/s (ft3/h) 0.7 (89) 0.83 (105.9) 0.96 (122) Flow 35oC temp. rise l/m (gpm) 9.6 (2.1) 11.5 (2.6) 13.1 (2.9) Flow 40oC temp. rise l/m (gpm) 8.4 (1.8) 10 (2.2) 11.5 (2.6) Domestic hot water specific rate l/m (gpm) 11.2 (2.5) 13.4 (3.0) 15.3 (3.4)

Table 3 - Performance Data - Domestic Hot Water

excel HE C24 excel HE C28 excel HE C32

Gas supply I2H - G20 - 20mbar Gas Supply Connection Rp 1/2" Injector Size 1.1 1.25 1.25 Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter mm (in) 100 (4) Average Flue Temp-Mass Flow Rate 75oC - 14g/s 80oC - 16g/s 80oC - 18g/s Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.5 (36.3) Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) 10.0 (145) Minimum Domestic Hot Water Inlet Pressure bar (lb/in2) 0.5 (7) Electrical Supply 230 V ~ 50 Hz. Power Consumption W 168 180 184 Fuse Rating External : 3A Internal : Water content Central Heating litre (gal) 1.9 (0.42) 2.0 (0.44)

Domestic Hot Water 0.2 (0.044) Packaged Weight kg (lb) 47 (103) 53 (117) 53 (117) Maximum Installation Weight kg (lb) 43 (95) 49 (108) 49 (108) Boiler Casing Size Height mm (in) 800 (31 1/2”)

Width mm (in) 450 (17 1/2”)

Depth mm (in) 320 (12 5/8”) NOX Classification Class 2 IP Rating IP20

Note. Quoted flow rates and temperature rises are those theoretically achievable. Flow rates measured during commissioning may diffe r (due, for example, to resistance of domestic hot water pipe lengths and fittings or available dynamic gas pressures).

5excel HE - Installation and Servicing

GENERAL

CONTENTS

Air Supply ..................................................................... 10

Benchmark Commissioning Checklist ... ..................58

Boiler Clearances ......................................................... 9

Boiler Exploded Diagram ....................................... 12,13

Condensate Drain .......................................................23

Electrical Connections ............................................... 26

Electrical Supply ......................................................... 10

Extension Ducts - Fitting ............................................. 18

Fault Finding ........................................................... 49-53

Flow Wiring Diagram .................................................. 29

Flue Fitting .............................................................. 15-18

Horizontal Flue Installation ........................................... 8

Roof Flue Kit Installation ....................................... 19-21

Gas Safety Regulations ........... .....................................7

Gas Supply ..................................................................... 8

Installation ............ .......................................... ....... 14-31

Mandatory Requirements ........................................7-11

Pump ......................... ......................................... ........46

Safe Handling ................................................................ 6

Servicing ................................................................ 32-48

Short List of Parts .......................................................54

Thermostatic Radiator valves ................................... 10

Water and Systems .............................................. 10-12

Water Connections .....................................................24

Water Treatment .........................................................12

Wiring Diagrams ................ ................................... 26-29

excel HE

Natural Gas only

Destination Country: GB, IE

ex7380

Boiler Page

Make and model .......................................................5

Appliance serial no. on data badge ...................... 13

SEDBUK No. % .........................................................4

Controls

Time and temperature control to heating ............. 27

Time and temperature control to hot water .......... 27

Heating zone valves .............................................. n/a

TRV's ...................................................................... 10

Auto bypass ............................................................ 11

Boiler interlock ....................................................... 10

For all boilers

Flushing to BS.7593 .............................................. 12

Inhibitor .................................................................. 12

Central heating mode

Heat input ................................................to be calculated

For assistance see Technical Helpline on the back page

Page

Burner operating pressure ...... measure and record

Central heating flow temp. ...... measure and record

Central heating return temp. ... measure and record

For combination boilers only

Scale reducer ..........................................................11

Hot water mode

Heat input ...............................................................n/a

Max. operating burner pressure ............................n/a

Max. operating water pressure .............................n /a

Cold water inlet temp ............................................ n/a

Hot water outlet temp. ........................................... n/a

Water flow rate at max. setting ..............................n/a

For condensing boilers only

Condensate drain .................................................. 23

For all boilers: complete, sign & hand over to customer

For GB, to comply with Building Regulations Part L1 (Part J 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

NOTE TO THE INSTALLER:

COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

Boiler size G.C. Appliance No. PI No.

(Benchmark No.)

C24 47 348 35 87 BP 46

C28 47 348 36 87 BP 46

C32 47 348 37 87 BP 46

excel HE - Installation and Servicing

GENERAL

BOILER WATER CIRCUIT DIAGRAM

INTRODUCTION

The excel HE range of boilers are wall mounted, full sequence, automatic spark ignition, low water content, fanned flue, high efficiency, condensing, combination gas boilers.

Note. Due to the high efficiency of the boiler a plume of water

vapour will form at the terminal during operation.

Central heating (CH) and instantaneous domestic hot water (DHW) outputs are fully modulating with a maximum of :

C24 23.4kW (80,000 Btu/h)

C28 28.0kW (95,500 Btu/h)

C32 32.0kW (109,000 Btu/h)

The boilers are supplied fully assembled with DHW plate heat exchanger, diverter valve, circulating pump, pressure gauge, safety valve and CH expansion vessel.

Variable CH and DHW temperature controls are fitted on the user control.

The boiler casing is of white painted mild steel with a plastic drop down controls access door.

The boiler temperature controls are located behind the controls access door.

The main heat exchanger is made of copper, the high efficiency recuperator is made of stainless steel and the DHW plate heat exchanger is made of stainless steel.

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.

A system bypass is not required when TRV’s are fitted to ALL radiators (see Frame 5). The boiler incorporates an automatic bypass.

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).

SAFE HANDLING

This boiler may require 2 operatives to move it to its installation site, remove it from its packaging and during movement into its installation location. Manoeuvring the boiler may include the use of a sack truck and involve lifting, pushing and pulling.

Caution should be exercised during these operations.

Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered:

• Grip the boiler as described in Frame 28.

• Be physically capable.

• Use PPE as appropriate, e.g. gloves, safety footwear.

During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or the weight is light.

• 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.

OPERATION

With no demand for CH, the boiler fires only when DHW is drawn off.

When there is a demand for CH, the heating system is supplied at the selected temperature of between 38oC and 82oC, until DHW is drawn off. The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW draw-off of :

C24 9.6 l/min (2.1 GPM) at 35

C rise. C28 11.5 l/min (2.6 GPM) at 35oC rise. C32 13.1 l/min (2.9 GPM) at 35oC rise.

Note. Quoted flow rates and temperature rises are those theoretically achievable. Flow rates measured during commissioning may differ (due, for example, to resistance of domestic hot water pipe lengths and fittings or available dynamic gas pressures).

Due to system variations and seasonal temperature fluctuations DHW flow rates/temperature rise will vary, requiring adjustment at the draw off tap.

At low DHW draw-off rate the maximum temperature is limited to 65o C by the modulating gas control.

Refer also to Frame 1 - 'Boiler Water Circuit Diagram'.

LEGEND

1. DHW plate heat exchanger

2. DHW flow switch

3. DHW outlet pipe

4. Domestic cold water inlet cock

5. 3 - way diverter valve

6. Main circuit drainage cock

7. CH flow cock

8. By-pass valve

9. CH return cock

10. 3 Bar pressure relief valve

11. Gas cock

12. Expansion vessel

13. Gas valve inlet pressure tap

14. Modulating gas valve

15. Burner pressure tap

16. Flame detection electrode

17. Ignition electrodes

18. Burner

19. Combustion chamber

20. Primary heat exchanger

21. Fan

ix7410

35 36

22. Air pressure switch

23. Venturi device

24. Flue outlet pipe

25. Air intake pipe

26. Automatic air vent

27. Overheat thermostat

28. Pump

29. Pump vent plug

30. CH thermistor

31. CH flow switch

32. DHW thermistor

33. CH temperature pressure gauge

34. Recuperator

35. Sensor dry fire/condensate blockage thermistor

36. Condensate pipe

37. Collector flue condensate

7excel HE - Installation and Servicing

GENERAL

OPTIONAL EXTRA KITS

FLUING:

” Flue Extension Ducts. ('D' Pack - 1000mm long).

C24-up to 3m C28-up to 2.675m C32-up to 1.725m

” 90o Elbow Kit (60/100 dia maximum no. per installation).

C24-up to 2 elbows C28-up to 2 elbows C32-up to 1 elbow

” 45o Elbow Kit (60/100 dia maximum no. per installation).

C24-up to 2 elbows C28-up to 2 elbows C32-up to 1 elbow

” Roof Flue Kit (80/125)

C24-up to a maximum length of 16 m C28-up to a maximum length of 12 m C32- up to a maximum length of 8 m

” Roof Flue Extension Duct Kit (80/125) ” Pitched Roof Tile (for roof flue kit) ” Flat Roof Tile (For roof flue kit) ” Ridge Tile Flue Terminal (For twin flue kit) ” Adaptor (60/100 to 80/125) ” Twin Flue Kit (80/80) ” Twin Flue Kit (60/60) ” Vertical Connector (60/100) ” Vertical Outlet Flue Kit with Elbow (60/100)

C24-up to a maximum length of 5.5 m C28-up to a maximum length of 4 m C32- up to a maximum length of 2.5 m

” 80mm Extension Duct ” 60mm Extension Duct ” 90

Elbow (80mm male/female)

” 90o Elbow (60mm male/female) ” 45

Elbow (80mm male/female)

” 45o Elbow (60mm male/female) ” Flue Finishing Kit ” 90

Elbow (80/125)

” 45

Elbow (80/125)

” Slip Coupling (80mm) ” Slip Coupling (60mm) ” High Level Flue Outlet Kit

OTHER OPTION KITS:

” Mechanical Programmer (24 hour) ” Electronic Programmer (7 day) ” Condensate Pump Kit ” Siphon Kit ” Stand Off Kit ” Pre-Piping Frame 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, or in IE a competent person. 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 bye-laws 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 I.S.813 "Domestic Gas Installations", the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

Detailed recommendations are contained in the following British Standard Codes of Practice:

BS. 5440:1 Flues (for gas appliances of rated input not

exceeding 70 kW).

BS. 5440:2 Ventilation (for gas appliances of rated input not

exceeding 70 kW).

BS. 5449 Forced circulation hot water systems.

BS. 5546 Installation of gas hot water supplies for

domestic purposes (2nd Family Gases)

BS. 6798 Installation of gas fired hot water boilers of rated

input not exceeding 70 kW.

BS. 6891 Low pressure installation pipes.

Health & 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 manufacture.

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.

excel HE - Installation and Servicing

GENERAL

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 I.S. 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 enclose the boiler should be designed and constructed specially for this purpose.

An existing cupboard or compartment may be used, provided that it is modified for the purpose.

In both cases, details of essential features of cupboard / compartment design, including airing cupboard installation, are to conform to the following:

” BS 6798 (No cupboard ventilation is required - see ‘Air

Supply’ for details).

” The position selected for installation MUST allow adequate

space for servicing in front of the boiler.

” For the minimum clearances required for safety and

subsequent service, see 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.

IMPORTANT.

Installation pipes must be fitted in accordance with BS.6891. In IE refer to IS.813:2002. Pipework from the meter to the boiler MUST be of an adequate size, i.e. not less than 22mm O.D. copper or

/4" B.S.P. iron.

The complete installation MUST be tested for gas soundness and purged as described in the above code.

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 I.S. 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. Tel. + 44 (0) 01732 359 888 Tower House, Vale Rise Fax. + 44 (0) 01732 354 445 Tonbridge. Kent TN9 1TB www.tfc-group.co.uk

Ensure that the guard is fitted centrally.

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 11.

Terminal Position

Minimum Spacing

1. Directly below, above or alongside of

another openable window, air vent, or other ventilation opening. 300 mm (12")

2. Below guttering, drain pipes or soil pipes 25 mm ( 1")

3. Below eaves 25 mm (1")

4. Below balconies or a car port roof 25 mm (1")

5. From vertical drain pipes or soil pipes 150 mm (6")

6. From an internal or external corner or

to a boundary along side the terminal. 100 mm (4")

7. Above adjacent ground, roof or balcony level 300 mm (12")

8. From a surface or a boundary facing the terminal 600 mm (24")

9. From a terminal facing a terminal 1200 mm (48")

10. From an opening in a car port

(e.g. door or window) into dwelling 1200 mm (48")

11. Vertically from a terminal on the same wall 1500 mm (60")

12. Horizontally from a terminal on the wall 300 mm (12")

Vertical Terminals

13. Above the roof pitch with roof slope 300 mm (12") of all angles to air inlet. Above flat roof to air inlet. 300 mm (12")

14. From single wall face 600 mm (24") From corner walls 1000 mm (40")

Twin Flue Applications

15. Centre distance between air inlet 120mm (5") and flue outlet ducts

Table 4

9excel HE - Installation and Servicing

GENERAL

450 (17 1/2")

331 (13")

119 (4 3/4")

800

(31

/2")

320 (12 5/8")

177 (7")

Flue terminal

Gas Inlet

CH Return

ondensate

Drain

DHW Inlet

DHW Outlet

Pressure Relief Outlet

CH Flow

ix7378

10 (3/8")

470 (18 1/2")

/8")35(13/8")53(21/8")65(25/8")60(21/2")

10 (3/8")

35 (1

/8")

109

/4")

200 (8") **

100 (4")*

from case

/2")

of water & gas connections

condensate

drain

BOILER DIMENSIONS, SERVICES & CLEARANCES

all dimensions in mm (in)

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").

Front clearance

The minimum front clearance when built in to a cupboard is 5mm (1/4") from the cupboard door but 450mm (17 3/4") overall clearance is still required, with the cupboard door open, to allow for servicing.

* Bottom clearance

Bottom clearance after installation can be reduced to 5mm. However, 100mm must be available for servicing.

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 b. 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.

SIDE FLUE ONLY **

Horizontal length of flue Top clearance

from boiler to required (MIN.)

outside wall Dim. A

C24 C28 C32

0.5 m 0.5 m 0.5 m 200 mm (7 7/8 ")

1.0 m 1.0 m 1.0 m 200 mm (7 7/8")

1.5 m 1.5 m 1.5 m 230 mm (9")

2.0 m 2.0 m 1.725 m 250 mm (9 13/16")

2.5 m 2.5 m N/A 260 mm (10 1/4")

3.0 m 2.675 m N/A 280 mm (11")

REAR FLUE ONLY **

MIN. Top clearance required = 200 mm (8")

excel HE - Installation and Servicing

GENERAL

General

1. The installation must comply with all relevant national and

local regulations.

2. The installation should be designed to work with flow temperatures of up to 82

3. All components of the system must be suitable for a working pressure of 3 bar and temperature of 110

C. 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.

b. Safety valve, with a non-adjustable preset lift pressure

of 3 bar.

c. Pressure gauge, covering a range of 0 to 4 bar.

d. A 7-litre expansion vessel, with an initial charge

pressure of 0.75 bar.

Notes

a. 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 water authority.

b. Antifreeze fluid, corrosion and scale inhibitor fluids suitable

for use with boilers having copper heat exchangers may be used in the central heating system.

Advice should be sought from a local water treatment company.

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 both 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

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 installed to ensure the boiler is switched off when there is no demand for heating or hot water.

When thermostatic radiator valves are used, the space heating temperature control over a living / dining area or hallway having a heating requirement of at least 10% of the boiler heat output should be achieved using a room thermostat, whilst other rooms are individually controlled by thermostatic radiator valves.

ELECTRICAL SUPPLY

WARNING.

This appliance must be earthed. Wiring external to the appliance MUST be in accordance with the current I.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.

CONDENSATE DRAIN Refer to Frame 27

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 boiler is standard 21.5mm (3/4”) overflow pipe.

SYSTEM REQUIREMENTS - Central Heating

Safety valve setting bar 3.0

Vessel charge pressure b ar 0.5 to 0.75

System pre-charge pressure ba r None 1. 0

System volume Expansion vessel

(litres) volume (litres)

25 1.6 1.8 50 3.1 3.7

75 4.7 5.5 100 6.3 7.4 125 7.8 9.2 150 9.4 11.0 175 10.9 12.9 190 11.9 14.0 200 12.5 14.7 250 15.6 18.4 300 18.8 22.1

For other system volumes multiply by the factor across 0.063 0.074

4. 'Make-up' Water. Provision must be made for replacing

water loss from the system, either :

a. From a manually filled 'make-up' vessel with a readily

visible water level. The vessel should be mounted at least 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.

continued . . . . . .

11excel HE - Installation and Servicing

GENERAL

CH Return

Ecl 6053

Hose unions

Mains

water supply

Temporary hose

(disconnect after filling)

Additional

stop valve

Double check valve

assembly

(

note direction of flow

)

SYSTEM REQUIREMENTS - CH (continued) and Hot Water

b. 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, 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 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. The domestic hot water service must be in accordance with

BS 5546 and BS 6700.

2. Refer to Table 1 for minimum and maximum working pressures.

3. The boilers are suitable for connection to most types of washing machine and dishwasher appliances.

4. 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.

The boiler does not need 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.

Turn up the room thermostat and adjust these lockshield valves to give boiler flow and return temperatures not more than 20

C apart.

These valves should now be left as set.

SYSTEM BALANCING

b. Hot and cold water supplies to the shower are of equal

pressure.

5. 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.

2. Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators, to give around 20oC temperature drop at each radiator.

3. Adjust the room thermostat and programmer to NORMAL settings.

Water Flow Rate and Pressure Loss

Max CH Output kW 23.4 28 32

(Btu/h) (80,000) (95,500) (109,000)

Water flow rate l/sec 0.28 0.33 0.38

(gal/min) (3.7) (4.4) (5.0)

Temp. Differential

C20 20 20

(

F) (36) (36) (36)

Head available for m .w.g. 3.3 1.5 1.1

system pump. (ft.w.g.) (10.8) (4.9) (3.6)

excel HE - Installation and Servicing

GENERAL

WATER TREATMENT

CENTRAL HEATING

The excel HE range of boilers have a copper main heat exchanger and a stainless steel high efficiency heat exchanger.

IMPORTANT. The application of any other treatment to this product may render the guarantee of Ideal Stelrad Group invalid.

Ideal Stelrad Group recommend Water Treatment in

accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems.

If water treatment is used Ideal Stelrad Group recommend only the use of 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. It is most important that the correct concentration of the

water treatment products is maintained in accordance with the manufacturers' instructions.

2. If the boiler is installed in 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.

3. In hard water areas, treatment to prevent lime scale may be necessary - however the use of artificially softened water is NOT permitted.

4. Under no circumstances should the boiler be fired before the system has been thoroughly flushed.

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 I scale reducing devices, which must be used in accordance with the manufacturers' instructions. For further information contact:

BOILER ASSEMBLY - Exploded View Legend

Fernox Manufacturing Co. Ltd Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ Tel: +44 (0) 1799 521133

Sentinel Performance Solutions The Heath Business & 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

1. Main heat Exchanger

2. Fan

5. Recuperator

6. Burner

8. Injectors

9. Detection electrode

10. Ignition electrode LH & RH

17. Safety Valve

19. Pump head

20. Divertor valve Actuator

21. Auto air vent valve

25. Casing controls door

26. Controls fascia

27. Knob potentiometer

28. Panel control cover

29. Panel control support

30. Panel user wiring cover

31. Main PCB

33. Pressure gauge

34. Lens clear

35. Expansion PCB

36. Mains switch

40. Ignition unit NAC

41. Air pressure switch

42. Panel front sealing

43. Casing LH side panel

44. Casing RH side panel

45. Casing front panel

46. Casing bottom panel

50. Gas valve

51. Condensate blockage thermistor

52. Overheat thermostat

53. Expansion vessel

56. Combustion chamber insulation

57. Thermistor waterset CH & DHW

58. Plate Heat Exchanger

INSTALLATION

excel HE - Installation and Servicing

BOILER ASSEMBLY - Exploded View

ex7484

Data Plate

Flue gas

sampling

point

User Data Plate

INSTALLATION

excel HE - Installation and Servicing

UNPACKING

The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to 775mm, rear or side flue outlet, in Pack B.

Unpack and check the contents.

Refer to Frame 10 for Unpacking.

Hardware Pack & Fittings

A Isolation ball valve - CH - 2 off

B Isolation ball valve - DHW - 1 off

C 3/4" sealing washer - 2 off

D Bulkhead elbow - 1 off

E 12mm sealing washer - 2 off

F Gas cock - 1 off

G Gas cock washer - 1 off

H Wallplug - 2 off

Pack A Contents

A The boiler

B Hardware pack and fittings

C Wall mounting plate

D These Installation & Servicing/

User’s instructions

E Wall mounting template

Pack B Contents

A Flue turret

B Flue terminal

F 1 year guarantee form

G Flue Restrictor - 1 off

24 kW - 39mm 28 kW - 43mm 32 kW - 45mm

nm7407

ix7408

J No 14x2in wood screw rd hd black - 2 off

K M5x10 pozi pan screw ZP - 1 off

L Turret clamp - 1 off

M Pressure relief valve discharge pipe - 1 off

N Pressure relief valve discharge pipe back nut - 1 off

P Pressure relief valve discharge pipe 15mm olive - 1 off

ix7429

INSTALLATION

excel HE - Installation and Servicing

PACKAGING REMOVAL

FLUE KITS Pack B - supplied as standard Pack D - optional extension kit for side flue or rear flue outlet.

Refer to 'Flue Extension Ducts'

Elbow Kit - resistance is equivalent to 1.5m length of flue pipe

45o Elbow Kit - resistance is equivalent to 1.0m length of flue pipe

Dimension X - Wall thickness. Dimension L - Wall thickness plus boiler spacing. Dimension R - Wall thickness plus boiler spacing.

DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED

For the 100mm concentric flue system

Note.

1. The flue duct MUST be inclined at 1.5 degrees to the horizontal to allow condensate to drain back into the boiler and out through the condensate drain. (Only necessary if using one or more 'D' extension duct packs)

Side

SideRear

Rear flue length

Side flue length

ix7416

450

(171/2")

25 (1")

177 (7")

119 (43/4")

Side flue length

450

(171/2")

25 (1")

331 (13")

1. Cut and remove straps.

2. Remove literature and wall

mounting template.

3. Lift off outer sleeve.

4. Lift off top tray.

5. Leave boiler in bottom tray to

protect exposed boiler connections during wall hanging.

Note. Hardware pack contained within bottom tray at back of boiler. Ensure components are withdrawn before discarding bottom tray.

ix7441

Total Flue length dimension Flue

Rear flue L.H. Side flue RH Side flue Extra packs Boiler

dim. X+177 dim. L+331 dim. R+119 required Size

Up to 775 mm Up to 775 mm Up to 775 mm none C24, C28, C32

Up to 1725 mm Up to 1725 mm Up to 1725 mm Pack D - 1 off C24, C28, C32

Up to 2675 mm Up to 2675 mm Up to 2675 mm Pack D - 2 off C24, C28

Up to 3000 mm Up to 3000 mm Up to 3000 mm Pack D - 3 off C24

INSTALLATION

excel HE - Installation and Servicing

FLUE OUTLET

305

Note. If wall thickness is greater than 305mm then dimension "H" must be reduced by the same amount and the offset may be adjusted accordingly.

60 80

See wall mounting template

ix7418

0.5

1.0

1.5

2.0

2.5

3.0

C24

C28

C32

"H" = Distance in metres from side of the boiler to the side wall

See Note

Note.

The template shows the positions of the fixing holes and the rear flue outlet hole centre for standard installation. Care MUST be taken to ensure the correct holes are drilled.

1. Tape template into the selected position. Ensure

squareness by hanging a plumbline as shown.

2. If fitting a side flue extend the flue centre line onto

the side wall and measure in 175mm for standard installation.

Note. If using stand-off kit distance increases to 211mm.

WALL MOUNTING TEMPLATE

FLUE ASSEMBLY - Exploded View

An optional flue duct extension kit is required for wall thicknesses greater than :

LH Side 420mm (161/2")

RH Side 630mm (243/4")

Rear 600mm (235/8")

Rear flue arrangement shown

LEGEND

1. Flue Elbow.

2. Flue Assembly.

3. Flue Restrictor.

4. M5 x 10 pozi pan screw.

5. Turret Clamp.

3. 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).

Note. Mark the centre of the hole as well

as the circumference

4. Remove the template from the wall.

ix7430

IMPORTANT. DO NOT fit flue restrictor if flue length is greater than 775 mm ('B' Pack).

ix7417

WA LL M OUNTING

TEMPLATE

175mm

Extended centre line

INSTALLATION

excel HE - Installation and Servicing

FLUE OUTLET

PREPARING THE WALL

IMPORTANT.

Ensure that, during the cutting operation, masonry falling outside of the building does not cause damage or personal injury.

1. Cut the flue hole (preferably with a 5" core boring tool), ensuring that the hole is square to the wall. Both wall faces immediately around the cut hole should be flat.

CUTTING THE FLUE - REAR Wall thicknesses of 114 to 600mm

Notes.

a. If using the extension ducts go to Frame 17, 18 and 19.

b. If the stand-off frame is used it is essential add 33mm to

'X' the measured wall thickness when marking the flue (this will allow for the fitted frame).

1. Measure and note wall thickness X. Refer to Frame 11.

2. Add 105mm (4 1/8") to dimension X and, measuring from

the ring, cut both outer and inner tube. Ensure support spring clip is in position to facilitate cutting.

3. To ensure the tube is cut square, mark the flue all the way around.

CUTTING THE FLUE - LH OR TO RH SIDE

Wall thicknesses of 114 to 420mm LH side or to 630mm RH side

Note. If using the extension ducts go to Frame 17,

18 and 19.

1. Measure and note side flue length L or R. Refer to Frame 11.

2. Add 284mm (11 3/16") to dimension L or 72mm (2 13/16") to dimension R and, measuring from the ring, cut both outer and inner tube. Ensure support spring clip is in position to facilitate cutting.

3. To ensure the tube is cut square, mark the flue all the way around.

7419

Section through wall

Note. Check all of the hole positions before drilling.

Side flue only 5" diameter hole

Rear flue only 5" diameter hole

cla7841

INSTALLATION

excel HE - Installation and Servicing

FLUE OUTLET

1. A maximum of 2 extension ducts for the C24/ C28 and a maximum of 1 extension duct for the C32 (one suitably cut) plus the standard flue duct may be used together.

2. Flue extensions of greater length than 1m (39") should be supported with the bracket provided, suitably adjusted. Refer to Frame 17.

FLUE EXTENSION DUCTS - continued

1. Fit the inner flue extension duct onto the

inner flue duct.

2. Fit the outer flue extension duct onto the outer air duct.

3. Repeat steps 1 and 2 if a second flue extension is required.

4. Measure and mark the flue length required onto the flue, measuring from the ring near the terminal. (Refer to Frames 11 and 16 for the detail of flue length calculation.)

5. To ensure a square cut, mark the flue all the way around.

6. De-burr the cut edges.

FITTING THE KIT

FLUE EXTENSION DUCTS - For flue lengths greater than 775mm

Pack D Flue extension duct kit contents

Note. Side flue shown

General arrangement

Use a maximum of 3m extended flue ONLY (C24)

Use a maximum of 2.675m extended flue ONLY (C28)

ex7786

(R or L)

Use a maximum of 1.725m extended flue ONLY (C32)

Measure from

this RING

mxhe7843

Flue duct support

Wall plugs - 2 off

Washers - 2 off

Extension duct & clamp

1.0m (39") long

Support fixing screws - 2 off

Clamp screws - 2 off

ix7411

INSTALLATION

excel HE - Installation and Servicing

FLUE OUTLET

ex7534

FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched)

Note.

A flat or pitched roof flashing plate (not supplied) is required before proceeding with the installation of this kit.

This kit is suitable for both flat and pitched roof terminations, using a concentric flue to run vertically from the top of the boiler and terminating above roof level.

Connection to the top of the boiler is made using 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

- 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 23, Flue Arrangement.

ROOF FLUE KIT CONTENTS / OPTIONS

A. Flue assembly with terminal

B. Flue seal collar

C. 3,5x13 screw

D. Pitched roof tile/flat roof tile

weather collar

E. Vertical connector (60/100)

F. Retention flange/screw

G. Adaptor (60/100 to 80/125)

H. Roof flue extension duct kit

(80/125)

I. 90

elbow kit (80/125)

J. 45o elbow kit (80/125)

Note. Items D, E, G, H, I and J are not supplied with the roof flue kit.

ix7467

INSTALLATION

excel HE - Installation and Servicing

FLUE OUTLET

80/125

Part No. Description Quantity

C24 C28 C32

n/a Maximum Flue Length (m) 16 12 8

201 548 Flue ext. 80/125 15 11 7

201 547 Terminal Vertical Roof 80/125 1 1 1

158 431 Weather Collar Pitched Roof 1 1 1

158 432 Weather Collar Flat Roof 1 1 1

201 550 90o Elbow kit (80/125) 4 4 4

201 551 45o Elbow kit (80/125) 4 4 4

201 184 Vertical Connector 1 1 1

201 549 Adaptor (60/100 - 80/125) 1 1 1

FLUE TERMINAL POSITION

610 mm

min.

ex7531

610 mm

min.

ex8389

*Flat Roof - 600mm

The terminal should be positioned so that products of combustion can safely disperse at all times.

Pluming may occur at the termination so, where possible, terminal positions where this could cause a nuisance should be avoided.

Minimum dimensions are shown below

FLUE ARRANGEMENT

Note.

The equivalent flue length resistance of the 90o elbow kit (80/125) is 1.5m and the 45o elbow kit (80/125) is 1.0m.

Terminal Position Minimum Dimension

Directly below an opening,

air brick, windows, etc. 300 mm

Below plastic / painted gutters 300 mm

Painted surface 300 mm

Below eaves or balcony 500 mm

INSTALLATION

excel HE - Installation and Servicing

FLUE OUTLET

ASSEMBLING THE ROOF FLUE KIT

Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied. (Refer to No. 6 below)

Ensure the cut pipe ends are free from any burrs.

1. Ensure the flue seal collar B is located onto the flue assembly A.

2. Position the roof flashing plate D (supplied separately) over the hole cut in the roof and insert flue assembly A from the roof end.

3. Push fit the vertical connector E (supplied seperately) into the boiler flue connection and retain with the retention flange F (supplied with the boiler) and securing screw. ENSURING

THE GASKETS IN THE BOILER FLUE OUTLET ARE CORRECTLY FI TTED.

4. "Push" fit the 60/100 to 80/125 adaptor G (supplied separately) into the vertical connector.

5. "Push" fit extension duct H (if required (supplied separately)) and the roof flue kit assembly A into the adaptor G.

6. If the last extension duct requires cutting, measure the distance (outer ducts) between the duct and the terminal and add 100 mm to this dimension. This gives the length of the last extension duct.

Note. Check the position of the inner flue duct relative to the outer duct on the assembled extension duct(s) and ensure the terminal flue duct is cut longer than the air duct to ensure engagement in the final flue duct seal.

7. Slide down and position the flue seal collar B over the roof plate D and secure it with the 3 screws C to the flue assembly A.

8. Finally ensure the roof flashing plate D is correctly sealed to the roof.

7469

ix7474

ix7472

Ø 60

Ø 100

7468

min 16

max 41

MAX LENGTH:

C24 - 16 m C28 - 12 m

C32 - 8 m

7470

ix7473

ex7533

INSTALLATION

excel HE - Installation and Servicing

FLUE OUTLET

FITTING THE OPTIONAL FLUE FINISHING KIT

Contents:

Outer wall sealing plate - 1off Inner rubber wall seal (White) - 1 off Outer rubber wall seal (black) - 1 off Wall plugs - 4 off Screws No. 10x2" - 4 off

1. Fit black outer wall seal over terminal and ensure the retaining rim is located in the terminal depression.

2. Fit flue pipe assembly through the hole previously cut in wall.

3. Fit white inner wall seal and push up to inner wall.

4. Fit turret to boiler (see Frame 30) and to the flue pipe assembly.

5. Fit outer wall sealing plate over outer wall seal and retain with the 4 screws and wall plugs provided.

ix7475

INSTALLATION

excel HE - Installation and Servicing

FITTING THE WALL MOUNTING PLATE

Fit the wall mounting plate either:

a. Directly to the wall

””

” Insert wall plugs.

””

” Put the screws into the wall plugs and leave 10mm

proud

””

” Hang the frame onto the screws (take care to use the

same hole position from each group as previously chosen with the wall template) and tighten up.

b. If using optional Stand-Off Frame or Pre-Piping Frame,

refer to instructions provided with kit.

CONDENSATE DRAIN

Refer also to the British Gas document: 'Guidance Notes for the Installation of Domestic Gas Condensing Boilers' (1989).

The boiler comes with an integral 100mm condensate trap. The boiler condensate drain must be connected to a drainage point, preferably within the building. This condensate drainage should be run in standard 21.5mm overflow pipe. Before fitting drain pipe remove plastic plug from connection. Connection to the boiler is by push fit into the rubber collar protruding from the boiler.

Ensure that the condensate trap is full of water before commissioning the boiler . Refer to Frame

30.

The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler, throughout its length.

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 or a condensate removal pump (both available as an option) 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.

The drain outlet on the boiler is standard 21.5mm overflow pipe. This size must not be reduced in any part of its length.

Wall plug

Screw

(10mm proud)

ix7428

ix77413

Condensate

drain

Side ViewFront View

25 mm

INSTALLATION

excel HE - Installation and Servicing

ix7443

flow

DHW

Outlet

Gas

DHW

Inlet

return

MOUNTING THE BOILER

CONNECTING THE FLUE TO THE BOILER

Note. Before fitting the flue turret fill the condensate trap or siphon 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.

IMPORTANT. DO NOT fit flue restrictor if flue length is greater than 775 mm ('B' Pack).

1. "Push" fit the flue restrictor (if necessary) into centre of plastic flue outlet. Refer to Frame 12.

2. Insert the flue assembly through the prepared hole in the wall.

3. Locate the flue turret on the top of the boiler. CHECK THAT THE FLUE SEAL LOCATED IN THE TOP OF THE F LUE MANIFOLD IS SECURE AND GIVING AN EFFECTIVE SEAL.

4. Locate the flue into the turret and push to ensure full engagement.

5. 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.

6. Flues over 1 metre long.

Fix the flue support bracket to the wall, using the 2 wall plugs and wood screws.

ix7431

CONNECTIONS - CH, DHW AND GAS

Notes.

1. Central Heating

For heating loads in excess of 60,000 Btu/h use 28mm x 22mm connectors to connect the boiler flow and return pipes to 28mm system pipework.

Flue Restrictor

ex7953

2. Central Heating, Domestic Hot Water and Gas

Do not subject any of the isolating valves to heat as the seals may be damaged.

3. Gas

Refer to Frame 2 for details of the gas connection position.

INSTALLATION

Note. The boiler may require two men to lift it onto the wall

mounting plate.

1. Lift the boiler by the packaging base onto the plate,

locating it over the tabs at the top of the bracket. Ensure the boiler is correctly retained on the wall mounting plate tabs. Remove packaging base.

Note. If side clearance is limited, the packaging base can be removed prior to lifting.

2. Ensure the plastic plugs are removed from both the CH

and DHW Connections. N.B. Some spillage of water may occur from the connections when mounting the boiler onto the wall plate.

3. Fit the two 22mm CH isolating ball valves to the two

CH connections on the boiler using the two 22mm washers provided.

4. Fit the 15mm isolating ball valve to the DHW inlet

connection on the boiler using the 12mm washer provided.

5. Fit the 15mm bulkhead elbow to the DHW outlet

connection on the boiler using the 12mm washer provided.

6. Fit the 15mm gas cock to the gas connection on the

boiler using the gas cock seal provided.

INSTALLATION

excel HE - Installation and Servicing

FILLING

Central Heating

1. Remove the front, RH side and bottom cover

panels. See Frames 44, 45 and 46.

2. Ensure the CH isolating valves are open.

3. Open the stopcock at the filling point connection

to the CH system until water is heard to flow.

4. Open each radiator vent starting at the lowest point of the system and fully fill and vent the system.

5. Bleed air from the pump and ensure it is free to rotate.

A. Remove the pump vent plug

B. Using a screwdriver, rotate the shaft

several times

C. Replace the pump vent plug.

Note. Some slight water leakage will occur.

Ensure control box wiring is protected.

6. Ensure the pressure indicated on the pressure gauge is between 1 and 1.5 bar.

Domestic Hot Water

1. Close all hot water draw off taps.

2. Open the cold water inlet valve.

3. Slowly open each draw off tap and close only

when clear and air bubble free water flows out.

The pressure relief valve is located at the bottom LHS of the boiler.

Remove front panel. See Frame 44.

The pressure relief pipe (to be found in the hardware pack) must be fitted to the pressure relief valve and sealed with the olive and back nut provided. Ensure the pipe is extended 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.

PRESSURE RELIEF VALVE DRAIN PIPE

INSTALLATION

ix7435

Pressure

relief pipe

Nut

Olive

ix7447

INSTALLATION

excel HE - Installation and Servicing

ELECTRICAL CONNECTIONS

For Ireland reference should be made to the current ETCI rules for electrical installations.

The supply connection is intended to be made via a double pole switch having a 3mm (1/8") contact separation in both poles, serving only the boiler and system controls.

The fuse rating should be 3A.

WARNING. This appliance MUST be earthed.

A mains supply of 230 V ~ 50 Hz is required.

Mains wiring should be 3 core PVC insulated flexible cord NOT LESS than 0.75mm

(24x0.2mm) and to BS. 6500, Table

16. (0.5mm2 flex is not acceptable - for mechanical, not electrical reasons.)

Mains wiring external to the boiler MUST be in accordance with the current I.E.E. (BS7671) Wiring Regulations and any local regulations.

INTERNAL WIRING

INCOMING MAINS WIRING DETAIL

To gain access to the power supply and external controls terminal block:

1. Remove the screws and the cover panel.

2. Remove the control box fixing screws.

3. Pull the control panel forward.

4. Remove the screws and the service panel.

Mains

ix7421

Link

LEGEND

L Live N Neutral

Earth F1 Frost Stat Switched Live F2 Frost Live Feed R1 Room Stat Switched Live R2 Room Live Feed R3 Programmer Common SWL

Note. Ensure that the lengths of the current conductors are shorter than the earth conductor so that if the cable slips in its anchorage the current carrying conductors become taut before the earth conductor.

Service

panel

ex7787

ix7424

INSTALLATION

excel HE - Installation and Servicing

EXTERNAL ELECTRICAL CONTROLS

WARNING. When the boiler is powered

'ON' mains voltage is present on terminals "F2" and "R2". PLEASE TAKE CARE.

Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS. 7671) Wiring Regulations.

For Ireland reference should be made to the current ETCI rules for electrical installation.

The controls internal fuse is a 2A fast blow 250V rated.

Lock the flexible cords in place with the clamps provided.

ELECTRICAL CONNECTIONS FOR A COMBI BOILER

Optional Programmer Kit

An optional 7 day digital programmer or 24hr mechanical programmer kit is available with its relevant instructions.

Room Thermostat

This should be wired as shown in diagram A.

Frost Protection

excel HE appliances are provided with a built in

anti-freeze system that operates the boiler when the temperature is below 5

C. Internal frost protection operates regardless of the position of the main switch and CH heating thermostat knob (B). Therefore, when the boiler is not lit and used in cold weather, with consequent risk of freezing, the supply to the boiler should be left switched on.

Central heating systems fitted wholly inside the house do not normally require frost protection as the house acts as a 'storage heater' and can normally be left at least 24 hours without frost damage.

However, 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.

To maintain frost protection with the programmer selector switches set to OFF, the mains supply and the boiler panel 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.

Wiring should be as shown, with minimal disturbance to other wiring.

External Programmers

This should be of the single channel type (as this boiler does not incorporate a pre-heat facility for the instantaneous hot water service).

Programmers with room thermostat - see diagram B.

ex9042

Optional

Frost Stat

Room

Stat

R2 and R3 connections are used for

the room stat when in conjunction

with integral programmer kit.

A No Programmer

ix7423

Optional

Frost Stat

Room

Stat

External

Programmer

B External Programmer

Earths are not shown for clarity but must never be omitted.

Note. These diagrams are schematic only and do not show external terminal strips etc.

INSTALLATION

excel HE - Installation and Servicing

PICTORIAL WIRING DIAGRAM

LEGEND

b-blue

bk - black

br - brown

gr - grey

or - orange

pk - pink

r-red

v-violet

w-white

y-yellow

g/y - green/yellow

ex8420

123456

1011

1213 14 1516

4445 46 47

5455 56

PCB1

BIC 580

12345

678

91011

1314 1516 17 18 19

20 21 22

PCB2

Terminal

Strip

Exp. Board

Earth

Fan 1 AC Fan, Single speed

NC3NO

Air Pressure Switch

Interference

suppressor

Detection Electrode

Ignition Electrode

Ignition

Electrode

NAC1

Ignitor/Gas Valve I/F

Overheat

Stat

Condensate

Blockage

Thermistor

1 2 3

AC Pump

6 7

1345

SIT Sigma 845 Gas Valve

In-line Spade

Divertor Valve

1 2

Pump Proving

Switch

DHW

Flow Switch

Flow

Thermistor

DHW Flow

Thermistor

12345678

Switch, SPST

Controls

Earth

Chassis

Earth

Burner

Earth

345

NAC Lead

17 18 19

20 21 22 23 24

25 26 27 28

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43

bk bk bk

bk bk bk bk

www

gr gr

br b

g/y

L N E F1 F2R1R2R3

bk r

oror

brbg/y

y y

v v

wwbrbrr

br bk b

or or r

4950 51 5253

INSTALLATION

excel HE - Installation and Servicing

FUNCTIONAL FLOW WIRING DIAGRAM

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.

A. Electrical Installation

1. Checks to ensure electrical safety should be carried out by a competent person.

2. ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit,

using a suitable test meter.

B. Gas Installation

1. The whole of the gas installation, including the meter, should be inspected and tested for soundness and purged in

accordance with the recommendations of BS. 6891. In IE refer to IS.813:2002.

2. Purge air from the gas installation by the approved methods only.

C. Flue Sealing

1. Check the integrity of the flue outlet and air inlet system to the boiler ensuring no leaks are evident from piping joints or flue/air

sampling points.

COMMISSIONING AND TESTING

LEGEND b-blue bk - black br - brown

gr - grey or - orange pk - pink r-red

v-violet w-white y-yellow g/y - green/yellow

DV Live 1 DV Live 2

DV Neutral

Pump Live

Pump Neutral

Pump Earth

Mod+

Mod-

GV + IGN Live

IGN Neutral

GV Neutral GV Neutral

GV Earth

APS APS

Fan Neutral

Fan Live

Analog input

24V

321

Control

OH OH

Flow Flow

DHW Temperature DHW Temperature

PPS PPS

DHW Flow DHW Flow

Ionisation

Burner PE Chassis PE

Supply Earth

R2 - SWL R1/F1 - Live feed F2 - Frost SWL Supply Neutral Supply Live

Fan Earth

BIC 580

Fan live in

Analogue out 24V 5V

Fan live 1 Fan live 2

Fume 1 Fume 2

Expansion Board

12345678

Terminal Strip

Earth

Fan2

AC Fan, Single speed

2NC3

Air

Pressure

Swirch

Divertor Valve

Detection Electrode

Ignition

Electrode

Ignition

Electrode

In line spade

Ignitor/Gas Valve I/F

Overheat

Stat

1 2 3

AC Pump

SIT Sigma 845 Gas Valve

Switch, SPST

DHW Thermistor

Flow Thermistor

Pump Proving Switch

DHW Flow Switch

Controls Earth

Chassis

Earth

Burner

Earth

Condensate Blockage Thermistor

ex7463

Interference

suppressor

rr bb

oror

g/y

b br

g/y

bk bk bk bk

w w w ww

w w

br r

g/y

NAC

lead

g/y

br b

g/y

br b

br bk b

INSTALLATION

excel HE - Installation and Servicing

ix7436

Gas Valve

INITIAL LIGHTING

1. Check that the system has been filled and that the boiler is

not airlocked. Ensure the automatic air vent cap (H) 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 RHS panel. Refer to Frame 45.

3. Replace control panel and secure with fixing screws.

4. Check that all the drain cocks are closed and that the CH

and DHW isolating valves (T, P and N) are OPEN.

5. Check that the electrical supply is OFF.

6. Check that the boiler on/off switch (A) is off.

7. Check that the gas service cock (R) is OPEN.

8. Slacken the screw in the inlet pressure test point (M) and

connect a gas pressure gauge via a flexible tube.

9. Slacken the screw in the burner pressure test point (J) and connect a gas pressure gauge via a flexible tube.

LEGEND A. Boiler On/Off switch. B. Main switch & CH thermostat knob. C. DHW thermostat knob D. Pressure gauge E. Operational lights (1 & 3) / Fault

indication light (2)

F. Optional programmer

10. Switch the electricity supply ON and check all external

controls are calling for heat.

11. CENTRAL HEATING

Set the main switch and CH thermostat knob (B) to position shown in diagram and switch the boiler on/off switch (A) to ON. The boiler control should now go through its ignition sequence until the burner is established. Green operational light 1 (E) will be illuminated when burner is lit.

12. If the boiler fails to light up to five times during the ignition sequence, the boiler will go to lockout and red operational light 2 (E) will be illuminated. To reset the ignition sequence turn the main switch (B) to '0' wait until the boiler reaches standby state, indicated by no fan or pump running (this can take up to 10 minutes in an overheat condition). Turn the main switch (B) to the winter setting, wait for 2 seconds then set the main switch (B) back to the desired position.

continued....................

G. Condensate drain H. Automatic air vent J. Burner pressure test point K. CH max. pressure

adjustment nut

L. DHW min. pressure

adjustment screw

if77434

Winter

Summer

Condensate

Drain

M. Gas inlet pressure test point N. CH return isolating valve P. DHW inlet isolating valve R. Gas service cock S. DHW flow T. CH flow isolating valve U. Gas valve electrical connectors

INSTALLATION

excel HE - Installation and Servicing

GENERAL CHECKS

Make the following checks for correct operation:

1. Hot water

a. Fully open all DHW taps in turn and ensure that water

flows freely from them.

b. Close all taps except the furthest one from the boiler

and check that the boiler is firing at maximum rate.

c. Ensure that DHW temperature rise of approximately

40oC is obtained at the tap. This corresponds to a flow rate of approximately:

8.4 (1.8) l/min (gpm) excel HE C24 10 (2.2) l/min (gpm) excel HE C28

11.5 (2.6) l/min (gpm) excel HE C32

Note. Quoted flow rates and temperature rises are those theoretically achievable. Flow rates measured during commissioning may differ (due, for example, to resistance of domestic hot water pipe lengths and fittings or available dynamic gas pressures).

If necessary reduce the flow rate using isolation valve 'S'. Refer to Frame 39.

d. Turn off the DHW tap.

2. Central heating

Operate each control separately and check that the main burner or circulating pump, as the case may be, responds.

3. Gas rate

Check the boiler gas rate when the boiler is at full output. The gas rate will normally be

45.8 (1.62) litres/min (ft

/min) for the model excel HE C24

53.5 (1.89) litres/min (ft3/min) for the model excel HE C28

62.1 (2.19) litres/min (ft3/min) for the model excel HE C32

checked at the gas meter, with no other appliance in use.

If this check is not possible, ensure that the burner pressure is:

13.4 (5.3) mbar (in. w.g.) for the model excel HE C24

10.5 (4.2) mbar (in. w.g.) for the model excel HE C28

12.9 (5.2) mbar (in. w.g.) for the model excel HE C32

In addition ensure the dynamic inlet pressure is 20mb.

4. Water circulation system. Refer to frame 6.

Note. A suitable flushing solution should be used during

the flushing procedure.

a. With the system HOT examine all water connections

for soundness.

b. With the system still HOT, turn off the gas, water and

electricity supplies to the boiler and drain down, to complete the flushing process.

c. Refill the system, adding inhibitor (see 'Water

Treatment'), if required. Refer to Frame 10

d. Balance the system. It is suggested that, initially, all

radiator handwheel valves (or TRVs if fitted) be set fully open, that all lockshield valves be set a half-turn open.

Make minor adjustments to each radiator to achieve the same differential on all.

Finally, set the system controls to the users requirements.

If an optional programmer kit is fitted refer to the instructions supplied.

INITIAL LIGHTING . . . . . CONTINUED

13. DOMESTIC HOT WATER

With the boiler firing, set the DHW thermostat knob (C) to maximum and fully open a DHW tap. The boiler should continue to run and provide hot water at the open tap. Green operational lights 1 and 3 (E) will be illuminated when burner is lit.

14. Turn off the tap.

15. Test for gas soundness around ALL boiler gas

components using leak detection fluid.

16. Operate for 10 minutes to stabilise the burner temperature.

17. The boiler is preset at the factory to its maximum output.

Check the burner pressures against the values quoted in Table 2 (page 4) by using the following procedure.

i. Remove plastic protective cap from the mechanical

pressure adjustment components (L&K).

ii. Start the boiler at its maximum power. Operate the

boiler in DHW mode or ensure that the boiler is not range rated if the test is carried out in CH mode.

Maximum valve setting - CH & DHW

Note.

The minimum CH pressure is automatically set electronically.

iii. If necessary, rotate the maximum gas pressure

brass hexagon nut adjustment (K) using a spanner until you obtain the required pressure as indicated on Table 2 (page 4) (burner pressure). By rotating clockwise the pressure increases.

Minimum valve setting - DHW Only

iv. Disconnect one of the two connectors (U).

v. If necessary, rotate the minimum gas pressure

adjustment (red cross point screw) (L) until you obtain the required pressure as indicated on Table 3 (page 4) (burner pressure). By rotating clockwise the pressure increases.

vi. Turn the boiler off and re-connect the wire to the

modulating operator (U).

vii. Start the boiler and check again the maximum gas

pressure setting.

viii. Turn the boiler off and disconnect the inlet and burner

pressure gauges and close the gas valve inlet and outlet pressure test points (J & M).

IMPORTANT.

After the gas pressure checks and any adjustment operations, all of the test points must be sealed and leak tested.

18. Refit the front panel and bottom panel.

INSTALLATION

SERVICING

excel HE - Installation and Servicing

SERVICING SCHEDULE

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. Check the gas consumption.

3. Connect a suitable gas analyser to the sampling point on

the top of the boiler 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. If this is the case, and the gas input is at least 90% of the nominal, then no further action need be taken. If not, proceed to Step 5.

4. Clean the main burner.

5. Clean the heat exchanger.

6. Check the condition of the combustion chamber insulation.

Any cracked or damaged pieces should be replaced.

7. Check the main injectors for blockage or damage.

8. Check that the flue terminal is unobstructed and that the

flue system is sealed correctly.

The servicing procedures are covered more fully in Frames 40 and 41 and MUST be carried out in sequence.

Note. In order to carry out either servicing or replacement of

components the boiler front panel and sealing panel must be removed. Refer to Frames 44 and 45.

WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing.

IMPORTANT.

9. After completing the servicing or exchange of components

always test for gas soundness and carry out functional checks in 3 and 4 above.

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.

12. Complete the service section of the Benchmark Commissioning Checklist.

HANDING OVER

6. Explain and demonstrate the function of time and

temperature controls, radiator valves etc., for the economic use of the system.

7. If a programmer is fitted draw attention to the Programmer Users Instructions and hand them to the householder.

8. Loss of system water pressure

Explain that the dial on the boiler control panel 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. In this event 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.

9. After installation and commissioning please complete the

commissioning Checklist before handover to

the customer. For IE it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 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.

11. 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 this boiler.

1. Hand the User Instructions to the householder and explain his/her responsibilities under the relevant national regulations.

2. Explain and demonstrate the lighting and shutting down procedures.

3. 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.

4. Explain the function and the use of the boiler heating and domestic hot water controls.

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”.

5. 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.

After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions:

SERVICING

excel HE - Installation and Servicing

ix7445

BOILER SIDE PANEL AND SEALING PANEL REMOVAL

BOILER FRONT PANEL REMOVAL

1. Remove the 2 fixing screws from the top

of the front panel.

2. Lift the front panel upwards and forward at the bottom to remove.

1. Slacken the 2 top and 2 bottom fixing screws from the LH and RH side panels and remove the panels.

2. To remove the sealing panel remove the 4 fixing screws from the front.

3. Remove the sealing panel by pulling forward to disengage rear clips.

4. Remove the fixing screws retaining the inner sealing panel and remove the panel taking care not to damage the front insulation panel.

ix7444

SERVICING

excel HE - Installation and Servicing

1. Remove the screw on the fan mounting bracket.

2. Carefully pull fan from the recuperator sealing gasket. Check the gasket for damage and replace if necessary.

3. Disconnect the electrical leads from the fan.

4. Disconnect APS sensing tube.

5. Inspect venturi and fan and clean as

necessary.

6. Reassemble in reverse order.

THE CONTROL BOX IN THE SERVICING POSITION

1. Remove the screws and the cover panel.

2. Remove the control box fixing screws.

3. Pull the control panel forward.

4. Remove the control box lid fixing screws and

remove lid.

ix7424

FAN AND VENTURI REMOVAL AND CLEANING

ix7426

SERVICING

excel HE - Installation and Servicing

BURNER REMOVAL AND CLEANING

CLEANING THE HEAT EXCHANGER

1. Carefully separate the detection lead in-line

connector.

2. Carefully pull off the two ignition leads from the

side of the PCB ignition unit.

3. Carefully pull the 3 leads through the rubber

sealing grommets.

4. Remove the earth lead and 4 burner fixing screws

and carefully withdraw the burner unit.

5. Inspect the burner and clean as necessary.

Note. Brushes with metallic bristles should not be

used.

6. Inspect all injectors for blockage or damage if

necessary.

7. Inspect the three electrodes/leads for damage

and check the spark gap is 3-5mm between the pair of ignition electrodes (centre and RH side).

1. Using a suitable tool as supplied in the standard

British Gas Flue brush kit, clean between the heat exchanger fins.

2. Access to the base of the combustion chamber is now

possible. Brush clean any deposits from the base of the combustion chamber and remove any loose deposits.

3. Check the condition of the combustion chamber

insulation. Any cracked or damaged pieces should be replaced.

RE-ASSEMBLY

1. Refit the burner assembly and earth tab.

2. Reconnect ignition and detection leads.

3. Reconnect the fan electrical leads.

4. Refit the fan / venturi assembly.

5. Refit the boiler sealing panel.

IMPORTANT

Ensure that the boiler sealing panel is correctly fitted and that a good seal is made.

6. Refit the control box cover.

7. Push the control box back into its working

position and secure.

8. Refit the boiler front and bottom panels.

9. Turn on the gas supply at the gas service cock.

10. Reconnect the electrical supply.

SERVICING

3-5mm

SERVICING

excel HE - Installation and Servicing

REPLACEMENT OF COMPONENTS

GENERAL

When replacing ANY component

1. Isolate the electricity supply.

2. Turn off the gas supply.

3. Remove the boiler front panel. Refer to Frame 38.

After replacing ANY component check operation of the boiler, including gas soundness, gas rate and combustion test.

IMPORTANT.

When work is complete, the sealing panel, if removed, must be correctly refitted - ensuring that a good seal is made.

Notes.

1. In order to assist fault finding, the control panel has an LED diagnostic display. The key to boiler fault conditions is shown in Frame 79.

2. In order to replace components in Frames 68-78 it is necessary to drain the boiler. Refer to Frame 67.

THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED

CONDENSATE BLOCKAGE THERMISTOR REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45.

3. Carefully pull off the green electrical connection.

4. Unscrew the condensate blockage thermistor.

5. Fit new condensate blockage thermistor complete with new washer.

6. Re-assemble in reverse order.

7. Check the operation of the boiler. Refer to

Frame 50 and 51.

FAN AND FAN SUPPRESSOR REPLACEMENT

FAN

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45.

3. Remove the fan mounting fixing screw.

4. Pull fan from the recuperator sealing gasket.

5. Disconnect electrical leads from the fan.

6. Pull plastic sensing pipe from venturi

connection.

7. Reconnect the fan electrical connections and fit the new fan in reverse order ensuring the plastic venturi pipe is replaced.

8. Re-assemble the boiler in reverse order.

9. Check the operation of the boiler. Refer to

Frame 50 and 51.

Fan Suppressor

1. As 1-5 above.

2. Pull off fan suppressor.

SERVICING

5,7

6,7

SERVICING

excel HE - Installation and Servicing

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing panels. Refer to

Frames 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Carefully separate the in-line connector from the detection lead.

4. Carefully pull off the two ignition leads from the side of the

ignition unit.

5. Carefully pull the three leads through the rubber sealing grommets.

6. Remove the earth lead and the four burner fixing screws and carefully withdraw the burner unit.

7. Unscrew each injector from the manifold.

8. Fit new injectors using new

copper washers provided.

9. Re-assemble in reverse order.

10. Check the operation of the boiler. Refer to Frame 50 and 51.

BURNER INJECTOR REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing panels. Refer

to Frames 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Carefully separate the in-line connector from the detection lead.

4. Carefully pull off the two ignition leads from the side of the ignition unit.

BURNER REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing panels. Refer to Frames 44

and 45.

3. Overheat Thermostat:

a. Carefully pull off the 2 electrical connections. b. Unclip thermostat from pipe. c. Fit 2 electrical connections onto new thermostat d. Clip new thermostat onto pipe ensuring correct positioning on heat

exchanger manifold and re-assemble in reverse order.

4. UNDER NO CIRCUMSTANCES REFIT THE OVERHEAT THERMOSTAT ONTO THE COLD RECUPERATOR RETURN PIPE.

5. Check the operation of the boiler. Refer to Frame 50 and 51.

OVERHEAT THERMOSTAT REPLACEMENT

5. Carefully pull the three leads through the rubber sealing

grommets.

6. Remove the earth lead and the four burner fixing screws and carefully withdraw the burner unit

7. Fit the new burner unit.

8. Re-assemble in reverse order.

9. Check the operation of the boiler. Refer to Frame 50 and 51.

SERVICING

Injectors

SERVICING

excel HE - Installation and Servicing

IGNITION ELECTRODE REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and

sealing panels. Refer to Frames 44 and

45. Put the control box into the servicing position. Refer to Frame 46.

3. Carefully separate the in-line connector from the detection lead.

4. Carefully pull off the two ignition leads from the side of the ignition unit.

5. Carefully pull the three leads through the rubber sealing grommets.

6. Remove the earth lead and the four burner fixing screws and carefully withdraw the burner unit.

7. Remove the fixing screws from the centre and RH electrodes and carefully withdraw the two ignition electrodes.

8. Fit new ignition electrodes.

9. Re-assemble in reverse

order.

10. Check the operation of the boiler. Refer to Frame 50 and 51.

FLAME DETECTION ELECTRODE REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frames 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Carefully separate the in-line connector from the detection lead.

4. Carefully pull off the two ignition leads from the side of the ignition unit.

5. Carefully pull the three leads through the rubber sealing grommets.

6. Remove the earth lead and the four burner fixing screws and carefully withdraw the burner unit.

7. Remove the fixing screw from the LH electrode and carefully withdraw the detection electrode.

8. Fit new detection electrode.

9. Re-assemble in reverse

order.

10. Check the operation of the boiler. Refer to Frame 50 and 51.

SERVICING

excel HE - Installation and Servicing

SPARK GENERATOR REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front and side panels. Refer to Frame 44

and 45 and put the control box into the servicing position. Refer to Frame 46.

3. Carefully pull off the two ignition leads from the side of the ignition unit.

4. Remove the electrical plug from the printed circuit board.

5. Carefully pull the spark generator forward to disengage the

4 pin connection at the top of the gas control.

6. Fit the new spark generator and re-assemble in reverse order.

7. Check the operation of the boiler. Refer to Frame 50 and 51.

1. Refer to Frame 51.

2. Remove the boiler front and side

panels. Refer to Frame 44 and 45 and put the control box into the servicing position. Refer to Frame 46.

3. Remove the spark generator. See Frame

59.

4. Pull the two electrical connections from the gas control valve.

5. Undo the gas inlet pipe union at the gas service cock.

6. Undo the union nut on the outlet of the gas control valve.

7. Remove the 2 gas control valve bracket fixing screws.

8. Withdraw the valve complete with bracket, inlet and outlet pipes.

9. Transfer the bracket, inlet pipe and outlet pipe to the new gas control valve.

10. Fit the new gas control valve , taking care not to trap wiring harness between bracket and chassis, ensuring that any seals showing signs of damage or deterioration are replaced.

11. Re-fit spark generator and fully reassemble in reverse order.

12. Check the operation of the boiler , refer to Frame 50 and 51, ensuring the gas pressure is correctly set. See Frame 39 and 40

GAS CONTROL VALVE REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front and side panels. Refer to Frame 44 and 45 and

put the control box into the servicing position. Refer to Frame 46.

3. Loosen retention clip with screw driver and pull the clip from the diverter valve.

4. Remove the three electrical connections noting their position.

5. Carefully remove the actuator.

6. Fit new actuator and re-assemble in reverse order ensuring the 3 wires

are correctly replaced as shown.

7. Check the operation of the boiler. Refer to Frame 50 and 51.

DIVERTER VALVE ACTUATOR REPLACEMENT

SERVICING

Blue

Black

Brown

SERVICING

excel HE - Installation and Servicing

COMBUSTION CHAMBER INSULATION REPLACEMENT

PCB REPLACEMENT (MAIN PCB AND EXPANSION PCB)

1. Refer to Frame 51.

2. Remove burner assembly. Refer to

Frame 55.

3. Remove the two screws retaining both left and right hand combustion chamber side panels.

4. Slide the combustion chamber side panel insulation from its retention and fit new insulation panels.

5. Lift rear insulation panel from its retention and replace with new panel.

6. Remove the front panel insulation (straighten 2 top retaining clips and lift from bottom retention return) and replace with new panel.

7. Reassemble in reverse order.

8. Check the operation of the boiler. Refer

to Frame 50 and 51.

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing panels. Refer to

frame 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Carefully remove all push on connectors and earth connections (main PCB only) from the printed circuit board.

4. Remove the PCB from the five plastic supports (main PCB) or two plastic supports (expansion PCB).

5. Fit new PCB and refit all push on connectors and earth connections.

6. Reassemble in reverse order.

7. Check the operation of the boiler. Refer to Frame 56 and 51.

Note. Antistatic precautions must be observed when

handling the main or expansion PCB.

SERVICING

excel HE - Installation and Servicing

MAINS SWITCH REPLACEMENT

CH AND DHW MICROSWITCH REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Remove the two electrical connections from the mains switch.

4. Depress the plastic side retention clips and remove the mains switch from the front of the control box.

5. Fit new mains switch and replace electrical connections.

6. Check the operation of the boiler. Refer to Frame 50 and 51.

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Pull microswitch forward to disconnect from diaphragm.

4. Lift plastic retention clip and remove electrical connection.

5. Fit electrical connection to new microswitch and refit to diaphragm.

6. Re-assemble in reverse order.

7. Check the operation of the boiler. Refer to

Frame 50 and 51.

SERVICING

microswitch

DHW

microswitch

SERVICING

excel HE - Installation and Servicing

AIR PRESSURE SWITCH REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front and left hand side

panel. Refer to Frame 44 and 45.

3. Remove sensing pipe from air pressure switch.

4. Remove the two screws retaining the air pressure switch.

5. Remove electrical connections.

6. Fit new air pressure switch and refit electrical

connections and sensing pipe.

7. Re-assemble in reverse order, ensuring the sensing pipe is replaced onto the top connection marked "L".

8. Check the operation of the boiler. Refer to Frame 50 and 51.

DRAINING THE BOILER

1. Refer to Frame 51.

2. Close all the water isolating valves (CH and

DHW).

3. To drain the central heating circuit, attach a length of hose to the drain point and open the drain valve.

Note. Some residual water may be experienced during the replacement of components.

ix7442

4. 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.

Note. Some residual water may be experienced during the replacement of components.

5. 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.

6. Check the operation of the boiler. Refer to Frame 50

and 51.

SERVICING

excel HE - Installation and Servicing

PRESSURE GAUGE REPLACEMENT

SERVICING

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Unscrew the pressure gauge sensing pipe retaining nut from the pressure relief valve.

4. Remove the pressure gauge head from the control panel front by depressing the plastic retention clips.

5. Fit the new pressure gauge and reconnect the sensing head to the pressure relief valve.

6. Re-assemble in reverse order.

7. Check the operation of the boiler.

Refer to Frame 50 and 51.

CH AND DHW DIAPHRAGM REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Drain the boiler water circuit. Refer to Frame

67.

4. Pull microswitch forward to disconnect from diaphragm.

5. Using a suitable tool, remove the four torx screws retaining the diaphragm.

6. Fit the new diaphragm and refit the microswitch.

7. Re-assemble in reverse order.

8. Check the operation of the boiler. Refer to

Frame 50 and 51.

SERVICING

excel HE - Installation and Servicing

AUTOMATIC AIR VENT REPLACEMENT

SERVICING

1. Refer to Frame 51.

2. Remove the boiler front and right hand

side panel. Refer to Frame 44 and 45.

3. Pull "U" shaped retaining clip forward.

4. Drain the boiler water circuit. Refer to

Frame 67.

5. Remove automatic air vent valve.

6. Fit new automatic air vent valve.

7. Re-assemble in reverse order.

8. Check the operation of the boiler.

Refer to Frame 50 and 51.

SAFETY RELIEF VALVE REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front panel. Refer to Frame

44.

3. Drain the boiler water circuit. Refer to Frame 67.

4. Put the control box into the servicing position.

Refer to Frame 46.

5. Remove the pressure gauge sensing head from the safety relief valve.

6. Undo the safety relief valve inlet and outlet union nut connections and remove safety relief valve.

7. Fit new safety relief valve and re-connect pressure gauge sensing head.

8. Re-assemble in reverse order.

9. Check the operation of the boiler. Refer to

Frame 50 and 51.

SERVICING

excel HE - Installation and Servicing

CH THERMISTOR AND DHW THERMISTOR

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Drain the boiler water circuits. Refer to Frame 67.

4. To remove the CH thermistor (red wires) pull out the "U" shaped retaining clip.

5. To remove the DHW thermistor (blue wires) pull out the "U" shaped retaining clip.

6. Fit new thermistor and retain with "U" shaped clip.

7. Re-assemble in reverse order.

8. Refill the boiler. Refer to Frame 32.

9. Check the operation of the boiler. Refer to

Frame 50 and 51.

DIVERTER VALVE MECHANISM REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Drain the boiler water circuits. Refer to Frame 67.

4. To remove the diverter valve mechanism, pull out the "U" shaped retaining clip.

5. Fit new diverter valve mechanism and retain with "U" shaped clip.

6. Re-assemble in reverse order.

7. Refill the boiler. Refer to Frame 32.

8. Check the operation of the boiler. Refer to

Frame 50 and 51.

SERVICING

excel HE - Installation and Servicing

PUMP HEAD REPLACEMENT

DHW PLATE HEAT EXCHANGER REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Drain the boiler water circuits. Refer to Frame 67.

4. Pull out the two "U" shaped clips retaining the copper bypass pipe and remove the pipe.

5. Unscrew the two allen screws retaining the DHW plate heat exchanger and remove the heat exchanger via the space vacated by the bypass pipe.

6. Fit the new plate heat exchanger being careful not to damage the 'O' rings and retain with the two allen screws.

7. Refit the bypass pipe and retain with two "U" shaped clips.

8. Re-assemble in reverse order.

9. Refill the boiler. Refer to Frame 32.

10. Check the operation of the boiler. Refer to

Frame 50 and 51.

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing

panels. Refer to Frame 44 and 45. Put the control box into the servicing position. Refer to Frame 46.

3. Drain the boiler water circuits. Refer to Frame

67.

4. Remove the pump electrical connection.

5. Remove the four allen screws retaining the

pump head.

6. Remove the pump head.

7. Fit the new pump head.

8. Re-assemble in reverse order.

9. Refill the boiler. Refer to Frame 32.

10. Check the operation of the boiler. Refer to

Frame 50 and 51.

SERVICING

excel HE - Installation and Servicing

HEAT ENGINE REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing panels.

Refer to Frame 44 and 45.

3. Drain the boiler water circuits. Refer to Frame 67.

4. Remove the inner sealing panel.

5. Remove overheat thermostat clip from heat

exchanger right hand side.

6. Pull off heat exchanger LH side retention clip and pull pipe downwards to disengage copper pipe 'O' ring seal.

7. Pull off recuperator LH side pipe connection retention clip and pull pipe downwards to disengage 'O' ring seal.

8. Disconnect recuperator plastic drain connection from recuperator RH side.

9. Unscrew the union connection on the recuperator RH side brass outlet connection and swivel the brass piece to clear the copper pipe.

10. The heat exchanger can now be pulled forward to remove (flex the collector hood sides to clear the heat exchanger and flex the pipe connections to facilitate removal).

11. Fit the new heat exchanger and re-connect all water pipe and drain connections.

Note. Ensure the recuperator RH side brass connection and its copper pipe are correctly aligned before tightening the union nut.

EXPANSION VESSEL REPLACEMENT

If the expansion vessel is faulty, there are two

options:

A. If it has a punctured diaphragm but is

otherwise leak free then it can be left in place and a new vessel added to the return side of the CH system, external to the boiler providing it is of adequate capacity and precharge pressure.

B. The boiler can be removed from the wall and

the expansion vessel replaced:

1. Refer to Frame 51.

2. Drain the boiler water circuits. Refer to

Frame 67.

3. Unscrew all of the gas water and condensate connection unions.

4. Remove the flue turret.

5. Remove the front and side panels. Refer to

Frame 44 and 45.

6. Lift the complete boiler from the wall mounting plate and place on a flat surface, face down to expose the expansion vessel.

7. Unscrew the expansion vessel flexible hose from the copper pipe.

8. Remove the top support bracket.

9. Lift the expansion vessel from its side

retaining brackets.

12. Re-connect the overheat thermostat clip to the heat exchanger pipe.

UNDER NO CIRCUMSTANCES REFIT THE OVERHEAT THERMOSTAT ONTO THE COLD RECUPERATOR RETURN PIPE.

13. Re-assemble in reverse order.

14. Re-fill the boiler. Refer to Frame 32.

15. Check the operation of the boiler. Refer to Frame 50 and 51.

10. Fit the new expansion vessel.

11. Re hang boiler on wall bracket and reconnect all water, gas

and flue connections.

12. Re-assemble in reverse order.

13. Refill the boiler. Refer to Frame 32.

14. Check the operation of the boiler. Refer to Frame 50 and 51.

SERVICING

excel HE - Installation and Servicing

RECUPERATOR REPLACEMENT

1. Refer to Frame 51.

2. Remove the boiler front, side and sealing panels. Refer

to Frame 44 and 45.

3. Drain the boiler water circuits. Refer to Frame 67.

4. Pull off the electrical connection from the condensate

blockage thermistor.

5. Unscrew the condensate blockage thermistor.

6. Pull off the recuperator LH side pipe retention clip and

pull the pipe downwards to disengage 'O' ring seal.

7. Disconnect recuperator plastic drain connection from recuperator RH side.

8. Unscrew the union connection on the recuperator RH side brass outlet connection and swivel the brass piece to clear the copper pipe.

9. Remove the condensate drain point from the top of the recuperator.

10. Remove the fan. Refer to Frame 53.

11. Remove the single fixing screw from the bottom rear of

the recuperator connecting the recuperator to the back panel.

12. Carefully pull the recuperator downwards to disengage the flue turret connection.

13. Fit the new recuperator and reconnect all flue, water pipe, condensate drain and thermostat connections with the new gaskets provided. Ensure the recuperator and fan are aligned correctly before tightening the recuperator fixing screw.

14. Re-assemble in reverse order.

15. Refill the boiler. Refer to Frame 32.

16. Check the operation of the boiler. Refer to Frame 50

and 51.

SERVICING

FAULT FINDING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

excel HE - Installation and Servicing

FAULT FINDING

The operation of the LED's and fault codes shall be as follows:

LED 1 - Burner status LED

LED 2 - Lockout / Error LED

LED 3 - Mode LED

(Refer to Frame 39 for LED positions)

During normal operation LED 1 and LED 3 will function as defined below:

Status LED 1 Green LED 3 Green

No demand, standby Off Off

CH demand, burning On Off

DHW demand, burning On On

CH demand, not burning Flashing Off

DHW demand, not burning Flashing On

Frost demand, burning On Flashing

Frost demand, not burning Flashing Flashing

Note. At all times LED 2 will be off.

Lockout and error conditions will be indicated by the illumination of LED 2 for a period of 10 seconds on and 2 seconds off. During the 10 second on period LED 3 will flash a variable number of times, 0.5 seconds on, 0.5 seconds off. The number of times that it flashes will define the error code as detailed below:

ERROR CODE 1 -

LOCKOUT

GO TO FRAME 80

ERROR CODE 2 -

OVERHEAT ALARM

GO TO FRAME 81

ERROR CODE 3 -

WPS / PPS ALARM

GO TO FRAME 82

ERROR CODE 4 -

APS / FAN ALARM

GO TO FRAME 83

ERROR CODE 5 -

CH THERMISTOR FAULT

GO TO FRAME 84

ERROR CODE 6 -

DHW THERMISTOR FAULT

GO TO FRAME 85

ERROR CODE 7 -

FLUE OVERHEAT

GO TO FRAME 86

ERROR CODE 8 -

CONDENSATE BLOCKAGE

GO TO FRAME 87

FAULT FINDING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

excel HE - Installation and Servicing

ERROR CODE 2 - OVERHEAT ALARM

ERROR CODE 1 - LOCKOUT

Causes: Failed to light after 5 ignition attempts or after flame failure.

Does the boiler light then

go out?

Check gas supply and

rectify

Is 20 mbar pressure

available at the inlet?

NO NO

Check detection electrode

and wiring for continuity,

condition and position.

Replace if necessary

YES YES

Is 240V AC available

between L(3) and N(1) at

the NAC connection with the

Gas Valve?

Check NAC wiring for

continuity. Is it OK?

Is 240V AC available

at the PCB?

YES

Is there a spark?

Replace PCB

Replace Gas Valve

YES

Is 240V AC available at the

PCB for the NAC?

Replace PCB

YES

Replace NAC

Replace ignition electrodes

YES

Replace NAC

Can the error be reset by the

reset procedure when the

boiler is cold? (See Frame 39)

YES YES

YES

Replace OH Stat

Replace wiring harness

Is wiring continuity OK?

Replace PCB

YES

Set CH control knob to max

temperature. If the OH trips

again measure flow temp:

Over 90oC - check flow

thermistor (Frame 72 & 84)

Under 90

C - replace O/H stat.

YES

Fill and vent system and open all isolation valves

Replace pump

Check:

- Gas Flow

- Spark

- Detection

Check ignition electrodes

for continuity, condition and

position. Are they both OK?

Is voltage across OH stat

0V dc?

When the boiler is fired does

the pump give a differential

across the heat exchanger inlet

and outlet of 10oC to 30oC?

NL N

Are the boiler and system

filled and all isolation

valves open?

Note.

Air pressure switch failure results in 5 Code 4 cycles followed by Error Code 1.

FAULT FINDING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

excel HE - Installation and Servicing

Can the error be reset by

the reset procedure?

Does the pressure gauge

read > 1bar?

YES YES

YES

Top up using filling loop

Fit and re-test

Check water pressure and

pump function

Is the PPS microswitch

fitted correctly?

(See Frame 65)

When pump is running, is

there 0V across PPS

contacts?

Can you measure 5V dc on PPS connector when pump is stopped and 0V dc when

pump is running?

YES

Is PCB connector fitted

correctly?

YES

Replace PCB

Fit and re-test

Remove microswitch

assembly. Is the pressure switch microswitch actuating pin extending a min length of

10 mm

Check diaphragm.

Replace water set / pump?

ERROR CODE 3 - WPS / PPS ALARM

YES

ERROR CODE 4 - APS / FAN ALARM

Does the fault clear

following the reset

procedure?

Is there movement from

the fan?

YES

YES NO

YES

Run and observe operation

Is there 240V AC on fan

motor?

Is PCB connector fitted

correctly?

Is harness continuity OK?

YES

Replace fan

YES

Measure V DC across

APS NO/C contact is it 0V?

Is APS sensing pipe fitted

between fan and pressure

switch port marked L?

Is harness PCB connector

fitted correctly?

Stop the fan. Is the

voltage across the APS

contacts approx 30V DC?

YES

Replace harness

Refit Hose

Replace harness

Is harness continuity OK?

Fit and retest

Replace PCB

FAULT FINDING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

excel HE - Installation and Servicing

ERROR CODE 5 - CH THERMISTOR FAULT

Unplug thermistor

connector. Is resistance

approx. 10K OHMS at

25oC?

Re-connect and measure

voltage across thermistor.

Is it 3.75V DC nominal?

YES

Replace PCB

Fit and re-test

Drain waterset and replace

thermistor

Is PCB connector fitted

correctly?

YES

Is harness continuity OK?

YES

Replace PCB

Replace harness

ERROR CODE 6 - DHW THERMISTOR FAULT

Unplug thermistor

connector. Is resistance

approx. 10K OHMS at 25oC?

Re-connect and measure voltage across thermistor.

Is it 3.75V DC nominal?

YES

Replace PCB

Fit and re-test

Drain waterset and replace

thermistor

Is PCB connector fitted

correctly?

YES

Is harness continuity OK?

YES

Replace PCB

Replace harness

FAULT FINDING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

excel HE - Installation and Servicing

YES

Replace PCB

YES

Replace PCB

ERROR CODE 7 - FLUE GAS OVERHEAT

YES

Can the fault condition be

reset by carrying out the

reset procedure?

YES

Is the system filled and vented and all isolation

valves open?

Re-connect and measure the voltage across the thermistor

nominally 3.75V DC.

Are the values correct?

Is the voltage correct?

Is PCB connector fitted

correctly?

Measure the wiring

harness continuity to the

thermistor. Is it OK?

Disconnect and

measure the value of

the recuperator

thermistor. Approx 10 K @ 25oC Approx 3.2K @ 60oC Approx 1.1K @ 95oC

YES

Check the value of the

thermistor. Is it OK?

Inspect the heat exchanger

and check for water flow.

Repair as necessary.

YES

Replace thermistor

Replace harness

Fit and re-test

Fill and vent the system.

Open all isolating valves

Replace thermistor

ERROR CODE 8 - CONDENSATE BLOCKAGE ALARM

Refit and re-test

Is there condensate in the

recuperator? Check this by

partially unscrewing the

recuperator thermistor (see

Frame 78)

Remove blockage and

re-test

YES

Does the error clear on

reset?

Measure the resistance of the recuperator thermistor

Approx 10 K @ 25oC Approx 3.2K @ 60oC Approx 1.1K @ 95oC

Is it correct

Replace thermistor

Re-connect and measure

voltage across thermistor.

Is it 3.75V DC nominal?

YES

Replace PCB

Is the connector fitted correctly to the PCB?

YES

Is the wiring harness

continuity OK?

YES

Observe operation and re-

test if necessary.

Replace

PCB

Replace harness

YES NO

SHORT LIST OF PARTS

excel HE - Installation and Servicing

1 Main heat exchanger + ‘o’ rings C24 1 173 854

C28/C32 1 173 855

2 Fan C24 1 173 856

C28/C32 1 173 857 5 Recuperator 1 173 861 6 Burner C24 1 173 862

C28/C32 1 173 863 8 Injectors C24 14 173 866

C28/C32 15 173 867 9 Detection electrode 1 173 868

10 Ignition electrode LH & RH 1 173 869 17 H07 717 Safety Valve 1 173 203 19 Pump head C24/C28 1 173 877

C32 1 173 878 20 Diverter Valve Actuator 1 173 879 21 Auto air vent valve 1 173 880 25 Casing Controls Door 1 173 884 26 Controls Fascia 1 173 885 27 Knob potentiometer 2 173 886 28 Panel Control Cover 1 173 887 29 Panel Control Support 1 173 888 30 Panel User Wiring Cover 1 173 889 31 Main PCB 1 173 890 33 Pressure Gauge 1 173 892 34 Lens Clear 3 173 893 35 Expansion PCB 1 173 894 36 H07 673 Mains Switch 1 173 161 40 Ignition Unit - NAC 1 173 901 41 Air pressure switch C 24 1 173 902

C28/C32 1 173 903 42 Panel Front Sealing 1 173 905 43 Casing LH Side Panel 1 173 906 44 Casing RH Side Panel 1 173 907 45 Casing Front Panel 1 173 908 46 Casing Bottom Panel 1 173 913 50 Gas valve & gaskets 1 173 925 51 Condensate Blockage Thermistor 1 173 926 52 Overheat thermostat 1 173 927 53 Expansion vessel 1 173 928 56 Combustion Chamber Insulation Pack C24 1 173 910

C28/C32 1 173 911 57 Thermistor - Waterset CH & DHW 1 173 932 58 H07 781 DHW plate heat exchanger C24 1 173 544

E69 408 C28 1 170 995

H07 782 C32 1 173 545 59 Gasket Kit (servicing) 1 173 936 60 Fixings Kit (servicing) 1 173 937 61 Fan Suppressor 1 174 051

When ordering spares please quote:

1. Boiler model

2. Appliance G.C. No.

3. Description.

4. Quantity.

5. Product number.

The following are parts commonly required due to damage or expendability. Their failure or absence is likely to affect safety or performance of this appliance.

The list is extracted from the British Gas List of Parts, which contains all available spare parts.

The full list is held by British Gas Services, Ideal Stelrad Group distributors and merchants.

Key No. G.C. Part No. Description Qty./Boiler Product Number

SHORT LIST OF PARTS

excel HE - Installation and Servicing

SHORT LIST

ex7466

NOTES

excel HE - Installation and Servicing

57excel HE - Installation and Servicing

INSTALLER NOTIFICATION GUIDELINES

IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE

In addition a change to Building Regulations (England and Wales) requires the installer to notify

when installing a heating appliance, as from 1st April 2005.

Competent Person's

SELF CERTIFICATION SCHEME

BUILDING CONTROL

Install and commission

this appliance to

manufacturers' instructions

Complete the

Benchmark Checklist

Choose

Buildings Regulations

notification route

Contact your relevant

Local Authority

Building Control (LABC) who

will arrange an inspection

or contact a government

approved inspector

LABC will record the data

and will issue a

certificate of compliance

If you notify via CORGI Scheme,

CORGI will then notify the

relevant Local Authority Building

Control (LABC) scheme

on members behalf

Scheme members only:

Call CORGI on 0870 88 88 777

or log onto:

www.corgi-notify.com

within 10 days

You must ensure that the

notification number

issued by CORGI is written

onto the Benchmark Checklist

CORGI will record the data and

will send a certificate of

compliance to the property

IT IS A CONDITION OF THE

MANUFACTURERS WARRANTY

THAT THE BENCHMARK

COMMISSIONING CHECKLIST IS

FULLY COMPLETED AND LEFT

WITH THE APPLIANCE

CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes

TIME & TEMPERATURE CONTROLTO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME & TEMPERATURE CONTROLTO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER

COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED

FOR ALL BOILERS CONFIRM THE FOLLOWING

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURERÕS INSTRUCTIONS? THE SYSTEM CLEANER USED THE INHIBITOR USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE ft3/hr BURNER OPERATING PRESSURE (IF APPLICABLE) mbar CENTRAL HEATING FLOW TEMPERATURE

CENTRAL HEATING RETURN TEMPERATURE

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED? YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE ft3/hr MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar COLD WATER INLETTEMPERATURE

HOT WATER OUTLET TEMPERATURE

WATER FLOW RATE

lts/min

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS? YES

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULA

TIONS

THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS

IF REQUIRED BY

THE MANUFACTURER, HAVE YOU RECORDED A CO/CO

TIO READING? N/A YES CO/CO

TIO

THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER

THE MANUFACTURER'S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

m3/hr

/hr

COMMISSIONING ENG'S NAME PRINT CORGI ID No.

SIGN DATE

BOILER SERIAL No. NOTIFICATION No.

BENCHMARK No.

GAS BOILER COMMISSIONING CHECKLIST

COLLECTIVE MARK

N/A

SERVICE INTERVAL RECORD

It is recommended that your heating system is serviced regularly

and that you complete the appropriate Service Interval Record Below.

Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service

as described in the boiler manufacturer's instructions. Always use the manufacturer's specified spare part when replacing all controls

SERVICE 1

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 2

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 3

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 4

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 5

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 6

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 7

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 8

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 9

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

SERVICE 10

DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS

SIGNATURE

Ideal Boilers,

P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137.

Technical Training

Ideal Stelrad Group pursues a policy of continuing

improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.

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.

For details of courses please ring: ............. 01482 498 432

CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001: 2000 Quality System accepted by BSI

The code of practice for the installation,

commissioning & servicing of central heating systems

deal Installer/Technical Helpline: 01482 498 663

www.idealboilers.com

users guide

excel

Your Ideal users guide

See reverse for

excel

installation & servicing instructions

HE C24, C28, C32

excel HE - User’s

In cases of repeated or continuous shutdown a CORGI registered installer or in Ireland a competent person should be called to investigate and rectify the condition causing this and carry out an operational test. Only the manufacturers original parts should be used for replacement.

Minimum Clearances

Clearances of 200mm (8") above, 100mm (4") below, 10mm (3/8") at the sides and 450mm (17 3/4") at the front of the boiler casing must be allowed for servicing.

The minimum front and bottom clearance allowed when built into a cupboard is 5mm.

To light the boiler.

If a programmer is fitted refer to separate instructions for the programmer before continuing.

1. Switch the electricity supply on.

2. If the boiler is to be used for CH and DHW position the main

switch (B) as in the following illustration.

Destination Countries: GB, IE

excel HE C24, C28, C32

(Natural Gas Only)

C24 G.C. Appliance No. 47-348-35

C28 G.C. Appliance No. 47-348-36

C32 G.C. Appliance No. 47-348-37

Introduction

The excel HE is a wall mounted, room sealed, condensing combination boiler, featuring full sequence automatic spark ignition and fan assisted combustion.

Due to the high efficiency of the boiler, condensate is produced from the flue gases and this is drained to a suitable disposal point through the plastic waste pipe at the lower rear of the boiler. A condensate 'plume' will also be visible at the flue terminal.

The excel HE is a combination boiler providing both central heating and domestic hot water on demand.

Safety

Current Gas Safety (Installation & Use) Regulations or rules in force.

In your own interest, and that of safety, it is the law that this boiler must be installed by a CORGI registered installer, in accordance with the above regulations.

In Ireland, the installation must be carried out by a Competent Person and installed in accordance with the current edition of I.S. 813 “Domestic Gas Installations”, the current Building Regulations and reference should be made to the current ETCI rules for electrical installation.

It is essential that the instructions in this booklet are strictly followed, for safe and economical operation of the boiler.

Electricity Supply

This appliance must be earthed.

Supply: 230 V ~ 50 Hz. The fusing should be 3A.

Connection must be made in a way that allows complete isolation of the electrical supply such as a double-pole switch, having a 3mm (1/8") contact separation in both poles, serving only the boiler and system controls. Alternatively, a 3-pin UNSWITCHED socket may be used. The means of isolation must be accessible to the user after installation.

Important Notes

” This appliance must not be operated without the casing

correctly fitted and forming an adequate seal.

” If the boiler is installed in a compartment then the

compartment MUST NOT be used for storage purposes.

” If it is known or suspected that a fault exists on the boiler

then it MUST NOT BE USED until the fault has been corrected by a CORGI registered installer or in Ireland a competent person.

” Under NO circumstances should any of the sealed components

on this appliance be used incorrectly or tampered with.

” This appliance is not intended for use by persons (including

children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instructions concerning use of the appliance by a person responsible for their safety.

” Children should be supervised to ensure that they do not

play with the appliance.

3. The boiler will commence the ignition sequence. The green operational light 1 (E) indicates boiler running for central heating.

Control of CH Temperature

The output temperature of CH water is adjustable from a minimum of about 38oC to a maximum of about 82oC by turning the knob B. The green operational light 1 (E) indicates boiler running for Central Heating.

Approx. CH flow temperature for the boiler thermostat settings:

Control of DHW Temperature

The temperature of the DHW leaving the boiler can be varied from a minimum of about 40oC to a maximum of about 65oC (within the power limits for the appliance) by turning the temperature control knob C. The green operational lights 1 and 3 (E) indicates boiler running for domestic hot water.

All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded in the Benchmark Commissioning Checklist. You can check your installer by calling CORGI direct on 01256 372300.

THE BENCHMARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE

Ideal Stelrad Group is a member of the Benchmark initiative and fully supports the aims of

the programme. Benchmark has been introduced to improve the standards of installation and commissioning of central heating systems in the UK and to encourage the regular servicing of all central heating systems to ensure safety and efficiency.

Minimum (38oC) Maximum (82oC)

Winter

Summer

3excel HE - User’s

Legend A. Boiler ON/OFF switch B. Main switch & CH thermostat knob C. DHW thermostat knob D. Pressure gauge E. Operational lights (1 & 3) / Fault indication light (2) F. Optional programmer G. Condensate drain

BOILER CONTROLS

Adjustment of the DHW temperature is completely separate from that of the CH circuit.

The adjustment system integrated within the boiler automatically controls the flow of gas to the burner in order to keep the temperature of DHW delivered constant, between the limits of maximum and minimum output.

Where the demand is at a low level or with the temperature set to the minimum, it is normal to see a cycle of lighting and extinguishing of the burner when running.

Adjustment

It is advisable to adjust the DHW temperature to a level suitable for the demand, minimising the need to mix with cold water. In this way, the automatic control facilities will be fully exploited.

Moreover, where the amount of limescale present in the water may be particularly great, not exceeding the position as shown in the following illustration (about 50

C) minimises annoying

incidence of scale deposits and clogging.

In these cases, however, it is advisable to install a small water treatment device or softener. With such a device you should avoid periodic descaling.

Consequently, the DHW heat exchanger will keep its performance consistent for a longer period of time with resulting gas savings.

To Shut Down the Boiler

For Short Periods

To turn the boiler off set the main switch (B) to the '0' position.

For long periods

When you do not expect to use the boiler for a long period:

1. Set the boiler 'ON/OFF' switch (A) to 'OFF' and switch the electricity supply off.

2. For longer periods the entire system should be drained.

To Relight the Boiler

Repeat the procedure detailed in 'To Light The Boiler'.

Frost protection

excel HE appliances are provided with a built in anti-freeze system that operates the boiler when the temperature is below 5oC. Internal frost protection operates regardless of the position of the main switch and CH heating thermostat knob (B). Therefore, when the boiler is not lit and used in cold weather, with consequent risk of freezing, the supply to the boiler should be left switched on.

If the system includes a frost thermostat then, during cold weather, the boiler should ONLY be turned OFF at the time switch (if fitted). The mains supply should be left switched ON, with the boiler thermostat left in the normal running position.

Loss of system water pressure

The gauge (D) indicates the central heating system pressure. If the pressure is seen to fall below the original installation pressure of 1-2 bar over a period of time then a water leak is indicated. In this event a CORGI registered installer or in Ireland a competent person should be consulted.

Note. THE BOILER WILL NOT FIRE IF THE PRESSURE HAS REDUCED TO ZERO FROM THE ORIGINAL SETTING.

Condensate Drain

The condensate drain (G) must not be modified or blocked. Blockage of the condensate drain, caused by debris or freezing,

can cause automatic shutdown of the boiler. If freezing is suspected and the pipe run is accessible an

attempt may be made to free the obstruction by pouring hot water over the exposed pipe and clearing any blockage from the end of the pipe. If this fails to remedy the problem the assistance of a CORGI registered installer or in Ireland a competent person should be sought.

Escape of gas

Should a gas leak or fault be suspected, contact your local gas supplier without delay.

Do NOT search for gas leaks with a naked flame.

Cleaning

For normal cleaning simply dust with a dry cloth.

To remove stubborn marks and stains, wipe with a damp cloth and finish off with a dry cloth.

DO NOT use abrasive cleaning materials.

Maintenance

The appliance should be serviced at least once a year by a CORGI registered installer or in Ireland a competent person.

if7383

Minimum (40oC) Maximum (65oC)

CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components

Ideal Boilers, P.O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN. Tel. 01482 492251 Fax. 01482 448858. Registration No. London 322 137.

Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.

Ideal Consumer Helpline

Tel: 01482 498660

www.idealboilers.com

POINTS FOR THE BOILER USER

Note. In line with our current warranty policy we would ask that you check through the following guide to identify any

problems external to the boiler prior to requesting a service engineers visit. Should the problem be found to be other than with the appliance we reserve the right to levy a charge for the visit, or for any pre-arranged visit where access is not gained by the engineer.

TROUBLESHOOTING - TYPICAL NON PRODUCT FAULTS

The nature of all combination boilers is to heat up water directly from the incoming mains water supply directly through the boiler to supply domestic hot water at the stated flow rates, (as shown in the boiler installation instructions), to achieve a set temperature rise. As the ambient temperature of the cold main varies during the summer and winter months it is likely in the colder winter months that the flow rate will need to be reduced at the outlet taps to achieve the same temperatures achieved in the warmer summer months. This is not a fault with the appliance but is relevant to the varying temperature of the incoming cold

mains water supply.

Problem Solution

Boiler is not working for central heating or hot water

• Is there power to the boiler – check by switching the boiler 'ON/OFF' switch (A) off and then back on. The lights (E) should flash. If not this is not a boiler fault - contact the installer.

• Check pressure gauge on boiler (D) shows a minimum of 1 bar. If not re-pressurise via the filling loop to 1 bar (if unsure contact your installer), turn off the tap on the filling loop and carry out ignition restart sequence detailed under 'Faults'. If unable to do so or if the pressure continues to drop then contact your installer.

• Is the fault indication light (2) alight - see Reset Procedure under 'Faults'.

Fan and pump run continuously but there is no attempt at ignition

• Check that the flue product test cap, on top of the boiler is fitted correctly.

Operating for hot water but will not operate for central heating.

• Check that integral programmer (if fitted) is set to an 'on' period and the function switch is set to 'auto' - If it still does not operate contact your installer.

• If fitted with an external programmer check that the central heating channel is set at an 'on' period - If it still does not operate contact your installer.

• Check the room thermostat is set at the required temperature - Test the room thermostat by turning fully up - If this does not respond contact your installer.

• Check the CH thermostat knob (B) is set at the winter setting for central heating.

Boiler goes through ignition sequence but will not fire for either central heating or hot water and then goes to ignition lockout

• Check gas supply (try another gas appliance – cooker/fire etc.) – If no gas supply then this is not a boiler fault – contact gas supplier.

Faults

No heating or hot water

Check that gas and electricity are available at the boiler and that all switches are on.

Check that the system water pressure gauge (D) reads at least

0.5 bar.

Reset Procedure

Check the red fault indication light (2). If it is illuminated turn the main switch (B) to '0', wait until the boiler reaches standby state, indicated by no fan or pump running. This can take up to 10 minutes in an overheat condition. Turn the main switch (B) to the winter setting wait for 2 seconds then set the main switch (B) back to the desired position to restart the ignition sequence.

Hot water but no heating (winter setting)

Check that the programmer and room thermostat (if fitted) are both calling for heat.

Heating but no hot water

Check that cold water flows out of the taps at a minimum rate of

3.5 litres per minute (or 1 pint in 10 seconds or less). If not, look for stop valves not fully open.

If these simple checks fail to solve the problem, or the problem recurs, consult your service engineer.

Excel HE C24, HE C28, HE C32 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual