Excel HE C24, HE C28, HE C32 User Manual
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
2
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
4
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
3
)
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
6
excel HE - Installation and Servicing
GENERAL
1
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
o
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
ix7410
23
34
37
24
25
35
36
27
12
1
2
32
5
3
4
6
7
8
9
13
14
15
18
16
17
19
20
21
22
11
31
29
28
26
30
10
33
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
o
Elbow (80mm male/female)
” 90o Elbow (60mm male/female)
” 45
o
Elbow (80mm male/female)
” 45o Elbow (60mm male/female)
” Flue Finishing Kit
” 90
o
Elbow (80/125)
” 45
o
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.
8
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
3
/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
1
/2")
320 (12 5/8")
177 (7")
Flue
terminal
Gas Inlet
CH Return
C
ondensate
Drain
DHW Inlet
DHW Outlet
Pressure Relief Outlet
CH Flow
ix7378
10 (3/8")
470 (18 1/2")
33
(1
3
/8")35(13/8")53(21/8")65(25/8")60(21/2")
25
10 (3/8")
35
(1
3
/8")
109
(4
1
/4")
200 (8") **
100 (4")*
from case
62
(2
1
/2")
of
water & gas
connections
C
L
of
condensate
drain
C
L
2
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")
10
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
o
C.
3. All components of the system must be suitable for a
working pressure of 3 bar and temperature of 110
o
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.
3
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.
or
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
)
4
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
o
C apart.
These valves should now be left as set.
5
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
o
C20 20 20
(
o
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)
12
excel HE - Installation and Servicing
GENERAL
6
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:
7
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
13
INSTALLATION
excel HE - Installation and Servicing
8
BOILER ASSEMBLY - Exploded View
ex7484
33
26
25
35
29
30
40
46
19
50
44
58
20
21
57
9
6
17
51
2
5
1
56
52
43
Data
Plate
45
42
10
8
41
53
Flue gas
sampling
point
28
31
36
27
34
User Data
Plate
INSTALLATION
14
INSTALLATION
excel HE - Installation and Servicing
9
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
B
C
E
A
D
F
G
ix7408
A
B
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
A
B
C
D
E
F
G
H
J
K
L
M
N
P
ix7429
INSTALLATION
15
INSTALLATION
excel HE - Installation and Servicing
10
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'
90
o
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.
11
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)
RH
Side
LH
SideRear
Rear flue length
Side flue length
ix7416
450
(171/2")
25 (1")
177 (7")
119 (43/4")
X
R
Side flue length
450
(171/2")
25 (1")
331 (13")
L
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.
3
5
4
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
16
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.
10
20
30
50
60 80
See wall mounting template
ix7418
0.5
1.0
1.5
2.0
2.5
3.0
V
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.
13
WALL MOUNTING TEMPLATE
12
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.
2
1
4
3
5
ix7430
IMPORTANT. DO NOT fit flue restrictor if flue
length is greater than 775 mm ('B' Pack).
ix7417
1
2
WA LL M OUNTING
TEMPLATE
175mm
Extended
centre
line
17
INSTALLATION
excel HE - Installation and Servicing
FLUE OUTLET
14
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.
15
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.
16
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
X
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
cla7841
18
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.
18
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.
19
FITTING THE KIT
17
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
1
2
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
19
INSTALLATION
excel HE - Installation and Servicing
FLUE OUTLET
ex7534
20
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
or
- Universal weather collar.
ACCESSORIES
Flue Duct Extension Kits are available for flue
lengths extending beyond 1m. These packs
contain 1m extension ducts and may be cut to
the desired length.
If the offset vertical option is used an elbow
Kit is required. For a full accessories list
refer to page 7, Optional Extras and Frame
23, Flue Arrangement.
21
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
o
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.
A
J
I
C
B
D
G
E
F
ix7467
H
Loading...