ideal Evo HE C22/24 User guide

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C22/24, C22/30, C22/35

(V3 Flue System)

Wall mounted, balanced flue, fanned gas boiler

Advanced High Efficiency Boilers

Installation & Servicing Instructions

See reverse for evo HE Users Guide

Manufactured exclusively for Wolseley Centers Ltd. by Ideal Boilers

For details of document amendments, refer to page 3

Packaged Boiler Contents have been

checked by Operator Number.......

September 2009 UIN 204427 A02

evo HE C - Installation and Servicing

DOCUMENT AMENDMENTS

Relevant Installation changes implemented in this book from Mod Level ........... A01 (July 08) to A02 (Sep 09)

Page 7, Optional Extra Kits

• Addition of Concentric flue Screw Retaining Kit

Page 16, Frame 12 - Determining the Flue Lengths and Packs Required

• New flue kit added.

Page 19, Frame 16 - Terminal Wall Seal Assembly / Position

• New frame added ref. positioning of terminal wall seal

Page 22, Frame 23 - Condensate Pipe Termination Configurations

• Update drawing 1 and not added ref BS6798 (2002)

Page 49, Frame 68 - Combustion Chamber Insulation Replacement

• Updated Frame to reflect new insulation.

Page 54, Frame 78 - Diverter Valve Internal Parts Replacement

• New item no. 6 added.

Page 63, Frame 92 - H9/L9 Heat Exchanger Overheat

• New flow chart.

Page 64 - Short Parts List

• New updated parts list

Page 68 - Code of Practice

• New Code of Practice Guidelines added.

Wolseley Centres Ltd. reserve the right to vary specification without notice

3evo HE C - Installation and Servicing

GENERAL

Table 1 - General Data

isar C22/24 C22/30 C22/35

Gas supply 2H - G20 - 20mbar

Gas Supply Connection 15mm copper compression

Injector Size Stereomatic 5.6mm dia. 5.7mm dia

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 (DHW) 66

Maximum Working Pressure (Sealed Systems) bar (lb/in

) 2.5 (36.3)

Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) 10.0 (145)

Minimum Domestic Hot Water Inlet Pressure* bar (lb/in

) 1.0 1.3 1.7**

Electrical Supply 230 V ~ 50 Hz.

Power Consumption 148 W 148 W 152 W

Fuse Rating External : 3A Internal : T3.15A L250 V

Water content Central Heating litre (gal) 2.0 (0.44)

Domestic Hot Water litre (gal) 0.5 (0.11)

Packaged Weight kg (lb) 53.3 (118) 53.4 (118) 53.6 (118)

Maximum Installation Weight kg (lb) 46.6 (103) 46.7 (103) 46.9 (103)

Boiler Casing Size Height mm (in) 687 (27)

Width mm (in) 390 (15 3/8)

Depth mm (in) 278 (11)

*Required for maximum flow rate. Boiler operates down to 0.2bar with reduced DHW delivery ** In areas of low water pressure the DHW restrictor can be removed

Table 2 - Performance Data - Central Heating

Boiler Input : Max. Min.

Table 3 - Performance Data - Domestic Hot Water

Maximum DHW Input : C22/24 C22/30 C22/35

Boiler Input ‘Q’ Nett CV kW 22.6 9.1

(Btu/h) (77 100) (31 000)

Gross CV kW 25.1 10.1

(Btu/h) (85 600) (34 400)

Gas Consumption l/s 0.65 0.26

(ft

/h) (82.5) (33.1)

Boiler Output :

Non Condensing kW 22 8.8

C Mean Water temp. (Btu/h) (75 000) (30 000)

Condensing kW 23.3 9.6

C Mean Water temp. (Btu/h) (79 500) (32 800)

Seasonal efficiency* (SEDBUK) Band A [90.1]%

Gas Consumption l/s 0.7 0.87 1.03

Maximum kW 23.4 29.3 35.2 DHW Output (Btu/h) (80 000) (100 000) (120 000)

DHW Flow Rate l/min 9.6 12.0 14.4 at 35°C temp. rise. (gpm) (2.1) 2.6 (3.2)

DHW Specific Rate l/min 11.2 14.0 16.8

NOx Classification Class 5

C-10g/s 74oC - 12 g/s 82oC-14g/s

Nett CV kW 24.3 30.2 36.0

(Btu/h) (82 900) (103 000) (122 800)

Gross CV kW 27.0 33.5 39.9

(Btu/h) (92 100) (114 400) (136 200)

(ft

/h) (89.0) (110) (131)

(gpm) (2.5) (3.1) (3.7)

* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which

it has been calculated have been certified by a notified body.

Note. Gas consumption is calculated using a calorific value of 38.7 MJ/m

(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/m

b. For ft

/h - divide the gross heat input (Btu/h)

)

by the gross C.V. of the gas (Btu/ft3)

CAUTION.

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

Key to symbols

GB = United Kingdom IE = Ireland (Countries of destination)

PMS = Maximum operating pressure of water

13 C33 C53

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

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

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

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

evo HE C - Installation and Servicing

GENERAL

evo HE

Natural Gas only

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

(Benchmark No.)

C22/24 47 348 32 87 BP 34

C22/30 47 348 33 87 BP 34

C22/35 47 348 34 87 BP 34

Destination Country: GB, IE

CONTENTS

Air Supply ....................................................................... 8

Benchmark Commissioning Checklist ............... 70-71

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

Boiler Exploded Diagram ............................................ 13

Condensate Drain ........................................... 10, 21-23

Electrical Connections ............................................... 32

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

Extension Ducts - Fitting ............................................. 20

Fault Finding ........................................................... 58-63

Flow Wiring Diagram .................................................. 35

Flue Fitting .................................................................... 16

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

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

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

Installation ............................................................. 12-39

Mandatory Requirements ....................................... 7-10

Pump .......................................................................... 55

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

Servicing ................................................................ 40-57

Short List of Parts ....................................................... 64

Thermostatic Radiator Valves ................................... 10

Water and Systems ........................................... 8,10-12

Water Connections ..................................................... 29

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

Wiring Diagrams ................................................... 32-35

For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist.

Before installing this boiler, read the Code of Practice sheet at the rear of this book.

BENCHMARK COMMISSIONING CHECKLIST DETAILS

Boiler Page

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

Appliance serial no. on data badge ....... Front Cover

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

Controls

Time and temperature control to heating ............. 3 3

Time and temperature control to hot water .......... 33

Heating zone valves .............................................. 3 3

TRV's ...................................................................... 1 0

Auto bypass ........................................................... 10

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

For all boilers

Flushing to BS.7593 .............................................. 1 2

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

Central heating mode

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

Burner operating pressure .................................... n/a

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

Central heating return temp. ... measure and record

For combination boilers only

Scale reducer ......................................................... n/a

Hot water mode

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

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

Max. operating water pressure ........... measure & record

Cold water inlet temp ..................... measure & record

Hot water outlet temp. .................... measure & record

Water flow rate at max. setting ............ measure & record

For condensing boilers only

Condensate drain .................................................. 22

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

For assistance see Technical Helpline on the back page

Page

NOTE TO THE INSTALLER:

COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

5evo HE C - Installation and Servicing

GENERAL

INTRODUCTION

The evo 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) output is fully modulating with a range of 8.8 to 22 kW (30,000 to 75,000 Btu/h)

Instantaneous domestic hot water (DHW) output is also fully modulating with a maximum of :

C22/24 23.4kW (80,000 Btu/h) C22/30 29.3kW (100,000 Btu/h) C22/35 35.2kW (120,000 Btu/h) The boiler is 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 and the boiler features a DHW preheat facility.

The boiler casing is of white painted mild steel with the user controls capable of being mounted remotely from the boiler if the option is required.

The boiler temperature controls are visible at the bottom RHS of the front panel.

The heat exchanger is of cast aluminium. The boiler is suitable for connection to fully pumped, sealed water systems

ONLY. Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework.

Pipework from the boiler is routed downwards as standard, but may be routed upwards behind the boiler using the stand-off frame (supplied in a separate kit).

BOILER WATER CIRCUIT DIAGRAMS

OPERATION

With no demand for CH, the boiler fires only when DHW is drawn off, or periodically for a few seconds without any DHW draw-off, in order to maintain the DHW calorifier in a heated condition.

When there is a demand for CH, the heating system is supplied at the selected temperature of between 30 oC 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

C22/24 9.6 l/min at 35

C22/30 12 l/min at 35 oC temperature rise.

C22/35 14.4 l/min at 35

The DHW draw off rate specified above is the nominal that the boiler flow regulator will give. 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 65 modulating gas control.

Refer also to Frame 1 - 'Boiler Water Circuit Diagrams'

The boiler features a comprehensive diagnostic system which gives detailed information on the boiler status when operating, and performance of key components to aid commissioning and fault finding.

C temperature rise.

C by the

SAFE HANDLING

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

Caution should be exercised during these operations.

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

• Grip the boiler at the base.

• 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.

evo HE C - Installation and Servicing

GENERAL

OPTIONAL EXTRA KITS

• Flue Extension Ducts (1000mm long).

C22/24 & 30-up to 6m C22/35-up to 3m

• Flue Finishing Kit

•90

Elbow Kit (maximum per installation).

C22/24 & 30-up to 4 elbows C22/35-up to 2 elbows

•45

Elbow Kit (maximum per installation).

C22/24 & 30-up to 4 elbows C22/35-up to 2 elbows

• Concentric Flue Screw Retaining Kit

• Roof Flue Kit (to a maximum of 7.5m).

• Powered Vertical Flue Kit (5m primary and 17m secondary

is a typical maximum length. For alternative details refer to Powered Vertical Instructions).

• High Level Flue Outlet Kits

• Flue Deflector Kit

• Weather Collar

• Horizontal Flue Terminal 600mm long

• Remote User Controls Kit

• Boiler Stand-off Kit

• Siphon Kit

• Valve Cover Kit

• Condensate Pump Kit

• Pre-piping Frame

• Adjustable flue support bracket

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 Gas Safe Registered Engineer. It must be carried out in accordance with the relevant requirements of the:

• Gas Safety (Installation and Use) Regulations

• The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (northern Ireland).

• The Water Fittings Regulations or Water byelaws in Scotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a Registered Gas Installer (RGII) 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 Wolseley Centers Ltd. in writing. If in doubt please enquire.

Any direct connection of a control device not approved by Wolseley Centers Ltd. 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.

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 must be installed in Zone 2, 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:

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

Supply’ for details).

z The position selected for installation MUST allow adequate

space for servicing in front of the boiler.

z 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.

7evo HE C - Installation and Servicing

GENERAL

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 Gas Safe Registered Engineer. In IE by a Registered Gas Installer (RGII).

An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the rate of gas supply required.

It is the responsibility of the Gas Installer to size the gas installation pipework in accordance with BS6891:2005. Whilst the principle of the 1:1 gas valve ensures the evo C range is able to deliver it’s full output at inlet pressures as low as 14mb, other gas appliances in the property may not be as tolerant. When operating pressures are found to be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation.

Allowing for the acceptable pressure loss of 1mb across the installation pipework, it can be assumed that a minimum permitted operating pressure of 18mb will be delivered to the inlet of the appliance. (Reference BS 6400-1 Clause 6.2 Pressure Absorption).

The integral appliance isolation valve and boiler pipework could further reduce the operating pressure by up to 1.5mb when measured at the inlet test point on the appliance gas valve. Therefore it has been identified that an operating pressure as low as 16.5mbar could be measured at the appliance inlet pressure test point on the gas valve.

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.

Table 4 - Balanced Flue Terminal Position

Flue Terminal Positions

1. Directly below, above or alongside an opening

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

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

BS5440-1 2000 75mm (3")

3. Below eaves. 25mm (1")*

BS5440-1 2000 200mm (8")

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

BS5440-1 2000 200mm (8")

5. From vertical drain pipes or soil pipes. 25mm (1")*

BS5440-1 2000 150mm (6")

6. From an internal or external corner or to a 25mm (1")* boundary along side the terminal. BS5440-1 2000 300mm (12")

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

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

9. From a terminal facing a terminal. 1,200mm (48")

10. From an opening in a car port

(e.g. door or window) into dwelling. 1,200mm (48")

11. Vertically from a terminal on the same wall. 1,500mm (60")

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

Vertical Terminals

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

Above flat roof. 300mm (12")

14. From a single wall face. 300mm (12") From corner walls. 300mm (12")

* Only one reduction down to 25mm is allowable per installation otherwise BS5440-1 2000 dimensions must be followed.

Min. Spacing*

The complete installation MUST be tested for gas tightness 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 12 .

AIR SUPPLY

It is NOT necessary to have a purpose-provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation; therefore the requirements of BS 6798, Clause 12, and BS 5440:2 may be disregarded.

WATER CIRCULATION SYSTEM

IMPORTANT.

A minimum length of 1 metre of copper pipe MUST be fitted to 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

evo HE C - Installation and Servicing

GENERAL

60 65 55 79 65

evfu9802

BOILER DIMENSIONS, SERVICES & CLEARANCES

The boiler connections are made on the boiler connection tails. Refer to Frames 32-35.

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"). Where

all dimensions in mm (in)

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.

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. N.B. The boiler will not fit into a standard depth wall unit. In order for it to do so the plastic fascia should be removed. See Frame 44.

* Bottom clearance

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

SIDE FLUE ONLY

Horizontal length of flue Top clearance from centre line of boiler required (MIN.)

to outside wall Dim. A

C22/24 C22/30 C22/35

0.5 m 0.5 m 0.5 m 160 mm (6

1.0 m 1.0 m 1.0 m 170 mm (6

1.5 m 1.5 m 1.5 m 185 mm (7 1/4")

1.5 m 1.5 m 1.5 m 200 mm ( 7

2.5 m 2.5 m 2.5 m 210 mm (8 1/4")

3.0 m 3.0 m 3.0 m 225 mm (8

3.5 m 3.5 m N/A 250 mm (9 7/8")

4.0 m 4.0 m N/A 260 mm (10

4.5 m 4.5 m N/A 265 mm (10 7/16")

5.0 m 5.0 m N/A 275 mm (10

5.5 m 5.5 m N/A 290 mm (11 3/8")

6.0 m 6.0 m N/A 300 mm (11

REAR FLUE ONLY

MIN. Top clearance required = 145 mm (5

5/16")

11/16)

7/8")

1/4")

13/16")

3/4")

9evo HE C - Installation and Servicing

GENERAL

BOILER CONTROL INTERLOCKS

Wolseley Centres Ltd. 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. However, if the system employs thermostatic radiator valves on all radiators, or two port valves, then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position.

SYSTEM REQUIREMENTS - Central Heating

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 aluminium heat exchangers may be used in the central heating system.

Advice should be sought from a local water treatment company.

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 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 6 bar.

d. An 8-litre expansion vessel, with an initial charge pressure

of 0.75 bar.

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.

C. Extra care

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.

Note. The fan voltage is 325V DC

CONDENSATE DRAIN Refer to Frames 22 & 54.

A condensate drain is provided on the boiler. This drain must be connected to a drainage point on site. All pipework and fittings in the condensate drainage system MUST be made of plastic - no other

materials may be used.

IMPORTANT.

Any external runs must be insulated

The drain outlet on the boiler is standard 21.5mm (3/4”) overflow pipe.

Safety valve setting bar 3.0

Vessel charge pressure bar 0.5 to 0.75

System pre-charge pressure bar 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

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,

evo HE C - 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

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 1bar and examine for leaks.

iii. Release water from the system until the

minimum system design pressure is reached;

1.0 bar if the system is to be pre-pressurised.

Water Flow Rate and Pressure Loss

Max CH Output kW 23.4

(Btu/h) (80 000)

Water flow rate l/sec 0.37

(gal/min) 4.8

Temperature Differential

C15

F) (27)

(

Head available for m.w.g. 2.3

system pump. (ft.w.g.) 7.5

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.

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

pressure.

SYSTEM BALANCING

The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of the minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available. See note regarding thermostatic radiator valves on page 10.

Note. Systems incorporating zone valves which could completely cut off the flow through the system must also include a bypass.

BALANCING

1. Set the programmer to ON.

Close the manual or thermostatic valves on all radiators, leaving the twin lockshield valves (on the radiators referred to above) in the OPEN position.

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.

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

These valves should now be left as set.

2. Open all manual or thermostatic radiator valves and adjust the lockshield valves on the remaining radiators, to give around 15

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

C temperature drop at each radiator.

11evo HE C - Installation and Servicing

INSTALLATION

WATER TREATMENT

CENTRAL HEATING

The evo HE range of boilers have an ALUMINIUM alloy heat exchanger.

IMPORTANT. The application of any other treatment to this product may render invalid the guarantee of Wolseley Centres Ltd.

Wolseley Centres Ltd. recommend Water Treatment in

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

If water treatment is used Wolseley Centres Ltd. recommend only the use of FERNOX-COPAL, MB1, GE BETZ or

SENTINEL X100 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.

DOMESTIC HOT WATER

In hard water areas where main water can exceed 200ppm Total Hardness (as defined by BS 7593:2006 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. Wolseley Centres Ltd. 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: Fernox Manufacturing Co. Ltd Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ +44 (0) 1799 521133

Sentinel Performance Solutions The Heath Business & Technical Park Runcorn Cheshire WA7 4QX Tel: 0800 389 4670 www.sentinel-solutions.net

2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. BS 7593:2006 details the steps necessary to clean a domestic heating system.

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.

BOILER ASSEMBLY - Exploded View Legend

Note that item numbers are linked to the spares list

1. Front casing panel.

2. Boiler sealing panel.

3. Sump cover.

4. Bottom casing panel.

5. Flue sensing nipple.

6. Return pipe.

8. Flue manifold.

10. Interpanel.

11. Burner.

12. Combustion chamber insulation.

13. Heat exchanger.

14. Injector and housing.

15. Venturi assembly.

16. Fan assembly.

17. Automatic air vent (Heat Exchanger)

18. Gas service cock.

19. Gas control valve.

20. Fan bracket.

21. Orifice plate.

23. Control thermistor (flow/return)

24. Overheat thermostat.

25. Ignition electrode.

26. Flame detection electrode.

32. Kit - Trap and seal.

35. User control.

36. Primary controls (PCB).

39. Mains switch.

40. Spark generator.

44. Wall mounting plate

51. Mains connector.

53. Turret gasket kit.

57. CH stub pipe.

Salamander Engineering Ltd The Heath Business & Technical Park Runcorn Cheshire WA7 4QX Tel: 0800 389 4670

Calmag Ltd. Unit 4-6, Crown Works Bradford Road Sandbeds, Keighley West Yorkshire BD20 5LN Tel: +44 (0) 1535 210 320

59. Flow restrictor.

60. DHW inlet/outlet pipe.

61. Pressure relief valve.

62. Expansion vessel.

64. Pressure gauge.

66. Diverter valve head.

67. Diverter valve.

68. Diverter valve manifold.

69. Pump

70. Pump manifold.

71. DHW plate heat exchanger.

75. Control box clamp.

94. Ignition lead.

98. Air Vent (Pump)

103. Dry fire thermistor.

evo HE C - Installation and Servicing

103

evfu9803

BOILER ASSEMBLY - Exploded View

INSTALLATION

evo HE C - Installation and Servicing

INSTALLATION

UNPACKING

The boiler is supplied fully assembled in one Pack A, together with a telescopic flue assembly for lengths up to 595mm, rear or side flue outlet, in Pack B.

Unpack and check the contents.

Pack A Contents

A Boiler

B Hardware Pack Box

C Wall Mounting Plate

D These Installation/Users

Instructions

INSTALLATION

E Wall Mounting Template

(located on internal protective packaging)

F 1 Year Guarantee

evfu9804

Hardware Pack Contents

A Support Bracket - 1 off

B Accessory Pack

C CH Flow Valve & Gauge Pack

D DHW Pack

Pack B Contents

A Telescopic flue terminal

B Flue turret

C Rubber Terminal Wall Seal

D Screw

E Sealing tape

E Gas Valve Pack

F CH Return Valve Pack

G “S” Trap Hose Moulding

isfu8751d

evo HE C - Installation and Servicing

PACKAGING REMOVAL

1. Ensure the boiler is on a sound flat

surface.

2. Carefully remove the strapping.

3. Fold back the top flaps to gain access to:

z Instructions

z 1 year guarantee

z Wall mounting plate

z Wall mounting template.

(located under pre-piping frame on protective packaging).

4. Remove the instructions and read thoroughly before unpacking the product.

5. When ready for installation lift off the cardboard carton.

INSTALLATION

Wall Mounting template/

protective packaging

INSTALLATION

Hardware pack box

BOTTOM AND FRONT PANEL REMOVAL

1. Remove the screw from the

underside of the boiler’s bottom panel.

2. Pull the right-hand side of the panel down, slide it to the right and withdraw.

3. Remove the screws from bottom of the front panel.

4. Lift panel up and off top pegs.

Boiler

evfu9805

evfu

9806

evo HE C - Installation and Servicing

INSTALLATION

Wall Thickness X

160 mm

160 + S = 193mm

nm8943

195mm

Wall Thickness X

Side flue length L

DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED

IMPORTANT. The boiler MUST be installed in a vertical position

Dimension X - Wall thickness.

Dimension L - Wall thickness plus boiler spacing.

Dimension S - Stand-off frame depth = 33mm

Note. MAXIMUM FLUE LENGTHS:

C22/24 & C22/30 - 6M (HORIZONTAL FLUE) C22/35 - 3M (HORIZONTAL FLUE)

C22/24, C22/30 & C22/35 - 7.5M (ROOF FLUE)

C22/24, C22/30 & C22/35 - 5M PRIMARY AND 17M SECONDARY IS A TYPICAL MAX.

FLUE LENGTH. (For alternative details refer to Powered Vertical Instructions)

ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 1M)

ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 0.6M)

MINIMUM HORIZONTAL FLUE LENGTHS - TELESCOPIC TERMINAL = 370MM

(Centre Line of turret to outside of wall terminal) - ONE PIECE TERMINAL = 285MM

FLUE KITS

Pack B - supplied as standard

Pack D - optional extension kit for side flue or rear flue outlet.

Screw Kit - Optional kit for mechanical fixing of flue joints

Finishing Kit - Supplied as an optional extra.

Refer to 'Flue Extension Ducts'

SIDE FLUE

REAR FLUE

FLUE OUTLET

evo HE C - Installation and Servicing

INSTALLATION

12A

Notes.

1. It is recommended that a support bracket is fitted for every 1 meter of extension pipe used and a bracket should be used at every joint, to ensure pipes are held at the correct angle.

If a slip joint coupling is to be used then a bracket should be used to secure the collar.

2. When extension ‘D’ packs are used the flue duct MUST be inclined at 1.5 degrees to the horizontal to allow condensate to drain back into the boiler and out through the condensate drain.

3. If the telescopic ‘B’ pack, or horizontal flue terminal (600 long) only are used, they may be mounted horizontally. The 1.5 degrees is taken care of by the inclination of the flue within the air pipe.

4. If the boiler is to be installed with upward piping routed behind the boiler then the optional stand-off kit should be used. Care must be taken when cutting the ducts and marking the wall to suit this condition.

5. Only use water as a lubricant during assembly. Do not use mineral based oils.

CONT’D DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED

Total Flue length dimension Flue

(measuring from CL of turret to outside wall)

Rear flue Side flue Extra packs Boiler

dim. X+160 dim. L+195 required Size

Up to 595 mm Up to 595 mm none C22/24,30 & 35

Up to 1545 mm Up to 1545 mm Pack D - 1 off C22/24,30 & 35

Up to 2495 mm Up to 2495 mm Pack D - 2 off C22/24,30 & 35

Up to 3445 mm Up to 3445 mm Pack D - 3 off C22/24,30 & 35*

Up to 4395 mm Up to 4395 mm Pack D - 4 off C22/24 & 30

Up to 5345 mm Up to 5345 mm Pack D - 5 off C22/24 & 30

Up to 6000 mm Up to 6000 mm Pack D - 6 off C22/24 & 30

*evo HE C22/35 is capable of 3m flue only

FLUE ASSEMBLY - Exploded View

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

Side 395mm

Rear 435mm

LEGEND

1. Duct assembly.

2. Flue turret.

3. Turret gasket.

4. M5 x 10 pozi screw.

5. Turret clamp.

Rear flue arrangement shown

TOP

The flue terminal MUST be fitted with the ‘TOP’ uppermost to allow the correct fit and use of the plume management system.

nm8760

FLUE OUTLET

evo HE C - Installation and Servicing

INSTALLATION

nm8772

C22/35

C22/24 & C22/30

WALL MOUNTING TEMPLATE

The wall mounting template is located on the internal protective packaging.

Note.

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

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 155mm for standard installation.

Note. If using stand-off kit distance increases to 188mm.

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 below).

Note. Mark the centre of the hole as well as the

circumference.

4. Remove the template from the wall.

Extended centre line

155

V - See Diagram Below

nm9279

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.

2. Drill 4 holes with a 7.5mm / 8mm masonry drill and insert the plastic plugs, provided, for the piping frame.

3. Locate 4 No.14 x 50mm screws in the piping frame (one at each side, in any of the 3 holes provided at each side) and screw home.

FLUE OUTLET

Section through wall

Rear flue only 5" diameter hole

Note. Check all of the hole positions before drilling.

evo HE C - Installation and Servicing

Side flue only 5" diameter hole

2011

INSTALLATION

var9784

Rubber

Terminal Wall Seal

nm8944

X + 75

Drill hole

Adhere sealing tape

Measurement to be

taken from this point

TERMINAL WALL SEAL ASSEMBLY / POSITIONING

Prior to fitting the flue, the rubber terminal wall seal provided in the flue pack MUST be fitted to the flue terminal as shown below in Figure 1.

FIGURE 1 FIGURE 2

Once the flue is installed it is IMPORTANT that the rubber terminal wall seal is pressed against the outside wall to create an adequate seal between the flue and wall as shown in Figure 2.

Wall Seal Lip

Step

Ensure lip of wall seal is positioned over step on plastic nose of flue terminal

(note, seal is cut away for clarity)

isfu9783

17A

SETTING THE FLUE - REAR Wall thicknesses of 210 to 435mm

Notes.

a. If using the extension ducts go to Frame 18.

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

to dimension X.

c. For shorter flue requirements less than 210mm, use non

telescopic B Pack.

1. Measure and note wall thickness X. Refer to Frame 12.

2. Add 75mm to dimension X and set telescopic flue length

as indicated in drawing.

3. Using a 3.5mm drill bit, drill one hole in outer air duct taking care not to pierce plastic inner flue.

4. Fix to length using self tappers provided.

5. Seal outer air duct using the tape provided.

17B

SETTING THE FLUE - SIDE Wall thicknesses of 170 to 395mm

Notes.

a. If using the extension ducts go to Frame 18.

b. For shorter flue requirements use non telescopic B

Pack.

1. Measure and note wall thickness X. Refer to Frame 12.

2. Measure distance from side of boiler to inside of wall

and add to wall thickness X=L. Refer to Frame 12.

3. Add 115mm to dimension L and set telescopic flue length as indicated in drawing.

4. Using a 3.5mm drill bit, drill one hole in outer air duct taking care not to pierce plastic inner flue.

5. Fix to length using self tappers provided.

6. Seal outer air duct using the tape provided.

evo HE C - Installation and Servicing

Drill hole

nm8945

Adhere sealing tape

L + 115

Measurement to be

taken from this point

FLUE OUTLET

INSTALLATION

nm8762

Boiler

Standard flue

Terminal grille

Flue length

Extension flue

FLUE EXTENSION DUCTS - For total flue lengths greater than 595mm

Pack D Flue extension duct kit contents

Extension duct & clamp

1.0m (39") long

nm8732

FLUE EXTENSION DUCTS - continued

Use a maximum of 6m extended flue ONLY (C22/24 &

30) Use a maximum of 3m extended flue ONLY (C22/35)

Flue duct support

General arrangement

1. A maximum of 6 extension ducts for the C22/24

and C22/30 and a maximum of 3 extension ducts for the C22/35 (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 Frames 18 and 26.

3. Only use water as a lubricant during assembly. Do not use mineral based oils.

Flue support cutting aid (shown folded up)

Wall plugs - 4 off

No. 10 x2" wood screw - 4 off

Note. Side flue shown

FITTING THE KIT

Because of the flexibility of the telescopic flue terminal it is not always necessary to cut an extension pack.

1. Measure the total flue length from the centre of the boiler outlet to the outside wall.

2. Subtract 70mm from this dimension.

3. Subtract 950mm for each ‘D’ pack to be used.

4. If the remainder Y is 300mm -

525mm this can be taken up by the adjustment in the telescopic flue.

5. If the remainder Y is 525mm 950mm it will be necessary to cut a ‘D’ pack to 400mm.

FLUE OUTLET

esp8940

6. if the remainder Y is less than 300mm, shorten the previous ‘D’ pack to 400mm and adjust the telescopic terminal.

7. Measure and mark the length on the flue, to ensure a square cut mark the flue all the way around and cut to length.

950

525

300

evo HE C - Installation and Servicing

INSTALLATION

FITTING THE WALL MOUNTING PLATE (Rear Flue outlet shown)

TO FIT THE WALL MOUNTING PLATE DIRECTLY TO THE WALL

• Insert wall plugs.

• Put the screws into the wall plugs and leave 10mm proud

• Hang the plate onto the screws (take care to use the same

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

• Locate the support bracket on the mounting plate.

TO FIT THE WALL MOUNTING PLATE USING THE STAND-OFF FRAME OPTION KIT (To allow pipework to be taken

upwards)

• Put the screws into the wall plugs and leave 10mm proud.

• Hang the stand-off frame onto the screws and tighten up.

• Fasten the wall mounting plate to the stand-off frame with the 6mm screws provided.

• Locate the support bracket on the mounting plate.

Note.

If the clearances above and below the boiler are less than the length of the pipes it will be necessary to position the pipes behind the wall mounting plate BEFORE the plate is screwed to the wall.

evo HE C - Installation and Servicing

FLUE OUTLET

CONDENSATE DRAIN

Before mounting the boiler on the wall, the condensate drain (provided in the h/ware pack) must be connected from the boiler ‘S’ trap to a drainage point, preferably within the building.

Ensure that the condensate trap is full of water before commissioning the boiler . Refer to Frame 26.

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

INSTALLATION

IMPORTANT.

If excessive external pipework cannot be avoided an additional siphon kit and insulation are recommended to prevent possible freezing.

All pipework and fittings in the condensate drain system must be made of plastic. No other materials may be used.

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

If external condensate pipe run is greater than 3m then pipe must be 32mm nominal diameter.

Consideration must be given to insulating external condensate pipe runs.

INSTALLATION

CONDENSATE PIPE TERMINATION CONFIGURATIONS

Notes: ALL PIPE RUNS MUST BE IN ACCORDANCE WITH BS6798

1. INTERNAL TO SINK WASTE UPSTREAM OF SINK WASTE TRAP

2. INTERNAL TO SINK WASTE

BOILER

cla7771b

BOILER

Sink constitutes

air break

DOWNSTREAM OF SINK WASTE TRAP (PREFERRED METHOD)

Air Break

cla9252

75mm trap

Open end of pipe direct into gulley below grating but above water level

Ground Level

DRAIN

Sink

Open end of pipe direct into gulley below grating but above water level

Ground Level

DRAIN

continued . . . .

evo HE C - Installation and Servicing

INSTALLATION

BOILER

External

wall

Ground Level

Termination

to Soak away

cla7774

minimum

500mm

CONDENSATE PIPE TERMINATION CONFIGURATIONS . . . continued

3. INTERNAL CONNECTION TO SOIL AND VENT STACK

Termination into a down pipe can take place providing it can be confirmed that the down pipe is part of a combined waste and rain water system.

* Make connection to SVP using a solvent welded saddle

4. TERMINATION TO SOAK AWAY

BOILER

Air Break

INSTALLATION

cla9253

5. TERMINATION TO DRAIN / GULLEY

evo HE C - Installation and Servicing

BOILER

External

wall

Open end of pipe direct into gulley below grating but above water level

cla7775

Ground Level

DRAIN

INSTALLATION

MOUNTING THE BOILER

1. Before mounting the boiler on the wall place it on its left hand

side and fit ‘S’ trap hose, supplied in the hardware pack.

2. Locate position of 15mm copper safety drain discharge pipe. Ensure this pipe is not strained or damaged when mounting the boiler.

3. Ensure that the plastic blanking plugs are removed from all of the boiler service connections before mounting. Note that some spillage of water may occur when mounting the boiler to the frame.

4. Lift the boiler onto the wall mounting frame, locating it over the tabs at the top of the frame. When handling the boiler take care not to place strain on safety valve discharge pipe.

5. Lower the boiler into position, engaging it onto the support bracket.

INSTALLATION

IMPORTANT: When handling the boiler take care not to place strain on the safety valve discharge pipe.

CONNECTING THE FLUE TO THE BOILER

Note. Before fitting the flue turret fill the condensate trap within the

boiler by pouring a cupful of water into the flue outlet A. Take care to ensure that the water is only poured into the flue outlet, and does not spill into the boiler casing.

1. Locate the flue into the turret.

2. Insert the flue assembly through the

prepared hole in the wall. Push through and pull back to seal against outside wall face.

3. Locate the flue turret on the top of the boiler, ensuring that the turret gasket is in place. Also ensure the turret is located concentric with the flue aperture on the boiler top panel. Check that the flue seal ‘A’ located in the top of the flue manifold is secure and giving an effective seal.

4. 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.

5. Flues over 1 metre long.

Fix the flue support bracket to the wall, using the 4 wall plugs and wood screws.

NB. The space bracket will utilise one fixing hole only whilst used in conjunction with the stand-off option.

nm8764

evo HE C - Installation and Servicing

INSTALLATION

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 31, Flue Arrangement.

nm8736

ROOF FLUE KIT CONTENTS / OPTIONS

Flue Terminal UIN 203132

Flue duct

support

Flue Seal Collar - Flat Roof UIN 152259

Flue Seal Collar - Tile Roof UIN 152258

Vertical connector UIN 203135

elbow

UIN 203131

Roof Flue Extension Duct UIN 203129

elbow

UIN 203130

evo HE C - Installation and Servicing

nm8735

FLUE OUTLET

INSTALLATION

rf8394-1

690mm

Fixed

300mm

min

rf8393-1

300mm

min

300mm

min

625mm

Fixed

Flat roof - with structure

FLUE TERMINAL POSITION

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

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

Minimum dimensions are shown below

rf8392

FLUE OUTLET

Terminal Position Minimum Dimension

Directly below an opening,

air brick, windows, etc. 300 mm

Below plastic / painted gutters 300 mm

Below eaves or balcony 500 mm

Painted surface 300 mm

evo HE C - Installation and Servicing

INSTALLATION

rf8737

rf8738

FLUE ARRANGEMENT

Note.

The equivalent flue length resistance of the elbow kits are:

elbow kit = 1m

elbow kit = 0.6m

evo HE C - Installation and Servicing

FLUE OUTLET

INSTALLATION

nm8740

Flue Terminal

Pitched roof tile

weather collar

Flat roof tile

weather collar

nm8741

Extension Duct

Vertical connector

Turret clamp

ASSEMBLING THE ROOF FLUE KIT

Determine the correct height that the flue should terminate above the roof. If after calculating or measuring the overall flue height from the top of the boiler, it is necessary to cut both pipes of assembly A, then ensure they are cut equally leaving the inner flue tube longer than the outer air tube as supplied.

Ensure the cut pipe ends are free from any burrs.

1. Position the roof flashing plate (supplied separately) over the

hole cut in the roof and insert flue terminal from the roof end.

MAX LENGTH:

7.5m

min 16

max 41

BOILER

2. Fit the vertical connector (supplied seperately) in accordance with the in the instructions provided with the vertical connector kit. ENSURE THE GASKETS IN THE BOILER FLUE OUTLET

ARE CORRECTLY FITTED.

3. "Push" fit extension duct (if required (supplied separately)) into

vertical connector.

nm8739

nm8743

FLUE OUTLET

'X'

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

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

5. Finally ensure the roof flashing plate is correctly sealed to the roof.

evo HE C - Installation and Servicing

INSTALLATION

WATER CONNECTIONS - CH

1. Connect boiler service valves and copper tails provided in the hardware pack to the threaded boss connections

provided at the lower rear of the boiler. Ensure all boss blanking plugs are removed before connecting hardware. Each valve must be fitted to the correct boss as shown in the picture. Guidance to correct connection location is also provided on the wall-mounting template. Ensure each union is fitted with fibre seals provided.

2. If connecting the boiler to heating loads in excess of 60,000 Btu/h, connecting flow and return heating system pipework must be sized in 28mm diameter at the point of pipe connection to the boiler tails. Use 22mm x 28mm pipe adaptors as appropriate.

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

WATER CONNECTIONS - DHW

1. The DHW inlet isolating valve incorporates a flow regulator / filter pre-fitted in the valve body Inspect it to ensure no

blockage is evident. Fit it to the DHW inlet ball valve, ensuring the seal provided is correctly located.

2. Fit DHW outlet pipe tail to DHW outlet connection, ensuring the seal provided is correctly located.

evo HE C - Installation and Servicing

FLUE OUTLET

INSTALLATION

GAS CONNECTION

IMPORTANT. The gas service cock is sealed with a non-metallic blue fibre washer, which must not be overheated when

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

A boiler gas supply pipe length of 20m and not less than 15mm O.D. can be connected to the boiler via the gas service cock union.

Ensure that the gas supply pipe does not foul the boiler casing.

For additional gas supply information refer to “Gas Supply” on page 8.

INSTALLATION

SAFETY VALVE DRAIN

The safety valve connection, located at the bottom right-hand side of the boiler, comprises a 15mm diameter stub pipe.

The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring. A 15mm compression fitting is supplied with the Hardware Pack to connect it to the stub pipe.

evo HE C - Installation and Servicing

INSTALLATION

IMPORTANT - when filling:

A. Ensure the dust cap on air vent located at the rear of

B. When filling, there may be a slight water leak from

Central Heating

1. Remove the front panel. Refer to Frame 49.

2. Ensure that the CH isolating valves are open.

3. Fill and vent the system. Check for water tightness.

4. Pressurise the system to 1 bar.

Domestic Hot Water

1. Fully open all DHW taps and ensure that water flows

2. Close all taps.

Note. The domestic hot water flow rate is

automatically regulated to a maximum: C22/24 = 9.6 l/m (2.1 gpm) C22/30 = 12.0 l/m (2.6 gpm) C22/35 = 14.4 l/m (3.2 gpm)

FILLING

the pump chamber is slightly unscrewed.

the air vent therefore electrical connections should be protected.

freely from them.

INSTALLATION

evo HE C - Installation and Servicing

ELECTRICAL CONNECTIONS

INSTALLATION

WARNING. This appliance MUST be earthed.

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

The fuse rating should be 3A. All external controls and wiring must be suitable for mains voltage.

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

INSTALLATION

INTERNAL WIRING

A pictorial wiring diagram is shown in Frame 40.

This photo shows an external programmer lead (on the left) and the mains cable (on the right).

1. Route the mains cable from bottom left-hand rear of boiler casing to plug & socket connection.

2. Wire the permanent live supply into the 5-way remote plug terminals, L3, N & .

IMPORTANT.

A permanent live is ESSENTIAL in order for the advanced diagnostic controls to function correctly.

Ensure that the lengths of the live and neutral wires

are shorter than the earth wires so that if the cable

slips in its anchorage the current carrying wire

become taut before the earth wires.

Wiring should be 3 core PVC insulated cable, not less than

0.75 mm2 (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for electrical installations.

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, or a plug and socket, serving only the boiler and system controls. The means of isolation must be accessible to the user after installation.

3. Wire any switched live supply into L2 or connect L1 and L2 via external control switching as shown in Frame 39. In either case remove the wire link fitted to L1 to L2.

4. Secure the mains lead with the cable clamp.

5. Connect the mains lead connector. Ensure it is fully

located into the socket.

6. Support the incoming cable(s) with the clips provided.

evo HE C - Installation and Servicing

INSTALLATION

EXTERNAL ELECTRICAL CONTROLS

Wiring External to the Boiler

The fuse rating should be 3A.

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

Room Thermostat

If the thermostat has a neutral connection, use it (it provides for more energy efficient operation by reducing switching temperature differentials).

Frost Protection

If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system.

This is usually done at the programmer, in which case the programmer selector switches are set to OFF and all the other controls MUST be left in the running position.

The frost thermostat should be sited in a cold place but where it can sense heat from the system.

Note. If the boiler is installed in a garage it may be necessary to fit a pipe thermostat, preferably on the return pipework.

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

Designation of the terminals will vary but the programmer and thermostat manufacturers' leaflets will give full details.

Mains in

Optional

Frost 'stat

Room 'stat

System controls

if required

l 6069 Ec

INSTALLATION

Diagram A

Shows an application to boilers fitted with a room thermostat only.

Diagrams B & C

show applications to boilers fitted with alternative time controls.

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

evo HE C - Installation and Servicing

nm9323

Dry fire

thermistor

Diverter

Valve

Permanent

black

link

y/g

gy r v

123

y/g

INSTALLATION

PICTORIAL WIRING DIAGRAM

LEGEND b-blue

bk - black br - brown gy - grey or - orange pk - pink

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

INSTALLATION

evo HE C - Installation and Servicing

FUNCTIONAL FLOW WIRING DIAGRAM

INSTALLATION

LEGEND

b-blue bk - black br - brown gy - grey

COMMISSIONING AND TESTING

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.

or - orange pk - pink r-red v-violet

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

B. Gas Installation

1. The whole of the gas installation, including the meter,

should be inspected and tested for tightness 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.

WARNING. Whilst effecting the required gas tightness test and purging air from the gas installation,

open all windows and doors, extinguish naked lights and DO NOT SMOKE.

evo HE C - Installation and Servicing

INITIAL LIGHTING

INSTALLATION

LEGEND

A. Boiler On/Off switch.

B. CH thermostat knob.

D. Burner On neon.

E. Reset button.

F. Injector pressure test

point.

G. Inlet pressure test point.

H. Gas service cock.

J. Casing pressure test point.

K. Overheat thermostat.

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

not airlocked. Ensure the automatic air vent cap (N) is open.

Note.

It is important the burner is not operated before the system is fully vented of air. If it is necessary to operate the appliance pump to assist venting of the air this must be done with the gas service cock turned off.

2. Refit the boiler sealing panel. Refer to Frame 50.

3. Check that the drain cock is closed and that the CH and DHW

isolating valves (T, W and S) are OPEN.

4. Check that the electrical supply is OFF.

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

6. Check that the gas service cock (H) is OPEN.

7. Slacken the screw in the inlet pressure test point (G) and

connect a gas pressure gauge via a flexible tube.

8. Switch the electricity supply ON and check all external controls are calling for heat.

CENTRAL HEATING

9. Set the boiler thermostat knob (B) to position 6 and switch

the boiler on/off switch (A) to ON. The boiler control should now go through its ignition sequence until the burner is established.

10. If the boiler does not light after 3 attempts the fault code will be displayed, Press the reset button (E) and the boiler will repeat its ignition sequence.

When the burner is established the WHITE 'Burner On' neon (D) will be illuminated, the LED display will show status

M. Control thermistor (flow).

N. Automatic air vent.

R. Pressure gauge.

S. CH Flow isolating valve.

T. CH Return isolating valve.

U. DHW outlet.

W. DHW inlet

Y. DHW thermostat knob.

Z. Spark generator.

Control Box Servicing Position. See Frame 51.

THE DISPLAY

The user control has one neon and one display to inform the user about the status. The display will show the status of the boiler. The neon will show the status of the flame. If no flame is detected the neon is blinking. When the flame is detected the neon will be lit permanently.

Below is a list with display function in normal operation.

Standby, no demand for heat present.

Boiler is active for central heating.

Boiler is active for domestic hot water.

Boiler is heating up the plate heat exchanger.

Note: Boiler frost protection is activated as follows:

1 Pump runs if temperature is below 5 degrees C 2 Boiler fires if temperature is below 3 degrees C

Boiler is in lockout for a specific error. Display will be blinking, alternating with a number or letter to show which error is detected.

Boiler is in lockout for a specific error. Display will be blinking, which error is detected.

alternating with a number or letter to show

evo HE C - Installation and Servicing

INSTALLATION

INITIAL LIGHTING - continued

DOMESTIC HOT WATER

11. With the boiler firing, set the DHW thermostat knob (Y) to

maximum and fully open a DHW tap.

The boiler should continue to run and the LED display should show status

12. Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output. Refer to Table 2.

For additional gas supply information refer to “Gas Supply” on page 8.

IMPORTANT

The gas input to the burner is regulated by the gas valve according to the air flow produced by the fan. It is NOT user-adjustable. Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void.

13. Turn off the DHW tap.

14. Set the boiler on/off switch (A) to OFF.

15. Swing the control box into the servicing position. Refer to

Frame 51.

16. Remove the pressure gauge and tube. Tighten the sealing screw in the pressure test point. Ensure a gas tight seal is made.

17. Swing the control box back into its working position and secure. Reconnect the ignition lead.

18. Refit the user control.

19. Fit the boiler front and bottom panels.

INSTALLATION

GENERAL CHECKS

Make the following checks for correct operation in:

DOMESTIC HOT WATER (DHW) MODE

1. With no call for CH or DHW the boiler should fire for a

short period to preheat the DHW plate heat exchanger. The display should read

returning to when the burner switches off.

Notes. a. If no DHW is drawn off, the boiler will fire periodically

for a short time, to maintain the plate heat exchanger temperature.

b. The DHW preheat operates 24 hours a day .

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

freely from them. The display should read:

neon flashing then: neon steady when the burner lights.

3. Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate.

This is factory set to give a DHW temperature rise of approximately 35 “operation”.

4. Reduce the DHW draw-off rate to about 3 l/min (0.7gpm) and check that the boiler modulates to deliver DHW at approximately 65

5. Close the DHW tap and check that the main burner extinguishes. The pump should overrun for a few seconds and the display sequence should read:

When the pump stops the display sequence should read:

Note. On systems in excess of 2 bar inlet pressure a water pressure governor may be required to prevent water noise.

C at the flow rate stated on page 6 under

evo HE C - Installation and Servicing

INSTALLATION

GENERAL CHECKS - continued

CENTRAL HEATING (CH) & DOMESTIC HOT WATER (DHW) MODE.

1. Ensure that the CH external controls are calling for heat.

The display should read:

after first satisfying DHW preheat if necessary. ( )

2. Fully open a DHW tap and check that hot water is delivered.

The display should read:

flashing

INSTALLATION

3. Gas Rate

Check the boiler gas rate when the boiler is at full DHW output.

Check at the gas meter, with no other appliance in use. Refer to Table 3 for gas rates.

4. Close the DHW tap. The burner should go off and the pump continue to run.

The display should read:

flashing

then

flashing

After 15 seconds the burner should relight, to supply central heating.The display should read:

5. Set the central heating external controls to OFF. The burner should go off and the pump continue to run for five minutes

The display should read:

returning to

when the pump stops.

6. Check the correct operation of the programmer (if fitted) and all other system controls. Operate each control separately and check that the main burner responds.

WATER CIRCULATION SYSTEM

1. With the system COLD, check that the initial pressure is

correct to the system design requirements.

For pre-pressurised systems, this should be 1.0 bar.

2. With the system HOT, examine all water connections for soundness. The system pressure will increase with temperature rise but should not exceed 2.5 bar.

3. With the system still hot, turn off the gas, water and electricity supplies to the boiler and drain down to complete the flushing process.

Note: A flushing solution should be used during the flushing

procedure. Flushing solutions: Fernox Superfloc, Sentinel X300 (new systems) or X400 (existing systems). Refer to Frame 6.

4. Refill and vent the system, add inhibitor (see Frame 6), clear all air locks and again check for water soundness. Affix the water treatment warning label, supplied in the hardware pack, in a prominent position on the system, to prevent the use of incorrect water treatment additives.

5. Reset the system initial pressure to the design requirement.

6. Balance the system. Refer to Frame 5.

7. Check the condensate drain for leaks and check that it is

discharging correctly.

8. Finally, set the controls to the User's requirements.

Note: The pump will operate briefly as a self-check once

every 24 hours in the absence of any system demand.

WATER TEMPERATURES

Temperatures can be selected using the CH and DHW thermostats.

Knob Setting CH Flow DHW Outlet

Temp Temp

C (oF)

Max 82 (180) 65 (150)

Min 30 (86) 42 (110)

C (oF)

evo HE C - Installation and Servicing

INSTALLATION

HANDING OVER

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

1. Hand the 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 Gas Safe Registered Installer consulted. In IE contact a Registered Gas Installer (RGII).

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 underneath the boiler indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated. Explain the repressurising procedure and if unable to repressurise or if the pressure continues to drop a registered local heating installer should be consulted.

WARNING. Do not fire the boiler if the system pressure is less than 0.5 bar.

After installation and commissioning please complete the Commissioning Checklist before handover to the customer. For IE, its is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 813:2002.

IMPORTANT

10. A comprehensive service should be carried out ANNUALLY.

Stress the importance of regular servicing by a Gas Safe Registered Installer. In IE servicing work must be carried out by a Registered Gas Installer (RGII).

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.

INSTALLATION

evo HE C - Installation and Servicing

SERVICING

SERVICING SCHEDULE

For the very latest copy of literature for specification and maintenance practices visit our website www.idealboilers.com, where you will be able to download relevant information. N.B. Technical Bulletins are also available on our website.

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

To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually.

It is the law that any service work must be carried out by a Gas Safe Registered Installer. In IE service work must be carried out by a Registered Gas Installer (RGII).

1. Light the boiler and carry out a pre-service check, noting any operational faults.

2. Clean the main burner.

3. Clean the heat exchanger & ‘S’ trap.

4. Check the condition of the combustion chamber insulation.

Any cracked, damaged or displaced pieces should be replaced. Ionisation probes are a servicable component and requires inspecting annually. Replace if distorted.

SERVICING

5. Check the main injector for blockage or damage.

6. Wherever possible remove and clean the condensate ‘S’

trap (refer to Frame 54) and check the drain for blockage.

7. Check that the flue terminal is unobstructed and that the flue system is sealed correctly.

8. Check the DHW filter for blockage. Refer to Frame 33.

The servicing procedures are covered more fully in Frames 49 -56 and MUST be carried out in sequence.

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 49 and 50.

IMPORTANT.

9. After completing the servicing or exchange of components

always test for gas tightness.

10. When work is complete the sealing panel MUST be correctly refitted, ensuring that a good seal is made.

Do NOT OPERATE the boiler if the sealing panel is not fitted.

11. If, for any reason, the condensate ‘S’ trap has been removed ensure the trap is refilled with water before reassembling.

12. Check the gas consumption.

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

the top of the boiler (refer to Frame 49) or into the flue terminal if access is possible (optional test). For correct boiler operation, the CO/CO gas should not be greater than 0.004 ratio.

14. Complete the service section in the Benchmark Commissioning Checklist.

content of the flue

evo HE C - Installation and Servicing

BOILER FRONT PANEL REMOVAL

1. Remove the 2 screws from the

underside of the boiler.

2. Pull the panel forward at the bottom and lift to disengage it from the top lugs.

SERVICING

BOILER SEALING PANEL / BOTTOM PANEL REMOVAL

1. To remove the sealing panel remove

the 4 screws.

2. Remove the panel.

3. To remove the bottom panel first

remove the screw.

4. Pull the right hand side of the panel down. Slide it to the right and withdraw.

SERVICING

evo HE C - Installation and Servicing

SERVICING

MOVING CONTROL BOX TO THE SERVICING POSITION

1. Remove the 2 screws and withdraw the user

control.

2. Unplug the low voltage electrical lead from the back of the user control.

3. Release the clamp,

4. Swing the control box down

5. Pull the control box slightly forward.

SERVICING

evo HE C - Installation and Servicing

SERVICING

FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING

1. Disconnect the electrical leads from the

fan.

2. Undo the gas pipe union connection to the injector housing.

3. Undo the screw on the fan mounting bracket.

4. Lift off fan and venturi assembly.

5. Inspect the injector for blockage or

damage.

BURNER REMOVAL AND CLEANING

1. Remove the 6 screws securing the

burner (the 3 screws at the rear are extended to ease access).

2. Lift off the burner from the combustion chamber.

IMPORTANT

The burner head is a ceramic plaque construction. Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic.

3. Brush off any deposits that may be on the ceramic with a SOFT brush.

4. Inspect the sealing gasket around the burner and combustion chamber insulation for any signs of damage. Replace as necessary.

Note.

Take care not to disturb the ionisation probes at the front and rear of the combustion chamber.

SERVICING

Ionisation Probes

nm7400

evo HE C - Installation and Servicing

nm7401

Sump cover

Ionisation probes

Heat exchanger

CLEANING THE CONDENSATE 'S' TRAP

Note: Ensure the condensate trap is

fully drained before removal.

1. Swing the control box down into the

servicing position. Refer to Frame 51.

2. Disconnect the condensate drain pipe.

3. Remove the 2 screws and pull the trap

down and forward to remove.

4. Flush out any deposits with clean water.

SERVICING

CLEANING THE HEAT EXCHANGER

Note: Ensure the sump is fully drained before removal.

1. Remove ignition and flame detection electrodes. Refer to

Frames 63 & 64.

2. Remove the 3 screws retaining the sump cover and remove.

SERVICING

3. Using a suitable tool as supplied in the standard British

Gas Flue brush kit, clean between the heat exchanger fins from the top of the heat exchanger.

4. Access to the base of the heat exchanger is now possible. Brush clean any deposits from the base of the heat exchanger and remove any loose deposits from the sump.

5. Inspect the ignition and detection electrodes. Ensure that they are clean and in good condition - replace if necessary.

6. Check the condition of the combustion chamber insulation. Any cracked or damaged pieces must be replaced.

Note. Take care not to disturb the ionisation probes at the

front and rear of the combustion chamber.

7. Check that the ignition and detection gaps are correct. Refer to Frames 63 & 64.

Reassemble the boiler in the following order:

1. Refit the condensate ‘S’ trap, ensuring that it is full of water.

2. Refit the sump cover.

3. Refit the electrodes. (Check dimensions; Frames 63 & 64).

4. Refit the burner.

5. Refit the fan / venturi assembly.

6. Reconnect the fan electrical lead.

REASSEMBLY

7. Refit the boiler sealing panel.

IMPORTANT.

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

8. Swing the control box back into its working position and secure.

9. Refit the display unit.

10. Refit the boiler front and bottom panels.

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

12. Reconnect the electrical supply.

evo HE C - Installation and Servicing

ispfu9797

REPLACEMENT OF COMPONENTS

SERVICING

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 49.

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

THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED

DRY FIRE THERMISTOR REPLACEMENT

1. Refer to Frame 57.

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

Frames 49 & 50.

3. Drain down the boiler. Refer to Frame 77.

4. Unplug the electrical lead.

5. Unscrew the thermistor.

6. Fit the new thermistor using the sealing washer

provided.

7. Reassemble in the reverse order.

8. Check the operation of the boiler. Refer to Frames 45

& 46.

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 84.

2. In order to replace components in Frames 74-82 it is necessary to drain the boiler. Refer to Frame 77.

SERVICING

FAN REPLACEMENT

1. Refer to Frame 57.

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

49 & 50.

3. Disconnect the electrical leads from the fan.

4. Undo the gas pipe union connection to the injector housing.

5. Remove the screw retaining the fan mounting bracket.

6. Remove the fan and venturi assembly. Refer to Frame 52.

7. Unscrew the 3 screws and remove the venturi assembly,

noting the orientation of the venturi in relation to the fan body.

8. Transfer the venturi assembly to the new fan, replacing the gasket if evidence of damage or deterioration is visible.

9. Fit the new fan / venturi assembly.

10. Reassemble the boiler in reverse order, taking care not to

overtighten the screw on the fan mounting bracket.

11. Check the operation of the boiler. Refer to Frames 45 & 46.

evo HE C - Installation and Servicing

SERVICING

nm7402

Ionisation Probes

BURNER INJECTOR REPLACEMENT

1. Refer to Frame 57.

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

49 & 50.

3. Disconnect the electrical leads from the fan.

4. Undo the gas pipe union connection to the injector housing.

5. Remove the screw retaining the fan mounting bracket.

6. Remove the fan and venturi assembly

7. Remove the 2 injector housing screws.

8. Withdraw the injector housing.

9. Fit the new injector housing complete with injector.

10. Reassemble in reverse order, ensuring that the new gas seal

supplied is located correctly in the injector housing.

11. Check operation of the boiler. Refer to Frames 45 & 46.

BURNER REPLACEMENT

1. Refer to Frame 57.

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

Frames 49 & 50.

3. Remove the fan assembly. Refer to Frame 59.

4. Remove the 6 screws securing the burner (the 3 screws at

the rear are extended to ease access).

5. Lift off the burner from the combustion chamber.

6. Fit the new burner, replacing any damaged or deteriorating

SERVICING

sealing gasket.

7. Reassemble in reverse order.

8. Check the operation of the boiler. Refer to Frames 45 & 46.

Note. Take care not to disturb the ionisation probes at the

front and rear of the combustion chamber.

Fan

Injector

Gas pipe union

Mounting bracket

Ecl 2400

CONTROL THERMISTOR, RETURN THERMISTOR & OVERHEAT ‘STAT RENEWAL

1. Refer to Frame 57.

2. Remove the boiler front and sealing panels.

Refer to Frames 49 & 50.

3. Unclip the thermistor A and thermostat B from the flow pipe C and withdraw it from the controls compartment.

4. Unclip the thermistor D from the return pipe E and withdraw

it from the controls compartment.

5. Disconnect the electrical leads from the thermistors or thermostat.

6. Reconnect the electrical leads and reassemble in reverse order, ensuring that the spring clips are securely on the pipes.

7. Check the operation of the boiler. Refer to Frames 45 & 46.

evo HE C - Installation and Servicing

SERVICING

IGNITION ELECTRODE REPLACEMENT

1. Refer to Frame 57.

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

Frames 49 & 50.

3. Unplug the ignition lead from the electrode.

4. Remove the earth lead from the ignition electrode.

5. Remove the remaining screw holding the ignition electrode

to the combustion chamber.

6. Remove the electrode.

7. Fit the new ignition electrode, using the new gasket

supplied. Check dimensions as shown.

8. Reassemble in reverse order, and check that no damage to the combustion chamber insulation has occurred during the electrode replacement.

9. Check the operation of the boiler. Refer to Frames 45 &

46.

FLAME DETECTION ELECTRODE REPLACEMENT

1. Refer to Frame 57.

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

Frames 49 & 50.

3. Unplug the flame detection lead from the electrode.

4. Remove the 2 screws holding the flame detection

electrode to the combustion chamber.

5. Remove the electrode.

ispfu9788

6. Fit the new flame detection electrode, using the new gasket supplied. Check dimensions as shown.

7. Reassemble in reverse order, and check that no damage to the combustion chamber insulation has occurred during the electrode replacement.

8. Check the operation of the boiler. Refer to Frames 45 & 46.

SERVICING

SPARK GENERATOR REPLACEMENT

1. Refer to Frame 57.

2. Disconnect the leads from the spark generator.

3. Remove the M4 screws securing the spark

generator to the boiler chassis.

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

5. Check operation of the boiler. Refer to Frames 45 &

46.

evo HE C - Installation and Servicing

ispfu9801

GAS CONTROL VALVE REPLACEMENT

1. Refer to Frame 57.

2. Swing the control box down into the

servicing position. Refer to Frame

51.

3. Unplug the electrical lead connection from the gas control valve and disconnect the earth wire.

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

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

6. Disconnect the white tube from the valve.

7. Remove the back nut retaining the valve to the bottom panel and withdraw the valve upwards.

8. Fit the new gas control valve and reconnect gas and electrical connections.

9. Re-connect the white tube to the valve.

10. Check operation of the boiler. Refer to Frames 45 & 46.

SERVICING

DIVERTER VALVE ACTUATOR REPLACEMENT

1. Refer to Frame 57.

2. Swing the control box down into the

servicing position. Refer to Frame 51.

3. Remove the electrical connections.

4. Using a suitable tool pull out the retaining

clip and lift the diverter head from the brass body.

5. Fit new actuator head and reassemble in reverse order Ensure the electrical connections are fitted correctly (left to right GREY - RED - PURPLE)

6. Check operation of the boiler. Refer to Frames 45 & 46.

evo HE C - Installation and Servicing

SERVICING

COMBUSTION CHAMBER INSULATION REPLACEMENT

Ideal Stelrad Group recommends that, for your own comfort and safety and to comply with good working practice, the procedure described below is followed:

1. Refer to 'Replacement of Components' Frame.

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

'Boiler Front Panel Removal' and 'Boiler Sealing Panel Removal' Frame.

3. Remove the fan / venturi assembly. Refer to 'Fan and Venturi Assembly removal and cleaning' Frame.

4. Remove the burner. Refer to 'Burner removal and cleaning' Frame.

5. Remove the ignition electrode. Refer to 'Ignition Electrode replacement' Frame.

6. Remove the flame detection electrode. Refer to 'Flame Detection electrode replacement' Frame.

7. Remove the front and rear ionisation probes and discard.

Prior to removal of the insulation piece the following protective equipment should be worn:

- Face mask supplied with the spare part.

- Gloves supplied with the spare part.

8. Damp down the combustion chamber area containing the insulation piece.

9. Remove the insulation piece. The replacement one piece insulation is supplied in a plastic bag, this bag should be retained and the discarded insulation should now be placed into it.

10. Sweep any dampened particles and place in the plastic bag.

11. Fit new insulation piece -

(a) Locate and align the insulation with the electrode

holes and position the insulation into the combustion chamber.

(b) Push the flexible material into the corners of the

combustion chamber ensuring it is flat and flush against the combustion chamber wall.

the combustion chamber.

(d) Again push the flexible material into the corners of the

combustion chamber ensuring it is flat and flush against the combustion chamber wall.

(e) Secure the insulation by replacing the ionisation

probes with those supplied in the kit. Note that ionisation probes are a serviceable component and require inspecting annually.

Note. The insulation is designed to be interlocking and

should be fitted as shown.

12. Remove the gloves and face mask and place them in the plastic bag.

13. Wash your hands and any areas of skin which may have come into contact with any of the particles from the insulation piece.

Note. Seal the plastic bag and dispose of it and its contents

into a commercial tip.

14. Reassemble in reverse order.

15. Check operation of the boiler. Refer to 'General Checks'

Frames.

SERVICING

Insulation

Combustion

chamber

evo HE C - Installation and Servicing

isfu9570

CONDENSATE 'S' TRAP REPLACEMENT

1. Refer to Frame 57.

Note: Ensure condensate trap is fully drained before

removal.

2. Remove the casing front & bottom panel. Refer to Frames 49 & 50.

3. Swing the control box down into the servicing position. Refer to Frame 51.

4. Disconnect the condensate drain pipe.

5. Remove the 2 securing screws and pull the trap

down and forward to remove.

6. Transfer the drain pipe to the new trap and reassemble in reverse order.

7. When reassembling ensure the trap is full of water.

SERVICING

8. Check operation of the boiler. Refer to Frames 45 &

46.

DHW THERMISTOR REPLACEMENT

1. Refer to Frame 77 for draining the appliance.

2. Swing the control box into the servicing position. Refer

to Frame 51.

SERVICING

3. Drain the DHW circuit. Refer to Frame 77.

4. Unscrew the knurled retaining nut.

5. Disconnect the in line electrical connection and withdraw

the thermistor.

6. Reassemble in reverse order.

7. Check operation of the boiler. Refer to Frames 45 & 46.

evo HE C - Installation and Servicing

SERVICING

CONTROL BOX REPLACEMENT

1. Refer to Frame 57.

2. Remove the casing front & bottom panel.

Refer to Frames 49 & 50.

3. Swing the control box down into the servicing position. Refer to Frame 51.

4. Unplug the user control electrical lead and low voltage lead from the control box and remove the control. Refer to diagram A.

5. Return the control box to the working position and secure with the clamp. Unscrew the mounting bracket screws to remove the bracket. Refer to diagram B.

6. Release the clamp and carefully remove the control box from the hinge arms. Refer to diagram C.

7. Unplug all the electrical wiring from the control box and remove.

8. Transfer mounting bracket and hinge arms to the new control box.

9. Reassemble in reverse order, ensuring that the control box is located correctly in the housing before reconnecting the electrical wiring.

10. Check operation of the boiler. Refer to Frames 45 & 46.

MAINS SWITCH REPLACEMENT

1. Refer to Frame 57.

2. Remove the casing front & bottom panel.

Refer to Frames 49 & 50.

3. Remove the 2 screws and allow the user control to lower.

4. Push out the mains switch from the rear, as shown.

5. Fit the new switch, ensuring that the electrical leads are

replaced on the correct terminals (refer to Frame 41) and the key on the switch is correctly aligned with the slot in the plastic moulding.

SERVICING

6. Reassemble in reverse order.

7. Check operation of the boiler. Refer to Frames 45 & 46.

evo HE C - Installation and Servicing

SERVICING

USER CONTROL REPLACEMENT

Note. Only the display unit is replaced.

1. Refer to Frame 57.

2. Loosen the screw on the underside of the user control.

3. Pull the display unit forward to remove.

4. Push the new display unit into position.

5. Reassemble in reverse order.

6. Check operation of the boiler. Refer to Frames 45 & 46.

Ecl 2044

Display unit

PRESSURE GAUGE RENEWAL

1. Refer to Frame 57.

2. Drain the boiler. Refer to Frame 77.

3. Unscrew the pressure gauge and discard.

SERVICING

4. Fit the new pressure gauge, using a suitable jointing compound.

5. Refill the boiler. Refer to Frame 36.

6. Check operation of the boiler. Refer to Framea 45 & 46.

SAFETY RELIEF VALVE RENEWAL

1. Refer to Frame 57.

2. Drain the boiler CH circuit. Refer to Frame 77.

3. Undo the 15mm compression fitting from the pressure

relief outlet pipe.

4. Remove self tapping screw located on chassis adjacent to outlet pipe.

5. Withdraw expansion vessel flexi hose clip and lift away from pump housing to improve access to the safety valve.

6. Withdraw the clip securing the safety valve.

7. Lift safety valve complete with its outlet pipe and support

bracket upwards. Note outlet pipe bracket is supported by key-hole fastener. Withdraw assembly from boiler.

8. Fit the new safety valve to the pipe and reassemble in reverse order.

9. Refill boiler. Refer to Frame 36. Check operation of boiler. Refer to Frames 45 & 46.

Viewed from back of boiler

evo HE C - Installation and Servicing

SERVICING

AUTOMATIC AIR VENT REPLACEMENT

HEAT EXCHANGER AIR VENT

1. Refer to Frame 57.

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

frames 49 & 50.

3. Drain the boiler. Refer to frame 77.

4. Remove the turret from the boiler. Refer to frame 26.

5. Release the silicon tubing from the sample point.

6. Release the electrical connections from the dry fire

thermistor.

7. Release the electrical connections from the spark generator.

8. Remove the M5 x 10 screw retaining the top flue manifold casting.

9. Remove the casting.

10. Remove the fan from the boiler. Refer to Frame 52.

11. Remove the burner from the heat exchanger. Refer to

Frame 53.

12. Unscrew the air vent from its heat exchanger mount and renew.

13. Re assemble the boiler in reverse order.

14. Refill the boiler. Refer to frame 36. Check for leaks

around the new air vent joint.

15. Check the operation of the boiler. Refer to Frames 45 & 46.

PUMP AIR VENT

1. Refer to Frame 57.

2. Swing the control box down into the servicing

position - refer to frame 51

3. Drain the boiler. Refer to frame 77.

4. Remove the circulating pump head - refer to frame

5. Locate the automatic air vent head located at the rear of the of pump chamber plastic housing. If increased access is required disconnect the 22mm pipe connection at top a pump chamber and swing pipe outwards.

6. The automatic air vent head is retained in the pump body with a bayonet connection. The air vent head and float assembly is removed by turning the head anti-clockwise (viewed from above) and pulling upwards.

7. Reassembly is the reverse of the above. Ensure the air vent head 0 ring seal is in place when refitting.

8. Refill the boiler. Refer to frame 36. Check for leaks around the new air vent joint.

9. Check the operation of the boiler. Refer to Frames 45 & 46.

SERVICING

Viewed from back of boiler

evo HE C - Installation and Servicing

SERVICING

DRAINING THE BOILER

1. Refer to frame 57.

2. Close all the water isolating (CH and DHW) valves on the boiler inlet.

3. To drain the central heating circuit: Attach a length of hose to the CH drain point and open the drain valve.

4. To drain the domestic hot water circuit. As there is no direct drain for the domestic hot water circuit, depending on

the location of the boiler, opening the lowest hot water tap may drain this circuit. However it must be noted that some residual water will be experienced during replacement of components.

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 with filling loop) before proceeding to check operation of the boiler.

6. Check operation of the boiler. Refer to Frames 45 & 46.

SERVICING

DIVERTER VALVE INTERNAL PARTS REPLACEMENT

1. Refer to Frame 57.

2. Swing the control box down into the

servicing position. Refer to Frame 51.

3. Drain the boiler. Refer to Frame 77.

4. Remove the divertor valve actuator head.

Refer to Frame 67.

5. Unscrew the top connection to access the internal parts.

6. To allow residual water within the waterset to drain, slacken CH isolation valve union nut connecting isolation valve to waterset.

NOTE. Failure to do this may result in compression of trapped residual water during diverter valve reassembly, resulting in damage to the pressure gauge located on the CH isolation valve.

7. Fit the new valve cartridge mechanism

ensuring correct fit of the pin.

8. Reassemble in reverse order ensuring CH isolation valve union is reconnected.

9. Refill the boiler. Refer to Frame 36.

10. Check operation of the boiler. Refer to

Frames 45 & 46.

Cartridge Mechanism Part No. 175 411

Important:

Slacken isolation valve union to drain residual water contained within waterset.

evo HE C - Installation and Servicing

SERVICING

DHW PLATE HEAT EXCHANGER REPLACEMENT

1. Refer to Frame 57.

2. Swing the control box down into the servicing

position. Refer to Frame 51.

3. Drain the boiler. Refer to Frame 77.

4. Remove divertor valve actuator. Refer to Frame

67.

5. Remove condensate “S” trap. Refer to Frame 54.

6. Remove the 2 allen screws securing the plate heat

exchanger to the brass housings.

7. Manoeuvre the plate heat exchanger out of the top left-hand side of the controls area.

8. Fit the new plate heat exchanger, using the new orings supplied.

9. Reassemble in reverse order.

10. Refill the boiler. Refer to Frame 36.

11. Check operation of the boiler. Refer to Frames 45

& 46.

PUMP HEAD REPLACEMENT

1. Refer to Frame 57.

2. Drain the boiler CH circuit. Refer to Frame 77.

3. Swing the control box down into the servicing

position. Refer to Frame 51.

4. Disconnect the electrical lead from the pump.

5. Remove the 4 Allen screws retaining the pump

head.

6. Remove the pump head.

7. Fit the new pump head.

8. Reassemble in reverse order.

9. Refill the boiler. Refer to Frame 36.

10. Check operation of the boiler. Refer to Frames 45

& 46.

SERVICING

evo HE C - Installation and Servicing

SERVICING

HEAT ENGINE RENEWAL

Refer also to Frame 8 - 'Boiler Exploded View'.

IMPORTANT

Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag.

1. Refer to Frame 57.

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

to Frames 49 & 50.

3. Drain the boiler. Refer to Frame 77.

4. Remove the control box and place on one side. Refer to

Frame 71.

5. Remove the fan / venturi assembly and place on one side. Refer to Frame 52.

6. Remove the burner and place on one side. Refer to Frame

53.

7. Remove the ignition and detection electrodes. Refer to Frames 63 & 64.

8. Remove the spark generator. Refer to Frame 65.

9. Release the flue from the turret. Refer to Frame 26.

10. Remove the turret from the boiler. Refer to Frame 26.

11. Release the silicone tubing from the sampling point.

12. Release the electrical connection to the dry fire thermistor.

13. Remove the M5 x 10 screw retaining the top flue manifold

casting.

14. Remove the top casting of the flue manifold from the appliance.

15. Remove the automatic air vent. Refer to Frame 76.

16. Undo the 4 M x 10 screws securing the bottom flue

SERVICING

manifold casting and remove.

17. Remove the edge clip securing the dry fire thermistor wiring.

18. Remove the clip securing the return pipe.

19. Remove the overheat thermostat and the control

thermistor. Refer to Frame 62.

20. Remove the clip to release the flow pipe.

21. Remove the condensate ‘S’ trap. Refer to Frame 69.

22. Remove the 2 M5 screws securing the interpanel to the

back panel.

23. Slide the heat exchanger and interpanel assembly upward to disengage and remove from the casing, complete with the flow pipe.

24. Remove the 2 M6 countersunk screws, remove the interpanel and transfer to the new heat exchanger.

25. Remove the M5 screw and remove the flow pipe securing bracket.

26. Remove the flow pipe and transfer to the new heat exchanger.

27. Reassemble in reverse order, replacing gaskets or seals if any sign of damage is evident. When replacing the spring clips located on both the flow and return pipe connections, ensure clip is oriented to correctly match connecting pipe diameters.

Note.The heat exchanger is supplied with new combustion

chamber insulation boards. These should be fitted (refer to Frame 68 before the burner and fan / venturi assembly and before the ignition and detection electrodes are replaced).

28. Refill the boiler. Refer to Frame 36.

29. Check operation of the boiler. Refer to Frames 45 & 46.

evo HE C - Installation and Servicing

SERVICING

EXPANSION VESSEL REPLACEMENT

1. Refer to Frame 57.

2. Drain the boiler. Refer to Frame 77.

3. Unscrew all the gas and water connection unions on the boiler side of the valves.

4. Remove the screw from the turret clamp and remove.

5. Remove the turret.

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

expansion vessel.

7. Unscrew the union nut on the vessel water connection pipe.

8. Unscrew the 2 screws from the securing clamp and remove.

9. Remove the expansion vessel.

10. Fit the new expansion vessel.

11. Reassemble in reverse order.

12. Refill the boiler. Refer to Frame 36.

13. Check operation of the boiler. Refer to Frames 45 & 46.

Note.

If preferred, and for convenience, a new expansion vessel may be installed elsewhere in the heating system, providing it ensures equivalent system protection.

BOILER SEALING PANEL SEAL REPLACEMENT

1. Refer to Frame 57.

2. Remove the boiler front and sealing

panels. Refer to Frames 49 & 50.

3. Remove the old seal from the casing and thoroughly clean the casing surfaces.

4. Fit the new adhesive seals, note that they are supplied to the correct length for the relevant sides.

5. Reassemble in reverse order.

6. Check operation of the boiler. Refer to

Frames 45 & 46.

Note. Ensure that the boiler sealing

panel is correctly sealed, compressing the seal to make an airtight joint.

SERVICING

evo HE C - Installation and Servicing

FAULT FINDING

FAULT FINDING CHART MAIN MENU

In order to assist fault finding the boiler has an LED diagnostic display. The key to the display codes is as follows:

ALTERNATING 'L' 'F'

ALTERNATING 'L' 'E'

ALTERNATING 'L' 'A'

ALTERNATING 'L' '8'

ALTERNATING 'H' '1'

ALTERNATING 'H' '2'

GO TO FRAME 85

GO TO FRAME 86

GO TO FRAME 87

GO TO FRAME 88

GO TO FRAME 89

GO TO FRAME 90

ALTERNATING 'H' '3'

ALTERNATING 'H' '4'

ALTERNATING 'H' 'F'

ALTERNATING 'H' 'n'

ALTERNATING 'H' 'E'

ALTERNATING 'H9'

GO TO FRAME 91

GO TO FRAME 92

GO TO FRAME 93

GO TO FRAME 94

GO TO FRAME 86

GO TO FRAME 92

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

ALTERNATING 'L9'

GO TO FRAME 92

evo HE C - Installation and Servicing

L.....F..... (FLAME DETECTION ERROR)

FAULT FINDING

If the boiler reset button is

pressed does the boiler ignite for

a short time then extinguish?

YES

Check the detection electrode and

associated harness for:

continuity, visual condition, position

(Refer to Frame 64).

Replace as necessary.

harness for continuity and visual condition.

Is gas pressure available at

the boiler inlet ?

YES

Is 200V DC supply available

at the gas valve ?

(see Note)

YES

Check spark generator and associated

(Refer to Frame 65).

Are these functioning correctly ?

YES

Check gas supply

and rectify fault

Check gas valve

wiring for

continuity

Replace PCB

Replace spark generator

Check the ignition electrode and associated harness

for: continuity, visual condition, position

(Refer to Frame 63).

Are these functioning correctly ?

Replace ignition electrode and associated

harness as necessary

Note. Due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to

measure the value (some may measure the possible peak voltage of 339V). In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve.

YES

Replace gas valve

Check syphon

and condensate

drain pipework for

blockage

evo HE C - Installation and Servicing

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

L.....E..... or H.....E..... (PCB ERROR)

FAULT FINDING

Check for an excess voltage between neutral and earth. Is the value below 50V?

YES

LE ONLY

Is continuity of OH thermostat correct?

YES

HE ONLY

Is earth wire connected to detection lead correctly?

YES

Have all earths been checked for continuity?

Check earth connection to the boiler. If it is still in excess of 50 V consult a qualified electrician to check the household electrical supply and circuitry.

Correct wiring or replace thermostat.

Correct wiring or replace detection lead.

Correct connections

YES

Internal fault within the PCB

Press and hold reset button for 2

seconds. Does boiler operate correctly?

Turn boiler off and wait for 5 seconds.

Turn boiler on.

Does boiler operate correctly?

Replace PCB

YES

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

evo HE C - Installation and Servicing

L.....A..... (OVERHEAT ERROR)

FAULT FINDING

Can the overheat condition be reset by pressing

the boiler reset button when the system is cold ?

YES

Is the boiler and CH system filled with water and

all isolation and radiator valves open?

YES

Is flow return differential across the boiler in

excess of 20 oC ?

Set CH control knob to maximum.

If the overheat trips again measure the flow temp:

Over 90 oC Check control thermistor

(Refer to Frame 89)

Under 90

L....8..... (FAN ERROR)

C Replace overheat 'stat

YES

Replace overheat thermostat

Fill and vent the system and open all

isolation valves

Check that the pump is rotating freely.

Is differential now below 20

Replace the system pump

C ?

YES

Is nominal 330 V DC present across

red and blue at the fan connector as

reset button is pressed?

Check wiring harness for continuity.

H.....1..... (CONTROL THERMISTOR [FLOW] ERROR)

Remove the boiler control thermistor from the

CH flow pipe and disconnect thermistor wires.

Check resistance using a suitable multimeter

connected across the thermistor’s terminal pins

C expect 9,700 - 10,300 Ohms

At 25

C expect 2,400 - 2,600 Ohms

At 60

C expect 1,000 - 1,100 Ohms

At 85

YES

Is there continuity?

Is 14V DC present across

yellow and pink at the fan

connector?

YES

Replace fan

Replace PCB

Replace harness

Are the thermistor values correct ?

YES

Is there continuity between the

PCB and the thermistor ?

evo HE C - Installation and Servicing

YES

Replace the thermistor

Replace PCB

Check and replace wiring as necessary

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

FAULT FINDING

H.....2..... (CONTROL THERMISTOR [RETURN] ERROR)

Remove the boiler return thermistor from the

CH return pipe.

Check resistance using a suitable multimeter

connected across the thermistor’s terminal pins

At 25 oC expect 9,700 - 10,300 Ohms

C expect 2,400 - 2,600 Ohms

At 60

C expect 1,000 - 1,100 Ohms

At 85

Are the thermistor values correct ?

YES

Is there continuity between the

PCB and the thermistor ?

H.....3..... (DHW THERMISTOR ERROR)

Remove the boiler DHW thermistor from the plate

heat exchanger and disconnect thermistor wires.

Check resistance using a suitable multimeter

connected across the thermistor’s terminal pins

YES

Replace the thermistor

Replace PCB

Check and replace wiring as necessary

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

At 25

C expect 9,700 - 10,300 Ohms

At 60

C expect 2,400 - 2,600 Ohms

C expect 1,000 - 1,100 Ohms

At 85

Are the thermistor values correct ?

YES

Is there continuity between the

PCB and the thermistor ?

YES

Replace the thermistor

Replace PCB

Check and replace wiring as necessary

evo HE C - Installation and Servicing

H.....4.... (DRY FIRE THERMISTOR ERROR)

Is water system correctly filled and vented with a

system pressure of approximately 1bar

YES

FAULT FINDING

H9/L9 (HEAT EXCHANGER OVERHEAT)

Is the system filled and vented and all isolation

valves open, including TRV's & Bypass?

Check the pump is operating correctly in

Heating & DHW and check temp diffs across

Flow & Return.

Can the fault condition be reset by switching off

the mains supply to the boiler ?

Check wiring for continuity from the

PCB to the dry fire thermistor

Check resistance using a suitable multimeter

connected across the thermistor’s terminal pins

C expect 9,700 - 10,300 Ohms

At 25

C expect 2,400 - 2,600 Ohms

At 60

C expect 1,000 - 1,100 Ohms

At 85

Are thermistor values correct ?

YES

Replace PCB

Replace thermistor

YES NO

Check Flow

fitted - making contact

with pipe

Check resistance, using a suitable multimeter

At 25 oC expect 9,700 - 10,300 Ohms

At 60

At 85 oC expect 1,000 - 1,100 Ohms

Check that a permanently open

bypass circuit is available during

the pump over-run period after

boiler shutdown. This can be

provided by either an automatic

bypass valve or a heat leak radiator

(no TRV) of at least 10% of the

minimum boiler output.

Note.

With V9 Primary Control PCB, overheat LA/HA or H9/L9 when reset will display 3 horizontal lines and will not attempt to refire until the temperature in the heat exchanger drops below 50oC.

stat is

YES

connected across the dry fire thermistor

terminal pins.

C expect 2,400 - 2,600 Ohms

Are thermistor values correct ?

YES

Fill and vent the

system and open all

isolating valves

Replace

thermistor

H......F..... (FLAME DETECTION ERROR)

Remove flame detection electrode terminal from PCB

Is there continuity between the 2 terminal pins ?

YES

Replace flame detection electrode

H......n..... (PHASE REVERSAL ERROR)

evo HE C - Installation and Servicing

Check wiring to the boiler for

reversed live and neutral

Replace PCB

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

SHORT LIST OF PARTS

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, Wolseley Centers Ltd. distributors and merchants.

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 Wolseley Centers Ltd.

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

1 - Front casing panel 1 173 670

4 H66-557 Bottom casing panel 1 175 414

11 - Burner 1 173 752 12 HO7-660 Combustion chamber insulation 1 173 520 14 E67-492 Injector and housing - C22/2430 1 170 908

HO7-770 Injector and housing - C22/35 1 173 522

16 E85-097 Fan assembly - C22/24/30 1 172 625

HO7-771 Fan assembly - C22/35 1 173 525 17 E69-286 Automatic air vent (Heat exchanger) 1 170 988 19 H58-082 Gas valve kit 1 174 789 23 H58-084 Thermistor (boiler control) 2 174 790 24 H58-086 Overheat thermostat 1 174 791 25 HO7-664 Ignition electrode kit 1 175 406 26 HO7-665 Flame detection electrode kit 1 173 529 32 H40-140 Kit - Trap and Seal 1 174 244 35 113-713 User control (display unit) 1 173 671 36 149-852 PCB primary controls kit (V9) 1 174 486 37 E67-519 Fuse PCB (3.15A L250V) 1 170 931 39 HO7-777 Mains switch c/w harness 1 173 537 40 HO7-731 Spark generator assy. 1 173 538 45 E67-527 Gasket kit (servicing) 1 170 938 52 E68-376 Seal kit (sealing panel) 1 171 014 53 E68-380 Turret gasket 1 171 022 61 H66-650 Pressure relief valve 1 175 413 62 H66-652 Expansion vessel 1 175 415 64 H69-341 Pressure gauge 1 170 991 65 H28-067 DHW thermistor 1 173 974 66 H58-165 Diverter valve motor head 1 174 813 67 H62-599 Diverter valve cartridge 1 175 411 69 H66-587 Pump Head 1 175 409 71 H66-588 Plate heat exchanger - C22/24 1 175 417

H66-589 Plate heat exchanger - C22/30 1 175 418

H66-592 Plate heat exchanger - C22/35 1 175 419 94 H66-644 Ignition lead 1 175 424 95 HO7-792 Detection lead 1 173 512 98 H58-225 Air vent (pump) 1 174 894

103 H29-018 Dry Fire Thermistor 1 174 087

Hardware Pack Contents (Ref. Frame 9) Pack B - Accessory Pack 1 175 437 Pack C - Flow Valve Pack 1 175 431 Pack D - DHW Pack C22/24 1 175 434

Pack E - Gas Pack 1 175 433 Pack F - Return Valve Pack 1 175 432

When ordering spares please quote:

1. Boiler model

2. Appliance G.C. No.

3. Description.

4. Quantity.

5. Product number.

C22/30 1 175 435 C22/35 1 175 436

(* Refer to boiler serial letter code on data plate to identify correct spare)

evo HE C - Installation and Servicing

nm9571a

103

SHORT LIST

SHORT LIST OF PARTS

evo HE C - Installation and Servicing

Ecl 2552a

BOILER CASING ASSEMBLY

1. Front casing panel with screws.

2. Sealing panel with screws.

4. Bottom panel with screw.

CONTROLS ASSEMBLY

33. Controls assy with screws.

34. Controls hinge bracket.

35. User controls (without item 38).

36. PCB (primary controls).

38. User controls housing

39. Mains switch.

54. Jumper link (not shown)

BURNER ASSEMBLY

11. Burner assembly with screws and gasket.

Ecl 1598

evo HE C - Installation and Servicing

67evo HE C - Installation and Servicing

INSTALLER NOTIFICATION GUIDELINES

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

Gas Safe Register they will

then notify the relevant

Local Authority Building

Control (LABC) scheme

on members behalf

Gas

Safe Register Engineers

log on to the engineers section

of the website at

www.gassaferegister.co.uk

or telephone

0800 408 5577

You must ensure that the

notification number issued by

Gas Safe Register is written

onto the Benchmark Checklist

Gas Safe

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

69evo HE C - Installation and Servicing

Gas Safe Register ID N

Gas Safe Register ID Number

Gas Safe Register ID Number Gas Safe Register ID Number

Gas Safe Register ID Number

The code of practice for the installation,

commissioning & servicing of central heating systems

Wolseley Installer/Technical Helpline

0870 849 8057

ideal Evo HE C22/24 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual