IDEAL icos HE12, icos HE15, icos HE24, icos HE18 Installation And Servicing

installation and servicing

icos

(V3 Flue System)

Your Ideal installation and servicing guide

For details of document amendments, refer to page 3

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

HE12, HE15, HE18, HE24

For users guide see reverse of book

For the very latest copy of literature for specification & maintenance practices visit our website www.idealboilers.com where you will be able to download the relevant information in pdf format.

Packaged Boiler Contents have

been Checked by Operator Number.......

September 2009 UIN 203318 A05

icos - Installation & Servicing

DOCUMENT AMENDMENTS

Relevant Installation changes implemented in this book from Mod Level ........... A04 (Apr 08) to A05 (Sep 09)

Page 7, Optional Extra Kits

• Addition of Concentric flue Screw Retaining Kit & Adjustable Flue Support Bracket

Page 8, Flue Installation - Table 3

• Item 14 - new dimensions

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

• New flue kit added.

• Notes - Items 4 & 5 added

Page 18, Frame 18 - Terminal Wall Seal Assembly / Position

• New frame added ref. positioning of terminal wall seal

Page 19, Frame 21 - Flue Extension Ducts

• Item no. 3 added.

Page 20, Frame 24 - Condensate Pipe Termination Configurations

• Update drawing 1 and note added ref BS6798

Page 29, Frame 37 - Pictorial Wiring Diagram

• Updated drawing showing removal of bracket from spark generator

Page 42, Frame 65 - Combustion Chamber Insulation Replacement

• Updated Frame to reflect new insulation.

Page 48, Frame 76 - H9/L9 Heat Exchanger Overheat

• New flow chart.

Page 49 - Short Parts List

• New updated parts list

Page 52 - Code of Practice

• New Code of Practice Guidelines added.

Ideal Stelrad Group reserve the right to vary specification without notice

icos - Installation & Servicing

GENERAL

Table 1 - Boiler Data

Boiler Size HE 12, HE 15, HE 18, HE 24

Gas supply type and connection 2H-G20-20 mbar Rc

Injector size Stereomatic 5.6mm dia. (HE 12 5.8mm dia).

Flow connection 22mm copper

Return connection 22mm copper

Flue terminal diameter mm (in.) 100 (4)

Maximum static water head m (ft.) 30.5 (100)

Minimum static water head m (ft.) 0.45 (1.5)

Electrical supply 230 V ~ 50 Hz

Boiler power consumption 38W

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

Water content litre (gal.) 1.7 (0.37)

Packaged weight kg (lb.) 38 (84)

Maximum installation weight kg (lb.) 31 (68)

Boiler size Height mm (in.) 582 (23)

Width mm (in.) 390 (15)

Depth mm (in.) 278 (11)

/2 (1/2" BSP Female)

Table 2 - Performance Data

Boiler Size HE 12 Max HE 15 Max HE 18 Max HE 24 Max HE 12 Min HE 15-24 Min

Boiler input 'Q' = Nett CV kW 12.2 15.1 18.7 24.4 9.8 9.1

Btu/h 41 600 51 500 63 800 83 300 33 400 31 000

Gross CV kW 13.5 16.8 20.7 27.1 10.9 10.1

Btu/h 46 000 57 200 70 800 92 500 37 200 34 400

Gas consumption l/s (cu.ft/h) 0.35 (44.2) 0.43 (54.7) 0.53 (68.0) 0.70 (89.7) 0.28 (35.6) 0.26 (33.3)

Boiler output 'P' = 70

C Mean water kW 12.0 14.6 18.2 23.4 9.3 8.8

temperature Btu/h 40 900 50 000 62 300 80,000 31 800 30,000

C Mean water kW 12.7 15.5 19.2 25.1 10.5 9.6

temperature Btu/h 43 300 53 000 65 700 85 700 35 900 32 800

Seasonal efficiency (SEDBUK) * Band A [90.3 ]% [9 0.4]% [90.3]% [90.2]%

NOx classification Class 5

* 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.

Key to symbols

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)

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.

CAUTION.

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

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

icos - Installation & Servicing

GENERAL

icos

Natural Gas only

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

Benchmark No.

HE12 41 397 95 87 BP 34

HE15 41 397 83 87 BP 34

HE18 41 397 84 87 BP 34

HE24 41 397 85 87 BP 34

Destination Countries: GB, IE

CONTENTS

Air Supply ....................................................................... 9

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

Boiler Clearances ......................................................... 6

Boiler Exploded Diagram ............................................ 14

Electrical Connections ............................................... 29

Electrical Supply ........................................................... 9

Electrical Systems Diagrams .................................... 31

Extension Ducts - Fitting ............................................. 21

Fault Finding ................................................................. 47

Flow Wiring Diagram .................................................. 31

Flue Fitting .............................................................. 17-21

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

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

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

Initial Lighting .............................................................. 33

Installation ............................................................. 14-34

Mandatory Requirements .............................................7

Safe Handling ................................................................ 7

Servicing ................................................................ 35-46

Short List of Parts ....................................................... 51

Thermostatic Radiator valves .................................... 9

Water and Systems ................................................ 9-13

Water Connections ................................................. 6, 29

Water Treatment ......................................................... 13

Wiring Diagrams ......................................................... 31

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 ............. 32

Time and temperature control to hot water .......... 32

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

TRV's ......................................................................... 9

Auto bypass ..............................................................9

Boiler interlock ..........................................................9

For all boilers

Flushing to BS.7593 .............................................. 13

Inhibitor .................................................................. 13

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 ............................................................... n/a

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

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

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

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

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

For condensing boilers only

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

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

For assistance see Technical Helpline on the back page

Page

NOTE TO THE INSTALLER:

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

icos - Installation & Servicing

COMPLETE

GENERAL

BOILER WATER CONNECTIONS

The boiler flow and return pipes are supplied fitted to the boiler ready for top connection

Notes.

a. For the heating loads in excess of 60,000 Btu/h, 28mm (1") flow

and return pipes should be used to and from the boiler.

b. This appliance is NOT suitable for use with a direct hot water

cylinder.

BOILER CLEARANCES all dimensions in mm (in.)

The following minimum clearances must be maintained for operation and servicing.

Additional space will be required for installation, depending upon site conditions.

Side and Rear Flue

a Provided that the flue hole is cut accurately, e.g. with a core drill,

the flue can be installed from inside the building where wall thicknesses do not exceed 600mm (24"). Where the space into which the boiler is going to be installed is less than the length of flue required the flue must be fitted from the outside.

Installation from inside ONLY

b. If a core boring tool is to be used inside the building the space in

which the boiler is to be installed must be at least wide enough to accommodate the tool.

REAR FLUE ONLY

MIN. Top clearance required = 145 mm (5 3/4")

SIDE FLUE ONLY

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

to outside wall Dim. A

0.5 m 165 mm (6

1.0 m 170 mm (6

1.5 m 185 mm (7 1

2.0 m 200 mm ( 7 7/8")

2.5 m 210 mm (8 1

3.0 m 225 mm (8 7/8")

3.5 m 235 mm (9

4.0 m 250 mm (10 7/8")

4.5 m 260 mm (10

5.0 m 275 mm (10 13/16")

5.5 m 290 mm (11

6.0 m 300 mm (11 13/16")

1/2")

11/16)

/4")

1/4")

3/8")

Front clearance

The minimum front clearance when built in to a cupboard is

1/4") from the cupboard door but 450mm (17 3/4")

5mm ( 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

nm8729

order for it to do so the plastic fascia should be removed. See Frame 41.

* Bottom clearance

after installation can be reduced to 5mm in an adequately ventilated enclosed cupboard. However, 100mm must be available for servicing.

icos - Installation & Servicing

GENERAL

INTRODUCTION

The icos range of boilers are a fully automatically controlled,

wall mounted, low water content, balanced flue, fanned, condensing gas boiler. It has full modulating central heating outputs of :

HE12 9.3 kW (32,000 Btu/h) to 12.0 kW (41,000 Btu/h). HE15 8.8 kW (30,000 Btu/h) to 14.6 kW (50,000 Btu/h). HE18 8.8 kW (30,000 Btu/h) to 17.6 kW (60,000 Btu/h). HE24 8.8 kW (30,000 Btu/h) to 23.4 kW (80,000 Btu/h).

Due to the high efficiency of the boiler a plume of water vapour will form at the flue terminal during operation depending on external conditions.

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 heat exchanger is of cast aluminium.

Note.

These boilers cannot be used on systems which include gravity circulation.

The boilers are suitable for connection to fully pumped, open vented or sealed water systems. Adequate arrangements for completely draining the system by provision of drain cocks MUST be provided in the installation pipework.

OPERATION

When there is a demand for heat, the heating system is supplied at the selected temperature of between 30oC and 82oC.

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

SAFE HANDLING

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

Caution should be exercised during these operations. Operatives should be knowledgeable in handling techniques

when performing these tasks and the following precautions should be considered:

• 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.

OPTIONAL EXTRA KITS

• Flue Extension Ducts (1000mm long up to 6m)

• Flue Finishing Kit

•90

Elbow Kit (maximum 4 elbows per installation).

•45o Elbow Kit (maximum 4 elbows per installation).

• Concentric Flue Screw Retaining Kit

icos - Installation & Servicing

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

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

is a typical maximum flue length. For further details refer to Powered Vertical Fluing Instructions.

• High Level Flue Outlet Kits

• Flue Deflector Kit

• Weather Collar

• Horizontal Flue 600mm long

• Remote User Control Kit

• Boiler Stand-off Kit

• Siphon Kit

• Condensate Pump Kit

• 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 Installer. It must be carried out in accordance with the relevant requirements of the:

• Gas Safety (Installation and Use) Regulations

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

• The Water Fittings Regulations or Water byelaws in Scotland.

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

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

In IE, the installation must be carried out by a 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 60 kW.

BS. 6891 Low pressure installation pipes.

Health & Safety Document No. 635

The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be taken, in any way, as overriding statutory obligations.

IMPORTANT. These appliances are CE certificated for safety and performance. It is, therefore, important that no external control devices, e.g. flue dampers, economisers etc., are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Ideal Stelrad Group in writing. If in doubt please enquire.

Any direct connection of a control device not approved by Ideal Stelrad Group may invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety Regulations and the above regulations.

GENERAL

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 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 Ireland 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.

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 icos HE range is able to deliver it’s full output at inlet pressures as low as 14mb, other gas appliances in the property may not be as tolerant. When operating pressures are found to be below the minimum meter outlet of 19mb these should be checked to ensure this is adequate for correct and safe operation.

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

The 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 I.S.813:2002. Pipework from the meter to the boiler MUST be of an adequate size.

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 which would 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.

Table 3 - 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*

icos - Installation & Servicing

GENERAL

3. Minimum acceptable spacing from the terminal to

obstructions and ventilation openings are specified in Table 3.

4. Where the lowest part of the terminal is fitted less than 2m (6'6") above a balcony, above ground or above a flat roof to which people have access, then the terminal MUST be protected by a purpose designed guard.

Ensure that the guard is fitted centrally.

Terminal guards are available from boiler suppliers. Ask for TFC Flue Guard Model No. K6 (round plastic-coated). In case of difficulty contact:

Grasslin (UK) Ltd. Tel. +44(0) 01732 359 888 Tower House, Vale Rise Fax. +44(0) 01732 354 445 Tonbridge. kent TN9 1TB www.ffc.ukco.com

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. In IE refer to I.S.813:2002.

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 14.

AIR SUPPLY

It is NOT necessary to have a purpose-provided air vent in the room or internal space in which the boiler is installed. Neither is it necessary to ventilate a cupboard or compartment in which the boiler is installed, due to the low surface temperatures of the boiler casing during operation; therefore the requirements of BS 6798, Clause 12, and BS 5440:2 may be disregarded. In IE the requirements of I.S.813:2002 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.

For the types of system and correct piping procedure see Frames 1, and 3 to 8.

The central heating system should be in accordance with BS.6798 and, in addition, for smallbore and microbore systems, BS.5449.

Graph 1 - Water flow rate and pressure loss

1.0

0.5

WATER TREATMENT - see Frame 9

The hot water storage cylinder MUST be of the indirect type and should preferably be manufactured of copper.

Single feed, indirect cylinders are not recommended and MUST NOT be used on sealed systems.

The appliances are NOT suitable for gravity central heating nor are they suitable for the provision of gravity domestic hot water.

The hot water cylinder and ancillary pipework, not forming part of the useful heating surface, should be lagged to prevent heat loss and any possible freezing - particularly where pipes run through roof spaces and ventilated underfloor spaces.

The boiler must be vented.

The hydraulic resistance of the boilers, at MAXIMUM OUTPUT, with an 11 Graph 1.

C (20 oF) temperature differential, is shown in

BOILER CONTROL INTERLOCKS

Ideal Stelrad Group recommend that heating systems utilising

full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radiators not fitted with such a valve as stated in BS. 5449.

Central heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating or hot water.

When thermostatic radiator valves are used, the space heating temperature control over a living / dining area or hallway having a heating requirement of at least 10% of the boiler heat output should be achieved using a room thermostat, whilst other rooms are individually controlled by thermostatic radiator valves. However, if the system employs thermostatic radiator valves on all radiators, or two port valves without end switches, then a bypass circuit must be fitted with an automatic bypass valve to ensure a flow of water should all valves be in the closed position.

ELECTRICAL SUPPLY

WARNING.

This appliance must be earthed.

Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations which apply. For Ireland 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 23 & 49

A condensate drain is provided on the boiler. This drain must be connected to a drainage point. 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.

Pressure Drop Across Boiler

(metres water)

8.8 11.7 14.7 17.6 20.5 Boiler Output (kW)

icos - Installation & Servicing

Ecl 1603

23.4

GENERAL

OPEN VENT SYSTEM REQUIREMENTS

The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150mm (6") away from the vent connection.

Note. Combined feed and vent pipes may also be fitted.

There should be a minimum height 450mm (18") of open vent above the cistern water level. If this is not possible refer to Frame 5. The vertical distance between the highest point of the system and the feed/expansion cistern water level MUST not be less than 450 mm (18"). The pump must be fitted on the flow side of the boiler.

A suitable pump is a domestic circulator capable of providing a maximum 11 whole of the heating circuit open (e.g. Grundfos UPS 15/50, 15/60 or equivalent). With the minimum flow circuit allowed by the controls the differential must not exceed 25 oC. (18oC for the HE15)

The vertical distance between the pump and feed/expansion cistern MUST comply with the pump manufacturer's minimum requirements, to avoid cavitation. Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Ideal Stelrad Group. The isolation valves should be fitted as close to the pump as possible.

C (20oF) temperature differential across the boiler with the

Return & flow connections

load 30 - 60 = 22 mm load 70 - 80 = 28 mm

SCHEMATIC PIPEWORK AND SYSTEM BALANCING

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

Balancing

1. Set the programmer to ON for both CH

and HW. Turn the cylinder thermostat down. Close the manual or thermostatic valves on all radiators, leaving the twin lockshield valves (on the radiators referred to above) in the open position. Turn up the room thermostat and adjust these lockshield valves to give boiler flow and return temperatures not more than

C apart. These valves should now be

20 left as set.

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

C temperature drop at each radiator.

3. Turn up the cylinder thermostat and adjust the cylinder balancing valve so that the cylinder achieves a maximum flow consistent with adequate flow to the radiators. Check that with only the domestic hot water loop in circuit a differential temperature of 20 the boiler is not exceeded.

4. Adjust room and cylinder thermostats and programmer to NORMAL settings.

C across

icos - Installation & Servicing

GENERAL

Non-return

valve

Automatic

air vent

Hose unions

Additional stop valve

Hose connector

Hosepipe

(disconnect

after filling)

Double check valve

assembly

(note direction of flow)

Temporary hose

(disconnect

after filling)

ecl6060

LOW HEAD AND LARGE SYSTEMS WITH EXTENSIVE PIPE RUNS - OPEN VENT

This arrangement is useful for large systems where radiators at the extremities are difficult to vent. This can lead to pumping over with conventional feed and vent arrangements.

The following conditions MUST be observed:

1. The top of the automatic air vent must be below the cold water level.

2. The static water level (cold) must be at least 200mm above the top of the horizontal flow pipe, fitted as shown. The vent connection MUST NOT be made immediately off the top of the boiler as venting is made less efficient.

3. The maximum practical length of 22mm cold feed pipe should be used in order to reduce the effective volume of hot system water expanding into the feed/expansion cistern to a minimum.

All dimensions in mm (in.).

Note. The pump manufacturers' minimum requirements must be complied with.

SEALED SYSTEM REQUIREMENTS

Notes.

a. The method of filling, refilling, topping up or flushing

sealed primary hot water circuit from the mains via a temporary hose connection is only allowed if acceptable to the local water authority.

NB. Imperial dimensions are approximate

b. When installing the

filling device, it must be connected as shown to fully comply with the water regulations. This may involve the fitting of an additional WRAS approval isolator valve to the mains supply.

1. General

a. The installation

must comply with the requirements of BS. 6798 and BS. 5449.

b. The installation should be designed to work with

flow temperatures of up to 82

c. All components of the system, including the heat

exchanger of the indirect cylinder, must be suitable for a working pressure of 3 bar (45lb/in and temperature of 110oC. Care should be taken in making all connections so that the risk of leakage is minimised.

2. Safety Valve

A spring loaded safety valve complying with the relevant requirements of BS. 6759 must be fitted in the flow pipe as close to the boiler as possible and with no intervening valve or restriction. The valve should have the following features:

icos - Installation & Servicing

)

a. A non-adjustable preset lift pressure not exceeding

3bar (45lb/in

b. A manual testing device.

c. Provision for connection of a discharge pipe.

The valve or discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or cause damage to electrical components and wiring.

3. Pressure Gauge

A pressure gauge covering at least the range 0-4 bar (0-60 lb/in

) must be fitted to the system. The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel.

GENERAL

SEALED SYSTEM REQUIREMENTS - continued

4. Expansion Vessel

a. A diaphragm type expansion vessel must be

connected to a point close to the inlet side of the pump, the connecting pipe being not less than 15 mm

1/2" nominal) size and not incorporating valves of

( any sort.

b. The vessel capacity must be adequate to accept the

expansion of the system water when heated to

110

C (230oF).

c. The charge pressure must not be less than the

static water head above the vessel. The pressure attained in the system when heated to 110 F) should be at least 0.35 bar (5 Ib/in2) less than the lift pressure of the safety valve. For guidance on vessel sizing refer to the table in Frame 8.

For further details refer to BS. 5449, BS. 7074:1 and the British Gas Corporation publication 'Material and Installation Specifications for Domestic Central Heating and Hot Water'. For IE refer to the current edition of I.S.813.

5. Cylinder

The cylinder must be either of the indirect coil type or a direct cylinder fitted with an immersion calorifier which is suitable for operating on a gauge pressure of 0.35 bar

) in excess of the safety valve setting. Single feed

(5 Ib/in indirect cylinders are not suitable for sealed systems.

6. Make-up Water

Provision must be made for replacing water loss from the system, either:

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

visible water level. The vessel should be mounted at least 150 mm (6") above the highest point of the system, and be connected through a non-return valve to the system, fitted at least 300 mm (12") below the make-up vessel on the return side of the domestic hot water cylinder or radiators.

b. Where access to a make-up vessel would be difficult

by pre-pressurisation of the system. Refer to 'Filling', below.

7. Mains Connection

There must be no direct connection to the mains water supply or to the water storage tank supplying domestic water, even through a non-return valve, without the approval of the local water authority.

8. Filling

The system may be filled by one of the following

methods:

a. Through a cistern, used for no other purposes, via a

ball valve permanently connected directly to a service pipe and/or a cold water distributing pipe. The static head available from the cistern should be adequate to provide the desired initial system design

C (230

pressure. The cold feed pipe from the cistern should include a non-return valve and a stop valve with an automatic air vent connected between them, the stop valve being located between the system and the automatic air vent. The stop valve may remain open during normal operation of the system if automatic water make-up is required.

b. Through a self-contained unit comprising a cistern,

pressure booster pump (if required) and, if necessary, an automatic pressure reducing valve and flow

restrictor. The cistern should be supplied through a temporary connection from a service pipe or cold water distributing pipe. This unit may remain permanently connected to the heating system to provide limited automatic water make-up. Where the temporary connection is supplied from a service pipe or distributing pipe which also supplies other draw-off points at a lower level then a double check valve shall be installed upstream of the draw-off point.

c. 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 shall be used to facilitate filling.

The following fittings shall form a permanent part of the system and shall be fitted in the order stated:

A stop valve complying with the requirements of BS. 1010, Part 2 (the hose from the draw-off tap shall be connected to this fitting). A test cock. A double check valve of an approved type.

• Thoroughly flush out the whole of the system with cold water, without the pump in position.

• With the pump fitted, fill and vent the system until the pressure gauge registers 1.5 bar (21.5lb/in

Examine for leaks.

• Check the operation of the safety valve by manually raising the water pressure until the valve lifts. This should occur within ± 0.3 bar (± 4.3lb/in

) of the

preset lift pressure.

• Release water from the system until the initial system design pressure is reached.

• Light the boiler and heat the system to the maximum working temperature. Examine for leaks.

• Turn off the boiler and drain the system while still hot.

• Refill and vent the system.

• Adjust the initial pressure to the required value.

Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be less than that given by the table on the following page, multiplied by a factor of 0.8 (for flow temperatures of less than 83 C).

icos - Installation & Servicing

GENERAL

SEALED SYSTEM REQUIREMENTS - continued

Safety valve setting 3.0 bar 2.5 bar 2.0 bar

Vessel charge and initial 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0 system pressure bar bar bar bar bar bar bar bar

Total water content of system Expansion vessel volume litres

litres

25 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0

50 4.2 5.4 7.8 4.7 6.7 11.8 5.6 10.0

75 6.3 8.2 11.7 7.0 10.0 17.7 8.4 15.0

100 8.3 10.9 15.6 9.4 13.4 23.7 11.3 20.0

125 10.4 13.6 19.5 11.7 16.7 29.6 14.1 25.0

150 12.5 16.3 23.4 14.1 20.1 35.5 16.9 30.0

175 14.6 19.1 27.3 16.4 23.4 41.4 19.7 35.0

200 16.7 21.8 31.2 18.8 26.8 47.4 22.6 40.0

225 18.7 24.5 35.1 21.1 30.1 53.3 25.4 45.0

250 20.8 27.2 39.0 23.5 33.5 59.2 28.2 50.0

275 22.9 30.0 42.9 25.8 36.8 65.1 31.0 55.0

300 25.0 32.7 46.8 28.2 40.2 71.1 33.9 60.0

Multiplying factors for

other system volumes 0.0833 0.109 0.156 0.094 0.134 0.237 0.113 0.20

WATER TREATMENT

The icos boiler range have an ALUMINIUM alloy heat exchanger

IMPORTANT.

Stelrad Group invalid.

Ideal Stelrad Group

Treatment in Central Heating systems.

Ideal Stelrad Group recommend the use of FERNOX-COPAL or MB1 or GE Betz Sentinel X100 inhibitors and

associated water treatment, 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

The application of any other treatment to this product may render the guarantee of Ideal

recommend water treatment in accordance with the Benchmark Guidance Notes on Water

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

Salamander Engineering Ltd The Heath Business & Technical Park Runcorn Cheshire WA7 4QX Tel: +44 (0) 121 3780952

Tel: +44 (0) 1799 521133

Notes

1. It is most important that the correct concentration of the water treatment product is maintained in accordance with the manufacturers' instructions.

2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing.

BS. 7593:2006 details the steps necessary to clean a domestic central 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.

icos - Installation & Servicing

nm8744b

INSTALLATION

BOILER ASSEMBLY - Exploded view

LEGEND

1. Front casing panel.

2. Sealing panel

3. Sump cover plate.

4. Bottom casing panel.

5. Flue sensing nipple.

6. Return pipe.

7. Flow pipe.

8. Flue manifold.

10. Interpanel.

11. Burner assy.

12. Combustion chamber

Insulation.

13. Heat exchanger

14. Injector & housing

15. Venturi assy.

16. Fan assy.

17. Gas pipe assy.

19. Gas control valve assy.

20. Fan bracket assy.

21. Orifice plate.

22. Flue thermistor.

23. Control thermistor.

24. Overheat thermostat.

25. Ignition electrode.

26. Flame detection electrode.

32. 'S' trap

33. Control assy.

40. Spark generator

44. Wall mounting plate.

53. Turret gasket kit.

94. Ignition lead

icos - Installation & 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 The boiler

B Wall mounting template

on cardboard

C Wall mounting plate

D 1 year guarantee form

E These Installation & Servicing/

User’s Instructions

F Hardware pack

INSTALLATION

nm9315

Hardware Pack

A 50mm x No.14 wood screws - 3 off

B Wall plugs (TP2B ) - 3 off

C Push-in caps - 6 off (Refer to Frame 36 no. 15)

D Mains connector - 1 off

B Pack Contents

A Telescopic flue terminal

B Flue turret

C Rubber Terminal Wall Seal

D Screw

E Sealing Tape

icos - Installation & Servicing

nm8465

isfu8751d

INSTALLATION

PACKAGING REMOVAL

1. Ensure the boiler is stood correctly, as marked on

the carton.

2. Cut and remove the strapping.

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

mounting plate, literature and wall mounting card template.

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

5. When ready for installation lift off the outer sleeve.

INSTALLATION

6. Remove the top protection packing/template and

save for further use.

7. Remove the two packaging ends.

8. Remove the hardware pack from under the pipes

and keep in a safe place.

FRONT AND BOTTOM PANEL REMOVAL

1. To remove the front panel remove the 2 screws from the

bottom panel.

2. Lift the panel up and off the top pegs.

3. To remove the bottom panel remove the 2 screws.

4. Pull the RH side of the panel down. Slide it to the right

and withdraw.

nm9282

nm 7802

icos - Installation & 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:

HORIZONTAL FLUE - 6M ROOF FLUE KIT - 7.5M POWERED VERTICAL FLUE KIT - 5m primary and 17m secondary is a typical maximum

length. For alternative details refer to Powered Vertical

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

Instructions.

FLUE KITS

Pack B - supplied as standard.

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

Finishing Kit - supplied as an optional extra.

Screw Kit - Optional kit for mechanical fixing of flue joints

Refer to 'Flue Extension Ducts'’

SIDE FLUE

REAR FLUE

Notes.

1. When extension ‘D’ packs are used the flue duct MUST be inclined

at 1.5 degrees to the horizontal to allow condensate to drain back into the boiler and out through the condensate drain.

2. If the telescopic ‘B’ pack or horizontal flue terminal (600 long) 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

3. If the boiler is to be installed with downward 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.

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.

It is recommended that a support bracket is fitted for every 1 metre of extension pipe used and also at every joint to ensure pipes are held at the correct angle. If a slip joint coupling is used then a support bracket must be used to secure the collar.

icos - Installation & Servicing

Total Flue length dimension Flue

(measuring from CL of turret to outside wall)

Rear flue Side flue Extra packs

dim. X+160 dim. L+195 r equired

Up to 595 mm Up to 595 mm none

Up to 1545 mm Up to 1545 mm Pack D - 1 off

Up to 2495 mm Up to 2495 mm Pack D - 2 off

Up to 3445 mm Up to 3445 mm Pack D - 3 off

Up to 4395 mm Up to 4395 mm Pack D - 4 off

Up to 5345 mm Up to 5345 mm Pack D - 5 off

Up to 6000 mm Up to 6000 mm Pack D - 6 off

FLUE OUTLET

nm9283

V - See Diagram Below

Extended centre line

155

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.

INSTALLATION

Rear flue arrangement shown

WALL MOUNTING TEMPLATE

The wall mounting template is located on the internal top 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 side with preference to top holes).

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.

nm8752

FLUE OUTLET

nm8731

icos - Installation & Servicing

INSTALLATION

var9784

Rubber Terminal Wall Seal

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 3 holes with a 7.5mm / 8mm masonry drill and insert the plastic plugs provided, for the wall mounting plate and the jacking screw plate.

Note.

If using the stand-off kit then drill 4 holes (choosing one from each group but not the jacking screw).

3. Locate 2 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.

Note.

If using the stand-off kit then locate the stand-off channel and screw home.

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

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

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.

icos - Installation & Servicing

FLUE OUTLET

INSTALLATION

19A

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.

Drill hole

Adhere sealing tape

X + 75

Measurement to be

taken from this point

nm8944

19B

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 14.

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

and add to wall thickness X=L. Refer to Frame 14.

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.

Drill hole

Adhere sealing tape

FLUE OUTLET

L + 115

Measurement to be

taken from this point

nm8945

icos - Installation & Servicing

INSTALLATION

nm8733

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

Flue duct support

General arrangement

1. A maximum of 6 extension ducts (one suitably

cut) plus the standard flue duct may be used together.

Flue support cutting aid (shown folded up)

Wall plugs - 4 off

No. 10 x2" wood screw - 4 off

2. Flue extensions of greater length than 1m (39") should be supported with the bracket provided, suitably adjusted. Refer to Frame 20 & 26.

3. Only use water as a lubricant during assembly.

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.

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

icos - Installation & Servicing

esp8940

FLUE OUTLET

BOILER

cla7771b

Sink constitutes

air break

DRAIN

Ground Level

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

cla9252

75mm trap

DRAIN

Sink

Ground Level

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

BOILER

Air Break

INSTALLATION

155mm

CONDENSATE DRAIN

Front View Side View

Condensate

drain

INSTALLATION

The condensate drain provided on the boiler must be connected to a drainage point, preferably within the building.

Ensure that the condensate trap is full of water before commissioning the boiler. Refer to Frame 27.

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

The drainage pipework must be arranged so that obstruction (e.g. through freezing) of external drainage pipe does not give rise to spillage within the dwelling.

IMPORTANT. If excessive external pipework cannot be avoided an additional siphon kit and insulation are recommended, in order 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.

A plastic cap is fitted to the end of the condensate drain adapter this must be removed before connection is made.

nm8734

If external condensate pipe run is greter than 3m then pipe must be 32mm nominal diameter. Consideration must be given to insulating external condensate pipe runs.

CONDENSATE PIPE TERMINATION CONFIGURATIONS

Note. ALL PIPE RUNS MUST BE IN ACCORDANCE WITH BS6798

1. INTERNAL TO SINK WASTE UPSTREAM OF SINK WASTE TRAP

2. INTERNAL TO SINK WASTE DOWNSTREAM OF SINK WASTE TRAP (PREFERRED METHOD)

continued . . . .

icos - Installation & 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

cla9253

Air Break

INSTALLATION

5. TERMINATION TO DRAIN / GULLEY

BOILER

icos - Installation & Servicing

External

wall

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

cla7775

Ground Level

DRAIN

nm8755

MOUNTING THE BOILER

INSTALLATION

1. Lift the boiler onto the wall mounting plate, as

shown.

2. Check the boiler alignment using a spirit level and adjust as necessary with the jacking screw.

3. Align the hole in the jacking plate with the predrilled hole in the wall and fix in position with the No.10 x 2" screw provided.

4. Fit condensate union connection

INSTALLATION

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 flue outlet A.

Make sure the plastic cap is removed from the end of the condensate drain adapter.

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 (at 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 wall plug and wood screw. For standard installations use the short wood screw.

If the stand-off option is used, secure the support bracket using the spacer bracket and long wood screw.

NB. The space bracket will utilise one fixing hole only whilst

used in conjunction with the stand-off option.

icos - Installation & 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

icos - Installation & Servicing

Weather Collar - Flat Roof UIN 152259

Weather Collar - Tile Roof UIN 152258

Vertical connector UIN 203135

elbow

45 UIN 203131

Roof Flue Extension Duct UIN 203129

elbow

UIN 203130

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

Painted surface 300 mm

Below eaves or balcony 500 mm

icos - Installation & Servicing

INSTALLATION

rf8737

rf8738

FLUE ARRANGEMENT

Note.

The equivalent flue length resistance of the elbow kits are:

elbow kit = 1m

45o elbow kit = 0.6m

icos - Installation & 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. Push fit the vertical connector (supplied seperately) into the boiler flue connection and retain with the turret clamp and securing screw (supplied with the boiler). ENSURING THE

GASKETS IN THE BOILER FLUE OUTLET ARE CORRECTLY FITTED.

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

vertical connector.

nm8739

FLUE OUTLET

nm8743

'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.

icos - Installation & Servicing

GAS CONNECTION

INSTALLATION

IMPORTANT. The gas service cock is sealed with a non-metallic

fibre washer seal so must not be overheated when making capillary connections.

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

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

BOILER WATER CONNECTIONS

The boiler flow and return pipes are supplied fitted to the boiler and ready for top connection.

Note.

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

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

Refer to Frame 41 for details of the pressure test point position.

INSTALLATION

TOP CONNECTION

Connect the system pipework to the boiler flow and return pipes.

Note.

The front panel is not fitted at this stage.

ELECTRICAL CONNECTIONS

WARNING. This appliance MUST be earthed.

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

All external controls and wiring MUST be suitable for mains voltage.

The fuse rating should be 3 A.

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

Wiring should be 3 core PVC insulated cable NOT LESS than 0.75 mm

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

(24 x 0.2mm) and to BS. 6500, Table 16.

1/8") contact separation in both poles,

icos - Installation & Servicing

INSTALLATION

Mains Connector

(supplied in hardware pack)

Socket

(fixed to boiler)

Remove link when connecting external programmer.

Ecl2367

Ecl 1542

INTERNAL WIRING

A pictorial wiring diagram is shown in Frame 37.

The mains lead connector is pre-fitted. This must be removed to allow wiring.

1. Route the mains cable into the bottom LHS rear of the casing. If using the stand-off kit then route through the grommet.

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

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

3. Wire the switched live supply into L2 or connect L1 and L2

INSTALLATION

via external control switching, as shown in Frame 32. In either case, remove the wire link fitted L1 to L2.

4. Secure the mains lead with the cable clamp.

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

Note.

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

Incoming mains wiring detail

icos - Installation & Servicing

Spark generator

nm 8076b

y/g

Ferrite

y/g

Flue thermistor

Overheat thermostat

Flow control thermistor

Gas valve

ON /OFF

Switch

Service

connection

MAINS

SUPPLY

230V 50Hz

Permanent black link

Fan

Chassis earth y/g

Control PCB

Fused at

3.15ATL

User

control

and

display

C G

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

LEGEND b-blue

FUNCTIONAL FLOW WIRING DIAGRAM

bk - black

Mains Switch

2 1

br - brown gy - grey or - orange pk - pink r-red v-violet w-white y-yellow y/g - yellow/green

icos - Installation & Servicing

DC Fan

CH return thermistor (not fitted)

nition electrod

Control thermistor

park generato

Flue thermisto

Flame detection electrode

Control PCB

bk y

y/g

User PCB

External switch e.g. room'stat, pro

or or

nm 7201

ramme

Overheat thermostat

as valv

EXTERNAL ELECTRICAL CONTROLS

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

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

The fuse should be 3A.

Room Thermostat

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

INSTALLATION

Frost Protection

If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system. This is usually done at the programmer, in which case the programmer selector switches are set to OFF and all other controls MUST be left in the running position.

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

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

Important. Ensure that the frost thermostat is wired so that the system pump and/or external diverter valve is energised, as appropriate.

INSTALLATION

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

Diagram A shows an application to boilers fitted with a room thermostat only.

Diagrams B and C show applications to boilers fitted with alternative time controls.

Earths are not shown for clarity but MUST NEVER BE OMITTED.

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.

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 I.S. 813:2002.

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

WARNING

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

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

icos - Installation & Servicing

INSTALLATION

INITIAL LIGHTING

1. Check that the system has been filled and that the boiler is not air locked.

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. Check that all drain cocks are closed and any valves in the flow and return are open.

3. Check the electrical supply is off.

4. Ensure the boiler sealing panel is fitted.

5. Check the gas service cock is open.

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

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.

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 codes will be displayed. Press the reset button (E); the boiler will then repeat its ignition sequence. When the burner is established the WHITE burner ON neon (D) will be permanently illuminated

11. 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.

12. Switch OFF the boiler on/off switch.

13. Remove the pressure gauge and tube. Tighten the

sealing screw in pressure test point. Ensure a gas tight seal is made.

14. Refit the boiler front panel and bottom panel.

15 . THE FASCIA

a. To remove the plastic fascia, prise off the

retaining star washers using a pair of pliers and place to one side.

b. Fill the remaining fixing holes with the white push

in caps provided.

L' 'F'

LEGEND

A On/Off switch.

B Thermostat knob.

D 'Burner On' neon.

E Reset button.

F Injector pressure test point.

G Inlet pressure test point.

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 and the neon will show the status of the flame. If no flame is detected the neon is blinking. When the flame is detected the neon will be lit permanently.

Below is a list with display function in normal operation.

Standby. No demand for heat present.

Boiler is active for central heating.

INSTALLATION

nm9474

H Gas service cock.

J Casing pressure test point.

K Overheat thermostat.

L Flue thermistor.

M Flow thermistor.

Z Spark generator.

icos - Installation & Servicing

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

Boiler frost protection

Note: Boiler frost protection occurs at a temperature less than 3 degrees. The boiler will fire.

GENERAL CHECKS

INSTALLATION

Make the following checks for correct operation:

1. Central Heating

The correct operation of ANY programmer and all other system controls should be proved. Operate each control separately and check that the main burner or circulating pump, as the case may be, responds. Ensure the external controls are calling for heat. After ignition the display should read:

INSTALLATION

2. Gas Rate

Operate the boiler for 10 minutes. Check the boiler gas rate (see Table 2), ensuring the boiler is at full output whilst measurements are recorded.

3. Water Circulation System

Knob Setting Flow Temperature

Min 30 86

Max 8 2 1 80

• The temperatures quoted alongside are approximate, and

vary between installations.

Note. Fernox Superfloc, Sentinel X300 (new systems) or

X400 (existing systems) flushing solutions should be used during the flushing procedure. Refer to Frame 9.

a. With the system HOT examine all water connections for

soundness.

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

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

c. Refill and vent the system, add inhibitor (see Frame 9),

clear all air locks and again check for water soundness. Adhere 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.

d. Balance the system. Refer to Frame 4.

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

discharging correctly

5. Finally set the controls to the user’s requirements.

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's Instructions to the householder and

explain his or her responsibilities under current Gas Safety (Installation and Use) Regulations or rules in force.

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 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 controls.

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 Engineer 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 any programmer is fitted then draw attention to the Programmer User’s Instructions and hand them to the householder.

After installation and commissioning please complete the Benchmark Commissioning Checklist before handover to the customer.

For IE, it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 813:2002.

9. Stress the importance of regular servicing by a Gas

Safe Registered Engineer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR. In IE, servicing work must be carried out by a Registered Gas Installer (RGII).

10. 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 household pack supplied with this boiler.

icos - Installation & 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 Engineer. 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 serviceable component and require annual inspection and replacement if distorted.

5. Check the main injector for blockage or damage.

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

trap (refer to Frame 44) and check the drain for blockage.

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

The servicing procedures are covered more fully in Frames 44-51 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 45 and 46.

IMPORTANT.

8. After completing the servicing or exchange of components

always test for gas tightness.

9. 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.

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

11. Check the gas consumption.

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

the top of the boiler (refer to Frame 45) or into the flue terminal if access is possible (optional test). For correct boiler operation, the CO/CO gas should not be greater than 0.004 ratio.

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

content of the flue

BOILER FRONT PANEL REMOVAL

1. Remove the 2 screws from the underside of the

appliance.

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

nm7808

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 remove the 2 screws.

4. Pull the RH side of the panel down. Slide it to the right

and withdraw.

SERVICING

icos - Installation & 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 the fan and venturi assembly.

5. Inspect the injector for blockage or

damage.

BURNER REMOVAL AND CLEANING

SERVICING

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.

Ecl 6073

Ionisation Probes

Note.

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

nm7400

icos - Installation & Servicing

SERVICING

nm7401

Sump cover

Ionisation probes

Heat exchanger

CLEANING THE CONDENSATE 'S' TRAP

1. Undo the plastic union nut on

the condensate ‘S’ trap outlet.

2. Remove the 2 screws.

3. Pull the trap down and forward

to remove.

4. Flush out any deposits with clean water.

CLEANING THE HEAT EXCHANGER

1. Remove ignition and flame detection electrodes.

Refer to Frames 56 & 57.

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

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 56 & 57.

SERVICING

REASSEMBLY

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 plate.

3. Refit the electrodes (check dimensions Frames 56 & 57).

4. Refit the burner.

5. Refit the fan / venturi assembly.

icos - Installation & Servicing

6. Reconnect the fan electrical leads.

7. Refit the boiler sealing panel.

IMPORTANT.

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

8. Refit the boiler front and bottom panels.

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

10. Reconnect the electrical supply.

SERVICING

nm9476

REPLACEMENT OF COMPONENTS

GENERAL

When replacing ANY component:

1. Isolate the electricity supply.

2. Turn off the gas supply.

3. Remove the boiler front panel. Refer to Frame 40.

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

THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED

IMPORTANT

When work is complete, the sealing panel must be correctly fitted, ensuring that a good seal is made.

Note.

In order to assist fault finding, the control panel has an LED diagnostic display. The key to boiler fault conditions is shown in Frame 69.

CONTROL THERMISTOR REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels. Refer

to Frames 45 & 46.

3. Pull the electrical leads off the control thermistor.

4. Pull the control thermistor and spring clip off the

SERVICING

flow pipe.

5. Replace thermistor and reconnect leads, ensuring that the spring clip is securely holding the thermistor to the flow pipe.

6. Reassemble the boiler in reverse order.

7. Check the operation of the boiler. Refer to Frame 52.

icos - Installation & Servicing

nm7402

Ionisation Probes

FAN REPLACEMENT

SERVICING

1. Refer to Frame 52.

2. Remove the boiler front and sealing

panels. Refer to Frames 45 & 46.

3. Disconnect the electrical leads from the fan.

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

5. Unscrew and remove the screw retaining the fan mounting bracket.

6. Remove the fan and venturi assembly.

7. Remove 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 Frame 52.

Orifice plate

Gasket

Ecl 2336

BURNER REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels.

Refer to Frames 45 & 46.

3. Remove the fan assembly. Refer to Frame 49.

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 sealing gasket.

7. Reassemble in reverse order.

8. Check the operation of the boiler. Refer to

Frame 52.

Note. Take care not to disturb the ionisation

probes at the front and rear of the combustion chamber.

SERVICING

icos - Installation & Servicing

IGNITION ELECTRODE REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels. Refer

to Frames 45 & 46.

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.

SERVICING

ispfu9788

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 operation of the boiler. Refer to Frame 52.

FLAME DETECTION ELECTRODE REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front, bottom & sealing panels.

SERVICING

Refer to Frames 45 & 46.

3. Unplug the flame detection lead from the electrode.

4. Remove the 2 screws holding the flame detection

electrode to the combustion chamber.

ispfu9801

5. Remove the flame detection electrode.

6. Fit the new flame detection electrode, using the

new gasket supplied. Check dimension 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 operation of the boiler. Refer to Frame 52.

icos - Installation & Servicing

SERVICING

Ecl 2340

Copper washer

Rubber moulded seal

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.

BURNER INJECTOR REPLACEMENT

1. Refer to Frame 52.

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

Frames 45 & 46.

3. Remove the fan / venturi assembly. Refer to Frame 54.

4. Remove the 2 injector housing screws.

6. Withdraw the injector housing.

7. Fit the new injector housing, complete with injector.

8. Reassemble in reverse order, ensuring that the new

gas seal supplied is located correctly in the injector housing.

9. Check operation of the boiler. Refer to Frame 52.

GAS CONTROL VALVE REPLACEMENT

1. Refer to Frame 52.

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

to Frames 45 & 46.

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

4. Remove the sensing tube from the gas control valve.

5. Undo the union nut between the gas valve and the gas

inlet cock.

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

7. Undo the gas valve bracket screw, slide the gas valve forward and remove.

8. Transfer the mounting bracket and gas inlet pipe to the new gas control valve.

9. Fit new gas control valve, ensuring that any seals showing damage or deterioration are replaced.

10. Reassemble in reverse order.

11. Ensure the sensing tubing is correctly replaced and

not kinked or blocked in any way.

12. Check operation of the boiler. Refer to Frame 52.

Ecl 2343

SERVICING

icos - Installation & Servicing

SERVICING

Ecl 2419

Mounting brackets

Control box

CONTROL BOX REPLACEMENT

1. Refer to Frame 52.

2. Remove the front panel.

3. Remove the bottom panel.

4. Remove the 2 control box screws.

5. Carefully unplug all the electrical wiring from the control box.

6. With the control box lowered, pull the assembly forward to

remove from the housing.

7. Remove the user control from the assembly.

8. Transfer the mounting brackets 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 Frame 52.

N.B. To change the user control only.

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

12. Pull the display unit forward to remove.

13. Push the new display unit into position.

14. Reassemble in reverse order.

15. Check the operation of the boiler. Refer to Frame 52.

nm7804

Ecl 2438

SERVICING

1. Refer to Frame 52.

2. Remove the boiler front and bottom panel.

Refer to Frames 45 & 46.

3. Remove the 2 control box screws and lower the control box.

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

5. Refit the new switch, ensuring that the electrical leads are replaced on the correct terminals (refer to Frame 38) and the key on the switch is correctly aligned with the slot in the plastic moulding.

6. Reassemble in reverse order.

7. Check operation of the boiler. Refer to

Frame 52.

MAINS SWITCH REPLACEMENT

icos - Installation & Servicing

OVERHEAT THERMOSTAT REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and

sealing panels. Refer to Frames 45 & 46.

3. Pull off the electrical leads from the thermostat body.

4. Pull the thermostat and clip from the pipe.

5. Fit the new thermostat, ensuring that the clip is securely holding the thermostat to the flow pipe.

6. Reassemble in reverse order.

7. Check operation of the boiler.

Refer to Frame 52.

SERVICING

FLUE THERMISTOR REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels. Refer to Frames 45 & 46.

3. Pull off the silicon tube from the thermistor housing.

4. Remove the aluminium nipple securing the thermistor to the flue manifold.

5. Withdraw the thermistor.

6. Unplug the inline electrical connector.

7. Fit the new thermistor, using the gasket supplied.

8. Reassemble in reverse order.

9. Check operation of the boiler. Refer to Frame 52.

nm9478

SERVICING

icos - Installation & Servicing

nm9479

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

isfu9570

icos - Installation & Servicing

nm9480

HEAT EXCHANGER REPLACEMENT

SERVICING

Refer also to Frame 10, 'Boiler exploded view'.

1. Refer to Frame 52.

2. Remove front, bottom and sealing panels. Refer to

Frames 45 & 46.

3. Remove the control box and place to one side. Refer to Frame 61.

4. Attach a length of hose to the drain nipple on the bottom of the heat exchanger and drain down the boiler.

5. Remove the fan assembly and place to one side. Refer to Frame 54.

6. Remove the burner and place to one side. Refer to Frame 48.

7. Remove the ignition and detection electrodes. Refer to Frames 56 & 57.

8. Remove the spark generator. Refer to Frame 58.

9. Release the flue from the turret.

10. Remove the turret from the boiler. Refer to Frame 15.

11. Release the silicon tubing from the sample point.

12. Release the electrical connections to the flue

thermistor.

13. Unscrew the M5 x 10 screw retaining the top manifold flue casing.

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

15. Undo the 4 M5 x 10 screws securing the bottom flue manifold casting.

16. Pull the CH return pipe, CH flow pipe and the bottom flue manifold together up and out of the heat exchanger.

17. Remove the condensate 'S' trap. Refer to Frame 49.

18. Unscrew the 2 M5 x 10 screws from the inter panel.

19. Slide the heat exchanger and inter panel assembly

upwards to disengage and remove from the casing.

20. Transfer the interpanel to the new heat exchanger.

21. Reassemble in reverse order, replacing gaskets or

seals if any sign of damage or deterioration is evident.

Note.

The heat exchanger is supplied with new combustion chamber insulation boards. These should be fitted (refer to Frame 65) before the burner and fan assembly and before the ignition and detection electrodes are replaced.

25. Check the operation of the boiler. Refer to Frame 52.

SERVICING

icos - Installation & Servicing

SERVICING

BOILER SEALING PANEL SEAL REPLACEMENT

1. Refer Frame 52.

2. Remove the front panel. Refer to Frame 45.

3. Remove the boiler sealing panel. Refer to

Frame 46.

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

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

6. Reassemble in reverse order.

Note.

Ensure that the boiler sealing panel is correctly seated, compressing the seal to make an airtight joint.

7. Check operation of boiler. Refer to Frame 52.

CONDENSATE 'S' TRAP REPLACEMENT

1. Refer to Frame 52.

SERVICING

2. Remove the boiler front panel. Refer to Frame 45.

3. Remove the boiler bottom panel. Refer to Frame 46.

4. Undo the plastic union nut on the condensate 'S' trap

outlet.

Seals

5. Remove the 2 screws.

6. Pull the trap down and forward to remove.

7. Reassemble in reverse order, ensuring that the new

trap is full of water.

8. Check operation of the boiler. Refer to Frame 52.

nm9481

nm 2902

icos - Installation & 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' 'F'

GO TO FRAME 70

GO TO FRAME 71

GO TO FRAME 72

GO TO FRAME 73

GO TO FRAME 74

GO TO FRAME 75

ALTERNATING 'H' '4'

ALTERNATING 'H' 'n'

ALTERNATING 'H' 'E'

ALTERNATING 'H9'

ALTERNATING 'L9'

icos - Installation & Servicing

GO TO FRAME 76

GO TO FRAME 77

GO TO FRAME 71

GO TO FRAME 76

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

L.....F....... (FLAME 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 57).

Replace as necessary.

Replace ignition electrode and associated

harness as necessary

harness for continuity and visual condition.

Refer to Frame 58. Are these functioning

Check the ignition electrode and associated harness for:

Is gas pressure available at

the boiler inlet ?

YES

Is 200V DC supply available

at the gas valve ?

YES

Check spark generator and associated

correctly?

YES

continuity, visual condition, position

(Refer to Frame 56).

Are these functioning correctly ?

Replace gas valve

YES

Check gas supply

and rectify fault

Check gas valve

wiring for

continuity

Replace PCB

Replace

spark generator

Check syphon

and condensate

drain pipework

for blockage

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

measure the value (some may measure the possible peak voltage of 339V). In general terms, a reading greater than 150V indicates that the correct voltage is supplied to the gas valve. As an alternative to a multimeter a mains checking device may be used. E.g. an electrical screwdriver or a mains tester.

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

Check for an excess voltage between neutral

LE ONLY: Check continuity of OH thermostat.

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

and earth. Is the value below 50V?

YES

Is this correct?

YES

HE ONLY: Check earth wire is connected to

detection lead. Is this correct?

YES

Check all earths for continuity

YES

Internal fault within the PCB

Check earth connection to the boiler. If value is still in

excess of 50V consult a Qualified Electrician to check the

household electrical supply and circuitry

Press and hold reset button for 2

seconds. Does boiler operate

Correct wiring or replace thermostat

Correct wiring or replace detection lead

Correct connections

YES

correctly?

Turn boiler off and wait for 5

seconds.Turn boiler on.

Does boiler operate correctly?

Replace PCB

YES

icos - Installation & 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 valves open ?

YES

Does the pump setting give a differential

across the boiler in excess of 25 oC ?

YES

Increase the pump setting.

Is differential now below 25

Replace the system pump

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

Is nominal 330 V DC present across red and blue at the fan connector as

reset button is pressed?

Check wiring harness for continuity. Is there continuity?

YES

C ?

YES

Is 14V DC present

across yellow and pink

at the fan connector?

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.

Replace overheat thermostat

Fill and vent the system and open all

isolation valves

Set CH control knob to maximum.

If the overheat trips again measure the flow temp:

Over 90 oC Check control thermistor

(Refer to Frame 71) .

Under 90

YES

C Replace overheat 'stat

Replace fan

Replace PCB

Replace harness

H.....1..... (FLOW THERMISTOR ERROR)

Remove the boiler flow thermistor from the CH flow

pipe and disconnect thermistor wires.

Check resistance, using a suitable multimeter

connected across the thermistors terminal pins

C expect 9,700 - 10,300 Ohms

At 25

At 60

C expect 2,400 - 2,600 Ohms

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

Are the thermistor values correct ?

Is there continuity between the

PCB and the thermistor ?

icos - Installation & 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......F........ (FLAME DETECTION - SHORT CIRCUIT ERROR)

Remove flame detection electrode terminal from PCB.

Is there continuity between the 2 terminal pins ?

YES

Replace flame detection electrode

H.....4...... (FLUE THERMISTOR ERROR)

Can the fault condition be reset by switching

off the mains supply to the boiler ?

Check wiring for continuity from the

PCB to the flue thermistor

Check resistance, using a suitable multimeter

connected across the thermistor terminal pins.

C expect 9,700 - 10,300 Ohms

At 25

At 60

C expect 2,400 - 2,600 Ohms

At 85

C expect 1,000 - 1,100 Ohms

Replace PCB.

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.

YES NO

Check Flow stat is

fitted - making contact

with pipe

YES

Check resistance, using a suitable multimeter

connected across the dry fire thermistor

terminal pins.

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

At 60 oC expect 2,400 - 2,600 Ohms

At 85

C expect 1,000 - 1,100 Ohms

Fill and vent the

system and open all

isolating valves

Replace PCB

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

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Are thermistor values correct ?

YES

Replace thermistor

YES

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 50

Check wiring to the boiler for

reversed live and neutral

Are thermistor values correct ?

Replace

thermistor

icos - Installation & Servicing

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, Ideal Stelrad Group 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 Ideal Boilers Limited.

Key No. GC Part No. Description Qty. Product No.

1 Front casing panel 1 173 508

4 E67-482 Bottom casing panel 1 170 900

11 E67-489 Burner 1 170 905

12 Combustion chamber insulation 1 173 520

14 E67-492 Injector and housing HE15, HE18, HE24 1 170 908

H18-545 Injector and housing HE12 1 173 779

16 E85-097 Fan assembly 1 172 625

When ordering spares please quote:

1. Boiler Model

2. Appliance G.C. Number

3. Description

4. Quantity

5. Product Number

19 E67-497 Gas control valve 1 170 913

22 E67-500 Flue thermistor 1 170 916

23 E67-501 Control thermistor 2 170 917

24 E67-502 Overheat thermostat 1 170 918

25 Ignition electrode kit 1 175 406

26 Flame detection electrode and gasket 1 173 529

32 E67-511 Condensate ‘S’ trap 1 170 926

34 E65-515 Controls hinge bracket kit 1 170 928

35 User controls 1 173 532

36 PCB primary controls kit (V9) 1 174 486

37 E67-519 Fuse PCB (3.15A L 250V) 1 170 931

39 Main switch c/w harness 1 173 537

45 E65-527 Gasket kit 1 170 938

52 E68-376 Seal kit - sealing panel 1 171 014

53 E68-380 Turret gasket 1 171 022

40 Spark generator 1 173 538

94 Ignition lead 1 175 424

95 Detection lead 1 173 511

icos - Installation & Servicing

nm8077d

SHORT LIST

SHORT LIST OF PARTS

BOILER CASING ASSEMBLY

1. Front casing panel with screws.

2. Sealing panel with screws.

4. Bottom casing panel with screws.

icos - Installation & Servicing

CONTROLS ASSEMBLY

33. Controls assy with screws.

34. Controls hinge bracket.

35. User controls (without item 38).

36. PCB (primary controls).

38. User control housing

39. Mains switch.

54. Jumper link.

LIST OF PARTS

BURNER ASSEMBLY

11. Burner assembly with screws

and gasket.

icos - Installation & Servicing

Ecl 1598

NOTES

icos - Installation & Servicing

NOTES

icos - Installation & 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 Register will record the

data and will send a certificate

of compliance to the property

IT IS A CONDITION OF THE

MANUFACTURERS WARRANTY

THAT THE BENCHMARK

COMMISSIONING CHECKLIST IS

FULLY COMPLETED AND LEFT

WITH THE APPLIANCE

icos - Installation & 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

use

icos

Your Ideal us

When replacing any part on assured conform to the safety use reconditioned or copy pa

HE12,

For installatio

The code of practice for the installation,

commissioning & servicing of central heating systems

Ideal Boilers,

HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137.

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

P.O. Box 103, National Ave, Kingston upon Hull,

Technical Training

The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers.

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

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

deal Installer/Technical Helpline: 01482 498 663

www.idealboilers.com

IDEAL icos HE12, icos HE15, icos HE24, icos HE18 Installation And Servicing

Specifications and Main Features

Frequently Asked Questions

User Manual