IDEAL INDUSTRIES HE12, HE15, HE9, HE18 User Manual

installation and servicing

classic

Your Ideal installation and servicing guide

See reverse for

classic

users guide

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

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

HE9, HE12, HE15, HE18

For details of document amendments, refer to page 3

January 2008 UIN 201 850 A06

classic HE - Installation & Servicing

DOCUMENT AMENDMENTS

Relevant Installation changes implemented in this book from Mod Level ............ A05 (Oct 06) to A06 (Jan 08)

• Various Pages

Company Name Change.

• Page 26 & 27, Frames 39 & 40 - Condensate Pipe Termination Configurations

BS6798 recommends that a second trap and an air break are required where the siphon trap within the boiler is less than 75mm for configuration 2 and 3

• Page 27, Frame 40 - Condensate Pipe Termination Configurations

Statement added with ref. to termination into a down pipe.

• Page 33, Frame 54 - Burner and Air Box Removal

Item No. 5 added.

• Users Guide, Page 2 - Important Notes

2 new bullet points added.

Ideal Stelrad Group reserve the right to vary specification without notice

classic HE - Installation & Servicing

GENERAL

Table 1 - General Data

Boiler Size HE9 HE12 HE15 HE18

Gas supply connection (in. BSP) Rc 1/2 (1/2) 1/2" (BSP Female)

Flow connection 22mm

copper

Return connection 22mm

copper

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; 100W

Fuse rating External; 3A Internal; F1A to BS.4265

Water content litre (gal.) 3.0 (0.67) 3.95 (0.87)

Packaged Weight kg (lb) 45 (99) 50 (110)

Maximum installation weight kg (lb) 40 (88) 45 (99)

Boiler size Height mm (in.) 700 (27.5)

Width mm (in.) 380 (15.0)

Depth mm (in.) 280 (11.25)

Flue duct diameter mm (in.) 100 (4.0)

Flue duct length (max) m (ft) 3 (9.8)

Table 2 - Performance Data

Boiler Size HE9 HE12 HE15 HE18

Input 'Q' Nett CV kW (Btu/h) 9.4 (32,100) 12.6 (43,000) 15.7 (53,600) 18.9 (64,500)

Gross CV kW (Btu/h) 10.5 (35,800) 14.0 (47,800) 17.4 (59,400) 20.9 (71,300)

Gas Consumption l/s (cu.ft/h) 0.27 (34.3) 0.36 (45.8) 0.45 (57.2) 0.54 (68.7)

Output 'P 70

C Mean Water temp. kW (Btu/h) 9.0 (30,700) 12.0 (40,900) 15.0 (51,200) 18.0 (61,400)

40oC Mean Water temp. kW (Btu/h) 9.8 (33,400) 13.1 (44,700) 16.2 (55,300) 19.4 (66,200)

Burner Setting Pressure (Hot) mbar (in w.g.) 12.0 (4.8) 10.4 (4.2) 12.3 (4.9) 12.7 (5.1)

Seasonal efficiency (SEDBUK) * Band B [87.2]% [87.2]% [86.8]% [86.8]%

NOx classification Class 3 Class 2 Class 1 Class 1

* The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of

dwellings. The test data from which it has been calculated have been certified by a notified body.

Note. Gas consumption is calculated using a calorific value of

38.7 MJ/m

(1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett

To obtain the gas consumption at a different calorific value:-

a. FOR L/S - divide the gross heat input (kW) by the gross C.V.

of the gas (MJ/m

b. FOR FT

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

)

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

Key to symbols

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

PMS = Maximum operating pressure of water

= A room sealed appliance designed for connection via

12 C32

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 down 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

classic HE - Installation & Servicing

GENERAL

classic HE

Natural Gas only

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

(Benchmark No.)

HE9 41-415-58 87 BQ 10

HE12 41-415-59 87 BQ 10

HE15 41-421-45 87 BQ 10

HE18 41-421-46 87 BQ 10

Destination Countries: GB, IE

CONTENTS

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

Benchmark Commissioning Checklist ..................... 46

Boiler Clearances .........................................................7

Boiler Exploded View ................................................. 13

Electrical Connections ............................................... 28

Electrical Regulations ................................................ 10

Extension Ducts - Fitting ............................................ 22

External Controls ........................................................28

Fault Finding ................................................................ 42

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

Rear installation ...................................................... 16

Side installation .......................................................19

Gas Safety ..................................................................... 6

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

Initial Lighting . .......................................................31,32

Installation ............................................................ 13-32

Mandatory Requirements ............................................ 6

Pump ........................................................................... 10

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

Servicing ............................................................... 33-41

Short List of Parts ...................................................... 43

Spares Replacement ................................................. 35

System Electrical Diagrams .................................29,30

Terminal Guards. .......................................................... 8

Water and Systems ..................................................... 9

Water Treatment ..........................................................9

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

BENCHMARK COMMISSIONING CHECKLIST

Boiler Page

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

Appliance serial no. on data badge ....................... 1 3

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

Controls

Time and temperature control to heating ......... 29/30

Time and temperature control to hot water ...... 29/30

Heating zone valves .......................................... 29/30

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

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

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

For all boilers

Flushing to BS.7593 .................................................9

Inhibitor...................................................................... 9

Central heating mode

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

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

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

Central heating return temp. ..... measure and record

For combination boilers only

Scale reducer .........................................................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 .................................................. 26

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

classic HE - Installation & Servicing

COMPLETE

GENERAL

INTRODUCTION

The classic HE 9, 12, 15 and 18 are a range of automatically fully

controlled, wall mounted, balanced flue, fanned, high efficiency, condensing gas boilers.

The primary heat exchanger is cast iron. The secondary heat exchanger is aluminium. The boiler casing is of white enamelled mild steel.

The boiler casing has a removable controls pod containing a drop-down door. The boiler thermostat is located behind the drop- down door.

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

See Frame 1 for details of the correct boiler tappings to use.

The boilers are supplied with a standard flue kit suitable for rear outlet from 114 mm (4

Side outlet applications require the optional extra side outlet kit.

The boilers are suitable for connection to the following open vented or sealed systems:

• Fully pumped CH and indirect DHW

• Pumped heating only.

• Pumped indirect DHW only.

1/2") to 705 mm (30 1/2").

SAFE HANDLING

This boiler may require 2 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. Refer to Frame 18.

• Split the boiler down to reduce the weight, e.g. remove casing and hardware pack. Refer to Frame 9.

• 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

FLUING:

z Flue Extension Ducts. (1000mm long) up to 3m

z 90

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

up to 2 elbows

z 45

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

up to 2 elbows

z Side Outlet Kit z Vertical Connector Kit z Flue Finishing Kit z Roof Flue Kit z High Level Flue Outlet Kit z Flue Deflector Kit

OTHER OPTIONAL KITS:

z Downward Piping Kit z Condensate Pump Kit

CURRENT GAS SAFETY (INSTALLATION AND USE) REGULATIONS OR RULES IN FORCE.

The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force.

In GB, the installation must be carried out by a CORGI Registered Installer. It must be carried out in accordance with the relevant requirements of the:

• Gas Safety (Installation and Use) Regulations

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

• The Water Fittings Regulations or Water byelaws in Scotland.

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

Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice. In IE, the installation must be carried out by a Competent Person and installed in accordance with the current edition of 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.6891 Low pressure installation pipes. BS.6798 Installation of gas fired hot water boilers 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.7593 Treatment of water in domestic hot water central

heating systems.

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. Health & Safety Document No. 635 The Electricity at Work Regulations, 1989. Manufacturer’s notes must NOT be taken in any way as overriding

statutory obligations.

IMPORTANT. These appliances are certificated by the British Standards Institution 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 otherwise recommended by Ideal Stelrad Group in writing. If in doubt please enquire.

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

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation panels which can cause irritation to the skin. No asbestos, mercury or CFCs are included in any part of this boiler.

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. 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.

continued on page 8 . . . . . . . . .

classic HE - Installation & Servicing

cla7635

(15 3/8")

BOILER WATER CONNECTIONS

This appliance in NOT suitable for use in a direct hot water system or for gravity circulation.

BOILER CLEARANCES

GENERAL

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.

Installation from inside ONLY

b. If a core boring tool is to be used inside

the building; the space in which the boiler is to be installed must be at least wide enough to accommodate the tool.

Front View Side View

Pumped return pipe

Front clearance: 450mm (17 3/4") from the front of the boiler casing.

Minimum front clearance when built behind a concealed panel is 5mm ( provided that the top and bottom of the casing is not enclosed and the side clearance is 40mm (2") at both sides.

See also Table 4.

380 (15")

296

(115/8")

Pumped flow pipe

12 (1/2")

(1 3/4")

100 (4")

/4")

Gas connection

20 (3/4")

classic HE - Installation & Servicing

133

(5 1/4")

Condensate drain point

141 (5 9/16")

700 (27 1/2")

Gas connection

70 (2 3/4")

280 (11")

Flue terminal

cla8230

38 (1 1/2")

64 (2 1/2")

GENERAL

Bathrooms

This range of appliances is rated IP 1XB.

The boiler may be installed in any room or internal space, although particular attention is drawn to the requirements of the current I.E.E. (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 waterjets are not going to be used for cleaning purposes (such as communal baths/showers), the appliance can be installed in Zone 3, as detailed in BS.7671.

Where installation will be in an unusual location, special procedures may be necessary and BS.6798 gives detailed guidance on this aspect.

Compartment Installations

A compartment used to enclose the boiler MUST be designed and constructed specially for this purpose. An existing cupboard or compartment may be used, provided it is modified for the purpose.

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

z BS. 6798.

z The position selected for installation MUST allow adequate

space for servicing in front of the boiler and for air circulation around the boiler. Refer to 'Air Supply'.

z For the minimum clearances required for safety and

subsequent service refer to the wall mounting diagram, 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 is to be installed only on a gas supply with a governed meter.

A gas meter can only be connected by the local gas supplier or by a local regional contractor.

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. A MINIMUM pressure of 20 mbar MUST be available at the boiler inlet with the boiler operating.

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 soundness and purged as described in the above code.

FLUE INSTALLATION

Pluming may 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.

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.

Terminals guards are available from boiler suppliers - ask for TFC Flue Guard, Model No. K6-round, plastic coated. In case of difficulty seek advice from:

Grasslin (UK) Ltd., Tower House, Vale Rise, Tonbridge, Kent TN9 1TB. Tel: +44 (0) 1732 359 888. Fax: +44 (0) 1732 354 445 www.tfc-group.co.uk

Ensure that the guard is fitted centrally.

5. The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of any building.

6. The air inlet/products outlet duct and the terminal of the boiler MUST NOT be closer than 25mm (1") to combustible material. Detailed recommendations on the protection of combustible material are given in BS.5440-1:2000. 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 reenter 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 'unsafe' and corrective action taken.

Table 3 - Balanced Flue Terminal Position

Flue Terminal Positions

1. Directly below 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. 600mm (24") From corner walls. 1000mm (40")

Twin Flue Applications

15. Centre distance between air inlet and flue

outlet ducts. 120mm (5")

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

Min. Spacing*

classic HE - Installation & Servicing

GENERAL

TERMINAL

The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Frame 10.

AIR SUPPLY

Detailed recommendations for air supply are given in BS.5440:2. In IE refer to I.S. 813:2002.

The following notes are for general guidance:

1. It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed.

2. If the boiler is to be installed in a cupboard or compartment, permanent air vents are required (for cooling purposes) in the cupboard/compartment, at both high and low levels. The air vents must either communicate with room/internal space, or be direct to outside air. The minimum effective areas of the permanent air vents, required in the cupboard/compartment, are specified in Table 4 and are related to maximum rated heat input.

Table 4 - High and low vent areas

Boiler Air from room/internal Air direct from

space, cm (in2 ) outside, cm (in2)

HE9 102 (16) 51 (8)

HE12 135 (21) 68 (11)

HE15 170 (26) 83 (13)

HE18 198 (31) 102 (16)

3. Both air vents MUST communicate with the same room or internal space or MUST be on the same wall to outside air.

4. In siting the air vents care must be taken to avoid the freezing of pipework.Water circulation system.

WATER CIRCULATION SYSTEM

The boiler must NOT be used for direct hot water supply. For the types of system and correct piping procedure refer to 'Introduction' and Frame 1.

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

The domestic hot water system, if applicable, should be in accordance with the relevant recommendations of BS. 5546. Copper tubing to BS. 2871:1 is recommended for water carrying pipework.

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 under floor spaces.

Boilers not fitted to a sealed system must be vented.

IMPORTANT

A minimum length of 1m of copper pipe MUST be fitted to both flow and return connections from the boiler before connection to any plastic piping. This applies to ALL types of installation.

Draining taps MUST be located in accessible positions, which permit the draining of the whole system - including the boiler

classic HE - Installation & Servicing

and hot water storage vessel. They should be at least nominal size and be in accordance with BS. 2879.

The boiler is fitted with a special drain plug, which is provided, to drain the BOILER ONLY, in the event of the system drain plug being unable to do so. The hydraulic resistance of the boilers, at MAXIMUM OUTPUT with an 11 differential, are shown in Table 5.

Maximum boiler operating temperature should be 82

Table 5 - Water flow rate and pressure loss

Boiler Size HE 9 1 2 1 5 1 8

Boiler kW 9.0 12 15 18 Output Btu/h x 1000 30.7 40.9 50.2 60.4

Water Flow l/min 11.7 15.6 19.5 23.4 Rate gal/h 155 206 258 309

Pressure mbar 54.0 93.5 98.4 142.5 Loss in wg 21.6 37.4 39.3 57

C (20OF) temperature

1/2" BSP

C (180oF).

WATER TREATMENT

These boilers incorporate a cast iron heat exchanger and an aluminium heat exchanger.

IMPORTANT. The application of any other treatment to this

product may render the guarantee of Ideal Stelrad Group INVALID.

Ideal Stelrad Group recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems.

Ideal Stelrad Group recommend the use of Fernox, GE Betz Sentinel or Salamander water treatment products, which must be used on accordance with the manufacturers instructions.

For further information contact:

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

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

Salamander Engineering Ltd, Unit 24, Reddicap Trading Estate, Sutton Coldfield, West Midlands B75 7BU. Tel. +44 (0) 121 378 0952

Notes.

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

2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. BS7593:1992 details the steps necessary to clean a domestic heating system.

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

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

BOILER 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.

continued . . . .

GENERAL

System return

Connections to boiler

Inverted cold feed entry

System flow to pump

150 (6") Max

15mm Cold feed

450 (17

/4")

Mimimum

450 (17

/4")

Mimimum

22mm Open vent

Feed / expansion cistern

Water level (cold)

cla7840

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.

The point of connection to the mains should be readily accessible and adjacent to the boiler, except that for bathroom installations; the point of connection to the mains MUST be situated outside of the bathroom.

Note.

Where a room sealed appliance is installed in a room containing a bath or shower then the appliance and any electrical switch or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower. See Frame 41 for details.

CONDENSATE DRAIN Refer to Frames 38, 39 and 40

A condensate drain siphon is provided on the boiler. This drain

ELECTRICAL SUPPLY

WARNING. The appliance MUST be efficiently 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.

must be connected to a drainage point on site. All pipework and fittings in the condensate drainage system MUST be made of plastic- no other materials may be used.

IMPORTANT.

Any external runs must be insulated.

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

OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED

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.

There should be a minimum height - 450mm (173/4") - of open vent above cistern water level. If this is impossible refer below.

The vertical distance between the highest point of the system and the feed/ expansion cistern water level MUST not be less than 450mm (17

/4"). The pump MUST be fitted on the flow side of the boiler. A suitable pump is a domestic circulator capable of providing an 11oC (20oF)

temperature differential (e.g. Grundfos UPS 15/50 or equivalent). The vertical distance between the pump and feed/expansion cistern MUST comply with the pump manufacturers 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.

Note. A cold water feed must be available back to the boiler, when all automatic valves are in the closed position (refer to BS. 6798) and when close coupled the feed must not be in a vertical leg.

The classic HE range of boilers can be installed in low head situations by fitting a 'surge arrester' in the expansion pipe as shown.

The following conditions MUST be observed:

1. The surge arrester must be at least 42mm in diameter x

2. The static water level (cold) must be at least 200mm

3. The maximum practical length of 15mm cold feed pipe

Note. The pump manufacturers minimum

requirements must be complied with.

LOW HEAD INSTALLATIONS

150mm long, thus ensuring a MINIMUM air gap and a MINIMUM depth of water below the static water level (cold) of 75mm.

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.

should be used in order to reduce the effective volume of system water expanding into the feed/expansion cistern to a minimum.

All dimensions in mm (in.). N.B. Imperial dimensions are approximate

Return

cla7839

450 (17 Min.

/4")

Minimum Requirements

75 (3) Min.

200 (8) Min.

Surge arrester

75 (3) Min.

Flow

Highest point of flow or return

classic HE - Installation & Servicing

Feed / expansion

cistern

22 (3/4)

Open vent

150

(6)

Max

Max. practical

Cold

water

level

To pump

length

SEALED SYSTEM REQUIREMENTS

ecl6060

GENERAL

Hose unions

Temporary hose

(disconnect

after filling)

Non-return

valve

Automatic

air vent

Hosepipe

(disconnect

after filling)

Additional stop valve

Double check valve

assembly

(note direction of flow)

Hose connector

Note.

The method of filling, refilling, topping up or flushing sealed primary hot water circuits from the mains via a temporary hose connection is only allowed if acceptable to the local water authority.

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 (45 lb/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:

a. A non-adjustable pre-set lift pressure not exceeding 3

bar (45 lb./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.

4. Expansion Vessel

a. A diaphragm type expansion vessel must be

connected at a point close to the inlet side of the pump, the connecting pipe being not less than 15mm ( 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 110oC

(230

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 110oC (230oF) should be at least 0.35 bar (5lb/in

) less than the lift pressure of the

safety valve.

For guidance on vessel sizing refer to the table in Frame

6. For further details refer to BS.5449. 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

(5lb./in

) in excess of the safety valve setting. Single feed

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 fitted make-up vessel with a readily

visible water level. The vessel should be mounted at least 150mm (6") above the highest point of the system and be connected through a non-return valve to the system, fitted at least 300mm (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.'

1/2"

classic HE - Installation & Servicing

GENERAL

SEALED SYSTEM REQUIREMENTS - continued

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 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 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.

) of the pre-set lift

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 Table 6, multiplied by a factor of 0.8 (for flow temperatures of less than 88 oC).

Table 6

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

classic HE - Installation & Servicing

Condensate

siphon trap

Data Plate

cla7926

BOILER ASSEMBLY - Exploded view

INSTALLATION

LEGEND

9. Sightglass

12. Main Burner

17. Gas Valve

19. Control Box

classic HE - Installation & Servicing

23. PCB25E

24. Air pressure switch

26. Controls Casing

27. Flue Protection Thermostat

30. Fan

35. Front Panel

37. Controls Door

ix7408

UNPACKING

The boiler is supplied fully assembled in Pack A, together with a standard flue assembly for lengths from 75mm (3") up to 705mm (27 from 270mm (10 5/8") up to 775mm (30 flue in Pack B.

Note. For side flue applications the optional extra side outlet kit is required.

Unpack and check the contents.

3/4") rear flue and

INSTALLATION

1/2") side

INSTALLATION

Pack A Contents

A The complete boiler

B Installation & Servicing/

User's Instructions

C Hardware Pack (listed below)

D Wall mounting template

E Wall mounting plate

F 1 year guarantee form

Hardware Pack 1 Contents

A Pipe - Flue extension - 1 off

B Nut Siphon - 1 off

C Washer - siphon sealing - 1 off

D 'O' ring - 1 off

E Washer M4 Form 'C' - 3 off

F No. 14x2" slotted woodscrew - 3 off

G Wallplug - 3 off

H Sealing ring - 1 off

cla7643

I Screw M4 x 8 PP Taptite - 3 off

J Nut M5 hex - 3 off

K Screw No. 8 x 8 PP S/tap - 3 off

L Polyurethane foam seal - 1 off

cla7673

Pack B Contents

z Terminal grille assy. - 1 off.

classic HE - Installation & Servicing

PACKAGING AND CASING REMOVAL

INSTALLATION

1. Cut straps and remove outer carton.

2. Remove packing from top of boiler (Note the wall mounting

plate is packed on this packing)

3. Leave bottom packing in place.

4. Slightly open plastic controls door to gain access to the front

panel fixing screws.

5. Remove the front casing as follows and place to one side to avoid damage.

a. Undo the 2 front casing retaining screws (a) retaining the

casing to the back panel.

b. Lift the bottom of the front of the boiler casing up slightly then

unhook from the top.

6. Remove the hardware pack from the inside of the boiler

7. Remove the boiler from its packaging base. But do not

remove bottom packaging. The boiler may now be stood upright on its controls support protection frame to ease handling and installation.

8. Unpack the boiler terminal box (pack 'B') and, if applicable, the extension flue box(es) (pack 'D').

DETERMINING THE FLUE LENGTH

It is MOST IMPORTANT that the boiler is installed in a vertical position.

FLUE KITS

Pack B: supplied as standard.

Pack D: optional extension kit for side flue or vertical flue outlet.

Refer to Frame 28.

Front panel

cla7630

(a) Casing

retaining screws

INSTALLATION

Packaging base

Controls pod casing

REAR FLUE

INSTALLATION

190mm 190mm

Flue length

for rear

SIDE FLUE

INSTALLATION

Jacking screw for boiler alignment

Note.

A roof flue kit is available as an optional extra for vertical flue installation, supplied with separate fitting instructions. Refer to Frames 31 to 35.

CLA7636

Side Outlet Kit: For side outlet applications. Refer to Frame 20-

27.

1. A maximum of 3 extension ducts (plus the standard flue duct) may be used together.

2. Flue extensions of greater than 1m (39") should be supported with the bracket provided.

Elbow kit (equivalent flue length resistance = 1.5m)

Elbow kit (equivalent flue length resistance = 1.0m)

Flue length

From 75 up to 705 (Rear flue)

From 270 up to 775 (Side flue)

775 to 1680 B Pack 1 off + D Pack, 1 off *

1680 to 2585 B Pack 1 off + D Pack, 2 off *

2585 to 3000 B Pack 1 off + D Pack, 3 off *

B Pack Product No. 201 816

mm*

or B Pack 1 off

Accessories

* Side flue only

D Pack Product No. 201 180

Side Outlet Kit Product No. 201 866

* Measured from centre line of boiler to outside of wall.

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

classic HE - Installation & Servicing

cla7661

FLUE ASSEMBLY - Exploded View

1. An optional flue duct extension kit is

required for wall thicknesses greater than 775mm (30 Frame 10.

/2") side flue. Refer to

INSTALLATION

LEGEND

1. Terminal

2. Weather seal

(optional extra)

3. Flue assembly

4. Boiler sealing ring

5. Flue extension pipe

6. 'O' ring

WALL MOUNTING TEMPLATE

Note. The template shows the positions of the fixing holes and the

rear flue outlet hole centre for standard installation. Care MUST be taken to ensure the correct holes are drilled.

1. Tape template into the selected position. Ensure squareness by hanging a plumbline as shown.

2. If fitting a side flue refer to Frame 21.

3. Mark onto the wall the following:

a. The wall mounting plate screw positions (choose one from

each group). Note. Mark the centre of the flue hole as well as the circumference.

b. The position of the flue duct hole.

c. The jacking screw fixing hole.

4. Remove the template from the wall.

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 125mm (5")

core boring tool, ensuring that the hole is square to the wall. If the hole has been quite accurately cut with a drill then making good the wall faces is not essential as seals are provided at both ends of the flue. However, both wall faces immediately around the cut hole should be flat; make good if necessary. For less accurate holes make good to approximately 125mm (5") diameter at the two wall faces.

2. Drill 3 holes (two for the wall mounting plate and

one for the jacking screw) with an 8mm ( masonry drill.

3. Insert the plastic plugs provided.

REAR FLUE OUTLET

5/16")

Note. Check all of the hole positions BEFORE drilling

classic HE - Installation & Servicing

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