IDEAL isar HE24 Installation And Servicing
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IDEAL isar HE24 Installation And Servicing

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installation and
servicing
isar
(V3 Flue System)
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
HE24, HE30, HE35
For users guide see reverse of book
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.
February 2008 UIN 203319 A03
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.

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  • Page 1 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. February 2008 UIN 203319 A03 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.
  • Page 2 back isar - Installation and Servicing...
  • Page 3 Page 15, Frame 10 - Packing Removal Wall Mounting Template change. • Page 17, Frame 14 - Wall Mounting Template Change to procedure for mounting boiler onto a wall. Ideal Stelrad Group reserve the right to vary specification without notice isar - Installation and Servicing...
  • Page 4 back GENERAL Table 1 - General Data isar HE24 HE30 HE35 Gas supply 2H - G20 - 20mbar Gas Supply Connection Rc 1/2 (1/2” BSP female) Injector Size Stereomatic 5.6mm dia. 5.7mm dia Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection Domestic Hot Water 15mm copper compression...

  • Page 5: Table Of Contents

    back GENERAL CONTENTS isar Air Supply ............... 8 Natural Gas only Benchmark Commissioning Checklist ..... 66 Boiler size G.C. Appliance No. PI No. Boiler Clearances ............9 (Benchmark No.) Boiler Exploded Diagram ..........13 HE24 47 348 31 87 BP 34 Condensate Drain ...........

  • Page 6: Controls

    back GENERAL BOILER WATER INTRODUCTION CIRCUIT DIAGRAMS The isar range of boilers are wall mounted, full sequence, automatic spark ignition, low water content, fanned flue, high efficiency, condensing, Central Heating Circuit combination gas boilers. Note. Due to the high efficiency of the boiler a plume of water vapour will form Expansion at the terminal during operation.

  • Page 7: Controls

    HE30-upto 4 elbows please enquire. HE35-upto 2 elbows Any direct connection of a control device not approved by Ideal Stelrad Group could invalidate the certification and the normal Roof Flue Kit (to a maximum of 7.5m). appliance warranty. It could also infringe the Gas Safety Powered Vertical Flue Kit (5m primary and 17m secondary Regulations and the above regulations.

  • Page 8: Flue Installation

    back GENERAL For the minimum clearances required for safety and FLUE INSTALLATION subsequent service, see the wall mounting template and Pluming will occur at the terminal so terminal positions where Frame 2. In addition, sufficient space may be required to this could cause a nuisance should be avoided.
  • Page 9 back GENERAL BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in) The boiler connections are made on the boiler piping frame. Refer to Frames 32-34. Where the space into which the boiler is going to be The following minimum clearances must be maintained for installed is less than the length of flue required the flue operation and servicing.

  • Page 10: Inhibitor

    GENERAL BOILER CONTROL INTERLOCKS ELECTRICAL SUPPLY WARNING. Ideal Stelrad Group recommend that heating systems This appliance must be earthed. utilising full thermostatic radiator valve control of Wiring external to the appliance MUST be in accordance with the temperature in individual rooms should also be fitted with current I.E.E.

  • Page 11: Domestic Hot Water

    back GENERAL SYSTEM REQUIREMENTS - CH (continued) and Hot Water an additional vessel MUST be installed on the return to the boiler. Water Flow Rate and Pressure Loss Guidance on vessel sizing is given in Frame 3. Max CH Output 23.4 5.

  • Page 12: Controls

    Water Treatment in Central Heating Systems. For further information contact: Fernox Manufacturing Co. Ltd Cookson Electronics If water treatment is used Ideal Stelrad Group recommend Forsyth Road only the use of FERNOX-COPAL or MB1, GE BETZ SENTINEL X100 Sheerwater...
  • Page 13 back INSTALLATION BOILER ASSEMBLY - Exploded View Data badge WILO pump shown isar - Installation and Servicing...
  • Page 14 back 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 Boiler Hardware Pack Box Pre-piping Frame...
  • Page 15 back INSTALLATION 10 PACKAGING REMOVAL 1. Ensure the boiler is on a sound flat surface. 2. Carefully remove the strapping. 3. Fold back the top flaps to gain access to: Instructions 1 year guarantee Pre-piping frame Wall mounting template/ Wall mounting template. protective packaging (located under pre-piping frame on Pre-piping...
  • Page 16 back INSTALLATION 12 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 FLUE KITS Pack B - supplied as standard Pack D - optional extension kit for side flue or rear flue outlet.
  • Page 17 back INSTALLATION 13 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. The flue terminal MUST be fitted with the ‘TOP’...
  • Page 18 back INSTALLATION 15 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. Rear flue only Side flue only Both wall faces immediately around the cut hole...
  • Page 19 back INSTALLATION 18 FLUE EXTENSION DUCTS - For total flue lengths greater than 595mm Pack D Flue extension duct kit contents Flue support cutting aid Extension duct & clamp (shown folded up) 1.0m (39") long Wall plugs - 4 off Flue duct support nm8732 No.
  • Page 20 back INSTALLATION 21 FITTING THE PIPING FRAME AND VALVES (Rear Flue outlet shown) Note. Isolating valves are supplied separately in the hardware pack box. Fit to the piping frame BEFORE mounting the boiler. TO FIT THE PRE-PIPING FRAME DIRECTLY TO THE WALL TO FIT THE PRE-PIPING FRAME USING THE STAND-OFF FRAME OPTION KIT (To allow pipework to be taken upwards) •...

  • Page 21: Condensate Drain

    back INSTALLATION 22 CONDENSATE DRAIN Refer also to the British Gas document: 'Guidance Notes for the Installation of Domestic Gas Condensing Boilers' (1989). Before mounting the boiler on the wall, the condensate drain (provided in the h/ware pack) must be connected from the boiler ‘S’...
  • Page 22 back INSTALLATION 24 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 BOILER cla7773...

  • Page 23: Mounting The Boiler

    back INSTALLATION 25 MOUNTING THE BOILER IMPORTANT. 5. Using the fibre washers supplied in the hardware pack box, engage and then tighten the 4 water unions. 1. Before mounting the boiler on the wall place it on its left 6. Engage and tighten the gas union, ensuring that the blue hand side, fit the 'S' trap hose moulding/nut and fold the fibre washer is in place.
  • Page 24 back INSTALLATION 27 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.

  • Page 25: Flue Terminal Position

    back INSTALLATION 29 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 300mm 625mm...
  • Page 26 back INSTALLATION 30 FLUE ARRANGEMENT Note. The equivalent flue length resistance of the elbow kits are: elbow kit = 1m elbow kit = 0.6m isar - Installation and Servicing...
  • Page 27 back INSTALLATION 31 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.
  • Page 28 back INSTALLATION 32 WATER CONNECTIONS - CH Notes. 1. For heating loads in excess of 60,000 Btu/h use 28mm x 22mm Isolating valve (shown in the Condensate drain pipe located here. connectors to connect the boiler open position) flow and return pipes to 28mm system pipework.

  • Page 29: Gas Connection

    back INSTALLATION 34 GAS CONNECTION IMPORTANT. The gas service cock is sealed with a non-metallic blue fibre washer so must not be overheated when making capillary connections. Refer to Frame 2 for details of the position of the gas connection. N.B.

  • Page 30: Electrical Connections

    back INSTALLATION 36 FILLING Central Heating IMPORTANT - when filling: 1. Remove the sealing panel. Refer to Frames 49 & 50. a. Remove the diverter valve actuator (refer to Frame 67) and depress the spindle several times during filling. Replace 2.

  • Page 31: Electrical Supply

    back INSTALLATION 37 ELECTRICAL CONNECTIONS Wiring should be 3 core PVC insulated cable, not less than WARNING. This appliance MUST be earthed. 0.75 mm (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for A mains supply of 230 V ~ 50 Hz is required.

  • Page 32: External Electrical Controls

    back INSTALLATION 39 EXTERNAL ELECTRICAL CONTROLS Wiring External to the Boiler The fuse rating should be 3A. Wiring external to the boiler MUST be in accordance with the L2 L1 current I.E.E. (BS.7671) Wiring Regulations and any local regulations. Room 'stat Room Thermostat If the thermostat has a neutral connection, use it (it provides for more energy efficient operation by reducing switching...
  • Page 33 back INSTALLATION 40 PICTORIAL WIRING DIAGRAM LEGEND b - blue - red bk - black v - violet br - brown w - white gy - grey y - yellow or - orange y/g - yellow/green pk - pink Dry fire thermistor Permanent black...

  • Page 34: Flow Wiring Diagram

    back INSTALLATION 41 FUNCTIONAL FLOW WIRING DIAGRAM Dry fire thermistor D i v e r t e r Val ve nm8949 LEGEND b - blue or - orange bk - black pk - pink w - white br - brown - red y - yellow gy - grey...

  • Page 35: Initial Lighting

    back INSTALLATION 43 INITIAL LIGHTING LEGEND A. Boiler On/Off switch. B. CH thermostat knob. N. Automatic air vent. D. Burner On neon. P . Control box (Servicing position). E. Reset button. R. Pressure gauge. F . Injector pressure test point. S.
  • Page 36 back INSTALLATION 44 INITIAL LIGHTING - continued 17. Turn off the DHW tap. 15. DOMESTIC HOT WATER 18. Set the boiler on/off switch (A) to OFF. With the boiler firing, set the DHW thermostat knob (Y) to 19. Swing the control box into the servicing position. Refer to maximum and fully open a DHW tap.
  • Page 37 back INSTALLATION 46 GENERAL CHECKS - continued WATER CIRCULATION SYSTEM CENTRAL HEATING (CH) & DOMESTIC HOT WATER (DHW) MODE. 1. With the system COLD, check that the initial pressure is correct to the system design requirements. 1. Ensure that the CH external controls are calling for heat. For pre-pressurised systems, this should be 1.0 bar.

  • Page 38: Gas Supply

    CORGI registered local heating benefits of the Ideal Care Scheme, details of which are installer consulted. In IE contact a competent person. outlined in the householder pack supplied with this boiler.
  • Page 39 back SERVICING 49 BOILER FRONT PANEL REMOVAL 1. Remove the 2 screws from the underside of the boiler. 2. Pull the panel forward at the bottom and lift to disengage it from the top lugs. 50 BOILER SEALING PANEL / BOTTOM PANEL REMOVAL 1.
  • Page 40 back SERVICING 51 THE CONTROL BOX IN THE SERVICING POSITION 1. Remove the 2 screws and withdraw the user control. 2. Unplug the low voltage electrical lead from the back of the user control. 3. Turn the clamp, swing the control box down and pull slightly forward.

  • Page 41: Burner Removal And Cleaning

    back SERVICING 52 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING 1. Disconnect the electrical leads from the fan. 2. Undo the gas pipe union connection to the injector housing. 3. Undo the screw on the fan mounting bracket. 4. Lift off fan and venturi assembly. 5.

  • Page 42: Cleaning The Heat Exchanger

    back SERVICING 54 CLEANING THE CONDENSATE 'S' TRAP 1. Swing the control box down into the servicing position. Refer to Frame 51. 2. Disconnect the condensate drain pipe. 3. Remove the screw and elongated bolt, pull the trap down and forward to remove.

  • Page 43: Replacement Of Components

    back SERVICING 57 REPLACEMENT OF COMPONENTS GENERAL IMPORTANT. When work is complete, the sealing panel, if removed, must When replacing ANY component be correctly refitted - ensuring that a good seal is made. 1. Isolate the electricity supply. Notes. 1. In order to assist fault finding, the control panel has an 2.
  • Page 44 back SERVICING 60 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 57. 2. Remove the boiler front and sealing panels. Refer to Frames Injector 49 & 50. 3. Disconnect the electrical leads from the fan. 4. Undo the gas pipe union connection to the injector housing. 5.
  • Page 45 back SERVICING 63 IGNITION ELECTRODE REPLACEMENT 1. Refer to Frame 57. 6. Remove the electrode. 2. Remove the boiler front and sealing panels. Refer to 7. Fit the new ignition electrode, using the new gasket Frames 49 & 50. supplied. Check dimensions as shown. 3.
  • Page 46 back SERVICING 66 GAS CONTROL VALVE REPLACEMENT 1. Refer to Frame 57. 2. Remove the casing front & bottom panel. Refer to Frames 49 & 50. 3. Swing the control box down into the servicing position. Refer to Frame 51. 4.
  • Page 47 9. Remove the split pin and washer from the RHS of the combustion chamber. Ideal Stelrad Group recommend that, for your own comfort and safety and to comply with good working practice, the 10. Remove the insulation boards. The replacement boards procedure described below is followed: are supplied in a plastic bag.

  • Page 48: Pump

    back SERVICING 69 CONDENSATE 'S' TRAP REPLACEMENT 1. Refer to Frame 57. 2. Remove the casing front & bottom panel. Refer to Frames 49 & 50. 3. Swing the control box down into the servicing position. Refer to Frame 51. 4.
  • Page 49 back SERVICING 71 CONTROL BOX REPLACEMENT 8. Transfer mounting bracket and hinge arms to the new control box. 1. Refer to Frame 57. 9. Reassemble in reverse order, ensuring that the control box 2. Remove the casing front & bottom panel. is located correctly in the housing before reconnecting the Refer to Frames 49 &...
  • Page 50 back SERVICING 73 USER CONTROL REPLACEMENT Note. Only the display unit is replaced. 1. Refer to Frame 57. 2. Loosen the screw on the underside of the user control. 3. Pull the display unit forward to remove. 4. Push the new display unit into position. 5.
  • Page 51 back SERVICING 75 SAFETY RELIEF VALVE REPLACEMENT 7. Remove the safety valve. 1. Refer to Frame 57. 8. Fit the new safety valve and refit the securing pin. 2. Remove the casing front and bottom panels. Refer to 9. Reassemble in reverse order, ensuring correct Frames 49 &...

  • Page 52: Draining The Boiler

    back SERVICING 77 DRAINING THE BOILER Compression gas cock 1. Refer to frame 57. 2. Remove the boiler bottom panel. Refer to Frame 50. 3. Close all the water isolating (CH and DHW) valves on the piping frame. 4. To drain the central heating circuit, attach a length of hose to the drain point and open the drain valve.
  • Page 53 back SERVICING 79 DHW PLATE HEAT EXCHANGER REPLACEMENT (WILO AND CP) 1. Refer to Frame 57. 2. Remove the casing front & bottom panel. Refer to Frames 49 & 50. 3. Drain the boiler. Refer to Frame 77. 4. Remove the 4 screws securing the rear support plate and withdraw the plate.
  • Page 54 back SERVICING 81 HEAT ENGINE REPLACEMENT 17. Remove the edge clip securing the dry fire thermistor Refer also to Frame 8 - 'Boiler Exploded View'. wiring. IMPORTANT 18. Remove the blind grommet to gain access to the return pipe securing bracket. Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag.
  • Page 55 back SERVICING 82 EXPANSION VESSEL REPLACEMENT 1. Refer to Frame 57. 2. Drain the boiler. Refer to Frame 77. 3. Unscrew all the gas and water connection unions on the boiler side of the valves. 4. Remove the screw from the turret clamp and remove. xpansion vessel 5.
  • Page 56 back FAULT FINDING 84 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' GO TO FRAME 85 ALTERNATING 'L' 'E' GO TO FRAME 86 ALTERNATING 'L' 'A' GO TO FRAME 87...

  • Page 57: Fault Finding

    back FAULT FINDING 85 L..F..(FLAME DETECTION ERROR) If the boiler reset button is Is gas pressure available at Check gas supply pressed does the boiler ignite for the boiler inlet ? and rectify fault a short time then extinguish? Is 200V DC supply available Check gas valve Check the detection electrode and at the gas valve ?
  • Page 58 back FAULT FINDING 87 L..A..(OVERHEAT ERROR) Can the overheat condition be reset by pressing Replace overheat thermostat the boiler reset button when the system is cold ? Is the boiler and CH system filled with Fill and vent the system and open all water and all isolation valves open ? isolation valves Does the pump setting give a differential...
  • Page 59 back FAULT FINDING 90 H..2..(CONTROL THERMISTOR [RETURN] ERROR) Remove the boiler return thermistor from the CH return pipe. Check resistance using a suitable multimeter connected across the thermistor’s terminal pins At 25 C expect 9,700 - 10,300 Ohms At 60 C expect 2,400 - 2,600 Ohms...
  • Page 60 back FAULT FINDING H9/L9 (HEAT EXCHANGER OVERHEAT) 92 H..4..(DRY FIRE THERMISTOR ERROR) Is the system filled and vented and all Can the fault condition be reset by switching off isolation valves open ? the mains supply to the boiler ? Is the pump operating correctly? Ensure flow through system.

  • Page 61: Short List Of Parts

    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.
  • Page 62 back SHORT LIST OF PARTS 95 SHORT LIST nm8415 isar - Installation and Servicing...

  • Page 63: Burner Assembly

    back LIST OF PARTS 96 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom panel with screws. 97 CONTROLS ASSEMBLY Controls assy with screws. Controls hinge bracket. User controls (without item 38). PCB (primary controls). User controls housing Mains switch.
  • Page 64 back NOTES isar - Installation and Servicing...

  • Page 65: Installer Notification Guidelines

    back INSTALLER NOTIFICATION GUIDELINES IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE In addition a change to Building Regulations (England and Wales) requires the installer to notify when installing a heating appliance, as from 1st April 2005. Install and commission this appliance to manufacturers' instructions...
  • Page 66 back...
  • Page 67 back...
  • Page 68 & servicing of central heating systems FM 59915 Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its products.

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