Ideal Boilers HE30 Installation And Servicing Manual
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Ideal Boilers HE30 Installation And Servicing Manual

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See also: Instructions for Installation and Servicing , User Manual
installation and
servicing
icos
Your Ideal installation and servicing guide
See reverse for icos users guide
For details of document amendments, refer to page 3
HE30, HE36
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.
January 2008
UIN 202414 A06
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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Summary of Contents for Ideal Boilers HE30

  • 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. January 2008...
  • Page 2 icos - Installation & Servicing...
  • Page 3 DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level .... A05 (Oct 06) to A06 (Jan 08) • Various Changes Company Name Change. • Page 9, Electrical Supply Note for fan voltage. • Page 21, Frame 25 - Condensate Pipe Termination Configurations Statement added with ref.
  • Page 4 GENERAL Table 1 - Boiler Data Boiler Size HE30, HE36 Gas supply type and connection 2H-G20-20 mbar Rc " BSP Female Injector size Stereomatic 5.6mm dia. Flow connection 28mm copper Return connection 28mm copper Flue terminal diameter mm (in.) 100 (4) Maximum static water head m (ft.)
  • Page 5 Boiler Clearances ............6 Boiler size G.C. Appliance No. PI No. (Benchmark No.) Boiler Exploded Diagram ..........14 Electrical Connections ..........26 HE30 41-399-10 87 BQ 79 Electrical Supply ............9 HE36 41-399-16 87 BQ 79 Electrical Wiring Diagrams ........28...

  • Page 6: Boiler Water Connections

    GENERAL BOILER WATER CONNECTIONS The boiler flow and return pipes (28mm) are supplied fitted to the boiler ready for top connection. The flow and return pipes should be continued in 28mm while the system load is above 60,000 Btu (17.6 kW). Below which they may be reduced to 22mm. Notes.

  • Page 7: Safe Handling

    High Level Flue Outlet Kit outputs of : Roof Flue Kit (to a maximum of 5m) HE30 10.4 kW (35,600 Btu/h) to 30.1 kW (102,700 Btu/h). Twin Flue Kit HE36 10.4 kW (35,600 Btu/h) to 37 kW (126,200 Btu/h). Vertical Outlet Kit...

  • Page 8: Location Of Boiler

    GENERAL An existing meter should be checked, preferably by the gas LOCATION OF BOILER supplier, to ensure that the meter is adequate to deal with the The boiler must be installed on a flat and vertical wall, capable rate of gas supply required. of adequately supporting the weight of the boiler and any ancillary equipment.

  • Page 9: Air Supply

    GENERAL 4. Where the lowest part of the terminal is fitted less than 2m The boiler must be vented. (6'6") above a balcony, above ground or above a flat roof to The hydraulic resistance of the boilers, at MAXIMUM OUTPUT, which people have access, then the terminal MUST be with an 11 C (20...
  • Page 10 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.
  • Page 11 GENERAL 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.
  • Page 12 GENERAL SEALED SYSTEM REQUIREMENTS - continued 4. Expansion Vessel A diaphragm type expansion vessel must be pressure. The cold feed pipe from the cistern should connected to a point close to the inlet side of the include a non-return valve and a stop valve with an pump, the connecting pipe being not less than 15 mm automatic air vent connected between them, the stop "...

  • Page 13: Water Treatment

    GENERAL SEALED SYSTEM REQUIREMENTS - continued Safety valve setting 3.0 bar 2.5 bar 2.0 bar Vessel charge and initial system pressure Total water content of system Expansion vessel volume litres litres 11.8 10.0 11.7 10.0 17.7 15.0 10.9 15.6 13.4 23.7 11.3 20.0...
  • Page 14 INSTALLATION 10 BOILER ASSEMBLY - Exploded view Data Badge nm8200 LEGEND 1 Front panel 22 Gas valve assembly 37 User Control 2 Front sealing panel 25 Dry Fire Thermostat 38 PCB primary control 4 Side panel RH/LH 26 Control Thermistor 41 Main switch c/w harness 6 Bottom panel 27 Overheat Thermostat...
  • Page 15 INSTALLATION 11 UNPACKING The boiler is supplied fully assembled in one Pack A, together with a standard flue assembly for lengths up to 650mm, rear or side flue outlet, in Pack B. Unpack and check the contents. Pack A Contents A The boiler B Wall mounting template C Wall mounting plate...
  • Page 16 INSTALLATION 13 FRONT AND BOTTOM PANEL REMOVAL 1. To remove the front panel remove the 4 screws from the bottom panel. 2. Lift the panel up and off the top pegs. 3. To remove the bottom panel remove the 4 screws and withdraw.

  • Page 17: Wall Mounting Template

    INSTALLATION 15 FLUE ASSEMBLY - Exploded View An optional flue duct extension kit is required for wall thicknesses greater than : Side 535mm (21") Rear 638mm(25 "). LEGEND 1. Duct assembly. 2. Flue turret. 3. Turret gasket. nm8165 Rear flue arrangement shown 16 WALL MOUNTING TEMPLATE Extended centre line Note.

  • Page 18: Preparing The Wall

    INSTALLATION 17 PREPARING THE WALL IMPORTANT. Ensure that, during the cutting operation, masonry falling outside Rear flue only of the building does not cause damage or 5" diameter hole personal injury. 1. Cut the flue hole (preferably with a 5" core boring tool), ensuring that the hole is square to the wall.
  • Page 19 INSTALLATION 20 FLUE EXTENSION DUCTS - For flue lengths greater than 775mm Pack D Flue extension duct kit contents. Extension duct Washers - 2 off 1.0m (39") long Wall plugs - 2 off Support fixing screws - 2 off Flue duct support nm8242 Clamp screws - 2 off 21 FLUE EXTENSION DUCTS - continued...

  • Page 20: Condensate Drain

    INSTALLATION 23 CONDENSATE DRAIN Refer also to the British Gas document: 'Guidance Notes for The condensate drain provided on the boiler must be the Installation of Domestic Gas Condensing Boilers' (1989). connected to a drainage point, preferably within the building. The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler, throughout its length.
  • Page 21 INSTALLATION 25 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.

  • Page 22: Mounting The Boiler

    INSTALLATION 26 MOUNTING THE BOILER Note. Refer to Safe Handling (Page 7). 1. Lift the boiler onto the wall mounting plate, as shown. 3. Fix boiler to wall mounting plate using self tapping screw (supplied in hardware pack). 2. Check the boiler alignment using a spirit level and adjust as necessary with the jacking screw.
  • Page 23 INSTALLATION 28 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 24: Flue Terminal Position

    Painted surface 300 mm Below eaves or balcony 500 mm 31 FLUE ARRANGEMENT Part No. Description 60/100 Quantity HE30 HE36 Maximum Flue Length (m) 201 180 Flue ext. 60/100 201 189 Terminal Vertical Roof 60/100 158 431 Weather Collar Pitched Roof...

  • Page 25: Assembling The Roof Flue Kit

    INSTALLATION 32 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 20mm longer than the outer air tube as supplied.

  • Page 26: Gas Connection

    INSTALLATION 33 GAS CONNECTION IMPORTANT. The gas service cock is sealed with a non-metallic A boiler gas supply pipe length of 20m and not less than fibre washer seal so must not be overheated when making 15mm O.D. can be connected to the boiler via the gas capillary connections.

  • Page 27: Internal Wiring

    INSTALLATION 36 INTERNAL WIRING A pictorial wiring diagram is shown in Frame 37. 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.
  • Page 28 INSTALLATION 37 PICTORIAL WIRING DIAGRAM LEGEND b - blue bk - black Dry fire thermistor br - brown gy - grey or - orange Overheat pk - pink thermostat - red Gas valve v - violet Control thermistor w - white Chassis y - yellow earth y/g...

  • Page 29: External Electrical Controls

    INSTALLATION 39 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.

  • Page 30: Initial Lighting

    INSTALLATION 41 INITIAL LIGHTING Note. Boiler is shown with the front panel and sealing panel removed. LEGEND A On/Off switch. G Gas service cock. B Thermostat knob. H Overheat thermostat. C 'Burner On' neon. J Control thermistor. D Reset button. K Spark generator.

  • Page 31: Handing Over

    INSTALLATION 42 GENERAL CHECKS Make the following checks for correct operation: Note. Fernox Superfloc, Sentinel X300 (new systems) or X400 (existing systems) flushing solutions should be 1. Central Heating used during the flushing procedure. Refer to Frame 9. The correct operation of ANY programmer and all other system controls should be proved.

  • Page 32: Servicing Schedule

    SERVICING 44 SERVICING SCHEDULE 8. Check that the flue terminal is unobstructed and that the To ensure the continued safe and efficient operation of the flue system is sealed correctly. appliance it is recommended that it is checked at regular intervals and serviced as necessary.

  • Page 33: Burner Removal And Cleaning

    SERVICING 47 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.

  • Page 34: Cleaning The Heat Exchanger

    SERVICING 49 CLEANING THE CONDENSATE 'S' TRAP If condensate pump fitted refer to separate instructions for cleaning procedure. Note. Care must be taken with residual water when removing the outlet pipe. 1. Remove the plastic union sealing nut on the bottom of the condensate ‘S’...

  • Page 35: Replacement Of Components

    SERVICING 52 REPLACEMENT OF COMPONENTS GENERAL When replacing ANY component: IMPORTANT When work is complete, the sealing panel must be 1. Isolate the electricity supply. correctly fitted, ensuring that a good seal is made. 2. Turn off the gas supply. Note.

  • Page 36: Fan Replacement

    SERVICING 54 FAN REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing Orifice plate panels. Refer to Frames 45 & 46. Gasket 3. Disconnect the electrical leads from the fan. 4. Unscrew the gas pipe union connection to the injector housing.

  • Page 37: Ignition Electrode Replacement

    56 IGNITION ELECTRODE REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front panels and inner 15mm + 1 (HE30, HE36) sealing panel. Refer to Frames 45 and 46. 3. Unplug the ignition lead from the electrode. S t r a i g h t 4.

  • Page 38: Spark Generator Replacement

    SERVICING 58 SPARK GENERATOR REPLACEMENT 1. Refer to Frame 52. 2. Disconnect the leads from the spark generator and bracket. 3. Remove the M4 screw securing the spark generator bracket to the casing side panel. 4. Remove the 2 M4 screws securing the spark generator to the bracket.

  • Page 39: Control Box Replacement

    SERVICING 61 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.

  • Page 40: Overheat Thermostat Replacement

    SERVICING 63 OVERHEAT THERMOSTAT REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front panels and inner sealing panel. 3. Pull off the 2 electrical leads from the thermostat body. 4. Remove the 2 screws retaining the O/H thermostat. 5.

  • Page 41: Heat Exchanger Replacement

    SERVICING 65 HEAT EXCHANGER REPLACEMENT Note. If the installation allows the boiler to be removed from 15. Remove the pipe cover plate off the boiler top panel. the wall, the replacement will be more easily conducted if this 16. Pull the flow pipe off the heat exchanger and remove from is done.
  • Page 42 SERVICING 66 HEAT EXCHANGER REPLACEMENT continued ......... 18. Undo the 5 retaining screws from the boiler bottom panel. 19. Remove the ‘S’ trap fixing bracket screw and disconnect the ‘S’ trap. Refer to Frame 68. 20. Undo the 2 fixing screws from the mounting brackets on the top left and top right of the heat exchanger. 21.

  • Page 43: Boiler Sealing Panel Seal Replacement

    SERVICING 67 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.

  • Page 44: Fault Finding

    FAULT FINDING 69 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 70 ALTERNATING 'L' 'E' GO TO FRAME 71 GO TO FRAME 72 ALTERNATING 'L' 'A'...
  • Page 45 FAULT FINDING 70 L..F..(FLAME ERROR) Is gas pressure available Check gas supply If the boiler reset button is at the boiler inlet ? and rectify fault pressed does the boiler ignite for a short time then extinguish? Is 200V DC supply Check gas valve available at the gas valve ? wiring for continuity...
  • Page 46 FAULT FINDING 71 L..E..H..E..(BOARD ERROR) Check earth connection to the boiler. If value is still Check for an excess voltage in excess of 50V consult a qualified electrician to between neutral and earth. check the household electrical supply and circuitry Is the value below 50V? LE ONLY: Correct wiring or replace...
  • Page 47 FAULT FINDING 72 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 Set CH control knob to maximum.
  • Page 48 FAULT FINDING 75 H..F..(FLAME DETECTION - SHORT CIRCUIT ERROR) Remove flame detection electrode terminal from PCB. Replace PCB. Is there continuity between the 2 terminal pins ? Replace flame detection electrode H9/L9 (FLUE GAS OVERHEAT) 76 H..4..(DRY FIRE THERMISTOR ERROR) Is the system filled and vented and all Can the fault condition be reset by isolation valves open ?
  • Page 49 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.

  • Page 50: Short List Of Parts

    SHORT LIST OF PARTS 78 SHORT LIST nm8120 icos - Installation & Servicing...
  • Page 51 NOTES icos - Installation & Servicing...
  • Page 52 NOTES icos - Installation & Servicing...

  • Page 53: Installer Notification Guidelines

    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 54 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...

  • Page 55: Service Interval Record

    SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer's instructions.
  • Page 56 & servicing of central heating systems Manufactured under a BS EN ISO 9001: 2000 Quality System accepted by BSI 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.

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