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installation and
servicing
icos
(V3 Flue System)
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
HE12, HE15, HE18, HE24
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.
April 2008 UIN 203318 A04
For t
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2 icos - Installation & Servicing
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DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level ......................... A03 to A04 (Apr 08) • Page 15, Frame 11 - Unpacking Change to boiler contents, wall mounting template now mounted on internal packaging. • Page 15, Frame 12 - Packaging Removal Wall mounting template now mounted on internal packaging, frame changed to reflect this. • Page 17, Frame 16 - Wall Mounting Template Wall mounting template now mounted on internal packaging, frame changed t
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GENERAL Table 1 - Boiler Data Boiler Size HE 12, HE 15, HE 18, HE 24 1 1 Gas supply type and connection 2H-G20-20 mbar Rc /2 ( /2" BSP Female) 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
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GENERAL CONTENTS icos Air Supply ....................................................................... 9 Natural Gas only Benchmark Commissioning Checklist ..................... 54 Boiler Clearances ......................................................... 6 Boiler size G.C. Appliance No. PI No. Boiler Exploded Diagram ............................................ 14 Benchmark No. Electrical Connections ............................................... 27 HE12 41 397 95 87 BP 34 Electrical Supply
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GENERAL 1 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. 2 BOILER CLEARANCES all dimensions in mm (in.) SIDE FLUE ONLY Horizontal length of flue Top clearance The following minimum clearances must be maintained for from cent
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GENERAL Powered Vertical Flue Kit 5 m primary and 17m secondary INTRODUCTION is a typical maximum flue length. For further details refer to The icos range of boilers are a fully automatically controlled, Powered Vertical Fluing Instructions. wall mounted, low water content, balanced flue, fanned, High Level Flue Outlet Kits condensing gas boiler. It has full modulating central heating Flue Deflector Kit outputs of : HE12 9.3 kW (32,000 Btu/h) to 12.0 kW (41,000 Btu/h). Weather Collar HE15
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GENERAL experienced ensure this is adequate for ALL other gas SAFE HANDLING OF SUBSTANCES appliances in the property. Care should be taken when handling the boiler insulation IMPORTANT. panels, which can cause irritation to the skin. No asbestos, Installation pipes MUST be fitted in accordance with BS. 6891. mercury or CFCs are included in any part of the boiler or its In IE refer to I.S.813:2002. Pipework from the meter to the boiler manufacture. MUST be of an adequate size, i.e. no longer tha
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GENERAL 6. The air inlet/products outlet duct and the terminal of the Single feed, indirect cylinders are not recommended and MUST boiler MUST NOT be closer than 25mm (1") to combustible NOT be used on sealed systems. material. Detailed recommendations on the protection of combustible material are given in BS.5440-1:2000. In IE The appliances are NOT suitable for gravity central heating nor refer to I.S.813:2002. are they suitable for the provision of gravity domestic hot water. IMPORTANT. The
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GENERAL 3 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
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GENERAL 5 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 conne
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GENERAL 7 SEALED SYSTEM REQUIREMENTS - continued 4. Expansion Vessel a. 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 (1/2" nominal) size and not incorporating valves of valve being located between the system and the any sort. automatic air ve
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GENERAL 8 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 1
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INSTALLATION 10 BOILER ASSEMBLY - Exploded view 40 94 23. Control thermistor. 24. Overheat thermostat. 25. Ignition electrode. LEGEND 26. Flame detection electrode. 15. Venturi assy. 1. Front casing panel. 8. Flue manifold. 16. Fan assy. 32. 'S' trap 2. Sealing panel 10. Interpanel. 33. Control assy. 17. Gas pipe assy. 3. Sump cover plate. 11. Burner assy. 19. Gas control valve assy. 40. Spark generator 4. Bottom casing panel. 12. Combustion chamber 20. Fan bracket assy. 44. Wall mounting plate.
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INSTALLATION 11 UNPACKING The boiler is supplied fully assembled in one Pack A, B together with a telescopic flue assembly for lengths up to C 595mm, rear or side flue outlet, in Pack B. A Unpack and check the contents. D Pack A Contents E A The boiler B Wall mounting template on cardboard C Wall mounting plate G F D 1 year guarantee form E These Installation & Servicing/ User’s Instructions F Water Treatment Warning Label G Hardware pack nm7890 A B Hardware Pack D A 50mm x No.14 wood screws -
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INSTALLATION 13 FRONT AND BOTTOM PANEL REMOVAL 3 1. To remove the front panel remove the 2 screws from the bottom panel. 2. Lift the panel up and off the top pegs. 1 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. 14 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. FLUE KITS
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INSTALLATION 15 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. 1 2. Flue turret. 3. Turret gasket. 4. M5 x 10 pozi screw. 5. Turret clamp. nm8752 Rear flue arrangement shown 16 WALL MOUNTING TEMPLATE The wall mounting template is located on the internal top Extended centre line protective packaging. 155 Note. V - See Diagram Below The template shows the positions of the fixing holes
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INSTALLATION 17 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 u
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INSTALLATION 20 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. 10 x2" wood screw - 4 off 21 FLUE EXTENSION DUCTS - continued Flue length Use a maximum of 6m extended flue ONLY Extension flue General arrangement 1. A maximum of 6 extension ducts (one suitably cut) plus the standard flue duct may be used togeth
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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. 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
