Page 2 - icos; Installation & Servicing
Page 3 - DOCUMENT AMENDMENTS; Page 17, Frame 16 - Wall Mounting Template
3 icos - Installation & Servicing DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level ......................... A03 to A04 (Apr 08) Ideal Stelrad Group reserve the right to vary specification without notice • Page 15, Frame 11 - Unpacking Change to boiler co...
Page 4 - GENERAL; For ft
4 icos - Installation & Servicing GENERAL Boiler Size HE 12 Max HE 15 Max HE 18 Max HE 24 Max HE 12 Min HE 15-24 Min Boiler input 'Q' = Nett CV kW 12.2 15.1 18.7 24.4 9.8 9.1 Btu/h 41 600 51 500 63 800 83 300 33 400 31 000 Gross CV kW 13.5 16.8 20.7 27.1 10.9 10.1 Btu/h 46 000 57 200 70 800 92 5...
Page 5 - CONTENTS; Central heating mode; Hot water mode; Boiler size; BENCHMARK COMMISSIONING CHECKLIST DETAILS
5 icos - Installation & Servicing GENERAL CONTENTS Air Supply ....................................................................... 9 Benchmark Commissioning Checklist ..................... 54 Boiler Clearances ......................................................... 6 Boiler Exploded Diagram...
Page 6 - Front clearance; The boiler will not fit into a standard depth wall unit. In; Bottom clearance; Horizontal length of flue; REAR FLUE ONLY
6 icos - Installation & Servicing GENERAL nm8729 The boiler flow and return pipes are supplied fitted to the boilerready for top connection Notes. a. For the heating loads in excess of 60,000 Btu/h, 28mm (1") flowand return pipes should be used to and from the boiler. b. This appliance is NO...
Page 9 - The boiler must be vented.; Ideal Stelrad Group; recommend that heating systems utilising; NOTE: THE FAN VOLTAGE IS 325V DC; other materials may be used.; WATER TREATMENT - see Frame 9; Pressure Drop Across Boiler; IMPORTANT; Graph 1 - Water flow rate and pressure loss
9 icos - Installation & Servicing GENERAL Single feed, indirect cylinders are not recommended and MUSTNOT be used on sealed systems. The appliances are NOT suitable for gravity central heating norare they suitable for the provision of gravity domestic hot water. The hot water cylinder and ancill...
Page 10 - Balancing; Combined feed and vent pipes may also be fitted.
10 icos - Installation & Servicing GENERAL 3 OPEN VENT SYSTEM REQUIREMENTS 4 SCHEMATIC PIPEWORK AND SYSTEM BALANCING The boiler does not normally need a bypass but at least someradiators on the heating circuit, of load at least 10% of theminimum boiler output, must be provided with twin lockshie...
Page 11 - LOW HEAD AND LARGE SYSTEMS WITH EXTENSIVE PIPE RUNS - OPEN VENT
11 icos - Installation & Servicing GENERAL Non-return valve Automatic air vent Hose unions Additional stop valve Hose connector Hosepipe (disconnect after filling) Double check valve assembly ( note direction of flow) Temporary hose (disconnect after filling) ecl6060 Note. The pump manufacturers...
Page 12 - Sizing procedure for expansion vessels:
12 icos - Installation & Servicing GENERAL 7 SEALED SYSTEM REQUIREMENTS - continued pressure. The cold feed pipe from the cistern shouldinclude a non-return valve and a stop valve with anautomatic air vent connected between them, the stopvalve being located between the system and theautomatic ai...
Page 13 - Benchmark
13 icos - Installation & Servicing GENERAL 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...
Page 14 - INSTALLATION; Heat exchanger; LEGEND; Sealing panel; 0 BOILER ASSEMBLY - Exploded view; Flame detection electrode.; INST
14 icos - Installation & Servicing INSTALLATION nm8744 40 94 8. Flue manifold. 10. Interpanel. 11. Burner assy. 12. Combustion chamberInsulation. 13. Heat exchanger 14. Injector & housing 15. Venturi assy. 16. Fan assy. 17. Gas pipe assy. 19. Gas control valve assy. 20. Fan bracket assy. 21....
Page 15 - Unpack and check the contents.; 2 PACKAGING REMOVAL
15 icos - Installation & Servicing INSTALLATION G C A B E F D nm7890 The boiler is supplied fully assembled in one Pack A,together with a telescopic flue assembly for lengths up to595mm, rear or side flue outlet, in Pack B. Unpack and check the contents. 11 UNPACKING Hardware Pack A 50mm x No.14...
Page 16 - 3 FRONT AND BOTTOM PANEL REMOVAL; The boiler MUST be installed in a vertical position.; 4 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED; - optional extension kit for side flue or rear flue outlet.; REAR FLUE; Wall Thickness X
16 icos - Installation & Servicing INSTALLATION Wall Thickness X 160 mm 160 + S = 193mm nm8943 13 FRONT AND BOTTOM PANEL REMOVAL 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...
Page 17 - FLUE OUTLET; 6 WALL MOUNTING TEMPLATE; Side; Rear flue arrangement shown; If using stand-off kit distance increases to 188mm.
17 icos - Installation & Servicing INSTALLATION FLUE OUTLET 1 nm8752 16 WALL MOUNTING TEMPLATE 15 FLUE ASSEMBLY - Exploded View LEGEND1. Duct assembly. 2. Flue turret. 3. Turret gasket. 4. M5 x 10 pozi screw. 5. Turret clamp. An optional flue duct extension kit is required forwall thicknesses gr...
Page 18 - 7 PREPARING THE WALL; If using the extension ducts go to Frame 18.
18 icos - Installation & Servicing INSTALLATION FLUE OUTLET 17 PREPARING THE WALL IMPORTANT. Ensure that, during the cutting operation, masonry falling outside of the building does not causedamage or personal injury. 1. Cut the flue hole (preferably with a 5" core boringtool), ensuring that ...
Page 19 - maximum; of 6 extension ducts (one suitably; 1 FLUE EXTENSION DUCTS - continued; Boiler; 0 FLUE EXTENSION DUCTS - For total flue lengths greater than 595mm; Pack D Flue extension duct kit contents.; Side flue shown; Use a maximum of 6m extended flue ONLY; General arrangement; 0 FITTING THE KIT; Subtract 70mm from this dimension.
19 icos - Installation & Servicing INSTALLATION FLUE OUTLET 1. A maximum of 6 extension ducts (one suitably cut) plus the standard flue duct may be usedtogether. 2. Flue extensions of greater length than 1m (39")should be supported with the bracket provided,suitably adjusted. Refer to Frame ...
Page 20 - If excessive external pipework cannot; Front View; INTERNAL TO SINK WASTE; 4 CONDENSATE PIPE TERMINATION CONFIGURATIONS
20 icos - Installation & Servicing INSTALLATION 23 CONDENSATE DRAIN The condensate drain provided on the boiler must beconnected to a drainage point, preferably within thebuilding.Ensure that the condensate trap is full of waterbefore commissioning the boiler. Refer to Frame 27.The routing of th...
Page 21 - INTERNAL CONNECTION TO SOIL AND VENT STACK; * Make connection to SVP using a solvent welded saddle
21 icos - Installation & Servicing INSTALLATION 25 CONDENSATE PIPE TERMINATION CONFIGURATIONS . . . continued cla9253 BOILER Air Break 3. INTERNAL CONNECTION TO SOIL AND VENT STACK * Make connection to SVP using a solvent welded saddle BOILER External wall Ground Level Termination to Soak away c...
Page 22 - Locate the flue into the turret.; 6 MOUNTING THE BOILER; Fit condensate union connection
22 icos - Installation & Servicing INSTALLATION nm8755 2 1 3 27 CONNECTING THE FLUE TO THE BOILER Note. Before fitting the flue turret fillthe condensate trap within theboiler by pouring a cupful ofwater into flue outlet A. Make sure the plastic cap isremoved from the end of thecondensate drain ...
Page 23 - elbow; 9 ROOF FLUE KIT CONTENTS / OPTIONS; WEATHER PROOFING; Flat roof weather collar; ACCESSORIES
23 icos - Installation & Servicing INSTALLATION FLUE OUTLET Flue duct support Vertical connectorUIN 203135 90 o elbow UIN 203130 45 o elbow UIN 203131 Roof Flue Extension DuctUIN 203129 nm8735 Flue TerminalUIN 203132 Flue Seal Collar - Flat RoofUIN 152259 Flue Seal Collar - Tile RoofUIN 152258 2...
Page 24 - Fixed; 0 FLUE TERMINAL POSITION; Flat roof - with structure; Minimum dimensions are shown below; Terminal Position; Directly below an opening,
24 icos - Installation & Servicing INSTALLATION FLUE OUTLET rf8394-1 690mm Fixed 300mm min 30 FLUE TERMINAL POSITION rf8393-1 300mm min 300mm min 625mm Fixed Flat roof - with structure The terminal should be positioned so that products ofcombustion can safely disperse at all times. Pluming may o...
Page 25 - 1 FLUE ARRANGEMENT
25 icos - Installation & Servicing INSTALLATION FLUE OUTLET rf8737 rf8738 31 FLUE ARRANGEMENT Note. The equivalent flue length resistance of the elbow kits are:90 o elbow kit = 1m 45 o elbow kit = 0.6m
Page 26 - 2 ASSEMBLING THE ROOF FLUE KIT; Ensure the cut pipe ends are free from any burrs.; Flue Terminal; ENSURING THE
26 icos - Installation & Servicing INSTALLATION FLUE OUTLET 32 ASSEMBLING THE ROOF FLUE KIT Determine the correct height that the flue should terminateabove the roof. If after calculating or measuring the overall flueheight from the top of the boiler, it is necessary to cut bothpipes of assembly...
Page 27 - 4 BOILER WATER CONNECTIONS; TOP CONNECTION; The front panel is not fitted at this stage.; 5 ELECTRICAL CONNECTIONS
27 icos - Installation & Servicing INSTALLATION 33 GAS CONNECTION IMPORTANT. The gas service cock is sealed with a non-metallic fibre washer seal so must not be overheated when makingcapillary connections. Refer to Frame 2 for details of the position of the gas connection. N.B. The principle of ...
Page 28 - Incoming mains wiring detail; A pictorial wiring diagram is shown in Frame 37.; lie
28 icos - Installation & Servicing INSTALLATION 36 INTERNAL WIRING Incoming mains wiring detail A pictorial wiring diagram is shown in Frame 37. The mains lead connector is pre-fitted. This must beremoved to allow wiring. 1. Route the mains cable into the bottom LHS rear of the casing.If using t...
Page 29 - 8 FUNCTIONAL FLOW WIRING DIAGRAM; Control PCB; 7 PICTORIAL WIRING DIAGRAM
29 icos - Installation & Servicing INSTALLATION Spark generator nm 8076 bk b br bk b bk r b v b r br b r r b r r r or or or or b pk pk y y y/g y/g Ferrite y/g y/g y/g y/g y/g y/g bk bk Flue thermistor Overheat thermostat Flow control thermistor Gas valve ON /OFF Switch Service connection MAINS S...
Page 30 - A. ELECTRICAL INSTALLATION; 0 COMMISSIONING AND TESTING; Room Thermostat; Earths are not shown for clarity but MUST NEVER BE OMITTED.
30 icos - Installation & Servicing INSTALLATION B. GAS INSTALLATION 1. The whole of the gas installation, including the meter,should be inspected and tested for soundness and purgedin accordance with the recommendations of BS. 6891.In IE refer to I.S. 813:2002. 2. Purge air from the gas installa...
Page 31 - icos HE; THE DISPLAY
31 icos - Installation & Servicing INSTALLATION nm8780 41 INITIAL LIGHTING LEGENDA On/Off switch. B Thermostat knob. D 'Burner On' neon. E Reset button. F Injector pressure test point. G Inlet pressure test point. H Gas service cock. J Casing pressure test point. K Overheat thermostat. L Flue th...
Page 32 - prominent position
32 icos - Installation & Servicing INSTALLATION 42 GENERAL CHECKS Make the following checks for correct operation: 1. Central Heating The correct operation of ANY programmer and allother system controls should be proved. Operateeach control separately and check that the mainburner or circulating...
Page 33 - SERVICING; supply to the appliance before servicing.; SER
33 icos - Installation & Servicing SERVICING 44 SERVICING SCHEDULE 45 BOILER FRONT PANEL REMOVAL 46 BOILER SEALING PANEL/ BOTTOM PANEL REMOVAL 1. Remove the 2 screws from the underside of theappliance. 2. Pull the front panel forward at the bottom and liftto disengage it from the top lugs. 1. To...
Page 34 - Lift off the fan and venturi assembly.; 8 BURNER REMOVAL AND CLEANING; as this may cause
34 icos - Installation & Servicing SERVICING 2 3 1 4 E c l 6073 47 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING 1. Disconnect the electrical leads fromthe fan. 2. Undo the gas pipe union connection tothe injector housing. 3. Undo the screw on the fan mountingbracket. 4. Lift off the fan and ven...
Page 35 - Reassemble the boiler in the following order.
35 icos - Installation & Servicing SERVICING 50 CLEANING THE HEAT EXCHANGER 49 CLEANING THE CONDENSATE 'S' TRAP 1. Undo the plastic union nut onthe condensate ‘S’ trap outlet. 2. Remove the 2 screws. 3. Pull the trap down and forwardto remove. 4. Flush out any deposits withclean water. 51 REASSE...
Page 36 - Isolate the electricity supply.; THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED; Pull the electrical leads off the control thermistor.; The key to boiler fault; 2 REPLACEMENT OF COMPONENTS
36 icos - Installation & Servicing SERVICING GENERAL When replacing ANY component: 1. Isolate the electricity supply. 2. Turn off the gas supply. 3. Remove the boiler front panel. Refer to Frame 40. After replacing ANY component check operation of the boilerincluding gas soundness, gas rate and ...
Page 37 - Gasket; 5 BURNER REPLACEMENT; Remove the fan and venturi assembly.
37 icos - Installation & Servicing SERVICING Gasket Orifice plate E c l 2336 5 3 7 4 55 BURNER REPLACEMENT 54 FAN REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealingpanels. Refer to Frames 45 & 46. 3. Disconnect the electrical leads fromthe fan. 4. Unscrew the gas pipe u...
Page 42 - Seal the plastic bag and dispose of it and its contents
42 icos - Installation & Servicing SERVICING 65 COMBUSTION CHAMBER INSULATION REPLACEMENT 1 Rear Front Combustion chamber LH Side RH Side nm8748 7 6 5 The insulation boards used in the combustion chamber ofthis product are made of high temperature glass fibres with abinder of organic and inorgan...
Page 44 - Seals
44 icos - Installation & Servicing 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 toFrame 46. 4. Remove the old seal from the casing andthoroughly clean the casing surfaces. 5. Fit the ...
Page 46 - FAULT FINDING; Refer to Frame 57; or
46 icos - Installation & Servicing FAULT FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING F AUL T FINDING 70 L.....F....... (FLAME ERROR) Check the ignition electrode and associated harness for: continuity, visual condition , position (Refer to Frame 56). Are these functio...
Page 49 - SHORT LIST OF PARTS
49 icos - Installation & Servicing SHORT LIST OF PARTS The following are parts commonly required due to damage orexpendability. Their failure or absence is likely to affect safety orperformance of this appliance. The list is extracted from the British Gas List of Parts, whichcontains all availab...
Page 50 - Front casing panel with screws.
50 icos - Installation & Servicing SHORT LIST OF PARTS nm8077 78 SHORT LIST 79 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom casing panel with screws.
Page 51 - 1 BURNER ASSEMBLY; Controls assy with screws.
51 icos - Installation & Servicing 81 BURNER ASSEMBLY E c l 1598 11. Burner assembly with screwsand gasket. LIST OF PARTS 80 CONTROLS ASSEMBLY 33. Controls assy with screws. 34. Controls hinge bracket. 35. User controls (without item 38). 36. PCB (primary controls). 38. User control housing 39. ...
Page 52 - NOTES
Page 53 - INSTALLER NOTIFICATION GUIDELINES; when installing a heating appliance, as from 1st April 2005.
53 icos - Installation & Servicing 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 20...
Page 56 - Ideal Boilers; Technical Training; pursues a policy of continuing
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. Technical Training Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its products. Theright is therefore...
Page 57 - users guide; Your Ideal users guide
users guide icos Your Ideal 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. HE12, HE...
Page 58 - Users; I n t r o d u c t i o n; The; is a wall mounted, room sealed, super efficient; S a f e t y; The appliance must be earthed.; Important Notes; Minimum Clearances; Clearances of; To light the boiler; During
2 icos - Users I n t r o d u c t i o n The icos is a wall mounted, room sealed, super efficient condensing boiler featuring full sequence automatic sparkignition and fan assisted combustion. Due to the very high efficiency, condensate is produced fromthe flue gases and this is drained to a suitable ...
Page 59 - Do NOT search for gas leaks with a naked flame.
3 icos - Users C o n t r o l o f w a t e r t e m p e r a t u r e The boiler controls the central heating radiator temperature to amaximum of 82 0 C, adjustable via the CH thermostat knob (C). Approx CH flow temperatures for the boiler thermostat settingsare: Knob Setting Flow Temperature o C o F Min...
Page 60 - Ideal Consumer Helpline; POINTS FOR THE BOILER USER; TROUBLESHOOTING - TYPICAL NON PRODUCT FAULTS; ALL
Ideal Boilers , P.O. Box 103, National Ave, Kingston Upon Hull, HU5 4JN. Tel. 01482 492251 Fax. 01482 448858. Registration No. London 322 137. Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specifi...