Page 2 - classic; HE; Installation & Servicing
2 classic HE - Installation & Servicing 201850-6.pmd 21/02/2008, 12:57 2
Page 3 - DOCUMENT AMENDMENTS; • Various Pages; Statement added with ref. to termination into a down pipe.; • Page 33, Frame 54 - Burner and Air Box Removal; new bullet points added.
classic HE - Installation & Servicing 3 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 BS6...
Page 4 - GENERAL; Table 1 - General Data
4 classic HE - Installation & Servicing GENERAL 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 Boiler Size HE9 HE12 HE15 HE18 Gas supply connection (in. BSP) Rc 1/2 (...
Page 5 - CONTENTS; BENCHMARK COMMISSIONING CHECKLIST; classic HE; Natural Gas only; NOTE TO THE INSTALLER: COMPLETE; Boiler size
classic HE - Installation & Servicing 5 GENERAL CONTENTS Air Supply . ..................................................................... 9 Benchmark Commissioning Checklist ..................... 46 Boiler Clearances ......................................................... 7 Boiler Exploded V...
Page 6 - SAFE HANDLING; SAFE HANDLING OF SUBSTANCES; LOCATION OF BOILER
6 classic HE - Installation & Servicing 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 heatexchanger is aluminiu...
Page 7 - Installation from inside ONLY; BOILER CLEARANCES; Front View
classic HE - Installation & Servicing 7 GENERAL This appliance in NOT suitable for use in a directhot water system or for gravity circulation. 1 BOILER WATER CONNECTIONS The following minimum clearances mustbe maintained for operation and servicing.Additional space will be required forinstallati...
Page 8 - Bathrooms; GAS SUPPLY; IMPORTANT; Table 3 - Balanced Flue Terminal Position
8 classic HE - Installation & Servicing GENERAL Bathrooms This range of appliances is rated IP 1XB. The boiler may be installed in any room or internal space, althoughparticular attention is drawn to the requirements of the currentI.E.E. (BS.7671) Wiring Regulations and, in Scotland, the electri...
Page 9 - WATER TREATMENT; BOILER CONTROL INTERLOCKS
classic HE - Installation & Servicing 9 GENERAL Boiler Size HE 9 12 15 18 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 L o s s in wg 21.6 37.4 39.3 57 Table 5 - Water flow rate an...
Page 10 - Minimum Requirements; LOW HEAD INSTALLATIONS; OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED; CONDENSATE DRAIN
10 classic HE - Installation & Servicing GENERAL Minimum Requirements Note. The pump manufacturers minimum requirements must be complied with. System return Connections to boiler Inverted cold feed entry System flow to pump 150 (6")Max 15mmCold feed 450 (17 3 / 4 ") Mimimum 450 (17 3 / 4...
Page 11 - Hose unions; SEALED SYSTEM REQUIREMENTS
classic HE - Installation & Servicing 11 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 5 SEALED SYSTEM REQUIR...
Page 13 - INSTALLATION; LEGEND; INST
classic HE - Installation & Servicing 13 INSTALLATION 7 BOILER ASSEMBLY - Exploded view LEGEND 24 30 27 35 9 12 19 37 26 23 17 Condensate siphon trap Data Plate cla7926 9. Sightglass 12. Main Burner 17. Gas Valve 19. Control Box 23. PCB25E 24. Air pressure switch 26. Controls Casing 27. Flue Pro...
Page 14 - Pack A; Unpack and check the contents.; UNPACKING; Pack A Contents
14 classic HE - Installation & Servicing INSTALLATION The boiler is supplied fully assembled in Pack A , together with a standard flue assembly for lengthsfrom 75mm (3") up to 705mm (27 3/4 ") rear flue and from 270mm (10 5/8") up to 775mm (30 1/2 ") side flue in Pack B. Note. Fo...
Page 16 - REAR FLUE OUTLET; 1 FLUE ASSEMBLY - Exploded View; 2 WALL MOUNTING TEMPLATE; 3 PREPARING THE WALL
16 classic HE - Installation & Servicing INSTALLATION REAR FLUE OUTLET 1 2 3 4 5 6 Note. Check all of the hole positions BEFORE drilling 11 FLUE ASSEMBLY - Exploded View LEGEND 1. Terminal 2. Weather seal(optional extra) 3. Flue assembly 4. Boiler sealing ring 5. Flue extension pipe 6. 'O' ring ...
Page 17 - 4 CUTTING THE FLUE; Do NOT drill the inner
classic HE - Installation & Servicing 17 INSTALLATION REAR FLUE OUTLET 14 CUTTING THE FLUE - wall thicknesses of 75 to 705mm 1. Measure and note the wall thickness X (Refer to Frame 10). 2. Mark the wall thickness onto the flue. 3. To ensure the tube is cut square, mark the flue all the wayaroun...
Page 18 - 8 MOUNTING THE BOILER; Jacking screw
18 classic HE - Installation & Servicing INSTALLATION REAR FLUE OUTLET 1. Locate the 3 sealing ring studs in the holes in the back panel. Note. The sealing ring studs will locate in the back panel one way only. This will ensure that the terminal grille is correctly aligned. 2. Secure the flue to...
Page 19 - SIDE FLUE OUTLET; 0 FLUE ASSEMBLY - Exploded view; 1 WALL MOUNTING TEMPLATE; 2 PREPARING THE WALL
classic HE - Installation & Servicing 19 INSTALLATION SIDE FLUE OUTLET cla7712 1 2 4 3 5 The optional side outlet kit is requiredfor all side flue applications.An optional flue duct extension kit isrequired for lengths (distance from theoutside wall to the relevant side of theboiler casing) grea...
Page 20 - 5 WALL MOUNTING PLATE; 4 FITTING THE FLUE ASSEMBLY; 3 CUTTING THE FLUE - For flue lengths 270 to 775mm ONLY
20 classic HE - Installation & Servicing INSTALLATION SIDE FLUE OUTLET cla7667 Downward piping bracket Wall mounting bracket 25 WALL MOUNTING PLATE For flue lengths greater than 775mm refer toFrames 28, 29 and 30 - Flue extension ducts. 1. Measure and note the side flue length "Y" (refer...
Page 21 - 6 MOUNTING THE BOILER; CHECK; Gasket
classic HE - Installation & Servicing 21 INSTALLATION SIDE FLUE OUTLET cla7672 8 Jacking screw 10 9 Note. The boiler may require two men to lift it onto the wall mounting plate.For downward routing of pipes the M5 spacer (supplied inthe downward piping kit) should now be fitted to theback of the...
Page 22 - 0 FITTING THE KIT; For flue lengths greater than 705mm rear flue or 775mm side flue; RING
22 classic HE - Installation & Servicing INSTALLATION SIDE FLUE OUTLET 30 FITTING THE KIT 1. Fit the inner flue extension duct ontothe inner flue duct. 2. Fit the outer flue extension duct ontothe outer air duct. 3. Repeat steps 1 and 2 if a second flueextension is required. 4. Measure and mark ...
Page 23 - FLUE OUTLET; 1 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched); WEATHER PROOFING; 2 ROOF FLUE KIT CONTENTS / OPTIONS
classic HE - Installation & Servicing 23 INSTALLATION FLUE OUTLET 31 FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched) Note. A flat or pitched roof flashing plate (not supplied) isrequired before proceeding with the installation of thiskit. This kit is suitable for both flat and pitched rooft...
Page 24 - 3 FLUE TERMINAL POSITION; Terminal Position; 4 FLUE ARRANGEMENT
24 classic HE - Installation & Servicing INSTALLATION FLUE OUTLET Part No. Description HE9 HE12 HE15 HE18 n/a Maximum Flue Length (m) 4 4 4 4 201 180 Flue ext. 60/100 3 3 3 3 201 189 Terminal Vertical Roof 60/100 1 1 1 1 158 431 Weather Collar Pitched Roof 1 1 1 1 158 432 Weather Collar Flat Roo...
Page 25 - 5 ASSEMBLING THE ROOF FLUE KIT
classic HE - Installation & Servicing 25 INSTALLATION FLUE OUTLET 35 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 both pipesof as...
Page 26 - minimum; 8 CONDENSATE DRAIN; INTERNAL TO SINK WASTE; 9 CONDENSATE PIPE TERMINATION CONFIGURATIONS
26 classic HE - Installation & Servicing INSTALLATION 37 WATER CONNECTIONS 1. Remove the plastic plugs from the flow andreturn pipes. 2. Make all water connections and check forwater soundness. 36 GAS CONNECTION Refer to 'Gas Supply ', page 8.Refer to Frame 2 for gas inlet service dimensions. A ...
Page 27 - INTERNAL CONNECTION TO SOIL AND VENT STACK
classic HE - Installation & Servicing 27 INSTALLATION 40 CONDENSATE PIPE TERMINATION CONFIGURATIONS . . . continued cla9253 BOILER Air Break 3. INTERNAL CONNECTION TO SOIL AND VENT STACK Termination into a down pipe can take place providing it can beconfirmed that the down pipe is part of a comb...
Page 28 - Potentiometer; 1 ELECTRICAL CONNECTIONS
28 classic HE - Installation & Servicing INSTALLATION cla7738 Limit thermostat O/heat thermostat Thermostat sensor L br br L On/Off switch ALL EARTHS must be connected(Not all earths are shown for clarity) Air pressureswitch Flue protection thermostat cla7856 Combined spark & sensing electro...
Page 29 - Flue protection; 3 PICTORIAL WIRING; Pumped only
classic HE - Installation & Servicing 29 INSTALLATION Flue protection thermostat Thermostat sensor Limitthermostat cla7677 Notes.1. Some earth wires are omitted forclarity. Ensure proper earth continuitywhen wiring. 2. Numbering of terminals onthermostats is specific to themanufacturer. 3. This ...
Page 30 - 6 FROST PROTECTION
30 classic HE - Installation & Servicing INSTALLATION Notes. 1. Some earth wires are omitted forclarity. Ensure proper earth continuitywhen wiring. 2. Numbering of terminals onthermostats is specific to themanufacturer. 3. This is a fully controlled system - setthe boiler thermostat to maximum. ...
Page 31 - A. ELECTRICAL INSTALLATION; TO LIGHT THE BOILER; Fitting the Boiler Casing; 8 INITIAL LIGHTING
classic HE - Installation & Servicing 31 INSTALLATION 47 COMMISSIONING AND TESTING A. ELECTRICAL INSTALLATION 1. Checks to ensure electrical safety should be carriedout by a competent person. 2. ALWAYS carry out preliminary electrical systemchecks, i.e. earth continuity, polarity, resistance toe...
Page 32 - After installation and commissioning please complete the; 1 HANDING OVER; Water Circulating System; Knob Setting
32 classic HE - Installation & Servicing INSTALLATION 49 INITIAL LIGHTING - continued 1. Hand the User's Instructions to the Householder andexplain his or her responsibilities under the current GasSafety (Installation and Use) Regulations or rules in force. 2. Draw attention to the Lighting Inst...
Page 33 - SERVICING; Ideal Care Scheme; 4 BURNER AND AIR BOX REMOVAL; SER
classic HE - Installation & Servicing 33 SERVICING cla7851 2 casing retaining screws To ensure the continued safe and efficient operation of theappliance it is recommended that it is checked at regularintervals and serviced as necessary.The frequency of servicing will depend upon the installatio...
Page 34 - 7 CLEANING THE RECUPERATOR
34 classic HE - Installation & Servicing SERVICING 1. Remove the air pressure switch and CO/CO 2 sensing pipes. 2. Disconnect the electrical connections. 3. Remove the 2 fan fixing screws and remove the fan by pullingforward. 55 CLEANING THE FAN ASSEMBLY / THE FLUEWAYS 56 CLEANING THE BURNER AND...
Page 35 - MAIN BURNER; REPLACEMENT OF PARTS; PILOT; Neon; 2 SIGHTGLASS REPLACEMENT
classic HE - Installation & Servicing 35 SERVICING MAIN BURNER After any servicing, reference should be made to Table 2which quotes details of the rated output with the relatedburner setting pressure and the heat input. Any requiredadjustments should be made by using the pressureadjustment screw...
Page 37 - 5 LIMIT THERMOSTAT REPLACEMENT
classic HE - Installation & Servicing 37 SERVICING 67 PILOT BURNER REPLACEMENT 1. Refer to Frame 61. 2. Remove the burner and air box assembly. Refer to Frame54. 3. Remove the electrode retaining nut and remove the pilotshield and electrode. 4. Unscrew the central pilot fixing screw and lift the...
Page 40 - Seal
40 classic HE - Installation & Servicing SERVICING 76 CASING FRONT SEAL REPLACEMENT 12. Remove the 2 rubber sealing grommets from the topof the back panel to facilitate fitting the new assembly. 13. Fit the new heat exchanger assembly, complete withwater pipes, and hang it on the bottom key hole...
Page 42 - FAULT FINDING; T FINDING F; START
42 classic HE - Installation & Servicing FAULT FINDING FA U L T FINDING F A UL T FINDING F A UL T FINDING Check all connections to PCB. If no fault found, replace PCB Reset the overheat 'stat. Set control 'stat to maximum. Allow the boiler to reach temperature - if the overheat 'stat trips again...
Page 43 - SHORT LIST OF PARTS; Description
classic HE - Installation & Servicing 43 SHORT LIST OF PARTS Key No. GC Part No. Description Qty. Product No. 9 E83-619 Sightglass Assembly Kit 1 171 414 12 E72-529 Main Burner Kit HE9, HE12 1 171 012 HE15, HE18 1 174 063 13 E85-308 Main Injector Kit HE9 1 171 424 E83-624 HE12 1 171 425 E83-625 ...
Page 45 - INSTALLER NOTIFICATION GUIDELINES
classic HE - Installation & Servicing 45 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 Ap...
Page 46 - GAS BOILER COMMISSIONING CHECKLIST
CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER COMBI BOI...
Page 47 - SERVICE INTERVAL RECORD; It is recommended that your heating system is serviced regularly
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...
Page 48 - Ideal Boilers; Technical Training; Ideal Stelrad Group
Ideal Boilers , P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. RegistrationNo. London 322 137. Technical Training Ideal Stelrad Group pursues a policy of continuing improvement in the design and performance of its products. The right istherefore...
Page 49 - users guide; Your Ideal users guide; installation & servicing instructions
users guide classic Your Ideal users guide See reverse for classic installation & servicing instructions 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 pa...
Page 50 - Users; INTRODUCTION; SAFETY; IMPORTANT NOTES; REFER TO FRAME 1
classic HE - Users 2 INTRODUCTION The classic HE is a wall mounted, room sealed, high efficiency 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 51 - View inside boiler controls area; BOILER CONTROLS; Do NOT search for gas leaks with a naked flame.; Do NOT use abrasive cleaning materials.
classic HE - Users 3 All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded in the BenchmarkC o m m i s s i o n i n g C h e c k l i s t . Yo u c a n c h e c k y o u r i n s t a l l e r b y c a l l i n g C O R G I d i r e c t o n 0 1 2 5 6 3 7 2...
Page 52 - Ideal Consumer Helpline; POINTS FOR THE BOILER USER; TROUBLESHOOTING - TYPICAL NON PRODUCT FAULTS
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...
