Ideal Industries Icos He12 Users Manual 203318 4.pmd

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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

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, HE15, HE18, HE24

For users guide see reverse of book

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.

April 2008 UIN 203318 A04

2icos - Installation & Servicing

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 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 to reflect this.

4icos - 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 92 500 37 200 34 400

Gas consumption l/s (cu.ft/h) 0.35 (44.2) 0.43 (54.7) 0.53 (68.0) 0.70 (89.7) 0.28 (35.6) 0.26 (33.3)

Boiler output 'P' = 70 oC Mean water kW 12.0 14.6 18.2 23.4 9.3 8.8

temperature Btu/h 40 900 50 000 62 300 80,000 31 800 30,000

40 oC Mean water kW 12.7 15.5 19.2 25.1 10.5 9.6

temperature Btu/h 43 300 53 000 65 700 85 700 35 900 32 800

Seasonal efficiency (SEDBUK) * Band A [90.1]% [90.4]% [90.3]% [90.2]%

NOx classification Class 5

Boiler Size HE 12, HE 15, HE 18, HE 24

Gas supply type and connection 2H-G20-20 mbar Rc1/2 (1/2" 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 V

Water content litre (gal.) 1.7 (0.37)

Packaged weight kg (lb.) 38 (84)

Maximum installation weight kg (lb.) 31 (68)

Boiler size Height mm (in.) 582 (23)

Width mm (in.) 390 (15)

Depth mm (in.) 278 (11)

*The value is used in the UK Government's Standard Assessment Procedure (SAP) for energy rating of dwellings.

The test data from which it has been calculated have been certified by a notified body.

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.

Note.

Gas consumption is calculated using a calorific value of

38.7 MJ/m3 (1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3)

nett. To obtain the gas consumption at a different calorific

value:-

a. For l/s - divide the gross heat input (kW) by the gross

C.V. of the gas (MJ/m3)

b. For ft3/h - divide the gross heat input (Btu/h) by the

gross C.V. of the gas (Btu/ft3)

Key to symbols

GB = United Kingdom IE = Ireland (Countries of destination)

PMS = Maximum operating pressure of water

C13 C33 C53 = A room sealed appliance designed for connection via

ducts to a horizontal or vertical terminal which admits

fresh air to the burner and discharges the products of

combustion to the outside through orifices which, in this

case, are concentric. The fan is up stream of the

combustion chamber.

I2H = An appliance designed for use on 2nd Family gas, Group

H only.

Table 2 - Performance Data

Table 1 - Boiler Data

icos - Installation & Servicing

GENERAL

CONTENTS

Air Supply ....................................................................... 9

Benchmark Commissioning Checklist ..................... 54

Boiler Clearances ......................................................... 6

Boiler Exploded Diagram ............................................ 14

Electrical Connections ............................................... 27

Electrical Supply ........................................................... 9

Electrical Systems Diagrams .................................... 30

Extension Ducts - Fitting ............................................. 19

Fault Finding ................................................................. 45

Flow Wiring Diagram .................................................. 29

Flue Fitting .............................................................. 16-19

Flue Installation Requirements .................................... 8

Gas Safety Regulations ................................................ 7

Gas Supply ..................................................................... 8

Initial Lighting .............................................................. 31

Installation ............................................................. 14-32

Mandatory Requirements ............................................. 7

Safe Handling ................................................................ 8

Servicing ................................................................ 33-44

Short List of Parts ....................................................... 49

Terminal Guards ............................................................ 8

Thermostatic Radiator valves .................................... 9

Water and Systems ................................................ 9-13

Water Connections ................................................. 6, 27

Water Treatment ......................................................... 13

Wiring Diagrams ......................................................... 29

icos

Destination Countries: GB, IE

Boiler Page

Make and model .......................................................5

Appliance serial no. on data badge ...................... 14

SEDBUK No. % .........................................................4

Controls

Time and temperature control to heating ............. 30

Time and temperature control to hot water .......... 30

Heating zone valves .............................................. n/a

TRV's .........................................................................9

Auto bypass .............................................................. 9

Boiler interlock ..........................................................9

For all boilers

Flushing to BS.7593 .............................................. 13

Inhibitor .................................................................. 13

Central heating mode

Heat input ................................................to be calculated

For assistance see Technical Helpline on the back page

Page

Burner operating pressure ....................................n/a

Central heating flow temp. ...... measure and record

Central heating return temp. ... measure and record

For combination boilers only

Scale reducer .........................................................n/a

Hot water mode

Heat input ...............................................................n/a

Max. operating burner pressure .............................. n/a

Max. operating water pressure ............................. n/a

Cold water inlet temp ............................................ n/a

Hot water outlet temp. ........................................... n/a

Water flow rate at max. setting .............................. n/a

For condensing boilers only

Condensate drain .................................................. 20

For all boilers: complete, sign & hand over to customer

For GB, to comply with Building Regulations Part L1 (Part 6 in Scotland) the boiler should be fitted in accordance with the

manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be

demonstrated by completing and signing the Benchmark Commissioning Checklist.

Boiler size G.C. Appliance No. PI No.

Benchmark No.

HE12 41 397 95 87 BP 34

HE15 41 397 83 87 BP 34

HE18 41 397 84 87 BP 34

HE24 41 397 85 87 BP 34

Natural Gas only

BENCHMARK COMMISSIONING CHECKLIST DETAILS

NOTE TO THE INSTALLER:

COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

6icos - Installation & Servicing

GENERAL

nm8729

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.

BOILER WATER CONNECTIONS

BOILER CLEARANCES all dimensions in mm (in.)

The following minimum clearances must be maintained for

operation and servicing.

Additional space will be required for installation, depending upon

site conditions.

Side and Rear Flue

aProvided that the flue hole is cut accurately, e.g. with a core drill,

the flue can be installed from inside the building where wall

thicknesses do not exceed 600mm (24"). Where the space into

which the boiler is going to be installed is less than the length of

flue required the flue must be fitted from the outside.

Installation from inside ONLY

b. If a core boring tool is to be used inside the building the space in

which the boiler is to be installed must be at least wide enough

to accommodate the tool.

Front clearance

The minimum front clearance when built in to a cupboard is

5mm (1/4") from the cupboard door but 450mm (17 3/4")

overall clearance is still required, with the cupboard door

open, to allow for servicing.

N.B. The boiler will not fit into a standard depth wall unit. In

order for it to do so the plastic fascia should be removed. See

Frame 41.

*Bottom clearance

after installation can be reduced to 5mm in an adequately

ventilated enclosed cupboard. However, 100mm must be

available for servicing.

SIDE FLUE ONLY

Horizontal length of flue Top clearance

from centre line of boiler required (MIN.)

to outside wall Dim. A

0.5 m 165 mm (6 1/2")

1.0 m 170 mm (6 11/16)

1.5 m 185 mm (7 1/4")

2.0 m 200 mm ( 7 7/8")

2.5 m 210 mm (8 1/4")

3.0 m 225 mm (8 7/8")

3.5 m 235 mm (9 1/4")

4.0 m 250 mm (10 7/8")

4.5 m 260 mm (10 1/4")

5.0 m 275 mm (10 13/16")

5.5 m 290 mm (11 3/8")

6.0 m 300 mm (11 13/16")

REAR FLUE ONLY

MIN. Top clearance required = 145 mm (5 3/4")

icos - Installation & Servicing

GENERAL

INTRODUCTION

The icos range of boilers are a fully automatically controlled,

wall mounted, low water content, balanced flue, fanned,

condensing gas boiler. It has full modulating central heating

outputs of :

HE12 9.3 kW (32,000 Btu/h) to 12.0 kW (41,000 Btu/h).

HE15 8.8 kW (30,000 Btu/h) to 14.6 kW (50,000 Btu/h).

HE18 8.8 kW (30,000 Btu/h) to 17.6 kW (60,000 Btu/h).

HE24 8.8 kW (30,000 Btu/h) to 23.4 kW (80,000 Btu/h).

Due to the high efficiency of the boiler a plume of water vapour

will form at the flue terminal during operation depending on

external conditions.

The boiler casing is of white painted mild steel with the user

controls capable of being mounted remotely from the boiler, if

the option is required.

The heat exchanger is of cast aluminium.

Note.

These boilers cannot be used on systems which include gravity

circulation.

The boilers are suitable for connection to fully pumped, open

vented or sealed water systems. Adequate arrangements for

completely draining the system by provision of drain cocks

MUST be provided in the installation pipework.

OPERATION

When there is a demand for heat, the heating system is

supplied at the selected temperature of between 30oC and

82oC.

The boiler features a comprehensive diagnostic system which

gives detailed information on the boiler status when operating,

and performance of key components to aid commissioning and

fault finding.

SAFE HANDLING

This boiler may require 2 or more operatives to move it to its

installation site, remove it from its packaging base and during

movement into its installation location. Manoeuvring the boiler

may include the use of a sack truck and involve lifting, pushing

and pulling.

Caution should be exercised during these operations.

Operatives should be knowledgeable in handling techniques

when performing these tasks and the following precautions

should be considered:

• Grip the boiler at the base.

• Be physically capable.

• Use PPE as appropriate, e.g. gloves, safety footwear.

During all manoeuvres and handling actions, every attempt

should be made to ensure the following unless unavoidable

and/or the weight is light.

• Keep back straight.

• Avoid twisting at the waist.

• Avoid upper body/top heavy bending.

• Always grip with the palm of the hand.

• Use designated hand holds.

• Keep load as close to the body as possible.

• Always use assistance if required.

OPTIONAL EXTRA KITS

zFlue Extension Ducts (1000mm long up to 6m)

zFlue Finishing Kit

z90o Elbow Kit (maximum 4 elbows per installation).

z45o Elbow Kit (maximum 4 elbows per installation).

zRoof Flue Kit (to a maximum of 7.5m)

zPowered Vertical Flue Kit 5 m primary and 17m secondary

is a typical maximum flue length. For further details refer to

Powered Vertical Fluing Instructions.

zHigh Level Flue Outlet Kits

zFlue Deflector Kit

zWeather Collar

zTwin Fluing Kits (to a maximum of 60m combined total of

flue and air ducts)

zHorizontal Flue 600mm long

zRemote User Control Kit

zBoiler Stand-off Kit

zSiphon Kit

zCondensate Pump Kit

SAFETY

Current Gas Safety (Installation and Use) Regulations or

rules in force.

The appliance is suitable only for installation in GB and IE and

should be installed in accordance with the rules in force.

In GB, the installation must be carried out by a CORGI

Registered Installer. It must be carried out in accordance with

the relevant requirements of the:

• Gas Safety (Installation and Use) Regulations

• The appropriate Building Regulations either The Building

Regulations, The Building Regulations (Scotland), Building

Regulations (northern Ireland).

• The Water Fittings Regulations or Water byelaws in

Scotland.

• The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be

made to the relevant British Standard Code of Practice.

In IE, the installation must be carried out by a Competent

Person and installed in accordance with the current edition of

I.S.813 "Domestic Gas Installations", the current Building

Regulations and reference should be made to the current ETCI

rules for electrical installation.

Detailed recommendations are contained in the following British

Standard Codes of Practice:

BS. 5440:1 Flues (for gas appliances of rated input not

exceeding 70 kW).

BS. 5440:2 Ventilation (for gas appliances of rated input not

exceeding 70 kW).

BS. 5449 Forced circulation hot water systems.

BS. 5546 Installation of gas hot water supplies for

domestic purposes (2nd Family Gases).

BS. 6798 Installation of gas fired hot water boilers of rated

input not exceeding 60 kW.

BS. 6891 Low pressure installation pipes.

Health & Safety Document No. 635

The Electricity at Work Regulations, 1989.

The manufacturer’s notes must NOT be taken, in any way, as

overriding statutory obligations.

IMPORTANT. These appliances are CE certificated for safety

and performance. It is, therefore, important that no external

control devices, e.g. flue dampers, economisers etc., are

directly connected to these appliances unless covered by these

Installation and Servicing Instructions or as otherwise

recommended by Ideal Stelrad Group in writing. If in doubt

please enquire.

Any direct connection of a control device not approved by Ideal

Stelrad Group may invalidate the certification and the normal

appliance warranty. It could also infringe the Gas Safety

Regulations and the above regulations.

8icos - Installation & Servicing

GENERAL

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation

panels, which can cause irritation to the skin. No asbestos,

mercury or CFCs are included in any part of the boiler or its

manufacture.

LOCATION OF BOILER

The boiler must be installed on a flat and vertical wall, capable

of adequately supporting the weight of the boiler and any

ancillary equipment.

The boiler may be fitted on a combustible wall and insulation

between the wall and the boiler is not necessary, unless

required by the local authority.

For electrical safety reasons there must be no access from the

back of the boiler.

The boiler must not be fitted outside.

Timber Framed Buildings

If the boiler is to be fitted in a timber framed building it should

be fitted in accordance with the Institute of Gas Engineering

document IGE/UP/7:1998.

Bathroom Installations

This appliance is rated IP20.

The boiler may be installed in any room or internal space,

although particular attention is drawn to the requirements of the

current IEE (BS.7671) Wiring Regulations and, in Scotland, the

electrical provisions of the building regulations applicable in

Scotland, with respect to the installation of the boiler in a room

or internal space containing a bath or shower. For Ireland

reference should be made to the current ETCI rules for

electrical installations and I.S.813:2002.

If the appliance is to be installed in a room containing a bath or

shower then, providing water jets are not going to be used for

cleaning purposes (as in communal baths/showers), the

appliance can be installed in Zone 3, as detailed in BS.7671.

Compartment Installations

A compartment used to enclose the boiler should be designed

and constructed specially for this purpose.

An existing cupboard or compartment may be used, provided

that it is modified for the purpose.

In both cases details of essential features of cupboard /

compartment design, including airing cupboard installation,

are to conform to the following:

zBS. 6798. (No cupboard ventilation is required - see “Air

Supply” for details).

zThe position selected for installation MUST allow adequate

space for servicing in front of the boiler.

zFor the minimum clearances required for safety and

subsequent service see the wall mounting template and

Frame 2. In addition, sufficient space may be required to

allow lifting access to the wall mounting plate.

GAS SUPPLY

The local gas supplier should be consulted, at the installation

planning stage, in order to establish the availability of an

adequate supply of gas. An existing service pipe must NOT be

used without prior consultation with the local gas supplier.

The boiler MUST be installed on a gas supply with a governed

meter only.

A gas meter can only be connected by the local gas supplier or

by a CORGI registered engineer. In IE by a Competent Person.

An existing meter should be checked, preferably by the gas

supplier, to ensure that the meter is adequate to deal with the

rate of gas supply required.

N.B. The principle of the 1:1 gas valve ensures that the icos

HE range is able to deliver it’s full output at inlet pressures

down to 14mb. However if dynamic pressures below 20mb are

experienced ensure this is adequate for ALL other gas

appliances in the property.

IMPORTANT.

Installation pipes MUST be fitted in accordance with BS. 6891.

In IE refer to I.S.813:2002. Pipework from the meter to the boiler

MUST be of an adequate size, i.e. no longer than 20m and not

less than 15mm O.D.

The complete installation MUST be tested for gas soundness

and purged as described in the above code.

FLUE INSTALLATION

Pluming will occur at the terminal so terminal positions which

would cause a nuisance should be avoided.

The flue must be installed in accordance with the

recommendations of BS.5440-1:2000. In IE refer to I.S.813:2002.

The following notes are intended for general guidance.

1. The boiler MUST be installed so that the terminal is exposed

to external air.

2. It is important that the position of the terminal allows the free

passage of air across it at all times.

3. Minimum acceptable spacing from the terminal to

obstructions and ventilation openings are specified in Table 3.

4. Where the lowest part of the terminal is fitted less than 2m

(6'6") above a balcony, above ground or above a flat roof to

which people have access, then the terminal MUST be

protected by a purpose designed guard.

Ensure that the guard is fitted centrally.

Terminal guards are available from boiler suppliers. Ask for

TFC Flue Guard Model No. K6 (round plastic-coated). In

case of difficulty contact:

Grasslin (UK) Ltd. Tel. +44(0) 01732 359 888

Tower House, Vale Rise Fax. +44(0) 01732 354 445

Tonbridge. kent TN9 1TB www.ffc.ukco.com

5. The flue assembly shall be so placed or shielded as to

prevent ignition or damage to any part of any building.

Flue Terminal Positions

Min. Spacing*

1. Directly below, above or alongside an opening

window, air vent or other ventilation opening. 300mm (12")

2. Below guttering, drain pipes or soil pipes. 25mm ( 1")*

BS5440-1 2000 75mm (3")

3. Below eaves. 25mm (1")*

BS5440-1 2000 200mm (8")

4. Below balconies or a car port roof. 25mm (1")*

BS5440-1 2000 200mm (8")

5. From vertical drain pipes or soil pipes. 25mm (1")*

BS5440-1 2000 150mm (6")

6. From an internal or external corner or to a 25mm (1")*

boundary along side the terminal. BS5440-1 2000 300mm (12")

7. Above adjacent ground, roof or balcony level. 300mm (12")

8. From a surface or a boundary facing the terminal. 600mm (24")

9. From a terminal facing a terminal. 1,200mm (48")

10. From an opening in a car port

(e.g. door or window) into dwelling. 1,200mm (48")

11. Vertically from a terminal on the same wall. 1,500mm (60")

12. Horizontally from a terminal on the wall. 300mm (12")

Vertical Terminals

13. Above the roof pitch with roof slope of all angles. 300mm (12")

Above flat roof. 300mm (12")

14. From a single wall face. 600mm (24")

From corner walls. 1000mm (40")

Table 3 - Balanced Flue Terminal Position

* Only one reduction down to 25mm is allowable per installation

otherwise BS5440-1 2000 dimensions must be followed.

icos - Installation & Servicing

GENERAL

Single feed, indirect cylinders are not recommended and MUST

NOT be used on sealed systems.

The appliances are NOT suitable for gravity central heating nor

are they suitable for the provision of gravity domestic hot water.

The hot water cylinder and ancillary pipework, not forming part

of the useful heating surface, should be lagged to prevent heat

loss and any possible freezing - particularly where pipes run

through roof spaces and ventilated underfloor spaces.

The boiler must be vented.

The hydraulic resistance of the boilers, at MAXIMUM OUTPUT,

with an 11 oC (20 oF) temperature differential, is shown in

Graph 1.

BOILER CONTROL INTERLOCKS

Ideal Stelrad Group recommend that heating systems utilising

full thermostatic radiator valve control of temperature in

individual rooms should also be fitted with a room thermostat

controlling the temperature in a space served by radiators not

fitted with such a valve as stated in BS. 5449.

Central heating systems controls should be installed to ensure

the boiler is switched off when there is no demand for heating

or hot water.

When thermostatic radiator valves are used, the space heating

temperature control over a living / dining area or hallway having

a heating requirement of at least 10% of the boiler heat output

should be achieved using a room thermostat, whilst other

rooms are individually controlled by thermostatic radiator

valves. However, if the system employs thermostatic radiator

valves on all radiators, or two port valves without end switches,

then a bypass circuit must be fitted with an automatic bypass

valve to ensure a flow of water should all valves be in the

closed position.

ELECTRICAL SUPPLY

WARNING.

This appliance must be earthed.

Wiring external to the appliance MUST be in accordance with

the current I.E.E. (BS.7671) Wiring Regulations and any local

regulations which apply. For Ireland reference should be made

to the current ETCI rules for electrical installations.

The point of connection to the mains should be readily

accessible and adjacent to the boiler.

NOTE: THE FAN VOLTAGE IS 325V DC

CONDENSATE DRAIN - Refer to Frames 23 & 49

A condensate drain is provided on the boiler. This drain must be

connected to a drainage point. All pipework and fittings in the

condensate drainage system MUST be made of plastic - no

other materials may be used.

IMPORTANT.

Any external runs must be insulated.

The drain outlet on the boiler is standard 21.5mm (3/4”)

overflow pipe.

TERMINAL

The terminal assembly can be adapted to accommodate

various wall thicknesses. Refer to Frame 14.

AIR SUPPLY

It is NOT necessary to have a purpose-provided air vent in the

room or internal space in which the boiler is installed. Neither is

it necessary to ventilate a cupboard or compartment in which the

boiler is installed, due to the low surface temperatures of the

boiler casing during operation; therefore the requirements of BS

6798, Clause 12, and BS 5440:2 may be disregarded. In IE the

requirements of I.S.813:2002 may be disregarded.

WATER CIRCULATION SYSTEM

IMPORTANT.

A minimum length of 1 metre of copper pipe MUST be fitted to

both flow and return connections from the boiler before

connection to any plastic piping.

For the types of system and correct piping procedure see

Frames 1, and 3 to 8.

The central heating system should be in accordance with

BS.6798 and, in addition, for smallbore and microbore

systems, BS.5449.

WATER TREATMENT - see Frame 9

The hot water storage cylinder MUST be of the indirect type and

should preferably be manufactured of copper.

Pressure Drop Across Boiler

(metres water)

0.5

1.0

Boiler Output (kW)

8.8 11.7 14.7 17.6 20.5 23.4

Ecl 1603

6. The air inlet/products outlet duct and the terminal of the

boiler MUST NOT be closer than 25mm (1") to combustible

material. Detailed recommendations on the protection of

combustible material are given in BS.5440-1:2000. In IE

refer to I.S.813:2002.

IMPORTANT.

It is absolutely ESSENTIAL to ensure, in practice, that products

of combustion discharging from the terminal cannot re-enter the

building or any other adjacent building through ventilators,

windows, doors, other sources of natural air infiltration, or forced

ventilation / air conditioning.

If this should occur the appliance MUST be turned OFF, labelled

as 'unsafe' until corrective action can be taken.

Graph 1 - Water flow rate and pressure loss

10 icos - Installation & Servicing

GENERAL

OPEN VENT SYSTEM REQUIREMENTS

SCHEMATIC PIPEWORK AND SYSTEM BALANCING

The boiler does not normally need a bypass but at least some

radiators on the heating circuit, of load at least 10% of the

minimum boiler output, must be provided with twin lockshield

valves so that this minimum heating load is always available

(see footnote re. thermostatic radiator valves).

Return & flow

connections

load 30 - 60 = 22 mm

load 70 - 80 = 28 mm

Balancing

1. Set the programmer to ON for both CH

and HW. Turn the cylinder thermostat

down. Close the manual or thermostatic

valves on all radiators, leaving the twin

lockshield valves (on the radiators

referred to above) in the open position.

Turn up the room thermostat and adjust

these lockshield valves to give boiler flow

and return temperatures not more than

20 oC apart. These valves should now be

left as set.

2. Open all manual or thermostatic radiator

valves and adjust the lockshield valves

on remaining radiators to give around

11oC temperature drop at each radiator.

3. Turn up the cylinder thermostat and

adjust the cylinder balancing valve so

that the cylinder achieves a maximum

flow consistent with adequate flow to the

radiators. Check that with only the

domestic hot water loop in circuit a

differential temperature of 20 oC across

the boiler is not exceeded.

4. Adjust room and cylinder thermostats

and programmer to NORMAL settings.

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 between the highest point of the

system and the feed/expansion cistern water level MUST not be

less than 450 mm (18"). The pump must be fitted on the flow side of

the boiler.

A suitable pump is a domestic circulator capable of providing a

maximum 11oC (20oF) temperature differential across the boiler with the

whole of the heating circuit open (e.g. Grundfos UPS 15/50, 15/60 or

equivalent). With the minimum flow circuit allowed by the controls the

differential must not exceed 25 oC. (18oC for the HE15)

The vertical distance between the pump and feed/expansion cistern

MUST comply with the pump manufacturer's minimum requirements, to

avoid cavitation. Should these conditions not apply either lower the

pump position or raise the cistern above the minimum requirement

specified by Ideal Stelrad Group. The isolation valves should be fitted

as close to the pump as possible.

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' minimum requirements must be complied with.

LOW HEAD AND LARGE SYSTEMS WITH EXTENSIVE PIPE RUNS - OPEN VENT

All dimensions in mm (in.).

NB. Imperial dimensions are approximate

SEALED SYSTEM REQUIREMENTS

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 connection MUST NOT be made

immediately off the top of the boiler as venting is

made less efficient.

3. The maximum practical length of 22mm cold feed pipe

should be used in order to reduce the effective volume

of hot system water expanding into the feed/expansion

cistern to a minimum.

a. A non-adjustable preset lift pressure not exceeding

3bar (45lb/in2).

b. A manual testing device.

c. Provision for connection of a discharge pipe.

The valve or discharge pipe should be positioned so

that the discharge of water or steam cannot create a

hazard to the occupants of the premises or cause

damage to electrical components and wiring.

3. Pressure Gauge

A pressure gauge covering at least the range 0-4 bar

(0-60 lb/in2) must be fitted to the system. The gauge

should be easily seen from the filling point and should

preferably be connected at the same point as the

expansion vessel.

Notes.

a. The method of filling, refilling, topping up or flushing

sealed primary hot water circuit from the mains via a

temporary hose connection is

only allowed if

acceptable to the

local water authority.

b. When installing the

filling device, it must be

connected as shown to

fully comply with the

water regulations. This

may involve the fitting of

an additional WRAS

approval isolator valve

to the mains supply.

1. General

a. The installation

must comply with the

requirements of BS. 6798

and BS. 5449.

b. The installation should be designed to work with

flow temperatures of up to 82 oC.

c. All components of the system, including the heat

exchanger of the indirect cylinder, must be

suitable for a working pressure of 3 bar (45lb/in2 )

and temperature of 110oC. Care should be taken

in making all connections so that the risk of

leakage is minimised.

2. Safety Valve

A spring loaded safety valve complying with the

relevant requirements of BS. 6759 must be fitted in

the flow pipe as close to the boiler as possible and

with no intervening valve or restriction. The valve

should have the following features:

12 icos - Installation & Servicing

GENERAL

SEALED SYSTEM REQUIREMENTS - continued

pressure. The cold feed pipe from the cistern should

include a non-return valve and a stop valve with an

automatic air vent connected between them, the stop

valve being located between the system and the

automatic air vent. The stop valve may remain open

during normal operation of the system if automatic

water make-up is required.

b. Through a self-contained unit comprising a cistern,

pressure booster pump (if required) and, if necessary,

an automatic pressure reducing valve and flow

restrictor. The cistern should be supplied through a

temporary connection from a service pipe or cold

water distributing pipe.

This unit may remain permanently connected to the

heating system to provide limited automatic water

make-up. Where the temporary connection is supplied

from a service pipe or distributing pipe which also

supplies other draw-off points at a lower level then a

double check valve shall be installed upstream of the

draw-off point.

c. Through a temporary hose connection from a draw-off

tap supplied from a service pipe under mains

pressure. Where the mains pressure is excessive a

pressure reducing valve shall be used to facilitate

filling.

The following fittings shall form a permanent part of

the system and shall be fitted in the order stated:

A stop valve complying with the requirements of

BS. 1010, Part 2 (the hose from the draw-off tap shall

be connected to this fitting).

A test cock.

A double check valve of an approved type.

• Thoroughly flush out the whole of the system with

cold water, without the pump in position.

• With the pump fitted, fill and vent the system until the

pressure gauge registers 1.5 bar (21.5lb/in2).

Examine for leaks.

• Check the operation of the safety valve by manually

raising the water pressure until the valve lifts. This

should occur within ± 0.3 bar (± 4.3lb/in2.) of the

preset lift pressure.

• Release water from the system until the initial system

design pressure is reached.

• Light the boiler and heat the system to the maximum

working temperature. Examine for leaks.

• Turn off the boiler and drain the system while still hot.

• Refill and vent the system.

• Adjust the initial pressure to the required value.

4. Expansion Vessel

a. A diaphragm type expansion vessel must be

connected to a point close to the inlet side of the

pump, the connecting pipe being not less than 15 mm

(1/2" nominal) size and not incorporating valves of

any sort.

b. The vessel capacity must be adequate to accept the

expansion of the system water when heated to

110oC (230oF).

c. The charge pressure must not be less than the

static water head above the vessel. The pressure

attained in the system when heated to 110o C (230o

F) should be at least 0.35 bar (5 Ib/in2) less than the

lift pressure of the safety valve.

For guidance on vessel sizing refer to the table in

Frame 8.

For further details refer to BS. 5449, BS. 7074:1 and

the British Gas Corporation publication 'Material and

Installation Specifications for Domestic Central

Heating and Hot Water'. For IE refer to the current

edition of I.S.813.

5. Cylinder

The cylinder must be either of the indirect coil type or a

direct cylinder fitted with an immersion calorifier which is

suitable for operating on a gauge pressure of 0.35 bar

(5 Ib/in2) in excess of the safety valve setting. Single feed

indirect cylinders are not suitable for sealed systems.

6. Make-up Water

Provision must be made for replacing water loss from the

system, either:

a. From a manually filled make-up vessel with a readily

visible water level. The vessel should be mounted at

least 150 mm (6") above the highest point of the

system, and be connected through a non-return valve

to the system, fitted at least 300 mm (12") below the

make-up vessel on the return side of the domestic

hot water cylinder or radiators.

b. Where access to a make-up vessel would be difficult

by pre-pressurisation of the system. Refer to 'Filling',

below.

7. Mains Connection

There must be no direct connection to the mains water

supply or to the water storage tank supplying domestic

water, even through a non-return valve, without the

approval of the local water authority.

8. Filling

The system may be filled by one of the following

methods:

a. Through a cistern, used for no other purposes, via a

ball valve permanently connected directly to a service

pipe and/or a cold water distributing pipe.

The static head available from the cistern should be

adequate to provide the desired initial system design

Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be

less than that given by the table on the following page, multiplied by a factor of 0.8 (for flow temperatures of less than 83o

C).

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

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 16.9 30.0

175 14.6 19.1 27.3 16.4 23.4 41.4 19.7 35.0

200 16.7 21.8 31.2 18.8 26.8 47.4 22.6 40.0

225 18.7 24.5 35.1 21.1 30.1 53.3 25.4 45.0

250 20.8 27.2 39.0 23.5 33.5 59.2 28.2 50.0

275 22.9 30.0 42.9 25.8 36.8 65.1 31.0 55.0

300 25.0 32.7 46.8 28.2 40.2 71.1 33.9 60.0

Multiplying factors for

other system volumes 0.0833 0.109 0.156 0.094 0.134 0.237 0.113 0.20

SEALED SYSTEM REQUIREMENTS - continued

WATER TREATMENT

The icos boiler range have an ALUMINIUM alloy heat exchanger

IMPORTANT. The application of any other treatment to this product may render the guarantee of Ideal

Stelrad Group invalid.

Ideal Stelrad Group recommend water treatment in accordance with the Benchmark Guidance Notes on Water

Treatment in Central Heating systems.

Ideal Stelrad Group recommend the use of FERNOX-COPAL or MB1,GE Betz Sentinel X100 OR Salamander Corrosion

Guard inhibitors and associated water treatment, which must be used in accordance with the manufacturers' instructions.

For further information contact:

Notes

1. It is most important that the correct concentration of the water

treatment product is maintained in accordance with the

manufacturers' instructions.

2. If the boiler is installed in an existing system any unsuitable

additives MUST be removed by thorough cleansing.

BS. 7593:1992 details the steps necessary to clean a

domestic central heating system.

3. In hard water areas, treatment to prevent lime scale

may be necessary - however, the use of artificially

softened water is NOT permitted.

4. Under no circumstances should the boiler be fired

before the system has been thoroughly flushed.

Sentinel Performance Solutions

The Heath Business & Technical Park

Runcorn

Cheshire

WA7 4QX

Tel: 0800 389 4670

www.sentinel-solutions.net

Fernox Manufacturing Co. Ltd

Cookson Electronics

Forsyth Road

Sheerwater

Woking

Surrey

GU21 5RZ

Tel: +44 (0) 1799 521133

Salamander Engineering Ltd

Unit 24

Reddicap Trading Estate

Sutton Coldfield

West Midlands

B75 7BU

Tel: +44 (0) 121 3780952

14 icos - Installation & Servicing

INSTALLATION

nm8744

8. Flue manifold.

10. Interpanel.

11. Burner assy.

12. Combustion chamber

Insulation.

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. Orifice plate.

22. Flue thermistor.

LEGEND

1. Front casing panel.

2. Sealing panel

3. Sump cover plate.

4. Bottom casing panel.

5. Flue sensing nipple.

6. Return pipe.

7. Flow pipe.

BOILER ASSEMBLY - Exploded view

23. Control thermistor.

24. Overheat thermostat.

25. Ignition electrode.

26. Flame detection electrode.

32. 'S' trap

33. Control assy.

40. Spark generator

44. Wall mounting plate.

53. Turret gasket kit.

94. Ignition lead

INSTALLATION

icos - Installation & Servicing

INSTALLATION

nm7890

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.

UNPACKING

Hardware Pack

A 50mm x No.14 wood screws - 3 off

B Wall plugs (TP2B ) - 3 off

C Push-in caps - 6 off (Refer to Frame 36 no. 15)

D Mains connector - 1 off

Pack A Contents

A The boiler

B Wall mounting template

on cardboard

C Wall mounting plate

D 1 year guarantee form

E These Installation & Servicing/

User’s Instructions

F Water Treatment Warning Label

G Hardware pack

B Pack Contents

A Telescopic flue terminal

B Flue turret

C Screws (2 off)

D Sealing Tape

1. Ensure the boiler is stood correctly, as marked on the

carton.

2. Cut and remove the strapping.

3. Fold back the top flaps to gain access to the wall

mounting plate, literature and wall mounting

template.

4. Remove the instructions and read thoroughly before

unpacking the product.

5. When ready for installation lift off the outer sleeve.

6. Remove the top protection packing/template and

save for further use.

7. Remove the two packaging ends.

8. Remove the hardware pack from under the pipes

and keep in a safe place.

PACKAGING REMOVAL

nm9282

nm8465

nm8751

INSTALLATION

16 icos - Installation & Servicing

INSTALLATION

Wall Thickness X

160 mm

160 + S = 193mm

nm8943

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 frame depth = 33mm.

1. To remove the front panel remove the 2 screws from the

bottom panel.

2. Lift the panel up and off the top pegs.

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.

DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED

FLUE KITS

Pack B - supplied as standard.

Finishing Kit - supplied as an optional extra.

Pack D - optional extension kit for side flue or rear flue outlet.

Refer to 'Flue Extension Ducts'

Note. MAXIMUM FLUE LENGTHS:

HORIZONTAL FLUE - 6M

ROOF FLUE KIT - 7.5M

POWERED VERTICAL FLUE KIT - 5m primary and 17m secondary is a typical maximum

length. For alternative details refer to Powered Vertical

Instructions.

90O ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 1M)

45O ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 0.6M)

60/60 TWIN FLUE KIT - 18M TOTAL AIR PLUS FLUE DUCT - Ref Graph within Kit Instructions

80/80 TWIN FLUE KIT - 60M TOTAL AIR PLUS FLUE DUCT - Ref Graph within Kit Instructions

MINIMUM HORIZONTAL FLUE LENGTHS - TELESCOPIC TERMINAL = 370MM

(Centre Line of turret to outside of wall terminal) - ONE PIECE TERMINAL = 285MM

Notes.

1.When extension ‘D’ packs are used the flue duct MUST be inclined at 1.5

degrees to the horizontal to allow condensate to drain back into the boiler

and out through the condensate drain.

2. If the telescopic ‘B’ pack or horizontal flue terminal (600 long) only are

used, they may be mounted horizontally. The 1.5 degrees is taken care of

by the inclination of the flue within the air pipe

3. If the boiler is to be installed with downward piping routed behind the boiler

then the optional stand-off kit should be used. Care must be taken when

cutting the ducts and marking the wall to suit this condition.

REAR FLUE

SIDE FLUE

195mm

Wall Thickness X

Side flue length L

Total Flue length dimension Flue

(measuring from CL of turret to outside wall)

Rear flue Side flue Extra packs

dim. X+160 dim. L+195 required

Up to 595 mm Up to 595 mm none

Up to 1545 mm Up to 1545 mm Pack D - 1 off

Up to 2495 mm Up to 2495 mm Pack D - 2 off

Up to 3445 mm Up to 3445 mm Pack D - 3 off

Up to 4395 mm Up to 4395 mm Pack D - 4 off

Up to 5345 mm Up to 5345 mm Pack D - 5 off

Up to 6000 mm Up to 6000 mm Pack D - 6 off

INSTALLATION

icos - Installation & Servicing

INSTALLATION

FLUE OUTLET

nm8752

WALL MOUNTING TEMPLATE

FLUE ASSEMBLY - Exploded View

LEGEND

1. 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 for

wall thicknesses greater than :

Side 395mm

Rear 435mm

nm9283

V - See Diagram Below

Extended centre line

155

Rear flue arrangement shown

nm8731

The wall mounting template is located on the internal top

protective packaging.

Note.

The template shows the positions of the fixing holes and

the rear flue hole centre for standard installation. Care

MUST be taken to ensure the correct holes are drilled.

1. Tape template into the selected position. Ensure

squareness by hanging a plumbline as shown.

2. If fitting a side flue extend the flue centre line onto the side

wall and measure in 155mm for standard installation.

Note. If using stand-off kit distance increases to 188mm.

3. Mark onto the wall the following:

aThe wall mounting plate screw positions (choose one

from each side with preference to top holes).

b. The position of the flue duct hole (see diagram below).

Note. Mark the centre of the hole as well as the

circumference.

4. Remove the template from the wall.

18 icos - Installation & Servicing

INSTALLATION

FLUE OUTLET

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 using the stand-off kit then drill 4 holes (choosing

one from each group but not the jacking screw).

3. Locate 2 No.14 x 50mm screws in the piping frame

(one at each side, in any of the 3 holes provided at

each side) and screw home.

Note.

If using the stand-off kit then locate the stand-off

channel and screw home.

SETTING THE FLUE - SIDE Wall thicknesses of 170 to 395mm

SETTING THE FLUE - REAR Wall thicknesses of 210 to 435mm

Notes.

a. If using the extension ducts go to Frame 18.

b. For shorter flue requirements use non telescopic B

Pack.

1. Measure and note wall thickness X. Refer to Frame 14.

2. Measure distance from side of boiler to inside of wall

and add to wall thickness X=L. Refer to Frame 14.

3. Add 115mm to dimension L and set telescopic flue

length as indicated in drawing.

4. Using a 3.5mm drill bit, drill two holes in outer air duct

taking care not to pierce plastic inner flue.

5. Fix to length using self tappers provided.

6. Seal outer air duct using the tape provided.

Notes.

a. If using the extension ducts go to Frame 18.

b. If the stand-off frame is used it is essential to add 33mm

to dimension X.

c. For shorter flue requirements less than 210mm, use non

telescopic B Pack.

1. Measure and note wall thickness X. Refer to Frame 12.

2. Add 75mm to dimension X and set telescopic flue length

as indicated in drawing.

3. Using a 3.5mm drill bit, drill two holes in outer air duct

taking care not to pierce plastic inner flue.

4. Fix to length using self tappers provided.

5. Seal outer air duct using the tape provided.

nm8944

X + 75

Drill hole Adhere sealing tape

Measurement to be

taken from this point

nm8945

L + 115

Drill hole Adhere sealing tape

Measurement to be

taken from this point

icos - Installation & Servicing

INSTALLATION

FLUE OUTLET

1. A maximum of 6 extension ducts (one suitably

cut) plus the standard flue duct may be used

together.

2. Flue extensions of greater length than 1m (39")

should be supported with the bracket provided,

suitably adjusted. Refer to Frame 20 & 26.

FLUE EXTENSION DUCTS - continued

nm8733

Boiler

Standard flue

Terminal grille

Flue length

Extension flue

FLUE EXTENSION DUCTS - For total flue lengths greater than 595mm

Pack D Flue extension duct kit contents.

Note. Side flue shown

Use a maximum of 6m extended flue ONLY

General arrangement

Flue duct support

Flue support cutting aid

(shown folded up)

Wall plugs - 4 off

Extension duct & clamp

1.0m (39") long

No. 10 x2" wood screw - 4 off

nm8732

FITTING THE KIT

Because of the flexibility of the telescopic flue terminal it is not

always necessary to cut an extension pack.

1. Measure the total flue length from the centre of the boiler

outlet to the outside wall.

2. Subtract 70mm from this dimension.

3. Subtract 950mm for each ‘D’ pack to be used.

4. If the remainder Y is 300mm -

525mm this can be taken up

by the adjustment in the

telescopic flue.

5. If the remainder Y is 525mm -

950mm it will be necessary to

cut a ‘D’ pack to 400mm.

6. if the remainder Y is less than 300mm, shorten the

previous ‘D’ pack to 400mm and adjust the telescopic

terminal.

7. Measure and mark the length on the flue, to ensure a

square cut mark the flue all the way around and cut to

length.

300

525

950

esp8940

20 icos - Installation & Servicing

INSTALLATION

CONDENSATE DRAIN

The condensate drain provided on the boiler must be

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 pipework must be arranged so that

obstruction (e.g. through freezing) of external

drainage pipe does not give rise to spillage within

the dwelling.

IMPORTANT. If excessive external pipework cannot

be avoided an additional siphon kit and insulation

are recommended, in order to prevent possible

freezing.

All pipework and fittings in the condensate drain

system must be made of plastic. No other materials

may be used.

The drain outlet on the boiler is standard 21.5mm

overflow pipe. This size must not be reduced in any

part of its length.

A plastic cap is fitted to the end of the condensate

drain adapter this must be removed before

connection is made.

nm8734

Front View Side View

155mm

Condensate

drain

Refer also to the British Gas document: 'Guidance Notes for

the Installation of Domestic Gas Condensing Boilers' (1989).

BOILER

cla7771 75mm trap

Sink constitutes

air break

DRAIN

Ground Level

Open end of pipe

direct into gulley

below grating but

above water level

cla9252

75mm trap

DRAIN

Sink

Ground Level

Open end of pipe

direct into gulley

below grating but

above water level

BOILER

Air Break

1. INTERNAL TO SINK WASTE

UPSTREAM OF SINK WASTE

TRAP

2. INTERNAL TO SINK WASTE

DOWNSTREAM OF SINK

WASTE TRAP (PREFERRED

METHOD)

Note. ALL EXTERNAL PIPE RUNS MUST BE INSULATED - MAXIMUM LENGTH 3M EXTERNAL

CONDENSATE PIPE TERMINATION CONFIGURATIONS

continued . . . .

INSTALLATION

icos - Installation & Servicing

INSTALLATION

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

cla7774

minimum

500mm

BOILER

External

wall

Ground Level

Open end of pipe

direct into gulley

below grating but

above water level

DRAIN

cla7775

4. TERMINATION TO SOAK AWAY

5. TERMINATION TO DRAIN / GULLEY

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.

INSTALLATION

22 icos - Installation & Servicing

INSTALLATION

nm8755

CONNECTING THE FLUE TO THE BOILER

Note.

Before fitting the flue turret fill

the condensate trap within the

boiler by pouring a cupful of

water into flue outlet A.

Make sure the plastic cap is

removed from the end of the

condensate drain adapter.

Take care to ensure that the

water is only poured into the flue

outlet, and does not spill into the

boiler casing.

1. Locate the flue into the turret.

2. Insert the flue assembly through the prepared hole in the

wall. Push through and pull back to seal against outside

wall face.

3. Locate the flue turret on the top of the boiler, ensuring that

the turret gasket is in place. Also ensure the turret is

located concentric with the flue aperture on the boiler top

panel. Check that the flue seal (at A) located in the top of

the flue manifold is secure and giving an effective seal.

4. Secure the flue turret on top of the boiler by inserting the

open ends of the turret clamp under the 2 studs and fixing

it in the middle with the single M5 x 10mm pozi-hex screw

provided.

5. Flues over 1 metre long.

Fix the flue support bracket to the wall, using the wall plug

and wood screw. For standard installations use the short

wood screw.

If the stand-off option is used, secure the support bracket

using the spacer bracket and long wood screw.

NB. The space bracket will utilise one fixing hole only whilst

used in conjunction with the stand-off option.

MOUNTING THE BOILER

1. Lift the boiler onto the wall mounting plate, as

shown.

2. Check the boiler alignment using a spirit level

and adjust as necessary with the jacking screw.

3. Align the hole in the jacking plate with the pre-

drilled hole in the wall and fix in position with the

No.10 x 2" screw provided.

4. Fit condensate union connection

INSTALLATION

icos - Installation & Servicing

INSTALLATION

FLUE OUTLET

Flue

duct

support

Vertical connector

UIN 203135

elbow

UIN 203130

elbow

UIN 203131

Roof Flue Extension Duct

UIN 203129

nm8735

Flue Terminal

UIN 203132

Flue Seal Collar - Flat Roof

UIN 152259

Flue Seal Collar - Tile Roof

UIN 152258

ROOF FLUE KIT CONTENTS / OPTIONS

FITTING THE OPTIONAL ROOF FLUE KIT (Flat or Pitched)

nm8736

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.

Connection to the top of the boiler is made using both a separately

supplied vertical connector and a 80/125 adaptor.

WEATHER PROOFING

Where the flue passes through the roof line an

adequate seal must be made. This is achieved

by using either:

- Flat roof weather collar

- Universal weather collar.

ACCESSORIES

Flue Duct Extension Kits are available for

flue lengths extending beyond 1m. These

packs contain 1m extension ducts and

may be cut to the desired length.

If the offset vertical option is used an elbow

Kit is required. For a full accessories list

refer to page 7, Optional Extras and Frame

31, Flue Arrangement.

24 icos - Installation & Servicing

INSTALLATION

FLUE OUTLET

rf8394-1

690mm

Fixed

300mm

min

FLUE TERMINAL POSITION

rf8393-1

300mm

min

300mm

min

625mm

Fixed

Flat roof - with structure

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

Terminal Position Minimum Dimension

Directly below an opening,

air brick, windows, etc. 300 mm

Below plastic / painted gutters 300 mm

Painted surface 300 mm

Below eaves or balcony 500 mm

rf8392

icos - Installation & Servicing

INSTALLATION

FLUE OUTLET

rf8737

rf8738

FLUE ARRANGEMENT

Note.

The equivalent flue length resistance of the elbow kits are:

90o elbow kit = 1m

45o elbow kit = 0.6m

26 icos - Installation & Servicing

INSTALLATION

FLUE OUTLET

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.

Ensure the cut pipe ends are free from any burrs.

1. Position the roof flashing plate (supplied separately) over the

hole cut in the roof and insert flue terminal from the roof end.

nm8739

min 16o

max 41o

MAX LENGTH:

7.5m

BOILER

nm8740

Flue Terminal

Pitched roof tile

weather collar

Flat roof tile

weather collar

nm8741

Extension

Duct

Vertical

connecto

Turret

clamp

nm8743

'X'

2. Push fit the vertical connector (supplied seperately) into the

boiler flue connection and retain with the turret clamp and

securing screw (supplied with the boiler). ENSURING THE

GASKETS IN THE BOILER FLUE OUTLET ARE CORRECTLY

FITTED.

3. "Push" fit extension duct (if required (supplied separately)) into

vertical connector.

4. If the last extension duct requires cutting, measure ‘X’, the distance

(outer ducts), between the duct and the terminal and add 100 mm to

this dimension. This gives the length of the last extension duct.

Note. Check the position of the inner flue duct relative to the outer duct

on the assembled extension duct(s) and ensure the terminal flue duct

is cut longer than the air duct to ensure engagement in the final flue

duct seal.

5. Finally ensure the roof flashing plate is correctly sealed to the roof.

icos - Installation & Servicing

INSTALLATION

GAS CONNECTION

IMPORTANT. The gas service cock is sealed with a non-metallic

fibre washer seal so must not be overheated when making

capillary connections.

Refer to Frame 2 for details of the position of the gas connection.

N.B. The principle of the 1:1 gas valve ensures that the icos

HE range is able to deliver it’s full output at inlet pressures

down to 14mb. However if dynamic pressures below 20mb

are experienced ensure this is adequate for ALL other gas

appliances in the property.

BOILER WATER CONNECTIONS

The boiler flow and return pipes are supplied fitted to the

boiler and ready for top connection.

Note.

For heating loads in excess of 60 000 Btu/h use 28mm x

22mm connectors to connect the boiler flow and return

pipes to 28mm.

TOP CONNECTION

Connect the system pipework to the boiler flow and return

pipes.

Note.

The front panel is not fitted at this stage.

A boiler gas supply pipe length of 20m and not less than

15mm O.D. can be connected to the boiler via the gas

service cock union.

Ensure that the gas supply pipe does not foul the boiler

casing.

Refer to Frame 41 for details of the pressure test point

position.

ELECTRICAL CONNECTIONS

WARNING. This appliance MUST be earthed.

A mains supply of 230 V ~ 50 Hz is required.

All external controls and wiring MUST be suitable for mains

voltage.

The fuse rating should be 3 A.

Wiring external to the boiler MUST be in accordance with the

current I.E.E. (BS.7671) Wiring Regulations and any local

regulations.

Wiring should be 3 core PVC insulated cable NOT LESS

than 0.75 mm2 (24 x 0.2mm) and to BS. 6500, Table 16.

For IE reference should be made to the current ETCI rules

for electrical installations.

Connection must be made in a way that allows complete

isolation of the electrical supply - such as a double pole

switch having a 3mm (1/8") contact separation in both poles,

or a plug and socket serving only the boiler and system

controls. The means of isolation must be accessible to the

user after installation.

INSTALLATION

28 icos - Installation & Servicing

INSTALLATION

INTERNAL WIRING

Incoming mains wiring detail

A pictorial wiring diagram is shown in Frame 37.

The mains lead connector is pre-fitted. This must be

removed to allow wiring.

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. A permanent live is ESSENTIAL in order for

the advanced diagnostic controls to function correctly.

3. Wire the switched live supply into L2 or connect L1 and L2

via external control switching, as shown in Frame 32. In

either case, remove the wire link fitted L1 to L2.

4. Secure the mains lead with the cable clamp.

5. Connect the mains lead connector. Ensure it is fully located.

Note.

Ensure that the lengths of the current carrying conductors are

shorter than the earth conductor so that if the cable slips in its

anchorage the current carrying conductors become taut

before the earth conductor.

Mains Connector

(supplied in hardware pack)

Socket

(fixed to boiler)

Remove link when connecting external programmer.

Ecl2367

Ecl 1542

INSTALLATION

icos - Installation & Servicing

INSTALLATION

Spark generator

nm 8076

y y

y/g

Ferrite

y/g

Flue

thermistor

Overheat

thermostat

Flow

control

thermistor

Gas valve

ON /OFF

Switch

Service

connection

MAINS

SUPPLY

230V 50Hz

Permanent

black link

Fan

Chassis

earth y/g

Control PCB

Fused at

3.15ATL

User

control

and

display

br b

FUNCTIONAL FLOW WIRING DIAGRAM

Overheat

thermostat

rbk

Mains Switch

Flame detection

electrode

Fan

nition electrod

CH return thermistor

(not fitted)

Control thermistor

as valv

Control PCB

User PCB

y/g

nm 7201

rmi

park

enerato

External switch e.

room'stat, pro

ramme

PICTORIAL WIRING DIAGRAM

LEGEND

b-blue

bk - black

br - brown

gy - grey

or - orange

pk - pink

r-red

v-violet

w-white

y-yellow

y/g - yellow/green

LEGEND

b-blue

bk - black

br - brown

gy - grey

or - orange

pk - pink

r-red

v-violet

w-white

y-yellow

y/g - yellow/green

INSTALLATION

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 purged

in accordance with the recommendations of BS. 6891.

In IE refer to I.S. 813:2002.

2. Purge air from the gas installation by the approved methods

only.

WARNING

. Whilst effecting the required gas soundness test and purging air from the gas

installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.

A. ELECTRICAL INSTALLATION

1. Checks to ensure electrical safety should be carried out by

a competent person.

2. ALWAYS carry out the preliminary electrical system checks,

i.e. earth continuity, polarity, resistance to earth and short

circuit, using a suitable test meter.

COMMISSIONING AND TESTING

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.

(It provides for more energy efficient operation by

reducing switching temperature differentials.)

Frost Protection

If parts of the pipework run outside the house or if

the boiler will be left off for more than a day or so

then a frost thermostat should be wired into the

system. This is usually done at the programmer, in

which case the programmer selector switches are

set to OFF and all other controls MUST be left in

the running position.

The frost thermostat should be sited in a cold place

but where it can sense heat from the system.

If the boiler is installed in a garage it may be

necessary to fit a pipe thermostat, preferably on

the return pipework.

Important. Ensure that the frost thermostat is

wired so that the system pump and/or external

diverter valve is energised, as appropriate.

Designation of the terminals will vary but the

programmer and thermostat manufacturers'

leaflets will give full details.

Diagram A shows an application to boilers fitted

with a room thermostat only.

Diagrams B and C show applications to boilers

fitted with alternative time controls.

Earths are not shown for clarity but MUST NEVER BE OMITTED.

INSTALLATION

icos - Installation & Servicing

INSTALLATION

nm8780

INITIAL LIGHTING

LEGEND

AOn/Off switch.

BThermostat knob.

D'Burner On' neon.

EReset button.

FInjector pressure test point.

GInlet pressure test point.

HGas service cock.

JCasing pressure test point.

KOverheat thermostat.

LFlue thermistor.

MFlow thermistor.

ZSpark generator.

Note.

It is important the burner is not operated before the system is fully

vented of air. If it is necessary to operate the appliance pump to

assist venting of the air this must be done with the gas service cock

turned off.

2. Check that all drain cocks are closed and any valves in the flow

and return are open.

3. Check the electrical supply is off.

4. Ensure the boiler sealing panel is fitted.

5. Check the gas service cock is open.

6. Check that the boiler on/off switch (A) is OFF

7. Slacken the screw in the inlet pressure test point (G) and

connect a gas pressure gauge via a flexible tube.

8. Switch the electricity supply ON and check all external controls

are calling for heat.

9. Set the boiler thermostat knob (B) to position 6 and switch the

boiler on/off switch (A) to ON. The boiler control should now go

through its ignition sequence until the burner is established.

10. If the boiler does not light after 3 attempts the fault codes

L' 'F'

will be displayed. Press the reset button (E); the boiler will

then repeat its ignition sequence. When the burner is

established the WHITE burner ON neon (D) will be

permanently illuminated

11. Ensure that with the boiler operating the dynamic gas

pressure is able to obtain maximum output. Refer to Table 2.

1. Check that the system has been filled and that the boiler is not air locked.

N.B. The principle of the 1:1 gas valve ensures that the

icos HE range is able to deliver it’s full output at inlet

pressures down to 14mb. However if dynamic

pressures below 20mb are experienced ensure this is

adequate for ALL other gas appliances in the property.

IMPORTANT.

The gas input to the burner is regulated by the gas

valve according to the air flow produced by the fan.

It is NOT user-adjustable. Any interference to

sealed settings on the gas valve will adversely

affect operation and render our warranty void.

12. Switch OFF the boiler on/off switch.

13. Remove the pressure gauge and tube. Tighten the

sealing screw in pressure test point. Ensure a gas

tight seal is made.

14. Refit the boiler front panel and bottom panel.

15. THE FASCIA

a. To remove the plastic fascia, prise off the

retaining star washers using a pair of pliers and

place to one side.

b. Fill the remaining fixing holes with the white push

in caps provided.

THE DISPLAY

The user control has one neon and one display to inform the

user about the status: the display will show the status of the

boiler and the neon will show the status of the flame. If no

flame is detected the neon is blinking. When the flame is

detected the neon will be lit permanently.

Below is a list with display function in normal operation.

Standby. No demand for heat present.

Boiler is active for central heating.

Boiler is in lockout for a specific error. The display will be

blinking, alternating with a number or letter to show which

error is detected.

Boiler is in lockout for a specific error. The display will be

blinking, alternating with a number or letter to show which

error is detected.

Boiler frost protection

Note: Boiler frost protection occurs at a temperature less

than 3 degrees. The boiler will fire.

INSTALLATION

32 icos - Installation & Servicing

INSTALLATION

GENERAL CHECKS

Make the following checks for correct operation:

1. Central Heating

The correct operation of ANY programmer and all

other system controls should be proved. Operate

each control separately and check that the main

burner or circulating pump, as the case may be,

responds.

Ensure the external controls are calling for heat.

After ignition the display should read:

2. Gas Rate

Operate the boiler for 10 minutes. Check the boiler

gas rate (see Table 2), ensuring the boiler is at full

output whilst measurements are recorded.

3. Water Circulation System

HANDING OVER

•The temperatures quoted alongside are approximate, and

vary between installations.

Note. Fernox Superfloc, Sentinel X300 (new systems) or

X400 (existing systems) flushing solutions should be

used during the flushing procedure. Refer to Frame 9.

a. With the system HOT examine all water connections for

soundness.

b. With the system still HOT, turn off the gas, water and

electricity supplies to the boiler and drain down to

complete the flushing process.

c. Refill and vent the system, add inhibitor (see Frame 9),

clear all air locks and again check for water soundness.

Adhere the water treatment warning label, supplied in

the hardware pack, in a prominent position on the

system, to prevent the use of incorrect water treatment

additives.

d. Balance the system. Refer to Frame 4.

4. Check the condensate drain for leaks and check that it is

discharging correctly

5. Finally set the controls to the user’s requirements.

Knob Setting Flow Temperature

oCo

Min 30 86

Max 8 2 1 8 0

1. Hand the User's Instructions to the householder and

explain his or her responsibilities under current Gas

Safety (Installation and Use) Regulations or rules in force.

2. Explain and demonstrate the lighting and shutting down

procedures.

3. The operation of the boiler and the use and adjustment of

ALL system controls should be fully explained to the

householder to ensure the greatest possible fuel

economy consistent with household requirements of both

heating and hot water consumption.

Advise the User of the precautions necessary to prevent

damage to the system and to the building in the event of

the system remaining inoperative during frosty conditions.

4. Explain the function and the use of the boiler heating

controls.

5. Explain the function of the boiler fault mode.

Emphasise that if a fault is indicated the boiler should be

turned off and a CORGI registered installer consulted. In

IE contact a competent person.

6. Explain and demonstrate the function of time and

temperature controls, radiator valves, etc., for the

economic use of the system.

7. If any programmer is fitted then draw attention to the

Programmer User's Instructions and hand them to the

householder.

8. After installation and commissioning please complete

the Commissioning Checklist before

handover to the customer.

For IE, its is necessary to complete a “Declaration of

Conformity” to indicate compliance to I.S. 813:2002.

9. IMPORTANT

Stress the importance of regular servicing by a CORGI

registered installer and that a comprehensive service

should be carried out AT LEAST ONCE A YEAR. In IE

servicing work must be carried out by a competent

person.

10. As the installer you may wish to undertake the service

contract yourself or alternatively offer to the customer the

benefits of the Ideal Care Scheme, details of which are

outlined in the household pack supplied with this boiler.

After completing the installation and commissioning of the system the installer should hand over to the householder

by the following actions:

INSTALLATION

icos - Installation & Servicing

SERVICING

SERVICING SCHEDULE

BOILER FRONT PANEL REMOVAL

BOILER SEALING PANEL/

BOTTOM PANEL REMOVAL

1. Remove the 2 screws from the underside of the

appliance.

2. Pull the front panel forward at the bottom and lift

to disengage it from the top lugs.

1. To remove the sealing panel remove the 4 screws.

2. Remove the panel.

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.

nm7808

WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity

supply to the appliance before servicing.

Note. In order to carry out either servicing or replacement of

components the boiler front panel and sealing panel

must be removed. Refer to Frames 45 and 46.

IMPORTANT.

8. After completing the servicing or exchange of components

always test for gas soundness.

9. When work is complete the sealing panel MUST be

correctly refitted, ensuring that a good seal is made.

Do NOT OPERATE the boiler if the sealing

panel is not fitted.

10. If, for any reason, the condensate ‘S’ trap has been

removed ensure the trap is refilled with water before

reassembling.

11. Check the gas consumption.

12. Connect a suitable gas analyser to the sampling point on

the top of the boiler (refer to Frame 45) or into the flue

terminal if access is possible (optional test).

For correct boiler operation, the CO/CO2 content of the flue

gas should not be greater than 0.004 ratio.

13. Complete the service section in the Benchmark

Commissioning Checklist.

To ensure the continued safe and efficient operation of the

appliance it is recommended that it is checked at regular

intervals and serviced as necessary. The frequency of

servicing will depend upon the installation condition and

usage but should be carried out at least annually.

It is the law that any service work must be carried out by a

CORGI registered installer. In IE service work must be

carried out by a competent person.

1. Light the boiler and carry out a pre-service check, noting

any operational faults.

2. Clean the main burner.

3. Clean the heat exchanger & ‘S’ trap.

4. Check the condition of the combustion chamber insulation.

Any cracked, damaged or displaced pieces should be

replaced.

5. Check the main injector for blockage or damage.

6. Wherever possible remove and clean the condensate ‘S’

trap (refer to Frame 44) and check the drain for blockage.

7. Check that the flue terminal is unobstructed and that the

flue system is sealed correctly.

The servicing procedures are covered more fully in Frames

44-51 and MUST be carried out in sequence.

SERVICING

34 icos - Installation & Servicing

SERVICING

Ecl 6073

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. Inspect the injector for blockage or

damage.

BURNER REMOVAL AND CLEANING

1. Remove the 6 screws securing the

burner (the 3 screws at the rear are

extended to ease access).

2. Lift off the burner from the combustion

chamber.

IMPORTANT

The burner head is a ceramic plaque

construction. Care must be taken to

ensure that the burner is not placed

down upon its face as this may cause

damage to the ceramic.

3. Brush off any deposits that may be on

the ceramic with a SOFT brush.

4. Inspect the sealing gasket around the

burner and combustion chamber

insulation for any signs of damage.

Replace as necessary.

Note.

Take care not to disturb the ionisation

probes at the front and rear of the

combustion chamber.

nm7400

Ionisation

Probes

SERVICING

icos - Installation & Servicing

SERVICING

CLEANING THE HEAT EXCHANGER

CLEANING THE CONDENSATE 'S' TRAP

1. Undo the plastic union nut on

the condensate ‘S’ trap outlet.

2. Remove the 2 screws.

3. Pull the trap down and forward

to remove.

4. Flush out any deposits with

clean water.

REASSEMBLY

Reassemble the boiler in the following order.

1. Refit the condensate ‘S’ trap, ensuring that it is full of water.

2. Refit the sump cover plate.

3. Refit the electrodes (check dimensions Frames 56 & 57).

4. Refit the burner.

5. Refit the fan / venturi assembly.

6. Reconnect the fan electrical leads.

7. Refit the boiler sealing panel.

IMPORTANT.

Ensure the boiler sealing panel is correctly fitted and

that a good seal is made.

8. Refit the boiler front and bottom panels.

9. Turn on the gas supply at the gas service cock.

10. Reconnect the electrical supply.

1. Remove ignition and flame detection electrodes.

Refer to Frames 56 & 57.

2. Remove the 3 screws retaining the sump cover and

remove.

3. Using a suitable tool as supplied in the standard

British Gas Flue brush kit, clean between the heat

exchanger fins from the top of the heat exchanger.

4. Access to the base of the heat exchanger is now

possible. Brush clean any deposits from the base of

the heat exchanger and remove any loose deposits

from the sump.

5. Inspect the ignition and detection electrodes. Ensure

that they are clean and in good condition - replace if

necessary.

6. Check the condition of the combustion chamber

insulation. Any cracked or damaged pieces must be

replaced.

Note. Take care not to disturb the ionisation probes at the

front and rear of the combustion chamber.

7. Check that the ignition and detection gaps are

correct. Refer to Frames 56 & 57.

nm7401

Sump cover

Ionisation

probes

Heat exchanger

SERVICING

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 boiler

including gas soundness, gas rate and combustion test.

THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED

CONTROL THERMISTOR REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels. Refer

to Frames 45 & 46.

3. Pull the electrical leads off the control thermistor.

4. Pull the control thermistor and spring clip off the

IMPORTANT

When work is complete, the sealing panel must be

correctly fitted, ensuring that a good seal is made.

Note.

In order to assist fault finding, the control panel has an

LED diagnostic display. The key to boiler fault

conditions is shown in Frame 69.

REPLACEMENT OF COMPONENTS

flow pipe.

5. Replace thermistor and

reconnect leads, ensuring that

the spring clip is securely

holding the thermistor to the

flow pipe.

6. Reassemble the boiler in

reverse order.

7. Check the operation of the

boiler. Refer to Frame 52.

nm8753

SERVICING

icos - Installation & Servicing

SERVICING

Gasket

Orifice plate

Ecl 2336

BURNER REPLACEMENT

FAN REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and sealing

panels. Refer to Frames 45 & 46.

3. Disconnect the electrical leads from

the fan.

4. Unscrew the gas pipe union

connection to the injector housing.

5. Unscrew and remove the screw

retaining the fan mounting bracket.

6. Remove the fan and venturi assembly.

7. Remove the 3 screws and remove the

venturi assembly, noting the

orientation of the venturi in relation to

the fan body.

8. Transfer the venturi assembly to the

new fan, replacing the gasket if

evidence of damage or deterioration

is visible.

9. Fit the new fan / venturi assembly.

10. Reassemble the boiler in reverse

order, taking care not to overtighten

the screw on the fan mounting

bracket.

11. Check the operation of the boiler.

Refer to Frame 52.

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels.

Refer to Frames 45 & 46.

3. Remove the fan assembly. Refer to Frame 49.

4. Remove the 6 screws securing the burner (the

3 screws at the rear are extended to ease

access).

5. Lift off the burner from the combustion

chamber.

6. Fit the new burner, replacing any damaged or

deteriorating sealing gasket.

7. Reassemble in reverse order.

8. Check the operation of the boiler. Refer to

Frame 52.

Note. Take care not to disturb the ionisation

probes at the front and rear of the

combustion chamber.

nm7402

Ionisation

Probes

SERVICING

38 icos - Installation & Servicing

SERVICING

FLAME DETECTION ELECTRODE REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front, bottom & sealing panels.

Refer to Frames 45 & 46.

3. Unplug the flame detection lead from the electrode.

4. Remove the 2 screws holding the flame detection

electrode to the combustion chamber.

IGNITION ELECTRODE REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels. Refer

to Frames 45 & 46.

3. Unplug the ignition lead from the electrode.

4. Remove the earth lead from the ignition electrode.

5. Remove the remaining screw holding the ignition

electrode to the combustion chamber.

6. Remove the electrode.

5. Remove the flame detection electrode.

6. Fit the new flame detection electrode, using the

new gasket supplied. Check dimension as

shown.

7. Reassemble in reverse order and check that no

damage to the combustion chamber insulation

has occurred during the electrode replacement.

8. Check operation of the boiler. Refer to Frame 52.

ecl2780

7. Fit the new ignition electrode, using the

new gasket supplied. Check dimensions

as shown.

8. Reassemble in reverse order and check

that no damage to the combustion

chamber insulation has occurred during

the electrode replacement.

9. Check operation of the boiler. Refer to

Frame 52.

SERVICING

icos - Installation & Servicing

SERVICING

Ecl 2340

Copper washer

Rubber moulded seal

BURNER INJECTOR REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels. Refer to

Frames 45 & 46.

3. Remove the fan / venturi assembly. Refer to Frame 54.

4. Remove the 2 injector housing screws.

6. Withdraw the injector housing.

7. Fit the new injector housing, complete with injector.

8. Reassemble in reverse order, ensuring that the new

gas seal supplied is located correctly in the injector

housing.

9. Check operation of the boiler. Refer to Frame 52.

GAS CONTROL VALVE REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front, bottom and sealing panels. Refer

to Frames 45 & 46.

3. Unplug the electrical lead from the gas control valve and

disconnect the earth wire.

4. Remove the sensing tube from the gas control valve.

5. Undo the union nut between the gas valve and the gas

inlet cock.

6. Undo the union nut on the outlet side of the gas

control valve.

7. Undo the gas valve bracket screw, slide the

gas valve forward and remove.

8. Transfer the mounting bracket and gas inlet

pipe to the new gas control valve.

9. Fit new gas control valve, ensuring that any

seals showing damage or deterioration are

replaced.

Ecl 2343

10. Reassemble in reverse order.

11. Ensure the sensing tubing is correctly replaced and

not kinked or blocked in any way.

12. Check operation of the boiler. Refer to Frame 52.

SPARK GENERATOR REPLACEMENT

1. Refer to Frame 52.

2. Disconnect the leads from the spark generator and

bracket.

3. Remove the screw securing the spark generator bracket to

the flue casting.

4. Remove the 2 M4 screws securing the spark generator to

the bracket.

5. Fit the new spark generator and re-assemble in reverse

order.

6. Check operation of the boiler. Refer to Frame 52.

nm8745

SERVICING

40 icos - Installation & Servicing

SERVICING

MAINS SWITCH REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front and bottom panel.

Refer to Frames 45 & 46.

3. Remove the 2 control box screws and lower

the control box.

4. Push out the mains switch from the rear, as

shown.

5. Refit the new switch, ensuring that the

electrical leads are replaced on the correct

terminals (refer to Frame 38) and the key

on the switch is correctly aligned with the

slot in the plastic moulding.

6. Reassemble in reverse order.

7. Check operation of the boiler. Refer to

Frame 52.

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.

7. Remove the user control from the assembly.

8. Transfer the mounting brackets to the new control box.

9. Reassemble in reverse order, ensuring that the control box is

located correctly in the housing before reconnecting the

electrical wiring.

10. Check operation of the boiler. Refer to Frame 52.

N.B. To change the user control only.

11. Loosen the screw on the underside of the user control.

12. Pull the display unit forward to remove.

13. Push the new display unit into position.

14. Reassemble in reverse order.

15. Check the operation of the boiler. Refer to Frame 52.

Ecl 2419

Mounting brackets

Control box

nm7804

Ecl 2438

SERVICING

icos - Installation & Servicing

SERVICING

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels. Refer to Frames 45 & 46.

3. Pull off the silicon tube from the thermistor housing.

4. Remove the aluminium nipple securing the thermistor to the flue manifold.

5. Withdraw the thermistor.

6. Unplug the inline electrical connector.

7. Fit the new thermistor, using the gasket supplied.

8. Reassemble in reverse order.

9. Check operation of the boiler. Refer to Frame 52.

1. Refer to Frame 52.

2. Remove the boiler front and

sealing panels. Refer to Frames

45 & 46.

3. Pull off the electrical leads from

the thermostat body.

4. Pull the thermostat and clip from

the pipe.

5. Fit the new thermostat, ensuring

that the clip is securely holding

the thermostat to the flow pipe.

6. Reassemble in reverse order.

7. Check operation of the boiler.

Refer to Frame 52.

OVERHEAT THERMOSTAT REPLACEMENT

FLUE THERMISTOR REPLACEMENT

nm8746

nm8747

SERVICING

42 icos - Installation & Servicing

SERVICING

COMBUSTION CHAMBER INSULATION REPLACEMENT

Rear

Front

Combustion

chamber

LH Side

RH Side

nm8748

The insulation boards used in the combustion chamber of

this product are made of high temperature glass fibres with a

binder of organic and inorganic materials.

Ideal Stelrad Group recommend that, for your own comfort

and safety and to comply with good working practice, the

procedure described below is followed:

1. Refer to Frame 52.

2. Remove the boiler front and sealing panels. Refer to

Frames 45 & 46.

3. Remove the fan / venturi assembly. Refer to Frame 54.

4. Remove the burner. Refer to Frame 48.

5. Remove the ignition electrode. Refer to Frame 56.

6. Remove the flame detection electrode. Refer to Frame 52.

7. Remove the front and rear ionisation probes.

Prior to removal of the board the following protective

equipment should be worn:

zFace mask supplied with the spare part.

zGloves supplied with the spare part.

8. Damp down the combustion chamber area containing the

insulation boards.

9. Remove the split pin and washer from the RHS of the

combustion chamber.

10. Remove the insulation boards. The replacement boards

are supplied in a plastic bag. This bag should be retained

and the discarded boards should now be placed into it.

11. Sweep any dampened particles and place in the plastic

bag.

12. Fit new insulation boards.

Note.

The boards are designed to be interlocking and should be

fitted as shown.

13. Fit the new split pin and washer in the RHS of the

chamber.

14. Remove the gloves and face mask and place them in the

plastic bag.

15. Wash your hands and any areas of skin which may have

come into contact with any of the particles from the

insulation board.

Note. Seal the plastic bag and dispose of it and its contents

into a commercial tip.

16. Reassemble in reverse order, remembering to re-fit the

ionisation probes first.

17. Check operation of the boiler. Refer to Frame 52.

Fit insulation in the following order:

1. Rear.

2. Left Hand Side.

3. Front.

4. Right Hand Side.

SERVICING

icos - Installation & Servicing

SERVICING

HEAT EXCHANGER REPLACEMENT

Refer also to Frame 10, 'Boiler exploded view'.

1. Refer to Frame 52.

2. Remove front, bottom and sealing panels. Refer to

Frames 45 & 46.

3. Remove the control box and place to one side. Refer to

Frame 61.

4. Attach a length of hose to the drain nipple on the bottom

of the heat exchanger and drain down the boiler.

5. Remove the fan assembly and place to one side. Refer

to Frame 54.

6. Remove the burner and place to one side. Refer to

Frame 48.

7. Remove the ignition and detection electrodes. Refer to

Frames 56 & 57.

8. Remove the spark generator. Refer to Frame 58.

9. Release the flue from the turret.

10. Remove the turret from the boiler. Refer to Frame 15.

11. Release the silicon tubing from the sample point.

12. Release the electrical connections to the flue

thermistor.

13. Unscrew the M5 x 10 screw retaining the top manifold

flue casing.

14. Remove the top half of the flue manifold from the

appliance.

15. Undo the 4 M5 x 10 screws securing the bottom flue

manifold casting.

16. Pull the CH return pipe, CH flow pipe and the bottom

flue manifold together up and out of the heat

exchanger.

17. Remove the condensate 'S' trap. Refer to Frame 49.

18. Unscrew the 2 M5 x 10 screws from the inter panel.

19. Slide the heat exchanger and inter panel assembly

upwards to disengage and remove from the casing.

20. Transfer the interpanel to the new heat exchanger.

21. Reassemble in reverse order, replacing gaskets or

seals if any sign of damage or deterioration is evident.

Note.

The heat exchanger is supplied with new combustion

chamber insulation boards. These should be fitted

(refer to Frame 65) before the burner and fan assembly

and before the ignition and detection electrodes are

replaced.

25. Check the operation of the boiler. Refer to Frame 52.

nm8749

SERVICING

44 icos - Installation & Servicing

SERVICING

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.

5. Fit the new adhesive seals - note that they

are supplied to the correct length for the

relevant sides.

6. Reassemble in reverse order.

Note.

Ensure that the boiler sealing panel is

correctly seated, compressing the seal to

make an airtight joint.

7. Check operation of boiler. Refer to

Frame 52.

CONDENSATE 'S' TRAP REPLACEMENT

1. Refer to Frame 52.

2. Remove the boiler front panel. Refer to Frame 45.

3. Remove the boiler bottom panel. Refer to Frame 46.

4. Undo the plastic union nut on the condensate 'S' trap

outlet.

nm 2902

5. Remove the 2 screws.

6. Pull the trap down and forward to remove.

7. Reassemble in reverse order, ensuring that the new

trap is full of water.

8. Check operation of the boiler. Refer to Frame 52.

nm8750

Seals

SERVICING

icos - Installation & Servicing

FAULT FINDING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

FAULT FINDING CHART MAIN MENU

ALTERNATING 'L' 'F' GO TO FRAME 70

ALTERNATING 'L' 'E' GO TO FRAME 71

ALTERNATING 'L' 'A' GO TO FRAME 72

ALTERNATING 'L' '8' GO TO FRAME 73

ALTERNATING 'H' '1' GO TO FRAME 74

ALTERNATING 'H' 'F' GO TO FRAME 75

ALTERNATING 'H' '4' GO TO FRAME 76

ALTERNATING 'H' 'n' GO TO FRAME 77

ALTERNATING 'H' 'E' GO TO FRAME 71

In order to assist fault finding the boiler has an LED diagnostic display. The key to the display codes is as follows:

ALTERNATING 'H9' GO TO FRAME 76

ALTERNATING 'L9' GO TO FRAME 76

46 icos - Installation & Servicing

FAULT FINDING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

L.....F....... (FLAME ERROR)

Check the ignition electrode and associated harness for:

continuity, visual condition, position

(Refer to Frame 56).

Are these functioning correctly ?

Check gas valve

wiring for

continuity

YES

Check the detection electrode and

associated harness for:

continuity, visual condition, position

(Refer to Frame 57).

Replace as necessary.

If the boiler reset button is

pressed does the boiler ignite for

a short time then extinguish?

Is 200V DC supply available

at the gas valve ?

YES

Is gas pressure available at

the boiler inlet ?

Replace PCB

Check gas supply

and rectify fault

Replace ignition electrode and associated

harness as necessary

Replace gas valve

YES

L.....E...... or H.....E...... (BOARD ERROR)

Internal fault within the PCB

Replace PCB

Note. Due to the wave form of the rectified voltage the reading will vary, depending on the type of meter used to

measure the value (some may measure the possible peak voltage of 339V). In general terms, a reading greater

than 150V indicates that the correct voltage is supplied to the gas valve. As an alternative to a multimeter a

mains checking device may be used. E.g. an electrical screwdriver or a mains tester.

Check spark generator and associated

harness for continuity and visual condition.

Refer to Frame 58. Are these functioning

correctly?

Replace

spark generator

YES

Press and hold reset button for 2

seconds. Does boiler operate

correctly?

Turn boiler off and wait for 5

seconds.Turn boiler on.

Does boiler operate correctly?

YES

YES OK

Check syphon

and condensate

drain pipework

for blockage

Check for an excess voltage between neutral

and earth. Is the value below 50V?

LE ONLY: Check continuity of OH thermostat.

Is this correct?

HE ONLY: Check earth wire is connected to

detection lead. Is this correct?

Check all earths for continuity

YES

Check earth connection to the boiler. If value is still in

excess of 50V consult a Qualified Electrician to check the

household electrical supply and circuitry

Correct wiring or replace thermostat

Correct wiring or replace detection lead

Correct connections

icos - Installation & Servicing

FAULT FINDING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

Does the pump setting give a differential

across the boiler in excess of 25 oC ?

Can the overheat condition be reset by pressing

the boiler reset button when the system is cold ?

YES

L.......A........ (OVERHEAT ERROR)

Fill and vent the system and open all

isolation valves

Is the boiler and CH system filled with

water and all isolation valves open ?

NO Replace overheat thermostat

L....8..... (FAN ERROR)

Is nominal 330 V DC present across

red and blue at the fan connector as

reset button is pressed?

Replace fan

YES

Replace harness

H.....1..... (FLOW THERMISTOR ERROR)

YES

Is there continuity between the

PCB and the thermistor ?

Check resistance, using a suitable multimeter

connected across the thermistors terminal pins

At 25 oC expect 9,700 - 10,300 Ohms

At 60 oC expect 2,400 - 2,600 Ohms

At 85 oC expect 1,000 - 1,100 Ohms

Remove the boiler flow thermistor from the CH flow

pipe and disconnect thermistor wires.

Are the thermistor values correct ? Replace the thermistor

YES Replace PCB

Check and replace wiring as necessary

Replace PCB

YES Is 14V DC present

across yellow and pink

at the fan connector?

Check wiring harness for continuity. Is there continuity?

YES

Replace the system pump

Increase the pump setting.

Is differential now below 25 oC ?

YES

NO YES

Set CH control knob to maximum.

If the overheat trips again measure the flow temp:

Over 90 oCCheck control thermistor

(Refer to Frame 71) .

Under 90 oCReplace overheat 'stat

Note.

With V9 Primary Control PCB, overheat LA/HA or H9/L9 when

reset will display 3 horizontal lines and will not attempt to refire

until the temperature in the heat exchanger drops below 50oC.

48 icos - Installation & Servicing

FAULT FINDING

FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING

H......F........ (FLAME DETECTION - SHORT CIRCUIT ERROR)

Replace flame detection electrode

Is there continuity between the 2 terminal pins ? Replace PCB.

YES

H.....4...... (FLUE THERMISTOR ERROR)

Check wiring for continuity from the

PCB to the flue thermistor

Can the fault condition be reset by switching

off the mains supply to the boiler ?

Is the system filled and vented and all

isolation valves open ?

Is the pump operating correctly? Ensure

flow through system.

Check resistance, using a suitable multimeter

connected across the thermistor terminal pins.

At 25 oC expect 9,700 - 10,300 Ohms

At 60 oC expect 2,400 - 2,600 Ohms

At 85 oC expect 1,000 - 1,100 Ohms

Are thermistor values correct ?

Replace PCB Replace thermistor

Fill and vent the

system and open all

isolating valves

YES

Check resistance, using a suitable multimeter

connected across the flue thermistor terminal

pins.

At 25 oC expect 9,700 - 10,300 Ohms

At 60 oC expect 2,400 - 2,600 Ohms

At 85 oC expect 1,000 - 1,100 Ohms

Are thermistor values correct ?

Inspect heat

exchanger for

blockage or damage

in the flueways.

Clean or replace as

necessary

Replace thermistor

H......n........ (PHASE REVERSAL ERROR)

Check wiring to the boiler for

reversed live and neutral

YES NO

Remove flame detection electrode terminal from PCB.

H9/L9 (HEAT EXCHANGER OVERHEAT)

Note.

With V9 Primary Control PCB, overheat LA/HA or H9/L9 when

reset will display 3 horizontal lines and will not attempt to refire

until the temperature in the heat exchanger drops below 50oC.

icos - Installation & Servicing

SHORT LIST OF PARTS

The following are parts commonly required due to damage or

expendability. Their failure or absence is likely to affect safety or

performance of this appliance.

The list is extracted from the British Gas List of Parts, which

contains all available spare parts.

The full list is held by British Gas Services, Ideal Stelrad Group

distributors and merchants.

When ordering spares please quote:

1. Boiler Model

2. Appliance G.C. Number

3. Description

4. Quantity

5. Product Number

1 Front casing panel 1 173 508

4 E67-482 Bottom casing panel 1 170 900

11 E67-489 Burner 1 170 905

12 Combustion chamber insulation 1 173 520

14 E67-492 Injector and housing HE15, HE18, HE24 1 170 908

H18-545 Injector and housing HE12 1 173 779

16 E85-097 Fan assembly 1 172 625

19 E67-497 Gas control valve 1 170 913

22 E67-500 Flue thermistor 1 170 916

23 E67-501 Control thermistor 2 170 917

24 E67-502 Overheat thermostat 1 170 918

25 Ignition electrode kit 1 173 528

26 Flame detection electrode and gasket 1 173 529

32 E67-511 Condensate ‘S’ trap 1 170 926

34 E65-515 Controls hinge bracket kit 1 170 928

35 User controls 1 173 532

36 PCB primary controls kit (V9) 1 174 486

37 E67-519 Fuse PCB (3.15A L 250V) 1 170 931

39 Main switch c/w harness 1 173 537

45 E65-527 Gasket kit 1 170 938

52 E68-376 Seal kit - sealing panel 1 171 014

53 E68-380 Turret gasket 1 171 022

40 Spark generator 1 173 538

94 Ignition lead 1 173 510

95 Detection lead 1 173 511

Key No. GC Part No. Description Qty. Product No.

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.

50 icos - Installation & Servicing

SHORT LIST OF PARTS

nm8077

SHORT LIST

BOILER CASING ASSEMBLY

1. Front casing panel with screws.

2. Sealing panel with screws.

4. Bottom casing panel with screws.

icos - Installation & Servicing

BURNER ASSEMBLY

Ecl 1598

11. Burner assembly with screws

and gasket.

LIST OF PARTS

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. Mains switch.

54. Jumper link.

52 icos - Installation & Servicing

NOTES

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 2005.

Competent Person's

SELF CERTIFICATION SCHEME BUILDING CONTROL

Install and commission

this appliance to

manufacturers' instructions

Complete the

Benchmark Checklist

Choose

Buildings Regulations

notification route

Contact your relevant

Local Authority

Building Control (LABC) who

will arrange an inspection

or contact a government

approved inspector

LABC will record the data

and will issue a

certificate of compliance

If you notify via CORGI Scheme,

CORGI will then notify the

relevant Local Authority Building

Control (LABC) scheme

on members behalf

Scheme members only:

Call CORGI on 0870 88 88 777

or log onto:

www.corgi-notify.com

within 10 days

You must ensure that the

notification number

issued by CORGI is written

onto the Benchmark Checklist

CORGI will record the data and

will send a certificate of

compliance to the property

IT IS A CONDITION OF THE

MANUFACTURERS WARRANTY

THAT THE BENCHMARK

COMMISSIONING CHECKLIST IS

FULLY COMPLETED AND LEFT

WITH THE APPLIANCE

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. The

right is therefore reserved to vary specification without notice.

The Ideal Boilers Technical Training Centre offers a series

of first class training courses for domestic, commercial and

industrial heating installers, engineers and system

specifiers.

For details of courses please ring: ............. 01482 498 432

CERTIFIED PRODUCT

Manufactured under a BS EN ISO 9001:

2000 Quality System accepted by BSI

The code of practice for the installation,

commissioning & servicing of central heating systems

deal Installer/Technical Helpline: 01482 498 663

www.idealboilers.com

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, HE15, HE18, HE24

For installation guide see reverse of book

2icos - Users

Introduction

The icos is a wall mounted, room sealed, super efficient

condensing boiler featuring full sequence automatic spark

ignition and fan assisted combustion.

Due to the very high efficiency, condensate is produced from

the flue gases and this is drained to a suitable disposal point

through the plastic waste pipe at the right lower rear of the

boiler. A condensate 'plume' will also often be visible at the

flue terminal.

Safety

Current Gas Safety (Installation & Use)

Regulations or rules in force.

In your own interest, and that of safety, it is the law that this boiler

must be installed by a CORGI registered installer.

In IE the installation must be carried out by a competent person

and installed in accordance with the current edition of I.S. 813

“domestic Gas Installations”, the current Building Regulations

and reference should be made to the current ETCI rules for

electrical installation.

It is essential that the instructions in this booklet are strictly

followed, for safe and economical operation of the boiler.

Electricity Supply

The appliance must be earthed.

Supply 230 V - 50 Hz. The fusing should be 3A.

This appliance is intended to be connected to the supply via a

double-pole switch, having a 3mm contact separation in both

poles, serving only the boiler and system controls. Alternatively,

a 3-pin UNSWITCHED socket may be used.

Important Notes

zThis appliance must not be operated without

the casing correctly fitted and forming an adequate seal.

zIf the boiler is installed in a compartment then the compartment

MUST NOT be used for storage purposes.

zUnder NO circumstances should any of the sealed components

on this appliance be used incorrectly or tampered with.

zIf it is known or suspected that a fault exists on the boiler

then it MUST NOT BE USED until the fault has been

corrected by a CORGI registered installer or in IE a

competent person.

Destination Countries: GB, IE

icos HE12, HE15, HE18, HE24

(Natural Gas Only)

HE12 G.C. Appliance No. 41-397-95

HE15 G.C. Appliance No. 41-397-83

HE18 G.C. Appliance No. 41-397-84

HE24 G.C. Appliance No. 41-397-85

zThis appliance is not intended for use by persons (including

chilcren) with reduced physical, sensory or mental

capabilities, or lack of experience and knowledge, unless they

have been given supervision or instructions concerning use

of the appliance by a person responsible for their safety.

zChildren should be supervised to ensure that they do not play

with the appliance.

In cases of repeated or continuous shutdown a CORGI

registered installer or in IE a competent person should be called

to investigate and rectify the condition causing this and carry out

an operational test after each intervention on the device. Only the

manufacturers original parts should be used for replacement.

Minimum Clearances

Clearances of 165mm (6 1/2") above, 100mm (4") below, 5mm

(1/4") at the sides and 450mm (17 3/4") at the front of the boiler

casing must be allowed for servicing.

The minimum front and bottom clearance allowed when built into

a cupboard is 5mm.

To light the boiler (Refer to Frame 1)

1. CHECK THAT THE ELECTRICITY SUPPLY TO THE BOILER

IS OFF.

2. Set the mains on/off switch (A) to off and the CH thermostat

knob (C) to maximum.

3. Switch on the electricity supply to the boiler and check that all

external controls, e.g. programmer, room thermostat, etc are on.

4. Set the mains on/off switch to ON.

The boiler will commence the ignition sequence, supplying heat

to the system when required.

Operation

In normal operation the control unit display (F) will show the

codes:

O - Standby (no demand for heat)

C - CH or DHW being supplied.

During ignition the LED (E) will flash.

During normal running the LED will remain illuminated.

Note. If the boiler fails to light after 3 attempts the fault code 'L' 'F'

will be displayed.

Press and hold the reset button for 2 seconds then release. The

boiler will repeat the ignition sequence. If the boiler fails to light

consult a CORGI registered installer or in IE a competent person.

All CORGI registered installers carry a CORGI ID card, and have a registration number. Both should be recorded

in the Benchmark Commissioning Checklist. You can check your installer by calling CORGI direct on 01256 372300.

THE BENCHMARK SERVICE INTERVAL RECORD MUST BE COMPLETED AFTER EACH SERVICE

Ideal Stelrad Group is a member of the Benchmark initiative and fully supports the aims of

the programme. Benchmark has been introduced to improve the standards of installation and

commissioning of central heating systems in the UK and to encourage the regular servicing of

all central heating systems to ensure safety and efficiency.

icos - Users

Control of water temperature

The boiler controls the central heating radiator temperature to a

maximum of 820C, adjustable via the CH thermostat knob (C).

Approx CH flow temperatures for the boiler thermostat settings

are:

Knob Setting Flow Temperature

o Co F

Minimum 30 86

Maximum 82 180

To shut down the boiler

1. For short periods

Set the mains on/off switch (A) to OFF.

2. For longer periods

Set the mains on/off switch (A) to OFF. Switch the electricity

supply to OFF. For longer periods the entire system should be

drained, inlcuding the domestic hot water supply.

To relight the boiler

Repeat the procedure detailed in 'To light the boiler'.

Frost Protection

If no frost protection is provided and frost is likely during a short

absence from home leave the heating controls (if fitted) at a

reduced temperature setting.

For longer periods the entire system should be drained.

If the system includes a frost thermostat then,during cold

weather, the boiler should be turned OFF at the time switch (if

fitted) ONLY. The mains supply should be left switched ON, with

the boiler thermostat left in the normal running position.

Boiler Overheat Thermostat

This thermostat will shut down the boiler in the event of

overheating. Should this occur a fault code 'L' 'A' will be

displayed. Press the reset button (D) and the boiler will relight.

If the fault recurs turn off the boiler and consult a CORGI

registered installer or in IE a competent person.

Flame failure

Should this occur a fault code L-F will be displayed. Press the

reset button and the boiler will relight. If the fault recurs, turn off

the boiler and consult a CORGI registered installer or in IE a

competent person.

Condensate Drain

The condensate drain must not be modified or blocked.

Blockage of the condensate drain, caused by debris or freezing,

can cause automatic shutdown of the boiler.

If freezing is suspected and the pipe run is accessible an attempt

may be made to free the obstruction by pouring hot water over the

exposed pipe and clearing any blockage from the end of the pipe.

If this fails to remedy the problem the assistance of a CORGI

registered installer or in IE a competent person should be sought.

Escape of gas

Should a gas leak or fault be suspected contact your local gas

supplier without delay.

Do NOT search for gas leaks with a naked flame.

Cleaning

For normal cleaning simply dust with a dry cloth.

To remove stubborn marks and stains use a damp cloth and mild

detergent.

DO NOT use abrasive cleaning materials.

Maintenance

The appliance should be serviced at least once a year by a CORGI

registered installer or in IE a competent person.

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.

Legend

ABoiler on/off switch

CCH thermostat knob

DReset button

ELED

FDisplay

GCondensate drain

1 BOILER CONTROLS

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 specification without notice.

Ideal Consumer Helpline

Tel: 01482 498660

www.idealboilers.com

POINTS FOR THE BOILER USER

Note. In line with our current warranty policy we would ask that you check through the following guide to identify any

problems external to the boiler prior to requesting a service engineers visit. Should the problem be found to be other than

with the appliance we reserve the right to levy a charge for the visit, or for any pre-arranged visit where access is not gained

by the engineer.

TROUBLESHOOTING - TYPICAL NON PRODUCT FAULTS

Problem Solution

Boiler is not working for

central heating or hot water.

• Check there is power to the boiler – switch (A) in the ON position and ‘

’ displayed on the

controls.

• If ‘

’ not displayed then not a boiler fault – contact your installer/service company.

• Check external programmer is set to an ‘ON’ period and the relevant function selected i.e.

central heating or domestic hot water. Test by overriding the programmer by setting to

‘continuous.

• Check room thermostat for central heating or the cylinder thermostat for domestic hot water,

are set at the required temperature. To test operation of either thermostat turn fully up. If no

response contact your installer.

Boiler is not working for

central heating or hot water

and the display shows ‘

L:A L:A

L:A

’

(flashing).

• Press reset button (D) for 2 seconds, the boiler should then re-light. If fault recurs this

indicates an overheat condition. The boiler should be turned off and your installer contacted.

• Check if ALL radiators have thermostatic radiator valves fitted. If they have contact your

installer.

Boiler is not working for

central heating or hot water

and the display shows ‘

H:A H:A

H:A

’

(flashing).

• Check if ALL radiators have thermostatic radiator valves fitted. If they have contact your

installer.

Boiler is not working for

central heating or hot water

but attempts to fire by going

through 3 ignition attempts.

Display shows ‘

L : F L : F

L : F

’ (flashing).

• Press reset button (D) for 2 seconds to repeat ignition sequence.

• Check gas supply (try another appliance – cooker/fire etc.) – If no gas supply then not a

boiler fault – contact gas supplier.

• Check condensate pipe is not blocked or frozen. If blocked, clear blockage – if not possible

to check contact your installer.

Ideal Industries Icos He12 Users Manual 203318 4.pmd

HE24 to the manual e8d22608-b50f-421d-8cf9-0b76595e2938

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