Ideal Boilers icos system m3080 User manual

2icos system condensing - Installation and Servicing
GENERAL
Gas supply 2H-G20-20mbar
Gas Supply Connection 22mm copper
Injector size Stereomatic 5.6mm dia.
Flow Connection Central Heating 22mm copper
Return Connection Central Heating 22mm copper
Flue Terminal Diameter mm (in) 100 (4)
Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.65 (38.5)
Electrical Supply / Power consumption 230 V ~ 50 Hz. / 148 W
Fuse Rating External : 3A Internal : 3.15A TL 250V
Water content Central Heating litre (gal) 2.0 (0.44)
Packaged Weight kg (lb) 47 (103)
Maximum Installation Weight kg (lb) 40 (88)
Boiler Casing Size Height mm (in) 687 (27)
Width mm (in) 390 (15 3/8)
Depth mm (in) 278 (11)
Table 1 - General Data
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)
Table 2 - Performance Data - Central Heating m3080
Boiler Input :
Nett CV kW
(Btu/h)
Gross CV kW
(Btu/h)
Gas Consumption l/s
(ft3/h)
Boiler Output :
Non Condensing kW
(Btu/h)
Condensing kW
(Btu/h)
Key to symbols
IE = Ireland (Countries of
GB = United Kingdom destination)
PMS = Maximum operating pressure of water
C13C33C52 = 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.
*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.
Max.
24.4
(83 300)
27.1
(92 500)
0.70
(89.1)
23.4
(80 000)
25.1
(85 700)
Min.
9.1
(31 000)
10.1
(34 400)
0.26
(33.2)
8.8
(30 000)
9.6
(32 800)
Seasonal efficiency (SEDBUK)* Band A [90.2]%
NOx Classification Class 4

3
icos system condensing - Installation and Servicing
GENERAL
CONTENTS
Air Supply ....................................................................... 7
Boiler Clearances ......................................................... 6
Boiler Exploded Diagram ...................................... 10, 11
Condensate Drain ......................................................... 8
Electrical Connections ............................................... 22
Electrical Supply ........................................................... 8
Extension Ducts - Fitting ............................................. 18
Fault Finding ....................................................... 45 to 50
Flow Wiring Diagram .................................................. 25
Flue Fitting
Rear outlet.............................................................. 13
Side outlet .............................................................. 13
Flue Installation ............................................................. 7
Gas Safety Regulations ................................................ 5
Gas Supply ..................................................................... 7
Installation ......................................................... 11 to 28
Mandatory Requirements ................................... 5 to 10
Pump .......................................................................... 42
Servicing ............................................................ 29 to 44
Short List of Parts ....................................................... 48
Thermostatic Radiator valves ..................................... 8
Water and Systems ............................................ 8 to 10
Water Connections ..................................................... 19
Water Treatment ......................................................... 10
Wiring Diagrams ............................................... 22 to 25
icos system
Natural Gas only
G.C. Appliance No. 41-391-52
PI No.0063BM9802
Destination Countries: UK, IE
NOTE TO THE INSTALLER: LEAVE THESE
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK
AND GIVE THIS TO THE CUSTOMER.
BENCHMARK LOG BOOK DETAILS
Boiler Page
Make and model .......................................................3
Appliance Serial No. on Data Badge ....................... 3
Controls ............................................... as applicable
For all boilers
Flushing to BS.7593 ........................................ 8 & 27
Inhibitor ..................................................................... 8
Gas inlet working pressure ...................................... 7
Burner operating pressure ................. Not applicable
Heat input .......................................... to be calculated
Temperature differential .......... measure and record
For combination boilers only ................... Not applicable
For domestic hot water mode ................. Not applicable
For condensing ............................................................ 20
For all boilers: complete, sign & hand over to customer
For assistance see Technical Helpline on the back page

4icos system condensing - Installation and Servicing
GENERAL
1 BOILER WATER CIRCUIT DIAGRAM
INTRODUCTION
The icos system m3080 boiler is a fully automatically
controlled wall mounted, low water content, fanned flue
condensing gas boiler.
Note. Due to the high efficiency of the boiler a plume of water
vapour will form at the terminal during operation.
The output is fully modulating with a range of:
8.8 to 23.4kW (30,000 to 80,000 Btu/h)
The boiler is supplied fully assembled with circulating pump,
pressure gauge, safety valve and expansion vessel.
Variable temperature control is fitted on the user control.
The boiler casing is of white painted zintec coated mild steel.
The boiler temperature controls are visible at the bottom RHS
of the front panel.
The heat exchanger is of aluminium.
The boiler is suitable for connection to fully pumped, sealed
water systems ONLY.
The system pipework MUST include drain cocks in appropriate
places.
Pipework from the boiler is routed downwards as standard, but
may be routed upwards behind the boiler using the stand-off
frame (supplied in a separate kit).
Expansion
vessel
Automatic
air vent
Heat
engine
Gas valve
Pump
Safety
relief valve
Condensate
's' trap
Water
pressure
gauge
Sump
Fan
Burner
Flow
Gas
Condensate drain
Discharge pipe
Ecl 2063
Return
OPERATION
When there is a demand for heat, the heating system is
supplied at the selected temperature of between 42oC and
82oC.
Refer also to Frame 1 - 'Boiler Water Circuit Diagrams'
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.
OPTIONAL EXTRA KITS
zFlue Extension Ducts Pack D up to 3m (122in).
zFlue Elbow Kit 90 degree pack.
zFlue Elbow Kit 45 degree pack (2 per pack).
zPowered Vertical Flue Kit (to a maximum primary flue
length of 4m + a maximum secondary flue length of 5m)
zRoof Flue Kit (to a maximum of 5m)
zRemote User Controls Kit
zBoiler Stand-off Kit
zSiphon Kit
zConcealment Panel Kit
zFlue Finishing Kit

5
icos system condensing - Installation and Servicing
GENERAL
SAFETY
Current Gas Safety (installation and use) regulations or rules
in force.
It is law that all gas appliances are installed and serviced by a
CORGI registered installer in accordance with the above
regulations. Failure to install appliances correctly could lead to
prosecution. It is in your own interest, and that of safety, to
ensure the law is complied with.
The installation of the boiler MUST also be in accordance with
the latest I.E.E (BS.7671) Wiring Regulations, local building
regulations, bye-laws of the local water authority, the building
regulations and the Building Standards (Scotland) and any
relevant requirements of the local authority.
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 Caradon Ideal Limited in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by
Caradon Ideal Limited could invalidate the certification and the
normal appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.
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 AND FLUE OUTLET
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 available
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.
Where installation will be in an unusual location, special
procedures may be necessary and BS.6798 gives detailed
guidance on this aspect.
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 or 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.

6icos system condensing - Installation and Servicing
GENERAL
Ecl 2064
390 (15 3/8")
Flue
terminal
687
(27")
278 (11")
5 (1/4")
100 (4") *
400 (15 3/4")
5 (1/4")
165
(6 1/2")
Inset A Water Connections and Gas Connection
See inset A above
CLEARANCES BOILER DIMENSIONS
43
A
Flow
Gas Control
Return
Flow
Gas Control
Condensate
Drain
Return
Centre
line of
boiler
112 49 123
2 BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in)
The boiler connections are made on the boiler piping frame.
Refer to Frame 17.
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
a. Provided 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.
* Bottom clearance
Bottom clearance after installation can be reduced to 5mm.
However, 100mm must be available for servicing.

7
icos system condensing - Installation and Servicing
GENERAL
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 4.
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.
Terminals guards are available from boiler suppliers. In
case of difficulty seek advice from:
Grasslin (UK) Ltd.,
Vale Rise, Tonbridge, Kent TN9 1TB
Telephone No. 01732 359 888
Ensure that the guard is fitted centrally.
5. Where the terminal is fitted within 850mm (34") of a plastic
or painted gutter or 450mm (18") of painted eaves then an
aluminium shield at least 750mm (30") long should be
fitted to the underside of the gutter or painted surface fitted
centrally above the flue.
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: Part 1, 2000.
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.
TERMINAL
The terminal assembly can be adapted to accommodate
various wall thicknesses. Refer to Frame 8 - Unpacking.
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.
WATER CIRCULATION SYSTEM
The central heating system should be in accordance with BS.
6798 and, in addition, for smallbore and microbore systems,
BS. 5449.
Draining taps MUST be located in accessible positions, which
permit the draining of the whole system. They should be at
least 1/2" BSP nominal size and be in accordance with BS
2879.
WATER TREATMENT - see Frame 6
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 registered CORGI engineer.
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. A minimum working gas pressure
of 20 mbar should be available at the boiler inlet.
Do not use pipes of a smaller size than the boiler inlet gas
connection.
IMPORTANT.
Installation pipes MUST be fitted in accordance with BS. 6891.
Pipework from the meter to the boiler MUST be 22mm 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 where possible, terminal
positions where this could cause a nuisance should be
avoided.
The flue must be installed in accordance with the
recommendations of BS. 5440: Part 1, 2000.
The following notes are intended for general guidance:
1. The boiler MUST be installed so that the terminal is
Table 4 - Balanced flue terminal position
Terminal Position
Minimum Spacing
1. Directly below or alongside an
opening window, air vent or other
ventilation opening 300 mm (12")
2. Below guttering, drain pipes or soil
pipes 75 mm ( 3")
3. Below eaves 200 mm ( 8")
4. Below balconies or a car port roof 200 mm ( 8")
5. From vertical drain pipes or soil pipes 150 mm ( 6")
6. From internal or external corners 300 mm ( 12")
7. Above adjacent ground, roof or
balcony level 300 mm (12")
8. From a surface facing the terminal 600 mm (24")
9. From a terminal facing a terminal 1200 mm (48")
10. From an opening in a car port
(e.g. door or window) into dwelling 1200 mm (48")
11. Vertically from a terminal on the
same wall 1500 mm (60")
12. Horizontally from a terminal on the wall 300 mm (12")

8icos system condensing - Installation and Servicing
GENERAL
3 SYSTEM REQUIREMENTS
Notes
a. The method of filling, refilling, topping up or flushing
sealed primary hot water circuits from the mains via
a temporary hose connection is only allowed if
acceptable to the local water authority.
b. Antifreeze fluid, corrosion and scale inhibitor fluids
suitable for use with boilers having aluminium heat
exchangers may be used in the central heating
system.
Advice should be sought from a local water
treatment company.
THERMOSTATIC RADIATOR VALVES (TRV)
Caradon Ideal Limited 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.
When thermostatic radiator valves are used, the space heating
temperature control over a living area having a heating
requirement of at least 0.9kW (3000Btu/h) of the boiler heat
output should be achieved using a room thermostat whilst
other rooms are individually controlled by thermostatic radiator
valves. A higher proportion of TRVs may be used, provided that
a bypass between the boiler flow and return is fitted, to ensure
adequate flow when all TRVs are closed - however this is NOT
recommended as a large proportion of TRVs can restrict water
circulation and inhibit the condensing mode of condensing
boilers, reducing fuel economy.
For further information refer to the 'Good Practice Guide 143', a
publication of the Energy Efficiency Office, available from the
Building Research Establishment, Garston, Watford WD2 7JR.
Tel: [phone].
ELECTRICAL SUPPLY
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.
The point of connection to the mains should be readily
accessible and adjacent to the boiler.
CONDENSATE DRAIN - Refer to Frames 28, 48
A condensate drain is provided on the boiler. This drain must
be connected to a drainage point on site. 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 3/4in (21.5mm)
overflow pipe.
Safety valve setting bar 3.0
Vessel charge pressure bar 0.5 to 0.75
System pre-charge pressure bar None 1.0
System volume Expansion vessel
(litres) volume (litres)
25 1.6 1.8
50 3.1 3.7
75 4.7 5.5
100 6.3 7.4
125 7.8 9.2
150 9.4 11.0
175 10.9 12.9
190 11.9 14.0
200 12.5 14.7
250 15.6 18.4
300 18.8 22.1
For other system volumes
multiply by the factor across 0.063 0.074
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
Graph 1 - Water flow rate and pressure loss
The hydraulic resistance of the boilers, at
MAXIMUM OUTPUT , with
an 11oC (20oF) temperature differential, is shown in Graph 1.

9
icos system condensing - Installation and Servicing
GENERAL
General
1. The installation must comply with all relevant national and
local regulations.
2. The installation should be designed to work with flow
temperatures of up to 82 0C.
3. All components of the system must be suitable for a working
pressure of 3 bar and temperature of 110 0C. Extra care
should be taken in making all connections so that the risk of
leakage is minimised.
The following components are incorporated within the
appliance:
a. Circulating pump.
b. Safety valve, with a non-adjustable preset lift pressure
of 3 bar.
c. Pressure gauge, covering a range of 0 to 6 bar.
d. A 8-litre expansion vessel, with an initial charge pressure
of 0.75 bar.
4. '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 150mm above the highest point of the system and
be connected through a non-return valve to the system,
fitted at least 150mm below the 'make-up' vessel on the
return side of the radiators.
or
b. Where access to a 'make-up' vessel would be difficult,
by pre-pressurisation of the system.
The maximum cold water capacity of the system
should not exceed 143 litres, if not pressurized.
However, if the system is to be pressurized, the
efficiency of the expansion vessel will be reduced and
a larger vessel (or smaller system volume) may be
necessary. If the capacity of the vessel is not
considered sufficient for this, or for any other reason,
an additional vessel MUST be installed on the return
to the boiler.
Guidance on vessel sizing is given above.
4 SYSTEM REQUIREMENTS (continued)
5. Filling. The system may be filled by the following method:
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
must be used to facilitate filling.
i. Thoroughly flush out the whole system with
cold water.
ii. Fill and vent the system until the pressure gauge
registers 1.5 bar, and examine for leaks.
iii. Check the operation of the safety valve by
raising the water pressure until the valve lifts. This
should occur within 0.3 bar of the preset lift pressure.
iv. Release water from the system until the
minimum system design pressure is reached;
1.0 bar if the system is to be pre-pressurised.
C.H. Return
Stop valve
Double check
valve assembly
Test cock
Ecl 2002
Hose unions
Mains
water supply
Temporary hose
(disconnect after filling)

10 icos system condensing - Installation and Servicing
GENERAL
The boiler does not normally need a bypass but at least
some radiators on the heating circuit, of load of 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 note regarding thermostatic radiator on
pages 8.
Note.
Systems incorporating zone valves which could completely
cut off the flow through the system, must be wired such that
the boiler will not fire or continue to fire when this occurs.
5 SYSTEM BALANCING BALANCING
1. Set the programmer to ON.
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 the remaining
radiators, to give around 11 oC temperature drop at
each radiator.
3. Adjust the room thermostat and programmer to
NORMAL settings.
6 WATER TREATMENT
The icos boiler has an ALUMINIUM alloy heat exchanger
IMPORTANT.
The application of any other treatment to this product may render the guarantee of Caradon Plumbing invalid.
If water treatment is used Caradon Ideal Limited recommend only the use of FERNOX-COPAL or SENTINEL X100 water
treatment products, which must be used in accordance with the manufacturers' instructions. For further information contact:
Fernox Manufacturing Co. Ltd.
Sentinel Division
Betz Dearborn Ltd., Widnes, Cheshire, WA8 8UD
Tel: [phone]
Tandem House, Marlowe Way, Croydon, Surrey, CRO
4XS
Tel: [phone]
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.
13. Heat engine.
14. Injector assembly.
15. Venturi assembly.
16. Fan assembly.
17. Automatic air vent.
18. Gas service cock.
19. Gas valve.
20. Fan bracket.
21. Orifice plate.
22. Dry fire thermostat.
23. Control thermistor.
1. Front panel.
2. Boiler sealing panel.
3. Sump cover.
4. Bottom panel.
5. Flue sensing nipple.
6. Return pipe.
8. Flue manifold.
9. Flue manifold fixing.
10. Interpanel.
11. Burner.
12. Comb. Chamb. insulation.
7 BOILER ASSEMBLY - Exploded View Legend
24. Overheat thermostat.
25. Ignition electrode.
26. Flame sensing electrode.
32. Condensate 's' trap.
35. User control.
36. Primary controls (PCB).
39. Mains switch.
42. Sightglass.
44. Piping frame.
51. Mains connector.
53. Turret seal.
57. CH return stub.
58. CH flow stub.
61. Pressure relief valve.
62. Expansion vessel.
63. Exp. vessel pipe assy.
64. Pressure gauge.
69. Pump.
70. Pump manifold.
75. Control box clamp

11
icos system condensing - Installation and Servicing
INSTALLATION
7 BOILER ASSEMBLY - Exploded View
44
5
53
8
14
13
21
62
64
4
2
63
1
61
70
69
35
36
24
23
32
17
12
20
11
26
25
42
19
6
58
Ecl 2065
16 15
22
9
10
39
75
51
57
3
18
INSTALLATION

12 icos system condensing - Installation and Servicing
INSTALLATION
8
UNPACKING
The boiler is supplied fully assembled in one Pack A,
together with a standard flue assembly for lengths up to
460mm, rear or side flue outlet, in Pack B.
Optional extras, if ordered, are available in separate boxes.
Unpack and check the contents.
Hardware Pack
z50mm x No.10 wood screws -
3 off.
zWall plugs (TP2B ) - 3 off.
zWater treatment warning
label.
zTurret clamp.
zM5 x 10 pozi Hex screw.
z22mm compression nut and
olive - 2 off.
zSafety drain pipe nut and
olive.
zFlow isolating valve c/w
pressure gauge.
z22mm fibre washers - 2 off.
Pack A Contents
Also contained in Pack A:
zHardware Pack (listed below).
zThese Installation & Servicing Instructions.
zThe User's Instructions.
zThe User Control.
zBenchmark log book.
1. Ensure the boiler is stood correctly as marked on the
carton.
2. Remove the strapping.
3. Fold back the top flaps to gain access to the wall
mounting plate, instructions, hardware pack and
user control.
4. Remove the instructions and read thoroughly before
unpacking the product. Unpack the user’s control
and hardware pack and retain in a safe place.
5. When ready for installation lift off the cardboard
carton.
6. Dispose of packaging.
9 PACKAGING REMOVAL
Pack B Contents
Flue turret.
Flue terminal.
Flue support cutting aid - 1 off.
2066
Ecl1460
Flue terminal
Flue turret assembly
2006
INSTALLATION

13
icos system condensing - Installation and Servicing
INSTALLATION
FLUE KITS
Pack B - supplied as standard
Pack D - optional extension kit for side flue
or rear flue outlet.
Refer to 'Flue Extension Ducts'
10 BOTTOM PANEL AND FRONT 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 kit depth = 33mm.
1. Undo the 4 retaining screws.
2. Allow the RHS of the bottom panel to lower slightly.
3. Withdraw the LHS of the bottom panel from the retaining
clips.
4. Lift front panel and remove.
5. Place bottom and front panel to one side to avoid
damage.
11 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED
Notes.
1. 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 boiler is to be installed with upward
piping routed behind the boiler then the
optional stand-off kit should be used. Care
must be taken when cutting the ducts and
marking wall to suit this condition.
Total Flue length dimension Flue
Rear flue Side Extra packs
dim. X+160 flue dim. L+195 required
Up to 480 mm Up to 480 mm none
Up to 1430 mm Up to 1430 mm Pack D - 1 off
Up to 2380 mm Up to 2380 mm Pack D - 2 off
Up to 3000 mm Up to 3000 mm Pack D - 3 off
2008
160mm
160 + S = 193mm
2067
Bottom panel
Front panel
Retaining clip
Note.
Powered Vertical Flue and
Roof Flue Kits are
available as optional extras
for vertical flue installations,
supplied with separate
fitting instructions.
INSTALLATION

14 icos system condensing - Installation and Servicing
INSTALLATION
2009
2
1
3
45
Note.
The template shows the positions of the fixing holes and
the flue hole centres for standard installation and for using
the stand-off. Care Must be taken to ensue the correct
holes are drilled.
1. Tape template into the selected position.
2. Ensure squareness by hanging a plumbline as shown. If
fitting a side flue extend the flue centre line onto the side
wall.
3. Mark onto the wall the following:
aThe piping frame screw positions (choose one from
each group).
b. The position of the flue duct hole.
Note. Mark the centre of the hole as well as the
circumference
4. Remove the template from the wall.
13 WALL MOUNTING TEMPLATE
12 FLUE ASSEMBLY - Exploded View
LEGEND
1. Duct assembly.
2. Flue Turret.
3. Turret seal.
4. M5 x 10 pozi screw.
5. Turret clamp.
1. An optional flue duct extension kit is required
for wall thicknesses greater than :
Side 300mm (11 3/4").
Rear 345mm (13 1/2").
Rear flue arrangement shown
Note.
Side flue only. If the system pipework is to be routed
up behind the boiler. The upward routing pipework
frame supplied as a separate kit MUST be used
secured to the piping frame. It is essential to use the
wall mounting template to mark the holes to be
drilled. Care MUST be taken to ensure the correct
holes are drilled.
V
2010
See wall mounting plate
18 31 44 57 70 83
2035
INSTALLATION

15
icos system condensing - Installation and Servicing
INSTALLATION
2011
X
Section
through wall
Note. Check all of the hole
positions before drilling.
Side flue only
5" diameter hole
Rear flue only
5" diameter hole
14 PREPARING THE WALL
Note. If the terminal is to be sited within 25-40mm of a corner or
vertical pipe then the hole MUST be accurately cut.
WARNING. 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 4 holes with a 7mm (1/4") masonry drill and insert
the plastic plugs provided, for the piping frame.
3. Locate 4 No.10 x 2" screws in the wall mounting plate
(one at each side, in any of the 3 holes provided at each
side) and screw home.
15 CUTTING THE FLUE - REAR Wall thicknesses of 114 to 345mm
Note.
a. If using the extension ducts go to Frame 21.
b. If the upward routing pipe stand off brackets are used it is
essential add 33mm to 'X' the measured wall thickness
when marking the flue (this will allow for the fitted
brackets).
1. Measure and note wall thickness X - Refer to Frame 11.
2. Add 75mm (3 ") to dimension X and, measuring from the
groove, cut the outer tube only.
3. To ensure the tube is cut square, mark the flue all the way
round. Use the cardboard support.
4. Cut the inner tube to a length 20mm (3/4") longer to aid
engagement.
16 CUTTING THE FLUE - SIDE Wall thicknesses of 114 to 300mm
Note.
a) If using the extension ducts go to Frame 21.
1. Measure and note wall thickness X - Refer to Frame 11.
2. Add 115mm (4 1/2") to dimension X and, measuring from
the groove, cut the outer tube only.
3. To ensure the tube is cut square, mark the flue all the way
round. Use the cardboard support.
4. Cut the inner tube to a length 20mm (3/4") longer to aid
engagement.
Ecl 1461
Ecl 1461
INSTALLATION

16 icos system condensing - Installation and Servicing
INSTALLATION
FLUE OUTLET
17 FITTING THE PIPING FRAME (Rear Flue outlet shown)
Note. The flow isolating valve (A), c/w pressure gauge, is
supplied separately in the hardware pack. Fit to the
piping frame BEFORE mounting the boiler.
Fit the wall mounting frame either:
a. Directly to the wall
zz
zz
zInsert wall plugs.
zz
zz
zPut the screws into the wall plugs and leave 10mm
proud
zz
zz
zHang the frame onto the screws (take care to use the
same hole position from each group as previously
chosen with the wall template) and tighten up.
zz
zz
zLocate the support bracket on the piping frame.
or
b. Use stand-off frame
(To allow pipework to be taken upwards).
zz
zz
zInsert wall plugs.
zz
zz
zPut the screws into the wall plugs and leave 10mm
proud.
zz
zz
zHang the stand-off frame onto the screws and tighten
up.
zz
zz
zFasten the piping frame to the stand-off frame with the
6mm screws and washers provided.
zz
zz
zLocate the support bracket on the piping frame.
Note. If the clearances above and below the boiler are
less than the length of the pipes it will be necessary to
position the pipes behind the wall mounting plate
BEFORE the plate is screwed to the wall.
Service connections may be made now, before mounting the
boiler, if required - refer to Frames 24 to 27.
Ecl 2086
Wall
plug
Screw
(10mm proud)
A
Four
positions
Piping frame
Support bracket
Ecl 2015
Piping
frame
A
Wall
plug
Screw
(10mm proud)
Four
positions
Four
positions
Stand off
frame
6mm Screw
Support bracket

17
icos system condensing - Installation and Servicing
INSTALLATION
FLUE OUTLET
Ecl 2018
2
4
A
3
1
REAR FLUE OUTLET
18 MOUNTING THE BOILER
1. Ensure that the plastic plugs are removed from both the
pipes before mounting.
N.B. Some spillage of water may occur from the pipework
when mounting the boiler to the frame.
2. Lift the boiler onto the wall mounting frame, locating it
over the tabs at the top of the frame.
3. Lower the boiler into position.
4. Using the fibre washers supplied in the hardware pack,
engage and then tighten the 2 water unions.
5. Engage and tighten the gas union, ensuring that the
rubber seal is in place. DO NOT overtighten.
6. Connect a pipe to the safety drain outlet using the nut
and olive supplied in the boiler hardware pack.
7. Disconnect the spark lead from the control box.
8. Turn the control box clamp and swing the control box into
the servicing position.
9. Plug the user control (supplied in the hardware pack)
into the control box. Refer to Frame 33.
10. Swing the control box back into its working position and
secure.
11. Screw the user control into position.
19 CONNECTING THE FLUE TO THE BOILER
Note.
a. BEFORE fitting the flue turret, fill the condensate trap within
the boiler by pouring a cupful of water into the flue outlet A.
b. Take care to ensure that the water is only poured into the
flue outlet, and does not spill into the boiler casing.
1. Insert the flue assembly through the prepared hole in the
wall.
2. Locate the flue turret on the top of the boiler ensuring that
the seal is in place and that the flue outlet seal at A is
correctly located.
3. Locate the flue into the turret.
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.
9
8
7
11
Ecl 2069

18 icos system condensing - Installation and Servicing
INSTALLATION
FLUE OUTLET
1. A maximum of 3 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 21.
22 FLUE EXTENSION DUCTS - continued
1. Remove the cardboard support aid from the flue and
place safely to one side.
2. Fit the inner flue extension duct onto the inner flue duct.
3. Fit the outer flue extension duct onto the outer air duct.
4. Using the clamp provided clamp the flue lengths
together.
5. Repeat steps 1-4 if a second flue extension is required.
6. Measure and mark the flue length required onto the flue,
measuring from the groove near the terminal.
7. To ensure a square cut, mark the flue all the way round.
8. Cut to length using the cardboard support aid.
9. Remove the cardboard off-cut and deburr the metal
edges.
23 FITTING THE KIT
21 FLUE EXTENSION DUCTS - For flue lengths greater than 480mm
Pack D Flue extension duct kit contents.
Note. Side flue shown
General arrangement
20 TERMINAL WALL PLATE (optional)
This plate is supplied in the Flue Finishing Kit (together with
one inner and one outer flue seal) it allows neat concealment
and full compression of the outer seal (if fitted). Its use is not
essential if the flue hole and flue ducts have been accurately
cut and the outside wall face is flat.
1. Position the terminal wall plate over the terminal.
2. Drill 4 fixing holes with a 7mm (1/4") masonry drill.
3. Insert the 4 plastic plugs provided.
4. Secure the plate with 4 of the No.10 x 2" screws provided.
Note. If the terminal is less than 2m (6' 6") above ground
level, an approved terminal guard should be fitted. Refer to
the Flue Installation, Page 8.
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
Ecl 1244
Ecl 1531
Boiler
Standard flue
Terminal grille
Flue length
Extension flue
GROOVE
2
3
9
Ecl 1532
Use a maximum of 3m extended flue ONLY
FLUE OUTLET

19
icos system condensing - Installation and Servicing
INSTALLATION
25 WATER CONNECTIONS
Refer to General Note, Frame 24, for guidance.
Note. Do not subject any of the isolating valves to heat as the
seals may be damaged.
General Notes
1. Fitting the Piping Frame, top entry pipework is an option,
as well as mounting from the bottom or through the wall.
If pipes are run vertically within the boiler back space
provided by optional stand-off frame positions they must
avoid any obstructions imposed by the channels and by a
rear facing flue, should this position be selected.
24 SERVICE CONNECTIONS
2. Horizontal connecting pipes, where used, must be run
outside the limits of the boiler casing.
2070
22mm copper pipe
Isolating valve
(shown in the
open position)
Piping frame
Drain
point
22mm copper pipe
Isolating valve
(shown in the
open position)
Pressure gauge
FLOW
RETURN
INSTALLATION

20 icos system condensing - Installation and Servicing
INSTALLATION
The safety valve is located at the bottom RHS of the boiler.
The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of
the premises or damage the electrical components and wiring.
27 SAFETY VALVE DRAIN
28 CONDENSATE DRAIN
Refer also to the British Gas document: 'Guidance Notes for
the Installation of Domestic Gas Condensing Boilers' (1989).
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 19.
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. Any external runs must be insulated.
Excessive external pipe runs should be avoided 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.
In order to defer the onset of freezing of the condensate drain
when the pipe is run externally the pipe should be run as far
26 GAS CONNECTION
1. Extend a gas supply pipe of not less than 15mm O.D.
copper to the boiler.
A working gas pressure of 20mbar (8" w.g) should be
available at the boiler inlet, with the boiler firing at full
output.
IMPORTANT.
The gas service cock contains a non-metallic
seal so must not be overheated when making
capillary connections.
GAS IN
2071
1Piping
frame
Rubber washer
Gas cock
(shown in the
open position)
2025
Condensate
drain
Front view
155mm
Side view
as possible within the building.
The boiler condensate drain connection is suitable for Marley
'Terrain' tubing.
A siphon kit is available to prevent freezing.
INSTALLATION