Ideal Boilers icos system m3080 User manual

2
GENERAL
icos system - Installation and Servicing
Gas supply 2H-G20-20mbar
Gas Supply Connection Rc1/2 (1/2" BSP Female)
Injector size Stereomatic 5.6mm dia.
Flow Connection Central Heating 22mm copper compression
Return Connection Central Heating 22mm copper compression
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 : T3.15A L 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)
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.
*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.
Boiler Size Max Min
Boiler input 'Q' = Nett CV kW 24.4 9.1
Btu/h 83 300 31 000
Gross CV kW 27.1 10.1
Btu/h 92 500 34 400
Boiler output 'P' = Gas consumption l/s (cu.ft/h) 0.70 (89.0) 0.26 (33.2)
70 °C Mean water kW 23.4 8.8
temperature Btu/h 80,000 30,000
40 °C Mean water kW 25.1 9.6
temperature Btu/h 85 700 32 800
Seasonal efficiency (SEDBUK) * Band A [90.2]%
NOx classification Class 4
Table 2 - Performance Data

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GENERAL
icos system - Installation and Servicing
CONTENTS
Air Supply ....................................................................... 7
Boiler Clearances ......................................................... 6
Boiler Interlocks............................................................ 8
Boiler Exploded Diagram ................................... 10 & 11
Condensate Drain ................................................ 8 & 21
Electrical Connections ............................................... 23
Electrical Supply ........................................................... 8
Extension Ducts - Fitting ............................................. 17
Fault Finding ........................................................... 45-48
Flow Wiring Diagram .................................................. 26
Flue Fitting .................................................................... 15
Flue Installation ............................................................. 7
Gas Safety Regulations ................................................ 5
Gas Supply ..................................................................... 7
Installation .............................................................. 11-29
Mandatory Requirements....................................... 5-10
Pump .......................................................................... 42
Servicing ................................................................ 30-44
Short List of Parts....................................................... 49
Thermostatic Radiator valves ..................................... 8
Water and Systems ................................................ 7-10
Water Connections ..................................................... 20
Water Treatment ......................................................... 10
Wiring Diagrams ................................................... 23-26
icos system m3080
Natural Gas only
G.C. Appliance No. 41 391 52
PI No. 0063BM9802
Destination Country: GB, 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 ....................... 11
SEDBUK No. % .........................................................2
Controls
Time and temperature control to heating ............. 24
Time and temperature control to hot water .......... 24
Heating zone valves .............................................. n/a
TRV's .........................................................................8
Auto bypass ..............................................................8
Boiler interlock ..........................................................8
For all boilers
Flushing to BS.7593 .............................................. 10
Inhibitor .................................................................. 10
Central heating mode
Heat input ................................................to be calculated
For assistance see Technical Helpline on the back page
Page
Burner operating pressure...... measure and record
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 .................................................. 21
For all boilers:
complete, sign & hand over to customer
For GB, to comply with Building Regulations Part L1 (Part J 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 log book.

4
GENERAL
icos system - Installation and Servicing
1 BOILER WATER CIRCUIT DIAGRAM
INTRODUCTION
The icos system m3080 is a cast aluminium wall mounted,
full sequence, automatic spark ignition, low water content,
fanned flue, high efficiency, condensing system 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 23.4 kW (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 coated 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.
The boiler is suitable for connection to fully pumped, sealed
water systems ONLY.
Adequate arrangements for completely draining the system
by provision of drain cocks MUST be provided in the
installation pipework.
Expansion
vessel
Automatic
air vent
Heat
exchanger
Gas valve
Pump
Safety
relief valve
Condensate
'S' trap
Water
pressure
gauge
Sump
Fan
Burner
Flow
Gas
Condensate drain
Discharge pipe
Ecl 2532
Return
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).
OPERATION
When there is a demand for heat, the heating system is
supplied at the selected temperature of between 30oC and 82oC.
Refer also to Frame 1 - 'Boiler Water Circuit Diagram'
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.

5
GENERAL
icos system - Installation and Servicing
OPTIONAL EXTRA KITS
!Flue Extension Ducts (1000mm long, up to 6m ) .
!Flue Finishing Kit
!90o Elbow Kit (Maximum 4 elbows / installation).
!45oElbow Kit (Maximum 4 elbows / installation).
!Powered Vertical Flue Kit (to a maximum primary flue
length of 8m + a maximum secondary flue length of 6m)
!Roof Flue Kit (to a maximum of 8m).
!Twin flueing Kit (to a maximum of 46m combined total of
flue and air ducts)
!Remote User Controls Kit.
!Boiler Stand-off Kit.
!Siphon Kit.
!Valve Cover Kit.
SAFETY
Current Gas Safety (Installation & 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 70 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
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.
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:
!BS. 6798 (No cupboard ventilation is required - see 'Air
Supply' for details).
!The position selected for installation MUST allow adequate
space for servicing in front of the boiler.
!For 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.

6
GENERAL
icos system - Installation and Servicing
2 BOILER DIMENSIONS, SERVICES & CLEARANCES
Centre
line of
boiler
112 49 123
Flow
Gas control
Return
Inset A Water Connections and Gas Connection
390 (15 3/8")
Flue
terminal
687
(27")
278 (11")
Condensate drain
43
5 (1/4")
5 (1/4")
165
(6 1/2")
100 (4")*
400 (15 3/4")
CLEARANCES
See inset A
BOILER DIMENSIONS
A
Ecl 2479
all dimensions in mm (in)
The boiler connections are made on the boiler piping frame.
Refer to Frames 20 & 21.
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
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
After installation can be reduced to 5mm in an adequately
ventilated enclosed cupboard. However, 100mm must be
available for servicing.
REAR FLUE ONLY
MIN. Top clearance required = 145 mm (5 3/
4")
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.
SIDE FLUE ONLY
Horizontal length of flue Top clearance
from centre line of boiler required (MIN.)
to outside wall Dim. A
0.5 m 160 mm (6 5/16")
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 265 mm (9 1/4")
3.5 m 250 mm (10 5/8")
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")

7
GENERAL
icos system - Installation and Servicing
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.
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., Tower House, Vale Rise, Tonbridge,
Kent TN9 1TB
Tel: [phone]. Fax: [phone]
www.tfc-group.co.uk
Ensure that the guard is fitted centrally.
5. The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any art of any building.
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.
TERMINAL
The terminal assembly can be adapted to accommodate
various wall thicknesses. Refer to Frame 12.
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 1metre of copper pipe MUST be fitted to
both flow and return connections from the boiler before
connection to any plastic piping.
The central heating system should be in accordance with
BS.6798 and, in addition, for smallbore and microbore
systems, BS.5449.
The hot water storage cylinder MUST be of the indirect type and
should preferably be made of copper.
Single feed, indirect cylinders MUST NOT be used. 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.
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 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
system is able to deliver its full output at inlet pressures
well below those required by BS. 6891.
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 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.5440-1:2000. 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.
Table 3 - Balanced Flue Terminal Position
Terminal Position
Minimum Spacing
1. Directly below or alongside an
opening window, air brick 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 an internal or external corner or
to a boundary alongside the terminal 300 mm ( 12")
7. Above adjacent ground, roof or
balcony level 300 mm (12")
8. From a surface or a boundary
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")

8
GENERAL
icos system - Installation and Servicing
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.
BOILER CONTROL INTERLOCKS
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.
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
WARNING. The appliance MUST be efficiently earthed.
Wiring external to the appliance MUST be in accordance with
the current I.E.E. (BS.7671) Wiring Regulations and any local
regualtions 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.
CONDENSATE DRAIN - Refer to Frames 27 & 45
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 21.5mm (3/4")
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
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.
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

9
GENERAL
icos system - Installation and Servicing
CH Return
Ecl 6053
Hose unions
Mains
water supply
Temporary hose
(disconnect after filling)
Additional
stop valve
Double check valve
assembly
(note direction of flow)
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. An 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 in Frame 3.
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.
When installing the filling device, it must be connected as
below to fully comply with the water regulations.
This may involve the fitting of an additional WRAS
approved isolator valve to the mains supply.
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.

10
GENERAL
icos system - Installation and Servicing
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 note regarding thermostatic radiator valves on page 8.
Note.
Systems incorporating zone valves which could completely cut
off the flow through the system, must also include a bypass.
BALANCING
1. Set the programmer to ON, for both CH and DHW. 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.
5 SYSTEM BALANCING
6 WATER TREATMENT
These boilers incorporate an ALUMINIUM heat exchanger.
IMPORTANT. The application of any other treatment to this product may render the guarantee of Caradon Ideal Limited INVALID.
Caradon Ideal Limited recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in
Central Heating Systems.
Caradon Ideal Limited recommend the use of Fernox Copal or MB1, GE Betz Sentinel X100 or Salamander Corrosion Guard
inhibitors and associated water treatment products, which must be used in accordance with the manufacturers instructions.
For further information contact:
Fernox Manufacturing Co. Ltd, Cookson Electronics, Forsyth Road, Sheerwater, Woking, Surrey. GU21 5RZ. Tel. [phone]
or
G E Betz Ltd, Sentinel Division, Foundry Lane, Widnes, Cheshire, WA8 8UD. Tel. [phone]
or
Salamander Engineering Ltd, Unit 24, Reddicap Trading Estate, Sutton Coldfield, West Midlands B75 7BU. Tel. [phone]
Notes.
1. It is most important that the correct concentration of the water treatment products 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.
BS7593:1992 details the steps necessary to clean a domestic heating system.
3. In hard water areas, treatment to prevent limescale 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 exchanger
14. Injector & housing.
15. Venturi assembly.
16. Fan assembly.
17. Automatic air vent.
18. Gas service cock.
19. Gas control valve.
20. Fan bracket.
21. Orifice plate.
22. Flue thermistor.
23. Control thermistor.
1. Front casing panel.
2. Sealing panel.
3. Sump cover.
4. Bottom casing panel.
5. Flue sensing nipple.
6. Return pipe.
8. Flue manifold.
9. Flue manifold fixing.
10. Interpanel.
11. Burner.
12. Combustion chamber ins.
7 BOILER ASSEMBLY - Exploded View Legend
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 15 oC 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 the room and cylinder thermostat and programmer
to NORMAL settings.
24. Overheat thermostat.
25. Ignition electrode.
26. Flame detection electrode.
32. Condensate 'S' trap.
35. User control.
36. Primary controls (PCB).
39. Mains switch.
44. Piping frame.
51. Mains connector.
53. Turret gasket.
57. CH return stub.
58. CH flow stub.
61. Pressure relief valve.
62. Expansion vessel.
63. Expansion vessel pipe assy.
64. Pressure gauge.
69. Pump.
70. Pump manifold.
75. Control box clamp

11
INSTALLATION
icos system - Installation and Servicing
8 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
19
6
58
Ecl 2533
16 15
22
9
10
39
75
51
57
3
18
Data
badge
INSTALLATION

12
INSTALLATION
icos system - Installation and Servicing
9 UNPACKING
The boiler is supplied fully assembled in one Pack A,
together with a standard flue assembly for lengths up to
650mm, rear or side flue outlet, in Pack B.
Unpack and check the contents.
Hardware Pack & Fittings
!50mm x No.14 wood screws - 4 off.
!Wall plugs (TP2B ) - 4 off.
!Water treatment warning label.
!Turret clamp.
!M5 x 10 pozi Hex screw.
Pack A Contents
!Hardware Pack & fittings.
!These Installation & Servicing Instructions.
!The User's Instructions.
!The User Control (Display unit).
!Benchmark log book.
!1 Year guarantee form.
Pack B Contents
Flue turret.
Flue terminal.
Flue support cutting aid.
Ecl 2354
Flue terminal
Flue turret
!'S' Trap hose.
!Safety drain pipe nut and olive.
!Flow isolating valve c/w pressure gauge.
!22mm fibre washers - 3 off.
!Mains connector.
INSTALLATION

13
INSTALLATION
icos system - Installation and Servicing
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:
!Wall mounting plate.
!Instructions.
!Hardware pack & fittings.
!User control.
!Pre-piping frame
4. Remove the instructions and read thoroughly
before unpacking the product.
5. When ready for installation lift off the cardboard
carton.
10 PACKAGING REMOVAL
Ecl 2356
11 BOTTOM PANEL AND FRONT PANEL REMOVAL
1. Remove the 2 retaining screws from the under
side of the boiler.
2. Pull the panel forward a the bottom and lift to
disengage it from the top lugs.
3. Unscrew and remove the screws from the
underside of the boiler.
4. Pull the RHS of the panel down, slide it to the
right and withdraw.
Ecl 2425
Bottom panel
Front panel
Retaining clip
1
3
INSTALLATION

14
INSTALLATION
icos system - Installation and Servicing
FLUE OUTLET
FLUE KITS
Pack B - supplied as standard
Pack D - optional extension kit for side flue or rear flue outlet.
Refer to 'Flue Extension Ducts'
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.
12 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 the wall to
suit this condition.
Total Flue length dimension Flue
Rear flue Side flue Extra packs
dim. X+160 dim. L+195 required
Up to 650 mm Up to 650 mm none
Up to 1600 mm Up to 1600 mm Pack D - 1 off
Up to 2550 mm Up to 2550 mm Pack D - 2 off
Up to 3500 mm Up to 3500 mm Pack D - 3 off
Up to 4450 mm Up to 4450 mm Pack D - 4 off
Up to 5400 mm Up to 5400 mm Pack D - 5 off
Up to 6000 mm Up to 6000 mm Pack D - 6 off

15
INSTALLATION
icos system - Installation and Servicing
FLUE OUTLET
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 kit. Care MUST be taken to ensure the correct
holes are drilled.
1. Separate the templates.
2. Tape template A into the selected position.
3. Ensure squareness by hanging a plumbline as shown. If
fitting a side flue extend the flue centre line onto the side
wall. Tape template Binto the selected position.
4. Mark onto the wall the following:
aThe piping frame screw positions (choose one from each
group).
b. The position of the flue duct hole (see diagram below and
template).
Note.
Mark the centre of the hole as well as the
circumference
5. Remove the template from the wall.
14 WALL MOUNTING TEMPLATE
13 FLUE ASSEMBLY - Exploded View
An optional flue duct extension kit is required for
wall thicknesses greater than :
Side 455mm (18").
Rear 490mm (19 1/4").
Rear flue arrangement shown
Ecl 2360
V
A
A
B
B
B
Ext
e
n
ded
ce
ntr
e
lin
e
305
S
ee Not
e
N
ote.
If wall thickness is
g
reater than 305mm then dimension H must be
reduced by the same amount and the offset may be adjusted accordingly.
1
8
31
44 57 70 83 96 109 122 135 148
See wall mountin
g
template
Ecl 2359
0
.
5
1.
0
1.
5
2.
0
2.
5
3
.
0
3
.
5
4.
0
4.
5
5
.
0
5
.
5
V
D
i
s
t
a
n
ce
in m
e
tr
es
fr
o
m
s
i
de
o
f th
e
bo
il
e
r t
o
th
e
s
i
de
w
a
ll
LEGEND
1. Duct assembly.
2. Flue Turret.
3. Turret gasket.
4. M5 x 10 pozi screw.
5. Turret clamp.

16
INSTALLATION
icos system - Installation and Servicing
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
15 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 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 piping frame
(one at each side, in any of the 3 holes provided at
each side) and screw home.
16 CUTTING THE FLUE - REAR Wall thicknesses of 114 to 490mm
Notes.
a. If using the extension ducts go to Frame 18.
b. If the stand-off frame is used it is essential add 33mm
to X, the measured wall thickness, when marking the
flue (this will allow for the fitted frame).
1. Measure and note wall thickness X. Refer to Frame
12.
2. Add 90mm (3 1/2") to dimension X and, measuring
from the ring, cut the outer tube only.
3. To ensure the tube is cut square, mark the flue all the
way round.
4. Cut the inner tube to a length 20mm (3/4") longer to
aid engagement, using the cardboard support.
17 CUTTING THE FLUE - SIDE Wall thicknesses of 114 to 455mm
1. Measure and note side flue length L. Refer to
Frame 12.
2. Add 125mm (5") to dimension L and, measuring
from the ring, cut the outer tube only.
3. To ensure the tube is cut square, mark the flue all
the way round.
4. Cut the inner tube to a length 20mm (3/4") longer
to aid engagement, using the cardboard support.
Note. If using the extension ducts go to Frame 18.
FLUE OUTLET

17
INSTALLATION
icos system - Installation and Servicing
FLUE OUTLET
Ecl 6085
Boiler
S
tandard flu
e
Terminal grille
Flue length
Ext
e
n
s
i
o
n fl
ue
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 Frames 18 & 23.
19 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 ring 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 and deburr the metal edges.
20 FITTING THE KIT
18 FLUE EXTENSION DUCTS - For flue lengths greater than 650mm
Pack D Flue extension duct kit contents.
Note. Side flue shown
General arrangement
Flue duct support
Fl
ue support cutt
i
n
g
a
id
(
shown folded up
)
Wall plu
g
s - 4 of
f
Extension duct & clamp
1.0m (39") long
No. 1
0
x2" wood screw - 4 of
f
Ecl 1244
Use a maximum of 6m extended flue ONLY
Measure from
this
RING
2
3
Ecl 2540

18
INSTALLATION
icos system - Installation and Servicing
FLUE OUTLET
21 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
!!
!!
!Insert wall plugs.
!!
!!
!Put the screws into the wall plugs and leave
10mm proud
!!
!!
!Hang 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.
!!
!!
!Locate the support bracket on the piping frame.
or
b. Use the stand-off frame
(To allow pipework to be taken upwards).
!!
!!
!Insert wall plugs.
!!
!!
!Put the screws into the wall plugs and leave
10mm proud.
!!
!!
!Hang the stand-off frame onto the screws and
tighten up.
!!
!!
!Fasten the piping frame to the stand-off
frame with the 6mm screws and washers
provided.
!!
!!
!Locate 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 & 25.
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

19
INSTALLATION
icos system - Installation and Servicing
FLUE OUTLET
2
5
4
4
A
Ecl 6067
1
Gasket
22 MOUNTING THE BOILER
IMPORTANT.
Before mounting the boiler on the wall fit the 'S' trap hose moulding/nut.
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, engaging it onto the support bracket.
Note.
Ensure the condensate drain pipe is correctly positioned before
continuing.
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. Plug the user control (display unit, Pack A) into the control box. Refer to
Frame 35.
8. Screw the user control into position.
23 CONNECTING THE FLUE TO THE BOILER
7
Ecl 2363
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 turret gasket is in place. Check that the flue 'A'
seal located in the top of the flue manifold is secure and
giving an effective seal.
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 plugs
and wood screws.
NB. The support
bracket will utilise
one fixing hole only
whilst used in
conjunction with the
stand-off option.
Note.
Before fitting the flue turret fill the condensate trap within the boiler by pouring a cupful of water into the flue outlet A.
Take care to ensure that the water is only poured into the flue outlet, and does not spill into the boiler casing.

20
INSTALLATION
icos system - Installation and Servicing
24 WATER CONNECTIONS
Notes.
1.
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
system pipework.
2. Do not subject any of the isolating valves to heat as the seals
may be damaged.
Ecl 2365
22mm copper pipe
Isolating valve
(shown in the
open position)
Piping frame
Drain
point
Condensate drain
pipe located here
22mm copper pipe
Isolating valve
(shown in the
open position)
Pressure gauge
FLOW
RETURN
INSTALLATION