Ideal Boilers Optia HE 12 User manual

installation and
servicing
icos
Your Ideal installation and servicing guide
For details of document amendments, refer to page 3
ENGINEERED FOR PEACE OF MIND
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.
September 2005 UIN 200 212 A10
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2icos - Installation & Servicing
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3
icos - Installation & Servicing
DOCUMENT AMENDMENTS
Relevant Installation changes implemented in this book from Mod Level ......... A09 (May 05) to A10 (Sept 05)
• Page 15, Frame 11 - Unpacking
Mains Connector added to hardware pack contents.
• Page 25, Frame 32 - Pictorial Wiring Diagram
Update to wiring diagram.
Caradon Ideal Limited reserve the right to vary specification without notice
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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
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5
icos - Installation & Servicing
GENERAL
CONTENTS
Air Supply ....................................................................... 9
Benchmark Commissioning Checklist ..................... 50
Boiler Clearances ......................................................... 6
Boiler Exploded Diagram ............................................ 14
Electrical Connections ............................................... 23
Electrical Supply ........................................................... 9
Electrical Systems Diagrams .................................... 26
Extension Ducts - Fitting ............................................. 19
Fault Finding ................................................................. 41
Flow Wiring Diagram .................................................. 25
Flue Fitting .............................................................. 16-19
Flue Installation Requirements .................................... 8
Gas Safety Regulations ................................................ 7
Gas Supply ..................................................................... 8
Initial Lighting .............................................................. 27
Installation ............................................................. 14-28
Mandatory Requirements ............................................. 7
Safe Handling ................................................................ 7
Servicing ................................................................ 29-40
Short List of Parts ....................................................... 45
Terminal Guards ............................................................ 8
Thermostatic Radiator valves .................................... 9
Water and Systems ................................................ 9-13
Water Connections ................................................. 6, 23
Water Treatment ......................................................... 13
Wiring Diagrams ......................................................... 25
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 ............. 26
Time and temperature control to hot water .......... 26
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 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 Commissioning Checklist.
Boiler size G.C. Appliance No. PI No.
Benchmark No.
HE12 41 397 95 0063 BO 3315
HE15 41 397 83 0063 BO 3315
HE18 41 397 84 0063 BO 3315
HE24 41 397 85 0063 BO 3315
Natural Gas only
BENCHMARK COMMISSIONING CHECKLIST DETAILS
NOTE TO THE INSTALLER: COMPLETE
THE BENCHMARK COMMISSIONING
CHECKLIST AND LEAVE THESE
INSTRUCTIONS WITH APPLIANCE
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6icos - Installation & Servicing
GENERAL
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.
1 BOILER WATER CONNECTIONS
A
2 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 36.
*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")
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7
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 14.7 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
!Flue Extension Ducts (1000mm long up to 6m)
!Flue Finishing Kit
!90o Elbow Kit (maximum 4 elbows per installation).
!45o Elbow Kit (maximum 4 elbows per installation).
!Roof Flue Kit (to a maximum of 8m)
!Powered Vertical Flue Kit (to a maximum primary flue length
of 8m + a maximum secondary flue length of 6m)
!Twin Flueing Kit (to a maximum of 46m combined total of
flue and air ducts)
!Remote User Control Kit
!Boiler Stand-off Kit
!Siphon 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 Caradon Ideal Limited in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by
Caradon Ideal Limited may 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.
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8icos - Installation & Servicing
GENERAL
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:
!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.
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. [phone]
Tower House, Vale Rise Fax. [phone]
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.
Table 3 - Balanced flue terminal position
Terminal Position Minimum Spacing
1. Directly below or alongside an
opening window, air brick or other 300 mm (12")
ventilation opening
2. Below guttering, drain pipes or soil
pipes 25 mm ( 1")*
3. Below eaves 25 mm ( 1")*
4. Below balconies or a car port roof 25 mm ( 1")*
5. From vertical drain pipes or soil pipes 25 mm ( 1")*
6. From an internal or external corner or
to a boundry along side the terminal. 25 mm ( 1")*
7. Above adjacent ground, roof or
balcony level 300 mm (12")
8. From a surface or boundry 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")
* Only 1 reduction down to 25mm is allowable per installation.
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9
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
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.
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.
CONDENSATE DRAIN - Refer to Frames 23 & 44
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
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10 icos - Installation & Servicing
GENERAL
3 OPEN VENT SYSTEM REQUIREMENTS
4 SCHEMATIC PIPEWORK AND SYSTEM BALANCING
The boiler does not normally need a bypass but at least 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 Caradon Ideal Limited. The isolation valves should be
fitted as close to the pump as possible.
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11
icos - Installation & Servicing
GENERAL
Non-return
valve
Automatic
air vent
Hose unions
Additional
stop valve
Hose connector
Hosepipe
(disconnect
after filling)
Double check valve
assembly
(note direction of flow)
Temporary hose
(disconnect
after filling)
ecl6060
Note. The pump manufacturers' minimum requirements must be complied with.
5 LOW HEAD AND LARGE SYSTEMS WITH EXTENSIVE PIPE RUNS - OPEN VENT
All dimensions in mm (in.).
NB. Imperial dimensions are approximate
6 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:
200212-10.pmd 9/5/2005, 8:58 AM11

12 icos - Installation & Servicing
GENERAL
7
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 110oC (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.
or
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).
200212-10.pmd 9/5/2005, 8:58 AM12

13
icos - Installation & Servicing
GENERAL
Safety valve setting 3.0 bar 2.5 bar 2.0 bar
Vessel charge and initial 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0
system pressure bar bar bar bar bar bar bar bar
Total water content of system Expansion vessel volume litres
litres
25 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0
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
8 SEALED SYSTEM REQUIREMENTS - continued
9 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
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, 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.
GE Betz Ltd
Sentinal Division
Foundry Lane
Widnes
Cheshire
WA8 8UD
Tel: [phone]
Fernox Manufacturing Co. Ltd
Cookson Electronics
Forsyth Road
Sheerwater
Woking
Surrey
GU21 5RZ
[phone]
Salamander Engineering Ltd
Unit 24
Reddicap Trading Estate
Sutton Coldfield
West Midlands
B75 7BU
Tel: [phone]
200212-10.pmd 9/5/2005, 8:58 AM13

14 icos - Installation & Servicing
INSTALLATION
nm7912
40
94
8. Flue manifold.
9. Flue fixing
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.
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.
10 BOILER ASSEMBLY - Exploded view
22. Flue thermistor.
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
200212-10.pmd 9/5/2005, 8:58 AM14

15
icos - Installation & Servicing
INSTALLATION
G
C
A
B
E
F
D
nm7890
The boiler is supplied fully assembled in one Pack A,
together with a standard flue assembly for lengths up to
650mm, rear or side flue outlet, in Pack B.
Unpack and check the contents.
11 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
C Wall mounting plate
D 1 year guarantee form
E These Installation & Servicing/
User’s Instructions
F Water Treatment Warning Label
G Hardware pack
Pack B Contents
A Flue turret
B Flue terminal
C Flue support cutting aid
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.
7. Remove the two packaging ends.
8. Remove the hardware pack from under the pipes
and keep in a safe place.
12 PACKAGING REMOVAL
nm7800
A
B
C
3
8
6
7
7
5
nm7801
A
B
C
nm8075
D
INSTALLATION
200212-10.pmd 9/5/2005, 8:58 AM15

16 icos - Installation & Servicing
INSTALLATION
195mm
195mm
Rear flue length X
Side flue length L
Jacking screw
160 mm
Ecl 1177
160 + S = 193mm
13 FRONT AND BOTTOM PANEL REMOVAL
IMPORTANT. The boiler MUST be installed in a vertical position
Dimension X - Wall thickness.
Dimension L - Wall thickness plus boiler spacing.
Dimension S - Stand-off 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.
14 DETERMINING THE FLUE LENGTH AND FLUE PACKS REQUIRED
FLUE KITS
Pack B - supplied as standard
Finishing Kit - supplied as standard
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 - 8M
POWERED VERTICAL FLUE KIT - 14M TOTAL
60/60 TWIN FLUE KIT - 20M TOTAL AIR PLUS FLUE DUCT
80/80 TWIN FLUE KIT - 46M TOTAL AIR PLUS FLUE DUCT
90OELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 1M)
45OELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 0.6M)
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 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.
nm 7802
3
1
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
INSTALLATION
200212-10.pmd 9/5/2005, 8:58 AM16

17
icos - Installation & Servicing
INSTALLATION
FLUE OUTLET
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 Ainto 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 2 wall mounting plate screw positions (choose
one from each group) and the jacking screw position.
If using the stand-off kit mark on 4 screw positions
(choosing 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.
16 WALL MOUNTING TEMPLATE
15 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 455mm (18")
Rear 490mm (19 1/4").
Ecl 2360
V
A
B
Extended centre line
Rear flue arrangement shown
200212-10.pmd 9/5/2005, 8:58 AM17

18 icos - Installation & Servicing
INSTALLATION
FLUE OUTLET
17 PREPARING THE WALL
IMPORTANT. Ensure that, during the cutting
operation, masonry falling outside of the building
does not 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 7mm (1/4") 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.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.
Note.
If using the stand-off kit then locate the stand-
off channel and screw home.
19 CUTTING THE FLUE - SIDE Wall thicknesses of 114 to 455mm
18 CUTTING THE FLUE - REAR Wall thicknesses of 114 to 490mm
Note. If using the extension ducts go to Frame 20.
1. Measure and note side flue length L. Refer to Frame 14.
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
around.
4. Cut the inner tube to a length 20mm (3/4") longer to aid
engagement, using the cardboard support.
Notes.
a. If using the extension ducts go to Frame 20.
b. If the stand-off frame is used it is essential to add 33mm
to dimension X.
1. Measure and note wall thickness X. Refer to Frame 14.
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 around.
4. Cut the inner tube to a length 20mm (3/4") longer to aid
engagement, using the cardboard support.
200212-10.pmd 9/5/2005, 8:58 AM18

19
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.
21 FLUE EXTENSION DUCTS - continued
Ecl 6085
Boiler
Standard flue
Terminal grille
Flue length
Extension flue
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
around.
8. Cut to length, using the cardboard support aid.
9. Remove the cardboard off-cut and deburr the metal
edges.
22 FITTING THE KIT
Measure from
this
RING
2
3
9Ecl 2540
20 FLUE EXTENSION DUCTS - For flue lengths greater than 480mm
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
Ecl 1244
200212-10.pmd 9/5/2005, 8:58 AM19

20 icos - Installation & Servicing
INSTALLATION
23 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.
Ecl 2332
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
BOILER
cla7772 75mm trap
DRAIN
Sink
Ground Level
Open end of pipe
direct into gulley
below grating but
above water level
1. INTERNAL TO SINK WASTE
UPSTREAM OF SINK WASTE
TRAP
2. INTERNAL TO SINK WASTE
DOWNSTREAM OF SINK
WASTE TRAP (PREFERRED
METHOD)
* If drain termination is to soil
stack, a 75mm trap will be
required
Note. ALL EXTERNAL PIPE RUNS MUST BE INSULATED
24 CONDENSATE PIPE TERMINATION CONFIGURATIONS
continued . . . .
INSTALLATION
200212-10.pmd 9/5/2005, 8:58 AM20