Ideal Boilers HE24 Installation And Servicing Instructions

Your Ideal installation and servicing guide 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. HE24, HE30, HE35 For details of document amendments, refer to page 3 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. October 2006 UIN 202851 A01 202851-1new.pmd 17/11/2006, 07:40 1

DOCUMENT AMENDMENTS Relevant Installation changes implemented in this book from Mod Level .....................................A01 (Oct 06) Caradon Ideal Limited reserve the right to vary specification without notice 202851-1new.pmd 17/11/2006, 07:40 3

GENERAL isar HE24+P HE30+P HE35+P Gas supply 2H - G20 - 20mbar Gas Supply Connection Rc 1/2 (1/2” BSP female) Injector Size Stereomatic 5.6mm dia. 5.7mm dia Inlet Connection Domestic Hot Water 15mm copper compression Outlet Connection Domestic Hot Water 15mm copper compression Flow Connection Central Heating 22mm copper compression Return Connection Central Heating 22mm copper compression Flue Terminal Diameter mm (in) 100 (4) Average Flue Temp-Mass Flow Rate (DHW) 66oC-10g/s 74 oC - 12 g/s 82oC-14g/s Maximum Working Pressure (Sealed Systems) bar (lb/in2) 2.65 (38.5) Maximum Domestic Hot Water Inlet Pressure bar (lb/in2) 10.0 (145) Minimum Domestic Hot Water Inlet Pressure bar (lb/in2) 0.5 (7) Electrical Supply 230 V ~ 50 Hz. Power Consumption 148 W 148 W 152 W Fuse Rating External : 3A Internal : T3.15A L250 V Water content Central Heating litre (gal) 2.0 (0.44) Domestic Hot Water 0.5 (0.11) Packaged Weight kg (lb) 52 (115) 52 (115) 53 (117) Maximum Installation Weight kg (lb) 42.5 (94) 43 (95) 43.5 ( 96) 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 ft 3/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 Table 2 - Performance Data - Central Heating Maximum DHW Input : HE24+P HE30+P HE35+P Nett CV kW 24.3 30.2 36.0 (Btu/h) (82 900) (103 000) (122 800) Gross CV kW 27.0 33.5 39.9 (Btu/h) (92 100) (114 400) (136 200) Gas Consumption l/s 0.7 0.87 1.03 (ft3/h) (89.0) (110) (131) Maximum kW 23.4 29.3 35.2 DHW Output (Btu/h) (80 000) (100 000) (120 000) DHW Flow Rate l/min 9.6 12.0 14.4 at 35°C temp. rise. (gpm) (2.1) 2.6 (3.2) DHW Specific Rate l/min 11.2 14.0 16.8 (gpm) (2.5) (3.1) (3.7) Table 3 - Performance Data - Domestic Hot Water Boiler Input : 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) Gas Consumption l/s 0.70 0.26 (ft3/h) (89.0) (33.1) Boiler Output : Non Condensing kW 23.4 8.8 70oC Mean Water temp. (Btu/h) (80 000) (30 000) Condensing kW 25.1 9.6 40oC Mean Water temp. (Btu/h) (85 700) (32 800) Seasonal efficiency* (SEDBUK) Band A [90.1]% NOx Classification Class 5 202851-1new.pmd 17/11/2006, 07:40 4

GENERAL Boiler size G.C. Appliance No. PI No. (Benchmark No.) HE24+P 47 348 43 0063 BO 3317 HE30+P 47 348 44 0063 BO 3317 HE35+P 47 348 45 0063 BO 3317 CONTENTS Air Supply ....................................................................... 8 Benchmark Commissioning Checklist ..................... 62 Boiler Clearances ......................................................... 9 Boiler Exploded Diagram ............................................ 13 Condensate Drain ........................................... 10, 21-22 Electrical Connections ............................................... 27 Electrical Supply ......................................................... 10 Extension Ducts - Fitting ............................................. 19 Fault Finding ........................................................... 52-56 Flow Wiring Diagram .................................................. 30 Flue Fitting .................................................................... 18 Flue Installation ............................................................. 8 Gas Safety Regulations ................................................ 7 Gas Supply ..................................................................... 8 Installation ............................................................. 12-33 Mandatory Requirements....................................... 7-10 Pump .......................................................................... 49 Safe Handling ................................................................ 6 Servicing ................................................................ 34-38 Short List of Parts....................................................... 57 Thermostatic Radiator Valves ................................... 10 Water and Systems ........................................... 8,10-12 Water Connections ............................................... 24-25 Water Treatment ......................................................... 12 Wiring Diagrams ................................................... 27-30 isar HE +P Natural Gas only Destination Country: GB, IE time P R O G R A M M E R prog prog select select + - Boiler Page Make and model .......................................................5 Appliance serial no. on data badge ...................... 13 SEDBUK No. % .........................................................4 Controls Time and temperature control to heating ............. 28 Time and temperature control to hot water .......... 28 Heating zone valves ..............................................n/a TRV's ...................................................................... 10 Auto bypass ........................................................... 10 Boiler interlock ....................................................... 10 For all boilers Flushing to BS.7593 .............................................. 12 Inhibitor .................................................................. 12 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 ..........................................to be calculated Max. operating burner pressure ..............................n/a Max. operating water pressure ........... measure & record Cold water inlet temp ..................... measure & record Hot water outlet temp. .................... measure & record Water flow rate at max. setting ............ measure & record 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 (Section 6 in Scotland) the boiler should be fitted in accordance with the manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be demonstrated by completing and signing the Benchmark Commissioning Checklist. BENCHMARK COMMISSIONING CHECKLIST DETAILS NOTE TO THE INSTALLER: COMPLETE THE BENCHMARK COMMISSIONING CHECKLIST AND LEAVE THESE INSTRUCTIONS WITH APPLIANCE 202851-1new.pmd 17/11/2006, 07:40 5

GENERAL INTRODUCTION The isar + programmer range of boilers is a wall mounted, full sequence, automatic spark ignition, low water content, fanned flue, high efficiency, condensing, combination gas boiler. A seven day programmer is built into the boiler, capable of 3 timed periods per day. Note.Due to the high efficiency of the boiler a plume of water vapour will form at the terminal during operation. Central heating (CH) output is fully modulating with a range of 8.8 to 23.4kW (30,000 to 80,000 Btu/h) Instantaneous domestic hot water (DHW) output is also fully modulating with a maximum of : HE24 23.4kW (80,000 Btu/h) HE30 29.3kW (100,000 Btu/h) HE35 35.2kW (120,000 Btu/h) The boiler is supplied fully assembled with DHW plate heat exchanger, diverter valve, circulating pump, pressure gauge, safety valve and CH expansion vessel. Variable CH and DHW temperature controls are fitted on the user control and the boiler features a DHW preheat facility. 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 boiler temperature controls are visible at the bottom RHS of the front panel. 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. 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 With no demand for CH, the boiler fires only when DHW is drawn off, or periodically for a few seconds without any DHW draw-off, in order to maintain the DHW calorifier in a heated condition. When there is a demand for CH, the heating system is supplied at the selected temperature of between 30 oC and 82oC, until DHW is drawn off. The full output from the boiler is then directed via the diverter valve to the plate heat exchanger to supply a nominal DHW draw-off of HE24 9.6 l/min at 35 oC temperature rise. HE30 12 l/min at 35 oC temperature rise. HE35 14.4 l/min at 35 oC temperature rise. The DHW draw off rate specified above is the nominal that the boiler flow regulator will give. Due to system variations and seasonal temperature fluctuations DHW flow rates/temperature rise will vary, requiring adjustment at the draw off tap. At low DHW draw-off rate the maximum temperature is limited to 65 oC by the modulating gas control. Refer also to Frame 1 - 'Boiler Water Circuit Diagrams' An additional feature incorporated within the boiler controls is boiler frost protection. If the flow temperature drops below 7 oC the pump will run. If the temperature continues to drop and goes below 4 oC, the boiler will fire until the temperature exeeds 7 oC. 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. 1 BOILER WATER CIRCUIT DIAGRAMS Central Heating Circuit Expansion vessel Automatic air vent Gas valve Plate heat exchanger Pump Safety relief valve Condensate 'S' trap Diverter valve Water pressure gauge Sump Fan Burner CH Flow Gas Condensate drain Discharg pipe CH Return Domestic Hot Water Circuit Expansion vessel Automatic air vent Heat exchanger Gas valve Pump Safety relief valve Condensate 'S' trap Diverter valve Water pressure gauge Sump Fan Burner DHW Hot out Gas Condensate drain Discharge pipe Ecl 2768 DHW Cold in Plate heat exchanger Heat exchanger 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. 202851-1new.pmd 17/11/2006, 07:40 6

GENERAL 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 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 IE 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: z BS 6798 (No cupboard ventilation is required - see ‘Air Supply’ for details). z The position selected for installation MUST allow adequate space for servicing in front of the boiler. OPTIONAL EXTRA KITS z Flue Extension Ducts (1000mm long). HE24-up to 6m HE30-up to 6m HE35-up to 3m z Flue Finishing Kit z 90 o Elbow Kit (maximum per installation). HE24-upto 4 elbows HE30-upto 4 elbows HE35-upto 2 elbows z 45 o Elbow Kit (maximum per installation). HE24-upto 4 elbows HE30-upto 4 elbows HE35-upto 2 elbows z Roof Flue Kit (to a maximum of 8m). HE24-upto 8m HE30-upto 8m HE35-upto 5m z Powered Vertical Flue Kit (to a maximum primary flue length of 8m + a maximum secondary flue length of 6m) HE24 HE30 HE35 Primary flue (m) 8 8 5 4 3 2 1 Secondary flue (m) 6 6 3 6 6 6 6 z Twin Fluing Kit (up to a maximum of 46m combined total flue and airducts) z Remote User Controls Kit z Boiler Stand-off Kit z Siphon Kit z Valve Cover Kit z System Frost Stat Fitting Kit 202851-1new.pmd 17/11/2006, 07:40 7

GENERAL z 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 isar 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 IS.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 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. 3. Minimum acceptable spacing from the terminal to obstructions and ventilation openings are specified in Table 4. 4. Where the lowest part of the terminal is fitted less than 2m (6'6") above a balcony, above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard. Terminal guards are available from boiler suppliers. (Ask for TFC flue guard model no. K6 - round, plastic coated). In case of difficulty contact: Grasslin (UK) Ltd. Tel. + 44 (0) 01732 359 888 Tower House, Vale Rise Fax. + 44 (0) 01732 354 445 Tonbridge. Kent TN9 1TB www.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 part 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. 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. 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. 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 6 Flue Terminal Positions Min. Spacing* 1. Directly below,above or alongside an opening window, air vent or other ventilation opening. 300mm (12") 2. Below guttering, drain pipes or soil pipes. 25mm ( 1")* BS5440-1 2000 75mm (3") 3. Below eaves. 25mm (1")* BS5440-1 2000 200mm (8") 4. Below balconies or a car port roof. 25mm (1")* BS5440-1 2000 200mm (8") 5. From vertical drain pipes or soil pipes. 25mm (1")* BS5440-1 2000 150mm (6") 6. From an internal or external corner or to a 25mm (1")* boundary along side the terminal. BS5440-1 2000 300mm (12") 7. Above adjacent ground, roof or balcony level. 300mm (12") 8. From a surface or a boundary facing the terminal. 600mm (24") 9. From a terminal facing a terminal. 1,200mm (48") 10. From an opening in a car port (e.g. door or window) into dwelling. 1,200mm (48") 11. Vertically from a terminal on the same wall. 1,500mm (60") 12. Horizontally from a terminal on the wall. 300mm (12") Vertical Terminals 13. Above the roof pitch with roof slope of all angles. 300mm (12") Above flat roof. 300mm (12") 14. From a single wall face. 600mm (24") From corner walls. 1000mm (40") Twin Flue Applications 15. Centre distance between air inlet and flue outlet ducts. 120mm (5") Table 4 - Balanced Flue Terminal Position * Only one reduction down to 25mm is allowable per installation otherwise BS5440-1 2000 dimensions must be followed. 202851-1new.pmd 17/11/2006, 07:40 8

GENERAL time P R O G R A M M E R prog select + - time P R O G R A M M E R prog select + - time P R O G R A M M E R prog select + - nm8426 2 BOILER DIMENSIONS, SERVICES & CLEARANCES all dimensions in mm (in) The boiler connections are made on the boiler piping frame. Refer to Frames 27-29. The following minimum clearances must be maintained for operation and servicing. Additional space will be required for installation, depending upon site conditions. Side and Rear Flue a. Provided that the flue hole is cut accurately, e.g. with a core drill, the flue can be installed from inside the building where wall thicknesses do not exceed 600mm (24"). 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 39. * Bottom clearance Bottom clearance after installation can be reduced to 5mm. However, 100mm must be available for servicing. 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. REAR FLUE ONLY MIN. Top clearance required = 145 mm (5 3/4") SIDE FLUE ONLY Horizontal length of flue Top clearance from centre line of boiler required (MIN.) to outside wall Dim. A HE24 HE30 HE35 0.5 m 0.5 m 0.5 m 160 mm (6 5/16") 1.0 m 1.0 m 1.0 m 170 mm (6 11/16) 1.5 m 1.5 m 1.5 m 185 mm (7 1/4") 1.5 m 1.5 m 1.5 m 200 mm ( 7 7/8") 2.5 m 2.5 m 2.5 m 210 mm (8 1/4") 3.0 m 3.0 m 3.0 m 225 mm (8 7/8") 3.5 m 3.5 m N/A 250 mm (9 7/8") 4.0 m 4.0 m N/A 260 mm (10 1/4") 4.5 m 4.5 m N/A 265 mm (10 7/16") 5.0 m 5.0 m N/A 275 mm (10 13/16") 5.5 m 5.5 m N/A 290 mm (11 3/8") 6.0 m 6.0 m N/A 300 mm (11 13/16") 202851-1new.pmd 17/11/2006, 07:40 9

GENERAL General 1. The installation must comply with all relevant national and local regulations. 2. The installation should be designed to work with flow temperatures of up to 82 oC. 3. All components of the system must be suitable for a working pressure of 3 bar and temperature of 110 oC. 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. 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. 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 IE 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 22 & 49. 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. 3 SYSTEM REQUIREMENTS - Central Heating 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 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, 202851-1new.pmd 17/11/2006, 07:40 10

GENERAL 4 SYSTEM REQUIREMENTS - CH (continued) and Hot Water an additional vessel MUST be installed on the return to the boiler. Guidance on vessel sizing is given in Frame 3. 5. Filling. The system may be filled by the following method: a. 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 shown 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. Water Flow Rate and Pressure Loss Max CH Output kW 23.4 (Btu/h) (80 000) Water flow rate l/sec 0.37 (gal/min) 4.8 Temperature Differential oC 15 ( oF) (27) Head available for m.w.g. 2.3 system pump. (ft.w.g.) 7.5 DOMESTIC HOT WATER 1. The domestic hot water service must be in accordance with BS 5546 and BS 6700. 2. Refer to Table 1 for minimum and maximum working pressures. 3. The boilers are suitable for connection to most types of washing machine and dishwasher appliances. 4. When connecting to suitable showers, ensure that: a. The cold inlet to the boiler is fitted with an approved anti-vacuum or syphon non-return valve. b. Hot and cold water supplies to the shower are of equal pressure. 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) The boiler does not normally need a bypass but at least some radiators on the heating circuit, of load of at least 10% of the minimum boiler output, must be provided with twin lockshield valves so that this minimum heating load is always available. See note regarding thermostatic radiator valves on page 10. 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. 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 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. Adjust the room thermostat and programmer to NORMAL settings. 5. Hard Water Areas Where the water hardness exceeds 200mg/litre, it is recommended that a proprietary scale reducing device is fitted into the boiler cold supply within the requirements of the local water company. IMPORTANT Provision MUST be made to accommodate the expansion of DHW contained within the appliance, if a non-return valve is fitted to the DHW inlet. 202851-1new.pmd 17/11/2006, 07:40 11

6 WATER TREATMENT CENTRAL HEATING The isar range of boilers have an ALUMINIUM alloy heat exchanger. IMPORTANT. The application of any other treatment to this product may render the guarantee of Caradon Ideal Limited. Caradon Ideal Limited recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems. If water treatment is used Caradon Ideal Limited recommend only 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. 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. BS 7593:1992 details the steps necessary to clean a domestic 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. DOMESTIC HOT WATER In hard water areas where main water can exceed 200ppm Total Hardness (as defined by BS 7593:1993 Table 2) a scale reducing device should be fitted into the boiler cold supply within the requirements of the local water company. The use of artificially softened water, however, is not permitted. Caradon Ideal Limited recommend the use of Fernox Qantomat, GE Betz Sentinel Combiguard and Calmag CalPhos I scale reducing devices, which must be used in accordance with the manufacturers' instructions. 19. Gas control valve. 20. Fan bracket. 21. Orifice plate. 23. Control thermistor (flow/return) 24. Overheat thermostat. 25. Ignition electrode. 26. Flame detection electrode. 32. Kit - Trap and seal. 35. User control. 36. Primary controls (PCB). 39. Mains switch. 44. Piping frame. 51. Mains connector. 53. Turret gasket kit. 54. Spark generator. 55. Ignition lead. 57. CH stub pipe. 1. Front casing panel. 2. Boiler 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 insulation. 13. Heat exchanger. 14. Injector and housing. 15. Venturi assembly. 16. Fan assembly. 17. Automatic air vent. 18. Gas service cock. 7 BOILER ASSEMBLY - Exploded View Legend 59. Flow restrictor. 60. DHW inlet/outlet pipe. 61. Pressure relief valve. 62. Expansion vessel. 63. Expansion vessel pipe. 64. Pressure gauge. 65. DHW thermistor. 66. *Diverter valve head. 67. *Diverter valve. 68. *Diverter valve manifold. 69. *Pump (Wilo pump shown). 70. Pump manifold. 71. DHW plate heat exchanger. 75. Control box clamp. 103. Dry fire thermistor. For further information contact: Fernox Manufacturing Co. Ltd Cookson Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ +44 (0) 1799 521133 Sentinel Performance Solutions The Heath Business & Technical Park Runcorn Cheshire WA7 4QXD Tel: 0800 389 4670 www.sentinel-solutions.net Salamander Engineering Ltd Unit 24 Reddicap Trading Estate Sutton Coldfield West Midlands B75 7BU Tel: +44 (0) 121 3780952 Calmag Ltd. Unit 4-6, Crown Works Bradford Road Sandbeds, Keighley West Yorkshire BD20 5LN Tel: +44 (0) 1535 210 320 *Note. Two waterset assemblies are used on this appliance, WILO and CP. These units are not interchangeable. 202851-1new.pmd 17/11/2006, 07:40 12

8 BOILER ASSEMBLY - Exploded View 8 5 44 53 14 13 15 62 59 18 64 4 75 35 36 66 67 23 23 68 24 71 17 26 25 3 19 57 60 6 11 12 40 103 39 32 21 16 69 70 61 57 60 51 65 10 9 20 2 63 1 nm8423 Data badge 94 WILO pump shown time P R O G R A M M E R prog prog select select + - INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 13

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. Pack A Contents A Boiler B Hardware Pack Box C Pre-piping Frame D These Installation/Users Instructions E Wall Mounting Template F 1 Year Guarantee Pack B Contents Flue turret. Flue terminal. Flue support cutting aid. Ecl 2354 Flue terminal Flue turret nm8424 B C E A D F time P R O G R A M M E R prog prog select select + - nm8452 A B C D E F G H I J K L R M N O P Q Hardware Pack Contents A Isolation valve c/w pressure gauge - 1 off B Isolation valve c/w drain - 1 off C Bulkhead connector - 1 off D Restrictor valve - 1 off E Compression gas cock - 1 off F Valve securing clip 22mm - 2 off G Valve securing clip 15mm - 3 off H Pre-piping frame support bracket - 1 off I S-trap hose - 1 off J 15mm olive - 1 off K Pressure relief valve nut - 1 off L No. 14x2in woodscrew - 4 off M Wallplug - 4 off N Fibre washer 19 ID x 26 OD - 3 off O 12mm sealing washer - 3 off P Gas line sealing washer - 1 off Q Hole plug white - 6 off R Mains connector - 1 off INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 14

1. Ensure the boiler is on a sound flat surface. 2. Carefully remove the strapping. 3. Fold back the top flaps to gain access to: z Instructions. z Wall mounting template. z 1 year guarantee. z 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 11 BOTTOM AND FRONT PANEL REMOVAL 1. Remove the screws from the underside of the boiler. 2. Pull the RHS of the panel down, slide it to the right and withdraw. 3. Remove the screws from bottom of the front panel. 4. Lift panel up and off top pegs. Boiler Hardware pack box Pre-piping frame nm8425 Retaining clip 2 1 3 time P R O G R A M M E R prog select + - INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 15

FLUE KITS Pack B - supplied as standard Pack D - optional extension kit for side flue or rear flue outlet. Finishing Kit - Supplied as an optional extra. 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. Note. MAXIMUM FLUE LENGTHS: HE24 AND 30 - 6M (HORIZONTAL FLUE) HE35 - 3M (HORIZONTAL FLUE) HE24 AND 30 - 8M (ROOF FLUE) HE35 - 5M (ROOF FLUE) HE 24 AND 30 - 14M TOTAL (POWERED VERTICAL FLUE) HE 35 - 8M TOTAL (POWERED VERTICAL FLUE) HE24 AND HE30 - 20M TOTAL (AIR PLUS FLUE DUCT-60/60 TWIN FLUE KIT) HE24, HE30 AND HE35 - 46M TOTAL (AIR PLUS FLUE DUCT - 80/80 TWIN FLUE KIT) 90O ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 1M) 45O ELBOW KIT 60/100 (EQUIVALENT FLUE LENGTH RESISTANCE = 0.6M) Total Flue length dimension Flue Rear flue Side flue Extra packs Boiler dim. X+160 dim. L+195 required size Up to 650 mm Up to 650 mm none HE24,30 & 35 Up to 1600 mm Up to 1600 mm Pack D - 1 off HE24,30 & 35 Up to 2550 mm Up to 2550 mm Pack D - 2 off HE24,30 & 35 Up to 3500 mm Up to 3500 mm Pack D - 3 off HE24 & 30 Up to 4450 mm Up to 4450 mm Pack D - 4 off HE24 & 30 Up to 5400 mm Up to 5400 mm Pack D - 5 off HE24 & 30 Up to 6000 mm Up to 6000 mm Pack D - 6 off HE24 & 30 INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 16

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 ensue 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 and tape template B into the selected position. 4. Mark onto the wall the following: a The 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 B Extended centre line LEGEND 1. Duct assembly. 2. Flue turret. 3. Turret gasket. 4. M5 x 10 pozi screw. 5. Turret clamp. 202851-1new.pmd 17/11/2006, 07:40 17

FLUE OUTLET 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 7.5mm / 8mm masonry drill and insert the plastic plugs, provided, for the piping frame. 3. Locate 4 No.14 x 50mm screws in the piping frame (one at each side, in any of the 3 holes provided at each side) and screw home. 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 around. 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 Note. If using the extension ducts go to Frame 18. 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 around. 4. Cut the inner tube to a length 20mm (3/4") longer to aid engagement, using the cardboard support. 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 202851-1new.pmd 17/11/2006, 07:40 18

FLUE OUTLET 1. A maximum of 6 extension ducts for the HE24/ HE30 and a maximum of 3 extension ducts for the HE35 (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 and 25. 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 around. 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 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 Use a maximum of 6m extended flue ONLY (HE24 & 30) Measure from this RING 2 3 9 Ecl 2540 Use a maximum of 3m extended flue ONLY (HE35) 202851-1new.pmd 17/11/2006, 07:40 19

FLUE OUTLET 21 FITTING THE PIPING FRAME AND VALVES (Rear Flue outlet shown) TO FIT THE PRE-PIPING FRAME 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. Note. Service connections may be made now, before mounting the boiler, if required. Refer to Frames 27-29. Piping frame Wall plug Screw (10mm proud) Support bracket nm8443 Note. Isolating valves are supplied separately in the hardware pack box. Fit to the piping frame BEFORE mounting the boiler. Piping frame Wall plug Screw (10mm proud) Support bracket nm8444 TO FIT THE PRE-PIPING FRAME USING THE STAND-OFF FRAME OPTION KIT (To allow pipework to be taken upwards) • 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 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. nm8453 Valve securing clip 15mm Valve securing clip 22mm Valve securing clip 22mm Isolation valve c/w pressure gauge Bulkhead connector Compression gas cock Restrictor valve Isolation valve c/w drain 1. Remove valves and clips from the hardware pack box. 2. Assemble valves to the frame and secure in place with clips provided. 3. Make sure to fit valves in correct order shown. 202851-1new.pmd 17/11/2006, 07:40 20

22 CONDENSATE DRAIN Refer also to the British Gas document: 'Guidance Notes for the Installation of Domestic Gas Condensing Boilers' (1989). Before mounting the boiler on the wall, the condensate drain (provided in the h/ware pack) must be connected from the boiler ‘S’ trap to a drainage point, preferably within the building. Ensure that the condensate trap is full of water before commissioning the boiler . Refer to Frame 26. 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 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. 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 23 CONDENSATE PIPE TERMINATION CONFIGURATIONS continued . . . . INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 21

24 CONDENSATE PIPE TERMINATION CONFIGURATIONS . . . continued BOILER cla7773 3. INTERNAL CONNECTION TO SOIL AND VENT STACK * Make connection to SVP using a solvent welded saddle BOILER External wall Ground Level Termination to Soak away cla7774 minimum 500mm BOILER External wall Ground Level Open end of pipe direct into gulley below grating but above water level DRAIN cla7775 4. TERMINATION TO SOAK AWAY 5. TERMINATION TO DRAIN / GULLEY INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 22

25 MOUNTING THE BOILER IMPORTANT. 1. Before mounting the boiler on the wall place it on its left hand side, fit the 'S' trap hose moulding/nut and fold the hose to facilitate fitting into pre-piping frame. 2. Ensure that the plastic plugs are removed from both the CH and DHW pipes before mounting. N.B. Some spillage of water may occur from the pipework when mounting the boiler to the frame. 3. Lift the boiler onto the wall mounting frame, locating it over the tabs at the top of the frame. 4. Lower the boiler into position, engaging it onto the support bracket. Note. Ensure the condensate drain pipe is correctly positioned through the hole in the pre-piping frame before continuing. 5. Using the fibre washers supplied in the hardware pack box, engage and then tighten the 4 water unions. 6. Engage and tighten the gas union, ensuring that the blue fibre washer is in place. DO NOT overtighten. 7. Connect a pipe to the safety drain outlet using the nut and olive supplied in the boiler hardware pack box. nm8024 time P R O G R A M M E R prog select + - 1 INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 23

C.H. FLOW C.H. RETURN nm8454 22mm copper pipe Isolating valve (shown in the open position) Piping frame Drain point 22mm copper pipe Isolating valve (shown in the open position) Pressure gauge Condensate drain pipe located here. Compression gas cock 27 WATER CONNECTIONS - CH 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. nm7898 2 1 3 26 CONNECTING THE FLUE TO THE BOILER Note. Before fitting the flue turret fill the condensate trap within the boiler by pouring a cupful of water into 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. 1. Locate the flue into the turret. 2. Insert the flue assembly through the prepared hole in the wall. 3. Locate the flue turret on the top of the boiler, ensuring that the turret gasket is in place. Check that the flue seal ‘A’ located in the top of the flue manifold is secure and giving an effective seal. 4. Secure the flue turret on top of the boiler by inserting the open ends of the turret clamp under the 2 studs and fixing it in the middle with the single M5 x 10mm pozi-hex screw provided. 5. Flues over 1 metre long. Fix the flue support bracket to the wall, using the 4 wall plugs and wood screws. NB. The space bracket will utilise one fixing hole only whilst used in conjunction with the stand-off option. INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 24

nm8456 Piping frame Blue fibre washer Compression gas cock (shown in the open position) GAS IN D.H.W. Inlet D.H.W. Outlet nm8455 15mm copper pipe 15mm copper pipe Regulator / Filter 'O' Ring Piping frame Isolating valve (shown in the open position) Compression gas cock Outlet connector Retaining screw Cross bar IMPORTANT. The gas service cock is sealed with a non-metallic blue fibre washer so must not be overheated when making capillary connections. Refer to Frame 2 for details of the position of the gas connection. N.B. The principle of the 1:1 gas valve ensures that the isar 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. A boiler gas supply pipe length of 20m and not less than 15mm O.D. can be connected to the boiler via the gas service cock union. Ensure that the gas supply pipe does not foul the boiler casing. Refer to Frame 38 or 'Servicing' for details of the pressure test point position. 29 GAS CONNECTION 28 WATER CONNECTIONS - DHW Note. The DHW inlet isolating valve incorporates a flow regulator / filter. It should be inspected to ensure no blockage is evident. 1. To remove, turn off the valve, undo the retaining screw and pull out the filter by grasping the crossbar with pliers. 2. Reassemble in reverse order, inserting in the direction of the arrow. INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 25

31 FILLING Central Heating 1. Remove the sealing panel. Refer to Frames 44 & 45. 2. Swing the control box down into the servicing position. Refer to Frame 46. 3. Ensure that the CH isolating valves are open. 4. Fill and vent the system. Check for water soundness. Note. The domestic hot water flow rate is automatically regulated to a maximum: HE24 = 9.6 l/m (2.1 gpm) HE30 = 12.0 l/m (2.6 gpm) HE35 = 14.4 l/m (3.2 gpm) The safety valve is located at the bottom RHS of the boiler. The discharge pipe should be positioned so that the discharge of water or steam cannot create a hazard to the occupants of the premises or damage the electrical components and wiring. 30 SAFETY VALVE DRAIN IMPORTANT - when filling: a. Remove the diverter valve actuator (refer to Frame 62) and depress the spindle several times during filling. Replace diverter valve actuator. b. When filling, there may be a slight water leak from the air vent therefore electrical connections should be protected. c. Bleed any air from the pump and ensure that it is free to rotate. For Wilo Pump: To ensure the pump is free to rotate: i. Remove the vent plug ii. Using a screwdriver, rotate the shaft several times For CP Pump: To ensure the pump is free to rotate: i. Unscrew the central cap. ii. Gently pull the cap out to engage with the shaft. iii. Rotate the cap and spindle. Note. Some slight water leakage will occur. Domestic Hot Water 1. Fully open all DHW taps and ensure that water flows freely from them. 2. Close all taps. To vent the pump: Repeat steps i. and ii. Move the fitting from side to side to allow air to vent. Ensure the cap is fully retightened. iii. Replace the vent plug. Note. Some slight water leakage will occur. Pump Automatic air vent Central Cap nm8412 c. INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 26

32 ELECTRICAL CONNECTIONS Wiring should be 3 core PVC insulated cable, not less than 0.75 mm2 (24 x 0.2mm), and to BS 6500 Table 16. For IE reference should be made to the current ETCI rules for electrical installations. Connection must be made in a way that allows complete isolation of the electrical supply such as a double pole switch having a 3mm (1/8") contact separation in both poles, or a plug and socket, serving only the boiler and system controls. The means of isolation must be accessible to the user after installation. WARNING. This appliance MUST be earthed. A mains supply of 230 V ~ 50 Hz is required. The fuse rating should be 3A. All external controls and wiring must be suitable for mains voltage. Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations. 1. Route the mains cable into the bottom rear centre of the boiler. 2. Wire the permanent live supply into the 5-way remote plug terminals, L3, N & . IMPORTANT. A permanent live is ESSENTIAL in order for the advanced diagnostic controls to function correctly. 33 INTERNAL WIRING 3. Wire the normal room thermostat switched live supply into L2 or connect L1 and L2 via external control switching as shown in Frame 34. In either case remove the wire link fitted to L1 to L2. 4. Secure the mains lead with the cable clamp. 5. Connect the mains lead connector. Ensure it is fully located. L3 N L2 L1 Mains Connector (supplied in hardware pack) Socket (fixed to boiler) Remove link when connecting external programmer. nm8071 Ecl 1542 A pictorial wiring diagram is shown in Frame 35. Note. Ensure that the lengths of the current carrying conductors are shorter than the earth conductor so that if the cable slips in its anchorage the current carrying conductors become taut before the earth conductor. INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 27

34 EXTERNAL ELECTRICAL CONTROLS Wiring External to the Boiler The fuse rating should be 3A. Wiring external to the boiler MUST be in accordance with the current I.E.E. (BS.7671) Wiring Regulations and any local regulations. Room Thermostat If the thermostat has a neutral connection, use it (it provides for more energy efficient operation by reducing switching temperature differentials). Frost Protection If parts of the pipework run outside the house or if the boiler will be left off for more than a day or so then a frost thermostat should be wired into the system. The frost thermostat should be sited in a cold place but where it can sense heat from the system. L3 L2 L1 N Room 'stat N if required nm8428 A Mains in System controls System Controls L N nm8429 Diagram A shows an application to boilers fitted with a room thermostat only. Diagram B shows the fitting of a frost thermostat. An option kit must be purchased to allow this. Earths are not shown for clarity but must never be omitted. INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 28

nm8413 Dry fire thermistor Diverter Valve Permanent black link br b bk y/g y/g 35 PICTORIAL WIRING DIAGRAM LEGEND b - blue bk - black br - brown gy - grey or - orange pk - pink r - red v - violet w - white y - yellow y/g - yellow/green INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 29

Dry fire thermistor nm8414 Diverter Valve 36 FUNCTIONAL FLOW WIRING DIAGRAM WARNING. Whilst effecting the required gas soundness test and purging air from the gas installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE. A. Electrical Installation 1. Checks to ensure electrical safety should be carried out by a competent person. 2. ALWAYS carry out the preliminary electrical system checks, i.e. earth continuity, polarity, resistance to earth and short circuit, using a suitable test meter. B. Gas Installation 1. The whole of the gas installation, including the meter, should be inspected and tested for soundness and purged in accordance with the recommendations of BS. 6891. In IE refer to IS.813:2002. 2. Purge air from the gas installation by the approved methods only. 37 COMMISSIONING AND TESTING LEGEND b - blue bk - black br - brown gy - grey or - orange pk - pink r - red v - violet w - white y - yellow y/g - yellow/green INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 30

nm8430 time P R O G R A M M E R prog prog select select + - B T S K H E D G J L M N Q F R P C 38 INITIAL LIGHTING 1. Check that the system has been filled and that the boiler is not airlocked. Ensure the automatic air vent cap (K) is open. Note. It is important the burner is not operated before the system is fully vented of air. If it is necessary to operate the appliance pump to assist venting of the air this must be done with the gas service cock turned off. 2. Refit the boiler sealing panel. Refer to Frame 45. 3. Check that all the drain cocks are closed and that the CH and DHW isolating valves (P, R and N) are OPEN. 4. Check that the electrical supply is OFF. 5. Check that the boiler on/off switch (A) is off. 6. Carefully align the user control and push gently into place. Secure with the single screw located underneath. 7. Check that the gas service cock (F) is OPEN. 8. Slacken the screw in the inlet pressure test point (E) and connect a gas pressure gauge via a flexible tube. 9. Swing the control box to the working position and secure with the clamp. 10. Connect the low voltage electrical lead from the user control to the control box (refer to Frame 46). 11. Screw the control into position. 12. Switch the electricity supply ON and check all external controls are calling for heat. 13. CENTRAL HEATING Switch the boiler on/off switch (A) to ON. The boiler control should now go through its ignition sequence until the burner is established. LEGEND A. Boiler On/Off switch B. LED display C. Select (reset) button D. Injector pressure test point E. Inlet pressure test point F. Gas service cock G. Casing pressure test point H. Overheat thermostat J. Control thermistor (flow) K. Automatic air vent L. Control box (Servicing position) M. Pressure gauge N. CH Flow isolating valve P. CH Return isolating valve Q. DHW outlet R. DHW inlet S. Spark generator T. Condensate drain 14. If the boiler does not light after 3 attempts the fault code “LF” will be displayed, Press the select button (C) and the boiler will repeat its ignition sequence. When the burner is established the flame 'Burner On' indicator will be illuminated, the LED display will show the radiator status symbol. The itime programmer display The LCD display has a number of indicators to show the operation of the boiler. In stand-by mode there are no additional indicators other than the time of day. Each channel, CH and DHW, status is shown as OFF, ON, TIMED or ADVANCE (see users guide). In a timed on period the status of the boiler is: Radiator symbol indicats CH demand. Tap symbol indicates DHW or preheat demand. Flame symbol indicates burner status. In error conditions the following indicates the error: Blocking error is proceeded by “H” on the LCD display. Locking out error is proceeded by a “L” on the LCD display. INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 31

40 GENERAL CHECKS 39 INITIAL LIGHTING - continued 15. DOMESTIC HOT WATER Ensure programmer is in an ‘ON’ DHW period. With the boiler firing, fully open a DHW tap. The boiler should continue to run and the LED display should show the tap status symbol. 16. Ensure that with the boiler operating the dynamic gas pressure is able to obtain maximum output. Refer to Table 2. N.B. The principle of the 1:1 gas valve ensures that the isar HE range is able to deliver it’s full output at inlet pressures down to 14mb. However if dynamic pressures below 20mb are experienced ensure this is adequate for ALL other gas appliances in the property. IMPORTANT The gas input to the burner is regulated by the gas valve according to the air flow produced by the fan. It is NOT user-adjustable. Any interference to sealed settings on the gas valve will adversely affect operation and render our warranty void. DOMESTIC HOT WATER (DHW) MODE 1. With no call for CH or DHW the boiler should fire for a short period to preheat the DHW plate heat exchanger. The LCD display symbol will be: returning to none when the burner switches off. Notes. a. If no DHW is drawn off, the boiler will fire periodically for a short time, to maintain the plate heat exchanger temperature. b. DHW pre-heat will be inhibited during programmed DHW off periods. 2. Fully open all DHW taps in turn and ensure that water flows freely from them. The LCD display symbols will be: then when the burner lights. Make the following checks for correct operation in: 3. Close all taps except the furthest one from the boiler and check that the boiler is firing at maximum rate. This is factory set to give a DHW temperature rise of approximately 35oC at the flow rate stated on page 6 under “operation”. 4. Reduce the DHW draw-off rate to about 3 l/min (0.7gpm) and check that the boiler modulates to deliver DHW at approximately 65oC. 5. Close the DHW tap and check that the main burner extinguishes. The pump should overrun for a few seconds and the display symbols should read: When the pump stops the display symbols clear Note. On systems in excess of 2 bar inlet pressure a water pressure governor may be required to prevent water noise. 17. Turn off the DHW tap. 18. Set the boiler on/off switch (A) to OFF. 19. Swing the control box into the servicing position. Refer to Frame 46. 20. Remove the pressure gauge and tube. Tighten the sealing screw in the pressure test point. Ensure a gas tight seal is made. 21. Swing the control box back into its working position and secure. Reconnect the ignition lead. 22. Refit the user control. 23. Fit the boiler front and bottom panels. 24. THE FASCIA a. To remove the plastic fascia, prise off the retaining star washers using a pair of pliers and place to one side. b. Fill the remaining fixing holes with the white push in caps provided. 25. Switch the boiler on again. INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 32

WATER TEMPERATURES Temperatures can be selected via the CH and DHW temperature settings (see users guide). 41 GENERAL CHECKS - continued Setting CH Flow DHW Outlet Temp Temp oC ( oF) oC ( oF) Max 82 (180) 65 (150) Min 30 (86) 42 (110) CENTRAL HEATING (CH) & DOMESTIC HOT WATER (DHW) MODE. 1. Ensure that the CH external controls are calling for heat. The LCD display symbols should be: 2. Fully open a DHW tap and check that hot water is delivered. The LCD display symbols should be: 3. Gas Rate Check the boiler gas rate when the boiler is at full DHW output. Check at the gas meter, with no other appliance in use. Refer to Table 3 for gas rates. 4. Close the DHW tap. The burner should go off and the pump continue to run. The LCD display symbol should be: then After 15 seconds the burner should relight, to supply central heating. The LCD display symbols should be: 5. Set the central heating external controls to OFF. The burner should go off and the pump continue to run for a few seconds. The LCD display symbols should be: returning to none when the pump stops. 6. Check the correct operation of the programmer (if fitted) and all other system controls. Operate each control separately and check that the main burner responds. WATER CIRCULATION SYSTEM 1. With the system COLD, check that the initial pressure is correct to the system design requirements. For pre-pressurised systems, this should be 1.0 bar. 2. With the system HOT, examine all water connections for soundness. The system pressure will increase with temperature rise but should not exceed 2.5 bar. 3. With the system still hot, turn off the gas, water and electricity supplies to the boiler and drain down to complete the flushing process. Note.A flushing solution should be used during the flushing procedure. Flushing solutions: Fernox Superfloc, Sentinel X300 (new systems) or X400 (existing systems). Refer to Frame 6. 4. Refill and vent the system, add inhibitor (see Frame 6), clear all air locks and again check for water soundness. Affix the water treatment warning label, supplied in the hardware pack, in a prominent position on the system, to prevent the use of incorrect water treatment additives. 5. Reset the system initial pressure to the design requirement. 6. Balance the system. Refer to Frame 5. 7. Check the condensate drain for leaks and check that it is discharging correctly. 8. Finally, set the controls to the User's requirements. Note.The pump will operate briefly as a self-check once every 24 hours in the absence of any system demand. INSTALLATION 202851-1new.pmd 17/11/2006, 07:40 33

43 SERVICING SCHEDULE To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular intervals and serviced as necessary. The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually. It is the law that any service work must be carried out by a CORGI registered installer. In IE service work must be carried out by a competent person. 1. Light the boiler and carry out a pre-service check, noting any operational faults. 2. Check the gas consumption. 3. Connect a suitable gas analyser to the sampling point on the top of the boiler (refer to Frame 45) or into the flue terminal if access is possible (optional test). For correct boiler operation, the CO/CO2 content of the flue gas should not be greater than 0.004 ratio. If this is the case, and the gas input is at least 90% of the nominal, then no further action need be taken. If not, proceed to Step 5 but see note above. 4. Clean the main burner. 5. Clean the heat exchanger & ‘S’ trap. 6. Check the condition of the combustion chamber insulation. Any cracked or damaged pieces should be replaced. 7. Check the main injector for blockage or damage. 8. Wherever possible remove and clean the condensate ‘S’ trap (refer to Frame 49) and check the drain for blockage. 9. Check that the flue terminal is unobstructed and that the flue system is sealed correctly. 10. Check the DHW filter for blockage. Refer to Frame 28. The servicing procedures are covered more fully in Frames 44-51 and MUST be carried out in sequence. Note. In order to carry out either servicing or replacement of components the boiler front panel and sealing panel must be removed. Refer to Frames 44 and 45. WARNING. Always turn OFF the gas supply at the gas service cock, and switch OFF and disconnect the electricity supply to the appliance before servicing. IMPORTANT. 11. After completing the servicing or exchange of components always test for gas soundness and carry out functional checks in 2 and 3 above. 12. When work is complete the sealing panel MUST be correctly refitted, ensuring that a good seal is made. Do NOT OPERATE the boiler if the sealing panel is not fitted. 13. If, for any reason, the condensate ‘S’ trap has been removed ensure the trap is refilled with water before reassembling. 14. Complete the service section in the Benchmark Commissioning Checklist. 42 HANDING OVER 6. Explain and demonstrate the function of time and temperature controls, radiator valves etc., for the economic use of the system. 7. Draw attention to the Programmer Users Instructions and hand them to the householder. 8. Loss of system water pressure Explain that the dial underneath the boiler indicates the central heating system pressure and that if the normal COLD pressure of the system is seen to decrease over a period of time then a water leak is indicated. Explain the re- pressurising procedure and if unable to repressurise or if the pressure continues to drop a registered local heating installer should be consulted. WARNING. Do not fire the boiler if the pressure has reduced to zero from the original setting. 9. After installation and commissioning please complete the Commissioning Checklist before handover to the customer. For IE, its is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 813:2002. 10. IMPORTANT A comprehensive service should be carried out ANNUALLY. Stress the importance of regular servicing by a CORGI registered installer. In IE servicing work must be carried out by a competent person. 11. As the installer you may wish to undertake the service contract yourself or alternatively offer to the customer the benefits of the Ideal Care Scheme, details of which are outlined in the householder pack supplied with this boiler. 1. Hand the User Instructions and Quick Reference Guide to the householder and explain his/her responsibilities under the relevant national regulations. 2. Explain and demonstrate the lighting and shutting down procedures. 3. The operation of the boiler and the use and adjustment of all system controls should be fully explained to the householder, to ensure the greatest possible fuel economy consistent with the household requirements of both heating and hot water consumption. Advise the User of the precautions necessary to prevent damage to the system and to the building, in the event of the system remaining inoperative during frosty conditions. 4. Explain the function and the use of the boiler heating and domestic hot water controls. Explain that due to system variations and seasonal temperature fluctuations DHW flow rates/temperature rise will vary, requiring adjustment at the draw off tap. It is therefore necessary to draw the users attention to the section in the Users Instructions titled “Control of Water Temperature” and the following statement: “Additionally, the temperature can be controlled by the user via the draw-off tap: the lower the rate the higher the temperature, and vice versa”. 5. Explain the function of the boiler fault mode. Emphasise that if a fault is indicated, the boiler should be turned off and a CORGI registered local heating installer consulted. In IE contact a competent person. After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions: SERVICING 202851-1new.pmd 17/11/2006, 07:40 34

45 BOILER SEALING PANEL / BOTTOM PANEL REMOVAL 44 BOILER FRONT PANEL REMOVAL 1. Remove the 2 screws from the underside of the boiler. 2. Pull the panel forward at the bottom and lift to disengage it from the top lugs. time P R O G R A M M E R prog prog select select + - nm8431 1. To remove the sealing panel remove the 4 screws. 2. Remove the panel. 3. To remove the bottom panel remove the 2 screws. 4. Pull the right hand side of the panel down. Slide it to the right and withdraw. time P R O G R A M M E R prog prog select select + - nm8432 SERVICING 202851-1new.pmd 17/11/2006, 07:40 35

46 THE CONTROL BOX IN THE SERVICING POSITION 1. Remove the 2 screws and withdraw the user control. 2. Unplug the low voltage electrical lead from the back of the user control. 3. Turn the clamp, swing the control box down and pull slightly forward. nm8433 time P R O G R A M M E R prog prog select select + - nm7540 SERVICING 202851-1new.pmd 17/11/2006, 07:40 36

2 3 1 4 Ecl 6073 47 FAN AND VENTURI ASSEMBLY REMOVAL AND CLEANING 48 BURNER REMOVAL AND CLEANING 1. Remove the 6 screws securing the burner (the 3 screws at the rear are extended to ease access). 2. Lift off the burner from the combustion chamber. IMPORTANT The burner head is a ceramic plaque construction. Care must be taken to ensure that the burner is not placed down upon its face as this may cause damage to the ceramic. 3. Brush off any deposits that may be on the ceramic with a SOFT brush. 4. Inspect the sealing gasket around the burner and combustion chamber insulation for any signs of damage. Replace as necessary. Note. Take care not to disturb the ionisation probes at the front and rear of the combustion chamber. 1. Disconnect the electrical leads from the fan. 2. Undo the gas pipe union connection to the injector housing. 3. Undo the screw on the fan mounting bracket. 4. Lift off fan and venturi assembly. 5. Inspect the injector for blockage or damage. nm7400 Ionisation Probes 1 2 4 SERVICING 202851-1new.pmd 17/11/2006, 07:40 37

50 CLEANING THE HEAT EXCHANGER Reassemble the boiler in the following order: 1. Refit the condensate ‘S’ trap, ensuring that it is full of water. 2. Refit the sump cover. 3. Refit the electrodes. (Check dimensions; Frames 58 & 59). 4. Refit the burner. 5. Refit the fan / venturi assembly. 6. Reconnect the fan electrical lead. 1. Remove ignition and flame detection electrodes. Refer to Frames 58 & 59. 2. Remove the 3 screws retaining the sump cover and remove. 3. Using a suitable tool as supplied in the standard British Gas Flue brush kit, clean between the heat exchanger fins from the top of the heat exchanger. 4. Access to the base of the heat exchanger is now possible. Brush clean any deposits from the base of the heat exchanger and remove any loose deposits from the sump. 5. Inspect the ignition and detection electrodes. Ensure that they are clean and in good condition - replace if necessary. 6. Check the condition of the combustion chamber insulation. Any cracked or damaged pieces must be replaced. Note. Take care not to disturb the ionisation probes at the front and rear of the combustion chamber. 7. Check that the ignition and detection gaps are correct. Refer to Frames 58 & 59. 7. Refit the boiler sealing panel. IMPORTANT. Ensure that the boiler sealing panel is correctly fitted and that a good seal is made. 8. Swing the control box back into its working position and secure. 9. Refit the display unit. 10. Refit the boiler front and bottom panels. 11. Turn on the gas supply at the gas service cock. 12. Reconnect the electrical supply. 51 REASSEMBLY 1. Swing the control box down into the servicing position. Refer to Frame 46. 2. Disconnect the condensate drain pipe. 3. Remove the screw and elongated bolt, pull the trap down and forward to remove. 4. Flush out any deposits with clean water. 49 CLEANING THE CONDENSATE 'S' TRAP nm7401 2 Sump cover 3 Ionisation probes Heat exchanger SERVICING 202851-1new.pmd 17/11/2006, 07:40 38

Gasket Orifice plate Ecl 2373 5 3 7 4 52 REPLACEMENT OF COMPONENTS GENERAL When replacing ANY component 1. Isolate the electricity supply. 2. Turn off the gas supply. 3. Remove the boiler front panel. Refer to Frame 44. After replacing ANY component check operation of the boiler, including gas soundness, gas rate and combustion test. 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 44 & 45. 3. Drain down the boiler. Refer to Frame 72. 4. Unplug the electrical lead. 5. Unscrew the thermistor. 6. Fit the new thermistor using the sealing washer provided. 7. Reassemble in the reverse order. 8. Check the operation of the boiler. 53 DRY FIRE THERMISTOR REPLACEMENT 54 FAN REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 44 & 45. 3. Disconnect the electrical leads from the fan. 4. Undo the gas pipe union connection to the injector housing. 5. Remove the screw retaining the fan mounting bracket. 6. Remove the fan and venturi assembly. Refer to Frame 47. 7. Unscrew the 3 screws and remove the venturi assembly, noting the orientation of the venturi in relation to the fan body. 8. Transfer the venturi assembly to the new fan, replacing the gasket if evidence of damage or deterioration is visible. 9. Fit the new fan / venturi assembly. 10. Reassemble the boiler in reverse order, taking care not to overtighten the screw on the fan mounting bracket. 11. Check the operation of the boiler. Refer to Frame 52. IMPORTANT. When work is complete, the sealing panel, if removed, must be correctly refitted - ensuring that a good seal is made. Notes. 1. In order to assist fault finding, the control panel has an LED diagnostic display. The key to boiler fault conditions is shown in Frame 79. 2. In order to replace components in Frames 69-77 it is necessary to drain the boiler. Refer to Frame 72. THE BOILER MUST NOT BE OPERATED WITHOUT THE SEALING PANEL FITTED nm8027 SERVICING 202851-1new.pmd 17/11/2006, 07:40 39

56 BURNER REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 44 & 45. 3. Remove the fan assembly. Refer to Frame 54. 4. Remove the 6 screws securing the burner (the 3 screws at the rear are extended to ease access). 5. Lift off the burner from the combustion chamber. 6. Fit the new burner, replacing any damaged or deteriorating sealing gasket. 7. Reassemble in reverse order. 8. Check the operation of the boiler. Refer to Frame 52. Note. Take care not to disturb the ionisation probes at the front and rear of the combustion chamber. 55 BURNER INJECTOR REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 44 & 45. 3. Disconnect the electrical leads from the fan. 4. Undo the gas pipe union connection to the injector housing. 5. Remove the screw retaining the fan mounting bracket. 6. Remove the fan and venturi assembly 7. Remove the 2 injector housing screws. 8. Withdraw the injector housing. 9. Fit the new injector housing complete with injector. 10. Reassemble in reverse order, ensuring that the new gas seal supplied is located correctly in the injector housing. 11. Check operation of the boiler. Refer to Frame 52. Mounting bracket 7 Ecl 2400 5 Injector Fan Gas pipe union time P R O G R A M M E R prog prog select select + - nm8434 57 CONTROL THERMISTOR, RETURN THERMISTOR & OVERHEAT ‘STAT REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 44 & 45. 3. Unclip the thermistor / thermostat from the flow / return pipe and withdraw it from the controls compartment. 4. Disconnect the electrical leads from the thermistor / thermostat. 5. Reconnect the electrical leads and reassemble in reverse order, ensuring that the spring clip is securely on the pipe. 6. Check the operation of the boiler. Refer to Frame 52. nm7402 Ionisation Probes 4 5 6 SERVICING 202851-1new.pmd 17/11/2006, 07:40 40

58 IGNITION ELECTRODE REPLACEMENT 59 FLAME DETECTION ELECTRODE REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 44 & 45. 3. Unplug the ignition lead from the electrode. 4. Remove the earth lead from the ignition electrode. 5. Remove the remaining screw holding the ignition electrode to the combustion chamber. 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 44 & 45. 3. Unplug the flame detection lead from the electrode. 4. Remove the 2 screws holding the flame detection electrode to the combustion chamber. 6. Remove the electrode. 7. Fit the new ignition electrode, using the new gasket supplied. Check dimensions as shown. 8. Reassemble in reverse order, and check that no damage to the combustion chamber insulation has occurred during the electrode replacement. 9. Check the operation of the boiler. Refer to Frame 52. 5. Remove the electrode. 6. Fit the new flame detection electrode, using the new gasket supplied. Check dimensions as shown. 7. Reassemble in reverse order, and check that no damage to the combustion chamber insulation has occurred during the electrode replacement. 8. Check the operation of the boiler. Refer to Frame 52. 60 SPARK GENERATOR REPLACEMENT 1. Refer to Frame 52. 2. Disconnect the leads from the spark generator and bracket. 3. Remove the M5 screw securing the spark generator bracket to the flue casting. 4. Remove the 2 M4 screws securing the spark generator to the bracket. 5. Fit the new spark generator and re-assemble in reverse order. 6. Check operation of the boiler. Refer to Frame 52. 4 2 3 nm7548 SERVICING 202851-1new.pmd 17/11/2006, 07:40 41

61 GAS CONTROL VALVE REPLACEMENT 1. Refer to Frame 52. 2. Remove the casing front & bottom panel. Refer to Frames 44 & 45. 3. Swing the control box down into the servicing position. Refer to Frame 46. 4. Unplug the electrical lead from the gas control valve and disconnect the earth wire. 5. Remove the sensing tube from the gas control valve. 6. Undo the gas inlet pipe union at the gas service cock. 7. Undo the union nut on the outlet of the gas control valve. 8. Slacken the screw securing the valve mounting bracket and withdraw the valve, complete with bracket and inlet pipe. 9. Transfer the mounting bracket and gas inlet pipe to the new gas control valve. 10. Fit the new gas control valve, ensuring that any seals showing damage or deterioration are replaced. Reassemble in reverse order. 11. Ensure the sensing tube is correctly replaced and not kinked or blocked in any way. 12. Check operation of the boiler. Refer to Frame 52. 62 DIVERTER VALVE ACTUATOR REPLACEMENT 1. Refer to Frame 52. 2. Remove the casing front & bottom panel. Refer to Frames 44 & 45. 3. Squeeze the tab and unplug the electrical lead from the valve actuator. 4. Rotate the actuator anticlockwise and pull forward to remove. 5. Fit new actuator and reassemble in reverse order. 6. Check operation of the boiler. Refer to Frame 52. 2040 Electrical lead Tab Diverter valve actuator SERVICING 202851-1new.pmd 17/11/2006, 07:41 42

Rear Front Combustion chamber LH Side RH Side nm8033 7 6 5 63 COMBUSTION CHAMBER INSULATION REPLACEMENT The insulation boards used in the combustion chamber of this product are made of high temperature glass fibres with a binder of organic and inorganic materials. Caradon Ideal Limited recommend that, for your own comfort and safety and to comply with good working practice, the procedure described below is followed: 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 44 & 45. 3. Remove the fan / venturi assembly. Refer to Frame 47. 4. Remove the burner. Refer to Frame 48. 5. Remove the ignition electrode. Refer to Frame 58. 6. Remove the flame detection electrode. Refer to Frame 59. 7. Remove the front and rear ionisation probes. Prior to removal of the board the following protective equipment should be worn: z Face mask supplied with the spare part. z Gloves supplied with the spare part. 8. Damp down the combustion chamber area containing the insulation boards. 9. Remove the split pin and washer from the RHS of the combustion chamber. 10. Remove the insulation boards. The replacement boards are supplied in a plastic bag. This bag should be retained and the discarded boards should now be placed into it. 11. Sweep any dampened particles and place in the plastic bag. 12. Fit new insulation boards. Note. The boards are designed to be interlocking and should be fitted as shown. 13. Fit the new split pin and washer in the RHS of the chamber. 14. Remove the gloves and face mask and place them in the plastic bag. 15. Wash your hands and any areas of skin which may have come into contact with any of the particles from the insulation board. Note. Seal the plastic bag and dispose of it and its contents into a commercial tip. 16. Reassemble in reverse order, remembering to re-fit the ionisation probes first. 17. Check operation of the boiler. Refer to Frame 52. Fit insulation in the following order: 1. Rear. 2. Left Hand Side. 3. Front. 4. Right Hand Side. SERVICING 202851-1new.pmd 17/11/2006, 07:41 43

64 CONDENSATE 'S' TRAP REPLACEMENT 1. Refer to Frame 52. 2. Remove the casing front & bottom panel. Refer to Frames 44 & 45. 3. Swing the control box down into the servicing position. Refer to Frame 46. 4. Disconnect the condensate drain pipe. 5. Remove the securing screw and elongated bolt, pull the trap down and forward to remove. 6. Transfer the drain pipe to the new trap and reassemble in reverse order. 7. When reassembling ensure the trap is full of water. 8. Check operation of the boiler. Refer to Frame 52. 65 DHW THERMISTOR REPLACEMENT 1. Refer to Frames 52 & 72 for draining the appliance. 2. Remove the casing front & bottom panel. Refer to Frames 44 & 45. 3. Remove the 4 screws securing the support plate and withdraw the plate. Note. The M4 screws fit the casing and the self-tapping screws fit the plastic pump and valve housings. 4. Withdraw the securing pin. 5. Disconnect the electrical lead. 6. Ease out the sensor and discard. 7. Fit the new sensor, ensuring silicone grease is applied to the 'O' ring. 8. Refit the securing pin. 9. Reassemble in reverse order, ensuring correct location of screws in support plate, and that tabs on the pump and valve housings engage in slots. 10. Check operation of the boiler. Refer to Frame 52. Support plate Discharge pipe M4 screw 2055 M4 screw Self tapper screw Sensor Electrical lead Securing pin 2042 SERVICING 202851-1new.pmd 17/11/2006, 07:41 44

Screws C. B . A. Hinge arms Control box mounting bracket Electrical lead Control box Control box Control box nm7541 Low voltage lead Clamp 3 nm8435 itime programmer unit User control time P R O G R A M M E R prog prog select select + - 1. Refer to Frame 52. 2. Remove the casing front & bottom panel. Refer to Frames 44 & 45. 3. Remove the 2 screws and allow the user control to lower. 4. Push out the mains switch from the rear, as shown. 5. Fit the new switch, ensuring that the electrical leads are 67 MAINS SWITCH REPLACEMENT 66 CONTROL BOX REPLACEMENT 1. Refer to Frame 52. 2. Remove the casing front & bottom panel. Refer to Frames 44 & 45. 3. Swing the control box down into the servicing position. Refer to Frame 46. 4. Unplug the user control electrical lead and low voltage lead from the control box and remove the control. Refer to diagram A. 5. Return the control box to the working position and secure with the clamp. Unscrew the mounting bracket screws to remove the bracket. Refer to diagram B. 6. Release the clamp and carefully remove the control box from the hinge arms. Refer to diagram C. 7. Unplug all the electrical wiring from the control box and remove. 8. Transfer mounting bracket and hinge arms to the new control box. 9. Reassemble in reverse order, ensuring that the control box is located correctly in the housing before reconnecting the electrical wiring. 10. Check operation of the boiler. Refer to Frame 52. nm8436 itime programmer unit replaced on the correct terminals (refer to Frame 36) and the key on the switch is correctly aligned with the slot in the plastic moulding. 6. Reassemble in reverse order. 7. Check operation of the boiler. Refer to Frame 52. SERVICING 202851-1new.pmd 17/11/2006, 07:41 45

time P R O G R A M M E R prog prog select select + - nm8437 itime programmer unit 2 itime programmer unit nm8438 time P R O G R A M M E R prog prog select select + - Note. Only the display unit is replaced. 1. Refer to Frame 52. 2. Loosen the screw on the underside of the user control. 3. Pull the display unit forward to remove. 4. Push the new display unit into position. 5. Reassemble in reverse order. 6. Check operation of the boiler. Refer to Frame 52. 68 USER CONTROL REPLACEMENT 69 PRESSURE GAUGE REPLACEMENT 1. Refer to Frame 52. 2. Drain the boiler. Refer to Frame 72. 3. Unscrew the pressure gauge and discard. 4. Fit the new pressure gauge, using a suitable jointing compound. 5. Refill the boiler. Refer to Frame 31. 6. Check operation of the boiler. Refer to Frame 52. 2041 Pressure gauge Flow isolation valve (shown in the open position) SERVICING 202851-1new.pmd 17/11/2006, 07:41 46

70 SAFETY RELIEF VALVE REPLACEMENT 1. Refer to Frame 52. 2. Remove the casing front and bottom panels. Refer to Frames 44 & 45. 3. Drain the boiler. Refer to Frame 72. 4. Remove the discharge pipe. 5. Remove the 4 screws retaining the rear support plate and withdraw the plate. Note.The M4 screws fit the casing and the self -tapping screws fit the plastic pump and valve housings, as shown. 6. Withdraw the securing pin. 71 AUTOMATIC AIR VENT REPLACEMENT 1. Refer to Frame 52 2. Remove the boiler front and sealing panels. Refer to frames 44 and 45. 3. Drain the boiler. Refer to frame 72. 4. Remove the turret from the boiler. Refer to frame 26. 5. Release the silicon tubing from the sample point. 6. Release the electrical connections from the dry fire thermistor. 7. Release the electrical connections from the spark generator. 8. Remove the M5 nut retaining the flue casting spring clip and remove the spring clip. 9. Undo the 2 M5 x 10 flue spring clip retaining bracket screws and remove the bracket. 10. Remove the M5 x 10 screw retaining the flue casting. 11. Remove the flue casting. 12. Remove the screw and rear bracket. Pull the air vent and plug assembly from the heat exchanger and replace with the parts supplied in the air vent kit. 13. Re assemble the boiler in reverse order. 14. Refill the boiler. Refer to frame 31. Check for leaks around the new air vent joint. 15. Check the operation of the boiler. Refer to frame 52. 7. Remove the safety valve. 8. Fit the new safety valve and refit the securing pin. 9. Reassemble in reverse order, ensuring correct location of screws in the support plate and that tabs on the pump and valve housings engage in slots. 10. Reconnect the discharge pipe. 11. Refill the boiler. Refer to Frame 31. 12. Check operation of the boiler. Refer to Frame 52. Support plate M4 screw 2012 M4 screw Self tapper screw Discharge pipe Safety relief valve Securing pin 2039 nm8028 10 9 8 6 Air vent Plug SERVICING 202851-1new.pmd 17/11/2006, 07:41 47

72 DRAINING THE BOILER 1. Refer to frame 52. 2. Remove the boiler bottom panel. Refer to Frame 45. 3. Close all the water isolating (CH and DHW) valves on the piping frame. 4. To drain the central heating circuit, attach a length of hose to the drain point and open the drain valve. However it must be noted that some residual water may be experienced during the replacement of components. 5. As there is no direct drain for the domestic hot water circuit, depending on the location of the boiler, opening the lowest hot water tap may drain this circuit. However it must be noted that some residual water will be experienced during replacement of components. 6. After replacing any component on the boiler, close the drain valve, remove the hose and open all system isolating valves (re-pressurise as appropriate) before proceeding to check operation of the boiler. 7. Check operation of the boiler. Refer to Frame 52. 73 DIVERTER VALVE MECHANISM REPLACEMENT 1. Refer to Frame 52. 2. Remove the casing front & bottom panel. Refer to Frames 44 & 45. 3. Drain the boiler. Refer to Frame 72. 4. Remove the 4 screws retaining the rear support plate and withdraw the plate. Refer to Frame 70. Note. The M4 screws fit the casing and the self- tapping screws fit the plastic pump and valve housings. 5. Remove the valve actuator head. Refer to Frame 62. 6. Remove the 4 Allen screws and remove the valve mechanism. 7. Fit the new valve mechanism and gasket, ensuring correct fit over the location pin. 8. Reassemble in reverse order, ensuring correct location of screws in the support plate and that tabs on the pump and valve housings engage in slots. 9. Refill the boiler. Refer to Frame 31. 10. Check operation of the boiler. Refer to Frame 52. isolating valve (shown closed) Isolating valves Drain point Drain valve nm8457 TO OPEN Compression gas cock nm7546 Valve mechanism Allen screws Locating pin hole Gasket SERVICING 202851-1new.pmd 17/11/2006, 07:41 48

75 PUMP HEAD REPLACEMENT (Wilo and CP) 1. Refer to Frame 52. 2. Remove the casing front & bottom panel. Refer to Frames 44 & 45. 3. Drain the boiler. Refer to Frame 72. 4. Swing the control box down into the servicing position. Refer to Frame 46. 5. Disconnect the electrical lead from the pump. 6. Remove the 4 Allen screws retaining the pump head. 7. Remove the pump head. 8. Fit the new pump head. 9. Reassemble in reverse order. 10. Refill the boiler. Refer to Frame 31 11. Check operation of the boiler. Refer to Frame 52. 74 DHW PLATE HEAT EXCHANGER REPLACEMENT (WILO AND CP) 1. Refer to Frame 52. 2. Remove the casing front & bottom panel. Refer to Frames 44 & 45. 3. Drain the boiler. Refer to Frame 72. 4. Remove the 4 screws securing the rear support plate and withdraw the plate. Refer to Frame 70. Note. The M4 screws fit the casing and the self-tapping screws fit the plastic pump and valve housings. 5. Remove the 2 Torx screws (allen screws on the CP waterset) securing the plate heat exchanger from the valve and pump housings. 6. Raise the RH side of the heat exchanger, lower the LH side through the bottom of the boiler and remove. 7. Fit the new heat exchanger, using the new gaskets supplied. 8. Reassemble in reverse order ,ensuring correct location of screws in the support plate and that tabs on the pump and valve housings engage in slots. 9. Refill the boiler. Refer to Frame 31. 10. Check operation of the boiler. Refer to Frame 52. Wilo pump shown SERVICING 202851-1new.pmd 17/11/2006, 07:41 49

nm8029 Refer also to Frame 8 - 'Boiler Exploded View'. IMPORTANT Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag. 1. Refer to Frame 52. 2. Remove the boiler front, bottom and sealing panels. Refer to Frames 44 & 45. 3. Drain the boiler. Refer to Frame 72. 4. Remove the control box and place on one side. Refer to Frame 66. 5. Remove the fan / venturi assembly and place on one side. Refer to Frame 47. 6. Remove the burner and place on one side. Refer to Frame 48. 7. Remove the ignition and detection electrodes. Refer to Frames 58 & 59. 8. Remove the spark generator. Refer to Frame 60. 9. Release the flue from the turret. Refer to Frame 26. 10. Remove the turret from the boiler. Refer to Frame 26. 11. Release the silicone tubing from the sampling point. 12. Release the electrical connection to the dry fire thermistor. 13. Remove the M5 nut retaining the flue casting spring clip and remove the spring clip. 14. Undo the 2 M5 x 10 flue spring clip retaining bracket screws and remove the bracket. 15. Remove the M5 x 10 screw retaining the flue casting. 16. Remove the flue casting. 76 HEAT ENGINE REPLACEMENT 17. Remove the automatic air vent. Refer to Frame 71. 18. Remove the edge clip securing the dry fire thermistor wiring. 19. Remove the blind grommet to gain access to the return pipe securing bracket. 20. Remove the M5 screw and remove the return pipe securing bracket by sliding forwards. 21. Remove the overheat thermostat and the control thermistor. Refer to Frame 57. 22. Remove the securing pin to release the flow pipe. 23. Remove the condensate ‘S’ trap. Refer to Frame 64. 24. Remove the 2 M5 screws securing the interpanel to the back panel. 25. Slide the heat exchanger and interpanel assembly upward to disengage and remove from the casing, complete with the flow pipe. 26. Remove the 2 M6 countersunk screws, remove the interpanel and transfer to the new heat exchanger. 27. Remove the M5 screw and remove the flow pipe securing bracket. 28. Remove the flow pipe and transfer to the new heat exchanger. 29. Reassemble in reverse order, replacing gaskets or seals if any sign of damage or deterioration is evident. Note.The heat exchanger is supplied with new combustion chamber insulation boards. These should be fitted (refer to Frame 63 before the burner and fan / venturi assembly and before the ignition and detection electrodes are replaced). 30. Refill the boiler. Refer to Frame 31. 31. Check operation of the boiler. Refer to Frame 52. SERVICING 202851-1new.pmd 17/11/2006, 07:41 50

time P R O G R A M M E R prog prog select select + - nm8439 78 BOILER SEALING PANEL SEAL REPLACEMENT 1. Refer to Frame 52. 2. Remove the boiler front and sealing panels. Refer to Frames 44 & 45 . 3. Remove the old seal from the casing and thoroughly clean the casing surfaces. 4. Fit the new adhesive seals, note that they are supplied to the correct length for the relevant sides. 5. Reassemble in reverse order. 6. Check operation of the boiler. Refer to Frame 52. Note. Ensure that the boiler sealing panel is correctly sealed, compressing the seal to make an airtight joint. 77 EXPANSION VESSEL REPLACEMENT 1. Refer to Frame 52. 2. Drain the boiler. Refer to Frame 72. 3. Unscrew all the gas and water connection unions on the boiler side of the valves. 4. Remove the screw from the turret clamp and remove. 5. Remove the turret. 6. Lift the complete boiler from the wall mounting frame and place on a flat surface, face down, to expose the expansion vessel. 7. Unscrew the union nut on the vessel water connection pipe. 8. Unscrew the 2 screws from the securing clamp and remove. 9. Remove the expansion vessel. 10. Fit the new expansion vessel. 11. Reassemble in reverse order. 12. Refill the boiler. Refer to Frame 31. 13. Check operation of the boiler. Refer to Frame 52. Note. If preferred, and for convenience, a new expansion vessel may be installed elsewhere in the heating system, providing it ensures equivalent system protection.

     

      SERVICING 202851-1new.pmd 17/11/2006, 07:41 51

isar + programmer - Installation and Servicing 79 FAULT FINDING CHART MAIN MENU 'L' 'F' GO TO FRAME 80 'L' 'E' GO TO FRAME 81 'L' 'A' GO TO FRAME 82 'L' '8' GO TO FRAME 83 'H' '1' GO TO FRAME 84 'H' '2' GO TO FRAME 85 'H' '3' GO TO FRAME 86 'H' '4' GO TO FRAME 87 'H' 'F' GO TO FRAME 88 In order to assist fault finding the boiler has an LED diagnostic display. The key to the display codes is as follows: 'H' 'n' GO TO FRAME 89 'H' 'E' GO TO FRAME 81 'H' '9' GO TO FRAME 87 'L' '9' GO TO FRAME 87 202851-1new.pmd 17/11/2006, 07:41 52

isar + programmer - Installation and Servicing 80 L.....F..... (FLAME DETECTION ERROR) Check the ignition electrode and associated harness for: continuity, visual condition, position (Refer to Frame 58). Are these functioning correctly ? Check gas valve wiring for continuity YES Check the detection electrode and associated harness for: continuity, visual condition, position (Refer to Frame 59). Replace as necessary. If the boiler select (reset) button is pressed does the boiler ignite for a short time then extinguish? Is 200V DC supply available at the gas valve ? (see Note) NO YES YES Is gas pressure available at the boiler inlet ? Replace PCB Check gas supply and rectify fault Replace ignition electrode and associated harness as necessary NO Replace gas valve YES NO NO 81 L.....E..... or H.....E..... (PCB ERROR) Note. Due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the value (some may measure the possible peak voltage of 339V). In general terms a reading greater than 150V indicates that the correct voltage is supplied to the gas valve. As an alternative to a meter, a mains voltage checking device may be used. E.g. an electrical screwdriver or mains tester. Check spark generator and associated harness for continuity and visual condition. (Refer to Frame 60). Are these functioning correctly ? Replace spark generator YES NO Internal fault within the PCB Replace PCB Press and hold boiler select (reset) button for 2 seconds. Does boiler operate correctly? Turn boiler off and wait for 5 seconds. Turn boiler on. Does boiler operate correctly? NO NO YES OK YES OK Check syphon and condensate drain pipework for blockage 202851-1new.pmd 17/11/2006, 07:41 53

isar + programmer - Installation and Servicing Does the pump setting give a differential across the boiler in excess of 25 oC ? Can the overheat condition be reset by pressing the boiler select (reset) button when the system is cold ? Replace the system pump Set CH control knob to maximum. If the overheat trips again measure the flow temp: Over 90 oC Check control thermistor (Refer to Frame 84) Under 90 oC Replace overheat 'stat YES YES Check that the pump is rotating freely. Is differential now below 25 oC ? NO NO 82 L.....A..... (OVERHEAT ERROR) Fill and vent the system and open all isolation valves YES Is the boiler and CH system filled with water and all isolation valves open ? OK NO YES NO Replace overheat thermostat 83 L....8..... (FAN ERROR) Is nominal 330 V DC present across red and blue at the fan connector as boiler select (reset) button is pressed? Replace fan YES NO Replace harness 84 H.....1..... (CONTROL THERMISTOR [FLOW] ERROR) YES Is there continuity between the PCB and the thermistor ? Check resistance using a suitable multimeter connected across the thermistor’s terminal pins At 25 oC expect 9,700 - 10,300 Ohms At 60 oC expect 2,400 - 2,600 Ohms At 85 oC expect 1,000 - 1,100 Ohms Remove the boiler control thermistor from the CH flow pipe and disconnect thermistor wires. Are the thermistor values correct ? Replace the thermistor NO NO YES Replace PCB Check and replace wiring as necessary Replace PCB YES Is 14V DC present across yellow and pink at the fan connector? Check wiring harness for continuity. Is there continuity? NO YES NO 202851-1new.pmd 17/11/2006, 07:41 54

isar + programmer - Installation and Servicing 85 H.....2..... (CONTROL THERMISTOR [RETURN] ERROR) YES Is there continuity between the PCB and the thermistor ? Remove the boiler return thermistor from the CH return pipe. Are the thermistor values correct ? Replace the thermistor NO NO YES Replace PCB Check and replace wiring as necessary 86 H.....3..... (DHW THERMISTOR ERROR) YES Is there continuity between the PCB and the thermistor ? Remove the boiler DHW thermistor from the plate heat exchanger and disconnect thermistor wires. Are the thermistor values correct ? Replace the thermistor NO NO YES Replace PCB Check and replace wiring as necessary Check resistance using a suitable multimeter connected across the thermistor’s terminal pins At 25 oC expect 9,700 - 10,300 Ohms At 60 oC expect 2,400 - 2,600 Ohms At 85 oC expect 1,000 - 1,100 Ohms Check resistance using a suitable multimeter connected across the thermistor’s terminal pins At 25 oC expect 9,700 - 10,300 Ohms At 60 oC expect 2,400 - 2,600 Ohms At 85 oC expect 1,000 - 1,100 Ohms 202851-1new.pmd 17/11/2006, 07:41 55

isar + programmer - Installation and Servicing 87 H.....4.... (DRY FIRE THERMISTOR ERROR) Check wiring for continuity from the PCB to the dry fire thermistor Can the fault condition be reset by switching off the mains supply to the boiler ? Is the system filled and vented and all isolation valves open ? Is the pump operating correctly? Ensure flow through system. NO Are thermistor values correct ? Replace PCB Replace thermistor Fill and vent the system and open all isolating valves YES Are thermistor values correct ? Inspect heat exchanger for blockage or damage in the flueways. Clean or replace as necessary Replace thermistor NO 89 H......n..... (PHASE REVERSAL ERROR) Check wiring to the boiler for reversed live and neutral YES NO YES NO 88 H......F..... (FLAME DETECTION ERROR) Replace flame detection electrode Is there continuity between the 2 terminal pins ? NO YES Remove flame detection electrode terminal from PCB Replace PCB Check resistance using a suitable multimeter connected across the thermistor’s terminal pins At 25 oC expect 9,700 - 10,300 Ohms At 60 oC expect 2,400 - 2,600 Ohms At 85 oC expect 1,000 - 1,100 Ohms Check resistance using a suitable multimeter connected across the dry fire thermistor’s terminal pins At 25 oC expect 9,700 - 10,300 Ohms At 60 oC expect 2,400 - 2,600 Ohms At 85 oC expect 1,000 - 1,100 Ohms H9/L9 (HEAT EXCHANGER OVERHEAT) 202851-1new.pmd 17/11/2006, 07:41 56

isar + programmer - Installation and Servicing When ordering spares please quote: 1. Boiler model 2. Appliance G.C. No. 3. Description. 4. Quantity. 5. Product number. The following are parts commonly required due to damage or expendability. Their failure or absence is likely to affect safety or performance of this appliance. The list is extracted from the British Gas List of Parts, which contains all available spare parts. The full list is held by British Gas Services, Caradon Ideal Limited distributors and merchants. Key No. G.C. Part No. Description Qty. Product Number 1 Front casing panel 1 173 509 4 E69-384 Bottom casing panel 1 171 027 11 E67-489 Burner 1 170 905 12 Combustion chamber insulation 1 173 520 14 E67-492 Injector and housing HE24/30 1 170 908 HE35 1 173 522 16 E85-097 Fan assembly HE24/30 1 172 625 HE35 1 173 525 17 E69-286 Automatic air vent 1 170 988 19 E69-288 Gas control valve 1 171 035 23 E67-501 Control thermistor (flow/return) 2 170 917 24 E67-502 Overheat thermostat 1 170 918 25 Ignition electrode kit 1 173 528 26 Flame detection electrode kit HE24/30 1 173 529 HE35 1 170 984 32 H40-140 Kit - Trap and Seal 1 174 244 35 itime user control programmer 1 174 487 36 V9 PCB primary ctrls (includes plastic housing) HE24/30/35 1 174 486 37 E67-519 Fuse PCB (3.15A L250V) 1 170 931 39 Mains switch c/w harness 1 173 537 40 Spark generator assy. 1 173 538 45 E67-527 Gasket kit (servicing) 1 170 938 52 E68-376 Seal kit (sealing panel) 1 171 014 53 E68-380 Turret gasket 1 171 022 61 E69-338 Pressure relief valve - Wilo * 1 170 992 Pressure relief valve - CP * 1 173 977 62 Expansion vessel 1 173 066 64 E69-341 Pressure gauge 1 170 991 65 E69-403 DHW thermistor - Wilo * 1 170 996 DHW thermistor - CP * 1 173 974 66 Diverter valve motor head - Wilo / CP* 1 173 628 67 Diverter valve body - Wilo / CP* 1 173 624 69 E69-342 Pump - Wilo * 1 170 990 Pump Head - CP * 1 173 963 71 E69-408 Plate heat exchanger - Wilo * HE24 1 173 544 HE30 1 170 995 HE35 1 173 545 Plate heat exchanger - CP * HE24 1 174 207 HE30 1 173 957 HE35 1 174 208 94 Ignition lead 1 173 510 95 Detection lead 1 173 512 103 Dry Fire Thermistor 1 173 617 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. (* Refer to boiler serial letter code on data plate to identify correct spare. Serial letter codes: Wilo= VU, CP= VX) 202851-1new.pmd 17/11/2006, 07:41 57

isar + programmer - Installation and Servicing 90 SHORT LIST nm8440 103 time P R O G R A M M E R prog prog select select + - 202851-1new.pmd 17/11/2006, 07:41 58

isar + programmer - Installation and Servicing Ecl 1598 91 BOILER CASING ASSEMBLY 1. Front casing panel with screws. 2. Sealing panel with screws. 4. Bottom panel with screws. 92 CONTROLS ASSEMBLY 33. Controls assy with screws. 34. Controls hinge bracket. 35. User controls (without item 38). 36. PCB (primary controls). 38. User controls housing 39. Mains switch. 54. Jumper link (not shown) 93 BURNER ASSEMBLY 11. Burner assembly with screws and gasket. nm8441 36 34 39 38 35 time P R O G R A M M E R prog prog select select + - 202851-1new.pmd 17/11/2006, 07:41 59

INSTALLER NOTIFICATION GUIDELINES IT IS A REQUIREMENT OF CORGI MEMBERSHIP TO REGISTER EVERY GAS APPLIANCE In addition a change to Building Regulations (England and Wales) requires the installer to notify when installing a heating appliance, as from 1st April 2005. Competent Person's SELF CERTIFICATION SCHEME BUILDING CONTROL Install and commission this appliance to manufacturers' instructions Complete the Benchmark Checklist Choose Buildings Regulations notification route Contact your relevant Local Authority Building Control (LABC) who will arrange an inspection or contact a government approved inspector LABC will record the data and will issue a certificate of compliance If you notify via CORGI Scheme, CORGI will then notify the relevant Local Authority Building Control (LABC) scheme on members behalf Scheme members only: Call CORGI on 0870 88 88 777 or log onto: www.corgi-notify.com within 10 days You must ensure that the notification number issued by CORGI is written onto the Benchmark Checklist CORGI will record the data and will send a certificate of compliance to the property IT IS A CONDITION OF THE MANUFACTURERS WARRANTY THAT THE BENCHMARK COMMISSIONING CHECKLIST IS FULLY COMPLETED AND LEFT WITH THE APPLIANCE 202851-1new.pmd 17/11/2006, 07:41 61

TIME & TEMPERATURE CONTROL TO HEATING ROOM T/STAT & PROGRAMMER/TIMER PROGRAMMABLE ROOMSTAT TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER COMBI BOILER HEATING ZONE VALVES FITTED NOT REQUIRED HOT WATER ZONE VALVES FITTED NOT REQUIRED THERMOSTATIC RADIATOR VALVES FITTED AUTOMATIC BYPASS TO SYSTEM FITTED NOT REQUIRED FOR ALL BOILERS CONFIRM THE FOLLOWING THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURERÕS INSTRUCTIONS? THE SYSTEM CLEANER USED THE INHIBITOR USED FOR THE CENTRAL HEATING MODE, MEASURE & RECORD GAS RATE ft3/hr BURNER OPERATING PRESSURE (IF APPLICABLE) mbar CENTRAL HEATING FLOW TEMPERATURE oC CENTRAL HEATING RETURN TEMPERATURE oC FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED? YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED? FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD GAS RATE ft3/hr MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE) mbar COLD WATER INLET TEMPERATURE oC HOT WATER OUTLET TEMPERATURE oC WATER FLOW RATE lts/min FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS? YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGULATIONS THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED IN ACCORDANCE WITH THE MANUFACTURER'S INSTRUCTIONS IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO2 RATIO READING? N/A YES CO/CO2 RATIO THE OPERATION OF THE APPLIANCE AND SYSTEM CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER THE MANUFACTURER'S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER m3/hr m3/hr COMMISSIONING ENG'S NAME PRINT CORGI ID No. SIGN DATE BOILER SERIAL No. NOTIFICATION No. BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST C O L L E C T I V E M A R K N/A N/A 202851-1new.pmd 17/11/2006, 07:41 62

It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record Below. Service Provider. Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer's instructions. Always use the manufacturer's specified spare part when replacing all controls SERVICE 1 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 2 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 7 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 8 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 9 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE SERVICE 10 DATE ENGINEER NAME COMPANY NAME TEL No. CORGI ID CARD SERIAL No. COMMENTS SIGNATURE 202851-1new.pmd 17/11/2006, 07:41 63

HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Technical Training Caradon Ideal Limited pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice. The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers. For details of courses please ring: .......... 01482 498 432 CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001: 2000 Quality System accepted by BSI The code of practice for the installation, commissioning & servicing of central heating systems Ideal Installer/Technical Helpline: 01482 498 663 www.idealboilers.com 202851-1new.pmd 17/11/2006, 07:41 64