IDEAL Classic SE12 FF, Installation And Servicing Manual

Page 1: ... 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 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 For details of document amendments r...

Page 2: ...2 Classic SE FF Installation Servicing ...

Page 3: ...emented in this book from Mod Level A04 May 05 to A05 Jan 08 Various Pages Company name change Page 29 Frame 51 Burner and Air Box Removal Item number 5 added Users Guide Page 2 Important Notes 2 new bullet points added Ideal Stelrad Group reserve the right to vary specification without notice ...

Page 4: ...ing pressure HOT mbar in w g 12 4 5 0 11 0 4 4 12 7 5 0 13 7 5 5 12 1 4 8 12 9 5 2 14 0 5 6 Seasonal Efficiency SEDBUK Band D 79 4 78 7 79 8 78 2 78 5 78 2 78 0 Boiler Size SE9FF SE12FF SE15FF SE18FF SE21FF SE24FF SE30FF Gas supply connection in BSP Rc 1 2 1 2 1 2 BSP Female Flow connection 22mm 28mm copper copper FEMALE Return connection 22mm 28mm copper copper FEMALE Maximum static water head m ...

Page 5: ...nly Boiler Page Make and model 5 Appliance serial no on data badge 13 SEDBUK No 4 Controls Time and temperature control to heating 25 26 Time and temperature control to hot water 25 26 Heating zone valves 25 26 TRV s 9 Auto bypass 9 Boiler interlock 9 For all boilers Flushing to BS 7593 9 Inhibitor 9 Central heating mode Heat input to be calculated For assistance see Technical Helpline on the back...

Page 6: ...E 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 Bui...

Page 7: ...ved in the direction of the arrow first lifting the casing slightly to disengage the casing top return from the back panel For this purpose a minimum clearance of 12mm is required between the top of the boiler and pelmet or other similar obstruction Front clearance 533mm 21 from the front of the boiler casing Minimum front clearance when built in to cupboard is 75 mm 3 380 15 300 12 Pumped return ...

Page 8: ... openings are specified in Table 3 4 Where the lowest part of the terminal is fitted less than 2m 6 6 above a balcony above ground or above a flat roof to which people have access then the terminal MUST be protected by a purpose designed guard The minimum spacing in Table 3 Nos 2 3 4 5 and 6 would be 75mm in order to allow a terminal guard to be fitted Terminals guards are available from boiler su...

Page 9: ...telrad Group INVALID Ideal Stelrad Group recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems Ideal Stelrad Group recommend the use of Fernox GE Betz Sentinel or Salamander water treatment products which must be used on accordance with the manufacturers instructions For further information contact Fernox Manufacturing Co Ltd Cookso...

Page 10: ...rad Group Note A cold water feed must be available back to the boiler when all automatic valves are in the closed position refer to BS 6798 and when close coupled the feed must not be in a vertical leg The Classic SE range of boilers can be installed in low head situations by fitting a surge arrester in the expansion pipe as shown The following conditions MUST be observed 1 The surge arrester must...

Page 11: ...e covering at least the range 0 4 bar 0 60 lb in2 must be fitted to the system The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel 4 Expansion Vessel a A diaphragm type expansion vessel must be connected at a point close to the inlet side of the pump the connecting pipe being not less than 15mm 1 2 nominal size and not...

Page 12: ... an automatic air vent connected between them the stop valve being located between the system and the automatic air vent The stop valve may remain open during normal operation of the system if automatic water make up is required b Through a self contained unit comprising a cistern pressure booster pump if required and if necessary an automatic pressure reducing valve and flow restrictor The cister...

Page 13: ...hown LEGEND 1A Heat exchanger 2 Flue baffles 3 Tie rods 4A Pumped flow pipe 5A Pumped return pipe 6 Collector hood assembly 7 Combustion chamber 12 Main burner 19 Control box 24 Pressure switch 30 Fan 40 Wall mounting plate 44B Programmer optional 52 Back panel 59 Limit thermostat cla 7158 INSTALLATION ...

Page 14: ...f z No 8 x 8 lg Pozi pan hd screws 3 off 8 UNPACKING Pack A Contents z The complete boiler z Installation Servicing Users Instructions z Hardware Pack listed below z Wall mounting template z Wall mounting plate z Side outlet terminal mounting plate z Flue extension tube 1 off z Boiler sealing ring 1 off Hardware Pack Contents z 50mm x No 14 wood screw 4 off z 50mm x No 10 wood screw 8 off z Wall p...

Page 15: ...dard Pack D optional extension kit for side flue or rear flue outlet Refer to Frame 33 1 A maximum of 2 extension ducts plus the standard flue duct may be used together 2 Flue extensions of greater than 1m 39 should be supported with the bracket provided If the stand off brackets have been used it is necessary in order to keep the flue aligned to use the spacer bracket with the support bracket It ...

Page 16: ... position 3 Ensure squareness by hanging a plumb line as shown 4 Mark onto the wall if required the following a The wall mounting plate screw positions choose one from each group Note Mark the centre of the flue hole as well as the circumference b The position of the flue duct hole c Downward pipe routing bracket screw positions 5 Remove the templates from the wall IMPORTANT Ensure that during the...

Page 17: ...e duct Ensure the boiler sealing ring is fully engaged Ensure the notch aligns with the groove on the outer flue duct This ensures correct alignment of the flue terminal 4 Stick the self adhesive foam strip provided in the hardware pack onto the flue immediately behind the boiler sealing ring 17 WALL MOUNTING PLATE 1 Fix the mounting plate to the wall with the No 14 x 50mm wood screws 2 If downwar...

Page 18: ...he boiler 1 Lift the boiler onto the wall mounting plate hooks as shown Do not use the burner controls for lifting 2 Fit the M8 screw washer and rectangular plate to retain the boiler Note Before fully tightening the M8 screw check the boiler alignment using a spirit level and adjust as necessary with the jacking screw 19 CONNECTING THE FLUE TO THE BOILER 20 TERMINAL WALL PLATE This plate allows n...

Page 19: ...he hole has been accurately cut with a drill then making good the wall faces is not essential as seals are provided at both ends of the flue However both wall faces immediately around the cut hole should be flat make good if necessary For less accurate holes make good to approximately 125mm 5 diameter at the 2 wall faces 2 Drill 4 holes with an 8mm 5 16 masonry drill and insert the plastic plugs p...

Page 20: ... is cut square mark the flue all the way round 4 Insert the cardboard duct ring for support and cut to length 5 Remove cardboard duct ring and remove any burrs 26 FITTING BOILER SEALING RING TO THE FLUE 1 Fit the boiler sealing ring inside the outer flue duct Ensure the boiler sealing ring is fully engaged Ensure the notch aligns with the groove on the outer flue duct This ensures correct alignmen...

Page 21: ...pes is required then the downward routing pipe brackets and M8 spacer supplied in the Downward Piping Kit should be fitted to the wall mounting plate now 3 Fit the bottom 2 screws to secure the bracket s to the wall through the wall mounting plate 4 Check with a spirit level that the plate is vertical Notes 1 Have ready to hand the M8 screw washer and rectangular plate supplied in the hardware pac...

Page 22: ...d to the fan 5 Pull the flue extension tube and engage onto the fan elbow and secure with the screw attached to the elbow Note The sealing ring studs will locate in the back panel one way only This will ensure that the terminal grille is correctly aligned This plate allows neat concealment and full compression of the rubber seal Its use is not essential if the flue hole and flue ducts have been ac...

Page 23: ...ot for SE30 FF model 35 FITTING THE KIT 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 Drill 3 3 2mm 1 8 dia holes through the outer air duct Do not drill the inner flue duct 5 Insert the self tapping screws provided to fix the air duct in positi...

Page 24: ...efer to Frame 43 3 If a proprietary system is used follow the instructions supplied by the manufacturer 4 System designs featuring controls or wiring arrangements which allow the boiler to fire when there is no pump circulation taking place should not be fitted Advice on required modifications to the wiring may be obtained from the component manufacturers Notes 1 Connection between a frost thermos...

Page 25: ...oiler thermostat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see the manufacturer s literature 40 PICTORIAL WIRING 41 MID POSITION VALVE Pumped only LEGEND b blue bk black br brown gy grey or orange pk pink r red v violet w white y yellow y g yellow green LEGEND b blue bk black br brown gy grey or orange pk pink r red v violet w white y yellow y g yellow ...

Page 26: ...l be left off for more than a day or so then a frost thermostat should be wired into the system This is usually done at the programmer in which case the programme selector switches are set to OFF and all other controls MUST be left in the running position The frost thermostat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown with minimal disturba...

Page 27: ...e servicing position See diagram B 4 Slacken the screw in the burner pressure test point F and connect a gas pressure gauge via a flexible tube 5 Swing the control box back into its working position 6 Press the overheat thermostat reset button J 45 INITIAL LIGHTING 7 Switch the electricity supply ON and check that all external controls are calling for heat 8 Set the boiler thermostat knob D to pos...

Page 28: ...the importance of regular servicing by a CORGI registered installer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR In IE servicing work must be carried out by a Competent Person After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions 48 HANDING OVER 47 GENERAL CHECKS Make the following...

Page 29: ... downwards to disengage the retention tab Remove the burner to a safe place for inspection and cleaning 2 Remove the control box fixing screw Pull the box forward and downward to disengage 3 Pull the HT lead connection off the printed circuit board and pull the lead upwards through the bottom panel grommet 4 Remove the 4 screws retaining the air box pilot assembly to the vertical manifold and care...

Page 30: ...the fan Disconnect the connector from the fan and slide into the flue 3b Side or top flue Slacken off two M4 screws securing the flue elbow and flue connector Disconnect the flue connector from the elbow and slide into the flue Remove the flue elbow 4 Disconnect the silicon rubber tube from the rear of the collector hood 5 Slacken the two M5 nuts on the front tie rods releasing the tie rods from t...

Page 31: ...hermostat and reassemble in reverse order 6 Check the operation of the boiler 55 GAS PRESSURE ADJUSTMENT cla7151 PILOT The pilot is factory set to maximum and no further adjustment is possible If after removing and checking the injector as detailed in Frame 61 and ensuring that there is an inlet pressure of 20 mbar available the pilot does not light then contact Ideal Stelrad Group Relight in acco...

Page 32: ...the sensor lead connector off the printed circuit board and cut the cable strap securing the thermistor harness to the bottom panel of the control box if fitted and remove the strap 6 Remove the sensor from the heat exchanger pocket and unclip from the back panel 7 Remove the strain relief bush from the back panel base 8 Remove the sensor lead through the grommet in the control box 9 Replace and r...

Page 33: ...asher is replaced when refitting the pilot injector 6 Replace the electrode and pilot shield retaining both with the electrode nut Check the spark gap 7 Reassemble in reverse order 8 Check the operation of the boiler 9 The pilot is factory set to maximum and no further adjustment is possible Ensure there is an inlet pressure of 20 mbar available Also check burner ignition and cross lighting 1 Refe...

Page 34: ...n of the procedure detailed below 1 Refer to Frame 56 2 Remove the burner and air box assembly Refer to Frame 51 3 Remove the electrode retaining nut 4 Remove the pilot shield 5 Remove the ignition electrode and integral lead 6 Refit the new electrode and lead in reverse order Ensure that the pilot shield is replaced 7 Check the spark gap Refer to Frame 61 8 Reassemble in reverse order 9 Check the...

Page 35: ...osts and withdraw from the control box 6 Fit the new PCB and reassemble in reverse order 7 Check the operation of the boiler Fuse To change the fuse prise it out of the holder and disengage the fuse Refer to Frame 74 for fuse location 1 Refer to Frame 56 2 Remove the APS fixing screw 3 Remove both sensing tubes from the APS 4 Remove the 3 electrical connections from the APS 5 Fit the new APS and r...

Page 36: ...te with water pipes and hang it on the key hole slots and screws Retighten the screws 12 Replace the 2 rubber sealing grommets 13 Reassemble in reverse order 14 Remake all water connections ensuring that the compression fittings if used are correctly refitted 15 Fully test all functions including water and gas soundness 69 HEAT EXCHANGER REPLACEMENT Note Refer to Frame 7 Boiler assembly Exploded v...

Page 37: ...locked YES Replace gas valve NO Is there a supply on terminals of main gas valve YES NO YES NO NO Is there a supply on the fan connector at PCB Molex marked FAN YES YES NO NO Check the polarity of the mains supply Check the continuity of the ignition lead from connector to electrode Does the spark now cease when gas is lit Ensure pilot and main gas valve leads are not crossed over Is there a suppl...

Page 38: ... 1 171 461 E87 032 SE30 FF 1 171 462 35 Boiler casing assembly complete H08 992 SE9 12 15 18 21 24 FF white 1 173 582 H08 993 SE9 12 15 18 21 24 FF silver 1 173 583 H08 995 SE30 FF white 1 173 584 H08 997 SE30 FF silver 1 173 585 37 H08 998 Controls casing door complete white 1 173 586 H08 999 silver 1 173 587 39 E85 313 Casing seal kit white 1 171 479 H08 736 silver 1 173 588 45 E83 682 Overheat ...

Page 39: ...Classic SE FF Installation Servicing 39 LIST OF PARTS cla 6113 45 59 23 12 18 19 30 24 39 9 17 26 15 14 13 13 A 72 SHORT PARTS LIST 73 BOILER CASING ASSEMBLY cla7150 ...

Page 40: ...and pilot assembly 12 Main burner 13 Main burner injector 16 Pilot shield 17 Gas control valve 42 Gas service cock 75 BURNER ASSEMBLY Exploded View LEGEND 19 Control box 21 Thermostat potentiometer 23 Printed circuit board 26 Thermostat knob 58 Mains on off switch 74 CONTROL BOX Exploded View ...

Page 41: ...t 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 withi...

Page 42: ...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 o C HOT WATER OUTLET TEMPERATURE o C 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 AL...

Page 43: ...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 SIGNATUR...

Page 44: ...ecification 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 commission...