IDEAL INDUSTRIES HE9, HE18, HE12, HE15 manual Sealed System Requirements

Page 12

GENERAL

6 SEALED SYSTEM REQUIREMENTS - continued

7.Mains Connection

There must be no direct connection to the mains water supply or to the water storage tank supplying domestic water, even through a non-return valve, without the approval of the local water authority.

8.Filling

The system may be filled by one of the following methods:

a. Through a cistern, used for no other purposes, via a ball valve permanently connected directly to a service pipe and / or a cold water distributing pipe.

The static head available from the cistern should be adequate to provide the desired initial system design pressure. The cold feed pipe from the cistern should include a non-return valve and a stop valve with an automatic air vent connected between them, the stop valve being located between the system and the automatic air vent. The stop valve may remain open during normal operation of the system if automatic water make-up is required.

b. Through a self-contained unit comprising a cistern, pressure booster pump (if required) and, if necessary, an automatic pressure reducing valve and flow restrictor. The cistern should be supplied through a temporary connection from a service pipe or cold water distributing pipe.

This unit may remain permanently connected to the heating system to provide limited automatic water make-up. Where the temporary connection is supplied from a service pipe or distributing pipe which also supplies other draw-off points at a lower level then a double check valve shall be installed upstream of the draw-off point.

c. Through a temporary hose connection from a draw-off tap supplied from a service pipe under mains pressure. Where the mains pressure is excessive a pressure-reducing valve shall be used to facilitate filling.

The following fittings shall form a permanent part of the system and shall be fitted in the order stated:

A stop valve complying with the requirements of BS. 1010, Part 2 (the hose from the draw-off tap shall be connected to this fitting).

A test cock.

A double check valve of an approved type.

Thoroughly flush out the whole of the system with cold water, without the pump in position.

With the pump fitted, fill and vent the system until the pressure gauge registers 1.5 bar (21.5lb/in2).

Examine for leaks.

Check the operation of the safety valve by manually raising the water pressure until the valve lifts. This should occur within ± 0.3 bar (± 4.3lb/in2.) of the pre-set lift pressure.

Release water from the system until the initial system design pressure is reached.

Light the boiler and heat the system to the maximum working temperature. Examine for leaks.

Turn off the boiler and drain the system while still hot.

Refill and vent the system.

Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be less than that given by Table 6, multiplied by a factor of 0.8 (for flow temperatures of less than 88 oC).

Table 6

Safety valve setting

 

3.0 bar

 

 

2.5 bar

 

2.0 bar

Vessel charge and initial

0.5

1.0

1.5

0.5

1.0

1.5

0.5

1.0

 

system pressure

bar

bar

bar

bar

bar

bar

bar

bar

 

 

 

 

 

 

 

 

Total water content of system

 

 

 

Expansion vessel volume

 

 

 

(litres)

 

 

 

 

(litres)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

25

2.1

2.7

3.9

2.3

3.3

5.9

2.8

5.0

 

50

4.2

5.4

7.8

4.7

6.7

11.8

5.6

10.0

 

75

6.3

8.2

11.7

7.0

10.0

17.7

8.4

15.0

 

100

8.3

10.9

15.6

9.4

13.4

23.7

11.3

20.0

 

125

10.4

13.6

19.5

11.7

16.7

29.6

14.1

25.0

 

150

12.5

16.3

23.4

14.1

20.1

35.5

16.9

30.0

 

175

14.6

19.1

27.3

16.4

23.4

41.4

19.7

35.0

 

200

16.7

21.8

31.2

18.8

26.8

47.4

22.6

40.0

 

225

18.7

24.5

35.1

21.1

30.1

53.3

25.4

45.0

 

250

20.8

27.2

39.0

23.5

33.5

59.2

28.2

50.0

 

275

22.9

30.0

42.9

25.8

36.8

65.1

31.0

55.0

 

300

25.0

32.7

46.8

28.2

40.2

71.1

33.9

60.0

 

 

 

 

 

 

 

 

 

 

 

Multiplying factors for

 

 

 

 

 

 

 

 

 

other system volumes

0.0833

0.109

0.156

0.094

0.134

0.237

0.113

0.20

 

12

classic HE - Installation & Servicing

Image 12
Contents Installation and servicing Classic HE Installation & Servicing Document Amendments Key to symbols GeneralGeneral Data HE12 HE15 HE18Classic HE General Introduction Safe HandlingOptional Extra Kits Location of BoilerInstallation from inside only General Boiler Water ConnectionsBoiler Clearances Side and Rear FlueFlue Installation Compartment InstallationsGAS Supply BathroomsGeneral Terminal AIR SupplyWater Treatment Water Circulation SystemLOW Head Installations Electrical SupplyOpen Vent System Requirements Fully Pumped Condensate Drain Refer to Frames 38, 39General Sealed System Requirements Sealed System Requirements Installation Boiler Assembly Exploded viewInstallation Unpacking Unpack and check the contents Pack a ContentsHardware Pack 1 Contents Pack B ContentsInstallation Packaging and Casing Removal Determining the Flue LengthPack Product No Side Outlet Kit Product NoFlue Assembly Exploded View Wall Mounting TemplatePreparing the Wall Cutting the Flue wall thicknesses of 75 to 705mm Cut to length X, refer to FrameRemove any burrs and remove the inner flue support ring Connecting the Flue to the Boiler Wall Mounting PlateMounting the Boiler Without Optional Flue finishing KitFor wall thickness 270mm to 775mm Fitting the Flue Assembly Cutting the Flue For flue lengths 270 to 775mm onlyInstallation Mounting the Boiler Flues over 1 metre longFlue Extension Ducts Fitting the KITRoof Flue KIT Contents / Options FlueInstallation Flue Terminal Position Terminal Position Minimum DimensionFlue Arrangement Installation Assembling the Roof Flue KIT Engagement in the final flue duct sealCondensate Pipe Termination Configurations GAS ConnectionWater Connections Condensate DrainCondensate Pipe Termination Configurations Electrical Connections External ControlsInstallation Pictorial Wiring MID Position Valve Pumped onlyThermostat Blue Black Brown Grey Orange Thermostat PinkInstallation TWO Spring Closed Valve Frost ProtectionBlue Yellow/green Black Orange Brown Violet Red Pink White Installation Commissioning and Testing Fitting the Boiler Casing See diagram A, FrameTo gain access to the gas valve Initial LightingInitial Lighting General ChecksHanding Over Water Circulating SystemServicing Servicing Schedule Boiler Front Panel RemovalBurner and AIR BOX Removal Disconnect the electrical supply and turn off gas supplyServicing Cleaning the FAN Assembly / the Flueways Cleaning the Burner and Pilot AssemblyCleaning the Recuperator Servicing Cleaning the Siphon ReassemblyGAS Pressure Adjustment Replacement of Parts GeneralServicing Overheat Thermostat Replacement On/off switchThermostat control Thermistor sensor leadServicing Limit Thermostat Replacement Flue Protection Thermostat ReplacementPilot Burner Replacement Pull off the two electrical connectionsServicing Ignition Electrode and Lead Replacement Main Burner and Main Burner Injector ReplacementGAS Control Valve Replacement Servicing FAN Replacement AIR Pressure Switch APS ReplacementPrinted Circuit Board PCB Replacement Combustion Chamber Insulation ReplacementHeat Exchanger Replacement Casing Front Seal ReplacementServicing Servicing Siphon Replacement Fault Finding FindingShort List of Parts GC Part No Description Qty Product NoShort List of Parts Short Parts List Installer Notification Guidelines GAS Boiler Commissioning Checklist Service 1 Date Service 3 DateService 5 Date Service 7 DateTechnical Training Certified ProductUsers guide Safety Electricity SupplyImportant Notes Minimum ClearancesControl of Water Temperature CleaningMaintenance To Shut Down the BoilerPoints for the Boiler User
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HE12, HE15, HE18, HE9 specifications

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