201850-6.pmd

classic

Installation & Servicing

GENERAL

CAUTION.

To avoid the possibility of injury during the installation, servicing or cleaning

of this appliance, care should be taken when handling edges of sheet steel components

Boiler Size

HE9

HE12

HE15

HE18

Gas supply connection

(in. BSP)

Rc 1/2 (1/2) 1/2" (BSP Female)

Flow connection

22mm

copper

Return connection

22mm

copper

Maximum static water head

m (ft.)

30.5 (100)

Minimum static water head

m (ft.)

0.45 (1.5)

Electrical supply

230 V 50 Hz Boiler power consumption; 100W

Fuse rating

External; 3A Internal; F1A to BS.4265

Water content

litre (gal.)

3.0 (0.67)

3.95 (0.87)

Packaged Weight

kg (lb)

45 (99)

50 (110)

Maximum installation weight

kg (lb)

40 (88)

45 (99)

Boiler size

Height mm (in.)

700 (27.5)

Width mm (in.)

380 (15.0)

Depth mm (in.)

280 (11.25)

Flue duct diameter

mm (in.)

100 (4.0)

Flue duct length (max)

m (ft)

3 (9.8)

Note. Gas consumption is calculated using a calorific value of
38.7 MJ/m

(1038 Btu/ft

) gross or 34.9 MJ/m

(935 Btu/ft

) 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/m

)

b. FOR FT

/H - divide the gross heat input (Btu/h) by the gross

C.V. of the gas (Btu/ft

)

Table 1 - General Data

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.

Table 2 - Performance Data

Key to symbols
GB = United Kingdom

IE = Ireland (Countries of destination)

PMS = Maximum operating pressure of water
C

= 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 down stream of
the combustion chamber.

An appliance designed for use on 2nd Family gas,
Group H only.

Boiler Size

HE9

HE12

HE15

HE18

Input 'Q'

Nett CV kW (Btu/h)

9.4 (32,100)

12.6 (43,000)

15.7 (53,600)

18.9 (64,500)

Gross CV kW (Btu/h)

10.5 (35,800)

14.0 (47,800)

17.4 (59,400)

20.9 (71,300)

Gas Consumption l/s (cu.ft/h)

0.27 (34.3)

0.36 (45.8)

0.45 (57.2)

0.54 (68.7)

Output 'P

C Mean Water temp. kW (Btu/h)

9.0 (30,700)

12.0 (40,900)

15.0 (51,200)

18.0 (61,400)

C Mean Water temp. kW (Btu/h)

9.8 (33,400)

13.1 (44,700)

16.2 (55,300)

19.4 (66,200)

Burner Setting Pressure (Hot)

mbar (in w.g.)

12.0 (4.8)

10.4 (4.2)

12.3 (4.9)

12.7 (5.1)

Seasonal efficiency (SEDBUK) *

Band B

[87.2]%

[86.8]%

NOx classification

Class 3

Class 2

Class 1

201850-6.pmd

21/02/2008, 12:57

classic

Installation & Servicing

GENERAL

CONTENTS

Air Supply. ..................................................................... 9
Benchmark Commissioning Checklist ..................... 46
Boiler Clearances ......................................................... 7
Boiler Exploded View ................................................. 13
Electrical Connections ............................................... 28
Electrical Regulations ................................................ 10
Extension Ducts - Fitting ............................................ 22
External Controls ........................................................ 28
Fault Finding ................................................................ 42
Flue Installation ............................................................. 8

Rear installation ...................................................... 16
Side installation ....................................................... 19

Gas Safety ..................................................................... 6
Gas Supply .................................................................... 8
Initial Lighting . .......................................................31,32
Installation ............................................................ 13-32
Mandatory Requirements ............................................ 6
Pump ........................................................................... 10
Safe Handling ................................................................ 6
Servicing ............................................................... 33-41
Short List of Parts ...................................................... 43
Spares Replacement ................................................. 35
System Electrical Diagrams .................................29,30
Terminal Guards. .......................................................... 8
Water and Systems ..................................................... 9
Water Treatment .......................................................... 9

oiler

Page

Make and model ....................................................... 5
Appliance serial no. on data badge ....................... 13
SEDBUK No. % ......................................................... 4

Controls

Time and temperature control to heating ......... 29/30
Time and temperature control to hot water ...... 29/30
Heating zone valves .......................................... 29/30
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

Page

Burner operating pressure ....... measure and record
Central heating flow temp. ........ measure and record
Central heating return temp. ..... measure and record

For combination boilers only

Scale reducer ......................................................... n/a

Hot water mode

Heat input ............................................................... n/a
Max. operating burner pressure ............................ n/a
Max. operating water pressure .............................. n/a
Cold water inlet temp ............................................. n/a
Hot water outlet temp. ............................................ n/a
Water flow rate at max. setting ............................... n/a

For condensing boilers only

Condensate drain .................................................. 26

For all boilers:

complete, sign & hand over to customer

For GB, to comply with Building Regulations Part L1 (Part J in Scotland) the boiler should be fitted in accordance with the
manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark Commissioning Checklist.

BENCHMARK COMMISSIONING CHECKLIST

classic HE

Destination Countries:

GB, IE

Natural Gas only

NOTE TO THE INSTALLER: COMPLETE

THE BENCHMARK COMMISSIONING

CHECKLIST AND LEAVE THESE

INSTRUCTIONS WITH APPLIANCE

Boiler size

G.C. Appliance No.

PI No.

(Benchmark No.)

HE9

41-415-58

87 BQ 10

HE12

41-415-59

87 BQ 10

HE15

41-421-45

87 BQ 10

HE18

41-421-46

87 BQ 10

201850-6.pmd

21/02/2008, 12:57

classic

Installation & Servicing

GENERAL

INTRODUCTION

The classic HE 9, 12, 15 and 18 are a range of automatically fully
controlled, wall mounted, balanced flue, fanned, high efficiency,
condensing gas boilers.
The primary heat exchanger is cast iron. The secondary heat
exchanger is aluminium. The boiler casing is of white enamelled
mild steel.
The boiler casing has a removable controls pod containing a drop-down
door. The boiler thermostat is located behind the drop- down door.
Note. These boilers cannot be used on systems which include
gravity circulation.
See Frame 1 for details of the correct boiler tappings to use.
The boilers are supplied with a standard flue kit suitable for rear
outlet from 114 mm (4

1/2

") to 705 mm (30

1/2

").

Side outlet applications require the optional extra side outlet kit.
The boilers are suitable for connection to the following open
vented or sealed systems:
·

Fully pumped CH and indirect DHW

Pumped heating only.

Pumped indirect DHW only.

SAFE HANDLING

This boiler may require 2 operatives to move it to its installation
site, remove it from its packaging base and during movement
into its installation location. Manoeuvring the boiler may include
the use of a sack truck and involve lifting, pushing and pulling.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques
when performing these tasks and the following precautions
should be considered:
·

Grip the boiler. Refer to Frame 18.

Split the boiler down to reduce the weight, e.g. remove casing
and hardware pack. Refer to Frame 9.

Be physically capable.

Use PPE as appropriate, e.g. gloves, safety footwear.

During all manoeuvres and handling actions, every attempt
should be made to ensure the following unless unavoidable
and/or the weight is light.
·

Keep back straight.

Avoid twisting at the waist.

Avoid upper body/top heavy bending.

Always grip with the palm of the hand.

Use designated hand holds.

Keep load as close to the body as possible.

Always use assistance if required.

OPTIONAL EXTRA KITS

FLUING:

Flue Extension Ducts. (1000mm long) up to 3m
90

Elbow Kit (60/100 dia maximum no. per installation)

up to 2 elbows
45

Elbow Kit (60/100 dia maximum no. per installation)

up to 2 elbows
Side Outlet Kit
Vertical Connector Kit
Flue Finishing Kit
Roof Flue Kit
High Level Flue Outlet Kit
Flue Deflector Kit

OTHER OPTIONAL KITS:

Downward Piping Kit
Condensate Pump Kit

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 Standards (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.6891

Low pressure installation pipes.

BS.6798

Installation of gas fired hot water boilers 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.7593

Treatment of water in domestic hot water central
heating systems.

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.

Health & Safety Document No. 635
The Electricity at Work Regulations, 1989.
Manufacturer's notes must NOT be taken in any way as overriding

statutory obligations.
IMPORTANT. These appliances are certificated by the British

Standards Institution 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

otherwise recommended by Ideal Stelrad Group in writing.

If in doubt please enquire.
Any direct reconnection of a control device not approved by Ideal

Stelrad Group could invalidate the BSI 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 this boiler.

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. 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.

continued on page 8 . . . . . . . . .

201850-6.pmd

21/02/2008, 12:57

classic

Installation & Servicing

GENERAL

This appliance in NOT suitable for use in a direct
hot water system or for gravity circulation.

BOILER WATER CONNECTIONS

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.
Installation from inside ONLY

b. If a core boring tool is to be used inside

the building; the space in which the
boiler is to be installed must be at least
wide enough to accommodate the tool.

Front clearance: 450mm (17

") from the front of the boiler casing.

Minimum front clearance when built behind a concealed panel is 5mm (

provided that the top and bottom of the casing is not enclosed and the side
clearance is 40mm (2") at both sides.
See also Table 4.

BOILER CLEARANCES

133

(5 1/4")

380
(15")

296

(115/8")

Pumped
return
pipe

Pumped
flow pipe

12 (1/2")

100

(4")

(1 3/4")

Flue
terminal

280 (11")

70 (2 3/4")

Gas
connection

700
(27 1/2")

141
(5 9/16")

cla8230

Front View

Side View

64 (2 1/2")

38 (1 1/2")

20 (3/4")

Gas
connection

Condensate
drain point

cla7635

(15 3/8")

201850-6.pmd

21/02/2008, 12:57

classic

Installation & Servicing

GENERAL

Bathrooms
This range of appliances is rated IP 1XB.
The boiler may be installed in any room or internal space, although
particular attention is drawn to the requirements of the current
I.E.E. (BS.7671) Wiring Regulations and, in Scotland, the electrical
provisions of the building regulations applicable in Scotland with
respect to the installation of the boiler in a room or internal space
containing a bath or shower. For Ireland reference should be
made to the current ETCI rules for electrical installations and
I.S.813:2002.
If the appliance is to be installed in a room containing a bath or
shower then, providing waterjets are not going to be used for
cleaning purposes (such as communal baths/showers), the
appliance can be installed in Zone 3, as detailed in BS.7671.
Where installation will be in an unusual location, special
procedures may be necessary and BS.6798 gives detailed
guidance on this aspect.
Compartment Installations
A compartment used to enclose the boiler MUST be designed
and constructed specially for this purpose.
An existing cupboard or compartment may be used, provided it
is modified for the purpose.
In both cases details of essential features of cupboards/
compartment design, including airing cupboard installation, are
to conform to the following :

BS. 6798.

The position selected for installation MUST allow adequate
space for servicing in front of the boiler and for air circulation
around the boiler. Refer to 'Air Supply'.

For the minimum clearances required for safety and
subsequent service refer to the wall mounting diagram,
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 is to be installed only on a gas supply with a governed meter.
A gas meter can only be connected by the local gas supplier or by
a local regional contractor.
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. A MINIMUM pressure of 20 mbar MUST be
available at the boiler inlet with the boiler operating.
Installation pipes MUST be fitted in accordance with BS. 6891. In
IE refer to I.S. 813:2002. Pipework from the meter to the boiler
MUST be of an adequate size.
The complete installation MUST be tested for gas soundness and
purged as described in the above code.

FLUE INSTALLATION

Pluming may occur at the terminal so terminal positions which
would cause a nuisance should be avoided.
The flue must be installed in accordance with the
recommendations of BS. 5440-1:2000. In IE refer to I.S. 813:2002.
The following notes are intended for general guidance:-
1. The boiler MUST be installed so that the terminal is exposed

to external air.

2. It is important that the position of the terminal allows the free

passage of air across it at all times.

3. Minimum acceptable spacing from the terminal to obstructions

and ventilation openings are specified in Table 3.

4. Where the lowest part of the terminal is fitted less than 2m

(6'6") above a balcony, above ground or above a flat roof to

which people have access then the terminal MUST be protected

by a purpose designed guard.
Terminals guards are available from boiler suppliers - ask for

TFC Flue Guard, Model No. K6-round, plastic coated. In case of

difficulty seek advice from:

Grasslin (UK) Ltd., Tower House, Vale Rise, Tonbridge,
Kent TN9 1TB.
Tel: +44 (0) 1732 359 888. Fax: +44 (0) 1732 354 445
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. In IE refer to I.S. 813:2002.

IMPORTANT. It is absolutely ESSENTIAL to ensure, in practice, that
products of combustion discharging from the terminal cannot re-
enter the building or any other adjacent building through ventilators,
windows, doors, other sources of natural air infiltration, or forced
ventilation/air conditioning.
If this should occur, the appliance MUST be turned OFF, labelled
'unsafe' and corrective action taken.

Flue Terminal Positions

Min. Spacing*

1. Directly below 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 3 - Balanced Flue Terminal Position

* Only one reduction down to 25mm is allowable per installation
otherwise BS5440-1 2000 dimensions must be followed.

201850-6.pmd

21/02/2008, 12:57

classic

Installation & Servicing

GENERAL

Boiler Size

Boiler

9.0

Output Btu/h x 1000

30.7

40.9

50.2

60.4

Water Flow

l/min

11.7

15.6

19.5

23.4

Rate

gal/h

155

206

258

309

Pressure

mbar

54.0

93.5

98.4

142.5

Loss

in wg

21.6

37.4

39.3

Table 5 - Water flow rate and pressure loss

TERMINAL

The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frame 10.

AIR SUPPLY

Detailed recommendations for air supply are given in BS.5440:2.
In IE refer to I.S. 813:2002.

The following notes are for general guidance:

1. It is NOT necessary to have a purpose provided air vent in the

room or internal space in which the boiler is installed.

2. If the boiler is to be installed in a cupboard or compartment,

permanent air vents are required (for cooling purposes) in
the cupboard/compartment, at both high and low levels. The
air vents must either communicate with room/internal space,
or be direct to outside air. The minimum effective areas of the
permanent air vents, required in the cupboard/compartment,
are specified in Table 4 and are related to maximum rated
heat input.

continued . . . .

and hot water storage vessel. They should be at least

1/2" BSP

nominal size and be in accordance with BS. 2879.
The boiler is fitted with a special drain plug, which is provided,
to drain the BOILER ONLY, in the event of the system drain plug
being unable to do so. The hydraulic resistance of the boilers,
at MAXIMUM OUTPUT with an 11

C (20

F) temperature

differential, are shown in Table 5.
Maximum boiler operating temperature should be 82

C (180

F).

Table 4 - High and low vent areas

Boiler

Air from room/internal

Air direct from

space, cm (in

)

outside, cm (in

)

HE9

102

(16)

(8)

HE12

135

(21)

(11)

HE15

170

(26)

(13)

HE18

198

(31)

102

(16)

3. Both air vents MUST communicate with the same room or

internal space or MUST be on the same wall to outside air.

4. In siting the air vents care must be taken to avoid the freezing

of pipework.Water circulation system.

WATER CIRCULATION SYSTEM

The boiler must NOT be used for direct hot water supply. For the
types of system and correct piping procedure refer to 'Introduction'
and Frame 1.
The central heating system should be in accordance with BS.6798
and, in addition, for Smallbore and Microbore systems, BS. 5449.
The domestic hot water system, if applicable, should be in
accordance with the relevant recommendations of BS. 5546. Copper
tubing to BS. 2871:1 is recommended for water carrying pipework.
The hot water storage cylinder MUST be of the indirect type and
should preferably be manufactured of copper.
Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating, nor
are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat loss
and any possible freezing - particularly where pipes run through
roof spaces and ventilated under floor spaces.
Boilers not fitted to a sealed system must be vented.

IMPORTANT

A minimum length of 1m of copper pipe MUST be fitted to both
flow and return connections from the boiler before connection to
any plastic piping. This applies to ALL types of installation.

Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler

WATER TREATMENT

These boilers incorporate a cast iron heat exchanger and an
aluminium heat exchanger.
IMPORTANT. The application of any other treatment to this
product may render the guarantee of Ideal Stelrad 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, Cookson Electronics, Forsyth Road,
Sheerwater, Woking, Surrey. GU21 5RZ. Tel. +44 (0) 1799 521133
or

Sentinel Performance Solutions,
The Heath Business & Technical Park, Runcorn, Cheshire
WA7 4QX. Tel: 0800 389 4670. www.sentinel-solutions.net

or
Salamander Engineering Ltd, Unit 24, Reddicap Trading Estate,
Sutton Coldfield, West Midlands B75 7BU. Tel. +44 (0) 121 378 0952
Notes.
1. It is most important that the correct concentration of the water

treatment products is maintained in accordance with the
manufacturers' instructions.

2. If the boiler is installed in an existing system any unsuitable

additives MUST be removed by thorough cleansing.
BS7593:1992 details the steps necessary to clean a
domestic heating system.

3. In hard water areas, treatment to prevent limescale may be

necessary - however the use of artificially softened water is
NOT permitted.

4. Under no circumstances should the boiler be fired before the

system has been thoroughly flushed.

BOILER CONTROL INTERLOCKS

Ideal Stelrad Group 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.

201850-6.pmd

21/02/2008, 12:57

classic

Installation & Servicing

GENERAL

Minimum Requirements

Note. The pump manufacturers minimum
requirements must be complied with.

System
return

Connections
to boiler

Inverted cold
feed entry

System
flow to
pump

150 (6")
Max

15mm
Cold
feed

450 (17

Mimimum

450 (17

Mimimum

22mm
Open vent

Feed / expansion
cistern

Water
level
(cold)

cla7840

Surge
arrester

75 (3)
Min.

450
(17

Min.

200
(8)
Min.

Highest
point of
flow or
return

150

(6)

Max

Max. practical

length

To pump

Cold

water

level

Feed / expansion

cistern

75 (3) Min.

Flow

Return

22 (3/4)

Open vent

cla7839

All dimensions in mm (in.). N.B. Imperial dimensions are approximate

LOW HEAD INSTALLATIONS

The system should be vented directly off the boiler flow pipe, as close to the
boiler as possible. The cold feed entry should be inverted and MUST be
positioned between the pump and the vent, and not more than 150mm (6")
away from the vent connection.
There should be a minimum height - 450mm (17

") - of open vent above

cistern water level. If this is impossible refer below.
The vertical distance between the highest point of the system and the feed/
expansion cistern water level MUST not be less than 450mm (17

").

The pump MUST be fitted on the flow side of the boiler.
A suitable pump is a domestic circulator capable of providing an 11

C (20

temperature differential (e.g. Grundfos UPS 15/50 or equivalent). The vertical
distance between the pump and feed/expansion cistern MUST comply with
the pump manufacturers minimum requirements to avoid cavitation. Should
these conditions not apply, either lower the pump position or raise the cistern
above the minimum requirement specified by Ideal Stelrad 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 HE 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 be at least 42mm in diameter x

150mm long, thus ensuring a MINIMUM air gap and a
MINIMUM depth of water below the static water level (cold)
of 75mm.

2. The static water level (cold) must be at least 200mm

above the top of the horizontal flow pipe, fitted as shown.
The vent connection MUST NOT be made immediately off
the top of the boiler, as venting is made less efficient.

3. The maximum practical length of 15mm cold feed pipe

should be used in order to reduce the effective volume of
system water expanding into the feed/expansion cistern to
a minimum.

OPEN VENT SYSTEM REQUIREMENTS - FULLY PUMPED

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. The appliance MUST be efficiently earthed.
Wiring external to the appliance MUST be in accordance with
the current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply. For Ireland reference should be
made to the current ETCI rules for electrical installations.

The point of connection to the mains should be readily accessible
and adjacent to the boiler, except that for bathroom installations; the
point of connection to the mains MUST be situated outside of the
bathroom.
Note.
Where a room sealed appliance is installed in a room containing
a bath or shower then the appliance and any electrical switch or
appliance control utilising mains electricity should be so situated
that it cannot be touched by a person using the bath or shower.
See Frame 41 for details.

CONDENSATE DRAIN

Refer to Frames 38, 39 and 40

A condensate drain siphon 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.

201850-6.pmd

21/02/2008, 12:57

classic

Installation & Servicing

GENERAL

Non-return

valve

Automatic

air vent

Hose unions

Additional

stop valve

Hose connector

Hosepipe

(disconnect

after filling)

Double check valve

assembly

(note direction of flow)

Temporary hose

(disconnect

after filling)

ecl6060

SEALED SYSTEM REQUIREMENTS

Note.

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.

1. General

a. The installation must comply with the requirements of

BS.6798 and BS.5449.

b. The installation should be designed to work with flow

temperatures of up to 82

c. All components of the system, including the heat

exchanger of the indirect cylinder, must be suitable for a
working pressure of 3 bar (45 lb/in

) and temperature of

110

C. Care should be taken in making all connections

so that the risk of leakage is minimised.

2. Safety Valve

A spring loaded safety valve complying with the relevant
requirements of BS.6759 must be fitted in the flow pipe, as
close to the boiler as possible and with no intervening valve
or restriction. The valve should have the following features:
a. A non-adjustable pre-set lift pressure not exceeding 3

bar (45 lb./in

)

b. A manual testing device.
c. Provision for connection of a discharge pipe. The valve

or discharge pipe should be positioned so that the
discharge of water or steam cannot create a hazard to
the occupants of the premises or cause damage to
electrical components and wiring.

3. Pressure Gauge

A pressure gauge covering at least the range 0-4 bar (0-60
lb./in

) 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 incorporating valves of any sort.

b. The vessel capacity must be adequate to accept the

expansion of the system water when heated to 110

(230

c. The charge pressure must not be less than the static

water head above the vessel The pressure attained in
the system when heated to 110

C (230

F) should be at

least 0.35 bar (5lb/in

) less than the lift pressure of the

safety valve.

For guidance on vessel sizing refer to the table in Frame
6. For further details refer to BS.5449. For IE refer to the
current edition of I.S. 813.

5. Cylinder

The cylinder must be either of the indirect coil type or a
direct cylinder fitted with an immersion calorifier which is
suitable for operating on a gauge pressure of 0.35 bar
(5lb./in

) in excess of the safety valve setting. Single feed

indirect cylinders are not suitable for sealed systems.

6. Make-up Water

Provision must be made for replacing water loss from the
system, either:
a. From a manually fitted make-up vessel with a readily

visible water level. The vessel should be mounted at
least 150mm (6") above the highest point of the
system and be connected through a non-return valve to
the system, fitted at least 300mm (12") below the
make-up vessel on the return side of the domestic hot
water cylinder or radiators.

b. Where access to a make-up vessel would be difficult by

pre-pressurisation of the system. Refer to 'Filling.'

201850-6.pmd

21/02/2008, 12:57