IDEAL imax W45 Installation And Servicing Manual Download Page 16

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Installation & Servicing

INSTALLATION

18 FLUE KIT ACCESSORIES

RF 5757

10.

90º elbow (concentric)

45º elbow (concentric)

90º elbow

45º elbow (pair)

Flat Weather Collar

Pitched Weather Collar

1m Extension (concentric)

1m Extension (pair)

Twin pipe adapter 80/80

Increaser 80-100

152616

152618

n/a

152611

152609

152400

n/a

152617

152619

n/a

152612

152610

152401

n/a

Accessory

80/125

100/150

Part No.

n/a

158773

158775

158780

158779

n/a

158771

158686

152404

n/a

158774

158776

158780

158779

n/a

158772

n/a

100

FLUE OUTLET

Summary of Contents for imax W45

Page 1: ......

Page 2: ...0 48 150 75 650 74 100 Gas Rate m3 h 4 76 1 84 6 35 2 45 8 46 3 27 ft3 h 168 65 224 86 299 115 Approx flue gas volume m3 h 72 68 98 93 131 123 ft3 h 2 540 2 400 3 460 3 280 4 620 4 340 CO2 Max Rate 8...

Page 3: ...Kingdom Countries of destination PMS Maximum operating pressure of water C13 C33 A room sealed appliance designed for connection via ducts to a horizontal or vertical terminal which admits fresh air...

Page 4: ...otland 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 o...

Page 5: ...of the installer 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 so...

Page 6: ...Systems Caradon Ideal Limited recommend the use of Fernox Copal or MB1 GE Betz Sentinel X100 or Salamander Corrosion Guard inhibitors and associated water treatment products which must be used in acco...

Page 7: ...urn Return Return Cond Drain Cond Drain Gas pipe Gas pipe Flue centre line 114 Flue centre line Flue centre line 80 125 Concentric Flue Connector W45 and W60 Minimum boiler top clearances for vertical...

Page 8: ...elevant requirements of BS 6759 Pt 1 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 no...

Page 9: ...plate 6 Internal flue tube 7 Air pressure switch 8 Fan 9 Mounting plate manifold 10 Gas Valve 11 Upper gas pipe 12 Lower gas pipe 12A Gas pipe 13 Sight glass complete 14 Ignition detection electrode...

Page 10: ...After following the instructions on the box the boiler should be laying on its back with the straps removed Carefully read these installation instructions before proceeding Remove the outer packing s...

Page 11: ...se damage or personal injury 1 Cut the flue hole 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 12mm 1 2 masonry dri...

Page 12: ...h the attached bracket Boiler Size W45 W45P W60 W60P Minimum vent free 190 265 area cm2 If installed in a compartment then permanent air vents are required at high and low level These vents may commun...

Page 13: ...e examples giving the maximum extensions which may be added The flue lengths achievable without any extensions are also provided For horizontal flues this is the distance from the flue outlet centre l...

Page 14: ...aser Terminal Locking Collars x2 Finishing plates x2 Bracket RF 2499 Flue System Part No Max Flue Ext W45 W60 Vertical roof kit 80 125 158654 m 9 5 7 8 suitable for W45 W60 Pa 60 78 Vertical roof kit...

Page 15: ...nal and the flue exhausted through either a vertical roof or horizontal wall terminal The maximum flue extension depends on the ratio of air to flue tube By fixing either the air or flue tube length y...

Page 16: ...ollar Pitched Weather Collar 1m Extension concentric 1m Extension pair Twin pipe adapter 80 80 Increaser 80 100 152616 152618 n a n a 152611 152609 152400 n a n a n a 152617 152619 n a n a 152612 1526...

Page 17: ...r or flue tube for the elbow required Concentric Flue Systems Pressure drop per component Pa m Pa m Pa m Terminals Vertical Roof flue kit 80 125mm 40 6 3 62 6 2 Vertical Roof flue kit 100 150mm 21 8 4...

Page 18: ...w 2 x 11 2 x 1 1 Total flue resistance 104 10 4 The total maximum flue resistance for an W60 is 140Pa or 11m 80 125 Therefore this installation is acceptable Example 2 22 EXAMPLES OF CALCULATING FLUE...

Page 19: ...llow correct connection of the ducts Care should be taken to support the inner duct when cutting the flue Note Horizontal flue runs must be angled down between 1 5 3 towards the boiler to allow the co...

Page 20: ...car port roof From a vertical drain pipe or soil pipe From an internal or external corner or to a boundary alongside the terminal Above ground roof or balcony level From a surface or a boundary facing...

Page 21: ...n the boiler capacity an ideal solution is to use multiple boiler arrangements The ideal way to control a multiple boiler installation is with our modulating sequencer See below a typical installation...

Page 22: ...ion located at the bottom of the appliance Note This appliance is NOT suitable for use with a direct hot water cylinder Plastic plugs fitted into the open ends of the flow and return pipes must be rem...

Page 23: ...e is used IMPORTANT The gas service cock contains a non metallic seal so must not be overheated when making capillary connections External wiring MUST be in accordance with the current I E E BS7671 Wi...

Page 24: ...onnections for programmable room thermostat and modulating sequencer kits L SUPPLY N L PROG DHW STAT CH PUMP DHW PUMP OR VALVE CH STAT N L N L N ima5385 230VAC permanent mains supply Optional 230VAC s...

Page 25: ...Burner switch KEY Blue Black Brown Red Yellow White g or v pk g y Grey Orange Violet Pink Green Yellow L DISPLAY BOARD b bk g y g or or or RY1 w v or y w r r r r b p bk w bk b g v RY2 1 2 3 4 5 6 7 8...

Page 26: ...with the error code shown Refer to page 50 for error codes The boiler will enter error mode under certain fault conditions The unit will be inoperative until the fault is rectified The reset button i...

Page 27: ...Parameter mode is entered from standby mode by pressing the mode button once S t b y P A R A Press the step button until the desired parameter is displayed Press the or buttons to change the values Th...

Page 28: ...de 37 STANDARD CONTROLS ACCESS CONT D i N F O P A R A Press Display I N F O Actual Flow Temperature T1 C Press Display Description Actual Return Temperature T2 C 1 2 1 2 2 1 3 3 7 OUTSIDE Temperature...

Page 29: ...th them 9 Code Mode By entering the service code the following additional features are accessible Parameters 5 to 42 Communication Mode Fan Speed Mode Error Mode Code Mode is entered from standby mode...

Page 30: ...ence temperature compensation 15 25 20 2 0 Lowest outside temperature C That can influence temperature compensation 20 10 5 0 2 Outside temperature correction C For boiler reading of outside temperatu...

Page 31: ...00 P15 Maximum fan speed DHW hundreds W45 55 W60 55 W80 Do not Do not 59 W45P adjust adjust 50 W60P 49 W80P 57 0 0 16 P16 Maximum fan speed DHW units W45 00 W60 00 W80 Do not Do not 00 W45P adjust ad...

Page 32: ...00 Note 01 RMCI off 0 0 CH type 00 x0 Room thermostat x1 Outside temperature x2 N A x3 N A x4 0 10V capacity using BMS 0 10V kit x5 0 10V temperature using BMS 0 10V kit x6 control 0x N A First digit...

Page 33: ...tion 1x CH pump off during heat request DHW normal pump function 2x CH pump normal function DHW pump 5 sec on delay after heat request 3x CH pump off during heat request DHW pump 5 sec on delay after...

Page 34: ...boiler control module and optional controls interface kit There is communication between all devices FLASHING FLASHING I N F O Actual Flow Temperature T1 C 1 2 1 FLASHING Actual Return Temperature T2...

Page 35: ...1st digit flashes and shows the current step The last two digits show the error code Error code see Table on page 48 for full list E R R O 1 3 6 FLASHING Boiler step 2 0 0 Flow temperature T1 Return...

Page 36: ...t System pump maximum load 1 amp connect via a relay for greater currents 49 MAINS VOLTAGE CH AND DHW CONTROLS WITH DHW PUMP OUTPUT Pump Pump Non return valve Non return valve Cylinder thermostat PUSH...

Page 37: ...cations see Frames 38 39 and 40 Parameter 35 03 If a live output is required from terminal 12 for positioning of the valve to satisfy CH demand Parameter 35 23 If a live output is required from termin...

Page 38: ...t digit indicating the boiler is operating at minimum rate 13 Press the reset button to return to normal operating mode Note It is possible to switch off the CH DHW systems if the mode and buttons are...

Page 39: ...inium oxide build up within the heat exchanger assembly is quite usual with this type of condensing boiler Though removal and cleaning is recommended annually the heat exchanger sump and condensate tr...

Page 40: ...burner sealing gasket can be re used providing it shows no sign of damage The eight nuts and washers should be fitted following a diagonal tightening sequence twice The nuts should be secured firmly...

Page 41: ...urner im 2524 62 HEAT EXCHANGER INSPECTION CLEANING 1 Remove the jacket front panel Refer to Frame 57 2 Remove the fan burner and gas valve assembly Refer to Frame 58 or 60 3 Inspect the heat exchange...

Page 42: ...washer 5 Remove the four nuts securing the fan to the burner hood and lift out of the boiler 6 Remove the 2 screws securing the venturi to the fan inlet 7 Replace the fan using the new gaskets and fib...

Page 43: ...Limited should be used as these are factory preset and require no adjustment 11 Reference should now be made to Frame 52 to check the gas rate 12 Check the operation of the boiler Refer to Frame 55 i...

Page 44: ...k for gas soundness 10 Only Venturi s supplied by Caradon Ideal Limited should be used as these are factory preset and require no adjustment 11 Reference should now be made to Frame 52 to check the ga...

Page 45: ...er to Frame 57 7 Pull the HT lead off the electrode 8 Remove the 2 screws 9 Replace the electrode using the new gasket provided ensuring that the earth lead is recaptivated under the screw and washer...

Page 46: ...ry from the self sealing fitting 3 Unscrew the two screws from the pressure gauge bracket and withdraw the unit from the boiler 4 Compress the retaining lugs and remove the gauge from the bracket 5 Re...

Page 47: ...rst to remove the transformer Refer to Frame 76 3 Disconnect the electrical connections from the module 4 Remove the four module fixing screws 5 Fit the new module and reassemble in reverse order 6 Ch...

Page 48: ...tion Action E 00 Flame error Check inlet gas pressure Check flue for blockage Check wiring to ignition detection electrode Check condition of ignition detection electrode E 02 No ignition after restar...

Page 49: ...meter Replace thermister E 32 Return thermistor short circuit Check wiring Disconnect terminals from thermister confirm short circuit using meter Replace thermister E 33 DHW thermistor short circuit...

Page 50: ...d system check charge pressure If open vent system check minimum head is 3m Check wiring to water pressure switch Check water pressure switch with meter replace if necessary b 30 Flow return temperatu...

Page 51: ...e 1 172 665 15 Auto air vent 1 172 668 21 Thermistor flow return 1 172 671 22 Transformer 1 172 657 23 Control Module W45 1 172 651 Control Module W60 1 172 652 Control Module W80 1 172 653 Control Mo...

Page 52: ...52 Installation Servicing SHORT LIST OF PARTS 81 SHORT LIST 28 25 27 ima5558 14 15 21 22 23 24 26 10 7 8 29 W80 W45 60 30 early model late model...

Page 53: ...53 Installation Servicing NOTES...

Page 54: ...54 Installation Servicing NOTES...

Page 55: ...55 Installation Servicing NOTES...

Page 56: ...ing 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...

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