IDEAL IMAX XTRA EL Installation And Servicing Download Page 29

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INSTALLATION

IMAX XTRA EL

Installation & Servicing

28 IMAX XTRA EL WITH EXTERNAL CONTROLS

VIA SWITCHED LIVE, 0-10V INPUT OR OPENTHERM

EXTERNAL CONTROLS - VIA OPENTHERM

EXTERNAL CONTROLS - VIA 0-10V INPUT

EXTERNAL CONTROLS - VIA SWITCHED LIVE

Note that the boiler requires a 2 minute pump overrun period.
The boiler warranty will be invalid if this is not provided.
It is recommended that the pump overrun functionality is

achieved by connecting the pump or pump control to the

boiler CH Pump connections (see diagram), although this

functionality can be replicated with external controls (for

example a Building Management System).

If the CH Pump connection is used and the electrical current

draw is 1.3A inductive or less then the pump may be connected

directly into the CH Pump connection.
If the current draw is more than this then an external relay or

contactor should be operated by the CH Pump connection, with

the external relay then powering the pump.

0-10+

0-10-

DHW+

DHW-

OWC+

OWC-

OT+

OT-

GND

INT

LOCKOUT

BURNER ON

L NO

L NC

LIVE OUT

CH CALL

LIVE OUT

DHW/CH2 CALL

HEAT

DEMAND

MAINS

230v

50Hz

DHW/

CH2

PUMP/

VALVE

CH/

BOI

LER

PUMP

VOLTS

FREE

CONTACTS

INTER/

LOCK

PUMP

CONTROL

0-10v

INPUT

TANK

SENSOR

OUTSI

SENSOR

OPEN

THERM

pump

control

supply

switched

live

0-10+

0-10-

DHW+

DHW-

OWC+

OWC-

OT+

OT-

GND

INT

LOCKOUT

BURNER ON

L NO

L NC

LIVE OUT

CH CALL

LIVE OUT

DHW/CH2 CALL

HEAT

DEMAND

MAINS

230v

50Hz

DHW/

CH2

PUMP/

VALVE

CH/

BOI

LER

PUMP

VOLTS

FREE

CONTACTS

INTER/

LOCK

PUMP

CONTROL

0-10v

INPUT

TANK

SENSOR

OUTSI

SENSOR

OPEN

THERM

0-10V

0 10

pump

control

supply

0-10+

0-10-

DHW+

DHW-

OWC+

OWC-

OT+

OT-

GND

INT

LOCKOUT

BURNER ON

L NO

L NC

LIVE OUT

CH CALL

LIVE OUT

DHW/CH2 CALL

HEAT

DEMAND

MAINS

230v

50Hz

DHW/

CH2

PUMP/

VALVE

CH/

BOI

LER

PUMP

VOLTS

FREE

CONTACTS

INTER/

LOCK

PUMP

CONTROL

0-10v

INPUT

TANK

SENSOR

OUTSI

SENSOR

OPEN

THERM

opentherm

master

- +

pump

control

supply

INST

ALLA

TION

Summary of Contents for IMAX XTRA EL

Page 1: ...fety and performance speci cation that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal For the very latest copy of literature for speci cation and main...

Page 2: ...n kW 58 9 72 6 85 2 100 7 114 9 Boiler output condensing Mean 40o C Max kW 323 1 399 5 475 8 552 7 628 9 Min kW 66 7 80 5 95 6 113 0 127 6 Boiler Input Max Rate Net kW 304 8 376 2 447 6 519 0 590 0 Gr...

Page 3: ...he room containing the boiler The combustion air is drawn directly from the room The fan is up stream of the combustion chamber C53 A room sealed appliance which is connected via its separate ducts to...

Page 4: ...ers have been tested and certified by BSI to EN 15502 for use with Natural Gas Detailed recommendations are contained in the following Standards and Codes of Practice BS 5854 Flue and flue Structures...

Page 5: ...possible duct the air supply into the boiler room from a clean source outside the boiler room building If the air filter accessory is fitted the 100Pa 10Pa pressure requirement must be checked at max...

Page 6: ...1 SENTINEL X100 or CALMAG CM100 inhibitors and associated water treatment products which must be used in accordance with the manufacturers instructions In hard water areas where mains water can exceed...

Page 7: ...7 25 10 1 168 3 24 11 7 195 0 24 13 3 221 7 24 Nominal ow 13 8 230 0 100 17 283 3 98 20 2 336 7 96 23 5 391 7 95 26 7 445 0 94 Nominal ow x1 5 20 7 345 0 225 25 5 425 0 221 30 3 505 0 216 35 2 586 7 2...

Page 8: ...8 IMAX XTRA EL Installation Servicing GENERAL 1 BOILER DIMENSIONS AND CLEARANCES FRONT VIEW REAR VIEW SIDE VIEW ELECTRICAL CABLE OUTLETS All dimensions in mm unless otherwise stated...

Page 9: ...CLEARANCES CONT D D C E B A Dimension A B C D E TOP Minimum 700 150 700 150 700 Recommended 1000 400 1000 400 1000 This clearance dimension applies independently of the installed flue system TOP VIEW...

Page 10: ...ards applicable to commercial sealed systems are BS 6880 Part 2 BS 1212 BS 6281 Part 1 BS 6282 Part 1 BS 6283 Part 4 3 VENTILATION The ventilation requirements of these boilers are dependant on the ty...

Page 11: ...f circulation in the system Systems designed to rise above the boiler flow tappings will automatically require a minimum static head higher than that shown 5 The position of the open vent safety pipe...

Page 12: ...et Strapping 301 PCB 309 Ignition Electrode 310 Ionisation Electrode 311 Air Pressure Switch 315 Air Pressure Switch Kroms 316 Buttons Potentiometer Knob 317 Pod CUI 318 PCB CUI 401 Heat Engine Gasket...

Page 13: ...ia crane hoist forklift truck or pallet truck If using pallet truck refer to diagram below 2 To remove the appliance from the pallet packaging and panels MUST be removed and stored safely 3 Remove the...

Page 14: ...to the instructions supplied with the kit If the kit is not being fitted the 2 BSP branch must be capped off as shown in image 3 6 The flange joint is DN80 PN6 A suitable mating flange with bolts and...

Page 15: ...ours without frost damage However if parts of the pipework run outside the building 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...

Page 16: ...Wiring Regulations For Ireland reference should be made to the current ETCI rules for electrical installations For wiring external controls to the boiler reference should be made to the systems wiring...

Page 17: ...6 SEQUENCER CONTROL OF MULTIPLE BOILERS In installations where the heat load is greater than the boiler capacity an ideal solution is to use multiple boiler arrangements The ideal way to control a mul...

Page 18: ...Volt Free Relay contacts will close when the Burner is on 4 Only Ideal Outside Sensor and DHW Tank Sensor kits should be connected to the boiler 5 The External Interlock connection is only used in con...

Page 19: ...MAINS SUPPLY PE MAINS SUPPLY N MAINS SUPPLY L DIVERTER VALVE L CH GAS VALVE PE DIVERTER VALVE L DHW GAS VALVE N PUMP PE PUMP N GAS VALVE L GAS VALVE N DIVERTER VALVE PE DIVERTER VALVE N FAN L IONISAT...

Page 20: ...on setup Line 5 indicates Switched Live or OpenTherm or 0 10V depending on which controls are connected to the boiler Hot Water DHW Switched Live On Burner On DHW Thermostat Flow Temp 80 C Domestic H...

Page 21: ...Frame 25 for adjusting the system frost protection temperature setpoint Cylinder Frost Protect Burner Power 100 Outside Temp 10 C Frost Setpoint 5 C Hot Water Temp 4 C Cylinder Frost Protection Mode...

Page 22: ...ti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Ideal imax XL 320 kW Normal Operation Set Flow Temp Set DHW Temp Press SELECT and a screen simil...

Page 23: ...vary as the boiler operates Press SELECT to exit this option Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation VIEWING THE FAUL...

Page 24: ...to 0 10V Input 0 10V Off 0 10V Capacity 0 10V Temperature Press and to change to the required setting and then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted...

Page 25: ...et Night Setback DHW Pump Valve Set Booster Press SELECT and the following screen will be displayed Set Night Setback On Off Press and to change to required setting and then press ENTER to store Rotat...

Page 26: ...ion Function is only operational if an Outside Sensor has been connected The CH pump is switched on if the Outside Temp is less than the System Frost Protection Temp The CH pump is switched off if the...

Page 27: ...o the DHW Thermistor input Rotate the KNOB clockwise until the following screen is displayed Rotate the KNOB clockwise until the following screen is displayed Installer Mode O S Room Temp DHW Sensor F...

Page 28: ...the following screen is displayed Installer Mode DHW Sensor Factory Settings Anti Legion Temp Anti Legion Enable Press SELECT and the following screen will be displayed Factory Settings Reset Press E...

Page 29: ...with the external relay then powering the pump 0 10 0 10 DHW DHW OWC OWC OT OT PWM GND INT INT LOCKOUT LOCKOUT BURNER ON BURNER ON N L NO L NC N L L N LIVE OUT CH CALL LIVE OUT DHW CH2 CALL HEAT DEMAN...

Page 30: ...ng instructions 7 The boiler will commence the ignition sequence If after 5 attempts the boiler has failed to light then it will lock out Press the reset button to restart the ignition sequence 8 Fit...

Page 31: ...me detected Demand On Temp Set point Anti cycle done Fan On 10s Fan Pre purge Pump On Fan on Spark Generator On Gas Valve On 5s Ignition Period Burner Output controlled relative to Heat Demand by vary...

Page 32: ...the case may be responds 2 Water circulation system a With the system HOT examine all water connections for soundness b With the system still HOT turn off the gas water and electricity supplies to th...

Page 33: ...Light the boiler and carry out function checks noting any operational faults 2 Run the boiler for 10 minutes and then check the gas consumption rate Refer to procedure opposite on how to force the bur...

Page 34: ...o front side panels have noise dampening insulation fitted SERVICING 37 REMOVAL OF BURNER MANIFOLD 1 Refer to Frames 34 36 2 Remove the four nuts securing the burner hood elbow to the heat exchanger 3...

Page 35: ...howing signs of damage it must be replaced 5 Re assemble in reverse order replacing any seals gaskets which show signs of wear When refitting ensure the burner is correctly engaged so the burner flang...

Page 36: ...ly insert the probe assembly engaging the securing stud 5 Replace the two nuts and tighten Re connect the earth lead and the spark generator lead IONISATION PROBE 6 Disconnect the wire from the ionisa...

Page 37: ...secure with the 8 bolts 42 CLEANING CONDENSATE TRAP 1 Refer to Frame 34 2 Unscrew the top fitting of the condensate trap 3 Unscrew the fitting at the flue outlet drain point 4 Unscrew the condensate o...

Page 38: ...e assembly forward on the interface plate 7 Remove the three nuts retaining the gas valve assembly to the fan scroll and remove the gas valve assembly taking care due to the weight of the gas valve 8...

Page 39: ...HERMISTOR X3 REPLACEMENT 1 Refer to Frames 34 36 2 Disconnect the 2 wires from each thermistor 3 Using a suitable sized spanner on the hexagon undo the thermistor and remove 4 Refit in reverse order u...

Page 40: ...t of the control pod 4 Refit in reverse order 47 BOILER CONTROL PCB REPLACEMENT 1 Refer to Frames 34 36 2 Remove all PCB electrical connections 3 Remove the PCB carefully by pulling gently towards you...

Page 41: ...Position the flexible duct over the air inlet and secure with the hose clip 7 Postion the flexible duct over the fan inlet and secure with the hose clip 3 2 Air inlet 1 Refer to Frame 34 2 Unscrew the...

Page 42: ...route back to the control box 5 Remove the connectors from the PCB 6 Remove the three bottom connectors on LHS of control box 7 Remove the earth post nut and release the earth connections 8 Feed the...

Page 43: ...S connectors 9 Feed the harness back to the components listed above using the retaining clips and connect 2 3 4 GAS VALVE Whirl Wind Mixer FAN Heat Exchanger Sump Air Pressure Switches APS 1 Refer to...

Page 44: ...ersed Cylinder Thermistor Fault Check Cylinder Thermistor Wiring Check Cylinder Thmr 10K 25 C 2K at 66 C Go to Frame 64 CylinderThermistor Fault Ext Interlock Off External Interlock Operated Reset Int...

Page 45: ...continuity visual condition and position refer to Frame 42 Check if the condensate pipe is blocked yes no Is the dynamic gas pressure available at the boiler 15mbar Check gas supply and rectify fault...

Page 46: ...ure wiring has continuity and is securely connected no Does the black wire from the Water Pressure Switch to the PCB have continuity and is it securely connected Check syphon and condensate drain Pipe...

Page 47: ...therwise replace the main PCB no yes Check Spark Generator and associated Harness for continuity visual condition and position refer to Frame 46 Are these functioning correctly Replace Spark Generator...

Page 48: ...ce main PCB no yes Is there continuity between the PCB and the thermistor 62 OUTSIDE SENSOR FAULT Fit a new Outside Sensor no Disconnect the wires to the Outside Sensor Check the resistance using a su...

Page 49: ...linder thermistor wiring between the boiler terminal strip and the PCB have continuity and is it securely connected Replace main PCB Change menu setting for DHW Sensor to Switched Live See Frame 26 no...

Page 50: ...30Vac at A There is no voltage from the external controls This is not a boiler fault Ensure voltage is supplied to the boiler by correcting external wiring no yes Is there 230Vac at B Check wiring fro...

Page 51: ...l wiring Rectify wiring from boiler to OpenTherm device no yes Does the system have a DHW Pump or Power Open Diverter Valve Is the system correctly set for a Power Closed Diverter Valve no no Set boil...

Page 52: ...PCB to user interface PCB no Does the cable from the main PCB to the user interface PCB have continuity and is it un damaged yes yes Replace main PCB yes Replace the user interface PCB still no displ...

Page 53: ...es Ensure between 2V and 10V is correctly connected to these terminals from the external device no Is a voltage of between 2V and 10V being supplied to F with positive and negative connected correctly...

Page 54: ...thorised by Ideal Failure to do so could affect safety or performance of this appliance Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www ide...

Page 55: ...iler firing mbar Gas manifold pressure dynamic all boiler firing mbar Burner pressure if required mbar Gas rate kW hr Detection Electrode A Flue gas temperature gross C Ambient temperature C O 2 CO 2...

Page 56: ...Inlet Pressure dynamic 1 Boiler mbar Gas Inlet Pressure dynamic all Boilers mbar CO2 CO CO2 Ratio Control Stat Setting C Temp Diff C Burner Pressure if applicable mbar Flue Gas Temp C Ambient Temp C...

Page 57: ...Inlet Pressure dynamic 1 Boiler mbar Gas Inlet Pressure dynamic all Boilers mbar CO2 CO CO2 Ratio Control Stat Setting C Temp Diff C Burner Pressure if applicable mbar Flue Gas Temp C Ambient Temp C...

Page 58: ...2 Ideal is a trademark of Ideal Boilers Registered Office Ideal Boilers Ltd PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 01482 492251 Fax 01482 448858 Registration No London 322 137 Ideal...

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