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IDEAL imax plus F80 Installation And Servicing

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servicing
Your Ideal installation and servicing guide
See reverse for
Models F80, F120, F160
& F200, F240, F280
When replacing any part on this appliance, use only spare parts that you 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.
January 2004 UIN 159 660 A01
plus
users guide
plus
ENGINEERED FOR PEACE OF MIND

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Summary of Contents for IDEAL imax plus F80

  • Page 1 When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not ENGINEERED FOR PEACE OF MIND use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers. January 2004 UIN 159 660 A01...
  • Page 2 15ºC and 1013.25 mbar. Installation and Servicing Instructions or as otherwise a . For l/s divide the gross heat input (kW) by the gross C.V. of recommended by Caradon Ideal Limited in writing. If in doubt the gas (MJ/m please enquire.
  • Page 3 GENERAL CONTENTS Natural Gas only Boiler Clearances............. 7 PI No. 0049 BM 3615 Commissioning and Testing.......... 32 Destination Countries: GB, IE Electrical Connections........... 14 Electrical Supply............... 5 Fault Finding..............36 Flue System Design............4 Gas Safety Regulations ............
  • Page 4 Gas Boosters availability of proprietary types of flue system can be obtained by contacting Caradon Ideal Limited. All joints or connections in A gas booster is required if the gas pressure available at the the flue system must be impervious to condensate leakage.

  • Page 5: Condensate Drain

    For these box incorporates a 5 minute pump overrun facility. A system reasons Caradon Ideal Limited strongly recommends that the pump must therefore be connected to the terminals provided in system be thoroughly cleaned prior to the use of a stable inhibitor the boiler.
  • Page 6 GENERAL F120 GRAPH 1 - WATER PRESSURE LOSS F160 1300 1250 1200 1150 1100 1050 1000 F 160 F 120 F 80 WATER FLOW l/s ima 5774 F200 F240 GRAPH 2 - WATER PRESSURE LOSS F280 1300 1250 F 280 1200 1150 1100...
  • Page 7 GENERAL BOILER DIMENSIONS, CONNECTIONS AND CLEARANCES The boiler must be positioned to ensure adequate space Sides - Minimum clearance of 50 mm one side only, with 450 available for access during operation and service. It must also mm on opposite side for flue baffle access and pipework comply with relevant local byelaws and safety regulations.
  • Page 8 GENERAL MIXING HEADER For the correct operation of the boiler, the use of a mixing The use of a mixing header means that compensating controls header is advisable because it provides: can be used to operate mixing valves on a variable temperature circuit, without affecting the water flow rate through the boiler.
  • Page 9 Should these conditions not apply either lower the pump position or raise the cistern above the Feed/expansion minimum requirement specified by Caradon Ideal cistern Limited. The isolation valves should be fitted as close to the pump as possible.
  • Page 10 GENERAL SEALED SYSTEM REQUIREMENTS Working pressure 6.0 bar maximum, 0.8 bar minimum. Examples of such situations are low water level and operating pressure or excessive pressure within the system. Depending There is no minimum water pressure switch on the boiler, with on circumstances, controls will need to be either manual or safety thermostats providing protection against dry firing.
  • Page 11 INSTALLATION SIDE VIEW WITH MAIN COMPONENTS Fans Pressure switch (2 to 7) (2 to 7) Air Intake Connection Gas Valves + CVI5 (2 to 7) Automatic Gas Pipe Air Vent Burner Cover Ignition Electrodes (2 to 7) Flame Ionisation Global Flow NTC Electrodes (2 to 7) Temperature Sensor Local NTC Temperature...
  • Page 12 INSTALLATION UNPACKING is delivered assembled and protected by a CONTENTS plastic bag inside a strong cardboard box and fixed on a Assembled boiler pallet. This allows the boiler to be handled by a forklift. The Front case attached to the back panel boiler with the packaging can go through a door 800mm wide, whereas, without packaging, it can go through a door 700mm Right hand panel attached to the left hand panel...

  • Page 13: Water Connection

    INSTALLATION WATER CONNECTION If installing the boiler onto an existing system it is strongly The boiler flow and return pipes are terminated with 2” BSP recommended that the system be thoroughly flushed before male taper threads on either the right or left hand side of the connecting the boiler.

  • Page 14: Flue Connection

    INSTALLATION 12 CASING PANEL FIXING The panels should be fitted before firing the boiler. The 4. Place the top panel in place and press down to engage the method of assembling the panels is as follows: latch studs. Then secure the top panel to the top edges of the front and back panels using the 2 screws provided in 1.
  • Page 15 INSTALLATION 15 MAINS ELECTRICAL CONNECTIONS 1. The appliance MUST be wired with a permanent live supply. Use the plug 'A' provided for this purpose. The mains supply must meet with the regulations in Frame 14. The boiler is phase sensitive so correct connection of the live and neutral wires is essential.
  • Page 16 3-contact relay DHW demand can be controlled using a Tank Lin e L in e Sensor Kit available from Caradon Ideal N e u tra l N eu tral Limited. Connection should be made to terminals 7 & 8, with the boiler automatically detecting its presence.

  • Page 17: Internal Wiring

    INSTALLATION 18 INTERNAL WIRING WHITE GREEN GREEN BLUE ORANGE ORANGE YEL/GRE BLUE MA IN SUPPLY 230 V - 50 Hz YEL/GRE BLUE BROWN BLACK BLUE BLUE FILTER GE - FITELEC BLACK BLUE Installation & Servicing...
  • Page 18 INSTALLATION 19 INTERNAL WIRING CONT'D Detail of electrical connections on the 'CVI' control boards mounted directly onto the gas valves. WARNING! E. ACC. To disconnect the ignition lead from the CVI hold directly on E. RIV. E. ACC.Ignition electrode the terminal (fast-on) E.
  • Page 19 INSTALLATION 21 INTERFACE BOARD - AM4 supplementary Board DHW Output Limiting It is possible to limit the output of the boiler when working in DHW mode. This is in order to avoid overheating when the DHW storage tank absorbed input is less than the boiler produced output.
  • Page 20 INSTALLATION 23 EXAMPLES OF HEATING SYSTEMS Heating system with DHW production (storage tank Output = Boiler Output) and mixing header. 16 17 18 3 way diverting valve Heating System Pump Storage Heating circuit tank output Flow boiler output 11 12 13 Return ima 5781 Filter...
  • Page 21 INSTALLATION 24 EXAMPLES OF HEATING SYSTEMS CONT'D Installation of Two Boilers in Cascade, with Mixing Header and One or more Radiator Groups Heating system pump Heating circuit non return Flow valve 11 12 13 Return ima 5782 Filter Boiler pump or storage tank Mixing Header...
  • Page 22 INSTALLATION 25 CONTROLS OPERATION AND DISPLAY Reset buttons for the different modules On/Off switch Pressure gauge Step Display Store Mode Reset ima 5784 Operation and indications on the display (example with 7 modules) During normal operation of the , the status of the appliance can be determined from the display. Display Status Boiler Status 0_xx...
  • Page 23 INSTALLATION 26 SERVICE CODE The letter C will be displayed along with a randomly generated To access the full list of parameters and the TEST and HOUR 2-digit number. modes , it is first necessary to enter the service code. This is only to be used by trained installers and service engineers.
  • Page 24 INSTALLATION 27 SERVICE CODE CONT'D +/- : it selects: It d ispla ys when it in cr eases - parameters in DATA mode. Reset or decr eases ch oo ses - data (all/single) It st or es when the boile r the displayed the mod e - test (all/single)

  • Page 25: Parameter Mode

    INSTALLATION 28 PARAMETER MODE By pressing the mode key once, PARA mode (abbreviation for parameter) is displayed. In this mode it is possible to change the settings of the boiler control module. Press Display P A R A Parameters accessible to user Lower Upper Factory...
  • Page 26 2nd digit - DHW pump overrun time (30 second increments) DHW hysteresis (degC) L. 2 0 1st digit - Burner System N. 2 0 0x = Ideal normal setup ADJUST ADJUST x2 to x7 2nd digit - Number of Modules...
  • Page 27 INSTALLATION 30 DATA MODE By pressing the mode key twice, DATA mode is displayed. In this mode it is possible to read information on the operation of the boiler. Press Display D A T A Twice Data Accessible to Installer and User. Data relevant to the whole boiler. Press Display Description...
  • Page 28 INSTALLATION 31 DATA MODE CONT'D Press Display Press Display Description Unit 1 . X X Local flow temperature, NTC1 ºC B U R 6 2 . X X Local return temperature, NTC2 ºC X X X X Module 6 fan speed set point rrpm xxxx X X X X Module 6 actual fan speed...

  • Page 29: Test Mode

    INSTALLATION 32 TEST MODE By pressing the mode key three times, TEST mode is displayed. In this mode it is possible to run either the entire boiler or individual burners at max. or min. rate. This mode is useful for measuring the combustion and gas rates. Press Display T E S T...
  • Page 30 INSTALLATION 33 HOUR MODE By pressing the mode key four times, HOUR mode is To reset all burner hours to zero, first of all the text HOUR displayed. In this mode it is possible to read the hours run of should be displayed.
  • Page 31 INSTALLATION 35 HEATING MODE OPERATION CONT'D Graph 4 2. Outside Sensor with night Time Set Back With the boiler configured to run with an outside sensor, there is a permanent call for heat. The set flow temperature Parameter 3 varies with changes in outside temperature (heating curve) in accordance with graph 4.

  • Page 32: Frost Protection

    INSTALLATION 36 FROST PROTECTION If the boiler global flow temperature falls below 3ºC, the boiler boiler has built into its control system the will fire at minimum rate in CH mode. When the global flow facility to protect only the boiler against freezing. temperature exceeds 10ºC the burner switches off and the If the boiler global flow temperature falls below 7ºC, the pump enters the overrun period before switching off.

  • Page 33: Burner Pressure Adjustment

    INSTALLATION 39 BURNER PRESSURE ADJUSTMENT Smoke sampling point The following burner pressure adjustment must be followed when service replacement of a gas valve is required. This procedure should also be followed to check if adjustment is required during commissioning and servicing.

  • Page 34: Servicing Schedule

    Caradon Ideal Limited does not accept any liability resulting from the use of unauthorised parts or the repair and servicing of appliances not carried out in accordance with the company's recommendations and specifications.
  • Page 35 SERVICING 44 SERVICING SCHEDULE CONT'D 7. Lift the gas manifold and resecure, at the 2 sides, in a position 10mm higher than the standard one. It is possible to get this position by securing the gas manifold flanges in correspondence with holes 'G', using the screws removed from holes 'E'.

  • Page 36: Fault Finding

    FAULT FINDING 45 FAULT FINDING SAFETY The air pressure switch does not close: In this situation the fan runs for 60 seconds, then goes into Refer to Frame 42 for essential guidance on safety when lockout, illuminating the relevant push button on the fascia. carrying out fault finding.
  • Page 37 FAULT FINDING 46 FAULT FINDING CONTD ERROR CODES RELATED TO LOCAL OPERATING TEMPERATURE SENSORS Error Code Description Alarm L1 4 Local Temperature NTC 1 short circuit L2 4 Local Temperature NTC 2 short circuit L3 4 Local Temperature NTC 3 short circuit L4 4 Local Temperature NTC 4 short circuit L5 4...
  • Page 38 FAULT FINDING 47 FAULT FINDING CONTD ERROR CODES RELATED TO GAS PRESSURE, AM-4 AND AM-5 Error Code Description Alarm The Min. Gas Pressure Switch is open The module AM-4 has not been detected The module AM-5 has not been detected (or number of AM-5 modules is wrong) Possible Causes and Solutions For E26 check the dynamic inlet gas pressure: it MUST be a minimum of 15 mbar.

  • Page 39: Short List Of Parts

    When replacing any part on this appliance use only spare parts that you 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.
  • Page 40 Technical Training 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 Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN.

This manual is also suitable for:

Imax plus f120Imax plus f160Imax plus f200Imax plus f240Imax plus f280

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