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IDEAL imax W45 Installation And Servicing Manual

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  • Page 2: Performance Data

    Installation and Servicing Instructions or as otherwise b. For ft/h divide the gross heat input (Btu/h) by the gross C.V. recommended by Caradon Ideal Limited in writing. If in doubt of the gas (Btu/ft please enquire. Propane gas consumption is calculated using a calorific value of Any direct connection of a control device not approved by 95.7 MJ/m...

  • Page 3: Table Of Contents

    GENERAL CONTENTS Natural Gas & LPG PI No. 0063 BN 3218 Boiler Assembly - exploded view........9 Destination Countries: GB,IE Boiler Clearances............. 7 Commissioning and Testing.......... 38 Electrical Connections........... 23 Electrical Supply............... 6 Fault Finding..............48 Flue Installation.

  • Page 4: Introduction

    GENERAL INTRODUCTION Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice. boilers are fully automatically controlled, wall mounted, fanned, super efficient condensing appliances. In IE, the installation must be carried out by a Competent Person condensing boilers can be installed either on the and installed in accordance with the current edition of I.S.813 wall or into a prefabricated floor mounted frame.

  • Page 5: Flue Installation

    Caradon Ideal Limited. infiltration, or forced ventilation / air conditioning. The boiler must not be fitted outside.

  • Page 6: Electrical Supply

    GENERAL Caradon Ideal Limited recommend the use of Fernox Copal or When sizing pumps, reference should be made to the graphs below which show the boiler resistance against flow rates, to MB1, GE Betz Sentinel X100 or Salamander Corrosion Guard inhibitors and associated water treatment products, which must achieve the required temperature differential.

  • Page 7: Boiler Clearances

    GENERAL BOILER CLEARANCES AND CONNECTIONS The following minimum clearances must be maintained for operation and servicing. Front of boiler - 450mm Sides of boiler - 50mm Above boiler - dependent upon the flue system see drawings Below boiler - 300mm Clearance between multiple boiler installations - 50mm 80/125 Concentric Flue Connector 80/80 Twin Pipe Connector...
  • Page 8 Should these conditions not apply either lower the pump position or raise the cistern System above the minimum requirement specified by Caradon Ideal System flow to Limited. The isolation valves should be fitted as close to the...

  • Page 9: Boiler Assembly - Exploded View

    INSTALLATION BOILER ASSEMBLY - Exploded View (W80 shown) W45/60 im 5564 Legend 1. Jacket side panel 11. Upper gas pipe 20. Manifold return 2. Jacket front panel assy. 12. Lower gas pipe 21. Thermistor flow or return 12A. Gas pipe 22.
  • Page 10 INSTALLATION PACKAGING REMOVAL • The boiler may now be stood on its base, with the cardboard • After following the instructions on the box, the boiler should bottom packing piece still in place to protect the connections. be laying on its back with the straps removed. Due care should be taken when standing up the boilers, with •...
  • Page 11 INSTALLATION WALL MOUNTING TEMPLATE Note: Horizontal flue runs must be inclined at 1.5-3º to the horizontal to allow Note. The template shows the positions for the condensate to drain back to the boiler. fixing holes. Care must be taken to ensure the correct holes are drilled.

  • Page 12: Mounting Boiler

    INSTALLATION MOUNTING THE BOILER • Due care should be taken when lifting the boilers, with respect to their weights, see below. W45 = 87kg W60 = 88kg W80 = 101kg • Lift the boiler onto the wall mounting plate as shown. Note: It is not necessary to hold the boiler at an angle to engage the wall mounting plate.

  • Page 13: Flue Kits

    A comprehensive range of flue kits are available from If elbows are to be used, then the equivalent length of that Caradon Ideal Limited. Examples of horizontal and vertical fitting (see page 17) must be subtracted from the maximum concentric, twin pipe and open flue options are demonstrated flue extensions allowed for that flue option.
  • Page 14 INSTALLATION 14 VERTICAL ROOF FLUE KIT Achievable flue Flue System Part No. Max Flue Ext. length without extensions Vertical roof kit 80/125 158654 m 0.65 suitable for W45 & W60 Vertical roof kit 100/150 158656 m suitable for Contents • Boiler adapter + screws (x6) •...
  • Page 15 INSTALLATION 16 OPEN FLUE KITS Flue System Part No. Max Flue Ext. Open flue kit 80/125 suitable 158662 + 13.3 W45 & W60 158769 Open flue kit 100/150 158663 + suitable for 158770 Contents 158662 / 158663 • Boiler adapter + screws (x6) •...
  • Page 16 INSTALLATION 18 FLUE KIT ACCESSORIES Part No. Accessory 80/125 100/150 90º elbow (concentric) 152616 152617 45º elbow (concentric) 152618 152619 90º elbow 158773 158774 45º elbow (pair) 158775 158776 Flat Weather Collar 152611 152612 158780 158780 Pitched Weather Collar 152609 152610 158779 158779...
  • Page 17 INSTALLATION 19 FLUE RESISTANCES Concentric Flue Systems CONCENTRIC FLUE SYSTEMS W45 W60 W80 Pressure drop per component Pa m Pa m Pa m For concentric flue systems with elbows fitted, use the table to correct the maximum flue extension capability. Alternatively Terminals use the table to design the flue system, deducting the Vertical Roof flue kit 80/125mm...
  • Page 18 INSTALLATION 21 EXAMPLES OF CALCULATING FLUE RESISTANCES/LENGTHS - EXAMPLE 2 Example 2 Vertical Roof flue for Resistance (Pa) Resistance (m) Flue size 80/125 80/125 Vertical flue kit 80/125 2 x 1m extension flue 2 x (10) 2 x (1) 2 x 45º elbow 2 x (11) 2 x (1.1) Total flue resistance...
  • Page 19 INSTALLATION 23 ASSEMBLING THE FLUE Note. Horizontal flue runs must be angled down between 1.5º - Flue terminals or extension ducts may be cut to shorter 3º towards the boiler to allow the condensate to drain. For this lengths if required. When cutting a duct ensure it is square by reason it is recommended that a support bracket is used for marking the length all the way around and only cut back the every 1m of extension pipe.
  • Page 20 INSTALLATION 24 FLUE TERMINATION POSITION Due to the high efficiency of these boilers pluming will occur. For this reason vertical termination is recommended, and in any case, terminal positions which could cause problems should where possible be avoided. Particular care should be taken in the case of large multiple boiler installations, and complying with the requirements of the Clean Air Act.

  • Page 21: Boiler Frame And Header Kits

    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 multiple boiler installation is with our modulating sequencer See below a typical installation with our modulating sequencer kit.

  • Page 22: Condensate Drain

    INSTALLATION 27 CONDENSATE DRAIN The condensate trap provided within the hardware pack must be connected to the condensate drain on the bottom of the boiler and then connected to a drainage point, preferably within the building. The pipe size from the condensate trap is 25mm. The routing of the drain must be made to allow a minimum fall of 1 in 20 away from the boiler, throughout its length.

  • Page 23: Electrical Connections

    INSTALLATION 30 GAS CONNECTION Refer to Frame 1 for details of the position of the gas Extend a gas supply pipe NOT LESS THAN 22mm O.D. to the connection. boiler and connect using the gas cock provided. A MINIMUM working gas pressure of 17.5 mbar (7" w.g.) must be Note.

  • Page 24: Installer Connections

    INSTALLATION 33 INSTALLER CONNECTIONS Optional 230VAC output for DHW pump or divertor valve. max 1 amp. 230VAC output for central Optional connections for heating system pump. programmable room thermostat max 1 amp. and modulating sequencer kits Optional connections for Optional connections for outside temperature sensor 230VAC DHW cylinder kit.
  • Page 25 INSTALLATION 34 INTERNAL WIRING Installation & Servicing...
  • Page 26 INSTALLATION 35 BASIC CONTROLS DISPLAY Followed by the blocking code 'bxx'. Refer to page 52 for Sequence Boiler Status Blocking Code references. DHW valve energised Standby, no heat request 6 1 8 Pre-purge, post purge Ignition 3. Error Mode Burner on in CH mode In error mode the display will flash on and off with the Burner on in DHW mode error code shown.
  • Page 27 INSTALLATION 36 STANDARD CONTROLS ACCESS Modes of Operation The standby, parameter and information modes are accessible without the service code. Standby Mode S t b y The standby mode will be shown after start up or reset of the boiler control module. If no buttons are pressed for 20 minutes the display will automatically be set to standby mode.
  • Page 28 INSTALLATION 37 STANDARD CONTROLS ACCESS CONT'D Info Mode i N F O Info mode is entered from standby mode by pressing the 'mode' button twice. Press Display P A R A I N F O Press the step button until the desired information is displayed. The dot after the 1st right digit will be flashing indicating the boiler is in 'info' mode.
  • Page 29 INSTALLATION 38 ADVANCED CONTROLS ACCESS There is little requirement for advanced controls access as factory preset values are satisfactory for most parameters. If parameter changes are required with the optional kits then further instructions are provided with them. 9. Code Mode C O D E By entering the service code the following additional features are accessible: •...
  • Page 30 INSTALLATION 39 ADVANCED CONTROLS ACCESS CONT'D Lower Upper Factory Press Display Description Limit Limit Setting P A R A DHW Temperature (ºC) 1. 6 0 Instant water heater Storage tank DHW System 00 = Off 2. 0 1 01 = On 02 = Off + pump continuous 03 = On + pump continuous CH System...
  • Page 31 INSTALLATION 40 ADVANCED CONTROLS ACCESS CONT'D Lower Upper Factory Press Display Description Limit Limit Setting Maximum fan speed CH (units) . 0 0 Do not Do not W45P adjust adjust W60P W80P Maximum fan speed DHW (hundreds) Do not Do not .
  • Page 32 INSTALLATION 41 ADVANCED CONTROLS ACCESS CONT'D Lower Upper Factory Press Display Description Limit Limit Setting DHW detection hysteresis on (ºC) DHW detection hysteresis off (ºC) Blocking time CH (seconds) Minimum off period between CH demands to reduce cycling Blocking time DHW (seconds) Minimum off period between DHW demands to reduce cycling Blocking time DHW to CH (seconds) 0=switch with burner on...
  • Page 33 INSTALLATION 42 ADVANCED CONTROL ACCESS CONT'D Lower Upper Factory Press Display Description Limit Limit Setting Manual fanspeed (for service use) . - 0 1 Note -1=off 00 = min fan speed 50 = mid rate 100 = max fan speed .
  • Page 34 INSTALLATION 43 INFORMATION MODE (with code) Press Display Description I N F O FLASHING 1. 2 1 Actual Flow Temperature T1 ºC 2. 2 1 Actual Return Temperature T2 ºC DHW Temperature T3 ºC 3. - 3 7 (-37 displayed if tank sensor kit not fitted) 4.
  • Page 35 INSTALLATION 45 FAN MODE (with code) Press Display Description F A N Fan speed 5 5 0 0 Actual fan speed ie 5500rpm 46 ERROR MODE (with code) Press Display Description In error mode the last error is shown, and the boiler status and readings at that time are E R R O available The 1st digit flashes and shows the current step.
  • Page 36 INSTALLATION 48 INDEPENDENT SYSTEM CONTROLS If the system controls are to be independent of the boiler, then the following method should be used for connecting the boiler. System pump (maximum load 230vac 1 amp) connect via Permanent a relay for greater main supply currents Frost Stat...
  • Page 37 INSTALLATION 50 MAINS VOLTAGE CH AND DHW CONTROLS WITH DHW VALVE OUTPUT Note. This system will provide heating to one zone only at a time with If all zones are fitted with individual zone valves a hydraulic bypass will be required to allow pump overrun. See page 6 DHW priority.

  • Page 38: Commissioning And Testing

    INSTALLATION 51 COMMISSIONING AND TESTING B. GAS INSTALLATION A. ELECTRICAL INSTALLATION 1. The whole of the gas installation, including the meter, 1. Checks to ensure electrical safety should be carried out by a competent person. should be inspected and tested for soundness and then purged in accordance with the recommendations of the 2.

  • Page 39: Servicing

    If not proceed to 4. Refer to Frames 57, 58, 59, 60, 61, 62, 63 and 64 for guidance. Caradon Ideal Limited does not accept any liability resulting from the use of unauthorised parts or the repair and servicing 4. Remove and clean the burner. Refer to Frames 57 and 59 or of appliances not carried out in accordance with the Company's recommendations and specifications.
  • Page 40 SERVICING 58 REMOVAL OF FAN, BURNER AND GAS VALVE ASSEMBLY W45, W60, W45P AND W60P 1. Remove the jacket front panel, Refer to Frame 57. 2. Disconnect the electrical connections from the gas valve. 3. Disconnect the electrical connection from the fan. 4.
  • Page 41 SERVICING 61 BURNER REMOVAL - W80/W80P 1. Remove the jacket front panel. Refer to Frame 57. 2. Remove fan, burner and gas valve assembly. Refer to Frame 60. Burner hood 3. The burner can now be removed. The burner can be cleaned using a soft brush, but Gasket Ribbed only on the back face.

  • Page 42: Condensate Trap

    SERVICING 64 CONDENSATE TRAP 1. Unscrew the nut and disconnect the flexible pipe. 2. Unscrew the nut and remove the condensate trap. 3. Remove the nut and plug from the condensate trap and flush out with water. 4. Reassemble in reverse order ensuring the condensate trap is full of water before firing.

  • Page 43: Gas Valve Replacement

    2518 9. Check for gas soundness. 10. Only valves 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 gas rate.
  • Page 44 8. Re-assemble in reverse order using the new seals and gaskets as supplied. 9. Check for gas soundness. 10. Only Venturi's supplied by Caradon Ideal Limited should be used as these are factory preset and require no adjustment. im 2541 11.
  • Page 45 SERVICING 71 IGNITION/DETECTION ELECTRODE TESTING/REPLACEMENT Refer to Frame 55, then: 1. Lower the controls fascia. Refer to Frame 57. 2. It is possible to measure the ionisation current with a voltmeter set at 0-10VDC. (0-10VDC = 0-10 micro amps ionisation current). 3.
  • Page 46 SERVICING 73 PRESSURE GAUGE REPLACEMENT Refer to Frame 55, then: 1. Remove the jacket front panel. Refer to Frame 57. 2. Unscrew the nut retaining the capillary from the self sealing fitting. 3. Unscrew the two screws from the pressure gauge bracket and withdraw the unit from the boiler.
  • Page 47 SERVICING 76 TRANSFORMER REMOVAL Refer to Frame 55, then: 1. Lower the controls fascia. Refer to Frame 57. 2. Disconnect the transformer connection from the boiler control module. 3. Remove the four transformer mounting screws. 4. Fit new transformer. 5. Reassemble in reverse order. 6.

  • Page 48: Fault Finding

    FAULT FINDING Detailed instructions on the replacement of faulty components Before attempting any electrical fault finding ALWAYS carry out are contained in the 'Servicing' section of these Installation & the preliminary electrical system checks as detailed in the Servicing Instructions. Instructions for the British Gas Multimeter or other similar commercially available meter.
  • Page 49 FAULT FINDING Boiler Control Module Error Codes Continued Code Description Action E 17 Internal failure Check wiring harnesses & connections If wiring OK replace boiler control module E 18 Flow temperature too high Check no air in system or boiler Check adequate flow of water through boiler E 19 Return temperature too high...
  • Page 50 FAULT FINDING Boiler Control Module Blocking Codes Code Description Action b 18 Flow temperature >95degC Check no air in system or boiler Check adequate flow of water through boiler b 19 Return temperature >95degC Check no air in system or boiler Check adequate flow of water through boiler b 24 Return temperature >...

  • Page 51: 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 52 SHORT LIST OF PARTS 81 SHORT LIST W45/60 early model late model ima5558 Installation & Servicing...
  • Page 53 NOTES Installation & Servicing...
  • Page 54 NOTES Installation & Servicing...
  • Page 55 NOTES Installation & Servicing...
  • Page 56 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 w60pImax w80Imax w45pImax w80pImax w60

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