Servicing - IDEAL imax W45 Installation And Servicing Manual

55 SAFETY
It is the law that any service work must be carried out by a
registered CORGI installer. In IE service work must be carried
out by a competent person.
WARNING . Always turn off the gas supply at the gas
service cock, and switch off and disconnect the electricity
supply to the appliance and any external controls before
servicing or replacing components.
NOTE.
When the burner switch is in the off position the boiler control
module remains live.
IMPORTANT.
After completing the servicing or replacement of components
always:
56 SERVICING SCHEDULE
To ensure the continued safe and efficient operation of the
appliance it is recommended that it is checked at regular
intervals and serviced as necessary. The frequency of
servicing will depend upon the installation condition and
usage but should be carried out at least annually.
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.
Note.
Some aluminium 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 trap must be inspected
and cleaned after a maximum of 2 years operation.
1. 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 Frame 52 for reference on how
to force the burner to maximum rate.
57 CASING REMOVAL
Front Panels
1. Press the centre of the lower controls door to unlatch the magnetic
catch and lower it.
2. Remove the two screws from the control fascia and lower it.
3. Remove the two screws from the jacket front panel and lift it off the top
locators. Place to one side.
Side Panels
Note.
Removal is not required for normal servicing.
4. Remove the three screws from the top and the three screws from the
bottom of the side panels.
5. Re-assemble in reverse order.
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Installation & Servicing

SERVICING

• Test for gas soundness.
• Check the water system is correctly filled and free of air. Air
in the boiler could cause damage to the heat exchanger.
For this reason the automatic air vent in the left top side
must never be shut off.
• Check the jacket front panel is correctly fitted, ensuring that
a good seal is made. Secure the controls fascia in place.
• With the system hot examine all water connections for
soundness.
• Check the gas rate and measure the combustion CO/CO
content. Refer to Frame 52 for reference on how to force
the burner to maximum rate. The CO/CO
gas should not be greater than 0.004 ratio.
• Carry out functional checks as appropriate.
3. Optional test - Connect a suitable gas analyser to the
sampling point fitted in the flue adapter. For correct boiler
operation the CO/CO
greater than 0.004 ratio. If this is the case and the gas input
is at least 90% of the nominal, once compliance with the
note above is ensured, then no further action need be taken.
If not proceed to 4. Refer to Frames 57, 58, 59, 60, 61, 62, 63
and 64 for guidance.
4. Remove and clean the burner. Refer to Frames 57 and 59 or
61.
5. Inspect the heat exchanger through the burner opening. If
there are signs of aluminium oxide build up, spray water
down the flueways. Refer to Frame 62.
6. Remove the sump cover and scrape out any deposits. Refer
to Frame 63
7. Remove the condensate trap and flush through with water.
Refer to Frame 64.
8. Check that the flue terminal is unobstructed and that the flue
system is sealed correctly.
9. After completion of servicing refer to Frame 55 for reference
to final safety checks.
ratio of the flue
2
ratio of the flue gas should not be
2
4
4
1
2
39