IDEAL IMAX XTRA E320, Installation And Servicing

Page 1: ...d 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 For the very latest copy of literature for s...

Page 2: ...3 b For ft h3 divide the gross heat input Btu h by the gross C V of the gas Btu ft3 HEALTH SAFETY DOCUMENT NO 635 The electricity at work regulations 1989 The manufacturer s notes must NOT be taken in...

Page 3: ...untries GB IE Key to symbols IE Ireland GB United Kingdom Countries of destination PMS Maximum operating pressure of water C53 A room sealed appliance which is connected via its separate ducts to two...

Page 4: ...ed recommendations are contained in the following Standards and Codes of Practice BS 5854 Flue and flue Structures in Buildings BS 6644 Installation of gas fired hot water boilers of rated inputs betw...

Page 5: ...ws the approximate maximum straight flue lengths and pressures available Boiler E320 E400 E480 E560 Flue Size mm 200 250 250 250 Approx max Straight Flue 57 129 67 40 Length m Flue Pressure Pa 76 80 6...

Page 6: ...the boiler The lower the return temperature to the boiler the higher the efficiency At return temperatures of 55o C and below the difference becomes marked because the water in the flue gases starts...

Page 7: ...NNECTION KIT FITTED All dimensions shown in mm im9615 Boiler Size SIDE VIEW FRONT VIEW PLAN VIEW REAR VIEW G Flow Return 17 Condensate Drain 110 91 Gas 113 Air Inlet Flow Connections R2 Return Connect...

Page 8: ...NS AND CONNECTIONS VERTICAL FLUE CONNECTION KIT FITTED All dimensions shown in mm 110 High Level Air Inlet Kit If Fitted Boiler Size REAR VIEW Return Connection R2 Air Inlet Ducts O110 Slave Module Co...

Page 9: ...he burner slots Unless the boiler room provides a dust free environment then direct connection of the air intake via ducting to clean outside air should be used IMPORTANT NOTE Ensure blue air inlet ca...

Page 10: ...6 SEALED SYSTEM REQUIREMENTS Open Vent Pipe Sizes Rated output Minimum bore Nominal Size DN kW mm in 301 to 600 38 1 1 2 Steel pipe sizes complying with medium or heavy quality or BS 1387 Cold Feed P...

Page 11: ...Venturi 12 Control Module 14 Damper Relay Board 19 Union Gas cock 20 Levelling feet 22 Heat exchanger 24 Sightglass 27 Burner manifold 31 Thermistor flow 33 Air pressure switch 37 Relay 38 Cable condu...

Page 12: ...FROM PALLET To unpack the modules Carefully remove the straps and lift off the casing assembly pack master only Open Master Module box and remove literature pack Remove the protective cardboard fittin...

Page 13: ...the hinge lugs 6 Remove and discard fascia retaining bracket x 4 from Slave and Master modules 9 ASSEMBLING THE MODULES 4 Control Fascia Panel Slave Module Remove 2 screws securing the outer fascia p...

Page 14: ...feet using a 13mm spanner Check module with spirit level IMPORTANT ENSURE MODULE IS LEVEL IN BOTH DIRECTIONS TO ENSURE SATISFACTORY ASSEMBLY 9 Remove 4 screws on each control box support channel and...

Page 15: ...located in casing assembly pack 15 Fit master fascia panel securing with 2 x M4 screws Ensure ribbon cable is re fitted 14 Place top panel onto both modules and secure at rear with 2 x M5 screws supp...

Page 16: ...E Connector C Bend x 87o F Adaptor REAR VIEW Flue Sampling Point A D B C im9161 Air inlet duct O110 AIR DUCT Combustion air can be drawn either from outside or from the boiler room When combustion ai...

Page 17: ...4 Fit the air inlet grille to 110 dia tube and fix with the 3 off self tapping screws provided 5 Using the existing screws holding the upper or centre back panel to the boiler fit the support bracket...

Page 18: ...ndependently supported Plastic plugs fitted on the open ends of the flow and return pipes must be removed before connecting the system pipework An air vent must be provided immediately after the flow...

Page 19: ...Regulations and any local regulations For Ireland reference should be made to the current ETCI rules for electrical installations Connection should be made in a way that allows complete isolation of t...

Page 20: ...by parameter 4 see Frame 31 Connect switched live to Master Module terminal marked CH CALL 2 Programmable Room Thermostat Kit The programmable room thermostat kit incorporates a room temperature sens...

Page 21: ...of 80o C 21 DHW CONTROLS CONNECTIONS DHW heat demand can be controlled by 1 ON OFF using a 230V switched to live DHW call terminal e g a cylinder thermostat and or programmer A call for heat will caus...

Page 22: ...10V INPUT MASTER RUN BS RY1 RY2 Note For BS open circuit is on closed circuit is off TTL DISPLAY TB2 FUSE LEGEND NTC1 NTC2 NTC5 NTC7 PW R1 R2 RY1 RY2 GV BS APS1 KEY Flow thermistor Return thermistor...

Page 23: ...ng Centre 1 TTL g GV PWM E L N TACH APS1 NTC5 NTC7 NTC1 NTC2 PW b b br bk bk w w g v bk bk b r pk y w v r pk w br br b br br 3 2 1 y g y g y g LEGEND NTC1 NTC2 NTC5 NTC7 PW R1 R2 RY1 RY2 GV BS APS1 KE...

Page 24: ...hydraulic bypass will be required to allow pump overrun See pages 6 and 10 for details Frost Stat if required 230 VAC Permanent mains supply Switched live 230 VAC from external controls generating ca...

Page 25: ...responding with a set flow temperature set by parameter 4 see Frame 31 If all zones are fitted with individual zone valves a hydraulic bypass will be required to allow pump overrun See page 6 and 10 f...

Page 26: ...ish to have a 3 way valve normally open towards the storage tank DHW circuit from AB to B Upon CH request terminal L on DHW PUMP OR VALVE is energised which through a relay powers the 3 way valve thus...

Page 27: ...performs a selfcheck i e the DHW valve is energised and the CH pump is switched on for 10 seconds This cycle repeats itself every 24hrs as long as no heat request is given in 24hrs Burner on off swit...

Page 28: ...ctive when the parameter mode is left 31 STANDARD CONTROLS ACCESS Modes of Operation The standby parameter and information modes are accessible without the service code Standby Mode P A R A Press Disp...

Page 29: ...sor kit not fitted 4 3 6 N A FLUE GAS Temperature T5 o C Set Flow Temperature o C 5 7 0 6 8 2 7 0 0 Rate of Return Temperature Rise o C s 8 0 0 Rate of Flow Temperature Rise o C s 9 0 0 N A A 3 6 N A...

Page 30: ...100 thousands 10 thousands I 0 0 Boiler Control Module Internal Temperature o C Number of Ignitions CH tens units Number of Ignitions CH thousands hundreds Info mode cont d continued Burner Run Hours...

Page 31: ...scription Min Load Run for 15 mins Press the mode and button simultaneously for 3 seconds H 8 0 Press Display Description Max Load Run for 15 mins OR Last 3 digits are actual flow temperature This mod...

Page 32: ...of access MUST NOT be entered by the user Code Mode By entering the service code the following additional features are accessible Parameters 5 to 53 Fan Speed Mode Communication Mode Error Mode Code...

Page 33: ...ars for 1 second then 10 Minimum outside temperature o C 20 10 05 Coldest outside temp the system is designed to work against 11 P11 Maximum outside temperature o C 15 25 20 Warmest outside temp the s...

Page 34: ...35 E400 25 E480 Do not Do not 25 E560 adjust adjust 25 3 5 28 P28 P23 Maximum fan speed CH units E320 00 E400 00 E480 Do not Do not 00 E560 adjust adjust 00 P24 Maximum fan speed DHW hundreds E320 52...

Page 35: ...P35 DHW modulation hysteresis on o C Do not Do not 03 Master adjust adjust 02 Slave 0 5 36 P36 DHW modulation hysteresis off o C Do not Do not 03 Master adjust adjust 10 Slave 0 5 37 P37 0 3 0 3 0 0...

Page 36: ...service use 01 100 01 Note 1 off 00 min fan speed 50 mid rate 100 max fan speed 48 49 50 51 N A 53 Low Off cycle 00 x0 off x1 on Special pump function CH DHW 0x CH normal pump function DHW normal pum...

Page 37: ...last error is shown and the boiler status and readings at that time are available The 1st digit flashes and shows the current step The last two digits show the error code Error code see Table on pages...

Page 38: ...nce measure the CO2 values at maximum and minimum rates whilst adjusting the gas valves if necessary Refer to Frame 51 9 Operate the boiler for 10 minutes and check the gas rate Table 1 You should obt...

Page 39: ...ate and measure the combustion CO CO2 content Refer to Frame 51 for reference on how to force the burner to maximum and minimum gas rates The CO CO2 ratio of the flue gas on each module should not be...

Page 40: ...r operates at minimum rate without modulating set the fan speeds to minimum 10 To set the fan speed to minimum Press and hold in the mode and buttons simultaneously on the Master Module The display wi...

Page 41: ...3 screws from the other side The panel will now slide to one side for removal REPEAT PROCEDURE FOR SLAVE MODULE 4 To remove completely release the ribbon cable from the display board raise slightly a...

Page 42: ...to Frame 49 2 Remove the jacket front inner front jacket right jacket top and controls fascia panels Refer to Frame 52 3 Disconnect the electrical connections from the fan 4 Remove 4 bolts securing in...

Page 43: ...eals gaskets which show signs of wear When re fitting the burner there are 2 small lugs cast into the end of the combustion chamber which support the end of the burner REPEAT PROCEDURE FOR SLAVE MODUL...

Page 44: ...ner front controls fascia top and side panels Refer to Frame 52 3 Place a container beneath the condensate trap to collect the condensate contained within 4 Remove bottom nut plug from the condensate...

Page 45: ...the clip over the pressure sensing tube using pliers to apply the grip Replace gas valve inlet outlet O rings if showing signs of wear 10 Refer to instruction sheet with spare gas valve for correct s...

Page 46: ...the HT and earth leads from the spark detection electrode 7 Remove the 2 nuts and washers 8 Check the electrode gap is 4 0mm 9 Replace the electrode using the new gasket provided 10 Re assemble in rev...

Page 47: ...the air in the heat exchanger is vented 9 Refer to Frame 49 for final safety checks 4 A 64 FLOW RETURN HEAT EXCHANGER FLUE THERMISTOR REPLACEMENT 1 Refer to Frame 49 2 Remove the jacket panels as app...

Page 48: ...t to the left Remove from boiler 6 Re assemble in reverse order 7 Refer to Frame 49 for final safety checks 65 TRANSFORMER REPLACEMENT 4 66 CONTROL MODULE REPLACEMENT 1 Refer to Frame 49 2 Remove the...

Page 49: ...in reverse order 7 Refer to Frame 49 for final safety checks 4 3 68 DISPLAY BOARD REPLACEMENT 1 Refer to Frame 49 2 Remove the front and inner front panels Refer to Frame 52 3 Squeeze tab and pull to...

Page 50: ...n the module that the air damper is to be removed 5 Remove 2 x M5 nuts retaining air duct lower support bracket on module that the air damper is to be removed Remove bracket 6 Pull air duct assembly f...

Page 51: ...on ALSO CHECK BOTH OT CENTERS ARE CORRECTLY CONFIGURED SEE FRAME 22 The boiler control module has replaceable fuses protecting the 230V and 24V circuits A common reason for the 230V fuse to blow would...

Page 52: ...damper is opening Check flue for blockage Check clean burner Check Air Pressure Switch sensing pipes condition Check fan speed Check air Pressure Switch replace if necessary 11 EPROM read write error...

Page 53: ...ailure Check wiring harness connections If wiring OK replace control module 52 Flue gas temperature too high Check no air in system or boiler Check adequate flow of water through boiler 60 Error readi...

Page 54: ...rt circuit Check wiring Disconnect terminals from thermistor confirm short circuit using meter Replace thermistor 38 Tank sensor open circuit Not fitted check parameter 46 settings 40 Flue thermistor...

Page 55: ...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 idealparts com...

Page 56: ...tinuing 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 fi...