IDEAL IMAX XTRA E320 Manuals

USER GUIDE IMAX XTRA E320 E400 E480 E560 For Installation Guide see reverse of book 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. For the very latest copy of literature for specification and maintenance practices visit our website www.idealcommercialboilers.com where you can download the relevant information in PDF format. CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components. All Gas Safe Registered Engineers carry a Gas Safe Register ID card, and have a registration number. Both should be recorded in your Log Book. You can check your installer by calling Gas Safe Register direct on 0800 4085500 Introduction The IMAX XTRA E boilers are fully automatically controlled, floor standing, fanned, super efficient condensing appliances. Due to the very high efficiency, condensate is produced from the flue gases and this is drained to a suitable disposal point through the plastic waste pipe at the bottom of the boiler. A condensate 'plume' will also often be visible at the flue terminal. Safety Current Gas Safety (Installation & Use) Regulations or rules in force. In your own interest, and that of safety, it is the law that this boiler must be installed and maintained by a Gas Safe Registered Engineer or in IE a competent person, in accordance with the above regulations. The appliance should be serviced at least once a year by a Gas Safe Registered Engineer or in IE a competent person. It is essential that the instructions in this booklet are strictly followed, for safe and economical operation of the boiler. Electricity Supply The appliance must be earthed. Supply 230 V - 50 Hz. The fusing should be 7A for E320-E560. This appliance is intended to be connected to the supply via two double-pole switches, having a 3mm contact separation in both poles, serving only the boiler and system controls. Alternatively, two 3-pin UNSWITCHED sockets may be used. Important Notes • This appliance must not be operated without the casing correctly fitted. • Do not store objects around or on the boiler, and keep access clear at all times. • Do not obstruct ventilation ducts, grilles or openings in the boiler room, room space or compartment that the appliance is installed in, or the passage of combustion and ventilation to the boiler. • Do not turn off the boiler if it is to be left unattended in frosty weather. • If it is known or suspected that a fault exists on the boiler then it MUST NOT BE USED until the fault has been corrected by a Gas Safe Registered Engineer or in IE a competent person. • Flammable materials must not be placed in close proximity to the appliance. Materials giving off flammable vapours must not be stored in the same room as the appliance. In cases of repeated or continuous shutdown a Gas Safe Registered Engineer or in IE a competent person should be called to investigate and rectify the condition causing this and carry out an operational test after each intervention on the device. Only the manufacturers original parts should be used for replacement. Minimum Clearances Rear: 1000mm or adequate space from the rear of the jacket to make the flue connections and access to the flue sample point, drain connection, flue and any safety or control devices. Left Side: 450mm. Right Side: 450mm. Front: 600mm; except, access doors may be closer, but not less than 200mm and 600mm must still be available for service across the width of the boiler. Top: 500mm. To light the boiler (Refer to Frame 1) 1. CHECK THAT THE ELECTRICITY SUPPLY TO THE BOILER IS OFF. 2. Set the burner on/off switch (A) to off. 3. Switch on the electricity supply to the boiler and check that all external controls, e.g. programmer, room thermostat etc. are on. Allow the boiler to carry out a self check. 4. Set the burner on/off switch (A) to ON. The boiler will commence the ignition sequence, supplying heat to the system when required. IMAX XTRA E Natural Gas only PI No. 86 CL 27 Destination Countries: GB, IE 2 0 I xtra MODE STEP STORE RESET + A B C D E F G H I im8219 MASTER MODULE CONTROL PANEL 1 BOILER CONTROLS / DISPLAY (MASTER PANEL SHOWN) In normal operation the display (C) shows the boiler status (see table above) and the water system flow temperature. Blocking Mode The boiler will enter blocking mode under certain fault conditions. Whilst in blocking mode the burner is switched off. Once the fault conditions are clear the boiler will automatically reset itself. In blocking mode the display will alternate between showing a '9' in digit one, along with the flow temperature in digits 2, 3 and 4, e.g. Followed by the blocking code 'bxx', e.g. Error Mode In error mode the display will flash on and off with the error code shown, e.g. The boiler will enter error mode under certain fault conditions. 9 9 6 b 1 8 The unit will be inoperative until the fault is rectified. The reset button is used to reset the boiler control module after an error has occurred. Self Check and Anti-Seize Modes After switching on the mains power or after a reset, the boiler performs a selfcheck, i.e. the DHW valve (if connected) is energised first for 15 seconds then the CH pump is switched on for a further 10 seconds. This cycle repeats itself every 24hrs, as long as no heat request is given in 24hrs. Burner on/off Switch With the burner switch set to 'off' the boiler will not respond to a CH demand. However, it will respond to a DHW demand and the pump anti-seize and frost protection modes are still operational any one of which could cause the boiler to fire. Note. The burner switch is NOT a mains isolation switch. CH/DHW Systems In standby mode pressing and holding the '+' button for 3 seconds turns the CH system on/off. In standby mode pressing and holding the '-' button for 3 seconds turns the DHW system on/off. E 3 6 3 RESET C D SLAVE MODULE CONTROL PANEL Sequence Boiler Status A DHW valve energised 0 Standby, no heat request 1 Pre-purge, post purge 2 Ignition 3 Burner on in CH mode 4 Burner on in DHW mode 5 Waiting for air pressure switch to open or close 6 Burner off because a set value has been reached 7 Pump overrun in CH mode  8 Pump overrun in DHW mode Operation LEGEND A. Burner switch B. Pressure gauge C. Display D. Reset button E. Mode button F. Step button G. Store button H. + button (to increase values) I. - button (to decrease values)

INSTALLATION AND SERVICING IMAX XTRA E320 E400 E480 E560 For Users Guide see reverse of book 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. For the very latest copy of literature for specification and maintenance practices visit our website www.idealcommercialboilers.com where you can download the relevant information in PDF format. January 2016 UIN 211216 A03 GENERAL 2 IMAX XTRA - Installation & Servicing CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of this appliance, care should be taken when handling edges of sheet steel components. Table 1 Performance Data Boiler E320 E400 E480 E560 Boiler output Max kW 314.6 393.2 471.8 550.5 (non-condensing) Btu/h 1,074,178 1,342,552 1,610,926 1,879,642 Mean 70oC Min kW 67.8 97.7 105.5 107.7 Btu/h 231,300 333,400 360,000 367,500 Boiler output Max kW 329.0 415.6 498.8 581.8 (condensing) Btu/h 1,122,500 1,418,000 1,701,900 1,985,100 Mean 40oC Min kW 75.3 107.5 116.1 118.3 Btu/h 256,900 366,800 396,100 403,600 Boiler Input Net kW 320 400 480 560 Max Rate Btu/h 1,091,800 1,364,800 1,637,800 1,910,700 Gross kW 355.4 444.2 533.0 621.8 Btu/h 1,212,600 1,515,600 1,818,600 2,121,600 Boiler Input Net kW 70 100 108 110 Min Rate Btu/h 238,800 341,200 368,500 375,300 Gross kW 77.6 110.9 119.8 122.0 Btu/h 264,800 378,400 408,800 416,300 Maximum Gas Rate m3/h 32.2 40.2 48.4 56.4 ft3/h 1138 1420 1710 1992 Approx. flue gas @ max. rate m3/h 484 604 726 846 volume (@80oC) i.e. non-condensing ft3/h 17,100 21,380 25,640 29,920 Max. Flue Resistance Pa 145 145 145 145 Flue Gas CO2 @ Max Rate % 9.3/9.8 9.3/9.8 9.3/9.8 9.3/9.8 G20/LNG @ Min. Rate % 9.1/9.6 9.1/9.6 9.1/9.6 9.1/9.6 NOx with O2 = 0% mg/kWh 35 26 26 26 ppm 20 15 15 15 Seasonal Boiler Efficiency (Building Regs L2) 95.7 95.7 95.7 95.7 Note. Natural gas consumption is calculated using a calorific value of 37.8MJ/m3 (1038Btu/ft3) gross or 34 MJ/m3 (910 Btu/ft3) nett at 15oC and 1013.25 mbar. a. For l/s divide the gross heat input (kW) by the gross C.V. of the gas (MJ/m3) 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 any way, as overriding statutory obligations. IMPORTANT. These appliances are CE certified for safety and performance. It is, therefore, important that no external control devices, e.g. flue dampers, economisers etc., are directly connected to these appliances unless covered by these Installation and Servicing Instructions or as otherwise recommended by Ideal Boilers in writing. If in doubt please enquire. Any direct connection of a control device not approved by Ideal Boilers could invalidate the certification and the normal appliance warranty. It could also infringe the Gas Safety Regulations and the above regulations. Electricity supply and Fuse rating for pumps etc. refer to manufacturer's instructions. * OPTIONAL HEADER PACK HAS DN80 CONNECTIONS FOR FLOW AND RETURN AND 2" BSP GAS CONNECTION Table 2 General Data Boiler E320 E400 E480 E560 Gas supply 2H - G20 - 20mbar Gas supply connection (in. BSP) 2 x R1 2 x R1 2 x R1 2 x R1 Flow connection (in. BSP) 2 x R2 2 x R2 2 x R2 2 x R2 Return connection (in. BSP) 2 x R2 2 x R2 2 x R2 2 x R2 Hydraulic Resistance @ 20oC mbar 100 105 110 120 (with optional water header pack fitted) Max Press (sealed system) bar (psi) 6 (87) 6 (87) 6 (87) 6 (87) Maximum Static Head m (ft) 61 (200) 61 (200) 61 (200) 61 (200) Boiler Electricity Supply 230V - 50Hz Boiler Fuse Rating 2 x External 5A supplies Internal 2AT.4AT (x2) Power Consumption (boiler only) W 800 800 800 800 Air Inlet O/D mm 110x2 110x2 110x2 110x2 Flue Size dia mm 200 250 250 250 Condensate drain mm 2x21.5 2x21.5 2x21.5 2x21.5 Boiler dry weight (unpacked exc. headers) kg (lb) 336 (740) 396 (874) 430 (948) 466 (1028) Water Content l (gal) 35 (7.8) 36.8 (8.2) 48.0 (10.6) 54.4 (12.0) * * GENERAL 3 IMAX XTRA - Installation & Servicing CONTENTS Boiler Assembly - exploded view. ..................................11 Boiler Clearances. .............................................................9 Boiler Dimensions. ......................................................7,8,9 Commissioning and Testing. ..........................................38 Electrical Connections. ...................................................18 Electrical Supply................................................................6 Fault Finding. ...................................................................51 Flue Installation. ................................................................5 Gas Safety Regulations ...................................................4 Gas Supply. ........................................................................4 Hydraulic Resistance. .......................................................5 Initial Lighting. .................................................................38 Installation. .......................................................................11 Option Kits. ........................................................................4 Performance Data. .............................................................2 Servicing. .........................................................................39 Short List of Parts. ..........................................................55 Ventilation. .........................................................................9 Water Circulation. ..............................................................6 Water Connections. .........................................................18 Water System Requirements. .........................................10 Water Treatment. ...............................................................6 Wiring Diagrams. ........................................................22,23 IMAX XTRA E Natural Gas only PI No. 86 CL 27 Destination Countries: 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 terminals that may terminate in zones of different pressure. C63 = A room sealed appliance intended to be connected to a separately approved and marketed system for the supply of combustion air and discharge of combustion products. The fan is up stream of the combustion chamber. B23 = An appliance intended to be connected to a flue which evacuates the products of combustion to the outside of the room containing the boiler. The combustion air is drawn directly from the room. The fan is up stream of the combustion chamber. NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER. GENERAL 4 IMAX XTRA - Installation & Servicing INTRODUCTION Th IMAX XTRA E boilers are fully automatically controlled, floor standing, fanned, super efficient condensing appliances. The imax xtra comprises of 2 modules, Master and Slave. The comprehensive boiler controls built into the appliance include: - 0-10V Boiler control input - Volt free 'alarm' contacts (lockout) - Volt free 'boiler run' contacts - Burner hours run meters - System temperature indication The boilers can draw their combustion air from the room or via ducting from outside. Through a sophisticated control system combined with premix burner technology and an aluminium heat exchanger, the boilers are capable of high operating efficiencies of 93% (gross) and low emissions. These boilers are certified to meet the requirements of the EC Gas Appliance Directive, Boiler Efficiency Directive, EMC and Low Voltage Directive. OPTIONAL EXTRA KITS • Modulating Sequencer - DHW Sensor - Room Sensor • Programmable Room Stat • Outside Sensor (only suitable for use in conjunction with Prog. Room Stat) • Water and Gas Header Pack • RS Air Duct Connector (E320 and E400 only) • Horizontal Flue Header * • Vertical Flue Header * * A flue header kit (horizontal or vertical) must be fitted to boiler. SAFETY Current Gas Safety (Installation and Use) Regulations or rules in force The appliance is suitable only for installation in GB and IE and should be installed in accordance with the rules in force. In GB, the installation must be carried out by a Gas Safe Registered Engineer or in IE by a competent person. It must be carried out in accordance with the relevant requirements of the: • Gas Safety (Installation and Use) Regulations • The appropriate Building Regulations either The Building Regulations, The Building Regulations (Scotland), Building Regulations (Northern Ireland). • The Water Fittings Regulations or Water byelaws in Scotland. • The Current I.E.E. Wiring Regulations. Where no specific instructions are given, reference should be made to the relevant British Standard Code of Practice. In IE, the installation must be carried out by a Competent Person and installed in accordance with the current Building Regulations and reference should be made to the current ETCI rules for electrical installation. The boilers have been tested by BSI and conform to EN483 and EN677 for use with Natural Gas. Detailed 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 between 70kW and 1.8MW (net) (2nd and 3rd family gases). BS. 6880 Low temperature hot water heating systems of output greater than 45kW. Part 1 Fundamental and design considerations. Part 2 Selection of equipment. Part 3 Installation, commissioning and maintenance. IGE/UP/1 Soundness testing and purging of industrial and commercial gas installations. IGE/UP/2 Gas installation pipework, boosters and compressors on industrial and commercial premises. IGE/UP/10 Installation of gas appliances in industrial and commercial premises. SAFE HANDLING OF SUBSTANCES No asbestos, mercury or CFCs are included in any part of the boiler or its manufacture. FOUNDATION / LOCATION OF BOILER The boiler must stand on a floor which must be flat, level and of a suitable load bearing capacity to support the weight of the boiler (when filled with water) and any ancillary equipment. Ideally the boiler should be placed on a plinth exceeding the plan area of the boiler by 75mm on each side and at least 100mm high. The boiler must not be fitted outside. GAS SUPPLY The local gas supplier should be consulted, at the installation planning stage, in order to establish the availability of an adequate supply of gas. An existing service pipe must NOT be used without prior consultation with the local gas supplier. A gas meter can only be connected by the local gas supplier or by a Gas Safe Registered Engineer or in IE by a competent person. An existing meter should be checked, preferably by the gas supplier, to ensure that the meter is adequate to deal with the rate of gas supply required. A minimum working gas pressure of 15mbar MUST be available at the boiler inlet for Natural gas. Do not use pipes of smaller size than the boiler inlet gas connection. The complete installation MUST be tested for gas soundness and purged in accordance with the appropriate standards. Gas Boosters A gas booster is required if the gas pressure available at the boiler is lower than that required by the boiler manufacturer to attain the flow rate for maximum burner input rating. Location of the booster requires careful consideration but should preferably be closer to the burner rather than the gas meter. Ventilation should also be considered to ensure ambient temperature do not exceed designed recommendations. Further guidance is provided in IGE/UP/2.