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W45, W60, W80 & W100
W45P, W60P & W80P
January 2008
UIN 203452 A03
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Installation & Servicing
GENERAL
Boiler
W45
W45P
W60
W60P
W80
W80P
W100
Gas supply
2H - G20 - 20mbar / 3P - G31 - 37mbar
Gas supply connection
22mm copper
Flow connection
R 1
1
/
4
"
Return connection
R 1
1
/
4
"
Max pressure (sealed system)bar (psi)
4.0 (58)
Maximum static head
(m)
40.7
(ft)
133.8
Electricity supply
230V ~ 50Hz
Fuse rating
Supply Input: 3A (4A for W100) PCB: 1x2AF & 1x4AT
Power consumption
(W)
51
84
120
300
IP rating
IP20
Nominal flue dia - concentric
(mm)
80/125
80/125
100/150
Nominal flue dia - twin pipe
(mm)
80/80
80/80
100/100
Condensate drain
(mm)
25
Water content
(l)
8
8
10
(gal)
1.76
1.76
2.2
Weight
(kg)
87
88
100
(lb)
191
194
220
Boiler
W45
W45P
W60
W60P
W80
W80P
W100
Boiler output
Max
kW
43.7
58.9
78.2
95.9
(non-condensing)
Btu/h
149,000
200,950
266,800
327,200
Mean 70
o
C
Min
kW
12.6
12.6
19.5
23.1
Btu/h
43,000
43,000
66,500
78,800
Boiler output
Max
kW
46.9
45.9
62.3
60.6
82.7
80.0
103.1
(condensing)
Btu/h
160,000
156,000
212,550
206,750
282,150
272,950
351,800
Mean 40
o
C
Min
kW
13.9
13.7
13.9
13.6
21.3
20.7
26.1
Btu/h
47,600
46,600
47,600
46,400
72,700
70,600
89,050
Boiler Input
Nett
kW
45.0
45.0
60.0
60.0
80.0
80.0
100
Max Rate
Btu/h
153,550
153,550
204,700
204,700
272,950
272,950
341,200
Gross
kW
49.9
48.9
66.5
65.1
88.7
86.9
110.9
Btu/h
170,250
166,850
227,000
222,300
302,700
296,350
378,400
Boiler Input
Nett
kW
13.0
13.0
13.0
13.0
20.0
20.0
25.0
Min Rate
Btu/h
44,350
44,350
44,350
44,350
68,250
68,250
85,300
Gross
kW
14.4
14.1
14.4
14.1
22.2
21.7
27.7
Btu/h
49,150
48,150
49,150
48,150
75,650
74,100
94,500
Gas Rate
m
3
/h
4.76
1.84
6.35
2.45
8.46
3.27
10.58
ft
3
/h
168
65
224
86
299
115
374
Approx. flue gas volume
m
3
/h
72
68
98
93
131
123
161
ft
3
/h
2,540
2,400
3,460
3,280
4,620
4,340
5,678
CO
2
@ Max Rate
%
9.1
11.3
9.3
11.3
9.0
10.0
9.7
@ Min Rate
%
8.4
9.9
8.2
9.4
8.1
9.1
9.0
NOx
mg/kWh
45
42
55
65
60
63
60
ppm
26
24
31
37
34
36
34
Seasonal Boiler efficiency (Building Regs L2)%
95.4
96.8
95.9
97.3
95.3
96.7
94.7
*SEDBUK efficiency
Band A
[90.0]%
[91.3]%
[90.4]%
N/A
N/A
N/A
N/A
Note.
Natural gas consumption is calculated using a calorific value of
37.8MJ/m
3
(1038Btu/ft
3
) gross or 34 MJ/m
3
(910 Btu/ft
3
) nett at
15
o
C and 1013.25 mbar.
a. For l/s divide the gross heat input (kW) by the gross C.V. of
the gas (MJ/m
3
)
b. For ft/h
3
divide the gross heat input (Btu/h) by the gross C.V.
of the gas (Btu/ft
3
).
Propane gas consumption is calculated using a calorific value of
95.7 MJ/m
3
(2500 Btu/ft.
3
) gross or 88.0 MJ/m
3
(2300 Btu/ft.
3
) net
at 15
o
C and 1013.25 mbar.
To obtain the fuel consumption in liquid form divide the above
figures by 270.
* The value is used in the UK Government's Standard Assessment
Procedure (SAP) for energy ratings of dwellings. The test data from
which it has been calculated have been certified by a notified body.
Table 1 Performance Data
Table 2 General Data
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 Stelrad Group in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by Ideal
Stelrad Group
could invalidate the certification and the normal
appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.
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Installation & Servicing
GENERAL
CONTENTS
Boiler Assembly - exploded view. .................................... 9
Boiler Clearances. ............................................................ 7
Commissioning and Testing. ......................................... 42
Electrical Connections. .................................................. 23
Electrical Supply. .............................................................. 6
Fault Finding. ................................................................... 51
Flue Installation. ................................................................ 5
Flue Kits. .......................................................................... 13
Gas Safety Regulations .................................................... 4
Gas Supply. ........................................................................ 5
Hydraulic Resistance. ...................................................... 6
Introduction. ...................................................................... 4
Initial Lighting. ................................................................. 42
Installer Connections. ............................................... 24,25
Installation. ........................................................................ 9
Mounting Boiler. .............................................................. 12
Option Kits. ........................................................................ 4
Performance Data. ........................................................... 2
Servicing. ........................................................................ 44
Short List of Parts. ......................................................... 54
Ventilation. ...................................................................... 12
Water Circulation. ............................................................ 5
Water Connections. ......................................................... 7
Water System Requirements. ......................................... 8
Water Treatment. ............................................................. 6
Wiring Diagrams. ....................................................... 26,27
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.
Natural Gas & LPG
PI No.
0063 BN 3218
0087 BS 61 (imax W100 only)
Destination Countries: GB, IE
Key to symbols
IE = Ireland, GB = United Kingdom (Countries of destination)
PMS =
Maximum operating pressure of water
C13 C33 =
A room sealed appliance designed for
connection via ducts to a horizontal or vertical
terminal, which admits fresh air to the burner
and discharges the products of combustion
to the outside through orifices which, in this
case, are concentric. The fan is down
stream of the combustion chamber.
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 down 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
down stream of the combustion chamber.
II2H3P =
An appliance designed for use on 2nd and
3rd Family gases.
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Installation & Servicing
GENERAL
INTRODUCTION
The imax boilers are fully automatically controlled, wall mounted,
fanned, super efficient condensing appliances.
The imax condensing boilers can be installed either on the wall
or into a prefabricated floor mounted frame.
The boilers are suitable for use with a room sealed flue or open
flue application.
Through a sophisticated control system combined with premix
burner arrangement the boilers are capable of high operating
efficiencies of 94% 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.
Note.
These boilers cannot be used on systems that include gravity
circulation.
The boiler are suitable for connection to fully pumped, open
vented or sealed water systems. Adequate arrangements for
completely draining the system by provision of drain cocks MUST
be provided in the installation pipework.
OPTIONAL EXTRA KITS
·
Vertical Roof Flue Kit 80/125 (Suitable for W45 and W60)
·
Vertical Roof Flue Kit 100/150 (Suitable for W45 and W60)
·
Vertical Roof Flue Kit 100/150 (Suitable for W80 and W100)
·
Horizontal Wall Flue Kit 80/125 (Suitable for W45 and W60)
·
Horizontal Wall Flue Kit 100/150 (Suitable for W45 and W60)
·
Horizontal Wall Flue Kit 100/150 (Suitable for W80 and W100)
·
Open Flue Kit 80 (Suitable for W45 and W60)
·
Open Flue Kit 100 (Suitable for W80 amd W100)
·
Twin Pipe Flue Option 80/80 (Suitable for W45 and W60)
·
Pitched and Flat Roof Tiles (For all vertical flue options)
·
Frame and Header Kits
·
Programmable Room Thermostat Kit
·
Modulating Sequencer Kit
·
Room Sensor Kit
·
BMS (0-10V) Kit
·
Outside Sensor Kit
·
Tank Sensor Kit
·
Control Interface Kit
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 CORGI
Registered Installer 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 edition of I.S.813
"Domestic Gas Installations", the current Building Regulations
and reference should be made to the current ETCI rules for
electrical installation.
The imax W45, W60, W80, W100 and W45P, W60P, W80P
boilers have been tested and certified to EN483 and EN677 for
use with Natural Gas and LPG.
Detailed recommendations are contained in the following
Codes of Practice:
BS. 6891
Installation of low pressure gas pipework of up
to 28mm (R1) in domestic premises (2nd
family gas).
BS. 5482 Pt. 1
Domestic butane and propane gas burning
installations.
IGE/UP/1
Soundness testing and purging of industrial
and commercial gas installation.
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.
BS. 6798
Installation of gas fired hot water boilers of
rated input not exceeding 60kW.
BS. 6644 : 2005 Installation of gas fired hot water boilers of
rated inputs between 70kW and 1.8MW (net)
(2nd and 3rd family gases).
BS. 5449
Forced circulation hot water central heating
systems for domestic premises. Note: only up
to 45kW.
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.
BS. 4814
Specification for: Expansion vessels using an
internal diaphragm, for sealed hot water
heating systems.
BS. 5440
Installation and maintenance of flues and
ventilation for gas appliances of rated input
not exceeding 70kW net (1st, 2nd and 3rd
family gases).
Part 1
Specification for installation of flues.
Part 2
Specification for installation and maintenance
of ventilation for gas appliances.
Where reference is made throughout these instructions
I.S.813:2002 "Domestic Gas Installations" reference should
also be made to I.S.820:2002 "Non-Domestic Gas Installations"
as applicable.
SAFE HANDLING OF SUBSTANCES
Care should be taken when handling the boiler insulation
panels, which can cause irritation to the skin. No asbestos,
mercury or CFCs are included in any part of the boiler or its
manufacture.
NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.
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Installation & Servicing
GENERAL
LOCATION OF BOILER
The boiler must be installed on a flat and vertical wall, capable
of adequately supporting the weight of the boiler and any
ancillary equipment or on a boiler frame supplied in kit form by
Ideal Stelrad Group.
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 registered CORGI 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 17.5mbar MUST be available at the boiler inlet for Natural gas
and 37mbar for Propane.
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 listed
on page 4.
FLUE INSTALLATION
The flue kits are suitable for use with the imax boiler only.
These kits and the associated options are suitable for both roof
and wall mounting applications.
The roof flue kits are suitable for both flat and pitched roof
termination, using either concentric or flue only terminals.
Connection to the top of the boiler is made using a separately
supplied vertical connector in concentric, twin pipe and open flue
configurations (supplied in our optional extra kits).
Additional information covering the selection and installation can
be found with this booklet.
Weather Proofing
Where the flue passes through the roof line an adequate seal
must be made. This can be achieved by using either:
·
Flat weather collar
·
Pitched weather collar
Flue duct extension kits are available for concentric flue
configuration. These packs contain additional 1 metre ducts
and may be cut to the desired length.
Flue duct extension kits are available for twin pipe and open flue
configurations. These packs contain 2 x 1 metre ducts and may
be cut to the desired length.
If obstructions prevent direct flue routing then both 90
o
and 45
o
elbows can be provided to offset the flue system.
Terminal Position
Due to the high efficiency of the 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.
IMPORTANT
It is the responsibility of the installer to ensure, in practice, that
products of combustion discharging from the terminal cannot re-
enter the building or any other adjacent building through
ventilators, windows, doors, other sources of natural air
infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF, labelled
as 'unsafe' and corrective action taken.
Where the lowest part of the terminal is fitted less than 2m (80")
above a balcony, above ground or above a flat roof to which
people have access then the terminal MUST be protected by a
purpose designed guard. The minimum spacing between the
balcony and the terminal should be 75mm, in order to allow a
terminal guard to be fitted.
Terminal guards are available from boiler suppliers - for all
requirements contact:
Grasslin (UK) Ltd., Tower House, Vale Rise,
Tonbridge, Kent TN9 1TB.
Tel: +44 (0) 1732 359 888. Fax: +44 (0) 1732 354 445
www.tfc-group.co.uk
Ensure that the guard is fitted centrally.
The air inlet/products outlet duct and the terminal of the boiler
MUST NOT be closer than 25mm (1") to combustible material.
Detailed recommendations on the protection of combustible
material are given in BS. 5440-1: 2000. In IE refer to I.S.813:2002.
The flue must be installed in accordance with Building
Regulations and the recommendations of BS. 5440-1:2000 for
inputs up to 70kW nett. For larger installation BS. 6644 should
be complied with. In IE refer to I.S.820:2000.
WATER CIRCULATION SYSTEM
The system pump MUST be connected to the boiler, see below.
The boiler must NOT be used for direct hot water supply. The
hot water storage cylinder MUST be of the indirect type.
Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat
loss and any possible freezing - particularly where pipes run
through roof spaces and ventilated underfloor spaces.
The boiler must be vented.
Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler
and hot water storage vessel. They should be at least 1/2" BSP
nominal size and be in accordance with BS. 2879.
The central heating system should be in accordance with the
relevant standards listed on page 4.
Due to the compact nature of the boiler the heat stored within the
castings at the point of shutdown of the burner must be
dissipated into the water circuit in order to avoid overheating. In
order to allow pump operation after burner shutdown the boiler
control box incorporates a 5 minute pump overrun facility. In
order to make use of this, the pump must be supplied from the
terminals inside the boiler. Note: for pumps requiring greater
than 1.0 amp current, they must be connected via a relay.
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Installation & Servicing
GENERAL
HYDRAULIC RESISTANCE W80 / W100
HYDRAULIC RESISTANCE W45 / W60
When sizing pumps, reference should be made to the graphs
below which show the boiler resistance against flow rates, to
achieve the required temperature differential.
Flow rates for common systems using either 11
o
C or 20
o
C
temperature differentials are given in the table below.
11
o
C
20
o
C
imax W45
0.94 l/s
0.53 l/s
imax W60
1.28 l/s
0.69 l/s
imax W80
1.69 l/s
0.94 l/s
imax W100
-
1.17 l/s
Note.
·
With the boiler firing at maximum rate, the temperature
differential should not be less than 10
o
C (14
o
C for W100).
High flow rates required for lower temperature differentials
could lead to errosion of the heat exchanger water ways.
·
With the boiler firing at minimum rate, the temperature
differential should not be greater than 35
o
C. Lower flow rates
generating higher temperature differentials will lead to lock
out of the boiler.
·
The lower the return temperature to the boiler, the higher the
efficiency.
In installations where all radiators have been provided with
thermostatic radiator valves, it is essential that water circulation
through the boiler is guaranteed. This can be best achieved by
means of a differential pressure valve, which is installed in a
bypass between the flow and return pipes. The bypass should
be fitted at least 6m from the boiler, and should use a minimum
size of 28mm pipe. The bypass should be capable of allowing a
minimum flow rate to achieve a temperature differential of no
greater than 35
o
C at minimum rate.
WATER TREATMENT
These boilers incorporate an ALUMINIUM heat exchanger.
IMPORTANT. The application of any other treatment to this
product may render the guarantee of Ideal Stelrad Group
INVALID.
Ideal Stelrad Group recommend Water Treatment in
accordance with Guidance Notes on Water Treatment in Central
Heating Systems.
Ideal Stelrad Group recommend the use of Fernox Copal or
MB1 or GE Betz Sentinel X100 inhibitors and associated water
treatment products, which must be used in accordance with the
manufacturers' instructions.
For further information contact:
Fernox Manufacturing Co. Ltd., Cookson Electronics,
Forsyth Road, Sheerwater, Woking, Surrey, GU21 5RZ
Tel: +44 (0) 1799 521133
or
Sentinel Performance Solutions, The Heath Business and
Technical Park, Runcorn, Cheshire, WA7 4QX
Tel: 0800 389 4670
www.sentinel-solutions.net
Notes.
1. It is most important that the correct concentration of the water
treatment products is maintained in accordance with the
manufacturers' instructions.
2. If the boiler is installed in an existing system any unsuitable
additives MUST be removed by thorough cleansing.
BS7593:1992 details the steps necessary to clean a
domestic heating system.
3. In hard water areas, treatment to prevent limescale may be
necessary - however the use of artificially softened water is
NOT permitted.
4. Under no circumstances should the boiler be fired before the
system has been thoroughly flushed.
ELECTRICAL SUPPLY
Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS7671) Wiring Regulations and any local
regulations which apply. For Ireland reference should be made
to the current ETCI rules for electrical installations
The point of connection to the mains should be readily
accessible and adjacent to the boiler.
CONDENSATE DRAIN
A condensate drain is provided on the boiler. This drain must be
connected to a drainage point on site. All pipework and fittings
in the condensate drainage system MUST be made of plastic -
no other materials may be used.
IMPORTANT. Any external runs must be insulated.
pressure drop (mbar)
0
200
150
100
50
0
0.5
1.0
1.5
waterflow litres/second
ima5391
pressure drop (mbar)
0
300
200
100
0
0.5
1.0
1.5
2.0
waterflow litres/second
ima5389
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Installation & Servicing
GENERAL
1
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
PUSH
W80 / W100
PUSH
W45 / W60
im9193
650
123
540
500
232
210
420
900
94
183
43
88
Flow
Cond.
Drain
Gas
pipe
151
43
71
Flow
Flow/
return
Return
Return
Cond.
Drain
Cond.
Drain
Gas
pipe
Gas
pipe
Flue
centre line
114
Flue
centre line
Flue
centre line
80/125 Concentric Flue Connector
imax W45 and W60
Minimum boiler top clearances:
for vertical flue 200mm
for horizontal flue 350mm (410mm for
100/150)
for open flue 350mm
80/80 Twin Pipe Connector
imax W45 and W60
Minimum boiler top clearances:
for vertical flue 200mm
for horizontal flue 300mm
100/150 Concentric Flue Connector
imax W80 and W100
Minimum boiler top clearances:
for vertical flue 200mm
for horizontal flue 365mm
for open flue 350mm
Flue centre
line
im9245
X=234 (80/125)
X=297 (100/150)*
* with 100/150 adaptor
(See Frame 13)
RF 2543
Flue centre line
120
Flue centre
line
X=242
RF 2544
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Installation & Servicing
GENERAL
Feed/expansion
cistern
500mm
minimum
3000mm
minimum
System
flow to
pump
Inverted cold
feed entry
Cold
Feed
Water
level
(cold)
Open vent
System
return
Connections
to boiler
ima5351
3000
minimum
3
SEALED SYSTEM REQUIREMENTS
Note. The method of filling, refilling, topping up or flushing
sealed primary hot water circuit from the mains for a non-
domestic property is shown below.
1. General
a. Detail reference should be made to the appropriate
standards listed on page 4. The information and
guidance given below is not intended to override any
requirements of these publications or the requirements
of the local authority, gas or water undertakings.
b. The installation should be capable of working with flow
temperatures of up to 90
o
C and a temperature
differential of up to 20
o
C.
c. All components of the system, including the heat
exchanger of the indirect cylinder, must be suitable for a
working pressure of 4 bar (60 lbf/in
2
) and temperature of
110
o
C. Care should be taken in making all
connections so that the risk of leakage is
minimised.
d. The boiler is fitted with an automatic air
vent, located in the left top side of the
interior. This air vent must never be shut
off, as this could result in dry firing of the
boiler and subsequent damage to the heat
exchanger.
2. Safety Valve
A spring loaded safety valve complying with
the relevant requirements of BS. 6759 Pt. 1
must be fitted in the flow pipe as close to the
boiler as possible and with no intervening
valve or restriction. The valve should have the
following features:
a. A non-adjustable preset lift pressure not
exceeding 4 bar (60 lbf/in
2
).
b. A manual testing device.
c. Provision for connection of a discharge pipe. The valve
or discharge pipe should be positioned so that the
discharge of water or steam is visible, but will not cause
hazard to user or plant.
3. Pressure Gauge
A pressure gauge covering at least the range 0-4bar must
be fitted to the system. The gauge should be easily seen
from the filling point and should preferably be connected at
the same point as the expansion vessel.
4. Expansion Vessel
Expansion vessels used must comply with BS. 4814.
Connection to the system must not incorporate an isolating
valve.
2
OPEN VENTED SYSTEM REQUIREMENTS
Detail reference should be made to the appropriate
standards listed on page 4.
The information and guidance given below is not intended to
override any requirements of the above publications or the
requirements of the local authority, gas or water undertakings.
The vertical distance between the pump and feed/expansion
cistern MUST comply with the pump manufacturer's minimum
requirements, to avoid cavitation. Should these conditions
not apply either lower the pump position or raise the cistern
above the minimum requirement specified by Ideal Stelrad
Group
. The isolation valves should be fitted as close to the
pump as possible.
The boiler is fitted with an automatic air vent, located in the left
top side of the interior. This air vent must never be shut off, as
this could result in dry firing of the boiler and subsequent
damage to the heat exchanger.
CV
CV
Resillient
seat control
valves
Supply
pipe
DT
CV = Control Valve
DT = Drain Tap
Air
gap
Tundish
Strainer
Type BA backflow
prevention device
(RP2 valve assembly)
primary flow
and return
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INSTALLATION
4
BOILER ASSEMBLY - Exploded View (W80 shown)
Legend
1. Jacket side panel
2. Jacket front panel assy.
3. Controls fascia
4. Controls door assy.
5. Wall mounting plate
6. Internal flue tube
8. Fan
9. Mounting plate manifold
10. Gas Valve
12. Gas pipe
13. Sight glass complete
14. Ignition/detection electrode
15. Auto air vent
16. Manifold flow
17. AH-5 heat exchanger assy.
18. Inspection cover assy.
19. Condensate outlet pipe
20. Manifold return
21. Thermistor flow or return
22. Transformer
23. Control module
24. Pressure gauge
25. Water pressure switch
52. 45
o
elbow (x 2 on W100)
5
6
1
1
12
4
3
20
23
24
15
16
21
18
17
19
25
21
13
14
2
8
10
52
9
9
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INSTALLATION
im9195
PUSH
A
B
F
H
J
K
L
G
C
DATUM 'X'
DA
TUM 'Y'
E
D
6
UNPACKING
5
PACKAGING REMOVAL
The boiler is supplied fully assembled in one
pack. When unpacking the boiler check the
contents against the list below. Do not dispose of
the packaging until all contents are accounted for,
as some parts are held within the cardboard
packing pieces.
Pack Contents
A
Fully assembled boiler
B
Installation & Servicing/User Instructions
C
Log Book
D
Wall mounting bracket
E
Wall mounting template
F
Condensate Trap
G
Condensate Flexible Hose
H
M10 x 70 Hex Head Coach Screws - 5 off
J
M10 Wall Plug - 5 off
K
Cable Clips - 4 off
L
Gas cock
·
After following the instructions on the box, the boiler should
be laying on its back with the straps removed.
·
Carefully read these installation instructions before
proceeding.
·
Remove the outer packing sleeve.
·
Remove the protective cardboard sheet from the front of the
boiler.
·
Remove the packing piece from the top of the boiler.
·
Check the contents against the list in Frame 6 'Unpacking'.
Note: some items are contained within the top packing
piece.
·
The boiler may now be stood on its base, with the cardboard
bottom packing piece still in place to protect the connections.
Due care should be taken when standing up the boilers, with
respect to their weights, see below
imax W45 = 87kg
imax W60 = 88kg
imax W80/W100 = 100kg
·
The cardboard bottom packing piece may be removed after
hanging the boiler on the wall.
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INSTALLATION
8
PREPARING THE WALL
7
WALL MOUNTING TEMPLATE
Note. The template shows the positions for the
fixing holes. Care must be taken to ensure the
correct holes are drilled.
1. Tape template into the selected position.
2. Ensure squareness by hanging a plumbline.
3. Mark onto the wall
a. The 4 wall mounting plate screw
positions.
b. The boiler lower fixing position
c. The position of the flue duct. Mark the
centre of the hole as well as the
circumference.
4. Remove the template from the wall.
IMPORTANT. Ensure that, during the cutting
operation, masonry falling outside of the building
does not cause damage or personal injury.
1. Cut the flue hole ensuring that the hole is
square to the wall. Both wall faces
immediately around the cut hole should be
flat.
2. Drill 4 holes with a 12mm (
1
/
2
") masonry drill
and insert the plastic plugs provided, for the
wall mounting plate.
3. Mark off and drill the boiler lower fixing
position with a 12mm (
1
/