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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

Return connection

R 1

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)

120

300

IP rating

IP20

Nominal flue dia - concentric

(mm)

80/125

100/150

Nominal flue dia - twin pipe

(mm)

80/80

100/100

Condensate drain

(mm)

Water content

(l)

(gal)

1.76

2.2

Weight

(kg)

100

(lb)

191

194

220

Boiler

W45

W45P

W60

W60P

W80

W80P

W100

Boiler output

Max

43.7

58.9

78.2

95.9

(non-condensing)

Btu/h

149,000

200,950

266,800

327,200

Mean 70

Min

12.6

19.5

23.1

Btu/h

43,000

66,500

78,800

Boiler output

Max

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

Min

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

45.0

60.0

80.0

100

Max Rate

Btu/h

153,550

204,700

272,950

341,200

Gross

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

13.0

20.0

25.0

Min Rate

Btu/h

44,350

68,250

85,300

Gross

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

4.76

1.84

6.35

2.45

8.46

3.27

10.58

168

224

299

115

374

Approx. flue gas volume

131

123

161

2,540

2,400

3,460

3,280

4,620

4,340

5,678

@ 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

ppm

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

Note.
Natural gas consumption is calculated using a calorific value of
37.8MJ/m

(1038Btu/ft

) gross or 34 MJ/m

(910 Btu/ft

) nett at

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

)

b. For ft/h

divide the gross heat input (Btu/h) by the gross C.V.

of the gas (Btu/ft

Propane gas consumption is calculated using a calorific value of
95.7 MJ/m

(2500 Btu/ft.

) gross or 88.0 MJ/m

(2300 Btu/ft.

) net

at 15

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.

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.

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.

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

and 45

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.

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

C or 20

temperature differentials are given in the table below.

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

C (14

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

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

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

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)

200

150

100

0.5

1.0

1.5

waterflow litres/second

ima5391

pressure drop (mbar)

300

200

100

0.5

1.0

1.5

2.0

waterflow litres/second

ima5389

Installation & Servicing

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

PUSH

W80 / W100

PUSH

W45 / W60

im9193

650

123

540

500

232

210

420

900

183

Flow

Cond.
Drain

Gas

pipe

151

Flow

Flow/

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

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

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

C and a temperature

differential of up to 20

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

) and temperature of

110

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

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.

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.

Resillient

seat control

valves

Supply

pipe

CV = Control Valve
DT = Drain Tap

Air

gap

Tundish

Strainer

Type BA backflow
prevention device

(RP2 valve assembly)

primary flow

and return

ima7349

Installation & Servicing

INSTALLATION

im9195

PUSH

DATUM 'X'

TUM 'Y'

UNPACKING

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

Fully assembled boiler

Installation & Servicing/User Instructions

Log Book

Wall mounting bracket

Wall mounting template

Condensate Trap

Condensate Flexible Hose

M10 x 70 Hex Head Coach Screws - 5 off

M10 Wall Plug - 5 off

Cable Clips - 4 off

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.

INST

ALLA

TION

Installation & Servicing

INSTALLATION

PREPARING THE WALL

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 (

") 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 (

") masonry drill,

insert the plastic plug provided .

4. Fix the wall bracket into place with 4 M10x70

hex head coach screws provided.

ima5400

104

Vertical Offset From X mm

Distance from flue centre line (Y) to outside wall surface.

For lengths greater than 4m, increase offset (X) by 26mm
for every additional 1m.

im9196

DATUM 'X'

TUM 'Y'

Note: Horizontal flue runs must be inclined
at 1.5-3

to the horizontal to allow

condensate to drain back to the boiler.

INST

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Installation & Servicing

INSTALLATION

10 VENTILATION

MOUNTING THE BOILER

The ventilation requirements of these boilers is dependant

on the type of flue system used, and their heat input. All

vents must be permanent with no means of closing, and

positioned to avoid accidental obstruction by blocking or

flooding.

imax W45, W60, W45P and W60P
Detail reference should be made to BS. 5440 Pt. 2. In IE
refer to the current edition of I.S. 813.

The following notes are for general guidance only:

If installed as a room sealed appliance in a room or internal
space, then no purpose provided ventilation is required.

If installed as an open flued appliance in a room or internal
space then a permanent air vent is required. The sizes
given below are for vents directly communicating with
outside air. For other situations refer to BS. 5440 Pt. 2. In IE
refer to the current edition of I.S. 813.

ima5361

Due care should be taken when lifting the boilers,
with respect to their weights, see below.

imax W45 = 87kg

imax W60 = 88kg

imax W80/W100 = 100kg

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.

Using the remaining coach screw, secure the bottom
of the boiler to the wall through the attached bracket.

Boiler Size

W45 & W45P

W60 & W60P

Minimum vent free

190

265

area (cm

)

If installed in a compartment, then permanent air vents are

required at high and low level. These vents may

communicate direct to outside air, or to a room/internal

space. If to a room/internal space, it must itself be

adequately ventilated as above.

imax W80, W80P, W100 and multiple boiler installations
Detail reference should be made to BS. 6644 for inputs
between 70kW and 1.8MW (net). In IE refer to the current
edition of I.S.820. The following notes are for general
guidance o nly:

If ventilation is to be provided by means of permanent high
and low vents communicating direct with outside air, then
reference can be made to the sizes below. For other
ventilation options refer to BS. 6644. In IE refer to the current
edition of I.S.820.

imax W80, W80P and W100

Open Flued Installations

450

900

225

450

High Level

Low Level

W45/W45P

To room or internal

space

To room or internal

space

450

225

Open-flued

Roomsealed

Minimum vent free

area (cm

)

positioned at:

W45, W60, W45P and W60P

Direct to outside air

W60/W60P W45/W45P W60/W60P W45/W45P W60/W60P W45/W45P W60/W60P

300

600

1200

300

600

Required area (cm

) per kW of total rated input (net)

Boiler room

Enclosure

Low level (inlet)

High level (outlet)

Note: Where a boiler installation is to operate in summer
months (e.g. DHW) additional ventilation requirements
are stated, if operating for more than 50% of time (refer
to BS6644).

Room Sealed Installations
A minimum of 2cm

free area per kW of net heat input at

both high and low level is required for boiler rooms. For
enclosures refer to BS6644.

The temperature within a boiler room shall not exceed 25

C within 100mm of the floor, 32

C at mid height and 40

within 100mm of the ceiling.

INST

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Installation & Servicing

INSTALLATION

RF 5756

12 HORIZONTAL WALL FLUE KIT

Flue System

Part No. Max Flue Ext.

W45

W60

Horizontal wall flue kit 80/125

158659 m

9.5

7.8

suitable for imax W45 & W60

W80 W100

Horizontal wall flue kit 100/150 158661 m

suitable for imax W80 & W100

100

Contents

Boiler adapter + screws (x6)

elbow

Terminal

Locking collars (x2)

Wall plates (x2)

13 HORIZONTAL WALL FLUE KIT - For longer flue lengths for the imax W45 and W60

Flue System

Part No.

Max Flue Ext.

W45

W60

Horizontal wall flue kit 100/150 158660 m

31.6

suitable for imax W45 & W60

108

Contents

Boiler adapter + screws (x6)

Increaser

elbow

Terminal

Locking collars (x2)

Wall plates (x2)

11 FLUE SYSTEMS

A comprehensive range of flue kits are available from
Ideal Stelrad Group. Examples of horizontal and vertical
concentric, twin pipe and open flue options are demonstrated
on the following pages. Tables are provided with these
examples, giving the maximum extensions which may be
added. The flue lengths achievable without any extensions
are also provided.

For horizontal flues: this is the distance from the flue outlet
centre line on the boiler to the outside wall.

For vertical flue: this is the distance from the top of the boiler
case to the aperture in the weather collar.

If elbows are to be used, then the equivalent length of that
fitting (see page 17) must be subtracted from the maximum
flue extensions allowed for that flue option.

Note: Horizontal terminal resistance includes 1 x 90

elbow.

Worked examples are shown on page 5, 17 and 18.

Alternatively the resistances of flue components are given on
page 17, together with the maximum flue resistance each
boiler can work against. These may be used to calculate the
total flue resistance of the system, and to determine if they are
acceptable to run on the boiler.

Multiple Imax W boilers may be installed with a common flue
header (not supplied by Ideal Boilers Ltd). The flue system
should be designed and supplied by a specialist flue
company. BS 6644 and IGE UP/10 provide guidance on
design and the drainage of condensate from flue stack and
headers. Condensate from a flue stack and header must be
collected and drained before entering the boiler.

Achievable flue length

without extensions

0.65

0.7

Achievable flue

length without

extensions

0.7

Note: See Frame 19 for elbow equivalent lengths.

FLUE OUTLET

RF 5755

Installation & Servicing

INSTALLATION

W45

W60

Flue T

ube Length (m)

Air Tube Length (m)

ima5452

16 OPEN FLUE KITS

Contents
158662 / 158663
·

Boiler adapter + screws (x6)

Air inlet grille

158769 / 158770
·

Terminal

17 TWIN PIPE FLUES imax W45 and W60

Twin pipe flue systems can be created using these kits. The air is drawn in from
a horizontal wall terminal and the flue exhausted through either a vertical roof or
horizontal wall terminal.
The maximum flue extension depends on the ratio of air to flue tube. By fixing
either the air or flue tube length, you can determine how much of the other can be
fitted using the appropriate line from the graph below. An example is marked on
the graph. The example assumes the air tube extension has been fixed at 4m.
From the graph we can determine that the allowable flue tube extension length
would be 17.3m for W45 and 10.6m for W60.

Note: See Frame 19 for elbow equivalent lengths.

RF 2501

Wall plug - 8 off

Screw - 8 off

Wall plug - 8 off

Screw - 8 off

RF 2545

Kit
158769

Kit
158773

Kit 158777

Kit 158771
(pair)

Kit
158773

Kit
158686

Kit 158778

Flue System

Part No. Max Flue Ext.

158662

W45

W60

Open flue kit 80

13.3

suitable for imax W45 & W60

158769 Pa

158663

W80 W100

Open flue kit 100

suitable for imax W80 & W100 158770 Pa

100

FLUE OUTLET

Installation & Servicing

INSTALLATION

19 FLUE RESISTANCES

CONCENTRIC FLUE SYSTEMS

For concentric flue systems with elbows fitted, use the

table to correct the maximum flue extension capability.

Alternatively use the table to design the flue system,

deducting the individual resistance of components

from the maximum pressure drop allowed in the flue

for that boiler.
The maximum pressure drop allowed in the flue is

given below.
Note: The resistances are given in Pa and also the

equivalent length of straight concentric pipe.

Equivalent lengths are not an indication of the

maximum flue length as terminal resistance must be

deducted from them, plus any elbows.

imax W45: 100Pa = 16m 80/125 = 40m 100/150

imax W60: 140Pa = 14m 80/125 = 26m 100/150

imax W80: 150Pa = 24m 100/150

imax W100: 160Pa = 21m 100/150

TWIN AND OPEN FLUE SYSTEMS

For twin or open flue systems with elbows fitted, use the table to
correct the maximum extension capability. The table shows the
equivalent length of either air or flue tube for the elbow required.

Concentric Flue Systems

Pressure drop per component

Pa m Pa m Pa m Pa m

Terminals
Vertical Roof flue kit 80/125mm

40 6.3 62 6.2 -

- -

Vertical Roof flue kit 100/150mm

21 8.4 32 7.6 50 8 60 8

Horiz. Wall kit 80/125mm + 90

elbow

40 6.3 62 6.2 -

Horiz. Wall kit 100/150 + 90

elbow

21 8.4 32 7.6 50 8 60 8

Pipes and elbows
45

bend Ø 80/125 mm

7 1.1 11 1.1 -

bend Ø100/150 mm

3 1.2 5 1.2 7.5 1.2 9.2 1.2

bend Ø 80/125 mm

10 1.6 16 1.6 -

bend Ø 100/150 mm

2 8.4 2 12.5 2 15.4 2

Straight pipe Ø 80/125 mm per m

6.3 1 10 1

Straight pipe Ø 100/150 mm per m

2.5 1 4.2 1 6.3 1 7.7 1

W45 W60 W80 W100

W45

W60

W80/W100

Fitting

Air

Flue

Air

Flue

Tube

Tube Tube

Tube

elbow (m)

1.4

2.1

1.4

2.1

2.7

elbow (m)

0.4

0.6

0.4

0.6

1.8

Twin and Open Flue Systems

20 EXAMPLES OF CALCULATING FLUE RESISTANCES/LENGTHS - EXAMPLE 1

ima5357

Horizontal flue for imax W45

Resistance (Pa)

Resistance (m)

Flue size

80/125

Horizontal wall flue kit 80/125

6.3

2 x 1m extension flue

2 x (6.3)

2 x (1)

1 x 90

elbow

1.6

Total flue resistance

62.6

9.9

The total maximum flue resistance for an imax W45 is 100Pa or 16m
80/125. Therefore this installation is acceptable.

Example 1

FLUE OUTLET

Installation & Servicing

INSTALLATION

Horizontal
concentric
terminal

RF 2546

Wall plate
painted

Wall plate
unpainted

24 ASSEMBLING THE FLUE

Flue terminals or extension ducts may be cut to shorter
lengths if required. When cutting a duct ensure it is square by
marking the length all the way around and only cut back the
plain end. When cutting concentric duct it is important that the
inner duct is maintained at 20mm longer than the outer duct to
allow correct connection of the ducts. Care should be taken to
support the inner duct when cutting the flue.

Note. Horizontal flue runs must be angled down between
1.5

- 3

towards the boiler to allow the condensate to drain.

For this reason it is recommended that a support bracket is
used for every 1m of extension pipe.

RF2548

Vertical
terminal

Weather collar
flat (shown)
or pitched

Care must be taken when assembling flues, not to damage
the seals.

See below for flue assembly examples.

23 EXAMPLES OF CALCULATING FLUE RESISTANCES/LENGTHS - EXAMPLE 4

ima5357

Horizontal flue for imax W100

Resistance (Pa)

Resistance (m)

Flue size

100/150

Horizontal wall flue kit 100/150

2 x 1m extension flue

2 x (7.7)

2 x (1)

1 x 90

elbow

15.4

Total flue resistance

90.8

The total maximum flue resistance for an imax W100 is 160Pa or
21m 100/150. Therefore this installation is acceptable.

Example 4

FLUE OUTLET

Installation & Servicing

INSTALLATION

ima5355

boundary

D, E

25 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.
The information below is extracted from BS. 5440 Pt. 1 and is for boilers with heat inputs not exceeding 70kW nett, and the latest
Building Regulation Part J. Detailed reference should still be made to these standards. In IE refer to I.S. 813:2002.

If the terminal is fitted less than 500 mm below
plastic gutters, painted eaves or any other
painted surface then an aluminium shield at
least 1m long should be fitted to protect the
surface.

For positioning of open flue terminals
reference should be made to BS. 5440 Pt. 1.
In IE refer to I.S.813.2002.

Concentric Wall Terminal Positions

Below an opening (1)
Above an opening (1)
Horizontally to an opening (1)
Below gutters, soil pipes or drain pipes
Below eves
Below balcony or car port roof
From a vertical drain pipe or soil pipe
From an internal or external corner or to a boundary alongside the terminal
Above ground, roof or balcony level
From a surface or a boundary facing the terminal
From a terminal facing the terminal
From an opening in the car port into the building
Vertically from a terminal on the same wall
Horizontally from a terminal on the same wall

300 mm
300 mm
300 mm

75 mm

200 mm
200 mm
150 mm
300 mm
300 mm
600 mm

1200 mm
1200 mm
1500 mm

300 mm

12 in
12 in
12 in

3 in
8 in
8 in
6 in

12 in
12 in
24 in
48 in
48 in
60 in
12 in

300 mm

500 mm*
500 mm*

500 mm

1000 mm

12 in
20 in
20 in
20 in
40 in

A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.

Minimum spacing

Concentric Roof Terminal Positions

Directly below an opening, air brick, windows, etc.
Below plastic/painted gutters
Below painted surface
Below eaves or balcony
From wall

* may be reduced to 300mm if a shield fitted

(1) An opening here means an openable element, such as a openable window, or a fixed opening such as an air vent. However,

in addition, the outlet should not be nearer than 150mm (fanned draught) to an opening into the building fabric formed for the

purpose of accommodating a built in element, such as a window frame.

ima5263

HEAT INPUTS IN EXCESS OF 70kW NETT
For boiler installations with total heat inputs in excess of 70kW nett, reference should be made to BS6644.
In IE refer to I.S.820.2000.

FLUE OUTLET

Installation & Servicing

INSTALLATION

PUSH

ima5461

26 BOILER FRAME AND HEADER KITS

Individual boiler frame kits are available,
providing the option of mounting the
boilers away from the boiler house wall.
These frames can be bolted together for
multiple installations.

A selection of 2 and 3 boiler water and
gas header kits are available. These are
suitable for a combination of different
boilers.

27 SEQUENCER CONTROL OF MULTIPLE BOILERS

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. This
device is capable of controlling up to
5 boilers.

Legend
1. Non-return valve
2. Safety valve
3. Service valve
4. Mixing header
5. System pump
6. Modulating Sequencer kit

complete with outdoor
sensor and flow sensor

7. Flue gas terminal
8. Drain cock
9. Shunt pump
10. Room Sensor

LEGEND

1. Frame kit
2. 3 Blr. flow & return header kit
3. 3 Blr. gas header kit
4. Connection kit (includes essential

connection and valve components)

5. Mixing header
6. Pump Kit (supplied separately if required)

ima5462

INST

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Refer to Frame 11 `Flue Systems' for
advice on common flue headers for
multiple boiler installations.

Installation & Servicing

INSTALLATION

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.

IMPORTANT. Any external runs must be kept to a minimum
and insulated. This is to avoid freezing in cold weather
causing blocking.

All pipework and fittings in the condensate drain system must
be made of plastic. No other materials may be used.

Ensure condensate trap is full of water before lighting.

28 CONDENSATE DRAIN

im 25003

29 BOILER WATER CONNECTIONS

The boiler flow and return pipes are
terminated with a 1

" BSP male taper

connection located at the bottom of the
appliance.

Note. This appliance is NOT suitable for use
with a direct hot water cylinder.

Plastic plugs fitted into the open ends of the
flow and return pipes must be removed
before connecting the system pipework.

PUSH

ima5356

Flow

Return

30 FROST PROTECTION

The imax boiler has built into its control system the facility to
protect the boiler only against freezing.
If the boiler flow temperature T

, falls below 7

C the pump runs

without the boiler firing until the temperature exceeds 10

If the flow temperature falls below 3

C the boiler will fire at

minimum rate until the temperature exceeds 10

Central heating systems fitted wholly inside the building
do not normally require frost protections as the building
acts as a 'storage heater' and can normally be left at least
24 hours without frost damage. However, if parts of the
pipework run outside the building or if the boiler will be left
off for more than a day or so, then a frost thermostat
should be wired into the system, see Frame 51.

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Installation & Servicing

INSTALLATION

Warning. This appliance MUST be efficiently earthed.

A mains supply of 230V 50Hz is required. The supply
wiring MUST be suitable for mains voltage. Wiring should
be 3 core PVC insulated cable NOT LESS than 0.75mm

(24 x 0.2 mm) and to BS. 6500, Table 16. The fuse rating
should be 3A (5A for W100).

Wiring external to the boiler MUST be in accordance with
the current I.E.E. (BS7671) Wiring 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 the electrical supply - such as a double pole

32 ELECTRICAL CONNECTIONS

switch, having a 3mm (1/8") contact separation in both poles,
or a plug and unswitched socket serving only the boiler and
system controls. The means of isolation must be accessible
to the user after installation.

When making mains electrical connections to the boiler it is
important that the wires are prepared in such a way that the
earth conductor is longer than the current carrying
conductors, such that if the cord anchorage should slip the
current carrying conductors become taut before the earthing
conductor.

4 self adhesive cable clips are provided to aid routing of the
wiring across the bottom panel of the boiler.

31 GAS CONNECTION

Refer to Frame 1 for details of the position of the gas
connection.

A MINIMUM working gas pressure of 17.5 mbar (7" w.g.) must be
available at the boiler inlet for natural gas and 37mbar for
propane with the boiler firing. Refer to 'Servicing' for details of
the pressure test point position.

Extend a gas supply pipe NOT LESS THAN 22mm O.D. to the
boiler and connect using the gas cock provided.

Note. If the pipe run from the meter to the boiler is greater than
3m (10') it is recommended that a 28 mm O.D. pipe is used.

IMPORTANT. The gas service cock contains a non-metallic seal
so must not be overheated when making capillary connections.

External wiring MUST be in accordance with the current I.E.E.
(BS7671) Wiring Regulations. For Ireland reference should be
made to the current ETCI rules for electrical installations.
The wiring diagrams illustrated in Frames 51, 52 and 53 cover
the systems most likely to be used with this appliance.
For wiring external controls to the boiler, reference should be
made to the systems wiring diagram supplied by the relevant
manufacturer in conjunction with the connection diagram
shown in Frame 34.
Difficulty in wiring should not arise, providing the following
directions are observed:
1. The appliance must be wired with a permanent live supply.

External controls should NOT be wired in series with this
mains input. Controlling the mains input in this way will
prevent the pump over-run sequence and may cause
damage to the heat exchanger.

2. 230V AC output is provided and must be used for the

system pump and optionally for a DHW pump or valve,
programmer and thermostats. Care must be taken to
ensure that the earth conductor is longer than the current
carrying conductors for reasons given in Frame 32.

33 EXTERNAL WIRING

3. Input terminals are available for connecting a variety of

system controls for heating demand, and optionally for DHW
demand.
Heating demand can be controlled by:
·

230V programmer and/or room thermostat

programmable room thermostat kit

Modulating sequencer kit

a bms (connected via optional board)

outside temperature sensor

DHW demand can be controlled by:
·

230V programmer and/or cylinder thermostat

tank sensor kit (this cannot be timer controlled except
when using our programmable room thermostat, which
can block DHW demand during the 'night' period).

The electrical supply and their inputs onto the boiler can be
seen in Frame 34.

4. An optional outside temperature sensor may be fitted for

outside weather compensation. See Frame 34 for
connection details.

INST

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Installation & Servicing

INSTALLATION

34 INSTALLER CONNECTIONS

DHW

TEMP

OUTSIDE

TEMP

CONT

ROLLER

ima5386

Connect a meter between this

terminal and earth to

measure 0-10VDC = 0-10

Micro amp flame ionisation

current

Optional connections for

DHW tank sensor kit

Optional connections for

outside temperature sensor kit

Optional connections for

programmable room thermostat

and modulating sequencer kits

MAINS IN

230V AC

permanent

mains supply

CH PUMP

DHW PUMP

OR V

SEQ. SUPPL

CALL

DHW

CALL

230V AC

output for CH

system pump.

max 1 amp

Optional 230V AC

output for DHW pump

or divertor valve.

max 1 amp.

Optional 230V AC

supply for

sequencer

Optional call for CH

Optional call for DHW

im8180

ima5412

'BoilerOn' Connection X2:

This relay is closed whilst the

boiler is satisfying a heat demand

'Boiler Lockout' Connection X1:

This relay is closed as soon as

lockout occurs

Remote Indication PCB

Note. Relays are suitable for switching 230VAC 8A resistive loads. If inductive loads are connected, take
precautions such as derating the relay contacts (typically 20%) or apply suitable protection (e.g. RC network).

INST

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Installation & Servicing

INSTALLATION

35 INTERNAL WIRING

COLOUR CODE

NTC1

NTC2

Flow thermistor

Return thermistor

ater pressure switch

Relay 1 230V

AC coil

Relay 2 230V

AC coil

Relay 1 Switch (signal)

Relay 2 Switch (signal)

Rectifying plug

Gas valve

Burner switch

KEY

Blue

Black

Brown

Red

ellow

White

g/y

Grey

Orange

iolet

Pink

Green/Y

ellow

PWM

TACH

DISPLA

MCBA5407D

TRANSFORMER

TB1

TB2

X3/4

X10

CONTROLLER

MAINS IN

CH PUMP

FAN

DHW PUMP

VALV

SEQ.

SUPPLY

CALL

DHW

CALL

DHW

REMOTE INDICA

TION

PCB

OPTIONAL

BMS (0-10V) KIT

TEMP

OUTSIDE

TEMP

SUPPRESSOR

y/g

RY1

NTC1

NTC2

bk
pk

y/g

FUSE

im9400

AM3

AM4

INST

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Notes:

(1.0)

When

burner switch is open circuit, burner is "on".

When burner switch is closed circuit, burner is "off".

(2.0)

Gas

valve electrical connection on Imax W100 model is not connected by a rectifying plug.

Installation & Servicing

INSTALLATION

36 BASIC CONTROLS DISPLAY

During the operation of the imax, the status of the appliance
can be determined by the display.

1. Normal Operation Mode

The unit will either be in standby or in operation. The first
digit on the display shows the boiler status (see table). The
last 3 digits show the flow temperature.

2. 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.

9 9 6

6 1 8

Followed by the blocking code 'bxx'. Refer to page 53 for
Blocking Code references.

3. Error Mode

In error mode the display will flash on and off with the
error code shown.

Refer to page 51 for error codes.

The boiler will enter error mode under certain fault
conditions. 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-sieze Modules

After switching on the mains power or after a reset, the
boiler performs a selfcheck. i.e. the DHW valve is
energised and the pump is switched on for 10 seconds.
This cycle repeats itself every 24hrs, as long as no heat
request is given in 24hrs.

CH/DHW Systems

In standby mode pressing and holding the '+' button turns
the CH system on/off.

In standby mode pressing and holding the '-' button turns
the DHW system on/off.

E 3 6

Sequence

Boiler Status

DHW valve energised

Standby, no heat request

Pre-purge, post purge

Ignition

Burner on in CH mode

Burner on in DHW mode

Waiting for air pressure switch to open or close

Burner off because a set value has been

reached

Pump overrun in CH mode

Pump overrun in DHW mode

INST

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Installation & Servicing

INSTALLATION

37 STANDARD CONTROLS ACCESS

Modes of Operation

The standby, parameter and information modes are accessible without the service code.

Standby Mode

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. If new parameters have been stored they will then become active.

Parameter Mode

In parameter mode it is possible to change the settings of the boiler control module. The following settings can be changed.

DHW Temperature

DHW System

CH System

Flow Temperature (T1)

Parameter settings and limits are listed below.

Parameter mode is entered from standby mode by pressing the 'mode' button once.

S T B Y

P A R A

Press the 'step' button until the desired parameter is displayed.

Press the '+' or '-' buttons to change the values.

The parameter setting can be stored by pressing and releasing the 'store' button, the new setting flashes twice to show it has
been accepted. The new setting will become active when the 'mode' button is pressed or if the display is left. If the display is
left, after 20 minutes it automatically returns to 'standby' mode.

P A R A

Press

Display

DHW Temperature (

Instant water heater

Storage Tank

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

DHW System

00 = Off

01 = On
02 = Off + pump continuous
03 = On + pump continuous

1. 6 0

2. 0 1

CH System

00 = Off
01 = On

02 = Off + pump continuous
03 = On + pump continuous

3. 0 1

CH Flow Temperature (

4. 8 2

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Service Mode

40 STANDARD CONTROLS ACCESS CONT'D

L 6 0

H 8 0

It is possible for servicing purposes to run the boiler on maximum or minimum loads.

This mode is entered from normal operating mode.

As found

Press

Display

Description

Standby display

X X X X

S t b y

0 2 8

Normal Display

several times

Press the 'mode' and '-' button simultaneously for 3 seconds.

L 6 0

Press

Display

Description

'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

Last 3 digits are actual flow temperature

This mode will end automatically after 15 minutes. Alternatively to escape sooner press the '+' and '-' simultaneously.

In order to set the boiler to a fixed fan speed proceed to CODE MODE (Page 33) and select 'PARA' mode 47 (Page 34).

Wait a few

seconds

Press

Display

Description

Info mode cont'd.........

Burner Run Hours, DHW
100 thousands/10 thousands

N. 0 0

Burner Run Hours, DHW
thousands/hundreds

Burner Run Hours, DHW
tens/units

I. 0 0

I . 0 0

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INSTALLATION

41 ADVANCED CONTROLS ACCESS

C O D E

Press

Display

C X X

Press

Display

C 5 4

Press

Display

C 5 4

Press

Display

FLASHING

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.

This mode must only be entered by a competent engineer. This level 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 56

Fan Speed Mode

Communication Mode

Error Mode

Code Mode is entered from 'standby' mode by pressing and holding the 'mode' and 'step' buttons. When the display
shows 'CODE' release the buttons.

Press the 'step' button once and the display will show 'C' as the first digit and a random number in the 3rd and 4th digits.

Use the '+' or '-' button to change the Code to 54.

continued...........

Press and release the 'store' button, the display flashes to show the code has been accepted.

Press the 'mode' button until the mode you want is displayed.

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INSTALLATION

42 ADVANCED CONTROLS ACCESS CONT'D

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

DHW Temperature (

C) T3

Instant water heater

Storage tank

P A R A

1. 6 0

2. 0 1

CH System

00 = Off

01 = On
02 = Off + pump continuous
03 = On + pump continuous

3. 0 1

DHW System

00 = Off

01 = On
02 = Off + pump continuous
03 = On + pump continuous

CH flow temperature (

C) T1 (max.)

CH flow temperature (min) (

Lowest set flow temperature on the warmest day (papa 12)

4. 8 2

. 2 0

P10 appears

for 1 second then

Minimum outside temperature (

-20

-05

Coldest outside temp. the system is designed to work against

P11

Maximum outside temperature (

Warmest outside temp. the system is designed to work against

P12

Outside temperature (

-30

-02

(at which frost protection starts)

P13

Steps 5 to 9 are not accessible.

Outside temperature correction (

-05

(for boiler reading of outside temperature)

P14

N/A

P15

N/A

P16

N/A

P17

Blocking CH flow temperature (

Boiler will not fire if the CH flow temperature set point is less than this

note 00 = Off

. 2 5

P18

continued...........

. - 0 5

. 2 0

. - 0 2

. 0 0

. 8 0

. 2 5

. 1 0

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Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

Booster time (minutes)

note 00 = Off

P19

CH flow parallel shift

For use with outside temperature sensor

P20

Tplus (

Temperature added to DHW temperature set point (parameter 1)

when storage tank used.

P21

Maximum fan speed CH (hundreds)

W45

W60

W80 Do not

Do not

W100 adjust

adjust

W45P

W60P

W80P

P22

43 ADVANCED CONTROLS ACCESS CONT'D

. 0 0

. 1 0

. 2 0

. 4 8

. 0 0

. 4 8

Ignition fan speed (hundreds)

W45

W60

W80 Do not

Do not

W100 adjust

adjust

W45P

W60P

W80P

. 3 5

P28

P23

Maximum fan speed CH (units)

W45

W60

W80 Do not

Do not

W100 adjust

adjust

W45P

W60P

W80P

P24

Maximum fan speed DHW (hundreds)

W45

W60

W80 Do not

Do not

W100 adjust

adjust

W45P

W60P

W80P

. 0 0

P25

Maximum fan speed DHW (units)

W45

W60

W80 Do not

Do not

W100 adjust

adjust

W45P

W60P

W80P

. 1 2

P26

Minimum fan speed (hundreds)

W45

W60

W80 Do not

Do not

W100 adjust

adjust

W45P

W60P

W80P

. 1 6

P27

Minimum fan speed (units)

W45

W60

W80 Do not

Do not

W100 adjust

adjust

W45P

W60P

W80P

continued...........

P29

Fan speed during forced low time (x100 rpm)

W45

W60

W80 Do not

Do not

W100 adjust

adjust

W45P

W60P

W80P

. 1 6

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DHW priority time over CH (secs)

120

0 = DHW always has priority
1-120 mins
The DHW has priority over CH until priority is switched back to CH.

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

Forced low time (secs)

Do not

adjust

P30

Slow start

P31

CH post pump time (minutes)

Note 0 = 10 seconds
Do not set below 05

. 0 5

P32

DHW post pump time (x 10 seconds)

. 0 3

P33

CH modulation hysteresis on (

. 0 5

P34

CH modulation hysteresis off (

. 0 5

P35

DHW modulation hysteresis on (

-03

. 0 5

P36

DHW modulation hysteresis off (

-03

. 0 5

P37

. 0 3

. 0 0

Blocking time DHW to CH (seconds)

0=switch with burner on
(x10.2 seconds)

. 0 0

. 2 5

P38

DHW detection hysteresis on (

-05

DHW detection hysteresis off (

-20

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

P39

P40

P41

P42

P43

continued...........

44 ADVANCED CONTROLS ACCESS CONT'D

TIME - Temp. differential between flow temp &

set point at which slow start ends.

TIME - Modulation rate in slow start X 400rpm/min

. 0 0

RMCI address

Note -01=RMCI off

P44

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INSTALLATION

DHW type

x0=N/A

x1=N/A

x2=Storage tank with tank sensor kit

x3=Storage tank with DHW cylinder thermostat

x4=N/A

x5=N/A

x6=N/A

x7=N/A

x8=N/A

x9=External heat request (by control interface kit)

0x=3 way valve normally open

1x=hot water pump

2x=3way valve normally closed

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

. 0 0

CH type

x0=Room thermostat

x1=Outside temperature

x2=N/A

x3=N/A

x4=0-10V: capacity (using BMS 0-10V kit)

x5=0-10V: temperature (using BMS 0-10V kit)

x6=+/- control

x7=NTC6 on AM4 + RT: capacity

x8=0-10V on AM4 + RT: temperature

0x=N/A - First digit factory set to '0'. Do not adjust

1x=N/A - First digit factory set to '0'. Do not adjust

2x=N/A - First digit factory set to '0'. Do not adjust

3x=N/A - First digit factory set to '0'. Do not adjust

4x=N/A - First digit factory set to '0'. Do not adjust

5x=N/A - First digit factory set to '0'. Do not adjust

6x=N/A - First digit factory set to '0'. Do not adjust

7x=N/A - First digit factory set to '0'. Do not adjust

8x=N/A - First digit factory set to '0'. Do not adjust

P45

. 1 3

P46

. - 0 1

P47

Manual fanspeed (for 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

Low/Off cycle

x0=off

x1=on

Special pump function CH/DHW

0x=CH normal pump function, DHW normal pump function

1x=CH pump off during heat request, DHW normal pump function

2x=CH pump normal function, DHW pump 5 sec on delay after

heat request

3x=CH pump off during heat request, DHW pump 5 sec on delay

after heat request

N/A

Do not

adjust

Slow start
0=CH only

1=CH & DHW

45 ADVANCED CONTROLS ACCESS CONT'D

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51 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.

No parameter modifications are required.

Frost Stat if required*

230 VAC

Permanent

mains supply

Switched live (230 VAC)
from external controls
generating call for heat*

System pump

(maximum load 1 amp)

connect via a relay for

greater currents

CALL

SEQUENCE SUPPLY

DHW PUMP OR VALVE

CH PUMP

MAINS IN

DHW

CALL

im8187

* The switched live from external
controls must be from the same
phase supply as the boiler mains
supply to ensure that when the
boiler supply is switched off the
controls are also isolated.

52 MAINS VOLTAGE CH AND DHW CONTROLS WITH DHW PUMP OUTPUT

No parameter
modifications are
required.

Alternatives: The Ideal
programmable room
thermostat, outside
sensor and tank sensor kit
provides enhanced user
comfort. Full instructions
provided with kits.

Pump

Non return

valve

Non return
valve

Cylinder
thermostat

Programmer

Room
stat

im9198

PUSH

* The switched live from external controls must be from the same phase supply as the boiler
mains supply to ensure that when the boiler supply is switched off the controls are also isolated.

230 VAC

Permanent

mains supply

If either pump requires more than
1 amp supply current, connection

must be made via a relay

Room
stat

Cyl

stat

DHW

External 230 VAC
Programmer *

CALL

SEQUENCE SUPPLY

DHW PUMP OR VALVE

CH PUMP

MAINS IN

DHW

CALL

im8192

D H W

This system provides heating to one zone at a time with DHW
priority controlled by parameter 43. To heat more than one zone
simultaneously, use zone thermostats to energise individual
zone valves with all calls for heat applied to 'CH CALL'. The
boiler will be limited to responding with a set flow temperature
set by parameter 4.

If all zones are fitted with individual zone valves a hydraulic
bypass will be required to allow pump overrun. See page
5 and 6 for details.

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INSTALLATION

Alternatives: The Ideal programmable room thermostat, outside sensor and tank sensor kit provides enhanced user comfort.
Full instructions provided with kits.

Parameter modifications see Frames 41 to 45.

Parameter 46 = 03 If a live output is required for positioning of
the valve to satisfy CH demand.

Parameter 46 = 23 If a live output is required for positioning of
the valve to satisfy DHW demand.

This system provides heating to one zone at a time with DHW
priority controlled by parameter 43. To heat more than one
zone simultaneously, use zone thermostats to energise
individual zone valves with all calls for heat applied to 'CH
CALL'. The boiler will be limited to responding with a set flow
temperature set by parameter 4.

If all zones are fitted with individual zone valves a hydraulic
bypass will be required to allow pump overrun. See page 5
and 6 for details.

im9199

Motorised valve

Pump

Cylinder
thermostat

Programmer

Room
stat

PUSH

* The switched live from external controls must be from the same phase supply as the boiler
mains supply to ensure that when the boiler supply is switched off the controls are also isolated.

230 VAC

Permanent

mains supply

If pump requires more

than 1 amp supply current,

connection must be made

via a relay

Motorised

Valve

(Not Mid-position)

Room
stat

Cyl

stat

DHW

External 230 VAC
Programmer *

CALL

SEQUENCE SUPPLY

DHW PUMP OR VALVE

M V

D H W

CH PUMP

MAINS IN

DHW

CALL

im8194

53 MAINS VOLTAGE CH AND DHW CONTROLS WITH DHW VALVE OUTPUT

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54 COMMISSIONING AND TESTING

A. ELECTRICAL INSTALLATION

1. Checks to ensure electrical safety should be carried out

by a competent person.

2. ALWAYS carry out the preliminary electrical system

checks, i.e. earth continuity, polarity, resistance to earth
and short circuit, using a suitable meter.

WARNING. Whilst effecting the required gas soundness test and purging air from the gas

installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.

55 INITIAL LIGHTING

1. Check that the system has been filled and the boiler is not

air locked - air in the boiler could damage the heat
exchanger. For this reason the airvent located in the left top
side must never be shut off.

2. Check that all the drain cocks are closed and any valves in

the flow and return are open.

3. Check that the GAS SERVICE COCK IS ON.

4. Fill the condensate trap with water before putting the unit

into operation (see Frame 66 for condensate trap removal).

5. Check the indication on the pressure gauge. If the

pressure is less than 1 bar the installation should be filled
up first (sealed system only).

6. Switch the electricity supply ON and check that all the

external controls are calling for heat. Check burner switch
is set to on.

7. The boiler will commence the ignition sequence. If after 5

attempts the boiler has failed to light then it will lock out.
Press the reset button to restart the ignition sequence.

B. GAS INSTALLATION

1. The whole of the gas installation, including the meter,

should be inspected and tested for soundness and then
purged in accordance with the recommendations of the
relevant standards listed on page 4.

In IE refer to I.S.813:2002.

Gas Rate

8. The gas valves are preset at the factory to nominal values.

Dependant on site installation conditions (e.g. flue length)
the boiler performance can vary. Check the performance by
operating the boiler and measuring the flue CO

values at

maximum and minimum rates, whilst adjusting the gas valve
as necessary. (Refer to Frame 58 and to tables below.)

9. Operate the boiler for 10 minutes and check the gas rate (Table 1).

You should be able to read at least 90% of the nominal.

Natural gas Propane

W45 W60 W80 W100 W45P W60P W80P

Max rate

9.1

9.3

9.0

9.7

11.3

10.0

Min rate

8.4

8.2

8.1

9.0

9.9

9.4

9.1

Jacket
Fitted

Natural gas Propane

W45 W60 W80 W100 W45P W60P W80P

Max rate

8.9

9.1

8.8

9.5

11.1

9.8

Min rate

8.2

8.0

7.9

8.8

9.7

9.2

8.9

Jacket
Removed

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ROUTINE OPERATION

Full instructions covering routine lighting and operation of the
boiler are given on the Lighting and Operation Instruction
Label located on the inside of the lower controls door.

Draw the attention of the boiler owner or his representative to
the Lighting and Operating Instruction Label. Give a practical
demonstration of the lighting and shutting down of the boiler.

Describe the function of the boiler and system controls and
show how they are adjusted and used.

Hand these Installation and Servicing Instructions, User's
Instructions and Log book to the customer and request him to
keep them in a safe place for ready reference. For IE, it is
necessary to complete a "Declaration of Conformity" to
indicate compliance to the appropriate standard.

Make the following checks for correct operation.
1. The correct operation of ANY secondary system controls

should be proved. Operate each control separately and
check that the main burner or circulating pump, as the case
may be, responds.

2. Water circulation system;

a. With the system HOT examine all water connections for

soundness.

b. With the system still HOT, turn off the gas, water and

electricity supplies to the boiler and drain down to
complete the flushing process.

c. Refill and vent the system, clear all air locks and again

check for water soundness.

d. Balance the system.

3. Check the condensate drain for leaks and check it is

discharging correctly.

4. Finally set the controls to the User's requirements.
Note. If an optional programmer kit is fitted then refer to the
instructions supplied with the kit.

56 GENERAL CHECKS

57 HANDING OVER

IMPORTANT. Point out to the owner that the boiler must have
regular maintenance and cleaning, at least annually, in order
to ensure reliable and efficient operation. Regular attention
will also prolong the life of the boiler and should preferably be
performed at the end of the heating season.

After servicing, complete the service section of the log book
and return to the owner or their representative.

Recommend that a contract for this work should be made with
the regional gas authority or a CORGI registered heating
installer. In IE servicing work must be carried out by a
competent person.

58 GAS RATE ADJUSTMENT

Maximum rate adjustment
The maximum gas rate is factory set. However, if this rate needs
to be checked then proceed as follows.
1. Switch the boiler on and operate for 10 minutes.
2. To ensure the boiler operates at maximum rate without

modulating set the fan speed to maximum.

3. To set the fan speed to maximum. Press and hold in the

'mode' and '+' buttons simultaneously. The display will show

as the first digit indicating the boiler is operating

at maximum rate.

4. Check that the CO

value with the casing OFF measures as

per Frame 55.

5. If the above values are not achieved, check that the adjusting

screw (not on W100) is no more than 5 turns in from fully
retracted and that the gas valve outlet orifice is stamped 7.60
(8.4 for W100) for Natural Gas or 5.5 for Propane operation.

6. For access to the outlet orifice refer to Frame 68.
Minimum rate adjustment
7. To ensure the boiler operates at minimum rate without

modulating, set the fan speed to minimum

8. To set the fan speed to minimum. Press and hold in the

'mode' and '-' buttons simultaneously. The display will show

as the first digit indicating the boiler is operating

at minimum rate.

9. Remove the protective cap and then using the offset

adjustment screw, adjust the valve until the CO

value

with the casing OFF measures as per Frame 55.
(nb anticlockwise reduces the CO

level).

10. Re-check the CO

level at maximum rate.

11. Re-fit the casing and check the CO

level for maximum

and minimum rates with Frame 55 and adjust as
necessary.

12. Press the 'reset' button to return to normal operating

mode.

im 2505

Not on
W100

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59 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:

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. The CO/CO

ratio of the flue gas should not be

greater than 0.004 ratio and the CO

should match the

values given in the tables in Frame 55. Refer to Frame 58
for gas valve adjustment.

Carry out functional checks as appropriate.

60 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.

Ideal Stelrad Group 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 58 for reference on how
to force the burner to maximum rate.

3. Optional test - Connect a suitable gas analyser to the

sampling point fitted in the flue adapter. For correct boiler
operation the CO/CO

ratio of the flue gas should not be

greater than 0.004 ratio and the CO

values should match

those in the tables in Frame 55. Refer to Frame 58 for gas
valve adjustment. 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 62-69 for guidance.

4. Remove and clean the burner. Refer to Frames 61 and

63.

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 64.

6. Remove the sump cover and scrape out any deposits.

Refer to Frame 65.

7. Remove the condensate trap and flush through with water.

Refer to Frame 66.

8. Check that the flue terminal is unobstructed and that the

flue system is sealed correctly.

9. After completion of servicing refer to Frame 59 for

reference to final safety checks.

61 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.

ima9248

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Installation & Servicing

SERVICING

63 BURNER REMOVAL

1. Remove the jacket front panel. Refer to Frame 61.

2. Remove fan, burner and gas valve assembly. Refer to

Frame 62.

3. The burner can now be removed.

The burner can be cleaned using a soft brush, but only
on the back face. The metal fibre surface must not be
brushed. If the burner is showing any signs of damage
it should be replaced.

4. After cleaning the burner, the sealing gasket can be re-

used providing it shows no sign of damage. If it is
damaged it must be replaced. On models with a ribbed
gasket, ensure that it is correctly retained within the
burner hood.

5. Reassemble in reverse order.

6. Check the operation of the boiler. Refer to Frame 59.

62 REMOVAL OF FAN, BURNER AND GAS VALVE ASSEMBLY

1. Remove the jacket front panel, Refer to Frame 61.
2. Disconnect the electrical connections from the gas valve.
3. Disconnect the electrical connection from the fan.
4. Undo the gas valve nut and retain the fibre washer.
5. Remove the eight nuts and washers securing the assembly to

the combustion chamber.

6. Pull off the H.T. lead to the spark/detection electrode.
7. Carefully remove the complete assembly taking care not to

damage the spark/detection electrode.

8. Re-assemble in reverse order. The burner sealing gasket can

be re-used providing it shows no sign of damage. The eight
nuts and washers should be fitted following a diagonal
tightening sequence twice. The nuts should be secured firmly.
Replace the fibre washer as necessary.

9. Check the operation of the boiler. Refer to Frame 59.

im 2514

Fan

Burner hood

Combustion
chamber

Gasket Ribbed

Burner

im 5765

Burner hood

Combustion
chamber

Burner

im 2524

64 HEAT EXCHANGER INSPECTION / CLEANING

1. Remove the jacket front panel. Refer to Frame

61.

2. Remove the fan, burner and gas valve

assembly. Refer to Frame 62.

3. Inspect the heat exchanger for signs of

aluminium oxide build up. If necessary, clean
the heat exchanger by spraying water down the
flueways.

4. Reassemble in reverse order.

5. Check the operation of the boiler. Refer to

Frame 59.

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VICING

Installation & Servicing

SERVICING

im5563-1

65 REMOVAL OF SUMP COVER

1. Remove the jacket front panel. Refer to Frame 61.

2. Disconnect HT Lead and earth lead from the ignition/

detection probe.

3. Make Adequate provision to protect boiler from water

spillage.

4. Undo 6 nuts and washers and remove sump cover.

5. Scrape out any deposits.

6. Reassemble in reverse order using a new sump cover

gasket if it shows any signs of damage.

7. Check the operation of the boiler. Refer to Frame 59.

66 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.

5. Check the operation of the appliance. Refer to

Frame 59.

ima5568

Refer to Frame 59, then:

1. Remove the jacket front panel. Refer to Frame 61.

2. Disconnect the electrical connections from the gas valve.

3. Disconnect the electrical connections from the fan.

4. Undo the gas valve nut and retain the fibre washer.

5. Remove the four nuts securing the fan to the burner hood

and lift out of the boiler.

6. Remove the 2 screws (3 screws on W100) securing the

venturi to the fan inlet.

7. Replace the fan using the new gaskets and fibre washer

as supplied.

8. Re-assemble in reverse order.

9. Check the operation of the boiler. Refer to Frame 59.

10. Only valves supplied by Ideal Stelrad Group should be

used. These valves, as a spare part, are not factory preset.

11. Reference should now be made to Frames 54 and 55 to
check the gas rate and CO

levels whilst adjusting the gas

valve as necessary.

67 FAN REPLACEMENT

Fan

im 2516

SER

VICING

Installation & Servicing

SERVICING

Fan

im 2518

Venturi

68 GAS VALVE REPLACEMENT

Refer to Frame 59, then:

1. Remove the jacket front panel. Refer to Frame 61.

2. Disconnect the electrical connections from the gas

valve.

3. Disconnect the electrical connections from the fan.

4. Undo the gas valve nut and remove the fibre washer.

5. Remove the 4 nuts securing the fan to the burner hood

and lift out of the boiler.

6. Remove the three screws securing the gas valve to the

venturi (4 screws on W100).

7. Replace the gas valve using the new rubber seal as

supplied.

8. Reassemble in reverse order using the new fan

gasket and fibre washer as supplied. Re-use the
existing orifice plate in the gas valve outlet.

9. Check for gas soundness.

10. Only valves supplied by Ideal Stelrad Group should be

used. These valves as a spare part are not factory
preset.

11. Reference should now be made to Frames 54 and 55

to check the gas rate and CO

levels whilst adjusting

the gas valve as necessary.

12. Check the operation of the boiler. Refer to Frame 59.

69 VENTURI REPLACEMENT

Refer to Frame 59, then:

1. Remove the jacket front panel. Refer to Frame 61.

2. Disconnect the electrical connections from the gas

valve.

3. Disconnect the electrical connections from the fan.

4. Undo the gas valve nut and remove the fibre washer.

5. Remove the 4 nuts securing the fan to the burner hood

and lift out of the boiler.

6. Remove the 3 screws (4 screws on W100) securing

the gas valve to the venturi.

7. Remove the 2 screws (3 screws on W100) securing

the venturi to the fan.

8. Re-assemble in reverse order using the new seals

and gaskets as supplied. Re-use the existing orifice
plate in the gas valve outlet.

9. Check for gas soundness.

10. Reference should now be made to Frames 55 and 58

to check the gas rate and CO

levels whilst adjusting

the gas valves if necessary.

11. Check the operation of the boiler. Refer to Frame 59.

Fan

im 2541

Venturi

SER

VICING

Installation & Servicing

SERVICING

70 IGNITION/DETECTION ELECTRODE TESTING/REPLACEMENT

Refer to Frame 59, then:

1. Lower the controls fascia. Refer to Frame 61.

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. With the boiler running, connect a meter between

the terminal marked and suitable earth.

4. Normal reading should be between 4-8V (4-8

A).

5. Replace the electrode if the reading is 3V or below.

6. To replace the ignition/detection electrode, first

remove the jacket front panel. Refer to Frame 61.

im 2519

7. Pull the HT lead off the electrode.

8. Remove the 2 screws

9. Replace the electrode using the new gasket provided

ensuring that the earth lead is recaptivated under the
screw and washer.

10. Check the electrode gap is 3.5mm.

11. Re-assemble in reverse order.

12. Check the operation of the boiler. Refer to Frame 59.

71 AUTOMATIC AIR VENT REMOVAL

Refer to Frame 59, then:

1. Remove the jacket front panel. Refer to Frame

61.

2. Unscrew the air vent from the self sealing fitting

on the LHS of the flow manifold.

3. Replace the air vent.

4. Ensure that the black plastic vent cap is loose to

allow air to escape. Air in the boiler could cause
damage to the heat exchanger.

5. Reassemble in reverse order.

6. Check the operation of the boiler. Refer to Frame

59.

im9201

im9200

DHW

TEMP

OUTSIDE

TEMP

CONT

ROLLER

SER

VICING

Installation & Servicing

SERVICING

im9203

73 WATER PRESSURE SWITCH REPLACEMENT

Refer to Frame 59, then:

1. Remove the jacket front panel. Refer to Frame 61.

2. Isolate water circuit and drain system

3. Disconnect the electrical connections from the

pressure switch.

4. Unscrew the water pressure switch

5. Fit the new water pressure switch.

6. Re-fill the system ensuring all the air in the heat

exchanger is vented through the air vent.

7. Re-assemble in reverse order.

8. Check the operation of the boiler. Refer to Frame 59.

72 PRESSURE GAUGE REPLACEMENT

Refer to Frame 59, then:

1. Remove the jacket front panel. Refer to Frame 61.

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.

4. Compress the retaining lugs and remove the gauge from

the bracket.

5. Replace the pressure gauge using the fresh gasket

supplied.

6. Reassemble in reverse order.

7. Check the operation of the boiler. Refer to Frame 59.

74 FLOW / RETURN THERMISTOR REMOVAL

Refer to Frame 59, then:

1. Remove the jacket front panel. Refer to Frame 61.

2. Isolate water circuit and drain system

3. Disconnect the electrical connections from the

thermistor.

4. Unscrew the thermistor.

5. Fit the new thermistor with built in 'O' ring seal.

Do not overtighten.

6. Refill the system ensuring all the air in the heat

exchanger is vented through the air vent.

7. Re-assemble in reverse order.

8. Check the operation of the boiler. Refer to Frame 59.

im9202

im9204

SER

VICING

Installation & Servicing

SERVICING

Refer to Frame 59, then:

1. Lower the controls fascia. Refer to Frame

61.

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. Check the operation of the boiler. Refer to

Frame 59.

75 TRANSFORMER REMOVAL

76 BOILER CONTROL MODULE REMOVAL

Refer to Frame 59, then:

1. Lower the controls fascia. Refer to Frame 61.

2. To facilitate the removal of the boiler control module it

may be necessary first to remove the transformer. Refer
to Frame 75.

3. Disconnect the electrical connections from the module.

4. Remove the four module fixing screws.

5. Fit the new module and reassemble in reverse order.

6. Check the operation of the boiler. Refer to Frame 59.

77 DISPLAY BOARD & REMOTE INDICATION BOARD REMOVAL

Refer to Frame 59, then:

1. Lower the controls fascia. Refer to Frame 61.

2. Disconnect the electrical connection from both boards.

3. To remove the display board undo and remove the 4

plastic nuts.

4. Lift the display board from the 4 studs being careful

not to disturb the loose fitted plastic sleeves.

5. To remove the remote indication board pull the board

off the 4 studs

6. Fit the new boards and re-assemble in reverse order.

7. Check the operation of the boiler. Refer to Frame 59.

im9205

Transformer

im9206

Transformer

im9207

Spacer

Display
Board

Remote
Indication
Board

SER

VICING

Installation & Servicing

FAULT FINDING

FAUL

T FINDING FAUL

T FINDING

Code

Description

Action

FUSE 24V circuit dead

Check Transformer & replace if necessary
Check 24V fuse on Control Board
If 24V fuse blown check for short circuits before replacing

Flame Error (signal present when there should not be)

Replace Control Module

No ignition after restart

Check inlet gas pressure
Check wiring to ignition/detection electrode
Check condition of ignition/detection electrode
If above OK replace control module

Internal Failure

Check gas valve wiring
Check gas valve solenoids not open circuit
Check general wiring harness and connections
If all OK. replace control module

Non-volatile lockout

Press reset

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

EPROM read/write error

Press reset. If fault keeps re-occuring Replace Control Module.

24V fuse blown

Check 24V fuse on Control Board
If 24V fuse blown check for short circuits before replacing
Check gas valve leads & solenoids for short circuit

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Flow temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Return temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Flow temperature rise too fast

Check no air in system or boiler
Check adequate flow of water through boiler

No tacho signal from fan

Check wiring to fan
If wiring OK replace fan

Before attempting any electrical fault finding ALWAYS carry out
the preliminary electrical system checks as detailed in the
Instructions for the British Gas Multimeter or other similar
commercially available meter.
The preliminary electrical system checks are the FIRST
electrical checks to be carried out during a fault finding
procedure.
On completion of any service/fault finding task which has
required the breaking and remaking of electrical connections
the following checks MUST be repeated:
a

Earth continuity

Polarity

Resistance to earth

Detailed instructions on the replacement of faulty components
are contained in the 'Servicing' section of these Installation &
Servicing Instructions.
Before carrying out Fault Finding ensure that all external controls
are calling for heat. There should be 230V ± 10% available at the
control box connection.
The boiler control module has replaceable fuses protecting the
230V and 24V circuits. A common reason for the 230V fuse to
blow would be if the pump connected to the boiler was drawing
more than 1 amp.
If the 230V fuse has blown, the display will be blank. Check for
short circuits and pump loads before replacing the fuse.

Boiler Control Module Error Codes

Installation & Servicing

FAULT FINDING

FAUL

T FINDING FAUL

T FINDING

Code

Description

Action

Incorrect tacho signal from fan

Check wiring to fan. If wiring OK replace fan.

Flow/return temperature differential too high

Check no air in system or boiler
Check adequate flow of water through boiler

Flow thermistor short circuit

Check wiring

Disconnect terminals from thermistor & confirm short
circuit using meter
Replace thermistor

Return thermistor short circuit

Check wiring
Disconnect terminals from thermistor & confirm short
circuit using meter
Replace thermistor

Tank sensor short circuit

Check wiring

Disconnect terminals from tank sensor & confirm short
circuit using meter
Replace tank sensor

Flow thermistor open circuit

Check wiring

Disconnect terminals from thermistor & confirm open
circuit using meter
Replace thermistor

Return thermistor open circuit

Check wiring
Disconnect terminals from thermistor & confirm open
circuit using meter
Replace thermistor

Tank sensor open circuit

If not fitted check parameter 46 settings
Check wiring
Disconnect terminals from tank sensor & confirm open
circuit using meter
Replace tank sensor

Internal Failure

Check wiring harness & connections
If wiring OK replace control module

Error reading parameters

Press reset. If fault keeps re-occuring replace control module.

113

No valid mains frequency detected

Check power supply to boiler

114

Invalid or conflicting cascade address

Press reset. If fault keeps re-occuring replace control module.

115

Internal error

Check wiring harness & connections
If wiring OK replace control module

Boiler Control Module Error Codes Continued

Installation & Servicing

FAULT FINDING

FAUL

T FINDING FAUL

T FINDING

Code

Description

Action

Flow temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Return temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Return temperature > Flow temperature for excessive time

Check no air in system or boiler
Check adequate flow of water through boiler

Flow temperature rise too fast

Check no air in system or boiler
Check adequate flow of water through boiler

No tacho signal from fan

Check wiring to fan
If wiring OK replace fan

Incorrect tacho signal from fan

Check wiring to fan. If wiring OK replace fan.

Flow/return temperature differential too high

Check no air in system or boiler
Check adequate flow of water through boiler

Tank sensor short circuit

Check wiring

Disconnect terminals from tank sensor &
confirm short circuit using meter
Replace tank sensor

Tank sensor open circuit

If not fitted check parameter 46 settings
Check wiring
Disconnect terminals from tank sensor &
confirm open circuit using meter
Replace tank sensor

Parameter values in EEPROM values out of range

Replace control module.

Fanspeed during start not within the dead band

Check wiring to fan. If wiring OK replace fan.

116

Mains frequency deviation > 1.5Hz or processor oscillator error

If mains supply frequency OK replace control module.

118

Flame current lost during burner on

Check wiring
Check condition of ignition/detection
electrode & replace if necessary

Boiler Control Module Blocking Codes

78 TECHNICAL CHARACTERISTICS - TEMPERATURE SENSORS

The table below gives the relationship between temperature and resistance for the following sensors; flow thermistor, return
thermistor, flue thermistor, heat exchanger thermistor, outside temperature sensor and DHW tank sensor.

Temperature in

Resistance in ohm

Temperature in

Resistance in ohm

22,800

32,250

14,700

2,340

9,800

1,710

6,650

1,260

4,610

100

950

Installation & Servicing

SHORT LIST OF PARTS

The following are parts commonly required as replacements,
due to damage or expendability.

A full list of spares is held by Ideal Stelrad Group distributors
and merchants.

Their failure or absence will affect the safety and/or
performance of this appliance.

When ordering spare parts please quote:
1. Boiler model
2. Boiler serial no. (refer to the data plate on boiler)
3. Boiler P.I. No. (refer to the data plate on boiler)
4. Description
5. Quantity
6. Part no.

Key No.

Description

Qty.

Part No.

Fan (W45 & W45P)

172 641

Fan (W60, W60P, W80 & W80P)

172 642

Fan (W100)

175 227

Gas Valve (W45, W60, W45P & W60P)

174 879

Gas Valve (W80 & W80P)

174 880

Ignition / detection electrode

172 665

Auto air vent

172 668

Thermistor (flow/return)

172 671

Transformer

172 657

Control Module (W45)

174 884

Control Module (W60)

174 885

Control Module (W80 & W80P)

174 886

Control Module (W45P)

174 887

Control Module (W60P)

174 888

Control Module (W100)

175 231

Pressure gauge

172 669

Water pressure switch

172 667

Display board

172 660

Relay

172 658

Control module fuses

172 663

Burner (W45, W45P, W60 & W60P)

172 647

Burner (W80, W80P & W100)

172 648

Burner Gasket Ribbed (W45, W45P, W60 & W60P)

173 062

Burner Gasket Ribbed (W80, W80P & W100)

173 063