00331477_MODULEX E8 INSTALLATORE-inglese.pmd

installation and

servicing

Your Ideal installation and servicing guide

See reverse for users guide

ENGINEERED FOR PEACE OF MIND

When replacing any part on this appliance, use only spare parts that you can be
assured conform to the safety and performance specification that we require. Do not
use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.

plus

III

Models F95, F145, F190
& F235, F285, F330

plus

III

March 2009 UIN 204111 A01

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CONTENTS

GENERAL INFORMATION ..................................................................................................................................................................................

1.1

Symbols used in this guide ...........................................................................................................................................................................

1.2

Correct use of the appliance ........................................................................................................................................................................

1.3

Water treatment .............................................................................................................................................................................................

1.4 I

nformation to be passed over to the person in charge of the appliance ..................................................................................................

1.5

Safety warnings .............................................................................................................................................................................................

1.6

Data badge ....................................................................................................................................................................................................

1.7

General warnings ..........................................................................................................................................................................................

TECHNICAL FEATURES AND DIMENSIONS ...................................................................................................................................................

2.1

Technical features .........................................................................................................................................................................................

2.2

Dimensions ....................................................................................................................................................................................................

2.3

Performance data .........................................................................................................................................................................................

2.4 RHS view showing main components ................................................................................................................................................10

INSTRUCTIONS FOR THE INSTALLER ..........................................................................................................................................................

3.1

3.2

Installation standards ................................................................................................................................................................................

3.3

Packaging ...................................................................................................................................................................................................

3.4

Boiler location in a boiler room .................................................................................................................................................................

3.5

Installation on existing systems ................................................................................................................................................................

3.6 Boiler connection ....................................................................................................................................................................................... 15
3.7

Gas connection ..........................................................................................................................................................................................

3.8

Connection return and flow system pipes ................................................................................................................................................

3.9

Primary circuit pump or boiler pump

......................................................................................................................................................... 18

3.10

Sealed system requirements ....................................................................................................................................................................

3.11

Wiring diagram for additional safety devices ........................................................................................................................................... 20

3.12 Safety pressure relief valve ..................................................................................................................................................................... 20
3.13 Mixing header filter .................................................................................................................................................................................... 21

3.1

4 Boiler freeze protection ............................................................................................................................................................................. 22

3.1

5 Mixing header ............................................................................................................................................................................................ 22

3.1

6 Condensing drain ...................................................................................................................................................................................... 23

3.1

7 Water treatment ......................................................................................................................................................................................... 24

3.1

8 Flue chimney connection .......................................................................................................................................................................... 25

19 Room sealed version ................................................................................................................................................................................. 25

3.2

0 Operation ................................................................................................................................................................................................... 27

3.2

1 Electrical connections ............................................................................................................................................................................... 29

3.2

2 Functional wiring diagram ......................................................................................................................................................................... 30

3.2

3 Wiring diagram for connection and managing ......................................................................................................................................... 32

3.2

4 Installation examples (functional wiring and connections description).................................................................................................. 34

Connections for boilers in cascade, controlled by outer compensators ............................................................................................... 36

3.2

5 Cascade manager BCM ........................................................................................................................................................................... 38

3.2

6 Configuration with a modulating pump ..................................................................................................................................................... 42

3.2

7 Filling the system ....................................................................................................................................................................................... 43

3.2

8 Burner adjustment .....................................................................................................................................................................................

Emergency functions ...............................................................................................................................................................................

3.3

Lighting and shutting down procedures ...................................................................................................................................................

SERVICING SCHEDULE ..................................................................................................................................................................................

Warning: this manual contains instructions to be used exclusively by the
installer and/or a competent person in accordance with the current laws in
force.
The end user MUST not make any alterations to the boiler.
Failure to follow the instructions indicated in this manual, which is supplied
with the boiler, could cause injury to persons, animals or damage to property.
Ideal Boilers shall not be held liable for any injury and/or damage.

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General Information

1.1 - SYMBOLS USED IN THIS GUIDE

When reading this guide particular care has to be given to the parts marked with the followings symbols:

1.2 - CORRECT USE OF THE APPLIANCE

The Imax Plus appliance has been designed utilizing today's heating technology and in compliance with the
current safety regulations.However, following an improper use, dangers could arise for the safety and life
of the user or of other people, or damage could be caused to the appliance or other objects.The appliance
is designed to be used in pumped hot water central heating systems. Any other use of this appliance will
be considered improper. Ideal Boilers declines any responsibility for any damage or injuries caused
by an improper use; in this case the risk is completely at the user's responsibility. In order to use the
appliance according to the scopes it was designed for it is essential to carefully follow the instructions
indicated in this guide.

1.3 - WATER TREATMENT

The Imax Plus III boiler has an Aluminium alloy heat exchanger.

· Ideal Boilers strongly recommends the system is thoroughly cleaned prior to the use of a suitable inhibitor.

For further details see section 3.17.

1.4 - INFORMATION TO BE HANDED OVER TO THE USER

GENERAL INFORMATION

NOTE!
Suggestions for the
user

WARNING!
Indicates a potentially dangerous
situation for the product and the
environment

DANGER!
Indicates serious danger
for your personal safety
and for your life

The user has to be instructed on the use and operation of his heating system, in particular:

Hand over these instructions to the end user, together with any other literature regarding this appliance, placed

inside the envelope contained in the packaging. The user has to keep these documents in a safe place in
order to always have them at hand for future reference.

Inform the user on the importance of air vents and of the flue outlet system, stressing the fact that is absolutely
forbidden to make any alterations to the boiler.

Inform the user how to check the system's water pressure as well as informing him how to restore the correct

pressure.

Explain the function of time and temperature controls, thermostats, heating controls and radiators, to ensure
the greatest possible fuel economy.

Remind the user that the appliance should be serviced annually by a Gas Safe Registered Engineer or in IE
by a competent person.

If the appliance is sold or transferred to another owner or if the present user moves home and leaves the

appliance installed, ensure yourself that the manual always follows the appliance so that it can be consulted by

the new owner and/or installer.

Failure to follow the instructions indicated in this guide, which is supplied with the boiler, could cause

injury to persons, animals or damage to property. The manufacturer shall not be held liable for any such

injury and/or damage.

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General Information

WARNING!

The installation, adjustment, and servicing of this appliance must be carried out by a competent person
and installed in accordance with the current standards and regulations. Failure to correctly install this
appliance could cause injury to persons, animals or damage to property. The manufacturer shall not be

held liable for any injury and/or damage.

DANGER!

Servicing or repairs of the appliance must be carried out by a Gas Safe Registered Engineer or in IE by a

competent person. Ideal Boilers recommends drawing up a service contract. Bad or irregular servicing could

compromise the safe operation of the appliance, and could cause injury to persons, animals or damage to property

for which Ideal Boilers shall not be held liable.

Modifications to parts connected to the appliance

Do not carry out any modifications to the following parts:

the boiler

to the gas, air, water supply pipes and electrical current

to the flue pipe, safety relief valve and its drainage pipe

to the constructive components which influence the appliance's safe operation

WARNING!

When tightening or loosening the screw pipe connections, use only adequate fork spanners.

The improper use and/or the use of inadequate equipment can cause damage (for example water or gas

leakages).

Smell of gas

If you smell gas follow these safety indications:

Do not turn on or off electrical switches

Do no smoke

Do not use the telephone

Close the main gas tap

Open all windows and doors where the gas leakage has occurred

Inform the gas society or a company specialized in installing and servicing heating systems

Explosive and easily inflammable substances

Do not use or leave explosive or easily inflammable material (as for example: petrol, paint, paper) in the room

where the appliance has been installed.

1.5 -

SAFETY WARNINGS

WARNINGS

The boiler has to be installed in such way as to avoid,

under the expected operation conditions, the freezing of the water and

to prevent the control devices being exposed to a temperature

lower than -15°C and higher than 40°C.

The boiler has to be protected against environmental variations with:

- The insulation of the hydraulic pipelines and the condensate evacuation

- The adoption of specific antifreeze products in the C.H. installation.

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General Information

1.6 - DATA PLATE

CE Marking

The CE marking documents that the boilers satisfy:

- The essential requirements of the Directive regarding gas

appliances (Directive 90/396/CEE)

- The essential requirements of the Directive regarding

electromagnetic compatibility (Directive 89/336/CEE)

- The essential requirements of the Efficiency Directive

(Directive 92/42/CEE)

- The essential requirements of the low voltage Directive

(Directive 73/23/CEE)

NOx Class

G.C. No.

Boiler Code

T. max °C

kg/h

m³/h

Flow rate (15°C - 1013 mbar)

Appliance type

Nom. Heat Input kW

Model:

Serial Nr.

Category

Nominal Output kW
Gas Type Supply Press.

G20 (Natural) 20 mbar

G31 (Propane) 37 mbar

Boiler to be installed with a gouverned meter.

Serial Letter Code

Specific flow rate D l/min

C.H. system : Max press. PMS bar
D.H.W. system: Max press. PMW bar
Electrical supply: W:

P.I.N. Code

Ideal Boilers Ltd.

Po Box 103, National Avenue

Hull, HU5 4JN

Manufacture date

Country of destination

1 = P.I.N. code
2 = Boiler type
3 = Model
4 = Serial Nr.
5 = Manufacture date
6 = Country of destination
7 = Gas category
8 = Appliance type
9 = Nominal heat output
10 = Nominal heat input

11 = Adjusted for gas type X
12 = Gas flow rate (min)
13 = Gas flow rate (max)
14 = Adjusted for gas type X
15 = Gas flow rate (min)
16 = Gas flow rate (max)
17 = Boiler code
18 = Serial letter code
19 = Gas Council No.
20 = Specific flow rate

21 = NOx class
22 = C.H. system max press PMS
23 = C.H. flow temp (max)
24 = Not applicable
25 = Not applicable
26 = Electrical supply
27 = Maximum absorbed power
28 = Protection rating
29 = CE no.

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General Information

SAFETY

Current Gas Safety (Installation and Use) Regulations or rules

in force.It is the law the that all gas appliances are installed

and serviced by a Gas Safe Registered Engineer, or in IE, by a

competent person, in accordance with the regulations below.

Failure to install appliances correctly could lead to prosecution.

It is in your own interest, and that of safety, to ensure the law is

complied with.

The installation of the boiler MUST also be in accordance with

the latest I.E.E. (BS7671) Wiring Regulations, local buildings

regulations, bye-laws of the local water authority, the building

regulations and the Building Standards (Scotland) and any

relevant requirements of the local authority.

Detailed recommendations are contained in the following codes

of practice:

BS 5854 Flues and Flue Structures in Buildings.

BS.6644 Installation of gas fired hot water boilers of

rated inputs between 70kW and 1.8MW (net)

(2nd and 3rd family gases).

BS.6880 Low temperature hot water heating systems of

output greater than 45kW.

Part 1 Fundamental and design considerations.

Part 2 Selection of equipment.

Part 3 Installation, commissioning andmaintenance.

73/23 EECLow Voltage Directive (Relevant Standard is

EN60335.1).

89/336 EEC Electro Magnetic Compatibility Directive.

IGE/UP/1 Soundness testing and purging of industrial

and commercial gas installations.

IGE/UP/2 Gas installation pipework, boosters and

compressors on industrial and commercial

premises.

IGE/UP/10 Installation of gas appliances in industrial and

commercial premises.

1.7 - GENERAL WARNINGS

This instruction manual is an integral and indispensable part

of the product and must be retained by the person in charge

of the appliance.

Please read carefully the instructions contained in this manual

as they provide important indications regarding the safe

installation, use and servicing of this appliance.

Keep this manual in a safe place for future reference.

The installation and servicing must be carried out in

accordance with the regulations in force according to the

manufacturer's instructions and by a Gas Safe Registered

Engineer or, in IE, by a competent person.

Bad or irregular servicing could compromise the safe operation

of the appliance, and could cause injury to persons, animals

or damage to property. The manufacturer shall not be held

liable for any such injury and/or damage.

Before carrying out any cleaning or servicing turn off the

electrical supply to the boiler by means of the ON/OFF switch

and/or by means of the appropriate shutdown devices.

Do not obstruct the intake/outlet terminal ducts.

In the event of failure and/or faulty functioning of the appliance,

switch off the boiler. Do not attempt to make any repairs: contact

qualified technicians.

Any repairs must be carried out a Gas Safe Registered

Engineer or, in IE, by a competent person using only

original spare parts.

Non-observance of the above requirement may jeopardize

the safety of the appliance.

To guarantee the efficiency and correct functioning of the

appliance the boiler should be serviced annually by a

qualified person.

If the boiler remains unused for long periods, ensure that any

dangerous parts are rendered innocuous.

Only original accessories must be used for all appliances

supplied with optionals or kits (including electrical ones).

This appliance must be used only for the purposes for which it

has been expressively designed. Any other use shall be

considered incorrect and therefore dangerous.

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Technical features and dimensions

2.1 - TECHNICAL FEATURES

Imax Plus is a compact, gas fired, Low NO

, condensing

boiler, made up

of one sectional boiler body,

This boiler body consists of two or more modules (from 2 to
7), which cannot be separated from each other, being

under the same protecting casing, and are set to operate

separately or in cascade. These modules are connected to

a single flue exhaust manifold and are controlled by a

single microprocessor, which manages completely the

temperatures from the point of view of both operation and

safety.

· Efficiency at full load with temperature 30/50°C = 101%.

At part load (30% of the nominal) with 30°C return

temperature = 106.8%.

· Each module is composed of a combustion chamber,

metallic fiber pre-mix burner, modulating fan, gas valve,

ignition electrode, flame detection, NTC sensor for

management control (BMM), local temperature control

and safety thermostat.

· Each single boiler is equipped with NTC sensors for global

temperature control on the flow and return manifolds.

· Integral, non allergic, synthetic wool insulation.
· Fully pre-mixed, radiating, modulating, metallic sponge

burner,

automatic no return diaphragm for separation from

combustion chamber.

· Combustion air intake system from boiler house (type B 23

appliances) or directly from outside the boiler house, via
an air duct (type C 63 appliances)

· Nominal input, per module: max. 48 kW, min. 12 kW.
· Noise level at maximum output: lower than 49 dBA.
· Modules configuration possibilities:
· Possible cascade installation of 2 or more

Imax Plus

· Heating Operation: setting of instantaneous output by a

main microprocessor, with a comparison parameters

presetting between the requested temperature (or

calculated by the outer compensator) and the global flow

temperature.

· Logic of operation:

A) Output sharing on as many modules as possible at min.
load (down to 12 kW) for the max. efficiency..
B) Automatic operation hour splitting-up system for each
module to guarantee the best homogeneous use.
C) D.H.W. production, via a storage tank loading pump or a
three way diverting valve, controlled by a priority sensor
through the E8 heating controller.
D) Output check of each module for any calibration and/or
assistance by secret access code.

· Possibility of controlling the output of each single module.
·

Heating request control: temperature set point

and

modulation level.

Monitoring of boiler and temperature status.

Alarm control.

Parameters setting.

Relay for control of the operation of a pump at constant
flow rate.

-10V analogical output for control of a modulating pump.

Emergency operation: it avoids C.H. system shut down
caused by

an interruption in communication with the boiler

plant's automation system: : (in case of remote control of
the complete boiler house):

Input for "Constant setpoint": 55°C, maximum output 50%.

Alarm reset input.

Alarm relay signal.

· Gas connecting pipes, flow/return water pipes, arranged

for any connection (by the opposite end).

· Integral easily removable panel set (painted steel panels).
·

Flue exhaust pipe, adjustable on the right, the left and

behind the heating system.

· Condensate collecting tank equipped with drain

trap

and stainless steel

flue chamber.

· Built-in air vent.
· Weights and dimensions are limited (see table at par. 1.2).

SENSORS supplied with the boiler:

· outdoor temperature sensor
· flow temperature sensor for mixed zone
· boiler temperature sensor
· D.H.W. storage temperature sensor

Optional accessories

· Air inlet socket & blanking plate kit
· Condensate level harness

(190-330 models LH or Rear flue) (see page 10).

· Cascade control-E8

Cascade control wall mounting kit

TECHNICAL FEATURES
AND DIMENSIONS

3
4

5
6

145
190

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Technical features and dimensions

CH flow system

CH safety system return

Imax Plus

Dimension
No. of Modules
Height

Width ''L''

Depth ''C''

Depth ''A''

Depth ''B''

Connections
Gas

mm (inch)

C.H. system Flow M

mm (inch)

C.H. system Return R

mm (inch)

Chimney connection ''D''

Chimney width ''H''

Condensate drain diameter

145

1053

695
820
695
820

38(1½ )

50 (2)
50 (2)

150
240

190

1053

834
820
695
820

38(1½ )

50 (2)
50 (2)

150
240

235

1053

968
820
695
820

38(1½ )

50 (2)
50 (2)

200
240

285

1053
1102

820
695
820

38(1½ )

50 (2)
50 (2)

200
240

330

1053
1236

820
695
820

38(1½ )

50 (2)
50 (2)

200
240

1053

695
820
695
820

38(1½ )

50 (2)
50 (2)

150
240

2.2 - DIMENSIONS

Warning:

Flow/Return connections ( M / R ) change their position

whether they are on the R.H. or on the L.H. side of the

boiler (see views).

FRONT VIEW

RIGHT HAND SIDE VIEW

(Delivery condition for R.H. side connection)

LEFT HAND SIDE VIEW

UPPER VIEW

Gas inlet

Outlet condensate drain

Øi D

268

350

345

223

= =

315 425

340

695

455

137

103

265

220

393

105

126

483

212

452

137

106

220

483

212

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Technical features and dimensions

BOILER TYPE

Imax Plus

Appliance category

II2H3P

Nominal Heat Input on P.C.I. Qn

Minimum Heat Input on P.C.I. Qmin

Nominal Output (Tr 60 / Tm 80 °C) Pn

Minimum Output (Tr 60 / Tm 80 °C) Pn min

Nominal Output (Tr 30 / Tm 50 °C) Pcond

Minimum Output (Tr 30 / Tm 50 °C) Pcond min

Efficiency at max. output (Tr 60 / Tm 80°C)

Efficiency at min. output (Tr 60 / Tm 80°C)

Efficiency at max. output (Tr 30 / Tm 50°C)

Efficiency at min. output (Tr 30 / Tm 50°C)

Efficiency at 30 % at part load (Tm 50°C)

Efficiency at 30 % at part load (Tr 30°C)

Efficiency Class acc. to Directive 92/42 CEE
Efficiency Class acc. to Directive 92/42 CEE (100%)

Efficiency Class acc. to Directive 92/42 CEE (30%) %
Combustion efficiency at nominal load

Combustion efficiency at part load

Stand-by losses (Q min.)

Stand-by losses (Q nom.)

Flue gas temperature tf-ta (min)

°C

Flue gas temperature tf-ta (max)

°C

Flue gas mass flow rate (min)

kg/h

Flue gas mass flow rate (max)

kg/h

Excess of air

(at min. output)

(at max. output)

(value according EN 297/A3 + EN 483)

mg/kWh

class

Flue losses with burner in operation (min.)

Flue losses with burner in operation (max)

Flue losses with burner off

Min. water flow rate in CH circuit (

T 20°C)

l/h

Minimum pressure in CH circuit

bar

Maximum pressure in CH circuit

bar

Gas Consumption Natural gas G 20 (20 mbar) Qn

Gas Consumption Natural gas G 20 (20 mbar) Qmin m

Boiler Dry Weight (un-packaged) kg

Max. available pressure at the chimney base

Condensate production

min-max kg/h

Emissions

Sound level

dBA

Electrical Data
Voltage / Frequency

V/Hz

Fuse on main supply

A (F)

Max power / Min power absorbed

Insulation degree

Standby Consumption

2.3 -

PERFORMANCE DATA

The Technical data plate is placed under the
casing front panel next to the panel board.

330

336

329,52

11,23

339,36

12,74
98,07

93,6

101

106,2
103,2
106,8

98,04
96,55

98,1

98,43

4,83
0,03
30,4
40,1
20,2

554,3
26,84

8,8

1,57
1,90

0,3

14169

0,5

35,53

1,27

357

100

21,1-56,4

<49

230/50

507/40

40
10

285

288

282,24

11,23

289,87

12,74

93,6

100,65

106,2
103,2
106,8

97,90
96,35
97,96
98,43

4,83
0,01
30,4
41,2
20,2

475

26,84

8,8

1,57
2,04

0,3

12136

0,5

30,45

1,27

312

100

18,1-48

<49

230/50

435/40

40
10

235

240

234,72

11,23

240,96

12,74

97,8
93,6

100,4
106,2
103,2
106,8

97,76
96,13

97,8

98,43

4,83
0,02
30,4
43,1
20,2

396

26,84

8,8

1,57
2,18

0,3

10265

0,5

25,38

1,27

272

100

15,1-40,8

<49

230/50

362/40

40
10

190

192

187,39

11,23

192,38

12,74

97,6
93,6

100,2
106,2
103,2
106,8

97,55
95,82

97,7

98,43

4,83
0,14
30,4
44,8
20,2

317

26,84

8,8

1,57
2,26

0,3

8058

0,5

20,30

1,27

230

100

12,1-32,4

<49

230/50

290/40

40
10

145

144

140,11

11,23

144,14

12,74

97,3
93,6

101,1
106,2
103,2
106,8

97,29
95,44

97,6

98,43

4,83
0,31
30,4
47,2
20,2

237,6
26,84

8,8

1,57
2,39

0,3

6025

0,5

15,23

1,27

191

100

8,9-24

<49

230/50

210/40

40
10

96
12

93,22

11,23

95,90
12,74

97,1
93,6
99,9

106,2
103,2
106,8

96,94
94,91

97,5

98,43

4,83
0,42
30,4
49,1
20,2

158,4
26,84

8,8

1,57
2,48

0,3

4008

0,5

10,15

1,27

156

100

6-15,9

<49

230/50

145/40

40
10

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Technical features and dimensions

The gr

illes for the air intake are placed

on the Right side, Left side and

Rear.

On the casing panels of the boiler there are some pre-cuttings for the gas connection. Once the connection
position has been selected, remove the

relevant pre-cut part.

Unless

a special order is placed, the boiler is supplied with:

Flue and condensate evacuation connection

on the R.H. side

C.H. flow connection

on the R.H. side

C.H. return connection

on the R.H. side

Gas connection

on the R.H. side

2.4 - R.H. SIDE VIEW, WITH MAIN COMPONENTS

f the position of the flue connection, for boilers Imax Plus 190 - 235 - 285 - 330, is changed from the

standard one (right side) it is necessary to place an order for the harness of the condensate

level sensor.

FAN

GAS VALVE

GAS PIPE

BURNER
COVER

IGNITION

IONIZATION

LOCAL NTC
SENSOR

BURNER

ALUMINIUM
HEAT

EXCHANGER

CONDENSATE
DRAIN

TRAP

CONDENSATE
COLLECTING

TRAY-

FLUE

MANIFOLD

C.H.

RETURN

C.H. FLOW

GLOBAL FLOW
NTC TEMPERAT.

SENSOR

AUTOMATIC

AIR VENT

H.L.
THERMOSTAT

DRAINING TAP

Min. Depth 100 mm

BOILER FRAME

CONDENSATE

LEVEL SENSOR

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Instructions for the installer

INSTRUCTIONS FOR
THE INSTALLER

3.1 -

GENERAL WARNINGS

WARNING!
This boiler has to be destined for the use for
which it has been expressively designed for.
Any other use shall be considered improper
and therefore dangerous.
This boiler is designed to heat water at a
temperature inferior to boiling point at an
atmospheric pressure.

WARNING!
These appliances are exclusively designed
to be installed inside adequate boiler rooms.
Therefore these appliances must not be
installed and operated externally.

Before installing the boiler the following points

have to be carried out by a competent engineer:

a) An accurate washing of all the pipes of the
installation to remove possible residues or
impurity that could jeopardize the good
operation of the boiler, also from the sanitary
point of view.

b) Check that the boiler has been preset for

operating with the gas type available.

This is verifiable via the indication on the

packaging and on the data badge.

c) Check that the chimney/flue pipe has an

adequate draught, does not have any

constrictions, and that no other appliance's

flue outlets have been fitted, unless the chimney

is serving more than one heating appliance,

according to the specific standards and

regulations in force.

The connection between the boiler and

chimney/flue outlet can be made only after this

verification has been carried out.

WARNING!
In rooms where there is the presence of
aggressive vapours or dust the appliance
must operate independently from the air
present in the boiler's location room!

WARNING!
The appliance must be installed by a Gas
Safe Registered Engineer or, in IE, by a
competent person

WARNING!

Install the appliance respecting the minimum
clearances for operation and servicing.

The boiler must be connected to a heating

system which is compatible to its performances

and output.

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Instructions for the installer

3.2 -

STANDARD CODES FOR
INSTALLATION

The appliance must be installed in compliance to the

instructions contained in this manual.

The installation must be carried out by a Gas Safe Registered

Engineer or, in IE, by a competent person.

The installation must be carried in accordance to the codes of

practice, the regulations and the requirements hereby indicated

which constitute an indicative list, but not a complete one, as

these continue to undergo evolve devolpments.

Moreover, the boiler must be installed in accordance to all the

regulations regarding the boiler room, the building regulations

and the prescriptions regarding central heating plants in force

in the country where the boiler is installed.

The appliance must be installed, commissioned and serviced

according to the regulations in force. This is also valid for the

hydraulic system, the flue outlet system and the boiler location

room.

For relevant codes of practice and safety information see page 6

back

Instructions for the installer

3.3 - PACKING

The

Imax Plus boiler is delivered assembled and

protected by a plastic bag inside a strong
cardboard box and fixed on

a pallet. This allows the

boiler to be handled by

a forklift. The boiler,

with the packaging, can go through a door of 800
mm, whereas, without packaging, it can go
through a door of 700 mm.

Remove both straps and finally the cardboard
box from above, making sure the product is
intact. The packing elements (cardboard box,
straps, plastic bags, etc...) shall not be left in
children's hands since they may be
dangerous.

Inside the packing, you can find,
on the boiler back:
- the front casing

attached to the back one by a plastic

film

- the condensate drain pipe,1 m long, placed under the

casing rear panel.

on the L.H. side of the boiler:
- the R.H. side panel

attached to the L.H. side one by a

plastic film.

on the boiler front:
- the

flue chamber/condensate collecting tray screwed to

the pallet

- a plastic bag containing:

· 3 gaskets (1 rectangular between condensate tray and
flue terminal, 1 square between flue socket base and flue
terminal and 1 for flue socket Ø 150 or Ø 200 mm according

to the model
· 2 bends + 1 Tee piece + 1 plastic plug, Ø 40 mm for

candensate drain.

· the screws necessary for fixing

· 1 plastic box containing the outer sensor.

on the boiler top:
- a plastic bag containing:

· This instruction manual

3.4 - BOILER LOCATION INSIDE A BOILER HOUSE

Special attention shall be paid to local regulations and laws
about boiler houses and particularly to the obligation of keeping
minimum clearances and empty space around the boiler. The

installation shall be in compliance with all latest regulations
and laws about boiler houses, installations of heating and hot-
water systems, ventilation, chimneys capable of evacuating
the flue gases of condensing boilers and any other applicable

requirement.

When selecting the position for the installation of the
boiler it has to be considered that, for the cleaning and
washing operations of the boiler body, one of the boiler
sides must be accessible for the removal of a special
baffle placed under the aluminum sections.

This baffle can be fixed

either from the R.H or L.H.

side of the condensate tray. If no modification has been

made, the boiler must have its R.H. side accessible, with the

flue connection fitted on the R.H or L.H. side. But, if the

· Warranty certificate
· Hydraulic certificate

· Controls instructions E8

flue terminal, with the flue socket, is left on the R.H. side

and if, from this same side, the baffle has to be re

moved,

then the flue socket must have the possibility to be

also

removed.

If it is preferred, the baffle can be moved in order to have its
fix

ing screw on the opposite side, regardless the position

of the

flue outlet.

The boiler can be put on a flat and sufficiently strong base

with the same dimensions as th

ose of boiler and at least

100mm high (see fig. 2), in order to assemble the conden-
sate drain

trap. An alternative to this base may be a

100mm deep well next to the boiler as

a trap housing

(see fig. 2). After installation the boiler shall be perfectly

horizontal and stable, to reduce any possible vibra

tions

or noises.

770
770
908

1042
1176

1310

145
190

780
780
780

780
780

780

181 kg
215 kg
256 kg

300 kg
341 kg

387 kg

1250
1250

back

Instructions for the installer

When the appliance is installed on existing systems, ensure

yourself that:

- The flue outlet pipe is suitable for condensing boilers, for

the temperature of the products of combustion, calculated

and manufactured according to the regulations in force. It

must be installed as much as possible in a straight line,

tested for soundness and must not have any occlusions

or restrictions.

- The flue outlet pipe has a connection for the discharge of

condensate.

- The boiler room has a suitable outlet for the discharge of

condensate produced by the boiler.

- The electrical system has been fitted in compliance to the

specific norms and the work has been carried out by a

competent person.

- The circulation pump's output, the head and flow direction

are suitable.

- The gas feed supply pipe is constructed according to the

regulations in force.

- The expansion vessels assure the total absorption of the

expansion of the fluid contained in the system.

- The system has been cleaned of impurities and lime scale.

When a

n Imax Plus boiler is installed onto an existing

heating system:

Before the replacement of an existing boiler in

an old system can be programmed, it

necessary to thoroughly clean out the system

with a basic solution. The system must be

cleaned 4 weeks before the substitution, with

the system firing at a temperature of 35°C to

40°C.

WARNING!
If it is noticed that a new

Imax Plus has replaced an existing

boiler in an old system without having first performed what is

said in the previous paragraph,

do not wash the system now

as residual products, present in the circuit, could lead to

them

gathering in the boiler body, causing damage.

Ideal Boilers recommends contacting a specialised company

for water treatment.

If installing an Imax Plus boiler in a new system,

it is

recommended to thoroughly clean out the system with an
adequate product and fit a filter

/strainer with two isolating valves

the boiler's return pipe, so that, when necessary, it can be

cleaned. This filter will protect the boiler from the dirt coming
from the heating system.

When sizing pumps, it is necessary to take into consideration

the pressure losses which occur

in the primary circuit.

3.5 -

INSTALLATION ON EXISTING HEATING SYSTEMS

Trap

A > 400 mm

B > 400 mm

C = 100 mm

D = 500 mm

Give the boiler the minimum
clearances as shown in the
drawing, in order to be able to
make the normal service and

cleaning operations.

* - Minimum clearance of 50 mm one side only, with 400

mm on opposite side for flue baffle access and pipework
connections. For side flue outlet increase to 600 mm
clearance. For pipework only allow 300 mm clearance.

Front - 600 mm; except compartment access doors may be
closer, but not less than 200 mm, and 600 mm must still be
available for service across the full width of the boiler.

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Instructions for the installer

3.6 - BOILER CONNECTION

s delivered the Imax Plus boiler has all the connections on

its R.H. side: hydraulic (flow / return), gas, and

flue outlet.

The locations of the air intake and the

flue outlet can be

decided on site by removing one of the notched parts available
on the boiler right, left and back sides. To fix the

terminal with

the flue socket, use the screws and the gaskets

supplied

inside the plastic bag and a min. 300 mm long cross

headed

screwdriver.

Hydraulic (flow/return) and gas connections can be also
moved

to the boiler L.H. side by inverting the madifolds

to the left side according to the following procedure:

- Remove the complete casing
- Remove the small plates fixing the flow and return global

temperature sensors

- Disassemble the flow and return manifolds, leaving

in their

place, on the aluminum sections, the rubber gaskets (on
the upper holes) and the diaphragms (on the lower holes).
The diaphragms on the end sections have a hole of 17
mm dia., while the others have a hole of 22 mm dia.

- Reassemble the manifolds with the threaded connection on

the opposite side as shown in the figure

right.

- Change, between them, the position of the drain cock and

the automatic air vent.

- Reposition the temperature sensor white and red leads onto

the new flow manifold and the temperature sensor white
and green leads onto the new return manifold.

- It is possible to keep the gas manifold inlet on the R.H. side

or, otherwise, it is possible to rotate it 180° to have it on
the L.H. side.

When changing the gas manifold from

R.H. side to L.H. side, only on the Imax Plus 95 will it be

necessary to

swap the plug C with the gas valve fitting A.

Ø 17 mm

Ø 22 mm

Ø 17 mm

Ø 22 mm

POSSIBLE GAS CONNECTION REVERSION

POSSIBLE WATER CONNECTIONS REVERSION

Ø 17 =

Diaphragm for the two collectors positioned at the
extreme ends

Ø 22 =

Diaphragm for the internal collectors.

REAR VIEW

C.H. Flow and Return R.H. side connections
(std delivery condition).

REAR VIEW
C.H. Flow and Return L.H. side connections
(after modification condition)

FRONT VIEW
Gas connections on the L.H. side
(after modification condition)

FRONT VIEW
Gas connections on the R.H. side
(std delivery condition).

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Instructions for the installer

3.7 -

GAS CONNECTION

The gas supply pipe must be connected to the boiler by a

1½" G

as pipe as indicated on page 8.

The gas supply pipe must have a section which is identical or

greater then the one used on the boiler and must assure a

correct gas pressure.

It is however important to comply with the specific norms and

requirements in force, foreseeing on-off valves, gas filter, anti-

vibrating joint etc.

Before commissioning an internal gas distribution system and

therefore before connecting it to the gas meter, the complete

installation must be tested for gas soundness.

If any part of the system is concealed from view the gas

soundness test must be carried out before covering the pipes.

DANGER!
The gas connection must be carried out by
a Gas Safe Registered Engineer who will
have to respect and comply to the
regulations in force and to the requirements
indicated by the local gas supplier.
An incorrect installation could cause injury
to persons, animals or damage to property.
The manufacturer shall not be held liable for
any injury and/or damage.

Before installing the boiler it is recommended

to thoroughly clean all the supply piping in order

to remove any residual grime which could

compromise the boilers correct function

If you smell gas:

a. Do not turn on or off electrical switches, use

the telephone or any other object which can

provoke sparks;

b. Open all doors and windows in order to allow

fresh air to enter and purify the room;

c. Close all gas cocks

d. Contact a service engineer, qualified installer

or the gas supply company.

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Instructions for the installer

3.8 -

FLOW AND RETURN PIPE
CONNECTIONS

The CH flow and return circuits have to be connected to the

boiler via the respective connections 2" M and R as indicated

on page 8.

When determining the size of the CH circuit pipes it is essential

to bear in mind the pressure losses induced by any of the

system's components and by the configuration of the system.

The route of the piping has to be conceived taking all the

necessary precautions in order to avoid air locks and to facilitate

the continuous purging of the system.

WARNING!
IT IS ABSOLUTELY FORBIDDEN TO FIT
ON-OFF VALVES ON THE BOILER BEFORE
THE SAFETY DEVICES

WARNING!
Before installing the boiler we recommend
that the system is flushed out with a suitable
product in order to eliminate any metallic
tooling or welding residues, oil and grime
which could reach the boiler and affect the
proper running of the boiler. The appoved
water treatments are given on page 24.

Non-observance of these instructions could
cause injury to persons, animals or damage
to property. The manufacturer shall not be
held liable for any such injury and/or
damage.

Ensure yourself that the system's piping is not

used as the earth clamps for the electrical or

telephonic system. They are absolutely

unsuitable for this use. In a short time this could

cause serious damage to the piping, boiler and

radiators.

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Instructions for the installer

3.9 -

DETERMINATION OF PRIMARY BOILER PUMP OR BOILER SYSTEM PUMP

The size of the pumps must be determined
by installers or technical engineers
according to boiler data and system design.

The water side resistance curve of the boiler
is shown in the following diagram.
The pump is not an integral part of the boiler.

It is recommended to choose a pump with
the rate and delivery head at about 2/3 of its
characteristic heating curve.

The boiler pump must have a delivery head which can ensure
the water flow rate as shown in the diagram "Water pressure
losses".

The following table gives an indication of the pump's flow rate
in function of the Ät of the primary circuit if the installation has
a mixing header.

145 190 2

35 285 330

6025

8058 10265 12136 14169

8032 10743 13457 16181 18301

4008

5344

Boiler Model

Max water flow rate
Demanded in l/h ( t=15 K)

Max water flow rate

Demanded in l/h ( t=20 K)

800
750
700
650
600
550
500
450
400
350
300
250
200
150
100

10 11 12 13 14 15 16 17 18 19 20 21

MOD

MOD 190

MOD 2

MOD 3

MOD 145

WATER FLOW m³/h

SSU

RE L

b
a

WATER SIDE PRESSURE LOSSES

NOTE: The use of a mixing header fitted between the boiler circuit and the system circuit is
always advisable. It becomes INDISPENSABLE if the system requires flow rates superior to the
maximum permitted boiler flow rates, which is to say lower than 15K.

For a

T 20 K, of an Imax Plus 235 boiler, the max. water flow rate requested is 10,3 m3/h.

From the graph of the boiler's pressure losses, it can be determined that the pump must be able
to guarantee a delivery head of at least 250 mbar.

back

Instructions for the installer

Working pressure 6.0 bar maximum, 0.8 bar minimum.

There is no minimum water pressure switch on the boiler, with
safety thermostats providing protection against dry firing.
However, should a minimum water pressure switch be
required in the system a ¼" connection is available on the
return manifold. The electrical connections should be made in
series with the minimum gas pressure switch.

Particular reference should be made to BS. 6644: Section 6
and Guidance note PM5 "Automatically controlled steam and
hot water boilers" published by the Health and Safety
Executive.

The information and guidance given below is not intended to
override any requirements of either of the above publications
or the requirements of the local authority, gas or water
undertakings.

In general commercial closed pressurised systems are
provided with either manual or automatic water make up.

On both instances it will be necessary to fit automatic controls
intended to protect the boiler, circulating system and ancillary
equipment by shutting down the boiler plant if a potentially
hazardous situation should arise.

3.10 - SEALED SYSTEM REQUIREMENTS

Examples of such situations are low water level and operating
pressure or excessive pressure within the system. Depending
on circumstances, controls will need to be either manual or
automatic reset. In the event of shutdown both visual and
audible alarms may be necessary.

Expansion vessels used must comply with BS. 4814 and must
be sized on the basis of the total system volume and initial
charge pressure.

Initial minimum charge pressure should not be less than 0.8
bar (11.6 psi) and must take account of static head and
specification of the pressurising equipment. The maximum
water temperatures permissible at the point of minimum
pressure in the system are specified in Guidance Note PM5.

When make-up water is not provided automatically it will be
necessary to fit controls which shut down the plant in the event
of the maximum system pressure approaching to within 0.35
bar (5 psi) of safety valve setting.

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Instructions for the installer

3.11 - WIRING DIAGRAM FOR ADDITIONAL

SAFETY DEVICES

SAFETY
VALVE

VISIBLE
DRAIN
FUNNEL

Pump management via E8

to the terminal 4 (A10)

from the IV connector

LINE

230 V

RELAY

LINE

230 V

Boiler mains

supply

230 V

3.12-

PRESSURE RELIEF VALVE DRAIN
PIPE

A pressure relief valve must be fitted on the flow

pipe, immediately next to the boiler. It must be

suitable for the capacity of the boiler and

must comply to the regulations in force,

WARNING!
Please remember that it is forbidden to
install, between the boiler and the
pressure relief valve, any type of cut-off
device. Moreover it is recommended to use
cut-off valves which do not exceed the
maximum allowable operating pressure.

WARNING!
In respect to the heating pressure relief
valve see right the installation of a
discharge pipe with a funnel and a trap
which lead to an adequate drainage. The
drainage has to be controllable by sight.
If this precaution is not made, an eventual
intervention of the pressure relief valve
could cause injury to persons, animals or
damage to property. The manufacturer shall
not be held liable for any injury and/or
damage.

Terminals EXT-MIN

interface WILO

modulating pump

LINE

230 V

RELAY

LINE

230 V

Boiler mains

supply

230 V

ON-OFF PUMP

MODULATING PUMP

back

Instructions for the installer

3.13 -

MIXING HEADER FILTER

Ideal Boilers suggests the installation of a
filter/strainer on the return pipe so that it can
be cleaned if necessary.
This will protect the boiler from the
heating system dirt.

back

Instructions for the installer

.14 - BOILER FREEZE PROTECTION

Should the flow temperature (measured at global flow tempera-
ture NTC) decrease under 7°C, the system pump

will run. Should

this temperature decrease to under 3°C, all modules will start at

min. output until the return temperature reaches 10°C.

Such protection devices

are exclusively for the boiler. For the

protection of the system, a second frost protection thermostat is

necessary to switch on the heating system pump.
To protect the C.H. system from freezing when boiler is not in
operation during cold season, it is necessary to add to the C.H.
system water an anti freez

e solution.

NB: The antifreeze solution must be compatible with the

materials present in the system, and mainly with the
aluminum.

3.15 -

MIXING HEADER

1/2''

CH FLOW

CH RETURN

CH FLOW

CH RETURN

Boiler

Circuit

Heating

System

Circuit

In order to ensure correct boiler operation it is

advisable to

use a mixing header which guarantees:

the separation and collection of circuit dirt

optimal air venting

hydraulic de-coupling of the two hydraulic circulation circuits

balancing of the circuits

WARNING
AFTER A LONG INOPERATION PERIOD OF
THE BOILER, IN CASE THE BOILER TEMPE-
RATURE IS BELOW 3°C, ABSOLUTELY DO

NOT TRY TO START THE BOILER.

THIS CAN BE ALLOWED ONLY IF YOU ARE SURE THAT AN
ANTIFREEZE SOLUTION HAS BEEN ADDED, IN THE PRO-
PER PERCENTAGE, TO THE C.H. WATER.

4.000

8.000

12.000

20.000

30.000

50.000

100

150

200

250

300

95 kW

145

190

- 2

85 kW

power supply

over > 3

30 kW

100

125
150

100

125

150

200

200
250

1.000

1.000
1.000

1.000

300

150

150
150

1.650
1.650

1.650

1.700

200
200

200

Note: The mixing header is not supplied by
Ideal Boilers. The information is provided as advice.

TABLE FOR THE RECOMMENDED DIMENSION OF THE
HYDRAULIC COMPENSATOR

The use of a mixing header means that compensating

controls can be used to operate mixing valves on a

variable temperature circuit, without affecting the water

flow rate through the boiler.

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Instructions for the installer

3.16 - CONDENSATE DRAIN

Avoid the condensate stagnation inside the combustion
products evacuation system, (for this reason the

condensate

rain must have an inclination toward the drain of at least 30

mm/m (3/8 in. / ft) except the liquid column, inside the
condensate

trap, which needs to be filled with water after

installation: its minimum height, when all the fans are in oper-
ation, must be at least 25 mm (1 in.).

In order to avoid ice formation while the boiler is operating,
which can cause the

boiler to stop, the whole condensate

evacuation system has to be well insulated. It is forbidden to
evacuate the condensate through a gutter

due to a risk of ice

forming and corrosion.

The connection to the sewer will be through a visible drain.

Given the acidity degree (pH 3 to 5) only plastic ma

terial

can be used for the condensate evacuation pipes.
Moreover it must be dimensioned and constructed so as
to allow the correct out-flow of drains, preventing any bot-
tleneck and any leakage.

BACK SIDE

BOILER
HOUSE
FLOOR

150

INITIAL

TRAP

FILLING-UP PLUG

The upper part of the drain
pipe shall not be higher
than the tray bottom.

Min. height of the condensate column, with all fans
operating at max. speed, requested by the EN
standards.

** Min. height of the condensate column, with all fans
operating at max. speed. If it is not possible to create
a 100 mm boiler base, install the boiler on the floor
and create a min. 100 mm deep well to lodge the trap.

The outlet of the condensate drain pipe will be on the same
side of the

flue chamber, passing below the flue cham-

ber.

Before commissioning the boiler fill the condensate trap
with water, from the dedicated filling-up plug.

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Instructions for the installer

3.17 - WATER TREATMENT

The imax plus

boiler has an ALUMINIUM alloy heat exchanger.

Corrosion will always occur within a heating/hot water system to
a greater or lesser degree irrespective of water characteristics,
unless the initial fill water from the mains is treated. For these
reasons Ideal Boilers strongly recommends that the

system

be thoroughly cleaned prior to the use of a stable inhibitor
which does not require continual topping up to combat the effects
of hardness, salts, and corrosion on the heat exchanger and its
associated systems.
Therefore it is important that if water treatment is used it is
suitable for the material of the heat exchanger. The ONLY water
treatments approved are Fernox Copal or MB1 or GE Betz
Sentinel X100 inhibitors and associated water treatments, which
must be used in accordance with manufactures instructions.
Current suitability should be confirmed directly with the
manufacturer.

Sentinel Performance Solutions
The Heath Business & Technical Park
Runcorn, Cheshire. WA7 4QX
Tel 0800 389 4670
www.sentinel-solutions.net

Fernox Manufacturing Co. Ltd.,
Cookson Electronics, Forsyth Road,
Sheerwater, Woking, Surrey, GU21 5RZ
Tel: 01799 521133

Artifically softened water must NOT be used to fill the system.

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3.18 - CONNECTION TO THE CHIMNEY

In a condensing boiler the

flue gases are evacuated at a

very low temperature (Max about 84°C). It is necessary that

the chimney is perfectly impermeble to the condensate of

the combustion products and is made of materials corrosion

resistant.

The different spigot joints must be well sealed and equipped
with suitable gaskets, in order to prevent the outlet of

condensate and the inlet of air.

Concerning the cross section and the height of the chimney, it
is necessary to make reference to the national and local rules
in force.

In order to prevent

the formation of ice, during the operation,

the temperature

of the internal wall of the combustion product

evacuation system, in all its length, has not to be below 0°C.
For condensation operating conditions of the appliance at the
external design temperature, it will be necessary to

install a

condensate evacuation system, discharging according to the
installation condition, in the boiler condensate tray or in
another dish

pan separated from it.

The

Imax Plus boiler is suitable also for installation in C 63

type, by taking the combustion air from outside the boiler

house via an air duct.

To convert the boiler for type C 63 operation, a special kit

is available

for order from Ideal Boilers - Air inlet socket & blanking plate kit

3.19 - ROOM SEALED VERSION

2
3
4

5
6
7

145
190

150
150
150

200
200
200

The type of flue pipe used should be 316 grade Stainless Steel

or be of equivalent corrosion resistance. Advice regarding the

availability of proprietary types of flue system can be obtained

by contacting Ideal Boilers. All joints or connections in the

flue system must be impervious to condensate leakage.

Low points in the flue system should be drained using pipe of

material resistant to condensate corrosion. All drains in the

flue should incorporate a water trap.

Flue Connections

It is possible to combine flue connections at any of the

positions of left, right and rear. To change connections,

simply remove the blanking plates from the connection

required and attach the flue connections. Seal off the

unused connections with the removed blanking plates.

Air Connections

Boiler sizes 95-145 are delivered with an air inlet filter

fitted on the right side with the left side and rear

connections blanked off. If required the filter can be

moved to the left side, using the removed end panel

and blanking plate on the right side. Boiler sizes

190-235 have an air inlet filter fitted to both sides.

Boiler sizes 285-330 have filters fitted to both sides

and the rear. Ducting air directly to the boiler from

outside is possible to the left or right side or rear by the

removal of all filter(s) andthe use of air inlet spigot kit(s).

These kits are obtainable from the boiler manufacturer.

Instructions for the installer

Maximum pressure available at flue outlet : 100Pa

back

Instructions for the installer

Imax Plus

145

190

235

285

330

Flue gas mass

flow rate (max)

kg/h

158,4

237,6

317

396

475

554,3

Example:

Imax Plus 235

Flue gas mass flow rate

396 Kg/h

Chimney height

25 m

Chimney connection Ø

250 mm

NOTE:
The diagram shows
t

he indicated values

Flue gas mass flow rate

content

d 125

d 400

d 315

d 250

d 200

d 160

d 110

d 75

100

120

140

160

180

200

300

400

500

600

700

800

900

1000

1200

1400

4,4

5,9

6,6

7,4

104

119

133

148

222

296

370

444

519

593

668

741

889

1037

3,4

3,9

4,4

5,0

5,6

100

111

167

222

277

333

389

445

555

667

778

0,001

0,002

0,003

0,004

0,005

0,006

0,007

0,008

0,009

0,010

0,015

0,020

0,030

0,035

0,040

0,050

0,060

0,070

0,080

0,090

0,100

0,150

0,200

0,250

0,300

0,350

0,400

0,500

0,600

0,700

9,0

10,8

12,0

14,4

108

126

144

180

216

252

288

324

360

540

720

900

1080

1260

1440

1800

2160

2520

100

120

140

160

180

200

300

400

500

600

700

800

900

1000

1200

1400

kg/s

kg/h

10%

mass flow rate

40 Pa

40°C

396

Chimney dimension
DIN 4705

Pressure avaible

Flue Gas Temperature

o
mi

l
H

i
n
p
u
t
(

k
W

)

i
n
a
l He

a
t
in

p
u
t
(

k
W)

t
h
CO

v
e
l

a
t

1

0
%

Flue gas

back

Instructions for the installer

The boiler consists of mutally connected combustion cham

bers:

each of them has its own burner - fan, with air pressure
switch for control - gas valve, with ignition and ionisation

device - BMM (Burner Modular Manager) control PCB.

In each cast aluminum section there is a temperature sensor
NTC (Negative Temperature Coefficient), called local NTC,
which locally checks the flow temperature of each aluminum
section, and a High Limit thermostat.

The flow temperature at the boiler outlet and the return

temperature at the boiler inlet are controlled by global NTC

temperature sensors.

When more heat is requested by heating or DHW systems, the

boiler st

arts up and water will be heated by an aluminum boiler

body. Then the boiler pump sends water to the mixing

header,

and, from here, the C.H. pump will send it to the radiators,
according to the heating system chosen.

The combustion air is supplied by fans and taken in from the
boiler room (for type B 23 boilers), or from outside through
pipes (for type C 63 boilers, i.e. room sealed combustion

boilers).

The combustion air is then pushed into the pre-combustion-
chamber through a diaphragm.
Beyond the diaphragm, the air mixes with gas and such

mixture

passing through the non-return valve is sent to the burner.
Then, on leaving the burner surface, the air/gas mixture

ignites electrically and the resulting combustion gases, after

being transported (and cooled) through pinned sections, enter

the condensate collecting manifold and then are evacuated

through the boiler chimney.

3.20 - BOILER OPERATION

Fan

C.H. Flow

Global Return

NTC temperat. sensor

Global Flow
NTC temperat. sensor

Burner

Ionization
electrode

Ignition
electrode

Combustion

Chamber

Local NTC
sensor

H.L.

Thermostat

Heat

xchanger

Condensate
collecting
tray

flue

manifold

Air press

ure switch

Gas valve

Flue outlet chamber

Gas

back

Instructions for the installer

Thermal element

(module) = 48 kW = 100%

Thermal elem.

= 48 kW x 4 = 192 kW = 400%

400% : 192 kW = 200% : X

X = (192 x 200) : 400 = 96 kW

input shared on 4

thermal elements

Input shared on 4 thermal elements : total input

= 96 : 192 = 0,5 = 50%

(kW)

100

103,2

% (p.c.i.)

102,4

100 % = 48 kW

50 % = 24 kW

1 thermal

element

1 thermal

element

When there is a heat request from the E8 controller or from a
BCM (Boiler Cascade Manager), the E8 or BCM calculates
the necessary output according to the difference between the
set temperature (or the temperature calculated by the outer
compensator) and the global flow temperature. The number
of thermal elements (each thermal element represents a ma-
ximum input of 48 kW) x 100% determines the maximum input
expressed in %.
When the input has been determined, the boiler pump (not
supplied by

Ideal) starts and the fan of one thermal element

is set in motion at starting speed. The gas valve opens

and

ignition occur

s within 5 sec. When the ionisation electrode

detects the flame, the thermal element starts operating.
Subsequently other thermal elements are likely to start in the
same way. One of the operation principles for this boiler is

letting as many burners as possible operate simultaneously

at minimum load to reach the maximum efficiency.

For example, if a 4 thermal element boiler is requested to
operate at its max input, this shall be 400% i.e. :

48 kW x 4 thermal elements = 192 kW = 400%.
If it is requested to operate at 200% input, thanks to the input

4 thermal elements of 48 kW each working

at 50% of the output give = 96 kW = (200%),

i.e. 24 kW / thermal element

sharing system on the highest number of thermal elements,
each thermal element will operate at 50% output i.e. :

200% : 4 thermal elements = 50%
equal to a total of 96 kW, that is 24 kW for each thermal
element.

Such

a principle provides clearly efficiencies much higher than

those obtained in traditional groups of small boilers installed
in cascade.
When the input shared on each thermal element is less than
12 kW

, one thermal element after the other is automatically

excluded and the remaining input is shared on thermal
elements having the smallest number of operation hours (by
the automatic operation-time calculating system).
Modulation, i.e. input reduction, is based on the difference
between the set temperature (or the temperature calculated
by the outer compensator) and the global flow temperature.
When no ignition occurs, the ignition device repeats two more
times the ignition sequence and then puts to lock out position
the thermal element concerned.

Efficiency of a thermal element working at full capacity

48 kW = 100 %

(in condensation)

Efficiency of a thermal element working at reduced capaci-
ty

24 kW = 102,4 %

(in condesation)

Efficiency of a thermal element working at minimum capa-
city

12 kW = 103,2 %

(in condesation)

All the thermal elements work in parallel at the same output,
equalizing, thus, the C.H. system efficiency to the one of the
thermal element.

back

Instructions for the installer

3.21 -

ELECTRICAL CONNECTIONS

Regulato

ry Requirements

The gas and water feeding pipes and the CH system pipes

cannot be used as protective earth.

Connections

Ideal Boilers refuses responsibility for any damage arising

from failure to earth the boiler correctly.

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.

For the appliance's general electrical supply the use of

adaptors, multiple sockets and/or extension cords is strictly

forbidden.

The use of any power supplied equipment implies the

observance of several fundamental rules, such as:

- Do not touch the appliance with any wet part of your body

and/or barefooted;

- Do not pull the supply cables

- Do not expose the boiler to sunlight, rain, etc.

- Do not permit children or non-expert people to use the

appliance.

Mains electrical supply connection 230V

The electric connections of the boiler are shown in the section

named "WIRING DIAGRAMS" (paragraph 3.18 page 30)

A mains supply of 230 V 50 Hz is required.

WARNING!
The appliance MUST be wired with a
permanent live supply. Use the plug
provided for this purpose. The boiler is
phase sensitive so correct connection
of the live and neutral wires is essential.
The supply must not be interrupted by
any system controls. Controlling the
mains input in this way will prevent the
pump over-run sequence and may cause
damage to the heat exchanger.

DANGER!
The electrical connections must be carried
out only by a qualified engineer.
Before carrying out the connections or any
other operation on the electrical parts,
always switch off and disconnect the
electricity supply and ensure yourself that it
cannot be accidentally turned on.

It is necessary to fit a double pole switch on the electrical supply

line, having a 3 mm contact separation in both poles, in an

easy accessible position in order to make quick and safe the

servicing operations.

The boiler electrical supply (230 V 50 Hz single phase) is
to be

made using the three pole plug supplied with the

boiler.

WARNING!
230 V cables shall be separated from 24 V
ones, using the two plastic conduits
supplied within the boiler casing L.H. side
panel.

back

Instructions for the installer

3.22 -

FUNCTIONAL WIRING DIAGRAM

TL1

25
4
1

L
.
/RE

I
M

VM1

RED

WHITE

BROWN

WHITE

1° Modul

RED

E.RIL.1

SR1

SRR

YEL/GREEN

F6A

BROWN

BLUE

BROWN

BLUE

BLACK

ORANGE

BROWN

RED

BLACK

BLUE

LIGHT BLUE

BROWN

F10A

L
-
G

EEN

BROWN

BLUE

BROWN

BLUE

230 V - 50Hz

T1T2

T3T

A10

A11

BUS

III

IMP

0 -10

F17

F15

FBR

VIII

PT1000

F14

F13

SPF

F12

F1 1

/ SPF

FBR

eBU

0 -1

0 V

VII

BLUE

Jp1

DL1 DL2

DL3

SW1

dbu

s - B

- A

PLC /

BMS

BCM

+
24

GREY

PINK

WHITE

BLACK

BROWN

A
C

BROWN

( -

)

( -

)

( +

)

BROWN

LIGHT BLUE

BROWN

BLUE

BROWN

BLUE

BROWN

BLUE

ORANGE

BROWN

RELE'

WHITE

BLUE

BROWN

TLG

BROWN

LTLG

7 moduls

2 to 6 moduls

SE8/BCM

BROWN

CONTROL E8

MAIN SUPPLY

CONNECTION

WIRE NEUTRAL (N)

CONTROL

MODULATION

PUMP

I
R

I
T

SER

BCM

eBUS

remote

(

Cascade manager)

external

ORANGE +

BLACK (-)

BROWN (PWM)

BLUE (TACHO)

LIGHT BLUE (N)
BROWN (L1)

YEL/GREEN

WHITE

L
U

YEL

L
-
G

WHITE

T
B

L
U

I
T

YEL

L
-
G

ARANCIO +

NERO (-)

MARRONE (PWM)

BLU (TACHO)

AZZURRO (N)
MARRONE (L1)

PV1

GIA/VER

SMG

WHITE

RED

Note: The pictures shown on the actual
wiring diagram, is purely indicative.

back

Instructions for the installer

Module 1

(Pos 0)

Module 2

(Pos 1)

Module 3

(Pos 2)

Module 4

(Pos 3)

Module 5

(Pos 4)

Module 6

(Pos 5)

Module 7

(Pos 6)

Setting of modules
selectors

Gas pressure swich

Fan pressure swich

High limit thermostat

Global

Ionization

Main switch

Global Flow Temperature Sensor E8
Minimum (not

supplied)

Global Flow Temperature Sensor BCM
Local Flow NTC Temperature sensor

Local Flow NTC Temperature sensor
Global Return NTC Temperature sensor

Local High limit thermostat

Gas Valve
Ignition Transformer

Modulating Fan

Ignition electrode

electrode

High limit thermostat

SR
SRR

TL 1....7
TLG

E.ACC 1....7
E.RIL 1....7

PV 1....7
SMG

1....7

TRA.ACC 1....7

VM 1....7

TR.ACC.1

E.ACC.1

VG1

TL2...TL7

PV2...PV7

SR2...SR7

25
4
1L

L
.
/RE

I
M

+ 2

4

V

E.RIL.2...E.RIL7

2° - 7° Modul

TR.ACC.2...TR.ACC.7

E.ACC.2...E.ACC.7

VG2...VG7

ORANGE +

BLACK (-)

BROWN (PWM)

BLUE (TACHO)

LIGHT BLUE (N)
BROWN (L1)

WHITE

YEL/GREEN

L
U

YEL

L
-
G

3° - 7° MODUL

WHITE

I
T
E

L
L
-
G

LIGHT BLUE

BROWN

T
B

YEL

L
-
G

YEL

L
-
G

LIGHT BLUE

BROWN

back

Instructions for the installer

3.23 - WIRING DIAGRAM FOR CONNECTIONS AND MANAGING

On the back side of the E8 regulator there are two terminal
blocks, of which one is for the mains (230 V) connections and
the other one is for the low

voltage connections.

The main controls, necessary for the C.H. system

management and for the boiler control, as well some

components which are part of the boiler house, must be

connected to the terminal blocks.

Power terminal assignments

Power

terminal

block

Sensor
terminal
block

A1 A2 A3 A4 A5

N L1 L1'

T1 T2

T3 T4

A8 A9

A10 A11

L H

BUS

50 Hz 230 V

III

IMP

0-10 V

F17

F15

FBR

VIII

PT1000

F14 F13

SPF

F12 F11

KF / SPF

F9 F8

F6 F5

F3 F2 F1

FBR

eBUS

0-10 V

VII

9 10

N L1 L1 1 2

Power supply

From BCM

Terminal II

1
'

T1
T2

1
0

1234

NL
1

L
1

L1:

L2:

Neutral conductor, mains

Power supply, unit

Power supply to relay

heating circuit pump HK 1

heating circuit pump HK 2

Storage tank charging pump

Mixer open, heating circuit 2

Mixer closed, heating circuit 2

T3
T4

Terminal VI

123

A1
0
A

1
1

I
V

Terminal IV

Mixer open, heating circuit 1

Mixer closed, heating circuit 1

Multifunction relay

Recycle pump /

back

Instructions for the installer

Sensor terminal assignments

Connection to BCM

For connection to remote control devices

Terminal VII

VII

Pin 1:

Pin 2:

eBUS (FA) or 0-10V output

(Ground)

Terminal I

2
3

4
5

Pin 4:

Pin 5:

Pin 6:

Pin 7:

Pin 8:

Pin 9:

Pin 10:

Flow sensor, heating circuit 2 (ground)

Flow sensor, heating circuit 2

Storage tank sensor

Storage tank and boiler sensor (ground)

Boiler sensor

Outdoor sensor

Outdoor sensor (ground)

SPF
SPF

KF
AF
AF

Buffer storage tank low sensor

Buf. stor. tank middle sensor / FBR heat. circ. 1 (room sensor)

Buf. stor. tank top sensor / FBR heat. circ. 1 (set value)

F
1
1

Terminal V

SPF

Pin 1: Flow sensor heating circuit 1 / sensor multifunction 1

Pin 2: Service water low sensor / sensor multifunction 2

I
I

1000

F
1
3

Terminal VIII

F13
F14

Pin 1: Sensor HS2 / Solar 2 / Multifunction relay 3

Pin 2: Sensor Solar 1 / Sensor multifunction relay 4

Terminal III

III

1
5

Pin 1:

Pin 2:

FBR heating circuit 2 (room sensor) / 0-10V IN / Light

FBR heating circuit 2 (ground)

F15

F17

Pin 3: FBR heating circuit 2 (set value) / Pulse counter for

Morsetto IX

CAN Bus Pin 1 = H (Data)

CAN Bus Pin 2 = L (Data)

CAN Bus Pin 3 = - (ground, Gnd)

CAN Bus Pin 4 = + (12V supply)

back

Instructions for the installer

3.24 -

INSTALLATION EXAMPLES (functional wiring and connections description)

INSTALLATION OF A BOILER WITH CONNECTION TO A DIRECT HEATING ZONE

INSTALLATION OF A BOILER WITH CONNECTION TO TWO DIRECT HEATING ZONES + D.H.W. PRODUCTION

(9-10) outdoor sensor

(6-7) Storage tank sensor

(4) Pump heating circuit 1

(5) Pump heating circuit 2

(6) Cylinder charging pump

SPF

(5) Re-circulation pump storage tank

(4-5) Flow sensor heating circuit 2

(9-10) outdoor sensor

(4) Pump heating circuit 1

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

(4) Collector pump

Safety devices

Mixing Header

Filter

Primary

system pump

Heating Circuit 1

Outside

Sensor

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Ric.

SPF

Filter

Heating Circuit 1

Heating Circuit 2

Outside

Sensor

Mixing Header

Safety devices

Primary

system pump

This sensor can also remain unused

necessary for enabling 2° circuit

This sensor can also remain unused

back

Instructions for the installer

INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION

(9-10) outdoor sensor

(4-5) Flow sensor heating circuit 2

(Optional)

(6-7) Storage tank sensor

(4) Pump heating circuit 1

(5) Pump heating circuit 2

(6) Cylinder charging pump
(7) Mixer motor heating circuit 2 OPEN

(8) Mixer motor heating circuit 2 CLOSE

INSTALLATION OF A BOILER WITH CONNECTION TO ONE MIXED AND ONE DIRECT HEATING ZONES + D.H.W. PROD.

SPF

(1) Mixer motor heating circuit 1 OPEN

(2) Mixer motor heating circuit 1CLOSE

(5) Re-circulation pump storage tank

(7) Mixer motor heating circuit 2 OPEN

(8) Mixer motor heating circuit 2 CLOSE

(5) Re-circulation pump storage tank

(9-10) outdoor sensor

(6-7) Storage tank sensor

(4) Pump heating circuit 1

(5) Pump heating circuit 2

(6) Cylinder charging pump

SPF

(4-5) Flow sensor heating circuit 2

(4) Collector pump

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Ric.

SPF

Filter

Heating Circuit 1

Heating Circuit 2

Outside

Sensor

Mixing Header

Safety devices

Primary

system pump

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

Filter

Heating Circuit 1

Ric.

Heating Circuit 2

SPF

Outside

Sensor

Mixing Header

Safety devices

Primary

system pump

This sensor can also remain unused

necessary for mixing valve control

back

Instructions for the installer

INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION BY SOLAR PANELS

(9-10) outdoor sensor

(4-5) Flow sensor heating circuit 2

(optional)

(6-7) Storage tank sensor

(4) Pump heating circuit 1

(5) Pump heating circuit 2

(6) Cylinder charging pump

SPF

(5) Re-circulation pump storage tank

(2) Hot water tank low / Multifunction relay sensor 2

(optional)

(2) PT1000 sensor solar 1 / Multifunction relay sensor 4

(optional)

PT1000

For the connection to a solar installation it is
necessary to change some parameters. See
Table:

Expert AREA

Level SOLAR / MF

MF 4

FUNCTION = `'23''

(4) Collector pump

(7) Mixer motor heating circuit 2 OPEN

(8) Mixer motor heating circuit 2 CLOSE
(1) Mixer motor heating circuit 1 OPEN

(2) Mixer motor heating circuit 1CLOSE

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

SPF

A11

PT1000

F14

F12

Mixing Header

Filter

Heating Circuit 1

Outside

Sensor

Heating Circuit 2

Safety devices

Primary

system pump

necessary for mixing valve control

back

Instructions for the installer

INSTALLATION OF A BOILER WITH CONNECTION TO TWO MIXED ZONES + D.H.W. PRODUCTION

Connections on to the MASTER controller
The connections of the secondary circuit have to be done on
to the MASTER controller.

(5) Re-circulation pump storage tank

ATTENTION!
In this type of installation it is necessary to adjust,
in the E8 controller, the parameter BUS-ID HS.

The external regulator E8 (MASTER) has to be set to:
----,
the boiler regulators E8 (SLAVES) have to be set to:
01 to 08.

(4) Collector pump

Ric.

SPF

Slave 1

Slave 2

Filter

Heating Circuit 1

Outside

Sensor

Filter

Heating Circuit 2

Remote

Master

Mixing Header

Safety devices

Primary

system pump

Safety devices

Primary

system pump

Boiler

Sensor

(1) Flow sensor heating circuit 1

(10) Ground outdoor sensor

(9-10) outdoor sensor

(4-5) Flow sensor heating circuit 2

(optional)

(6-7) Storage tank sensor

(4) Pump heating circuit 1

(5) Pump heating circuit 2

(6) Cylinder charging pump

SPF

(7) Mixer motor heating circuit 2 OPEN

(8) Mixer motor heating circuit 2 CLOSE

(1) Mixer motor heating circuit 1 OPEN

(2) Mixer motor heating circuit 1CLOSE

necessary for mixing valve control

back

Instructions for the installer

3.25 - CASCADE MANAGER (BCM)

Application

The BCM completes the range of functions offered by the

Imax Plus boilers:

- ON/OFF alarm control
- Control of a modulating header pump with the aim of

significantly increasing efficiency at low heating loads.

- Possibility of integrating the

Imax Plus boilers in PLC

controlled boiler plants

- Thanks to LonWorks/Modbus protocol converters been

readily available also opens the road to installing

Imax Plus boilers in the most advanced Building

Automation Systems.

Features

The BCM can be connected to the automation system of
a boiler plant via one of its interfaces:
- eBUS: for connection to the series of E8 heating

controllers or to an additional BCM

- Modbus: application in PLC controlled boiler plants

The communication protocols enable complete system
management:
- Control of heating request: temperature set point and

modulation level

- Monitoring of boiler operation and temperature status
- Alarm control
- Functional parameters setting

Management of the header pump:
- Relay command for running a pump at fixed rate
- 0

-10 analogical output for control of a modulating pump

Special functions
Emergency: it avoids system shutdown caused by an
interruption in communication with the boiler plant's
automation system:
- Input for "Constant setpoint" request: 55°C, maximum

output 50%

- Alarm reset input
- Alarm relay signal

Monitor

a BCM connected to a group of heating generators
managed by a E8 heating controller, automatically selects
the "monitor" mode.
In this condition the following services are supplied:
- Acquisition of all the operating data and diagnostics via

the Modbus interface.

- Control of the modulating pump
- Control of the Alarm relays and control of the header

pump

- If the E8 malfunctions, the BCM automatically resets

normal boiler operation control and can enable the
emergency function previously described.

back

Instructions for the installer

Connection for boilers in a cascade arrangement managed by a E8 heating controller with PLC supervision.

WARNING!
In this connection the "BUS-ID HS,,
parameter must be set on the E8 heating
controller

The external E8 heating controller (MASTER) must be
set to: - - - -,
The E8 heating controllers fitted on each boiler (SLAVE)
must be set from: 01 to 08.

Jp1

DL
1
DL
2
DL
3

SW
1

Modbus - B
Modbus - A

BC
M

eBUS -

eBUS +

+ 24 V

System Supervisor

PLC/BMS board

Modbus

BUS

III

1000

F
1
3

SPF

123

L
1

BUS

Cascade Manager

- System Supervisor

CanBUS

- Cascade Manager

PLC/BMS board

SLAVE 1

SLAVE 2

MASTER

Modbus

Change-over

in II position

I = Comunication

by MODBUS

II = Comunication

by E8

Position II

back

Instructions for the installer

Connection for boilers in a cascade arrangement connected to an external BCM and managed by PLC/BMS
(E8 disconnected).

WARNING!
In this connection the E8 heating controller
has to be disconnected from the eBUS on
the BCM board.

- Cascade Manager
- System Monitor

BCM board

eBUS

Modbus

- System Manager
- System Supervisor

PLC/BMS board

Modbus

2 3 4

BCM

(Pos 0)

2 3 4

BCM

(Pos 1)

2 3 4

BCM

(Pos 2)

The applications in a cascade arrangement
managed with an additional BCM or controlled
via Modbus also require the correct boiler
address setting within the cascade formation
via the BCM's internal SWI selector: 0....7, all
different and in sequence, exactly as
requested by the single burner modules.

Jp1

DL
1
D

2
DL
3

SW
1

eBUS remoto

BC
M

eBUS -

eBUS +

+ 24 V

eBUS

Modbus

- System Manager
- System Supervisor

PLC/BMS board

Modbus

- Cascade Manager

- System Monitor

- System Manager
- System Supervisor

BCM board

eBUS remoto

Change-over

in I position

I = Comunication

by MODBUS

II = Comunication

by E8

Position I

back

Instructions for the installer

Connection for boilers in a cascade arrangement managed by an external PLC (E8 disconnected)

WARNING!
In this connection the E8 heating controller
has to be disconnected from the eBUS on
the BCM board.

1 for each multiple boiler formation

- System Supervisor

- Cascade Manager

PLC/BMS board

Modbus

Jp1

DL
1
D

2
DL
3

SW
1

Modbus - B
Modbus - A

BC
M

eBUS -

eBUS +

+ 24 V

System Supervisor

PLC/BMS board

Modbus

Cascade Manager

Change-over

in I position

I = Comunication

by MODBUS

II = Comunication

by E8

Position I

back

Instructions for the installer

The BCM board monitors the data of the thermal head (Dt

between primary flow and return and supplied

heat

output). When the supplied heat output diminishes,

the

number of the pump's revolutions decreases and
subsequently the hourly rate, maintaining the thermal head
practically constant

, thus obtaining a higher efficiency in

condensing mode and reducing energy costs.

3.26 - CONFIGURATION WITH A:

The 0-10 Volt modulation signal is preset to:

-3 for minimum speed
-10 Volt for maximum speed
These values can be changed according
to the type of pump fitted. For further
information on the 0-10 Volt signal, please
also refer to the pump manual.

MODULATING PUMP

ON-OFF PUMP

MODULATING PUMP

Jp1

DL1 DL2

DL3

SW1

PUMP

BCM

+ 2

4

V

POWER TERMINALS E8

Mains supply

230 V - 50 Hz

RELAY

Mains supply

230 V - 50 Hz

Jp1

DL1 DL2

DL3

SW1

BCM

TERMINALS 0-10 V

INTERFACE

WILO MODULATING PUMP

(-)

1
0
V

)

Supply

Modulating

Pump

APM

ARM

Mains supply

230 V -50 Hz

back

Instructions for the installer

3.27 -

FILLING THE SYSTEM

Warning!

Always mix the CH system water with anti-

freeze or anti-corrosion solutions using the

correct concentration! Failure to do so could

cause damage to the washers and create

noise during normal boiler operation.

Ideal Boilers refuses all liability for injury to

persons, animals or damage to property

resulting from not following the above

mentioned recommendations.

The system itself shall be equipped with its own drain tap,
whose size depends on the system capacity. The

fitting

of a filter on the return pipe to the boiler is advisable.

back

Instructions for the installer

Follow this procedure also for the other

burners

If the CO

percentage is too low, check if the air and

flue

ducts are not obstructed. If they are not obstructed, check if the
burner and/or the exchanger (aluminium sections) are well
cleaned.

MINIMUM OUTPUT ADJUSTMENT

Force the desired burner

to be working at minimum

output (CASCADE MAN 10%)

Check that the C0

values are within the values indicated

in the table "Burner pressures"

If necessary correct the value by turning the

adjustment screw "B" in a CLOCKWISE direction to

increase the value and in an ANTICLOCKWISE

direction in order to decrease it.

MAXIMUM OUTPUT ADJUSTMENT

Remove the cap of the combustion gases sampling point

Connect a suitable C0

gas analyser to the sampling point

in the flue outlet terminal.

Force the desired burner

to be working at nominal output

(CASCADE MAN 100%)

Check that the C0

values are within the values indicated

in the table "Burner pressures"

If necessary correct the value by turning the adjustment
screw "A" in a CLOCKWISE direction to decrease the

value and in an ANTICLOCKWISE direction in order to

increase it.

Flue sampling point

3.28 -

BURNER ADJUSTMENT

WARNING!
All the instructions indicated below are for the

exclusive use of qualified Ideal Boilers

service technicians or installers.

All the boilers are supplied already calibrated

and tested.

MAXIMUM OUTPUT

ADJUSTMENT SCREW

MINIMUM OUTPUT

ADJUSTMENT

SCREW

back

Instructions for the installer

Check the C0

levels often, especially at low flow rate

INJECTORS PRESSURES

levels (%)

Gas type

Supply

pressure

(mbar)

Starting

power

(%)

Injectors

( m m )

Fan speed

Diaphragm

COMPLETION OF THE BASIC
ADJUSTMENTS

Check the C0

values at the minimum and maximum outlet