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BOILER PUMP KITINSTRUCTIONS
IMAX XTRA EL
When replacing any part on this appliance, use only spare parts that you can beassured 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.
October 2016UIN 213987 A02
2 BOILER PUMP KIT - INSTRUCTIONS
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C DG H
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KIT CONTENTS
A. Stratos 80 Pump - 1 off (c/wflangegaskets&insulation)B. IFModule-1offC. M16x65Bolts-8offD. M16 Nuts - 8 offE. PumpControlLeadSet-1offF. 230VRelay-1offG. M3 Nuts - 2 offH. M3Washer-2offJ. InstallationInstructions-1off
ThisBoilerPumpKitissuitableforthefollowingboilerslisted:
IMAX XTRA EL RANGE
TheBoilerPumpKitshouldbefittedontothereturnflangeoftheboiler.Ideallyitwouldbefittedinconjunctionwithalowlossheaderorheatexchanger,toprovidehydronicseparationoftheboilertothesystem.
These instructions must be read in conjunction with the Installation & Servicing Instructions supplied with the boiler.
ThehydraulicresistanceandnominalflowsfortheboilerrangearegivenintheInstallationManualandshouldbelookedatwhenspecifyingapump.Atableshowingtheavailableheadatnominalflowareshownbelowforeachboilerintherange
Themanufacturer'sinstructionsareprovidedandshouldbereadfullytounderstandtheoperationofthepump.Thepumpshouldbefittedtothereturnmanifoldusingtheflangegaskets,boltsandnutsprovided.
Boiler Size320 395 470 545 620
AvailableHead(m) 1.2 1.6 2.1 3.1 4NominalFlow(m3/h) 13.8 17.0 20.2 23.5 26.7
3BOILER PUMP KIT - INSTRUCTIONS
These instructions must be read in conjunction with the Installation & Servicing Instructions supplied with the boiler.
INSTALLING THE IF MODULE
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INSTALLINGToensureimmunityinindustrialenvironments(EN61000-6-2)thedataandcontrolcablesmustbeshieldedcablesandmustbeusedwithanEMCcompliantcablegland(includedwiththemodule).
WARNING!Dangerofelectricshock!
Thepumpshouldbeelectricallyisolatedandsecuredagainstunauthorisedswitch-onbeforebeginninginstallationoftheIF-Module.
InstallationstepsinaccordancewithDiagramabove:• Removethelidofthepump'sterminalbox• Removethecover(1)• InstalltheIF-Moduleinthepump'sterminalbox(2)• Pushtheconnectionpluginalltheway(3)• RemovetheexistingPG9screwedconnections(4a)• InstalltheaccompanyingmetalEMCcableglands(4b)• Stripandpreparetheshieldandthecorewires(4c)• Insertthecable(4d)• Screwthecableglandintoplace(4e)
ELECTRICAL CONNECTIONWARNING!Dangerofelectricshock!
Electrical connection must be carried out by an electrician authorised by the local electricity supply company and in accordance with the applicable Wiring Regulations, BS7671.
• Carryoutinstallationasdescribedintheprevioussection.• Carryoutelectricalinstallationofthepumpasspecifiedin
therelevantinstallationandoperatinginstructions.• Theelectricalconnectionmustbeestablishedviaafixed
powercable(3x1.5mm2minimalcross-section),equippedwithaplugandsocketconnectororanall-poleswitchwithaminimumcontactopeningwidthof3mm.
• Thefollowingminimumrequirementsaretobemetifshutdowntakesplacebymeansofanonsitenetworkrelay:nominalcurrent≥10A,nominalvoltage250VAC.
• Fuseprotection:10/16A,slow-bloworautomaticfusewithCcharacteristic.
• CheckthetechnicalspecificationsoftheelectriccircuitsbeingconnectedtoensuretheyarecompatiblewiththeelectricalspecificationsoftheIF-ModuleTerminalnumberingasshowninPos.(3)frombottomtotop.
IF-MODULE Stratos Ext. Off
TerminalNo. Terminal*1 Ext.Off*2 Ext.Off3 0-10V4 GND(for0-10V5 DP6 DP
*Removelinkandconnectcontrolcablewireshere.• CheckthattheExt.Offwiresarefreeofinterferencevoltage.
FINAL WORK - ALL MODULES• Checktheterminalboxsealforanyvisibledamage.• Closetheterminalboxlidwiththescrewsprovidedsothat
thesealistightallaround.• Carryoutcommissioning/functionaltestinaccordancewith
thefollowingsection.
COMMISSIONINGThefollowingsectiondescribestestingthefunctioningoftheinputs/outputs.Itisrecommendedtotesttogetherwiththeconnectedsystem.Thepump'sinstallationandoperatinginstructionsareneededforsomesettings.
EXT. OFF INPUT• ContactviaExt.Offterminalsisclosed.• Switchonthepumpviathemenu:symbolfor“On”appears.• ContactviaExt.Offterminalsisopened:pumpswitchesoff,
symboldisappears.
Ideal Boilers Ltd., P.O.Box103,NationalAve,KingstonuponHull,HU54JN.Telephone:01482492251Fax:01482448858.RegistrationNo.London322137.
Technical Training
Ideal Boilers Ltd.pursuesapolicyofcontinuingimprovementinthedesignandperformanceofitsproducts.Therightisthereforereservedtovaryspecificationwithoutnotice.
TheIdealBoilersTechnicalTrainingCentreoffersaseriesoffirstclasstrainingcoursesfordomestic,commercialandindustrialheatinginstallers,engineersandsystemspecifiers.Fordetailsofcoursespleasering:................................ 01482498432
Ideal Installer/Technical Helpline: 01482 498 376www.idealcommercialboilers.com
PUMP KIT INSTALLATIONOncompletionofinstallingtheIFmoduleontothepump,takethePumpControlLeadandinstallintothecontrolboxontheRH,frontuppersideoftheboiler.
1. ToaccesscontrolsboxonRHside,removeboilerpanels.RefertoInstallationInstructions
2. MounttherelayontotheleftmostM3studsandsecureusingthetwowashersandnutsprovided.
3. RemovethepumpconnectionfromtheburnercontrolPCBandreplacewiththeconnectoronthepumpcontrollead.
4. RemovethepluglocatedinthePWMinstallerconnection.Placethistoonesideasitwillbeusedlater.UnclipthePWMinstallerconnectorfromthefrontpanelinstallerconnectionarea
5. Replacewiththeconnectoronthepumpcontrollead.
6. Usingasuitable2corecable,asspecifiedfortheIFmodule,connectthepumpcontrolcablebetweentheIFmoduleandthepumpcontrolplug,routingthecableconnectorthroughtheSELVconduitfromthebackoftheboilerandsecuringattheboilerwiththecableclamps.
7. Powerupthepumpandfollowthecommissioninginstructions.
8. Finallypluginthepumpcontrolplugintotheinstallerpumpcontrolconnection,labelled"PumpPWM".
9. Checkthatthepumpstartswhentheboilerpumpsignalison.
10.Replaceandsecureallboilerpanelsinreverseorder.