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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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.