Ideal Heating IMAX XTRA 2 User manual

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 Heating.
For the very latest copy of literature for specification and maintenance practices visit our website idealheating.com
where you can download the relevant information in PDF format.
Sep 2021
UIN 228011 A02
CONVERSION KIT
NATURAL GAS TO
PROPANE
IMAX XTRA 2
80 120 160 200 240
HEATING

2
Conversion Kit
INTRODUCTION
The kits can be applied to the boilers as per the table below.
Current Gas Safety (Installation & Use) Regulations or rules in force MUST be adhered to. It is law that
all gas appliances are installed and serviced by a Gas Safe Registered Installer or in IE a competent person,
in accordance with the regulations. 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.
kW (NG) Product No.
Imax Xtra 2 80 225464
Imax Xtra 2 120 225465
Imax Xtra 2 160 225466
Imax Xtra 2 200 225467
Imax Xtra 2 240 225468
WARNING
ALWAYS TURN OFF THE GAS SUPPLY AT THE GAS SERVICE
COCK, AND SWITCH OFF AND DISCONNECT THE ELECTRICITY
SUPPLY TO THE APPLIANCE AND ANY EXTERNAL CONTROLS
BEFORE SERVICING OR REPLACING COMPONENTS.
NOTE: Boilers that have CAT. II included on the boiler data badge can be converted from
natural gas to propane and vice versa using a model specic conversion kit.
Boilers that show CAT. I on the data badge cannot be converted.
NOTE: Screen displays shown in this manual are correct at date of issue. Software updates
installed after the date of issue may result in minor changes to screen displays.
2H3P

3
Conversion Kit
KIT CONTENTS
LEGEND
A. 4 o󰀨 - M5 x15 mm bolts
B. Self adhesive propane data plate
C. Orice plate seal
D. Orice plate (see table)
E. Overlay label
F. O-ring
G. Flue Adaptor (200 kW only)
THIS BOILER HAS BEEN
CONVERTED TO PROPANE
PLACE ONE TEAR OFF LABEL OVER THE LABEL ON THE REAR OF THE BOILERAND ONE OVER THE LABEL ON THE LITERATURE
RECORD THE ORIGINAL BOILER DETAILS
EXAMPLE: VR 22546400000001
PLACE THIS LABEL OVER THE EXISTING
NATURALGAS DATAPLATE LABEL
DATE CONVERTED
80KW LPG IMAX XTRA 2 80KW LPG IMAX XTRA 2
80 kW 9 mm
120 kW 9 mm
160 kW 10 mm
200 kW 11.5 mm
240 kW 12 mm
A
E
B
F
C
G
D
SAFETY
80 kW shown
200 kW only
MAX. FLOW TEMPERATURE 90`C
kW (Btu/h)
I.P.20
NOX CLASS 6
24.0 (81,900)
23.1(78,781)
kW (Btu/h)
BOILER TYPE:C 53 C 63 B 23
76.9(262,263)
MAX
24.2(82,533)
NON-COND'G
BOILER TO BE INSTALLED
MADE IN THE UK BY IDEAL BOILERS LTD.
kW (Btu/h)
26.1(89,012)
HEAT OUTPUT "P" =
MIN
HEAT INPUT "Q" =
COUNTRIES OF DESTINATION: GB, IE
NET
OPERATING WATER PRESSURE
PMS = 6.0 bar MAX, 0.3 bar MIN
0086 21
CAT.II 2H3P PROPANE
230V 50HZ FUSED AT 13A
3P-G31-37mbar
MIN
80.5(274,836)
POWER CONSUMPTION 110W
87.0(296,708)
MAX
kW (Btu/h)
GROSS
80.0(272,950)
CONDENSING
80kW IMAX XTRA 2
*AGA23036000000001XXXX*
FOR PROPANE ONLY
WITH A GOVERNED METER
GAS SUPPLY PRESSURE 37mbar
PO BOX 103, NATIONAL AVENUE, HULL,
EAST YORKSHIRE, HU5 4JN
IMPORTANT
After completing the servicing or replacement of components always:
• Test for gas soundness.
• Check the water system is correctly lled and free of air. Air in the boiler
could cause damage to the heat exchanger.
•With the system hot examine all water connections for soundness.
• Check the gas rate and measure the combustion CO/CO2content. The
CO/CO2 ratio of the ue gas should not be greater than 0.004 ratio & the
CO should not exceed 350ppm.
• Carry out functional checks as appropriate.
It is the law that any service work must be
carried out by a Suitably qualied Gas Safe
Registered Engineer. In IE service work
must be carried out by a competent person.
WARNING
ALWAYS TURN OFF THE GAS SUPPLY
AT THE GAS SERVICE COCK, AND
SWITCH OFF AND DISCONNECT
THE ELECTRICITY SUPPLY TO THE
APPLIANCE AND ANY EXTERNAL
CONTROLS BEFORE SERVICING OR
REPLACING COMPONENTS.

4
Conversion Kit
CASING REMOVAL AND ACCESS
Side Panels
4. On the side panel, undo the two screws at the rear and
two at the front.
Lift from the frame and remove.
Top Panel
1. Remove the two bolts at the rear of the top panel. Lift up
from side panel retention studs and remove.
Front Panel
3. Remove the 3 bolts along the top of the front panel. The
bolts are visible when the control pod is removed. Pull
the panel forwards at the top, lift out of bottom slot and
remove.
Control Pod
2. Remove the bolt at the rear of the control pod.
Disconnect the electrical harnesses from the rear.
Lift the pod up and remove.
CONTROL POD
REMOVAL
DETAIL C
SCALE 1:5
CONTROL POD
REMOVAL (SCREW)
DETAIL
B
SCALE
1:5
SECTION 3.7
REMOVAL AND ACCESS
SECTION 3.8
FAN REMOVAL

5
Conversion Kit
1. Whilst supporting the gas valve, remove the four bolts
securing the gas valve to the venturi.
2. Insert the gasket and orice plate in the order as shown
in the exploded view above. Replace the existing O-ring
on the gas valve side with the new O-ring supplied in the
conversion kit and ensure it is secure.
3. The orice plate should be orientated so that the etching
on the plate is facing the venturi and is visible . See views
below for correct orientation.
4. Replace the four bolts that have been removed with the
four new M5 x 15mm bolts supplied in the conversion kit.
Ensure an even tightening sequence of the bolts.
INSTALLING THE ORIFICE PLATE
Gasket
Orice plate
Gas valve
Venturi
O-ring Bolts
MODELS: 80 kW & 120 kW MODELS: 160 kW, 200 kW & 240 kW
Etching on top
Etching this side
Orientation of Orice Plate

6
Conversion Kit
1. Remove the existing ue condensate collector from its
location in the boiler ue outlet as shown in the image
above.
2. Once the condensate collector has been removed, insert
the ue adaptor into the ue outlet ensuring that it is pushed
past the lip seal inside the ue outlet and sits on top of the
supports that are part of the casting.
3. The ue adaptor has a cutaway which needs to be
orientated to the rear of the boiler for clearance against the
elbow of the ue outlet as shown in the image below.
4. Ensure that the lip seal is in place within the groove on the
ue outlet and adjust where necessary before reinstalling
the ue condensate collector.
Condensate
collector
Flue
adaptor
Cutaway
Flue outlet
elbow
INSTALLING THE FLUE ADAPTOR (200 kW BOILER ONLY)

7
Conversion Kit
> 3
seconds
Quick
start
After loading the settings
the User Menu will appear NEXT
Config
Config Menu
Yes
Select the boiler type then press NEXT
Select the boiler size from the list using
the up/down arrows then press SELECT
No
Boiler Conversion
Proceed
MENU
CONFIRM
NEXT
LOADING THE PROPANE PARAMETERS
Imax Xtra 2 280kW assisted commissioning process
Main Board Firmware V1.0 Display Firmware V1.0
MENU
Switched Live Control
Burner Stabilisation
HeatingHot Water
ACTUALTARGET
75°75°
ACTUALTARGET
75°75°
Demand OnNo Demand
100%8°
NEXT
No Yes
Boiler Conversion
Gas Type
NEXTNEXTNEXT
Natural Gas ANZ
LPG
Natural Gas
Boiler Setup
Assisted Quick Start
NEXT
Boiler/System Pump:
CH1 Pump:
DHW/CH2 Pump:
CH2 Pump:
CH2 Valve:
Boiler Pump
CH1 Pump
DHW Pump
CH2 Pump
CH2 Valve
Configuration List
Menu
Status Settings
Configuration
Service
Access Level
NEXT
No Yes
Restore Current Configuration
NEXT
Configuration Diagram
View Config Flow Temperature
Boiler Conversion Factory Reset
Configuration
PROCEEDCANCEL
Performing this action will cause all the
configuration settings to be deleted!
Are you sure?
Gas Type
Boiler Power
Set
LPG
80kW
20
Gas Type
NEXTNEXTCONFIRM
NEXT
Boiler Power
80kW
Steps to follow for boiler with no initial conguration
This is when the Imax boiler has been installed into a facility with the LPG i.e. the Imax will be run on LPG immediately following
initial commission.

8
Conversion Kit
MENU
Switched Live Control
Burner Stabilisation
HeatingHot Water
ACTUALTARGET
75°75°
ACTUALTARGET
75°75°
Demand OnNo Demand
100%8°
NEXT
No Yes
Boiler Conversion
Gas Type
NEXTNEXTNEXT
Natural Gas ANZ
LPG
Natural Gas
Menu
Status Settings
Configuration
Service
Access Level
View Config Flow Temperature
Boiler Conversion Factory Reset
Configuration
NEXT
No Yes
Restore Current Configuration
PROCEEDCANCEL
Performing this action will reconfigure
using current configuration settings.
Are you sure?
NEXT
Boiler Power
80kW
Gas Type
Boiler Power
Set
LPG
80kW
20
Gas Type
NEXTNEXTCONFIRM
Yes Yes
Config
User Menu
Select the boiler type then press NEXT
Boiler Conversion
Select the boiler size from the list using
the up/down arrows then press SELECT
Proceed
MENU
CONFIRM
1. Refer to safety section.
2. Enter service mode using access code 529. Please refer to
the Installation & Servicing manual for further information
on this.
3. Follow the steps below to upload the parameters for
propane.
Steps to follow for boiler that has been previously congured
This is when the Imax boiler has been installed and congured i.e. converted from a congured NG boiler to a LPG boiler.

9
Conversion Kit
GAS VALVE ADJUSTMENT
Maximum rate adjustment
1. Switch the boiler on and set the boiler into service mode
maximum which will last for 10 mins but can be exited
earlier.
2. To ensure the boiler operates at maximum rate without
modulating, set the fan speed to maximum following the
steps in the gas valve adjustment diagram on the next page.
3. Using the maximum rate adjustment screw adjust the valve
until the CO2 valve measures 10.8% (Note:- clockwise
reduces the CO2).
Minimum rate adjustment
4. To ensure the boiler operates at minimum rate without
modulating, set the fan speed to minimum following the
steps in the gas valve adjustment diagram on the next page.
5. Using the minimum rate adjustment screw adjust the valve
until the CO2 valve measures 10.0% (Note:- Anticlockwise
reduces the CO2).
6. Reset the boiler back to maximum rate and measure the
CO2.
If this does not measure 10.8% ± 0.2% repeat steps 3 to 5 above. Press the Home button to return to the Home screen. Seal the
adjustment screw with tamper proof paint and replace caps where applicable.
MODELS: 160 kW, 200 kW & 240 kW
Maximum rate adjustment screw
Minimum rate adjustment screw
(Remove cap for access)
Maximum rate adjustment screw
(Remove cap for access)
MODELS: 80 kW & 120 kW
Minimum rate adjustment screw
(Remove cap for access)

10
Conversion Kit
ACCESSING SERVICE MODE FOR GAS VALVE ADJUSTMENT
MENU
Switched Live Control
Burner Stabilisation
HeatingHot Water
ACTUALTARGET
75°75°
ACTUALTARGET
75°75°
Demand OnNo Demand
100%8°
Menu
Status Settings
Configuration
Service
Access Level
Maximum Rate
Target Fan Speed
Actual Fan Speed
Time Remaining
Flow Temperature
Return Temperature
Flame Current
6800 rpm
6800 rpm
10 Minutes
75°c
60°c
5.7µA
MIN RATE
Minimum Rate
Target Fan Speed
Actual Fan Speed
Time Remaining
Flow Temperature
Return Temperature
Flame Current
6800 rpm
6800 rpm
10 Minutes
75°c
60°c
5.7µA
MAX RATE
To set the boiler to run at
Maximum Rate for 10 Minutes
press Maximum Rate
The boiler will run at Maximum Rate for
10 minutes unless the system load is
insufficent
The boiler will automatically move back
to normal operation after 10 minutes
To move directly to Minimum Rate
press MIN RATE
The boiler will run at Minimum Rate for
10 minutes unless the system load is
insufficent
The boiler will automatically move back
to normal operation after 10 minutes
To move directly to Maximum Rate
press MAX RATE
To set the boiler to run at
Minimum Rate for 10 Minutes
press Minimum Rate
Press MENU
Press Service

11
Conversion Kit
PROPANE DATA LABEL AND OVERLAY
1. Ensure that the boiler has had the correct orice plate tted
and the parameters have been updated for Propane.
2. The boiler front panel will need to have been removed to
expose the location where the labels are to be a󰀩xed.
3. Record the date the boiler is being converted to Propane
onto the Overlay label that is provided in the kit.
4. Record the original boiler serial number (located on the
Natural Gas Data Label) onto the Overlay label and the two
tear o󰀨 strips.
5. Once all details have been recorded, adhere one of the two
tear o󰀨 strips over the existing label at the rear of the boiler
and the other one over the existing label on the cover of the
installation manual.
6. Adhere the Overlay label over the existing Natural Gas data
label located at the front of the boiler as shown below.
7. Adhere the Propane data plate label that is provided in the
kit next to the Overlay label as shown below.
Overlay label a󰀩xed here
over existing Natural Gas
data label
Propane data plate
label a󰀩xed here next
to Overlay label Existing Master
Barcode label
Typical view looking at the front of all boilers (front panel removed)

Technical Training
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For details please contact:
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Ideal is a trademark of Ideal Boilers.
Registered Office
Ideal Boilers Ltd., National Avenue, Hull, East Yorkshire, HU5 4JB
Tel [phone] Fax [phone]
Registration No. London 322 137
Ideal Commercial Technical Helpline: 01482 498376
Ideal Parts: 01482 498665
idealheating.com
Ideal Boilers Ltd., pursues a policy of continuing improvement in the design and performance of its products.
The right is therefore reserved to vary specification without notice.
HEATING
At Ideal Heating we take our environmental impact seriously, therefore when installing any Ideal Heating product please make sure to dispose of any
previous appliance in an environmentally conscious manner. Households can contact their local authority to find out how.
See https://www.gov.uk/managing-your-waste-an-overview for guidance on how to efficiently recycle your business waste.
Manufactured under
an ISO 9001
registered quality
management system
FM 59915
WEEE DIRECTIVE 2012/19/EU
Waste Electrical and Electronic Equipment Directive
• At the end of the product life, dispose of the
packaging
and product in a corresponding recycle centre.
• Do not dispose of the unit with the usual domestic refuse.
• Do not burn the product.
• Remove the batteries.
• Dispose of the batteries according to the local statutory
requirements and not with the usual domestic refuse.