IDEAL Evomax 30 Installation & Servicing Manual

Evomax condensing boilers

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Page 1 Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
Page 2 (MJ/m these Installation and Servicing Instructions or as otherwise recommended by Ideal Stelrad Group in writing. If in doubt b. For ft/h divide the gross heat input (Btu/h) by the gross C.V. of the gas (Btu/ft please enquire.
Page 3 GEnERAL EVomAX ContEntS 30, 40, 60, 80, 100, 120, & 150 boiler Assembly - Exploded view........9 30P, 40P, 60P & 80P boiler Clearances..............7 Commissioning and testing...........40 Natural Gas & LPG Electrical Connections............25 Destination Countries: GB, IE Electrical Supply..............6 fault finding.
Page 4: Safe Handling
GEnERAL IntRoDuCtIon The Evomax boilers have been tested and certified to; The EVOMAX boilers are fully automatically controlled, wall EN 483, EN 677, PREN 15420, BSEN 15417, BSEN 656, BSEN mounted, fanned, super efficient condensing appliances. 60335-2-102, BSEN 55014-1 and BSEN 55014-2 for use with The EVOMAX condensing boilers can be installed either on the Natural Gas &...
Page 5: Location Of Boiler
If this should occur the appliance MUST be turned OFF, labelled equipment or on a boiler frame supplied in kit form by Ideal as ‘unsafe’ and corrective action taken. Stelrad Group.
Page 6: Electrical Supply
Guidance Notes on Water Treatment in Central Heating Systems. Ideal Stelrad Group recommend the use of Fernox Copal or MB1 or GE Betz Sentinel X100 inhibitors and associated water treatment products, which must be used in accordance with the manufacturers’...
Page 7: Boiler Clearances
Above boiler - dependent upon the flue system see drawings Below boiler - 300mm Clearance between multiple boiler installations - 25mm 80/125 Concentric Flue Connector 100/150 Concentric Flue Connector EVOMAX 30, 40, 60 & 80 EVOMAX 100, 120 & 150 Minimum boiler top clearances: Minimum boiler top clearances: for vertical flue 200mm...
Page 8 MUST comply with the pump manufacturer’s minimum Feed requirements, to avoid cavitation. Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Ideal Stelrad Group. System System flow to...
Page 9 InStALLAtIon boILER ASSEmbLy - Exploded View 206210-10387 Evomax 80 shown Auto Air Vent Dry Fire Thermistor Kit Fascia Plastic Burner Fixings Kit Lead Ignition Kit HMI Board Ignitor Unit Primary PCB Gas Valve Kit Electrode Detection Kit Jacket Assembly Evomax Kit Venturi 30kW Kit Ignition Electrode Kit Door Assembly Evomax Kit...
Page 10 InStALLAtIon PACkAGInG REmoVAL • Check the contents against the list in Frame 6 ‘Unpacking’. • The boiler should be laying on its back with the straps Note: some items are contained within the top packing removed. piece. • Carefully read the installation instructions before proceeding. •...
Page 11: Wall Mounting Template
InStALLAtIon WALL mountInG tEmPLAtE note: Horizontal flue runs must be inclined at 1.5-3 to the horizontal to allow note. The template shows the positions for the condensate to drain back to the boiler. top fixing holes. Care must be taken to ensure the correct holes are drilled.
Page 12: Mounting The Boiler
InStALLAtIon mountInG tHE boILER • Due care should be taken when lifting the boilers, with respect to their weights, see Table 2 on Page 2. Also refer to Safe Handling on Page 4. 1. Lift the boiler onto the wall mounting plate as shown.
Page 13: Flue Systems
Multiple boilers may be installed with a common flue header not available for Evomax 150. (not supplied by Ideal Heating). The flue system should be For vertical flue: this is the distance from the top of the boiler designed and supplied by a specialist flue company. BS 6644 case to the aperture in the weather collar.
Page 14 InStALLAtIon 14 VERtICAL Roof fLuE kIt Evomax vertical concentric flue application ~ maximum lengths and pressure differentials Model 30/30P 40/40P 60/60P 80/80P Max flue length (m) 17.6 Max flue press diff (Pa) Flue Size 80 / 125 100 / 150 Vertical flue kit No 158654 158656 Contents • Boiler adapter + screws (x6) •...
Page 15 InStALLAtIon 17 fLuE kIt ACCESSoRIES Accessory Part no. 80/125 100/150 elbow (concentric) 152616 152617 elbow (concentric) 152618 152619 elbow 158773 158774 elbow (pair) 158775 158776 Flat Weather Collar 152611 152612 158780 158780 Pitched Weather Collar 152609 152610 158779 158779 1m Extension (concentric) 152400 152401 1m Extension (pair)
Page 16: Concentric Flue Systems
InStALLAtIon 18 fLuE RESIStAnCES ConCEntRIC fLuE SyStEmS For concentric flue systems with elbows fitted, use the table to correct the maximum flue extension capability. Alternatively use the table to design the flue system, deducting the individual resistance of components from the maximum pressure drop allowed in the flue for that boiler.
Page 17 InStALLAtIon 19 EXAMPlES OF CAlCUlATING FlUE RESISTANCES/lENGTHS - EXAMPlE 1 Example 1 Horizontal Flue for Evomax 40 Resistance (Pa) Resistance (m) Flue Size 80/125 80/125 Horizontal Wall Flue Kit 80/125 2 x 1m extension flue 2 x (4.8) 2 x (1) 1 x 90º elbow Total Flue Resistance 68.6 10.6 The total maximum flue resistance for an Evomax 40 is 200Pa or 42m...
Page 18 5 x 1 2 x 45º elbow 2 x 0.6 Total Flue Resistance The maximum flue extension for an Evomax 30 on open flue is 65m. Therefore this installation is acceptable. 22 EXAMPlES OF CAlCUlATING FlUE RESISTANCES/lENGTHS - EXAMPlE 4 Example 4 Horizontal Flue for Evomax 120...
Page 19 InStALLAtIon 23 ASSEmbLInG tHE fLuE Flue terminals or extension ducts may be cut to shorter lengths Care must be taken when assembling flues, not to damage if required. When cutting a duct ensure it is square by marking the seals. the length all the way around and only cut back the plain end.
Page 20 InStALLAtIon 24 fLuE tERmInAtIon PoSItIon Due to the high efficiency of these boilers pluming will occur. For this reason vertical termination is recommended, and in any case, terminal positions which could cause problems should where possible be avoided. Particular care should be taken in the case of large multiple boiler installations, and complying with the requirements of the Clean Air Act.
Page 21 InStALLAtIon 25 boILER fRAmE AnD HEADER kItS Heat output to a maximum of 600kW can be achieved by cascading up to six Evomax boilers. This can be achieved by the use of Evomax multiple boiler Frame & Header Option Kits. Boilers can be fitted either side by side or back to back using Frame &...
Page 22: Condensate Drain
InStALLAtIon 26 SEquEnCER ContRoL of muLtIPLE boILERS Legend In installations where the heat load is greater than the boiler capacity an ideal solution is to use multiple boiler 1. Non-return valve 7. Flue gas terminal arrangements. 2. Safety valve 8. Drain cock 3.
Page 23 InStALLAtIon 28 ConDEnSAtE PIPE tERmInAtIon ConfIGuRAtIonS Notes: ALL EXTERNAL PIPE RUNS MUST BE IN ACCORDANCE WITH BS 6798 1. IntERnAL to SInk WAStE uPStREAm of SInk WAStE tRAP BOILER Open end of pipe direct into gulley below grating but above water level cla7771a Ground Level DRAIN...
Page 24: Boiler Water Connections
InStALLAtIon 29 boILER WAtER ConnECtIonS The boiler flow and return pipes are terminated with a 1 ” BSP male taper connection located at the bottom of the appliance. note. This appliance is NOT suitable for use with a direct hot water cylinder. Plastic plugs fitted into the open ends of the flow and return pipes must be removed before connecting the system pipework.
Page 25: Electrical Connections
InStALLAtIon 32 ELECtRICAL ConnECtIonS Warning. This appliance MUST be efficiently earthed. switch, having a 3mm (1/8”) contact separation in both poles, or a plug and unswitched socket serving only the boiler and A mains supply of 230V 50Hz is required. The supply wiring system controls.
Page 26 InStALLAtIon 34 InStALLER ConnECtIonS EVOMAX - Installation & Servicing...
Page 27 InStALLAtIon 35 IntERnAL WIRInG EVOMAX - Installation & Servicing...
Page 28 InStALLAtIon 36 bASIC ContRoLS DISPLAy EVomAX uSER IntERfACE Ideal mains on When the mains to the boiler is switched on a screen similar to the following will be displayed The designation at the end of the bottom line indicates whether the boiler is suitable for Natural Gas...
Page 29 InStALLAtIon 37 bASIC ContRoLS DISPLAy ContInuED..Central Heating mode Central Heating Central Heating If there is an ongoing Central Heating Demand screens similar to CH Switched Live On Burner Power 100% the following will be displayed Burner On Outside Temp’ 10°C Line 2 indicates whether Switched Live or OpenTherm is controlling Flow Setpoint...
Page 30 Press SELECT and a screen similar to the following will be displayed The kW output number in the 1st line will vary depending the Ideal Evomax 80kW maximum output of the boiler Ideal Evomax 80kW normal operation Set Flow Temp’...
Page 31 The kW output number in the 1st line will vary depending the maximum The kW output number in the 1st line will vary depending the output of the boiler maximum output of the boiler Ideal Evomax 80kW Ideal Evomax 80kW normal operation Set Flow Temp’...
Page 32 InStALLAtIon 40 EVomAX uSER IntERfACE - ADVAnCED oPERAtInG InStRuCtIonS SEttInG to 0-10V Press SELECT and then hold + and - down together for more than 5s, the following screen will be displayed Installer Mode normal operation Set Flow Temp’ Set DHW Temp’ Rotate the KNOB clockwise until the following screen is displayed Installer Mode Show Hours Run...
Page 33 InStALLAtIon 41 EVomAX uSER IntERfACE - ADVAnCED oPERAtInG InStRuCtIonS ContInuED..EnAbLInG nIGHt SEtbACk Note- Booster Function is only operational if Outside Sensor has Note- Night Setback is only operational if Outside Sensor has been connected been connected When Night Setback is enabled the boiler will run at the normal flow temp. If Booster function is enabled and CH Demand is ongoing for more during CH Demand and reduced temperature when for no demand than 10 minutes then the Flow Temp.
Page 34 InStALLAtIon 42 EVomAX uSER IntERfACE - ADVAnCED oPERAtInG InStRuCtIonS CHAnGInG tHE mAXImum fLoW tEmPERAtuRE SEtPoInt CHAnGInG tHE SyStEm fRoSt PRotECtIon tEmP. SEtPoInt Boiler default setting is that maximum flow temperature setpoint is 80°C Note that System Frost Protection Function is only operational if an This feature limits the maximum flow temperature that can be set in the Outside Sensor has been connected Basic Operating Mode...
Page 35 SELECT to return to normal operation Thermostat providing a 230V input to the DHW Switched Live Instead a DHW Thermistor, available as a kit from Ideal, can be CHAnGInG tHE AntI-LEGIonELLA tEmPERAtuRE connected to the DHW Thermistor input Note Anti-Legionella Temp.
Page 36 InStALLAtIon 44 EVomAX uSER IntERfACE - ADVAnCED oPERAtInG InStRuCtIonS ContInuED..DISAbLInG tHE AntI-LEGIonELLA funCtIon CHAnGInG tHE VoLt fREE buRnER on RELAy to oPERAtE AS An LPG RELAy foR bELoW GRounD LEVEL LPG Note that the Anti-Legionella Temperature Function is only APPLICAtIonS operational if a Domestic Hot Water Thermistor has been connected Care should be taken in disabling this function as an unsafe condition...
Page 37 Note that a hydraulic bypass is required to allow pump overrun. Note that the boiler can use an Outside Sensor, which is available from ideal Note that a Frost Stat can be as a Weather Compensation Kit. In connected into CH call.
Page 38 To heat more Note 1. The boiler can use an Outside than one zone simultaneously use Sensor, which is available from Ideal zone thermostats to energise individual as a Weather Compensation Kit. zone valves with a call for heat applied Note 2.
Page 39: External Controls
InStALLAtIon 49 EVomAX WItH EXtERnAL ContRoLS VIA SWItCHED LIVE, 0-10V InPut oR oPEntHERm Note that the boiler requires a 4 minute pump overrun If the CH Pump connection is used and the electrical current period. draw is 1.3A inductive or less then the pump can be connected directly into the CH Pump connection (a Grundfos 40/50 UPS is The boiler warranty will be invalid if this is not provided.
Page 40: Commissioning And Testing
Programamble Room thermostat is available from Ideal as a kit. Note 2. The Tank Temperature Sensor is available from ideal as a kit. Note 3. The boiler must be configured to control a Power Open diverter Valve (See page 34)
Page 41: Initial Lighting
InStALLAtIon 52 InItIAL LIGHtInG 6. Switch the electricity supply ON and check that all 1. Check that the system has been filled and the boiler is not air locked - the external controls are calling for heat. Check air in the boiler could damage the heat exchanger. For this reason the boiler is set for winter operation - see Evomax user airvent located in the left top side must never be shut off.
Page 42: Handing Over
InStALLAtIon 53 GEnERAL CHECkS c. Refill and vent the system, clear all air locks and again Make the following checks for correct operation. check for water soundness. 1. The correct operation of ANY secondary system controls should be proved. Operate each control separately and d.
Page 43: Servicing Schedule
The kW output number in the 1st line will vary depending on the Ideal Stelrad Group does not accept any liability resulting maximum output of the boiler. from the use of unauthorised parts or the repair and...
Page 44: Electrical Connections
SERVICInG 58 REmoVAL of fAn AnD GAS VALVE ASSEmbLy 1. Refer to Frame 55. 7. Disconnect the electrical connections from the gas valve/s. 2. Remove the upper front panel, Refer to Frame 57. 8. Disconnect the electrical connections from the fan. 3.
Page 45: Burner Removal
SERVICInG 59 buRnER REmoVAL 1. Refer to Frame 55. 2. Remove the front panel (Refer to frame 57) 3. Remove the fan and gas valve assembly (Refer to frame 58) 4. Remove the six/eight extended nuts securing the burner to release the burner body.
Page 46: Fan Replacement
30, 40, 60, 80, 100 & 120 or mixing chambers (150 8. Reassemble in reverse order replacing all gaskets. only)). 9. Check the operation of the boiler (Refer to frame 55). Evomax 30, 40 & 60 Evomax 80 Evomax 100 Evomax 120 Evomax 150 Gas Management Assembly Part No’s...
Page 47: Gas Valve Replacement
10. Reassemble in reverse order replacing all gaskets. fixing screws (100/120 only Refer to frame 63). 11. Check the operation of the boiler (Refer to frame 55). 6. Remvove the four screws retaining the gas valve. Evomax 30, 40 & 60 Evomax 80 Evomax 100 Evomax 120 Evomax 150 Gas Management Assembly Part No’s...
Page 48: Ignition Electrode Replacement
SERVICInG 65 VEntuRI REPLACEmEnt 1. Refer to Frame 55. 2. Remove the front panel (Refer to frame 57) 3. Remove the fan and gas assembly (Refer to frame 58) 4. Remove venturi from fan / mixture chamber and gas valve (Refer to frame 63/64) 5.
Page 49 SERVICInG 68 AutomAtIC AIR VEnt REmoVAL 1. Refer to Frame 55. 2. Remove the front panel. Refer to Frame 67. 3. Unscrew the air vent (A) from the self sealing fitting (B) on the top left of the flow pipe. 4.
Page 50 SERVICInG 71 mAIn PCb REPLACEmEnt 1. Refer to Frame 55. 4. Pull off all of the main PCB connectors. 2. Remove the upper front panel & put the control panel 5. Remove the four plastic nuts retaining the main PCB. into the service position.
Page 51: Fault Finding
fAuLt fInDInG 73 fAuLt fInDInG CHARt - mAIn mEnu Overheat Lockout Return Thmr Fault Fill System to 1 Bar Check Return Go to Frame 81 Go to Frame 74 Vent System Thermistor Wiring Return Thermistor Fault Overheat Lockout Check Pump Spins Free Check Return Thmr Reset Boiler (10K @ 25°C,2K at 66°C)
Page 52 fAuLt fInDInG 74 oVERHEAt LoCkout Has PCB just been replaced? Reset Boiler Fill and vent the system and open all Are the boiler and CH/DHW system isolation valves, then reset the boiler. filled with water and are all isolation valves and radiator valves open? Check the flow and return Is the flow/return differential across thermistors (refer to Frame 80 &...
Page 53 fAuLt fInDInG 76 FAlSE FlAME lOCKOUT / ERROR 20 Check routing and integrity of internal boiler Reset the boiler, does boiler work OK? wiring is OK. Check condition of Flame Sense Electrode and replace if deteriorated. Disconnect the electrical connection to the Flame Replace Flame Detection Electrode Sense Electrode.
Page 54 fAuLt fInDInG 79 fAn fAuLt Rectify wiring & connections Does the wiring from the Fan to the PCB have secure connections at both ends and has not deteriorated? Does the wiring have continuity? Replace main PCB Is there 230Vac at the blue and brown connections to the 3 way connection on the Fan? Replace Fan 80 fLoW tHERmIStoR fAuLt...
Page 55 fAuLt fInDInG 82 outSIDE SEnSoR fAuLt Is the wiring securely connected at both the boiler and Securely connect the wiring at both Outside Sensor? the boiler and Outside sensor Fit a new outside sensor Disconnect the wires to the Outside Sensor. Check the resistance using a suitable multimeter connected across the thermistor’s terminal pins.
Page 56 fAuLt fInDInG 84 CyLInDER tHERmIStoR fAuLt Change menu setting for DHW Sensor Is a DHW Thermistor connected to the boiler? to “Switched Live” (See Frame 36) Is the wiring securely connected at both the boiler and Securely connect the wiring at both cylinder thermistor? the boiler and cylinder thermistor Fit a new cylinder thermistor...
Page 57 Open the Radiator Valves Is an OpenTherm device connected to the boiler (note Does the wiring from the boiler to the that the Ideal Prog Room Stat is an OpenTherm device)? OpenTherm device have continuity? There is no voltage from the Timer/ Room Stat.
Page 58 Frame 38 for setting DHW Temp.) Is an OpenTherm device connected to the Does the wiring from the boiler to the boiler (note that the ideal programmable Room OpenTherm device have continuity? Stat is an OpenTherm device)? There is no voltage from the Rectify wiring Timer/Cylinder Stat.
Page 59 fAuLt fInDInG 89 no DISPLAy Supply power to the boiler Is there 230Vac to the boiler at (E)? Connect the wiring from the terminal block Is the wiring from the boiler terminal block to the main to the main PCB securely PCB connected securely? Connect the cable from the main PCB to Is the cable from the main PCB to the user interface PCB...
Page 60 fAuLt fInDInG 90 0-10V IntERfACE Set the boiler to accept a 0-10V input (see Is the boiler set to accept a 0-10V Input? Frame 37) Set the boiler to Winter Mode (see Frame Is the boiler set to Winter Mode? Ensure between 2V and 10V is correctly Is a voltage of between 2V and 10V being supplied to connected to these terminals from the...
Page 61: Short List Of Parts
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.
Page 62 The Ideal Heating Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers. For details of courses please ring: ........ 01482 498 432 Ideal boilers, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN.

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IDEAL Evomax 30 Installation & Servicing Manual

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