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IDEAL DN100 Installation Manual

Frame & header kits for evomax 30, 40, 60, 80, 100, 120, 150, 30p, 40p, 60p 80p
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FRAME &
HEADER KITS
EVOMAX
30 - 150
30P - 80P
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.
For the very latest copy of literature for specification and maintenance practices visit our website
www.idealcommercialboilers.com where you can download the relevant information in PDF format.
February 2016
UIN 207333 A05

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Summary of Contents for IDEAL DN100

  • Page 1 Do not use reconditioned or copy parts that have not been clearly authorised by Ideal. For the very latest copy of literature for specification and maintenance practices visit our website www.idealcommercialboilers.com where you can download the relevant information in PDF format.

  • Page 2: Table Of Contents

    This kit is suitable for the following boilers: Evomax 30, 40, 60, 80, 100, 120, 150, 30P, 40P, 60P 80P CONTENTS 1 Introduction ..............3 2 General Description of Cascade Systems ....3 3 Multiple Boiler System Components ......5 4 Installation Drawings for Multiple Boiler Systems ..8 Side by Side Frame Kit Configuration ......8 Back to Back Frame Kit Configuration .......13 5 Wall Mounted Installation Procedure ......18...

  • Page 3: Introduction

    INTRODUCTION This technical data contains information for dimensioning & assembly of a cascade system kit for the Evomax range of products. Header and Frame kits are available in both ‘in line’ (6 boilers long) and back to back options (3 boilers long). GENERAL DESCRIPTION OF FRAME &...
  • Page 4 2030x1096 209908 4/150 2580x663 209802 4/150 1480x1276 209904 5/120 3130x663 209804 In line frame kit 206970 Mixing header kit DN80 206972 Mixing header kit DN100 206973 Pump kit (30-100kW) 210362 Pump kit (120-150kW) 210363 EVOMAX - Frame & Header Kits...

  • Page 5: Multiple Boiler System Components

    Each header kit provides water flow and return headers sized either DN80 or DN100 dependent on total maximum combined heating output required.
  • Page 6 3.3 GAS HEADER The Gas header consists of a custom manufactured 2” manifold. This is located in a cradle incorporated within the header mounting skid. 3.4 MIXING HEADER The mixing headers are insulated and are supplied with an auto air vent and drain point as standard. 3.5 BOILER SHUNT PUMP Shunt pumps for inclusion within each boiler return leg are provided in the hardware pack.
  • Page 7 IMPORTANT POINTS Before commencing installation: If Wall mounting; • Ensure wall is capable of supporting the weight of boilers to be mounted • Mark drill points of header using floor mounting template • Mark height on to the wall from the floor to the top of the boiler •...

  • Page 8: Installation Drawings For Multiple Boiler Systems

    INSTALLATION DRAWINGS FOR MULTIPLE BOILER SYSTEMS 4.1 GENERAL The multiple boiler systems are available in three formats: • 2 to 6 boilers in a linear configuration, mounted on a wall. • 2 to 6 boilers in a linear configuration, mounted on a free-standing frame. •...
  • Page 9 4.2.2 INSTALLATION DRAWING WITH 2 - 120/150 BOILERS (SIDE BY SIDE) 100/150 Concentric Flue Connector 550 CRS BETWEEN BOILERS 1480 663 - 150kW 573 - 120kW 1100 SYSTEM FLOW DN80 FLANGE CONN SYSTEM RETURN DN80 FLANGE CONN Note 1: Mixing header and gas connections can be 2"...
  • Page 10 2030 663 - 150kW 1650 573 -120kW SYSTEM FLOW DN100 FLANGE CONN SYSTEM RETURN DN100 FLANGE CONN Note 1: Mixing header and gas connections can be 2" BSP Female located either on the LHS or RHS of the assembly to Gas Connection suit needs of each particular system.
  • Page 11 2580 663 - 150kW 2200 573 - 120kW SYSTEM FLOW DN100 FLANGE CONN SYSTEM RETURN DN100 FLANGE CONN Note 1: Mixing header and gas connections can be 2" BSP Female located either on the LHS or RHS of the assembly to Gas Connection suit needs of each particular system.
  • Page 12 BOILERS BOILERS BOILERS 3130 2750 SYSTEM FLOW DN100 FLANGE CONN SYSTEM RETURN DN100 FLANGE CONN 2" BSP Female Note 1: Mixing header and gas connections can be Gas Connection located either on the LHS or RHS of the assembly to suit needs of each particular system.

  • Page 13: Back To Back Frame Kit Configuration

    4.3 BACK TO BACK FRAME KIT CONFIGURATION- 4.3.1 INSTALLATION DRAWING WITH 2 – 30-100 BOILERS (BACK TO BACK) 264 CRS Concentric Flue Connector 100kW = 100/150 30-80kW = 80/125 1096 - 100kW 776 - 30 to 80kW SYSTEM FLOW DN80 FLANGE CONN SYSTEM RETURN DN80 FLANGE CONN 2"...
  • Page 14 2" BSP Female SYSTEM FLOW Gas Connection DN100 FLANGE CONN SYSTEM RETURN DN100 FLANGE CONN Frame & header Kit 120/150kW UIN209902 with three Evomax 120/150kW boilers mounted bk to bk ALL DIMENSIONS ARE IN mm EVOMAX - Frame &...
  • Page 15 2" BSP Female SYSTEM FLOW Gas Connection DN100 FLANGE CONN SYSTEM RETURN DN100 FLANGE CONN Frame & header Kit 30/100kW UIN209905 with four Evomax 30/100kW boilers mounted bk to bk ALL DIMENSIONS ARE IN mm 4.3.6 INSTALLATION DRAWING WITH 4 –...
  • Page 16 2" BSP Female SYSTEM FLOW Gas Connection DN100 FLANGE CONN SYSTEM RETURN DN100 FLANGE CONN Frame & header Kit 30-100kW UIN209907 with five Evomax 30-100kW boilers mounted bk to bk ALL DIMENSIONS ARE IN mm 4.3.8 INSTALLATION DRAWING WITH 5 –...
  • Page 17 2" BSP Female SYSTEM FLOW Gas Connection DN100 FLANGE CONN SYSTEM RETURN DN100 FLANGE CONN Frame & header Kit 30-100kW UIN209908 with six Evomax 30-100kW boilers mounted bk to bk ALL DIMENSIONS ARE IN mm EVOMAX - Frame &...

  • Page 18: Wall Mounted Installation Procedure

    WALL MOUNTED INSTALLATION PROCEDURE 5.1 WALL MOUNTED SIDE BY SIDE OPTION Ensure wall is capable of supporting the weight of boilers to be mounted. Note. boiler weights can found in the boiler Installation Instructions. 1. Cut the sides off the cardboard wall mounting 4.
  • Page 19 5.1 WALL MOUNTED SIDE BY SIDE OPTION CONT'D.... SIDE VIEW PLAN VIEW Careful consideration MUST be given to the installation tolerances. If these are not adhered to, hoses may become kinked or connections may not fit. Bolt header to floor using template provided (front fixings only). Connect up hoses (see page 18) EVOMAX - Frame &...

  • Page 20: Frame Kit Installation Procedure

    FRAME KIT INSTALLATION PROCEDURE 6.1 SIDE BY SIDE FRAME KIT MOUNTING PROCEDURE 1. Place the frame kit sections in the required position and bolt them together at the top and bottom with the bolts, nuts and washers provided. 2. If additional stability is required remove the plastic foot covers and drill the floor in order to floor bolt the frame assembly to its required...

  • Page 21: Header Kit Assembly

    6.2 BOILER MOUNTING 1. As appropriate mount the boilers onto either the wall plates or the side by side frame kit. 2. Ensure the boiler bottom fixing bracket is screwed to the frame or wall. HEADER KIT ASSEMBLY 7.1 FITTING MIXING HEADER AND BLANKING FLANGES 1.
  • Page 22 7.2 FITTING HEADER KIT ASSEMBLY 1. Slide the header kit assembly between the frame legs but do not screw the header kit to the frame at this stage. 2. Screw the header legs to the frame feet with the bolts, nuts &...
  • Page 23 7.3 FITTING GAS CONNECTION 1. Fit the gas isolation valve assembly to the boiler gas connection ensuring the sealing washer is fitted. 2. Fit the copper gas pipe provided in the connection kit to the isolating valve and the header gas connection using 22mm compression fittings provided.

  • Page 24: Electrical Connections

    Technical Training The Ideal Boilers 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 is a trademark of Ideal Boilers.

This manual is also suitable for:

Dn80

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