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ideal commercial EVOMAX 30 Installation And Servicing

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INSTALLATION AND
SERVICING
EVOMAX
30 40 60 80 100 120 150
30P 40P 60P 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.
June 2018
UIN 206210 A17

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  • Page 1 INSTALLATION AND SERVICING EVOMAX 30 40 60 80 100 120 150 30P 40P 60P 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.
  • Page 2 ERP DATA MODEL SYMBOL UNITS Condensing Boiler Low Temperature Boiler B1 Boiler Cogeneration Space Heater Equipped with a Supplementary Heater Combination Heater Nominal Heat Output for Space Heating Full Load Part Load 19.5 19.5 Auxiliary Electricity Consumption Full Load 0.134 0.134 0.135 0.135...
  • Page 3 PRODUCT FICHE EVOMAX HEAT BOILER Ideal Boilers ERP DATA SYMBOL UNITS MODEL Condensing boiler Seasonal Space heating efficiency class Rated heat output ƞ Seasonal space heating energy efficiency Annual energy consumption 92.9 91.9 123.9 122.6 185.8 181.9 Sound power level, indoors Seasonal Space Heating Energy Efficiency of the Boiler Temperature control (from fiche of temperature control) Class I...
  • Page 4 EVOMAX - Installation & Servicing...
  • Page 5 EVOMAX - Installation & Servicing...
  • Page 6 GENERAL Table 1 Performance Data (Natural Gas) Evomax Model Boiler Output (non- condensing) Mean 70°C 31.54 30.9 42.0 41.2 63.5 62.1 84.4 82.6 103.9 124.7 158.0 Boiler Output (condensing) Mean 40°C 12.7 15.5 17.2 21.2 21.6 26.0 32.5 Nett 30.4 30.4 40.5 40.5...
  • Page 7 GENERAL EVOMAX CONTENTS 30, 40, 60, 80, 100, 120, & 150 Boiler Assembly - Exploded view........15 30P, 40P, 60P & 80P Boiler Clearances............12 Commissioning and Testing...........44 Natural Gas & LPG Electrical Connections............29 Destination Countries: GB, IE Electrical Supply..............
  • Page 8 GENERAL INTRODUCTION made to the relevant British Standard Code of Practice. The EVOMAX boilers are fully automatically controlled, wall In IE, the installation must be carried out by a Competent Person mounted, fanned, super efficient condensing appliances. and installed in accordance with the current edition of I.S.813 The EVOMAX condensing boilers can be installed either on the “Domestic Gas Installations”...
  • Page 9 GENERAL • Grip the boiler at the base. The roof flue kits are suitable for both flat and pitched roof termination, using either concentric or flue only terminals. • Be physically capable. • Use personal protective equipment as appropriate, e.g. Connection to the top of the boiler is made using a separately gloves, safety footwear.
  • Page 10 Flow rates for common systems using either 11ºC, 15ºC or 20ºC temperature differentials and hydraulic resistances are given in the table below. Flowrate (l/min) Hydraulic Resist- ance (mbar) 11ºC 15ºC 20ºC 11ºC 15ºC 20ºC Evomax 30/30P 39.1 28.7 21.5 Evomax 40/40P 52.1 38.2 28.7 Evomax 60/60P 78.2 57.3 43.0 Evomax 80/80P 104.2...
  • Page 11 GENERAL WATER TREATMENT ELECTRICAL SUPPLY These boilers incorporate an ALUMINIUM heat exchanger. Wiring external to the appliance MUST be in accordance with the current I.E.E. (BS7671) Wiring Regulations and any local IMPORTANT. The application of any other treatment to this regulations which apply.
  • Page 12 Flow Return Flow Return 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 for vertical flue 200mm for horizontal flue 350mm (415mm for 100/150)
  • Page 13 GENERAL OPEN VENTED SYSTEM REQUIREMENTS Detail reference should be made to the appropriate standards listed on page 8. The information and guidance given below is not intended to override any requirements of the above publications or the requirements of the local authority, gas or water undertakings. The vertical distance between the pump and feed/expansion cistern MUST comply with the pump manufacturer’s minimum requirements, to avoid cavitation.
  • Page 14 GENERAL SEALED SYSTEM REQUIREMENTS Note. The method of filling, refilling, topping up or flushing sealed primary hot water circuit from the mains for a non-domestic property is shown below. 1. General 3. Pressure Gauge A pressure gauge covering at least the range 0-6 bar must a.
  • Page 15 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 16 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 17 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 18 For other situations accidental obstruction by blocking or flooding. refer to BS. 5440 Pt. 2. In IE refer to the current edition of I.S. 813. EVOMAX 30/30P, 40/40P, 60/60P Boiler Size 30 & 30P 40 &...
  • Page 19 INSTALLATION 11 FLUE SYSTEMS A comprehensive range of flue kits are available from Note: Horizontal terminal resistance includes 1 x 90 elbow. Ideal Boilers. Examples of horizontal and vertical concentric Worked examples are shown on page 22. and open flue options are demonstrated on the following pages. A multiple boiler flue header system is available ‘Ideal Multiline’.
  • Page 20 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) 14.3 17.6 Flue Size 80 / 125 100 / 150 Vertical flue kit No 213264 213266 Contents...
  • Page 21 INSTALLATION 17 FLUE KIT ACCESSORIES Accessory Part No. 80/125 100/150 elbow (concentric) 213259 213263 elbow (concentric) 213260 213258 elbow 158773 158774 elbow (pair) 158775 158776 Flat Weather Collar 152611 152612 158780 158780 Pitched Weather Collar 152609 152610 158779 158779 1m Extension (concentric) 213261 213262 1m Extension (pair)
  • Page 22 INSTALLATION 18 PERMISSIBLE FLUE LENGTH The maximum permissible flue lengths for each model is shown in Table X below, these lengths are inclusive of the terminal resistance. The value shown is the max available length for extension. The equivalent length of elbows is shown in Table xx Table X Max Permissible Equivalent Flue Length (inc terminal resistance) meters Concentric...
  • Page 23 INSTALLATION 19 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 24 INSTALLATION 20 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 25 INSTALLATION 21 BOILER FRAME AND HEADER KITS Heat output to a maximum of 600kW (632kW condensing) 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 26 INSTALLATION 23 CONDENSATE DRAIN Condensate Pump Where gravity discharge to an internal termination is not physically possible or where very long internal pipe runs would be required to reach a suitable discharge point, a condensate pump of a specification recommended by the boiler or pump manufacturer should be used terminating into a suitable internal foul water discharge point such as an internal soil and vent stack or internal kitchen or bathroom waste pipe etc.
  • Page 27 INSTALLATION 24 CONDENSATE DRAIN - CONT’D..Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to Method (see manufacturers detailed instructions) External Soil & Vent Stack Boiler Water/weather with 75mm Visible air break proof insulation Boiler sealed...
  • Page 28 INSTALLATION 25 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 29 INSTALLATION 28 ELECTRICAL CONNECTIONS switch, having a 3mm (1/8”) contact separation in both poles, Warning. This appliance MUST be efficiently earthed. 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 30 INSTALLATION 30 INSTALLER CONNECTIONS EVOMAX - Installation & Servicing...
  • Page 31 INSTALLATION 31 INTERNAL WIRING EVOMAX - Installation & Servicing...
  • Page 32 INSTALLATION 32 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 Initialising Please Wait or LPG.
  • Page 33 INSTALLATION 33 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 34 INSTALLATION 34 EVOMAX USER INTERFACE - BASIC OPERATING INSTRUCTIONS SETTING SUMMER, WINTER AND STANDBY OPERATION SETTING FLOW TEMPERATURE Note that Standby Mode will disable Domestic Hot Water and Press SELECT and a screen similar to the following will be displayed Central Heating, Summer Mode will disable Central Heating The kW output number in the 1st line will vary depending the maximum output of the boiler...
  • Page 35 INSTALLATION 35 EVOMAX USER INTERFACE - BASIC OPERATING INSTRUCTIONS CONTINUED... VIEWING THE STATE OF THE BOILER INPUTS VIEWING THE FAULT HISTORY OF THE BOILER Press SELECT and a screen similar to the following will be displayed Press SELECT and a screen similar to the following will be displayed 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...
  • Page 36 INSTALLATION 36 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 37 INSTALLATION 37 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 38 INSTALLATION 38 EVOMAX USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS Note: if this menu option is not displayed then the “2nd sL DHW/CH” menu CHANGING THE MINIMUM FLOW TEMPERATURE SETPOINT option has been set for CH. CH Priority can be set from the “2nd sL DHW/ Boiler default setting is that minimum flow temperature setpoint is 30°C CH”...
  • Page 39 INSTALLATION 39 EVOMAX USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS CONTINUED..ENABLING THE DOMESTIC HOT WATER THERMISTOR CHANGING THE SOFT START TIME The Soft Start Time is the time for which the boiler will run at the ignition The default is for a DHW Heat Demand to be indicated by a DHW rate after a flame is detected Thermostat providing a 230V input to the DHW Switched Live This feature helps make the boiler fully compatible with the CH/DHW...
  • Page 40 INSTALLATION 40 EVOMAX USER INTERFACE - ADVANCED OPERATING INSTRUCTIONS CONTINUED..REVERTING TO FACTORY SETTINGS DISABLING THE ANTI-LEGIONELLA FUNCTION Press SELECT, hold + and - together for more than 5s, the Note that the Anti-Legionella Temperature Function is only following screen will be displayed operational if a Domestic Hot Water Thermistor has been connected.
  • Page 41 INSTALLATION 41 EVOMAX WITH S PLAN SYSTEM 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 42 INSTALLATION 43 EVOMAX WITH BOILER CONTROL OF CH AND DHW PUMPS Note 4. This system provides heating to one zone at a time. 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.
  • Page 43 INSTALLATION 45 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 44 INSTALLATION 46 EVOMAX WITH OPENTHERM 2 CHANNEL PROGRAMMABLE ROOM STAT Note 1. The OpenTherm 2 Channel 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) W Plan...
  • Page 45 INSTALLATION 48 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 46 INSTALLATION 49 GENERAL CHECKS Make the following checks for correct operation. c. Refill and vent the system, clear all air locks and again check for water soundness. 1. The correct operation of ANY secondary system controls should be proved. Operate each control separately and d.
  • Page 47 SERVICING 52 SERVICING SCHEDULE To ensure the continued safe and efficient operation of the appliance it is recommended that it is checked at regular SETTING TO MAXIMUM OUTPUT intervals and serviced as necessary. The frequency of Ensure that there is a current CH demand to the boiler (e.g. the servicing will depend upon the installation condition and CH Switched Live is on) Press SELECT and the following screen witll be displayed.
  • Page 48 SERVICING 54 REMOVAL OF FAN AND GAS VALVE ASSEMBLY 1. Refer to Frame 51. 7. Disconnect the electrical connections from the gas valve/s. 2. Remove the upper front panel, Refer to Frame 53. 8. Disconnect the electrical connections from the fan. 3.
  • Page 49 SERVICING 55 BURNER REMOVAL 1. Refer to Frame 51. 2. Remove the front panel (Refer to frame 53) 3. Remove the fan and gas valve assembly (Refer to frame 54) 4. Remove the six/eight extended nuts securing the burner to release the burner body.
  • Page 50 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 51). Evomax 80 Evomax 30, 40 & 60 Evomax 100 Evomax 120 Evomax 150 Gas Management Assembly Part No’s...
  • Page 51 (100/120 only Refer to frame 59). 11. Check the operation of the boiler (Refer to frame 51). 6. Remvove the four screws retaining the gas valve. Evomax 80 Evomax 30, 40 & 60 Evomax 100 Evomax 120 Evomax 150 Gas Management Assembly Part No’s...
  • Page 52 SERVICING 61 VENTURI REPLACEMENT 1. Refer to Frame 51. 2. Remove the front panel (Refer to frame 53) 3. Remove the fan and gas assembly (Refer to frame 54) 4. Remove venturi from fan / mixture chamber and gas valve (Refer to frame 59/60) 5.
  • Page 53 SERVICING 64 AUTOMATIC AIR VENT REMOVAL 1. Refer to Frame 51. 2. Remove the front panel. Refer to Frame 63. 3. Unscrew the air vent (A) from the self sealing fitting (B) on the top left of the flow pipe. 4.
  • Page 54 SERVICING 67 MAIN PCB REPLACEMENT 1. Refer to Frame 51. 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 55 FAULT FINDING 69 FAULT FINDING CHART - MAIN MENU Overheat Lockout Return Thmr Fault Fill System to 1 Bar Check Return Go to Frame 77 Go to Frame70 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 56 FAULT FINDING 70 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 76 &...
  • Page 57 FAULT FINDING 72 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 58 FAULT FINDING 75 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 76 FLOW THERMISTOR FAULT...
  • Page 59 FAULT FINDING 78 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 60 FAULT FINDING 80 CYLINDER THERMISTOR FAULT Change menu setting for DHW Sensor Is a DHW Thermistor connected to the boiler? to “Switched Live” (See Frame 32) 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 61 FAULT FINDING 83 NO CH BUT DHW OK Set for Winter operation (see Frame 32) Is the boiler set for Winter operation? Ensure that the Timer and Room Are the Timer and Room Thermostat calling for Heat? Thermostat are calling for heat Are the Radiator Valves open? Open the Radiator Valves Is an OpenTherm device connected to the boiler (note...
  • Page 62 FAULT FINDING 84 NO DHW BUT CH OK Are the Timer and Cylinder Thermostat/ Ensure that the Timer and Cylinder Stat/Thermistor Thermistor calling for Heat? are calling for heat (if a DHW Thermistor is used see Frame 34 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...
  • Page 63 FAULT FINDING 85 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 64 FAULT FINDING 86 0-10V INTERFACE Set the boiler to accept a 0-10V input (see Is the boiler set to accept a 0-10V Input? Frame 33) 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 65 SPARE 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. Failure to do so could affect safety or performance of this appliance.
  • Page 66 Technical Training The Ideal 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 498432 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.

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