Hamworthy EVO S 80 User manual

EVO S
Frame and Header Kit
80, 100, 120, 150
80P, 100P, 120P
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 ACV.
For the very latest copy of literature for
specification and maintenance practices
visit our website www/acv/com/gb
where you can download the relevant
information in PDF format.
Instructions
06/2023
UIN 236071 A03

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80-150 kW Frame & Header Kits Manual
This kit is suitable for the following boilers:
Evo S 80,100,120 & 150 using Natural Gas and 80P, 100P & 120P using Propane
IMPORTANT
THESE KITS CAN BE USED IN CONJUNCTION WITH
LOW LOSS HEADERS & PLATE HEAT EXCHANGERS
SUPPLIED AS PART OF THE EVO S OPTIONS RANGE
CONTENTS
1 Introduction.....................................................................3
2 General Description of Systems ...................................3
3 Multiple Boiler System Components............................6
4 Frame Kit Installation Procedure ..................................9
5 Header Kit Assembly....................................................10
6 Installation Drawings for Multiple Boiler Systems....13
7 Electrical Connections & Wiring Diagram..................21
8 Commissioning and Testing........................................23

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80-150 kW Frame & Header Kits Manual
1 INTRODUCTION
This technical data contains information for dimensioning & assembly
of a cascade system kit for the Evo S.
Frame and header kits are available 'in line' congurations only.
GENERAL DESCRIPTION OF FRAME & HEADER KITS
A requirement to spread the total required heat output over several
boilers can be accommodated by the use of the ACV multiple boiler
frame & header kit options.
All headers and pipe work should be insulated in accordance
with the Non Domestic Building Services Compliance Guide. To
ensure compliance with the maximum heat loss criteria, insulation
thickness should be calculated according to BS EN ISO 12241 using
standardised assumptions.
* Max 6 x 100 kW only.
2.1 FRAME AND HEADER KIT DESIGN OPTIONS
The Evo S boilers are suitable for use in a multiple boiler conguration. The Evo S multiple boiler system is available in side by
side and giving the opportunity to choose the optimum footprint size or wall space for a given output. 80-150 kW kits include the
support frame. Boilers can be wall mounted required.
2 GENERAL DESCRIPTION OF SYSTEMS
continued . . . . .
Available Rig
Congurations
Total Output
Required kW
Number of boilers
and Frames
Footprint Size
W x D x H (mm)
Frame and Header Kit
Range Size Prod. No
Single Frame Congurations 80-120 1 500 x 704 x 1535 DN80 XB150011
Twin Frame Congurations 160-240 2 1000 x 704 x 1535 DN80 XB150012
Triple Frame Congurations 240-360 3 1500 x 704 x 1535 DN80 XB150013
Quad Frame Congurations 320-480 4 2000 x 704 x 1535 DN80 XB150014
Five Frame Congurations 400-600 5 2500 x 704 x 1535 DN80 XB150015
Six Frame Congurations 480-600 6* 3000 x 704 x 1535 DN80 XB150016
Available Rig
Congurations
Total Output
Required kW
No of boilers
and Frames
Footprint Size
W x D x H (mm)
Size Frame and Header Kit
Range No sep/
LLH PHEX sep
Single Frame Congurations 150 1 500 x 794 x 1830 DN100 XB150017 XB150023
Twin Frame Congurations 300 2 1000 x 794 x 1830 DN100 XB150018 XB150024
Triple Frame Congurations 450 3 1500 x 794 x 1830 DN100 XB150019 XB150025
Quad Frame Congurations 600 4 2000 x 794 x 1830 DN100 XB150020 XB150026
Five Frame Congurations 750 5 2500 x 794 x 1830 DN100 XB150021 XB150027
Six Frame Congurations 900 6 3000 x 794 x 1830 DN100 XB150022 XB150028
Note. All boilers need to be sized in accordance to the total required heat load and the modulation capabilities of the appliances.
H=Height from oor to top of frame, D=Depth from installed wall to front of kit, W=Width of installed kit
DN80 DN100
XB150030 XB150031
kW Product No.
Evo S 80 100008264400
Evo S 100 100008264500
Evo S 120 100008264600
Evo S 150 100008264700
Table 1 80-120 kW
Table 2 150 kW only
Table 3 Available Evo S Boilers Table 4 Low Loss Header Accessories
** See Table 6 for Gas Header sizing.
** See Table 6 for Gas Header sizing.

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80-150 kW Frame & Header Kits Manual
Product Number Frame and Header Size PHEX kW
XB150038 DN80 150
XB150039 DN80 300
XB150040 DN80 450
XB150041 DN80 300
XB150042 DN100 300
XB150043 DN100 450
XB150044 DN100 600
XB150045 DN100 750
XB150046 DN100 900
Boiler Water Header Size 4-Wide 5-Wide 6-Wide
Evo S 80 DN80 2" 3" 3"
Evo S 100 DN80 2" 3" 3"
Evo S 120 DN80 3" 3" 3"
Evo S 150 DN100 3" 3" 3"
System separation PHEX kits are o󰀨ered at the below kW ratings and are supplied with suitable pipe spools for connection to
frame and header kits.
Table 5 System Separation PHEX Kits
Table 6 Gas Header Size / Cascade

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80-150 kW Frame & Header Kits Manual
2.2 MULTIPLE BOILER INSTALLATIONS
The product range includes water and gas headers capable of assembly using threaded socket, compression and PN6 ange
connections.
2.3 HYDRONIC ISOLATION: LOW LOSS HEADER & PLATE HEAT EXCHANGER
A low loss header or plate heat exchanger allows ow separation within a hydronic system.
This allows two ow circuits to operate with their own ow and pressure drop environments whilst e󰀨ectively transferring heat to its
adjoined water circuit.
This enables the modern high resistant, high e󰀩ciency boilers to operate under their optimum conditions, while the main heating circuit
operates to its own controlled optimum requirements.
2.4 OUTPUT CONTROL
All pumps should be wired to the appliance to allow a controlled pump over run.
If using an external pump control system the capability of a timed pump over run signal provided by the appliance must be maintained
at all times.
2.5 GAS SUPPLY
For Evo S the 80, 100, 120 & 150 boilers are congured for use with natural gas, or 80,100 & 120 running on Propane.
Connection to the gas supply must be in accordance to with all the applicable regulations.
The water header kits are supplied with a 2” or 3" gas header (see Table 6) and associated components and hoses to make the
connection to the appliance.
Note. Test points are provided at each end of the gas headers.
It must be noted that the following pressure drops should be taken into consideration when sizing pipe dimensions and run lengths.
Boiler Model Pressure Loss (mBar)
Evo S 40 < 0.9
Evo S 60 < 0.9
Evo S 70 < 0.9
Evo S 80 0.9
Evo S 100 1.4
Evo S 120 2
Evo S 150 2.85
Note.
1. Pressure drop is present within the dedicated gas header to boiler inlet pipework when supplied by ACV.
2. A minimum working pressure of 16.5 mBar should be available at the gas header test point.
2.6 ASSEMBLY
The frames must be located in a suitable place that a󰀨ords a at and level oor-area of suitable load bearing capacity. Care must be
taken when locating the frames that space is available for the servicing, installation and maintenance of the appliance and all of the
associated connections and equipment. (See Appliance manuals)
When using multiple frames they must be bolted together and secured to the oor.
2.7 SAFE HANDLING
Installation may require 2 or more operatives to move it to its installation site, remove it from its packaging base and during movement into its
installation location. Manoeuvring may include the use of a sack truck and involve lifting, pushing and pulling.
Caution should be exercised during these operations.
Table 7 Gas Line Pressure Drop (Natural Gas)

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80-150 kW Frame & Header Kits Manual
Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be considered:
• Grip the boiler at the base.
• Be physically capable.
• Use personal protective equipment as appropriate, e.g. gloves, safety footwear.
During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or the
weight is light:
• Keep back straight.
• Avoid twisting at the waist.
• Avoid upper body/top heavy bending.
• Always grip with the palm of the hand.
• Use designated hand holds.
• Keep load as close to the body as possible.
• Always use assistance if required.
3 MULTIPLE BOILER SYSTEM COMPONENTS
3.1 GENERAL
The multiple boiler systems consist of the following components:
• Pipekit (1 and 2 wide congurations)
• Boiler gas header.
• Boiler ow and return headers supported on mounting skid
• Low loss mixing header (optional)
• Hardware pack (includes essential connection and valve components)
• Circuit extension kits (optional)
• Plate Heat exchanger kit (optional)
• Boiler pump
3.2 MAIN WATER HEADERS
The main water headers consist of: water ow, water return headers custom sized for all boilers. It is possible to extend the system to a
maximum of 6 boilers in a linear conguration.
Each header kit provides water ow and return headers sized either DN80 or DN100 dependent on total maximum combined heating
output required.
3.3 GAS HEADER
The Gas header consists of a custom manufactured 2” or 3" manifold. This is located in a cradle incorporated within the header mounting
skid.
3.4 BOILER PUMP
Pump kits and External pump controls (sold separately) are designed to provide the optimum ow around the appliance water circuit
ensuring the maximum ow rates are contained within the design constrains of the appliance.
3.5 BOILER WATER CONNECTION KITS
The connection kit contains the following components:
1. Boiler return leg complete with isolating valve, pump, non return valve, drain cock and bre seals.
2. Boiler ow leg complete with isolating valve, pressure relief valve and bre seals.
3. Header blanking anges, fasteners and gaskets.
4. Mixing header fasteners and gasket.

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80-150 kW Frame & Header Kits Manual
4
1
2
3
4
5
6
1
2
3
3
4
5
6
7
1
2
3
4
56
7
8
9
3
2
1
5
3.6 BOILER GAS CONNECTION KITS
Item 2" Gas, 1 Wide 2" Gas, 2 Wide 3" Gas, 1 Wide 3" Gas, 2 Wide
Gas Header
Pipe 1-No 2" 1-No 2" 1-No 3" 1-No 3"
Gas Hose 1-No 1" 2-No 1" 1-No 1" 2-No 1"
End Cap 2-No 2" threaded cap 2-No 2" threaded cap N/A N/A
Gas Blind Kit
(Boxed)
1-No DN12 x 1/2" Taper Plug
1-No DN50-2" Mac Union
1-No DN50-2" to DN12-1/2" Reducer
1-No DN12 x 1/2" Taper Plug
1-No DN50-2" Mac Union
1-No DN50-2" to DN12-1/2" Reducer
1-No DN80 Blind Flange
2-No DN80 Gaskets
1-No Bolt Set (8-No M16 x 60)
1-No DN80 Blind Flange
2-No DN80 Gaskets
1-No Bolt Set (8-No M16 x 60)
Gas Adapter
Kit (Bagged) N/A N/A
2-No Gas Adapter Brackets
4-No M10 x 30 Bolts
4-No M10 Plain Washers
4-No M10 HEX Nuts
2-No Gas Adapter Brackets
4-No M10 x 30 Bolts
4-No M10 Plain Washers
4-No M10 HEX Nuts
3.7 INSTALLATION AREA AND DIMENSIONS
Care must be taken to ensure adequate access for boiler / cascade system installation and servicing.
A minimum of 450 mm clearance must be provided from the front of the installed boilers in cascade to facilitate boiler servicing.
Additional clearance must also be considered in the event of boiler replacement.
Consideration to connecting heating ow and return pipework, gas supply and condensate drainage must be given. Routing of the
condensate drain must be made to allow a minimum fall of 1 in 20 away from the installed boilers in cascade, throughout its length.
Adequate room above the boilers must be provided to install and service the boiler ue system. Further information with respect to
ue and condensate drain connection is provided in the installation and servicing instructions provided within the boilers packaging
carton.
FLOW RETURN
LEGEND
1. Isolation Valve
2. Boiler Flow Flexible
Connection
3. Pump Union
4. Pump inc Gaskets
5. Non Return Valve
6. 1 ¼” x 1 ¼” x ¾” Tee
7. Drain Cock
LEGEND
1. Isolation Valve
2. 1 ¼” Male/Female Swivel
Elbow
3. Boiler Flow Flexible
Connection
4. 1 ¼” Male Parallel/Taper
Hex Nipple
5. 1 ¼” x 1 ¼” x ¾” Tee
6. ¾” Taper Plug
LEGEND
1. Isolation Valve
2. 1 ¼” Male/Female Mac
Union
3. Boiler Flow Flexible
Connection
4. Pump inc Gaskets
5. Flange Pump Adapter
6. 1 ¼” Male Parallel/Taper
Hex Nipple
7. Non Return valve
8. 1 ¼” x 1 ¼” x ½” Tee
9. Drain Cock
LEGEND
1. Isolation Valve
2. Boiler Flow Flexible
Connection
3. 1 ¼” Male Parallel/Taper
Hex Nipple
4. 1 ¼” x 1 ¼” x ¾” Tee
5. ¾” Taper Plug
Figure 1. DN 80
Figure 2. DN 100
Table 8 Gas Line Pressure Drop (Natural Gas)

8
80-150 kW Frame & Header Kits Manual
IMPORTANT POINTS
Before commencing installation:
• The frames must stand on a at and level oor of suitable load
bearing capacity.
• The header must be bolted to the frame before the hoses are
connected to the boiler.
MOUNTING FRAME MUST BE SECURED
TO THE FLOOR WITH BOLTS
Allowances must be made for installation where features are in place
that may a󰀨ect the nominal installation conditions.

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80-150 kW Frame & Header Kits Manual
4 FRAME KIT INSTALLATION PROCEDURE
4.1 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.
IMPORTANT: MOUNTING FRAME MUST BE SECURED TO THE FLOOR WITH BOLTS
2. Remove the plastic foot covers and
drill the oor in order to oor bolt
the frame assembly to its required
location. (Bolts not supplied in kit)
2
1

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80-150 kW Frame & Header Kits Manual
5 LOW LOSS HEADER ASSEMBLY (OPTIONAL ACCESSORY)
4.2 BOILER MOUNTING
1. As appropriate mount the boilers onto either the wall plates or the side by side pipekit.
5.1 FITTING LOW LOSS HEADER AND BLANKING FLANGES
1. Fit the low loss header and blanking anges in the chosen positions.
Note. Low loss header can be located either LHS or RHS of the headers.
Low Loss Header
Blanking Flange
Note. For instructions relating
to PHEX accessory,
please see separate
installation manual.