ideal commercial Evomax 30 User manual

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

2EVOMAX - Installation & Servicing
MODEL
SYMBOL UNITS 30 30P 40 40P 60 60P
Condensing Boiler n/a n/a yes yes yes yes yes yes
Low Temperature Boiler n/a n/a no no no no no no
B1 Boiler n/a n/a no no no no no no
Cogeneration Space Heater n/a n/a no no no no no no
Equipped with a Supplementary Heater n/a n/a no no no no no no
Combination Heater n/a n/a no no no no no no
Nominal Heat Output for Space Heating
Full Load P4kW 30 30 40 40 60 60
Part Load P1kW 9.7 9.7 13 13 19.5 19.5
Auxiliary Electricity Consumption
Full Load elmax kW 0.134 0.134 0.135 0.135 0.092 0.092
Part Load elmin kW 0.03 0.03 0.03 0.03 0.026 0.026
Standby PSB kW 0.006 0.006 0.006 0.006 0.006 0.006
Seasonal Space Heating Energy Efciency
Full Load ƞ4% 89.6 91.6 89.6 91.5 89.7 91.7
Part Load ƞ1% 98.4 99.6 97.8 99.5 97.9 99.7
Standby Loss Pstby kW 0.08 0.08 0.08 0.08 0.11 0.11
Ignition Pign kW000000
Emissions NOxmg/kWh 28 71 35 72 28 73
Annual Energy Consumption QHE GJ 93.0 91.9 123.9 122.6 185.8 181.9
Sound Power Level, Indoors LWA dB 53 53 53 53 52 52
ERP DATA
 

3
EVOMAX - Installation & Servicing
EVOMAX HEAT BOILER
Ideal Boilers
ERP DATA
SYMBOL UNITS MODEL
30 30P 40 40P 60 60P
Condensing boiler Yes
Seasonal Space heating efciency class A
Rated heat output kW 30 30 40 40 60 60
Seasonal space heating energy efciency ƞs% 93* 93* 93* 93* 93* 93*
Annual energy consumption QHE GJ 92.9 91.9 123.9 122.6 185.8 181.9
Sound power level, indoors LWA dB 53 53 53 53 52 52
Seasonal Space Heating Energy Efciency of the Boiler *%
Temperature control (from che of temperature control) %
Class I Class II Class III Class IV Class V Class VI Class VII Class VIII
1% 2% 1.5% 2% 3% 4% 3.5% 5%
PRODUCT FICHE
 
The energy efciency of the package of products provided for in this document may not correspond to its actual energy efciency once installed in a
building, as the efciency is inuenced by further factors such as heat loss in the products in relation to the building size and its characteristics
Collector Size
(in m2)Tank Volume (in m3)Collector Efciency
(in %)
Tank rating
A* = 0.95
A = 0.91
B = 0.86
C = 0.83
D-G = 0.81
Solar Contribution (from che of solar device)
Seasonal Space Heating Energy Efciency of Package TOTAL: A+B+C=
Seasonal Space Heating Energy Efciency Class of Package
= (‘III ’x + ‘IV ’ x ) x 0.9 x ( / 100 x = %
%
GG F E D C B A A+ A++ A+++
< 30% ≥ 30% ≥ 34% ≥ 36% ≥ 75% ≥ 82% ≥ 90% ≥ 98% ≥ 125% ≥ 150%
A
B
C

4EVOMAX - Installation & Servicing

5
EVOMAX - Installation & Servicing

6EVOMAX - Installation & Servicing
GENERAL
Note.
Natural gas consumption is calculated using a caloric value of
37.8MJ/m3 (1038Btu/ft3) gross or 34 MJ/m3 (910 Btu/ft3) nett at
15oC and 1013.25 mbar.
a. For l/s divide the gross heat input (kW) by the gross C.V. of the
gas (MJ/m3)
b. For ft/h3 divide the gross heat input (Btu/h) by the gross C.V. of
the gas (Btu/ft3).
c. For m3/h multiply l/s by 3.6.
d. 1kW = 3412 BTU/hr.
e. 1m3 = 35.3ft3
f. 1mg/kWh (NOx) = 0.568 ppm DAF (natural gas).
Propane gas consumption is calculated using a caloric value of
95.7 MJ/m3 (2500 Btu/ft.3) gross or 88.0 MJ/m3 (2300 Btu/ft.3) net
at 15oC and 1013.25 mbar.
To obtain the fuel consumption in liquid form divide the above
gures by 270.
* The value is used in the UK Government’s Standard Assessment
Procedure (SAP) for energy ratings of dwellings. The test data from which
it has been calculated have been certied by a notied body.
Table 2 General Data
HEALTH & SAFETY DOCUMENT NO. 635
The electricity at work regulations, 1989. The manufacturer’s
notes must NOT be taken, in any way, as overriding statutory
obligations.
IMPORTANT. These appliances are CE certied for safety
and performance. It is, therefore, important that no external
control devices, e.g. ue dampers, economisers etc., are
directly connected to these appliances unless covered by
these Installation and Servicing Instructions or as otherwise
recommended by Ideal Boilers in writing. If in doubt please
enquire.
Any direct connection of a control device not approved by Ideal
Boilers could invalidate the certication and the normal appliance
warranty. It could also infringe the Gas Safety Regulations and
the above regulations.
Evomax Model 30 30P 40 40P 60 60P 80 80P 100 120 150
Boiler Output
(non-
condensing)
Mean 70°C
Max kW 30 30 40 40 60 60 80 80 100 120 150
Min kW 6 6 8 8 12 15 16 20 20 24 30
Boiler Output
(condensing)
Mean 40°C
Max kW 31.54 30.9 42.0 41.2 63.5 62.1 84.4 82.6 103.9 124.7 158.0
Min kW 6.5 6.4 8.5 8.3 12.7 15.5 17.2 21.2 21.6 26.0 32.5
Boiler Input
Max Rate
Nett kW 30.4 30.4 40.5 40.5 60.8 60.7 82.0 81.9 102.4 122.9 153.7
Gross kW 33.7 33 44.9 44 67.4 66 90.9 88.9 113.6 136.4 170.5
Boiler Input
Min Rate
Nett kW 6.1 6.1 8.1 8.1 12.2 15.2 16.4 20.5 20.5 24.6 30.7
Gross kW 6.7 6.6 9.0 8.8 13.5 16.5 18.2 22.2 22.7 27.3 34.1
Gas Rate Max Rate m3/hr 3.2 1.26 4.3 1.69 6.4 2.53 8.7 3.41 10.8 13.0 16.2
Flue Gas
Flow Rate Max Rate m3/hr 47.6 46.5 63.4 62.1 95.1 93.1 128.3 125.4 160.3 192.5 240.7
CO2 (±0.5%) * Max Rate % 9.7 11.4 9.7 11.4 9.7 11.4 9.7 11.4 9.7 9.7 9.7
Min Rate % 8.7 10.2 8.7 10.2 8.7 10.5 8.7 10.5 8.7 8.7 8.7
NOxweighted mg/kWh 31.0 79 39.1 80 32.3 83.8 39.8 68 39.6 38.8 38.1
Efciency Seasonal % 96.7 97.2 96.2 96.7 96.4 96.9 97.2 97.7 96.7 96.6 96.7
*SEDBUK 2009 % 89.6 90.6 89.3 90.3 89.4 90.5 n/a n/a n/a n/a n/a
*CO2 measurements taken using controlled reference natural gas. Readings on mains gas quality may vary
Evomax Model 30 30P 40 40P 60 60P 80 80P 100 120 150
Gas Supply 2H – G20 – 20mbar / 3P - G31 - 37mbar
Gas Supply Connection G 3/4
Flow Connection G1 1/4
Return Connection G1 1/4
Max Pressure (sealed sys) Bar (psi) 6.0 (87)
Maximum Static Head m61.0
Electricity Supply 230V - 50Hz
Fuse Rating A4.0
Power Consumption W126 207 131 265 370 403 400
IP Rating IP20
Nominal ue dia - Concent. 80/125 100/150
Condensate Drain 25
Water Content L3.0 5.0 7.0 9.2
Dry Weight Kg 49 60.30 75.70 89.75
Table 1 Performance Data (Natural Gas)

7
EVOMAX - Installation & Servicing
GENERAL
CONTENTS
Boiler Assembly - Exploded view..................................15
Boiler Clearances............................................................12
Commissioning and Testing...........................................44
Electrical Connections....................................................29
Electrical Supply..............................................................11
Fault Finding....................................................................55
Flue Installation.................................................................9
Flue Kits...........................................................................19
Gas Safety Regulations ...................................................8
Gas Supply.........................................................................9
Hydraulic Resistance......................................................10
Introduction........................................................................8
Initial Lighting..................................................................45
Installer Connections......................................................30
Installation........................................................................15
Mounting Boiler...............................................................18
Option Kits.........................................................................8
Performance Data..............................................................6
Servicing..........................................................................47
Short List of Parts...........................................................65
Ventilation........................................................................18
Water Circulation.............................................................10
Water Connections..........................................................28
Water System Requirements..........................................13
Water Treatment..............................................................11
Wiring Diagrams..............................................................31
Key to symbols
IE = Ireland, GB = United Kingdom (Countries of destination)
PMS = Maximum operating pressure of water
C13 C33 = A room sealed appliance designed for
connection via ducts to a horizontal or vertical
terminal, which admits fresh air to the burner
and discharges the products of combustion
to the outside through orices which, in this
case, are concentric. The fan is up stream
of the combustion chamber. Note: Evomax
Room Sealed Flues must be used.
B23 = An appliance intended to be connected
to a ue which evacuates the products
of combustion to the outside of the room
containing the boiler. The combustion air is
drawn directly from the room. The fan is up
stream of the combustion chamber.
Note: Evomax Air Inlet Kit must be used.
II2H3P = An appliance designed for use on 2nd and 3rd
Family gases.
EVOMAX
30, 40, 60, 80, 100, 120, & 150
30P, 40P, 60P & 80P
Natural Gas & LPG
Destination Countries: GB, IE
Boiler size G.C. Appliance No.
(Benchmark No.)
30 41-750-33A
40 41-750-34A
60 41-750-35A
80 41-750-36A
100 41-750-37A
120 41-750-38A
150 41-750-39A
30P 41-750-40
40P 41-750-41
60P 41-750-42
80P 41-750-43
NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.

8EVOMAX - Installation & Servicing
GENERAL
INTRODUCTION
The EVOMAX boilers are fully automatically controlled, wall
mounted, fanned, super efcient condensing appliances.
The EVOMAX condensing boilers can be installed either on the
wall or into a prefabricated oor mounted frame.
The boilers are suitable for use with a room sealed ue or open
ue application.
Through a sophisticated control system combined with premix
burner arrangement the boilers are capable of high seasonal
efciencies of >96% and low emissions.
These boilers are certied to meet the requirements of the EC
Gas Appliance Directive, Boiler Efciency Directive, EMC and Low
Voltage Directive.
Note. These boilers cannot be used on systems that include
gravity circulation.
The boiler are suitable for connection to fully pumped, open vented
or sealed water systems. Adequate arrangements for completely
draining the system by provision of drain cocks MUST be provided
in the installation pipework.
OPTIONAL EXTRA KITS
• External Vertical Terminal Extension Kit 80/125
• External Vertical Terminal Extension Kit 100/150
• Vertical Roof Flue Kit 80/125
• Vertical Roof Flue Kit 100/150
•Horizontal Wall Flue Kit 80/125
• Horizontal Wall Flue Kit 100/150
•Open Flue Kit 80
•Open Flue Kit 100
•Cascade Flue Kit
•Pitched and Flat Roof Tiles
•Frame and Header Kits
• Pump Kits
•Programmable Room Thermostat Kit
•Modulating Sequencer Kit
• Sequencer 6 Zone Expansion Kit
•Outside Sensor Kit
•Tank Sensor Kit
• Room Sensor Kit
• Safety Interlock Kit
• Plume Kit
• Propane to Natural Gas Conversion Kit
Please note propane variants of the Evomax are Cat II2H3P (20/37) and
may be converted to natural gas operation only using the approved
conversion kit supplied by Ideal.
Natural gas variants of the Evomax are Cat I2H and cannot be
converted to propane operation.
SAFETY
Current Gas Safety (Installation and Use) Regulations
or rules in force
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a Gas Safe
Registered Engineer or in IE by a competent person. It must be
carried out in accordance with the relevant requirements of the:
•Gas Safety (Installation and Use) Regulations
•The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
•The Water Fittings Regulations or Water byelaws in Scotland.
•The Current I.E.E. Wiring Regulations.
Where no specic instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a Competent Person
and installed in accordance with the current edition of I.S.813
“Domestic Gas Installations” or I.S. 820 “Non-Domestic Gas
Installations” as appropriate, the current Building Regulations and
reference should be made to the current ETCI rules for electrical
installation.
The Evomax boilers have been tested and certied to;
EN 483, EN 677, PREN 15420, BSEN 15417, BSEN 656, BSEN
60335-2-102, BSEN 55014-1 and BSEN 55014-2 for use with
Natural Gas & LPG.
Detailed recommendations are contained in the following Codes of
Practice:
BS. 6891
Installation of low pressure gas pipework of up to
28mm (R1) in domestic premises (2nd family gas).
BS. 5482 Pt. 1 Domestic butane and propane gas burning
installations.
BS. 5440
Inst. and maintenance of ues and ventilation for gas
appliances of rated input not exceeding 70kW net
(1st, 2nd and 3rd family gases).
Part 1 Specication for installation of ues.
Part 2 Specication for installation and maintenance of
ventilation for gas appliances.
BS. 6644 : 2005 Installation of gas red hot water boilers of rated
inputs between 70kW and 1.8MW (net) (2nd and
3rd family gases).
BS. 6798
Installation and maintenance of gas red hot water
boilers of rated input not exceeding 70kW net.
BS. 6880 Low temperature hot water heating systems of
output greater than 45kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
BSEN.12828:2003 Heating Systems in buildings: Design for water
based systems.
BSEN.12831:2003 Heating Systems in buildings: Method for
calculation of the design heat load.
BSEN.13831 Specication for: Expansion vessels using an
internal diaphragm, for sealed hot water heating
systems.
BSEN.14336:2004 Heating Systems in buildings: Installation and
commissioning of water based heating systems.
IGEM/UP/1 Soundness testing and purging of industrial and
commercial gas installation.
IGEM/UP/2 Gas installation pipework, boosters and
compressors on industrial and commercial
premises.
IGEM/UP/10 Installation of gas appliances in industrial and
commercial premises.
Where reference is made throughout these instructions I.S.813:2002
“Domestic Gas Installations” reference should also be made to
I.S.820:2000 “Non-Domestic Gas Installations” as applicable.
SAFE HANDLING
This boiler 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 the boiler may include the use of a
sack truck and involve lifting, pushing and pulling.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques when
performing these tasks and the following precautions should be
considered:

9
EVOMAX - Installation & Servicing
GENERAL
• 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.
SAFE HANDLING OF SUBSTANCES
No asbestos, mercury or CFCs are included in any part of the
boiler or its manufacture.
LOCATION OF BOILER
The boiler must be installed on a at and vertical wall, capable of
adequately supporting the weight of the boiler and any ancillary
equipment or on a boiler frame supplied in kit form by Ideal
Boilers.
The boiler must not be tted outside.
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
A gas meter can only be connected by the local gas supplier or by
a Gas Safe Registered Engineer or in IE by an RGI engineer.
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the
rate of gas supply required. A minimum working gas pressure of
17.5mbar MUST be available at the boiler inlet for Natural gas
and 37mbar for Propane.
Do not use pipes of smaller size than the boiler inlet gas
connection.
The complete installation MUST be tested for gas soundness and
purged in accordance with the appropriate standards listed on
page 8.
FLUE INSTALLATION
DANGER; ONLY USE IDEAL ROOM SEALED FLUE
GAS SYSTEMS. THE BOILER CE MARK IS VALID
ONLY IF THE APPLIANCE IS OPERATED WITH IDEAL
ROOM SEALED FLUE KITS. OTHER FLUE SYSTEMS
ARE NOT TESTED WITH THIS APPLIANCE.
The ue kits are suitable for use with the EVOMAX boiler only.
These kits and the associated options are suitable for both roof
and wall mounting applications. The Horizontal Wall Flue Kit
is not for use with Evomax 150 boilers in compliance with the
requirements of the Clean Air Act Memorandom.
The roof ue kits are suitable for both at and pitched roof
termination, using either concentric or ue only terminals.
Connection to the top of the boiler is made using a separately
supplied vertical connector in concentric and open ue
congurations (supplied in our optional extra kits).
Additional information covering the selection and installation can
be found with this booklet.
Weather Proong
Where the ue passes through the roof line an adequate seal
must be made. This can be achieved by using either:
•Flat weather collar
•Pitched weather collar
Flue duct extension kits are available for concentric ue
conguration. These packs contain additional 1 metre ducts and
may be cut to the desired length.
Flue duct extension kits are available for open ue congurations.
These packs contain 2 x 1 metre ducts and may be cut to the
desired length.
If obstructions prevent direct ue routing then both 90oand 45o
elbows can be provided to offset the ue system.
Terminal Position
Due to the high efciency of the 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.
IMPORTANT
It is the responsibility of the installer to ensure, in practice, that
products of combustion discharging from the terminal cannot
re-enter the building or any other adjacent building through
ventilators, windows, doors, other sources of natural air inltration,
or forced ventilation / air conditioning.
If this should occur the appliance MUST be turned OFF, labelled
as ‘unsafe’ and corrective action taken.
Where the lowest part of the terminal is tted less than 2m (80”)
above a balcony, above ground or above a at roof to which
people have access then the terminal MUST be protected by a
purpose designed guard. The minimum spacing between the
balcony and the terminal should be 75mm, in order to allow a
terminal guard to be tted.
Terminal guards are available from boiler suppliers - for all
requirements contact:
Grasslin (UK) Ltd., Tower House, Vale Rise,
Tonbridge, Kent TN9 1TB.
Tel: [phone]. Fax: [phone]
www.tfc-group.co.uk
Ensure that the guard is tted centrally.
The air inlet/products outlet duct and the terminal of the
boiler MUST NOT be closer than 25mm (1”) to combustible
material. Detailed recommendations on the protection of
combustible material are given in BS. 5440-1: 2008. In IE refer to
I.S.813:2002.
The ue must be installed in accordance with Building
Regulations and the recommendations of BS. 5440-1:2008 for
inputs up to 70kW nett. For larger installation BS. 6644 should be
complied with. In IE refer to I.S.820:2000.
!
DANGER; ONLY USE OPEN FLUE GAS SYSTEMS
WHERE THE EVOMAX AIR INLET KIT IS USED. THE
BOILER CE MARK IS VALID ONLY IF THE APPLIANCE
IS OPERATED WITH THE IDEAL AIR INLET KIT.
!

10 EVOMAX - Installation & Servicing
GENERAL
WATER CIRCULATION SYSTEM
The system pump MUST be connected to the boiler, see below.
The boiler must NOT be used for direct hot water supply. The hot
water storage cylinder MUST be of the indirect type.
Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat loss
and any possible freezing - particularly where pipes run through
roof spaces and ventilated underoor spaces.
The boiler must be vented.
Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler
and hot water storage vessel. They should be at least 1/2” BSP
nominal size and be in accordance with BS. 2879.
The central heating system should be in accordance with the
relevant standards listed on page 8.
Due to the compact nature of the boiler the heat stored within the
castings at the point of shutdown of the burner must be dissipated
into the water circuit in order to avoid overheating. In order to
allow pump operation after burner shutdown the boiler control box
incorporates a 4 minute pump overrun facility. In order to make use
of this, the pump must be supplied from the terminals inside the
boiler. Note: for pumps requiring a current greater than 1.3 amps
inductive, they must be connected via a relay.
When sizing pumps, reference should be made to the table below
which show the boiler resistance against ow rates, to achieve the
required temperature differential.
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 21.5 425 225 127
Evomax 40/40P 52.1 38.2 28.7 875 405 225
Evomax 60/60P 78.2 57.3 43.0 435 180 83
Evomax 80/80P 104.2 76.4 57.3 750 420 180
Evomax 100 * 95.6 71.7 * 315 134
Evomax 120 * * 86.0 * * 218
Evomax 150 * * 107.5 * * 230
* Not recommended due to excessive owrates which may cause
erosion of the casting.
Note.
• With the boiler ring at maximum rate, the temperature
differential should not be less than gures quoted in table
above. High ow rates required for lower temperature
differentials could lead to errosion of the heat exchanger water
ways.
• With the boiler ring at minimum rate, the temperature
differential should not be greater than 35oC. Lower ow rates
generating higher temperature differentials will lead to lock out
of the boiler.
• The lower the return temperature to the boiler, the higher the
efciency.
In installations where all radiators have been provided with
thermostatic radiator valves, it is essential that water circulation
through the boiler is guaranteed. This can be best achieved
by means of a differential pressure valve, which is installed in a
bypass between the ow and return pipes. The bypass should
be tted at least 6m from the boiler, and should use a minimum
size of 28mm pipe. The bypass should be capable of allowing
a minimum ow rate to achieve a temperature differential of no
greater than 35oC at minimum rate.