IDEAL Evomax 30 User manual

February 2016
UIN 211389 A02
MULTILINE FLUE KIT
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.

EVOMAX - MULTILINE FLUE KITS
2
GENERAL
CONTENTS
Introduction ...................................................................... 3
Cascade Flue Components ............................................. 4
Assembly .......................................................................... 5
Flue Design ....................................................................... 6
Commissioning ................................................................ 9
Starter Kit Components ................................................. 10
Extension Kit Components ........................................... 12
NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.

EVOMAX - MULTILINE FLUE KITS 3
INTRODUCTION
1.0 EVOMAX CASCADE FLUE SYSTEM
1.1 INTRODUCTION
The Cascade Flue system enables Evomax boilers of ‘open
ue’ Type B23 to be connected via a common ue header.
The Cascade Header may be coupled to a bespoke ue outlet
system designed by a ue specialist (section 3).
To ensure safety of operation non-return valves are
incorporated to prevent back-ow of combustion products
through any individual boiler that is not ring.
The condensate produced within the ue drains through the
central trough of the header duct and exits via a siphon.
The maximum permissible system capacity is limited to
the value shown in Table 1.2; this is necessary to ensure
acceptable operation of any individual boiler operating at
its minimum output under the inuence of the total system
pressure generated by the adjacent boilers.
There are optional system congurations that will provide
different characteristics, these options should be considered to
optimise the system performance. (Table 1.2).
1.2 SYSTEM CONFIGURATIONS
Choosing the most appropriate conguration to the required
application will inuence the performance in the following ways;
• System Capacity.
• Number of Boilers
• Turn-Down capability
•Flue length capability Refer to Section 3.0 for details
Option Gas Type Evomax Models
Max
number
of boilers
Max
System
Capacity
1
Natural
Gas
Combinations of
100,120,150 6600kW
2
Combinations
that include a
30,40,60 or 80
6400kW
3 Propane Combinations of
30P,40P,60P,80P 6400kW
Non Return Valves Header
Condensate Drain
(Siphon) Evomax Cascade Boilers (Type B23)
3.0°

COMPONENTS
2.0 CASCADE FLUE COMPONENTS
(FIGURE 2.1)
4EVOMAX - MULTILINE FLUE KITS
2
13
4
5
6
7
8
9
1End Cap
2Siphon
3Collector Pipe (200 dia)
4Elbow (90° x 100)
5Non-Return Valve Connector (100 x 150)
6Non-Return Valve Body (150 x 100 or 80)
7Flue Extension Tube (100 or 80)
8Air Intake Grill
9Flue Connector (100/150 or 80/125)
The Cascade Flue system is supplied in two kits.
A Starter Kit & Extension Kit.
Wire retaining clips are also provided to prevent movement
of the tube connections by the inuence of expansion and
contraction. These must be tted to the ductwork to ensure
safe operation of the system.
2.2 STARTER KIT
This kit comprises all of the items shown in Figure 2.1.
There are two Kits available;
UIN 210264 for the 30-80 models
UIN 210268 for the 100-150 models
Drawings appended (p10 & p11)
2.3 EXTENSION KIT
This kit comprises the components required to t additional
single boilers to the system.
There are two Kits available;
UIN 210265 for the 30-80 models
UIN 210269 for the 100-150 models
Drawings appended (p12 & 13)

COMPONENTS
5EVOMAX - MULTILINE FLUE KITS
2.4 ASSEMBLY
It is recommended that Evomax applications of the Cascade
Flue System should be installed in combination with the Ideal
Frame & Header Kit.
The Polypropylene ue tubes are designed to assemble
together by push t connection, a recessed exible seal is
incorporated to create a gas tight join.
The seal should be lubricated with water to facilitate assembly.
Other lubricants must not be used.
The non-return valve is a two part assembly; the valve connector
and the valve body. The valve connector has an eccentric axis, by
rotation of the connector the relative position of the boiler and header
may be adjusted. This feature will accommodate any positional
tolerance of the header during installation and permit 30-80 models
and 100-150 models within the same system (Figure 2.5).
The ue extension tube is either 80mm dia or 100mm dia
according to the models being installed, the supplied ue tube
length is 500mm.
The header gradient should be 3 degrees falling to the
condensate drain end to allow adequate condensate drainage;
to create this slope the extension tubes of adjacent boilers
must be cut to the required length (Fig 2.6).
Condensate Drain Connection
For the correct termination of the condensate drain refer to
the advice given with respect to condensate drain acceptable
practice as provided in the Installation and Servicing
Instructions provided with the Evomax appliance.
The ue connector is specic to either the 30-80 models
or 100-150 models, the inner tube is manufactured in
Polypropylene in accordance with the cascade system. Flue
connectors with an aluminium inner tube must not be used.
2.7 WIRE RETAINING CLIPS
To prevent movement of the tube connections by the inuence
of expansion and contraction, securing clips are provided. The
wire spring clip locates under the rim of the female component
and is secured by a nut and bolt around the locating spigot,
this creates a resistance to any opposing force. (Fig 2.9)
There is one Wire Retaining Clip provided for each of the
ue connections.
The wire retaining clips must be tted to every join to ensure
safe operation of the system.
FIGURE 2.5 ECCENTRIC VALVE
CONNECTOR POSITIONING
Cascade Header
Evomax 30-80
Evomax 100-120
550 mm
550 mm
130 mm
226 mm
550mm
Extension Tube Length
29mm
3deg
Increase in the
extension tube
length required
between
adjacent boilers
= 29mm
2.8 HEADER INSTALLATION
The Cascade Header is suspended from a ceiling or overhead
structure by studding attaching to brackets holding the
circumference of the header duct. There is one bracket and
stud rod supplied with each of the Starter & Extension Kits.
(Fig 2.9)
The boiler ue tube of each boiler is secured by a clamp and
tie rod either to a wall or supporting structure. (Fig 2.9)
FIGURE 2.9
Support
Bracket
Clip
Clip
Clip
Clip
FIGURE 2.6 CONDENSATE
FALL DIMENSIONS
Wire retaining clips are also tted to the starter kit
End Cover and Syphon connection (not shown).
Refer to diagrams shown in pages 10-13 for
correct location of all wire retaining clips.
Important: All wire retaining clips must be tted
to the ductwork to ensure safe operation of the
system.

EVOMAX - MULTILINE FLUE KITS
6
FLUE DESIGN
!
3.0 FLUE DESIGN
3.01 The following standards are relevant to the
construction, installation & testing of ue systems.
BSEN 14471 Plastic Chimneys –
requirements and test methods
BSEN 1856-1 Metal Chimneys – Requirements
BSEN 1859 Metal Chimneys – Test methods
BS 6644 Installation & Maintenance
of gas red hot water
boilers 70kW – 1.8MW
3.0.2 The Flue Stack must be specied by a Flue Specialist
3.0.3 Design of the connecting ue spigot must refer to the
dimensions of the mating collar (Fig 3.1).
3.0.4 The Polypropylene header and EPDM seal are certied
to BSEN 14471.
3.0.5 Integrity of the ue joints and safety of operation must
be proven by the installer.
3.0.6 The ue resistance at ‘A’ in Figure 3.2 is not permitted to
exceed the maximum static pressure specication [Pmax]
quoted in Table 3.3 when operating at the maximum
capacity.
IMPORTANT: LEAKAGE OF FLUE PRODUCTS INTO THE ROOM WILL DEPLETE
THE OXYGEN LEVEL & INHIBIT SAFE COMBUSTION .
3.0.7 The ue route should be planned to enable the least
directional change, one elbow is recommended as
depicted in Figure 3.2.
3.0.8 The ue pipe diameter must be at least 200mm, larger
diameters will permit longer ue length.
3.0.9 The ue material must be suitable for condensing
operation.
3.0.10 The terminal guard must prevent the ingress of objects
greater than 15mm diameter to comply with EN15502.
3.0.11 The Flue Terminal design should be selected to create the
least resistance and not compromise the potential ue
length. A wire mesh type is recommended with a
14mm grid.
3.0.12 Rain ingress may be ignored as the header design
enables excess water to be discharged through the
condensate drain.
FIGURE 3.1
(CASCADE HEADER INTERFACE DETAIL - FEMALE FLUE SOCKET CONNECTION)
70.0 mm
Sealing Ring
PR-RING 1-LIPS HR-EPDM 200 ZWART
Inside 202.0 mm
+0.6 mm
-1.0 mm
Cascade Header Interface Detail
Cascade Header
NOTE: Connecting ue must comply with CE approval requirements

EVOMAX - MULTILINE FLUE KITS 7
FLUE DESIGN
Evomax
Model Output Cascade System Limits Combustion Products Data
Model
Maximum
System
Capacity
Maximum
Permissible
Header
Pressure
‘A’
(Static)
max
rate
CO2
min
rate
CO2
Temperature
Max
Max Min Hmax Pmax ± 0.5 ± 0.5
kW kW kW Pa % % C
30 7.5
400 40
9.7 9.0
72
40 10
60 15
80 20
100 25
600 80120 30
150 37.5
30P 7.5
400 40 11.4 10.6
40P 10
60P 15
80P 20
FIGURE 3.2
(FLUE SYSTEM LAYOUT)
Customer specified components
'A''A'
At the maximum system
capacity the static pressure
generated against the ue
resistance at position [A]
must not exceed the value
Pmax quoted in Table 3.3.
3.3 EVOMAX CASCADE FLUE SYSTEM DATA 3.4 DESIGN PROCEDURE
1. Determine the required total heat output. (Htot) [maximum
of 6 boilers per system].
2. Determine the required minimum heat output.
3. From Table 3.3 select the Evomax models required.
4. Using Figure 3.5 read the Combustion Products Flow Rate
(Qmax) at the Total System Capacity (Htot).
5. Record the information in Table 3.6
6. Calculate the maximum permissible ue length at
conditions Qmax & Pmax.
L = [a – (c + d)] / b (Table 3.6)

EVOMAX - MULTILINE FLUE KITS
8
FLUE DESIGN
FIGURE 3.5
(COMBUSTION PRODUCTS FLOW RATE)
FIGURE 3.6
(EVOMAX CASCADE FLUE SYSTEM DATA)
System System
Models System Capacities Combustion Products Data Flue Data
Total Min
Turn
Down
Ratio
Flow Rate
Qmax
Header
Pressure
Pmax
Pressure Losses Max
length
Htot Hmin Mass
Vol
@
50C
(a)
static
(b)
1m
(c)
90°
(d)
guard L
kW kW Kg/hr m3/hr Pa Pa Pa Pa m
Ex 1 (4x80) +
(1x30) 350 7.5 40:1 550 525 40
Ex 2 3 x 120 360 30 12:1 560 550 80
050100 150200 250300 350400 450500 550600 650
0
100
200
300
400
500
600
700
800
900
1000
1100
Mass Flow Rate [kg/hr/
Volume Flow Rate @ mean flue temp 50C [cu m/hr]
Cascade Total System Capacity - Htot [kW]
Cascade Flow Rate - Qmax
Cascade Total System Capacity - Htot [kW]
Cascade Flow Rate - Qmax
Example 1
This example requires a total output of 350kW and comprises
(4 x 80) + (1 x 30) models; the inclusion of the 30kW model
enables the greatest turn-down (40:1) but the maximum
permissible header pressure is limited to 40Pa.
Example 2
The heat requirement here is also 350kW; by selecting 3 x
120kW models (360kW) the maximum permissible header
pressure is raised to 80Pa which will enable greater ue
length. The turn-down ratio will be reduced to 12:1.

EVOMAX - MULTILINE FLUE KITS 9
COMMISSIONING
4.1 EVOMAX CASCADE FLUE SYSTEM – MINIMUM RATE BOILER SETTINGS & DATA
Evomax Boiler Model 30 30P 40 40P 60 60P 80 80P 100 120 150
Fan Speed rpm 1980 2100 2400 2340 1800 1800 2340 2220 2280 1860 1800
Input net kW 7.6 7.6 10.1 10.1 15.2 15.2 20.5 20.5 25.6 30.7 38.4
gross kW 8.4 8.3 11.2 11.0 16.9 16.5 22.7 22.3 28.4 34.1 42.6
Output
non-condensing kW 7.5 7.5 10 10 15.0 15.0 20 20 25.0 30.0 37.5
Output
condensing kW 8.0 7.8 10.7 10.4 16.0 15.7 21.6 21.2 27.0 32.4 40.5
Flue CO2± 0.5 %9.0 10.6 9.0 10.6 9.0 10.6 9.0 10.6 9.0 9.0 9.0
NOx
(weighted) Cat 5 mg/kWh 33 82 41 84 35 84 42 68 43.5 41 40.5
4.0 COMMISSIONING
To accommodate the ue pressure generated by the
connection of multiple boilers to a common ue, the minimum
rate (equivalent to minimum fan speed) of each Evomax
appliance operating on the Multiline cascade system is
increased to offset the maximum back-pressure created.
Table 4.1 shows the revised performance of each Evomax
model where it differs from standard standalone operation as
shown in the Evomax Installation & Servicing instructions.
To convert Evomax operation with the Multiline ue as
described, the change is made by accessing the operating
parameters on the Evomax user interface control panel
following the procedure below. This change must be made to
each Evomax operating on the Multiline cascade system.
Procedure for selecting Multiline cascade ue operation
on Evomax user interface control panel.
1.0 Press SELECT and then hold + and – buttons down
together for more then 5 seconds, the following screen
will be displayed.
2.0 Rotate the KNOB clockwise and scroll downwards
towards the end of the list until the following screen is
displayed.
3.0 Press SELECT and the following screen will be
displayed.
4.0 Press + or - to highlight ‘Multiline Flue’ and then press
ENTER to store.
5.0 Rotate the KNOB clockwise until Normal Operation
is highlighted again and press SELECT to return to
normal operation.
INSTALLER MODE
NORMAL OPERATION
SET FLOW TEMP’
SET DHW TEMP’
INSTALLER MODE
FLAME/LPG RELAY
FLUE SETTING
NORMAL OPERATION
INSTALLER MODE
STANDARD FLUE
MULTILINE FLUE

STARTER KITS
10 EVOMAX - MULTILINE FLUE KITS
STARTER KIT COMPONENTS FOR 30-80 MODELS [UIN 210264]
1
2
3
5
49
14
813 6 7
10
11
12 12
15
16
POS. QTY. DESCRIPTION
11 ADAPTER CONCENTRIC PP 80/125 + MP
21 AIR INLET GRILL AL 125-80 H=85
31 EXTENSION PP 80x500
41 VALVE PP 80-150
51 REDUCER EXC. PP 150-100
61 ELBOW SHORT PP 100 90°
71 COLLECTOR PP 200x610 1x100 45°
81 COVER PP 200 + CONDENSATE
91 SYPHON PP H=150
10 1 LOCKING CLIP 80
11 1 LOCKING CLIP 150
12 2LOCKING CLIP 100
13 1 LOCKING CLIP 200
14 1LOCKING CLIP 32
15 1 WALL BRACKET 80 RAL-9016
16 2WALL BRACKET AL 200 + WALL PLATE
Dn 80