IDEAL Evomax 30 User manual

EVOMAX
CONDENSING
BOILER
PRODUCT & FLUE GUIDE
WE HAVE IT COVERED.

02
Ideal Commercial Boilers is the UK’s market leader of
high efficiency commercial heating solutions.
Operating from its Hull manufacturing plant and offices
since 1906, Ideal Commercial Boilers is one of the few
true British manufacturers left in the heating industry.
Your phone or tablet can let you
appreciate our Evomax range in
a new dimension.
The Ideal Commercial Eye app
uses the latest technology to
project 3D renders from the page
of this brochure on to your device.
To see this for yourself, simply
download the Ideal Commercial
Eye app for free from your device’s
app store. Open the app and then
place your device over the boiler
image that has this icon next to it:
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03
2 Introduction
4-13 Evomax 30 - 150kW
14-25 Evomax Cascade 30 - 600kW
26-37 Evomax Flue Options
38-39 Flue Types
40-46 Guide to Flue Installation
& Regulation
47 Condensate Pumps
48-49 Ideal Training & Support

04
EVOMAX
30 - 150kW
*5 year warranty subject to Terms and Conditions. 5 years parts and labour warranty available subject to being commissioned by Ideal Boilers.

05

06
EVOMAX
30 - 150kW
Available in outputs of 30, 40, 60, 80, 100, 120 and 150kW, the
Evomax is designed to ensure all installation requirements can be
achieved. There is also an LPG Evomax range from 30 - 80 kW for
off mains installations.
• 5 year warranty*
• Robust & light aluminium silicon alloy
heat exchanger
• Up to 110% part load efficiency
• High 5:1 turndown
• Compact – one width & height for easy siting
• Simple controls interface with large
backlit display
• Comprehensive range of flue, fixing and
control options
• Designed for easy installation, commissioning
and servicing
• Proven reliability through design, component
selection and proving
• NOx <40mg/kWh (Class 5) for all natural gas
models for maximum BREEAM points
FEATURES & BENEFITS
*5 year warranty subject to Terms and Conditions. 5 years parts and labour warranty available subject to being commissioned by Ideal Boilers.
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07
1
3
4
5
7
68
9
10
12
11
2
500
‘C’
850
59 59
Gas
Flow Return
299
206210-10155
‘B’
‘A’
155
81
68
Gas pipe
Flow/return
Condensate drain
Flue centre line Flue centre line
DIMENSIONS & CLEARANCES
BOILER ASSEMBLY
BOILER DIM A DIM B DIM C
30, 40, 60, 80 360 130 118
100, 120 520 226 118
150 610 233 120
The following minimum clearances must be
maintained for operation and servicing:
TOP: DEPENDENT
ON FLUE SIZE SIDES: 25mm
FRONT: 450mm BOTTOM: 300mm
CLEARANCE BETWEEN MULTIPLE BOILER
INSTALLATIONS: 25mm
KEY
1. Auto Air Vent
2. Burner Fixings
3. Fan
4. Gas Valve
5. Venturi
6. Flow Thermistor
7. Ignitor Unit
8. Electrode Detection
9. Ignition Electrode
10. Fascia and Controls
11. Door Assembly
12. Water pressure sensor
INTERNAL VIEW
(80kW MODEL SHOWN)
All dimensions in mm

08
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
Net 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
Net 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
NOx with O₂
= 0% Weighted
mg/
kWh 31.0 79 39.1 80 32.3 83.8 39.8 68 39.6 38.8 38.1
ppm 17.6 45 22.2 45 18.3 47. 5 22.9 38.5 22.5 22.0 21.6
Efficiency
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
Operating
Temperature Max ˚C 82
EVOMAX 30 - 150 KW
PERFORMANCE DATA

09
EVOMAX 30 - 150 KW
GENERAL DATA
MODEL 30/30P 40/40P 60/60P 80/80P 100 120 150
Gas Supply 2H - G20 - 20mbar / 3P - G31 - 37mbar
Gas Supply
Connection G ¾
Flow Connection G1 ¼
Return Connection G1 ¼
Max Pressure
(sealed system) Bar (psi) 4.0 (58)
Maximum Static Head m 40.7
Electricity Supply 230V - 50Hz
Fuse Rating A 4.0
Power Consumption W 126 207 131 265 370 403 400
IP Rating IP20
Nominal Flue Size
(concentric) mm 80/125* 100/150 100/150**
Condensate Drain mm 25
Water Content l 3.0 5.0 7.0 9.2
Dry Weight Kg 49 60.30 75.70 89.75
*Optional kit available on 60/80 models for 100/150mm flue **For use with vertical flues only.
BOILER EVOMAX
Remote indication (run & alarm)
Hours run
BMS (0-10v) operation
Pump overrun
Large backlit LCD controls,
including 5 line plain text display
BOILER EVOMAX
Modulating Sequencer kit
Programmable Room Thermostat kit
Outside sensor kit
Tank Sensor kit
Room sensor kit
Safety Interlock kit
Fittings kit
Pump kit
Multi boiler frame & header kits
(includes low height options)
Connection kit (includes isolation valve
1¼”, non return valve, safety valve and
drain cock)
INCLUDED AS STANDARD OPTIONAL KITS

10
SUGGESTED ENGINEERING SPECIFICATION
OVERVIEW
The boilers must be fully automatically controlled, wall
mounted, fanned, super-efficient condensing appliances
utilising an aluminium silicon alloy heat exchanger and be
suitable for connection to fully pumped open vented or
sealed water systems.
CONTROLS
The condensing boilers must have connectivity
for all common types of BMS integration including
0-10v, volt free and OpenTherm connections. Additional
modules may be used for BACnet, LONWorks and
MODBus gateways. Where no BMS is present a
modulating sequencer must be available.
The boiler must be fully modulating with a 5:1 turndown
ratio and include control features enabling set point
adjustment, heating circuit control of one constant
temperature and one DHW circuit or 2 constant
temperature circuits, and safety lock out parameters
including fault diagnosis for both boiler and external
components such as sensors or pumps.
Boiler capabilities must include, with the use of
external components, frost protection, weather or room
compensation and system pump control.
FLUE
The condensing boilers must be suitable for use with a
room sealed flue or open flue applications including
C13, C33 and B23 classifications. The combined flue
outlet and air inlet must be situated on the top
of the boiler.
HYDRAULIC
The condensing boiler must be and be suitable for
connection to fully pumped open vented or sealed
water systems. All hydraulic connections including flow
return and condensate drain must be located on the
bottom of the boiler. Hydraulic connections must be
uniform across the outputs available in the range to
ensure ease of installation and maintenance in mixed
output cascades. The boiler must have a maximum
operating pressure of 6 bar and be suitable for heating
and indirect hot water systems.
DIMENSIONS
The condensing boiler range must have a universal
compact width and height across the range to ensure
mixed output cascades maintain the same universal
configuration. Maximum permitted wall area of 0.43m².
MOUNTING
The condensing boilers can be installed either on the
wall or into a prefabricated floor mounted frame. Wall
brackets must be located at the top of the boiler and
visible from the front to aid installation.
EFFICIENCY
The condensing boilers are capable of high seasonal
efficiencies with a minimum requirement of 96.2% and
low NOx emissions no greater than 39.8mg/kWH for
natural gas and 80mg/kWH for LPG.
30, 40 and 60kW models must have a Seasonal Space
Heating Energy Efficiency of A.
APPROVALS
The boiler must be tested and certified 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. Boilers are certified to meet the
requirements of the EC Gas Appliance Directive, Boiler
Efficiency Directive, EMC and Low Voltage Directive.
The manufacturer must be ISO 9001 accredited.
SPECIFICATION
• The 30, 40, 60 and 80kW boiler will be capable of
flow rates for common systems using either 11ºC,
15ºC or 20°C temperature differentials.
• The 100kW boiler will be capable of flow rates for
common systems using either 15°C or 20°C
temperature differentials.
• The 120 and 150kW boiler will be capable of
flow rates for common systems using 20°C
temperature differentials.
SOURCING
The condensing boiler must be manufactured or finally
assembled in the United Kingdom.
CASCADE
The boiler must be configurable up to 6 boilers (max
600kW) in cascade using a prefabricated frame and
header kit.
WARRANTY
The boiler must be available with a 5 year warranty.

11
SYSTEM TEMPERATURE
CONTROL KITS
FLUE SYSTEMS
DIFFERENTIALS
Flow rates for common systems using either 11°C, 15°C or 20°C temperature differentials
are given in the table below.
FLOW RATE (L/MIN) HYDRAULIC RESISTANCE (MBAR)
BOILER 11°C 15°C 20°C 11°C 15°C 20°C
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 N/A 95.6 71.7 N /A 315 134
Evomax 120 N/A N /A 86.0 N/A N/A 218
Evomax 150 N/A N /A 107.5 N /A N /A 230
• 30-80 kW boilers must operate with temperature differentials from 11 to 20°C.
• 100 kW boilers must operate with temperature differentials not less than 15 to 20°C.
• 120-150 kW boilers must operate with temperature differentials not less than 20°C.
See pages 74-77 for further system requirements
A comprehensive range of flue kits are available from
Ideal Commercial Boilers including horizontal and vertical
concentric and open flue options.
For horizontal flues: this is the distance from the flue outlet
centre line on the boiler to the outside wall. Horizontal flue
termination is not available for Evomax 150.
For vertical flue: this is the distance from the top of the
boiler case to the aperture in the weather collar. If elbows
are to be used, then the equivalent length of that fitting
must be subtracted from the maximum flue extensions
allowed for that flue option.
Note: Horizontal terminal resistance includes 1 x 90° elbow.
When installing Evomax boilers with concentric flue
(horizontally or vertically) the Ideal Commercial flue
system must be used.
The resistance of flue components, together with the
maximum flue resistance each boiler can work against, may
be used to calculate the total flue resistance of the system,
and to determine if they are acceptable to run on the boiler.
Multiple boilers may be installed with a common
flue header.
The flue system should be designed and supplied by a
specialist flue company. BS 6644 and IGEM UP/10 provide
guidance on design and the drainage of condensate from
flue stack and headers. Condensate from a flue stack and
header must be collected and drained before entering
the boiler.
For Ventilation requirements please refer to the
installation manual..
PROGRAMMABLE ROOM THERMOSTAT KIT.
Timed control of central heating. Includes a built in
electronic room sensor, optimised start and on/off
controlled DHW.
MODULATING SEQUENCER KIT.
Controls up to 5 boilers for cascade operation.
Air and Flow Header sensors are included.
OUTSIDE SENSOR KIT.
Provides weather compensation directly or with
Programmable Room Thermostat kit.
TANK SENSOR KIT.
Provides DHW temperature control. Also for use with
Sequencer kit.
ROOM SENSOR KIT.
Used with Modulating Sequencer kit for CH control.
SAFETY INTERLOCK KIT.
Provides boiler shut down via an external signal.

12
S1
PRESSURISATION UNIT
BOILER PUMP
HEATING PUMP
TO HEATING CIRCUITS
PRIMARY HWS 1
HWS SENSOR
FROM HEATING CIRCUITS
P1
P2
P3
S2
TO DRAIN
S3
TANK
SECONDARY
HWS 1
P5
LOW
LOSS
MIXING
HEADER
SYSTEM LAYOUT
TYPICAL SYSTEM BOILER LAYOUT
* Low loss header may not be required depending on system design and pump sizing

13

14

15
EVOMAX
CASCADE
30 - 600kW

16
EVOMAX CASCADE
FRAME & HEADER KITS
BOILER FRAME AND HEADER KITS
The Frame and Header Kits are suitable for modular (cascade) boiler
installations, and are available up to a maximum output of
600 kW, in both in-line and back-to-back arrangements.
IN-LINE KITS
Kits include flow & return headers with mixing header and gas
header, all with fixing brackets. For easy connection flexible stainless
steel pipe and connections are supplied together with pressure relief
valves, boiler shut off valves and drain cock.
Appropriately sized ErP modulating shunt pumps are also included.
Flow, return and low loss headers together with the flexible boiler
connections are all pre insulated. Separate single boiler frame kits
are available for use with in-line kits if required.
BACK-TO-BACK KITS
Kits include all the in-line contents plus the required special frame
kits for such compact installations. Both types of kit are available
for the following number of boilers and sizes. Mixing header kits and
modulating pump kits are also available separately.
In-line kits do not include the support frame as the boilers can be wall mounted, but a frame kit is
available if the wall is unsuitable to facilitate boiler mounting.
For full details of all configurations & specifications, please refer to the installation manual.
MODELS SIZE
2 boilers 30-100 DN80
2 boilers 120-150 DN80
3 boilers 30-100 DN80
3 boilers 120-150 DN100
4 boilers 30-100 DN100
4 boilers 120-150 DN100
5 boilers 30-100 DN100
5 boilers 120 DN100
6 boilers 30-100 DN100
Please note, the Evomax boilers are to be ordered separately.
AVAILABLE OPTIONS
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17
FRAME & HEADER KITS
300
650
300
650
1100
25
1480
25
2 X EVOMAX 30 - 150 KW
3 X EVOMAX 30 - 150 KW
4 X EVOMAX 30 - 150 KW
HEADER
KITS RATING HEIGHT (mm)
LENGTH
(mm)
DEPTH
(mm)
DN
FLANGE
SIZE
CONCENTRIC
FLUE
UIN209799
30-80kW 1945 1100 552 DN80 80/125
100kW 1945 1100 552 DN80 100/150
UIN209798 120-150kW 1945 1100 552 DN80 100/150
HEADER
KITS RATING HEIGHT (mm)
LENGTH
(mm)
DEPTH
(mm)
DN
FLANGE
SIZE
CONCENTRIC
FLUE
UIN209801
30-80kW 1945 1650 552 DN80 80/125
100kW 1945 1650 552 DN80 100/150
UIN209800 120-150kW 1945 1650 552 DN100 100/150
HEADER
KITS RATING HEIGHT (mm)
LENGTH
(mm)
DEPTH
(mm)
DN
FLANGE
SIZE
CONCENTRIC
FLUE
UIN209803
30-80kW 1945 2200 552 DN100 80/125
100kW 1945 2200 552 DN100 100/150
UIN209802 120-150kW 1945 2200 552 DN100 100/150
1945
300
650
300
650
1100
25
1480
25
300
650
300
650
1100
25
1480
25
Measurements are without boilers attached. 100-150kW boilers are deeper than Frame and Header Kit.
Measurements are without boilers attached. 100-150kW boilers are deeper than Frame and Header Kit.
Measurements are without boilers attached. 100-150kW boilers are deeper than Frame and Header Kit.

18
5 X EVOMAX 30 - 120 KW
6 X EVOMAX 30 - 100 KW
300
650
300
650
1100
25
1480
25
1945
300
650
300
650
1100
25
1480
25
1945 1945
HEADER KITS RATING HEIGHT
(mm)
LENGTH
(mm)
DEPTH
(mm) DN FLANGE SIZE CONCENTRIC FLUE
UIN209805
30-80kW 1945 2750 552 DN100 80/125
100kW 1945 2750 552 DN100 100/150
UIN209804 120kW 1945 2750 552 DN100 100/150
HEADER KITS RATING HEIGHT
(mm)
LENGTH
(mm)
DEPTH
(mm) DN FLANGE SIZE CONCENTRIC FLUE
UIN209806
30-80kW 1945 3300 552 DN100 80/125
100kW 1945 3300 552 DN100 100/150
Measurements are without boilers attached. 100-120kW boilers are deeper than Frame and Header Kit.
Measurements are without boilers attached. 100kW boilers are deeper than Frame and Header Kit.

19
SYSTEM DESIGN OPTIONS
TOTAL OUTPUT
REQUIRED KW
NO.
OF BOILERS
SIDE BY SIDE OPTION
– BOILER MODELS
SIDE BY SIDE
FOOTPRINT SIZE
W X D (MM)
HEADER KIT
PRODUCT NO.
SIDE BY SIDE
BOILER
MODELS
BACK TO BACK
FOOTPRINT SIZE
W X D (MM)
FRAME/
HEADER
PRODUCT NO.
BACK TO BACK
60 2 30 1480 x 552 209799 30 930x950 209901
70 2 30 + 40 1480 x 552 209799 30 + 40 930x950 209901
80 2 40 1480 x 552 209799 40 930x950 209901
90 2 30 + 60 1480 x 552 209799 30 + 60 930x950 209901
100 2 40 + 60 1480 x 552 209799 40 + 60 930x950 209901
110 2 30 + 80 1480 x 552 209799 30 + 80 930x950 209901
120 2 60 1480 x 552 209799 60 930x950 209901
130 3 30, 40 + 60 2030 x 552 209801 30, 40 + 60 480x950 209903
140 2 60 + 80 1480 x 552 209799 60 + 80 930x950 209901
150 3 30, 40 + 80 2030 x 552 209801 30, 40 + 80 480x950 209903
160 2 80 1480 x 552 209799 80 930x950 209901
170 3 30, 60 + 80 2030 x 552 209801 30, 60 + 80 480x950 209903
180 2 80 + 100 1480 x 573 209799 80 + 100 930x1096 209901
190 3 30, 60 + 100 2030 x 573 209801 30, 60 + 100 480x1096 209903
200 2 100 1480 x 573 209799 100 930x1096 209901
210 4 30, 40, 60 + 80 2580 x 552 209803 30, 40, 60
+ 80 1480x950 209905
220 3 2 x 60 + 100 2030 x 573 209801 2 x 60 + 100 1480x1096 209903
230 4 30, 40, 60 + 80 2580 x 573 209803 30, 40, 60
+ 100 1480x1096 209905
240 2 120 1480 x 663 209798 120 930x1276 209900
250 4 30, 60, 2 x 80 2580 x 552 209803 30, 60, 2 x 80 1480x950 209905
260 3 60, 2 x 100 2030 x 573 209801 60, 2 x 100 1480x1096 209903
270 2 120 + 150 1480 x 663 209798 120 + 150 930x1276 209900
280 3 80, 2 x 100 2030 x 573 209801 80, 2 x 100 1480x1096 209903
290 4 30, 60, 2 x 100 2580 x 573 209803 30, 60, 2 x 100 1480x1096 209905
300 2 150 1480 x 663 209798 150 930x1276 209900
310 4 30, 80, 2 x 100 2580 x 573 209803 30, 80, 2 x 100 1480x1096 209905
320 4 40, 80, 2 x 100 2580 x 573 209803 40, 80, 2 x 100 1480x1096 209905
330 4 30, 3 x 100 2580 x 573 209803 30, 3 x 100 1480x1096 209905
340 4 60, 80, 2 x 100 2580 x 573 209803 60, 80, 2 x 100 1480x1096 209905
350 5 30, 40, 80, 2 x 100 3130 x 573 209805 30, 40, 80,
2 x 100 2030x1096 209907
FRAME & HEADER KITS

20
TOTAL OUTPUT
REQUIRED KW
NO. OF
BOILERS
SIDE BY SIDE OPTION –
BOILER MODELS
SIDE BY SIDE
FOOTPRINT SIZE
W X D (MM)
HEADER KIT
PRODUCT NO.
SIDE BY SIDE
BOILER
MODELS
BACK TO BACK
FOOTPRINT SIZE
W X D (MM)
FRAME/HEADER
PRODUCT NO.
BACK TO BACK
360 3 120 2030x663 209800 120 1480x1276 209902
370 5 30, 40, 3 x 100 3130x573 209805 30, 40, 3 x 100 2030x1096 209907
380 4 80, 3 x 100 2030x573 209801 80, 2 x 100 1480x1096 209903
390 3 2 x 120 + 150 2030x663 209800 2 x 120 + 150 1480x1276 209902
400 4 100 2580x573 209803 100 1480x1096 209905
410* 5 30, 80, 3 x 100 3130x573 209805 30, 80, 3 x 100 2030x1096 209907
420 3 120, 2 x 150 2030x663 209800 120, 2 x 150 1480x1276 209902
430* 5 30, 4 x 100 2580x573 209805 30, 4 x 100 1480x1096 209905
440* 5 40, 4 x 100 2580x573 209805 40, 4 x 100 1480x1096 209905
450 3 150 2030x663 209800 150 1480x1276 209902
460* 5 60, 4 x 100 3130x573 209805 60, 4 x 100 2030x1096 209907
470* 6 30, 40, 3 x 100 3680x573 209806 30, 40, 3 x 100 2030x1096 209908
480 4 120 2580x663 209802 120 480x1276 209904
490* 6 30, 60, 4 x 100 3680x663 209806 30, 60, 4 x 100 2030x1096 209908
500 5 100 3130x573 209805 100 2030x1096 209908
510 4 3 x 120 + 150 2580x663 209802 3 x 120 + 150 1480x1276 209904
520* 6 40, 80, 4 x 100 3680x573 209806 40, 80, 4 x 100 2030x1096 209908
530* 6 30, 5 x 100 3680x573 209806 30, 5 x 100 2030x1096 209908
540 4 2 x 120, 2 x 150 2580x663 209802 2 x 120, 2 x 150 1480x1276 209904
550 N/A N/A N/A N /A N/A N/A
560* 6 60, 5 x 100 3680x573 209806 60, 5 x 100 2030x1096 209908
570 4 120, 3 x 150 2580x663 209802 120, 3 x 150 1480x1276 209904
580* 6 80, 5 x 100 3680x573 209806 80, 5 x 100 2030x1096 209908
590 N /A N /A N /A N /A N/A N /A
600 4 150 2580x663 209802 150 1480x1276 209904
SYSTEM DESIGN OPTIONS - CONTINUED
OPTION GAS TYPE EVOMAX MODELS MAX NUMBER OF BOILERS MAX SYSTEM CAPACITY
1
Natural gas
Combinations of 100, 120, 150 6 600kW
2Combinations that include a
30, 40, 60 or 80 6 400kW
3 Propane Combinations of
30P, 40P, 60P, 80P 6 400kW
• Allows Evomax boilers installed as open flue to be connected via a
common flue header, creating a single line connection point
• Basic kit includes, appliance connection, non-return flue damper,
condensate tee and trap and all clips to secure the flue
• Extension pack includes appliance connection, non-return
flue damper, and all clips to secure the flue
• Available for both 80/125 & 100/150 flue adaptor applications
• For installations up to 600kW as both a starter kit and extension pack
Flue height = 570mm from the top of the first boiler in the system.
Increase the height 29mm for each adjacent boiler.
* Not suitable configuration for multiline flue
FEATURES AND BENEFITS
MULTILINE FLUE CASCADE