IDEAL DN50 User manual

February 2016
UIN 252427 A02
LOW HEIGHT FRAME
& HEADER KITS
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.

2
EVOMAX - Low Height Frame & Header Kits
Evomax 30, 40, 60, 80, 100, 120, 150, 30P, 40P, 60P 80P
This kit is suitable for the following boilers:
CONTENTS
1 Introduction.....................................................................3
2 General Description Of Systems...................................4
3 System Components......................................................6
4 Installation Drawings For Boiler Systems....................8
5 Installation Procedure..................................................10
6 Electrical Connections.................................................14
7 Commissioning And Testing .......................................14
IMPORTANT
THESE KITS MUST ONLY BE USED IN CONJUNCTION WITH
LOW LOSS HEADERS
IDEAL PROVIDE 3 OPTIONAL LOW LOSS HEADER KITS
DN50 - UIN 209394
DN65 - UIN 209395
DN80 - UIN 252437

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EVOMAX - Low Height Frame & Header Kits
1 INTRODUCTION
These low height rig kits have been designed to
enable them to be tted in a standard height room
leaving ample space for ue installations and are
supplied with gas and water header kits designed
for use with a low loss header system.
They are based around a single frame structure with
provision to bolt multiple frames side by side up to
3 wide, along with all the necessary mounting holes
to enable the tting of the header kits and frame
securing bolts.
This manual contains all the technical and
dimensional data required to install these kits.
GENERAL DESCRIPTION OF FRAME AND
HEADER KITS
These are a compact system with three single
frame congurations and integrated water and gas
headers, affording oor mounting capability to the
entire Evomax range of products. These systems
are adapted to incorporate the use of low loss
headers and optional sequencer control systems.
All these kits are supplied with the relevant
number of energy efcient pumps and necessary
parts needed to connect these kits to the
separately purchased Evomax appliances.
Check the kit contents with the list below.
UNPACKING
Kit Contents
Frame Water Header Hardware Pack
Connection
Hardware Pack
Misc
Pump
DN50 1 off 1 off 1 off n/a 1 off
DN65 2 off 1 off 1 off 1 off 2 off
DN80 3 off 1 off 1 off 1 off 3 off
The ue congurations for the Evomax range of appliances using these system kits are C13, C33 & B23 (See appliance
manual). Note. In the case of the 150kW boiler, this must be ued in accordance to the clean air act.
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

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EVOMAX - Low Height Frame & Header Kits
Available Rig
Congurations
Total Output
Required (KW)
Number of
boilers and
Frames
Footprint Size
WxDxH (mm)
Header Kit
Range Size
Prod No.
Single Frame Congurations 30 to 150 1 550 x 642 x 1550 DN 50 210012
Twin Frame Congurations 60 to 300 2 1100 x 642 x 1550 DN 65 210029
Triple Frame Congurations 90 to 450 31650 x 642 x 1550 DN 80 210020
Available Evomax Appliances
kW (NG) Product No.
30 205957
40 205958
60 205959
80 205960
100 205961
120 205962
150 205963
kW (Propane) Product No.
30P 205964
40P 205965
60P 205966
80P 205967
Low Loss Header Accessories
DN50 DN65 DN80
209394 209395 252437
Note.
All boilers need to be sized in accordance to the total required heat load and the modulation capabilites of the appliances.
Note.
When tted with 150 appliance, D=666 (from rear frame bolt to front of boiler)
A single boiler system is dened as tting one appliance on a single frame with a DN50 water header.
A two and three boiler system (cascade) is dened as tting two to three appliances on single frames that are bolted together
and share a common water and gas header (DN65 & DN80).
2.1 FRAME AND HEADER KIT DESIGN OPTIONS
2 GENERAL DESCRIPTION OF SYSTEMS
1. These water headers and pumps are designed for use with a low loss header system only.
2. Appliances are not provided with these kits and will be required to be purchased separately.

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EVOMAX - Low Height Frame & Header Kits
2.2 MULTIPLE BOILER INSTALLATIONS
When sizing multiple appliance installations, the minimum and maximum system heat load requirements need to be matched to the
minimum and maximum appliance load capabilities.
These water header & pump kits are design to supply the optimum water ow around the appliance water circuit only and must be used
in conjunction with a suitably sized low loss header (mixing header).
2.3 HYDRONIC ISOLATION: LOW LOSS HEADER
A low loss header allows ow separation within a hydronic system.
This allows two ow circuits to operate with their own ow and pressure drop environments whilst effectively transferring heat to its
adjoined water circuit.
This enables the modern high resistant, high ef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 provided are designed to 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 signalled provided by the appliance must be
maintained at all times.
External sequencers can be used with these appliances and are available as an option.
2.5 GAS SUPPLY
The 30, 40, 60 & 80 kW boilers are suitable for use with both natural gas and propane, category ll2H3P. The 100 120 & 150kW boiler
are only available for natural gas l2H.
Connection to the gas supply must be in accordance to with all the applicable regulations.
A single frame and DN50 water header kit will require the gas inlet to be made up to the gas tap provided, connecting it to the inlet of
the appliance.
2 and 3 boiler units will be supplied with a 2” gas header and all the necessary components and pipe work to connect it to the
appliances.
Note: Test points are provided at each end of the 2” gas header. The test point nearest to the gas inlet is intended to be used as the
appliance inlet pressure point.
2.6 ASSEMBLY
The frames must be located in a suitable place that affords 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 where necessary 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.
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.

6
EVOMAX - Low Height Frame & Header Kits
3.1 GENERAL
• Frames: These are provided in a single frame format and are
designed to be bolted side by side up to a maximum of three
frames and must be bolted together using the bolts provide.
• Water header with built in gas header cradles and mounting
brackets that allow its connection to the frames can be
obtained in DN50 single boiler format, DN 65 two boiler
format or a DN 80 three boiler format.
• 2” gas header with inlet test points
• All the pumps, associated safety controls, pipes and
ttings required to connect the water and gas header to the
appliances are supplied.
3.2 MAIN WATER HEADERS
The main water header consists of un-insulated water ow and
return pipes incorporating location and frame mounting brackets
sized to cater for the Evomax range of products available for use
with these kits.
The Single unit water header is a DN 50 pipe system with
threaded connections. (Threaded anges are provided with DN50
Evomax low height Low loss header kit).
The twin water header is a DN 65 pipe system with anged
connections and is available with the DN65 Evomax low height
Low loss header kit.
The three unit system uses a DN 80 pipe system with anged
connections and is available with the DN 80 Evomax low height
Low loss header kit.
3.3 GAS HEADER
The gas header consists of a 2” manifold tailored to t the two
or three unit versions available and is located in the cradle
incorporated in the water header bracket structure.
All the pipe work and connections are provided to connect the
header to the required appliance.
Test points are provided at each end of the 2” gas header. The test
point nearest to the gas inlet is intended to be used as the appliance
inlet pressure point.
3.4 LOW LOSS HEADERS (MIXING HEADERS)
All variants of these kits must be tted to suitably sized low loss header.
The Evomax low height low loss headers have been designed to
match the lower positioned water headers used in these kits. This has
required the drain point to be moved the lowest side point available.
Note; Bespoke low loss headers may not be able to connect directly
to these headers due to the change in pitch and position of the
header pipe work used in these kits. (See frame t low loss header)
Ideal recommend:- DN 50 – 209394, DN 65 – 209395,
DN 80 - 252437.
3.5 BOILER SHUNT PUMP
The pumps supplied with these kits are design to provide the
optimum ow around the appliance water circuit ensuring the
maximum ow rates are contain within the design constrains of
the appliance.
It is not recommended to t additional pumps directly to the
appliance circuit unless they have been designed to ensure the
maximum permissible appliance ow rate is not exceeded.
It is recommended that the appliance circuit pumps are set to
Constant Pressure setting.
Pumps supplied with these rigs are designed to be connected to
the relevant appliance electrical connections to ensure pump over
run capability is available to manage the appliances operation.
3.6 BOILER CONNECTION KITS
These boiler connections are un-insulated and contain the
following:
LEGEND
1. Tee 1 1/4" X 3/4" X 1 1/4"
2. Brass union 3/4" X 3/4"
3. Safety relief valve 3 bar
4. 1 1/4" X 1/2" X 1 1/4" Tee
5. Drain plug
6. Pump tting
7. Non return valve
8. Pump inc. gaskets
9. 1
1/4" taper male to 1 1/4" parallel hex adapter
Note. For boiler connection assembly, refer to Frame 5.3
3.7 FREE-STANDING FRAMES
The low height frames are designed to provide a compact oor
mounted structure capable of having any of the Evomax range of
appliances tted to them. Incorporating all the required mountings
and assembly systems to bolt up to three frames together in a
side by side format and mount the relevant water and gas heater
kits.
Provision is also provided to allow the frames to be bolted to the oor.
Note: Floor mounting bolts are NOT provided.
3.8 INSTALLATION AREA AND DIMENSIONS
Care must be taken to ensure adequate access for boiler /
cascade system installation and servicing.
A minimum of 450mm must be provided from the front of the
installed boilers to facilitate boiler servicing.
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, 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.
3 SYSTEM COMPONENTS
3
2
1
9
FLOW RETURN
4
5
6
7
8
Note. Isolating Valves
are tted to water
header along with
exible connecting
pipes.

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EVOMAX - Low Height Frame & Header Kits
IMPORTANT POINTS
Before commencing installation:
MOUNTING FRAME(S) MUST STAND
ON A FLAT AND LEVEL FLOOR.
WHEN ASSEMBLING THE HEADER KIT
THE HEADER MUST BE BOLTED TO THE
FRAME BEFORE THE FLEXIBLE HOSE
CONNECTIONS ARE MADE.

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EVOMAX - Low Height Frame & Header Kits
4 INSTALLATION DRAWINGS FOR BOILER SYSTEMS
4.1 GENERAL
The boiler systems are available in side by side format:
• 1 to 3 boilers in a linear conguration, mounted on a free-standing frame.
These boiler and cascade systems are sized to provide a ow and return differential of 20º∆T.
4.2 INSTALLATION DRAWING WITH 1 30-150 BOILER

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EVOMAX - Low Height Frame & Header Kits
4.3 INSTALLATION DRAWING WITH 2 30-150 BOILERS
4.4 INSTALLATION DRAWING WITH 3 30-150 BOILERS

10 EVOMAX - Frame & Header Kits
5 INSTALLATION PROCEDURE
5.1 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.
2. Drill and t the required oor bolt's
(not provided) through the hole
provided in the front of the frame
feet. (Note, this must be done
before tting water headers)
2
1

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EVOMAX - Frame & Header Kits
5.2 BOILER MOUNTING
12. Ensure the boiler bottom xing bracket is
screwed to the frame.
2
1. As appropriate mount the boilers onto the frame kit.
1. Fit adaptor into the tee for exible hose connection.
2. Attach tee to boiler ow.
3. Fit pressure relief valve.( If tted to the tee before it will foul
on the frame).
4. Attach pressure relief pipe and terminate in a safe place.
(See appliance manual).
5. Fit condensate trap and pipe work (See appliance
instruction, pipe runs must have 1:20 slope away from the
appliance).
6. Fit gas connection & tap.
7. Fit tee with pre-assembled non return valve and pump
union to the return ensuring the ow arrow is point toward
the base of the appliance.
8. Attach the drain tap to the return tee ensuring the
connection and activation point are accessible.
9. Fit Pump (check the ow arrow is pointing towards the
base of the appliance and the correct rubber wash is tted
in the connection union).
5.3 BOILER ASSEMBLY
5
9
7
73
4
1
6
8

12
EVOMAX - Low Height Frame & Header Kits
5.4 HEADER ASSEMBLY
5.5 FITTING THE GAS HEADER
1. Check lower pump connection is tted.
2. Check taps are operational.
3. Fit water header blanking anges and gaskets.
1. Fit the blanking cap to the required end.
2. Fit ¾” female to 22 compression tting to ¾” stub pipe on the side of
the gas header.
3. Place the gas header in the pre-cut cradle to the rear of the header.
2
1
2
3

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EVOMAX - Low Height Frame & Header Kits
5.6 ASSEMBLE HEADER ONTO FRAME
1. Four threaded anges are provided with the Evomax
low height low loss header DN50 kit to enable its
connection to the DN 50 water header.
2. Fit low loss header to the water header using the
bolts and gaskets provided.
3. Wire pumps to boiler termination (see appliance
instructions).
NOTE:
In multi boiler applications the pumps will remain on
until the switched demand to the appliance is met, it
is from this point the 4 minute pump over run time will
commence.
The switch demand is normally control by associated
control / sequencers.
1. Locate header into required position on the frame legs.
2. Align bolt holes and t bolts. (loosely)
3. Connect the return pump union to the pump (ensuring the
correct rubber washer is used).
4. Connect the ow connector to the boiler ow pipe adaptor
(ensuring the bre washer provided is correctly tted)
5. Tighten the heater bolts on to the frame.
6. Ensure the test points on the gas header are accessible.
(Note; the test point nearest the inlet to the rigs is deemed
as the appliance pressure test point for the appliances
tted.
7. Cut copper pipe to length, t gas tap onto boiler and tighten
up and test all gas joints.
2
1
3
2
2
4
5
5
7
6
5.7 FIT LOW LOSS HEADER (NOT SUPPLIED WITH FRAME & HEADER KIT)
DN50 SHOWN

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EVOMAX - Low Height Frame & Header Kits
6 ELECTRICAL CONNECTIONS
7 COMMISSIONING AND TESTING
1. Refer to the Installer Wiring Connection section in the boiler Installation Instructions for wiring details.
2. Ensure the boiler shunt pumps are wired to the boiler in order to ensure the boiler pump overrun facility is provided.
1. Electrical and gas safety checks must be carried out on completion of installation as with individual boiler
commissioning.
2. Pump setting adjustment. Follow instructions on pump type shown below;
Adjust red control potentiometer fully
clockwise to position 8, as shown below.
This is the constant pressure modulation
function.

15
EVOMAX - Low Height Frame & Header Kits

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EVOMAX - Low Height Frame & Header Kits
Ideal is a trademark of Ideal Boilers.
Registered Ofce
Ideal Boilers Limited National Avenue, Hull, HU5 4JB.
Telephone: [phone] Fax: [phone]
Registered in England no. 322137.
Technical Training
Ideal Boilers Limited pursues a policy of continuing improvement
in the design and performance of its products. The right is
therefore reserved to vary specication without notice.
The Ideal Boilers Technical Training Centre offers a series of rst class training courses for domestic, commercial and industrial
heating installers, engineers and system speciers. For details of courses please ring: ................................ 01482 498 432
I deal Installer/Technical Helpline: 01482 498 376
www.idealcommercialboilers.com