IDEAL DN100 User manual

February 2016
UIN 207333 A05
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 - Frame & Header Kits
CONTENTS
1 Introduction.....................................................................3
2 General Description of Cascade Systems ...................3
3 Multiple Boiler System Components............................5
4 Installation Drawings for Multiple Boiler Systems......8
Side by Side Frame Kit Conguration..........................8
Back to Back Frame Kit Conguration.......................13
5 Wall Mounted Installation Procedure .........................18
6 Frame Kit Installation Procedure ................................20
7 Header Kit Assembly....................................................21
8 Electrical Connections.................................................24
9 Commissioning and Testing........................................24
Evomax 30, 40, 60, 80, 100, 120, 150, 30P, 40P, 60P 80P
This kit is suitable for the following boilers:

3
EVOMAX - Frame & Header Kits
1 INTRODUCTION
This technical data contains information for dimensioning & assembly of a cascade system kit for the Evomax range of products.
Header and Frame kits are available in both ‘in line’ (6 boilers long) and back to back options (3 boilers long).
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 Evomax multiple
boiler frame & header kit options.
A sequencer kit can be specied to switch boilers in cascade on or off dependent on total heat demand.
2.1 FRAME AND HEADER KIT DESIGN OPTIONS
The Evomax boilers are suitable for use in a multiple boiler conguration. The Evomax multiple boiler system is available in
both side by side and back to back options giving the opportunity to choose the optimum footprint size or wall space for a given
output. The table overleaf states options available and gives the minimum number of appliances required, the appropriate oor
space & the kit product number (N.B. The kits do not include the boilers).
Side by side kits do not include the support frame as the boilers can be wall mounted but a frame kit is available if wall space
etc. does not facilitate boiler/header wall mounting.
2 GENERAL DESCRIPTION OF CASCADE SYSTEMS
continued . . . . .

4
EVOMAX - Frame & Header Kits
Total Output
Required Kw
Side By Side Option –
Number Of Boilers/Output
Required
Side by Side
Footprint Size
W x D (mm)
Header Kit
Product No.
Side By Side
Back To Back Option –
Number Of Boilers/Output
Required
Back to Back
Footprint Size
W x D (mm)
Frame/Header
Product No.
Back To Back
60 2/30 1480x552 209799 2/30 930x950 209901
70 2/30&40 1480x552 209799 2/30&40 930x950 209901
80 2/40 1480x552 209799 2/40 930x950 209901
90 2/30&60 1480x552 209799 2/30&60 930x950 209901
100 2/40&60 1480x552 209799 2/40&60 930x950 209901
110 2/30&80 1480x552 209799 2/30&80 930x950 209901
120 2/60 1480x552 209799 2/60 930x950 209901
130 3/30,40&60 2030x552 209801 3/30,40&60 1480x950 209903
140 2/60&80 1480x552 209799 2/60&80 930x950 209901
150 3/30,40&80 2030x552 209801 3/30,40&80 1480x950 209903
160 2/80 1480x552 209799 2/80 930x950 209901
170 3/30,60&80 2030x552 209801 3/30,60&80 1480x950 209903
180 2/80&100 1480x573 209799 2/80&100 930x1096 209901
190 3/30,60&100 2030x573 209801 3/30,60&100 1480x1096 209903
200 2/100 1480x573 209799 2/100 930x1096 209901
210 4/30,40,60&80 2580x552 209803 4/30,40,60&80 1480x950 209905
220 3/60,60&100 2030x573 209801 3/60,60&100 1480x1096 209903
230 4/30,40,60&100 2580x573 209803 4/30,40,60&100 1480x1096 209905
240 2/120 1480x663 209798 2/120 930x1276 209900
250 4/30,60,80&80 2580x552 209803 4/30,60,80&80 1480x950 209905
260 3/60,100&100 2030x573 209801 3/60,100&100 1480x1096 209903
270 2/120&150 1480x663 209798 2/120&150 930x1276 209900
280 3/80,100&100 2030x573 209801 3/80,100&100 1480x1096 209903
290 4/30,60,100&100 2580x573 209803 4/30,60,100&100 1480x1096 209905
300 2/150 1480x663 209798 2/150 930x1276 209900
310 4/30,80,100&100 2580x573 209803 4/30,80,100&100 1480x1096 209905
320 4/40,80,100&100 2580x573 209803 4/40,80,100&100 1480x1096 209905
330 4/30,100,100&100 2580x573 209803 4/30,100,100&100 1480x1096 209905
340 4/60,80.100&100 2580x573 209803 4/60,80.100&100 1480x1096 209905
350 5/30,40,80,100&100 3130x573 209805 5/30,40,80,100&100 2030x1096 209907
360 3/120 2030x663 209800 3/120 1480x1276 209902
370 5/30,40,100,100&100 3130x573 209805 5/30,40,100,100&100 2030x1096 209907
380 4/80,100, 100 &100 2580x573 209803 4/80,100, 100 &100 1480x1096 209905
390 3/120,120&150 2030x663 209800 3/120,120&150 1480x1276 209902
400 4/100 2580x573 209803 4/100 1480x1096 209905
410 5/30,80,100,100&100 3130x573 209805 5/30,80,100,100&100 2030x1096 209907
420 3/120,150&150 2030x663 209800 3/120,150&150 1480x1276 209902
430 5/30,100,100, 100 &100 3130x573 209805 4/30,100,100&100 2030x1096 209907
440 5/40,100,100, 100 &100 3130x573 209805 4/40,100,100,100&100 2030x1096 209907
450 3/150 2030x663 209800 3/150 1480x1276 209902
460 5/60,100,100,100&100 3130x573 209805 5/60,100,100,100&100 2030x1096 209907
470 6/30,40,100,100,100&100 3680x573 209806 6/30,40,100,100,100&100 2030x1096 209908
480 4/120 2580x663 209802 4/120 1480x1276 209904
490 6/30,60,100,100,100&100 3680x573 209806 6/30,60,100,100,100&100 2030x1096 209908
500 5/100 3130x573 209805 5/100 2030x1096 209907
510 4/120,120,120&150 2580x663 209802 4/120,120,120&150 1480x1276 209904
520 6/40,80,100,100,100 &100 3680x573 209806 6/40,80,100,100,100&100 2030x1096 209908
530 6/30,100,100,100,100 &100 3680x573 209806 6/30,100,100,100,100&100 2030x1096 209908
540 4/120,120,150&150 2580x663 209802 4/120,120,150&150 1480x1276 209904
550 N/A N/A N/A N/A N/A N/A
560 6/60,100,100,100,100&100 3680x573 209806 6/60,100,100,100,100&100 2030x1096 209908
570 4/120,150,150&150 2580x663 209802 4/120,150,150&150 1480x1276 209904
580 6/80,100,100,100,100&100 3680x573 209806 6/80,100,100,100,100&100 2030x1096 209908
590 N/A N/A N/A N/A N/A N/A
600 4/150 2580x663 209802 4/150 1480x1276 209904
600 5/120 3130x663 209804
In line frame kit 206970
Mixing header kit DN80 206972
Mixing header kit DN100 206973
Pump kit (30-100kW) 210362
Pump kit (120-150kW) 210363
FRAME AND HEADER KIT SYSTEM DESIGN OPTIONS

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EVOMAX - Frame & Header Kits
2.2 MULTIPLE BOILER INSTALLATIONS
For installing 2 to 6 boilers, the product range includes water and gas headers capable of assembly using threaded socket,compression
and ange connections.
2.3 HYDRAULIC ISOLATION: MIXING HEADER (HEADER KITS INCLUDE A LOW LOSS MIXING HEADER)
Creating hydraulic isolation between the boiler circuit and the system circuit is benecial, this is provided by using a low loss mixing
header. This allows a widely varying volume ow on the system side to hardly inuence the volume ow on the boiler side. Conversely
a widely varying volume ow on the boiler side hardly inuences the volume ow on the system side.
2.4 OUTPUT CONTROL
A sequencer kit is available to maximise the efciency of a multiple boiler installation. Instructions for installation and use are contained
in the sequencer kit. The sequencer kit facilitates control of up to ve boilers in cascade.
2.5 GAS SUPPLY
The 30,40,60 & 80kW boilers are suitable for use with both natural gas and Propane, category II2H3P. The 100, 120 & 150kW boilers
are only available for natural gas, category I2H. Connect the boilers to the gas mains in accordance with the applicable regulations
The gas header connection is a 2” female thread. Refer to the boiler Installation & Servicing Instructions for general GAS SUPPLY
details.
2.6 ASSEMBLY
The frames and headers must stand on a at and level oor of suitable load bearing capacity.
2.7 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:
• 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:
• Frame kit. (Optional only with In-line kits)
• Boiler gas header.
• Boiler ow and return headers supported on mounting skid
• Low loss mixing header
• Hardware pack (includes essential connection and valve components including individual boiler shunt pumps)
3.2 MAIN WATER HEADERS
The main water headers consist of: insulated water ow, insulated 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 or 2 x 3 boilers in a back-to-back conguration. In a back-to-back
conguration with an odd number of boilers, the unused connections must also be capped off using blanking caps provided.
Each header kit provides water ow and return headers sized either DN80 or DN100 dependent on total maximum combined heating
output required.

6
EVOMAX - Frame & Header Kits
3.3 GAS HEADER
The Gas header consists of a custom manufactured 2” manifold. This is located in a cradle incorporated within the header mounting skid.
3.4 MIXING HEADER
The mixing headers are insulated and are supplied with an auto air vent and drain point as standard.
3.5 BOILER SHUNT PUMP
Shunt pumps for inclusion within each boiler return leg are provided in the hardware pack.
Wilo Stratos 25/1-8T3 IH are provided for boilers between 30 & 100kW.
Wilo Stratos 30/1-8T3 IH are provided for the 120 & 150kW boilers.
3.6 BOILER CONNECTION KITS
The connection kit is insulated and 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 gaskets.
LEGEND
1. 1 1/4" X 3/4" X 1 1/4" Tee
2. Close taper nipple
3. Safety relief valve 3 bar
4. Isolation valve
5. 1
1/4" X 1/2" X 1 1/4" Tee
6. Drain plug
7. Pump tting
8. Non return valve
9. Isolation Valve
10. Pump inc. gaskets
11. Boiler return exible connection from header
12. Boiler ow exible connection from header
13. 1 1/4" taper male to 1 1/4" parallel hex adapter
14. 1 1/4" male hex nipple
3.7 FREE-STANDING FRAMES
If boilers in cascade are positioned in-line the installer has the option to either wall mount the boilers or mount boilers on optional frame
kits available. If mounting in-line product on frames, optional frame kit UIN 206970 must be specied in the correct quantity, one frame
kit for each boiler installed in cascade.
If boilers in cascade are positioned back-to-back the correct sized frame mounting kit is supplied as part of the main installation kit.
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 in cascade 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 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.
3
2
1
14
FLOW RETURN
5
6
7
9
11
13
13
8
7
10
4
12

7
EVOMAX - Frame & Header Kits
IMPORTANT POINTS
Before commencing installation:
If Wall mounting;
• Ensure wall is capable of supporting the weight of boilers to be
mounted
• Mark drill points of header using oor mounting template
• Mark height on to the wall from the oor to the top of the boiler
• Ensure oor is at and level and is of suitable load bearing capacity
If Frame mounting;
• The frames must stand on a at and level oor of suitable load
bearing capacity.
• If using a frame kit (UIN 206970) the header must be bolted to the
frame before the hoses are connected to the boiler.
These Installations refer to perpendicular wall and oor. If walls
are not perpendicular, it is recommended that a frame kit be used
(206970). The correct number of frames should be ordered (1 per
boiler).
Allowances must be made for installation where skirting boards or
other features are in place that may affect the nominal installation
conditions.

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EVOMAX - Frame & Header Kits
4 INSTALLATION DRAWINGS FOR MULTIPLE BOILER SYSTEMS
4.1 GENERAL
The multiple boiler systems are available in three formats:
• 2 to 6 boilers in a linear conguration, mounted on a wall.
• 2 to 6 boilers in a linear conguration, mounted on a free-standing frame.
• 2 to 6 boilers in a back-to-back conguration, mounted on a freestanding frame.
The boiler side of the cascade systems is sized to water ow and return differential 20∆T.
4.2.1 INSTALLATION DRAWING WITH 2 – 30-100 BOILERS (SIDE BY SIDE)
300
650
2" BSP Female
Gas Connection
1945 (to top of Frame)
440
380
413 - 30 to 80kW
850
207
573 - 100kW
552
200
530
1918 (to top boiler)
BOILERS
30-80kW = 80/125
BETWEEN
Concentric Flue Connector
100kW = 100/150
360 (30-80kW)
500
224 (100kW) 520 (100kW)
500
50
128 (30-80kW)
143550 CRS
SYSTEM RETURN
DN80 FLANGE CONN
ALL DIMENSIONS ARE IN mm
DN80 FLANGE CONN
SYSTEM FLOW
Inline frame & header Kit 30-100kW UIN209799
with two Evomax 30-100Kw boilers mounted onto
optional frames
Note 1: Mixing header and gas connections can be
located either on the LHS or RHS of the assembly to
suit needs of each particular system.
Note 2: Optional frame (UIN206970) one req'd per boiler
1480
25
1100
25
4.2 SIDE BY SIDE FRAME KIT CONFIGURATION –
FOR BACK TO BACK CONFIGURATIONS - GO TO PAGE 13

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EVOMAX - Frame & Header Kits
300
650
2" BSP Female
with two Evomax 120/150kW boilers mounted onto
optional frames
BOILERS
BETWEEN
100/150 Concentric Flue Connector
Inline frame & header Kit 120/150kW UIN209798
ALL DIMENSIONS ARE IN mm
DN80 FLANGE CONN
SYSTEM FLOW
DN80 FLANGE CONN
SYSTEM RETURN
Gas Connection
Note 1: Mixing header and gas connections can be
located either on the LHS or RHS of the assembly to
suit needs of each particular system.
Note 2: Optional frame (UIN206970) one req'd per boiler
1100
25
1480
25
530
573 - 120kW
663 - 150kW
380
200
850
232 (150kW) 224 (120kW)
550 CRS
500
143
500
520 (120Kw) 610 (150Kw)
50
440
207
552
1945 (to top of Frame) 1918 (to top boiler)
4.2.2 INSTALLATION DRAWING WITH 2 - 120/150 BOILERS (SIDE BY SIDE)
4.2.3 INSTALLATION DRAWING WITH 3 – 30-100 BOILERS (SIDE BY SIDE)
300
650
Note 1: Mixing header and gas connections can be
located either on the LHS or RHS of the assembly to
suit needs of each particular system.
Note 2: Optional frame (UIN206970) one req'd per boiler
DN80 FLANGE CONN
SYSTEM RETURN
DN80 FLANGE CONN
optional frames
with three Evomax 30-100kW boilers mounted onto
Inline frame & header Kit 30-100kW UIN209801
SYSTEM FLOW
ALL DIMENSIONS ARE IN mm
25
2030
1650
25
2" BSP Female
Gas Connection
200
850
530
573 - 100kW
413 - 30 to 80kW
380
BOILERS
BETWEEN
30-80kW = 80/125
BETWEEN
BOILERS
Concentric Flue Connector
100kW = 100/150
50
500
128 (30-80kW)
224 (100kW)
520 (100kW)
360 30-80kW)
550 CRS
500
143
500
550 CRS
50
440
207
552
1945 (to top of Frame) 1918 (to top boiler)

10
EVOMAX - Frame & Header Kits
4.2.5 INSTALLATION DRAWING WITH 4 – 30-100 BOILERS (SIDE BY SIDE)
300
650
2" BSP Female
ALL DIMENSIONS ARE IN mm
Gas Connection
with four Evomax 30-100kW boilers mounted onto
optional frames
SYSTEM RETURN
DN100 FLANGE CONN
SYSTEM FLOW
DN100 FLANGE CONN
BETWEEN
BOILERS
BETWEEN
BOILERS
Inline frame & header Kit 30-100kW UIN209803
BETWEEN
BOILERS
Note 1: Mixing header and gas connections can be
located either on the LHS or RHS of the assembly to
suit needs of each particular system.
Note 2: Optional frame (UIN206970) one req'd per boiler
Concentric Flue Connector
100kW = 100/150
30-80kW = 80/125
500500
143
500
128 (30-80kW)
224 (100kW)
500
50 50 50
550 CRS 550 CRS 550 CRS
520 (100kW)
360 (30-80kW)
25
2200
25
2580
530 850
200
380
573 - 100kW
413 - 30 to 80kW
552
452
207
1945 (to top of Frame) 1918 (to top boiler)
300
650
530
850
573 -120kW
552
452
663 - 150kW
207
200
380
1650
25 25
2030
2" BSP Female
Inline frame & header Kit 120/150kW UIN209800
BOILERS
BETWEEN
SYSTEM FLOW
BOILERS
BETWEEN
100/150 Concentric Flue Connector
DN100 FLANGE CONN
ALL DIMENSIONS ARE IN mm
Gas Connection
optional frames
with three Evomax 120/150kW boilers mounted onto
DN100 FLANGE CONN
SYSTEM RETURN
Note 1: Mixing header and gas connections can be
located either on the LHS or RHS of the assembly to
suit needs of each particular system.
Note 2: Optional frame (UIN206970) one req'd per boiler
500 500
224 (120kW)
500
232 (150kW)
50 50
143
550 CRS
550 CRS
610 (150kW) 520 (120kW)
1945 (to top of Frame) 1918 (to top boiler)
4.2.4 INSTALLATION DRAWING WITH 3 – 120/150 BOILERS (SIDE BY SIDE)