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EVOMAX

Installation & Servicing

INSTALLATION

BOILER ASSEMBLY -

Exploded View

INST

ALLA

TION

206210-10387

308

502

309

304

306

105

302

305

208

232

230

231

310

301

501

Evomax 80 shown

KEY

105 Auto Air Vent

208 Burner Fixings Kit

230 Fan

231 Gas Valve Kit

232 Venturi 30kW Kit

301 Dry Fire Thermistor Kit

302 Lead Ignition Kit

304 Ignitor Unit

305 Electrode Detection Kit

306 Ignition Electrode Kit

308 Fascia Plastic

309 HMI Board

310 Primary PCB

501 Jacket Assembly Evomax Kit

502 Door Assembly Evomax Kit

Summary of Contents for Evomax 30

Page 1: ...rm to the safety and performance speci cation 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 speci cat...

Page 2: ...30 30 40 40 60 60 Part Load P1 kW 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 St...

Page 3: ...V Class V Class VI Class VII Class VIII 1 2 1 5 2 3 4 3 5 5 PRODUCT FICHE The energy efficiency of the package of products provided for in this document may not correspond to its actual energy efficie...

Page 4: ...4 EVOMAX Installation Servicing...

Page 5: ...5 EVOMAX Installation Servicing...

Page 6: ...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...

Page 7: ...al or vertical terminal which admits fresh air to the burner and discharges the products of combustion to the outside through orifices which in this case are concentric The fan is up stream of the com...

Page 8: ...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 a...

Page 9: ...configurations supplied in our optional extra kits Additional information covering the selection and installation can be found with this booklet Weather Proofing Where the flue passes through the roof...

Page 10: ...relay When sizing pumps reference should be made to the table below which show the boiler resistance against flow rates to achieve the required temperature differential Flow rates for common systems...

Page 11: ...rough cleansing 3 In hard water areas treatment to prevent lime scale may be necessary however the use of artificially softened water is NOT permitted 4 Under no circumstances should the boiler be fir...

Page 12: ...centric Flue Connector EVOMAX 100 120 150 Minimum boiler top clearances for vertical flue 200mm for horizontal flue 370mm for open flue 350mm Flue centre line im9245 X 224 5 80 125 X 289 5 100 150 wit...

Page 13: ...or the requirements of the local authority gas or water undertakings The vertical distance between the pump and feed expansion cistern MUST comply with the pump manufacturer s minimum requirements to...

Page 14: ...c air vent located in the left top side of the interior This air vent must never be shut off as this could result in dry firing of the boiler and subsequent damage to the heat exchanger 2 Safety Valve...

Page 15: ...310 301 501 Evomax 80 shown KEY 105 Auto Air Vent 208 Burner Fixings Kit 230 Fan 231 Gas Valve Kit 232 Venturi 30kW Kit 301 Dry Fire Thermistor Kit 302 Lead Ignition Kit 304 Ignitor Unit 305 Electrod...

Page 16: ...rd wall mounting template from the front of the boiler Remove the packing piece from the top of the boiler Check the contents against the list in Frame 6 Unpacking Note some items are contained within...

Page 17: ...age or personal injury 1 Cut the flue hole ensuring that the hole is square to the wall Both wall faces immediately around the cut hole should be flat 2 Drill 4 boiler top fixing holes with a 12mm 1 2...

Page 18: ...oiler to the wall through the attached brackets The temperature within the boiler room shall not exceed 25 C within 100mm of the floor 32 C at mid height and 40 C within 100mm of the ceiling 70kW AND...

Page 19: ...racted from the maximum flue extensions allowed for that flue option Note Horizontal terminal resistance includes 1 x 90o elbow Worked examples are shown on page 22 A multiple boiler flue header syste...

Page 20: ...99 Note See Frame 18 for elbow equivalent lengths FLUE OUTLET Evomax vertical concentric flue application maximum lengths and pressure differentials Model 30 30P 40 40P 60 60P 80 80P 100 120 150 Max f...

Page 21: ...260 213258 n a n a 3 90o elbow n a n a 158773 158774 4 45o elbow pair n a n a 158775 158776 5 Flat Weather Collar 152611 152612 158780 158780 6 Pitched Weather Collar 152609 152610 158779 158779 7 1m...

Page 22: ...0 80 100 45 0 85 1 25 0 45 0 60 90 1 6 1 9 1 0 1 0 Table X Max Permissible Equivalent Flue Length inc terminal resistance meters Concentric Open Flue Flue Size 80 125 100 150 80 100 Model 30 30P 42 65...

Page 23: ...tion of the ducts Care should be taken to support the inner duct when cutting the flue Note Horizontal flue runs must be angled down between 1 5o 3o towards the boiler to allow the condensate to drain...

Page 24: ...to a boundary alongside the terminal Above ground roof or balcony level From a surface or a boundary facing the terminal From a terminal facing the terminal From an opening in the car port into the b...

Page 25: ...heat load is greater than the boiler capacity an ideal solution is to use multiple boiler arrangements The ideal way to control a multiple boiler installation is with our modulating sequencer See bel...

Page 26: ...Drain Connections The use of an externally run condensate drainage pipe should only be considered after exhausting all internal termination options as described previously An external system must term...

Page 27: ...use Minimum connection height up to 3 storeys Soil vent stack 450 Boiler with 75mm sealed condensate trap Min 19mm Internal pipe Min 30mm Internal pipe Water weather proof insulation 75 Boilers withou...

Page 28: ...see Frame 45 INSTALLATION Flow Return 206210 10216 27 GAS CONNECTION Refer to Frame 1 for details of the position of the gas connection A MINIMUM working gas pressure of 17 5 mbar 7 w g must be availa...

Page 29: ...dulating sequencer kit a bms outside temperature sensor DHW demand can be controlled by 230V programmer and or cylinder thermostat tank sensor kit The electrical supply and their inputs onto the boile...

Page 30: ...Grundfos 40 60 UPS is satisfactory If the current draw is more than this eg a Grundfos 40 120 UPS then an external relay should be operated by the CH Pump or DHW Pump connections with the external rel...

Page 31: ...n Flow Thermistor Return Thermistor Flame Sensor Electrode Spark Electrode Spark Generator PCB Gas Valve Water Pressure Switch Diagnostic Connection Chassis Earth w bk bk bk bk br b b b b b b r or r b...

Page 32: ...a screen similar to the following will be displayed line 5 may vary depending on setup Line 5 indicates Switched Live or OpenTherm or 0 10V depending on which controls are connected to the boiler Hot...

Page 33: ...erates See Frame 38 for adjusting the system frost protection temperature setpoint Cylinder Frost Protect Burner Power 100 Outside Temp 10 C Frost Setpoint 5 C Hot Water Temp 4 C Cylinder Frost Protec...

Page 34: ...KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Ideal Evomax 80kW Normal Operation Set Flow Temp Set DHW Temp Press SELECT and a screen s...

Page 35: ...uts will vary as the boiler operates Press SELECT to exit this option Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation VIEWING...

Page 36: ...10V Input 0 10V Off 0 10V Capacity 0 10V Temperature Press and to change to the required setting and then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted aga...

Page 37: ...Night Setback DHW Pump Valve Set Booster Press SELECT and the following screen will be displayed Set Night Setback On Off Press and to change to required setting and then press ENTER to store Rotate...

Page 38: ...ystem Frost Protection Function is only operational if an Outside Sensor has been connected The CH pump is switched on if the Outside Temp is less than the System Frost Protection Temp The CH pump is...

Page 39: ...the DHW Thermistor input Rotate the KNOB clockwise until the following screen is displayed Rotate the KNOB clockwise until the following screen is displayed Installer Mode O S Room Temp DHW Sensor Fa...

Page 40: ...alve Press and to change to the required setting and then press ENTER to store Rotate the KNOB clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation 40 E...

Page 41: ...he link from position 9 to position 10 in the installer terminal block should be removed and a wire added from position 10 to the DHW Call input on the boiler Note that a hydraulic bypass is required...

Page 42: ...into CH Call INSTALLATION 44 EVOMAX WITH BOILER CONTROL OF PUMP AND DIVERTER VALVE Pump CH Pump Timer L N CH On HW On Boiler DHW Pump Fused Spur L N E C S R S 206210 10233 Note 1 The boiler can use an...

Page 43: ...L N E 206210 10236 EXTERNAL CONTROLS VIA OPENTHERM EXTERNAL CONTROLS VIA 0 10V INPUT EXTERNAL CONTROLS VIA SWITCHED LIVE Note that the boiler requires a 4 minute pump overrun period The boiler warran...

Page 44: ...hould be carried out by a competent person 2 ALWAYS carry out the preliminary electrical system checks i e earth continuity polarity resistance to earth and short circuit using a suitable meter WARNIN...

Page 45: ...nter operation see Evomax user interface basic operating instructions 7 The boiler will commence the ignition sequence If after 5 attempts the boiler has failed to light then it will lock out Press th...

Page 46: ...GENERAL CHECKS 50 HANDING OVER IMPORTANT Point out to the owner that the boiler must have regular maintenance and cleaning at least annually in order to ensure reliable and efficient operation Regular...

Page 47: ...rames 55 and 56 5 Inspect the heat exchanger through the burner opening If there are signs of aluminium oxide build up spray water down the flueways Refer to Frame 56 6 Remove the sump cover and scrap...

Page 48: ...elbow fixing screws and remove elbow by pulling downwards 7 Disconnect the electrical connections from the gas valve s 8 Disconnect the electrical connections from the fan 9 Undo the gas valve union n...

Page 49: ...2 Remove the front panel Refer to frame 53 3 Remove the fan and gas assembly Refer to frame 54 4 Remove the burner Refer to frame 55 5 Remove the ignition and detection electrodes Refer to frame 62 6...

Page 50: ...Transfer venturi and gas valve assembly to the new fan 8 Reassemble in reverse order replacing all gaskets 9 Check the operation of the boiler Refer to frame 51 Evomax 30 40 60 Evomax 80 Evomax 100 E...

Page 51: ...et flange to gas valve transfer to new valve 100 120 only 9 Fit new gas valve to venturi using the new seal provided ensure gas injector is fitted correctly 10 Reassemble in reverse order replacing al...

Page 52: ...e the front panel Refer to frame 53 3 Pull off the spark lead and earth connection 4 Remove the two retaining cap head screws 5 Pull out the electrode and pull off the old gasket 6 Replace with new el...

Page 53: ...he boiler 4 Disconnect the electrical connections from the switch 5 Unscrew the water pressure switch 6 Refit new switch 7 Connect electrical connections 8 Refill the system ensuring all the air escap...

Page 54: ...the operation of the boiler Refer to Frame 51 4 68 USER INTERFACE BOARD 1 Refer to Frame 51 2 Remove the upper front panel put the control panel into the service position Refer to Frame 53 3 Fit the...

Page 55: ...linderThermistor Fault Ext Interlock Off External Interlock Operated Reset Interlock Go to Frame 81 Ext Interlock Off Ignition Lockout Check Gas to Boiler Check Condensate Pipe Refer to Instructions R...

Page 56: ...heck gas supply and rectify fault no yes Is the following voltage available at the Gas Valve approximately 215Vdc for 30 40 60 80 and 150kW approximately 240Vac for 100 and 120kW See note Check wiring...

Page 57: ...e Pipe is blocked Check if the Flue is blocked Replace as necessary yes If the boiler is Reset does the boiler Ignite for a short time and then Extinguish no Check Gas Supply and rectify fault no Is t...

Page 58: ...ing a suitable multimeter connected across the thermistor s terminal pins At 25 C expect 9 700 10 300 At 60 C expect 2 400 2 600 At 85 C expect 1 000 1 100 Is the thermistor value correct yes Check an...

Page 59: ...C expect 19 000 21 000 At 20 C expect 12 000 13 000 Is the thermistor value correct yes Ensure the wiring has continuity and is securely connected no Does the Outside Sensor wiring between the boiler...

Page 60: ...no Is the wiring securely connected at both the boiler and cylinder thermistor yes 81 EXTERNAL INTERLOCK OFF Is an External Interlock connected to the boiler yes Has the External Interlock operated no...

Page 61: ...vice connected to the boiler note that the Ideal Prog Room Stat is an OpenTherm device Does the wiring from the boiler to the OpenTherm device have continuity yes no Rectify wiring from boiler to Open...

Page 62: ...for a Power Closed Diverter Valve no no Set boiler correctly See page 43 yes Is there 230Vac at D Check wiring from PCB to D no yes yes Does wiring to external DHW Pump have continuity and is to the c...

Page 63: ...ain PCB connected securely yes yes Connect the cable from the main PCB to the user interface PCB securely no Is the cable from the main PCB to the user interface PCB connected securely yes yes Replace...

Page 64: ...to Winter Mode see Frame 32 no Is the boiler set to Winter Mode yes yes Ensure between 2V and 10V is correctly connected to these terminals from the external device no Is a voltage of between 2V and 1...

Page 65: ...affect safety or performance of this appliance Comprehensive spares parts information and details of approved Ideal Parts Distributors are available on www idealparts com Our Parts team are also avail...

Page 66: ...2 Ideal is a trademark of Ideal Boilers Registered Office Ideal Boilers Ltd PO Box 103 National Avenue Kingston Upon Hull HU5 4JN Tel 01482 492251 Fax 01482 448858 Registration No London 322 137 Ideal...

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