IDEAL EVOMAX 2 80 Installation And Servicing Download Page 1

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INSTALLATION AND

SERVICING

EVOMAX 2

30 40 60 80 100 120 150

30P 40P 60P 80P 100P 120P

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.

August 2019

UIN 219458 A01

Summary of Contents for EVOMAX 2 80

Page 1: ...conform 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 spec...

Page 2: ...7 9 7 13 13 19 5 19 5 Auxiliary Electricity Consumption Full Load elmax kW 0 081 0 081 0 138 0 138 0 082 0 082 Part Load elmin kW 0 027 0 027 0 029 0 029 0 0251 0 0251 Standby PSB kW 0 003 0 003 0 00...

Page 3: ...lass 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 efficiency once installed in a buildi...

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

Page 5: ...2 31 General Checks 49 2 32 Handing Over 49 2 33 Safety 49 3 SERVICING 50 3 1 Servicing Schedule 50 3 2 Removal of Casing 51 3 3 Removal of Fan and Gas Valve Assembly 52 3 4 Removal of Non Return Val...

Page 6: ...6 8 8 12 12 16 16 20 20 24 24 30 Boiler Output condensing Mean 40 C Max kW 31 5 30 9 42 41 2 63 5 62 1 84 4 82 6 103 9 101 7 124 7 123 3 158 Min kW 6 5 6 4 8 5 8 3 12 7 12 4 17 2 16 8 21 6 21 3 26 25...

Page 7: ...ucts of combustion to the outside of the room containing the boiler The combustion air is drawn directly from the room The fan is up stream of the combustion chamber Note Air Inlet Kit must be used II...

Page 8: ...installed in accordance with the rules in force In GB the installation must be carried out by a suitably qualified Gas Safe registered engineer or in IE by a competent person It must be carried out i...

Page 9: ...standards listed on page 8 1 8 FLUE INSTALLATION DANGER ONLY USE IDEAL ROOM SEALED FLUE GAS SYSTEMS THE BOILER CE MARK IS VALID ONLY IF THE APPLIANCE IS OPERATED WITH IDEAL ROOM SEALED FLUE KITS OTHER...

Page 10: ...35 9 28 7 435 180 83 57 30 80 80P 104 2 76 4 57 3 47 8 38 2 750 420 180 125 70 100 100P 95 6 71 7 59 8 47 8 315 134 97 60 120 120P 86 71 7 57 3 218 149 80 150 107 5 89 6 71 7 230 158 85 Not recommende...

Page 11: ...nd adjacent to the boiler 1 12 CONDENSATE DRAIN Refer to 19 A condensate drain is provided on the boiler This drain must be connected to a drainage point on site All pipework and fittings in the conde...

Page 12: ...0 120 150 Minimum boiler top clearances for vertical flue 200mm for horizontal flue 370mm for open flue 350mm Flue centre line 194 5 80 125 259 5 100 150 with 100 150 adaptor See Frame 13 Flue centre...

Page 13: ...er undertakings b The installation should be capable of working with flow temperatures of up to 90o C and a temperature differential of up to 35o C at minimum rate only c All components of the system...

Page 14: ...er 208 Burner Fixings Kit 230 Fan 231 Gas Valve Kit 232 Venturi 80kW Kit 301 Thermistor Kit 302 Lead Ignition Kit 304 Ignitor Unit 305 Electrode Detection Kit 306 Ignition Electrode Kit 308 Fascia Pla...

Page 15: ...front of the boiler 5 Remove the packing piece from the top of the boiler 6 Check the contents against the list in Section 2 3 Unpacking Note some items are contained within the top packing piece 7 T...

Page 16: ...return valve Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Cut the flue hole ensuring that the hole is square to the wall...

Page 17: ...flow and return connections to the boiler to prevent the boiler becoming detached The temperature within the boiler room shall not exceed 25 C within 100mm of the floor 32 C at mid height and 40 C wit...

Page 18: ...al Multiline This permits up to 6 boilers to be connected to a single flue header with a maximum total output of 600kW Other flue header systems should be designed and supplied by a specialist flue co...

Page 19: ...ue application maximum lengths Model 30 30P 40 40P 60 60P 80 80P 100 100P 120 120P 150 Max flue length m 33 30 17 5 10 10 9 6 Flue Size 80 125 100 150 Vertical flue kit No 220915 220918 60 80 vertical...

Page 20: ...ded Elbow 100 150 Single 222005 Expander 80 125 100 150 222133 Flue Kits Open Flue Flue Kit Description UIN Wall Bracket 125mm 202242 Wall Bracket 150mm 202243 Open Flue Kit 80 221216 Open Flue Kit 10...

Page 21: ...60 60P 80 125mm Max flue 17 5m 80 80P 80 125mm 0 5 up to max 12m max flue 60 60P 100 150mm 0 18 up to 30m max flue 80 80P 100 150mm 0 27 up to 35m max flue 100 100P 100 150mm 0 5 up to 14 3m max flue...

Page 22: ...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 For this reason it is recommended that a support bracket i...

Page 23: ...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 building Vertically from a terminal on the same wall...

Page 24: ...hieved by cascading up to six boilers Boilers can be fitted side by side using the standard height frame and header kits Low Height Frame and Header Kit Heat output to a maximum of 600kW can be achiev...

Page 25: ...inage pipe should only be considered after exhausting all internal termination options as described previously An external system must terminate at a suitable foul water discharge point or purpose des...

Page 26: ...h a 75mm trap and visible air break 2 rows of three 12mm holes 25mm centres 50mm from the bottom of the tube facing away from the house minimum gradient 1 19 Minimum connection height up to 3 storeys...

Page 27: ...ction 1 13 for details of the position of the gas connection A MINIMUM working gas pressure of 17 5 mbar 7 w g must be available at the boiler inlet for natural gas and minimum of 32mbar for propane w...

Page 28: ...PC Boiler run S OT or P2 P PC2 Room S RT SC Boiler fault Outside S OT P1 0 10V P PC Tank S HWS or P2 SL1 RT PC P3 P HWSC SL2 TS HWS Standalone Boiler Partial Hydraulics Single Boiler with a CT Pump Ci...

Page 29: ...CT1 P1 0 10V V CT1 SL2 TS HWS or P2 S OT or P2 Tank S RT CT2 P1 0 10V Opentherm1 or SL1 Opentherm2 or SL2 Boiler CT Pump Circuit CT Pump Circuit Single Boiler with CT and HWS Zone Circuits S RT PC1 RT...

Page 30: ...One per heating circuit Modulating sequencer kit an external BMS an outside temperature sensor Optional Room Temperature sensor kit one for each heating circuit configured Optional Header Temperature...

Page 31: ...V 50Hz Typical setting SL1 Heating Circuit 1 SL2 Heating Circuit 2 DHW l3 Optional Interlock input 230V 50Hz l4 Auxiliary Mains Supply Output 230V 50Hz Live Neutral I5 Multifunction Volts Free Relay O...

Page 32: ...ns supply preferable through the same isolator External controls via switched live demand Boiler Pump controlled directly from MFR1 I1 I2 I3 I4 I5 I6 1 2 3 1 2 3 4 1 2 1 2 1 2 3 4 5 6 1 2 3 4 L N PE S...

Page 33: ...r pump controlled via remote volts free enabled from MFR1 External controls via OpenTherm Master Boiler Pump speed control via 0 10V output I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 1 2 3 1 2 3 4 1 2 1 2 1 2 3 4...

Page 34: ...ls via Switched Live or OpenTherm or Room temperature sensors for Two Heating Circuits Heating Circuit Pumps controlled directly from MFR1 and MFR2 I1 I2 I3 I4 I5 I6 I8 I9 I10 1 2 3 1 2 3 4 1 2 1 2 1...

Page 35: ...B GAS INSTALLATION 1 The whole of the gas installation including the meter should be inspected and tested for soundness and then purged in accordance with the recommendations of the relevant standard...

Page 36: ...nd highlight the first menu item Enter the highlighted menu sub menu or parameter if in a menu or sub menu If in a parameter setting select a parameter which will then flash for adjustment once adjust...

Page 37: ...t with the available heating circuits so that they may have HC numbers allocated and then later configured If any heating circuits are required for the boiler then number them sequentially from 1 If t...

Page 38: ...em in any HC s or DHW circuits Hydraulic Separation If the boiler has Hydraulic Separation from the intermediate or final circuits in the heating system then set this Option to Yes System Pump If the...

Page 39: ...mperature setpoint Switched Live 1 Input Function The SL1 input can be configured as a Plant function if this is not required select None Where is your shunt pump None PWM 0 10V MFR1 Where is your shu...

Page 40: ...00 00 Done Single Friday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Saturday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Sunday Period 1...

Page 41: ...on indication Holidays Period 2 Start 01 01 2000 End 01 01 2000 Done Holidays Period 1 Start 01 01 2000 End 01 01 2000 Done Configure holiday prog No Yes Configure holiday prog No Yes Select loc n of...

Page 42: ...urn to Note The boiler number now has a tick next to it showing that it has been configured If you completed the boiler configuration select Done Boiler fault indication None PWM 0 10V MFR1 Local boil...

Page 43: ...ture unless specific configuration options are chosen Switched Live 1 input function The SL1 input can be configured as a HC function if this is not required select None Select loc n of HC pump None P...

Page 44: ...00 00 00 00 Done Multiple Mon Fri Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Multiple Mon Fri Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Configure hol...

Page 45: ...ist Otherwise set to None For weekday set the following parameters followed by Done Then set the desired Antilegionalla temperature followed by Done Configure pump protection No Yes Configure pump pro...

Page 46: ...Period 3 00 00 00 00 Done Single Tuesday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Single Wednesday Period 1 06 00 22 00 Period 2 00 00 00 00 Period 3 00 00 00 00 Done Singl...

Page 47: ...t configuration select Done The system will now reboot The boiler configuration is now complete and the display will show the boiler status screen IDEAL Evomax 2 120kW Operation Off Flow temp 0 0 C Fl...

Page 48: ...the ignition sequence If after 5 attempts the boiler has failed to light then it will lock out Press the reset button to restart the ignition sequence 8 Operate the boiler for 10 minutes and check the...

Page 49: ...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 attention will al...

Page 50: ...the case and the gas input is at least 90 of the nominal once compliance with the note above is ensured then no further action need be taken If not proceed to 4 4 Remove and clean the burner Refer to...

Page 51: ...t the panel to remove 3 Lower the control panel to the service position 3 2 REMOVAL OF CASING Side Panels Note Removal of side panels is not required for normal service 4 Remove the screws from the to...

Page 52: ...reverse order replacing all gaskets MODEL 150 1 Refer to Section 2 33 2 Remove the upper front panel Refer to Section 3 2 3 Disconnect the condensate pipe from the upper flue elbow 4 Remove the three...

Page 53: ...2 3 Remove the fan and gas valve assembly Refer to Section 3 3 4 Remove the four or six screws and the two extended nuts securing the burner to release the burner body 5 Lift the burner body by lifti...

Page 54: ...o Section 3 2 3 Prepare boiler for possible condensate spillage during the process 4 Remove the two screws from the helmholtz sump cover and pull away from the boiler 5 Scrape out any deposits 6 Reass...

Page 55: ...i to the fan for 30 40 60 100 120 5 Remove the extended nuts holding the venturi to the fan 80 only 6 Remove the screws retaining the fan plate 80 only 7 Transfer venturi and gas valve assembly to the...

Page 56: ...fixing screws 100 120 150 only Refer to Section 3 9 6 Remove the four screws retaining the gas valve 100 120 150 7 Remove the 4 screws retaining the inlet flange to gas valve transfer to new valve 8...

Page 57: ...Section 2 33 2 Remove the front panel Refer to Section 3 2 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 gask...

Page 58: ...lectrical 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 escapes via the air vent 9 Reasse...

Page 59: ...the 4 PCB retaining screws 8 Fit new PCB refit in reverse order and refer to Replacement PCB Instructions 9 Check the operation of the boiler Refer to Section 2 33 3 18 REMOVAL OF MAIN PCB 1 Refer to...

Page 60: ...the spare PCB to your wrist and to a suitable earthed metal 5 The System Manager is fitted beneath the main PCB To access follow points 5 7 in Section 3 18 6 With access to the System Manager remove...

Page 61: ...SIb Return Return Flow Flow X11 Thermistors Flue Flue Heat Ex Heat Ex 0 10V 1 OpenTherm 0 10V CAN 5V CAN GND CAN 24V GV Chassis PE C Chassis PE NO PE C NO PE CH1 Boiler System CH2 DHW Shunt Valve Pum...

Page 62: ...CAN Bus CAN VCCon CAN Mode CAN Tx CAN Bus CAN Bus 4 2 SYSTEM MANAGER WIRING DIAGRAM 4 3 OPTIONAL VARICAN ADAPTER WIRING DIAGRAM 1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 7 OpenTherm lead CC 5V CC GND CC 24V Vari...

Page 63: ...ed and any of the faults may be selected to retrieve the fault description IDEAL Evomax 2 100kW Operation Htg With temp Flow setp 82 C Flow temp 40 4 C Fault List Fault Fault Fault Fault Description F...

Page 64: ...YSTEM FLAME FAN HYDRAULIC ETC B Low water pressure 51 5 6 W No flame signal at start restart 52 5 7 W Flameloss during operation endless restarts Parameter endless restarts activated 53 5 7 L Flamelos...

Page 65: ...0 and 150kW approximately 240Vac for 100 and 120kW See note Check wiring from Gas Valve to PCB and replace if necessary otherwise replace the main PCB no yes Unplug the Gas Valve is the resistance bet...

Page 66: ...e and then Extinguish no Check Gas Supply and rectify fault no Is the Gas Pressure available at the boiler 18mBar yes Is the following voltage available at the Gas Valve approximately 215Vdc for 30 40...

Page 67: ...iring connections no Does the wiring from the Fan to the PCB have secure connections at both ends and has not deteriorated Does the wiring have continuity yes Replace main PCB Replace Fan no yes Is th...

Page 68: ...e main PCB Change menu setting for DHW Sensor to Switched Live no Is a DHW Thermistor connected to the boiler yes Securely connect the wiring at both the boiler and cylinder thermistor no Is the wirin...

Page 69: ...for the pump depending on the configuraiton 1 230V supply from isolate or boiler MFR 2 Volts free enable from MFR 3 0 10V signal from boiler 0 10V output Rectify fault as required Set for day or in a...

Page 70: ...the pump depending on the configuraiton 1 230V supply from isolate or boiler MFR 2 Volts free enable from MFR 3 0 10V signal from boiler 0 10V output Rectify fault as required There is no voltage fro...

Page 71: ...the Fuse on the combination manager PCB OK yes yes Replace combination manager PCB no Replace the system manager PCB still no display 5 17 0 10V INTERFACE Configure the boiler to accept a 0 10V input...

Page 72: ...at have not been clearly authorised by ourselves Failure to do so could affect safety or performance of this appliance When calling and to ensure we can provide you with the most accurate parts inform...

Page 73: ...BEEN FITTED BY PERSONS OTHER THAN THE BOILER INSTALLER visually check the integrity of the whole flue system to confirm that all components are correctly assembled fixed and supported Check that maxim...

Page 74: ...ck that flue and flue terminal are not obstructed Check that no seals e g Those on flue extensions have been displaced during installation Rectify if necessary Turn off appliance and call Ideal Techni...

Page 75: ...75 Installation Servicing NOTES...

Page 76: ...76 Installation Servicing NOTES...

Page 77: ...77 Installation Servicing NOTES...

Page 78: ...78 Installation Servicing NOTES...

Page 79: ...79 Installation Servicing NOTES...

Page 80: ...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 Technical Helpline 01482...

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