IDEAL EVOMOD 250 Installation And Servicing Download Page 1

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INSTALLATION AND

SERVICING

EVOMOD

250 500 750 1000

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 2018

UIN 206810 A06

Summary of Contents for EVOMOD 250

Page 1: ...fety 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 cation and main...

Page 2: ...69 7 3 559 6 Approx flue gas max rate m3 h 391 783 1174 1566 volume 80o C i e non condensing ft3 h 13 808 27 615 41 459 55 303 Max Flue Resistance Pa 105 105 105 105 Flue Gas CO2 Max Rate 9 1 0 2 9 1...

Page 3: ...irements 14 15 Water Treatment 6 Wiring Diagrams 24 250 500 750 1000 Natural Gas only Destination Countries GB IE Key to symbols IE Ireland GB United Kingdom Countries of destination PMS Maximum opera...

Page 4: ...ce with the relevant requirements of the Gas Safety Installation and Use Regulations The appropriate Building Regulations either The Building Regulations The Building Regulations Scotland Building Reg...

Page 5: ...the stack will be relatively small The boiler is supplied with an integral fan which is fully matched to the boiler in each case to provide correct combustion air flow and overcome the flue resistance...

Page 6: ...The lower the return temperature to the boiler the higher the efficiency At return temperatures of 55o C and below the difference becomes marked because the water in the flue gases starts to condense...

Page 7: ...1 BOILER DIMENSIONS AND CONNECTIONS 250 MODEL All dimensions shown in mm 9202 Back View Front View Side View EVOMOD 250 Note shown with optional connection kit fitted 7 Installation Servicing GENERAL...

Page 8: ...2 BOILER DIMENSIONS AND CONNECTIONS 500 MODEL Back View Front View Side View All dimensions shown in mm EVOMOD 500 8 Installation Servicing GENERAL...

Page 9: ...3 BOILER DIMENSIONS AND CONNECTIONS 750 MODEL Back View Front View Side View All dimensions shown in mm EVOMOD 750 9 Installation Servicing GENERAL...

Page 10: ...4 BOILER DIMENSIONS AND CONNECTIONS 1000 MODEL Back View Front View Side View All dimensions shown in mm EVOMOD 1000 10 Installation Servicing GENERAL...

Page 11: ...l dimensions shown in mm 5 HEADER KITS EVOMOD 500 KW HEADER ASSY Note Optional header includes valves shown Dimensions for optional header without valves also provided 11 Installation Servicing GENERA...

Page 12: ...l dimensions shown in mm 6 HEADER KITS EVOMOD 750 KW HEADER ASSY Note Optional header includes valves shown Dimensions for optional header without valves also provided 12 Installation Servicing GENERA...

Page 13: ...l dimensions shown in mm 7 HEADER KITS EVOMOD 1000 KW HEADER ASSY Note Optional header includes valves shown Dimensions for optional header without valves also provided 13 Installation Servicing GENER...

Page 14: ...HG H SDQVLRQ FLVWHUQ 2SHQ YHQW VDIHW SLSH P PLQLPXP VHH QRWHV 6 VWHP IORZ 6KXQW 3XPS LI UHTXLUHG QYHUWHG FROG IHHG HQWU ROG HHG DWHU OHYHO FROG 2SHQ YHQW 6 VWHP UHWXUQ LP RQQHFWLRQV WR ERLOHU Determin...

Page 15: ...be sized on the basis of the total system volume and initial charge pressure Initial minimum charge pressure should not be less than 1 0 bar 14 7psi and must take account of the static head and specif...

Page 16: ...the header kits 500 750 1000 come on a separate pallet Evomod 1000 This boiler comes packed as above except the boiler is split onto 2 pallets The header assembly comes split across 2 pallets a gas m...

Page 17: ...itted 1 Pull out support brackets Module Hanging Point Evomod 250 500 750 Position the boiler in its desired position Use the adjustable feet to level the boiler lock in place with the backing nuts Bo...

Page 18: ...lastic front cover s in reverse order 3 Remove the push on connectors M5 screws from the front of the frame 4 Hang the side panels over the 2 retaining pins on the back of the frame then secure at the...

Page 19: ...MUST be fitted to the 1 boss provided on the flexible flow pipe of each module 8 A 1 boss is provided on the underside of the flexible return pipe to enable a drain valve to be fitted 9 The header th...

Page 20: ...sembly Remove any blanking plates from the side to mate with the first header assembly Remove the flue header support frame by removing the 6 nuts and bolts Position the header assembly at the rear of...

Page 21: ...T be earthed A mains supply of 230V 50Hz is required Live Neutral and Earth An additional Earth is required to be connected to the Master Module chassis Earth Bonding point on the rear RHS vertical st...

Page 22: ...iring Box may be linked to the Live In terminal The Live In or Live Out terminals may be commonised using a suitable DIN rail terminal linking bar if desired Note The circuit protective device isolati...

Page 23: ...sor Mains Earth Mains Live Module Pump Neutrals Mains Neutral Optional Module Pump 1 Live Out Optional Module Pump 2 Live Out Optional Module Pump 3 Live Out Optional Module Pump 4 Live Out Optional M...

Page 24: ...Pump 2 Live Out etc Master PCB Installer Wiring Box Spark Electrode Flame Sense Electrode Gas Valve Spark Generator Module Pump Relay Module PCB Diagnostic Connection Condenstate Protection Switch Wa...

Page 25: ...500kW boiler only Module1 and Module2 will be shown etc Heat Demand On 0 10V Capacity Operating Mode If there is an ongoing Heat Demand generated by the 0 10V signal to the boiler and the boiler is c...

Page 26: ...ress and to change to the required setting and then press ENTER to store Rotate the KNOB anti clockwise until Normal Operation is highlighted again and press SELECT to return to normal operation Ideal...

Page 27: ...he following will be displayed The kW output number in the 1st line will vary depending on the maximum output of the boiler Ideal 750kW Normal Operation Set Flow Temp Set Off On Rotate KNOB clockwise...

Page 28: ...nimum flow temperature setpoint is 30 C This feature limits the minimum flow temperature that can be set in the Normal Access Mode Press SELECT and then hold and down together for more than 5s the fol...

Page 29: ...ration is highlighted again and press SELECT to return to normal operation CHANGING THE LEAD MODULE Installer Mode Normal Operation Set Flow Temp Set Off On The boiler default setting is that the boil...

Page 30: ...m the Installer Wiring Box EVOMOD WITH SWITCHED LIVE CONTROL EVOMOD WITH 0 10V CONTROL Note that the boiler must be configured for a 0 10V Input see frame 28 Installer Wiring Box Master PCB Box Master...

Page 31: ...SELECT and the following screen will appear Rotate the knob clockwise until a screen similar to the following is displayed Press SELECT and a screen similar to the following will be displayed Rotate...

Page 32: ...Valve Off 120s Pump Overrun Fan Off Module Pump Off Yes Standby Flame Detected Yes Less than 5 Ignition Attempts No Yes Lockout No Standby Heat Demand from Master PCB On Yes Fan On 2 m ins Fan P r e...

Page 33: ...the number of burners fitted Standby Heat Demand from Switched Live or 0 10V Input Yes Header Pump On Standby 1 Burner On 2 Burners On 3 Burners On 4 Burners On Heat Demand Off Temp Set point Heat Dem...

Page 34: ...ting the servicing or replacement of components always Test for gas soundness Test the burner manifold flanges for soundness This can be done with leak detection spray whilst operating the boiler The...

Page 35: ...pressure has been checked 5 Remove and inspect the fan venturi assembly Refer to Frame 45 6 Remove the burner assembly and inspect the electrodes and sightglass Refer to Frame 46 7 Remove and clean t...

Page 36: ...13 Connect a suitable flue analyser to the flue sampling point on the next Module 14 Remove the protective cap and then using the offset adjustment screw adjust the valve on the Module until the CO2...

Page 37: ...he two support brackets forward to provide a temporary hanging point for the cover carefully place the cover on the support brackets Alternatively the module cover can be placed on the floor adjacent...

Page 38: ...h show signs of wear 12 Refer to Frame 39 for final safety checks REPEAT THE PROCEDURE FOR THE SLAVE MODULE S 45 REMOVAL OF FAN VENTURI FOR INSPECTION 1 Refer to Frame 40 2 Remove the module front cov...

Page 39: ...y only using a soft brush and or vacuum The metal fibre outer surface MUST NOT BE BRUSHED If the burner shows signs of damage it must be replaced 7 Inspect the ignition and detection electrodes for si...

Page 40: ...h the heat exchanger heating surface to flush debris out of the collector 5 Replace collector cover taking care to inspect and if necessary replace the seal 6 Re assemble in reverse order 7 Refer to f...

Page 41: ...the right hand side panel refer to Frame 15 4 Pull off the sensing tube at the pressure switch 5 Remove the two pressure switch fixing screws 6 Remove the four socket cap screws retaining the gas valv...

Page 42: ...he ignition plug cap and the earth connection 4 Remove the two cap screws retaining the ignition electrode and carefully withdraw the electrode 5 Fit the new electrode and re assemble in reverse order...

Page 43: ...overtighten 8 Re assemble in reverse order 9 Re fill the system ensuring all the air in the boiler is vented 10 Refer to Frame 39 for final safety checks 5 6 55 FLAPPER VALVE REPLACEMENT 1 Refer to F...

Page 44: ...efer to Frame 39 for final safety checks 58 SPARK GENERATOR 6 5 57 FLOW AND RETURN THERMISTOR REPLACEMENT 1 Refer to Frame 40 2 Remove the module front cover refer to Frame 44 3 Remove the right hand...

Page 45: ...urner ensuring all seals and gaskets are inspected for wear or damage and replaced accordingly 6 Re assemble in reverse order 7 Refer to frame 39 for final safety checks 59 FAN REPLACEMENT 1 Refer to...

Page 46: ...CUI PCB 8 Fit new CUI PCB re assemble in reverse order 9 Refer to Frame 39 for final safety checks 3 Note Observe all ESD Handling Procedures 1 Refer to Frame 40 2 Remove the module front cover refer...

Page 47: ...e 12 Remove the water pressure switch and flow and return thermistor electrical connections Refer to Frames 56 57 13 Disconnect and remove the heat exchanger condensate debris collector Refer to Frame...

Page 48: ...Module 01 Check Gas Supply Check Electrodes Check Burner for Blockage False Flame Lockout Module 01 Check Flame Electrode Check Flame Sense Electrode Wiring Flame Loss Module 01 Check Electrodes Check...

Page 49: ...ck Module Wiring Check Module PCB Check Primary PCB Header Thmr Fault Check Header Thermistor Wiring Check Header Thmr 8k to 30k at 20 C CUI Wiring Fault Check CUI Wiring Check CUI PCB Check Master PC...

Page 50: ...essary otherwise replace the main PCB no yes Unplug the Gas Valve is the resistance between the outside pins between 1k and 10k Replace Gas Valve no yes Check Spark Generator and associated Harness fo...

Page 51: ...tion Electrode and associated Harness as necessary no yes Replace Gas Valve Replace Gas Valve no 72 LOW WATER PRESSURE OR CONDENSATE BLOCKAGE yes Disconnect the wires to the Water Pressure Switch Are...

Page 52: ...y no Is there continuity between the PCB and the Flow Thermistor Fit a new return thermistor no Disconnect the electrical connection to the Return Thermistor and check the resistance using a suitable...

Page 53: ...ing the thermostat Protocol By following your recommendations for the maintenance to the boiler 1 Remove the burner door 2 Check the condition of door gaskets replace if necessary 3 Check the conditio...

Page 54: ...Interface PCB no Does the Wiring from the Master PCB to the User Interface PCB have continuity yes No further action required yes Replace The User Interface PCB Has the fault disappeared yes Replace t...

Page 55: ...ctify wiring to Header pump no yes Is the Header pump stuck Free the Header pump yes yes Does the Header Pump operate no yes Does wiring to Module Pump have continuity and is to the correct connection...

Page 56: ...the cable from the main PCB to the user interface PCB connected securely yes yes Replace cable from main PCB to user interface PCB no Does the cable from the main PCB to the user interface PCB have co...

Page 57: ...TERFACE Set the boiler to accept a 0 10V input see Frame 27 no Is the boiler set to accept a 0 10V Input yes yes Set the boiler to On Mode see Frame 28 no Is the boiler set to On Mode yes yes Ensure b...

Page 58: ...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 available to help...

Page 59: ...59 Installation Servicing NOTES...

Page 60: ...60 Installation Servicing NOTES...

Page 61: ...61 Installation Servicing NOTES...

Page 62: ...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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