ideal commercial Evomax 40 Manual de usuario
STANDARD HEIGHT
FRAME & HEADER KITS
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.
April 2019
UIN 220380 A01
EVOMAX
30 - 150
30P - 80P
EVOMAX 2
30 - 150
30P - 120P
2
Standard Height Frame & Header Kits
This kit is suitable for the following boilers:
Evomax 30, 40, 60, 80, 100, 120, 150, 30P, 40P, 60P 80P
Evomax 2 30, 40, 60, 80, 100, 120, 150, 30P, 40P, 60P 80P, 100P, 120P
IMPORTANT
THESE KITS CAN BE USED IN CONJUNCTION WITH
LOW LOSS HEADERS & PLATE HEAT EXCHANGERS
SUPPLIED AS PART OF THE EVOMAX OPTIONS RANGE
CONTENTS
1 Introduction.....................................................................3
2 General Description of Cascade Systems ...................3
3 Multiple Boiler System Components............................5
4 Wall Mounted Installation Procedure ...........................8
5 Frame Kit Installation Procedure ................................10
6 Header Kit Assembly....................................................11
7 Installation Drawings for Multiple Boiler Systems....14
Side by Side Frame Kit Conguration........................14
Back to Back Frame Kit Conguration.......................19
8 Electrical Connections & Wiring Diagram..................24
9 Commissioning and Testing........................................25
3
Standard Height Frame & Header Kits
1 INTRODUCTION
This technical data contains information for dimensioning & assembly
of a cascade system kit for the Evomax and Evomax 2 ranges.
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.
The Varican optional accessory can be installed (1 per boiler) for
cascade control, see Varican Installation Instructions for further
information.
The ue configurations for the 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.
2.1 FRAME AND HEADER KIT DESIGN OPTIONS
The Evomax boilers are suitable for use in a multiple boiler configuration. 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. Frame 7 states 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).
Standard height 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 . . . . .
Available Evomax 2 Appliances
kW (NG) Product No.
Ideal Evomax 2 30 220814
Ideal Evomax 2 40 220815
Ideal Evomax 2 60 220816
Ideal Evomax 2 80 220817
Ideal Evomax 2 100 220818
Ideal Evomax 2 120 220919
Ideal Evomax 2 150 220820
kW (Propane) Product No.
Ideal Evomax 2 30 Propane 220823
Ideal Evomax 2 40 Propane 220824
Ideal Evomax 2 60 Propane 220825
Ideal Evomax 2 80 Propane 220826
Ideal Evomax 2 100 Propane 220827
Ideal Evomax 2 120 Propane 220828
Note.
All boilers need to be sized in accordance to the total required heat load and the modulation capabilities of the appliances.
Low Loss Header Accessories
(Mixing Header)
DN80 DN100 DN150
219552 219553 219554
4
Standard Height 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 HYDRONIC ISOLATION: LOW LOSS HEADER & PLATE HEAT EXCHANGER
A low loss header or plate heat exchanger 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 efficiency 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 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 signal provided by the appliance must be maintained
at all times.
The optional Varican accessory control can be installed (1 per boiler) to enable cascade control.
2.5 GAS SUPPLY
For Evomax the 30, 40, 60, 80, 100, 120 & 150 boilers are configured for use with natural gas. The 30P, 40P, 60P & 80P boilers are
configured for use with LPG / Propane.
For Evomax 2 the 30, 40, 80, 60, 100, 120 & 150 boilers are configured for use with natural gas. The 30P, 40P, 60P, 80P, 100P & 120P
boilers are configured for use with LPG / Propane.
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, 3, 4 and 6 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.
5
Standard Height Frame & Header Kits
3 MULTIPLE BOILER SYSTEM COMPONENTS
3.1 GENERAL
The multiple boiler systems consist of the following components:
• Frame kit (optional 1 per boiler)
• Boiler gas header.
• Boiler ow and return headers supported on mounting skid
• Low loss mixing header (optional)
• Hardware pack (includes essential connection and valve components)
• Plate Heat exchanger kit (optional)
• Boiler Shunt pump (MUST be used, sold seperately)
3.2 MAIN WATER HEADERS
The main water headers consist of: water ow, water return headers custom sized for all boilers. It is possible to extend the system to
a maximum of 6 boilers in a linear configuration or 2 x 3 boilers in a back-to-back configuration. In a back-to-back configuration 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, DN100 or DN150 dependent on total maximum combined
heating output required.
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 LOW LOSS HEADERS (MIXING HEADER) OPTION
The mixing headers are supplied with an auto air vent and drain point as standard.
3.5 BOILER SHUNT PUMP
Pump kits and External pump controls (sold separately) are designed to provide the optimum ow around the appliance water circuit
ensuring the maximum ow rates are contained within the design constrains of the appliance.
It is not recommended to fit additional pumps directly to the appliance circuit unless they have been designed to ensure the maximum
permissible appliance ow rate is not exceeded.
6
Standard Height Frame & Header Kits
3.6 BOILER CONNECTION KITS
The connection kit contains the following components:
1. Boiler return leg complete with isolating valve, pump,
non return valve, drain cock and fibre seals.
2. Boiler ow leg complete with isolating valve, pressure
relief valve and fibre seals.
3. Header blanking anges, fasteners and gaskets
4. Mixing header fasteners and gasket
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 cock
7. Pump union
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
Gas Connection: Conical Adapter, Flexi-hose
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 specified in the correct quantity, one frame
kit for each boiler installed in cascade for in-line and back to back.
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 clearance must be provided from the front of the installed boilers in cascade to facilitate boiler servicing.
Additional clearance must also be considered in the event of boiler replacement.
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.
10
5
13
9
11
7
7
8
6
FLOW RETURN
1
2
3
14
12
13
4
7
Standard Height 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.
MOUNTING FRAME MUST BE SECURED TO THE FLOOR WITH
BOLTS
These Installations refer to perpendicular wall and oor. If walls are
not perpendicular, it is recommended that a frame kit be used. 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.
8
Standard Height Frame & Header Kits
4 WALL MOUNTED INSTALLATION PROCEDURE
4.1 WALL MOUNTED SIDE BY SIDE OPTION
Ensure wall is capable of supporting the weight of boilers to be mounted. Note. boiler weights can found in the boiler
Installation Instructions.
1. Cut the sides off the cardboard wall mounting template/s (found in the boiler packaging) to create the 50mm side clearance
required.
2. Mark the height on to the wall from the oor to the top of the boiler 1919mm.
3. Tape the template/s to the wall ensuring the 50mm side clearance per boiler requirement is adhered to.
4. Drill the required holes in the wall to fit the wall mounting plate plugs. (See boiler Installation Instructions for details)
5. Screw the wall mounting plate(s) to the wall.
5
4
50 mm
2
3
continued . . . . .
9
Standard Height Frame & Header Kits
4.1 WALL MOUNTED SIDE BY SIDE OPTION CONT'D............
PLAN VIEWSIDE VIEW
7
Careful consideration MUST be given to the installation tolerances. If these are
not adhered to, hoses may become kinked or connections may not t.
Plate Heat
Exchanger
or Low Loss
Header optional
10
Standard Height Frame & Header Kits
5 FRAME KIT 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.
IMPORTANT: MOUNTING FRAME MUST BE SECURED TO THE FLOOR WITH BOLTS
2. If additional stability is required
remove the plastic foot covers and
drill the oor in order to oor bolt
the frame assembly to its required
location. (Bolts not supplied in kit)
2
1
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