Evomax 2 Installation Manual 219458 1
Evomax 2 Installation Manual 219458 1
Evomax 2 Installation Manual 219458 1
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
ERP DATA
MODEL
SYMBOL UNITS 30 30P 40 40P 60 60P
Condensing Boiler n/a n/a yes yes yes yes yes yes
Low Temperature Boiler n/a n/a no no no no no no
B1 Boiler n/a n/a no no no no no no
Cogeneration Space Heater n/a n/a no no no no no no
Equipped with a Supplementary Heater n/a n/a no no no no no no
Combination Heater n/a n/a no no no no no no
Nominal Heat Output for Space Heating
Full Load P4 kW 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 0.081 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 0.003 0.003 0.003 0.003
Seasonal Space Heating Energy Efficiency
Full Load ƞ4 % 89.6 91.6 89.6 91.5 89.7 91.7
Part Load ƞ1 % 98.4 99.6 97.8 99.5 97.9 99.7
Standby Loss Pstby kW 0.08 0.08 0.08 0.08 0.11 0.11
Ignition Pign kW 0 0 0 0 0 0
A
Temperature control (from fiche of temperature control) %
Class I Class II Class III Class IV Class V Class VI Class VII Class VIII
1% 2% 1.5% 2% 3% 4% 3.5% 5% B
%
= (‘III ’x + ‘IV ’ x ) x 0.9 x ( / 100 x = C
%
Seasonal Space Heating Energy Efficiency of Package TOTAL: A+B+C=
G F E D C B A A+ A++ A+++
< 30% ≥ 30% ≥ 34% ≥ 36% ≥ 75% ≥ 82% ≥ 90% ≥ 98% ≥ 125% ≥ 150%
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
building, as the efficiency is influenced by further factors such as heat loss in the products in relation to the building size and its characteristics
1 GENERAL.......................................................................... 8 3 SERVICING...................................................................... 50
1.1 Introduction......................................................................... 8 3.1 Servicing Schedule........................................................... 50
1.2 Optional Extra Kits.............................................................. 8 3.2 Removal of Casing........................................................... 51
1.3 Safety................................................................................. 8 3.3 Removal of Fan and Gas Valve Assembly....................... 52
1.4 Safe Handling..................................................................... 9 3.4 Removal of Non Return Valve.......................................... 53
1.5 Safe Handling of Substances............................................. 9 3.5 Removal of Burner........................................................... 53
1.6 Location of Boiler................................................................ 9 3.6 Heat Exchanger Inspection / Cleaning............................ 54
1.7 Gas Supply......................................................................... 9 3.7 Removal of Condensate Trap........................................... 54
1.8 Flue Installation.................................................................. 9 3.8 Removal of Sump Cover.................................................. 54
1.9 Water Circulation System................................................. 10 3.9 Removal of Fan................................................................ 55
1.10 Water Treatment............................................................... 10 3.10 Removal of Gas Valve..................................................... 56
1.11 Electrical Supply............................................................... 11 3.11 Removal of Venturi / Air Inlet Damper.............................. 57
1.12 Condensate Drain............................................................ 11 3.12 Removal of Ignition Electrode.......................................... 57
1.13 Boiler Clearances and Connections................................. 12 3.13 Removal of Detection Electrode....................................... 57
1.14 Open Vented System Requirements................................ 13 3.14 Removal of Automatic Air Vent......................................... 58
1.15 Sealed System Requirements.......................................... 13 3.15 removal of Water Pressure Switch................................... 58
3.16 Removal of Flow / Return / Heat exchanger Thermistor.. 58
2 INSTALLATION................................................................ 14
3.17 Removal of Spark Generator............................................ 59
2.1 Boiler Assembly - Exploded View..................................... 14
3.18 Removal of Main PCB ..................................................... 59
2.2 Packaging Removal......................................................... 15
3.19 Removal of System Manager........................................... 60
2.3 Unpacking ....................................................................... 15
2.4 Wall Mounting Template................................................... 16 4 WIRING............................................................................ 61
2.5 Preparing the wall............................................................. 16 4.1 Internal Wiring Combustion Manager............................... 61
2.6 Mounting the Boiler.......................................................... 17 4.2 System Manager Wiring Diagram.................................... 62
2.7 Ventilation......................................................................... 17 4.3 Optional Varican Adapter wiring Diagram......................... 62
2.8 Flue Systems.................................................................... 18
5 FAULT FINDING.............................................................. 63
2.9 Horizontal Wall Flue Kit.................................................... 18
5.1 Fault Finding SCREENS.................................................. 63
2.10 Horizontal Wall Flue Kit - For longer flue lengths for the
60 & 80kW......................................................................... 18 5.2 Fault Finding MENU......................................................... 64
2.11 Vertical Roof Flue kit........................................................ 19 5.3 Overheat Lockout............................................................. 65
2.12 Vertical Roof Flue kit........................................................ 19 5.4 Ignition Lockout................................................................ 65
2.13 Open Flue Kits.................................................................. 19 5.5 False Flame Lockout / Error 20........................................ 66
2.14 Flue Kit Accessories......................................................... 20 5.6 Low Water Pressure......................................................... 66
2.15 Permissible Flue Length................................................... 21 5.7 Flame Loss....................................................................... 66
2.16 Assembling the Flue......................................................... 22 5.8 Fan Fault.......................................................................... 67
2.17 Flue Termination Position................................................. 23 5.9 Flow / Return Thermistor or Heat Exchanger thermistor fault.....67
2.18 Boiler Frame and header Kits........................................... 24 5.10 Outside Sensor Fault (if fitted).......................................... 67
2.19 condensate drain.............................................................. 25 5.11 Flow/Return Reversed...................................................... 68
2.21 Frost Protection................................................................ 27 5.12 Cylinder thermistor fault (if fitted)..................................... 68
2.20 Boiler Water Connections................................................. 27 5.13 External interlock open..................................................... 68
2.22 Gas Connection................................................................ 27 5.14 No CH but DHW OK......................................................... 69
2.23 Stand alone boiler - partial hydraulics.............................. 28 5.15 No DHW but CH OK......................................................... 70
2.24 Electrical Connections...................................................... 30 5.16 No Display........................................................................ 71
2.25 External Wiring................................................................. 30 5.17 0-10V Interface................................................................. 71
2.26 Installer Connections........................................................ 31
6 SPARE PARTS................................................................ 72
2.27 Boiler with External Controls ........................................... 32
2.28 Controls Configuration, Commissioning and Testing........ 35 7 COMBUSTION AND FLUE INTEGRITY.......................... 73
2.29 User Interface................................................................... 36 7.1 Flowchart for CO Level and Combustion Ratio Check
2.30 Initial Lighting................................................................... 48 on Commissioning A Condensing Boiler.......................... 73
2.31 General Checks................................................................ 49
2.32 Handing Over................................................................... 49
2.33 Safety............................................................................... 49
Boiler Input Nett kW 30.4 30.4 40.5 40.5 60.8 60.7 82 81.9 102.4 102.4 122.9 122.9 153.7
Max Rate Gross kW 33.7 33 44.9 44 67.4 66 90.9 88.9 113.6 111.2 136.4 133.4 170.5
Boiler Input Nett kW 6.1 6.1 8.1 8.1 12.2 12 16.4 16.2 20.5 20.4 24.6 24.5 30.7
Min Rate Gross kW 6.7 6.6 9 8.8 13.5 13.1 18.2 17.5 22.7 22.2 27.3 26.7 34.1
3
Gas Rate Max Rate m /hr 3.2 1.26 4.3 1.69 6.4 2.53 8.7 3.41 10.8 4.35 13 5.23 16.2
Flue Gas Flow Rate Max Rate m3/hr 41.3 44.09 54.05 61.68 80.65 88.66 110.1 121.57 140.5 153.6 173.33 183.81 210.7
Max Rate % 9.76 10.9 10.2 11.2 9.4 11.4 9.3 11.4 9.4 10.8 9.62 11.2 9.44
CO2 (±0.5%) *
Min Rate % 8.56 10.3 8.6 9.7 8.6 10.2 8.7 10.8 8.6 10.1 8.98 10.1 8.51
NOx (gross) weighted mg/kWh 34.1 52.3 33.2 64.4 35.2 67.7 34.9 63.2 34.8 65.3 33.9 41.6 35.7
Seasonal % 96.7 97.2 96.2 96.7 96.4 96.9 97.2 97.7 96.7 96.7 96.6 96.6 96.7
Efficiency
**SEDBUK 2009 % 89.6 90.6 89.3 90.3 89.4 90.5 n/a n/a n/a n/a n/a n/a n/a
*CO2 measurements taken using controlled reference natural gas. Readings on mains gas quality may vary
** The value is used in the UK Government’s Standard Assessment Procedure (SAP) for energy ratings of dwellings. The test data from which it has been calculated have
been certified by a notified body.
Evomax 2
30, 40, 60, 80, 100, 120, & 150
30P, 40P, 60P, 80P, 100P & 120P
Natural Gas & Propane
Destination Countries: GB, IE
CE No. 696943
Key to symbols
IE = Ireland, GB = United Kingdom (Countries of destination)
PMS = Maximum operating pressure of water
C13 C33 C53 = A room sealed appliance designed for connection via ducts to a horizontal 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 combustion chamber. Note: Room Sealed Flues must be used.
B23 = An appliance intended to be connected to a flue which evacuates the products 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.
II2H3P = An appliance designed for use on 2nd and 3rd Family gases.
NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.
Flow rates for common systems using either 11ºC, 15ºC, 20ºC, Scalemaster Water Treatment Products
25ºC and 30ºC temperature differentials and hydraulic resistances www.scalemaster.co.uk
are given in the table below Tel: +44 (0) 1785 811636
Flowrate (l/min) Hydraulic Resistance (mbar)
Calmag Ltd.
11ºC 15ºC 20ºC 25ºC 30ºC 11ºC 15ºC 20ºC 25ºC 30ºC www.calmagltd.com
Tel: +44 (0) 1535 210320
30/30P 39.1 28.7 21.5 17.9 N/A 425 225 127 89 N/A
40/40P 52.1 38.2 28.7 23.9 19.1 875 405 225 163 100 Adey
www.adey.com
60/60P 78.2 57.3 43 35.9 28.7 435 180 83 57 30 Tel: +44 (0) 1242 546700
80/80P 104.2 76.4 57.3 47.8 38.2 750 420 180 125 70
Notes.
100/100P * 95.6 71.7 59.8 47.8 * 315 134 97 60
1. It is most important that the correct concentration of the water
120/120P * * 86 71.7 57.3 * * 218 149 80 treatment products is maintained in accordance with the
manufacturers’ instructions.
150 * * 107.5 89.6 71.7 * * 230 158 85
2. If the boiler is installed in an existing system any unsuitable
additives MUST be removed by thorough cleansing.
* Not recommended due to excessive flowrates which may cause 3. In hard water areas, treatment to prevent lime scale may be
erosion of the casting. necessary - however the use of artificially softened water is
NOT permitted.
4. Under no circumstances should the boiler be fired before the
system has been thoroughly flushed.
850
=202
Flue centre
line
line
2m
3m
ima5400
4m 83 83
minimum
requirements of the local authority, gas or water undertakings. Feed
3000
The vertical distance between the pump and feed/expansion
cistern MUST comply with the pump manufacturer’s minimum System
System flow to
requirements, to avoid cavitation. Should these conditions return pump
not apply either lower the pump position or raise the cistern
above the minimum requirement specified by Ideal Boilers. The Inverted cold
feed entry
isolation valves should be fitted as close to the pump as possible.
The boiler is fitted with an automatic air vent, located in the left Connections
top side of the interior. This air vent must never be shut off, as to boiler
this could result in dry firing of the boiler and subsequent damage
ima5351
to the heat exchanger.
2 INSTALLATION
2.1 BOILER ASSEMBLY - Exploded View
700
Data Plate
230 231
512
232
301 208
105
302
203
305
306
511
304
202
201
501
301
80kW shown
308
325
KEY
105 Auto Air Vent 301 Thermistor Kit 325 Bulkhead
201 Gas pipe 302 Lead Ignition Kit 501 Jacket Assembly Kit
202 Flue manifold (lower) 304 Ignitor Unit 502 Door Assembly Kit
203 Flue manifold (upper) 305 Electrode Detection Kit 511 Non Return Valve Assembly
208 Burner Fixings Kit 306 Ignition Electrode Kit 512 Air Inlet Damper
230 Fan 308 Fascia Plastic 700 Flue Adapter
231 Gas Valve Kit 309 System Manager Board
232 Venturi 80kW Kit 310 Primary PCB
INSTALLATION
2.2 PACKAGING REMOVAL
2.3 UNPACKING
x1
User Guide x2
x1
Log Book
x6 x1
x1 x1
x1 Wall Plug Gas Cock
Connector Kit Wall Mounting Bracket
Warranty
x1 x1 x1 x6 x1
Ø12mm
17 mm
332 mm
INSTALLATION
2.6 MOUNTING THE BOILER
• Due care should be taken when lifting the boilers, with
respect to their weights, see Table 2 on Page 6. Also
refer to Section 1.4 Safe Handling.
1. Lift the boiler onto the wall mounting plate as shown.
Note: It is not necessary to hold the boiler at an angle
to engage the wall mounting plate.
2. Using the remaining coach screws, secure the bottom
of the boiler to the wall through the attached brackets.
IMPORTANT NOTE It is essential that these bolts be
fitted prior to making up the flow and return connections to
the boiler to prevent the boiler becoming detached .
2.7 VENTILATION
BOILERS NOT EXCEEDING 70kW
The ventilation requirements of these boilers is dependant on If installed as an open flued appliance in a room or internal space
the type of flue system used, and their heat input. All vents must then a permanent air vent is required. The sizes given below are for
be permanent with no means of closing, and positioned to avoid vents directly communicating with outside air. For other situations
accidental obstruction by blocking or flooding. refer to BS. 5440 Pt. 2. In IE refer to the current edition of I.S. 813.
30/30P, 40/40P, 60/60P
Boiler Size 30 & 30P 40 & 40P 60 & 60P
Detail reference should be made to BS. 5440 Pt. 2. In IE refer to
the current edition of I.S. 813. Minimum vent
117 167 269
free area (cm2)
The following notes are for general guidance only:
If installed in a compartment, then permanent air vents are
If installed as a room sealed appliance in a room or internal
required at high and low level. These vents may communicate
space, then no purpose provided ventilation is required.
direct to outside air, or to a room/internal space. If to a room/
internal space, it must itself be adequately ventilated as above.
Ventilation Requirements (not exceeding 70kW net Input) when installed in a compartment
Room Sealed Application - Min. Vent Free Area (cm2) Open Flue Application - Min. Vent Free Area (cm2)
To a room or internal space To outside Air To a room or internal space To Outside Air
Boiler Size 30 40 60 30 40 60 30 40 60 30 40 60
High Level 310 410 610 155 205 305 310 410 610 155 205 305
Low level 310 410 610 155 205 305 620 820 1220 310 410 610
The temperature within the boiler room shall not exceed 25ºC within 100mm of the floor, 32ºC at mid height and 40ºC within 100mm
of the ceiling.
Contents
• 90o elbow
• Terminal
• Locking collars (x2)
• Wall plates (x2)
2.10 HORIZONTAL WALL FLUE KIT - For longer flue lengths for the 60 & 80kW
Contents
• Increaser
• 90o elbow
• Terminal
• Locking collars (x2)
• Wall plates (x2)
Contents
• Terminal
• Locking Collar
• Finishing plates (x2)
• Bracket
Contents
• Increaser
• Terminal
• Locking Collars (x2)
• Finishing plates (x2)
• Bracket
FLUE OUTLET
Note: See Section 2.15 for elbow equivalent lengths.
Contents
221216 / 221218
• Air inlet grille
158771 / 158772
• Extension tube (x2)*
158769 / 158770
• Terminal
220919
152610
220921
FLUE OUTLET
221218
152404 222133
Table A
Max Permissible Equivalent Flue Length (inc terminal resistance) meters
Concentric Open Flue
Flue Size 80/125 100/150 80 100
Model
30/30P 33 - 65 -
40/40P 30 - 70 -
60/60P 17.5 28 25 -
80/80P 10 18 15.3 -
100/100P - 10 - 20
120/120P - 9 - 34
150 - 6 - 32
Table B
Equivalent Length of Elbows (meters)
Concentric Open Flue
Size 80/125 100/150 80 100
45º 0.85 1.25 0.45 0.60
90º 1.6 1.9 1.0 1.0
Table C
19 Examples of Flue Length Calculation
Example Elbows
Max Permissible
Equivalent Total Max permissible
Flue Equivalent
Model Type Length No Equivalent Straight Length
Type Length (Table A)
FLUE OUTLET
(Table B) Length
60 80/125 17.5 90 1.6 2 3.2 14.3
60 100/150 28 90 1.9 2 3.8 24.2
80 80/125 10 90 1.6 3 4.8 5.2
120 100/150 9 90 1.9 4 7.6 1.4
Maximum lengths due to the resistance presented by extended concentric flue lengths a slight reduction in the maximum
boiler output will occur where flue lengths exceed the stated lengths. In such cases the boiler output will be reduced up to
0.8% per additional metre and should not exceed those stated in Table D.
Table D
Maximum lengths
Model Flue Size Reduction per Additional Metre
30/30P 80/125mm 0.15% (up to 42m max flue)
40/40P 80/125mm 0.16% (up to 42m max flue)
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)
120/120P 100/150mm 0.55% (up to 16.0m max flue)
150 100/150mm 0.8% (up to 7.5m max flue)
Flue terminals or extension ducts may be cut to shorter lengths Care must be taken when assembling flues, not to damage
if required. When cutting a duct ensure it is square by marking the seals.
the length all the way around and only cut back the plain end.
When cutting concentric duct it is important that the inner duct is See below for flue assembly examples.
maintained at 20mm longer than the outer duct to allow correct
connection 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.
For this reason it is recommended that a support bracket is
used for every 1m of extension pipe.
Black Cut the white terminal tube to the correct length and
terminal ensure the painted wall plate is pushed hard up to the
collar black terminal collar when fitted.
Wall plate
unpainted
Important. There should be NO white terminal tube
visible when viewed from the outside.
Vertical
terminal
Weather collar
RF2548
flat (shown)
or pitched
If the terminal is fitted less than 500 mm below plastic gutters, painted eaves or any other painted surface then an aluminium shield at least 1m
long should be fitted to protect the surface.
Vertical terminals must be a minimum of 550mm apart.
For positioning of open flue terminals reference should be made to BS. 5440 Pt. 1. In IE refer to I.S.813.2002.
FLUE OUTLET
boundary
D, E
I
B
H F C
J
N
A
L F M
G
F
I
boundary K
A A
A
A = 600mm
B = 2000mm
B
RF
98
07
Standard Height Frame & Header Kit - Heat output to a maximum of 900kW, except when using the multiline flue when a
maximum of 600kW (See Multiline flue manual) can be achieved 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 achieved by cascading up to four boilers.
Boilers can either be fitted side by side or back to back using the low height frame and header kits.
FLUE OUTLET
INSTALLATION
2.19 CONDENSATE DRAIN
Internal Drain Connections
Wherever possible, the condensate drainage pipe should be routed
to drain by gravity to a suitable internal foul water discharge point
such as an internal soil and vent stack or kitchen or bathroom
waste pipe etc. See Figs 1 and 2.
Condensate Pump
Where gravity discharge to an internal termination is not physically
possible or where very long internal pipe runs would be required
to reach a suitable discharge point, a condensate pump of a
specification recommended by the boiler or pump manufacturer
should be used terminating into a suitable internal foul water
discharge point such as an internal soil and vent stack or internal
kitchen or bathroom waste pipe etc. (fig 3).
External Drain Connections
The use of an externally run condensate drainage pipe should
This appliance is fitted with a 75mm condensate trap system that only be considered after exhausting all internal termination options
requires filling before operating the appliance for the 1st time or as described previously. An external system must terminate at a
after maintenance. suitable foul water discharge point or purpose designed soak away.
If an external system is chosen then the following measures must
All condensate pipework should conform to the following: be adopted:
a. Where a new or replacement boiler is being installed, access to The external pipe run should be kept to a minimum using the most
an internal ‘gravity discharge’ termination should be one of the direct and “most vertical” route possible to the discharge point, with
main factors considered in determining boiler location. no horizontal Sections in which condensate might collect.
b. Plastic with push fit or solvent connections. - For connections to an external soil/vent stack see Fig 4.
Insulation measures as described should be used.
c. Internal plastic pipe work a minimum of 19mm ID (typically
22mm OD) - When a rainwater downpipe is used, an air break must be
installed between the condensate drainage pipe and the
d. External plastic pipe must be a minimum of 30mm ID (typically downpipe to avoid reverse flow of rainwater into the boiler
32 OD) before it passes through the sleeved wall. should the downpipe become flooded or frozen, see Fig 5.
e. All horizontal pipe runs, must fall a minimum of 45mm per metre - Where the condensate drain pipe terminates over an open
away from the boiler at a minimum gradient of 1:19. foul drain or gully, the pipe should terminate below the grating
f. External & unheated pipe work should be kept to a minimum level, but above water level, to minimise “wind chill” at the open
and insulated with Class “O” waterproof pipe insulation. end. The use of a drain cover (as used to prevent blockage by
leaves) may offer further prevention from wind chill.
g. All installations must be carried out in accordance to the
relevant connection methods as shown in the “Condensate - Where the condensate drain pipe terminates in a purpose
installation diagrams” & BS6798:2009 designed soak away (see BS 6798) any above ground
condensate drain pipe Sections should be run and insulated as
h. Pipe work must be installed so that it does not allow spillage described above. See Fig 6.
into the dwelling in the event of a blockage (through freezing) Unheated Internal Areas
i. All internal burrs should be removed from the pipe work and any Internal condensate drain pipes run in unheated areas, e.g. lofts
fittings. basements and garages, should be treated as external pipe.
In order to minimise the risk of freezing during prolonged very cold Ensure the customer is aware of the effects created by a frozen
spells, one of the following methods of terminating condensate condensate and is shown where this information can be found in
drainage pipe should be adopted. the user manual.
Boiler Boiler
with 75mm with 75mm
sealed sealed
condensate
Soil & vent stack
condensate
trap trap
Min Ø 19mm
Internal soil & vent stack
Sink/basin/
Minimum
bath or
connection shower
≥ 450
minimum height up to 3
gradient storeys
1:19
Figure 3 - Connection of a Condensate Pump Typical Figure 4 - Connection of condensate Drainage Pipe to
Method (see manufacturers detailed instructions) External Soil & Vent Stack
Boiler Water/weather
Visible air break with 75mm proof insulation
Boiler sealed
condensate
with 75mm
trap
75
minimum
gradient
Min Ø 19mm 1:19 Minimum
≥ 450
Internal pipe connection
height up to 3
Condensate pump Boilers without 75mm sealed storeys
(Install in accordance with condensate trap must be fitted with
manufacturers instructions) a 75mm trap and visible air break
Figure 5 - Connection of a Condensate Drainage Pipe to an Figure 6 - Connection of a Condensate Drainage Pipe to an
External Rainwater Downpipe (only combined foul/rainwater External Purpose Made Soak Away.
drain)
Boiler
with 75mm minimum
Boiler sealed gradient
with 75mm condensate 1:19
sealed ≤ 3000 trap
Water/
condensate Min Ø 30mm Water/Weather
weather proof Internal pipe
trap proof insulation
insulation
Min Ø 19mm
Min Ø 19mm Internal pipe Max 3m external
combined foul/
75
≥ 25
Min Ø 30mm External air
Internal pipe break
≥ 300
Air gap Boilers without 75mm sealed Limestone
Terminated condensate trap must be fitted with chippings
minimum a 75mm trap and visible air break
and cut at 45º
gradient ≥ 500 ≤ 3000
1:19 43mm 90º male/ 68mm Ø PVCU 2 rows of three Ø12mm holes
female bend Strap on fitting 25mm centres, 50mm from
the bottom of the tube, facing
away from the house
INSTALLATION
2.20 BOILER WATER CONNECTIONS
FLOW RETURN
The boiler has built into its control system the facility to protect a ‘storage heater’ and can normally be left at least 24 hours
the boiler, only against freezing. without frost damage. However, if parts of the pipework run
outside the building or if the boiler will be left off for more than
If the boiler flow temperature T1, falls below 5oC the pump and a day or so, then a frost thermostat should be wired into the
burner run until the temperature exceeds 19oC. system.
Central heating systems fitted wholly inside the building do
not normally require frost protections as the building acts as
Refer to Section 1.13 for details of the position of In order to determine the actual working gas pressure at the
the gas connection. boiler inlet the figure from the table below must be added to the
measured pressure (refer to Section 3.3).
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 Gas Line Pressure Drop
with the boiler firing. Refer to Section 3.3 for (Natural Gas)
details of the pressure test point position.
Boiler Model mbar
Extend a gas supply pipe NOT LESS THAN 22mm
30 0.6
O.D. to the boiler and connect using the gas cock
provided. 40 0.8
IMPORTANT. The gas service cock contains a 60 1.4
non-metallic seal so must not be overheated when 80 1.6
making capillary connections. 100 1.1
120 2.7
150 3.0
The pressure loss for LPG versions is negligible due to the very low
velocity through the pipe work.
Note. It should be noted that this pressure drop is present within the
internal boiler pipe work and is irrespective of the fact that manifold
headers are used. This pressure drop will be experienced on each
individual boiler regardless of single or multiple installation.
28
Single Boiler with a CT Pump Circuit and DHW Tank
Standalone Boiler ‐ Partial Hydraulics
Boiler Connections
Single Boiler with a CT Pump
S‐RT‐PCCircuit and RT‐PC,
DHWT‐HWS
Tank Inputs Outputs
Opentherm RT‐PC Boiler run
Room Boiler Connections
S‐RT‐SC Boiler fault
S‐OT P‐PC
S‐RT‐PC RT‐PC, T‐HWS P‐HWSC OutsideInputs S‐OT P1 (0‐10V)
Outputs
P‐PC
Opentherm
Tank RT‐PC
S‐HWS Boiler
or P2run
SL1
Room RT‐PC
S‐RT‐SC Boiler
P3fault P‐HWSC
S‐OT P‐PC P‐HWSC SL2
Outside TS‐HWS
S‐OT P1 (0‐10V)
P‐PC
TS‐HWS Tank S‐HWS or P2
SL1 RT‐PC P3 P‐HWSC
SL2 TS‐HWS
S‐HWS
TS‐HWS
S‐HWS
*Opentherm or SL1
Boiler CT Pump Circuit Hot Water Storage SL2 or (SL2 and T‐HWS:Opentherm DHW bit)
*Opentherm or SL1
Boiler CT Pump Circuit Hot Water Storage SL2 or (SL2 and T‐HWS:Opentherm DHW bit)
Single Boiler with 2 x CT Pump Circuits
Boiler Connections
Single Boiler with 2 x CT Pump
S‐RT‐PC1 Circuits RT‐PC1 S‐RT‐PC2 RT‐PC2 Inputs Outputs
Opentherm1 RT‐PC1 Boiler run
2.23 STAND ALONE BOILER - PARTIAL HYDRAULICS
continued............
S‐HWS
*Opentherm or SL1
Boiler CT Pump Circuit Hot Water Storage SL2 or (SL2 and T‐HWS:Opentherm DHW bit)
Single Boiler with 2 x CT Zone Circuits
Boiler Connections
S‐RT‐CT1 RT‐PC1 S‐RT‐CT2 RT‐PC2 Inputs Outputs
Single Boiler with 2 x CT Zone Circuits Opentherm1 RT‐PC1 Boiler run
Opentherm2 RT‐PC2 Boiler fault
S‐OT V‐CT1 V‐CT2 Room Boiler Connections
S‐RT‐PC1 P1 (0‐10V)
S‐RT‐CT1 RT‐PC1 S‐RT‐CT2 RT‐PC2 P‐SYS
OutsideInputs S‐OT or P2 Outputs
Opentherm1
Tank RT‐PC1 Boiler
S‐RT‐CT2 P1 (0‐10V) run
Opentherm2 RT‐PC2 Boiler fault V‐CT1
SL1 RT‐CT1 or P2
SECTION 2 - INSTALLATION
29
INSTALLATION
SECTION 2 - INSTALLATION
INSTALLATION
External wiring MUST be in accordance with the current I.E.T. Heating demand can be controlled by:
(BS7671) Wiring Regulations. For Ireland reference should be
made to the current ETCI rules for electrical installations. • 230V SL1 and SL2 inputs where configured for two
heating circuits
The wiring diagrams illustrated in Section 2.27 covers examples
• Two OpenTherm bus interfaces for the connection of
of the range of systems that may be used with this appliance.
OpenTherm compatible room control kits. One per heating
For wiring external controls to the boiler, reference should be circuit.
made to the systems wiring diagram supplied by the relevant • Modulating sequencer kit
manufacturer in conjunction with the connection diagram shown
in Section 2.27. • an external BMS
Difficulty in wiring should not arise, providing the following • an outside temperature sensor.
directions are observed:
• Optional Room Temperature sensor kit, one for each
1. The appliance must be wired with a permanent live supply. heating circuit configured.
2. Four Multi Function Relay Volts free outputs are provided • Optional Header Temperature sensor where hydraulic
that may be configured to control Pumps, Valves and other separation or a combined flow temperature control is
devices over the voltage ranges specified: 24V DC to 230V required
50Hz DHW demand can be controlled by:
An additional option kit may be added to control a Pump • 230V programmer and/or cylinder thermostat
using a modulating 0-10V DC control signal.
• tank sensor kit.
3. Input terminals are available for connecting a variety of
system controls for heating demand, and optionally for DHW • One 2 channel OpenTherm interface for a Heating and a
demand. DHW circuit.
The electrical supply and other inputs for the boiler can be
seen in Section 2.26.
INSTALLATION
2.26 INSTALLER CONNECTIONS
PELV
I7 I8 I9 I10
1 2 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 7 8
I0 I1 PWM GND 10V 10V GND OT1+ OT1- OT2+ OT2- S1 GND S2 GND S3 GND S4 GND
KEY
PELV Only I10 Optional Sensors:
I7 Optional Interlock input. Header Sensor for Cascade Control.
I8 Optional Pump Modulation Control, 0-10V. DHW Tank Temperature or Heating Circuit 2 Room
I9 Boiler Control: Temperature.
0-10V Capacity or Temperature. Heating Circuit 1 Room Temperature.
OpenTherm Interface 1. Boiler, Heating Circuit 1 and/or Outside Temperature Sensor for Heating Curve.
DHW Circuit Control.
OpenTherm Interface 2. Heating Circuit 2 Control.
*Note: The items grayed out are not standard and are connections provided by the relevant option kits.
Voltage Load
Input - SL1, SL2 230V 50Hz 3kΩ min
Input - 0-10V 0 to 10V DC 5mA max
Sensor - Outside
Sensor - Header 10kΩ @ 25ºC β(25/85)=3977
5V DC
Sensor - Room
Sensor - DHW Tank
24 V DC to 230V 50Hz 1.0 A max at CosØ = 0.6
Output - MFR1..4 output 230V 50Hz Peak Surge 20A < 20ms
230V 50Hz Peak Transient 100A < 10uS
Output - Pump 0-10V output 0 to 10V DC 10mA max
Bus - OT1, OT2 OpenTherm V 4.0
Bus - VariCAN CAN Open, proprietary protocol
1 2 3 1 2 3 4 1 2 1 2 1 2 3 4 5 6 1 2 3 4
Switched Live
Fused Spur
/ Volts Free
/ Isolator
Contact
L N PE
continued............
L N PE
1 2 3 1 2 3 4 1 2 1 2 1 2 3 4 5 6 1 2 3 4 1 2 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 7 8
L N PE
continued............
33
INSTALLATION
INSTALLATION
34
External Controls via OpenTherm Master and Optional Tank Temperature Sensor
Heating Circuit Pump and DHW Tank Charge Pump controlled directly from MFR1
External controls via OpenTherm Master and Optional Tank Temperature Sensor
Heating Circuit Pump and DHW Tank Charge Pump controlled directly from MFR1
1 2 3 1 2 3 4 1 2 1 2 1 2 3 4 5 6 1 2 3 4 1 2 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 7 8
Tank Overheat
Tank
Fused Spur and optional OpenTherm
Temperature
/ Isolator Control Master
Sensor
Thermostat
L N PE
Mains Supply External Controls Heating Circuit DHW Tank BMS or Room Control
Pump Charging Pump
External Controls via Switched Live or OpenTherm or Room Temperature Sensors for Two Heating Circuits
Heating Circuit Pumps controlled directly from MFR1 and MFR2
External controls via Switched Live/ or OpenTherm/ or Room temperature sensors for Two Heating Circuits
Heating Circuit Pumps controlled directly from MFR1 and MFR2
1 2 3 1 2 3 4 1 2 1 2 1 2 3 4 5 6 1 2 3 4 1 2 1 2 3 1 2 3 4 5 6 1 2 3 4 5 6 7 8
L N PE
Mains Supply Optional HC Room Thermostats Heating Circuit 1 Heating Circuit 2 Optional HC Room Controls Optional HC Room Temperature Sensors
Pump Pump
INSTALLATION
Connecting Multiple Room Sensors
10kΩ
1%
0.25W
Sensor 1 Sensor 1 Sensor 1 Sensor 3 Sensor 1 Sensor 3
10kΩ 10kΩ
1% 1%
0.25W 0.25W
Sensor 2 Sensor 2 Sensor 3 Sensor 4
Note.
Where multiple sensors are used the overall accuracy of temperature measurement is reduced, this can be compensated for by trimming the parallel resistors
Siting of multiple room sensors for large spaces should be carefully considered to avoid significant temperature differences between sensors
1. Checks to ensure electrical safety should be carried out 1. The whole of the gas installation, including the meter,
by a competent person. should be inspected and tested for soundness and then
purged in accordance with the recommendations of the
2. ALWAYS carry out the preliminary electrical system
relevant standards listed on page 8, by the installer.
checks, i.e. earth continuity, polarity, resistance to earth
and short circuit, using a suitable meter. In IE refer to I.S.813:2002.
TO QUALIFY FOR FREE COMMISSIONING, BOILERS MUST BE COMMISSIONED WITHIN 3 MONTHS OF INSTALLATION.
TO ARRANGE COMMISSIONING REFER TO CONTACT DETAILS ON BACK PAGE.
WARNING. Whilst effecting the required gas soundness test and purging air from the gas
installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.
A B C D E F
OK BACK
INSTALLATION
Power up the boiler The system will then scan the bus to The display will now prompt for selection of
Initailly the software revision of the determine if any other devices are the boiler number, this is necessary to identify
System Manager with be displayed in the present: the boiler should it become part of a iCCS
top LHS of the screen. (Commercial Control System), by default a
Scan devices Master boiler will have a setting of 01:
The following screens will then be
sequentially displayed:
Set boiler number
Boiler ##
< BRAND LOGO > Done
Pairing devices
Once the language is either confirmed or Date The system will now scan the known
selected then this is stored and set as the Year: 2018 devices on the bus to determine what
default. Month: 7 Heating Circuits are available in the boiler
Day: 4 for configuration:
For a standalone boiler the controller
Done
must be selected as a Master:
Controller Date
Year: 2018
Slave Month: 7
Master Day: 4
Done Once this is completed, the display will
prompt with the available heating circuits
Controller Date so that they may have HC numbers
Slave Year: 2018 allocated, and then later configured.
Master Month: 7
Day: 4 Set HC number
Done
HC ## Boiler 1.1
Initialize communication Time HC ## Boiler 1.2
Hour: 0 Done
Minute: 0
Auto su/wi time: If any heating circuits are required for the
Done boiler, then number them sequentially
from 1. If there are no heating circuits to
Configure as master Time be configured to this boiler just move on
Hour: 0 past by selecting "Done". Examples:
Minute: 0
Auto su/wi time: Single Heating Circuit:
Done
Set HC number
Time
HC 01 Boiler 1.1
Hour: 0
HC ## Boiler 1.2
Minute: 0
Done
Auto su/wi time:
Done
Set HC number
Two Heating Circuits: The system will now scan the known System Pump:
devices on the bus to determine what If the boiler has a Plant System Pump
Set HC number Plant functions are available in the boiler connected then select the output that is
for configuration: used to control it from the list. Otherwise
HC 01 Boiler 1.1
HC ## Boiler 1.2 select ‘None’.
Done
Once an output has been configured the
selected function is shown in brackets
Set HC number
behind the output name.
HC 01 Boiler 1.1
HC 02 Boiler 1.2
Done If you wish to configure any of the Do you have a system pump?
following plant functions, then select 'Yes',
if not continue by selecting 'No' and move None
Set HC number past this Section. ONLY configure these PWM/0-10V ()
HC 02 Boiler 1.2 functions here if you are not going to use MFR1
Done
them in any HC's or DHW circuits.
DHW 01 Boiler 1
Done
INSTALLATION
Shunt Pump: 0-10V input Temp. Setp. 0V: Plant OpenTherm interface:
Shunt Pump. If the boiler has a Plant Temp. setp. 0V Plant OpenTherm control. If the boiler has
Shunt Pump connected between the the requirement to use the OpenTherm
8ºC
Flow and Return headers then select the interface then select the connection type
output that is used to control it from the
used from the list. Otherwise set to ‘None’.
list. Otherwise select ‘None’. Done
Once an output has been configured the Configure OpenTherm
selected function is shown in brackets Temp. setp. 0V
None
behind the output name.
8ºC
On demand
Temperature demand
Where is your shunt pump?
Done
Configure OpenTherm
None 0-10V input Temp. Setp. 10V:
PWM/0-10V () None
MFR1 () On demand
Temp. setp. 10V
Temperature demand
80ºC
Capacity demand
Where is your shunt pump?
None For On demand there is an associated
PWM/0-10V () Done flow temperature setpoint:
MFR1 ()
MFR2 () OpenTherm Temp. Setpoint
Temp. setp. 10V
60ºC
Configure 0-10V parameter?
Where is your shunt pump?
MFR1 No Done
MFR2 () Yes
MFR3 ()
MFR4 () Configure OpenTherm
On demand
Configure 0-10V parameter?
Where is your shunt pump? Temperature demand
No Capacity demand
MFR2 ()
Yes
MFR3 ()
MFR4 ()
Configure OpenTherm
Voltage life zero. This setting determines Temperature demand
Where is your shunt pump? the minimum keep alive voltage where the Capacity demand
MFR3 () system expects a voltage to be present on
MFR4 () an operational interface, anything below
this indicates a wiring fault: Switched Live 1 Input Function:
Configure voltage life zero The SL1 input can be configured as a Plant
0-10V Input: function, if this is not required select ‘None’.
If the Plant is to be controlled by a single
0-10V signal, this can be configured.
2.0V Configure SL1
Otherwise set to ‘None’. Done
None
The options are Capacity or Temperature Enable
Configure voltage life zero
control, with additional parameters for
Temperature control:
2.0V Configure SL1
Configure 0-10V input Done None
Enable
None Voltage demand. This setting determines
0-10V Capacity the switching point at which demand is
0-10V Temperature expected by the system, anything below
this is at keep alive voltage: Plant Setp. SL1
Configure 0-10V input
85ºC
Configure voltage demand
None
0-10V Capacity
0-10V Temperature 3.0V Done
Done
Plant Setp. SL1
Configure 0-10V input
85ºC
Configure voltage demand
0-10V Capacity
0-10V Temperature
3.0V Done
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 06:00-22:00
Period 2 00:00-00:00
Period 3 00:00-00:00 Done
Single
Monday
Period 1 06:00-22:00
Period 2 00:00-00:00
Period 3 00:00-00:00 Done
Single
Monday
Period 1 06:00-22:00
Period 2 00:00-00:00
Period 3 00:00-00:00 Done
INSTALLATION
Holiday Programme: Boiler Configuration: Boiler On Indication:
Holiday programme. Up to 8 holiday periods Select boiler to configure If the boiler has the requirement to signal
can be set, each has a start and end date. when the burner is lit then select the
Boiler 1 output that is used to control it from the
Configure holiday prog?
Done list. Otherwise select ‘None’.
No
Boiler on indication
Yes
Select boiler to configure
None
Boiler 1
PWM/0-10V ()
Done
Configure holiday prog? MFR1 (Local boiler pump)
No
Yes
Boiler on indication
None
Boiler Pump Location: PWM/0-10V ()
MFR1 (Local boiler pump)
Holiday Programme Holidays: If the boiler has an individual Boiler Pump
MFR2 ()
connected then select the output that is
Holidays
used to control it from the list. Otherwise
Period 2 Boiler on indication
Start 01/01/2000
select ‘None’.
PWM/0-10V ()
End 01/01/2000 MFR1 (Local boiler pump)
Done Select loc'n of boiler pump
MFR2 ()
MFR3 ()
None
Holidays
PWM/0-10V ()
Period 1 Boiler on indication
MFR1 ()
Start 01/01/2000 MFR1 (Local boiler pump)
End 01/01/2000 MFR2 ()
Done Select loc'n of boiler pump
MFR3 ()
MFR4 ()
Once all are set select ‘Done’ to continue. PWM/0-10V ()
MFR1 ()
MFR2 ()
Once an output has been configured the
selected function is shown in brackets
Select loc'n of boiler pump
behind the output name:
PWM/0-10V () Example MFR3 as a boiler on indication:
MFR1 ()
MFR2 () Boiler on indication
MFR3 () MFR2 ()
MFR3 (Boiler on indication)
Select loc'n of boiler pump MFR4 ()
MFR1 ()
MFR2 ()
MFR3 ()
MFR4 ()
INSTALLATION
Heating Circuit Configuration: The HC maximum temperature set-point Control variant. The HC must have a
can be set, it defaults to the maximum control variant that is used to determine
Heating circuit selection for configuration.
output of the boiler model, but this can be the demand. This is usually set to Flow
Select the HC from the available heating
decreased: Temperature unless specific configuration
circuits in the list:
options are chosen.
Set max flow temp
Select HC to configure
Control Variant
HC1 Boiler1.1
Done
80ºC Flow
Done Weather
Room
HC pump location. If the HC has an Set max flow temp
individual HC Pump connected then Control Variant
select the output that is used to control it
from the list. Otherwise select ‘None’.
80ºC Flow
Weather
Done
Room
Weather and Room
Select loc'n of HC pump The HC minimum set-point can be set,
it defaults to the minimum output of the
None Control Variant
PWM/0-10V ()
boiler model, but this can be increased: Weather
MFR1 () Room
Set min flow temp Weather and Room
15ºC
Select loc'n of HC pump
None
PWM/0-10V () Control Variant
Done
MFR1 () Room
MFR2 () Weather and Room
Set min flow temp
Select loc'n of HC pump
PWM/0-10V ()
MFR1 ()
15ºC Switched Live 1 input function. The SL1
Done
MFR2 () input can be configured as a HC function,
MFR3 () if this is not required select 'None'.
Room Sensor. If the HC has a Room
Select loc'n of HC pump Sensor connected then select 'Yes' from
Configure SL1
MFR1 () the list. Otherwise set to 'None'.
MFR2 () None
MFR3 () HC enable
Room sensor available?
MFR4 () Override
None
Select loc'n of HC pump Yes Configure SL1
MFR2 () None
MFR3 () HC enable
MFR4 () Override
Room sensor available?
None Holiday
Yes
Select loc'n of HC pump Configure SL1
MFR3 () HC enable
MFR4 () Override
Outside Sensor. If the HC has a specific Holiday
Outside Sensor connected then select Frost
'Yes' from the list. Otherwise set to
Once an output has been configured the 'None'. Configure SL1
selected function is shown in brackets Override
behind the output name: Holiday
Outside sensor available?
Frost
Example, MFR1 as a HC pump:
None
Select loc'n of HC pump Yes
Configure SL1
PWM/0-10V ()
Holiday
MFR1 (HC1 pump)
Frost
MFR2 () Outside sensor available?
MFR3 () None
Yes
OpenTherm input function. The Single day timer is programmable for Multiple day timer is programmable for
OpenTherm interface can be configured each of the 7 days with 3 periods per day, Mon-Fri and Sat-Sun with 3 periods per
as a HC function, if this is not required Monday through Sunday: group of days:
select 'None'.
Time clock
Configure OpenTherm Time clock
Single
Multiple
None Single
On/Off Multiple
Temperature control
Multiple
Configure OpenTherm Single
Mon-Fri
None Monday
Period 1 06:00-22:00
On/Off Period 1 06:00-22:00
Period 2 00:00-00:00
Temperature control Period 2 00:00-00:00
Period 3 00:00-00:00 Done
Period 3 00:00-00:00 Done
Multiple
Configure OpenTherm Single
Sat-Sun
On/Off Tuesday
Period 1 06:00-22:00
Temperature control Period 1 06:00-22:00
Period 2 00:00-00:00
Period 2 00:00-00:00
Period 3 00:00-00:00 Done
Period 3 00:00-00:00 Done
Single
Sunday
Configure holiday prog?
Period 1 06:00-22:00
No
Period 2 00:00-00:00
Yes
Period 3 00:00-00:00 Done
Single
Monday
Period 1 06:00-22:00 Holidays
Period 2 00:00-00:00 Period 1
Period 3 00:00-00:00 Done Start 01/01/2000
End 01/01/2000
Done
Single
Monday
Period 1 06:00-22:00 Holidays
Period 2 00:00-00:00 Period 1
Period 3 00:00-00:00 Done Start 01/01/2000
End 01/01/2000
Done
INSTALLATION
Pump protection. To enable seizure The HC has now been configured and the Example, MFR2 as a DHW pump:
protection on pumps/valves connected to display will return to:
Select loc'n of DHW pump
the HC, select 'Yes'. MFR1 ()
Select HC to configure
MFR2 (DHW1 pump)
Configure pump protection? MFR3 ()
HC1 Boiler1.1 ü MFR4 ()
No Done
Yes The DHW maximum tank temperature set-
point can be set, it defaults to the maximum
Note, that the HC number now has a
DHW output of the boiler model, but this
tick next to it showing that it has been
Configure pump protection? can be decreased:
configured. If you have completed the
No
Yes
HC configuration, select 'Done'. Set max tank temp
Select HC to configure
HC1 Boiler1.1 ü
60ºC
Done
Done
DHW priority. If the HC is requried to
give priority to any DHW demands in the Set max tank temp
system then select 'Yes'.
DHW priority?
DHW Configuration
60ºC
DHW circuit selection for configuration. Done
None
DHW pump location. If the DHW circuit has Weekday
Interval
an individual DHW Pump connected then
Operating mode. The operating mode of
select the output that is used to control it
the HC can be set from a scrolling field, Antilegionella?
from the list. Otherwise select 'None'.
once this is set then the HC configuration None
is completed by selecting 'Done'. Weekday
Select loc'n of DHW pump
Interval
Operating mode
None
PWM/0-10V ()
Standby For weekday set the following parameters,
MFR1 ()
Done followed by 'Done':
Select loc'n of DHW pump Antilegionella timing
None Weekday: Saturday
Operating mode
PWM/0-10V () Start time: 01:00
MFR1 () Done
Time clock single day
MFR2 ()
Done
Antilegionella timing
Select loc'n of DHW pump
Weekday: Saturday
PWM/0-10V ()
Operating mode Start time: 01:00
MFR1 ()
Done
MFR2 ()
Time clock multiple day
MFR3 ()
Done
Antilegionella timing
Select loc'n of DHW pump Weekday: Saturday
MFR1 () Start time: 01:00
Operating mode
MFR2 () Done
MFR3 ()
Day
MFR4 ()
Done
Then set the desired Antilegionalla
Select loc'n of DHW pump temperature, followed by 'Done':
MFR2 ()
Operating mode Antilegionella temperature
MFR3 ()
MFR4 ()
65ºC
Night
Done
Done
Select loc'n of DHW pump
MFR3 ()
MFR4 () Antilegionella temperature
65ºC
Done
Tank Sensor. If the DHW has a Tank Single day timer is programmable for Multiple day timer is programmable for
Sensor connected then select 'Yes' from each of the 7 days with 3 periods per day, Mon-Fri and Sat-Sun with 3 periods per
the list. Otherwise set to 'None'. Monday through Sunday: group of days:
None
Single Multiple
DHW enable
Thursday Mon-Fri
DHW override
Period 1 06:00-22:00 Period 1 06:00-22:00
Period 2 00:00-00:00 Period 2 00:00-00:00
OpenTherm Input Function. The Period 3 00:00-00:00 Done Period 3 00:00-00:00 Done
OpenTherm interface can be configured as
a DHW circuit control function, if this is not Single Once all days and times are set, select
required, select 'None'. Friday
'Done' to continue.
Period 1 06:00-22:00
Period 2 00:00-00:00 Holiday programme. Up to 8 holiday
Configure OpenTherm Period 3 00:00-00:00 Done periods can be set, each has a start and
None
end date. Once all are set select 'Done'
Single to continue:
Temperature demand
Saturday
Period 1 06:00-22:00 Configure holiday prog?
Period 2 00:00-00:00
Configure OpenTherm Period 3 00:00-00:00 Done No
None
Yes
Temperature demand
Single
Sunday
Period 1 06:00-22:00
Configure holiday prog?
Internal timeclock. A timeclock can be Period 2 00:00-00:00
No
Period 3 00:00-00:00 Done
set for the DHW circuit, this will control Yes
all functions. It can be set as a single or
multiple day timer. Single
Monday
Period 1 06:00-22:00
Use an internal timeclock Period 2 00:00-00:00 Holidays
Period 3 00:00-00:00 Done Period 1
No Start 01/01/2000
Yes End 01/01/2000
Single
Done
Monday
Period 1 06:00-22:00
Use an internal timeclock Period 2 00:00-00:00 Holidays
No Period 3 00:00-00:00 Done Period 1
Yes Start 01/01/2000
End 01/01/2000
Done
INSTALLATION
The DHW circuit has now been
configured and the display will return to:
DHW1 Boiler1 ü
Done
Max Rate 9.76 10.2 9.4 9.3 9.4 9.6 9.4 10.9 11.2 11.4 11.4 10.8 11.2
Min Rate 8.56 8.6 8.6 8.7 8.6 9.0 8.5 10.3 9.7 10.2 10.8 10.1 10.1
OPERATING SEQUENCE
no
Standby Heat demand on?
yes
Pump On
no
Temp. < setpoint?
yes
Fan On
Fan Pre-purge
Spark Generator On
Gas Valve On
3s Ignition Period
no
Flame detected?
yes
Soft Start
yes
Demand no
off or Temp. >setpoint?
yes
INSTALLATION
2.31 GENERAL CHECKS
Make the following checks for correct operation. c. Refill and vent the system, clear all air locks and again
1. The correct operation of ANY secondary system controls check for water soundness.
should be proved. Operate each control separately and d. Balance the system.
check that the main burner or circulating pump, as the case
may be, responds. 3. Check the condensate drain for leaks and check it is
discharging correctly.
2. Water circulation system;
a. With the system HOT examine all water connections for 4. Finally set the controls to the User’s requirements.
soundness.
Note. If an optional programmer kit is fitted then refer to the
b. With the system still HOT, turn off the gas, water and instructions supplied with the kit.
electricity supplies to the boiler and drain down to
complete the flushing process.
ROUTINE OPERATION
Full instructions covering routine lighting and operation of the IMPORTANT. Point out to the owner that the boiler must have
boiler are given in the User Guide located on the inside of the regular maintenance and cleaning, at least annually, in order
lower controls door.. to ensure reliable and efficient operation. Regular attention
will also prolong the life of the boiler and should preferably be
Draw the attention of the boiler owner or his representative to
performed at the end of the heating season.
the User Guide. Give a practical demonstration of the lighting
and shutting down of the boiler. After servicing, complete the service Section of the log book
and return to the owner or their representative.
Describe the function of the boiler and system controls and
show how they are adjusted and used. Recommend that a contract for this work should be made with
the regional gas authority or a suitably qualified Gas Safe
Hand these Installation and Servicing Instructions, and Log
Registered Engineer. In IE servicing work must be carried out
book to the customer and request him to keep them in a safe
by a competent person.
place for ready reference. Place the User Guide back into
the lower controls door. For IE, it is necessary to complete
a “Declaration of Conformity” to indicate compliance to the
appropriate standard.
2.33 SAFETY
It is the law that any service work must be carried out by a • Check the jacket front panel is correctly fitted, ensuring
Suitably qualified Gas Safe Registered Engineer. In IE service that a good seal is made. Secure the controls fascia in
work must be carried out by a competent person. place.
WARNING. Always turn off the gas supply at the gas • With the system hot examine all water connections for
service cock, and switch off and disconnect the electricity soundness.
supply to the appliance and any external controls before • Check the gas rate and measure the combustion CO/
servicing or replacing components. CO2 content. The CO/CO2 ratio of the flue gas should
not be greater than 0.004 ratio & the CO should not
exceed 350ppm.
IMPORTANT.
• Carry out functional checks as appropriate.
After completing the servicing or replacement of components
always:
• Test for gas soundness.
• Check the water system is correctly filled and free of air. Air
in the boiler could cause damage to the heat exchanger.
For this reason the automatic air vent / vent tube in the left
top side must never be blocked.
3 SERVICING
3.1 SERVICING SCHEDULE SETTING TO MAXIMUM OR MINIMUM OUTPUT
Ensure that there is a current CH demand to the boiler (e.g. the
Note. Refer to “System Set up information” at rear of User CH Switched Live is on)
Guide.
IDEAL Evomax 2 100kW
To ensure the continued safe and efficient operation of the
Operation: Off
appliance it is recommended that it is checked at regular Flow setp: 0.0ºC
intervals and serviced as necessary. The frequency of Flow temp.: 40.4ºC
servicing will depend upon the installation condition and usage
but should be carried out at least annually.
Ideal Boilers does not accept any liability resulting from Press "OK" and the following screen witll be displayed.
the use of unauthorised parts or the repair and servicing of
appliances not carried out in accordance with the Company’s Menu
Press "OK" and the boiler will go to Maximum Rate for 10 minutes
after which normal operation will resume.
Front Panels
1. Open the control casing door.
2. Remove the two screws retaining the front panel, lift the
panel to remove.
3. Lower the control panel to the service position.
SERVICING
Side Panels
Note. Removal of side panels is not required for
normal service.
4. Remove the screws from the top and bottom of
the side panels.
5. Re-assemble in reverse order.
MODEL: 150 4
SERVICING
3.5 REMOVAL OF BURNER
4
1. Refer to Section 2.33.
2. Remove the front panel. Refer to Section 3.2.
3. Remove the fan and gas valve assembly. Refer to
Section 3.3.
4. Remove the four or six screws and the two extended 7
nuts securing the burner to release the burner body.
5. Lift the burner body by lifting out of its recess.
6. The burner can now be cleaned on the back face 6
only, the metal fibre surface must not be touched. The
burner must be replaced if it shows signs of damage.
7. After cleaning the burner replace it in the recess and
check the burner body seal for signs of damage.
If damage is apparent it must be replaced. The
upstream (stainless steel) side may be cleaned of dust
and debris.
8. Reassemble in reverse order. Ensure the notch in
the burner aligns with the up-stand feature in the
heat engine. The four or six screws and 2 extended
nuts should be fitted following a diagonal tightening
sequence twice. All fittings should be secured firmly.
9. Check the operation of the boiler (Refer to Section
2.33).
SERVICING
100kW 120kW
150kW
SERVICING
100kW 120kW
8
8
150kW
8
8
8
SERVICING
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 electrode and gasket supplied
checking the spark gap is 3.5mm ±1.
4
7. Reassemble in reverse order.
8. Check the operation of the boiler (Refer to 3
Section 2.33. 5
4
3.15 REMOVAL OF WATER PRESSURE SWITCH
1. Refer to Section 2.33.
5 x2
2. Remove the front panel. Refer to Section 3.2.
SERVICING
SERVICING
2. Isolate the electrical supply to the boiler and fully
isolate the boiler from any external supply.
3. Remove the upper front panel and put the control
panel into the service position. Refer to Section 3.2.
6
4. Fit the earth strap provided with the spare PCB to
your wrist and to a suitable earthed metal.
5. Remove the PELV harness from the securing clips
located on the rear of the control box cover
6. Pull off all of the main PCB connectors.
7. Remove 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.
7 6 7
DP
View from rear
FS 3 ION Analogue
2
230VAC - 350VDC
1 2 ION PE
X5
CC TX 1
1 ION Digital CC RX 2
ChipCom
CC 5V 3
X7
CC GND 4
CC 24V 5
Varican TTL lead
To SM X1 DHW
CAN VCCon 1 OpenTherm Header Tank Room Outside
CAN Mode 2 0-10V 1 2 Sensor Sensor Sensor Sensor
X8
10V OT1+ OT2+ S GND S GND S GND S GND
I9 GND OT1- OT2- I10
CAN 5V 5
Boiler Boiler
Run Fault CAN GND 6
C NO C NO CAN 24V 7
I6 1 2 3 4 5 6 1 2 3 4 5 6 7 8
OpenTherm Slave
OT- 1
OT+ 2
0-10V &
1 2 3 4
X9
0-10V - 3 OpenTherm lead
To SM X2
0-10V + 4
CH2/DHW/ Header - 1
CH1/Boiler
Shunt Valve/
System 5 Lockout COM Header + 2
Pump
Room - 3
Thermistors
C NO PE C NO PE
Volts Free 24V - 230VAC
I5 4 Lockout NO Room + 4
X10
OWC - 5
3 OWC + 6
X4
1 2 3 4 5 6 DHW GND 7
2 Burner ON COM DHW + 8
Flow + 4
X11
Return - 5
5 Pump DHW COM Return + 6
Heat Ex - 7
Volts Free 24V - 230VAC
3 P PWM 1 1 FC
X3
2
Pump ctrl
3 5 4 3 2 1
P GND 2
PCa
2 Pump CH COM P 0-10V 3
X12
F PWM 4
Fan ctrl
1 Pump CH NO F GND 5
F FB 6
Turbine GND 2
8 Valve AC N2 Turbine 5V 3 WPSb
X13
WPS Signal 4
7 Valve AC N1 WPS GND 5
GV WPS 5V 6 PELV *Option
8 7 6 5 Interlock Kit
6 Valve DC+
4 3 2 1 I0 I1
S Interlock b 1 I7
Mains Voltage
3
X14
2 2
X2
4 Valve AC L2 S Interlock a 4 1 1
5 SIa SIb
3 Valve AC L1 APS a 6
Chassis PE
1 IGN Live
1 2 3
L N L N PE
I4 I1
2 DHW SWL
1 CH SWL
1 2 1 2 3
WIRING
CH/CH2 Chassis PE
DHW Demand
SL1 L SL2 L
I2
1 2 3 4
SM X3 SM X2 SM X1
CAN VCCon
CAN Mode
CAN GND
CAN 24V
CC GND
CAN 5V
CAN Rx
CAN Tx
CC 24V
CC 5V
CC RX
CC TX
OT2+
OT1+
OT2‐
OT1‐
1 2 3 4 5 1 2 3 4 1 2 3 4 5 6 7
4 3 2 1
L
‐
To SM
CAN GND
1 2 3 4 5 6 7
5 FAULT FINDING
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
5.1 FAULT FINDING SCREENS
Fault management
When a fault occurs on the boiler the status screen with alternate as shown below:
To show the fault description scroll right (Clockwise) to show the detail.
If a single fault is present then the screen will show:
Fault ## {Description}
{Fault description
for the actual error}
Press Reset
If multiple faults are present a list will appear in fault priority order:
The list can now be scrolled and any of the faults may be selected to retrieve the fault description:
Fault ## {Description}
{Fault description
for the actual error}
Press Reset
L Flameloss during stabilisation => Lockout after restarts attempt are used 56 5.7
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
yes
Has PCB just been replaced? Reset Boiler
no
no
Is the gas pressure available at the boiler > 18mbar? Check gas supply and rectify fault
yes
yes
no
Unplug the Gas Valve, is the resistance between the Replace Gas Valve
outside pins between 1kΩ and 10kΩ?
yes
no
Check Spark Generator and associated Harness Replace Spark Generator and
for continuity, visual condition and position (Refer to Harness as necessary
Section 3.17). Are these functioning correctly?
yes
no
Replace Ignition Electrode and
Check Ignition Electrode and associated Harness
associated Harness as necessary
for continuity, visual condition and position (Refer to
Section 3.12). Are these functioning correctly?
yes
no
Check condensate trap and condensate drain pipework for Replace Gas Valve
blockage and rectify if necessary. Boiler now working OK?
* Note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the
value. In general terms a reading of greater than 150V indicates that the correct voltage is supplied to the gas valve.
yes
Disconnect the electrical connection to the Flame Replace Flame Detection Electrode
Sense Electrode. Is there continuity between the no
Electrode and earth? Check routing and integrity of internal boiler wiring
Is the following voltage available at the Gas Valve? no Check wiring from Gas Valve to PCB
(approximately 215Vdc for 30, 40, 60, 80 and 150kW) and replace if necessary, otherwise
(approximately 240Vac for 100 and 120kW) (*See note) replace the main PCB
yes
yes
* Note: due to the wave form of the rectified voltage, the reading will vary depending on the type of meter used to measure the
value. In general terms a reading of greater than 150V indicates that the correct voltage is supplied to the gas valve
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
no Rectify wiring & connections
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
no
Replace main PCB
Is there 230Vac at the blue and brown
connections to the 3 way connection on the Fan? yes
Replace Fan
yes
no
Check and replace wiring as necessary
Is there continuity between the PCB and the Thermistor? yes
Replace main PCB
no
Is the wiring securely connected at both the boiler and Securely connect the wiring at both
Outside Sensor? the boiler and Outside sensor
yes
no
Disconnect the wires to the Outside Sensor. Check the Fit a new outside sensor
resistance using a suitable multimeter connected across
the thermistor’s terminal pins.
At 0°C expect 32,000 - 33,000 Ω
At 10°C expect 19,000 - 21,000 Ω
At 20°C expect 12,000 - 13,000 Ω
Is the thermistor value correct?
yes
no
Is the Pump connected the correct way? Reverse Pump
yes
yes
Has the External Interlock operated? Reset the External Interlock
no
no
Ensure the wiring has continuity and is
Does the wiring from the Interlock Relay (mounted securely connected
within the boiler) to the terminal strip have continuity and
yes
is securely connected?
Replace the Interlock Relay Kit
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
Is the heating circuit set for day or Set for day or in a timed (on)
no
in a timed (on) period operation? period operation?
yes
no
Are the Radiator Valves open? Open the Radiator Valves
yes
no
no
yes
This is not a boiler fault.
no Ensure voltage is supplied to
Is there a 230 av at SL1?
the boiler by correcting ther
yes external wiring
yes
yes
5.16 NO DISPLAY
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
no
Is there 230Vac to the boiler at the mains supply inlet? Supply power to the boiler
yes
no
Is the wiring from the boiler terminal block to the Connect the wiring from the terminal block
combination manager PCB connected securely? to the combination manager PCB securely
yes
no
Is the cable from the combination manager PCB to the Connect the cable from the combination
system manager PCB connected securely? manager PCB to the system manager PCB
securely
yes
no
Does the cable from the combination manager PCB to the Replace cable from combination manager
system manager PCB have continuity and is un-damaged? PCB to system manager PCB
yes
no
Is the Fuse on the combination manager PCB OK? Check for shorts on Pumps/Diverter Valve/
Fan/Spark Generator/Gas Valve and
replace Fuse
yes
no
Replace the system manager PCB, still no display? Replace combination manager PCB
no
Is the boiler configured to accept a 0-10V Input? Configure the boiler to accept a 0-10V
input
yes
no
Is the boiler set to Day mode? Set the boiler to Day mode
yes
no
Is a voltage of between the configured voltage demand Ensure the configured voltage demand
threshold and 10V being supplied to the 0-10V input, threshold and 10V is correctly connected
with positive and negative connected correctly? to these terminals from the external device
yes
no
Is the wiring from the boiler terminal strip to the combustion Ensure that the wiring is securely
manager PCB securely connected and has continuity? connected and has continuity
yes
When calling, and to ensure we can provide you with the most accurate parts information, please ensure you have the following to
hand;
- Boiler Model e.g. 120
- Appliance GC Number (UK only) e.g. 41-750-38A
- Boiler Serial Number e.g. ACK 205962000000480101
KEY:
CO = carbon monoxide
CO2 = carbon dioxide
O2 = oxygen
Combustion Ratio = The CO reading measured in ppm divided by the CO2 reading first converted to ppm
ppm = parts per million
GS(I&U)R = Gas Safety (Installation and Use) Regulations
continued.........
Start
Set Boiler to Maximum Gas Rate Carry Out Flue Integrity Check Using Analyser
In accordance with boiler instructions, Insert analyser probe into air inlet test point (where available) and allow
set boiler to operate at maximum rate readings to stabilise.
(full load condition). Allow sufficient Note. Where no air inlet test point is provided then a flue integrity check with
time for combustion to stabilise. the analyser is not possible. The installer should verify that flue integrity has
Note. Do not insert analyser probe been visually checked in accordance with the “Prior to CO level and
during this period to avoid possible combustion ratio check” (see previous page) before proceeding to the
flooding of sensor. “check CO level and combustion ratio at maximum rate” stage below.
Yes
Turn off appliance and call Ideal Technical Helpline for advice
The appliance must not be commissioned until problems are identified Is
and resolved. If commissioning cannot be fully completed, the appliance CO level less
No than 350ppm AND CO/CO2
must be disconnected from the gas supply in accordance with GSIUR.
ratio less than
0.0040?
Ideal Boilers Ltd. pursues a policy of continuing improvement in the design and performance of its products.
The right is therefore reserved to vary specification without notice.