Evomax 2 Installation Manual 219458 1

INSTALLATION AND
SERVICING
EVOMAX 2
30 40 60 80 100 120 150
30P 40P 60P 80P 100P 120P
When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance
speciﬁcation that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
For the very latest copy of literature for speciﬁcation and maintenance practices visit our website www.idealcommercialboilers.com
where you can download the relevant information in PDF format.
August 2019
UIN 219458 A01
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
Emissions NOx mg/kWh 34.1 52.3 33.2 64.4 35.2 67.7

Annual Energy Consumption QHE GJ 93 91 124 121 186 182
Sound Power Level, Indoors LWA dB 55.2 55.2 57.7 57.7 59 59
2 Installation & Servicing


PRODUCT FICHE
EVOMAX 2 HEAT BOILER

Ideal Boilers
ERP DATA
SYMBOL UNITS MODEL
30 30P 40 40P 60 60P
Condensing boiler Yes
Seasonal Space heating efficiency class A
Rated heat output kW 30 30 40 40 60 60
Seasonal space heating energy efficiency ƞs % 93* 93* 93* 93* 93* 93*
Annual energy consumption QHE GJ 93 91 124 121 186 182
Sound power level, indoors LWA dB 55.2 55.2 57.7 57.7 59 59
Seasonal Space Heating Energy Efficiency of the Boiler *%
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

Solar Contribution (from fiche of solar device)
Collector Size Tank Volume Collector Tank rating

(in m2) (in m3) Efficiency A* = 0.95
(in %) A = 0.91
B = 0.86
C = 0.83
D-G = 0.81
%
= (‘III ’x + ‘IV ’ x ) x 0.9 x ( / 100 x = C
%
Seasonal Space Heating Energy Efficiency of Package TOTAL: A+B+C=
Seasonal Space Heating Energy Efficiency Class of Package
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

Installation & Servicing 3

CONTENTS
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

SECTION 1 - GENERAL
Table 1 Performance Data (Natural Gas & Propane (P))
Model 30 30P 40 40P 60 60P 80 80P 100 100P 120 120P 150
Boiler Output Max kW 30 30 40 40 60 60 80 80 100 100 120 120 150
(non-condensing)
Mean 70°C Min kW 6 6 8 8 12 12 16 16 20 20 24 24 30
Boiler Output Max kW 31.5 30.9 42 41.2 63.5 62.1 84.4 82.6 103.9 101.7 124.7 123.3 158
(condensing)
Mean 40°C Min kW 6.5 6.4 8.5 8.3 12.7 12.4 17.2 16.8 21.6 21.3 26 25.7 32.5
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
DB 55.2 55.2 57.7 57.7 59 59 59.9 59.9 62 62 62 62 59
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
Max. operating temp sealed sys. ºC 85
Max. operating temp open vented sys. ºC 82
*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.
Table 2 General Data

Model 30 30P 40 40P 60 60P 80 80P 100 100P 120 120P 150
Gas Supply 2H – G20 – 20mbar / 3P - G31 - 37mbar
Gas Supply Connection G¾
Flow Connection G 1¼
Return Connection G1¼
Max Pressure (sealed sys) Bar (psi) 6.0 (87)
Maximum Static Head m 61.0
Electricity Supply 230V - 50Hz
Fuse Rating A 4.0
Power Consumption W 81 138 82 149 187 243 240
IP Rating IPX4D
Nominal flue dia - Concent. 80/125 100/150
Condensate Drain mm 25
Water Content L 3.0 5.0 7.0 9.2
Packaged Kg 53.5 63.5 80 88
Unpackaged (dry weight) Kg 47.5 57.5 73 81
Note. HEALTH & SAFETY DOCUMENT NO. 635

Natural gas consumption is calculated using a calorific value of The electricity at work regulations, 1989. The manufacturer’s
37.8MJ/m3 (1038Btu/ft3) gross or 34 MJ/m3 (910 Btu/ft3) nett at notes must NOT be taken, in any way, as overriding statutory
15oC and 1013.25 mbar. obligations.
a. For l/s divide the gross heat input (kW) by the gross C.V. of the IMPORTANT. These appliances are CE certified for safety
gas (MJ/m3) and performance. It is, therefore, important that no external
b. For ft/h3 divide the gross heat input (Btu/h) by the gross C.V. of control devices, e.g. flue dampers, economisers etc., are
the gas (Btu/ft3). directly connected to these appliances unless covered by
these Installation and Servicing Instructions or as otherwise
c. For m3/h multiply l/s by 3.6.
recommended by Ideal Boilers in writing. If in doubt please
d. 1kW = 3412 BTU/hr.
enquire.
e. 1m3 = 35.3ft3
f. 1mg/kWh (NOx) = 0.568 ppm DAF (natural gas). Any direct connection of a control device not approved by Ideal
Boilers could invalidate the certification and the normal appliance
Propane gas consumption is calculated using a calorific value of warranty. It could also infringe the Gas Safety Regulations and
95.7 MJ/m3 (2500 Btu/ft.3) gross or 88.0 MJ/m3 (2300 Btu/ft.3) net the above regulations.
at 15oC and 1013.25 mbar.
To obtain the fuel consumption in liquid form divide the above
figures by 270.

SECTION 1 - GENERAL
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
Boiler size G.C. Appliance No.

(Benchmark No.)
30 41-796-26
40 41-796-27
60 41-796-28
80 41-796-29
100 41-796-30
120 41-796-31
150 41-796-32
30P 41-796-33
40P 41-796-34
60P 41-796-35
80P 41-796-36
100P 41-796-37
120P 41-796-38
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.

SECTION 1 - GENERAL
1 GENERAL 1.3 SAFETY
Current Gas Safety (Installation and Use) Regulations
1.1 INTRODUCTION or rules in force
The boilers are fully automatically controlled, wall mounted, The appliance is suitable only for installation in GB and IE and
fanned, super efficient condensing appliances. should be installed in accordance with the rules in force.
The condensing boilers can be installed either on the wall or into In GB, the installation must be carried out by a suitably qualified
a prefabricated floor mounted frame. Gas Safe registered engineer or in IE by a competent person. It
The boilers are suitable for use with a room sealed flue or open must be carried out in accordance with the relevant requirements
flue application. of the:
Through a sophisticated control system combined with premix • Gas Safety (Installation and Use) Regulations
burner arrangement the boilers are capable of high seasonal • The appropriate Building Regulations either The Building
efficiencies of >96% and low emissions. Regulations, The Building Regulations (Scotland), Building
These boilers are fitted with an integral flue non-return valve Regulations (Northern Ireland).
which negates the fitting of same in shared flue (B23) systems. • The Water Fittings Regulations or Water byelaws in Scotland.
These boilers are certified to meet the requirements of the EC
Gas Appliance Directive, Boiler Efficiency Directive, EMC and • The Current I.E.T. Wiring Regulations.
Low Voltage Directive. Where no specific instructions are given, reference should be
Note. These boilers cannot be used on systems that include made to the relevant British Standard Code of Practice.
gravity circulation. In IE, the installation must be carried out by a Competent Person and
The boiler are suitable for connection to fully pumped, open installed in accordance with the current edition of I.S.813 “Domestic
vented or sealed water systems. Adequate arrangements for Gas Installations” or I.S. 820 “Non-Domestic Gas Installations” as
completely draining the system by provision of drain cocks MUST appropriate, the current Building Regulations and reference should
be provided in the installation pipework. be made to the current ETCI rules for electrical installation.
The Boiler boilers have been tested and certified to;
1.2 OPTIONAL EXTRA KITS
BSEN 15502-1, BSEN 15502-2, BSEN 15502-2-1, BSEN 60335-1,
• External Vertical Terminal Extension Kit 80/125 BSEN 60335-1, BSEN 60335-2-102, BSEN 55014-1 and BSEN
• External Vertical Terminal Extension Kit 100/150 55014-2 for use with Natural Gas & Propane.
• Vertical Roof Flue Kit 80/125
• Vertical Roof Flue Kit 100/150 Detailed recommendations are contained in the following Codes
• Horizontal Wall Flue Kit 80/125 of Practice:
• Horizontal Wall Flue Kit 100/150 BS. 6891 Installation of low pressure gas pipework of up to
• Open Flue Kit 80 28mm (R1) in domestic premises (2nd family gas).
• Open Flue Kit 100 BS. 5440 Inst. and maintenance of flues and ventilation for
• Cascade Flue Kit gas appliances of rated input not exceeding 70kW
• Plume kit net (1st, 2nd and 3rd family gases).
• Pitched and flat weather collars Part 1 Specification for installation of flues.
• 90º Extended Elbow 80/125 Single Part 2 Specification for installation and maintenance of
• 90º Extended Elbow 100/150 Single
ventilation for gas appliances.
• Expander 80/125 - 100/150
BS. 6644 : 2011 Installation of gas fired hot water boilers of rated
System inputs between 70kW and 1.8MW (net) (2nd
• Frame and Header Kits & accessories and 3rd family gases).
• Pump kits
BS. 6798 Installation and maintenance of gas fired hot water
Controls
boilers of rated input not exceeding 70kW net.
• Outside temperature sensor
• DHW tank sensor/Flow sensor/Header sensor. Pocket version BS. 6880 Low temperature hot water heating systems of
• DHW tank sensor/Flow sensor/Header sensor. Strap-on version output greater than 45kW.
• Room temperature sensor
• OpenTherm room control Part 1 Fundamental and design considerations.
• 0-10V Pump control kit Part 2 Selection of equipment.
• Safety interlock kit Part 3 Installation, commissioning and maintenance.
• Cascade, first boiler BSEN.12828:2012 Heating Systems in buildings: Design for water
• Cascade, subsequent boiler based systems.
• Extension module BSEN.12831:2017 Heating Systems in buildings: Method for
• Modulating sequencer kit calculation of the design heat load.
• Sequencer, OpenTherm room control
• 6 relay zone expansion kit BSEN.13831 Specification for: Expansion vessels using an
• Sequencer and zone expansion pocket sensor, DHW or flow temp internal diaphragm, for sealed hot water heating
• RDG, remote diagnostic gateway systems.
• OpenTherm to Modbus gateway BSEN.14336:2004 Heating Systems in buildings: Installation and
• OpenTherm to BACnet gateway commissioning of water based heating systems.
• OpenTherm to LONworks gateway IGEM/UP/1 Soundness testing and purging of industrial and
• OpenTherm to KNX gateway commercial gas installation.
Fuel IGEM/UP/2 Gas installation pipework, boosters and
• Propane to Natural Gas Conversion Kit compressors on industrial and commercial
Please note propane variants of the boiler are Cat II2H3P (20/37) and premises.
may be converted to natural gas operation only using the approved
conversion kit. Natural gas variants of the Boiler are Cat I2H and IGEM/UP/10 Installation of gas appliances in industrial and
cannot be converted to propane operation. commercial premises.

SECTION 1 - GENERAL
ICOM Water treatment and conditioning of commercial 1.8 FLUE INSTALLATION
heating systems guide.
DANGER; ONLY USE IDEAL ROOM SEALED FLUE
Where reference is made throughout these instructions I.S.813:2002
GAS SYSTEMS. THE BOILER CE MARK IS VALID
“Domestic Gas Installations” reference should also be made to
I.S.820:2000 “Non-Domestic Gas Installations” as applicable. ! ONLY IF THE APPLIANCE IS OPERATED WITH IDEAL
ROOM SEALED FLUE KITS. OTHER FLUE SYSTEMS
ARE NOT TESTED WITH THIS APPLIANCE.
1.4 SAFE HANDLING
This boiler will require 2 or more operatives to move it to its DANGER; ONLY USE OPEN FLUE GAS SYSTEMS
installation site, remove it from its packaging base and during WHERE THE BOILER AIR INLET KIT IS USED. THE
movement into its installation location. Manoeuvring the boiler ! BOILER CE MARK IS VALID ONLY IF THE APPLIANCE
may include the use of a sack truck and involve lifting, pushing IS OPERATED WITH THE IDEAL AIR INLET KIT.
and pulling.
The flue kits are suitable for use with this boiler range only.
Caution should be exercised during these operations.
Operatives should be knowledgeable in handling techniques when These kits and the associated options are suitable for both roof
performing these tasks and the following precautions should be and wall mounting applications.
considered: The roof flue kits are suitable for both flat and pitched roof
• Grip the boiler at the base. termination, using either concentric or flue only terminals.
• Be physically capable.
All flue options are connected using the flue adaptor fitted to the
• Use personal protective equipment as appropriate, e.g.
boiler at the time of manufacture.
gloves, safety footwear.
During all manoeuvres and handling actions, every attempt Additional information covering the selection and installation can
should be made to ensure the following unless unavoidable and/ be found with this booklet.
or the weight is light.
Weather Proofing
• Keep back straight.
• Avoid twisting at the waist. Where the flue passes through the roof line an adequate seal
• Avoid upper body/top heavy bending. must be made. This can be achieved by using either:
• Always grip with the palm of the hand.
• Flat weather collar
• Use designated hand holds.
• Keep load as close to the body as possible. • Pitched weather collar
• Always use assistance if required. Flue duct extension kits are available for concentric flue
configuration. These packs contain additional 1 metre ducts and
1.5 SAFE HANDLING OF SUBSTANCES may be cut to the desired length.
No asbestos, mercury or CFCs are included in any part of the Flue duct extension kits are available for open flue configurations.
boiler or its manufacture. These packs contain 2 x 1 metre ducts and may be cut to the
desired length.
1.6 LOCATION OF BOILER If obstructions prevent direct flue routing then both 90o and 45o
elbows can be provided to offset the flue system.
The boiler must be installed on a flat and vertical wall capable of
adequately supporting the weight of the boiler and any ancillary Terminal Position
equipment or on a boiler frame supplied in kit form. Due to the high efficiency of the boilers pluming will occur. For
The wall must be 90º (±5º) from the perpendicular. This is to allow this reason, vertical termination is recommended, and in any
safe operation of the integral flue non return valve. case, terminal positions which could cause problems should
The boiler must not be fitted outside. where possible be avoided. Particular care should be taken in the
case of large multiple boiler installations, and complying with the
1.7 GAS SUPPLY requirements of the Clean Air Act.
The local gas supplier should be consulted, at the installation IMPORTANT

planning stage, in order to establish the availability of an adequate It is the responsibility of the installer to ensure, in practice, that
supply of gas. An existing service pipe must NOT be used without products of combustion discharging from the terminal cannot
prior consultation with the local gas supplier. re-enter the building or any other adjacent building through
A gas meter can only be connected by the local gas supplier or ventilators, windows, doors, other sources of natural air infiltration,
by a suitably qualified Gas Safe registered engineer or in IE by a or forced ventilation / air conditioning.
competent person. If this should occur the appliance MUST be turned OFF, labelled
as ‘unsafe’ and corrective action taken.
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the Where the lowest part of the terminal is fitted less than 2m above
rate of gas supply required. A minimum working gas pressure of a balcony, above ground or above a flat roof to which people
17.5mbar MUST be available at the boiler inlet for Natural gas have access then the terminal MUST be protected by a purpose
and 32mbar for Propane. designed guard. The minimum spacing between the balcony and
the terminal should be 75mm, in order to allow a terminal guard to
Do not use pipes of smaller size than the boiler inlet gas connection.
be fitted.
The complete installation MUST be tested for gas soundness and
Terminal guards are available from boiler suppliers - for all
purged in accordance with the appropriate standards listed on page 8.
requirements contact:
TFC Group
www.tfc-group.co.uk
Tel: +44 (0) 1732 351 680

SECTION 1 - GENERAL
Ensure that the guard is fitted centrally. Note.
The air inlet/products outlet duct and the terminal of the boiler • With the boiler firing at maximum rate, the temperature
MUST NOT be closer than 25mm to combustible material. Detailed differential should not be less than figures quoted in table above.
recommendations on the protection of combustible material are High flow rates required for lower temperature differentials could
given in BS. 5440-1: 2008. In IE refer to I.S.813:2002. lead to erosion of the heat exchanger water ways.
The flue must be installed in accordance with Building Regulations • With the boiler firing at minimum rate, the temperature
and the recommendations of BS. 5440-1:2008 for inputs up to differential should not be greater than 35oC. Lower flow rates
70kW nett. For larger installation BS. 6644 should be complied generating higher temperature differentials will lead to lock out
with. In IE refer to I.S.820:2000. of the boiler.
• The lower the return temperature to the boiler, the higher the
1.9 WATER CIRCULATION SYSTEM efficiency.
The system pump MUST be connected to the boiler, see below.
In installations where all radiators have been provided with
The boiler must NOT be used for direct hot water supply. The hot thermostatic radiator valves, it is essential that water circulation
water storage cylinder MUST be of the indirect type. through the boiler is guaranteed. This can be best achieved
Single feed, indirect cylinders are not recommended and MUST by means of a differential pressure valve, which is installed in a
NOT be used on sealed systems. bypass between the flow and return pipes. The bypass should
be fitted at least 6m from the boiler, and should use a minimum
The appliances are NOT suitable for gravity central heating nor size of 28mm pipe. The bypass should be capable of allowing
are they suitable for the provision of gravity domestic hot water. a minimum flow rate to achieve a temperature differential of no
The hot water cylinder and ancillary pipework, not forming part of greater than 35oC at minimum rate.
the useful heating surface, should be lagged to prevent heat loss
and any possible freezing - particularly where pipes run through 1.10 WATER TREATMENT
roof spaces and ventilated underfloor spaces. These boilers incorporate an ALUMINIUM heat exchanger.
The boiler must be vented. IMPORTANT. The application of any other treatment to this
Draining taps MUST be located in accessible positions, which product may render the warrnaty of Ideal Boilers INVALID.
permit the draining of the whole system - including the boiler
Ideal Boilers recommend Water Treatment in accordance with
and hot water storage vessel. They should be at least 1/2” BSP
Guidance Notes on Water Treatment in Central Heating Systems.
nominal size and be in accordance with BS. 2879.
The central heating system should be in accordance with the If water treatment is used Ideal Boilers recommend only the
relevant standards listed on page 8. use of SCALEMASTER SM-1 PRO, FERNOX, MBI, ADEY MC1,
SENTINEL X100 or CALMAG CM100 inhibitors and associated water
Due to the compact nature of the boiler the heat stored within the treatment products, which must be used in accordance with the
castings at the point of shutdown of the burner must be dissipated manufacturers’ instructions.
into the water circuit in order to avoid overheating. In order to
allow pump operation after burner shutdown the boiler control box For further information contact:
incorporates a 4 minute pump overrun facility. In order to make use Fernox
of this, the pump must be supplied from the terminals inside the www.fernox.com
boiler. Note: for pumps requiring a current greater than 1.3 amps Tel: +44 (0) 3301 007750
inductive, they must be connected via a relay.
When sizing pumps, reference should be made to the table below Sentinel Performance Solutions
which show the boiler resistance against flow rates, to achieve the www.sentinelprotects.com
required temperature differential. Tel: +44 (0) 1928 704330
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.

SECTION 1 - GENERAL
1.11 ELECTRICAL SUPPLY

Wiring external to the appliance MUST be in accordance with
the current I.E.T. (BS7671) Wiring Regulations and any local
regulations which apply. For Ireland reference should be made to
the current ETCI rules for electrical installations
The point of connection to the mains should be readily accessible
and adjacent to the boiler.
1.12 CONDENSATE DRAIN

Refer to 19
A condensate drain is provided on the boiler. This drain must be
connected to a drainage point on site. All pipework and fittings in
the condensate drainage system MUST be made of plastic - no
other materials may be used.
IMPORTANT.
Installation must be in accordance with BS 6798.
The drain outlet on the boiler is sized for standard 21.5mm
overflow pipe. It is a universal fitting to allow use of different
brands of pipework.

SECTION 1 - GENERAL
1.13 BOILER CLEARANCES AND CONNECTIONS

The following minimum clearances must be Boiler Dim. A Dim. B
maintained for operation and servicing. 30, 40, 60, 80 360 130
Front of boiler - 450mm 100, 120 520 226
Sides of boiler - 25mm 150 610 233
Above boiler - dependent upon the flue A 500

system see drawings B 118
Below boiler - 300mm

Clearance between multiple boiler
installations - 25mm
850
FLOW CONDENSE GAS RETURN

GAS & CONDENSE OUTLETS 68 59
209
FLOW &RETURN CONNECTIONS 81 299 59
80/125 CONCENTRIC FLUE CONNECTOR 100/150 CONCENTRIC FLUE CONNECTOR

30, 40, 60 & 80 100, 120 & 150
Minimum boiler top clearances: Minimum boiler top clearances:
for vertical flue 200mm for vertical flue 200mm
for horizontal flue 350mm (415mm for 100/150) for horizontal flue 370mm
for open flue 350mm for open flue 350mm
=259.5 (100/150)*
=194.5 (80/125)
Flue centre
=202
Flue centre
line
line
* with 100/150 adaptor

(See Frame 13)
Vertical Offset From X mm 26 52 78 104

OPEN FLUE KIT OPEN FLUE KIT
Y
100 / 150 80 / 125
X
100 80
1m
2m
3m
ima5400
4m 83 83
Distance from flue centre line (Y) to outside wall surface.

For lengths greater than 4m, increase offset (X) by 26mm 148.5 125
for every additional 1m.

SECTION 1 - GENERAL
1.14 OPEN VENTED SYSTEM REQUIREMENTS Feed/expansion

cistern
500mm
Water minimum
Detail reference should be made to the appropriate standards level
listed on page 8. (cold)
The information and guidance given below is not intended

to override any requirements of the above publications or the Open vent 3000mm
Cold
minimum
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.
1.15 SEALED SYSTEM REQUIREMENTS

Note. The method of filling, refilling, topping up or flushing sealed primary hot water circuit from the mains for a non-domestic
property is shown below.
1. General 3. Pressure Gauge
a. Detail reference should be made to the appropriate A pressure gauge covering at least the range 0-6 bar must be
standards listed on page 8. The information and guidance fitted to the system. The gauge should be easily seen from the
given below is not intended to override any requirements of filling point and should preferably be connected at the same
these publications or the requirements of the local authority, point as the expansion vessel.
gas or water undertakings. IMPORTANT NOTE: If the boilers are installed on to an Ideal
b. The installation should be capable of working with flow frame & header kit and operated in excess of 3 bar then all
temperatures of up to 90oC and a temperature differential of safety relief valves will require upgrading. The boiler has a
up to 35oC at minimum rate only. maximum operating pressure of 6 bar.
c. All components of the system, including the heat exchanger 4. Expansion Vessel
of the indirect cylinder, must be suitable for a working Expansion vessels used must comply with BS. EN 13831.
pressure of 6 bar (87lbf/in2) and temperature of 110oC. Care Connection to the system must not incorporate an isolating
should be taken in making all connections so that the risk of valve.
leakage is minimised.
d. The boiler is fitted with an automatic air vent, located in
the left top side of the interior. This air vent must never be
shut off, as this could result in dry firing of the boiler and
subsequent damage to the heat exchanger.
e. Suitable isolation valves and drain points
must be provided by the installer.
2. Safety Valve
primary flow
A spring loaded safety valve complying with and return
Type BA backflow
the relevant requirements of BS. 6759 Pt. 1 prevention device
must be fitted in the flow pipe as close to the (RPZ valve assembly)
boiler as possible and with no intervening
valve or restriction. The valve should have the
Strainer
following features:
a. A non-adjustable preset lift pressure not
exceeding 6 bar (87lbf/in2).
b. A manual testing device.
CV CV
c. Provision for connection of a discharge
Resillient
ima7349
pipe. The valve or discharge pipe should seat control

be positioned so that the discharge of Air valves
water or steam is visible, but will not cause gap
DT Tundish
hazard to user or plant.
CV = Control Valve Supply
DT = Drain Tap pipe

SECTION 2 - INSTALLATION
INSTALLATION
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
502 309 310
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
1. The boiler should be laying on its back with

the straps removed.
2. Carefully read the installation instructions
3
before proceeding.
3. Remove the outer packing sleeve.
4. Remove the protective cardboard wall
mounting template from the front of the
boiler.
5. Remove the packing piece from the top of
the boiler.
6. Check the contents against the list in 4
Section 2.3 ‘Unpacking’. Note: some items
are contained within the top packing piece. 5
7. The boiler may now be stood on its base,

with the cardboard bottom packing piece
still in place to protect the connections.
Due care should be taken when standing
up the boilers, with respect to their
weights, see Table 2 on page 6.
2.3 UNPACKING
The boiler is supplied fully assembled in one pack.

When unpacking the boiler check the contents against the items below.
Do not dispose of the packaging until all contents are accounted for, as some parts are held within the cardboard packing pieces.
Boiler Wall Mounting Template Installation Guide Grommet Condensate Trap
x1
User Guide x2
Hex Head Coach Screws
x1
Log Book
x6 x1
x1 x1
x1 Wall Plug Gas Cock
Connector Kit Wall Mounting Bracket
Warranty
x1 x1 x1 x6 x1

INSTALLATION
2.4 WALL MOUNTING TEMPLATE Note: Horizontal flue runs must be

inclined at 1.5-3o to the horizontal to allow
Note. The template shows the positions for the condensate to drain back to the boiler.
top fixing holes. Care must be taken to ensure
the correct holes are drilled.
1. Tape template into the selected position. B
2. Ensure squareness by hanging a plumbline.
3. Mark on to the wall:
a. The top 4 wall mounting plate screw
positions.
b. The 2 boiler lower fixing positions using
diagram below
c. The position of the flue duct. Mark
the centre of the hole as well as the
circumference.
4. Remove the template from the wall.
BOILER LOWER FIXING POSITIONS

850mm to top of boiler
Ø12mm
17 mm
332 mm
2.5 PREPARING THE WALL

IMPORTANT. The wall must be vertical 90º (±5º)
from the perpendicular to allow safe operation of
the integral flue non return valve.
Ensure that, during the cutting operation, masonry
falling outside of the building does not cause
damage or personal injury.
1. Cut the flue hole ensuring that the hole
is square to the wall. Both wall faces
immediately around the cut hole should be flat.
2. Drill 4 boiler top fixing holes with a 12mm
masonry drill and insert the plastic plugs
provided, for the wall mounting plate.
3. Drill the 2 boiler lower fixing holes with a 12mm
masonry drill, insert the plastic plugs provided .
4. Fix the wall bracket into place with 4 M10x70
hex head coach screws provided.

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.
BOILERS 70kW AND OVER

80, 80P, 100, 100P, 120, 120P, 150 and multiple boiler 80, 80P, 100, 100P, 120, 120P & 150
applications
Open Flued Installations
Detail reference should be made to BS. 6644 and IGEM/UP/10
for inputs between 70kW and 1.8MW (net). In IE refer to the Required area (cm2) per kW of total rated input (net)
current edition of I.S.820. The following notes are for general Boiler Room Enclosure
guidance only:
Low level (inlet) 4 10
If ventilation is to be provided by means of permanent high and
High level (outlet) 2 5
low vents communicating direct with outside air, then reference
can be made to the sizes below. For other ventilation options Note: Where a boiler installation is to operate in summer months (e.g.
refer to BS. 6644 and IGEM/UP/10. In IE refer to the current DHW) additional ventilation requirements are stated, if operating for
edition of I.S.820. more than 50% of time (refer to BS6644) and IGEM/UP/10.
Room Sealed Installations
A minimum of 2cm2 free area per kW of net heat input at both
high and low level is required for boiler rooms. For enclosures
refer to BS6644 and IGEM/UP/10.

INSTALLATION
2.8 FLUE SYSTEMS

A multiple boiler flue header system is available ‘Ideal Multiline’.
A comprehensive range of flue kits are available from
This permits up to 6 boilers to be connected to a single flue
Ideal Boilers. Examples of horizontal and vertical concentric
header with a maximum total output of 600kW.
and open flue options are demonstrated on the following pages.
Tables are provided with these examples, giving the maximum Other flue header systems should be designed and supplied
extensions which may be added. by a specialist flue company. BS 6644 and IGE UP/10 provide
guidance on design and the drainage of condensate from flue
For horizontal flues: this is the distance from the flue outlet
stack and headers. Condensate from a flue stack and header
centre line on the boiler to the outside wall.
must be collected and drained before entering the boiler.
For vertical flue: this is the distance from the top of the boiler
For room sealed flues concentric flues must be used.
case to the aperture in the weather collar.
NOTE. When installing an Evomax 2 boiler onto an exisitng
If elbows are to be used, then the equivalent length of that
Muliline system, you must remove the non-return valve
fitting (see page 21) must be subtracted from the maximum flue
assembly and replace with either of the following Multline
extensions allowed for that flue option.
Extensions (exluding NRV):
Note: Horizontal terminal resistance includes 1 x 90o elbow. 80 dia = Part No. 220968
100 dia = Part No. 222068
2.9 HORIZONTAL WALL FLUE KIT

Horizontal concentric flue application ~ maximum lengths
Model 30/30P 40/40P 60/60P 80/80P 100/100P 120/120P 150
Max flue length (m) 33 30 17.5 10 10 9 6
Flue Size 80 / 125 100 / 150
Wall flue kit No 220920 220921
Contents
• 90o elbow
• Terminal
• Locking collars (x2)
• Wall plates (x2)
Note: See Section 2.15 for elbow equivalent lengths.
2.10 HORIZONTAL WALL FLUE KIT - For longer flue lengths for the 60 & 80kW
60 & 80 horizontal concentric flues of longer length
Model 60/60P 80/80P
Max flue length (m) 28 18
Flue Size 100 / 150
Wall flue kit No 220920
Contents
• Increaser
• 90o elbow
• Terminal
• Locking collars (x2)
• Wall plates (x2)

2.11 VERTICAL ROOF FLUE KIT
Vertical concentric flue application ~ maximum lengths
Model 30/30P 40/40P 60/60P 80/80P 100/100P 120/120P 150

Max flue length (m) 33 30 17.5 10 10 9 6
Flue Size 80 / 125 100 / 150
Vertical flue kit No 220915 220918
Contents
• Terminal
• Locking Collar
• Finishing plates (x2)
• Bracket
2.12 VERTICAL ROOF FLUE KIT
60 & 80 vertical concentric flues of longer length
Model 60/60P 80/80P

Max flue length (m) 28 18
Flue Size 100 / 150
Vertical flue kit No 220916
Contents
• Increaser
• Terminal
• Locking Collars (x2)
• Finishing plates (x2)
• Bracket
FLUE OUTLET
2.13 OPEN FLUE KITS

Open flue application ~ maximum lengths and pressure differentials
Model 30/30P 40/40P 60/60P 80/80P 100/100P 120/120P 150

Max flue length (m) 65 70 25 15.3 20 49 32
Max flue press diff (Pa) 180 277 146 312 220 473 332
Flue Size 80/125 100/150
Open flue kit No 221216 + 158771 + 158769 221218 + 158772 + 158770
Contents
221216 / 221218
• Air inlet grille
158771 / 158772
• Extension tube (x2)*
158769 / 158770
• Terminal

2.14 FLUE KIT ACCESSORIES

Flue Kits - Concentric Flue Kits - Open Flue
Flue Kit Description UIN Flue Kit Description UIN
Vertical Roof Flue Kit 80/125 (30 - 80kW) 220915 Wall Bracket 125mm 202242
Vertical Roof Flue Kit 100/150 (60 & 80kW) 220916 Wall Bracket 150mm 202243
Vertical Roof Flue Kit 100/150 (100 - 150kW) 220918 Open Flue Kit 80 221216
Horizontal Wall Flue Kit 80/125 (30 - 80kW) 220920 Open Flue Kit 100 221218
Horizontal Wall Flue Kit 100/150 (60 & 80kW) 220919 Vertical Flue Terminal 80 158769
Horizontal Wall Flue Kit 100/150 (100 -150kW) 220921 Vertical Flue Terminal 100 158770
Extension Kit 80/125 213261 Extension Pipes 80 (pair) 158771
Extension Kit 100/150 213262 Extension Pipes 100 (pair) 158772
Pitched Weather Collar 80/125 152609 90° Elbow 80 (single) 158773
Pitched Weather Collar 100/150 152610 90° Elbow 100 (single) 158774
Flat Weather Collar 80/125 152611 45° Elbow 80 (pair) 158775
Flat Weather Collar 100/150 152612 45° Elbow 100 (pair) 158776
90° Elbow 80/125 (single) 213259 Pitched Weather Collar 80 & 100 158777
90° Elbow 100/150 (single) 213263 Flat Weather Collar 80 & 100 152259
45° Elbow 80/125 (single) 213260 Increaser 80-100 152404
45° Elbow 100/150 (single) 213258 Increaser Adapter 80/125 to 100/150 222133
90º Extended Elbow 80/125 Single 222004
90º Extended Elbow 100/150 Single 222005
Expander 80/125 - 100/150 222133
FLUE KITS CONCENTRIC
220915 220916 220918 220920 213261 213262 152609
220919
152610
220921
FLUE OUTLET
222004 222005 152611
152612 213259 213263 213260 213258 202242 202243 222133
FLUE KITS - OPEN FLUE
221216 158769 158770 158771 158772 158773 158774 158775
158776 158777 152259
221218
152404 222133

2.15 PERMISSIBLE FLUE LENGTH

The maximum permissible flue lengths for each model is shown in Table A below, these lengths are inclusive of the
terminal resistance.
The value shown is the max available length for extension.
The equivalent length of elbows is shown in Table B.
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)
60/60P 80/125mm Max flue 17.5m
80/80P 80/125mm 0.5% (up to max 12m 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)

2.16 ASSEMBLING THE 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.
White Wall plate

terminal painted
tube
FLUE OUTLET
Vertical
terminal
Weather collar
RF2548
flat (shown)
or pitched

2.17 FLUE TERMINATION POSITION

Due to the high efficiency of these boilers pluming will occur. For this reason vertical termination is recommended, and in any
case, terminal positions which could cause problems should where possible be avoided.
Particular care should be taken in the case of large multiple boiler installations, and complying with the requirements of the Clean Air Act.
The information below is extracted from BS. 5440 Pt. 1 and is for boilers with heat inputs not exceeding 70kW nett, and the latest
Building Regulation Part J. Detailed reference should still be made to these standards. In IE refer to I.S. 813:2002.
Concentric Wall Terminal Positions Minimum spacing

A. Below an opening (1) 300 mm
B. Above an opening (1) 300 mm
C. Horizontally to an opening (1) 300 mm
D. Below gutters, soil pipes or drain pipes 75 mm
E. Below eves 200 mm
F. Below balcony or car port roof 200 mm
G. From a vertical drain pipe or soil pipe 150 mm
H. From an internal or external corner or to a boundary alongside the terminal 300 mm
I. Above ground, roof or balcony level 300 mm
J. From a surface or a boundary facing the terminal 600 mm
K. From a terminal facing the terminal 1200 mm
L. From an opening in the car port into the building 1200 mm
M. Vertically from a terminal on the same wall 1500 mm
N. Horizontally from a terminal on the same wall 300 mm
Concentric Roof Terminal Positions
Directly below an opening, air brick, windows, etc. 300 mm
Below plastic/painted gutters 500 mm*
Below painted surface 500 mm*
Below eaves or balcony 500 mm
From wall 1000 mm
Below velux window 2000 mm
Above or side of velux window 600 mm
* may be reduced to 300mm if a shield fitted
(1) An opening here means an openable element, such as a openable window, or a fixed opening such as an
air vent. However, in addition, the outlet should not be nearer than 150mm (fanned draught) to an opening
into the building fabric formed for the purpose of accommodating a built in element, such as a window frame.
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
The flue terminal shall not

penetrate the shaded area ima5355
of the roof
HEAT INPUTS IN EXCESS OF 70kW NETT

For boiler installations with total heat inputs in excess of 70kW nett, reference should be made to BS6644 and IGEM/UP/10. In IE refer
to I.S.820.2000.

2.18 BOILER FRAME AND HEADER KITS
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.
Figure 2 - Connection of a Condensate Drainage Pipe

Figure 1 - Connection of Condensate Drainage Pipe to
Downstream of a Sink, Basin, Bath or Shower Water Trap to
Internal Soil & Vent Stack
Internal Soil Vent Stack
Boiler Boiler
with 75mm with 75mm
sealed sealed
condensate
Soil & vent stack
condensate
trap trap
Min Ø 19mm
Internal soil & vent stack
Internal pipe Min Ø 19mm

Internal pipe
≥ 100
Sink/basin/
Minimum
bath or
connection shower
≥ 450
minimum height up to 3
gradient storeys
1:19
minimum Boilers without 75mm sealed

Boilers without 75mm sealed
condensate trap must be fitted with gradient condensate trap must be fitted with
a 75mm trap and visible air break 1:19 a 75mm trap and visible air break
continued . . . . .

INSTALLATION
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
Soil & vent stack

sealed Min Ø 30mm
condensate Internal pipe minimum
trap gradient
Min Ø 19mm
Internal pipe 1:19
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
Internal pipe rain water drain pipework
≥ 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
The boiler flow and return pipes are

terminated with a 1 1/4” BSP male taper
connection located at the bottom of the
appliance.
Note. This appliance is NOT suitable for use
with a direct hot water cylinder.
Plastic plugs if fitted into the open ends of
the flow and return pipes must be removed
before connecting the system pipework.
FLOW RETURN
2.21 FROST PROTECTION
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
2.22 GAS CONNECTION
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.

INSTALLATION
Standalone Boiler ‐ Partial Hydraulics
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
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
Opentherm2 Boiler Connections

RT‐PC2 Boiler fault
S‐OT P‐PC1
S‐RT‐PC1 RT‐PC1 P‐PC2
S‐RT‐PC2 RT‐PC2 Room InputsS‐RT‐PC1 P1 (0‐10V) Outputs
P‐PC1
Opentherm1
Outside RT‐PC1
S‐OT Boiler
or P2run
Tank
Opentherm2 S‐RT‐PC2
RT‐PC2 Boiler
P3fault P‐PC2
S‐OT P‐PC1 P‐PC2 SL1
Room RT‐PC1
S‐RT‐PC1 P1 (0‐10V)
P‐PC1
SL2
Outside RT‐PC2
S‐OT or P2
Tank S‐RT‐PC2 P3 P‐PC2

SL1 RT‐PC1
SL2 RT‐PC2
*Opentherm1 or SL1, Opentherm2 or SL2

Boiler CT Pump Circuit CT Pump Circuit

Single Boiler with CT and HWS Zone Circuits
Boiler Connections
continued............
Installation & Servicing

Single Boiler with CT andS‐RT‐PC1 RT‐PC1, TS‐HWS
HWS Zone Circuits Inputs Outputs
Opentherm RT‐PC1 Boiler run
Room Boiler Connections
S‐RT‐PC1 Boiler fault

Single Boiler with CT and HWS Zone Circuits
Boiler Connections
S‐RT‐PC1 RT‐PC1, TS‐HWS Inputs Outputs
Single Boiler with CT and HWS Zone Circuits Opentherm RT‐PC1 Boiler run
Room S‐RT‐PC1 Boiler fault
Boiler

S‐OT Outside S‐OT Connections
P1 (0‐10V)
S‐RT‐PC1 RT‐PC1, TS‐HWS Inputs P‐SYS
Tank S‐RT‐CT2 or P2Outputs
V‐CT V‐HWS Opentherm
SL1 RT‐PC1
RT‐CT1 Boiler run
P1 (0‐10V)
Room S‐RT‐PC1 Boiler fault V‐CT1
SL2 TS‐HWS or P2
S‐OT TS‐HWS Outside S‐OT P1 (0‐10V)
P3 V‐HWS
P‐SYS
Tank S‐RT‐CT2 or P2
V‐CT V‐HWS SL1 RT‐CT1 P1 (0‐10V)
V‐CT1
S‐HWS SL2 TS‐HWS or P2
TS‐HWS P3 V‐HWS
P‐SYS
S‐HWS
P‐SYS *Opentherm or SL1

*Opentherm or SL1
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
S‐OT V‐CT1 V‐CT2 Room

SL2 S‐RT‐PC1
RT‐CT2 P1 (0‐10V)
P3 V‐CT2
P‐SYS
Outside S‐OT or P2
Tank S‐RT‐CT2 P1 (0‐10V)
V‐CT1
SL1 RT‐CT1 or P2
SL2 RT‐CT2 P3 V‐CT2
P‐SYS
P‐SYS *Opentherm1 or SL1, Opentherm2 or SL2


29
INSTALLATION
INSTALLATION
2.24 ELECTRICAL CONNECTIONS
Warning. This appliance MUST be efficiently earthed.

A mains supply of 230V 50Hz is required. The supply wiring
MUST be suitable for mains voltage. Wiring should be 3 core
PVC insulated cable NOT LESS than 0.75mm2 (24 x 0.2 mm)
and to BS. 6500, Table 16. The fuse rating should be 4A.
Wiring external to the boiler MUST be in accordance with
the current I.E.T. (BS7671) Wiring Regulations and any local
regulations. For Ireland reference should be made to the
current ETCI rules for electrical installations.
Connection should be made in a way that allows complete
isolation of the electrical supply - such as a double pole switch,
having a 3mm contact separation in both poles, or a plug and
unswitched socket serving only the boiler and system controls.
The means of isolation must be accessible to the user after
installation.
2.25 EXTERNAL WIRING
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
Mains Voltage/230V 50Hz KEY
I1 I2 I3 I4 l1 Mains Supply Connector, 230V

50Hz. Live, Neutral, PE.
1 2 3 1 2 3 4 1 2 1 2 l2 Demand inputs, Multifunctional,
230V 50Hz. Typical setting:
SL1, Heating Circuit 1
SL2, Heating Circuit 2/DHW
l3 Optional Interlock input, 230V
50Hz
L N PE SL1 L SL2 L ~ ~ L N
l4 Auxiliary Mains Supply Output,
230V 50Hz 230V 50Hz 230V 50Hz. Live, Neutral.
Mains Supply Demand inputs Interlock Auxiliary
Volts Free Contacts KEY
I5 I6 I5 Multifunction Volts Free Relay

Outputs, 24V DC to 230V 50Hz.
1 2 3 4 5 6 1 2 3 4 Typical setting:
MFR1 Heating Circuit 1 Pump
MFR2 DHW Circuit Pump
I6 MFR3 Burner On Indication
MFR4 Boiler Fault Indication
C NO PE C NO PE C NO C NO
MFR1 MFR2 MFR3 MFR4
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
PELV DHW Tank / Outside

Interlock Pump control 0-10V OpenTherm Header Room 2 Room 1 Temp.
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.

INSTALLATION
2.27 BOILER WITH EXTERNAL CONTROLS

1. The boiler must be provided with a 4 minute pump overrun 3. The pump load and switch on surge current must be within
period. Failure to do so may invalidate the boiler warranty. the limits of the output if it is powered directly from the Volts
2. It is preferable that any pump used to circulate water Free Contact. The limits are as specified in the Electrical
through an individual boiler is controlled by the local boiler. Specification Table below.
Either as a 230V 50Hz supply as shown, enabled by the A slave contactor may be used to power the pump where
Volts Free Contacts e.g. MFR1 or controlled by the option needed.
kit for 0-10V pump control. If not then a pump overrun 4. If the switched live is provided without a Volts Free Contact
function MUST be provided by the controlling system. then this MUST be taken from the same phase as the
boiler mains supply, preferable through the same isolator.
Electrical Specifications for External Connections
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
External Controls via Switched Live Demand

Boiler pump controlled directly from MFR1
External controls via switched live demand

Boiler Pump controlled directly from MFR1
Mains Voltage/230V 50Hz Volts Free Contacts

I1 I2 I3 I4 I5 I6
L N PE SL1 L SL2 L ~ ~ L N C NO PE C NO PE C NO C NO
230V 50Hz 230V 50Hz

Mains Supply Demand inputs Interlock Auxiliary MFR1 MFR2 MFR3 MFR4
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
Mains Supply External Controls Boiler Pump

External Controls via 0-10V Input
Boiler pump controlled via remote volts free enabled from MFR1
External controls via 0‐10V input
Boiler Pump controlled via remote Volts Free enable from MFR1
Mains Voltage/230V 50Hz Volts Free Contacts PELV

I1 I2 I3 I4 I5 I6 I7 I8 I9 I10
L N PE SL1 L SL2 L ~ ~ L N C NO PE C NO PE C NO C NO I0 I1 PWM GND 10V 10V GND OT1+ OT1‐ OT2+ OT2‐ S1 GND S2 GND S3 GND S4 GND
230V 50Hz 230V 50Hz PELV DHW Tank / Outside

Mains Supply Demand inputs Interlock Auxiliary MFR1 MFR2 MFR3 MFR4 Interlock Pump control 0‐10V OpenTherm Header Room 2 Room 1 Temp.

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
Fused Spur 0‐10V

/ Isolator Source
L N PE
Mains Supply Boiler Pump BMS
External Controls via OpenTherm Master

Boiler pump speed controlled via 0-10V output
External controls via OpenTherm Master
Boiler Pump speed control via 0‐10V output

I1 I2 I3 I4 I5 I6 I7 I8 I9 I10

1 2 3 1 2 3 4 1 2 1 2 1 2 3 4 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
Fused Spur OpenTherm

/ Isolator Master
L N PE
Mains Supply External Controls Boiler Pump BMS or Room Control
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

I1 I2 I3 I4 I5 I6 I8 I9 I10

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

I1 I2 I3 I4 I5 I6 I8 I9 I10

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
Heating Circuit 2 Heating Circuit 1

Room Room OpenTherm OpenTherm
Fused Spur Room Room
Thermostat Thermostat Master Master
/ Isolator Temperature Temperature
HC1 HC2 HC 1 HC 2
Sensor Sensor
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
Connecting Multiple Room Sensors
One Two Three Four
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
2.28 CONTROLS CONFIGURATION, COMMISSIONING AND TESTING
A. ELECTRICAL INSTALLATION B. GAS INSTALLATION
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.

INSTALLATION
2.29 USER INTERFACE
A B C D E F
OK BACK
A. ROTARY KNOB C. BURNER LED E. BACK BUTTON

• Enter a menu, if in the normal • Will be on if the burner is lit. • In a menu, return to the previous
operation screen, and highlight the menu layer.
first menu item. • In parameter setting, exit the
• Scroll up (anti-clockwise) or down D. SELECT BUTTON parameter without storing the value.
(clockwise) in a menu • Enter a menu, if in the normal • In a guided assistant, go back to the
• Change the value in parameter operation screen, and highlight the previous screen.
setting. first menu item.
• If an error is showing in the title • Enter the highlighted menu (sub
bar, scroll to the associated error menu or parameter), if in a menu or F. RESET BUTTON
screen(s), and return. sub menu. • Reset the associated boiler module
• If in a parameter setting, select a error, if a resettable (lockout) error is
parameter which will then flash for active.
B. LCD DISPLAY SCREEN adjustment, once adjusted using the • Return to the normal operation
• Menu and status display. rotary knob press again to store and screen.
move on.

BOILER GUIDED CONFIGURATION STAND ALONE BOILER
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
Set boiler number

At start up the default language is
selected and shown on the display, Boiler 01
Done
this can be changed if required or just The current date followed by the time can
confirmed: now be set:
Language Set boiler number
Date
Year: 2018
English Boiler 01
Month: 7
Francais Done
Day: 4
Nederlands Done
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
Time HC 01 Boiler 1.1

HC ## Boiler 1.2
Hour: 0
Done
Minute: 0
Auto su/wi time: 
Done
Set HC number
HC ## Boiler 1.2
Done

INSTALLATION
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.
Configure plant? None

The system will now scan the known PWM/0-10V ()
No MFR1 ()
devices on the bus to determine what
Yes MFR2 ()
DHW circuits are available in the boiler
for configuration:
Do you have a system pump?
Configure plant? PWM/0-10V ()
No MFR1 ()
Yes MFR2 ()
MFR3 ()
Do you have a system pump?
Once this is completed, the display will Hydraulic Separation: MFR1

MFR2 ()
prompt with the available DHW circuits so If the boiler has Hydraulic Separation MFR3 ()
that they may have DHW circuit numbers from the intermediate or final circuits in MFR4 ()
allocated, and then later configured. the heating system then set this Option
to ‘Yes’: Do you have a system pump?
Set DHW number
MFR2 ()
Do you have hydraulic separation? MFR3 ()
DHW ## Boiler 1
MFR4 ()
Done
No
Yes
If any DHW circuits are required for the Do you have a system pump?
boiler then number them sequentially MFR3 ()

Do you have hydraulic separation? MFR4 ()
from 1. If there are no DHW circuits to be
configured to this boiler just move on past No
by selecting 'Done'. Example: Yes
Set DHW number
DHW 01 Boiler 1
Done
Set DHW number

DHW 01 Boiler 1
Done
The system will now configure the System

Manager for these circuits.

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
None For On demand there is an associated
PWM/0-10V () Done flow temperature setpoint:
MFR1 ()
MFR2 () OpenTherm Temp. Setpoint
Temp. setp. 10V

80ºC 60ºC
PWM/0-10V ()
Done Done
MFR1 ()
MFR2 ()
MFR3 ()
Configure 0-10V Parameters: OpenTherm Temp. Setpoint
60ºC
Configure 0-10V parameter?
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

INSTALLATION
Outside Sensor: Internal Time Clock Single: Internal Timeclock Multiple:

This sensor can be selected and used Single day timer is programmable for Multiple day timer is programmable for
for all demands to the boiler, if this is not each of the 7 days with 3 periods per day, Mon-Fri and Sat-Sun with 3 periods per
required select ‘None’: Monday through Sunday: group of days:
Outside sensor available? Time Clock Time Clock
Single
None Single Multiple
Yes Multiple
Outside sensor available?

Single Multiple
None
Monday Mon-Fri
Yes
Period 1 06:00-22:00 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
Internal Time Clock:
Single Multiple
Internal timeclock. A timeclock can be set Tuesday Sat-Sun
for the Plant, this will control all functions. It Period 1 06:00-22:00 Period 1 06:00-22:00
can be set as a single or multiple day timer. Period 2 00:00-00:00 Period 2 00:00-00:00
Use an internal time clock
Single Multiple
No Wednesday Mon-Fri
Yes Period 1 06:00-22:00 Period 1 06:00-22:00
Period 2 00:00-00:00 Period 2 00:00-00:00
Use an internal time clock
No Single Multiple
Yes Thursday Mon-Fri
Period 1 06:00-22:00 Period 1 06:00-22:00
Period 2 00:00-00:00 Period 2 00:00-00:00
Single Once all days and times are set, select

Friday ‘Done’ to continue.
Period 1 06:00-22:00
Period 2 00:00-00:00
Period 3 00:00-00:00 Done
Single
Saturday
Period 1 06:00-22:00
Period 2 00:00-00:00
Single
Sunday
Period 1 06:00-22:00
Period 2 00:00-00:00
Single
Monday
Period 1 06:00-22:00
Period 2 00:00-00:00
Single
Monday
Period 1 06:00-22:00
Period 2 00:00-00:00
Once all days and times are set, select

‘Done’ to continue.

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 ()
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 ()

MFR2 ()
MFR3 ()
MFR4 ()

MFR3 ()
MFR4 ()

Example MFR1 as a boiler pump.

PWM/0-10V ()
MFR2 ()
MFR3 ()

INSTALLATION
Boiler Fault Indication: LPG Valve: Flue Damper:

Boiler fault indication. If the boiler has the If the boiler has the requirement to control If the boiler has the requirement to control
requirement to signal when the Boiler is an external LPG valve then select the an external flue damper then select the
at fault then select the output that is used output that is used to control it from the output that is used to control it from the
to control it from the list. Otherwise select list. Otherwise select 'None'. list. Otherwise select 'None'.
‘None’.
LPG Valve Flue damper
Boiler fault indication
None None
None PWM/0-10V () PWM/0-10V ()
PWM/0-10V () MFR1 (Local boiler pump) MFR1 (Local boiler pump)
Boiler fault indication None None
None PWM/0-10V () PWM/0-10V ()
MFR1 (Local boiler pump) MFR2 () MFR2 ()
MFR2 ()
Boiler fault indication PWM/0-10V () PWM/0-10V ()
MFR2 () MFR3 () MFR3 ()
Boiler fault indication MFR1 (Local boiler pump) MFR1 (Local boiler pump)
MFR2 () MFR3 () MFR3 ()
MFR3 (Boiler on indication) MFR4 () MFR4 ()
MFR4 ()
Once an output has been configured the Once an output has been configured the
Boiler fault indication selected function is shown in brackets selected function is shown in brackets
MFR2 () behind the output name: behind the output name:
MFR4 ()
Example MFR3 as an LPG valve control. Example MFR3 as a flue damper control:

MFR2 () MFR2 ()
Once an output has been configured the MFR3 (LPG valve) MFR3 (Flue damper)
selected function is shown in brackets MFR4 () MFR4 ()
Example MFR4 as a boiler fault
The boiler has now been configured and
indication.
the display will return to:
Boiler fault indication
MFR4 (Boiler fault indication)
Boiler 1 ü
Done
Note. The boiler number now has a

tick next to it showing that it has been
configured. If you completed the boiler
configuration, select 'Done'.

Boiler 1 ü
Done

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

INSTALLATION
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
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
If the external OpenTherm device has its Single Multiple

own timeclock then confirm this on the Wednesday Mon-Fri
next screen Period 1 06:00-22:00 Period 1 06:00-22:00
Period 2 00:00-00:00 Period 2 00:00-00:00
Internal timeclock. A timeclock can be set Period 3 00:00-00:00 Done Period 3 00:00-00:00 Done
for the HC, this will control all functions.
It can be set as a single or multiple day Single Multiple
timer. Thursday Mon-Fri
Period 1 06:00-22:00 Period 1 06:00-22:00
Use an internal timeclock Period 2 00:00-00:00 Period 2 00:00-00:00
No
Yes Once all days and times are set, select
Single
'Done' to continue.
Friday
Period 1 06:00-22:00 Holidy programme. Up to 8 holiday
Use an internal timeclock Period 2 00:00-00:00 periods can be set, each has a start and
No Period 3 00:00-00:00 Done
Yes
end date. Once all are set select 'Done'
to continue:
Single
Saturday Configure holiday prog?
Period 1 06:00-22:00
Period 2 00:00-00:00 No
Period 3 00:00-00:00 Done Yes
Single
Sunday
Period 1 06:00-22:00
No
Period 2 00:00-00:00
Yes
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 ()
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
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
No Select the DHW circuit from the available

Yes DHW circuits in the list: Antilegionella. If the DHW tank requires
the Antilegionella function then select
Select DHW to configure either 'Weekday' or 'Interval' from the list.
DHW priority? Otherwise set to 'None'.
DHW1 Boiler 1
No
Done Antilegionella?
Yes
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
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
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
MFR3 ()
MFR4 () Antilegionella temperature
65ºC
Done

INSTALLATION
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:
Tank Sensor? Time clock Time clock

Single
None Single Multiple
Yes Multiple
Tank Sensor? Single Multiple

None Monday Mon-Fri
Yes Period 1 06:00-22:00 Period 1 06:00-22:00
Period 2 00:00-00:00 Period 2 00:00-00:00
SL2 input function: The SL2 input can be

Single Multiple
configured to act as an enable, in the case
Tuesday Sat-Sun
of a tank thermostat with the internal timer, Period 1 06:00-22:00 Period 1 06:00-22:00
or as an override switch/tank thermostat Period 2 00:00-00:00 Period 2 00:00-00:00
with external timer. By default the SL2 Period 3 00:00-00:00 Done Period 3 00:00-00:00 Done
input must be wired via a safety thermostat
and isolating valve on a pressurised DHW Single Multiple
tank, and must always be present for the Wednesday Mon-Fri
DHW tank charge to operate. Period 1 06:00-22:00 Period 1 06:00-22:00
Period 2 00:00-00:00 Period 2 00:00-00:00
Configure SL2 Period 3 00:00-00:00 Done Period 3 00:00-00:00 Done
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
Internal timeclock. A timeclock can be Period 2 00:00-00:00
No
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:
Select DHW to configure
DHW1 Boiler1 ü
Done
Note, that the DHW circuit number now

has a tick next to it showing that it has
been configured. If you have completed
the DHW circuit configuration, select
'Done':
Select DHW to configure

DHW1 Boiler 1 ü
Done
The system will now reboot:
System will reboot
Loading system table
The boiler configuration is now complete

and the display will show the boiler status
screen:
IDEAL Evomax 2 120kW

Operation: Off
Flow temp: 0.0ºC
Flow temp: 37.5ºC

INSTALLATION
2.30 INITIAL LIGHTING

1. Check that the system has been filled and the boiler is 6. Switch the electricity supply ON and check that all the
not air locked - air in the boiler could damage the heat external controls are calling for heat. Check boiler is set for
exchanger. For this reason the air vent located in the left top winter operation - see boiler user interface basic operating
side must never be shut off. instructions.
2. Check that all the drain cocks are closed and any valves in 7. The boiler will commence the ignition sequence. If after 5
the flow and return are open. attempts the boiler has failed to light then it will lock out.
3. Check that the GAS SERVICE COCK IS ON. Press the reset button to restart the ignition sequence.
4. Fill the condensate trap with water before putting the unit 8. Operate the boiler for 10 minutes and check the gas
into operation (see Section 3.7 for condensate trap removal). rate (Table 1). You should be able to read at least 90%
5. Check the indication on the pressure gauge. If the pressure of the nominal. If this is not possible contact the boiler
is less than 1 bar the installation should be filled up first manufacturer.
(sealed system only).
Flue CO2 % measurements (hot condition)

30 40 60 80 100 120 150 30P 40P 60P 80P 100P 120P
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
Spark Generator Off

1st Stabilisation Period
Demand On Burner Output controlled relative to

& Temp. <Set point & Anti-cycle Heat Demand by varying Fan Speed
no Burner On
done?
Demand no
off or Temp. >setpoint?
yes
Gas Valve Off

Pump Overrun
Fan off. Pump off
yes no
Heat Demand Off?
Standby

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.
2.32 HANDING OVER
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.

SECTION 3 - SERVICING
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
recommendations and specifications.

Configuration
Note. Some aluminium oxide build-up within the heat Boiler Menu
exchanger assembly is quite usual with this type of condensing Plant
boiler. Though removal and cleaning is recommended
annually, the heat exchanger, sump and condensate trap Menu
must be inspected and cleaned after a maximum of 2 years
operation. Boiler Menu
1. Light the boiler and carry out function checks, noting any Plant
Heating circuits
operational faults.
2. Run the boiler for 5 minutes and then check the gas
Boiler Menu
consumption rate. Refer to procedure opposite on how to
force the burner to maximum rate.
Service
SERVICING
3. Optional test - Connect a suitable gas analyser to the Hours run

sampling point fitted in the flue adapter. For correct boiler Fault history
operation the CO/CO2 ratio of the flue gas should not be
greater than 0.004 ratio and the CO2 values should match Service
those in table 1. If this is the case and the gas input is at
least 90% of the nominal, once compliance with the note Service min
above is ensured, then no further action need be taken. If Service max
not proceed to 4. Service variable
4. Remove and clean the burner. Refer to Sections 3.5. If after

cleaning the burner the gas input is not at least 90% of the Service
nominal then contact the boiler manufacturer. Service min
Service max
5. Inspect the heat exchanger through the burner opening. If Service variable
there are signs of aluminium oxide build up, spray water
down the flueways. Refer to Section 3.6.
6. Remove the sump cover/Helmholtz where fitted and scrape Service max
out any deposits. Refer to Section 3.8.
Boiler 1
7. Remove the condensate trap and flush through with water.
Refer to Section 3.7.
8. Check that the flue terminal is unobstructed and that the
flue system is sealed correctly. Boiler 1 Service
9. After completion of servicing Refer to Section 2.33 for Operation: Service max
reference to final safety checks. Flow temp.: 40.4ºC
Capacity: 100%
Press "OK" and the boiler will go to Maximum Rate for 10 minutes
after which normal operation will resume.

3.2 REMOVAL OF CASING

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.

3.3 REMOVAL OF FAN AND GAS VALVE ASSEMBLY
MODELS: 30 / 40 / 60 / 80 / 100 / 120 3

1. Refer to Section 2.33.
2. Remove the upper front panel, Refer to
Section 3.2.
3. Remove the three screws retaining the
upper and lower flue manifold.
5
4. To remove the flue manifold lift up
the flue Sections and disengage from
the sump then pull the flue Sections
downwards and remove.
5. Remove the air inlet damper fixing *not applicable on
screw and then remove the air inlet 100 & 120kW
*
damper and seal. 7 6
6. Disconnect the electrical connections 3
Inlet Gas
from the gas valve. Pressure Test
7. Disconnect the electrical connections Point
from the fan.
8. Undo the gas valve union nut and
replace the fibre washer.
9. Remove the three screws retaining
the fan assembly and remove the fan
8
assembly.
SERVICING
10. Inspect & clean as necessary.

11. Re-assemble in reverse order replacing
all gaskets. 9
MODEL: 150 4

2. Remove the upper front panel, Refer 6
to Section 3.2.
3. Disconnect the condensate pipe from
the upper flue elbow.
3
4. Remove the three screws retaining
the upper and lower flue manifold.
5. To remove the flue manifold lift up
the flue Sections and disengage from
the sump then pull the flue Sections
Inlet Gas
downwards and remove. Pressure Test
8 Point 7
6. Remove the air inlet damper.
4
7. Disconnect the electrical connections
from the gas valve.
8. Disconnect the electrical connections
from the fan.
9. Undo the gas valve union nut and
replace the fibre washer. 9
10. Remove the four screws retaining
the fan assembly and remove the fan
assembly.
PLAN VIEW
11. Inspect & clean as necessary.
12. Re-assemble in reverse order
replacing all gaskets.
10

3.4 REMOVAL OF NON RETURN VALVE

2. Remove the upper front panel. Refer to
3
Section 3.2.
3. Remove the screw retaining the lower flue 4
manifold to the heat exchanger.
4. Lift up the flue Sections and disengage
from the sump then pull the flue Sections
downwards and remove.
5. Remove the Non Return Valve assembly
and check for damage and that the non 3
return valve moves freely. If any damage
is apparent the whole assembly must be
replaced. Ensure correctly sized non
return valve is fitted.
6. Reassemble in reverse order, ensuring
all flue manifold seals are located and
undamaged. Replace if required.
7. Check the operation of the boiler. Refer to
Section 2.33.
SERVICING
3.5 REMOVAL OF BURNER
4
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).

3.6 HEAT EXCHANGER INSPECTION / CLEANING

3. Remove the fan and gas assembly. Refer to Section 3.3.
4. Remove the burner. Refer to Section 3.5.
5. Remove the ignition and detection electrodes. Refer to
Sections 3.12 & 3.13.
6. Inspect the heat exchanger for signs of aluminium oxide
deposits. If necessary clean the heat exchanger by
spraying water down the flue ways. PLAN VIEW
7. Reassemble in reverse order replacing all gaskets. 30/40kW shown
8. Check the operation of the boiler. Refer to Section 2.33.
3.7 REMOVAL OF CONDENSATE TRAP

2. Unscrew the nut and disconnect the flexible pipe.
3. Unscrew the top nut and remove the condensate trap.
4. Remove the ball from the condensate trap and flush out with
water to remove any debris.
5. Reassemble in reverse order. 3 2
SERVICING
6. Check the operation of the boiler. Refer to Section 2.33.

4
3.8 REMOVAL OF SUMP COVER

2. Remove the front panel. Refer to
Section 3.2.
3. Prepare boiler for possible condensate
spillage during the process.
4. Remove the two screws from the
helmholtz / sump cover and pull away
from the boiler.
Models 30 / 80 / 100
5. Scrape out any deposits.
6. Reassemble in reverse order replacing
all gaskets.
7. Check the operation of the boiler.
Models 40 / 60 / 120 / 150

3.9 REMOVAL OF FAN

1. Refer to Section 2.33. 5. Remove the extended nuts holding the venturi to the fan
2. Remove the upper front panel (Refer to Section 3.2). (80 only).
3. Remove the fan and gas assembly and air inlet damper 6. Remove the screws retaining the fan plate (80 only).
(Refer to Section 3.2). 7. Transfer venturi and gas valve assembly to the new fan.
4. Remove the screws retaining the venturi to the fan (for 30, 8. Reassemble in reverse order replacing all gaskets.
40, 60, 100 & 120. 9. Check the operation of the boiler.
10. Refer to Section 2.33
30, 40 & 60kW 80kW


SERVICING
100kW 120kW


150kW

3.10 REMOVAL OF GAS VALVE

1. Refer to Section 2.33. 6. Remove the four screws retaining the gas valve (100, 120 &
2. Remove the upper front panel (Refer to Section 3.2). 150).
3. Remove the fan and gas assembly and air inlet damper 7. Remove the 4 screws retaining the inlet flange to gas valve
(Refer to Section 3.2). & transfer to new valve.
4. Remove the 3 screws holding the gas valve to the venturi 8. Fit new gas valve to venturi using the new seal provided,
(30,40,60,80 only). ensure gas injector is fitted correctly.
5. Remove the venturi from the fan to access the gas valve 9. Reassemble in reverse order replacing all gaskets.
fixing screws (100, 120 & 150 only Refer to Section 3.9). 10. Check the operation of the boiler.
30, 40 & 60kW 80kW


 
SERVICING
100kW 120kW
 
 

8

8
150kW

8

8

8

3.11 REMOVAL OF VENTURI / AIR INLET DAMPER

3. Remove the flue manifold complete with seal and
remove the air damper Section (all but the 150kW
have a fixing screw) refer to Section 3.4. If the air
inlet damper is damaged go to points 6-8.
4. Remove the fan and gas assembly. Refer to Section
3.3.
5. Remove venturi from fan and gas valve. Refer to
Sections 3.9 & 3.10.
Venturi
6. Replace with new venturi/ air inlet damper if
necessary ensuring the gas orifice is fitted and seal Air inlet damper
is replaced.
7. Reassemble in reverse order replacing all gaskets.
8. Check the operation of the boiler. Refer to Section
2.33
3.12 REMOVAL OF IGNITION ELECTRODE

3.5mm ±1

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
3.13 REMOVAL OF DETECTION ELECTRODE

5
3. Pull off the detection lead and earth connection.
4
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 ensuring
correct electrode is fitted.
3
3
Section 2.33.

3.14 REMOVAL OF AUTOMATIC AIR VENT

2. Remove the front panel. Refer to Section
3.2.
4
3. Unscrew the air vent (A) from the self
sealing fitting (B) on the top left of the flow
pipe.
4. Remove the clear tubing from the air vent
spigot. A
5. Fit the new air vent.

B
6. Refit the clear plastic drain tubing ensuring
there are no kinks as air in the boiler could
cause damage to the heat exchanger.
Section 2.33.
4
3.15 REMOVAL OF WATER PRESSURE SWITCH
5 x2
SERVICING
3. Isolate the water circuit and drain the boiler.

4. Disconnect the electrical connections from the switch.
5. Unscrew the water pressure switch.
6. Refit new switch.
7. Connect electrical connections.
8. Refill the system ensuring all the air escapes via the
air vent.
2.33.
3.16 REMOVAL OF FLOW / RETURN / HEAT EXCHANGER THERMISTOR

3. Isolate the water circuit and drain the system.
4. Disconnect the electrical connections from the 5
thermistor. 4
HX
5. Unscrew the thermistor.
6. Fit the new thermistor and seal. Do not
overtighten. Return
7. Refill the system ensuring all the air in the

heat exchanger is vented through the air vent. Flow

Section 2.33.

3.17 REMOVAL OF SPARK GENERATOR

2. Remove the front panel. Refer to Section 3.2. 4
3. Isolate the electrical supply to the boiler

and fully isolate the boiler from any external
supply.
4. Remove the three electrical connections from
the spark generator.
5. Gently push down the ignitor to remove from
the bracket.
6. Replace unit and reasseble in reverse order,
ensuring all connections are fully inserted.
Section 2.33.
3.18 REMOVAL OF MAIN PCB
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.
2.33.
7 6 7

3.19 REMOVAL OF SYSTEM MANAGER

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. 7 7 7
4. Fit the earth strap provided with the

spare PCB to your wrist and to a
suitable earthed metal.
5. The System Manager is fitted beneath
the main PCB. To access follow points
5 - 7 in Section 3.18.
6. With access to the System Manager,
remove the electrical connections
7. Remove the six retaining screws.
8. Replace with new system manager, refit
in reverse order and refer to System
Manager Replacement Instructions. 7 6
9. Check the operation of the boiler.
SERVICING

SECTION 4 - WIRING
vomax 2 Schematic Diagram 4Rev. 1.8 WIRING

(To be updated at next revision)
4.1 INTERNAL WIRING COMBUSTION MANAGER
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
Terminal (CAN TTL)

CAN Tx 3
CAN Rx 4
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 Ret H/X

1 Burner ON NO Flue - 1 Pump control *Option
1 2 1 2 1 2 Kit
PELV
Flue + 2 PWM GND 10V

I8
Flow - 3
Chassis PE
Thermistors
Flow + 4
X11
Return - 5
5 Pump DHW COM Return + 6
Heat Ex - 7
Volts Free 24V - 230VAC
4 Pump DHW NO Heat Ex + 8
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 Signal 1 WPSa

Sensors / Switches
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
5 Valve DC- APS b 2

Digital inputs
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
IGN 2 IGN Neutral
1 IGN Live
1 2 3
5 Mains Aux Live
Chassis PE 4 Mains Neutral

Mains Voltage
230V 50Hz Mains Supply

Auxiliary 3 Mains Live
X1
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

SECTION 4 - WIRING
4.2 SYSTEM MANAGER WIRING DIAGRAM
SM X3 SM X2 SM X1
ChipCom OpenTherm Terminal (CAN TTL)
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
OpenTherm lead Varican TTL lead from KM821‐i5 X8

From I9
4.3 OPTIONAL VARICAN ADAPTER WIRING DIAGRAM
4 3 2 1
Varican TTL lead

To SM X1
H
+
L
‐
CAN Bus (High power)
RJ11 6P4 / 1 CAN Bus
CAN Bus External Interface
To SM
Terminal (CAN TTL)
RJ11 6P4 / 2 CAN Bus

CAN VCCon
CAN Mode
CAN GND
CAN Bus External Interface

CAN 24V
CAN 5V
CAN Rx
CAN Tx
WIRING
1 2 3 4 5 6 7
Varican TTL lead from KM821‐i5 X8

SECTION 5 - FAULT FINDING
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:
IDEAL Evomax 2 100kW > Fault >

Operation: Htg. With temp. Operation: Htg. With temp.
Flow setp: 82.ºC Flow setp: 82.0ºC
Flow temp.: 40.4ºC Flow temp.: 40.4ºC
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:
Fault List Fault List Fault List

Fault ## Fault ##
Fault ## Fault ## Fault ##
Fault ## Fault ##
Fault ##
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

5.2 FAULT FINDING MENU
ERROR TYPE ERROR

REFER TO
(Warning, Blocking, DESCRIPTION CODE SECTION...
Lockout) (OpenTherm)
HARDWARE (THERMISTORS, ACTUATORS)
B Flow thermistor open circuit (blocking) 1 5.9
B Flow thermistor short circuit (blocking) 2 5.9
B Return thermistor open circuit (blocking) 3 5.9
B/W Return thermistor short circuit (blocking) 4 5.9
B/W Flue thermistor open circuit (blocking) 5 n/a
B Flue thermistor short circuit (blocking) 6 n/a
W DHW thermistor open circuit 7 5.12
W DHW thermistor short circuit 8 5.12
W Outside thermistor defect (open / short) 9 5.10
B Water pressure sensor defect 10 n/a
L Flow thermistor open circuit (lockout after 24h) 11 5.9
L Flow thermistor short circuit (lockout after 24h) 12 5.9
L Return thermistor open circuit (lockout after 24h) 13 5.9
L Return thermistor short circuit (lockout after 24h) 14 5.9
L Flue thermistor open circuit (lockout after 24h) 15 n/a
L Flue thermistor short circuit (lockout after 24h) 16 n/a
L Heat thermistor open circuit (lockout after 24h) 17 5.9
L Heat thermistor short circuit (lockout after 24h) 18 5.9
TEMPERATURE SUPERVISIONS
B Blocking due to flow overheat 30 5.3
B Blocking due to return overheat 31 5.3
B Blocking due to flue overheat 32 n/a
B Flow & return reversed 33 5.11
B Flow gradient supervision 36 5.3
B Flue gradient supervision (reserved) 37 n/a
B Blocking delta temp flow/return 38 5.3
L Lockout flow overheat 39 5.3
L Lockout return overheat 40 5.3
SYSTEM (FLAME, FAN, HYDRAULIC, ETC.)
B Low water pressure 51 5.6
W No flame signal at start (restart) 52 5.7
W Flameloss during operation => endless restarts (Parameter “endless restarts” activated) 53 5.7
L Flameloss during operation, => Lockout after restarts attempts are used (Parameter “endless restarts” deactivated) 54 5.7
W Flameloss during stabilisation => restart attempts 55 5.7
L Flameloss during stabilisation => Lockout after restarts attempt are used 56 5.7
L False flame (with heat demand) 57 5.7

L No flame after restarts 58 5.4
B/L Fan speed, stand still check 59 5.8
L Fan speed not achieved, e.g. Pre-purge-test, post-purge-test etc. 60 5.8
B/L Error fan speed during pre-purge (5* restarts => lockout ) 61 5.8
W Error min/max supervision fan speed during operation (restart) 62 5.8
W Warning due to mains overvoltage 63 check mains supply
B Blocking due to mains undervoltage 64 check mains supply
W Opentherm plus error (communication faulty; no connection anymore , etc) 65 5.14, 5.15
L Too many remote resets 66 power cycle the boiler
B HX water flow fault (feedback < min flow rate) 70 n/a
INTERNAL SYSTEM
L Request for re-update 94 contact service provider
B Blocking due to programming mode 95 contact service provider
L Lockout parameter mismatch 96 contact service provider
L Lockout parameter set 97 contact service provider
B/L Internal blocking error 98 contact service provider
L System lockout (internal lockout error) 99 contact service provider

5.3 OVERHEAT LOCKOUT
yes
Has PCB just been replaced? Reset Boiler
no
no Fill and vent the system and open all

Are the boiler and CH/DHW system
filled with water and are all isolation isolation valves, then reset the boiler.
valves and radiator valves open?
yes
no Check the flow, return and heat exchanger
Is the flow/return differential across thermistors (Refer to Section 3.16)
the boiler in excess of 30ºC?
yes
no Replace the pump, then restart the boiler
Check that the pump is rotating freely.
Is the differential now below 20ºC?. yes
Restart the boiler
5.4 IGNITION LOCKOUT

yes Check the detection electrode and associated harness
If the boiler is reset, does it ignite for a for continuity, visual condition and position (Refer to
short time and then extinguish? Section 3.13). Check if the condensate pipe is blocked.
no
no
Is the gas pressure available at the boiler > 18mbar? Check gas supply and rectify fault
yes
no Check wiring from Gas Valve to PCB

Is the following voltage available at the Gas Valve?
(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
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
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.

5.5 FALSE FLAME LOCKOUT / ERROR 20
yes Check routing and integrity of internal boiler

Reset the boiler, does boiler work OK? wiring is OK. Check condition of Flame
Sense Electrode and replace if deteriorated.
no
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
5.6 LOW WATER PRESSURE
no Fill and vent the system and open all

Are the boiler and CH system filled with water and all
Isolation Valves
Isolation and Radiator Valves open?
yes
no Ensure wiring has continuity and is
Does the wiring from the Water Pressure Switch to the securely connected
PCB have continuity and is it securely connected? yes
Replace Water Pressure Switch
5.7 FLAME LOSS

Check the Detection Electrode and associated Harness
yes for continuity, visual condition and position (Refer to
If the boiler is Reset, does the boiler Ignite
Section 3.13). Check if the Condensate Pipe is blocked.
for a short time and then Extinguish
Check if the Flue is blocked. Replace as necessary.
no
Is the Gas Pressure available at the boiler > 18mBar? no

Check Gas Supply and rectify fault
yes
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
Check Spark Generator and associated Harness no

for continuity, visual condition and position (Refer to Replace Spark Generator and
Section 3.17). Are these functioning correctly? Harness as necessary
yes
Check Ignition Electrode and associated Harness no

Replace Ignition Electrode and
for continuity, visual condition and position (Refer to
associated Harness as necessary
yes
Check Syphon and condensate drain pipework for no

blockage and rectify if necessary. Boiler now working OK? Replace Gas Valve
* 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

5.8 FAN FAULT
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
5.9 FLOW / RETURN THERMISTOR OR HEAT EXCHANGER THERMISTOR FAULT
no Fit a new thermistor

Disconnect the electrical connection to the Flow
Thermistor and check the resistance using a suitable
multimeter connected across the thermistor’s terminal
pins.
At 25°C expect 9,700 - 10,300 Ω
At 60°C expect 2,400 - 2,600 Ω
At 85°C expect 1,000 - 1,100 Ω
Is the thermistor value correct?
yes
no
Check and replace wiring as necessary
Is there continuity between the PCB and the Thermistor? yes
Replace main PCB
5.10 OUTSIDE SENSOR FAULT (IF FITTED)
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 Ensure the wiring has continuity and is

Does the Outside Sensor wiring between the boiler securely connected
terminal strip and the PCB have continuity and is
securely connected? yes
Replace main PCB

5.11 FLOW/RETURN REVERSED
no
Is the Pump connected the correct way? Reverse Pump
yes
Check that the system pipework is correct
5.12 CYLINDER THERMISTOR FAULT (IF FITTED)

no
Is a DHW Thermistor connected to the boiler? Change menu setting for DHW Sensor
to “Switched Live”
yes
Is the wiring securely connected at both the boiler and no

Securely connect the wiring at both
cylinder thermistor?
the boiler and cylinder thermistor
yes
no Fit a new cylinder thermistor

Disconnect the wires to the cylinder thermistor. Check
the resistance using a suitable multimeter connected
across the thermistor’s terminal pins.
At 25°C expect 9,700 - 10,300 Ω
At 60°C expect 2,400 - 2,600 Ω
At 85°C expect 1,000 - 1,100 Ω no Ensure the wiring has continuity and is
Is the thermistor value correct? securely connected
yes
Does the cylinder thermistor wiring between the boiler

terminal strip and the PCB have continuity and is yes
securely connected? Replace main PCB
5.13 EXTERNAL INTERLOCK OPEN
no Ensure that a link wire is securely connected

Is an External Interlock connected to the boiler? across the terminals marked “External
Interlock” in the boiler terminal strip
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

5.14 NO CH BUT DHW OK
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
Ensure that the Timer and

Are the Timer and Room no Room Thermostat are calling
Thermostat calling for Heat?
for heat
yes
no
Are the Radiator Valves open? Open the Radiator Valves
yes
no Rectify wiring from boiler to

Is an OpenTherm device connected Does the wiring from
OpenTherm device
to the boiler (note that the Ideal yes the boiler to the
Prog Room Stat is an OpenTherm OpenTherm device yes
device)? have continuity?
no
Is there a room sesnor configured yes Check wiring continuity:

and connected for the heating circuit? R(25ºC) = 10,000 Ω
no
Is there an outside sensor

configured and connected for the
heating circuit?
no
no Is a switched live being used as a

heating circuit demand?
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
Does the boiler have a system or

heating circuit pump connected? no
Check system for water circulation
yes
Check the control signal for the pump

depending on the configuraiton.
1. 230V supply from isolate or boiler MFR
2. Volts free enable from MFR
3. 0-10V signal from boiler 0-10V output
(Rectify fault as required)

5.15 NO DHW BUT CH OK

There is no voltage from the timer/cylinder stat. This

no
Is there a 230V on SL2 input is not a boiler fault. Ensure voltage is supplied to the
boiler by correcting external wiring.
yes
If a tank thermistor is configured and

no Check thermister and external wiring and replace as
fitted in place of a cylinder thermostat,
necessary.
check the connection continuity and
thermistor
R(25ºC) = 10,000 Ω
Is the resistance correct?
yes
Is an OpenTherm device connected

to the boiler (note that the Ideal yes
Does the wiring from the Rectify wiring from
boiler to the OpenTherm no boiler to OpenTherm
programmable room stat is an
OpenTherm device)? device have continuity? device.
no yes
Is the DHW circuit set for day or in

a timed (on) period, or if it has an
OpenTherm device connected adn
no
configured for DHW check that it is Set the DHW system to call for heat
calling for DHW.
yes
Does the system hav a DHW pump or no

diverter valve? Check system for water circulation
yes
Is the boiler correctly set for a DHW no

pump or diverter valve? Set boiler correctly
yes
Check the control signal for the pump

depending on the configuraiton.
1. 230V supply from isolate or boiler MFR
2. Volts free enable from MFR
3. 0-10V signal from boiler 0-10V output
(Rectify fault as required)

5.16 NO DISPLAY
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
5.17 0-10V INTERFACE
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
Replace combustion manager PCB

SECTION 6 - SPARE PARTS
6 SPARE PARTS
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 ourselves. Failure to do
so could affect safety or performance of this appliance.
When calling, and to ensure we can provide you with the most accurate parts 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

SECTION 7 - COMBUSTION & FLUE INTEGRITY CHECKS
7 COMBUSTION AND FLUE INTEGRITY

7.1 FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO CHECK ON COMMISSIONING A
CONDENSING BOILER
FLOWCHART FOR CO LEVEL AND COMBUSTION RATIO
CHECK ON COMMISSIONING A CONDENSING BOILER
Important Preliminary Information on Checks

The air gas ratio valve is factory-set and must not be adjusted DURING COMMISSIONING.
If the boiler requires conversion to operate with a different gas family (e.g. conversion from natural gas to LPG)
separate guidance is provided with the conversion kit supplied and this must be followed.
PRIOR TO CO LEVEL AND COMBUSTION RATIO CHECK

The installation instructions must have been followed, gas type verified and gas supply pressure / gas rate checked as
required prior to commissioning.
As part of the installation process, ESPECIALLY WHERE A FLUE HAS BEEN FITTED BY PERSONS OTHER THAN
THE BOILER INSTALLER, visually check the integrity of the whole flue system to confirm that all components are
correctly assembled, fixed and supported. Check that maximum flue lengths have not been exceeded and all guidance
has been followed (e.g. Gas Safe Register Technical Bulletin (TB) 008 where chimney/flues are in voids).
The ECGA should be of the correct type, as specified by BS 7967.
Prior to its use, the ECGA should have been maintained and calibrated as specified by the manufacturer. The installer
must have the relevant competence for use of the analyser.
Check and zero the analyser IN FRESH AIR in accordance with the analyser manufacturer’s instructions.
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.........

SECTION 7 - COMBUSTION & FLUE INTEGRITY CHECKS
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.
Verify Flue Integrity Is

Analyser readings indicate that combustion products and inlet air O2 more than or
No equal to 20.6% OR CO2
must be mixing. Further investigation of the flue is therefore required.
Check that flue components are assembled, fixed and supported as less than or equal to
per instructions. Check that flue and flue terminal are not obstructed. 0.2%?
Yes
Is Check CO level and Combustion Ratio

O2 more than or at Maximum Gas Rate
equal to 20.6% OR CO2 Yes
With boiler still set at maximum gas rate,
less than or equal to insert analyser probe into flue gas
0.2%? sampling point. Allow readings to stabilise
No before recording.
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?
Check that no seals, e.g. Those on flue extensions, have Yes

been displaced during installation. Rectify if necessary.
Set Boiler to Minimum Gas Rate
(refer to Section 3.1)
In accordance with boiler instructions, set boiler to
Is operate at minimum rate (to minimum load condition).
CO level less Yes Allow sufficient time for combustion to stabilise.
than 350ppm AND CO/CO2
ratio less than
0.0040?
Check CO and Combustion Ratio at Minimum Gas Rate
No With boiler set at minimum rate, insert analyser probe into flue
gas sampling point. Allow readings to stabilise before recording.
Turn off Appliance and Call Ideal Technical Helpline

The appliance must not be commissioned until problems Is
are identified and resolved. If commissioning cannot be CO level less
No than 350ppm AND CO/CO2
fully completed, the appliance must be disconnected from
the gas supply in accordance with GS(I&U)R. NOTE: ratio less than
Check and record CO level and combustion ratio at both 0.0040?
maximum AND minimum rate before contacting Ideal.
Yes
Boiler is Operating Satisfactorily

No further actions required.
Ensure test points are capped, boiler case is correctly replaced and all
other commissioning procedures are completed. Complete Benchmark
Checklist, recording CO and combustion ratio readings as required.

NOTES

NOTES

NOTES

NOTES

NOTES

Technical Training
The Ideal Technical Training Centre offers a series of first class training courses for domestic,
commercial and industrial heating installers, engineers and system specifiers.
For details of courses please ring:............ 01482 498432
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.
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 Technical Helpline: 01482 498376

www.idealcommercialboilers.com
Ideal Spare Parts: 01482 498665

www.idealparts.com

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INSTALLATION AND

Emissions NOx mg/kWh 34.1 52.3 33.2 64.4 35.2 67.7

2 Installation & Servicing

EVOMAX 2 HEAT BOILER

Seasonal Space Heating Energy Efficiency of the Boiler *%

Solar Contribution (from fiche of solar device)

Collector Size Tank Volume Collector Tank rating

Seasonal Space Heating Energy Efficiency Class of Package

Installation & Servicing 3

Installation & Servicing 5

DB 55.2 55.2 57.7 57.7 59 59 59.9 59.9 62 62 62 62 59

Max. operating temp sealed sys. ºC 85

Max. operating temp open vented sys. ºC 82

Table 2 General Data

Note. HEALTH & SAFETY DOCUMENT NO. 635

6 Installation & Servicing

Boiler size G.C. Appliance No.

Installation & Servicing 7

8 Installation & Servicing

The local gas supplier should be consulted, at the installation IMPORTANT

Installation & Servicing 9

10 Installation & Servicing

1.11 ELECTRICAL SUPPLY

1.12 CONDENSATE DRAIN

Installation & Servicing 11

1.13 BOILER CLEARANCES AND CONNECTIONS

Above boiler - dependent upon the flue A 500

Below boiler - 300mm

FLOW CONDENSE GAS RETURN

80/125 CONCENTRIC FLUE CONNECTOR 100/150 CONCENTRIC FLUE CONNECTOR

* with 100/150 adaptor

Vertical Offset From X mm 26 52 78 104

Distance from flue centre line (Y) to outside wall surface.

12 Installation & Servicing

1.14 OPEN VENTED SYSTEM REQUIREMENTS Feed/expansion

The information and guidance given below is not intended

1.15 SEALED SYSTEM REQUIREMENTS

pipe. The valve or discharge pipe should seat control

Installation & Servicing 13

502 309 310

14 Installation & Servicing

1. The boiler should be laying on its back with

7. The boiler may now be stood on its base,

The boiler is supplied fully assembled in one pack.

Boiler Wall Mounting Template Installation Guide Grommet Condensate Trap

Hex Head Coach Screws

Installation & Servicing 15

2.4 WALL MOUNTING TEMPLATE Note: Horizontal flue runs must be

BOILER LOWER FIXING POSITIONS

2.5 PREPARING THE WALL

16 Installation & Servicing

BOILERS 70kW AND OVER

Installation & Servicing 17

2.8 FLUE SYSTEMS

2.9 HORIZONTAL WALL FLUE KIT

Model 30/30P 40/40P 60/60P 80/80P 100/100P 120/120P 150

Max flue length (m) 33 30 17.5 10 10 9 6

Flue Size 80 / 125 100 / 150

Wall flue kit No 220920 220921