GT Condenser Leaflet 10/2001

The new GT Condenser provides higher efficiencies and low

running costs from the Ideal range of pressurised gas boilers.

Extracting additional heat normally lost with the flue gases. Ideal also

provides specifiers, contractors and building owners with trade mark

benefits of simplicity and flexibility of installation and operation.

The addition of a GT Condenser to the boiler can provide up to

16% more heat by cooling the flue gases to gain both sensible and

latent heat from condensation. The lower the system return

temperature being fed into the Condenser the more the gain. It all

provides benefits in lower emissions & lower fuel bills.

The GT Condenser range is suitable for gas fired boilers only but

can be fitted to dual fuel boilers with suitable flue design. Six models

are available to suit Harrier, Viceroy and Viscount boilers with a boiler

output range suitability from 180kW (614,000 Btu/h) to 986 kW

(3,364,000 Btu/h). Three output models cover this range and to

ensure easy flue installation, each is available with or without a fan to

overcome the flue pressure loss of the GT Condenser if necessary. A 6

bar working pressure capability ensures system application is straight-

forward.

The GT Condenser is entirely manufactured from stainless steel

which ensures long term durability. The unit is designed for easy

installation in restricted boiler houses taking minimal floor space.

Clever design allows both flue and system connections to be made in

the most simple and convenient manner. Both upper and lower flue

casings may be rotated independently around the heat exchanger by

360' allowing all connections to be made in the easiest manner. High

levels of insulation ensure that heat gains are kept in the system

where required.

The heat exchanger is a multi tubed cylinder with flue gases

passing from top to bottom, condensate draining to the lower flue

casing where an outlet connection is provided. Servicing is simplicity

with the flue tubes being easily washed through.

The Ideal GT Condenser range is suitable for Harrier, Viceroy and

Viscount boilers. Advanced performance from the market leader, Ideal

Boilers.

Up to 16% extra heat.

Compact size.

Adjustable flue and system
connections.

Low flue and system
resistances.

High insulation levels.

Fanned or standard versions.

Suitable for Harrier, Viceroy and
Viscount boilers.

"Highest efficiencies...

Advanced Performance"

GT condenser

condensing heat exchanger

Flue inlet (RCI... V models)

RCI & RCI ... V

Flue inlet (RCI models)

Upper flue casing (grey)

Pressure tube (flow rate
measurement for
RCI... V models)

Upper flue unit
(stainless steel
316L - rotatable)

Lifting hook

Insulation
- 40mm rockwool

ground flue
box

- 40mm fibreglass

wool around
heat exchanger

Tubular heat
exchanger with
baffles (all
stainless steel
316L) rotatable
through 360°

Heat exchanger
casing (ivory)

Lower flue unit
(stainless steel 316L)
rotatable

Flue outlet

Adjustable feet

RCI... V
Fan unit in stainless steel
- 230V/400V motor 3 phase with

cooling fan, 1 speed

- IP55 protection, class F
- 3 optional positions inlet from

left, right or beneath

Note: inlet cannot

be from above

Safety valve connection
(RC

)

Flow connection
(316L stainless steel with
rotaing PN10 flange)

Return connection
(316L stainless steel with
rotaing PN10 flange)

Flow switch connection
(RC 1

)

Drain connection (RC

)

Condensate drain outlet

performance

The Ideal GT Condenser provides high operating efficiencies

when used in conjunction with Harrier, Viceroy or Viscount pressurised

gas boilers. They are manufactured from stainless steel for long life,

with the option of fan flue options permitting a wide variety of system

applications. The efficiency of these high quality boilers can be

increased by up to 16% using the GT Condenser. The greatest

benefits are achieved with low system return temperatures as

condensing operation starts to occur below 54°C return as shown on

the chart adjacent. Overall system running costs can therefore be

minimised using a GT Condenser.

construction

Entirely manufactured in 316L stainless steel containing

molybdenum for extra corrosion resistance. The multi-tubular vertical

shell has removable flue baffles and is insulated with 40mm of

aluminium backed fibreglass. Both upper and lower flue casings are

also manufactured from 316L stainless steel. The upper flue casing

being insulated with 40mm Rockwool.

Both upper and lower flue casings can be independently rotated

through 360° around the heat exchanger.

A drain connection is provided on the lower casing.

The fan option consists of a 3 phase motor (230/400V) fitted to a

stainless steel fan. The intake position can be fitted in three different

orientations.

packing

Factory assembled condenser on a pallet with strapped on

carton.

For RCI ... V option, a crated fan is provided separately.

Up to 16%

efficiency benefit

quality

As with all Ideal boilers the GT Condenser is engineered to the

highest quality standards. Ideal boiler products meet or exceed the

requirements of every relevant standard. Ideal Boilers are recognised

as a World Class Manufacturer.

system applications

GT Condensers are suitable for use with Harrier, Viceroy and

Viscount gas or dual fuel boilers.

They may be applied to heating only or heating and hot water

systems. They may be used as preheaters in indirect hot water

circuits.

Suitable for both Open Vent and Pressurised/Sealed Systems, all

of which must be fully pumped.

The maximum static head for open vent systems is 61 metres

(200 feet). The maximum working pressure for pressurised systems is

6 bar (87 psi).

Maximum service temperature 110°C.

options

Fan versions of standard GT Condensers

RCI

300V

RCI 400V

RCI

500V

product

specification

system design

GT Condensers can be applied to suitable boilers in new or

existing systems and may be fitted in heating only or heating and hot

water systems. They may also be used in open vent or pressurised

sealed systems.

A wide variety of system designs can therefore utilise a GT

Condenser:

Heating only (constant & variable temperature)

Heating & hot water circuits

Preheat of hot water and many others.

The following points should be noted for system design:

System design must allow for adequate circulation within the boiler

and Condenser during , and immediately after burner firing.

A tapping is provided on the flow connection for a safety valve.

This can be used if there are any valves which may isolate the

Condenser.

Heating and hot water controls should be electrically interlocked

with the burner to prevent firing when there is no demand for heat.

Design should ensure the lowest temperature supply to the

Condenser to maximise condensation and thus efficiency.

Information and guidance on system design may be consulted in

BS 5449 Part 1, BS 5410 Part 2, BS 5376 Part 2 and BS 6644

Section 2, subsection 11 and Guidance Note PM5 `Automatically

controlled steam and hot water boilers' published by the Health &

Safety executive.

Other British standards applicable to commercial sealed systems are:

BS 1212

BS 6880 Part 2

BS 6281 Part 1

BS 6282 Part 1

BS 6283 Part 4

Requirements of Local Authority, gas or water undertakings must

always be adhered to.

A tapping is provided on the Condenser return pipe for a flow

switch.

In the event of no water flow, the flow switch must be able to:

(a) stop burner when RCI connected in series in flue circuit

(b) stop fan when RCIV connected in parallel in flue circuit

circuit.

water circulation

system design examples

There are many possible system designs that may use a Condenser:

heating only circuits (constant and variable temperature)

heating and hot water circuits

Preheat of hot water

The three examples given below cannot cover all installations which may be encountered. Their purpose is to provide basic guidance and

suggest some possible GT Condenser applications.

In all cases, standard installation practices, along with national and local regulations currently in force, must be respected.

1. Single Circuit (Heating Only)

The GT Condenser is fitted in series with the boiler flue circuit,

the flue system design allowing for the Condenser pressure drop.

The system variable temperature return is piped to the

Condenser inlet to give low return temperatures and therefore

increase energy savings. The heated Condenser flow passes to

the boiler and is then raised to desired system temperature.

In this layout the GT Condenser may be sized to suit the

maximum boiler output.

If constant temperature circuits are also within such a system the

GT Condenser can be sized to suit the variable temperature

circuit(s) only with suitable pipework.

2. Multiple Heating Circuit - Multiple Boilers

The GT Condenser is fitted in parallel to the

boilers flue circuit to be independent of

number of boilers firing. Both constant and

variable temperature circuits are present taken

from a vertical header.

The Condenser is located on the variable

temperature circuit to utilise low return system

temperatures and effectively preheat the

header return. It should be sized to the

variable temperature circuit load.

In fully mixed state, then valve A should be

open.

3. Heating installation (1 Circuit) and sanitary hot water

with pre-heating unit, linked to boiler flue - RCI in parallel

(dynamic):

The system uses a preheater for the D.H.W calorifier. The

GT Condenser is connected to the preheater to achieve

energy savings on D.H.W use by utilising boiler flue heat.

The heating circuit is laid out as required, not being

connected to the Condenser circuit.

The Condenser is installed in a loop design in the building. It is

better to choose the RCI ... V version connected as a by-pass

to the flue so as to be able to control the water temperature

by stopping the fan without having to stop the boiler.

ID5198

ID5199

ID5200

flue system

design

requirements

The use of a Condenser leads in most cases to flue

temperatures comparable to those obtained with dedicated

condensing boilers. The flue temperature is about 15°C above

that of the return heating water. In all cases, it will not be less

than 40°C.

Reminder of a few important, practical rules:

limit the number of boiler - Condenser groups connected to

the same flue. Minimise the number of elbows.

drainage of condensate must be at the base of the flue and at

the lowest points of the lower flue box. Drain pipes must be

in corrosion resistant material and of a constant diameter.

The type of flue pipe used should conform to BS 715 Section 2,

Stainless Steel or be of equivalent corrosion resistance. All joints

or connections in the flue system must be impervious to

condensate leakage.

RCI without fan installed in series in the boiler's flue

ID5021

In this case;

The boiler's burner must be capable of overcoming the

additional Condenser (including that of the connecting flue

between the boiler and the Condenser) pressure loss.

there should be a fan fitted on the flue capable of

overcoming that additional pressure loss.

If this is not possible, it will be necessary to consider:

either adapting the burner or replacing it,

or, if the installation allows, reduce the boiler output.

If the above is not possible an RCI... V with fan unit must be used.

ID5202

RCI ... V with fan

RCI ... V with fan, installed in series or in parallel

in the boiler's flue:

In series: the fan overcomes the pressure loss

of the Condenser where the boiler or flue cannot

provide sufficient draught.

In parallel: this type of connection is only

allowed if a fan is installed.

The advantages are:

it is independent of the output of the

associated boiler.

it has an effect on all the boilers in a system

in "cascade" formation, whatever the order

of the cascade or the number of boilers in use.

it allows the boiler to operate with the

Condenser switched off. In particular, this

may be desired in summer with D.H.W only

required. This simplifies the hydraulic connection

of any domestic hot water only boiler.

it allows dual fuel oil/gas burners to be used

provided an interlock to prevent Condenser

use when oil firing is applied.

ID5203

ID5204

ID5205

RCI ... V in Series

RCI ... V in Parallel

electrical connections

RCI Without Fan

A flow switch (not provided) is:

connected in series with the control circuit of the burner where a

standard control panel is used.

RCI ... V (with Fan)

The fan must have a 230 or 400 Volt three phase supply. In all design

layouts the operation of the fan must be interlocked to the boiler

burner operation.

Where the system uses several boilers in cascade, connection of the

RCI ... V (installed in parallel in the flue circuit) should be made so that

the fan starts as soon as one boiler starts.

If a dual fuel boiler is installed using a parallel flue circuit for the RCI ...

V, then the Condenser fan operation must be interlocked to operate

only when gas is being fired. Fan operation must stop on changeover

to oil.

A water flow switch (not supplied) should be connected in series with

the control circuit to prevent the burner firing in the event of low flow.

Water circuit pressure loss

Flue circuit pressure loss

Example:
A flow rate of
15 m

/h in the RCI

300 equates to a
water pressure loss
of 15 mb.

Example:
Boiler heat input
= 400kW.
Flue circuit
pressure loss for
RCI 400 = 1 mb.

- Temperature at at

inlet of
RCI ~ 200°C

- CO

: 10%

- Depression at

flue outlet of RCI
0,05 mbar.

general data

Boiler input

199 to 500

253 to 747

433 to 1096

Boiler output

180 to 450

230 to 670

390 to 986

Pressure losses - flue circuit

mbar

0.5 to 2.7

0.3 to 2.5

0.4 to 2.7

Nominal water flow rate

9 to 25

12 to 36

19 to 58

Minimum water flow rate

1 to 2.5

1.2 to 3.6

1.9 to 5.8

Maximum water flow rate

27 to 75

36 to 108

57 to 174

Pressure loss - water circuit

mbar

8 to 35

7 to 33

8 to 50

Water capacity (Condenser)

litres

114

190

Maximum working pressure

bar

Maximum service temperature

°C

110

Power consumption

250

550

1100

Fan speed

rpm

1500

Current 230 V - 3 phase

1.50

2.85

4.70

Current 400 V - 3 phase

0.85

1.65

2.70

Net weight

153

180

210

233

312

348

Delivery weight

177

229

238

286

342

373

Model

RCI 300

RCI 300V

RCI 400

RCI 400V

RCI 500

RCI 500V

GT Condenser RCI 500 or 500V

Model

Heat Output

Heat Input

GT Condenser Output (by Temp.)

Pressure Drop Pressure Drop

(Boiler) (kW)

45/30°C

60/45°C

75/60°C

Flue Circuit

Water Circuit

(kW)

RCI Only (mb) RCI Only (mb)

Viceroy 8

390

433

0.5

Viceroy 9

450

501

0.8

Viceroy 10

540

598

1.1

Viceroy 11

600

669

106

1.2

Viceroy 12

670

747

118

1.4

Viceroy 13

720

803

126

1.5

Viceroy 14

780

870

135

104

1.8

Viscount 14

812

902

143

105

1.9

Viscount 15

870

967

154

113

Viscount 16

928

1031

164

120

2.3

Viscount 17

986

1096

174

127

2.6

general

data

Example: Total heat output of Viceroy 8 section with RCI 500 GT Condenser at 45°C/30°C return system temperatures.

Viceroy 8 section = 390 kW
RCI 500

66 kW

Total

456 kW

GT Condenser RCI 300 or 300V

Model

Heat Output

Heat Input

GT Condenser Output (by Temp.)

Pressure Drop Pressure Drop

(Boiler) (kW)

45/30°C

60/45°C

75/60°C

Flue Circuit

Water Circuit

(kW)

RCI Only (mb) RCI Only (mb)

Harrier 6

180

199

0.6

Harrier 7

230

253

0.9

Harrier 8

280

309

1.5

Harrier 9

330

361

1.6

Viceroy 8

390

433

2.2

Viceroy 9

450

501

2.8

GT Condenser RCI 400 or 400V

Model

Heat Output

Heat Input

GT Condenser Output (by Temp.)

Pressure Drop Pressure Drop

(Boiler) (kW)

45/30°C

60/45°C

75/60°C

Flue Circuit

Water Circuit

(kW)

RCI Only (mb) RCI Only (mb)

Harrier 7

230

253

35.5

24.5

15.5

0.5

Harrier 8

280

309

45.5

32.5

0.7

Harrier 9

330

361

0.9

Viceroy 8

390

433

1.1

Viceroy 9

450

501

1.4

Viceroy 10

540

598

1.9

Viceroy 11

600

669

103

2.3

Viceroy 12

670

747

112

technical training

The Caradon Plumbing Solutions 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.

customer care helplines

Helplines are open 8.30am to 6.00pm Monday to Friday. Please

ring 01482 498376.

world class manufacturer

Ideal Boilers has been adjudged by IBM Consulting and

The London Business School to be a World Class Manufacturer.

Ideal Boilers Limited
PO Box 103 National Avenue Kingston upon Hull HU5 4JN
Tel: 01482 498690 Fax: 01482 498621

B/G/C/10/01

Issued subject to standard conditions

Ideal Boilers pursues a policy of continuous
improvement in design and performance of
its products and reserves the right to vary
specification without notice. Statutory rights
of the consumer are not affected.

Assurance of quality
BS EN ISO 9001: 1994

CERTIFICATE No. FM 14648

SIC 3284

100 150 200

600

800

1000

1500

3500

136

340 511 682

2047

2729

3412

5118

11942

Boiler output

Concord CXS, CXSD

Concord CXC Condensing

Concord CXSi, CXDi

Concord ES

Concord CXA, CXS,
CXSD Modular

Concord Super Series 4

Maximiser SE

Buccaneer GT

Falcon GTE

Harrier GT

Viceroy GT

Viscount GTE

Vanguard S, HT

Btu/h (000)

Concord CXA

40-120

46-116

110-180

140-340

80-720

50-600

14-60

Concord Super Plus

200-600

16-40

36-102

105-330

300-780

754-1450

130-3500

Buccaneer / Falcon
Combination Boilers

Senator Calorifiers

16-64

150-1000 litres

Atmospheric Boilers

High Efficiency Boilers

Pressure Jet Boilers

Hot water solutions

the ideal commercial range

GT Condenser

180-990