C:\Caradon\idealcommercialboilers\current\docs\html\gt_condenser

Ideal GT Condenser -

Installation & Servicing

GENERAL

CONTENTS

Introduction. .................................................................. 2

Performance Date ......................................................... 3

Pressure Losses ........................................................... 3

Resistance Table .......................................................... 4

Main Dimensions ................................................... 4 & 5

System Design ....................................................... 5 & 6

Water Circulation .......................................................... 5

Condenser - Exploded View ........................................ 7

Unpacking ..................................................................... 7

Installation ..................................................................... 8

Fan Flue Inlet ................................................................ 9

Flue System Design ................................................... 10

RCI without Fan .......................................................... 10

RCI... V with Fan ......................................................... 11

Condensate Drain Connection .................................. 11

Electrical Connections ............................................... 12

Commissioning ........................................................... 12

Cleaning ....................................................................... 13

INTRODUCTION

General

The Ideal GT Condenser range of secondary heat exchangers
are designed for use with gas-fired boilers of output between
180kW and 986kW.

The following boilers are suitable:

Ideal Harrier GT
Ideal Viceroy GT
Ideal Viscount GT and GTE

Ideal GT Condensers are designed to increase the efficiency of
these boilers by up to 16%. This is dependant on the method of
application together with system return and flue gas
temperatures.

To maximise fuel savings system designs should keep the return
temperature to the GT Condenser as low as possible.
(Condensation will commence at around 54ºC - 55ºC. Above
this temperature the efficiency gain is of the order of 5 - 8%.
Beneath this temperature the latent heat of condensation is also
gained and the lower the temperature the more this gain (13 -
16% at 30ºC return, dependant on model). This is achieved by
gaining heat from the flue gases which is normally lost to
atmosphere.

The GT Condenser consists of a tubular stainless steel heat
exchanger with upper and lower flue units also in stainless steel.

Flue and system water connections can be positioned for
maximum convenience as the upper and lower flue units can be
rotated about the heat exchanger.

The GT Condenser is available as two model ranges.

RCI ... V Condenser with fan

These three output models are available with a fan at the
Condenser flue inlet, for cases where the pressure loss of
the Condenser cannot be overcome by the boiler burner, or
where a parallel flue circuit is used. The fan orientation is
variable through three positions. The fan motor is 230/400V
3 phase.

RCI Condenser without fan

These three output models without fan are for use where the
flue has a fan or the boiler burner is capable of overcoming
the GT Condenser pressure loss.

Three output models are available in each type for different
boiler outputs:

RCI 300V and RCI 300 180kW to 459kW
RCI 400V and RCI 400 230kW to 670kW
RCI 500V and RCI 500 390kW to 986kW

Fuel

The range of GT Condensers are suitable for:

1. Gas fired boilers

2. Dual fuel boilers - only when firing on gas. (A parallel flue

bypass arrangement is required.)

They are NOT suitable for oil fired boilers.

Ideal GT Condenser -

Installation & Servicing

GENERAL

Model

RCI 300 RCI 300V

RCI 400 RCI 400V

RCI500 RCI 500V

Boiler Heat Input

199 to 501

253 to 747

433 to 1096

Boiler Heat 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

litres

114

190

Maximum working pressure

bar

Maximum service temperature

ºC

110

Power consumption

250

550

1100

Fan speed

rpm

1500

230V - 3 phase

1.50

2.85

4.70

400V - 3 phase

0.85

1.65

2.70

Net weight

153

180

210

233

312

348

Delivery weight

177

229

238

286

342

373

1 HYDRAULIC PRESSURE LOSSES -
GT CONDENSER ONLY

Temperatures at inlet of RCI

200ºC

CO2: 10%

Depression at flue outlet RCI: 0.05mbar

100

10 20 30 40 50

100

Waterflow (m

/h)

4+1 #

4+1 #8

4+1 "

4+1 "8

4+1 !

4+1 !8

1,#&&

Pressure

loss

water

circuit

(mbar)

2 FLUE CIRCUIT PRESSURE LOSSES -
GT CONDENSER ONLY

200

100

300

400

500

600

700

800

900

1000

1500

0.5

1.5

2.5

3.5

Pressure loss in flue circuit (mbar)

Heat

Input

1,#&'

4+1 #

4+1 "

4+1 !

Table 1 - Performance Data

Ideal GT Condenser -

Installation & Servicing

GENERAL

3 MAIN DIMENSIONS - RCI

Table 2 - GT Condenser Resistance Table

øB

Flue inlet

(moveable

through 360º)

Flue outlet

(moveable

through 360º)

ID5190

øM

øE(int)

øM

øE(int)

øG

øH

RC 1

Condensate (R 1

RCI 300

RCI 400

RCI 500

ø int. E ø G

ø H

1687

1777

1883

610

698

830

270

300

330

1476

1546

1623

300

350

400

330

380

430

360

410

460

1156

1250

1376

350

400

460

540

645

630

DN65

DN 80

DN 100

569

630

657

671

658

634

380

455

550

Boiler

Harrier

Viceroy

180

230

280

330

390

450

199

253

309

361

433

501

0.6

0.9

1.5

1.6

2.2

2.8

230

280

330

390

450

540

600

670

253

309

361

433

501

598

669

747

35.5

45.5

103

112

24.5

32.5

15.5

0.5

0.7

0.9

1.1

1.4

1.9

2.3

390

450

540

600

670

720

780

812

870

928

986

433

501

598

669

747

803

870

902

967

1031

1096

106

118

126

135

143

154

164

174

104

105

113

120

127

0.5

0.8

1.1

1.2

1.4

1.5

1.8

1.9

2.3

2.6

RCI 300 or RCI 300V

Harrier

Viceroy

RCI 400 or RCI 400V

Viceroy

Viscount

RCI 500 or RCI 500V

Boiler

Heat Output

(kW)

Boiler

Heat Input

(kW)

45/30C (kW) 60/45C (kW)

GT Condenser Output (by Temp)

75/60C (kW)

Press. Drop

Flue Circuit

RCI Only (mb)

Press. Drop

Water Circuit

RCI Only (mb)

Ideal GT Condenser -

Installation & Servicing

GENERAL

4 MAIN DIMENSIONS - FAN FOR RCI ... V MODELS

330

112

290

183

120

162

ø265 (ext)

280

221

501

150

øE

øG

øH

8 ø 10

ID5191

V 300

V 400

V 500

ø E

ø G

ø H

531

555

300

350

400

330

380

430

360

410

460

249

273

262

287

312

5 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.

A wide variety of system design can therefore utilise a GT Condenser and it is not possible to provide examples of all.

The following points should be noted for system design:

The Condenser must be water cooled to ensure correct operation.

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.

Design should ensure the lowest temperature supply to the Condenser to maximise condensation and thus efficiency.

6 WATER CIRCULATION

GT Condenser in series in flue circuit

The flow through the Condenser can equal that through the boiler. It is acceptable to use a bypass to reduce hydraulic
pressure loss, through the Condenser if required. Minimum flow should be not less than 10% of boiler flow.

GT Condenser in parallel in flue circuit

The Condenser can be linked to a single boiler or series of boilers with a total heat input greater than the maximum heat
input of the Condenser in that situation. The maximum heat input of the Condenser (see page 3) is used to calculate
permitted water flow rate through it.

Example:

Total Boiler(s) Heat Input

= 2000 kW

Max input RCI 500V

= 1100 kW

Max output of RCI 500V at 92% efficiency = 1012 kW
Water Flow through GT Condenser Q = 0.86 x 1012 = 58m

/h.

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

1. stop burner when RCI connected in series in flue circuit

2. stop fan when RCI ... V connected in parallel in flue circuit

3. stop burner and fan when RCI ... V connected in series in

flue circuit.

Ideal GT Condenser -

Installation & Servicing

GENERAL

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.

7 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 system
layout to maintain low GT Condenser inlet temperatures.

RCI

GT...

with

pressurised

gas burner

Heating

circuit

ID5198

C Temp.

Circuit

Variable Temp.

Circuit

ID5199

Heating

Circuit

Cold

Inlet

RCI

GT...

with

pressurised

gas burner

pre-heater

ID5200

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.

Ideal GT Condenser -

Installation & Servicing

INSTALLATION

INST

ALLA

TION

INST

ALLA

TION

8 CONDENSER - Exploded View

The GT Condensers are manufactured entirely in stainless
steel 316L. They comprise the following parts:

1. Upper flue casing (entirely stainless) mounted on a

circular flange, rotatable round 360

2. Stainless heat exchanger with removable flue baffles and

a lifting hook.

3. Lower flue casing (entirely stainless and bolted on a

flange), which can be turned round 360

and

mounted on

four welded feet.

4. System (inlet): Stainless steel, return pipe with the flow

switch and drain connections. The pipes have a shaped
collar and a rotatable flange PN 10.

5. System (outlet): Stainless steel, flow pipe with connection

for a safety valve. The pipes have a shaped collar and a
rotatable flange PN 10.

6. Metal casing for the upper flue case, lagged with rockwool.

7. Sheet metal jacket for the exchanger body, lagged with

insulation.

8. Teflon gasket (delivered with RCI in the instruction leaflet).

9. 4 "Silentbloc" padded feet for screwing under the RCI feet.

10. Motorised fan unit for optional RCI ... V models with

extractor motor, fan and stainless steel fan casing.

- 230/380 V 3-phase motor with cooling fan, single

speed, fixed with B5 connector, IP55 protection class F.

Before installation of the GT Condenser, check the table below to confirm that all parts for a given pack are there.

Note.
The GT Condenser pack contains the RCI complete in its jacket, 4 "silentbloc" padded feet packed in a plastic bag and placed
in the lower flue casing, and 1 Teflon gasket for the connecting joint (upper flue casing) in the instruction leaflet sachet.

Siting and Access

GT Condensers are delivered on wooden pallets no wider than
800 mm for models RCI 300 and RCI 400 so that they can
easily pass through a boilerhouse door. The RCI 500 has a
pallet width of 920 mm.

They are easily separated into 3 parts (if required): upper flue
case, heat exchanger, lower flue case. The exchanger is
equipped with a hook enabling it to be mechanically lifted.

The siting of the Condenser will be dependent on the space
available in the boilerhouse. Nevertheless, the flue connection
between the boiler and the Condenser must be as short as
possible and insulated in order to reduce heat losses at this
point.

UNPACKING

Clearances

There must be a minimum space left around the Condenser so
that maintenance operations can be carried out (350 mm
minimum is necessary above the upper flue casing so that it can
be lifted when the exchanger is cleaned).
Allowance must be made for condensate drain arrangements
from the GT Condenser. If necessary install the Condenser on a
plinth.
WARNING. Please note that boilers and Condensers installed in
or near premises where the atmosphere can be polluted with
chlorine or fluorine compounds, may be subject to corrosion.
For example: hairdressing salons, industrial premises with
solvents, refrigeration equipment etc ...
Condensers installed in such locations shall not be covered by
the warranty.

360°

10*

ID5192

RCI ... V

Models only

Description

Pack no

RCI 300

RCI 300 V

RCI 400

RCI 400 V

RCI 500

RCI 500 V

Condenser RCI 300

Condenser RCI 400

Condenser RCI 500

Fan V 300

Fan V 400

Fan V 500

DZ 1

DZ 2

DZ 3

DZ 10

DZ 11

DZ 12

Ideal GT Condenser -

Installation & Servicing

INSTALLATION

10 INSTALLATION

The GT Condenser is delivered in a box and fixed on
a pallet by 4 right-angled brackets (1).

1. Unscrew the 4 brackets (1)

2. For ease of handling and to position the

Condenser, a lifting hook is provided.

To gain access:

- Lift the casing (3)
- Take off the upper flue unit (6) by unscrewing

the bolts (12).

3. To rotate the lower flue unit (11) in relation to the

system connection pipes (if required) :

- Take off the jacket (8) by unscrewing the

securing screws (9), carefully open the jacket
and lift it away

- Take off the exchanger (13) by unscrewing the

bolts (7) (taking off the exchanger by means of
the hook (10) so as not to damage the
waterproof joint)

- Screw the 4 "silentbloc" padded feet under the

lower flue unit (11)

- Place the lower flue unit (11) in the correct

orientation taking account of the bolt positions
(30

for model RCI 300 and 20

for models

RCI 400/500)

- Refit the exchanger (13), positioning the system

connections in the required position and tighten
the bolts so as to ensure a watertight fit

- Replace the outer jacket (8)

4. If Section 3 was not required. Screw the 4

"silentbloc" padded feet under the lower flue unit
(11)

5. Replace the upper flue unit (6) in the required

position and tighten the bolts (12)

6. Replace the casing (3)

7. Drill the jacket (8) with two holes 3.8 mm in

diameter, in line with the two holes in the upper
casing (3), insert the 2 screws (4)* and tighten

The 4 "silentbloc" pads (2) along with the screws
(4) are in a plastic bag packed in the lower flue
unit

LEGEND

1. Packing brackets

2. Silentblock feet

3. Upper flue casing

4. Casing screws

5. Flue baffles

6. Upper flue unit

7. Fixing bolts (lower)

8. Jacket

9. Jacket screws

10. Lifting hook

11. Lower flue unit

12. Fixing bolts (upper)

13. Heat exchanger

360°

1,#'!

INST

ALLA

TION

INST

ALLA

TION

Ideal GT Condenser -

Installation & Servicing

INSTALLATION

FLUE SYSTEM DESIGN

15 FLUE SYSTEM DESIGN

16 RCI WITHOUT FAN INSTALLED IN SERIES IN THE BOILER'S FLUE

In this case, check:

that the boiler's burner is capable of overcoming
the additional Condenser (including that of the
connecting flue between the boiler and the
Condenser) pressure loss.

that there is a fan fitted on the flue capable of
overcoming that additional pressure loss.

If this is not the case, 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.

Boiler fitted

with pressurised

gas burner

4+1

ID5202

PVC syphon

Drain T

(to be sited as

close as

possible to RCI

Air Tight Connections

Flue

Inspection syphon

RCI

GT...

with

pressurised

gas burner

Drain

(as regulations)

Slope > 3

ID5021

Slope > 3

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 15ºC above
that of the return heating water. In all cases,
it will not be less than 40ºC.

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
BS715 Section 2, Stainless Steel or be of
equivalent corrosion resistance. All joints or
connections in the flue system must be
impervious to condensate leakage.

Ideal GT Condenser -

Installation & Servicing

INSTALLATION

FLUE SYSTEM DESIGN

17 RCI...V WITH FAN

RCI...V with fan, installed in series
or in parallel in the boiler's flue:

In series: the effect of the fan is
that it 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 main 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 function

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 boiler.

- it allows dual fuel oil/gas burners

to be used provided there is an
interlock to prevent Condenser
use when oil firing.

Note.
In the case of a common flue header
for several boilers, ensure that this is
not pressurised, whatever the number
of boilers in use, so as to avoid any
risk of backing-up in one of the boilers.

18 CONDENSATE DRAIN CONNECTION

An R 1

outlet connection is provided on the lower flue

casing. This must be connected via a deep sealed trap to a
suitable waste, standard PVC or corrosion resistant material is
suitable for this purpose. (Natural gas condensate is mildly
acidic with a pH value of about 4).

A condensate drain should also be provided at the base of any
appropriate flue connection (see Frame 15).

The maximum flow of condensate is of the order of 1 l per m

of gas used.

ID5203

RCI

RCI . . . V in Series

Boiler fitted with

pressurised

gas burner

ID5204

RCI

RCI . . .V in Parallel

Boiler fitted with

pressurised

gas burner

1.8m minimum

ID5205

RCI

RCI . . .V in Parallel

Boiler

1.8m minimum

Ideal GT Condenser -

Installation & Servicing

INSTALLATION

19 ELECTRICAL CONNECTIONS

WARNING. Connections must be made by a qualified
electrician.

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 - see

Frame 17) 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.

Note
The water flow switch (not )provided is connected to the
boiler's control panel.

When the flow switch detects a flow which is too low (10% of
nominal flow) the burner is stopped.

20 COMMISSIONING

Checks Before Commissioning

- Check that the various connections have been made

according to the current standards and Regulations and to
those in this leaflet.

Check that the boiler and the GT Condenser have correct
water flow rates.

Check that any flue damper fitted is not fully closed.

Where an RCI...V is connected in series in the flue circuit, the
pressure drop must be adjusted as below.

Check that the boiler installation has been completed
according to the manufacturer's instructions.

2HAIIKHA 6K>A

1,# $

ID5207

200

300

400

500

600

700

800

900

1000

0,5

1,5

2,5

Boiler

Output

(kW)

Pressure Loss of Flue Circuit (mbar)

RCI 300

RCI 400

RCI 500