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

Introduction

Ideal Boilers' Super range is the most successful modular boiler

system on the market. Proven to deliver exceptional high efficiency

commercial and industrial heating performance.

The Super range consists of the Super Series 4 comprising identical

50kW modules with outputs from 50kW to 600kW and the Super

Plus comprising of 100kW modules with outputs from 200kW to

600kW.

Heat exchangers are sited in a combined casing/combustion

chamber assembly, effectively creating semi-condensing conditions

within each module. This design achieves efficiencies of up to 85%

gross cv (94% nett cv) at both full and part load conditions. Because

of its modular design, Super range eliminates oversizing problems to

offer optimum operating efficiency. Maximum system load

determines the appropriate number of modules for a given

installation - from 50kW (170,600 Btu/h) up to 600kW (2,047,200

Btu/h). Sequence controlled operation automatically matches the

number of modules firing to requirements, so reducing fuel

consumption.

Ideal for simple vertical or horizontal assembly, Super range

installation can save over 30% of the typical plantroom space

normally used by conventional boilers. And the system incorporates a

range of design innovations reducing boiler installation and servicing

time.

Super efficient, straightforward to specify, easy to install and service.

Ideal's Super range is the proven performer in high efficiency

modular boiler systems.

Conforms with all relevant
European standards and
requirements

Performance

Heat output from each boiler module is 50kW (Super Series 4)

and 100kW (Super Plus) with the number of modules in use

dependent on the maximum load. Fitted on slide rails, the modules

are located in an insulated stainless steel boiler casing. The products

of combustion first give up their heat to water flowing through the

modules then are discharged.

Water flows continuously through all the modules on the reverse

return principle. It enters the return header on the left hand side of

the boiler and then flows through the modules to the flow header on

the right hand side. As the load is satisfied the upper module

switches off first, then the middle, and lastly the lower module.

Water flowing through the upper modules is kept warm by exhaust

gas from lower modules which are firing. There is only a minimal loss

of efficiency as modules shut down. Modules are connected in

parallel across the two headers via flexible hose connections on

boilers of 200kW output and above.

The Super range complies with the new Building Regulations

2000 - Conservation of Fuel & Power (Part L).

Approved efficiency is approx 94% net (85% gross) full load, at

part load high efficiencies are maintained at virtually full load levels.

Construction

The stainless steel boiler casing is externally insulated with stucco

finish, aluminium-faced insulation. Module covers are stove-enamelled

orange. Super Series 4 - The heat exchanger consists of extruded

copper finned tubes in a circular arrangement around the gas burner.

Copper tubes are expanded into cast iron headers, onto which cast iron

cover plates are bolted. Super Plus - The heat exchanger is constructed

in the same manner but in aluminium alloy. The front cover plate is cast

iron with similar flow and return elbows. The mating surfaces are

ground and a seal is made with gaskets. Each module is pressure tested

to 11 bars (160 lb/in

). The module water inlet and outlet castings are

" nominal bore and are connected to the flow and return headers

with standard flanges to BS 4504. The buoyancy of hot gases from the

gas burner is overcome by using a slotted aluminium distribution screen

arranged around the outside of the finned tubes. The slots have

sufficient resistance to ensure even gas flows over the finned tubes.

Burner

The burner is a perforated stainless steel cylinder producing a

perfectly symmetrical gas flame. Gas and air in the correct proportions

are pre-mixed in the burner fan which blows the gas/air mixture into

the inside of the burner. A mixture distribution cone ensures even flow

through holes in the cylindrical burner. Hot products of combustion

flow radially outwards around the finned tubes, giving up their heat to

the water flowing through the tubes. Exhaust gases are then

discharged into the boiler casing. Ignition and burner performance can

be observed through the sight glass mounted on the front plate.

Gas Controls

Each module has the following items in the gas supply train:

Module gas cock on gas header branch

Twin a.c. solenoid valve

Gas air control unit

- Gas

injector

The positive and negative pressure lines from the fan act on the

diaphragm of the gas/air control unit (Super Plus: gas pressure

switch). This allows gas to pass to the burner in proportion to the

amount of air delivered by the fan, thereby accommodating

variations in flue draught. A closed flue will allow no gas to pass. The

minimum dynamic gas supply pressure required at the inlet to the

boiler is 15 mbar (6 in. w.g.) with all modules firing. Maximum gas

supply pressure is 25 mbar (10 in. w.g.).

Options

Boiler

Range

Certificate No.

Notified Body

Reference

Super Series 4

50 - 600kW models

BE-87/97/3/MI

Advantica

0087

Super Plus

200 - 600kW models

Technologies Ltd

0087

Boiler

Water flow switch for boiler protection
in the event of pump failure

External sequence control kit

Remote indication of boiler on,
lockout and overheat for each module

Module blanking off pack

Super Series 4

Super Plus

product specification

The module is protected against blockage of the burner, heat

exchanger, or flue and against fan failure by the compensating valve

set. This senses the differences in pressure across the multi-hole

plate and controls the gas injector pressure according to the amount

of air flow. After combustion, the products flow past the finned tubes

and through the gas distribution screen into the boiler casing, so

giving up heat to the water flowing through the tubes.

Electrical Controls

Each module has its own independent complete control system

incorporating:

To achieve correct matching of boiler output and variations in

load, modules switch in sequence automatically. The electronic

control thermostat senses return water temperature to each module

and makes simple adjustments quickly and accurately. The

electronic control arrangements also provide step-start ignition of

modules on initial light-up.

System Application

The Super range is designed for central heating of

commercial/industrial premises and also for supplying domestic hot

water via a calorifier or plate heat exchanger. It is suitable for open

vented and pressurised systems and can be connected to fully

pumped, open vented or pressurised central heating, indirect

domestic hot water and combined systems.

Note: The Super range is not suitable for direct hot water supply or

gravity heating/hot water systems.

Quality

As with all Ideal boilers, the Super range is engineered to the

highest quality standards. Ideal boiler products meet or exceed the

requirements of all relevant standards. Before despatch each module

is fired and the control system, fan and burner are fully tested. The

control valve is also adjusted to give the correct gas flow rate. Ideal

Boilers are recognised as a world class manufacturer.

assurance of quality

BS EN ISO 9001: 2000

Packing

Operation

Super Series 4

In certain conditions the normal mode of boiler operation is

preceded by a period in which the complete boiler casing is given a

three volume air change. In the case of a single 50kW boiler with no

wiring centre, only its own 5 second nominal pre-purge period

occurs. When the module electronic thermostat calls for heat the fan

switches on and purges the combustion chamber for 15 seconds.

Then the ignition spark is generated from the ignition electrode to

the burner and the gas valves are opened.

Super Plus

When the electronic thermostat calls for heat and no modules

are firing, all fans will purge the casing for 70 seconds. The fan from

the first module called upon will then purge its own combustion

chamber for an additional 35 seconds and each subsequent module

likewise prior to the start of the ignition sequence. Then the ignition

spark is generated from the ignition electrode to the burner and the

gas valves are opened.

Gas is delivered through the injector to the distribution plate at

the inlet to the fan. This pre-mixes the gas with the air. It then passes

from the fan through a multi-hole plate to the burner, where it is

ignited. The flame is sensed via the ionisation probe and the PCB

control. The valves remain open until the thermostat is satisfied.

low NOx (Class 5)

performance for life

Boiler

Boiler casing

Water headers

Gas header

Modules

Super Series 4 / Super Plus

Boiler

2 x 2 PCB with separate spark generator

Ignition electrode

Ionisation probe

Adjustable water temperature electronic
control thermostat

Non-adjustable limit thermostat with
manual reset

On/off switch

LEDs to provide visual indication
of mains on, burner on,

Ignition lockout and overheat lockout

Module electrical plug

Super Series 4 / Super Plus

Boilers are supplied in the following packs:-

A full site assembly and commissioning service is

available at an extra charge.

Maximum static head

61 metres (200 feet)

Maximum working pressure

6 bar (87psi)

Maximum design flow temperature

82°C (180°F)

Installation

For safety, a competent CORGI (Council for the Registration of

Gas Installers) registered installer must fit this appliance. CORGI

requires its members to work to satisfactory standards.

Boiler installation should comply with relevant British Standard

Specifications, Codes of Practice, and current Building Regulations,

together with any special regional requirements of the Local

Authorities, Gas Supplier, and Insurance Company, and in particular:

BS 6891: Low pressure installation pipes, BS 6644: Installation

of Gas Fired Boilers, BS 6880: Part 1-3 Central Heating by low

pressure hot water, CP 342.2 Centralised hot water supply, British

Gas publications IM/II Flues for commercial and industrial gas fired

boilers and air heaters.

All electrical wiring must comply with IEE Regulations for the

electrical requirement of buildings.

Manufacturer's notes must not be taken as overriding statutory

obligations.

vertical or horizontal

models, easy to install

Minimum clearances from walls or other fixed objects to allow

for installation, maintenance, and the free access of combustion air

are shown in the boiler clearance diagram.

The Super range is easy to install. Even the largest boiler in the

range will go through a standard doorway. If the water headers and

the modules are removed from the boiler casing, then one man can

easily handle up to the 100kW unit, and two men up to the largest

size. Assembly on site does not require any special tools. Because of

the very high efficiency of the Super range precautions must be

taken to provide condensate drains at the lowest bend in the flue

system. A drainpipe, suitable for connection to 22mm pipe, is

located at the bottom of the boiler casing. Condensation will occur

only on warming up, when the return water temperature is below

55°C (131°F) - the dew point of water.

To ensure efficient and reliable boiler operation:

The constant water flow through the boiler, within 10% of

that indicated in the data table, must be maintained at all

times when any of the modules are operating. At these flow

rates, the hydraulic resistance is Super Series 4 125mbar

(50 in. w.g.) or Super Plus 98mbar (39 in. w.g.) plus or

minus 20% irrespective of boiler size.

Protection against circulating pump failure must be provided.

The chimney system must be CLASS 1 specification and be

lined and insulated with the equivalent of 50mm (2in) of

mineral wool. A drainage point must be provided.

The chimney draught must be controlled between neutral and

0.2mbar (0.08 in. w.g.).

Boiler house cleanliness is important and concrete floors

should be sealed to keep dust levels down to a minimum.

Regular maintenance by competent personnel is essential to

the safe and reliable operation of the boiler.

Full details of these requirements are given in the Installation and

Servicing Instruction books available on request from Ideal Boilers.

Water Treatment

The Super Plus boiler has an aluminium alloy heat exchanger.

The ONLY water treatments Ideal Boilers have approved are `Fernox

Copal' and `Betz Dearborn Sentinel X100' (current suitability should

be confirmed with the manufacturer). ANY OTHER treatment will

render the guarantee of Ideal Boilers for this product INVALID.

The above is not applicable to the Super Series 4.

Water contained in all heating and indirect hot water systems,

particularly open vented systems, requires basic treatment. It is

wrong to assume that because boilers are operating in conjunction

with what is an apparently closed circuit, an open vented system will

not under normal circumstances allow damage or loss of efficiency

owing to hardness salts and corrosion once the initial charge of water

has been heated several times. One millimetre of lime reduces the

heat conversion from flame via metal to water by 10%. In practice

the accumulation of these salts is liable to cause noises from the

boiler body or even premature boiler failure. Corrosion and the

formation of black iron oxide sludge will ultimately result in

premature radiator failure.

Open vented systems are not completely sealed off from the

atmosphere, because it is necessary to provide a tank open to

atmosphere if proper venting and expansion of system water is to be

achieved. The same tank is used to fill the system with water and it

is through the cold feed pipe that system water expands into the

tank when the boiler passes heat into the system. Conversely, when

the system cools, water previously expanded is drawn back from the

tank into the system together with a quantity of dissolved oxygen.

Even if leakage from the heating and hot water system is

eliminated there will be evaporation losses from the surface of the

tank. Depending on ambient temperature these may be high enough

to evaporate a large portion of the system water capacity over a full

heating season.

Corrosion will always occur within a heating/hot water system to

a greater or lesser degree irrespective of water characteristics, unless

the initial fill water from the mains is treated. Even the water in

closed systems will promote corrosion unless treated.

system requirements

Ventilation

Detailed recommendations for air supply are quoted in BS 6644.

The following notes are for general guidance and the standard

should be consulted for full information.

Natural Ventilation

Permanent openings at low and high level communicating

directly with the outside air must be provided. The total minimum

free area of the openings must be as follows:

Low level (inlet)

540 cm

plus 4.5 cm

per kW in excess of 60kW total rated

input (gross).

High level (outlet)

270 cm

plus 2.25 cm

per kW in excess of 60kW total rated

input (gross).

Mechanical Ventilation

Air can be supplied:

(a) By a fan connected to a low level opening and discharged

naturally via one or more high level openings.

(b) By a fan connected to a low level opening and discharged by

means of a second fan at a high level opening.

Note: Any fan installed for extraction purposes must not cause a

negative pressure (relative to the outside atmosphere) to develop in

the boiler house as this will affect burner performance.

The air flow rates for forced draught boilers are calculated from

the formula.

Inlet air

- 0.9m

/sec per 1000kW of heat input.

Extract air

- 0.6m

/sec per 1000kW of heat input.

All air inlet and extract fans must be fitted with automatic

controls causing safety shutdown or lockout of the boiler(s) in the

event of inlet or extract air flow failing.

Flue Systems

Depending on particular site conditions the flue size required

may be as much as two sizes smaller than that required for a

conventional atmospheric gas boiler of similar output. The fitting of a

draught stabiliser will be necessary on all individual boilers. In

certain circumstances it may be possible to use a chimney sized

smaller than the flue connection provided on the boiler.

single flue outlet

Existing brick chimneys can be used provided they are lined,

insulated and drained. Super range boilers are suitable for fan

diluted or induced draught fan flue systems. The following sizes of

boiler are supplied with one or more blanking plates fitted:

Super Series 4

alternative 150

250 vertical and horizontal

350 vertical

450 to 550 vertical and horizontal models

Super Plus

300/3 (3 in 400 casing)

300/3 alternative (3 in 600 casing)

400/4 alternative (4 in 600 casing)

500/5 (5 in 600 casing)

The output of these boilers can be increased by the removal of

blank plates and the fitting of additional modules provided that the

flue system is sized for the higher output on initial installation.

Water Treatment continued

For these reasons, Ideal Boilers strongly recommends that when

necessary the system be thoroughly cleaned prior to the use of a

stable inhibitor which does not require continual topping up to

combat the effects of hardness, salts, and corrosion on the heat

exchanger and its associated systems.

The company advises direct contact with major water treatment

specialists such as Betz Dearborn Ltd, Sentinel Division, Widnes,

Cheshire, WA8 8UD Telephone: 0151 424 5351 or Fernox, Fry

Technology UK, Tandem House, Marlowe Way, Beddington Farm

Road, Croydon CRO 4XS Telephone: 0870 601 5000.

System Design

The Super range is suitable for connection to all types of fully

pumped systems provided that the constant water flow through the

boiler is not affected by manual or automatic operation of controls

within the system. Protection against pump failure must be provided,

eg; by the fitting of a water flow switch. A suitable switch can be

obtained from Ideal Boilers. The modular arrangement of the boiler

and its high tolerance to condensation allows for efficient control of

heat output without the use of mixing valves.

Operation should be at constant volume flow rate with 11°C

(20°F) temperature difference across boiler and system.

General guidance on system layouts are shown in the diagrams

below (see Figures 2, 3 and 4).

Figure 2 is intended as a guide ONLY with the following

assumptions and conditions applying:

Open vent and cold feed connections are made to the boiler

flow and return manifolds respectively.

The pump is positioned on the flow. The water velocity is

assumed to be below 1.5m/s (5ft/s) and the volume flow rate

to be 1.07 l/s (14.1 gal/m - Super Series 4) or

2.15 l/s (28.4 gal/m - Super Plus) per boiler module.

In an existing system a filter/strainer should be positioned

into the common return pipework to prevent debris entering

the heat exchangers.

Note:

Single module boiler requirements are as for multi-module

boilers.

Hydraulic resistance for all

Super Series 4 boilers is 125 mbar (50 in.w.g.) or

Super Plus boilers is 98 mbar (39 in.w.g.)

at the design flow rate.

Minimum tank height dimensions shown may have to be

increased to comply with pump manufacturer's requirements

to avoid cavitation. It may also be necessary to consider the

requirements of Guidance Note: PM5, issued by the Health &

Safety Executive. Refer also to the Installation Instructions.

Mixing headers should be sized at 1 standard pipe size larger

than the common flow and return pipework.

* Super Series 4: 2000mm (79 in.), Super Plus: 1600mm (63 in.).

1. Cold feed

Sizes MUST comply

2. Open vent

with BS 6644

3. Safety valve

4. Water flow switch

5. Dual primary pumps

6. Mixing header

7. Feed and expansion tank

Figure 2: Simple combined heating and DHW System

}

system requirements

Figure 4: example 1 shows an application with independent

boiler primary pumps based on 11°C (20°F) temperature difference

across boiler. Boiler primary pumps (dual sets) are rated at 4.28 I/s

(56.4 gal/m) against 125 mbar (50 in.w.g - Super Series 4) or

8.6 I/s (113.8 gal/m) against 98 mbar (39 in.w.g - Super Plus) plus

pipework resistance. Example 2 shows an application with common

boiler primary pump based on an 11°C (20°F) temperature difference

across the boiler. Boiler primary pump (dual set) is rated at 8.56 l/s

(112.8 gal/m) against 125 mbar (50 in.w.g - Super Series 4) or

17.2 I/s (227.6 gal/m) against 98 mbar (39 in.w.g - Super Plus)

plus pipework resistance. Note: In both cases modules should be

switched on each boiler simultaneously to give a variety of turndown

ratios. Boiler primary pumps must run at all times, irrespective of the

number of modules firing on either boiler.

Figure 3: Example of multi-zone heating and DHW system

connected to multi-module boiler

Figure 4: Example of multi-zone heating and DHW system

connected to two multi-module boilers

1. Cold feed

2. Open vent

3. Safety valve

4. Water flow switch

5. Dual primary pumps

6. Mixing header

7. Feed / expansion cistern

8. Compensator

Note:
Super Series 4
The primary pump duty is 1.07 l/s x 4 modules and 4.28 l/s
(56.6 gal/m) against 125 mbar (50 in. w.g) plus pipework
resistance.

Super Plus
The primary pump duty is 2.15 l/s x 4 modules and 8.6 l/s
(113.8 gal/m) against 98 mbar (39 in. w.g) plus pipework
resistance.

C - Cylinder thermostat controls pump

E - Air temperature sensors

T - Timers

Open vents, cold feet and safety valves OMITTED for clarity

Example 1

Example 2

System Design

General Data - Super Series 4 (50V - 300H)

Model

50V

100V

150V

200V

250V

300V

150VA

250H

300H

No. of modules

Boiler input

58.8

117.6

176.4

235.2

294.0

352.8

176.9

294.0

352.8

Btu/h

200.6

401.3

601.9

802.5

1003.1

1203.8

601.9

1003.1

1203.8

Boiler output

100

150

200

250

300

150

250

300

Btu/h

170.6

341.2

511.8

682.4

853.0

1023.6

511.8

853.0

1023.6

Gas rate

5.5

11.0

16.5

22.1

27.6

33.1

16.5

27.6

33.1

195

389

584

779

973

1168

584

973

1168

9.0% CO

0.027

0.055

0.082

0.110

0.137

0.164

0.082

0.137

0.164

Approx flue gas volume 120°C

at 120°C (248°F)

9.0% CO

116

174

232

290

384

174

290

348

248°F

Hydraulic resistance

kN/m

12.5

in.w.g.

Power consumption

watts

150

300

450

600

750

900

450

750

900

Flow tappings & Return tappings

Maximum static water head

200

Required water flow rate +/-10%

l/s

1.07

2.14

3.21

4.28

5.35

6.42

3.21

5.35

6.42

gal/m

14.1

28.2

42.3

56.4

70.5

84.6

42.3

70.5

84.6

Gas inlet connection

in. BSP

Min. dynamic gas pressure required

mbar (gauge)

15.0

at the boiler inlet for the rated input

in.w.g.

6.0

Electricity supply

230V ~ 50Hz single phase

Nominal flue size (to BS 835)

125

175

200

250

300

200

250

300

Diverter outlet socket

159

213

238

288

339

238

288

339

internal diameter

Weight modules

106

159

212

265

318

159

212

318

116

232

348

464

580

696

348

580

696

Weight casing / insulation

29.1

47.7

61.5

76.6

106.6

98.9

84.0

107.0

99.0

64.1

105.2

135.5

168.8

235.0

218.0

185.0

235.0

218.0

Weight gas / water headers

53.6

59.4

89.4

94.3

53.4

92.2

96.7

118

131

197

208

118

203

213

Water content

4.5

11.9

20.7

26.2

37.7

44.5

21.7

39.7

44.5

gal

1.0

2.6

4.6

5.9

8.3

9.9

4.9

8.8

9.9

Note: To obtain gas consumption in l/s, divide gross heat input (kW) by a calorific value of 37.8 (MJ/m

Note: Flange sizes to BS 4504: Part 1: Table 16.

general data