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

Introduction

Caradon Ideal continue to lead the market with value for money

Pressure Jet boilers for commercial or industrial applications.

Ideal boasts the widest range of Pressure Jet boilers which provide

outputs from 21kW to 3500kW giving the customer a boiler for all

situations. They are designed to be compact in size yet extremely

powerful and efficient in performance, meeting all requirements at

both full load and part load for low emissions and high operating

efficiency (92-93% net efficiency).

All models are suitable for gas or oil firing, whilst dual fuel options

can be provided on selected models only. Comprehensive control

panels are provided with optional panels for high/low burner

operation available to minimise running costs.

The cast iron range from 21kW to 1450kW is designed to obtain the

largest heat exchange surface in the most space efficient size, yet

maintain long life and easy servicing. Low modulated temperature

operation down to 40°C allows more fuel savings.

The Vanguard L range of steel boilers from 130kW to 3500kW

provides an increased range of outputs, with careful combustion

chamber and flue tube design for robust long life. The compact,

reverse flame design is one of the narrowest available making access

easier.

All boilers have thick fibreglass insulation to minimise standing

losses, and installation is simple with `either hand' burner door

hinging and easy access to all connections.

The Pressure Jet range comprises two categories:

Cast Iron

Buccaneer GTE

21kW - 39kW

Falcon GTE

36kW - 102kW

Harrier GTE

105kW - 330kW

Viceroy GT

300kW - 780kW

Viscount GTE

754kW - 1450kW

Steel

Vanguard L

130kW - 3500kW

The Ideal Pressure Jet range - optimum power and optimum

performance.

Conforms with all relevant
European standards and
requirements

Performance

Tested and certified to EN303.1 the European standard

governing safety and performance of commercial and industrial

boilers, the CE approved Pressure Jet range offers high efficiency

performance. The approved efficiency of the range at full load is

approximately 92-93%. At 30% load, 94-96% (Vanguard 92-93%)

is achieved based on the net calorific value of the fuel. The Pressure

Jet range is also good for the environment, reducing both CO

and

NOx emissions.

The latest refinements ensure higher efficiencies at both full and

part loads to meet the new BUILDING REGULATIONS 2000.

Certification for this can be provided on request.

Construction

GTE Cast Iron range

Manufactured in robust cast-iron the sections are cast in full

form with a water cooled base. Sections incorporate moulded studs

to provide maximum heat exchanger surface for section size. Housed

within stove enamelled sheet steel casings, the boiler body is

assembled using slip nipples and held by tie rods.

Vanguard Steel Pressure Jet range

The Vanguard boiler is housed within a stylish silver-grey stove

enamelled sheet steel casing. The heat exchangers are manufactured

from high quality steel (Type S235 JR G2). The combustion chamber

is constructed with a reverse flame design which maximises

efficiency. The cylindrical combustion chamber is positioned into the

lower part of the boiler ensuring a completely wet surface below the

burner flame. The heat exchanger is designed so the the lower part

of the combustion chamber is free to expand and contract,

minimising stress.

The positioning of the combustion chamber also allows for a

great number of flue gas tubes to be concentrated in the higher part

of the heat exchanger thereby gaining the maximum heat transfer

and minimising resistance.

The flue gas tubes are specially designed to provide longer life

expectancy as they are constructed from 4mm thick steel, whereas

conventional steel boilers use only 2.9mm thickness tubes.

Turbulators are inserted into the flue tubes to slow down the flue

gasses and therefore increase efficiency.

A further feature of the tube design is that they have been

extended into the rear plate in order that any condensation formation

is quickly evaporated.

Maintenance is simple by the provision of boiler waterway

inspection covers and flushing points (above 1100kW models).

Boiler

Range

Certificate No.

Notified Body

Reference

Buccaneer GTE

4 - 6 Sections

49BM3528

AFNOR, Paris

0049

Falcon GTE

4 - 8 Sections

49AT2527

AFNOR, Paris

0049

Harrier GTE

5 - 9 Sections

49AQ950

AFNOR, Paris

0049

Viceroy GT

9 - 14 Sections

80142

Bureau Veritas Quality

ISO 9001

International - Paris

Viscount GTE

14 - 25 Sections

80142

Bureau Veritas Quality

ISO 9001

International - Paris

Vanguard L

130 - 3500

0461BN0688

Technigas, Belgium

ISO 9001

Insulation

Buccaneer GTE, Falcon GTE, Harrier GTE

A minimum of 100mm fibreglass wool insulation is provided

around the boiler body. Ceramic fibre insulation is used on burner

and cleaning doors.

Viceroy GT, Viscount GTE

A minimum of 100mm fibreglass wool insulation is provided,

140mm thick insulation surrounds the hottest parts of the boiler.

Vanguard L

A minimum of 100mm (80mm 170-480 models) thick mineral

wool fibreglass insulation surrounds the whole of the boiler body.

product specification

Electrical Controls

Quality

As with all Ideal boilers, the Pressure Jet range is engineered to

the highest quality standards. Ideal Boilers products meet or exceed

the requirements of all relevant standards. Before despatch each

boiler is fired and fully tested. Ideal Boilers are recognised as a

World Class Manufacturer.

assurance of quality

BS EN ISO 9001: 2000

Control panels are mounted on the front of the boiler casing and provide the following functions.

Boiler

Standard Panel

Mains on / off switch

Control thermostat

Overheat thermostat (with manual reset)

Boiler thermometer

Summer / Winter switch

Overheat thermostat test switch

High / Low thermostats

Circuit breaker

Fuse

Burner on / off switch

System pump switch

Burner lockout light

Flue gas thermometer

Hours run meter

De Luxe Panel (additional functions)

High / Low indicator lights

High / Low selection switch

Burner lockout light

Summer / Winter switch

Hours run (x2) meter

Flue Gas thermometer

O = Optional

Buccaneer GTE

30 - 90°C

(CH & DHW)

110°C

Falcon GTE

30 - 85°C

110°C

option

Harrier GTE

110°C

30 - 90°C

Viceroy GT

100°C

30 - 90°C

Viscount GTE

110°C

30 - 90°C

Vanguard L

100°C

30 - 90°C

Control Panel - Buccaneer GTE

Packing

Boiler

Casing & installation

Boiler body

Control panel

Accessories pack

Burner door

Tie rods

Baffles

Base frame

Cableway

Smoke hood

Document pack including flow switch

Burner (as specified)

Buccaneer GTE

Falcon GTE

Harrier GTE

Viceroy GT

(x2)

Viscount GTE

(x2)

Vanguard L

Boilers are supplied in the following packs:-

Burner

The Pressure Jet range are suitable for use with oil, gas or dual

fuel burners as previously noted - only on selected outputs. Nu-way,

EOGB and Riello burners can be supplied as standard. Burners from

other manufacturers can be supplied on request. Oil burners meet

BS 2869 Class D requirements for gas oil. Gas burners are suitable

for natural gas.

Details on LPG, dual fuel, modulating and low NOx burners are

available on request.

Burner Operation Availability

Boiler

Buccaneer GTE

Falcon GTE

Harrier GTE

Viceroy GT

Viscount GTE

Vanguard L

High / Low

(7 & 8 only)

On / Off

(420 max)

Duty

The Pressure Jet range provide central heating and indirect hot

water for a range of systems:

Open Vented Systems

All boilers

· Combined pumped domestic hot water and pumped central heating

· Pumped central heating only

· Pumped domestic hot water systems only

Pressurised or Sealed Systems

Fully pumped systems as above

Boiler

Buccaneer GTE

Falcon GTE

Harrier GTE

Viceroy GT

Viscount GTE

Vanguard L

Maximum static head

41 metres (135 feet)

61 metres (200 feet)

Maximum working pressure

4 bar (58psi)

6 bar (87psi)

product specification

Viceroy GT - Boiler Assembly - Exploded View

Flue outlet with

2 cleaning traps

accessible

without

dismantling the

casing

Plug for optional
drain cock

Large flue ways

with fins and

turbulators

offering a high

efficiency and a

very easy

maintenance

Eutectic cast iron

boiler body with

3 flue ways

Combustion

chamber largely

sized

Water return

flange

Complete
fibreglass

wool insulation,

100mm thick

Steel base frame

Geometry of the
front section very
well adapted for
the use of low
NOx burners

Silicon
thermocord
assuring flue
gas tightness

Insulation of the front panel:
fibreglass wool 100mm thick

Snap on burner connectors

compatible 2 stage,

delivered with de luxe

control panel and

standard panel

Pre-cut casing allowing
the fitting of the quick
opening valve

Removable
burner plate

Ceramic fibre insulated
burner door, from 80 to
140mm thick

Hinged burner
door (right hand
side or left
hand side)

Flame
inspection
windows
(1 right hand
side and 1 left
hand side)

Ceramic fibre
insulated
cleaning doors,
80mm thick

Fibreglass
wool insulated
front panel,
60mm thick

Hinged flue
way cleaning
doors (1 right
hand side and 1
left hand side)

Pocket for
sensors of
thermostats

Control panel designed for easy
access to wiring connections

Eutectic cast iron boiler body, particularly
resistant to thermal shocks and corrosion,

allowing low modulated temperature

operation and a total stop between 2

heating periods

Cast iron

turbulators

placed in the

boiler flue

ways

2 large wiring ducts

directly accessible

under top casings

Pre-set flow
switch

Water flow flange

Note: The view represents general boiler construction, jacket design will vary from that shown.

boiler assembly

The Pressure Jet range has a low minimum static head

requirement, depending on the particular characteristics of the

system design and boiler model. (see diagram).

The information provided is based on the following assumptions:

An independent open vent/safety pipe connection is made to the

redundant boiler flow tapping or is positioned immediately after the

system flow-pipe connection to the header, as shown.

An independent cold feed/expansion pipe connection is made to

the redundant boiler return tapping. Cold feed/expansion pipe

connections made to the system return will create an increase in

static head requirements, brought about by the additional resistance

of the distributor tube. Surging may also increase.

The maximum flow rate through the boiler is based on a

temperature difference of 11°C (20°F) at full boiler output with the

circulating pump positioned in the flow of the system.

The boiler is at the highest point of circulation in the system.

Systems designed to rise above the flow tappings will, of course,

automatically require a minimum static head higher than shown.

The position of the open vent/safety pipe above the expansion

cistern water level is given as a guide only. The final position will

depend upon particular characteristics of the system. Pumping over

of water into the expansion cistern should be avoided.

Cold Feed/Open Vent

The independent cold feed and the open vent must comply with

BS 6644.

Open Systems

system requirements

Particular reference should be made to BS 6644: Section 2;

Subsection 11 and Guidance note PM5 "Automatically controlled

steam and hot water boilers" published by the Health and Safety

Executive.

The information and guidance given below is not intended to

override any requirements of either of the above publications or the

requirements of the Local Authority, gas or water undertakings.

In general, commercial closed pressurised systems are provided

with either manual or automatic water make up.

In both instances it will be necessary to fit automatic controls

intended to protect the boiler circulating system and ancillary

equipment by shutting down the boiler plant if a potentially

hazardous situation should arise.

Examples of such situations are low water level and operating

pressure or excessive pressure within the system. Depending on

circumstances, controls will need to be either manual or automatic

reset. In the event of shut down, both visual and audible alarms may

be necessary.

Pressure vessels used must comply with BS 4814 and must

be sized on the basis of the total system volume and initial

charge pressure.

Initial minimum charge pressure should not be less than 0.5 bar

(7.2psi) and must take account of static head and specification of

the pressurising equipment. The maximum water temperatures

permissible at the point of minimum pressure in the system is

specified in Guidance Note PM5.

When make up water is not provided automatically it will be

necessary to fit controls which shut down the plant in the event of

the maximum system pressure approaching to within 0.35 bar (5psi)

of the safety valve setting.

Other British Standards applicable to commercial sealed systems are:

BS 6880: Part 2

BS 1212

BS 6281: Part 1

BS 6282: Part 1,

BS 6283: Part 4

Sealed (Pressurised) Systems

Installation

For safety, a competent installer must fit this appliance. All gas

fired appliances must be installed by a CORGI registered installer.

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, I.G.E.

publication UP/10 Installation of gas fired appliances in commercial

and industrial premises - Flues.

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.

Minimum clearances from walls or other fixed objects to allow

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

correct functioning of the draught diverters are shown in the boiler

clearance diagram.

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 shut-down or lock-out of the boiler(s) in the

event of inlet or extract air flow failing.

Commissioning

All burner units should be commissioned by a fully trained

burner engineer. if required, Ideal Boilers can arrange

commissioning.

Further details and prices are available on request.

Foundation

The boiler must stand on a non-combustible floor (ie concrete or

brick). This surface must be flat, level and of a suitable load bearing

capacity to support the weight of the boiler (when filled with water)

and any ancillary equipment. If the boiler is mounted on a plinth,

the dimensions must exceed the plan area of the boiler by at least

75mm (3") on each side.

system requirements

Water Treatment

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

due 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.

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 of the boiler and its associated systems.

The company advises direct contact with major water treatment

specialists such as BetzDearborn Ltd, Sentinel Division, Foundry

Lane, Widnes, Cheshire WA8 8UD Telephone: 0151 424 5351 or

Fernox, Fry Technology UK, Tandem House, Marlowe Way,

Beddington Farm Road, Croydon CR0 4XS Telephone: 01799

550811.

Flue Systems

Detailed recommendations concerning flue design for gas fired

appliances are contained in BS 6644, and I.G.E. publication UP/10.

BS 5410 Part 3 contains similar information on oil fired appliances.

These notes are for general guidance only and relevant standards

must be consulted for complete, detailed information.

The chimney and any associated flue connection must have a

cross section area at least equal to that of the smokehood outlet.

Flexible stainless steel liners should not be used for oil fired boilers

in the Pressure Jet range, unless a guarantee of suitability is

obtained from the flue liner manufacturer. The chimney must

generate the minimum smokehood draught requirement given in the

general data table.

Where chimney draught exceeds this requirement, gas fired

boiler installations can be fitted with a draught stabiliser. Care

should be taken when positioning such a stabiliser as its operation

may have side effects, such as burner pulsation, if it is sited where

air turbulence may occur. Installation of draught stabilisers with oil

fired boilers is not recommended because it can cause condensation

and smutting. Ideal Boilers recommends installation of modulating

motorised dampers to provide the most efficient draught control for

oil or gas fired boilers.

Use of a chimney outlet nozzle should be considered if an

increase in gas velocity is required. Discharge velocity should not

exceed 4.9 metres per second (15 feet per second) if used with a

natural draught chimney. If higher discharge velocities are required

use of an induced draught fan should be considered. Care must be

taken to ensure excessive back pressure does not occur when the

boiler fires as this may cause pulsation and lock out of the boiler

control box.

The shortest possible horizontal flue pipe run, connecting the

boiler to the chimney, should be used and bends should be restricted

to a minimum. Sharp 90° bends or tees should not be used.

Whenever possible 90° sweep bends together with 135° bends and

tees should be used.

Chimney termination point should be sited to avoid the risk of

downdraught and should terminate at least 1 metre (3 feet) above

the ridge of the building roof. The possible effect of adjacent

structures upon chimney draught must also be considered. GLC,

GCI, or similar vent terminals are primarily designed for use with

natural draught appliances and are not suitable for boilers in Ideal

Boilers Pressure Jet range.

Exposed chimneys must be adequately insulated to maintain

buoyancy and restrict corrosion. External flue pipes should be well

insulated throughout their length and be designed to offer the

minimum resistance to the flow of flue products. Flue pipe

connections between boiler and chimney must terminate flush with

the inside of the chimney. Existing chimneys should be swept and

brought up to the required standards before the boiler is connected.

Oversize steel chimneys should not be used without a suitably

sized insulated liner of material specification suitable for the flue

being used. Existing brick chimneys should also be lined and

insulated as recommended above.

Buccaneer GTE

Model

GTE 4

GTE 5

GTE 6

No. of sections

Maximum heat output

Btu/h x 10

92.1

112.6

133.1

Minimum heat output

Btu/h x 10

71.7

92.1

112.6

Boiler water content

24.5

35.5

gal

5.4

6.6

7.8

Hydraulic resistance at 11K

mbar

5.3

7.9

10.9

in.w.g.

2.1

3.2

4.4

Hydraulic resistance at 20K

mbar

1.6

2.4

3.3

in.w.g.

0.6

1.0

1.3

Combustion chamber

mbar

0.23

0.22

resistance

in.w.g.

0.01

Boiler DRY weight less

162

187

213

burner unit

357

412

470

Gas firing data

Maximum gas rate

3.10

3.79

4.47

109.4

133.8

158.1

Maximum flue gas volume

/sec

0.019

0.026

0.027

/min

Maximum flue gas temperature

9% CO

180°C

190°C

Oil firing data

Maximum oil rate

l/h

3.11

3.8

4.49

gal/h

0.69

0.84

0.99

Maximum flue gas volume

/sec

0.017

0.022

0.025

/min

Maximum flue gas temperature

12% CO

180°C

190°C

Minimum Flow Rates

Normal water flow rate temperature

l/s

0.586

0.717

0.847

difference 11°C (20°F)

gal/min

7.74

9.46

11.18

Mimimun water flow rate temperature

l/s

0.184

0.225

0.266

difference 35°C (63°F)

gal/min

2.43

2.97

3.51

All temperatures are above ambient.

Note: Fuel rates and flue gas data relate to maximum output ratings. Gas firing data relates to the use of NATURAL GAS ONLY.

Details for the use of LPG are available on request from Ideal Boilers Limited. The gas rate at calorific values differing from the standard quoted above may

be calculated by direct proportion CALORIFIC VALUE: 38.5 MJ/m

(1,035 Btu/ft

general data