Concord
Super Series 4
Installation, Commissioning and
Servicing Instructions
50 to 600 Vertical and 250 to 600 Horizontal
Modular Gas Fired Boilers
Assembly and Installation Instructions for Ideal Concord Super Series 4 Modular Gas Fired heating boilers should be read in
conjunction with the general technical data tables enclosed.
CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of this appliance care should be taken
when handling edges of sheet steel components.
G.C. Appliance
Number
G.C. Appliance
Number
Concord Super Series 4
50 V
41 429 78
Concord Super Series 4
350 V
41 429 85
Concord Super Series 4
100 V
41 429 79
Concord Super Series 4
400 V
41 429 86
Concord Super Series 4
150 V
41 429 80
Concord Super Series 4
450 V
41 429 87
Concord Super Series 4
150 VA 41 429 81
Concord Super Series 4
500 V
41 429 88
Concord Super Series 4
200 V
41 429 82
Concord Super Series 4
550 v
41 429 89
Concord Super Series 4
250 V
41 429 83
Concord Super Series 4
600 V
41 429 90
Concord Super Series 4
300 V
41 429 84
Concord Super Series 4
450 H
41 429 91
Concord Super Series 4
250 H
41 429 92
Concord Super Series 4
500 H
41 429 94
Concord Super Series 4
300 H
41 429 93
Concord Super Series 4
550 H
41 429 95
Concord Super Series 4
600 H
41 429 96
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2
Concord Super Series 4 -
Installation & Servicing
CONTENTS
Assembly ..................................................................... 19
Commissioning and Testing ....................................... 22
Electrical Data ............................................................. 14
Exploded Diagrams ..................................................... 19
Combustion Data Sheet .............................................. 36
General ........................................................................... 2
Installation Requirements ............................................. 3
Technical Data ............................................................... 4
Boiler House Clearances .............................................. 6
Flue Requirements ........................................................ 7
Design Requirements ................................................. 12
Service & Fault Finding ................................................ 26
Cleaning ....................................................................... 27
Short List of Parts ....................................................... 33
INTRODUCTION
The Ideal Concord Super range of boilers is suitable for
connection to fully pumped, open vented or pressurised
central heating, indirect domestic hot water and combined
systems - in commercial and industrial premises.
Note. British Gas certification does not apply to pressurised
systems.
DUTY
The range of boiler is suitable for: combined indirect pumped
domestic hot water and central heating systems; independent
indirect pumped domestic hot water or central heating
systems.
Fully pumped systems may be open vented or sealed.
The range of boiler is NOT suitable for:
1. Gravity DHW systems.
2. Gravity heating systems.
3. Direct domestic hot water supply.
FOUNDATION
The boiler must stand on a non-combustible floor (i.e.
concrete or brick) which 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.
INSTALLATION REQUIREMENTS
IMPORTANT
GAS SAFETY (INSTALLATION AND USE) REGULATIONS, 1994
All gas appliances must, by law, be installed by competent
persons, e.g. CORGI in accordance with the above
regulations. Failure to install appliances correctly could lead
to prosecution.
It is in your own interest, and that of safety, to ensure that the
law is complied with.
In addition, the installation must comply with the relevant
British Standard Specifications and Codes of Practice:
IGE-UP-1
Purging Procedures for Non-domestic Gas
Installations and Soundness Testing Procedures
for Industrial and Commercial Gas Installations.
IGE-UP-2
Guidance for Installation of Gas Pipework
Boosters and Compressors for Customers
Premises.
BS. 6644
Installation of Gas Fired Hot Water Boilers of
Rated Inputs between 70kW and 1.8MW (net).
BS. 6880
Central Heating by Low Pressure Hot Water.
IGE-UP-10
Installation of Gas Appliances in Industrial and
Commercial Premises.
IM/22
Installation Guide for High Efficiency
(Condensing) Boilers (industrial and
Commercial Appliances).
Note: The Ideal Concord Super is a partially
condensing boiler therefore the condensate
drain should be run in accordance with IM/122.
BS. 5440:2
Specification for Installation of Ventilation for
Gas Appliances.
CP 342.2
Centralised Hot Water Supply.
Health and Safety Document No. 635.
The Electricity at Work Regulations 1989.
Note: All threaded gas and water connections must be sealed
using appropriate jointing compound.
GENERAL
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Concord Super Series 4 -
Installation & Servicing
GENERAL
3
BOILER DESCRIPTION
Each boiler consists of;
(a) The insulated stainless steel casing with flue outlet,
flue coupling point and condensate drain.
(b) The heat exchanger module(s).
(c) The module control pack.
(d) Wiring centre with high & low voltage wiring harnesses.
and in case of multi-module boilers;
(e) Gas header - complete with individual module gas
service taps and mains inlet gas tap.
(f) Flow and return water headers.
(g) Each boiler is supplied with instructions for installation
and use.
The 50kW boiler is supplied with a module gas service tap
only.
Each module is connected in parallel across the flow and
return water headers, ensuring that water is flowing
through all of the modules at all times.
The Ideal Concord Super range of boilers provides good
load matching & sequence control by the following method:
As the load on the boiler decreases so the return water
temperature increases.
Each module is fitted with an electronic thermostat
capable of being set to within 0.5
o
C. These thermostats
sense the return water temperature.
Once the flow temperature reaches 82
o
C (i.e. the return
reaches 71
o
C) the modules are set to switch off at
intervals to maintain the flow at 82
o
C ± 3
o
C.
With basic controls the modules switch off from left to
right and from top to bottom. Thus the top left module is
always the first to go off and the bottom right the last.
The standard wiring centre, on the side of the boiler, is
the connection point for the mains supply, the low gas
inlet pressure and low water pressure switches -
provided for boiler protection. The centre also provides
facilities for the wiring in (via voltage free connections)
of remote indicators/alarms, for `burner on', `lock out'
and `overheat'. (Indicating that at least one module is in
the signalled condition).
Facility is also provided for the connection of the `Boiler
Management System'. Additional controls such as water
flow switch, programmer, energy management systems
etc. may also be used.
MODULE DESCRIPTION
Each module can be sub-divided into 4 main elements:
(a) The heat exchanger, which consists of finned copper
tubes expanded into cast iron end plates, and cast iron
flow and return elbows (refer to Frame 15).
(b) The gas line, which supplies and regulates the gas flow
to the burner (refer to Frame 17).
(c) The fan assembly, which draws gas (from the injector)
and air, mixes them and supplies the mixture to the
burner. (Refer to Frame 16).
(d) The electrical control assembly.
MODE OF OPERATION
The normal mode of operation of the boiler is preceded, in
certain conditions, by a period in which the complete boiler
casing is given a three volume air change. The air change
is an important safety feature of the European
requirements, with which the boiler is designed to comply.
The air change will occur whenever the boiler goes from a
situation of no modules firing to a situation of one module
firing. This includes morning start-up and those occasions
of low load when the last module firing goes off on its
thermostat (or external controls) and is called again.
The air change will NOT occur if one or more modules are
firing and a further module is called.
The three volume air change period operates as follows, in
the case of multi-module boilers: All the module fans are
energised and run for a period of not less than 30
seconds. At the end of this period all the fans switch off.
After a delay of approximately 1 second, the fan of the
module being called begins its 15 second pre-purge
period. Refer to Frame 30.
In the case of single module boilers: only its own 15
second nominal prepurge period occurs.
When the electronic adjustable control thermostat calls for
heat, the fan is switched on and purges the combustion
chamber for 15 seconds. At the end of this time the ignition
sequence starts; the control box delivers a spark from the
ignition electrode to the burner and the gas valves are
opened.
Gas is delivered, via the injector, to the distribution plate at
the inlet to the fan. This pre-mixes the gas with the air
which then passes from the fan through a multi-hole plate
to the burner, where it is ignited. The flame is sensed via
the ionization electrode and the controls keep the valves
open until the thermostat is satisfied.
The module is protected against blockage of the burner,
heat exchanger or flue, and against fan failure by the gas/
air control. This senses the difference in pressure across
the multi-hole plate and controls the gas injector pressure
according to the amount of air flowing.
After combustion, the products flow past the finned copper
tubes and through the gas distribution screen into the
boiler casing. In doing so, heat is given up to the water
flowing through the tubes.
The installation must also conform to current building
regulations, any requirement of the local authority health
and safety executive, gas region, insurance companies
and the Health and Safety at Work Act 1974. All wiring
must conform to I.E.E. (BS. 7671) regulations for the
electrical equipment of buildings.
The boiler modules are very quiet in operation and no
additional noise soundproofing is required.
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Installation & Servicing
GENERAL
4
TECHNICAL DATA
Table 1
Notes.
* Flue gas volumes are calculated from a calorific
value of 38.4 MJ/m
3
(1,031 Btu/ft.
3
) at 15
o
C and
1.013 bar - based on a CO
2
content of 9.0%.
** For further information on minimum head
requirements refer to page 10.
Total weights of all headers, fully assembled.
The minimum gas supply pressure is with all modules firing.
Flange size; refer to BS. 4504.
For 150 VA, 250 V and 250 H models ONLY, a flue adaptor is
supplied as standard.
Boiler
50 V
100 V
150 V
200 V
250 V
300 V
150 VA
250 H
300 H
No. of modules
1
2
3
4
5
6
3
5
6
Heat output
kW
50
100
150
200
250
300
150
250
300
Btu/h x 10
3
170.6
341.2
511.8
682.4
853.0
1023.6
511.8
853.0
1023.6
Heat input
kW
58.8
117.6
176.4
235.2
294.0
352.8
176.4
294.0
352.8
Btu/h x 10
3
200.6
401.3
601.9
802.5 1003.1 1203.8
601.9
1003.1 1203.8
Gas rate
m
3
/h
5.5
11.0
16.5
22.1
27.6
33.1
16.5
27.6
33.1
ft.
3
/h
195
389
584
779
973
1168
584
973
1168
Flue gas mass
g/s
25
50
75
100
125
150
75
125
150
volume*
l/s
27
55
82
110
137
164
82
137
164
at 120
o
C (248
o
F)
ft.
3
/min
58
116
174
232
290
348
174
290
348
Required water
l/s
1.07
2.14
3.21
4.28
5.35
6.42
3.21
5.35
6.42
flow rate ± 10%
gal./min.
14.1
28.2
42.3
56.4
70.5
84.6
42.3
70.5
84.6
Hydraulic resistance
12.5 kN/m
2
(50 in w.g.)
Minimum static head**
2 m (6.5 ft.)
Maximum static head
60.0 m (197 ft.) 6.0 bar 85 lb/in
2
)
Electricity supply
230 V ~ 50 Hz,
Power consumption
W
90
180
270
360
450
540
270
450
540
Gas supply pressure
20.0 mbar (8 in. w.g.)
Boiler height
m m
782
1432
1912
1550
2060
2060
1550
1480
1480
(overall)
in.
30.8
56.4
75.3
61.0
81.1
81.1
61.0
58.3
58.3
Boiler width
m m
475
942
955
1425
1441
1441
1425
1817
1817
(overall)
in.
18.7
37.1
37.6
56.1
56.7
56.7
56.1
71.5
71.5
Boiler depth (overall)
698 mm (27.4 in.)
Weight of casing
kg.
29.1
47.7
61.5
76.6
106.6
98.9
84.0
107.0
99.0
and insulation
lb.
64.1
105.2
135.5
168.8
235.0
218.0
185.0
235.0
218.0
Weight of
kg.
53
106
159
212
265
318
159
212
318
modules
lb.
116
232
348
464
580
696
348
580
696
Weight of gas &
kg.
-
34.0
53.6
59.4
89.4
94.3
53.4
92.2
96.7
water headers
lb.
-
75
118
131
197
200
118
203
213
Water content
l.
4.5
11.9
20.7
26.2
37.7
44.5
21.7
39.7
44.5
boiler
gal.
1.0
2.6
4.6
5.9
8.3
9.9
4.9
8.8
9.9
Flow and return
m m
40
50
65
65
80
80
65
80
80
connection
in.
1
1
/
2
2
2
1
/
2
2
1
/
2
3
3
2
1
/
2
3
3
Gas connection
Rc
3
/
4
1
1
1
/
4
1
1
/
4
1
1
/
2
1
1
/
2
1
1
/
4
1
1
/
2
1
1
/
2
in. BSP
3
/
4
1
1
1
/
4
1
1
/
4
1
1
/
2
1
1
/
2
1
1
/
4
1
1
/
2
1
1
/
2
Flue pipe size
m m
125
175
200
250
250
300
200
250
300
(nominal bore)
in.
5
7
8
10
10
12
8
10
12
Flue socket size
m m
159
213
238
288
288
339
238
288
339
in.
6
1
/
4
8
3
/
8
9
3
/
8
11
3
/
8
11
3
/
8
13
3
/
8
9
3
/
8
11
3
/
8
13
3
/
8
Injector size
7.3 mm (0.28 in.)
Type of gas
Natural gas (G20 only)
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Concord Super Series 4 -
Installation & Servicing
GENERAL
5
TECHNICAL DATA
Table 2
Boiler
350 V
400 V
450 V 500 V
550 V 600 V 450 H
500 H
550 H 600 H
No. of modules
7
8
9
10
11
12
9
10
11
12
Heat output
kW
350
400
450
500
550
600
450
500
550
600
Btu/h x 10
3
1194
1365
1535
1706
1877
2047 1535
1706
1877
2047
Heat input
kW
411.6
470.4
592.2 588.0
646.8
705.6 529.2
588.0
646.8 705.6
Btu/h x 10
3
1404
1605
1806
2006
2207
2407 1806
2006
2207
2407
Gas rate
m
3
/h
38.6
44.1
49.7
55.2
60.7
66.2
49.7
55.2
60.7
66.2
ft.
3
/h
1363
1557
1752
1947
2143
2336 1752
1947
2143
2336
Flue gas mass
g/s
175
200
225
250
275
300
225
250
275
300
volume*
l/s
191
219
246
273
301
328
246
273
301
328
at 120
o
C (248
o
F)
ft.
3
/min
406
464
522
580
638
696
522
580
638
696
Required water
l/s
7.49
8.56
9.63
10.70
11.77
12.84 9.63
10.70
11.77 12.84
flow rate ± 10%
gal./min.
98.7
112.8
126.9 141.0
155.1
169.2 126.9
141.0
155.1 169.2
Hydraulic resistance
12.5 kN/m
2
(50 in w.g.)
Minimum static head**
2 m (6.5 ft.)
Maximum static head
60.0 m (197 ft.) 6.0 bar 85 lb/in
2
)
Electricity supply
230 V ~ 50 Hz,
Power consumption
W
630
720
810
900
990
1080
810
900
990
1080
Gas supply pressure
20.0 mbar (8 in. w.g.)
Boiler height
m m
1618
1618
2144
2144
2144
2144 1467
1467
1467
1467
(overall)
in.
63.7
63.7
84.4
84.4
84.4
84.4
57.8
57.8
57.8
57.8
Boiler width
m m
1822
1822
1833
1833
1833
1833 2393
2393
2393
2393
(overall)
in.
71.7
71.7
72.2
72.2
72.2
72.2
94.2
94.2
94.2
94.2
Boiler depth (overall)
1350 mm (53.1 in.)
Weight of casing
kg.
134
126
197
190
182
175
197
190
182
175
and insulation
lb.
295
278
435
418
402
386
435
418
402
386
Weight of
kg.
371
424
477
530
583
636
477
530
583
636
modules
lb.
818
935
1052
1168
1282
1402 1052
1168
1282
1402
Weight of gas &
kg.
260
263
311
313
315
318
298
300
302
304
water headers
lb.
573
580
686
690
694
701
657
661
665
670
Water content
l.
63.3
68.1
97.6
102.4
107.2
112
92.6
97.4
102.2
107
boiler
gal.
14.1
15.1
21.6
22.7
23.9
24.9
20.5
21.6
22.7
23.7
Flow and return
m m
100
100
125
125
125
125
125
125
125
125
connection
in.
4.0
4.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
5.0
Gas connection
Rc
2
2
2
2
2
2
2
2
2
2
in. BSP
2
2
2
2
2
2
2
2
2
2
Flue pipe size
m m
350
350
400
400
450
450
400
400
450
450
(nominal bore)
in.
14
14
16
16
18
18
16
16
18
18
Flue socket size
m m
400
400
450
450
501
501
450
450
501
501
in.
15
3
/
4
15
3
/
4
17
1
/
4
17
1
/
4
19
3
/
4
19
3
/
4
17
3
/
4
17
3
/
4
19
3
/
4
19
3
/
4
Injector size
7.3 mm (0.28 in.)
Type of gas
Natural gas (G20 only)
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Concord Super Series 4 -
Installation & Servicing
GENERAL
6
1
RECOMMENDED BOILER-HOUSE
CLEARANCES 50 - 300KW
2
RECOMMENDED BOILER-HOUSE
CLEARANCES 350 - 600KW
All dimensions in millimetres (inches)
All dimensions in millimetres (inches)
LOCATION
The floor must be flat, level, and capable of supporting the
weight of the WET boiler pipework. In addition concrete
floors must be sealed. The siting of the boiler must be in
accordance with the guidance given in BS. 6644 and with
reference to minimum boiler-house clearances. Refer to
Frames 1 & 2.
CONNECTION TO GAS SUPPLY
The gas installation MUST be in accordance with the
requirements of the local gas region (refer also IM/16).
The gas supply must be capable of maintaining a
minimum pressure of 15.0 mbar (6 in.w.g.) at the inlet to
the boiler, with all modules firing. Gas consumption is
given in Tables 1 & 2.
The boilers are for use with NATURAL GAS ONLY.
FLUE REQUIREMENTS
Open flue, induced draught and fan diluted systems may
be used but must comply with the following basic
requirements:
1. A draught diverter MUST NOT be fitted.
2. A draught stabiliser MUST be fitted to all types of flue
systems within 1 metre of the flue outlet and set to
control the draught in the casing between neutral and
0.2 mbar (0.08 in.wg.) irrespective of flue height or
number of modules firing. Refer to Frames 3 and 4 for
further guidance.
3. ALL flue systems must be insulated and/or lined and
impervious to acid condensate. Prefabricated
chimneys must have a 'U' value of no greater than 1.4
W/m
2
o
C at 540
o
C (0.25 Btu/h ft.
2
o
F at 1000
o
F.)
4. Drainage must be provided at the base of the chimney
or liner. All boiler casings are fitted with a condensate
drain point - refer to Frame 14.
5. For fan diluted or induced draught systems, air flow/
pressure switches MUST be fitted to protect against fan
failure. Switches should be set to open if the air flow
reduces by more than 15%.
6. Flue products must not be allowed to enter the boiler
house or adjacent buildings.
7. Refer also to BS. 6644 and to IGE UP/10 Installation of
Gas Appliances in Industrial and