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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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.
Gas Safe Registered Engineer
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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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 Commercial
Premises and IM/22 for further guidance.
AIR SUPPLY
Detailed recommendations for air supply are given in BS.
5440:2 and BS. 6644 which MUST be consulted before
proceeding.
Contamination of the air supply from any external source
must be avoided, with particular reference to dust,
insulation debris and flue products. Concrete floors must
be sealed. If any work is to be carried out in the boiler-
house which is likely to generate dust (e.g. structural
alterations or the lagging of pipework) it is recommended
that the boiler is shut down and the modules covered with
a dust sheet, otherwise the boiler will require cleaning and
servicing.
1. In particular, the contamination of the air supply with
chlorides must be avoided as they will cause the
deterioration of the aluminium fan impellor.
2. The boiler-house requires ventilation openings at
BOTH high and low levels, direct from the outside.
Allowances MUST be made for stabiliser dilution in all
cases.
3. Mechanically forced ventilation systems must include
provision for boiler shut down in the event of fan failure.
4. High speed air streams within the boiler house must
be avoided.
5. Extraction mounted ventilation fans alone are NOT
permitted.
6. The minimum effective areas of the permanent air
vents direct from the outside by natural ventilation are
as follows:
BOILER HOUSE CLEARANCES
Required area (cm
2
) per kW of total rated input (net)
Boiler room
Enclosure
Low level (inlet)
4
10
High level (outlet)
2
5
Note: Where a boiler installation is to operate in summer
months (e.g. DHW) additional ventilation requirements
are stated, if operating for more than 50% of time (refer
to BS6644).
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Concord Super Series 4 -
Installation & Servicing
GENERAL
7
FLUE REQUIREMENTS
3
APPLICATION OF DRAUGHT STABILISER - SINGLE BOILER INSTALLATION
Note: The discharge from both types of system MUST
not allow recirculation of combustion products into
the boilerhouse or adjacent buildings.
Note: Air intake and discharge should be on the
same outside wall face. Design must comply with
British Gas requirements -refer page 5 and
Publication IM/11.
All dimensions in millimetres (inches)
Notes:
The draught at the boiler casing must be controlled
between neutral and 0.2 mbar (0.08 in. w.g.) negative
irrespective of the number of modules firing. The draught
stabiliser must be fitted within 1 metre of the boiler casing.
4
FLUEING - GENERAL GUIDANCE BOILER INSTALLATION
To achieve the minimum neutral draught condition a vertical
flue length of 2 metres is needed plus whatever extra height
is necessary to overcome the resistance of any bend or duct
work between the boiler casing and the vertical flue.
Contact should be made with the Customer Care department o
f
Ideal Stelrad Group
for further advice and information on this subject.
All dimensions in millimetres (inches)
FAN DILUTED FLUE (FDF) SYSTEM
INDUCED DRAUGHT
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Concord Super Series 4 -
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GENERAL
8
DIMENSIONAL DATA
5
BOILER DIMENSIONS 50KW - 150KW MODELS
All dimensions in millimetres (inches)
fp = Foot Projection
gc = Gas Connection
50kW V
ertical
100kW V
ertical
150kW V
ertical
150kW V
ertical/Alternative
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Concord Super Series 4 -
Installation & Servicing
GENERAL
9
DIMENSIONAL DATA
6
BOILER DIMENSIONS 200KW - 300KW MODELS
All dimensions in millimetres (inches)
fp = Foot Projection
gc = Gas Connection
rc = Return Connection
200kW
V
ertical
250kW / 300kW V
ertical
250kW / 300kW Horizontal
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Concord Super Series 4 -
Installation & Servicing
GENERAL
10
DIMENSIONAL DATA
7
BOILER DIMENSIONS 350KW - 600KW MODELS
All dimensions in millimetres (inches)
gc = Gas Connection
350kW - 400kW V
ertical
450kW - 600kW V
ertical
450kW - 600kW Horizontal
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Concord Super Series 4 -
Installation & Servicing
INSTALLATION
11
DIMENSIONAL DATA
8
SITE ASSEMBLY - 600kW Vertical Boiler
Note.
1. To aid the assembly procedure, on the flow &
return manifolds and the flow & return spools,
the flanges are left loose for site welding.
2. The double M/F elbows (16) are to enable ease
of fit and squareness.
LEGEND
1. Insulated boiler casing (c/w feet).
2. 80 nom. bore elbow.
3. Flow manifold (long).
4. Flow and return headers.
5. Flexible bellows unit.
6. Blank flange.
7. Gas header complete with gas cocks.
8. Rc 1
1
/
2
union elbows.
9. Space nipple.
10. Flow and return spools.
11. Rc1
1
/
2
elbow.
12. Space nipple.
13. Short space nipple.
14. Main gas cock (not shown).
15. Rc 2 twin elbow (with two hex bushes).
16. 1
1
/
2
M/F elbow.
17. Return manifold (short).
9
SITE ASSEMBLY - 600kW Horizontal Boiler
Note.
1. To aid the assembly procedure,
on the flow & return manifolds
and the flow & return spools, the
flanges are left loose for site
welding.
2. The double M/F elbows (12) are
to enable ease of fit and
squareness.
LEGEND
1. Insulated boiler casing (c/w feet).
2. 125 nom. bore elbow.
3. Flow manifold (long).
4. Flow and return headers.
5. Flexible bellows unit.
6. Blank flange.
7. Gas header complete with gas
cocks.
8. Rc 1
1
/
2
union elbows.
9. Short space nipple.
10. Main gas cock (not shown).
11. Rc 2 twin elbow (with two hex
bushes).
12. 1
1
/
2
M/F elbow.
13. Return manifold (short).
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Concord Super Series 4 -
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GENERAL
12
DESIGN REQUIREMENTS
7. The minimum air requirements by mechanical
ventilation are as follows:
A purpose designed flueing ventilation system based solely
on a high level permanent opening to an otherwise sealed
boiler-house or compartment may be used, provided that
specialist advice is taken, and that the combustion air and
ventilation requirements of the boiler is provided in line with
BS6644. In addition to this, the boiler house temperature
must be prevented from exceeding 32°C at mid-level.
BS6644 provides details of temperature requirements.
WATER CIRCULATION SYSTEM
DESIGN REQUIREMENTS
Ideal Concord Super gas boilers are intended for use in
conjunction with FULLY PUMPED, OPEN VENTED or
PRESSURISED systems - subject to the requirements
detailed below. They are NOT suitable for use on gravity
circulation systems.
Water Flow Rate
1.07 l/s (14.1 gal/min) ± 10% through each module.
Thus a six module boiler requires 6.42 l/s (84.6 gal/min)
volume flow rate. Refer to Tables 1 & 2 for other boilers.
Note. Failure to maintain this flow rate will result in
operation of the module overheat cut off device.
The boilers are suitable for operation when connected to
systems requiring lower flow rates than those quoted above
and to systems where the volume flow varies with load,
PROVIDED they are installed in accordance with Frame 10.
Any other method of installation should be discussed with
Ideal Stelrad Group
before proceeding.
Hydraulic Resistance - refer Graph 1
When operating at the correct volume flow rate given above,
the hydraulic resistance of all Ideal Concord Super boilers
is 12.5 kN/m
2
(50 in.w.g.).
Pump Over-run
A pump over-run time of 30 seconds minimum must be
allowed for on plant shutdown.
Maximum Static Head
60m (197 ft.), i.e. maximum operating pressure 6.0 bar (85
Ib/in
2
).
Minimum Static Head
Minimum static head requirements for open vented
systems must comply with boiler design characteristics,
pump manufacturer's requirements and the requirements
of the Health and Safety executive Publication PM5.
In order to comply with the above, a minimum static head of
2m (6.5 ft), i.e. 0.20 bar (3 lb/in
2
) will be adequate under
most operating conditions, measured either from the
highest circulating point of the system or from the boiler
when the boiler house is roof mounted.
Type of boiler
Flow rate per kW total rated
heat input (net)
Inlet air
Extract air
(combustion
(ventilation)
ventilation)
Forced/induced
2.6 m
3
/h
1.25 m
3
/h
draught boilers
±0.18m
3
/h
Table 3 - MECHANICAL VENTILATION FLOW RATES
Note. In some cases, pump manufacturers will require a
head as high as 12m (40ft). This must be allowed for and
the minimum head increased accordingly. Refer to Frame
10 for further clarification.
Safety Valve
A safety valve must be sized and fitted in accordance with
BS. 6644. The valve should be set at 0.7 bar (10 lb/in
2
)
above the available static head of water over the boiler.
The maximum safety valve setting is 0.7 bar (10 lb/in
2
)
above the maximum design operating head of 6.0 bar (85
Ib/in
2
), i.e. 6.7 bar (95 Ib/in
2
).
Table 4 - VENT, COLD FEED
The open vent and cold feed pipe sizes must comply with
BS. 6644 and must be of the following minimum size.
Boiler
Cold feed
Open vent
nominal dia.
nominal dia.
50 V
19 mm
25 mm
100 V, 150 V
25 mm
32 mm
200 V, 250 V, 300 V
32 mm
38 mm
150 VA
25 mm
32 mm
250 H, 300 H
32 mm
38 mm
350 V - 600 V
38 mm
50 mm
450 H - 600 H
38 mm
50 mm
Drain
The drain valve must comply with BS. 2879 and be
operated with a removable key.
Pressure Gauge
The water pressure gauge and temperature gauge must
the fitted in accordance with BS. 6644.
Water flow switch
A water flow switch must be fitted to protect the boiler from
pump failure.
Graph 1 - HYDRAULIC RESISTANCE
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Concord Super Series 4 -
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GENERAL
13
DESIGN REQUIREMENTS
Frame 10 is intended to provide basic information only on
the application of the Ideal Concord Super boiler. British
Gas approval has not been sought in the matter.
It is impossible to cover all applications and installers are
recommended to contact
Ideal Stelrad Group
if advice on a
specific application is required.
It is essential that the water flow rates given in Tables 1 & 2
be maintained within the limits stated - therefore any
compensating devices must not be connected to Ideal
Concord Super boilers directly but may be used in
conjunction with a mixing header. The mixing header must
be sized at least one pipe size larger than the boiler flow
and return manifold size. This will avoid hydraulic
interference between the boiler primary pump and system
zone pumps. The use of a mixing header means that
compensating controls can be used to operate mixing
valves on a variable temperature circuit, without affecting
the water flow rate through the boiler.
GENERAL GUIDANCE ON APPLICATIONS
10 GUIDE TO MINIMUM REQUIREMENTS FOR OPEN VENT - Feed / Expansion Tank
Height and boiler Primary Circuit
1. Roof top or single storey applications.
LEGEND
1. Cold Feed
(sizes MUST comply
with BS. 6644).
2. Open vent. (sizes MUST
comply
with BS. 6644).
3. Safety valve.
4. Water flow switch.
5. Dual primary pumps.
6. Mixing header
- see note above.
7. Feed and expansion tank.
8. Mixing valve.
9. Highest point in
the system.
All dimensions in millimetres (inches)
2. Ground floor or basement applications.
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Concord Super Series 4 -
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GENERAL
14
ELECTRICAL DATA
Frame 10 shows how constant and variable temperature
circuits can be used on low and high head applications.
The following points should be noted:
1. The recommended positions of the cold feed and open
vent are shown. Sizes should comply with BS. 6644. If
isolating valves are to be fitted in the flow and return
pipes of the boiler they must not isolate the boiler from
the open vent, safety valve or cold feed.
2. The minimum tank height shown is measured from the
highest point of the system and must be increased, if
necessary, to comply with pump manufacturers'
requirements.
3. The open vent height above tank water level cannot be
guaranteed adequate in all circumstances and does not
take into account any instantaneous changes in head
brought about by ancillary equipment operating.
4. Water flow switch is shown in its recommended position. It
MUST NOT be located on the mixing header where
operation of zone pumps can cause reduction in flow.
5. Production of condensate: When operating normally
and the design return temperature has reached 71
o
C.,
the boilers produce no condensate. At lower
temperatures the amount of condensate increases. It is
normal for condensate to be produced as the boiler
heats up from cold and, provided the time taken for the
return to reach 71
o
C. is not excessive, no harm will
result. If, however, large quantities of condensate are
produced for long periods, this can adversely affect
burner performance and cause the control box to
lockout. If the water content of a system is very large it is
advisable to switch on individual zones from cold, in
sequence, with a time delay sufficient to allow the boiler
return temperature to reach 55
o
C as quickly as
possible.
6. Water treatment for hot water and heating boilers.
There is a basic need to treat the water contained in all
heating and indirect water systems, particularly open
vented systems. This may be regarded as an essential
requirement for systems incorporating Ideal Concord
Super boilers. It is assumed, incorrectly, that because
boilers are operating in conjunction with what is
apparently a 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 up a few
times.
This is not the case. Open vented systems are not
completely sealed off from the 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 as the system heats up.
Conversely, as the system cools, water is drawn back
from the tank into the system, together with a quantity of
dissolved oxygen. Also there will be evaporation losses
from the surface of the tank which, depending on
ambient temperature, maybe high enough to evaporate
a large portion of the system water capacity over a full
heating season. For these reasons, even if the system
is completely free from leaks, there will always be
corrosion or salt deposition within a heating or hot water
system, irrespective of water characteristic unless the
initial fill water from the mains is treated. 1mm of lime
reduces the heat transfer from metal to water by 10%.
Lime deposition can also cause noises from the boiler
body or even premature failure. Corrosion and the
formation of black iron oxide sludge will ultimately result
in premature radiator and pump failure
Existing systems and, where necessary, new systems
should 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 exchangers of the boiler and associated systems.
Ideal Stelrad Group
, advise contact directly with specialists
on water treatment, such as:
Fernox, Cookson Electronics,
Forsyth Road, Sheerwater, Woking,
Surrey, GU21 5RZ
Tel. +44 (0) 1799 550811
or
G E Betz, Sentinel Division,
Foundry Lane, Widnes, Cheshire, WA8 8UD
Tel. +44 (0) 151 420 9563
ELECTRICAL SUPPLY
230 V - 50 Hz. Consumption: 90W per module (excluding
remote alarms etc.)
Note. External wiring and any installer-supplied remote
warning lights MUST be in accordance with the I.E.E. (BS.
7671) regulations and any local regulations which apply.
The method of connection to the mains supply should
facilitate complete electrical isolation of the boiler.
Connection should be made via a fused double pole
switch or fused spur box, serving the boiler only, and
incorporating contacts with a separation of at least 3 mm in
all poles. The point of connection should be readily
accessible and adjacent to the boiler.
The length of the power supply conductors between the
cable anchorage and the terminals must be such that the
current conductors become taut before the earth conductor,
if the cable slips out of the cable anchorage.
The water flow switch and any other overriding safety
devices should be wired in series with the isolation mains
supply to the boiler.
50 kW SINGLE MODULE BOILERS ONLY (Frame 11)
50 kW boilers are supplied with a multi-pin plug for
connection to the mains, as follows:
EARTH .................... Terminal 1
LIVE ......................... Terminal 2
NEUTRAL ............... Terminal 4
Link betweenTerminals 6 & 8 ....... by installer
5
4
3
2
8
1
7
6
con
6
111
11 MULTI-PIN PLUG WIRING FOR
SINGLE MODULE BOILER ONLY
Legend:
Terminal 1 - EARTH (Green/Yellow)
Terminal 2 - LIVE (Brown)
Terminal 4 - NEUTRAL (Blue)
Terminal 6 - linked to Terminal 8 by installer
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Concord Super Series 4 -
Installation & Servicing
GENERAL
15
ELECTRICAL DATA
12 WIRING FOR MULTI-MODULE BOILERS & SINGLE MODULE BOILERS FITTED
WITH A WIRING CENTRE
For boilers larger than 300kW
Two wiring centres, as shown in Frame 12, are supplied fitted one each side of the boiler case.
It is important to ensure that the electrical wiring takes this factor into account.
Each wiring centre can accommodate up to six modules.
LEGEND
PCB - Printed circuit board
b - blue
bk - black
br - brown
r -red
y -yellow
w -white
g/y - green/yellow
or - orange
v -violet
pk - pink
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Concord Super Series 4 -
Installation & Servicing
GENERAL
16
ELECTRICAL DATA
13 50KW MODULE WIRING
LEGEND
br -
brown
b -
blue
r -
red
g -
grey
v -
violet
pk -
pink
y -
yellow
w -
white
or -
orange
bk -
black
g/y -
green/yellow
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Concord Super Series 4 -
Installation & Servicing
ASSEMBLY
17
PACKAGING
The boiler casing is supplied complete with insulation and
feet, strapped to a packaging base and shrink-wrapped.
Boilers up to and including 150kW will have their water and
gas headers packed and shrink-wrapped with the casing.
Boilers of 200kW and above will have their water and gas
headers supplied on a pallet, shrink-wrapped. The water
header bellows units, flanges, gaskets etc., will be packed
in cartons in the bottom of the casing. The modules are
supplied individually packed on a packaging base.
FOUNDATION
An insulated foundation is NOT necessary, as the bottom of
the boiler casing will not exceed a temperature of 80
o
C.
(176
o
F.).
The foundation MUST be flat and level, fireproof, dust free
and capable of supporting the weight of the WET boiler.
CASING AND DRAIN CONNECTION
A 22 mm copper street elbow is supplied in the water
header hardware pack, for connection to the casing drain
point. This elbow can be fitted in any direction and the
compression nut tightened. A suitable drain should be
connected to the elbow. Refer to Frame 14.
Note. Condensation will only occur on warming up, when
the return water temperature is below 55
o
C. (131
o
F.) - the
water dew point.
The boiler casing can now be placed in position.
N.B. EXTREME CARE MUST BE TAKEN WHEN HANDLING
THE CASING, WHICH IS FITTED WITH AN ALUMINIUM
FACED, INSULATING CLADDING. THIS CLADDING CAN BE
KEPT CLEAN BY WIPING WITH A DAMP CLOTH.
ASSEMBLING THE MODULE AND WATER HEADERS
TO THE BOILER CASING (REFER FRAMES 8, 9 & 14).
WARNING:
CRACKING MAY OCCUR IF THE FLOW AND RETURN
MODULE CASTINGS ARE OVER-STRESSED.
The following procedure is to be adopted:-
1. Ensuring all cables are held clear and with the module
cover removed, fit the module(s) to the casing but do
NOT tighten the four fixing nuts.
2. For boilers over 150kW ONLY:
Screw the flanged bellows unit into the internally
threaded branches of the water headers, using a wrench
on the hexagon at the end of the bellows to tighten in
position. When tight, the flange on the bellows should
finish approximately 470 mm (18
1
/2 in.) away from the
fixed flanges, with the flange holes in a vertical and
horizontal attitude - refer frame 14.
UNDER NO CIRCUMSTANCES MUST THE FLANGE OR
BELLOWS BE USED FOR TIGHTENING
3. Secure the flow and return water headers to the modules
(rigid flanges first) using the gaskets and screws provided,
and taking adequate precaution to support the headers
during assembly.
For 150kW ALTERNATIVE and 250kW V boilers only
Ensure that the flange support bracket is fitted to the water
header and module blanking plate.
Note: Care should be taken to avoid damage to the
bellows units whilst tightening the screws securing the
bellow flanges.
GAS HEADERS 100kw - 150kW boilers only:
Remove the adaptors from the flexible gas hoses and
screw them to the elbows on the individual modules.
Offer up the gas header by lowering over the projecting
studs on the water flow header so that the gas inlet
pressure test point is at the top. Fasten with the nuts and
washers provided.
Assemble the flexible hoses to the gas header and the
individual modules, ensuring all connections are tight.
150kW A and boilers over 150kW
Remove the adaptors from the short flexible gas hoses
and one of the adaptors from the long flexible gas hoses.
Then assemble them to the elbows on the individual
modules.
Remove the other adaptors from each of the long flexible
gas hoses and fix them to the appropriate cocks on the
gas header. (horizontal cocks on vertical models and
vertical cocks on horizontal models). Then screw the long
flexible gas hoses back onto the adaptors.
Screw the short flexible gas hoses to the appropriate gas
cocks on the gas header (vertical cocks on vertical models
and horizontal cocks in horizontal models).
Offer up the gas header so that it locates over the
projecting studs on the water flow header and the gas inlet
pressure test point is at the right hand end (horizontal
boilers) or at the top (vertical boilers). Fasten with the nuts
and washers provided.
Assemble the flexible gas hoses to the adaptors ensuring
all connections are tight.
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Concord Super Series 4 -
Installation & Servicing
ASSEMBLY
18
ELECTRICAL DATA
CONNECTING BOILERS TO THE FLUE SYSTEM
Details of the flue design are in Frames 3 and 4. Boiler
socket and flue pipe sizes are indicated by Tables 1 & 2.
WATER CONNECTIONS AND PRESSURES
Refer Installation Requirements.
All service pipework linking the flow and return headers
must be adequately supported, so that no strain is
imposed upon them.
Allowance must be made for any additional service
pipework expansion.
Provision is made for draining the boiler by an adaptor on
the model 50V, a tapped flange on models 250/300H and
450/600H, and tappings in the water headers of other
models.
Note. Care should be taken when fitting the adaptor or
tapped flanges to ensure that the drain tapping is at the
underside or lowest point respectively.
Additional drain points may also be required at the lowest
points in the system.
A safety valve MUST be fitted.
The valve should be set at 0.7 bar (10 lb/in
2
) ABOVE the
available static head of water over the boiler, or the design
operating pressure of the system - whichever applies.
If isolating valves are fitted in the flow and return pipes to
the boiler they must NOT isolate the boiler from the open
vent safety valve or cold feed.
The maximum safety valve setting is 0.7 bar (10 lb/in
2
)
above the maximum design operating head, or pressure of
the boiler - 6.0 bar (85 lb/in
2
).
ELECTRICAL CONNECTIONS (refer Frames 12 & 13)
a) Each module
Undo the two M4 screws on the right hand side of the
control box and swing the front control panel out.
b) 50kw single module boiler only:
Fit the prewired low voltage 10-way plug (supplied in the
hardware pack) into the socket at the top RH corner of
Board No. 28. Note that it will fit only one way round, with
the clip to the outside. Do not change or remove the factory-
fitted link wires. Refer to Page 16, Frame 13 for mains
connections details.
c) All multi-module boilers:
Pass the low voltage 10-way plug through the grommetted
hole in the rear control panel and fasten it to its socket on
Board No.28. Note that it will fit only one way round, with the
clip to the outside. Secure the wires to the 3 cable clips on
the control panel support bracket, ensuring that the wires
are not trapped by the clip. Connect the module mains
plug. Repeat for other modules.
Undo the four M4 screws and lift off the cover over Board
No. 30 on the boiler casing fight hand side.
Feed the mains incoming wire through the bottom cable
clamp. Connect the live, neutral and earth wires to the
terminal strip on the bottom.
The water flow switch and any other over-riding safety
devices should be wired in series with the isolation mains
supply to the boiler.
Secure the cable using the cable clamp and refit the board
cover.
All boiler sizes
Finally tighten the four brass fixing nuts on each module
and fit the module casings, securing them by the two M6
screws.
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Concord Super Series 4 -
Installation & Servicing
ASSEMBLY
19
EXPLODED DIAGRAMS
14 BOILER ASSEMBLY - Exploded View (300kW Vertical Boiler Shown)
LEGEND
1. Flue sampling point.
2. Wiring centre.
3. Water header.
4. Gas pressure test point.
5. 50kW module.
6. Module cover.
Note.
M12 flange bolts must be fitted pointing away from
the module for the outer connections and pointing
towards the module for the inner connections.
DETAIL OF DRAIN ASSEMBLY
DETAIL OF GAS HEADER FLEXIBLE HOSES
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Concord Super Series 4 -
Installation & Servicing
ASSEMBLY
20
EXPLODED DIAGRAMS
15 MODULE ASSEMBLY - Exploded View
LEGEND
1.
Control chassis assembly
.
2.
Multi-hole plate and cork gaskets.
3.
Safety temp. limiter pocket.
4.
Square to round casting.
5.
Ignition electrode.
6.
Burner cork gasket.
6A.
Burner fibre gasket.
7.
Flow header
.
8.
Flow header gasket.
9.
Burner
.
10.
T
op cover plate.
11
.
Cover plate gasket.
12.
T
op tube plate.
13.
Gas distribution screen.
14.
Finned copper tubes.
15.
Bottom tube plate.
16.
Cover plate gasket.
17.
Bottom cover plate.
18.
Sight glass.
19.
Flame sensor
.
20.
Return header gasket.
21.
Return header
.
22.
Gas / air control.
23.
Gas valve.
24.
Fan assy
.
25.
Thermostat pocket.
Note.
Items 22 & 23 supplied
as
an assembly
.
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Concord Super Series 4 -
Installation & Servicing
ASSEMBLY
21
EXPLODED DIAGRAMS
16 ELECTRICAL CONTROLS - Exploded View
LEGEND
1. LED's.
2. Lockout reset button.
3. PCB No. 28.
4. Safety temperature limiter.
5. Mains socket.
6. Fan motor.
7. Fan impeilor.
8. Fan scroll.
8a. Fan gasket.
9. Flame sensing lead.
10. Ignition lead.
11. PCB No. 29.
12. On/Off switch.
13. Thermostat knob.
17 GAS LINE
LEGEND
1. Injector washer.
2. Injector.
3. Gas outlet pressure test point.
4. Gas/air suction pressure test point.
5. Iron elbow - gas connection.
6. Gas/air control.
7. Gas Inlet pressure lest point.
8. Gas valve.
9. 4 mm Sensing lines.
Note. Items 6 & 8 supplied as an assembly.
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21
Concord Super Series 4 -
Installation & Servicing
COMMISSIONING AND TESTING
22
The Ideal Concord Super boiler must be commissioned
and tested by a qualified gas/heating engineer. A
knowledge of electrical wiring is necessary.
Upon request,
Ideal Stelrad Group
, will provide a quote for
commissioning or re-commissioning after servicing.
Make sure that the electrical supply to the boiler is OFF at
the main isolator switch. Remove the orange module
covers. Check that the black mains voltage plug on the left-
hand side of each module is pulled out.
FILLING THE BOILER WITH WATER
Fill the system by admitting water at the lowest point. This
will ensure air is forced from the tubes of the heat
exchangers.
WATER CIRCULATION
Switch on the pump motor and check that water is
circulating and the pump is vented.
Check the operation of the water flow switch. It should
switch off the electrical supply to the modules if the water
flow rate fails below two-thirds of design water flow-rate (in
Tables 1 & 2).
HEADER GAS SOUNDNESS & PURGING THE GAS LINE
Turn the top module gas service tap ON. Connect a
manometer to the tapping point at the top of the gas
header (see Frame 14 & PTP1 - Frame 29).
Slacken the nut on the union, connecting the top module to
the gas header, and purge the gas header by turning the
mains inlet gas tap on until gas is smelt then re-tighten the
union connection.
Turn off the top module gas service tap and ensure all
other module gas service taps are in the off position. Take
note of the manometer reading and turn off the mains inlet
gas tap. A subsequent fall in pressure indicates a leak
between the mains inlet gas tap and individual module
gas service taps which MUST be made good.
The mains inlet gas tap can then be turned on again.
CONTROL LINE GAS SOUNDNESS (Frames 14,17 & 29)
Carry out the following test on each module in turn:
1. Turn on the module gas service tap.
2. Turn off the mains inlet gas tap, and observe the
manometer pressure as above. This pressure should
NOT fall by more than 2.5 mbar (1 in.w.g.) in one
minute. If this rate of fall is exceeded, leakage past the
combination gas control seat or leakage from joints in
this section of gas line MUST be investigated.
3. Turn off the module gas service tap and continue with
the next module.
Pre-firing check (refer Frames 15, 16,17 & 18).
Ensure that:
(a) The electrical supply to the boiler is OFF.
(b) The orange covers are removed.
(c) The black mains plugs on the left side of each module
are removed.
Note: EXTREME CARE SHOULD BE TAKEN WHEN THE
MODULE IS RUN WITHOUT A COVER.
Each module should be checked as follows:
1. Switch the module on/off switch to OFF. (Frame 16).
2. Turn the module gas service tap to OFF.
3. Check that the low voltage 10-way plug is fitted to
printed circuit Board No. 28.
4. Fit the black mains voltage plug into the connection
point on the left-hand side of the module (refer Frame
18).
5. Switch ON the electrical supply to the boiler at the main
isolator switch.
6. Switch the module on/off switch to ON.
The following sequence of events will occur:
(a) The module 'mains ON' light will be illuminated.
(b) For multi-module boilers: The fans will start and run for
approx 30 seconds (part of the 3 volume air change
safety feature). The fan will stop for from 1 to 50 secs.
depending on its position in the switching order, It will
then restart & run for approx. 15 sec. If the lockout
warning light illuminates at this stage press the lockout
reset button.
For single module boilers: the fan will start and run for
approximately 15 seconds.
(c) The ignition spark commences, continues for 4
seconds then ceases. (The spark can be seen through
the sight glass in the module front).
(d) At the end of the 4 second ignition period, the
combustion lockout light will be illuminated. The mains
ON light will remain illuminated and the fan will continue
to run.
(e) Turn the module on/off switch to OFF. The lights will be
extinguished and the fan will stop.
Turn OFF the electrical supply to the boiler.
DIFFERENTIAL AIR PRESSURE
Connect an inclined gauge to measure the pressure
difference across the multi-hole plate. The pressure
tapping is connected to the lower pressure test point of the
gas-air ratio control and the suction tapping to the upper
test point (Frame 20).
If when the fan is operating on air alone the differential air
pressure is less than 1.1 mbar (0.44 in. wg.) the
commissioning procedure must not continue.
Check the soundness of the connections and the fan
performance.
Note. It is not possible to check the soundness of the
suction line connections using leak detection fluid.
18 MAINS PLUG
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Concord Super Series 4 -
Installation & Servicing
COMMISSIONING AND TESTING
23
20 PRESSURE TEST POINTS
21 LOCKOUT - RESET
19 PANEL REMOVAL
IMPORTANT:
The gas setting pressures MUST NOT be reset to the
values given in the following section unless the differential
air pressure is greater than 1.1 mbar (0.44 in.w.g.).
FIRING CHECKS (Frames 14,16 and 17)
Note:
(i) The minimum gas pressure in the gas header should
be 15 mbar (6 in.w.g.) with all modules firing. The
maximum pressure should not exceed 25 mbar (10
in.w.g.).
(ii) The draught stabiliser should be set to control between
neutral and 0.2 mbar (0.08 in.w.g.) draught in the
casing, with one or all modules firing.
A test point is provided in the boiler casing adjacent to the
flue outlet socket.
Carry out the following firing checks on each individual
module, commencing with the top left module and finishing
with the bottom right. Ensure that the boiler is full of water
and that the main and any boiler primary pumps are
running.
1. Swing out together as one unit the inner and outer front
panels by releasing the single M5 screw (see Frame
19) observed through the panel right-hand cutaway. This
screw fastens the inner front panel to the fan plate.
2. Connect a manometer to the pressure test point at the
outlet end of the gas valve ( Frame 20).
3. Connect a manometer to the pressure test point at the
inlet end of the gas valve.
4. Turn on the module service gas tap and mains inlet gas
tap.
5. Switch ON the boiler mains isolator and put the module
on/off switch to ON. The following sequence of events
should occur:
(a)The mains ON light will illuminate.
(b)For multi-module boilers.
The fan will start and run for approximately 30 seconds
(part of the 3 volume air change safety feature) then
stop for 1 - 50 seconds, depending upon the
module's position in the switching sequence. It will
then re-start and run for approximately 15 seconds.
For single module boilers
The fan will start and run for approximately 15 seconds. If
the lockout warning light illuminates at this stage
press the lockout reset button.
(c)The ignition period will commence, the gas valves will
open and a spark will be generated between the
ignition electrode and the burner (visible through the
sightglass).
(d)The burner will light and the burner ON light will be
illuminated.
If the burner fails to light, the lockout light will be
illuminated at the end of the 4 second ignition period and
the fan will run on.
Another attempt at ignition can be made by waiting 10
seconds and then pressing the lockout button.
After 10 - 20 seconds of pre-purge fan run sequence (c)
and (d) will be repeated. Should any module still not fire
and the gas line has been properly purged, refer to the
fault-finding instructions.
6. When the burner is firing allow the module to run for at
least 3 minutes. The gas valve outlet pressure should
then be 6.8 mbar (2.7 in.w.g.) and the gas valve inlet
pressure not less than 13.5 mbar (5.4 in. w.g.) A valve
inlet pressure of less than 13.5 mbar indicates either a
manifold pressure below the minimum 15.0 mbar (6.0
in. w.g.) or a part blockage between manifold and valve
inlet.
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Concord Super Series 4 -
Installation & Servicing
COMMISSIONING AND TESTING
24
22 PRESSURE ADJUSTMENT
23 SAFETY TEMPERATURE LIMITER
7. If adjustment is necessary remove the screw cap of the
gas/air control unit which projects horizontally at the far
right-hand side of the module (refer Frame 22).
DO NOT ATTEMPT TO ADJUST THE FACTORY PRE-
SET GAS RATE LIMITER WHICH FACES YOU ON THE
FRONT OF THE GAS VALVE.
Using a screwdriver, turn the adjustment screw within
the projecting tube under the cap until the gas valve
outlet pressure is 6.8 mbar (2.7 in.w.g.).
Switch the module OFF and then ON again to check that
the pressure is correct, again allowing several minutes
of firing for the pressure to stabilize. If the setting is
consistently repeated, refit the screw cap of the gas/air
control unit.
8. Switch OFF, disconnect the manometers and screw
down the sealing screws within the gas valve test points.
Close the front panel and retain with the M5 pozi-drive screw.
SAFETY CHECKS TO BE CARRIED OUT ON ALL MODULES
1. Ensuring lockout
With the module running, turn off the module gas
service tap. The burner will stop firing, the burner ON
light will be extinguished and the fan will run on. A single
attempt to relight will be made as follows: After approx
15 seconds during which only the mains on light is
illuminated, the ignition sequence will start, the spark
will operate for 4 seconds after which the lockout and
mains on lights will be illuminated. The fan will run on.
If this sequence of events does not occur, replace
printed circuit board No. 28 to which the lights are
attached.
2. Combustion
Fire each module, on its own, blanking off the fan air
inlets of ALL the NON-FIRING modules, using the
sheets of self adhesive paper supplied in the module
hardware pack. Measure CO and CO
2
for each module.
A sampling point is provided in the top of the boiler
casing, adjacent to the flue outlet socket (Frame 14).
For DRAEGAR tests note the following:
(a)The sampling line, however short, should ALWAYS be
purged.
(b)CO
2
tubes are marked in per cent divisions and ONE
pump only is required. CO tubes are also marked in
divisions indicating parts per million (p.p.m.),
(c)The ratio % CO / % CO
2
should not exceed 0.001. For
convenient reference, the table below (Table 5) shows
maximum CO levels in p.p.m. (read direct from tube)
related to various CO
2
levels.
Low CO
2
levels are included to cover dilutions due to
casing and flue volume on the larger boilers.
Remove the fan inlet blanking material from all
modules and fire all modules together. Measure the
gas pressure at the gas header test point and ensure
that it is not less than 15 mbar (6 in.w.g.).
Check also that the draught stabiliser is controlling
draught between neutral and 0.2 mbar (0.08 in.w.g.).
With all modules firing, measure CO and CO
2
levels
again and refer to Table 5 for maximum allowable CO
content.
IMPORTANT
After the combination tests have been conducted it is essential
that in order to comply with the European requirements to
provide a three times the casing volume prepurge the boiler
should always be left to operate with at least half the modules
switched on and their fans in working order.
3. Detector current
The main burner flame detector current may be checked
by breaking the in-line connector lead and inserting a
micro-ammeter. The flame current should be 6-8 µA.
4. Safety temperature limiter
If the water flow rate through the boiler is adequate the
safety temperature limiter should not operate when the
load on the boiler is GRADUALLY reduced from
maximum to minimum.
The safety temperature limiter is mounted on the steel
panel at the left-hand side of the module. Reset by
pushing in the `reset' button (refer to Frame 23).
ONCE COMMISSIONING HAS BEEN COMPLETED, ALL
MODULE COVERS SHOULD BE REPLACED.
Ensure that all module on/off switches are left in the ON
position.
Table 5 MAXIMUM ALLOWABLE CO CONTENT
CO
2
(as read)
1.9
2.6
3.2 3.9
4.5
5.1 5.8 6.4
7.1 7.7
8.4 9.0
9.6 10.3 10.9 11.6
Maximum allowable
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
CO p.p.m. (as read)
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Concord Super Series 4 -
Installation & Servicing
COMMISSIONING AND TESTING
25
ADJUSTMENT OF SEQUENCE CONTROL
Thermometers mounted in the flow and return pipes to the boiler will give a check on the
thermostat settings and will indicate whether the water flow rate is correct to give a temperature
rise across the boiler of 10
o
C. to 12
o
C.
Each module's individual electronic adjustable control thermostat (which is mounted on the
right - hand face of the front panel) should be set with reference to Table 6 and Frame 24, which
shows the boiler thermostat scale.
This method of adjustment will give approximate control of the flow temperature which will be
adequate for most applications. For more accurate control
Ideal Stelrad Group
, can quote for a
commissioning which can, if required, include the accurate calibration of the electronic
adjustable thermostats.
Table 6
Mixed RETURN temperature settings for module electronic
adjustable control thermostat for individual boilers.
Two or more boilers of the same size may be
considered as a `single' boiler with the
corresponding modules or each side
switching virtually together.
Two boilers of a different size e.g. 200kW and
150kW may be treated as a 'single' 350kW
boiler.
Those arrangements should result in a turn
down ratio of up to 6/1 maximum, which will
suffice for most applications. If a turn down
ratio of more than 6/1 is required, on
installations where the total number of
modules fitted to single or multiple boilers
exceeds six,
Ideal Stelrad Group
will be
pleased to quote for accurate calibration of
the electronic adjustable control thermostats.
This work can be carried out as a part of the
commissioning procedure. The maximum
practical turn down ratio is 12/1.
REMOTE WARNING LIGHTS
Multi-module boilers only.
Remote warning lights supplied by the
installer indicating flame failure lockout,
burner on, and overheat may be wired to the
wiring centre - refer to Frame 12.
Note.
Due to the different starting characteristics built into individual wiring
centres, modules set at the same control position may not start or shut
down at exactly the same time.
Boiler sizes kW
Thermostat Settings
Individual Boiler
50 V
1
100 V
1
4
150 V
1
3
5
150 VA
B
1
3
5
200 V
1
2.5
4
5.5
250 V
B
1
2.2
3.4
4.6
5.8
250 H
B
1
2.2
3.4
4.6
5.8
300 V
1
2
3
4
5
6
300 H
1
2
3
4
5
6
350 V
Front
B
1
2.5
4
Rear
1
2.5
4
5.5
400 V
Front
1
2.5
4
5.5
Rear
1
2.5
4
5.5
450 V
Front
B
B
1
2.2
3.4
4.6
450 H
Front
B
1
2.2
3.4
B
4.6
450 VH
Rear
B
1
2.2
3.4
4.6
5.8
500 VH
Front
B
1
2.2
3.4
4.6
5.8
Rear
B
1
2.2
3.4
4.6
5.8
550 VH
Front
B
1
2
3
4
5
Rear
1
2
3
4
5
6
600 VH
Front
1
2
3
4
5
6
Rear
1
2
3
4
5
6
Module No.
6
5
4
3
2
1
refer Frames 5, 6 & 7
B - denotes blank
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Concord Super Series 4 -
Installation & Servicing
SERVICING AND FAULT FINDING
26
24 BOILER ELECTRONIC
ADJUSTABLE CONTROL
THERMOSTAT
25 IGNITIONN ELECTRODE SETTING
SERVICING INSTRUCTIONS
IMPORTANT
In order to ensure sate and reliable operation of Ideal
Concord Super boilers it is essential that regular
maintenance be carried out by competent staff who have
received instruction in maintenance, fault finding and
commissioning procedures for this boiler series.
ANNUAL servicing is recommended.
BEFORE CARRYING OUT ANY SERVICING PROCEDURE:
1. Isolate the boiler electrical supply.
2. Turn off the gas service tap on the module being
serviced.
3. Be aware that the 4 mm pipes connecting the gas
valve to the gas/air control unit are factory sealed and
MUST NOT be disturbed.
The following procedure should be carried out annually.
Preparation for servicing.
Possible spares required:
Fan motor impellor housing gasket.
Round cork burner gasket.
Round foil-faced glass-fibre gasket complete with 'U'
shaped extension.
Square cork fan outlet gaskets (2).
Ignition electrode with lead.
Flame sensing probe with lead.
1. Unscrew the two retaining screws from the front of the
orange cover and remove the cover.
2. Withdraw the multi-pin plug from the left-hand side of
the module and switch off the module on/off switch.
3. Unscrew the M5 screw at the right-hand side of the
rear control panel (see Frame 19) & swing the panel to
the left.
4. Disconnect the lead to the ignition electrode from
Board No. 29 control box and withdraw it through the
cable tie wrapped round the return elbow behind the
gas valve.
5. Release the fan motor lead and mains harness lead
from the clip at the left-hand underside of the fan plate.
6. Unfasten the plug and socket connection to the fan
motor.
7. Unfasten the plug and socket connection to the flame
sensor.
8. Undo the 6 mm suction sensing line union connections
at the `square to round' casting and at the gas/air
control unit and remove the sensing line.
9. Undo the 6 mm pressure sensing line union
connections at the fan housing base and at the gas/air
control unit and remove the sensing line.
10. Undo the 3 elongated M8 nuts with slotted heads,
securing the fan assembly.
11. Remove the fan assembly, taking care not to damage
the fan impellor.
12. Disconnect the burner earth lead from the earthing post
at the left-hand rear side of the chassis.
13. Remove burner, complete with its integral ignition
electrode.
Servicing the ignition electrode and burner
1. Brush the inside and outside of the burner, making
sure to clear any blockages in the burner.
2. It the burner shows any sign of deterioration it should
be replaced.
3. Inspect the ignition electrode. If it shows any sign of
erosion or if there is damage to the insulation or
integral lead, it should be replaced.
Undo the retaining nut and withdraw the electrode from
its housing. Fit new electrode.
4. Check the spark gap and adjust, if necessary. It should
be 4-5 mm - see Frame 25.
Servicing the flame sensing probe
Undo the retaining nut and withdraw the probe. If it shows
any signs of erosion, damage to insulation or to the
integral lead IT MUST BE REPLACED.
Inspecting the finned tubes of the heat exchanger(s)
Inspect the DRY side of the heat exchanger finned tubes by
viewing through the burner opening, using an electric torch
and mirror.
In general, on intermittently operated systems, it will not be
necessary to undertake chemical cleaning more than once
every two years although, as mentioned above, the DRY
side should be examined at least once a year to assess
the rate of build up of debris.
When systems are operated virtually continuously, heat
exchangers should not exceed 3,000 hours firing time
between chemical cleaning. For instructions on chemical
cleaning, see relevant section.
Settings
Temperature
1
67
o
C
2
70
o
C
3
73
o
C
4
76
o
C
5
79
o
C
6
82
o
C
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Concord Super Series 4 -
Installation & Servicing
SERVICING AND FAULT FINDING
27
26 REMOVAL OF MODULE COVER
FILTER
Cleaning the fan.
1. Unscrew the three M4 screws securing the fan motor/
impellor assembly and remove the assembly from the
fan scroll housing.
2. Using a soft brush, remove any accumulation of dust
from the fan blades, the inside of the fan scroll, the
`square to round' casting and the area around the
multi-hole plate.
3. Refit the fan motor limpellor assembly in reverse
order, ensuring the motor leads are at the left-hand
side to avoid interference of the motor with the flow
pipe and the control panel.
Cleaning the module cover filter.
The module cover is fitted with a polyurethane foam filter,
which forms the bottom of the cover. This filter is retained
by two edge clips and two M5 nuts.
To remove the filter, remove the two M5 nuts, then prise
open the edge clips and release the wire frame of the
filter from the clips (see Frame 26).
Wash the filter in lukewarm soapy water. It should then be
thoroughly rinsed and allowed to dry.
Refit in reverse order.
Re-assembly
1. Replace the flame sensing probe in position and
lightly tighten its retaining nut.
2. Replace the burner in the module, renewing the round
foil faced, glass-fibre gasket complete with the 'U'
shaped extension.
Ensure the ignition electrode lug is fully seated into its
recess.
3. Remake the burner earth connection to the earth post.
4. Replace the fan assembly and secure it with the three
elongated M8 nuts.
Notes:
(i) Do NOT overtighten the nuts as damage to the casting
may occur.
(ii) If the round cork gasket between the 'square to round'
casting and the burner is damaged it must be
replaced.
5. Remake the 6 mm suction and pressure sensing lines.
Note. Both lines should be blown through to ensure
they are free from obstruction. Ensure that the
compression fittings are secure.
6. Remake the flame sensor plug and socket connection.
7. Remake the fan motor plug and socket connection.
8. Secure the fan motor lead and mains harness lead in
the clip on the left-hand underside of the fan plate.
9. Pass the ignition lead through the cable tie wrapped
round the return elbow behind the gas valve.
10. Remake the ignition electrode lead connection.
11. Secure the control panel with the M5 screw.
12. Remake the multi-pin plug connection.
13. Switch the on/off switch to ON.
14. Replace the front cover.
IMPORTANT
On completion of the Service, recommission and test the
boiler in accordance with the "Commissioning and Testing"
Instructions, page 22, with particular reference to
measuring the differential air pressure, and to fan
performance and safety checks.
HEAT EXCHANGER - CLEANING INSTRUCTIONS
Chemical cleaning of the dry side of boiler modules
WARNING. Before carrying out any servicing procedure:
1. Isolate the boiler electricity supply.
2. Turn off the gas service taps on the modules being
serviced.
This method of cleaning uses either FERNOX DS.10 or
SENTINEL DRY SIDE CLEANSER which are available from
local stockists or the manufacturers:
Fernox, Cookson Electronics,
Forsyth Road, Sheerwater, Woking,
Surrey, GU21 5RZ
Tel. +44 (0) 1799 550811
or
G E Betz, Sentinel Division,
Foundry Lane, Widnes, Cheshire, WA8 8UD
Tel. +44 (0) 151 420 9563
The following method of cleaning assumes there is an
adequate supply of mains pressure water and a suitable
drain on site.
CAUTION.
When added to water both Sentinel Dry Side Cleanser and
Fernox DS.10 produce acid and MUST be treated with all
the required precautions.
Ingestion and contact with skin, eyes and clothing must be
avoided.
Wear rubber gloves and protective clothing, including
safety glasses to avoid splashes in eyes.
Accidental splashes should be NEUTRALISED
IMMEDIATELY with household soda as solution in water.
Sensitive areas, such as eyes, can be rinsed first with
SODIUM BICARBONATE, followed by plain water. Obtain
the aid of a medical practitioner in the case of personal
accident.
CLEANING
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Concord Super Series 4 -
Installation & Servicing
SERVICING AND FAULT FINDING
28
27 SOLUTION LEVEL
FERNOX DS.10 does NOT produce fumes or toxic gases,
but it is recommended to work under good conditions of
ventilation.
Contact with zinc, aluminium, magnesium, cement,
asbestos and bathtub enamel MUST be MINIMISED or, at
best, COMPLETELY AVOIDED.
KEEP ALL CHEMICALS AWAY FROM CHILDREN.
Materials and spares required in addition to those listed
under servicing.
1. A solution of Fernox DS.10 or Sentinel dry side cleanser.
2. Container, minimum dimensions 350 mm x 350 mm x
350 mm.
3. Gas distribution screen (aluminium wrapper) and
screws.
4. 40 mm nominal bore gaskets (module to header).
5. Triangular gaskets between module flow and return
headers and top cover plate.
6. Cover plate gasket (top).
7. Cover plate gasket (bottom).
Preparing the boiler
1. Unscrew the two retaining screws from the front of the
orange cover and remove the cover.
2. Withdraw the multi-pin plug from the left-hand side of
the module and switch off the module on/off switch.
3. Unscrew the two M4 screws at the right-hand edge of
the control panel and open the front control panel door
(refer to Frame 19).
4. Unplug the low voltage 10-way plug from the top right-
hand corner (viewed from inside) of the circuit board
and withdraw it through the rear control panel.
Note. The captive catch on the side of the 10-way plug
must be un-latched.
5. Unscrew the three cable clips securing the low voltage
harness at the left-hand side of the control panel
support bracket and pull the harness clear.
6. Close the control panel front door and secure with the
two M4 screws.
7. Isolate the boiler from the flow and return water pipes.
8. Drain the boiler.
9. Uncouple the flanges connecting the modules to the
flow and return headers.
10. Release the union nuts connecting the gas inlet
manifold to the modules.
11. Remove the fan, burner with ignition electrode and the
flame sensing probe, as described in the Servicing
Instructions.
12. Remove the module gas line as follows:
(i) Remove the four M4 x 10 mm lg. pozi-screws
securing the injector pipe to the cast iron return pipe.
(ii)Remove the nut securing the gas line bracket to its
fixing stud.
13. Withdraw the adjustable control thermostat and safety
temperature limiter sensors from their pockets.
14. Unscrew the two M5 x 10 mm lg. pozi-screws securing
the control panel support bracket to the angle bracket
and remove the control panel assembly.
15. Unscrew the four M10 nuts securing the module to the
casing and withdraw the module.
16. Unscrew the screws holding the gas distribution
screen over the finned tubes and remove the screen.
The module heat exchanger is now ready for cleaning.
Preparing the solution
For normal cleaning, dissolve Fernox DS.10 or Sentinel dry
side cleaner in water to make a solution in the proportions
of 7 kg. per 70 litres of water.
This should provide a solution strength to adequately clean
a lightly scaled heat exchanger in approximately five
minutes, depending upon the severity of the scaling. In
order to reduce the cleaning time, a more concentrated
solution may be made of proportions up to but NOT
exceeding 2 kg. per 10 litres of water.
Pour the solution into a suitable container - the MINIMUM
dimensions of which should be 350 mm x 350 mm x 350
mm.
A container of this size will require approximately 28 litres
(6 gallons) of prepared solution to set up the initial bath.
When more than one module is to be cleaned, additional
solution should be prepared for topping up the container.
Note. Refer Frame 27
There should be sufficient solution in the container to
ensure, with the module immersed, that the solution level
just reaches the underside of the top tube plate casting.
Cleaning
1. Immerse the module in the solution.
The period of immersion will depend upon the severity
of the scaling.
Lightly scaled tubes can be successfully cleaned in
approximately five minutes.
Note. For best results, agitate the module periodically in
the solution.
2. Remove the module from the container and
THOROUGHLY rinse - a length of hose, fitted with a
piece of flattened copper tube to form a nozzle, will be
found to be adequate for this purpose.
3. For severely scaled heat exchangers, it may be
necessary to remove any remaining stubborn deposits
by brushing and then re-immersing into the solution for
a few minutes.
In extreme cases, it may be necessary to repeat this
process.
After the final immersion, the heat exchanger should be
given a THOROUGH rinse.
4. Repeat the cleaning operation for EACH module,
topping up the solution each time to the underside of
the top tube plate casting.
CLEANING
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Concord Super Series 4 -
Installation & Servicing
SERVICING AND FAULT FINDING
29
Re-assembly
Re-assemble the module gas line, burner with spark
electrode, fan and control chassis assembly, and flame
sensing probe in the reverse procedure to that detailed in
`Preparing the boiler.'
SPECIAL ATTENTION should be made to the following
points:
1. ENSURE the gap between the gas distribution star
plate and the gas injector is 6 mm - 10 mm.
2. The slots in the gas distribution screen (aluminium
wrapper) MUST BE IN LINE with the outermost points of
the finned tubes.
3. The gas distribution screen MUST BE HELD TIGHTLY
against the finned tubes when the securing screws are
tightened.
4. Replace the burner in the module.
The round cork gasket which seals the fan assembly to
the burner, and also the round gasket complete with `U'
shaped extension, sealing the burner to the module
casing, MUST BE RENEWED.
Module waterway cleaning instructions
WARNING: Before carrying out any servicing procedure:
1. Isolate the boiler electrical supply.
2. Turn off the gas service taps on the modules being
serviced.
If, as a result of make-up water entering the system, or for
any other reason, it is considered necessary to remove
limescale from all modules, then this operation may be
undertaken using the cleansers Fernox DS.3 or Sentinel
scale clean with the boiler disconnected or isolated from
the system but retaining all modules in situ.
Should it be suspected that one or two modules only
require de-scaling individually then these modules may be
removed and cleaned whilst the remaining modules
continue to operate and provide some degree of heat
service.
Module blanking plates and blank pipe flanges are
available from
Ideal Stelrad Group
, for this purpose.
The manufacturer of Femox DS.3:
Fernox, Cookson Electronics,
Forsyth Road, Sheerwater, Woking,
Surrey, GU21 5RZ
Tel. +44 (0) 1799 550811
and Sentinel Scale Clean:
G E Betz, Sentinel Division,
Foundry Lane, Widnes, Cheshire, WA8 8UD
Tel. +44 (0) 151 420 9563
will provide general information and literature on the most
efficient procedure and local stockists.
An inspection of the module waterways may be undertaken
before and for after cleaning. The procedure below details
the method of draining down the boiler, removing a module
and dismantling for inspection of the waterways.
Preparing the boiler
1. Unscrew the two retaining screws from the front of the
orange cover and remove the cover.
2. Withdraw the multi-pin plug from the left-hand side of
the module and switch off the module on/off switch.
3. Unscrew the two M4 screws at the right-hand edge of
the control panel and open the front control panel door -
refer Frame 19.
4. Unplug the low voltage 10-way plug from the top right-
hand corner (viewed from inside) of the circuit board
and withdraw it through the rear control panel.
Note. The captive catch on the side of the 10-way plug
must be un-latched.
5. Unscrew the three cable clips securing the low voltage
harness at the left-hand side of the control panel
support bracket and pull the harness clear.
6. Close the control panel front door and secure with the
two M4 screws.
7. Isolate the boiler from the flow and return water pipes.
8. Drain the boiler.
9. Uncouple the flanges connecting the modules to the
flow and return headers.
10. Release the union nuts connecting the gas inlet
manifold to the modules.
11. Remove the fan, burner with ignition electrode and the
flame sensing probe, as described in the Servicing
Instructions.
12. Remove the module gas line as follows:
(i) Remove the four M4 x 10 mm lg. pozi-screws
securing the injector pipe to the cast iron return pipe.
(ii)Remove the nut securing the gas line bracket to its
fixing stud.
13. Withdraw the adjustable control temperature and safety
temperature limiter sensors from their pockets.
14. Unscrew the two M5 x 10 mm lg, pozi-screws securing
the control panel support bracket to the angle bracket
and remove the control panel assembly.
15. Unscrew the four M10 nuts securing the module to the
casing and withdraw the module.
16. Unscrew the screws holding the gas distribution
screen over the finned tubes and remove the screen.
17. Remove the twelve 8 mm bolts and the centre 8 mm
bolt which hold the bottom cover plate in the bottom
tube plate.
The plates can now be separated.
The waterways can now be examined.
If the tubes are scaled or partially blocked, the top cover
plate MUST be removed by unscrewing the twelve 8mm
bolts, disposed around the periphery, and the six 8mm
bolts around the centre.
The water passages in the tube plates and tubes can
now be cleaned, either by replacing the module in the
boiler and cleaning all modules (refer Fernox or
Sentinel literature) or by immersing individual modules
in a solution of DS.3 or Sentinel Scale Clean.
CLEANING
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28 ALIGNMENT LUGS
REPLACEMENT
Re-assembly of the module after water tube cleaning
TAKE CARE:
1. The triangular lugs on the cover plates are in
register with the corresponding lugs on the header
castings - refer Frame 28.
2. NEW gaskets should be used between mating
flanges.
3. Tighten the securing bolts EVENLY to a torque of 20
N/m (15 f/lbf).
Re-assembly can then be continued as detailed in the
foregoing section.
REPLACEMENT OF COMPONENTS
WARNING - Before working on the appliance:
1.
Isolate the boiler electrical supply.
2.
Turn OFF the gas supply at the inlet gas cock.
Note.To replace the following components, it will be
necessary to remove the module cover as previously
described in the Servicing Instructions.
It may also be necessary to open the control panel front
and/or rear doors to gain access - refer to Frame 19.
Sight Glass
1. Undo the two screws securing the sight glass
assembly to the front header casting.
2. Fit the replacement sight glass, ensuring the parts are
in the correct order, i.e., gasket, glass, gasket and
frame.
3. Retighten the two screws to ensure an airtight seal.
DO NOT OVERTIGHTEN.
Boiler Adjustable Control Thermostat Sensing Probe
1. Remove the retaining clip from the thermostat pocket in
the boiler return header and withdraw the sensing
probe.
2. Unplug the thermostat lead from printed circuit board
No. 28 behind the front control panel door and withdraw
the lead.
3. Fit the replacement probe in reverse order.
Boiler Adjustable Control Thermostat Potentiometer
1. Unplug the potentiometer lead from printed circuit
board No. 28, behind the front control panel door.
2. Loosen the retaining screw of the thermostat control
knob on the right hand side of the fascia and pull off the
knob.
3. Undo the hexagon nut securing the potentiometer to the
fascia and withdraw the potentiometer.
4. Fit the replacement potentiometer in reverse order.
Printed Circuit Board No. 28
1. Release the front control panel door.
2. Unplug all the push-on terminals from the board.
3. Release the board from the PCB stand-offs by
depressing the tabs and withdrawing the board.
4. Fit the replacement board in reverse order.
Printed Circuit Board No. 29 (complete with black box)
1. Release the front and rear control panel doors together.
2. Unplug the push-on terminal strip at the right-hand side
and the spark electrode lead.
3. Undo the four screws securing the black box complete.
4. Fit replacement box in reverse order.
Safety Temperature Limiter
1. Pull out the split pin & remove the phial & its metal
retainer from its pocket in the flow elbow - refer to
Frame 15.
2. Release the capillary from the edge clip.
3. Unscrew the two screws securing the control cover
plate and remove the plate - refer to Frame 23.
4. Pull off the two electrical connections from the safety
temperature limiter.
5. Fit the replacement device in reverse order, ensuring
the capillary is routed above and behind the fan and
secured in the edge clip.
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REPLACEMENT
Burner
1. Remove the fan assembly as previously described in
the Servicing Instructions.
2. Withdraw the burner, complete with its integral ignition
electrode.
3. Undo the nut securing the ignition electrode and
transfer the electrode to the new burner.
4. Fit the replacement burner in reverse order.
Note. Always fit new foil-faced and cork gaskets.
5. The module MUST now be recommissioned with
particular reference to measuring the differential air
pressure. Refer to Commissioning and Testing (pages
22-25).
Ignition Electrode
1. Unplug the push-on terminal from the control box.
2. Undo the locking nut securing the electrode and
withdraw the electrode from the burner.
3. Withdraw the lead through the cable tie wrapped round
the return elbow behind the gas valve and remove the
electrode.
4. Fit the replacement electrode in reverse order.
Flame Sensing Probe
1. Unfasten the plug and socket connection in the flame
sensing lead.
2. Undo the nut securing the probe in the front casting
and withdraw the probe.
3. Fit the replacement probe in reverse order.
Fan
1. Remove the fan assembly as previously described in
the Servicing Instructions.
2. Undo the four bolts securing the `square to round'
casting to the fan outlet and transfer the casting to the
new fan unit, replacing any damaged or deteriorating
gaskets.
3. Fit the replacement fan assembly in reverse order.
4. The module MUST now be recommissioned with
particular reference to measuring the differential air
pressure. Refer to Commissioning and Testing (pages
22-25).
Gas Valve - Gas/air Control Unit Assembly
WARNING:
This assembly is supplied only as a complete service unit
and changed as such - do not separate. The factory fitted
4mm pipes are sealed and MUST NOT be disturbed.
1. Turn off the module gas service tap.
2. Disconnect the gas valve leads from the four push-on
terminals and the earth screw.
3. Undo the 6 mm suction and pressure sensing lines at
both ends and remove.
4. Unscrew the four M4 x 10 mm lg. screws securing the
gas valve to the inlet pipe.
5. Unscrew the four M4 x 10 mm lg. screws securing the
injector pipe to the water return elbow.
6. Remove the gas valve - gas/air control unit assembly.
7. Unscrew the four M4 x 10 mm lg. screws securing the
injector pipe to the gas valve and transfer to the new
gas valve, complete with `O' ring seal.
8. Re-assemble in reverse order, taking care to ensure
that the `O' rings in the gas valve inlet and outlet are
correctly fitted.
9. The module MUST now be recommissioned with
particular reference to measuring the differential air
pressure. Refer to Commissioning and Testing (pages
22-25).
Gas Injector
1. Unscrew the injector from the end of the gas outlet pipe.
2. Fit the replacement injector, renewing the gasket and
ensuring that the gap between the gas distribution plate
and injector is 6-10 mm.
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REPLACEMENT
30 CONTROL SEQUENCE LOGIC
Gas Distribution Screen
1. Remove the heat exchanger from the casing as
described in `Heat Exchanger - Cleaning Instructions.'
2. Undo the screws securing the gas distribution screen
and remove the screen.
3. Fit the replacement screen ensuring:
(a)The slots in the screen are in line with the outermost
points of the finned tubes.
(b)The screen is held tightly against the finned tubes
when the securing screws are tightened.
4. Re-assemble in reverse order to removal, renewing any
damaged or deteriorated gaskets as necessary.
Module Cover Filter
1. Unscrew the M5 nut on each side of the cover, then
prise open the edge clips and release the wire frame of
the filter (see Frame 26)
2. Fit the replacement filter in reverse order.
Wiring Centre (Board No. 30)
1. Unscrew the four screws securing the wiring centre
cover and remove the cover.
2. Disconnect the mains supply and individual module
leads from the board, noting that the plug on the grey
leads has its retaining clip underneath.
3. Release the board from the PCB stand-off's by
depressing the tabs and withdrawing the board.
4. Fit the replacement board in reverse order.
Note 1 (Minimum time in seconds).
Module 1-0 s
Module 3-10 s
Module 5-20 s
Module 2-5 s
Module 4-15 s
Module 6-25 s
29 GAS LINE SCHEMATIC
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SHORT LIST OF PARTS
The following list comprises parts commonly required as
replacement components due to damage, expendability, or
such that their failure or absence is likely to affect safety or
performance.
The list is extracted from the British Gas List of Parts,
which contains all available spare parts.
Details of the British Gas Lists are held by gas regions,
Ideal Stelrad Group
distributors and by merchants.
Ideal Concord Super Series 4, 50-600 Vert., 350-600 Hor.
When ordering spares please quote:
1. Boiler Model
2. Appliance G.C. Number
3. Product Code
4. Quantity
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Key No. Description
Qty.
Product No.
Burner bar (Bray)
Ignition electrode
Sensing electrode
Burner cork gasket (round)
Burner fibre glass gasket
Fan assembly
Sight glass frame, glass and gasket
Burner injector and gasket
Gas valve with gas/air control unit assembly
Negative pressure sensing line assembly
Positive pressure sensing line assembly
Safety temperature limiter manual reset LM5
Adjustable control knob - Bulgin
Adjustable control thermostat sensor
Adjustable control thermostat potentiometer assembly
Reset switch assembly (Lockout)
Printed circuit board PCB No. 28
Printed circuit board PCB No. 29
Module cover assembly - Vertical
Module cover filter
Printed circuit board PCB No. 30
Module flange gaskets
Module top cover plate gasket
Module bottom cover plate gasket
Module cover assembly - Horizontal
Header gaskets (triangular)
Gas distribution screen (aluminium wrapper)
Fan outlet cork gasket (square)
Fan scroll gasket (round)
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
2
1
2
1
058 014
100 613
100 612
012 589
057 860
100 321
078 881
079 722
079 723
079 724
079 725
004 038
013 241
058 512
100 614
004 346
100 646
100 647
100 823
100 619
100 648
012 745
100 936
100 935
100 824
012 593
100 804
057 860
-- ---
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YES
NO
YES
NO
NO
YES
NO
YES
YES
YES
YES
NO
NO
YES
YES
YES
NO
YES
YES
YES
NO
YES
YES
YES
NO
NO
NO
NO
YES
YES
Are any modules mains
lights on?
Are any mains
lights off?
Does fan start within
1 minute?
Is lockout light on?
Are external fuses
intact?
Are module on/of f
switches operating?
Is overheat light on?
Wait for 30 seconds.
Reset lockout.
Does light go out?
Is there a mains supply
to the wiring centr e and
are its fuses intact?
Are all electrical
connections made?
Reset safety
temperature limiter.
Does overheat light go
out?
Fit a new reset button.
Does light go out?
Are all external
interlocks made?
Are Board No. 30 fuses
intact?
Fit new
module sensor
Fit a new Board No. 28.
Are Board No. 30 fuses
intact?
Fit a new Board No. 28.
Is mains light on?
Fit new safety
temperature limiter.
Are all electrical
connections made?
Fit a new Board No. 30.
Is there mains voltage
to the fan?
Are module on/of f
switches operating?
Fit a new fan.
Fit a new Board No. 30.
Are any mains light on?
Fit a new Board No. 28.
Does fan start?
Fit a new Board No. 28.
Fit a new Board No. 30.
NO
NO
NO
NO
NO
NO
YES
Does boiler
sequence start in
1 minute?
Fit a new Board
No. 30.
Does module
sequence start in
1 minute?
Fit a new Board
No. 28. Does
ignition start?
Fit a new Board
No. 28.
Is gas pressure
set at 6.8 mbar?
Can gas/air control
be adjusted?
Fit a new gas
valve - gas/air
control unit.
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35
NO
YES
NO
NO
YES
YES
kout light on?
or 30 seconds.
set lockout.
light go out?
ew reset button.
light go out?
w Board No. 28.
NO
NO
NO
NO
NO
YES
YES
YES
NO
NO
YES
NO
NO
NO
NO
YES
NO
YES
NO
YES
YES
YES
YES
NO
YES
YES
YES
YES
NO
NO
YES
Does boiler
sequence start in
1 minute?
Is there a spark
at the burner?
Does the burner
light?
Does the burner
remain alight?
Is burner 'on'
light illuminated?
Fit a new Board
No. 30.
Is spark gap
correctly set at
4 - 5 mm?
Are the gas
cocks open?
When firing, is the
minimum inlet gas
pressure > 15mb
measured at the
gas header point?
Fit a new Board
No. 28.
Does module
sequence start in
1 minute?
Fit a new ignition
probe.
Is there a spark?
Is detection pr obe
and lead OK?
Fit a new Board
No. 28. Does
ignition start?
Fit a new Board
No. 28.
Fit a new Board
No. 29.
Do the gas valves
open?
Fit a new Board
No. 29. Does
burner remain
alight?
Fit a new Board
No. 28.
Is gas pressure
set at 6.8 mbar?
Is differential air
pressure above 1.1
mbar?
Is there mains
voltage to the gas
valve?
Fit a new Board
No. 28. Is there a
mains supply?
Are 6 mm sensing
tubes clear?
Fit a new gas
valve - gas/air
control unit.
Fit a new Board
No. 29. Is there a
mains supply?
Can gas/air control
be adjusted?
Check and as
necessary clean
/replace: air filters, fan
impellor, heat exchanger
flues & burner.
Fit a new gas
valve - gas/air
control unit.
Set burner gas
pressure to
6.8 mbar.
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1. BOILER MODEL (see data plate)
(Please tick appropriate box)
50v
100v
150v
150va
200v
250v
300v
250h
300h
350v
400v
450v
500v
550v
600v
450h
500h
550h
600h
Serial No.
Year of Manufacture
1.
Module bur ner pressure
in w.g/mbar
Note 1 (all modules firing)
2.
Thermal rating:
(i) Volume of gas, cubic
ft/litr es
(Note 1)
(ii) Time for volume
seconds
(Note 1)
(iii) Heat input
Btu/h/kW
(Note 1)
{ (1) (2) x CV x 3600 Note 2 }
{ (1)
(2) x CV Note 3 }
3.
Combustion data measur ed at
sampling point at top of boiler
(see Table 3)
(i)
CO%
(ii)
CO
2
%
(iii) CO/CO
2
4.
Fan pressure
in w.g./mbar
Differential
(Note 1)
1
2
3
4
5
6
7
8
9
10
11
12
MODULE NO.
ALL
MODULES
FIRING
Note 1: Delete units as appropriate.
Note 2: CV is 1031 Btu/cubic ft. if volume is measured in cu.ft. and gives heat input in Btu/h.
CV is 38.4 kJ/l if volume is measured in litres and gives heat input in kW.
.
.
.
.
COMBUSTION DATA SHEET
Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull, HU5
4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration
No. London 322 137.
August
200
9
UIN 100 920
A10
Technical Training
Ideal Stelrad Group
pursues a policy of continuing
improvement in the design and performance of its products. The
right is therefore reserved to vary specification without notice.
The Ideal Boilers 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 498 432
Ideal Installer/Technical Helpline: 01482 498 376
www.idealboilers.com
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