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IDEAL Concord Super Series 4 50 V Installation And Servicing

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INSTALLATION AND
SERVICING
CONCORD SUPER SERIES 4
50 - 600 VERTICAL
250 - 600 HORIZONTAL
When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance
specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
For the very latest copy of literature for specification and maintenance practices visit our website www.idealcommercialboilers.com
where you can download the relevant information in PDF format.
July 2018
UIN 100920 A12

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Summary of Contents for IDEAL Concord Super Series 4 50 V

  • Page 1: Installation And Servicing

    When replacing any part on this appliance, use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal.
  • Page 3 Assembly and Installation Instructions for Ideal Concord Super Series 4 Modular Gas Fired heating boilers should be read in con- junction 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.

  • Page 4: Installation Requirements

    INTRODUCTION CONTENTS 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 Assembly ...................19...

  • Page 5: Boiler Description

    15 second pre-purge period. Refer to of the modules at all times. Frame 30. The Ideal Concord Super range of boilers provides good load In the case of single module boilers: only its own 15 second matching & sequence control by the following method: nominal pre purge period occurs.
  • Page 6 GENERAL TECHNICAL DATA Table 1 Boiler 50 V 100 V 150 V 200 V 250 V 300 V 150 VA 250 H 300 H No. of modules Heat output Btu/h x 10 170.6 341.2 511.8 682.4 853.0 1023.6 511.8 853.0 1023.6 Heat input 58.8...
  • Page 7 GENERAL 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 Heat output Btu/h x 10 1194 1365 1535 1706 1877 2047 1535 1706 1877...

  • Page 8: Flue Requirements

    GENERAL RECOMMENDED BOILER-HOUSE RECOMMENDED BOILER-HOUSE CLEARANCES 50 - 300KW CLEARANCES 350 - 600KW All dimensions in millimetres (inches) All dimensions in millimetres (inches) LOCATION AIR SUPPLY The floor must be flat, level, and capable of supporting the Detailed recommendations for air supply are given in BS weight of the WET boiler pipework.
  • Page 9 GENERAL 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.
  • Page 10 GENERAL BOILER DIMENSIONS 50KW - 150KW MODELS Concord Super Series 4 - Installation & Servicing...
  • Page 11 GENERAL BOILER DIMENSIONS 200KW - 300KW MODELS Concord Super Series 4 - Installation & Servicing...
  • Page 12 GENERAL BOILER DIMENSIONS 350KW - 600KW MODELS Concord Super Series 4 - Installation & Servicing...
  • Page 13 INSTALLATION SITE ASSEMBLY - 600KW Vertical Boiler Note. To aid the assembly procedure, on the flow & return manifolds and the flow & return spools, the flanges are left loose for site welding. The double M/F elbows (16) are to enable ease of fit and squareness.
  • Page 14 Any other method of installation should be discussed with Ideal Boilers before proceeding. HYDRAULIC RESISTANCE - refer to 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 (50 in.w.g.). Pump Over-run A pump over-run time of 30 seconds minimum must be allowed for on plant shutdown.
  • Page 15 It is impossible to cover all applications and installers are The use of a mixing header means that compensating recommended to contact Ideal Boilers if advice on a specific controls can be used to operate mixing valves on a variable application is required.

  • Page 16: Electrical Supply

    1. The recommended positions of the cold feed and open Ideal Boilers advise contact directly with specialists on vent are shown. Sizes should comply with BS. 6644. If isolating valves are to be fitted in the flow and return pipes...

  • Page 17: Wiring Centre

    GENERAL 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.
  • Page 18 GENERAL 13 50KW MODULE WIRING Concord Super Series 4 - Installation & Servicing...
  • Page 19 ASSEMBLY PACKAGING FOR 150kW ALTERNATIVE and 250kW V boilers only The boiler casing is supplied complete with insulation and feet, strapped to a packaging base and shrink-wrapped. Ensure that the flange support bracket is fitted to the water Boilers up to and including 150kW will have their water and header and module blanking plate.
  • Page 20 ASSEMBLY CONNECTING BOILERS TO THE FLUE SYSTEM ELECTRICAL CONNECTIONS (Refer Frames 12 & Details of the flue design are in Frames 3 and 4. Boiler socket and flue pipe sizes are indicated by Tables 1 & 2. a. Each module WATER CONNECTIONS AND PRESSURES Undo the two M4 screws on the right hand side of the control box and swing the front control panel out.
  • Page 21 ASSEMBLY 14 BOILER ASSEMBLY - EXPLODED VIEW (300kW VERTICAL BOILER SHOWN) LEGEND Flue sampling point Wiring centre Water header Gas pressure test point 50kW module 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.
  • Page 22 ASSEMBLY 15 MODULE ASSEMBLY - Exploded View Concord Super Series 4 - Installation & Servicing...
  • Page 23 ASSEMBLY 16 ELECTRICAL CONTROLS - Exploded View LEGEND LED’s Lockout reset button PCB No. 28 Safety temperature limiter Mains socket Fan motor Fan impellor Fan scroll 8a. Fan gasket Flame sensing lead 10. Ignition lead 11. PCB No. 29 12. On/Off switch 13.

  • Page 24: Commissioning And Testing

    COMMISSIONING AND TESTING The Ideal Concord Super boiler must be commissioned and Turn off the module gas service tap and continue with the tested by a qualified gas/heating engineer. A knowledge of next module. electrical wiring is necessary. Pre-firing check (refer Frames 15, 16, 17 & 18).
  • Page 25 COMMISSIONING AND TESTING IMPORTANT: Connect a manometer to the pressure test point at the inlet end of the gas valve. The gas setting pressures MUST NOT be reset to the values given in the following section unless the differential air Turn on the module service gas tap and mains inlet gas pressure is greater than 1.1 mbar (in.w.g.).
  • Page 26 COMMISSIONING AND TESTING If adjustment is necessary remove the screw cap of the b. CO tubes are marked in per cent divisions and ONE gas/air control unit which projects horizontally at the far pump only is required. CO tubes are also marked in right-hand side of the module (refer Frame 22).
  • Page 27 This method of adjustment will give approximate control of the flow temperature which will be adequate for most applications. For more accurate control Ideal Boilers, can quote for a commissioning, which can, if required, include the accurate calibration of the electronic adjustable thermostats.

  • Page 28: Servicing Instructions

    IMPORTANT Undo the 6 mm pressure sensing line union connections In order to ensure safe and reliable operation of Ideal at the fan housing base and at the gas/air control unit and Concord Super boilers it is essential that regular remove the sensing line.
  • Page 29 SERVICING AND FAULT FINDING Cleaning the fan. Remake the 6 mm suction and pressure sensing lines. Unscrew the three M4 screws securing the fan motor/ Note. Both lines should be blown through to ensure they impellor assembly and remove the assembly from the fan are free from obstruction.
  • Page 30 SERVICING AND FAULT FINDING FERNOX DS. 10 does NOT produce fumes or toxic gases, 12. Remove the module gas line as follows. but it is recommended to work under good conditions of Remove the four M4 x 10mm lg. pozi-screws ventilation.
  • Page 31 Module blanking plates and blank pipe flanges are available remove the control panel assembly. from Ideal Boilers, for this purpose. 15. Unscrew the four M10 nuts securing the module to the casing and withdraw the module.
  • Page 32 SERVICING AND FAULT FINDING Re-assembly of the module after water tube cleaning TAKE CARE: The triangular lugs on the cover plates are in register with the corresponding lugs on the header castings - refer Frame 28. NEW gaskets should be used between mating flanges. Tighten the securing bolts EVENLY to a torque of 20 N/m (15 f/lbf).
  • Page 33 SERVICING AND FAULT FINDING Burner Gas Valve - Gas/air Control Unit Assembly Remove the fan assembly as previously described in the WARNING: Servicing Instructions. This assembly is supplied only as a complete service unit and Withdraw the burner, complete with its integral ignition changed as such - do not separate.
  • Page 34 SERVICING AND FAULT FINDING GAS DISTRIBUTION SCREEN Wiring Centre (Board No. 30) Remove the heat exchanger from the casing as Unscrew the four screws securing the wiring centre cover described in ‘Heat Exchanger - Cleaning Instructions’. and remove the cover. Undo the screws securing the gas distribution screen and Disconnect the mains supply and individual module leads remove screen.
  • Page 35 Product Code The list is extracted from the British Gas List of Parts, which contains all available spare parts. Quantity Details of the British Gas Lists are held by gas regions, Ideal Boilers distributors and by merchants. Key No. Description Qty.
  • Page 36 SERVICING AND FAULT FINDING Are any modules Are any mains lights Does fan start within Is lockout light on? mains lights on? off? 1 minute? Wait for 30 seconds. Are external fuses Are module on/off Is overheat light on? Reset lockout. intact? switches operating? Does light go out?
  • Page 37 SERVICING AND FAULT FINDING Does boiler Is the burner ‘on’ Is there a spark at Does the burner Does the burner sequence start in light illuminated? the burner? light? remain alight? 1 minute? Is spark gap When firing, is the Fit a new Board Fit a new Board Are the gas cocks...
  • Page 38 COMBUSTION DATA SHEET 1. BOILER MODEL (see data plate) (Please tick appropriate box) 100v 150v 150va 200v 250v 300v 250h 300h 350v 400v 450v 500v 550v 600v 450h 500h 550h 600h Serial No. ALL FIRING MODULE NO. MODULES Year of Manufacture 1.
  • Page 39 Concord Super Series 4 - Installation & Servicing...
  • Page 40 For details of courses please ring: ... 01482 498432 Ideal Boilers Ltd. pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice.

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