Table of Contents
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INSTALLATION AND
SERVICING
SUPER PLUS
200/S 200/2 300/3 400/4 500/5
600/6
300/3 Alternative
400/4 Alternative
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.
June 2018
UIN 110531 A11
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Table of Contents
Related Manuals for IDEAL SUPER PLUS 200/S
Summary of Contents for IDEAL SUPER PLUS 200/S
- Page 1 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 2 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. Super Plus - Installation and Servicing...
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Page 3: Table Of Contents
Super Plus 200/S, 300/3, 400/4, 300/3 Alternative, 400/4 Alternative, 500/5 & 600/6 Destination Countries: GB & IE INTRODUCTION CONTENTS CURRENT GAS SAFETY (INSTALLATION AND USE) REGULATIONS OR RULES IN FORCE Assembly of Boiler ............15 It is the law that all gas appliances are installed and serviced by a Gas Safe registered installer in accordance with the above Boiler Description .............5... - Page 4 (at 15 C & 1013.25 mb) single skin and metal flues may need a suitable adapter. 2. For further information on head requirements see page 6. Further advice may be obtained from Ideal Boilers. 3. The minimum gas supply pressure is with all modules firing. 4. Flange size: refer to BS.4504 Pt.1 Super Plus - Installation and Servicing...
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Page 5: Boiler Description
GENERAL Regular maintenance by competent personnel is essential occasions of low load when the last module firing goes off on its to the safe and reliable operation of the boiler. Full details of thermostat (or external controls) and is then called again. The air these requirements are given in these Installation &... -
Page 6: Electrical Controls
GENERAL LEGEND 1. Controls box assembly gasket 19. Main gas line 2. Fan motor 11. Aluminium top tube cover 20. Water return elbow 3. Venturi and gaskets 12. Gas distribution screen 21. Module thermostat pocket 22. Burner 4. Pressure switch 13. -
Page 7: Gas Line
GENERAL LEGEND 1. Main gas pressure test point 2. Main gas injector 3. Pressure switch electrical leads 4. Pressure switch 5. Pressure switch pressure pipe 6. Pressure switch suction pipe 7. Pressure switch test points 8. Gas manifold flange connection 9. -
Page 8: Boiler House Clearances
GENERAL LOCATION Flue products must not be allowed to enter the boilerhouse or adjacent buildings. The floor must be flat, level and capable of supporting the weight Refer also BS.6644 and to IGE/UP/10 Installation of Gas of the WET boiler pipework. In addition, concrete floors must Appliances in Industrial and Commercial Premises and IM/22 be sealed. -
Page 9: Boiler Dimensions
For 10 in. Flue Pipe 160(6.3) in. Water flow Pipe (0.5) 1420 1400 1610(63.4) (55.9) (55.1) in. Water Return Pipe (8.3) (7.9) Flange 150(5.9) Connection 800(31.5) 600(23.6) Fig.8 BOILER DIMENSIONS - SUPER PLUS 200/S boiler only Super Plus - Installation and Servicing... - Page 10 GENERAL SUPER PLUS 400/4 Boiler shown All dimensions in mm (in) Note: On 300/3 Module 1 is blanked off Fig.9 BOILER DIMENSIONS - SUPER PLUS 300/3 & 400/4 boilers only All dimensions in mm (in) SUPER PLUS 600/6 Boiler shown Note: On 500/5 Module 1 is blanked off Fig.10 BOILER DIMENSIONS - SUPER PLUS 500/5 &...
- Page 11 GENERAL All dimensions in mm (in) 5 in. flange connection 5 in. flange connection Fig.11 Module Arrangement - Super Plus 300/3 alternative All dimensions in mm (in) 5 in. flange connection 5 in. flange connection Fig.12 Module Arrangement - Super Plus 400/4 alternative Super Plus - Installation and Servicing...
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Page 12: Water Circulation System
Any other method of installation should be discussed with Ideal set at 90 C and wired to terminals S2 and S3 in the wiring centre. -
Page 13: Electrical Supply
GENERAL The following points should be noted: Safety Valve: 1. The recommended positions of the cold feed and open vent A safety valve must be sized and fitted in accordance with BS.6644. are shown, sizes should comply with BS.6644:1986. If isolating The valve should be set at 0.7 bar (1 0 lb/in ) above the available valves are to be fitted in the flow and return pipes of the boiler... - Page 14 INSTALLATION Note*: The installer must make these connections for each module. Fig.14 Wiring for Boilers with a Wiring Centre NOTES 1. Isolate mains supply to boiler. All incoming earth connections must first be made to the earthing post and terminal block inside the wiring centre casing. 2. Terminals S1, S2 and S3 provide facility for direct wiring of safety devices.
- Page 15 INSTALLATION ASSEMBLY Remove the water flexibles from the module fixing pack and screw them into the appropriate, internally threaded, branches of the PACKAGING water headers - using a wrench on the hexagon at the end of the bellows (see Figs.6 to 10). When tight the flange on the bellows The boiler casing is supplied complete with insulation and feet, should finish approximately 600 mm from the top of the internally strapped to a packing base and shrink wrapped.
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Page 16: Commissioning And Testing
Force, the engineer shall be Gas Safe registered. CONNECTING BOILERS TO THE FLUE Upon request, Ideal Boilers, will provide a quote for commissioning SYSTEM or recommissioning after servicing. Details of the flue design are shown in Figs. 6 and 7. -
Page 17: Safety Checks
INSTALLATION CONTROL LINE GAS SOUNDNESS (ii) The draught stabiliser should be set to control between neutral and 0.2 mbar (0.08 in.w.g.) draught in the Refer to Figs. 1, 4 & 19 casing, with one or all modules firing. A test point is Carry out the following tests on each module in turn. - Page 18 For more accurate The overheat cut-off device is reset by pushing in the control Ideal Boilers can quote for a commissioning which can, 'OVERHEAT RESET' button. if required, include the accurate calibration of the electronic Once commissioning has been completed, all module thermostats.
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Page 19: Servicing Instructions
SERVICING SERVICING & FAULT FINDING IMPORTANT: In order to ensure the safe and reliable operation Pull off the venturi casting and gasket. of SUPER PLUS boilers it is essential that regular maintenance Remove the main burner-complete with the spark electrode and is carried out by competent staff who have received instruction in flame sensing probe. -
Page 20: Replacement Of Components
SERVICING Resecure the pressure switch lead and fan motor lead, to the clips If the tubes are scaled or partially blocked then the module must be in the control chassis. Ensure all connections are tight. cleaned, either by replacing the module into the boiler and cleaning Refit the overheat thermostat coil into its pocket on the flow header all the modules at the same time, or individually. - Page 21 SERVICING Control Thermostat Potentiometer Overheat Thermostat 1. Unplug the potentiometer lead from the PCB 9B, inside the 1. Pull the overheat thermostat coil, retaining strip and split pin controls box. from the pocket in the flow elbow. 2. Slacken the small securing screw in the control knob and pull 2.
- Page 22 SERVICING Main Gas Valve / Main/Governor 3. it the replacement screen ensuring: (a) The slots in the screen are in line with the outermost points 1. Undo the screws securing the electrical plugs to the main gas of the finned tubes. valves and pull them out, complete with gaskets.
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Page 23: Control Sequence Logic
SERVICING Shows all controls and positions of pressure test points INDIVIDUAL MODULE P.T.P.1 Main gas Main gas valves governor P.T.P.2 P.P.T.3 Main burner Module gas service cock Main inlet gas cock Fig.19 Diagram of Gas Supply Manifold Individual module operation Flame proving Main burner Pilot burner... -
Page 24: Fault Finding
FAULT FINDING FAULT FINDING NO SPARK AT IGNITION ELECTRODE Check that: MODULE 'MAINS ON' LIGHT NOT i) The ignition electrode and lead are sound and that all ILLUMINATED connections are clean and tight and there is no arcing anywhere but at the spark gap. Check that: ii) The electrode spark gap is 3.5 ±... -
Page 25: Short List Of Parts
SHORT LIST OF PARTS Key No. Product Code No. Description 110 536 Burner Assembly Complete 1333 726 Burner Bar (Bray) 110 526 Ignition Electrode 134 727 Sensing Electrode 013 760 Burner Cork Gasket 110 539 Fan and Controls Assembly 133 058 Fan Motor 057 841 Sight Glass... - Page 26 NOTES Super Plus - Installation and Servicing...
- Page 27 NOTES Super Plus - Installation and Servicing...
- Page 28 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.