IDEAL SUPER PLUS 200/S Installation And Servicing page 15

ASSEMBLY
PACKAGING
The boiler casing is supplied complete with insulation and feet,
strapped to a packing base and shrink wrapped.
At site locations where access is restricted, the boiler casing can
be split horizontally by removing the cable trunking insulation
retaining trims and then the securing nuts, washers and screws.
Re-assemble in reverse order.
On re-assembly, great care must be taken to ensure that the
casing sealing strips are undamaged and correctly positioned.
The water and gas headers are supplied on a pallet, shrink
wrapped.
The water header flexible connections, flange and gaskets etc.,
are in the module fixing pack.
The modules are supplied individually packed on a pallet.
FOUNDATION
An insulated foundation is NOT necessary as the bottom of the
boiler casing will not exceed a temperature of 60
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 then the compressing
nut tightened. A suitable drain should be connected to the elbow.
Refer Fig. 17.
Note: Condensation will only occur over the initial warming up
period, when the return water temperature is below 55
flue products Dew Point).
The boiler casing can now be placed in position.
Fig. 16 Casing Drain Assembly
NOTE: 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 to Fig.1
WARNING: CRACKING MAY OCCUR IF THE FLOW AND
RETURN MODULE CASTINGS ARE OVER-STRESSED.
The following procedure is to be adopted:
Super Plus -
Installation and Servicing
INSTALLATION
Remove the water flexibles from the module fixing pack and screw
them into the appropriate, internally threaded, branches of the
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
should finish approximately 600 mm from the top of the internally
threaded branch and with the flange holes at 45
the water header. Under no circumstances must the flange or
bellows be used for tightening.
Undo the retaining screw from the front of the module upper cover
and remove it by pulling forward and lifting slightly at the back to
clear the shoulder nuts. Undo the screw at the base of the controls
chassis and remove the lower cover by lifting it to clear the shoulder
nuts and pulling it forwards.
Remove the module from the pallet by unscrewing its retaining
screws. Offer up the module to the casing so that the square cutout
lugs on the rear end plates sit over the runners within the casing,
and push the module home.
Note: Lift the module at the front by the water flow or return elbows;
DO NOT LIFT VIA THE CONTROLS BOX OR GAS LINE.
Fit the nuts and washers over the 4 fixing studs but do not tighten
C (140 F).
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yet. Repeat for the remaining modules.
Remove the gas cock half of the union gas cocks on the gas line
extensions (both solid and flexible) and screw them to the gas
header. Ensure that the dimensions between the header and the
end face of the gas cock halves are the same, and that the gas
cocks will face forward when finally assembled.
Fit the end cap and the elbow to the gas header in the required
positions.
It is important that a gas cock is fitted to the inlet gas pipe adjacent
to the boiler.
Fit the solid and flexible gas line extensions to the top flange on
C (the
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the module gas train using the gaskets and screws provided. Place
the gas header in position so that the union gas cocks can be
reconnected - taking care to adequately support the header during
assembly. Ensure that all swivel joints on the flexible extensions
are tight.
Secure the flow and return water headers to the modules, rigid
flanges first, using the gaskets and screws provided. Take adequate
precautions to support the headers during assembly.
Note: Care should be taken to avoid damage to the flexible
connections whilst tightening the screws securing the flanges.
Finally, tighten each of the modules 4 fixing nuts.
300/3 and 500/5 Boilers only (see Figs 9 & 10).
The RH bottom module water connections and gas connection
must be blanked off.
A 1" BSP cap is supplied in the module fixing pack to seal the gas
header connection.
The return water header support bracket is supplied in the water
header pack. First remove the bottom and RH nuts and washers
securing the casing blanking plate and use these fixings to secure
the support bracket to the blanking plate.
Blank off the water return header connection, using the blank flange
and the 2 gaskets supplied. (return water header - gasket - blank
flange - gasket - support bracket). Blank off the water flow header
connection using the 2" BSP cap and close taper point supplied.
400/4 Alternative Boiler only (Refer Fig.12)
The procedure to blank off the bottom RH module must be carried
out as described for the 500/5 boiler above. In addition the centre
bottom module opening in the casing must be blanked off.
First remove one of the M10 slotted nuts and backnut from the
centre bottom module opening in the casing and replace by one
of the longer studs in the blanking kit. Screw the MB threaded
portion of the new stud through the cast support ring and through
the hole in the interior support strut. Fit the M8 nut and washer
from the back and tighten.
to the line of
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