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Ideal Boilers Super Plus 200/S Installation And Servicing
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Ideal Boilers Super Plus 200/S Installation And Servicing

Ideal Boilers Super Plus 200/S Installation And Servicing

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installation and
servicing
Super Plus
Your Ideal installation and servicing guide
200/S, 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 Boilers.
ENGINEERED FOR PEACE OF MIND

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Summary of Contents for Ideal Boilers 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 ENGINEERED FOR PEACE OF MIND use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
  • 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...
  • Page 3 Super Plus 200/S, 300/3, 400/4, 300/3 Alternative, 400/4 Alternative, 500/5 & 600/6 B.G. Certified - P.I. No. 87AP18 Destination Countries: GB & IE INTRODUCTION CONTENTS CURRENT GAS SAFETY (INSTALLATION AND USE) REGULATIONS OR RULES IN FORCE Assembly of Boiler ............15...
  • Page 4 GENERAL Boiler Model No. 200/S 300/3 400/4 300/3 400/4 500/5 600/6 Alternative Alternative No. of Modules Heat Output Btu/h x 10 682.4 1023.6 1364.8 1023.6 1364.8 1706.0 2047.2 Heat Input Btu/h x 10 802.9 1204.4 1607.0 1204.4 1607.0 2006.2 2408.8 Gas Rate 22.1 33.1...
  • Page 5 GENERAL 5. The chimney draught must be controlled between neutral The normal mode of operation of the boiler (described below) is and 0.2mbar (0.08 in.w.g.). preceded in certain conditions by a phase in which the complete boiler casing is given a 5-volume air change. This air change is 6.
  • Page 6 GENERAL LEGEND 19. Main gas line 1. Controls box assembly 10. Cast iron top cover plate gasket 20. Water return elbow 2. Fan motor 11. Aluminium top tube cover 3. Venturi and gaskets 12. Gas distribution screen 21. Module thermostat pocket 4.
  • Page 7 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 GENERAL Flue products must not be allowed to enter the LOCATION boilerhouse or adjacent buildings. The floor must be flat, level and capable of supporting the weight of the WET boiler pipework. In addition, concrete floors must be Refer also BS.6644 and to IGE/UP/10 Installation of Gas sealed.
  • Page 9 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...
  • Page 12 GENERAL WATER CIRCULATION SYSTEM Maximum Static Head: DESIGN REQUIREMENTS 60.0m (197 ft.), i.e. maximum operating pressure 6.0 bar (85 lb/ SUPER PLUS Gas Boilers are intended for use in conjunction with FULLY PUMPED, OPEN VENTED OR PRESSURISED Minimum Static Head systems, subject to the requirements below.
  • Page 13 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 The valve should be set at 0.7 bar (1 0 lb/in ) above the available isolating valves are to be fitted in the flow and return pipes of...
  • 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.
  • Page 15 INSTALLATION Remove the water flexibles from the module fixing pack and screw ASSEMBLY 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 should finish approximately 600 mm from the top of the internally feet, strapped to a packing base and shrink wrapped.
  • Page 16 INSTALLATION ELECTRICAL CONNECTIONS Repeat for the other 3 studs. Take the round blanking plate supplied and fit it into the central Refer to Fig.14 bottom module opening in the casing. Secure it using the 4 M10 The mains input to the boiler must be wired into the 3 way terminal nuts and washers provided.
  • Page 17 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 Refer to Figs. 1, 4 & 19 in the casing, with one or all modules firing. A test Carry out the following tests on each module in turn.
  • Page 18 INSTALLATION Each module's individual electronic thermostat should be set with Check also that the draught stabiliser is controlling the reference to Table 4 and Fig.17 (which shows the boiler thermostat draught between neutral and 0.2 mbar (0.08 in.w.g.). With all modules firing, measure the CO and CO , levels again scale).
  • Page 19 SERVICING SERVICING & FAULT FINDING Pull off the venturi casting and gasket. IMPORTANT: In order to ensure the safe and reliable operation of Remove the main burner-complete with the spark electrode and SUPER PLUS boilers it is essential that regular maintenance is flame sensing probe.
  • Page 20 SERVICING the ferrule. Refit the inline connector of flame sensing lead. and remove all fittings from the module cast iron top plate. Resecure the pressure switch lead and fan motor lead, to the 2. Remove the 16 x M10 screws and the 9 central M8 screws clips in the control chassis.
  • Page 21 SERVICING 4. Carefully fit the new probe; note that the plug will only fit its 4. Fit the top and bottom terminal strips ensuring that the 10- correct socket. way strip is at the top and the 8-way is at the bottom. Tighten all terminal strip connections.
  • Page 22 SERVICING Spark Generator 14. Refit the control thermostat sensor into the pocket in the return 1. Pull the overheat thermostat coil, retaining strip and split pin header and push it fully home securing it with its retaining from the pocket in the flow elbow. clip.
  • Page 23 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 vi) The flame probe circuit has not shorted to earth. Replace parts (as appropriate). Pressure switch, flame probe, PCBs 9B and 12. MODULE 'MAINS ON' LIGHT NOT ILLUMINATED NO SPARK AT IGNITION ELECTRODE Check that: Check that: i) External fuses are intact and that the external controls are i) The ignition electrode and lead are sound and that all calling for heat.
  • Page 25 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 CV is 387.7 kJ/I if volume is measured in litres and gives heat input kW Technical Training 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 Boilers, P.O.

This manual is also suitable for:

Super plus 300/3Super plus 400/4Super plus 300/3 alternativeSuper plus 400/4 alternativeSuper plus 500/5Super plus 600/6