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GENERALTECHNICAL DATATable 2Boiler350 VNo. of modulesHeat outputHeat inputGas rate400 V450 V 500 V550 V600 V 450 H500 H550 H 600 tu/h x 470.4592.2 588.0646.8705.6 529.2588.0646.8 705.6Btu/h x 10314041605180622072407200622072006180624073m 63155717521947214323361752194721432336Flue gas 219246273301328246273301328at 120 C (248 F)3ft. /min406464522580638696522580638696Required waterl/s7.498.569.6310.7011.7712.849.6310.7011.77 12.84flow rate 10%gal./min.98.7112.8126.9 141.0155.1169.2 126.9141.0155.1 169.2oo12.5 kN/m2 (50 in w.g.)Hydraulic resistanceMinimum static head**2 m (6.5 ft.)60.0 m (197 ft.) 6.0 bar 85 lb/in2)Maximum static headElectricity supply230 V 50 Hz,Power consumptionW630720810900Boiler .484.4Boiler widthmm182218221833(overall)in.71.771.772.2Weight of casingkg.134126197190182and insulationlb.295278435418Weight ofkg.371424477530moduleslb.81893510521168Gas supply pressure .0 mbar (8 in. w.g.)Boiler depth (overall)1350 mm (53.1 in.)Weight of gas &kg.260263311313315318298300302304water headers ‡lb.573580686690694701657661665670Water Flow and returnmm100100125125125125125125125125connection ††in.4.04.05.05.05.05.05.05.05.05.0Gas connectionRc22222222222222222222Flue pipe sizemm350350400400450450400400450450(nominal bore) †††in.14141616181816161818Flue socket sizemm400400450450501501450450501501in.15 3/415 3/417 1/417 1/419 3/419 3/417 3/417 3/419 3/419 3/4in. BSPInjector size7.3 mm (0.28 in.)Type of gasNatural gas (G20 only)Concord Super Series 4 - Installation & Servicing100920-9.pmd5511/8/2005, 1:31 PM

BOILER HOUSE CLEARANCESGENERAL1RECOMMENDED BOILER-HOUSECLEARANCES 50 - 300KWAll dimensions in millimetres (inches)2RECOMMENDED BOILER-HOUSECLEARANCES 350 - 600KWAll dimensions in millimetres (inches)LOCATIONAIR SUPPLYThe floor must be flat, level, and capable of supporting theweight of the WET boiler pipework. In addition concretefloors must be sealed. The siting of the boiler must be inaccordance with the guidance given in BS. 6644 and withreference to minimum boiler-house clearances. Refer toFrames 1 & 2.Detailed recommendations for air supply are given in BS.5440:2 and BS. 6644 which MUST be consulted beforeproceeding.CONNECTION TO GAS SUPPLYThe gas installation MUST be in accordance with therequirements of the local gas region (refer also IM/16).The gas supply must be capable of maintaining aminimum pressure of 15.0 mbar (6 in.w.g.) at the inlet tothe boiler, with all modules firing. Gas consumption isgiven in Tables 1 & 2.The boilers are for use with NATURAL GAS ONLY.FLUE REQUIREMENTSOpen flue, induced draught and fan diluted systems maybe used but must comply with the following basicrequirements:1. A draught diverter MUST NOT be fitted.2. A draught stabiliser MUST be fitted to all types of fluesystems within 1 metre of the flue outlet and set tocontrol the draught in the casing between neutral and0.2 mbar (0.08 in.wg.) irrespective of flue height ornumber of modules firing. Refer to Frames 3 and 4 forfurther guidance.3. ALL flue systems must be insulated and/or lined andimpervious to acid condensate. Prefabricatedchimneys must have a ’U’ value of no greater than 1.4W/m2 oC at 540oC (0.25 Btu/h ft.2 oF at 1000oF.)4. Drainage must be provided at the base of the chimneyor liner. All boiler casings are fitted with a condensatedrain point - refer to Frame 14.5. For fan diluted or induced draught systems, air flow/pressure switches MUST be fitted to protect against fanfailure. Switches should be set to open if the air flowreduces by more than 15%.6. Flue products must not be allowed to enter the boilerhouse or adjacent buildings.Contamination of the air supply from any external sourcemust be avoided, with particular reference to dust,insulation debris and flue products. Concrete floors mustbe sealed. If any work is to be carried out in the boilerhouse which is likely to generate dust (e.g. structuralalterations or the lagging of pipework) it is recommendedthat the boiler is shut down and the modules covered witha dust sheet, otherwise the boiler will require cleaning andservicing.1. In particular, the contamination of the air supply withchlorides must be avoided as they will cause thedeterioration of the aluminium fan impellor.2. The boiler-house requires ventilation openings atBOTH high and low levels, direct from the outside.Allowances MUST be made for stabiliser dilution in allcases.3. Mechanically forced ventilation systems must includeprovision for boiler shut down in the event of fan failure.4. High speed air streams within the boiler house mustbe avoided.5. Extraction mounted ventilation fans alone are NOTpermitted.6. The minimum effective areas of the permanent airvents direct from the outside by natural ventilation areas follows:Required area (cm2) per kW of total rated input (net)Boiler roomEnclosureLow level (inlet)410High level (outlet)25Note: Where a boiler installation is to operate in summermonths (e.g. DHW) additional ventilation requirementsare stated, if operating for more than 50% of time (referto BS6644).7. Refer also to BS. 6644 and to IGE UP/10 Installation ofGas Appliances in Industrial and CommercialPremises and IM/22 for further guidance.Concord Super Series 4 - Installation & Servicing6100920-9.pmd611/8/2005, 1:31 PM

FLUE REQUIREMENTS3GENERALAPPLICATION OF DRAUGHT STABILISER - SINGLE BOILER INSTALLATIONNote: The discharge from both types of system MUSTnot allow recirculation of combustion products intothe boilerhouse or adjacent buildings.Note: Air intake and discharge should be on thesame outside wall face. Design must comply withBritish Gas requirements -refer page 5 andPublication IM/11.INDUCED DRAUGHTAll dimensions in millimetres (inches)4FAN DILUTED FLUE (FDF) SYSTEMFLUEING - GENERAL GUIDANCE BOILER INSTALLATIONNotes:The draught at the boiler casing must be controlledbetween neutral and 0.2 mbar (0.08 in. w.g.) negativeirrespective of the number of modules firing. The draughtstabiliser must be fitted within 1 metre of the boiler casing.To achieve the minimum neutral draught condition a verticalflue length of 2 metres is needed plus whatever extra heightis necessary to overcome the resistance of any bend or ductwork between the boiler casing and the vertical flue.Contact should be made with the Customer Care department ofIdeal Stelrad Group for further advice and information on this subject.All dimensions in millimetres (inches)Concord Super Series 4 - Installation & Servicing100920-9.pmd7711/8/2005, 1:31 PM

8100920-9.pmd811/8/2005, 1:32 PMAll dimensions in millimetres (inches)50kW Vertical100kW Vertical150kW Vertical150kW Vertical/Alternative5gc Gas Connectionfp Foot ProjectionGENERALDIMENSIONAL DATABOILER DIMENSIONS 50KW - 150KW MODELSConcord Super Series 4 - Installation & Servicing

100920-9.pmd9Concord Super Series 4 - Installation & Servicing11/8/2005, 1:32 PMAll dimensions in millimetres (inches)200kW Verticalrc Return Connection250kW / 300kW Vertical250kW / 300kW Horizontal6gc Gas Connectionfp Foot ProjectionDIMENSIONAL DATAGENERALBOILER DIMENSIONS 200KW - 300KW MODELS9

DIMENSIONAL DATAGENERAL450kW - 600kW HorizontalBOILER DIMENSIONS 350KW - 600KW MODELSConcord Super Series 4 - Installation & Servicing10100920-9.pmdAll dimensions in millimetres (inches)350kW - 400kW Vertical450kW - 600kW Verticalgc Gas Connection71011/8/2005, 1:32 PM

DIMENSIONAL DATA8INSTALLATIONSITE ASSEMBLY - 600kW Vertical BoilerNote.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 easeof fit and squareness.LEGEND1. 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).9SITE ASSEMBLY - 600kW Horizontal BoilerNote.1. To aid the assembly procedure,on the flow & return manifoldsand the flow & return spools, theflanges are left loose for sitewelding.2. The double M/F elbows (12) areto enable ease of fit andsquareness.LEGEND1. 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 gascocks.8. Rc 1 1/2 union elbows.9. Short space nipple.10. Main gas cock (not shown).11. Rc 2 twin elbow (with two hexbushes).12. 1 1/2 M/F elbow.13. Return manifold (short).Concord Super Series 4 - Installation & Servicing100920-9.pmd111111/8/2005, 1:32 PM

DESIGN REQUIREMENTSGENERAL7. The minimum air requirements by mechanicalventilation are as follows:Table 3 - MECHANICAL VENTILATION FLOW RATESType of boilerForced/induceddraught boilersFlow rate per kW total ratedheat input (net)Inlet airExtract air(combustion(ventilation)ventilation)2.6 m3/h1.25 m3/h 0.18m3/hA purpose designed flueing ventilation system based solelyon a high level permanent opening to an otherwise sealedboiler-house or compartment may be used, provided thatspecialist advice is taken, and that the combustion air andventilation requirements of the boiler is provided in line withBS6644. In addition to this, the boiler house temperaturemust be prevented from exceeding 32 C at mid-level.BS6644 provides details of temperature requirements.WATER CIRCULATION SYSTEMDESIGN REQUIREMENTSIdeal Concord Super gas boilers are intended for use inconjunction with FULLY PUMPED, OPEN VENTED orPRESSURISED systems - subject to the requirementsdetailed below. They are NOT suitable for use on gravitycirculation systems.Note. In some cases, pump manufacturers will require ahead as high as 12m (40ft). This must be allowed for andthe minimum head increased accordingly. Refer to Frame10 for further clarification.Safety ValveA safety valve must be sized and fitted in accordance withBS. 6644. The valve should be set at 0.7 bar (10 lb/in2)above the available static head of water over the boiler.The maximum safety valve setting is 0.7 bar (10 lb/in2)above the maximum design operating head of 6.0 bar (85Ib/in2), i.e. 6.7 bar (95 Ib/in2).Table 4 - VENT, COLD FEEDThe open vent and cold feed pipe sizes must comply withBS. 6644 and must be of the following minimum size.Boiler50 V100 V, 150 V200 V, 250 V, 300 V150 VA250 H, 300 H350 V - 600 V450 H - 600 HCold feednominal dia.19 mm25 mm32 mm25 mm32 mm38 mm38 mmOpen ventnominal dia.25 mm32 mm38 mm32 mm38 mm50 mm50 mmDrainWater Flow Rate1.07 l/s (14.1 gal/min) 10% through each module.The drain valve must comply with BS. 2879 and beoperated with a removable key.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.Pressure GaugeNote. Failure to maintain this flow rate will result inoperation of the module overheat cut off device.The water pressure gauge and temperature gauge mustthe fitted in accordance with BS. 6644.The boilers are suitable for operation when connected tosystems requiring lower flow rates than those quoted aboveand 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 withIdeal Stelrad Group before proceeding.Water flow switchHydraulic Resistance - refer Graph 1When operating at the correct volume flow rate given above,the hydraulic resistance of all Ideal Concord Super boilersis 12.5 kN/m2 (50 in.w.g.).A water flow switch must be fitted to protect the boiler frompump failure.Graph 1 - HYDRAULIC RESISTANCEPump Over-runA pump over-run time of 30 seconds minimum must beallowed for on plant shutdown.Maximum Static Head60m (197 ft.), i.e. maximum operating pressure 6.0 bar (85Ib/in2).Minimum Static HeadMinimum static head requirements for open ventedsystems must comply with boiler design characteristics,pump manufacturer’s requirements and the requirementsof the Health and Safety executive Publication PM5.In order to comply with the above, a minimum static head of2m (6.5 ft), i.e. 0.20 bar (3 lb/in2) will be adequate undermost operating conditions, measured either from thehighest circulating point of the system or from the boilerwhen the boiler house is roof mounted.Concord Super Series 4 - Installation & Servicing12100920-9.pmd1211/8/2005, 1:32 PM

DESIGN REQUIREMENTSGENERALGENERAL GUIDANCE ON APPLICATIONSFrame 10 is intended to provide basic information only onthe application of the Ideal Concord Super boiler. BritishGas approval has not been sought in the matter.It is impossible to cover all applications and installers arerecommended to contact Ideal Stelrad Group if advice on aspecific application is required.It is essential that the water flow rates given in Tables 1 & 2be maintained within the limits stated - therefore anycompensating devices must not be connected to IdealConcord Super boilers directly but may be used inconjunction with a mixing header. The mixing header mustbe sized at least one pipe size larger than the boiler flowand return manifold size. This will avoid hydraulicinterference between the boiler primary pump and systemzone pumps. The use of a mixing header means thatcompensating controls can be used to operate mixingvalves on a variable temperature circuit, without affectingthe water flow rate through the boiler.10 GUIDE TO MINIMUM REQUIREMENTS FOR OPEN VENT - Feed / Expansion TankHeight and boiler Primary Circuit1. Roof top or single storey applications.2. Ground floor or basement applications.LEGEND1. Cold Feed(sizes MUST complywith BS. 6644).2. Open vent. (sizes MUSTcomplywith 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 inthe system.All dimensions in millimetres (inches)Concord Super Series 4 - Installation & Servicing100920-9.pmd131311/8/2005, 1:32 PM

ELECTRICAL DATAGENERALExisting systems and, where necessary, new systemsshould be thoroughly cleaned prior to the use of a stableIdeal Stelrad Group, advise contact directly with specialistson water treatment, such as:Fernox, Cookson Electronics,Forsyth Road, Sheerwater, Woking,Surrey, GU21 5RZTel. 44 (0) 1799 550811orG E Betz, Sentinel Division,Foundry Lane, Widnes, Cheshire, WA8 8UDTel. 44 (0) 151 420 9563ELECTRICAL SUPPLY230 V - 50 Hz. Consumption: 90W per module (excludingremote alarms etc.)Note. External wiring and any installer-supplied remotewarning 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 shouldfacilitate complete electrical isolation of the boiler.Connection should be made via a fused double poleswitch or fused spur box, serving the boiler only, andincorporating contacts with a separation of at least 3 mm inall poles. The point of connection should be readilyaccessible and adjacent to the boiler.The length of the power supply conductors between thecable anchorage and the terminals must be such that thecurrent conductors become taut before the earth conductor,if the cable slips out of the cable anchorage.The water flow switch and any other overriding safetydevices should be wired in series with the isolation mainssupply to the boiler.50 kW SINGLE MODULE BOILERS ONLY (Frame 11)50 kW boilers are supplied with a multi-pin plug forconnection to the mains, as follows:EARTH . Terminal 1LIVE . Terminal 2NEUTRAL . Terminal 4Link betweenTerminals 6 & 8 . by installer11 MULTI-PIN PLUG WIRING FORSINGLE MODULE BOILER ONLY56743182Legend:Terminal 1 - EARTH (Green/Yellow)Terminal 2 - LIVE (Brown)Terminal 4 - NEUTRAL (Blue)Terminal 6 - linked to Terminal 8 by installerConcord Super Series 4 - Installation & Servicing14100920-9.pmdinhibitor, which does not require continual topping up tocombat the effects of hardness salts and corrosion on theheat exchangers of the boiler and associated systems.con 6111Frame 10 shows how constant and variable temperaturecircuits can be used on low and high head applications.The following points should be noted:1. The recommended positions of the cold feed and openvent are shown. Sizes should comply with BS. 6644. Ifisolating valves are to be fitted in the flow and returnpipes of the boiler they must not isolate the boiler fromthe open vent, safety valve or cold feed.2. The minimum tank height shown is measured from thehighest point of the system and must be increased, ifnecessary, to comply with pump manufacturers’requirements.3. The open vent height above tank water level cannot beguaranteed adequate in all circumstances and does nottake into account any instantaneous changes in headbrought about by ancillary equipment operating.4. Water flow switch is shown in its recommended position. ItMUST NOT be located on the mixing header whereoperation of z

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 100920-9.pmd 1 11/8/2005, 1:31 PM. 2 Concord Super Series 4 - Installation & Servicing CONTENTS