Condensing Boilers. Floor Mounted - Evomod, Imax Xtra & Imax Plus III. Commercial Heating Solutions.

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1 Condensing Boilers Floor Mounted - Evomod, Imax Xtra & Imax Plus III Commercial Heating Solutions

2 Introduction - Ideal Commercial & Industrial Pioneering heating solutions since 1905 Here at Ideal, we understand that you want a reliable, long term partner that has the skills and expertise to deliver you a wide range of reliable and pragmatic solutions. As well as being able to help you rise to the challenge of the UK building regulations, we also provide a dedicated support service throughout the design, planning and after sales stages, giving you total peace of mind that we will provide you with the complete one-stop solution, all from one manufacturer. With over 100 years of manufacturing experience, you can be confident to know that our capabilities stretch beyond traditional boiler technologies Ideal Commercial Heating provides a range of condensing solutions both wall hung or floor mounted, all perfectly designed to meet your individual building requirements. When you choose to partner with Ideal you can be confident to know that you re partnering with a British manufacturer that s supported by a dedicated national service team, delivering help and advice to you and your customers throughout the year. We have been keeping British buildings warm for over a century and believe in making products which are reliable, energy efficient and easy to use, combining the latest technology with common sense engineering that make our products easy to specify, simple to install & maintain and most importantly are reliable.

3 Contents Condensing boilers 4-19 Evomod ( kw) Imax xtra ( kw) Imax plus III ( kw) Imax range system requirements 40 Evomod system requirements Ideal Service & Support 42 Ideal Service & Support 03

4 Floor Mounted Condensing Boilers Evomod Evomod kw With premix burner technology and a stainless steel heat exchanger, the Evomod range of boilers are capable of high operating efficiencies and low emissions that contribute to reducing running costs and are certified to meet the requirements of the Boiler Efficiency Directive. The Evomod range introduces fully condensing modular benefits to higher outputs in a steel frame of up to 3 high stacking, providing minimum floor area that makes access through a standard (700mm frame width) doorway possible. When required in a difficult area of installation, the modular construction of the frame can be broken down into individual heat exchanger modules. Each module provides a maximum of 250 kw heat output and will modulate down through a sophisticated control system. In this way a decreasing load is continuously matched for optimum efficiency, by modulating one module at a time. Available in 250, 500, 750 and 1000 kw, the Evomod will achieve an output up to 1MW from a single unit solution together with a minimum footprint that enables the product to be installed where space is limited. 04

5 The Evomod is not only simple to operate with its simple controls interface with large backlight display, it is also an extremely compact unit making design easier as the boiler uses minimum floor area. Installation of the range is made easier as the Evomod has smaller parts and is lighter in weight than many other floor mounted boilers. The option of assembled, or on site assembly also adds to this. Maintenance is also made simple through the boilers valved header kits. The Evomod range comes complete with two years parts and labour warranty as standard and as with all products from Ideal Commercial is completely manufactured and built in the UK. Features and Benefits Made in the UK 2 Year Warranty Floor Standing NOx Class 5 - Heat maintained during service - Easier installation as lighter, smaller parts 05 Condensing

6 Commercial Heating Solutions Evomod kw Performance data Model Mean 70 C Mean 40 C Boiler Input Max Rate Boiler Input Min Rate Gas Rate Max Min Max Min Gross Gross Max Rate kw ,378 1,586,774 2,350,184 3,173,512 kw , , , ,325 kw ,530 1,723,060 2,584,590 3,446,120 kw , , , ,404 kw ,056 1,624,112 2,486,168 3,248, kw ,109 1,802,218 2,703,327 3,604,436 kw , , , ,411 kw , , , ,256 m ft , ,559.6 Approx. flue gas Max Rate i.e. noncondensing m volume (@80 C) ft 3 13,808 27,615 41,459 55,303 Max. Flue Resistance Pa Max Rate % 9.1 ± ± ± ±0.2 Min Rate % 8.4 ± ± ± ± ppm Seasonal Boiler Efficiency % Optional kits Included as standard Boiler Evomod Boiler Evomod Water & gas header assembly packaged Remote indication (run & alarm) standard Hours run standard Water connection kit (250) BMS (0-10v) operation standard Air inlet collar Pump overrun standard including 5 line plain text display standard 06

7 General data Model Gas Supply 2H - G20-20mbar Gas Supply Connection (in. BSP) R1¼ R2 R2 R2 ½ Flow Connection (in. BSP) Return Connection (in. BSP) Hydraulic 20 C (with optional water header pack fitted) mbar Max Press (sealed system) bar (psi) 6 (87) Maximum Static Head m (ft) 61 (200) Boiler Electricity Supply Boiler Fuse Rating 1 x 5A Internal 2 x 5A Internal 3 x 5A Internal 4 x 5A Internal Power Consumption (boiler only) W Air Inlet (optional) x 2 mm Condensate drain mm x x x 21.5 Boiler dry weight (unpacked exc. headers) kg Water Content l (gal) 14.8 (3.26) 29.6 (6.52) 44.4 (9.78) 59.2 (13.0) IP Rating IP20 Electricity supply and Fuse rating for pumps etc. refer to manufacturer's instructions ) nett at 15 C and mbar. 3 ) 3 3 ) c. For M 3 Boiler Clearances The minimum dimensions as indicated must be respected to ensure good access around the boiler. Recommended minimum clearances are as follows. Rear: 750mm or adequate space from the rear of the jacket to make the flue connections, drain connection, flue and any safety or control devices. Left Side: 400mm Right Side: 450mm Front: 600mm for normal service and replacement of components. However, it is noted that 1.2m is required in the event of heat exchanger replacement. Top: 300mm (clearance above boiler casing). 07 Condensing

8 Commercial Heating Solutions Boiler assembly - exploded view Key 1 Fan 4 Burner Sequence Controller 5 Mains Connection Box 6 Heat exchanger 7 Thermistor (flow) 8 Thermistor (return) 9 Condensate Blockage Pressure Switch 10 Ignition Electrode 11 Detection electrode 13 Flue Sampling Point 14 Water Pressure Switch 15 Condensate Debris Collector 08

9 Evomod Dimensions All dimensions shown in mm Back View Side View Front View EVOMOD Condensing

10 Commercial Heating Solutions Evomod Dimensions All dimensions shown in mm Back View Side View Front View EVOMOD

11 Evomod Dimensions All dimensions shown in mm Back View Side View Front View EVOMOD Condensing

12 Commercial Heating Solutions Evomod Dimensions All dimensions shown in mm Back View Side View Front View EVOMOD

13 Header kits - Evomod 500 All dimensions shown in mm EVOMOD 500 KW HEADER ASSY (Note: Optional header includes valves shown. Dimensions for optional header without valves also provided.) 13 Condensing

14 Commercial Heating Solutions Header kits - Evomod 750 All dimensions shown in mm EVOMOD 750 KW HEADER ASSY (Note: Optional header includes valves shown. Dimensions for optional header without valves also provided.) 14

15 Header kits - Evomod 1000 All dimensions shown in mm EVOMOD 1000 KW HEADER ASSY (Note: Optional header includes valves shown. Dimensions for optional header without valves also provided.) 15 Condensing

16 Commercial Heating Solutions System application Ideal Evomod boilers are designed for central heating of large domestic and commercial premises and also for supplying domestic hot water via a domestic hot water systems. Boiler Evomod 61 metres (200 feet) 6 bar (87psi) Maximum design flow temperature is 80 C (180F) Pump overrun is provided as standard, and a period of 2 minutes must be allowed for in system design. Frost protection is built into the boiler control, if the boiler sensor falls below 5 C, this will result in the appliance firing. This will protect the boiler only, not exposed system elements. Range packaging Evomod 250, 500, 750 The boiler is delivered on a wooden pallet with protective cardboard packing pieces at the front. The side panels & bottom side panels are contained within cardboard packs strapped to the sides of the boilers. The footer is contained in a cardboard box, strapped to the boiler, or placed on the flue header pallet. All condensate traps are individually boxed & stored within the footer box. A protective plastic wrap protects the contents of the pallet. The flue components are in a cardboard box on a separate pallet. The water connection kit (250) comes in a separate box, the header kits (500, 750, 1000) come on a separate pallet. Evomod 1000 This boiler comes packed as above except the boiler is split onto 2 pallets. The header assembly comes split across 2 pallets + a gas manifold. 1. Boiler on pallet(s) 2. Side panel pack(s) 3. Footer pack(s) inc. condensate traps 4. Flue components boxes, store in a safe place safe place boxes from within the footer box, store in a safe place. packing from the front. wooden pallet & disassemble the pallet. A full commissioning service is available at an extra charge. 16

17 Minimum water flow Due to the compact nature of the boiler the heat stored within the heat exchanger at the point of shutdown of the burner must be dissipated into the water circuit in order to avoid overheating. In order to allow pump operation after burner shutdown the boiler control box incorporates a 2 minute pump overrun facility. In order to make use of this, a pump must be controlled via the terminals inside the boiler. System design must allow for adequate internal circulation and sufficient heat release from the boiler body whenever the burner is firing or during pump overrun. (See flow rate table below for details). Additionally, the system must be controlled so that part of the load is available during the pump overrun period to dissipate heat. Pump Choice: The choice of pump should take into account the hydraulic resistance given in the table below. Flow rates for common systems using a 20 C temperature differential are given in the table below. Model Hydraulic resistance at 20 C Water flow rate temperature difference 20 C (36 F) mb in. w.g m differentials will lead to poor system performance. because the water in the flue gases starts to condense, releasing its latent heat. In installations where all radiators have been provided with thermostatic radiator valves, it is essential that water circulation through the boiler is guaranteed. A mixing header will perform this task. Alternatively this can be best achieved by means of a differential pressure valve, which is installed in a bypass between the flow and return pipes. The bypass should be fitted at least 6m from the boiler, and should be capable of allowing a minimum flow rate to achieve a temperature differential of no greater than 35 C at minimum rate. 17 Condensing

18 Commercial Heating Solutions Ventilation The ventilation requirements of these boilers are dependant on the type of flue system used, and their heat input. All vents must be permanent with no means of closing, and positioned to avoid accidental obstructions by blocking or flooding. Detail reference should be made to BS for inputs between 70kW and 1.8MW (net). Dust contamination in the combustion air may cause blockage of the burner slots. Unless the boiler room provides a dust free environment then direct connection of the air intake via ducting to clean outside air should be used. IMPORTANT NOTE: If combustion air is drawn from within the boiler room, ensure no dust or airborne debris can be ingested into the appliance. Dusty concrete flooring should be sealed to reduce the presence of dust. The temperature within a boiler room shall not exceed 25 C within 100 mm of the floor, 32 C at mid height and 40 C within 100 mm of the ceiling. Open Flued Installations below. For other ventilation options refer to BS In IE refer to the current edition of I.S.820. Required area (cm2) per kw of total rated input (net) Boiler Room Enclosure 4 10 High level (outlet) 2 5 of time (refer to BS6644). Water Treatment must be used in accordance with the manufacturers' instructions. Telephone: Telephone: It is most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers' instructions. 2. If the boiler is installed in an existing system any unsuitable additives MUST be removed by thorough cleansing. 3. In hard water areas, treatment to prevent limescale may be necessary. 4. Under no circumstances should the boiler be fired before the system has been thoroughly flushed. 18

19 Flue Installation The flue header for boilers is supplied. IMPORTANT. It is the responsibility of the installer to ensure, in practice, that products of combustion discharging from the terminal cannot re-enter the If this should occur the appliance MUST be isolated from the gas supply and labelled as 'unsafe' until corrective action can be taken. Terminal Position Due to the high efficiency of the boilers pluming will occur. Particular care should be taken in the case of large output boiler installations, and complying with the requirements of the Clean Air Act. The flue must be installed in accordance with the appropriate Building Regulations and standards and in compliance with BS6644. Flue system design Due to the high efficiency of these boilers, the flue gas temperatures are low and the buoyancy in the stack will be relatively small. The boiler is supplied with an integral fan which is fully matched to the boiler in each case to provide correct combustion air flow and overcome the flue resistance. The power of this fan is such that there is a large reserve of pressure available to overcome a significant length of flue without affecting the combustion performance of the boiler. The maximum pressure available at the base of the flue to overcome flue resistance is 105Pa. This includes the resistance of any air ducts used to connect the air inlet direct to outside air. Care should be taken with tall flue systems to ensure excess buoyancy is not created. A negative pressure must not be created at the boiler flue outlet. See table below for approximate maximum straight flue length. Boiler Ø150 Ø250 Ø250 Ø300 Approx. max. Straight Flue The addition of elbows and their positions in the flue will have a significant effect on the maximum allowable flue and air duct lengths. Consult with your flue supplier for detailed design work. IMPORTANT NOTE. If combustion air is drawn from within the boiler room, ensure no dust or airborne debris can be ingested into the appliance. Dusty concrete flooring should be sealed to reduce the presence of dust. Ideally where possible duct the air supply Material With no requirement for buoyancy to discharge flue products and with low flue gas temperatures, single wall flues are suitable for most installations. Care should still be taken to maintain compliance with building regulations and relevant standards. The flue used should be a suitably approved flue for use on a pressurised condensing flue system. The boiler is not suitable for use on plastic flue systems. Condensate produced in the flue should be drained separately before entering the boiler. A Drain point at the bottom of the Header Kit (500, 750 and 1,000) is provided for this purpose. Advice regarding the availability of proprietary types of flue system can be obtained by contacting Ideal Stelrad Group. All joints or connections in the flue system must be impervious to using pipe of material resistant to condensate corrosion. All drains in the flue should incorporate a water trap. Care should also be taken in the selection of flue terminals as these tend to accentuate Care should be taken to ensure the specification of the chimney is suitable for the application by reference to the manufacturers literature. NOTE:- Long Flues It is recommended that a support bracket is fitted at least every 1m of flue length and a bracket must be fitted at every flue joint to ensure flue seal and alignment of flue. 19 Condensing

20 Floor Mounted Condensing Boilers Imax xtra Imax xtra kw The Imax xtra range of condensing boilers is offered in ten models with outputs from 80 to 560 kw suitable for floor standing application in either single or multiple applications. The Imax Xtra range utilises cast aluminium - silicon alloy heat exchangers incorporating a premix burner with gas and air control for excellent efficiency and emission performance. High efficiencies are achieved 95%. Heat exchangers are of sectional build front to back ensuring that all models have the same width, e.g. 600mm (80-280) and 1200mm ( ). All models are capable of being transported through standard 600mm doorways as models are supplied as two modules. The fully modulating burner operation ensures that the boiler operates as efficiently as possible throughout its firing cycle even down to 20% of the maximum rating. This enables the unit to match its output to all system requirements no matter of a microprocessor readily accessible on the boiler front. Commissioning and full fault diagnostics are provided whilst remote indication of boiler run and alarm is standard. A wide range of control options ensures easy application of BMS systems, sequencing and sensor control. The Imax xtra range meets the requirements of the 20

21 F models comprise two modules within a single boiler, each being of similar construction to smaller Imax xtra units. The modules operate together to provide the required load with a designated master and slave operation sequence. Flue and air dampers fitted to each module are linked to enhance efficiency and control. This arrangement allows one module to maintain heat under adverse circumstances. Features and Benefits Made in the UK 1 Year Warranty Floor Standing NOx Class 5 21 Condensing

22 Commercial Heating Solutions Imax xtra kw Performance data Model Mean 70 C Mean 40 C Boiler Input Max Rate Boiler Input Min Rate Gas Rate Max Min Max Min Gross Gross Max Rate kw , , , , , ,500 kw ,500 79,500 99, , , ,000 kw , , , , , ,550 kw ,000 88, , , , ,750 kw , , , , , ,350 kw , , , , ,300 1,060,800 kw ,900 81, , , , ,400 kw ,750 90, , , , ,850 m ft Approx. flue gas Max Rate i.e. noncondensing m volume (@80 C) ft 3 4,270 6,410 8,550 10,690 12,820 14,960 Max. Flue Resistance Pa Max Rate % Min Rate % ppm Seasonal Boiler Efficiency % General data Model Gas Supply 2H - G20-20mbar Gas Supply Connection R (in. BSP) Flow Connection R (in. BSP) Return Connection R (in. BSP) Hydraulic 20 C mbar Max Press (sealed system) bar (psi) 6 (87) 6 (87) 6 (87) 6 (87) 6 (87) 6 (87) Maximum Static Head m (ft) 61 (200) 61 (200) 61 (200) 61 (200) 61 (200) 61 (200) Boiler Electricity Supply Boiler Fuse Rating Power Consumption (boiler only) W Air Inlet (optional) mm Condensate drain mm Boiler dry weight (unpacked) kg (lb) 132 (291) 150 (331) 168 (370) 198 (437) 215 (474) 233 (514) Water Content l (gal) 11.0 (2.4) 14.3 (3.2) 17.5 (3.9) 18.4 (4.1) 24.0 (5.3) 27.2 (6.0) 22

23 Imax xtra kw Performance data Model Mean 70 C Mean 40 C Boiler Input Max Rate Boiler Input Min Rate Gas Rate Max Min Max Min Gross Gross Max Rate kw ,063,200 1,333,400 1,600,200 1,867,000 kw , , , ,500 kw ,122,500 1,418,000 1,701,900 1,985,100 kw , , , ,600 kw ,091,800 1,364,800 1,637,800 1,910,700 kw ,212,600 1,515,600 1,818,600 2,121,600 kw , , , ,300 kw , , , ,300 m ft Approx. flue gas Max Rate i.e. noncondensing m volume (@80 C) ft 3 17,100 21,380 25,640 29,920 Max. Flue Resistance Pa Max Rate % Min Rate % ppm Seasonal Boiler Efficiency % General data Model Gas Supply 2H - G20-20mbar Gas Supply Connection (in. BSP) 2 x R1 2 x R1 2 x R1 2 x R1 Flow Connection (in. BSP) 2 x R2 2 x R2 2 x R2 2 x R2 Return Connection (in. BSP) 2 x R2 2 x R2 2 x R2 2 x R2 Hydraulic 20 C (with optional water header pack fitted) mbar Max Press (sealed system) bar (psi) 6 (87) 6 (87) 6 (87) 6 (87) Maximum Static Head m (ft) 61 (200) 61 (200) 61 (200) 61 (200) Boiler Electricity Supply Boiler Fuse Rating 2 x External 5A supplies Internal 2AT.4AT (x2) Power Consumption (boiler only) W x2 Air Inlet (optional) 110x2 110x2 110x2 110x2 mm Condensate drain mm 2x21.5 2x21.5 2x21.5 2x21.5 Boiler dry weight (unpacked) kg (lb) 336 (740) 396 (874) 430 (948) 466 (1028) Water Content l (gal) 35 (7.8) 36.8 (8.2) 48.0 (10.6) 54.4 (12.0) Electricity supply and Fuse rating for pumps etc. refer to manufacturer's instructions. 23 Condensing

24 Commercial Heating Solutions Imax xtra kw - Dimensions All dimensions shown in mm SIDE VIEW Flue Centre Line High Level Air Inlet Kit (If Fitted) FRONT VIEW 510 A 51 B 600 R2" Flow Connection R1" Gas Connection PLAN VIEW Flue OD REAR VIEW 678 Electrical Conduit R2" Return Connection Electrical Conduit Air Inlet O110 C Boiler A B C D Recommended minimum clearances are as follows

25 Imax xtra kw - Dimensions Horizontal Flue Connection Kit Fitted All dimensions shown in mm 110 SIDE VIEW High Level Air Inlet Kit (If Fitted) FRONT VIEW 17 (Condensate Drain) G (Flow & Return) Slave Module Master Module 113 (Air Inlet) 91 (Gas) Flow Connections R2" REAR VIEW Gas R1" PLAN VIEW im9615 Boiler A B C D E F G Return Connection R2" Air Inlet Ducts O Condensing

26 Commercial Heating Solutions Imax xtra kw - Dimensions Vertical Flue Connection Kit Fitted All dimensions shown in mm 110 SIDE VIEW High Level Air Inlet Kit (If Fitted) FRONT VIEW Condensate Drain Slave Module Master Module PLAN VIEW REAR VIEW Return Connection R2" Air Inlet Ducts O110 Boiler A B C D E F G

27 Imax xtra kw - Dimensions Optional water and gas header kit and rs air duct connector (F320 & F400 only) fitted All dimensions shown in mm SIDE VIEW REAR VIEW Flow connection Return connection im9159 Note. F320 Model shown Boiler clearances ( ) Recommended minimum clearances are as follows. any safety or control devices. 27 Condensing

28 Commercial Heating Solutions Imax xtra Optional kits Boiler Imax xtra Modulating sequence control for controlling multiple boiler installations Programmable room thermostat Tank sensor kit standard Room sensor kit Boiler Imax xtra Sequencer DHW sensor kit Control interface kit standard Flow, return & gas header kit RS air duct connector only Boiler assembly - exploded view F280 shown Data plate Key 1. Control fascia panel 2. Burner switch 3. Pressure gauge 5. Casing front panel 6. Casing top panel 7. Casing side panel 8. Fan 12. Control Module 19. Union Gas cock 22. Heat exchanger 24. Sightglass 25. Air inlet Burner manifold 33. Air pressure switch 37. Relay 38. Cable conduit 49. Manifold - Flow 5 28

29 Imax xtra System application Ideal Imax xtra boilers are designed for central heating of large domestic and commercial premises and also for supplying domestic hot water via a domestic hot water systems. Boiler Imax xtra 61 metres (200 feet) 6 bar (87psi) Maximum design flow temperature is 82 C (180F) (This is adjustable to 90 C if required at the control panel). Pump overrun is provided as standard, and a period of 5 minutes must be allowed for in system design. Frost protection is built into the boiler control, if the boiler sensor falls below 7 C, this will result in the appliance firing. This will protect the boiler only, not exposed system elements. Range packing The Ideal Imax xtra is dispatched from works as one pack as follows. (readily removed to allow passage through standard doors) A full commissioning service is available at an extra charge. Minimum water flow System design must allow for adequate internal circulation and sufficient heat release from the boiler body whenever the burner is firing or during pump overrun. (See flow rate table below for details). Additionally, the system must be controlled so that part of the load is available during the pump overrun period to dissipate heat. Pump Choice: The choice of pump should take into account the hydraulic resistance given in the table below. Model Hydraulic resistance at 20 C 11 K (20 F) Minimum water flow rate temperature difference 20 K (36 F) mb in. w.g m m Model Hydraulic resistance at 20 C 11 K (20 F) Minimum water flow rate temperature difference 20 K (36 F) mb in. w.g m m Condensing

30 Floor Mounted Condensing Boilers Imax plus III Imax plus III kw The Imax plus III offers greater flexibility of installation and operation with outputs from 95kW to 330kW in a range of six compact floor standing boilers. The range can be installed in multiple formation to provide even larger outputs if the system requires. efficiency is maintained down to as low as 11.2kW output, achieved even with the largest model as the unique design optimises load matching. Each boiler comprises of several sections, each flueway or module having its own burner, fan, gas valve, ignition and safety controls. As system load decreases the boiler modulates down to the combined minimum. As load further decreases modules are switched off to further match the reducing load. Wasteful boiler cycling is minimised whilst stand-by back up is built into the design. The range is designed for ease of installation ensuring boiler house siting is as simple and as fast as possible. The Imax plus III is also 30

31 Advanced microprocessor based controls are used to operate all electrical functions and provide full commissioning and fault diagnostic displays. The units also include Hours Run Meters and BMS control built-in, along with an outside sensor for weather compensation supplied as standard. Features and Benefits 1 Year Warranty Floor Standing NOx Class 5 31 Condensing

32 Commercial Heating Solutions Imax plus III kw Performance data Model Boiler output (non-condensing) Boiler Input Max Rate Boiler Input Min Rate Gas Rate Max Min Max Min Gross Gross kw , , , , ,866 1,124,254 kw ,214 kw , , , , ,139 1,158,033 kw ,332 kw , , , , ,656 1,146,432 kw , , , ,857 1,090,628 1,272,400 kw 12 40,950 kw ,400 m ft ,075 1,255 Approx. flue gas volume m (non condensing) max rate ft Max. Flue Resistance Pa 100 ppm Seasonal Boiler Efficiency % General data Model Flow connection BSP R2 Return connection BSP R2 m 61 Maximum static water head ft 200 Bar 6 Maximum pressure psi 87 Gas inlet connection BSP R1½ Pressure required at the boiler inlet for mbar 15.0 in. w.g. 6.0 Electricity supply mm mm 150 Condensate drain mm 40 Water content l gal kg Weight lb Power consumption W

33 Imax plus III kw - Dimensions Warning: Flow/return connections change their position whether they are on the R.H. or on the L.H. side of the boiler (see views above). Flue connection shown on RH side, options shown dotted at rear or left. Model A B Weight kg Connections Gas Flow Return Condensate Drain Boiler house clearances service across the full width of the boiler. between boilers. 33 Condensing

34 Commercial Heating Solutions Imax plus III Boiler construction The construction of the Imax plus III sectional heat exchanger design is of cast aluminium. Individual downfiring burners, fans, gas valves and ignition safety controls for each flueway or module are provided. A non-return valve ensures no reverse circulation of flue products through modules not operating. A stainless steel sump collects the flue products and diverts them to the flue, whilst allowing drainage of condensate products. Multiple Boiler Installations Imax plus III boilers are suitable for installations where the load requires more than one boiler. The flexibility of flue connection position (left, right or rear) and system and gas connections (left or right) allows multiple boilers to be sited more easily in confined boiler homes. Imax plus III boilers can be laid out for example with rear sides facing each other and flues at the same end. Many more options are possible to minimise plant room area. 34

35 Imax plus III Flue systems To ensure safe and satisfactory operation, the boiler must be connected to a chimney system capable at all times of adequately evacuating the combustion products. Ideal Imax plus III boilers are suitable for use in both room sealed and open flue fan assisted operation. A vertical flue outlet can be positioned to left, right or rear. The air inlet is at the left or right. If installing a room sealed air inlet arrangement, optional air inlet blanking plate kits will be required. The boiler is suitable for use in either single or multiple flue configurations and can be fitted with a wide variety of flue systems. any condensate formed can be discharged through the boiler. All joints or connections in the flue system must be impervious to condensate leakage and also any low points in the flue system should be drained using pipe of material resistant to condensate corrosion. The flue duct termination point must be positioned so that it will not be affected by adverse wind conditions and be free from any obstructions. Therefore where possible terminal positions which could cause problems due to pluming should be avoided. the chimney system without prior consultation with Ideal Stelrad Group. Flues and terminal positions should be designed with strict regard to these for multiple boiler installations and if required, the Clean Air Act. Proprietary flue systems are available for use with this range. A pressure of 100Pa is available at the flue outlet. Optional kits Boiler DHW sensor Mixing circuit sensor Remote indication Hours run meter(s) BMS (0-10v) Air inlet socket and blanking plate kit Cascade control Cascade control wall mounting kit Imax plus III standard standard standard standard standard standard Minimum water flow System design must allow for adequate internal circulation and sufficient heat release from the boiler body whenever the burner is firing or during pump overrun. (See flow rate table below for details). Additionally, the system must be controlled so that part of the load is available during the pump overrun period to dissipate heat. Pump Choice: The choice of pump should take into account hydraulic resistance given in the table below. Model Hydraulic resistance at 20 C 11 K (20 F) Minimum water flow rate temperature difference 20 K (36 F) mb in. w.g m m Condensing

36 Commercial Heating Solutions System design The efficiency of this range of boilers is higher than conventional boilers because of the increased heat exchange area. At return temperatures of 55 C and below, the differences become more marked because the water in the flue gases starts to condense releasing its latent heat. In general, the lower the return temperature, the better the efficiency. In new systems it is best to design for the lowest flow and return temperatures that are practical (subject to the lower limit mentioned above). For optimum operation it is advised that the system be designed on a temperature differential of 20 C. 36

37 Imax plus III System application Ideal Imax plus III boilers are designed for central heating of large domestic and commercial premises and also for supplying domestic hot water via domestic hot water systems. Boiler Imax plus III 61 metres (200 feet) 6 bar (87psi) Maximum design flow temperature is 82 C (180F) (This is adjustable to 90 C if required at the control panel). Pump overrun is provided as standard, and a period of 5 minutes must be allowed for in system design. Frost protection is built into the boiler control, if the boiler sensor falls below 7 C, this will result in the appliance firing. This will protect the boiler only, not exposed system elements. Condensate drain Ideal Imax plus III boilers will produce condensate whenever the temperature of the return water from the system is below approximately 55 C (the dew point of the combustion products). Pipework is supplied for fitting beneath the boiler and includes a filling point for initial charging of a condensate siphon (not supplied). The pipe should be installed with an adequate slope (eg 1 in 50) and consideration should be given to frost protection. 37 Condensing

38 Commercial Heating Solutions Imax Range Ventilation Open flued application Safe, efficient, and trouble-free operation of conventionally flued gas boilers is vitally dependent on the provision of an adequate supply of fresh air to the room in which the appliance is installed. The Imax plus III range is also fitted with air inlet filters for such applications. be according to the scale below. The use of an extractor fan in the same room as the boiler (or in an adjacent room in communication) can, in certain conditions, adversely affect the safe operation of the boiler. Where such a fan is already fitted, or if an extractor fan is likely to be installed at a later date, then the advice of the gas supplier should be obtained. BS Inputs greater than 70kW (nett) Total gross input rating of boilers Position of air vents Air vent areas* (cm2) (air direct from outside) 70kW to 1.8MW 70kW to 1.8MW High level Boiler room Enclosure 2 5 Boiler room Enclosure 4 10 requirements are stated. If operating for more than 50% of time refer to BS Balanced flue applications However, air may be required to ventilate the boiler house and remove any excess heat generated by the boiler (2cm2 free area per kw nett heat input at both high and low level BS 6644). Imax xtra & Imax plus III boilers have an air inlet connection which may be used with proprietary ducting if required. A separate flue connection is still required. Water Treatment the mains is treated. For these reasons Ideal Boilers strongly recommends that when necessary the system be thoroughly cleaned prior to the use of a stable inhibitor which does not require continual topping up to combat the effects of hardness, salts and corrosion on the heat exchanger and its associated systems. The Ideal Imax xtra & Imax plus III boilers have an aluminium alloy heat exchanger. Therefore it is important that if water treatment is used it is suitable for Telephone: or Fernox Telephone: for technical information. 38

39 Imax Range Open Systems The system should be vented directly off the boiler flow pipe, as close to the boiler as possible. The cold feed entry should be inverted and MUST be positioned between the pump and the vent, and not more than 150mm (6 ) away from the vent connection. There should be a minimum height, 500mm (20 ) of open vent above the cistern water level. The vertical distance between the highest point of the system and the The boiler is at the highest point of the circulation system. Systems designed to raise above the flow tappings will, of course, automatically require a minimum static head higher than shown. given as a guide only. The final position will depend upon particular characteristics of the system. Pumping over of water into the expansion cistern should be avoided minimum Feed/expansion cistern Wa ter level (cold) Open vent System return Cold Feed 500mm minimum 3000mm minimum System flow to pump Inverted cold feed entry Cold Feed/Open Vent The independent cold feed and the open vent must comply with Connections to boiler Boiler output (kw) Cold feed Open vent (25mm) 1 ¼ (32mm) ¼ (32mm) 1 ½ (38mm) ½ (38mm) 2 (50mm) must be fitted on the return. This diagram does not show safety valves, water flow switches etc. necessary for the safe operation of the system. Sealed Systems Working pressure 6 bar (87psi) maximum. Subsection 11, Guidance note PM5 Automatically controlled steam and hot water boilers published by the Health and Safety Executive and Water Regulations Guide. Authority, gas or water undertakings. In general, commercial closed pressurised systems are provided with either manual or automatic water make up. In both instances it will be necessary to fit automatic controls intended to protect the boiler circulating system and ancillary equipment by shutting down the Examples of such situations are low water level and operating pressure or excessive pressure within the system. Depending on circumstances, controls will need to be either manually or automatically reset. In the event of shut down, both visual and audible alarms may be necessary. Initial minimum charge pressure should not be less than 0.5 bar (7.2psi) and must take account of static head and specification of the pressurising equipment. When make up water is not provided automatically it will be necessary to fit controls which shut down the plant in the event of the maximum system pressure approaching to within 0.35 bar (5psi) of the safety valve setting. BS Condensing

40 Commercial Heating Solutions Evomod System requirements - open vented The information and guidance given below is not intended to override any requirements of the above publications or the requirements of the local authority, gas or water undertakings. with the pump manufacturer's minimum requirements, to avoid cavitation. Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Ideal Stelrad Group. The isolation valves should be fitted as close to the pump as possible. 1. system flow pipe connection The maximum flow rate through the boiler is based on a temperature difference of 20 o C at full boiler output. 4. The boiler is at the highest point of circulation in the system. Systems designed to rise above the boiler flow tappings will automatically require a minimum static head higher than that shown. 5. given as a guide only. The final position will depend upon the particular characteristics of the system. Pumping over of water into the expansion cistern must be avoided. 6. Note. This diagram does not show safety valves, safe operation of the system. Open Vent Pipe Sizes Rated output kw Minimum bore mm Nominal Size (DN) in 301 to and above Cold Feed Pipe Sizes Rated output kw Minimum bore mm Nominal Size (DN) in 301 to ½ 601 and above 50 2 R R 2 ) System requirements - sealed system Working pressure 6 bar maximum. Particular reference should be made to BS and Guidance note PM5 "Automatically controlled steam and hot water boilers" published by the Health and Safety Executive. The information and guidance given below is not intended to override any requirements of either of the above publications or the requirements of the local authority, gas or water undertakings. In general commercial closed pressurised systems are provided with either manual or automatic water make up. In both instances it will be necessary to fit automatic controls intended to protect the boiler, circulating system and ancillary equipment by shutting down the boiler plant if a potentially Examples of such situations are low water level and operating pressure or excessive pressure within the system. Depending on circumstances, controls will need to be either manual or automatic reset. In the event of a shutdown both visual and audible alarms may be necessary. charge pressure. Initial minimum charge pressure should not be less than 1.0 bar (14.7psi) and must take account of the static head and specification of the pressurising equipment. The maximum water temperatures permissible at the point of minimum When make up water is not provided automatically it will be necessary to fit controls which shut down the plant in the event of the maximum system pressure approaching to within 0.35bar (5psi) of the safety valve setting. BS

41 The Ideal Commercial product range Boiler output kw Btu/h (000) Atmospheric Boilers Concord CXA/H Concord CXS/H Concord CXSi/H Concord ESi Concord Modular High Efficiency Boilers Concord Super Series Concord Super Plus Condensing Boilers Evomax Evomod Imax plus III Imax xtra Pressure Jet Boilers Buccaneer GTE Falcon GTS Harrier GTS Viceroy GTS Viscount GTS Vanguard L Approval Ideal Commercial Heating pursues a policy of continuous improvement in design and performance of its products and reserves the right to vary specification without notice. Statutory rights of the consumer are not affected. Please note: The information in this brochure was correct at the time of going to print. Ideal Heating reserve the right to make any modifications to product specifications or any other details, without prior notification. For further clarification, please enquire in writing to the head office address on the reverse of this brochure. 41 Condensing

42 Ideal Service & Support At Ideal Heating, we are committed towards delivering the highest levels of customer service. With over a century of experience in the heating industry, we know how important confidence and trust is to our customers. partnering with a British manufacturer that s supported by a dedicated national service team, delivering help and advice to you and your customers throughout the year. procedures and manufacturing quality control checks, ensures that all of our products are total comfort and peace of mind. The call centre team, based in Hull, East provide tailored advice. All calls will be answered by trained members of staff who will take ownership of the call. All of our trained staff are on-hand to assist with enquiries or help diagnose and resolve faults over the telephone. Should that not be possible, we will arrange an appointment for one of of engineers are fully trained to exacting standards and are all Gas Safe registered. Ideal Commercial Heating Service Sales Technical Training commercial_services@idealheating.com 42

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