Condensing Heat Exchanger Suitable Gas Fired Ideal GT & GTE boiler ranges

Condensing Heat Exchanger Suitable Gas Fired Ideal GT & GTE boiler ranges

2 The new GT Condenser provides higher efficiencies and low running costs from the Ideal range of pressurised gas boilers. Extracting additional heat normally lost with the flue gases. Ideal also provides specifiers, contractors and building owners with trade mark benefits of simplicity and flexibility of installation and operation. Highest efficiencies... Advanced Performance Up to 16% extra heat. Compact size. Adjustable flue and system connections. Low flue and system resistances. High insulation levels. Fanned or standard versions. Suitable for Harrier, Viceroy and Viscount boilers. The addition of a GT Condenser to the boiler can provide up to 16% more heat by cooling the flue gases to gain both sensible and latent heat from condensation. The lower the system return temperature being fed into the Condenser the more the gain. It all provides benefits in lower emissions & lower fuel bills. The GT Condenser range is suitable for gas fired boilers only but can be fitted to dual fuel boilers with suitable flue design. Six models are available to suit Harrier, Viceroy and Viscount boilers with a boiler output range suitability from 180kW (614,000 Btu/h) to 986 kw (3,364,000 Btu/h). Three output models cover this range and to ensure easy flue installation, each is available with or without a fan to overcome the flue pressure loss of the GT Condenser if necessary. A 6 bar working pressure capability ensures system application is straightforward. The GT Condenser is entirely manufactured from stainless steel which ensures long term durability. The unit is designed for easy installation in restricted boiler houses taking minimal floor space. Clever design allows both flue and system connections to be made in the most simple and convenient manner. Both upper and lower flue casings may be rotated independently around the heat exchanger by 360 allowing all connections to be made in the easiest manner. High levels of insulation ensure that heat gains are kept in the system where required. The heat exchanger is a multi tubed cylinder with flue gases passing from top to bottom, condensate draining to the lower flue casing where an outlet connection is provided. Servicing is simplicity with the flue tubes being easily washed through. The Ideal GT Condenser range is suitable for Harrier, Viceroy and Viscount boilers. Advanced performance from the market leader, Ideal Boilers.

GT condenser condensing heat exchanger 3 RCI & RCI... V Flue inlet (RCI... V models) Flue inlet (RCI models) Upper flue casing (grey) RCI... V Fan unit in stainless steel - 230V/400V motor 3 phase with cooling fan, 1 speed - IP55 protection, class F - 3 optional positions inlet from left, right or beneath Note: inlet cannot be from above Pressure tube (flow rate measurement for RCI... V models) Upper flue unit (stainless steel 316L - rotatable) Lifting hook Insulation - 40mm rockwool ground flue box - 40mm fibreglass wool around heat exchanger Safety valve connection (RC 3 /4) Flow connection (316L stainless steel with rotaing PN10 flange) Tubular heat exchanger with baffles (all stainless steel 316L) rotatable through 360 Flow switch connection (RC 1 1 /2) Heat exchanger casing (ivory) Return connection (316L stainless steel with rotaing PN10 flange) Lower flue unit (stainless steel 316L) rotatable Drain connection (RC 1 /2) Flue outlet Condensate drain outlet Adjustable feet

4 performance The Ideal GT Condenser provides high operating efficiencies when used in conjunction with Harrier, Viceroy or Viscount pressurised gas boilers. They are manufactured from stainless steel for long life, with the option of fan flue options permitting a wide variety of system applications. The efficiency of these high quality boilers can be increased by up to 16% using the GT Condenser. The greatest benefits are achieved with low system return temperatures as condensing operation starts to occur below 54 C return as shown on the chart adjacent. Overall system running costs can therefore be minimised using a GT Condenser. Up to 16% efficiency benefit construction Entirely manufactured in 316L stainless steel containing molybdenum for extra corrosion resistance. The multi-tubular vertical shell has removable flue baffles and is insulated with 40mm of aluminium backed fibreglass. Both upper and lower flue casings are also manufactured from 316L stainless steel. The upper flue casing being insulated with 40mm Rockwool. Both upper and lower flue casings can be independently rotated through 360 around the heat exchanger. A drain connection is provided on the lower casing. The fan option consists of a 3 phase motor (230/400V) fitted to a stainless steel fan. The intake position can be fitted in three different orientations. system applications GT Condensers are suitable for use with Harrier, Viceroy and Viscount gas or dual fuel boilers. They may be applied to heating only or heating and hot water systems. They may be used as preheaters in indirect hot water circuits. quality As with all Ideal boilers the GT Condenser is engineered to the highest quality standards. Ideal boiler products meet or exceed the requirements of every relevant standard. Ideal Boilers are recognised as a World Class Manufacturer. packing Factory assembled condenser on a pallet with strapped on carton. For RCI... V option, a crated fan is provided separately. options Fan versions of standard GT Condensers RCI 300V RCI 400V RCI 500V Suitable for both Open Vent and Pressurised/Sealed Systems, all of which must be fully pumped. The maximum static head for open vent systems is 61 metres (200 feet). The maximum working pressure for pressurised systems is 6 bar (87 psi). Maximum service temperature 110 C.

product specification 5 system design GT Condensers can be applied to suitable boilers in new or existing systems and may be fitted in heating only or heating and hot water systems. They may also be used in open vent or pressurised sealed systems. A wide variety of system designs can therefore utilise a GT Condenser: Heating only (constant & variable temperature) Heating & hot water circuits Preheat of hot water and many others. water circulation A tapping is provided on the Condenser return pipe for a flow switch. In the event of no water flow, the flow switch must be able to: (a) stop burner when RCI connected in series in flue circuit (b) stop fan when RCIV connected in parallel in flue circuit (c) stop burner and fan when RCI... V connected in series in flue circuit. The following points should be noted for system design: System design must allow for adequate circulation within the boiler and Condenser during, and immediately after burner firing. A tapping is provided on the flow connection for a safety valve. This can be used if there are any valves which may isolate the Condenser. Heating and hot water controls should be electrically interlocked with the burner to prevent firing when there is no demand for heat. Design should ensure the lowest temperature supply to the Condenser to maximise condensation and thus efficiency. Information and guidance on system design may be consulted in BS 5449 Part 1, BS 5410 Part 2, BS 5376 Part 2 and BS 6644 Section 2, subsection 11 and Guidance Note PM5 Automatically controlled steam and hot water boilers published by the Health & Safety executive. Other British standards applicable to commercial sealed systems are: BS 1212 BS 6880 Part 2 BS 6281 Part 1 BS 6282 Part 1 BS 6283 Part 4 Requirements of Local Authority, gas or water undertakings must always be adhered to.

6 system design examples There are many possible system designs that may use a Condenser: - heating only circuits (constant and variable temperature) - heating and hot water circuits - Preheat of hot water The three examples given below cannot cover all installations which may be encountered. Their purpose is to provide basic guidance and suggest some possible GT Condenser applications. In all cases, standard installation practices, along with national and local regulations currently in force, must be respected. 1. Single Circuit (Heating Only) The GT Condenser is fitted in series with the boiler flue circuit, the flue system design allowing for the Condenser pressure drop. The system variable temperature return is piped to the Condenser inlet to give low return temperatures and therefore increase energy savings. The heated Condenser flow passes to the boiler and is then raised to desired system temperature. In this layout the GT Condenser may be sized to suit the maximum boiler output. ID5198 If constant temperature circuits are also within such a system the GT Condenser can be sized to suit the variable temperature circuit(s) only with suitable pipework. 2. Multiple Heating Circuit - Multiple Boilers The GT Condenser is fitted in parallel to the boilers flue circuit to be independent of number of boilers firing. Both constant and variable temperature circuits are present taken from a vertical header. The Condenser is located on the variable temperature circuit to utilise low return system temperatures and effectively preheat the header return. It should be sized to the variable temperature circuit load. In fully mixed state, then valve A should be open. ID5199 3. Heating installation (1 Circuit) and sanitary hot water with pre-heating unit, linked to boiler flue - RCI in parallel (dynamic): The system uses a preheater for the D.H.W calorifier. The GT Condenser is connected to the preheater to achieve energy savings on D.H.W use by utilising boiler flue heat. The heating circuit is laid out as required, not being connected to the Condenser circuit. The Condenser is installed in a loop design in the building. It is better to choose the RCI... V version connected as a by-pass to the flue so as to be able to control the water temperature by stopping the fan without having to stop the boiler. ID5200

design requirements 7 flue system The use of a Condenser leads in most cases to flue temperatures comparable to those obtained with dedicated condensing boilers. The flue temperature is about 15 C above that of the return heating water. In all cases, it will not be less than 40 C. Reminder of a few important, practical rules: - limit the number of boiler - Condenser groups connected to the same flue. Minimise the number of elbows. - drainage of condensate must be at the base of the flue and at the lowest points of the lower flue box. Drain pipes must be in corrosion resistant material and of a constant diameter. The type of flue pipe used should conform to BS 715 Section 2, Stainless Steel or be of equivalent corrosion resistance. All joints or connections in the flue system must be impervious to condensate leakage. ID5021 RCI without fan installed in series in the boiler s flue In this case; - The boiler s burner must be capable of overcoming the additional Condenser (including that of the connecting flue between the boiler and the Condenser) pressure loss. or there should be a fan fitted on the flue capable of overcoming that additional pressure loss. If this is not possible, it will be necessary to consider: - either adapting the burner or replacing it, - or, if the installation allows, reduce the boiler output. If the above is not possible an RCI... V with fan unit must be used. ID5202

8 RCI... V with fan RCI... V with fan, installed in series or in parallel in the boiler s flue: RCI... V in Series - In series: the fan overcomes the pressure loss of the Condenser where the boiler or flue cannot provide sufficient draught. - In parallel: this type of connection is only allowed if a fan is installed. The advantages are: - it is independent of the output of the associated boiler. - it has an effect on all the boilers in a system in cascade formation, whatever the order of the cascade or the number of boilers in use. - it allows the boiler to operate with the Condenser switched off. In particular, this may be desired in summer with D.H.W only required. This simplifies the hydraulic connection of any domestic hot water only boiler. - it allows dual fuel oil/gas burners to be used provided an interlock to prevent Condenser use when oil firing is applied. RCI... V in Parallel RCI... V in Parallel ID5203 ID5204 ID5205 electrical connections RCI Without Fan A flow switch (not provided) is: - connected in series with the control circuit of the burner where a standard control panel is used. RCI... V (with Fan) The fan must have a 230 or 400 Volt three phase supply. In all design layouts the operation of the fan must be interlocked to the boiler burner operation. Where the system uses several boilers in cascade, connection of the RCI... V (installed in parallel in the flue circuit) should be made so that the fan starts as soon as one boiler starts. If a dual fuel boiler is installed using a parallel flue circuit for the RCI... V, then the Condenser fan operation must be interlocked to operate only when gas is being fired. Fan operation must stop on changeover to oil. A water flow switch (not supplied) should be connected in series with the control circuit to prevent the burner firing in the event of low flow.

dimensional data 9 Dimensions RCI & RCI... V ID5190 Dimensions RCI... V ID5191 Model A B C D Ø int. E ØG ØH J K L M N O P R S T U RCI 300/300 V 1687 610 270 1476 300 330 360 1156 350 540 DN 65 569 671 80 531 249 262 380 RCI 400/400 V 1777 698 300 1546 350 380 410 1250 400 645 DN 80 630 658 90 555 273 287 455 RCI 500/500 V 1883 830 330 1623 400 430 460 1376 460 830 DN 100 657 634 95 555 273 312 550

10 general data Model RCI 300 RCI 300V RCI 400 RCI 400V RCI 500 RCI 500V Boiler input kw 199 to 500 253 to 747 433 to 1096 Boiler output kw 180 to 450 230 to 670 390 to 986 Pressure losses - flue circuit mbar 0.5 to 2.7 0.3 to 2.5 0.4 to 2.7 Nominal water flow rate m 3 /h 9 to 25 12 to 36 19 to 58 Minimum water flow rate m 3 /h 1 to 2.5 1.2 to 3.6 1.9 to 5.8 Maximum water flow rate m 3 /h 27 to 75 36 to 108 57 to 174 Pressure loss - water circuit mbar 8 to 35 7 to 33 8 to 50 Water capacity (Condenser) litres 86 114 190 Maximum working pressure bar 6 6 6 Maximum service temperature C 110 110 110 Power consumption W - 250-550 - 1100 Fan speed rpm - 1500-1500 - 1500 Current 230 V - 3 phase A - 1.50-2.85-4.70 Current 400 V - 3 phase A - 0.85-1.65-2.70 Net weight kg 153 180 210 233 312 348 Delivery weight kg 177 229 238 286 342 373 Water circuit pressure loss Flue circuit pressure loss - Temperature at at inlet of RCI ~ 200 C -CO 2 : 10% - Depression at flue outlet of RCI 0,05 mbar. Example: A flow rate of 15 m 3 /h in the RCI 300 equates to a water pressure loss of 15 mb. Example: Boiler heat input = 400kW. Flue circuit pressure loss for RCI 400 = 1 mb.

general data 11 GT Condenser RCI 300 or 300V Model Heat Output Heat Input GT Condenser Output (by Temp.) Pressure Drop Pressure Drop (Boiler) (kw) (Boiler) (kw) 45/30 C 60/45 C 75/60 C Flue Circuit Water Circuit (kw) (kw) (kw) RCI Only (mb) RCI Only (mb) Harrier 6 180 199 29 20 13 0.6 10 Harrier 7 230 253 35 24 15 0.9 13 Harrier 8 280 309 45 32 21 1.5 19 Harrier 9 330 361 54 39 25 1.6 21 Viceroy 8 390 433 65 46 30 2.2 31 Viceroy 9 450 501 74 53 34 2.8 41 GT Condenser RCI 400 or 400V Model Heat Output Heat Input GT Condenser Output (by Temp.) Pressure Drop Pressure Drop (Boiler) (kw) (Boiler) (kw) 45/30 C 60/45 C 75/60 C Flue Circuit Water Circuit (kw) (kw) (kw) RCI Only (mb) RCI Only (mb) Harrier 7 230 253 35.5 24.5 15.5 0.5 8 Harrier 8 280 309 45.5 32.5 21 0.7 9 Harrier 9 330 361 54 40 26 0.9 13 Viceroy 8 390 433 67 49 32 1.1 17 Viceroy 9 450 501 78 56 38 1.4 20 Viceroy 10 540 598 93 68 45 1.9 25 Viceroy 11 600 669 103 75 50 2.3 29 Viceroy 12 670 747 112 83 55 3 33 GT Condenser RCI 500 or 500V Model Heat Output Heat Input GT Condenser Output (by Temp.) Pressure Drop Pressure Drop (Boiler) (kw) (Boiler) (kw) 45/30 C 60/45 C 75/60 C Flue Circuit Water Circuit (kw) (kw) (kw) RCI Only (mb) RCI Only (mb) Viceroy 8 390 433 66 48 32 0.5 12 Viceroy 9 450 501 78 56 37 0.8 15 Viceroy 10 540 598 94 78 45 1.1 19 Viceroy 11 600 669 106 76 51 1.2 23 Viceroy 12 670 747 118 90 58 1.4 27 Viceroy 13 720 803 126 92 62 1.5 29 Viceroy 14 780 870 135 104 68 1.8 32 Viscount 14 812 902 143 105 71 1.9 33 Viscount 15 870 967 154 113 76 2 39 Viscount 16 928 1031 164 120 81 2.3 41 Viscount 17 986 1096 174 127 86 2.6 46 Example: Total heat output of Viceroy 8 section with RCI 500 GT Condenser at 45 C/30 C return system temperatures. Viceroy 8 section = 390 kw RCI 500 66 kw Total 456 kw

the ideal commercial range kw 20 40 100 150 200 600 800 1000 1500 3500 Boiler output Btu/h (000) 68 136 340 511 682 2047 2729 3412 5118 11942 Atmospheric Boilers Concord CXA 40-120 Concord CXS, CXSD Concord CXC Condensing 40-120 46-116 Concord CXSi, CXDi Concord ES Concord CXA, CXS, CXSD Modular 110-180 140-340 80-720 High Efficiency Boilers Concord Super Series 4 50-600 Concord Super Plus 200-600 Maximiser SE 14-60 Pressure Jet Boilers Buccaneer GT 16-40 Falcon GTE 36-102 Harrier GT 105-330 Viceroy GT 300-780 Viscount GTE Vanguard S, HT 130-3500 754-1450 GT Condenser 180-990 Hot water solutions Buccaneer / Falcon Combination Boilers 16-64 Senator Calorifiers 150-1000 litres technical training The Caradon Plumbing Solutions 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 498432. customer care helplines Helplines are open 8.30am to 6.00pm Monday to Friday. Please ring 01482 498376. world class manufacturer Ideal Boilers has been adjudged by IBM Consulting and The London Business School to be a World Class Manufacturer. CERTIFICATE No. FM 14648 SIC 3284 Assurance of quality BS EN ISO 9001: 1994 Ideal Boilers 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. Ideal Boilers Limited PO Box 103 National Avenue Kingston upon Hull HU5 4JN Tel: 01482 498690 Fax: 01482 498621 B/G/C/10/01 Issued subject to standard conditions 2001 Caradon (Ideal Boilers) Limited