HEATING SOLUTIONS FIREBIRD LIGHT COMMERCIAL CASCADING SYSTEM

HEATING SOLUTIONS FIREBIRD LIGHT COMMERCIAL CASCADING SYSTEM

HEATING SOLUTIONS ENVIRONMENT INNOVATION TECHNOLOGY About Us Firebird is proud to declare over 35 years manufacturing in the heating industry, developing some of the most renowned products on the market. A company s research and development centre plays an integral role in the life cycle of a product. At Firebird, our internal R&D department is a crucial component for innovation and a key factor in development. All Firebird products are designed using the very latest in CAD-CAM technology. Our products are approved to all relevant European and national standards and are rigorously tested before launch. Firebird has enjoyed a string of industry firsts including the first PCDB Band A Combi boiler on the market. We are all aware that the regulations require us to build more energy conscious houses with respect to insulation, heating and orientation. This is why at Firebird, we continue to expand and improve our product range. We now manufacture the most efficient boiler in Europe - the Enviromax Blue Supreme with an exceptional 97.4% seasonal efficiency. From the robust, elite manufacturing process, through to the dedicated sales, technical and training teams, Firebird can guarantee the highest quality product and service. Our dedication to quality is second to none and continuous improvement programmes have resulted in higher quality products with an even greater degree of flexibility and efficiency. Firebird has invested heavily to automate and streamline production in order to meet rapidly changing market demands and future needs. Today most of our manufacturing processes are automated, including Trump punching centres, robotic folding, welding and an automated paint line. 2

LIGHT COMMERCIAL HEATING HEATING SOLUTIONS LIGHT COMMERCIAL HEATING SOLUTIONS FROM A SINGLE SOURCE. The 2009/125/EC Directive states: Boilers with rated heat outputs greater than 70kW (and less than 400kW) that are installed in new builds or as refurbishment projects MUST comply with the directive and achieve greater than 86% GCV. Can Firebird help to meet the Directive requirements - Absolutely Yes! Firebird condensing boilers have been designed to be as efficient as possible so not only can the directive be met, significant operational cost savings can also be made when using modern Firebird oil fired condensing boilers, compared with older cast iron single output units currently found in light commercial situations (up to 20%). Light commercial projects such as nursing homes, small hotels and schools, have always relied upon large single unit standard efficiency boilers - predominantly manufactured from cast iron. These new directives provide new challenges for the existing industry. Alternatives when planning for the provision of heating systems in light commercial projects will have to be considered: The use of smaller, highly efficient condensing boilers will become standard practice. Multiple smaller output boilers in a cascade arrangement will become common place. Linking boilers into a management cascade system can deliver significant efficiency gains as the system can reduce overall boiler output, dependent on demand. By smart thinking and design, the use of smaller boilers and management systems can significantly reduce capital cost compared with large single source heating units. 3

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HOW IT WORKS HEATING SOLUTIONS For larger heat demands, all Firebird high efficiency condensing boilers can easily be multi cascaded (modulation) through the Low Loss Header Management System. These cascade units can provide a condensing output of up to 600kW with the ability to reduce overall output down to a ratio of 1:4. This ensures efficiency is maintained even when demand is low. The controller manages the boilers to deliver heat to the Low Loss Header, depending on demand from the Low Loss Header. System Features ErP Compliant when used with a Firebird condensing oil boiler. High efficiency boilers/system. Fully condensing. Low Loss Header Features Easy to install - 4 mounting points. Rotational to facilitate pipe work. Large tapping for larger boilers (can be bushed down as required). Easy accessible draining tap. Convenient tapping points for expansion provison. Management Controller Features Controls up to 4 equal sized boilers. Weather compensation built in. Timed control rotation of master/slave function (10-800hrs). Two button navigation selection. Clearly marked electrical connections. Easy set up. 5

TYPICAL LAYOUT SYSTEM Management Controller Boiler 1 L o w Boiler 2 Boiler 3 L o s s H e a d e r Boiler 4 6

LOW LOSS HEADER HEATING SOLUTIONS Key Benefits & Features Available in three sizes: 100kW, 200kW and 600kW max. input. Compact space saving design. Achieves hydraulic separation between boilers and system. The correct temperature balance between the boiler flow and return is attained. The fitting of a Low Loss Header ensures that the boilers function at their peak efficiencies. Robust construction. Tappings for air vent/drain/expansion vessel and sensor pocket as standard. Flexible installing options. Highly insulated protective casing. 5 year warranty. Off-the-shelf availability. MULTI BOILER CASCADE SYSTEMS For larger heat demands, the Enviromax boiler range can be easily combined as part of a multi boiler cascade system. When used in combination with the Low Loss Header, 2-4 boilers can be connected. This ensures that high levels of efficiency can be achieved all year round, even when demand for heat is low. Boilers can be sequenced to come into and out of operation when required, evenly spreading their usage. Sales Codes: Low Loss Header ACC003LLH ACC004LLH ACC006LLH Firebird 3S Low Loss Header Firebird 4S Low Loss Header Firebird 6S Low Loss Header Cascading Management Controller ACC000CCK LLH Cascading Controller Kit 7

Case Study - SCHOOL LESSONS The installation features in a school built in 1961 originally heated by a single 180kW cast iron boiler. The school went through a refurbishment programme including an extension. After an energy assessment was carried out, the existing heating system was replaced with three 100kW high efficiency condensing boilers from the Firebird Silver Boilerhouse range. The new boilers were designed as a cascading system via a Low Loss Header and sequence control unit. Current figures conclusively support the systems efficiency, showing substantial savings are being made in comparison with the old boiler. The school is obviously delighted with the improved heating and cost savings which on average are seeing a 25% reduction in fuel costs. Before installation took place, Firebird suggested that a cascading package would best be suited for the schools needs along with the type of boiler and the fluing system that would be required to suit the installation. For this our flue partners (MI Flues) were consulted and came up with the required solution of placing the boilers on a flue manifold. The installer was keen to ensure that the boilers were operating at their peak efficiencies by having the correct flow rate through the heat exchangers. By supplying the information that was required, the installer was confident in making the correct choice of a circulation pump. Firebird have access to Lowara technical design services who will always be able to advise on the perfect pump specification. Project Data: 3 x 100kW boilers installed in series controlled by relay panel, automatically cascading boilers. 300 litre expansion vessel capacity installed. 5 linked flue system to chimney outlet. Stats. installed on pipe work zoned areas to call for boiler heat requirement. 3 motorised valves for each zone. Control panel set up in teacher staff room. Energy Savings: over 2500 litres of oil saved in the first year of installation. The expected payback period is 2.5 years. THE SCHOOL IS OBVIOULSY DELIGHTED WITH THE IMPROVED HEATING AND COST SAVINGS WHICH ON AVERAGE ARE SEEING A 25% REDUCTION IN FUEL COSTS. 8

System Location HEATING SOLUTIONS The Low Loss Header must be attached vertically to a solid wall/object. Sufficient space should be left around the Low Loss Header to facilitate pipe work, fittings and to allow access to the drain cock for servicing/draining the unit. In order for the unit to work to its optimum, please review the schematics carefully, choosing the most appropriate set up for the installation, failure to do so may cause this unit to operate inefficiently. kw Needed * Boiler No. Boiler kw ** LLH Size mm LLH Code Pump Size m Flow Rate ltr/min. No. of Pumps No. of Non- Return Valves No. of Pipe Thermostats Oil Pipe Sizing mm Flue Size for each Boiler mm Min. dia. Main Flue Size mm 52 2 26 75 LLH3 6 65.52 2 2 2 15 80 115 70 2 35 75 LLH3 6 88.20 2 2 2 15 80 115 78 3 26 75 LLH3 6 147.42 3 3 3 15 80 140 88 2 44 75 LLH3 8 110.88 2 2 2 15 100 150 104 4 26 100 LLH4 6 262.08 4 4 4 20 80 160 105 3 35 100 LLH4 6 198.45 3 3 3 15 80 140 116 2 58 100 LLH4 8 146.16 2 2 2 20 100 150 132 3 44 100 LLH4 8 249.48 3 3 3 20 100 175 140 4 35 100 LLH4 6 352.80 4 4 4 20 80 160 146 2 73 100 LLH4 8 183.96 2 2 2 20 125 180 174 3 58 100 LLH4 8 328.86 3 3 3 20 100 180 176 4 44 100 LLH4 8 443.52 4 4 4 20 100 200 200 2 100 100 LLH4 8 252.00 2 2 2 20 150 220 219 3 73 100 LLH4 8 413.91 3 3 3 20 125 220 232 4 58 100 LLH4 8 584.64 4 4 4 20 125 200 292 4 73 150 LLH6 8 735.84 4 4 4 20 125 250 300 3 100 150 LLH6 8 567.00 3 3 3 20 150 260 400 4 100 150 LLH6 8 1,008.00 4 4 4 20 150 300 * Max. kw Needed ** Min. kw Needed eg. zone or lowest zone demand It is recommended by the burner manufacturers that at least 8mm id. supply pipe be used for a burner of up to 35kW and 10mm id. for a burner of up to 100kW in order to have an adequate supply of oil. Using a cross sectional calculation, 20mm id. pipe is sufficient to supply 4x100 and T d off to each boiler with 10mm id. pipe. For smaller systems, 15mm is sufficient. NOTE: these calculations are based on an oil tank level with or above the level of the burner. The condensate from the boilers needs to be transferred to an appropriate disposal drain by means of a 40mm/1½ wastepipe made from a suitable material and T d off so each boiler can be evacuated. 9

Flue Options B B B C D E BOILER 1 BOILER 2 BOILER 3 BOILER 4 A A A E D C B B B BOILER 4 BOILER 3 BOILER 2 BOILER 1 A A A 10

Flue Options HEATING SOLUTIONS Boilers kw H W D Flue dia. for Each Boiler Min. Space Between Boilers Space + Flue Center to Center Main Header Size for 2 Boilers Main Header Size for 3 Boilers Main Header Size for 4 Boilers 100 1052 625 745 150 150 775 250 300 300 73 873 530 525 125 150 680 250 250 250 58 815 470 531 100 150 620 150 200 200 44 815 470 531 100 150 620 150 200 200 35 684 441 381 80 150 591 125 150 200 26 684 441 381 80 150 591 125 150 200 20 684 441 381 80 150 591 125 150 200 18 684 344 381 80 150 494 125 150 200 12 684 344 381 80 150 494 125 150 200 All dimensions are in mm. Sales Codes PDK080RTA PDK080RTB PDK080RTC PDK100RTA PDK100RTB PDK125RTA PDK150RTA PDK150RTB Description PDK 80mm into 125mm Reducing Tee PDK 80mm into 150mm Reducing Tee PDK 80mm into 150mm Reducing Tee PDK 100mm into 150mm Reducing Tee PDK 100mm into 200mm Reducing Tee PDK 125mm into 250mm Reducing Tee PDK 150mm into 250mm Reducing Tee PDK 150mm into 300mm Reducing Tee For all other flue parts or boiler sales codes, please consult our product guide or contact our technical team here at Firebird on 026 45253 or service@firebird.ie. The product guide and boiler information can also be found on our website www.firebird.ie. 11

Customer Service Firebird pride themselves on offering the highest levels of customer service possible. The level of service provided is monitored on a regular basis to ensure customers requirements are always met. Technical Support Our Technical Team provides customers with a comprehensive technical support package which is designed to make the specification and installation process as simple as possible. For technical support please contact the Firebird Technical Team on 026 45253 or service@firebird.ie Quality All Firebird products are produced to the highest quality standards and are put through rigorous testing procedures by external standards agencies. Every product is designed to meet a specific requirement and has been manufactured using premium quality materials to precise standards and tolerances. Warranty Firebird offers a 5 year warranty on our Boilers, Heat Pump, Solar, Stoves and Range cookers. HEATING SOLUTIONS Firebird Heating Solutions Ltd. Údarás Industrial Estate, Baile Mhic Íre, Co. Cork, Ireland, P12 HK51. t: +353 (0)26 45253 f: +353 (0)26 45309 e: info@firebird.ie www.firebird.ie Firebird Heating Solutions Ltd. Shean, Forkhill, Newry, BT35 9SY. t: +44 (0)28 3088 8330 f: +44 (0)28 3088 9096 e: firebirdproducts@hotmail.co.uk www.firebird.ie Firebird Products Ltd, Phoenix House, Eastern Wood Road, Language Industrial Estate, Plympton, Plymouth, PL7 5ET. t: +44 (0)1752 691177 f: +44 (0)1752 691131 e: sales@firebird.uk.com www.firebird.uk.com