installation and servicing

installation and servicing
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.
110531-9.pmd
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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.
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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
CONTENTS
INTRODUCTION
Boiler Dimensions ............................................................ 9
CURRENT GAS SAFETY (INSTALLATION AND USE)
REGULATIONS OR RULES IN FORCE
It is the law that all gas appliances are installed and serviced by
a CORGI registered installer in accordance with the above
regulations. Failure to install appliances correctly could lead to
prosecution. It is in your own interest, and that of safety, to ensure
that the law is complied with.
Boiler House Clearances ................................................. 8
BOILER OPERATIONAL REQUIREMENTS
Boiler Operational Requirements .................................... 3
The SUPER PLUS range of boilers is suitable for fully pumped
open vented or pressurised central heating, indirect domestic
hot water and combined systems.
Assembly of Boiler ......................................................... 15
Boiler Description ............................................................. 5
Boiler Specifications ........................................................ 4
Combustion Data Sheet ................................................. 26
Commissioning and Testing .......................................... 16
Control Sequence Logic ................................................. 23
WARNING: In order to ensure safe, efficient and reliable
operation of the boiler, particular attention should be made to
the following points:
1. The Super Plus incorporates an aluminium alloy heat
exchanger. As part of the installation the central heating system
should be thoroughly flushed with appropriate water treatment
in order to comply with BS7593:1992.
Electrical Supply ............................................................. 13
Under no circumstances should the boiler be fired before the
system has been thoroughly flushed.
Exploded Views
Caradon Ideal Limited recommend only the use of Femox or
Betz Dearborn water treatment products, which must be used
in accordance with the manufacturers instructions. For further
information contact:
Boiler Assembly ........................................................... 5
Electrical Controls ....................................................... 6
Gas Line ........................................................................ 7
Module .......................................................................... 6
Fault Finding .................................................................... 24
Fernox, Fry Technology UK, Tandem House, Marlowe Way,
Beddington Farm Road, Croydon. CRO 4XS, tel. 0870 5601
5000 - or - Betz Dearborn Ltd., Sentinel Division, Foundry
Lane, Widnes, Cheshire WA8 8UD, Tel. (0151) 424 5351
Flue Requirements ......................................................... 10
IMPORTANT : ANY OTHER TREATMENT FOR THIS PRODUCT
WILL RENDER THE GUARANTEE OF CARADON IDEAL LIMITED
INVALID.
General Information .................................................. 3 - 13
Notes.
Installation ............................................................... 14 - 18
If an inhibitor is used, and in hard water areas where treatment
to prevent lime deposits is necessary, it is most important that
the water treatment MUST be maintained at the correct
concentrations recommended by the treatment manufacturer.
Installation Requirements ................................................ 7
Location ............................................................................ 8
Persons responsible for the continued operation of this boiler
should be made aware of this requirement.
Replacement of Components ........................................ 20
If the boiler is installed in an existing system then any
unsuitable water additives MUST be thoroughly drained.
Safety Checks ................................................................ 17
Artificially softened water must not be used in the system,
under any circumstances.
Servicing Instructions .................................................... 19
In old systems the fitting of a filter to the return pipework, in
order to prevent debris reaching the heat exchanger, is
essential.
Servicing and Fault Finding ..................................... 19 - 24
Short List of Parts .......................................................... 25
Water Circulation System .............................................. 12
Wiring Diagrams ............................................................. 14
2. The constant water flow rate through the boiler, within ±10%
of that indicated in the data table, must be maintained at all
times when any of the modules are operating. At these flow
rates the hydraulic resistance is 98 mbar (39 in.w.g.) ±20%,
irrespective of the size of the boiler.
3. Protection against circulating pump failure must be provided.
4. The chimney system must be double skinned, or single wall
lined and insulated with the equivalent of 50 mm (2") of mineral
wool, aluminium covered. A drainage point must be provided.
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GENERAL
GENERAL
Boiler Model No.
200/S
No. of Modules
300/3
400/4
300/3
400/4
Alternative Alternative
500/5
600/6
2
3
4
3
4
5
6
Heat Output
kW
Btu/h x 103
200
682.4
300
1023.6
400
1364.8
300
1023.6
400
1364.8
500
1706.0
600
2047.2
Heat Input
kW
Btu/h x 103
235
802.9
353
1204.4
471
1607.0
353
1204.4
471
1607.0
588
2006.2
706
2408.8
m 3/h
ft3/h
22.1
778.8
33.1
1168.0
44.2
1558.7
33.1
1168.0
44.2
1558.7
55.1
1945.8
66.2
2336.4
l/s
ft3/min
109
231
164
397
218
463
164
347
218
463
273
578
327
694
l/s
gal/min
4.3
56.8
6.5
85.2
8.6
113.6
6.5
85.2
8.6
113.6
10.8
142.0
12.9
170.4
Gas Rate
(Note 1)
Flue Gas Volume
at 100oC, 8.5% CO2
Required Water Flow Rate
(+/-10%)
Hydraulic Resistance
mb (in.w.g)
98 (39)
98 (39)
98 (39)
98 (39)
98 (39)
98 (39)
98 (39)
Min. Static Head (Note 2)
m (ft)
1.6 (5)
1.6 (5)
1.6 (5)
1.6 (5)
1.6 (5)
1.6 (5)
1.6 (5)
Max. Static Head
m (ft)
60 (197)
60 (197)
60 (197)
60 (197)
60 (197)
60 (197)
60 (197)
Electricity Supply
Nominal 230 V, 50 Hz, Single Phase. Max start current 1.9 A per module
Max. Running Power
W
400
600
800
600
800
1000
1200
mb
in. w.g
14.6
5.8
14.8
5.8
15.1
6.1
14.8
5.9
15.1
6.1
15.5
6.2
16.0
6.4
Boiler Height - overall
mm
in
1800
71
1900
74.8
1900
74.8
1900
74.8
1900
74.8
1900
74.8
1900
74.8
Boiler Width - overall
mm
in
910
35.8
1510
59.5
1510
59.5
2115
83.25
2115
83.25
2115
83.25
2115
83.25
Boiler Depth - overall
mm (in)
990 (39)
990 (39)
990 (39)
990 (39)
990 (39)
990 (39)
990 (39)
134
296
144
318
144
318
208
459
208
459
208
459
208
459
Min. Gas Supply
Pressure ( Note 3)
Weight of casing
kg
lb
Weight of Each Module
kg
69.2
69.2
69.2
69.2
69.2
69.2
69.2
lb
152.5
152.5
152.5
152.5
152.5
152.5
152.5
Weight of Water Header
kg
lb
16.3
36
38.2
84.2
38.2
84.2
49.8
109.8
49.8
109.8
49.8
109.8
49.8
109.8
Weight of Gas Header
kg
lb
3.5
7.7
9.4
20.7
9.4
20.7
12.6
27.7
12.6
27.7
12.6
27.7
12.6
27.7
Water Content
(excluding header)
l
gal
19.8
4.4
29.7
6.5
39.6
8.7
29.7
6.5
39.6
8.7
49.5
10.9
59.4
13.1
Weight of Dry Boiler
kg
lb
308.5
681.2
437.4
964.3
506.6
1116.9
437.4
1964.3
506.6
1116.9
666.2
1468.7
735.4
1621.3
Weight of Wet Boiler
kg
lb
328.3
724.9
466.9
1029.3
546.1
1203.9
466.9
1029.3
546.1
1203.9
715.6
1577.7
794.6
1752.3
Flow and Return
Connection (Note 4)
mm
in
65
2.5
125
5
125
5
125
5
125
5
125
5
125
5
Gas Connection
Rc (in. BSP)
40 (1.5)
2 (2)
Flue Pipe Size
(nominal bore)
mm
in
250
10
350
14
350
14
450
18
450
18
450
18
450
18
Flue Socket Size
(Note 5)
mm
in
288
11.3
401
15.8
401
15.8
500
19.7
500
19.7
500
19.7
500
19.7
Burner Injector Size
mm
in
12.0
0.47
12.0
0.47
12.0
0.47
12.0
0.47
12.0
0.47
12.0
0.47
12.0
0.47
2.7 (1.1)
2.7 (1.1)
2.7 (1.1)
2.7 (1.1)
2.7 (1.1)
2.7 (1.1)
2.7 (1.1)
Main Burner Pressure
mbar (in.w.g)
Fan Motor
Type BCP 1506E : 230 V, 50 Hz, Single Phase, 75W, ‘06’ rating
Gas Type
I2H
Notes:
1. Flue gas volumes and gas rates are calculated using a C.V. of
1031 Btu/ft3 (at 15oC & 1013.25 mb)
2. For further information on head requirements see page 6.
3. The minimum gas supply pressure is with all modules firing.
5. Flues to BS.835 will fit directly onto the 300/3 Alternative,
400/4 Alternative, 500/5 and 600/6 boilers. For all boilers
single skin and metal flues may need a suitable adapter.
Further advice may be obtained from Caradon Ideal
Limited.
4. Flange size: refer to BS.4504 Pt.1
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5. The chimney draught must be controlled between neutral
and 0.2mbar (0.08 in.w.g.).
6. Boilerhouse cleanliness is important and concrete floors
should be sealed to keep dust to a minimum. Contamination
of the air supply with chlorides should be avoided.
Regular maintenance by competent personnel is essential to
the safe and reliable operation of the boiler. Full details of these
requirements are given in these Installation & Servicing
Instructions.
The normal mode of operation of the boiler (described below) is
preceded in certain conditions by a phase in which the complete
boiler casing is given a 5-volume air change. This air change is
an important safety feature of BS.5978 and will occur whenever
the boiler goes from a situation of no modules firing to a situation
of one module firing. This includes morning start-up and those
occasions of low load when the last module firing goes off on its
thermostat (or external controls) and is then called again. The
air change will NOT occur if one or more modules are firing and
a further module is called.
BOILER DESCRIPTION
The 5-volume air change phase operates as follows:
Each boiler consists of the following packs:
All the module fans are energised and run for approximately 70
seconds. At the end of this period all the fans are switched off
except for that on the module being called which then immediately
enters its 35 second, pre-purge period, (see Fig. 20).
When the electronic control thermostat calls for heat, the fan is
switched on and purges the combustion chamber for
approximately 35 seconds. At the end of this period the ignition
sequence starts:
The spark generator is energised and delivers a spark to the
main burner and at the same time the main gas valves are
opened.
Once the flame is sensed and proved by the flame detection
probe, the controls keep the main gas valves open until the
control thermostat is satisfied.
The module is protected against blockage of burner, heat
exchanger, flue or fan by the pressure switch. This senses the
differential pressure between the pressure in the fan housing
and the suction in the venturi casting, preventing the ignition
sequence starting or causing safety shut down should the
pressure be outside the design limits. After combustion, the
products flow past the finned aluminium tubes, and through the
gas distribution screen into the boiler casing, transferring heat
to the water flowing through the tubes.
Each module is connected in parallel across the flow and return
water headers, so that water is flowing through all the modules
at all times.
(a) The insulated stainless steel casing with flue outlet,
condensate drain, wiring centres and wiring harnesses and
for 300/3 or 500/5 boilers only, blanking kit.
(b) Boiler modules.
(c) Gas header, flow and return water headers and module
fixing packs.
(d) Extra blanking kit and support bracket kits for the 300/3
Alternative and 400/4 Alternative boilers only.
Note: The 300/3 Alternative and 400/4 Alternative are sold with
a view to later upgrading.
MODULE DESCRIPTION
The module can be subdivided into 3 main elements:
(a) The heat exchanger consisting of finned aluminium tubes
expanded into cast aluminium tube plates. The bottom cover
plate is cast aluminium. The top cover plate is cast iron,
fitted with cast iron flow and return elbows.
(b) The gas line which supplies and regulates the gas flow to
the main burners.
(c) The controls assembly which incorporates the fan (supplying
air for combustion) and the electrical controls.
LEGEND
1. Flue test point
2. Water header
3. Gas pressure test
point
4. Module
5. Module upper cover
6. Module lower cover
7. Gas header
Fig.1 Boiler Assembly - Exploded View
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GENERAL
GENERAL
GENERAL
GENERAL
LEGEND
1. Controls box assembly
2. Fan motor
3. Venturi and gaskets
4. Pressure switch
5. Pressure switch test connections
6. Overheat thermostat pocket
7. Water flow elbow
8. Gas inlet flange
9. Cast iron top cover plate
19. Main gas line
20. Water return elbow
21. Module thermostat pocket
22. Burner
23. Spark electrode
24. Flame sensing electrode and lead
25. Main gas injector
10. Cast iron top cover plate gasket
11. Aluminium top tube cover
12. Gas distribution screen
13. Aluminium finned tube heat exchanger
14. Aluminium bottom tube plate
15. Bottom cover plate gasket
16. Aluminium bottom cover plate
17. Module lower cover fixing screw
18. Sight glass assembly
Fig.2 Module - Exploded View
4
3
LEGEND
1. Module electrical plug
2. LED grommets
3. PCB No.9B
4. Control thermostat
potentiometer
5. PCB No.12
6. Flame sensing head
7. Main gas valve leads
2
8. Fan motor
9. Pressure switch
connections
1
10. Fan connections
11. Spark/sensing
12. Fan rotor
13. Fan housing
14. Spark generator
15. Overheat thermostat
capillary
16. Main thermostat sensor
17. Lockout reset button
18. Control thermostat knob
5
6
7
8
9
10
18
11
12
17
Detail of Pressure Switch
Connection (Ref.9)
Black
Brown
Blue
15
13
14
Fig.3 Electrical Controls - Exploded View
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GENERAL
GENERAL
8
LEGEND
1. Main gas pressure test point
2. Main gas injector
3. Pressure switch electrical leads
4. Pressure switch
9
7
5. Pressure switch pressure pipe
6. Pressure switch suction pipe
6
7. Pressure switch test points
8. Gas manifold flange connection
10
4
9. Main gas governor
10. Main gas valve pressure test point
3
11. Main gas valves
5
11
2
1
Fig.4 Gas Line - Exploded View
Super Plus boilers provide good load-matching sequence control
by the following method:
As the load on the boiler decreases so the return water
temperature increases.
Each module is fitted with an electronic thermostat capable of
being set to within 0.5oC and these thermostats sense the return
water temperature. Once the return temperature reaches 71oC
the modules are set to switch off at intervals, to maintain the flow
at approx. 82oC.
The modules switch off from left to right and from top to bottom
thus the top left module is always the first to switch off and the
bottom right the last.
The sequence control wiring centre gives a step-start operation
of the boiler.
The modules are allowed to fire only in sequence, starting from
right to left and bottom to top so that the bottom RH module is the
first to fire and the top LH is the last. This step-start prevents
excessive load on gas or electricity supplies.
The wiring centre provides facilities for wiring remote indicators/
alarm of 'Bumer On', 'Lockout' and 'Overheat' for up to 6 modules.
Provision is also made for main supply and direct connection of
any interlock devices such as the water flow system.
INSTALLATION REQUIREMENTS
CURRENT GAS SAFETY (INSTALLATION AND USE)
REGULATIONS OR RULES IN FORCE
It is the law that all gas appliances are installed and serviced
by a CORGI registered installer in accordance with the above
regulations.
Failure to install appliances correctly could lead to prosecution. It
is in your own interest, and that of safety, to ensure the law is
complied with.
In addition the installation must comply with the relevant British
Standard Specifications and Codes of Practice, viz;
BS 6880 Part 1-3 Central Heating by Low Pressure Hot Water.
BS 6644
Installation of Gas Fired Hot Water Boilers of Rated
Inputs Between 70kW and 1.8mW (net).
IGE UP/1
Soundness Testing and Purging Procedures for
Non-domestic Gas Installations.
IGE UP/2
Guidance for Installation of Gas Pipework Boosters
and Compressors for Customers Premises.
IGE UP/10 Installation of Gas Appliances in Industrial and
Commercial Premises.
IM/22
Installation Guide for High Efficiency Condensing
Boilers (Industrial and Commercial Appliances).
Note. The Super Plus is a partially condensing boiler: the
condensate drain should be run in accordance with IM/22.
CP342:2
Centralised Hot Water Supply.
The installation must also conform to current building regulations,
any requirement of the local authority health and safety executive,
gas region, insurance companies and the Health and Safety at
Work Act 1985.
All wiring must conform to IEE (BS7671) Regulations for the
electrical equipment of buildings.
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GENERAL
GENERAL
LOCATION
The floor must be flat, level and capable of supporting the weight
of the WET boiler pipework. In addition, concrete floors must be
sealed. The siting of the boiler must be in accordance with the
guidance given in BS.6644 and with reference to minimum
boilerhouse clearances - refer to Fig. 5.
Inflammable materials MUST NOT be placed in close proximity
to the appliance. Materials giving off flammable vapours MUST
NOT be stored in the same room as the appliance.
Note: Headroom must be the boiler height
(Table 1) Plus any pipework and flue
requirements
Flue products must not be allowed to enter the
boilerhouse or adjacent buildings.
7.
Refer also BS.6644 and to IGE/UP/10 Installation of Gas
Appliances in Industrial and Commercial Premises and IM/22
for further guidance.
AIR SUPPLY
Detailed recommendations for air supply are given in BS.6644
which MUST be consulted before proceeding.
Contamination of the air supply from any external source must
be avoided - with particular reference to dust, insulation debris,
and flue products and concrete floors must be sealed. If any
work is to be carried out in the boilerhouse which is likely to
generate dust (e.g. structural alterations or lagging pipework), it
is recommended that the boiler be shut down and the modules
covered with a dust sheet, otherwise the boiler may require
cleaning and servicing.
900
(352)
500
(191/2)
6.
500
(191/2)
25(1)
1.
In particular the contamination of the air supply with chlorides
must be avoided as they will cause the deterioration of the
aluminium heat exchanger.
2.
The boiler requires ventilation openings at BOTH high and
low levels, direct from outside, and allowance MUST be
made for stabiliser dilution in all cases.
3.
Mechanically forced ventilation systems must include
provision for boiler shut down in the event of fan failure.
4.
High speed air streams within the boilerhouse must be
avoided.
5.
Extraction mounted ventilation fans alone are NOT permitted.
6.
The minimum effective areas of the permanent air vents
direct from the outside by natural ventilation are as follows:
Fig.5 Recommended Boiler House Clearances
for Comfortable Servicing Access (Plan View)
Required area (cm2) per kW of total rated input (net)
CONNECTION TO GAS SUPPLY
The gas installation MUST be in accordance with the
requirements of the local gas region (refer also to CP 331:3 and
CP 332:3 where applicable).
The gas supply must be capable of maintaining a minimum
pressure as indicated in Table 1, measured at the inlet to the
boiler, with all modules firing (gas consumption is given in
Table 1.) Static inlet pressure should not exceed 50 mb.
The boilers are for use with NATURAL GAS ONLY.
FLUE REQUIREMENTS
Open flue, induced draught and fan diluted systems may be used
but must comply with the following basic requirements:
1.
A draught diverter MUST NOT be fitted.
2.
A draught stabiliser MUST be fitted to all types of flue systems
and set to control the draught in the casing between neutral
and 0.2 mbar (0.08 in.w.g.) irrespective of flue height or
number of modules firing. (see Figs. 6 and 7 for further
guidance).
3.
ALL flue systems must be insulated and/or lined and
impervious to acid condensate. Prefabricated chimneys must
have a 'U' value of no greater than 1.4 W/m2 oC at 540 oC (0.25
Btu/h ft2 0F at 1000oF).
4.
Drainage must be provided at the base of the chimney or
liner. (All boiler casings have a condensate drain point - see
Fig. 17)
5.
For fan diluted or induced draught systems, air flow/pressure
switches MUST be fitted to protect against fan failure.
Switches should be set to open if the air flow reduces by
more than 15%.
Enclosure
Low level (inlet)
4
10
High level (outlet)
2
5
Note: Where a boiler installation is to operate in summer
months (e.g. DHW) additional ventilation requirements are
stated, if operating for more than 50% of time (refer to
BS6644).
7.
The minimum air requirements by mechanical ventilation
are as follows:
Table 2
Mechanical ventilation flow rates
Type of boiler
Forced/induced
draught boilers
Flow rate per KW total rated heat input (net)
Inlet air
(Combustion
ventilation)
Extract
air
(ventilation)
2.6 m3/h
1.25m3/h
± 0.18m 3/h
A purpose designed flueing ventilation system based solely on a
high level permanent opening to an otherwise sealed boilerhouse or compartment may be used, provided that specialist
advice is taken and that the combustion air and ventilation
requirements of the boiler is provided in line with BS.6644. In
addition this boiler house temperature must be prevented from
exceeding 32 oC at mid-level. BS 6644 provides details of
temperature requirements.
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INDUCED DRAUGHT
GENERAL
GENERAL
All dimensions in mm (in)
Note: The discharge from both types of system MUST
not allow recirculation of combustion products into
the boilerhouse or adjacent buildings.
Note: The discharge from both types of
system MUST not allow recirculation of
combustion products into the
boilerhouse or adjacent buildings.
'FAN DILUTED FLUE (FDF)' SYSTEM
Note: Air intake and discharge should be on the same outside wall
face. Design must comply with British Gas requirements - refer P7
and IM/11.
Fig.6 Application of Draught Stabiliser
Fig.7 Flueing - General Guidance
All dimensions in mm (in)
990(39)
910(35.8)
11/2in. Gas
connection
600(23.6)
65(2.6)
250(10)
165
(6.5)
25(1.0)
For 10 in.
Flue Pipe
160(6.3)
21/2in. Water flow Pipe
10
(0.5)
2
1420
(55.9)
1400
(55.1)
1610(63.4)
1
21/2in. Water Return Pipe
21/2in. Flange
Connection
210
(8.3)
150(5.9)
200
(7.9)
800(31.5)
600(23.6)
Fig.8 BOILER DIMENSIONS - SUPER PLUS 200/S boiler only
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GENERAL
GENERAL
All dimensions in mm (in)
SUPER PLUS 400/4 Boiler shown
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 & 600/6 boilers only
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GENERAL
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
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GENERAL
GENERAL
WATER CIRCULATION SYSTEM
Maximum Static Head:
DESIGN REQUIREMENTS
60.0m (197 ft.), i.e. maximum operating pressure 6.0 bar (85 lb/
in2).
SUPER PLUS Gas Boilers are intended for use in conjunction
with FULLY PUMPED, OPEN VENTED OR PRESSURISED
systems, subject to the requirements below. They are NOT
SUITABLE for use on gravity circulation systems.
Water flow rate:
28.4 gal/min (2.15 l/s) ± 10% through each module. Thus a 6
module boiler (Super Plus 600/6) requires 170.4 gal/min (12.9 l/
s) volume flow rate.
Note:Failure to maintain this flow rate will result in operation of
the module overheat thermostat.
Any other method of installation should be discussed with
Caradon Ideal Ltd. before proceeding.
Hydraulic Resistance:
When operating at the correct volume flow rate given above, the
Hydraulic Resistance of all Super Plus boilers is 98 mb (39
in.w.g.) ± 20%.
Pump Overrun:
A pump overrun time of 30 seconds minimum must be allowed
for on plant shutdown.
Minimum Static Head
Minimum static head requirements for open vented systems
must comply with boiler design characteristics, pump
manufacturer's requirements and the requirements of the Health
and Safety Executive Publication PM5.
A minimum static head of 1.6 m is required to overcome the
boiler hydraulic resistance and give a reasonable safety margin.
This requirement is specific to the boiler but installed systems
must also comply with Health and Safety Executive Guidance
Note PM5. In those cases with minimum static head available it
will be necessary to fit a further overheat thermostat in the mixed
flow from the boiler set at 900C and wired to terminals S2 and S3
in the wiring centre.
Note: In some cases pump manufacturers will require a head
as high as 12 m (40 ft), This must be allowed for the minimum
head increase accordingly.
See Fig.14 for further clarification
All dimensions in mm (in.)
1. Roof top or single storey applications
LEGEND
1. Cold feed (size must
comply with BS 6644)
2. Open vent (size must
comply with CP:332:3)
3. Safety valve
4. Water flow switch
5. Dual primary pumps
6. Mixing header
7. Feed expansion tank
8. Mixing valve
9. Highest point in system
l
Super
Plus
Boiler
2. Ground floor or basement applications
System Zones
Minimum head
required by boiler,
but additional
head may be
required by the
pump
manufacturer or to
comply with
Health and Safety
Executive
Guidance Note
PM5
HIGH
LEVEL
ZONE
Super
Plus
Boiler
MID
LEVEL
ZONE
HIGH LEVEL ZONE
Fig.13 Guide to Minimum Requirements - Feed / expansion tank height & boiler primary circuit
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Safety Valve:
The following points should be noted:
A safety valve must be sized and fitted in accordance with BS.6644.
The valve should be set at 0.7 bar (1 0 lb/in2) above the available
static head of water over the boiler.
1. The recommended positions of the cold feed and open vent
are shown, sizes should comply with BS.6644:1986. If
isolating valves are to be fitted in the flow and return pipes of
the boiler they must not isolate the boiler from the open vent,
safety valve or cold feed.
The maximum safety valve setting is 0.7 bar (10 lb/in2) above the
maximum design operating head of 6.0 bar (85 lb/in2, i.e. 6.7 bar
(95 lb/in2)
Pressure Gauge
The water pressure gauge and temperature gauge must comply
with BS.6644.
Water flow switch
A water flow switch must be fitted to protect the boiler from pump
failure.
Vent, Cold Feed
The open vent and cold feed pipe sizes must comply with BS.6644
and must be of the following minimum size:
Boiler
cold feed
nom.dia(in)
1
1
1
1
1
1
1
200/S
300/3
400/4
300/3 alternative
400/4 alternative
500/5
600/6
open vent
nom. dia(in)
1/4
1/2
1/2
1/2
1/2
1/2
1/2
1 1/2
2
2
2
2
2
2
The drain valve must comply with BS.2879 and be operated with
a removable key.
2. The minimum tank height shown is measured from the
highest point of the system and must be increased, if
necessary, to comply with pump manufacturers' requirements.
3. The open vent height above tank water level cannot be
guaranteed adequate in all circumstances and does not take
into account any instantaneous changes in head brought about
by ancillary equipment operating.
4. Water flow switch is shown in its recommended position. It
MUST NOT be located on the mixing header where operation
of zone pumps can cause reduction in flow.
5. Production of condensate: When operating normally and
the design return temperature has reached 700C the boiler
produces virtually no condensate. At lower temperatures the
amount of condensate increases. It is normal for
condensate to be produced as the boiler heats up from cold
and, provided the time taken for the return to reach 710C is
not excessive, no harm will result.
If, however, large quantities of condensate are produced for
long periods, this can adversely affect burner performance
and cause the control box to lock out.
If the water contents of a system is very large, it is advisable to
switch on individual zones from cold, in sequence with a time
delay sufficient to allow the boiler return temperature to reach
550C as quickly as possible.
The condensate drain should be run in accordance with British
Gas Publication IM22.
ELECTRICAL SUPPLY
GENERAL GUIDANCE ON APPLICATIONS
230 Volt 50 Hz Single Phase A.C.
See Fig.13
Consumption:
Fig.13 is intended to provide basic information only on the
application of the Super Plus Boilers.
450 Watts maximum per module (excluding remote alarms, etc.)
It is essential that the water flow rates given above be maintained
within the limits stated. Therefore, any compensating devices
must not be connected to the boilers directly, but may be used in
conjunction with a mixing header. The mixing header must be
sized at least one size larger than the boiler flow and return
manifold size; to avoid hydraulic interference between the boiler
primary pump and system zone pumps.
The use of a mixing header means that compensating controls
can be used to operate mixing valves on a variable temperature
circuit, without affecting the water flow rate through the boiler.
Fig. 14 shows how constant and variable temperature circuit can
be used on low and high head applications.
Note:
External wiring and any installer supplied remote warning lights
MUST be in accordance with the I.E.E. (BS7671) Regulations
and any local regulations which apply.
The method of connection to the mains supply should facilitate
complete electrical isolation of the boiler.
Connection should be made via a fused double pole switch, or
fused spur box, serving the boiler only and incorporating contacts
with a separation of at least 3 mm in all poles. The point of
connection should be readily accessible and adjacent to the boiler.
The water flow switch and any other overriding safety devices
should be wired in series with the isolation mains supply to the
boiler. Remote indication connections of 'Burner On', 'Lockout'
and 'Overheat are provided in the sequence control wiring centres.
The loads should not exceed 1 amp resistive
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GENERAL
GENERAL
INSTALLATION
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.
2. Terminals S1, S2 and S3 provide
facility for direct wiring of safety devices.
The water flow switch should be
connected between S1 and S2, and
any other safety devices wired in series
between S2 and S3. (Typical safety
devices are: Air pressure switches,
auxiliary switches on motorised valves,
and safety relays activated by fire
sensors). Terminal S2 is voltage free.
If no other safety devices are to be
used, the water flow switch should be
connected across S1 and S3. If all
overriding safety devices are wired in
series with the isolation mains supply
to the boiler then link terminals S1-S3.
The neutral connection must be taken
from the installers junction box.
3. These connections provide a 230 Volt
AC supply outlet for remote indicators
and alarms with a maximum lead of 1
Ampere resistive.
O/H: becomes live when the
module overheat cutoff device has
operated.
L/O: becomes live when the
module has gone to lockout.
v
r
B/O: becomes live when the
module is running.
Note: 200/S does not employ PCB 10
SP8321
Fig.15 Boiler Module Internal Wiring
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ASSEMBLY
PACKAGING
The boiler casing is supplied complete with insulation and
feet, strapped to a packing base and shrink wrapped.
At site locations where access is restricted, the boiler casing
can be split horizontally by removing the cable trunking
insulation retaining trims and then the securing nuts, washers
and screws. Re-assemble in reverse order.
On re-assembly, great care must be taken to ensure that the
casing sealing strips are undamaged and correctly positioned.
The water and gas headers are supplied on a pallet, shrink
wrapped.
Remove the water flexibles from the module fixing pack and screw
them into the appropriate, internally threaded, branches of the
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
should finish approximately 600 mm from the top of the internally
threaded branch and with the flange holes at 450 to the line of the
water header. Under no circumstances must the flange or
bellows be used for tightening.
Undo the retaining screw from the front of the module upper
cover and remove it by pulling forward and lifting slightly at the
back to clear the shoulder nuts. Undo the screw at the base of
the controls chassis and remove the lower cover by lifting it to
clear the shoulder nuts and pulling it forwards.
The modules are supplied individually packed on a pallet.
Remove the module from the pallet by unscrewing its retaining
screws. Offer up the module to the casing so that the square
cutout lugs on the rear end plates sit over the runners within the
casing, and push the module home.
FOUNDATION
Note: Lift the module at the front by the water flow or return elbows;
DO NOT LIFT VIA THE CONTROLS BOX OR GAS LINE.
An insulated foundation is NOT necessary as the bottom of the
boiler casing will not exceed a temperature of 600C (1400F).
Fit the nuts and washers over the 4 fixing studs but do not tighten
yet. Repeat for the remaining modules.
The foundation MUST be flat and level, fireproof, dust free and
capable of supporting the weight of the WET boiler.
Remove the gas cock half of the union gas cocks on the gas line
extensions (both solid and flexible) and screw them to the gas
header. Ensure that the dimensions between the header and the
end face of the gas cock halves are the same, and that the gas
cocks will face forward when finally assembled.
The water header flexible connections, flange and gaskets etc.,
are in the module fixing pack.
CASING AND DRAIN CONNECTION
A 22 mm copper street elbow is supplied in the water header
hardware pack, for connection to the casing drain point. This
elbow can be fitted in any direction and then the compressing
nut tightened. A suitable drain should be connected to the elbow.
Refer Fig. 17.
Note: Condensation will only occur over the initial warming up
period, when the return water temperature is below 550C (the
flue products Dew Point).
The boiler casing can now be placed in position.
Fit the end cap and the elbow to the gas header in the required
positions.
It is important that a gas cock is fitted to the inlet gas pipe adjacent
to the boiler.
Fit the solid and flexible gas line extensions to the top flange on
the module gas train using the gaskets and screws provided.
Place the gas header in position so that the union gas cocks can
be reconnected - taking care to adequately support the header
during assembly. Ensure that all swivel joints on the flexible
extensions are tight.
Secure the flow and return water headers to the modules, rigid
flanges first, using the gaskets and screws provided. Take
adequate precautions to support the headers during assembly.
Note: Care should be taken to avoid damage to the flexible
connections whilst tightening the screws securing the flanges.
Finally, tighten each of the modules 4 fixing nuts.
300/3 and 500/5 Boilers only (see Figs 9 & 10).
The RH bottom module water connections and gas connection
must be blanked off.
A 1" BSP cap is supplied in the module fixing pack to seal the gas
header connection.
The return water header support bracket is supplied in the water
header pack. First remove the bottom and RH nuts and washers
securing the casing blanking plate and use these fixings to secure
the support bracket to the blanking plate.
Fig. 16 Casing Drain Assembly
NOTE: EXTREME CARE MUST BE TAKEN WHEN HANDLING
THE CASING, WHICH IS FITTED WITH AN ALUMINIUM FACED,
INSULATING CLADDING. THIS CLADDING CAN BE KEPT
CLEAN BY WIPING WITH A DAMP CLOTH.
ASSEMBLING THE MODULE AND WATER
HEADERS TO THE BOILER CASING
Refer to Fig.1
WARNING: CRACKING MAY OCCUR IF THE FLOW AND
RETURN MODULE CASTINGS ARE OVER-STRESSED.
The following procedure is to be adopted:
Blank off the water return header connection, using the blank
flange and the 2 gaskets supplied. (return water header - gasket
- blank flange - gasket - support bracket). Blank off the water flow
header connection using the 2" BSP cap and close taper point
supplied.
400/4 Alternative Boiler only (Refer Fig.12)
The procedure to blank off the bottom RH module must be carried
out as described for the 500/5 boiler above. In addition the centre
bottom module opening in the casing must be blanked off.
First remove one of the M10 slotted nuts and backnut from the
centre bottom module opening in the casing and replace by one
of the longer studs in the blanking kit. Screw the MB threaded
portion of the new stud through the cast support ring and through
the hole in the interior support strut. Fit the M8 nut and washer
from the back and tighten.
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INSTALLATION
INSTALLATION
INSTALLATION
Repeat for the other 3 studs.
INSTALLATION
ELECTRICAL CONNECTIONS
Take the round blanking plate supplied and fit it into the central
bottom module opening in the casing. Secure it using the 4 M10
nuts and washers provided. Fit the blank flanges and gaskets to
the return water header connection. Blank off the water flow
header connection using the 2 in. BSP cap and close taper point
supplied.
A 1" BSP cap is supplied to seal the gas header connection.
300/3 Alternative Boiler (Refer Fig.11)
The procedure to blank off the bottom RH module and the central
bottom module must be carried out as detailed under 500/5
boiler and 400/4 Alternative boiler above. In addition the top right
hand module opening in the casing must be blanked off.
First remove one of the four M10 slotted studs and backnut from
the top right hand opening in the casing, and replace by one of
the longer studs in the blanking kit. Screw the M8 threaded portion
of the new stud through the cast support ring and through the
hole in the interior support strut. Fit the M8 nut and washer from
the back and tighten.
Repeat for the other 3 studs.
Take the round blanking plate supplied and fit it into the top right
hand module opening in the casing. Secure it at the bottom and
right hand sides using the M10 nuts and washers.
Secure the water flow header support bracket to the round
blanking plate using the top and LHS fixings. Blank off the water
flow header using the blank flange and the 2 gaskets supplied
(flow water header, gasket, blank flange, gasket & support bracket)
A 1" BSP cap is supplied to seal the gas header connection.
Blank off the return water header connection using the 2" BSP
cap and close the taper nipple supplied.
Refer to Fig.14
The mains input to the boiler must be wired into the 3 way terminal
block on the lower of the 3 wiring centres (PCB No. 11) on the left
hand side of the boiler.
Terminals S1, S2 & S3 allow safety devices to be wired directly
into the boiler. Thus the water flow switch should be wired
between S1 & S2 and other devices wired between S2 & S3 (e.g.,
a fan diluted flue switch). Terminal S2 is voltage free.
If all safety devices are wired in series with the isolation mains
supply then terminals S1 & S3 must be linked.
The length of the conductors between the cord anchorage and
the terminals must be such that the current carrying conductors
become taut before the earthing conductor, if the cable or cord
slips out of the cord anchorage.
The live and neutral conductors for each module are disconnected
and insulated within the wiring centre for safety purposes on
leaving the works. These wires must be connected to the
appropriate L and N terminal strip connections on printed circuit
boards 10 and 11 within the wiring centre (see Fig.8 to 12 and
Fig. 14) for each module.
If a 300/3 Alternative or 400/4 Alternative boiler is fitted, the unused
module wiring must be left disconnected to ensure the module
multipin plug remains electrically safe.
COMMISSIONING AND TESTING
The Super Plus boiler must be commissioned and tested by a
competent person. In the case of installations covered by the
Current Gas Safety (Installation and Use) Regulations or
Rules in Force, the engineer shall be CORGI registered.
CONNECTING BOILERS TO THE FLUE
SYSTEM
Upon request, Caradon Ideal Limited, will provide a quote for
commissioning or recommissioning after servicing.
Details of the flue design are shown in Figs. 6 and 7.
FILLING THE BOILER WITH WATER
The boiler socket and flue pipe sizes are given in Table 1.
Fill the system by admitting water at the lowest point This will
ensure air is forced from the tubes of the heat exchangers.
WATER CONNECTIONS AND PRESSURES
Refer to 'Installation Requirements'
All service pipework, linking the flow and return headers, should
be adequately supported, taking care that no strain is imposed
upon them.
Allowance must be made for any additional service pipework
expansion.
Provision for draining the boiler should be made at the lowest
point in the system.
A safety valve MUST be fitted.
The valve should be set at 0.7 bar (10 lb/ in2) ABOVE the available
static head of water over the boiler or design operating pressure
of the system, whichever applies, with a maximum value of 6.7
bar (95 lb/in2 )
If isolating valves are fitted in the flow and return pipes to the
boiler, they must NOT isolate the boiler from the open vent, safety
valve or cold feed.
The maximum safety valve setting is 0.7 bar (10 lb/in2) above the
maximum design operating head, or pressure of the boiler - 6.0
bar (85 lb/in2)
WATER CIRCULATION
Switch on the pump motor and check that water is circulating and
the pump is vented.
Check the operation of the water flow switch. It should switch off
the electrical supply to the modules when the water flow falls to
NO MORE THAN one third of the design water flow-rate (given in
Table 1).
HEADER GAS TIGHTNESS & PURGING THE
GAS LINE
Turn the module gas service cock that is furthest from the gas
inlet.
Connect the manometer to the tapping point at the end of the gas
header (PTP No.1, Fig.19)
Slacken the nut on the 1" union, connecting the module to the
gas header, and purge the gas header by turning the mains inlet
gas tap on until gas is smelled. Retighten the union connection
(see also IM/2). Turn off the module gas service cock and ensure
that all other module gas service cocks are in the OFF position.
Take note of the manometer reading and turn off the mains inlet
gas cock. A subsequent fall in pressure, after allowing for
temperature stabilizing, indicates a leak between the mains inlet
gas and individual module gas service which MUST be made
good. The mains inlet gas can then be turned on again.
In all gas soundness checks, wait for 1 minute for temperature
stabilisation and then check for pressure drop during the next 2
minutes.
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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
in the casing, with one or all modules firing. A test
point is provided in the boiler casing adjacent to the
flue outlet socket.
Refer to Figs. 1, 4 & 19
Carry out the following tests on each module in turn.
Turn on the module gas service cock, and turn off the pilot gas
cock.
Turn off the main inlet gas cock and observe the manometer
pressure as above (at PTP No. 1 ).
To test the second main gas valve, remove the screw from the
pressure test point at the outlet side of the first main gas valve
(PTP 2) and connect a manometer via a 'T' piece, to the pressure
test point at the gas header (PTP 1).
Carry out the following firing checks on each individual module,
commencing with the top left module and finishing with the bottom
right. Ensure that the boiler is full of water and that the main and
any shunt pumps are running. Modules not being checked should
have their multipin plugs removed.
Switch on the electrical supply to the boiler. Wait for 15 seconds
and then press in and release the lockout reset button.
Close the main gas inlet cock and observe the manometer.
The mains on light will be illuminated.
Any leakage from joints in the line or past the appropriate gas
valve seats must be investigated and curved.
The fan will start and run for approximately 70 seconds ( part of
the 5-volume air change safety feature). Then depending on the
modules position in the switching sequence, either the fan will
continue to run for approximately a further 35 seconds or the fan
will stop for up to 35 seconds and then restart and run for
approximately a further 35 seconds.
PREFIRING CHECK
Refer to Figs. 3 & 4
Ensure that the electrical supply to the boiler is off.
EXTREME CARE SHOULD BE TAKEN WHEN THE MODULE IS
RUN WITHOUT A COVER.
Modules not being checked should have their multipin plug
removed.
Each individual module should be checked as follows:
1. Turn the module gas service cock to OFF.
2. Plug in the module multipin electrical plug.
3. Switch ON the electricity supply to the boiler:
The following sequence of events will occur:(a) The module mains ON light will illuminate.
(b) The fan will start and run for approximately 70 seconds.
(part of the 5-volume air change safety feature). Then either
the fan will continue to run for approximately 35 seconds
or the fan will stop for up to 35 seconds depending on the
module's position in the switching sequence then restart
and run for approximately 35 seconds.
Switch on the electricity supply to the boiler. The ignition cycle will
recommence. After the pilot gas flame has been lit, the main gas
valves will open and the main burner will ignite. The pressure
should be 2.7 mbar; should adjustment be necessary then
remove the screw cap on the main gas governor and screw the
adjustment screw clockwise to increase, and anticlockwise to
decrease the pressure. Switch the electricity supply to off and
then on again to check the pressure settings.
On completion of adjustment replace all pressure tapping screws
and the governor screw caps. Carry out the prefiring checks on
all other modules.
SAFETY CHECKS TO BE CARRIED OUT ON
ALL MODULES
Note: Pull out the multipin electrical plug from all modules not
being tested.
1.
With the module running, turn off the module gas service
cock.
(c) The ignition spark commences, continues for 4 seconds
then ceases. (The spark can be seen through the
sightglass in the module front).
(d) At the end of the 4-second ignition period, the lockout light
will be illuminated. The mains on light will remain
illuminated and the fan will continue to run.
4. Turn off the electrical supply to the boiler. The lights will
extinguish and the fan will stop.
FAN PERFORMANCE CHECKS
Connect a manometer to measure the pressure difference
between the fan housing and the venturi casting.
Ensuring Lockout
The burner will stop firing and the BURNER ON light will be
extinguished with the LOCKOUT light being illuminated.
2.
Combustion
Fire each module on its own, blanking off the fan air inlets
of ALL the NON-FIRING modules, using the sheets of selfadhesive paper supplied with these Instructions.
Measure the CO and CO2 content for each module - a
sampling point is provided in the top of the boiler casing,
adjacent to the flue outlet socket (Fig.1).
For DRAEGER Tests note the following:
The pressure tapping should be connected to the rear pressure
test point on the pressure switch and the suction tapping to the
front pressure test point on the pressure switch, (See Figs 2 & 4).
If, when the fan is operated as above, the manometer reading is
less than 5.5 mb then the commissioning cannot proceed.
(a) The sampling line, however short, should ALWAYS be
purged.
If the pressure is low, check that the fan impeller blades are
clean and free to rotate and that the venturi casting and burner
are free from obstructions. (Refer to 'Servicing' for details of
dismantling). Check also to see if the flue is unobstructed. Do
NOT attempt to adjust the pressure switch, which is factory set.
(c) The ratio CO/CO 2 should not exceed 0.001. For
convenient reference Table 3 shows maximum p.p.m.
CO levels in p.p.m (read direct from tube) related to
various C02 levels. Low CO levels are included to cover
the dilutions due to casing and flue volume on the larger
boilers.
FIRING CHECKS
Remove the fan inlet blanking material from all modules
and fire all modules together.
Refer to Figs. 1, 3 & 4
Note:
(b) C02 tubes are marked in percent divisions and one pump
ONLY is required (CO 2 tubes are also marked in
divisions indicating parts per million (P.P.M)).
(i) The minimum gas pressure in the gas header
should be as indicated in Table 1, with all modules
firing. The maximum pressure should not exceed
25 mbar (10 in.w.g.).
Measure the gas pressure at the gas header test point (PTP
No.1, Fig.17) and ensure that it is not less than that indicated
in Table 1.
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INSTALLATION
INSTALLATION
INSTALLATION
INSTALLATION
Check also that the draught stabiliser is controlling the
draught between neutral and 0.2 mbar (0.08 in.w.g.). With
all modules firing, measure the CO and CO2, levels again
and refer to Table 3 for the maximum allowable CO content.
3.
Each module's individual electronic thermostat should be set with
reference to Table 4 and Fig.17 (which shows the boiler thermostat
scale). The module numbers are given in Figs. 8 to 12.
Pressure Switch
Switch off the electricity supply to the boiler. Pull out the
black push-on connection, from the pressure switch at the
right hand side of the controls box.
Switch on the electrical supply. The fan will run for 70
seconds and then for a further 35 seconds after a variable
delay (as previously described), but at the end of this time
the ignition sequence will not start.
Switch off the electrical supply and refit the push-on
connection from the pressure switch.
4.
Detector Current
The pilot and main burner flame detector current may be
checked by breaking the in-line connector in the flame
detector lead and inserting a micro-ammeter. The pilot
current should be 3 - 4µ A and the main burner current 6 7µA
5.
Overheat Cut-off Device
Fig.17 Boiler thermostat knob
If the water flow rate through the boiler is adequate, the
cut-off devices should not operate when the load on the
boiler is GRADUALLY reduced from maximum to
minimum.
The overheat cut-off device is reset by pushing in the
'OVERHEAT RESET' button.
Once commissioning has been completed, all module
electrical multipin plugs should be refitted.
ADJUSTMENT OF SEQUENCE CONTROL
Thermometers mounted in the flow and return pipes to the
boiler will give a check on the thermostat settings, and will
indicate whether the water flow rate is correct to give a
temperature rise across the boiler of 100C to 120C.
This method of adjustment will give control of the flow temperature
which will be adequate for most applications. For more accurate
control Caradon Ideal Limited can quote for a commissioning which
can, if required, include the accurate calibration of the electronic
thermostats.
Peel off the red adhesive vinyl arrow from the data plate on the right
hand side of the boiler casing and reapply it to indicate the size of
the boiler.
The combustion data sheet included at the end of this Installation
book should be connected for each module and left attached to
these Instructions.
Once commissioning has been completed, all module covers must
be replaced.
Table 3 - MAXIMUM ALLOWABLE CO CONTENT
CO2 (as read)
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
8.5
9.0
9.5
10.0
10.5
Max allowable CO
p.p.m.(as read)
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
Once commissioning has been completed then all module covers should be replaced
Table 4 - THERMOSTAT SETTINGS
Boiler Size/
module No.s
1
2
200/S
4
1
300/3
400/4
5.6
3
4
5.1
3
1
4
2.5
1
5
6
3
1
300/3 Alternative
5.1
400/4 Alternative
5.6
4
2.5
1
5.8
4.6
3.4
2.2
1
5
4
3
2
1
500/5
600/6
6
Super Plus - Installation and Servicing
18
110531-9.pmd
Note: module numbers refer to the order
in which the modules are connected to the
wiring centres (Figs. 8 to 12)
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IMPORTANT: In order to ensure the safe and reliable operation of
SUPER PLUS boilers it is essential that regular maintenance is
carried out by competent staff who have received instruction in
maintenance, fault finding and commissioning procedures for
this boiler series. Inadvertent substitution or replacement of
similar components particularly those with plug-in bases could
cause a hazard.
Remove the main burner-complete with the spark electrode and
flame sensing probe.
Brush the inside and outside of the burner, making sure to clear
any blockages in the burner.
Check the pilot wedge holes and make sure that they are clear,
If the burner shows any sign of deterioration it should be replaced.
SERVICING INSTRUCTIONS
Inspect the spark electrode and the flame sensing probe. If there
is any sign of damage or erosion the part should be replaced.
ANNUAL servicing is recommended.
Check the spark gap - it should be 3.5 ± 0.5 mm (Fig.18).
BEFORE CARRYING OUT ANY SERVICING PROCEDURE:
1.
ISOLATE THE BOILER ELECTRICAL SUPPLY.
2.
TURN OFF THE GAS SERVICE TAP ON THE MODULE
BEING SERVICED.
The following procedure should be carried out annually.
PREPARATION FOR SERVICING
(See Figs 2, 3 & 4)
Undo the retaining screw from the front of the module upper
cover and remove the cover by pulling forwards and lifting it slightly
at the back to clear the shoulder nuts. Pull out the multi-pin
electrical plug from the side of the module.
HEAT EXCHANGER
Inspect the dry side of the heat exchanger finned tubes via the
burner opening, using a torch, and by removing the inspection
panels on the sides of the boiler.
The inside of the heat exchanger can be brushed free of deposits,
using a suitable brush.
Should the inspection indicate that a more thorough cleaning is
required, necessitating the removal of the module from the boiler,
then refer to 'MODULE CLEANING'. The burner opening in the
top cover plate should be brushed free of any deposits.
CLEANING THE FAN
Undo the screw at the base of the controls chassis and remove
the lower cover by lifting it to clear the shoulder nuts and pulling
it forwards.
Undo the 4 screws retaining the fan housing to the controls box
assembly and remove the housing. The fan impeller blades can
now be cleaned using a soft brush.
Unscrew & remove ferrule (Fig.18) from spark electrode &
disconnect ignition lead. Pull off in-line connector in the flame
sensing probe lead.
CLEANING THE MODULE COVER FILTER
The module lower cover is fitted with a polyurethane foam filter
which forms the bottom panel of the cover.
To remove the filter pull it from the module cover. Wash the filter in
warm soapy water. It should then be thoroughly rinsed and left to
dry.
RE-ASSEMBLY
Push the module filter back into its retaining slots on the
underside of the module lower cover. Ensure that it is correctly
positioned, i.e. with the stiffening framework to the bottom and
the central U cutout in the framework to the rear. Refit the fan
housing to the controls box assembly.
If any of the venturi cork gaskets are damaged or in any way
unsound then the gasket must be replaced.
Carefully refit the burner to the module, ensuring that the extended
gasket is between the module and burner.
Fig. 18 Spark Electrode Setting
Undo the screws fastening the electrical plugs to the 2 main gas
valves Pull out the plugs.
Unclip the fan motor lead and pressure switch lead from the
clips on the controls chassis.
Pull out the split pin, retaining clip and overheat thermostat in the
flow elbow, release the clip from the pocket in the return elbow
and pull out the main thermostat sensor. Undo the suction
sensing line connection at the venturi casting and at the pressure
switch. Remove the line.
Undo the pressure sensing line connection at the base of the fan
housing and at the pressure switch and remove the line. Pull out
the 3 push-on connections and unscrew the earth connection
from the pressure switch on the RHS of the controls box.
Take the weight of the fan and controls box assembly, undo the 4
nuts and washers securing it to the venturi casting and remove
the assembly.
Fit one of the square gaskets and then the venturi casting over
the 4 studs. Ensure that the venturi is correctly positioned, i.e.
with the suction sensing line connection on the left hand side
and with its larger face towards the front. Refit the fan and controls
box assembly ensuring that the other square gasket is fitted
between the fan housing and the venturi casting. DO NOT
OVERTIGHTEN the elongated M8 studs or damage to the casting
may occur.
Both pressure and suction sensing lines should be blown through
to free them from possible obstruction.
Refit the pressure sensing line to the pressure switch rear
connection and to the fan housing connection. Refit the suction
sensing line to the venturi casting and to the pressure switch
front connection.
Reconnect the 3 push-on connections from the pressure switch
on the side of the controls box carefully observing the correct
positioning. In particular NEVER connect the black wire to the
blue connection. Refer to Fig.3.
Secure the 2 main gas valves and gaskets (with the white cables),
securing them with the screws; the pressure switch earth
connection. Reconnect the spark electrode lead and screw down
Super Plus - Installation and Servicing
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19
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SERVICING
SERVICING
SERVICING & FAULT FINDING
Pull off the venturi casting and gasket.
SERVICING
SERVICING
the ferrule. Refit the inline connector of flame sensing lead.
Resecure the pressure switch lead and fan motor lead, to the
clips in the control chassis. Ensure all connections are tight.
Refit the overheat thermostat coil into its pocket on the flow
header and secure with the retaining strip and split pin. Refit the
control thermostat sensor into the pocket in the return elbow and
push it fully home, securing it with the retaining clip. Replace the
module multipin electrical plug.
MODULE CLEANING INSTRUCTIONS
If the inspection of the dry side of the heat exchanger has shown
that a thorough cleaning is required, it is necessary to remove
the module from the boiler.
Preparing the Boiler
1. Undo the retaining screw from the front of the module upper
cover and remove it by pulling forwards and lifting slightly at
the back to clear the shoulder nuts,
and remove all fittings from the module cast iron top plate.
2. Remove the 16 x M10 screws and the 9 central M8 screws
which secure the cast iron top plate to the aluminium top tube
plate and lift the top plate off.
3. The waterways can now be examined.
If the tubes are scaled or partially blocked then the module must
be cleaned, either by replacing the module into the boiler and
cleaning all the modules at the same time, or individually.
Note: the heat exchanger is of aluminium and so any chemical
descaling must be suitable for aluminium. Advice on the
procedure for descaling the waterways can be obtained from
specialists such as Fernox, Fry Technology UK, Tandem House,
Marlowe Way, Beddington Farm Road, Croydon. CRO 4XS, tel.
0870 5601 5000 - or - Betz Dearborn Ltd., Sentinel Division,
Foundry Lane, Widnes, Cheshire WA8 8UD, tel. (0151) 424 5351
Re-assembly
2. Pull out the multipin electrical plug from the side of the module.
1. New gaskets should be used between mating flanges. The
gaskets should be lightly greased before use.
3. Undo the screw at the base of the controls box and remove
the lower cover by lifting it to clear the shoulder nuts and
pulling it forwards.
2. Tighten the central 9 x M8 screws evenly to a torque of 24.4 to
27 N/m (18 to 20 ft Ib). This maximum torque must not be
exceeded.
4. Isolate the boiler from the flow and return water pipes and
drain the boiler.
3. Tighten the 16 outer M10 screws evenly to a torque of 48.8 to
54 N/m (36 - 40 ft Ib). This maximum torque must not be
exceeded.
5. Remove the fan and controls box assembly, venturi casting
and burner, as described under Servicing. Uncouple the
flanges connecting the modules to the flow and return water
headers.
6. It may be necessary to remove the flow and return elbows
from the module front plate to release the flange gaskets.
The elbows should then be replaced for lifting purposes, after
ensuring that the gaskets between the elbows and the front
plate are sound.
7. Isolate the electrical supply to the boiler and remove from the
wiring centre the appropriate fuse controlling the module, to
ensure that the module multipin plug is electrically isolated.
4. Reassemble the boiler as previously described.
UPON COMPLETION OF A SERVICE
OPERATION:
RE-COMMISSlON AND TEST THE BOILER IN ACCORDANCE
WITH THE COMMISSIONING AND TESTING INSTRUCTIONS
WITH PARTICULAR REFERENCE TO THE FAN PERFORMANCE
CHECKS.
REPLACEMENT OF COMPONENTS
WARNING:
8. Remove the 4 screws securing the module gas inlet flange.
Slacken the union nut on the module gas cock. Undo the 4
nuts securing the module to the boiler. Withdraw the module
to be cleaned from the boiler.
Before working on the appliance:
9. Take care as the module will not be completely empty of water.
Note: To replace the following components first undo the retaining
screw from the front of the module upper cover. Remove the
cover by pulling forwards and lifting slightly at the back to clear
the shoulder nuts.
10. In order to provide continual support for the water flow and
return headers and the gas header, it is advisable to remove
only one module at a time from the boiler.
11. Undo the 3 screws holding the gas distribution screen round
the finned tubes and remove it.
12. The finned tubes can now be thoroughly brushed clean from
both inside and out, using a suitable brush.
13. Re-assemble the gas distribution screen, ensuring that the
slots in the screen are in line with the outermost point of the
finned tubes.
14. Re-assemble the module to the casing and refit the water
and gas flanges.
15. Refit the burner venturi casting, fan and controls box assembly,
as described under 'Servicing'. All damaged gaskets must
be replaced.
16. Retighten the module gas cock union.
17. Repeat the cleaning procedure for other modules as
necessary.
MODULE WATERWAYS
The procedure below details the method of draining down the
boiler, removing a module and dismantling for inspection of the
waterways.
1. Remove the module from the boiler, as previously described
2. Turn off the gas supply at the inlet gas cock.
Pull out the multi-pin electrical plug from the side of the module.
Undo the screw at the base of the controls chassis and remove
the lower cover by lifting it to clear the shoulder nuts and pulling
it forwards.
Sight Glass
1 . Undo the 2 screws securing the sight glass assembly to the
front header casing.
2. Fit the replacement sightglass, ensuring the parts are in the
correct order, i.e. gasket, glass, gasket and frame.
3. Retighten the 2 screws to ensure an airtight seal.
DO NOT OVERTIGHTEN.
Control Thermostat Sensing Probe
1. Pull out the overheat thermostat coil, retaining clip and split
pin from its pocket in the flow elbow. Undo the 2 screws
securing the 2 halves of the control box and carefully lower
the front half.
2. Pull out the control thermostat sensing probe and retaining
clip from its pocket in the return elbow and undo the strain
relief bush from the controls box back panel.
3. Unplug the lead from the printed circuit board 9B, inside the
controls box, and remove the sensing probe.
Super Plus - Installation and Servicing
20
110531-9.pmd
1. Isolate the boiler electrical supply.
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18/05/2006, 14:21
4. Carefully fit the new probe; note that the plug will only fit its
correct socket.
5. Refit the strain relief bush, ensuring that the probe is pushed
fully home in its thermostat pocket. Retain it with its retaining
clip.
4. Fit the top and bottom terminal strips ensuring that the 10way strip is at the top and the 8-way is at the bottom. Tighten
all terminal strip connections.
Re-assembly
1. Lift up the controls box front and refasten it using the 2 screws.
6. Refit the overheat thermostat coil to its pocket in the flow
elbow and secure with its retaining strip and split pin.
2. Refit the overheat thermostat coil and retaining strip to the
pocket on the flow header and secure with its split pin.
Control Thermostat Potentiometer
Overheat Thermostat
1. Unplug the potentiometer lead from the PCB 9B, inside the
controls box.
1. Pull the overheat thermostat coil, retaining strip and split pin
from the pocket in the flow elbow.
2. Slacken the small securing screw in the control knob and pull
it off.
2. Undo the 2 screws securing the 2 halves of the controls box
and carefully lower the front half.
3. Undo the backnut and washer securing the potentiometer to
the control box and remove it.
3. Remove printed circuit board No.9B as described above.
4. Fit the new potentiometer, ensuring that the locating lug is
correctly positioned in the hole in the controls box.
4. Pull off the 2 push-on connections to the overheat thermostat
and undo the 2 screws, nuts and washers securing the
thermostat body to remove it.
5. Refit the plug into the printed circuit board and replace the
control knob.
5. Fit the new thermostat and reconnect the push-on
connections.
Spark Electrode / Flame Sensing Probe
6. Refit printed circuit Board No.9B, as described above, ensuring
that the overheat thermostat capillary is fed through the
grommet on the right hand side.
1. Unscrew and remove the ferrule (Fig.19) from the spark
electrode and disconnect the ignition lead. Pull off the inline
connector in the flame sensing probe lead.
7. Lift up the controls box and refasten it using the 2 screws.
2. Remove the screw securing the electrode / probe to the burner
front plate and pull out the electrode / probe.
8. Refit the overheat thermostat coil into its pocket in the flow
elbow and secure it with its retaining strip and split pin.
3. Carefully fit the new item and reconnect the leads. If applicable
check that the spark gap is 3.5 ± 0.5 mm (Fig.19).
Burner
Pull out the overheat thermostat coil, retaining strip and split
pin from its pocket in the flow elbow.
1. Unscrew and remove the ferrule (Fig.l9) from the spark
electrode and disconnect the ignition lead. Pull off the in-line
connector in the flame sensing probe lead. Undo the pressure
switch earth lead.
Undo the 2 screws securing the 2 halves of the controls box and
carefully lower the front half.
2. Undo the screws fastening the electrical plugs to the 2 main
gas valves and pull out the plugs and gaskets.
Board No.9
3. Pull out the control thermostat sensing probe and retaining
clip from its pocket in the return elbow and the overheat
thermostat coil, retaining strip and split pin from its pocket in
the flow elbow.
Printed Circuit Boards No.8 and No.12
1. Unplug from board No.9
(a) the wiring from the module multipin socket.
(b) the wiring from the top of printed board No.12
(c) the pressure switch
(d) the fan
(e) the control thermostat potentiometer
(f) the control thermostat sensor.
4. Undo the suction sensing line at the venturi casting and at the
pressure switch. Remove the line.
5. Undo the pressure sensing line union connection at the base
of the fan housing and at the pressure switch. Remove the
line.
2. Without exerting undue pressure, undo the 4 screws securing
PCB 9 to the controls box and remove it, feeding the overheat
thermostat capillary through the grommet in the right hand
side.
6. Pull out the 3 push-in connections from the pressure switch
on the rhside of the controls box. Unclip the pressure switch
lead and the fan motor lead from the clip on the controls
chassis.
3. Carefully fit the new Board, ensuring that the neons lockout
reset button and overheat thermostat reset button fit through
their respective holes without damage.
7. Take the weight of the controls box and fan assembly, undo
the front nuts securing it to the venturi casting and remove it.
Pull off the venturi casting gasket.
4. Unwind the overheat thermostat capillary and feed it through
the grommet in the right hand side.
8. Remove the main burner complete with spark electrode and
flame sensing probe.
5. Refit the 6 plugs into the new board. Note that each plug will
only fit its correct socket, though care must be taken to fit the
fan plug into the socket marked 'BLOWER'.
9. Remove the screws securing the electrode and probe and
transfer them to the new burner,
Board No.12
1 . Slacken the 8 terminal strip connections at the rh side and
the 8 at the bottom of Board No.12 and those terminals at the
top marked 'A' to 'H' only. Remove both top and bottom terminal
strips from the board.
2. Remove the Board by squeezing in the retaining barbs on the
4 supports.
3. Fit the new Board by relocating the connections into the right
hand side terminal strip and pushing the board home on its 4
supports.
10. Note: they can only be assembled one way round. Replace
any worn or damaged gaskets.
11. Fit the new burner, ensuring that the extended gasket is in
place between the burner and module front plate.
12. Reassemble in reverse order, ensuring that a gasket is in
place between the burner and venturi casting and between
the venturi casting and fan and controls box assembly, and
that the M8 nuts are not overtightened. Ensure that the gaskets
are in place before refitting the main gas valve plugs.
13. Refit the overheat thermostat coil into its pocket on the flow
header and secure with its retaining strip and split pin.
Super Plus - Installation and Servicing
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SERVICING
SERVICING
SERVICING
SERVICING
14. Refit the control thermostat sensor into the pocket in the return Spark Generator
header and push it fully home securing it with its retaining 1. Pull the overheat thermostat coil, retaining strip and split pin
from the pocket in the flow elbow.
clip.
15. Ensure that the pressure switch connections are correctly 2. Undo the 2 screws securing the 2 halves of the controls box
and carefully lower the front half.
made to the side of the controls box. In particular NEVER
connect the black wire to the blue connection.
3. Pull out the spark electrode lead from the spark generator.
Unscrew the generator earth connection and the 2 electrical
Gas Distribution Screen.
connections at the terminal strip on the RH side of PCB No.12
1. Remove the heat exchanger from the casing as described in
4. Undo the 2 screws securing the generator to the controls box
'MODULE - CLEANING INSTRUCTIONS'
and remove it.
2. Undo the screws securing the gas distribution screen and
5. Fit the generator and reassemble in reverse order.
remove the screen.
Main Gas Valve / Main/Governor
3. it the replacement screen ensuring:
(a) The slots in the screen are in line with the outermost 1. Undo the screws securing the electrical plugs to the main
points of the finned tubes.
gas valves and pull them out, complete with gaskets.
(b) The screen is held tightly against the finned tubes when
2. Undo the iron union in the main gas train. Undo the 4 screws,
the securing screws are tightened.
nuts and washers securing the main gas train flange and
4. Re-assemble in reverse order to removal, renewing any
remove the train complete.
damaged or deteriorated gaskets as necessary.
3. The gas valve(s) or governor can now be unscrewed and
Module Cover Filter
replaced. Ensure the arrow on the replaced part points in the
direction of gas flow. Use approved jointing compound on all
Pull the filter out from the bottom cover. Fit the new filter ensuring
gas joints.
that it is correctly positioned with the stiffening framework to
the bottom and central U cutout in the framework to the rear. 4. Check that, if the first main gas valve is to be replaced, the
new valve comes complete with the inlet strainer and a
Wiring Centre (PCBs 10 & 15)
pressure test point.
1. Undo the 4 screws securing the wiring centre cover and remove
5. Reassemble in reverse order.
the cover.
2. Disconnect the electrical leads from the printed circuit board Pressure Switch
and earth posts - noting their positions - Refer to Fig.15.
1. Pull off the 3 push-on connections on the side of the control
box and undo the earth connection.
3. Undo the 4 screws securing the printed circuit board and
remove the Board.
2. Unclip the pressure switch lead from the clip on the controls
chassis. Undo and remove the suction sensing line between
4. Fit the new board and reconnect the wiring (fig.15). Refit the
the pressure switch and the venturi casting. Undo and remove
wiring centre cover and secure with the 4 screws and washers.
the pressure sensing line between the pressure switch and
Fan
the fan housing.
1. Remove the fan and controls box assembly as previously
3.
Unscrew the brass fixing nut holding the pressure switch to
described under 'Burner'.
the module bottom bracket and remove it.
2. Pull out the 2 push-on connections from the fan to the right
4.
Fit the new pressure switch and reassemble in reverse order.
hand side of the controls box and undo the earth connection.
Ensure that the push-on connections on the pressure switch
3. Undo the 4 screws securing the fan housing to the controls
lead are correctly made to the side of the controls box. In
box assembly and remove it. Using an Allen key, undo the
particular NEVER connect the black wire to the blue
screw securing the fan impeller to the fan and remove the
connection.
impeller.
5. If the electrical wiring inside the pressure switch is disturbed
4. To remove the fan motor, undo the 2 screws securing it to the
it is essential that it is reconnected correctly:
assembly.
Blue wire to Common connection marked COM
5. Fit the new part and reassemble in reverse order.
Black wire to Normally Open connection marked NO
6. Care must be taken when refitting the fan impeIler to ensure
Brown wire to Normally Closed connection marked NC
that it does not foul the fan housing. If appropriate, unscrew
Earth wire to Screw connection marked
the pressure sensing probe fitting from the base of the old
housing and fit it to the new housing, If either sealing gasket Main Burner Injector
is damaged or deteriorated it should be replaceD.
1. The main burner injector is a screw fit into the end of the main
Wiring Centre (PCB11)
gas line. Unscrew the injector and discard it.
1. Undo the 4 screws securing the wiring centre cover and remove 2. Fit the new injector.
the cover.
2. Undo the 2 screws securing the filter to the top of the box (to
allow access to the PCB fixing screws).
3. Disconnect the electrical leads from the PCB noting their
positions - refer to Fig. 14.
4. Undo the 4 screws securing the PCB and remove the board.
5. Fit the new board and reconnect the wiring (Fig 14). Refit the
filter with the 2 screws and shakeproof washers. Refit the
wiring centre cover and secure with the 4 screws and washers.
Super Plus - Installation and Servicing
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SERVICING
SERVICING
Shows all controls and positions of pressure test points
INDIVIDUAL MODULE
P.T.P.1
Main gas
governor
Main gas valves
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
All modules on prepurge
if starting from cold.
(i.e. all modules have been
off, giving boiler five volume air change)
Up to 35s
approx. 70s
(all fans running)
8s
Pilot burner
ignition can occur
at any time during
4s spark ignition
period
Purge period
4s
Fans start in sequence approx.
with delays as follows: 35s
Module 1 - 0s
Module 2 - 7s approx.
Module 3 - 14s approx.
Module 4 - 21s approx.
Module 5 - 28s approx.
Module 6 - 35s approx.
Main burner
Fan
Spark ignition period
Fig.20 Control Sequence Logic
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FAULT FINDING
FAULT FINDING
FAULT FINDING
MODULE 'MAINS ON' LIGHT NOT
ILLUMINATED
vi) The flame probe circuit has not shorted to earth. Replace
parts (as appropriate). Pressure switch, flame probe, PCBs
9B and 12.
NO SPARK AT IGNITION ELECTRODE
Check that:
Check that:
i) External fuses are intact and that the external controls are
calling for heat.
i) The ignition electrode and lead are sound and that all
connections are clean and tight and there is no arcing
anywhere but at the spark gap.
ii) There is mains electrical supply (230V) at both S3 terminals
on PCBs 10 and 11 in the wiring centre (see Fig.14 ), and that
the wiring centre fuses and connections are sound.
iii) All connections are sound in the module multipin plug and in
the control box; there is mains electrical supply (230V) at
terminals 2 and 4 in the multipin plug (Fig.14)
ii) The electrode spark gap is 3.5 ± 0.5 mm (Fig.l7)
iii) There is mains electrical supply (230V) at the spark generator
at the correct time during the ignition sequence (Fig. 19)
Replace parts (as appropriate) spark generator, ignition electrode
and feed or PCBs 13, 12, or 9B
Replace parts (as appropriate) PCBs 11, 10, 15 or 9.
FAN DOES NOT START
Check that:
i) Module thermostat is calling for heat. Note that at any particular
time the return water temperature may be higher than the
individual module thermostat setting; module is not out on
overheat if so press in overheat reset button and see Fault
Finding No.8)
ii) There Is electrical continuity between the brown and blue
pressure switch connections (note that these wires carry
230V); pressure and suction lines and connections are sound.
ill) There is mains electrical supply (230V) to the fan motor and
that fan impeller is free to rotate (note that the fan motor is
fitted with a thermal trip, so if impeller is jammed, free it and
allow time for the motor to cool)
MAIN BURNER DOES NOT STAY ALIGHT
Check that:
i) The pilot flame detector current is approximately 6µA by
breaking the inline connector in the flame detector lead and
inserting a micro-ammeter.
ii) That all connections are sound in the control box and flame
detector lead.
iii) The flame detector and electrode is sound and correctly
connected.
Replace parts (as appropriate) flame detector electrode and
flyaway lead, flame detector lead, PCBs 13, 12 or 9B or main
burner complete with pilot pipe.
MAIN BURNER DOES NOT LIGHT
iv) Connections are sound in the control box
Check that:
Replace parts (as appropriate) fan motor, PCB 9B, pressure
switch and thermostat sensor.
i) Main burner pressure is 2.7 mbar, and that main burner injector
is clean and undamaged.
IGNITION SEQUENCE DOES NOT START
ii) There is mains electrical supply (230V) at both main gas
valves and that both gas valves are open.
Check that:-
iii) There is a minimum dynamic gas inlet pressure available.
i) The normal boiler operation is that where no modules are
firing, all module fans will start and run for a minimum of 70
seconds and then, depending on the module's position in
the firing sequence, the fan will stop for a delay varying between
0 second and 35 seconds, after which the fan will run for
approximately a further 35 seconds. Only then will the ignition
sequence start.
Replace parts (as appropriate) main gas governor, main gas
valves, PCBs 12 or 9B or main gas injector.
ii) The 'lockout' light is not illuminated: if it is wait for 15 seconds
and then press in and release the lockout reset button.
iii) All connections are sound at the control box and the pressure
switch, and that the fan is operating.
iv) The pressure switch differential pressure is >5.5 mb. If not
check the fan impeller, cast venturi, pressure and suction
lines, burner, module heat exchanger or flue for blockage or
leakage.
MODULE OUT ON OVERHEAT
Check that:
i) Water temperature difference across module when it is firing
is 10 - 12oC. Adjust water flow rate as necessary.
ii) Main thermostat sensor is pushed fully home in its pocket
and is secured with its retaining clip.
iii) Overheat thermostat is operating at its correct setting of
100oC.
Replace parts (as appropriate) overheat thermostat, control
thermostat sensor, control thermostat potentiometer or PCB 9B.
v) There is electrical continuity between the blue and black
pressure switch connections (note that these wires carry 230V)
Super Plus - Installation and Servicing
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Key No.
Product Code No.
11
12
13
14
15
18
21
22
23
24
25
27
28
29
30
110 536
1333 726
110 526
134 727
013 760
110 539
133 058
057 841
057 973
057 840
133 070
013 764
013 842
111 566
113 204
058 511
013 755
004 038
133 133
013 241
013 755
058 511
134 713
134 515
013 750
Burner Assembly Complete
Burner Bar (Bray)
Ignition Electrode
Sensing Electrode
Burner Cork Gasket
Fan and Controls Assembly
Fan Motor
Sight Glass
Sight Glass Frame
Sight Glass Gasket
Pressure Switch Assembly
Main Gas Line Injector
Main Gas Line Solenoid Valve (ASCO)
Main Gas Line Solenoid Valve with Strainer (ASCO)
Main Gas Line Govenor
Potentiometer Assembly
Sensor Assembly
Module Control Centre
Overheat Thermostat with Manual Reset LM5
Printed Circuit Board Assembly PCB. 9
Control Knob - Bulgin
Control Thermostat Sensor
Control Termostat Potentiometer Assembly
Reset Switch Assembly
Spark Generator Assembly
Printed Circuit Board PCB. 12
133 125
133 126
132 002
013 868
154 470
134 463
133 464
134 465
134 466
134 459
134 460
154 326
133 270
133 271
133 272
133 273
Module Surround Assembly, Top
Module Cover Assembly, Lower
Module Cover Filter
Printed Circuit Board PCB 15
Wiring Centre Assembly PCB. 11 200/S
Wiring Centre Assembly PCB. 11 300/3
Wiring Centre Assembly PCB. 11 400/4
Wiring Centre Assembly PCB. 11 500/5
Wiring Centre Assembly PCB. 11 600/6
Wiring Centre Assembly PCB. 10 300/3, 400/4
Wiring Centre Assembly PCB. 10 500/5, 600/6
Boiler Casing Assembly Complete 200/S
Boiler Casing Assembly Complete 300/3
Boiler Casing Assembly Complete 400/4
Boiler Casing Assembly Complete 500/5
Boiler Casing Assembly Complete 600/6
41
42
43
44
46
47
49
51
52
54
55
56
65
Description
Super Plus - Installation and Servicing
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SHORT LIST OF PARTS
SHORT LIST OF PARTS
25
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NOTES
Super Plus - Installation and Servicing
26
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NOTES
Super Plus - Installation and Servicing
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COMBUSTION DATA SHEET
1. BOILER MODEL (see Data Plate) please tick appropriate box
200/S
300/3
400/4
300/3A
400/4A
500/5
600/6
MODULE NO.
1
2. Pilot Burner Pressure
(Note. 1)
2
3
4
5
6
ALL
MODULES
FIRING
in. w. g/bar
3. Pilot Burner Pressure
in. w. g/bar
Note. 1 (all modules firing)
4. Thermal rating
(i) Volume of gas, cubic.
(Note. 1)
(ii) Time for volume,
(Note. 1)
(iii) Heat input'
(Note. 1)
ft/litres
seconds
Btu/h/kW
{ (1) (2) x CV x 3600
Note 2 }
{ (1) (2) x CV x Note 3)
5. Combustion Data
measured at sampling
point at top of boiler
(see Table 3)
(i)
CO%
(ii)
CO%
(iii) CO/CO2
6. Pressure Switch
Differential
(Note. 1)
in. w. g/bar
Note 1: Delete units as appropriate
Note 2: CV is 1031 Btu/cubic ft if volume is measured in cu ft and gives heat input in Btu/h.
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. Box 103, National Ave, Kingston upon Hull, HU5
4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration
No. London 322 137.
Caradon Ideal Limited pursues a policy of continuing
improvement in the design and performance of its products. The
right is therefore reserved to vary specification without notice.
November 2005 UIN 110 531 A09
Ideal Commercial Technical Helpline: 01482 498 376
www.idealboilers.com
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