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FUMECO Heat ExchangerInstallation, Operation and Maintenance Manual

To be kept by the user October 2010

heating specialists

Data TableFUMECOType

FUMECOMaximum

BoilerOutput

Hmm

Lmm

Imm

Ømm

Ø ofFlue

Entry &Exit mm

WaterConnecti

onSize PN10

mm

Amm

Bmm

Cmm

Weightkg

Fanned

MotorkW

UnfannedPressure

Dropmm.w.g

25.15/7330.15/111

314 kW477 kW

21792229

707759

500500

350400

200250

8080

356356

13901390

20762101

200210

1.11.1

4040

35.15/15740.15/191

675 kW820 kW

22792329

8591059

530580

450500

300350

100100

368368

13651365

21252151

280340

1.11.1

4040

45.15/27350.15/330

1173 kW1418 kW

23702421

10591159

630680

550600

400450

125125

378381

13461340

21672192

400470

2.22.2

4040

55.15/41160.15/475

1766 kW2041 kW

26142669

12591359

790790

650700

500550

125150

428445

13461311

23602390

570650

33

4040

65.15/52370.15/651

2247 kW2800 kW

26692770

14091468

830880

750800

550600

150200

445521

13111260

23902467

705835

33

4040

HeadMovable

FUMECO Fan

B

Wat

er C

onne

ctio

n

A

I

200

20C

Ø F

lue

Condensate Ø1”Condensate Vision

L

5

Ø Flue Exit

H Ø

HeadMovable

B

Wat

er

A

I200 20

CØ F

lue

Condensate Ø1”Condensate Vision

L

5

Ø Flue Exit

H Ø

Fanned Unfanned

GENERALThe FUMECO heat exchanger is designed to recoup up to 24% of heatnormally lost in the flue gases from conventional boilers. Effectively theFUMECO converts a standard gas fired boiler into a fully condensing unit

2 Construction

The FUMECO is a shell and tube heat exchanger manufactured in 316grade stainless steelThe flue collector boxes are also constructed in stainless steelThe inlet flue box can be swivelled through 360°for easy alignment withexisting flue systemsTwo versions of the FUMECO are available, with or without fan. Theunfanned version can be used where there is already a fan in the flue orwhere the boiler/burner unit is capable of sufficient over pressure toovercome the resistance of the FUMECO

3 Sizing the Fumeco

The proportion of energy recovered by the Fumeco depends on the watertemperature entering the unit. The nominal dew point of the flue gaseswhen firing on natural gas is about 54°C . Therefore to start condenserecovery (latent heat) the water entering the unit will need to be below54°C.As the water temperature reduces the more energy is recovered (seefig 1)

C O N D E N S I N G E F F I C I E N C Y A T V A R Y I N G W A T E R C O N D E N S I N G E F F I C I E N C Y A T V A R Y I N G W A T E R C O N D E N S I N G E F F I C I E N C Y A T V A R Y I N G W A T E R C O N D E N S I N G E F F I C I E N C Y A T V A R Y I N G W A T E R T E M P ST E M P ST E M P ST E M P S

8 0

9 0

1 0 0

1 1 0

2 0 3 0 4 0 5 0 6 0 7 0 8 0R E T U R N W A T E R T E M P ° C

BO

ILER

EFF

ICIE

NC

Y%

N e t e f f ic ie n c y

G r o s s e f f ic i e n c y

5 4

1

Fig

If the whole system runs at low temperature or i8s variable temperaturethen size the unit to suit the maximumboiler output and fitted into the mainboiler return

.

Where there is a mixture of hightemperature and variable temperaturecircuits it is possible to size the FUMECO units to suit theload on thevariable temperature circuits onWhere multiple boilers are installed the FUMECO will be installed inparallel with the flue system rather than in series(see fig 3

Fig2 FUMECO Linked to VT Circuit

VT CircuitCT Circuit

3 System requirementsPipework

Install the FUMECO into the circuit return pipework with a by pass betweenthe connections as shown in figure 3. This will enable the flow to bebalanced on the system.

Ensure that water is always flowing through the FUMECO when any boileris firing otherwise very high water temperatures and boiling may resultCondensate Drain

Run the condensate drain to a suitable gully using plastic pipework . Adeep seal trap should be fitted to prevent the escape of flue gases throughthe pipework. There shou8ld also be an air break to prevent syphoning thetrap. Do not use copper

Flue system

The Flue system downstream of the FUMECO must meet normalcondensing boiler criteria ie• Corrosion resistant smoothwall• Water and gas tight• Free draining• Vertical discharge• Adequately drainedFlue connections to the FUMECO should have a removable section toallow maintenance of the flueways

Electrical connections

All motors supplied with the FUMECO are suitable for 3 phase 400velectrical supplyThe unit should be fitted with a local suitably sized fused isolator .The motor should be interlocked to the boilers to ensure that both units runtogether

4 Installation And Assembly

Fumeco is delivered packed on its side on a pallet with the fan assemblypacked separately

Siting

Decide on a suitable position for the unit avoiding complicatedand resistive flue runs.Remove the unit from the pallet and position on a suitable levelbase adequate to support the weight of the unit when full

The fan housing is fitted with a rope sealing gasket(fig5).Loosen the clamps on top of the main unit (fig 6) andposition the fan housing on top then tighten down theclamps

Fig 5

Sealing gasket

Connect flue system taking into account of maintenance requirements ofthe FUMECOConnect pipework ensuring that the unit is adequately ventedConnect the electrical supply to the fan motor allowing sufficient flexiblewiring to allow removal of the fan housing for maintenance .

6 Maintenance

Occasional maintenance is required but is only a matter of cleaning out anydebris from the lower flue box via the cleanout door (Fig 7). Frequencyonce per year.

Clamp plates

Fig 6

FIG 7Cleanout door

Approximately biannually the top fan housing should be removed .Check the fan unit and motor and maintain as necessary.

Wash down the tubes using a hose and mains water

Baxi Commercial DivisionWood Lane, Erdington, Birmingham B24 9QP Email: potterton.commercial@baxigroup.comwww.pottertoncommercial.co.uk

Sales:

0845 070 1056Technical:

0845 070 1057 heating specialists

Commercial sales technical & service enquiries

Tel: 0845 070 1055Fax: 0845 070 1059Sales hotline: 0845 070 1056Technical helpline: 0845 070 1057Service hotline: 0845 070 1058e-mail: potterton.commercial@baxigroup.comweb: www.pottertoncommercial.co.uk

Spares

Potterton Commercial spares are available nationwide through the interpart network of approved stockists.Alternatively please contact:-

InterpartBrooks HouseCoventry RoadWarwick CV34 4LL

Tel: 0844 871 1540

Applications & Installations

Our experienced technical support team are available to offeradvice on any aspect of heating system design and boilerinstallation.

Please contact: 0845 070 1057

Commercial service offices

Our service organisation covers the whole of the UK to look afteryour needs for all Potterton Commercial products.

Our service office offers a wide range of specialised servicesincluding:

• Burner commissioning for all fuels• Boiler service contracts• Breakdown and repair services• Burner and boiler replacement• Oil/gas conversions• Water treatment and descaling• Packaged units

All descriptions and illustrations contained within this leaflet havebeen carefully prepared, but we reserve the right to makechanges and improvements in our products which may affectthe accuracy of the information in this leaflet.