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COROLLA 503 504
System Design
Modular
boilers Corolla Pack 503 and Corolla Pack 504 have
3 or 4 boiler modules inside which are joined to
the gas and water system in parallel. Each units
is made up by the following components:
Regulation system (named master/slave) made of
a master PCB and as many slave PCBs as there are
boiler modules. Each slave controls the single
boiler module it is connected to.
Pre-mix module made by a
modulating gas valve integrated with a high
performance fan. The system guarantees both a
constant gas and air mix under any running
condition with a flue gas system through 160 mm
plastic (polypropylene) pipes whose length can
reach up 55 meters approx.
Non-return valves prevent flue gas
recirculation through non firing boiler
modules.
High efficiency, 50 kW heat exchanger equipped
with continuous internal bi-metal corrugated
helical tube (copper on water side and stainless
steel on flue sides). The micro-flame burner is
located on the top centre of the heat exchanger
with single spark ignition.
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Corolla
Pack 503 Master DEP
Master type boilers can be
either stand-alone modules or modular
installations with several slave boilers. The module is
equipped with flue and gas manifolds, condensate
drain trap and with a board for
the electronic control of both the
boiler modulesand the heating circuits. Useful output
goes from 15 to 128 kW
(Hs) but 115 kW Hi.
Corolla Pack
503 Master
Master type boilers can be
either stand-alone modules or modular installations with
several slave boilers. The module is equipped with
flue and gas manifolds, condensate drain trap
and with a board for the electronic
control of both the boiler modules
and the heating circuits. Useful output goes
from 15 to 150 kW
(Hs)
Corolla Pack 503
Slave
Slave type boilers are suitable
only for modular installation with a main master boiler. The module
is equipped with flue and gas manifolds
condensate drain trap and with a board
for the electronic control of both the boiler
modules and the heating circuits. Useful output
goes from 15 to 150 kW
(Hs).
Corolla Pack 504
Master
Master type boilers can be
either stand-alone modules or modular
installations
in with several slave boilers. The module is
equipped with flue and gas manifolds, condensate
drain trap and with a board for the
electronic control of both the boiler
modules and the heating circuits. Useful output
goes from 15 to 200 kW
(Hs)
Corolla Pack 504
Slave
Slave type boilers are suitable
only for modular installation with a main master
boiler. The module is equipped
with flue and gas manifolds, condensate drain
trap and with a board for the electronic
control of both the boiler modules and
the heating circuits. Useful output goes
from 15 to 200 kW
(Hs)
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Eşanjör
The
exchanger (identical to the Corolla 501/502 one)
has a cylindrical shape
and it is made of the following
components :
• Micro-flame burner
• Stainless steel covering AISI 316L
• Continuous bi-metallic
corrugated helical tube (copper on the water side
and stainless steel on the flue side) which
is coiled up inside the cover.
• Refractory plug which
keeps the heat inside the
combustion chamber and forces the flue gases
over the heat exchanger surfaces
optimising the thermal heat exchange
performance. | | |
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Corolla 503 - 504
Legend
1. Flue
manifold DN 160 mm
2.
Gas isolating valve
3. Gas manifold DN 3"
4. Flow manifold DN 5"
5. Water differential pressure
switch
6. Return manifold DN 5"
7. Limit
termostat
8.
Automatic air vent
9.
Gas valve valvola gas
10. Flue
gas analysis test point
11. Control
panel
12. Fan
13. Combustion air inlet
pipe
14. Heat exchanger
15. Motorized two port
isolating valve
16. Return isolating
valve |
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Mounting
Corolla
packmodular boilers are pre-set for modular
installation.Water, gas, condensate and flue
manifolds can be easily joined
together to create a modular installation
of 4 Corolla Pack reaching
a total output of 800 kW (which can be
installed in parallel to reach a maximum
output of 3000 kw).
The modular design allows close
matching of any variable output
system demands with either new or
existing installations. Further still the
space saving design (650 mm depth) ensures the
boiler can be installed in an existing
plantroom with minimal alterations.
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Safety Devices:
The integrated safety system
called SPS (self protection system) ensures that
the boiler operates in a safe condition to prevent
damage to either the boiler or the environment in
which it is installed.
Should a safety
critical condition arise the boiler will shut down
and display the relevant fault code on the master
control screen.
Safety systems include the
following: ionisation flame detection device, flue
exhaust control device, frost protection system,
safety valve, flow rate control device.
This
system provides both safe operation and easy fault
diagnosis, ensuring the maintenance engineer can
quickly rectify problems with minbimal down
time.
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Assembly drawing for flue
pipe on a modular installation of 3
Corolla Pack 504 with condensate drain kit
located prior to the vertical section of the flue.
The condensate drain kit is necessary when the
vertical section length is greater than 4
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Flue Exhaust
Owing to the low flue gas
temperature, not exceeding 80 oC, the
flue gas system can be constructed from plastic PP
(polyproplene) flue components. For Corolla Pack
503/504 models, the flue gas manifold is located
inside the boiler module providing a compact and
versatile installation.
The picture on the left shows the flue
manifold and the individual boiler flue
connections with non return valves to
prevent flue gas recirculation through non
firing modules.
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 System Control
Corolla Pack 503/504 control
is managed by the microprocessor master control,
where the system operating parameters may be
programmed and system status is displayed on the
LED screen. Fault dianosis codes are also
displayed clearly on this screen.
The safety and operating functions of each
slave boiler module and managed by a dedicated
slave PCB control. Each slave control is managed
from the master control allowing up to 60 slave
boiler modules to operate in cascade mode
closely matching varying heat loads within the
building. Close boiler matching provides more
opportunity for the boiler to maximise the energy
saving associated with condensing operation.
Additionally the master control can manage the
requirements of 3 seperate heating circuits
operating at 3 different temperatures. Moreoever
the low and high temperature circuit can be
governed for either constant or varible
temperature. This latter can be achieved by
connecting the outside air temperature sensor
supplied with the
boiler.
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Regulation and control drawing of Corolla 500
series. Equipment can be remotely controlled
according to user requirements.
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Remote Control
Kit
Master boilers can be
connected to a remote control (see picture)
providing individual time management to each
heating circuit and anit-legionellae function for
the domestic hot water supply. Maximum distance
between boilers and remote control is 100
meters. |
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| Standalone installation of
Corolla Pack 504 having simultaneous control of
3 different circuits (High / Low
temperature and water circuit) at 3 different
temperatures. Example with reverse
return. | |
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| 3 Corolla Pack 504
installation drawing and simultaneous
control of 3 circuits at three different temperatures.
Example with direct
return. | |
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| Modular
Installation |
| Examples of
modular installations are shown
below for Corolla Pack 503/504 with
associated dimensions and
outputs. |
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| Output Range Of Corolla 500
Series |
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The Corolla 500 series of modular boiler can be
configured, if required using specialised
accesories from Fontecal, to provide varying
installation schemes over a large output
range.
By sharing the whole system load across several
boiler modules it is possible to achieve higher
seasonal efficiencies compared to using a single
high output boiler.
The chart below illustrates
how varying system loads can be
split across multiple boiler
modules achieve an efficient modular
system.
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