AIC Condensing Boilers

Condensing Boilers Stainless steel heat exchangers A complete range of stainless steel heat exchangers suited for gas and oil condensing boilers, residential and commercial sizes.

VC Line Compact condensing boilers 24–60 kW 80–205 kBTU/h

4

Nominal capacities

60 kW

205 kBTU/h

Maximum power rating

3 bar

50 PSIG

Maximum allowable working pressure

The VC platform - the new range of heat exchangers, suited for residential heating systems. The simple sleek design of this stainless steel heat exchanger is AIC’s response to today’s stringent demands for high-efficiency products.

AIC’s engineering team implemented continued product suited for heat-only and combi-boilers alike. The VC was created through extensive CFD analysis

where combustion and fluid dynamics modeling as well as simulation of heat releases were applied.

The other principle in the VC project was to provide boiler market with the most cost-effective solution possible.

As a result, VC’s construction matches the high thermal performance of other market-proven AIC heat exchangers with reduced manufacturing costs.

Key features Stainless steel construction Inside the heat exchanger, there are fire tubes and special water baffles Plastic removable condensate collector ensures the lightweight construction Automated laser welding process guarantees product quality and reliability during operation Product designed and analyzed in advanced virtual enviornment simulation software Design improved with CFD tools Optimized water velocity streamlines to eliminate hot spots

2

3

VC dimple tube

Gas blower

Burner door

Water outlet

Tube packet

Water inlet

Detachable condensate drain pan (Polypropylene)

6

Technical specification

Model

Power rating

Weight

Flue pipe connection size

kW

BTU/h

kg

lbs

mm

in.

mm

in.

VC 24

24

80,000

8.8

19.4

82

3.23

25

1

VC 30

30

102,000

10.2

22.4

82

3.23

25

1

VC 45

45

153,000

14.5

31.9

82

3.23

25

1

VC 60

60

205,000

18.0

39.6

82

3.23

25

1

Model

A (height)

B* (height)

C (depth)

D (width)

mm

in.

mm

in.

mm

in.

mm

in.

VC 24

375

14.76

555

21.85

255

10.04

280

11.02

VC 30

375

14.76

555

21.85

270

10.63

300

11.81

VC 45

375

14.76

580

22.38

320

12.60

345

13.58

VC 60

375

14.76

580

22.38

345

13.58

375

14.76

*dimension depends on assembly configuration

B

A

D

C

7

Water connection size

PG Line High efficiency condensing boilers 16–150 kW 55–510 kBTU/h

9

Nominal capacities

5.5 bar

80 PSIG

Maximum allowable working pressure

All components of the PG condensing heat exchanger have been engineered for optimized performance and highest efficiency of heating boilers.

The PG design concept was developed through a combination of experience in thermal technology, engineering knowhow, 3D modelling and advanced CFD simulations. High-grade stainless steel alloys ensure product durability and corrosion resistance.

Automated assembly of PG heat ex‐ changers supported by robotized laser welding, advanced vision systems and functional tooling ensure production effectiveness, stability and unblemished product quality.

Market-proven heat exchanger design, essential part of modern boiler systems, suitable for both residential and light commercial applications.

Key features Reduces a lengthy boiler development process Provides a set of reliable and compatible boiler components Shortens a supply chain Large heat transfer surface area Complete stainless steel welded construction Self-cleaning flue gas tubes eliminate combustion residue High quality stainless steel alloys ensure superior corrosion resistance Automated assembly process with robotized welding system 8

9

PG Fire Tube

60°C

Water flow

20°C

Gas flow

1200°C 1000°C

200°C The combustion process begins with the entry of the air/gas mixture into the burner chamber and ensures low NOx levels and a large modulation range (up to 12:1)

50°C

The transfer of energy is maximized by the turbulence created by the flow of gasses from top to bottom, counter current to the flow of water

The water flow is directed by special baffles resulting in optimal heat exchange and very low pressure drop

The water completely envelops the flue pipes of the exchanger and flows from the base upwards, counter current to the gasses

The condensation process within the flue pipes ensures the self-cleaning function that washes away deposits and greatly reduces maintenance operations

Water outlet

Water inlet

The PG heat exchanger features a conical shell with top and bottom tube-sheets holding the water cooled combustion chamber, a system of heat transfer fire tubes and a set of water distribution baffles.

10

Applications

PG Line typical applications Apartments

Office buildings (cascade system)

Single-family houses

Hotels (cascade system)

Residentials

Hotels (cascade system)

Restaurants

11

Customization

360°

360°

Optional angular location of gas blower

Optional angular location of water connections

360°

360°

360°

Optional angular location of drain pan

12

Optional angular location of sensor ports

AIC's continuous research into product development brought to life a complete heating package - the PG Heat Engine

Our engineering team conceived a thoroughly tested heat engine system for the most common of boiler outputs available on the market today.

Typical AIC heat engine assembly includes PG Heat exchanger Combustion chamber cover (door) Combustion air blower Gas valve and venturi Ignition and ionisation electrodes Sight glass Burner Refractory insulation Gaskets

13

14

Vertical gas blower (horizontal as an option)

Water outlet connection: – flexible coupling – threaded

Water inlet connection: – flexible coupling – threaded

Condensate drain pan (plastic or stainless steel)

15

Technical specification Model

Power rating

Weight

Flue pipe connection size

kW

BTU/h

kg

lbs

mm

in.

mm

in.

PG 16

16

55,000

11.0

24.2

62

2.44

25

1

PG 24

24

80,000

12.0

26.5

82

3.23

25

1

PG 32

32

110,000

13.4

29.5

82

3.23

25

1

PG 45

45

155,000

19.5

43.0

82

3.23

25

1

PG 60

60

205,000

24.0

52.9

102

4.02

32

1 1/4

PG 80

80

275,000

28.2

62.2

102

4.02

32

1 1/4

PG 100

100

345,000

43.3

95.5

152

5.91

40

1 1/2

PG 120

120

399,000

51.3

113.1

152

5.91

40

1 1/2

PG 150

150

510,000

65.0

145.0

152

5.91

40

1 1/2

Model

A (height)

B* (height)

C (width)

D (depth)

mm

in.

mm

in.

mm

in.

mm

in.

PG 16

600

23.62

785

30.91

240

9.45

260

9.45

PG 24

600

23.62

785

30.91

270

10.63

280

11.02

PG 32

600

23.62

785

30.91

270

10.63

280

11.02

PG 45

600

23.62

785

30.91

290

11.42

310

12.20

PG 60

600

23.62

805

31.69

360

14.17

370

14.57

PG 80

600

23.62

805

31.69

360

14.17

370

14.57

PG 100

650

25.59

885

34.84

450

17.72

470

18.50

PG 120

650

25.59

885

34.84

450

17.72

470

18.50

PG 150

700

27.56

940

37.01

530

20.87

460

18.11

*dimension depends on assembly configuration

D

C 16

A

B

Water connection size

PGT Line High efficiency condensing boilers 120–300 kW 400–1000 kBTU/h

97% Maximum efficiency

11 bar

160 PSIG

Maximum allowable working pressure

AIC designers were yet again challenged to optimize the heat exchanger to provide high thermal efficiency along with a small footprint. Unique, anti-scaling baffling system and stainless steel construction ensure product durability and corrosion resistance.

Key features Stainless steel construction Self cleaning fire tubes High corrosion resistance

Small footprint Anti-scaling baffling system 17

Built according to ASME and PED industry design codes, the PGT is suited for light commercial boiler applications. The PGT Line was designed as floor-standing units, and is available as heat exchangers only or as heat engines, i.e. heating packages with burners, fans, gas valves etc.

18

19

PGT dimple tube profile

Blower, gas valve, mixer

Burner

Water outlet

Tube packet

Water intlet

Stainless steel condensate dish

21

Technical specification

Model

Power rating

Weight

Flue pipe connection size

kW

kBTU/h

kg

lbs

mm

in.

mm

in.

PGT 400

120

400

105

230

131

4

60.3

2.0

PGT 550

160

550

125

275

131

4

60.3

2.0

PGT 700

200

700

165

365

180

6

73.0

2.5

PGT 850

250

850

175

385

180

6

73.0

2.5

PGT 1000

300

1000

225

495

180

6

73.0

2.5

Model

A (height)

B* (height)

C (width)

D (depth)

mm

in.

mm

in.

mm

in.

mm

in.

PGT 400

1080

42.5

1330

52.5

445

17.5

639

25.2

PGT 550

1080

42.5

1360

53.5

445

17.5

639

25.2

PGT 700

1087

42.8

1360

53.5

490

19.3

738

29.0

PGT 850

1087

42.8

1360

53.5

490

19.3

738

29.0

PGT 1000

1087

42.8

1360

53.5

510

20.0

765

30.0

*dimension depends on assembly configuration

B

A

C

D

22

Water connection size

Ventura Single-core style condensing boiler 280–1260 kW 1,000–5,000 kBTU/h

96% Maximum efficiency

11 bar

160 PSIG

Maximum allowable working pressure

Proven-fire tube construction design was assisted by advanced fluid dynamics software. Patented special tube pattern ensures product’s elevated performance in highoutput commercial and industrial-size boilers.

Built entirely from high quality stainless steel and is characterized by high thermal efficiency, durability and corrosion resistance.

Available as an OEM-product (single heat exchanger) or as a heat engine package.

Key features Stainless steel construction Single core heat exchanger Pattented special tube pattern Customized water outlets and flue transitions

23

24

Customized sensor ports

Customized outlet water connection

Combustion chamber

Extended heat transfer area in special high efficiency fire tubes

Customized inlet water connection

25

Stainless steel condensate dish

Technical specification

Model

Power rating

Weight

kW

kBTU/h

kg

lbs

mm

in.

mm

in.

Ventura 1M

280

1,000

290

640

180

6

88.9

3 flange

Ventura 1.5M

420

1,500

350

770

200

8

88.9

3 flange

Ventura 2M

570

2,000

405

890

200

8

88.9

3 flange

Ventura 3M

840

3,000

550

1210

250

10

88.9

3 flange

Ventura 5M

1260

5,000

940

2070

310

12

168.3 6 flange

Model

Flue pipe connection size

Water connection size

A (height)

B* (height)

C (width)

D* (depth)

mm

in.

mm

in.

mm

in.

mm

in.

Ventura 1M

1727.0

68

1865

73.5

608

24.0

1017

40.0

Ventura 1.5M

1727.0

68

1865

73.5

687

27.0

1100

43.3

Ventura 2M

1727.0

68

1865

73.5

750

29.5

1158

45.6

Ventura 3M

1752.7

69

1865

73.5

849

33.0

1273

50.0

Ventura 5M

1858.0

73

1988

78.3

1080

43.0

1560

61.5

*dimension depends on assembly configuration

B A

C

D

26

PG Oil Stainless steel oil condensing boilers 20–50 kW 70–170 kBTU/h

360°

Optional angular location of condensate drain dish

2 bar

30 PSIG

Maximum allowable working pressure

27

All modern, condensing technology brings high efficiency but also challenge for heat exchanger manufacturers.

Appropriate selection of top class stain‐ less steel alloys is crucial to guarantee long life of product.

Combustion of oil creates aggressive flue gases and condensate due to much higher, than in gas, content of sulfur.

For this reason heat exchangers for condensing oil boilers must be designed and manufactured to be resistant to extremely corrosive working conditions.

Heat exchangers used for condensing oil boilers must be of extremely high quality, both with regards to the design and a choice of construction materials. Oil condensing boilers are a popular choice in the areas with limited access to natural gas.

28

AIC has developed a carefully crafted solution for oil condensing boilers. The heat exchanger design is again, based on the reliable and market proven PG technology.

However due to the fact oil has less energy tied up in the latent heat, AIC paid close attention to the design of combustion chamber and extended water channels.

Better water distribution and enhanced heat transfer. Selected components of the PG Oil heat exchanger are made of a higher grade of stainless steel, which ensures longevity of the product.

29

30

Stainless steel heat exchanger

Stainless steel condense dish

31

Technical specification

Model

Power rating

Weight

kW

BTU/h

kg

lbs

mm

in.

mm

in.

PG Oil 20

20

70,000

32

70.4

82

3.23

32

1 1/4

PG Oil 32

32

110,000

36

79.4

82

3.23

32

1 1/4

PG Oil 50

50

170,000

53

116.6

82

3.23

32

1 1/4

Model

Flue pipe connection size

Water connection size

A (height)

B (width)

C (depth)

mm

in.

mm

in.

mm

in.

PG Oil 20

721

28.37

400

15.75

418

16.46

PG Oil 32

721

28.37

400

15.75

418

16.46

PG Oil 50

780

30.71

512

20.14

514

20.28

A

C

B

32

PGiant High efficiency modular construction 175–1400 kW 600–4800 kBTU/h

96% Maximum efficiency

1.4 MW

4 MMBTU/h

Possible output

AIC reaches out to a commercial sector with a new condensing heat exchanger designed for high output applications.

The PGiant, a high output heat exchanger engineered for use on gas-fired condens‐ ing boilers, in commercial and industrial appliances.

11 bar

Key features

Maximum allowable working pressure

Scalability of the construction

160 PSIG

Stainless steel construction Modular design and compactness Standard 36″ doorway or elevator fit Easy final boiler assembly Unified arrangement of inlet and outlet water manifolds

33

Made entirely from high quality stainless steel and built on proven fire-tube technology, PGiant constitutes a natural progression from lower residential application outputs of up to 175 kW (600 kBTU/h), into higher performances of commercial ranges of up to 1.4 MW (4.8 MMBTU/h).

34

Construction

PGiant 0.6M 175 kW (600 kBTU/h) includes 2 x P300 heat exchanger inserts PGiant 0.8M 235 kW (800 kBTU/h) includes 2 x P400 heat exchanger inserts

PGiant 1.2M

PGiant 1.8M

350 kW (1200 kBTU/h) includes 4 x P300 heat exchanger inserts

525 kW (1800 kBTU/h) includes 6 x P300 heat exchanger inserts

PGiant 1.6M

PGiant 2.4M

470 kW (1600 kBTU/h) includes 4 x P400 heat exchanger inserts

700 kW (2400 kBTU/h) includes 64 x P600 heat exchanger inserts

PGiant 3.6M 1050 kW (3600 kBTU/h) includes 6 x P300 heat exchanger inserts double-stacked PGiant 4.8M PGiant 3.2M 935 kW (3200 kBTU/h) includes 4 x P400 heat exchanger inserts double-stacked

1400 kW (4800 kBTU/h) includes 6 x P400 heat exchanger inserts double-stacked

The PGiant’s construction evokes experience in thermal technology with validated fire-tube design, and combines it with a modular concept of detachable, scalable heat exchanger sections, a flexible solution for the end-users.

Each module has two PG heat exchangers inserts connected together and topped with a combustion chamber. Tube bundle modules can be joined side-by-side, in two or three rows, reaching 470 or 700 kW (1.6 or 2.4 MMBTU/h).

PGiant is built from tube bundle modules, each carrying 175 or 235 kW capacity (600 or 800 kBTU/h), allowing for easy configuration depending on final output required.

Double or triple modules are stackable, therefore the total PGiant output can achieve up to 1.4 MW (4.8 MMBTU/h).

36

Water outlet

Combustion chamber

Outlet water manifolds

Burner plate

Cover plate

Supporting frame

Tube packets

Water inlet

Inlet water manifolds

Condensate dish Flue outlet Condensate drain outlet

38

Technical specification Model

Power rating

Tube bundle configuration*

Flue connection size

Water connection inlet

outlet

in.

in.

in.

kW

kBTU/h

PGiant 0.6M

175

600

2 x P300

6

3

2

PGiant 0.8M

235

800

2 x P400

6

3

2

PGiant 1.2M

350

1200

4 x P300

8

3

3

PGiant 1.6M

470

1600

4 x P400

8

3

3

PGiant 1.8M

525

1800

6 x P300

8

3

3

PGiant 2.4M

700

2400

6 x P400

8

3

3

PGiant 3.2M

935

3200

4 x P400 double-stacked

8

3

3

PGiant 3.6M

1050

3600

6 x P300 double-stacked

8

3

3

PGiant 4.8M

1400

4800

6 x P400 double-stacked

8

3

3

Weight

A (width)

B (length)

C (height)

kg

lbs

mm

in.

mm

in.

mm

in.

PGiant 0.6M

210

463

850

33.5

872

34.3

973

38.3

PGiant 0.8M

220

485

850

33.5

872

34.3

973

38.3

PGiant 1.2M

350

772

850

33.5

1252

49.3

973

38.3

PGiant 1.6M

370

816

850

33.5

1252

49.3

973

38.3

PGiant 1.8M

490

1080

850

33.5

1632

64.3

973

38.3

PGiant 2.4M

520

1146

850

33.5

1632

64.3

973

38.3

PGiant 3.2M

740

1631

850

33.5

1252

49.3

1946

76.6

PGiant 3.6M

980

2161

850

33.5

1632

64.3

1946

76.6

PGiant 4.8M

1040

2293

850

33.5

1632

64.3

1946

76.6

*tube bundle configuration refers to heat exchanger insert as per below P300 insert - single heat exchanger with 126 heating tubes P400 insert - single heat exchanger with 147 heating tubes

Model

C

B 39

A

Predator Water tube solution for commercial application 600–1200 kW 2,000–4,000 kBTU/h

97% Maximum efficiency

11 bar

160 PSIG

Maximum allowable working pressure 40

Predators combine a primary water tube heat exchanger along with a brazed condenser to deliver an exceptional thermal performance.

These products were designed to provide maximum thermal output in a smallest possible footprint. Sophisticated manu‐ facturing line was set up with a semi automatic process to ensure adequate quality levels and repeatability.

Both Predator models are extremely compact in size as 600 kW (2 MMBTU/h) and 1.2 MW (4 MMBTU/h) models fit through a standard 36″ doorway or elevator. This means lower installation costs as no rigging is required.

41

100% Stainless steel

F-Line technology Brazed fin-and-tube construction with stainless steel ribbon channels provides increased heat transfer. Easily scalable modular concept with tightly packed fins results in reduced footprint.

42

Predator combines two technologies, water tube (for water-cooled combustion chamber) and brazed fin-andtube for the lower condensing section (F-line technology).

Brazed stainless steel ribbon channels provide increased heat transfer area.

Water outlet

Water inlet

43

Primary heat exchanger of water tube design

Stainless steel brazed ribbon channels for increased heat transfer area

Technical specification

Model

Power rating

Weight

kW

kBTU/h

kg

lbs

mm

in.

mm

in.

Predator 2M

600

2,000

275

606

252.7

10

88.9

3

Predator 4M

1200

4,000

445

981

252.7

10

114.3

4

Model

Flue pipe connection size

Water connection size

A (height)

B (width)

C (length)

D* (length)

mm

in.

mm

in.

mm

in.

mm

in.

Predator 2M

1350

53.0

610

24.0

1205

47.5

1637

65.9

Predator 4M

1438

56.6

660

25.9

1420

55.9

1717

67.6

*dimension depedns on assembly configuration

A

D

B

C

44

AIC is an acclaimed designer and provider of heat transfer solutions for heating and cooling applications, used in a variety of industries worldwide.

Established in 2001, AIC fairly soon reached the status of specialists in the field of design, engineering, and manufacture of heat exchangers and pressure vessels. In just over 20 years, a small engineering office that initially focused on conceptual designs of heat exchangers, transformed into a large organization, with innovative products, sophisticated manufacturing technologies, and a strong R&D center.

Today AIC has three manufacturing facilities in Europe, sales offices in North America and Asia, and a distribution center in the U.S. AIC is leading the way in heat transfer design solutions, working with industry leaders and embarking on the most demanding projects.

We are certified in accordance with renowned international codes and standards. Our quality process and management systems fulfill the requirements of ISO 9001 Quality Management System.

AIC heat exchangers are designed, manufactured and inspected in accordance with ASME Boiler and Pressure Vessel Code (BPVC) Sections IV, VIII-1 and PED 2014/68/EU regulations.

PED

SELO

National Board R

Europe

China

USA

www.myaic.com

Condensing Boilers | Edition 06.2022 | Version 1.0

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