IDEAL INDUSTRIES H-180-H, H-CXSi-160, H-CXSi-180-H, H-CXSi-120, CXSi 110 User Manual

...
Installers guide to commercial central heating boilers
BOILERS
Concord
CXSi 110/H-180/H
INSTALLATION
MANUAL
& SERVICING
GENERAL
2
Concord CXSi/H - Installation & Servicing
GENERAL
Table 1 - Performance Data
Boiler CXSi 110/H CXSi 120/H CXSi 140/H CXSi 160/H CXSi 180/H
Boiler Input Gross kW 93.9 102.5 119.5 136.6 153.7
Low Rate Btu/h x 1000 320.5 349.6 407.9 466.1 524.4
Nett kW 84.6 92.3 107.7 123.1 138.5
Btu/h x 1000 288.7 315.0 367.4 419.9 472.4
Boiler Input Gross kW 134.2 146.4 170.8 195.2 219.6
High Rate Btu/h x 1000 457.8 499.4 582.7 665.9 749.1
Nett kW 120.9 131.9 153.8 175.8 197.8
Btu/h x 1000 412.4 449.9 524.9 599.9 674.9
Boiler Output kW 110 120 140 160 180
High Rate Btu/h x 1000 375.3 409.4 477.7 545.9 614.2
3
Gas rate High m
Approx. flue
gas volume At 4.5% CO
At 4.5% CO2 & 100°C m
& 212°F ft
2
Burner High mbar 10.4 10.1 9.7 9.6 9.7
setting in.w.g. 4.2 4.0 3.9 3.8 3.9
pressure Low mbar 5.1 4.9 4.8 4.7 4.8
/h 12.78 13.95 16.27 18.59 20.92
ft3/h 451.5 492.5 574.6 656.7 738.8
3
/h 0.112 0.122 0.142 0.163 0.183
3
/h 237 259 301 345 388
in.w.g. 2.0 2.0 1.9 1.9 1.9
Part load efficiency % 83.0 81.6 82.5 82.9 82.8
Note. To obtain gas consumption in l/s divide gross heat input (kW) by a calorific value of 37.8(MJ/m2)
Table 2 - General Data
Boiler CXSi 110/H CXSi 120/H CXSi 140/H CXSi 160/H CXSi 180/H
Number of sections 7 7 8 9 10
Flow connections Rc 65 mm (2
1/2") nominal bore. Flange to BS.4504 (PN6)
Return tappings Rc 2 x 2
Maximum static head m. (ft) 61.0 (200)
Maximum pressure bar (psi) 6.0 (87)
Gas inlet connection Rc 1
1/2
Minimum dynamic mbar 17.5 17.5 17.5 17.5 17.5 gas pressure in. 7 7 7 7 7
Electricity supply 230 Volts - single phase, 50 Hz, fuse 5 A
Nominal flue size (to BS. 835) mm 250 250 250 250 300
in. 10 10 10 10 12
Diverter outlet socket mm 288 288 288 288 344
internal diameter in. 11.3 11.3 11.3 11.3 13.5
Length of burner bars (overall) mm 535 535 535 535 535
in 21.1 21.1 21.1 21.1 21.1
Approximate dry weight kg 538 538 608 678 748
lb. 1186 1186 1340 1494 1648
Water content litre 53 53 60 68 76
gal. 11.7 11.7 13 15 17
Concord CXSi/H - Installation & Servicing
3
GENERAL
Concord CXSi 110/H-180/H (Natural gas) B.G. Certified - P.I. No. 87/AQ/341 Destination Countries: GB and IE
INTRODUCTION
CONTENTS
Air Supply. ........................................................................ 9
Boiler Assembly - exploded view. ............................... 10
CONSTRUCTION
BOILER BODY
The sectional boiler body is of cast iron and is supplied with a sheet steel combustion chamber and integral draught diverter. The boiler is supplied in sectioned form for site assembly.
Boiler Clearances. ........................................................... 6
Burner Assemblies - exploded views. ............................
CXSi 110/H-160/H. ................................................. 25
CXSi 180/H. ............................................................ 26
Casing Assembly. ......................................................... 14
Chimney System. ............................................................ 9
Commissioning. ............................................................ 20
Electrical Connections. ................................................ 17
Electrical Supply. ............................................................ 9
Fault Finding. ................................................................ 29
Gas Safety Regulations .................................................. 4
Gas Supply. ...................................................................... 9
Hydraulic Resistance. ..................................................... 6
Initial Lighting. .............................................................. 21
Installation. .................................................................... 10
Mandatory Requirements. .............................................. 8
Option Kits. ...................................................................... 5
Pump. ............................................................................... 7
CASING
The casing is manufactured in stove enamelled sheet steel and is easily assembled on site.
BURNERS
The burners are of stainless steel construction.
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.
The Concord CXSi 110/H-180/H range of boilers has been tested and certified by British Gas to prEN656 for use with natural gas
only.
Note. Concord CXSi 110/H - 180/H boilers are intended for use as COMMERCIAL BOILERS and are NOT certified for use in domestic applications. A domestic installation is defined as an installation where the boiler takes its combustion air from a living space or from a room directly or indirectly connected with the living space. It is important, therefore, that no external control devices - e.g. flue dampers, economisers etc., are directly connected to this appliance unless covered by these Installation and Servicing Instructions or otherwise recommended by Caradon Ideal Limited in writing. If in doubt please enquire.
Any direct connection of a control device not approved by Caradon Ideal Limited could invalidate the British Gas Certification, the normal appliance warranty and could also infringe the Gas Safety Regulations. Table 1, Table 2 and the descriptive notes which follow contain all the essential data likely to be required by the installer.
Servicing. ....................................................................... 24
Short List of Parts. ........................................................ 31
Static Head Requirements. ............................................ 7
System Connections. .................................................... 13
Ventilation. ....................................................................... 9
Water Circulation. ........................................................... 5
Water Connections. ........................................................ 5
Water Treatment. ............................................................. 7
Wiring Diagrams. .......................................................... 19
CAUTION.
this appliance, care should be taken when handling edges of sheet steel components.
To avoid the possibility of injury during the installation, servicing or cleaning of
4
GAS CONTROLS
The boiler lights at Low rate (approximately 70% of Full rate) by direct burner ignition. After about 1 minute the boiler goes to High rate and will continue at High rate until the thermostat sensor set point is reached. The boiler will then drop to the Low rate; if the temperature continues to rise the boiler will go Off; if the temperature falls the boiler will revert to High rate.
ELECTRICAL CONTROLS
The boiler is supplied with 2 printed circuit boards; Board S4561B1047 is the ignition board containing the flame-proving logic; Board W4115A1020 contains the electronic thermostat and pump overrun timer. A preset overheat thermostat is also provided. The mains voltage supply is via a terminal plug in connection at the control box. The control box displays neons indicating boiler status as follows:
- Boiler on
- Lockout
- Overheat
An anti-cycle delay is built in to the controls to prevent rapid cycling.
Concord CXSi/H - Installation & Servicing
GENERAL
FROST PROTECTION
Frost protection is incorporated in the boiler as long as there is a permanent Live supply wired to Terminal L1 on the terminal plug-in connection at the control box and the boiler thermostat knob is not switched to Off.
If the temperature sensed by the boiler thermostat falls to about
0
C the boiler will fire until the temperature reaches 180C.
5
Note that this is designed to protect the boiler and may not necessarily protect remote parts of the system.
The mains voltage supply is via a terminal plug-in connection at the control box.
OPTION KITS
Remote Indication Kit
This kit gives the facility of remote indication of boiler status.
Pressure Gauge Kit
A pressure gauge kit is available.
DUTY
The range of boilers is suitable for: Combined indirect pumped domestic hot water and central heating systems; Independent indirect pumped domestic hot water or central heating systems.
Fully pumped systems may be open vented or sealed.
WATER CIRCULATION SYSTEM
Due to the compact nature of the boiler the heat stored within the castings at the point of shutdown of the burner must be dissipated into the water circuit in order to avoid the overheat thermostat tripping. In order to allow pump operation after burner shutdown the boiler control box incorporates a pump overrun facility which operates for approximately 6 minutes after the burner shuts down and, in order to make use of this, the pump must be wired to the appropriate terminal L2 (pump) in the boiler control box.
1. The minimum flow rate as given in Table 4 must be maintained whenever the boiler is firing and during the pump overrun period.
2. During the period of pump overrun there must be an open circuit of adequate water volume and/or load. The minimum size of this circuit is given by the use of Graph 1.
Examples shown on Graph 1
a. For the CXSi 110/H and CXSi 120/H the minimum circuit
during pump overrun could be a load of 7 kW with a volume of 42 litres or any other combination given by the relevant line.
b. For the CXSi 180/H the minimum circuit during pump overrun
could be a load of 9 kW with a volume of 70 litres or any other combination given by the relevant line.
The above circuit capacity during pump overrun may be achieved either by provision of an adequate bypass circuit or by ensuring that a zone of suitable size is open for circulation during this period by relevant control of zone valves or pumps.
The range of boilers is NOT suitable for:
1. Gravity DHW systems.
2. Gravity heating systems.
3. Direct domestic hot water supply.
1
WATER CONNECTIONS
Flow connection is 65mm (2 1/2") nominal bore flange to BS.4504 (PN6)
Return tappings are 2" BSP.
The distributor tube must be fitted into the return connection. The flow header must be fitted in the flow pipe.
The open vent must be brought to either the 1 on the flow header or to the unused 2" BSP tapping at the top rear of the boiler.
The cold feed may be brought to the LH front bottom tapping in order to avoid excessive surging or pumping over. The unused bottom rear tapping must not be used for the cold feed pipe as it is practically blocked by the distributor tube.
Safety Valve
A safety valve must be sized and fitted in accordance with BS. 6644 for every type of system. The valve should be set at 0.7 bar (10 lb/in.2) above the operating pressure in the boiler. The maximum safety valve setting is 0.7 bar (10 lb/in.2) above the maximum design operating pressure of 6.0 bar (87 lb/in.2).
1/2" BSP tapping
The wiring diagrams in Frames 16,17 &18 illustrate the control methods for achieving the above.
3. Pump selection should take account of the hydraulic resistance given in Graph 2.
Cold Feed/Open Vent
The independent cold feed and the open vent must comply with BS. 6644 and be of the following minimum size.
Boiler Size Cold Feed Open Vent
CXSi 110/H 1" 1
CXSi 120/H 1" 1
CXSi 140/H 1" 1
CXSi 160/H 1
CXSi 180/H 1
1/4"1 1/2"
1/4"1 1/2"
1/4"
1/4"
1/4"
Concord CXSi/H - Installation & Servicing
5
GENERAL
CXSi 180
/H
CXSi 160
/H
CXSi 110/H
CXSi 120
/H
CXSi 140/H
Con 1900
CXSi 180/H
CXSi 160/H
CXSi 110/H
CXSi 120/H
CXSi 140/H
Con 1898
Con 1899
+:5E
CONCORD




Return Rc
(2" BSP)
Graph 1 - Heat Load / Water Volume
2
CLEARANCES & DIMENSIONS
Graph 2 - Hydraulic Resistance
Table 3
Boiler Size CXSi 110/H CXSi 120/H CXSi 140/H CXSi 160/H CXSi 180/H
Front clearance mm (in) 700 (27
1/2)
Rear clearance mm (in) 200 (8)
Side clearance mm (in) 100 (4) - not including clearance for side fitted flow header
Dimension A mm (in) 1036 (40
Dimension B mm (in) 175 (7) 175 (7) 175 (7) 197 (7
Dimension C mm (in) 1107 (43
Dimension D mm (in) 816 (32
Dimension E mm (in) 553 (21
Dimension F mm (in) 220 (8
3/4) 1036 (40 3/4) 1036 (40 3/4) 1086 (42 3/4) 1140 (45)
3/4) 250 (10)
3/4) 1107 (43 3/4) 1230 (48 1/2) 1353 (53 1/4) 1476 (58 1/8)
1/8) 816 (32 1/8) 939 (37) 1062 (42 3/4) 1185 (46 5/8)
3/4) 553 (21 3/4) 615 (24 1/4) 676 (26 5/8) 738 (29)
5/8) 220 (8 5/8) 220 (8 5/8) 220 (8 5/8) 320 (12 1/2)
1
POSITION OF BOILER
Minimum clearances required from walls or other fixed objects to allow for the free access of combustion air are shown in Table 3 above.
Any combustible material adjacent to the boiler and its flue system must be so placed or shielded as to ensure that its temperature does not exceed 65
0
C (150 0F).
6
Concord CXSi/H - Installation & Servicing
GENERAL
PUMP POSITIONS
Whenever practically possible the circulating pump(s) should be positioned so that it pressurises the system being served. The vertical distance between the pump(s) and any cold feed and expansion cistern MUST comply with the pump manufacturers requirements, in order to avoid cavitation. These requirements override the information given in Frame 3 if the static head required for the pump(s) exceeds that required for the boiler.
MINIMUM FLOW OF WATER - Refer to Table 4
The system design must provide for an adequate flow rate through the boiler at all times when the boiler is firing. The minimum flow rate should correspond to a temperature difference across the boiler flow and return of 35°C (63°F), assessed at catalogue rating.
Table 4 - Flow rates for fully pumped systems
Boiler Minimum flow rates for a
temperature difference of 35°C (63°F)
l/s g.p.m.
CXSi 110/H 0.75 9.9
CXSi 120/H 0.82 10.8
CXSi 140/H 0.96 12.7
CXSi 160/H 1.10 14.6
CXSi 180/H 1.24 16.4
WATER TREATMENT FOR HOT WATER AND HEATING BOILERS
There is a basic need to treat the water contained in all heating and indirect water systems, particularly open vented systems. It is assumed, incorrectly, that because boilers are operating in conjunction with what is apparently a closed circuit an open vented system will not, under normal circumstances, allow damage or loss of efficiency due to hardness salts and corrosion once the initial charge of water has been heated up a few times.
1mm of lime reduces the heat transfer from metal to water by 10%.
In practice the deposition of these salts is liable to cause noises from the boiler body or even premature boiler failure. Corrosion and the formation of black iron oxide sludge will ultimately result in premature radiator failure.
Open vented systems are not completely sealed from the atmosphere if proper venting and expansion of system water is to be achieved. The same tank is used to fill the system with water and it is through the cold feed pipe that system water expands into the tank when the boiler passes heat into the system. Conversely, when the system cools, water previously expanded is drawn back from the tank into the system, together with a quantity of dissolved oxygen.
Even if leakage from the heating and hot water system is eliminated there will be evaporation losses from the surface of the tank which, depending upon ambient temperature, may be high enough to
3
OPEN VENTED SYSTEMS - minimum static head requirements
The information provided is based on the following assumptions:
1. The open vent MUST be brought to either
2. An independent cold feed/expansion pipe
3. The maximum flow rate through the boiler
4. The boiler is at the highest point of
Note. This diagram does not show safety valves, water flow
switches, etc., necessary for the safe operation of the system.
Particular reference should be made to BS. 6644: Section 2; Subsection 10 and Guidance note PM5 "Automatically controlled steam and hot water boilers" published by the Health and Safety Executive. The information and guidance given below is not intended to override any requirements of either of the above publications or the requirements of the local authority, gas or water undertakings.
Other British Standards applicable are BS.5422 and BS.6700.
5. The position of the open vent/safety pipe
1/2" BSP tapping on the flow header
the 1 provided or to the unused 2" BSP flow tapping at the top rear of the boiler.
connection is made to the LH lower front connection. Cold feed/expansion pipe connections made to the pumped system return will result in an increase in the static head requirement, caused by the additional resistance of the distributor tube. Surging may also increase.
is based on a temperature difference of 11°C at full boiler output and the circulating pump is positioned in the flow to the system.
circulation in the system. Systems designed to rise above the boiler flow tappings will automatically require a minimum static head higher than that shown.
above the expansion cistern water level is given as a guide only. The final position will depend upon the particular characteristics of the system. Pumping over of water into the expansion cistern must be avoided.
Concord CXSi/H - Installation & Servicing
7
GENERAL
evaporate a large portion of the system water capacity over a full heating season.
There will always be corrosion within a heating or hot water system to a greater or lesser degree, irrespective of water characteristics, unless the initial fill water from the mains is treated. Even the water in closed systems will promote corrosion unless treated.
For the reason stated Caradon Ideal Limited strongly recommend that when necessary the system is thoroughly cleaned, prior to the use of stable inhibitor, which does not require continual topping up to combat the effects of hardness salts and corrosion on the heat exchangers of the boiler and associated systems.
Caradon Ideal Limited advise contact directly with specialists on water treatment such as:
Fernox Manufacturing Co. Ltd., or Sentinel Division, Tandem House, Marlowe Way Betz Dearborn Ltd., Croydon. Widnes, Surrey CRO 4XS Cheshire, WA8 8UD Tel 0870 601 5000 Tel. 0151 424 5351.
SAFE HANDLING OF SUBSTANCES
Care should be taken when handling the boiler insulation panels, which can cause irritation to the skin. No asbestos, mercury or CFCs are included in any part of the boiler.
INSTALLATION REQUIREMENTS
The appliance must be installed by a CORGI registered installer,
The installation of the boiler must be in accordance with the relevant requirements of the Gas Safety Regulations, current I.E.E. (BS.7671) Regulations, Model Water Bye-laws, local water authority bye-laws and it should also comply with any relevant requirements of the local gas supplier, local authority and the relevant British Standard Codes of practice and building regulations.
Limitations of Intended Operating Environment
These appliances are NOT suitable for installation where they will be exposed to the elements.
A boiler room shall be constructed or adapted to meet the requirements of BS 6644.
The maximum ambient temperature is 32 °C at 1.5 metres from the floor with a maximum humidity of 90% RH.
FOR SMALL PIPE INSTALLATIONS;
BS. 6891: Installation of low pressure pipework
FOR LARGE PIPE INSTALLATIONS
Gas Installations
IGE-UP-1: Purging Procedures of Non-domestic Gas
Installations. Soundness Testing Procedures for Industrial and Commercial.
IGE-UP-2: Guidance notes on the Installation of Gas
Pipework, Boosters and Compressors in Customer’s Premises Equal to or Greater than 25mm (Non-domestic).
IGE-UP-10: Installation of Gas Appliances in Industrial and
Commercial Premises.
BS.6644: Installation of Gas Fired Hot Water Boilers
70kW to 1.8MW (net).
BS 6880 Pt 1-3: Water Supply.
CP342:2: Centralised Hot Water Supply.
Model Water Bye-laws
Manufacturers notes must not be taken, in any way, as overriding statutory obligations.
The appliance must be installed in a room separated from living rooms and provided with appropriate ventilation direct to the outside
- see Table 5.
4
SEALED (PRESSURISED) SYSTEMS
Working pressure 6.0 bar maximum.
Particular reference should be made to BS. 6644: Section 6 and Guidance note PM5 "Automatically controlled steam and hot water boilers" published by the Health and Safety Executive.
The information and guidance given below is not intended to override any requirements of either of the above publications or the requirements of the local authority, gas or water undertakings.
In general commercial closed pressurised systems are provided with either manual or automatic water make up.
On both instances it will be necessary to fit automatic controls intended to protect the boiler, circulating system and ancillary equipment by shutting down the boiler plant if a potentially hazardous situation should arise.
Examples of such situations are low water level and operating pressure or excessive pressure within the system. Depending on circumstances, controls will need to be either manual or
automatic reset. In the event of shutdown both visual and audible alarms may be necessary.
Pressure vessels used must comply with BS. 4814 and must be sized on the basis of the total system volume and initial charge pressure.
Initial minimum charge pressure should not be less than 0.5 bar (7.2 psi) and must take account of the static head and specification of the pressurising equipment. The maximum water temperatures permissible at the point of minimum pressure in the system are specified in Guidance Note PM5.
When make up water is not provided automatically it will be necessary to fit controls which shut down the plant in the event of the maximum system pressure approaching to within 0.35 bar (5 psi) of the safety valve setting.
Other British Standards applicable to commercial sealed systems are:-
BS. 6880: Part 2
BS. 1212
BS. 6281: Part 1
BS. 6282: Part 1
BS. 6283: Part 4
8
Concord CXSi/H - Installation & Servicing
GENERAL
FOUNDATION
The boiler must stand on a non-combustible floor (i.e. concrete or brick) which must be flat, level and of a suitable load bearing capacity to support the weight of the boiler (when filled with water) and any ancillary equipment.
If the boiler is mounted on a plinth then the dimensions must exceed the plan area of the boiler by at least 75mm on each side.
VENTILATION
Safe, efficient and trouble-free operation of conventionally flued gas boilers is vitally dependent on the provision of an adequate supply of fresh air to the room in which the appliance is installed. Ventilation by grilles communicating directly with the outside air is required at both high and low levels. The minimum free areas of these grilles must be according to the following scale:
Table 5 - Ventilation Requirements
Required area (cm2) per kW of total rated input (net)
Boiler room 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).
Position ventilation grilles to avoid the risk of accidental obstruction by blockage or flooding. If further guidance on ventilation is required then consult BS.6644.
CHIMNEY SYSTEM
To ensure the safe and satisfactory operation of the boiler then the chimney system (which may be common or individual, in the case of twin or multiple boiler installations) must be capable of the complete evacuation of combustion products at all times. The effective height of the chimney terminal(s) above the boiler outlet(s) must ensure sufficient buoyancy to overcome the resistance of the bends, tees and runs of the flue pipe involved and shall terminate in a down draught free zone. The number of bends and lengths of horizontal flue pipe used should be kept to a minimum in order to reduce gas flow resistance.
Compliance with the recommendations made in BS.6644, IGE UP/10 Installation of Gas Appliances in Industrial and Commercial Premises and the 'Third Edition of the 1956 Clean Air Act Memorandum' should be strictly observed where applicable.
The chimney design should avoid the formation of excessive quantities of condensate. For this reason it is recommended that all chimneys are insulated and lined. In the case of brick or similar structures a stainless steel rigid or flexible flue liner (grade 304/
316) may be used in conjunction with a 50 mm (minimum) thick layer of vermiculite or perlite granules between the liner and the inner skin of the chimney body. Liners should be sealed at both top and bottom.
As the Concord CXSi/H range of boilers is supplied complete with an integral draught diverter, a diverter MUST NOT be fitted within the chimney system.
Drainage points positioned at the bottom of all vertical chimney sections should be provided. Drain pipes should be no less than 25 mm I.D., manufactured from acid condensate resistant material such as stainless steel and be positioned so that pipe runs and discharge points are not subject to the effects of frost and that flue gases cannot leak into the boiler room.
AIR SUPPLY BY MECHANICAL VENTILATION
The supply of air by mechanical means to a space housing the boiler should be by mechanical inlet with natural or mechanical extraction. Mechanical extract ventilation with natural inlet must not be used.
Where a mechanical inlet and a mechanical extract system is applied, the design ventilation flow rates should be as in Table 4 of BS.6644.
The requirements for air supply by mechanical ventilation are given in BS.6644.
Note. For mechanical ventilation systems an automatic control should be provided to cause safety shutdown or lockout of the boiler(s) in the event of failure of air flow in either inlet or extract fans.
IMPORTANT.
The use of an extractor fan in the same room as the boiler (or in an adjacent communicating room) can, in certain conditions, adversely affect the safe operation of the boiler. Where such a fan is already fitted (or if it is intended to fit an extractor fan after installation of the appliance) the advice of the gas supplier should be obtained.
Tests for spillage of products from the draught diverter when the extractor fan is running and all doors and windows are shut should be carried out after installation. If spillage is detected, the area of permanent ventilation must be increased.
Care should be taken to ensure the specification of the chimney is suitable for the application by reference to the manufacturers literature. Caradon Ideal Limited can offer advice on the design of suitable chimney systems.
GAS SUPPLY
If there is any doubt regarding the capacity of the gas meter, the available gas pressure, the adequacy of existing service pipes or the size required for new service pipes then the advice of the gas supplier should be requested.
Installation pipework should be fitted and tested for gas soundness in accordance in accordance with BS. 6891;
IGE-UP-1 for small installations IGE-UP-2 for large installations.
The local gas supplier must be consulted if it is necessary to employ a gas pressure booster.
ELECTRICAL SUPPLY
WARNING. This appliance must be efficiently earthed.
A 230 V - 50 Hz mains supply is required, fused at 5 amps.
Wiring external to the appliance MUST be in accordance with the I.E.E. (BS. 7671) Wiring Regulations and any local regulations which apply.
Concord CXSi/H - Installation & Servicing
For details of connections see Frame 14.
9
5
INSTALLATION
INSTALLATION
CONCORD CXSi BOILER ASSEMBLY - Exploded view
Insulation not shown
Legend
1. Cleanout cover
2. Collector hood
3. Middle section
4. Flow header
5. Section alignment rings & 'O' rings.
6. Thermostat pocket.
7. End section.
10
8. Distribution tube.
9. Downdraught deflector.
10. Section bolt.
11. Drain cock.
12. Base plate.
13. Combustion chamber.
14. Tie rods.
15. Lightback shield.
16. Burner manifold assy.
17. NOx duct.
18. Insulation bracket
Concord CXSi/H - Installation & Servicing
INSTALLATION
6
BOILER SECTION ASSEMBLY
The site assembled boiler is supplied in the following packages:
! Combustion chamber / manifold / burner assembly.
! Platework package.
! Casing package.
! Controls box package.
! End and centre sections.
GENERAL
The installation of the boiler must be in accordance with current Gas Safety (Installation and Use) Regulations or rules in force, building regulations, I.E.E. (BS.7671) Regulations and the bye­laws of the local water undertaking. It should also be in accordance with the relevant British Standard Codes of Practice together with any relevant requirements of the local gas supplier and local authority.
ASSEMBLY
The combustion chamber should be positioned as near as possible to the installation site.
IMPORTANT.
It must be remembered that the boiler distribution tube has to be fitted into the rear return tapping of the assembled boiler before final siting.
Prior to assembling the sections it will be necessary to remove the manifold assembly and burners from the combustion chamber. To do this:
1. Undo the two M5 screws and washers securing the spark generator bracket to the combustion chamber. Undo the union securing the gas valve assembly and remove the gas valve and spark generator assembly from the boiler.
2. Undo the 4 nuts securing the burner manifold to the combustion chamber legs.
3. Undo the nuts securing the burner light back shield to the combustion chamber and lift it off.
4. Pull the whole burner assembly forward on its runners, ensuring that no wires are trapped, and remove it completely from the combustion chamber.
PREPARATION OF SECTIONS
Each section should be brushed clean on all external surfaces and any debris which may have accumulated within the sections should be removed via the bottom ports.
TOOLS REQUIRED
! Spanners
! Torque wrench
! Pozi screwdriver
! Mallet
Section Assembly - refer to the exploded view
5. Take an end section and lift it onto the combustion chamber
so that the combustion chamber side panel return is inside the section rear lip.
6. Locate a slotted steel ring and an ‘O' ring seal into each of the 4 ports. It will be necessary to squeeze the steel ring slightly to enable it to be pushed fully into the recess.
7. Lift a middle section onto the combustion chamber and carefully offer it up to the end section until it engages the projecting steel rings. It may be necessary to use a mallet and hardwood block to ensure that the steel rings are pushed fully into the recessing and that the sections are butted up to each other.
Note. Until the final section is fitted and the tie rods fastened, the sections in the assembly are not fixed together therefore CARE MUST BE TAKEN TO PREVENT the installed sections coming apart.
8. Repeat the assembly procedure for all of the sections until complete.
9. Fit the 4 tie rods through the holes in the sides of the end sections and fit a flat steel washer, a shakeproof washer and a nut to both ends of each tie rod. Screw up all the nuts equally, in turn and, finally, tighten them to a torque of 38-41 Nm (28-30 lb. ft).
10. For open vented systems a site test must be carried out at a hydraulic pressure equal to 1 pressure given in Table 2, for a period of 30 minutes.
Note. If it is a sealed system the hydraulic pressure must be equal to twice the given design pressure for 30 minutes.
11. Fit the 4 coach bolts into the lugs at the bottom of the end sections and through the hole in the retaining angle of the combustion chamber. Fit a flat washer and nut and secure the section assembly to the combustion chamber.
1/2 times the design
INSTALLATION
Concord CXSi/H - Installation & Servicing
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