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.
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/Hrange 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 CaradonIdeal 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.
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.
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
BoilerMinimum flow rates for a
temperature difference of 35°C (63°F)
l/sg.p.m.
CXSi 110/H0.759.9
CXSi 120/H0.8210.8
CXSi 140/H0.9612.7
CXSi 160/H1.1014.6
CXSi 180/H1.2416.4
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:
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 roomEnclosure
Low level (inlet)410
High level (outlet)25
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:
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
11
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