Concord
range
CXA/H, CXS/H, CXSi/H, ES/H, Modular
Gas atmospheric boilers 40-720kW
Commercial & Industrial Boilers
the Concord range
2
Conforms with all relevant
European standards and
requirements
Contents
Introduction
2
Concord CXA/H,CXAP/H, CXS/H
3
Technical data
4 - 5
Dimensional data
6
General data
7
Concord CXSi/H
8
Technical data
9
Dimensional data
10
General data
11
Concord ES/H
12
Technical data
13
Dimensional data
14
Concord Modular
15
System requirement
16 - 17
General & dimensional data
18 - 19
Flue design
20 - 21
General data
22
Concord range
23 - 27
Ideal's Concord range continues to lead the market with value for
money gas atmospheric boilers for commercial or industrial applications.
Ideal boasts the widest range of gas atmospheric boilers, which
incorporate outputs from 40kW to 380kW in a singular boiler and
up to 720kW in Modular format. The Concord range has a host of
features making them suitable for most heating systems.
The Concord range includes:
CXA/H
Now with Auto ignition
(40-120kW)
CXAP/H
Propane option
(40-100kW)
CXS/H
High / Low operation with Standard control panel
(40-120kW)
CXSi/H
High output with Standard control panel
(110-180kW)
ES/H
High output providing adjustable High / Low operation
(140-380kW)
Concord Modular
(80-720kW)
As well as having a boiler for every application, Ideal Boilers are
also committed to improving boiler efficiency and reducing
emissions, as a result we can now demonstrate conformance to the
new Building Regulations 2006 Part L2 (Section 6).
Ideal is the only company in its field to have achieved `Word Class
Manufacturer' accreditation in the prestigious IBM and London
Business School UK manufacturing survey. Our Hull based factory is
part of only 2% of all manufacturing sites in the UK that have been
independently judged as meeting the criteria of World Class manu-
facturing status, while our superior manufacturing facilities mean
that we can achieve `right first time' quality. In accordance with the
company's World Class status, we have adopted a programme of
continuous improvement which ensures that we constantly measure
and monitor our performance to drive improvement through
innovation.
To ensure the products' reliability, each of our boilers is subjected to
an extraordinarily stringent regime of product assessment. This
includes rigorous application testing, as well as extensive laboratory
and field trials.
3
·
Ultra reliable gas atmospheric boilers
·
Widest range of models and outputs (in modular format to 720kW)
·
High full and part load efficiencies -
Meets Building Regulations 2006 (Part L2)
·
CXA/H models with auto ignition
·
CXS/H models with two stage operation
·
Remote indication kit options
·
Modular boiler kit available 80 - 720kW
The Concord CXA/H
The Concord CXS/H control panel
Concord CXA/H, CXAP/H, CXS/H
40 - 120kW
4
technical data
40/H
50/H
60/H
70/H
80/H
90/H
100/H
110/H
120/H
40P/H
50P/H
60P/H
70P/H
80P/H
90P/H
100P/H
3
4
4
5
5
6
6
7
7
Rc
2x2 at rear
in. BSP
2x2 at rear
Rc
2x2 at rear
in. BSP
2x2 at rear
m
61
ft
200
bar
6
psi
87
Rc
3
/
4
3
/
4
3
/
4
3
/
4
3
/
4
1
1
1
1
in. BSP
3
/
4
3
/
4
3
/
4
3
/
4
3
/
4
1
1
1
1
mbar (gauge)
15.0
15.0
16.5
15.0
16.5
15.5
16.5
17.0
17.5
in. BSP
6.0
6.0
6.6
6.0
6.6
6.2
6.6
6.8
7.0
mbar (gauge)
15.5
15.5
16.5
15.0
16.0
17.5
16.0
17.5
17.5
in. BSP
6.2
6.2
6.6
6.0
6.4
7.0
6.4
7.0
7.0
230V nom single phase 50Hz fuse 5A
mm
150
150
175
175
200
200
200
250
250
in
6
6
7
7
8
8
8
10
10
mm
184
184
213
213
238
238
238
288
288
in
7
1
/
4
7
1
/
4
8
3
/
8
8
3
/
8
9
3
/
8
9
3
/
8
9
3
/8
11
3
/
8
11
3
/
8
kg
210
265
265
330
330
395
395
490
490
lb
463
584
584
727
727
871
871
1078
1078
l
22
30
30
37
37
45
45
53
53
gal
4.8
6.6
6.6
8.2
8.2
9.9
9.9
11.7
11.7
Note: (P) Figures in brackets denote propane
(*) Pressure required at the burner inlet for propane boilers is 37mbar (14.9 in. w.g.) across the range
Flow tappings
No. of sections
Return tappings
Maximum static water head
Maximum pressure
Gas inlet connection
Pressure required at boiler
inlet for rated input* (CXA/H)
Pressure required at boiler
inlet for rated input* (CXS/H)
Electricity supply
Nominal flue size
(to BS 835)
Diverter outlet socket
Approximate dry weight
Water content
Model
General Data CXA/H, CXS/H (natural gas) - CXAP/H (propane gas)
5
40/H
50/H
60/H
70/H
80/H
90/H
100/H
110/H
120/H
3
4
4
5
5
6
6
7
7
kW
40.0
50.0
60.0
70.0
80.0
90.0
100.0
110.0
120.0
Btu/h
136,500
170,600
204,700
238,800
273,000
307,100
341,200
375,300
409,400
Nett
kW
43.5
54.3
65.2
76.1
87.0
97.8
108.7
119.6
130.4
Btu/h
148,300
185,400
222,500
259,600
296,700
333,800
370,900
408,000
445,000
Gross
kW
48.3
60.3
72.4
84.5
96.5
108.6
120.7
132.7
144.8
Btu/h
164,700
205,800
247,000
288,200
329,300
370,500
411,700
452,800
494,000
m
3
/h
4.60
5.75
6.90
8.05
9.20
10.35
11.50
12.64
13.79
ft
3
/h
162.4
203.0
243.6
284.2
324.8
365.4
406.0
446.6
487.1
mbar
9.7
9.8
10.2
10.0
9.3
9.6
10.7
11.1
12.1
in. w.g.
3.9
3.9
4.1
4.0
3.7
3.8
4.3
4.4
4.8
m
3
/s
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.12
ft
3
/min
85
106
127
148
170
191
212
233
254
%
83.6
83.4
83.3
82.4
82.6
83.7
82.2
83.6
84.8
%
82.2
81.8
82.7
82.1
82.5
82.6
83.2
84.2
82.7
Boiler output
No. of sections
Boiler input
*Gas rate
Manifold setting
pressure
Approx flue
At 4.5% CO
2
& 100°C
gas volume
At 4.5% CO
2
& 212°F
Seasonal efficiency
CXA/H
Seasonal efficiency
CXS/H
*Note: The gas rates quoted are for NATURAL GAS only and assume a gross C.V. of 37.8MJ/m
3
(1000 Btu/ft
3
). The gas rate at calorific values differing
from that figure may be calculated by dividing the calorific value of the gas into the figure given in the 'INPUT' column of the table above.
Note: Low rate operation for CXS/H models is approx. 70% of full rate
Model
Performance Data CXA/H, CXS/H (natural gas)
40P/H
50P/H
60P/H
70P/H
80P/H
90P/H
100P/H
3
4
4
5
5
6
6
kW
42
49.68
60.4
69.2
83.28
89.72
103.68
Btu/h
143,300
169,500
206,100
236,100
284,200
306,100
353,800
Nett
kW
48.4
57.3
69.6
79.8
96.0
108.4
119.5
Btu/h
165,100
195,400
237,500
272,200
327,500
352,800
407,700
Gross
kW
52.5
62.1
75.5
86.5
104.1
112.15
129.6
Btu/h
179,100
211,900
257,600
295,100
355,200
382,700
442,200
m
3
/h
1.98
2.34
2.83
3.26
3.92
4.22
4.88
ft
3
/h
69.9
82.6
99.9
115.1
138.4
149
172.3
mbar
35.7
35.3
35.5
35.8
35.2
35.4
34.8
in. w.g.
14.3
14.2
14.3
14.4
14.2
14.2
14
6.6%
CO
2
0.051
0.060
0.073
0.083
0.099
0.108
0.125
150°C
m
3
/s
6.6%
CO
2
108
127
155
176
210
229
265
302°F
ft
3
/m
%
85.4
85.3
85.1
84.3
84.4
85.6
84.0
Boiler output
No. of sections
Boiler input
*Gas rate
Manifold setting
pressure
Approx flue gas
volume in secondary
flue of chimney
system
Seasonal efficiency
*Note: The gas rates quoted are for PROPANE GAS only and assume a gross C.V. of 95.7MJ/m
3
(2520 Btu/ft
3
). The gas rate at calorific values differing
from that figure may be calculated by dividing the calorific value of the gas into the figure given in the 'INPUT' column of the table above.
Model
Performance Data CXAP/H (propane gas)
6
dimensional data
All measurements in mm
Rear elevation showing
tapping centres
Note re gas inlet connection position:
60 from left on front elevation
60
60
480
705
348
Boiler Dimensions (natural gas and propane boilers) CXA/H, CXS/H
40/H
50/H
60/H
70/H
80/H
90/H
100/H
110/H
120/H
40P/H
50P/H
60P/H
70P/H
80P/H
90P/H
100P/H
mm
750
882
882
1042
1042
1212
1212
1385
1385
mm
108
108
122.5
122.5
135
190
190
160
160
mm
932
932
932
932
932
894
894
894
894
mm
177.5
187.5
187.5
224.5
224.5
271.5
271.5
321.5
321.5
Front
mm
750
Back
mm
0
0
0
150
150
300
300
300
300
Sides
mm
50
50
50
50
50
100
100
100
100
`A' Dimension
`B' Dimension
`C' Dimension
`D' Dimension
Model
Boiler Dimensions (natural gas and propane boilers) CXA/H, CXS/H
Boiler
Clearances
Boiler Assembly - Concord CXA/H, CXS/H
7
Note: CXA/H shown (CXS/H differs with gas valve model only)
general data
Model
40/H
50/H 60/H 70/H
80/H
90/H 100/H
110/H
120/H
40P/H
50P/H 60P/H 70P/H
80P/H
90P/H
100P/H
mb
15
19
26
32
40
52
62
73
83
in. w.g.
6
7.6
10.4
12.8
16
20.8
24.8
29.2
33.2
l/s
0.91
1.08
1.30
1.53
1.75
1.97
2.16
2.38
2.62
gal/m
12.03
14.25
17.16
20.19
23.10
26.00
28.50
31.50
34.58
l/s
0.28
0.34
0.41
0.48
0.55
0.62
0.68
0.75
0.82
gal/m
3.7
4.5
5.4
6.3
7.3
8.2
9.0
9.9
10.9
Hydraulic resistance
at 11°K (20°F)
Minimum water flow rate
temperature difference
35°K (63°F)
Normal water flow rate
temperature difference
11°K (20°F)
General Data CXA/H, CXS/H, CXAP/H
1. Cleanout cover
2. Collector hood
3. Middle section
4. Section alignment rings and 'O' rings
5. End section
6. Gas cock
7. Drain cock
8. NOx assembly
9. Front plate
10. Gas control
11. Base tray (heat shield)
12. Combustion chamber
13. Section bolt
14. Distributor tube
(shown on the left hand side for clarity)
15. Tie rod
16. Thermostat pocket
17. Spillage skirt
18. Gas inlet pipe
8
Concord CXSi/H 110 -180kW
The Concord CXSi/H Control panel
The Concord CXSi/H
·
High / Low operations on all models
·
Robust cast iron heat exchanger
·
Easy to install and service
·
Remote indication kit options
9
technical data
No.of sections
7
7
8
9
10
Flow tappings
Rc
2x2 at sides
in. BSP
2x2 at sides
Return tappings
Rc
2x2 at sides
in. BSP
2x2 at sides
Maximum static water head
m
61
ft
200
Maximum pressure
bar
6
psi
87
Gas inlet connection
Rc
1
1
/
2
1
1
/
2
1
1
/
2
1
1
/
2
1
1
/
2
in. BSP
1
1
/
2
1
1
/
2
1
1
/
2
1
1
/
2
1
1
/
2
Min. dynamic gas pressure required
mbar (gauge)
17.5
17.5
17.5
17.5
17.5
at the boiler inlet for the rated input
in.w.g.
7
7
7
7
7
Electricity supply
230 Volts - single phase 50Hz fuse 5A
Nominal flue size
mm
250
250
250
250
300
(to BS 835)
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
Approximate dry weight
kg
520
520
587
654
721
lb
1146
1146
1294
1442
1590
Water content
l
53
53
60
68
76
gal
11.7
11.7
13.0
15.0
17.0
General Data CXSi/H
Model
110
120
140
160
180
Model
110
120
140
160
180
No.of sections
7
7
8
9
10
Boiler output, high rate
kW
110
120
140
160
180
Btu/h x 1000
375.3
409.4
477.7
545.9
614.2
Gross
kW
93.9
102.5
119.5
136.6
153.7
Boiler input, 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
Gross
kW
134.2
146.4
170.8
195.2
219.6
Boiler input, 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
*Gas rate, high rate
m
3
/h
12.78
13.95
16.27
18.59
20.92
ft
3
/h
451.5
492.5
574.6
656.7
738.8
Burner setting pressure
mbar
10.4
10.1
9.7
9.6
9.7
in.w.g.
4.2
4.0
3.9
3.8
3.9
4.5% CO
2
m
3
/s
0.112
0.122
0.142
0.163
0.183
Approx flue gas
& 100°C
volume
4.5% CO
2
ft
3
/m
237
259
301
345
388
& 212°F
Seasonal efficiency
%
83.2
81.9
82.7
83.0
83.0
Performance Data CXSi/H
*Note: To obtain gas consumption in m
3
/h divide gross heat input (kW) by a calorific value of 37.8 (MJ/m
3
).
10
`A' Dimension
mm
1036
1036
1036
1086
1140
`B' Dimension
mm
175
175
175
197
250
`C' Dimension
mm
1107
1107
1230
1353
1476
`D' Dimension
mm
816
816
939
1062
1185
`E' Dimension
mm
553
553
615
676
738
`F' Dimension
mm
220
220
220
220
320
Front
mm
700
`B' Dimension
mm
200
`C' Dimension
mm
100 (not including clearance for side fitted flow header)
Model
110/H
120/H
140/H
160/H
180/H
Boiler Dimensions CXSi/H
Boiler Dimensions CXSi/H
All measurements in mm
Boiler
Clearances
dimensional data
11
general data
General Data CXSi/H
Model
110/H
120/H
140/H
160/H
180/H
mb
53
64
88
115
150
in. w.g.
21.2
25.6
35.2
46
60
l/s
2.38
2.6
3.04
3.5
3.9
gal/m
31.3
34.2
40.0
46.1
51.4
l/s
0.75
0.82
0.96
1.11
1.24
gal/m
9.9
10.8
12.7
14.6
16.4
Hydraulic resistance
at 11°K (20°F)
Minimum water flow rate
temperature difference
35°K (63°F)
Normal water flow rate
temperature difference
11°K (20°F)
1. Cleanout cover
2. Collector hood
3. Middle section
4. Baffle
5. Section alignment rings
and `O' rings
6. Thermostat pocket
7. End section
8. Distributor tube
(shown on the left hand
side for clarity)
9. Spillage skirt
10. Section bolt
11. Drain cock
12. Base tray (heat shield)
13. Combustion chamber
14. Tie rod
15. Front plate
16. Gas control
17. NOx assembly
18. Flow header
(shown on left hand side
for clarity)
Boiler Assembly - Concord CXSi/H
12
The Concord ES/H
·
High / Low adjustable operation on all models
·
Assembled or unassembled heat exchanger availability
·
Robust cast iron heat exchanger
·
Easy to install and service
·
Low return temperature capability
·
High full and part load efficiencies
Meets Building Regulations 2006 (Part L2)
Concord ES/H 140 - 380kW
13
Main burner injector
mm
3,9
Ignition burner injector
mm
0,8
Maximum flow temperature
°C
90
Maximum operating pressure
bar
6
Electrical connection
V/Hz
230/50
Maximum electrical power
W
450
Gas connection
(inch BSP)
1"
1"
1"
1"
1"
1"
1
/
4
1"
1
/
4
1"
1
/
4
1"
1
/
2
Flow & return connections
(inch BSP)
2"
Flue outlet diameter
mm
250
250
300
300
300
350
350
350
400
Water content
litre
61
68
76
84
91
106
122
137
154
Water circuit resistance
at T= 11 k mbar
66
87
110
136
164
229
305
392
489
at T= 20 k mbar
20
26
33
41
50
69
92
118
148
Dry weight
kg
677
741
806
875
943
1111
1245
1380
1500
General Data ES/H
Model
ES 140/H ES 160/H ES 180/H ES 200/H ES 220/H ES 260/H ES 300/H ES 340/H
ES 380/H
*Note: Minimum and maximum outputs/inputs are adjustable to 85% of full rates stated.
Model
ES 140/H ES 160/H ES 180/H ES 200/H ES 220/H ES 260/H ES 300/H ES 340/H
ES 380/H
No.of sections
8
9
10
11
12
14
16
18
20
*Boiler output
2nd stage kW
140
160
180
200
220
260
300
340
380
1st stage kW
98
112
126
140
154
182
210
238
266
*Boiler input (Nett CV)
2nd stage kW
153.0
174.7
196.3
217.9
239.4
282.6
325.4
368.4
411.3
1st stage kW
108.9
124.3
139.7
155.0
170.4
201.1
231.5
262.1
295.6
*Gas flow rate
2nd stage m
3
/h
16.19
18.48
20.77
23.05
25.33
29.91
34.43
38.98
43.52
1st stage m
3
/h
9.8-11.5
13.0-15.0
12.6-14.8 14.0-16.4
15.4-18.0
18.2-21.3
21.0-24.5
23.7-27.7
26.5-31.0
Burner pressure
2nd stage mbar
8.8-11.8
1st stage mbar
1st stage pressure = 0,5 x adjusted 2nd stage pressure
Approx flue gas volume
m
3
/sec
0.115
0.123
0.148
0.163
0.171
0.209
0.228
0.247
0.304
Flue gas temperature
°C
125
133
123
125
130
126
133
140
126
CO
2
%
6.4
7
6.3
6.4
6.8
6.5
7
7.5
6.5
Seasonal efficiency
%
81.7
82.0
82.3
82.6
82.9
83.2
83.4
83.7
83.9
Performance Data ES/H
technical data
General Data ES/H
Model
ES140/H
ES 160/H
ES 180/H ES 200/H
ES 220/H ES 260/H
ES 300/H
ES340/H
ES 380/H
mb
66
87
110
136
164
229
305
392
489
in. w.g.
26.4
34.8
44
54.4
65.6
91.6
122
156.8
195.6
l/s
3.04
3.5
3.9
4.35
4.79
5.66
6.53
7.4
8.25
gal/m
40.0
46.1
51.4
57.4
63.2
74.7
86.2
97.7
109.1
l/s
0.96
1.1
1.2
1.4
1.5
1.77
2.05
2.32
2.59
gal/m
12.7
14.5
16.2
18
19.8
23.4
27
30.6
34.3
Hydraulic resistance
at 11°K (20°F)
Minimum water flow rate
temperature difference
35°K (63°F)
Normal water flow rate
temperature difference
11°K (20°F)
14
dimensional data
No. of sections
8
9
10
11
12
14
16
18
20
`A' Dimension
1362
1362
1362
1362
1362
1412
1412
1412
1462
`B' Dimension
970
1058
1146
1234
1322
1498
1674
1850
2026
`øC' Dimension
250
250
300
300
300
350
350
350
400
`D' Dimension
632
720
808
896
984
1160
1336
1512
1688
`E' Dimension
165
165
165
165
165
190
190
190
220
`øF' Dimension
Rp 1
Rp 1
Rp 1
Rp 1
Rp 1
Rp 1
1
/
4
Rp 1
1
/
4
Rp 1
1
/
4
Rp 1
1
/
2
`G' Dimension
447
491
535
579
623
704
792
880
963
`H' Dimension
445
445
445
445
445
454
454
454
507
`J' Dimension
1094
1094
1094
1094
1094
1194
1194
1194
1194
`K' Dimension
1406
1406
1406
1406
1406
1406
1406
1406
1406
Front
1000
Back
(measured from rear edge of jacket)
500
Sides
Water connection side (RH or LH)
400
Sides
Non connection side (RH or LH)
200
E
1406
B
H
=
=
ø C
D
64
G
J
410
375
130
A
1006
130
60
ø
F
Heating
flow
R 2
Heating
return
R 2
Drain
Rp 3/4
Model
ES 140/H
ES 160/H
ES 180/H
ES 200/H
ES 220/H
ES 260/H
ES 300/H
ES 340/H
ES 380/H
Boiler Dimensions ES/H
Boiler Dimensions ES/H
Boiler
Clearances
1. Draught diverter
2. Heating water flow
3. Heating water return
4. Drain
5. Boiler body insulation
6. Burner drawer guide system
7. Ignition transformer
8. Pilot gas valve
9. Multiblock gas valve
10. Minimum gas press switch
11. Ignition burner sight hole
12. Atmospheric gas burners
13. Safety control box
14. Pre wired control panel
15. Flue socket
Note: Control Panel supplied varies
slightly from illustration.
Boiler Assembly - Concord ES/H
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
15
concord modular 40 - 720kW
Introduction
Ideal Concord boilers can be installed in modular configuration with the `Modular Pipework Kit'. Modular installation of 2 or more Ideal
Concord boilers for medium scale commercial systems offers an attractive alternative to the use of one larger unit. Operating efficiency is
maximised by firing the minimum number of boilers to match the system load.
Advantages to the user
Multiple boiler installations are much more flexible in supplying
variable requirements for heating and domestic hot water. The
failure of one unit does NOT mean a total shutdown of the heating
facility. The offending boiler is simply isolated whilst maintenance
work is carried out. Similarly for cleaning and servicing each unit
can be isolated in turn. Ease of control is provided with a straight-
forward Sequencer Kit. Remote monitoring for BMS systems is
easily accomplished using Remote Indication Kits available with volt
free contacts.
The Ideal Concord 40-120/H range of boilers is especially
suitable for use in multiple arrangements. The boilers are compact,
easy to install, and designed for reliability. They also have a notable
advantage in that all servicing is carried out from the front of the
boiler without disturbing the flue system. The Ideal Concord
Modular Pipework Kit ensures full isolation of water flow through
non-fired boilers, ensuring fuel savings are maximised.
Advantages to the heating engineer
Multiple boiler installations can be installed in a variety of
locations. These systems are particularly suitable for roof-top instal-
lations as the load is well distributed. The small size of the units
makes transportation easy, normal doorways and stairways are
adequate for manoeuvring units. The flexibility in arrangements and
wide range of output options enable the boiler installation to be
tailored to the needs of the system. Additional features enhance the
Concord range: CXA/H models feature automatic ignition and on/off
operation; CXS/H models have high/low and simple analogue
controls.
"a standard pipework kit to make multiple installation simple"
·
Suitable for all Concord CXA/H and CXS/H models
·
A range of compact units ideally suited to modular
installations
·
Wide choice of unit options... from 40kW to 120kW
(136,500 Btu/h to 409,000 Btu/h)
·
All servicing and maintenance from the front of boilers
·
Simple and quick to install
·
Boilers for site assembly available to special order
·
Sequencer Kit available
·
Remote Indication Kits available
·
Installation concept designed for use with equipment
available from leading control and flue manufacturers.
·
Multiple installations. Outputs from 80kW
to 720kW (273,000 Btu/h to 2,456,400 Btu/h)
·
Maximum fuel savings - non firing boilers isolated
16
system requirement
The use of modular boilers in commercial and industrial
installations covers a whole range of system designs. It is not
possible to cover all variations here and general guidance only
is provided.
A typical combined heating and domestic hot water system
including mixing and diverter valves is shown. Two versions
covering the use of the single pipe header system (A) or a
reverse return system (B) are shown. System B is providing no
flow through non-firing boilers and therefore achieving similar
operating efficiencies as System A.
System A - Single pipe low loss modular
pipework kit (as available for the
Concord CXA, CXS)
System B - Reverse return pipework layout
Boilers must be installed so water flow is evenly balanced
across all boilers. The reverse return, or flow principle must be
used unless balanced flow is achieved with an alternative
design such as System A.
Boiler flow/return pipework connections are normally made
to opposite ends of the boiler. Connections may be made to
same or opposite sides.
Systems
17
The individual boilers can be controlled by each accurate
electronic thermostat or by a sequence controller (SC) when the
load changes. Individual boiler pumps P1, P2, and P3, are switched
by the timer built into each Ideal Concord CXA/H or CXS/H boiler
control panel (see System A, page 4).
The supply to each pump is interrupted approximately 6 minutes
after the appropriate boiler has switched off in order to dissipate
residual heat in the system and reduce standing losses.
When the plant shuts down on clock control the boiler primary
pump (BPP) and a system zone pump capable of dissipating, sufficient
residual heat MUST overrun for a period of 5 minutes through an
independent timing device (not supplied).
The sequencer is shown fitted to the flow, however return sensing
is also possible with the Ideal Sequencer Kit if preferred.
Two-zone operating for domestic hot water and central heating
featuring Diverter Valve, Mixing Valve, and Compensator Control (see
System B, page 4).
Note: Alternatively butterfly valves may be used, but ONLY in
conjunction with automatic by-passes to simulate the operation of a
diverter valve, if maximum cost saving is to be achieved.
The pump BPP MUST provide a volume flow rate based on full
boiler output at design temperature difference.
The boiler primary pump (BPP) maintains a constant volume
flow of water through each firing boiler, whilst the diverter
valves (DV) ensure water is diverted away from off load boilers
directly into the flow manifold. Water flow through the mixing
header (MH) is also constant.
The balancing valve (BV) is used to ensure the by-pass has the
same resistance as the boiler.
Boiler mixed water flow temperature entering the system from
the mixing header (MH) is maintained within close tolerances
about the design flow temperature by means of the sequence
controller (SC) which, through its sensor (SCS) mounted in the
flow manifold, is able to sequence boilers to match load
variations. When the flow temperatures reaches a pre-
determined level, the sequence controller will interrupt the
supply to the boiler no longer required to maintain load and
then commence to drive the diverter valve (DV) to by-pass, after
the dissipation of any residual heat into the system, see below.
Individual system zones may be operated together, or independently,
and may be designed to operate a greater temperature difference
than the boiler primary circuit.
1)
2)
3)
4)
5)
Independent zones may operate at different design temperature
differences. In the example shown, domestic hot water temperature
is controlled by means of a cylinder thermostat (CT), operating a
diverter valve (V1). Heating control is by way of a compensator (C)
controlling a mixing valve (V2).
The compensator senses mixed water temperature (WTS), also
inside (ITS) and outside (ETS) air temperature.
THE SYSTEM DESIGN MUST PROVIDE FOR ADEQUATE
DISSIPATION OF RESIDUAL HEAT WHEN INDIVIDUAL BOILERS
SHUT DOWN.
Each boiler control panel features a built-in relay and timer
operating from a permanent live supply. This is in conjunction with
additional relays and auxiliary switch contacts available on the
diverter valve which will ensure the diverter valves remain open for a
sufficiently long period to dissipate heat after the boiler has shut
down. Alternatively, independent timers and any other equipment
may be incorporated in the boilerhouse main control panel. When
the plant shuts down on clock control, the boiler primary pump
(BPP) and a system zone pump capable of dissipating sufficient
residual heat MUST overrun for a period of FIVE MINUTES MINIMUM.
Note: For multiple boiler installations not featuring a sequencer,
to achieve effective control, the operating range of the boiler
electronic thermostats must be adjusted on site. For further
information contact Ideal Boilers.
Single pipe low loss modular pipework kit - System A
Reverse return pipework - System B
Reverse return pipework - System B
Independent zones
Cold feed and expansion cistern height requirements for open
vented systems.
In order to comply with Guidance Note PM5 from the Health
and Safety Executive, a MINIMUM feed and expansion cistern
height must be provided.
For example: For a modular arrangement with water flow giving
a temperature difference across the boiler of 11°C (20°F) designed
to function at a mixed water flow temperature of 82°C (180°F).
No individual boiler need be operated at a flow temperature
exceeding 93°C (200°F), or at a limit thermostat set point exceeding
105°C 3°C. A height of 4.6m (15ft) measured from the boiler(s)
flow outlet to the cistern water level MUST be provided.
Open vent and cold feed connections to the system shall be
made to the common flow and common return manifolds serving the
boilers - respectively, or to the individual boiler flow and return stub
pipe connections to the manifolds, or to the redundant flow/return
to pipes which may be available for use on individual boilers.
Output
Open vent size
Cold feed size
< 60 kW
25mm (1")
19mm (
3
/
4
")
61 - 150 kW
32mm ( 1
1
/
4
")
25mm (1")
151 - 300 kW
38mm ( 1
1
/
2
")
32mm ( 1
1
/
4
")
301 - 600 kW
50mm (2")
38mm ( 1
1
/
2
")
For outputs > 601 kW, reference should be made to appropriate standards.
Open Vented System
+
_
18
general & dimensional data
Width
No. of
CX 40 - 80
CX 90 - 120
boilers
A
B
A
B
2
650
1300
700
1400
3
1300
1950
1400
2100
4
1950
2600
2100
2800
5
2600
3250
2800
3500
6
3250
3900
3500
4200
Water Header
F
80mm
3"
200
100mm
4"
220
125mm
5"
250
Gas Header
G
40 - 60
932
70 - 80
911
90 - 120
873
Dimensions in mm (inches) are approximate due to build up of
tolerance
*Complete flow header and manifolds may be reversed if
required. Ensure all connections are correct.
For appropriate header flange diameter for multiple system selected
see `General Data' page 19.
Note: All dimensions are expressed in mm
Boiler Dimensions
Depth
Boiler size
C
D
E
40
750
222
150
50/60
882
212
140
70/80
1042
175
103
90/100
1212
128
56
110/120
1390
112
41
Headers
19
General Data: Single pipe low loss modular pipework kit
2x 40
80
273
80
3"
1250
750
50
2"
28mm
1"
35mm
1
1
/
4
"
3x 40
120
410
80
3"
1900
750
50
2"
35mm
1
1
/
4
"
40mm
1
1
/
2
"
4x 40
160
546
80
3"
2550
750
50
2"
40mm
1
1
/
2
"
40mm
1
1
/
2
"
5x 40
200
683
80
3"
3200
750
50
2"
40mm
1
1
/
2
"
50mm
2"
6x 40
240
819
80
3"
3850
750
50
2"
50mm
2"
50mm
2"
2x 50
100
341
80
3"
1250
882
50
2"
35mm
1
1
/
4
"
35mm
1
1
/
4
"
3x 50
150
511
80
3"
1900
882
50
2"
40mm
1
1
/
2
"
40mm
1
1
/
2
"
4x 50
200
682
80
3"
2550
882
50
2"
40mm
1
1
/
2
"
50mm
2"
5x 50
250
853
80
3"
3200
882
50
2"
50mm
2"
50mm
2"
6x 50
300
1023
80
3"
3850
882
50
2"
50mm
2"
50mm
2"
2x 60
120
410
80
3"
1250
882
50
2"
35mm
1
1
/
4
"
40mm
1
1
/
2
"
3x 60
180
615
80
3"
1900
882
50
2"
40mm
1
1
/
2
"
40mm
1
1
/
2
"
4x 60
240
820
80
3"
2550
882
50
2"
50mm
2"
50mm
2"
5x 60
300
1025
80
3"
3200
882
50
2"
50mm
2"
50mm
2"
6x 60
360
1230
100
4"
3850
882
50
2"
50mm
2"
50mm
2"
2x 70
140
480
80
3"
1250
1042
50
2"
40mm
1
1
/
2
"
40mm
1
1
/
2
"
3x 70
211
720
80
3"
1900
1042
50
2"
40mm
1
1
/
2
"
50mm
2"
4x 70
281
960
80
3"
2550
1042
50
2"
50mm
2"
50mm
2"
5x 70
351
1200
100
4"
3200
1042
50
2"
50mm
2"
50mm
2"
6x 70
422
1440
100
4"
3850
1042
50
2"
50mm
2"
65mm
2
1
/
2
"
2x 80
160
546
80
3"
1250
1042
50
2"
40mm
1
1
/
2
"
40mm
1
1
/
2
"
3x 80
240
819
80
3"
1900
1042
50
2"
50mm
2"
50mm
2"
4x 80
320
1092
80
3"
2550
1042
50
2"
50mm
2"
50mm
2"
5x 80
400
1365
100
4"
3200
1042
50
2"
50mm
2"
65mm
2
1
/
2
"
6x 80
480
1638
100
4"
3850
1042
50
2"
65mm
2
1
/
2
"
65mm
2
1
/
2
"
2x 90
180
614
80
3"
1300
1212
50
2"
40mm
1
1
/
2
"
40mm
1
1
/
2
"
3x 90
270
921
80
3"
2000
1212
50
2"
50mm
2"
50mm
2"
4x 90
360
1228
100
4"
2700
1212
50
2"
50mm
2"
50mm
2"
5x 90
450
1536
100
4"
3400
1212
50
2"
50mm
2"
65mm
2
1
/
2
"
6x 90
540
1843
125
5"
4100
1212
50
2"
65mm
2
1
/
2
"
65mm
2
1
/
2
"
2x 100
200
682
80
3"
1300
1212
50
2"
40mm
1
1
/
2
"
50mm
2"
3x 100
300
1023
80
3"
2000
1212
50
2"
50mm
2"
50mm
2"
4x 100
400
1364
100
4"
2700
1212
50
2"
50mm
2"
65mm
2
1
/
2
"
5x 100
500
1706
100
4"
3400
1212
50
2"
65mm
2
1
/
2
"
65mm
2
1
/
2
"
6x 100
600
2047
125
5"
4100
1212
50
2"
65mm
2
1
/
2
"
65mm
2
1
/
2
"
2x 110
220
751
80
3"
1300
1390
50
2"
40mm
1
1
/
2
"
50mm
2"
3x 110
330
1126
100
4"
2000
1390
50
2"
50mm
2"
50mm
2"
4x 110
440
1501
100
4"
2700
1390
50
2"
50mm
2"
65mm
2
1
/
2
"
5x 110
550
1877
125
5"
3400
1390
50
2"
65mm
2
1
/
2
"
65mm
2
1
/
2
"
6x 110
660
2252
125
5"
4100
1390
50
2"
65mm
2
1
/
2
"
65mm
2
1
/
2
"
2x 120
240
819
80
3"
1300
1390
50
2"
40mm
1
1
/
2
"
50mm
2"
3x 120
360
1228
100
4"
2000
1390
50
2"
50mm
2"
50mm
2"
4x 120
480
1638
100
4"
2700
1390
50
2"
50mm
2"
65mm
2
1
/
2
"
5x 120
600
2047
125
5"
3400
1390
50
2"
65mm
2
1
/
2
"
65mm
2
1
/
2
"
6x 120
720
2456
125
5"
4100
1390
50
2"
65mm
2
1
/
2
"
65mm
2
1
/
2
"
* For Natural Gas only
Total output
Water manifold
Floor area
Guide to gas pipework sizing
Boiler module size
11°C (20°F)
(Boiler only)
Gas manifold
across boilers
width
depth
Length of main including bends*
1000
kW
Btu/h
mm
BSP
mm
mm
mm
BSP
10m
33ft
15m
49ft
20
flue design
The diverter provided with each boiler forms an integral part of
the appliance. No additional diverter, stabiliser or draught break
should be fitted without reference to Caradon Ideal Limited, who
will give advice on the application.
Although 500mm (19") minimum length of vertical flue pipe
between the boiler flue outlet and the common header will in nearly
all instances be satisfactory, in practice any additional headroom
should be taken advantage of, as an increase in vertical height will
always be beneficial to the overall efficiencies of the flue system.
Ideal Concord CXA or CXS boilers, whether or not installed in
multiple installations, are entirely suitable for installation with
mechanically induced flue systems. Design requirements and full
information on fan sizing are contained in IGE UP/10
`Installation of Gas Appliances in Industrial and Commercial
Premises'.
These requirements and recommendations must be adhered to
if safe and efficient operation is to be assured.
Ideal Boilers will be pleased to offer general advice on design.
Flue design for natural draught systems
1) The guide to chimney height requirements above is based on
the use of prefabricated chimney systems or lined and insulated
existing chimneys having a "U" value of no more than 1.4W/m
2
at
540°C (0.25 Btu/h ft
2
°F at 1000°F). Chimney systems having a
higher "U" value may be used. Caradon Ideal Ltd will be pleased to
advise on dimensional requirements.
2) In order to reduce chimney height requirements and the risk
of condensate damage, prefabricated chimney systems and lined or
existing chimneys should be insulated. However, the use of Class II
chimney systems and lined, uninsulated, or unlined chimneys is
permissible provided account is taken of any deterioration in chimney
performance or damage to the structure likely to occur as a result of
condensate formation.
3) Notwithstanding recommended heights or header diameters
associated with them, conventional chimneys MUST terminate in a
downdraught-free zone.
4) Boilers must light up in sequence on cold start, commencing
with the boiler nearest the chimney. A MINIMUM time delay of two
minutes is recommended for up to three boilers and three minutes
from three to six boilers in line - THE MAXIMUM NUMBER.
5) The effective chimney height should be a minimum of 1.5
times greater than the horizontal header length.
6) Local site conditions can effect chimney performance. On
any site known to have history of downdraught, a chimney system
designed to operate using a principle similar to a balanced flue
such as that manufactured by Monodraught Flues Limited may be
considered.
7) The general layouts shown in this book MUST be used in
conjunction with this table. Other configurations are possible and
Ideal Boilers will advise on flue system design if consulted.
8) The guidance given is not intended to supersede the information
contained in the IGE UP/10 `Installation of Gas Appliances in
Industrial & Commercial Premises'. It may be necessary to use
UP/10 when designing the flue system for Ideal Concord boilers,
depending on the requirements of the Local Area Gas Division.
Local Authority requirements must also be taken into consideration.
Notes
21
2x 40
254
10"
254
10"
254
10"
254
10"
203
8"
203
8"
203
8"
203
8"
203
8"
203
8"
3x 40
305
12"
305
12"
305
12"
305
12"
254
10"
254
10"
254
10"
254
10"
254
10"
254
10"
4x 40
305
12"
305
12"
305
12"
305
12"
254
10"
305
12"
5x 40
Not recommended
Not recommended
356
14"
356
14"
305
12"
356
14"
305
12"
305
12"
6x 40
356
14"
356
14"
356
14"
356
14"
305
12"
356
14"
2x 50
305
12"
305
12"
254
10"
254
10"
254
10"
254
10"
254
10"
254
10"
203
8"
203
8"
3x 50
356
14"
356
14"
305
12"
356
14"
305
12"
305
12"
254
10"
305
12"
254
10"
254
10"
4x 50
356
14"
356
14"
305
12"
305
12"
305
12"
305
12"
5x 50
Not recommended
Not recommended
356
14"
356
14"
356
14"
356
14"
356
14"
356
14"
6x 50
406
16"
406
16"
356
14"
356
14"
356
14"
356
14"
2x 60
356
14"
356
14"
305
12"
305
12"
254
10"
254
10"
254
10"
254
10"
254
10"
254
10"
3x 60
406
16"
406
16"
406
16"
406
16"
356
14"
356
14"
305
12"
305
12"
305
12"
305
12"
4x 60
356
14"
356
14"
356
14"
356
14"
356
14"
356
14"
5x 60
Not recommended
Not recommended
406
16"
406
16"
356
14"
356
14"
356
14"
356
14"
6x 60
457
18"
457
18"
406
16"
406
16"
406
16"
406
16"
2x 70
356
14"
356
14"
305
12"
305
12"
305
12"
305
12"
254
10"
305
12"
254
10"
254
10"
3x 70
457
18"
457
18"
406
16"
406
16"
356
14"
356
14"
305
12"
305
12"
305
12"
356
14"
4x 70
406
16"
406
16"
356
14"
356
14"
356
14"
356
14"
5x 70
Not recommended
Not recommended
457
18"
457
18"
406
16"
406
16"
406
16"
406
16"
6x 70
508
20"
508
20"
457
18"
457
18"
406
16"
406
16"
2x 80
406
16"
406
16"
356
14"
356
14"
305
12"
305
12"
305
12"
305
12"
305
12"
305
12"
3x 80
457
18"
457
18"
406
16"
406
16"
356
14"
356
14"
356
14"
356
14"
356
14"
356
14"
4x 80
406
16"
406
16"
406
16"
406
16"
406
16"
406
16"
5x 80
Not recommended
Not recommended
457
18"
457
18"
406
16"
406
16"
406
16"
406
16"
6x 80
508
20"
508
20"
457
18"
457
18"
457
18"
457
18"
2x 90
406
16"
406
16"
406
16"
406
16"
356
14"
356
14"
305
12"
305
12"
305
12"
305
12"
3x 90
508
20"
508
20"
457
18"
457
18"
406
16"
406
16"
356
14"
356
14"
356
14"
356
14"
4x 90
457
18"
457
18"
406
16"
406
16"
406
16"
406
16"
5x 90
Not recommended
Not recommended
508
20"
508
20"
457
18"
457
18"
457
18"
457
18"
6x 90
559
22"
559
22"
508
20"
508
20"
508
20"
508
20"
2x 100 457
18"
457
18"
406
16"
406
16"
356
14"
356
14"
305
12"
305
12"
305
12"
305
12"
3x 100 508
20"
508
20"
457
18"
457
18"
406
16"
406
16"
356
14"
356
14"
356
14"
356
14"
4x 100
457
18"
457
18"
457
18"
457
18"
406
16"
406
16"
5x 100
Not recommended
Not recommended
559
22"
559
22"
508
20"
508
20"
457
18"
457
18"
6x 100
610
24"
610
24"
559
22"
559
22"
508
20"
508
20"
2x 110 457
18"
457
18"
406
16"
406
16"
356
14"
356
14"
305
12"
305
12"
305
12"
305
12"
3x 110 508
20"
508
20"
457
18"
457
18"
406
16"
406
16"
356
14"
356
14"
356
14"
356
14"
4x 110
457
18"
457
18"
457
18"
457
18"
406
16"
406
16"
5x 110
Not recommended
Not recommended
559
22"
559
22"
508
20"
508
20"
457
18"
457
18"
6x 110
610
24"
610
24"
559
22"
559
22"
508
20"
508
20"
2x 120 457
18"
457
18"
406
16"
406
16"
356
14"
356
14"
305
12"
305
12"
305
12"
305
12"
3x 120 508
20"
508
20"
457
18"
457
18"
457
18"
457
18"
406
16"
406
16"
406
16"
406
16"
4x 120
508
20"
508
20"
457
18"
457
18"
457
18"
457
18"
5x 120
Not recommended
Not recommended
610
24"
610
24"
559
22"
559
22"
508
20"
508
20"
6x 120
661
26"
661
26"
610
24"
610
24"
559
22"
559
22"
Height of chimney above draught diverter (H m(ft)) Refer to diagram on page 9
No. /
2m (6.5ft)
3m (10ft)
6m (20ft)
10m (33ft)
20m (66ft)
Boiler
Smooth bore
Flex liner
Smooth bore
Flex liner
Smooth bore
Flex liner
Smooth bore
Flex liner
Smooth bore
Flex liner
Flue Dimensions
22
Ideal Concord boilers may be installed with flue centres down to
a MINIMUM of 650mm (25
1
/
2
") leaving approximately 50mm (2")
between boiler casings for 40-80 models, and 100mm (4") between
boiler casings for 90-120 models. If an induced draught or fan
diluted flue system is used, minimum flue centres can be reduced
to 610mm (24") leaving approximately 10mm between boiler
casings.
For water manifold and boiler stub connection sizes refer to the
Concord CXA/H or CXS/H technical data brochure. If external control
of water temperature is envisaged, the boiler control thermostat
should be set above the requirements of the sequence controller.
Under NO circumstances should these thermostats be by-passed.
Alternatively, adequate air for dilution, combustion and
ventilation may be introduced into a sealed boilerhouse and the
combustion products discharged through a chimney system capable
of efficient operation using a principle similar to a balanced flue
such as the Monodraught System.
Detailed recommendations for air supply are quoted in
BS 6644:2005.
Ideal Concord CXA/H and CXS/H boilers are suitable for modular
configurations with kits available to provide simple installation. The
Modular Pipework Kit is specially designed for these ranges giving a
single pipe, low loss header with tappings for all relevant system
connections. The Modular Pipework Kit incorporates as standard:
·
Single pipe low loss header
·
Individual boiler pumps
·
Isolating valves
·
Non-return valve
·
3 way vent cock
·
Flexible connector
·
Gas header
·
Flow and return sensing manifold for connection of safety valve,
flow switch, open vent and temperature gauge
Boiler control is available with the Ideal Sequencer Kit, which
can control from 2 to 8 CXA/H or CXS/H boilers. (maximum of 6
boilers to one Reader Kit & flue system) This permits the minimum
number of boilers to be operated to match load requirements. Volt
free contacts for all boilers, ie B.M.S., are available with Remote
Indication Kits.
In all multiple boiler arrangements, the Flue Gas Thermostat Kit
option must be fitted to all boilers. Sited on the boiler diverter rear, the
thermostat switches the boiler off in the event of downdraught
conditions.
Product Specification
General Recommendations
The Ideal Sequencer Kit provides the capability to control the
firing of up to 8 CXA/H boilers, CXS/H high/low boilers. (maximum
of 6 boilers to one Header Kit & flue system) It is independently
mounted in a high impact fully enclosed case with easy to read LED
display. The sequencer will detect variations of heating demand to
start and stop boilers to minimise fuel consumption. Close control
over the mixed flow temperature is maintained through flow or
return sensing.
Control is via two push buttons to access:
·
Change of system temperatures
·
Shut down temperature
·
Boiler switching time delay
·
Night set back temperature
·
Sequence direction
·
Compensation
The unit is capable of weather compensation with the air and
water sensors supplied as standard. Boiler sequencing may be
adjusted to even boiler operating times. Night set back is built in as
standard.
Sequencer Kit
general data
23
Concord range
All boilers are manufactured to the highest standards of quality.
World Class manufacture is carried out to meet all relevant standards.
BS EN ISO9001: 1994
CXA/H, CXAP/H: Control is by automatic ignition of an intermit-
tent pilot with flame rectification proving. The single or double gas
valves (according to model) open to give full heat output. Mains
input is via a terminal plug allowing easy isolation for servicing.
CXS/H, CXSi/H: Control is by direct automatic ignition at low
firing rate (approximately 70% full rate) with flame rectification
proving. After approximately 1 minute the boiler fires at high rate
until the boiler reaches the thermostat set point. The boiler then
drops to low rate: If the temperature continues to rise the boiler
shuts down; if the temperature falls the boiler reverts to high rate.
ES/H: Control is by automatic ignition of an intermittent pilot
with flame rectification proving. Main burners operate at low rate
(70%) or high rate. These are adjustable (85% of maximum).
The complete Concord range has been tested and certified to
EN656, the European Standard governing safety and performance of
Commercial / Industrial gas boilers ensuring high quality performance.
With compact insulated high efficiency heat exchangers, they also
meet the requirements of the European Boiler Efficiency Directive.
The latest refinements ensure even higher efficiencies at both full and
part loads to meet the new `Building Regulations 2006' conservation
of fuel and power (Part L2). Approved efficiency is approximately
92% based on net calorific value of fuel (83% gross) at full load
dependent on range. At 30% part load, the efficiencies exceed
90.6% net (81.6% gross)
All models feature energy efficient automatic ignition and the
different ranges provide a choice of single stage or two stage operation
to maximise further energy savings.
CXA/H, CXAP/H: Auto ignition via intermittent pilot and on/off
single stage operation
CXS/H, CXSi/H: Direct automatic ignition and high/low two stage
operation. Low fire is approximately 70% of full rate
ES/H: Auto ignition via intermittent pilot and 2 stage operation
The Concord family is good for the environment. It features a
unique integral re-circulation assembly design to reduce boiler Nox
emissions to Class 3 rating. ES/H models are Class 2.
Performance
Quality
Boiler Operation
Boiler
Range
Certificate No.
Notified Body
Reference
Concord CXA/H
40/H - 120/H
BE-87/97/08/M2
Advantica
0087
Concord CXS/H
40/H - 120/H
BE-87/97/09/M2
Technologies Ltd
0087
Concord CXAP/H
40/H - 100/H
BE-87/97/08/M2
0087
Concord CXSi/H
110/H - 180/H
BE-87/97/12/M2
0087
Concord ES/H
140/H - 380/H
00-0154-CWE
DVGW - Bonn
0085
24
Concord range
The Concord range has a low minimum
static head requirement, depending on the
particular characteristics of the system design
and boiler model. (see diagram).
The information provided is based on the
following assumptions:
An independent open vent/safety pipe
connection is made to the redundant boiler flow
tapping or is positioned immediately after the
system flow-pipe connection to the header, as
shown.
An independent cold feed/expansion pipe
connection is made to the redundant boiler
return tapping. Cold feed/expansion pipe
connections made to the system return will
create an increase in static head requirements,
brought about by the additional resistance of
the distributor tube. Surging may also increase.
The maximum flow rate through the boiler is based on a
temperature difference of 11°C (20°F) at full boiler output with the
circulating pump positioned in the flow of the system.
The boiler is at the highest point of circulation in the system.
Systems designed to rise above the flow tappings will, of course,
automatically require a minimum static head higher than shown.
The position of the open vent/safety pipe above the expansion
cistern water level is given as a guide only. The final position will
depend upon particular characteristics of the system. Pumping over
of water into the expansion cistern should be avoided.
Open vent/safety pipe
Expansion
cistern
Independent cold
feed/expansion pipe
Main pump
Independent return to boiler
Shunt pump (if required)
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 output
(kW)
Cold feed
Open vent
40 50
61 - 150
151 - 300
301 - 600
Min. vent
height
CXA/H, AP/H, S/H,
CXSi/H,
ES/H
0.5
0.75
0.75
Min. tank
height
2.5
2.75
3.4
3
/
4
"
1"
1
1
/
4
"
1
1
/
2
"
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 scale below. The use of an
extractor fan in the same room as the boiler (or in an adjacent room
in communication) can, in certain conditions, adversely affect the
safe operation of the boiler. Where such a fan is already fitted, or if
an extractor fan is likely to be installed at a later date, then the
advice of the Gas Region 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.
Total gross input
rating of boilers
Position of
air vents
Air vent areas
(air direct from outside
cm
2
per kW nett input)
70kW to 1.8MW
70kW to 1.8MW
High level
2
Low level
4
BS 6644 - Inputs greater than 70kW (Nett)
4060kW boilers
Max. nett input rating
Air vent areas
(air direct from outside)
Up to 70kW
5cm
2
per kW nett input
BS 5440: 2 2000 - Inputs not exceeding 70kW (Nett)
Open Systems
Ventilation
1"
1
1
/
4
"
1
1
/
2
"
2"
Note: For enclosure installations see BS 6644. Where a boiler installa-
tion is to operate in summer months (e.g. DHW) additional ventilation
requirements are stated if operating more than 50% of the time.
25
CXA/H CXAP/H, CXS/H, CXSi/H: These boilers are supplied with a
control panel including two printed circuit boards, one providing
ignition and flame proving and the second contains an electronic
thermostat with off position and a pump overrun timer. Three neon
warning lights indicating `boiler on', `lockout' and `overheat' are
provided in the panel along with the reset button.
The electronic thermostat as supplied gives a maximum flow
temperature of 82°C (180°F) and the overheat thermostat is set at
100°C (212°F).
Frost Protection is built in as standard provided the thermostat
is not switched off. If the thermostat senses 5°C or less the boiler
will fire until 18°C is sensed. Note: this is to protect the boiler only
and may not protect remote parts of the system.
ES/H: The boiler is supplied with a control panel for 1 and 2
stage burner operation. It offers boiler control by two thermostats for
high/low operation, Indicator lights, Overheat safety thermostat and
Thermometer giving boiler flow temperature.
The standard thermostats provide a maximum flow temperature
of 90°C (188°F) adjustable to a setting of 40°C (84°F).
Electrical Controls
Manufactured in robust cast iron, the Concord family's sectional
insulated heat exchanger is designed for reliable long life. It is
mounted on an insulated sheet steel combustion chamber to
minimise standing losses. The collector hood and integral draft
diverter are sheet steel and ensure a low boiler height. An
enamelled casing is quick and easy to assemble after installation.
Four flow and return connections are provided for easy installation.
For ease of installation each boiler can be supplied in a number
of forms. Please see table below for delivery options:
Construction
M
= Mandatory
Option Kits
CXA/H
CXS/H
CXSi/H
ES/H
Modular
M
Volt Free Contacts, boiler
run, overheat & lockout
Down draft thermostat kit
Hours run meter
(1 or 2 hours)
Sequencer kit
Header kits
(available from merchants)
Flue gas thermometer
Multiple boiler kits (see page 20)
S
= standard
O
= optional
CXA/H
CXS/H
CXSi/H
ES/H
S
S
O
S
S
S
S
S
S
O
O
S
S
O
O
S
S
S
S
S
S
Assembled boiler
Casings fastening, flue
brush & Instruction Book
Upper front panel/Control
Box
Loose sections
strapped to a pallet
Platework crate strapped
together with jacket carton
Loose sections strapped to
a pallet (unassembled)
Package of boiler
accessories
Gas train package
Casing & Insulation package
Pair of tie rods
Delivery Options
26
Example A - Heating only utilising a mixing valve
A shunt pump sized on the minimum flow rate required MUST
be fitted. Both heating and shunt pumps MUST run on during
the overrun period of 5 minutes. (ES - 3mins)
The mixing valve MUST NOT be capable of complete closure
to bypass, in order that residual heat can be dissipated.
Example B - Combined domestic hot water and heating using a mixing valve
A shunt pump sized on the minimum flow rate required MUST
be fitted. Provided adequate heat dissipation can be achieved
at all times the shunt and DHW primary pumps only may run
on during the overrun period of 5 mins (ES - 3mins) - allowing
the heating pump to be switched off. This example assumes
the DHW primary pump flow rate required is less than that
required for the shunt pump.
Example C - Combined domestic hot water using a diverter valve and heating using a mixing valve
The example assumes flow rate required through the DHW
storage cylinder is less than that required by the boiler. A
combined shunt/DHW primary pump sized on the minimum
flow to be required MUST be fitted. Provided adequate heat
dissipation can be achieved at all times the combined
pump may run on during the overrun period - allowing the
heating pump to switch off. In order to achieve adequate
heat dissipation into the DHW storage cylinder, the diverter
valve MUST always open during the overrun period of 5
minutes (ES - 3mins).
Notes:
Minimum static head requirements with limit thermostat set at: 95°C (203°F) - 1.5 m 100°C (212°F) - 2.4 m (CX only)
The examples illustrated are intended as a general guide only
Ideal Boilers Ltd will be pleased to advise on specific applications
Design and minimum flow rate tables are shown in this leaflet
Working pressure 6 bar (87psi) 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.
In 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 shut down, 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 (7.2psi) and must take account of static head and specification
of the pressurising equipment. The maximum water temperatures
permissible at the point of minimum pressure in the system is
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
(5psi) 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
Sealed (Pressurised) Systems
System Alternatives
Concord range
27
The boiler must stand on a non-combustible floor (ie concrete
or brick). This surface 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, the dimensions must exceed the plan area of the boiler by at
least 75mm (3") on each side.
Natural gas models: If there is any doubt concerning the capacity
of the gas meter, available gas pressure, adequacy of existing pipes
or the size required for new service pipes, contact the Gas Region
for advice. Installation pipework should be fitted and tested for gas
soundness in accordance with BS 6891. The local Gas Region must
be consulted if a gas pressure booster is needed.
Propane gas models: Contact the local propane gas supplier at
the installation planning stage to ensure availability of an adequate
supply of gas. Installation pipes, cylinders and pressure regulators
should be fitted in accordance with BS 5482: 1. Bulk tank installations
must comply with the Home Office Codes of Practice for the storage
of LPG at fixed installations.
To ensure safe and satisfactory operation, the boiler must be
connected to a chimney system capable at all times of adequately
evacuating the combustion products (see performance data table on
page 14-15 for approximate volumes).
The flue design recommendations contained in BS 6644,
should be strictly observed.
Because the Concord family is supplied complete with an
integral draught diverter, No additional diverter, stabiliser or draught
break should be installed in the chimney system without prior
consultation with Ideal Boilers.
The integral draught diverter also allows specification of a
smaller flue size than is normally possible with other products,
thereby reducing component costs.
Gas
The Concord boiler family provides central heating and indirect
hot water for a range of systems.
Open Vented Systems
All boiler sizes:
· Combined pumped domestic hot water and pumped central
heating
· Pumped central heating only
· Pumped domestic hot water only systems
The maximum static head for open vent systems is 61 metres (200
feet) Pressurised or Sealed Systems
· Fully pumped systems as above
The maximum working pressure for pressurised systems is 6 bar
(87 psi).
Note: The Concord boiler family is not suitable for direct hot
water supply or gravity heating/hot water systems.
Pump overrun is provided as standard on all models (not the ES/H).
System efficiency is enhanced via an anticycling delay built in to
the Concord range controls preventing rapid cycling (not the ES/H).
For safety, a competent CORGI (Council for the Registration of
Gas Installers) registered installer must fit this appliance. CORGI
requires its members to work to satisfactory standards.
Boiler installation should comply with relevant British Standard
Specifications, Codes of Practice, and current Building Regulations,
together with any special regional requirements of the Local
Authorities, Gas Supplier, and Insurance Company, and in particular:
BS 6891 low pressure installation pipes, BS 6644 Installation
of Gas Fired Boilers, BS 6880: Part 13 Central Heating by low
pressure hot water, CP 342.2 Centralised hot water supply, IGE
UP/10 `Installation of Gas Appliances in Industrial and Commercial
Premises'.
All electrical wiring must comply with IEE Regulations for the
electrical requirement of buildings.
Manufacturer's notes must not be taken as overriding statutory
obligations.
Minimum clearances from walls or other fixed objects to allow
for installation, maintenance, the free access of combustion air, and
correct functioning of the draught diverters are shown in the boiler
clearance diagram.
Installation
Foundation
Flue Systems
System Application
Pump Choice: The choice of pump should take account of
hydraulic resistance given in the table below.
System design must allow for adequate internal circulation and
sufficient heat release from the boiler body whenever the burner is
firing or during pump overrun. See flow rate table below for details.
Additionally, the system must be controlled so that part of the load
is available during the pump overrun period to dissipate heat.
Minimum Water Flow
20
40
100 150 200
600
800
1000
1500
3500
68
136
340 511 682
2047
2729
3412
5118
11942
Boiler output
Concord CXS/H
Concord CXSi/H
Concord ES/H
Concord Modular
Concord Super Series 4
Buccaneer GTE
Falcon GTE
Harrier GTE
Viceroy GT
Viscount GTE
Vanguard L
kW
Btu/h (000)
Concord CXA/H
40-120
40-120
80-560
110-180
140-380
80-720
50-600
45-80
Concord Super Plus
200-600
21-39
36-102
105-330
300-780
754-1450
130-3500
Atmospheric Boilers
High Efficiency Boilers
Pressure Jet Boilers
Assurance of quality
BS EN ISO 9001: 2000
Contact Numbers
© 2007 Ideal Boilers Limited
Sales
Tel:
01482 498690
Fax:
01482 498621
Technical
Tel:
01482 498376
Fax:
01482 498621
Training
Tel:
01482 498432
Fax:
01482 498605
Approval
These appliances are certified to
G.A.D. 90/396 and B.E.D. 92/42
safety and performance Directives
for gas boilers.
Ideal Boilers pursues a policy of
continuous improvement in design
and performance of its products
and reserves the right to vary
specification without notice.
Statutory rights of the consumer
are not affected.
Condensing Boilers
GT Condenser
180-990
Concord CXC
48-116
The Ideal Commercial Range
icos HE
W
plus
xtra
80-280
30-36
Ideal Boilers Limited, PO Box 103, National Avenue, Kingston upon Hull HU5 4JN.
www.idealcommercialboilers.com email: commercial_heating@idealboilers.com
Concord/5/07
Issued subject to standard conditions