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2
Concord CXAP/H
- Installation and Servicing
GENERAL
Boiler
CXAP 40/H
CXAP 50/H
CXAP 60/H
CXAP 70/H CXAP 80/H CXAP 90/H CXAP 100/H
Number of sections
3
4
4
5
5
6
6
Flow tappings
Rc (in. BSP)
2 x 2 at rear
Return tappings
Rc (in. BSP)
2 x 2 at rear
Maximum static head
metres (feet)
61 (200)
Maximum pressure
bar (p.s.i.)
6.0 (87)
Gas inlet connection
Rc (in. BSP)
3/4 (3/4)
1 (1 )
Dynamic gas
mbar gauge
37.0
37.0
37.0
37.0
37.0
37.0
37.0
pressure required
at boiler inlet
in.w.g.
14.9
14.9
14.9
14.9
14.9
14.9
14.9
Electricity supply
230 Volts- single phase, 50 Hz, fuse 5 A
Nominal flue size (to BS. 835)
mm
150
150
175
175
200
200
200
in.
6
6
7
7
8
8
8
Diverter outlet socket
mm
184
184
213
213
238
238
238
internal diameter
in.
7.3
7.3
8.4
8.4
9.4
9.4
9.4
Length of burner bars (overall)
mm
377
497
497
617
617
737
737
in.
14.8
19.5
19.5
24.3
24.3
29.0
29.0
Main burner injectors (3 off)
size, mm
2.15
2.3
2.54
2.69
2.96
3.09
3.27
Approximate dry weight
kg
210
265
265
330
330
395
395
lb.
463
584
584
727
727
871
871
Water content
litre
22
30
30
37
37
45
45
gal.
4.8
6.6
6.6
8.2
8.2
9.9
9.9
Boiler
CXAP 40/H
CXAP 50/H CXAP 60/H CXAP 70/H CXAP 80/H CXAP 90/H CXAP 100/H
Number of sections
3
4
4
5
5
6
6
Boiler input
Nett
kW
48.4
57.3
69.6
79.8
96.0
103.4
119.5
Btu/hr x 1000
165.1
195.4
237.5
272.2
327.5
352.8
407.7
Gross
kW
52.5
62.1
75.5
86.5
104.1
112.15
129.6
Btu/hr x 1000
179.1
211.9
257.6
295.1
355.2
382.7
442.2
Boiler output to water
kW
42.0
49.68
60.4
69.2
83.28
89.72
103.68
Btu/hr x 1000
143.3
169.5
206.1
236.1
284.2
306.1
353.8
Gas rate
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
149.0
172.3
Approximate flue 6.5% CO
2
& 150°C.m
3
/s
0.051
0.060
0.073
0.083
0.099
0.108
0.125
gas volume in the
secondary flue
6.5% CO
2
& 302°F. ft.
3
m
108
127
155
176
210
229
265
Manifold setting pressure
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
14.0
Part Load efficiency (Gross)
%
80.0
80.5
81.5
80.7
81.7
81.8
82.7
Seasonal efficiency (SEDBUK)*
[78.2]%
[78.6]%
[79.7]%
[78.8]%
[79.4]%
[79.6]%
[80.0]%
Table 1- Performance Data
Note. To obtain gas consumption in l/s divide gross heat input in kW by the gross CV of the gas in MJ/m
3
.
The gross CV is the value quoted by the gas supplier.
Table 2 - General Data
*The value is used in the UK government's Standard Assessment Procedure (SAP) for energy rating of dwellings.
The test data from which it has been calculated have been certified by Advantica 0087.
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Concord CXAP/H -
Installation and Servicing
3
CONTENTS
Air Supply. ........................................................................ 8
Boiler Assembly - exploded view. ................................. 9
Boiler Clearances. ........................................................... 5
Burner Assemblies - exploded views.
CXAP 40/H-80/H. ....................................................... 22
CXAP 90/H-100/H. ..................................................... 22
Casing Assembly. ...........................................................11
Chimney System. ............................................................. 8
Commissioning & Testing. ............................................ 17
Electrical Connections. ................................................. 13
Electrical Supply. ............................................................. 8
Fault Finding. ................................................................. 28
Gas Safety Regulations ................................................... 3
Gas Supply. ....................................................................... 8
Hydraulic Resistance. ...................................................... 5
Initial Lighting. ............................................................... 17
Installation. ....................................................................... 9
Mandatory Requirements. ............................................... 7
Option Kits. ....................................................................... 4
Pump. ................................................................................ 6
Servicing. ........................................................................ 19
Short List of Parts. ......................................................... 30
Site Assembled Boilers. ................................................ 26
Static Head Requirements. ............................................. 6
System Connections. ......................................................11
Ventilation. ........................................................................ 8
Water Circulation. ............................................................ 4
Water Connections. ......................................................... 4
Water Treatment. .............................................................. 6
Wiring Diagrams. ........................................................... 14
Concord CXAP 40/H-100/H (Propane) B.G. Certified - P.I. No. 87/AP/80
Destination Countries: GB and IE
INTRODUCTION
CONSTRUCTION
Boiler body
The sectional boiler body is of cast iron and is supplied assembled
on a sheet steel combustion chamber with an integral draught
diverter. The boiler can be supplied in sectioned form to special
order for site assembly - refer to the section headed `Instructions
for Site Assembled Boilers'.
Casing
The casing is manufactured in stove enamelled sheet steel and
is easily assembled on site.
Burners
The 3 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 CXAP 40/H-100/H range of boilers has been tested
and certified by British Gas to prEN656 for use with PROPANE only.
Multiple boiler installations
The Concord CXAP/H range is certificated for use in multiple
boiler installations, providing that the following conditions are
satisfied.
1. A downdraught thermostat kit MUST be fitted to ALL boilers in
the installation.
2. A maximum of 6 boilers may be used with a single flue
header.
3. For clearances see Frame 2.
A comprehensive guide to multiple installations of Concord
CXAP/H boilers is available.
WARNING. Failure to use a downdraught kit on every boiler in a
multiple boiler installation will negate the certification of the
installation and therefore contravene the essential requirements of
the Gas Appliance Directive.
Note. Concord CXAP 40/H, CXAP 50/H and CXAP 60/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.
CAUTION.
To avoid the possibility of injury during the installation, servicing or cleaning of
this appliance care should be taken when handling edges of sheet steel components.
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Concord CXAP/H
- Installation and Servicing
GENERAL
Boiler Size
Cold Feed
Open Vent
CXAP/H 40 - 50
3/4
"
1"
CXAP/H 60 -100
1"
1
1/4
"
Sealed system filling point - refer to Frame 8
Flow and return connections are 2" BSP.
A 1" BSP tapping is provided in the redundant return flange for
the cold feed or expansion vessel connection.
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
).
Cold Feed/Open Vent
The independent cold feed and the open vent must comply
with BS. 6644 and be of the following minimum size.
1
WATER CONNECTIONS
GAS CONTROLS
Control is by automatic ignition of intermittent pilot; once the
presence of a flame has been proved the main gas valve opens to
give full heat input. The mains voltage supply is via a terminal plug
connection at the control box.
A 4 minute anti-cycle delay is built in to the controls to prevent rapid
cycling. A preset overheat thermostat is also provided.
ELECTRICAL CONTROLS
The boiler is supplied with 2 printed circuit boards; Board
S4561B1054 is the ignition board containing the flame proving
logic and the on-board spark generator. Board W4115A1020
contains the electronic thermostat and the pump overrun timer. A
preset overheat thermostat is also fitted. The control box displays
neons indicating boiler status as follows:
!
Boiler on
!
Lockout
!
Overheat
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
5
o
C the boiler will fire until the temperature reaches 18
o
C. Note
that this is designed to protect the boiler and may not necessarily
protect the remote parts of the system.
OPTION KITS
Remote indication kit
This kit gives the facility of remote indication of the boiler status.
Pressure gauge kit
An optional pressure gauge is also available for the range of boilers.
Details for fitting are included with the pressure gauge.
Downdraught thermostat kit
This kit is optional when used on a single CXAP/H installation, but
mandatory when used on a multiple boiler installation.
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.
The range of boilers is NOT suitable for:
1. Gravity DHW systems.
2. Gravity heating systems.
3. Direct domestic hot water supply.
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 burner shutdown 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 CXAP 90/H and CXAP 100/H the minimum circuit
during pump overrun could be a load of 6 kW with a volume
of 31 litres or any other combination given by the relevant
line.
b. For the CXAP 70/H and CXAP 80/H the minimum circuit
during pump overrun could be a load of 2 kW with a volume
of 45 litres or any other combination given by the relevant
line.
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Installation and Servicing
5
GENERAL
MULTIPLE BOILER INSTALLATIONS
The minimum installation clearances must conform to the
dimensions given below:
CXAP 40/H, 50/H, 60/H, 70/H & 80/H
Clearance between boilers = 50mm
Clearance at both ends of the multiple installation = 50mm*
2
CLEARANCES & DIMENSIONS
CXAP 90/H & 100/H
Clearance between boilers = 100mm
Clearance at both ends of the multiple installation = 100mm*
Rear clearance: sufficient clearance should be given at the rear
of the boiler for connection of gas and water pipework.
*Additional clearance is required for access at either end of the
installation.
Boiler Size
CXAP 40/H
CXAP 50/H
CXAP 60/H
CXAP 70/H
CXAP 80/H
CXAP 90/H CXAP 100/H
Front clearance
mm (in)
750 (29
1/2
)
Rear clearance
mm (in)
0
0
0
150 (6)
150 (6)
300 (12)
300 (12)
Side clearance
mm (in)
50 (2)
50 (2)
50 (2)
50 (2)
50 (2)
100 (4)
100 (4)
Dimension A
mm (in)
750 (29
1/2
)
882 (34
3/4
)
882 (34
3/4
)
1042 (41)
1042 (41)
1212 (47
3/4
)
1212 (47
3/4
)
Dimension B
mm (in)
108 (4
1/4
)
108 (4
1/4
)
122 (4
7/8
)
122 (4
7/8
)
135 (5
3/8
)
190 (7
1/2
)
190 (7
1/2
)
Dimension C
mm (in)
931 (36
5/8
)
931 (36
5/8
)
931 (36
5/8
)
931 (36
5/8
)
931 (36
5/8
)
893 (35
3/16
)
893(35
3/16
)
Dimension D
mm (in)
177 (7)
187 (7
3/8
)
187 (7
3/8
)
224 (8
7/8
)
224 (8
7/8
)
271 (10
5/8
)
271 (10
5/8
)
Dimension E
mm (in)
69 (2
3/4
)
79 (3
1/8
)
79 (3
1/8
)
116 (4
5/8
)
116 (4
5/8
)
163 (6
1/2
)
163 (6
1/2
)
Table 3
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.
However, for maintenance
purposes we suggest a minimum
rear clearance of 50mm.
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
o
C (150
o
F).
10
9
8
7
6
5
4
3
2
1
0
10
20
30
40
50
60
70
80
CON5223
Example A
Example B
CXAP
100/H & CXAP
90/H
CXAP
80/H & CXAP
70/H
CXAP
40/H
CXAP
60/H & CXAP
50/H
Heat Load During Pump Overrun (kW)
Water Volume in Circuit during Pump Overrun (litres)
Relationship between load and water volume for the
minimum capacity of water circuit during the 6 minute
pump overrun period for different boiler outputs.
Graph 1 - Heat Load / Water Volume
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
190 200
160 170 180
120
110
100
90
80
70
60
50
40
30
20
10
0
Graph 2 - Hydraulic Resistance
Hydraulic Resistance (mbar)
Flow (litres/min)
11
o
C(20
o
F) - CXAP
40/H
11
o
C(20
o
F) - CXAP
50/H
11
o
C(20
o
F) - CXAP
60/H
11
o
C(20
o
F) - CXAP
70/H
11
o
C(20
o
F) - CXAP
80/H
11
o
C(20
o
F) - CXAP
90/H
11
o
C(20
o
F) - CXAP
100/H
CON5224
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Concord CXAP/H
- Installation and Servicing
GENERAL
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.
The information provided is based on the following
assumptions:
1. 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.
2. An independent cold feed/expansion pipe connection is
made to the redundant boiler return tapping. 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.
3. The maximum flow rate through the boiler is based on a
temperature difference of 11 °C at full boiler output and
the circulating pump is positioned in the flow to the
Note A. This minimum height must be
increased, if necessary, to comply with the
minimum head required by the pump
manufacturer in order to avoid cavitation.
Note B. This diagram does not show safety
valves, water flow switches, etc., necessary
for the safe operation of the system.
system.
4. The boiler is at the highest point of circulation in the system. Systems
designed to rise above the boiler flow tappings will automatically require
a minimum static head higher than that shown.
5. 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
the particular characteristics of the system. Pumping over of water into
the expansion cistern must be avoided.
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 wiring diagrams in Frames 17,18 &19 illustrate the
control methods for achieving the above.
3. Pump selection should take account of the hydraulic
resistance given in Graph 2.
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
o
C (63
o
F), assessed at catalogue rating.
3 OPEN VENTED SYSTEMS - Minimum static head requirements
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%.
Table 4 - Flow rates for fully pumped systems
Boiler
Minimum flow rates for a
temperature difference of 35
0
C (63
0
F)
l/s
g.p.m.
CXAP 40/H
0.28
3.7
CXAP 50/H
0.34
4.5
CXAP 60/H
0.41
5.4
CXAP 70/H
0.48
6.3
CXAP 80/H
0.55
7.3
CXAP 90/H
0.62
8.2
CXAP 100/H
0.68
9
CON5349
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Concord CXAP/H -
Installation and Servicing
7
GENERAL
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
expelled 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
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
Tandem House,
Marlowe Way,
Croydon.
Surrey CRO 4XS
Tel 0870 601 5000
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 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 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
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.
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 region, local authority and the relevant
British Standard Codes of practice and building regulations.
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.
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.
4
SEALED (PRESSURISED) SYSTEMS
INSTALLATION REQUIREMENTS
The appliance must be installed by a CORGI registered installer.
Sentinel Division
Betz Dearborn Ltd.,
Widnes,
Cheshire,
WA8 8UD
Tel. 0151 424 5351.
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Concord CXAP/H
- Installation and Servicing
GENERAL
VENTILATION
Safe, efficient and trouble-free operation of open 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 to the outside air
is required; the minimum free area and the required positioning
of these grilles must be in accordance with Tables 5 and 6.
Position ventilation grilles to avoid the risk of accidental
obstruction by blockage or flooding.
Every installation must comply with the ventilation requirements
of BS.6644 or BS.5440:2:2000
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 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.
CHIMNEY SYSTEM
To ensure the safe and satisfactory operation of the boiler 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 vemiculite 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 CXAP/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.
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 region should be requested.
Installation pipework should be fitted and tested for gas
soundness in accordance with BS. 6891;
IGE-UP-1 for small installations
IGE-UP-2 for large installations.
The local gas region 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.
For details of connections refer to Frame 14.
Table 5 - (to BS5440)
CXAP 40/H-60/H boilers installed in a room or internal space
Boiler size
Air vent free area cm
2
40
209
50
252
60
313
This air vent shall be direct to outside air or to a room or internal
space itself with an air vent to outside air of the same size.
Table 6 - (to BS6644)
CXAP 70/H-100/H boilers
Required area (cm
2
) 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).
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8
Concord CXAP/H -
Installation and Servicing
9
INSTALLATION
CASING PACK contains:
·
Front panel ...................... 1 off
·
Side panel ....................... 2 off
·
Top panel......................... 1 off
·
Top support bracket ........ 2 off
·
Flue brush ....................... 1 off
·
Casing hardware pack .... 1 off
Legend
1. Cleanout cover
2. Collector hood
3. Middle section
4. Section alignment rings & 'O' rings
5. End section
6. Gas cock
10. Burner manifold assy.
11. Base plate
12. Combustion chamber
7. Drain cock
8. NOx duct
9. Front plate
5
CONCORD CXAP/H BOILER ASSEMBLY - Exploded view
6
PACKAGING
Check that all these packages are complete and have been
correctly received on site.
Factory assembled boilers are despatched from the works as fully
packaged units comprising:
1. Assembled boiler body (with distributor tube) on a wooden pallet
base enclosed in a wooden crate.
2. Carton containing the casing, fastenings and flue brush.
3. Carton containing the installation pack and instruction books.
4. Carton containing the control box.
INSTALLATION HARDWARE PACK contains:
·
M10 washer ......................................... 4 off
·
Split pin ............................................... 1 off
·
Strain relief bush ................................. 1 off
·
M10 x 25 Hex. Hd. screw .................... 2 off
·
M10 x 35 Hex. Hd. screw .................... 2 off
·
Gasket EPDM Type EP600 ................. 3 off
·
Plug 2" taper Sq.Hd. ........................... 3 off
·
Installation & Servicing Instructions .... 1 off
·
User's Instructions ............................... 1 off
·
Flange RC 1" ....................................... 1 off
·
2" BSP Flange (distributor tube) ......... 1 off
·
2" Installation pipe (handling bars) ..... 2 off
·
Thermostat pockets ............................ 2 off
13. Section bolt
14. Distribution tube
15. Tie rods
16. Thermostat pocket
17. Spillage skirt
18. Gas pipe
Con 1942
Alignment notches
Distribution tube detail
1
2
18
3
4
5
7
8
6
9
10
11
12
13
14
15
16
17
INST
ALLA
TION
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9
10
Concord CXAP/H
- Installation and Servicing
INSTALLATION
7
PACKAGING AND BOILER REMOVAL
1. Remove the casing carton and outer packaging frame.
2. Remove the casing pack support frame.
3. Remove the distributor tube pack, controls package and
installation pack.
4. Remove the 2" BSP steel handling bars from the
installation pack.
5. Remove the 4 base bolts holding assembly to the
packaging base.