157295-3.pmd

Concord CXDi/H -

Installation and Servicing

GENERAL

Boiler

CXDi 110/H

CXDi 120/H

CXDi 140/H

CXDi 160/H

CXDi 180/H

Boiler Input

Gross

93.9

102.5

119.5

136.6

153.7

Low Rate

Btu/h x 1000

320.5

349.6

407.9

466.1

524.4

Nett

84.6

92.3

107.7

123.1

138.5

Btu/h x 1000

288.7

315.0

367.4

419.9

472.4

Boiler Input

Gross

134.2

146.4

170.8

195.2

219.6

High Rate

Btu/h x 1000

457.8

499.4

582.7

665.9

749.1

Nett

120.9

131.9

153.8

175.8

197.8

Btu/h x 1000

412.4

449.9

524.9

599.9

674.9

Boiler Output

110

120

140

160

180

High Rate

Btu/h x 1000

375.3

409.4

477.7

545.9

614.2

Gas rate

High

12.78

13.95

16.27

18.59

20.92

451.5

492.5

574.6

656.7

738.8

Approx. flue

At 4.5% CO

& 100°C

0.112

0.122

0.142

0.163

0.183

gas volume

At 4.5% CO

& 212°F

/min

237

259

301

345

388

Burner

High

mbar

10.4

10.1

9.7

9.6

9.7

setting

in.w.g.

4.2

4.0

3.9

3.8

3.9

pressure

Low

mbar

5.1

4.9

4.8

4.7

4.8

in.w.g.

2.0

1.9

Part load efficiency (Gross)

83.0

81.6

82.5

82.9

82.8

Electricity supply

230 V ~ 50 Hz fuse 5A

Ignition

5 attempts followed by non-volatile lockout

Gas valve

High/Low and Off

Gas safety time

Maximum of 10 secs with 5 attempts with 1 minute between attempts.

Safety check

The control de-energises every 4 hours to check internal control functions.

Pump

Pump overrun operates if the flow temperature is greater than 75

Boiler thermostat

The boiler thermostat hysteresis is a maximum of 3

Table 1 - Performance Data

Table 3 - Boiler Control specification

Maximum flow temperature 85

Boiler

CXDi 110/H

CXDi 120/H

CXDi 140/H

CXDi 160/H

CXDi 180/H

Number of sections

Flow connection

65mm (2

") nominal bore flange to BS4504 (PN6)

Return tappings

2 x 2

Maximum static head

m. (ft)

61.0 (200)

Maximum pressure

bar (psi)

6.0 (87)

Gas inlet connection

1/2

Minimum dynamic

mbar

17.5

gas pressure

in.

Electricity supply

230 Volts - single phase, 50 Hz, fuse 5 A

Nominal flue size (to BS. 835)

250

300

in.

Diverter outlet socket

288

344

internal diameter

in.

11.3

13.5

Length of burner bars (overall)

535

21.1

Approximate dry weight

520

587

654

721

lb.

1146

1294

1442

1590

Water content

litre

gal.

11.7

Table 2 - General Data

Note. To obtain gas consumption in l/s divide gross heat input (kW) by a calorific value of 37.8(MJ/m

)

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Concord CXDi/H -

Installation and Servicing

CONTENTS

Air Supply. ........................................................................ 8

Boiler Assembly - exploded view. ................................. 9

Boiler Clearances. ........................................................... 5

Burner Assemblies - exploded views. .............................

CXDi 110/H-160/H. ..................................................... 28
CXDi 180/H. ............................................................... 29

Casing Assembly. .......................................................... 13

Chimney System. ............................................................. 8

Commissioning. ............................................................. 19

Electrical Connections. ................................................. 16

Electrical Supply. ............................................................. 8

Fault Finding. ................................................................. 32

Gas Safety Regulations ................................................... 2

Gas Supply. ....................................................................... 8

Hydraulic Resistance. ...................................................... 5

Initial Lighting. ............................................................... 19

Installation. ....................................................................... 9

Mandatory Requirements. ............................................... 7

Option Kits. ....................................................................... 4

Pump. ................................................................................ 6

Servicing. ........................................................................ 26

Short List of Parts. ......................................................... 35

Static Head Requirements. ............................................. 6

System Connections. ..................................................... 12

Ventilation. ........................................................................ 8

Water Circulation. ............................................................ 4

Water Connections. ......................................................... 4

Water Treatment. .............................................................. 6

Wiring Diagrams. ........................................................... 17

INTRODUCTION
CONSTRUCTION

BOILER BODY

The sectional boiler body is of cast iron and is supplied with a sheet
steel combustion chamber and integral draught diverter. The boiler
is supplied in sectioned form for site assembly.

CASING

The casing is manufactured in stove enamelled sheet steel and is
easily assembled on site.

BURNERS

The burners are of stainless steel construction.

Current Gas Safety (Installation and Use)
Regulations or rules in force

It is the law that all gas appliances are installed and serviced by a
CORGI registered installer in accordance with the above regulations.
Failure to install appliances correctly could lead to prosecution. It
is in your own interest, and that of safety, to ensure that the law is
complied with.

The Concord CXDi 110/H-180/H range of boilers has been tested
and certified by British Gas to prEN656 for use with natural gas only.

Note.
Concord CXDi 110/H - 180/H boilers are intended for use as
COMMERCIAL BOILERS and are NOT certified for use in domestic
applications. A domestic installation is defined as an installation
where the boiler takes its combustion air from a living space or from
a room directly or indirectly connected with the living space. It is
important, therefore, that no external control devices - e.g. flue
dampers, economisers etc., are directly connected to this appliance
unless covered by these Installation and Servicing Instructions or
otherwise recommended by Caradon Ideal Limited in writing. If in
doubt please enquire.

Any direct connection of a control device not approved by Caradon
Ideal Limited could invalidate the British Gas Certification, the
normal appliance warranty and could also infringe the Gas Safety
Regulations. Table 1, Table 2 and the descriptive notes which follow
contain all the essential data likely to be required by the installer.

GAS CONTROLS

The gas controls consist of a high / low arrangement with direct
burner ignition.

ELECTRICAL CONTROLS

WARNING

.The ON/STANDBY [1/0] button does NOT electrically

isolate the boiler.

The Concord CXDi/H incorporates an advanced microprocessor-
based control system which operates all electrical functions of the
boiler, including ignition, flame detection, thermostatic control and
high/low operation. In addition, the microprocessor has onboard
servicing and commissioning instructions and a fault diagnosis
programme.
The illuminated LED display gives a continual read-out of the
boiler status and functions but, in the (unlikely) event of a fault
condition, will display the fault areas.

Concord CXDi 110/H-180/H (Natural gas) B.G. Certified - P.I. No. 87/AQ/341 Destination Countries: GB and IE

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 CXDi/H -

Installation and Servicing

GENERAL

Boiler Size

Cold Feed

Open Vent

CXDi 110/H

1/4

CXDi 120/H

1/4

CXDi 140/H

1/4

CXDi 160/H

1/4

1/2

CXDi 180/H

1/4

1/2

WATER CONNECTIONS

Flow connection is 65mm (2

") nominal bore flange to BS4504 (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

1/2

" BSP tapping 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.

) above the operating pressure in the boiler. The

maximum safety valve setting is 0.7 bar (10 lb/in.

) above the

maximum design operating pressure of 6.0 bar (87 lb/in.

Cold Feed/Open Vent
The independent cold feed and the open vent must comply with
BS. 6644 and be of the following minimum size.

OPTION KITS

Remote indication board (volt free)
This provides the ability for remote indication of lockout and
overheat conditions.

Outside sensor
This kit provides temperature compensation when the outside
temperature changes.

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. To allow pump operation after burner shutdown, the boiler
control box incorporates a pump overrun facility which operates when
the boiler switches off and until the flow temperature is below 75°C

- in order to make use of this the pump must be wired to the
appropriate terminal L

(pump) in the boiler control box.

1. The minimum flow rate as given in Table 5 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 CXDi 110/H and CXDi 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 CXDi 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 wiring diagrams in Frames 16,17 and 18 illustrate the control
methods for achieving the above.

3. Pump selection should take account of the hydraulic resistance

given in Graph 2.

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Concord CXDi/H -

Installation and Servicing

GENERAL

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 4 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

(150

F).

Graph 2 - Hydraulic Resistance

Boiler Size

CXDi 110/H

CXDi 120/H

CXDi 140/H

CXDi 160/H

CXDi 180/H

Front clearance

mm (in)

700 (27

1/2

)

Rear clearance

mm (in)

200 (8)

Side clearance

mm (in)

100 (4) - not including clearance for side fitted flow header

Dimension A

mm (in) 1036 (40

3/4

) 1036 (40

3/4

)

1036 (40

3/4

)

1086 (42

3/4

)

1140 (45)

Dimension B

mm (in)

175 (7)

197 (7

3/4

)

250 (10)

Dimension C

mm (in) 1107 (43

3/4

)

1107 (43

3/4

)

1230 (48

1/2

)

1353 (53

1/4

)

1476 (58

1/8

)

Dimension D

mm (in)

816 (32

1/8

)

816 (32

1/8

)

939 (37)

1062 (42

3/4

)

1185 (46

5/8

)

Dimension E

mm (in)

553 (21

3/4

)

553 (21

3/4

)

615 (24

1/4

)

676 (26

5/8

)

738 (29)

Dimension F

mm (in)

220 (8

5/8

)

220 (8

5/8

)

220 (8

5/8

)

220 (8

5/8

)

320 (12

1/2

)

CLEARANCES & DIMENSIONS

Table 4

Graph 1 - Heat Load / Water Volume

CXDi

160/H

Con

1935

CXDi

110/H

CXDi

120/H

CXDi

140/H

CXDi

180/H

CXDi

180

CXDi

160/H

CXDi

1
1
0
/H

CXDi

120

CXDi

140

Con

1936

Con

1934

+:,E

C O N C O R D

EXIT COPY ENTER

YES

ADV

Return Rc2

(2" BSP)

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Concord CXDi/H -

Installation and Servicing

GENERAL

Note. This diagram does not show safety valves, water flow switches, etc.,
necessary for the safe operation of the system.

3 OPEN VENTED SYSTEMS - minimum static head requirements

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. The open vent MUST be brought to either

the 1

1/2

" BSP tapping on the flow header

provided or to the unused 2" BSP flow
tapping at the top rear of the boiler.

2. An independent cold feed/expansion pipe

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.

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
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.

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,

Table 5 - Flow rates for fully pumped systems

Boiler

Minimum flow rates for a

temperature difference of 35°C (63°F)

l/s

g.p.m.

CXDi 110/H

0.75

9.9

CXDi 120/H

0.82

10.8

CXDi 140/H

0.96

12.7

CXDi 160/H

1.10

14.6

CXDi 180/H

1.24

16.4

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 5

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.

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Concord CXDi/H -

Installation and Servicing

GENERAL

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 6.

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

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.

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.,

Sentinel Division,

Tandem House, Marlowe Way

Betz Dearborn Ltd.,

Croydon.

Widnes,

Surrey CRO 4XS

Cheshire, WA8 8UD

Tel 0870 601 5000

Tel. 0151 424 5351.

SAFE HANDLING OF SUBSTANCES

Care should be taken when handling the boiler insulation panels,
which can cause irritation to the skin. No asbestos, mercury or
CFCs are included in any part of the boiler.

INSTALLATION REQUIREMENTS

The appliance must be installed by a CORGI registered installer.

The installation of the boiler must be in accordance with the relevant
requirements of the Gas Safety Regulations, current I.E.E.
(BS.7671) Regulations, Model Water Bye-laws, local water
authority bye-laws and it should also comply with any relevant
requirements of the local gas supplier, local authority and the
relevant British Standard Codes of practice and building
regulations.

SEALED (PRESSURISED) SYSTEMS

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Concord CXDi/H -

Installation and Servicing

GENERAL

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 CXDi/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
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.

For details of connections see Frame 14.

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 6 - Ventilation Requirements

Required area (cm

) per kW of total rated input (net)

Boiler room

Enclosure

Low level (inlet)

High level (outlet)

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.

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.

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Concord CXDi/H -

Installation and Servicing

INSTALLATION

BOILER SECTION ASSEMBLY

The site assembled boiler is supplied in the following packages:

! Combustion chamber / manifold / burner assembly.

! Platework package.

! Casing package.

! Controls box package.

! End and centre sections.

TOOLS REQUIRED

Spanners

Torque wrench

Pozi screwdriver

Mallet

GENERAL

The installation of the boiler must be in accordance with current
Gas Safety (Installation and Use) Regulations or rules in force,
building regulations, I.E.E. (BS.7671) Regulations and the bye-
laws 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 2 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.

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

1/2

times the design

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.

INST

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Concord CXDi/H -

Installation and Servicing

INSTALLATION

BOILER SECTION ASSEMBLY - continued

12. Offer the downdraught deflector to the projecting studs at

the back of the combustion chamber and fix, using the
nuts and washers provided to the downdraught deflector.

13. Fit insulation brackets with the screws provided.
14. Refit the burner assembly to the combustion chamber

and tighten the 4 nuts securing the burner manifold to the
combustion chamber legs. Offer up the burner light back
shield to the combustion chamber - with the cutout for the
flame detector electrode at the LH end - and fasten, using
the M5 nuts and washers.

15. Fit the gas valve and spark generator assembly to the

boiler by doing up the union in the gas line and by
fastening the spark generator bracket to the
combustion chamber using the two M5 screws and
washers.

16. Fit the gas inlet pipe and retain by the semi-circular

clamp, screws and washers provided. Tighten both
unions and the inlet pipe retaining clamp, ensuring that
the gas valve assembly is vertical.

17. To fit the collector hood align the back edge of the

horizontal side returns with the rear of the section
assembly and fasten down the collector hood (using
the M6 screws and nuts provided) through the side
fixing points.

18. Wrap insulation around heat exchanger with foil

outside, tuck behind insulation brackets on
downdraught deflector. Fasten at edge using foil tabs
and tape provided.

19. Fit the NOx ducts into the burner aeration intakes and

fasten to the collector hood, using the M5 elongated
nuts. Insualtion must be behind NOx ducts, note that
the insulation will be compressed flat behind ducts.

Side elev. of d/deflector-insulation assy.

Con

1902

Sealing rope

Downdraught

deflector

Fixing screw

Collector hood flange

INST

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157295-3.pmd

11/7/2005, 3:21 PM

Concord CXDi/H -

Installation and Servicing

INSTALLATION

BOILER ASSEMBLY

1. Fit the distributor tube into the selected return connection.

Ensure that the tube flange aligns horizontally and that the
2 sealing gaskets are correctly assembled on the tube -
refer to alignment notches.

1. Complete the secondary flue connection.

The boiler is designed to accept flues to BS.835. If a
suitable adaptor is used then flues to BS715 may be fitted.

2. Seal with an approved boiler putty.

3. A split socket should be fitted immediately above the boiler

to facilitate disconnection of the flue.

FLUE CONNECTION

Connect the gas supply to the gas inlet pipe - Table 2
gives details of the inlet pipe size.

The use of an approved gas cock and union is
recommended here.

Fit the 2" tapped flange, using the M10 x 35mm screws and
washers provided.

2. Fit the blank flange to the other lower rear connection, using

the gasket and M10 x 25mm screws and washers provided.

3. Fit the blank flange to the RH front connection, using the

gasket and M10 x 25mm screws provided.

4. The 1

4" tapped flange and gasket shou