157602-4.pmd

Concord ES

- Installation and Servicing

GENERAL

Boiler

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

Number of Sections

Boiler Output

2nd stage kW 119-140 136-160 153-180 170-200 187-220 221-260 255-300 289-340 323-380

1st stage kW

83-98

95-112 107-126 119-140 131-154 155-182 179-210 202-238 226-266

Boiler Input

2nd stage kW

131,1-153 149,7-174,7 168,2-196,3 186,7-217,9 205,2-239,4 242,2-282,6 278,8-325,4 315,7-368,4 352,4-411,3

(Nett CV)

1st stage kW

93,1-108,9 106,3-124,3 119,4-139,7 132,5-155 145,6-170,4 171,9-201,1 197,9-231,5 224-262,1 250,1-295,6

Gas

2nd stage m

13,88-16,1915,84-18,48 17,80-20,77 19,76-23,05 21,71-25,33 25,63-29,91 29,51-34,43 33,40-38,98 37,29-43,52

flow rate

1st stage m

9,85-11,52 11,24-13,15 12,63-14,78 14,02-16,41 15,41-18,03 18,19-21,28 20,94-24,50 23,71-27,74 26,47-30,97

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

/sec

0.115

0.123

0.148

0.163

0.171

0.209

0.228

0.247

0.304

Flue Gas Temperature

ºC

125

133

123

125

130

126

133

140

126

6.4

6.3

6.4

6.8

6.5

7.5

6.5

Table 1 - Performance Data

Boiler

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

Main burner injector

m m

3, 9

Ignition burner injector

m m

0,8

Maximum flow temperature

ºC

Maximum operating pressure

bar

Electrical connection

V / Hz

230 / 50

Maximum electrical power

450

Gas connection

(inch BSP)

Flow & return connections

(inch BSP)

Flue outlet diameter

m m

250

300

350

400

Water content

litre

106

122

137

154

Water circuit

at T = 11 K mbar

110

136

164

229

305

392

489

resistance

at T = 20 K mbar

118

148

Dry weight

667.5

730.25

807

879.5

934

1096

1226.75 1363.5

1475.5

Table 2 - General Data

Note: The above tables show both 85% and 100% full output figures. The output is adjustable.

Concord ES -

Installation and Servicing

CONTENTS

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

Boiler Clearances. ......................................................... 11

Boiler Dimensions. .......................................................... 5

Boiler Operation - Controls. .......................................... 10

Casing Assembly. .......................................................... 22

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

Commissioning & Testing. ............................................ 31

Control Panel Description. ............................................ 28

Data Tables. ..................................................................... 2

Electrical Connections. ................................................. 27

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

Gas Safety Regulations ................................................... 3

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

Hydraulic Resistance. ..................................................... 4

Initial Lighting. ................................................................ 31

Installation. ..................................................................... 12

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

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

Pack Lists. ..................................................................... 12

Pump. ............................................................................... 4

Servicing. ....................................................................... 33

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

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

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

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

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

Wiring Diagrams. .......................................................... 30

INTRODUCTION

CONSTRUCTION

Concord ES boilers are
sectional cast iron boilers,
with an atmospheric two-
stage gas burner and
electronic ignition via an
ignition burner. The heat
output is adjustable to 85% of
full output. The combustion
chamber and draught diverter
are sheet steel. They are
designed for use with a hot
water central heating system,
and have a heat output range
of: 119 - 380 kW

They must be connected to a chimney. The heat exchanger can
be supplied, assembled, or unassembled for site assembly.
They are suitable for natural gas only.

CERTIFICATION
EC:

The Concord ES boilers meet the requirements of the following
European directives and are tested according to EN 656:
-

90.396 EEC Gas Appliances Directive

92.42 EEC Boiler Efficiency Directive

73.23 EEC Low Voltage Directive
Relevant standard: EN 60.335.1

89.336 EC Electromagnetic Compatibility Directive Relevant
standards: EN 50.081.1 / EN 50.082.1 / EN 55.014.

The boilers are of the B11 type
EC No: CE 0085 BL 0187 (Concord ES)

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.

Note. Concord ES 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 Certification, the
normal appliance warranty and could also infringe the Gas
Safety Regulations. Table 1 and 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.

Concord ES

- Installation and Servicing

GENERAL

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 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.

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 heat input according to thermostat settings. The mains
voltage supply is via a terminal strip connection at the control
box.

ELECTRICAL CONTROLS

The boiler is supplied with a control box providing full logic and
sequence control. A separate ignition transformer is fitted.
Details of the control panel are given in Frame 40.

FROST PROTECTION

If frost is likely, leave the boiler thermostat at a reduced
temperature setting and do not turn off the gas cock. Ensure
external controls allow the boiler to operate if necessary. Note
that this may not protect remote parts of the system, in which
case a separate frost thermostat should be fitted or the system
drained and the boiler shut down, as for Long Periods.

OPTION KITS

Hours run meter kit (IC8)
One or two hours run meters to measure 1st and 2nd stage
operation.

Flue gas thermometer kit (ID28)
Provides measurement of flue gas temperature.

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. The system controls must allow a pump
overrun period, after burner shutdown, of 3 minutes.

1. The minimum flow rate given by:

min flow rate = 0.86.P m

/hour

where P = max. heat output of boiler (kW)

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.

3. Pump selection should take account of the hydraulic

resistance given in the Data Tables on page 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.

CON5252

G Drain (tapped 3/4")

H 2" threaded flow connection

2" threaded return connection

System connections H and I must be on the same side (either
on the right or on the left but never to opposite sides).

Note

The connections may be welded.

Boiler Size

Cold Feed

Open Vent

61 - 150

1/4

151 - 300

1/4

1/2

301 - 600

1/2

Concord ES -

Installation and Servicing

GENERAL

DIMENSIONS

Table 3

Hydraulic connections must be made on one side only (either on the right or on the left side), but never on opposite sides.
The connections may be welded.

Gas inlet connection F may be made either from the right or the left side of the boiler.

LOW TEMPERATURE OPERATION

The flow temperature from the Concord ES boiler can be reduced to a minimum of 40ºC dependent on the heat load requirement of
the system. This is permissible in those situations where low modulated temperature operation is achieved using weather
compensation. It is NOT permissible to design the system to run the boiler constantly at 40ºC flow. The return temperature must
not be less than 35ºC.

Boiler Size

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

Dimension A

1362

1412

1462

Dimension B

970

1058

1146

1234

1322

1498

1674

1850

2026

Dimension øC

250

300

350

400

Dimension D

632

720

808

896

984

1160

1336

1512

1688

Dimension E

165

190

220

Dimension øF

Rp 1

Dimension G

447

491

535

579

623

704

792

880

963

Dimension H

445

454

507

Dimension J

1094

1194

Dimension K

1406

Concord ES

- 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.

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.

3 OPEN VENTED SYSTEMS - Minimum static head requirements

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 normal design 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
expelled is drawn back from the tank into the system together
with a quantity of dissolved oxygen.

Concord ES -

Installation and Servicing

GENERAL

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

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 region, local authority and the relevant British
Standard Codes of practice and building regulations.

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 0.3
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 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.

SEALED (PRESSURISED) SYSTEMS

Sentinel Division
Betz Dearborn Ltd.,
Widnes,
Cheshire, WA8 8UD
Tel. 0151 424 5351.

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.

Concord ES

- Installation and Servicing

GENERAL

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 and 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 ES 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

A minimum of 17.5 mbar (7 in w.g.) dynamic gas pressure must
be available for boiler operation.

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 39.

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 required positioning of
these grilles must be in accordance with Table 6.

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).

Concord ES

- Installation and Servicing

GENERAL

OPERATION OF THE BOILER FITTED WITH THE DGAI 73 MOD. 10.1.0 TCL-G
SAFETY CONTROL BOX

OPERATING PRINCIPLE

The boiler can operate either in the 2nd or in the 1st stage,
depending upon the heat requirements of the installation.

The burner ignition and monitoring cycle is performed by the
safety control box.

When heating is required, the boiler thermostat TCH1 closes
the contact. After a time delay tw, the ignition transformer TA
produces a number of sparks at the ignition electrode and,
after a pre-ignition delay tvz, the ignition burner valve VG and
the safety valve VS open.

A flame appears at the ignition burner and the ionisation probe
SF detects a flame signal with a minimum ionisation current of
1

µA. After the ionisation current has stabilised, the main

burner 1st stage BR1 (or 2nd stage BR1 + BR2 if the 2nd stage
thermostat TCH2 requires heating) starts.

BEHAVIOUR IN ABNORMAL CONDITIONS

If the flame is not detected before the end of safety time ts,
the safety control box goes to lockout and the red indicator
on the control panel lights up and remains on until it is
reset manually.

If the flame is lost during normal operation, the safety
control box automatically repeats the start-up sequence. If
the flame is not re-established then, the control box will
lockout.

RESETTING

If at lockout, the safety control box is reset by pressing the reset
button. If the first resetting does not give the expected result,
wait for at least 15 seconds before resetting once again.

Note 1
When it is started up for the first time, the safety control box
may be in safety position: press the reset button to release it.

Note 2
If the resetting button is pressed during normal operation, the
gas valves close and the safety control box starts up a new
sequence.

TCH1

BR 2

BR 1

TCH2

tvz

: Beginning of start-up operation

: Flame established at the ignition burner and

start-up of the main burner

BR1

: 1st stage

BR2

: 2nd stage

: Safety device goes to lockout because

there is no flame signal

: Ignition burner flame signal

: Ignition transformer

TCH1 : 1st stage boiler thermostat

TCH2 : 2nd stage boiler thermostat

: Safety time, max. 10 seconds

tvz

: Pre-ignition time (10 s.)

: Waiting time (5 s.)

: Alarm and safety control box lockout

indicator

: Ignition valve + safety valve VS

- Normal operating cycle

t s

TCH1

BR 2

BR 1

TCH2

Safety box output signals

Required control signal

2nd stage operation

Call for 2nd stage heating

tvz

Operating cycle (switching the safety control box

off while starting to check absence of flame signal)

CON5256

Concord ES -

Installation and Servicing

GENERAL

500

1006

100

400*

200

2200

min

1406

a =

500

1600

b=1600

CON5257

The combustion air

must reach the burner

from the front

BOILER CLEARANCES AND INSTALLATION

The figures indicate the minimum recommended
dimensions for providing easy access around the boiler.

Boiler dimensions are given in mm.

* Clearance for water connections side is 400mm.
This may be either right or left hand side.

For unassembled boiler bodies leave clearance
equal to dimensions a and b for assembly tools
(simplified JD tools for boilers with 8 to 14 sections or
JD-TE tools for boilers with 8 to 20 sections or JD-TE
Plus tools for any other model). Note: not supplied
with the boiler, contact supplier of boiler for the hire of
the same if required.

if a = 500mm ; b = 1600mm
if a = 1600mm ; b = 500mm

Multiple Boiler Installations

A clearance of 200mm must be allowed between
boilers when installed in multiple.

No. of boiler sections

A mm

970

1058

1146

1234

No. of boiler sections

A mm

1322 1498

1674

1850

No. of boiler sections

A mm

2026

Note

Please note that boilers installed in or close to rooms in which the atmosphere is polluted by chlorine of fluorine compounds may
be subject to high corrosion.

For example: hairdressing salons, industrial premises (solvents), cooling equipment, etc.

Boilers installed in such locations will not be covered by the guarantee.

Concord ES

- Installation and Servicing

INSTALLATION

ASSEMBLY

Tools required:
1

8-mm spanner

10-mm spanner

13-mm spanner

19-mm spanner

Phillips head screwdriver

* Simplified JD assembly tool (8 to 14 sections)

or 1

* JD-TE assembly tool for any model

or 1

* JD-TE Plus assembly tool for any model

* Not supplied with the boiler

Packaging: the tables below provide the numbers of the packages making up the boiler.
The packages are listed in the order in which they are to be opened during assembly

ES140/H

Type of Boiler

ES160/H ES180/H ES200/H ES220/H ES260/H ES300/H ES340/H ES380/H

GD 209

Boiler body:

GD 210

GD 211

GD 212

GD 213

GD 214

GD 215

GD 216

GD 217

- Gas train package

+ piping + base frame

+ combustion chamber

Left-hand side sect.

8358-0003
Intermediate sect.

8358-0001
Right hand side sect.

8358-0002
Set oftwo

tie rods

Package ofunassemb-

led body accessories

Draught diverter

package

Casing & insulation

package

Control panel

BOILER WITH ASSEMBLED BODY

BOILER WITH UNASSEMBLED BODY

8350-

7121

8350-

7122

8350-

7123

8350-

7124

8350-

7125

8350-

7126

8350-

7127

8350-

7128

8358-

7074

GD 12

GD 32

GD 42

GD 51

GD 13

GD 33

GD 43

GD 51

GD 14

GD 34

GD 44

GD 51

GD 15

GD 35

GD 45

GD 51

GD 16

GD 36

GD 46

GD 51

GD 17

GD 37

GD 47

GD 51

GD 18

GD 38

GD 48

GD 51

GD 19

GD 39

GD 49

GD 51

GD 20

GD 40

GD 50

GD 51

GD 2

GD 32

GD 42

GD 51

GD 3

GD 33

GD 43

GD 51

GD 4

GD 34

GD 44

GD 51

GD 5

GD 35

GD 45

GD 51

GD 6

GD 36

GD 46

GD 51

GD 7

GD 37

GD 47

GD 51

GD 8

GD 38

GD 48

GD 51

GD 9

GD 39

GD 49

GD 51

GD 10

GD 40

GD 50

GD 51

GD 209

GD 210

GD 211

GD 212

GD 213

GD 214

GD 215

GD 216

GD 217

- Gas train package

+ piping + base frame

+ combustion chamber

Draught diverter

package

Assembled boiler

body package

Casing & insulation

package

Control panel

CON5258

INST

ALLA

TION

Concord ES

- Installation and Servicing

INSTALLATION

CON5263

'°

CON5262

11 BASE FRAME

12 ASSEMBLING THE HEATING BODY

Make the base frame level in both directions and ensure a
right angle.

14 to 20 sections boilers: mount the central foot (1) on the
front of the base frame (this is only used to assemble the
sections).

The rear central foot is pre-assembled (14 to 20 sections
models).

Fix the 2 positioning brackets (2), supplied in the
accessories package, onto the base frame (on the left or
right-hand side**) using 2 H M6x25 screws.

** The side is to be determined according to the space

available in the boiler room (see Frame 7) and the
mounting direction chosen.

Put the first section (3) in place and fasten it to the brackets
(2) with 2 H8 x 30 screws + H8 nuts + M8N washers
(washers on the cast iron side).

Coat the edges of the side section or the sealing grooves
with iron putty.

Fit the nipples in the connections after having cleaned and
coated them with a lubricant.

Note: Assembled Boiler Bodies

In the case of an assembled body,
place the body on the base frame
and fasten it with the 2 squares (2),
then go to Frame 19.

INST

ALLA

TION

Concord ES -

Installation and Servicing

INSTALLATION

CON5266

19 ASSEMBLING THE PIPING

Fasten the 16 M12 studs supplied in the accessories package onto the side sections connections, taking care to screw the
short thread of the studs in the cast iron.

Fasten the flow pipe, the return pipe, the threaded flange
and the plain flange (4 H12 nuts and 1 seal for each pipe or
flange).

All hydraulic connections must be carried out on the
same side (either on the right-hand side or on the left-
hand side), but never diagonally.

The pocket must in all cases be placed on the left-hand
side of the boiler.

- If the flow and the return are on the left-hand side: put the

pocket in the flow pipe opening and the 1/2" plug in the
threaded flange.

- If the flow and return are on the right-hand side: put the

pocket in the threaded flange and the 1/2" plug in the flow
pipe opening.

CON5267

Flow and return pipes mounted on the

left-hand side of the boiler

Flow and return pipes mounted on the

right-hand side of the boiler

18 SYSTEM CONNECTIONS

INST

ALLA

TION

Concord ES

- Installation and Servicing

INSTALLATION

CON5280

32 FITTING THE PROBES

Unreel the flexible ionisation probe cable (5)
and push through opening (6) located in the
lower part of the control panel.

Push the capillaries (7) of the thermostats,
the thermometer and the probe through
opening (8).

Caution:

The non-insulated parts of the capillaries must
be located outside of the panel.

Combine the 4 capillaries and fit the probes
in pocket (9), taking care to push them to the
bottom.

Electrical Connections:

Complete the various electrical connections
of the control panel (see technical
instructions Frame 39).

Put the retaining spring (10) in place.

Close the control panel.

33 ASSEMBLING THE LEFT-HAND SIDE PANEL

CON5281

Put the left-hand side panel (1) on
the side angle bars of the base
frame inserting the openings on the
bushes, then lock pushing the panel
backward.

Fasten it on the front support with 1
screw (2) + serrated washer, and on
the stiffener (3) with a self tapping
screw (4).

After adjusting the side panels,
tighten the screws fastening the
stiffener (see Frame 21).

INST

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TION

Concord ES -

Installation and Servicing

INSTALLATION

39 ELECTRICAL CONNECTIONS

The electrical wiring has been thoroughly checked
in the factory and the internal connections of the
control panel must in no case be modified.

The electrical connections shall be made in compliance with
the instructions given in the electrical diagrams supplied with
the boiler and the guidelines provided in the manual. The
electrical connection must comply with the standards in force.

Connection must be made in a way that allows complete
isolation of the electrical supply - such as a double pole
switch, having a 3mm (1/8") contact separation in both poles,
or a plug and socket serving only the boiler and system
controls. The means of isolation must be accessible to the
user after installation.

CON5287

50H

- T

IMENT

ATIO

STR

FÜHR

IN S

POMPE

E R

ECYCLA

KESSELKRE

PUMPE

SHUNT

UMP

Y A

ALA

E T

LAR

MLEUC

LAR

DIC

ATO

Y ANT

LARME

LAR

UCHTE

VANNE

URIT

SIC

HER

HEIT

SVE

NTIL

CONT

T D

E S

ECUR

SIC

RHE

ONT

ACT

CON5288

x
0,75 mm

mini.

x
0,75 mm

mini.

ALI

230V 50Hz

VA-TS

N L

Heating

pump

230V

Main supply

CON5289

All the connections shall be made to the terminal block
provided for that purpose in the boiler control panel.

Proceed as follows to open the control panel (if required):

1. Remove the boiler top panel.

2. Unhook the intermediate front panel.

3. Remove the upper front panel.

4. Remove the connection board cover.

5. After removing the 4 fastening screws, tilt the front cover to

open the control panel.

6. Fasten the cables to the board supporting plate using cable

clamps (6 cable clamps supplied in a bag) that are to be
assembled as shown opposite.

Make the connections
as shown opposite.

Note

If switched mains supply is
used, then the pump overrun
must be provided by an
external timer to the boiler.

INST

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TION

Concord ES

- Installation and Servicing

INSTALLATION

CON5290

1. 3-Position Switch

Auto / Manual / TEST STB

MANUAL : manual position. It is regulated by the boiler
thermostats (item 5).

The switch may be left either manual or automatic AUTO
position.

TEST STB: momentary action for testing the safety
thermostat:
Press the TEST STB switch and place the pump cut-off
switch (2) to the "Summer" position.

2. Double switch Burner / Heating pump:

This switch controls the burner and the heating pump.

In the "Winter" position, both heating and domestic hot
water are operating.

In the "Summer" position, only domestic hot water is
operating (if a domestic hot water tank is connected).

3. Main On / Off switch.

4. Locations for hour run meters

for the first and the second stages (optional package IC8)

5. Boiler thermostats (40º to 90ºC):

A factory-mounted stop limits the maximum temperature to
75ºC. This stop may be moved if necessary (see Frame
50).

6. Stage 1 or stage 2 operation indicators:

They only light up when the relevant thermostat require
heating and the safety contact is closed.

7. Boiler thermometer

8. Location for flue gas thermometer

(Optional package ID 28)

9. Safety thermostat with manual reset

(cut-off temperature: 110ºC)

10. 4 A circuit-breaker

time-delay circuit-breaker with manual reset.

13. Switch selecting the number of stages of the burner.

14. Burner alarm indicator and reset switch.

CONTROL PANEL DESCRIPTION

40 CONTROL PANEL DESCRIPTION

41 CONNECTING THE SAFETY THERMOSTAT ALARM INDICATOR

ALI

230V 50Hz

VA-TS

N L

x
0,75 mm

mini.

alarm indicator

CON5292

A remote alarm to indicate overheat may be wired as
shown. This will be mains voltage.

INST

ALLA

TION

Concord ES -

Installation and Servicing

INSTALLATION

42 CONNECTING THE OPTIONAL FLUE GAS THERMOMETER KIT (Package ID 28)

An optional flue gas thermometer may be fitted to the front of
the control panel.

Proceed as follows:

Cut the cover off with a knife along the edges of the
coloured rectangle.

Clip the thermometer into the opening.

Bring the sensor to the back of the boiler via the cable
channel and insert it in the flue gas pipe.

CON5291

43 CONNECTING THE OPTIONAL HOUR RUN METER(S) KIT (Package IC 8)

One or two optional hour run meters (stages 1 and 2) may be
fitted to the front of the control panel.

Proceed as follows:

Cut the cover off with a knife along the edges of the
coloured rectangle.

Pull out the 2 wires prepared in the control panel.

Connect the wires to the hour run meter (the wires are
interchangeable).

Clip the hour run meter into the control panel.

If the burner used is a two-stage burner, the counters display
the operating time of each stage.

CON5293

INST

ALLA

TION

Concord ES

- Installation and Servicing

INSTALLATION

44 ELECTRICAL DIAGRAMS

SCHEMATIC DIAGRAM

A P2 B BA BPR-V

CH1 CH2 CS DJ4A ECS FF PSG RG SCS S1

LOAD PUMP

SHUNT

PUMP

BURNER

CONNECTING BOARD

BURNER RESET

BUTT

AND

ALARM INDICA

HOUR RUN METER 1st ST

AGE (OPTIONAL)

HOUR RUN METER 2nd ST

AGE (OPTIONAL)

SAFETY

CONT

ACT

CIRCUIT

BREAKER

DOMESTIC HOT

TER

EEU SUPRESSOR

GAS PRESSURE SWITCH

REGULA

SAFETY

CONTROL

BOX

IONISA

TION PROBE

TA TCH1 TCH2 TS VA VA

-
T
S

VB1 VB2 VG VP ZB ZB1 ZG ZI

IGNITION TRANSFORMER

BOILER THERMOST

1st

AGE

BOILER THERMOST

2nd

AGE

SAFETY

THERMOST

ALARM INDICA

SAFETY

THERMOSTT

ALARM

INDICA

ON/OFF INDICA

OR 1st ST

AGE

ON/OFF INDICA

OR 2nd ST

AGE

GAS V

L
V

MAIN GAS V

L
V

BURNER SWITCH

SUMMER-WINTER SWITCH

MAIN SWITCH

TEST

SWITCH

CON8135

ECS

Ä P2
Ä P2
Ä P2
Ä P2

Ä A
Ä A
Ä A
Ä A

ECS

V
A-T

ZEH

DJ4

T
CH2

T
CH1

I
7

BPR-V

ECS

PSG

SU2

VB1

VB2

CH2

CH1

CS
CS
CS
CS

Ä A

INST

ALLA

TION

Concord ES -

Installation and Servicing

INSTALLATION

GAS CONNECTIONS

Gas connections can be carried out either on the left-hand
side or on the right-hand side of the boiler.
Gas connections shall be in compliance with applicable
regulations and standards.
In all cases a shut-off valve shall be located as close to the
boiler as possible.

46 FLUE CONNECTION

1. Complete the flue connection.

2. Details of flue outlet sizes are given in Table 2.

3. Seal with an approved boiler putty.

47 COMMISSIONING AND TESTING

GENERAL

Check that all drain cocks are closed, that any stop valves fitted
to the flow and return pipes are open and that the system has
been filled and properly vented.

PURGING

Check that the electricity supply is switched OFF.
Remove the casing lower front panel.
Extinguish all naked lights and open all doors and windows.
DO NOT SMOKE. Check that the gas supply is turned ON at the
meter and open the main gas inlet cock. Loosen the union
and allow air to be purged from the gas line until gas is
smelled. Refer to BS 6891 or IGE-UP-1 for further details.
Retighten the union .

TESTING FOR GAS SOUNDNESS

Close the gas supply cock at the meter.

Connect a gas pressure gauge to the inlet test point. Take
particular care to ensure a gas-tight connection. Open the gas
supply cock at the meter and the appliance gas cock; record the
static pressure. Next, close the gas supply cock at the meter.
Wait for 1 minute for temperature stabilisation then observe the
pressure gauge over a period of 2 minutes.

Any leaks must be cured.

Replace all pressure test point screws.

4 3 2

80+

50+

75+

30-

35-

40-

45-

50-

90+

70+

CON5299

49 MOVING THE THERMOSTAT STOP

The stop is factory-set to limit the maximum
temperature to 75ºC. To move the stop, proceed as
follows:

Pull the thermostat button out.

Remove the stop using pliers.

Place the stop in the hole corresponding to the
desired higher temperature (maximum 90ºC).

48 INITIAL LIGHTING

Before turning the boiler on, make sure that the installation is
filled with water.

Carry out the start-up operations in the order indicated below:
Refer to Frame 40 for identification.

Open the main gas shut-off valve.

Check the position of the 3-position switch 1.

- it may be either on the manual or on the automatic

AUTO position.

Set the Summer / Winter switch 2 to the "Winter" position.

Switch on the electrical supply to the boiler.

Set all the controls (thermostats 5, external controls etc.) so
that heat is required.

The 1st stage thermostat always must be set to a value
approximately 5ºC higher than the 2nd stage thermostat.

Set the On / Off switch 3 to the "On" position.

The boiler will light and thermostat indicator light (6) will
illuminate. If it does not light the burner indicator (14) will be
illuminated. Press in and release the reset switch (14). The
controls will reset and attempt to light.

Check all connections for gas soundness, using leak
detection fluid.

INST

ALLA

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Concord ES

- Installation and Servicing

INSTALLATION

50 SETTING PROCEDURE (all boilers)

CON5295

CON5296

CON5297

1. Adjusting the 2nd stage pressure:

Connect the pressure gauge to the manifold pressure tapping.

Operate the boiler at the 2nd stage acting upon the thermostat(s).

Adjust the burner injector pressure indicated in Table 1 as follows:

· unscrew the slotted head screw C by approximately one turn and

unscrew completely the adjusting knob D (turning it counter-
clockwise), then tighten again screw C.

· adjust the injector pressure adjustment screw B of the regulator.

Clockwise rotation increases the pressure, counter-clockwise
rotation decreases it.

2. Adjusting the 1st stage pressure:

Operate the boiler at the 1st stage acting upon the burner
operation selecting switch located on the boiler control panel.

Adjust the flow in order to obtain the injector pressure indicated in
Table 1 (0.5 x the 2nd stage pressure) as follows:

Adjust the 1st stage flow with the help of ring E. Clockwise rotation
decreases the pressure. Counter-clockwise rotation increases
the pressure

Tighten locking screw C.

3. Adjusting the starting rate (or initial flow):

Start rate is factory-set to the minimum (9 mb starting pressure).

Depending on the installation conditions, one may adjust the start rate
setting in order to ensure an optimal start of the boiler. The maximum
permissible is 12 mb.

Proceed as follows:

Unscrew protection cap G, turn it over and use it as a key to turn
adjusting spindle H until obtaining the initial flow required.

Counter-clockwise rotation increases the initial flow, clockwise rotation
decreases it.

After adjustment, put cap G back in place.

51 CHECKING GAS PRESSURE SWITCH

The minimum gas pressure switch fitted on the gas valve is
factory set to 12.5 mbar. If the gas supply pressure drops,
the minimum pressure switch turns the boiler off.

52 SPILLAGE CHECK

Check there is no spillage of combustion products from the
boiler draught diverter by carrying out a spillage test, as
detailed in BS. 5440:1.

INST

ALLA

TION

Concord ES -

Installation and Servicing

SERVICING

53 SERVICING

(to be performed by a CORGI registered installer)

The burner and the heat exchanger must be cleaned regularly in order to ensure their efficiency.

Cleaning is recommended at least once a year or more if necessary.

WARNING
Always turn OFF the gas supply at the gas cock and disconnect the electricity supply to the appliance BEFORE
servicing or replacing any components.

drawer

CON5300

54 CLEANING THE BURNER

Removing the burner:

Disconnect the power supply to the boiler.

Isolate the gas supply.

Remove the lower boiler panel 1.

Remove the intermediate boiler panel 2.

Disconnect gas valve connector 3 and gas pressure switch
connector 4 located under the control panel.

Disconnect ignition transformer circuit 5.

Disconnect ionisation cable 6 as well as the earthing wire
on the ionisation probe side.

Unscrew the pipe union 7 on the gas inlet pipe.

Unscrew the 4 burner drawer fastening nuts 8.

Remove the burner drawer 9.

Cleaning the main burner:

Clean the burner rails (slots) using a soft brush or a vacuum
cleaner.

Cleaning the ignition burner:

Disconnect the ignition burner gas supply pipe 10 using a
13mm spanner.

Clean injector 11, ignition burner 12 and flame tube 13
located inside the ignition burner.

DO NOT USE A METAL BRUSH

SER

VICING