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Installation & Servicing

GENERAL

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.

Table 1 Performance Data

Boiler

F80

F120

F160

F200

F240

F280

Boiler output

Max

77.9

116.9

155.8

195.4

234.5

273.6

(non-condensing)

Btu/h

265,800

398,900

531,600

666,700

800,100

933,500

Mean 70

Min

23.3

29.1

43.1

47.0

51.0

Btu/h

79,500

99,300

147,050

160,350

174,000

Boiler output

Max

82.2

123.4

164.5

207.8

249.4

290.9

(condensing)

Btu/h

280,450

421,050

561,250

709,000

850,950

992,550

Mean 40

Min

25.8

32.3

47.3

51.6

55.9

Btu/h

88,000

110,200

161,400

176,050

190,750

Boiler Input

Net

120

160

200

240

280

Max Rate

Btu/h

272,950

409,450

545,900

682,400

818,900

955,350

Gross

88.8

133.3

177.7

222.1

266.5

310.9

Btu/h

303,000

454,800

606,300

757,800

909,300

1,060,800

Boiler Input

Net

Min Rate

Btu/h

81,900

102,350

150,150

163,800

177,400

Gross

26.6

33.3

48.9

53.3

57.7

Btu/h

90,750

113,600

166,850

181,850

196,850

Maximum Gas Rate

8.1

12.1

16.1

20.1

24.2

28.2

286

427

569

710

855

996

Approx. flue gas

@ max. rate m

121

182

242

302

363

423

volume (@80

C) i.e. non-condensing ft

4,270

6,410

8,550

10,690

12,820

14,960

Max. Flue Resistance

100

150

Flue Gas CO

@ Max Rate

9.3/9.8

G20/LNG @ Min. Rate

9.1/9.6

NOx with O

= 0% mg/kWh

ppm

Seasonal Boiler Efficiency (Building Regs L2)

95.1

95.2

Note.
Natural gas consumption is calculated using a calorific value of
37.8MJ/m

(1038Btu/ft

) gross or 34 MJ/m

(910 Btu/ft

) nett at

C and 1013.25 mbar.

a. For l/s divide the gross heat input (kW) by the gross C.V. of

the gas (MJ/m

)

b. For ft/h

divide the gross heat input (Btu/h) by the gross C.V.

of the gas (Btu/ft

HEALTH & SAFETY DOCUMENT NO. 635

The electricity at work regulations, 1989. The manufacturer's
notes must NOT be taken, in any way, as overriding statutory
obligations.

IMPORTANT. These appliances are CE certified for safety and
performance. It is, therefore, important that no external control
devices, e.g. flue dampers, economisers etc., are directly
connected to these appliances unless covered by these
Installation and Servicing Instructions or as 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 and the
normal appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.

* Electricity supply and Fuse rating for pumps etc. refer to manufacturer's instructions.

Table 2 General Data

Boiler

F80

F120

F160

F200

F240

F280

Gas supply

2H - G20 - 20mbar

Gas supply connection

R (in. BSP)

Flow connection

R (in. BSP)

Return connection

R (in. BSP)

Hydraulic Resistance @ 20

mbar

100

105

Max Press (sealed system)

bar (psi)

6 (87)

Maximum Static Head

m (ft)

61 (200)

Boiler Electricity Supply

230V - 50Hz

Boiler Fuse Rating

External: 3A* Internal: 2AT, 4AT

External: 5A* Internal: 2AT, 4AT

Power Consumption (boiler only)

250

400

Air Inlet

O/D

m m

110

Flue Size dia

m m

150

200

Condensate drain

m m

21.5

Boiler dry weight (unpacked)

kg (lb)

132 (291)

150 (331)

168 (370)

198 (437)

215 (474)

233 (514)

Water Content

l (gal)

11.0 (2.4)

14.3 (3.2)

17.5 (3.9)

18.4 (4.1)

24.0 (5.3)

27.2 (6.0)

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GENERAL

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CONTENTS

Boiler Assembly - exploded view. .................................. 10

Boiler Clearances. ............................................................ 8

Boiler Dimensions. ........................................................... 7

Commissioning and Testing. ......................................... 31

Electrical Connections. .................................................. 13

Electrical Supply. .............................................................. 6

Fault Finding. ................................................................... 42

Flue Installation. ................................................................ 5

Gas Safety Regulations .................................................... 4

Gas Supply. ........................................................................ 4

Hydraulic Resistance. ...................................................... 2

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

Installation. ...................................................................... 10

Locating/Levelling the Boiler. ......................................... 11

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

Performance Data. ........................................................... 2

Servicing. ........................................................................ 32

Short List of Parts. ......................................................... 45

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

Water Circulation. ............................................................ 5

Water Connections. ......................................................... 7

Water System Requirements. ......................................... 9

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

Wiring Diagrams. ............................................................ 16

Natural Gas only
PI No. 0063 BR 3123
Destination Countries: GB,IE

Key to symbols
IE = Ireland, GB = United Kingdom (Countries of destination)
PMS =

Maximum operating pressure of water

C53 =

A room sealed appliance which is connected
via its separate ducts to two terminals that
may terminate in zones of different pressure.

C63 =

A room sealed appliance intended to be
connected to a separately approved and
marketed system for the supply of
combustion air and discharge of combustion
products. The fan is up stream of the
combustion chamber.

B23 =

An appliance intended to be connected to a
flue which evacuates the products of
combustion to the outside of the room
containing the boiler. The combustion air is
drawn directly from the room. The fan is up
stream of the combustion chamber.

NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.

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Installation & Servicing

GENERAL

INTRODUCTION

The

xtra

boilers are fully automatically controlled, floor

standing, fanned, super efficient condensing appliances.
The comprehensive boiler controls built into the appliance
include:

Volt free 'alarm' contacts (lockout)

Volt free 'boiler run' contacts

Burner hours run meters

System temperatures

The boilers can draw their combustion air from the room or via
ducting from outside.
Through a sophisticated control system combined with premix
burner technology and an aluminium heat exchanger, the boilers
are capable of high operating efficiencies of 93% (gross) and
low emissions.
These boilers are certified to meet the requirements of the EC
Gas Appliance Directive, Boiler Efficiency Directive, EMC and
Low Voltage Directive.

OPTIONAL EXTRA KITS

BMS (0-10V) Kit

Control Interface Kit

DHW Sensor Kit

Modulating Sequencer Kit

Outside Sensor Kit

Room Sensor Kit

Tank Sensor Kit

SAFETY

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

The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI
Registered Installer or in IE by a competent person. It must be
carried out in accordance with the relevant requirements of the:
·

Gas Safety (Installation and Use) Regulations

The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).

The Water Fittings Regulations or Water byelaws in
Scotland.

The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a Competent Person
and installed in accordance with the current Building
Regulations and reference should be made to the current ETCI
rules for electrical installation.
The boilers have been tested and certified by Gastec to EN483
and EN677 for use with Natural Gas.

Detailed recommendations are contained in the following
Standards and Codes of Practice:
BS. 5854

Flue and flue Structures in Buildings.

BS. 6644

Installation of gas fired hot water boilers of
rated inputs between 70kW and 1.8MW (net)
(2nd and 3rd family gases).

BS. 6880

Low temperature hot water heating systems of
output greater than 45kW.

Part 1

Fundamental and design considerations.

Part 2

Selection of equipment.

Part 3

Installation, commissioning and maintenance.

IGE/UP/1

Soundness testing and purging of industrial
and commercial gas installations.

IGE/UP/2

Gas installation pipework, boosters and
compressors on industrial and commercial
premises.

IGE/UP/10

Installation of gas appliances in industrial and
commercial premises.

SAFE HANDLING OF SUBSTANCES

No asbestos, mercury or CFCs are included in any part of the
boiler or its manufacture.

FOUNDATION / LOCATION OF BOILER

The boiler must stand on a floor 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.
Ideally the boiler should be placed on a plinth exceeding the

plan area of the boiler by 75mm on each side and at least

100mm high.
The boiler must not be fitted outside.

GAS SUPPLY

The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an
adequate supply of gas. An existing service pipe must NOT be
used without prior consultation with the local gas supplier.
A gas meter can only be connected by the local gas supplier or
by a registered CORGI engineer or in IE by a competent person.
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the
rate of gas supply required. A minimum working gas pressure
of 15mbar MUST be available at the boiler inlet for Natural gas.
Do not use pipes of smaller size than the boiler inlet gas
connection.
The complete installation MUST be tested for gas soundness
and purged in accordance with the appropriate standards.
Gas Boosters
A gas booster is required if the gas pressure available at the

boiler is lower than that required by the boiler manufacturer to

attain the flow rate for maximum burner input rating.
Location of the booster requires careful consideration but

should preferably be closer to the burner rather than the gas
meter. Ventilation should also be considered to ensure ambient
temperature do not exceed designed recommendations.
Further guidance is provided in IGE/UP/2.

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Installation & Servicing

GENERAL

FLUE INSTALLATION

IMPORTANT. It is the responsibility of the installer to ensure, in

practice, that products of combustion discharging from the

terminal cannot re-enter the building or any other adjacent

building through ventilators, windows, doors, other sources of

natural air infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be isolated from the

gas supply and labelled as 'unsafe' until corrective action can be

taken.
Terminal Position
Due to the high efficiency of the boilers pluming will occur.

Vertical termination is recommended and terminal positions

which could cause problems should be avoided. Particular care

should be taken in the case of large output boiler installations,

and complying with the requirements of the Clean Air Act.
The flue must be installed in accordance with the appropriate

Building Regulations and standards listed on page 4 and in

compliance with BS6644. In IE refer to I.S.820:2000.

FLUE SYSTEM DESIGN

Due to the high efficiency of these boilers, the flue gas

temperatures are low and the buoyancy in the stack will be

relatively small. The boiler is supplied with an integral fan which

is fully matched to the boiler in each case to provide correct

combustion air flow and overcome the flue resistance.
The power of this fan is such that there is a large reserve of

pressure available to overcome a significant length of flue

without affecting the combustion performance of the boiler. The

maximum pressure available at the base of the flue to overcome

flue resistance is 100Pa (0.4" w.g.) for F80 and F120, and 150Pa

(0.6" w.g.) for F160, F200, F240 and F280. This includes the

resistance of any air ducts used to connect the air inlet direct to

outside air. Care should be taken with tall flue systems to

ensure excess buoyancy is not created. A negative pressure

must not be created at the boiler flue outlet.
See table below for approximate maximum straight flue lengths.

The addition of elbows and their positions in the flue will have a

significant effect on the maximum flue length. Consult with your
flue supplier for detailed design work.

Boiler

F80

F120

F160

F200

F240

F280

Flue Size (mm) Ø150

Ø150

Ø200

Approx. max.
Straight Flue

240

109

100

256

180

138

Length (m)

Material
With no requirement for buoyancy to discharge flue products and
with low flue gas temperatures, single wall flues are suitable for
most installations. Care should still be taken to maintain
compliance with building regulations and relevant standards.
The type of flue pipe used should be aluminium, 316 grade
Stainless Steel or be of equivalent corrosion resistance unless
the flue is manufactured from aluminium, the condensate
from the flue must be collected and drained before entering
the sump of the boiler. Advice regarding the availability of
proprietary types of flue system can be obtained by contacting
Caradon Ideal Limited. All joints or connections in the flue
system must be impervious to condensate leakage. Low points
in the flue system should be drained using pipe of material
resistant to condensate corrosion. All drains in the flue should
incorporate a water trap.
Care should also be taken in the selection of flue terminals as
these tend to accentuate the formation of a plume and could
freeze in cold weather conditions.
Care should be taken to ensure the specification of the chimney
is suitable for the application by reference to the manufacturers
literature.

WATER CIRCULATION SYSTEM

A circulation pump MUST be connected to the boiler, see below.
The boiler must NOT be used for direct hot water supply. The hot
water storage cylinder MUST be of the indirect type.
Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.

The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat loss
and any possible freezing - particularly where pipes run through
roof spaces and ventilated underfloor spaces.

The boiler must be vented. There must be no low points
between the boiler flow connection and a system vent point,
which should be positioned as close as practically possible to
the boiler flow connection.
Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler and
hot water storage vessel. They should be at least 1/2" BSP
nominal size and be in accordance with BS. 2879. Do not use
the boiler drain tap to drain the system as this can induce sludge
into the heat exchanger.
The central heating system should be in accordance with the
relevant standards listed on page 4.
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 overheating. In
order to allow pump operation after burner shutdown the boiler
control box incorporates a 5 minute pump overrun facility. In
order to make use of this, a pump must be supplied from the
terminals inside the boiler. Note: for pumps requiring greater
than 1.0 amp current, they must be connected via a relay.
When sizing pumps, reference should be made to the Hydraulic
Resistandce Table on page 6 which show the boiler resistance
against flow rates, to achieve the required temperature
differential.
Flow rates for common systems using either 11

C or 20

temperature differentials are given in the table below.

Water flow rate temp.

difference 11

C (20

difference 20

C (36

l/s

F80

1.78

6.41

0.98

3.53

F120

2.68

9.65

1.47

5.3

F160

3.57

12.85

1.96

7.06

F200

4.51

16.24

2.48

8.93

F240

5.42

19.51

2.98

10.73

F280

6.32

22.75

3.47

12.49

Note.
·

With the boiler firing at maximum rate, the temperature
differential should not be less than 10

C. High flow rates

required for lower temperature differentials could lead to
erosion of the heat exchanger water ways.

With the boiler firing at minimum rate, the temperature
differential should not be greater than 35

C. Lower flow rates

generating higher temperature differentials will lead to lock
out of the boiler.

The lower the return temperature to the boiler, the higher the
efficiency. At return temperatures of 55

C and below, the

difference becomes marked because the water in the flue
gases starts to condense, releasing its latent heat.

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GENERAL

In installations where all radiators have been provided with
thermostatic radiator valves, it is essential that water circulation
through the boiler is guaranteed. A mixing header will perform
this task. Alternatively this can be best achieved by means of a
differential pressure valve, which is installed in a bypass
between the flow and return pipes. The bypass should be fitted
at least 6m from the boiler, and should be capable of allowing a
minimum flow rate to achieve a temperature differential of no
greater than 35

C at minimum rate.

WATER TREATMENT

These boilers incorporate an ALUMINIUM heat exchanger.
IMPORTANT. The application of any other treatment to this
product may render the guarantee of Caradon Ideal Limited
INVALID.
Caradon Ideal Limited recommend Water Treatment in
accordance with Guidance Notes on Water Treatment in Central
Heating Systems.
Caradon Ideal Limited recommend the use of Fernox Copal or
MB1 or GE Betz Sentinel X100 inhibitors and associated water
treatment products, which must be used in accordance with the
manufacturers' instructions.
For further information contact:
Fernox Manufacturing Co. Ltd., Cookson Electronics,
Forsyth Road, Sheerwater, Woking, Surrey, GU21 5RZ
Tel: +44 (0) 1799 521133

G E Betz Ltd., Sentinel Division, Foundry Lane, Widnes,
Cheshire, WA8 8UD
Tel: +44 (0) 151 424 5351

Notes.
1. It is most important that the correct concentration of the water

treatment products is maintained in accordance with the
manufacturers' instructions.

2. If the boiler is installed in an existing system any unsuitable

additives MUST be removed by thorough cleansing.

3. In hard water areas, treatment to prevent limescale may be

necessary - however the use of artificially softened water is
NOT permitted.

4. Under no circumstances should the boiler be fired before

the system has been thoroughly flushed.

ELECTRICAL SUPPLY

WARNING. This appliance must be earthed.
Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS7671) Wiring Regulations and any local
regulations which apply. For Ireland reference should be made
to the current ETCI rules for electrical installations.
The point of connection to the mains should be readily
accessible and adjacent to the boiler.

CONDENSATE DRAIN

A condensate drain is provided on the boiler. This drain must
be connected to a drainage point on site. All pipework and
fittings in the condensate drainage system MUST be made of
plastic - no other materials may be used.
IMPORTANT. Any external runs must be insulated to avoid
freezing in cold weather causing blocking.

Boiler

Pressure Drop (mbar) @ 20

Pressure Drop (mbar) @ 11

280

105

347

240

100

330

200

314

160

297

120

281

264

HYDRAULIC RESISTANCE

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Installation & Servicing

GENERAL

VENTILATION

The ventilation requirements of these boilers are dependant
on the type of flue system used, and their heat input. All vents
must be permanent with no means of closing, and positioned
to avoid accidental obstructions by blocking or flooding.
Detail reference should be made to BS. 6644 for inputs
between 70kW and 1.8MW (net). In IE refer to the current
edition of I.S.820. The following notes are for general
guidance only:
Dust contamination in the combustion air may cause blockage
of the burner slots. Unless the boiler room provides a dust
free environment then direct connection of the air intake via
ducting to clean outside air should be used.
The temperature within a boiler room shall not exceed 25

within 100 mm of the floor, 32

C at mid height and 40

C within

100 mm of the ceiling.

Open Flued Installations
If ventilation is to be provided by means of permanent high and
low vents communicating direct with outside air, then reference
can be made to the sizes below. For other ventilation options
refer to BS. 6644. In IE refer to the current edition of I.S.820.

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).

Room Sealed Installations
A minimum of 2cm

free area per kW of net heat input at both

high and low level is required for boiler rooms. For enclosures
refer to BS6644.

BOILER CLEARANCES

The minimum dimensions as indicated must be respected
to ensure good access around the boiler.
Recommended minimum clearances are as follows.

Rear:
700mm or adequate space from the rear of the jacket to
make the flue connections and access to the flue sample
point, drain connection, flue and any safety or control devices.

Left Side:
450mm

Right Side:
150mm

Front:
600mm; except, access doors may be closer, but not
less than 200mm and 600mm must still be available
for service across the width of the boiler.
Top:
500mm.

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Installation & Servicing

GENERAL

Rated output

Minimum bore

Nominal Size (DN)

m m

61 to 150

151 to 300

'Steel pipe sizes complying with medium or heavy quality or BS 1387.

Detail reference should be made to the appropriate standards listed on
page 4.
The information and guidance given below is not intended to override any
requirements of the above publications or the requirements of the local
authority, gas or water undertakings.
The vertical distance between the pump and feed/expansion cistern MUST
comply with the pump manufacturer's minimum requirements, to avoid
cavitation. Should these conditions not apply either lower the pump
position or raise the cistern above the minimum requirement specified by
Caradon Ideal Limited. The isolation valves should be fitted as close to
the pump as possible.
The information provided is based on the following assumptions:
1. An independent open vent/safety pipe connection is made immediately

after the system flow pipe connection.

2. An independent cold feed/expansion pipe connection is made

immediately after the open vent/safety pipe connection.

3. The maximum flow rate through the boiler is based on a temperature

difference of 11

C at full boiler output.

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.

6. Both open vent/safety pipe and cold feed/expansion pipes must be of

adequate diameter to suit the output of the boiler. Refer to Tables
below.

OPEN VENTED SYSTEM REQUIREMENTS

Note.
·

With a cold feed head of <8m, the pump
must be fitted on the return to the boiler.

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

SEALED SYSTEM REQUIREMENTS

Open Vent Pipe Sizes

Rated output

Minimum bore

Nominal Size (DN)

m m

60 to 150

151 to 300

'Steel pipe sizes complying with medium or heavy quality or BS 1387.

Cold Feed Pipe Sizes

Note. Refer to Frame 22 for typical system arrangements.

Feed/expansion

cistern

Open vent
safety pipe

3 m
minimum
see notes

System
flow

Shunt Pump

(if required)

Inverted

cold feed

entry

Cold

Feed

Water

level

(cold)

Open vent

System
return

im8250

Connections

to boiler

Working pressure 6 bar maximum.
Particular reference should be made to BS. 6644 and
Guidance note PM5 "Automatically controlled steam and hot
water boilers" published by the Health and Safety Executive.
The information and guidance given below is not intended to
override any requirements of either of the above publications or
the requirements of the local authority, gas or water
undertakings.
In general commercial closed pressurised systems are
provided with either manual or automatic water make up.
In both instances it will be necessary to fit automatic controls
intended to protect the boiler, circulating system and ancillary
equipment by shutting down the boiler plant if a potentially
hazardous situation should arise.
Examples of such situations are low water level and operating
pressure or excessive pressure within the system. Depending
on circumstances, controls will need to be either manual or
automatic reset. In the event of a shutdown both visual and
audible alarms may be necessary.

Expansion vessels used must comply with BS. 4814 and must
be sized on the basis of the total system volume and initial
charge pressure.
Initial minimum charge pressure should not be less than 0.5
bar (7.2psi) and must take account of 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
0.35bar (5psi) of the safety valve setting.
Other British Standards applicable to commercial sealed
systems are:
BS. 6880: Part 2
BS. 1212
BS. 6281: Part 1
BS. 6282: Part 1
BS. 6283: Part 4

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