C:\Caradon\idealcommercialboilers\current\docs\html\vanguard_l

Vanguard L -

Installation & Servicing

GENERAL

Note.

Fuel rates and flue gas data relate to maximum output ratings.
Gas firing data relates to the use of NATURAL GAS ONLY.
Details for the use of LPG are available on request from Caradon
Ideal Ltd.
Natural gas consumption is calculated using a calorific value of
38.7MJ/m

(1038Btu/ft

) gross or 34.9MJ/m

(935Btu/ft

) nett at

15ºC and 1013.25mbar.

Table 1 Performance Data

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.

Boiler Size

170

240

290

340

420

510

630

760

870

970

1100 1320

1570

1850

2200

2650

3000

3500

Maximum Heat Output

170

240

290

340

420

510

630

760

870

970

1100 1320

1570

1850

2200

2650

3000

3500

Btu/hx10

580

819

990

1160 1433 1740

2150

2593 2969

3301 3753 4504

5357

6312

7507

9042

10236 11942

Minimum Heat Output

130

180

220

255

315

385

480

580

660

750

860

1000

1200

1400

1700

2000

2300

2700

Btu/hx10

444

614

751

870

1075 1314

1638

1980 2252

2559 2934 3412

4095

4777

5800

6824

7848

9212

Hydraulic resistance 11K

mbar 27.5

60.4

38.4 51.2

31.1

45.8

69.5

47.6

60.4

75.0

54.9

64.1

60.4

82.4

62.2

87.9

113.5 153.7

in wg 11.0

24.2

15.4 20.5

12.4

18.3

27.8

19.0

24.2

30.0

22.0

25.6

24.2

32.9

24.9

35.1

45.4

61.5

Hydraulic resistance 20K

mbar

8.3

18.3

11.6

15.5

9.4

13.8

21.0

14.4

18.3

22.7

16.6

19.4

18.3

24.9

18.8

26.6

34.3

46.5

in wg

3.3

7.3

4.7

6.2

3.8

5.5

8.4

5.8

7.3

9.1

6.6

7.8

7.3

10.0

7.5

10.6

13.7

18.6

Combustion chamber

mm w.g.

resistance (at zero draught)

in w.g. 0.59

1.06

0.87 1.18

1.10

1.65

1.81

1.38

1.81

2.24

1.65

2.36

1.93

2.68

2.04

2.99

2.36

3.07

Flow connection

(T1) DN PN6

100

125

150

175

200

Return connection

(T2) DN PN6

100

125

150

175

200

Max. operating pressure

bar

Max. boiler therm. setting

ºC 50-90 50-90 50-90 50-90 50-90 50-90 50-90

50-90 50-90

50-90 50-90 50-90

50-90 50-90 50-90 50-90

50-90 50-90

Safety thermostat setting

ºC

100

High-low setting

ºC 44-84 44-84 44-84 44-84 44-84 44-84 44-84

44-84 44-84

44-84 44-84 44-84

44-84 44-84 44-84 44-84

44-84 44-84

Min. draught at smokehood

mbar

0.0

outlet (for max. output)

in w.g.

0.0

Safety valve & expansion

(T3) BSP/DN PN6 1

100

125

Drain

(T4) in

3/4

Flue outlet

(T5) mm

200

250

350

400

450

520

570

620

7.8

9.8

13.8

15.7

17.7

20.5

22.4

24.4

Boiler water content

190

251

264

298

398

462

565

671

753

836

1040 1242

1418

1617

2086

2324

2553

4862

gal 41.8

55.2

58.1 65.6

87.5 101.6 124.3

147.6 165.6

183.9 228.8 273.2

311.9 355.7 458.9 511.2

561.6 1069.6

Boiler DRY weight less

435

510

588

629

796

919

1047

1341 1447

1553 1821 2030

2780

3280

4145

4465

5110

6700

burner unit

959

1124 1296 1387 1755 2026

2313

2956 3190

3424 4015 4475

6129

7231

9138

9844

11266 14771

Boiler Size

170

240

290

340

420

510

630

760

870

970

1100 1320

1570

1850

2200

2650

3000

3500

Maximum oil rate

l/h

19.1

27.0

32.5 38.1

47.1

57.2

70.8

85.2

97.4

108.6 123.2 147.9

176.0 207.4 247.1 297.3

336.6 393.1

gal/h

4.2

5.9

7.2

8.4

10.4

12.6

15.6

18.7

21.4

23.9

27.1

32.5

38.7

45.6

54.4

65.4

74.0

86.5

Maximum flue

/sec

0.10

0.14

0.17 0.20

0.25

0.31

0.37

0.44

0.52

0.56

0.64

0.76

0.91

1.07

1.26

1.52

1.72

1.99

gas volume

/min

209

299

356

417

523

648

775

932

1102

1189 1348 1620

1926

2255

2670

3213

3638

4221

Flue Gas CO

at 195ºC

13.0

12.8

13.0 13.0

12.8

12.5

13.0

12.5

13.0

13.1

13.2

13.3

Table 2 Oil Firing Data

Boiler Size

170

240

290

340

420

510

630

760

870

970

1100

1320 1570

1850

2200

2650

3000

3500

Maximum Gas Rate

19.1

26.9

32.4 38.0

47.0

57.0

70.5

84.9

97.1

108.3 122.8

147.5 175.4 206.7 246.3 296.4

335.6 391.9

Gross

673.2

949.4

1144.7 1340.6 1657.9 2013.1 2489.5

2996.7 3426.7

3820.6 4332.6

5204.8 6190.6 7294.6 8693.5 10460.4 11841.9 13830.5

Maximum flue

/sec

0.10

0.14

0.17 0.19

0.25

0.30

0.37

0.45

0.52

0.57

0.65

0.78

0.93

1.08

1.26

1.51

1.75

2.04

gas volume

/min

211

293

360

411

519

633

775

946

1098

1211

1368 1657

1967

2299

2671

3203

3717

4332

Flue Gas CO

at 195ºC

10.0

10.1

10.0 10.2

9.9

10.2

9.9

9.8

10.0

10.1

10.2

Table 3 Gas Firing Data

Assembly and Installation Instructions for Ideal Vanguard L heating boilers should be read in conjunction

with the general technical data tables enclosed and any other technical publication supplied with the burner.

Vanguard L -

Installation & Servicing

GENERAL

van 5652

CONTENTS

Assembly. ................................................................... 15-23

Boiler Clearances. ............................................................ 9

Boiler Dimensions. ........................................................ 6-8

Burner Connection. ........................................................ 24

Commissioning and Testing. ................................ 28 & 29

Electrical Connections. .................................................. 25

Electrical Supply. .............................................................. 5

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

Fluing. .............................................................................. 12

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

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

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

Initial Start Up Lighting. .................................................. 29

Introduction. ...................................................................... 3

Installation. ...................................................................... 13

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

Positioning of the Turbulators. ........................................ 9

Servicing. ........................................................................ 31

Ventilation. ...................................................................... 11

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

Water Connections. ......................................................... 6

Water System Requirements. ............................... 10 & 11

Water Treatment. ............................................................. 5

Wiring Diagrams. ................................................... 25 & 26

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.

Vanguard 'L'

Gas and Fuel Oil

PI No. 0461BN0658

Destination Countries: GB, IE

INTRODUCTION

The Vanguard L boilers are a range of steel shell pressure jet
boilers offering high efficiency operation, ease of maintenance,
fuel flexibility and low emissions.

Suitable for oil or gas operation the Vanguard L range is
supplied in a choice of 18 standard models, rated in outputs
from 130kW (443,000 Btu/h) to 3500 kW (11,942,000 Btu/h). The
range has a maximum operation pressure of 6 bar.

Designed with a large combustion chamber that is positioned in
the lower part of the heat exchanger, the Vanguard L range
ensures maximum heat transfer efficiency (up to 92.5% net).

Through the use of an increased number of flue ways tubes
which are positioned in the hottest area of the heat exchanger
and constructed from a thicker steel construction than that of
traditional boilers, the Vanguard L range is capable of an
impressive output to size ratio.

Duty

The range of boiler 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.

Vanguard L -

Installation & Servicing

GENERAL

SAFETY

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

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

The following must be conformed with:

Current Building Regulations and Clean Air Act

Water Authority Regulations

Local Authority Regulations and Regional Bylaws

Gas Safety Regulations

Any special regional requirements of local Electricity and Gas
undertaking.

Fire Service and Insurance Company requirements.

In the interests of safety, a competent installer should be
employed to effect the installation of the appliance.
Manufacturer's notes must NOT, in any way, be taken as over
riding statutory obligations.

The installation of the boiler MUST also be in accordance with
the latest I.E.E. (BS7671) Wiring Regulations, local buildings
regulations, bye-laws of the local water authority, the building
regulations and the Building Standards (Scotland) and any
relevant requirements of the local authority.

Detailed recommendations are contained in the following
Codes of Practice:

BS 799 Pt4 & 7

Oil burning equipment.

BS 799 Pt5

Oil storage tanks.

BS 5410 Pt2

Installation for space heating, hot water and
steam supply.

BS 5854

Flues and flue structures in buildings.

BS 5885 Pt1

Gas burners - with inputs 60kW and above.

BS 6644

Installation of gas fired hot water boilers of
rated input between 60kW and 2MW (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.

BS 6891

Installation of low pressure gas pipework of
up to 28mm (R1) in domestic premises (2nd
family gas).

EN 303.1

Heating boilers with forced draught burners.
General requirements.

EN 303.2

Heating boilers with forced draught burners
with atomizing oil burners.

NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE BOILER.

EN 304

Test code for heating boilers for atomizing oil
burners.

73/23 EEC

Low voltage directive. (Relevant standard is
EN60335.1)

89336 EEC

Electromagnetic Compatibility Directive.
(Relevant standards are EN50081.1,
EN50082.1 and EN55014.)

90396 EEC

Gas Devices Directive. (Relevant standards
are EN303.1, EN303.2 and EN304.)

IGE/UP/1

Soundness testing and purging of industrial
and commercial gas installation.

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

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 or its
manufacture.

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.

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 17.5mbar MUST be available at the boiler inlet for Natural gas
and 37mbar for Propane.

Do not use pipes of smaller size than the burner inlet gas
connection.

The complete installation MUST be tested for gas soundness
and purged in accordance with the appropriate standards listed
above.

Gas Boosters

A gas booster is required if the gas pressure available at the
burner is lower than that required by the burner 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
temperatures do not exceed designed recommendations.
Further guidance is provided in IGE/UP/2 as listed above.

Assembly and Installation Instructions for Ideal Vanguard L heating boilers should be read in conjunction with the general
technical data tables enclosed and any other technical publication supplied with the burner.

Vanguard L -

Installation & Servicing

GENERAL

FLUE INSTALLATION

IMPORTANT
It is the responsibility of the installer to ensure that products of
combustion discharging from the terminal cannot re-enter the
building or any other adjacent building.

Fan dilution systems may be incorporated into the flue system.
However, ventilation must take into account the additional air
requirement of the boiler house and interlocking must be
provided to ensure adequate air flow is attained before burner
operation proceeds.

The flue must be installed in accordance with the appropriate
standards listed on page 4.

WATER CIRCULATION SYSTEM

The system pump MUST be connected to the boiler.

The boiler must NOT be used for direct hot water supply. The
calorifier MUST be of the indirect type.

The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.

The calorifier 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.

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.

The central heating system should be in accordance with the
relevant standards listed on page 4.

Due to the nature of the boiler the heat stored at the point of
shutdown of the burner must be dissipated in order to avoid
overheating. In order to allow pump operation after burner
shutdown the boiler control box incorporates a pump overrun
facility. In order to make use of this, the pump must be supplied
from the terminals inside the boiler. Note: for pumps requiring
greater than 1.0amp current or using 3 phase they must be
connected via a relay.

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.

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 systems
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:

Betz Dearborn Ltd

Fernox Manufacturing Co. Ltd.

Widnes,

Tandem House, Marlowe Way,

Cheshire,

Croydon, Surrey, CRO 4XS

Tel: 0151 424 5351

Tel: 0870 601 5000

ELECTRICAL SUPPLY

WARNING

This appliance must be earthed.

Control Panel:
A 230V - 50Hz. Fused at 4 amps.

Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS7671) Wiring Regulations and any local
regulations which apply.

Burner and Pump:
These may be 1ph or 3ph. Refer to manufacturer's instructions.

The point of connection to the mains should be readily
accessible and adjacent to the boiler.

LOCATION OF THE BOILER

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.

The boiler must not be fitted outside.

Vanguard L -

Installation & Servicing

GENERAL

van5654

BOILER WATER CONNECTIONS

BOILER DIMENSIONS

The Vanguard L boilers are provided with flanged
connections for both flow and return.

Dimensions vary depending on the boilers output and
details can be found in the General Data Table on
page 4.

The boiler shell is also provided with separate
connections for a drain and safety valve.

Dimensional details can also be found in the General
Data Table on page 4.

1. Control Panel
2. Burner mating flange with gasket
3. Flue collector hood cleaning door
4. Flame inspection tube with pressure

test nipple and cooling line connection

van 5653

Vanguard L 170 - 630

T1. Flow connection
T2. Return connection
T3. Safety valve and expansion connection
T4. Drain connection
T5. Flue connection
T6. Burner connection

Boiler Size

170

240

290

340

420

510

630

Dimension A

m m

820

860

890

Dimension B

m m

885

1145

1080

1210

1275

1470

1780

Dimension C

m m

1082

1182

1352

Dimension D

m m

190

Dimension E

m m

139

Dimension F

m m

145

Dimension G

m m

648

708

748

Dimension H

m m

380

400

440

Dimension I

m m

1169

1429

1366

1496

1561

1756

2066

Dimension L

m m

130

125

Dimension M*

m m

1210

1310

1485

Dimension N

m m

175

215

255

Dimension O

m m

130

390

210

340

285

480

790

Dimension P

m m

185

250

315

Dimension Q*

m m

710

750

780

Dimension R*

m m

785

1045

982

1112

1177

1372

1682

* Minimum dimensions for boiler room access requirements.