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Care should be taken to ensure the specification of the chimney is suitable for the application by reference to the manufacturers literature. Caradon Ideal Limited can offer advice on the design of suitable chimney systems. GAS SUPPLY If there is any doubt regarding the capacity of the gas meter, the available gas pressure, the adequacy of existing service pipes or the size required for new service pipes then the advice of the gas supplier should be requested. Installation pipework should be fitted and tested for gas soundness in accordance in accordance with BS. 6891; IGE-UP-1 for small installations IGE-UP-2 for large installations. The local gas supplier must be consulted if it is necessary to employ a gas pressure booster. ELECTRICAL SUPPLY WARNING. This appliance must be efficiently earthed. A 230 V - 50 Hz mains supply is required, fused at 5 amps. Wiring external to the appliance MUST be in accordance with the I.E.E. (BS. 7671) Wiring Regulations and any local regulations which apply. For details of connections see Frame 14. Concord CXSi/H -Installation & Servicing INSTALLATION 10 Concord CXSi/H - Installation & Servicing 5 CONCORD CXSi BOILER ASSEMBLY - Exploded view Legend 1. Cleanout cover 2. Collector hood 3. Middle section 4. Flow header 5. Section alignment rings & ’O’ rings. 6. Thermostat pocket. 7. End section. 15. Lightback shield. 16. Burner manifold assy. 17. NOx duct. 18. Insulation bracket 8. Distribution tube. 9. Downdraught deflector. 10. Section bolt. 11. Drain cock. 12. Base plate. 13. Combustion chamber. 14. Tie rods. Insulation not shown INSTALLATION INSTALLATION Concord CXSi/H - Installation & Servicing 11 6 BOILER SECTION ASSEMBLY The site assembled boiler is supplied in the following packages: ! Combustion chamber / manifold / burner assembly. ! Platework package. ! Casing package. ! Controls box package. ! End and centre sections. TOOLS REQUIRED ! Spanners ! Torque wrench ! Pozi screwdriver ! Mallet GENERAL The installation of the boiler must be in accordance with current Gas Safety (Installation and Use) Regulations or rules in force, building regulations, I.E.E. (BS.7671) Regulations and the byelaws of the local water undertaking. It should also be in accordance with the relevant British Standard Codes of Practice together with any relevant requirements of the local gas supplier and local authority. ASSEMBLY The combustion chamber should be positioned as near as possible to the installation site. IMPORTANT. It must be remembered that the boiler distribution tube has to be fitted into the rear return tapping of the assembled boiler before final siting. Prior to assembling the sections it will be necessary to remove the manifold assembly and burners from the combustion chamber. To do this: 1. Undo the two M5 screws and washers securing the spark generator bracket to the combustion chamber. Undo the union securing the gas valve assembly and remove the gas valve and spark generator assembly from the boiler. 2. Undo the 4 nuts securing the burner manifold to the combustion chamber legs. 3. Undo the nuts securing the burner light back shield to the combustion chamber and lift it off. 4. Pull the whole burner assembly forward on its runners, ensuring that no wires are trapped, and remove it completely from the combustion chamber. PREPARATION OF SECTIONS Each section should be brushed clean on all external surfaces and any debris which may have accumulated within the sections should be removed via the bottom ports. Section Assembly - refer to the exploded view 5. Take an end section and lift it onto the combustion chamber so that the combustion chamber side panel return is inside the section rear lip. 6. Locate a slotted steel ring and an .O’ ring seal into each of the 4 ports. It will be necessary to squeeze the steel ring slightly to enable it to be pushed fully into the recess. 7. Lift a middle section onto the combustion chamber and carefully offer it up to the end section until it engages the projecting steel rings. It may be necessary to use a mallet and hardwood block to ensure that the steel rings are pushed fully into the recessing and that the sections are butted up to each other. Note. Until the final section is fitted and the tie rods fastened, the sections in the assembly are not fixed together therefore CARE MUST BE TAKEN TO PREVENT the installed sections coming apart. 8. Repeat the assembly procedure for all of the sections until complete. 9. Fit the 4 tie rods through the holes in the sides of the end sections and fit a flat steel washer, a shakeproof washer and a nut to both ends of each tie rod. Screw up all the nuts equally, in turn and, finally, tighten them to a torque of 38-41 Nm (28-30 lb. ft). 10. For open vented systems a site test must be carried out at a hydraulic pressure equal to 1 1/2 times the design pressure given in Table 2, for a period of 30 minutes. Note. If it is a sealed system the hydraulic pressure must be equal to twice the given design pressu...

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