Flue Installation; Flue System Design; Gas Supply; Gas Boosters - IDEAL imax plus F80 Installation And Servicing

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 5854 Flues and Flue Structures in Buildings.
BS.6644 Installation of gas fired hot water boilers of rated
inputs between 60kW and 20MW (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.
73/23 EEC Low Voltage Directive (Relevant Standard is
EN60335.1).
89336 EEC Electro Magnetic Compatibility Directive.
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.

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 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
15 mbar MUST be available at the boiler inlet.
Do not use pipes of smaller size than the boiler inlet gas
connection.
The completed 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
boiler is lower than that required to attain the flow rate for
maximum input rating.
Location of the booster requires careful consideration but should
preferably be closer to the boiler 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.
NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE BOILER.
4
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, 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 above.

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
with integral fans which are fully matched to the boiler in each
case to provide correct combustion air flow and overcome the
flue resistance.
The power of these fans is such that there is a large reserve of
pressure available to overcome a significant length of the 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.). 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
Flue Size (mm) Ø150
Approx. max.
Straight Flue 240
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 316 grade Stainless Steel
or be of equivalent corrosion resistance. 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. The Technical Support Department of Caradon Ideal
Limited, can offer advice on the design of suitable chimney
systems.
condensing boiler is supplied
F120 F160 F200 F240
Ø150 Ø150 Ø200 Ø200
109 67 171 120
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Installation & Servicing
F280
Ø200
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