IDEAL Concord CXi 110 Installation & Servicing Manual page 11

6 BOILER SECTION ASSEMBLY
The site assembled boiler is supplied in the following packages:
Combustion chamber / manifold / burner assembly.
Platework package.
Jacket package.
Controls box package.
End and centre sections.
GENERAL
The installation of the boiler must be in accordance with the
Gas Safety (Installation and Use) Regulations 1994,
amendments 1996 or rules in force, building regulations, I.E.E.
(BS.7671) Regulations and the bye-laws 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.
Concord CXi -
Installation
INSTALLATION
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
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 pressure for 30
minutes.
11. Fit the 4 coach bolts into the lugs at the bottom of the
end sections and through the hole in the retaining angle
of the combustion chamber.
Fit a flat washer and nut and secure the section
assembly to the combustion chamber.
TOOLS REQUIRED
Spanners
Torque wrench
Pozi screwdriver
Mallet
times the design
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