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Ideal Boilers Concord CXD 40-100, Installation & Servicing Manual

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Ideal Boilers Concord CXD 40-100 Installation & Servicing Manual Download Page 10

10

Concord CXD  -  

Installation

5

CONCORD CXD BOILER ASSEMBLY - Exploded view

INSTALLATION

INST

ALLA

TION

Legend

1

. Cleanout cover

2.

Collector hood

3.

Middle section

4.

Section alignment rings & 'O' rings

5.

End section

6.

Gas cock

7.

Drain cock

8.

NOx duct

9.

Front plate

10.

Burner manifold assy.

11.

Base plate

12.

Combustion chamber

13.

Section bolt

14.

Distribution tube

15.

Tie rods

16.

Thermostat pocket

17.

Spillage skirt

18.

Flueway baffles

19.

Gas pipe

Summary of Contents for Concord CXD 40-100

Page 1: ......

Page 2: ...2 Concord CXD Installation 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 ...

Page 3: ... ensure that the law is complied with The Concord CXD 40 100 range of boilers has been tested and certified by British Gas to prEN656 for use with Natural gas only Multiple boiler installations The Concord CXD range is certificated for use in multiple boiler installations providing that the following conditions are satisfied 1 A downdraught thermostat kit MUST be fitted to ALL boilers in the insta...

Page 4: ...5 High Rate Nett kW 47 3 56 3 67 7 79 2 90 7 102 3 112 6 Btu hr x 1000 161 4 192 1 231 0 270 2 309 5 349 0 385 2 Boiler output kW 42 0 50 0 60 08 70 34 80 56 90 8 100 0 High Rate Btu hr x 1000 143 3 170 6 205 0 240 0 274 9 309 8 341 2 Gas rate m3 h 5 0 5 96 7 16 8 38 9 6 10 82 11 91 ft3 h 176 6 210 5 252 9 295 9 339 0 382 1 420 6 Approximate 4 5 CO2 100 C 0 044 0 052 0 063 0 073 0 084 0 094 0 104 ...

Page 5: ...e indication of lockout and overheat conditions Outside Sensor This kit provides a sensor for temperature compensation when the outside temperature changes DUTY The range of boilers 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 ra...

Page 6: ...ITION OF BOILER Minimum clearances required from walls or other fixed objects to allow for the free access of combustion air are shown in Table 4 above However for maintenance purposes we suggest a minimum rear clearance of 50mm Any combustible material adjacent to the boiler and its flue system must be so placed or shielded as to ensure that its temperature does not exceed 65 0 C 150 0 F MULTIPLE...

Page 7: ...cessary for the safe operation of the system PUMP POSITIONS Whenever practically possible the circulating pump s should be positioned so that it pressurises the system being served The vertical distance between the pump s and any cold feed and expansion cistern MUST comply with the pump manufacturers requirements in order to avoid cavitation These requirements override the information given in Fra...

Page 8: ...ns IGE UP 1 Purging Procedures of Non domestic Gas Installations Soundness Testing Procedures for Industrial and Commercial IM11 Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters Gas Installations IGE UP 2 Guidance notes on the Installation of Gas Pipework Boosters and Compressors in Customer s Premises Equal to or Greater than 25mm Non domestic BS 6644 Installation of Gas Fire...

Page 9: ...imney system which may be common or individual in the case of twin or multiple boiler installations must be capable of the complete evacuation of combustion products at all times The effective height of the chimney terminal s above the boiler outlet s must ensure sufficient buoyancy to overcome the resistance of the bends tees and runs of the flue pipe involved and shall terminate in a down draugh...

Page 10: ... cover 2 Collector hood 3 Middle section 4 Section alignment rings O rings 5 End section 6 Gas cock 7 Drain cock 8 NOx duct 9 Front plate 10 Burner manifold assy 11 Base plate 12 Combustion chamber 13 Section bolt 14 Distribution tube 15 Tie rods 16 Thermostat pocket 17 Spillage skirt 18 Flueway baffles 19 Gas pipe ...

Page 11: ...ove the wood screws securing the front cross member on the packaging base 7 Remove the gas cock by unscrewing the union and screw in the handling bars into the 2 front tappings Protect the exposed inlet gas union from ingress of dirt 8 Knock out front spacing blocks from the packaging base ensuring that the boiler assembly is supported using 2 BSP handling bars 9 Using the handling bars manoeuvre ...

Page 12: ...r lower rear connection using the gasket and M10 x 25mm screws and washers provided 3 Temporarily screw the 2 handling bars 2 pipe into the top tappings and manoeuvre the boiler into position 4 Complete the system connections using suitable jointing compound as follows a The flow connection may be made to either of the rear top tappings either at the same side as the return or opposite the return ...

Page 13: ...able 2 gives details of the inlet connection size and the minimum working pressures INSTALLATION INSTALLATION 12 CASING ASSEMBLY 1 Unpack the control box from its carton and release the temperature sensing probe strapped to the back of the box The boiler casing should now be fitted A jacket hardware pack contains all the screws required for assembly 2 Slide bottom of the side panel on to the studs...

Page 14: ...ough the cable clips as shown Ensure the phial is correctly seated in the correct pocket opposite side to the flow connection Refer to Frame 9 Secure with the split pin provided 8 Route the temperature sensing probe through the cable clips provided and into the thermostat pocket adjacent to the flow connection Fit the plastic Heyco bush over the sensor lead at the line shown and insert it into the...

Page 15: ...nk may be fitted in place of the flow switch but the control will not be able to analyse the faulty flow switch if such a failure should occur Either of the above must be fitted or the boiler will not operate Any system controls should be connected via volt free contacts to the terminals marked EXT C Do NOT connect an external clock to these contacts or any mains voltage If no external controls ar...

Page 16: ...ndividually be able to satisfy the conditions in the foregoing paragraph If not all zones can do this then consider other means of control detailed on other sheets Normal operation When any thermostat is satisfied while others are calling for heat power is 15 INTERNAL WIRING v violet pk pink y g yellow green or orange y yellow w white br brown r red LEGEND b blue bk black At the start of the next ...

Page 17: ... the normally open contacts of the relay 17 ZONES WITH INDIVIDUALLY PUMPED ZONES 3 zones shown IMPORTANT Terminal L2 may control the appropriate pump s directly provided that the total running or starting current does not exceed 6A resistive or inductive if this rating would be exceeded then appropriate switchgear must be used to control the pumps indirectly Three zones are illustrated but the pri...

Page 18: ...econds to indicate the boiler status The boiler will commence it s ignition sequence 5 The boiler should light initially at low rate for a period of approximately 30 sec before proceeding to maximum rate If the boiler fails to light allow the controls to cycle until ignition is established If the boiler fails to light after 5 attempts the display will show Detection Fault In this case the ignition...

Page 19: ...to adjust the maximum setting first 4 Adjust the system controls to ensure that the boiler will operate at high rate for a reasonable period then remove the dust cover and adjust the high rate burner pressure setting using a suitable spanner Turn the maximum adjuster 7 clockwise to increase or anticlockwise to decrease the pressure After setting to the indicated pressure allow the boiler to operat...

Page 20: ...wever the temperature falls below the set point whilst on low fire the controls will automatically turn the burner back up to maximum rate This system has the advantages of ensuring that the boiler accurately maintains the set temperature without the large temperature swings that can be associated with on off boilers prevents rapid or short cycling and provides more efficient system operation CXD ...

Page 21: ...d does not replace a conventional system programmer serving more than one heating zone OUTSIDE SENSOR Optional extra If the optional outside sensor is fitted the control system will recognise this and automatically regulate the boiler flow temperature with respect to changes in the external temperature If the sensor is fitted an extra status information screen will appear stating whether the devic...

Page 22: ... CXD Installation 28 DESCRIPTION AND OPERATION OF BOILER CONTROLS continued The diagram below shows the sequence of steps to be taken when reading the instructions on the following pages INSTALLATION INSTALLATION ...

Page 23: ...Programme Hours option is selected the boiler will go on and off subject to the times programmed If ALL DAY usage is selected the boiler will come on at the first ON period selected and off on the last OFF period selected ignoring all other time settings Based on the above backup programme this means the boiler would run subject to any other external controls from 07 30 to 22 00 hours If 24 HOUR i...

Page 24: ...ls INSTALLATION INSTALLATION procedure should be followed but the NO button pressed PROGRAMME HOURS Enables a user timed programme to be entered The following display will be available with the hours 06 flashing Using the UP or DOWN button select the correct hour and press ENTER The minutes will now flash and the correct minutes should be selected using the UP or DOWN button followed by pressing E...

Page 25: ...ence IMPORTANT Point out to the owner that the boiler must have regular maintenance and cleaning at least annually in order to ensure reliable and efficient operation Regular attention will also prolong the life of the boiler and should preferably be performed at the end of the heating season Recommend that a contract for this work should be made with a Corgi registered engineer 35 SERVICING Carad...

Page 26: ...rews are tight 2 The electrodes are correctly positioned Refer to Frames 40 or 41 3 Reassemble in reverse order Refit the flue baffles cleanout cover NOx duct and casing panels TESTING AFTER SERVICING After re assembly restore the electricity and gas supplies Light the boiler Refer to the Lighting Instructions and also Frame 19 Testing for Gas Soundness Check burner manifold pressures Frame 22 and...

Page 27: ...ance and set the manifold pressures as described in Frames 22 and 23 or 24 1 Remove the NOx duct and burner front plate as previously described in Frame 35 2 On the CXD 40 50 60 remove the screws holding the HT heat shield from the LH leg of the combustion chamber Raise slightly and withdraw the heat shield taking care not to damage the leads 3 Each burner can be removed by sliding back to clear t...

Page 28: ...y and withdraw the assembly 2 Undo the 2 screws securing the thermostat cover to the support bracket and withdraw the thermostat from the cover 3 Remove the push on tags from the thermostat body noting their positions 4 Trace the thermostat capillary to the thermostat pocket remove the split pin from the thermostat pocket and lift out the thermostat phial 5 Undo the single nut securing the thermos...

Page 29: ...tor box behind the control box Release the connector box plug Frame 43 4 Replace the sensor and reassemble in reverse order Ensure that the lead is rerouted along the casing in the clips provided and check that the sensor is correctly fitted and secured in the thermostat pocket 1 Remove the lower front panel 2 Slacken the 2 screws securing the control box front panel Carefully lift it up and hinge...

Page 30: ...r recommend that for your own comfort and to comply with good working practise the procedure described below is followed IMPORTANT Turn OFF the gas and DISCONNECT the electricity supply To replace the insulation boards the major boiler components including the heat exchanger and burners have to be removed to gain access to the combustion chamber Prior to removal of the boards the following protect...

Page 31: ...elevant requirements of the local gas supplier and local authority TOOLS REQUIRED z Spanners z Torque wrench z Pozi screwdriver z Mallet 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 siting Prior to assemb...

Page 32: ...c test should be carried out at 1 1 2 times the design pressure given in Table 2 for a period of 30 minutes 12 On a pressurised system the test should be at twice the design pressure for a period of 30 minutes 13 Fit the 4 coach bolts into the lugs at the bottom of the front and rear sections Secure with the nuts and washers provided 14 Fit the flue baffles which are located between the fins 15 Fi...

Page 33: ...valves operate on High Low and Off principle At start up with the flow temperature less than 55 0 C the boiler will start at low rate and after 1 3minutes the high rate gas valve will open On reaching the set point determined by the 51 BOILER CONTROL user the boiler will go to low rate and when the temperature reaches the set point plus 3 o C the low rate gas valve will close When the temperature ...

Page 34: ...RT OF OPERATION SHUTDOWN DELAY IGNITION LOW RATE HIGH RATE Prepurge completed Flame ON PUMP OVERRUN IF 75 C OFF 75 C Temp set point Flame ON For 55 C no delay If 55 C 3 minutes Demand off Overrun completed Demand ON If than set point FAULT FINDING FAULT FINDING ...

Page 35: ...heck flue system Wait 15 mins Does boiler fire Replace TTB Refer to screens Check gas pressure Press Copy Check wiring Press Copy Replace faulty solenoid Press Copy Refer to screens Change gas valve or solenoid Press Copy Observe the display Take actions as follows depending upon the display Check system Press Copy Replace sensor Press Copy Check gas Press Copy Press Copy Check gas valve wiring Pr...

Page 36: ... 40 60 1 111 867 HONEYWELL VR4605A 1104 CXD 70 100 1 138 896 HONEYWELL VR4605AB 1019 CXD 70 100 1 111 869 29H Gas restrictor CXD 70 100 1 150371 30 Spark generator assy generator and terminals 1 112 721 32 Ignition electrode BE 3417 SI 1 112 365 33 Detection electrode BE 3459 SI 1 112 364 37 Thermistor 1 112 289 40 Overheat thermostat RAK 77 4 3835 1 153 914 41 Control box assembly complete 1 138 ...

Page 37: ...XD 40 1 111 650 CXD 50 1 111 651 CXD 60 1 111 651 CXD 70 1 111 652 CXD 80 1 111 652 CXD 90 100 1 111 653 50 Jacket top panel white stove enamel CXD 40 1 111 293 CXD 50 1 111 294 CXD 60 1 111 295 CXD 70 1 111 296 CXD 80 1 111 297 CXD 90 100 1 111 298 51 Jacket lower front panel white stove enamel complete with lighting instructions 1 077 107 52 Jacket upper front control panel less controls white s...

Page 38: ...d pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice Technical Training The Caradon Plumbing Limited Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses pleas...

Page 39: ...be giving away a free boiler for the five best ideas every year to be selected by our Technical Director Please complete this form using extra sheets if required and post it or fax it to us on 01482 498699 Boiler details Model Size e g Classic RS 230 Mexico CF 3 60 etc Details on control panel door Date of Installation Installer details Name Address Post Code Telephone Please include STD code How ...

Page 40: ...ase arrange for me to join an Ideal factory tour Range guides required The Ideal Guide a specifier s and installer s introduction to the Ideal domestic boiler range The Ideal Householders Guide to assist the installer when presenting to his her customers Technical manuals required The Ideal C class combi boiler The Ideal Classic wall hung boiler The Ideal Classic System wall hung boiler The Ideal ...

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