Ideal Boilers Concord CXSD 100 Installation & Servicing Manual Download | Manualshive

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Concord CXSD/H -

Installation & Servicing

FAULT FINDING

FAUL

T FINDING FAUL

T FINDING FAUL

T FINDING FAUL

T FINDING FAUL

T FINDING FAUL

T FINDING

52 SIMPLE FLOW CHART 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

Temp >

than set

point

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Summary of Contents for Concord CXSD 100

Page 1: ......

Page 2: ...e is greater than 75 o C Boiler thermostat The boiler thermostat hysteresis is a maximum of 3 o C Table 1 Performance Data Boiler CXSD40 H CXSD50 H CXSD60 H CXSD70 H CXSD80 H CXSD90 H CXSD100 H CXSD110 H CXSD120 H Boiler Input Gross kW 33 8 42 2 50 7 59 1 67 6 76 0 84 5 92 9 101 3 Low Rate Btu hr x 1000 115 3 144 1 172 9 201 7 230 5 259 3 288 2 317 0 345 8 Nett kW 30 4 38 0 45 7 53 3 60 9 68 5 76 ...

Page 3: ...rrectly could lead to prosecution It is in your own interest and that of safety to ensure that the law is complied with The Concord CXSD 40 H 120 H range of boilers has been tested and certified by British Gas to prEN656 for use with Natural gas only Multiple boiler installations The Concord CXSD H range is certificated for use in multiple boiler installations providing that the following conditio...

Page 4: ...dication 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 range ...

Page 5: ...re that its temperature does not exceed 65 0 C 150 0 F MULTIPLE BOILER INSTALLATIONS The minimum installation clearances must conform to the dimensions given below CXSD 40 H 50 H 60 H 70 H 80 H Clearance between boilers 50mm Clearance at both ends of the multiple installation 50mm CXSD 90 H 100 H 110 H 120 H Clearance between boilers 100mm Clearance at both ends of the multiple installation 100mm ...

Page 6: ...es 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 Frame 3 if the static head required for the pump s exceeds that required for the boiler MINIMUM FLOW OF WATER Refer to Table 5 The system design must provide...

Page 7: ...t Water Supply Model Water Bye laws Manufacturers notes must not be taken in any way as overriding statutory obligations The appliance must be installed in a room separated from living rooms and provided with appropriate ventilation direct to the outside see Table 6 FOUNDATION The boiler must stand on a non combustible floor i e concrete or brick which must be flat level and of a suitable load bea...

Page 8: ...s steel rigid or flexible flue liner grade 304 316 may be used in conjunction with a 50 mm minimum thick layer of vemiculite or perlite granules between the liner and the inner skin of the chimney body Liners should be sealed at both top and bottom As the Concord CXSD H range of boilers is supplied complete with an integral draught diverter a diverter MUST NOT be fitted within the chimney system D...

Page 9: ...ection 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 Gas pipe Con 1855 Alignment notches Distribution tube detail 1 2 18 3 4 5 7 8 6 9 10 11 12 13 14 15 16 17 INSTALLATION ...

Page 10: ...ood 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 the boile...

Page 11: ... 5 2 Fit the 1 tapped flange to the other 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 si...

Page 12: ...de of the boiler 2 Table 2 gives details of the inlet connection size and the minimum working pressures 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 casing hardware pack contains all the screws required for assembly 2 Slide bottom of the side panel on to the studs on th...

Page 13: ...ostat capillary through 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...

Page 14: ...y 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 are fit...

Page 15: ...run all zones MUST individually 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 available 15 INTERNAL WIRING v violet pk pink y gyellow green or orange y yellow w white br brown r red b blue bk black At ...

Page 16: ...pen Zone 1 valve via 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 ill...

Page 17: ...onds to indicate the boiler status The boiler will commence its ignition sequence 5 The boiler should light initially at low rate for a period of approximately 30 seconds 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 ignitio...

Page 18: ...XSD H 3 It is essential 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 al...

Page 19: ...alve and using a suitable spanner set the burner pressure adjuster 7 to the value given in Table 8 Refit the electrical plug and secure with the screw Remove the dust cover from the adjuster 11 on the LH gas valve and set the pressure to the value given in Table 8 Now set the Low burner pressure by unscrewing and removing the lower electrical plug from the LH gas valve and High Low plug from the R...

Page 20: ...on the microprocessors will identify the fault area and display a suitable message on the display Further to these accessible features there are other features present in the system which the installer service engineer should be aware of HOURSRUNLOG This feature enables the installer to determine the workload of the boiler PUMPOVERRUN If the flow temperature is above 75 o C at the time of boiler s...

Page 21: ... Installation Servicing 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 ...

Page 22: ...e or 24 hour If the 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 0...

Page 23: ...tails 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 ENTER This will cause th...

Page 24: ...r ready reference 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 After servicing complete the service section of the log book and return to the owner or their...

Page 25: ...rse order Refit the cleanout cover NOx duct and casing panels CXSD 120 H boiler only Refit collector hood baffles within collector hood using M5 securing screws 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 adjust if neces...

Page 26: ...res as described in Frames 22 and 23 or 24 1 Remove the NOx duct and burner front plate as previously described in Frame 35 and 36 2 On the CXSD 40 H 50 H 60 H 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 the injector then l...

Page 27: ...rheat thermostat 14 Detection electrode assembly PTP Pressure test point 42 OVERHEAT THERMOSTAT 1 Remove the split pin from the overheat thermostat pocket and remove the phial 2 Unclip the capillary from its clips on the casing side panel 3 Loosen the 2 x M3 screws and remove the thermostat assembly from its fixing bracket 4 Undo the screw and remove the cover 5 Remove the wires 6 Undo the backnut...

Page 28: ...ntrol 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 Undo the 2 screws securing the control box front panel Carefully lift it up and lower it 3 Release the ribbon...

Page 29: ...commend 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 protective ...

Page 30: ...l 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 assembling the sections it will be nec...

Page 31: ...ented systems a hydraulic 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 insulation wrap around heat excha...

Page 32: ...he heating load and ensure efficient boiler operation The gas 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 3 minutes the high rate gas valve will open On reaching the set point determined by the user the boiler will go to low rate and when the temperature 51 BOILER CONTROL reaches the set point plu...

Page 33: ...G FAULT FINDING FAULT FINDING FAULT FINDING 52 SIMPLE FLOW CHART 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 Temp than set point ...

Page 34: ... R T O I D E A L B O I L E R S Is there a spark NO DOWNDRAUGHT FAULT Check 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 senso...

Page 35: ...ize 5 5mm CXSD110 H 3 157 904 Size 5 6mm CXSD120 H 3 154 840 29 Gas control valves HONEYWELL VR4605PB 2003 CXSD 40 120 H 1 111 867 HONEYWELL VR4605AB 1019 CXSD 100 120 H 1 111 869 29 7 Gas control valve plug and lead assemblies CXSD 40 120 H 1 111 870 CXSD 40 120 H 1 154 734 29 6 CXSD 100 120 H 1 112 431 29 5 CXSD 100 120 H 1 139 269 32 Ignition electrode BE 3417 SI 1 112 365 33 Flame detector ele...

Page 36: ...1 157 480 CXSD 60 H 1 157 481 CXSD 70 H 1 157 482 CXSD 80 H 1 157 483 CXSD 90 100 H 1 157 484 CXSD 110 120 H 1 157 485 Key No Description Qty Product No SHORT LIST OF PARTS Ideal Boilers P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 November 2005 UIN 157292 A03 Technical Training Caradon Ideal Limited pursues a policy o...

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