Ideal Boilers Concord CXSD 40/H Installation & Servicing Manual Download Page 9

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Concord CXSD/H -

Installation & Servicing

INSTALLATION

CONCORD CXSD/H BOILER ASSEMBLY - Exploded view

Legend

. Cleanout cover

Collector hood

Middle section

Section alignment rings & 'O' rings

End section

Gas cock

Drain cock

NOx duct

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

INST

ALLA

TION

Summary of Contents for Concord CXSD 40/H

Page 1: ......

Page 2: ...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...

Page 3: ...rectly 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 Bri...

Page 4: ...ication 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 Combine...

Page 5: ...e 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 Clearan...

Page 6: ...s 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 requi...

Page 7: ...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 provid...

Page 8: ...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...

Page 9: ...ction 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 rod...

Page 10: ...od 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 uni...

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 mano...

Page 12: ...e 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 p...

Page 13: ...stat 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 Ro...

Page 14: ...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 opera...

Page 15: ...un 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...

Page 16: ...en 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 to...

Page 17: ...nds 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 r...

Page 18: ...SD 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 adjus...

Page 19: ...lve 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...

Page 20: ...n 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...

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 p...

Page 22: ...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...

Page 23: ...ails 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...

Page 24: ...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 wil...

Page 25: ...se 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 assembl...

Page 26: ...es 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 shi...

Page 27: ...heat 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 fr...

Page 28: ...trol 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...

Page 29: ...ommend 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 insu...

Page 30: ...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 sit...

Page 31: ...nted 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 pre...

Page 32: ...e 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 a...

Page 33: ...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 O...

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 R...

Page 35: ...ze 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 valv...

Page 36: ...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 Na...

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