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Page 2: ...time Maximum of 10 secs with 5 attempts with 1 minute between attempts Safety check The control de energises every 4 hours to check internal control functions Pump Pump overrun operates if the flow temperature is greater than 75 o C Boiler thermostat The boiler thermostat hysteresis is a maximum of 3 o C Table 1 Performance Data Table 3 Boiler Control specification Maximum flow temperature 85 o C ...
Page 3: ...for use in domestic applications A domestic installation is defined as an installation where the boiler takes its combustion air from a living space or from a room directly or indirectly connected with the living space It is important therefore that no external control devices e g flue dampers economisers etc are directly connected to this appliance unless covered by these Installation and Servici...
Page 4: ...al heating systems Fully pumped systems may be open vented or sealed The range of boilers is NOT suitable for 1 Gravity DHW systems 2 Gravity heating systems 3 Direct domestic hot water supply WATER CIRCULATION SYSTEM Due to the compact nature of the boiler the heat stored within the castings at the point of shutdown of the burner must be dissipated into the water circuit in order to avoid the ove...
Page 5: ...t including clearance for side fitted flow header Dimension A mm in 1036 40 3 4 1036 40 3 4 1036 40 3 4 1086 42 3 4 1140 45 Dimension B mm in 175 7 175 7 175 7 197 7 3 4 250 10 Dimension C mm in 1107 43 3 4 1107 43 3 4 1230 48 1 2 1353 53 1 4 1476 58 1 8 Dimension D mm in 816 32 1 8 816 32 1 8 939 37 1062 42 3 4 1185 46 5 8 Dimension E mm in 553 21 3 4 553 21 3 4 615 24 1 4 676 26 5 8 738 29 Dimen...
Page 6: ...open vented systems It is assumed incorrectly that because boilers are operating in conjunction with what is apparently a closed circuit an open vented system will not under normal circumstances allow damage or loss of efficiency due to hardness salts and corrosion once the initial charge of water has been heated up a few times 1mm of lime reduces the heat transfer from metal to water by 10 In pra...
Page 7: ... guidance given below is not intended to override any requirements of either of the above publications or the requirements of the local authority gas or water undertakings In general commercial closed pressurised systems are provided with either manual or automatic water make up On both instances it will be necessary to fit automatic controls intended to protect the boiler circulating system and a...
Page 8: ...essure booster ELECTRICAL SUPPLY WARNING This appliance must be efficiently earthed A 230 V 50 Hz mains supply is required fused at 5 amps Wiring external to the appliance MUST be in accordance with the I E E BS 7671 Wiring Regulations and any local regulations which apply For details of connections see Frame 14 FOUNDATION The boiler must stand on a non combustible floor i e concrete or brick whic...
Page 9: ...nout cover 2 Collector hood 3 Middle section 4 Flow header 5 Section alignment rings O rings 6 Thermostat pocket 13 Combustion chamber 14 Tie rods 15 Lightback shield 16 Burner manifold assy 17 NOx duct 18 Insulation Bracket 7 End section 8 Distribution tube 9 Downdraught deflector 10 Section bolt 11 Drain cock 12 Base plate INSTALLATION ...
Page 10: ...ECTIONS 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 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...
Page 11: ...bustion chamber using the two M5 screws and washers 16 Fit the gas inlet pipe and retain by the semi circular clamp screws and washers provided Tighten both unions and the inlet pipe retaining clamp ensuring that the gas valve assembly is vertical 17 To fit the collector hood align the back edge of the horizontal side returns with the rear of the section assembly and fasten down the collector hood...
Page 12: ... expansion pipe is to be brought directly to the boiler the close taper nipple and 1 1 4 tee must be fitted so that the drain cock is horizontal This will reduce the possibility of the drain becoming blocked by debris 5 Complete the system connections using suitable jointing compound as follows The cast iron flow header must be fitted in the chosen flow connection which will be either of the 2 top...
Page 13: ... framework with the overheat thermostat at the bottom and with its green Legend 1 Side panel 2 Supporting angle 3 Top panel 4 Upper front panel 5 Control box 6 Bracket 7 Support frame 8 Door panel 9 Lower panel button facing to the RH side and secure to the front fixing bracket s using the M5 screws and washers and to each side panel using the No 8 screws 5 Fit the 4 shoulder screws into the fixin...
Page 14: ... the control box to the support frame and fix at the bottom using the 2 self tapping screws provided 4 Fit the earth connections from the terminal plug in connections to the appropriate earth posts on the back of the control box Connect the earth lead prefitted to the control box back panel to the threaded hole in the casing support frame IMPORTANT 5 Offer up the spark generator assembly to the co...
Page 15: ... pocket in the flow header using the spring clip 10 Fit the earth connections from the terminal plug in connections to the appropriate earth posts on the back of the control box Connect the earth lead prefitted to the control box back panel to the threaded hole in the casing support frame 11 Fit the casing upper front panel with its location buttons in the slots and push down to locate Fasten at t...
Page 16: ...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 All wiring that is associated with the EXT C terminals should be separated from other current carrying cables by a minimum of 100mm...
Page 17: ...rmal operation When any thermostat is satisfied while others are calling for heat power is available via relay contacts to close the valve for that zone When all thermostats are satisfied also when the clock period ends all relays will be off so the zone valves which were open will remain open for the pump overrun period Pump Supply Control panel earth stud Detail of connection box MAINS Voltage P...
Page 18: ...ill open 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 ar...
Page 19: ...tion In addition the microprocessor also has onboard commissioning and servicing instructions and a fault diagnosis programme The next section describes the minimum procedure to light and commission the boiler Full operating instructions for the microprocessor control and details of the high low operation system are included in Frames 25 30 GENERAL Check that all drain cocks are closed that any st...
Page 20: ...d out 2 If desired it is possible to use the onboard commissioning instructions using the UP DOWN arrow buttons However the following paragraphs provide more detailed instructions and are recommended until the installer is familiar with the Concord CXDi H 3 It is essential to adjust the maximum setting first SETTING THE HIGH BURNER PRESSURE 4 Adjust the system controls to ensure that the boiler wi...
Page 21: ... However the following paragraphs provide more detailed instructions and are recommended until the installer is familiar with the Concord CXDi H 3 It is essential to adjust the maximum setting first SETTING THE HIGH BURNER PRESSURE 4 Adjust the system controls to ensure that the boiler will operate at high rate for a reasonable period 5 Press the 0 1 button to turn the boiler off 6 Undo the screws...
Page 22: ...n addition to the operational characteristics described above the control system incorporates the following features accessible to the user or service engineer ADJUSTABLE BOILER TEMPERATURE CONTROL This is factory preset at 82 C but may be adjusted by the user between 60 C and 85 C Refer to Frame 30 PROGRAMMER TIMER A maximum of 3 time periods per day can be programmed in to the boiler Note This a...
Page 23: ...nstallation and 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 24: ...gramme 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 is s...
Page 25: ...OFF for a minimum of 3 minutes or until the boiler flow temperature has dropped by 3 o C whichever is the greater time If the boiler load is such that it cycles between high and low operation the boiler will fall through 3 degrees before the high rate gas valve is energised Delayed High Rate Gas Valve Operation When the boiler is started from cold the high rate gas valve will be delayed for 3 minu...
Page 26: ...k panel from the boiler with plugs in place CLEANING THE BOILER Remove the casing door panel Lift and remove the casing lower front panel Undo and pull off all the plugs from the gas valve solenoids Turn off the gas at the gas inlet cock Undo the 2 unions at either side of the gas valve assembly and remove the assembly complete 33 ADJUSTMENT OF WATER FLOW RATE THROUGH THE BOILER When commissioning...
Page 27: ...ORE working on the appliance 37 REPLACEMENT OF COMPONENTS Refer to Frames 5 40 and 41 Pull off the leads to the spark electrode on the RH end burner access via the side of the combustion chamber Pull off the lead to the flame detector electrode at the LH end burner Lift off the casing top panel Undo the 3 elongated nuts from each of the NOx ducts and remove all the ducts Undo the M5 nuts and washe...
Page 28: ...en or remove all the screws on either the inlet or the outlet manifold and only those 4 screws securing the faulty gas valve on the other manifold The faulty gas valve can then be removed and replaced Ensure that the arrow on the gas valve points in the direction of flow 4 Ensure that new O ring seals are fitted and that the O ring seals on the remaining gas valves are correctly in place Ensure th...
Page 29: ...e the cover 7 Remove the wires 8 Undo the backnut and remove the thermostat 9 Fit new thermostat and secure with backnut 10 Reconnect wires as follows 1 Pink 1 White 3 Red Reconnect the earth terminal LEGEND 1 Main gas inlet cock 2 Gas inlet union 3 O ring seal 4 High Low Gas control valve 42 OVERHEAT THERMOSTAT 5 Gas control valve 6 Spark generator 7 Burner manifold 8 Main injector 9 Main burner ...
Page 30: ...e 7 plastic mounting pins and 2 screws and pull it forward 7 Reassemble in reverse order 44 CONTROL SENSOR 1 Lift off the casing top panel 2 Trace the sensor lead to the pocket in the flow header remove the spring clip and remove the sensor phial 3 Unclip the sensor lead from its clips on the casing Undo the screws on the connector box plug and remove it 4 Fit the new sensor and reassemble in reve...
Page 31: ...mmend 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 eq...
Page 32: ...NOT electrically isolate the boiler Before attempting any electrical fault finding ALWAYS carry out the preliminary electrical system checks as detailed in the Instructions for the British Gas Multimeter or other similar commercially available meter The preliminary electrical system checks are the FIRST electrical checks to be carried out during a fault finding procedure On completion of any servi...
Page 33: ...ION 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 FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING ...
Page 34: ... R S Is there a spark NO 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 Press Copy Check detection probe Pre...
Page 35: ...d lead CXDi 110 H 120 H 140 H 160 H 180 H 1 155 657 28 7 Plug and lead CXDi 180 H 2 111 870 29 Spark generator 1 139 300 31 Injector 4 02 mm diameter CXDi 110 H 6 013 175 Injector 4 20 mm diameter CXDi 120 H 6 013 180 Injector 4 20mm diameter CXDi 140 H 7 013 180 Injector 4 20mm diameter CXDi 160 H 8 013 180 Injector 4 20mm diameter CXDi 180 H 9 013 180 32 Flame detection electrode 1 138 895 32 1 ...
Page 36: ...per front panel CXDi 140 H 1 155 644 61 Casing upper front panel CXDi 160 H 1 155 645 61 Casing upper front panel CXDi 180 H 1 155 646 62 Casing top panel CXDi 110 H 120 H 1 138 465 62 Casing top panel CXDi 140 H 1 138 464 62 Casing top panel CXDi 160 H 1 138 463 62 Casing top panel CXDi 180 H 1 138 462 63 2 Overheat thermostat 1 155 269 Ideal Boilers P O Box 103 National Ave Kingston upon Hull HU...
