IDEAL Concord CXA 100/H Installation & Servicing Manual Download | Manualshive

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Summary of Contents for Concord CXA 100/H

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Page 2: ...8 1078 Water content litre 22 30 30 37 37 45 45 53 53 gal 4 8 6 6 6 6 8 2 8 2 9 9 9 9 11 7 11 7 Table 2 General Data This value is in the UK government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated has been certified by Advantica 0087 Boiler CXA 40 H CXA 50 H CXA 60 H CXA 70 H CXA 80 H CXA 90 H CXA 100 H CXA 110 H CXA 120 H Numbe...

Page 3: ...the law is complied with The Concord CXA 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 CXA H 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 installation...

Page 4: ...s is designed to protect the boiler and may not necessarily protect the remote parts of the system OPTION KITS Remote indication kit This kit gives the facility of remote indication of the boiler status Pressure gauge kit In addition to the above control kit an optional pressure gauge is also available for the range of boilers Details for fitting are included with the pressure gauge Downdraught th...

Page 5: ...errun litres Relationship between load and water volume for the minimum capacity of water circuit during the 6 minute pump overrun period for different boiler outputs Graph 1 Heat Load Water Volume CXA110 H CXA120 H 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 190 200 160 170 180 120 110 100 90 80 70 60 50 40 30 20 10 0 Graph 2 Hydraulic Resistance Hydraulic Resistance mbar Flow litres min 1...

Page 6: ...r into the expansion cistern must be avoided The above circuit capacity during pump overrun may be achieved either by provision of an adequate bypass circuit or by ensuring that a zone of suitable size is open for circulation during this period by relevant control of zone valves or pumps The wiring diagrams in Frames 17 18 19 illustrate the control methods for achieving the above 3 Pump selection ...

Page 7: ...12 BS 6281 Part 1 BS 6282 Part 1 BS 6283 Part 4 Working pressure 6 bar maximum Particular reference should be made to BS 6644 Section 6 and Guidance note PM5 Automatically controlled steam and hot water boilers published by the Health and Safety Executive The information and guidance given below is not intended to override any requirements of either of the above publications or the requirements of...

Page 8: ...nless 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 CXA H range of boilers is supplied complete with an integral draught diverter a diverter MUST NOT be fitted within the chimney syste...

Page 9: ...Assembled boiler body with distributor tube on a wooden pallet base enclosed in a wooden crate 2 Carton containing the casing fastenings and flue brush 3 Carton containing the installation pack and instruction books 4 Carton containing the control box INSTALLATION HARDWARE PACK contains M10 washer 4 off Split pin 1 off Strain relief bush 1 off M10 x 25 Hex Hd screw 2 off M10 x 35 Hex Hd screw 2 of...

Page 10: ... and the flow tapping d Complete the water connections by plugging the 2 front top tappings with the 2 BSP plugs provided 1 Fit the distributor tube supplied with the boiler into one of the return connection That is one of the rear lower ports refer to Frame 5 Fit the flange using the M10 x 35mm screws and washers provided Ensure that the notch in the tube flange sits correctly into the groove on ...

Page 11: ...ostat phial and control sensor are correctly secured in the pockets Refer to Frame 13 9 SYSTEM CONNECTIONS One flow and return connection should be made to the rear of the boiler either on one side or opposite sides The distributor tube and gaskets supplied with the boiler must be connected into the pumped return connection Refer to Frame 8 Two thermostat pockets are supplied in the installation p...

Page 12: ...ostat pocket adjacent to the flow connection Fit the plastic Heyco bush over the sensor lead at the line shown and insert it into the thermostat pocket Ensure that the Heyco bush is correctly located 13 CASING ASSEMBLY continued 9 Fit the earth lead to the casing support angle as shown 4 Fit 3 clips to the top of each side panel 5 Fit the spire clips to the side casing panels 6 Hook on the control...

Page 13: ... unswitched live supply which the boiler requires to allow the pump overrun facility to operate should be controlled by the above switched fused supply but should connect from there directly to the boiler and not via any automatic time or temperature controls The switched live supply should be subject to control by time and temperature controls in the usual way The controls incorporate a pump over...

Page 14: ...14 Concord CXA H Installation and Servicing INSTALLATION 16 INTERNAL WIRING br brown r red LEGEND b blue bk black y yellow w white y g yellow green or orange v violet pk pink INSTALLATION ...

Page 15: ...e any zone may be the load during overrun 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 17 ZONES WITH BI DIRECTIONAL MOTORISED VALVES Normal operation When any thermostat is satisfied while others are calling for heat power is available via relay contacts to close t...

Page 16: ...1 now calls for heat its thermostat will open Zone 1 valve via the normally open contacts of the relay 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...

Page 17: ...f 2 minutes Any leaks must be cured Replace all pressure test point screws 21 INITIAL LIGHTING 1 Check that the boiler thermostat knob on the control box is OFF 2 Ensure that the main gas inlet cock is open groove in the square head in line with the pipe 3 Press in the overheat reset button 4 Switch on the electrical supply to the boiler 5 Turn the boiler thermostat knob on the control panel to nu...

Page 18: ...rectly to manual on off operations of any controls fitted in the gas control circuit Check in the following manner the operation of the flame failure safety device 1 Extinguish the main burner and pilot burner by turning off the main gas inlet cock 2 The controls will go to lockout almost immediately and the lockout light on the control panel will light 3 Turn the gas cock again and press in and r...

Page 19: ...x door lift it and carefully drop it down Pull off the flame detector lead and the spark electrode lead connections from the S4561B1054 PCB the left hand board Undo the strain relief clamp and feed the sleeved leads out of the box The burner can now be fully removed from the boiler Undo the screws securing the clean out cover and lift it off to give access to the flue ways CLEANING THE BOILER Refe...

Page 20: ...l on the inside of the casing front panel and check the gas connections for tightness as detailed under Testing for Gas Soundness Frame 20 Check gas pressures and the gas rate test as instructed in Frame 22 Manifold Gas Pressure and Testing Adjust any time and temperature controls to User s requirements and remember to reset any time control which may have been switched off to the correct time of ...

Page 21: ...n Frame 27 2 Both RH and centre burners can be removed by sliding each one back to clear the injector and then lifting out 3 To exchange the LH burner remove it from the boiler as previously described in Frame 27 Remove pilot burner as described in Frame 30 4 Fit new LH burner and the centre and RH burners Note Ensure that the pilot burner is correctly fitted i e facing the front and that the pilo...

Page 22: ...t 35 BURNER AND CONTROLS ASSEMBLY Exploded View CXA 40 H 80 H 36 BURNER AND CONTROLS ASSEMBLY Exploded View CXA 90 H 120 H LEGEND 1 Main gas inlet cock 2 Gas inlet union 3 Gas control valves 4 O ring seal 5 Gas inlet manifold 6 Main injector 3 off 7 RH burner 8 Centre burner 9 LH burner 10 Overheat thermostat 11 Mounting brackets 12 Pilot draught shield not fitted to CXA 120 H 13 Flame detector el...

Page 23: ...cuit board and release cable clamp from the back panel 5 Pull the sensor lead through the grommeted hole in the back panel and the wire clips 6 Fit the new sensor and reassemble in reverse order ensuring that the lead is rerouted along the casing in the clips provided 1 Remove the lower front and top panel Refer to Frame 27 2 Remove the sensor from the thermostat pocket in the rear heat exchanger ...

Page 24: ...the lower front panel 2 Undo the 2 screws securing the control box front panel Carefully lift it up and lower down 3 Pull off the 2 plugs and 3 push on connections from the board The board can now be removed by squeezing in the retaining barbs 4 Re assemble in reverse order ensuring that the push on connections are as follows from left to right spark electrode blank earth flame detector Printed ci...

Page 25: ...re part Gloves supplied with the spare part 1 Damp down the combustion chamber area containing the insulation boards 2 Remove the insulation boards The replacement boards are supplied in a plastic bag This bag should be retained and the discarded boards should now be placed into it 3 Sweep any dampened particles and place in the plastic bag 4 Fit new insulation boards 5 Remove the gloves and face ...

Page 26: ... remove the left hand burner the pilot gas pipe connection at the gas valve must be removed 4 The left hand burner may now be removed by pushing it back to clear the injector and lifting it out taking care not to damage the pilot gas pipe while the burner is out of the appliance 5 Undo the nut securing the manifold assembly to the combustion chamber pull the manifold assembly to the right and lift...

Page 27: ...mbly are not fixed together therefore CARE MUST BE TAKEN TO PREVENT the installed section coming apart 8 Repeat the above procedure for all of the remaining sections until the assembly is 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 fi...

Page 28: ...sk which has required the breaking and remaking of electrical connections the following checks MUST be repeated Check that the gap between the electrode and pilot burner is 3 4 mm Ensure that the H T lead and electrode are sound clean and undamaged and that the connections are secure Check that the spark generator is operative by carefully holding an earthed screwdriver 3mm from the H T output ter...

Page 29: ...GOES OUT ON OVERHEAT THERMOSTAT Are the thermostat sensors in their correct pockets YES Is there an unswitched live supply to terminal L1 on the plug in terminal connection at the control box Is the pump or shunt pump wired to terminal L2 in the control box NO YES Is there sufficient open circuit water volume or load available on boiler shut down for the pump overrun YES Refer to installation inst...

Page 30: ...ector 1 077 105 28 Pilot burner injector HONEYWELL 45900421 011 1 004 545 29 Gas control valve HONEYWELL V4601 AB 1034 1 154 810 Gas control valve HONEYWELL VR4605 AB 1019 CXA 90 120 H 1 111 869 Gas valve plugs and lead assy CXA 40 120 H 1 154 733 Gas valve plugs and lead assy CXA 90 120 H 1 112 431 Gas valve plugs and lead assy CXA 90 120 H 1 139 269 32 Ignition electrode and H T lead assy 1 154 ...

Page 31: ...52 CXA 80 H 1 111 652 CXA 90 100 H 1 111 653 CXA 110 120 H 1 154 898 50 Casing top panel white stove enamel CXA 40 H 1 111 293 CXA 50 H 1 111 294 CXA 60 H 1 111 295 CXA 70 H 1 111 296 CXA 80 H 1 111 297 CXA 90 100 H 1 111 298 CXA 110 120 H 1 154 897 51 Casing lower front panel white stove enamel c w lighting instructions 1 171 842 52 Casing upper front control panel less controls 1 154 846 53 Casi...

Page 32: ...tinuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice The Ideal Boilers 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 please ring 01482 498 432 Ideal Installer Technical Helpline...

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