IDEAL Concord CXS 120 Installation & Servicing Manual Download

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Installers guide to commercial central heating boilers

I N S T A L L A T I O N

I D E A L

M A N U A L

T H E

& S E R V I C I N G

Concord

CXS 40 - 120

Summary of Contents for Concord CXS 120

Page 1: ...stallers guide to commercial central heating boilers I N S TA L L AT I O N I D E A L I D E A L I D E A L I D E A L I D E A L M A N U A L T H E T H E T H E T H E T H E S E R V I C I N G Concord CXS 40 120 ...

Page 2: ...ncord CXS Installation Servicing 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: ... to ensure that the law is complied with The Concord CXS 40 120 range of boilers has been tested and certified by British Gas to prEN656 for use with Natural gas only Multiple boiler installations The Concord CXS 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 in...

Page 4: ...6 7 Nett kW 28 4 33 8 40 6 47 5 54 4 61 4 67 6 74 0 81 0 Btu hr x 1000 97 0 115 3 138 5 162 5 185 6 209 5 231 7 252 5 276 4 Boiler Input Gross kW 52 5 62 5 75 1 87 93 100 7 113 5 125 0 137 4 149 8 Btu hr x 1000 179 1 213 3 256 2 300 0 343 6 387 3 426 5 468 8 511 2 High Rate Nett kW 47 3 56 3 67 7 79 2 90 7 102 3 112 6 123 8 135 0 Btu hr x 1000 161 4 192 1 231 0 270 2 309 5 349 0 385 2 422 4 460 6 ...

Page 5: ... The mains voltage supply is via a terminal plug in connection at the control box OPTION KITS Remote Indication Kit This kit gives the facility of remote indication of boiler status Pressure Gauge Kit A pressure gauge kit is available Downdraught Thermostat Kit This kit is optional when used on a single CXS installation but mandatory when used on a multiple boiler installation DUTY The range of bo...

Page 6: ... 163 0 167 213 in 2 3 4 3 1 8 3 1 8 4 5 8 4 5 8 6 1 2 6 1 2 6 5 8 8 3 8 Table 4 POSITION 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...

Page 7: ...ositioned 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 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 ...

Page 8: ...Hot Water Boilers 60kW to 2MW BS 6880 Pt1 3 Water Supply CP342 2 Centralised Hot 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 ...

Page 9: ...Boilers and Air Heaters and the Third Edition of the 1956 Clean Air Act Memorandum should be strictly observed where applicable The chimney design should avoid the formation of excessive quantities of condensate For this reason it is recommended that all chimneys are insulated and lined In the case of brick or similar structures a stainless steel rigid or flexible flue liner grade 304 316 may be u...

Page 10: ...anout 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: ...g 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 boiler forward on the p...

Page 12: ...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 side as the return or opposite the ret...

Page 13: ...r 2 Table 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 casing hardware pack contains all the screws required for assembly 2 Slide bottom of the side panel on to the ...

Page 14: ...y 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 insert it int...

Page 15: ...l box is shown in Frame 15 Wiring should be in four core PVC insulated cable not less than 0 75mm2 24 0 2mm All fuses must be ASTA approved to BS 1362 The length of the conductor between the cord anchorage and the terminals must be such that the current carrying conductors become taut before the earthing conductor if the cable or cord slips out of the cord anchorage The boiler can be controlled ei...

Page 16: ...16 Concord CXS Installation Servicing 15 INTERNAL WIRING v violet pk pink y gyellow green or orange y yellow w white br brown r red LEGEND b blue bk black INSTALLATION INSTALLATION W4115A1020 T2 ...

Page 17: ... 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 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 i...

Page 18: ...es Any leaks must be cured Replace all pressure test point screws 18 ZONES WITH SPRING RETURN MOTORISED VALVES 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 illustr...

Page 19: ...tton 4 4 Switch on the electrical supply to the boiler 5 Ensure that all system controls time switch system controls etc are calling for heat 6 Turn the boiler thermostat knob 1 to position 6 20 INITIAL LIGHTING INSTALLATION INSTALLATION CXS 40 90 boilers shown 7 The boiler will light at Low rate and the Boiler on light 5 will be illuminated If it does not light the Lockout light 6 will be illumin...

Page 20: ...lows CXS 40 90 Boilers Refer to Frame 20 illustration Numbers in brackets in this 40 90 section also refer to Frame 20 The location of the manifold pressure adjuster 8 on the gas valve is shown in Frame 20 Prise off the plastic cover on the gas valve 9 and using a suitable spanner set the High burner pressure adjuster 10 to the value given in Table 1 Undo the screw retaining the electrical plug 11...

Page 21: ...ust 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 26 SERVICING Caradon Plumbing Limited does not accept any liability resul...

Page 22: ...ectrode shield and base fixing screws are tight 2 The electrodes are correctly positioned Refer to Frames 31 or 32 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 burne...

Page 23: ...23 or 24 1 Remove the NOx duct and burner front plate as previously described in Frame 26 2 On the CXS 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 the injector then lifting out Disconnect the ignition leads from th...

Page 24: ...llows 1 pink 2 white 3 red Reconnect the earth terminal 5 Reassemble in reverse order ensuring that the thermostat connections are facing front before fitting the top bracket and that the capillary goes through the slot in the top panel LEGEND 1 Main gas inlet cock 2 Gas inlet union 3 O ring seals 4 Gas control valve 5 Gas control valve 6 Spark generator 7 Burner manifold 8 Main injector 3 off 9 M...

Page 25: ... 4 Pull out the sensor plug from the PCB and remove the strain relief bush Remove the sensor and lead 5 Fit the new sensor in reverse order ensuring that the lead is routed along the casing in the clips provided SERVICING 5 Terminal strip 6 Back panel 7 Lockout reset button 8 Thermostat knob 1 2 3 12 5 4 6 8 9 7 2 10 11 LEGEND 1 Wiring clamp 2 Connection box plug 3 Connection box 4 PCB S456B1047 9...

Page 26: ... its contents into a commercial tip 35A CONTROL SENSOR POTENTIOMETER ASSEMBLY 1 Undo the thermostat knob retaining screw and pull off the knob 2 Remove the lower front panel 3 Undo the backnut and washer retaining the potentiometer 4 Undo the 2 screws securing the control box front panel lift it and carefully lower it 5 Pull off the connections at the back of the potentiometer and the plug from th...

Page 27: ...Practice together with any relevant 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 b...

Page 28: ...ems 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 the flue baffles which are located between ...

Page 29: ... pump with a maximum current of 3A is connected to the boiler pump terminals pump overrun will be in operation when the demand for heat is satisfied and will continue to run for 6 minutes Frost protection is inbuilt with the boiler If the flow temperature falls to approximately 5 o C then the boiler will operate until the flow temperature exceeds 18 o C Note that it is designed to protect the boil...

Page 30: ...k generator Replace PCB S4561B1047 YES YES 44 BOILER LIGHTS BUT GOES TO LOCKOUT NO Measure the flame current expect approximately 3 5µA Replace PCB S4561B1047 Check RH burner inlet and burner pressure check the RH burner injector YES 45 BOILER GOES OUT ON OVERHEAT THERMOSTAT NO YES Is the flame detector and its lead and connections sound and secure and correctly positioned on the RH burner YES NO ...

Page 31: ...WELL VR4605AB 1019 CXS 100 120 1 111 869 29D Gas control valve plug and lead assemblies CXS 40 120 1 111 870 29E CXS 40 120 1 154 734 29F CXS 100 120 1 112 431 29G CXS 100 120 1 139 269 29H 30 Spark generator assembly generator and terminals 1 112 721 32 Ignition electrode BE 3417 SI 1 112 365 33 Flame detection electrode BE 3459 SI 1 112 364 37 Thermistor Honeywell 1 154 816 40 Overheat thermosta...

Page 32: ... 154 867 A02 Ideal Installer Technical Helpline 01482 498376 SHORT LIST OF PARTS Key No Description Qty Product No 48 RH casing side panel white stove enamel CXS 40 1 111 650 CXS 50 60 1 111 651 CXS 70 80 1 111 652 CXS 90 100 110 1 111 653 CXS 120 1 49 LH casing side panel white stove enamel CXS 40 1 111 650 CXS 50 60 1 111 651 CXS 70 80 1 111 652 CXS 90 100 110 1 111 653 CXS 120 1 50 Casing top p...

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