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IDEAL Concord CXDi 120/H Installation And Servicing Manual

Commercial central heating boilers
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  • Page 2 GENERAL Table 1 - Performance Data Boiler CXDi 110/H CXDi 120/H CXDi 140/H CXDi 160/H CXDi 180/H Boiler Input Gross 93.9 102.5 119.5 136.6 153.7 Low Rate Btu/h x 1000 320.5 349.6 407.9 466.1 524.4 Nett 84.6 92.3 107.7 123.1 138.5 Btu/h x 1000 288.7...

  • Page 3: Table Of Contents

    Installation and Servicing Instructions or Installation................ 9 otherwise recommended by Caradon Ideal Limited in writing. If in doubt please enquire. Mandatory Requirements..........7 Any direct connection of a control device not approved by Caradon Option Kits.

  • Page 4: Option Kits

    GENERAL OPTION KITS - in order to make use of this the pump must be wired to the (pump) in the boiler control box. appropriate terminal L Remote indication board (volt free) 1. The minimum flow rate as given in Table 5 must be maintained This provides the ability for remote indication of lockout and whenever the boiler is firing and during the pump overrun period.

  • Page 5: Hydraulic Resistance

    GENERAL Graph 1 - Heat Load / Water Volume Graph 2 - Hydraulic Resistance CLEARANCES & DIMENSIONS Table 4 Boiler Size CXDi 110/H CXDi 120/H CXDi 140/H CXDi 160/H CXDi 180/H Front clearance mm (in) 700 (27 Rear clearance mm (in) 200 (8) Side clearance mm (in)

  • Page 6: Pump

    GENERAL PUMP POSITIONS WATER TREATMENT FOR HOT WATER AND HEATING BOILERS Whenever practically possible the circulating pump(s) should be positioned so that it pressurises the system being served. The There is a basic need to treat the water contained in all heating vertical distance between the pump(s) and any cold feed and and indirect water systems, particularly open vented systems.
  • Page 7 The maximum ambient temperature is 32 °C at 1.5 metres from the floor with a maximum humidity of 90% RH. For the reason stated Caradon Ideal Limited strongly recommend that when necessary the system is thoroughly cleaned, prior to FOR SMALL PIPE INSTALLATIONS;...

  • Page 8: Air Supply

    Caradon Ideal Limited can offer advice on the design of extraction. Mechanical extract ventilation with natural inlet must not suitable chimney systems.

  • Page 9: Boiler Assembly - Exploded View

    INSTALLATION CONCORD CXDi/H BOILER ASSEMBLY - Exploded view Insulation not shown Legend 7. End section. 1. Cleanout cover. 13. Combustion chamber. 8. Distribution tube. 2. Collector hood. 14. Tie rods. 9. Downdraught deflector. 3. Middle section. 15. Lightback shield. 10. Section bolt. 4.
  • Page 10 INSTALLATION BOILER SECTION ASSEMBLY TOOLS REQUIRED Spanners The site assembled boiler is supplied in the following packages: Torque wrench Combustion chamber / manifold / burner assembly. Pozi screwdriver Platework package. Mallet Casing package. Section Assembly - refer to the exploded view Controls box package.
  • Page 11 INSTALLATION BOILER SECTION ASSEMBLY - continued Side elev. of d/deflector-insulation assy. 12. Offer the downdraught deflector to the projecting studs at the back of the combustion chamber and fix, using the nuts and washers provided to the downdraught deflector. 13. Fit insulation brackets with the screws provided. 14.

  • Page 12: System Connections

    INSTALLATION BOILER ASSEMBLY 5. Complete the system connections (using suitable jointing compound) as follows: 1. Fit the distributor tube into the selected return connection. Ensure that the tube flange aligns horizontally and that the The cast iron flow header must be fitted in the chosen flow 2 sealing gaskets are correctly assembled on the tube - connection which will be either of the 2 top rear tappings.

  • Page 13: Casing Assembly

    INSTALLATION 11 CASING ASSEMBLY 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. 1. Fit the support angle to the collector hood and fasten, using the M5 screws and washers.
  • Page 14 INSTALLATION 12 CONTROL BOX 1. Make the 3 electrical connections from the overheat thermostat (fixed to the upper front framework) to the C N/O N/C terminals marked 'Limit Stat' on the electrical plug-in connector from the gas valve plug lead assembly, as follows: C Pink N/O Red...
  • Page 15 INSTALLATION 13 CONTROL BOX - continued 7. Run the flame detector lead through the clips on the front of the combustion chamber base tray and plug it into the flame NOx duct detector electrode on the LH end burner. Ensure that any slack is tucked neatly into the clips then fasten the clips.

  • Page 16: Electrical Connections

    The means of isolation must be accessible to the an external frost thermostat is required contact Caradon user after installation. Ideal Limited. This should serve only the boiler, together with its controls The internal wiring of the boiler control box is shown in Frame and pumps.
  • Page 17 Link Control panel earth stud Control panel earth stud Note: Link y pk v w or b br Detail of connection box Ideal No. 34 MAINS Voltage Plug -in connector N L2 FLOW ** Remote PUMP UNSWITCHED CONTROLS SW indication...
  • Page 18 INSTALLATION 17 ZONES WITH INDIVIDUALLY PUMPED ZONES (3 zones shown) IMPORTANT Terminal L2 may control the appropriate Permanent Live Supply pump(s) directly, provided that the total running or starting current does not exceed 6A Boiler terminals (resistive or inductive): if this rating would be L1 N L2 N exceeded then appropriate switchgear must...

  • Page 19: Commissioning

    INSTALLATION 19 COMMISSIONING AND TESTING GENERAL TESTING FOR GAS SOUNDNESS Check that all drain cocks are closed, that any stop valves fitted Close the gas supply cock at the meter. to the flow and return pipes are open and that the system has Remove the screw in the inlet pressure test point, Frames 23/ been filled and properly vented.
  • Page 20 INSTALLATION 22 CHECKING THE MANIFOLD PRESSURES Turn the boiler OFF by pressing the [0/1] button and allow the before proceeding to high rate (this will only happen if the flow flow temperature to cool to less than 50 temperature is below 55 C otherwise the boiler will proceed immediately to high rate).
  • Page 21 INSTALLATION 24 ADJUSTING THE MANIFOLD PRESSURES - CXDi 180/H only 1. Press the [ENTER] button on the fascia panel, press either 13. Turn the boiler on and set the low burner pressure to the the [UP] or [DOWN] arrow button until the display shows: value given in Table 1, using the low rate adjustment screw inside the spindle of the top valve.
  • Page 22 INSTALLATION 26 ADDITIONAL FEATURES OF THE CONTROL SYSTEM FAULT DIAGNOSIS In addition to the operational characteristics described above, In the unlikely event of a fault condition, the microprocessors the control system incorporates the following features will identify the fault area and display a suitable message on the accessible to the user or service engineer: display.
  • Page 23 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. Concord CXDi/H - Installation and Servicing...
  • Page 24 INSTALLATION 29 DESCRIPTION AND OPERATION OF BOILER CONTROLS - continued MENU To access the menu screen ensure that the information screens are being displayed. - to select any of them use the [UP] or [DOWN] button until the Any key, except the [1/0] button, may now be pressed to required option is displayed then press [ENTER].
  • Page 25 INSTALLATION 30 DESCRIPTION AND OPERATION OF BOILER CONTROLS - continued PROGRAMME HOURS Delayed High Rate Gas Valve Operation When the boiler is started from cold the high rate gas valve Enables a user-timed programme to be entered. will be delayed for 3 minutes and then energised. If the boiler The following display will be available:- flow temperature is equal to or greater than 55 C then this...

  • Page 26: Servicing

    SERVICING 35 SERVICING Caradon Ideal Limited does not accept any liability resulting from the use of unauthorised parts or the repair and servicing of appliances not carried out in accordance with the Company’s recommendations and specifications.
  • Page 27 SERVICING 36 SERVICING - continued Pull off the leads to the spark electrode on the RH end burner - If available, an industrial vacuum cleaner may be useful to access via the side of the combustion chamber. Pull off the lead assist in this work.
  • Page 28 SERVICING 39 MAIN BURNER 38 GAS CONTROL VALVE 1. Remove the burner tray from the boiler, as described in 1. Undo and pull off all the plugs from the gas valve Frame 36. solenoids. 2. Each burner can be removed by lifting it at the back and 2.

  • Page 29: Cxdi 180/H

    SERVICING 41 BURNER AND CONTROLS ASSEMBLY - Exploded view - CXDi 180/H LEGEND 9. Main burner (LH). 5. Gas control valve. 1. Main gas inlet cock. 10. Main burner (RH). 6. Spark generator. 2. Gas inlet union. 11. Ignition electrodes. 3.
  • Page 30 SERVICING 43 CONTROL BOX - Basic Boiler Exploded View LEGEND 1. Wiring clamp. 9. Printed circuit board No. RTC/34. 5. Back panel. 2. Connection box plug. 10. EMC filter. 6. Controls box. 3. Connection box. 11. Controls box fascia (not shown). 7.
  • Page 31 • Face mask supplied with the spare part. Caradon Ideal Limited, however, recommend that for • Gloves supplied with the spare part. your own comfort and to comply with good working practise the procedure described below is followed.

  • Page 32: Fault Finding

    Fault codes numbered 1 to 24 are displayed where applicable. start up, with the flow temperature less than 55°C, the boiler will In this event contact Caradon Ideal Limited. start at low rate and, after 1 to 3 minutes, the high rate gas valves will open.
  • Page 33 FAULT FINDING 50 SIMPLE FLOW CHART OF OPERATION SHUTDOWN Demand = ON DELAY Prepurge completed IGNITION Overrun Flame = ON completed If > than LOW RATE set point Flame = ON Temp >set For > 55°C no delay point If < 55°C ≅ ≅ ≅ ≅ ≅ 3 minutes Demand = off HIGH RATE...
  • Page 34 FAULT FINDING 51 FAULT FINDING FLOW CHART Boiler will not light Is 230V ± 10% Carry out electrical available at checks. appliance ? Check all fuses. Do any external Reset external controls call for controls as heat ? appropriate Check boiler Reset timer or status programme timer and as appropriate...

  • Page 35: Short List Of Parts

    When replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.
  • Page 36 155 269 Technical Training 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 Boilers, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN.

This manual is also suitable for:

Concord cxdi 180/hConcord cxdi 140/hConcord cxdi 160/hConcord cxdi 110/h

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