Ideal Boilers Concord CXD 40-100 Installation & Servicing Manual
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Ideal Boilers Concord CXD 40-100 Installation & Servicing Manual

Ideal Boilers Concord CXD 40-100 Installation & Servicing Manual

Commercial central heating boilers
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Summary of Contents for Ideal Boilers Concord CXD 40-100

  • Page 2 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. Concord CXD - Installation...

  • Page 3: Table Of Contents

    Concord CXD 40-CXD 100 (Natural gas) B.G. Certified - P.I. No. 87/AQ/103 Destination Countries: GB & IE INTRODUCTION CONTENTS CONSTRUCTION BOILER BODY Air Supply................9 The sectional boiler body is of cast iron and is supplied assembled on a sheet steel combustion chamber with an integral draught Boiler Assembly - exploded view.
  • Page 4 GENERAL Table 1- Performance Data Boiler CXD 40 CXD 50 CXD 60 CXD 70 CXD 80 CXD 90 CXD 100 Number of sections Boiler Input Gross 31.5 37.5 45.1 52.8 60.4 68.1 75.0 Low Rate Btu/hr x 1000 107.5 128.0 154.0 180.0 206.0...

  • Page 5: Controls

    GENERAL domestic hot water and central heating systems; Independent GAS CONTROLS indirect pumped domestic hot water or central heating systems. The gas controls consist of a high / low arrangement with direct burner ignition. Fully pumped systems may be open vented or sealed. The range of boilers is NOT suitable for: ELECTRICAL CONTROLS 1.

  • Page 6: Hydraulic Resistance

    GENERAL Graph 1 - Heat Load / Water Volume Graph 2 - Hydraulic Resistance CLEARANCES & DIMENSIONS Table 4 Boiler Size CXD 40 CXD 50 CXD 60 CXD 70 CXD 80 CXD 90 CXD 100 Front clearance mm (in) 750 (29 Rear clearance mm (in) 150 (6)

  • Page 7: Pump

    GENERAL The wiring diagrams in Frames 16,17 &18 illustrate the control MINIMUM FLOW OF WATER - Refer to Table 5 methods for achieving the above. The system design must provide for an adequate flow rate through the boiler at all times when the boiler is firing. The 3.

  • Page 8: Installation Requirements

    GENERAL atmosphere if proper venting and expansion of system water is to relevant requirements of the local gas supplier, local authority be achieved. The same tank is used to fill the system with water and the relevant British Standard Codes of practice and building and it is through the cold feed pipe that system water expands regulations.

  • Page 9: Air Supply

    GENERAL FOUNDATION CHIMNEY SYSTEM The boiler must stand on a non-combustible floor (i.e. concrete or To ensure the safe and satisfactory operation of the boiler then brick) which must be flat, level and of a suitable load bearing the chimney system (which may be common or individual, in the capacity to support the weight of the boiler (when filled with water) case of twin or multiple boiler installations) must be capable of the and any ancillary equipment.

  • Page 10: Boiler Assembly - Exploded View

    INSTALLATION CONCORD CXD BOILER ASSEMBLY - Exploded view Legend 13. Section bolt 7. Drain cock 1. Cleanout cover 14. Distribution tube 8. NOx duct 2. Collector hood 15. Tie rods 9. Front plate 3. Middle section 16. Thermostat pocket 10. Burner manifold assy. 4.
  • Page 11 INSTALLATION PACKAGING INSTALLATION HARDWARE PACK contains Check that all these packages are complete and have been correctly received on site. M10 washer ........4 off Factory assembled boilers are despatched from the works as fully packaged units comprising: Split pin ..........1 off 1.

  • Page 12: System Connections

    INSTALLATION BOILER ASSEMBLY 1. Fit the distributor tube (supplied with the boiler) into one Note. Frame 9 shows the relationship between the of the return connections. That is one of the rear lower overheat thermostat and the flow tapping. ports. Refer to Frame 5. d.

  • Page 13: Casing Assembly

    INSTALLATION 10 FLUE CONNECTION 11 GAS CONNECTION 1. Complete the flue connection. 1. Connect the gas supply to the gas inlet pipe at the 2. The boiler is designed to accept flues to BS. 835 and rear LH side of should be sealed with an approved boiler putty.
  • Page 14 INSTALLATION 13 CASING ASSEMBLY - continued 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 box to side panels. Screw in self tapping screws at the bottom of the control box to fix it to the side panels.

  • Page 15: Electrical Connections

    INSTALLATION 14 ELECTRICAL CONNECTIONS voltage. If no external controls are fitted a link must be fitted Connection must be made in a way that allows complete across 'EXT C' terminals. isolation of the electrical supply - such as a double pole switch, having a 3mm (1/8") contact separation in both poles, The boiler provides frost protection via the boiler sensor.
  • Page 16 INSTALLATION 15 INTERNAL WIRING LEGEND b blue br brown y/g yellow/green v violet y yellow bk black or orange w white pk pink 16 ZONES WITH BI-DIRECTIONAL 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...
  • Page 17 INSTALLATION 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.

  • Page 18: Commissioning

    INSTALLATION 19 COMMISSIONING AND TESTING GENERAL TESTING FOR GAS SOUNDNESS Check that all drain cocks are closed, that any stop valves Close the gas supply cock at the meter. fitted to the flow and return pipes are open and that the Remove the screw in the inlet pressure test point, Frames system has been filled and properly vented.
  • Page 19 INSTALLATION 22 CHECKING THE MANIFOLD PRESSURES Turn the boiler OFF by pressing the [0/1] button and allow the Observe the burner pressures and compare them to the flow temperature to cool to less than 50 values given in Table 1. If either pressure differs by more than 10%, reset the pressures by following the procedure in Connect a pressure gauge to the burner manifold test point Frames 23 or 24.

  • Page 20: Operating Instructions

    INSTALLATION 24 ADJUSTING THE MANIFOLD PRESSURES CXD 70, 80 90 &100 ONLY 5. Press the [0/1] button again to light the burner. Allow the burner to run at low rate for several minutes, then check 1. Press the [ENTER] button on the fascia panel, then press that the low burner pressure is as shown in Table 1 for either the up or down arrow button until the display shows: the appropriate boiler size.
  • Page 21 INSTALLATION 26 ADDITIONAL FEATURES OF THE CONTROL SYSTEM In addition to the operational characteristics described above, FAULT DIAGNOSIS the control system incorporates the following features In the unlikely event of a fault condition, the microprocessors accessible to the user or service engineer: will identify the fault area and display a suitable message on the display.
  • Page 22 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 CXD - Installation...
  • Page 23 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 the above use the [UP] or [DOWN] button until Any key, except the [1/0] button, may now be pressed to the option required is displayed and press [ENTER].
  • Page 24 INSTALLATION 30 DESCRIPTION AND OPERATION OF BOILER CONTROLS - continued valve is energised. procedure should be followed but the [NO] button pressed. 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.

  • Page 25: Servicing

    SERVICING 31 SPILLAGE CHECK 32 TESTING Check that the main burner responds correctly to manual on/off Check there is no spillage of operations of any controls fitted in the gas control circuit. combustion products from the boiler Check, in the following manner, the operation of the flame failure safety draught diverter by carrying out a device.
  • Page 26 SERVICING 36 SERVICING - continued Ensure that they are clean and in good condition. Unscrew the extended nuts at the top of the NOx duct behind In particular, check that: the control box and lift the NOx duct clear of the burners as illustrated below.

  • Page 27: Main Burner

    SERVICING 38 GAS CONTROL VALVE 39 MAIN BURNER 1. Disconnect the electrical connections to the faulty gas 1. Remove the NOx duct and burner front plate, as valve. previously described in Frame 35. 2. Check that the gas inlet cock is OFF, unscrew the 4 2.

  • Page 28: Cxd 70-100

    SERVICING 41 BURNER AND CONTROLS ASSEMBLY - Exploded View - CXD 70-100 LEGEND Main injector, 3 off. Gas control valve, Low. Main gas inlet cock. Main (centre/RH) burner, 2 off. Gas control valve, High. Gas inlet union. Spark generator. 10. Main (LH) burner, 1 off. 'O' ring seal.
  • Page 29 SERVICING 43 CONTROL BOX - Basic Boiler, Exploded View LEGEND 1. Wiring clamp. 5. Back panel. 9. Ribbon cable. 2. Connection box plug. 6. Hinge pin. 10. Printed circuit board No. RTC/34. 3. Connection box. 7. Controls box. 11. EMC Filter 4.
  • Page 30 SERVICING 46 PC BOARD NO. 35 47 PC BOARD NO. RTC/34 1. Remove the lower front panel. 1. Remove the lower front panel. 2. Slacken the 2 screws securing the control box front 2. Slacken the 2 screws securing the control box front panel.

  • Page 31: Site Assembled Boilers

    SITE ASSEMBLY 49 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS Legend TOOLS REQUIRED 10. Burner manifold assy. 1. Cleanout cover. 11. Base plate. Spanners 2. Collector hood. Torque wrench 12. Combustion chamber. 3. Middle section. Pozi screwdriver 13. Section bolt. 4. Section alignment Mallet 14.
  • Page 32 SITE ASSEMBLY 50 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS - continued PREPARATION OF SECTIONS Each section should be brushed clean on all external surfaces and any debris which may have accumulated within the section should be removed via the bottom ports. Section assembly - Refer to exploded view 6.

  • Page 33: Fault Finding

    FAULT FINDING 51 BOILER CONTROL WARNING user, the boiler will go to low rate and when the temperature The ON/STANDBY [1/0] button does NOT electrically reaches the set point plus 3 C the low rate gas valve will isolate the boiler. close.
  • Page 34 FAULT FINDING 52 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 35 FAULT FINDING 53 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 programme timer and status as...

  • Page 36: Short List Of Parts

    SHORT LIST OF PARTS When ordering spare parts please quote: The following are parts commonly 1. Boiler model required as replacements due to 2. Boiler serial no. (refer to data plate on the combustion chamber) damage or expendability. Their failure 3.
  • Page 37 SHORT LIST OF PARTS Key No. Description Qty. Product No. Gas valve plug and lead ..........CXD 40 / 60 111 872 ................... CXD 70 /100 112 430 ................... CXD 70 /100 112 431 ................... CXD 40 /100 111 870 Right hand jacket side panel - white stove enamel CXD 40 111 650...
  • Page 38 Caradon Plumbing Limited pursues Technical Training a policy of continuing improvement in the design and performance of its The Caradon Plumbing Limited Technical Training Centre products. The right is therefore offers a series of first class training courses for domestic, reserved to vary specification without commercial and industrial heating installers, engineers and notice.
  • Page 39 Your feedback and your chance to win a free boiler At Ideal we've been leaders in the design and engineering of robust and reliable boilers for over 90 years. We want to continue as leaders by listening to your suggestions for how to improve our boilers and our service. We'll be giving away a free boiler for the five best ideas every year (to be selected by our Technical Director).

  • Page 40: Further Information

    Further information If you would like information about Ideal Boilers please complete this sheet and fax it to us on 01482 498699 or post it to Caradon Plumbing Limited, PO Box 103, National Avenue, Kingston upon Hull, HU5 4JN. Installer details...

This manual is also suitable for:

Concord cxd 40-60Concord cxd 70-100

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