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Table of Contents
Related Manuals for IDEAL Concord CXA 40/H
Summary of Contents for IDEAL Concord CXA 40/H
- Page 2 GENERAL Table 1- Performance Data 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 Number of Sections Boiler Input Gross 48.3 60.3 72.4 84.5 96.5 108.6 120.7 132.7 144.8 Btu/hr x 1000 164.7 205.8 247.0 288.2...
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Page 3: Table Of Contents
Site Assembled Boilers..........26 Appliance Directive. Static Head Requirements..........6 Note. Concord CXA 40/H, CXA 50/H and CXA 60/H boilers are intended for use as COMMERCIAL BOILERS and are NOT System Connections............11 certified for use in domestic applications. A domestic installation is defined as an installation where the boiler takes its combustion Ventilation. -
Page 4: Option Kits
GENERAL GAS CONTROLS Downdraught thermostat kit This kit is optional when used on a single CXA/H installation, but Control is by automatic ignition of intermittent pilot; once the mandatory when used on a multiple boiler installation. presence of a flame has been proved the single (or double) main gas valves open to give full heat input. -
Page 5: Hydraulic Resistance
GENERAL Relationship between load and water volume for the minimum capacity of water circuit during the 6 minute pump overrun period for different boiler outputs. Example A Example B Water Volume in Circuit during Pump Overrun (litres) 90 100 110 120 130 140 150 160 170 180 190 200 Flow (litres/min) -
Page 6: Pump
GENERAL The above circuit capacity during pump overrun may be PUMP POSITIONS achieved either by provision of an adequate bypass circuit Whenever practically possible the circulating pump(s) should be or by ensuring that a zone of suitable size is open for positioned so that it pressurises the system being served. -
Page 7: Installation Requirements
BS.6644: Installation of Gas Fired Hot Water Boilers For the reason stated, Caradon Ideal Limited strongly recommend 70kW to 1.8MW (net). that, when necessary, the system is thoroughly cleaned, prior to the use of stable inhibitor, which does not require continual topping BS 6880 Pt 1-3: Water Supply. -
Page 8: Air Supply
Care should be taken to ensure the specification of the chimney is suitable for the application by reference to the manufacturers literature. Caradon Ideal Limited can offer advice on the design Position ventilation grilles to avoid the risk of accidental of suitable chimney systems. -
Page 9: Boiler Assembly - Exploded View
INSTALLATION CONCORD CXA/H BOILER ASSEMBLY - Exploded view Alignment notches Distribution tube detail Legend 1. Cleanout cover 13. Section bolt 2. Collector hood 14. Distribution tube 3. Middle section 15. Tie rods 7. Drain cock 4. Section alignment rings & 'O' rings 10. -
Page 10: Boiler Assembly
INSTALLATION PACKAGING AND BOILER REMOVAL 1. Remove the casing carton and outer packaging 9. Using the handling bars, manoeuvre the boiler forwards frame. on the packaging base and slide over collapsing base on to the floor. 2. Remove the casing pack support frame. Note. -
Page 11: System Connections
INSTALLATION SYSTEM CONNECTIONS Position the overheat thermostat phial into the thermostat One flow and return connection should be made to the pocket at the opposite side to the flow pipe. The illustrations rear of the boiler - either on one side or opposite sides. below show the rear of the boiler with the flow and relative The distributor tube and gaskets, supplied with the boiler, overheat thermostat positions. - Page 12 INSTALLATION 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 the side panels. Screw in self tapping screws at the bottom of the control box to fix it to the side panels.
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Page 13: Electrical Connections
INSTALLATION 14 ELECTRICAL CONNECTIONS The internal wiring of the boiler control box is shown in Frame Connection must be made in a way that allows complete Wiring should be in four core PVC insulated cable, not less than isolation of the electrical supply - such as a double pole 0.75mm (24/0.2mm). - Page 14 INSTALLATION 16 INTERNAL WIRING LEGEND b blue br brown y yellow y/g yellow/green v violet bk black w white or orange pk pink Concord CXA/H - Installation and Servicing...
- Page 15 INSTALLATION 17 ZONES WITH BI-DIRECTIONAL MOTORISED VALVES IMPORTANT Normal operation Terminal L2 may control the appropriate pump(s) directly, provided that the total running or starting current does not When any thermostat is satisfied while others are calling for exceed 6A (resistive or inductive): if this rating would be heat, power is available via relay contacts to close the valve for exceeded then appropriate switchgear must be used to that zone.
- Page 16 INSTALLATION 18 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.
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Page 17: Initial Lighting
INSTALLATION 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 system has been filled and properly vented. Remove the screw in the inlet pressure test point (Frames 21/22) and connect a gas pressure gauge to the test point. -
Page 18: Gas Pressure
INSTALLATION 22 GAS PRESSURE Failure to follow this procedure may result in the correct burner pressure being set but the 2 gas valve governors not working MANIFOLD PRESSURE correctly. The manifold setting pressure must now be checked and CXA 110/H and 120/H boilers: adjusted as necessary. -
Page 19: Servicing
SERVICING 27 SERVICING (CXA 120/H boiler only) Caradon Ideal Limited does not accept any liability Remove four M5 securing screws retaining internal turning resulting from the use of unauthorised parts or the repair baffles from side of collector hood. Slide turning baffles to rear... - Page 20 SERVICING 28 SERVICING - continued Refit the LH burner, ensuring that the flame detector lead is properly connected. Reconnect both electrode leads at the S4561B1054 PCB in the control box. Ensure the sleeving passes through the strain relief clamp before refastening it. Main burner flame ports Refit the centre and RH burners.
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Page 21: Main Burners
SERVICING 31 SPARK ELECTRODE AND LEAD Pilot draught shield (not fitted to CXA 120/H) 1. Remove the LH burner as previously described in Frame 27 2. Remove the 2 screws securing the control box front LH burner panel, lift it and carefully lower it. Flame detector 3. -
Page 22: Cxa 90/H-120/H
SERVICING 35 BURNER AND CONTROLS ASSEMBLY - Exploded View CXA 40/H - 80/H LEGEND Main gas inlet cock Gas inlet union Gas control valve 'O' ring seal Gas inlet manifold Main injector, 3 off RH burner Centre burner LH burner 10. -
Page 23: Overheat Thermostat
SERVICING 38 CONTROL SENSOR 42 OVERHEAT THERMOSTAT POTENTIOMETER ASSEMBLY 1. Remove the split pin from the overheat 1. Undo the thermostat knob retaining screw and pull thermostat pocket off the knob. and remove the phial. 2. Remove the lower front panel 2. - Page 24 SERVICING 40 CONTROL BOX - Basic Boiler, Exploded View Printed circuit board support detail " & LEGEND Terminal strip Potentiometer Wiring clamp. Back panel 10. Warning light lens Connection box plug. Lockout reset button 11. Controls box Connection box. Thermostat knob 12.
- Page 25 2. Remove the insulation boards. The replacement boards are supplied in a plastic bag. This bag should be Caradon Ideal Limited, however, recommend that for retained and the discarded boards should now be your own comfort and to comply with good working placed into it.
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Page 26: Site Assembled Boilers
SITE ASSEMBLY 44 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS Alignment notches Distribution tube detail Legend TOOLS REQUIRED 10. Burner manifold assy. 1. Cleanout cover. Spanners 11. Base plate. 2. Collector hood. Torque wrench 12. Combustion chamber. 3. Middle section. Pozi screwdriver 13. - Page 27 SITE ASSEMBLY 45 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, Frame 44 6.
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Page 28: Fault Finding
FAULT FINDING Before attempting any electrical fault finding ALWAYS carry out Earth continuity the preliminary electrical system checks as detailed in the Polarity Instructions for the British Gas Multimeter or other similar Resistance to earth commercially available meter. Detailed instructions on the replacement of faulty components The preliminary electrical system checks are the FIRST are contained in the 'Servicing' section of these Installation &... - Page 29 FAULT FINDING 48 PILOT LIT BUT NO MAINS GAS Are the plugs on the gas valve(s) secure Secure and tighten and tight ? Are the connections at the plug-in terminal strip at the control box secure ? Fit new S4561B1054 PCB Is there 230V ±10% at the gas valve plug(s) ? Fit new gas valve 49 BOILER GOES OUT ON OVERHEAT THERMOSTAT...
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Page 30: Short List Of Parts
SHORT LIST OF PARTS The following are parts commonly When ordering spare parts please quote: required as replacements, due to 1. Boiler model damage or expendability. 2. Boiler serial no. (refer to the data plate on the combustion chamber) 3. Boiler B.G. P.I. No. (refer to the data plate on the combustion chamber) 4. - Page 31 SHORT LIST OF PARTS Key No. Description Qty. Product No. Right hand casing side panel - white stove enamel .. CXA 40/H 111 650 ..................CXA 50/H 111 651 ..................CXA 60/H 111 651 ..................CXA 70/H 111 652 ..................CXA 80/H 111 652 ..................
- Page 32 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.