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Related Manuals for IDEAL Concord CXC 48
Summary of Contents for IDEAL Concord CXC 48
- 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 CXC - Installation...
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Page 3: Table Of Contents
It is in your own interest, and that of safety, to ensure that the law is complied with. Option Kits................ 5 The Concord CXC 48/116 range of boilers has been tested and Pump................. 7 certified by British Gas to prEN656 for use with Natural gas only. - Page 4 GENERAL Table 1- Performance Data Boiler CXC 48 CXC 70 CXC 94 CXC 116 Number of sections Boiler output High Rate 48.83 69.84 93.65 116.25 Condensing Btu/h x 1000 166 600 238 300 319 500 396 600 Boiler output High Rate 44.63 63.84 85.6...
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Page 5: Controls
GENERAL The range of boilers is NOT suitable for: GAS CONTROLS 1. Gravity DHW systems. The gas controls consist of a high / low arrangement with direct 2. Gravity heating systems. burner ignition. 3. Direct domestic hot water supply. ELECTRICAL CONTROLS SYSTEM DESIGN WARNING . -
Page 6: Hydraulic Resistance
GENERAL Graph 2 - Heat Load/ Water Volume Graph 3 - Hydraulic Resistance CLEARANCES & DIMENSIONS Table 4 Boiler Size CXC 48 CXC 70 CXC 94 CXC 116 Front clearance mm (in) 750 (29 1/2) Rear clearance mm (in) 200 (8) see text Side clearance mm (in) 50 (2) -
Page 7: Pump
GENERAL or by ensuring that a zone of suitable size is open for and cost. Graph 1 is based on a 20°C temperature difference circulation during this period by relevant control of zone across the boiler. valves or pumps. WATER CIRCULATION SYSTEM The wiring diagrams in Frames 16, 17 and 18 illustrate Due to the compact nature of the boiler the heat stored within the the control methods for achieving the above. -
Page 8: Water Treatment
GENERAL MINIMUM FLOW OF WATER - Refer to Table 5 the cold feed pipe that system water expands into the tank when The system design must provide for an adequate flow rate through the boiler passes heat into the system. Conversely, when the the boiler at all times when the boiler is firing. -
Page 9: Air Supply
GENERAL capacity to support the weight of the boiler (when filled with water) 2. Artificially softened water must not be used in the system, under and any ancillary equipment. any circumstances. If the boiler is mounted on a plinth then the dimensions must exceed 3. -
Page 10: Boiler Assembly - Exploded View
INSTALLATION CONDENSATE DRAIN be fitted and tested for gas soundness in accordance with BS. 6891 for small installations or IGE-UP-1 and IGE-UP-2 for large The Concord CXC boiler will produce condensate whenever the installations. temperature of the return water from the system is below approximately 55 C (the Dew Point of the combustion products). - Page 11 INSTALLATION PACKAGING JACKET PACK contains The Concord CXC boiler is despatched from the factory fully assembled except for the casing, controls and installation packs which are packed separately within the same wooden Lower front panel ....1 off crate as the boiler. Upper front panel ....
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Page 12: Condensate Drain Connection
INSTALLATION BOILER ASSEMBLY AND SYSTEM CONNECTIONS Manoeuvring the boiler 1. Remove the gas cock to access the LHS tapping. 2. Screw the 2 handling bars (2" pipe supplied) into the 2 top tappings. 3. Screw in 2 bars (not supplied), 1 into the LH rear top tapping and the second into the tee at the RH top tapping. -
Page 13: Casing Assembly
INSTALLATION 11 GAS CONNECTION 1. Refit the gas cock. 2. Connect the gas supply to the gas pipe elbow. The gas pipe should enter the boiler at the top LH side of the boiler. 3. Table 2 gives details of the inlet connection size and the minimum working pressures. - Page 14 INSTALLATION 13 CASING ASSEMBLY - continued 9. Route the overheat thermostat capillary 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 8. Secure with the split pin provided. 10.
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Page 15: Electrical Connections
INSTALLATION 14 ELECTRICAL CONNECTIONS The length of the conductors between the cord anchorage and the terminals must be such that the current conductors WARNING. become taut before the earthing conductor, if the cable or This boiler must be efficiently earthed. cord slips out of the cord anchorage. -
Page 16: Concord Cxc - Installation
INSTALLATION 15 INTERNAL WIRING y/g yellow/green LEGEND b blue br brown y yellow v violet or orange bk black 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: Concord Cxc - Installation
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 DO NOT SMOKE. Check that the gas supply is turned ON at 19 COMMISSIONING AND TESTING the meter and open the main gas inlet cock. Loosen the union GENERAL and allow air to be purged from the gas line until gas is Check that all drain cocks are closed, that any stop valves smelled. -
Page 19: Concord Cxc - Installation
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°C. values given in Table 1. If either pressure differs by more than 10%, reset the pressures by following the procedure in Frame Connect a pressure gauge to the burner manifold test point 23 or 24. -
Page 20: Concord Cxc - Installation
INSTALLATION 24 ADJUSTING THE MANIFOLD PRESSURES CXC 94 & 116 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: Concord Cxc - Installation
INSTALLATION 26 ADDITIONAL FEATURES OF THE CONTROL SYSTEM FAULT DIAGNOSIS In addition to the operational characteristics described above, 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: Concord Cxc - Installation
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 CXC - Installation... -
Page 23: Concord Cxc - Installation
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: Concord Cxc - Installation
INSTALLATION 30 DESCRIPTION AND OPERATION OF BOILER CONTROLS - continued Delayed High Rate Gas valve Operation If the Advance has been selected, then to cancel it the same When the boiler is started from cold the high rate gas valve will procedure should be followed but the [NO] button pressed. -
Page 25: Servicing
SERVICING 31 COMBUSTION SYSTEM 32 TESTING SOUNDNESS CHECKS Check that the main burner responds correctly to manual on/off operations of any controls fitted in the gas control circuit. Check, in the following Remove the upper front casing panel. manner, the operation of the flame failure safety device. Check that there is no leakage of 1. -
Page 26: Concord Cxc - Installation
Remove the fan plate, inspect the fan impeller and clean if necessary. Concord CXC 48/70 Lift out the flue baffles. Undo the screws securing the cleanout cover and lift it off to give access to the flue ways. Lift out the flue All boilers baffles. -
Page 27: Concord Cxc - Installation
SERVICING 37 SERVICING - continued TESTING AFTER SERVICING Remove the secondary heat exchanger front plate (6 screws) then slide out the secondary heat exchanger After re-assembly restore the electricity and gas supplies. baffles. Clean the fins with the brush provided and remove Light the boiler (refer to the Lighting Instructions) and test for all debris. -
Page 28: Concord Cxc - Installation
SERVICING 41 BURNER AND CONTROLS ASSEMBLY - Exploded View - CXC 48 & 70 LEGEND 11. Overheat thermostat generator mounting bracket. 1. Main gas inlet cock. 6. Burner manifold. 12. Overheat thermostat. 2. Gas inlet union. 7. Main injector, 3 off. 13. -
Page 29: Cxc 94-116
SERVICING 42 BURNER AND CONTROLS ASSEMBLY - Exploded View - CXC 94 & 116 8. Main injector, 3 off. 4. Gas control valve, Low. LEGEND 9. Main (centre/RH) burner, 2 off. 5. Gas control valve, High. 1. Main gas inlet cock. 10. -
Page 30: Concord Cxc - Installation
SERVICING 44 CONTROL BOX - Exploded View 8. Printed circuit board No. 35. LEGEND 9. Ribbon cable. 4. Printed circuit board No. 34. 1. Wiring clamp. 10. Printed circuit board No. RTC/34. 5. Back panel. 2. Connection box plug. 11. EMC Filter 6. -
Page 31: Concord Cxc - Installation
SERVICING 47 PC BOARD NO. 35 48 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 32: Concord Cxc - Installation
SERVICING 50 AIR PRESSURE SWITCH Before replacing the pressure switch, the pressure switch reading should be checked as follows: Connect the positive side of a manometer to the pressure sensing line from the fan scroll and the negative side of the manometer to the pressure sensing line connected to the flue box. -
Page 33: Fault Finding
FAULT FINDING 52 FLOAT SWITCH REPLACEMENT 9. Replace the saddle bracket. 1. Unscrew the screw located on the top edge of the upper 10. Run electrical leads through the clips and wire into the front panel and remove this panel. plug-in connector. -
Page 34: Concord Cxc - Installation
FAULT FINDING 54 BOILER CONTROL - continued If the HT generator should cease to function it is impossible The boiler control has a unique fault diagnostic feature which can, to automatically display this condition. Should this fault in the unlikely event of a failure, display a message indicating the nature of the fault to assist a speedy and effective repair. -
Page 35: Concord Cxc - Installation
FAULT FINDING 56 FAULT FINDING DIAGNOSTIC 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: Concord Cxc - Installation
SHORT LIST OF PARTS Key No. Description Qty. Product No. Ignition electrode BE/3417/SI 112 365 Overheat thermostat - RAK 77.4/3835 153 914 Control box assembly complete 112 125 Thermistor 112 289 PCB 34 112 718 PCB 35 112 719 Real time clock 112 749 PCB 34 and real time clock 112 722... - Page 38 NOTES Concord CXC - Installation...
- Page 39 NOTES Concord CXC - Installation...
- Page 40 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.