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Table of Contents
Related Manuals for IDEAL Concord CXi 110
Summary of Contents for IDEAL Concord CXi 110
- 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 CXi - Installation...
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Page 3: Table Of Contents
It is in your own interest, and that of safety, to Electrical Supply.............. 9 ensure that the law is complied with. The Concord CXi 110-180 range of boilers has been tested and Fault Finding..............33 certified by British Gas to prEN656 for use with natural gas only. - Page 4 GENERAL Table 1 - Performance Data Boiler CXi 110 CXi 120 CXi 140 CXi 160 CXi 180 Boiler Input Gross 86.55 94.63 110.79 126.94 152.16 Low Rate Btu/h x 1000 295.31 322.88 378.02 433.12 519.17 Nett 77.98 85.26 99.82 114.37 137.10 Btu/h x 1000 266.07...
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Page 5: Option Kits
GENERAL OPTION KITS 75°C - in order to make use of this the pump must be wired to the appropriate terminal L (pump) in the boiler control box. 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 6: Boiler Clearances
GENERAL Graph 1 - Heat Load / Water Volume Graph 2 - Hydraulic Resistance CLEARANCES & DIMENSIONS Table 4 Boiler Size CXi 110 CXi 120 CXi 140 CXi 160 CXi 180 Front clearance mm (in) 750 (29 Rear clearance mm (in) 200 (8) Side clearance mm (in) -
Page 7: 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 8: Mandatory Requirements
GENERAL Limitations of Intended Operating Environment depending upon ambient temperature, may be high enough to evaporate a large portion of the system water capacity over a full These appliances are NOT suitable for installation where they will heating season. be exposed to the elements. There will always be corrosion within a heating or hot water system A boiler room shall be constructed or adapted to meet the to a greater or lesser degree, irrespective of water characteristics,... -
Page 9: Air Supply
GENERAL CHIMNEY SYSTEM FOUNDATION To ensure the safe and satisfactory operation of the boiler then The boiler must stand on a non-combustible floor (i.e. concrete the chimney system (which may be common or individual, in the or brick) which must be flat, level and of a suitable load bearing case of twin or multiple boiler installations) must be capable of the capacity to support the weight of the boiler (when filled with complete evacuation of combustion products at all times. -
Page 10: Boiler Assembly - Exploded View
INSTALLATION CONCORD CXi BOILER ASSEMBLY - Exploded view Legend 13. Combustion chamber. 7. End section. 1. Cleanout cover. 14. Tie rods. 8. Distribution tube. 2. Collector hood. 15. Lightback shield. 9. Downdraught deflector. 3. Middle section. 16. Burner manifold assy. 10. - Page 11 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 Jacket package. Section Assembly - refer to the exploded view Controls box package.
- Page 12 INSTALLATION BOILER SECTION ASSEMBLY - continued 12. Fit a flueway baffle into each of the section flueways. Offer the downdraught deflector to the projecting studs at the back of the combustion chamber and fix, using the nuts and washers provided. 13.
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Page 13: System Connections
INSTALLATION BOILER ASSEMBLY 1. Fit the distributor tube into the selected return connection. 5. Complete the system connections (using suitable jointing compound) as follows: Ensure that the tube flange aligns horizontally and that the 2 sealing gaskets are correctly assembled on the tube - The cast iron flow header must be fitted in the chosen refer to alignment notches. -
Page 14: 11 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 15 INSTALLATION 12 CONTROL BOX Unpack the control box. 1. Fasten the 2 electrical connections from the overheat thermostat on the upper front framework to the terminals marked 'OSTAT' on the plug-in connector from the gas valve plug lead assembly (polarity not important.) 2.
- Page 16 INSTALLATION 13 CONTROL BOX - continued 6. Run the flame detector lead through the clips on the front of the combustion chamber base tray and plug it into the flame detector electrode on the LH end burner. Ensure that any slack is tucked neatly into the clips then fasten the clips.
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Page 17: 14 Electrical Connections
INSTALLATION 14 ELECTRICAL CONNECTIONS Any system controls should be connected, via volt free contacts, to the terminals marked 'EXT C'. Do NOT connect WARNING. This boiler must be efficiently earthed. an external clock to these contacts or any mains voltage. Connection must be made in a way that allows complete All wiring that is associated with the EXT C terminals should isolation of the electrical supply - such as a double pole... -
Page 18: Wiring Diagrams
INSTALLATION 15 INTERNAL WIRING LEGEND b blue y yellow v violet br brown g/y green/yellow w white pk pink bk black or orange 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 appropriate... - Page 19 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.
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Page 20: Commissioning
INSTALLATION 20 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 24/ system has been filled and properly vented. - Page 21 INSTALLATION 23 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 Frames Connect a pressure gauge to the burner manifold test point 24 &...
- Page 22 INSTALLATION 25 ADJUSTING THE MANIFOLD PRESSURES - continued 8. Turn the appliance off and reconnect all the solenoid plugs. Do not overtighten the solenoid plug fixing screws. Refit the dust cover over the adjustment screws and refit the pressure test point screw. Check for gas soundness.
- Page 23 INSTALLATION 27 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 24 INSTALLATION 29 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 CXi - Installation...
- Page 25 INSTALLATION 30 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 26 INSTALLATION 31 DESCRIPTION AND OPERATION OF BOILER CONTROLS - continued operation the boiler will fall through 3 degrees before the high procedure should be followed but the [NO] button pressed. rate gas valve is energised. PROGRAMME HOURS Delayed High Rate Gas Valve Operation When the boiler is started from cold the high rate gas valve will Enables a user-timed programme to be entered.
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Page 27: Servicing
SERVICING 32 SPILLAGE CHECK 33 TESTING Check that the main burner responds correctly to manual on/off operations of any Check that there is no spillage of controls fitted in the gas control circuit. Check, in the following manner, the combustion products from the boiler operation of the flame failure safety device. - Page 28 SERVICING 37 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 assist in this work.
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Page 29: Cxi 110-160
SERVICING 40 MAIN BURNER 39 GAS CONTROL VALVE 1. Undo and pull off all the plugs from the gas valve 1. Remove the burner tray from the boiler, as described in solenoids. Frames 36-37. 2. Each burner can be removed by lifting it at the back and 2. -
Page 30: Cxi 180
SERVICING 42 BURNER AND CONTROLS ASSEMBLY - Exploded view - CXi 180 LEGEND 6. Spark generator. 10. Main burner (RH). 1. Main gas inlet cock. 7. Burner manifold. 11. Ignition electrodes. 2. Gas inlet union. 12. Detection electrode assembly. 3. 'O' ring seal. 8. - Page 31 SERVICING 44 CONTROL BOX - Basic Boiler Exploded View LEGEND 1. Wiring clamp. 9. Ribbon cable. 5. Back panel. 2. Connection box plug. 10. Printed circuit board No. RTC/34. 6. Hinge pin. 3. Connection box. 11. EMC filter. 7. Controls box. 4.
- Page 32 SERVICING 48 PC BOARD NO. RTC/34 47 PC BOARD NO. 35 1. Remove the casing door panel. 1. Remove the casing door panel. 2. Slacken the 2 screws securing the control box front 2. Slacken the 2 screws securing the control box front panel.
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Page 33: Fault Finding
FAULT FINDING 50 BOILER CONTROL user, the boiler will go to low rate and when the temperature reaches the set point plus 3 °C the low rate gas valve will WARNING close. When the temperature falls 2 °C the boiler will start at The ON/STANDBY [1/0] button does NOT electrically low rate and remain there until the temperature falls to the set isolate the boiler. - Page 34 FAULT FINDING 51 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 52 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...
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Page 36: Short List Of Parts
SHORT LIST OF PARTS The following are parts commonly When ordering spare parts please quote: required as replacements, due to damage 1. Boiler model or expendability. 2. Boiler serial no. (refer to the data plate on the combustion chamber) 3. Boiler P.I. No. (refer to the data plate on the combustion chamber) Their failure or absence is likely to affect the safety and/or performance of this 4. - Page 37 SHORT LIST OF PARTS Key No. Description Qty. Product No. Casing assembly complete CXi 110 & 120 138 767 CXi 140 138 768 CXi 160 138 769 CXi 180 138 770 Casing - Front panel CXi 110 & 120 138 480 CXi 140 138 479 CXi 160...
- Page 38 Caradon Plumbing Limited, P .O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Registered Office: National Avenue, Kingston upon Hull, HU5 4JN. A subsidiary of Caradon plc Ideal Installer/Technical Helpline: 01482 498376 Concord CXi - Installation...
- 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.
- Page 40 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...