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Related Manuals for IDEAL Concord CXA120
Summary of Contents for IDEAL Concord CXA120
- Page 1 Concord CXA 40 - 120...
- 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 CXA - Installation and Servicing...
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Page 3: Table Of Contents
Concord CXA 40-120 (Natural gas) B.G. Certified - P.I. No. 87/AP/80 Destination Countries: GB and 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 Boiler Assembly - exploded view. - Page 4 GENERAL Table 1- Performance Data Boiler CXA 40 CXA 50 CXA 60 CXA 70 CXA 80 CXA 90 CXA 100 CXA110 CXA120 Number of sections Boiler Input Nett 47.3 56.3 67.7 79.2 90.7 102.3 112.6 123.8 135.0 Btu/h (x 1000) 161.4 192.1 230.9...
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Page 5: Option Kits
GENERAL GAS CONTROLS Downdraught thermostat kit This kit is optional when used on a single CXA 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 6: Boiler Clearances
GENERAL Graph 1 - Heat load / water volume Graph 2 - Hydraulic Resistance CLEARANCES & DIMENSIONS Table 3 Boiler Size CXA 40 CXA 50 CXA 60 CXA 70 CXA 80 CXA 90 CXA100 CXA110 CXA120 No. of sections Front clearance mm (in) 750 (29 Rear clearance mm (in) 150 (6) -
Page 7: 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 8: Mandatory Requirements
GENERAL In practice the deposition of these salts is liable to cause relevant requirements of the Gas Safety Regulations, current I.E.E. noises from the boiler body or even premature boiler failure. (BS.7671) Regulations, Model Water Bye-laws, local water Corrosion and the formation of black iron oxide sludge will authority bye-laws and it should also comply with any relevant ultimately result in premature radiator failure. -
Page 9: Air Supply
GENERAL VENTILATION CHIMNEY SYSTEM Safe, efficient and trouble-free operation of open flued gas To ensure the safe and satisfactory operation of the boiler the boilers is vitally dependent on the provision of an adequate chimney system (which may be common or individual, in the supply of fresh air to the room in which the appliance is case of twin or multiple boiler installations) must be capable of installed. -
Page 10: Boiler Assembly - Exploded View
INSTALLATION CONCORD CXA BOILER ASSEMBLY - Exploded view Legend 13. Section bolt 1. Cleanout cover 14. Distribution tube 2. Collector hood 15. Tie rods 3. Middle section 16. Thermostat pocket 7. Drain cock 4. Section alignment rings & 'O' rings 10. - Page 11 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.
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Page 12: System Connections
INSTALLATION SYSTEM CONNECTIONS One flow and return connection should be made to the Position the overheat thermostat phial into the thermostat rear of the boiler - either on one side or opposite sides. pocket at the opposite side to the flow pipe. The illustrations 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 13: Casing Assembly
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. -
Page 14: 14 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 15: Wiring Diagrams
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 - Installation and Servicing... - Page 16 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 exceed 6A (resistive or inductive): if this rating would be for heat, power is available via relay contacts to close the exceeded then appropriate switchgear must be used to valve for that zone.
- Page 17 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 18: Commissioning & Testing
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 system has been filled and properly vented. - Page 19 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 100-120 boilers: adjusted as necessary.
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Page 20: Servicing
SERVICING 27 SERVICING Caradon Plumbing Limited does not accept any liability Remove the 2 screws securing the control box door, lift it resulting from the use of unauthorised parts or the repair and carefully drop it down. Pull off the flame detector lead and servicing of appliances not carried out in accordance and the spark electrode lead connections from the with the Company’s recommendations and specifications. - Page 21 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 Main burner flame ports passes through the strain relief clamp before refastening it. 3 - 4mm Refit the centre and RH burners.
- Page 22 SERVICING Pilot draught shield (not fitted to CXA 120) 31 SPARK ELECTRODE AND LEAD 1. Remove the LH burner as previously described in Frame 27 LH burner 2. Remove the 2 screws securing the control box front panel, lift it and carefully lower it. Flame detector 3.
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Page 23: Cxa 40-80
SERVICING 35 BURNER AND CONTROLS ASSEMBLY - Exploded View CXA 40 - 80 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 24 SERVICING 37 OVERHEAT THERMOSTAT 38 CONTROL SENSOR POTENTIOMETER ASSEMBLY 1. Remove the split pin Thermostat from the overheat 1. Undo the thermostat knob retaining screw and pull phial thermostat pocket and off the knob. remove the phial. 2. Remove the lower front panel 2.
- Page 25 SERVICING 40 CONTROL BOX - Basic Boiler, Exploded View Printed circuit board support detail Retention barbs Retention Back screw panel LEGEND Terminal strip Potentiometer Wiring clamp. Back panel 10. Warning light lens Connection box plug. Lockout reset button 11. Controls box Connection box.
- Page 26 SERVICING Retaining 42 PC BOARD W 4115A1020 barbs 1. Remove the lower front panel. 2. Undo the 2 screws securing the control box front panel. Carefully lift it up and lower it. 3. Pull off the 4 plugs from the board. Plugs 4.
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Page 27: Site Assembled Boilers
SITE ASSEMBLY 44 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS 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. Section bolt. 4. Section alignment Mallet 14. - Page 28 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 29: Fault Finding
FAULT FINDING Before attempting any electrical fault finding ALWAYS carry Earth continuity out the preliminary electrical system checks as detailed in Polarity the Instructions for the British Gas Multimeter or other Resistance to earth similar commercially available meter. Detailed instructions on the replacement of faulty The preliminary electrical system checks are the FIRST components are contained in the 'Servicing' section of these electrical checks to be carried out during a fault finding... - Page 30 FAULT FINDING 47 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 ? Is there 230V ±10% at the gas valve plug(s) ? Fit new S4561B1054 PCB Fit new gas valve 48 BOILER GOES OUT ON OVERHEAT THERMOSTAT...
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Page 31: 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 32 For details of courses please ring: .... 01270 413624 May 2000 154866 A01 Ideal Installer/Technical Helpline: 01482 498 376...