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INSTALLATION & SERVICING MANUAL
Models covered by these instructions
CXA 40-120
THE IDEAL
Concord CXA 40-120
Installers guide to commercial central heating boilers
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 40-120 (Natural gas) B.G. Certified - P.I. No. 87/AP/80 Destination Countries: GB and IE
CONTENTS
Air Supply
Boiler Assembly - exploded view
Boiler Clearances
Burner Assemblies - exploded views.
CXA 40-80
CXA 90-120
Casing Assembly
Chimney System
Commissioning & Testing
Electrical Connections
Electrical Supply
Fault Finding
Gas Safety Regulations
Gas Supply
Hydraulic Resistance
Initial Lighting
Installation
Mandatory Requirements
Option Kits
Pump
Servicing
Short List of Parts
Site Assembled Boilers
Static Head Requirements
System Connections
Ventilation
Water Circulation
Water Connections
Water Treatment
Wiring Diagrams
Concord CXA 40-120
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Related Manuals for Ideal Boilers Concord CXA 40
Summary of Contents for Ideal Boilers Concord CXA 40
- Page 1 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 40-120 (Natural gas) B.G. Certified - P.I. No. 87/AP/80 Destination Countries: GB and IE CONTENTS...
- Page 2 NOTE: Concord CXA 40, CXA 50 and CXA 60 boilers are intended for use as COMMERCIAL BOILERS and are NOT certified for use in domestic applications. A domestic installation is defined as an installation where the boiler takes its combustion air from a living space or from a room directly or indirectly connected with the living space.
- Page 3 Boiler Number of sections Flow tappings Rc (in. BSP) 2 × 2 at rear Return tappings Rc (in. BSP) 2 × 2 at rear Maximum static head metres (feet) 61 (200) Maximum pressure bar (p.s.i.) 6.0 (87) Gas inlet connection Rc (in.
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Page 4: Water Connections
1. The minimum flow rate as given in Table 4 must be maintained whenever the boiler is firing and during the pump overrun period. 2. During the period of pump overrun there must be an open circuit of adequate water volume and/or load. The minimum size of this circuit is given by the use of Graph 1. -
Page 5: Multiple Boiler Installations
Boiler Size CXA 40 CXA 50 CXA 60 CXA 70 CXA 80 CXA 90 CXA100 CXA110 CXA120 No. of sections Front mm (in) 750 (29 1/2) clearance Rear mm (in) 150 (6) 150 (6) 300 (12) 300 (12) 300 (12) 300 (12) clearance Side... - Page 6 Boiler Minimum flow rates for a temperature difference of 35°C (63°F) g.p.m. CXA 40 0.28 CXA 50 0.34 CXA 60 0.41 CXA 70 0.48 CXA 80 0.55 CXA 90 0.62 CXA 100 0.68 CXA 110 0.75 CXA 120 0.82 10.9 PUMP POSITIONS Whenever practically possible the circulating pump(s) should be positioned so that it pressurises the system being served.
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Page 7: Installation Requirements
NOTE: A. This minimum height must be increased, if necessary, to comply with the minimum head required by the pump manufacturer in order to avoid cavitation. NOTE: B. This diagram does not show safety valves, water flow switches, etc., necessary for the safe operation of the system. In practice the deposition of these salts is liable to cause noises from the boiler body or even premature boiler failure. - Page 8 BS. 6891; Installation of low pressure pipework FOR LARGE PIPE INSTALLATIONS: British Gas Publications: IM11: Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters. Gas Installations Purging Procedures of Non-domestic Gas Installations. IGE-UP-1: Soundness Testing Procedures for Industrial and Commercial. Guidance notes on the Installation of Gas Pipework, Boosters IGE-UP-2: and Compressors in Customer’s Premises Equal to or Greater...
- Page 9 Total input rating of boilers Position of air vents Air vent areas (air direct from outside) 270 cm plus 2.25 cm per kW input in Up to 2 MW HIGH LEVEL excess of 60 kW total rated input 540 cm plus 4.5 cm per kW input in Up to 2 MW...
- Page 10 6 PACKAGING Check that all these packages are complete and have been correctly received on site. Factory assembled boilers are despatched from the works as fully packaged units comprising: 1. Assembled boiler body (with distributor tube) on a wooden pallet base enclosed in a wooden crate. 2.
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Page 11: Boiler Assembly
Thermostat pockets ......2 off 7 PACKAGING AND BOILER REMOVAL 1. Remove the casing carton and outer packaging frame. 2. Remove the casing pack support frame. 3. Remove the distributor tube pack, controls package and installation pack. 4. Remove the 2″ BSP steel handling bars from the installation pack. 5. -
Page 12: System Connections
9 SYSTEM CONNECTIONS One flow and return connection should be made to the rear of the boiler - either on one side or opposite sides. The distributor tube and gaskets, supplied with the boiler, must be connected into the pumped return connection. Refer to Frame Two thermostat pockets are supplied in the installation pack. -
Page 13: Casing Assembly
12 CASING ASSEMBLY 1. Unpack the control box from its carton and release the temperature sensing probe strapped to the back of the box. The boiler casing should now be fitted. A casing hardware pack contains all the screws required for assembly. 2. - Page 14 7. 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 9. Secure with the split pin provided. 8. Route the temperature sensing probe through the cable clips provided and into the thermostat pocket adjacent to the flow connection. Fit the plastic Heyco bush over the sensor lead at the line shown and insert it into the thermostat pocket.
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Page 15: Electrical Connections
14 ELECTRICAL CONNECTIONS Connection must be made in a way that allows complete isolation of the electrical supply - such as a double pole switch, having a 3mm (1/8″) contact separation in both poles, or a plug and socket serving only the boiler and system controls. The means of isolation must be accessible to the user after installation. -
Page 16: Internal Wiring
16 INTERNAL WIRING... - Page 17 17 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 switchgear must be used to control the pumps indirectly. Three zones are illustrated but the principles may be extended as required, provided the above conditions are met.
- Page 18 Since any zone may be the load during overrun, all zones MUST individually be able to satisfy the conditions in the foregoing paragraph. If not all zones can do this then consider other means of control detailed on other sheets. Normal operation When any thermostat is satisfied while others are calling for heat, power is available via relay contacts to close the valve for that zone.
- Page 19 IMPORTANT: Terminal L2 may control the appropriate (s) directly, provided that the total pump 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. Three zones are illustrated but the principles may be extended as required, provided the above conditions are met.
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Page 20: Commissioning And Testing
When the clock period ends, Zone valve 1 will (stay) open via normally closed relay contacts to achieve pump overrun. 20 COMMISSIONING AND TESTING GENERAL Check that all drain cocks are closed, that any stop valves fitted to the flow and return pipes are open and that the system has been filled and properly vented. -
Page 21: Gas Pressure
22 GAS PRESSURE MANIFOLD PRESSURE The manifold setting pressure must now be checked and adjusted as necessary. Start the adjustment procedure with the system cold, on full load and with all temperature controls set to maximum to avoid thermostatic shutdown. Remove the blanking screw in the manifold setting pressure test point and connect a suitable gas pressure gauge. -
Page 22: Spillage Check
23 SPILLAGE CHECK Check there is no spillage of combustion products from the boiler draught diverter by carrying out a spillage test, as detailed in BS. 5440:1. 24 TESTING 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 manner, the operation of the flame failure safety device: 1. - Page 23 Unscrew the extended nuts at the top of the NOx duct behind the control box and lift the NOx duct clear of the burners as illustrated below. Undo the 4 wing nuts securing the burner front plate. Pull the front plate forwards, at the top, and lift it out - taking care not to damage the insulation. The centre and RH burners can be lifted out after they have been pushed back to clear the injector.
- Page 24 NOTE: Casing omitted for clarity 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. Refit the centre and RH burners.
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Page 25: Pilot Burner Assembly
GENERAL WARNING: Always turn OFF the gas supply at the gas inlet cock and switch OFF and DISCONNECT the electricity supply BEFORE WORKING on the appliance. To facilitate the replacement of components, remove and replace the lower front panel, NOx duct and the burner front plate as necessary - described under ‘Servicing’. -
Page 26: Gas Control Valve
32 FLAME DETECTOR AND LEAD 1. Remove the LH burner as previously described in Frame 27 2. Pull off the lead at the electrode and unscrew the flame detector electrode. 3. Fit the new electrode and reassemble in reverse order. 4. - Page 27 4. Fit new LH burner and the centre and RH burners. NOTE: Ensure that the pilot burner is correctly fitted, i.e. facing the front, and that the pilot injector has not been omitted. 7. Reconnect the pilot gas pipe connection to the gas valve. IMPORTANT: Care must be taken to prevent damage to the combustion chamber insulation when replacing burners.
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Page 28: Overheat Thermostat
37 OVERHEAT THERMOSTAT 1. Remove the split pin from the overheat thermostat pocket and remove the phial. 2. Undo the two M3 screws and remove the thermostat assembly from its fixing bracket. 3. Undo the backnut and two M3 screws to release the top bracket. 4. -
Page 29: Control Sensor
38 CONTROL SENSOR POTENTIOMETER ASSEMBLY 1. Undo the thermostat knob retaining screw and pull off the knob. 2. Remove the lower front panel 3. Undo the backnut and washer retaining the potentiometer. 4. Undo the 2 screws securing the control box front panel, lift it and carefully lower it down. 5. - Page 30 4. Pull out the sensor plug from the printed circuit board and release cable clamp from the back panel. 5. Pull the sensor lead through the grommeted hole in the back panel and the wire clips. 6. Fit the new sensor and reassemble in reverse order, ensuring that the lead is rerouted along the casing in the clips provided. 40 CONTROL BOX - Basic Boiler, Exploded View...
- Page 31 41 PC BOARD NO. S4561B1054 1. Remove the lower front panel. 2. Undo the 2 screws securing the control box front panel. Carefully lift it up and lower down. 3. Pull off the 2 plugs and 3 push-on connections from the board. The board can now be removed by squeezing in the retaining barbs. 4.
- Page 32 42 PC BOARD W 4115A1020 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. 4. The board can now be removed by squeezing in the retaining barbs. 5.
- Page 33 2. Remove the insulation boards. The replacement boards are supplied in a plastic bag. This bag should be retained and the discarded boards should now be placed into it. 3. Sweep any dampened particles and place in the plastic bag. 4.
- Page 34 ASSEMBLY The combustion chamber should be positioned as near as possible to the installation site. IMPORTANT: It must be remembered that the boiler distribution tube has to be fitted into the rear return tapping of the assembled boiler before siting. Prior to assembling the sections it will be necessary to remove the burner and controls assembly from the combustion chamber.
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Page 35: Fault Finding
14. Fit the flue baffles which are located between the fins. (not fitted to CXA 110 or 120 boilers) 15. Fit the collector hood. Ensure the underside returns running across the hood sit within the front and rear section flueways. Fasten down, using the four M6 screws and nuts provided, through the front and rear fixing points. - Page 36 46 PILOT WILL NOT LIGHT 47 PILOT WILL NOT STAY LIT 47 PILOT LIT BUT NO MAINS GAS...
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Page 37: Short List Of Parts
48 BOILER GOES OUT ON OVERHEAT THERMOSTAT SHORT LIST OF PARTS The following are parts commonly required as replacements, due to damage or expendability. Their failure or absence is likely to affect the safety and/or performance of this appliance. When ordering spare parts please quote: 1. - 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 Technical Training The Caradon Plumbing Limited Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial heating installers, engineers and system specifiers.
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