Ideal Boilers Concord CXD 40 Installation & Servicing Manual
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Ideal Boilers Concord CXD 40 Installation & Servicing Manual

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INSTALLATION & SERVICING MANUAL
Models covered by these instructions
CXD 40
CXD 50
CXD 60
CXD 70
CXD 80
CXD 90
CXD 100
THE IDEAL
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 CXD CXD 100 (Natural gas)
CONTENTS
Air Supply
Boiler Assembly - exploded view
Boiler Clearances
Burner Assemblies - exploded views CXD 40-60
CXD 70-100
Casing Assembly
Chimney System
Commissioning
Controls
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
Concord CXD 40
Concord CXD 50
Concord CXD 60
Concord CXD 70
Concord CXD 80
Concord CXD 90
Concord CXD 100
B.G.
Destination
Certified -
Countries:
P.I. No.
GB & IE
87/AQ/103

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Summary of Contents for Ideal Boilers Concord CXD 40

  • Page 1 INSTALLATION & SERVICING MANUAL Models covered by these instructions CXD 40 Concord CXD 40 CXD 50 Concord CXD 50 CXD 60 Concord CXD 60 CXD 70 Concord CXD 70 CXD 80 Concord CXD 80 CXD 90 Concord CXD 90 CXD 100...
  • Page 2 Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure that the law is complied with. The Concord CXD 40/100 range of boilers has been tested and certified by British Gas to prEN656 for use with Natural gas only. Multiple boiler installations The Concord CXD range is certificated for use in multiple boiler installations, providing that the following conditions are satisfied.

  • Page 3: Gas Controls

    Approximate 4.5% CO flue gas 0.044 0.052 0.063 0.073 0.084 0.094 0.104 /sec volume in &100°C. secondary 4.5% CO flue of the chimney & 212°F. system Manifold setting mbar pressure Low Rate in.w.g. Manifold setting mbar 11.7 10.5 12.2 10.4 10.3 11.2 11.5...

  • Page 4: Option Kits

    instructions and a fault diagnosis programme. The illuminated LED display gives a continual read-out of the boiler status and functions, but in the unlikely, event of a fault condition, will display the fault areas. OPTION KITS Pressure Gauge Kit A pressure gauge is available for the range of boilers. Details for fitting are included with the pressure gauge. Downdraught thermostat This kit is optional when used on a single CX D installation, but mandatory when used on a multiple boiler installation.

  • Page 5: Clearances & Dimensions

    Graph 1 - Heat Load/Water Volume Graph 2 - Hydraulic Resistance 2 CLEARANCES & DIMENSIONS Table 4 Boiler Size CXD 40 CXD 50 CXD 60 CXD 70 CXD 80 CXD 90 CXD 100 Front clearance mm (in) 750 (29 ½)

  • Page 6: Multiple Boiler Installations

    Rear clearance mm (in) 150 (6) 150 (6) 300 (12) 300 (12) Side clearance mm (in) 50 (2) 50 (2) 50 (2) 50 (2) 50 (2) 100 (4) 100 (4) 1047 (41 1047 (41 Dimension A mm (in) 754 (29¾) 887 (35) 887 (35) 1217 (48) 1217 (48) ¼)
  • Page 7 CXD 40 0.28 CXD 50 0.34 CXD 60 0.41 CXD 70 0.48 CXD 80 0.55 CXD 90 0.62 CXD100 0.68 MINIMUM FLOW OF WATER - Refer to Table 5 The system design must provide for an adequate flow rate through the boiler at all times when the boiler is firing. The minimum flow rate should correspond to a temperature difference across the boiler flow and return of 35°C (63°F), assessed at catalogue rating.

  • Page 8: Installation Requirements

    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. B. This diagram does not show safety valves, water flow switches, etc., necessary for the safe operation of the system. atmosphere if proper venting and expansion of system water is to be achieved.

  • Page 9: Air Supply By Mechanical Ventilation

    NOTE: PM5. When make up water is not provided automatically it will be necessary to fit controls which shut down the plant in the event of the maximum system pressure approaching to within 0.35 bar (5 psi) if safety valve setting. Other British Standards applicable to commercial sealed systems are:- BS.

  • Page 10: Gas Supply

    Drainage points positioned at the bottom of all vertical chimney sections should be provided. Drain pipes should be no less than 25 mm I.D., manufactured from acid condensate resistant material such as stainless steel and be positioned so that pipe runs and discharge points are not subject to the effects of frost and that flue gases cannot leak into the boiler room.
  • Page 11 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.

  • Page 12: Boiler Assembly

    INSTALLATION HARDWARE PACK contains M10 washer ........4 off Split pin ..........1 off Strain relief bush ........ 1 off M10 × 25 Hex. Hd. screw ....2 off M10 × 35 Hex. Hd. screw ....2 off Gasket EPDM Type EP600 ....3 off Plug 2″...

  • Page 13: System Connections

    d. Complete the water connections by plugging the two front top tappings with the 2″ BSP plugs provided. 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.

  • Page 14: 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 jacket hardware pack contains all the screws required for assembly. 2.
  • Page 15 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. Ensure that the Heyco bush is correctly located.

  • Page 16: 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 17: Internal Wiring

    The boiler provides frost protection via the boiler sensor. If an external frost thermostat is required contact Caradon Plumbing Limited. If the Downdraught flue thermostat is to be fitted then the link (marked TTB) should be removed from the plug-in connector. The internal wiring of the boiler control box is shown in Frame Wiring should be PVC insulated cable, not less than 0.75mm...
  • Page 18 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 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 19 At the start of the next call for heat (or the next clock period) valves on zones not calling for heat will motor shut. Water circulation system - refer to page 5 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 20: Commissioning And Testing

    During overrun periods, Zone 1 pump performs the overrun facility; this zone, therefore, must satisfy the conditions in the foregoing paragraphs Graph Normal operation During a call for heat on Zone 1 only, Zone 1 thermostat energises the boiler, which in turn energises Zone 1 pump from terminal L2. During a call for heat on other zones the appropriate relay directs power to L1 to energise the boiler, at the same time ensuring that Zone 1 pump is controlled by Zone 1 thermostat.

  • Page 21: Initial Lighting

    Extinguish all naked lights and open all doors and windows. DO NOT SMOKE. Check that the gas supply is turned ON at the meter and open the main gas inlet cock. Loosen the union and allow air to be purged from the gas line until gas is smelled. Refer to BS 6891 or IGE-UP-1 for further details.
  • Page 22 That as the boiler flow temperature approaches the thermostat setting, the boiler is automatically reduced to low rate. This feature is designed to improve overall operating efficiency and reduce short cycling under low load conditions. The controls will automatically switch the boiler between high and low upon demand. 22 CHECKING THE MANIFOLD PRESSURES Turn the boiler OFF by pressing the [0/1] button and allow the flow temperature to cool to less than 50°C.
  • Page 23 10. High/low solenoid connector. 24 ADJUSTING THE MANIFOLD PRESSURES CXD 70, 80 90 &100 ONLY 1. Press the [ENTER] button on the fascia panel, then press either the up or down arrow button until the display shows: COMMISSIONING then press [ENTER]. The microprocessor is now in commissioning mode. Failure to enter the commissioning mode will result in a fault condition being detected when the following actions are carried out.
  • Page 24 LEGEND 1. Fascia panel display. 2. Overheat thermostat reset button. 3. Main gas inlet cock. 4. Union. 5. Gas control valve low rate. 6. Gas control valve high rate. 7. Low rate adjusting screw. 8. High rate adjusting screw. 9. Burner setting pressure test point. 10.
  • Page 25 This a boiler timer only and does not replace a conventional system programmer serving more than one heating zone. OUTSIDE SENSOR (Optional extra) If the optional outside sensor is fitted, the control system will recognise this and automatically regulate the boiler flow temperature with respect to changes in the external temperature.

  • Page 26: Information Screens

    INFORMATION SCREENS If the optional outside temperature kit, enabling weather compensation, has been fitted the display will indicate the compensated set point temperature. An example of the display is as follows :- MONDAY 14 : 10 19/09/95 ON HIGH 50°C HOURS RUN 250 TEMP SET 82°C PROGRAMMER ON...

  • Page 27: Program Timer

    29 DESCRIPTION AND OPERATION OF BOILER CONTROLS - continued MENU To access the menu screen ensure that the information screens are being displayed. Any key, except the [1/0] button, may now be pressed to access this feature but, as indicated on the information screen, the [ENTER] button is the preferred means.

  • Page 28: Set Time & Date

    If the weather compensation option is fitted then a further screen will be displayed after commissioning. The [UP] button will access the above options in reverse. When the option required is displayed and the [ENTER] button pressed another set of menus will be available as discussed on the following pages.

  • Page 29: Temperature Set Point

    PROGRAMME HOURS Enables a user-timed programme to be entered. The following display will be available:- with the hours, 06, flashing Using the [UP] or [DOWN] button select the correct hour and press [ENTER]. The minutes will now flash and the correct minutes should be selected, using the [UP] or [DOWN] button followed by pressing [ENTER].

  • Page 30: Spillage Check

    When using this option arrow keys will be in evidence to indicate if the [UP] or [DOWN] buttons should be used. It is IMPORTANT that these instructions are carried out precisely and in the order displayed. FAULT DIAGNOSIS In the unlikely event of a fault condition, the microprocessors will identify the fault area and display a message indicating the nature of the fault to assist a speedy and effective repair.
  • Page 31 36 SERVICING - continued 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 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 or the detection electrode.

  • Page 32: Gas Control Valve

    37 REPLACEMENT OF COMPONENTS - Refer to Frames 5, 40, 41 and 42. GENERAL WARNING: ALWAYS turn OFF the gas supply at the gas inlet cock 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 33 6. Burner manifold. 7. Main injector, 3 off. 8. Main burner (centre/RH), 2 off. 9. Main burner (LH), 1 off. 10. Ignition electrodes. 11. Overheat thermostat generator mounting bracket. 12. Overheat thermostat. 13. Detection electrode assembly. 14. HT leads heat shield. 15.

  • Page 34: Overheat Thermostat

    9. Main (centre/RH) burner, 2 off. 10. Main (LH) burner, 1 off. 11. Ignition electrodes. 12. Overheat thermostat mounting bracket. 13. Overheat thermostat. 14. Detection electrode assembly. 15. Gas pipe. 16. Gas restrictor PTP Pressure test point 42 OVERHEAT THERMOSTAT 1.

  • Page 35: Control Sensor

    43 CONTROL BOX - Basic Boiler, Exploded View 44 CONTROL SENSOR 1. Remove the casing top panel. 2. Remove the sensor from the thermostat pocket in the rear heat exchanger section by removing the Heyco bush.
  • Page 36 3. Trace the lead back to the connector box behind the control box. Release the connector box plug (Frame 43). 4. Replace the sensor and reassemble in reverse order. Ensure that the lead is rerouted along the casing in the clips provided, and check that the sensor is correctly fitted and secured in the thermostat pocket.
  • Page 37 1. Damp down the combustion chamber area containing the insulation boards. 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.

  • Page 38: Tools Required

    16. Thermostat pocket. 17. Spillage skirt. 18. Flueway baffles. 19. Gas pipe. The site assembled boiler is supplied in the following packages: Combustion chamber/manifold/burner assembly. Platework package. Jacket package. Controls box package. End and centre sections. GENERAL The installation of the boiler must be in accordance with the Gas Safety (Installation and Use) Regulations 1994 (as amended), building regulations, I.E.E.
  • Page 39 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. 16. Locate the fibreglass rope in rear section grooves to form a seal with the spillage skirts. Fit the spillage skirts onto the collector hood using the self tapping screws provided.

  • Page 40: Boiler Control

    FAULT FINDING 51 BOILER CONTROL WARNING: The ON/STANDBY [1/0] button does NOT electrically isolate the boiler. Before attempting any electrical fault finding ALWAYS carry out the preliminary electrical system checks as detailed in the Instructions for the British Gas Multimeter or other similar commercially available meter. The preliminary electrical system checks are the FIRST electrical checks to be carried out during a fault finding procedure.

  • Page 41: Fault Finding

    If the [0/1] switch on the front panel is at “Standby..0” then the pump will continue to run indefinitely. In this state the frost protection can not operate. In “Lockout” the pump will continue to run only if the temperature is greater than 75°C. If it is less then the pump will be off. FAULT FINDING The boiler control has a unique fault diagnostic feature which can, in the unlikely event of a failure, display a message indicating the nature of the fault to assist a speedy and effective repair.

  • Page 42: Fault Finding Flow Chart

    53 FAULT FINDING FLOW CHART...

  • Page 43: Short List Of Parts

    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. Boiler model 2.
  • Page 44 Ideal Installer/Technical Helpline: 01482 498376 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.
  • Page 45 General information required Please send me details of Ideal Training Courses. Please arrange for a technical representative to contact me. Please arrange for me to join an Ideal factory tour. Range guides required The Ideal Guide: a specifier's and installer's introduction to the Ideal domestic boiler range. The Ideal Householders Guide: to assist the installer when presenting to his/her customers.

This manual is also suitable for:

Concord cxd 50Concord cxd 60Concord cxd 70Concord cxd 80Concord cxd 90Concord cxd 100 ... Show all

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