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IDEAL Concord CXSD 40 Installation & Servicing Manual

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INSTALLATION & SERVICING MANUAL
Models covered by these instructions
CXSD 40 - 120
THE IDEAL
Concord
Concord CXSD 40 - 120 (Natural gas)
B.G. Certified - P.I. No. 87/AQ/103
Destination Countries: GB & IE
CONTENTS
Air Supply
Boiler Assembly - exploded view
Boiler Clearances
Burner Assemblies - exploded views
CXSD 40-90
CXSD 100-120
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
Ventilation
Water Circulation
Water Connections
Water Treatment
Wiring Diagrams
INTRODUCTION
CONSTRUCTION
Concord CXSD 40 - 120

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  • Page 1 Models covered by these instructions CXSD 40 - 120 Concord CXSD 40 - 120 THE IDEAL Concord Concord CXSD 40 - 120 (Natural gas) B.G. Certified - P.I. No. 87/AQ/103 Destination Countries: GB & IE CONTENTS Air Supply Boiler Assembly - exploded view...
  • 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 CXSD 40-120 range of boilers has been tested and certified by British Gas to prEN656 for use with Natural gas only.

  • Page 3: Gas Controls

    Boiler CXSD 40 CXSD 50 CXSD 60 CXSD 70 CXSD 80 CXSD 90 CXSD 100 CXSD 110 CXSD 120 Seasonal efficiency [76.2]% [76.2]% [77.7]% [76.7]% [77.0]% [77.3]% [77.6]% [77.2]% [77.4]% (SEDBUK)∗ ∗ This value is in the UK government's Standard Assessment Procedure (SAP) for energy rating of dwellings. The test data from which it has been calculated has been certified by BG plc 0087 NOTE: To obtain gas consumption, divide gross heat input (kW) by a calorific value of 37.8 (MJ/m...

  • Page 4: Water Circulation System

    Downdraught thermostat This kit is optional when used on a single CXSD installation, but mandatory when used on a multiple boiler installation. Remote Indication Board (volt free) This provides the ability for remote indication of lockout and overheat conditions. Outside Sensor This kit provides a sensor for temperature compensation when the outside temperature changes DUTY The range of boilers is suitable for: Combined indirect pumped domestic hot water and central heating systems;...

  • Page 5: Clearances & Dimensions

    Sealed system filling point - refer to Frame 8 2 CLEARANCES & DIMENSIONS Table 4 Boiler Size CXSD 40 CXSD 50 CXSD 60 CXSD 70 CXSD 80 CXSD 90 CXSD 100 CXSD 110 CXSD 120 Front clearance mm (in) 750 (29 1/2) Rear clearance mm (in) 150 (6)

  • Page 6: Multiple Boiler Installations

    Boiler Size CXSD 40 CXSD 50 CXSD 60 CXSD 70 CXSD 80 CXSD 90 CXSD 100 CXSD 110 CXSD 120 Dimension C 931.6 931.6 931.6 931.6 931.6 893.6 893.6 893.6 893.6 36 5/8 36 5/8 36 5/8 36 5/8 36 5/8 35 3/16 35 3/16 35 3/16...
  • Page 7 Minimum flow rates for a temperature difference of 35°C (63°F) Boiler g.p.m. CXSD 100 0.68 CXSD 110 0.75 CXSD 120 0.82 10.9 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

    NOTE: B. This diagram does not show safety valves, water flow switches, etc., necessary for the safe operation of the system. Conversely, when the system cools, water previously expelled is drawn back from the tank into the system together with a quantity of dissolved oxygen.

  • Page 9: Air Supply By Mechanical Ventilation

    If the boiler is mounted on a plinth then the dimensions must exceed the plan area of the boiler by at least 75mm on each side. 4 SEALED (PRESSURISED) SYSTEMS Working pressure 6 bar maximum. Particular reference should be made to BS. 6644: Section 2; Subsection 11 and Guidance note PM5 “Automatically controlled steam and hot water boilers”...

  • Page 10: Chimney System

    Tests for spillage of products from the draught diverter when the extractor fan is running and all doors and windows are shut should be carried out after installation, If spillage is detected, the area of permanent ventilation must be increased. CHIMNEY SYSTEM To ensure the safe and satisfactory operation of the boiler then the chimney system (which may be common or individual, in the case of twin or multiple boiler installations) must be capable of the complete evacuation of combustion products at all times.
  • 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

    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″ taper Sq. Hd 3 off Flange RC 1″ 1 off 2″...

  • Page 13: 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 2 thermostat pockets are supplied in the installation pack.

  • 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 casing hardware pack contains all the screws required for assembly. 2.

  • Page 16: Electrical Connections

    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 side panels. Screw in self tapping screws at the bottom of the control box to fix it to the side panels. 7.

  • Page 17: Internal Wiring

    The control box incorporates a pump overrun device which is necessary to dissipate residual heat after plant shutdown. It is essential that the main pump (or shunt pump if used) is wired to the pump terminals marked L2, N on the plug-in Mains voltage connector shown below and in Frame The earth must be wired to the earth post as shown in Frame...
  • 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 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. Three zones are illustrated but the principles may be extended as required, provided the above conditions are met.

  • Page 20: Commissioning And Testing

    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

    Close the gas supply cock at the meter. Remove the screw in the inlet pressure test point, Frames 23/24, and connect a gas pressure gauge to the test point. Take particular care to ensure a gas-tight connection. Open the gas supply cock at the meter and the appliance gas cock; record the static pressure. Next, close the gas supply cock at the meter.
  • Page 22 Observe the burner pressures and compare them to the values given in Table 1. If either pressure differs by more than 10%, reset the pressures by following the procedure in Frames 23 or 24. 23 ADJUSTING THE MANIFOLD PRESSURES: CXSD 40- 90 ONLY 1.
  • Page 23 Remove the dust cover from the adjuster (11) on the LH gas valve and set the pressure to the value given in Table Now set the Low burner pressure by unscrewing and removing the lower electrical plug from the LH gas valve and High/Low plug from the RH gas valve.
  • Page 24 If the boiler fails to light, the gas valve is closed and there will be a delay of 1 minute before the cycle is repeated. If, after 5 attempts the burner has failed to light, the boiler will go to lockout and ‘detection fault’ will be displayed on the screen:- DETECTION FAULT When the boiler flow temperature reaches the thermostat set point, the controls will turn the burner to low rate.

  • Page 25: Information Screens

    When this switch is in the STANDBY position the display will show :- STANDBY 0 On initial start up the boiler will indicate the hardware and software code, the boiler type and indicate if the boiler is ON or at STANDBY. If the boiler is at STANDBY the rotating information screens will not be in evidence.

  • Page 26: 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 27 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. PROGRAMMER TIMER The programmer has 3 time zones per day for each day of the week. Each day can be programmed for the requirements of that day, giving 7 programmed days, or, using the [COPY] facility, any number of days can be the same.

  • Page 28: Temperature Set Point

    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]. This will cause the hours to flash and if the correct ON time has been entered the [EXIT] button should be pressed.

  • Page 29: Spillage Check

    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. See “Fault Finding” section for more details. 31 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.
  • Page 30 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 31: 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 32 41 BURNER AND CONTROLS ASSEMBLY - Exploded View - CXSD 100-120...

  • Page 33: Overheat Thermostat

    42 OVERHEAT THERMOSTAT 1. Remove the split pin from the overheat thermostat pocket and remove the phial. 2. Loosen the 2 × M3 screws and remove the thermostat assembly from its fixing bracket. 3. Undo the RH M4 screw and remove the thermostat cover. 4.

  • Page 34: Control Sensor

    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. 3. Trace the lead back to the connector box behind the control box. Release the connector box plug (Frame 43).
  • Page 35 47 PC BOARD NO. RTC/34 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. Remove the real time clock board (PCB No. RTC/34) from PCB No. 34 by squeezing the 4 mounting pins and pulling forwards. 4.

  • Page 36: Tools Required

    TOOLS REQUIRED Spanners Torque wrench Pozi screwdriver Mallet The site assembled boiler is supplied in the following packages: Combustion chamber/manifold/burner assembly. Platework package. Casing package. Controls box package and instruction books. End and centre sections. GENERAL The installation of the boiler must be in accordance with the Gas Safety (Installation and Use) Regulations 1994, amendments 1996 or rules in force, building regulations, I.E.E.
  • Page 37 50 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 6.

  • Page 38: Boiler Control

    22. Fit the Nox duct using the reverse procedure to that shown in Frame 36 and secure with the extended nuts. 23. The boiler is now ready for installation. Go to Frame 8 and continue the installation from there. FAULT FINDING 51 BOILER CONTROL WARNING: The ON/STANDBY [1/0] button does NOT electrically isolate the boiler.

  • Page 39: Fault Finding

    If the system pump, with a maximum current of 3A, is connected to the boiler pump terminals, pump overrun will be in operation if the flow temperature is greater than 75°C, when the heat demand is satisfied, and will continue to run until the boiler flow is less than 75°C. If the flow temperature is less than 75°C, when the demand for heat is satisfied, then the pump will cease to operate.

  • Page 40: Fault Finding Flow Chart

    53 FAULT FINDING FLOW CHART...

  • Page 41: 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 42 Caradon Plumbing Limited pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved to vary specification without notice. June 2001 154868 A02 P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Ideal Installer/Technical Helpline: 01482 498376 www.idealboilers.com...

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