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IDEAL Concord CXS 40 Installation & Servicing Manual

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Concord
CXS 40 - 120

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Summary of Contents for IDEAL Concord CXS 40

  • Page 1 Concord CXS 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 CXS - Installation & Servicing...

  • Page 3: Table Of Contents

    Electrical Supply.............. 9 ensure that the law is complied with. Fault Finding..............29 The Concord CXS 40-120 range of boilers has been tested and certified by British Gas to prEN656 for use with Natural gas only. Gas Safety Regulations ........... 3 Multiple boiler installations Gas Supply.
  • Page 4 GENERAL Table 1- Performance Data Boiler CXS 40 CXS 50 CXS 60 CXS 70 CXS 80 CXS 90 CXS 100 CXS 110 CXS120 Number of sections Boiler Input Gross 31.5 37.5 45.1 52.8 60.4 68.1 75.0 82.1 89.9 Low Rate Btu/hr x 1000 107.5 128.0...

  • Page 5: Controls

    GENERAL GAS CONTROLS DUTY The boiler lights at Low rate (approximately 60% of Full rate) by The range of boilers is suitable for: Combined indirect pumped direct burner ignition. After about 3 minutes the boiler goes to domestic hot water and central heating systems; Independent High rate and will continue at High rate until the thermostat indirect pumped domestic hot water or central heating systems.

  • Page 6: Hydraulic Resistance

    GENERAL Graph 1 - Heat Load / Water Volume Graph 2 - Hydraulic Resistance CLEARANCES & DIMENSIONS Table 4 Boiler Size CXS 40 CXS 50 CXS 60 CXS 70 CXS 80 CXS 90 CXS 100 CXS 100 CXS 120 Front clearance mm (in) 750 (29 Rear clearance...

  • Page 7: Pump

    GENERAL PUMP POSITIONS difference across the boiler flow and return of 35 C (63 assessed at catalogue rating. Whenever practically possible the circulating pump(s) should be positioned so that it pressurises the system being served. The WATER TREATMENT FOR HOT WATER AND vertical distance between the pump(s) and any cold feed and HEATING BOILERS expansion cistern MUST comply with the pump manufacturers...

  • Page 8: Installation Requirements

    GENERAL FOR SMALL PIPE INSTALLATIONS; Even if leakage from the heating and hot water system is eliminated there will be evaporation losses from the surface of the tank which, BS. 6891: Installation of low pressure pipework depending upon ambient temperature, may be high enough to evaporate a large portion of the system water capacity over a full FOR LARGE PIPE INSTALLATIONS: heating season.

  • Page 9: Air Supply

    GENERAL VENTILATION Tests for spillage of products from the draught diverter when the Safe, efficient and trouble-free operation of open flued gas extractor fan is running and all doors and windows are shut should boilers is vitally dependent on the provision of an adequate be carried out after installation, If spillage is detected, the area of supply of fresh air to the room in which the appliance is permanent ventilation must be increased.

  • Page 10: Boiler Assembly - Exploded View

    INSTALLATION CONCORD CXS BOILER ASSEMBLY - Exploded view Legend 13. Section bolt 7. Drain cock 1. Cleanout cover 14. Distribution tube 8. NOx duct 2. Collector hood 15. Tie rods 9. Front plate 3. Middle section 16. Thermostat pocket 10. Burner manifold assy. 4.
  • Page 11 INSTALLATION PACKAGING INSTALLATION HARDWARE PACK contains Check that all these packages are complete and have been correctly received on site. M10 washer ........4 off Factory assembled boilers are despatched from the works as fully packaged units comprising: Split pin ..........1 off 1.

  • Page 12: System Connections

    INSTALLATION BOILER ASSEMBLY 1. Fit the distributor tube (supplied with the boiler) into one Note. Frame 9 shows the relationship between the of the return connections. That is one of the rear lower overheat thermostat and the flow tapping. ports. Refer to Frame 5. d.

  • Page 13: Casing Assembly

    INSTALLATION 10 FLUE CONNECTION 11 GAS CONNECTION 1. Complete the flue connection. 1. Connect the gas supply to the gas inlet pipe at the 2. The boiler is designed to accept flues to BS. 835 and rear LH side of should be sealed with an approved boiler putty.
  • Page 14 INSTALLATION 13 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 side panels. Screw in self tapping screws at the bottom of the control box to fix it to the side panels.

  • Page 15: Electrical Connections

    INSTALLATION 14 ELECTRICAL CONNECTIONS Connection must be made in a way that allows complete The internal wiring of the boiler control box is shown in Frame isolation of the electrical supply - such as a double pole switch, having a 3mm (1/8") contact separation in both poles, Wiring should be in four core PVC insulated cable, not less or a plug and socket serving only the boiler and system than 0.75mm...
  • Page 16 INSTALLATION 15 INTERNAL WIRING LEGEND b blue br brown y/g yellow/green v violet y yellow bk black or orange w white pk pink Concord CXS - Installation & Servicing...
  • Page 17 INSTALLATION 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.

  • Page 18: Commissioning

    INSTALLATION 18 ZONES WITH SPRING-RETURN 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.

  • Page 19: Initial Lighting

    INSTALLATION 20 INITIAL LIGHTING 7. The boiler will light at Low rate and the Boiler-on light (5) 1. Check that the boiler thermostat knob (1) on the control will be illuminated. If it does not light the Lockout light (6) box (2) is OFF.
  • Page 20 INSTALLATION 21 MANIFOLD GAS PRESSURE Refit the electrical plugs and the dust and plastic covers. Failure to follow this procedure may result in the correct burner The manifold setting pressure must now be checked and pressure being set but the 2 gas valve governors not working adjusted as necessary.

  • Page 21: Servicing

    SERVICING 23 TESTING 22 SPILLAGE CHECK Check the main burner responds correctly to manual on/off operations of Check there is no spillage of any controls fitted in the gas control circuit. combustion products from the boiler Check the operation of the flame failure safety system by lighting the draught diverter by carrying out a boiler and then turning the gas inlet cock off.
  • Page 22 SERVICING 27 SERVICING - continued Unscrew the extended nuts at the top of the NOx duct behind condition. In particular, check that: the control box and lift the NOx duct clear of the burners as illustrated below. 1. The ignition electrode shield and base fixing screws are tight.

  • Page 23: Main Burner

    SERVICING 29 GAS CONTROL VALVE 30 MAIN BURNER 1. Disconnect the electrical connections to the faulty gas 1. Remove the NOx duct and burner front plate, as valve. previously described in Frame 26. 2. Turn the gas inlet cock OFF and unscrew the 4 screws 2.

  • Page 24: Overheat Thermostat

    SERVICING 32 BURNER AND CONTROLS ASSEMBLY - Exploded View - CXS 100 - 120 LEGEND Main injector, 3 off. Gas control valve Main gas inlet cock. Main (centre/RH) burner, 2 off. Gas control valve Gas inlet union. Spark generator 10. Main (LH) burner, 1 off. 'O' ring seals.
  • Page 25 SERVICING 34 CONTROL BOX - Basic Boiler, Exploded View Printed circuit board support detail Retention barbs Retention Back screw panel LEGEND Potentiometer Wiring clamp. Terminal strip 10. Warning light lens Connection box plug. Back panel 11. Controls box Lockout reset button Connection box.

  • Page 26: Combustion Chamber

    SERVICING 35A CONTROL SENSOR POTENTIOMETER ASSEMBLY 1. Undo the thermostat knob retaining screw and pull off the knob. Washer Plug 2. Remove the lower front panel. 3. Undo the backnut and washer retaining the potentiometer. Thermostat 4. Undo the 2 screws securing the control box front panel, lift it and knob carefully lower it.

  • Page 27: Site Assembled Boilers

    SITE ASSEMBLY 39 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS Legend 10. Burner manifold assy. TOOLS REQUIRED 1. Cleanout cover. 11. Base plate. Spanners 2. Collector hood. Torque wrench 12. Combustion chamber. 3. Middle section. Pozi screwdriver 13. Section bolt. Mallet 4. Section alignment 14.
  • Page 28 SITE ASSEMBLY 40 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 39.

  • Page 29: Fault Finding

    FAULT FINDING 41 BOILER CONTROL rapidly. This feature reduces component wear and ensures Before attempting any electrical fault finding ALWAYS carry continuous trouble free operation. The anti-cycle duration is 4 out the preliminary electrical system checks as detailed in the minutes.
  • Page 30 FAULT FINDING Before carrying out any Fault Finding, ensure that all internal controls are calling for heat and that the overheat thermostat has not operated. There should be 230V ± 10% available at the control box connection. 43 BOILER DOES NOT LIGHT Is the spark gap approximately 4mm and are the Is there a spark at the electrode? electrodes, leads and connections clean and secure?

  • Page 31: Short List Of Parts

    SHORT LIST OF PARTS When ordering spare parts please quote: The following are parts commonly 1. Boiler model required as replacements due to 2. Boiler serial no. (refer to data plate on the combustion chamber) damage or expendability. Their failure 3.
  • Page 32 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...

This manual is also suitable for:

Concord cxs 120

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