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Concord CX - 

Installation

3

CONTENTS

Air Supply

. ........................................................................

9

Boiler Assembly - exploded view

. ...............................

10

Boiler Clearances

. ...........................................................

6

Burner Assemblies - exploded views.

CX 40-60

. ...................................................................

24

CX 70-100

. .................................................................

25

Casing Assembly

. ..........................................................

13

Chimney System

. .............................................................

9

Commissioning

. .............................................................

18

Electrical Connections

. .................................................

15

Electrical Supply

. .............................................................

9

Fault Finding

. .................................................................

30

Gas Safety Regulations

...................................................

3

Gas Supply

. .......................................................................

9

Hydraulic Resistance

. ......................................................

6

Initial Lighting

. ................................................................

18

Installation

. .....................................................................

10

Mandatory Requirements

. ...............................................

8

Option Kits

. .......................................................................

5

Pump

. ................................................................................

7

Servicing

. ........................................................................

21

Short List of Parts

. .........................................................

32

Site Assembled Boilers

. ................................................

28

Static Head Requirements

. .............................................

7

System Connections

. .....................................................

12

Ventilation

. ........................................................................

9

Water Circulation

. ............................................................

5

Water Connections

. .........................................................

5

Water Treatment

. ..............................................................

7

Wiring Diagrams

. ...........................................................

16

Concord CX 40-100 

(Natural gas)

B.G. Certified

 - 

P.I. No

.87/AP/80

Destination Countries:

 GB and IE

INTRODUCTION
CONSTRUCTION

BOILER BODY

The sectional boiler body is of cast iron and is supplied assembled
on a sheet steel combustion chamber with an integral draught
diverter.  The boiler can be supplied in sectioned form to special
order for site assembly - refer to the section headed ‘Instructions
for Site Assembled Boilers’.

CASING

The casing is manufactured in stove enamelled sheet steel and
is easily assembled on site.

BURNERS

The 3 burners are of stainless steel construction.

Gas Safety (Installation and Use) Regulations, 1994,
amendments 1996 or rules in force.

It is the law that 

all

 gas appliances are installed and serviced by a

CORGI registered installer (identified by  ) in accordance with
the above regulations. 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 CX40/100

 range of boilers has been tested and

certified by British Gas to prEN656 for use with 

Natural gas only.

Multiple boiler installations

The 

Concord CX range

 is certificated for use in multiple boiler

installations, providing that the following conditions are satisfied.

1.

A downdraught thermostat kit MUST be fitted to ALL boilers
in the installation.

2.

A maximum of 6 boilers may be used with a single flue
header.

3.

For clearances see Frame 2.

A comprehensive guide to multiple installations of Concord CX
boilers is available.

WARNING.

Failure to use a downdraught kit on every boiler in a multiple boiler
installation will negate the certification of the installation and
therefore contravene the essential requirements of the Gas
Appliance Directive.

Note.

 

Concord CX40, CX50 and CX60

 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. It is important, therefore, that no external control devices -
e.g. flue dampers, economisers etc., are directly connected to this
appliance unless covered by these Installation and Servicing
Instructions or otherwise recommended by  

Caradon Plumbing

Limited

 in writing. If in doubt, please enquire.

Any direct connection of a control device not approved by 

Caradon

Plumbing Limited 

could invalidate the British Gas Certification,

the normal appliance warranty and could also infringe the Gas
Safety Regulations. Table 1, Table 2 and the descriptive notes
which follow contain all the essential data likely to be required by
the installer.

GAS CONTROLS

Summary of Contents for Concord CX40

Page 1: ......

Page 2: ...2 Concord CX Installation 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...

Page 3: ...the law is complied with The Concord CX40 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 CX range...

Page 4: ...in BSP 2 x 2 at rear Return tappings Rc in BSP 2 x 2 at rear Maximum static head metres feet 45 7 150 Maximum pressure bar p s i 4 5 65 Gas inlet connection Rc in BSP 3 4 3 4 1 1 Minimum dynamic mbar...

Page 5: ...auge kit In addition to the above control kit an optional pressure gauge is also available for the range of boilers Details for fitting are included with the pressure gauge Downdraught thermostat kit...

Page 6: ...learance should be given at the rear of the boiler for connection of gas and water pipework Additional clearance is required for access at either end of the installation 2 CLEARANCES DIMENSIONS Boiler...

Page 7: ...n will depend upon the particular characteristics of the system Pumping over of water into the expansion cistern must be avoided achieved either by provision of an adequate bypass circuit or by ensuri...

Page 8: ...setting Other British Standards applicable to commercial sealed systems are BS 6880 Part 2 BS 1212 BS 6281 Part 1 BS 6282 Part 1 BS 6283 Part 4 Working pressure 4 5 bar maximum Particular reference s...

Page 9: ...em 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 The effective height of the chi...

Page 10: ...ngs 5 End section 6 Gas cock 13 Section bolt 14 Distribution tube 15 Tie rods 16 Thermostat pocket 17 Spillage skirt 18 Flueway baffles 19 Gas pipe 7 Drain cock 8 NOx duct 9 Front plate 10 Burner mani...

Page 11: ...g 2 BSP handling bars 9 Using the handling bars manoeuvre the boiler forwards on the packaging base and slide over collapsing base on to the floor Note Before manoeuvring the boiler into its final pos...

Page 12: ...er lower rear connection using the gasket and M10 x 25mm screws and washers provided 3 Temporarily screw the 2 handling bars 2 pipe into the top tappings and manoeuvre the boiler into position 4 Compl...

Page 13: ...e the flue connection 2 The boiler is designed to accept flues to BS 835 and should be sealed with an approved boiler putty 11 GAS CONNECTION 1 Connect the gas supply to the gas inlet pipe at the rear...

Page 14: ...e 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...

Page 15: ...cal 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...

Page 16: ...atisfy 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 othe...

Page 17: ...ls for heat its thermostat will open Zone 1 valve via the normally open contacts of the relay IMPORTANT Terminal L2 may control the appropriate pump s directly provided that the total running or start...

Page 18: ...groove in square head in line with the pipe 5 Press the overheat thermostat reset button 2 6 Push in and retain fully depressed the grey button 4 on the gas control 5 At the same time repeatedly push...

Page 19: ...ilitate speedy approximate adjustment of the gas rate After setting to the indicated pressure allow the boiler to operate for about 15 minutes to stabilise then check the gas rate by reference to a wa...

Page 20: ...the minimum flow rate given in Table 4 when that part of the system intended to be used for dissipation of residual heat only is in operation 26 HANDING OVER ROUTINE OPERATION Full instructions coveri...

Page 21: ...sitioned 3 The ignition electrode and lead are clean undamaged secure and correctly dimensioned Refer to diagram in Frame 28 4 The thermocouple tip is NOT burned or cracked 5 The thermocouple terminal...

Page 22: ...front plate fits behind the burner retaining returns when it is replaced Refit the flue baffles cleanout cover NOx duct casing top panel and casing door PILOT BURNER Check that 1 The pilot flame cover...

Page 23: ...ble in reverse order checking that the spark gap is as shown in Frame 28 SERVICING SERVICING To facilitate the replacement of components remove and replace the lower front panel NOx duct and the burne...

Page 24: ...ge connection 7 Test for gas soundness 35 MAIN BURNER 1 Remove the NOx duct and burner front plate as previously described in Frame 27 2 Both left and right hand burners can be removed by sliding each...

Page 25: ...in injector 3 off 9 Gas inlet manifold 10 Pilot gas pipe 11 Overheat thermostat piezo generator mounting bracket 12 O ring seal 13 Thermocouple 14 Spark electrode 15 Pilot draught shield 16 Pilot burn...

Page 26: ...ing in the clips provided Detail of Printed Circuit Board Support SERVICING 40 CONTROL BOX Basic Boiler Exploded View 41 CONTROL SENSOR 1 Remove the lower front panel Refer to Frame 27 2 Remove the se...

Page 27: ...OMBUSTION CHAMBER INSULATION REPLACEMENT The insulation boards used in the combustion chambers of these products contain man made fibres refractory fillers organic and inorganic binders and as such ar...

Page 28: ...mocouple and pilot gas pipe connections at the gas valve must be removed and the igniter lead pulled off at the igniter 4 The centre burner may now be removed by pushing it back to clear the injector...

Page 29: ...oming apart 8 Repeat the above procedure for all of the remaining sections until the assembly is complete 9 Fit the 4 tie rods through the holes in the sides of the end sections and fit a flat steel w...

Page 30: ...ical checks to be carried out during a fault finding procedure On completion of any service fault finding task which has required the breaking and remaking of electrical connections Check that the gap...

Page 31: ...ling for heat if necessary withdraw the sensor from the thermostat pocket NO NO 49 PILOT LIT BUT NO MAINS GAS NO NO Have you confirmed that the system controls are calling for heat YES FAULT FINDING Y...

Page 32: ...racket VERNITRON 60080 002 1 003 939 32 Ignition electrode and H T lead assembly VERNITRON 1 130 947 33 Thermocouple HONEYWELL Q 309 A 2762 1200mm long 1 002 937 34 Thermocouple interrupter lead assem...

Page 33: ...1 111 651 CX 70 1 111 652 CX 80 1 111 652 CX 90 100 1 111 653 50 Jacket top panel white stove enamel CX 40 1 111 293 CX 50 1 111 294 CX 60 1 111 295 CX 70 1 111 296 CX 80 1 111 297 CX 90 100 1 111 298...

Page 34: ...ursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice Technical Training The Caradon Plumbing Lim...

Page 35: ...giving away a free boiler for the five best ideas every year to be selected by our Technical Director Please complete this form using extra sheets if required and post it or fax it to us on 01482 498...

Page 36: ...lease 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 a...

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