IDEAL Concord CXC 116, Installation & Servicing Manual

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Page 2: ...2 Concord CXC 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: ...is maintained in the primary heat exchanger to prevent corrosion CASING The combined boiler bodies are enclosed in a white stove enamelled casing which incorporates a control panel fascia The casing is specially designed to ensure easy access for both servicing and cleaning of both heat exchangers BURNERS The 3 burners are of stainless steel construction Gas Safety Installation and Use Regulations...

Page 4: ...4 67 58 Btu h x 1000 96 900 138 500 185 800 230 600 Boiler Input Gross kW 52 5 75 1 100 7 125 Btu h x 1000 179 100 256 200 343 600 426 500 High Rate Nett kW 47 3 67 67 90 73 112 6 Btu h x 1000 161 400 230 900 309600 384 200 Gas rate m3 h 4 4 7 0 9 4 11 6 ft3 h 172 247 331 411 Approx flue gas 8 0 CO2 60 C m3 sec 0 023 0 033 0 045 0 056 volume non condensing High rate 8 0 CO2 140 F ft 3 m 49 70 95 1...

Page 5: ...d central heating systems Independent indirect pumped domestic hot water or central heating systems Fully pumped systems may be open vented or sealed Flow and return connections are 2 BSP Safety Valve A safety valve must be sized and fitted in accordance with BS 6644 for every type of system The valve should be set at 0 7 bar 10 lb in 2 above the operating pressure in the boiler The maximum safety...

Page 6: ...ts flue system must be so placed or shielded as to ensure that its temperature does not exceed 65 o C 150 o F MULTIPLE BOILER INSTALLATIONS The minimum installation clearances must conform to the dimensions given below CXC 48 70 Clearance between boilers 50mm Clearance at both ends of the multiple installation 50mm CXC 94 116 Clearance between boilers 100mm Clearance at both ends of the multiple i...

Page 7: ...ll depend upon the particular characteristics of the system Pumping over of water into the expansion cistern must be avoided and cost Graph 1 is based on a 20 C temperature difference across the boiler WATER CIRCULATION SYSTEM Due to the compact nature of the boiler the heat stored within the castings at the point of shutdown of the burner must be dissipated into the water circuit in order to avoi...

Page 8: ...tem then any unsuitable water additives MUST be thoroughly drained 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 0 C 63 0 F assessed at catalogue rating It is essential that the main p...

Page 9: ... the flue system must be impervious to condensate leakage and also any low points in the flue system should be drained using pipe of material resistant to condensate corrosion Care should also be taken in the selection of flue terminals as these tend to accentuate the formation of a plume Care should be taken to ensure the specification of the chimney is suitable for the application by reference t...

Page 10: ...n pipework should INSTALLATION INSTALLATION be fitted and tested for gas soundness in accordance with BS 6891 for small installations or IGE UP 1 and IGE UP 2 for large installations The local gas supplier must be consulted if it is necessary to employ a gas pressure booster ELECTRICAL SUPPLY WARNING This appliance must be efficiently earthed A 230 V 50 Hz mains supply is required fused at 5 amps ...

Page 11: ...Note Before manoeuvring the boiler into its final position see Frame 8 INSTALLATION INSTALLATION 6 PACKAGING The Concord CXC boiler is despatched from the factory fully assembled except for the casing controls and installation packs which are packed separately within the same wooden crate as the boiler JACKET PACK contains Lower front panel 1 off Upper front panel 1 off Lower LH side panel 1 off L...

Page 12: ...y into the normal drainage system The pipe should be installed with an adequate slope e g 1 in 50 and consideration should be given to frost protection The drain should be in accordance with IM 22 Connections to BS 5355 can be used directly or connections to BS 5354 may be used with a suitable adaptor Note A condensate trap is built into the boiler sump therefore an external trap is not necessary ...

Page 13: ...k of the control box Unpack the control box from its carton and find the mains plug strapped to the back of the box The boiler casing should now be fitted The jacket hardware pack contains all the screws required for assembly 1 Fit support angles to the collector hood and sump The angle with the hole for the earth screw fits to the front Ensure the rear support angle is fitted as shown 2 Wire up t...

Page 14: ...t earth leads as shown 9 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 8 Secure with the split pin provided Complete the following after reaching Frame 32 15 Fit the lower top panel Fit the lower front panel 16 The upper front panel has 2 hooks at the bottom Dro...

Page 15: ...contacts or any mains voltage If no external controls are fitted a link must be fitted across EXT C The boiler provides frost protection via the boiler sensor If an external frost thermostat is required contact Caradon Plumbing Limited Wiring should be PVC insulated cable not less than 0 75mm2 24 0 2mm All fuses must be ASTA approved to BS 1362 The length of the conductors between the cord anchora...

Page 16: ...ividually 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 15 INTERNAL WIRING At the start of the next call for heat or the next clock period valves on the zones not calling for heat will motor shut Water...

Page 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 provide...

Page 18: ...han 55 C before proceeding to maximum rate If the boiler fails to light allow the controls to cycle until ignition is established If the boiler fails to light after 5 attempts the display will show Detection Fault In this case the ignition sequence should be reset by pressing the COPY button Check that the gas inlet pressure is at least the minimum value stated in Table 2 when the boiler is firing...

Page 19: ...ential to adjust the maximum setting first 4 Adjust the system controls to ensure that the boiler will operate at high rate for a reasonable period then remove the dust cover and adjust the high rate burner pressure setting using a suitable spanner Turn the maximum adjuster 7 clockwise to increase or anticlockwise to decrease the pressure After setting to the indicated pressure allow the boiler to...

Page 20: ...r 5 attempts the burner has failed to light the boiler will go to lockout and will be displayed on the screen When the boiler flow temperature reaches the thermostat set point the controls will turn the burner to low rate If the flow temperature continues to rise the burner and fan will be turned off at 3 o C above the set point If however the temperature falls below the set point whilst on low fi...

Page 21: ...DBY the rotating information screens will not be in evidence 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 ENTER FOR MENU To switch the boiler on press the On Standby 1 0 button The display will show This display will be retained for 5 seconds before the information screens are displayed INFORMATION SCREENS If the optional outs...

Page 22: ... CXC Installation 28 DESCRIPTION AND OPERATION OF BOILER CONTROLS continued The diagram below shows the sequence of steps to be taken when reading the instructions on the following pages INSTALLATION INSTALLATION ...

Page 23: ...y usage or 24 hour If the Programme Hours option is selected the boiler will go on and off subject to the times programmed If ALL DAY usage is selected the boiler will come on at the first ON period selected and off on the last OFF period selected ignoring all other time settings Based on the above backup programme this means the boiler would run subject to any other external controls from 07 30 t...

Page 24: ...uld be repeated for all 3 time zones for Monday After the last EXIT the display will ask if this day s programmes require to be copied to Tuesday If the YES button is pressed Tuesday s programme will be the same as Monday This action can be repeated for all the days or as many as required If the NO button is pressed then all 3 time slots will need to be programmed with the required times TEMPERATU...

Page 25: ... WARNING ALWAYS turn OFF the gas supply at the gas cock and switch OFF and disconnect the electricity supply to the appliance BEFORE servicing or replacing any components CLEANING THE BOILER Pull and lift off the lower front panel Remove the screw from the top of upper front panel Pull the panel forward and lift the bottom hooks clear of the lower top panel 32 TESTING 33 ADJUSTMENT OF WATER FLOW R...

Page 26: ...changer especially from between the fins using the brush provided and remove all debris from the combustion chamber floor Examine the burner assembly Clean the burner bars by brushing them down with a stiff bristle not wire brush Check each bar carefully to ensure that all flame ports are clear that there are no cracks and that all surfaces are free from accumulated deposits If available an indust...

Page 27: ...ove and replace the casing top and front panels fan NOx duct and the burner front plate as necessary described under Servicing 39 GAS CONTROL VALVE 1 Disconnect the electrical connections to the faulty gas valve 2 Check that the gas inlet cock is OFF unscrew the 4 screws on the gas valve inlet flange the 4 screws on the outlet flange and remove the valve 3 If the valve has a brass restrictor fitte...

Page 28: ...Gas inlet union 3 Gas control valve 4 O ring seal 5 Spark generator 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 PTP Pressure test point ...

Page 29: ...ting bracket 13 Overheat thermostat 14 Detection electrode assembly 15 Gas pipe 16 Gas restrictor PTP Pressure test point Overheat thermostat Con 1462 3 2 4 Reset button 1 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 R H M4 screw and remove the thermostat cover 4 Undo the 2...

Page 30: ...ING SERVICING 4 Printed circuit board No 34 5 Back panel 6 Hinge pin 7 Controls box LEGEND 1 Wiring clamp 2 Connection box plug 3 Connection box 45 CONTROL SENSOR 1 Remove the upper front panel and lower 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...

Page 31: ...d however recommend that for your own comfort and to comply with good working practise the procedure described below is followed IMPORTANT Turn OFF the gas and DISCONNECT the electricity supply To replace the insulation boards the major boiler components including the heat exchanger and burners have to be removed to gain access to the combustion chamber Prior to removal of the boards the following...

Page 32: ...er front casing panel 1 Unscrew the pressure switch from its mounting bracket Transfer the electrical connections and sensing pipes to the new pressure switch 2 Reassemble in reverse order 51 FAN REPLACEMENT 7 Unscrew the 5 screws securing the fan assembly and remove the assembly by pivoting it to the right 8 Unscrew the fan from the fan plate replace the fan and reassemble in reverse order 9 Chec...

Page 33: ...5 o C when the heat demand is satisfied and will continue to run until the boiler flow is less than 75 o C If the flow temperature is less than 75 o C when the demand for heat is satisfied then the pump will cease to operate Frost protection is inbuilt with the boiler If the flow temperature falls to approximately 3 o C then the boiler will operate until the flow temperature exceeds 4 o C If an ex...

Page 34: ...DES Fault codes numbered 1 to 24 are displayed where applicable In this event contact Caradon Plumbing Limited SHUTDOWN Demand ON If temperature senses than set point Demand off Flame ON For 55 C no delay If 55 C 1 3 minutes Reaches temp set point FAULT FINDING FAULT FINDING 54 BOILER CONTROL continued The boiler control has a unique fault diagnostic feature which can in the unlikely event of a fa...

Page 35: ...OPY Replace faulty solenoid Press COPY Refer to screens Change gas valve or solenoid Press COPY Observe the display Take actions as follows depending upon the display Check system Press COPY Replace sensor Press COPY Press COPY Check gas valve wiring Press COPY YES Replace detection probe Boiler will not light Do any external controls call for heat Is 230V 10 available at appliance Reset timer or ...

Page 36: ...alves 28 HONEYWELL VR4605PB 2003 CXC 48 70 1 111 867 28A HONEYWELL VR4605A 1104 CXC 94 116 1 138 896 28B HONEYWELL VR4605AB 1019 CXC 94 116 1 111 869 28C Plug gas valve CXC 48 70 1 111 872 28D Plugs and leads gas valve CXC 94 116 1 112 430 28E Plugs and leads gas valve CXC 94 116 1 112 431 28F Plugs and leads gas valve CXC 48 70 94 116 1 111 870 28J Gas valve restrictor CXC 94 to 116 1 150 371 29 ...

Page 37: ...serts clips studs CXC 48 1 077 725 CXC 70 1 077 727 CXC 94 1 077 729 CXC116 1 077 731 59 Casing RH side panel white stove enamel including nutserts clips studs CXC 48 1 077 726 CXC 70 1 077 728 CXC 94 1 077 730 CXC116 1 077 732 60 Casing lower top panel white stove enamel CXC 48 1 112 798 CXC 70 1 138 387 CXC 94 1 138 385 CXC116 1 112 752 61 Casing upper front panel white stove enamel 1 112 755 62...

Page 38: ...38 Concord CXC Installation NOTES ...

Page 39: ...39 Concord CXC Installation NOTES ...

Page 40: ...tinuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 Ideal Installer Technical Helpline...