IDEAL Concord CXC 48, 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: ...s 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...

Page 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...

Page 5: ...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...

Page 6: ...s 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 dimen...

Page 7: ...l 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...

Page 8: ...em 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 t...

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...

Page 10: ...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 supp...

Page 11: ...ote 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...

Page 12: ...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 Conn...

Page 13: ...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 scre...

Page 14: ...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 t...

Page 15: ...ontacts 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 require...

Page 16: ...vidually 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...

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...

Page 18: ...an 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 Det...

Page 19: ...ntial 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 b...

Page 20: ...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 th...

Page 21: ...BY 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 switc...

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 I...

Page 23: ...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 se...

Page 24: ...ld 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 b...

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 l...

Page 26: ...hanger 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...

Page 27: ...ve 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...

Page 28: ...as 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 therm...

Page 29: ...ing 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 t...

Page 30: ...NG 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 low...

Page 31: ...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 repl...

Page 32: ...r 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 REPLA...

Page 33: ...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 pum...

Page 34: ...ES 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 de...

Page 35: ...PY 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 se...

Page 36: ...lves 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 an...

Page 37: ...erts 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...

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

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

Page 40: ...inuing 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 fir...