IDEAL Concord CXi 110, Installation & Servicing Manual

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Page 2: ...2 Concord CXi 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: ... CXi 110 180 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...

Page 4: ...safety time Maximum of 10 secs with 5 attempts with 1 minute between attempts Safety check The control de energises every 4 hours to check internal control functions Pump Pump overrun operates if the flow temperature is greater than 75 o C Boiler thermostat The boiler thermostat hysteresis is a maximum of 3 o C Table 1 Performance Data Table 3 Boiler Control specification Maximum flow temperature ...

Page 5: ...s may be open vented or sealed The range of boilers is NOT suitable for 1 Gravity DHW systems 2 Gravity heating systems 3 Direct domestic hot water supply 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 avoid the overheat thermostat tripping To allow pum...

Page 6: ...0 CXi 180 Front clearance mm in 750 29 1 2 Rear clearance mm in 200 8 Side clearance mm in 100 4 not including clearance for side fitted flow header Dimension A mm in 1036 40 3 4 1036 40 3 4 1036 40 3 4 1086 42 3 4 1140 45 Dimension B mm in 175 7 175 7 175 7 197 7 3 4 250 10 Dimension C mm in 1107 43 3 4 1107 43 3 4 1230 48 1 2 1353 53 1 4 1476 58 1 8 Dimension D mm in 816 32 1 8 816 32 1 8 939 37...

Page 7: ...pen vented systems It is assumed incorrectly that because boilers are operating in conjunction with what is apparently a closed circuit an open vented system will not under normal circumstances allow damage or loss of efficiency due to hardness salts and corrosion once the initial charge of water has been heated up a few times 1mm of lime reduces the heat transfer from metal to water by 10 In prac...

Page 8: ...ade to BS 6644 Section 2 Subsection 11 and Guidance note PM5 Automatically controlled steam and hot water boilers published by the Health and Safety Executive The information and guidance given below is not intended to override any requirements of either of the above publications or the requirements of the local authority gas or water undertakings In general commercial closed pressurised systems a...

Page 9: ... 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 Wiring external to the appliance MUST be in accordance with the I E E BS 7671 Wiring Regulations and any local regulations which apply For details of connections see Frame 14 FOUNDATION The boiler must stand on a non combustible floor i e con...

Page 10: ...e section 4 Flueway baffles 5 Section alignment rings O rings 6 Thermostat pocket INSTALLATION INSTALLATION 13 Combustion chamber 14 Tie rods 15 Lightback shield 16 Burner manifold assy 17 NOx duct 18 Gas cock not shown 7 End section 8 Distribution tube 9 Downdraught deflector 10 Section bolt 11 Drain cock 12 Base plate ...

Page 11: ...S Each section should be brushed clean on all external surfaces and any debris which may have accumulated within the sections should be removed via the bottom ports Section Assembly refer to the exploded view 5 Take an end section and lift it onto the combustion chamber so that the combustion chamber side panel return is inside the section rear lip 6 Locate a slotted steel ring and an O ring seal ...

Page 12: ...ashers 14 Fit the gas valve and spark generator assembly to the boiler by doing up the union in the gas line and by fastening the spark generator bracket to the combustion chamber using the two M5 screws and washers 15 Fit the gas inlet pipe and retain by the semi circular clamp screws and washers provided Tighten both unions and the inlet pipe retaining clamp ensuring that the gas valve assembly ...

Page 13: ...s to be brought directly to the boiler the close taper nipple and 1 1 4 tee must be fitted so that the drain cock is horizontal This will reduce the possibility of the drain becoming blocked by debris 5 Complete the system connections using suitable jointing compound as follows The cast iron flow header must be fitted in the chosen flow connection which will be either of the 2 top rear tappings A ...

Page 14: ...for the other side panel 4 Fit the upper front framework with the overheat thermostat at the bottom and with its green Legend 1 Side panel 2 Supporting angle 3 Top panel 4 Upper front panel 5 Control box 6 Bracket 7 Support frame 8 Door panel 9 Lower panel button facing forwards and secure to the front fixing bracket s using the M5 screws and washers and to each side panel using the No 8 screws 5 ...

Page 15: ...s and washers 3 Offer up the control box to the RH side of the upper front framework so that the location buttons on the back of the control box locate in the slots Push down to locate and fasten using the No 8 screws IMPORTANT 4 Offer up the spark generator assembly to the combustion chamber base tray and secure the bracket using the M5 screws and washers Plug the spark generator leads onto the s...

Page 16: ...mostat phial through the clips on the appropriate casing side panel to the flow header ensuring that both leads run under the support angle 8 Secure both phials into the thermostat pocket in the flow header using the spring clip 9 Fit the earths lead as shown in the illustration 10 Fit the casing upper front panel with its location buttons in the slots and push down to locate Fasten at the bottom ...

Page 17: ...d or the boiler will not operate Fit the plug in connector into the mains voltage connection box at the back of the control box and fasten using the M4 screws and washers Check that the other 2 plug in connectors are fitted into their respective boxes Finally fit the casing top panel and push down to locate INSTALLATION INSTALLATION Any system controls should be connected via volt free contacts to...

Page 18: ...one may be the load during overrun all zones MUST individually be able to satisfy the conditions in the foregoing paragraph and Graph 1 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 available via relay contacts to close the valve for that zone When all thermosta...

Page 19: ... the normally open contacts of the relay 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 pri...

Page 20: ...d high low burner operation In addition the microprocessor also has onboard commissioning and servicing instructions and a fault diagnosis programme The next section describes the minimum procedure to light and commission the boiler Full operating instructions for the microprocessor control and details of the high low operation system are included in Frames 26 31 INSTALLATION INSTALLATION GENERAL ...

Page 21: ... 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 24 25 24 ADJUSTING THE MANIFOLD PRESSURES 2 If desired it is possible to use the onboard commissioning instructions using the UP DOWN arrow buttons However the following paragraphs provide more detailed instructions and are recomm...

Page 22: ...stem has the advantages of ensuring that the boiler accurately maintains the set temperature without the large temperature swings that can be associated with on off boilers prevents rapid or short cycling and provides more efficient system operation 25 ADJUSTING THE MANIFOLD PRESSURES continued After setting allow the boiler to operate for 3 minutes to stabilise then recheck the setting Note CXi 1...

Page 23: ...racteristics described above the control system incorporates the following features accessible to the user or service engineer ADJUSTABLE BOILER TEMPERATURE CONTROL This is factory pre set at 82 C but may be adjusted by the user between 60 C and 85 C Refer to Frame 31 PROGRAMMER TIMER A maximum of 3 time periods per day can be programmed in to the boiler Note This a boiler timer only and does not ...

Page 24: ... CXi Installation 29 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 25: ...he 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 to 22 00 hours If 24 HOU...

Page 26: ...emain OFF for a minimum of 3 minutes or until the boiler flow temperature has dropped by 3 o C whichever is the greater time If the boiler load is such that it cycles between high and low operation the boiler will fall through 3 degrees before the high rate gas valve is energised Delayed High Rate Gas Valve Operation When the boiler is started from cold the high rate gas valve will be delayed for ...

Page 27: ...door panel Lift and remove the casing lower front panel Undo and pull off all the plugs from the gas valve solenoids Turn off the gas at the gas inlet cock Undo the 2 unions at either side of the gas valve assembly and remove the assembly complete 34 ADJUSTMENT OF WATER FLOW RATE THROUGH THE BOILER When commissioning the heating domestic hot water system the shunt pump must be adjusted to give the...

Page 28: ...8 REPLACEMENT OF COMPONENTS Refer to Frames 5 41 and 42 SERVICING SERVICING Pull off the leads to the spark electrode on the RH end burner access via the side of the combustion chamber Pull off the lead to the flame detector electrode at the LH end burner Lift off the casing top panel Undo the 3 elongated nuts from each of the NOx ducts and remove all the ducts Undo the M5 nuts and washers retaini...

Page 29: ...move all the screws on either the inlet or the outlet manifold and only those 4 screws securing the faulty gas valve on the other manifold The faulty gas valve can then be removed and replaced Ensure that the arrow on the gas valve points in the direction of flow 4 Ensure that new O ring seals are fitted and that the O ring seals on the remaining gas valves are correctly in place Ensure that all s...

Page 30: ... the cover 7 Remove the push on terminals from the thermostat body noting their positions SERVICING SERVICING LEGEND 1 Main gas inlet cock 2 Gas inlet union 3 O ring seal 4 Gas control valve 5 Gas control valve 43 OVERHEAT THERMOSTAT 6 Spark generator 7 Burner manifold 8 Main injector 9 Main burner 10 Main burner RH 11 Ignition electrodes 12 Detection electrode assembly PTP Pressure test point 8 F...

Page 31: ... from the 7 plastic mounting pins and 2 screws and pull it forward 7 Reassemble in reverse order 45 CONTROL SENSOR 1 Lift off the casing top panel 2 Trace the sensor lead to the pocket in the flow header remove the spring clip and remove the sensor phial 3 Unclip the sensor lead from its clips on the casing Undo the screws on the connector box plug and remove it 4 Fit the new sensor and reassemble...

Page 32: ...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 protective equipment should be wo...

Page 33: ... ON STANDBY 1 0 button does NOT electrically isolate the boiler Before attempting any electrical fault finding ALWAYS carry out the preliminary electrical system checks as detailed in the Instructions for the British Gas Multimeter or other similar commercially available meter The preliminary electrical system checks are the FIRST electrical checks to be carried out during a fault finding procedur...

Page 34: ...RT OF OPERATION SHUTDOWN DELAY IGNITION LOW RATE HIGH RATE Prepurge completed Flame ON PUMP OVERRUN IF 75 C OFF 75 C Temp set point Flame ON For 55 C no delay If 55 C 3 minutes Demand off Overrun completed Demand ON If than set point FAULT FINDING FAULT FINDING ...

Page 35: ... L B O I L E R S Is there a spark NO Refer to screens Check gas pressure Press Copy Check wiring Press Copy 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 Check gas Press Copy Press Copy Check gas valve wiring Press Copy Check detecti...

Page 36: ...nd lead gas valve CXi 110 120 140 160 180 1 139 270 28G Plug and lead gas valve CXi 180 1 111 870 29 Spark generator 1 139 300 31 Injector 4 02 mm diameter CXi 110 6 013 175 Injector 4 2mm diameter CXi 120 6 013 180 CXi 140 7 013 180 CXi 160 8 013 180 CXi 180 9 013 180 32 Flame detection electrode 1 33 Main burners Worgas CXi 110 5 138 663 Worgas CXi 120 5 138 663 Worgas CXi 140 6 138 663 Worgas C...

Page 37: ...de panel CXi 110 to 180 1 076 978 59 Casing RH side panel CXi 110 to 180 1 079 979 60 Casing Lower front panel CXi 110 120 1 138 475 CXi 140 1 138 474 CXi 160 1 138 473 CXi 180 1 138 472 61 Casing Upper front panel CXi 110 120 1 138 470 CXi 140 1 138 469 CXi 160 1 138 468 CXi 180 1 138 467 62 Casing Top panel CXi 110 120 1 138 465 CXi 140 1 138 464 CXi 160 1 138 463 CXi 180 1 138 462 63A Overheat ...

Page 38: ... pursues 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 Limited 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...

Page 39: ...be 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 498699 Boiler details Model Size e g Classic RS 230 Mexico CF 3 60 etc Details on control panel door Date of Installation Installer details Name Address Post Code Telephone Please include STD code How ...

Page 40: ...e 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 assist the installer when presenting to his her customers Technical manuals required The Ideal C class combi boiler The Ideal Classic wall hung boiler The Ideal Classic System wall hung boiler The Ideal Cl...