IDEAL Concord CXSi 110, Installation & Service Manual

Page 1: ...Installers guide to commercial central heating boilers BOILERS Concord CXSi 110 H 180 H INSTALLATION M A N U A L SERVICING ...

Page 2: ...GENERAL 2 Concord CXSi H Installation Servicing ...

Page 3: ...i 110 H CXSi 120 H CXSi 140 H CXSi 160 H CXSi 180 H Boiler Input Gross kW 93 9 102 5 119 5 136 6 153 7 Low Rate Btu h x 1000 320 5 349 6 407 9 466 1 524 4 Nett kW 84 6 92 3 107 7 123 1 138 5 Btu h x 1000 288 7 315 0 367 4 419 9 472 4 Boiler Input Gross kW 134 2 146 4 170 8 195 2 219 6 High Rate Btu h x 1000 457 8 499 4 582 7 665 9 749 1 Nett kW 120 9 131 9 153 8 175 8 197 8 Btu h x 1000 412 4 449 ...

Page 4: ...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 Ideal Limited in writing If in doubt please enquire Any di...

Page 5: ...indirect pumped domestic hot water and central heating systems Independent indirect pumped domestic hot water or central heating systems Fully pumped systems 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 t...

Page 6: ... 180 H Front clearance mm in 700 27 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 10...

Page 7: ...ed 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 practice the deposition of these s...

Page 8: ...utomatically 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 are provided with either manual or automatic water make up On b...

Page 9: ...sure 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 concrete or brick which ...

Page 10: ...hood 3 Middle section 4 Flow header 5 Section alignment rings O rings 6 Thermostat pocket 7 End section 15 Lightback shield 16 Burner manifold assy 17 NOx duct 18 Insulation bracket 8 Distribution tube 9 Downdraught deflector 10 Section bolt 11 Drain cock 12 Base plate 13 Combustion chamber 14 Tie rods Insulation not shown INSTALLATION ...

Page 11: ...ch 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 into...

Page 12: ...k generator bracket to the combustion chamber using the two M5 screws and washers 16 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 is vertical 17 To fit the collector hood align the back edge of the horizontal side returns with the rear of the section assembly and ...

Page 13: ...eed expansion pipe is 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 ...

Page 14: ...anel 4 Fit the upper front support framework with the overheat thermostat at the bottom and with its green Con 1466 6 5 7 8 9 4 3 1 2 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 to the RH side and secure to the front fixing bracket s using the M5 screws and washers and to each side panel usi...

Page 15: ...9 C N O N C 2 push in connections Con 1913 Electrical cover Flame detector lead 6 3 Con 1468 5 Spark generator leads Con 1912 3 Fit the control box to the support frame and fix to the bottom using the 2 self tapping screws provided 4 Fit the earth connections from the terminal plug in connections to the appropriate earth posts on the back of the control box Connect the earth lead prefitted to the ...

Page 16: ...support angle 9 Secure both phials into the thermostat pocket in the flow header using the spring clip 10 Fit the earth connections from the terminal plug in connections to the appropriate earth posts on the back of the control box Connect the earth lead prefitted to the control box back panel to the threaded hole in the casing support frame 11 Fit the casing upper front panel with its location bu...

Page 17: ...ection facility to operate Failure to operate this procedure will result in nuisance overheat thermostat operation The internal wiring of the boiler control box is shown in Frame 15 Wiring should be in four core PVC insulated cable not less than 0 75mm2 24 0 2mm All fuses must be ASTA approved to BS 1362 The length of the conductor between the cord anchorage and the terminals must be such that the...

Page 18: ...ACTS L4 N L3 N N O DET OVERHEAT THERMOSTAT 2 3 PINK PUMP FACTORY FITTED LINKS EXTERNAL CONTROLS TTB N L2 T1 T1 L1 X2 N SUPPLY F1 C F2 X1 LOCKOUT OVERHEAT L5 1 N BR BR BR B Y G Y G N C GV1 LOW WHITE RED BR DETECTION ELECTRODE SPARK GEN CONTACT REMOVED AND FITTED TO MATING HALF 2 X VIOLET 2 X RED 2 X YELLOW DETECTION LEAD YELLOW YELLOW RED RED RED RED BLACK WHITE ORANGE BK GREY BLUE ORANGE ORANGE VI...

Page 19: ...ntacts to close the valve for that zone When all thermostats are satisfied also when the clock period ends all relays will be off so the zone valves which were open will remain open for the pump overrun period 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...

Page 20: ...iod of 2 minutes Any leaks must be cured Replace all pressure test point screws 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 Three zon...

Page 21: ...ase the overheat thermostat button 4 4 Switch on the electrical supply to the boiler 5 Ensure that all system controls time switch system controls etc are calling for heat 6 Turn the boiler thermostat knob 1 to position 6 20 INITIAL LIGHTING 7 The boiler will light at Low rate and the Boiler on light 5 will be illuminated If it does not light the Lockout light 6 will be illuminated Press in and re...

Page 22: ...e with the system cold on full load and with all temperature controls set to maximum to avoid thermostatic shutdown Remove the screw in the burner setting pressure test point and connect a suitable gas pressure gauge Turn on the electrical supply to light the boiler and let it operate for about 10 minutes to stabilise the burners Check the pressure and if it differs noticeably from that given in T...

Page 23: ...st now be checked and adjusted as necessary It is essential to set the High Pressure first Start the adjustment procedure with the system cold on full load and with all temperature controls set to maximum to avoid thermostatic shutdown Remove the screw in the burner setting pressure test point and connect a suitable gas pressure gauge Turn on the electrical supply to light the boiler and let it op...

Page 24: ... cleaning at least annually in order to ensure reliable and efficient operation Regular attention will also prolong the life of the boiler and should preferably be performed at the end of the heating season After servicing complete the service section of the log book and return it to the owner or their representative Recommend that a contract for this work should be made with a CORGI registered in...

Page 25: ...ch of the NOx ducts and remove all the ducts Undo the M5 nuts and washers retaining the burner light back shield and remove it Undo the four M6 nuts and washers securing the burner tray and carefully pull it from the boiler ensuring that no wires are trapped Undo the screws securing the cleanout cover s and remove Remove all loose deposits from the heat exchanger especially from between the fins u...

Page 26: ... 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 screws are retightened 5 Test for gas soundness 6 Recommission the appliance and set the manifold pressure as d...

Page 27: ...ver 7 Remove the wires 8 Undo the backnut and remove the thermostat 9 Fit the new thermostat and secure with the backnut 10 Reconnect the wires as follows 1 Pink 2 White 3 Red Reconnect the earth terminal LEGEND 1 Main gas inlet cock 2 Gas inlet union 3 O ring seal 33 OVERHEAT THERMOSTAT 4 High low gas control valve 5 Gas control valve 6 Spark generator 7 Burner manifold 8 Main injector 9 Main bur...

Page 28: ...ug from the PCB and remove the strain relief bush Remove the sensor and lead 5 Fit the new sensor ensuring that the lead is routed along the casing in the clips provided 6 Reassemble in reverse order 34 CONTROL BOX Basic Boiler Exploded View 5 Terminal strip 6 Back panel 7 Lockout reset button 8 Thermostat knob LEGEND 1 Wiring clamp 2 Connection box plug 3 Connection box 4 PCB S456B1047 9 Potentio...

Page 29: ... from the potentiometer When reassembling ensure the arrow on the body is lined up in the OFF position 4 Remove the back nut and brass washer securing the thermostat knob to the panel 5 Undo and remove the 2 screws securing the control box front panel Carefully lift it up and lower it 6 Remove the terminal plugs from the back of the potentiometer 7 Undo the purse clips holding the wires from the p...

Page 30: ...ti cycle duration is 4 minutes If the system pump with a maximum current of 3A is connected to the boiler pump terminals pump overrun will be in operation when the demand for heat is satisfied and will continue to run for 6 minutes Frost protection is inbuilt with the boiler If the flow temperature falls to approximately 5 o C then the boiler will operate until the flow temperature exceeds 18 o C ...

Page 31: ... at the control box YES Is there 230V 10 at the spark generator Replace spark generator Replace PCB S4561B1047 YES YES 43 BOILER LIGHTS BUT GOES TO LOCKOUT NO Measure the flame current expect approximately 3 5µA Replace PCB S4561B1047 Check LH end burner inlet and burner pressure check the LH end burner injector YES 44 BOILER GOES OUT ON OVERHEAT THERMOSTAT NO YES Is the flame detector and its lea...

Page 32: ...120 H 140 H 160 H 1 139 269 28 5 Plug and lead CXSi 110 H 120 H 140 H 160 H 1 112 431 28 6 Plug and lead CXSi 110 H 120 H 140 H 160 H 180 H 1 155 657 28 7 Plug and lead CXSi 180 H 2 111 870 29 Spark generator 1 139 300 31 Injector 4 02 mm diameter CXSi 110 H 6 013 175 Injector 4 20mm diameter CXSi 120 H 6 013 180 Injector 4 20mm diameter CXSi 140 H 7 013 180 Injector 4 20mm diameter CXSi 160 H 8 0...

Page 33: ...ing RH side panel CXSi 110 H 180 H 1 076 979 60 Casing lower front panel CXSi 110 H 120 H 1 138 475 60 Casing lower front panel CXSi 140 H 1 138 474 60 Casing lower front panel CXSi 160 H 1 138 473 60 Casing lower front panel CXSi 180 H 1 138 472 61 Casing upper front panel CXSi 110 H 120 H 1 155 643 61 Casing upper front panel CXSi 140 H 1 155 644 61 Casing upper front panel CXSi 160 H 1 155 645 ...

Page 34: ...NOTES Concord CXSi H Installation Servicing 34 Concord CXSi H Installation Servicing ...

Page 35: ...NOTES Concord CXSi H Installation Servicing 35 Concord CXSi H Installation Servicing ...

Page 36: ...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...