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Concord CXD 40-100 Series 3

1. 12 Concord CXD Installation INSTALLATION 11 GAS CONNECTION 10 FLUE CONNECTION Gas inlet pipe 1 Connect the gas supply to the gas inlet pipe at the rear LH side of the boiler 1 Complete the flue connection 2 The boiler is designed to accept flues to BS 835 and should be sealed with an approved boiler putty Table 2 gives details of the inlet connection size and the minimum working pressures 12 CASING ASSEMBLY 1 Unpack the control box from its carton and release the 2 Slide bottom of the side panel on to the studs on the temperature sensing probe strapped to the back of the base tray box 3 Screw the side panel to the support angle The boiler casing should now be fitted Repeat for other side A jacket hardware pack contains all the screws required for assembly Concord CXD Installation 13 INSTALLATION INSTALLATION INSTALLATION 13 CASING ASSEMBLY continued 8 Route the 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 it into the thermostat pocket Ensure that the Heyco bush is correctly located 9 Fit earth leads as shown 14 4 Fit 3 clips to the top of each side panel 5 Fit the spire clips to the side casing panels 6 Hook on the control box to si
2. Control panel earth stud GV2 GV1 O heat stat kk Optional extra o x o x 9220 20 LOW Voltage MAINS 000 Voltage Plug in connector OO OO O OF OP OO Plug in connector ACAO Ae Ae AO OO OO O OF Q OOF CO a TTB Link prewired to be removed if Downdraught thermostat is to be fitted G c GV2 V1 DET IGN OSTAT 16 ZONES WITH BI DIRECTIONAL MOTORISED VALVES Permanent live supply OLOLOLHOHOVOHOLOLOLO esasa arora or O ORO 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 connector Three zones are illustrated but the principles be extended as required provided the above conditions are met Each relay will then require as many contacts as there are zones Zone thermostats Overrun Since any zone may be the load during overrun all zones MUST individually 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 available via relay contacts to close the valve for that Zone When all thermostats are satisfied also when th
3. 11 On open vented systems a hydraulic test should be carried out at 1 1 2 times the design pressure given in Table 2 for a period of 30 minutes 12 On a pressurised system the test should be at twice the design pressure for a period of 30 minutes 13 Fit the 4 coach bolts into the lugs at the bottom of the front and rear sections Secure with the nuts and washers provided 14 Fit the flue baffles which are located between the fins 15 Fit the collector hood Ensure the underside returns running across the hood sit within the front and rear section flueways Fasten down using the four M6 screws and nuts provided through the front and rear fixing points 23 The boiler is now ready for installation Go to Frame 8 in this publication and continue the installation from there 16 Locate the fibreglass rope in rear section grooves to form a seal with the spillage skirts Fit the spillage skirts onto the collector hood using the self tapping screws provided Collector hood 17 Refit the manifold assembly Position the boiler insulation over the gas line tie bracket Fasten the bolt securing the bracket to the front section before wrapping and securing insulation around the boiler body 18 Insert the burner rear supports into the slots at the back of the combustion chamber Lift the front of the burners over the l l injectors and pull Spillage skirt forward to engage Sealing rope 32 Concord CXD
4. It is essential that the main pump or shunt pump if used is wired to the pump terminals marked L2 N on the plug in Mains voltage connector shown below and in Frame 15 The earth must be wired to the earth post as shown in Frame 13 If no external controls are fitted it is essential that a link is wired in place of it on the mains voltage connector The flow switch should be connected via volt free contacts to the Flow S terminals A link may be fitted in place of the flow switch but the control will not be able to analyse the faulty flow switch if such a failure should occur Either of the above must be fitted or the boiler will not operate Any system controls should be connected via volt free contacts to the terminals marked EXT C Do NOT connect an external clock to these contacts or any mains Installer connections so Unswitched Live Supply Concord CXD Installation MAINS Voltage Plug in connector voltage If no external controls are fitted a link must be fitted across EXT C terminals The boiler provides frost protection via the boiler sensor If an external frost thermostat is required contact Caradon Plumbing Limited If the Downdraught flue thermostat is to be fitted then the link marked TTB should be removed from the plug in connector The internal wiring of the boiler control box is shown in Frame 15 Wiring should be PVC insulated cable not less than 0 75mm 24 0 2mm
5. Prior to assembling the sections it will be necessary to remove the burner and controls assembly from the combustion chamber Remove the assembly as follows 1 Undo the 4 wing nuts securing the burner front plate Pull the front plate forwards from the top and lift it out 2 On the CXD 40 50 amp 60 remove the screws holding the HT heat shield from the LH leg of the combustion chamber Raise slightly and withdraw the heat shield taking care not to damage the leads 3 The burners may now be lifted out after they have been pushed back to clear the injector 4 Disconnect the electrode leads and take care not to damage the electrode assemblies 5 Undo the nut securing the manifold assembly to the combustion chamber pull the manifold assembly to the right and lift out 31 SITE ASSEMBLY 50 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS continued PREPARATION OF SECTIONS Each section should be brushed clean on all external surfaces and any debris which may have accumulated within the section should be removed via the bottom ports Section assembly Refer to exploded view 6 Take the back section with 1 2 BSP tappings in the top and lift it onto the combustion chamber so that the combustion chamber back panel return is inside the section rear lip Locate a slotted steel ring and an O ring seal into each of the 4 ports It will be necessary to squeeze the steel ring slightly to enable it to be pushed fully into the
6. above the maximum design operating pressure of 4 5 bar 65 Ib in Cold Feed Open Vent The independent cold feed and the open vent must comply with BS 6644 and be of the following minimum size CXD 40 50 Open Vent CXD 60 100 Sealed system filling point refer to Frame 8 Concord CXD Installation 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 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 In order to allow pump operation after burner shutdown the boiler control box incorporates a pump overrun facility which operates when the boiler switches off and until the flow temperature is below 75 C and in order to make use of this the pump must be wired to the appropriate terminal L pump in the boiler control box 1 The minimum flow rate as given in Table 5 must be maintained whenever the boiler is firing and during the pump overrun period 2 During the period of pump overrun there must be an open circuit of adequate water volume and or load The minimum size of this circuit is
7. Down Set Time Date Press Down p y m ss Enter Press Down All Day Press Down Press Down Enter Down mess Press POWA Enter E Press Commissioning Reh press choice is made Set Time Zones Press Enter Set Temp to required setting Enter Set Time Date Follow Choose instructions requirement Follow Instructions Concord CXD Installation INSTALLATION 29 DESCRIPTION AND OPERATION OF BOILER CONTROLS continued MENU To access the menu screen ensure that the information screens are being displayed Any key except the 1 0 button may now be pressed to access this feature but as indicated on the information screen the ENTER button is the preferred means On entering this option the first screen displayed will be PROGRAM TIMER The DOWN button can be pressed consecutively to access the features required which are as follows TEMP SET SERVICE COMMISSIONING If the weather compensation option is fitted then a further screen will be displayed after commissioning The UP button will access the above options in reverse When the option required is displayed and the ENTER button pressed another set of menus will be available as discussed on the following pages PROGRAMMER TIMER The programmer has 3 time zones per day for each day of the week Each day can be programmed for the requirements of that day giving 7 programmed days or using the copy facility
8. Installation FAULT FINDING 51 BOILER CONTROL WARNING The 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 procedure On completion of any service fault finding task which has required the breaking and remaking of electrical connections the following checks MUST be repeated a Earth continuity b Polarity c Resistance to earth Detailed instructions on the replacement of faulty components are contained in the Servicing section of these Installation amp Servicing Instructions GENERAL INFORMATION If a flow switch is not connected to the boiler a link should be fitted between the 2 terminals for the flow switch If the terminals are left disconnected the display will indicate No flow and the boiler will not operate Anti cycle will be in operation each time the boiler thermostat is satisfied and a rapid demand for heat is required The same situation will occur if the external controls operate rapidly This feature reduces component wear and ensures continuous troublefree operation The Anti cycle duration is 1 3 minutes If the system pump with a maximum current of 3A i
9. floor Note Before manoeuvring the boiler into its final position see Remove the 2 BSP steel handling bars from installation Frans pack Remove 4 base bolts holding assembly to the packaging base Remove the wood screws securing the front cross x a member on the packaging base NA Remove the gas cock by unscrewing the union and screw So in the handling bars into the 2 front tappings Protect the 3 D exposed inlet gas union from ingress of dirt Concord CXD Installation 11 INSTALLATION INSTALLATION INSTALLATION 8 BOILER ASSEMBLY 1 Fit the distributor tube supplied with the boiler into one Note Frame 9 shows the relationship between the of the return connections That is one of the rear lower overheat thermostat and the flow tapping ports Refer to Frame 5 d Complete the water connections by plugging the two Fit the flange using the M10 x 35mm screws and front top tappings with the 2 BSP plugs provided washers provided Ensure that the tube flange aligns horizontally and that the 2 sealing gaskets are correctly assembled on the tube Refer to alignment notches in Frame 5 Fit the 1 tapped flange to the other lower rear connection using the gasket and M10 x 25mm screws and washers provided Temporarily screw the 2 handling bars 2 pipe into the top tappings and manoeuvre the boiler into position Complete the system connections using suitable jointing compound as f
10. 3 minutes A Y Demand off HIGH RATE PUMP OVERRUN IF gt 75 C OFF lt 75 C 0 a L h 34 Concord CXD Installation FAULT FINDING 53 FAULT FINDING FLOW CHART Boiler will not light 1 Is 230V 10 NO Carry out electrical available at h checks appliance Check all fuses b Do any external NO Reset external controls call for gt controls as heat appropriate l YES Check boiler NO Reset timer or programme timer and ___ p status as status as described appropriate in Frame 28 Does programme timer require heat YES Observe the display Take actions as follows depending upon the display STANDBY Press 0 1 button Press O H reset OVERHEAT Check system Replace o h stat Refer to R FAUT p Press Copy PF Press Copy gt screens F BOILER ne SENSOR Check wiring p Check system p Replace sen
11. 50 0 34 4 5 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 C 63 F assessed at catalogue rating WATER TREATMENT FOR HOT WATER AND HEATING BOILERS There is a basic need to treat the water contained in all heating and indirect water systems particularly open 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 practice the deposition of these salts is liable to cause noises from the boiler body or even premature boiler failure Corrosion and the formation of black iron oxide sludge will ultimately result in premature radiator failure Open vented systems are not completely sealed from the 3 OPEN VENTED SYSTEMS Minimum static head requirements Particular reference should be made to BS 6644 Section 2 Subsection 10 and Guidance note PM5 Automatically controlled steam and hot water boilers published by the Health and Safety Executive The information and guidance
12. All fuses must be ASTA approved to BS 1362 The length of the conductors between the cord anchorage and the terminals must be such that the current carrying conductors become taut before the earthing conductor if the cable or cord slips out of the cord anchorage The earth connection MUST NEVER be omitted Wire the earths as shown in Frame 13 All wiring between entry at the rear of the boiler and the connection box must be secured neatly under the cable clips provided Wiring must never be allowed to come into contact with any heated surfaces Carefully route the electrical leads from the gas valve spark generator behind the LH panel return and secure with clip as shown Fit the plug in connector into the mains voltage connection box behind the control box 248 0 15 INSTALLATION INSTALLATION LEGEND b blue br brown bk black r red 15 INTERNAL WIRING y yellow w white Pump Supply Control panel earth stud Detail of connection box MAINS Voltage INSTALLATION br y b or bk Plug in connector Remote indication 5 z board No 36 Ideal No 35 LCD Board Unswitched Live Supply E g O Installer connections Detail of connection box Detail of connection box O Q e x O OF o l OF OO O OF O OF lt O OP OO O OP O OF cs
13. COPY ENTER 1 OOOO ADV YES 0 CONCORD CX D Up down buttons ON STANDBY 1 0 BUTTON Turns the boiler on and to STANDBY WARNING STANDBY does NOT electrically isolate the boiler When this switch is in the STANDBY position the display will show STANDBY 0 On initial start up the boiler will indicate the hardware and software code the boiler type and indicate if the boiler is ON or STANDBY If the boiler is at STANDBY the rotating information screens will not be in evidence Concord CXD Installation On Standby button To switch the boiler on press the On Standby 1 0 button The display will show BOILER ON 1 This display will be retained for five seconds before the information screens are displayed INFORMATION SCREENS If the optional outside temperature kit enabling weather compensation has been fitted the display will indicate the compensated set point temperature An example of the display is as follows MONDAY 14 1019 09 95 ON HIGH 50 C HOURS RUN 250 TEMP SET 82 C PROGRAMMER ON ENTER FOR MENU 21 INSTALLATION 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 INSTALLATION 22 following pages C BOILER ON 1 Wait 5 seconds Scrolling Screens Press 1 0 press Enter Press Enter 5 Press pown Press
14. Caradon Plumbing Ltd PO Box 103 National Avenue Kingston upon Hull HU5 4JN Telephone 01482 492251 Fax 01482 448858 Ideal Installer Technical Helpline 01482 498376 U I N 112 166 AO
15. Connections 12 VentilaHon 000 9 Water Girculation U m s b rreren 5 o D 0 5 YVaterlrealinent rer 7 VViring Diagrams iit coer 16 Concord CXD Installation 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 amp 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 CXD 40 100 range of boilers has been tested and certified by British Gas to prEN656 for use with Natural gas only Multiple boiler installations The Concord CXD range is certificated for use in multiple boiler installations providing
16. Lo 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 Flovv litres min Graph 2 Hydraulic Resistance Rear clearance i 0 0 0 150 6 150 6 300 12 300 12 Side clearance i 50 2 50 2 50 2 50 2 50 2 100 4 100 4 Dimension A i 754 293 4 887 35 887 35 1047 41 1 4 1047 41 1 4 1217 48 1217 48 Dimension B i 108 4 1 4 108 41 4 122 5 47 8 122 5 4 7 8 135 5 3 8 190 7 1 2 190 7 1 2 Dimension i 931 6 36 5 8 931 6 36 5 8 931 6 36 5 8 931 6 36 5 8 931 6 36 5 8 893 6 35 3 16 893 6 35 3 16 Dimension i 177 5 T 187 5 7 3 8 187 5 7 3 8 224 5 8 7 8 224 5 87 8 271 5 10 5 8 271 5 10 5 8 Dimension i 69 0 2 3 4 79 0 3 1 8 79 0 3 1 8 116 0 45 8 116 0 4 5 8 163 0 6 1 2 163 0 6 1 2 600 24 A POSITION OF BOILER Gas conn of flue 300 12 B 154 6 Minimum clearances required a from walls or other fixed objects to allow for the free access of combustion air are shown in Table 4 above However for maintenance s purposes vve suggest a minimum rear clearance of 50mm y Any combustible material Y adiacent to the boller and its C ve flue system must be so placed 7 or shielded as to ensure that n its tempera
17. bearing capacity to support the weight of the boiler when filled with water and any ancillary equipment If the boiler is mounted on a plinth then the dimensions must exceed the plan area of the boiler by at least 75mm on each side VENTILATION Safe efficient and trouble free operation of conventionally flued gas boilers is vitally dependent on the provision of an adequate supply of fresh air to the room in which the appliance is installed Ventilation by grilles communicating directly with the outside air is required at both high and low levels The minimum free areas of these grilles must be according to the following scale Table 6 Ventilation Requirements Total input Position of air Air vent areas air rating of boilers vents direct from outside Upto 2 MW HIGH LEVEL 270 cm plus 2 25 cm per kW in excess of 60 kVV total rated input 540 cm plus 4 5 cm per kVV in excess of 60 kVV total rated input Upto 2 MVV LOVV LEVEL Position ventilation grilles to avoid the risk of accidental obstruction by blockage or flooding If further guidance on ventilation is required then consult BS 6644 AIR SUPPLY BY MECHANICAL VENTILATION The supply of air by mechanical means to a space housing the boiler should be by mechanical inlet with natural or mechanical extraction Mechanical extract ventilation with natural inlet must not be used Where a mechanical inlet and a mechanical extract system is applied the desi
18. dynamic gas mbar gauge G m pressure required at boiler inlet n vv 7 6 0 6 0 6 5 6 0 6 2 Electricity 230 Volts single phase 50 Hz fuse 5 A Diverter outlet socket 184 184 213 213 238 238 238 internal diameter 7 3 1 3 8 4 8 4 9 4 9 4 9 4 Length of burner bars overall 377 497 497 617 617 137 137 5 19 5 19 5 24 3 24 3 m Main burner iniectors 3 off ize 382 82 412 12 457 0 57 4 486 Approximate dry weight E A 0 E a 463 584 584 727 727 871 871 Water content litre 22 30 30 37 37 45 45 gal 4 8 6 6 6 6 8 2 8 2 9 9 9 9 Table 3 Boiler Control specification Maximum Flow temperature 85 C Electricity supply 230V 50Hz fuse Ignition 5 attempts followed by non volatile lockout Gas valve High Low and Off Gas safety time Maximum of 10 secs with 5 attempts with one min between attempts Safety check The control de energises every four hours to check internal control functions Pump Pump over run operates if the flow temperature is greater than 75 C Boiler thermostat The boiler thermostat hysteresis is a maximum of 3 C 4 Concord CXD Installation GENERAL GAS CONTROLS The gas controls consist of a high low arrangement with direct burner ignition ELECTRICAL CONTROLS WARNING THE ON STANDBY 1 0 button does NOT electrically isolate the boiler The CX D incorporates an advanced microprocessor based control
19. given by the use of Graph 1 Examples shown on Graph 1 a For the CXD 90 and CXD 100 the minimum circuit during pump overrun could be a load of 6 kW with a volume of 31 litres or any other combination given by the relevant line b For the CXD 70 and CXD 80 the minimum circuit during pump overrun could be a load of 2 kW with a volume of 45 litres or any other combination given by the relevant line The above circuit capacity during pump overrun may be achieved either by provision of an adequate bypass circuit or by ensuring that a zone of suitable size is open for circulation during this period by relevant control of zone valves or pumps GENERAL Relationship between load amp water volume for the minimum capacity of water circuit during the 6 minute pump overrun period for different boiler outputs o Oo N O A Heat Load During Pump Overrun kW O 0 10 20 30 40 50 60 70 80 Water Volume in Circuit during Pump Overrun litres Graph 1 Heat Load Water Volume 2 CLEARANCES amp DIMENSIONS Table 4 120 olol o 110 Se 66606 OPT OY O 100 ns s ES eS n Q ENE MET SEEE m l O O O 80 2 2 ale mx 60 0 40 57 77 75 30 5 DE 3 s 20 Lael
20. system which operates all electrical functions of the boiler including ignition flame detection thermostatic control and high low operation In addition the microprocessor has onboard servicing and commissioning instructions and a fault diagnosis programme The illuminated LED display gives a continual read out of the boiler status and functions but in the unlikely event of a fault condition will display the fault areas OPTION KITS Pressure Gauge Kit A pressure gauge is available for the range of boilers Details for fitting are included with the pressure gauge Downdraught thermostat This kit is optional when used on a single CX D installation but mandatory when used on a multiple boiler installation Remote Indication Board volt free This provides the ability for remote indication of lockout and overheat conditions Outside Sensor This kit provides a sensor for temperature compensation when the outside temperature changes DUTY The range of boilers is suitable for Combined indirect pumped 1 WATER CONNECTIONS Flow and return connections are 2 BSP A 1 BSP tapping is provided in the redundant return flange for the cold feed or expansion vessel connection 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 Ib in above the operating pressure in the boiler The maximum safety valve setting is 0 7 bar 10 Ib in
21. 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 CXD 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 The CXD 40 CXD 50 and CXD 60 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
22. vent safety pipe ol 0 5m see note 5 Expansion cistern 2 5 mminimum 45 7m Maximum see note A ndependent cold feed expansion pipe Main pump lt CN shan pute Independent return to boiler Note A This minimum height must be increased if necessary to comply with the minimum head required by the pump manufacturer in order to avoid cavitation Note B This diagram does not show safety valves water flow switches etc necessary for the safe operation of the system GENERAL atmosphere if proper venting and expansion of system water is to be achieved The same tank is used to fill the system with water and it is through the cold feed pipe that system water expands into the tank when the boiler passes heat into the system Conversely when the system cools water previously expelled is drawn back from the tank into the system together with a quantity of dissolved oxygen Even if leakage from the heating and hot water system is eliminated there will be evaporation losses from the surface of the tank which depending upon ambient temperature may be high enough to evaporate a large portion of the system water capacity over a full heating season There will always be corrosion within a heating or hot water system to a greater or lesser degree irrespective of water characteristics unless the initial fill water from the mains is treated Even the water in closed systems will promote corros
23. ING 36 SERVICING continued Unscrew the extended nuts at the top of the NOx duct behind the control box and lift the NOx duct clear of the burners as illustrated below Undo the wing nuts securing the burner front plate Pull the front plate forwards at the top and lift it out faking care not to damage the insulation or the detection electrode On the CXD 40 50 amp 60 remove the screws holding the HT heat shield from the LH leg of the combustion chamber Raise slightly and withdraw the heat shield taking care not to damage the leads The burners may be lifted out after they have been pushed back to clear the injectors Take care not to damage the ignition electrode assembly and carefully detach the ignition leads when removing the left hand burner Take care not to damage the detection electrode when removing the RH burner Undo the screws securing the cleanout cover and lift it off to give access to the flueways Lift out the flue baffles Remove all loose deposits from the heat exchanger especially from between the fins Ensure that they are clean and in good condition In particular check that 1 The ignition electrode shield and base fixing screws are tight 2 The electrodes are correctly positioned Refer to Frames 40 or 41 3 Reassemble in reverse order Refit the flue baffles cleanout cover NOx duct and casing panels TESTING AFTER SERVICING After re assembly restore the electricity and gas su
24. OILER CONTROLS continued procedure should be followed but the NO button pressed PROGRAMME HOURS Enables a user timed programme to be entered The following display will be available MON 1 ON 06 30 with the hours 06 flashing Using the UP or DOWN button select the correct hour and press ENTER The minutes will now flash and the correct minutes should be selected using the UP or DOWN button followed by pressing ENTER This will cause the hours to flash and if the correct ON time has been entered the EXIT button should be pressed The display will now show the OFF for time zone one This procedure should 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 TEMPERATURE SET POINT Enables the temperature at which the boiler is required to operate to be set It has a range of 60 C 85 Using the UP or Down button select the TEMP SET from the menu and press ENTER The following will be displayed with the temperature flashing The UP and Down button should be pressed until the correct temperature is selected and then the ENTER button should be p
25. a status information screen will appear stating whether the device has been activated or not i e compensator on off COMMISSIONING INSTRUCTIONS These are provided to assist the installer to commission the boiler SERVICING INSTRUCTIONS These are provided to assist the service engineer FAULT DIAGNOSIS In the unlikely event of a fault condition the microprocessors will identify the fault area and display a suitable message on the display Further to these accessible features there are other features present in the system which the installer service engineer should be aware of HOURS RUN LOG This feature enables the installer to determine the workload of the boiler PUMP OVERRUN If the flow temperature is above 75 C at the time of boiler shutdown the controls will maintain pump operation until the residual heat within the appliance has been dispersed and the flow temp is below 75 C ANTI CYCLE DEVICE On any heating system if the heating load is very low there is a tendency for the boiler to cycle on and off rapidly This is inefficient and can lead to shortened boiler life The high low operating system of the CXD minimises the risk of this but in addition the controls prevent the boiler from short cycling by preventing subsequent ignition within a period of 2 minutes When active the display will show ANTICYCLE flow temp 27 DESCRIPTION AND OPERATION OF BOILER CONTROLS Display 5 Id al EXIT
26. any number of days can be the same If a particular time zone is not required then the ON and OFF periods should be programmed for the same time Each button has an auto repeat function The programmer is based on a 24 hour clock and the boiler comes with a backup programme set for All The boiler will respond to this programme unless an alternative s programmed in Day Using the UP or DOWN button select the Programmer Timer from the menu and press ENTER The following menus will be available using the UP or DOWN buttons STATUS or SET TIME DATE or ADVANCE Concord CXD Installation or PROGRAM HOURS To select any of the above use the UP or DOWN button until the option required is displayed and press ENTER STATUS Enables the selection of programme hours all day 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 to 22 00 hours If 24 HOUR is selected the programme times will be ignored and the boiler will run subject to the external controls until one of the other options is again selected SET TIME DATE Enables the correct time and
27. appliance gas cock record the static pressure Next close the gas supply cock at the meter Wait for 1 minute for temperature stabilisation then observe the pressure gauge over a period of 2 minutes Any leaks must be cured Replace all pressure test point screws Display 5 Ideal EXIT COPY ENTER 1 OOOO ADV YES 0 CONCORD CX D On Standby button COPY button Check that the gas inlet pressure is at least the minimum value stated in Table 2 when the boiler is firing at maximum rate High Whilst the boiler is warming up observe the display to become familiar with its operation The display changes automatically between the Boiler status and flow temperature Hours run Temp set Programmer status Enter for menu Day 5 Date and time Note That as the boller flov temperature approaches the thermostat setting the boiler is automatically reduced to low rate This feature is designed to improve overall operating efficiency and reduce short cycling under low load conditions The controls will automatically switch the boiler between high and low upon demand Concord CXD Installation INSTALLATION 22 CHECKING THE MANIFOLD PRESSURES Turn the boiler OFF by pressing the 0 1 button and allow the flow temperature to cool to less than 50 C Connect a pressure gauge to the burner manifold test point Frame 23 or 24 Press the 0 1 button again to turn the boiler ON The boiler will operate at low ra
28. bustion products from the boiler draught diverter by carrying out a spillage test as detailed in BS 5440 1 33 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 minimum flow rate given in Table 3 when that part of the system intended to be used for dissipation of residual heat only is in operation 35 SERVICING SERVICING 32 TESTING Check that the main burner responds correctly to manual on off operations of any controls fitted in the gas control circuit Check in the following manner the operation of the flame failure safety device 1 Extinguish the main burner by turning off the main gas inlet cock Refer to Frames 23 amp 24 Check that the display shows DETECTION LOCKOUT Turn on the gas cock and reset by pressing COPY Fit the lower casing front panel Important Commissioning Operating Instructions Do not operate this appliance for long periods or take any combustion readings with the casing or any part of the casing removed 34 HANDING OVER ROUTINE OPERATION Full instructions covering routine lighting and operation of the boiler are given on the Lighting and Operation Instruction Label located on the inside of the casing door Draw the attention of the boiler owner or his representative to the Lighting and Operating Instruction Label on the inside of the casing door Give a practical demon
29. ck for gas soundness 7 Press EXIT to leave the commissioning mode and return to the main menu 8 Press EXIT again to return to the status displays LEGEND 1 Fascia panel display Screw minimum adjuster 3 t is essential to adjust the maximum setting first 2 Overheat thermostat 7 Gas rate adjuster maximum reset button i 4 Adjust the system controls to ensure that the boiler will l l 5 l 3 Main gas inlet cock point operate at high rate for a reasonable period then remove l l the dust cover and adjust the high rate burner pressure 4 Union 9 Inlet pressure test point setting using a suitable spanner Turn the maximum 5 Gas control valve 10 High low solenoid connector adjuster 7 clockwise to increase or anticlockwise to decrease the pressure After setting to the indicated pressure allow the boiler to operate for about 5 minutes to 220 3 stabilise then recheck the burner pressure gt 7 2 4 gt 1 R O emove 5 o cA 8 8 172 1 Concord CXD Installation Con 170 7 19 INSTALLATION INSTALLATION INSTALLATION 24 ADJUSTING THE MANIFOLD PRESSURES CXD 70 80 90 amp 100 ONLY 1 Press the ENTER button on the fascia panel then press either the up or down arrow button until the display shows COMMISSIONING then press ENTER The microprocessor is now in commissioning mode Failure to enter the c
30. cover Collector hood Middle section Section alignment rings amp O rings End section Gas cock Drain cock NOx duct Front plate SITE ASSEMBLY 49 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS 17 14 10 Burner manifold assy 11 Base plate 12 Combustion chamber 13 Section bolt 14 Distribution tube 15 Tie rods 16 Thermostat pocket 17 Spillage skirt 18 Flueway baffles 19 Gas pipe The site assembled boiler is supplied in the following packages Combustion chamber manifold burner assembly Jacket package GENERAL Platework package Controls box package End and centre sections The installation of the boiler must be in accordance with the Gas Safety Installation and Use Regulations 1994 as amended building regulations E E BS 7671 regulations and the bye laws of the local water undertaking It should also be in accordance with the relevant British Standard Codes of Practice together with any relevant requirements of the local gas supplier and local authority Concord CXD Installation TOOLS REQUIRED Spanners Torque wrench Pozi screwdriver Mallet ASSEMBLY The combustion chamber should be positioned as near as possible to the installation site IMPORTANT It must be remembered that the boiler distribution tube has to be fitted into the rear return tapping of the assembled boiler before siting
31. data likely to be required by the installer GENERAL Table 1 Performance Data gs o ss Boiler nput Gross Lovv Rate Btu hr x Nett kVV Btu hr x 1000 Boiler Input Btu hr x 1000 High Rate Nett kW Btu hr x m Boiler output 42 0 50 0 60 08 70 34 80 56 90 8 100 0 High Rate Btu hr x 1000 143 3 170 6 205 0 240 0 274 9 309 8 341 2 fer 176 6 210 5 252 9 295 9 339 0 382 1 420 6 Approximate 4 5 CO amp 100 C 0 044 0 052 0 063 0 073 0 084 0 094 0 104 flue gas volume m sec inthe secondary 4 5 CO amp 212 F flue of the chimney system ft m 93 110 133 155 178 199 220 Manifold setting pressure mbar 3 9 3 0 3 9 30 3 8 3 6 4 1 Low Rate in W g 1 6 1 4 1 6 1 4 1 5 1 4 1 6 Manifold setting pressure mbar 11 7 10 5 12 2 10 4 10 3 11 2 11 5 High Rate in w g 4 7 4 2 4 9 4 2 4 1 4 5 4 6 Seasonal efficiency SEDBUK 76 21 76 21 76 71 77 00 77 3 77 6 The value is used in the UK government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated have been certified by BGplc 0087 Note To obtain gas consumption divide gross heat input kW by a calorific value of 37 8 Table 2 General Data Numberofsections 3 4 4 5 5 6 6 Flow tappings Rc in BSP 2 x 2 atrear 2 x 2 atrear 45 7 150 4 5 65 Return tappings Rc in BSP Maximum static head metres feet Maximum pressure bar 7 I Min
32. date to be entered The display will show a flashing day of the week as follows The correct day can be selected by use of the UP or Down button and when correct the ENTER button should be pressed The time and date will now be displayed as follows 20 57 20 09 95 with first two digits the hours flashing By use of the UP or Down button the correct hour is selected and the ENTER button pressed The minutes will now be flashing and by use of the UP or DOWN button the correct minutes selected and the ENTER button pressed This method is repeated until the correct day month and year are selected On selecting the correct year and pressing ENTER the hours will flash then if all the data is correct the EXIT button should be pressed for the control to accept this information ADVANCE Enables the programme to be advanced by 1 hour The following display will be available ADVANCE 1HR Y N If the YES button is pressed and the programmer is in an OFF period the boiler will be brought on for 1 hour subject to external controls If the boiler is on with less than 1 hour to a programmed off period then the difference between this time and 1 hour is the time of the extended on period If the boiler is in the 24 hour mode then this option will have no effect If this advance has been selected to cancel it then the same 23 NS TALLATION INSTALLATION INSTALLATION 30 DESCRIPTION AND OPERATION OF B
33. de panels Screw in self tapping screws at the bottom of the control box to fix it to the side panels Route the 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 9 Secure with the split pin provided Earth connections sm QN oe Supply amp Pump earths GV1 amp GV2 and 2x O heat thermostat earths 174 3 Concord CXD Installation INSTALLATION 14 ELECTRICAL CONNECTIONS Connection must be made in a way that allows complete isolation of the electrical 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 the user after installation This should serve only the boiler together with its controls and pumps The supply must be wired direct to the boiler control box and must not be interrupted by any system controls The pump s and any system controls must be wired back to the boiler control box The mains supply to the boiler must be wired into the boiler terminals L1 N on the plug in Mains voltage connector shown below and in Frame 15 The earth must be wired to the earth post as shown in Frame 13 The control box incorporates a pump overrun device which is necessary to dissipate residual heat after plant shutdown
34. down draught free zone The number of bends and lengths of horizontal flue pipe used should be kept to a minimum in order to reduce gas flow resistance Compliance with the recommendations made in BS 6644 British Gas publication IM 11 Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters and the Third Edition of the 1956 Clean Air Act Memorandum should be strictly observed where applicable The chimney design should avoid the formation of excessive quantities of condensate For this reason it is recommended that all chimneys are insulated and lined In the case of brick or similar structures a stainless steel rigid or flexible flue liner grade 304 316 may be used in conjunction with a 50 mm minimum thick layer of vemiculite or perlite granules between the liner and the inner skin of the chimney body Liners should be sealed at both top and bottom As the Concord CXD range of boilers is supplied complete with an integral draught diverter a diverter MUST NOT be fitted within the chimney system Drainage points positioned at the bottom of all vertical chimney sections should be provided Drain pipes should be no less than 25 mm D manufactured from acid condensate resistant material such as stainless steel and be positioned so that pipe runs and discharge points are not subject to the effects of frost and that flue gases cannot leak into the boiler room Care should be taken to ensure the specification of t
35. e clock period ends all relays will be off so the zone valves which were open will remain open for the pump overrun period 16 v violet pk pink y g Control panel v earth stud Front panel earth lead Control panel earth stud y g yellow green or orange Con 173 4 l CTRLSTAT O SEN 7 777 flue t stat N Relay R4 Zone R1 1 valves At the start of the next call for heat or the next clock period valves on zones not calling for heat will motor shut Water circulation system refer to page 5 Concord CXD Installation INSTALLATION 17 ZONES WITH INDIVIDUALLY PUMPED ZONES 3 zones shown Permanent live supply EXT C Relay Contact R4 1 Zone o0 0 thermostats oe m Schematic 00 VViring oo R 7 Zone 3 O pure R3 IMPORTANT Terminal L2 may control the appropriate pump s directly provided that the total running or starting current does not exceed 6A Three zones are illustrated but the principles may be extended as required provided the above conditions are met For each zone except Zone 1 a relay with 2 C O contacts is O required PEOD Plug in resistive or inductive if this rating would be connector exceeded then appropriate switchgear must be sie N used to control the pumps indirectly Relay No 4 R3 1 Overrun During overrun periods Zone 1 pump performs the overrun facility this zo
36. e the ribbon cable from PCB No 34 by pushing the Trace the lead back to the connector box behind the retaining tabs sideways control box Release the connector box plug Frame 43 Release all plug connections from the board Replace the sensor and reassemble in reverse order Ensure that the lead is rerouted along the casing in the clips provided and check that the sensor is correctly fitted and secured in the thermostat pocket Remove the real time clock board PCB No RTC 34 from PCB No 34 by squeezing the 4 mounting pins and pulling forwards Release PCB No 34 from the 9 plastic mounting pins and replace the board Re assemble in reverse order Concord CXD Installation SERVICING SERVICING SERVICING 46 PC BOARD NO 35 Remove the lower front panel Slacken the 2 screws securing the control box front panel Carefully lift it up and hinge forwards Release the ribbon cable plug from PCB No 35 Release PCB No 35 from the 6 plastic mounting pins and replace the board Re assemble in reverse order 47 PC BOARD NO RTC 34 Remove the lower front panel Slacken the 2 screws securing the control box front panel Carefully lift it up and hinge forwards Remove the real time clock board PCB No RTC 34 from PCB No 34 by squeezing the 4 mounting pins and pulling forwards Re assemble in reverse order 48 COMBUSTION CHAMBER INSULATION REPLACEMENT The insu
37. energise the boiler If in addition Zone 1 now calls for heat its thermostat will open Zone 1 valve via the normally open contacts of the relay Concord CXD Installation Permanent live supply Plug in connector N Relay No 2 S P Relay 2 Contact f required Zone thermostats Schematic valve 1 Wiring When the clock period ends Zone valve 1 will stay open via normally closed relay contacts to achieve pump overrun Water circulation system refer to page 5 17 INSTALLATION INSTALLATION INSTALLATION 19 COMMISSIONING AND TESTING GENERAL Check that all drain cocks are closed that any stop valves fitted to the flow and return pipes are open and that the system has been filled and properly vented PURGING Check that the electricity supply is switched OFF Remove the jacket lower front panel Extinguish all naked lights and open all doors and windows DO NOT SMOKE Check that the gas supply is turned ON at the meter and open the main gas inlet cock Loosen the union and allow air to be purged from the gas line until gas is smelled Refer to BS 6891 or IGE UP 1 for further details Retighten the union 20 INITIAL LIGHTING The CXD incorporates an advanced microprocessor based control system which operates all electrical functions of the boiler including automatic ignition flame detection thermostatic control and high low burner operation In addition the microprocessor also has onboard co
38. eplacing burners 40 BURNER AND CONTROLS ASSEMBLY Exploded View CXD 40 60 LEGEND l 1 Main gas inlet cock 6 Burner manifold Gas inlet union 7 Main injector 3 off Gas control valve 8 Main burner centre RH 2 off m 9 Main burner LH 1 off 10 Ignition electrodes O ring seal Spark generator Concord CXD Installation 11 Overheat thermostat generator mounting bracket 12 Overheat thermostat 13 Detection electrode assembly 14 HT leads heat shield 15 Gas pipe PTP Pressure test point Con76 3 27 SERVICING SERVICING 41 BURNER AND CONTROLS ASSEMBLY Exploded View CXD 70 100 LEGEND 4 Gas control valve Low 8 Main injector 3 off 1 Main gas inlet cock 5 Gas control valve High 9 Main centre RH burner 2 off 2 Gas inlet union 6 Spark generator 10 Main LH burner 1 off 3 O ring seal 7 Burner manifold 11 Ignition electrodes 12 Overheat thermostat mounting bracket 13 Overheat thermostat 14 Detection electrode assembly 15 Gas pipe 16 Gas restrictor PTP Pressure test point 10 Con177 3 SERVICING 42 OVERHEAT THERMOSTAT Undo the 2 screws retaining the overheat thermostat assembly and withdraw the assembly Undo the 2 screws securing the thermostat cover to the support bracket and withdraw the thermostat from the cover Con 1294 1 Remove the push on tags from the thermostat body noting their posi
39. 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 Other British Standards applicable are BS 5422 amp BS 6700 The information provided is based on the following assumptions 1 An independent open vent safety pipe connection is made to the redundant boiler flow tapping or is positioned immediately after the system flow pipe connection to the header as shown Anindependent cold feed expansion pipe connection is made to the redundant boiler return tapping Cold feed expansion pipe connections made to the pumped system return will result in an increase in the static head requirement caused by the additional resistance of the distributor tube Surging may also increase The maximum flow rate through the boiler is based on a temperature difference or 11 C at full boiler output and the circulating pump is positioned in the flow to the system The boiler is at the highest point of circulation in the system Systems designed to rise above the boiler flow tappings will automatically require a minimum static head higher than that shown The position of the open vent safety pipe above the expansion cistern water level is given as a guide only The final position will depend upon the particular characteristics of the system Pumping over of water into the expansion cistern must be avoided Concord CXD Installation Open
40. gn ventilation flow rates should be as in Table 4 of BS 6644 The requirements for air supply by mechanical ventilation are given in BS 6644 Note For mechanical ventilation systems an automatic control should be provided to cause safety shutdovvn or lockout of the boiler s in the event of failure of air flow in either inlet or extract fans IMPORTANT The use of an extractor fan in the same room as the boiler or in an adjacent communicating room can in certain conditions adversely affect the safe operation of the boiler Where such a fan is already fitted or if it is intended to fit an extractor fan after installation of the appliance the advice of the gas supplier should be obtained Tests for spillage of products from the draught diverter when the extractor fan is running and all doors and windows are shut should be carried out after installation If spillage is detected the area of permanent ventilation must be increased Concord CXD Installation CHIMNEY SYSTEM To ensure the safe and satisfactory operation of the boiler then the chimney system 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 chimney terminal s above the boiler outlet s must ensure sufficient buoyancy to overcome the resistance of the bends tees and runs of the flue pipe involved and shall terminate in a
41. he chimney is suitable for the application by reference to the manufacturers literature Caradon Plumbing Limited can offer advice on the design of suitable chimney systems GAS SUPPLY If there is any doubt regarding the capacity of the gas meter the available gas pressure the adequacy of existing service pipes or the size required for new service pipes then the advice of the gas supplier should be requested Installation pipework should be fitted and tested for gas soundness in accordance with BS 689 1 IGE UP 1 for small installations 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 Wiring external to the appliance MUST be in accordance with the 1 E E BS 7671 Wiring Regulations and any local regulations which apply For details of connections see Frame 14 INSTALLATION 5 CONCORD CXD BOILER ASSEMBLY Exploded view 10 Distribution tube detail Legend O a fF OO N Cleanout cover Collector hood Middle section Section alignment rings amp O rings End section Gas cock INSTALLATION 7 Drain cock 8 NOx duct 9 Front plate 10 Burner manifold assy 11 Base plate 12 Combustion chamber 13 Section bolt 14 Distribution tube 15 Tie rods 16 Thermosta
42. ion CXD 40 1 150 093 CXD 50 60 1 150 094 S S xx xl d CXD 70 80 1 150 095 eee ee eee eee CXD 90 100 1 150 096 Worgas 0 087 751 40 1 150 153 Worgas 0 087 753 CXD 50 60 1 150 154 BA AE ST 00 7 Worgas 0 087 755 CXD 70 80 1 150 155 0 087 757 90 100 1 150 156 Main burners 0 087 750 40 2 150 149 mesum Anma Worgas 0 087 752 CXD 50 60 2 150 150 ZEY vit Moment eb R Worgas 0 087 754 CXD 70 80 2 150 151 s s b b S b Worgas 0 087 756 CXD 90 100 2 150 152 Main burner injectors Size 3 4 mm CXD 40 3 111 323 2686065 Size 3 82mm CXD 50 3 111 324 0000000700 acai Bas aah tute se Gal ie Size 4 12mm CXD 60 3 111 325 85 een emanate eater Size 4 57mm CXD 70 3 111 326 ee Size 4 86mm CXD 80 3 013 177 s Size 5 2mm CXD 90 3 111 328 Size 5 3mm CXD100 3 013 179 Gas control valves HONEYWELL VR4605PB 2003 CXD 40 60 1 111 867 HONEYWELL VR4605A 1104 CXD 70 100 1 138 896 HONEYWELL VR4605AB 1019 CXD 70 100 1 111 869 Gas restrictor CXD 70 100 1 150371 Spark generator assy generator and terminals 1 112 721 Ignition electrode BE 3417 SI 1 112 365 Detection electrode BE 3459 SI 1 112 364 Thermistor 1 112 289 Overheat thermostat RAK 77 4 3835 1 153 914 Control box as
43. ion unless treated For the reason stated Caradon Plumbing Limited strongly recommend that when necessary the system is thoroughly cleaned prior to the use of stable inhibitor which does not require continual topping up to combat the effects of hardness salts and corrosion on the heat exchangers of the boiler and associated systems Caradon Plumbing Limited advise contact directly with specialists on water treatment such as Sentinel Division Betz Dearborn Ltd Widnes Cheshire WA8 8UD Tel 0151 424 5351 Fernox Manufacturing Co Ltd or Tandem House Marlowe Way Croydon Surrey CRO 4X5 Tel 0870 5601 5000 INSTALLATION REQUIREMENTS The appliance must be installed by a CORGI registered installer identified by amp The installation of the boiler must be in accordance with the relevant requirements of the Gas Safety Regulations current BS 7671 Regulations Model Water Bye laws local water authority bye laws and it should also comply with any 4 SEALED PRESSURISED SYSTEMS Working pressure 4 5 bar maximum Particular reference should be made 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 c
44. is botler My general comments for Ideal Caradon aa Plumbing Solutions Ideal Installer Technical Helpline 01482 498376 Concord CXD Installation 39 Further information If you would like information about Ideal Boilers please complete this sheet and fax it to us on 01482 498699 or post it to Caradon Plumbing Limited PO Box 103 National Avenue Kingston upon Hull HU5 4JN Installer details Z o D Address Post Code Telephone Please include STD code General information required R Please send me details of Ideal Training Courses C Please arrange for a technical representative to contact me C Please arrange for me to join an Ideal factory tour Range guides required C The Ideal Guide a specifier s and installer s introduction to the Ideal domestic boiler range C 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 Classic LX Deluxe wall hung boiler The Ideal Mexico floor standing boiler The Ideal Minimiser heat saving boiler The Ideal Response combi boiler The Ideal Response SE super efficiency combi boiler The Ideal Systemiser SE super efficiency system boiler The Ideal Concord high output boiler E L OOGO OUO DO UO L The Ideal Buccaneer oil fired boiler Caradon aa Plumbing Solutions
45. lation boards used in the combustion chambers of these products contain man made fibres refractory fillers organic and inorganic binders and as such are deemed to be harmless to humans Caradon Plumbing Limited 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 30 Prior to removal of the boards the following protective equipment should be worn e Face mask supplied with the spare part e Gloves supplied with the spare part 1 Damp down the combustion chamber area containing the insulation boards 2 Remove the insulation boards The replacement boards are supplied in a plastic bag This bag should be retained and the discarded boards should now be placed into it 3 Sweep any dampened particles and place in the plastic bag 4 Fit new insulation boards 5 Remove the gloves and face mask and place them in the plastic bag 6 Wash your hands and any areas of skin which may have come into contact with any of the particles from the insulation board 7 Seal the plastic bag and dispose of it and its contents into a commercial tip Concord CXD Installation Distribution tube detail Legend 1 Cleanout
46. mmissioning 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 27 30 21 LIGHTING INSTRUCTIONS 1 Check that the gas and electricity supplies to the boiler are turned off Connect a gas pressure gauge to the inlet pressure test point Frame 23 or 24 Turn on the gas and electricity supplies The display will initially show a start up code followed by STANDBY 0 Press the 1 0 button The display will change to BOILER ON 1 then change every few seconds to indicate the boiler status The boiler will commence it s ignition sequence The boiler should light initially at low rate for a period of approximately 30 sec 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 18 Up down buttons TESTING FOR GAS SOUNDNESS Close the gas supply cock at the meter Remove the screw in the inlet pressure test point Frames 23 24 and connect a gas pressure gauge to the test point Take particular care to ensure a gas tight connection Open the gas supply cock at the meter and the
47. n is intended as a memory aid to the more comprehensive servicing instructions to be found in this manual Using the UP or Down button select SERVICE from the menu and press ENTER The following display will be available REFER TO SERVICE GUIDE ON DOOR The 2 screens will alternate to display this whole message When using this option arrow keys will be in evidence to indicate if the UP or DOWN buttons should be used t is IMPORTANT that these instructions are carried out precisely and in the order displayed COMMISSIONING The Commissioning option is intended as a memory aid to the more comprehensive commissioning instructions to be found in this manual Using the UP or Down button select Commissioning from the menu and press ENTER The following display will be available REFER TO SERVICE GUIDE ON DOOR The 2 screens will alternate to display this whole message When using this option arrow keys will be in evidence to indicate if the UP or DOWN buttons should be used t is IMPORTANT that these instructions are carried out precisely and in the order displayed FAULT DIAGNOSIS In the unlikely event of a fault condition the microprocessors will identify the fault area and display a message indicating the nature of the fault to assist a speedy and effective repair See Fault Finding section for more details Concord CXD Installation 31 SPILLAGE CHECK Check there is no spillage of com
48. ne therefore must satisfy the conditions in the foregoing paragraphs and Graph 1 nal AZ Normal operation pump TSP During a call for heat on Zone 1 only Zone 1 if required thermostat energises the boiler which in turn energises Zone 1 pump from terminal L2 During a call for heat on other zones the appropriate relay directs power to L1 to energise the boiler at the same time ensuring that Zone 1 pump is controlled by Zone 1 thermostat Water circulation system refer to page 5 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 zones are illustrated but the principles may be extended as required provided the above conditions are met Only one relay is required irrespective of the number of zones Overrun During overrun and dormant periods Zone Valve 1 is held open This zone therefore MUST satisfy the conditions in the foregoing paragraphs and Graph 1 Normal operation During a call for heat on Zone 1 only the boiler energises via Zone 1 thermostat and the normally closed contacts of the relay During a call for heat on other zone s the relay will be energised by the auxiliary switch on the zone valves This provides power to
49. ollows a The flow connection may be made to either of the rear top tappings either at the same side as the return or opposite the return To avoid air locks any reduction in pipe size must be made in the vertical plane or achieved by using eccentric bushes The 1 tapping in the redundant return flange may be used for the cold feed on an open system or connection of a pressure vessel if on a sealed system If not required for this purpose it should be plugged Fit the 2 thermostat pockets Refer to Frame 9 9 SYSTEM CONNECTIONS One flow and return connection should be made to the rear of Position the overheat thermostat phial into the thermostat the boiler either on one side or opposite sides pocket at the opposite side to the flow pipe The illustrations below show the rear of the boiler with the flow and relative The distributor tube and gaskets supplied with the boiler must overheat thermostat positions be connected into the pumped return connection Refer to Frame 8 Ensure that the overheat thermostat phial and control sensor are correctly secured in the pockets Refer to Frame 13 2 thermostat pockets are supplied in the installation pack These must be fitted in the 2 top 1 2 BSP tappings at either side of the rear of the heat exchanger G Overheat S Control Thermostat D sensor S S SS Thermostat AY 1 Control Overheat Hh Overheat E Thermostat
50. ommercial closed pressurised systems are provided with either manual or automatic water make up On both instances it will be necessary to fit automatic controls intended to protect the boiler circulating system and ancillary equipment by shutting down the boiler plant if a potentially hazardous situation should arise Examples of such situations are low water level and operating pressure or excessive pressure within the system Depending on circumstances controls will need to be either manual or automatic reset In the event of shut down both visual and audible relevant requirements of the local gas supplier local authority and the relevant British Standard Codes of practice and building regulations These appliances are NOT suitable for installation where they will be exposed to the elements A boiler room shall be constructed or adapted to meet the requirements of BS 6644 The maximum ambient temperature is 32 C at 1 5 metres from the floor with a maximum humidity of 90 RH FOR SMALL PIPE INSTALLATIONS BS 6891 Installation of low pressure pipework FOR LARGE PIPE INSTALLATIONS British Gas Publications IGE UP 1 Purging Procedures of Non domestic Gas Installations Soundness Testing Procedures for Industrial and Commercial Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters IM11 Gas nstallations IGE UP 2 Guidance notes on the Installation of Gas Pipework Boosters and Compressors in Cus
51. ommissioning mode will result in a fault condition being detected when the following actions are carried out 2 f 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 recommended until the installer is familiar with the CXD 3 t is essential to adjust the LOW setting first 4 Press the 0 1 button to turn the appliance OFF then disconnect the power leads from the right hand HIGH gas valve 1 3 Ie i 5 6 silin 2 5 To 9 172 2 Con 171 5 25 OPERATING INSTRUCTIONS The CXD features direct burner ignition high low burner operation and a microprocessor control system Upon a demand for heat the controls open the low rate gas valve and provides a rapid spark at the ignition electrode for up to 10 seconds The burner will light and remain at low rate for approximately 3 minutes before proceeding to high rate when the microprocessor opens the remaining gas valve If the boiler fails to light the gas valve is closed and there will be a delay of 1 minute before the cycle is repeated If after 5 attempts the burner has failed to light the boiler will go to lockout and DETECTION FAULT will be displayed on the screen 20 5 Press the 0 1 button again to light the burner Allow the burner to run at low rate for several min
52. pplies Light the boiler Refer to the Lighting Instructions and also Frame 19 Testing for Gas Soundness Check burner manifold pressures Frame 22 and adjust if necessary Frames 23 or 24 Finally reset any external controls to the desired position 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 industrial vacuum cleaner may be useful to assist in this work When cleaning the burner bars take care to avoid damage from rough handling to the ignition or detection electrodes Inspect the ignition and detection electrodes 37 REPLACEMENT OF COMPONENTS Refer to Frames 5 40 41 and 42 GENERAL WARNING ALWAYS turn OFF the gas supply at the gas inlet cock and DISCONNECT the electricity supply BEFORE WORKING on the APPLIANCE 26 To facilitate the replacement of components remove and replace the lower front panel NOx duct and the burner front plate as necessary described under Servicing Concord CXD Installation SERVICING 38 GAS CONTROL VALVE 1 Disconnect the electrical connections to the faulty gas valve Check that the gas inlet cock is OFF un
53. recess 7 Lift a middle section onto the combustion chamber and carefully offer it up to the back section until it engages the 19 Fit the support angles contained in the platework package projecting steel rings It may be necessary to use a mallet to the collector hood The angle with the hole for the earth and hardwood block to ensure that the steel rings are screw fits to the front pushed fully into the recesses and that the sections are 20 Fit the gas inlet pipe bracket to the rear support angle on butted up to each other the LH side using the self tapping screws Note Until the final section is fitted and the tie rods 21 Fit the gas inlet pipe and make good the union between the fastened the sections in the assembly are not fixed gas cock and the valve inlet pipe together therefore CARE MUST BE TAKEN TO PREVENT 22 Fit the Nox duct using the reverse procedure to that shown the installed section coming apart in Frame 36 and secure with the extended nuts 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 washer a shakeproof washer and a nut to both ends of each tie rod Screw up all the nuts equally in turn and finally tighten them to a torque of 38 41 Nm 28 30 Ib ft 10 Fit the distributor tube assembly as described in Frame 8 Fit the drain cock refer to exploded view Frame 49
54. ressed the temperature selected will become stationary Pressing the EXIT button will ensure that the control accepts the new setting and return to the menu High Low Operation In the example above when the boiler flow temperature is equal to 82 C the high rate gas valve will close allowing the boiler to run at low rate When the flow temperature exceeds the set temperature by 3 C in the example above 85 C the low rate gas valve will close and the boiler will be off The information screen will display STANDBY 85 C The boiler will remain OFF for a minimum of 3 minutes or until the boiler flow temperature has dropped by 3 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 before the high rate gas 24 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 3 minutes and then energised If the boiler flow temperature is equal to or greater than 55 C then this delay will NOT occur Notes 1 f a fault occurs with the boiler thermostat the fault display screen will show C H Sensor Fault 2 When the low rate gas valve is de energised as the temperature required has been obtained the boiler will go into an anti cycle route for 2 minutes The display will indicate anti cycle and the current flow temperature SERVICING The SERVICE optio
55. s The right is therefore commercial and industrial heating installers engineers and reserved to vary specification without system specifiers notice For details of courses please ring 01270 413624 January 2000 112 166 A08 Ideal Caradon Plumbing Limited P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 Registered Office National Avenue Kingston upon Hull HU5 4JN A subsidiary of Caradon pic Ideal Installer Technical Helpline 01482 498376 38 Concord CXD Installation Your feedback and your chance to win a free boiler At Ideal we ve been leaders in the design and engineering of robust and reliable boilers for over 90 years We want to continue as leaders by listening to your suggestions for how to improve our boilers and our service We ll 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 NOYER Installer details Name Lei dd MHA ih eat Me ress r a r s ir Post Code Telephone Please include STD code How I would improve th
56. s connected to the boiler pump terminals pump overrun will be in operation if the flow temperature is greater than 75 C when the heat demand is satisfied and will continue to run until the boiler flow is less than 75 C If the flow temperature is less than 75 C when the demand for heat is satisfied then the pump will cease to operate Frost protection is in built with the boiler If the flow temperature falls to approximately 3 C then the boiler will operate until the flow temperature exceeds 4 C If an external frost thermostat is required the internal programmer should be set to 24 hours under the programme status menu and an external programmer and frost thermostat wired and connected to the volt free external control terminals on the boiler There is an option kit available with 2 sets of volt free contacts One set of volt free contacts is for Lockout and Overheat combined and one set of volt free contacts is for Boiler run There is an option kit available to enable temperature compensation to be used The outside temperature adjusts the boiler flow temperature to satisfy the heating load and ensure efficient boiler operation The gas valves operate on High Low and Off principle At start up with the flow temperature less than 55 C the boiler will start at low rate and after 1 3minutes the high rate gas valve will open On reaching the set point determined by the Concord CXD Installation user the boiler
57. s the thermostat set point the controls will turn the burner to low rate If the flow temperature continues to rise the burner will be turned off at 3 C above the set point If however the temperature falls below the set point whilst on low fire the controls will automatically turn the burner back up to maximum rate This system 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 Concord CXD Installation INSTALLATION 26 ADDITIONAL FEATURES OF THE CONTROL SYSTEM In addition to the operational characteristics 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 30 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 replace a conventional system programmer serving more than one heating zone OUTSIDE SENSOR Optional extra If the optional outside sensor is fitted the control system will recognise this and automatically regulate the boiler flow temperature with respect to changes in the external temperature If the sensor is fitted an extr
58. screw the 4 screws on the gas valve inlet flange the 4 screws on the outlet flange and remove the valve lf the valve has a brass restrictor fitted to its outlet remove by unscrewing and refit into the new valve It is imperative that the gas restrictor is fitted to the low rate valve Replace the gas control valve and re assemble in reverse order ensuring that the arrow indicating the direction of flow is in the correct position Ensure that new O ring seals are correctly placed in each flange connection Test for gas soundness Recommission the appliance and set the manifold pressures as described in Frames 22 and 23 or 24 39 MAIN BURNER 1 5 Remove the NOx duct and burner front plate as previously described in Frame 35 On the CXD 40 50 amp 60 remove the screws holding the HT heat shield from the LH leg of the combustion chamber Raise slightly and withdraw the heat shield taking care not to damage the leads Each burner can be removed by sliding back to clear the injector then lifting out Disconnect the ignition leads from the LH burner and the detection lead from the RH burner Remove the 2 screws securing the electrode assembly and heat shield to the LH burner bracket and the 2 screws securing the detection electrode bracket to the RH burner Reassemble in reverse order IMPORTANT Care must be taken to prevent damage to the combustion chamber insulation when r
59. sembly complete 1 138 299 PCB 34 1 069 957 PCB 35 1 069 960 Real time clock 1 069 958 PCB 34 and real time clock 1 069 959 Ribbon cable 1 069 961 Concord CXD Installation SHORT LIST OF PARTS Right hand jacket side panel white stove enamel Left hand jacket side panel white stove enamel Jacket top panel white stove enamel CXD 40 7 60 CXD 70 100 70 100 40 100 40 50 60 70 80 90 100 40 50 60 70 80 90 100 CXD 40 50 60 70 80 90 100 Jacket lower front panel white stove enamel complete with lighting instructions Jacket upper front control panel less controls white stove enamel Jacket assembly complete white stove enamel Concord CXD Installation CXD 40 CXD 50 CXD 60 CXD 70 CXD 80 CXD 90 7 100 Product No 111 872 112 430 112 431 111 870 111 650 111 651 111 651 111 652 111 652 111 653 111 650 111 651 111 651 111 652 111 652 111 653 111 293 111 294 111 295 111 296 111 297 111 298 077 107 076 923 112 312 112 313 112 314 112 315 112 316 112 317 Caradon Plumbing Limited pursues Technical Training a policy of continuing improvement in The Caradon Plumbing Limited Technical Training Centre the design and performance of its offers a series of first class training courses for domestic product
60. sor Refer to FAULT Press Copy Press Copy Press Copy screens R Check HT leads Check wiring to Replace T heck 0 gt ee ree Copy 7 and electrode h generator m generator O sa positions Press Copy Press Copy YES 1 Check D DOWNDRAUGHT ences Wait 15 mins ee detection Replace FAULT gt 5 5 oe Refer to E ire i ress robe screens Copy 0 r L 7 Check Change GAS VALVE Check wiring Check gas Replace faulty gas B m pressure gt solenoid a a FAULT Press Copy p C p C valve or Refer to PES C b l wiring solenoid screens 7 Press Press OUTSIDE Chede Change outside Copy Copy L SENSOR l 57 Co a sensor E FAULT py Press Copy j r R iy Check pump Check water la l S PUMP FAULT connections H fiovv gt Press Copy Press Copy ca py screens 7 Concord CXD Installation 35 SHORT LIST OF PARTS When ordering spare parts please quote The following are parts commonly required as replacements due to damage or expendability Their failure or absence is likely to affect the safety and or performance of this appliance Boiler model Boiler serial no refer to data plate on the combustion chamber Boiler B G P I No refer to the data plate on the combustion chamber Description Quantity Product no PAR WN a Boiler body insulat
61. ss qroq Bunre uv EN fElL LZ ULULO O pinB si lle3sui 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 2 Concord CXD Installation Concord CXD 40 CXD 100 Natural gas B G Certified P I No 87 AQ 103 Destination Countries GB amp IE CONTENTS PAP SUD DIYS ee os og ere ee ey Soon eae ree ete ee 9 Boiler Assembly exploded view 10 Boiler Clearances n ee oe 6 Burner Assemblies exploded views 40 0 etme ner ener asec A 27 70 4000 06 28 Casing Assembly a 13 Chimney oystem eee 9 Cominissioning ee ee 18 5 Electrical Connections eene a 15 9 33 Gas Safety Regulations 3 GaS SUP ply ee oe 9 Hydraulic Resistance 26 6 initial Bighitingi o 18 Installation e e US 10 Mandatory Requirements 8 5 Pump 7 ee 25 hOrUE SEOTEaris 36 Site Assembled Boilers 22555 222562 31 Static Head Requirements 7 System
62. stration of the lighting and shutting down of the boiler Describe the function of the boiler and system controls and show how they are adjusted and used Describe the function of the downdraught thermostat if fitted Hand over these and the User s Instructions to the customer and request him to keep them in a safe place for ready reference IMPORTANT Point out to the owner that the boiler must have regular maintenance and 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 Recommend that a contract for this work should be made with a Corgi registered engineer Caradon Plumbing Limited does not accept any liability resulting from the use of unauthorised parts or the repair and servicing of appliances not carried out in accordance with the Company s recommendations and specifications A comprehensive service should be carried out at least once a year The User is advised to make a contract with a Corgi registered engineer 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 and top panel from the boiler casing Concord CXD Installation 25 SERVICING SERVICING SERVIC
63. t pocket 17 Spillage skirt 18 Fluevvay baffles 19 Gas pipe Concord CXD Installation INSTALLATION 6 PACKAGING Check that all these packages are complete and have been INSTALLATION HARDWARE PACK contains correctly received on site M10 washer Factory assembled boilers are despatched from the works as fully packaged units comprising Split pin Assembled boiler body with distributor tube on a wooden Strain relief bush pallet base enclosed in a wooden crate M10 x 25 Hex Hd screw Carton containing the casing fastenings and flue brush M10 x 35 Hex Hd screw Carton containing the installation pack and instruction books Gasket EPDM Type EP600 Carton containing the control box Plug 2 taper Sq Hd Inst Service instructions JACKET PACK contains User s instructions Front panel Side panel Flange RC 1 Top panel 2 BSP Flange distributor tube Flue brush 2 Installation pipe handling bars 2 off Jacket hardware pack Thermostat pockets PACKAGING AND BOILER REMOVAL Remove the jacket carton and outer packaging frame Knock out front spacing blocks from the packaging base ensuring that the boiler assembly is supported using 2 BSP handling bars Remove the jacket pack support frame Using the handling bars manoeuvre the boiler forward on Remove the distributor tube pack controls package and the packaging base and slide over collapsing base on to the installation pack
64. te for approximately 3 minutes before proceeding to high rate this will only happen if the flow temperature is below 55 C otherwise the boiler will proceed immediately to high rate 23 ADJUSTING THE MANIFOLD PRESSURES CXD 40 50 amp 60 ONLY 1 Press the ENTER button on the fascia panel then press either the UP or DOWN arrow button until the display shows COMMISSIONING then press ENTER The microprocessor is now in commissioning mode Failure to enter the Commissioning mode will result in a fault condition being detected when the following actions are carried out 2 f 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 recommended until the installer is familiar with the CXD Observe 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 23 or 24 5 Press the 0 1 button to turn the appliance off then disconnect the high low solenoid connector plug 10 from the gas valve Turn the appliance on and repeat the above sequence but using the low rate adjustment screw 6 inside the spindle 6 Turn the appliance off reconnect the high low solenoid plug refit the dust cover over the adjustment screws and refit both pressure test point screws Che
65. the nature of the fault to assist a speedy and effective repair The faults that are diagnosed are overheat thermostat pump boiler sensor gas valve s air pressure switch if fitted fan If fitted float switch if fitted outside sensor if fitted with indication of combustion lockout In the unlikely event of a fault the display will indicate precisely the fault and give a step by step indication of the method of correcting the fault If the HT generator should cease to function its impossible to automatically display this condition Should this fault occur then DETECTION FAULT would be displayed and the subsequent display screens would direct attention to the spark generator Should a gas valve fail the diagnostics will indicate that it is valve 1 or 2 that is at fault If the boiler has a gas line of 2 double solenoids the diagnostics will indicate which solenoid of the double solenoid is at fault The last fault instruction will be retained FAULT CODES Fault codes numbered 1 to 24 are displayed where applicable In this event contact Caradon Plumbing Limited 33 0 Z a 2 L h FAULT FINDING 52 SIMPLE FLOW CHART OF OPERATION SHUTDOWN Demand ON DELAY Prepurge completed IGNITION ON Overrun completed Y A Flame ii than 4 LOVV RATE set point Flame ON Temp gt set For gt 55 C no delay point If lt 55 C
66. tions Trace the thermostat capillary to the thermostat pocket remove the split pin from the thermostat pocket and lift out the thermostat phial ez Reset Undo the single nut securing the thermostat to the bracket button i l Overheat Fit the new thermostat in reverse order ensuring that the 75 thermostat capillary is located in the notch provided in the support bracket Reconnect the push on tags to terminals 1 2 and on the overheat thermostat body Ensure that the phial is secured with the split pin in the pocket on the rear section and the capillary is rerouted along the side casing in the clips provided 28 Concord CXD Installation SERVICING 43 CONTROL BOX Basic Boiler Exploded View Detail of Printed Circuit Board support Retention barb arbs Controls box back panel LEGEND 1 VViring clamp Back panel 9 Ribbon cable 2 Connection box plug Hinge pin 10 Printed circuit board No RTC 34 3 Connection box Controls box 11 EMC Filter 4 Printed circuit board No 34 Printed circuit board No 35 12 Controls box fascia not shown 44 CONTROL SENSOR 45 PC BOARD NO 34 Remove the casing top panel Remove the lower front panel Remove the sensor from the thermostat pocket in the Slacken the 2 screws securing the control box front panel rear heat exchanger section by removing the Heyco Carefully lift it up and hinge forwards bush Releas
67. tomer s Premises Equal to or Greater than 25mm Non domestic BS 6644 Installation of Gas Fired Hot Water Boilers 60kW to 2MVV CP341 Water Supply CP342 2 Centralised Hot Water Supply Model Water Byelaws Manufacturers notes must not be taken in any way as overriding statutory obligations The appliance must be installed in a room separated from living rooms and provided with appropriate ventilation direct to the outside see Table 6 alarms may be necessary Pressure vessels used must comply with BS 4814 and must be sized on the basis of the total system volume and initial charge pressure Initial minimum charge pressure should not be less than 0 5 bar 7 2 psi and must take account of static head and specification of the pressurising equipment The maximum water temperatures permissible at the point of minimum pressure in the system is specified in Guidance Note PM5 When make up water is not provided automatically it will be necessary to fit controls which shut down the plant in the event of the maximum system pressure approaching to within 0 35 bar 5 psi if safety valve 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 Concord CXD Installation GENERAL FOUNDATION The boiler must stand on a non combustible floor i e concrete or brick which must be flat level and of a suitable load
68. ture does not exceed 65 C 150 F n 60 2 3 8 z 480 19 60 2 3 8 CX 90 amp 100 MULTIPLE BOILER INSTALLATIONS The minimum installation clearances must conform to the dimensions given below CXD 40 50 60 amp 70 Clearance between boilers 50mm Clearance at both ends of the multiple installation 50mm Clearance between boilers 100mm Clearance at both ends of the multiple installation 100mm Rear clearance sufficient clearance 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 Concord CXD Installation GENERAL The wiring diagrams in Frames 16 17 amp 18 illustrate the control methods for achieving the above 3 Pump selection should take account of the hydraulic resistance given in Graph 2 PUMP POSITIONS Whenever practically possible the circulating pump s should be positioned so that it pressurises the system being served The vertical distance between the pump s and any cold feed and expansion cistern MUST comply with the pump manufacturers requirements in order to avoid cavitation These requirements override the information given in Frame 3 if the static head required for the pump s exceeds that required for the boiler Table 5 Flow rates for fully pumped systems Boiler Minimum flow rates for a temperature difference of 35 C 63 F I s g p m CXD 40 0 28 3 CXD
69. utes then check that the low burner pressure is as shown in Table 1 for the appropriate boiler size If necessary adjust the low burner pressure adjusting screw 7 6 Press the 0 1 button to turn the boiler off reconnect the power leads to the RH valve and press the 0 1 button again to relight the boiler Adjust the system controls to allow the boiler to fire at high rate for several minutes then remove the dust cover and adjust the high burner pressure adjusting screw 8 After setting to the indicated pressure replace the dust cover and allow the boiler to operate for about 5 minutes to stabilise then re check the burner pressure Note f high rate pressure is not achievable as above check that the gas restrictor in the low rate valve is fitted see Frames 38 amp 41 7 Press the 0 1 button to turn the boiler off then refit both pressure test point screws Check for gas soundness 8 Press EXIT to leave the commissioning mode and return to the main menu 9 Press EXIT again to return to the status displays LEGEND 1 Fascia panel display 2 Overheat thermostat reset 11 button 3 Main gas inlet cock 4 Union 5 Gas control valve low rate 6 Gas control valve high rate 7 8 9 8 Low rate adjusting screw High rate adjusting screw Burner setting pressure test point 11 10 Inlet pressure test point 11 RH High gas valve power connector When the boiler flow temperature reache
70. will go to low rate and when the temperature reaches the set point plus 3 C the low rate gas valve will close When the temperature falls 2 C the boiler will start at low rate and remain there until the temperature falls to the set point less 2 C then the high rate gas valve will operate On start up the high rate gas valve will operate immediately after detection if the boiler flow rate is greater than 55 C In order to determine the continued correct operation of the control every 4 hours the boiler will shut down for a maximum of 30 seconds to do a self check operation and restart automatically The control will display the number of operational hours of the boiler to the nearest hour and cannot be reset The boiler thermostat has a range of 60 C 80 C in 1 C steps with an accuracy of 2 C and hysteresis of 3 C The full sequence control enables 5 attempts at ignition with one minute intervals between attempts followed by nonvolatile lockout if detection does not take place If the 0 1 switch on the front panel is at Standby 0 then the pump will continue to run indefinitely In this state the frost protection can not operate In Lockout the pump will continue to run only if the temperature is greater than 75 C If it is less then the pump will be off FAULT FINDING The boiler control has a unique fault diagnostic feature which can in the unlikely event of a failure display a message indicating

Concord CXD 40-100 Series 3

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