ICP DAS USA PCI-P16POR16 Computer Hardware User Manual
Contents
1. Installers guide to commercial central heating boilers GENERAL Concord Installation amp Servicing Table 1 Performance Data Boiler Boiler Input Low Rate Btu h x 1000 GENERAL CXSi 110 H CXSi 120 H CXSi 140 H CXSi 160 H CXSi 180 H kW Btu h x 1000 Boiler Input High Rate kW Btu h x 1000 kW Btu h x 1000 Boiler Output High Rate Gas rate High Approx flue At 4 5 CO amp 100 C gas volume At 4 5 amp 212 F Burner setting kW Btu h x 1000 m h ft3 h m h ft h pressure Part load efficiency Note To obtain gas consumption in I s divide gross heat input kW by a calorific value of 37 8 Table 2 General Data Boiler Number of sections CXSi 110 H CXSi 120 H CXSi 140 H CXSi 160 H CXSi 180 H 7 8 9 10 Flow connections Rc 65 mm 2 1 2 nominal bore Flange to BS 4504 PN6 Return tappings Rc 2x2 Maximum static head m ft 61 0 200 Maximum pressure bar psi 6 0 87 Gas inlet connection Rc 1 1 2 17 5 7 17 5 7 17 5 7 Electricity supply 230 Volts single phase 50 Hz fuse 5A Nominal flue size to BS 835 250 10 250 10 250 10 Diverter outlet socket internal diameter 288 11 3 288 11 3 288 11 3 Len2. lt Q lt E lt FAULT FINDING 40 BOILER CONTROL 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 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 trouble free operation The anti cycle duration is 4 minutes If the system pump with a maximum current of 3A is connected to the boiler pump terminals pump overrun will be in operation when the demand for heat is satisfied and will continue to run for 6 minutes Frost protection is inbuilt with the boiler If the flow temperature
3. Table 4 Flow rates for fully pumped systems Minimum flow rates for a temperature difference of 35 C 63 F I s g p m CXSi 110 H CXSi 120 H CXSi 140 H CXSi 160 H CXSi 180 H 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 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 expanded is drawn back from the tank into the system together with a quantity of dissolved oxygen Even i
4. Water Volume Relationship between load amp water volume for the system circuit during the pump overrun period Heat Load During Pump Overrun kW Con 1898 Hydraulic resistance mbar Water Volume in Circuit During Pump Overrun litres Graph 2 Hydraulic Resistance 11 20 F CXSi 120 H N 20 F CXSi 140 H 20 30 50 70 90 110 mS Flow litres min 150 250 2 CLEARANCES amp DIMENSIONS Table 3 Rear clearance 200 8 Side clearance 100 4 not including clearance for side fitted flow header 1036 40 3 4 1036 40 3 4 1086 42 3 4 1140 45 175 7 175 7 197 7 3 4 250 10 1107 43 3 4 1230 48 1 2 1353 53 1 4 1476 58 1 8 816 32 1 8 939 37 1062 42 3 4 1185 46 5 8 553 21 3 4 615 24 1 4 676 26 5 8 738 29 220 8 5 8 220 8 5 8 Dimension 1036 40 3 4 Dimension 175 7 Dimension 1107 43 3 4 Dimension 816 32 1 8 Dimension 553 21 3 4 Dimension 220 8 5 8 170 245 11 2 BSP pem for open vent only Pressure gauge Pocket for boiler thermostat and overheat thermostat uL sensors only 2 M amp F eee 1 2 BSP for not lied pressure g ela gauge only 65mm 2 1 2 nominal bore flange to BS4504 PN6 Detail of flow header position options for either left or right hand side of boiler Con
5. 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 25 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 4 when that part of the system intended to be used for dissipation of residual heat only is in operation 26 HANDING OVER ROUTINE OPERATION Hand over these the User s Instructions and the Commissioning amp Servicing Log Book to the customer and request him to keep them in Full instructions covering routine lighting and operation of a safe place for ready reference the boiler are given on the Lighting and Operation Instruction Label located on the inside of the casing door 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 Draw the attention of the boiler owner or their representative to the Lighting and Operating Instruction Label on the inside of the front panel Give a practical demonstration of the lighting and shutting down of the boil After servicing complete the service section of the log book and oiler return it to th
6. 1938 C D Ci of Flue Led J HEEL ELLE POSITION OF BOILER Minimum clearances required from walls or other fixed objects to allow for the free access of combustion air are shown in Table 3 above Return Rc 2 BSP lt 705 27 3 4 348 13 3 4 220 8 5 8 A 320 12 1 2 Any combustible material adjacent to the boiler and its flue system must be so placed or shielded as to ensure that its temperature does not exceed 65 C 150 F lt 766 30 3 16 122 4 3 4 Con 1899 Concord CXSI H Installation amp Servicing GENERAL 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 MINIMUM FLOW OF WATER Refer to Table 4 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
7. Valve 1 is held open This zone therefore S P MUST satisfy the conditions in the foregoing If required paragraphs and Graph 1 NB Contacts shown at room temperature with power off INSTALLATION Normal operation Pipework ee During call for heat on Zone 1 only the Main Circulating Pump boiler energises via Zone 1 thermostat and the normally closed contacts of the relay gt i one valves During a call for heat on other zone s the relay will be energised by the auxiliary switch Zone loads on the zone valves This provides power to energise the boiler If in addition Zone 1 now calls for heat its thermostat will open Zone 1 When the clock period ends Zone valve 1 will stay open via Be via the normally open contacts of the normally closed relay contacts to achieve pump overrun relay Con1740 Water circulation system refer to page 5 19 COMMISSIONING AND TESTING GENERAL TESTING FOR GAS SOUNDNESS Check that all drain cocks are closed that any stop valves Close the gas supply cock at the meter fitted to the flow and return pipes are open and that the system has been filled and properly vented Remove the screw in the inlet pressure test point Frames 20 21 and connect a gas pressure gauge to the test point PURGING Take particular care to ensure a gas tight connection Open Check that the electricity supply is switched OFF the gas supply cock at the meter and the appliance gas cock record the static p
8. Ventilation eme EECUOT IUNII UE 9 Water Circulation e aeee e eene 5 Water Connections 2 2 E E 5 Water Treatment us 7 Wiring Diagrams eee 19 INTRODUCTION CONSTRUCTION BOILER BODY The sectional boiler body is of cast iron and is supplied with a sheet steel combustion chamber and integral draught diverter The boiler is supplied in sectioned form for site assembly CASING The casing is manufactured in stove enamelled sheet steel and is easily assembled on site BURNERS The burners are of stainless steel construction CURRENT GAS SAFETY INSTALLATION AND USE REGULATIONS OR RULES IN FORCE It is the law that all gas appliances are installed and serviced by a CORGI registered installer 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 CXSi 110 H 180 H range of boilers has been tested and certified by British Gas to prEN656 for use with natural gas only Note Concord CXSi 110 H 180 H 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 de
9. adjustment screw adjuster out until the burner pressure is approximately 9 0 mbar inside the spindle of the top valve Turn the boiler off and refit the electrical plug on the bottom 11 Turn the appliance off and reconnect all the electrical valve plugs Turn the boiler on and remove the dust cover from the adjustment 12 Refit both dust covers over the adjustment screws and screw in the bottom valve Set the burner pressure to the value in refit the pressure test point screw Table 1 13 Check for gas soundness After setting allow the boiler to operate for 3 minutes to stabilise then recheck the setting Concord CXSI H Installation amp Servicing 23 INSTALLATION INSTALLATION SERVICING 23 SPILLAGE CHECK 24 TESTING Check the main burner responds correctly to manual on off operations of any controls fitted in Check that there i ill the gas control circuit of combustion products from Check the operation of the flame failure safety system by lighting the boiler and then turning the boiler draught diverter by the gas inlet cock off carrying out a spillage test as a The Burner On light will go out and the controls will try to relight the boiler After a period of detailed in BS 5440 1 about 5 seconds the Lockout light will be illuminated Turn on the gas cock again and press in and release the Lockout button The boiler will relight Complete the Commissioning section of the boiler log book
10. falls to approximately 5 C then the boiler will operate until the flow temperature exceeds 18 C Note that it is designed to protect the boiler and may not protect remote parts of the system Neither the pump overrun nor the inbuilt frost protection will operate if the boiler thermostat is switched OFF The gas valves operate on High Low and Off principle The boiler will start at low rate and after 1 minute the high rate gas valve will open On reaching the set point determined by the user the boiler will go to low rate and when the temperature reaches the set point plus 3 C the low rate gas valve will close Should the temperature fall below the set point the boiler will go back to the high rate The full sequence control enables a single ignition attempt lasting about 5 seconds and will go to lockout if detection does not take place 41 SIMPLE FLOW CHART OF OPERATION SHUTDOWN Demand ON IGNITION Flame ON Overrun completed Temp gt than set point LOW RATE A um Y Temp at set point Demand off HIGH RATE PUMP OVERRUN 6 minutes 4 minutes anti cycle 30 Concord CXSI H Installation amp Servicing FAULT FINDING Before carrying out any Fault Finding ensure that all internal controls are calling for heat and that the overheat thermostat has not operated There should be 230V 10 avail
11. of Gas Fired Hot Water Boilers 70kW to 1 8MW net BS 6880 Pt 1 3 Water Supply CP342 2 Centralised Hot Water Supply Model Water Bye laws 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 5 automatic reset In the event of shutdown both visual and audible 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 the static head and specification of the pressurising equipment The maximum water temperatures permissible at the point of minimum pressure in the system are 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 of the 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 Installation amp Servicing GENERAL FOUNDATION The boiler must stand on a non combustible floor i e concrete or brick which must be flat l
12. of the potentiometer 37 PC BOARD S 4561B1047 Flame detector connection Earth connection Con 1910 N W 0 Gael Retaining barbs N lt as S Remove the lower front panel Potentiometer Thermostat knob Con 1500 are made either to the top 2 tags or the bottom 2 tags and that the lug on the body of the potentiometer locates through the hole in the front panel of the control box Also ensure that the potentiometer is rotated fully anticlockwise and clicks before commencing the reassembling 38 PC BOARD W4115A1020 Retaining barbs Undo and remove the 2 screws securing the control box front panel Carefully lift it up and lower it Pull off the 2 plugs and the 2 push on connections from the board The board can now be removed by squeezing in the retaining barbs Fit the new board and reassemble in reverse order ensuring that the push on connections are correctly fitted as follows from left to right Earth flame detector lead 39 COMBUSTION CHAMBER Remove the lower front panel Undo and remove the 2 screws securing the control box front panel Carefully lift it up and lower it Remove the 4 plugs from the board The board can now be removed by squeezing in the retaining barbs Reassemble in reverse order Prior to removal of the boards the following protective equipment should be worn INSULATION REPLACEMENT The insulati
13. the projecting studs at the back of the combustion chamber and fix using the nuts and washers provided 13 Fit the insulation brackets with the screws provided to the downdraught deflector 14 Refit the burner assembly to the combustion chamber and tighten the 4 nuts securing the burner manifold to the combustion chamber legs Offer up the burner light back shield to the combustion chamber with the cutout for the flame detector electrode at the LH end and fasten using the M5 nuts and washers spark generator bracket to the combustion chamber 15 Fit the gas valve and spark generator assembly to the boiler using the two M5 screws and washers by doing up the union in the gas line and by fastening the Fit the gas inlet pipe and retain by the semi circular clamp screws and washers provided Tighten both unions and the inlet pipe retaining clamp ensuring that the gas valve assembly is vertical To fit the collector hood align the back edge of the horizontal side returns with the rear of the section assembly and fasten down the collector hood using the M6 screws and nuts provided through the side fixing points 18 Wrap the insulation around the heat exchanger with the foil outside tuck behind the insulation brackets on the downdraught deflector and fasten at the edge using the foil tabs and tape provided 19 Fit the NOx ducts into the burner aeration intakes Sealing rope and fasten to the collector hood us
14. 110 H 120 H 140 H 160 H amp 180 H 155 657 Plug and lead CXSi 180 H 111 870 Spark generator 139 300 Injector 4 02 mm diameter CXSi 110 H 013 175 Injector 4 20mm diameter CXSi 120 H 013 180 Injector 4 20mm diameter CXSi 140 H 013 180 Injector 4 20mm diameter CXSi 160 H 013 180 Injector 4 20mm diameter CXSi 180 H 013 180 Flame detection electrode 138 895 Flame detection lead 139 271 Main burners CXSi 110 H amp 120 H 139 824 Main burners CXSi 140 H 139 824 Main burners CXSi 160 H 139 824 Main burners CXSi 180 H 139 824 Main burner RH end Worgas CXSi 110 H 180 H 139 825 Ignition electrode 112 365 32 Concord CXSI H Installation amp Servicing SHORT LIST OF PARTS 45 Control box complete 155 641 46 Thermistor 154 816 PCB S4561B1047 ignition 154 814 PCB W4115A1020 Aquastat 154 815 Casing assembly complete CXSi 110 H amp 120 H 157 449 Casing assembly complete CXSi 140 H 157 450 Casing assembly complete CXSi 160 H 157 451 Casing assembly complete XSi 180 H 157 452 Casing front panel CXSi 110 H amp 120 H 155 647 Casing front panel CXSi 140 H 155 648 Casing front panel CXSi 160 H 155 649 Casing front panel CXSi 180 H 155 650 Casing LH side panel CXSi 110 H 180 H 076 978 Casing RH side panel CXSi 110 H 180 H 076 979 Casing lower front panel CXSi 110 H amp 120 H 138 475 Casing lower front panel CXSi 140 H 138 474 Casing lower front panel CXSi 160 H 138 473 Casing lower front panel CXSi 180 H 138 47
15. 2 Casing upper front panel CXSi 110 H amp 120 H 155 643 Casing upper front panel CXSi 140 H 155 644 Casing upper front panel CXSi 160 H 155 645 Casing upper front panel CXSi 180 H 155 646 Casing top panel CXSi 110 H amp 120 H 138 465 Casing top panel CXSi 140 H 138 464 Casing top panel CXSi 160 H 138 463 Casing top panel CXSi 180 H 138 462 Overheat thermostat RAK77 4 3835 155 791 Boiler status neons Boiler ON 154 854 Boiler status neons Overheat amp Lockout 154 855 Lockout reset button assembly 155 269 Concord CXSi H Installation amp Servicing 33 34 NOTES Concord Installation amp Servicing Concord Installation amp Servicing NOTES 35 Technical Training The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498 432 Ideal Boilers P O Box 103 National Ave Kingston upon Hull Aa BOILERS HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 J e Caradon Ideal Limited pursues a policy of continuing improvement in the design and performance of its products The right is therefore reserved to vary specification without notice November 2005 157 294 A03 Caradon Ideal Limited Ideal Installer Technical Helpline 01482 498 376 www idealboilers com
16. E TAKEN TO PREVENT the installed sections coming apart Repeat the assembly procedure for all of the sections until complete 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 For open vented systems a site test must be carried out at a hydraulic pressure equal to 1 1 2 times the design pressure given in Table 2 for a period of 30 minutes Note f it is a sealed system the hydraulic pressure must be equal to twice the given design pressure for 30 minutes Fit the 4 coach bolts into the lugs at the bottom of the end sections and through the hole in the retaining angle of the combustion chamber Fit a flat washer and nut and secure the section assembly to the combustion chamber Concord CXSI H Installation amp Servicing 14 INSTALLATION INSTALLATION INSTALLATION BOILER SECTION ASSEMBLY continued Down draught deflector Insulation bracket Down draught deflector Side elev of d deflector insulation assy o 12 Offer the downdraught deflector to
17. Flow header 65mm 21 2 nominal bore flange to BS4504 PN6 10 GAS CONNECTION Connect the gas supply to the gas inlet pipe Table 2 gives details of the inlet pipe size The use of an approved gas cock and union is recommended here 13 INSTALLATION INSTALLATION 11 CASING ASSEMBLY Legend Side panel Supporting angle Top panel Upper front panel Control box Bracket Support frame INSTALLATION Door panel SS Oo wm 2 0 N Lower panel 1 Fit the support angle to the collector hood and fasten using the M5 screws and washers D qum aum Q f ju b Fitthe front fixing bracket s to the collector hood and fasten using the M5 screws and washers through the slotted holes Fit one side panel over its brackets on the combustion chamber base tray and fasten to the support angle using the M5 screw and washer Repeat for the other side panel Fit the upper front support framework with the overheat thermostat at the bottom and with its green button facing to the RH side and secure to the Insulation not shown front fixing bracket s using the M5 screws and washers and to each side panel using the No 8 screws Fit the 4 shoulder screws into the fixings at the bottom of the front return of the casing side panels Finally ensure correct alignment by slackening and retightening the screws i
18. able at the control box connection 42 BOILER DOES NOT LIGHT Is the spark gap approximately 4mm and are the electrodes leads and connections clean and secure Y YES Y YES Are the gas valve electrical plugs clean and secure Is there a spark at the electrode Is there 230V 10 at the spark generator YES Y Y NO Y YES Is there 230V 10 at the gas valve plugs Are connections sound at the plug on terminal strip Y at the control box Replace spark generator YES Is the gas valve inlet pressure sufficient Y YES YES Replace Y S4561B1047 Replace the gas valve 43 BOILER LIGHTS BUT GOES TO LOCKOUT Is the flame detector and its lead and connections sound and secure and correctly positioned on the LH end Clean and secure burner Qe Measure the flame current expect approximately 3 5uA y YES Replace PCB S4561B1047 Check LH end burner inlet and burner pressure check the LH end burner injector 44 BOILER GOES OUT ON OVERHEAT THERMOSTAT Is there an unswitched Live supply to terminal L1 on the plug on terminal connection at the control box Y YES Is there sufficient open circuit water volume or load available on boiler shutdown for the pump overrun Y YES Is the pump or shunt pump wired to terminal L2 in the control box Y YES Has the boiler thermostat kn
19. above publications or the requirements of the local authority gas or water undertakings In general commercial closed pressurised systems are provided with either manual or automatic water make up On 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 Limitations of Intended Operating Environment 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 Gas Installations IGE UP 1 Purging Procedures of Non domestic Gas Installations Soundness Testing Procedures for Industrial and Commercial IGE UP 2 Guidance notes on the Installation of Gas Pipework Boosters and Compressors in Customer s Premises Equal to or Greater than 25mm Non domestic IGE UP 10 Installation of Gas Appliances in Industrial and Commercial Premises BS 6644 Installation
20. adjustment screw Remove plastic dust cover Gas rate adjuster maximum High solenoid plug SETTING THE HIGH BURNER PRESSURE SETTING THE LOW BURNER PRESSURE 1 Remove the dust cover from the adjustment screw in So inthe Poller MEMOS tat knot ta us bottom valve and gently screw the adjustment in 6 Disconnect the high solenoid plug from the top valve ully 7 Disconnect the LH electrical plug from the bottom valve Remove the plastic dust cover from the adjustment screw on the top high low valve and using a spanner Turn the boiler on and set the low pressure to the value screw the adjuster gently fully in then screw the adjuster given in Table 1 using the low rate adjustment screw inside out until the burner pressure is approximately 10 9 mbar the spindle of the top valve Finally screw out the adjustment on the bottom valve Turn the appliance off and reconnect all the electrical plugs until the burner pressure is correctly set to the value Do not overtighten the electrical plug fixing screws given in Table 1 10 Refit both dust covers over the adjustment screws and refit After setting allow the boiler to operate for 3 minutes to the pressure test point screw stabilise then recheck the setting 11 Check for gas soundness 22 Concord Installation amp Servicing INSTALLATION 22 MANIFOLD GAS PRESSURE CXSi 180 H ONLY The manifold setting pressure must now be checke
21. ark electrode connections on the RH end burner access via the side of the combustion chamber 6 Ensure the electrical cover is correctly fastened to the spark generator Flame detector lead Electrical cover Con 1913 connections Concord CXSI H Installation amp Servicing 15 INSTALLATION INSTALLATION 13 CONTROL BOX continued 7 Unstrap the thermostat sensor lead and run both the INSTALLATION Run the flame detector lead through the clips on the front of the combustion chamber base tray and plug it into the flame detector electrode on the LH end burner NOx duct Ensure that any slack is tucked neatly into the clips then fasten the clips 1915 sensor the overheat thermostat phial through the clips on the appropriate casing side panel to the flow header ensuring that both leads run under the support angle Secure both phials into the thermostat pocket in the Flame flow header using the spring clip 10 Fit the earth connections from the 16 terminal plug in connections to the appropriate earth posts on the back of the control box Connect the earth lead prefitted to the control box back panel to the threaded hole in the casing support frame Fit the casing upper front panel with its location buttons in the slots and push down to locate Fasten at the bottom using the No 8 screws Fit the casing lower front panel by locating its slots ove
22. as necessary In order to be able to remove the faulty gas valve it will be necessary to slacken or remove all the screws on either the inlet or the outlet manifold and only those 4 screws securing the faulty gas valve on the other manifold The faulty gas valve can then be removed and replaced Ensure that the arrow on the gas valve points in the direction of flow Test for gas soundness g 3 Reassemble in reverse order Recommission the appliance and set the manifold pressure as described in Frame 21 31 BURNER AND CONTROLS ASSEMBLY Exploded View CXSi 110 H 160 H LEGEND 10 Main burner RH 1 Main gas inlet cock 4 High Low gas control valve 7 Burner manifold 11 Ignition electrodes 2 Gas inlet union 5 Gas control valve 8 Main injector 12 Detection electrode assembly 3 O ring seal 6 Spark generator 9 Main burner LH PTP Pressure test point SERVICING Burner PTP 26 Concord Installation amp Servicing SERVICING 32 BURNER AND CONTROLS ASSEMBLY Exploded view CXSi 180 H 10 Main burner RH 7 Burner manifold 11 Ignition electrodes 8 Main injector 12 Detection electrode assembly 9 Main burner LH PTP Pressure test point LEGEND 1 Main gas inlet cock 4 High low gas control valve 2 Gas inlet union 5 Gas control valve 3 O ring seal 6 Spark generator 33 OVERHEAT THERMOSTAT Pull out the spring clip in the thermosta
23. ator assembly from the boiler Undothe 4 nuts securing the burner manifold to the combustion chamber legs Undo the nuts securing the burner light back shield to the combustion chamber and lift it off Pull the whole burner assembly forward on its runners ensuring that no wires are trapped and remove it completely from the combustion chamber PREPARATION OF SECTIONS Each section should be brushed clean on all external surfaces and any debris which may have accumulated within the sections should be removed via the bottom ports TOOLS REQUIRED e Spanners Torque wrench Pozi screwdriver e Mallet Section Assembly refer to the exploded view Take an end section and lift it onto the combustion chamber so that the combustion chamber side panel return is inside the section rear lip 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 recess Lift a middle section onto the combustion chamber and carefully offer it up to the end section until it engages the projecting steel rings It may be necessary to use a mallet and hardwood block to ensure that the steel rings are pushed fully into the recessing and that the sections are butted up to each other Note Until the final section is fitted and the tie rods fastened the sections in the assembly are not fixed together therefore CARE MUST B
24. d and adjusted as necessary It is essential to set the High Pressure first Start the adjustment procedure with the system cold on full load and with all temperature controls set to maximum to avoid thermostatic shutdown Remove the screw in the burner setting pressure test point and connect a suitable gas pressure gauge Turn on the electrical supply to light the boiler and let it operate for about 10 minutes to stabilise the burners Check the pressure and if it differs noticeably from that given in Table 1 for the appropriate boiler size adjust it as follows Con 6023 Dust cover Remove plastic Low rate dust cover adjustment screw Gas rate adjuster maximum High solenoid plug IMPORTANT Do not adjust the middle valve which is factory set SETTING THE HIGH BURNER PRESSURE SETTING THE LOW BURNER PRESSURE Turn the boiler thermostat knob to OFF 7T Turn the boiler thermostat knob to OFF Undo the screws holding the electrical plug on the bottom gas 8 Disconnect the high solenoid plug from the top valve valve and pull it off 9 Disconnect the electrical plug from the bottom and middle valves Turn the boiler on and remove the plastic dust cover from the adjustment screw the top gas valve and using a suitable 10 Turn the boiler on and set the low pressure to the value spanner screw the adjuster gently fully in Then screw the given in Table 1 using the low rate
25. e owner or their representative Describe the function of the boiler and system controls and Recommend that a contract for this work should be made with a show how they are adjusted and used CORGI registered installer 24 Concord CXSI H Installation amp Servicing SERVICING 27 SERVICING Caradon Ideal 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 installer WARNING ALWAYS turn OFF the gas supply at the gas cock and disconnect the electricity supply to the appliance BEFORE servicing or replacing any components If access is required to the electrical plug in terminals at the back of the control box then remove the casing top panel it is not advisable to try and remove the control box back panel from the boiler with the plugs in place CLEANING THE BOILER Remove the casing door panel Lift and remove the casing lower front panel Undo and pull off all the plugs from the gas valve solenoids Turn off the gas at the gas inlet cock Undo the 2 unions at either side of the gas valve assembly and remove the assembly complete Pull off the leads to the spark electrode on the RH end burner access via the side of the combustion chamber Pu
26. ecuring the control box front panel Carefully lift up and lower it Pull out the sensor plug from the PCB and remove the strain relief bush Remove the sensor and lead Fit the new sensor ensuring that the lead is routed along the casing in the clips provided Reassemble in reverse order 28 Printed circuit board support detail Retention barbs Controls box back panel Potentiometer Warning light lens Controls box PCB W 4115A1020 WA QU Spring clip 1 O heat thermostat capillary Control thermostat lead Thermostat pocket Concord CXSI H Installation amp Servicing SERVICING 36 CONTROL SENSOR POTENTIOMETER ASSEMBLY Prise the front cap from the thermostat knob Carefully loosen the brass retaining nut one full turn anticlockwise Gently pull the thermostat knob from the potentiometer When reassembling ensure the arrow on the body is lined up in the OFF position Remove the back nut and brass washer securing the thermostat knob to the panel Undo and remove the 2 screws securing the control box front panel Carefully lift it up and lower it Remove the terminal plugs from the back of the potentiometer Undo the purse clips holding the wires from the potentiometer to the PCB then pull the wires out Remove the connections from the PCB Fit the new potentiometer and reassemble in reverse order Ensure that the connections to the back
27. ed then flues to BS715 may be fitted Seal with an approved boiler putty A split socket should be fitted immediately above the boiler to facilitate disconnection of the flue Concord CXSI H Installation amp Servicing 5 Complete the system connections using suitable jointing compound as follows The cast iron flow header must be fitted in the chosen flow connection which will be either of the 2 top rear tappings A length of 2 BSP pipe is contained in the Plateware Package for this purpose Fit the flow header so that the 1 1 2 vent tapping in the header is vertical Screw the thermostat pocket into one of the 1 2 tappings The other 1 2 tapping is used for the pressure gauge provided The flow header terminates in a 2 1 2 flange connection The 1 1 2 BSP tapping on the top of the flow header is for a vent pipe ONLY and MUST NOT be used for any other purpose A safety valve may be fitted in the remaining top rear tapping in accordance with CP332 3 The unused top rear tapping may be used as an alternative and independent open vent safety pipe connection The LH front bottom tappings may be used for an independent cold feed expansion pipe connection In order to avoid air locks reduction in pipe sizes should be made in the vertical plane or eccentric bushes used Finally plug the unused tappings using the 2 BSP plugs supplied Pressure Vent pipe gauge Thermostat pocket Con 1905
28. equire continual topping up to combat the effects of hardness salts and corrosion on the heat exchangers of the boiler and associated systems Caradon Ideal Limited advise contact directly with specialists on water treatment such as Fernox Manufacturing Co Ltd or Sentinel Division Tandem House Marlowe Way Betz Dearborn Ltd Croydon Widnes Surrey CRO 4XS Cheshire WA8 8UD Tel 0870 601 5000 Tel 0151 424 5351 SAFE HANDLING OF SUBSTANCES Care should be taken when handling the boiler insulation panels which can cause irritation to the skin No asbestos mercury or CFCs are included in any part of the boiler INSTALLATION REQUIREMENTS The appliance must be installed by a CORGI registered installer The installation of the boiler must be in accordance with the relevant requirements of the Gas Safety Regulations current E E BS 7671 Regulations Model Water Bye laws local water authority bye laws and it should also comply with any relevant requirements of the local gas supplier local authority and the relevant British Standard Codes of practice and building regulations 4 SEALED PRESSURISED SYSTEMS Working pressure 6 0 bar maximum Particular reference should be made to BS 6644 Section 6 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
29. evel and of a suitable load 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 5 Ventilation Requirements Required area cm per kW of total rated input net Enclosure High evel out Note Where a boiler installation is to operate in summer months e g DHW additional ventilation requirements are stated if operating for more than 50 of time refer to BS6644 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 des
30. f 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 Independent return to boiler water boilers published by the Health and Safety Executive the local authority gas or water undertakings Other British Standards applicable are BS 5422 and BS 6700 3 OPEN VENTED SYSTEMS minimum static head requirements I Open vent safety following assumptions 750mm pipe see notes 1 The open vent MUST be brought to either Y the 1 1 2 BSP tapping on the flow header E provided or to the unused 2 BSP flow tapping at the top rear of the boiler 2 independent cold feed expansion pipe independen me i This height MUST Mud en ue dan LH lower front 2 75m be increased if necessary feed expansion connection Cold feed expansion pipe minimum to comply with the pipe connections made to the pumped system minimum head required return will result in an increase in the static by the pump head requirement caused by the manufacturers additional resistance of the distributor tube to avoid cavitation Surging may also increase 3 The maximum flow rate through the boiler is based a temperature difference of Feared MA Flow header 11 C at full boiler output and the circulating pump is positioned in the flow to the 9 system Note This diagram does not sho
31. gth of burner bars overall 535 21 1 535 21 1 535 21 1 Approximate dry weight 538 1186 608 1340 678 1494 Water content Concord CXSI H Installation amp Servicing 53 11 7 60 13 68 15 GENERAL Concord CXSi 110 H 180 H Natural gas B G Certified P I No 87 AQ 341 Destination Countries GB and IE CONTENTS Air SUPPLY onere deer eR E as 9 Boiler Assembly exploded view 10 Boller Clearances 6 Burner Assemblies exploded views CXSi 110 160 222 25 GXSI 180 2 eee 26 Casing Assembly ere a 14 Chimney System nas 9 Commissioning n n a reset 20 Electrical Connections 17 Electrical Supp oe s n 9 Fault Finding u n u EE 29 Gas Safety Regulations 4 Gas Supply 4o eee eee 9 Hydraulic Resistance 6 21 Installation ecu n 10 Mandatory Requirements 8 Optiom 5 Pump e Y reese eee 7 Servicing e a ERE 24 Short Listo 31 Static Head Requirements 7 System Connections 13
32. her means of control detailed on other sheets Pipework 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 the clock period ends all relays will be off so the zone valves which were open will remain open for the pump overrun period thermostat if required Zone R1 1 thermostats valves CXSi boiler terminal connections NB Contacts shown at room temperature with power off Main Circulating Pump Zone loads if required Con1738 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 17 ZONES WITH INDIVIDUALLY PUMPED ZONES 3 zones shown Schematic Wiring thermostat if required Zone thermostats NB Contacts shown at room temperature with power off Pipework Main Circulating Pump Y Non return valves Q Q V 7 Zone valves Zone loads if required Concord CXSI H Installation amp Servicing 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 Lt Three zones are illustrated but the
33. ign 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 shutdown 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 itis 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 CXSI H Installation amp Servicing 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 sha
34. ing the M5 pt elongated nuts Note Downdraught The insulation MUST be behind the NOx ducts it will be deflector compressed behind the ducts Collector hood flange Fixing screw 12 Concord Installation amp Servicing INSTALLATION 8 BOILER ASSEMBLY 1 Fit the distributor tube into the selected return connection Ensure that the tube flange aligns horizontally and that the 2 sealing gaskets are correctly assembled on the tube refer to alignment notches Sealing gaskets Alignment notches Fit the 2 tapped flange using the M10 x 35mm screws and washers provided 2 Fit the blank flange to the other lower rear connection using the gasket and M10 x 25mm screws and washers provided Fit the blank flange to the RH front connection using the gasket and M10 x 25mm screws provided The 1 1 4 tapped flange and gasket should be fitted to the LH front connection with the reducing bush and 1 2 drain cock If the cold feed expansion pipe is to be brought directly to the boiler the close taper nipple and 1 1 4 tee must be fitted so that the drain cock is horizontal This will reduce the possibility of the drain becoming blocked by debris 41 4 1 7 Nipple Equal tee 11 4 x 1 2 Reducing bush Drain cock 9 FLUE CONNECTION 1 Complete the secondary flue connection The boiler is designed to accept flues to BS 835 If a suitable adaptor is us
35. ll off the lead to the flame detector electrode at the LH end burner Lift off the casing top panel Undo the 3 elongated nuts from each of the NOx ducts and remove all the ducts Undo the M5 nuts and washers retaining the burner light back shield and remove it Undo the four M6 nuts and washers securing the burner tray and carefully pull it from the boiler ensuring that no wires are trapped Undo the screws securing the cleanout cover s and remove Remove all loose deposits from the heat exchanger especially from between the fins using the brush provided and remove all debris from the combustion chamber floor take care not to damage the insulation 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 Detection electrode Concord CXSI H Installation amp Servicing 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 Ensure that they are clean and in good condition In particular check that 1 The ignition electrode shield and base fixing screws are tight The electrodes are correctl
36. ll terminate in a 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 IGE UP 10 Installation of Gas Appliances in Industrial and Commercial Premises 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 vermiculite 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 CXSi H 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 the chim
37. nal bore flange to BS 4504 PN6 Return tappings are 2 BSP The distributor tube must be fitted into the return connection The flow header must be fitted in the flow pipe The open vent must be brought to either the 1 1 2 BSP tapping on the flow header or to the unused 2 BSP tapping at the top rear of the boiler The cold feed may be brought to the LH front bottom tapping in order to avoid excessive surging or pumping over The unused bottom rear tapping must not be used for the cold feed pipe as it is practically blocked by the distributor tube 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 above the maximum design operating pressure of 6 0 bar 87 Ib in Boiler Size Cold Feed CXSi 110 H CXSi 120 H CXSi 140 H CXSi 160 H CXSi 180 H Open Vent 1 1 4 1 1 4 1 1 4 1 1 2 1 1 2 Concord CXSI H Installation amp Servicing 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 for appr
38. ney is suitable for the application by reference to the manufacturers literature Caradon Ideal 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 in accordance with BS 6891 IGE UP 1 for small installations 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 E E BS 7671 Wiring Regulations and any local regulations which apply For details of connections see Frame 14 INSTALLATION 5 CONCORD CXSi BOILER ASSEMBLY Exploded view Insulation not shown INSTALLATION 16 13 14 15 Legend 1 Cleanout cover 8 Distribution tube 15 Lightback shield 2 Collector hood 9 Downdraught deflector 16 Burner manifold assy 3 Middle section 10 Section bolt 17 NOx duct 4 Flow header 11 Drain cock 18 I
39. ng the time switch settings all other controls including the boiler thermostat knob should be in the normal running position The earth connections 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 the hot boiler body If a flow switch is fitted it should be wired between F and F on the terminal plug in connection on the bottom box at the rear of the control box Do not wire these connections in conduit up to the boiler as this will make it impossible to remove the control box for servicing or maintenance Finally fit the casing top panel and push down to locate Plastic front panel Con 1907 M4 screw 17 INSTALLATION INSTALLATION Note Diagrammatic only physical positions not shown L JONVHO TEMPERATURE CONTROL NC T7335B1051 ON OFF SWITCH 26 THERMISTOR VOLT FREE BOARD OPTION v violet 5456181047 W4115AIC1020 YELLOW GREEN missing pin on board blanking pin in female half LO HL2 R O H N FHIHDPL PL HLI GV HD N yon L O L O ON 0 0 O 0O O ooo 00000 y g yellow green or orange YELLOW YELLOW Concord CXSI H Installation amp Servicing g
40. nsulation bracket 5 Section alignment rings amp O rings 12 Base plate 6 Thermostat pocket 13 Combustion chamber 7 End section 14 Tie rods 10 Concord Installation amp Servicing INSTALLATION 6 BOILER SECTION ASSEMBLY The site assembled boiler is supplied in the following packages Combustion chamber manifold burner assembly Platework package Casing package Controls box package End and centre sections GENERAL The installation of the boiler must be in accordance with current Gas Safety Installation and Use Regulations or rules in force 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 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 final siting Prior to assembling the sections it will be necessary to remove the manifold assembly and burners from the combustion chamber To do this 1 Undo the two M5 screws and washers securing the spark generator bracket to the combustion chamber Undo the union securing the gas valve assembly and remove the gas valve and spark gener
41. nto the slotted holes in the front fixing bracket s Con 1906 Overheat stat reset button 14 Concord CXSI H Installation amp Servicing INSTALLATION 12 CONTROL BOX 1 Make the 3 electrical connections from the overheat thermostat fixed to the upper front framework to the terminals marked Limit Stat on the electrical plug in connector from the gas valve plug lead assembly as follows C Pink N O Red N C White Ensure that the lead is securely fastened under the strain relief clamp but bring the earth wire outside the clamp before tightening 2 Unpack the control box Fit the plug in connector from the gas valve plug lead assembly to the bottom box at the back of the control box and fasten using the M4 screws and washer Con 1468 Spark generator Con 1912 Con 1309 Earth overheat EO stat lead Overheat stat reset button 3 Fit the control box to the support frame and fix to the bottom using the 2 self tapping screws provided 4 Fit the earth connections from the terminal plug in connections to the appropriate earth posts on the back of the control box Connect the earth lead prefitted to the control box back panel to the threaded hole in the casing support frame IMPORTANT 5 Offer up the spark generator assembly to the combustion chamber base tray and secure the bracket using the M5 screws and washers Plug the spark generator leads onto the sp
42. ob been switched to OFF Replace PCB W4115A1020 Y YES Advise USER Refer to Installation Instructions for details FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING Concord CXSi H Installation amp Servicing 31 SHORT LIST OF PARTS When ordering spare parts please quote The following are parts commonly required as replacements due to damage or 1 Boiler model expendability 2 Boiler serial no refer to the data plate on the combustion chamber 3 Boiler P I No refer to the data plate on the combustion chamber Their failure or absence is likely to affect the 4 Description safety and or performance of this appliance 5 Quantity 6 Product no When replacing a part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers Gas valve HONEYWELL VR4605PB2003 CXSi 110 H 120 H 140 H 160 H amp 180 H 111 867 HONEYWELL VR4605A 1104 CXSi 110 amp 120 H 138 896 HONEYWELL VR4605A 1104 CXSi 180 H 138 896 HONEYWELL VR4605AB 1019 CXSi 140 H amp 160 H 111 869 Plug and lead CXSi 110 H 120 H 140 H 160 H amp 180 H 154 734 Plug and lead CXSi 110 H 120 H 140 H amp 160 H 139 269 Plug and lead CXSi 110 H 120 H 140 H amp 160 H 112 431 Plug and lead CXSi
43. on 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 Ideal 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 Concord CXSI H Installation amp Servicing Face mask supplied with the spare part Gloves supplied with the spare part Damp down the combustion chamber area containing the insulation boards 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 Sweep any dampened particles and place in the plastic bag Fit new insulation boards Remove the gloves and face mask and place them in the plastic bag Wash your hands and any areas of skin which may have come into contact with any of the particles from the insulation board Seal the plastic bag and dispose of it and its contents into a commercial tip 29 SERVICING Q E u ES u lt Z lt
44. oximately 6 minutes after the burner shuts down and in order to make use of this the pump must be wired to the appropriate terminal L2 pump in the boiler control box 1 The minimum flow rate as given in Table 4 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 given by the use of Graph 1 Examples shown on Graph 1 a For the CXSi 110 H and CXSi 120 H the minimum circuit during pump overrun could be a load of 7 kW with a volume of 42 litres or any other combination given by the relevant line b Forthe CXSi 180 H the minimum circuit during pump overrun could be a load of 9 kW with a volume of 70 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 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 Cold Feed Open Vent The independent cold feed and the open vent must comply with BS 6644 and be of the following minimum size GENERAL Graph 1 Heat Load
45. 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 required CXSi boiler terminal connections S P If required Overrun During overrun periods Zone 1 pump performs the overrun facility 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 Zone 1 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 19 INSTALLATION INSTALLATION 18 ZONES WITH SPRING RETURN MOTORISED VALVES Schematic Wiring IMPORTANT Terminal L2 may control the appropriate pump s directly provided that the total ee running or starting current does not exceed if required 6A resistive or inductive if this rating would Zone be exceeded then appropriate switchgear thermostats must be used to control the pumps indirectly CXSi boiler terminal strip 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
46. pump and shunt pump if fitted is wired to the pump terminals marked L2 N and Earth on the plug in terminal strip on the top box at the rear of the control box The main supply to the boiler must be wired to the boiler terminals L1 N and Earth on the plug in terminal strip This live connection must be UNSWITCHED that is a supply not interrupted by any automatic temperature or time control to enable the pump overrun and the frost protection facility to operate Failure to operate this procedure will result in nuisance overheat thermostat operation The internal wiring of the boiler control box is shown in Frame 15 Wiring should be in four core PVC insulated cable not less than 0 75mm 24 0 2mm All fuses must be ASTA approved to BS 1362 The length of the conductor between the cord anchorage and the terminals must be such that the current carrying conductors become taut before the earthing conductor if the cable or cord slips out of the cord anchorage Concord CXSI H Installation amp Servicing The boiler can be controlled either by volt free external contacts connected between terminals X1 and X2 or by a switched live supply brought to X2 after removal of the factory fitted link between X1 and X2 accompanied in each case by a permanent live supply to terminal L1 If a separate frost thermostat is fitted it must be wired across the time switch contacts and if frost is likely the System should be turned off usi
47. r the shoulder screws in the side panels and pushing down to locate o O C detector LH Burner 9 Con 1916 Spring clip Overheat thermostat capillary Control thermostat lead Thermostat pocket Earth connections GV1 amp GV2 amp o heat thermostat earths Con 1917 Concord Installation amp Servicing INSTALLATION 14 ELECTRICAL CONNECTIONS To gain access to the inside of the control box remove the 2 M4 screws lift up the plastic front panel and lower 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 unswitched live supply which the boiler requires to allow the pump overrun facility to operate should be controlled by the above switched fused supply but should connect from there directly to the boiler and not via any automatic time or temperature controls The switched live supply should be subject to control by time and temperature controls in the usual way The controls incorporate a pump overrun facility which is necessary to dissipate residual heat on plant shutdown It is essential therefore that the main
48. ressure Next close the gas supply Remove the casing lower front panel cock at the meter Wait for 1 minute for temperature stabilisation then observe the pressure gauge over a period Extinguish all naked lights and open all doors and windows of 2 minutes DO NOT SMOKE Check that the gas supply is turned ON at the meter and open the main gas inlet cock Loosen the Any leaks must be cured 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 Replace all pressure test point screws Retighten the union 20 Concord Installation amp Servicing INSTALLATION 20 INITIAL LIGHTING 2 Ensure that the mains gas inlet cock 3 is open groove in the square head in line with the gas pipe 3 Press in and release the overheat thermostat button 4 4 Switch on the electrical supply to the boiler 9 5 Ensure that all system controls time switch system detection controls etc are calling for heat 6 Turn the boiler thermostat knob 1 to position 6 the required settings i Ideal CONCORD GxSi Con 1495 OA O Oe Uo 10 6 _ 1 a 1 1 1 Lh 1909 1 Check that the boiler thermostat knob 1 on the control 7 The boiler will light at Low rate and the Boiler on light 5 box 2 is OFF will be illuminated If it does not light
49. t z br brown YELLOW ORANGE 2 X YELLOW 2 X VIOLET DETECTION LEAD E m LEGEND bk black dp CONTACT REMOVED AND FITTED TO MATING HALF lt 1 1 1 1 2 N 12 N C F1 15 I3 N N L4 sw PINK L SUPPLY ee e 3 Y Y Y LOCKOUT BOILER ON SPARK GV1 GV2 OVERHEAT GEN LOW HIGH WHITE Con 6019 CONTROLS FACTORY FITTED 1 LINKS OVERHEAT THERMOSTAT AGOYLOATA NOILO313G VOLT FREE CONTACTS 2 15 INTERNAL WIRING 18 OILY TIVLSNI INSTALLATION 16 ZONES WITH BI DIRECTIONAL MOTORISED VALVES Schematic Wiring 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 Each relay will then require as many contacts as there are zones 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 ot
50. t in to the controls to prevent rapid cycling 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 Concord Installation amp Servicing GENERAL FROST PROTECTION Frost protection is incorporated in the boiler as long as there is a permanent Live supply wired to Terminal L1 on the terminal plug in connection at the control box and the boiler thermostat knob is not switched to Off If the temperature sensed by the boiler thermostat falls to about 5 C the boiler will fire until the temperature reaches 18 C Note that this is designed to protect the boiler and may not necessarily protect remote parts of the system The mains voltage supply is via a terminal plug in connection at the control box OPTION KITS Remote Indication Kit This kit gives the facility of remote indication of boiler status Pressure Gauge Kit A pressure gauge kit is available DUTY The range of boilers is suitable for Combined indirect pumped domestic hot water and central heating systems Independent indirect pumped domestic hot water or central heating systems Fully pumped systems may be open vented or sealed The range of boilers is NOT suitable for 1 Gravity DHW systems 2 Gravity heating systems 3 Direct domestic hot water supply 1 WATER CONNECTIONS Flow connection is 65mm 2 1 2 nomi
51. t pocket in the flow header and pull out the overheat thermostat phial and capillary Ensure that the electrical supply is switched OFF Lift off the casing front panel and top panel Unclip the capillary from its clips on the casing side panel Undo the 2 screws securing the overheat thermostat assembly and withdraw the assembly Undo the screw and remove the cover Remove the wires Undo the backnut and remove the thermostat Fit the new thermostat and secure with the backnut Reconnect the wires as follows 1 Pink 2 White 3 Red Reconnect the earth terminal Concord CXSI H Installation amp Servicing Spring clip O heat thermostat capillary Control thermostat lead Thermostat pocket 11 Reassemble in reverse order 12 Ensure that the thermostat capillary is rerouted through the casing side panel clips and that the phial is secure in the pocket fitted to the flow header using the spring clip 27 SERVICING SERVICING SERVICING 34 CONTROL BOX Basic Boiler Exploded View lt cuc LEGEND Wiring clamp Terminal strip Connection box plug Back panel Connection box Lockout reset button PCB S456B1047 Thermostat knob 35 CONTROL SENSOR Lift off the casing top panel and front panel Trace the sensor lead to the pocket in the flow header remove the spring clip and remove the sensor phial Undo and remove the 2 screws s
52. the Lockout light 6 will be illuminated Press in and release the Lockout button 7 The controls will reset and attempt to relight 8 The burner will remain at Low rate for about 1 minute before going to High rate Check all connections for gas soundness using leak 10 Set the boiler thermostat knob and the system controls to 11 Turn off the electrical supply to the boiler LEGEND Boiler thermostat knob Control box Mains inlet gas cock Overheat thermostat Boiler on light Lockout light Lockout reset button Burner pressure test point Inlet pressure test point Overheat light High low gas valve Concord CXSI H Installation amp Servicing 21 INSTALLATION INSTALLATION INSTALLATION 21 MANIFOLD GAS PRESSURE CXSi 110 H 160 H ONLY The manifold setting pressure must now be checked and adjusted as necessary It is 5 essential to set the High Pressure first Inlet Start the adjustment procedure with the system cold on full load and with all temperature controls set to maximum to avoid thermostatic shutdown Remove the screw in the burner setting pressure test point and connect a suitable gas pressure gauge Turn on the electrical supply to light the boiler and let it operate for about 10 minutes to stabilise the burners Check the pressure and if it differs noticeably from that given in Table 1 for the appropriate boiler size adjust it as follows Con 1498 Low rate
53. vices e g flue dampers economisers etc are directly connected to this appliance unless covered by these Installation and Servicing Instructions or otherwise recommended by Caradon Ideal Limited in writing If in doubt please enquire Any direct connection of a control device not approved by Caradon Ideal 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 data likely to be required by the installer GAS CONTROLS The boiler lights at Low rate approximately 70 of Full rate by direct burner ignition After about 1 minute the boiler goes to High rate and will continue at High rate until the thermostat sensor set point is reached The boiler will then drop to the Low rate if the temperature continues to rise the boiler will go Off if the temperature falls the boiler will revert to High rate ELECTRICAL CONTROLS The boiler is supplied with 2 printed circuit boards Board 54561 1047 is the ignition board containing the flame proving logic Board W4115A1020 contains the electronic thermostat and pump overrun timer A preset overheat thermostat is also provided The mains voltage supply is via a terminal plug in connection at the control box The control box displays neons indicating boiler status as follows Boiler on Lockout Overheat An anti cycle delay is buil
54. w safety valves water flow switches etc necessary for the safe operation of the system Particular reference should be made to BS 6644 Section 2 Subsection 10 and Guidance note PM5 Automatically controlled steam and hot The information and guidance given below is not intended to override any requirements of either of the above publications or the requirements of The information provided is based on the 4 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 5 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 CXSI H Installation amp Servicing GENERAL 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 corrosion unless treated For the reason stated Caradon Ideal Limited strongly recommend that when necessary the system is thoroughly cleaned prior to the use of stable inhibitor which does not r
55. y positioned 2 3 Check that the gap between the electrode tips is 4mm 4 Reassemble in reverse order Ensure that no wires are trapped when replacing the burner tray Refit the flue baffles cleanout cover light back shield NOx ducts electrode connections and casing panels When refitting the plugs to the gas valve solenoids do NOT overtighten the fixing screws Shield Screws Ignition electrodes Base fixing Screws generator leads 25 SERVICING SERVICING 28 REPLACEMENT OF COMPONENTS Refer to Frames 5 31 and 32 GENERAL WARNING ALWAYS turn OFF the gas supply at the gas inlet cock and switch OFF and DISCONNECT the electricity supply BEFORE working on the appliance 29 GAS CONTROL VALVE 30 MAIN BURNER Undo and pull off all the plugs from the gas valve solenoids 1 Remove the burner tray from Turn off the gas at the gas inlet cock Undo the 2 unions at either side of the gas valve the boiler as described in assembly and remove the assembly complete to a suitable working area Frames 27 28 Each burner can be removed by lifting it at the back and pushing it backward to clear the injector Disconnect the spark electrode assembly and heat shield from the RH Ensure that new O ring seals are fitted and that the O ring seals on the remaining burner or the flame detector gas valves are correctly in place Ensure that all screws are retightened electrode from the LH burner
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