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IDEAL INDUSTRIES CXSi 110 manual

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Table of contents for the manual

  • Page 1

    Installers guide to commercial central heating boilers BOILERS Concord CXSi 1 10/H-180/H INST ALLA TION MANUAL & SER VICING 157294-3.pmd 11/8/2005, 9:58 AM 1[...]

  • Page 2

    GENERAL 2 Concord CXSi/H - Installation & Servicing 157294-3.pmd 11/8/2005, 9:58 AM 2[...]

  • Page 3

    GENERAL 3 Concord CXSi/H - Installation & Servicing Boiler CXSi 1 10/H CXSi 120/H CXSi 140/H CXSi 160/H CXSi 180/H Number of sections 7 7 8 9 10 Flow connections Rc 65 mm (2 1/2 ") nominal bore. Flange to BS.4504 (PN6) Return tappings Rc 2 x 2 Maximum static head m. (ft) 61.0 (200) Maximum pressure bar (psi) 6.0 (87) Gas inlet connection R[...]

  • Page 4

    GENERAL 4 Concord CXSi/H - Installation & Servicing CONTENTS Air Supply . ........................................................................ 9 Boiler Assembly - exploded view . ............................... 10 Boiler Clearances . ........................................................... 6 Burner Assemblies - exploded views . .........[...]

  • Page 5

    GENERAL 5 Concord CXSi/H - Installation & Servicing Boiler Size Cold Feed Open V ent CXSi 1 10/H 1" 1 1/4 " CXSi 120/H 1" 1 1/4 " CXSi 140/H 1" 1 1/4 " CXSi 160/H 1 1/4 "1 1/2 " CXSi 180/H 1 1/4 "1 1/2 " 1 W A TER CONNECTIONS Flow connection is 65mm (2 1/2 ") nominal bore flange to BS.4504 [...]

  • Page 6

    GENERAL 6 Concord CXSi/H - Installation & Servicing POSITION OF BOILER Minimum clearances required from walls or other fixed objects to allow for the free access of combustion air are shown in T able 3 above. Any combustible material adjacent to the boiler and its flue system must be so placed or shielded as to ensure that its temperature does [...]

  • Page 7

    GENERAL 7 Concord CXSi/H - Installation & Servicing Note. This diagram does not show safety valves, water flow switches, etc., necessary for the safe operation of the system. 3 OPEN VENTED SYSTEMS - minimum static head requirements Particular reference should be made to BS. 6644: Section 2; Subsection 10 and Guidance note PM5 "Automaticall[...]

  • Page 8

    GENERAL 8 Concord CXSi/H - Installation & Servicing 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[...]

  • Page 9

    GENERAL 9 Concord CXSi/H - Installation & Servicing CHIMNEY SYSTEM T o 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 [...]

  • Page 10

    INST ALLA TION 10 Concord CXSi/H - Installation & Servicing 5 CONCORD CXS i BOILER ASSEMBL Y - Exploded view Legend 1 . Cleanout cover 2. Collector hood 3. Middle section 4. Flow header 5. Section alignment rings & 'O' rings. 6. Thermostat pocket. 7. End section. 15. Lightback shield. 16. Burner manifold assy . 17. NOx duct. 18. I[...]

  • Page 11

    INST ALLA TION 11 Concord CXSi/H - Installation & Servicing 6 BOILER SECTION ASSEMBLY The site assembled boiler is supplied in the following packages: ! Combustion chamber / manif old / burner assembly . ! Platew o rk package. ! Casing package . ! Controls box pac kage. ! End and centre sections. TOOLS REQUIRED ! Spanners ! T orque wrench ! Poz[...]

  • Page 12

    INST ALLA TION 12 Concord CXSi/H - Installation & Servicing 7 BOILER SECTION ASSEMBLY - continued 12. Offer the downdraught deflector to 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 bu[...]

  • Page 13

    INST ALLA TION 13 Concord CXSi/H - Installation & Servicing 8 BOILER ASSEMBL Y 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. 1. Complete the secondary flue connection. The boiler is [...]

  • Page 14

    INST ALLA TION 14 Concord CXSi/H - Installation & Servicing 11 CASING ASSEMBL Y Con 1906 Overheat 'stat reset b utton 1. Fit the support angle to the collector hood and fasten, using the M5 screws and washers. 2. Fit the front fixing bracket(s) to the collector hood and fasten, using the M5 screws and washers through the slotted holes. 3. [...]

  • Page 15

    INST ALLA TION 15 Concord CXSi/H - Installation & Servicing 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 t[...]

  • Page 16

    INST ALLA TION 16 Concord CXSi/H - Installation & Servicing 8 Con 1914 LH Burner Flame detector NOx duct 7 Con 1915 13 CONTROL BOX - continued 7. 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 . Ensure that any slack is tucked neat[...]

  • Page 17

    INST ALLA TION 17 Concord CXSi/H - Installation & Servicing 14 ELECTRICAL CONNECTIONS T o 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"[...]

  • Page 18

    INST ALLA TION 18 Concord CXSi/H - Installation & Servicing 15 INTERNAL WIRING v violet pk pink y/g yellow/green or orange y yellow w white br brown r red LEGEND b blue bk black TEMPERA TURE CONTROL ON/OFF SWITCH T7335B1051 THERMISTOR Note: Diagrammatic only - physical positions not shown VOL T -FREE BOARD (OPTION) missing pin on board blanking[...]

  • Page 19

    INST ALLA TION 19 Concord CXSi/H - Installation & Servicing 16 ZONES WITH BI-DIRECTIONAL MOT ORISED V AL VES IMPORT ANT T erminal 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[...]

  • Page 20

    INST ALLA TION 20 Concord CXSi/H - Installation & Servicing 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 casing lower fro[...]

  • Page 21

    INST ALLA TION 21 Concord CXSi/H - Installation & Servicing CXSi CONCORD Con 1495 OFF OFF 6 5 4 3 2 1 L O C K O U T R E S E T BOILER ON BOIL ER ON OVERHEA T OVER HEA T LOCKOUT LOCK OUT LEGEND 1. Boiler thermostat knob. 2. Control box. 3. Mains inlet gas cock. 4. Overheat thermostat . 5. Boiler on light. 6. Lockout light. 7. Lockout reset button[...]

  • Page 22

    INST ALLA TION 22 Concord CXSi/H - Installation & Servicing 21 MANIFOLD GAS PRESSURE - CXSi 1 10/H-160/H ONL Y SETTING THE HIGH BURNER PRESSURE 1. Remove the dust cover from the adjustment screw in the bottom valve and gently screw the adjustment in fully . 2. Remove the plastic dust cover from the adjustment screw on the top (high/low) valve a[...]

  • Page 23

    INST ALLA TION 23 Concord CXSi/H - Installation & Servicing SETTING THE HIGH BURNER PRESSURE 1. T urn the boiler thermostat knob to OFF . 2. Undo the screws holding the electrical plug on the bottom gas valve and pull it off. 3. T urn the boiler on and remove the plastic dust cover from the adjustment screw on the top gas valve and, using a sui[...]

  • Page 24

    SERVICING 24 Concord CXSi/H - Installation & Servicing 25 ADJUSTMENT OF W A TER FLOW RA TE 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 T able 4, when that part of the system intended to be used for dissipation of residual heat only is in opera[...]

  • Page 25

    SERVICING 25 Concord CXSi/H - Installation & Servicing LH burner 27 SER VICING 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 carrie[...]

  • Page 26

    SERVICING 26 Concord CXSi/H - Installation & Servicing 1. Remove the burner tray from the boiler , as described in Frames 27-28. 2. 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 burner (or the flame detector electrode from [...]

  • Page 27

    SERVICING 27 Concord CXSi/H - Installation & Servicing 32 BURNER AND CONTROLS ASSEMBL Y - Exploded view - CXSi 180/H 1. Pull out the spring clip in the thermostat pocket in the flow header and pull out the overheat thermostat phial and capillary . 2. Ensure that the electrical supply is switched OFF . 3. Lift of f the casing front panel and top[...]

  • Page 28

    SERVICING 28 Concord CXSi/H - Installation & Servicing 35 CONTROL SENSOR 1. Lift off the casing top p anel and front panel. 2. T race the sensor lead to the pocket in the flow header, remove the spring clip and remove the sensor phial. 3. Undo and remove the 2 screws securing the control box front panel. Carefully lift up and lower it. 4. Pull [...]

  • Page 29

    SERVICING 29 Concord CXSi/H - Installation & Servicing 39 COMBUSTION CHAMBER INSULA TION REPLACEMENT The insulation 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 f[...]

  • Page 30

    FAUL T FINDING FAUL T FINDING FAUL T FINDING FAUL T FINDING FAUL T FINDING FAUL T FINDING FAUL T FINDING 30 Concord CXSi/H - Installation & Servicing Before attempting any electrical fault finding AL W A YS carry out the preliminary electrical system checks as detailed in the Instructions for the British Gas Multimeter or other similar commerci[...]

  • Page 31

    FAUL T FINDING FAUL T FINDING FAUL T FINDING FAUL T FINDING FAUL T FINDING FAUL T FINDING FAUL T FINDING 31 Concord CXSi/H - Installation & Servicing Is there a spark at the electrode? Are the gas valve electrical plugs clean and secure? 42 BOILER DOES NOT LIGHT Before carrying out any Fault Finding, ensure that all internal controls are callin[...]

  • Page 32

    SHORT LIST OF P ARTS 32 Concord CXSi/H - Installation & Servicing When ordering spare parts please quote: 1. Boiler model 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) 4. Description 5. Quantity 6. Product no. Key No. Description Qt y . Product No[...]

  • Page 33

    SHORT LIST OF P ARTS 33 Concord CXSi/H - Installation & Servicing 45 Control box complete 1 155 641 46 Thermistor 1 154 816 47.1 PCB S4561B1047 (ignition) 1 154 814 48.1 PCB W41 15A1020 (Aquastat ) 1 154 815 56 Casing assembly complete .................................................. CXSi 1 10/H & 120/H 1 157 449 56 Casing assembly comple[...]

  • Page 34

    NOTES Concord CXSi/H - Installation & Servicing 34 Concord CXSi/H - Installation & Servicing 157294-3.pmd 11/8/2005, 9:59 AM 34[...]

  • Page 35

    NOTES Concord CXSi/H - Installation & Servicing 35 Concord CXSi/H - Installation & Servicing 157294-3.pmd 11/8/2005, 9:59 AM 35[...]

  • Page 36

    Ideal Boilers , P .O. Box 103, National A ve, Kingston upon Hull, HU5 4JN. T elephone: 01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. November 2005 UIN 157 294 A03 T echnical T raining Caradon Ideal Limited pursues a policy of continuing improvement in the design and performance of its products. The right is therefore reserved t[...]