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2
Concord CXAP/H
- Installation and Servicing
GENERAL
Boiler
CXAP 40/H
CXAP 50/H
CXAP 60/H
CXAP 70/H CXAP 80/H CXAP 90/H CXAP 100/H
Number of sections
3
4
4
5
5
6
6
Flow tappings
Rc (in. BSP)
2 x 2 at rear
Return tappings
Rc (in. BSP)
2 x 2 at rear
Maximum static head
metres (feet)
61 (200)
Maximum pressure
bar (p.s.i.)
6.0 (87)
Gas inlet connection
Rc (in. BSP)
3/4 (3/4)
1 (1 )
Dynamic gas
mbar gauge
37.0
37.0
37.0
37.0
37.0
37.0
37.0
pressure required
at boiler inlet
in.w.g.
14.9
14.9
14.9
14.9
14.9
14.9
14.9
Electricity supply
230 Volts- single phase, 50 Hz, fuse 5 A
Nominal flue size (to BS. 835)
mm
150
150
175
175
200
200
200
in.
6
6
7
7
8
8
8
Diverter outlet socket
mm
184
184
213
213
238
238
238
internal diameter
in.
7.3
7.3
8.4
8.4
9.4
9.4
9.4
Length of burner bars (overall)
mm
377
497
497
617
617
737
737
in.
14.8
19.5
19.5
24.3
24.3
29.0
29.0
Main burner injectors (3 off)
size, mm
2.15
2.3
2.54
2.69
2.96
3.09
3.27
Approximate dry weight
kg
210
265
265
330
330
395
395
lb.
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
Boiler
CXAP 40/H
CXAP 50/H CXAP 60/H CXAP 70/H CXAP 80/H CXAP 90/H CXAP 100/H
Number of sections
3
4
4
5
5
6
6
Boiler input
Nett
kW
48.4
57.3
69.6
79.8
96.0
103.4
119.5
Btu/hr x 1000
165.1
195.4
237.5
272.2
327.5
352.8
407.7
Gross
kW
52.5
62.1
75.5
86.5
104.1
112.15
129.6
Btu/hr x 1000
179.1
211.9
257.6
295.1
355.2
382.7
442.2
Boiler output to water
kW
42.0
49.68
60.4
69.2
83.28
89.72
103.68
Btu/hr x 1000
143.3
169.5
206.1
236.1
284.2
306.1
353.8
Gas rate
m
3
/h
1.98
2.34
2.83
3.26
3.92
4.22
4.88
ft
3
/h
69.9
82.6
99.9
115.1
138.4
149.0
172.3
Approximate flue 6.5% CO
2
& 150°C.m
3
/s
0.051
0.060
0.073
0.083
0.099
0.108
0.125
gas volume in the
secondary flue
6.5% CO
2
& 302°F. ft.
3
m
108
127
155
176
210
229
265
Manifold setting pressure
mbar
35.7
35.3
35.5
35.8
35.2
35.4
34.8
in.w.g.
14.3
14.2
14.3
14.4
14.2
14.2
14.0
Part Load efficiency (Gross)
%
80.0
80.5
81.5
80.7
81.7
81.8
82.7
Seasonal efficiency (SEDBUK)*
[78.2]%
[78.6]%
[79.7]%
[78.8]%
[79.4]%
[79.6]%
[80.0]%
Table 1- Performance Data
Note. To obtain gas consumption in l/s divide gross heat input in kW by the gross CV of the gas in MJ/m
3
.
The gross CV is the value quoted by the gas supplier.
Table 2 - General Data
*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 Advantica 0087.
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Concord CXAP/H -
Installation and Servicing
3
CONTENTS
Air Supply. ........................................................................ 8
Boiler Assembly - exploded view. ................................. 9
Boiler Clearances. ........................................................... 5
Burner Assemblies - exploded views.
CXAP 40/H-80/H. ....................................................... 22
CXAP 90/H-100/H. ..................................................... 22
Casing Assembly. ...........................................................11
Chimney System. ............................................................. 8
Commissioning & Testing. ............................................ 17
Electrical Connections. ................................................. 13
Electrical Supply. ............................................................. 8
Fault Finding. ................................................................. 28
Gas Safety Regulations ................................................... 3
Gas Supply. ....................................................................... 8
Hydraulic Resistance. ...................................................... 5
Initial Lighting. ............................................................... 17
Installation. ....................................................................... 9
Mandatory Requirements. ............................................... 7
Option Kits. ....................................................................... 4
Pump. ................................................................................ 6
Servicing. ........................................................................ 19
Short List of Parts. ......................................................... 30
Site Assembled Boilers. ................................................ 26
Static Head Requirements. ............................................. 6
System Connections. ......................................................11
Ventilation. ........................................................................ 8
Water Circulation. ............................................................ 4
Water Connections. ......................................................... 4
Water Treatment. .............................................................. 6
Wiring Diagrams. ........................................................... 14
Concord CXAP 40/H-100/H (Propane) B.G. Certified - P.I. No. 87/AP/80
Destination Countries: GB and IE
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.
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 CXAP 40/H-100/H range of boilers has been tested
and certified by British Gas to prEN656 for use with PROPANE only.
Multiple boiler installations
The Concord CXAP/H range is certificated for use in multiple
boiler installations, providing 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
CXAP/H 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. Concord CXAP 40/H, CXAP 50/H and CXAP 60/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
devices - e.g. flue dampers, economisers etc., are directly connected
to this appliance unless covered by these Installation and Servicing
Instructions or otherwise recommended by Caradon Ideal Limited
in writing. If in doubt, please enquire.
Any 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.
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.
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Concord CXAP/H
- Installation and Servicing
GENERAL
Boiler Size
Cold Feed
Open Vent
CXAP/H 40 - 50
3/4
"
1"
CXAP/H 60 -100
1"
1
1/4
"
Sealed system filling point - refer to Frame 8
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 lb/in.
2
) above the operating pressure in the boiler. The
maximum safety valve setting is 0.7 bar (10 lb/in.
2
) above the
maximum design operating pressure of 6.0 bar (87 lb/in.
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.
1
WATER CONNECTIONS
GAS CONTROLS
Control is by automatic ignition of intermittent pilot; once the
presence of a flame has been proved the main gas valve opens to
give full heat input. The mains voltage supply is via a terminal plug
connection at the control box.
A 4 minute anti-cycle delay is built in to the controls to prevent rapid
cycling. A preset overheat thermostat is also provided.
ELECTRICAL CONTROLS
The boiler is supplied with 2 printed circuit boards; Board
S4561B1054 is the ignition board containing the flame proving
logic and the on-board spark generator. Board W4115A1020
contains the electronic thermostat and the pump overrun timer. A
preset overheat thermostat is also fitted. The control box displays
neons indicating boiler status as follows:
!
Boiler on
!
Lockout
!
Overheat
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
o
C the boiler will fire until the temperature reaches 18
o
C. Note
that this is designed to protect the boiler and may not necessarily
protect the remote parts of the system.
OPTION KITS
Remote indication kit
This kit gives the facility of remote indication of the boiler status.
Pressure gauge kit
An optional pressure gauge is also available for the range of boilers.
Details for fitting are included with the pressure gauge.
Downdraught thermostat kit
This kit is optional when used on a single CXAP/H installation, but
mandatory when used on a multiple boiler installation.
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.
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 approximately 6 minutes after burner shutdown 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 CXAP 90/H and CXAP 100/H 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 CXAP 70/H and CXAP 80/H 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.
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Installation and Servicing
5
GENERAL
MULTIPLE BOILER INSTALLATIONS
The minimum installation clearances must conform to the
dimensions given below:
CXAP 40/H, 50/H, 60/H, 70/H & 80/H
Clearance between boilers = 50mm
Clearance at both ends of the multiple installation = 50mm*
2
CLEARANCES & DIMENSIONS
CXAP 90/H & 100/H
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.
Boiler Size
CXAP 40/H
CXAP 50/H
CXAP 60/H
CXAP 70/H
CXAP 80/H
CXAP 90/H CXAP 100/H
Front clearance
mm (in)
750 (29
1/2
)
Rear clearance
mm (in)
0
0
0
150 (6)
150 (6)
300 (12)
300 (12)
Side clearance
mm (in)
50 (2)
50 (2)
50 (2)
50 (2)
50 (2)
100 (4)
100 (4)
Dimension A
mm (in)
750 (29
1/2
)
882 (34
3/4
)
882 (34
3/4
)
1042 (41)
1042 (41)
1212 (47
3/4
)
1212 (47
3/4
)
Dimension B
mm (in)
108 (4
1/4
)
108 (4
1/4
)
122 (4
7/8
)
122 (4
7/8
)
135 (5
3/8
)
190 (7
1/2
)
190 (7
1/2
)
Dimension C
mm (in)
931 (36
5/8
)
931 (36
5/8
)
931 (36
5/8
)
931 (36
5/8
)
931 (36
5/8
)
893 (35
3/16
)
893(35
3/16
)
Dimension D
mm (in)
177 (7)
187 (7
3/8
)
187 (7
3/8
)
224 (8
7/8
)
224 (8
7/8
)
271 (10
5/8
)
271 (10
5/8
)
Dimension E
mm (in)
69 (2
3/4
)
79 (3
1/8
)
79 (3
1/8
)
116 (4
5/8
)
116 (4
5/8
)
163 (6
1/2
)
163 (6
1/2
)
Table 3
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.
However, for maintenance
purposes we suggest a minimum
rear clearance of 50mm.
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
o
C (150
o
F).
10
9
8
7
6
5
4
3
2
1
0
10
20
30
40
50
60
70
80
CON5223
Example A
Example B
CXAP
100/H & CXAP
90/H
CXAP
80/H & CXAP
70/H
CXAP
40/H
CXAP
60/H & CXAP
50/H
Heat Load During Pump Overrun (kW)
Water Volume in Circuit during Pump Overrun (litres)
Relationship between load and water volume for the
minimum capacity of water circuit during the 6 minute
pump overrun period for different boiler outputs.
Graph 1 - Heat Load / Water Volume
10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
190 200
160 170 180
120
110
100
90
80
70
60
50
40
30
20
10
0
Graph 2 - Hydraulic Resistance
Hydraulic Resistance (mbar)
Flow (litres/min)
11
o
C(20
o
F) - CXAP
40/H
11
o
C(20
o
F) - CXAP
50/H
11
o
C(20
o
F) - CXAP
60/H
11
o
C(20
o
F) - CXAP
70/H
11
o
C(20
o
F) - CXAP
80/H
11
o
C(20
o
F) - CXAP
90/H
11
o
C(20
o
F) - CXAP
100/H
CON5224
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Concord CXAP/H
- Installation and Servicing
GENERAL
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 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 and 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.
2. An independent 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.
3. The maximum flow rate through the boiler is based on a
temperature difference of 11 °C at full boiler output and
the circulating pump is positioned in the flow to the
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.
system.
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.
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 17,18 &19 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.
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
o
C (63
o
F), assessed at catalogue rating.
3 OPEN VENTED SYSTEMS - Minimum static head requirements
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%.
Table 4 - Flow rates for fully pumped systems
Boiler
Minimum flow rates for a
temperature difference of 35
0
C (63
0
F)
l/s
g.p.m.
CXAP 40/H
0.28
3.7
CXAP 50/H
0.34
4.5
CXAP 60/H
0.41
5.4
CXAP 70/H
0.48
6.3
CXAP 80/H
0.55
7.3
CXAP 90/H
0.62
8.2
CXAP 100/H
0.68
9
CON5349
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Concord CXAP/H -
Installation and Servicing
7
GENERAL
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
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 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 require 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
Tandem House,
Marlowe Way,
Croydon.
Surrey CRO 4XS
Tel 0870 601 5000
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 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 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
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 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
automatic reset. In the event of shutdown both visual and
audible alarms may be necessary.
The installation of the boiler must be in accordance with the
relevant requirements of the Gas Safety Regulations, current I.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 region, local authority and the relevant
British Standard Codes of practice and building regulations.
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 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.
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 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.
4
SEALED (PRESSURISED) SYSTEMS
INSTALLATION REQUIREMENTS
The appliance must be installed by a CORGI registered installer.
Sentinel Division
Betz Dearborn Ltd.,
Widnes,
Cheshire,
WA8 8UD
Tel. 0151 424 5351.
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Concord CXAP/H
- Installation and Servicing
GENERAL
VENTILATION
Safe, efficient and trouble-free operation of open 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 to the outside air
is required; the minimum free area and the required positioning
of these grilles must be in accordance with Tables 5 and 6.
Position ventilation grilles to avoid the risk of accidental
obstruction by blockage or flooding.
Every installation must comply with the ventilation requirements
of BS.6644 or BS.5440:2:2000
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 design 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 it is intended to fit
an extractor fan after installation of the appliance) the advice of
the Gas Region 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.
CHIMNEY SYSTEM
To ensure the safe and satisfactory operation of the boiler 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 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 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 CXAP/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 I.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 chimney
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 region should be requested.
Installation pipework should be fitted and tested for gas
soundness in accordance with BS. 6891;
IGE-UP-1 for small installations
IGE-UP-2 for large installations.
The local gas region 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 I.E.E. (BS. 7671) Wiring Regulations and any local
regulations which apply.
For details of connections refer to Frame 14.
Table 5 - (to BS5440)
CXAP 40/H-60/H boilers installed in a room or internal space
Boiler size
Air vent free area cm
2
40
209
50
252
60
313
This air vent shall be direct to outside air or to a room or internal
space itself with an air vent to outside air of the same size.
Table 6 - (to BS6644)
CXAP 70/H-100/H boilers
Required area (cm
2
) per kW of total rated input (net)
Boiler room
Enclosure
Low level (inlet)
4
10
High level (outlet)
2
5
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).
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9
INSTALLATION
CASING PACK contains:
·
Front panel ...................... 1 off
·
Side panel ....................... 2 off
·
Top panel......................... 1 off
·
Top support bracket ........ 2 off
·
Flue brush ....................... 1 off
·
Casing hardware pack .... 1 off
Legend
1. Cleanout cover
2. Collector hood
3. Middle section
4. Section alignment rings & 'O' rings
5. End section
6. Gas cock
10. Burner manifold assy.
11. Base plate
12. Combustion chamber
7. Drain cock
8. NOx duct
9. Front plate
5
CONCORD CXAP/H BOILER ASSEMBLY - Exploded view
6
PACKAGING
Check that all these packages are complete and have been
correctly received on site.
Factory assembled boilers are despatched from the works as fully
packaged units comprising:
1. Assembled boiler body (with distributor tube) on a wooden pallet
base enclosed in a wooden crate.
2. Carton containing the casing, fastenings and flue brush.
3. Carton containing the installation pack and instruction books.
4. Carton containing the control box.
INSTALLATION HARDWARE PACK contains:
·
M10 washer ......................................... 4 off
·
Split pin ............................................... 1 off
·
Strain relief bush ................................. 1 off
·
M10 x 25 Hex. Hd. screw .................... 2 off
·
M10 x 35 Hex. Hd. screw .................... 2 off
·
Gasket EPDM Type EP600 ................. 3 off
·
Plug 2" taper Sq.Hd. ........................... 3 off
·
Installation & Servicing Instructions .... 1 off
·
User's Instructions ............................... 1 off
·
Flange RC 1" ....................................... 1 off
·
2" BSP Flange (distributor tube) ......... 1 off
·
2" Installation pipe (handling bars) ..... 2 off
·
Thermostat pockets ............................ 2 off
13. Section bolt
14. Distribution tube
15. Tie rods
16. Thermostat pocket
17. Spillage skirt
18. Gas pipe
Con 1942
Alignment notches
Distribution tube detail
1
2
18
3
4
5
7
8
6
9
10
11
12
13
14
15
16
17
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- Installation and Servicing
INSTALLATION
7
PACKAGING AND BOILER REMOVAL
1. Remove the casing carton and outer packaging frame.
2. Remove the casing pack support frame.
3. Remove the distributor tube pack, controls package and
installation pack.
4. Remove the 2" BSP steel handling bars from the
installation pack.
5. Remove the 4 base bolts holding assembly to the
packaging base.
6. Remove the wood screws securing the front cross
member on the packaging base.
7. Remove the gas cock by unscrewing the union and
screw in the handling bars into the 2 front tappings.
Protect the exposed inlet gas union from ingress of dirt.
8. Knock out the front spacing blocks from the packaging
base, ensuring that the boiler assembly is supported,
using 2" BSP handling bars.
9. Using the handling bars, manoeuvre the boiler forwards
on the packaging base and slide it over collapsing base
on to the floor.
Note. Before manoeuvring the boiler into its final position
see Frame 8
c. Fit the 2 thermostat pockets. Refer to Frame 9.
Note. Frame 9 shows the relationship between
the overheat thermostat and the flow tapping.
d. Complete the water connections by plugging the 2
front top tappings with the 2" BSP plugs provided.
1. Fit the distributor tube (supplied with the boiler) into
one of the return connection. That is one of the rear
lower ports - refer to Frame 5.
Fit the flange, using the M10 x 35mm screws and
washers provided.
Ensure that the notch in the tube flange sits correctly
into the groove on the section and that the 2 sealing
gaskets are correctly assembled on the tube.
2. Fit the 1" tapped flange to the other lower rear
connection, using the gasket and M10 x 25mm screws
and washers provided.
3. Temporarily screw the 2 handling bars (2" pipe) into the
top tappings and manoeuvre the boiler into position.
4. Complete the system connections, using suitable
jointing compound, as follows:
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.
b. 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.
8
BOILER ASSEMBLY
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11
INSTALLATION
Position the overheat thermostat phial into the thermostat
pocket at the opposite side to the flow pipe. The
illustrations below show the rear of the boiler with the flow
and relative overheat thermostat positions.
Ensure that the overheat thermostat phial and control
sensor are correctly secured in the pockets. Refer to
Frame 13.
1. Unpack the control box from its carton and
release the temperature sensing probe strapped
to the back of the box.
The boiler casing should now be fitted.
A casing hardware pack contains all the screws
required for assembly.
2. Slide the bottom of the side panels on to the
location buttons on the base tray.
3. Screw the side panel to support angles. Repeat
for the other side.
9
SYSTEM CONNECTIONS
One flow and return connection should be made to the rear
of the boiler - either on one side or opposite sides.
The distributor tube and gaskets, supplied with the boiler,
must be connected into the pumped return connection.
Refer to Frame 8.
Two 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.
10 FLUE CONNECTION
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.
11 GAS CONNECTION
1. Connect the gas
supply to the gas
inlet pipe at the
rear LH side of the
boiler.
2. Table 2 gives
details of the inlet
connection size
and the minimum
working pressures.
12
CASING ASSEMBLY
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INSTALLATION
7. Route the overheat 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.
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.
13
CASING ASSEMBLY (continued)
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 the side panels. Screw in
self-tapping screws at the bottom of the control box to
fix it to the side panels.
9. Fit earth leads as shown.
Earth connections
GV1 & GV2 earths
Con 2384
9
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13
INSTALLATION
The internal wiring of the boiler control box is shown in Frame
16.
Wiring should be in four core PVC insulated cable, not less
than 0.75mm
2
(24/0.2mm). 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 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 using 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 Frames 13 and 16.
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.
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.
If fitted, a flow switch should be wired between F
1
and F
2
on the terminal plug in connector on the bottom box at the
rear of the control box.
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 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 mains supply to the boiler must be wired to the boiler
terminals L1, N and Earth on the plug-in term13inal 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.
If the downdraught flue thermostat is to be fitted then the
link (marked TTB) should be removed from the plug in
connector.
14 ELECTRICAL CONNECTIONS
15 CONTROLS ASSEMBLY
Remove the 2 screws from the box at the bottom of the
control box back panel and push in the terminal plug-in
connector containing the gas valve wiring harnesses;
secure with the 2 screws.
Fit the earth terminals to the earth post at the left hand
side of the control box back panel.
Undo the 2 screws securing the control box front panel
and carefully lower it. Undo the stress relief clamp
situated on the LH side of the control box above the
grommeted hole.
Free the sleeving containing the spark electrode lead
and the flame detector lead and pass the terminals
and sleeving through the grommetted hole; connect
them to the appropriate terminals of the S4561B1054
PCB; refer to wiring diagram Frame 16.
Refit the stress relief clamp ensuring that the sleeving
passes through the clamp before tightening.
Flame detector lead
terminal
Spark electrode lead
terminal
PCB S546B1054
Grommetted hole
Con 1966
Stress
relief
clamp
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Concord CXAP/H
- Installation and Servicing
INSTALLATION
16 INTERNAL WIRING
br brown
r
red
LEGEND
b blue
bk black
y yellow
w white
y/g yellow/green
or orange
v violet
pk pink
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Installation and Servicing
15
INSTALLATION
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
other means of control detailed on other sheets.
17 ZONES WITH BI-DIRECTIONAL MOTORISED VALVES
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. At
the start of the next call for heat (or the next clock period)
valves on zones not calling for heat will motor shut.
L1
L2
X2
CXAP/
H
CXAP boiler terminal connections
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- Installation and Servicing
INSTALLATION
19 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
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.
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.
For each zone (except Zone 1) a relay
with 2 C/O contacts is 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.
When the clock period ends, Zone valve 1 will (stay) open via normally
closed relay contacts to achieve pump overrun.
18 ZONES WITH INDIVIDUALLY PUMPED ZONES (3 zones shown)
L1
CXAP/H boiler terminal connections
L2
X2
CXAP/
H
CXAP/
H
L1
CXAP/H boiler terminal connections
L2
X2
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Installation and Servicing
17
INSTALLATION
20 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 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.
TESTING FOR GAS SOUNDNESS
Close the gas supply cock at the meter.
Remove the screw in the inlet pressure test point (Frames
20/21) and connect a gas pressure gauge to the test point.
Take particular care to ensure a gastight connection. Open
the gas supply cock at the meter and the 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.
21 INITIAL LIGHTING
1. Check that the boiler thermostat knob on the control box is
'OFF'.
2. Ensure that the main gas inlet cock is open (groove in the
square head in line with the pipe).
3. Press in the overheat reset button.
4. Switch on the electrical supply to the boiler.
5. Turn the boiler thermostat knob on the control panel to number
6.
6. If the boiler does not light at the end of its ignition period, the
LEGEND
1. Thermostat knob
2. Main gas inlet cock
3. Overheat thermostat
reset button
lockout light will be illuminated. Press in and release the
lockout reset button on the control box. The controls will
reset and after a period of time will attempt to relight.
7. Once the pilot has lit, the controls will open the main gas
valves and the main burners will light. The burner on light
will be illuminated.
8. When the boiler has lit, check all connections for tightness
using leak detection fluid.
9. Set the boiler thermostat knob to the required setting.
10. Turn off the electrical supply to the boiler at the mains.
4. Lockout light
5. Lockout reset button
6. Burner on light
7. Control box
1
6
5
4
8
2
7
9
8. Control panel
9. Main gas control valve
10. Manifold pressure setting adjuster
11. Overheat light
11
2
9
3
Con 1967
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- Installation and Servicing
INSTALLATION
22 MANIFOLD GAS PRESSURE
The manifold setting pressure must now be checked against
the values given in Table 2.
No adjustment should be necessary if a pressure regulator
complying with the requirements of BS.3016, providing an
outlet pressure of 37.0 mbar (14.9 in. w.g.), is used.
Burner pressure adjustment can only be achieved externally
to the appliance. Do not attempt to interfere with the gas valve
governor setting, which is factory sealed.
Check for any gas leaks around the test point with a suitable
leak detection fluid.
Check there is no spillage of combustion products from
the boiler draught diverter by carrying out a spillage test,
as detailed in BS. 5440:1.
23 SPILLAGE CHECK
24 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 and pilot burner by turning
off the main gas inlet cock.
2. The controls will go to lockout almost immediately and
the lockout light on the control panel will light.
3. Turn the gas cock again, and press in and release the
lockout reset button on the control box. After a period of
time the controls reset the boiler and it will relight.
4. Complete the commissioning section of the boiler log
book.
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
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 demonstration 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 Installation and Servicing Instructions, User's
Instructions and Log book 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.
After servicing complete the service section of the log book and
return to the owner or their representative.
Recommend that a contract for this work should be made with
the regional gas authority or a CORGI registered heating installer.
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Concord CXAP/H -
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19
SERVICING
CLEANING THE BOILER. Refer to Frame 5
Pull and lift off the lower front panel and top panel from the boiler
casing.
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.
Undo the 4 wing nuts securing the burner front plate. Pull the
front plate forwards, at the top, and lift it out - taking care not to
damage the insulation.
The centre and RH burners can be lifted out after they have
been pushed back to clear the injector.
To remove LH burner the pilot gas pipe connection at the gas
valve must be removed. The LH burner may now be removed by
pushing it back to clear the injector and lifting it out. To remove it
away from the boiler, the flame detector lead and spark lead
must be disconnected in the control box.
Remove the 2 screws securing the control box door, lift it and
carefully drop it down. Pull off the flame detector lead and the
spark electrode lead connections from the S4561B1054 PCB
(the LH board). Undo the strain relief clamp and feed the sleeved
leads out of the box. The burner can now be fully removed from
the boiler.
Undo the screws securing the cleanout cover and lift it off to give
access to the flue ways. Lift out the flue baffles.
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.
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 pilot pipe, electrodes and
leads.
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 the local
Gas Region or a CORGI registered heating installer.
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.
Plan view showing the pilot and electrode positions
4mm
Pilot draught
shield
Main burner
flame port
Flame detector
electrode
Spark
electrode
3 - 4mm
Spark gap
Pilot burner
Inspect the pilot burner, injector, ignition electrode, and flame
detector electrode. Ensure that they are clean and in good
condition. In particular, check that:
1. The pilot burner is firmly secured.
2. The pilot shield is clean and correctly positioned.
3. The ignition electrode and lead are clean, undamaged,
secure and correctly dimensioned. Refer to plan view
below.
4. The flame detector electrode and lead is clean,
undamaged, secure and correctly dimensioned. Refer
to plan view below.
5. The pilot burner head is clean and undamaged.
27 SERVICING
Refit the LH burner, ensuring that the flame detector lead is
properly connected. Reconnect both electrode leads at the
S456A1054 PCB in the control box. Ensure the sleeving
passes through the strain relief clamp before refastening it.
Refit the centre and RH burners. Ensure that care is taken
not to damage the combustion chamber insulation and that
the burner front plate fits beyond the burner retaining returns
when it is refitted.
Refit the flue baffles, clean out cover, NO
X
ducts, control box
door, casing top and front panels.
Con 1943
NOx duct
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Concord CXAP/H
- Installation and Servicing
SERVICING
29 REPLACEMENT OF COMPONENTS - Refer to Frames 5, 23, 34 and 35
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.
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'.
1. Remove the LH burner as previously described in Frame
26.
2. Remove the 2 screws securing the control box front
panel, lift it and carefully lower it.
3. Remove the flame detector lead and the spark lead
connections from the S4561B1054 PCB in the control
box. Undo the strain relief clamp and pass the sleeved
wires through the grommeted hole in the back panel.
4. Remove the spark electrode by undoing the back nut.
Pull off the flame detector lead connection and unscrew
the electrode.
5. Undo the pilot pipe connection and undo the 2 screws
retaining the pilot burner and remove it.
6. Fit the new pilot burner, ensuring that it faces towards the
front of the burner and that the pilot injector is in position
before connecting the pilot pipe.
7. Reassemble in reverse order, ensuring that the spark
electrode lead passes through the sleeving and that the
sleeving passes through the strain relief clamp in the
control box before retightening.
30 PILOT BURNER ASSEMBLY
1. Remove the LH burner as previously described in
Frame 27.
2. Remove the 2 screws securing the control box front
panel, lift it and carefully lower it.
3. Remove the spark lead and flame detector lead
connection from PCB S4561B1054 in the control box.
Undo the strain relief clamp and pass the sleeved
wires through the grommeted hole in the back panel.
4. Remove the spark electrode by undoing the back nut.
5. Fit the new electrode and reassemble in reverse
order, ensuring that the spark electrode lead passes
through the sleeving and that the sleeving passes
through the strain relief clamp in the control box
before retightening. Ensure that the push-on
connections are as follows (from left to right): spark
electrode, blank, earth, flame detector.
31 SPARK ELECTRODE AND LEAD
28 SERVICING - continued
Pilot burner
Pilot draught shield
Fixing screw (2)
LH burner
Flame detector
electrode
Spark electrode
Backnut
Flame detector
lead
Pilot burner
Fixing screw (2)
LH burner
Flame detector
electrode
Spark electrode
Backnut
Flame detector
electrode
Pilot draught shield
TESTING AFTER SERVICING
After re-assembly, restore the electricity and gas supplies.
Light the boiler (refer to the Lighting and Operating Instruction
Label on the inside of the casing front panel) and check the
gas connections for tightness, as detailed under `Testing for
Gas Soundness' - Frame 20.
Check gas pressures as instructed in Frame 22
`Manifold Gas Pressure' and 'Testing'. Adjust any time and
temperature controls to User's requirements and remember
to reset any time control, which may have been switched off,
to the correct time of day.
Refit the lower front panel.
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21
SERVICING
33 GAS CONTROL VALVE
1. Undo the pilot gas pipe connection at the gas control
valve (if required).
2. Undo the screws securing the electrical plugs on the
gas valve and lift them off.
4. Check that the gas inlet cock is OFF, unscrew the 4
screws from the inlet flange, and the 4 screws from
the outlet flange and remove the valve.
(CXAP 90/H/100H, loosen the other 4 screws on the
inlet flange securing the other gas valve).
5. 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.
6. Ensure that a new `O' ring seal is correctly placed in
each flange connection.
7. Test for gas soundness.
34 MAIN BURNERS
1. Remove the NOx duct and burner front plate, as
previously described in Frame 27.
2. Both RH and centre burners can be removed by sliding
each one back to clear the injector, and then lifting out.
3. To exchange the LH burner remove it from the boiler as
previously described in Frame 27. Remove pilot burner
as described in Frame 30.
4. Fit the new LH burner and the centre and RH burners.
Note. Ensure that the pilot burner is correctly fitted, i.e.
facing the front, and that the pilot injector has not been
omitted.
7. Reconnect the pilot gas pipe connection to the gas
valve.
IMPORTANT. Care must be taken to prevent damage to the
combustion chamber insulation when replacing burners.
1. Remove the LH burner as previously described in
Frame 27.
2. Pull off the lead at the electrode and unscrew the flame
detector electrode.
3. Fit the new electrode and reassemble in reverse order.
4. To change the lead, remove the 2 screws securing the
control box front panel, lift it and carefully lower it.
Remove the flame detector lead and spark lead
connection from PCB S4561B1054 in the control box,
undo the strain relief clamp and pass the sleeved wires
through the grommeted hole in the back panel.
5. Pull the lead through the sleeving. The new lead must
be passed through the sleeving small fitting first.
6. Reassemble in reverse order ensuring that the sleeving
passes through the strain relief clamp before tightening.
Ensure that the push-on connections are as follows
(from left to right): spark electrode, blank, earth, flame
detector.
32 FLAME DETECTOR AND LEAD
Pilot burner
Fixing screw (2)
LH burner
Flame detector
electrode
Spark electrode
Backnut
Flame detector
electrode
Pilot draught
shield
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Concord CXAP/H
- Installation and Servicing
SERVICING
LEGEND
1.
Main gas inlet cock
2.
Gas inlet union
3.
Gas control valve
4.
'O' ring seal
5.
Gas inlet manifold
6.
Main injector, 3 off
7.
RH burner
8.
Centre burner
9.
LH burner
10. Overheat thermostat
11. Mounting brackets
12. Pilot draught shield
13. Flame detector electrode
14. Spark electrode
15. Pilot gas pipe
16. Pilot burner
PTP pressure test point
35 BURNER AND CONTROLS ASSEMBLY - Exploded View CXAP 40/H - 80/H
36 BURNER AND CONTROLS ASSEMBLY - Exploded View CXAP 90/H - 100/H
LEGEND
1.
Main gas inlet cock
2.
Gas inlet union
3.
Gas control valves
4.
'O' ring seal
5.
Gas inlet manifold
6.
Main injector, 3 off
7.
RH burner
8.
Centre burner
9.
LH burner
10. Overheat thermostat
11. Mounting brackets
12. Pilot draught shield
13. Flame detector electrode
14. Spark electrode
15. Pilot gas pipe
16. Pilot burner
PTP pressure test point
Con 1970
11
10
1
2
3
4
5
7
8
9
12
13
6
14
15
16
Con 1969
11
10
1
2
3
4
5
7
8
9
12
13
6
14
15
16
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23
SERVICING
38 CONTROL SENSOR
POTENTIOMETER ASSEMBLY
1. Undo the thermostat knob retaining screw and
pull off the knob.
2. Remove the lower front panel. Refer to Frame
27.
3. Undo the 2 screws securing the control box front
panel. Carefully lift it up and lower it.
4. Undo the backnut and washer retaining the
potentiometer and pull the plug from the PCB.
Pull off the connections on the potentiometer.
5. Fit the new potentiometer and reassemble in
reverse order, ensuring that the connections on
the back of the potentiometer are made to either
the top 2 or the bottom 2 tags and that the lug on
the potentiometer body locates through the hole
in the front panel of the control box.
37 OVERHEAT THERMOSTAT
39 CONTROL SENSOR
3. Slacken the 2 screws securing the control box front
panel, lift it and carefully lower it.
4. Pull out the sensor plug from the printed circuit board
and release cable clamp from the back panel.
5. Pull the sensor lead through the grommeted hole in
the back panel and the wire clips.
6. Fit the new sensor and reassemble in reverse order,
ensuring that the lead is rerouted along the casing in
the clips provided.
1. Remove the lower front panel and top panel. Refer to
Frame 27.
2. Remove the sensor from the thermostat pocket in the rear
heat exchanger section by removing the Heyco bush.
Sensor
pocket
sensor
lead
Heyco
bush
Overheat
thermostat
Reset
button
1
CON5231
1. Remove the split pin
from the overheat
thermostat pocket
and remove the phial.
2. Unclip the capillary
from its clips on the
casing side panel.
3. Loosen the 2 x M3
screws and remove
the thermostat
assembly from its
fixing bracket.
4. Undo the screw and
remove the cover.
5. Remove the wires.
6. Undo the backnut
and remove the
thermostat.
7. Fit the new
thermostat and
secure with the
backnut.
8. Reconnect the wires as follows:
1. Pink
2. White
3. Red
Reconnect the earth terminal
9. Reassemble in reverse order.
Con 1500
PCB
Plug
Potentiometer
Backnut
Thermostat knob
Printed circuit
board
Con 1968
Cable clamp
Sensor plug
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Concord CXAP/H
- Installation and Servicing
SERVICING
40 CONTROL BOX - Basic Boiler, Exploded View
LEGEND
1.
Wiring clamp.
2.
Connection box plug.
3.
Connection box.
4.
PCB No W4115A1020
5.
Terminal strip
6.
Back panel
7.
Lockout reset button
8.
Thermostat knob
9.
Potentiometer
10. Warning light lens
11. Controls box
12. PCB No.S4561B1054
41 PC BOARD NO. S4561B1054
1. Remove the lower front panel.
2. Undo the 2 screws securing the control box front
panel. Carefully lift it up and lower.
3. Pull off the 2 plugs and 3 push-on connections
from the board. The board can now be removed
by squeezing in the retaining barbs.
4. Re-assemble in reverse order, ensuring that the
push-on connections are as follows (from left to
right): spark electrode, blank, earth, flame
detector.
Printed circuit board support detail
11
1
2
3
12
5
8
9
Con 1911
1
2
10
4
6
7
Earth connection
Flame detector connection
PCB
Retaining
barbs
Con
1963
Plugs
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25
43 COMBUSTION CHAMBER INSULATION 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 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.
Prior to removal of the boards the
following protective equipment should
be worn:
· Face mask supplied with the spare part.
· 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.
SERVICING
42 PC BOARD NO. W 4115A1020
1. Remove the lower front panel.
2. Undo the 2 screws securing the control box front
panel. Carefully lift it up and lower it.
3. Pull off the 4 plugs from the board.
4. The board can now be removed by squeezing in the
retaining barbs.
5. Fit the new board in reverse order.
PCB
Retaining barbs
Con 1910
Plugs
Plugs
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SITE ASSEMBLY
44 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS
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.
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.
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 forward from the top and lift it out.
2. The right and centre burners may now be lifted out after
they have been pushed back to clear the injector.
3. In order to remove the left hand burner, the pilot gas pipe
connection at the gas valve must be removed.
4. The left hand burner may now be removed by pushing it
back to clear the injector and lifting it out - taking care not
to damage the pilot gas pipe while the burner is out of the
appliance.
5. Undo the nut securing the manifold assembly to the
combustion chamber, pull the manifold assembly to the
right and lift out.
GENERAL
The installation of the boiler must be in accordance with the
Gas Safety (Installation and Use) Regulations or rules in
force, building regulations, I.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 Region and local authority.
Legend
1. Cleanout cover.
2. Collector hood.
3. Middle section.
4. Section alignment
rings & 'O' rings.
5. End section.
6. Gas cock.
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. Thermostat pocket.
17. Spillage skirt.
18. Gas pipe.
Con 1942
Alignment notches
Distribution tube detail
1
2
18
3
4
5
7
8
6
9
10
11
12
13
14
15
16
17
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27
SITE ASSEMBLY
45 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS - continued
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 injectors and pull forward to engage.
19. Fit the support angles (contained in the platework
package) to the collector hood. The angle with the hole
for the earth screw fits to the front.
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, Frame 44
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 recess.
7. Lift a middle section onto the combustion chamber and
carefully offer it up to the back 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 recesses 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 BE TAKEN TO
PREVENT the installed section coming apart.
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 lb. ft.).
10. Fit the distributor tube assembly as described in Frame 8.
Fit the drain cock (refer to exploded view in Frame 44).
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 insulation wrap around heat exchanger. Secure with
clips provided.
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.
16. Locate the fibreglass rope in the 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.
20. Fit the gas inlet pipe bracket to the rear support angle, on
the LH side using the self tapping screws.
21. Fit the gas inlet pipe and make good the union between
the gas cock and the valve inlet pipe.
22. Fit the NOx duct, using the reverse procedure to that
shown in Frame 27, and secure with the extended nuts.
23. The boiler is now ready for installation. Go to Frame 8 and
continue the installation from there.
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Concord CXAP/H
- Installation and Servicing
FAULT FINDING
FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING
Allow time to purge any air present.
Ensure that there is gas pressure at the
boiler inlet.
Check that the pilot jet is not blocked.
Is there gas at the pilot burner ?
Is the pilot flame of the correct length ?
NO
Clean or replace.
Is inlet pressure satisfactory ?
Is pilot burner, injector and pipe clean and
undamaged ?
NO
NO
YES
Pilot should now light
Faulty PCB S4561B1054 - replace
NO
NO
YES
Is there a spark at the ignition electrode ?
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:
Check that the gap between the electrode and
pilot burner is 3-4 mm.
Ensure that the H/T lead and the electrode are
sound, clean and undamaged and that the
connections are secure.
Check that the spark generator is operative by
carefully holding an earthed screwdriver 3mm from
the H/T output terminal of PCB S4561B1054 in the
control box with the ignition lead removed and
then switching the boiler on.
Is there a spark across the gap ?
Is the detection electrode, its lead and
connections clean, tight and undamaged ?
Check flame current; expect 1
1
/
2
µ A
Faulty PCB S4561B1054 - replace
Check earth connections
YES
YES
NO
47 PILOT WILL NOT STAY LIT
YES
YES
46 PILOT WILL NOT LIGHT
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 & Servicing Instructions.
Before carrying out fault finding ensure that all external
controls calling for heat and the overheat thermostat have
not operated. There should be 230V ± 10% available at the
control box connection.
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Installation and Servicing
29
FAULT FINDING
FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING
NO
Secure and tighten
NO
48 PILOT LIT BUT NO MAINS GAS
Are the plugs on the gas valve(s) secure
and tight ?
YES
Are the connections at the plug-in terminal strip
at the control box secure ?
Fit new gas valve
NO
YES
Is there 230V ± 10% at the gas valve plug(s) ?
YES
Fit new S4561B1054 PCB
NO
Refer to installation instructions for details.
49 BOILER GOES OUT ON OVERHEAT THERMOSTAT
Are the thermostat sensors in their correct
pockets ?
YES
Is there an unswitched live supply to terminal L1
on the plug in terminal connection at the
control box ?
Is the pump (or shunt pump) wired to terminal
L2 in the control box ?
NO
YES
Is there sufficient open circuit water volume
or load available on boiler shut down for the
pump overrun ?
YES
Refer to installation instructions
Has boiler thermostat knob been switched to
off ? (this overrides the pump overrun facility)
YES
Advise User
YES
NO
Replace PCB W4115A1020
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Concord CXAP/H
- Installation and Servicing
SHORT LIST OF PARTS
Key No.
Description
Qty.
Product No.
12.4
Boiler body insulation ................................ CXA 40P/H
1
150 093
.................................................................. CXA 50/60P/H
1
150 094
.................................................................. CXA 70/80P/H
1
150 095
.................................................................. CXA 90/100P/H
1
150 096
23
LH main burner ......................................... Worgas 0.087.751 CXA 40P/H
1
150 153
.................................................................. Worgas 0.087.753 CXA 50/60P/H
1
150 154
.................................................................. Worgas 0.087.755 CXA 70/80P/H
1
150 155
.................................................................. Worgas 0.087.757 CXA 90/100P/H
1
150 156
24
Centre & RH main burners ........................ Worgas 0.087.750 CXA 40P/H
2
150 149
.................................................................. Worgas 0.087.752 CXA 50/60P/H
2
150 150
.................................................................. Worgas 0.087.754 CXA 70/80 P/H
2
150 151
.................................................................. Worgas 0.087.756 CXA 90/100P/H
2
150 152
26
Main burner injectors ................................. Size 2.15mm; CXA 40P/H
3
013 569
.................................................................. Size 2.3mm; CXA 50 P/H
3
013 570
.................................................................. Size 2.54mm; CXA 60P/H
3
013 571
.................................................................. Size 2.69mm; CXA 70P/H
3
013 572
.................................................................. Size 2.96mm; CXA 80P/H
3
013 573
.................................................................. Size 3.09mm; CXA 90P/H
3
013 574
.................................................................. Size 3.27mm; CXA 100P/H
3
013 575
27
Pilot burner - HONEYWELL Q 349 A1067 complete with injector
1
077 106
28
Pilot burner injector - HONEYWELL 45004114004B
1
004 590
29
Gas control valve - HONEYWELL V4601 AB 1034
1
154 930
Gas control valve - HONEYWELL VR4605 AB 1019 (CXA 90 - 100)
1
154 931
Gas valve plugs and lead assy. CXA 40 -100P/H
1
154 733
Gas valve plugs and lead assy. CXA 90 -100P/H
1
112 431
Gas valve plugs and lead assy. CXA 90 -100P/H
1
139 269
32
Ignition electrode and HT lead assy.
1
154 967
33
Flame sensing electrode
1
154 818
Boiler status neons .................................... Burner on
1
154 854
.................................................................. Overheat
1
154 855
.................................................................. Lockout
1
154 855
37
Electronic thermostat sensor & lead assembly
1
154 816
38
Thermostat potentiometer assembly
1
154 850
39
Thermostat knob
1
170 859
40
Overheat thermostat
1
155 791
41
Control box assembly, complete
1
157 152
When ordering spare parts please quote:
1. Boiler model
2. Boiler serial no. (refer to the data plate on the combustion chamber)
3. Boiler B.G. P.I. No. (refer to the data plate on the combustion chamber)
4. Description
5. Quantity
6. Product no.
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.
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31
SHORT LIST OF PARTS
Key No.
Description
Qty.
Product No.
42
Printed circuit board S4561B1054
1
154 813
43
Printed circuit board W4115A1020
1
154 815
48
Right hand casing side panel - white stove enamel
CXA 40P/H
1
111 650
CXA 50P/H
1
111 651
CXA 60P/H
1
111 651
CXA 70P/H
1
111 652
CXA 80P/H
1
111 652
CXA 90/100P/H
1
111 653
49
Left hand casing side panel - white stove enamel
CXA 40P/H
1
111 650
CXA 50P/H
1
111 651
CXA 60P/H
1
111 651
CXA 70P/H
1
111 652
CXA 80P/H
1
111 652
CXA 90/100P/H
1
111 653
50
Casing top panel - white stove enamel
CXA 40P/H
1
111 293
CXA 50P/H
1
111 294
CXA 60P/H
1
111 295
CXA 70P/H
1
111 296
CXA 80P/H
1
111 297
CXA 90/100P/H
1
111 298
51
Casing lower front panel - white stove enamel complete with
lighting instructions.
1
171 843
52
Casing upper front control panel (less controls)
1
154 846
53
Casing assembly, complete - white stove enamel
CXA 40P/H
1
157 507
CXA 50P/H
1
157 508
CXA 60P/H
1
157 509
CXA 70P/H
1
157 510
CXA 80P/H
1
157 511
CXA 90/100P/H
1
157 512
55
Reset switch assembly
1
155 269
157293-3.pmd
11/7/2005, 1:56 PM
31
Ideal Boilers, P.O. Box 103, National Ave, Kingston upon Hull,
HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858.
Registration No. London 322 137.
November 2005
UIN 157293 A03
Technical Training
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.
The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic, commercial and industrial
heating installers, engineers and system specifiers. For details of courses please ring: ................ 01482 498 432
Ideal Installer/Technical Helpline: 01482 498 376
www.idealboilers.com
157293-3.pmd
11/7/2005, 1:56 PM
32