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Concord CXS/H -
Installation & Servicing
GENERAL
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.
Boiler
CXS 40/H
CXS 50/H
CXS 60/H
CXS 70/H
CXS 80/H
CXS 90/H
CXS 100/H
CXS 110/H
CXS 120/H
Number of sections
3
4
4
5
5
6
6
7
7
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)
61.0 (200)
Maximum pressure
bar (p.s.i.)
6.0 (87)
Gas inlet connection
Rc (in. BSP)
3/4 (3/4)
1 (1 )
Min. dynamic gas
mbar gauge
15.5
15.5
16.5
15.0
16.0
17.5
16.0
17.5
17.5
pressure required at boiler inlet in.w.g.
6.2
6.2
6.6
6.0
6.4
7.0
6.4
7.0
7.0
Electricity supply
230 Volts- single phase, 50 Hz, fuse 5 A
Nominal flue size (to BS. 835)
m m
150
150
175
175
200
200
200
250
250
in.
6
6
7
7
8
8
8
10
10
Diverter outlet socket
m m
184
184
213
213
238
238
238
288
288
internal diameter
in.
7.3
7.3
8.4
8.4
9.4
9.4
9.4
11.2
11.2
Length of burner bars (overall)
m m
377
497
497
617
617
737
737
837
837
in
14.8
19.5
19.5
24.3
24.3
29.0
29.0
33.7
33.7
Main burner injectors (3 off)
size, mm
3.4
3.82
4.12
4.57
4.86
5.2
5.3
5.5
5.6
Approximate dry weight
kg
210
265
265
330
330
395
395
490
490
lb.
463
584
584
727
727
871
871
1078
1078
Water content
litre
22
30
30
37
37
45
45
53
53
gal.
4.8
6.6
6.6
8.2
8.2
9.9
9.9
11.5
11.5
Table 1- Performance Data
Table 2 - General Data
Boiler
CXS 40/H
CXS 50/H
CXS 60/H
CXS 70/H
CXS 80/H
CXS 90/H
CXS 100/H
CXS 110/H
CXS 120/H
Boiler Input
Gross
kW
33.8
42.2
50.7
59.1
67.6
76.0
84.5
92.9
101.3
Low Rate
Btu/hr x 1000 115.3
144.1
172.9
201.7
230.5
259.3
288.2
317.0
345.8
Nett
kW
30.4
38.0
45.7
53.3
60.9
68.5
76.1
83.7
91.3
Btu/hr x 1000 103.8
129.8
155.8
181.7
207.7
233.6
259.6
285.6
311.5
Boiler Input
Gross
kW
48.3
60.3
72.4
84.5
96.5
108.6
120.7
132.7
144.8
High Rate
Btu/hr x 1000 164.7
205.8
247.0
288.2
329.3
370.5
411.7
452.8
494.0
Nett
kW
43.5
54.3
65.2
76.1
87.0
97.8
108.7
119.6
130.4
Btu/hr x 1000 148.3
185.4
222.5
259.6
296.7
333.8
370.9
408.0
445.0
Boiler output
kW
40
50
60
70
80
90
100
110
120
High Rate
Btu/hr x 1000 136.5
170.6
204.7
238.8
273.0
307.1
341.2
375.3
409.4
Gas rate
High
m
3
/h
4.60
5.75
6.90
8.05
9.20
10.35
11.50
12.64
13.79
ft
3
/h 162.4
203.0
243.6
284.2
324.8
365.4
406.0
446.6
487.1
Approx. flue
4.5% CO
2
&100°C.m
3
/s
0.04
0.05
0.06
0.07
0.08
0.09
0.10
0.11
0.12
gas volume
4.5% CO
2
& 212°F. ft.
3
/m
85
106
127
148
170
191
212
233
254
Manifold setting pressure
mbar
9.7
9.8
10.2
10.0
9.3
9.6
10.7
11.1
12.1
High
in.w.g.
3.9
3.9
4.1
4.0
3.7
3.8
4.3
4.4
4.8
Manifold setting pressure
mbar
4.8
4.8
5.0
4.9
4.6
4.7
5.2
5.4
5.9
Low
in.w.g.
1.9
1.9
2.0
2.0
1.8
1.9
2.1
2.2
2.4
Part load efficiency (Gross)
%
81.9
81.6
82.7
82.0
82.5
82.5
83.2
83.4
82.4
Seasonal efficiency (SEDBUK)*
[80.4]% [80.3]% [80.4]% [80.4]% [80.4]% [80.4]% [80.4]% [80.4]% [80.4]%
* This value is in the UK government's Standard Assessment Procedure (SAP) for energy rating of dwellings.
The test data from which it has been calculated has been certified by Advantica 0087.
Note. To obtain gas consumption in l/s, divide gross heat input (kW) by a calorific value of 37.8 (MJ/m
3
).
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Concord CXS/H -
Installation & Servicing
GENERAL
CONTENTS
Air Supply. ......................................................................... 8
Boiler Assembly - exploded view. .................................... 9
Boiler Clearances. ............................................................ 5
Burner Assemblies - exploded views. ..............................
CXS 40/H-90/H. .......................................................... 22
CXS100/H-120/H ........................................................ 23
Casing Assembly. ........................................................... 12
Chimney System. .............................................................. 8
Commissioning. .............................................................. 17
Controls. ............................................................................ 4
Electrical Connections. .................................................. 14
Electrical Supply. .............................................................. 8
Fault Finding. ................................................................... 28
Gas Safety Regulations .................................................... 3
Gas Supply. ........................................................................ 8
Hydraulic Resistance. ...................................................... 5
Initial Lighting. ................................................................. 18
Installation. ........................................................................ 9
Mandatory Requirements. ............................................... 7
Option Kits. ........................................................................ 4
Pump. ................................................................................ 6
Servicing. ........................................................................ 20
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. ............................................................ 15
Concord CXS 40/H - 120/H (Natural gas)
B.G. Certified - P.I. No. 87/AQ/103
Destination Countries: GB & 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.
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 CXS 40/H-120/H range of boilers has been tested
and certified by British Gas to prEN656 for use with Natural gas
only.
Multiple boiler installations
The Concord CXS/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
CXS/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. The CXS 40/H, CXS 50/H and CXS 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.
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Concord CXS/H -
Installation & Servicing
GENERAL
Boiler Size
Cold Feed
Open Vent
CXS 40/H - 50/H
3/4
"
1"
CXS 60/H-120/H
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:
Table 3
1
WATER CONNECTIONS
GAS CONTROLS
The boiler lights at Low rate (approximately 70% of Full rate) by
direct burner ignition. After about 1 minute the boiler goes to
High rate and will continue at High rate until the thermostat
sensor set point is reached. The boiler will then drop to the Low
rate; if the temperature continues to rise the boiler will go Off, if
the temperature falls the boiler will revert to High rate.
ELECTRICAL CONTROLS
The boiler is supplied with 2 printed circuit boards; Board
S4561B1047 is the ignition board containing the flame-proving
logic; Board W4115A1020 contains the electronic thermostat and
pump overrun timer. A preset overheat thermostat is also provided.
The mains voltage supply is via a terminal plug in connection at
the control box. The control box displays neons indicating boiler
status as follows:
- Boiler on
- Lockout
- Overheat
A 4 minute anti-cycle delay is built in to the controls to prevent
rapid cycling.
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
0
C the boiler will fire until the temperature reaches 18
0
C.
Note that this is designed to protect the boiler and may not
necessarily protect remote parts of the system.
The mains voltage supply is via a terminal plug-in connection at
the control box.
OPTION KITS
Remote Indication Kit
This kit gives the facility of remote indication of boiler status.
Pressure Gauge Kit
A pressure gauge kit is available.
Downdraught Thermostat Kit
This kit is optional when used on a single CXS/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 the burner shuts down
and, in order to make use of this, the pump must be wired to the
appropriate terminal L2 (pump) in the boiler control box.
1. The minimum flow rate as given in Table 5 must be maintained
whenever the boiler is firing and during the pump overrun
period.
2. During the period of pump overrun there must be an open circuit
of adequate water volume and/or load. The minimum size of
this circuit is given by the use of Graph 1.
Examples shown on Graph 1
a. For the CXS 90/H and CXS 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 CXS 70/H and CXS 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.
The above circuit capacity during pump overrun may be
achieved either by provision of an adequate bypass circuit or
by ensuring that a zone of suitable size is open for circulation
during this period by relevant control of zone valves or pumps.
The wiring diagrams in Frames 16,17 &18 illustrate the control
methods for achieving the above.
3. Pump selection should take account of the hydraulic resistance
given in Graph 2.
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Concord CXS/H -
Installation & Servicing
GENERAL
2
CLEARANCES & DIMENSIONS
Boiler Size
CXS 40/H CXS 50/H CXS 60/H CXS 70/H CXS 80/H CXS 90/H CXS 100/H CXS 110/H CXS 120/H
Front clearance
mm (in)
750 (29
1/2
)
Rear clearance
mm (in)
0
0
0
150 (6)
150 (6)
300 (12) 300 (12) 300 (12) 300 (12)
Side clearance
mm (in)
50 (2)
50 (2)
50 (2)
50 (2)
50 (2)
100 (4)
100 (4)
100 (4)
100 (4)
Dimension A
m m
750
882
882
1042
1042
1212
1212
1385
1385
in
29
1/2
34
3/4
34
3/4
41
41
47
3/4
47
3/4
54
1/2
54
1/2
Dimension B
m m
108
108
122
122
135
190
190
160
160
in
4
1/4
4
1/4
4
7/8
4
7/8
5
3/8
7
1/2
7
1/2
6
1/4
6
1/4
Dimension C
m m
931
931
931
931
931
893
893
893
893
in
36
5/8
36
5/8
36
5/8
36
5/8
36
5/8
35
3/16
35
3/16
35
3/16
35
3/16
Dimension D
m m
177
187
187
224
224
271
271
321
321
in
7
7
3/8
7
3/8
8
7/8
8
7/8
10
5/8
10
5/8
12
5/8
12
5/8
Dimension E
m m
69
79
79
116
116
163
163
213
213
in
2
3/4
3
1/8
3
1/8
4
5/8
4
5/8
6
1/2
6
1/2
8
3/8
8
3/8
Table 4
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 4 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
0
C (150
0
F).
MULTIPLE BOILER INSTALLATIONS
The minimum installation clearances must
conform to the dimensions given below:
CXS 40/H, 50/H, 60/H, 70/H & 80/H
Clearance between boilers = 50mm
Clearance at both ends of the multiple installation = 50mm*
CXS 90/H,100/H, 110/H & 120/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.
10
9
8
7
6
5
4
3
2
1
0
10
20
30
40
50
60
70
80
90
100
12
CON5217
Example A
Example B
CXS 1
10/H & CXS 120/H
CXS 100/H & CXS 90/H
CXS 80/H & CXS 70/H
CXS 40/H
CXS 60/H & CXS 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) - CXS 40/H
11
o
C(20
o
F) - CXS 50/H
11
o
C(20
o
F) - CXS 60/H
11
o
C(20
o
F) - CXS 70/H
11
o
C(20
o
F) - CXS 80/H
11
o
C(20
o
F) - CXS 90/H
11
o
C(20
o
F) - CXS 100/H
11
o
C(20
o
F) - CXS 1
1
0/H
11
o
C(20
o
F) - CXS 120/H
CON5218
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Concord CXS/H -
Installation & 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 & 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 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.
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.
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 5
The system design must provide for an adequate flow rate
through the boiler at all times when the boiler is firing. The
minimum flow rate should correspond to a temperature
difference across the boiler flow and return of 35
o
C (63
o
F),
assessed at catalogue rating.
WATER TREATMENT FOR HOT WATER AND
HEATING BOILERS
There is a basic need to treat the water contained in all heating
and indirect water systems, particularly open vented systems. It is
assumed, incorrectly, that because boilers are operating in
conjunction with what is apparently a closed circuit an open vented
system will not, under normal circumstances, allow damage or
loss of efficiency due to hardness salts and corrosion once the
initial charge of water has been heated up a few times.
1mm of lime reduces the heat transfer from metal to water by
10%.
In practice the deposition of these salts is liable to cause noises
from the boiler body or even premature boiler failure. Corrosion
and the formation of black iron oxide sludge will ultimately result
in premature radiator failure.
Open vented systems are not completely sealed from the
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.
Table 5 - Flow rates for fully pumped systems
Boiler
Minimum flow rates for a
temperature difference of 35
o
C (63
o
F)
l/s
g.p.m.
CXS 40/H
0.28
3.7
CXS 50/H
0.34
4.5
CXS 60/H
0.41
5.4
CXS 70/H
0.48
6.3
CXS 80/H
0.55
7.3
CXS 90/H
0.62
8.2
CXS 100/H
0.68
9
CXS 110/H
0.75
9.9
CXS 120/H
0.82
10.9
3 OPEN VENTED SYSTEMS - Minimum static head requirements
CON5349
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Concord CXS/H -
Installation & Servicing
GENERAL
4
SEALED (PRESSURISED) SYSTEMS
Working pressure 6.0 bar maximum.
Particular reference should be made to BS. 6644: Section 6
and Guidance note PM5 "Automatically controlled steam and
hot water boilers" published by the Health and Safety Executive.
The information and guidance given below is not intended to
override any requirements of either of the 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.
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
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.
The appliance must be installed in a room separated from
living rooms and provided with appropriate ventilation direct to
the outside - see Table 6
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.
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 Sentinel Division,
Tandem House,
Betz Dearborn Ltd.,
Marlowe Way,
Widnes,
Croydon,
Cheshire, WA8 8UD
Surrey, CRO 4XS
Tel. 0151 424 5351
Tel. 0870 601 5000
INSTALLATION REQUIREMENTS
The appliance must be installed by a CORGI registered installer.
The installation of the boiler must be in accordance with the
relevant requirements of the Gas Safety Regulations, current
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 supplier, local authority
and the relevant British Standard Codes of practice and building
regulations.
These appliances are NOT suitable for installation where they will
be exposed to the elements. A boiler room shall be constructed or
adapted to meet the requirements of BS 6644.
The maximum ambient temperature is 32
0
C at 1.5 metres from
the floor with a maximum humidity of 90% RH.
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GENERAL
Position ventilation grilles to avoid the risk of accidental
obstruction by blockage or flooding. If further guidance on
ventilation is required then consult BS.6644 and
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 supplier
should be obtained.
Tests for spillage of products from the draught diverter when
the extractor fan is running and all doors and windows are shut
should be carried out after installation, If spillage is detected,
the area of permanent ventilation must be increased.
CHIMNEY SYSTEM
To ensure the safe and satisfactory operation of the boiler then
the chimney system (which may be common or individual, in
the case of twin or multiple boiler installations) must be
capable of the complete evacuation of combustion products at
all times. The effective height of the chimney terminal(s) above
the boiler outlet(s) must ensure sufficient buoyancy to
overcome the resistance of the bends, tees and runs of the
flue pipe involved and shall terminate in a 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 CXS/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 supplier should be requested.
Installation pipework should be fitted and tested for gas
soundness in accordance with BS. 689:1 IGE-UP-1 for small
installations and IGE-UP-2 for large installations.
The local gas supplier must be consulted if it is necessary to
employ a gas pressure booster.
ELECTRICAL SUPPLY
WARNING. This appliance must be efficiently earthed.
A 230 V - 50 Hz mains supply is required, fused at 5 amps.
Wiring external to the appliance MUST be in accordance with
the I.E.E. (BS. 7671) Wiring Regulations and any local
regulations which apply.
For details of connections see Frame 14.
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 of these grilles must be in
accordance with Tables 6 and 7.
Table 6 - (to BS5440)
CXS 40/H-60/H boilers installed in a room or internal space
Boiler size
Air vent free area cm
2
40
202
50
247
60
304
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 7 - (to BS6644)
CXS 70/H-120/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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INSTALLATION
5
CONCORD CXS/H BOILER ASSEMBLY - Exploded view
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 1855
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
CASING PACK contains
!
Front panel ....................... 1 off
!
Side panel ........................ 2 off
!
Top panel .......................... 1 off
!
Flue brush ........................ 1 off
!
Casing hardware pack ..... 1 off
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
!
Flange RC 1" ..................................... 1 off
!
2" BSP Flange (distributor tube) ....... 1 off
!
2" Installation pipe (handling bars) ... 2 off
!
Thermostat pockets .......................... 2 off
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 installation
pack.
5. Remove 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 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 forward 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
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.
4. Carton containing the control box and instruction books.
7
PACKAGING AND BOILER REMOVAL
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INSTALLATION
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.
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.
8
BOILER ASSEMBLY
1. Fit the distributor tube (supplied with the boiler) into
one of the return connections. 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 tube flange aligns horizontally and that
the 2 sealing gaskets are correctly assembled on the
tube. Refer to alignment notches in Frame 5.
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.
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.
2 thermostat pockets are supplied in the installation pack.
These must be fitted in the 2 top
1/2
" BSP tappings at either
side of the rear of the heat exchanger.
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INSTALLATION
11 GAS CONNECTION
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.
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
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 bottom of the side panel on to the studs on the
base tray.
3. Screw the side panel to the support angle.
Repeat for other side.
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INSTALLATION
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 side panels.
Screw in self tapping screws at the bottom of
the control box to fix it to the side panels.
7. Route the thermostat capillary through the cable clips as
shown.
Ensure the phial is correctly seated in the correct pocket
opposite side to the flow connection. Refer to Frame 9.
Secure with the split pin provided.
8. Route the temperature sensing probe through the
cable clips provided and into the thermostat pocket
adjacent to the flow connection.
Fit the plastic Heyco bush over the sensor lead at the
line shown and insert it into the thermostat pocket.
Ensure that the Heyco bush is correctly located.
9. Fit earth leads as shown
Earth connections
GV1 & GV2 earths
Con 2384
9
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INSTALLATION
14 ELECTRICAL CONNECTIONS
Connection must be made in a way that allows complete
isolation of the electrical supply - such as a double pole
switch, having a 3mm (1/8") contact separation in both
poles, or a plug and socket serving only the boiler and
system controls. The means of isolation must be
accessible to the user after installation.
This should serve only the boiler, together with its controls
and pumps. The 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 main supply to the boiler must be wired to the boiler
terminals L1, N and Earth on the plug-in terminal strip.
This live connection must be unswitched, that is a supply
not interrupted by any automatic temperature or time
control, to enable the pump overrun (and the frost protection
facility) to operate.
Failure to operate this procedure will result in nuisance
overheat thermostat operation.
If a down draught flue thermostat is to be fitted then the
link (marked TTB) should be removed from the plug-in
connector.
The internal wiring of the boiler control box is shown in Frame
15.
Wiring should be 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 conductor between the cord anchorage and
the terminals must be such that the current carrying conductors
become taut before the earthing conductor, if the cable or
cord slips out of the cord anchorage.
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 connection MUST NEVER be omitted.
Wire the earths as shown in Frame 13.
All wiring between entry at the rear of the boiler and the
connection box must be secured neatly under the cable clips
provided.
Wiring must never be allowed to come into contact with the
hot boiler body.
If a flow switch is fitted, it should be wired between F
1
and F
2
or the terminal plug-in connection on the bottom box at the
rear of the control box.
Do not wire these connections in conduit up to the boiler as
this will make it impossible to remove the control box for
servicing or maintenance.
14A ELECTRICAL CONNECTIONS
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 LH side of the
control box back panel.
Check that the flame detector lead is properly connected to the
flame detector electrode on the RH burner.
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INSTALLATION
15 INTERNAL WIRING
y/gyellow/green
or orange
y yellow
w white
br brown
r
red
LEGEND
b blue
bk black
W41
15A1020
T2
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INSTALLATION
16 ZONES WITH BI-DIRECTIONAL 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.
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.
Normal operation
When any thermostat is satisfied while
others are calling for heat, power is
At the start of the next call for heat (or the next clock period)
valves on zones not calling for heat will motor shut.
Water circulation system - refer to page 4
available via relay contacts to close the valve for that zone.
When all thermostats are satisfied (also when the clock period
ends) all relays will be off, so the zone valves which were
open will remain open for the pump overrun period.
17 ZONES WITH INDIVIDUALLY PUMPED ZONES (3 zones shown)
IMPORTANT
Terminal L2 may control the appropriate
pump(s) directly, provided that the total running
or starting current does not exceed 6A
(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.
Water circulation system - refer to page 4
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INSTALLATION
19 COMMISSIONING AND TESTING
GENERAL
Check that all drain cocks are closed, that any stop valves
fitted to the flow and return pipes are open and that the
system has been filled and properly vented.
PURGING
Check that the electricity supply is switched OFF.
Remove the 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 gas-tight 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.
18 ZONES WITH SPRING-RETURN MOTORISED VALVES
IMPORTANT
Terminal L2 may control the appropriate
pump(s) directly, provided that the total
running or starting current does not exceed
6A (resistive or inductive): if this rating would
be exceeded then appropriate switchgear
must be used to control the pumps indirectly.
Three zones are illustrated but the principles
may be extended as required, provided the
above conditions are met. Only one relay is
required, irrespective of the number of zones.
Overrun
During overrun and dormant periods, Zone
Valve 1 is held open. This zone, therefore,
MUST satisfy the conditions in the foregoing
paragraphs and Graph 1.
Normal operation
During a call for heat on Zone 1 only, the
boiler energises via Zone 1 thermostat and
the normally closed contacts of the relay.
During a call for heat on other zone(s), the
relay will be energised by the auxiliary switch
on the zone valves. This provides power to
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.
When the clock period ends, Zone valve 1 will (stay) open via
normally closed relay contacts to achieve pump overrun.
Water circulation system - refer to page 4
X2
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INSTALLATION
LEGEND
1.
Thermostat knob
2.
Control box
3.
Mains inlet gas cock
4.
Overheat thermostat reset button
5.
Boiler on light
6.
Lockout light
7.
Lockout reset button
8.
Manifold pressure adjuster
9.
Gas control valve
10. High burner pressure adjuster
11. High/low solenoid electrical plug
12. Low burner pressure adjuster
13. Manifold pressure test point
14. Overheat light
1. Check that the boiler thermostat knob (1) on the control
box (2) is OFF.
2. Ensure that the mains gas inlet cock (3) is open (groove in
the square head in line with the gas pipe).
3. Press in and release the overheat thermostat button (4).
4. Switch on the electrical supply to the boiler.
5. Ensure that all system controls (time switch, system
controls etc.) are calling for heat.
6. Turn the boiler thermostat knob (1) to position 6.
20 INITIAL LIGHTING
CXS 40/H - 90/H boilers shown
7. The boiler will light at Low rate and the Boiler-on light (5)
will be illuminated. If it does not light the Lockout light (6)
will be illuminated. Press in and release the Lockout
button (7). The controls will reset and attempt to relight.
8. The burner will remain at Low rate for about 1 minute
before going to High rate.
9. Check all connections for gas soundness, using leak
detection fluid.
10. Set the boiler thermostat knob and the system controls to
the required settings.
11. Turn off the electrical supply to the boiler.
1
5
7
6
3
13
2
14
10
12
3
9
11
8
4
Con 1961
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INSTALLATION
4
6
3
5
2
Con 1962
8
7
1
Refit the electrical plugs and the dust and plastic covers.
Failure to follow this procedure may result in the correct burner
pressure being set but the 2 gas valve governors not working
correctly.
CXS 110/H - 120/H Boilers
The setting procedure must be done in 2 steps.
The location of the manifold pressure adjusters (1 & 2) on the
gas valves are shown below. Remove the dust cover and using
a screwdriver screw in the adjuster (1) on the LH gas valve nearly
fully.
Prise off the plastic cover on the High/Low solenoid (3) on the
RH valve and using a suitable spanner set the burner pressure
adjuster (4) to the value given in Table 8 below. Then unscrew
the adjuster (1) on the LH valve until the burner pressure falls
and then reset it to the value given in the Table 8.
Now set the Low burner pressure by unscrewing and removing
the lower electrical plug from the LH gas valve and the High/
Low plug from the RH gas valve. Using a screwdriver turn the
screw (6) within the spindle on the RH valve to set the burner
pressure to the value given in Table 8 below.
Refit the electrical plugs, the dust cover and the plastic cover.
Failure to follow this procedure may result in the burner pressure
being set but the 2 gas valve governors not working correctly.
Table 8 Manifold gas pressure settings
21 MANIFOLD GAS PRESSURE
The manifold setting pressure must now be checked and
adjusted as necessary. It is essential to set the High Pressure
first
Start the adjustment procedure with the system cold, on full
load and with all temperature controls set to maximum to avoid
thermostatic shutdown. Remove the screw in the manifold setting
pressure test point and connect a suitable gas pressure gauge.
Turn on the electrical supply to light the boiler and let it operate
for about 10 minutes to stabilise the burners. Check the pressure
and if it differs noticeably from that given in Table 1 for the
appropriate boiler size adjust it as follows:
CXS 40/H - 90/H Boilers.
Refer to Frame 20 illustration. (Numbers in brackets in this 40-
90 section also refer to Frame 20).
The location of the manifold pressure adjuster (8) on the gas
valve is shown in Frame 20. Prise off the plastic cover on the
gas valve (9) and, using a suitable spanner, set the High burner
pressure adjuster (10) to the value given in Table 1.
Undo the screw retaining the electrical plug (11) on the High/
Low solenoid on the gas valve and pull it out.
Using a screwdriver turn the screw within the spindle to set the
Low burner pressure adjuster (12) to the value given in Table 1.
Refit the electrical plugs and the dust and plastic covers.
CXS 100/H boilers
The setting procedure must be done in 2 steps. The location
of the manifold pressure adjusters (1 & 2) on the gas valve is
shown below. Undo the screw holding the lower electrical plug
on the LH gas valve and pull it off. Prise off the plastic cover on
the High/Low solenoid (3) on the RH valve and, using a suitable
spanner, set the burner pressure adjuster (4) to the value given
in Table 8. Refit the electrical plug and secure with the screw.
Remove the dust cover from the adjuster (1) on the LH gas
valve and set the pressure to the value given in Table 8.
Now set the Low burner pressure by unscrewing and removing
the lower electrical plug from the LH gas valve and High/Low
plug from the RH gas valve. Using a screwdriver, turn the screw
(6) within the spindle on the RH valve to set the Low burner
pressure to the value given in Table 8.
LEGEND
1. Manifold pressure adjuster (LH valve).
2. Manifold pressure adjuster (RH valve)
3. Main gas inlet cock
9
7. Left hand gas control valve.
8. Right hand gas control valve.
9. Manifold pressure test point
3
7
8
4. High burner pressure adjuster (RH valve).
5. High/low solenoid connector.
6. Low burner pressure adjuster (RH valve).
At the end of the adjustment procedure ensure that all
covers are replaced, disconnect the gas pressure gauge
and replace the blanking screw in the manifold pressure
test point.
Boiler
RH valve
LH valve
Low rate
adjustment
and Final
pressure
pressure
adjustment
- mbar
- mbar
pressure
- mbar
CXS 100/H
10.0
10.7
5.2
CXS 110/H
11.6
11.1
5.4
CXS 120/H
12.6
12.1
5.9
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SERVICING
Check the main burner responds correctly to manual on/off operations
of any controls fitted in the gas control circuit.
Check the operation of the flame failure safety system by lighting the
boiler and then turning the gas inlet cock off.
The Burner On light will go out and the controls will try to relight the
boiler. After a period of about 5 seconds, the Lockout light will be
illuminated.
Turn on the gas cock again and press in and release the Lockout
button. The boiler will relight.
Complete the commissioning section of the boiler log book.
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 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 a CORGI
registered engineer.
26 SERVICING
Caradon Ideal Limited does not accept any liability
resulting from the use of unauthorised parts or the repair
and servicing of appliances not carried out in accordance
with the Company's recommendations and specifications.
A comprehensive service should be carried out at least
once a year. The User is advised to make a contract with a
CORGI registered engineer.
WARNING. ALWAYS turn OFF the gas supply at the gas
cock and switch OFF and disconnect the electricity supply
to the appliance BEFORE SERVICING OR REPLACING
ANY COMPONENTS.
CLEANING THE BOILER
Pull and lift off the lower front panel and top panel from the
boiler casing.
23 TESTING
22 SPILLAGE CHECK
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.
When commissioning the heating/domestic
hot water system the shunt pump must be
adjusted to give the minimum flow rate given
in Table 3, when that part of the system
intended to be used for dissipation of
residual heat only is in operation.
24 ADJUSTMENT OF WATER
FLOW RATE THROUGH
THE BOILER
25 HANDING OVER
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SERVICING
27 SERVICING - continued
Unscrew the extended nuts at the top of the NOx duct
behind the control box and lift the NOx duct clear of the
burners as illustrated below.
Undo the wing nuts securing the burner front plate.
Pull the front plate forwards, at the top, and lift it out,
taking care not to damage the insulation or the
detection electrode.
On the CXS 40/H, 50/H & 60/H remove the screws
holding the HT heat shield from the LH leg of the
combustion chamber. Raise slightly and withdraw the
heat shield, taking care not to damage the leads.
The burners may be lifted out after they have been
pushed back to clear the injectors. Take care not to
damage the ignition electrode assembly and carefully
detach the ignition leads when removing the left hand
burner. Take care not to damage the detection
electrode when removing the RH burner.
Undo the screws securing the cleanout cover and lift it
off to give access to the flueways.
(CXS 120/H boiler only)
Remove four M5 securing screws retaining internal
turning baffles from side of collector hood. Slide
turning baffles to rear of collector hood void to facilitate
access to flue ways for cleaning.
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 ignition or detection electrodes.
Inspect the ignition and detection electrodes.
Ensure that they are clean and in good condition.
In particular, check that:
1. The ignition electrode shield and base fixing
screws are tight.
2. The electrodes are correctly positioned. Refer to
Frames 31 or 32.
3. Reassemble in reverse order. Refit, cleanout
cover, NOx duct, and casing panels.
GENERAL
WARNING
ALWAYS turn OFF the gas supply at the gas inlet
cock 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'.
(CXS 120/H boiler only)
Refit collector hood baffles within collector hood using M5
securing screws.
TESTING AFTER SERVICING
After re-assembly, restore the electricity and gas supplies.
Light the boiler. Refer to the Lighting Instructions and also
Frame 19 `Testing for Gas Soundness' .
Check burner manifold pressures (Frame 21) and adjust if
necessary (Frame 21).
Finally, reset any external controls to the desired position.
28 REPLACEMENT OF COMPONENTS - Refer to Frame 5
Con 1944
Baffle
Baffle
4, Baffle screws
4, Cover screws
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SERVICING
15
1
2
3
4
5
6
PTP
PTP
7
9
10
8
13
8
9
11
12
14
CON1960
LEGEND
1. Main gas inlet cock.
2. Gas inlet union.
3. Gas control valve.
4. 'O' ring seal.
5. Spark generator.
29 GAS CONTROL VALVE
31 BURNER AND CONTROLS ASSEMBLY - Exploded View - CXS 40/H - 90/H
30 MAIN BURNER
1. Disconnect the electrical connections to the faulty gas
valve.
2. Turn the gas inlet cock OFF and unscrew the 4 screws
on the outlet flange then unscrew the 4 screws on the
inlet flange.
CXS 90/H -120/H only - loosen the other 4 screws on the
inlet flange securing the other gas valve.
3. Fit the new valve and reassemble in the reverse order,
ensuring that the arrow on the back of the valve points in
the direction of the gas flow and that new 'O' ring seals
are correctly placed in each flange connection.
4. Test for gas soundness.
5. Recommission the appliance and set the manifold
pressures as described in Frames 22 and 23 or 24.
1. Remove the NOx duct and burner front plate, as
previously described in Frame 26 and 27.
2. On the CXS 40/H, 50/H & 60/H remove the screws
holding the HT heat shield from the LH leg of the
combustion chamber. Raise slightly and withdraw the
heat shield, taking care not to damage the leads.
3. Each burner can be removed by sliding back, to clear
the injector, then lifting out. Disconnect the ignition
leads from the LH burner and the detection lead from
the RH burner.
4. Remove the 2 screws securing the electrode assembly
and heat shield to the LH burner bracket and the 2
screws securing the detection electrode bracket to the
RH burner.
5. Reassemble in reverse order.
IMPORTANT. Care must be taken to prevent damage to the
combustion chamber insulation when replacing burners.
6. Burner manifold.
7. Main injector, 3 off.
8. Main burner (centre/RH), 2 off.
9. Main burner (LH), 1 off.
10. Ignition electrodes.
11. Overheat thermostat mounting bracket.
12. Overheat thermostat.
13. Detection electrode assembly.
14. HT leads heat shield.
15. Gas pipe.
PTP
Pressure test point.
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SERVICING
Con 1959
12
13
1
2
3
4
5
6
7
14
9
9
10
10
11
8
32 BURNER AND CONTROLS ASSEMBLY - Exploded View - CXS 100/H - 120/H
33 OVERHEAT THERMOSTAT
LEGEND
1.
Main gas inlet cock.
2.
Gas inlet union.
3.
'O' ring seals.
4.
Gas control valve
5.
Gas control valve
6.
Spark generator
7.
Burner manifold.
8.
Main injector, 3 off.
9.
Main (centre/RH) burner, 2 off.
10. Main (LH) burner, 1 off.
11. Ignition electrodes.
12. Overheat thermostat mounting bracket.
13. Overheat thermostat.
14. Detection electrode assembly.
PTP Pressure test point
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.
Overheat
thermostat
Reset
button
1
CON5232
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SERVICING
34 CONTROL BOX - Basic Boiler, Exploded View
35 CONTROL SENSOR
1. Remove the casing top panel and lower front panel.
2. Remove the sensor from the thermostat pocket in the
rear heat exchanger section by removing the Heyco
bush.
3. Undo the 2 screws securing the control box front
panel. Carefully lift up and lower it .
4. Pull out the sensor plug from the PCB and remove the
strain relief bush. Remove the sensor and lead
5. Fit the new sensor in reverse order, ensuring that the
lead is routed along the casing in the clips provided.
5.
Terminal strip
6.
Back panel
7.
Lockout reset button
8.
Thermostat knob
LEGEND
1.
Wiring clamp.
2.
Connection box plug.
3.
Connection box.
4.
PCB S456B1047
9.
Potentiometer
10. Warning light lens
11. Controls box
12. PCB W 4115A1020
Printed circuit board support detail
11
1
2
3
12
5
8
9
Con 1911
1
2
10
4
6
7
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SERVICING
Earth connection
Flame detector connection
PCB
Retaining
barbs
Con 1910
Plugs
38 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.
35A CONTROL SENSOR POTENTIOMETER ASSEMBLY
1. Undo the thermostat knob retaining screw and pull off the knob.
2. Remove the lower front panel.
3. Undo the backnut and washer retaining the potentiometer.
4. Undo the 2 screws securing the control box front panel, lift it
and carefully lower it.
5. Pull off the connections at the back of the potentiometer and the
plug from the PCB.
6. Fit the new potentiometer and reassemble in reverse order,
ensuring that the connections on the back of the potentiometer
are made either to 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.
36 PC BOARD S4561B1047
1. Remove the lower front panel.
2. Undo the 2 screws securing the control box front panel.
Carefully lift it up and lower it down.
3. Pull off the 2 plugs and the 2 push-on connections from
the board. The board can now be removed by squeezing
in the retaining barbs.
4. Fit the new board and reassemble in reverse order,
ensuring that the push-on connections are correctly fitted,
as follows (from left to right): Earth - flame detector lead.
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. Remove the 4 plugs from the board. The board can now
be removed by squeezing in the retaining barbs.
4. Reassemble in reverse order.
37 PC BOARD W4115A1020
PCB
Retaining barbs
Con 1910
Plugs
Plugs
Con 1500
PCB
Plug
Potentiometer
Backnut
Thermostat knob
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SITE ASSEMBLY
39 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS
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.
The site assembled boiler is supplied in the following
packages:
! Combustion chamber / manifold / burner assembly.
! Platework package.
! Casing package.
! Controls box package with instruction books.
! End and centre sections.
GENERAL
The installation of the boiler must be in accordance with the
Gas Safety (Installation and Use) Regulations 1994,
amendments 1996 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 supplier and local authority.
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 forwards from the top and lift it out.
2. On the CXS 40/H, 50/H & 60/H remove the screws
holding the HT heat shield from the LH leg of the
combustion chamber. Raise slightly and withdraw the
heat shield taking care not to damage the leads.
3. The burners may now be lifted out after they have been
pushed back to clear the injector.
4. Disconnect the electrode leads and take care not to
damage the electrode assemblies.
5. Undo the nut securing the manifold assembly to the
combustion chamber, pull the manifold assembly to the
right and lift out.
Con 1855
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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SITE ASSEMBLY
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 39.
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, Frame 39).
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 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.
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.
40 INSTRUCTIONS FOR SITE ASSEMBLED BOILERS - continued
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.
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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FAULT FINDING
Before attempting any electrical fault finding ALWAYS carry out
the preliminary electrical system checks as detailed in the
Instructions for the British Gas Multimeter or other similar
commercially available meter.
The preliminary electrical system checks are the FIRST electrical
checks to be carried out during a fault finding procedure.
On completion of any service/fault finding task which has
required the breaking and remaking of electrical connections
the following checks MUST be repeated:
a. Earth continuity
b. Polarity
c. Resistance to earth
Detailed instructions on the replacement of faulty components
are contained in the 'Servicing' section of these Installation &
Servicing Instructions.
GENERAL INFORMATION
Anti-cycle will be in operation each time the boiler thermostat is
satisfied and a rapid demand for heat is required. The same
situation will occur if the external controls operate rapidly. This
41 BOILER CONTROL
feature reduces component wear and ensures continuous
trouble free operation. The anti-cycle duration is 4 minutes.
If the system pump, with a maximum current of 3A, is connected
to the boiler pump terminals, pump overrun will be in operation
when the demand for heat is satisfied, and will continue to run
for 6 minutes.
Frost protection is inbuilt with the boiler. If the flow temperature
falls to approximately 5
o
C then the boiler will operate until the
flow temperature exceeds 18
o
C. Note that it is designed to
protect the boiler and may not protect remote parts of the system.
Neither the pump overrun nor the inbuilt frost protection will
operate if the boiler thermostat is switched OFF.
The gas valves operate on High/Low and Off principle. The
boiler will start at low rate and after 1 minute the high rate gas
valve will open. On reaching the set point, determined by the
user, the boiler will go to low rate and when the temperature
reaches the set point plus 3
o
C the low rate gas valve will close.
Should the temperature fall below the set point the boiler will go
back to the high rate.
The full sequence control enables a single ignition attempt
lasting about 5 seconds and will go to lockout if detection does
not take place.
42 SIMPLE FLOW CHART
OF OPERATION
SHUTDOWN
IGNITION
LOW RATE
HIGH RATE
Flame = ON
PUMP OVERRUN
(6 minutes)
Temp at
set point
Flame = ON
(1 minute Low rate)
Overrun
completed
Demand = ON
Temp
> than
set point
4 minutes anti-cycle
Demand
= off
FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING
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FAULT FINDING
F
AUL
T FINDING
Is there a spark at the electrode?
Are the gas valve electrical plugs clean and secure?
43 BOILER DOES NOT LIGHT
Before carrying out any Fault Finding, ensure that all internal controls are calling for heat and that the overheat thermostat has
not operated. There should be 230V ± 10% available at the control box connection.
Is the spark gap approximately 4mm and are the
electrodes, leads and connections clean and secure?
NO
YES
YES
Is there 230V
±
10% at the gas valve plugs?
Is the gas valve inlet pressure sufficient?
Replace the gas valve
YES
YES
Are connections sound at
the plug-on terminal strip
at the control box?
YES
Is there 230V
±
10% at the spark generator
Replace
spark generator
Replace
PCB S4561B1047
YES
YES
44 BOILER LIGHTS BUT GOES TO LOCKOUT
NO
Measure the flame current - expect approximately 3.5
µA
Replace PCB S4561B1047
Check RH burner, inlet and burner pressure; check the
RH burner injector
YES
45 BOILER GOES OUT ON OVERHEAT THERMOSTAT
NO
YES
Is the flame detector and its lead and connections sound
and secure and correctly positioned on the RH burner?
YES
NO
Clean and secure
NO
Are the thermostat sensors in their correct pockets?
Refer to Installation Instructions for details
NO
Is there an unswitched Live supply to terminal L1 on
the plug-on terminal connection at the control box?
YES
YES
Is there sufficient open circuit water volume or load
available on boiler shutdown for the pump overrun?
YES
Is the pump (or shunt pump) wired to terminal L2
in the control box?
NO
Has the boiler thermostat knob been switched to OFF?
Replace PCB W4115A1020
Refer to Installation Instructions for details
YES
Advise USER
FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING FAUL
T FINDING
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SHORT LIST OF PARTS
Key No.
Description
Qty.
Product No.
12.4
Boiler body insulation ........................................................... CXS 40/H
1
150 093
.............................................................................................. CXS 50/60/H
1
150 094
.............................................................................................. CXS 70/80/H
1
150 095
.............................................................................................. CXS 90/100/H
1
150 096
.............................................................................................. CXS 110/120/H
1
154 856
23
Main burner ......................................... Worgas 0.087.751 CXS 40/H
1
150 153
............................................................ Worgas 0.087.753 CXS 50/60/H
1
150 154
............................................................ Worgas 0.087.755 CXS 70/80/H
1
150 155
............................................................ Worgas 0.087.757 CXS 90/100/H
1
150 156
............................................................ Worgas 0.087.761 CXS 110/120/H
1
154 812
24
Main burners ....................................... Worgas 0.087.750 CXS 40/H
2
150 149
............................................................ Worgas 0.087.752 CXS 50/60/H
2
150 150
............................................................ Worgas 0.087.754 CXS 70/80/H
2
150 151
............................................................ Worgas 0.087.756 CXS 90/100/H
2
150 152
............................................................ Worgas 0.087.760 CXS 110/120/H
2
154 811
26
Main burner injectors .......................... Size 3.4 mm;
CXS 40/H
3
111 323
............................................................ Size 3.82mm;
CXS 50/H
3
111 324
............................................................ Size 4.12mm;
CXS 60/H
3
111 325
............................................................ Size 4.57mm;
CXS 70/H
3
111 326
............................................................ Size 4.86mm;
CXS 80/H
3
013 177
............................................................ Size 5.2mm;
CXS 90/H
3
111 328
............................................................ Size 5.3mm;
CXS100/H
3
013 179
............................................................ Size 5.5mm;
CXS110/H
3
157 904
............................................................ Size 5.6mm;
CXS120/H
3
154 840
29
Gas control valves
HONEYWELL VR4605PB 2003 ............................................ CXS 40 - 120/H
1
111 867
HONEYWELL VR4605AB 1019 ............................................ CXS 100 - 120/H
1
111 869
29.7
Gas control valve plug and lead assemblies ...................... CXS 40 - 120/H
1
111 870
.............................................................................................. CXS 40 - 120/H
1
154 734
29.6
.............................................................................................. CXS 100 - 120/H
1
112 431
29.5
.............................................................................................. CXS 100 - 120/H
1
139 269
30
Spark generator assembly
1
112 721
32
Ignition electrode BE/3417/SI
1
112 365
33
Flame detection electrode BE/3459/SI
1
112 364
37
Thermistor (Honeywell)
1
154 816
40
Overheat thermostat
1
155 791
41
Control box assembly - complete
1
154 401
42.1
Printed circuit board S4561B1047
1
154 814
43.1
Printed circuit board S4115A1020
1
154 815
Flame detector lead
1
112 448
Boiler status neon - Boiler ON
1
154 854
Boiler status neon - Overheat
1
154 855
Boiler status neon - Lockout
1
154 855
When ordering spare parts please quote:
1. Boiler model
2. Boiler serial no. (refer to 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
Concord CXS/H -
Installation & Servicing
SHORT LIST OF PARTS
48
RH casing side panel - white stove enamel ............. CXS 40/H
1
111 650
................................................................................... CXS 50/60/H
1
111 651
................................................................................... CXS 70/80/H
1
111 652
................................................................................... CXS 90/100/H
1
111 653
................................................................................... CXS 110/120/H
1
154 898
49
LH casing side panel - white stove enamel .............. CXS 40/H
1
111 650
................................................................................... CXS 50/60/H
1
111 651
................................................................................... CXS 70/80/H
1
111 652
................................................................................... CXS 90/100/H
1
111 653
................................................................................... CXS 110/120/H
1
154 898
50
Casing top panel - white stove enamel .................... CXS 40/H
1
111 293
................................................................................... CXS 50/H
1
111 294
................................................................................... CXS 60/H
1
111 295
................................................................................... CXS 70/H
1
111 296
................................................................................... CXS 80/H
1
111 297
................................................................................... CXS 90/100/H
1
111 298
................................................................................... CXS 110/120/H
1
154 897
51
Casing lower front panel - white stove enamel c/w lighting instructions
1
171 844
52
Casing upper front control panel (less controls)
1
154 846
53
Casing assembly, complete - white stove enamel ... CXS 40/H
1
157 479
................................................................................... CXS 50/H
1
157 480
................................................................................... CXS 60/H
1
157 481
................................................................................... CXS 70/H
1
157 482
................................................................................... CXS 80/H
1
157 483
................................................................................... CXS 90/100/H
1
157 484
................................................................................... CXS 110/120H
1
157 485
55
Reset Switch Assembly
1
155 269
56
Neon Assembly
1
154 969
Key No.
Description
Qty.
Product No.
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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 157291 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
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32