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BOILERS
INSTALLATION
& SERVICING
MANUAL
Concord
CXSi 110/H-180/H
157294-3.pmd 1 11/8/2005, 9:58 AM
Installers guide to commercial central heating boilers
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GENERAL 2 Concord CXSi/H - Installation & Servicing 157294-3.pmd 2 11/8/2005, 9:58 AM
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GENERAL Table 1 - Performance Data Boiler CXSi 110/H CXSi 120/H CXSi 140/H CXSi 160/H CXSi 180/H Boiler Input Gross kW 93.9 102.5 119.5 136.6 153.7 Low Rate Btu/h x 1000 320.5 349.6 407.9 466.1 524.4 Nett kW 84.6 92.3 107.7 123.1 138.5 Btu/h x 1000 288.7 315.0 367.4 419.9 472.4 Boiler Input Gross kW 134.2 146.4 170.8 195.2 219.6 High Rate Btu/h x 1000 457.8 499.4 582.7 665.9 749.1 Nett kW 120.9 131.9 153.8 175.8 197.8 Btu/h x 1000 412.4 449.9 524.9 599.9 674.9 Boiler Output kW 110 120 140 160 18
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GENERAL Concord CXSi 110/H-180/H (Natural gas) B.G. Certified - P.I. No. 87/AQ/341 Destination Countries: GB and IE INTRODUCTION CONTENTS CONSTRUCTION BOILER BODY Air Supply......................................................................... 9 The sectional boiler body is of cast iron and is supplied with a sheet steel combustion chamber and integral draught diverter. The boiler Boiler Assembly - exploded view. ............................... 10 is supplied in sectioned form for site assem
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GENERAL FROST PROTECTION WATER CIRCULATION SYSTEM Due to the compact nature of the boiler the heat stored within the Frost protection is incorporated in the boiler as long as there is a castings at the point of shutdown of the burner must be dissipated permanent Live supply wired to Terminal L1 on the terminal plug-in into the water circuit in order to avoid the overheat thermostat connection at the control box and the boiler thermostat knob is not tripping. In order to allow pump operation afte
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GENERAL Graph 2 - Hydraulic Resistance Graph 1 - Heat Load / Water Volume 2 CLEARANCES & DIMENSIONS Table 3 Boiler Size CXSi 110/H CXSi 120/H CXSi 140/H CXSi 160/H CXSi 180/H Front clearance mm (in) 700 (27 1/2) Rear clearance mm (in) 200 (8) Side clearance mm (in) 100 (4) - not including clearance for side fitted flow header Dimension A mm (in) 1036 (40 3/4) 10
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GENERAL PUMP POSITIONS WATER TREATMENT FOR HOT WATER AND Whenever practically possible the circulating pump(s) should be HEATING BOILERS positioned so that it pressurises the system being served. The There is a basic need to treat the water contained in all heating and vertical distance between the pump(s) and any cold feed and indirect water systems, particularly open vented systems. It is expansion cistern MUST comply with the pump manufacturers assumed, incorrectly, that because boilers are o
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GENERAL evaporate a large portion of the system water capacity over a full Limitations of Intended Operating Environment heating season. These appliances are NOT suitable for installation where they will be exposed to the elements. There will always be corrosion within a heating or hot water system to a greater or lesser degree, irrespective of water characteristics, A boiler room shall be constructed or adapted to meet the unless the initial fill water from the mains is treated. Even the wate
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GENERAL CHIMNEY SYSTEM FOUNDATION To ensure the safe and satisfactory operation of the boiler then the The boiler must stand on a non-combustible floor (i.e. concrete chimney system (which may be common or individual, in the case or brick) which must be flat, level and of a suitable load bearing of twin or multiple boiler installations) must be capable of the capacity to support the weight of the boiler (when filled with complete evacuation of combustion products at all times. The water) and any
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INSTALLATION 5 CONCORD CXSi BOILER ASSEMBLY - Exploded view Insulation not shown Legend 8. Distribution tube. 15.Lightback shield. 1. Cleanout cover 9. Downdraught deflector. 16. Burner manifold assy. 2. Collector hood 10. Section bolt. 17. NOx duct. 3. Middle section 11. Drain cock. 18.Insulation bracket 4. Flow header 12. Base plate. 5. Section alignment rings & 'O' rings. 13.Combustion chamber. 6. Thermostat pocket. 14. Tie rods. 7. End section. 10 Concord CXSi/H - Installation & Servicing 15
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INSTALLATION 6 BOILER SECTION ASSEMBLY TOOLS REQUIRED The site assembled boiler is supplied in the following packages: ! Spanners ! Combustion chamber / manifold / burner assembly. ! Torque wrench ! Pozi screwdriver ! Platework package. ! Mallet ! Casing package. ! Controls box package. Section Assembly - refer to the exploded view ! End and centre sections. 5. Take an end section and lift it onto the combustion chamber GENERAL so that the combustion chamber side panel return is inside the secti
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INSTALLATION 7 BOILER SECTION ASSEMBLY - continued 12. Offer the downdraught deflector to the projecting studs at the back of the combustion chamber and fix, using the nuts and washers provided. 13. Fit the insulation brackets with the screws provided to the downdraught deflector. 14. Refit the burner assembly to the combustion chamber and tighten the 4 nuts securing the burner manifold to the combustion chamber legs. Offer up the burner light back sh
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INSTALLATION 8 BOILER ASSEMBLY 1. Fit the distributor tube into the selected return connection. 5. Complete the system connections (using suitable jointing compound) as follows: Ensure that the tube flange aligns horizontally and that the 2 sealing gaskets are correctly assembled on the tube - The cast iron flow header must be fitted in the chosen refer to alignment notches. flow connection which will be either of the 2 top rear tappings. A length of 2" BSP pipe is contained in the Plateware Pa
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Con 1466 INSTALLATION 11 CASING ASSEMBLY 4 3 Legend 2 1. Side panel. 2. Supporting angle. 5 3. Top panel. 1 4. Upper front panel. 5. Control box. 6 6. Bracket. 7 7. Support frame. 8 8. Door panel. 9. Lower panel. 9 1. Fit the support angle to the collector hood and fasten, using the M5 screws and washers. 2. Fit the front fixing bracket(s) to the collector hood and fasten, using the M5 screws and washers through the slotted holes. 3. Fit one side panel over its brackets on the combustion chamber
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INSTALLATION 12 CONTROL BOX 1. Make the 3 electrical connections from the overheat thermostat (fixed to the upper front framework) to the terminals marked 'Limit Stat' on the electrical plug-in connector from the gas valve plug lead assembly, as N/O N/C C follows: C Pink N/O Red N/C White Ensure that the lead is securely fastened under the strain relief clamp - but bring the earth wire outside the clamp before tightening 2. Unpack the control box. Fit the plug-in connector from the gas valve
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INSTALLATION 13 CONTROL BOX - continued 7. Run the flame detector lead through the clips on the front of the combustion chamber base tray and plug it NOx duct into the flame detector electrode on the LH end burner. Ensure that any slack is tucked neatly into the clips then fasten the clips. 8. Unstrap the thermostat sensor lead and run both the sensor and the overheat thermostat phial through the clips on the appropriate casing side panel to the flow header, ensuring that both leads run under th
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INSTALLATION 14 ELECTRICAL CONNECTIONS The boiler can be controlled either by volt-free external contacts To gain access to the inside of the control box remove connected between terminals X1 and X2 or by a switched the 2 M4 screws, lift up the plastic front panel and live supply brought to X2 (after removal of the factory-fitted lower. link between X1 and X2), accompanied in each case by a Connection must be made in a way that allows permanent live supply to terminal L1. complete isolation of t
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BR B BR B BR B BK B O/H L/O ON RESET Note: Diagrammatic only - physical positions not shown TEMPERATURE CONTROL T7335B1051 ON/OFF SWITCH THERMISTOR VOLT-FREE BOARD S4561B1047 (OPTION) W4115AIC1020 missing pin on board P 250 U blanking pin in female half 250 M R L/O HL2 O/H N/C N/O P N PL N NNC N NF HI HD PL PL SL HL1 GV HD ON L/O L/O O/H ON YELLOW VIOLET RED RED BLUE Y/G Y/G B B BR BR CF N/O F12 DET N L5 L3 N N NL L1 T1 T1 X1 X2 N2 N/C L4 PINK RED BR BR LOCKOUT BOILER ON 2 PUMP SUPPLY
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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 ther
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INSTALLATION 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 X2 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 num
