IDEAL INDUSTRIES Concord H CXSi 140 User Manual
INSTALLATION  
& SERVICING  
MANUAL  
Concord  
CXSi 110/H-180/H  
BOILERS  
GENERAL  
Table 1 - Performance Data  
Boiler  
CXSi 110/H  
CXSi 120/H  
CXSi 140/H  
CXSi 160/H  
CXSi 180/H  
Boiler Input  
Low Rate  
Gross  
Nett  
kW  
Btu/h x 1000  
kW  
93.9  
320.5  
84.6  
288.7  
134.2  
457.8  
120.9  
412.4  
110  
102.5  
349.6  
92.3  
119.5  
407.9  
107.7  
367.4  
170.8  
582.7  
153.8  
524.9  
140  
136.6  
466.1  
123.1  
419.9  
195.2  
665.9  
175.8  
599.9  
160  
153.7  
524.4  
138.5  
472.4  
219.6  
749.1  
197.8  
674.9  
180  
Btu/h x 1000  
kW  
315.0  
146.4  
499.4  
131.9  
449.9  
120  
Boiler Input  
High Rate  
Gross  
Nett  
Btu/h x 1000  
kW  
Btu/h x 1000  
kW  
Boiler Output  
High Rate  
Gas rate  
Btu/h x 1000  
m3/h  
375.3  
12.78  
451.5  
0.112  
237  
409.4  
13.95  
492.5  
0.122  
259  
477.7  
16.27  
574.6  
0.142  
301  
545.9  
18.59  
656.7  
0.163  
345  
614.2  
20.92  
738.8  
0.183  
388  
High  
ft3/h  
m3/h  
ft3/h  
Approx. flue At 4.5% CO2 & 100°C  
gas volume At 4.5% CO2 & 212°F  
Burner  
setting  
High  
mbar  
in.w.g.  
mbar  
in.w.g.  
10.4  
4.2  
10.1  
9.7  
9.6  
9.7  
4.0  
3.9  
3.8  
3.9  
pressure  
Low  
5.1  
4.9  
4.8  
4.7  
4.8  
2.0  
2.0  
1.9  
1.9  
1.9  
Part load efficiency  
%
83.0  
81.6  
82.5  
82.9  
82.8  
Note. To obtain gas consumption in l/s divide gross heat input (kW) by a calorific value of 37.8(MJ/m2)  
Table 2 - General Data  
Boiler  
CXSi 110/H  
CXSi 120/H  
CXSi 140/H  
CXSi 160/H  
CXSi 180/H  
Number of sections  
Flow connections  
Return tappings  
Maximum static head  
Maximum pressure  
Gas inlet connection  
7
7
8
9
10  
Rc  
Rc  
65 mm (2 1/2") nominal bore. Flange to BS.4504 (PN6)  
2 x 2  
61.0 (200)  
6.0 (87)  
1 1/2  
m. (ft)  
bar (psi)  
Rc  
Minimum dynamic  
gas pressure  
mbar  
in.  
17.5  
7
17.5  
7
17.5  
7
17.5  
7
17.5  
7
Electricity supply  
230 Volts - single phase, 50 Hz, fuse 5 A  
Nominal flue size (to BS. 835)  
mm  
in.  
250  
10  
250  
10  
250  
10  
250  
10  
300  
12  
Diverter outlet socket  
internal diameter  
mm  
in.  
288  
11.3  
288  
11.3  
288  
11.3  
288  
11.3  
344  
13.5  
Length of burner bars (overall)  
mm  
in  
535  
21.1  
535  
21.1  
535  
21.1  
535  
21.1  
535  
21.1  
Approximate dry weight  
Water content  
kg  
lb.  
538  
1186  
53  
538  
1186  
53  
608  
1340  
60  
678  
1494  
68  
748  
1648  
76  
litre  
gal.  
11.7  
11.7  
13  
15  
17  
Concord CXSi/H - Installation & Servicing  
3
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  
Boiler Assembly - exploded view. ............................... 10  
Boiler Clearances............................................................ 6  
The sectional boiler body is of cast iron and is supplied with a sheet  
steel combustion chamber and integral draught diverter. The boiler  
is supplied in sectioned form for site assembly.  
CASING  
The casing is manufactured in stove enamelled sheet steel and is  
easily assembled on site.  
Burner Assemblies - exploded views. ............................  
CXSi 110/H-160/H. ................................................. 25  
CXSi 180/H. ............................................................ 26  
BURNERS  
The burners are of stainless steel construction.  
Casing Assembly. ......................................................... 14  
Chimney System. ............................................................ 9  
Commissioning. ............................................................ 20  
Electrical Connections. ................................................ 17  
Electrical Supply. ............................................................ 9  
Fault Finding. ................................................................ 29  
Gas Safety Regulations .................................................. 4  
Gas Supply. ...................................................................... 9  
Hydraulic Resistance. ..................................................... 6  
Initial Lighting. .............................................................. 21  
Installation. .................................................................... 10  
Mandatory Requirements. .............................................. 8  
Option Kits. ...................................................................... 5  
Pump. ............................................................................... 7  
Servicing. ....................................................................... 24  
Short List of Parts. ........................................................ 31  
Static Head Requirements. ............................................ 7  
System Connections..................................................... 13  
Ventilation. ....................................................................... 9  
Water Circulation. ........................................................... 5  
Water Connections. ........................................................ 5  
Water Treatment. ............................................................. 7  
Wiring Diagrams. .......................................................... 19  
CURRENT GAS SAFETY (INSTALLATION AND USE)  
REGULATIONS OR RULES IN FORCE.  
It is the law that all gas appliances are installed and serviced by a  
CORGI registered installer in accordance with the above regulations.  
Failure to install appliances correctly could lead to prosecution. It  
is in your own interest, and that of safety, to ensure that the law is  
complied with.  
The Concord CXSi 110/H-180/H range of boilers has been tested  
and certified by British Gas to prEN656 for use with natural gas  
only.  
Note. Concord CXSi 110/H - 180/H boilers are intended for use  
as COMMERCIAL BOILERS and are NOT certified for use in  
domestic applications. A domestic installation is defined as an  
installation where the boiler takes its combustion air from a living  
space or from a room directly or indirectly connected with the  
living space. It is important, therefore, that no external control  
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.  
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  
An anti-cycle delay is built in to the controls to prevent rapid cycling.  
CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of  
this appliance, care should be taken when handling edges of sheet steel components.  
Concord CXSi/H - Installation & Servicing  
4
GENERAL  
FROST PROTECTION  
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.  
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  
50C the boiler will fire until the temperature reaches 180C.  
Note that this is designed to protect the boiler and may not  
necessarily protect remote parts of the system.  
1. The minimum flow rate as given in Table 4 must be maintained  
whenever the boiler is firing and during the pump overrun period.  
The mains voltage supply is via a terminal plug-in connection at the  
control box.  
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.  
OPTION KITS  
Examples shown on Graph 1  
Remote Indication Kit  
This kit gives the facility of remote indication of boiler status.  
a. For the CXSi 110/H and CXSi 120/H the minimum circuit  
during pump overrun could be a load of 7 kW with a volume  
of 42 litres or any other combination given by the relevant  
line.  
Pressure Gauge Kit  
A pressure gauge kit is available.  
b. For the CXSi 180/H the minimum circuit during pump overrun  
could be a load of 9 kW with a volume of 70 litres or any  
other combination given by the relevant line.  
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.  
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.  
Fully pumped systems may be open vented or sealed.  
The range of boilers is NOT suitable for:  
The wiring diagrams in Frames 16,17 &18 illustrate the control  
methods for achieving the above.  
1. Gravity DHW systems.  
2. Gravity heating systems.  
3. Direct domestic hot water supply.  
3. Pump selection should take account of the hydraulic resistance  
given in Graph 2.  
1
WATER CONNECTIONS  
Cold Feed/Open Vent  
Flow connection is 65mm (2 1/2") nominal bore flange to  
BS.4504 (PN6)  
The independent cold feed and the open vent must comply  
with BS. 6644 and be of the following minimum size.  
Return tappings are 2" BSP.  
The distributor tube must be fitted into the return connection.  
The flow header must be fitted in the flow pipe.  
The open vent must be brought to either the 1 1/2" BSP tapping  
on the flow header or to the unused 2" BSP tapping at the top  
rear of the boiler.  
The cold feed may be brought to the LH front bottom tapping in  
order to avoid excessive surging or pumping over. The unused  
bottom rear tapping must not be used for the cold feed pipe as  
it is practically blocked by the distributor tube.  
Safety Valve  
A safety valve must be sized and fitted in accordance with BS.  
6644 for every type of system. The valve should be set at 0.7  
bar (10 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).  
Boiler Size  
CXSi 110/H  
CXSi 120/H  
CXSi 140/H  
CXSi 160/H  
CXSi 180/H  
Cold Feed  
Open Vent  
1 1/4"  
1"  
1"  
1 1/4"  
1"  
1 1/4"  
1 1/4"  
1 1/4"  
1 1/2"  
1 1/2"  
Concord CXSi/H - Installation & Servicing  
5
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  
700 (27 1/2)  
200 (8)  
CXSi 160/H  
CXSi 180/H  
Front clearance  
Rear clearance  
Side clearance  
Dimension A  
Dimension B  
Dimension C  
Dimension D  
Dimension E  
Dimension F  
mm (in)  
mm (in)  
mm (in)  
100 (4) - not including clearance for side fitted flow header  
mm (in) 1036 (40 3/4) 1036 (40 3/4)  
mm (in) 175 (7) 175 (7)  
mm (in) 1107 (43 3/4) 1107 (43 3/4)  
1036 (40 3/4)  
175 (7)  
1086 (42 3/4)  
197 (7 3/4)  
1140 (45)  
250 (10)  
1230 (48 1/2)  
939 (37)  
1353 (53 1/4)  
1062 (42 3/4)  
676 (26 5/8)  
220 (8 5/8)  
1476 (58 1/8)  
1185 (46 5/8)  
738 (29)  
mm (in) 816 (32 1/8)  
mm (in) 553 (21 3/4)  
mm (in) 220 (8 5/8)  
816 (32 1/8)  
553 (21 3/4)  
220 (8 5/8)  
615 (24 1/4)  
220 (8 5/8)  
320 (12 1/2)  
1
POSITION OF BOILER  
Minimum clearances required from walls or other fixed  
objects to allow for the free access of combustion air are  
shown in Table 3 above.  
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 0C (150 0F).  
Concord CXSi/H - Installation & Servicing  
6
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  
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.  
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.  
MINIMUM FLOW OF WATER - Refer to Table 4  
The system design must provide for an adequate flow rate through 1mm of lime reduces the heat transfer from metal to water by 10%.  
the boiler at all times when the boiler is firing. The minimum flow  
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.  
rate should correspond to a temperature difference across the boiler  
flow and return of 35°C (63°F), assessed at catalogue rating.  
Table 4 - Flow rates for fully pumped systems  
Open vented systems are not completely sealed from the  
atmosphere if proper venting and expansion of system water is to  
be achieved. The same tank is used to fill the system with water  
and it is through the cold feed pipe that system water expands into  
the tank when the boiler passes heat into the system. Conversely,  
when the system cools, water previously expanded is drawn back  
from the tank into the system, together with a quantity of dissolved  
oxygen.  
Boiler  
Minimum flow rates for a  
temperature difference of 35°C (63°F)  
l/s  
g.p.m.  
CXSi 110/H  
CXSi 120/H  
CXSi 140/H  
CXSi 160/H  
CXSi 180/H  
0.75  
0.82  
0.96  
1.10  
1.24  
9.9  
10.8  
12.7  
14.6  
16.4  
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  
3
OPEN VENTED SYSTEMS - minimum static head requirements  
The information provided is based on the  
following assumptions:  
1. The open vent MUST be brought to either  
the 1 1/2" BSP tapping on the flow header  
provided or to the unused 2" BSP flow  
tapping at the top rear of the boiler.  
2. An independent cold feed/expansion pipe  
connection is made to the LH lower front  
connection. 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.  
Note. This diagram does not show safety valves, water flow  
switches, etc., necessary for the safe operation of the system.  
Particular reference should be made to BS. 6644: Section 2; Subsection  
10 and Guidance note PM5 "Automatically controlled steam and hot  
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.  
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.  
Other British Standards applicable are BS.5422 and BS.6700.  
Concord CXSi/H - Installation & Servicing  
7
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,  
unless the initial fill water from the mains is treated. Even the water  
in closed systems will promote corrosion unless treated.  
A boiler room shall be constructed or adapted to meet the  
requirements of BS 6644.  
The maximum ambient temperature is 32 °C at 1.5 metres from the  
floor with a maximum humidity of 90% RH.  
For 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.  
FOR SMALL PIPE INSTALLATIONS;  
BS. 6891:  
Installation of low pressure pipework  
Caradon Ideal Limited advise contact directly with specialists on  
water treatment such as:  
FOR LARGE PIPE INSTALLATIONS  
Gas Installations  
Fernox Manufacturing Co. Ltd.,  
Tandem House, Marlowe Way  
Croydon.  
Surrey CRO 4XS  
Tel 0870 601 5000  
or  
Sentinel Division,  
Betz Dearborn Ltd.,  
Widnes,  
Cheshire, WA8 8UD  
Tel. 0151 424 5351.  
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).  
SAFE HANDLING OF SUBSTANCES  
Care should be taken when handling the boiler insulation panels,  
which can cause irritation to the skin. No asbestos, mercury or  
CFCs are included in any part of the boiler.  
IGE-UP-10:  
BS.6644:  
Installation of Gas Appliances in Industrial and  
Commercial Premises.  
Installation of Gas Fired Hot Water Boilers  
70kW to 1.8MW (net).  
BS 6880 Pt 1-3: Water Supply.  
INSTALLATION REQUIREMENTS  
The appliance must be installed by a CORGI registered installer,  
CP342:2:  
Centralised Hot Water Supply.  
Model Water Bye-laws  
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.  
Manufacturers notes must not be taken, in any way, as overriding  
statutory obligations.  
The appliance must be installed in a room separated from living  
rooms and provided with appropriate ventilation direct to the outside  
- see Table 5.  
4
SEALED (PRESSURISED) SYSTEMS  
automatic reset. In the event of shutdown both visual and  
audible alarms may be necessary.  
Working pressure 6.0 bar maximum.  
Pressure vessels used must comply with BS. 4814 and must  
be sized on the basis of the total system volume and initial  
charge pressure.  
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.  
Initial minimum charge pressure should not be less than 0.5  
bar (7.2 psi) and must take account of the static head and  
specification of the pressurising equipment. The maximum water  
temperatures permissible at the point of minimum pressure in  
the system are specified in Guidance Note PM5.  
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.  
When make up water is not provided automatically it will be  
necessary to fit controls which shut down the plant in the event  
of the maximum system pressure approaching to within 0.35  
bar (5 psi) of the safety valve setting.  
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.  
Other British Standards applicable to commercial sealed systems  
are:-  
BS. 6880: Part 2  
BS. 1212  
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  
BS. 6281: Part 1  
BS. 6282: Part 1  
BS. 6283: Part 4  
Concord CXSi/H - Installation & Servicing  
8
GENERAL  
CHIMNEY SYSTEM  
FOUNDATION  
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.  
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.  
VENTILATION  
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.  
Safe, efficient and trouble-free operation of conventionally flued gas  
boilers is vitally dependent on the provision of an adequate supply  
of fresh air to the room in which the appliance is installed. Ventilation  
by grilles communicating directly with the outside air is required at  
both high and low levels. The minimum free areas of these grilles  
must be according to the following scale:  
The chimney design should avoid the formation of excessive  
quantities of condensate. For this reason it is recommended that all  
chimneys are insulated and lined. In the case of brick or similar  
structures a stainless steel rigid or flexible flue liner (grade 304/  
316) may be used in conjunction with a 50 mm (minimum) thick  
layer of vermiculite or perlite granules between the liner and the  
inner skin of the chimney body. Liners should be sealed at both top  
and bottom.  
Table 5 - Ventilation Requirements  
Required area (cm2) per kW of total rated input (net)  
Boiler room  
Enclosure  
Low level (inlet)  
4
2
10  
5
High level (outlet)  
As the Concord CXSi/H range of boilers is supplied complete with  
an integral draught diverter, a diverter MUST NOT be fitted within  
the chimney system.  
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).  
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.  
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.  
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.  
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.  
GAS SUPPLY  
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.  
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.  
The requirements for air supply by mechanical ventilation are given  
in BS.6644.  
Installation pipework should be fitted and tested for gas soundness  
in accordance in accordance with BS. 6891;  
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.  
IGE-UP-1 for small installations  
IGE-UP-2 for large installations.  
The local gas supplier must be consulted if it is necessary to employ  
a gas pressure booster.  
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.  
ELECTRICAL SUPPLY  
WARNING. This appliance must be efficiently earthed.  
A 230 V - 50 Hz mains supply is required, fused at 5 amps.  
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.  
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.  
Concord CXSi/H - Installation & Servicing  
9
INSTALLATION  
5
CONCORD CXSi BOILER ASSEMBLY - Exploded view  
Insulation not shown  
Legend  
1. Cleanout cover  
8. Distribution tube.  
9. Downdraught deflector.  
10. Section bolt.  
15. Lightback shield.  
16. Burner manifold assy.  
17. NOx duct.  
2. Collector hood  
3. Middle section  
11. Drain cock.  
18. Insulation bracket  
4. Flow header  
12. Base plate.  
5. Section alignment rings & 'O' rings.  
6. Thermostat pocket.  
7. End section.  
13. Combustion chamber.  
14. Tie rods.  
Concord CXSi/H - Installation & Servicing  
10  
INSTALLATION  
6
BOILER SECTION ASSEMBLY  
TOOLS REQUIRED  
The site assembled boiler is supplied in the following packages:  
!
!
!
!
Spanners  
! Combustion chamber / manifold / burner assembly.  
! Platework package.  
Torque wrench  
Pozi screwdriver  
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  
so that the combustion chamber side panel return is inside  
the section rear lip.  
GENERAL  
The installation of the boiler must be in accordance with current  
Gas Safety (Installation and Use) Regulations or rules in force,  
building regulations, I.E.E. (BS.7671) Regulations and the bye-  
laws of the local water undertaking. It should also be in accordance  
with the relevant British Standard Codes of Practice together with  
any relevant requirements of the local gas supplier and local  
authority.  
6. 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 end section until it engages the  
projecting steel rings. It may be necessary to use a mallet  
and hardwood block to ensure that the steel rings are  
pushed fully into the recessing and that the sections are  
butted up to each other.  
ASSEMBLY  
The combustion chamber should be positioned as near as possible  
to the installation site.  
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 sections coming apart.  
IMPORTANT.  
It must be remembered that the boiler distribution tube has to be  
fitted into the rear return tapping of the assembled boiler before  
final siting.  
8. Repeat the assembly procedure for all of the sections until  
complete.  
Prior to assembling the sections it will be necessary to remove the  
manifold assembly and burners from the combustion chamber. To  
do this:  
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).  
1. Undo the two M5 screws and washers securing the spark  
generator bracket to the combustion chamber. Undo the union  
securing the gas valve assembly and remove the gas valve  
and spark generator assembly from the boiler.  
10. For open vented systems a site test must be carried out at  
a hydraulic pressure equal to 1 1/2 times the design  
pressure given in Table 2, for a period of 30 minutes.  
2. Undo the 4 nuts securing the burner manifold to the combustion  
chamber legs.  
3. Undo the nuts securing the burner light back shield to the  
Note. If it is a sealed system the hydraulic pressure must  
combustion chamber and lift it off.  
be equal to twice the given design pressure for 30 minutes.  
4. Pull the whole burner assembly forward on its runners, ensuring  
that no wires are trapped, and remove it completely from the 11. Fit the 4 coach bolts into the lugs at the bottom of the end  
combustion chamber.  
sections and through the hole in the retaining angle of the  
combustion chamber.  
Fit a flat washer and nut and secure the section assembly  
to the combustion chamber.  
PREPARATION OF SECTIONS  
Each section should be brushed clean on all external surfaces  
and any debris which may have accumulated within the sections  
should be removed via the bottom ports.  
Concord CXSi/H - Installation & Servicing  
11  
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  
shield to the combustion chamber - with the cutout for the  
flame detector electrode at the LH end - and fasten, using  
the M5 nuts and washers.  
spark generator bracket to the combustion chamber  
using the two M5 screws and washers.  
15. Fit the gas valve and spark generator assembly to the boiler  
by doing up the union in the gas line and by fastening the  
16. Fit the gas inlet pipe and retain by the semi-circular  
clamp, screws and washers provided. Tighten both  
unions and the inlet pipe retaining clamp, ensuring  
that the gas valve assembly is vertical.  
17. To fit the collector hood align the back edge of the  
horizontal side returns with the rear of the section  
assembly and fasten down the collector hood (using  
the M6 screws and nuts provided) through the side  
fixing points.  
18. Wrap the insulation around the heat exchanger with  
the foil outside, tuck behind the insulation brackets  
on the downdraught deflector and fasten at the edge,  
using the foil tabs and tape provided.  
19. Fit the NOx ducts into the burner aeration intakes  
and fasten to the collector hood, using the M5  
elongated nuts.  
Note.  
The insulation MUST be behind the NOx ducts (it will be  
compressed behind the ducts.)  
Concord CXSi/H - Installation & Servicing  
12  
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 -  
refer to alignment notches.  
The cast iron flow header must be fitted in the chosen  
flow connection which will be either of the 2 top rear  
tappings. A length of 2" BSP pipe is contained in the  
Plateware Package for this purpose.  
Fit the flow header so that the 1 1/2" vent tapping in the  
header is vertical. Screw the thermostat pocket into one  
of the 1/2" tappings.  
The other 1/2" tapping is used for the pressure gauge  
provided. The flow header terminates in a 2 1/2" flange  
connection.  
The 1 1/2" BSP tapping on the top of the flow header is  
for a vent pipe ONLY and MUST NOT be used for any  
other purpose.  
A safety valve may be fitted in the remaining top rear  
tapping, in accordance with CP332:3.  
The unused top rear tapping may be used as an  
alternative and independent open vent / safety pipe  
connection. The LH front bottom tappings may be used  
for an independent cold feed / expansion pipe  
connection.  
Fit the 2" tapped flange, using the M10 x 35mm screws and  
washers provided.  
2. Fit the blank flange to the other lower rear connection,  
using the gasket and M10 x 25mm screws and washers  
provided.  
In order to avoid air locks, reduction in pipe sizes should  
be made in the vertical plane or eccentric bushes used.  
3. Fit the blank flange to the RH front connection, using the  
gasket and M10 x 25mm screws provided.  
Finally , plug the unused tappings, using the 2" BSP  
plugs supplied.  
4. The 1 1/4" tapped flange and gasket should be fitted to the  
LH front connection with the reducing bush and 1/2" drain  
cock. If the cold feed/expansion pipe is to be brought  
directly to the boiler, the close taper nipple and 1 1/4" tee  
must be fitted so that the drain cock is horizontal. This will  
reduce the possibility of the drain becoming blocked by  
debris.  
10 GAS CONNECTION  
9
FLUE CONNECTION  
1. Complete the secondary flue connection.  
Connect the gas supply to the gas inlet pipe - Table 2 gives  
details of the inlet pipe size.  
The boiler is designed to accept flues to BS.835. If a  
suitable adaptor is used then flues to BS715 may be fitted.  
The use of an approved gas cock and union is  
recommended here.  
2. Seal with an approved boiler putty.  
3. A split socket should be fitted immediately above the  
boiler to facilitate disconnection of the flue.  
Concord CXSi/H - Installation & Servicing  
13  
INSTALLATION  
11 CASING ASSEMBLY  
4
3
Legend  
2
1. Side panel.  
2. Supporting angle.  
3. Top panel.  
5
1
4. Upper front panel.  
5. Control box.  
6. Bracket.  
6
7
7. Support frame.  
8. Door panel.  
9. Lower panel.  
8
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 base  
tray and fasten to the  
support angle, using the  
M5 screw and washer.  
Repeat for the other side  
panel.  
4. Fit the upper front support  
framework with the  
overheat thermostat at the  
bottom and with its green  
button facing to the RH side and secure to the  
front fixing bracket(s), using the M5 screws and  
washers, and to each side panel, using the No.8  
screws.  
Insulation not shown  
5. Fit the 4 shoulder screws into the fixings at the  
bottom of the front return of the casing side  
panels.  
6. Finally, ensure correct alignment by slackening  
and retightening the screws into the slotted holes  
in the front fixing bracket(s).  
Overheat 'stat reset button  
Concord CXSi/H - Installation & Servicing  
14  
INSTALLATION  
12 CONTROL BOX  
1. Make the 3 electrical connections from the overheat  
thermostat (fixed to the upper front framework) to the  
terminals marked 'Limit Stat' on the electrical plug-in  
connector from the gas valve plug lead assembly, as  
follows:  
N/C  
N/O  
C
C Pink  
N/O Red  
N/C White  
Ensure that the lead is securely fastened under the  
strain relief clamp - but bring the earth wire outside  
the clamp before tightening  
2. Unpack the control box. Fit the plug-in connector  
from the gas valve plug lead assembly to the bottom  
box at the back of the control box and fasten, using  
the M4 screws and washer.  
3
3. Fit the control box to the support frame and fix  
to the bottom, using the 2 self-tapping screws  
provided.  
4. Fit the earth connections from the terminal  
plug-in connections to the appropriate earth  
posts on the back of the control box. Connect  
the earth lead prefitted to the control box back  
panel to the threaded hole in the casing support  
frame.  
IMPORTANT  
5. Offer up the spark generator assembly to the  
combustion chamber base tray and secure the  
bracket, using the M5 screws and washers.  
Plug the spark generator leads onto the spark  
electrode connections on the RH end burner -  
access via the side of the combustion chamber.  
Con 1468  
6. Ensure the electrical cover is correctly fastened  
to the spark generator.  
Flame detector lead  
Electrical cover  
5
Spark  
generator  
leads  
6
2 push-in  
connections  
Concord CXSi/H - Installation & Servicing  
15  
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  
into the flame detector electrode on the LH end burner.  
Ensure that any slack is tucked neatly into the clips  
then fasten the clips.  
NOx duct  
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 the support  
angle.  
Flame  
detector  
9. Secure both phials into the thermostat pocket in the  
7
flow header, using the spring clip.  
LH Burner  
8
9
Spring clip  
Overheat thermostat capillary  
Control thermostat lead  
Thermostat pocket  
Earth connections  
10  
10. Fit the earth connections from the  
terminal plug-in connections to  
the appropriate earth posts on the  
back of the control box. Connect  
the earth lead prefitted to the  
control box back panel to the  
threaded hole in the casing  
support frame.  
11. Fit the casing upper front panel  
with its location buttons in the  
slots and push down to locate.  
Fasten at the bottom, using the  
No.8 screws.  
GV1 & GV2 & o/heat  
thermostat earths  
12. Fit the casing lower front panel by  
locating its slots over the  
shoulder screws in the side  
panels and pushing down to  
locate.  
Con 1917  
Concord CXSi/H - Installation & Servicing  
16  
INSTALLATION  
14 ELECTRICAL CONNECTIONS  
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.  
To gain access to the inside of the control box remove  
the 2 M4 screws, lift up the plastic front panel and  
lower.  
Connection must be made in a way that allows  
complete isolation of the electrical supply - such as  
a double pole switch, having a 3mm (1/8") contact  
separation in both poles, or a plug and socket serving  
only the boiler and system controls. The means of  
isolation must be accessible to the user after  
installation.  
If a separate frost thermostat is fitted it must be wired  
across the time switch contacts and if frost is likely the  
system should be turned off using the time switch settings  
- all other controls including the boiler thermostat knob  
should be in the normal running position.  
The earth connections MUST NEVER be omitted.  
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.  
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.  
The switched live supply should be subject to control  
by time and temperature controls in the usual way.  
If a flow switch is fitted, it should be wired between F1 and  
F2 on the terminal plug-in connection on the bottom box  
at the rear of the control box.  
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.  
Do not wire these connections in conduit up to the boiler  
as this will make it impossible to remove the control box  
for servicing or maintenance.  
Finally, fit the casing top panel and push down to locate.  
The main supply to the boiler must be wired to the  
boiler terminals L1, N and Earth on the plug-in  
terminal strip. This live connection must be  
UNSWITCHED, that is a supply not interrupted by  
any automatic temperature or time control, to enable  
the pump overrun (and the frost protection facility) to  
operate.  
Failure to operate this procedure will result in nuisance  
overheat thermostat operation.  
The internal wiring of the boiler control box is shown  
in Frame 15.  
Wiring should be in four core PVC insulated cable,  
not less than 0.75mm2 (24/0.2mm). All fuses must  
be ASTA approved to BS. 1362.  
The length of the conductor between the cord  
anchorage and the terminals must be such that the  
current carrying conductors become taut before the  
earthing conductor, if the cable or cord slips out of the  
cord anchorage.  
Concord CXSi/H - Installation & Servicing  
17  
INSTALLATION  
LEGEND  
15 INTERNAL WIRING  
b
blue  
br brown  
red  
y/g yellow/green  
or orange  
y
yellow  
v
violet  
bk black  
r
w white  
pk pink  
BLUE  
YELLOW  
PINK  
RED  
RED  
ORANGE  
BLUE  
O R A N  
W H I T E  
B L A C K  
BROWN  
WHITE  
RED  
YELLOW  
BK  
E L E C T R O D E  
D E T E C T I O N  
WHITE  
VIOLET  
ORANGE  
ORANGE  
BLUE  
BLUE  
GREY  
YELLOW  
DETECTION LEAD  
YELLOW/GREEN  
2 X YELLOW  
2 X RED  
2 X VIOLET  
CONTACT REMOVED AND  
FITTED TO MATING HALF  
Concord CXSi/H - Installation & Servicing  
18  
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  
available via relay contacts to close the valve for that zone.  
At the start of the next call for heat (or the next clock period)  
valves on zones not calling for heat will motor shut.  
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.  
Water circulation system - refer to page 5  
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 5  
Concord CXSi/H - Installation & Servicing  
19  
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  
6A (resistive or inductive): if this rating would  
be exceeded then appropriate switchgear  
must be used to control the pumps indirectly.  
X2  
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 5  
19 COMMISSIONING AND TESTING  
GENERAL  
TESTING FOR GAS SOUNDNESS  
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.  
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.  
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 .  
Any leaks must be cured.  
Replace all pressure test point screws.  
Concord CXSi/H - Installation & Servicing  
20  
INSTALLATION  
20 INITIAL LIGHTING  
1. Check that the boiler thermostat knob (1) on the control  
7. The boiler will light at Low rate and the Boiler-on light (5)  
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.  
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).  
8. The burner will remain at Low rate for about 1 minute  
3. Press in and release the overheat thermostat button (4).  
before going to High rate.  
4. Switch on the electrical supply to the boiler.  
9. Check all connections for gas soundness, using leak  
detection fluid.  
5. Ensure that all system controls (time switch, system  
controls etc.) are calling for heat.  
10. Set the boiler thermostat knob and the system controls to  
the required settings.  
6. Turn the boiler thermostat knob (1) to position 6.  
11. Turn off the electrical supply to the boiler.  
7
5
1
LEGEND  
1. Boiler thermostat knob.  
2. Control box.  
OFF  
BOILER ON  
6
C
3. Mains inlet gas cock.  
4. Overheat thermostat .  
5. Boiler on light.  
OVERHEAT  
5
C O N C O R D CXSi  
LOCKOUT  
4
1
3
2
6. Lockout light.  
7. Lockout reset button.  
8. Burner pressure test point.  
9. Inlet pressure test point.  
10. Overheat light.  
6
10  
11. High/low gas valve  
2
11  
9
3
4
8
Concord CXSi/H - Installation & Servicing  
21  
INSTALLATION  
21 MANIFOLD GAS PRESSURE - CXSi 110/H-160/H ONLY  
The manifold setting pressure must now be  
checked and adjusted as necessary. It is  
essential to set the High Pressure first  
Start the adjustment procedure with the  
system cold, on full load and with all  
temperature controls set to maximum to  
avoid thermostatic shutdown. Remove the  
screw in the burner setting pressure test  
point and connect a suitable gas pressure  
gauge.  
Turn on the electrical supply to light the  
boiler and let it operate for about 10 minutes  
to stabilise the burners. Check the pressure  
and if it differs noticeably from that given in  
Table 1 for the appropriate boiler size adjust  
it as follows:  
SETTING THE HIGH BURNER PRESSURE  
SETTING THE LOW BURNER PRESSURE  
5. Turn the boiler thermostat knob to OFF.  
1. Remove the dust cover from the adjustment screw in  
the bottom valve and gently screw the adjustment in  
fully.  
6. Disconnect the 'high' solenoid plug from the top valve.  
7. Disconnect the LH electrical plug from the bottom valve.  
2. Remove the plastic dust cover from the adjustment  
screw on the top (high/low) valve and, using a spanner,  
screw the adjuster gently fully in then screw the adjuster  
out until the burner pressure is approximately 10.9 mbar.  
8. Turn the boiler on and set the low pressure to the value  
given in Table 1, using the low rate adjustment screw inside  
the spindle of the top valve.  
3. Finally, screw out the adjustment on the bottom valve  
until the burner pressure is correctly set to the value  
given in Table 1.  
9. Turn the appliance off and reconnect all the electrical plugs.  
Do not overtighten the electrical plug fixing screws.  
10. Refit both dust covers over the adjustment screws and refit  
4. After setting, allow the boiler to operate for 3 minutes to  
the pressure test point screw.  
stabilise then recheck the setting.  
11. Check for gas soundness.  
Concord CXSi/H - Installation & Servicing  
22  
INSTALLATION  
22 MANIFOLD GAS PRESSURE - CXSi 180/H ONLY  
The manifold setting pressure must now be  
checked and adjusted as necessary. It is  
essential to set the High Pressure first  
Inlet PTP  
Start the adjustment procedure with the  
system cold, on full load and with all  
temperature controls set to maximum to avoid  
thermostatic shutdown. Remove the screw in  
the burner setting pressure test point and  
connect a suitable gas pressure gauge.  
Turn on the electrical supply to light the boiler  
and let it operate for about 10 minutes to  
stabilise the burners. Check the pressure and  
if it differs noticeably from that given in Table 1  
for the appropriate boiler size adjust it as  
follows:  
5
Dust cover  
3
Remove plastic  
dust cover  
Low rate  
adjustment  
screw  
Gas rate  
adjuster  
maximum  
High solenoid plug  
IMPORTANT. Do not adjust the middle valve, which is factory set.  
SETTING THE LOW BURNER PRESSURE  
SETTING THE HIGH BURNER PRESSURE  
7. Turn the boiler thermostat knob to OFF.  
1. Turn the boiler thermostat knob to OFF.  
8. Disconnect the 'high' solenoid plug from the top valve.  
2. Undo the screws holding the electrical plug on the bottom gas  
valve and pull it off.  
9. Disconnect the electrical plug from the bottom and middle  
valves.  
3. Turn the boiler on and remove the plastic dust cover from the  
adjustment screw on the top gas valve and, using a suitable  
spanner, screw the adjuster gently fully in. Then screw the  
adjuster out until the burner pressure is approximately 9.0 mbar.  
10. Turn the boiler on and set the low pressure to the value  
given in Table 1, using the low rate adjustment screw  
inside the spindle of the top valve.  
4. Turn the boiler off and refit the electrical plug on the bottom  
11. Turn the appliance off and reconnect all the electrical  
valve.  
plugs.  
5. Turn the boiler on and remove the dust cover from the adjustment  
screw in the bottom valve. Set the burner pressure to the value in  
Table 1.  
12. Refit both dust covers over the adjustment screws and  
refit the pressure test point screw.  
13. Check for gas soundness  
6. After setting, allow the boiler to operate for 3 minutes to stabilise  
then recheck the setting.  
Concord CXSi/H - Installation & Servicing  
23  
SERVICING  
24 TESTING  
23 SPILLAGE CHECK  
Check the main burner responds correctly to manual on/off operations of any controls fitted in  
the gas control circuit.  
Check that there is no spillage  
of combustion products from  
the boiler draught diverter by  
carrying out a spillage test, as  
detailed in BS. 5440:1.  
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.  
Important Commissioning / Operating Instructions:  
Do not operate this appliance for long periods or take any combustion readings with the  
casing or any part of the casing removed.  
25 ADJUSTMENT OF WATER FLOW RATE THROUGH THE BOILER  
When commissioning the heating/domestic hot water system the shunt pump must be  
adjusted to give the minimum flow rate given in Table 4, when that part of the system  
intended to be used for dissipation of residual heat only is in operation.  
26 HANDING OVER  
Hand over these, the User’s Instructions and the Commissioning &  
Servicing Log Book to the customer and request him to keep them in  
a safe place for ready reference.  
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.  
IMPORTANT. Point out to the owner that the boiler must have  
regular maintenance and cleaning, at least annually, in order to  
ensure reliable and efficient operation. Regular attention will also  
prolong the life of the boiler and should preferably be performed at  
the end of the heating season.  
Draw the attention of the boiler owner or their  
representative to the Lighting and Operating Instruction  
Label on the inside of the front panel. Give a practical  
demonstration of the lighting and shutting down of the  
boiler.  
After servicing, complete the service section of the log book and  
return it to the owner or their representative.  
Describe the function of the boiler and system controls and  
show how they are adjusted and used.  
Recommend that a contract for this work should be made with a  
CORGI registered installer.  
Concord CXSi/H - Installation & Servicing  
24  
SERVICING  
27 SERVICING  
Caradon Ideal Limited does not accept any liability resulting  
from the use of unauthorised parts or the repair and servicing  
of appliances not carried out in accordance with the Company’s  
recommendations and specifications.  
A comprehensive service should be carried out at least once a  
year. The User is advised to make a contract with a CORGI  
registered installer.  
WARNING. ALWAYS turn OFF the gas supply at the gas cock  
and disconnect the electricity supply to the appliance BEFORE  
servicing or replacing any components.  
If access is required to the electrical plug-in terminals at the  
back of the control box then remove the casing top panel; it is  
not advisable to try and remove the control box back panel  
from the boiler with the plugs in place.  
CLEANING THE BOILER  
Remove the casing door panel. Lift and remove the casing lower  
front panel. Undo and pull off all the plugs from the gas valve  
solenoids. Turn off the gas at the gas inlet cock. Undo the 2  
unions at either side of the gas valve assembly and remove  
the assembly complete.  
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.  
Pull off the leads to the spark electrode on the RH end burner  
- access via the side of the combustion chamber. Pull off the  
lead to the flame detector electrode at the LH end burner.  
Inspect the ignition and detection electrodes.  
Ensure that they are clean and in good condition. In particular, check  
that:  
Lift off the casing top panel. Undo the 3 elongated nuts from  
each of the NOx ducts and remove all the ducts. Undo the M5  
nuts and washers retaining the burner light back shield and  
remove it. Undo the four M6 nuts and washers securing the  
burner tray and carefully pull it from the boiler, ensuring that no  
wires are trapped. Undo the screws securing the cleanout  
cover(s) and remove.  
1. The ignition electrode shield and base fixing screws are tight.  
2. The electrodes are correctly positioned .  
3. Check that the gap between the electrode tips is 4mm.  
Remove all loose deposits from the heat exchanger (especially  
from between the fins), using the brush provided, and remove  
all debris from the combustion chamber floor - take care not to  
damage the insulation.  
4. Reassemble in reverse order. Ensure that no wires are  
trapped when replacing the burner tray. Refit the flue baffles,  
cleanout cover, light back shield, NOx ducts, electrode  
connections and casing panels.  
When refitting the plugs to the gas valve solenoids do NOT  
overtighten the fixing screws.  
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.  
LH burner  
Concord CXSi/H - Installation & Servicing  
25  
SERVICING  
28 REPLACEMENT OF COMPONENTS - Refer to Frames 5, 31 and 32  
GENERAL  
WARNING. ALWAYS turn OFF the gas supply at the gas inlet cock and switch OFF  
and DISCONNECT the electricity supply BEFORE working on the appliance.  
29 GAS CONTROL VALVE  
30 MAIN BURNER  
1. Undo and pull off all the plugs from the gas valve solenoids.  
1. Remove the burner tray from  
the boiler, as described in  
Frames 27-28.  
2. Turn off the gas at the gas inlet cock. Undo the 2 unions at either side of the gas valve  
assembly and remove the assembly (complete) to a suitable working area.  
2. Each burner can be removed  
by lifting it at the back and  
pushing it backward to clear  
the injector. Disconnect the  
spark electrode assembly and  
heat shield from the RH  
3. In order to be able to remove the faulty gas valve it will be necessary to slacken or  
remove all the screws on either the inlet or the outlet manifold and only those 4 screws  
securing the faulty gas valve on the other manifold. The faulty gas valve can then be  
removed and replaced. Ensure that the arrow on the gas valve points in the direction  
of flow.  
burner (or the flame detector  
electrode from the LH burner),  
as necessary.  
4. Ensure that new ‘O’ ring seals are fitted and that the 'O' ring seals on the remaining  
gas valves are correctly in place. Ensure that all screws are retightened.  
5. Test for gas soundness.  
3. Reassemble in reverse order.  
6. Recommission the appliance and set the manifold pressure, as described in Frame 21.  
31 BURNER AND CONTROLS ASSEMBLY - Exploded View - CXSi 110/H - 160/H  
LEGEND  
10. Main burner RH.  
7. Burner manifold.  
8. Main injector.  
1. Main gas inlet cock.  
2. Gas inlet union.  
3. 'O' ring seal.  
4. High/Low gas control valve  
5. Gas control valve.  
11. Ignition electrodes.  
12. Detection electrode assembly.  
PTP Pressure test point.  
9. Main burner - LH.  
6. Spark generator.  
Concord CXSi/H - Installation & Servicing  
26  
SERVICING  
32 BURNER AND CONTROLS ASSEMBLY - Exploded view - CXSi 180/H  
LEGEND  
10. Main burner (RH).  
1. Main gas inlet cock.  
2. Gas inlet union.  
3. 'O' ring seal.  
7. Burner manifold.  
8. Main injector.  
4. High/low gas control valve.  
5. Gas control valve.  
11. Ignition electrodes.  
12. Detection electrode assembly.  
PTP Pressure test point.  
9. Main burner - LH.  
6. Spark generator.  
33 OVERHEAT THERMOSTAT  
1. Pull out the spring clip in the thermostat pocket in the flow  
header and pull out the overheat thermostat phial and  
capillary.  
2. Ensure that the electrical supply is switched OFF.  
3. Lift off the casing front panel and top panel.  
4. Unclip the capillary from its clips on the casing side panel.  
5. Undo the 2 screws securing the overheat thermostat  
assembly and withdraw the assembly.  
6. Undo the screw and remove the cover.  
7. Remove the wires  
8. Undo the backnut and remove the thermostat.  
9. Fit the new thermostat and secure with the backnut.  
10. Reconnect the wires as follows:  
11. Reassemble in reverse order.  
12. Ensure that the thermostat capillary is rerouted through the  
casing side panel clips and that the phial is secure in the  
pocket fitted to the flow header, using the spring clip.  
1. Pink  
2. White  
3. Red  
Reconnect the earth terminal.  
Concord CXSi/H - Installation & Servicing  
27  
SERVICING  
34 CONTROL BOX - Basic Boiler, Exploded View  
1
2
Printed circuit board support detail  
6
5
12  
3
7
2
1
4
8
10  
11  
9
LEGEND  
1. Wiring clamp.  
5. Terminal strip  
9. Potentiometer  
2. Connection box plug.  
3. Connection box.  
4. PCB S456B1047  
6. Back panel  
10. Warning light lens  
11. Controls box  
7. Lockout reset button  
8. Thermostat knob  
12. PCB W 4115A1020  
35 CONTROL SENSOR  
1. Lift off the casing top panel and front panel.  
2. Trace the sensor lead to the pocket in the flow header,  
remove the spring clip and remove the sensor phial.  
3. Undo and remove the 2 screws securing the control box  
front panel. Carefully lift up and lower it.  
4. Pull out the sensor plug from the PCB and remove the  
strain relief bush. Remove the sensor and lead.  
5. Fit the new sensor, ensuring that the lead is routed along  
the casing in the clips provided.  
6. Reassemble in reverse order.  
Concord CXSi/H - Installation & Servicing  
28  
SERVICING  
36 CONTROL SENSOR POTENTIOMETER ASSEMBLY  
1. Prise the front cap from the thermostat knob.  
PCB  
Plug  
2. Carefully loosen the brass retaining nut one full turn  
anticlockwise  
3. Gently pull the thermostat knob from the potentiometer. When  
reassembling ensure the arrow on the body is lined up in the  
OFF position.  
Backnut  
4. Remove the back nut and brass washer securing the thermostat  
knob to the panel.  
Potentiometer  
Thermostat knob  
5. Undo and remove the 2 screws securing the control box front  
panel. Carefully lift it up and lower it.  
6. Remove the terminal plugs from the back of the potentiometer.  
Con 1500  
7. Undo the purse clips holding the wires from the potentiometer  
are made either to the top 2 tags or the bottom 2 tags and that the  
lug on the body of the potentiometer locates through the hole in  
the front panel of the control box.  
to the PCB then pull the wires out.  
8. Remove the connections from the PCB.  
Also ensure that the potentiometer is rotated fully anticlockwise  
and clicks before commencing the reassembling.  
9. Fit the new potentiometer and reassemble in reverse order.  
Ensure that the connections to the back of the potentiometer  
37 PC BOARD S4561B1047  
38 PC BOARD W4115A1020  
Flame detector connection  
Earth connection  
Retaining barbs  
Plugs  
Plugs  
Plugs  
Retaining  
barbs  
PCB  
PCB  
1. Remove the lower front panel.  
Con 1910  
2. Undo and remove the 2 screws securing the control box front  
panel. Carefully lift it up and lower it.  
1. Remove the lower front panel.  
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.  
2. Undo and remove 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  
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.  
be removed by squeezing in the retaining barbs.  
4. Reassemble in reverse order.  
Prior to removal of the boards the following protective equipment  
should be worn:  
39 COMBUSTION CHAMBER  
INSULATION REPLACEMENT  
•
•
Face mask supplied with the spare part.  
Gloves supplied with the spare part.  
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.  
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.  
Caradon Ideal Limited, however, recommend that for  
your own comfort and to comply with good working  
practise the procedure described below is followed.  
3. Sweep any dampened particles and place in the plastic bag.  
4. Fit new insulation boards.  
IMPORTANT. Turn OFF the gas and DISCONNECT the  
electricity supply.  
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  
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.  
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.  
Concord CXSi/H - Installation & Servicing  
29  
FAULT FINDING  
40 BOILER CONTROL  
feature reduces component wear and ensures continuous  
trouble free operation. The anti-cycle duration is 4 minutes.  
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.  
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.  
The preliminary electrical system checks are the FIRST  
electrical checks to be carried out during a fault finding  
procedure.  
Frost protection is inbuilt with the boiler. If the flow  
temperature falls to approximately 5 oC then the boiler will  
operate until the flow temperature exceeds 18 oC. 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.  
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  
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 oC the low rate gas valve will  
close. Should the temperature fall below the set point the  
boiler will go back to the high rate.  
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  
The full sequence control enables a single ignition attempt  
lasting about 5 seconds and will go to lockout if detection  
does not take place.  
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 SIMPLE FLOW CHART  
OF OPERATION  
SHUTDOWN  
Demand = ON  
IGNITION  
Overrun  
completed  
Flame = ON  
Temp  
> than  
set point  
LOW RATE  
HIGH RATE  
Temp at  
set point  
Demand  
= off  
PUMP OVERRUN  
(6 minutes)  
4 minutes anti-cycle  
Concord CXSi/H - Installation & Servicing  
30  
FAULT FINDING  
Before carrying out any Fault Finding, ensure that all internal controls are calling for heat and that the overheat thermostat has not  
operated. There should be 230V ± 10% available at the control box connection.  
42 BOILER DOES NOT LIGHT  
NO  
Is the spark gap approximately 4mm and are the  
electrodes, leads and connections clean and secure?  
Is there a spark at the electrode?  
YES  
YES  
Are the gas valve electrical plugs clean and secure?  
YES  
Is there 230V ± 10% at the spark generator  
NO  
YES  
Is there 230V ± 10% at the gas valve plugs?  
YES  
Are connections sound at  
the plug-on terminal strip  
at the control box?  
Replace  
spark generator  
YES  
Is the gas valve inlet pressure sufficient?  
YES  
Replace  
PCB S4561B1047  
Replace the gas valve  
43 BOILER LIGHTS BUT GOES TO LOCKOUT  
Is the flame detector and its lead and connections sound  
NO  
and secure and correctly positioned on the LH end  
Clean and secure  
burner?  
YES  
NO  
Check LH end burner, inlet and burner pressure; check  
the LH end burner injector  
Measure the flame current - expect approximately 3.5µA  
YES  
Replace PCB S4561B1047  
44 BOILER GOES OUT ON OVERHEAT THERMOSTAT  
Is there an unswitched Live supply to terminal L1 on  
the plug-on terminal connection at the control box?  
YES  
NO  
Is there sufficient open circuit water volume or load  
Refer to Installation Instructions for details  
available on boiler shutdown for the pump overrun?  
YES  
Is the pump (or shunt pump) wired to terminal L2  
in the control box?  
YES  
NO  
Has the boiler thermostat knob been switched to OFF?  
Replace PCB W4115A1020  
YES  
Advise USER  
Concord CXSi/H - Installation & Servicing  
31  
SHORT LIST OF PARTS  
When ordering spare parts please quote:  
The following are parts commonly required as  
replacements, due to damage or  
expendability.  
1. Boiler model  
2. Boiler serial no. (refer to the data plate on the combustion chamber)  
3. Boiler P.I. No. (refer to the data plate on the combustion chamber)  
Their failure or absence is likely to affect the  
safety and/or performance of this appliance.  
4. Description  
5. Quantity  
6. Product no.  
When replacing a part on this appliance, use only spare parts that you can be assured conform to the safety and performance  
specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.  
Key No.  
Description  
Qty.  
Product No.  
Gas valve  
28  
HONEYWELL VR4605PB2003  
CXSi 110/H, 120/H, 140/H, 160/H & 180/H  
CXSi 110/H & 120/H  
1
1
2
1
111 867  
138 896  
138 896  
111 869  
28.1  
HONEYWELL VR4605A 1104  
HONEYWELL VR4605A 1104  
HONEYWELL VR4605AB 1019  
CXSi 180/H  
28.2  
CXSi 140/H & 160/H  
28.3  
28.4  
28.5  
28.6  
28.7  
Plug and lead  
Plug and lead  
Plug and lead  
Plug and lead  
Plug and lead  
CXSi 110/H, 120/H, 140/H, 160/H & 180/H  
CXSi 110/H, 120/H, 140/H & 160/H  
CXSi 110/H, 120/H, 140/H & 160/H  
CXSi 110/H, 120/H, 140/H, 160/H & 180/H  
CXSi 180/H  
1
1
1
1
2
154 734  
139 269  
112 431  
155 657  
111 870  
29  
31  
Spark generator  
1
139 300  
Injector 4.02 mm diameter  
Injector 4.20mm diameter  
Injector 4.20mm diameter  
Injector 4.20mm diameter  
Injector 4.20mm diameter  
CXSi 110/H  
CXSi 120/H  
CXSi 140/H  
CXSi 160/H  
CXSi 180/H  
6
6
7
8
9
013 175  
013 180  
013 180  
013 180  
013 180  
32  
Flame detection electrode  
Flame detection lead  
1
1
138 895  
139 271  
32.1  
33  
Main burners ............... Worgas  
Main burners ............... Worgas  
Main burners ............... Worgas  
Main burners ............... Worgas  
CXSi 110/H & 120/H  
CXSi 140/H  
5
6
7
8
139 824  
139 824  
139 824  
139 824  
CXSi 160/H  
CXSi 180/H  
34  
36  
Main burner (RH end) . Worgas  
Ignition electrode  
CXSi 110/H - 180/H  
1
1
139 825  
112 365  
Concord CXSi/H - Installation & Servicing  
32  
SHORT LIST OF PARTS  
Key No.  
Description  
Qty.  
Product No.  
45  
Control box complete  
Thermistor  
1
1
1
1
155 641  
154 816  
154 814  
154 815  
46  
47.1  
48.1  
PCB S4561B1047 (ignition)  
PCB W4115A1020 (Aquastat)  
56  
56  
56  
56  
Casing assembly complete .................................................. CXSi 110/H & 120/H  
Casing assembly complete ................................................................ CXSi 140/H  
Casing assembly complete ................................................................ CXSi 160/H  
Casing assembly complete ................................................................... XSi 180/H  
1
1
1
1
157 449  
157 450  
157 451  
157 452  
57  
57  
57  
57  
Casing front panel ................................................................ CXSi 110/H & 120/H  
Casing front panel .............................................................................. CXSi 140/H  
Casing front panel .............................................................................. CXSi 160/H  
Casing front panel .............................................................................. CXSi 180/H  
1
1
1
1
155 647  
155 648  
155 649  
155 650  
58  
59  
Casing LH side panel ...............................................................CXSi 110/H-180/H  
Casing RH side panel ..............................................................CXSi 110/H-180/H  
1
1
076 978  
076 979  
60  
60  
60  
60  
Casing lower front panel ...................................................... CXSi 110/H & 120/H  
Casing lower front panel .................................................................... CXSi 140/H  
Casing lower front panel .................................................................... CXSi 160/H  
Casing lower front panel .................................................................... CXSi 180/H  
1
1
1
1
138 475  
138 474  
138 473  
138 472  
61  
61  
61  
61  
Casing upper front panel...................................................... CXSi 110/H & 120/H  
Casing upper front panel.................................................................... CXSi 140/H  
Casing upper front panel.................................................................... CXSi 160/H  
Casing upper front panel.................................................................... CXSi 180/H  
1
1
1
1
155 643  
155 644  
155 645  
155 646  
62  
62  
62  
62  
Casing top panel .................................................................. CXSi 110/H & 120/H  
Casing top panel ................................................................................ CXSi 140/H  
Casing top panel ................................................................................ CXSi 160/H  
Casing top panel ................................................................................ CXSi 180/H  
1
1
1
1
138 465  
138 464  
138 463  
138 462  
63A  
78  
Overheat thermostat ..................... RAK77.4/3835  
Boiler status neons ...............................Boiler ON  
Boiler status neons .............. Overheat & Lockout  
Lockout reset button assembly  
1
1
1
1
155 791  
154 854  
154 855  
155 269  
79  
80  
Concord CXSi/H - Installation & Servicing  
33  
NOTES  
Concord CXSi/H - Installation & Servicing  
34  
NOTES  
Concord CXSi/H - Installation & Servicing  
35  
Technical Training  
The Ideal Boilers Technical Training Centre offers a series of first class training  
courses for domestic, commercial and industrial heating installers, engineers and  
system specifiers. For details of courses please ring: ..........  
01482 498 432  
Ideal Boilers P.O. Box 103, National Ave, Kingston upon Hull,  
,
HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858.  
Registration No. London 322 137.  
Caradon Ideal Limited pursues a policy of continuing  
improvement in the design and performance of its products. The  
right is therefore reserved to vary specification without notice.  
November 2005  
UIN 157 294 A03  
I
deal Installer/Technical Helpline: 01482 498 376  
www.idealboilers.com  

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