Ideal Boilers Mexico Super CF445, Installation Manual

Page 1: ...ENGINEERED FOR PEACE OF MIND When replacing any 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 CF445 CF455 CF465 CF475 May 2004 UIN 200 943 A02 ...

Page 2: ...on mm in 100 4 125 5 Table 1 General Data Table 2 Performance Data Key to symbols GB United Kingdom Countries of IE Ireland destination PMS Maximum operating pressure of water B11BS An appliance designed for connection to a flue discharging the products of combustion outside the room with air for combustion being drawn directly from the room where the appliance is installed without a fan in the co...

Page 3: ...Scale reducer n a Hot water mode Heat input n a Max operating burner pressure n a Max operating water pressure n a Cold water inlet temp n a Hot water outlet temp n a Water flow rate at max setting n a For condensing boilers only Condensate drain n a For all boilers complete sign hand over to customer For GB to comply with Building Regulations Part L1 Part J in Scotland the boiler should be fitted...

Page 4: ...ot exceeding 60 kW BS 5449 1 Forced circulation hot water systems small bore and microbore domestic central heating systems BS 5546 Installation of gas hot water supplies for domestic purposes 2nd Family Gases BS 5440 1 Flues for gas appliances of rated input not exceeding 60 kW BS 5440 2 Ventilation for gas appliances of rated input not exceeding 60 kW BS 7593 Treatment of water in Domestic Hot W...

Page 5: ... LH side or the RH side DURING installation A MINIMUM clearance of 25mm 1 MUST also be maintained between the flue pipe and any adjacent combustible material In addition a MINIMUM clearance of 533mm 21 MUST be available at the front of the boiler for servicing GAS SUPPLY The local gas supplier should be consulted at the installation planning stage in order to establish the availability of an adequ...

Page 6: ...oss sectional area of the flue serving the boiler MUST NOT be less than the area of the flue outlet of the boiler If flue pipe is to be used it MUST NOT be less than the diameter of the flue outlet connection on the boiler 2 Flue pipes and fittings should be constructed from one of the following materials a Aluminium or stainless steel b Cast iron coated on the inside with acid resistant vitreous ...

Page 7: ...ol over a living dining area or hallway having a heating requirement of at least 10 of the boiler heat output should be achieved using a room thermostat whilst other rooms are individually controlled by thermostatic radiator valves However if the system employs thermostatic radiator valves on all radiators or two port valves without end switches then a bypass circuit must be fitted with an automat...

Page 8: ...IMUM inclination of 25 mm per 3 m run 1 per 10 is required to avoid air locks If the above conditions cannot be met then pumped primaries should be used 1 Open vent and cold feed connections must be made to the boiler flow and return tappings according to the options shown in Frame 11 2 The boiler is assumed to be the highest point of the circulating system 3 The circulating pump is positioned on ...

Page 9: ... 4 Expansion Vessel a A diaphragm type expansion vessel must be connected at a point close to the inlet side of the pump the connecting pipe being not less than 15mm 1 2 nominal size and not incorporating valves of any sort b The vessel capacity must be adequate to accept the expansion of the system water when heated to 110 o C 230 o F c The charge pressure must not be less than the static water h...

Page 10: ...between them the stop valve being located between the system and the automatic air vent The stop valve may remain open during normal operation of the system if automatic water make up is required b Through a self contained unit comprising a cistern pressure booster pump if required and if necessary an automatic pressure reducing valve and flow restrictor The cistern should be supplied through a te...

Page 11: ...e LEGEND 1 Heat exchanger assy 2 End section 3 Middle section 4 Section alignment rings and O rings 6 Thermostat pocket 7 Distributor tube 8 Combustion chamber 12 Collector hood 16 Front plate assy 18 Burner manifold 24 Gas valve 28 Gas cock 30 PCB assy 41 Draught diverter back panel assembly 41 1 TTB downdraught thermostat bracket 49 Flue baffle 46 Boiler base plate 68 Phial retaining clip 69 Spl...

Page 12: ...tion and Servicing Users Instructions The boiler is supplied fully assembled in Pack A Unpack and check the contents 8 UNPACKING HARDWAREPACK 1 BSP plugs 5 off 1 x 1 2 BSP reducing bush 1 off Distributor tube Thermostat pocket 1 off Thermostat clip 1 off Thermostat retaining pin 1 off Cable strap 2 off 28mm Comp nut 1 off 28mm olive 1 off INSTALLATION ...

Page 13: ...ad 4 Remove the Burner On neon cable from the back of the control panel 5 Unplug the in line connector to the TTB thermostat 6 Remove the 2 screws securing the control panel and disengage the panel by lowering and pulling it forward 7 Remove the 2 screws securing the top panel to the side 8 Draw the top panel forward and lift it off the boiler 9 Remove the 2 screws securing the LH side panel to th...

Page 14: ...s to the rear tappings and plug any unused tappings Note If using iron elbows fit a short straight connector into the boiler tapping first to clear the casing when fitted 5 Place the boiler in position Note The pump may be fitted on the FLOW or RETURN Table 6 Fully Pumped Systems Connections as viewed at front Thermostat position Back Section Front Section Flow Return Top LH LH LH LH RH LH RH RH R...

Page 15: ...4 0 1799 521133 or G E Betz Ltd Sentinel Division Foundry Lane Widnes Cheshire WA8 8UD Tel 44 0 151 424 5351 or Salamander Engineering Ltd Unit 24 Reddicap Trading Estate Sutton Coldfield West Midlands B75 7BU Tel 44 0 121 378 0952 Notes 1 It is most important that the correct concentration of the water treatment products is maintained in accordance with the manufacturers instructions 2 If the boi...

Page 16: ...iance MUST be efficiently earthed A mains supply of 230 V 50 Hz fused at 3A is required All external controls and wiring MUST be suitable for mains voltage Wiring should be in 3 core PVC insulated cable NOT LESS than 0 75 mm2 24 x 0 2 mm to BS 6500 Table 16 Wiring external to the boiler MUST be in accordance with current l E E BS 7671 Wiring Regulations and local regulations For Ireland reference ...

Page 17: ...sure proper earth continuity when wiring 2 Numbering of terminals on thermostats is specific to the manufacturer 3 This is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see manufacturer s literature MEX 2132 Room Thermostat Terminal Mid Position valve details Cylinder Thermostat Terminal Boiler supply conn...

Page 18: ...nals of the programmer Diagram B shows a change over frost thermostat which will cover most systems which do use CH OFF If however on such a system the HW pipework is in an isolated part of the house a second frost thermostat may be used to protect it If in doubt ask your installer for advice Central heating systems fitted wholly inside the house do not normally require frost protection as the hou...

Page 19: ...p the LH side panel locating it with the peg in the baseplate and push the panel back 2 Secure the panel to the baseplate and collector hood 3 Repeat steps 1 2 to refit the RH side panel 4 Place the top panel on top and push back 5 Secure the top panel to the side panels IMPORTANT Wiring within the boiler casing must be neatly secured with the cable straps provided and MUST NOT be allowed to touch...

Page 20: ...tinuing until the pilot is established The main burner will then cross light smoothly If this sequence does not occur refer to the Fault Finding section 6 Test for gas soundness around ALL boiler gas components using leak detection fluid 7 Operate the boiler for 10 minutes to stabilise the burner temperature 8 The boiler is preset at the factory to its nominal rating If the burner setting pressure...

Page 21: ...ion of the TTB downdraught thermostat 4 The operation of the boiler and the use and adjustment of ALL system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent damage to the system and to the building in the event o...

Page 22: ...essary The frequency of servicing will depend upon the installation condition and usage but should be carried out at least annually It is the law that any service work must be carried out by a CORGI registered installer In IE servicing work must be carried out by a Competent Person a Light the boiler and carry out a pre service check noting any operational faults b Clean the main burner s and lint...

Page 23: ...injector using an approved jointing compound 5 Inspect the pilot burner and ignition electrode ensure that they are clear and in good condition MEX2232 Gas service union nut Combustion chamber Wing nuts MEX 2231 MEX 2211 1 Remove the 2 screws lift off the front panel and remove the grille assembly Refer to Frame 30 2 Disconnect the electrical leads from the gas valve 3 Disconnect the ignition lead...

Page 24: ...ensuring the TTB thermostat is connected Refit the control panel ensuring that the thermostat phial and phial retaining clip are correctly located in the thermostat pocket and secured by the split pin Refer to Frame 30 4 Check the sightglass in the front plate clean or renew as necessary 5 Renew any damaged or deteriorating front plate gasket 6 Refit the burner and controls assembly 7 Reconnect th...

Page 25: ...e assemble in reverse order ensuring that a The injector is in position when refitting the pilot supply b A gas tight joint is made c The spark gap is correct Refer to Frame 44 When replacing any component 1 Isolate the electricity supply 2 Remove the lower front panel and grille assembly 3 Turn off the gas supply at the boiler REPLACEMENT OF PARTS 38 SIGHTGLASS REPLACEMENT 1 Refer to Frame 37 2 U...

Page 26: ... lower panel Refer to Frame 30 3 Disconnect the in line connector on the PCB lead 4 Remove the Burner On neon cable from the back of the control panel 5 Pull off the thermostat knob 6 Remove the 2 screws and pull down the control panel tabs clear of the top panel 7 Remove the thermostat phial from the pocket Refer to Frame 30 8 Remove the bottom screw and remove the cover 9 Remove the top screw an...

Page 27: ... not important 6 Fit the new thermostat ensuring that the alignment peg on the thermostat sits in the small hole adjacent to the main fixing hole and reassemble in reverse order 7 Replace the lower front panel and secure with the 2 fixing screws 8 Check the operation of the boiler 1 Refer to Frame 37 2 Remove the 2 screws lift off the front panel and remove the grille assembly Refer to Frame 30 3 ...

Page 28: ... burner and pull the assembly clear of the main burner 7 Remove the 2 nuts and washers securing the burner to the front plate and manifold Withdraw the burner 8 Fit the new burner and reassemble in reverse order taking care not to damage the main burner injector which is screwed into the burner manifold 1 Refer to Frame 37 2 Remove the 2 screws lift off the lower front panel then remove the grille...

Page 29: ...nd withdraw the valve from the burner manifold 9 Fit the new gas valve ensuring that 1 Refer to Frame 37 2 Remove the 2 screws lift off the lower front panel then remove the grille assembly Refer to Frame 30 3 Disconnect the electrical leads from the gas valve 4 Disconnect the ignition lead from the PCB 5 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly ...

Page 30: ...of the boiler 7 Locate and fit the new TTB downdraught thermostat bracket and lead and reassemble in reverse order ensuring that the in line connector is secured 49 PRINTED CIRCUIT BOARD PCB REPLACEMENT 1 Refer to Frame 37 2 Remove the 2 screws and lift off the lower front panel Refer to Frame 30 3 Undo the PCB cover fixing screw and remove the cover 4 Remove the HT lead from the PCB 5 Remove the ...

Page 31: ...erheat stat Has the fuse on the PCB blown Reset the overheat stat Set control stat to maximum Allow the boiler to reach temperature if the overheat stat trips again measure flow temperature If above 90 C replace control stat If below 90 C replace overheat stat YES Is there a spark at the ignition electrode Does the pilot burner light NO Is there a gas supply to the boiler has the gas supply been p...

Page 32: ... 171 991 398 059 CF455 1 004 305 E01 553 CF465 1 112 934 398 064 CF475 1 004 049 22 382 944 Pilot burner with injector 1 172 008 23 Pilot injector 1 004 712 24 Gas valve 1 153 726 26 397 945 Ignition electrode 1 004 713 27 E26 397 HT lead 900 mm long 1 058 826 30 H20 882 PCB25E 1 173 799 44 1 TTB downdraught thermostat 1 173 143 49 Flue baffle 2 157 924 66 E05 070 Thermostat 1 151 903 67 308 557 T...

Page 33: ...33 SHORT LIST OF PARTS Mexico Super CF445 CF475 Installation Servicing 50 SHORT PARTS MEX 2229 17 20 22 23 30 26 21 27 24 67 66 44 1 ...

Page 34: ... 62 Casing complete 63 Control panel complete 73 Casing side panel 75 Casing lower front panel 76 Casing top panel 77 Grille panel 78 Casing fixing pack Legend 63 Control panel complete 64 Control panel 65 Control box 66 Control thermostat 67 Thermostat knob 71 Control front panel door 72 Magnetic strip 52 BOILER CONTROL PANEL Exploded View ...

Page 35: ...nly used on 465 no gauze 475 with gauze 54 PCB BOX Exploded View Legend 29 PCB chassis assy 30 PCB sub assy 33 PCB support 37 PCB cover 33 29 30 37 MEX 2155 Legend 16 Front plate assy 17 Sightglass assy 18 Burner manifold assy 19 Pilot burner pipe 20 Main burner 21 Main burner injector 22 Pilot burner assy 24 Gas valve 25 O ring 26 Ignition electrode 27 HT lead 28 Gas cock ...

Page 36: ...of first class training courses for domestic commercial and industrial heating installers engineers and system specifiers For details of courses please ring 01482 498432 THIS SYMBOL IS YOUR ASSURANCE OF QUALITY These appliances are designed for use with Natural Gas only They have been tested and conform with the provisions of BS 6332 and BS 5258 CERTIFIED PRODUCT Manufactured under a BS EN ISO 900...