Ideal Boilers 4100 4125 Installation And Service Manual Download Page 36

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SERVICING

Mexico Super 4100 FF & 4125 FF -

Installation

74 AIR PRESSURE SWITCH (APS) REPLACEMENT

1. Remove the lower front panel, control panel and top panel. Refer to Frame 57.

2. Remove the silicon rubber tube from the fan sensing point.

3. Disconnect the fan leads.

4. Remove the M4 screw securing the flue connector to the fan.

5. Slacken the 2 M4 screws securing the flue connector to the turret front panel.

6. Disconnect the silicon rubber tube from the top of the collector hood.

7. Remove the 4 M4 screws on the top of the

collector hood and by sliding it forwards remove
collector hood / fan assembly.

8. Remove the three M4 screws retaining the fan to

the collector hood.

9. Re-assemble in reverse order. Lubricate fan 'O'

ring with silicon grease. Ensure the fan leads
and 2 sensing tubes are connected.

10. Refit the boiler casing.

11. Check the boiler operation.

73 FAN REPLACEMENT

1. Remove the lower front panel, control panel and

the top panel. Refer to Frame 57.

2. Remove the APS fixing screw.

3. Remove both sensing tubes from the APS.

4. Remove the 3 electrical connections from the

APS.

5. Connect the new APS in reverse order.

6. Refit the APS with the fixing screw.

7. Refit the boiler casing.

8. Check the boiler operation.

75 PRINTED CIRCUIT BOARD (PCB) REPLACEMENT

1. Remove the 2 screws and lift off the

lower front panel. Refer to Frame 57.

2. Undo the PCB cover fixing screw and

remove the cover.

3. Remove the HT lead from the PCB

4. Remove the 6 push-in connectors

from the PCB.

5. Compress the barbs on the PCB

stand-offs to release the PCB from
the box

6. Fit the new PCB and re-assemble in

reverse order.

7. Refit the boiler casing.

8. Check the operation of the boiler.

SER

VICING

Summary of Contents for 4100 4125

Page 1: ......

Page 2: ...test data from which it has been calculated have been certified by a notified body CAUTION To avoid the possibility of injury during the installation servicing or cleaning of this appliance care should be taken when handling edges of sheet steel components Boiler Size 4100 FF 4125 FF Gas Supply Connection in BSP Rc 1 2 1 2 Number of Boiler Sections 4 5 Flow and Return Connections Rc 1 1 BSP MAXIMU...

Page 3: ...ake and model 3 Appliance serial no on data badge 8 SEDBUK No 2 Controls Time and temperature control to heating 25 Time and temperature control to hot water 25 Heating zone valves 25 TRV s 7 Auto bypass 7 Boiler interlock 7 For all boilers Flushing to BS 7593 7 Inhibitor 7 Central heating mode Heat input to be calculated For assistance see Technical Helpline on the back page Page Burner operating...

Page 4: ...stallation must be carried out by a Competent Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice BS 6891 Low pressure installation pipes BS 6798 I...

Page 5: ...e boiler is to be fitted in a timber framed building it should be fitted in accordance with the Institute of Gas Engineers document IGE UP 7 1998 Bathrooms The boiler may be installed in any room or internal space although particular attention is drawn to the requirements of the current I E E BS 7671 Wiring Regulations and in Scotland the electrical provisions of the building regulations applicabl...

Page 6: ...es over 600mm 23 1 2 or with an inaccurately cut hole the minimum spacing in Table 3 Nos 2 3 4 5 6 would be 60mm 2 1 2 in order to allow the terminal wall plate to be fitted 7 The flue assembly shall be so placed or shielded as to prevent ignition or damage to any part of any building IMPORTANT It is absolutely ESSENTIAL to ensure in practice that products of combustion discharging from the termin...

Page 7: ...land reference should be made to the current ETCI rules for electrical installations The boiler is supplied for 230 V 50 Hz single phase The fuse rating is 3A 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 mean...

Page 8: ...valve assy 28 Gas cock 30 PCB assembly 38 Pressure switch 41 Turret assembly 42 Turret access cover assy 46 Boiler base plate 47 Baseplate heat shield 49 Flue baffle 68 Thermostat phial retaining clip 69 Phial split pin LEGEND 1 Heat exchanger assembly 2 Front section 3 Centre section 4 Section alignment rings and O rings 5 Back section 6 Thermostat pocket 7 Distributor tube 8 Combustion chamber 1...

Page 9: ... BOILER HARDWARE PACK 1 BSP plugs 5 off 1 x 1 2 BSP reducing bush 1 off Distributor tube 1off 28mm Comp nut 1off 28mm Olive 1off Thermostat pocket 1 off Thermostat clip RS 3 50 RS 3 60 RS 3 70 RS 3 80 only 1 off Thermostat retaining pin 1 off FLUE PACK Pack B Contents Duct cutting support 2 off cardboard Terminal wall plate 1 off Terminal grille assy 1 off Polyurethane foam seal 400 lg 1 off No 8 ...

Page 10: ...w the top panel forward and lift it off the boiler 8 Remove the 2 screws securing the LH side panel to the turret front panel and baseplate 9 Pull the panel forward disengaging from the collector hood tab lifting it clear of the locating peg and remove 10 Repeat steps 8 and 9 to remove the RH panel 11 The boiler is held to the packaging base by 4 M6 hex head screws Remove the front screws slacken ...

Page 11: ... Section Front Section CH DHW Flow Return Flow Return Top LH LH RH RH LH LH RH RH LH LH RH RH LH LH RH RH LH LH RH RH Table 6 Gravity Domestic Hot Water and Pumped Central Heating Table 5 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 RH RH LH RH 9 REAR FLUE ASSEMBLY Exploded view LEGEND 1 Terminal 2 Weathe...

Page 12: ...immediately around the cut hole should be flat make good if necessary For less accurate holes make good to approximately 125mm 5 diameter at the 2 wall faces 4 Remove the template from the wall Note If the terminal is to be sited within 25 40mm of a corner or vertical pipe refer to Table 3 then the hole MUST be accurately cut and the rubber weather seal trimmed around the groove provided The termi...

Page 13: ...ure the notch is at the top This will aid the location of the studs into the boiler back panel 3 Proceed to Frame 15 item B B Outside fitting Proceed to Frame 15 1 Secure the flue to the boiler using the three M5 wing nuts provided Note The sealing ring studs will locate in the back panel one way only This will ensure that the terminal is correctly aligned 13 FITTING THE FOAM SEAL 1 To determine t...

Page 14: ...dboard support provided 18 PREPARING THE WALL 1 Tape the template into the selected position 2 Mark onto the wall the position of the flue duct hole IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 3 Cut the flue hole preferably with a 125mm 5 core boring tool ensuring that the hole is square to the wall If the hole...

Page 15: ...ness and mark it onto the flue measuring from the groove near the terminal 2 Wrap the self adhesive foam strip round the flue ensuring that the foam is on the terminal side of the line This seals the gap between the flue and the wall 21 FITTING THE FOAM SEAL 1 Fit the boiler sealing ring inside the outer flue duct Ensure the boiler sealing ring is fully engaged Ensure the notch aligns with the gro...

Page 16: ...LOCATING THE BOILER A If the flue assembly can be fitted from the outside proceed as follows 1 Move the boiler into position ensuring that the flue outlet is in line with the wall opening 2 Insert the flue assembly ensuring that the flue slides into the flue extension and the 3 sealing ring studs locate into the boiler B If the flue assembly has been fitted from the inside proceed as follows 1 Mov...

Page 17: ...lengths distance from the outside wall to the relevant side of the boiler casing greater than 600mm 23 1 2 Refer to Frame 7 7 When cutting the ducts always use the cardboard support provided 27 PREPARING THE WALL 1 Mark onto the wall the position of the flue duct hole IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury...

Page 18: ...iate length A of outer flue duct refer to Frame 7 Ensure the boiler sealing ring is fully engaged 2 Drill 3 holes 3 2mm 1 8 dia through the outer flue duct and boiler sealing ring Do not drill the inner flue duct 3 Insert the self tapping screws provided in order to fix the boiler sealing ring in position 4 Fit the turret access cover to the sealing ring 1 To determine the position for the foam se...

Page 19: ...n 25mm to the side wall the side outlet plate must be fitted now 1 Split the side outlet plate into 2 down the split line 2 Fit the 2 halves of the side outlet plate to the wall ensuring they are behind the boiler sealing ring 33 LOCATING THE BOILER Position the boiler beneath the flue assembly 1 Connect the flue terminal to the boiler using the length A of flue duct previously cut and ensuring th...

Page 20: ... B 1 off B 1 off 152 227 600 to 1000 B 1 off D 1 off B 1 off D 1 off 152227 152132 600 to 1550 B 1 off D 1 off N A 152 227 152132 1 off 1550 to 2000 B 1 off D 2 off N A 152 227 152132 2 off Top outlet flue length A B Elbow allowance 90 o Elbow 1m 45 o Elbow 0 7m 37 FITTING THE KIT 1 Remove the cardboard support aid from the flue and place safely to one side 2 Fit the inner flue extension duct onto...

Page 21: ... pressure of 20 mbar 8 in w g MUST be available at the boiler inlet with the boiler operating 2 Extend a gas supply pipe NOT LESS THAN 15mm 1 2 OD to the boiler and connect to the gas cock situated at the front LH side of the boiler 3 Test the gas installation for soundness and purge in accordance with BS 6891 1988 Refer to Frame 52 Boiler Dimension A 4100 FF 327 12 7 8 4125 FF 400 15 3 4 38 TERMI...

Page 22: ...tween the top of the boiler and the base of the cylinder 41 MINIMUM REQUIREMENTS Fully pumped systems 1 Open vent and cold feed connections must be made to the boiler flow and return tappings according to the options shown in Frame 8 2 The boiler is assumed to be the highest point of the circulating system 3 The circulating pump is positioned on the FLOW and the vertical distance between the pump ...

Page 23: ...erminal strip as shown Notes a Secure each lead with one of the cable clamps b The mains lead connection MUST be made so that should the lead slip from its anchorage the current conductors become taut before the earthing conductor 45 EXTERNAL CONTROLS External wiring must be in accordance with the current I E E BS 7671 Wiring Regulations Fore Ireland reference should be made to the current ETCI ru...

Page 24: ...24 Mexico Super 4100 FF 4125 FF Installation INSTALLATION 46 PICTORIAL WIRING LEGEND w white r red bk black br brown p purple b blue gy grey y g yellow green INSTALLATION ...

Page 25: ...ls on thermostats is specific to the manufacturer 3 This is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster Autozone has grey and orange auxiliary switch leads but the GREY NOT the orange wire must be connected to the incoming live supply Pumped only 49 HONEYWELL C PLAN Notes 1 Some earth wires are omitted for clarity Ensure proper earth continuity when wiring 2 Numbe...

Page 26: ...n outside the house or if the boiler will be left off for more than a day or so then a frost stat should be wired into the system This is usually done at the programmer in which case the programme selector switches are set to OFF and all other controls MUST be left in the running position The frost stat should be sited in a cold place but where it can sense heat from the system Wiring should be as...

Page 27: ... switch to OFF 10 Remove the pressure gauge and tube Retighten the sealing screw in the pressure test point 11 Turn ON and check for gas soundness at the pressure test point 12 Refit the lower front panel and secure with the 2 fixing screws 52 COMMISSIONING AND TESTING WARNING Whilst effecting the required gas soundness test and purging air from the gas installation open all windows and doors exti...

Page 28: ...s 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 of the system remaining inoperative during frosty conditions Notes If an optional programmer kit is fitted refer to t...

Page 29: ...an the heat exchanger f Clean the main injectors g Check that the flue terminal is unobstructed and that the flue system is sealed correctly h If the appliance has been installed in a compartment check that the ventilation areas are clear a Light the boiler and carry out a pre service check noting any operational faults The servicing procedures are covered more fully in Frames 58 to 62 and MUST be...

Page 30: ... have fallen onto the burner head ensuring that the flame ports are unobstructed and remove any debris that may have collected Note Brushes with metallic bristles MUST NOT be used 2 Remove the main burner injector Check clean or replace as required 3 Refit the injector using an approved jointing compound 4 Inspect the pilot burner and ignition detection electrode ensure they are clear and in good ...

Page 31: ...own 3 Retighten the 2 M5 hexagon nuts to ensure an airtight seal Do NOT overtighten 61 RE ASSEMBLY 62 GAS PRESSURE ADJUSTMENT 1 Pilot Pressure Pilot adjustment is factory set to maximum and no adjustment is possible 64 SIGHTGLASS REPLACEMENT Re assemble the boiler in the following order 1 Refit the flue baffles 2 Inspect the collector hood rope gasket and replace if necessary ensuring that the sel...

Page 32: ...s and washers and withdraw the pilot burner 6 Fit the new pilot burner and re 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 69 1 Remove the 2 screws and lift off the lower front panel Refer to Frame 57 2 Pull off the thermostat knob 3 Remove the 2 screws and pull down the c...

Page 33: ...10 Insert control thermostat phial into pocket and secure with the split pin 11 Refit the in line electrical connector between the control box and the PCB box 12 Remove control box cover and make electrical supply connections to the terminal strip Refer to Frame 46 1 Remove the 2 screws and lift off the lower front panel Refer to Frame 57 2 Slacken the screw at the thermostat pocket and withdraw t...

Page 34: ...ng nuts and withdraw the burner and controls assembly complete from the boiler 2 Disconnect the ignition lead from the PCB 3 Prise the retaining clip out of the groove in the electrode using a small screwdriver and withdraw the electrode 4 Push in the new electrode until the retaining clip locates in the groove and re assemble in reverse order 2 Disconnect the ignition lead from the PCB 3 Remove t...

Page 35: ...R INJECTOR REPLACEMENT 1 Remove the 2 screws and lift off the lower front panel then remove the grille assembly Refer to Frame 57 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 2 Disconnect the ignition lead from the PCB 3 Undo the pilot supply connection 4 Unscrew the gas inlet pipe from the valve 72 GAS VALVE REPLACEMENT 5 Re...

Page 36: ...n grease Ensure the fan leads and 2 sensing tubes are connected 10 Refit the boiler casing 11 Check the boiler operation 73 FAN REPLACEMENT 1 Remove the lower front panel control panel and the top panel Refer to Frame 57 2 Remove the APS fixing screw 3 Remove both sensing tubes from the APS 4 Remove the 3 electrical connections from the APS 5 Connect the new APS in reverse order 6 Refit the APS wi...

Page 37: ...at switch greater than 0 9 mbar Change fan YES NO Change pressure switch Does the pilot light NO YES NO YES Does the spark stop after pilot is lit NO Is there a gas supply to the boiler Is the pilot injector blocked YES Replace gas valve NO Is there a supply on terminals of main gas valve YES NO YES NO NO Is there a supply on the fan connector at PCB Molex marked FAN YES YES NO NO Check the polari...

Page 38: ... 871 LH AEROMATIC No AC 19 123 300 4125 FF 1 153 203 E01 374 RH AEROMATIC No AC 19 123 298 4125 FF 1 150 865 21 Main injector 398 055 BRAY Cat 010 size 1400 4100 FF 2 003 361 E01 490 BRAY Cat 103 size 1700 4125 FF 2 150 986 22 E01 505 Pilot burner Injector Fittings HONEYWELL Q 385 A 2036 1 075 291 23 381 656 Pilot injector HONEYWELL 4500 4108 001 1 003 825 24 Gas valve assembly VR 4601CA 1018 O ri...

Page 39: ...39 SHORT LIST OF PARTS Mexico Super 4100 FF 4125 FF Installation 76 SHORT PARTS Mex 1879 ...

Page 40: ...r 4100 FF 4125 FF Installation Legend 63 Control panel complete assembly 65 Control box assembly 66 Control thermostat 77 BOILER CONTROL PANEL Exploded View 67 Control thermostat knob 71 Control front panel door 72 Magnetic strip ...

Page 41: ...41 LIST OF PARTS Mexico Super 4100 FF 4125 FF Installation 78 PCB BOX Exploded View Legend 29 PCB chassis assembly 30 PCB sub assembly 34 PCB support 37 PCB cover ...

Page 42: ...AND CONTROLS ASSEMBLY Exploded View Legend 16 Front plate assy 17 Sightglass assy 18 Burner manifold 19 Pilot pipe 20 Main burner 21 Main injector 22 Pilot burner 24 Gas valve 25 O ring 26 Ignition electrode 27 Ignition lead 28 Gas cock 50 Sealing gasket 51 Sealing plate ...

Page 43: ...100 FF 4125 FF Installation Legend 46 Baseplate 62 Casing complete 63 Controls panel complete 71 Controls front panel door 73 Side panel LH 74 Side panel RH 75 Lower front panel 76 Top panel 77 Grille panel 80 BOILER CASING ASSEMBLY ...

Page 44: ...ers 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 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...

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