Ideal Boilers 4134899 Installation And Servicing Manual Download | Manualshive

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Mexico Super CF 3/60P - 3/140P -

Installation

Ideal Installer/Technical Helpline: 01482 498663

Caradon Plumbing Limited

, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone: 01482 492 251

Fax: 01482 448 858. Registration No. London 322 137. Registered Office: National Avenue, Kingston upon Hull,
HU5 4JN.

A subsidiary of Caradon p.l.c

Technical Training

Caradon Plumbing 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.

September 1999

151 912 A02

The Caradon Plumbing Limited 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: ...........

01270 413 624

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.

THIS SYMBOL IS YOUR
ASSURANCE OF QUALITY

CERTIFIED PRODUCT
Manufactured under a BS EN ISO 9001: 1994
Quality System accepted by BSI

The code of practice for the installation,

commissioning & servicing of central heating systems

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Summary of Contents for 4134899

Page 1: ......

Page 2: ...for all models and a pump kit that can be housed within the casing available for all models except the Super CF 3 140 CF 3 140P Full system suitability All models are suitable for connection to pumped open vent central heating systems pumped central heating combined with pumped or gravity indirect domestic hot water supply systems They can also be used on sealed water systems when used in conjunct...

Page 3: ...7 0 14 8 37 0 14 8 37 0 14 8 Flue Gas Flow Rate g s 10 6 13 1 17 2 20 8 25 7 Flue Gas Temperature o C 125 134 129 140 132 Seasonal Efficiency SEDBUK 72 7 72 3 72 0 72 8 73 0 Table 2 Performance Data Notes 1 Gas consumption is calculated using a calorific value of 95 0 MJ m3 2500 Btu ft 3 2 To obtain the fuel consumption in liquid form divide the above figures by 270 3 The appliance is pre set at t...

Page 4: ...instructions are included with this kit Overheat Available to allow the boiler to be used Thermostat Kit on sealed water systems GENERAL CONTENTS Air Supply 7 Boiler Assembly Exploded view 9 Boiler Clearances 6 Burner Assembly Exploded view 39 40 Control Panel Assembly Exploded view 41 Downdraught Thermostat 7 Electrical Connections 15 Electrical Diagram 15 Electrical Supply 8 Fault Finding 34 Flu...

Page 5: ...d for gas soundness and purged as described in the above code GAS SAFETY Gas Safety Installation and Use Regulations 1994 amendments 1996 or rules in force It is law that all gas appliances are installed by a CORGI registered installer identified by in accordance with the above regulations Failure to install appliances correctly could lead to prosecution It is in your own interest and that of safe...

Page 6: ... 50 2 210 8 1 4 CF 3 140P 20 3 4 150 6 300 12 Note 3 100P ONLY If minimum LH side clearance is used the TTB downdraught thermostat and bracket should be moved to the RH side of the boiler alternative location Boiler Size Width Depth Height CF3 60P 75P 550 21 5 8 535 21 870 34 1 4 CF3 100P 575 22 5 8 535 21 870 34 1 4 CF3 125P 650 25 5 8 600 23 5 8 870 34 1 4 CF3 140P 740 29 1 8 750 29 1 2 870 34 1...

Page 7: ... used then the flue MUST be thoroughly swept clean of any soot or loose material If a register plate restrictor plate or damper etc is fitted in the flue then it MUST be removed before connecting the boiler to or inserting a liner into the flue 6 The flue should terminate in accordance with the relevant recommendations given in BS 5440 1 7 The flue MUST be fitted with a terminal or ridge tile up t...

Page 8: ...preferably be manufactured of copper Single feed indirect cylinders are not recommended and must NOT be used on sealed systems The hot water cylinder and ancillary pipework not forming part of the useful heating surface should be lagged to prevent heat loss and any possible freezing particularly where pipes run through roof spaces and ventilated underfloor spaces IMPORTANT The boiler must be vente...

Page 9: ...and O rings 5 Thermostat pocket 6 Distributor tube 7 Combustion chamber 11 Collector hood 12 Cleanout cover Mexico Super CF 3 60P shown 13 Front plate assy 21 Gas valve 23 Piezo igniter 27 Gas cock 33 Phial retaining clip 34 Split pin 45 Flue baffle 46 Boiler base plate 48 Draught diverter back panel assembly 49 TTB downdraught thermostat bracket 50 Heat shield INSTALLATION ...

Page 10: ...cing Instructions z User s Instructions INSTALLATION INSTALLATION The boiler is supplied fully assembled in Pack A Unpack and check the contents 4 UNPACKING HARDWARE PACK z 1 BSP plugs 6 off z 1 x 1 2 BSP reducing bush 1 off z Distributor tube z Thermostat pocket 1 off z Thermostat clip 1 off z Thermostat retaining pin 1 off z Output setting label 1 off ...

Page 11: ...isengage the panel by lowering and pulling it forward 6 Remove the 2 screws securing the top panel to the side 7 Draw the top panel forward and lift it off the boiler 8 Remove the 2 screws securing LH side panel to the flue collector and baseplate 9 Pull the panel forward lifting it clear of the locating peg and remove 10 Repeat steps 7 and 8 to remove the RH panel 11 The boiler is held to the pac...

Page 12: ...ed heating return tapping using an appropriate jointing material It is IMPERATIVE that the INDEX MARK on the distributor bush is in alignment with the mark on the section boss as shown in Frame 3 DO NOT disturb it when connecting subsequent pipework Fully pumped systems using more than 1 pump serving separate zones must have a common return connection to the distributor tube 2 Select the desired p...

Page 13: ... vent and cold feed connections must be made to the boiler flow and return tappings according to the options shown in Frame 7 2 The boiler is assumed to be the highest point of the circulating system 3 The circulating pump is positioned on the FLOW the vertical distance between the pump and feed expansion tank must comply with the pump manufacturer s minimum requirements to avoid cavitation Should...

Page 14: ...ions are used for each service All possible configurations are given in Frame 7 and ONLY those shown should be used 2 The schematic pipework graph is based on the assumption that NO MORE than 8 elbows are used in the gravity loop including entry to the boiler 3 For each extra elbow in excess of 8 R MUST be reduced by 300 mm 12 or H increased by 100 mm 4 4 Whatever value is selected for R the value...

Page 15: ...o be overridden Refer to Frame 20 WARNING The appliance 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 Regula...

Page 16: ...k black br brown r red 17 MID POSITION VALVE Pumped only Notes 1 Some earth wires are omitted for clarity Ensure 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 ...

Page 17: ...the OFF terminals 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 protecti...

Page 18: ...tallation may be expedited by loosening the union on the gas service cock on the boiler and purging until gas is detected 3 Retighten the union and check for gas soundness 1 Offer up the RH 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 and 2 to refit the LH side panel 4 Place the top panel and pu...

Page 19: ...ase If the pilot burner fails to remain alight at this stage repeat the procedure detailed above but wait longer than 15 seconds before releasing the gas control knob A 7 Check the appearance of the pilot flame to ensure that it envelops the tip of the thermocouple and is approximately 25mm 1 long The pilot flame is factory set and no adjustment is possible 8 Switch the boiler thermostat control k...

Page 20: ...mostat 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 of the system remaining inoperat...

Page 21: ...rvice work must be carried out by a CORGI registered installer a Light the boiler and carry out a pre service check noting any operational faults b Clean the main burner s and lint gauze s c CF3 100P CF 3 125P CF 3 140P only Clean the lower front panel lint gauze d Clean the heat exchanger e Clean the main injector s f Check the condition of the thermocouple g Check that the flue is unobstructed a...

Page 22: ...emove the grille assembly refer Frames 28 29 Undo the gas cock union Undo the 4 wing nuts and remove the burner controls from the boiler Remove the manifold nuts to remove both burners from the burner front plate manifold assembly 2 From each burner remove the 2 air box securing nuts and CAREFULLY remove the air box and venturi arrangement 3 Withdraw both lint gauzes 31 LINT GAUZE REMOVAL CF 3 100...

Page 23: ...as valve is clean 6 Clean or renew components as necessary 1 Clean the lint gauze s to remove any deposits of lint fluff etc 2 Brush off any deposits that may have fallen on to 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 3 Remove the main burner injector s Check clean or replace as...

Page 24: ...Burner Pressure After servicing reference should be made to Table 1 page 3 which quotes details of the rated output with the related burner pressure and heat input 36 GAS PRESSURE ADJUSTMENT retaining clip are correctly located in the thermostat pocket and secured by the split pin Refer to Frame 28 5 Check the sightglass in the front plate Clean or renew as necessary 6 Renew any damaged or deterio...

Page 25: ...ilot injector which is a push fit in the pilot burner housing 5 Remove the 2 securing screws 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 Frames 46 47 REPLACEMENT OF PARTS SERVICING 37 GENERAL 1 Unfasten...

Page 26: ...0 Fit the new thermostat and re assemble in reverse order 42 CONTROL THERMOSTAT REPLACEMENT SERVICING 1 Lift off front panel and remove the grille assembly refer Frames 28 29 Undo the gas cock union Undo the 4 wing nuts and remove the burner controls from the boiler 2 Remove the ignition electrode Refer to Frames 46 47 3 Unscrew the thermocouple nut and pull the thermocouple clear 4 Undo the pilot...

Page 27: ...as valve 4 Unscrew the 2 screws and pull down the control panel so that the 2 tabs clear the top panel 5 Remove the thermostat phial from the pocket Refer to Frame 28 6 Remove the bottom screw and remove the cover from the control box 7 Remove the top screw and ease the control box off the control panel 8 Disconnect the mains electrical supply from the terminal strip and release from its clamp 9 R...

Page 28: ...nd the piezo unit and withdraw the lead 4 Fit the new lead and re assemble in reverse order 46 IGNITION ELECTRODE REPLACEMENT CF 3 60P CF 3 75P ONLY SERVICING Pilot burner assembly Detail of pilot flame length and spark gap 1 Lift off front panel and remove the grille assembly refer Frames 28 29 Undo the gas cock union Undo the 4 wing nuts and remove the burner controls from the boiler 2 Disconnec...

Page 29: ...l of pilot flame length and spark gap Pilot burner assembly 48 THERMOCOUPLE REPLACEMENT CF 3 60P CF 3 75P ONLY SERVICING 1 Lift off front panel and remove the grille assembly refer Frames 28 29 Undo the gas cock union Undo the 4 wing nuts and remove the burner controls from the boiler 2 Remove the purse clip 3 Undo the thermocouple connection at the pilot burner and pull the thermocouple clear 4 U...

Page 30: ... in reverse order Note Avoid sharp bends in the thermocouple lead and ensure that it follows the same route as previously SERVICING 1 Lift off front panel and remove the grille assembly refer Frames 28 29 Undo the gas cock union Undo the 4 wing nuts and remove the burner controls from the boiler 2 Remove the 2 screws securing the pilot burner and pull the assembly clear of the main burner 3 Remove...

Page 31: ... off front panel and remove the grille assembly refer to Frames 28 29 2 Undo the gas cock union Undo the 4 wing nuts and remove the burner controls from the boiler 3 Remove the 2 nuts and washers securing the bottom burner baffle and remove the baffle SERVICING 1 Lift off front panel and remove the grille assembly refer Frames 28 29 Undo the gas cock union Undo the 4 wing nuts and remove the burne...

Page 32: ...assemble in reverse order 1 Lift off front panel and remove the grille assembly refer Frames 28 29 Undo the gas cock union Undo the 4 wing nuts and remove the burner controls from the boiler 2 Undo the pilot supply connection 3 Undo the thermocouple connection 4 Unscrew the gas inlet pipe from the valve 5 Remove the 4 securing screws and withdraw the valve from the burner manifold 6 Fit the new ga...

Page 33: ...te The TTB thermostat is located at the LH or RH side of the diverter panel 4 Reach down the side of the boiler and carefully lift the TTB bracket from its retaining slot and clip 5 Withdraw the thermostat bracket and lead down the side of the boiler 6 Locate and fit the new TTB downdraught thermostat bracket and lead and re assemble in reverse order ensuring that all electrical connections are co...

Page 34: ...the gas control knob is being pressed fully in that there is gas pressure at the boiler inlet and that the pilot jet is not blocked NO NO Replace the gas control valve If no supply check controls Reference may be made to the British Gas Multimeter Instruction Book Check the settings of the room thermostat and cylinder thermostat Check the control system Reference may be made to the British Gas Mul...

Page 35: ... AC 19 123 289 CF 3 140P 1 100 164 18 Main burner injector BRAY E01 493 Cat 10 size 650 CF 3 60P 1 003 862 398 043 Cat 10 size 800 CF 3 75P 1 004 858 389 612 Cat 10 size 520 CF 3 100P 2 003 861 E01 493 Cat 10 size 650 CF 3 125P 2 003 862 398 043 Cat 10 size 800 CF 3 140P 2 004 858 19 Pilot burner with injector HONEYWELL E01 548 Q 385 A 1020 CF 3 60P 3 75P 1 079 390 E01 549 Q 349 A 1067 CF 3 100P 3...

Page 36: ...36 Mexico Super CF 3 60P 3 140P Installation LIST OF PARTS 59 SHORT PARTS CF 3 60P CF 3 75P ONLY ...

Page 37: ...37 Mexico Super CF 3 60P 3 140P Installation LIST OF PARTS 60 SHORT PARTS CF 3 100P CF 3 125P CF 3 140P ONLY ...

Page 38: ... 140P Installation LIST OF PARTS Legend 29 Control panel complete assy 30 Control box 31 Control thermostat 32 Thermostat knob 35 Control panel 36 Magnetic strip 37 Control front panel door 61 BOILER CONTROL PANEL Exploded View ...

Page 39: ...EMBLY CF 3 60P CF 3 75P ONLY Exploded View Legend 13 Front plate 14 Sightglass 15 Burner manifold 16 Pilot pipe 17 Burner 18 Burner injector 19 Pilot burner 20 Pilot injector 21 Gas valve 22 O ring 23 Piezo unit 24 Ignition electrode 25 H T lead 26 Thermocouple 27 Gas service cock union ...

Page 40: ...EMBLY CF 3 100P CF 3 125P CF 3 140P ONLY Exploded View 21 Gas valve 22 O ring 23 Piezo unit 24 Ignition electrode 25 Ignition lead 26 Thermocouple 27 Gas service cock Legend 13 Front plate 14 Sightglass 15 Burner manifold 16 Pilot pipe 17 Burner 18 Burner injector 2 off 19 Pilot burner ...

Page 41: ...F 3 60P 3 140P Installation LIST OF PARTS 64 BOILER CASING ASSEMBLY Legend 28 Casing complete 29 Controls panel complete 40 Casing side panel 41 Casing top panel 42 Grille panel 43 Casing lower front panel 46 Base plate ...

Page 42: ...erved to vary specification without notice September 1999 151 912 A02 The Caradon Plumbing Limited 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 01270 413 624 These appliances are designed for use with Natural Gas only They have been tested and co...

Page 43: ...e We ll be giving away a free boiler for the five best ideas every year to be selected by our Technical Director Please complete this form using extra sheets if required and post it or fax it to us on 01482 498699 Boiler details Model Size e g Classic RS 230 Mexico CF 3 60 etc Details on control panel door Date of Installation Installer details Name Address Post Code Telephone Please include STD c...

Page 44: ... arrange for me to join an Ideal factory tour Range guides required The Ideal Guide a specifier s and installer s introduction to the Ideal domestic boiler range The Ideal Householders Guide to assist the installer when presenting to his her customers Technical manuals required The Ideal C class combi boiler The Ideal Classic wall hung boiler The Ideal Classic System wall hung boiler The Ideal Cla...

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