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Ideal Boilers CF#/125, Installation And Servicing Manual

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Ideal Boilers CF#/125 Installation And Servicing Manual Download Page 29

29

Mexico Super CF 3/100, 3/125, 3/140 - 

Installation

48 GAS VALVE REPLACEMENT

SERVICING

49 TTB DOWNDRAUGHT THERMOSTAT REPLACEMENT

1.

Remove the  control panel. Refer to Frame 41.

2.

Remove the securing screws and lift off the control
box cover.

3.

Disconnect the TTB thermostat and remove from
the cable clamp and control box.  Refer to Frame
54.

Note.

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 correctly remade and cables
secured.

Note

.

 CF 3/100

If minimum LH side clearance is used on the CF 3/100
boilers, the 

TTB downdraught thermostat

 and bracket

should be moved to the RHS of the boiler (alternative
location).

1.

Lift off the front panel and remove
the grille assembly.  Refer to
Frames 28 & 29.
Remove the burner and controls
assembly.

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 gas valve, ensuring
that:

a.

The valve is fitted the correct
way round - an arrow engraved
on the valve indicates the
direction of flow.

b.

The sealing 'O' ring supplied
with the valve is correctly fitted
at the outlet flange.

c.

An approved jointing compound
is used when reconnecting the
gas inlet pipe.

SER

VICING

Summary of Contents for CF#/125

Page 1: ......

Page 2: ...t 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 conjun...

Page 3: ...ly Pressure 20 mb Gas Type Natural 2 H Electrical Supply 230 V 50 Hz External Fuse Rating Power Consumption 3 A 5 W Water Content litre gal 9 8 2 1 12 2 2 7 14 6 3 2 Dry Weight kg lb 111 245 134 295 157 346 Boiler Size Height mm in 850 33 5 Width mm in 440 17 4 Depth mm in 533 21 0 600 23 6 750 29 5 GENERAL Table 1 General Data Table 2 Performance Data Key to symbols GB United Kingdom IE Ireland C...

Page 4: ...he casing Separate fitting instructions are included with this kit Not available on the CF 140 Overheat Is available to allow the boiler to be used Thermostat Kit on sealed water systems GENERAL INTRODUCTION Mexico Super CF Mexico Super CF 3 100 G C No 41 348 18 Mexico Super CF 3 125 G C No 41 348 20 Mexico Super CF 3 140 G C No 41 348 21 Natural Gas only Appliance type B11 BS Certified P I No 87 ...

Page 5: ...ions and the above regulations or other statutory requirements LOCATION OF BOILER The boiler must be installed on a flat and level floor capable of adequately supporting the weight of the boiler and any ancillary equipment The boiler may be fitted on a combustible floor Insulation is not necessary unless required by the local authority The boiler must not be fitted outside The boiler must not be i...

Page 6: ...H side or the RH side DURING installation Refer to Frame 7 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 533 mm 21 MUST be available at the front of the boiler for servicing Boiler Clearances Top One side Aggregate A or B A B CF 3 100 mm in 20 3 4 35 1 3 8 135 5 1 4 CF 3 125 mm in 20 3 4 50 2 210...

Page 7: ...f 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 enamel c Other approved material 3 If twin walled flue pipe is used it should be of a type acceptable...

Page 8: ...commended 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 vented If venting cannot be done via a flow connection a separate vent MUST be fitted by the installer Draining taps MUST ...

Page 9: ... Thermostat pocket 6 Distributor tube 7 Combustion chamber 11 Collector hood 12 Cleanout cover 13 Front plate assy 21 Gas valve 23 Piezo spark generator 27 Gas cock 33 Retention 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 Mexico Super CF 3 100 shown with the casing removed INSTALLATION ...

Page 10: ...vicing 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: ...Release the gas valve lead from the retaining clip 5 Remove the thermostat phial from the pocket as shown 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 LH side panel to the flue collector and ba...

Page 12: ...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 pumped flow tapping 3 Screw the supplied boiler thermostat pocket into the appropriate front section tapping using an approved jointing material Refer to Tables 5 and 6 4 Connect pipe fittings to the rear tappings and plug any unus...

Page 13: ...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 these conditions no...

Page 14: ...iler flue connection outlet size is suitable for flue pipe conforming to BS 567 If sheet steel flue pipe is fitted a suitable adaptor must be used b To facilitate installation and subsequent disconnection it is recommended that a slip or split socket be included in the flue installation adjacent to the boiler flue outlet connection c A minimum of 600mm 2 of vertical flue directly above the boiler ...

Page 15: ... lead in parallel with the control s to 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 wi...

Page 16: ...k br brown r red or orange w white gy grey y g yellow green 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 literatu...

Page 17: ...systems which do not use 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 normal...

Page 18: ...installation 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 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 and 2 to refit the RH side panel 4 Place the top panel and...

Page 19: ... 15 seconds after the pilot burner has ignited then release 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 adjustm...

Page 20: ...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 4 Water circulation System a With the system HOT examine all water connections for soundness b With the system still ...

Page 21: ... installed in a compartment check that the ventilation areas are clear The servicing procedures are covered more fully in Frames 28 35 and MUST BE CARRIED OUT IN SEQUENCE WARNING Always turn OFF the gas supply at the gas service cock and switch OFF and DISCONNECT the electrical supply to the appliance BEFORE SERVICING IMPORTANT After completing the servicing or exchange of components always test f...

Page 22: ... to remove both burners from the burner front plate manifold assembly 3 From each burner remove the 2 air box securing nuts and CAREFULLY remove the air box and venturi arrangement 4 Withdraw both lint gauzes 1 Lift off the front panel and remove the grille assembly from the casing 2 Undo the gas service cock union nut 1 Clean the lint gauze s to remove any deposits of lint fluff etc 2 Brush off a...

Page 23: ...nt is possible Re assemble the boiler in the following order 1 Refit the flue baffles into the boiler flueways ensuring that they are correctly repositioned Refer to Frame 6 2 Refit the flue cleanout cover renewing any damaged or deteriorating sealing gasket 3 Refit the casing top panel 4 Reconnect the electrical wiring and refit the controls panel ensuring that the thermostat phial and phial reta...

Page 24: ...OT LOSE the pilot 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 Frame 44 When replacing any component 1 Isolate the ...

Page 25: ... the thermostat knob 3 Disconnect the electrical connections from the gas 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 e...

Page 26: ...ad 4 Fit the new lead and re assemble in reverse order 43 OVERHEAT THERMOSTAT REPLACEMENT if fitted SERVICING 1 Lift off front lower panel Refer to Frame 28 2 Slacken the screw at the thermostat pocket and withdraw the phial from the pocket 3 Remove the thermostat backnut 4 Remove the 2 Eco leads 5 Fit the new thermostat lead polarity immaterial ensuring that the alignment peg on the thermostat si...

Page 27: ...connection at the gas valve and withdraw the thermocouple 5 Fit the new thermocouple and re assemble in reverse order Note Avoid sharp bends in the thermocouple lead and ensure that it follows the same route as previously Detail of pilot burner assembly 1 Lift off front panel and remove the grille assembly refer to Frames 28 29 Undo the gas cock union and the 4 wing nuts to remove the burner contr...

Page 28: ...in reverse order 4 Remove the 2 screws securing the pilot burner and pull the assembly clear of the main burner 5 Remove the 2 nuts and washers securing the burner s to the front plate and manifold Withdraw the burner 6 Fit the new burner s and re assemble in reverse order taking care not to damage the main burner injector which is screwed into the burner manifold 1 Lift off front lower panel and ...

Page 29: ...ensuring that all electrical connections are correctly remade and cables secured Note CF 3 100 If minimum LH side clearance is used on the CF 3 100 boilers the TTB downdraught thermostat and bracket should be moved to the RHS of the boiler alternative location 1 Lift off the front panel and remove the grille assembly Refer to Frames 28 29 Remove the burner and controls assembly 2 Undo the pilot su...

Page 30: ...e 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 Multi...

Page 31: ...MATIC No AC 19 123 288 CF 3 140 1 100 163 378 377 LH AEROMATIC No AC 19 123 289 CF 3 140 1 100 164 18 Main burner injector 398 055 BRAY Cat 10 size 1400 CF 3 100 2 003 361 398 059 BRAY Cat 10 size 1700 CF 3 125 2 004 305 E01 553 BRAY Cat 10 size 2000 CF 3 140 2 112 934 19 382 945 Pilot burner HONEYWELL Q 349 A 1067 1 079 356 20 381 791 Pilot injector HONEYWELL 4500 4108 005 double orifice 0 56 0 4...

Page 32: ...nstallation LIST OF PARTS 53 SHORT PARTS 54 BOILER CONTROL PANEL Exploded View Legend 29 Controls panel complete assy 30 Control box 31 Boiler control thermostat 32 Thermostat knob 35 Controls panel 36 Magnetic strip 37 Controls front panel ...

Page 33: ...lete assembly 40 Side panel 41 Top panel 42 Grille panel 43 Front panel 55 BURNER AND CONTROLS ASSEMBLY Exploded View Legend 13 Front plate 14 Sightglass 15 Burner manifold 16 Pilot pipe 17 Burner 18 Burner injector 2 off 19 Pilot burner 21 Gas valve 22 O ring 23 Piezo unit 24 Ignition electrode 25 Ignition lead 26 Thermocouple 27 Gas service cock ...

Page 34: ...ormance of its products The right is therefore reserved to vary specification without notice 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 The Caradon Plumbing Limited Technical Training Centre offers a series of first class training courses for domestic commercial an...

Page 35: ...vice 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 ST...

Page 36: ...to contact me Please 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 System wall hung boiler The Ideal Classic LX Deluxe ...

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