Page 1: ......
Page 2: ... Type Natural 2 H Gas Supply Pressure 20 mb Table 1 General Data Boiler Size RS445 Boiler Input kW Btu h 16 3 55 600 Gas Consumption l s ft 3 h 0 42 53 6 Boiler Output to Water kW Btu h 13 2 45 000 Burner Setting Pressure hot mbar in w g 10 6 4 2 Flue gas flow rate maximum g s 7 6 Flue gas temperature o C 147 Seasonal efficiency SEDBUK Band D 78 4 Table 2 Performance Data Note Gas consumption is c...
Page 3: ... SEDBUK No 2 Controls Time and temperature control to heating 18 19 Time and temperature control to hot water 18 19 Heating zone valves 18 19 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 pressure measure and record Central heati...
Page 4: ...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 Water Central Heating Systems Health and Safety Document No 635 The Elect...
Page 5: ...h or appliance control utilising mains electricity should be so situated that it cannot be touched by a person using the bath or shower Where installation will be in an unusual location special procedures may be necessary and BS 6798 gives detailed guidance on this aspect Compartment Installations A compartment used to enclose the boiler MUST be designed and constructed specially for this purpose ...
Page 6: ...ntilators windows doors other sources of natural air infiltration or forced ventilation air conditioning If this should occur the appliance MUST be turned OFF labelled unsafe and corrective action taken TERMINAL The terminal assembly can be adapted to accommodate various wall thicknesses Refer to Frame 11 PLUMING Pluming may occur at the terminal so terminal positions which would cause a nuisance ...
Page 7: ... Electronics Forsyth Road Sheerwater Woking Surrey GU21 5RZ Tel 44 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 maintain...
Page 8: ...UST be made if surging is liable to occur If in any doubt contact Caradon Ideal Limited 3 MINIMUM REQUIREMENTS Fully pumped systems 1 Separate flow and return connections are used for each service All possible configurations are given in Frame 1 but ONLY those shown should be used 2 The use of a cylinder thermostat is recommended This will prevent excessive DHW temperatures and thus reduce gas con...
Page 9: ...on 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 head above the vessel The pressure attained in ...
Page 10: ...een 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 tempor...
Page 11: ...6 Thermostat pocket 16 Front plate 18 Burner manifold 21 Main burner 24 Gas valve 28 Gas service cock 29 PCB assy 44 Flue duct 45 Air duct 46 Boiler feet assy 49 Flue baffle 68 Retaining clip 69 Split pin 94 Cleanout cover Terminal grille MEX2251 44 6 69 68 49 94 29 24 18 16 28 46 1 45 21 Data badge INSTALLATION back ...
Page 12: ... CONTENTS complete boiler assembly the Hardware Pack listed separately below these Installation and Servicing Instructions User s Instructions FLUE PACKS PACKS B B1 AND C CONTENTS Flue terminal assembly Sachet of sealing mastic 2 off Wall thickness Flue Dimension duct length X shown above pack s Boiler fitted flush with wall Boiler fitted in line with 600 mm kitchen units required 114 to 191 mm 4 ...
Page 13: ...ne connector on the PCB lead 4 Remove the Burner On neon cable from the back of the control panel 5 Remove the 2 screws securing the control panel and disengage the panel by lowering and pulling it forward 6 Remove the 2 screws securing the top panel to the side 7 Lift the top panel off the boiler 8 Undo the 2 screws securing the PCB box to the side panels and carefully rest it on the top of the g...
Page 14: ...uilding to the given dimensions BEFORE fitting the boiler to facilitate sealing between the terminal and the wall when the boiler is in position b The terminal MUST NOT come into contact with a combustible material such as that used in non standard construction of timber frame and plasterboard etc 2 Place the boiler in the selected position 3 Make good the brickwork around the air duct inside INST...
Page 15: ...the wall face 5 Ensure that the duct is level and make good between the wall and duct from OUTSIDE of the building 6 Terminal grille securing screws 2 off 7 Terminal flue securingscrews 4 off Legend 1 Boiler air duct 2 Boiler flue duct 3 Terminal air duct 4 Terminal flue duct 5 Terminal grille 6 From OUTSIDE of the building seal the air duct join A with the mastic provided 7 From OUTSIDE of the bu...
Page 16: ...h BS 6891 1988 Refer to Frame 24 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 This connection should be readily accessible and be made adja...
Page 17: ...fitted to this appliance For wiring external controls to the Mexico Slimline RS445 boiler reference should be made to the system wiring diagrams supplied by the relevant manufacturer in conjunction with the flow wiring diagram below and also Frame 18 Difficulty in wiring should not arise providing the following directions are observed 1 Controls that switch the system ON and OFF e g a time switch ...
Page 18: ...e manufacturer indicated 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 6037 Room Thermostat Terminal Mid Position valve details Cylinder Thermostat Terminal Boiler supply connector Pump Terminal strip suitably enclosed Typical programmer CH may be selected indepe...
Page 19: ...iler supply connector Pump Terminal strip suitably enclosed Typical programmer CH may be selected independently MAINS mex 6038 21 HONEYWELL C PLAN Gravity HW Pumped CH 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 Boiler supply connector Pump Terminal strip suitably enclosed Typica...
Page 20: ...holly inside the house do not normally require frost protection as the house acts as a storage heater and can normally be left at least 24 hrs without frost damage However if parts of the pipework run 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 sele...
Page 21: ...f switch is OFF 3 Slacken the screw in the burner pressure test point B and connect a gas pressure gauge via a flexible tube 4 Switch the electricity supply ON and check that all external controls are calling for heat 5 Set the boiler thermostat knob G to position 6 The pilot solenoid valve should open and the intermittent spark commence continuing until the pilot is established The main burner wi...
Page 22: ...d leave this with the customer For IE it is necessary to complete a Declaration of Conformity to indicate compliance to I S 813 2002 9 Stress the importance of regular servicing by a CORGI registered installer and that a comprehensive service should be carried out AT LEAST ONCE A YEAR In IE servicing work must be carried out by a Competent Person Make the following checks for correct operation 1 T...
Page 23: ...ecked at regular intervals and serviced as necessary 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 operati...
Page 24: ... 32 CLEANING THE FLUEWAYS 30 BURNER AND CONTROLS ASSEMBLY 1 Brush off any deposits that may 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 I...
Page 25: ...e into the boiler flueway ensuring that it is correctly repositioned Refer to Frame 10 2 Refit the flue cleanout cover renewing any damaged or deteriorating sealing gasket 3 Refit the casing top panel 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 1 Pilot Pressure Pilot adjustmen...
Page 26: ...e front plate 3 Fit the new sightglass and reassemble as shown 4 Retighten the 2 wing nuts to ensure an airtight seal Do NOT overtighten 1 Refer to Frame 35 2 Undo the 2 screws lift off the front panel and remove the grille assembly Refer to Frame 29 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 2 wing nuts and...
Page 27: ...l panel 10 Disconnect the mains electrical supply from the terminal strip and release from its clamp 11 On the new control box gain access to the control thermostat as described above 12 Assemble new control box and panel and fit to the casing in reverse order 1 Refer to Frame 35 2 Remove 2 screws and lift off the front lower panel Refer to Frame 29 3 Disconnect the in line connector on the PCB le...
Page 28: ...e replacement polarity is not important 9 Fit the new thermostat ensuring that the alignment peg on the thermostat sits in the small hole adjacent to the main fixing hole 10 Reassemble in reverse order 11 Replace the lower front panel and secure with the 2 fixing screws 12 Check the operation of the boiler 1 Refer to Frame 35 2 Remove the 2 screws lift off the front panel and remove the grille ass...
Page 29: ...ffle to the burner 8 Remove the 2 screws securing the pilot burner and pull the assembly clear of the main burner 9 Remove the 4 nuts and washers securing the main burner to the front plate and manifold Withdraw the burner 10 Fit the new burner and assemble in reverse order taking care not to damage the main burner injector which is screwed into the burner manifold Note Ensure the burner baffle is...
Page 30: ...fold 9 Fit the new injector using an approved jointing compound and reassemble in reverse order 1 Refer to Frame 35 2 Remove the 2 screws lift off the lower front panel then remove the grille assembly Refer to Frame 29 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 2 wing nuts and withdraw the burner and control...
Page 31: ...Parts which contains all available spare parts The full list is held by British Gas Caradon Ideal Limited distributors and merchants When ordering spares please quote 1 Boiler model 2 Appliance G C number 3 Description 4 Quantity 5 Product no When replacing any parts on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require D...
Page 32: ...32 Mexico Slimline RS445 Installation Servicing SHORT LIST OF PARTS 47 SHORT PARTS MEX 2255 17 20 22 21 24 23 26 27 30 66 67 back ...
Page 33: ...SSEMBLY Exploded View Legend 63 Control panel complete 65 Control box assy 66 Thermostat 67 Thermostat knob 71 Control front panel 72 Magnetic strip 48 BOILER CASING ASSEMBLY Legend 62 Casing complete 63 Controls panel complete 73 LH side panel 74 RH side panel 75 Lower front panel 76 Top panel 77 Grille assembly MEX 2252 76 75 77 73 74 63 back ...
Page 34: ...t plate assembly 17 Sightglass 18 Burner manifold 19 Pilot pipe 20 Main burner 21 Main burner injector 22 Pilot burner 22 1 Pilot burner bracket 24 Gas valve 25 O ring 26 Ignition electrode 27 Ignition HT lead 28 Gas cock 50 Pilot sealing gasket 51 Pilot sealing plate 51 PCB BOX Exploded View MEX 2257 34 30 37 29 Legend 29 PCB chassis assy 30 PCB sub assy 34 PCB support 37 PCB cover back ...
Page 35: ...set 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 purged of air Connect or rectify and purge th...
Page 36: ...s 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 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...
