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Ideal Boilers Mexico Super CF 3/40, Installation & Servicing Manual

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Ideal Boilers Mexico Super CF 3/40 Installation & Servicing Manual Download Page 34

34

Mexico Super CF 3/40 - 3/80 - 

Installation

Ideal Installer/Technical Helpline Tel: 01482 498 663

Caradon Plumbing Ltd

, 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 Ltd.

 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 UIN 151 909  A03

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 413624

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

Summary of Contents for Mexico Super CF 3/40

Page 1: ......

Page 2: ...r 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 conjunctio...

Page 3: ... Connections Rc 1 1 BSP MAXIMUM Static Water Head m ft 30 5 100 3 bar MINIMUM Static Water Head m ft 1 0 3 3 Electrical Supply 230 V 50 Hz External Fuse Rating Power Consumption 3 A 5 W Water Content litre gal 5 0 1 1 7 4 1 6 7 4 1 6 7 4 1 6 7 4 1 6 Dry Weight kg lb 68 150 90 198 90 198 90 198 90 198 Boiler Size Height mm in 850 33 5 Width mm in 440 17 4 Depth mm in 533 21 0 Gas Type Natural 2 H G...

Page 4: ...g instructions are included with this kit Overheat Available to allow the boiler to be used on Thermostat Kit sealed water systems GENERAL CONTENTS Air Supply 7 Boiler Assembly Exploded view 9 Boiler Clearances 6 Burner Assembly Exploded view 33 Control Panel Assembly Exploded view 32 Downdraught thermostat 7 Electrical Connections 15 Electrical Diagram 15 Electrical Supply 8 Fault Finding 30 Flue...

Page 5: ...ATION 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 installed in a bedroom or in a room containing a bath or shower Tim...

Page 6: ...he back of the boiler may be fitted up to the wall BOILER CLEARANCES The minimum overall dimensions of the space in which the boiler is to operate and to facilitate servicing are as follows Boiler Clearances Top One side Aggregate Total A or B A B Width C CF3 40 20 3 4 10 3 8 50 2 490 19 1 4 CF3 50 60 70 20 3 4 10 3 8 110 4 1 2 550 21 5 8 CF3 80 20 3 4 55 2 1 4 110 4 1 2 550 21 5 8 Additional spac...

Page 7: ... 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 to 5 flue diameter The terminal shall be of a type which has been tested and found satisfactory by British Gas This termi...

Page 8: ...ure a flow of water should all the valves be in the closed position ELECTRICAL SUPPLY WARNING The appliance MUST be efficiently earthed Wiring external to the appliance MUST be in accordance with the current I E E BS 7671 Wiring Regulations and any local regulations which apply The boiler is supplied for 230 V 50 Hz single phase Fuse rating is 3A Connection must be made in a way that allows comple...

Page 9: ...gnment rings and O rings 5 Thermostat pocket 6 Distributor tube 7 Combustion chamber 11 Collector hood 12 Cleanout cover 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: ...uctions 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 CF3 50 60 70 80 z Thermostat retaining pin 1 off z Output setting label 1 off ...

Page 11: ...lear of the locating peg remove To install the boiler the casing MUST be removed 1 Lift off the lower front panel 2 Remove 2 screws and lift off grille assembly 3 Remove the gas valve cover by removing the retaining screw Disconnect the electrical leads 4 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 con...

Page 12: ...an 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 unused tappings Note If using iron elbows fit a short stra...

Page 13: ...appings 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 not apply either lower the pump position or raise the feed...

Page 14: ... fireclay cement Notes a The boiler 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 ...

Page 15: ...d 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 with c...

Page 16: ... 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 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: ...lation 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 2 to refit the RH side panel 4 Place the top panel on top and pu...

Page 19: ...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 9 Test for gas soundness around the boiler gas component joints using leak dete...

Page 20: ... function 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 e...

Page 21: ...the continued safe and efficient operation of the appliance it is recommended that it is checked 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 a Light the boiler and carry out a pre serv...

Page 22: ...on 2 Undo the 4 wing nuts and remove the burner controls from the boiler 3 Remove the burner end cap 4 Withdraw the venturi baffle and lint gauze 31 CLEANING THE BURNER ASSEMBLY 1 Clean the lint gauze 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 collect...

Page 23: ...suitable brush Remove all debris from the combustion chamber base 4 Check that the flue outlet duct is unobstructed 32 CLEANING THE FLUEWAYS 5 Check the sightglass in the front plate clean or renew as necessary 6 Renew any damaged or deteriorating front plate gasket 7 Refit the burner and controls assembly 8 Reconnect the gas service cock 9 Refit the grille assembly 33 RE ASSEMBLY Re assemble the ...

Page 24: ...ot burner DO NOT 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 43 When replacing any component ...

Page 25: ... 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 elect...

Page 26: ... withdraw the lead 4 Fit the new lead and re assemble in reverse order 42 OVERHEAT THERMOSTAT REPLACEMENT if fitted 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 thermos...

Page 27: ...n 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 and controls a...

Page 28: ...rew the burner injector from the manifold 5 Fit the new injector using an approved jointing compound and re assemble in reverse order 3 Remove the 2 nuts and washers securing the burner to the front plate and manifold Withdraw the burner 4 Fit the new burner 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 fron...

Page 29: ...d with the valve is correctly fitted at the outlet flange c An approved jointing compound is used when reconnecting the gas inlet pipe 48 TTB DOWNDRAUGHT THERMOSTAT REPLACEMENT 1 Remove the control panel Refer to Frame 28 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 52 Note The TTB the...

Page 30: ... 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 Multim...

Page 31: ...CF 3 80 1 013 870 18 Main burner injector 398 051 BRAY Cat 10 size 1200 CF 3 40 1 004 190 398 055 BRAY Cat 10 size 1400 CF 3 50 1 003 361 398 059 BRAY Cat 10 size 1700 CF 3 60 1 004 305 398 064 BRAY Cat 10 size 2200 CF 3 70 CF 3 80 1 004 049 19 382 944 Pilot burner with injector HONEYWELL Q 385 A 1020 1 079 355 20 381 656 Pilot injector HONEYWELL 4500 4108 001 double orifice 0 38 0 36 1 003 825 21...

Page 32: ...Installation LIST OF PARTS Legend 29 Control panel complete 30 Control box 31 Control thermostat 32 Thermostat knob 35 Control panel 36 Magnetic strip 37 Control front panel door 52 SHORT PARTS 53 BOILER CONTROL PANEL Exploded View ...

Page 33: ...ss 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 HT lead 26 Thermocouple 27 Gas service cock union 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 34: ...ore reserved to vary specification without notice September 1999 UIN 151 909 A03 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 413624 These appliances are designed for use with Natural Gas only They have been tes...

Page 35: ... 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 code ...

Page 36: ...ge for a technical representative 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 b...

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