Ideal Boilers Mexico Super CF495 Installation And Servicing Manual Download Page 11

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INSTALLATION

Mexico Super CF495 - CF4140

Installation & Servicing

7 BOILER ASSEMBLY - Exploded View

Mex 22

Detail of distributor
tube alignment

Index mark on
section boss

Distributor tube

CF 495 to 4120
alignment

CF 4140
alignment

LEGEND

Heat exchanger.

End section.

Middle section.

Section alignment rings
and 'O' rings.

Thermostat pocket.

Distributor tube.

Combustion chamber.

12.

Collector hood.

16.

Front plate assy.

18.

Burner manifold

24.

Gas valve.

28.

Gas cock.

41.

Draught diverter back panel
assembly.

41.1.

TTB downdraught thermostat &

bracket.

46.

Boiler base plate.

49.

Flue baffle.

47.

Heat shield.

68.

Retention clip.

69.

Split pin.

94.

Cleanout cover.

41.1

Tie rod

Mex 2127

Data badge

Mexico Super CF495 shown (with the casing removed)

INST

ALLA

TION

200944-1.p65

3/8/2004, 3:41 PM

Summary of Contents for Mexico Super CF495

Page 1: ...ENGINEERED FOR PEACE OF MIND When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reco...

Page 2: ...in 533 21 0 600 23 6 750 29 5 Table 1 General Data Table 2 Performance Data Key to symbols GB United Kingdom Countries of IE Ireland destination PMS Maximum operating pressure of water B11BS An appli...

Page 3: ...ly Scale reducer n a Hot water mode Heat input n a Max operating burner pressure n a Max operating water pressure n a Cold water inlet temp n a Hot water outlet temp n a Water flow rate at max setting...

Page 4: ...s are certificated by the British Standards Institution for safety and performance It is important therefore that no external control devices e g flue dampers economisers etc are directly connected to...

Page 5: ...r the LH side or the RH side DURING installation Refer to Frame 11 A MINIMUM clearance of 25mm 1 MUST also be maintained between the flue pipe and any adjacent combustible material In addition a MINIM...

Page 6: ...ed with a non porous acid resistant material it should be lined with a stainless steel flexible flue liner which complies with BS 715 5 Before connecting the boiler to or inserting a liner into a flue...

Page 7: ...e located in accessible positions which permit the draining of the whole system including the boiler and hot water storage vessel They should be at least 1 2 BSP nominal size and be in accordance with...

Page 8: ...e MUST be made if surging is liable to occur If in any doubt contact Caradon Ideal Limited 3 MINIMUM REQUIREMENTS Fully pumped systems 4 GRAVITY HOT WATER PUMPED CENTRAL HEATING 1 Separate flow and re...

Page 9: ...expansion 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 ca...

Page 10: ...between 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 Th...

Page 11: ...ignment rings and O rings 6 Thermostat pocket 7 Distributor tube 8 Combustion chamber 12 Collector hood 16 Front plate assy 18 Burner manifold 24 Gas valve 28 Gas cock 41 Draught diverter back panel a...

Page 12: ...tion and Servicing Users Instructions The boiler is supplied fully assembled in Pack A Unpack and check the contents 8 UNPACKING HARDWAREPACK Thermostat pocket 1 off Thermostat clip 1 off Thermostat r...

Page 13: ...the PCB lead 4 Remove the Burner On neon cable from the back of the control panel 5 Unplug the in line connector to the TTB thermostat 6 Remove the 2 screws securing the control panel and disengage th...

Page 14: ...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 t...

Page 15: ...rectly above the boiler should be provided 14 WATER TREATMENT These boilers incorporate a cast iron heat exchanger IMPORTANT The application of any other treatment to this product may render the guara...

Page 16: ...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 insul...

Page 17: ...e details Cylinder Thermostat Terminal Boiler supply connector Pump Terminal strip suitably enclosed Typical programmer CH may be selected independently MAINS Notes 1 Some earth wires are omitted for...

Page 18: ...nge gy grey y g yellow green Gravity HW Pumped CH Diagram A shows a double pole frost thermostat which should suffice for all systems which do not use the OFF terminals of the programmer Diagram B sho...

Page 19: ...retaining clip Split pin MEX 729 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...

Page 20: ...uing until the pilot is established The main burner will then cross light smoothly If this sequence does not occur refer to the Fault Finding section 6 Test for gas soundness around ALL boiler gas com...

Page 21: ...stem 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...

Page 22: ...s 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 a...

Page 23: ...the manifold nuts to remove both burners from the burner front plate manifold assembly 5 From each burner remove the 2 air box securing nuts and CAREFULLY remove the air box and venturi arrangement 6...

Page 24: ...they are 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 Reconnect the electrical wiring en...

Page 25: ...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 45 When replacing any component 1 Isolate the electricity suppl...

Page 26: ...reverse order 1 Refer to Frame 38 2 Remove the 2 screws and lift off the lower front panel Refer to Frame 30 3 Pull off the thermostat knob 4 Disconnect the in line connector on the PCB lead 5 Remove...

Page 27: ...p 7 Disconnect the ignition lead from the base of the electrode and the PCB and withdraw the lead 8 Fit the new lead and reassemble in reverse order 1 Refer to Frame 38 2 Remove the 2 screws and lift...

Page 28: ...hers securing the bottom burner baffle and remove the baffle 7 Remove the 2 screws securing the pilot burner and pull the assembly clear of the main burner 8 Remove the 4 nuts and washers securing the...

Page 29: ...GAS VALVE REPLACEMENT Gas control valve Gas inlet pipe Pilot supply connection MEX 2150 Burner manifold 6 7 4 8 O ring seal Securing screws 1 Refer to Frame 38 2 Remove the 2 screws lift off the lower...

Page 30: ...the boiler and carefully lift the TTB bracket from its retaining slot and clip 6 Withdraw the thermostat bracket and lead down the side of the boiler 7 Locate and fit the new TTB downdraught thermosta...

Page 31: ...verheat stat Has the fuse on the PCB blown Reset 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...

Page 32: ...ndraught thermostat 1 173 143 49 E01 540 Flue baffle CF495 2 134 737 Flue baffle CF4120 2 157 924 E01 530 Flue baffle CF4140 1 135 770 67 308 557 Thermostat knob 1 111 904 The following are parts comm...

Page 33: ...HORT PARTS MEX 2151 17 20 22 23 30 26 21 27 24 67 66 44 1 52 BOILER CASING ASSEMBLY MEX 2152 76 63 73 75 77 46 73 Legend 46 Baseplate 62 Casing complete 63 Controls panel complete 73 Side panel 75 Cas...

Page 34: ...te 17 Sightglass 18 Burner manifold 19 Pilot pipe 20 Burner 21 Burner injector 2 off 22 Pilot burner 24 Gas valve 25 O ring 26 Ignition electrode 27 Ignition lead 28 Gas service cock Legend 63 Control...

Page 35: ...LIST OF PARTS 35 Mexico Super CF495 CF4140 Installation Servicing 55 PCB BOX Exploded View Legend 29 PCB chassis assy 30 PCB sub assy 33 PCB support 37 PCB cover 33 29 30 37 MEX 2155...

Page 36: ...f 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...

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Ideal Boilers Mexico Super CF495, Installation And Servicing Manual

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