Ideal Boilers Mexico Super FF440 Installation And Servicing Manual Download

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Mexico Super FF440 - FF480 -

Installation & Servicing

INSTALLATION

BOILER CASING REMOVAL

The boiler is supplied fully assembled in Pack A,
together with a standard flue assembly for lengths
up to 600mm (23

1/2

") rear or side flue outlet in

Pack B.

Unpack and check the contents.

UNPACKING

complete boiler assembly

BOILER HARDWARE PACK

1" BSP plugs - 5 off.

1" x

1/2

" BSP reducing bush - 1 off.

Cable strap - 2 off.

Distributor tube

Thermostat pocket -1 off

Thermostat clip (RS 3/50, RS 3/60,
RS 3/70 & RS 3/80 only) - 1 off

Thermostat retaining pin - 1 off

To install the boiler the casing MUST be removed.

Undo the 2 screws and lift off the lower front panel.

Remove 2 screws and lift off the grille assembly.

Disconnect the in-line electrical connector between
the control box and the PCB box.

Remove the thermostat phial from the pocket as
shown in Frame 6.

Remove the 2 screws securing the control panel and
pull down to release the tabs from under the top
panel.

Remove the 2 screws securing the top panel to the
side.

FLUE PACK. Pack B Contents

Duct cutting support, 2 off (cardboard )

Terminal wall plate, 1 off.

Terminal grille assy., 1 off.

Polyurethane foam seal 400 lg., 1 off.

No. 8 x 8 lg. Pozi pan hd. screws, 3 off.

FLUE HARDWARE PACK

PACK A CONTENTS

Complete boiler assembly

These Installation & Servicing/Users Instructions

The Hardware Pack (listed separately below)

Template

INST

ALLA

TION

Flue extension tube (rear)

Flue extension tube (side)

Flue extension tube (top)

Elbow

Sealing ring

M5 wing nuts - 3 off

No.10 x 2” Rd. Hd.
woodscrew - 8 off.

Wall Plug - brown - 8 off.

Side outlet plate

28mm Comp nut - 1 off.

28mm olive - 1 off.

INST

ALLA

TION

200939-1.p65

3/1/2004, 4:33 PM

Summary of Contents for Mexico Super FF440

Page 1: ...INEERED 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 reconditioned or copy parts that have not been clearly authorised by Ideal Boilers FF440 FF450 FF460 FF470 FF480 June 2004 UIN 200 939 A02 ...

Page 2: ...60 FF470 FF480 Boiler Input GROSS kW Btu h 14 4 49 100 18 1 61 700 21 7 74 000 25 0 85 300 28 9 98 600 l s ft 3 h 0 37 47 3 0 47 59 4 0 56 71 3 0 65 83 1 0 75 95 0 Boiler Input NET kW Btu h 13 0 44 300 16 3 55 600 19 5 66 500 22 8 77 800 26 0 88 700 Boiler Output to Water kW Btu h 11 7 40 000 14 7 50 000 17 6 60 000 20 5 70 000 23 4 80 000 Burner Setting Pressure hot mbar in w g 10 3 4 4 11 8 4 7 ...

Page 3: ...l heating only pumped central heating combined with either a pumped or gravity circulating indirect DHW circuit Mexico Super FF B G Certified P I No 87AU83 Destination Countries GB IE Appliance type C12 Models G C Appliance No Mexico Super FF440 41 392 26 Mexico Super FF450 41 392 27 Mexico Super FF460 41 392 28 Mexico Super FF470 41 392 29 Mexico Super FF480 41 392 30 Natural Gas only BENCHMARK L...

Page 4: ... Practice In IE the installation must be carried out by a Competent Person and installed in accordance with the current edition of I S 813 Domestic Gas Installations the current Building Regulations and reference should be made to the current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice BS 6891 Low pressure instal...

Page 5: ...ate and to facilitate servicing are as shown in the table Additional space will be required for installation depending upon site conditions IMPORTANT In order to facilitate gas connection a clearance of at least 100 mm 4 must be available at either the left hand side or the right hand side DURING installation Refer to Frame 39 In addition a MINIMUM clearance of 533 mm 21 MUST be available at the f...

Page 6: ...ing notes are for general guidance 1 It is NOT necessary to have a purpose provided air vent in the room or internal space in which the boiler is installed 2 If the boiler is to be installed in a cupboard or compartment permanent air vents are required for cooling purposes in the cupboard compartment at both high and low levels The air vents must either communicate with room internal space or be d...

Page 7: ...cially softened water is NOT permitted 4 Under no circumstances should the boiler be fired before the system has been thoroughly flushed BOILER CONTROL INTERLOCKS Caradon Ideal Limited recommend that heating systems utilising full thermostatic radiator valve control of temperature in individual rooms should also be fitted with a room thermostat controlling the temperature in a space served by radi...

Page 8: ...on 6 Thermostat pocket 7 Distributor tube 8 Combustion chamber 12 Collector hood 14 Fan assembly 16 Front plate assy 42 38 12 14 49 41 5 1 7 Tie rod 8 46 Mex 1878 Data badge 28 16 18 30 6 69 68 2 4 3 24 INSTALLATION 18 Burner manifold 24 Gas valve assy 28 Gas cock 30 PCB assembly 38 Pressure switch 41 Turret assembly 42 Turret access cover assy 46 Boiler base plate 49 Flue baffle 68 Thermostat phi...

Page 9: ...the in line electrical connector between the control box and the PCB box 4 Remove the thermostat phial from the pocket as shown in Frame 6 5 Remove the 2 screws securing the control panel and pull down to release the tabs from under the top panel 6 Remove the 2 screws securing the top panel to the side FLUE PACK Pack B Contents Duct cutting support 2 off cardboard Terminal wall plate 1 off Termina...

Page 10: ...her 2 Flue extensions of greater than 1m 39 should be supported with the bracket provided It is MOST IMPORTANT that the boiler is installed in a vertical position 7 DETERMINING THE FLUE LENGTH 6 BOILER CASING REMOVAL continued 11 The boiler is held to the packaging base by 4 M6 hex head screws Remove the front screws slacken the rear screws and remove the boiler from the packaging base Flue length...

Page 11: ...hermostat Position Back Section Front Section CH DHW Flow Return Flow Return Top LH LH RH RH LH LH RH RH LH LH RH RH LH LH RH RH LH LH RH RH Table 6 Gravity Domestic Hot Water and Pumped Central Heating Table 5 Fully Pumped Systems Connections as viewed at front Thermostat Position Back Section Front Section Flow Return Top LH LH LH LH RH LH RH RH RH RH LH RH 9 REAR FLUE ASSEMBLY Exploded view LEG...

Page 12: ...r against the wall stick the self adhesive foam strip provided in the hardware pack onto the flue immediately behind the boiler sealing ring otherwise refer to Frame 13 1 Tape the template into the selected position 2 Mark onto the wall the position of the flue duct hole IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal inj...

Page 13: ...d the location of the studs into the boiler back panel 3 Proceed to Frame 15 item B B Outside fitting Proceed to Frame 15 item A 1 Secure the flue to the boiler using the three M5 wing nuts provided Note The sealing plate studs will locate in the back panel one way only This will ensure that the terminal is correctly aligned 16 CONNECTING THE FLUE TO THE BOILER 13 FITTING THE FOAM SEAL 1 To determ...

Page 14: ...ly cut and the rubber weather seal trimmed around the groove provided The terminal wall plate need not be fitted 17 SIDE FLUE ASSEMBLY Exploded view For wall thickness 114mm to 600mm 1 The boiler turret assembly is factory built for rear flue installation 2 Remove the turret access cover 3 Remove the sealing plate from the appropriate side to be used and refit in the rear outlet 4 An optional flue...

Page 15: ...nsure the notch aligns with the groove on the outer flue duct This ensures correct alignment of the flue terminal 2 Drill 3 holes 3 2mm 1 8 dia through the outer flue duct and boiler sealing ring Do not drill the inner flue duct 3 Insert the self tapping screws provided in order to fix the boiler sealing ring in position 19 CUTTING THE FLUE wall thicknesses of 114 to 600mm 1 Measure and note the w...

Page 16: ...CATING THE BOILER A If the flue assembly can be fitted from the outside proceed as follows 1 Move the boiler into position ensuring that the flue outlet is in line with the wall opening 2 Insert the flue assembly ensuring that the flue slides into the flue extension and the 3 sealing ring studs locate into the boiler B If the flue assembly has been fitted from the inside proceed as follows Move th...

Page 17: ...ant side of the boiler casing greater than 600mm 23 1 2 Refer to Frame 7 7 When cutting the ducts always use the cardboard support provided 27 PREPARING THE WALL 1 Mark onto the wall the position of the flue duct hole IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 2 Cut the flue hole preferably with a 125mm 5 core...

Page 18: ...opriate length A of outer flue duct refer to Frame 7 Ensure the boiler sealing ring is fully engaged 2 Drill 3 holes 3 2mm 1 8 dia through the outer flue duct and boiler sealing ring Do not drill the inner flue duct 3 Insert the self tapping screws provided in order to fix the boiler sealing ring in position 4 Fit the turret access cover to the sealing ring 1 To determine the position for the foam...

Page 19: ...than 25mm to the side wall the side outlet plate must be fitted now 1 Split the side outlet plate into 2 down the split line 2 Fit the 2 halves of the side outlet plate to the wall ensuring they are behind the boiler sealing ring 33 LOCATING THE BOILER Position the boiler beneath the flue assembly 1 Connect the flue terminal to the boiler using the length A of flue duct previously cut and ensuring...

Page 20: ...90 o Elbow 1m 45 o Elbow 0 7m 37 FITTING THE KIT 1 Remove the cardboard support aid from the flue and place safely to one side 2 Fit the inner flue extension duct onto the inner flue duct 3 Fit the outer flue extension duct onto the outer air duct 4 Drill 3 3 2mm 1 8 dia holes through the outer air duct Do not drill the inner flue duct 5 Insert the self tapping screws provided to fix the air duct ...

Page 21: ...as pressure of 20 mbar 8 in w g MUST be available at the boiler inlet with the boiler operating 2 Extend a gas supply pipe NOT LESS THAN 15mm 1 2 OD to the boiler and connect to the gas cock situated at the front LH side of the boiler 38 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the rubber seal Its use is not essential if the flue hole and flue ducts have been ...

Page 22: ...e between the top of the boiler and the base of the cylinder 41 MINIMUM REQUIREMENTS Fully pumped systems 1 Open vent and cold feed connections must be made to the boiler flow and return tappings according to the options shown in Frame 8 2 The boiler is assumed to be the highest point of the circulating system 3 The circulating pump is positioned on the FLOW and the vertical distance between the p...

Page 23: ...ical leads into the box and wire into the terminal strip as shown Notes a Secure each lead with one of the cable clamps b The mains lead connection MUST be made so that should the lead slip from its anchorage the current conductors become taut before the earthing conductor 45 EXTERNAL CONTROLS PCB 25 mex7390 Note If there are no external controls the circulating pump MUST be wired into the control...

Page 24: ...24 Mexico Super FF440 FF480 Installation Servicing INSTALLATION 46 PICTORIAL WIRING LEGEND w white r red bk black br brown p purple b blue gy grey y g yellow green INSTALLATION ...

Page 25: ...inals on thermostats is specific to the manufacturer 3 This is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster Autozone has grey and orange auxiliary switch leads but the GREY NOT the orange wire must be connected to the incoming live supply Pumped only 49 HONEYWELL C PLAN Notes 1 Some earth wires are omitted for clarity Ensure proper earth continuity when wiring 2 Nu...

Page 26: ... 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 selector switches are set to OFF and all other controls MUST be left in the running position The frost stat should be sited in a cold place but where it can sense heat from the system Wiring should be...

Page 27: ...ge 2 If adjustment is necessary remove the sealing cap and turn the adjusting screw clockwise to increase anticlockwise to decrease the pressure until the required burner pressure is achieved Refit the sealing cap 9 Set the boiler mains on off switch to OFF 10 Remove the pressure gauge and tube Retighten the sealing screw in the pressure test point 11 Turn ON and check for gas soundness at the pre...

Page 28: ...ls 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 inoperative during frosty conditions Notes If an optional programmer kit is fitted refer to ...

Page 29: ...oceed to step d d Clean the main burner e Clean the heat exchanger f Clean the main injectors g Check that the flue terminal is unobstructed and that the flue system is sealed correctly h If the appliance has been installed in a compartment check that the ventilation areas are clear The servicing procedures are covered more fully in Frames 58 to 62 and MUST be carried out in sequence Note In order...

Page 30: ... FF450 Only 1 Remove the 2 screws and lift off the lower front panel Refer to Frame 57 2 Remove the grille assembly Undo the gas cock union 3 Disconnect the ignition lead from the PCB 4 Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 5 Place on a convenient working surface 1 Brush off any deposits that may have fallen onto the burner head ensuring that...

Page 31: ... the front plate 2 Fit the new sightglass and re assemble as shown 3 Retighten the 2 M5 hexagon nuts to ensure an airtight seal Do NOT overtighten 61 RE ASSEMBLY 62 GAS PRESSURE ADJUSTMENT 1 Pilot Pressure Pilot adjustment is factory set to maximum and no adjustment is possible 64 SIGHTGLASS REPLACEMENT Re assemble the boiler in the following order 1 Refit the flue baffles 2 Inspect the collector ...

Page 32: ...L THERMOSTAT REPLACEMENT 1 Remove the 2 screws and lift off the lower front panel then remove the grille assembly Refer to Frames 57 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 2 Disconnect the ignition lead from the PCB 3 Prise the retaining clip out of the groove in the electrode using a small screwdriver and withdraw the ...

Page 33: ...nd release from its clamp 9 Assemble new control box and panel and fit to the casing in reverse order 10 Insert control thermostat phial into pocket and secure with the split pin 11 Refit the inline electrical connector between the control box and the PCB box 12 Remove control box cover and make electrical supply connections to the terminal strip Refer to Frame 46 1 Remove the 2 screws and lift of...

Page 34: ...he PCB 3 Prise the retaining clip out of the groove in the electrode using a small screwdriver and withdraw the electrode 1 Remove the 2 screws and lift off the lower front panel then remove the grille assembly Refer to Frame 57 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 2 Disconnect the ignition lead from the PCB 3 Remove ...

Page 35: ...jointing compound and re assemble in reverse order 1 Remove the 2 screws and lift off the lower front panel then remove the grille assembly refer to Frame 57 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 2 Disconnect the ignition lead from the PCB 3 Undo the pilot supply connection 4 Unscrew the gas inlet pipe from the valve 5...

Page 36: ...press the barbs on the PCB stand offs to release the PCB from the box 6 Fit the new PCB and reassemble in reverse order 7 Refit the boiler casing 8 Check the operation of the boiler 1 Remove the lower front panel control panel and top panel Refer to Frame 57 2 Remove the silicon rubber tube from the sensing point 3 Disconnect the fan leads 4 Remove the M4 screw securing the flue connector to the f...

Page 37: ...ce at switch greater than 0 9 mbar Change fan YES NO Change pressure switch Does the pilot light NO YES NO YES Does the spark stop after pilot is lit NO Is there a gas supply to the boiler Is the pilot injector blocked YES Replace gas valve NO Is there a supply on terminals of main gas valve YES NO YES NO NO Is there a supply on the fan connector at PCB Molex marked FAN YES YES NO NO Check the pol...

Page 38: ...Ignition electrode HONEYWELL 45900413 004 1 151 079 27 HT lead 900 mm FF440 450 460 470 480 1 058826 30 PCB sub assembly 1 170 665 38 Pressure switch HONEYWELL C6065F1316B 1 155 412 49 Flue baffle kit FF440 2 079890 FF450 FF460 4 079890 FF470 FF480 4 079890 66 Thermostat RANCO K36 P1354 1 151 903 67 308 557 Thermostat knob 1 111 904 The following are parts commonly required as replacement componen...

Page 39: ...39 Mexico Super FF440 FF480 Installation Servicing SHORT LIST OF PARTS 76 SHORT PARTS Mex 1879 ...

Page 40: ... Installation Servicing LIST OF PARTS Legend 63 Control panel complete assy 65 Control box assy 66 Control thermostat 77 BOILER CONTROL PANEL Exploded View 67 Control thermostat knob 71 Control front panel door 72 Magnetic strip ...

Page 41: ...41 Mexico Super FF440 FF480 Installation Servicing LIST OF PARTS 78 PCB BOX Exploded View Legend 29 PCB Chassis assembly 30 PCB sub assembly 34 PCB support 37 PCB cover ...

Page 42: ...ER AND CONTROLS ASSEMBLY Exploded View Legend 16 Front plate assy 17 Sightglass assy 18 Burner manifold 19 Pilot pipe 20 Main burner 21 Main injector 22 Pilot burner 24 Gas valve 25 O ring 26 Ignition electrode 27 Ignition Iead 28 Gas cock 50 Sealing gasket 51 Sealing plate ...

Page 43: ...llation Servicing LIST OF PARTS Legend 46 Baseplate 62 Casing complete 63 Controls panel complete 71 Controls front panel door 73 Side panel LH 74 Side panel RH 75 Lower front panel 76 Top panel 77 Grille assy 80 BOILER CASING ASSEMBLY ...

Page 44: ...of 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 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 EN ISO 90...

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