IDEAL Mexico Super 440 FF Installation Manual Download Page 1

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Mexico Super 440 FF - 480 FF -

Installation

Summary of Contents for Mexico Super 440 FF

Page 1: ...1 Mexico Super 440 FF 480 FF Installation...

Page 2: ...0 000 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 12 2 4 9 10 6 4 3 13 2 5 3 Seasonal Efficiency SEDBUK Band D 78 2 78 9 79 0 80 5 79 8 Bo...

Page 3: ...OG BOOK DETAILS Boiler Page Make and model 3 Appliance serial no on data badge 8 SEDBUK No 2 Controls Time and temperature control to heating 25 Time and temperature control to hot water 25 Heating zo...

Page 4: ...current ETCI rules for electrical installation Detailed recommendations are contained in the following British Standard Codes of Practice BS 6891 Low pressure installation pipes BS 6798 Installation o...

Page 5: ...l 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...

Page 6: ...es 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...

Page 7: ...y 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 heati...

Page 8: ...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 IN...

Page 9: ...ectrical 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 t...

Page 10: ...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 CAS...

Page 11: ...tat 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 Tab...

Page 12: ...inst 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 selecte...

Page 13: ...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 T...

Page 14: ...t 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 as...

Page 15: ...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 dr...

Page 16: ...G 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 a...

Page 17: ...ide 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 fl...

Page 18: ...te 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...

Page 19: ...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...

Page 20: ...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 f...

Page 21: ...sure 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...

Page 22: ...ween 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...

Page 23: ...ctrical 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 it...

Page 24: ...24 Mexico Super 440 FF 480 FF Installation 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: ...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...

Page 26: ...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 selec...

Page 27: ...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 sea...

Page 28: ...ould 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 precauti...

Page 29: ...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...

Page 30: ...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 nu...

Page 31: ...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...

Page 32: ...RMOSTAT 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 a...

Page 33: ...lease 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 electr...

Page 34: ...B 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 ass...

Page 35: ...ing 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...

Page 36: ...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 fron...

Page 37: ...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 inj...

Page 38: ...nition electrode HONEYWELL 45900413 004 1 151 079 27 HT lead 900 mm 440 450 460 470 480 FF 1 058826 30 PCB sub assembly 1 170 665 38 Pressure switch HONEYWELL C6065F1316B 1 155 412 49 Flue baffle kit...

Page 39: ...39 Mexico Super 440 FF 480 FF Installation SHORT LIST OF PARTS 76 SHORT PARTS Mex 1879...

Page 40: ...80 FF Installation 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...

Page 41: ...41 Mexico Super 440 FF 480 FF Installation 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: ...D 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 elec...

Page 43: ...Installation 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...

Page 44: ...rs 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 498 432 THIS SYMBOL IS YO...

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IDEAL Mexico Super 440 FF, Installation Manual

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