Ideal Boilers Mexico Super RS4100 Installation And Servicing Download | Manualshive

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installation and
servicing

Mexico Super

Your Ideal installation and servicing guide

See reverse for

Mexico Super

users guide

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 reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.

RS485, RS4100 & RS4125

May 2004 UIN 200 942 A02

200942-2.pmd

6/2/2004, 9:14 AM

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Summary of Contents for Mexico Super RS4100

Page 1: ...e 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 reconditioned or copy parts that have not been clearly authorised by Ideal Boilers RS485 RS4100 RS4125 May 2004 UIN 200 942 A02 ...

Page 2: ...on via ducts to a horizontal terminal which admits fresh air to the burner and discharges the products of combustion to the outside without a fan in the combustion products circuit I2H An appliance designed for use on 2nd Family gas Group H only The value is used in the UK government s Standard Assessment Procedure SAP for energy rating of dwellings The test data from which it has been calculated ...

Page 3: ...sure and record Central heating flow temp measure and record Central heating return temp measure and record For combination boilers only Scale reducer n a Hot water mode Heat input n a Max operator 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 n a For condensing boilers only Condensate drain n a For all boile...

Page 4: ...al 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 Electricity at Work Regulations 1989 M...

Page 5: ...tem 2 If the boiler is to be used on a sealed system an Overheat Thermostat Kit is available and must be installed in accordance with the instructions supplied with the kit 1 BOILER WATER CONNECTIONS 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 ...

Page 6: ...at roof to which people have access then the terminal MUST be protected by a purpose designed guard Terminals guards are available from boiler suppliers In case of difficulty seek advice from Grasslin UK Ltd Tower House Vale Rise Tonbridge Kent TN9 1TB Tel 44 0 1732 359 888 Fax 44 0 1732 354 445 www tfc group co uk Ensure that the guard is fitted centrally 5 Where the terminal is fitted within 100...

Page 7: ...nnection a separate vent MUST be fitted by the installer Draining taps MUST be 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 BS 2879 If required a drain tap not supplied may be fitted to an unused bottom 1 BSP tapping on the front of the boiler BO...

Page 8: ... etc Due allowance 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 return connections are used for each service All possible configurations are given in Frame 11 and ONLY those shown should be used 2 The schematic pipework graph is based on the assumpt...

Page 9: ... 4 Expansion Vessel a A diaphragm type 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 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 h...

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 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 te...

Page 11: ...215 Detail of distributor tube alignment Index mark on section boss Distributor tube 12 Collector hood 18 Front plate 24 Gas control valve 28 Gas cock 30 PCB 44 Air flue duct assy 46 Baseplate 47 Heat shield 49 Baffles 68 Phial clip 69 Split pin 94 Cleanout cover LEGEND 1 Heat exchanger assy 2 Front section 3 Middle section 4 Section alignment rings O rings 5 Back section 6 Thermostat pocket 7 Dis...

Page 12: ... 2 off HARDWAREPACK Thermostat clip 1 off Thermostat pocket 1 off Thermostat retaining pin 1 off 1 BSP plugs 5 off 1 x 1 2 BSP reducing bush 1 off Distributor tube Cable strap 2 off 28mm Comp nut 1 off 28mm olive 1 off Wall thickness Flue Dimension duct length X shown above pack Boiler fitted flush with wall Boiler fitted in line with 600mm kitchen units required RS485 114 to 191 mm 4 1 2 to 7 1 2...

Page 13: ... grille assembly 3 Disconnect the in line 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 Draw the top panel forward and lift it off the boiler 8 Remove the 2 screws securing the LH side...

Page 14: ... tappings and plug any unused tappings Note If using iron elbows fit a short straight connector into the boiler tapping first to clear the casing Connections as viewed at front Thermostat 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 8 Gravity Domestic Hot Water and Pumped Central Heating Table 7 Fully Pumpe...

Page 15: ...OUTSIDE of the building 5 From OUTSIDE the building seal the duct join A with the mastic provided 13 FITTING THE FLUE ASSEMBLY 6 From OUTSIDE the building pass the terminal flue duct through the wall opening and slide it into the boiler flue duct pushing the flue duct fully in up to the locating stops Locate it as shown 7 From OUTSIDE of the building seal the duct join B with the mastic provided 8...

Page 16: ...alves are open Fill and vent the system and check for water soundness Notes a Isolating valves must be fitted as close to the pump as possible b The boiler is not suitable for use with a direct hot water cylinder 16 WATER TREATMENT These boilers incorporate a cast iron heat exchanger IMPORTANT The application of any other treatment to this product may render the guarantee of Caradon Ideal Limited ...

Page 17: ...ng should not arise providing the following directions are observed 1 Remove the securing screw and lift off the control box cover 2 Route the electrical 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 ...

Page 18: ...lightly see manufacturer s literature Pumped only 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 independently MAINS LEGEND b blue bk black br brown r red or orange w white gy grey y g yellow green 20 PICTORIAL WIRING Mex 2554 r r br b b b br bk bk bk br w ...

Page 19: ...ive supply Pumped only 23 HONEYWELL C PLAN 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 LEGEND w white r red bk black br brown or orange b blue gy grey y g yellow green Gravity HW Pumped CH LEGEND b blue bk black br brown r red w white or orange y g yellow green gy grey Boiler sup...

Page 20: ...th the peg in the baseplate and push the panel back 2 Secure the panel to the baseplate and collector hood 3 Repeat steps 1 and 2 to refit the LH side panel 4 Place the top panel and push back 5 Secure the top panel to the side panels IMPORTANT Wiring within the boiler casing must be neatly secured with the cable straps provided and MUST NOT be allowed to touch the burner front plate or the cleano...

Page 21: ...e 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 components using leak detection fluid 7 Operate the boiler for 10 minutes to stabilise the burner temperature 8 The boiler is preset at the factory to its nominal rating Refer to Table 2 page 2 If adjustment is necessary remove the sealing c...

Page 22: ...onsistent 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 5 Explain the function and the use of the boiler thermostat and external controls 29 HANDING OVER After completing the installation and commissioning...

Page 23: ...edures are covered more fully in Frames 31 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 appliance BEFORE SERVICING IMPORTANT After completing the servicing or exchange of components always test for gas soundness and carry out functional checks as appropriate 31 BOILER CASING REMOVAL ...

Page 24: ...asing top panel 3 Reconnect the electrical wiring and refit the control panel ensuring that the thermostat phial and phial retaining clip are correctly located in the thermostat pocket and secured by the split pin Refer to Frame 31 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 7...

Page 25: ...uts and washers Remove the assembly from the front plate 3 Fit the new sightglass and reassemble as shown 4 Retighten the 2 M5 hexagon nuts to ensure an airtight seal Do NOT overtighten 1 Refer to Frame 37 2 Undo the 2 screws lift off the front panel and remove the grille assembly Refer to Frame 31 3 Disconnect the electrical leads from the gas valve 4 Disconnect the ignition lead from the PCB 5 U...

Page 26: ... leads 10 Unscrew the thermostat nut to withdraw the thermostat 11 Fit the new thermostat and reassemble in reverse order MEX 1931 Thermostat bracket Control thermostat Mex 2198 10 7 3 4 6 9 8 Cover 1 Refer to Frame 37 2 Remove the 2 screws lift off the front panel and remove the grille assembly Refer to Frame 31 3 Disconnect the electrical leads from the gas valve 4 Disconnect the ignition lead f...

Page 27: ... from its clamp 10 Assemble new control box and panel and fit to the casing in reverse order 11 Insert control thermostat phial into pocket and secure with the split pin 12 Refit the inline electrical connector between the control box and the PCB box 13 Remove control box cover and remake electrical supply connections to the terminal strip 1 Refer to Frame 37 2 Remove the 2 screws and lift off the...

Page 28: ...he new electrode until the retaining clip locates in the groove and reassemble in reverse order 1 Refer to Frame 37 2 Remove the 2 screws lift off the lower front panel then remove the grille assembly Refer to Frame 31 3 Disconnect the electrical leads from the gas valve 4 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 5 Discon...

Page 29: ...in reverse order Gas control valve Gas inlet pipe Pilot supply connection MEX 2217 Burner manifold 6 7 4 8 O ring seal Securing screws 1 Refer to Frame 37 2 Remove the 2 screws lift off the lower front panel then remove the grille assembly Refer to Frame 31 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 4 wing n...

Page 30: ... panel Refer to Frame 31 3 Undo the PCB cover fixing screw and remove the cover 4 Remove the HT lead from the PCB 5 Remove the 6 push in connectors from the PCB 6 Compress the barbs on the PCB stand offs to release the PCB from the box 7 Fit the new PCB and reassemble in reverse order 8 Refit the boiler casing 9 Check the operation of the boiler MEX 2325 6 4 3 5 SERVICING ...

Page 31: ...et 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 the system of air NO YES ...

Page 32: ...fety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers Key No G C Part No Description Qty Product No 17 319 494 Sightglass assembly 1 079 334 20 383 598 Main burner LH RS485 RS4100 1 012 959 E01 372 Main burner RH RS485 RS4100 1 150 871 E26 392 Main burner LH RS4125 1 153 203 E01 374 Main burner RH RS4125 1 1...

Page 33: ...33 Mexico Super RS485 RS4125 Installation Servicing LIST OF PARTS 48 SHORT PARTS Mex 1932 ...

Page 34: ...t bracket Mex 2214 Cable clamps PCB lead 71 72 67 64 65 66 Cover Legend 63 Control panel complete 64 Control panel 65 Control box 66 Control thermostat 67 Control thermostat knob 71 Control front panel door 72 Magnetic strip Legend 46 Baseplate 62 Casing complete 63 Controls panel complete 73 Side panel 75 Lower front panel 76 Top panel 77 Grille assy 78 Casing fixing pack not shown ...

Page 35: ...B sub assy 33 PCB support 37 PCB cover 33 29 30 37 MEX 2324 19 17 25 Mex 1952 21 16 50 51 18 22 28 26 20 27 24 Legend 16 Front plate assy 17 Sightglass assy 18 Burner manifold assy 19 Pilot burner pipe 20 Main burner 21 Main burner injector 22 Pilot burner assy 24 Gas valve 25 O ring 26 Ignition electrode 27 HT lead 28 Gas cock 50 Sealing plate gasket 51 Sealing plate ...

Page 36: ...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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