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GENERAL

10

Mexico Super CF495 - CF4140

 -

 Installation & Servicing

Sizing procedure for expansion vessels:

 The volume of the expansion vessel (litres) fitted to a sealed system shall not be

less than that given by Table 5, multiplied by a factor of 0.8 (for flow temperatures of less than 88 

o

C).

Safety valve setting

3.0 bar

2.5 bar

2.0 bar

Vessel charge and initial

0.5

1.0

1.5

0.5

1.0

1.5

0.5

1.0

system pressure

bar

bar

bar

bar

bar

bar

bar

bar

Total water content of system

Expansion vessel volume

 (litres)

(litres)

25

2.1

2.7

3.9

2.3

3.3

5.9

2.8

5.0

50

4.2

5.4

7.8

4.7

6.7

11.8

5.6

10.0

75

6.3

8.2

11.7

7.0

10.0

17.7

8.4

15.0

100

8.3

10.9

15.6

9.4

13.4

23.7

11.3

20.0

125

10.4

13.6

19.5

11.7

16.7

29.6

14.1

25.0

150

12.5

16.3

23.4

14.1

20.1

35.5

16.9

30.0

175

14.6

19.1

27.3

16.4

23.4

41.4

19.7

35.0

200

16.7

21.8

31.2

18.8

26.8

47.4

22.6

40.0

225

18.7

24.5

35.1

21.1

30.1

53.3

25.4

45.0

250

20.8

27.2

39.0

23.5

33.5

59.2

28.2

50.0

275

22.9

30.0

42.9

25.8

36.8

65.1

31.0

55.0

300

25.0

32.7

46.8

28.2

40.2

71.1

33.9

60.0

Multiplying factors for

other system volumes

0.0833

0.109

0.156

0.094

0.134

0.237

0.113

0.20

7. Mains Connection

There must be no direct connection to the mains water
supply or to the water storage tank supplying domestic
water, even through a non-return valve, without the approval
of the local water authority.

8. Filling

The system may be filled by one of the following methods:

a.

Through a cistern, used for no other purposes, via a
ball valve permanently connected directly to a service
pipe and / or a cold water distributing pipe.
The static head available from the cistern should be
adequate to provide the desired initial system design
pressure. The cold feed pipe from the cistern should
include a non-return valve and a stop valve with an
automatic air vent connected 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 temporary connection from a service pipe or cold
water distributing pipe.
This unit may remain permanently connected to the
heating system to provide limited automatic water
make-up.  Where the temporary connection is
supplied from a service pipe or distributing pipe
which also supplies other draw-off points at a lower

level then a double check valve shall be installed
upstream of the draw-off point.

c.

Through a temporary hose connection from a draw-off tap
supplied from a service pipe under mains pressure. Where
the mains pressure is excessive a pressure-reducing valve
shall be used to facilitate filling.
The following fittings shall form a permanent part of the
system and shall be fitted in the order stated:
A stop valve complying with the requirements of
BS. 1010, Part 2 (the hose from the draw-off tap shall be
connected to this fitting).
A test cock.
A double check valve of an approved type.

• Thoroughly flush out the whole of the system with cold

water, without the pump in position.

• With the pump fitted, fill and vent the system until the

pressure gauge registers 1.5 bar (21.5lb/in

2

).

Examine for leaks.

• Check  the operation of the safety valve by manually

raising the water pressure until the valve lifts.  This
should occur within ± 0.3 bar (± 4.3lb/in

2.

) of the preset

lift pressure.

• Release water from the system until the initial system

design pressure is reached.

• Light the boiler and heat the system to the maximum

working temperature. Examine for leaks.

• Turn off the boiler and drain the system while still hot.
• Refill and vent the system.

6

SEALED SYSTEM REQUIREMENTS - continued

Table 5

200944-1.p65

3/8/2004, 3:41 PM

10

Содержание Mexico Super CF495

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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