Page 1
installation and
servicing
Mexico Slimline
Your Ideal installation and servicing guide
See reverse for
Mexico Slimline
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.
CF440
December 2003 UIN 200 946 A01
Page 2
GENERAL
Table 1 - General Data
Boiler Size CF440
Gas Supply Connection in. BSP Rc 1/2 (1/2)
Flow and Return Connections Rc 1 (1" BSP)
MAXIMUM Static Water Head m (ft.) 30.5 (100) (3 bar)
MINIMUM Static Water Head m (ft.) 1.0 (3.3)
Electrical Supply (power consumption) 230 V ~ 50 Hz (10W)
External Fuse Rating 3 A
Water Content litre (gal.) 20 (4.4)
Dry Weight kg. (lb.) 94 (207)
Max. Inst Weight kg. (lb.) 83 (183)
Boiler Size Height mm (in.) 850 (33.5)
Width mm (in.) 255 (10.0)
Depth mm (in.) 535 (21.0)
Gas Type Natural 2 H
Gas Supply Pressure 20 mb
Table 2 - Performance Data
Boiler Size CF440
Boiler Input kW (Btu/h) 14.3 (48,800)
Gas Consumption l/s (ft.3/h) 0.37 (47.0)
Boiler Output to Water kW (Btu/h) 11.7 (40,000)
Burner Setting Pressure (hot) mbar (in w.g.) 11.2 (4.5)
Flue gas flow rate (maximum) g/s 6.7
o
Flue gas temperature
C85
Seasonal Efficiency (SEDBUK)* Band D [78.5]%
* 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 have been certified by Advantica 0087.
Note.
Gas consumption is calculated using a calorific
value of 38.7 MJ/m
3
(1038 Btu/ft3) gross or 34.9
MJ/m3 (935 Btu/ft3) nett
Key to symbols
GB = United Kingdom IE = Ireland (Countries of destination)
PMS = Maximum operating pressure of water
To obtain the gas consumption at a different
calorific value:-
a. For l/s - divide the gross heat input (kW) by
the gross C.V. of the gas (MJ/m
3
b. For ft
/h - divide the gross heat input (Btu/h)
3
).
by the gross C.V. of the gas (Btu/ft3).
CAUTION.
To avoid the possibility of injury during the installation, servicing or cleaning of this
= An appliance designed for connection to a flue discharging the
B
11BS
products of combustion outside the room, with air for combustion
being drawn directly from the room where the appliance is
installed, without a fan in the combustion products circuit and
fitted with a combustion products discharge safety device.
= An appliance designed for use on 2nd Family gas, Group H only.
I
2H
appliance, care should be taken when handling edges of sheet steel components.
2
Mexico Slimline CF440 - Installation & Servicing
Page 3
GENERAL
CONTENTS
Air Supply. ...................................................................... 6
Boiler Assembly - Exploded view ............................... 11
Boiler Clearances .......................................................... 5
Burner Assembly - Exploded view ............................. 34
Electrical Connections ................................................ 15
Electrical Diagrams .....................................................15
Electrical Supply ............................................................ 7
Fault Finding ................................................................. 30
Flue Connection ........................................................... 15
Flue Installation .............................................................. 6
Frost Protection ........................................................... 18
Gas Safety Regulations ................................................. 4
Gas Supply ..................................................................... 5
Initial Lighting ............................................................... 20
Installation ................................................................... 11
Mandatory Requirements ............................................. 4
Pump .............................................................................. 8
Servicing ...................................................................... 22
Short List of Parts ....................................................... 31
System Electrical Diagrams ....................................... 17
Thermostatic Radiator valves. ..................................... 7
TTB Thermostat. ............................................................ 6
Water Circulation .......................................................... 7
Water Systems .............................................................. 8
Water Treatment ........................................................... 7
Mexico Slimline
B.G. Certified - P.I. No. 87AT15
Destination Countries: GB & IE Appliance type: B
Models G.C. Appliance No.
Mexico Slimline CF 440 ................. 41 392 89
Natural Gas only
BS
11
INTRODUCTION
The Mexico Slimline CF 440 is a floor standing, conventional
flue gas boiler. It is rated to provide central heating output of
11.7 kW (40,000 Btu/h)
The boiler has a cast iron heat exchanger and is supplied fully
assembled, complete with a white enamelled mild steel
casing.
The boiler thermostat control is located behind the upper front
panel (drop down door).
The boiler is suitable, as standard, for connection to openvented systems ONLY.
The systems may be:
• pumped or gravity circulating indirect DHW only
• pumped central heating only
• pumped central heating combined with either a pumped or
gravity circulating indirect DHW circuit.
This boiler may require 2 or more operatives to move it to its
installation site, remove it from its packaging base and during
movement into its installation location. Manoeuvring the boiler
may include the use of a sack truck and involve lifting, pushing
and pulling. The use of 1" pipe stubs of suitable lengths may
be temporarily screwed into the boiler tappings to act as
handles.
Caution should be exercised during these operations.
For GB, to comply with Building Regulations Part L1 (Part J in Scotland) the boiler should be fitted in accordance with the
manufacturer's instructions. Self-certification that the boiler has been installed to comply with Building Regulations can be
demonstrated by completing and signing the Benchmark log book.
BENCHMARK LOG BOOK DETAILS
Boiler Page
Make and model .......................................................3
Appliance serial no. on data badge ........................ 11
SEDBUK No. % .........................................................2
Controls
Time and temperature control to heating ......... 17/18
Time and temperature control to hot water ...... 17/18
Heating zone valves .......................................... 17/18
TRV's ......................................................................... 7
Auto bypass ............................................................... 7
Boiler interlock ..........................................................7
For all boilers
Flushing to BS.7593 .................................................7
Inhibitor......................................................................7
Central heating mode
Heat input ................................................. to be calculated
Burner operating pressure ....... measure 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. 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 ............................... n/a
For condensing boilers only
Condensate drain .................................................. n/a
For all boilers: complete, sign & hand over to customer
For assistance see Technical Helpline on the back page
Page
NOTE TO THE INSTALLER:
LEAVE THESE
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK
AND GIVE THIS TO THE CUSTOMER.
Mexico Slimline CF440 - Installation & Servicing
3
Page 4
GENERAL
Operatives should be knowledgeable in handling techniques
when performing these tasks and the following precautions
should be considered:
• Split the boiler down to reduce the weight, e.g. remove
casing and hardware pack. Refer to Frame 9.
• Be physically capable.
• Use PPE as appropriate, e.g. gloves, safety footwear.
During all manoeuvres and handling actions, every attempt
should be made to ensure the following unless unavoidable
and/or the weight is light.
• Keep back straight.
• Avoid twisting at the waist.
• Avoid upper body/top heavy bending.
• Always grip with the palm of the hand.
• Use designated hand holds.
• Keep load as close to the body as possible.
• Always use assistance if required.
OPTIONAL EXTRA KITS
Programmer Kit Fits neatly within the casing. Separate
fitting instructions are included with this kit.
Overheat Available to allow the boiler to be used
Thermostat Kit on sealed water systems.
GAS SAFETY
CURRENT GAS SAFETY (INSTALLATION AND USE)
REGULATIONS OR RULES IN FORCE.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI
Registered Installer. It must be carried out in accordance with
the relevant requirements of the:
• Gas Safety (Installation and Use) Regulations
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (northern Ireland).
• The Water Fittings Regulations or Water byelaws in Scotland.
• The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of 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 installation pipes.
BS. 6798 Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS. 5449:1 Forced circulation hot water systems (small bore
and microbore domestic central 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.
Manufacturer’s notes must NOT be taken in any way as overriding
statutory obligations.
IMPORTANT. These appliances 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 these appliances
unless covered by these Installation and Servicing Instructions or
otherwise recommended by Caradon Ideal Limited in writing. If in
doubt please enquire.
Any direct connection of a control device not approved by Caradon
Ideal Limited could invalidate the BSI Certification and the normal
appliance warranty. It could also infringe the Gas Safety Regulations
and the above regulations or other statutory requirements.
SAFE HANDLING OF SUBSTANCES
Care should be taken when handling the boiler insulation
panels, which can cause irritation to the skin. No asbestos,
mercury or CFCs are included in any part of the boiler.
1
BOILER WATER CONNECTIONS
1. This appliance is NOT suitable for use in a direct hot water
system.
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.
3. All water connections are Rc1 (1" BSP). The front top and
bottom plugged connections must not be used. 2 spare
blanking off plugs are provided, in the hardware pack, for use
as necessary in the rear flow or return water connections.
4. Pipework connections to all systems may use flow and
return connections on the same side, or opposite sides of
the boiler.
That is:
Fully pumped system
In a fully system, either a LH or a RH flow connection, together
with LH or RH return connection, may be used.
Gravity domestic hot water and pumped central heating.
In a gravity DHW and pumped CH system separate flow and
return connections are used for each service.
4
The use of a cylinder thermostat is recommended. This will
prevent excessive domestic hot water temperatures.
Mexico Slimline CF440 - Installation & Servicing
Page 5
GENERAL
LOCATION OF BOILER
The boiler must be installed on a flat and level floor, capable of
adequately supporting the weight of the boiler and any ancillary
equipment.
The boiler may be fitted on a combustible floor.
Insulation is not necessary, unless required by the local authority.
The boiler must not be fitted outside.
The boiler must not be installed in a bedroom or in a room
containing a bath or shower.
Timber Framed Buildings
If the boiler is to be fitted in a timber framed building it should be
fitted in accordance with the Institute of Gas Engineering
document IGE/UP/7:1998.
Compartment Installations
A compartment used to enclose the boiler MUST be designed
and constructed specially for this purpose.
An existing cupboard or compartment may be used, providing it
is modified for the purpose.
Details of essential features of cupboards/compartment design,
including airing cupboard installation, are to conform to the
following:
!!
! BS. 6798.
!!
!!
! The position selected for installation MUST allow
!!
adequate space for servicing in front of the boiler
and for air circulation around the boiler.
! This position MUST also permit the provision of a
satisfactory flue and an adequate air supply.
! For the minimum clearances required for safety and
subsequent service see Frame 2.
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an
adequate supply of gas. An existing service pipe must NOT be
used without prior consultation with the local gas supplier.
The boiler is to be installed only on a gas supply with a
governed meter.
A gas meter can only be connected by the local gas supplier or
by a local regional contractor.
Check that the appliance is suitable for the proposed gas
supply. An existing meter should be checked, preferably by the
gas supplier, to ensure that the meter is adequate to deal with
the rate of gas supply required. A minimum gas pressure of
20mbar MUST be available at the boiler inlet, with the boiler
operating.
Installation pipes MUST be fitted in accordance with BS. 6891.
In IE refer to I.S. 813:2002. Pipework from the meter to the
boiler MUST be of an adequate size. Do not use pipes of a
smaller size than the boiler gas connection.
The complete installation MUST be tested for gas soundness
and purged as described in the above code.
2
FLOOR MOUNTING AND BOILER CLEARANCES
Flammable materials must not be placed in
close proximity to the appliance. Materials
giving off flammable vapours must not be
stored in the same room as the appliance.
FLOOR MOUNTING
1. The floor must be flat, level and of
suitable load bearing capacity.
2. The back of the boiler may be fitted
up to the wall.
BOILER CLEARANCES
The minimum overall dimensions of the space in which the
boiler is to operate and to facilitate servicing are as follows:
Boiler Clearances Top One side Aggregate Total
'A' or 'B' 'A' + 'B' Width C
CF440 20 (3/4") 25 (1") 100 (4") 350 (14")
IMPORTANT.
A MINIMUM clearance of 25mm (1") MUST also be maintained
between the flue pipe and any adjacent combustible material.
Mexico Slimline CF440 - Installation & Servicing
In addition a MINIMUM clearance of 533 mm (21") MUST
be available at the front of the boiler, for servicing.
5
Page 6
GENERAL
FLUE INSTALLATION
The flue must be installed in accordance with the
recommendations of BS. 5440-1:2000. In IE refer to I.S. 813:2002.
The following notes are intended for general guidance:
1. The cross-sectional area of the flue, serving the boiler, MUST
NOT be less than the area of the flue outlet of the boiler.
If flue pipe is to be used it MUST NOT be less than the diameter
of the flue outlet connection on the boiler.
2. Flue pipes and fittings should be constructed from one of the
following materials:
a. Aluminium or stainless steel.
b. Cast iron, coated on the inside with acid resistant vitreous
enamel.
c. Other approved material.
3. If twin walled flue pipe is used it should be of a type
acceptable to British Gas.
4. If a chimney is to be used it should preferably be one that is
composed of, or lined with, a non-porous acid resistant
material.
Notes.
Chimneys lined with salt -glazed earthenware pipes are
acceptable if the pipes comply with BS.65 and BS.54401:2000.
A flue pipe constructed from one of the materials listed in
2 a-c should form the initial connection to the lined chimneys.
Where a chimney is to be used that is not composed of, or
lined 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
that has been previously used then the flue MUST be
thoroughly swept clean of any soot or loose material. If a
register plate, restrictor plate or damper etc., is fitted in the
flue then it MUST be removed before connecting the boiler to,
or inserting a liner into, the flue.
6. The flue should terminate in accordance with the relevant
recommendations given in BS.5440-1:2000. In IE refer to
I.S.813:2002.
7. The flue MUST be fitted with a terminal (or ridge tile up to 5"
flue diameter). The terminal shall be of a type which has
been tested and found satisfactory by British Gas. This
terminal must NOT be installed within 600mm (24") of an
opening window, air vent or any other ventilation opening.
8. The chimney / flue lining MUST be sealed at both the top and
the bottom.
IMPORTANT. It is absolutely ESSENTIAL to ensure, in practice,
that the flue discharge is in a downdraught- free zone and that
products of combustion discharging from the terminal cannot reenter the building or any other adjacent building through
ventilators, windows, doors, other sources of natural air
infiltration or forced ventilation / air conditioning systems.
TTB DOWNDRAUGHT THERMOSTAT
This appliance is fitted with a TTB downdraught thermostat for
added safety and protection. If this thermostat should operate
and switch off the appliance it is because the flue is subject to
downdraught, probably as a result of adverse wind conditions .
The TTB is an automatic reset thermostat which will reset once
the wind conditions have returned to normal, subject to a built-in
reset delay in excess of 10 minutes
The TTB is an important safety device and must not be put out of
action or interfered with in any way.
This device is not a substitute for an independently mounted
carbon monoxide detector.
In cases of repeated or continuous shutdown a competent
person should be called to investigate and rectify the condition
causing this and carry out an operational test after each
intervention on the device. Only the manufacturer's original parts
should be used for replacement.
AIR SUPPLY
Detailed recommendations for air supply are given in
BS.5440:2. In IE refer to I.S. 813:2002.
The following notes are for general guidance:
1. The room or internal space in which the boiler is installed
MUST have, or be provided with, a permanent air vent. This
vent MUST be either direct to outside air or to an adjacent
room or internal space which must itself have, or be provided
with, a permanent air vent at least the same size direct to
outside air.
The minimum effective area of the permanent air vent(s) are
specified in Table 3 and are related to maximum rated heat
input of the boiler.
Table 3 - Air Supply
CF440 cm
Effective area 38 6
The air vent(s) must NOT have provision for closing or
adjustment and should be sited to avoid risk of accidental
damage or blockage.
If other methods of ventilation are envisaged, British Gas
should be consulted before proceeding.
2. If the boiler is to be installed in a cupboard or compartment,
permanent air vents are required (for combustion, flue
dilution and cooling purposes) in the cupboard /
compartment, at both high and low levels to ensure safe and
efficient combustion and ventilation.
The air vents may either communicate with room/internal
space (appropriately ventilated) or be direct to outside air.
The minimum effective areas of the permanent air vents,
required in the cupboard / compartment, are specified in
Table 4 and are related to maximum rated heat input of the
boiler.
Notes.
a. Both air vents MUST communicate with the same room or
internal space or MUST be on the same wall to outside air.
b. In siting the air vents care must be taken to avoid the freezing
of pipework.
c. Where cupboard / compartment air vents are open to a room
or internal space, the room or internal space MUST itself be
provided with a permanent air vent, as previously specified.
d. The cupboard / compartment air vents must NOT communicate
with a bedroom, bed-sitting room or a room containing a bath
or shower.
Table 4 - High and low vent areas
CF440 Air from room Air from outside
High Level Low Level High Level Low Level
cm
in
2
2
140 280 70 140
22 44 11 22
2
EFFECT OF AN EXTRACTOR FAN
If there is any type of extractor fan fitted in the premises there is a
possibility that, if an adequate air inlet area from outside is not
provided, spillage of the boiler flue products could occur when
the fan is in operation. Where such installations occur a spillage
test, as detailed in BS.5440:1 MUST be carried out and any
necessary action taken.
2
in
6
Mexico Slimline CF440 - Installation & Servicing
Page 7
GENERAL
VENTILATION IN SERIES
In installations requiring 2 ventilators to be fitted in series, e.g.
across a cavity wall, EACH ventilator should be sized in
accordance with the above data. Where there are more than 2
ventilators in series, EACH should have an area of 50% in
excess of the value quoted above.
WATER CIRCULATION SYSTEM
The boiler must NOT be used for direct hot water supply.
The following indirect open vented systems are suitable:
! Combined gravity domestic hot water (DHW) and pumped
central heating (CH)
! Combined pumped gravity domestic hot water and pumped
central heating.
! Pumped central heating only.
! Gravity domestic hot water only, up to a minimum domestic
hot water cylinder storage capacity of 180 litres (40 gal.)
The resistance with an 11
approximately 2 in.w.g. (5 mbar).
Table 5 - Water Flow Rate and Pressure Loss
Boiler size CF440
Boiler output k W 11.7
Water Flow l/sec 0.25
Pressure kPa 0.27
Loss m 0.027
The central heating system should be in accordance with
BS. 6798 and, in addition, with BS. 5449:1 for smallbore and
microbore systems.
The domestic hot water system, if applicable, should be in
accordance with the relevant recommendations of BS. 5546.
Copper tubing to BS. 2871:1 is recommended for water carrying
pipework.
The hot water storage cylinder MUST be of the indirect type and
should preferably be manufactured of copper.
The hot water cylinder and ancillary pipework not forming part of
the useful heating surface should be lagged to prevent heat loss
and any possible freezing, particularly where pipes run through
roof spaces and ventilated underfloor spaces.
The flow and return connections to a fully pumped system may
be made either at one side of the boiler or diagonally, to suit
convenience. In a combined pumped heating and gravity
domestic hot water system the gravity flow and return
connections must be made to the same side of the boiler and
the pumped connections to the opposite side.
IMPORTANT
The boiler must be vented. If venting cannot be done via a flow
connection 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
nominal size and be in accordance with BS. 2879.
o
C temperature difference will be
Btu/h 40 000
gpm 3.3
ft 0.09
1/2" BSP
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
INVALID.
Caradon Ideal Limited recommend Water Treatment in
accordance with the Benchmark Guidance Notes on Water
Treatment in Central Heating Systems.
Mexico Slimline CF440 - Installation & Servicing
Caradon Ideal Limited recommend the use of Fernox, GE Betz
Sentinel or Salamander water treatment products, which must
be used on accordance with the manufacturers instructions.
For further information contact:
Fernox Manufacturing Co. Ltd, Cookson Electronics,
Forsyth Road, Sheerwater, Woking, Surrey.
GU21 5RZ. Tel. +44 (0) 1799 521133
or
G E Betz Ltd, Sentinel Division, Foundry Lane, Widnes,
Cheshire, WA8 8UD.
Tel. +44 (0) 151 424 5351
or
Salamander Engineering Ltd, Unit 24, Reddicap Trading Estate,
Sutton Coldfield, West Midlands B75 7BU.
Tel. +44 (0) 121 378 0952
Notes.
1. It is most important that the correct concentration of the water
treatment products is maintained in accordance with the
manufacturers' instructions.
2. If the boiler is installed in an existing system any unsuitable
additives MUST be removed by thorough cleansing.
BS7593:1992 details the steps necessary to clean a
domestic heating system.
3. In hard water areas, treatment to prevent limescale may be
necessary - however the use of artificially 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 radiators not fitted with such a
valve as stated in BS. 5449.
Central heating systems controls should be installed to ensure the
boiler is switched off when there is no demand for heating or hot water.
When thermostatic radiator valves are used, the space heating
temperature control over a living / dining area or hallway having a
heating requirement of at least 10% of the boiler heat output should
be achieved using a room thermostat, whilst other rooms are
individually controlled by thermostatic radiator valves. However, if
the system employs thermostatic radiator valves on all radiators,
or two port valves without end switches, then a bypass circuit must
be fitted with an automatic bypass valve to ensure a flow of water
should all valves be in the closed position.
ELECTRICAL SUPPLY
WARNING. The appliance MUST be efficiently earthed.
Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS.7671) Wiring Regulations and any local
regulations which apply. For Ireland reference should be made
to the current ETCI rules for electrical installations.
The boiler is supplied for 230 V ~ 50 Hz single phase.
The fuse rating is 3A.
Connection must be made in a way that allows complete
isolation of the electrical supply - such as a double pole switch,
having a 3mm (1/8") contact separation in both poles, or a plug
and socket serving only the boiler and system controls.
The means of isolation must be accessible to the user after
installation.
7
Page 8
GENERAL
3
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 1.
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 pump and feed/ expansion tank, must
comply with the pump manufacturer's minimum requirements,
to avoid cavitation. Should these conditions not apply, either
lower the pump position or raise the feed/ expansion tank
above the minimum requirements of Caradon Ideal Limited.
4. The water velocity through the boiler flow/return pipes is
assumed to be below 1 m/s (3 ft./s), whilst the pump flow rate is
set to provide a temperature difference of 11
the boiler flow/return, at design input.
5. This information is intended as a GUIDE ONLY and cannot take
into account instantaneous changes in heat caused by the
operation of motorised valves, pumps etc.
Due allowance MUST be made if surging is liable to occur.
o
C (20 oF) across
If in any doubt, contact Caradon Ideal Limited.
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 1 but ONLY those
shown should be used.
2. The use of a cylinder thermostat is recommended. This will
prevent excessive DHW temperatures and thus reduce gas
consumption.
3. The schematic pipework graph is based on the assumption that
NO MORE than 8 elbows are used in the gravity loop, including
entry to the boiler.
4. For each extra elbow in excess of 8, (R) MUST be reduced by 300
mm (12") or (H) increased by 100 mm (4")
5. Whatever value is selected for (R) the value of (H) MUST be at
least that indicated by the graph.
R = the horizontal distance between the centre line of the
cylinder and the boiler tappings used (measured
along the pipe run).
H = the vertical distance between the top of the boiler
and the base of the cylinder.
Notes.
a. Flow and return pipes should rise vertically on leaving
the boiler.
b. Horizontal pipes should be ABOVE ceiling level and as
short as possible.
c. A MINIMUM inclination of 25 mm per 3 m run (1" per 10')
is required to avoid air locks.
If the above conditions cannot be met pumped primaries
should be used.
8
Mexico Slimline CF440 - Installation & Servicing
Page 9
5
SEALED SYSTEM REQUIREMENTS
ecl6060
GENERAL
Hose unions
Temporary hose
(disconnect
after filling)
Non-return
valve
Automatic
air vent
Hosepipe
(disconnect
after filling)
Additional
stop valve
Double check valve
assembly
(note direction of flow)
Hose connector
Note.
The method of filling, refilling, topping up or flushing sealed
primary hot water circuits from the mains via a temporary hose
connection is only allowed if acceptable to the local water authority.
1. General
a. The installation must comply with the requirements of
BS.6798 and BS.5449.
b. The installation should be designed to work with flow
temperatures of up to 82
o
C.
c. All components of the system, including the heat exchanger
of the indirect cylinder, must be suitable for a working
pressure of 3 bar (45 lb/in
2
) and temperature of 110oC.
Care should be taken in making all connections so that
the risk of leakage is minimised.
2. Safety Valve
A spring loaded safety valve complying with the relevant
requirements of BS.6759 must be fitted in the flow pipe, as
close to the boiler as possible and with no intervening valve
or restriction. The valve should have the following features:
a. A non-adjustable preset lift pressure not exceeding 3 bar
(45 lb./in
2
)
b. A manual testing device.
c. Provision for connection of a discharge pipe. The valve or
discharge pipe should be positioned so that the discharge
of water or steam cannot create a hazard to the occupants
of the premises or cause damage to electrical components
and wiring.
3. Pressure Gauge
A pressure gauge covering at least the range 0-4 bar (0-60
lb./in2) must be fitted to the system. The gauge should be
easily seen from the filling point and should preferably be
connected at the same point as the expansion vessel.
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
(230oF)
c. The charge pressure must not be less than the static
water head above the vessel The pressure attained in
the system when heated to 110oC (230oF) should be at
least 0.35 bar (5lb/in2) less than the lift pressure of the
safety valve.
For guidance on vessel sizing refer to Table 6, Frame 6. For
further details refer to BS.5449. For IE refer to the current
edition of I.S. 813.
5. Cylinder
The cylinder must be either of the indirect coil type or a direct
cylinder fitted with an immersion calorifier which is suitable
for operating on a gauge pressure of 0.35 bar (5lb./in
excess of the safety valve setting. Single feed indirect
cylinders are not suitable for sealed systems.
6. Make-up Water
Provision must be made for replacing water loss from the
system, either:
a. From a manually fitted make-up vessel with a readily visible
water level. The vessel should be mounted at least
150mm (6") above the highest point of the system and be
connected through a non-return valve to the system, fitted
at least 300mm (12") below the make-up vessel on the
return side of the domestic hot water cylinder or radiators.
b. Where access to a make-up vessel would be difficult by
pre-pressurisation of the system. Refer to 'Filling.'
2
) in
o
C
Mexico Slimline CF440 - Installation & Servicing
9
Page 10
GENERAL
6
SEALED SYSTEM REQUIREMENTS - continued
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 makeup. 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
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/in2.) 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.
2
).
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 6, multiplied by a factor of 0.8 (for flow temperatures of less than 88 oC).
Table 6
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
10
Mexico Slimline CF440 - Installation & Servicing
Page 11
MEX2237
6
69
68
49
66
29
24
18
16
28
46
1
95
20
44.1
Data badge
7
BOILER ASSEMBLY - Exploded View
INSTALLATION
insulation not shown for clarity
INSTALLATION
LEGEND
1. Heat exchanger.
6. Thermostat pocket.
16. Front plate assembly.
18. Burner manifold
20. Main burner.
24. Gas valve.
28. Gas cock.
29. PCB box.
Mexico Slimline CF440 - Installation & Servicing
44.1. TTB downdraught 'stat & bracket.
46. Boiler feet assembly.
49. Flue baffle
66. Thermostat
68. Retaining clip
69. Split pin.
95. Draught diverter assy.
11
Page 12
INSTALLATION
8
UNPACKING
To avoid damage to the boiler casing it is recommended that the casing is removed BEFORE the boiler body is taken off the pallet.
PACK CONTENTS
! Complete boiler assembly
! The Hardware Pack (listed separately)
! These Installation and Servicing/Users
Instructions.
INSTALLATION
9
BOILER CASING REMOVAL
It is preferable to remove the casing to install the boiler.
1. Undo the 2 screws and lift off the lower front panel.
2. Remove 2 screws and lift off the 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.
complete
boiler
assembly
HARDWARE PACK
! 1" BSP plugs - 2 off
! Split pin - 1 off
5. Unplug the in-line connector to the TTB thermostat.
6. Remove the 2 screws securing the control panel and
disengage the panel by lowering and pulling it forward.
In order to remove the control panel entirely the TTB
thermostat in-line connector has to be unplugged.
7. Remove the 2 screws securing the top panel to the
side.
8. Draw the top panel forward and lift it off the boiler.
8
10
12
9
7
9. Undo the 2 screws securing the PCB box to the
side panels and carefully rest it on the top of the
gas valve.
10. Remove the 3 screws securing each side panel
to the boiler.
11. Remove each side panel.
12. The boiler is held to the packaging base by 2 M6
hex head screws. Remove the screws and
remove the boiler from the packaging base.
12
MEX 2280
Mexico Slimline CF440 - Installation & Servicing
Page 13
10
CHECKING THE FLUEWAY BAFFLES
1. Remove the flue cleanout cover.
2. Check that the baffle is seated correctly.
11
PREPARING THE BOILER
INSTALLATION
INSTALLATION
Note.
Before placing the boiler in the selected position
any gas and water connections at the rear of the
boiler should be prepared, due to the possible
lack of access.
1. Fully pumped systems using more than 1 pump, serving
separate zones, must have a common return connection
to the boiler .
2. Select the desired pumped flow tapping.
3. Connect pipe fittings to the rear tappings and plug any
unused tappings.
4. Place the boiler in position.
Note. The pump may be fitted on the FLOW or RETURN.
Mexico Slimline CF440 - Installation & Servicing
13
Page 14
INSTALLATION
12
GAS CONNECTION
1. A MINIMUM working gas 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 (
to the boiler and connect to the gas cock situated at the
bottom LH side of the boiler. Attachment to the gas supply
may be either left or right hand.
3. Test the gas installation for soundness and purge in
accordance with BS.6891: 1988. Refer to Frame 24.
INSTALLATION
1/2") OD
13
WATER CONNECTIONS
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.
c. Gravity connections MUST be at least 28 mm (1").
d. The front top and bottom plugged connections MUST
NOT BE USED.
e. 2 spare blanking off plugs are provided in the
Hardware Pack, for use as necessary in the rear flow
or return water connections.
14
1. Connect the system flow and return pipework to the
boiler as appropriate.
Refer to Frames 3 and 4 for guidance on system design.
2. Ensure that all valves are open.
Fill and vent the system and check for water soundness.
Mexico Slimline CF440 - Installation & Servicing
Page 15
14
FLUE CONNECTION
Connect the flue pipe to the flue outlet.
The flue pipe spigot and socket connections
should be sealed with fibreglass rope or
similar, and suitable fireclay cement.
Notes.
a. The boiler flue connection outlet size is
suitable for flue pipe conforming to BS 567.
If sheet steel flue pipe is fitted, a suitable
adaptor must be used.
b. To facilitate installation and subsequent
disconnection it is recommended that a slip
or split socket be included in the flue
installation, adjacent to the boiler flue outlet
connection.
c. A minimum of 600mm (2') of vertical flue
directly above the boiler should be
provided.
INSTALLATION
INSTALLATION
15
ELECTRICAL CONNECTIONS
WARNING
The appliance MUST be efficiently earthed.
A mains supply of 230 V ~ 50 Hz is required.
All external controls and wiring MUST be suitable for mains
voltage.
Wiring should be in 3-core PVC insulated cable NOT LESS
than 0.75 mm
16
INTERNAL WIRING
Flow and pictorial wiring diagrams
are shown in Frames 17 and 18.
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.
2
(24 x 0.2 mm) to BS.6500, Table 16.
Wiring external to the boiler MUST be in accordance with
current l.E.E. (BS 7671) Wiring Regulations and local
regulations. For Ireland reference should be made to the
current ETCI rules for electrical installations.
Connection must be made in a way that allows complete
isolation of the electrical supply - such as a double pole
switch, having a 3mm (1/8") contact separation in both
poles, or a plug and socket serving only the boiler and
system controls. The means of isolation must be
accessible to the user after installation.
The fuse rating should be 3A.
LEGEND
b blue
bk black
br brown
w white
y/g yellow/green
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.
Mexico Slimline CF440 - Installation & Servicing
15
Page 16
17
EXTERNAL CONTROLS
INSTALLATION
External wiring must be in accordance with the current
I.E.E. (BS 7671) Wiring Regulations. For Ireland
reference should be made to the current ETCI rules for
electrical installations.
The wiring diagrams illustrated in Frames 19-21 cover
the systems most likely to be fitted to this appliance.
For wiring external controls to the Mexico Slimline
CF440 boiler reference should be made to the system
wiring diagrams supplied by the relevant manufacturer,
in conjunction with the flow wiring diagram below and
also Frame 18.
INSTALLATION
Difficulty in wiring should not arise, providing the
following directions are observed:
1. Controls that switch the system ON and OFF, e.g. a
time switch, MUST be wired, in series, in the live
mains lead to the boiler.
2. Controls that override an ON/OFF control, e.g. a frost
thermostat, MUST be wired into the mains lead, in
parallel, with the control(s) to be overridden. Refer to
Frame 20.
Flow wiring diagram
PCB
TTB
From systems controls
Gas valve
Boiler thermostat
3. If a proprietary system is used, follow the instructions
supplied by the manufacturer.
Note. If there are no external controls the circulating pump
MUST be wired into the control box.
MEX 2130
18
PICTORIAL WIRING
LEGEND
w white
r red
bk black
br brown
v violet
b blue
gy grey
y/g yellow/green
16
Mexico Slimline CF440 - Installation & Servicing
Page 17
19
MID POSITION VALVE
Pumped Only
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
indicated.
3. This is a fully controlled system - set
the boiler thermostat to maximum.
4. 'Switchmaster Midi' is similar in
operation but the wiring differs slightly;
see manufacturer's literature.
INSTALLATION
Room
Thermostat
Terminal
Pump
Mid Position
valve details
Cylinder
Thermostat
Terminal
Terminal strip
suitably
enclosed
MEX 2132
INSTALLATION
LEGEND
b blue
bk black
br brown
r red
20
TWO SPRING CLOSED VALVES
or orange
w white
gy grey
y/g yellow/green
Pumped Only
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.
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.
Pump
MAINS
Boiler supply connector
Terminal strip
suitably
enclosed
Typical programmer CH may
be selected independently
mex 2133
LEGEND
b blue
bk black
br brown
r red
or orange
w white
gy grey
y/g yellow/green
Mexico Slimline CF440 - Installation & Servicing
MAINS
Boiler supply connector
Typical programmer CH may
be selected independently
17
Page 18
21
HONEYWELL 'C' PLAN
Gravity HW & Pumped CH
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.
INSTALLATION
INSTALLATION
MEX 2134
Terminal strip
suitably
enclosed
LEGEND
b blue
bk black
br brown
r red
or orange
w white
gy grey
y/g yellow/green
20
FROST PROTECTION
Central heating systems fitted wholly inside
the house do not normally require frost
protection as the house acts as a 'storage
heater' and can normally be left at least 24
hrs. without frost damage. However, if parts
of the pipework 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.
Pump
N
E
L
MAINS
Boiler supply connector
Typical programmer CH may
be selected independently
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 as shown, with minimal
disturbance to other wiring of the
programmer.
Designation of the terminals will vary, but
the programmer and thermostat
manufacturer's leaflets will give full details.
18
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 shows a 'change-over' frost thermostat, which will cover most
systems which do use CH OFF. If, however, on such a system the HW
pipework is in an isolated part of the house, a second frost thermostat may
be used to protect it.
If in doubt, ask your installer for advice.
Mexico Slimline CF440 - Installation & Servicing
Page 19
INSTALLATION
23
FITTING THE CASING
1. Offer up the LH side panel and secure the panel to
the baseplate and heat exchanger.
2. Repeat step 1 to refit the RH side panel.
3. Place the top panel on top of the side panels.
4. Secure the top panel to the side panels.
IMPORTANT.
Wiring within the boiler casing must be neatly routed
and MUST NOT be allowed to touch the burner front
plate, cleanout cover or the collector hood.
1
3
7
4
INSTALLATION
Thermostat phial
Phial retaining
clip
Split pin
Thermostat pocket
MEX 729
5. Insert the thermostat phial into the thermostat pocket. Take
care not to kink the thermostat capillary as it is unwound,
and secure it with the split pin as shown.
6. Replace the control box cover and refit the control panel
using the screws previously removed.
7. Secure the PCB box to the casing side panels.
8. Reconnect the PCB in-line connector, TTB thermostat in-
line connector and the Burner On neon cable.
MEX 2281
24
COMMISSIONING AND TESTING
The Benchmark Log Book or equivalent self certification should be completed and signed to demonstrate
compliance with Building Regulations.
A. ELECTRICAL INSTALLATION
1. Checks to ensure electrical
safety should be carried out by
a competent person.
2. ALWAYS carry out preliminary
electrical system checks, i.e.
earth continuity, polarity,
resistance to earth and short
circuit using a suitable test
meter.
B. GAS INSTALLATION
1. The whole of the gas installation,
including the meter, MUST be inspected
and tested for soundness, and purged in
accordance with the recommendations of
BS. 6891. In I.E. refer to I.S.813:2002.
2. Purging air from the gas installation may
be expedited by loosening the union on
the gas service cock on the boiler and
purging until gas is detected.
3. Retighten the union and check for gas
soundness.
C. WATER CIRCULATING
SYSTEM
1. The whole of the system
should be thoroughly flushed
out with cold water WITHOUT
the pump in position. Ensure
that all valves are open.
2. With the pump fitted the
system should be filled and
air locks cleared. Check for
water soundness.
WARNING. Whilst effecting the required gas soundness test and purging air from the gas
installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.
Mexico Slimline CF440 - Installation & Servicing
19
Page 20
INSTALLATION
Mex 2259
G
A
C
DB
H
J
F
E
25
INSTALLATION
INITIAL LIGHTING
LEGEND
A Gas control valve.
B Burner pressure test point.
C Main burner pressure adjuster.
D Inlet pressure test point.
E Gas service cock.
F Sightglass.
G Boiler On neon.
H Boiler thermostat knob.
J Overheat thermostat reset
button (optional)
TO LIGHT THE BOILER
1. Check that all the drain cocks are closed and any valves in
the flow and return are open.
2. Check that the gas service cock (E) is OPEN and the
boiler mains on/off switch is OFF.
3. Slacken the screw in the burner pressure test point (B)
and connect a gas pressure gauge via a flexible tube.
4. Switch the electricity supply ON and check that all external
controls are calling for heat.
5. Set the boiler thermostat knob (G) to position 6. The pilot
solenoid valve should open and the intermittent spark
commence, continuing 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
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. If the burner setting
requires adjustment remove the sealing cap and turn the
adjusting screw clockwise to increase; anticlockwise to
decrease the pressure until the required burner pressure
is achieved. Refer to Table 2, page 2. Refit the sealing cap.
9. Immediately check that there is no spillage of combustion
products from the draught diverter outlets by carrying out a
spillage test, as detailed in BS.5440-1:2000.
10. Set the boiler mains on/off switch to OFF.
11. Remove the pressure gauge and tube. Retighten the
sealing screw in the pressure test point.
12. Turn ON and check for gas soundness at the pressure test
point.
13. Refit the grille and lower front panel, and secure with the
fixing screws.
20
Mexico Slimline CF440 - Installation & Servicing
Page 21
INSTALLATION
26
GENERAL CHECKS
Make the following checks for correct operation:
1. Turn the boiler thermostat OFF and ON to check that the
main burner is extinguished and relit in response.
2. Set the boiler thermostat knob to position 6 and operate
the mains on/off switch. Check that the main burner lights
and extinguishes in response.
3. Check that the programmer, if fitted, and all other system
controls function correctly.
Notes.
a. If an optional programmer kit is fitted refer to the
separate Programmer Kit Installation Instructions
and User's Instructions.
b. The temperatures quoted below are approximate
and vary between installations.
Operate each control separately and check that the main
burner or circulating pump (as the case may be)
responds.
4. Water Circulation System
a. With the system HOT, examine all water connections
for soundness.
b. With the system still hot, turn off the gas, water and
electricity supplies to the boiler and drain down, in
order to complete the flushing process.
c. Refill and vent the system, clear all air locks and again
check for water soundness.
d. Balance the system.
5. Finally, set the controls to the user's requirements and
refit the lower panel and close the controls door.
27
HANDING OVER
After completing the installation and commissioning of the system the
installer should hand over to the householder by the following actions:
Thermostat Flow Temperature
Knob Setting
1 54 130
2 60 140
3 66 150
4 71 160
5 77 170
6 82 180
0
C
0
F
INSTALLATION
1. Hand the User's Instructions to the householder and
explain his or her responsibilities under the current Gas
Safety (Installation and Use) Regulations or rules in force.
2. Draw attention to the lighting instruction label affixed to the
inside of the controls door.
3. Explain and demonstrate the lighting and shutting down
procedures including the function of the TTB downdraught
thermostat.
4. The operation of the boiler and the use and adjustment of
ALL system 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 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.
Mexico Slimline CF440 - Installation & Servicing
6. Explain and demonstrate the function of time and
temperature controls, radiator valves etc., for the
economic use of the system.
7. If an optional Programmer Kit is fitted then draw attention
to the Programmer User's Instructions and hand them to
the householder.
8. After installation, commissioning and customer hand-
over please complete the
book and leave this with the customer. For IE, it is
necessary to complete a "Declaration of Conformity" to
indicate compliance to I.S. 813:2002.
9. Stress the importance of regular servicing by a CORGI
registered installer and that a comprehensive service
should be carried out AT LEAST ONCE A YEAR. In IE
servicing work must be carried out by a Competent
Person.
appliance log
21
Page 22
SERVICING
28
SCHEDULE
To ensure the continued safe and efficient operation of the
appliance, it is recommended that it is checked at regular
intervals and serviced as necessary. The frequency of
servicing will depend upon the installation condition and
usage but should be carried out at least annually .
It is the law that any service work must be carried out by a
CORGI registered installer. In IE servicing work must be
carried out by a Competent Person.
e. Check that the flue is unobstructed and that the flue
system, including the flue cleanout cover, is sealed
correctly.
f. 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 29
to 34 and MUST be carried out in sequence.
a. Light the boiler and carry out a pre-service check, noting
any operational faults.
b. Clean the main burner.
c. Clean the heat exchanger.
d. Clean the main injectors.
29
BOILER CASING REMOVAL
1. Undo the 2 screws and lift off the lower front panel.
2. Remove 2 screws and lift off the 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. Unplug the in-line connector to the TTB thermostat.
Thermostat phial
Phial retaining
clip
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 and test for spillage.
SERVICING
Split pin
Thermostat pocket
6. Remove the 2 screws securing the
control panel and disengage the panel
by lowering and pulling it forward.
7. Undo the 2 screws securing the PCB box
to the side panels and carefully rest it on
the top of the gas valve.
8. Remove the thermostat phial from the
pocket, as shown.
9. If the boiler is not fitted under a work top,
access for flue cleaning will be improved
by removing the top panel.
MEX 729
22
Mexico Slimline CF440 - Installation & Servicing
Page 23
30
BURNER AND CONTROLS ASSEMBLY
1. Remove the 2 screws and lift off the front
panel and remove the grille assembly from
the casing. Refer to Frame 29.
SERVICING
2. Disconnect the electrical
leads from the gas valve.
3. Disconnect the ignition
lead from the PCB.
4. Undo the gas service
cock union nut.
5. Remove the 2 wing nuts
and withdraw the burner
and controls assembly,
complete, from the boiler.
6. When replacing a
defective main burner
bar it is most important
that the baffles are fitted
to the new burner.
31
CLEANING THE BURNER ASSEMBLY
1. Remove the 2 split pins securing the burner end cap.
The cap, together with the circular gauze, can now be
removed from the burner bar. Clean the gauze to
remove any deposits of lint, fluff etc.
2. Brush off any deposits that may have fallen onto the
burner head, ensuring that the flame ports are
unobstructed, and remove any debris that may have
collected.
Note. Brushes with metallic bristles MUST NOT be used.
3. Remove the main burner injector. Check, clean or
replace, as required.
4. Refit the injector, using an approved jointing compound.
MEX 2285
MEX 2286
1
5. Inspect the pilot burner and ignition electrode; ensure
they are clear and in good condition.
Check that:
a. The pilot burner is clean and unobstructed.
b. The pilot shield is clean and unobstructed.
c. The ignition electrode is clean and undamaged.
d. The ignition lead is in good condition and securely
connected.
e. The spark gap is correct. Refer to Frame 42.
f. The sightglass is clean and undamaged.
6. Clean or renew components as necessary.
2
SERVICING
32
CLEANING THE FLUEWAYS
1. Lift off lower front panel and remove the grille
assembly. Refer to Frames 28 & 29.
2. Undo the gas cock union. Remove the burner
assembly.
3. Undo the 2 wing nuts to remove the cleanout
cover.
4. Lift out the flue baffle.
5. Remove all loose deposits from the heat
exchanger, especially from between the fins,
using a suitable brush.
Remove all debris from the combustion
chamber base
6. Check that the flue outlet duct is unobstructed.
Mexico Slimline CF440 - Installation & Servicing
23
Page 24
33
REASSEMBLY
Reassemble the boiler in the following order :
SERVICING
7. Refit the thermostat phial and phial retaining clip,
ensuring that they are correctly located in the thermostat
pocket and secured by the split pin. Refer to Frame 29.
1. Refit the flue baffle into the boiler flueway, ensuring that it
is 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. 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.
34
GAS PRESSURE ADJUSTMENT
1. Pilot Pressure
Pilot adjustment is factory set to maximum and no
adjustment is possible,
8. Refit the PCB box to the side panels.
9. Refit the control panel.
10. Reconnect the Burner On neon cable to the back of the
control panel
11. Refit the in-line connector on the PCB lead and in-line
connector to the TTB thermostat.
12. Remake the electrical connections to the gas valve.
13. Reconnect the gas service cock.
14. Refit the grille assembly.
Any required adjustments should be made using the
pressure adjustment screw. Refer to Frame 25, 'Initial
Lighting'.
2. Main Burner Pressure
After servicing, reference should be made to Table 2,
page 2, which quotes details of the output with the
burner pressure and heat input.
SERVICING
Refit the lower front panel in reverse order. Refer to
Frame 29.
24
Mexico Slimline CF440 - Installation & Servicing
Page 25
MEX 2264
35
GENERAL
SERVICING
REPLACEMENT OF PARTS
When replacing any component:
1. Isolate the electricity supply.
2. Remove the lower front panel and grille
assembly.
3. Turn off the gas supply at the boiler.
The boiler MUST NOT be operated if the casing is not fitted.
36
SIGHTGLASS REPLACEMENT
1. Refer to Frame 35.
2. Unfasten the 2 wing nuts and washers. Remove the
assembly from the front plate.
3. Fit the new sightglass and reassemble, as shown.
4. Retighten the 2 wing nuts to ensure an airtight seal.
Do NOT overtighten.
Note. In order to assist fault finding, the control box PCB is fitted
with 2 indicator lights which represent the following boiler conditions:
Neon I3 Mains electricity ON.
Neon SG1 Flashes to indicate ignition operation (stops after
detection.)
For replacement of programmer units refer to the separate
Programmer Kit instructions.
37
PILOT BURNER REPLACEMENT
1. Refer to Frame 35.
2. Undo the 2 screws, lift off the front panel and
remove the grille assembly. Refer to Frame 29.
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 2 wing nuts
and withdraw the burner and controls assembly,
complete, from the boiler.
6 . Remove the ignition electrode. Refer to Frame 42.
7. Undo the pilot supply pipe connection and ease
clear of the pilot burner. DO NOT LOSE the pilot
injector, which is a push-fit in the pilot burner
housing.
8. Remove the 2 securing screws and washers, and
withdraw the pilot burner.
9. Fit the new pilot burner and reassemble in reverse
order, ensuring that:
a. The injector is in position when refitting the pilot
supply.
b. A gas-tight joint is made.
SERVICING
Mexico Slimline CF440 - Installation & Servicing
c. The spark gap is correct.
10. Reassemble in reverse order.
25
Page 26
SERVICING
38
CONTROL THERMOSTAT REPLACEMENT
1. Refer to Frame 35.
2. Remove 2 screws and lift off the front
lower panel. Refer to Frame 29.
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. Pull off the thermostat knob.
6. Remove the 2 screws and pull down the control
panel tabs clear of the top panel.
7. Remove the thermostat phial from the pocket.
Refer to Frame 29.
8. Remove the bottom screw and remove the
cover.
9. Remove the top screw and ease the control
box off the control panel.
10. Remove the 2 screws to release the
thermostat bracket.
11. Disconnect the electrical leads.
12. Unscrew the thermostat nut to withdraw the thermostat.
13. Fit the new thermostat and reassemble in reverse order.
39
CONTROL PANEL REPLACEMENT
1. Refer to Frame 35.
2. Remove the 2 screws and lift off the lower
front panel. Refer to Frame 29.
3. Pull off the thermostat knob.
SERVICING
4. Disconnect the in-line connector on the PCB
lead.
5. Remove the Burner On neon cable from the
back of the control panel.
6. Unscrew the 2 screws and pull down the
control panel so that the 2 tabs clear the top
panel.
7. Remove the thermostat phial from the
pocket. Refer to Frame 29.
8. Remove the bottom screw and remove the
cover from the control box.
9. Remove the top screw and ease the control
box off the control panel.
10. Disconnect the mains electrical supply from
the terminal strip and release from its
clamp.
11. Remove the 2 screws to release the
thermostat bracket.
12. Unplug the in-line connector to the TTB
thermostat.
13. On the new control box gain access to the
control thermostat as described above.
14. Reconnect the TTB thermostat lead to the control thermostat and terminal
strip marked 'L
15. Assemble new control box and panel and fit to the casing in reverse order.
'.
G
26
Mexico Slimline CF440 - Installation & Servicing
Page 27
40
OVERHEAT THERMOSTAT REPLACEMENT
1. Refer to Frame 35.
2. Remove the 2 screws and lift off the lower front
panel. Refer to Frame 29.
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 and pull down the
control panel tabs to clear the top panel.
SERVICING
7
6. Remove the split pin at the thermostat pocket
and withdraw the phials from the pocket.
7. Remove the thermostat retaining nut and
withdraw the thermostat from the PCB box.
8. Transfer the electrical leads from the old
thermostat to the replacement (polarity is not
important).
9. Fit the new thermostat, ensuring that the
alignment peg on the thermostat sits in the
small hole adjacent to the main fixing hole.
10. Reassemble in reverse order.
11. Replace the lower front panel and secure with
the 2 fixing screws.
12. Check the operation of the boiler.
41
IGNITION LEAD REPLACEMENT
1. Refer to Frame 35.
2. Remove the 2 screws, lift off the front
panel and remove the grille assembly.
Refer to Frame 29.
3. Disconnect the electrical leads from
the gas valve.
4. Disconnect the ignition lead from the
PCB.
MEX 2291
Reset
8
button
SERVICING
5
5. Undo the gas cock union. Remove the
2 wing nuts and withdraw the burner
and controls assembly, complete, from
the boiler.
6. Remove the purse clip.
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.
Mexico Slimline CF440 - Installation & Servicing
MEX 2292
5
27
Page 28
42
Main burner
Pilot burner
Pilot burner
bracket
mex 2294
$
MEX 2264
IGNITION ELECTRODE REPLACEMENT
1. Refer to Frame 35.
2. Remove the 2 screws, lift off the lower front panel
then remove the grille assembly. Refer to Frame 29.
3. Disconnect the electrical leads from the gas valve.
4. Disconnect the ignition lead from the PCB.
SERVICING
5. Undo the gas cock union. Remove the 2
wing nuts and withdraw the burner and
controls assembly, complete, from the
boiler.
6. Remove the electrode retaining nut and
withdraw the electrode.
43
MAIN BURNER REPLACEMENT
1. Refer to Frame 35.
2. Remove the 2 screws, lift off the lower front panel
then remove the grille assembly. Refer to Frame
SERVICING
29.
3. Disconnect the electrical leads from the gas valve.
4. Disconnect the ignition lead from the PCB.
7. Fit the new electrode.
8. Reassemble in reverse order.
8
67
MEX 2295
10
5. Undo the gas cock union. Remove the 2 wing nuts and
withdraw the burner and controls assembly, complete, from
the boiler.
6. Undo the nut securing the pilot bracket to the main burner
and remove the pilot bracket.
7. Remove the nut securing the burner baffle to the burner.
28
8. Remove the 2 screws securing the pilot burner and pull
the assembly clear of the main burner.
9. Remove the 4 nuts and washers securing the main
burner to the front plate and manifold. Withdraw the
burner.
10. Fit the new burner and assemble in reverse order, taking
care not to damage the main burner injector, which is
screwed into the burner manifold.
Note. Ensure the burner baffle is fitted to the new burner.
Mexico Slimline CF440 - Installation & Servicing
Page 29
44
MAIN BURNER INJECTOR REPLACEMENT
1. Refer to Frame 35.
2. Remove the 2 screws, lift off
the lower front panel then
remove the grille assembly.
Refer to Frame 29.
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 2 wing nuts and
withdraw the burner and
controls assembly, complete,
from the boiler.
6. Undo the pilot supply
connection.
7. Undo the manifold securing
nuts and remove the manifold
from the front plate.
8. Unscrew the burner injector
from the manifold.
9. Fit the new injector, using an
approved jointing compound,
and reassemble in reverse
order.
SERVICING
8
MEX 2296
5
Front
plate
6
Manifold
7
5
45
GAS VALVE REPLACEMENT
1. Refer to Frame 35.
2. Remove the 2 screws, lift off the lower front
panel then remove the grille assembly.
Refer to Frame 29.
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 2
wing nuts and withdraw the burner and
controls assembly, complete, from the
boiler.
6. Undo the pilot at the gas valve.
7. Unfasten the 4 screws securing the gas
inlet pipe to the LH side of the gas valve.
8. Unfasten the 4 screws securing the gas
manifold. The 2 sealing 'O' rings should be
discarded and new 'O' rings fitted.
9. Fit the new gas valve, ensuring that:
a. The valve is fitted the correct way round -
an arrow engraved on the valve
indicates the direction of flow.
b. The sealing 'O' rings supplied with the
valve are correctly fitted at the inlet and
outlet flanges.
'O' ring
7
Gas valve
Gas inlet
pipe
6
MEX 2276
8
'O' ring
Manifold
SERVICING
Mexico Slimline CF440 -
Installation & Servicing
29
Page 30
SERVICING
46
TTB DOWNDRAUGHT THERMOSTAT REPLACEMENT
1. Refer to Frame 35.
2. Remove the control panel. Refer to Frame 29.
3. Remove the securing screws and lift off the
control box cover.
4. Unplug the in-line connector to the TTB
thermostat.
Note.
The TTB thermostat is located at the LH side of
the diverter panel.
5. Reach down the side of 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
thermostat, bracket and lead and reassemble
in reverse order, ensuring that the in-line
connector is secured.
47
PCB BOX REPLACEMENT
SERVICING
1. Refer to Frame 35.
2. Remove the 2 screws and lift off the
lower front panel. Refer to Frame 29.
3. Undo the PCB cover fixing screws
and remove the cover.
4. Remove the HT lead from the PCB.
5. Remove the 6 push-in connectors
from the PCB.
PCB stand-off
PCB
3
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.
30
MEX 2299
Mexico Slimline CF440 - Installation & Servicing
Page 31
SHORT LIST OF PARTS
The following are parts commonly required as replacement
components, due to damage or expendability. Their failure or absence
is likely to affect safety or performance of this appliance.
The list is extracted from the British Gas List of Parts, which contains all
available spare parts.
The full list is held by British Gas, Caradon Ideal Limited distributors
and merchants.
When replacing any parts 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.
Key No. G.C. Part No. Description Qty. Product No.
17 319 494 Sightglass assembly 1 079 334
20 398 252 Main burner 1 012 532
21 398 323 Main burner injector 1 002 608
22 Pilot burner with injector Key No. 23 1 172 010
When ordering spares please
quote:
1. Boiler model
2. Appliance G.C. number
3. Description
4. Quantity
5. Product no.
23 Pilot burner injector: 1 004 982
24 Gas valve assy 1 170 664
26 388 396 Ignition electrode 1 003 038
27 E01 412
30 PCB sub assy. 1 170 665
44.1 Downdraught thermostat (TTB) 1 173 143
49 Flue baffle 1 172 011
66 Thermostat 1 151 903
67 308 557 Thermostat knob 1 111 904
HT lead 750mm long 1 057 599
Mexico Slimline CF440 - Installation & Servicing
31
Page 32
48
MEX 2242
17
20
22
21
24
23
26
27
30
66
67
44.1
SHORT PARTS
LIST OF PARTS
32
Mexico Slimline CF440 - Installation & Servicing
Page 33
49
BOILER CASING ASSEMBLY
Legend
LIST OF PARTS
76.1
76
74
62. Casing complete.
63. Control panel complete.
73. LH side panel.
74. RH side panel.
75. Front lower panel.
76. Top panel.
76.1. Top panel infill piece.
77. Grille panel.
50
CONTROL BOX ASSEMBLY - Exploded View
63
75
MEX 2239
77
73
Legend
63. Control panel complete.
64. Control panel.
65. Control box.
66. Control thermostat.
67. Thermostat knob.
71. Control front panel.
72. Magnetic strip.
Mexico Slimline CF440 - Installation & Servicing
33
Page 34
LIST OF PARTS
51
BURNER AND CONTROLS ASSEMBLY - Exploded View
22.1
22
23
19
26, 27
Legend
16. Front plate assembly.
16.1. Inlet pipe.
17. Sightglass assembly.
18. Burner manifold
19. Pilot pipe.
20. Main burner.
20
16
21. Main burner injector.
22. Pilot burner.
22.1. Pilot burner bracket assy.
24. Gas valve.
25. 'O' ring.
24
17
26. Ignition electrode.
27. Ignition (HT) lead.
28. Gas cock.
16.1
28
21
19
25
18
MEX 2240
52
PCB BOX - Exploded View
Legend
29. PCB chassis assy.
30. PCB sub-assy.
34. PCB support.
37. PCB cover.
34
29
30
37
MEX 2257
34
Mexico Slimline CF440 - Installation & Servicing
Page 35
FAULT FINDING
Before attempting any electrical fault finding ALWAYS carry
out preliminary electrical system checks, i.e. earth continuity,
polarity and resistance to earth using a suitable meter.
Detailed instructions on the cleaning and adjustment or
replacement of faulty components are contained in the
'Servicing' section of this publication.
Check mains neon on PCB.
Is it illuminated?
YES
Is there a live supply to
both terminals of overheat
'stat? (If no overheat 'stat
fitted go to next step).
YES
Check the control 'stat is
set to max. and mains
switch is on.
Is there a regular spark
from tube SG1 on the
PCB?
YES
Is there a spark at the
ignition electrode?
YES
NO
NO
NO
NO
be reset with the system cold?
Has the fuse on the PCB blown?
Replace the PCB.
Check gap at ignition electrode. Check electrode and leads are not damaged.
Check mains supply and fuses. Check controls are calling for heat. Check
boiler wiring connections are OK. Check if the TTB downdraught thermostat has
operated in adverse wind conditions.
NO
Can the overheat thermostat
YES
NO
Check the lead is not shorting to earth. Rectify as necessary.
YES
Replace fuse but before restoring power check for short circuit
between L/N and L/Earth on all components plugged into the PCB.
Replace the overheat 'stat.
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 90°C replace control 'stat.
If below 90°C replace overheat 'stat.
Does the pilot burner light?
YES
Does the spark stop
after the pilot is lit?
YES
Does the main burner
cross-light from the pilot?
YES
NO
Ensure pilot and main gas valve leads are not crossed
over. Is there a supply voltage at the pilot gas valve?
NO
NO
Is there a gas supply to the boiler &
has the gas supply been purged of air?
YES
YES
Is the pilot injector
blocked or the pilot
supply pipe damaged?
Check polarity of mains supply. Check
continuity of ignition lead.
Does spark now stop when pilot is lit?
YES
Is there a supply voltage at the main gas valve?
YES
Is the main injector blocked?
YES
YES
NO
YES
NO
NO
NO
NO
NO
Rectify or replace as necessary
NO
NO
Replace main gas solenoid valve.
Connect or rectify and
purge the system of air.
Check connections at the gas
valve and rectify as necessary.
If no connection fault found
replace PCB.
Replace gas valve
Check connections
to PCB.
If no fault change
PCB.
Does the main burner light?
Clear blockage and refit.
Does main burner light?
Boiler
operating
satisfactorily
Mexico Slimline CF440 - Installation & Servicing
YES
YES
Check for correct gas
supply pressure.
Rectify as necessary.
NO
Replace
gas
valve
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
35
Page 36
The code of practice for the installation,
commissioning & servicing of central heating systems
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.
Technical Training
The Ideal Boilers Technical Training Centre offers 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
CERTIFIED PRODUCT
Manufactured under a BS EN ISO 9001: 2000
Quality System accepted by BSI
Ideal Boilers,
HU5 4JN. Telephone: 01482 492 251 Fax: 01482 448 858.
Registration No. London 322 137.
Caradon Ideal Limited pursues a policy of continuing
improvement in the design and performance of its products. The
right is therefore reserved to vary specification without notice.
P.O. Box 103, National Ave, Kingston upon Hull,
I
deal Installer/Technical Helpline: 01482 498663
www.idealboilers.com
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