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.
CF495, CF4120 & CF4140
May 2004 UIN 200 944 A02
GENERAL
Table 1 - General Data
Boiler Size CF495 CF4120 CF4140
Gas Supply Connection in. BSP Rc 1/2 (1/2) Rc 3/4 (3/4)
Flue Connection mm (in.) 125 (5) 150 (6) 150 (6)
Number of Boiler Sections 4 5 6
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)
Gas Supply Pressure 20 mb
Gas Type Natural 2 H
Electrical Supply 230 V ~ 50 Hz
External Fuse Rating(Power Consumption) 3 A (10 W)
Water Content litre (gal.) 9.8 (2.1) 12.2 (2.7) 14.6 (3.2)
Dry Weight kg. (lb.) 112 (247) 132 (291) 155 (342)
Max. Inst Weight kg. (lb.) 102 (225) 120 (265) 142 (313)
Boiler Size Height mm (in.) 850 (33.5)
Width mm (in.) 440 (17.4)
Depth mm (in.) 533 (21.0) 600 (23.6) 750 (29.5)
Table 2 - Performance Data
Boiler Size CF495 CF4120 CF4140
Boiler Input kW (Btu/h 34.2 (116 700) 43.1 (147 100) 50.1 (170 900)
Gas Consumption l/s (ft.3/h) 0.88 (112) 1.11 (142) 1.29 (165)
Boiler Output to Water kW (Btu/h 27.8 (95 000) 35.2 (120 000) 41.0 (140 000)
Burner Setting
Pressure (hot) mbar (in w.g.) 10.5 (4.2) 12.3 (4.9) 11.9 (4.8)
Flue Gas Flow Rate g/s 16.1 20.3 23.5
Flue Gas Temperature
o
C 115 112 115
Seasonal Efficiency (SEDBUK)* Band D [78.8]% [79.0]% [78.6]%
* 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/m3 (1038 Btu/ft3) gross or 34.9 MJ/m3 (935
Btu/ft3) nett
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) by the
3
).
gross C.V. of the gas (Btu/ft3).
Key to symbols
GB = United Kingdom (Countries of
IE = Ireland destination)
PMS = Maximum operating pressure of water
= An appliance designed for connection to a flue
B
11BS
discharging the 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,
I
2H
Group H only.
CAUTION.
To avoid the possibility of injury during the installation, servicing or cleaning of this
appliance, care should be taken when handling edges of sheet steel components.
2
Mexico Super CF495 - CF4140 - Installation & Servicing
GENERAL
CONTENTS
Air Supply. ............................................................................ 6
Boiler Assembly - Exploded view ..................................... 11
Boiler Clearances ................................................................5
Burner Assembly - Exploded view .................................. 34
Downdraught thermostat ................................................... 6
Electrical Connections ..................................................... 16
Electrical Diagrams .......................................................... 16
Electrical Supply .................................................................. 7
Fault Finding ...................................................................... 31
Flue Connection ................................................................ 15
Flue Installation ....................................................................6
Frost Protection ................................................................ 18
Gas Safety Regulations .......................................................4
Gas Supply ...........................................................................4
Initial Lighting .................................................................... 20
Installation ......................................................................... 11
Mandatory Requirements ...................................................4
Pump .................................................................................... 8
Servicing ........................................................................... 22
Short List of Parts ............................................................ 32
System Electrical Diagrams .................................... 17 & 18
Water Connections .................................................... 7 & 15
Water Systems .................................................................... 8
Water Treatment .............................................................. 15
Mexico Super CF
B.G. Certified - P.I. No. 87AT15
Destination Countries: GB & IE Appliance type:
Models G.C. Appliance No.
Mexico Super CF495 ..................... 41 392 85
Mexico Super CF4120 ...................41 392 86
Mexico Super CF4140 ...................41 392 87
Natural Gas only
B
BS
11
INTRODUCTION
The Mexico Super CF range is of floor standing, natural draught,
open flue gas boilers. They are rated to provide central heating
outputs of 27.8kW (95,000 Btu/h) to 41.0 kW (140,000 Btu/h).
The boiler has a cast iron heat exchanger and is supplied fully
assembled, complete with a white enamelled mild steel casing.
The boilers are suitable, as standard, for connection to openvented systems ONLY. An overheat thermostat kit is available to
allow the boiler to be used on sealed water systems.
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 will require 2 operatives or more 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 .............................................. 15
Inhibitor ................................................................... 15
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 Super CF495 - CF4140 - Installation & Servicing
3
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 Is available to allow the boiler to be used
Thermostat Kit on sealed water systems.
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.
4
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.
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 cupboard/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.
Mexico Super CF495 - CF4140 - Installation & Servicing
GENERAL
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.
Boiler size Dim. A Dim. B Dim. C
CF495 299 (11 3/4") 122 (4 3/4") 533 (21")
CF4120 373 (14 3/4") 122 (4 3/4") 600 (23 5/8")
CF4140 446 (17 1/2") 197 (7 3/4") 750 (29 1/2")
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 Size Width Depth Height
CF495
CF4120
CF4140
mm (in.) 575 (22 5/8) 535 (21) 870 (34 1/4)
mm (in.) 650 (25 5/8) 600 (23 5/8) 870 (34 1/4)
mm (in.) 740 (29 1/8) 750 (29 1/2) 870 (34 1/4)
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 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 MINIMUM clearance of 533 mm (21") MUST be
available at the front of the boiler, for servicing.
Boiler Clearances Top One side Aggregate
'A' or 'B' 'A' + 'B'
CF495
CF4120
CF4140
mm (in.) 20 (3/4) 35 (1 3/8) 135 (5 1/4)
mm (in.) 20 (3/4)) 50 (2) 210 (8 1/4)
mm (in.) 20 (3/4) 150 (6) 300 (12)
Mexico Super CF495 - CF4140 - Installation & Servicing
Note. CF495 only
If minimum LH side
clearance is used on
CF495 boilers, the TTB
downdraught thermostat
and bracket should be
moved to the RH side of
the boiler (alternative
location).
5
GENERAL
The complete installation MUST be tested for gas soundness
and purged as described in the above code.
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.5440:1.
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.
The TTB is an automatic device 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
Boiler size CF495 CF4120 CF4140
Effective 146 189 211
area
2
(in2) (23) (30) (32)
cm
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.
Table 4 - High and low vent areas
Boiler Air from room/internal Air direct from outside
space cm
High Level Low Level High level Low Level
2
(in.2)cm
2
(in.2)
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.
6
CF495 354 (55) 708 (110) 177 (28) 354 (55)
CF4120 440 (69) 880 (138) 220 (35) 440 (69)
CF4140 485 (74) 970 (148) 243 (37) 485 (74)
Mexico Super CF495 - CF4140 - Installation & Servicing
GENERAL
+. "'# +. "
+. "
+. ""
+. ""
+. "'#
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.
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.5440-1:2000, MUST be carried
out and any necessary action taken.
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 is suitable for connection to pumped open vent
central heating systems, pumped central heating combined with
pumped or gravity indirect domestic hot water supply systems
and gravity or pumped indirect domestic hot water supply
systems.
The boiler is NOT suitable for gravity heating systems.
The hydraulic resistance of the boiler at maximum output with
o
o
C (20
11
graph:
Water Flow Rate and Pressure Loss
F) temperature differentials are shown in the following
The central heating system should be in accordance with
BS. 6798 and, in addition, for smallbore and microbore
systems, BS. 5449:1.
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.
Single feed, indirect cylinders are not recommended.
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.
IMPORTANT
A minimum length of 2 metres of copper pipe MUST be fitted to
both flow and return connections from the boiler before
connection to any plastic piping.
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.
If required, a drain tap (not supplied) may be fitted to an unused
bottom (1" BSP) tapping on the front of the boiler.
1/2" BSP
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.
Dotted lines indicate flow rates equivalent to a
temperature rise of 11oC (20oF)
Mexico Super CF495 - CF4140 - Installation & Servicing
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.
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 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 accessible to the user after installation.
7
GENERAL
CF 495
mex6046
CF 4120
CF 4140 up to 8 bends
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 11.
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
o
F) across the boiler flow / return, at design input.
5. This information is intended as a GUlDE ONLY and cannot
take into account instantaneous changes in head caused
by the operation of motorised valves, pumps etc.
Due allowance MUST be made if surging is liable to occur.
If in any doubt, contact Caradon Ideal Limited.
o
C (20
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
assumption that NO MORE than 8 elbows are used in
the gravity loop, including entry to the boiler.
3. For each extra elbow in excess of 8 (R) MUST be
reduced by 300 mm (12") or (H) increased by 100mm
(4")
4. 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 Super CF495 - CF4140 - Installation & Servicing
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 82oC.
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 pre-set 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
2
) must be fitted to the system. The gauge should be
lb./in
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 110
least 0.35 bar (5lb/in
2
) less than the lift pressure of the
o
C (230oF) should be at
safety valve.
For guidance on vessel sizing refer to Table 5, Frame 6. For
further details refer to BS.5449 and the British Gas
Corporation publication : Material and Installation
Specifications for Domestic Central Heating & Hot Water.
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 Super CF495 - CF4140 - Installation & Servicing
9
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
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
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
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
).
2.
) of the preset
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 oC).
Table 5
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 Super CF495 - CF4140 - Installation & Servicing
INSTALLATION
94
49
41.1
2
1
7
Tie rod
8
46
Mex 2127
Data badge
28
16
18
30
6
69
68
2
4
3
24
12
41
47
7
BOILER ASSEMBLY - Exploded View
Mexico Super CF495 shown (with the casing removed)
INSTALLATION
Detail of distributor
tube alignment
Index mark on
section boss
CF 495 to 4120
alignment
Mex 2202
Distributor tube
CF 4140
alignment
Mexico Super CF495 - CF4140 - Installation & Servicing
LEGEND
1. Heat exchanger.
2. End section.
3. Middle section.
4. Section alignment 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
assembly.
41.1. TTB downdraught thermostat &
bracket.
46. Boiler base plate.
49. Flue baffle.
47. Heat shield.
68. Retention clip.
69. Split pin.
94. Cleanout cover.
11
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