Page 1
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.
CF445, CF455, CF465 & CF475
May 2004 UIN 200 943 A02
Page 2
GENERAL
Table 1 - General Data
Boiler Size CF445 CF455 CF465 CF475
Gas Supply Connection in. BSP Rc 1/2 (1/2)
Number of Boiler Sections 3 3 3 3
Flow and Return Connections in. BSP 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 230 V ~50 Hz
External Fuse Rating (Power Consumption) 3 A (10 W)
Water Content litre (gal.) 7.4 (1.6)
Dry Weight kg. (lb.) 91 (201)
Max. Inst Weight kg. (lb.) 84 (185)
Boiler Size Height mm (in.) 850 (33.5)
Width mm (in.) 440. (17.4)
Depth mm (in.) 533 (21.0)
Gas Type Natural 2 H
Gas Supply Pressure 20 mb
Flue Connection mm (in.) 100 (4) 125 (5)
Table 2 - Performance Data
Boiler Size CF445 CF455 CF465 CF475
Boiler Input kW (Btu/h) 16.2 (55,400) 19.9 (67,700) 23.2 (79,000) 27.1 (92,600)
Gas Consumption l/s (ft.3/h) 0.41 (53.4) 0.51 (65.2) 0.6 (76.1) 0.7 (89.2)
Boiler Output to Water kW (Btu/h) 13.2 (45,000) 16.1 (55,000) 19.1 (65,000) 22.0 (75,000)
Burner Setting Pressure (hot) mbar (in w.g.) 11.0 (4.4) 10.5 (4.2) 10.2 (4.1) 13.0 (5.2)
Flue Gas Flow Rate g/s 7.6 9.4 10.9 12.8
o
Flue Gas Temperature
C 83 85 108 100
Seasonal Efficiency (SEDBUK)* Band D [78.5] % [78.5] % [79.7]% [78.9]%
* 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
34.9MJ/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 ft3/h - divide the gross heat input (Btu/h) by
the 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 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.
I
= An appliance designed for use on 2nd Family gas, Group H only.
2H
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 CF445 - CF475 - Installation & Servicing
Page 3
GENERAL
CONTENTS
Air Supply .......................................................................... 6
Boiler Assembly - Exploded view .................................. 11
Boiler Clearances ............................................................. 5
Burner Assembly - Exploded view ................................ 35
Control Panel Assembly - Exploded view ..................... 34
Downdraught thermostat ................................................ 6
Electrical Connections .................................................. 16
Electrical Diagram .......................................................... 16
Electrical Supply ............................................................... 7
Fault Finding .................................................................... 31
Flue Connection .............................................................. 15
Flueing ............................................................................... 6
Gas Safety Regulations .................................................... 4
Gas Supply ........................................................................ 5
Initial Lighting .................................................................. 20
Installation ...................................................................... 11
Mandatory Requirements ................................................ 4
Pump ................................................................................. 8
Servicing ......................................................................... 22
Short List of Parts .......................................................... 32
System Electrical Diagrams .......................................... 17
Water Circulation ............................................................. 7
Water Connections .......................................................... 5
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 CF445 ..................... 41 392 81
Mexico Super CF455 ..................... 41 392 82
Mexico Super CF465 ..................... 41 392 83
Mexico Super CF475 ..................... 41 392 84
Natural Gas only
B
BS
11
INTRODUCTION
The Mexico Super CF range is of floor standing, natural
draught, open flue gas boilers. They provide central heating
outputs of 13.2 kW (45,000 Btu/h) to 22.0 kW (75,000 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.
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 CF445 - CF475 - Installation & Servicing
3
Page 4
GENERAL
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.
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 on
Thermostat Kit 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 or in IE a competent person. 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).
4
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.
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.
Side clearance is only necessary for installation. The amount
of side clearance will depend upon the type of connection used.
! 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.
Mexico Super CF445 - CF475 - Installation & Servicing
Page 5
GENERAL
A
B
20 (
3/4
")
550 (21
5/8
")
mex 6044
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.
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.
850 (33 1/2")
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 20 mbar 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.
The complete installation MUST be tested for gas soundness and
purged as described in the above code.
533 (21
"
)
440 (17
358 (14 1/8")
3/8"
)
Water conn
335
560 (22")
(13
1/4"
226
(8
7/8"
)
)
122
(4
3/4"
MEX 2235
)
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 One side Aggregate
CF445, 455 & 465 10 (
CF475 55 (2
'A' or 'B' 'A' + 'B'
3/8") 110 (4 1/2")
1/4") 110 (4 1/2")
All dimensions in mm (in.)
IMPORTANT. In order to facilitate gas connection, a
clearance of at least 100mm (4") must be available at
either the LH side or the RH side DURING installation.
A MINIMUM clearance of 25mm (1") MUST also be
maintained between the flue pipe and any adjacent
combustible material.
Additional space will be required for installation, depending upon
site conditions.
Mexico Super CF445 - CF475 - Installation & Servicing
In addition a MINIMUM clearance of 533mm (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.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.
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 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 in 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
Boiler size CF455 CF455 CF465 CF475
Effective 56 7 2 93 111
area 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.
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.
2
(in2) (9) (12) (15) (18)
6
Mexico Super CF445 - CF475 - Installation & Servicing
Page 7
GENERAL
CF 465 & CF 475
CF 465
CF 475
CF 445 & CF455
CF 445 & CF455
MEX 2216
Table 4 - High and low vent areas
Boiler Air from room/internal Air direct from outside
space cm2 (in.2)cm
High Level Low Level High level Low Level
CF445 174 (27) 348 (54) 87 (14) 174 (27)
CF455 206 (32) 412 (64) 103 (16) 206 (32)
CF465 248 (39) 496 (78) 124 (20) 248 (39)
CF475 284 (44) 586 (88) 142 (22) 284 (44)
2
(in.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.5440-1:2000, 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 11 oC
o
(20
F) temperature differentials are shown in the following graph:
Water Flow Rate and Pressure Loss
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 1/2" BSP
nominal size and be in accordance with BS. 2879.
If required, a drain tap (not supplied) may be fitted to an unused
bottom (1" BSP) tapping on the front of the boiler.
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 11 oC (20 oF)
Mexico Super CF445 - CF475 - 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
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 11.
2. The boiler is assumed to be the highest point of the
circulating system.
3. The circulating pump is positioned on the FLOW - 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
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 (20oF)
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 100 mm
(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 then
pumped primaries should be used.
8
Mexico Super CF445 - CF475 - 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 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
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 110oC
(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 5, 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./
2
in
) 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.'
Mexico Super CF445 - CF475 - 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 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/in2.) of the pre-set
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 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 CF445 - CF475 - Installation & Servicing
Page 11
7
94
49
41
41.1
2
1
7
Tie rod
8
46
Mex 2128
Data badge
28
16
18
30
6
69
68
2
4
3
24
12
BOILER ASSEMBLY - Exploded View
INSTALLATION
insulation not
shown for clarity
INSTALLATION
Detail of distributor
tube alignment
Index mark on
section boss
Mex 2215
Distributor tube
Mexico Super CF445 - CF475 - Installation & Servicing
LEGEND
1. Heat exchanger assy.
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.
30. PCB assy.
41. Draught diverter back panel
assembly
41.1. TTB downdraught thermostat &
bracket.
49. Flue baffle.
46. Boiler base plate.
68. Phial retaining clip.
69. Split pin.
94. Cleanout cover.
11
Page 12
8
UNPACKING
The boiler is supplied fully assembled in Pack A.
Unpack and check the contents.
Pack A Contents
! Complete boiler
! The Hardware Pack (listed separately below)
INSTALLATION
! These Installation and Servicing/Users
Instructions
INSTALLATION
HARDWARE PACK
! 1" BSP plugs - 5 off
! 1" x 1/2" BSP reducing bush - 1 off
! Cable strap - 2 off
! Distributor tube
! 28mm Comp nut - 1 off.
! 28mm olive - 1 off.
! Thermostat pocket -1 off
! Thermostat clip - 1 off
! Thermostat retaining pin - 1 off
12
Mexico Super CF445 - CF475 - Installation & Servicing
Page 13
INSTALLATION
MEX 2205
Baffles
MEX 2139
8
9
7
9
12
9
BOILER CASING REMOVAL
To install the boiler the casing MUST be removed.
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 .
6. Remove the 2 screws securing the control panel
and disengage the panel by lowering and pulling it
forward.
7. Remove the 2 screws securing the top panel to the
side.
INSTALLATION
10
1. Remove the flue cleanout cover.
2. Ensure that the baffle(s) are fully
inserted in the flueways.
8. Draw the top panel forward and lift it off the
boiler.
9. Remove the 2 screws securing the LH side
panel to the flue collector and baseplate.
10. Pull the panel forward, lifting it clear of the
locating peg and remove.
11. Repeat steps 8 and 9 to remove the RH panel.
12. The boiler is held to the packaging base by 4
M6 hex head screws. Remove the front screws,
slacken the rear screws and remove the boiler
from the packaging base.
CHECKING THE FLUEWAY BAFFLES
Side view of
boiler sections
Mex 6043
showing the
baffle
arrangements
Mexico Super CF445 - CF475 - Installation & Servicing
13
Page 14
11
PREPARING THE BOILER
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. Screw the distributor tube (supplied with a 1" BSP x
28mm copper adaptor) into the selected heating
return tapping, using an appropriate jointing
material.
It is IMPERATIVE that the INDEX MARK on the
distributor bush is in alignment with the mark on
INSTALLATION
the section boss, as shown in Frame 7.
DO NOT disturb it when connecting subsequent
pipework.
Fully pumped systems using more than 1 pump,
serving separate zones, must have a common
return connection to the distributor tube.
2. Select the desired pumped flow tapping.
3. Screw the supplied boiler thermostat pocket into
the appropriate front section tapping, using an
approved jointing material. Refer to Tables 6 and 7.
4. Connect pipe fittings to the rear tappings and plug
any unused tappings. Note. If using iron elbows fit
a short straight connector into the boiler tapping
first, to clear the casing when fitted.
5. Place the boiler in position. Note. The pump may
be fitted on the FLOW or RETURN.
Table 6 - Fully Pumped Systems
Connections - as viewed at front Thermostat position
Back Section Front Section
Flow Return Top
LH LH LH
LH RH LH
RH RH RH
RH LH RH
Table 7 - Gravity Domestic Hot Water & Pumped Central Heating
Connections - as viewed at front Thermostat Position
Back Section Front Section
CH DHW
Flow Return Flow Return Top
LH LH RH RH LH
LH RH RH LH LH
RH RH LH LH RH
RH LH LH RH RH
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 to
the boiler (for size refer to
Table 1, page 2) and
connect to the gas cock
situated at the front LH side
of the boiler.
3. Test the gas installation for
soundness and purge in
accordance with BS.6891:
1988. Refer to Frame 25.
14
440 (17
)
1/2"
Gas conn
850 (33
(1
3/8")
410 (16
1/8
256 (10")
28
1/8"
)
Gas conn
All dimensions in mm
Mexico Super CF445 - CF475 - Installation & Servicing
")
MEX 2233
Page 15
13
WATER CONNECTION
INSTALLATION
1. Connect the system flow and return pipework to the boiler
as appropriate. Refer to Frames 3 and 4 for guidance on
system design.
CF455, CF465 & CF475 only
28mm (1") pumped flow and return pipes should be
used, both to and from the boiler.
Gravity connections MUST be at least 28mm (1").
14
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.
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.
2. Ensure that all valves are open. Fill and vent the
system and check for water soundness.
Notes.
a. Isolating valves must be fitted as close to the pump
as possible.
b. The boiler is not suitable for use with a direct hot
water cylinder.
INSTALLATION
15
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.
Mexico Super CF445 - CF475 - Installation & Servicing
15
Page 16
INSTALLATION
MEX 2129
16
ELECTRICAL CONNECTIONS
WARNING.
The appliance MUST be efficiently earthed.
A mains supply of 230 V ~ 50 Hz fused at 3A is required.
All external controls and wiring MUST be suitable for mains
voltage.
Wiring should be in 3-core PVC insulated cable NOT LESS than
0.75 mm
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.
2
(24 x 0.2 mm) to BS.6500, Table 16.
INSTALLATION
17
INTERNAL WIRING
Flow and pictorial wiring diagrams are
shown in Frames 18 and 19.
1. Remove the securing screw and lift
off the control box cover.
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 (except in the case of bathroom installations for
domestic boilers where the point of connection to the mains
MUST be outside of the bathroom).
LEGEND
b blue
bk black
br brown
w white
y/g yellow/green
2. Route the electrical leads into the
box and wire into the terminal strip,
as shown.
Notes.
a. Secure each lead with one of the
cable clamps.
b. The mains lead connection MUST be
made so that, should the lead slip
from its anchorage, the current
conductors become taut before the
earthing conductor.
18
EXTERNAL CONTROLS
External wiring must be in accordance with the current
I.E.E. (BS 7671) Wiring Regulations. Fore Ireland
reference should be made to the current ETCI rules for
electrical installations.
The wiring diagrams illustrated in Frames 20-22 cover
the systems most likely to be fitted to this appliance.
For wiring external controls to the Mexico Super CF boiler
reference should be made to the system wiring diagrams
supplied by the relevant manufacturer, in conjunction with
this flow wiring diagram and Frame 23.
Flow wiring diagram
TTB
From systems controls
PCB
Gas valve
16
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 23.
Boiler thermostat
3. If a proprietary system is used, follow the instructions
supplied by the manufacturer.
Advice on required modifications to the wiring may be
obtained from the component manufacturers.
Note. If there are no external controls the circulating pump
MUST be wired into the control box.
MEX 2130
Mexico Super CF445 - CF475 - Installation & Servicing
Page 17
19
PICTORIAL WIRING
LEGEND
b blue
bk black
br brown
y/g yellow/green
r red
w white
INSTALLATION
INSTALLATION
20
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.
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.
LEGEND
b blue
bk black
br brown
r red
or orange
w white
gy grey
y/g yellow/green
Pump
Room
Thermostat
Terminal
Boiler supply connector
Mid Position
valve details
MAINS
Cylinder
Thermostat
Terminal
Terminal strip
suitably
enclosed
MEX 2132
Typical programmer CH may
be selected independently
Mexico Super CF445 - CF475 - Installation & Servicing
17
Page 18
INSTALLATION
Boiler supply connector
Pump
Terminal strip
suitably
enclosed
Typical programmer CH may
be selected independently
MAINS
MEX 2134
E
N
L
21
TWO SPRING CLOSED VALVES
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 WIRE ONLY must be connected to the live supply.
INSTALLATION
LEGEND
b blue
bk black
22
HONEYWELL 'C' PLAN
br brown
r red
w white
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.
or orange
gy grey
y/g yellow/green
Pump
MAINS
Boiler supply connector
Terminal strip
suitably
enclosed
mex 2133
Typical programmer CH may
be selected independently
LEGEND
w white
r red
23
FROST PROTECTION
bk black
br brown
or orange
b blue
gy grey
y/g yellow/green
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.
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 manufacturers' leaflets will give full details.
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.
18
Mexico Super CF445 - CF475 - Installation & Servicing
Page 19
INSTALLATION
24
FITTING THE CASING
1. Offer up the LH side panel, locating it with the peg in the
baseplate, and push the panel back.
2. Secure the panel to the baseplate and collector hood.
3. Repeat steps 1 & 2 to refit the RH side panel.
4. Place the top panel on top and push back.
5. Secure the top panel to the side panels.
4
2
5
2
IMPORTANT.
Wiring within the boiler casing must be neatly secured with
the cable straps provided and MUST NOT be allowed to
touch the burner front plate or the cleanout cover and the
collector hood.
Thermostat phial
Phial retaining
clip
Split pin
Thermostat pocket
MEX 729
8. Insert the thermostat phial and phial retaining clip 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.
MEX 2135
INSTALLATION
6. Replace the control box cover and refit the control
panel, using the screws previously removed.
7. Reconnect the in-line connector on the PCB lead.
Refit the Burner On neon cable.
9. Reconnect the in-line connector to the TTB thermostat.
10. Refit the grille assembly
25
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.
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.
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 IE 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.
Mexico Super CF445 - CF475 - Installation & Servicing
19
Page 20
MEX 2138
26
INSTALLATION
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
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 will 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.
F Sightglass
G Boiler thermostat knob
H Main Burner on neon
J Overheat thermostat
(optional) reset button
7. Operate the boiler for 10 minutes to stabilise the burner
temperature.
8. The boiler is preset at the factory to its nominal rating. If
the burner setting pressure 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. Immmediately 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.
Note. This must be done before any building in.
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.
6. Test for gas soundness around ALL boiler gas components
using leak detection fluid.
20
12. Turn ON and check for gas soundness at the pressure
test point.
Mexico Super CF445 - CF475 - Installation & Servicing
Page 21
27
GENERAL CHECKS
INSTALLATION
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.
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, refit the
lower front panel, securing with the 2 screws, and close
the controls door.
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.
Thermostat Flow Temperature
Knob Setting
2 60 140
3 66 150
4 71 160
5 77 170
6 82 180
o
C
o
F
INSTALLATION
WARNING. The boiler must not be operated with the casing removed.
28
HANDING OVER
After completing the installation and commissioning of the boiler system the installer
should hand over to the householder by the following actions:
1. Hand the User's Instructions to the householder and
explain his or her responsibilities under 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.
5. Explain the function and the use of the boiler thermostat
and external controls.
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 Kit User's Instructions and hand them
to the householder.
8. After installation, commissioning and customer hand-
over please complete the appliance log
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.
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.
Mexico Super CF445 - CF475 - Installation & Servicing
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.
21
Page 22
29
SCHEDULE
SERVICING
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.
a. Light the boiler and carry out a pre-service check,
noting any operational faults.
b. Clean the main burner(s) and lint gauze(s).
c. Clean the heat exchanger.
d. Clean the main injector(s).
WARNING. The boiler must not be operated with the casing removed.
30
BOILER CASING REMOVAL
1. Remove the 2 screws and lift off the lower front
panel.
2. Remove the 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.
e. Check that the flue terminal 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 30-35
and MUST BE CARRIED OUT IN SEQUENCE.
WARNING. Always turn OFF the gas supply at the gas service
cock and switch OFF and DISCONNECT the electrical supply to
the appliance BEFORE SERVICING.
IMPORTANT. After completing the servicing or exchange of
components always test for gas soundness, carry out functional
checks as appropriate and test for spillage (Frame 26).
Note. It may be necessary to remove the boiler casing to carry out
the spillage test.
SERVICING
7. Remove the 2 screws securing the control panel and pull
down to release the tabs from under the top panel.
8. If the boiler is not fitted under a work top, access for flue
cleaning will be improved by removing the top panel.
5. Unplug the in-line connector to the TTB
thermostat.
6. Remove the thermostat phial from the pocket, as
shown.
Thermostat phial
Phial retaining
clip
Split pin
Thermostat pocket
MEX 729
22
Mexico Super CF445 - CF475 - Installation & Servicing
Page 23
SERVICING
MEX 2232
31
BURNER AND CONTROLS ASSEMBLY REMOVAL
1. Remove the 2 screws, lift off the front panel and
remove the grille assembly. Refer to Frame 30.
2. Disconnect the electrical leads from the gas
valve.
3. Disconnect the ignition
lead from the PCB.
4. Undo the gas cock
union. Remove the 4
wing nuts and
withdraw the burner
and controls assembly,
complete, from the
boiler.
5. Place on a convenient
working surface.
32
LINT GAUZE REMOVAL
MEX 2211
Combustion
chamber
MEX 2231
Gas service
union nut
Wing nuts
1. Remove the 2 screws, lift off the front panel
and remove the grille assembly. Refer to
Frame 30.
2. Disconnect the electrical leads from the gas
valve.
3. Disconnect the ignition lead from the PCB.
4. Undo the gas cock union. Remove the 4
wing nuts and withdraw the burner and
controls assembly, complete, from the
boiler.
5. Remove the burner end cap.
6. Withdraw the venturi baffle and lint gauze.
33
CLEANING THE BURNER ASSEMBLY
1. Clean the lint gauze to remove any deposits of lint, fluff etc.
2. Brush off any deposits that may have fallen on to 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.
SERVICING
Check that:
a. The pilot burner is clean and unobstructed.
b. The ignition electrode is clean and undamaged.
c. The ignition lead is in good condition and
securely connected.
d. The spark gap is correct. Refer to Frame 44.
4. Refit the injector, using an approved jointing compound.
5. Inspect the pilot burner and ignition electrode - ensure
that they are clear and in good condition.
Mexico Super CF445 - CF475 - Installation & Servicing
6. Clean or renew components as necessary.
23
Page 24
34
MEX 2205
Baffles
CLEANING THE FLUEWAYS
1. Remove the 2 wing nuts and lift
off the cleanout cover.
2. Lift out the flue baffles.
3. 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.
4. Check that the flue outlet duct is
unobstructed.
5. Refit the flue baffles. Refer to
Frame 10.
SERVICING
35
REASSEMBLY
Reassemble the boiler in the following order :
1. Refit the flue cleanout cover, renewing any damaged or
ERVICING
deteriorating sealing gasket.
2. Refit the casing top panel.
3. Reconnect the electrical wiring ensuring the TTB
thermostat is connected. Refit the control panel, ensuring
that the thermostat phial and phial retaining clip are
correctly located in the thermostat pocket and secured by
the split pin. Refer to Frame 30.
36
GAS PRESSURE ADJUSTMENT
1. Pilot Pressure
Pilot adjustment is factory set to maximum and no
adjustment is possible,
4. Check the sightglass in the front plate - clean or renew
as necessary.
5. Renew any damaged or deteriorating front plate gasket.
6. Refit the burner and controls assembly.
7. Reconnect the gas service cock.
8. Refit the grille assembly.
Any required adjustments should be made using the
pressure adjustment screw. Refer to Frame 26, '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.
24
Refit the lower front panel in reverse order. Refer to
Frame 24.
Mexico Super CF445 - CF475 - Installation & Servicing
Page 25
37
SERVICING
REPLACEMENT OF PARTS
GENERAL
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.
38
SIGHTGLASS REPLACEMENT
1. Refer to Frame 37.
2. Unfasten the 2 M5 hexagon nuts and washers.
Remove the assembly from the front plate.
3. Fit the new sightglass and reassemble, as shown.
4. Retighten the 2 M5 hexagon nuts to ensure an
airtight seal. Do NOT overtighten.
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.
39
PILOT BURNER REPLACEMENT
1. Refer to Frame 37.
2. Undo the 2 screws, lift off the front panel and remove the
grille assembly. Refer to Frame 30.
3. Disconnect the electrical leads from the gas valve.
4. Disconnect the ignition lead from the PCB.
5. Undo the gas cock union. Remove the 4 wing nuts and
withdraw the burner and controls assembly, complete, from
the boiler.
6. Prise the retaining clip out of the groove in the electrode,
using a small screwdriver, and withdraw the electrode.
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 re-assemble in reverse order,
ensuring that:
a. The injector is in position when refitting the pilot supply.
b. A gas-tight joint is made.
c. The spark gap is correct. Refer to Frame 44.
SERVICING
Mexico Super CF445 - CF475 - Installation & Servicing
25
Page 26
40
CONTROL THERMOSTAT REPLACEMENT
1. Refer to Frame 37.
2. Remove 2 screws and lift off the front
lower panel. Refer to Frame 30.
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 30.
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.
SERVICING
41
CONTROL PANEL REPLACEMENT
1. Refer to Frame 37.
2. Remove the 2 screws and lift off the lower
front panel. Refer to Frame 30.
SERVICING
3. Pull off the thermostat knob.
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 30.
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 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 Super CF445 - CF475 - Installation & Servicing
Page 27
42
"
mex2209
IGNITION LEAD REPLACEMENT
1. Refer to Frame 37.
2. Remove the 2 screws, lift off the
front panel and remove the grille
assembly. Refer to Frame 30.
3. Disconnect the electrical leads
from the gas valve.
4. Disconnect the ignition lead from
the PCB.
5. Undo the gas cock union.
Remove the 4 wing 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.
SERVICING
Ignition
lead
MEX 2146
Purse clip
Pilot supply
43
OVERHEAT THERMOSTAT REPLACEMENT (if fitted)
1. Refer to Frame 37.
2. Remove the 2 screws and lift off the lower front
panel. Refer to Frame 30.
3. Slacken the screw at the thermostat pocket and
withdraw the phial from the pocket.
4. Remove the thermostat retaining nut and
withdraw the thermostat from the control panel.
5. Transfer the electrical leads from the old
thermostat to the replacement (polarity is not
important).
6. Fit the new thermostat, ensuring that the
alignment peg on the thermostat sits in the
small hole adjacent to the main fixing hole, and
reassemble in reverse order.
7. Replace the lower front panel and secure with
the 2 fixing screws.
8. Check the operation of the boiler.
SERVICING
Thermostat
pocket
Mex 1861
Mexico Super CF445 - CF475 - Installation & Servicing
Hook plate
Sensor end
27
Page 28
SERVICING
44
IGNITION ELECTRODE REPLACEMENT
1. Refer to Frame 37.
2. Remove the 2 screws, lift off the lower front panel then
remove the grille assembly. Refer to Frame 30.
3. Disconnect the electrical leads from the gas valve.
4. Disconnect the ignition lead from the PCB.
Detail of pilot flame length and spark gap
5. Undo the gas cock union. Remove the 4 wing nuts and
withdraw the burner and controls assembly, complete,
from the boiler.
6. Prise the retaining clip out of the groove in the
electrode, using a small screwdriver, and withdraw the
electrode.
45
MAIN BURNER REPLACEMENT
1. Refer to Frame 37.
2. Remove the 2 screws, lift off the
SERVICING
lower front panel then remove
the grille assembly. Refer to
Frame 30.
3. Disconnect the electrical leads
from the gas valve.
4. Disconnect the ignition lead
from the PCB.
5. Undo the gas cock union.
Remove the 4 wing nuts and
withdraw the burner and
controls assembly, complete,
from the boiler.
6. Remove the 2 screws securing
the pilot burner and pull the
assembly clear of the main
burner.
7. Remove the 2 nuts and
washers securing the burner to
the front plate and manifold.
Withdraw the burner.
8. Fit the new burner and reassemble in reverse
order, taking care not to damage the main burner
injector which is screwed into the burner manifold.
Pilot burner
assembly
MEX 2147
Main burner
Front plate
7. Push in the new electrode until the retaining clip
locates in the groove and reassemble in reverse order.
6
Gas cock
union
Main burner injector
Gas control valve
Burner
7
manifold
28
Mexico Super CF445 - CF475 - Installation & Servicing
Page 29
46
MAIN BURNER INJECTOR REPLACEMENT
SERVICING
1. Refer to Frame 37.
2. Remove the 2 screws, lift off the lower front
panel then remove the grille assembly.
Refer to Frame 30.
3. Disconnect the electrical leads from the
gas valve.
4. Disconnect the ignition lead from the PCB.
5. Undo the gas cock union. Remove the 4
wing 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.
MEX 2148
Gas cock union
8
Burner
Main burner injector
7
manifold
47
GAS VALVE REPLACEMENT
1. Refer to Frame 37.
2. Remove the 2 screws, lift off the lower front panel
then remove the grille assembly. Refer to Frame 30.
3. Disconnect the electrical leads from the gas valve.
4. Disconnect the ignition lead from the PCB.
5. Undo the gas cock union. Remove the 4 wing nuts
and withdraw the burner and controls assembly,
complete, from the boiler.
'O' ring seal
Gas control
valve
7
Gas inlet
pipe
6. Undo the pilot supply connection.
7. Unscrew the gas inlet pipe from the valve.
8. Remove the 4 securing screws and withdraw the valve
from the burner manifold.
9. Fit the new gas valve, ensuring that:
Pilot supply connection
6
8
Securing
screws
a. The valve is fitted the correct
way round - an arrow engraved
on the valve indicates the
direction of flow.
b. The sealing 'O' ring supplied
with the valve is correctly fitted
at the outlet flange.
c. An approved jointing compound
is used when reconnecting the
gas inlet pipe.
SERVICING
4
MEX 2150
Burner manifold
Mexico Super CF445 - CF475 - Installation & Servicing
29
Page 30
SERVICING
48
TTB DOWNDRAUGHT THERMOSTAT REPLACEMENT
1. Refer to Frame 37.
2. Remove the control panel. Refer to Frame 30.
3. Remove the securing screws and lift off the
control box cover.
4. Unplug the in-line connector to the TTB
thermostat.
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.
49
SERVICING
PRINTED CIRCUIT BOARD (PCB) REPLACEMENT
6
5
4
MEX 2156
3
1. Refer to Frame 37.
2. Remove the 2 screws and lift off the
lower front panel. Refer to Frame 30.
3. Undo the PCB cover fixing screw and
remove the cover.
4. Remove the HT lead from the PCB
5. Remove the 6 push-in connectors
from the PCB.
6. Compress the barbs on the PCB
stand-offs to release the PCB from
the box
7. Fit the new PCB and reassemble in
reverse order.
8. Refit the boiler casing.
9. Check the operation of the boiler.
30
Mexico Super CF445 - CF475 - Installation & Servicing
Page 31
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.
NO
NO
NO
be reset with the system cold?
Has the fuse on the PCB blown?
Replace the PCB.
Check mains supply and fuses. Check controls are calling for heat. Check
boiler wiring connections are OK. Check if the TTB downdraught thermostat has
Can the overheat thermostat
NO
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
Detailed instructions on the cleaning and adjustment or
replacement of faulty components are contained in the
'Servicing' section of this publication.
operated in adverse wind conditions.
NO
YES
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.
Is there a spark at the
ignition electrode?
YES
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?
NO
NO
Ensure pilot and main gas valve leads are not crossed
over. Is there a supply voltage at the pilot gas valve?
NO
NO
Check gap at ignition electrode. Check electrode and leads are not damaged.
Check the lead is not shorting to earth. Rectify as necessary.
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
NO
YES
NO
NO
Rectify or replace as necessary
NO
NO
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.
YES
Is the main injector blocked?
Clear blockage and refit.
Does main burner light?
Boiler
operating
satisfactorily
Mexico Super CF445-475 - Installation & Servicing
YES
YES
YES
NO
NO
NO
Replace main gas solenoid valve.
Does the main burner light?
YES
Check for correct gas
supply pressure.
Rectify as necessary.
Replace
valve
gas
NO
FAULT FINDING FAULT FINDING FAULT FINDING FAULT FINDING
31
Page 32
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 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.
Key No. G.C. Part No. Description Qty. Product No.
17 319 494 Sightglass assembly 1 079 334
20 Main burner 1 171 990
21 Main burner injector CF445 1 171 991
398 059 CF455 1 004 305
E01 553 CF465 1 112 934
398 064 CF475 1 004 049
When ordering spares please quote:
1. Boiler model
2. Appliance G.C. number
3. Description
4. Quantity
5. Product no.
22 382 944 Pilot burner with injector 1 172 008
23 Pilot injector 1 004 712
24 Gas valve 1 153 726
26 397 945 Ignition electrode 1 004 713
27 E26 397 HT lead - 900 mm long 1 058 826
30 H20-882 PCB25E 1 173 799
44.1 TTB downdraught thermostat 1 173 143
49 Flue baffle 2 157 924
66 E05 070 Thermostat 1 151 903
67 308 557 Thermostat knob 1 111 904
32
Mexico Super CF445 - CF475 - Installation & Servicing
Page 33
MEX 2229
17
20
22
23
30
26
21
27
24
67
66
44.1
50
SHORT PARTS
SHORT LIST OF PARTS
Mexico Super CF445 - CF475 - Installation & Servicing
33
Page 34
51
BOILER CASING ASSEMBLY
Legend
46. Base plate
62. Casing complete
63. Control panel complete
73. Casing side panel
75. Casing lower front panel
76. Casing top panel
77. Grille panel
78. Casing fixing pack
LIST OF PARTS
73
46
76
63
73
75
77
MEX 2152
52
BOILER CONTROL PANEL - Exploded View
Legend
63. Control panel complete
64. Control panel.
65. Control box.
66. Control thermostat.
67. Thermostat knob.
71. Control front panel (door).
72. Magnetic strip.
34
Mexico Super CF445 - CF475 - Installation & Servicing
Page 35
LIST OF PARTS
53
BURNER AND CONTROLS ASSEMBLY - Exploded View
28
Legend
16. Front plate assy.
22
24
25
19
27
17. Sightglass assy.
18. Burner manifold assy.
19. Pilot burner pipe
20. Main burner
21. Main burner injector
22. Pilot burner assy.
24. Gas valve
25. 'O' ring
26. Ignition electrode
27. HT lead
28. Gas cock
26
20
Silencer shroud
only used on:
465 - no gauze
475 - with gauze
Mex 2230
16
21
18
17
54
PCB BOX - Exploded View
Legend
29. PCB chassis assy.
30. PCB sub-assy.
33. PCB support.
37. PCB cover.
33
29
37
30
Mexico Super CF445 - CF475 - Installation & Servicing
MEX 2155
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 498432
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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