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.
FF440, FF450, FF460,
FF470 & FF480
June 2004 UIN 200 939 A02
GENERAL
Table 1 - General Data
Boiler Size FF440 FF450 FF460 FF470 FF480
Gas Supply Connection in. BSP Rc 1/2 (1/2)
Number of Boiler Sections 2 3 3 3 3
Flow and Return Connections Rc 1 (1" BSP)
MAXIMUM Static Water Head m (ft.) 30.5 (100) (3 bar)
MINIMUM Static Water Head m (ft.) 1.0 (3.3)
Electrical Supply (Power Consumption) 230 V ~50 Hz (100 W)
Fuse Rating External: 3 A Internal: 1A to BS4265
Water Content litre (gal.) 5.0 (1.1) 7.4 (1.6)
Dry Weight kg. (lb.) 72 (159) 94 (207)
Maximum Inst Weight kg. (lb.) 65 (143) 88 (194)
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 duct diameter mm (in.) 100 (4.0)
Flue duct length (max) m (ft) 3 (9.8)
Table 2 - Performance Data
Boiler Size FF440 FF450 FF460 FF470 FF480
Boiler Input
(GROSS) kW (Btu/h) 14.4 (49 100) 18.1(61 700) 21.7 (74 000) 25.0 (85 300) 28.9 (98 600)
l/s (ft.3/h) 0.37 (47.3) 0.47 (59.4) 0.56 (71.3) 0.65 (83.1) 0.75 (95.0)
Boiler Input
(NET) kW (Btu/h) 13.0 (44 300) 16.3 (55 600) 19.5 (66 500) 22.8 (77 800) 26.0 (88 700)
Boiler Output to Water kW (Btu/h) 11.7 (40 000) 14.7 (50 000) 17.6 (60 000) 20.5 (70 000) 23.4 (80 000)
Burner Setting Pressure (hot)
mbar (in w.g.) 10.3 (4.4) 11.8 (4.7) 12.2 (4.9) 10.6 (4.3) 13.2 (5.3)
Seasonal Efficiency (SEDBUK)* Band D [78.2]% [78.9]% [79.0]% [80.5]% [79.8]%
* 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 a notified body.
Note.
Gas consumption is calculated using a calorific value of 38.7
3
MJ/m
(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
b. For ft3/h - divide the gross heat input (Btu/h) by the gross
C.V. of the gas (Btu/ft3)
c. The appliance is preset at the factory to the highest
nominal rating.
3
)
Key to symbols
GB = United Kingdom IE = Ireland (Countries of destination)
PMS = Maximum operating pressure of water
= A room sealed appliance designed for connection via
C
12
ducts to a horizontal terminal, which admits fresh air to
the burner and discharges the products of combustion to
the outside through orifices which, in this case, are
concentric. The fan is down stream of the combustion
chamber.
= 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 FF440 - FF480 - Installation & Servicing
GENERAL
CONTENTS
Air Supply. ...................................................................... 6
Boiler Assembly - Exploded view ................................ 8
Boiler Clearances ......................................................... 5
Burner Assembly - Exploded view ............................ 42
Electrical Connections ............................................... 23
Electrical Diagram ...................................................... 23
Electrical Supply ........................................................... 7
Extension Ducts - Fitting ............................................. 20
Fault Finding ................................................................. 37
Flue Fitting ............................................................... 11-20
Flue Installation ............................................................. 6
Gas Safety Regulations ................................................ 4
Gas Supply ..................................................................... 5
Initial Lighting .............................................................. 27
Installation ..................................................................... 8
Mandatory Requirements ............................................. 4
Pump ............................................................................ 22
Servicing ...................................................................... 29
Short List of Parts ....................................................... 38
System Diagrams (Electrical) ....................................25
Terminal Guards. ........................................................... 6
Water Connections .............................................. 4 & 21
Water Systems ...........................................................22
Water Treatment ........................................................... 7
Mexico Super FF
B.G. Certified - P.I. No. 87AU83
Destination Countries: GB & IE Appliance type: C
Models G.C. Appliance No.
Mexico Super FF440 ...................... 41 392 26
Mexico Super FF450 ...................... 41 392 27
Mexico Super FF460 ...................... 41 392 28
Mexico Super FF470 ...................... 41 392 29
Mexico Super FF480 ...................... 41 392 30
Natural Gas only
12
INTRODUCTION
Mexico Super FF above range is of floor standing, fanned flue
gas boilers. They are rated to provide central heating outputs
of 11.7 kW (40,000 Btu/h) to 23.4 kW
(80,000 Btu/h).
The boiler has a cast iron heat exchanger and is supplied fully
assembled, complete with a white enamelled mild steel
casing.
A door at the top of the casing front panel hinges down,
revealing the boiler thermostat control (and programmer, if
fitted).
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 ......................... 8
SEDBUK No. % ......................................................... 2
Controls
Time and temperature control to heating ............. 25
Time and temperature control to hot water .......... 25
Heating zone valves .............................................. 25
TRV's ......................................................................... 7
Auto bypass ..............................................................7
Boiler interlock ..........................................................7
For all boilers
Flushing to BS.7593 ................................................. 7
Inhibitor ..................................................................... 7
Central heating mode
Heat input ................................................to be calculated
Burner operating pressure ...... measure and record
Central heating flow temp. ...... measure and record
Central heating return temp. ... measure and record
For combination boilers only
Scale reducer ......................................................... n/a
Hot water mode
Heat input ............................................................... n/a
Max. operating burner pressure ............................ n/a
Max. operating water pressure .............................n/a
Cold water inlet temp ............................................n/a
Hot water outlet temp. ........................................... n/a
Water flow rate at max. setting ..............................n/a
For condensing boilers only
Condensate drain .................................................. n/a
For all boilers: complete, sign & hand over to customer
For assistance see Technical Helpline on the back page
Page
NOTE TO THE INSTALLER:
LEAVE THESE
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK
AND GIVE THIS TO THE CUSTOMER.
Mexico Super FF440 - FF480 - Installation & Servicing
3
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 Frames 5 & 6.
• 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
Extension Duct Kit Pack D.
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.
Flue Elbow Kits 90 degree pack
45 degree pack
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 by 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).
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
Ltd. in writing. If in doubt please enquire.
Any direct connection of a control device not approved by
Caradon Ideal Ltd. 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.
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 Dimension A
FF440 152mm (6")
FF450 / FF460
FF470 / FF480
226mm (8 7/8")
226mm (8 7/8")
4
Mexico Super FF440 - FF480 - Installation & Servicing
GENERAL
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.
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 Engineers
document IGE/UP/7 : 1998.
Bathrooms
The boiler may be installed in any room or internal space,
although particular attention is drawn to the requirements of the
current I.E.E. (BS 7671) Wiring Regulations and, in Scotland,
the electrical provisions of the building regulations applicable
in Scotland with respect to the installation of the boiler in a
room or internal space containing a bath or shower. For
Ireland reference should be made to the current ETCI rules for
electrical installations and I.S. 813: 2002.
Where a room-sealed appliance is installed in a room
containing a bath or shower then the appliance and any
electrical switch or appliance control utilising mains electricity
should be so situated that it cannot be touched by a person
using the bath or shower.
Where installation will be in an unusual location, special
procedures may be necessary and BS.6798 gives detailed
guidance on this aspect.
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.
In both cases details of essential features of cupboards/
compartment design, including airing cupboard installation,
are to conform to the following:
!!
! BS. 6798.
!!
!!
! The position selected for installation MUST allow
!!
adequate space for servicing in front of the boiler
and for air circulation around the boiler.
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 termination.
! 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
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.
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 shown in the table.
Additional space will be required for installation, depending upon
site conditions.
IMPORTANT.
In order to facilitate gas connection, a clearance of at least 100
mm (4") must be available at either the left hand side or the right
hand side DURING installation. Refer to Frame 39.
In addition a MINIMUM clearance of 533 mm (21") MUST be
available at the front of the boiler, for servicing.
Boiler Flue Overall Space Dimension
Model Length Depth Height Width Width Rear Flue Side/Top Flue
Rear Flue Side/Top
FF440, FF450,
FF460, FF470
FF480
FF440, FF450,
FF460, FF470
FF480 (23
114 to 533 mm 870 mm 460 mm 510 mm 10 mm 35 mm
600 mm (21") (34 1/4") (18 1/8") (20 1/8")(3/8") (1 3/8")
(4 1/2"-23 5/8")
600 to 533 mm 870 mm 510 mm 510 mm 35 mm 35 mm
3000mm (21") (34 1/4") (20 1/8") (20 1/8") (1 3/8") (1 3/8")
5/8"-11 8")
Minimum Side Clearance 'A'
Mexico Super FF440 - FF480 - Installation & Servicing
5
GENERAL
FLUE INSTALLATION
Some pluming may occur at the termination so terminal
positions where this could cause a nuisance should be
avoided.
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 boiler MUST be installed so that the terminal is
exposed to external air.
2. It is important that the position of the terminal allows the
free passage of air across it at all times.
3. Minimum acceptable spacing from the terminal to
obstructions and ventilation openings are specified in Table 3.
4. Where the lowest part of the terminal is fitted less than 2m
(6'6") above a balcony, above ground or above a flat roof to
which people have access then the terminal MUST be
protected by a purpose designed guard. The minimum
spacing in Table 3, Nos. 2,3, 4, 5 and 6 would be 75mm in
order to allow a terminal guard to be fitted.
Terminals guards are available from boiler suppliers - ask for
TFC Flue Guard Model K1. In case of difficulty seek advice
from:
Grasslin (UK) Ltd., Tower House, Vale Rise, Tonbridge,
Kent TN9 1TB.
Tel: +44 (0) 1732 359 888. Fax: +44 (0) 1732 354 445
www.tfc-group.co.uk
Ensure that the guard is fitted centrally.
5. The air inlet/products outlet duct and the terminal of the boiler
MUST NOT be closer than 25mm (1") to combustible material.
Detailed recommendations on the protection of combustible
material are given in BS.5440-1:2000.
I.S.813:2002.
Table 3 - Balanced flue terminal position
Approved Manufacturer’s Clearances
Terminal Position Minimum Spacing
1a. Directly BELOW an opening, air brick,
opening window, etc. 300 mm (12")
1b. Directly ABOVE an opening, air brick,
opening window, etc. 300 mm (12")
1c. HORIZONTALLY to an opening,
air brick,opening window, etc. 300 mm (12")
2. Below guttering, drain pipes or soil
pipes 25 mm ( 1")
3. Below eaves 25 mm ( 1")
4. Below balconies or a car port roof 25 mm ( 1")
5. From vertical drain pipes or soil pipes 25 mm ( 1")
6. From an internal or external corner or
to a boundary alongside the terminal 25 mm ( 1")
7. Above adjacent ground, roof or
balcony level 300 mm (12")
8. From a surface or a boundary
facing the terminal 600 mm (24")
9. From a terminal facing a terminal 1200 mm (48")
10. From an opening in a car port
(e.g. door or window) into dwelling 1200 mm (48")
11. Vertically from a terminal on the
same wall 1500 mm (60")
12. Horizontally from a terminal on the wall 300 mm (12")
In IE refer to
6. Where it is essential that the terminal wall plate is fitted, i.e.
wall thicknesses over 600mm (23 1/2") or with an inaccurately
cut hole, the minimum spacing in Table 3 Nos. 2,3, 4, 5 and 6
would be 60mm (2
plate to be fitted.
7. The flue assembly shall be so placed or shielded as to
prevent ignition or damage to any part of any building.
IMPORTANT. It is absolutely ESSENTIAL to ensure, in practice,
that products of combustion discharging from the terminal cannot
re-enter the building or any other adjacent building through
ventilators, windows, doors, other sources of natural air infiltration
or forced ventilation/air conditioning. If this should occur, the
appliance MUST be turned OFF, labelled 'unsafe' and corrective
action taken.
1/2") in order to allow the terminal wall
TERMINAL
The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frames 7 and 27.
AIR SUPPLY
Detailed recommendations for air supply are given in
BS.5440:2.
The following notes are for general guidance:
1. It is NOT necessary to have a purpose provided air vent in
the room or internal space in which the boiler is installed.
2. If the boiler is to be installed in a cupboard or compartment,
permanent air vents are required (for cooling purposes) in
the cupboard/compartment, at both high and low levels. The
air vents must either communicate with room/internal
space, or be direct to outside air. The minimum effective
areas of the permanent air vents, required in the cupboard/
compartment, are specified as follows and are related to
maximum rated heat input.
3. Both air vents MUST communicate with the same room or
internal space or MUST be on the same wall to outside air.
4. In siting the air vents care must be taken to avoid the
freezing of pipework.
Table 4 - High and low vent areas
Boiler Air from room/internal Air direct from
FF440 143 (23) 143 (23) 72 (12) 72 (12)
FF450 173 (27) 173 (27) 87 (14) 87 (14)
FF460 208 (33) 208 (33) 104 (17) 104 (17)
FF470 245 (38) 245 (38) 123 (19) 123 (19)
FF480 282 (44) 282 (44) 141 (22) 141 (22)
In IE refer to I.S. 813:2002.
space cm2 (in.2) outside cm2 (in.2)
High level Low level High level Low level
WATER CIRCULATION SYSTEM
The boiler must NOT be used for direct hot water supply. 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.
The boiler is NOT suitable for gravity heating systems. The
hydraulic resistances of the boilers at maximum output with 11ºC
(20ºF) temperature differentials are shown in the graph below.
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.
6
Mexico Super FF440 - FF480 - Installation & Servicing
GENERAL
FLOW RATE (gals/hr)
PRESSURE LOSS (mbar)
FLOW RATE (l/min)
PRESSURE LOSS (ft.water)
140
100
60
20
10
20
30
40
50
MEX 1875
1.0
2.
3.0
4.0
5.0
200
400
600
470FF & 480FF
440FF
460FF
470FF
480FF
450FF & 460FF
440FF
450FF
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 and MUST
NOT be used on sealed systems.
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
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.
Water Flow Rate and Pressure Loss
1/2" BSP nominal
Fernox Manufacturing Co. Ltd, Cookson Electronics, Forsyth Road,
Sheerwater, Woking, Surrey. GU21 5RZ. Tel. +44 (0) 1799 521133
or
G E Betz Ltd, Sentinel Division, Foundry Lane, Widnes, Cheshire,
WA8 8UD. Tel. +44 (0) 151 424 5351
or
Salamander Engineering Ltd, Unit 24, Reddicap Trading Estate,
Sutton Coldfield, West Midlands B75 7BU. Tel. +44 (0) 121 378 0952
Notes.
1. It is most important that the correct concentration of the
water treatment products is maintained in accordance with
the manufacturers' instructions.
2. If the boiler is installed in an existing system any unsuitable
additives MUST be removed by thorough cleansing.
BS7593:1992 details the steps necessary to clean a
domestic heating system.
3. In hard water areas, treatment to prevent limescale may be
necessary - however the use of artificially softened water is
NOT permitted.
4. Under no circumstances should the boiler be fired before
the system has been thoroughly flushed.
BOILER CONTROL INTERLOCKS
Caradon Ideal Limited recommend that heating systems
utilising full thermostatic radiator valve control of temperature in
individual rooms should also be fitted with a room thermostat
controlling the temperature in a space served by radiators not
fitted with such a valve as stated in BS. 5449.
Central heating systems controls should be installed to ensure
the boiler is switched off when there is no demand for heating
or hot water.
When thermostatic radiator valves are used, the space heating
temperature control over a living / dining area or hallway having
a heating requirement of at least 10% of the boiler heat output
should be achieved using a room thermostat, whilst other
rooms are individually controlled by thermostatic radiator
valves. However, if the system employs thermostatic radiator
valves on all radiators, or two port valves without end switches,
then a bypass circuit must be fitted with an automatic bypass
valve to ensure a flow of water should all valves be in the
closed position.
Dotted lines indicate flow rates equivalent to a
temperature rise of 11 OC (20 OF)
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:
Mexico Super FF440 - FF480 - 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. The fuse
rating is 3A.
Connection must be made in a way that allows complete isolation
of the electrical supply - such as a double pole switch, having a
1/8") contact separation in both poles, or a plug and socket
3mm (
serving only the boiler and system controls.
The means of isolation must be accessible to the user after
installation.
For bathroom installations the point of connection to the mains
must be situated outside the bathroom.
7
INSTALLATION
42
38
12
14
49
41
5
1
7
Tie rod
8
46
Mex 1878
Data badge
28
16
18
30
6
69
68
2
4
3
24
BOILER ASSEMBLY - Exploded View
3
INSTALLATION
INSTALLATION
Mexico Super FF with casing removed.
LEGEND
1. Heat exchanger assembly.
2. Front section.
3. Centre section.
4. Section alignment rings and 'O' rings.
5. Back section.
6. Thermostat pocket.
7. Distributor tube.
8. Combustion chamber.
12. Collector hood.
14. Fan assembly.
16. Front plate assy.
18. Burner manifold.
24. Gas valve assy.
28. Gas cock.
30. PCB assembly.
38. Pressure switch.
41. Turret assembly.
42. Turret access cover assy.
46. Boiler base plate.
49. Flue baffle.
68. Thermostat phial retaining clip
69. Phial split pin.
8
Mexico Super FF440 - FF480 - Installation & Servicing
INSTALLATION
4
UNPACKING
The boiler is supplied fully assembled in Pack A,
together with a standard flue assembly for lengths
up to 600mm (23 1/2") rear or side flue outlet in
Pack B.
Unpack and check the contents.
PACK A CONTENTS
! Complete boiler assembly
! These Installation & Servicing/Users Instructions
! The Hardware Pack (listed separately below)
! Template
complete boiler assembly
BOILER HARDWARE PACK
! 1" BSP plugs - 5 off.
! 1" x
! Cable strap - 2 off.
! Distributor tube
! 28mm Comp nut - 1 off.
! 28mm olive - 1 off.
! Thermostat pocket -1 off
! Thermostat clip (RS 3/50, RS 3/60,
! Thermostat retaining pin - 1 off
1/2" BSP reducing bush - 1 off.
RS 3/70 & RS 3/80 only) - 1 off
FLUE HARDWARE PACK
! Flue extension tube (rear)
INSTALLATION
INSTALLATION
FLUE PACK. Pack B Contents
! Duct cutting support, 2 off (cardboard )
! Terminal wall plate, 1 off.
! Terminal grille assy., 1 off.
! Polyurethane foam seal 400 lg., 1 off.
! No. 8 x 8 lg. Pozi pan hd. screws, 3 off.
5
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.
! Flue extension tube (side)
! Flue extension tube (top)
! Elbow
! Sealing ring
! M5 wing nuts - 3 off
! No.10 x 2” Rd. Hd.
woodscrew - 8 off.
! Wall Plug - brown - 8 off.
! Side outlet plate
3. Disconnect the in-line electrical connector between
the control box and the PCB box.
4. Remove the thermostat phial from the pocket as
shown in Frame 6.
5. Remove the 2 screws securing the control panel and
pull down to release the tabs from under the top
panel.
6. Remove the 2 screws securing the top panel to the
side.
Mexico Super FF440 - FF480 - Installation & Servicing
9
INSTALLATION
6
BOILER CASING REMOVAL - continued
7. Draw the top panel forward and lift it off the boiler.
8. Remove the 2 screws securing the LH side panel to the
turret front panel and baseplate.
9. Pull the panel forward, disengaging from the collector hood
tab, lifting it clear of the locating peg and remove.
10. Repeat steps 8 and 9 to remove the RH panel.
INSTALLATION
11. 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.
7
DETERMINING THE FLUE LENGTH
It is MOST IMPORTANT that the boiler is installed in a vertical position.
WARNING.
For top outlet installation the flue terminal
MUST always be in the horizontal position.
Top outlet flue length
= A + B + Elbow allowance
o
Elbow = 1m
90
o
Elbow = 0.7m
45
FLUE KITS
Pack B: supplied as standard.
Pack D: optional extension kit for
side flue or rear flue outlet. Refer
to 'Flue Extension Ducts'
1. A maximum of 3 extension
ducts (plus the standard flue
duct) may be used together.
2. Flue extensions of greater
than 1m (39") should be
supported with the bracket
provided.
10
Flue length
Up to 600 B, 1 off 152 227
600 to 1550 B, 1 off + D, 1 off 152227+152132
1550 to 2500 B, 1 off + D, 2 off 152 227+
2500 to 3000 B, 1 off + D, 3 off 152 227+
mm
Pack Requirement Product No.
152132, 2 off
152132, 3 off
Mexico Super FF440 - FF480 - Installation & Servicing
INSTALLATION
8
PREPARING THE BOILER
Table 5 - 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 6 - Gravity Domestic Hot Water
and 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
Notes.
! 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.
! The pump may be fitted to the FLOW or the RETURN.
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.
IMPORTANT. It is IMPERATIVE that the index mark on the
distributor tube bush is in alignment with the mark on the
section boss, as shown in Frame 3. 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 5 and 6.
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.
9
REAR FLUE ASSEMBLY - Exploded view
Note. The boiler turret assembly is factory built, ready for rear flue installation.
1. Remove the turret access cover.
2. Locate the LONG flue extension tube (with the air
deflector ring) in the flue accessories pack.
3. FF440 models only. Undo the 2 self-tapping screws
securing this ring and slide to the centre of the flue tube.
LEGEND
1. Terminal.
2. Weather seal.
3. Flue assembly.
4. Boiler sealing ring.
5. Flue extension tube (long, with ring).
6. Sealing plate.
7. Flue connector.
8. Turret access cover.
4. Offer the extension tube down through the access hole
and partly out through the rear turret hole.
5. FF440 models only. Relocate the air deflector ring - it will
only fit one way, due to the offset tabs - and secure its rear
tab in the rear hole with a self-tapping screw (inserting this
from the outside of the turret).
6. Pull the flue extension tube foward to the flue connector
and secure to the fan outlet assembly with the M4 screw.
7. FF440 models only. Refit the front self-tapping screw to
the second fixing tab on the air ring.
REAR FLUE OUTLET
Mexico Super FF440 - FF480 - Installation & Servicing
11
10
PREPARING THE WALL
1. Tape the template into the selected
position.
2. Mark onto the wall the position of the
flue duct hole.
IMPORTANT. Ensure that, during the
cutting operation, masonry falling outside
of the building does not cause damage or
personal injury.
3. Cut the flue hole, preferably with a
125mm (5") core boring tool, ensuring
that the hole is square to the wall. If
the hole has been quite accurately cut
with a drill then making good the wall
faces is not essential as seals are
provided at both ends of the flue.
However, both wall faces immediately
around the cut hole should be flat;
make good if necessary. For less
accurate holes make good to
approximately 125mm (5") diameter
at the 2 wall faces.
4. Remove the template from the wall.
INSTALLATION
Note.
If the terminal is to be
sited within 25-40mm
of a corner or vertical
pipe (refer to Table 3)
then the hole MUST
be accurately cut and
the rubber weather
seal trimmed around
the groove provided.
The terminal wall plate
need not be fitted.
11
CUTTING THE FLUE - wall thicknesses of 114 to 600mm
1. Measure and note the wall thickness X.
2. Mark the wall thickness onto the flue.
3. To ensure the tube is cut square, mark
the flue all the way round.
4. Cut to length X, using the cardboard ring
for support.
5. Remove cardboard ring and remove any
burrs.
12
FITTING THE BOILER SEALING RING TO THE FLUE
1. Fit the boiler sealing ring inside the outer flue duct. Ensure
the boiler sealing ring is fully engaged.
Ensure the notch aligns with the groove on the outer flue
duct. This ensures correct alignment of the flue terminal.
2. Drill 3 holes 3.2mm (
and boiler sealing ring.
1/8") dia. through the outer flue duct
Do NOT drill the inner flue
duct.
3. Insert the self-tapping screws, provided, in order to fix the
boiler sealing ring in position.
4. If the boiler is located with the rear against the wall, stick
the self-adhesive foam strip, provided in the hardware
pack, onto the flue immediately behind the boiler sealing
ring, otherwise refer to Frame 13.
REAR FLUE OUTLET
12
Mexico Super FF440 - FF480 - Installation & Servicing
13
FITTING THE FOAM SEAL
INSTALLATION
14
FITTING THE FLUE ASSEMBLY
1. To determine the position for the foam
seal measure the wall thickness and
mark it onto the flue, measuring from the
groove near the terminal.
2. Wrap the self-adhesive foam strip round
the flue, ensuring that the foam is on the
terminal side of the line. This seals the
gap between the flue and the wall.
A. Inside fitting.
If the flue assembly cannot be fitted from the outside, proceed as
follows:
1. Insert the flue assembly through the hole far enough to allow the
rubber seal to unfold completely and form an adequate seal on
the outside wall.
2. Ensure the notch is at the top. This will aid the location of the
studs into the boiler back panel.
3. Proceed to Frame 15, item B.
B. Outside fitting.
Proceed to Frame 15, item A.
15
LOCATING THE BOILER
A. If the flue assembly can be fitted from the outside,
proceed as follows:
1. Move the boiler into position ensuring that the flue
outlet is in line with the wall opening.
2. Insert the flue assembly ensuring that the flue slides
into the flue extension and the 3 sealing ring studs
locate into the boiler.
16
CONNECTING THE FLUE TO THE BOILER
1. Secure the flue to the boiler using the
three M5 wing nuts provided.
Note.
The sealing plate studs will locate in the
back panel one way only. This will ensure
that the terminal is correctly aligned.
B. If the flue assembly has been fitted from the inside
proceed as follows:
1. Move the boiler into position ensuring that the
flue slides into the flue extension tube and the 3
sealing ring studs locate into the boiler back panel.
Mexico Super FF440 - FF480 - Installation & Servicing
REAR FLUE OUTLET
13
17
SIDE FLUE ASSEMBLY - Exploded view
For wall thickness 114mm to 600mm
INSTALLATION
1. The boiler turret assembly is factory built for rear
flue installation.
2. Remove the turret access cover.
3. Remove the sealing plate from the appropriate side
to be used and refit in the rear outlet.
LEGEND
1. Terminal.
2. Weather seal.
3. Flue assembly.
4. Boiler sealing ring.
5. Flue extension tube (medium with ring).
4. An optional flue duct extension kit is required for lengths
(distance from the outside wall to the relevant side of the
boiler casing) greater than 600mm (23
Frame 7.
5. When cutting the ducts always use the cardboard
support provided.
6. Elbow.
7. Side outlet plate.
8. Flue connector.
9. Sealing plate.
10. Turret access cover.
1/2") Refer to
18
PREPARING THE WALL
SIDE FLUE OUTLET
Note. If the
terminal is to be
sited within 2540mm of a
corner or
vertical pipe
(refer to Table
3) then the hole
MUST be
accurately cut
and the rubber
weather seal
trimmed around
the groove
provided.
The terminal
wall plate need
not be fitted.
14
Mexico Super FF440 - FF480 - Installation & Servicing
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