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.
RS440, RS450 RS460 & RS470
May 2004 UIN 200 941 A02
GENERAL
Table 1 - General Data
Boiler Size RS440 RS450 RS460 RS470
Gas Supply Connection in. BSP Rc 1/2 (1/2)
Number of Boiler Sections 2 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 230 V ~50 Hz
External Fuse Rating (Power Consumption) 3 A (5 W)
Water Content litre (gal.) 5.0 (1.1) 7.4 (1.6) 7.4 (1.6) 7.4 (1.6)
Dry Weight kg. (lb.) 71 (157) 93 (206) 93 (206) 93 (206)
Max. Inst Weight kg. (lb.) 64 (141) 87 (192) 87 (192) 87 (192)
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
Table 2 - Performance Data
Boiler Size RS440 RS450 RS460 RS470
Boiler Input
Gas Consumption kW (Btu/h) 14.4 (49 100) 17.9 (61 100) 21.7 (74 000) 25.1 (85 600)
3
/h) 0.37 (47.3) 0.46 (58.9) 0.56 (71.3) 0.65 (82.5)
l/s (ft.
Boiler Output to Water kW (Btu/h) 11.7 (40 000) 14.7 (50 000) 17.6 (60 000) 20.5 (70 000)
Burner Setting Pressure (hot) mbar (in w.g.) 9.9 (4.0) 11.5 (4.6) 12.8 (5.1) 11.4 (4.6)
Flue Gas Flow Rate g/s 6.7 8.3 10.2 11.8
O
Flue Gas Temperature
C 102 107 119 137
*Seasonal Efficiency (SEDBUK) Band D [78.5]% [79.0]% [78.9]% [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.
Key to symbols
Gas consumption is calculated using a calorific value of 38.7 MJ/
m3 (1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett. To obtain
the gas consumption at a different calorific value:-
IE = Ireland (Countries
GB = United Kingdom of destination)
a. For l/s - divide the gross heat input (kW) by the gross C.V. of
the gas (MJ/m
3
b. For ft
/h - divide the gross heat input (Btu/h) by the gross C.V.
3
)
of the gas (Btu/ft3)
PMS = Maximum operating pressure of water
= A room sealed appliance designed for connection via ducts
C
11
to a horizontal terminal, which admits fresh air to the burner
and discharges the products of combustion to the outside
without a fan in the combustion products circuit.
c. The appliance is preset at the factory to the highest nominal
rating.
= An appliance designed for use on 2nd Family gas, Group H
I
2H
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 RS440 - RS470 - Installation & Servicing
GENERAL
CONTENTS
Air Supply. ............................................................................. 6
Boiler Assembly - Exploded view ...................................... 11
Boiler Clearances .................................................................5
Burner Assembly - Exploded view .................................... 35
Electrical Connections ....................................................... 17
Electrical Diagram ..............................................................17
Electrical Supply ................................................................... 7
Fault Finding ........................................................................30
Flue Fitting ...........................................................................15
Flue Installation ..................................................................... 6
Gas Safety Regulations ........................................................ 4
Gas Supply ............................................................................ 6
Initial Lighting ......................................................................21
Installation .......................................................................... 11
Mandatory Requirements ....................................................4
Pump ..................................................................................... 8
Servicing ............................................................................. 23
Short List of Parts .............................................................. 31
System Diagrams (Electrical) ............................................ 18
Terminal Guards. .................................................................. 6
Terminal Sizes. ................................................................... 14
Water Connections ..................................................... 4 & 16
Water Systems ..................................................................... 8
Water Treatment ................................................................16
Mexico Super RS
B.G. Certified - P.I. No. 87AT14
Destination Countries: GB & IE Appliance type: C
Models G.C. Appliance No.
Mexico Super RS440 ..................... 41 392 74
Mexico Super RS450 ..................... 41 392 75
Mexico Super RS460 ..................... 41 392 76
Mexico Super RS470 ..................... 41 392 77
Natural Gas only
11
INTRODUCTION
The Mexico Super RS range is of floor standing, natural
draught, balanced flue gas boilers. They are rated to provide
central heating outputs of 11.7 kW (40,000 Btu/h) to 20.5 kW
(70,000 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 ........................ 11
SEDBUK No. % .........................................................2
Controls
Time and temperature control to heating ......... 18/19
Time and temperature control to hot water ...... 18/19
Heating zone valves .......................................... 18/19
TRV's ......................................................................... 7
Auto bypass ............................................................... 7
Boiler interlock ..........................................................7
For all boilers
Flushing to BS.7593 .............................................. 16
Inhibitor ................................................................... 16
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 RS440 - RS470 - 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 Frame 9.
• Be physically capable.
• Use PPE as appropriate, e.g. gloves, safety footwear.
During all manoeuvres and handling actions, every attempt
should be made to ensure the following unless unavoidable
and/or the weight is light.
• Keep back straight.
• Avoid twisting at the waist.
• Avoid upper body/top heavy bending.
• Always grip with the palm of the hand.
• Use designated hand holds.
• Keep load as close to the body as possible.
• Always use assistance if required.
OPTIONAL EXTRA KITS
Programmer Kit
Fits neatly within the casing. Separate fitting instructions are
included with this kit.
Overheat Available to allow the boiler to be used
Thermostat Kit on sealed water systems.
GAS SAFETY
CURRENT GAS SAFETY (INSTALLATION AND USE)
REGULATIONS OR RULES IN FORCE.
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI
Registered Installer, 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).
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.
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.
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.
4
Mexico Super RS440 - RS470 - Installation & Servicing
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
RS440 152mm (6")
RS450, RS460 226mm (8 7/8")
RS470
GENERAL
2
FLOOR MOUNTING AND BOILER CLEARANCES
Flammable materials must not be placed in close proximity
to the appliance. Materials giving off flammable vapours
must not be stored in the same room as the appliance.
Floor mounting
1. The floor must be flat, level and of suitable load bearing
capacity.
2. The back of the boiler may be fitted up to the wall.
Boiler clearances
The minimum overall dimensions of the space in which the
boiler is to operate and to facilitate servicing are as follows:-
Boiler Size Width Depth Height
RS440, RS450, 460 mm 533 mm 870 mm
RS460 & RS470. (18") (21") (34 1/4")
Additional space will be required for installation, depending
upon site conditions.
IMPORTANT.
In order to facilitate gas connection, a clearance of at least
100 mm (4") must be available at either the LH side or the
RH side DURING installation. Refer to Frame 14.
In addition a MINIMUM clearance of 533 mm (21") MUST be
available at the front of the boiler, for servicing.
Terminal sizes
Boiler Size Depth Height Width
RS440, RS450, 152 338 372
RS460 & RS470
Mexico Super RS440 - RS470 - Installation & Servicing
5
GENERAL
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.
Table 3 - Balanced flue terminal position
Terminal Position
1a. Directly BELOW an opening, 600
air brick,opening window etc. (24") (60")
1b. Directly ABOVE an opening, 300
air brick,opening window etc. (12") (12")
1c. HORIZONTALLY to an opening, 400
air brick,opening window etc. (16") (24")
2. Below guttering, drain pipes or soil
pipes 300 mm (12")
3. Below eaves 300 mm (12")
4. Below balconies or a car port roof 600 mm (24")
From vertical drain pipes or soil pipes
5.
6. From an internal or external corner or
to a boundary alongside the terminal 600 mm (24")
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 600 mm (24")
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")
Horizontally from a terminal on the wall
12.
Minimum Spacing
440
450,460,470
mm
1500
mm
mm
300 mm
mm
600
mm
300 mm (12")
300 mm (12")
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.
Terminal guards are available from boiler suppliers. 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. Where the terminal is fitted within 1000mm (39 1/2") of a
plastic or painted gutter or 500mm (19 1/2") of painted eaves
then an aluminium shield at least 1000mm (39 1/2") long
should be fitted to the underside of the gutter or painted
surface.
6. 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.
In IE refer to I.S.
813:2002.
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.
TERMINAL
The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frame 8.
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. 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.
6
Mexico Super RS440 - RS470 - Installation & Servicing
GENERAL
FLOW RATE (l/min)
FLOW RATE (gals/hr.)
PRESSURE LOSS (ft. water)
PRESSURE LOSS (mbar)
RS 440
RS 450
RS 460
RS 470
RS 440
RS 450 & RS 460
RS 470
Mex 1945
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
space cm
2
(in.2) outside cm2 (in.2)
High level Low level High level Low level
RS440 143 (23) 143 (23) 72 (12) 72 (12)
RS450 173 (27) 173 (27) 87 (14) 87 (14)
RS460 208 (33) 208 (33) 104 (17) 104 (17)
RS470 245 (38) 245 (38) 123 (19) 123 (19)
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
resistance of the boilers at maximum output with 11 OC (20 OF)
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.
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 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.
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.
Water Flow Rate and Pressure Loss
Mexico Super RS440 - RS470 - Installation & Servicing
Dotted lines indicate
flow rates equivalent
to a temperature rise
of 11 OC (20 OF)
7
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 and
the vertical distance, between the pump and feed/
expansion tank, must comply with the pump
manufacturer's minimum requirements, to avoid
cavitation. Should these conditions not apply, either
lower the pump position or raise the feed/ expansion
tank above the minimum requirements of Caradon Ideal
Limited.
4. The water velocity through the boiler flow / return pipes
is assumed to be below 1 m/s (3 ft./s), whilst the pump
flow rate is set to provide a temperature difference of
o
C (20 oF) across the boiler flow / return, at design
11
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.
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
b. Horizontal pipes should be ABOVE ceiling level and as
c. A MINIMUM inclination of 25 mm per 3 m run (1" per 10')
If the above conditions cannot be met pumped primaries
should be used.
the boiler.
short as possible.
is required to avoid air locks.
8
Mexico Super RS440 - RS470 - Installation & Servicing
SEALED SYSTEM REQUIREMENTS
5
ecl6060
GENERAL
Hose unions
Temporary hose
(disconnect
after filling)
Non-return
valve
Automatic
air vent
Hosepipe
(disconnect
after filling)
Additional
stop valve
Double check valve
assembly
(note direction of flow)
Hose connector
Note.
The method of filling, refilling, topping up or flushing sealed
primary hot water circuits from the mains via a temporary hose
connection is only allowed if acceptable to the local water
authority.
1. General
a. The installation must comply with the requirements of
BS.6798 and BS.5449.
b. The installation should be designed to work with flow
temperatures of up to 82
o
C.
c. All components of the system, including the heat
exchanger of the indirect cylinder, must be suitable for a
working pressure of 3 bar (45 lb/in
2
) and temperature of
110oC. Care should be taken in making all connections
so that the risk of leakage is minimised.
2. Safety Valve
A spring loaded safety valve complying with the relevant
requirements of BS.6759 must be fitted in the flow pipe, as
close to the boiler as possible and with no intervening valve
or restriction. The valve should have the following features:
a. A non-adjustable preset lift pressure not exceeding 3 bar
(45 lb./in
2
)
b. A manual testing device.
c. Provision for connection of a discharge pipe. The valve
or discharge pipe should be positioned so that the
discharge of water or steam cannot create a hazard to
the occupants of the premises or cause damage to
electrical components and wiring.
3. Pressure Gauge
A pressure gauge covering at least the range 0-4 bar (0-60
lb./in2) must be fitted to the system. The gauge should be
easily seen from the filling point and should preferably be
connected at the same point as the expansion vessel.
4. Expansion Vessel
a. A diaphragm type expansion vessel must be
connected at a point close to the inlet side of the
pump, the connecting pipe being not less than 15mm
1/2" nominal) size and not incorporating valves of any
(
sort.
b. The vessel capacity must be adequate to accept the
expansion of the system water when heated to 110
(230oF)
c. The charge pressure must not be less than the static
water head above the vessel The pressure attained in
the system when heated to 110
least 0.35 bar (5lb/in
2
) less than the lift pressure of the
o
C (230oF) should be at
safety valve.
For guidance on vessel sizing refer to Table 5, Frame 6.
For further details refer to BS.5449. 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
2
(5lb./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.'
o
C
Mexico Super RS440 - RS470 - Installation & Servicing
9
GENERAL
6
SEALED SYSTEM REQUIREMENTS - continued
7. Mains Connection
There must be no direct connection to the mains water
supply or to the water storage tank supplying domestic
water, even through a non-return valve, without the approval
of the local water authority.
8. Filling
The system may be filled by one of the following methods:
a. Through a cistern, used for no other purposes, via a
ball valve permanently connected directly to a service
pipe and / or a cold water distributing pipe.
The static head available from the cistern should be
adequate to provide the desired initial system design
pressure. The cold feed pipe from the cistern should
include a non-return valve and a stop valve with an
automatic air vent connected between them, the stop
valve being located between the system and the
automatic air vent. The stop valve may remain open
during normal operation of the system if automatic
water make-up is required.
b. Through a self-contained unit comprising a cistern,
pressure booster pump (if required) and, if
necessary, an automatic pressure reducing valve and
flow restrictor. The cistern should be supplied through
a temporary connection from a service pipe or cold
water distributing pipe.
This unit may remain permanently connected to the
heating system to provide limited automatic water
make-up. Where the temporary connection is
supplied from a service pipe or distributing pipe
which also supplies other draw-off points at a lower
level then a double check valve shall be installed
upstream of the draw-off point.
c. Through a temporary hose connection from a draw-off tap
supplied from a service pipe under mains pressure. Where
the mains pressure is excessive a pressure-reducing valve
shall be used to facilitate filling.
The following fittings shall form a permanent part of the
system and shall be fitted in the order stated:
A stop valve complying with the requirements of
BS. 1010, Part 2 (the hose from the draw-off tap shall be
connected to this fitting).
A test cock.
A double check valve of an approved type.
• Thoroughly flush out the whole of the system with cold
water, without the pump in position.
• With the pump fitted, fill and vent the system until the
pressure gauge registers 1.5 bar (21.5lb/in
Examine for leaks.
• Check the operation of the safety valve by manually
raising the water pressure until the valve lifts. This
should occur within ± 0.3 bar (± 4.3lb/in
lift pressure.
• Release water from the system until the initial system
design pressure is reached.
• Light the boiler and heat the system to the maximum
working temperature. Examine for leaks.
• Turn off the boiler and drain the system while still hot.
• Refill and vent the system.
2
).
2.
) of the preset
Sizing procedure for expansion vessels: The volume of the expansion vessel (litres) fitted to a sealed system shall not be
less than that given by Table 5, multiplied by a factor of 0.8 (for flow temperatures of less than 88 oC).
Table 5
Safety valve setting 3.0 bar 2.5 bar 2.0 bar
Vessel charge and initial 0.5 1.0 1.5 0.5 1.0 1.5 0.5 1.0
system pressure bar bar bar bar bar bar bar bar
Total water content of system Expansion vessel volume
(litres) (litres)
25 2.1 2.7 3.9 2.3 3.3 5.9 2.8 5.0
50 4.2 5.4 7.8 4.7 6.7 11.8 5.6 10.0
75 6.3 8.2 11.7 7.0 10.0 17.7 8.4 15.0
100 8.3 10.9 15.6 9.4 13.4 23.7 11.3 20.0
125 10.4 13.6 19.5 11.7 16.7 29.6 14.1 25.0
150 12.5 16.3 23.4 14.1 20.1 35.5 16.9 30.0
175 14.6 19.1 27.3 16.4 23.4 41.4 19.7 35.0
200 16.7 21.8 31.2 18.8 26.8 47.4 22.6 40.0
225 18.7 24.5 35.1 21.1 30.1 53.3 25.4 45.0
250 20.8 27.2 39.0 23.5 33.5 59.2 28.2 50.0
275 22.9 30.0 42.9 25.8 36.8 65.1 31.0 55.0
300 25.0 32.7 46.8 28.2 40.2 71.1 33.9 60.0
Multiplying factors for
other system volumes 0.0833 0.109 0.156 0.094 0.134 0.237 0.113 0.20
10
Mexico Super RS440 - RS470 - Installation & Servicing
INSTALLATION
Mex 1921
12
94
49
44
5
1
7
Tie rod
8
46
Data badge
28
18
30
24
6
69
68
2
4
3
47
Terminal
grille
7
BOILER ASSEMBLY - Exploded View
Mexico Super RS with casing removed for clarity - RS450/460 shown.
INSTALLATION
Detail of distributor
tube alignment
Index mark on
Mex 2215
section boss
Distributor tube
Mexico Super RS440 - RS470 - Installation & Servicing
LEGEND
1. Heat exchanger assy.
2. Front section.
3. Middle section.
4. Section alignment rings and 'O' rings.
5. Back section.
6. Thermostat pocket.
7. Distributor tube.
8. Combustion chamber.
12. Collector hood.
18. Front plate.
24. Gas control valve.
28. Gas cock.
30. PCB.
44. Air/flue duct assy.
46. Baseplate.
49. Flue baffle.
68. Phial clip.
69. Split pin.
94. Cleanout cover.
11
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