Ideal Boilers Mexico Slimline RS 3/40 Installation & Servicing Manual Download Page 11 | Manualshive

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11

Mexico Slimline RS 3/40 & 3/50 -

Installation

5

BOILER CASING REMOVAL

INSTALLATION

INST

ALLA

TION

1.

Remove the flue cleanout cover.

2.

Check that the baffle is seated correctly.

6

CHECKING THE FLUEWAY BAFFLES - RS 3/40 ONLY

It is preferable to removed the casing to install the boiler

1.

Lift off the lower front panel.

2.

Remove 2 screws and lift off the grille assembly.

3.

Remove the gas valve cover by removing the retaining
screw. Disconnect the electrical leads.

4.

Release the gas valve lead from the retaining clip.

5.

Remove the 2 screws securing the control panel and
disengage the panel by lowering and pulling it forward.

6.

Remove the 2 screws securing the top panel to the side.

7.

Lift the top panel off the boiler.

8.

Remove the 3 screws securing each side
panel to the boiler.

9.

Remove the side panel.

10.

The boiler is held to the packaging base by 2
M6 hex. head screws. Remove the screws
and remove the boiler from the packaging
base.

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Summary of Contents for Mexico Slimline RS 3/40

Page 1: ......

Page 2: ...for all models and a pump kit that can be housed within the casing available for all models except the Super CF 3 140 CF 3 140P Full system suitability All models are suitable for connection to pumped open vent central heating systems pumped central heating combined with pumped or gravity indirect domestic hot water supply systems They can also be used on sealed water systems when used in conjunct...

Page 3: ...MINIMUM kW Btu h 11 3 38 500 15 0 51 200 Gas Consumption l s ft 3 h 0 29 37 0 0 39 49 3 MID kW Btu h 12 7 43 500 16 7 57 100 Gas Consumption l s ft 3 h 0 33 47 7 0 43 54 7 MAXIMUM kW Btu h 14 5 49 400 18 5 63 200 Gas Consumption l s ft 3 h 0 37 47 5 0 48 60 8 Boiler Output MINIMUM kW Btu h 8 8 30 000 11 7 40 000 to Water MID kW Btu h 10 3 35 000 13 2 45 000 MAXIMUM kW Btu h 11 7 40 000 14 7 50 000...

Page 4: ...ogrammer 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 CONTENTS Air Supply 7 Boiler Assembly Exploded view 9 Boiler Clearances 6 Burner Assembly Exploded view 34 Electrical Connections 15 Electrical Diagram 16 Electrical Supply 8 Extension Ducts Fitting 13 Fault ...

Page 5: ... are directly connected to these appliances unless covered by these Installation and Servicing Instructions or otherwise recommended by Caradon Plumbing Limited in writing If in doubt please enquire Any direct connection of a control device not approved by Caradon Plumbing Limited could invalidate the BSI Certification and the normal appliance warranty It could also infringe the Gas Safety Regulat...

Page 6: ...on 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 Where side units are modified to facilitate installation then no clearance is required z This position MUST also permit the provision of a satisfactory flue termination...

Page 7: ...than 30mm 2 to combustible material Detailed recommendations on the protection of combustible material are given in BS 5440 1 Table 4 High and low vent areas Boiler Air from room internal Air direct from space cm2 in 2 outside cm2 in 2 High level Low level High level Low level RS 3 40 140 22 140 22 70 11 70 11 RS 3 50 190 30 190 30 95 15 95 15 IMPORTANT It is absolutely ESSENTIAL to ensure in prac...

Page 8: ... exchangers fitted to these boilers have been internally treated with aluminium paint and only Fernox Copal or Sentinel X100 water treatment products should be used For further information on these products contact Fernox Manufacturing Co Ltd or Sentinel Division Britannica Works Betz Dearborn Clavering Widnes Essex Cheshire CB11 4QZ WA8 8UD Tel 01799 550 811 Tel 0151 424 5351 THERMOSTATIC RADIATO...

Page 9: ...TALLATION INSTALLATION 3 BOILER ASSEMBLY Exploded View LEGEND 1 Heat exchanger 2 Boiler feet assy 3 Thermostat pocket 4 Cleanout cover 5 Front plate 8 Main burner 13 Gas valve 19 Gas service cock 38 Air duct 39 Flue duct 40 Flue baffle RS 3 40 only ...

Page 10: ... boiler assembly z the Hardware Pack listed separately z these Installation and Servicing Instructions z User s Instructions FLUE PACKS PACKS B B1 AND C CONTENTS z Flue terminal assembly z Sachet of sealing mastic 2 off z Adhesive tape z sachet of sealing mastic 2 off z Flue terminal extension PACK D CONTENTS Wall thickness Flue Dimension duct length X shown above pack s Boiler fitted flush with w...

Page 11: ...3 Remove the gas valve cover by removing the retaining screw Disconnect the electrical leads 4 Release the gas valve lead from the retaining clip 5 Remove the 2 screws securing the control panel and disengage the panel by lowering and pulling it forward 6 Remove the 2 screws securing the top panel to the side 7 Lift the top panel off the boiler 8 Remove the 3 screws securing each side panel to the...

Page 12: ...k around the air duct inside INSTALLATION 1 Cut the appropriate hole in the wall for insertion of the terminal assembly Notes a Make good the hole on the INSIDE of the building to the given dimensions BEFORE fitting the boiler to facilitate sealing between the terminal and the wall when the boiler is in position b The terminal MUST NOT come into contact with a combustible material such as that use...

Page 13: ... the wall opening and slide it into the boiler flue duct Locate it as shown and fix it in position with the 4 screws previously removed 8 From OUTSIDE of the building seal the flue duct join B with the mastic provided 9 Fasten the terminal grille to the duct assembly 1 BEFORE PLACING THE BOILER IN POSITION loosely fit the extension air duct and terminal assembly to the boiler air duct and adjust t...

Page 14: ...ve the minimum requirements of Caradon Plumbing Limited 4 The water velocity through the boiler flow return pipes is assumed to be below 1 m s 3 ft s whilst the pump flow rate is set to provide a temperature difference of 11 o C 20 o F across the boiler flow return at design input 5 This information is intended as a GUlDE ONLY and cannot take into account instantaneous changes in heat caused by th...

Page 15: ...en 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 1 Separate flow and return connections are used for each service All possible configurations are given in Frame 1 but ONLY those shown should be used 2 The use of a cylinder thermostat is recommended This will prevent excessi...

Page 16: ...he control s to be overridden Refer to Frame 21 3 Controls that switch the circulating pump only on and off e g a room thermostat MUST be wired in series with the pump in the live pump lead 4 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 extern...

Page 17: ...stat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see manufacturer s literature 19 FULLY PUMPED S PLAN 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 Aut...

Page 18: ... 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 termina...

Page 19: ...s service cock on the boiler and purging until gas is detected 3 Retighten the union and check for gas soundness 23 COMMISSIONING AND TESTING 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 1 Offer up the LH side panel and secure the panel to the baseplate and heat exchanger 2 Rep...

Page 20: ...est point ensuring that a gas tight seal is made 1 Connect the gas valve electrical leads and refit the cover 2 Check that the gas service cock E is ON and that the boiler thermostat control knob H is OFF 3 Loosen the screw in the burner pressure test point B and connect a gas pressure gauge via a flexible tube 4 Turn the gas control knob A CLOCKWISE until resistance is felt and then release it Wa...

Page 21: ...to the householder to ensure the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption Advise the User of the precautions necessary to prevent damage to the system and to the building in the event of the system remaining inoperative during frosty conditions Notes a If an optional programmer kit is fitted refer to the separate Programmer Kit...

Page 22: ...s and lift off the grille assembly 3 Remove the gas valve electrical cover and disconnect the electrical leads 4 Release the gas valve lead from the retaining clip 28 BOILER CASING REMOVAL 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 installat...

Page 23: ...osits from the heat exchanger especially from between the fins using a suitable brush Remove all debris from the combustion chamber base 5 Check that the flue outlet duct is unobstructed 31 CLEANING THE FLUEWAYS 29 BURNER AND CONTROLS ASSEMBLY 1 Lift off lower front panel refer to Frame 28 and remove the grille assembly Undo the gas cock union 2 Remove the wing nuts and washers securing the burner...

Page 24: ...split pin Refer to Frame 28 1 Pilot pressure Pilot adjustment is factory set to maximum and no adjustment is possible 2 Main burner pressure After servicing reference should be made to Table 2 which quotes details of the rated output with the related burner pressure and heat input Any required adjustments should be made using the pressure adjustment screw Refer to Frame 24 Initial Lighting Refit t...

Page 25: ...ect order i e gasket glass gasket and frame as shown 3 Retighten the 2 wing nuts to ensure an airtight seal Do NOT overtighten SERVICING 37 PILOT BURNER REPLACEMENT 1 Lift off lower front panel and remove the grille assembly refer to Frames 28 29 Undo the gas cock union Remove the burner assembly 2 Remove the ignition electrode Refer to Frame 42 3 Unscrew the thermocouple nut and pull the thermoco...

Page 26: ... Refer Frames 28 29 2 Pull off the thermostat knob 3 Disconnect the electrical connections from the gas valve 4 Unscrew the 2 screws and pull down the control panel so that the 2 tabs clear the top panel 5 Remove the bottom screw and remove the cover from the control box 6 Remove the top screw and ease the control box off the control panel 7 Disconnect the mains electrical supply from the terminal...

Page 27: ...e new lead and re assemble in reverse order 41 IGNITION LEAD REPLACEMENT 1 Lift off the lower front panel Refer to Frame 28 2 Remove the 2 screws and pull down the control panel tabs clear of the top panel 3 Remove the split pin at the thermostat pocket and withdraw the phials from the pocket 4 Remove the thermostat backnut 5 Remove the 2 Eco leads 6 Fit the new thermostat lead polarity immaterial...

Page 28: ...ward 3 Re assemble in reverse order 42 IGNITION ELECTRODE REPLACEMENT 43 THERMOCOUPLE REPLACEMENT 1 Lift off lower front panel and remove the grille assembly refer to Frames 28 29 Undo the gas cock union Remove the burner assembly 2 Undo the thermocouple nut at the pilot burner and connection at the gas valve and pull the thermocouple clear 3 Fit the new thermocouple Note Avoid sharp bends in the ...

Page 29: ...n reverse order SERVICING 1 Lift off lower front panel and remove the grille assembly Refer to Frames 28 29 Undo the gas cock union and the 2 wing nuts to remove the burner and controls assembly 2 Undo the nut securing the pilot bracket to the main burner and remove the pilot bracket 3 Remove the 4 nuts and washers securing the main burner to the front plate and gas manifold Withdraw the burner 4 ...

Page 30: ...curing the gas inlet pipe to the LH side of the gas valve 4 Unfasten the 4 screws securing the gas manifold The 2 sealing O rings should be discarded and new O rings fitted SERVICING 5 Fit the new gas valve ensuring that a The valve is fitted the correct way round an arrow engraved on the valve indicates the direction of flow b The sealing O rings supplied with the valve are correctly fitted at th...

Page 31: ...or Heat YES NO YES Check the settings of the room thermostat and the cylinder thermostat Check the control system Reference may be made to the British Gas Multimeter Instruction Book Is there gas at the pilot burner when the gas valve knob is pressed YES YES Does the pilot light when a match is applied NO NO Allow time to purge any air present by increasing the pilot gas rate done by adjusting the...

Page 32: ...88 396 Ignition electrode MORGAN MATROC 1 003 038 17 E01 412 HT lead 460mm long 1 052 888 18 390 039 Thermocouple HONEYWELL Q 309 A 2739 600mm lg 1 000 842 24 Thermostat RANCO K36 P1354 1 151 903 25 308 557 Thermostat knob 1 111 904 40 E01 428 Flue baffle RS 3 40 only 1 151 061 SHORT LIST OF PARTS The following are parts commonly required as replacement components due to damage or expendability Th...

Page 33: ...33 Mexico Slimline RS 3 40 3 50 Installation SHORT LIST OF PARTS 50 SHORT PARTS ...

Page 34: ...o unit 16 Ignition electrode 17 Ignition HT lead 18 Thermocouple 19 Gas cock 41 Outlet pipe 42 Inlet pipe 44 Pilot sealing gasket 45 Pilot sealing plate Legend 5 Front plate assembly 6 Sightglass 7 Pilot pipe 8 Main burner 9 Main burner injector 10 Pilot burner 12 Pilot burner bracket assy 13 Gas valve 14 O ring ...

Page 35: ... RS 3 40 3 50 Installation 52 CONTROL BOX ASSEMBLY Exploded View LIST OF PARTS Legend 21 Controls panel complete 22 Control box 24 Thermostat 25 Thermostat knob 26 Controls panel 27 Magnetic strip 28 Controls front panel ...

Page 36: ...imline RS 3 40 3 50 Installation 53 BOILER CASING ASSEMBLY LIST OF PARTS 33 Top panel 34 Grille assembly 35 Lower front panel Legend 20 Casing complete 21 Controls panel complete 31 L H side panel 32 R H side panel ...

Page 37: ...37 Mexico Slimline RS 3 40 3 50 Installation ...

Page 38: ... therefore reserved to vary specification without notice September 1999 151 906 A04 The Caradon Plumbing Limited 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 01270 413 624 These appliances are designed for use with Natural Gas only They have been...

Page 39: ...We ll be giving away a free boiler for the five best ideas every year to be selected by our Technical Director Please complete this form using extra sheets if required and post it or fax it to us on 01482 498699 Boiler details Model Size e g Classic RS 230 Mexico CF 3 60 etc Details on control panel door Date of Installation Installer details Name Address Post Code Telephone Please include STD cod...

Page 40: ...se arrange for me to join an Ideal factory tour Range guides required The Ideal Guide a specifier s and installer s introduction to the Ideal domestic boiler range The Ideal Householders Guide to assist the installer when presenting to his her customers Technical manuals required The Ideal C class combi boiler The Ideal Classic wall hung boiler The Ideal Classic System wall hung boiler The Ideal C...

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