Ideal Boilers Mexico Super 100 FF Installation And Servicing Manual Download

Page: 26 / 48

Mexico Super 100 FF & 125 FF -

Installation

INST

ALLA

TION

INSTALLATION

47 MID POSITION VALVE

Notes.

Some earth wires are omitted for clarity. Ensure proper
earth continuity when wiring.

Numbering of terminals on thermostats is specific to the
manufacturer indicated.

This is a fully controlled system - set the boiler
thermostat to maximum.

'Switchmaster Midi' is similar in operation but the wiring
differs slightly; see manufacturer's literature.

Pumped only

48 TWO SPRING CLOSED VALVES

Notes.

Some earth wires are omitted for clarity. Ensure proper
earth continuity when wiring.

Numbering of terminals on thermostats is specific to the
manufacturer.

This is a fully controlled system - set the boiler
thermostat to maximum.

'Switchmaster Autozone' has grey and orange auxiliary
switch leads but the ORANGE (NOT the grey) wire must
be connected to the incoming live supply.

Pumped only

49 HONEYWELL 'C' PLAN

Notes.

Some earth wires are omitted for clarity. Ensure proper
earth continuity when wiring

Numbering of terminals on thermostats is specific to the
manufacturer.

LEGEND

blue

black

white

grey

y/g

yellow/green

Gravity HW & Pumped CH

brown

red

orange

y/g

yellow/green

grey

brown

red

white

LEGEND
b

blue

black

brown

orange

LEGEND
w

white

red

blue

grey

y/g

yellow/green

Summary of Contents for Mexico Super 100 FF

Page 1: ......

Page 2: ...ly 250mm wide 8 propane Super models and 7 Fanned models Option kit availability includes an easy to use programmer kit available on all models an overheat thermostat kit 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 and all fanned models Full system suitability All models are suitable for connection to pumped open v...

Page 3: ...M kW Btu h 29 3 100 000 36 6 125 000 Burner Setting Pressure hot MINIMUM mbar in w g 7 3 2 9 8 4 3 4 MID mbar in w g 9 3 3 7 10 8 4 3 MAXIMUM mbar in w g 11 5 4 6 13 2 5 3 Seasonal Efficiency SEDBUK 77 4 77 6 Table 2 Performance Data Note Gas consumption is calculated using a calorific value of 38 7 MJ m3 1038 Btu ft3 gross or 34 9 MJ m3 935 Btu ft3 nett To obtain the gas consumption at a differen...

Page 4: ... Extension Duct kit 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 CONTENTS Air Supply 7 Boiler Assembly Exploded view 9 Boiler Clearances 6 Burner Assembly Exploded view 43 Electrical Connections 24 Electrical Diagrams 24 25 Electrical Supply 8 Extensi...

Page 5: ...ork 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...

Page 6: ...r servicing 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 z z z z z BS 6798 z z z z z The position selected for installation MUST allow adequate space for servicing in front of the boiler and for air circulatio...

Page 7: ...lation 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 boi...

Page 8: ...al regulations which apply 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 3mm 1 8 contact separation in both poles or a plug and socket serving only the boiler and system controls The means of isolation must be accessible to the user after instal...

Page 9: ...re switch 41 Turret assembly 42 Turret access cover assy 46 Boiler base plate 47 Baseplate heat shield 49 Flue baffle 68 Thermostat phial retaining clip 69 Phial split pin 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 ...

Page 10: ...complete boiler assembly BOILER HARDWARE PACK z 1 BSP plugs 5 off z 1 x 1 2 BSP reducing bush 1 off z Distributor tube z Thermostat pocket 1 off z Thermostat clip RS 3 50 RS 3 60 RS 3 70 RS 3 80 only 1 off z Thermostat retaining pin 1 off z Output setting label 1 off FLUE PACK Pack B Contents z Duct cutting support 2 off cardboard z Terminal wall plate 1 off z Terminal grille assy 1 off z Polyuret...

Page 11: ...e side 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 11 The boiler is held to the packaging base by 4 M6 hex head screws Remove the front scr...

Page 12: ...sing an approved jointing material Refer to Tables 7 and 8 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 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...

Page 13: ...mmediately 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 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 termin...

Page 14: ...re 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 1 Secure the flue to the boiler using the three M5 wing nuts provided Note The sealing ring studs will locate in the back panel one way only This will ensure that the terminal is correctly aligned 13 FITTING THE FOAM SEAL 1 To determine th...

Page 15: ...board support provided 18 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 ...

Page 16: ...ess 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 21 FITTING THE FOAM SEAL 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 groo...

Page 17: ...OCATING 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 B If the flue assembly has been fitted from the inside proceed as follows 1 Move...

Page 18: ...ide wall to the relevant side of the boiler casing greater than 600mm 23 1 2 Refer to Frame 7 7 When cutting the ducts always use the cardboard support provided 27 PREPARING THE WALL 1 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 2 Cut the flue hole preferabl...

Page 19: ...ue duct refer to Frame 7 Ensure the boiler sealing ring is fully engaged 2 Drill 3 holes 3 2mm 1 8 dia through the outer flue duct and boiler sealing ring 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 Fit the turret access cover to the sealing ring 1 To determine the position for the foam seal measure the wall thick...

Page 20: ...de outlet plate must be fitted now 1 Split the side outlet plate into 2 down the split line 2 Fit the 2 halves of the side outlet plate to the wall ensuring they are behind the boiler sealing ring INSTALLATION 33 LOCATING THE BOILER Position the boiler beneath the flue assembly 1 Connect the flue terminal to the boiler using the length A of flue duct previously cut and ensuring that the inner flue...

Page 21: ... off D 1 off B 1 off D 1 off 152227 152132 600 to 1550 B 1 off D 1 off N A 152 227 152132 1 off 1550 to 2000 B 1 off D 2 off N A 152 227 152132 2 off INSTALLATION TOP REAR SIDE FLUE OUTLET Top outlet flue length A B Elbow allowance 90 o Elbow 1m 45 o Elbow 0 7m 37 FITTING THE KIT 1 Remove the cardboard support aid from the flue and place safely to one side 2 Fit the inner flue extension duct onto ...

Page 22: ...pressure of 20 mbar 8 in w g MUST be available at the boiler inlet with the boiler operating 2 Extend a gas supply pipe NOT LESS THAN 15mm 1 2 OD to the boiler and connect to the gas cock situated at the front LH side of the boiler 3 Test the gas installation for soundness and purge in accordance with BS 6891 1988 Refer to Frame 52 Boiler Dimension A 100 FF 327 12 7 8 125 FF 400 15 3 4 38 TERMINAL...

Page 23: ...e top of the boiler and the base of the cylinder 41 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 8 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...

Page 24: ...rical leads into the box and wire into the terminal strip as shown Notes a Secure each lead with one of the cable clamps b The mains lead connection MUST be made so that should the lead slip from its anchorage the current conductors become taut before the earthing conductor 45 EXTERNAL CONTROLS External wiring must be in accordance with the current I E E BS 7671 Wiring Regulations The wiring diagr...

Page 25: ...25 Mexico Super 100 FF 125 FF Installation INSTALLATION 46 PICTORIAL WIRING LEGEND w white r red bk black br brown p purple b blue gy grey y g yellow green INSTALLATION ...

Page 26: ...y when wiring 2 Numbering of terminals on thermostats is specific to the manufacturer 3 This is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster Autozone has grey and orange auxiliary switch leads but the ORANGE NOT the grey wire must be connected to the incoming live supply Pumped only 49 HONEYWELL C PLAN Notes 1 Some earth wires are omitted for clarity Ensure proper ...

Page 27: ...should be wired into the system This is usually done at the programmer in which case the programme selector switches are set to OFF and all other controls MUST be left in the running position The frost stat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown with minimal disturbance to other wiring of the programmer Designation of the terminals wil...

Page 28: ...OPEN and the boiler mains on off switch is OFF 3 If the boiler output is to be set to minimum or mid affix the appropriate indicator label supplied in the hardware pack to the data plate 4 Slacken the screw in the burner pressure test point B and connect a gas pressure gauge via a flexible tube 5 Switch the electricity supply ON and check that all external controls are calling for heat 6 Set the b...

Page 29: ... boiler and the use and adjustment of ALL system controls should be fully explained to the householder to ensure the greatest possible fuel economy consistent with household requirements of both heating and hot water consumption 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 ...

Page 30: ...e main injectors g Check that the flue terminal is unobstructed and that the flue system is sealed correctly h If the appliance has been installed in a compartment check that the ventilation areas are clear a Light the boiler and carry out a pre service check noting any operational faults The servicing procedures are covered more fully in Frames 58 to 62 and MUST be carried out in sequence Note In...

Page 31: ...have fallen onto the burner head ensuring that the flame ports are unobstructed and remove any debris that may have collected Note Brushes with metallic bristles MUST NOT be used 2 Remove the main burner injector Check clean or replace as required 3 Refit the injector using an approved jointing compound 4 Inspect the pilot burner and ignition detection electrode ensure they are clear and in good c...

Page 32: ...shown 3 Retighten the 2 M5 hexagon nuts to ensure an airtight seal Do NOT overtighten 61 RE ASSEMBLY 62 GAS PRESSURE ADJUSTMENT 1 Pilot Pressure Pilot adjustment is factory set to maximum and no adjustment is possible 64 SIGHTGLASS REPLACEMENT Re assemble the boiler in the following order 1 Refit the flue baffles 2 Inspect the collector hood rope gasket and replace if necessary ensuring that the s...

Page 33: ... and washers and withdraw the pilot burner 6 Fit the new pilot burner and re assemble in reverse order ensuring that a The injector is in position when refitting the pilot supply b A gas tight joint is made c The spark gap is correct Refer to Frame 69 1 Remove the 2 screws and lift off the lower front panel Refer to Frame 57 2 Pull off the thermostat knob 3 Remove the 2 screws and pull down the co...

Page 34: ...cure with the split pin 11 Refit the in line electrical connector between the control box and the PCB box 12 Remove control box cover and make electrical supply connections to the terminal strip Refer to Frame 46 1 Remove the 2 screws and lift off the lower front panel Refer to Frame 57 2 Slacken the screw at the thermostat pocket and withdraw the phial from the pocket 3 Remove the thermostat reta...

Page 35: ...nuts and withdraw the burner and controls assembly complete from the boiler 2 Disconnect the ignition lead from the PCB 3 Prise the retaining clip out of the groove in the electrode using a small screwdriver and withdraw the electrode 4 Push in the new electrode until the retaining clip locates in the groove and re assemble in reverse order SERVICING 2 Disconnect the ignition lead from the PCB 3 R...

Page 36: ... INJECTOR REPLACEMENT 1 Remove the 2 screws and lift off the lower front panel then remove the grille assembly Refer to Frame 57 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 2 Disconnect the ignition lead from the PCB 3 Undo the pilot supply connection 4 Unscrew the gas inlet pipe from the valve 72 GAS VALVE REPLACEMENT 5 Rem...

Page 37: ... grease Ensure the fan leads and 2 sensing tubes are connected 10 Refit the boiler casing 11 Check the boiler operation 73 FAN REPLACEMENT 1 Remove the lower front panel control panel and the top panel Refer to Frame 57 2 Remove the APS fixing screw 3 Remove both sensing tubes from the APS 4 Remove the 3 electrical connections from the APS 5 Connect the new APS in reverse order 6 Refit the APS wit...

Page 38: ...Change pressure switch Does the pilot light NO YES NO YES Does the spark stop after pilot is lit NO Is there a gas supply to the boiler Is the pilot injector blocked YES Replace gas valve NO Is there a supply on terminals of main gas valve YES NO YES NO NO Is there a supply on the fan connector at PCB Molex marked FAN YES YES NO NO Check the polarity of the mains supply Check the continuity of the...

Page 39: ...ssembly VR 4601CA 1018 O ring 100 125FF 1 170 664 26 386 575 Ignition electrode HONEYWELL 45900413 004 1 151 079 27 HT lead 1100mm 100 125FF 1 130 918 30 PCB sub assembly 1 170 665 38 Pressure switch HONEYWELL C6065F1316B 1 152427 49 Flue baffle kit 100 FF 6 079 890 125 FF 4 079 891 66 Thermostat RANCO K36 P1354 1 151 903 67 308 557 Thermostat knob 1 111 904 SHORT LIST OF PARTS The following are p...

Page 40: ...40 Mexico Super 100 FF 125 FF Installation LIST OF PARTS 76 SHORT PARTS ...

Page 41: ...FF Installation Legend 63 Control panel complete assembly 65 Control box assembly 66 Control thermostat 77 BOILER CONTROL PANEL Exploded View 67 Control thermostat knob 71 Control front panel door 72 Magnetic strip LIST OF PARTS ...

Page 42: ...42 Mexico Super 100 FF 125 FF Installation LIST OF PARTS 78 PCB BOX Exploded View Legend 29 PCB chassis assembly 30 PCB sub assembly 34 PCB support 37 PCB cover ...

Page 43: ...ND CONTROLS ASSEMBLY Exploded View Legend 16 Front plate assy 17 Sightglass assy 18 Burner manifold 19 Pilot pipe 20 Main burner 21 Main injector 22 Pilot burner 24 Gas valve 25 O ring 26 Ignition electrode 27 Ignition lead 28 Gas cock 50 Sealing gasket 51 Sealing plate ...

Page 44: ...Installation Legend 46 Baseplate 62 Casing complete 63 Controls panel complete 71 Controls front panel door 73 Side panel LH 74 Side panel RH 75 Lower front panel 76 Top panel 77 Grille panel 80 BOILER CASING ASSEMBLY LIST OF PARTS ...

Page 45: ...45 Mexico Super 100 FF 125 FF Installation ...

Page 46: ...rses please ring 01270 413624 THIS SYMBOL IS YOUR ASSURANCE OF QUALITY These appliances are designed for use with Natural Gas only They have been tested and conform with the provisions of BS 6332 and BS 5258 CERTIFIED PRODUCT Manufactured under a BS EN ISO 9001 1994 Quality System accepted by BSI Ideal Installer Technical Helpline 01482 498663 Caradon Plumbing Ltd P O Box 103 National Ave Kingston...

Page 47: ...We will 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 c...

Page 48: ...or a technical representative to contact me Please 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 I...

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