Ideal Boilers Mexico Super RS 3/100P Installation And Servicing Manual Download Page 9

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Mexico Super RS 3/60P - 3/100P -

Installation

3 BOILER ASSEMBLY - Exploded View

Mexico Super RS 3/60P with casing removed.

INSTALLATION

INST

ALLA

TION

LEGEND

Heat exchanger assy.

End section.

Middle section.

Section alignment rings and 'O' rings.

Thermostat pocket.

Distributor tube.

Combustion chamber.

12.

Collector hood.

13.

Cleanout cover.

14.

Front plate assy.

22.

Gas control valve.

24.

Piezo igniter.

28.

Gas cock.

34.

Phial clip.

35.

Split pin

46.

Air duct assy.

47.

Boiler base plate.

52.

Heat shield.

Summary of Contents for Mexico Super RS 3/100P

Page 1: ......

Page 2: ...imline models at only 250mm wide and 8 propane Super 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 Full system suitability All models are suitable for connection to pumped open vent central heating...

Page 3: ...nce converted it is not possible to convert back to propane gas Key to symbols IE Ireland GB United Kingdom Countries of destination PMS Maximum operating pressure of water C11 A room sealed appliance designed for connection via ducts 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 circu...

Page 4: ...atly within the casing Separate fitting instructions are included with this kit Pump 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 36 37 Electrical Connections...

Page 5: ...ations 1989 1 BOILER WATER CONNECTIONS GENERAL 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 ...

Page 6: ...ING installation Refer to Frame 6 In addition a MINIMUM clearance of 533 mm 21 MUST be available at the front of the boiler for 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 ...

Page 7: ... guard 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 60P 212 33 212 33 106 17 106 17 RS 3 75P 269 42 269 42 135 21 135 21 RS 3 100P 350 55 350 55 175 28 175 28 Terminals guards are available from boiler suppliers In case of difficulty seek advice from Tower Flue Components Ltd Vale Rise T...

Page 8: ...e 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 THERMOSTATIC RADIATOR VALVES Caradon Plumbing Ltd 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 no...

Page 9: ... LEGEND 1 Heat exchanger assy 2 End section 3 Middle section 4 Section alignment rings and O rings 6 Thermostat pocket 7 Distributor tube 8 Combustion chamber 12 Collector hood 13 Cleanout cover 14 Front plate assy 22 Gas control valve 24 Piezo igniter 28 Gas cock 34 Phial clip 35 Split pin 46 Air duct assy 47 Boiler base plate 52 Heat shield ...

Page 10: ...at pocket 1 off z Thermostat clip 1 off z Thermostat retaining pin 1 off z Output setting label 1 off z Sachet of sealing mastic 2 off Pack D contents z Adhesive tape 4 UNPACKING complete boiler assembly Wall thickness Flue Dimension duct length X shown above pack s Boiler fitted flush with wall Boiler fitted in line with 600 mm kitchen units required 114 to 191 mm 4 1 2 to 7 1 2 up to 125 mm up t...

Page 11: ...ve 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 sides 7 Draw the top panel forward and lift it off the boiler 8 Remove the 2 screws securing LH side panel to the flue collector and baseplate 9 Pull the panel forward lifting it clear of the locating peg and remove 10 Repeat steps 8 and 9 to rem...

Page 12: ... 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 7 and 8 4 Connect pipe fittings to the rear tappings and plug any unused tappings Note If using iron elbows fi...

Page 13: ... from OUTSIDE of the building 6 From OUTSIDE of the building seal the air duct join A with the mastic provided 7 From OUTSIDE of the building pass the terminal flue duct through 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 Fas...

Page 14: ...Terminal grille A Air duct join B Flue duct join C Terminal air duct join D Terminal flue duct join 6 Extension air duct 7 Extension flue duct 1 BEFORE PLACING THE BOILER IN POSITION loosely fit the extension air duct and terminal assembly to the boiler air duct and adjust to the required overall duct length Note Ensure that any of the duct overlaps are not less than 50 mm 2 2 Secure the extension...

Page 15: ...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 an...

Page 16: ...t thermostat MUST be wired into the mains lead in parallel with the control s to be overridden Refer to Frame 22 3 If a proprietary system is used follow the instructions supplied by the manufacturer Advice on required modifications to the wiring may be obtained from the component manufacturers Note If there are no external controls the circulating pump MUST be wired into the control box 18 PICTOR...

Page 17: ...g 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 LEGEND b blue bk black br brown r red w white or orange g ygreen yellow gy grey Pumped only 21 HONEYWELL C PLAN Notes 1...

Page 18: ...so then a frost stat should be wired into the system This is usually done at the programmer in which case the programme selector switches are set to OFF and all other controls MUST be left in the running position The frost stat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown with minimal disturbance to other wiring of the programmer Designation...

Page 19: ...uge via a flexible tube 4 Turn the gas control knob A CLOCKWISE until resistance is felt and then release it 5 Push in and retain fully depressed the gas control knob A Press and release the piezo unit button G repeatedly until the pilot is seen to light through the sightglass F 6 Hold the gas control knob A depressed for 15 seconds after the pilot burner has ignited then release If the pilot burn...

Page 20: ...holder by the following actions INSTALLATION INSTALLATION 1 Hand the User s Instructions to the householder and explain his or her responsibilities under the Gas Safety Installation and Use Regulations 1994 Amendments 1996 or rules in force 2 Draw attention to the lighting instruction label affixed to the inside of the controls door 3 Explain and demonstrate the lighting and shutting down procedur...

Page 21: ... been installed in a compartment check that the ventilation areas are clear The servicing procedures are covered more fully in Frames 30 to 35 and MUST be carried out in sequence WARNING Always turn OFF the gas supply at the gas service cock and switch OFF and DISCONNECT the electrical supply to the appliance BEFORE SERVICING IMPORTANT After completing the servicing or exchange of components alway...

Page 22: ...ls panel ensuring that the thermostat phial and phial 1 Brush off any deposits that may 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 Inspe...

Page 23: ... centre if necessary Refit the lower front panel 1 Disconnect the ignition lead from the piezo unit body 2 Remove the retaining nut and withdraw the unit as shown 3 Fit the new unit and reassemble in reverse order REPLACEMENT OF PARTS 3 Remove the lower front panel For replacement of pumps or programmer units refer to the separate Pump Kit or Programmer Kit Instructions When replacing any componen...

Page 24: ...r of the pilot burner DO NOT lose the pilot injector which is a push fit in the pilot burner housing 40 PILOT BURNER REPLACEMENT RS 3 100P ONLY 1 Lift off front panel and remove the grille assembly refer to Frames 30 31 Undo the gas cock union Remove the burner and controls assembly 2 Remove the ignition electrode Refer to Frame 46 3 Unscrew the thermocouple connection and pull the thermocouple cl...

Page 25: ... panel and fit to the casing reverse order 10 Insert control thermostat phial into pocket and secure with the split pin 11 Connect gas valve electrical leads 12 Remove control box cover and make electrical supply connections to the terminal strip Refer to frame 17 13 Replace front lower panel 42 CONTROLS PANEL REPLACEMENT 43 OVERHEAT THERMOSTAT REPLACEMENT if fitted 1 Lift off front lower panel Re...

Page 26: ...es in the groove and re assemble in reverse order 45 IGNITION ELECTRODE REPLACEMENT RS 3 60P RS 3 75P ONLY Detail of pilot flame length and spark gap SERVICING 1 Lift off front panel and remove the grille assembly refer to Frames 30 31 Undo the gas cock union Remove the burner and controls assembly 2 Remove the purse clip 3 Undo the 2 securing nuts and washers Remove the sealing plate and gasket 4...

Page 27: ...pilot burner and pull the thermocouple clear 5 Undo the thermocouple connection at the gas valve 6 Remove the sealing plate and gasket refer to Frame 44 and withdraw the thermocouple 7 Fit the new thermocouple and re assemble in reverse order Note Avoid sharp bends in the thermocouple lead and ensure that it follows the same route as previously SERVICING 1 Lift off front panel and remove the grill...

Page 28: ... re assemble in reverse order taking care not to damage the main burner injector which is screwed into the burner manifold 1 Lift off front panel and remove the grille assembly refer to Frames 30 31 Undo the gas cock union Remove the burner and controls assembly 2 Remove the spark electrode Refer to Frame 46 3 Remove the purse clip 4 Undo the thermocouple connection at the pilot burner and pull th...

Page 29: ...urner 5 Fit the new burner and re assemble in reverse order taking care not to damage the main burner injector which is screwed into the burner manifold SERVICING 51 MAIN BURNER INJECTOR REPLACEMENT RS 3 60P RS 3 75P ONLY 1 Lift off front panel and remove the grille assembly refer to Frames 30 31 Undo the gas cock union Unscrew the 4 wing nuts and remove the burner and controls assembly from the b...

Page 30: ...d jointing compound and re assemble in reverse order 53 GAS VALVE REPLACEMENT 1 Lift off front panel and remove the grille assembly refer to Frames 30 31 Undo the gas cock union Unscrew the 4 wing nuts and remove the burner and controls assembly from the boiler 2 Undo the pilot supply connection 3 Undo the thermocouple connection 4 Unscrew the gas inlet pipe from the valve 5 Remove the 4 securing ...

Page 31: ... Check that there is no blockage in the pilot line or pilot injector NO NO Replace the gas control valve 56 PILOT LIT BUT NO MAINS GAS If no supply check the controls Reference may be made to the British Gas Multimeter Instruction Book NO Check the supply voltage e g by using a multimeter set on the 300V AC range between the L and N terminals Expect 230V 10 6 If no supply check the fuse in the plu...

Page 32: ... LH AEROMATIC No AC 19 123 227 RS 3 100P 1 013 280 E01 489 RH AEROMATIC No AC 19 123 228 RS 3 100P 1 013 281 19 Main burner injector E01 493 BRAY Cat 10 size 650 RS 3 60P 1 003 862 398 044 BRAY Cat 10 size 850 RS 3 75P 1 003 240 389 612 BRAY Cat 10 size 520 RS 3 100P 2 003 861 20 Pilot burner with injector Key No 21 E01 548 HONEYWELL Q 385 A 1020 RS 3 60P 3 75P 1 079 390 E01 549 HONEYWELL Q 349 A ...

Page 33: ...33 Mexico Super RS 3 60P 3 100P Installation LIST OF PARTS 57 SHORT PARTS ...

Page 34: ...ico Super RS 3 60P 3 100P Installation LIST OF PARTS 58 BOILER CASING ASSEMBLY Legend 29 Casing complete 30 Controls panel complete 41 Side panel 42 Top panel 43 Grille assy 44 Lower front panel 47 Baseplate ...

Page 35: ...100P Installation 59 BOILER CONTROL PANEL Exploded View Legend 30 Control panel complete 31 Control box 32 Control thermostat 33 Control thermostat knob 36 Control panel 37 Magnetic strip 38 Control front panel door LIST OF PARTS ...

Page 36: ...ed View Legend 14 Front plate assy 15 Sightglass assy 16 Burner manifold 17 Pilot pipe 18 Main burner 19 Main injector 20 Pilot burner 22 Gas valve 23 O ring 24 Piezo unit spark generator 25 Ignition electrode 26 Ignition lead 27 Thermocouple 28 Gas cock 50 Sealing gasket 51 Sealing plate LIST OF PARTS ...

Page 37: ...htglass assy 16 Burner manifold 17 Pilot pipe 18 Main burner 19 Main injector 20 Pilot burner 22 Gas valve 23 O ring 24 Piezo unit spark generator 26 Ignition lead 28 Gas cock 50 Sealing gasket 51 Sealing plate 61 BURNER AND CONTROLS ASSEMBLY RS 3 100P Exploded View LIST OF PARTS ...

Page 38: ...red Office National Avenue Kingston upon Hull HU5 4JN A subsidiary of Caradon p l c The Caradon Plumbing 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 413624 The code of practice for the installation commissioning servicing of central heatin...

Page 39: ...s for how to improve our boilers and our service 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...

Page 40: ... 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 Classic LX Deluxe wall hung boiler The Ideal Mexico floor standing boiler The Ideal Minimiser heat saving boiler The Ideal Response ...

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