ideal Mexico Super 100 FF User guide

Mexico:

The Floor Standing Gas Boiler

The Ideal Mexico is a range of cast iron floor standing gas central heating boilers. Balanced, conventional or fanned flue versions are available. A complete range of both natural gas and propane models. The range offers Super models and, for when space is tight, there are Slimline models available.

Mexico: Britain’s biggest selling floor standing boiler

The ideal replacement boiler...

Easy to install, easy to operate and easy to service. The Ideal Mexico really is the ultimate replacement floor standing range - you can depend on it.

Proven reliability...

Proven cast iron heat exchanger engineered and refined to be the most dependable floor standing boiler ensuring totally calm operation and quiet running, whatever the system demands.

Complete range...

34 models, including 4 Slimline models at only 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 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 conjunction with the optional Overheat Thermostat Kit.

Free Guarantee: 1st Year Ideal Care

The home owner is entitled to 12 months free Ideal Care, which includes both parts and labour, to restore the boiler to full function. Please encourage the home owner to complete and return the registration form in their Householder’s pack within 30 days of installation.

Optional Extra Year Cover with Ideal Care

You may wish to offer your own annual service plan or you may wish to advise the home owner to complete their application form for the appropriate level of extended Ideal Care - Silver, Gold or Platinum. Full details are available in the Ideal Care brochure.

CAUTION. this appliance, care should be taken when handling edges of sheet steel components.

To avoid the possibility of injury during the installation, servicing or cleaning of

Mexico Super 100 FF & 125 FF - Installation

GENERAL

Table 1 - General Data

Boiler Size 100 FF 125 FF

Gas Supply Connection in. BSP Rc 1/2 (1/2)

Number of Boiler Sections 4 5

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.) 9.8 (2.1) 12.2 (2.7)

Dry Weight kg. (lb.) 113 (249) 136 (300)

Boiler Size Height mm (in.) 850 (33.5)

Width mm (in.) 440 (17.4)

Depth mm (in.) 533 (21.0) 600 (23.6)

Gas Type Natural 2 H

Gas Supply Pressure 20 mb

Flue duct diameter mm (in.) 100 (4.0)

Flue duct length (max) m (ft) 2 (6.5) 1 (3.25)

Table 2 - Performance Data

Boiler Size 100 FF 125 FF

Boiler Input

MINIMUM kW (Btu/h) 29.5 (100 600) 36.9 (125 800)

Gas Consumption l/s (ft.

/h) 0.76 (96.9) 0.95 (121.2)

MID kW (Btu/h) 33.1 (112 900) 41.4 (141 200)

Gas Consumption l/s (ft.

/h) 0.86 (108.8) 1.07 (136.0)

MAXIMUM kW (Btu/h) 36.6 (125 000) 45.8 (156 300)

Gas Consumption l/s (ft.

/h) 0.95 (120.4) 1.18 (150.5)

Boiler Output to Water

MINIMUM kW (Btu/h) 23.4 (80 000) 29.3 (100 000)

MID kW (Btu/h) 26.4 (90 000) 33.0 (112 500)

MAXIMUM 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]%

* 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 BG plc 0087.

Note.

Gas consumption is calculated using a calorific value of 38.7

(1038 Btu/ft3) gross or 34.9 MJ/m3 (935 Btu/ft3) nett. To

MJ/m 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/m3)

b. For ft

/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.

Mexico Super 100 FF & 125 FF - Installation

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

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,

Group H only.

GENERAL

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

Extension Ducts - Fitting ........................................... 21

Fault Finding ............................................................... 38

Flue Fitting ............................................................. 13-21

Flue Installation ............................................................ 7

Gas Safety Regulations ............................................... 5

Gas Supply .................................................................... 7

Mexico Super FF

Mexico Super 100 FF G.C. No. 41 349 83

Mexico Super 125 FF G.C. No. 41 349 84

Natural Gas only Appliance type: C

Certified - P.I. No. 87AU83

Destination Countries: GB & IE.

INTRODUCTION

Mexico Super FF above range is of floor standing, fanned flue gas boilers. They are range-rated to provide central heating outputs of 23.4 kW (80,000 Btu/h) to

36.6 kW (125,000 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).

Initial Lighting ............................................................. 28

Installation ..................................................................... 9

Mandatory Requirements ......................................... 5-6

Pump ............................................................................ 23

Servicing ...................................................................... 30

Short List of Parts ...................................................... 39

System Diagrams (Electrical) .................................... 26

Terminal Guards. .......................................................... 7

Water Connections .............................................. 5 & 22

Water Circulation .......................................................... 8

Water Systems ............................................................ 23

Water Treatment ............................................................ 8

The boilers are suitable, as standard, for connection to open-vented systems ONLY - an overheat thermostat kit is available to allow the boiler to be used on sealed water systems.

The systems may be:

z pumped or gravity circulating indirect DHW only

z pumped central heating only

z pumped central heating combined with either a

pumped or gravity circulating indirect DHW circuit.

OPTIONAL EXTRA KITS

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.

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 100 FF & 125 FF - Installation

GENERAL

GAS SAFETY

Gas Safety (Installation and Use) Regulations, 1994, and amendments 1996 or the rules in force.

It is law that all gas appliances are installed by a CORGI registered installer (identified by above regulations. Failure to install appliances correctly could

lead to prosecution. It is in your own interest, and that of safety, to ensure the law is complied with.

The installation of the boiler MUST also be in accordance with the latest I.E.E (BS 7671) Wiring Regulations, local building regulations, bylaws of the local water authority, the Building Regulations and Building Standards (Scotland) and any relevant requirements of the local authority.

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.

) in accordance with the

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 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 Regulations and the above regulations or other statutory requirements.

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 Engineers document IGE/UP/7 : 1998.

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.

Dimension A B

100 FF 299mm (11

125 FF 373mm (14

3/4") 533mm (21")

5/8") 600mm (23 5/8")

Mexico Super 100 FF & 125 FF - Installation

GENERAL

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.

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.

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.

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 BS. 6798.

z 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.

z This position MUST also permit the provision of a

satisfactory flue termination.

z For the minimum clearances required for safety, and

subsequent service, see Frame 2.

Additional space will be required for installation, depending upon site conditions.

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:-

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 30.

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 Min Side Clearance 'A'

Model Length Depth Height Width Width Rear Flue Side/Top Flue

Rear Flue Side/Top Flue

(

114 to 600

100 FF 600 to 2000 533 (21") 870 (34

(23 5/8 to 78 3/4")

114 to 600 (

125 FF 600 to 1000 600

23 5/8" to 39 1/4")

(

4 1/2 to 23 5/8

") 533 (21") 870 (34 1/4") 460 (18 1/8") 510 (20 1/8") 10 (3/8") 35(1 3/8")

1/4") 510 (20 1/8") 510 (20 1/8") 35 (1 3/8") 35(1 3/8")

") 600 (23 5/8") 870 (34 1/4") 550 (21 5/8") 550 (21 5/8") 55 (2 1/4") 55(2 1/4")

(23 5/8") 870 (34 1/4") 550 (21 5/8") 550 (21 5/8") 55 (2 1/4") 55(2 1/4")

Mexico Super 100 FF & 125 FF - Installation

GENERAL

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. Pipework from the meter to the boiler MUST be of an adequate size. Both 100 FF and 125 FF models should be piped in 22mm minimum. The final metre may be run in 15mm if it is visible.

The complete installation MUST be tested for gas soundness and purged as described in the above code.

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.

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

Table 3 - Balanced flue terminal position

Terminal Position

1. Directly below or alongside an

opening window, air vent or other ventilation opening 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 internal or external corners 25 mm ( 1")

7. Above adjacent ground, roof or

balcony level 300 mm (12")

8. From a surface 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")

Minimum Spacing

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 Tower Flue Guard, Model K1. In case of difficulty seek advice from:

Tower Flue Components Ltd., Vale Rise, Tonbridge, Kent TN9 1TB (Model K1) Telephone No. 01732 351 555

Ensure that the guard is fitted centrally.

5. Where the terminal is fitted within 1000mm (39 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: 1990.

7. 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 & 6

- would be 60mm (2 1/2") in order to allow the terminal wall plate to be fitted.

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") of a

TERMINAL

WARNING.

For top outlet installation (100 FF only) the flue terminal MUST always be in the horizontal position.

The terminal assembly can be adapted to accommodate various wall thicknesses. Refer to Frames 7 & 36.

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

space cm2 (in.2) outside cm2 (in.2)

High level Low level High level Low level

100 FF 354 (55) 354 (55) 177 (28) 177 (28)

125 FF 438 (68) 438 (68) 219 (34) 219 (34)

Mexico Super 100 FF & 125 FF - Installation

GENERAL

WATER CIRCULATION SYSTEM

The boiler must NOT be used for direct hot water supply or for sealed systems. 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

C (20 oF) temperature differentials are shown in the graph

11 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.

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 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.

Water Flow Rate and Pressure Loss

1/2" BSP

WATER TREATMENT

The Mexico Super FF incorporates a cast iron heat exchanger. As part of the installation the central heating system should be thoroughly flushed with appropriate water treatment in order to comply with BS7593:1992

Caradon Plumbing Limited recommend the use of Fernox or Betz Dearborn water treatment products which must be used in accordance with the manufacturers instructions. For further information contact :-

Fernox Manufacturing. Co. Ltd., Tandem House, Marlowe Way, Croydon, Surrey CRO 4XS, tel 0870 5601 5000

Betz Dearborn Ltd., Widnes, Cheshire, tel. 0151 424 5351

IMPORTANT.

ANY OTHER TREATMENT FOR THIS PRODUCT WILL RENDER THE GUARANTEE OF CARADON PLUMBING LIMITED INVALID.

Notes.

1. If an inhibitor is used, and in hard water areas where

treatment to prevent lime deposits is necessary, it is most important that the water treatment MUST be maintained at the correct concentrations recommended by the treatment manufacturer.

2. Artificially softened water must not be used in the system, under any circumstances.

THERMOSTATIC RADIATOR VALVES

Caradon Plumbing 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.

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 must be fitted in order to ensure a flow of water should all the 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.

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 ( and socket serving only the boiler and system controls.

The means of isolation must be accessible to the user after installation.

Dotted lines indicate flow rates equivalent to a

temperature rise of 11 oC (20 oF)

For bathroom installations the point of connection to the mains must be situated outside the bathroom.

Mexico Super 100 FF & 125 FF - Installation

1/8") contact separation in both poles, or a plug

INSTALLATION

BOILER ASSEMBLY - Exploded View

Mexico Super 100 FF shown with casing removed .

INSTALLATION

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.

Mexico Super 100 FF & 125 FF - Installation

18. Burner manifold.

28. Gas cock.

30. PCB assembly.

38. Pressure 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.

INSTALLATION

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

z complete boiler assembly

z User's Instructions

INSTALLATION

z these Installation and Servicing Instructions

z the Hardware Pack (listed separately below)

z Template

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 Polyurethane foam seal 400 lg., 1 off. z No. 8 x 8 lg. Pozi pan hd. screws, 3 off.

complete boiler assembly

BOILER HARDWARE PACK

z 1" BSP plugs - 5 off

z 1" x

z Distributor tube

z Thermostat pocket -1 off

z Thermostat clip (RS 3/50, RS 3/60,

z Thermostat retaining pin - 1 off

z Output setting label -1 off

1/2" BSP reducing bush - 1 off

RS 3/70 & RS 3/80 only) - 1 off

FLUE HARDWARE PACK

z Flue extension tube (rear)

z Flue extension tube (side)

z Flue extension tube (top)

z Elbow

z Sealing ring

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.

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.

z M5 wing nuts - 3 off

z Side outlet plate

Mexico Super 100 FF & 125 FF - Installation

INSTALLATION

BOILER CASING REMOVAL - continued

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.

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.

DETERMINING THE FLUE LENGTH

It is MOST IMPORTANT that the boiler is installed in a vertical position.

WARNING.

For top outlet installation (100 FF only) the flue terminal MUST always be in the horizontal position.

Flue length

Up to 600 B, 1 off B, 1 off 152 227

100 FF Pack Req. 125 FF Pack Req. Product No.

Top outlet flue length

= A + B + Elbow allowance

Elbow = 1m

45o Elbow = 0.7m

FLUE KITS

Pack B: supplied as standard.

Pack D: optional extension kit for side

flue, top or rear flue outlet. Refer to 'Flue Extension Ducts'

1. A maximum of 2 extension ducts (plus the standard flue duct) may be used together for 100 FF or 1 extension duct for 125 FF.

2. Flue extensions of greater than 1m (39") should be supported with the bracket provided.

600 to 1000 B, 1 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+

1505 to 2000 B, 1 off + D, 2 off N/A 152 227+

Mexico Super 100 FF & 125 FF - Installation

152132, 1 off

152132, 2 off

INSTALLATION

PREPARING THE BOILER

Table 7 - 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 8 - 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.

z 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.

z 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 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.

REAR FLUE ASSEMBLY - Exploded view

For wall thickness 114mm to 600mm

1. The boiler turret assembly is factory built for rear flue installation.

2. Remove the turret access cover.

3. Fit the long flue extension tube (with ring) to the flue connector,

rotate in the bayonet slot and secure with the M4 screws.

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.

REAR FLUE OUTLET

Mexico Super 100 FF & 125 FF - Installation

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.

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.

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.

Mexico Super 100 FF & 125 FF - Installation

REAR FLUE OUTLET

FITTING THE FOAM SEAL

INSTALLATION

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.

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.

CONNECTING THE FLUE TO THE BOILER

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.

B. If the flue assembly has been fitted from 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.

REAR FLUE OUTLET

Mexico Super 100 FF & 125 FF - Installation

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 1/2") Refer to 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.

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.

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.

SIDE FLUE OUTLET

Mexico Super 100 FF & 125 FF - Installation

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