Mexico:
The Floor Standing Gas Boiler
The Ideal Mexico is a range of cast iron floor standing gas central heating boilers. Both
balanced or conventional 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...
27 models, including 4 Slimline 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 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.
of this appliance, care should be taken when handling edges of sheet steel components.
2
To avoid the possibility of injury during the installation, servicing or cleaning
Mexico Super CF 3/100, 3/125, 3/140 - Installation
GENERAL
Table 1 - General Data
Boiler Size CF 3/100 CF 3/125 CF 3/140
Gas Supply Connection in. BSP Rc 1/2 (1/2) Rc 3/4 (3/4)
Flue Connection mm (in.) 125 (5) 150 (6) 150 (6)
Number of Boiler Sections 4 5 6
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)
Gas Supply Pressure 20 mb
Gas Type Natural 2 H
Electrical Supply 230 V ~ 50 Hz
External Fuse Rating (Power Consumption) 3 A (5 W)
Water Content litre (gal.) 9.8 (2.1) 12.2 (2.7) 14.6 (3.2)
Dry Weight kg. (lb.) 111 (245) 134 (295) 157 (346)
Boiler Size Height mm (in.) 850 (33.5)
Width mm (in.) 440 (17.4)
Depth mm (in.) 533 (21.0) 600 (23.6) 750 (29.5)
Table 2 - Performance Data
Boiler Size CF 3/100 CF 3/125 CF 3/140
Boiler MINIMUM kW (Btu/h) 29.5 (100800) 37.5 (127900) 46.1 (157400)
Input Gas Consumption l/s (ft.3/h) 0.76 (96.9) 0.97 (123) 1.19 (151)
MID kW (Btu/h) 33.3 (113500) 41.9 (142900) 48.8 (166400)
3
Gas Consumption l/s (ft.
/h) 0.86 (109) 1.08 (138) 1.26 (160)
MAXIMUM kW (Btu/h) 37.0 (126300) 46.1 (157400) 51.9 (177200)
3
Gas Consumption l/s (ft.
/h) 0.96 (121) 1.19 (151) 1.34 (170)
Boiler MINIMUM kW (Btu/h) 23.4 (80000) 29.3 (100000) 36.6 (125000)
Output MID kW (Btu/h) 26.4 (90000) 33.0 (112500) 38.8 (132500)
to Water MAXIMUM kW (Btu/h) 29.3 (100000) 36.6 (12500) 41.0 (140000)
Burner MINIMUM mbar (in w.g.) 8.5 (3.4) 10.2 (4.1) 11.6 (4.6)
Setting MID mbar (in w.g.) 10.6 (4.2) 12.6 (5.0) 13.1 (5.2)
Pressure
(hot) MAXIMUM mbar (in w.g.) 13.3 (5.3) 15.1 (6.0) 14.6 (5.8)
Flue Gas Flow Rate g/s 17.4 21.7 24.4
o
Flue Gas Temperature
C 125 139 128
Seasonal Efficiency (SEDBUK)* % 71.7 71.4 73.0
*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 BGplc 0087
Note.
Gas consumption is calculated using a calorific value
of 38.7 MJ/m
3
(1038 Btu/ft3) gross or 34.9 MJ/m3 (935
Btu/ft3) nett
To 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 ft3/h - divide the gross heat input (Btu/h) by the
gross C.V. of the gas (Btu/ft3).
Key to symbols
GB = United Kingdom IE = Ireland (Countries of destination)
PMS = Maximum operating pressure of water
= An appliance designed for connection to a flue discharging the products
B
11BS
of combustion outside the room, with air for combustion being drawn
directly from the room where the appliance is installed, without a fan
in the combustion products circuit and fitted with a combustion products
discharge safety device.
I
= An appliance designed for use on 2nd Family gas, Group H only.
2H
Mexico Super CF 3/100, 3/125, 3/140 - Installation
3
GENERAL
Mexico Super CF
Mexico Super CF 3/100 ........... G.C. No. 41 348 18
Mexico Super CF 3/125 ........... G.C. No. 41 348 20
Natural Gas only
Appliance type: B
BS
11
Certified - P.I. No. 87 AT 15
Mexico Super CF 3/140 ........... G.C. No. 41 348 21
CONTENTS
Air Supply. ..................................................................... 7
Boiler Assembly - Exploded view ................................ 9
Boiler Clearances .......................................................... 6
Burner Assembly - Exploded view ............................ 33
Downdraught thermostat ............................................. 7
Electrical Connections ............................................... 15
Electrical Diagrams ..................................................... 15
Electrical Supply ........................................................... 8
Fault Finding ................................................................ 30
Flue Connection .......................................................... 14
Flue Installation ............................................................. 7
Destination Countries: GB, IE
INTRODUCTION
The Mexico Super CF range is of floor standing, natural
draught, open flue gas boilers. They are range-rated to provide
central heating outputs of 23.4kW (80,000 Btu/h) to 41.0 kW
(140,000 Btu/h).
The boiler has a cast iron heat exchanger and is supplied fully
assembled, complete with a white enamelled mild steel casing.
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:
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.
Frost Protection .......................................................... 17
Gas Safety (Installation & Use
Regulations, 1994.......................................................... 5
Gas Supply .................................................................... 5
Initial Lighting.............................................................. 19
Installation ..................................................................... 9
Mandatory Requirements ............................................. 5
Pump ............................................................................ 13
Servicing ...................................................................... 21
Short List of Parts ....................................................... 31
System Electrical Diagrams .............................. 16 & 17
Water Connections ............................................... 6 &13
Water Systems ............................................................ 14
OPTIONAL EXTRA KITS
Programmer Kit Fits neatly 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.
(Not available on the CF 140)
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.
4
Mexico Super CF 3/100, 3/125, 3/140 - Installation
GENERAL
GAS SAFETY
Gas safety (Installation and Use) Regulations, 1994
amendments 1996 or 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
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.
The boiler must not be installed in a bedroom or in a room
containing a bath or shower.
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.
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.
Details of essential features of cupboards /compartment design,
including airing cupboard installation, are to conform to the
following:
zz
z BS. 6798.
zz
zz
z The position selected for installation MUST allow
zz
adequate space for servicing in front of the boiler
and for air circulation around the boiler.
z This position MUST also permit the provision of a
satisfactory flue and an adequate air supply.
z For the minimum clearances required for safety, and
subsequent service, see Frame 2.
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.
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.
The complete installation MUST be tested for gas soundness
and purged as described in the above code.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
5
GENERAL
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 size Dim. A Dim. B Dim. C
CF 3/100 299 (11 3/4") 122 (4 3/4") 533 (21")
CF 3/125 373 (14 3/4") 122 (4 3/4") 600 (23 5/8")
CF 3/140 446 (17 1/2") 197 (7 3/4") 750 (29 1/2")
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
CF 3/100
CF 3/125
CF 3/140
mm (in.) 575 (22 5/8) 535 (21) 870 (34 1/4)
mm (in.) 650 (25 5/8) 600 (23 5/8) 870 (34 1/4)
mm (in.) 740 (29 1/8) 750 (29 1/2) 870 (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 7.
A MINIMUM clearance of 25mm (1") MUST also be
maintained between the flue pipe and any adjacent
combustible material.
In addition a MINIMUM clearance of 533 mm (21") MUST be
available at the front of the boiler, for servicing.
Boiler Clearances Top One side Aggregate
'A' or 'B' 'A' + 'B'
CF 3/100
CF 3/125
CF 3/140
mm (in.) 20 (3/4) 35 (1 3/8) 135 (5 1/4)
mm (in.) 20 (3/4)) 50 (2) 210 (8 1/4)
mm (in.) 20 (3/4) 150 (6) 300 (12)
Note. CF 3/100
If minimum L.H. side
clearance is used on the
CF 3/100 boilers, the TTB
downdraught thermostat
and bracket should be
moved to the R.H. side of
the boiler (alternative
location).
6
Mexico Super CF 3/100, 3/125, 3/140 - Installation
GENERAL
FLUE INSTALLATION
The flue must be installed in accordance with the
recommendations of BS. 5440:1.
The following notes are intended for general guidance:
1. The cross-sectional area of the flue, serving the boiler,
MUST NOT be less than the area of the flue outlet of the
boiler.
If flue pipe is to be used it MUST NOT be less than the
diameter of the flue outlet connection on the boiler.
2. Flue pipes and fittings should be constructed from one of the
following materials:
a. Aluminium or stainless steel.
b. Cast iron, coated on the inside with acid resistant vitreous
enamel.
c. Other approved material.
3. If twin walled flue pipe is used it should be of a type
acceptable to British Gas.
4. If a chimney is to be used it should preferably be one that is
composed of, or lined with, a non-porous acid resistant
material.
Notes.
Chimneys lined with salt -glazed earthenware pipes are
acceptable if the pipes comply with BS.65 and BS.5440:1.
A flue pipe constructed from one of the materials listed in
2 a-c should form the initial connection to the lined chimneys.
Where a chimney is to be used that is not composed of, or
lined with, a non-porous, acid resistant material it should be
lined with a stainless steel flexible flue liner which complies
with BS.715.
5. Before connecting the boiler to, or inserting a liner into, a flue
that has been previously used then the flue MUST be
thoroughly swept clean of any soot or loose material. If a
register plate, restrictor plate or damper etc., is fitted in the
flue then it MUST be removed before connecting the boiler
to, or inserting a liner into, the flue.
6. The flue should terminate in accordance with the relevant
recommendations given in BS.5440:1.
7. The flue MUST be fitted with a terminal (or ridge tile up to 5"
flue diameter). The terminal shall be of a type which has
been tested and found satisfactory by British Gas. This
terminal must NOT be installed within 600mm (24") of an
opening window, air vent or any other ventilation opening.
8. The chimney / flue lining MUST be sealed at both the top
and the bottom.
IMPORTANT. It is absolutely ESSENTIAL to ensure, in practice,
that the flue discharge is in a downdraught- free zone and that
products of combustion discharging from the terminal cannot reenter the building or any other adjacent building through
ventilators, windows, doors, other sources of natural air
infiltration or forced ventilation / air conditioning systems.
TTB DOWNDRAUGHT THERMOSTAT
This appliance is fitted with a TTB downdraught thermostat for
added safety and protection. If this thermostat should operate
and switch off the appliance it is because the flue is subject to
downdraught, probably as a result of adverse wind conditions .
The TTB is an automatic device which will reset once the wind
conditions have returned to normal, subject to a built-in reset
delay in excess of 10 minutes
The TTB is an important safety device and must not be put out
of action or interfered with in any way.
This device is not a substitute for an independently mounted
carbon monoxide detector.
In cases of repeated or continuous shutdown a competent
person should be called to investigate and rectify the condition
causing this and carry out an operational test after each
intervention on the device. Only the manufacturer's original parts
should be used for replacement.
AIR SUPPLY
Detailed recommendations for air supply are given in BS.5440:2.
The following notes are for general guidance:
1. The room or internal space in which the boiler is installed
MUST have, or be provided with, a permanent air vent. This
vent MUST be either direct to outside air or to an adjacent
room or internal space which must itself have, or be provided
with, a permanent air vent at least the same size direct to
outside air.
The minimum effective area of the permanent air vent(s) are
specified below and are related to maximum rated heat input
of the boiler (see Table 3).
Table 3
Boiler size CF 3/100 CF 3/125 CF 3/140
Effective 146 189 211
area
cm2 (in2) (23) (30) (32)
The air vent(s) must NOT have provision for closing or
adjustment and should be sited to avoid risk of accidental
damage or blockage.
If other methods of ventilation are envisaged, British Gas
should be consulted before proceeding.
2. If the boiler is to be installed in a cupboard or compartment,
permanent air vents are required (for combustion, flue
dilution and cooling purposes) in the cupboard /
compartment, at both high and low levels to ensure safe and
efficient combustion and ventilation.
The air vents may either communicate with room/internal
space (appropriately ventilated) 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 of the
boiler (see Table 4).
Notes.
a. Both air vents MUST communicate with the same room or
internal space or MUST be on the same wall to outside air.
b. In siting the air vents care must be taken to avoid the
freezing of pipework.
c. Where cupboard / compartment air vents are open to a room
or internal space, the room or internal space MUST itself be
provided with a permanent air vent, as previously specified.
d. The cupboard / compartment air vents must NOT
communicate with a bedroom, bed-sitting room or a room
containing a bath or shower.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
7
GENERAL
Table 4 - High and low vent areas
Boiler Air from room/internal Air direct from outside
space cm
High Level Low Level High level Low Level
CF 3/100 354 (55) 708 (110) 177 (28) 354 (55)
CF 3/125 440 (69) 880 (138) 220 (35) 440 (69)
CF 3/140 485 (74) 970 (148) 243 (37) 485 (74)
2
(in.2)cm
2
(in.2)
EFFECT OF AN EXTRACTOR FAN
If there is any type of extractor fan fitted in the premises there is
a possibility that, if an adequate air inlet area from outside is not
provided, spillage of the boiler flue products could occur when
the fan is in operation. Where such installations occur a spillage
test, as detailed in BS.5440:1 MUST be carried out and any
necessary action taken.
VENTILATION IN SERIES
In installations requiring 2 ventilators to be fitted in series, e.g.
across a cavity wall, EACH ventilator should be sized in
accordance with the above data. Where there are more than 2
ventilators in series, EACH should have an area of 50% in
excess of the value quoted above.
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.
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.
1/2" BSP
WATER CIRCULATION SYSTEM
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
and gravity or pumped indirect domestic hot water supply
systems.
The boiler is NOT suitable for gravity heating systems.
The hydraulic resistance of the boiler at maximum output with 11
o
o
C (20
F) temperature differentials are shown in the following
graph:
Water Flow Rate and Pressure Loss
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 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.
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 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 accessible to the user after installation.
Dotted lines indicate flow rates equivalent to a
temperature rise of 11oC (20oF)
8
Mexico Super CF 3/100, 3/125, 3/140 - Installation
INSTALLATION
3
BOILER ASSEMBLY - Exploded View
Mexico Super CF 3/100 shown (with the casing removed)
INSTALLATION
LEGEND
1. Heat exchanger.
2. End section.
3. Middle section.
4. Section alignment rings
and 'O' rings.
5. Thermostat pocket.
6. Distributor tube.
7. Combustion chamber.
11. Collector hood.
12. Cleanout cover.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
13. Front plate assy.
21. Gas valve.
23. Piezo spark generator.
27. Gas cock.
33. Retention clip.
34. Split pin
45. Flue baffle.
46. Boiler base plate.
48. Draught diverter back panel assembly.
49. TTB downdraught thermostat & bracket.
50. Heat shield.
9
4
UNPACKING
The boiler is supplied fully assembled in Pack A.
Unpack and check the contents.
Pack A Contents
z complete boiler
INSTALLATION
z the Hardware Pack (listed separately below)
z these Installation and Servicing Instructions
z User's Instructions.
INSTALLATION
HARDWARE PACK
z 1" BSP plugs - 6 off
z 1" x
z Distributor tube
1/2" BSP reducing bush - 1 off
z Thermostat pocket -1 off
z Thermostat clip - 1 off
z Thermostat retaining pin - 1 off
z Output setting label -1 off
10
Mexico Super CF 3/100, 3/125, 3/140 - Installation
INSTALLATION
5
BOILER CASING REMOVAL
To install the boiler the casing MUST be removed.
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 thermostat phial from the pocket as shown.
6. Remove the 2 screws securing the control panel and
disengage the panel by lowering and pulling it forward.
INSTALLATION
7. Remove the 2 screws securing the top panel to the side.
8. Draw the top panel forward and lift it off the boiler.
9. Remove the 2 screws securing LH side panel to the flue
collector and baseplate.
10. Pull the panel forward, lifting it clear of the locating peg,
and remove.
11. Repeat steps 9 &10 to remove the RH panel.
12. 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.
6
CHECKING THE FLUEWAY BAFFLES
1. Remove the flue cleanout cover.
2. CF 3/100 & CF 3/140 only.
Ensure that the baffles (if fitted) are fully inserted in the flueways.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
11
7
PREPARING THE BOILER
INSTALLATION
Notes.
• 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.
• If an optional Pump Kit is to be used then it must be
fitted at this stage. Refer to separate fitting
instructions included with the kit.
1. Screw the distributor tube (supplied with a 1" BSP x
28mm copper adaptor) into the selected heating
INSTALLATION
return tapping, using an appropriate jointing
material.
It is imperative that the index mark on the
distributor 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 5 and 6.
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 when fitted.
5. Place the boiler in position. Note. The pump may be
fitted on the FLOW or RETURN.
Table 5 - 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
CF 3/140 ONLY
LH LH LH
RH RH RH
Table 6 - Gravity Domestic Hot Water & 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
CF 3/140 ONLY
LH LH RH RH LH
RH RH LH LH RH
8
GAS CONNECTION
1. A MINIMUM working gas 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 to the boiler
(for size refer to Table 1 on page 3)
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 22.
Boiler size Dim. A Dim. B Dim. C
CF 3/100 482(19") 256(10") 28(1
CF 3/125 553(21
CF 3/140 704(273/4") 286(111/4") 57(21/4")
3/4") 256(10") 28(11/8")
12
1/8")
Mexico Super CF 3/100, 3/125, 3/140 - Installation
WATER CONNECTION
9
INSTALLATION
1. Connect the system flow and return pipework
to the boiler as appropriate. Refer to Frames
10 and 11 for guidance on system design.
Connection sizes
All water connections are RC 1 (1" BSP) but
pumped pipework must be increased to:
CF 125 only 35 mm (1
CF 140 only 42 mm (1 1/2" BSP)
immediately after leaving the boiler.
10
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 7.
2. The boiler is assumed to be the highest
point of the circulating system.
1/4" BSP)
2. Ensure that all valves are open. Fill and vent the system
Gravity pipework and connections must be at least:
CF 100 - CF 125 28 mm (1" BSP)
CF 140 only 35 mm (1
and check for water soundness.
Notes.
a. Isolating valves must be fitted as close to the pump as
possible.
b. The boiler is not suitable for use with a direct hot
water cylinder.
1/4" BSP)
INSTALLATION
3. The circulating pump is positioned on the
FLOW - 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 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
(20oF) 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 head caused by
the operation of motorised valves, pumps
etc.
o
C
Due allowance MUST be made if surging is
liable to occur.
If in any doubt, contact Caradon Plumbing Limited
Mexico Super CF 3/100, 3/125, 3/140 - Installation
13
11
GRAVITY HOT WATER & PUMPED CENTRAL HEATING
1. Separate flow and return connections are used for
each service. All possible configurations are given
in Frame 7 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")
INSTALLATION
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
INSTALLATION
CF 3/140 ONLY
Cylinder capacity:
160 litres minimum
360 litres maximum
12
FLUE CONNECTION
Connect the flue pipe to the flue outlet.
The flue pipe spigot and socket connections should be sealed
with fibreglass rope, or similar, and suitable fireclay cement.
Notes.
a. The boiler flue connection outlet size is suitable for flue pipe
conforming to BS 567.
If sheet steel flue pipe is fitted, a suitable adaptor must be
used.
b. To facilitate installation and subsequent disconnection it is
recommended that a slip or split socket be included in the
flue installation, adjacent to the boiler flue outlet connection.
c. A minimum of 600mm (2') of vertical flue directly above the
boiler should be provided.
Notes.
a. Flow and return pipes should rise vertically on
leaving the boiler.
b. Horizontal pipes should be ABOVE ceiling level
and as short as possible.
c. A MINIMUM inclination of 25 mm per 3 m run
(1" per 10') is required to avoid air locks.
If the above conditions cannot be met then
pumped primaries should be used.
14
Mexico Super CF 3/100, 3/125, 3/140 - Installation
13
ELECTRICAL CONNECTIONS
INSTALLATION
WARNING.
The appliance MUST be efficiently earthed.
A mains supply of 230 V ~ 50 Hz fused at 3A is required.
All external controls and wiring MUST be suitable for mains
voltage.
Wiring should be in 3-core PVC insulated cable NOT LESS
than 0.75 mm
Wiring external to the boiler MUST be in accordance with
current l.E.E. (BS 7671) Wiring Regulations and local
regulations.
14
INTERNAL WIRING
Flow and pictorial wiring diagrams are shown in
Frames 15 and 16.
1. Remove the securing screw and lift off the
control box cover.
2. Route the electrical leads into the box and wire
into the terminal strip, as shown.
2
(24 x 0.2 mm) to BS.6500, Table 16.
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
installation (except in the case of bathroom installations for
domestic boilers where the point of connection to the mains
MUST be outside of the bathroom).
INSTALLATION
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.
15
EXTERNAL CONTROLS
External wiring must be in accordance with the current I.E.E.
(BS 7671) Wiring Regulations.
The wiring diagrams illustrated in Frames 17-19 cover the
systems most likely to be fitted to this appliance.
For wiring external controls to the Mexico Super CF boiler
reference should be made to the system wiring diagrams
supplied by the relevant manufacturer, in conjunction with this
flow wiring diagram and Frame 14.
Difficulty in wiring should not arise, providing the following
directions are observed:
1. Controls that switch the system on and off, e.g. a time
switch, MUST be wired, in series, in the live mains lead
to the boiler.
2. Controls that override an on/off control, e.g. a frost
thermostat, MUST be wired into the mains lead, in
parallel, with the control(s) to be overridden. Refer to
Frame 20.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
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.
15
16
INSTALLATION
INSTALLATION
PICTORIAL WIRING
LEGEND
b blue
bk black
br brown
y/g yellow/green
17
MID POSITION VALVE
Pumped only
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 Midi' is similar in
operation but the wiring differs slightly;
see manufacturer's literature.
LEGEND
b blue
bk black
br brown
r red
or orange
w white
gy grey
y/g yellow/green
16
Mexico Super CF 3/100, 3/125, 3/140 - Installation
INSTALLATION
18
TWO SPRING CLOSED VALVES
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 Autozone' has grey and orange auxiliary switch leads
but the orange wire only must be connected to the live supply.
LEGEND
b blue
bk black
19
HONEYWELL 'C' PLAN
br brown
r red
w white
or orange
gy grey
y/g yellow/green
Gravity HW & Pumped CH
Pumped only
INSTALLATION
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.
LEGEND
w white
r red
bk black
20
FROST PROTECTION
Central heating systems fitted wholly inside the house do
not normally require frost protection as the house acts as a
'storage heater' and can normally be left at least 24 hrs.
without frost damage. However, if parts of the pipework run
outside the house or if the boiler will be left off for more than
a day or so then a frost 'stat should be wired into the
system.
br brown
or orange
b blue
gy grey
y/g yellow/green
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 will vary, but the programmer
and thermostat manufacturers' leaflets will give full details.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
Diagram A shows a double pole frost thermostat, which should suffice
for all systems which do not use the OFF terminals of the programmer.
Diagram B shows a 'change-over' frost thermostat, which will cover
most systems which do use CH OFF. If, however, on such a system the
HW pipework is in an isolated part of the house, a second frost
thermostat may be used to protect it.
If in doubt, ask your installer for advice.
17
21
FITTING THE CASING
1. Offer up the LH side panel, locating it with
the peg in the baseplate, and push the
panel back.
2. Secure the panel to the baseplate and
collector hood.
3. Repeat steps 1 and 2 to refit the RH side
panel.
4. Place the top panel and push back.
INSTALLATION
5. Secure the top panel to the side panels.
IMPORTANT.
Wiring within the boiler casing must be neatly
secured with the cable straps provided and
MUST NOT be allowed to touch the burner
front plate, or the cleanout cover and the
collector hood.
INSTALLATION
22
COMMISSIONING AND TESTING
A. ELECTRICAL INSTALLATION
1. Checks to ensure electrical safety should be carried
out by a competent person.
2. ALWAYS carry out preliminary electrical system
checks, i.e. earth continuity, polarity, resistance to
earth and short circuit using a suitable test meter.
6. Replace the control box cover and refit the
control panel using the screws previously
removed.
7. Insert the thermostat phial and phial retaining
clip into the thermostat pocket. Take care not
to kink the thermostat capillary as it is
unwound and secure it with the split pin as
shown.
8. Refit the grille assembly
B. GAS INSTALLATION
1. The whole of the gas installation, including the meter,
MUST be inspected and tested for soundness, and
purged in accordance with the recommendations of
BS. 6891.
2. Purging air from the gas installation may be expedited by
loosening the union on the gas service cock on the boiler
and purging until gas is detected.
3. Retighten the union and check for gas soundness.
18
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.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
INITIAL LIGHTING
23
Boiler controls
INSTALLATION
LEGEND
A Gas control knob.
B Burner pressure test point.
C Main burner pressure
adjuster.
D Inlet pressure test point.
E Gas service cock.
F Sightglass.
G Piezo ignition button.
H Boiler thermostat knob.
J Overheat thermostat
(optional) reset button.
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..
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 burner fails to remain alight at this stage, repeat
the procedure detailed above but wait longer than 15
seconds before releasing the gas control knob (A).
7. Check the appearance of the pilot flame to ensure that it
envelops the tip of the thermocouple and is approximately
25mm (1") long. The pilot flame is factory set and no
adjustment is possible.
8. Switch the boiler thermostat control knob (H ) to
position 6 and check that the burner cross-lights
smoothly from the pilot flame.
Note. The pilot burner connection can be tested
for gas soundness. Refer to Frame 24.
9. Test for gas soundness around the boiler gas
component joints, using leak detection fluid.
10. Operate the boiler for 10 minutes to stabilise the burner
temperature. The boiler is preset at the factory to its
maximum nominal rating but can be range-rated to suit the
system design requirements. Refer to Table 2, page 3.
If the burner setting pressure requires adjustment, remove
the silver threaded protection cap on the top of the
regulator. Adjust the main burner pressure adjuster (C) until
the required main burner pressure is achieved.
Note. Continual adjustment in either direction will produce
the opposite effect.
11. If the boiler output is set to MID or MINIMUM affix the
appropriate indicator label, supplied, to the data plate (front
of baseplate).
12. Immediately check that there is no spillage of combustion
products from the draught diverter outlets by carrying out a
spillage test as detailed in BS.5440:1.
Note. This must be done before any building in.
13. Turn the boiler thermostat knob (H) to OFF.
14. Remove the pressure gauge and tube. Retighten the
screw in the pressure test point, ensuring that a gas-tight
seal is made.
INSTALLATION
24
PILOT BURNER CONNECTION GAS SOUNDNESS
1. Turn the gas service cock to OFF and undo the union nut.
2. Remove the 4 wing nuts and withdraw the burner and controls
assembly, complete, from the boiler.
3. Invert the burner assembly and reconnect to the gas service
cock.
4. Turn the gas service cock to ON.
5. Light the pilot burner. Refer to Frame 23.
6. Test for gas soundness around the pilot burner connection, using
leak detection fluid.
7. Turn the gas service cock to OFF and return the burner and
controls assembly to the normal working position.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
19
25
GENERAL CHECKS
INSTALLATION
Make the following checks for correct operation:
1. Turn the boiler thermostat OFF and ON to check that the
main burner is extinguished and relit in response.
2. Check that the programmer, if fitted, and all other system
controls function correctly.
Operate each control separately and check that the main
burner or circulating pump (as the case may be) responds.
3. Flame failure device
INSTALLATION
Check the operation of the flame failure device in the gas
control valve as follows:
a. Extinguish the pilot flame by closing the gas service
cock and note the time taken for the flame failure
device to shut down - identified by a click within the gas
control valve. This must not be longer than 60 seconds.
b. Open the gas service cock and relight the pilot.
c. Turner the boiler thermostat ON. The burner should light.
d. Turn the gas control knob to the OFF position - refer to
Frame 23. The main burner and pilot flame should shut
down immediately. Note. A latch in the gas control valve
provides a safety delay period of approximately 30
seconds before the pilot can be relit.
4. Water circulation System
a. With the system HOT, examine all water connections for
soundness.
b. With the system still hot, turn off the gas, water and
electricity supplies to the boiler and drain down, in order
to complete the flushing process.
c. Refill and vent the system, clear all air locks and again
check for water soundness.
d. Balance the system.
5. Finally, set the controls to the user's requirements, refit the
lower front panel and close the controls door.
Notes.
a. If an optional Programmer Kit is fitted refer to the
separate Programmer Kit Installation Instructions
and User's Instructions.
b. The temperatures quoted below are approximate
and vary between installations.
Thermostat Flow Temperature
Knob Setting
2 60 140
3 66 150
4 71 160
5 77 170
6 82 180
o
C
o
F
26
HANDING OVER
After completing the installation and commissioning of the boiler system the installer
should hand over to the householder by the following actions:
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
procedures, including the function of the TTB downdraught
thermostat.
4. The operation of the 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.
5. Explain the function and the use of the boiler thermostat
and external controls.
6. Explain and demonstrate the function of time and
temperature controls, radiator valves etc., for the
economic use of the system.
7. If an optional Programmer Kit is fitted then draw attention
to the Programmer Kit User's Instructions and hand them
to the householder.
8. After installation, commissioning and customer hand-
over instructions please complete the
appliance log book and leave this with the customer.
9. Stress the importance of regular servicing by a CORGI
registered installer and that a comprehensive service
should be carried out AT LEAST ONCE A YEAR.
20
Mexico Super CF 3/100, 3/125, 3/140 - Installation
27
SCHEDULE
SERVICING
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 installation condition and
usage but should be carried out at least annually .
It is the law that any service work must be carried out by a
CORGI registered installer.
a. Light the boiler and carry out a pre-service check, noting
any operational faults.
b. Clean the main burners and lint gauzes.
c. Clean the lower front panel lint gauze.
d. Clean the heat exchanger.
e. Clean the main injectors.
f. Check the condition of the thermocouple.
28
BOILER CASING FRONT REMOVAL
1. Lift off the lower front panel.
2. Remove the 2 screws and lift off the grille assembly.
3. Remove the gas valve electrical cover and disconnect
the electrical leads.
g. Check that the flue is unobstructed and that the flue
system, including the flue cleanout cover, is sealed
correctly.
h. If the appliance has been installed in a compartment,
check that the ventilation areas are clear.
The servicing procedures are covered more fully in Frames 2835 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 always test for gas soundness, carry out
functional checks as appropriate and test for spillage (Frame
23). Note. It may be necessary to remove the boiler casing to
carry out the spillage test. Refer to Frame 5.
4. Release the gas valve lead from the retaining clip.
5. Remove the thermostat phial from the pocket, as
shown.
6. Remove the 2 screws securing the control panel
and pull down to release the tabs from under the
top panel.
7. If the boiler is not fitted under a work top, access for
flue cleaning will be improved by removing the top
panel.
SERVICING
Mexico Super CF 3/100, 3/125, 3/140 - Installation
21
SERVICING
29
BURNER AND CONTROLS ASSEMBLY REMOVAL
1. Lift off the front panel and remove the grille
assembly from the casing.
2. Undo the gas service cock union nut.
3. Remove the 4 wing
nuts and withdraw
the burner and
controls assembly,
complete, from the
boiler.
30
LINT GAUZE REMOVAL
1. Lift off front panel and remove the
grille assembly. Refer to Frames 28 &
29.
Remove the burner and controls
assembly.
2. Remove the manifold nuts to remove
both burners from the burner front
plate / manifold assembly.
3. From each burner remove the 2 air box
securing nuts and CAREFULLY
remove the air box and venturi
SERVICING
arrangement.
4. Withdraw both lint gauzes.
31
CLEANING THE BURNER ASSEMBLY
1. Clean the lint gauze(s) to remove any deposits of lint, fluff
etc.
2. Brush off any deposits that may have fallen on to 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.
3. Remove the main burner injectors. Check, clean or replace,
as required.
4. Refit the injectors, using an approved jointing compound.
5. Inspect the pilot burner, thermocouple and ignition
electrode - ensure that they are clear and in good condition.
Check that:
a. The pilot burner is clean and unobstructed.
b. The ignition electrode is clean and undamaged.
c. The ignition lead is in good condition and securely
connected.
d. The spark gap is correct. Refer to Frame 44.
e. The thermocouple tip is not burned or cracked.
f. The position of the thermocouple relative to the pilot
burner is correct. Refer to Frame 44.
g. The thermocouple terminal at the gas valve is clean.
6. Clean or renew components as necessary.
22
Mexico Super CF 3/100, 3/125, 3/140 - Installation
SERVICING
32
CLEANING THE LOWER FRONT PANEL LINT ARRESTING GAUZE
1. Unclip the gauze from the grille assembly and lift
it clear of the bottom return edge.
2. Clean the gauze to remove any deposits of lint or
fluff.
3. Refit the gauze by entering the bottom edge
behind the grille return edge and engaging the
top in the clips.
34
33
CLEANING THE FLUEWAYS
RE-ASSEMBLY
1. Remove the 2 wing nuts and lift off the cleanout cover.
2. CF 3/100 and CF 3/140 only.
Lift out the flue baffles.
3. Remove all loose deposits from the heat exchanger,
especially from between the fins, using a suitable brush.
Remove all debris from the combustion chamber base.
4. Check that the flue outlet duct is unobstructed.
Re-assemble the boiler in the following order :
1. Refit the flue baffles into the boiler flueways, ensuring
that they are correctly repositioned. Refer to Frame 6.
2. Refit the flue cleanout cover, renewing any damaged or
deteriorating sealing gasket.
3. Refit the casing top panel.
4. Reconnect the electrical wiring and refit the controls
panel, ensuring that the thermostat phial and phial
retaining clip are correctly located in the thermostat
pocket and secured by the split pin. Refer to Frame 28.
5. Check the sightglass in the front plate - clean or renew
as necessary.
6. Renew any damaged or deteriorating front plate gasket.
7. Refit the burner and controls assembly.
8. Reconnect the gas service cock.
9. Refit the grille assembly.
SERVICING
35
GAS PRESSURE ADJUSTMENT
1. Pilot Pressure
Pilot adjustment is factory set to maximum and no
adjustment is possible.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
2. Main Burner Pressure
After servicing, reference should be made to Table 1,
page 3, 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 23.
Refit the lower front panel
23
REPLACEMENT OF PARTS
36
GENERAL
When replacing any component:
1. Isolate the electricity supply.
2. Turn off the gas supply at the boiler.
3. Remove the lower front panel .
For replacement of pumps or
programmer units refer to the
separate Pump Kit or Programmer
Kit instructions.
38
PIEZO UNIT REPLACEMENT
SERVICING
37
SIGHTGLASS REPLACEMENT
1. Unfasten the 2 M5 hexagon nuts and washers. Remove
the assembly from the front plate.
2. Fit the new sightglass
and re-assemble, as
shown.
3. Retighten the 2 M5
hexagon nuts to ensure
an airtight
seal. Do NOT
overtighten.
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.
SERVICING
39
PILOT BURNER REPLACEMENT
1. Lift off front panel and remove the grille assembly - refer
to Frames 28 & 29.
Undo the gas cock union and the 4 wing nuts to remove
the burner / controls assembly.
2. Remove the ignition electrode . Refer to Frames 44 .
3. Unscrew the thermocouple connection and pull the
thermocouple clear. Refer to Frame 45.
4. Undo the pilot supply pipe connection and ease clear of
the pilot burner. DO NOT LOSE the pilot injector, which is
a push-fit in the pilot burner housing.
5. Remove the 2 securing screws 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 44.
24
Mexico Super CF 3/100, 3/125, 3/140 - Installation
40
CONTROL THERMOSTAT REPLACEMENT
1. Lift off the front door. Refer to
Frame 28.
2. Pull off the thermostat knob.
3. Remove the 2 screws and pull
down the control panel so that
the tabs clear the top panel.
4. Remove the thermostat phial
from the pocket. Refer to Frame
28.
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. Remove the 2 screws to release
the thermostat bracket.
8. Disconnect the electrical leads
from the thermostat.
9. Unscrew the thermostat nut to
withdraw the thermostat.
10. Fit the new thermostat and reassemble in reverse order.
SERVICING
41
CONTROLS PANEL REPLACEMENT
1. Lift off the lower front panel. Refer Frame 28
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 thermostat phial from the
pocket. Refer to Frame 28.
6. Remove the bottom screw and remove
the cover from the control box.
7. Remove the top screw and ease the
control box off the control panel.
8. Disconnect the mains electrical supply
from the terminal strip and release from
its clamp.
9. Remove the 2 screws to release the
thermostat bracket.
10. Disconnect the TTB thermostat leads
from the terminal strip and control
thermostat. Then release from its bush.
11. On the new control box gain access to
the control thermostat as described
above.
12. Discard the control thermostat lead that
connects to terminal strip marked 'L
13. Reconnect the TTB thermostat lead to the control thermostat and
terminal strip marked 'L
14. Assemble new control box and panel and fit to the casing reverse order.
'.
G
'.
G
SERVICING
Mexico Super CF 3/100, 3/125, 3/140 - Installation
25
42
IGNITION LEAD REPLACEMENT
1. Lift off front panel and remove the grille
assembly. Refer to Frames 28 & 29.
Undo the gas cock union and the 4 wing
nuts to remove the burner / controls
assembly.
2. Remove the purse clip.
3. Disconnect the ignition lead from the
base of the electrode and the piezo unit,
and withdraw the lead.
4. Fit the new lead and re-assemble in
reverse order.
SERVICING
43
OVERHEAT THERMOSTAT REPLACEMENT (if fitted)
1. Lift off front lower panel. Refer to Frame 28.
SERVICING
2. Slacken the screw at the thermostat pocket
and withdraw the phial from the pocket.
3. Remove the thermostat backnut.
4. Remove the 2 Eco leads.
5. Fit the new thermostat (lead polarity
immaterial), ensuring that the alignment peg
on the thermostat sits in the small hole
adjacent to the main fixing hole and
reassemble in reverse order.
6. Replace the lower front panel.
7. Check the operation of the boiler.
26
Mexico Super CF 3/100, 3/125, 3/140 - Installation
44
IGNITION ELECTRODE REPLACEMENT
1. Lift off front panel and remove the grille
assembly - refer to Frames 28 & 29.
Undo the gas cock union and the 4 wing nuts
to remove the burner / controls assembly.
2. Disconnect the ignition lead.
3. Remove the electrode retaining nut and
withdraw the electrode.
4. Fit the new electrode and re-assemble in
reverse order.
SERVICING
Detail of pilot burner assembly
Detail of pilot flame length and spark gap
45
THERMOCOUPLE REPLACEMENT
1. Lift off front panel and remove the grille
assembly - refer to Frames 28 & 29.
Undo the gas cock union and the 4 wing nuts
to remove the burner / controls assembly.
2. Remove the purse clip.
3. Undo the thermocouple connection at the pilot
burner and pull the thermocouple clear.
4. Undo the thermocouple connection at the gas
valve and withdraw the thermocouple.
5. 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
Mexico Super CF 3/100, 3/125, 3/140 - Installation
27
SERVICING
46
MAIN BURNER REPLACEMENT
1. Lift off front lower panel and remove the grille assembly.
Refer to Frame 29.
2. Undo the gas cock union and 4 wing nuts to remove the
burner and controls assembly complete from the boiler.
3. Remove the 2 nuts and washers securing the bottom
burner baffle and remove the baffle.
4. Remove the 2 screws securing the pilot burner and
pull the assembly clear of the main burner.
5. Remove the 2 nuts and washers securing the
burner(s) to the front plate and manifold. Withdraw the
burner.
6. Fit the new burner(s) and re-assemble in reverse
order, taking care not to damage the main burner
injector which is screwed into the burner manifold.
SERVICING
47
MAIN BURNER INJECTOR REPLACEMENT
1. Lift off front panel and remove the grille assembly.
Refer to Frames 28 & 29. Undo the gas cock union
and the 4 wing nuts to remove the
burner / controls assembly.
2. Remove the manifold from the
front plate.
3. Unscrew the burner injectors from
the manifold.
4. Fit the new injectors, using an
approved jointing compound, and
re-assemble in reverse order.
28
Mexico Super CF 3/100, 3/125, 3/140 - Installation
48
GAS VALVE REPLACEMENT
1. Lift off the front panel and remove
the grille assembly. Refer to
Frames 28 & 29.
Remove the burner and controls
assembly.
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 screws
and withdraw the valve from the
burner manifold.
6. 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' ring supplied
with the valve is correctly fitted
at the outlet flange.
c. An approved jointing compound
is used when reconnecting the
gas inlet pipe.
SERVICING
49
TTB DOWNDRAUGHT THERMOSTAT REPLACEMENT
1. Remove the control panel. Refer to Frame 41.
2. Remove the securing screws and lift off the control
box cover.
3. Disconnect the TTB thermostat and remove from
the cable clamp and control box. Refer to Frame
54.
Note.The TTB thermostat is located at the LH or
RH side of the diverter panel.
4. Reach down the side of the boiler and carefully lift
the TTB bracket from its retaining slot and clip.
5. Withdraw the thermostat, bracket and lead down
the side of the boiler.
6. Locate and fit the new TTB downdraught
thermostat, bracket and lead and re-assemble in
reverse order, ensuring that all electrical
connections are correctly remade and cables
secured.
Note. CF 3/100
If minimum LH side clearance is used on the CF 3/100
boilers, the TTB downdraught thermostat and bracket
should be moved to the RHS of the boiler (alternative
location).
SERVICING
Mexico Super CF 3/100, 3/125, 3/140 - Installation
29
FAULT FINDING
Before attempting any electrical fault finding ALWAYS carry
out preliminary electrical system checks, i.e. earth continuity,
polarity and resistance to earth using a suitable meter.
50
PILOT WILL NOT LIGHT
Is there a spark at the ignition electrode ?
YES
Is there gas at the pilot burner when the gas valve
Does the pilot light when a
match is applied ?
Check that there is no blockage
in the pilot line or pilot injector.
knob is pressed ?
YES
NO
Replace the
gas control
valve
NO
YES
NO
NO
Detailed instructions on the cleaning and adjustment or
replacement of faulty components are contained in the
'Servicing' section of this publication.
Check that the gap between the electrode and the pilot
burner is 3-4 mm. Refer to Frame 44.
Check that the HT lead and electrode are undamaged and
the connections are NOT close to earthed metalwork.
Check the piezo unit is operative - by holding an earthed
screwdriver approx. 3mm from the HT output terminal
(with the ignition lead removed) and by operating the
button.
Is there a spark across the gap ?
Allow time to purge any air
present.
Check that the gas control knob is
being pressed fully in, that there is
gas pressure at the boiler inlet and
that the pilot jet is not blocked
Faulty piezo
unit - replace
NO
51
PILOT WILL NOT STAY LIT WHEN THE GAS CONTROL VALVE KNOB IS RELEASED
Does the overheat thermostat (if fitted) require resetting ?
NO
Is the connection between the thermocouple and
the gas control valve clean and tight ?
YES
Is the pilot flame correctly set to maximum ?
YES
Check the thermocouple output (6-10 mV closed circuit). Replace
thermocouple if output is outside the stated range. Reference may
be made to the British Gas Multimeter Instruction book
Does the pilot now stay alight ?
52
PILOT LIT BUT NO MAINS GAS
Is there a supply voltage at the input to the control box?
YES
Set any CH and HW controls to the 'Continuous'
position. Is there a supply voltage between CH and N,
also between HW and N? Expect 230 V +10% -6%
YES
Have you confirmed that the system controls
Is there a supply voltage between the gas control valve
terminals ? Expect 230 V +10% -6%
Does the main burner light ?
are 'Calling for Heat' ?
YES
YES
NO
Replace the gas
control valve
NO
NO
NO
NO
YES
NO
Clean the contacts and reconnect securely
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 plug or other supply point.
If no supply, check controls. Reference may be made
to the British Gas Multimeter Instruction Book
Check the settings of the room thermostat and cylinder
thermostat. Check the control system. Reference may
be made to the British Gas Multimeter Instruction Book
Check the boiler thermostat. Reference may be
made to the British Gas Multimeter Instruction Book.
Check the TTB downdraught thermostat. Is there
Does the pilot now stay alight ?
NO
Replace the overheat thermostat
Replace the gas control valve
downdraught in the flue ?
FAULT FINDING
Note. After any faults have been corrected, return all thermostatic and other controls to the previously noted settings
30
Mexico Super CF 3/100, 3/125, 3/140 - Installation
SHORT LIST OF PARTS
The following are parts commonly required as replacement
components, due to damage or expendability. Their failure or absence
is likely to affect safety or performance of this appliance.
The list is extracted from the British Gas List of Parts, which contains
all available spare parts.
The full list is held by British Gas, Caradon Plumbing Limited
distributors and merchants.
Key No. G.C. Part No. Description Qty. Product No.
14 319 494 Sightglass assembly, comprising: sightglass, frame, 1 079 334
2 sightglass gaskets, 2 M5 wing nuts
17 Main burner
378 372 RH AEROMATIC No. AC 19/123 284: CF 3/100 1 100 159
378 373 LH AEROMATIC No. AC 19/123 285: CF 3/100 1 100 160
378 375 RH AEROMATIC No. AC 19/123 287: CF 3/125 1 100 162
378 374 LH AEROMATIC No. AC 19/123 286: CF 3/125 1 100 161
378 376 RH AEROMATIC No. AC 19/123 288: CF 3/140 1 100 163
378 377 LH AEROMATIC No. AC 19/123 289: CF 3/140 1 100 164
When ordering spares please quote:
1. Boiler model
2. Appliance G.C. number
3. Description
4. Quantity
5. Product no.
18 Main burner injector
398 055 BRAY Cat. 10 - size 1400 CF 3/100 2 003 361
398 059 BRAY Cat. 10 - size 1700 CF 3/125 2 004 305
E01 553 BRAY Cat. 10 - size 2000 CF 3/140 2 112 934
19 382 945 Pilot burner
HONEYWELL Q 349 A 1067: 1 079 356
20 381 791 Pilot injector HONEYWELL 4500 4108 005,
double orifice (0.56/0.42) 1 004 545
21 E01-507 Gas valve assy. (V4600A1130 - 230V) 1 079756
23 395 705 Piezo unit - MORGAN / MATROC 60080-002 1 033 939
24 382 519 Ignition electrode - MORGAN / MATROC 1 003 777
25 HT lead - 750 mm long 1 057 599
26 Thermocouple
390 038 HONEYWELL Q 309 A 2754, 900mm lg. CF 3/125 &140 1 030 032
390 210 HONEYWELL Q 309 A 2747, 750mm lg. CF 3/100 1 003 876
31 Thermostat - RANCO K36 - P1354 1 151 903
32 308 557 Thermostat knob 1 111 904
45 E01 540 Flue baffle CF 3/100 2 134 737
E01 530 Flue baffle CF 3/140 5 135 770
49 TTB downdraught thermostat 1 075 372
Mexico Super CF 3/100, 3/125, 3/140 - Installation
31
53
SHORT PARTS
LIST OF PARTS
54
BOILER CONTROL PANEL - Exploded View
Legend
29. Controls panel complete assy.
30. Control box.
31. Boiler control thermostat.
32. Thermostat knob.
35. Controls panel.
36. Magnetic strip.
37. Controls front panel.
32
Mexico Super CF 3/100, 3/125, 3/140 - Installation
LIST OF PARTS
55
BURNER AND CONTROLS ASSEMBLY - Exploded View
Legend
13. Front plate.
14. Sightglass.
15. Burner
manifold.
16. Pilot pipe.
17. Burner.
18. Burner injector
- 2 off.
19. Pilot burner.
21. Gas valve.
22. 'O' ring.
23. Piezo unit.
24. Ignition
electrode.
25. Ignition lead.
26. Thermocouple.
27. Gas service cock.
56
BOILER CASING ASSEMBLY
Legend
28. Casing complete assembly.
29. Controls panel complete assembly.
40. Side panel.
41. Top panel.
42. Grille panel.
43. Front panel.
Mexico Super CF 3/100, 3/125, 3/140 - Installation
33
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.
The code of practice for the installation,
commissioning & servicing of central heating systems
CERTIFIED PRODUCT
Manufactured under a BS EN ISO 9001: 1994
Quality System accepted by BSI
Technical Training
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 413624
Caradon Plumbing Ltd, P.O. Box 103, National Ave, Kingston upon Hull, HU5 4JN. Telephone:
01482 492 251 Fax: 01482 448 858. Registration No. London 322 137. Registered Office: National
Avenue, Kingston upon Hull, HU5 4JN. A subsidiary of Caradon p.l.c
Caradon Plumbing Ltd. pursues a
policy of continuing improvement in
the design and performance of its
products. The right is therefore
reserved to vary specification without
notice.
September 1999 UIN 151 910 A03
Ideal Installer/Technical Helpline: 01482 498663
34
Mexico Super CF 3/100, 3/125, 3/140 - Installation
Your feedback
and your chance to win a free boiler
At Ideal we've been leaders in the design and engineering of robust and
reliable boilers for over 90 years. We want to continue as leaders by
listening to your suggestions for how to improve our boilers and our service.
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 code)
How I would improve this boiler:
My general comments for Ideal:
:
Ideal Installer/Technical Helpline: 01482 498663
Mexico Super CF 3/100, 3/125, 3/140 - Installation
35
Further information
If you would like information about Ideal Boilers please complete this
sheet and fax it to us on 01482 498699 or post it to Caradon Plumbing
Limited, PO Box 103, National Avenue, Kingston upon Hull, HU5 4JN.
Installer details
Name
Address
Post Code Telephone (Please include STD code)
General information required
Please send me details of Ideal Training Courses.
Please arrange for 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 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 combi. boiler
The Ideal Response SE super efficiency combi boiler
The Ideal Systemiser SE super efficiency system boiler
The Ideal Concord high output boiler
The Ideal Buccaneer oil fired boiler
Caradon Plumbing Ltd, PO Box 103, National Avenue, Kingston upon Hull, HU5 4JN. Telephone: 01482 492251 Fax: 01482 448858.
H
enrad Installer/Technical Helpline: 01482 498663
U.I.N. 151 910 A0
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