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.
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.
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 of
Mexico Super RS 3/100 & 3/125 - Installation
GENERAL
Table 1 - General Data
Boiler SizeRS 3/100RS 3/125
Gas Supply Connectionin. BSPRc 1/2 (1/2)
Number of Boiler Sections45
Flow and Return ConnectionsRc 1 (1" BSP)
MAXIMUM Static Water Headm (ft.)30.5 (100)(3 bar)
MINIMUM Static Water Headm (ft.)1.0 (3.3)
Electrical Supply230 V ~ 50 Hz
External Fuse Rating(Power Consumption)3 A (5 W)
Water Contentlitre (gal.)9.8 (2.1)12.2 (2.7)
Dry Weightkg. (lb.)113 (249)136 (300)
Boiler SizeHeightmm (in.)850 (33.5)
Widthmm (in.)440. (17.4)
Depthmm (in.)533 (21.0)600 (23.6)
Gas TypeNatural 2 H
Gas Supply Pressure20 mb
Table 2 - Performance Data
Boiler SizeRS 3/100RS 3/125
Boiler Input
MINIMUMkW (Btu/h)29.8 ( 101 800)37.5 (128 000)
Gas Consumptionl/s (ft.
3
/h)0.77 (98)0.97 (123)
MIDkW (Btu/h)33.4 (113 900)41.7 (142 400)
3
Gas Consumptionl/s (ft.
/h)0.86 (110)1.08 (137)
MAXIMUMkW (Btu/h)36.9 (125 800)45.1 (153 800)
3
Gas Consumptionl/s (ft.
/h)0.95 (121)1.17 (148)
Boiler Output to Water
MINIMUMkW (Btu/h)23.4 (80 000)29.3 (100 000)
MIDkW (Btu/h)26.4 (90 000)33.0 (112 5000)
MAXIMUMkW (Btu/h)29.3 (100 000)35.8 (122 000)
Burner Setting Pressure (hot)
MINIMUMmbar (in w.g.)8.6 (3.4)10.8 (4.3)
MIDmbar (in w.g.)11.0 (4.4)13.0 (5.2)
MAXIMUMmbar (in w.g.)13.4 (5.4)15.0 (6.0)
Flue Gas Flow Rateg/s17.321.2
o
Flue Gas Temperature
C167163
Seasonal Efficiency (SEDBUK)*%72.372.6
*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 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)
c. The appliance is preset at the factory to the highest
nominal rating.
Mexico Super RS 3/100 & 3/125 - Installation
Key to symbols
GB = United KingdomIE = Ireland
(Countries of destination)
PMS = Maximum operating pressure of water
= A room sealed appliance designed for connection via
C
11
ducts to a horizontal terminal, which admits fresh air to
the burner and discharges the products of combustion
to the outside without a fan in the combustion products
circuit.
I
= An appliance designed for use on 2nd Family gas,
2H
Group H only.
3
GENERAL
CONTENTS
Air Supply. ..................................................................... 7
Gas Safety Regulations ................................................ 5
Mexico Super RS
Mexico Super RS 3/100G.C. No 41 349 32
Mexico Super RS 3/125G.C. No 41 349 33
Natural Gas onlyAppliance type: C
Certified - P.I. No. 87 AT 14
Destination Countries: GB & IE.
INTRODUCTION
Mexico Super RS above range is of floor standing,
natural draught, balanced flue gas boilers. They are
range-rated to provide central heating outputs of 23.4 kW
(80,000 Btu/h) to 35.8 kW (122,000 Btu/h).
The boiler has a cast iron heat exchanger and is supplied
fully assembled, complete with a white enamelled mild
steel casing.
11
Gas Supply .................................................................... 7
Water Connections ....................................................... 5
Water Circulation .......................................................... 8
Water Systems ............................................................ 14
A door at the top of the casing front panel hinges down,
revealing the boiler thermostat control (and programmer,
if fitted).
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
Programmer KitFits neatly within the casing. Separate
fitting instructions are included with this kit.
Pump KitFits neatly within the casing. Separate
fitting instructions are included with this kit.
Overheatis available to allow the boiler to be used
Thermostat Kiton 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 RS 3/100 & 3/125 - 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. 6891Low pressure installation pipes.
BS. 6798Installation of gas fired hot water boilers of rated
input not exceeding 60 kW.
BS. 5449:1Forced circulation hot water systems (small bore
and microbore domestic central heating systems).
BS. 5546Installation of gas hot water supplies for domestic
purposes (2nd Family Gases).
BS. 5440: 1Flues for gas appliances of rated input not
exceeding 60 kW.
BS. 5440: 2Ventilation for gas appliances of rated input not
exceeding 60 kW.
BS 7593Treatment of water in Domestic Hot Water Central
Heating Systems.
Health and Safety Document No. 635.
) in accordance with the
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 theInstitute of Gas Engineering
document IGE/UP/7:1998.
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.
DimensionAB
RS 3/100299mm (11
RS 3/125373 mm (14
3/4")533 (21")
5/8")600 (23 5/8")
Mexico Super RS 3/100 & 3/125 - Installation
5
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.
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:-
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:
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.
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.
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 10.
In addition a MINIMUM clearance of 533 mm (21") MUST be
available at the front of the boiler, for servicing.
Boiler SizeWidthDepthHeight
RS 3/100mm (in.)460 (18)533 (21)870 (34 1/4)
RS 3/125mm (in.) 550 (21
1/2) 600 (23 5/8) 870 (34 1/4)
Terminal sizes
Boiler SizeDepthHeightWidth
RS 3/100 & RS 3/125182431372
DimensionA
RS 3/10010 mm (
RS 3/12555 mm (2
6
Mexico Super RS 3/100 & 3/125 - Installation
3/8")
1/4")
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.
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.
Table 3 - Balanced flue terminal position
Terminal Position
1. Directly below an opening window,
air vent or other ventilation opening300 mm (12")
2. Below guttering, drain pipes or soil
pipes300 mm (12")
3. Below eaves300 mm (12")
4. Below balconies or a car port roof600 mm (24")
5. From vertical drain pipes or soil pipes75 mm ( 3")
6. From internal or external corners600 mm (24")
7. Above adjacent ground, roof or
balcony level300 mm (12")
8. From a surface facing the terminal600 mm (24")
9. From a terminal facing a terminal600 mm (24")
10. From an opening in a car port
(e.g. door or window) into dwelling1200 mm (48")
11. Vertically from a terminal on the
same wall1500 mm (60")
12. Horizontally from a terminal on the wall300 mm (12")
Minimum Spacing
4. Where the lowest part of the terminal is fitted less than 2m
(6' 6") above a balcony, above ground or above a flat roof to
which people have access then the terminal MUST be
protected by a purpose designed guard.
Terminals guards are available from boiler suppliers. In case
of difficulty seek advice from:
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.
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
The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frame 8.
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
BoilerAir from room/internalAir direct from
space cm
High level Low level High level Low level
RS 3/100354 (55)354 (55)177 (28)177 (28)
RS 3/125438 (68)438 (68)219 (34)219 (34)
2
(in.2)outside cm2 (in.2)
Mexico Super RS 3/100 & 3/125 - Installation
7
GENERAL
WATER CIRCULATION SYSTEM
The boiler must NOT be used for direct hot water supply. 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 resistance of the boilers at maximum output with 11
o
oC (20
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.
F) temperature differentials are shown in the graph
1/2" BSP
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.
For bathroom installations the point of connection to the mains
must be situated outside the bathroom.
1/8") contact separation in both poles, or a plug
Water Flow Rate and Pressure Loss
Dotted lines indicate
flow rates equivalent to
a temperature rise of
11 oC (20 oF)
8
Mexico Super RS 3/100 & 3/125 - Installation
INSTALLATION
3
BOILER ASSEMBLY - Exploded View
Mexico Super RS with casing removed - RS 3/100 shown.
INSTALLATION
LEGEND
1. Heat exchanger assy.
2. Front section.
3. Middle section.
4. Section alignment rings & 'O' rings
6. Thermostat pocket.
7. Distributor tube.
8. Combustion chamber.
12. Collector hood.
Mexico Super RS 3/100 & 3/125 - Installation
13. Cleanout cover.
14. Front plate.
22. Gas control valve.
24. Piezo unit.
28. Gas cock.
34. Phial clip.
35. Split pin.
46. Air/flue duct assy.
47. Baseplate.
52. Heat shield.
9
4
UNPACKING
The boiler is supplied fully assembled in Pack
A, together with either one or two of four
packs: B, B1, C or D. Packs B, B1 or C
contain the flue terminal appropriate to the wall
thickness. Pack D contains the flue terminal
extensions.
Unpack and check the contents.
INSTALLATION
complete
boiler
assembly
PACK 'A' CONTENTS
z complete boiler assembly
INSTALLATION
z the Hardware Pack (listed separately)
z these Installation and Servicing Instructions
z User's Instructions.
FLUE PACK
Packs B, B1 and C contents
z Flue terminal assembly
z Sachet of sealing mastic - 2 off
Pack D contents
HARDWARE PACK
z 1" BSP plugs - 6 off
z 1" x
z Distributor tube
z Thermostat pocket -1 off
z Thermostat clip - 1 off
z Thermostat retaining pin - 1 off
z Output setting label -1 off
1/2" BSP reducing
bush - 1 off
z Flue terminal extension
z sachet of sealing mastic - 2 off
z Adhesive tape
Table 6: this table shows the number of flue packs required for the given wall thicknesses
Wall thicknessFlue
Dimension (duct length) X shown abovepack(s)
Boiler fitted flush with wallBoiler fitted in line with 600 mm kitchen unitsrequired
RS 3/100114 to 191 mm(4
229 to 305 mm(9" to 12")163 to 242 mm(6
318 to 394 mm(12 1/2" to 15 1/2")253 to 332 mm(10" to 13")B1
406 to 584 mm(16" to 23")340 to 518 mm(13 1/2" to 20 1/2")B & D
RS 3/125114 to 191mm (4 1/2" to 7 1/2")C
1/2" to 7 1/2")up to 125 mm(up to 5")C
1/2" to 9 1/2")B
229 to 305 mm (9" to 12")B
318 to 394 mm (12
1/2" to 15 1/2")B1
10
Mexico Super RS 3/100 & 3/125 - 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 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
Mexico Super RS 3/100 & 3/125 - 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 7 and 8 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.
11
INSTALLATION
6
PREPARING THE BOILER
Table 7 - Fully Pumped Systems
Connections - as viewed at frontThermostat Position
Back SectionFront Section
FlowReturnTop
LHLHLH
LHRHLH
RHRHRH
RHLHRH
INSTALLATION
Table 8 - Gravity Domestic Hot Water
and Pumped Central Heating
Connections - as viewed at frontThermostat Position
Back SectionFront Section
CHDHW
Flow ReturnFlowReturnTop
LHLHRHRHLH
LHRHRHLHLH
RHRHLHLHRH
RHLHLHRHRH
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 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.
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.
7
PREPARING THE WALL
1. Cut the appropriate hole in the wall for insertion of the
terminal assembly.
Notes.
a. Make good the hole on the INSIDE of the building to
the given dimensions BEFORE fitting the boiler, to facilitate
sealing between the terminal and the wall when the boiler is
in position.
b. The terminal MUST NOT come into contact with a
combustible material such as that used in non-standard
construction of timber frame and plasterboard etc.
2. Place the boiler in the
selected position.
Note. If an extension duct
D is to be fitted, this must
be done BEFORE the
boiler is placed in position.
Refer to Frame 9.
3. Make good the brickwork
around the air duct.
BoilerDimension A
RS 3/100533 mm (21")
RS 3/125600 mm (23
5/8")
12
Mexico Super RS 3/100 & 3/125 - Installation
INSTALLATION
8
FITTING THE FLUE ASSEMBLY - Duct lengths up to 400 mm (16")
A. Air duct join
B. Flue duct join
Legend
1.Boiler air duct.
2.Boiler flue duct.
3.Terminal air duct.
4.Terminal flue duct.
1. Remove the 2 screws and separate the terminal grille,
terminal air duct and terminal flue duct.
2. From OUTSIDE of the building, pass the terminal air duct
through the wall opening and slide it into the extension air
duct, locating it as shown.
3. Push the duct fully in until the fixing brackets contact the
wall face.
4. Ensure that the duct is level and make good between the
wall and the duct from OUTSIDE of the building.
5. From OUTSIDE the building, seal the duct join (A) with the
mastic provided.
9
EXTENSION DUCTS - Duct lengths greater than 400 mm (16")
5.Terminal grille assembly.
6.Terminal grille.
7.Securing screws - 2 off.
8.Splitter plate.
6. From OUTSIDE the building, pass the terminal flue duct
through the wall opening and
slide it into the boiler flue duct
pushing the flue duct fully in,
up to the locating stops.
Locate it as shown .
7. From OUTSIDE of the
building, seal the duct join (B)
with the mastic provided.
8. Fasten the terminal grille to
the duct assembly.
Extension ducts shown fitted
Flue terminal
shown in position
INSTALLATION
Typical minimum
overlap - 50mm (2")
Legend
1. Boiler air duct
2. Boiler flue duct
3. Terminal air duct
4. Terminal flue duct
5. Terminal grille
6. Extension air duct
7. Extension flue
duct
A. Air duct join
B. Flue duct join
C. Terminal air
duct join
D. Terminal flue
duct join
1. BEFORE PLACING THE BOILER IN POSITION, loosely fit
the extension air duct and terminal assembly to the boiler
air duct and adjust to the required overall duct length.
Note.
Ensure that any of the duct overlaps are not less than
50 mm (2").
2. Secure the extension air duct in position, using the
adhesive tape provided, at join (A). Ensure that a good seal
is made, particularly at the 2 bottom corners
where the boiler duct is flanged .
3. Remove the terminal assembly.
4. Place the boiler in position, entering the extension
duct into the wall opening.
5. Make good the brickwork around the air duct
inside.
6. Separate the terminal grille, terminal air duct and
terminal flue duct. Refer to Frame 8.
7. From OUTSIDE of the building, pass the terminal
air duct through the wall opening and slide it into
the extension air duct, locating it as shown.
8. Push the duct fully in until the fixing brackets
contact the wall face.
9. Ensure that the duct is level and make good
between the wall and the duct from OUTSIDE of
the building.
10. From OUTSIDE of the building, seal the duct join
(C) with the mastic provided
11. From OUTSIDE of the building, slide the
extension flue duct into the boiler flue duct to the
same distance as the extension air duct. Seal the
duct join (D) with the mastic provided
12. Go to Frame 8 note 6.
Mexico Super RS 3/100 & 3/125 - Installation
13
GAS CONNECTION
10
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 NOT LESS
THAN 15mm (
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 24.
1/2") OD to the boiler and
INSTALLATION
BoilerDimension A
RS 3/100473(8 5/8")
RS 3/125546(21 1/2")
11
WATER CONNECTIONS
INSTALLATLON
1. Connect the system flow and return pipework to the boiler
as appropriate. Refer to Frames 12 and 13 for guidance on
system design.
Note. When the required output exceeds 14.4 kW (49 000
Btu/h) then 28mm (1") pumped flow and return pipes
should be used, both to and from the boiler.
Gravity connections MUST be at least 28mm (1").
12
MINIMUM REQUIREMENTSFully 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 6.
2. The boiler is assumed to be the highest point of the
circulating system.
3. The circulating pump is positioned on the FLOW
and the vertical distance, between the pump and
feed/ 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.
2. Ensure that all valves are open. Fill and vent the system
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.
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
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.
Due allowance MUST be made if surging is liable to
occur.
If in any doubt, contact Caradon Plumbing Ltd.
o
C (20 oF) across the boiler flow /
14
Mexico Super RS 3/100 & 3/125 - Installation
INSTALLATION
13
GRAVITY HOT WATER & PUMPED CENTRAL HEATING
1. Separate flow and return connections are used for each
service. All possible configurations are given in Frame 6
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")
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
14
ELECTRICAL CONNECTIONS
WARNING.
The appliance MUST be efficiently earthed.
A mains supply of 230 V ~ 50 Hz is required.
The fuse rating should be 3A.
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
2
(24 x 0.2 mm) to BS.6500, Table 16.
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 pumped
primaries should be used.
Wiring external to the boiler MUST be in accordance with
current l.E.E. (BS7671) Wiring Regulations and local
regulations.
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.
This connection should be readily accessible and be made
adjacent to the boiler (except in the case of bathroom
installations for domestic boilers where the point of
connection to the mains MUST be outside of the bathroom).
Mexico Super RS 3/100 & 3/125 - Installation
15
INSTALLATION
15
INTERNAL WIRING
Flow and pictorial wiring diagrams are shown in Frames 16 and 17.
A schematic wiring diagram is included in the Lighting Instruction
label.
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.
Notes.
a. Secure each lead with one of the cable
clamps.
INSTALLATION
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.
16
EXTERNAL CONTROLS
17
PICTORIAL WIRING
External wiring must be in accordance with the current I.E.E.
(BS 7671) Wiring Regulations.
The wiring diagrams illustrated in Frames 18-20 cover the
systems most likely to be fitted to this appliance.
For wiring external controls to the Mexico Super 3 RS boiler
reference should be made to the system wiring diagrams
supplied by the relevant manufacturer, in conjunction with the
flow wiring diagram below and also Frame 15.
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 21.
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.
16
LEGEND
b bluebr browny/g yellow/green
Mexico Super RS 3/100 & 3/125 - Installation
INSTALLATION
18
MID POSITION VALVE
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 indicated.
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
rred
or orange
Pumped only
wwhite
gy grey
y/g yellow/green
INSTALLATION
19
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 GREY (NOT the orange) wire must be connected to
the incoming live supply.
LEGEND
b blue
bk black
20
HONEYWELL 'C' PLAN
br brown
rred
w white
or orange
y/g yellow/green
gy grey
Gravity HW & Pumped CH
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.
LEGEND
w white
rred
bk black
br brown
or orange
b blue
gy grey
y/g yellow/green
Mexico Super RS 3/100 & 3/125 - Installation
17
INSTALLATION
21
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.
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.
INSTALLATION
Designation of the terminals will vary, but the programmer and
thermostat manufacturer's leaflets will give full details.
Diagram A shows a double pole frost thermostat, which
should suffice for all systems which do not use the OFF
terminals of the programmer.
22
FITTING THE CASING
1. Offer up the RH 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 LH side panel.
4. Place the top panel and push back.
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.
6. Replace the control box cover and refit the control panel
using the screws previously removed.
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.
23
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.
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.
18
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.
Mexico Super RS 3/100 & 3/125 - Installation
INITIAL LIGHTING
24
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 unit ignition
H Boiler thermostat knob
J Overheat thermostat reset
button (optional)
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.
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 rangerated 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. Turn the boiler thermostat knob (H) to OFF.
13. Remove the pressure gauge and tube. Retighten the
screw in the pressure test point, ensuring that a gas-tight
seal is made.
INSTALLATION
25
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 24.
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 RS 3/100 & 3/125 - Installation
Burner and controls assembly
19
26
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
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
INSTALLATION
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 and the burner should
light.
d. Turn the gas control knob to the OFF position - refer to
Frame 24. 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.
zz
z If an optional programmer kit is fitted refer to the
zz
separate Programmer Kit Installation Instructions and
Programmer Kit User's Instructions.
zz
z The temperatures quoted below are approximate and
zz
vary between installations.
ThermostatFlow Temperature
Knob Setting
260140
366150
471160
577170
682180
o
C
o
F
27
HANDING OVER
After completing the installation and commissioning of the 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.
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 RS 3/100 & 3/125 - Installation
SERVICING
28
SCHEDULE
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 burner.
e. Check the condition of the thermocouple.
f. Check that the flue terminal is unobstructed and that the
flue system, including the flue cleanout cover, is sealed
correctly.
g. 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 29
to 34 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.
c. Clean the heat exchanger.
d. Clean the main injectors.
29
BOILER CASING 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.
4. Release the gas valve lead from the retaining clip.
5. Remove the thermostat phial from the pocket as shown.
IMPORTANT. After completing the servicing or exchange of
components always test for gas soundness and carry out
functional checks as appropriate.
SERVICING
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.
Mexico Super RS 3/100 & 3/125 - Installation
21
SERVICING
30
BURNER AND CONTROLS ASSEMBLY REMOVAL
1. Lift off front panel and remove the grille
assembly. Refer to
Frame 29.
Undo the gas cock
union.
2. Remove the 4 wing nuts
and withdraw the burner
and controls assembly,
complete, from the
boiler.
3. Place on a convenient
working surface.
31
CLEANING THE BURNER ASSEMBLY
1. Brush off any deposits that may have fallen onto the
burner head (ensuring that the flame ports are
unobstructed) and remove any debris that may have
collected.
Note. Brushes with metallic bristles MUST NOT be used.
2. Remove the main burner injector .Check, clean or
replace, as required.
3. Refit the injector, using an approved jointing compound.
4. Inspect the pilot burner, thermocouple and ignition
electrode; ensure they are clear and in good condition.
SERVICING
32
CLEANING THE FLUEWAYS
1. Remove the 2 wing nuts and lift off the cleanout
cover.
2. 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.
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 41.
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 41.
g. The thermocouple terminal at the gas valve is clean.
5. Clean or renew components as necessary.
3. Check that the flue outlet duct is unobstructed.
33
RE-ASSEMBLY
Re-assemble the boiler in the following order :
1. Refit the flue cleanout cover, renewing any damaged or
deteriorating sealing gasket.
2. Refit the casing top panel.
3. Reconnect the electrical wiring and refit the controls
panel, ensuring that the thermostat phial and phial
22
retaining clip are correctly located in the thermostat pocket
and secured by the split pin. Refer to Frame 29.
4. Check the sightglass in the front plate - clean or renew as
necessary.
5. Renew any damaged or deteriorating front plate gasket.
6. Refit the burner and controls assembly.
7. Reconnect the gas service cock.
8. Refit the grille assembly.
Mexico Super RS 3/100 & 3/125 - Installation
34
GAS PRESSURE ADJUSTMENT
1. Pilot Pressure
Pilot adjustment is factory set to maximum and no
adjustment is possible.
2. Main Burner Pressure
After servicing, reference should be made to Table 1,
REPLACEMENT OF PARTS
35
GENERAL
SERVICING
which quotes details of the rated output with the related
burner pressure and heat input. Any required
adjustments should be made using the pressure
adjustment screw. Refer to Frame 24, 'Initial Lighting.
Refit the lower front panel
When replacing any component:
1. Isolate the electricity supply.
2. Turn off the gas supply at the boiler.
36
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.
3. Remove the lower front panel grille assembly.
For replacement of pumps or programmer units refer to
the separate Pump Kit or Programmer Kit Instructions.
SERVICING
37
PIEZO UNIT REPLACEMENT
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.
Mexico Super RS 3/100 & 3/125 - Installation
23
SERVICING
38
PILOT BURNER REPLACEMENT
1. Lift off front panel and remove the grille assembly - refer to Frames 29 & 30.
Undo the gas cock union and the 4 wing nuts to remove the burner / controls
assembly.
2. Prise the retaining clip out of the groove in the electrode, using a small
screwdriver, and withdraw the electrode.
3. Unscrew the thermocouple nut and pull the thermocouple clear..
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 43.
39
CONTROL THERMOSTAT REPLACEMENT
1. Lift off the front door - Refer to Frame
29.
2. Pull off the thermostat knob.
3. Remove the 2 screws and pull down
the control panel tabs clear of the top
panel.
4. Remove the thermostat phial from the
pocket - refer to Frame 29.
5. Remove the bottom screw and remove
the cover.
6. Remove the top screw and ease the
control box off the control panel.
SERVICING
7. Remove the 2 screws to release the
thermostat bracket.
8. Disconnect the electrical leads.
9. Unscrew the thermostat nut to
withdraw the thermostat.
10. Fit the new thermostat and reassemble in reverse order.
40
IGNITION LEAD REPLACEMENT
1. Lift off front panel and remove the grille assembly -
refer to Frames 29 & 30.
Undo the gas cock union and the 4 wing nuts to
remove the burner / controls assembly.
2. Remove the purse clip.
3. Undo the 2 securing nuts and washers. Remove
the sealing plate and gasket.
4. Disconnect the ignition lead from the base of the
electrode and the piezo unit, and withdraw the
lead.
5. Fit the new lead and re-assemble in reverse order.
24
Mexico Super RS 3/100 & 3/125 - Installation
41
CONTROLS PANEL REPLACEMENT
1. Lift off the lower front panel. Refer Frame 29
2. Pull off the thermostat knob.
3. Disconnect the electrical connections
from the gas valve.
4. Unscrew the 2 screws and pull down the
control panel so that the 2 tabs clear the
top panel.
5. Remove the thermostat phial from the
pocket. Refer to Frame 29.
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. Assemble new control box and panel
and fit to the casing reverse order.
SERVICING
10. Insert control thermostat phial into
pocket and secure with the split pin.
11. Connect gas valve electrical leads.
12. Remove control box cover and make
electrical supply connections to the
terminal strip. Refer to frame 17.
13. Replace front lower panel.
42
OVERHEAT THERMOSTAT REPLACEMENT (if fitted)
1. Lift off front lower panel. Refer to Frame 29.
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.
SERVICING
Mexico Super RS 3/100 & 3/125 - Installation
25
SERVICING
43
IGNITION ELECTRODE REPLACEMENT
1. Lift off front panel and remove the grille assembly - refer to Frames 29 &
30. Undo the gas cock union and the 4 wing nuts to remove the burner /
controls assembly.
2. Disconnect the ignition
lead.
3. Prise the retaining clip out
of the groove in the
electrode, using a small
screwdriver, and withdraw
the electrode.
4. Push in the new electrode
until the retaining clip
locates in the groove and
re-assemble in reverse
order.
Detail of pilot flame length and spark gap
44
THERMOCOUPLE REPLACEMENT
1. Lift off front panel and remove the grille assembly - refer to Frames 29 & 30.
Undo the gas cock union and the 4 wing nuts to remove the burner / controls
assembly.
2. Prise the retaining clip out of the groove in the electrode, using a small
screwdriver, and withdraw the electrode.
3. Remove the purse clip.
4. Undo the thermocouple nut at the pilot burner and pull the thermocouple clear.
5. Undo the thermocouple connection at the gas valve.
6. Remove the sealing plate and gasket (refer to Frame 40) and withdraw the
thermocouple.
7. Fit the new thermocouple and re-assemble in reverse order
SERVICING
Note. Avoid sharp bends in the thermocouple lead and ensure that it follows the
same route as previously.
45
MAIN BURNER REPLACEMENT
1. Lift off front panel and remove the grille
assembly - refer to Frames 29 & 30.
Undo the gas cock union and the 4
wing nuts to remove the burner /
controls assembly.
2. Remove the 2 screws securing the
pilot burner and pull the assembly
clear of the main burner. Refer
Frame 44.
3. Remove the nut that secures the
bottom baffle to the burner.
4. Remove the 2 nuts and washers
securing the burner to the front
plate and manifold. Withdraw the
burner.
5. Fit the new burner and re-assemble
in reverse order, taking care not to
damage the main burner injector
which is screwed into the burner
manifold.
26
Mexico Super RS 3/100 & 3/125 - Installation
47
MAIN BURNER INJECTOR REPLACEMENT
1. Lift off front panel and remove the grille
assembly - refer to Frames 29 & 30.
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 reassemble in reverse order.
SERVICING
48
GAS VALVE REPLACEMENT
1. Lift off front panel and remove the grille assembly.
Refer to Frames 29 & 30.
Undo the gas cock union and the 4 wing nuts to
remove the burner / 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
Mexico Super RS 3/100 & 3/125 - Installation
27
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.
49
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
Replace the
gas control
valve
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
NO
YES
NO
NO
burner is 3-4 mm. Refer to Frame 43.
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
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
present.
Faulty piezo
unit - replace
NO
50
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 ?
51
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%
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 the controls. Reference may be made
to the British Gas Multimeter Instruction Book.
Does the pilot now stay alight ?
NO
Replace the overheat thermostat
Replace the gas control valve
YES
Have you confirmed that the system controls
Is there a supply voltage between the gas control valve
terminals ? Expect 230 V +10% -6%
FAULT FINDING
Note. After any faults have been corrected, return all thermostatic and other controls to the previously noted settings
are 'Calling for Heat' ?
YES
YES
Does the main burner light ?
28
NO
NO
NO
Check the settings of the room thermostat and the
cylinder thermostat. Check the control system.
Reference may be made to the British Gas Multimeter
Instruction Book.
Check the boiler thermostat. Reference may be made
to the British Gas Multimeter Instruction Book.
Replace the gas control valve
Mexico Super RS 3/100 & 3/125 - 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
390 210HONEYWELL Q 309 A 2747, 750mm lg.RS 3/1001003 876
390 038HONEYWELL Q 309 A 2788, 900mm lg.RS 3/1251030 032
32Thermostat - RANCO K36 - P13541151 903
33308 557Thermostat knob1111 904
Mexico Super RS 3/100 & 3/125 - Installation
29
52
SHORT PARTS
LIST OF PARTS
53
BURNER AND CONTROLS ASSEMBLY - Exploded View
Legend.
14. Front plate assy.
15. Sightglass assy.
16. Burner manifold.
17. Pilot pipe.
18. Main burner.
19. Main injector.
20. Pilot burner.
22. Gas valve.
23. 'O' ring.
24. Piezo unit spark generator.
25. Ignition electrode.
26. Ignition lead.
27. Thermocouple.
28. Gas cock.
50. Sealing plate gasket.
51. Sealing plate.
30
Mexico Super RS 3/100 & 3/125 - Installation
LIST OF PARTS
54
BOILER CONTROL PANEL - Exploded View
Legend.
30. Control panel complete.
31. Control box.
32. Control thermostat.
33. Control thermostat knob.
36. Control panel.
37. Magnetic strip.
38. Control front panel (door)
55
BOILER CASING ASSEMBLY
Legend.
29. Casing complete.
30. Controls panel complete.
41. Side panel.
42. Top panel.
43. Grille assy.
44. Lower front panel.
47. Baseplate.
Mexico Super RS 3/100 & 3/125 - Installation
31
32
Mexico Super RS 3/100 & 3/125 - Installation
Mexico Super RS 3/100 & 3/125 - Installation
33
THIS SYMBOL IS YOUR
ASSURANCE OF QUALITY
The code of practice for the installation,
commissioning & servicing of central heating systems
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.
Caradon Plumbing Limited, 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
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
Ideal Installer/Technical Helpline: 01482 498663
34
Caradon Plumbing Limited
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 151 908 A03
Mexico Super RS 3/100 & 3/125 - 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 will be giving away a free boiler for the five best ideas every year (to
be selected by our Technical Director). Please complete this form, using
extra sheets if required, and post it or fax it to us on 01482 498699.
Boiler details
Model / Size(e.g. Classic RS 230, Mexico CF 3/60 etc. Details on control panel door)
Date of Installation
Installer details
Name
Address
Post CodeTelephone (Please include STD code)
How I would improve this boiler:
My general comments for Ideal:
:
Ideal Installer/Technical Helpline: 01482 498663
Mexico Super RS 3/100 & 3/125 - 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 CodeTelephone (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.
Ideal Installer/Technical Helpline: 01482 498663
U.I.N. 151908 A0
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