Ideal Boilers Mexico Super RS 3/40, Installation & Servicing Manual

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Page 2: ...line 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 s...

Page 3: ...ctions 2 3 3 3 3 Flow and Return Connections Rc 1 1 BSP MAXIMUM Static Water Head m ft 30 5 100 3 bar MINIMUM Static Water Head m ft 1 0 3 3 Electrical Supply 230 V 50 Hz External Fuse Rating Power Consumption 3 A 5 W Water Content litre gal 5 0 1 1 7 4 1 6 Dry Weight kg lb 68 150 90 198 Boiler Size Height mm in 850 33 5 Width mm in 440 17 4 Depth mm in 533 21 0 Gas Type Natural 2 H Gas Supply Pre...

Page 4: ...re included with this kit Pump Kit Fits neatly within the casing Separate fitting instructions are included with this kit Overheat Available to allow the boiler to be used Thermostat Kit on sealed water systems CONTENTS Air Supply 7 Boiler Assembly Exploded view 9 Boiler Clearances 6 Burner Assembly Exploded view 31 Electrical Connections 15 Electrical Diagram 16 Electrical Supply 8 Extension Duct...

Page 5: ...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 Ins...

Page 6: ...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 Additional space will be required for installation d...

Page 7: ...al on the wall 300 mm 12 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 Tower Flue Components Ltd Vale Rise Tonbridge Kent TN9 1TB Telephone No 01732 351 555 Ensure that the guard is fitted centrally 5 Where t...

Page 8: ...e mains must be situated outside the bathroom Dotted lines indicate flow rates equivalent to a temperature rise of 11 O C 20 O F 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...

Page 9: ... 1 Heat exchanger assy 2 Front section 3 Middle section 4 Section alignment rings and O rings 6 Thermostat pocket 7 Distributor tube 8 Combustion chamber 12 Collector hood 13 Cleanout cover 14 Front plate 22 Gas control valve 24 Piezo unit 28 Gas cock 34 Phial clip 35 Split pin 46 Air flue duct assy 47 Baseplate 49 Flue baffle 52 Heat shield ...

Page 10: ... 6 1 2 to 9 1 2 B 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 Table 6 This table shows the number of flue packs required for the given wall thicknesses PACK A CONTENTS z complete boiler assembly z the Hardware Pack listed separately below z these Installation and Servicing Instructions z User s Instructions HARDWARE PACK z 1 BS...

Page 11: ...s 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 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 the LH side panel to the flue collector and baseplate 10...

Page 12: ...s to the rear tappings and plug any unused tappings Note If using iron elbows fit a short straight connector into the boiler tapping first to clear the casing Connections as viewed at front Thermostat Position Back Section Front Section CH DHW Flow Return Flow Return Top LH LH RH RH LH LH RH RH LH LH RH RH LH LH RH RH LH LH RH RH Table 8 Gravity Domestic Hot Water and Pumped Central Heating 8 PREP...

Page 13: ...uct 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 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...

Page 14: ...t 5 Terminal grille A Air duct join B Flue duct join C Terminal air duct join D Terminal flue duct join 6 Extension air duct 7 Extension flue duct 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 bric...

Page 15: ...d 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 o C 20 o F across the boiler flow return at design input 5 This information is intended as a GUlDE ONLY and cannot take into account instantaneous changes ...

Page 16: ...thermostat MUST be wired into the mains lead in parallel with the control s to be overridden Refer to Frame 23 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 19 PICTORIA...

Page 17: ...f terminals on thermostats is specific to the manufacturer 3 This is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster Autozone has grey and orange auxiliary switch leads but the ORANGE NOT the grey wire must be connected to the incoming live supply Pumped only 22 HONEYWELL C PLAN Notes 1 Some earth wires are omitted for clarity Ensure proper earth continuity when wirin...

Page 18: ...inimal disturbance to other wiring of the programmer Designation of the terminals will vary but the programmer and thermostat manufacturer s leaflets will give full details 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 p...

Page 19: ...ved 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 1 Connect the ga...

Page 20: ...ned 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 b With the system still hot turn off the gas water and electricity supplies to t...

Page 21: ...een installed in a compartment check that the ventilation areas are clear The servicing procedures are covered more fully in Frames 31 to 36 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 ...

Page 22: ...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 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 45 e The therm...

Page 23: ...rogrammer units refer to the separate Pump Kit or Programmer Kit Instructions 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 39 PIEZO UNIT REPLACEMENT 1 Disconnect the ignition lead from the piezo unit body 2 Remove the retaining n...

Page 24: ...crew the thermostat nut to withdraw the thermostat 10 Fit the new thermostat and re assemble in reverse order 42 IGNITION LEAD REPLACEMENT 1 Lift off front panel and remove the grille assembly refer to Frames 31 32 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 2 Remove the purse clip 3 Undo the 2 securing nuts and washers Remo...

Page 25: ...mble new control box and panel and fit to the casing reverse order 10 Insert control thermostat phial into pocket and secure with the split pin 11 Connect gas valve electrical leads 12 Remove control box cover and make electrical supply connections to the terminal strip Refer to frame 17 13 Replace front lower panel 1 Lift off front lower panel Refer to Frame 31 2 Slacken the screw at the thermost...

Page 26: ...w electrode until the retaining clip locates in the groove and re assemble in reverse order 1 Lift off front panel and remove the grille assembly refer to Frames 31 32 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 2 Remove the ignition electrode 3 Remove the purse clip 4 Undo the thermocouple nut at the pilot burner and pull t...

Page 27: ... MAIN BURNER INJECTOR REPLACEMENT 1 Lift off front panel and remove the grille assembly Refer to Frames 31 32 Undo the gas cock union Remove the 4 wing nuts and withdraw the burner and controls assembly complete from the boiler 2 Undo the pilot supply connection 3 Undo the thermocouple connection 4 Unscrew the gas inlet pipe from the valve 5 Remove the 4 securing screws and withdraw the valve from...

Page 28: ...ot jet is not blocked Does the pilot light when a match is applied Check that there is no blockage in the pilot line or pilot injector NO NO Replace the gas control valve 52 PILOT LIT BUT NO MAINS GAS If no supply check the controls Reference may be made to the British Gas Multimeter Instruction Book NO Check the supply voltage e g by using a multimeter set on the 300V AC range between the L and N...

Page 29: ...njector HONEYWELL 4500 4108 001 double orifice 0 38 0 36 1 003 825 22 E01 507 Gas valve assembly V4600A1130 230V 1 079756 24 395 705 Piezo unit MORGAN MATROC 60080 002 1 003 939 25 397 945 Ignition electrode BUCCLEUCH with HT lead 1 004 713 26 E01 412 HT lead 460 mm 1 052 888 27 390 210 Thermocouple HONEYWELL Q 309 A 2747 750mm lg 1 003 876 32 Thermostat RANCO K36 P1354 1 151 903 33 308 557 Thermo...

Page 30: ...30 Mexico Super RS 3 40 3 80 Installation LIST OF PARTS 53 SHORT PARTS ...

Page 31: ...loded View Legend 14 Front plate assy 15 Sightglass assy 16 Burner manifold 17 Pilot pipe 18 Main burner 19 Main injector 20 Pilot burner 22 Gas valve 23 O ring 24 Piezo unit spark generator 25 Ignition electrode 26 Ignition lead 27 Thermocouple 28 Gas cock 50 Sealing gasket 51 Sealing plate ...

Page 32: ... Installation LIST OF PARTS Legend 30 Control panel complete assy 31 Control box 32 Control thermostat 33 Control thermostat knob 36 Control panel 37 Magnetic strip 38 Control front panel door 55 BOILER CONTROL PANEL Exploded View ...

Page 33: ...exico Super RS 3 40 3 80 Installation Legend 29 Casing complete 30 Controls panel complete 41 Side panel 42 Top panel 43 Grille assy 44 Lower front panel 47 Baseplate LIST OF PARTS 56 BOILER CASING ASSEMBLY ...

Page 34: ...red Office National Avenue Kingston upon Hull HU5 4JN A subsidiary of Caradon p l c The Caradon Plumbing Ltd 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 These appliances are designed for use with Natural Gas only They have been test...

Page 35: ... for how to improve our boilers and our service We will be giving away a free boiler for the five best ideas every year to be selected by our Technical Director Please complete this form using extra sheets if required and post it or fax it to us on 01482 498699 Boiler details Model Size e g Classic RS 230 Mexico CF 3 60 etc Details on control panel door Date of Installation Installer details Name ...

Page 36: ...rses 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 S...