IDEAL Mexico RS 3/100 User Manual

5
Mexico Super RS 3/100 & 3/125 - Installation
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
) in accordance with the
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.
Health and Safety Document No. 635.
GENERAL
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. This appliance is NOT suitable for use in a direct
hot water system.
2. If the boiler is to be used on a sealed system, an
Overheat Thermostat Kit is available and must
be installed in accordance with the instructions
supplied with the kit.
Dimension A B
RS 3/100 299mm (11
3/4") 533 (21")
RS 3/125 373 mm (14
5/8") 600 (23 5/8")
1 BOILER WATER CONNECTIONS

IDEAL Mexico RS 3/100 Specifications

General

Brand	IDEAL
Model	Mexico RS 3/100
Category	Boiler
Language	English

Summary

Introduction to Mexico Super RS Boilers

Optional Extra Kits

Details of optional kits like Programmer, Pump, and Overheat Thermostat.

Gas Safety Regulations and Boiler Location

Location of Boiler Requirements

Requirements for boiler placement, including floor and environmental considerations.

Boiler Water Connections

Information on connecting the boiler to water systems and potential kits.

Floor Mounting and Boiler Clearances

Installation Location and Clearance Requirements

Guidelines for boiler placement in bathrooms, compartments, and required clearances.

Gas Supply and Flue Installation

Flue Installation Guidance

Guidance on installing the flue system and terminal positions.

Air Supply Requirements

Guidelines for ensuring adequate air supply for the boiler's operation.

Water Circulation System

General System Requirements

Guidelines for connecting the boiler to central heating and DHW systems.

Thermostatic Radiator Valves

System Control Recommendations

Advice on using thermostatic radiator valves and room thermostats for efficient heating.

Electrical Supply and Safety

Wiring and Safety Precautions

Requirements for earthing, mains supply, and isolation methods for the boiler.

Boiler Assembly - Exploded View

Component Identification

A list of numbered components shown in the exploded view of the boiler assembly.

Unpacking the Boiler

Pack 'A' Contents

Details of the main boiler assembly and included documentation.

Hardware Pack Contents

List of fittings and components found in the hardware pack.

Flue Pack Contents

Items included in the flue packs (B, B1, C) and extension pack (D).

Boiler Casing Removal

Step-by-Step Procedure

Instructions on how to safely remove the boiler casing panels for installation.

Preparing the Boiler for Installation

System Connection Preparation

Guidance on preparing boiler connections for pumped and gravity systems.

Preparing the Wall for Flue Installation

Wall Opening and Terminal Sealing

Instructions for cutting wall openings and sealing flue terminals.

Fitting the Flue Assembly

Standard Duct Lengths (up to 400 mm)

Instructions for installing the flue assembly with standard duct lengths.

Extension Ducts for Flue Assembly

Longer Duct Lengths (over 400 mm)

Guidance on fitting extension ducts for flue lengths exceeding 400 mm.

Gas and Water System Connections

Gas Connection Requirements

Specifications for gas pressure, supply pipes, and installation testing.

Water Connections and System Requirements

Guidance on water pipework, valve settings, and system requirements for pumped systems.

Electrical Connections and Wiring

Safety and Wiring Standards

Requirements for mains supply, earthing, and wiring standards for safe electrical connection.

Wiring Diagrams and Controls

Internal Wiring and Control Box Connections

Instructions for making internal electrical connections within the control box.

External Control Wiring and Pictorial Schematics

Guidance on wiring external controls and overview of pictorial wiring diagrams.

Wiring Configurations for System Controls

Mid Position and Spring Closed Valve Systems

Wiring diagrams for mid-position and two spring closed valve heating systems.

Honeywell 'C' Plan System Wiring

Wiring for gravity HW and pumped CH systems using Honeywell 'C' Plan.

Installation and Commissioning Procedures

Frost Protection and Casing Installation

Instructions for frost protection wiring and fitting the boiler casing.

Commissioning and Safety Checks

Procedures for ensuring electrical safety and gas soundness before operation.

Initial Boiler Lighting

Pilot Flame and Burner Operation

Step-by-step guide for lighting the pilot and main burners.

Pilot Burner Gas Soundness Testing

Testing Pilot Gas Connections

Procedure for checking gas soundness around the pilot burner connection.

General Operational Checks

System Controls and Flame Failure Test

Verifying programmer, thermostat, and flame failure device operation.

Handing Over to the Householder

User Instructions and System Explanation

Explaining boiler operation, controls, and maintenance to the customer.

Boiler Servicing Procedures

Recommended Maintenance Checks

Routine checks and servicing recommended for safe and efficient boiler operation.

Boiler Casing Removal for Servicing

Step-by-step guide to removing the boiler casing for servicing procedures.

Boiler Component Servicing

Burner and Controls Assembly Handling

Steps for removing, cleaning, and re-assembling the burner and controls.

Cleaning and Reassembly Steps

Guide for cleaning flueways and reassembling the boiler after servicing.

Boiler Maintenance and Component Replacement

Gas Pressure Adjustment and Safety

Procedures for adjusting gas pressure and general component replacement safety.

Sightglass and Piezo Unit Replacement

Instructions for replacing the sightglass and piezo unit.

Boiler Component Replacements

Pilot Burner and Ignition Lead Replacement

Steps for replacing the pilot burner, electrode, and ignition lead.

Control Thermostat Replacement

Procedure for replacing the boiler's control thermostat and phial.

Boiler Controls Panel and Thermostat Replacement

Control Box and Panel Installation

Steps for replacing the boiler's control panel and associated wiring.

Overheat Thermostat Replacement

Procedure for replacing the overheat thermostat and checking its operation.

Boiler Component Replacements

Ignition Electrode and Thermocouple Replacement

Instructions for replacing ignition electrode and thermocouple.

Main Burner Replacement

Procedure for replacing the main burner and its associated injector.

Boiler Component Replacements

Main Burner Injector Replacement

Steps for replacing main burner injectors with correct jointing compound.

Gas Valve Replacement

Procedure for replacing the gas valve, ensuring correct orientation and seals.

Fault Finding Procedures

Pilot Ignition and Flame Issues

Troubleshooting steps for pilot ignition and flame stability problems.

Main Burner Ignition Issues

Diagnostic steps when the pilot is lit but the main burner fails to ignite.

Burner and Controls Assembly - Exploded View

Component Identification for Assembly

A detailed exploded view and legend of the burner and controls assembly.

Boiler Control Panel - Exploded View

Control Panel Component Identification

Exploded view and legend of the boiler's control panel components.

Boiler Casing Assembly

Casing Component Identification

Exploded view and legend of the boiler casing assembly parts.