Ideal Boilers Mexico Super RS 3/40 User guide

2Mexico Super RS 3/40 - 3/80 - Installation
CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning of
this appliance, care should be taken when handling edges of sheet steel components.
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.

3
Mexico Super RS 3/40 - 3/80 - Installation
Boiler Size RS 3/40 RS 3/50 RS 3/60 RS 3/70 RS 3/80
Boiler Input
MINIMUM kW (Btu/h) 11.3 ( 38 500) 15.1 (51 500) 18.5 (63 300) 22.2 (75 900) 26.2 (89 500)
Gas Consumption l/s (ft.3/h) 0.29 (37.0) 0.39 (49.4) 0.48 (60.5) 0.57 (73) 0.68 (86)
MID kW (Btu/h) 13.0 (44 200) 16.7 (56 800) 20.3 (69 200) 24.0 (81 900) 27.9 (95 200)
Gas Consumption l/s (ft.3/h) 0.34 (42.6) 0.43 (54.7) 0.52 (65.8) 0.62 (79) 0.72 (92)
MAXIMUM kW (Btu/h) 14.7 (50 300) 18.4 (62 600) 21.9 (74 800) 25.7 (87 700) 29.8 (101 700)
Gas Consumption l/s (ft.3/h) 0.38 (48.1) 0.48 (60.2) 0.57 (71.7) 0.66 (84) 0.77 (98)
Boiler Output to Water
MINIMUM kW (Btu/h) 8.8 (30 000) 11.7 (40 000) 14.7 (50 000) 17.6 (60 000) 20.5 (70 000)
MID kW (Btu/h) 10.3 (35 000) 13.2 (45 000) 16.1 (55 000) 19.1 (65 000) 22.0 (75 000)
MAXIMUM kW (Btu/h) 11.7 (40 000) 14.7 (50 000) 17.6 (60 000) 20.5 (70 000) 23.4 (80 000)
Burner Setting Pressure (hot)
MINIMUM mbar (in w.g.) 6.2 (2.5) 8.4 (3.4) 9.5 (3.8) 8.8 (3.5) 11.2 (4.5)
MID mbar (in w.g.) 8.0 (3.2) 10.4 (4.2) 11.3 (4.5) 10.3 (4.1) 12.6 (5.0)
MAXIMUM mbar (in w.g.) 10.6 (4.2) 12.7 (5.1) 13.1 (5.2) 11.9 (4.8) 14.2 (5.7)
Flue Gas Flow Rate g/s 6.9 8.6 10.3 12.1 14.0
Flue Gas Temperature OC 138 142 129 118 173
*Seasonal Efficiency (SEDBUK) % 72.7 71.7 73.6 72.5 72.1
Boiler Size RS 3/40 RS 3/50 RS 3/60 RS 3/70 RS 3/80
Gas Supply Connection in. BSP Rc 1/2 (1/2)
Number of Boiler Sections 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 Pressure 20 mb
GENERAL
Table 1 - General Data
Table 2 - Performance Data
Key to symbols
IE = Ireland GB = United Kingdom (Countries of destination)
PMS = Maximum operating pressure of water
C11 = A room sealed appliance designed for connection via
ducts to a horizontal terminal, which admits fresh air
to the burner and discharges the products of
combustion to the outside without a fan in the
combustion products circuit.
I2H = An appliance designed for use on 2nd Family gas,
Group H only.
Note.
Gas consumption is calculated using a calorific value of 38.7
MJ/m3(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 pre-set at the factory to the highest
nominal rating.
*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.

4Mexico Super RS 3/40 - 3/80 - Installation
INTRODUCTION
Mexico Super RS range is of floor standing, natural draught,
balanced flue gas boilers. They are range-rated to provide
central heating outputs of 8.8 kW (30,000 Btu/h) to 23.4 kW
(80,000 Btu/h).
The boiler has a cast iron heat exchanger and is supplied
fully assembled, complete with a white enamelled mild
steel casing.
A door at the top of the casing front panel hinges down,
revealing the boiler thermostat control (and programmer,
if fitted).
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:
zpumped or gravity circulating indirect DHW only
zpumped central heating only
zpumped central heating combined with either a
pumped or gravity circulating indirect DHW circuit.
PTIONAL 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.
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 Ducts - Fitting ............................................ 14
Fault Finding ................................................................ 28
Flue Fitting ................................................................... 13
Flue Installation ............................................................. 7
Gas Safety Regulations ................................................ 5
Gas Supply .................................................................... 7
Initial Lighting .............................................................. 19
Installation ..................................................................... 9
Mandatory Requirements ............................................. 5
Pump ............................................................................ 15
Servicing ...................................................................... 21
Short List of Parts ....................................................... 29
System Diagrams (Electrical) .................................... 17
Terminal Guards. ........................................................... 7
Terminal Sizes. .............................................................. 6
Water Connections .............................................. 5 & 14
Water Systems ............................................................ 15
GENERAL
Mexico Super RS
Mexico Super RS 3/40 G.C. No. 41 349 27
Mexico Super RS 3/50 G.C. No. 41 349 28
Mexico Super RS 3/60 G.C. No. 41 349 29
Mexico Super RS 3/70 G.C. No. 41 349 30
Mexico Super RS 3/80 G.C. No. 41 349 31
Natural Gas only Appliance type: C11
Certified - P.I. No. 87 AT 14
Destination Countries: GB & IE.
NOTE TO THE INSTALLER: LEAVE THESE
INSTRUCTIONS ADJACENT TO THE GAS METER.
ALSO COMPLETE THE BENCHMARK LOG BOOK
AND GIVE THIS TO THE CUSTOMER.

5
Mexico Super RS 3/40 - 3/80 - 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.
GENERAL
Health and Safety Document No. 635.
The Electricity at Work Regulations, 1989.
Manufacturer’s notes must NOT be taken in any way as overriding
statutory obligations.
IMPORTANT. These appliances are certificated by the British
Standards Institution for safety and performance. It is important,
therefore, that no external control devices, e.g. flue dampers,
economisers etc., are directly connected to these appliances unless
covered by these Installation and Servicing Instructions or
otherwise recommended by Caradon Plumbing Limited in writing.
If in doubt please enquire.
Any direct connection of a control device not approved by Caradon
Plumbing Limited could invalidate the BSI Certification and the
normal appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations or other statutory
requirements.
LOCATION OF BOILER
The boiler must be installed on a flat and level floor, capable of
adequately supporting the weight of the boiler and any ancillary
equipment.
The boiler may be fitted on a combustible floor.
Insulation is not necessary, unless required by the local authority.
The boiler must not be fitted outside.
Timber Framed Buildings
If the boiler is to be fitted in a timber framed building it should be
fitted in accordance with the Institute of Gas 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.
1 BOILER WATER CONNECTIONS Boiler Dimension A
RS 3/40 152mm (6")
RS 3/50 / 3/60 226mm (8 7/8")
RS 3/70 / 3/80

6Mexico Super RS 3/40 - 3/80 - Installation
Terminal sizes
Boiler Size Depth Height Width
RS 3/40, RS 3/50, 107 198 281
RS 3/60,
RS 3/70, 152 338 372
RS 3/80 167 392 372
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.
An existing cupboard or compartment may be used, providing it
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:-
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 5.
In addition a MINIMUM clearance of 533 mm (21") MUST be
available at the front of the boiler, for servicing.
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
zz
zBS. 6798.
zz
zz
zThe position selected for installation MUST allow
adequate space for servicing in front of the boiler
and for air circulation around the boiler.
Side clearance is only necessary for installation. The amount
of side clearance will depend upon the type of connection
used.
zThis position MUST also permit the provision of a
satisfactory flue termination.
zFor the minimum clearances required for safety, and
subsequent service, see Frame 2.
Boiler Size Width Depth Height
RS 3/40, RS 3/50, 460 mm 533 mm 870 mm
RS 3/60, RS 3/70, (18") (21") (34 1/4")
RS 3/80

7
Mexico Super RS 3/40 - 3/80 - Installation
GENERAL
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
The boiler is to be installed only on a gas supply with a governed
meter.
A gas meter can only be connected by the local gas supplier or by
a local regional contractor.
Check that the appliance is suitable for the proposed gas supply.
An existing meter should be checked, preferably by the gas supplier,
to ensure that the meter is adequate to deal with the rate of gas
supply required. A minimum gas pressure of
20 mbar MUST be available at the boiler inlet, with the boiler
operating.
Installation pipes MUST be fitted in accordance with BS. 6891.
Pipework from the meter to the boiler MUST be of an adequate
size.
The complete installation MUST be tested for gas soundness and
purged as described in the above code.
FLUE INSTALLATION
Some pluming may occur at the termination so terminal
positions where this could cause a nuisance should be avoided.
The flue must be installed in accordance with the
recommendations of BS. 5440:1.
The following notes are intended for general guidance:-
1. The boiler MUST be installed so that the terminal is exposed
to external air.
2. It is important that the position of the terminal allows the free
passage of air across it at all times.
3. Minimum acceptable spacing from the terminal to
obstructions and ventilation openings are specified in
Table 3.
4. Where the lowest part of the terminal is fitted less than 2m
Table 3 - Balanced flue terminal position
Terminal Position Minimum Spacing
1. Directly below an opening window,
air vent or other ventilation opening 300 mm (12")
2. Below guttering, drain pipes or soil
pipes 300 mm (12")
3. Below eaves 300 mm (12")
4. Below balconies or a car port roof 600 mm (24")
5. From vertical drain pipes or soil pipes 75 mm ( 3")
6. From internal or external corners 600 mm (24")
7. Above adjacent ground, roof or
balcony level 300 mm (12")
8. From a surface facing the terminal 600 mm (24")
9. From a terminal facing a terminal 600 mm (24")
10. From an opening in a car port
(e.g. door or window) into dwelling 1200 mm (48")
11. Vertically from a terminal on the
same wall 1500 mm (60")
12. Horizontally from a terminal on the wall 300 mm (12")
(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 the terminal is fitted within 1000mm (39 1/2") of a 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.
TERMINAL
The terminal assembly can be adapted to accommodate various
wall thicknesses. Refer to Frames 9 and 10.
AIR SUPPLY
Detailed recommendations for air supply are given in BS.5440:2.
The following notes are for general guidance:
1. It is NOT necessary to have a purpose provided air vent in
the room or internal space in which the boiler is installed.
2. If the boiler is to be installed in a cupboard or compartment,
permanent air vents are required (for cooling purposes) in
the cupboard/compartment, at both high and low levels. The
air vents must either communicate with room/internal space,
or be direct to outside air. The minimum effective areas of the
permanent air vents, required in the cupboard/compartment,
are specified as follows and are related to maximum rated
heat input.
3. Both air vents MUST communicate with the same room or
internal space or MUST be on the same wall to outside air.
4. In siting the air vents care must be taken to avoid the freezing
of pipework.
Table 4 - High and low vent areas
Boiler Air from room/internal Air direct from
space cm2(in.2) outside cm2(in.2)
High level Low level High level Low level
RS 3/40 143 (23) 143 (23) 72 (12) 72 (12)
RS 3/50 173 (27) 173 (27) 87 (14) 87 (14)
RS 3/60 208 (33) 208 (33) 104 (17) 104 (17)
RS 3/70 245 (38) 245 (38) 123 (19) 123 (19)
RS 3/80 282 (44) 282 (44) 141 (22) 141 (22)

8Mexico Super RS 3/40 - 3/80 - Installation
GENERAL
Water Flow Rate and Pressure Loss
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 (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.
For bathroom installations the point of connection to the mains
must be situated outside the bathroom.
Dotted lines indicate
flow rates equivalent
to a temperature rise
of 11 OC (20 OF)
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 OC (20 OF)
temperature differentials are shown in the graph 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 1/2" BSP 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.

9
Mexico Super RS 3/40 - 3/80 - Installation
3 BOILER ASSEMBLY - Exploded View
Mexico Super RS with casing removed.
INSTALLATION
INSTALLATION
LEGEND
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.

10 Mexico Super RS 3/40 - 3/80 - Installation
INSTALLATION
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.
4 UNPACKING
INSTALLATION
complete
boiler
assembly
Wall thickness Flue
Dimension (duct length) X shown above pack(s)
Boiler fitted flush with wall Boiler fitted in line with 600 mm kitchen units required
114 to 191 mm (4 1/2" to 7 1/2") up to 125 mm (up to 5") C
229 to 305 mm (9" to 12") 163 to 242 mm (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
zcomplete boiler assembly
zthe Hardware Pack (listed separately below)
zthese Installation and Servicing Instructions
zUser's Instructions.
HARDWARE PACK
z1" BSP plugs - 6 off
z1" x 1/2" BSP reducing bush -
1 off
zDistributor tube
zThermostat pocket -1 off
zThermostat clip (RS 3/50, RS
3/60, RS 3/70 & RS 3/80 only)
- 1 off
zThermostat retaining pin - 1 off
zOutput setting label -1 off
FLUE PACKS
Packs B, B1 and C contents
zFlue terminal assembly
zSachet of sealing mastic - 2 off
zSachet of sealing mastic - 2 off
zAdhesive tape
Pack D contents
zFlue terminal extension

11
Mexico Super RS 3/40 - 3/80 - Installation
5 BOILER CASING REMOVAL
INSTALLATION
INSTALLATION
1. Remove the flue cleanout cover.
2. RS 3/40 & RS 3/70 only.
Ensure that the baffles are fully inserted in the flueways.
6 CHECKING THE FLUEWAY BAFFLES
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.
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. Pull the panel forward, lifting it clear of the locating peg and
remove.
11. Repeat steps 9 and 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.

12 Mexico Super RS 3/40 - 3/80 - Installation
INSTALLATION
7 PREPARING THE BOILER Notes.
zBefore 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.
zIf 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.
zThe pump may be fitted to the FLOW or the RETURN.
1. Screw the distributor tube (supplied with a 1" BSP x
INSTALLATION
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.
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 PREPARING THE WALL
Table 7 - Fully Pumped Systems
Connections - as viewed at front Thermostat Position
Back Section Front Section
Flow Return Top
LH LH LH
LH RH LH
RH RH RH
RH LH RH
b. The terminal MUST NOT come into
contact with a combustible material
such as that used in nonstandard
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 11.
3. Make good the brickwork around the air
duct inside.
Boiler Size Dim A Dim B
RS 3/40, RS 3/50, 696 (27 3/8") 200 (7 7/8")
RS 3/60
RS 3/70 672 (26 1/2") 248 (9 3/4")
RS 3/80 640 (25 1/8") 312 (12 1/4")
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.

13
Mexico Super RS 3/40 - 3/80 - Installation
INSTALLATION
INSTALLATION
5. Ensure that the duct is level and make good between the
wall and duct, from OUTSIDE of the building.
6. From OUTSIDE of the building, seal the air duct join (A) with
the mastic provided.
7. From OUTSIDE of the building, pass the terminal flue duct
through the wall opening and slide it into the boiler flue duct.
Locate it as shown and fix it in position with the 4 screws
previously removed.
8. From OUTSIDE of the building seal the flue duct join (B)
with the mastic provided.
9. Fasten the terminal grille to the duct assembly.
9 FITTING THE FLUE ASSEMBLY - Duct lengths up to 400 mm (16") -
RS 3/40, RS 3/50 & RS 3/60 only
Flue terminal
shown in position
A. Air duct join
B. Flue duct join
10 FITTING THE FLUE ASSEMBLY - Duct lengths up to 400 mm (16") - RS 3/70 & 3/80 only
Flue terminal
shown in
position
A. Air duct join
B. Flue duct join
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.
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.
5.Terminal grille assembly.
6.Terminal grille.
7.Securing screws - 2 off.
8.Splitter plate.
Legend
1.Boiler air duct.
2.Boiler flue duct.
3.Terminal air duct.
4.Terminal flue duct.
6.Terminal grille
securing screws - 2 off.
7.Terminal flue securing screws - 4 off.
Legend
1.Boiler air duct.
2.Boiler flue duct.
3.Terminal air duct.
4.Terminal flue duct.
5.Terminal grille.
1. Remove the 2 securing screws (6) and separate the terminal
grille from the terminal assembly.
2. Remove the 4 securing screws (7) and separate the terminal
flue duct from the terminal air duct.
3. From OUTSIDE of the building, pass the terminal air duct
through the wall opening and slide it into the boiler air duct,
locating it as shown.
4. Push the terminal air duct fully in until the fixing brackets
contact the wall face.

14 Mexico Super RS 3/40 - 3/80 - Installation
INSTALLATION
INSTALLATION
11 EXTENSION DUCTS - Duct lengths greater than 400 mm (16")
Extension ducts shown fitted
Typical minimum
overlap - 50mm (2")
12 GAS CONNECTION
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.
Boiler Dimension A
RS 3/40 327 (12 7/8")
RS 3/50 - RS 3/80 400 (15 3/4")
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 (1/2") OD to the boiler 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 24.
13 WATER CONNECTIONS
1. Connect the system flow and return pipework to the boiler
as appropriate. Refer to Frames 14 and 15 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").
Legend
1. Boiler air duct
2. Boiler flue duct
3. Terminal air duct
4. Terminal flue duct
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 brickwork around the air duct
inside.
6. Separate the terminal grille, terminal air duct
and terminal flue duct. Refer to Frame 9 or 10.
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. RS 3/40-60
Go to Frame 9 note. 7
RS 3/70 & 80
Go to Frame 10 note. 6
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

15
Mexico Super RS 3/40 - 3/80 - Installation
INSTALLATION
INSTALLATION
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 mm2 (24 x 0.2 mm) to BS.6500, Table 16.
Wiring external to the boiler MUST be in accordance with current
16 ELECTRICAL CONNECTIONS
(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.
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.
14 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.
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.
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 oC (20 oF) 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.
Due allowance MUST be made if surging is liable to occur.
If in any doubt, contact Caradon Plumbing Limited
1. Separate flow and return connections are used for each service. All
possible configurations are given in Frame 8 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.
l.E.E. (BS.7671) 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.)
15 GRAVITY HOT WATER & PUMPED CENTRAL HEATING
INSTALLATION

16 Mexico Super RS 3/40 - 3/80 - Installation
17 INTERNAL WIRING
18 EXTERNAL CONTROLS
External wiring must be in accordance with the current I.E.E.
(BS 7671) Wiring Regulations.
The wiring diagrams illustrated in Frames 20-22 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 19.
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 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 PICTORIAL WIRING
LEGEND
bblue br brown y/g yellow/green
INSTALLATION
INSTALLATION
Flow and pictorial wiring diagrams are shown in
Frames 18 and 19. 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.
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.

17
Mexico Super RS 3/40 - 3/80 - Installation
20 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.
Pumped only
21 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 (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 wiring
2. Numbering of terminals on thermostats is specific to the
manufacturer.
INSTALLATION
LEGEND
bblue
bk black
wwhite
gy grey
y/g yellow/green
Gravity HW & Pumped CH
INSTALLATION
br brown
rred
or orange
or orange
y/g yellow/green
gy grey
br brown
rred
wwhite
LEGEND
bblue
bk black
bk black
br brown
or orange
LEGEND
wwhite
rred
bblue
gy grey
y/g yellow/green

18 Mexico Super RS 3/40 - 3/80 - Installation
23 FROST PROTECTION
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.
INSTALLATION
24 FITTING THE CASING
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
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.
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 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.
25 COMMISSIONING AND TESTING
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.
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.
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.

19
Mexico Super RS 3/40 - 3/80 - Installation
INSTALLATION
26
INITIAL LIGHTING
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 26.
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.
INSTALLATION
27 PILOT BURNER CONNECTION GAS SOUNDNESS
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 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. 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 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
Burner and controls assembly
LEGEND
AGas control knob
BBurner pressure test point
CMain burner pressure adjuster
DInlet pressure test point
EGas service cock
FSightglass
GPiezo unit ignition
HBoiler thermostat knob
JOverheat thermostat reset button
(optional)

20 Mexico Super RS 3/40 - 3/80 - Installation
28 GENERAL CHECKS
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
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 26. 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.
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.
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
zz
zIf an optional programmer kit is fitted refer to the
separate Programmer Kit Installation Instructions and
Programmer Kit User's Instructions.
zz
zz
zThe temperatures quoted below are approximate and
vary between installations.
29 HANDING OVER
After completing the installation and commissioning of the system the
installer should hand over to the householder by the following actions:
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.
INSTALLATION
INSTALLATION
Thermostat Flow Temperature
Knob Setting oCoF
260 140
366 150
471 160
577 170
682 180