Ideal Boilers Classic FF 360, Installation And Servicing

Page 1: ......

Page 2: ...tain 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 FT 3 H divide the gross heat input Btu h by the gross C V of th...

Page 3: ...talled to comply with Building Regulations can be demonstrated by completing and signing the Benchmark log book CONTENTS Air Supply 6 Boiler Clearances 5 Boiler Exploded View 11 Burner Exploded View 3...

Page 4: ...cury or CFCs are included in any part of the boiler LOCATION OF BOILER The boiler must be installed on a flat and vertical wall capable of adequately supporting the weight of the boiler and any ancill...

Page 5: ...fit or remove the casing during installation and subsequent servicing is impaired by pelmets etc this operation can be made easier by first removing the controls pod casing in line with the following...

Page 6: ...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...

Page 7: ...ll valves be in the closed position 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 installe...

Page 8: ...n Ideal Limited Note A cold water feed must be available back to the boiler when all automatic valves are in the closed position refer to BS 6798 and when close coupled the feed must not be in a verti...

Page 9: ...pansion Vessel a A diaphragm type expansion vessel must be connected at a point close to the inlet side of the pump the connecting pipe being not less than 15mm 1 2 nominal size and not incorporating...

Page 10: ...een them the stop valve being located between the system and the automatic air vent The stop valve may remain open during normal operation of the system if automatic water make up is required b Throug...

Page 11: ...330 shown LEGEND 1 Heat exchanger 2 Flue baffles 3 Hook bolts 4 Flow pipe assy 5 Return pipe assy 6 Collector hood assembly 7 Combustion chamber 12 Main burner 19 Control box cla 6115 59 24 Pressure s...

Page 12: ...ion kit Cl 1724 Hardware Pack Contents 50mm x No 14 wood screw 4 off 50mm x No 10 wood screw 8 off Wall plug 12 off M8 washer 1 off M5 wing nut 3 off Sealing plate 1 off M8 x 12 Hx Hd screw 1 off The...

Page 13: ...n frame to ease handling and installation 4 Unpack the boiler terminal box and if applicable the extension flue box es 9 PACKAGING AND CASING REMOVAL SIDE FLUE INSTALLATION REAR FLUE INSTALLATION FLUE...

Page 14: ...following a The wall mounting plate screw positions choose one from each group Note Mark the centre of the flue hole as well as the circumference b The position of the flue duct hole 5 Remove the tem...

Page 15: ...aligns with the groove on the outer flue duct This ensures correct alignment of the flue terminal 4 Stick the self adhesive foam strip provided in the hardware pack onto the flue immediately behind th...

Page 16: ...o the wall plug Use the washer and rectangular sealing plate to seal the slot and retain the boiler Note Before fully tightening the retaining screw check the boiler alignment using a spirit level and...

Page 17: ...insert the plastic plugs provided for the wall mounting plate 3 Drill 1 further hole below the wall plate fixing screws in the position shown on the template for boiler fixing with the same 8mm 5 16 m...

Page 18: ...t square mark the flue all the way round 4 Insert the cardboard duct ring for support and cut to length 5 Remove cardboard duct ring and remove any burrs 1 Fit the boiler sealing ring inside the outer...

Page 19: ...the mounting plate to the wall with the No 14 x 50mm wood screws 2 Check with a spirit level that the plate is horizontal 3 Cupboard Supports In some applications existing wooden supports may hinder t...

Page 20: ...the flue extension tube and engage onto the fan elbow and secure with the screw attached to the elbow Note The sealing ring studs will locate in the back panel one way only This will ensure that the t...

Page 21: ...G THE KIT 1 Remove the cardboard support aid from the flue and place safely to one side 2 Fit the inner flue extension duct onto the inner flue duct 3 Fit the outer flue extension duct onto the outer...

Page 22: ...rved 1 Controls that switch the system on or 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 frost thermostat must be...

Page 23: ...ontrolled system set the boiler thermostat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see the manufacturer s literature 40 PICTORIAL WIRING LEGEND b blue bk...

Page 24: ...ill be left off for more than a day or so then a frost thermostat should be wired into the system This is usually done at the programmer in which case the programme selector switches are set to OFF an...

Page 25: ...ve the controls support casing Release the controls support front fixing screws 3 turns only Remove the pod by pulling it forward to disengage from the keyhole slots b Remove the control box securing...

Page 26: ...NCE A YEAR In IE servicing work must be carried out by a Competent Person 11 As the installer you may wish to undertake the service contract yourself or alternatively offer to the customer the benefit...

Page 27: ...this is the case and the gas input is at least 90 of the nominal then no further action need be taken If not proceed to paragraph c c Clean the main burner Refer to Frame 51 d Clean the heat exchange...

Page 28: ...ved jointing compound sparingly 4 Inspect the pilot burner and ignition detection electrode Ensure that they are clean and in good condition Check that a The pilot burner injector is not blocked or da...

Page 29: ...elight in accordance with Initial Lighting Frame 45 Note In order to assist fault finding the control box printed circuit board is fitted with 2 indicator lights which represent the following boiler c...

Page 30: ...tor harness to the bottom panel of the control box if fitted and remove the strap 6 Remove the sensor from the heat exchanger pocket and unclip from the back panel 7 Remove the strain relief bush from...

Page 31: ...washer is replaced when refitting the pilot injector 6 Replace the electrode and pilot shield retaining both with the electrode nut Check the spark gap 7 Reassemble in reverse order 8 Check the opera...

Page 32: ...as required Ensure that a new copper sealing washer is used 5 Fit the new burner ensuring that the retention tab is correctly located in the air box slot and reassemble in reverse order 6 Check the bu...

Page 33: ...ubber tube from the rear of the collector hood 6 Slacken the two M5 nuts on the front tie rods releasing the tie rods from the combustion chamber 7 Remove the M5 central fixing screw at the rear of th...

Page 34: ...s if used are correctly refitted 15 Fully test all functions including water and gas soundness 69 HEAT EXCHANGER REPLACEMENT Note Refer to Frame 7 Boiler assembly Exploded view for illustration of the...

Page 35: ...blocked YES Replace gas valve NO Is there a supply on terminals of main gas valve YES NO YES NO NO Is there a supply on the fan connector at PCB Molex marked FAN YES YES NO NO Check the polarity of th...

Page 36: ...embly complete with sightglass assy insulation M5 x 16 dogpoint pozi pan hd FF 330 360 1 171 949 37 Controls casing door with Lighting Instructions 1 171 475 39 Casing seal pack complete with screws 1...

Page 37: ...Classic Slimline FF Installation Servicing 37 SHORT LIST OF PARTS 71 SHORT PARTS LIST cla 6113 45 59 23 12 18 19 30 24 39 9 17 26 15 14 13 13 A 72 BOILER CASING ASSEMBLY...

Page 38: ...box and pilot assembly 12 Main burner 13 Main burner injector 16 Pilot shield 17 Gas control valve 42 Gas service cock 74 BURNER ASSEMBLY Exploded View LEGEND 19 Control box 21 Thermostat potentiomet...

Page 39: ...Classic Slimline FF Installation Servicing 39 NOTES...

Page 40: ...the design and performance of its products The right is therefore reserved to vary specification without notice The Ideal Boilers Technical Training Centre offers a series of first class training cour...