Ideal Boilers FF 350, Installation And Servicing

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Page 2: ...37 4 82 5 43 1 95 0 Boiler size Height mm in 700 27 5 Width mm in 380 15 0 Depth mm in 300 11 8 Flue duct diameter mm in 100 4 0 Boiler Size FF 350 P FF 360 P FF 380 P Boiler input kW 18 3 21 9 29 3...

Page 3: ...AVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER ALSO COMPLETE THE BENCHMARK LOG BOOK AND GIVE THIS TO THE CUSTOMER Classic FF Data Badge on top of the controls support B G Certified P I No 87AP107 De...

Page 4: ...vicing instructions or otherwise recommended by Caradon Ideal Limited in writing If in doubt please enquire Any direct reconnection of a control device not approved by Caradon Ideal Limited could inva...

Page 5: ...lled must be at least wide enough to accommodate the tool c If using the Complete Sealed System Unit then refer to the instructions packed with the unit for the necessary clearances Pelmet restriction...

Page 6: ...tted 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 The minimum spacing in Table 3 Nos 2...

Page 7: ...al heating systems controls should be installed to ensure the boiler is switched off when there is no demand for heating or hot water When thermostatic radiator valves are used the space heating tempe...

Page 8: ...ctical length To pump Cold water level Feed expansion cistern 75 3 Min Flow Return 22 3 4 Open vent The Classic range of boilers can be installed in low head situations by fitting a surge arrester in...

Page 9: ...nsion 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 va...

Page 10: ...stop valve with an automatic air vent connected between 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 sy...

Page 11: ...330 shown LEGEND 1A Heat exchanger 2 Flue baffles 3 Tie rods 4A Pumped flow pipe 5A Pumped return pipe 6 Collector hood assembly 7 Combustion chamber 12 Main burner 19 Control box 24 Pressure switch...

Page 12: ...lg 1 off No 8 x 8 lg Pozi pan hd screws 3 off 8 UNPACKING Pack A Contents The complete boiler Installation Servicing Instructions User s Instructions Hardware Pack listed below Wall mounting template...

Page 13: ...trols pod casing 1 Unpack the boiler 2 Remove the casing as follows and place to one side to avoid damage a Undo the 2 casing retaining screws a retaining the casing to the back panel b Swing the bott...

Page 14: ...ote Check all of the hole positions BEFORE drilling 11 FLUE ASSEMBLY Exploded View 2 When cutting the ducts always use the cardboard support rings provided 1 An optional flue duct extension kit is req...

Page 15: ...e duct and boiler sealing ring Do NOT drill the inner flue duct 3 Insert the self tapping screws provided in order to fix the boiler sealing ring in position 4 Stick the self adhesive foam strip provi...

Page 16: ...mounting plate and locate the 3 studs in the holes in the back panel 2 Secure the flue to the boiler using the three M5 wing nuts provided 3 Pull the flue extension tube and engage onto fan locate and...

Page 17: ...the wall Note If the terminal is to be sited within 25 40mm of a corner or vertical pipe refer to Table 3 then the hole MUST be accurately cut 23 PREPARING THE WALL IMPORTANT Ensure that during the cu...

Page 18: ...not drill the inner flue duct 3 Insert the self tapping screws provided in order to fix the boiler sealing ring in position 1 To determine the position for the foam seal measure the wall thickness an...

Page 19: ...gular plate to retain the boiler 1 Fix the mounting plate to the wall with the No 14 x 50mm wood screws 2 If the downward routing of pipes is required then the downward routing pipe brackets and M8 sp...

Page 20: ...ews provided Note If the terminal is less than 2m 6 6 above ground level an approved terminal guard should be fitted Refer to the Contents List on Page 3 1 Pull the flue through the side outlet plate...

Page 21: ...tandard flue Terminal grille Extension tube Boiler Flue length Accessories Product No Up to 600 B Pack 1 off see Frame 10 600 to 1550 B Pack 1 off D Pack 1 off see Frame 10 1550 to 2500 B Pack 1 off D...

Page 22: ...ructions supplied by the manufacturer 5 System designs featuring controls or wiring arrangements which allow the boiler to fire when there is no pump circulation taking place should not be fitted Advi...

Page 23: ...ntrolled system set the boiler thermostat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see manufacturer s literature 41 MID POSITION VALVE Pumped only 40 PICT...

Page 24: ...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 thermostat should be sited in a cold p...

Page 25: ...he unit casing in order to inspect the top casing seal To gain access to the gas valve a Remove the controls support casing Release the controls support front fixing screws 3 turns only Remove the pod...

Page 26: ...s 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 an...

Page 27: ...stered installer In IE service work must be carried out by a Competent Person As the installer you may wish to undertake the service contract yourself or alternatively offer to the customer the benefi...

Page 28: ...61 for removal details b The pilot burner is clean and unobstructed c The ignition detection electrode is clean and undamaged d The ignition detection lead is in good condition e The spark gap is cor...

Page 29: ...t finding the control box printed circuit board is fitted with 2 indicator lights which represent the following boiler conditions Neon I3 Mains electricity ON Neon SG1 Flashes to indicate spark operat...

Page 30: ...the sensor lead connector off the printed circuit board and cut the cable strap securing the thermistor harness to the bottom panel of the control box if fitted and remove the strap 6 Remove the sens...

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: ...lead in reverse order Ensure that the pilot shield is replaced 7 Check the spark gap Refer to Frame 61 8 Reassemble in reverse order 9 Check the operation of the boiler 64 GAS CONTROL VALVE REPLACEME...

Page 33: ...n rubber 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...

Page 34: ...hole fixings Pull the assembly downward to clear the water pipes from the back panel 10 Remove the 2 rubber sealing grommets from the top of the back panel to facilitate fitting the new assembly 11 F...

Page 35: ...s the pilot injector 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 Che...

Page 36: ...ilot burner injector Propane stamped 20 23P 1 171 436 15 173 117 Pilot burner head with injector Propane 1 171 440 17 Gas control valve 1 172 006 18 308 317 Ignition electrode complete with lead and b...

Page 37: ...Classic FF Propane Installation Servicing 37 LIST OF PARTS 73 BOILER CASING ASSEMBLY 72 SHORT PARTS LIST cla 6113 45 59 23 12 18 19 30 24 39 9 17 26 15 14 13 13 A...

Page 38: ...ometer 23 Printed circuit board 26 Thermostat knob 58 Mains on off switch 75 BURNER ASSEMBLY Exploded View CL1870 Solenoid valve Sealing gasket Sealing gasket 10 11 13 12 16 42 17 LEGEND 10 Burner man...

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

Page 40: ...ation without notice The Ideal Boilers Technical Training Centre offers a series of first class training courses for domestic commercial and industrial heating installers engineers and system specifie...