IDEAL classic FF 240, Installation & Servicing Manual

Page 1: ...INSTALLATION M A N U A L Classic Slimline the wall hung boiler Wall hung fanned flue gas fired boiler FF 230 260 Installers guide to central heating boilers SERVICING BOILERS ...

Page 2: ...in this case are concentric The fan is down stream of the combustion chamber I2H An appliance designed for use on 2nd Family gas Group H only Data Badge on top of the controls support B G Certified P I No 87 BL 43 Destination Countries GB IE Appliance type C12 Slimline models G C Appliance No Classic FF 230 41 387 74 Classic FF 240 41 387 75 Classic FF 250 41 387 76 Classic FF 260 41 387 77 CAUTIO...

Page 3: ... input Btu h by the gross C V of the gas Btu ft3 Table 1 General Data Table 2 Performance Data 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 BG plc 0087 Boiler Size FF 230 FF 240 FF 250 FF 260 Boiler input MINIMUM kW 5 6 11 3 15 0 18 5 Gross Btu h x 1000 19 1 38 5 51 2...

Page 4: ...invalidate the certification and the normal appliance warranty It could also infringe the Gas Safety Regulations and the above regulations SAFE HANDLING OF SUBSTANCES Care should be taken when handling the boiler insulation panels which can cause irritation to the skin No asbestos mercury or CFCs are included in any part of the boiler LOCATION OF BOILER The boiler must be installed on a flat and v...

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 instructions a Release the controls pod casing fixing screws a 3 full turns only Remove the pod by pulling it forward to disengage from the keyhole slots b Undo the 2 screws b retaining casing to the...

Page 6: ...al 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 6 6 above a balcony above ground or above a flat roof to which people have access then the terminal MUST be pro...

Page 7: ...ater supply For the types of system and correct piping procedure refer to Introduction and Frame 1 The central heating system should be in accordance with BS 6798 and in addition for Smallbore and Microbore systems BS 5449 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 pip...

Page 8: ...omestic circulator capable of providing an 11 C 20 F temperature differential e g Grundfos UPS 15 50 or equivalent The vertical distance between the pump and feed expansion cistern MUST comply with the pump manufacturers minimum requirements to avoid cavitation Should these conditions not apply either lower the pump position or raise the cistern above the minimum requirement specified by Caradon P...

Page 9: ...etween 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 Through a self contained unit comprising a cistern pressure booster pump if required and if necessary an automatic pressure reducing valve and flow restrictor The cistern should be supplied through a tem...

Page 10: ...ve setting 3 0 bar Vessel charge and 0 5 1 0 1 5 initial system pressure bar bar bar Total water content of system Expansion vessel volume litres 25 litres 2 1 2 7 3 9 50 4 2 5 4 7 8 75 6 3 8 2 11 7 100 8 3 10 9 15 6 125 10 4 13 6 19 5 150 12 5 16 3 23 4 175 14 6 19 1 27 3 200 16 7 21 8 31 2 225 18 7 24 5 35 1 250 20 8 27 2 39 0 275 22 9 30 0 42 9 300 25 0 32 7 46 8 Multiplying factors for other s...

Page 11: ... Classic FF 230 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 24 Pressure switch 30 Fan 40 Wall mounting plate 52 Back panel 56 Baffle plate 250 260 only INSTALLATION ...

Page 12: ...on 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 KITS Pack B supplied as standard Pack D optional extension kit for side flue or rear flue outlet Refer to Flue Extension Ducts A maximum of 1 extension duct plus the standard flue duct may be used t...

Page 13: ...e 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 templates from the wall IMPORTANT Ensure that during the cutting operation masonry falling outside of the building does not cause damage or personal injury 1 Cut the flue hole preferably with a 125mm 5 ...

Page 14: ... 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 the boiler sealing ring 17 WALL MOUNTING PLATE 1 Fix 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 som...

Page 15: ...to 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 adjust as necessary with the jacking screw 19 CONNECTING THE FLUE TO THE BOILER 20 TERMINAL WALL PLATE This plate allows neat concealment and full compression of the rubber seal Its use is not essen...

Page 16: ... 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 masonry drill and insert the plastic plug provided 4 Drill 4 holes with a 7mm 9 32 masonry drill and insert the plastic plugs provided for the side mounting plate 22 WALL MOUNTING TEMPLATE 1 Separate ...

Page 17: ...e the tube is cut 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 26 FITTING BOILER SEALING RING TO THE FLUE 1 Fit the boiler sealing ring inside the outer flue duct Ensure the boiler sealing ring is fully engaged Ensure the notch aligns with the groove on the outer flue duct This ensures correc...

Page 18: ...e jacking screw 1 Fix 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 28 FITTING THE SIDE OUTLET PLATES 30 MOUNTING THE BOILER Note If the boiler is fitted closer than 25mm to the side wall the side outlet plate must be fitted now 1 Split the side outlet plate into 2 down the split line 2 Fit the 2 halves of the side outlet ...

Page 19: ...n 5 Pull 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 terminal grille is correctly aligned This plate allows neat concealment and full compression of the rubber seal Its use is not essential if the flue hole and flue ducts have been accurately cu...

Page 20: ...NG 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 air duct 4 Drill 3 3 2mm 1 8 dia holes through the outer air duct Do not drill the inner flue duct 5 Insert the self tapping screws provided to fix the air duct in position Flue length Accessories Pr...

Page 21: ...ride an on off control e g frost thermostat must be wired into the mains lead in parallel with the control s to be overridden Refer to Frame 43 3 If a proprietary system is used follow the instructions supplied by the manufacturer 4 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 Advice on r...

Page 22: ... is a fully controlled system set the boiler thermostat to maximum 4 Switchmaster Midi is similar in operation but the wiring differs slightly see the manufacturer s literature LEGEND b blue bk black br brown r red w white y g yellow green or orange gy grey 40 PICTORIAL WIRING LEGEND b blue bk black br brown r red y yellow w white or orange v violet p pink gy grey y g yellow green 41 MID POSITION ...

Page 23: ...will 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 and all other controls MUST be left in the running position The frost thermostat should be sited in a cold place but where it can sense heat from the system Wiring should be as shown with minimal distu...

Page 24: ...d by pulling it forward to disengage from the keyhole slots b Remove the control box securing screws and swing it down into the servicing position See diagram B 5 Slacken the screw in the burner pressure test point F and connect a gas pressure gauge via a flexible tube 6 Swing the control box back into its working position 7 Press the overheat thermostat reset button J 8 Switch the electricity sup...

Page 25: ...staller you may wish to undertake the service contract yourself or alternatively offer to the customer the benefits of the Caradon Ideal Services details of which are outlined in the household pack supplied with this boiler After completing the installation and commissioning of the system the installer should hand over to the householder by the following actions 48 HANDING OVER 47 GENERAL CHECKS W...

Page 26: ... 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 exchanger Refer to Frame 50 e Clean the main and pilot injectors Refer to Frame 51 49 SCHEDULE f Remove any debris from inside the base of the casing g Check that the flue terminal is unobstructed and that th...

Page 27: ...approved 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 damaged Refer to Frame 59 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 conditi...

Page 28: ...d Relight 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 conditions Neon I3 Mains electricity ON Neon SG1 Flashes to indicate ignition operation stops after detection The boiler MUST NOT be operated if the casing is not fitted 57 SIGHTGLASS REPLACEMENT 1 ...

Page 29: ...rder On off switch 10 Disconnect the electrical connectors from the rear of the switch 11 Press in the 2 side retaining clips and remove the switch 12 Reassemble in reverse order 1 Refer to Frame 56 2 Remove the burner and air box assembly Refer to Frame 49 3 Remove the electrode retaining nut and remove the pilot shield and electrode 4 Unscrew the central pilot fixing screw and lift the pilot cle...

Page 30: ... 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 burner for cross lighting and flame stability Note Refer also to Frame 69 of Exploded Views for illustration of the procedure detailed below 1 Refer to Frame 56 2 Remove the burner and air box assembly...

Page 31: ...on 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 the collector hood and remove collector hood fan assembly 8 Remove the three M4 screws retaining the fan to the collector hood 9 Fit the new fan and reassemble in reverse order ensuring the fan lead...

Page 32: ... all functions including water and gas soundness 68 HEAT EXCHANGER REPLACEMENT Note Refer to Frame 8 Boiler assembly Exploded view for illustration of the procedure detailed below 1 Refer to Frame 56 2 Remove the burner air box assembly Refer to Frame 51 3 Drain the system 4 Disconnect the water connections If compression fittings are used then cut the pipes both above and below the fittings in or...

Page 33: ...ing correctly fitted Does the pilot light NO YES NO YES Does the spark stop after pilot is lit NO Is there a gas supply to the boiler Is 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 Check the polarity of the mains supply Check the continuity of the i...

Page 34: ...at knob PCB potentiometer and on off switch 1 156047 23 386 149 Automatic ignition printed circuit board PACTROL PCB 25 B 1 079716 24 385 861 Pressure switch HONEYWELL YAMATAKE C6065 F137312 1 155412 26 308 283 Thermostat knob 1 079601 30 E02 661 Fan assembly SIFAN No FFB 1701 037 155331 35 Boiler casing assembly complete with sightglass assy insulation M5 x 16 dogpoint pozi pan hd FF 230 260 1 15...

Page 35: ...Classic Slimline FF Installation Servicing 35 SHORT LIST OF PARTS 70 BOILER CASING ASSEMBLY 71 SHORT PARTS LIST 15 ...

Page 36: ...ox and pilot assembly 12 Main burner 13 Main burner injector 16 Pilot shield 72 BURNER ASSEMBLY Exploded View LEGEND 19 Control box 21 Thermostat potentiometer 23 Printed circuit board 26 Thermostat knob 58 Mains on off switch 17 Gas control valve 42 Gas service cock 73 CONTROL BOX Exploded View ...

Page 37: ...Classic Slimline FF Installation Servicing 37 NOTES ...

Page 38: ...38 Classic Slimline FF Installation Servicing NOTES ...

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

Page 40: ...don Plumbing Limited P O Box 103 National Ave Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 The Caradon Plumbing Limited 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 01482 498432 Technical Tra...