Ideal Boilers Classic Combi FF 280 Installation And Servicing Download Page 1

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Classic Combi FF 280

Installation & Servicing

Wall Mounted, Fanned, Balanced Flue Gas Boilers

NOTE TO THE INSTALLER:

LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER

Classic Combi

G.C. Appliance No.

FF 280 .............................47 415 08

Natural Gas Models Only

CAUTION.

To avoid the possibility of injury during the installation and servicing of this appliance, care should be taken when handling edges of sheet components.

Summary of Contents for Classic Combi FF 280

Page 1: ...O THE INSTALLER LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER Classic Combi G C Appliance No FF 280 47 415 08 Natural Gas Models Only CAUTION To avoid the possibility of injury during the installation and servicing of this appliance care should be taken when handling edges of sheet components ...

Page 2: ...conds in order to maintain the DHW calorifier in a preheated condition Note The DHW preheat operates 24 hours a day unless an external programmer is fitted when it can be timed When there is demand for DHW the boiler fires at full gas rate the diverter valve remains de energised and the full output from the boiler is directed to the DHW calorifier providing a maximum DHW draw off of 9 6 l m 2 1 gp...

Page 3: ... Internal 2A F Water content Central Heating litre gal 4 65 1 0 Domestic Hot Water litre gal 0 55 0 12 Dry weight total kg lb 78 7 173 Maximum installation weight kg lb Combi module 11 4 25 1 Boiler module 52 6 116 Boiler casing size Height mm in 1045 41 1 4 Width mm in 380 15 0 Depth mm in Top water connections 300 11 3 4 Bottom water connections 345 13 1 2 Table 1 General Data GENERAL Note Gas c...

Page 4: ...Classic Combi FF 280 Installation 4 1 BOILER WATER CIRCUIT DIAGRAMS GENERAL ...

Page 5: ...ler 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 British Gas publication Guide for Gas Installations in Timber Frame Housing reference DM2 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 767...

Page 6: ...d it is necessary in order to keep the flue aligned to use the spacer bracket with the support bracket Dimension Side Flue Rear Flue A 425mm 390mm B 25mm 5mm flue side both sides 40mm non flue side Additional space will be required for installation depending upon site conditions Side Flue only Provided that the flue hole is cut accurately e g with a core drill The following minimum clearances must...

Page 7: ...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 Part 1 7 Where it is essential that the terminal wall plate is fitted i e wall thicknesses over 600mm 23 5 8 or with ...

Page 8: ...stem in w g 63 47 157 GENERAL THERMOSTATIC RADIATOR VALVES Caradon Ideal Ltd 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...

Page 9: ...s may be used in the central heating system For further information contact Fernox Manufacturing Co Ltd Britannic Works Clavering Essex CB11 4QZ Tel 01799 550 811 or Grace Service Chemicals Grace Dearborn Ltd Widnes Cheshire WA8 8UD Tel 0151 424 5351 1 General a The installation must comply with the requirements of BS 6891 1988 and BS 5449 1 b The installation should be designed to work with flow ...

Page 10: ...d by radiators not fitted with such a valve Such an arrangement will provide for a more efficient control of the environment and will also avoid the continuous running of the circulation pump during programmed heating ON periods saving electrical energy It is therefore strongly recommended that when thermostatic radiator valves are used the space heating temperature control over a living dining ar...

Page 11: ...all mounting plate z Stand off brackets 2 off z Side outlet terminal mounting plate Hardware Pack Contents z No 14 x 50mm wood screws 8 off for wall mounting plate z No 10 x 50mm wood screws 8 off for side outlet plate and terminal wall plate z Wall plugs 16 off z M6 nuts 8 off for stand off brackets z M6 screws 8 off for stand off brackets z M6 washers 8 off for stand off brackets z Sealing plate...

Page 12: ...ng it forward to disengage from the keyhole slots b Undo the 4 screws b retaining the casing to the back panel c Remove the casing in the direction of the arrows 3 Remove the boiler from its packaging base The boiler may now be stood upright on its controls support protection frame to ease handling and installation 4 Unpack the flue assembly extension flue box es a Controls pod fixing screws 2 off...

Page 13: ...rate holes make good to approximately 125mm 5 diameter at the 2 wall faces 2 Drill 9 holes for the wall mounting plate with an 8mm 5 16 masonry drill 3 Insert the plastic plugs provided 1 An optional flue duct extension kit is required for wall thicknesses greater than 600mm 23 1 2 Refer to Frame 36 9 WALL MOUNTING TEMPLATE Note The template shows the positions for the fixing holes and the flue ho...

Page 14: ...r plate and stand off brackets on the top fixing screws 2 Locate six No 14 x 2 screws in the lower fixing holes and drive home all screws 3 Check with a spirit level that the plate is vertical 15 WALL MOUNTING PLATE REAR FLUE OUTLET 13 FITTING THE STAND OFF BRACKETS screws MUST be fitted in the top holes marked with the symbol with the shakeproof washers positioned under the screw heads 1 Measure ...

Page 15: ...n to the system pipework may now be made BEFORE the boiler is mounted on the wall PROCEED TO FRAME 42 INSTALLATION 17 PRE WIRING The mains supply and other external wiring may now be made if required BEFORE the boiler and Combi modules are mounted on the wall refer to Frames 46 to 49 REAR SIDE FLUE OUTLET IMPORTANT For installations with bottom water connections only the following pipe runs must b...

Page 16: ...onto the wall plate hooks and is retained by the central M8 screw plain washer and large rectangular plate Note Have ready to hand the M8 screw plain washer and rectangular plate supplied in the hardware pack 1 Lift the boiler onto the wall mounting plate hooks as shown DO NOT USE THE BURNER CONTROLS ASSEMBLY FOR LIFTING IMPORTANT The boiler module MUST be positioned CENTRALLY on the wall mounting...

Page 17: ...ther the brackets are used or not Note Mark the centre of the hole as well as the circumference d The side of the casing nearest the flue outlet SIDE FLUE OUTLET 5 Remove both templates from the wall 22 PREPARING 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 18: ...e duct 3 Insert the self tapping screws provided in order to fix the boiler sealing ring in position 24 FITTING THE FOAM SEAL 1 To determine the position for the foam seal measure the wall thickness and mark it onto the flue measuring from the groove near the terminal 2 Wrap the self adhesive foam strip round the flue ensuring that the foam is on the terminal side of the line This seals the gap be...

Page 19: ...uts screws and shakeproof washers provided so that the plate is located BEHIND the front returns of the brackets as shown Note If the clearances above and below the boiler are less than the length of the pipes to be fitted behind the wall mounting plate then refer to Frame 16 IMPORTANT To ensure earth continuity securing screws MUST be fitted in the top holes marked with the symbol with the shakep...

Page 20: ...The boiler mounts onto the wall plate hooks and is retained by the central M8 screw plain washer and large rectangular plate Terminal mounting plate The air duct spigot engages in the hole in the side panel 33 CONNECTING THE FLUE TO THE BOILER 1 Pull the flue through the side outlet plate and locate the 3 studs in the hole in the side of the boiler 2 Secure the flue to the boiler using the three M...

Page 21: ...XTENSION DUCTS For flue lengths greater than 600mm 34 TERMINAL WALL PLATE 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 cut and the outside wall face is flat 1 Position the terminal wall plate over the terminal 2 Drill 4 fixing holes with an 7mm 9 32 masonry drill 3 Insert the 4 plastic plugs...

Page 22: ...s cut square mark the flue all the way round 13 Using the cardboard ring for support cut to length 14 Remove cardboard ring and remove any burrs 15 For rear outlet flue follow the procedure from Frame 8 For side outlet flue follow the procedure from Frame 20 Safety valve drain pipe Central heating connections Domestic hot water connections Boiler CH expansion vessel 3 Slacken the retaining screw l...

Page 23: ...ler module with CH expansion vessel in the servicing position 10 Connect the DHW inlet and outlet pipes safety valve drain pipe and the CH flow and return pipes to the bulkhead fittings on top of the wall mounting plate using the 5 sealing washers provided Fully tighten Refer to the view opposite Notes a Make the 2 outside connections first i e DHW inlet and CH flow Tighten and draw the assembly u...

Page 24: ...lace the vent plug Note Some slight water leakage will occur INSTALLATION Vent plug Detail of pump selector switch Refer to Gas Supply page 5 for gas inlet service dimensions Frame 2 A minimum pressure of 20mbar MUST be available at the boiler inlet with the boiler operating The main gas cock is on the left hand side of the gas control valve To facilitate connection the gas cock may be removed fro...

Page 25: ...boiler and check that the boiler is firing at maximum rate c Turn the DHW flow adjuster CLOCKWISE to reduce the DHW flow rate until a rate of approximately 9 6 l min 2 1gpm is obtained at the tap d Turn off the DHW tap WARNING The appliance must be efficiently earthed A mains supply of 230 V 50 Hz is required All external controls and wiring must be suitable for mains voltage Wiring should be in 3...

Page 26: ...harness to the earth post on the underside of the boiler control support 3 Connect the lead from the wiring harness to the flying lead connection outside the control box Notes a The mains lead connection MUST be made in such a way that should the lead slip from the anchorage the current conductors become taut before the earthing conductor b The T rating of the mains lead should be 70 0 C c Ensure ...

Page 27: ... 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 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 all other controls MUST be left in the running position The frost thermostat should be sited in a cold ...

Page 28: ... 50 SCHEMATIC WIRING DIAGRAM INSTALLATION INSTALLATION LEGEND b blue bk black g y green yellow bk w black white br brown r red y yellow w white v violet gy grey LEGEND b blue bk black br brown r red y yellow w white g y green yellow bk w black white v violet gy grey ...

Page 29: ...ghten the union and check for gas soundness 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 z The casing must seat correctly and compress the sealing strip to make an airtight joint Visually check the side seals but if side clearances are limited then check that the top and bottom...

Page 30: ...essurised systems this should be 1 0 bar 14 5 psi 2 Set the RED fill pressure indicator on the pressure gauge E to the initial system pressure Refer to Frame 4 Filling INSTALLATION CENTRAL HEATING 1 Set the CH HW switch B to CH HW and the burner on off switch C to ON Check that a The pump is running b The diverter valve energises no resistance should be felt when the manual lever is moved by hand ...

Page 31: ...conditions 5 Explain the function and the use of the boiler heating and domestic hot water controls 6 Explain the function of the boiler overheat thermostat and emphasise that if cutout occurs the boiler should be turned off and a CORGI registered installer consulted 7 Explain and demonstrate the function of time and temperature controls radiator valves etc for the economic use of the system 8 If ...

Page 32: ...ry out a pre service check noting any operational faults b Clean the main burner c Clean the heat exchanger d Clean the main and pilot injectors e Remove any debris from inside the base of the casing f Check that the flue terminal is unobstructed and that the flue system including the inner cover is sealed correctly g If the appliance has been installed in a compartment check that the ventilation ...

Page 33: ...r removal details b The pilot burner is clean and unobstructed c The ignition detection electrode is clean and undamaged e The ignition detection lead is in good condition f The spark gap is correct Frame 68 Clean or renew as necessary Note The pilot shield is located around the pilot assembly bracket and is located by the electrode retaining nut 5 Refit the control box 6 Reconnect the gas supply ...

Page 34: ... detection electrode The pilot is factory set to maximum and no further adjustment is possible If however the pilot flame length is incorrect then remove and inspect the pilot injector Refer to Frame 68 Relight in accordance with Initial lighting Frames 52 and 53 MAIN BURNER After any servicing reference should be made to Table 2 which quotes details of the rated output with the related burner set...

Page 35: ...htglass assembly to the casing front panel 3 When fixing the new assembly ensure that the parts are in the correct order The frame must have the return edge at the bottom 4 Retighten the 2 nuts to ensure an airtight seal DO NOT OVERTIGHTEN 5 Replace the boiler casing Refer to Frame 52 66 DHW PREHEAT CONTROL OVERHEAT AND CH CONTROL THERMOSTAT REPLACEMENT 1 Refer to Frame 64 2 Release the retaining ...

Page 36: ...ked cleaned or replaced as required Ensure that an approved jointing compound is used sparingly 5 Fit the new burner ensuring that the retention tab is correctly located in the air box slot 6 Refit the M5 retaining screw and washer 7 Refit the boiler casing 8 Check the burner for cross lighting and flame stability 1 Refer to Frame 64 2 Remove the burner and air box assembly Refer to Frame 58 3 Rem...

Page 37: ...the procedure detailed below 1 Refer to Frame 64 2 Remove the burner support bracket burner and air box assembly Refer to Frame 58 3 Remove the control box fixing screw Pull the box forward and downward to disengage 4 Remove the gas control valve electrical connections 5 Disconnect and remove the gas union from the gas control valve 6 Whilst supporting the gas control valve remove the 2 screws ret...

Page 38: ...ation SERVICING SERVICING 1 Refer to Frame 64 2 Remove the control box fixing screw Pull the box forward and downward to disengage 3 Remove the HT lead from the PCB 4 Remove the 4 push in electrical connectors from the PCB 5 Remove the neutral wire on the PCB from its connection to the back of the socket inside the control box 6 Remove the earth wire on the PCB from its connection to the earth stu...

Page 39: ... the 2 captive screws B and lift the actuator off the valve body Note At this stage if required the Syncron motor may be replaced Refer to the instructions supplied with the replacement motor 7 Fit the new actuator PRESET TO THE OPEN POSITION and reassemble in reverse order 77 LOGIC PCB 27 REPLACEMENT Logic PCB 27 1 Refer to Frame 64 The Combi module cover only need be removed 2 Release the retain...

Page 40: ...ose the CH isolating valves 3 Remove the heat exchanger drain plug using a 3 16 Allen key and drain the water into a suitable receptacle 4 Refit the drain plug using a suitable jointing compound 5 In order to refill the boiler refer to Frame 4 80 DHW FILTER REPLACEMENT 1 Refer to Frame 64 The Combi module cover only need be removed 2 Remove the DHW flow switch Refer to Frame 79 3 Prise the filter ...

Page 41: ...me 81 3 Release the retaining screw and hang the CH expansion vessel in the servicing position Refer to Frame 45 4 Disconnect the pressure gauge capillary from the safety valve 5 Compress the 2 retaining lugs and withdraw the gauge from the bracket 1 Refer to Frame 64 2 Drain the boiler Refer to Frame 81 3 Disconnect the flexible pipe from the vessel 4 Release the retaining screw and withdraw the ...

Page 42: ...ing agent c Rinse thoroughly with clean water d Re assemble in reverse order WARNING The agents are highly corrosive ingestion or contact with skin eyes and clothing MUST be avoided Protective clothing should be worn and the descaling operation conducted out of doors in a well ventilated area Note The names and addresses of suppliers of suitable descaling agents are given in Frame 4 1 Refer to Fra...

Page 43: ...replaced a Remove the 4 socket screws and withdraw the pump head b Fit the new head and re assemble in reverse order To remove the COMPLETE pump proceed as follows 8 Undo the boiler return elbow unions 9 Undo the pump return union 10 Swing the pump to disengage the boiler return pipe from the clip and withdraw the pump complete with return pipe 11 Undo the pump flow union and using one of the new ...

Page 44: ...milar Note Refer to Frame 93 Boiler Assembly Exploded View for illustration of the procedure detailed below 1 Drain the boiler 2 Remove the CH expansion vessel Refer to Frame 83 3 Disconnect the electrical lead Remove the Combi module following the procedure in reverse order described in Frame 38 Note An extraction tool is provided in the Hardware Pack to remove the push fit brass elbow from the b...

Page 45: ... boiler back panel 3 Fit the new self adhesive seals INNER VIEW OF BOILER CASING 51 Flexible hose 53 CH expansion vessel 104 CH expansion vessel support bracket A Pressure gauge height adjustment screws and locking nuts 2 off LEGEND 27 Automatic air vent 28 Pressure gauge 32 Safety valve 35 Pump 38 Push fit elbow 41 Diverter valve 43 CH thermostatic valve 45 Calorifier 47 DHW flow switch SERVICING...

Page 46: ...preheat thermostat 35 Pump 45 Calorifier 55 Sealing plates 2 off 58 Wall mounting plate 59 Stand off brackets LH RH side 62 Back panel 100 DHW inlet isolating valve 101 DHW outlet connection 102 Safety valve drain connection 103 CH flow and return isolating valves 105 Inter panel 106 Pumped return pipe 107 Pumped flow pipe 108 Rubber sealing grommets 109 Overheat thermostat 110 Boiler drain point ...

Page 47: ...s list 20 Control box 21 CH HW switch 24 CH HW switch knob 25 Printed circuit board 26 Mains on off switch 27 Air pressure switch SERVICING SERVICING LEGEND Numbers up to 67 relate to the B G spares list 11 Burner manifold 12 Air box and pilot assembly 13 Main burner 14 Main burner injector 17 Pilot shield 18 Gas control valve 42 Gas service cock ...

Page 48: ...heat Has the DHW flowswitch operated Is the DHW overheat thermostat calling for heat Replace the thermostat Replace the flow switch Replace Logic PCB No 27 Switch ON the mains supply and fully open a DHW tap Does neon I3 on PCB No 25B glow Does the pump start Does neon I2 on PCB No 25B glow Switch OFF the mains supply disconnect the DHW preheat thermostat Does neon I1 on PCB No 25B glow YES NO YES...

Page 49: ... PCB No 25B NO The boiler is operating correctly Replace the gas control valve Replace the gas control valve FAULT FINDING Check the sensing pipes for blockage and bad connections Does the air pressure switch now operate Replace the pressure switch NO YES Refer to Frame 68 Check the gap between the electrode and hood Check that the HT lead and electrode are undamaged and that connections are not c...

Page 50: ...hermostat calling for heat Replace the thermostat Is the DHW preheat thermostat calling for heat Check that the pump is free to rotate Does the pump now start Replace the pump YES YES Does the pump start Does the neon I3 on PCB No 25B glow Does neon I2 glow YES YES YES Does neon I1 glow NO NO NO NO NO NO NO YES YES YES NO Has the air pressure switch operated YES NO NO YES NO YES NO YES NO NO NO NO...

Page 51: ... the DHW preheat thermostat Is there a supply voltage at the pilot valve terminals 230 V AC 10 6 Refer to Frame 68 Check the gap between the electrode and hood Check that the HT lead and electrode are undamaged and that connections are not close to earthed metalwork Is there a regular flash from the tube on automatic ignition PCB No 25B YES YES YES YES YES NO NO NO NO NO YES Is there a gas supply ...

Page 52: ...ed Replace Logic PCB No 27 NO NO Is the air pressure switch in the NC position at the start of the ignition sequence Check that the pump is free to rotate Does the pump now start Does the diverter valve operate NO NO NO NO NO NO YES Check that the manual lever is free to move Does the valve now open Replace the valve actuator NO Replace the pump NO YES NO NO NO Check all fuses Replace the switch R...

Page 53: ...ignition PCB No 25B YES Does the main burner cross light from the pilot NO YES Replace the gas control valve Replace Logic PCB No 27 NO Replace the CH control thermostat NO FAULT FINDING Does the pilot light YES YES Does the boiler flow temperature rise to approx 600 C before allowing hot water to the system approx 10 mins Does the burner extinguish in response to an increase in CH temp erature Th...

Page 54: ...dot 1 079 635 31 378 075 DHW control thermostat ELMWOOD 2455 R 192 941 yellow dot 1 079 636 32 374 045 Safety valve CALEFFI 3141 1 113 026 33 374 074 Combi module cover with fixing screw 1 079 637 35 374 076 Pump GRUNDFOS 15 50 1 005 595 41 374 081 Diverter valve assy HONEYWELL 4044 C 1536 1 005 871 43 374 083 CH thermostatic valve 1 005 803 47 374 086 DHW flow switch assy HONSBERG Fluvatest UM 15...

Page 55: ...Classic Combi FF 280 Installation 55 99 SHORT PARTS LIST SHORT LIST OF PARTS ...

Page 56: ...n 01482 498 432 Technical Training CARADON IDEAL Ltd P O Box 103 National Avenue Kingston upon Hull HU5 4JN Telephone 01482 492 251 Fax 01482 448 858 Registration No London 322 137 Registered Office National Avenue Kingston upon Hull HU5 4JN A subsidiary of Caradon p l c CARADON IDEAL Ltd pursues a policy of continuing improvement in the design and performance of its products The right is therefor...

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