Ideal Boilers Classic FF 3 100 Installation And Servicing Download | Manualshive

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installation and
servicing

Classic

Your Ideal installation and servicing guide

ENGINEERED FOR PEACE OF MIND

When replacing any part on this appliance use only spare parts that you can be
assured conform to the safety and performance specification that we require. Do not
use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers.

FF 330 - 3100

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Summary of Contents for Classic FF 3 100

Page 1: ...NEERED FOR PEACE OF MIND When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance specification that we require Do not use reconditioned or copy parts that have not been clearly authorised by Ideal Boilers FF 330 3100 ...

Page 2: ...mm 28mm copper copper FEMALE Maximum static water head m ft 30 5 100 Minimum static water head m ft 0 45 1 5 Electrical supply 230 V 50 Hz Boiler power consumption 100W Fuse rating External 3A Internal F1A to BS 4265 Water content litre gal 2 7 0 6 3 65 0 8 4 65 1 0 4 65 1 0 Dry Weight kg lb 40 9 90 3 46 6 102 8 52 6 116 0 52 6 116 Maximum installation weight kg lb 31 4 69 3 37 4 82 5 43 1 95 43 1...

Page 3: ...107 Destination Countries GB IE Models G C Appliance No Classic FF 330 41 391 54 Classic FF 340 41 391 95 Classic FF 350 41 391 96 Classic FF 360 41 391 97 Classic FF 370 41 391 98 Classic FF 380 41 391 99 Classic FF 3100 41 391 01 Natural Gas only Appliance Type Boiler size C12 C32 FF 330 340 350 370 C72 FF 360 380 only C12 FF 3 100 only BENCHMARK LOG BOOK DETAILS Boiler Page Make and model 3 App...

Page 4: ...deal Limited could invalidate the BSI 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 this boiler LOCATION OF BOILER The boiler must be i...

Page 5: ...ons packed with the unit for the necessary clearances Pelmet restrictions If the ability to 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 i...

Page 6: ...ings 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 protected by a purpose designed guard The minimum spacing in Table 3 Nos 2 3 4 5 and 6 would be 75mm in order to allow a terminal guard to be fitted Terminals guards are available from boiler supplie...

Page 7: ...eal Limited INVALID Caradon Ideal Limited recommend Water Treatment in accordance with the Benchmark Guidance Notes on Water Treatment in Central Heating Systems Caradon Ideal Limited recommend the use of Fernox GE Betz Sentinel or Salamander water treatment products which must be used on accordance with the manufacturers instructions For further information contact Fernox Manufacturing Co Ltd Coo...

Page 8: ... 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 vertical leg The Classic range of boilers can be installed in low head situations by fitting a surge arrester in the expansion pipe as shown The following conditions MUST be observed 1 The surge arrester must be ...

Page 9: ...covering at least the range 0 4 bar 0 60 lb in2 must be fitted to the system The gauge should be easily seen from the filling point and should preferably be connected at the same point as the expansion vessel 4 Expansion 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 i...

Page 10: ...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 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...

Page 11: ...0 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 30 Fan 40 Wall mounting plate 44B Programmer optional 52 Back panel 59 Limit thermostat INSTALLATION ...

Page 12: ... 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 Wall mounting plate Side outlet terminal mounting plate Flue extension tube 1 off Boiler sealing ring 1 off Hardware Pack Contents 50mm x No 14 wood screw 4 off 50mm x No 10 wood screw 8 off Wall plug 1...

Page 13: ...rd Pack D optional extension kit for side flue or rear flue outlet Refer to Frame 33 1 A maximum of 2 extension ducts plus the standard flue duct may be used together 2 Flue extensions of greater than 1m 39 should be supported with the bracket provided If the stand off brackets have been used it is necessary in order to keep the flue aligned to use the spacer bracket with the support bracket It is...

Page 14: ...on 3 Ensure squareness by hanging a plumb line as shown 4 Mark onto the wall if required the 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 c Downward pipe routing bracket screw positions 5 Remove the templates from the wall IMPORTANT Ensure that during the cuttin...

Page 15: ...duct Ensure the boiler sealing ring is fully engaged Ensure the notch 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 If downward ...

Page 16: ... boiler 1 Lift the boiler onto the wall mounting plate hooks as shown Do not use the burner controls for lifting 2 Fit the M8 screw washer and rectangular plate to retain the boiler Note Before fully tightening the M8 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 nea...

Page 17: ... hole has been accurately cut with a drill then making good the wall faces is not essential as seals are provided at both ends of the flue However both wall faces immediately around the cut hole should be flat make good if necessary For less accurate holes make good to approximately 125mm 5 diameter at the 2 wall faces 2 Drill 4 holes with an 8mm 5 16 masonry drill and insert the plastic plugs pro...

Page 18: ...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 correct alignment...

Page 19: ...es is required then the downward routing pipe brackets and M8 spacer supplied in the Downward Piping Kit should be fitted to the wall mounting plate now 3 Fit the bottom 2 screws to secure the bracket s to the wall through the wall mounting plate 4 Check with a spirit level that the plate is vertical Notes 1 Have ready to hand the M8 screw washer and rectangular plate supplied in the hardware pack...

Page 20: ... to the fan 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 acc...

Page 21: ... for FF 3 100 model 35 FITTING 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 positio...

Page 22: ...r 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 required modifications to the wiring may be obtained from the component manufacturers Notes 1 Connection between a frost thermostat...

Page 23: ...lled 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 41 MID POSITION VALVE Pumped only LEGEND b blue bk black br brown gy grey or orange pk pink r red v violet w white y yellow y g yellow green LEGEND b blue bk black br brown gy grey or orange pk pink r red v violet w white...

Page 24: ...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 disturbanc...

Page 25: ... servicing position See diagram B 4 Slacken the screw in the burner pressure test point F and connect a gas pressure gauge via a flexible tube 5 Swing the control box back into its working position 6 Press the overheat thermostat reset button J 45 INITIAL LIGHTING 7 Switch the electricity supply ON and check that all external controls are calling for heat 8 Set the boiler thermostat knob D to posi...

Page 26: ...2002 10 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 In IE servicing work must be carried out by a Competent Person 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 Mak...

Page 27: ...he LH bottom rear of the burner and pull the burner downwards to disengage the retention tab Remove the burner to a safe place for inspection and cleaning 2 Remove the control box fixing screw Pull the box forward and downward to disengage 1 If the Classic Sealed System Unit is fitted lift off the casing 2 Open the controls pod door and release the 2 captive screws at the bottom of the casing Swin...

Page 28: ...to the fan Disconnect the connector from the fan and slide into the flue 3b Side or top flue Slacken off two M4 screws securing the flue elbow and flue connector Disconnect the flue connector from the elbow and slide into the flue Remove the flue elbow 4 Disconnect the silicon rubber tube from the rear of the collector hood 5 Slacken the two M5 nuts on the front tie rods releasing the tie rods fro...

Page 29: ...thermostat and reassemble in reverse order 6 Check the operation of the boiler 55 GAS PRESSURE ADJUSTMENT PILOT The pilot is factory set to maximum and no further adjustment is possible If after removing and checking the injector as detailed in Frame 61 and ensuring that there is an inlet pressure of 20 mbar available the pilot does not light then contact Caradon Ideal Limited Relight in accordanc...

Page 30: ...e 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 sensor from the heat exchanger pocket and unclip from the back panel 7 Remove the strain relief bush from the back panel base 8 Remove the sensor lead through the grommet in the control box 9 Replace and rea...

Page 31: ...sher 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 operation of the boiler 9 The pilot is factory set to maximum and no further adjustment is possible Ensure there is an inlet pressure of 20 mbar available Also check burner ignition and cross lighting 1 Refer...

Page 32: ...of the procedure detailed below 1 Refer to Frame 56 2 Remove the burner and air box assembly Refer to Frame 51 3 Remove the electrode retaining nut 4 Remove the pilot shield 5 Remove the ignition electrode and integral lead 6 Refit the new electrode and 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 o...

Page 33: ...sts and withdraw from the control box 6 Fit the new PCB and reassemble in reverse order 7 Check the operation of the boiler Fuse To change the fuse prise it out of the holder and disengage the fuse Refer to Frame 74 for fuse location 1 Refer to Frame 56 2 Remove the APS fixing screw 3 Remove both sensing tubes from the APS 4 Remove the 3 electrical connections from the APS 5 Fit the new APS and re...

Page 34: ... with water pipes and hang it on the key hole slots and screws Retighten the screws 12 Replace the 2 rubber sealing grommets 13 Reassemble in reverse order 14 Remake all water connections ensuring that the compression fittings 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 vie...

Page 35: ...cked 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 ignition lead from connector to electrode Does the spark now cease when gas is lit Ensure pilot and main gas valve leads are not crossed over Is there a supply ...

Page 36: ...1 929 30 Fan assembly E83 665 FF 330 380 1 171 461 E87 032 FF 3100 1 171 462 35 Boiler casing assembly complete with sightglass assy insulation and M5 x 16 dogpoint pozi pan hd FF 330 380 1 171 471 FF 3100 1 171 472 37 Controls casing door with Lighting Instructions 1 171 475 39 E85 313 Casing seal pack complete with screws 1 171 479 45 E83 682 Overheat thermostat 1 171 950 59 Limit thermostat 1 1...

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

Page 38: ...d pilot assembly 12 Main burner 13 Main burner injector 16 Pilot shield 17 Gas control valve 42 Gas service cock 75 BURNER ASSEMBLY Exploded View LEGEND 19 Control box 21 Thermostat potentiometer 23 Printed circuit board 26 Thermostat knob 58 Mains on off switch 74 CONTROL BOX Exploded View ...

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

Page 40: ...ication 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 specifiers For details of courses please ring 01482 498 432 THIS SYMBOL IS YOUR ASSURANCE OF QUALITY These appliances are designed for use with Natural Gas only They have been tested and conform with the pr...

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